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1. Oo o O O Do M32 5 Option Socket 4980S003AB S 3 2 3 PWB IF Interface Board O O IEEE1284 parallel port El ch USB port O O 4980S004AA S 4 3 UTILITY MODE e This mode is used to set various machine functions 3 1 Utility Mode Function Tree 1 AUTO PANEL RESET 2 ENERGY SAVE MODE 3 DENSITY ADF MACHINE SETTING 4 DENSITY BOOK 5 PRINT DENSITY 6 LCD CONTRAST 7 LANGUAGE 8 LAMP OFF TIME UTILITY MODE PAPER SOURCE SETUP 1 TRAY1 PAPER 2 TRAY SETTING 1 PAPER PRIORITY 2 DENSITY PRIORITY L COPY SETTING 3 DENSITY LEVEL A 4 DENSITY LEVEL M 5 OUTPUT PRIORITY 6 RESOLUTION 3 2 Utility Mode Setting Procedure lt Procedure gt 1 Press the Utility key 2 The first Utility mode screen appears lt Exiting Procedure gt e Press the Panel Reset key lt Changing the Settings for Utility Mode Functions gt 1 Press the Zoom Select key Density Select key or the 10 Key Pad to select the desired function 2 Press the Zoom Select key Density Select key or the 10 Key Pad to select the desired setting 3 Press the Yes key to apply the setting 4 To return to the previous screen press the No C key
2. Actuator Paper Empty Sensor PE2 4980M007AA Electrical Parts Control Signal Blocked Unblocked WIRING DIAGRAM PE1 PWB P MPJ12P 3 L H A 5 pve MELISS 4 Paper take up retry function To reduce the number of paper misfeeds as a result of a paper take up failure a paper take up retry sequence is carried if the PaperTake Up Switch is not actuated and deac tuated within a predetermined period of time e This function is provided for paper take up from any printer paper tray M 23 11 IMAGE TRANSFER 11 1 Overview The toner image formed on the surface of the PC Drum during the developing process is transferred onto the paper e This printer adopts the roller image transfer system in which the Image Transfer Roller is used to transfer the image onto the paper e In the roller image transfer system the paper is pinched between the PC Drum and the Image Transfer Roller at all times during the print cycle This results in a very little amount of ozone being produced and there is a little chance of a double transferred image occurring To clean the Image Transfer Roller reverse bias is applied to the Image Transfer Roller e The cleaning sequence is carried out when the printer is started a print command is issued a print cycle is completed and when the printer is started after a misfeed has been cleared e There is the Charge Neutralizing Needle installed for neutralizing the p
3. 4136M516AA Electrical Parts Control Signal Blocked Unblocked WIRING DIAGRAM PS1 PWB P MPJ8P 3 L H F to G 2 M 29 14 MISCELLANEOUS 14 1 Cooling of the Printer Interior e The Cooling Fan Motors provided on the right and left frames of the printer draw outside air from the outside into the printer interior and discharge heat inside the printer out It thereby prevents the temperature of the PH Unit and the printer interior from increasing Cooling Fan Motor 1 M3 PH Unit Cooling Fan Motor 2 M2 4980M001AA Electrical Parts Control Signal WIRING DIAGRAM M2 PWB P MPJ13P 1 to 4 1 3 M3 PWB P MPJ6P 1 to 4 1 3 M 30 14 2 Original Cover Open Close Detection Mechanism e There is a magnet provided in the Original Cover allowing the printer to detect the posi tion of the cover whether the cover is raised or lowered e This magnet attracts the Original Cover Set Sensor provided on the printer side thus activating the sensor The printer will then detect the position of the Original Cover Magnet Original Cover Set Sensor PS2 ASS0MOOEAA Electrical Parts Control Signal Blocked Unblocked WIRING DIAGRAM PS2 PWB O P7010 1 to 2 L H F 9 M 31 MAINTENANCE 1 MAINTENANCE SCHEDULE To ensure that the printer produces good printed pages and to extend its service life it is recommended that the maintenance jobs described in this schedule be carried out as
