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SERVICE MANUAL

1. i L GND GND vce YCg THAOTHONDOLENLTL YC4 1 1 2 30 29 vazzo lt q lt m gt QzZzzza mr BUZERDRN KEY1N 18 17 H YC1 3 4 SD EN 28 27 EE KEYON SCAN7N 16 15 SWN SH NONDZOO TOHMHWEE 28 GND CPN 26 25 YOSG2 S On 59002 SCANG6N SCANSN 14 13 5 6 7 8 GND RSN 24 23 Onn Oe E SCAN4N SCAN3N 12 11 7 8 Optional DIMM slot 9 10 TGND CCDCLK 2221 e d SCAN2N SCAN1N 109 9 10 11 12 20 19 ar m Scanner GND CCDCLKN OO SCANON LEDEN 8 7 Home 13 14 GNDGND 1817 LEDSN LEDAN 6 5 CCD board 45 16 SNDGND 16 15 position KP 5065 5 16 SND CCDG O LED3N LED2N 4 3 17 187 GND CCDB E 13 18 LED1N LEDON 2 1 S sensor 19 20 SND CCDR 12 11 YC5 2 25 26 PGNDPGND 5 L eee GND SW 2019 1 2 2 2 DATAN 2 2 27 28 TAMPIAMP ae KP 5063 SWN CCDCLKN 18 174 3 4 3 Eer 3 3 GND CCDCLK 16 15 5 5 Main board 4 4 QUTPEN 1 Laser scanner gaz GND RSN 14 134 7 8 KP 5060 5 515 WEE GND CPN 12 11 9 10 6 6 6 lt 5 4449222 GND SH 10 9 11 12 7 7 7 ISUMOTA ZIORA AAA GND GND 8 7 13 14 8 8 8 Scanner ISUMOTNB G ml DI GND CCDG O Ip H 15 16 3 motor ISUMOTNA ES56S0S5S55 GND CCDB E 4 3 117 18 ISUMOTB OwWSZZZZ25605 GND CCDR 2 1 19 20 SS OO Waste toner Eraser lamp W D U O OO O u u u PWB Inverter FAXANDD TTT YC2 YC3 sensor PWB tes a board or SELA Pocitos EE KP 786 uta r 95 N SD SEET iO co N G zz u _ N x To operation pane z zZ ae DS Z gt Z 4 pop ee
2. a 1 6 52 13 Adjusting the Reie Ce 1 6 53 14 Adjusting the margins for scanning the original from the DP 1 6 54 2 1 Mechanical construction 2 1 1 Paper feeding system ccccccsesecccnesseeecaueeeeeceauseeeessueeeecsaeeeessaueeeesaeseeesauaeeeseseeeeeesaeeeessseeessnseessseges 2 1 1 1 Paper feed control EE 2 1 2 2 Paper feeding mechanism a asar 2 1 3 2 1 2 Original scanning system a ra R REE E ERE E REE R REESE REESE ERE E ERE E RES 2 1 4 OU WA SNE EET o e e 2 1 6 2 1 3 Electrophotographic system un 2 1 7 1 Electrophotograpnic cycle 2 1 7 1 1 Prosess unit mechanism ccccssseecccceeeeececeeeeeecseeeeeeceueeeeesaaseeecauaueeessaaeeeessaueeeeeseeeessaseees 2 1 8 2 Main charg BE 2 1 9 2 1 Photo conductive drum EE 2 1 9 2 2 Charging the drum aa aa aasssassrsssssssssrsssssssrsssssssssa 2 1 10 3 TOS UNC geeiert 2 1 11 3 1 Laser scanner unt 2 1 12 3 2 Drum surface potential a r REE ERE E ERR REE RER R RES 2 1 13 4 Development a rr arssssssssssssssss
3. ISUMOTA ISUMOTNA S ISUMOTB ISUMMOTONB Ger KP 5063 7 Main board LAMPLAMPHI LAMPLOW KP 5060 RSTIN PLGCLK Scanner home Reset IC position U3 sensor N CPU CY k U1 Exposure 2 PLGDRN lamp N PLGRDYN PFMDRN PFSEN PFPFPER PFCLK 3G B G Laser scanner unit MOTORN hb US D SWIN FA E ea i RESIT motor i PAPERN Feed clutch al FEDDRN Registration clutch RESDRN CC QS Bias board MP feed clutch KP 5067 Heater lamp control circuit RRS MP paper sensor HANDSN LA Eraser SLEEP Eraser amp TONER ERASER Amp control circuit Cooling fan Waste O Toner sensor Sensor W O N Interlock s switch A sensor Thermistor a High voltage board Power supply board Figure 2 3 2 Engine board circuit block diagram 2 3 2 2DC 1 Eraser lamp control circuit The CPU U1 turns pin 86 ERASER of U1 to H level transistors Q18 turns on consequently and the 24 V DC given at pin 1 of connector YC14 applies to the eraser lamps The eraser lamps thus illuminate as the current flows through the eraser lamp the pin 2 of connector YC14 resistors R109 R110 and R111 transistor Q18 and the ground Engine board Se Eraser lamp Eraser lamp cotrol circuit YC14 ERASPW ERASER R109 R110 3 ERASER PDL15 AD15 128 CT aie Figure 2 3 3 Eraser lamp control circuit 2 3 3 2DC 2 Heater lamp contro
4. a a a 1 2 1 1 3 Installation 1 3 1 Unpacking and installation EE 1 3 1 1 Installation el tele 1 3 1 1 3 2 Installing the document processor option cccccccceccsesseeeeeceseeeeeeeeeeeeeeeceeeesseaeeeeeesesaeeeeeeessaaaeeeeees 1 3 15 1 3 3 Installing the expanding memory option a 1 3 18 1 4 Maintenance Mode 1 4 1 Maintenance mode AAA 1 4 1 1 Executing a maintenance item a 1 4 1 2 Maintenance mode item ei 1 4 2 3 Contents of maintenance mode items kk NER ERE aa a a sssssrrrrrrsssssssa 1 4 4 1 5 Troubleshooting 1 5 1 Paper misfeed detection a ssssnsssnssssssssssssssssaa 1 5 1 1 Paper misfeed nelle 1 5 1 2 Paper misfeed detection conditions R ERE REE E REESE ERNE ERR ENES 1 5 2 3 Paper MISTER OS sessirnir eaea a r aerea 1 5 4 1 5 2 TE e e e s sisien reirei rinier a ea EDERE eE RERE EAE Er EN dese net bie ER EEN EnA irai 1 5 8 AR Ee Le Leg ie E 1 5 8 2 Self diagnostic codes 0 cccececcseeseseecceceeeececeeeeeeseeceeceeeeseeeaesessceeeeeeeseeseaeseeseceeeeeeeesesaeessseeeeeeeeessaeaaas 1 5 8 1 5 3 un Le Eed deier nt EEN 1 5 13 1 No image appears entirely white 1 5 13 2 No image appears entirely black 1 5 13 3 image IS TOO MOMS E 1 5 13 4 Background is 1S le E 1 5 13
5. Diversion mirror Figure 2 1 12 Laser scanner unit Laser e E Emits diffused visible laser 2 Cylindrical lens Compensates the vertical angle at which the laser beam hits a polygon mirror segment 3 Polygon mirror motor Has six mirror segments around its hexagonal circumference each mirror corresponding to one scanned line width on the drum when laser beam scans on it 4 F theta lens The f theta lens equalizes focusing distortion on the far ends of the drum Sensor mirror T uuu aa sssssasssakasas Bends the very first shot of a laser scan towards the beam detection sensor 6 6 Pin photo sensor T When shone by the sensor mirror above this photo sensor generates a trigger signal for the engine controller to start activating the paper feeding system 2 1 12 2DC 3 2 Drum surface potential The laser beam is continually switched on and off depending on the print data It is on for a black exposed dot and off for a white blank dot Since the drum surface is evenly charged whenever it is illuminated by the laser beam the electrical resistance of the photoconductor is reduced and the potential on the photoconductor is also lowered Resulted on the drum surface is an electrostatic image which represen
6. A CAUTION e Wear safe clothing If wearing loose clothing or accessories such as ties make sure they are A safely secured so they will not be caught in rotating sections e Use utmost caution when working on a powered machine Keep away from chains and belts SN e Handle the fixing section with care to avoid burns as it can be extremely hot A N abnormally high ln Q e Check that the fixing unit thermistor heat and press rollers are clean Dirt on them can cause e Do not remove the ozone filter if any from the copier except for routine replacement S e Do not pull on the AC power cord or connector wires on high voltage components when removing S them always hold the plug WSOM E Do not route the power cable where it may be stood on or trapped If necessary protect it with a S cable cover or other appropriate item E e Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks Q e Remove toner completely from electronic components A e Run wire harnesses carefully so that wires will not be trapped or damaged e After maintenance always check that all the parts screws connectors and wires that were connector trapped wire and missing Ee removed h
7. 3 Remove the heat roller See page 1 6 22 4 Remove the two screws 5 Remove the thermal cutout Figure 1 6 27 Removing the thermal cutout 1 6 25 2DC 6 Removing the press roller WARNING e The press roller is extremely hot immediately after the copier was running Allow substantial period of time until it cools down 1 Remove and split the fuser unit See page 1 6 18 2 Remove the press roller from the fuser unit Press roller Figure 1 6 28 Removing the press roller 1 6 26 2DC 1 6 10 Removing the scanner unit 1 Remove the right and left cover See page 1 6 4 2 Remove the five connectors and two flexible flat cables from the scanner board 3 Remove the five screws and then remove the scanner board Screw Scanner board GI CO Ef ge FRR gt 7 Flexible flat cables Figure 1 6 29 Removing the scanner PWB 1 6 27 2DC 4 Remove the two screws 5 Slide the scanner unit and then remove the scanner unit Figure 1 6 30 Removing the scanner unit 1 6 28 2DC 1 6 11 Removing the laser scanner unit and the eraser lamp 1 Remove the scanner unit See page 1 6 27 2 Remove each two screws and then remove two grounding plates 3 Remove each two screws and then remove the right and left scanner stays Screws Screws Left scanner stay Right scanner stay x m Figure 1 6 31 Removing the right and left stays Screw
8. 1 4 14 2DC Maintenance Description item No P Setting the exposure density gradient Description Changes the exposure density gradient in manual density mode depending on respective image modes text text and photo photo Purpose To set how the image density is altered by a change of one step in the manual density adjustment Also used to make copy image darker or lighter Start 1 Press the start key A selection item appears 2 Select the image mode to be adjusted by lighting image mode LEDs using the image mode selection key 3 Press the start key The machine enters the setting mode O Auto Exp Density in text mode O A T 4ml Text amp Photo O f Photo drot O auto Exp Density in text and photo mode O AT 4ml Text amp Photo 4a Photo T Text O auto Exp Density in photo mode 4T 4ql Text amp Photo 4m Photo 41 Text o Off e On Setting 1 Select the item to be adjusted by lighting a copy exposure indicator using the copy exposure adjustment keys 2 Adjust the setting using the zoom keys Copy exposure Er DS l indicator Description Setting range Initial setting Exp 1 Change in density when manual density is set dark 0 to 3 Exp 2 Change in density when manual density is set light O to 3 Increasing the setting makes the change in density larger and decreasing it makes the change smaller Image density Setting 3 Setting 0 Dark x x Set
9. Description Switches the operations and screens of the machine according to the destination Purpose To return the destination setting to its default setting after initializing the backup RAM by running maintenance item U020 Method Press the start key Setting 1 Select the destination using the zoom keys Inch North America specifications Metric Europe specifications Metric Asia Pacific specifications 2 Press the start key The setting is set and the machine automatically returns to the same status as when the power is turned on Completion To exit this maintenance item without changing the current count press the stop clear key The indication for selecting a maintenance item No appears 1 4 21 2DC Maintenance Description item No Turning auto start function on off Description Selects if the auto start function is turned on Purpose Normally no change is necessary If incorrect operation occurs turn the function off this may solve the problem Method Press the start key Setting 1 Select either on or oFF using the zoom keys on Auto start function on oFF Auto start function off Initial setting on 2 Press the start key The setting is set and the indication for selecting a maintenance item No appears Completion To exit this maintenance item without changing the current setting press the stop clear key The indication for selecting a maintenance item No appe
10. See page 1 5 15 See page 1 5 16 See page 1 5 16 See page 1 5 16 9 Black dots appear on 10 Image is blurred 11 The leading edge of the 12 Paper creases the image image is consistently misaligned with the original See page 1 5 17 See page 1 5 17 See page 1 5 17 See page 1 5 18 13 Offset occurs 14 Image is partly missing 15 Fixing is poor 16 Image center does not align with the original center See page 1 5 18 See page 1 5 18 See page 1 5 19 See page 1 5 19 1 5 13 2DC 1 No image appears Causes entirely white 1 No transfer charging Causes Check procedures corrective measures 1 No transfer charging A The connector terminals of the high voltage Reinsert the connector Also check for continuity within the board make poor contact connector cable If none remedy or replace the cable B Defective engine board KP 5061 Replace the engine board KP 5061 and check for correct operation C Defective high voltage board Replace the high voltage board and check for correct operation 2 No image appears Causes entirely black 1 No main charging 2 Exposure lamp fails to light Causes Check procedures corrective measures No main charging Replace the process unit Replace the process unit The connector terminals of the high voltage Reinsert the connector Also check for continuity within the board make poor contact connector cable If none remedy or replace the cable Replace th
11. 1 4 5 2DC Maintenance D DOE item No ada ceed Initializing all data Description Initializes all the backup RAM on the main board to return to the original settings U004 however is not initialized Purpose Run as needed Method 1 Press the start key 2 Select on using the zoom keys Canceling initialization Executing initialization 3 Press the start key All data in the backup RAM is initialized and the original settings for EUROPE specifications are set When initialization is complete the machine automatically returns to the same status as when the main switch is turned on Completion To exit this maintenance item without executing initialization press the stop clear key The indication for selecting a maintenance item No appears Initializing memories Description Initializes the setting data other than that for adjustments due to variations between respective machines i e settings for counters service call history and mode settings As a result initializes the backup RAM according to the specifications depending on the destination selected in U252 U004 however is not initialized Purpose Used to return the machine settings to the factory settings Method 1 Press the start key 2 Select on using the zoom keys Canceling initialization on Executing initialization 3 Press the start key All data other than that for adjustments due to variations between m
12. 6 Remove the scanner belt from the belt hook of scanner unit 7 Remove the ISU unit from the scanner shaft Remove the ISU unit taking care not to lose the M4 nut located in the ISU unit Scanner unit Belt hoo Scanner belt Flexible flat cable ISU unit Figure 1 6 38 Removing the ISU unit 1 6 33 2DC 1 6 13 Removing the exposure lamp 1 Remove the ISU unit See page 1 6 32 2 Remove the two connectors from the inverter board 3 Remove the one screw and then remove the inverter board ISU unit Inverter board Connectors e Figure 1 6 39 Removing the inverter board 4 While unhooking the hook and then slide the exposure lamp mount Exposure lamp mount ISU unit Figure 1 6 40 Removing the exposure lamp mount 1 6 34 2DC 5 Remove the exposure lamp and cables from the exposure lamp mount e Do not touch the glass surfaces of the exposure lamp with bare hands Exposure lamp a Exposure lamp mount Cables Figure 1 6 41 Removing the exposure lamp 1 6 35 2DC 1 6 14 Removing the scanner mirror A 1 Remove the ISU unit See page 1 6 32 2 Remove the exposure lamp See page 1 6 34 3 Unhook the two mirror A holders and then Mirror A holder remove the scanner mirror A Figure 1 6 42 Removing the scanner mirror A 1 6 36 1 6 15 Removing the scanner motor 1 Remove the original holder cover See page 1 6 32 2 Remove the left cover See page 1 6
13. Sets or cancels the restriction on the number of sheets to be ejected continuously When the restriction is set the number of sheets that can be ejected continuously to the internal eject tray will be limited to 100 Purpose According to user request sets or cancels restriction on the number of sheets Method Press the start key Setting 1 Select on or oFF using the zoom keys Display Description on The number of sheets restricted oFF The number of sheets not restricted Initial setting on 2 Press the start key The setting is set The indication for selecting a maintenance item No appears Completion To exit this maintenance item without changing the current setting press the stop clear key The indication for selecting a maintenance item No appears 2DC Maintenance Description item No P Adjusting margins of image printing Adjustment See page 1 6 43 Adjusting margins for scanning an original on the contact glass Adjustment See page 1 6 49 Adjusting margins for scanning an original from the DP Adjustment See page 1 6 54 Checking clearing copy counts by paper feed locations Description Displays or clears copy counts by paper feed locations Purpose To check the time to replace consumable parts Also to clear the counts after replacing the consumable parts Method 1 Press the start key 2 Select the paper feed location group No for which the coun
14. Checking motor operation SSS feed and paper Uost Checking sensors forpaperconveying 2 coweying ups Checking clutchoperaton l o oyo U034 Adjusting the print start timing e Adjusting the leading edge registration e Adjusting the center line C U051 Adjusting the amount of slack in the paper e Drawer e Bypass tray e Optional drawer Optical U060 Adjusting the scanner input properties U063 Adjusting the shadingposition sss Adjusting the shadingposition sss shading position U065 Adjusting the scanner magnification e Main scanning direction e auxiliary Scanning direction U066 Adjusting the leading edge registration for scanning an original on the contact glass U067 Adjusting the center line for scanning an original on the contact glass U070 Adjusting the DP magnification 071 Adjusting the DP scanning timing e Adjusting leading edge registration Adjusting trailing edge registration 072 Adjusting the DP center line 073 Checking scanner operation 074 Adjusting the DP input light luminosity Turning the DP scanning position adjust mode on off e Setting the mode on off e Setting the reference data for identifying dust 088 Serine the input filter moir reduction mode e Text text and photo photo mode Setting the main high voltage Setting the other high voltages e Developing bias clock frequency e Developing bias clock duty e Transfer charging output OFF ti
15. Off e On Flashing Figure 1 4 1 1 4 13 2DC Maintenance Description item No a When scanning is performed before shading the scan value at the machine center should be slightly different from those at the machine front and rear When scanning is performed after shading there should be no difference between respective values Any differences between the values at machine front and rear indicates that scanner problem causes the fixing unevenness If the displayed results indicate no shading problems the fixing unevenness uneven copy density is caused by factors other than in the scanner section shading or CCD If a black line appears the cause may be assumed based on the results of the scanning operation before shading if a white line appears they may be assumed based on the results of the scanning operation after shading Note that depending on the thickness and location of the black or white line it may not be possible to use this method to determine the cause This is because the displayed values obtained from scanning at the limit of nine points are insufficient to provide significant information 5 Press the stop clear key The selected item appears Completion Press the stop clear key while a selection item is displayed The indication for selecting a maintenance item No appears Adjusting the scanner automatically Description Makes auto scanner adjustments in the order below using the specified original
16. The scanner board consists of scanner driver circuit Q1 to Q5 and exposure lamp driver circuit U1 relays signals from engine board main board operation board CCD board and optional document processor Scanner board MOTA rn ISUMOTA MOTNA Driver _ ISUMOTNA Scanner circuit ISUMOTB motor U1 ISUMOTNB CCD board Engine nai Exposure lamp Exposure lamp driver Inverter circuit board Q1 2 3 4 5 Scanner HK position switch LAMP LAMPHI LAMPLOW Main board Operation ee eg eng F e Figure 2 3 13 Scanner board circuit block diagram 2 3 14 2DC SEN Seel SW QOL I SW 06 SU GL Jaded Adoo uj L L X 2 18 HvW JO sl99us OM Oluo jeUIBLIO LL x 2 18 Hpy ue Jo BulAdod snonulju04y SW 0LL H SW QOL SW 9 I su 9 SW QOL SW 18 SW 9 SW 06 SW QOL FLA 6 LOA L ZOA Z 80A 9L ZOA ZVLOA OL LOA 8 80A Z 90A L VOA Diet G 80A 6 VOA FELL v OLOA v EOA 2 4 1 TASIAH c dSd L Gd cIQAH1 dCGAHIH NH3SVH3 N1IX3 LISSY NHOCO NHGC33 XM TOAH ddAHW NYOLOW GNLOW BLOW VNLOW VLOW NMSdH ONASAO L ON Heyo Huru 2DC SW OO l C O VI LOA SW QOL SW Ol 6 LOA LL ZOA hh CHA SW QOL SW ZG SW QOL sw 9 9 Z9A cY LOA 0L ZOA 8 894 C 9OA L VOA veel LLIA G 89A 6 VOA SU GZ L Vee LOK
17. printing ratio Executes toner loading operation between sheets of paper every time Initial setting 0 2 Press the start key The value is set Completion Press the stop clear key The indication for selecting a maintenance item No appears U157 Checking clearing the developing drive time Description Displays the developing drive time for checking clearing or changing a figure Purpose To check the developing drive time Method 1 Press the start key 2 Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys Copy exposure indicator Setting range Initial setting Exp 1 First 3 digits 000 to 999 min 000 Exp 2 Last 3 digits 000 to 999 min 000 Exp 3 Clearing the drive time Clearing 1 Light exp 3 2 Press the start key The time is cleared and the indication for selecting a maintenance item No appears Setting 1 Change the drive time in minutes using the zoom keys 2 Press the start key The time is set and the indication for selecting a maintenance item No appears Completion To exit this maintenance item without changing the time press the stop clear key The indication for selecting a maintenance item No appears 14 47 2DC Maintenance Description item No Checking clearing the developing count Description Displays the developing count for checking clearing or changing a figure Purpose To check the developing count Method 1
18. seal it in the protective bag and place it on flat surface Do not place the process unit in a dusty area e Do not give impact to the process unit e Do not place floppy disks near the process unit 1 6 2 2DC 1 6 3 Removing the principal outer covers 1 Removing the front top cover face down output tray 1 Remove the one screw and then remove the memory cover 2 Remove the one screw and then remove the rear cover ae Rear cover Memory cover b Screw Figure 1 6 2 Removing the memory cover and rear cover 3 While unlatching the two latches and then remove the front top cover face down output tray front top cover lt Itace down Ee output tray d Front top cover face down output tray Figure 1 6 3 Removing the front top cover face down output tray 1 6 3 2DC 2 Removing the right cover 1 Remove the front top cover face down output tray See page1 6 3 2 Remove the memory cover See page 1 6 3 3 Unlatch the snaps and hook remove the right cover e Snap Hook x inside cover Right cover Figure 1 6 4 Removing the right cover 3 Removing the left cover 1 Remove the front top cover face down output tray See page1 6 3 2 Unlatch the snaps and hooks remove the left cover Left cover Left cover Figure 1 6 5 Removing the left cover 1 6 4 2DC 1 6 4 Removing the feed roller CAUTION When refit the feed roller fit t