4. 4136D003AB D 14 3 3 Removal of Units 1 Removal of the IR Unit 1 Remove the Left Cover ss D 7 2 Remove the Right Cover tx D 7 3 Remove the Rear Cover tx D 7 4980D007AA 4980D006AA 4980D008AB 4 Unplug the connector 5 Unplug the two flat cables from the Controller Mechanical Control Board NOTE Be extremely careful not to break the flat cables 6 Remove the two screws unhook the two tabs and then remove the IR Unit D 15 2 Removal of the PH Unit NOTES NEVER attempt to replace the PH Unit with power being supplied to the printer Doing that could lead to exposure to the laser beam resulting in blindness NEVER attempt to disassemble or adjust the PH Unit Doing that could lead to exposure to the laser beam resulting in blindness 1 Remove the IR Unit we D 15 2 Remove the Fusing Unit E 8 3 Remove the Exit tray te D 7 4 Remove the four screws unhook the four tabs and then remove the Upper Cover 5 Disconnect one flat cable from the Controller Mechanical Control Board NOTE e Use utmost care not to snap off the flat cable 4980D005AA 2 6 Remove three screws and the PH Unit NOTE e When reinstalling the PH Unit tighten the screws in the numerical order shown in the illustration 4136D008AC D 16 Precautions for Removal Reinstallation of the PH Unit NEVER touch the window
5. lt Exiting Procedure gt Press the Panel Reset key lt Changing the Settings for Service Mode Functions gt 1 2 Press the Zoom Select key to select the desired function Press the Zoom Select key Density Select key or the 10 Key Pad to select the desired setting Press the Yes key to apply the setting To return to the previous screen press the No C key NOTE In order for the settings for the Service mode functions to be changed the machine must be turned off then on again S 11 4 3 1 Service Mode Functions Service s Choice e Various machine service functions can be specified Function Purpose Setting Details Precautions SHIPMENT DESTINATION To switch the fixed zoom ratios and paper sizes according to the selected marketing area The default setting is either METRIC or INCH METRIC INCH LEADING EDGE ERASE To change the laser emission tim ing to adjust the width of the image area that is erased at the leading edge When the PH unit has been replaced The default setting is 4mm Omm 1mm 2mm 3mm 4mm 5mm TRAILING EDGE ERASE To change the laser emission tim ing to adjust the width of the image area that is erased at the trailing edge When the PH unit has been replaced e The default setting is 4mm Omm 1mm 2mm 3mm 4mm 5mm VERTICAL EDGE ERASE To change the laser emission tim ing to adjust the width of th
6. e Communication could not be established with the Controller Control Board within 5 sec onds while printing lt Troubleshooting Procedures gt Relevant Electrical Components Controller Mechanical Control Board PWB P WIRING DIAGRAM Action Control Signal Location Electric Parts Replace PWB P 10 C133D ROM checksum error lt Detection Timing gt Description A malfunction occurred in the ROM lt Troubleshooting Procedures gt Relevant Electrical Components Controller Mechanical Control Board PWB P WIRING DIAGRAM Action Ref Page E Control Signal Location Electric Parts Replace PWB P T 20 11 C13FO Laser error lt Detection Timing gt Description e The laser output exceeds the upper limit value e The laser output remains lower than the lower limit value lt Troubleshooting Procedures gt Relevant Electric Parts PH Unit Controller Mechanical Control Board PWB P Flat cable WIRING DIAGRAM Action Location Control Signal Electric Parts Check cables for connection and correct as necessary Replace PH Unit Replace PWB P 12 C1468 EEPROM error lt Detection Timing gt Description An EEPROM not written with initial data was detected lt Troubleshooting Procedures gt Relevant Electric Parts Controller Mechanical Control Board PWB P i WIRING DIAGRAM Action Ref Page Contes
7. ABCDE 4136T003AA lt Troubleshooting Procedures gt Check Replace Controller Mechani cal Control Board PWB P Current data Result Action Is Fusing Roller faulty YES Replace Fusing Unit Fusing Roller Is Image Transfer Roller faulty T 38 YES Replace Image Transfer Roller 16 Printer system Uneven image lt Typical Faulty Images gt 51 mm pitch uneven image 51 8 mm pitch uneven image o o 4136T004AA 4136T008AA 75 3 mm pitch uneven image 4136T005AA 94 2 mm pitch uneven image a 4136T006AA lt Troubleshooting Procedures gt Check Result Action YES Cause Is uneven image at a pitch of 50 6 mm Image Transfer Roller is scratchy or dirty Replace Image Transfer Roller Is uneven image at a pitch of 51 8 mm Flexible Sleeve is scratchy or dirty YES Replace Toner Car tridge Is uneven image at a pitch of 75 3 mm Pressure Roller is scratchy or dirty YES Replace Fusing Unit Is uneven image at a pitch of 94 2 mm PC Drum is scratchy or dirty YES Replace Drum Cartridge Fusing Roller is scratchy or dirty T 39 YES Replace Fusing Unit DEVELOP Copyright 2003 Develop Printed in Germany AF 11 Service Manual CONTENTS GENERAL 1 SPECIFICATIONS Iiia ARA G 1 MECHANICAL ELECTRICAL 1 COMPONENTS LAYOUT scirpe aa aaan M 1 2 DRIVE SYSTE