19. 1 6 14 2DC 6 Remove the engine board See page 1 6 9 7 Remove wires from wire saddles on the cord cover 8 Remove one screw 9 Remove the cord cover Screw MY 9 N 6 7 se ie Le NZ BE SS Cord cover Figure 1 6 17 Removing the cord cover 1 6 15 2DC 10 Remove the main board See page 1 6 10 11 Remove one screw and then remove the grounding plate 12 Remove one screw and then remove the feed clutch 13 Remove three stop rings 14 Remove MP feed clutch gear feed clutch gear and registration clutch gear MP feed clutch gear Grounding Stop ring plate we Ba S Screw SS Registration clutch gear Stop ring Feed clutch Figure 1 6 18 Removing the clutches 1 6 16 2DC 15 Remove the four screws 16 Remove the drive unit Figure 1 6 19 Removing the drive unit 1 6 17 2DC 1 6 9 Removing and splitting the fuser unit WARNING e The fuser unit is hot after the copier was running Wait until it cools down CAUTION e When refitting the fuser unit make sure the fuser unit gear and the copier s drive gear are properly meshed with each other For this rotate the main motor several turns before fixing screws 1 Remove the rear cover See page 1 6 3 2 Remove the right and left cover See page 1 6 4 3 Remove the two connectors 4 Remove two screws 5 Remove the fuser unit i S g Screws Connectors Fuser unit Screws Ba
20. 32 to exit maintenance mode Initial setting 0 Changing the value by 1 moves the copy image by 0 254 mm Is the image correct Figure 1 6 61 Copy example 2 1 6 51 2DC 12 Adjusting the DP trailing edge registration Perform the following adjustment if the original scanning end position is not correct when the DP is used Caution If the copy image looks like copy example 2 clean the DP original scanning section Procedure Enter maintenance mode Enter 071 using the copy exposure adjustment keys or zoom keys Original Copy Copy example 1 example 2 Press the start key Figure 1 6 62 Select Exp 2 DP trailing edge registration using the copy exposure adjustment keys Press the program key and the Press the start key machine enters the test copy mode The new setting is stored Place an original on the DP and make a test copy I e For copy example 1 decrease the value using the zoom key e For copy example 2 Ves increase the value using the zoom key Press the stop reset key Setting range 42 32 to exit maintenance mode Initial setting 0 Changing the value by 1 moves the copy image by 0 254 mm Is the image correct End 1 6 52 2DC 13 Adjusting the DP center line Perform the following adjustment if there is a regular error between the centers of the original and the copy image U034 U067 A x 2 Caution Befor
21. A VTC PG pattern is output Completion Press the stop clear key The indication for selecting a maintenance item No appears e Checking the fixing performance fixing pressure 1 4 30 2DC 1 5 1 Paper misfeed detection 1 Paper misfeed indication When a paper misfeed occurs the copier immediately stops copying and displays the jam location on the operation panel Paper misfeed counts sorted by the detection condition can be checked in maintenance item U903 To remove paper jammed in the copier open the face up output tray front top cover front cover or pull the drawer out To remove original jammed in the DP open the DP original cover Paper misfeed detection can be reset by opening and closing the respective covers to turn interlock switch off and on Figure 1 5 1 1 Misfeed in the paper feed section 2 Misfeed in the paper conveying section fixing section or the exit section 3 Misfeed in the DP 4 Misfeed in the optional drawer 1 5 1 2DC 2 Paper misfeed detection conditions 1 5 2 Figure 1 5 2 a w N ki Registration sensor 2DC Section Jamcode Description Conditiins System 00 No paper feed When the main switch is turned on the machine detects acti vation of the registration sensor or the exit sensor 04 Cover open JAM A cover open state is detected during copying 0 5 Secondary paper feed When the machine w
22. Figure 1 6 60 Press the start key The new setting is stored Change the setting e For copy example 1 increase the value using the zoom key to make the copy image longer e For copy example 2 decrease the value using the zoom keys to make the copy image shorter Setting range 25 25 Initial setting 0 Changing the value by 1 changes the magnification by 0 1 Increase the value makes the image longer and decreasing it make the image shorter 11 Adjusting the DP leading edge registration 2DC Perform the following adjustment if there is a regular error between the leading edge of the original and the copy image U034 U066 Caution Before making the following adjustment ensure that the above adjustments have been made in maintenance mode Procedure Start Enter maintenance mode Enter 071 using the copy exposure adjustment keys or zoom keys Original Copy example 1 Press the start key Select Exp 1 DP leading edge registration using the copy exposure adjustment keys Press the program key and the machine enters the test copy mode Press the start key The new setting is stored Place an original on the DF and make a test copy e For copy example 1 decrease the value using the zoom key e For copy example 2 increase the value using Yes the zoom key Press the stop clear key Setting range 32
23. Paper feeding mechanism Driving power train A For process unit drum From main unit For process unit toner container developing roller etc From main unit From process unit drum To transfer roller 1 Main motor gear 2 Registration clutch 3 MP feed clutch 4 Feed clutch 5 MP feed roller 6 Feed roller 7 Registration gear Z13 Registration gear Z20 9 Gear 53 Lower registration roller 1 Upper registration roller 2 Transfer roller 3 TC gear Z18 Press roller 45 Heat roller Heat gear Z33 7 Lower exit roller Exit gear Z23 Upper exit roller GO Exit gear Z23 UP GO Gear 21 2 Gear 95 21 3 Gear 36 21 GA Gear 24 65 Gear 21 Gei Gear 48 21 Figure 2 1 3 Paper feeding mechanism 2DC 2 1 2 Original scanning system The scanner unit consists of the image scanning unit ISU for main direction scanning and drive part for traveling the ISU unit to sub direction a a sss IVID Figure 2 1 4 Scanner unit 1 Original holder 2 Scanner upper frame 3 Scanner lower frame 4 Contact glass 5 DP Contact glass 6 Scanner rail 7 Scanner motor Mount Tension pulley mount 9 Scanner belt Scanner motor 1 Tension pulley 2 Scanner gear 45 18 3 Scanner gear 39 22 Scanner shaft 45 ISU housing CCD image sensor 7 Exposure lamp Exposure lamp mount CCD board Go ISU lens Mirror A 2 Mirror B 3 M
24. Press the stop clear key when operation stops The indication for selecting a maintenance item No appears Checking the operation of the DP motors Description Turns the motors in the DP on Purpose To check the operation of the DP motors Method 1 Press the start key 2 Select the motor to be operated using the copy exposure adjustment keys 3 Press the start key The operation starts Indication copy exposure indicator F 0 exp 1 Drives the original feed system C 0 exp 2 Drives the original conveying system 1 4 20 2DC Maintenance Description item No H Checking the DP switches Description Displays the status of the switches in the DP Purpose To check if switches in the DP operate correctly Method 1 Press the start key S appears 2 Manually turn on and off each switch to check the status When the on status of a switch is detected the image mode LED corresponding to the operated switch lights Q Auto Exp DP original detection switch O T 4ml Text amp Photo O 4m Photo O TlText O Auto Exp DP timing switch T Text amp Photo O Ag Photo O 4T Text O Auto Exp DP open close switch O AT 4ml Text amp Photo 4m Photo O T Text O Auto Exp DP original cover switch O AT 4ml Text amp Photo O 4m Photo Tl Text o Off e On Completion Press the stop clear key The indication for selecting a maintenance item No appears Setting the destination
25. Text O auto Exp 4T 4al Text amp Photo O Am Photo O T Text o Off e On Completion Press the stop clear key The indication for selecting a maintenance item No appears Registration sensor 1 4 7 2DC Maintenance Description item No H Checking clutch operation Description Turns each clutch on Purpose To check the operation of each clutch Method 1 Press the start key A selection item appears 2 Select the clutch to be operated using the copy exposure adjustment keys 3 Press the start key The selected clutch turns on for 1 s P1 Feed clutch Pb MP feed clutch 2F Registration clutch Completion Press the stop clear key The indication for selecting a maintenance item No appears Adjusting the print start timing Adjustment See pages 1 6 41 and 42 Adjusting the amount of slack in the paper Adjustment See page 1 6 44 Adjusting the scanner input properties Description Adjusts the image scanning density Purpose Used when the entire image appears too dark or light Method Press the start key Setting 1 Change the setting using the zoom keys Setting range Initial setting image scanning density 010 23 Increasing the setting makes the density lower and decreasing it makes the density higher 2 Press the start key The value is set Test copy mode While this maintenance item is being performed copying from an original can be made in test copy mode Completion Press
26. To check the developing bias clock and the transfer charging output timing Do not change the preset value Method Press the start key The screen for selecting an item is displayed Setting 1 Select the item to be set by lighting a copy exposure indicator using the copy exposure adjustment keys 2 Change the setting using the zoom keys Copy exposure SC Di i indicator Description Setting range Initial setting Exp 1 lit Developing bias clock frequency 2 to 255 26 Exp 2 lit Developing bias clock duty 1 to 99 Exp 3 lit Transfer charging output OFF timing 0 to 255 Exp 1 flashing Transfer charging output ON timing 0 to 255 3 Press the start key The value is set Completion Press the stop clear key while a selection item is displayed The indication for selecting a maintenance item No appears 1 4 16 2DC Maintenance item No Setting toner loading operation Description Sets toner loading operation Purpose To run when drum filming background blur in paper edge section occurs Change the setting value to 3 when poor quality paper is used and filming occurs frequently Method Press the start key The screen for selecting an item is displayed Setting 1 Change the setting using the zoom keys 0 1 2 3 Description Toner not loaded Executes toner loading operation before starting driving based on the printing ratio Executes toner loading operation between sheets of paper based on the
27. V OLOA SIT OTT IT sw zez SU 8S T sw G 8 V COA saded Adod 2 8X 2 1G HSV JO s199uS OM O UO IEUIDUO 2 8X 2 G HSV ue Jo BulAdoo snonunuog Z ON meya Buluu L TASIAH c dSd L 1d4Sd cIQAH1 cIQAHl1d Ndd3SVd3 N1IX3 REEL NHOCO NHGC33 XM TOAH ddAHW NYOLOW 8N1ON ALON VNLOW VLOW NMSdH ONASAO 2DC SW QOL VI LOA 6 LOA LL ZOA CHA SW QOL 9L ZOA c YLOA OL ZOA 8 894 CHA L VOA Z OA A sui 9Z suu 068 G 89A 6 VOA SW L V EZ L LLDA Su OTT b OLDA Su 9LL SW G C SW 899p V EOA 2 4 3 TASIAH 1dSd L Gd ddAHL ddAHLd NH3SVH3 N1IX3 LISSY NO NHGC33 XM TOAH ddAHW NYOLOW ANLOW BLOW VNLOW VLOW NMSdH ONASAO Jaded Adoo ysg JO Sjaays OM Oluo jeUIBIIO yog Ue Jo HulAdod snonunuog ON meyo Hulwiy 2DC Wiring diagram AB EG JL To optional document feeder
28. ZA symbol indicates a warning including danger and caution The specific point of attention is shown inside the symbol A General warning AN Warning of risk of electric shock A Warning of high temperature indicates a prohibited action The specific prohibition is shown inside the symbol General prohibited action OO 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 1 Installation Precautions AA WARNING e 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 check that it is adequate for the rated current a e Connect the ground wire to a suitable grounding point Not grounding the copier may cause fire or electric shock Connecting the earth wire to an object not approved for the purpose may cause explosion 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 the proper ALLA E AXCAUTION S e Do not place the copier on an infirm or angled surface the copier may tip over causing injury e Do not install the copier i
29. _ GE 5V 5V A10 B10 A10 B10 NI N 24V1 o gt 24V1 13 13 SW1 SGND 5V A11 B11 A11 B11 AC inlet SGND 14 14 SGND SGND A12 B12 A12 B12 SGND 15 15 pp BE GH l Jj dj KYOCERA MITA EUROPE B V Hoeksteen 40 2132 MS Hoofddorp The Netherlands Phone 31 0 20 654 000 Home page http www kyoceramita europe com Email info kyoceramita europe com KYOCERA MITA NEDERLAND B V Hoeksteen 40 2132 MS Hoofddorp The Netherlands Phone 31 0 20 587 7200 KYOCERA MITA UK LTD 8 Beacontree Plaza Gillette Way Reading Berks RG2 OBS UK Phone 44 0 118 931 1500 KYOCERA MITA ITALIA S P A Via Verdi 89 91 20063 Cernusco sul Naviglio Italy Phone 39 02 921 79 1 S A KYOCERA MITA BELGIUM N V Hermesstraat 8A 1930 Zaventem Belgium Phone 32 0 2 720 9270 KYOCERA MITA FRANCE S A Parc Les Algorlthmes Saint Aubin 91194 GIF SUR YVETTE France Phone 33 0 1 6985 2600 KYOCERA MITA ESPANA S A Edificio Kyocera Avda de Manacor N 2 Urb Parque Rozas 28290 Las Rozas Madrid Spain Phone 34 0 91 631 8392 KYOCERA MITA FINLAND OY Kirvesmiehenkatu 4 00810 Helsinki Finland Phone 358 0 9 4780 5200 KYOCERA MITA SCHWEIZ AG Holzliwisen Industriestrasse 28 8604 Volketswil Switzerland Phone 41 0 1 908 4949 KYOCERA MITA DEUTSCHLAND GMBH Mollsfeld 12 D 40670 Meerbusch Germany Phone 49 0 2159 918 0 KYOCERA MITA GMBH AUSTRIA Eduard Kittenberger Gasse 95 1230 Wien
30. adjustment if the magnification in the auxiliary scanning direction is not correct U065 U065 main scanning auxiliary scanning 070 direction P 1 6 45 direction P 1 6 50 Caution Before making the following adjustment ensure that the above adjustments have been made in maintenance mode Enter maintenance mode Procedure Enter 065 using the copy exposure Original Copy Ga adjustment keys or zoom keys example 1 example 2 Figure 1 6 56 Press the start key Select Exp 2 auxiliary scanning direction using the copy exposure adjustment keys Press the program key and the machine enters the test copy mode Place an original and press the start key to make a test copy Press the start key The new setting is stored For copy example 1 increase the value using the zoom key Is the image correct For copy example 2 decrease the value using the zoom key Setting range 25 25 Initial setting 0 Press the stop clear key to Changing the value by 1 changes exit maintenance mode the magnification by 0 1 Increasing the value makes the image longer and decreasing it End make the image shorter 1 6 46 2DC 7 Adjusting the scanner leading edge registration Perform the following adjustment if there is regular error between the leading edges of the copy image and original U034 U071 P 1 6 41 2988 P 1 6 51 Caution Before making the following ad
31. contact in the operation board connector terminals Defective external temperature ther mistor Poor contact in the operation board connector terminals Defective external temperature ther mistor Defective waste toner sensor Defective engine board KP 5061 Defective waste toner sensor Defective engine board KP 5061 Causes Check procedures corrective measures Reinsert the connector Also check for con tinuity within the connector cable If none remedy or replace the cable Replace the operation board and check for correct operation Reinsert the connector Also check for con tinuity within the connector cable If none remedy or replace the cable Replace the operation board and check for correct operation Replace the waste toner sensor and check for correct operation Replace the engine board KP 5061 and check for correct operation Replace the waste toner sensor and check for correct operation Replace the engine board KP 5061 and check for correct operation 2DC 1 5 3 Image formation problems 1 No image appears 2 No image appears 3 Image is too light 4 Background is visible entirely white entirely black See page 1 5 14 See page 1 5 14 See page 1 5 15 See page 1 5 15 5 A white line appears 6 A black line appears 7 A black line appears 8 One side of the copy longitudinally longitudinally laterally image is darker than the other
32. feed clutch does not operate cccccccsssesecceeceeesseceeeecceeeeeeeecsaeaeeeeeessaeeeeeeeesseasseeeeessaaaeeeeees 1 5 20 6 The MP feed clutch does not operate cccccccccecesesseeeeeeceeeseeceeeseeaeeeeeeeeseueeseeeeesseasseeeeeessaeeeeees 1 5 21 7 The registration Clutch does not operate a 1 5 21 2DC 8 The eraser lamp does not turn on EE 1 5 21 9 The exposure lamp does not turn On BEE 1 5 21 10 The exposure lamp does not turn off r 1 5 21 11 The heater lamp does not turn On ERE E REESE REEKS ERNE ERR E RES 1 5 21 12 The heater lamp does not turn off a aaa geed 1 5 21 13 Main charging is not ee E 1 5 22 14 Transfer charging is not performed r 1 5 22 15 A paper jam in the paper feed or exit section is indicated when the main switch is turned on EE 1 5 22 16 The message requesting covers to be closed is displayed when the front cover is closed DE 1 5 22 bag 1 5 22 1 5 5 Mechanical problems LLULLU ERE Es ANE EAA RENE 1 5 23 1 No primary paper TS ME 1 5 23 2 No secondary paper feed seed ee 1 5 23 3 Skewed paper TEC DEE 1 5 23 4 The scanner does not travel a
33. florin to prevent toner from accumulating on the roller after a long run Care must be taken while handling the heat roller not to scratch the roller surface as doing so may result in print problems The heat roller has four claws which are continuously in contact with its surface These claws prevent the paper on which toner has been fused from being wound around the heat roller causing paper jam The pressure roller is made of the heat resistant silicon rubber This roller is used to strongly press the paper towards the heat roller by means of coil springs The temperature of the heat roller is constantly monitored by the engine board using the thermistor and triac Should the temperature of the heat roller exceed the predetermined value the thermal cutout is activated to effectively disconnect the heater halogen lamp from power 2 1 16 6 1 Fuser unit mechanism 2DC Figure 2 1 17 Fuser unit mechanism 1 Heat roller 2 Idle gear Z34 3 Exit gear Z23 4 Idle gear Z18 5 Heat gear Z33 6 Press roller 7 Heater lamp Thermal cutout 9 Separator s Thermistor 1 Exit pulley s 2 Lower exit roller 2 1 17 2DC 7 Cleaning After the transferring process the drum needs to be physically cleaned of toner which is residual after the development process The cleaning blade A is constantly pressed against the drum B and scrapes the residual toner off to the sweep roller The waste toner is collected at the o
34. margin 3 2 5 mm Ejection direction A o reference Scanner sie Scanner left margin right margin 3 2 5 mm 3 2 5 mm Scanner trailing edge margin 3 2 5 mm Figure 1 6 59 Press the start key The new setting is stored Change the setting Increasing the value using the zoom key makes the margin wider Decreasing the value using the zoom key makes the margin narrower Setting range initial setting change in value per step Scanner left margin 0 10 2 0 0 5 mm Scanner leading edge margin 0 10 3 0 0 5 mm Scanner right margin 0 10 2 0 0 5 mm Scanner trailing edge margin 0 10 2 0 0 5 mm 1 6 49 2DC 10 Adjusting the DP magnification Adjust magnification in the auxiliary scanning direction if magnification is incorrect when the DP is used U065 7 P 6 46 Caution Before making the following adjustment ensure that the above adjustments have been made in maintenance mode Procedure Enter maintenance mode Enter 070 using the copy exposure adjustment keys or zoom keys Press the start key Press the program key and the machine enters the test copy mode Place an original on the DP and make a test copy Is the image correct We Press the stop clear key to exit maintenance mode 1 6 50 Main scanning direction Auxiliary scanning direction Original Copy Copy example 1 example 2
35. the connector Also check for continuity within the con nector cable If none remedy or replace the cable Check visually and replace the main motor if necessary Run maintenance item U030 and check if the main motor oper ates and replace the main motor if necessary Run maintenance item U030 and check if YC4 9 on the engine board KP 5061 go low If not replace the engine board KP 5061 Check for continuity across the coil If none replace the scanner motor Reinsert the connector Also check for continuity within the con nector cable If none remedy or replace the cable Check for continuity across the coil If none replace Cooling fan Reinsert the connector Also check for continuity within the con nector cable If none remedy or replace the cable Check for continuity across the coil If none replace the feed clutch Reinsert the connector Also check for continuity within the con nector cable If none remedy or replace the cable Run maintenance item U032 and check if YC4 1 on the engine board KP 5061 goes low If not replace the engine board KP 5061 2DC Problem Causes Check procedures corrective measures Check for continuity across the coil If none replace the MP feed 6 The MP feed clutch does not operate 7 The registration clutch does not op erate 8 The eraser lamp does not turn on 9 The exposure lamp does not turn on 10 The exposure lamp does not
36. the stop clear key The indication for selecting a maintenance item No appears i 4 12 2DC Maintenance Description item No P Checking shading Description Performs scanning under the same conditions as before and after shading is performed displaying the original scanning values at nine points of the contact glass Purpose To check the change in original scanning values before and after shading The results may be used to decide the causes for fixing unevenness uneven density of the gray area of an image either due to optical shading or CCD or other problems Also to check the causes for a white or black line appearing longitudinally Method 1 Press the start key A selection item appears 2 Select the item to be operated using the zoom keys on Performs scanning before shading and displays the result oFF Performs scanning after shading and displays the result 3 Press the start key Scanning is performed under the selected conditions and the result is displayed 4 Change the measurement point by lighting a copy exposure indicator or making one flash using the copy exposure adjustment keys For the correspondence between the measurement points and the copy exposure indicators see Figure 1 4 1 100 mm from the machine center toward machine rear Machine center 100 mm from the machine center toward machine front 200 mm from the machine left 150 mm from machine left e O exp 1 exp 2 o