8. 1 2 to 2 3 0 o U19 U26 7 Hare CJ1 omm c CJ2 O o OO DO 4980D052AA 5 Attach Service Download BIOS U19 and U26 to memory sockets U19 and U26 on the Controller Mechanical Control Board Service Service Download Download BIOS U19 BIOS U26 CJ1 CJ2 Service Download BIOS U19 and U26 Parts No 4980 1157 xx 4980D069AA 6 Use a USB cable to connect the printer to the host computer 7 Start up the host computer D 45 8 Turn on the printer The following message appears in the display WAIT PROGRAM UPDATE F W NOW 4980D053AA 9 Perform steps 6 through 10 of Procedure for Updating the GDI Firmware to update the firmware 10 Check that the following message appears in the display to indicate that the updating of the firmware has been completed correctly FIRMWARE UPDATE OK MACHINE POWER OFF ON 4980D051AB 11 Turn off the printer 12 Change the settings for jumper switches CJ1 and CJ2 on the Controller Mechanical Control Board from 2 3 to 1 2 Return them to their default settings 13 Remove Service Download BIOS U19 and U26 from memory sockets U19 and U26 on the Controller Mechanical Control Board 14 Turn on the printer D 46 5 5 Moving the EEPROM NOTE
9. After the Controller Mechanical Control Board PWB P is replaced be sure to move the EEPROM form the old Controller Mechanical Control Board to the new one Remove the EEPROM U39 from the old Controller Mechanical Control Board and then attach it to the new Controller Mechanical Control Board EEPROM New Controller Mechanical Control Old Controller Mechanical Control Board Board 4980D059AB 2 NOTE Be sure to install the EEPROM U39 so that notch A faces the correct direction 1171D049AA D 47 CONTROL PANEL SERVICE MODE DESCRIPTIONS 1 CONTROL PANEL DESCRIPTIONS 1 1 Names of Control Panel Parts and Their Functions Printer E Error HE Utility C 2000 O Start gt E Coad ig i lt adi gt D Paper v i Zoom i a o 4 L L 18 17 16 14 15 14 11 12 11 10 9 Key Name 4980S001AA Function Printer key Press to enter Printer mode Utility key Press to enter Utility mode Error lamp The indicator lights up if an error or malfunction occurs Display Shows the number of copies to be made the zoom ratio and other settings No C key Press to reset the number of copies to 1 Press to clear various settings Press to return to the previous screen Press to specify various settings Yes key Press to apply the specified setting
10. Continuous printed page per job PM Parts Clean Manual When a paper Paper Take Up Roll take up failure occurs When a paper take up failure occurs NOTES K 1 000 printed pages The contents of the Maintenance List are subject to change without notice Forthe part numbers see Parts Manual and Parts Modification Notice D 1 2 REPLACEMENT CLEANING OF PARTS 1 Cleaning of the Paper Take Up Roll 1 Raise the main unit to separate it from the Paper Feed Cassette 2 Using a soft cloth wipe clean the surface of the Paper Take Up Roller 2 Replacement of the Paper Take Up Roll 1 Raise the main unit to separate it from the Paper Feed Cassette 2 Remove the Paper Take Up Roller at the two t points indicated 2 4136E004AC 3 DISASSEMBLY REASSEMBLY 3 1 Identification of Exterior Parts and Removal Procedures for Them Name 4516D001AA Removal Procedure Rear Cover Remove the five screws Remove the Rear Cover Right Cover Remove the Rear Cover Remove the Right Cover Tray 2 Hold down the Paper Feed Cassette with one hand and remove Tray 1 Left Cover Remove the Rear Cover gt Remove the Left Cover 3 2 Removal of Circuit Boards NOTE When removing a circuit board refer to the precautions for handling printed circuit boards and follow the corresponding removal procedures Th
11. ADJUST Menu 1 Enter the Service mode 2 Press the A or W key to select the ADJUST menu 3 Printing a Test Page NOTE Print a test page when making the following adjustments Leading edge tilt adjustment Automatic Document Feeder sub scanning zoom ratio adjustment Automatic Document Feeder main scanning amp sub scanning registration adjustments Enter the Service mode Press the A or y key to select the function Select PRINT TEST PATTERN gt TEST PATTERN 1 Press the Start key to begin printing the test page Rw No D 9 4 Height Adjustment 1382U025AB Adjusting 1382U026AA 1 Check the gap between the Original Glass and the spacer on the Automatic Document Feeder NOTE Be sure to open then close the Automatic Docu ment Feeder and then check during pre lighting of the scanner 2 If there is a gap perform the adjustment described in step 3 3 Turn the adjusting screw in the hinge of the Auto matic Document Feeder until the spacer contacts the Original Glass Screw rotation direction Clockwise Raises the Automatic Document Feeder Counterclockwise Lowers the Automatic Document Feeder D 10 5 Leading Edge Tilt Adjustment 1 Print the test pattern 2 Draw lines 100 mm A and B from the center of the test pattern as shown in the illustration 100 mm 100 mm 1382D007AA 3 Load
12. DC Stabilized Controller Mechanical Power Unit PU gt Control Board PWB P Fi Feed Main oe Drive PH KUN Fi Di 4980T001AA N lt 2 gt Control System Line PAPER MISFEED Initial Check Items 2 2 1 e When a paper misfeed occurs in the printer first make the following initial checks Check Action Does the paper meet product specifications Replace paper Is the paper curled wavy or damp Replace paper Instruct user in correct paper storage Is the paper transport path deformed dirty or obstructed with foreign matter Clean the paper path and replace if necessary Are the Paper Separator Fingers dirty deformed or worn Replace Fusing Unit Is the roller dirty deformed or worn Are Edge Guides at correct position to accommo date paper Does the actuator operate correctly when checked Precautions for Clearing Misfeed Clean the roller and replace if neces sary Slide the Edge Guides up against the edges of the paper stack Correct or replace the actuator Reset the misfeed condition by opening and closing the Front Door after the misfeed has been cleared 2 2 Paper Misfeed Displays e The Error indicator lights up and a message appears in the display when a paper mis feed occurs lt Paper Take Up Section Misfeed gt CAUTION PAPER MISFEED CAUTION OPEN FRONT COVER PER lt Transport Section Misfeed gt CAUTION PAPER
13. DEVELOP SERVICE MANUAL 8 OPTIONS D 16G 4986 7991 00 INDEX Field Service GENERAL MECHANICAL ELECTRICAL MAINTENANCE DIS REASSEMBLY ADJUSTMENT CONTROL PANEL SERVICE MODE DESCRIPTIONS TROUBLESHOOTING CONTENTS GENERAL lo SPECIFICATIONS Aiii 22 HR G 1 GJ Main Un Ec aaee a ae a e a a a E ATR G 1 2 GDI Printer FUNGON orizon ae a a G 3 2 PRECAUTIONS FOR INSTALLATION unssersensenrnennnnnnnnnnen nennen nennnnnnnnnnn nen G 4 2 1 Installati h SiO 22 2 2222 kn G 4 2 2 Power SOUICE nnuennnennennnnnnnnennnnnnnnnnnnnennnnnennnnnnnnnnnnnnnnnnnn nennen nnnnnnnnnnnnnn en G 4 3 PRECAUTIONS FOR SE conocia G 5 3 1 To Ensure the Printer is Used in an Optimum Condition G 5 3 2 Operating Environment ira iaa iieiaeie G 5 3 3 Power Requirements 24urn00sssssnnnsnennonnsnennusnnnonensnenseenonsssennnentannenes G 5 4 HANDLING OF THE CONSUMABLES uunneessennennnnnnennnnnennnnnnnnnnennnnnnnnnnan G 6 5 MISCELLANEOUS PRECAUTIONS u uensrsensennnnnnnnnnnnnnnnennennnnn nennen G 6 6 PARTS IDENTIFICATION unnensserseesnensnnnnnnnnnnnnnnnnnnnnnnnnennennnennennnnnnn nennen nen G 7 MECHANICAL ELECTRICAL 1 COMPONENTS LAYOUT teed ar a rennen M 1 2 COPY PROCESS imitar euere ae M 2 3 PAPER RATH Si A AAA M 4 4 2DRIVE SYSTEM sarria air M 5 5 OPERATING SEQUENGE cocida as M 6 551 Print Start SEQUENCE srutra iie o A cid M 6 1 When the pre st
14. I Mode 0 Mode 1 180 sec 300 sec 208 sec Thermistor detected temperature at temperature control start Less than 50 C 50 C to 125 C 125 C or more Power OFF Front Door open close Mode before Mode 0 Mode 2 Mode 3 temperature control Mode 1 Mode 0 Mode 0 Mode 0 2 Temperature control The fusing temperature is increased to a predetermined level during the warm up cycle e The warm up control is provided when power is turned ON the Front Door is opened and closed and the Energy Save mode is canceled In the standby state the fusing temperature is set to a level 130 C lower than that dur ing a print cycle thereby cutting down power consumption e The temperature control mode when the control is resumed when power is turned ON the Front Door is opened and closed or the Energy Save mode is canceled is set according to the mode and the fusing temperature valid before the interruption Inthe Energy Save mode the Fusing Roller Heater Lamp is turned OFF to reduce power consumption M 26 3 Temperature control mode The fusing temperature is controlled during a print cycle according to the period of time elapsed from the completion of the warm up cycle e Mode 0 Mode 1 lasts for 3 min If the temperature detected by the Thermistor is 50 C or more when mode 0 is interrupted the operation is switched to mode 1 Mode 1 starts when mode 0 is completed