37. the stop clear key at the screen for selecting an item The indication for selecting a maintenance item No appears Caution The following settings are also reset to the initial values by performing this maintenance item e Exposure density gradient set in maintenance mode U093 e Exposure set in the copy default item of the copier management mode 1 4 8 2DC Maintenance Description item No P Adjusting the shading position Description Changes the shading position Purpose Used when white lines continue to appear longitudinally on the image after the shading plate is cleaned This is due to flaws or stains inside the shading plate To prevent this problem the shading position should be changed so that shading is possible without being affected by the flaws or stains Method 1 Press the start key 2 Change the setting using the zoom keys Setting range Initial setting Change in value per step Shading position 15 to 15 O 5 0 254 mm Increasing the setting moves the shading position toward the machine left and decreasing it moves the position toward the machine right 3 Press the start key The value is set Test copy mode While this maintenance item is being performed copying from an original can be made in test copy mode Completion Press the stop clear key at the screen for adjustment The indication for selecting a maintenance item No appears Adjusting the scanner magnification Adjustment Se
38. to DARKER Light i i Density adjustment Light Center x Dark c Density adjustment range Normal Density adjustment range Special area Figure 1 4 2 Exposure density gradient 3 Press the start key The value is set 4 Press the stop clear key The selected item appears Test copy mode While this maintenance item is being performed copying from an original can be made in test copy mode Completion Press the stop clear key while a selection item is displayed The indication for selecting a maintenance item No appears 1 4 15 2DC Maintenance Description item No Setting the main high voltage Description Performs main charging Purpose Checks the main charging Method 1 Press the start key A selection item appears 2 Select the item using the cpoy exposure adjustment keys on exp 1 Turning the main charger on on2 exp 2 Turning the main charger on and the laser scanner unit on and off 3 Press the start key The selected operation starts 4 To stop operation press the stop clear key Test copy mode While this maintenance item is being performed copying from an original can be made in test copy mode Completion Press the stop clear key when main charger output stops while a selection item is displayed The indication for selecting a maintenance item No appears Setting the other high voltages Description Changes the developing bias clock and the transfer charging output timing Purpose
39. unit For toner container developing roller etc From main unit For main unit Transfer roller For toner container Figure 2 1 8 Process unit mechanism 1 Main charger unit 3 DLP screw B 2 Charger wire DLP screw A 3 Grid 45 Drum 4 Developing roller Drum gear Z35H 5 Gear Z14 Z18 7 Drum shaft 6 Gear Z14 Z36 Drum gear Z36 7 Gear Z18 Z36 Sweep gear Z13 Free gear Z40 GO Idle gear 18H 9 Gear Z18 Z35H 1 Cleaning blade MAG gear Z24H 2 Sweep roller 1 Mixer gear Z20 B 3 Waste toner reservoir 2 Mixer gear Z20 A 2DC 2 Main charging 2 1 Photo conductive drum The durable layer of organic photoconductor OPC is coated over the aluminum cylinder base The OPC tend to reduce its own electrical conductance when exposed to light After a cyclic process of charging exposure and development the electrostatic image is constituted over the OPC layer Since the OPC is materialized by resin it is susceptible to damage caused by sharp edges such as a screwdriver etc resulting in a print quality problem Also finger prints can cause deterioration of the OPC layer therefore the drum in the process unit must be handled with care Substances like water alcohol organic solvent etc should be strictly avoided As with all other OPC drums the exposure to a strong light source for a prolonged period can cause a print quality problem The limit is approximately 500 lux for less than five minute
40. 1 5 17 2DC 12 Paper creases Causes 1 Paper curled 2 Paper damp 1 Paper curled Check the paper storage conditions 2 Paper damp Check the paper storage conditions 13 Offset occurs Causes 1 Defective cleaning blade 1 Defective cleaning blade Replace the process unit 14 Image is partly miss Causes ing 1 Paper damp 2 Paper creased 3 Flawed drum 1 Paper damp Check the paper storage conditions 2 Paper creased Replace the paper 3 Flawed drum Replace the process unit 1 5 18 2DC 15 Fixing is poor Causes 1 Wrong paper 2 Flawed press roller Causes Check procedures corrective measures 1 Wrong paper Check if the paper meets specifications 2 Flawed press roller Replace the press roller see page 1 6 26 16 Image center does not Causes align with the original 1 Misadjusted center line of image printing center 2 Misadjusted scanner center line 3 Original placed incorrectly 1 Misadjusted center line of image printing Readjust the center line of image printing see pages 1 6 42 2 Misadjusted scanner center line Readjust the scanner center line See page 1 6 48 3 Original placed incorrectly Place the original correctly 1 5 19 2DC 1 5 4 Electrical problems Problem Causes Check procedures corrective measures 1 The machine does not operate when the main switch is turned on 2 The main motor does not operat
41. 2 3 7 Operation board 2DC The operation board consists of key switches LEDs and 7 segment LED The lighting of LEDs is determined by scan signals SCANON to SCAN5N and LED lighting selection signals LEDON to LED7N from the main board The key switches operated are identified by the scan signals SCAN0N to SCANSN and the return signals KEYON to KEY2N As an example to light L1 the LED lighting selection signal LEDON should be driven low in synchronization with a low level on the scan signal SCANON LEDs can be lit dynamically by repeating such operations As another example if K2 is pressed the corresponding key switch is turned on feeding the low level of the scan signal SCAN1N back to the main board via the return signal KEYON The main board locates the position where the line outputting the scan signal and the line inputting the return signal cross and thereby determines which key switch was operated Operation board Main board Key switches KEY2N Ki1 K12 K13 K14 K15 KEY1N K6 K7 K8 l K9 K10 a YC1 16 xl wl wel ww we KEYON K1 K2 K3 K4 K5 vD1 w w yD4 wb GC ANN YC1 14 YC1 10 SCANON SCANON e LED7N LED6N 7 segment LED LED5N F IF 11 LIT LED4N LED3N LED2N LEDIN LEDON Figure 2 3 12 Operator board circuit block diagram 2 3 13 2DC 2 3 8 Scanner board
42. 4 3 Remove the one connector from the scanner board 4 Remove two screws and then remove two grounding plates 5 Loosen two screws and then release the tension of a scanner belt 6 Remove the scanner belt 2DC Je Ge FS Scanner board Connector Figure 1 6 43 Removing the scanner motor 1 e Screw Screw Grounding plates Figure 1 6 44 Removing the scanner motor 2 Scanner belt Figure 1 6 45 Removing the scanner motor 3 1 6 37 2DC 7 Remove three screws and then remove the grounding plate Screws ed K Grounding plate Figure 1 6 46 Removing the scanner motor 4 8 Remove the one stopper ring and then detach the scanner shaft Detach the shaft taking care to tilt it as little Stopper ring as possible mi Scanner shaft i Ko mt U SVIN Sati C 2 eS Figure 1 6 47 Removing the scanner motor 5 1 6 38 2DC 9 Remove the cable from the cable clamps 10 Remove the four screws and then remove the scanner motor mount with scanner motor Screws Cable clamps Figure 1 6 48 Removing the scanner motor 6 11 Remove the one screw and then remove the scanner motor Screw Scanner motor mount Figure 1 6 49 Removing the scanner motor 7 1 6 39 2DC 1 6 16 Removing the main charger unit 1 Remove the process unit from the copier See page 1 6 2 2 Unlatch the three snaps and rem
43. 5 2DC 6 A black line appears Causes longitudinally Dirty contact glass Dirty or flawed drum Deformed or worn cleaning blade Dirty scanner mirror Pe Do E 7 A black line ap Causes pears laterally 1 Flawed drum 2 Dirty developing section 3 Leaking main charger housing 8 One side of the Causes copy image is 1 Dirty main charger wire darker than the 2 Defective exposure lamp other 1 Dirty main charger wire Replace the process unit 2 Defective exposure lamp Check if the exposure lamp light is distributed evenly If not replace the exposure lamp see page 1 6 34 1 5 16 2DC 9 Black dots appear Causes on the image 1 Dirty or flawed drum 2 Dirty contact glass 3 Deformed or worn cleaning blade 10 Image is blurred Causes 1 Deformed press roller 2 Paper conveying section drive problem 1 Deformed press roller Replace the press roller see page 1 6 26 2 Paper conveying section drive problem Check the gears and belts and if necessary grease them 11 The leading edge of Causes the image is consist 1 Misadjusted leading edge registration ently misaligned with 2 Misadjusted scanner leading edge the original registration 1 Misadjusted leading edge registration Readjust the leading edge registration see pages 1 6 41 2 Misadjusted scanner leading edge Readjust the scanner leading edge registration see page 1 6 47 registration
44. 5 A white line appears longitudinally a ra 1 5 13 6 A black line appears longitudinally E SEERE ERE REE E ERE SERENE ERE 1 5 13 7 A black line appears laterally cccccecccccsseseeeceeeeeeceseeeeeeceaeeeeseaeeeeeeesseeessgeeesssaeesesseeeeessaeeeeeeas 1 5 13 8 One side of the copy image is darker than the other r 1 5 13 9 Black dots appear ON the Image 1 5 13 10 mage ele ME 1 5 13 11 The leading edge of the image is consistently misaligned with the original 1 5 13 T2 Paper eS as Seege 1 5 13 13 SC OCCU eet 1 5 13 14 Image is partiy MNS ere EE 1 5 13 lO yr MS OO ON EE 1 5 13 16 Image center does not align with the original center 1 5 13 1 5 4 Electrical problems bank 1 5 20 1 The machine does not operate when the main Switch is turned on 1 5 20 2 The main motor does not operate C2000 a a 1 5 20 3 The scanner motor does NOt operate a a ssrssrrrsssssssssa 1 5 20 4 Cooling fan does NOt operate 2 0 ccccccceccseseseeeeeceeeeseeceeesseeeceeeeeeesseaeeeeeeeeeeeeeessaeaeaeeseeeeeeeeeeseaaaas 1 5 20 5 The
45. Austria Phone 43 0 1 86338 0 KYOCERA MITA SVENSKA AB Box 1402 171 27 Solna Sweden Phone 46 0 8 546 550 00 KYOCERA MITA NORGE Postboks 150 Oppsal NO 0619 Oslo Olaf Helsetsvei 6 NO 0694 Oslo Phone 47 0 22 62 73 00 2003 KYOCERA MITA CORPORATION IR KYOCER is a trademark of Kyocera Corporation KYOCERA MITA DANMARK A S Hovedkontor Slotsmarken 11 DK 2970 H rsholm Denmark Phone 45 70 22 3880 KYOCERA MITA PORTUGAL LDA Rua de Campolide 55 5 Dt 1070 029 Lisboa Portugal Phone 351 0 21 032 0900 KYOCERA MITA SOUTH AFRICA PTY LTD 527 Kyalami Boulevard Kyalami Business Park 1685 Midrand South Phone 27 0 11 466 3290 KYOCERA MITA AMERICA INC Headquarters 225 Sand Road P O Box 40008 Fairfield New Jersey 07004 0008 U S A Phone 973 808 8444 KYOCERA MITA AUSTRALIA PTY LTD Level 3 6 10 Talavera Road North Ryde N S W 2113 Australia Phone 02 9888 9999 KYOCERA MITA NEW ZEALAND LTD 1 3 Parkhead Place Albany P O Box 302 125 NHPC Auckland New Zealand Phone 09 415 4517 KYOCERA MITA THAILAND CORP LTD 9 209 Ratchada Prachachem Road Bang Sue Bangkok 10800 Thailand Phone 02 586 0320 KYOCERA MITA SINGAPORE PTE LTD 121 Genting Lane 3rd Level Singapore 349572 Phone 67418733 KYOCERA MITA HONG KONG LIMITED 11 F Mita Centre 552 566 Castle Peak Road Tsuen Wan New Territories Hong Kong Phone 24297422 KYOCERA MITA TAIWAN CO
46. C 446 F for 40 ms Abnormally low fixing unit ther mistor temperature e The fixing temperature remains below 90 C 194 F for 1 s Zero crossing signal problem e The engine board KP 5061 does not detect the zero crossing signal for the time specified below At power on 3s Others 5 s Poor contact in the thermistor connector termi nals Thermistor in stalled incorrectly Thermal cutout triggered Heater lamp in stalled incorrectly Broken heater lamp wire Shorted ther mistor Broken heater control circuit on the power supply board KP 5059 Poor contact in the thermistor connector termi nals Broken thermistor wire Thermistor in stalled incorrectly Thermal cutout triggered Heater lamp in stalled incorrectly Broken heater lamp wire Poor contact in the connector ter minals Defective power supply board KP 5059 Defective engine board KP 5061 2DC Causes Check procedures corrective measures Check the connection of connector CN4 on the power supply board KP 5059 and the continuity across the connector terminals Repair or replace if necessary Check for continuity If none replace the thermal cutout Check for continuity If none replace the heater lamp Measure the resistance If it is 0 Q replace the thermistor Replace the power supply board KP 5059 and check for correct operation Check the connection of connector CN4 on
47. E ERE E REEL E EL EEE ER EES 1 5 23 5 Multiple sheets of paper are fed at one time aa aaa rrr s 1 5 23 DEE EE e ai 1 5 23 7 Abnormal noise is heard sccncsanccestyacennacnseoenddedsbocsaddennnesdeincnunatisinsiaadeeaanenbaiidemestebestervaeessanensiasaencebedarses 1 5 23 1 6 Assembly and Disassembly 1 6 1 Precautions for assembly and disassembly cccccccccessececeeeseeeeeeeeeeeeeaeeeeeeesseeeeseeeessaaseeeeeeseaaaeeerees 1 6 1 1 EE 1 6 1 1 6 2 Removing the process unt 1 6 2 1 6 3 Removing the principal outer covers ar rasssssrsssssssssssissasassa 1 6 3 1 Removing the front top cover face down output tray REENEN 1 6 3 2 REMOVING the right COver E 1 6 4 3 Removing the EE 1 6 4 1 6 4 Removing the feed roller ccccccecccccceceeseeeceeceeeeeeeeeeseeeeeceeeeseeaseeeeeeesaeeeeeeeesseaeeeeeesssaeeeeeesseaaeeeeeeeaas 1 6 5 1 6 5 Removing the MP feed roller cccccccccsssseeecececeeeeeeeeeeeeaeesceeeeseaeeeeeeeeeseeuseeeeeeeesaaseseeesseaegeeeeeessaeseeeeees 1 6 6 1 6 6 Removing the transfer roller cccccccccssssecccensececaueeeececeaeeeeeseaeeeecsaseeeseuseeeeseeeeeseseeeeeessueeeessaneeesesaaes 1 6 8 1 6 7 Removing the principal circuit boardS 2 0 cece ccccccsseeeeeeeceeeeeeeeeeecaaeeeeeeeeseasceeeeeeseeeseeeessaaaeeeeeesaaaseeeees 1 6 9 1 Removing the engine board a ra aa
48. Figure 1 6 20 Removing the fuser unit 1 6 18 2DC 7 Open and split the fuser unit 6 Remove two screws s Screw Cc SA LL Figure 1 6 21 Splitting the fuser unit 1 6 19 2DC 1 Removing the separation claws WARNING The separation claws are extremely hot immediately after the copier was running Allow substantial period of time until it cools down 1 Remove and split the fuser unit See page 1 6 18 2 Loosen the stopper screws 3 Hold the separation claw upright and remove the separation claw and separation claw springs Separation claw spring Figure 1 6 22 Removing the separation claws 1 6 20 2DC 2 Removing the heater lamp WARNING e The heater lamp is extremely hot immediately after the copier was running e Allow substantial period of time until it cools down Also the heater lamp is fragile Handle it with great care CAUTION e The heater lamps are fragile Use extreme care when handling not to drop or break e Do not directly touch on the heater lamp Finger prints on the heater lamp s outer surface can prevent proper fusing of toner on paper When holding e When refitting the heater lamp direct the short distance side from the projection in the middle of the lamp facing the machine s left side 1 Remove and split the fuser unit See page 1 6 18 2 Remove all four separation claws See previous page 3 Remove one screw release the tension of t
49. KYOCERA mita mmm KM 1500 SERVICE MANUAL Published in Feb 703 842DC110 CAUTION 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 CAUTION Double pole neutral fusing KSULERd mild 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 personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property These symbols are described below A DANGER High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol AAWARNING Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol AACAUTION Bodily injury or damage to property may result from insufficient attention to or incorrect compliance with warning messages using this symbol Symbols The triangle
50. Press the start key 2 Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys Copy exposure indicator Setting range Initial setting First 3 digits 000 to 999 Last 3 digits 000 to 999 Clearing the count Clearing 1 Light exp 3 2 Press the start key The count is cleared and the indication for selecting a maintenance item No appears Setting 1 Change the count using the zoom keys 2 Press the start key The count is set and the indication for selecting a maintenance item No appears Completion To exit this maintenance item without changing the count press the stop clear key The indication for selecting a maintenance item No appears Setting the fixing control temperature Description Changes the fixing control temperature Purpose Normally no change is necessary However can be used to prevent curling or creasing of paper or solve a fixing problem on thick paper Method Press the start key The screen for selecting an item is displayed Setting 1 Select the item to be set by lighting a copy exposure indicator using the copy exposure adjustment keys 2 Change the setting using the zoom keys Copy exposure Sek s WEEN Description Setting range Initial setting Exp 1 lit Primary stabilization fixing temperature Exp 2 lit Secondary stabilization fixing temperature Exp 3 lit Copying operation temperature 1 Exp 1 flashing Copying operation
51. RPORATION 7F 1 2 No 41 Lane 221 Gangchi Rd Neihu District Taipei Taiwan 114 R O C Phone 02 87511560 KYOCERA MITA CORPORATION 2 28 1 chome Tamatsukuri Chuo ku Osaka 540 8585 Japan Phone 06 6764 3555 http www kyoceramita com mifa is a registered trademark of KYOCERA MITA CORPORATION Printed in Holland
52. S e The paper sizes are marked on the bottom of the cassette e The default setting is for A4 Letter size paper aper width guide Figure 1 3 29 4 Set the paper in the drawer so that the leading edge is aligned against the paper stopper but Paper stopper making sure that none of the paper gets caught on the overhanging tabs Figure 1 3 30 1 3 13 2DC NOTES e DO NOT set more paper than indicated by the lines located on the paper width guides Paper width guide e Be sure to load paper with the side to be copied onto facing down Figure 1 3 31 5 Push the cassette securely all the way back into the copier until it stops Cassette Figure 1 3 32 Make test copies Completion of machine installation 1 3 14 1 3 2 Installing the document processor option Procedure 1 Remove all of the components to the document processor from the box CAUTION Be sure to hold both sides of the document processor when carrying it as shown in the illustration Be particularly careful NOT to touch the guide film or the thin white surface indicated by the A in the illustration 2 Turn the main switch to the copier OFF O 3 Open the original cover and lift it upward to remove it from the copier 2DC Document processor Figure 1 3 33 _ r E Das Power switch s Figure 1 3 34 Figure 1 3 35 1 3 15 2DC 4 Attach the document processor to t
53. achines is initialized based on the destination setting When initialization is complete the machine automatically returns to the same status as when the main switch is turned on Completion To exit this maintenance item without executing initialization press the stop clear key The indication for selecting a maintenance item No appears 2DC Maintenance Description item No il Checking motor operation Description Drives each motor Purpose To check the operation of each motor Method 1 Press the start key A selection item appears 2 Select the motor to be operated using the copy exposure adjustment keys When selecting the feed motor pull out the optional drawer in advance Display A Main motor F1 Optional feed motor 3 Press the start key The selected motor operates 4 To stop operation press the stop reset key Completion Press the stop clear key after operation stops The indication for selecting a maintenance item No appears Checking sensors for paper conveying Description Displays the on off status of each paper detection sensor on the paper path Purpose To check if the sensors for paper conveying operate correctly Method 1 Press the start key 2 Turn each sensor on and off manually to check the status When the on status of a sensor is detected the image mode LED corresponding to the operated sensor lights Q Auto Exp Exit sensor O A T 4ml Text amp Photo O 4mm Photo O 41
54. aits for secondary paper feed 30 s or timeout more have elapsed Paper feed 10 No paper feed from the The registration sensor does not turn on within 1350 ms of section MP tray the MP feed clutch turning on the clutch is then successively held off for 1 s and turned back on once but the sensor again fails to turn on within 1350 ms No paper feed from the Registration sensor does not turn on within 1120 ms of the drawer feed clutch turning on the clutch is then successively turned off for 1 s and turned back on once but the sensor again fails to turn on within 1120 ms No paper feed from the Registration sensor does not turn on within 1160 ms of the optional drawer feed clutch turning on the clutch is then successively turned off for 1 s and turned back on once but the sensor again fails to turn on within 1160 ms 2 Multiple sheets in the MP The registration sensor does not turn off within 5055 ms of the registration clutch turning on when paper is fed from the MP tray 2 Multiple sheets in the The registration sensor does not turn off within 5055 ms of drawer the registration clutch turning on when paper is fed from the drawer 2 4 5 Multiple sheets in the op The registration sensor does not turn off within 5055 ms of tional drawer the registration clutch turning on when paper is fed from the optional drawer 11 12 0 1 2 Fixing sec 0 Misfeed in the fixing sec The exit sensor does not turn on within 2765 ms of the regi
55. alue using the zoom key Is the leading edge registration correct Setting range 3 0 3 0 Initial setting 0 0 Changing the value by 1 moves the leading edge by 1 0 mm Press the stop clear key to exit maintenance mode 1 6 41 2DC 2 Adjusting the center line of image printing Make the following adjustment if there is a regular error between the center lines of the copy image and original when paper is fed from the drawer U067 U072 P 1 6 48 P 1 6 52 Caution Check the copy image after the adjustment If the image is still incorrect perform the above adjustments in maintenance mode Procedure Center line of printing Enter maintenance mode i Correct image Output Output adjustment keys or zoom keys Figure 1 6 52 Press the start key Select the item to be adjusted using the copy exposure adjustment keys Exp 3 lit Center line from the drawer Exp 1 flashing Center line from the bypass tray Exp 2 flashing Center line from the optional drawer Press the program key Press the start key The new setting is stored Press the start key to output a test pattern For output example 1 increase the value using the zoom key For output example 2 decrease the value using the zoom key Is the image correct Setting range 1 0 3 0 f Initial setting 0 0 Press the stop clear key to exit Changing the value by 1 moves the main