15. e Temperature 10 to 30 C e Humidity 15 to 85 Rate of temperature change 10 C h Rate of humidity change 20 Rh h 3 3 Power Requirements The power source voltage requirements are as follows e Voltage fluctuation AC110 V 10 AC127 V 6 Function AC220 240 V 10 Function AC110 V 15 AC127 V 6 Paper Feeding AC220 240 V 10 15 Paper Feeding Frequency fluctuation 50 60 Hz 3 Hz 4 HANDLING OF THE CONSUMABLES Before using any consumables always read the label on its container carefully e Paper can easily damp To prevent absorption of moisture store paper in a place with lit tle moisture e Keep consumables out of the reach of children e Do not touch the PC Drum with bare hands e The same sized paper is of two kinds short grain and long grain Short grain paper should only be fed through the printer crosswise while long grain paper should only be fed lengthwise The wrapper of the paper is properly marked e If your hands become soiled with toner wash them with soap and water Do not throw away any used consumables They are to be collected e Do not burn bury in the ground or throw into the water any consumables e Do not store consumables in a place which Is hot and humid Is subject to direct sunlight x Has an open flame nearby 5 MISCELLANEOUS PRECAUTIONS Use the following precautions when performing service jobs for a printer that uses a laser e Wh
16. 1 e Various settings for the machine s operating environment can be specified Machine Setting Function Purpose Setting Details Precautions To specify the time until the auto panel reset operation is performed after a copy cycle has been com pleted or after the last key opera tion The default setting is 1 AUTO PANEL minute RESET OFF ON 0 512345 To specify the time until the machine enters Energy Save mode after a copy cycle has been completed or after the last key operation The default setting is 15 min ENERGY utes SAVE MODE The length of time can be set between 1 and 240 minutes The default setting is MODE To specify the scanning density when using the Automatic Docu ment Feeder MODE 1 NOTE For a lighter copy density in DENSITY ADF In order to reduce the appear ance of spots in copies the Automatic Document Feeder density level is set for lighter copies as a default order to reduce the appear ance of spots in copies MODE 2 For printing copies with the same density as the docu ment Function Purpose Setting Details Precautions DENSITY BOOK To specify the scanning density when using the Original Glass The default setting is MODE MODE1 For printing copies with the same density as the docu ment MODE2 For a lighter copy density in order to reduce the appear ance of spots in copies PRINT
17. PRECAUTIONS FOR INSTALLATION 2 1 Installation Site To ensure utmost safety and avoid breakdown the printer should NOT be used in a place Where it will be subjected to extremely high or low temperature or humidity Where it will be subjected to sudden fluctuations in either temperature or humidity Which is exposed to direct sunlight e Which is in the direct air stream of an air conditioner heater or ventilator e Which has poor ventilation or is dusty e Which does not have a stable level floor or where it will receive undue vibration Which is near any kind of heating device Which is near volatile flammables thinner gasoline etc Where it may be splashed with water and electric leakage is likely to occur Which puts the operator in the direct stream of exhaust from the printer e Where ammonia gas might be generated 2 2 Power Source e If any other electrical equipment is sourced from the same power outlet make sure that the capacity of the outlet is not exceeded e Use a power source with little voltage fluctuation Never connect by means of a multiple socket any other appliances or machines to the outlet being used for the printer e Ensure that the printer does not ride on the power cord or communications cable of other electric equipment and that it does not become wedged into or underneath the mecha nism e Make the following checks at frequent intervals Is the power plug abnormally