56. arly marked on the right side of the inside portion of the front cover 1 3 6 Figure 1 3 8 Front cover Figure 1 3 9 CE Figure 1 3 10 Paper tag 2DC 3 Remove the process unit from the copier CAUTIONS e Place the process unit on a clean level surface e Never expose the process unit to any sort of impact or shock e The drum in the process unit is sensitive to light Never expose the drum even to normal office lighting 500 lux for more than five minutes Figure 1 3 11 4 Remove the protective cardboard Protective cardboard Figure 1 3 12 5 Move the lock lever until it is in its unlocked position marked UNLOCK Lock lever Figure 1 3 13 1 3 7 2DC 6 Shake the toner container horizontally back and forth five or six times so that the toner inside of it becomes evenly distributed 7 Remove the orange protective seal 8 Set the toner container into the process unit 1 3 8 Toner container Process unit Figure 1 3 14 Figure 1 3 15 Seal Toner container Figure 1 3 16 2DC 9 Hold the process unit stable and push in on the areas of the toner container marked PUSH HERE until the container clicks into place in the p
57. ars Setting auto clear time Description Sets the time to return to initial settings after copying is complete Purpose To be set according to frequency of use Set to a comparatively long time for continuous copying at the same settings and a comparatively short time for frequent copying at various settings Method Press the start key The current setting is displayed Setting 1 Change the setting using the zoom keys rr x Auto clear time 0 to 270 s The setting can be changed by 10 s per step When set to 0 the auto clear function is cancelled 2 Press the start key The value is set and the indication for selecting a maintenance item No appears Completion To exit this maintenance item without changing the current setting press the stop clear key The indication for selecting a maintenance item No appears 14222 2DC Maintenance Description item No P Switching copy operation at toner empty detection Description Selects if continuous copying is enabled after toner empty is detected Method Press the start key The screen for selecting an item is displayed The current setting is displayed Setting 1 Select single or continuous copying using the zoom keys Sin Enables only single copying Con Enables single and continuous copying Initial setting Sin 2 Press the start key The setting is set and the indication for selecting a maintenance item No appears Completion Press the s
58. ation sensor on off manually Replace registration sensor if indication of the responding sensor is not light and cor Run maintenance item U032 and select the registration clutch to be turned on and off Check the status and remedy if necessary Run maintenance item U031 and turn exit sensor on and off manually Replace exit sensor if indication of the corresponding sensor is not light Run maintenance item U032 and select the registration clutch to be turned on and off Check the status and remedy if necessary Check visually and remedy if necessary Check visually and remedy if necessary Clean or replace if necessary Clean or replace if necessary 1 5 5 2DC Problem Causes check procedures Corrective measures 9 Defective registration sen Run maintenance item U031 and turn registration sensor on and A paper jam in the Sor off manually Replace registration sensor if indication of the cor exit section is indi responding sensor is not light Caled during CODy az ae ee S i PA ed C DU A U U l ee ing jam in the exit section Jam code 50 Defective exit sensor Run maintenance item U031 and turn exit sensor on and off manually Replace exit sensor if indication of the corresponding sensor is not light Check if the lower exit Check visually and remedy if necessary roller and exit pulleys con tact each other Check if the upper exit Check visually and remedy if necessary roller and exit pulley
59. auses check procedures Corrective measures 1 Check if the surfaces of the feed roller and Clean with isopropyl alcohol No primary paper feed MP feed roller are dirty with paper powder Check if the feed roller and MP feed roller Check visually and replace any deformed are deformed rollers see page 1 6 5 6 Electrical problem with the feed clutch and See pages 1 5 20 21 MP feed clutch 2 Check if the surfaces of the upper and lower Clean with isopropyl alcohol No secondary paper registration rollers are dirty with paper pow feed der Electrical problem with the registration See page 1 5 21 clutch Deformed width guide in a drawer Repair or replace if necessary ARE paper feed The scanner motor malfunctions See page 1 5 20 sA scanner does not travel 5 Deformed drawer claw Check the drawer claw visually and correct Multiple sheets of paper or replace if necessary are fed at one time 6 Check if the paper is curled Change the paper Paper jams Deformed guides along the paper conveying Check visually and replace any deformed path Check if the contact between the upper and lower registration rollers is correct Check if the press roller is extremely dirty or deformed Check if the contact between the heat roller Repair if any springs are off the separation and its separation claws is correct claws 7 Check if the rollers and gears operate Abnormal noise is smoothly heard C
60. ave been refitted correctly Special attention should be paid to any forgotten e Check that all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling Replace with new ones if necessary e 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 main switch on Always wash hands afterwards e Never dispose of toner or toner bottles in fire Toner may cause sparks when exposed directly to S fire in a furnace e e Should smoke be seen coming from the copier remove the power plug from the wall outlet aaan Eal E E SIE ener ee ee ee enor eee ee ee eee ee eee eT ee eee 3 Miscellaneous AA WARNING e Never attempt to heat the drum or expose it to any organic solvents such as alcohol other than S the specified refiner it may generate toxic Oase 2DC CONTENTS 1 1 Specifications E Eelere E 1 1 1 En EE NIME OL GUS spaces uuu E AE a a a 1 1 2 O pir sss EET S S S S uu u xs 2 1 1 2 2 Operation panel E 1 1 3 1 2 Handling Precautions DL TOMI E 1 2 1 1 2 2 Installation environment
61. board KP 5061 Communication problem between the main board KP 5060 and engine board KP 5061 e When the power is turned on the ma chine does not detect the low level of SBSY and the high level of SDIR for three seconds A is displayed on the market 1 5 8 Defective backup RAM or main board KP 5060 Problem with the backup memory data Defective backup RAM Defective backup RAM or engine board KP 5061 Problem with the backup memory data Defective backup RAM Defective main board KP 5060 or engine board KP 5061 Defective main board KP 5060 or engine board KP 5061 Poor contact in the connector ter minals Defective main board KP 5060 or engine board KP 5061 Causes Check procedures corrective measures Replace the main board KP 5060 and check for correct operation Turn interlock switch off and back on and run maintenance item U020 to set the con tents of the backup memory data again If the C0110 is displayed after re setting the backup memory contents replace the backup RAM or main board KP 5060 Replace the engine board KP 5061 and check for correct operation Turn interlock switch off and back on and run maintenance item U020 to set the con tents of the backup memory data again If the C0160 is displayed after re setting the backup memory contents replace the backup RAM or engine board KP 5061 Replace the main board KP 5060 or
62. ding a liaison connection with the power supply board bias board and the engine board High voltage board High voltage output circuit Engine board Bias board Main Control charger driver 8 circuit ae THVDR RTHVDR Transfer roller PSEL1 Control PSEL2 and driver HVISEL circuit Transfer bias output ositive voltage cuit Power supply board 24V2 24V3 n Interlock switch SP 24V1 FAN HEATN SLEEPN ZCROSS THERM EXITN Figure 2 3 9 High voltage board circuit block diagram 2 3 10 2DC 1 Interlock switch The interlock switch is located on the high voltage board and opened and closed in conjunction with the front cover or the front top cover via the interlock lever This switch connects and disconnects the 24 V DC power supply line If the front cover or the front top cover is open the interlock switch is open and the 24 V DC to the high voltage output circuit bias board engine board and the power supply board is disconnected deactivating the high voltage output laser output Main motor output for safety The cooling fan is an exception Since the cooling fan is directly fed with 24 V DC from the power supply unit at the primary side 24V1 of the interlock switch the cooling fan is not deactivated even the cover is open Front top cover SR y Interlock lever Projection Engine board B
63. e C2000 3 The scanner motor does not operate 4 Cooling fan does not operate 5 The feed clutch does not operate 1 5 20 No electricity at the power outlet The power cord is not plugged in properly The front cover is not closed completely Broken power cord Defective Main switch Blown fuse in the power supply board KP 5059 Defective interlock switch Defective power supply board KP 5059 Poor contact in the main motor connector terminals Broken main motor gear Defective main motor Defective engine board KP 5061 Broken scanner motor coil Poor contact in the scan ner motor connector termi nals Broken Cooling fan coil Poor contact in the Cool ing fan connector termi nals Broken feed clutch coil Poor contact in the feed clutch connector terminals Defective engine board KP 5061 Measure the input voltage Check the contact between the power plug and the outlet Check the front cover Check for continuity If none replace the cord Check for continuity across the contacts If none replace the main switch Check for continuity If none remove the cause of blowing and replace the fuse Check for continuity across the contacts of switch If none re place the switch With AC present check for 24 V DC at CN2 6 and 5 V DC at CN2 1 on the power supply board KP 5059 If none replace the power supply board KP 5059 Reinsert
64. e replace the eraser lamp KP con If the eraser lamp turns on when YC 14 2 on the engine board KP 5061 is held low replace the engine board KP 5061 Reinsert the connector Also check for continuity within the nector cable If none remedy or replace the cable con Check if the exposure lamp turns on with YC6 1 and YC6 2 on the scanner board KP 5063 goes low If not replace the s ner board KP 5063 Check if the exposure lamp turns on with YC11 10 on the e board KP 5061 goes low If not replace the engine board 5061 can ngine KP Check if the exposure lamp turns on with YC6 1 and YC6 2 on the scanner board KP 5063 goes low If not replace the s ner board KP 5063 Check if the exposure lamp turns on with YC11 10 on the e board KP 5061 goes low If not replace the engine board 5061 can ngine KP Check for continuity across heater lamp If none replace the heater lamp Check for continuity across thermal cutout If none remove cause and replace the thermal cutout Measure the resistance If it is Q replace the thermistor Check visually and clean the thermistor sensor parts the 1 5 21 2DC Problem Causes Check procedures corrective measures 13 Broken main charger wire Main charging is not performed 14 Transfer charging is not performed 15 A paper jam in the paper feed or exit section is indicated when the main switch is
65. e 1 3 23 Memory Overflow Add Toner Figure 1 3 24 1 3 11 2DC Load paper 1 Pull the cassette out of the copier e Cassette Figure 1 3 25 2 Adjust the paper stopper in the rear portion of the cassette to fit the size of the paper being loaded there by pressing in on the release buttons and sliding the paper stopper to the corresponding paper size NOTES e The paper sizes are marked on the bottom of the cassette e The default factory setting is for A4 Letter size paper Paper stopper Figure 1 3 26 Adjusting the paper stopper for Folio or Oficio Il iopperextension size paper lock 1 Remove the stopper extension lock from the paper stopper 2 Slide the paper stopper towards the rear of the cassette until the grooves that are cut into the paper stopper are aligned with the rear edge of the cassette 3 Insert the stopper extension lock into the holes in the paper stopper as shown in the illustration Stopper extension lock Figure 1 3 27 1 3 12 2DC 4 Press down on the stopper extension lock and slide the paper stopper towards the rear of the cassette to set the lock into place The paper stopper is in position for Folio and Oficio II size paper Paper stopper Figure 1 3 28 3 Adjust the paper width guides by pressing in on the release buttons and sliding the guides to fit the width of the paper being loaded in the Paper width guide cassette NOTE
66. e Adjusting the scanner center line U067 e Adjusting the scanner leading edge registration U066 e Adjusting scanner magnification in the auxiliary direction U065 When this maintenance item is performed the settings in U065 U066 and U067 are also changed Purpose Used to make respective auto adjustments for the scanner Method Place the specified original P N 2A168070 on the contact glass Press the start key on appears Press the start key Auto adjustment starts When adjustment is complete Gd appears Display each setting value after adjustment by lighting a copy exposure indicator using the copy exposure adjustment keys Copy exposure indicator Setting value Exp 1 Scanner center line Exp 2 Scanner leading edge registration Exp 3 Scanner magnification in the auxiliary scanning direction If a problem occurs during auto adjustment nG is displayed and operation stops Lighting the copy exposure indicator exp 3 and then exp 5 using the copy exposure adjustment keys will display the error code Determine the details of the problem and either repeat the procedure from the beginning or adjust the remaining items manually by running the corresponding maintenance items Completion Press the stop clear key after auto adjustment is complete The indication for selecting a maintenance item No appears If the stop clear key is pressed during auto adjustment adjustment stops and no settings are changed
67. e engine board KP 5061 and check for correct operation Replace the high voltage board and check for correct operation The connector terminals of the exposure Reinsert the connector Also check for continuity within the lamp make poor contact connector cable If none remedy or replace the cable Replace the CCD board KP 5065 and check for correct operation Replace the scanner board KP 5063 and check for correct operation Defective engine board KP 5061 Replace the engine board KP 5061 and check for correct operation 1 5 14 2DC 3 Image is too Causes light 1 Insufficient toner 2 Deteriorated developer 3 Dirty or deteriorated drum 1 Insufficient toner If the add toner indicator lights replace the toner container 2 Deteriorated developer Replace the process unit 3 Dirty or deteriorated drum Replace the process unit 4 Background is visible Causes 1 Deteriorated developer 1 Deteriorated developer Replace the process unit 5 A white line appears Causes longitudinally 1 Dirty or flawed main charger wire 2 Foreign matter in the developing section 3 Flawed drum 4 Dirty shading plate Causes Check procedures corrective measures 1 Dirty or flawed main charger wire Replace the process unit 2 Foreign matter in the developing section Replace the process unit 3 Flawed drum Replace the process unit 4 Dirty shading plate Clean the shading plate 1 5 1
68. e item U031 and turn registration sensor on and off manually Replace registration sensor if indication of the cor responding sensor is not light Run maintenance item U032 and select the feed clutch to be turned on and off Check the status and remedy if necessary Change the paper Check visually and replace any deformed roller Run maintenance item U031 and turn registration sensor on and off manually Replace registration sensor if indication of the cor responding sensor is not light Run maintenance item U032 and select the feed clutch to be turned on and off Check the status and remedy if necessary 2DC Problem Causes check procedures Corrective measures 5 A paper jam in the paper feed section is indicated during copying multiple sheets in the MP tray Jam code 20 6 A paper jam in the paper feed section is indicated during copying multiple sheets in the drawer Jam code 21 7 A paper jam in the paper feed section is indicated during copying multiple sheets in the op tional drawer Jam code 22 8 A paper jam in the fixing section is indi cated during copy ing jam in the fixing section Jam code 40 Check if the MP feed roller is deformed Defective registration sen Sor Check if the registration clutch malfunctions Electrical problem with the registration clutch Check if the feed roller is deformed Defective registration sen sor Check if the reg
69. e making the following adjustment ensure that the above adjustments have been made in maintenance mode Eq II H Enter maintenance mode Original Copy Copy example 1 example 2 Figure 1 6 63 Procedure Enter 072 using the copy exposure adjustment keys or zoom keys Press the start key Press the program key and the machine enters the test copy mode Place an original on the DP and make a test copy Change the setting e For copy example 1 increase Is the image correct the value using the zoom key e For copy example 2 decrease the value using the zoom key Setting range 6 6 6 6 Press the stop clear key Initial setting 1 5 to exit maintenance mode Changing the value by 1 moves the center line by 0 17 mm Press the start key The new setting is stored End 1 6 53 2DC 14 Adjusting the margins for scanning the original from the DP Perform the following adjustment if margins are not correct U402 U403 P 1 6 43 P 1 6 49 SCH Caution Before making the following adjustment ensure that the above adjustments have been made in maintenance mode Procedure DP leading edge margin 3 2 5 mm Ejection direction A ff ee reference Enter maintenance mode DP left margin DP right margin 3 2 5 mm 3 2 5 mm Enter 404 using the copy exposure adjustment keys or zoom keys Press the start key DP trail
70. e pages 1 6 45 and 46 Adjusting the leading edge registration for scanning an original on the contact glass Adjustment See page 1 6 47 Adjusting the center line for scanning an original on the contact glass Adjustment See page 1 6 48 Adjusting the DP magnification Adjustment See page 1 6 50 Adjusting the DP scanning timing Adjustment See pages 1 6 51 and 52 Adjusting the DP center line Adjustment See page 1 6 53 1 4 9 2DC Maintenance item No U073 U074 1 4 10 Description Checking scanner operation Description Simulates the scanner operation under arbitrary conditions Purpose To check scanner operation Method 1 Press the start key 2 Select the item to be changed by lighting a copy exposure indicator using the copy exposure adjustment keys 3 Change the setting using the zoom keys Copy exposure indicator Operating conditions Setting range Exp 1 Magnification 50 to 200 Exp 2 Paper size See below Exp 3 On and off of the exposure lamp on or off Paper size for each setting Folio 81 2 x 14 81 2 x11 R 51 2 x 81 2 R 4 Press the start key Scanning starts under the selected conditions 5 To stop operation press the stop clear key Completion Press the stop clear key when scanning stops The indication for selecting a maintenance item No appears Adjusting the DP input light luminosity Description Adjusts the luminosity of the exposure lamp for scann
71. e power supply board and high voltage board 1 Remove the left cover See page 1 6 4 Remove three connectors from the power supply board Remove eight screws Remove the power supply board and high voltage board Note The high voltage board is directly connected to the o1 W PO Remove the process unit See page 1 6 2 bias board Separate the high voltage board from the power supply board Bias board High voltage board Screws Figure 1 6 14 Removing the power supply board and high voltage board 1 6 12 2DC 4 Removing the bias board 1 Remove the left cover See page 1 6 4 Remove the power supply board and high voltage board See the previous page Stand the machine with the front side up Remove one connector from the bias board oO O O T G pO Remove the cassette and process unit See page 1 6 2 Remove five screws Remove the bottom cover Remove the two connectors from the bias board Remove the bias board Screws J a Bottom cover Connector Screws Figure 1 6 15 Removing the bias board 1 6 13 2DC 1 6 8 Removing the main motor and drive unit 1 Remove the cassette and process unit See page 1 6 2 2 Remove the right cover See pages 1 6 4 3 Remove three connectors from the main motor 4 Remove four screws 5 Remove main motor Screws lt 7 Screws Figure 1 6 16 Removing the main motor
72. e the machine on a level surface maximum allowance inclination 1 e Avoid air borne substances that may adversely affect the machine or degrade the photoconductor such as mercury acidic of alkaline vapors inorganic gasses NOx SOx gases and chlorine based organic solvents e Select a room with good ventilation 6 Allow sufficient access for proper operation and maintenance of the machine Machine front 1000 mm 393 s Machine rear 300 mm 1113 16 Machine right 300 mm 111 16 Machine left 300 mm 1 113 16 a 385 mm 153 16 b 460 mm 181 3 c 496 mm 199 16 d 421 mm 16 s e 665 mm 263 16 f 740 mm 293 16 Figure 1 2 1 Installation dimensions 1 2 1 2DC 1 3 1 Unpacking and installation 1 Installation procedure Start Unpack Remove the tapes pads and sheets Remove the pin holding scanner unit Install a toner container Connect the power cord Inisializing the copier Load paper Make test copies Completion of the machine installation 3 2DC Kr d el M 2 e l Z a S Figure 1 3 1 Unpacking 1 Copier 1 Front spacer 2 Power cord 2 Front pad 3 Toner container 3 Bottom spacer 4 Operation guide 44 Corner support 5 Installation guide 45 Products cover 6 Cleaning cloth Plastic bag 7 Outer case 7 Bar code labels Bottom pad Pocket spacer 9 Upper pad Plas
73. ed and the indication for selecting a maintenance item No appears Completion To exit this maintenance item without changing the accumulated time press the stop clear key The indication for selecting a maintenance item No appears 1 4 29 2DC Maintenance Description item No Checking the scanner count Description Display the scanner count value Purpose To check the scanner count value Method 1 Press the start key 2 Change the indication of the copy quantity display by lighting a copy exposure indicator using the copy exposure adjustment keys Copy exposure indicator Copy quantity display count value Exp 1 First 3 digits of the scanner count Exp 2 Last 3 digits of the scanner count Completion Press the stop clear key The indication for selecting a maintenance item No appears Outputting a VTC PG pattern Description Selects and outputs a VTC PG pattern created in the copier Purpose When performing respective image printing adjustments used to check the machine status apart from that of the scanner with a non scanned output VTC PG pattern Method 1 Press the start key 2 Select the VTC PG pattern to be output using the copy exposure adjustment keys H e Lateral squareness adjustment e Magnification adjustment 2 3 Press the program key The machine enters the PG pattern output mode 4 Press the start key
74. eesesaass 1 6 36 1 6 15 Removing the scanner moior ENEE 1 6 37 1 6 16 Removing the main Charger unt 1 6 40 1 6 17 Adjustment the maintenance mode 1 6 41 1 Adjusting the leading edge registration Of image printing 1 6 41 2 Adjusting the center line Of IMAGE printing r 1 6 42 3 Adjusting the margins fOr printing a a raaasssrssrrsssssssssa 1 6 43 4 Adjusting the amount of Slack in the paper 1 6 44 5 Adjusting magnification of the scanner in the main scanning direction 1 6 45 6 Adjusting magnification of the scanner in the auxiliary scanning direction 1 6 46 7 Adjusting the scanner leading edge registration 1 6 47 8 Adjusting the Scanner center line cccccccceeeecececeeeeeeeeeeesseeeeceeeseaaeeeeeeeessaeaseeeeessaaaaeeeeeessaeeeeees 1 6 48 9 Adjusting the margins for scanning an original on the Contact glass 1 6 49 10 Adjusting the DP eelere 1 6 50 11 Adjusting the DP leading edge registration a 1 6 51 12 Adjusting the DP trailing edge registration
75. electing a maintenance item No appears 1 4 25 2DC Maintenance Description item No Checking clearing the paper jam counts Description Displays or clears the jam counts by jam locations Purpose To check the paper jam status Also to clear the jam counts after replacing consumable parts Method 1 Press the start key 2 Display the jam code to check the count using the copy exposure adjustment keys 3 Press the start key The jam count appears If the jam count is a 4 digit value the first digit and the last 3 digits are displayed alternately 4 Press the stop clear key The jam code appears again Copy exposure Copy exposure adjustment keys adjustment keys Stop Start key Stop clear key Copy exposure Clear key adjustment keys 10 Figure 1 4 3 Clearing all jam counts 1 Display CLE using the copy exposure adjustment keys Jam counts cannot be cleared individually 2 Press the start key The counts are cleared Completion Press the stop clear key The indication for selecting a maintenance item No appears Checking clearing the service call counts Description Displays or clears the service call code counts by types Purpose To check the service call code status by types Also to clear the service call code counts after replacing consumable parts Method 1 Press the start key 2 Display the service call code to check the count using the copy exposure adjustment keys 3 Press the start k
76. en gine board KP 5061 and check for correct operation Replace the main board KP 5060 or en gine board KP 5061 and check for correct operation Check the connection of connectors YC3 on the main board KP 5060 and YC3 on the engine board KP 5061 and the conti nuity across the connector terminals Re pair or replace if necessary Replace the main board KP 5060 or en gine board KP 5061 and check for correct operation Contents C0610 A0610 Bitmap DIMM problem e There is a problem with the data or address bus of the bitmap DRAM C0620 A0620 Memory input interface problem e Reading in of an image does not complete within 10 s of the start of image transmission DMA problem DMA transmission of compressed decompressed rotated relocated or blanked out image data does not complete within the specified period of time C0630 A0630 C0800 A0800 Image processing problem e JAMO5 is detected twice C2000 A2000 Main motor problem e LOCK ALM signal remains high for 1 s 1 s after the main motor has turned on C3100 A3100 Scanner carriage problem e The home position is not correct when the power is turned on or copy ing the document placed on the con tact glass A is displayed on the market Defective main board KP 5060 DIMM installed incorrectly Defective DIMM Defective main board KP 5060 Defective main board KP 5060 Defecti
77. escription Resets the detection of a service call code indicating a problem in the fixing section Purpose To prevent accidents due to an abnormally high fixing temperature Method 1 Press the start key CLE appears 2 Press the start key The fixing problem data is initialized Completion Press the stop clear key The indication for selecting a maintenance item No appears Checking the fixing temperature Description Displays the fixing temperature and the ambient temperature Purpose To check the fixing temperature and the ambient temperature Method 1 Press the start key 2 Display each temperature by lighting the respective copy exposure indicator using the copy exposure adjustment keys Exp 1 Fixing temperature C Exp 2 Ambient temperature C Completion Press the stop clear key The indication for selecting a maintenance item No appears Turning all LEDs on Description Turns all the LEDs on the operation panel on Purpose To check if all the LEDs on the operation panel light Method Press the start key All the LEDs on the operation panel light Press the stop clear key or wait for 10 s The LEDs turns off and the indication for selecting a maintenance item No appears 1 4 19 2DC Maintenance Description item No i Operating DP separately Description Simulates the original conveying operation separately in the DP Purpose To check the DP Method 1 Press the start key 2 Place an ori
78. ey The service call count appears If the service call count is a 4 digit value the first digit and the last 3 digits are displayed alternately 4 Press the stop clear key The service call code appears again Copy exposure Copy exposure adjustment keys adjustment keys 010 Stop Start key Stop clear key Copy exposure Clear key adjustment keys 10 Figure 1 4 4 Clearing counts by service call codes 1 Display the service call code to clear the count 2 Press the reset key The count is cleared Clearing all service call counts 1 Display CLE using the copy exposure adjustment keys 2 Press the start key The counts are cleared Completion Press the stop clear key The indication for selecting a maintenance item No appears 1 4 26 2DC Maintenance Description item No P Checking clearing counts by the DP Description Displays or clears the counts of the DP Purpose To check the use of the DP Also to clear the counts after replacing consumable parts Method 1 Press the start key 2 Change the indication of the copy quantity display by lighting a copy exposure indicator using the copy exposure adjustment keys Copy exposure indicator Copy quantity display count value Exp 1 First 3 digits of the number of original replacement Exp 2 Last 3 digits of the number of original replacement Exp 3 Clearing the count CLE Clearing 1 Light exp 3 using the copy exposure adjustment keys 2 Press t
79. g edge margin 5 10 3 5 0 5 mm Proceed to another mode No Press the stop clear key to exit maintenance mode 1 6 43 2DC 4 Adjusting the amount of slack in the paper Make the following adjustment if the leading edge of the copy image is Missing or varies randomly or if the copy paper is Z folded Procedure Enter maintenance mode Enter 051 using the copy exposure Original Copy Copy adjustment keys or zoom keys example 1 example 2 Figure 1 6 54 Select the item to be adjusted using the copy exposure adjustment keys Exp 1 lit Drawer Exp 2 lit Bypass tray Exp 3 lit Optional drawer Press the program key and the machine enters the test copy mode Press the start key to make a test copy Is the leading edge of the image missing or varying randomly copy example 1 Press the start key The new setting is stored Increase the value using the zoom key Is the copy paper Z folded copy example 2 Decrease the value using the zoom key Setting range 50 50 Initial setting 0 Changing the value by 1 changes the amount of slack by 0 32 mm The greater the value Press the stop clear key to the larger the amount of slack exit maintenance mode the smaller the value the smaller the amount of slack End 1 6 44 2DC 5 Adjusting magnification of the scanner in the main scanning direction Perf
80. ginal in the DP if running this simulation with paper 3 Select the item to be operated using the copy exposure adjustment keys Display copy exposure indicator Operation d P exp 1 With paper d n exp 2 Without paper continuous operation 4 Press the start key The operation starts 5 To stop continuous operation press the stop clear key Completion Press the stop clear key when the operation stops The indication for selecting a maintenance item No appears U207 Checking the operation panel keys Description Checks operation of the operation panel keys Purpose To check operation of all the keys and LEDs on the operation panel Method 1 Press the start key 2 1 appears on the copy quantity display and the leftmost LED on the operation panel lights 3 As the keys on the operation panel are pressed in order from the left to right the figure shown on the copy quantity display increases in increments of 1 If there is an LED corresponding to the key pressed the LED will light 4 When all the keys on the operation panel have been pressed all the LEDs light for up to 10 seconds 5 When the LEDs go off press the start key All the LEDs light for 10 seconds again Completion Press the stop clear key The indication for selecting a maintenance item No appears e After this check starts the operation cannot be canceled until all the keys are checked 4 To turn each motor off press the stop clear key Completion
81. he D cut shaft into the D shape hole of the feed roller 1 Remove the paper cassette and the process unit See page 1 6 2 2 Stand the machine the front side up 3 Move the feed roller in the direction A and remove the feed roller Figure 1 6 6 Removing the feed roller 1 6 5 2DC 1 6 5 Removing the MP feed roller 1 Remove the engine board See page 1 6 9 2 Remove one screw 3 Remove the grounding plate 4 Remove one stop ring 5 Remove the MP feed clutch MP feed J KO clutch Stop ring p lt KEE E IO pen ge p Figure 1 6 7 Removing the MP feed clutch 2DC 6 Remove one screw 7 Remove the toner sensor and spring 8 Remove two screws 9 While pressing the latch by using the driver and then remove the MP feed unit Toner sensor amp Screw MP feed unit Figure 1 6 8 Removing the MP feed unit 10 Remove the stop ring and then remove the MP feed roller Stop ring MP feed roller kt N Figure 1 6 9 Removing the MP feed roller 2DC 1 6 6 Removing the transfer roller CAUTION Do not touch the transfer roller sponge surface Oil and dust particles of paper etc on the transfer roller can significantly deteriorate the print quality white spots etc When refitting the bushes and springs make sure to refit the black colored bush and spring on the left side Also observe the correct direction to which the bush is fit in reference to the paper pas
82. he clips on both ends of the DIMM socket 4 Insert the DIMM into the DIMM socket so that the notches on the DIMM align with the Stopper corresponding protrusions in the slot 5 Close the clips on the DIMM slot to secure the DIMM Memory socket ____ Memory Memory cover Figure 1 3 41 Inserting the DIMM 1 3 18 2DC 1 4 1 Maintenance mode The copier is equipped with a maintenance function which can be used to maintain and service the machine 1 Executing a maintenance item Press the stop clear key start key and the left copy exposure adjustment key in the order presented and hold them down Press the stop clearkey Ir Entering the maintenance mode Enter the number of the maintenance item to be executed using the copy Selecting a maintenance item exposure adjustment keys or the zoom keys Press the start key The maintenance item is run Press the stop clear key Run the item again Run another maintenance Enter 001 using the copy exposure 7 adjustment keys or the zoom Exiting the maintenance mode keys and press the start key End 1 4 4 2DC 2 Maintenance mode item list Initial KL Maintenance item contents setting General Outputting an own status report Exiting the maintenance mode Checking the machine number Copying without paper Displaying the ROM version Initialization Initializing all data Initializing memories Drive paper U030
83. he copier CAUTION Be sure that the connection cable does not get caught between the document processor and the copier when attaching the document processor to the copier 5 Gently close the document processor Document processor Figure 1 3 37 6 Attached the open end of the connection cable to the connector on the copier Document processor Connection cable gt Figure 1 3 38 1 3 16 2DC CAUTION Be sure to tighten the pins securely when connecting the cable Figure 1 3 39 7 Turn the main switch to the copier back ON Warm up will begin 1 will appear on the operation panel and the Start indicator will light when the copier is in a copy ready state EES SCH EE gt Power switch a 7 7 7 U U Ge wes Figure 1 3 40 1 3 17 2DC 1 3 3 Installing the expanding memory option The main board of the copier is equipped with one socket for memory expansion Expansion memory is available in the form of DIMM Dual In line Memory Module CAUTION Take precautions that no foreign substances such as metal chips or liquid get inside the copier during the installation process Operation of the copier during the presence of a foreign substance may lead to fire or electric shock WARNING Turn the copier s power switch off Unplug the copier s power cable Procedure 1 Remove the one screw and then remove the memory cover 3 Open t
84. he counts after replacing the consumable parts Method 1 Press the start key 2 Select the paper size group No for which the count is to be checked or cleared by lighting image mode LEDs using the image mode selection key 3 Change the indication of the copy quantity display by lighting a copy exposure indicator using the copy exposure adjustment keys 1 4 28 o OH e On O Auto Exp O T 4ml Text amp Photo O 4m Photo O T Text A Eco Copy O Auto Exp O T 4m Text amp Photo O f lPhoto TlText Eco Copy O Auto Exp O Kr Text amp Photo a Photo T Text Eco Copy O Auto Exp 6T 4q Text amp Photo a Photo T Text Eco Copy e Auto Exp 4T 4a Text amp Photo 4m Photo drot A Eco Copy Auto Exp 4T 4q Text amp Photo 4m Photo T Text o A Eco Copy e Auto Exp 6T 4a Text amp Photo 4m Photo E AT Text o A Eco Copy e Auto Exp 6T 4a Text amp Photo O f Photo Se AT Text Re A Eco Copy e Auto Exp Se gd ke ltevt amp Photo O Ga Photo O AT Text O A Eco Copy c Flashing G Image mode LED group No LED group No Copy exposure indicator Copy quantity display count value A4 display the A4 size First 3 digits of A4 size copy count Last 3 digits of A4 size copy count Clearing the count CLE A5 display the A5 size First 3 d
85. he lamp A holder 4 Remove the heater lamp form the lamp B holder 5 Remove the heater lamp from the heat roller Lamp A holder Machine lt lt gt right side s aa e Machine left side Lamp B holder Figure 1 6 23 Removing the heater lamp 1 6 21 2DC 3 Removing the heat roller WARNING e The heat roller is extremely hot immediately after the copier was running Allow substantial period of time until it cools down 1 Remove and split the fuser unit See page 1 6 18 2 Remove the heater lamp See previous page 3 Press the lamp A holder away from the heat roller Pull up both heat R bush and heat L bush at the same time Heat R bush Heat L bush Figure 1 6 24 Removing the heat R bush and heat L bush 1 6 22 2DC 4 Remove the heat gear Z33 heat R bush and heat L bush from the heat roller Heat gear Z33 S o Heat R bush Heat L bush D Heat roller Figure 1 6 25 Removing the heat roller 1 6 23 2DC 4 Removing the thermistor 1 Remove and split the fuser unit See page 1 6 18 2 Remove the heater lamp See page 1 6 21 3 Remove the heat roller See page 1 6 22 4 Remove one screw 5 Remove the thermistor Figure 1 6 26 Removing the thermistor 1 6 24 2DC 5 Removing the thermal cutout CAUTION e Do not bend the terminals of the thermal cutout 1 Remove and split the fuser unit See page 1 6 18 2 Remove the heater lamp See page 1 6 21
86. he start key The count is cleared Completion Press the stop clear key The indication for selecting a maintenance item No appears Exp 1 First 3 digits of the total count Exp 2 Last 3 digits of the total count Completion Press the stop clear key The indication for selecting a maintenance item No appears U908 Checking the total count Description Display the total count value Purpose To check the total count value Method 1 Press the start key 2 Change the indication of the copy quantity display by lighting a copy exposure indicator using the copy exposure adjustment keys Copy exposure indicator Copy quantity display count value 3 Press the start key The accumulated black ratio data is cleared Completion To exit this maintenance item without clearing the data press the stop clear key The indication for selecting a maintenance item No appears Clearing the black ratio data Description Clears the accumulated black ratio data for A4 11 x 81 2 sheets Purpose To clear data as required at times such as during maintenance service Method 1 Press the start key 2 Select on using the zoom keys _ Canceling the clearing on Executing the clearing 1 4 27 2DC Maintenance Description item No Checking clearing copy counts by paper size Description Displays or clears the paper feed count value by paper size Purpose To check the time to replace consumable parts Also to clear t
87. he total count and the scanner count The counts however can be cleared only one time If either of the total count or the scanner count exceeds 1 000 this mode cannot be run Purpose To start the counters with value 0 when installing the machine Method 1 Press the start key If the counters have been already cleared or either of the total counter or the scanner counter exceeds 1 000 this mode cannot be run and nG is displayed 2 Select on using the zoom keys Canceling the clearing Executing the clearing 3 Press the start key The accounting counter is cleared Completion To exit this maintenance item without clearing the data press the stop clear key The indication for selecting a maintenance item No appears Checking clearing the time for the exposure lamp to light Description Displays or clears the accumulated time for the exposure lamp to light Purpose To check duration of use of the exposure lamp Also to clear the accumulated time for the lamp after replacement Method 1 Press the start key 2 Change the indication of the copy quantity display by lighting a copy exposure indicator using the copy exposure adjustment keys Copy exposure indicator Copy quantity display Exp 1 First 3 digits of the lamp on time minutes Exp 2 Last 3 digits of the lamp on time minutes Exp 3 Clearing the lamp on time CLE Clearing 1 Light exp 3 2 Press the start key The accumulated time is clear
88. heck if the following electromagnetic Correct clutches are installed correctly feed clutch MP feed clutch and registration clutch 1 5 23 2DC 1 6 1 Precautions for assembly and disassembly 1 Precautions e Be sure to turn the main switch off and disconnect the power plug before starting disassembly e When handling PCBs do not touch connectors with bare hands or damage the board e Do not touch any PCB containing ICs with bare hands or any object prone to static charge e Use only the specified parts to replace the fixing unit thermostat Never substitute electric wires as the copier may be seriously damaged e Do not perform aging without the waste toner tank installed during maintenance service e Use the following testers when measuring voltages Hioki 3200 Sanwa MD 180C Sanwa YX 360TR Beckman TECH300 Beckman DM45 Beckman 330 Beckman 3030 Beckman DM850 Fluke 8060A Arlec DMM1050 Arlec YF1030C Capable of measuring RMS values e Prepare the following as test originals 1 NTC new test chart 2 NPTC newspaper test chart 1 6 1 2DC 1 6 2 Removing the process unit 1 Open the front top cover 2 Open the front cover 3 Lift the process unit together with the toner container out of the copier Front top cover Front cover s Process unit Figure 1 6 1 Removing the process unit CAUTIONS e After removing the process unit
89. hers Checking clearing copy counts by paper feed locations U993 Outputting a VTC PG pattern Initial setting for executing maintenance item U020 2DC 3 Contents of maintenance mode items Maintenance Description item No i Outputting an own status report Description Outputs lists of the current settings of the maintenance items and paper jam and service call occurrences Purpose To check the current setting of the maintenance items or paper jam or service call occurrences Before initializing the backup RAM output a list of the current settings of the maintenance items to reenter the settings after initialization or replacement Method 1 Press the start key A selection item appears 2 Select the item to be output using the copy exposure adjustment keys Display d L List of the current settings of the maintenance modes J L List of the paper jam occurrences C L List of the service call occurrences 3 Press the start key The test copy mode is entered and a list is output When A4 11 x 81 2 paper is available a report of this size is output If not specify the paper feed location When output is complete the selected item appears Completion Press the stop clear key while a selection item is displayed The indication for selecting a maintenance item No appears Exiting the maintenance mode Description Exits the maintenance mode and returns to the normal copy mode Purpose To exit the maintenance mode Me
90. ias board 3 a F Power supply unit 24V2 ls ront cover 24V2 High voltage interlock 24V2 output circuit n A ee Triac etc lt SWITC 24V2 24 V DC 24V1 24V1 output Machine left side view High voltage board Cooling fan Figure 2 3 10 Interlock switch 2 3 11 2DC 2 3 6 CCD board The CCD board consists mainly of a CCD sensor U4 that scans an original The CCD sensor U4 is driven to scan an original by the CCD sensor control signals CCDCLKN GH BW SH_RGB SW SWN CPN and RSN based on the clock for driving the CCD sensor CCDCLK supplied from the main board through the scanner board The image signals obtained from scanning of an original are divided into three analog signals CCDR2 CCDG2 and CCDB2 for output These signals are current amplified by the amplification circuit that consists of transistors TR1 to TR6 operational amplifiers U6 and U7 and so on and transmitted to the analog signal processing circuit on the main board through the scanner board Also the CCD board relays signal lines of the scanner home position sensor and the exposure lamp Main board CCD board Transistors TR1 2 3 4 5 6 OP AMPs U6 7 Scanner board Original NS CCDG2 SJ CCDB2 CCD sensor U4 Drivers U2 3 5 CCDCLK Exposure lamp Inverter board Li Scanner home position sensor Engine board Figure 2 3 11 CCD board circuit block diagram 2 3 12