18. Press to specify various settings 10 Key Pad Use to type in the number of copies to be made and any other numeric data Stop key e Press to stop the print operation e Press to stop the scan operation e The indicator lights up in orange when the machine is paused or while copying Panel Reset key Press to reset all copy functions to their default set tings Start key Press to start a scanning operation Press to start a print operation e Press to specify various settings Key Name Function A V key e Press to change the zoom ratio between x0 50 and x2 00 in x0 01 increments e Press to show the various settings and informa tion e Press to specify various settings Zoom key Press to select a zoom ratio from the preset fixed ratios Paper key Press to select the paper in the desired paper tray lt gt key e Press to adjust the image density e Press to specify various settings Auto Photo key Press to change the image density mode Status key Press to display each counter value Sort key Press to select the Sort function 2in1 key Press to select the 2in1 copy function 2 FUNCTIONS OF SWITCHES AND PARTS ON PWBs 2 1 Circuit Board Locations 4980S002AA 2 2 PWB P Controller Mechanical Control Board 0
19. have reached the end of cleaning the PM parts replacement cycles There are adjustments that can Perform the improve image quality problems by adjustment again being performed again T 24 5 3 Troubleshooting for Specific Image Quality Problems e Determine if the failure is attributable to the input system Image Reading Section or the output system Engine section Result Copy made at a reduced zoom ratio 1177T03YA Full size copy Reduced copy 1177T04YA Full size copy Reduced copy 1177T05YA T 25 Input image reading system Output printer system 1 Image reading system Blank or black prints lt Sample of Image Quality Problem gt 4011T035AA 4011T036AA lt Troubleshooting Procedures gt Check Result Action Are there no bent connector pins on the NO Correctly plug in the connectors cables connecting the control boards Replace connection cables are all connectors correctly plugged in and are no cables broken Does the Exposure Lamp light up Replace the Scanner Assy 1 26 2 Image reading system Low image density lt Sample of Image Quality Problem gt 4011T003AA lt Troubleshooting Procedures gt Check Result Action Is the surface of the Original Glass dirty YES Clean it Are the Shading Sheet or back surface of the Original Glass dirty YES Clean them Are the mirror or l
20. instructed Ref Page PM Parts Clean Replace 1 Replace 2 in This Manual When a paper w E 3 Paper Take Up Roll take up failure Replace Wnion a papsr take up Secure failure occurs Image Transfer Roller Drum Cartridge Toner Cartridge Fusing Unit Replace 1 Average number of prints during continuous printing Replace 2 Average number of prints during intermittent printing 2 pages job NOTES K 1 000 printed pages As a rule the Drum Cartridge and Toner Cartridge are to be replaced by the user The contents of the Maintenance List are subject to change without notice For the part numbers see Parts Manual and Parts Modification Notice 1 1 Guidelines for Life Specifications Values by Unit e The life specifications value represents the number of printed pages produced or figures equivalent to it when given conditions see the Table given below are met It can be more or less depending on how each individual printer is used Print Conditions Job type 2P J Paper size A4 L Letter L B W ratio B W 6 1 Life Specifications Values Unit name Life value Detection The remaining amount of toner is detected Toner Cartridge 4 3 K A TONER EMPTY error is detected according to this value 2 REPLACEMENT CLEANING OF PARTS 1 Cleaning of the Paper Take Up Roll 1 Remove the Imaging Cartridge we E 5 NOTE The Imaging Cartridge is the Drum Cartridge to