91. igits of A5 size copy count Last 3 digits of A5 size copy count Clearing the count CLE A6 display the A6 size First 3 digits of A6 size copy count Last 3 digits of A6 size copy count Clearing the count CLE Fo display the FOLIO size First 3 digits of FOLIO size copy count Last 3 digits of FOLIO size copy count Clearing the count CLE Lg display the Legal size First 3 digits of Legal size copy count Last 3 digits of Legal size copy count Clearing the count CLE Lt display the Letter size First 3 digits of Letter size copy count Last 3 digits of Letter size copy count Clearing the count CLE SU display the Statement size First 3 digits of Statement size copy count Last 3 digits of Statement size copy count Clearing the count CLE ot display the other size First 3 digits of other size copy count Last 3 digits of other size copy count Clearing the count CLE Clearing all counts CLE 2DC Maintenance Description item No P Clearing copy counts by paper size 1 Select the paper size to clear the count 2 Display CLE using the copy exposure adjustment keys 3 Press the start key The count is cleared Clearing copy counts for all paper size 1 Select group 9 2 Press the start key The counts are cleared Completion Press the stop clear key The indication for selecting a maintenance item No appears U927 Clearing accounting counter Description Clears t
92. ing edge margin 3 2 5 mm Select the item to be adjusted using Figure 1 6 64 the copy exposure adjustment keys Exp 1 lit DP left margin Exp 2 lit DP leading edge margin Exp 3 lit DP right margin Exp 1 flashing DP trailing edge margin Press the program key and the machine enters the test copy mode Press the start key The new setting is stored Place an original on the DP and press the start key to make a test copy Are the margins correct Change the setting e Increasing the value using the zoom key makes the margin wider e Decreasing the value using the zoom key makes the margin narrower Setting range initial setting change in value per step DP left margin 0 10 2 0 0 5 mm DP leading edge margin 0 10 3 0 0 5 mm DP right margin 0 10 2 0 0 5 mm DP trailing edge margin 0 10 2 0 0 5 mm Y SS Proceed to another mode No Press the stop clear key to exit maintenance mode 1 6 54 2DC 2 1 1 Paper feeding system The paper feeding system picks up paper from the cassette MP tray or if installed the paper feeder feeds it in the copier and delivers in the output tray Paper is fed at the precise timing in synchronization with data processing The paper feeding system finally delivers the printed page to either the face down or face up tray as manipulated by the user The figure below shows the components in the paper feeding system and the paths
93. ing originals from the DP Purpose Used if the exposure amount differs significantly between when scanning an original on the contact glass and when scanning an original from the DP Method Press the start key Setting 1 Change the setting using the zoom keys Setting range Initial setting Increasing the setting makes the luminosity higher and decreasing it makes the luminosity lower 2 Press the start key The value is set Test copy mode While this maintenance item is being performed copying from an original can be made in test copy mode Completion Press the stop clear key The indication for selecting a maintenance item No appears 2DC Maintenance Description item No U087 Turning the DP scanning position adjust mode on off Description Turns on or off the DP scanning position adjust mode in which the DP original scanning position is adjusted automatically by determining the presence or absence of dust on the slit glass Also changes the reference data for identifying dust Reference In the DP original scanning position adjust mode the presence or absence of dust is determined by comparing the scan data of the original trailing edge and that taken after the original is conveyed past the DP original scanning position If dust is identified the DP original scanning position is adjusted for the following originals Purpose Used to prevent appearance of black lines due to dust adhering in the original scanning
94. ions e Number of copies continuous copying is performed when set to 99 e Copy density e Keys on the operation panel other than the energy saver preheat key To control the paper feed pulley remove all the paper in the drawers or the drawers With the paper present the paper feed pulley does not operate Press the start key The operation starts Copy operation is simulated without paper under the set conditions When operation is complete the selected item appears To stop continuous operation press the stop reset key Completion Press the stop clear key at the screen for selecting an item The indication for selecting a maintenance item No appears Displaying the ROM version Description Displays the part number of the ROM fitted to each board Purpose To check the part number or to decide if the ROM version is new from the last digit of the number Method 1 Press the start key A selection item appears 2 Select the item to be displayed using the image mode selection key and copy exposure adjustment keys Copy exposure ee Image mode LEDs Copy quantity display O MaAuto Exp number of the main ROM O AT 4ml Text amp Photo O Ciil Photo number of the main ROM sub T Text O Q Auto Exp number of the engine ROM O A T 4ml Text amp Photo 4 Photo T Text o Off e On Completion Press the stop clear key The indication for selecting a maintenance item No appears number of the engine ROM sub
95. irror A 4 Scanner home position sensor Scanner unit EE EE a ee Ee ISU unit Exposure Original image Scanner board SW Main board YC1 4 lt YC1 5 sensor SWN Inverter YC1 14 lt board CCD board YC1 12 CCDCLKN CCDCLK YC1 10 lt YC1 8 RSN CPN YC2 2 YC1 6 la YC1 18 CCDG O CCDB E YC1 20 YC1 22 Scanner BR position sensor YG1 29 30 Scanner motor CCDR LAMP __LAMPHI Engine board YC11 10 YC11 11 __ LAMPLOW YC11 12 Figure 2 1 5 Scanner control circuit block diagram CN11 1 wass Sua 2DC 2 1 5 2DC 1 ISU unit The ISU unit consists of an exposure lamp three mirrors an ISU lens a CCD board and so on Also an inverter board for driving the exposure lamp and a scanner home position sensor for detecting the home position of the ISU unit are incorporated The original on the contact glass is exposed to the light of the exposure lamp that is reflected by the reflector The image is input through reflection by the three mirrors and through the ISU lens to the CCD image sensor on the CCD board The CCD image sensor scans one row of the image in the main scan direction converts it to electric signals and outputs them to the main board Then the ISU unit is moved in the sub scan direction along the scanner shaft and the CCD image sensor scans the next row of the image in the mai
96. istration clutch malfunctions Electrical problem with the registration clutch Check if the feed roller of the optional drawer is de formed Defective registration sen sor Check if the registration clutch malfunctions Electrical problem with the registration clutch Defective exit sensor Check if the registration clutch malfunctions Electrical problem with the registration clutch Check if the upper and lower registration rollers contact each other Check if the lower exit roller and exit pulleys con tact each other Check if the press roller is extremely dirty or de formed Check if the separators are dirty or deformed Check visually and replace any deformed roller Run maintenance item U031 and turn registration sensor on and off manually Replace registration sensor if indication of the cor responding sensor is not light Run maintenance item U032 and select the registration clutch to be turned on and off Check the status and remedy if necessary Check visually and replace any deformed roller Run maintenance item U031 and turn registration sensor on and off manually Replace registration sensor if indication of the cor responding sensor is not light Run maintenance item U032 and select the registration clutch to be turned on and off Check the status and remedy if necessary Check visually and replace any deformed roller Run maintenance item U031 and turn registr
97. justment ensure that the above adjustments have been made in maintenance mode Procedure Enter maintenance mode Original Copy Copy Enter 066 using the copy exposure example 1 example 2 adjustment keys or zoom keys Figure 1 6 57 Press the start key Press the program key and the machine enters the test copy mode Place an original and press the start key to make a test copy For copy example 1 decrease Is the scanner the value using the zoom key leading edge registration For copy example 2 increase correct the value using the zoom key Yes Press the stop clear key to exit maintenance mode Press the start key The new setting is stored Setting range 32 32 Initial setting 0 Changing the value by 1 moves the leading edge by 0 17 mm 1 6 47 2DC 8 Adjusting the scanner center line Perform the following adjustment if there is a regular error between the center lines of the copy image and original U034 P 1 6 42 Caution U072 P 6 53 Before making the following adjustment ensure that the above adjustments have been made in maintenance mode Procedure 1 6 48 Scanner center line Enter maintenance mode Original Copy Enter 067 using the copy exposure example 1 adjustment keys or zoom keys Figure 1 6 58 Press the start key Press the program key and the machine enters the test copy mode Place a
98. l circuit Activation of the heater lamp is dominated by the HEAT signal which is derived by the engine CPU U1 at its pin 74 When its level is high transistor Q8 turns on photo triac PC2 and triac TRC1 turn on simultaneously and the heater lamp is applied with the primary AC voltage in turn Switching of triac TRC1 as affected by the HEAT signal is made in synchronization with the zero cross signal ZCROSS which is generated by the power supply unit The zero cross signal detector watches the transition of alternating plus and negative current and detects the zero crosses This detector derives the resultant ZCROSS signal at its pin 43 of the engine CPU U1 Since abrupt change in the current flow can be significantly avoided by synchronizing triac TRC1 with the zero cross signal the possibility of noise due to the primary AC supply is greatly reduced Engine board P72 ANI2 lt Heater lamp control circuit PDL3 AD3 43 POS INTP2 I Power supply unit AC input Be gt GC Thermal cutout Se High voltage board Heat roller Heater lamp lt II Thermistor Figure 2 3 4 Heater lamp control circuit 2 3 4 2DC The AC power for the heater is applied in one of the five variations of the zero cross switchings as shown in Figure 2 3 5 Each variation is constituted with the unit of ten positive and negative envelops in five cycles as obtained by varying the dura
99. lamp problem e In indicator check before starting copying the average value in scan ning of the shading plate with the CCD is 128 or more C3300 A3300 Optical system AGC problem e After AGC correct input is not ob tained at CCD C4000 A4000 Polygon motor synchronization problem e The polygon motor does not reach the stable speed within 15 s of the START signal turning on C4010 A4010 Polygon motor steady state problem e The polygon motor rotation is not Stable for 5 s after the polygon motor rotation has been stabilized C4200 A4200 BD steady state problem e The MIC detects a BD error for 600 ms after the polygon motor rotation has been stabilized A is displayed on the market 1 5 10 Defective scanner board KP 5063 Defective expo sure lamp or in verter board Incorrect shading position Poor contact of the connector ter minals Insufficient expo sure lamp lumi nosity Defective scanner board KP 5063 Incorrect shading position Poor contact in the polygon motor connector termi nals Defective polygon motor Defective engine board KP 5061 Poor contact in the polygon motor connector termi nals Defective polygon motor Defective engine board KP 5061 Defective laser diode Defective polygon motor Defective main board KP 5060 Causes Check procedures corrective measures Replace the scanner board KP 5063 a
100. memory and 5 MB of image storage memory Approx 30 pages of memory possible with A4 6 black originals Additional memory 1 slot 16 MB 32 MB 64 MB or 128 MB Continuous copying 1 99 sheets Scanning system Flat bed scanning by CCD image sensor Resolution u u uU u uuu uu s 600 x 600 dpi Light source Cold cathode lamp Photoconductor OPC drum diameter 30 mm Charging system Single positive corona charging Developing system Single element reversing process Transfer system Transfer roller Fixing system Heat roller Heat source halogen heaters 750 W Control temperature 180 C 356 F at normal ambient temperature Abnormally high temperature protection device thermal cutout Charge erasing system Exposure by cleaning lamp Cleaning system Cleaning blade Dimensions 496 W x 421 D x 385 H mm 199 16 W x 165 8 D x 159 16 H Weight Approx 14 kg 30 8 Ibs Floor requirements 496 W x 740 D mm 199 16 W x 298 16 D Functions Auto exposure adjustment Eco copy mode Zoom mode Preset zo
101. ming e Transfer charging output ON timing Setting toner loading operation High voltage U100 Checking clearing the developing drive time Developing U144 U157 U158 Checking clearing the developing count Initial setting for executing maintenance item U020 1 4 2 O1 N gt G O G O uo os Wa k N 2DC I Initial Maintenance item contents GES setting Fixing and U161 Setting the fixing control temperature cleaning e Primary stabilization fixing temperature 125 e Secondary stabilization fixing temperature 135 e Copying operation temperature 1 180 e Copying operation temperature 2 195 e Number of sheets for fixing control 5 EECHER ue Resetting the fixing problem data Um Checking the fixing temperature I Operaion UE Ing ali fee O paneland Un Operating DP separately a Suppor TS Checking the operation panclieys 0 U243 Checking the operation of the DP moos U244 CheckingtheDPswithes Mode seting s Turing auto start funtion eng o ss Setting autocleartime e a U 3 4 On Si Setting the destination specifications O G Setting the size conversion factor Setting the ejection restriction U Image U402 Adjusting margins for printing Oo U403 Adjusting margins for scanning an original on the contact glass processing Adjusting margins for scanning an original on the contact glass 1 4 3 Adjusting margins for scanning an original from the DP Ot
102. n a humid or dusty place This may cause fire or electric shock S e Do not install the copier near a radiator heater other heat source or near flammable material This may cause TE 425 lll l l Ea deste e de pei aval ona E E e a ai E RE E e Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool as possible Insufficient ventilation may cause heat buildup and poor copying performance e Always handle the machine by the correct locations when MOVING it e Always use anti toppling and locking devices on copiers so equipped Failure to do this may cause the copier to move unexpectedly or topple leading to injury Gei O O e Avoid inhaling toner or developer excessively Protect the eyes If toner or developer is accidentally ingested drink a lot of water to dilute it in the stomach and obtain medical attention TIC CICA e EE Q immediately If it gets into the eyes rinse immediately with copious amounts of water and obtain e Advice customers that they must always follow the safety warnings and precautions in the copier s Q mer cion NandDOOK E 2 Precautions for Maintenance A WARNING e Always remove the power plug from the wall outlet before starting machine disassembly e Always follow the procedures for maintenance described in the service man
103. n original and press the start key to make a test copy For copy example 1 increase Is the scanner the value using the zoom key center line correct For copy example 2 decrease the value using the zoom key Yes Press the stop clear key to exit maintenance mode End Press the start key The new setting is stored Setting range 66 66 Initial setting 15 Changing the value by 1 moves the center line by 0 17 mm Copy example 2 2DC 9 Adjusting the margins for scanning an original on the contact glass Perform the following adjustment if the margins are not correct U402 U404 ka co Caution Before making the following adjustment ensure that the above adjustments have been made in maintenance mode Procedure Enter maintenance mode Enter 403 using the copy exposure adjustment keys or zoom keys Press the start key Select the item to be adjusted using the copy exposure adjustment keys Exp 1 lit Scanner left margin Exp 2 lit Scanner leading edge margin Exp 3 lit Scanner right margin Exp 1 flashing Scanner trailing edge margin Press the program key and the machine enters the test copy mode Place an original and press the start key to make a test copy i No re the margins correct Yes Yes Proceed to another mode No Press the stop clear key to exit maintenance mode End Scanner leading edge
104. n scan direction The operation described above is repeated for scanning the overall image of the original If an optional DP is used the ISU unit stops at the position of the DP contact glass and scans sequentially one row of the image on the original in synchronization with the moving timing of the Original in the sub scan direction by driving the DP Original Figure 2 1 6 ISU unit 1 Exposure lamp 2 Scanner reflector 3 Mirror A 4 Mirror A 5 Mirror B 6 ISU lens 7 CCD image sensor CCD board 2 1 6 2DC 2 1 3 Electrophotographic system Electrophotography is the technology used in laser printing which transfer data representing texts or graphics objects into a visible image which is developed on the photosensitive drum finally fusing on paper using light beam generated by a laser diode This section provides technical details on the copier s electrophotography system 1 Electrophotographic cycle The electrophotography system of the copier performs a cyclic action made of six steps as follows Each step is technically explained in the following sections Laser scaner unit Process unit Exposure Drum I y Cleaning 3 Developing Fuser unit Figure 2 1 7 Electrophotographic cycle The sections for main charging exposure drum developing and cleaning are modularized in one Process unit 2 1 7 2DC 1 1 Process unit mechanism Driving power train A For drum From main
105. nd check for correct operation Replace the exposure lamp or inverter Adjust the position of the contact glass shading plate If the problem still occurs replace the scanner home position sensor Check the connection of connector YC 6 on the scanner board KP 5063 and the continuity across the connector terminals Repair or replace if necessary Replace the exposure lamp or inverter Replace the scanner board KP 5063 and check for correct operation Adjust the position of the contact glass shading plate If the problem still occurs replace the scanner home position sensor Reinsert the connector Also check for con tinuity within the connector cable If none remedy or replace the cable Replace the engine board KP 5061 and check for correct operation Reinsert the connector Also check for con tinuity within the connector cable If none remedy or replace the cable Replace the engine board KP 5061 and check for correct operation Replace the main board KP 5060 and check for correct operation Code C6000 C6020 C6050 C6400 Broken fixing heater wire e In fixing warm up the time to reach 50 C 122 F exceeds 13 5 s the time to reach 100 C 212 F exceeds 10 s the time to reach the primary stabili zation exceeds 10 s or the time to reach the secondary stabilization ex ceeds 24 s Abnormally high fixing unit ther mistor temperature e The fixing temperature exceeds 230
106. nevenness moir on halftone image areas of the copy image in text mode and text and photo mode Such moir is more likely to appear when an enlargement or reduction copy is made in text mode from an original containing large halftone image areas Method Press the start key Setting 1 Select on or oFF using the zoom keys on Moire reduction mode OFF Normal copy mode Initial setting OFF If more on the copy image is significant change the setting to on Note that when the moire reduction mode is turned on the resolution may be slightly reduced 2 Press the start key The value is set The indication for selecting a maintenance item No appears Completion To exit this maintenance item without changing the current setting press the stop clear key The indication for selecting a maintenance item No appears U089 Outputting a MIP PG pattern Description Selects and outputs a MIP PG pattern created in the copier Purpose When performing respective image printing adjustments used to check the machine status apart from that of the scanner with a non scanned output MIP PG pattern Method 1 Press the start key 2 Select the MIP PG pattern to be output using the copy exposure adjustment keys G S Gray scale 0 Mono level 0 to 255 FFL 256 level 1 d 1 dot level 3 Press the program key The machine enters the PG pattern output mode 4 Press the start key A MIP PG pattern is output Completion Press
107. nner home position sensor 6 Scanner motor 7 Exposure lamp 2 3 1 Main board 2DC Scanner I F CCDCLKN CCDCLK RSN CPN SH 2 5V Regulator IMG7 0 5V 2 5V ADCCLK SHD LCLP CCDG O OEB AFESDENB A F E CCDG AFESDIN AFESDCLK CCDR E Operat I F SYSTEM perator pane Xtal VIDEO SKR add KEYON KEY1N EY2N 17 483375MHz SCANON SCANIN SCAN2N SCAN3N SCAN4N SCAN5N Xtal CCD l LEDON LED1N LED2N LED3N 14 798200MHz ASIC CPUCLK LED4N LED5N LED6N BUZERDRN 9 71MHz 9 71MHz PLL EEDIO SYSTEM CPU EESCL EEPROM ASIC debugger I F 19 42MHz DBRXD DBOUT7 0 MEMORY READYN Debugger DBOUT7 0 INTREQN DBTXD connector RD WR DQM3 1 RASN CASN WEN BA1 BAO CPUA18 0 CK2 CK3 MCS4N MCSGN IICSCL CPUD7 0 IICSDA CPUA23 21 Z a SRAM 256kbit SDRAM data bus ae DRAM S address bus CPUAI7 0 EL WR RD a SDRAM ke BS RD BMB kl ZS CSROMN DID DIMM A 0 slot z CSAION CPUD7 0 CPUA17 0 SDRAM 8MB CE j Engine I F SCKN FGSO SBSY EGSI SDIR EGIRN PDMASKN APC I F VDATA SAMPLEN PLGCLK OUTPEN PDMASKN OVSYNCN Figure 2 3 1 Main board circuit block diagram 2 3 1 2DC 2 3 2 Engine board Engine board KP 5061 Scanner motor
108. oduct name on the reports that users print Purpose To be set according to user request Method Press the start key The current setting appears Setting 1 Enter 0 or 2 using the zoom keys 0 Product name printed 2 Product name not printed Initial setting 0 2 Press the start key The setting is set Completion To exit this maintenance item without changing the current setting press the stop clear key The indication for selecting a maintenance item No appears Setting the size conversion factor Description Sets the coefficient of nonstandard sizes in relation to the A4 11 x 81 2 size The coefficient set here is used to convert the black ratio in relation to the A4 11 x 81 2 size and to display the result in user simulation Purpose To set the coefficient for converting the black ratio for nonstandard sizes in relation to the A4 11 x 81 2 size for copying and printing respectively Method Press the start key The current setting is displayed Setting 1 Change the setting using the zoom keys Description Setting range Initial setting Size conversion factor 0 0 to 3 0 1 0 2 Press the start key The value is set and the indication for selecting a maintenance item No appears Completion To exit this maintenance item without changing the current setting press the stop clear key The indication for selecting a maintenance item No appears Setting the ejection restriction Description
109. om mode Off mode Low power mode Layout modes Sort mode and Program function Power source 120 V AC 60 Hz 7 3 A 220 240 V AC 50 60 Hz 2 6 A average Power consumptlion 854 W leide E Paper feeder Document processor and Additional memory ee 2DC 1 1 2 Name of parts 1 Copier JER au Ke 18 GT EE ES SS w CS s M oI na T T CGT Z tap K ed Figure 1 1 1 Name of parts 1 Original holder 3 Paper guide 2 Contact glass Paper stopper 3 Original size indicator 45 Paper stopper 4 Operation panel Face down output tray 5 Front top cover 7 MP tray 6 Front cover Extension tray 7 Process unit Slider Toner container GO Power swtch 9 Lock lever GO Face up output tray Toner container release lever 2 Power cord 1 Main charger cleaner 3 DF interface connector 2 Cassette 4 Memory cover s 2DC 2 Operation panel oz 2in1 f 4in1 O Stop Clear J Sort Ye 200 Max 141 A5 A4 129 STMT gt LTR 100 78 LGL gt LTR 70 A4 A5 50 Min gt Start gt ETRE e O ES ee O Auto Exp o T o Thick Paper Text amp Photo O 4m Photo S o T Text Lighter Darker paa Mococoff a ae o Figure 1 1 2 1 Start key Indicator 2 Reset Power key 3 Sto
110. oping roller A is also AC biased to ensure contrast in yielding by compensating the toner s attraction and repelling action during development 2 1 14 5 Transfer 2DC The image developed by toner on the drum A is transferred onto the paper because of the electrical attraction between the toner itself and the transfer roller B The transfer roller is negatively biased so that the positively charged toner is attracted onto the paper while it is pinched by the drum and the transfer roller Transfer bias High voltage board Bias A RTHVDR THVDR HVISEL CN2 A6 CN2 A5 PSEL1 sh PSEL2 Figure 2 1 15 Transfer Engine board YC7 16 YC8 2 YC7 14 YC7 11 YC7 9 The nominal transfer bias is set to approximately 1 8 kV limit with the 6 mA current Since the ideal potential of the transfer bias depends on the thickness of paper the bias is raised to approximately 2 5 kV 6 mA for thicker paper On the other hand the bias current is reduced to 1 8 kV 6 mA for thin paper 2 1 15 2DC 6 Fusing The toner on the paper is molten and pressed into the paper as it passes between the heat roller A and the press roller in the fuser unit Figure 2 1 16 Fusing The heat roller has a halogen lamp inside which continuously turns on and off by the thermistor to maintain the constant temperature onto the heat roller surface The heat roller is resin coated by
111. orm the following adjustment if the magnification in the main scanning direction is not correct U065 _U065 main scanning auxiliary scanning direction direction P 1 6 46 Caution Before making the following adjustment ensure that the above adjustments have been made in maintenance mode Also perform 6 Adjusting magnification of the scanner in the auxiliary scanning direction page 1 6 46 and 8 Adjusting the scanner center line page 1 6 48 after this adjustment Enter maintenance mode Enter O65 using the copy exposure adjustment keys or zoom keys Original Copy Copy example example 2 Procedure Select Exp 1 main scanning direction using the copy exposure adjustment keys chine enters te tet copy mo machine enters the test copy mode Press the start key The new setting Place an original and press is stored the start key to make a test copy For copy example 1 increase the f value using the zoom key Is the image correct For copy example 2 decrease the value using the zoom key Setting range 25 25 Initial setting 0 Press the stop clear key to Changing the value by 1 changes exit maintenance mode the magnification by 0 1 Increasing the value makes the image wider and decreasing it makes the image narrower End 1 6 45 2DC 6 Adjusting magnification of the scanner in the auxiliary scanning direction Perform the following
112. ove the main charger cap 3 Draw the main charger unit in the direction of arrow A then pull it out in the direction of arrow GB Main charger unit Main charger cap Main charger unit Figure 1 6 50 Removing the main charger unit CAUTION e When refitting the main charger unit hold terminal down then push frontwards Use care not to deform the terminal 1 6 40 2DC 1 6 17 Adjustment the maintenance mode 1 Adjusting the leading edge registration of image printing Make the following adjustment if there is a regular error between the leading edges of the copy image and original U066 U071 Caution Check the copy image after the adjustment If the image is still incorrect perform the above adjustments in maintenance mode Procedure Leading edge registration F Enter maintenance mode Enter 034 using the copy exposure Correct image Output Output adjustment keys or zoom keys example 1 example 2 Figure 1 6 51 Press the start key Select the items to be adjusted using the copy exposure adjustment keys Exp 1 lit Leading edge registration from the drawer Exp 2 lit Leading edge registration from the bypass tray Press the program key and the Press the start key machine enters the test copy mode The new setting is stored Press the start key to output a test pattern For output example 1 decrease the value using the zoom key For output example 2 increase the v
113. p Clear key 4 Copy quantity magnification display 5 Copy exposure adjustment keys 6 Image mode selection key 7 Number of Copies Zoom key Number of Copies Zoom key 9 Recall Enter key Reduce Enlarge key 1 Paper Select key 2 Thick Paper key 2DC 1 2 1 Drum Note the following when handling or storing the drum e When removing the process unit never expose the drum surface to strong direct light e Keep the drum at an ambient temperature between 10 C 50 F and 32 5 C 90 5 F and at a relative humidity not higher than 80 RH Avoid abrupt changes in temperature and humidity e Avoid exposure to any substance which is harmful to or may affect the quality of the drum e Do not touch the drum surface with any object Should it be touched by hands or stained with oil clean it 1 2 2 Installation environment 1 Temperature 10 32 5 C 50 90 5 F 2 3 4 oF Humidity 20 80 RH Power supply 120 V AC 7 3 A 220 240 V AC 2 6 A average Power source frequency 50 Hz 0 3 60 Hz 0 3 Installation location e Avoid direct sunlight or bright lighting Ensure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams e Avoid extremes of temperature and humidity abrupt ambient temperature changes and hot or cold air directed onto the machine e Avoid dust and vibration e Choose a surface capable of supporting the weight of the machine e Plac
114. position on the slit glass when the DP is used Method 1 Press the start key 2 Select the item to be set by lighting a copy exposure indicator using the copy exposure adjustment keys Copy exposure indicator Description Exp 1 Setting the mode on off Exp 2 Setting the reference data for identifying dust Setting the mode on off 1 Select on or oFF using the zoom keys on DP scanning position adjust mode on oFF DP scanning position adjust mode off Initial setting on 2 Press the start key The setting is set Setting the reference data for identifying dust Available only when the mode is turned on 1 Change the setting using the zoom keys Minimum density to be regarded as dust 10 to 95 Example The figure indicates the density in 256 levels of gray 0 white 255 black When the setting is 35 data of the level of 35 or higher is regarded as dust and data of lower level is regarded as the background scan data taken when there is no original 2 Press the start key The value is set Completion To exit this maintenance item without changing the current setting press the stop clear key The indication for selecting a maintenance item No appears A 2DC Maintenance Description item No i U088 Setting the input filter moir reduction mode Description Turns moir reduction mode on and off by switching the input filter on and off Purpose Used to prevent regular density u
115. r Paper on the MP tray is extremely curled Check if the MP feed roller is deformed Defective registration sen sor Check if the MP feed clutch malfunctions Electrical problem with the MP feed clutch Paper in the drawer is ex tremely curled Check if the feed roller is deformed Defective registration sen sor Check if the feed clutch malfunctions Electrical problem with the feed clutch Paper in the optional drawer is extremely curled Check if the feed roller of the optional drawer is de formed Defective registration sen sor Check if the feed clutch malfunctions Electrical problem with the feed clutch Check visually and remove it if any Run maintenance item U031 and turn registration sensor on and off manually Replace registration sensor if indication of the cor responding sensor is not light Run maintenance item U031 and turn exit sensor on and off manually Replace exit sensor if indication of the corresponding sensor is not light Change the paper Check visually and replace any deformed roller Run maintenance item U031 and turn registration sensor on and off manually Replace registration sensor if indication of the cor responding sensor is not light Run maintenance item U032 and select the MP feed clutch to be turned on and off Check the status and remedy if necessary Change the paper Check visually and replace any deformed roller Run maintenanc
116. r Current input switch fuse SW1 F1 Power supply unit Heater lamp f Thermal Of cutout 2 3 8 Exit EXITN 7 oan sensor Transformer T1 24V1 rectifier 24 V DC SLEEPN smooth shutoff ing circuit Circuit EAN Cooling fan 24V1 5 V 5V DC detection rectifier smooth ing circuit PGND SGND THERM I _ _ x Photo Over voltage Thermistor ae coupler detection fe U PC1 circuit Un ss 24V2 a E Transistor ZCROSS pler Q8 PC3 Zero cross signal detection circuit HEATN Figure 2 3 7 Power supply board circuit block diagram 2DC 2 3 4 Bias board The bias board contains the developing bias output circuit registration sensor paper empty sensor and the cassette switch It also provides a liaison connection to the high voltage board power supply and the toner sensor Bias board KP 5067 5V Engine board TONER TONEREPY 24V2 SLEEP Regist ration sensor High voltage board PAPERN RTHVDR HVISEL PSEL1 PSEL2 FAN1 FAN FAN2 HEATN ZCROSS SLEEPN EXTIN THERM 275V DC AC aa bias output circuit Developing roller Figure 2 3 8 Bias board circuit block diagram 2 3 9 2DC 2 3 5 High voltage board The high voltage board contains the high voltage output circuit interlock switch circuit as well as provi
117. r powder The conveying roller and Check and remedy conveying pulleys do not contact correctly The exit roller and exit pul Check and remedy leys do not contact cor rectly 1 5 7 2DC 1 5 2 Self diagnosis 1 Self diagnostic function This unit is equipped with a self diagnostic function When a problem is detected copying is disabled C and a number between 0100 and 7990 altenates indicating the nature of the problem After removing the problem the self diagnostic function can be reset by turning interolck switch off and back on 2 Self diagnostic codes C0100 C0110 A0110 C0160 A0160 C0210 A0210 Backup memory read write problem main board KP 5060 e Read and write data does not match Backup memory data problem main board KP 5060 Data in the specified area of the backup memory does not match the specified values Backup memory read write problem engine board KP 5061 e Read and write data does not match Backup memory data problem en gine board KP 5061 e Data in the specified area of the backup memory does not match the specified values Accounting count problem e When the power is turned on the to tal count and the scan count are ab normal both on the main board KP 5060 and the engine board KP 5061 Machine number mismatch e When the power is turned on the ma chine number does not match be tween the main board KP 5060 and the engine
118. rect electrostatic system Side lat EE Sheets of paper Maximum original size folio 81 2 x 14 legal Platen Sheets of paper books 3 dimensional objects Maximum original size folio 81 2 x 14 legal Original feed system Contact glass fixed Document processor optional sheet through CODY paper Cassette Plain paper 60 90 g m thick paper mode 90 105 g m2 Bypass table Plain paper 60 90 g m thick paper mode 90 163 g m Special paper Transparencies letterhead colored paper recycled paper Note Use the bypass table for special paper Copying sizes Maximum folio 81 2 x 14 legal Minimum A6R 51 2 x 81 2 Magnification ratios Manual mode 50 200 1 increments Copy speed At 100 magnification in copy mode A4R 81 2 x 11 15 copies min First CODY Din uuu lu uu us Within 9 5 s A4 81 2 x 11 original placed on the platen Warm up time Within 15 s room temperature 23 C 73 4 F humidity 50 RH Recovery from the low power mode Within 10 s room temperature 23 C 73 4 F humidity 50 RH Paper feed system Automatic feed Capacity Cassette 250 sheets 80 g m Manual feed Capacity Bypass 50 sheets 80 g m Standard memory 16 MB 11 MB of bitmapping
119. rocess unit Toner container SS E H eiw de Figure 1 3 17 10 Push the lock lever back into its locked position 11 Set the process unit into the copier by aligning the pins on both sides of the process unit with the N guides inside the copier and then slide the T process unit all the way back into the copier until it stops Pin Pin Figure 1 3 19 1 3 9 2DC 12 Close the front cover Figure 1 3 20 13 Close the front top cover Front top cover Figure 1 3 21 1 3 10 Connect the power cord 1 Connect the power cord Initializing the copier 1 Turn the main switch to the copier ON First 900 will appear in the copy quantity magnification display on the copier s operation panel The copier will then begin operation and a countdown of the time until the copier will be ready will be shown 900 seconds 15 minutes As the copier is carrying out the necessary toner Supply operation you will need to wait until that operation is completed Once the copier is in a copy ready state 1 will appear in the copy quantity magnification display and the Start indicator will light 2DC Power cord Figure 1 3 22 TT ER l EES SCH k Power switch REES ee ENEE Memory Overflow Figur
120. rsssnrrrssssssrrssssssisssa 1 6 9 2 REMOVING the main board REESE REESE EET rrenen rrenen 1 6 10 3 Removing the power supply board and high voltage board 1 6 12 4 Removing the bias board cccccccccseesseceeeceeeeeeeeeeceaaeeeeeeeesaeaeeeeeeesseeeceeeesseaeaeeeeeessaaeeeeeeessaaeeeeees 1 6 13 1 6 8 Removing the main motor and drive unit cccceccecceeceeeeeeeeceeceeeseeeeeeeseeeeceeeseeeaseeeeeeseeaeeeeeeessaaseeeees 1 6 14 1 6 9 Removing and splitting the fuser unt 1 6 18 1 Removing the separation craws a ERE SEES SEES REESE REELLE 1 6 20 2 Removing the heater lompe 1 6 21 3 Removing the heat roller ccccccccccsssssecececeseeeeeeeeeeuaeeceeeeeseeeeeeeeeesseaeceeeesseaeeeeeeeesseaeeeeeeessaeeeeees 1 6 22 4 Removing the thermistor cccccccccccsssececeeeeeececeeeeeeceeeeeeecsasseeeseaeceesaeeeeesseaeeeseseuseeessneeesseaeeeeess 1 6 24 5 Removing the thermal cutout a aaa sarrrrrssssssrrsssssssssa 1 6 25 6 Removing the press roller aa r aarsnsrrrrssssssrsssssssssrsssssssssa 1 6 26 1 6 10 Removing ANd scanner unt 1 6 27 1 6 11 Removing the laser scanner unit and heeraserlamp 1 6 29 1 6 12 Removing the ISU unt 1 6 32 1 6 13 Removing the exposure lamp ENEE 1 6 34 1 6 14 Removing the scanner Mirror A cccccseececcceeseeeeceeeeeeccueeeeceaaeeeecsauceeesaueeeessaaeeeessuaeeeessaeeessaan
121. s 4 Remove four connectors 5 Remove six screws and then remove the LSU shield Screw When refitting the LSU shield tighten a LSU shield screw in order of 4 from 1 BZ en x z eg wem SI Connectors oe id Screw Figure 1 6 32 Removing the LSU shield Screws 1 6 29 2DC 6 Remove three screws 7 Remove two connectors from the laser scanner unit 8 Remove the laser scanner unit When refitting the laser scanner unit tighten a screw in order of 3 from 1 Screws Laser scanner unit Conncetor Figure 1 6 33 Removing the laser scanner unit 1 6 30 2DC 9 Remove the eraser lamp 5 2 34 Removing the eraser lamp 1 6 31 1 6 32 2DC 1 6 12 Removing the ISU unit 1 Unhook the two hooks by using screw driver through the holes and then remove the operation unit Operation unit H Hook i Hole Ca 2 Remove two screws and then remove the original holder cover Original holder cover Figure 1 6 35 Removing the operation unit prm A Figure 1 6 36 Removing the original holder cover 2DC 3 Remove two screws and then remove two grounding plates 4 Remove the one stopper ring and then detach the scanner shaft Detach the shaft taking care to tilt it as little as possible Stopper ring n Scanner shaft 5 Remove the flexible flat cable from the ISU board s connector
122. s tion tion tration clutch turning on 70 71 Exit sec Misfeed in the exit sec The exit sensor does not turn off within 2765 ms of the regis tion tion tration sensor turning off No original feed When the main switch is turned on the machine detects acti vation of the DP timing switch The machine cannot detect activation of the DP timing switch even after 600 ms elapses since the start of primary paper feed and cannot detect it at the same timing even after four times of retry An original jam in the The machine cannot detect deactivation of the DP timing Original conveying sec switch even after 4100 ms elapses since the start of second tion ary paper feed 1 5 3 2DC 3 Paper misfeeds e Copier Problem Causes check procedures Corrective measures 1 A paper jam in the conveying fixing or exit section Is indi cated as soon as the main switch is turned on Jam code 00 2 A paper jam in the paper feed section is indicated during copying no paper feed from the MP tray Jam code 10 3 A paper jam in the paper feed section is indicated during copying no paper feed from the drawer Jam code 11 4 A paper jam in the paper feed section is indicated during copying no paper feed from the op tional drawer Jam code 12 1 5 4 A piece of paper torn from copy paper is caught around registration sensor or exit sensor Defective registration sen sor Defective exit senso
123. s If the drum process unit remains removed form the copier it should be stored in a cool dark place Photo conductive layer Aluminum base cylinder Figure 2 1 9 Photo conductive drum 2 1 9 2DC 2 2 Charging the drum The following shows a simplified diagram of the electrophotographic components in relation to the engine system Charging the drum is done by the main charger unit A High voltage board Bias Engine board board CN2 A4 EE YC8 5 YC M Main charging output Figure 2 1 10 Charging the drum As the drum rotates in a clean neutral state its photoconductive layer is given a uniform positive corona charge dispersed by the main charger wire 8 Due to high voltage scorotron charging the charging wire can get contaminated by oxidization after a long run Therefore it must be cleaned periodically from time to time Cleaning the charging wire prevents print quality problems such as black streaks 2 1 10 2DC 3 Exposure The charged surface of the drum A is then scanned by the laser beam from the laser scanner unit B Figure 2 1 11 Exposure The laser beam 780 nm wavelength beam is dispersed as the polygon motor polygon mirrors revolves to reflect the laser beam over the drum Various lenses and mirror are housed in the scanner unit adjust the diameter of the laser beam and focalize it at the drum surface 2AA 2DC 3 1 Laser scanner unit
124. s con tact each other 1 5 6 2DC DP Problem Causes check procedures Corrective measures 1 A piece of paper torn from Remove any found An original jams an original is caught when the main around the DP timing switch is turned on switch Defective DP timing Run maintenance item U244 and turn DP timing switch on and switch off manually Replace DP timing switch if indication of the corre sponding switch is not light 2 Defective DP timing Run maintenance item U244 and turn DP timing switch on and An original jams in switch off manually Replace DP timing switch if indication of the corre the DP is indicated sponding switch is not light during copying no Original feed Jam code 70 Check if the forwarding Check visually and replace the deformed pulley pulley or feed pulley is de formed 3 Defective DP timing Run maintenance item U244 and turn DP timing switch on and An original jams in switch off manually Replace DP timing switch if indication of the corre the DP during copy sponding switch is not light ing a jam in the original conveying section Jam code 71 Check if the conveying Check visually and replace the deformed roller roller or exit roller is de formed 4 An original outside the Use only originals conforming to the specifications Original jams fre specifications is used quently The forwarding pulley or Clean with isopropyl alcohol feed pulley is dirty with pa pe
125. sing direction 1 Remove the process unit See page 1 6 2 2 Remove the transfer roller from the both bushes Paper passing direction J Long Short ikin a Transfer roller Z k SET fe Ba B h Gear US N K Bush Black colored K k N Ki Spring Ki K Black colored x N Transfer roller i N KU N d SY 3 SS i 5 J A a om Transfer roller Figure 1 6 10 Removing the transfer roller 1 6 8 1 6 7 Removing the principal circuit boards 1 Removing the engine board 1 Remove the right cover See pages1 6 4 2 Remove all twelve connectors from the engine board 3 Remove three screws 4 Remove the engine board ss Engine board Figure 1 6 11 Removing the engine board 2DC 2 Removing the main board 1 Remove the right cover See page 1 6 4 2 Remove the three connectors 3 Remove the one flexible flat cable 4 Remove the seven screws and then remove the main controller shield with main board Main controller shield with main board Flexible flat cable Connectors lt s Screw Screws Figure 1 6 12 Removing the main controller shield with main board 1 6 10 2DC 5 Remove two screws at the back of the main board Main board Screws 3 I I D Figure 1 6 13 Removing the main board 1 6 11 2DC 3 Removing th