21. H 80 mm 3 1 4 in Weight 3 2 kg 7 Ib Operating environment Same as the copier Original types Possible problems Originals bound with staples or paper clips Incorrect paper take up damaged originals or drive malfunctions due to jammed paper clips Originals bound with glue Incorrect paper take up or damaged origi nals Folded torn or extremely wrinkled originals Incorrect paper take up or damaged origi nals Curled originals more than 10 mm from Paper misfeeds due to folded or skewed front edge originals G 1 MECHANICAL ELECTRICAL 1 COMPONENTS LAYOUT gt 3 2 1382M005AA 1 Pick up Roller 4 Transport Roll 2 Exit Roller 5 Take up Roller 3 Transport Roller M 1 2 DRIVE SYSTEM 1382M007AA 4 Transport Roller 5 Exit Roller 1 Pick up Roller 2 Take up Roller 3 Document Feed Shaft M 2 3 ELECTRICAL PARTS LAYOUT PWB A AF PC1 1382M006AA PWB A AF AF Control Board M5 AF Main Motor PC2 Paper take Up Sensor S3 AF door set switch CL1 Paper take Up clutch PC1 Original detection Sensor PC3 Leading Edge Detection Sensor 3 1 Document Take up Mechanism 1 Document Take up Mechanism Document Feeder The Original Detection Sensor detects a document that has been properly loaded in the The Document Stopper establishes the leading edge position of the document loaded in the Document Feeder The stopper is l
22. Item Setting Range Leading Edge Erase 0to5 1 increment 1 mm Service s Choice Trailing Edge Erase Vertical Edge Erase Perform this adjustment in the following cases When the user requests a smaller margin lt Adjustment Procedure gt 1 Enter Service s Choice in the Service mode 2 Select LEADING EDGE ERASE 3 Specify the setting Setting Overview To reduce the margin Decrease the setting To increase the margin Increase the setting 4 Specify settings for the TRAILING EDGE ERASE and the VERTICAL EDGE ERASE functions in the same way D 30 5 Printer s Main Scanning Registration Adjustment lt Requirement gt e Adjust the amount that widths A and B in the printed test pattern are shifted so that the following B specification is met A 1382D011AA Specification Mode Function Item Setting Range 60 to 140 1 increment 0 1 mm 0 2 0 mm ADJUST menu PRN MAIN REGIST Perform this adjustment in the following cases After the PH Unit has been replaced lt Adjustment Procedure gt 1 Print the test pattern 2 Check the amount that widths A and B in the test pattern are shifted If the shift is out of specification adjust it according to the following procedure 3 Enter the ADJUST menu in the Service mode 4 Change the setting If the width of A is less than the width of B Increase the setting If the width o
23. M 27 5 Fusing temperature protect control BE 13 PAPEREXIT ale REIS re 13 1 Paper Exit Mechanism uursssnsrnnnnsnnennnnnnnnnnnnnennnnnnnnennnnnnnnnnnnnnnnenn 14 MISCELLANEOUS 21222 ts taa 14 1 Cooling of the Printer Interior ocoonncncnnncnncnnnnncoconncnccnarnnccnnrnrnrcnrnnrncnnno 14 2 Original Cover Open Close Detection Mechanism ooonccncccccnnnnccconnccnons M 31 MAINTENANCE 1 MAINTENANCE SCHEDULE leas E 1 1 1 Guidelines for Life Specifications Values by Unit ueeeesseenenenneen E 2 1 Life Specifications Values uersenseesnnsensnnnnnnnnnnnnnnnnnnnnnnnnnnnennnn nn E 2 2 REPLACEMENT CLEANING OF PARTS essensen E 3 1 Cleaning of the Paper Take Up Roll l enn E 3 2 Replacement of the Paper Take Up Roll ooooooccoinconicacicncnaccnanncnnno E 3 3 Replacement of the Image Transfer Roller E 4 3 REPLACEMENT OF UNITS ieii onoaiiae aeaaea aiaa ao S eaa aai aaia E 5 1 Replacement of the Toner Cartridge sessen E 5 2 Replacement of the Drum Cartridge seese E 7 3 Replacement of the Fusing Unit DIS REASSEMBLY ADJUSTMENT 1 SAFETY INFORMATION erseenserseesennnnnsnennnnnnnnnnnnennnnnennnnnnnnnnn e ei paai A D 1 1 1 Laser Safety coomcciconnnicnnnnocnncnnocnnnnnncncnnrc rca D 1 1 2 Internal Laser Radiation onnnnnnininnonnnnnocanoccnnnnnnarncnonc ran cana ran conc orar D 1 1 3 Laser Safety Label ooococcnnccnncnncinnnnnncncnonncncnnnnrnccnnnnnn cnn rrn rara crac D 4 1 4 Laser C
24. Procedure gt Press the Start key to begin the scanner test Press the Stop key to stop the scanner test 6 Fixed Zoom Change e The fixed zoom ratios can be changed lt Procedure gt 1 Select the fixed zoom ratio that you wish to change 2 Use the 10 Key Pad to type in the desired fixed zoom ratio Default fixed zoom ratios and setting ranges according to marketing area lt Metric gt Initial fixed zoom ratio Reduction 2 70 51 to 70 Reduction 1 81 71 to 99 Expansion 1 115 101 to 140 Expansion 2 141 141 to 199 Setting Range Setting Name lt Inch gt Initial fixed zoom ratio Setting Range Setting Name Reduction 2 64 51 to 64 Reduction 1 65 to 99 Expansion 1 101 to 153 Expansion 2 154 to 199 lt OEM1 Inch gt Initial fixed zoom ratio Reduction 2 64 51 to 64 Setting Name Setting Range Reduction 1 77 65 to 99 Expansion 1 129 101 to 154 Expansion 2 155 155 to 199 S 21 7 Factory Test e Operation tests can be performed during manufacturing PANEL BUZZER TEST RAM TEST To test reading and writing of the memory To check the operation of the display and all indicators and buttons 8 Clear Data Each type of data can be cleared Function Purpose Setting Details Precautions To clear the settings for the func All functions of the Utility tions listed at the right and return mode