126. sssssssssssssssssssssssassa 2 1 14 3 TANGICE Junu REE SEE SEERE EEN Ee eEeEe 2 1 15 0 FI e EE 2 1 16 6 1 Fuser unit mechanism EE 2 1 17 7 CIGANINO 2s oe secaneectasaancusaveceestnaastcsac neatponseebeatanstaceascamssaedsansam cenecosstens atesaxeasel ocuiacteaceae teuseartiesesmeacnas 2 1 18 2 2 Electrical Parts Layout 2 2 1 Electrical parts layout EE 2 2 1 ell aI TUE 2 2 1 2 Scanner ini uu uu uuu u 2 uu spsssssscssessasashassp ssa ssisssesspassatasshastushayakassk2ssissaspaqisstaasas 2 2 2 2 3 Operation of the PCBs E WO ln Kee e EE 2 3 1 2 3 2 Engine board ME 2 3 2 1 Eraser lamp E eieiei 2 3 3 2 Heater lamp control circuit cece eecceccseeeeeeceeeeeeeceeseeeeeseueeeceseeeeeeceaeeeeseaeeeeeseeeeessaaeeesseaeeeeeeseeeeeeeas 2 3 4 3 Polygon motor conformel de ae be aaaeaii 2 3 7 2 3 3 Power supply board NEE 2 3 8 2 A Bia Le e u u u apaautakspascsstasshasustusukawqkiaackapaypaususupuaautupuqswswkaosuqastuwsqussuauatiwquwbtsykaqsvbapayaasqiwacwskkua 2 3 9 2 3 5 High voltage board a s E REESE REESE RER E REE E REESE ERE enne 2 3 10 1 OOCK SWIG WE 2 3 11 236 CCD DOO eebe Eeer 2 3 12 237 Operation e e 2 3 13 2 3 8 Scanner board E 2 3 14 2 4 Appendixes TGE i Ce GE 2 4 1 Timing elin Te GE 2 4 2 Tin qa m I NO EE 2 4 3 Wima dagian WE 2 4 4 2DC 1 1 1 Specifications WV OG FEE Er Eee unas Desktop Copying system Indi
127. t is to be checked or cleared by lighting image mode LEDs using the image mode selection key 3 Change the indication of the copy quantity display by lighting a copy exposure indicator using the copy Copy exposure Copy quantity display count value exposure adjustment keys Image mode LED group No O auto Exp O T 4ml Text amp Photo O 4m Photo e Text O auto Exp O AT 4ml Text amp Photo 4m Photo e Text O Auto Exp 4T 4al Text amp Photo 4m Photo e Text Q Auto Exp 4T 4al Text amp Photo 4a Photo e Text o Off e On First 3 digits of bypass copy count Last 3 digits of bypass copy count Clearing the count CLE First 3 digits of the drawer copy count Last 3 digits of the drawer copy count Clearing the count CLE First 3 digits of the optional drawer copy count Last 3 digits of the optional drawer copy count Clearing the count CLE Clearing all counts CLE Note When no optional paper feed device is installed the counts corresponding to optional paper feed devices will not appear Clearing copy counts by paper feed locations 1 Select the paper feed location to clear the count 2 Light exp 3 using the copy exposure adjustment key 3 Press the start key The count is cleared Clearing copy counts for all paper feed locations 1 Select group 4 2 Press the start key The counts are cleared Completion Press the stop clear key The indication for s
128. temperature 2 Exp 2 flashing Number of sheets for fixing control 1 to 99 Copying operation temperature 1 Temperature in copying operation at the start of copying Copying operation temperature 2 Temperature in copying operation after the specified number of sheets for fixing control have passed Number of sheets for fixing control The number of sheets to be counted for switching from copying operation temperature 1 to copying operation temperature 2 The temperatures are to be set such that Secondary 2 Primary 3 Press the start key The value is set Completion To exit this maintenance item without changing the current setting press the stop clear key The indication for selecting a maintenance item No appears 1 4 18 2DC Maintenance Description item No P Stabilizing fixing forcibly Description Stops the stabilization fixing drive forcibly regardless of fixing temperature Purpose To forcibly stabilize the machine before the fixing section reaches stabilization temperature Method 1 Press the start key on appears 2 Press the start key The forced stabilization mode is entered and stabilization operation stops regardless of fixing temperature The indication for selecting a maintenance item No appears To exit the forced stabilization mode turn the power off and on Completion Press the stop clear key The indication for selecting a maintenance item No appears Resetting the fixing problem data D
129. tenance mode center line by 1 mm End 1 6 42 2DC 3 Adjusting the margins for printing Make the following adjustment if the margins are not correct U403 U404 P 1 6 49 P 1 6 54 Caution Check the copy image after the adjustment If the margins are still incorrect perform the above adjustments in maintenance mode Procedure Printer leading edge margin Kaz mm Enter maintenance mode Ejection direction TET T reference Printer lt Printer Enter 402 using the copy exposure left margin right margin adjustment keys or zoom keys 2 0775 mm 2 0235 mm Press the start key Printer trailing edge margin Select the item to be adjusted using 3425 Se 9 9 the copy exposure adjustment keys FE Exp 1 lit Printer leading edge margin Figure 1 6 53 Exp 2 lit Printer left right margins Exp 3 lit Printer trailing edge margin Press the program key and the machine enters the test copy mode Press the start key to output a test pattern Press the start key The new setting is stored Change the setting Increasing the value using the zoom re the margins correct key makes the margin wider Decreasing the value using the zoom key makes the margin narrower Setting range initial setting change in value per step Printer leading edge margins 0 10 3 0 0 5 mm Printer left right margin 0 10 3 5 0 5 mm Printer trailin
130. the power supply board KP 5059 and the continuity across the connector terminals Repair or replace if necessary Measure the resistance If it is Q replace the thermistor Check for continuity If none replace the thermal cutout Check for continuity If none replace the heater lamp Check the connection of connectors YC7 on the engine board KP 5061 and CN2 on the power supply board KP 5059 and the continuity across the connector termi nals Repair or replace if necessary Check if the zero crossing signal is output from CN2 11 on the power supply board KP 5059 If not replace the power supply board KP 5059 Replace the engine board KP 5061 if C6400 is detected while CN2 11 on the power supply board KP 5059 outputs the zero crossing signal 1 5 11 2DC C7800 A7800 C7810 A7810 Contents Broken external temperature ther mistor e The input voltage is 0 5 V or less Short circuited external temperature thermistor e The input voltage is 4 5 V or more Waste toner reservoir overflow probrem when the total number of copies is less than 100 thousand sheets e After E31 is displayed 1 000 sheets are copied Or waste toner exceeds 5 g Waste toner reservoir overflow probrem when the total number of copies is 100 thousand sheets or more e After E31 is displayed 1 000 sheets are copied Or waste toner exceeds 5 g A is displayed on the market 1 5 12 Poor
131. thod Press the start key The normal copy mode is entered Checking the machine number Description Displays the machine number Purpose To check the machine number Method 1 Press the start key The currently set machine number is displayed 2 Change the indication of the copy quantity display by lighting a copy exposure indicator using the copy exposure adjustment keys Copy exposure indicator Copy quantity display 1st digit of machine number 2nd digit of machine number 3rd digit of machine number flashing 4th digit of machine number flashing oth digit of machine number flashing 6th digit of machine number flashing 7th digit of machine number 8th digit of machine number 9th digit of machine number 10th digit of machine number flashing flashing flashing Completion Press the stop clear key The indication for selecting a maintenance item No appears 1 4 4 2DC Maintenance Description item No P Copying without paper Description Simulates the copy operation without paper feed Purpose To check the overall operation of the machine Method 1 Press the start key A selection item appears 2 Select the item to be operated using the copy exposure adjustment keys Display Operation Only the copier operates Both the copier and DP operate Press the program key Set the operation conditions required Changes in the following settings can be made e Paper feed locations e Magnificat
132. through which the paper travels The sensors clutches etc are described in the following pages E gg AET TE Figure 2 1 1 Paper feeding path 1 Cassette 1 Upper registration roller 2 MP tray 2 Transfer roller 3 Face down output tray 43 Drum 4 Face up output tray Heat roller 5 Process unit 45 Press roller 6 Fuser unit Lower exit roller 7 Feed roller 7 Exit pulley Feed pulley Upper exit roller 9 MP feed roller Exit pulley Lower registration roller S i 2DC 1 Paper feed control The following diagram shows interconnectivity of the feeding system components including the sensors and rollers The engine board provides the signals in conjunction with the electrophotography process that is driven by the main board Toner container Process unit Registration sensor MP tray a Ghee MP paper sensor Developing roller Y NOS OL CO Registration clutch em P u uu i Paper Optional paper feeder Power supply board High voltage board Bias board Main motor HANDSN FEDDRN II RESDRN MPFDRN EXITN MOTORN Engine board G MP feed roller Feed roller Gi Lower registration roller 4 Upper registration roller 5 Transfer roller 6 Heat roller 7 Lower exit roller Upper exit roller Figure 2 1 2 Paper feed control 2 1 2 2DC 2
133. tic bag Side pad 2DC CAUTIONS e Be sure to hold both the front and rear sides of the copier when carrying it as shown in the illustration e Be sure not to pull the cassette out when holding the front of the copier e Be sure that the original cover is closed whenever transporting the copier e DO NOT attempt to carry the copier by holding only the top portion Doing so may result in you dropping the copier and thereby damaging the copier and or its covers Figure 1 3 2 1 3 3 2DC Remove the tapes pads and sheets 1 Remove the sheet and the two tapes 2 Open the original cover Original cover Figure 1 3 4 2DC 3 Remove the nine tapes the three pads and the sheet Figure 1 3 5 4 Pull the cassette out of the copier Q o o O 2 weng s gt LL e D Wu WA G O te WA O Dum O G Q Be gt O E D EE LO Figure 1 3 7 1 3 5 2DC Remove the pin holding scanner unit 1 Remove the yellow pin for scanner unit and the paper tag from the left side of the copier Install a toner container 1 Open the front top cover and front cover 2 Store the pin for scanner unit on the inside of the front cover as shown in the illustration Be sure to save this pin as it is essential that it be used whenever the copier is moved The location for storing the pin is cle
134. tion during which TRC1 turns on The heater lamp is energized while TRC1 is kept on the heater lamp is turned off while TRC1 is kept off For example the duty cycle the period of a cycle during which the heater lamp is turned on is maximum for variation No 1 as the heater lamp is energized for the whole envelops The duty cycle is 60 for variation No 3 as the heater lamp is energized for the 6 positive and negative envelops out of 10 The duty cycle is 0 since the heater lamp is kept turned off for the whole envelops CPU U1 selectively switches among those variations for applying voltages to the heater lamp according to the THERMA signal which appears at pin 98 as feedback A fraction of THERMA is applied to pin 2 of comparator U6 1 The comparator maintains comparison of the potential at pin 2 and pin 3 which gives a reference for the possible anomaly in the heater temperature bred by resistors R52 and R57 Should the voltage at pin 2 exceed that at pin 98 the level at pin 1 becomes low Since pin 1 is wired to the output line for the HEAT signal the HEAT signal is enforced to be low regardless the behavior of CPU U1 thus preventing possible heat overrun 2 3 5 2DC Heater lamp turn on pattern in 1 cycle 10 half waves 1 2 3 4 5 6 7 8 9 10 AC wave Variation No 1 0 V 4 Der E U V g U Zero 7 cross edie RE On On On On On On On On On On TRC1 Variation No 2 D
135. top clear key while a selection item is displayed The indication for selecting a maintenance item No appears Changing the copy count timing Description Changes the copy count timing for the total counter and other counters Purpose To be set according to user copy service provider request If a paper jam occurs frequently in the eject section when the number of copies is counted at the time of paper ejection copies are provided without copy counts The copy service provider cannot charge for such copying To prevent this the copy timing should be made earlier If a paper jam occurs frequently in the paper conveying or fixing sections when the number of copies is counted before the paper reaches those sections copying is charged without a copy being made To prevent this the copy timing should be made later Method Press the start key Setting 1 Select the copy count timing using the zoom keys Display Description FEd When secondary paper feed starts EJE When the paper is ejected Initial setting EJE 2 Press the start key The setting is set and the indication for selecting a maintenance item No appears Completion To exit this maintenance item without changing the current setting press the stop clear key The indication for selecting a maintenance item No appears 1 4 23 2DC Maintenance 5 m item No escription Setting the destination specifications Description Sets whether or not to print the pr
136. ts the data to print Note that the area to be printed black has the low potential constituting a positively exposed image Laser beam Exposed surface potential approximately 60 to 80 V Charged surface potential 400 15 V Drum Aluminum cylinder gt D si i ir a Figure 2 1 13 Drum surface potential 2 1 13 2DC 4 Development The latent image constituted on the drum is developed into a visible image The developing roller A contains a 3 pole S N S magnet core B and an aluminum cylinder rotating around the magnet core B Toner attracts to the developing roller A since it is powdery ink made of black resin bound to iron particles Doctor blade C magnetized by magnet D is positioned approximately 0 3 mm above the developing roller A to constitute a smooth layer of toner in accordance with the roller revolution Developing bias output 275 5 V DC AC Engine board HVCLK Figure 2 1 14 Development The developing roller is applied with the AC weighted positive DC power source Toner E on the developing roller A is given a positive charge The positively charged toner E is then attracted to the areas of the drum which was exposed to the laser light The gap between the drum F and the developing roller is approximately 0 3 mm The non exposed areas of the drum repel the positively charged toner as these areas maintain the positive charge The devel
137. turn off 11 The heater lamp does not turn on 12 The heater lamp does not turn off Broken MP feed clutch Poor contact in the MP feed clutch connector ter minals Defective engine board KP 5061 Broken registration clutch Poor contact in the regis tration clutch connector terminals Defective engine board KP 5061 Poor contact in the eraser lamp connector terminals Defective engine board KP 5061 Poor contact in the expo sure lamp connector termi Defective scanner board KP 5063 Defective engine board KP 5061 Defective scanner board KP 5063 Defective engine board KP 5061 Broken wire in heater Dirty sensor part of the thermistor clutch Reinsert the connector Also check for continuity within the con nector cable If none remedy or replace the cable Run maintenance item U032 and check if YC5 2 on the engine board KP 5061 goes low If not replace the engine board 5061 KP Check for continuity across the coil If none replace the registra tion clutch Reinsert the connector Also check for continuity within the con nector cable If none remedy or replace the cable Run maintenance item U032 and check if YC6 2 on the engine board KP 5061 goes low If not replace the engine board 5061 Reinsert the connector Also check for continuity within the nector cable If none remedy or replace the cable Check for continuity If non
138. turned on 16 The message re questing cover to be closed is displayed when the front cover is closed 17 Others 1 5 22 Leaking main charger housing Poor contact in the high voltage board connector terminals Defective engine board KP 5061 Defective high voltage board Poor contact in the high voltage board connector terminals Defective engine board KP 5061 Defective high voltage board A piece of paper torn from copy paper is caught around registration snsor or exit Sensor Defective registration sen sor Defective exit sensor Poor contact in the con nector terminals of inter lock switch Defective interlock switch Wiring is broken shorted or makes poor contact See page 1 5 14 See page 1 5 14 Check and remove if any Run maintenance item U031 and turn registration sensor on and off manually Replace registration sensor if indication of the cor responding sensor is not light Run maintenance item U031 and turn exit sensor on and off manually Replace exit sensor if indication of the corresponding sensor is not light Reinsert the connector Also check for continuity within the con nector cable If none remedy or replace the cable Check for continuity across switch If there is no continuity when the switch is on replace it Check for continuity If none repair Locate the source of noise and remove 2DC 1 5 5 Mechanical problems Problem C
139. u lt miss TO mae m an 4 a Q oza ste OO ole Oe let e DS lt lt GESEIS Bee 82233 SSES azo CS Co aloo SSSSlenC 35 Sma E el lee mi KHAMTNORAMDS KAMTMNORADLETAV E TEE AMO QN co f LO cO co o cN co r to eo lt co ox 9 N NGdOFA DE 24V2 1 1 H5ERPRN 1111 YC10 YC11 YC3 YC12 YC13 YC14 To PGND 2 2 PFPER 22 optional PFMDRN 3 3 PFCLK 31939 YC4 i paper 4 4 5EMDRN d A Engine board 5 5 Main 5 5 515 KP 5061 feeder Sele 616 PGND ele 7 7 ARDY 1717 8 8 8 8 Feed 9 9 MOTORN 919 YC6 YC5 YC9 YC7 YC8 clutch 10 10 SN 140110 EE pp PP y aa 2R S ooneowon z z zZ Toner mm OO OIO sensor PWB gt Heater lamp Fg Sib gt 5 KP 786 Dei Bed Bee I us Thermistor Registration MP feed MP paper Z nn FE H fan clutch clutch sensor of O z r Thermal rr lt Zenner board gt OG cutout E KP 788 ee ey 2 ZS 2 r TN OYC M Transfer roller TT 4 um KHANMTMNORADLOT VOTO Amt NnOKn Dae TAST o CNS NS CN4 oi CN CN2 1 T 4 1CN1 CN2 TEE ET EE KA N O O O EE 7 a z 2 HOV 2 2 24V2 24V2 A1 B1 A1 B1 E YC302 Eegen 7 ck FAN 3 3 PGND PGND A2 B2 A2 B2_ yo 304 PGND 4 4 24V3 x 24V3 A3 B3 A3 B3 ES PGND Hiah vol board A4 B4 A4 B4 Power switch l 92 6 8 gh voltage boar THVDR THERM A5 B5 A5 B5 RTHVDR HEATN A6 B6 A6 B power Supply Peale HEATN 8 8 HVISEL SLEEPN CET A7 B Ble sole KP 5059 GE L M PSEL1 EXITN A8 B8 A8 B8 KP 5067 LIL PSEL2 ZCROSS A9 B9 A9 B9
140. ual and other related l t e Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits a rrrssssssssssssssssssa e Always use parts having the correct specifications e Always use the thermostat or thermal fuse specified in the service manual or other related brochure when replacing them Using a piece of wire for example could lead to fire or other SS OS AC CIS EE e When the service manual or other serious brochure specifies a distance or gap for installation of a part always use the correct scale and measure Carefully e Always check that the copier is correctly connected to an outlet with a ground connection e 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 e Never attempt to disassemble the optical unit in machines using lasers Leaking laser light may CAMA SCY el GE e Handle the charger sections with care They are charged to high potentials and may cause electric Shock if handled improperly a aaa arrrasssssrssss sa
141. utput end of the sweep roller and sent back to the toner container into the waste toner reservoir Figure 2 1 18 Drum cleaning and erasing static charge After the drum B is physically cleaned it then must be cleaned to the electrically neutral state This is necessary to erase any residual positive charge ready to accept the uniform charge for the next print process The residual charge is canceled by exposing the drum 8 to the light emitted from the eraser lamp E This lowers the electrical conductivity of the drum surface making the residual charge on the drum surface escape to the ground 2 1 18 2 2 1 Electrical parts layout 1 Main unit 2DC Figure 2 2 2 Main unit G Main board KP 5060 2 Engine board KP 5061 3 Power supply board KP 5059 Power switch Exit sensor AC Inlet 4 High voltage board D Interlock switch 5 Bias board KP 5067 E Cassette switch F Registration sensor Paper sensor 6 Main motor 7 Cooling fan Registration clutch 9 Feed clutch MP feed clutch 1 MP paper sensor 4 Toner sensor PWB KP 786 3 Waste toner sensor PWB KP 786 Eraser lamp PWB KP 790 45 Laser scanner unit Heater lamp 7 Thermal cutout Thermistor Paper feeder interface connector 2 2 1 2DC 2 Scanner unit 2 2 2 Figure 2 2 2 Scanner unit 1 Operation board 2 CCD board KP 5065 3 Scanner board KP 5063 4 Inverter board 5 Sca
142. uty 80 Variation No 3 Duty 60 Variation No 4 Duty 40 Variation No 5 Duty 0 Off Off Off Off Off Off Off Off Off Off Figure 2 3 5 Heater lamp turn on variations 2 3 6 2DC 3 Polygon motor control circuit The main controller board supplies the 2598 4 Hz clock pulse PLGCLK via the engine board to the PLL control IC IC1 for the polygon motor To begin printing the engine CPU U1 turns PLGDR to H level the PLL control IC IC1 starts to revolve the polygon motor so that the revolution is 25 984 rom which depends on the PLGCLK clock pulse When PLL control IC IC1 finds that the polygon motor is revolving at the rated speed turns PLGDRN to L level to acknowledge the engine CPU that the rated speed has been achieved On the contrary if PLGRDYN does not turn to L level within 8 seconds since PLGDRN has been L level Engine board Laser scanner unit Polygon motor control circuit Polygon motor C2 NL S 25 984 rpm PLGRDYN Main board 3 3V gt control IC PLGCLK 2598 4 Hz Figure 2 3 6 Polygon motor control circuit 2 3 7 2DC 2 3 3 Power supply board The power supply board provides the AC power input and DC power and outputs The high voltage bias generator circuit is mounted on a separate board A simplified schematic diagram is shown below AC Powe
143. ve engine board KP 5061 Poor contact in the main motor connector termi nals Defective main motor rotation control circuit Defective drive transmission sys tem Poor contact of the connector ter minals Defective scanner home position sensor Defective engine board KP 5061 or scanner board KP 5063 Defective scanner motor 2DC Causes Check procedures corrective measures Replace the main board KP 5060 and check for correct operation Check if the DIMM is inserted into the socket on the main board KP 5060 cor Replace the DIMM and check for correct operation Replace the main board KP 5060 and check for correct operation Replace the main board KP 5060 and check for correct operation Replace the engine board KP 5061 and check for correct operation Reinsert the connector Also check for con tinuity within the connector cable If none remedy or replace the cable Check if the rollers and gears rotate smoothly If not grease the bushings and gears Check for broken gears and replace if any Check the connection of connectors YC10 11 on the engine board KP 5061 and the continuity across the connector terminals Repair or replace if necessary Replace the scanner home position sen Replace the engine board KP 5061 or scanner board KP 5063 and check for correct operation Replace the scanner motor 1 5 9 2DC Contents C3200 A3200 Exposure

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