25. coomionconncononorsnnanccnonacino cansan nocnorna rana n ian M 19 9 3 Laser Emission Timing ooonnnocnnnnnonincnnonnnanacann conca nana nan conca n arc c nan nrn rca M 20 9 4 Laser Emission Area oononconinnnonannonennnonanananicnarananncnnnnc rana raro conan rananancnnos M 21 1 Main scanning direction 2 Sub scanning direction 10 PAPER TAKE UP SECTION 10 1 Tray 1 er En ron M 22 1 Paper take up mechanism ueessserssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn M 22 2 Double feed preventive MECHANISM uusnessenesnnnnnnnnnnnnnnnnnnnnn M 23 3 Paper empty detection ococconncnnnconicncnonanacnnnonn nan cn nn aran c crono rana M 23 4 Paper take up retry function ueneessenessnnnsnnennnnnnnnnnnnnnnnnennnnnnnnnnnnnn M 23 11 1MAGE TRANSFER 82 en BI pn M 24 11 1 Overview ne hi Ben nn nie M 24 12 FUSING UNIT Sua taa res nennen M 25 12 BL O 17 1 67 ERS ae aA EAG Tia Aa EET Aa FA RRE Aos aa AE ane Pa e SAA SEa M 25 12 2 Fusing Temperature Control nnessersnnensnnnnennnnnnnnnennnnnnennn nennen nenn M 26 1 Temperature changes plain paper having a length of 186 mm or more M 26 2 Temperature control uuneesssesssensnnnnsnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnn M 26 3 Temperature control mode uueneeesnesnnensnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn M 27 4 Printing temperature by paper type in different temperature control modes 0 0 eee eee nennen
26. different regions Therefore check the Toner Cartridge type before replacing it lt Toner Cartridge Types for Each Region gt US amp Canada Toner Cartridge 101 C Europe Toner Cartridge 101 A Other regions Toner Cartridge 101 B 2 Replacement of the Drum Cartridge lt Removal Procedures gt 1 Remove the Imaging Cartridge we E 5 4136E011AC lt Installation Procedures gt 4136E012AC 4136E010AA 2 Pull the lever of the Toner Cartridge in the direc tion shown in the illustration and disconnect the Drum Cartridge 1 Mount the Toner Cartridge to a new Drum Car tridge NOTE Insert the Toner Cartridge along the guide provided on the new Drum Cartridge side and make sure that the Toner Cartridge is not tilted when inserted 2 Install the Imaging Cartridge in the printer NOTE Insert the Imaging Cartridge along the guide pro vided on the printer side Ensure that the Imaging Cartridge is not slid obliquely 3 Close the Front Door NOTE After replacing the Drum Cartridge be sure to reset the I C counter in the Service Mode 3 Replacement of the Fusing Unit NOTE Immediately after turning off the printer the area around the Fusing Unit is extremely hot Therefore in order to reduce the risk of burns wait until the unit has cooled down before performing any operation lt Removal Procedures gt 1 Remove the Rear Cover ss D 7 2 Unpl
27. drive C Copy them into the highest directory on drive C 4 Use a USB cable to connect the printer to the host computer Wait until the hardware is detected 5 Display the System Properties dialog box Properties for My Computer click the Hardware tab click the Device Manager button select Imaging devices and then check that Develop D 16G has been added 21 A Device M General Network Identification Hardware User Profes Advanced Action view e gt Ga A m Hardware Wizard EE The Hardware wizard helps you instal urinstal repair 2 En RES unplug eject and configure your hardware Batteries H Computer En H O Disk drives f Display adapters 19 29 DVD CD ROM drives Device Manager gt Ba The Device Manager lists all the hardware devices installed on your computer Use the Device Manager to change the properties of any device Hardware Profiles 2 IDE ATAJATAPI contrWers 2 Imaging devices 2 Minolta Di1610 3 Keyboards erf inting devices E Monitors Hardware profiles provide a way for you to set up and store EA diferent hardware configurations EB Network adapters bo PCMCIA adapters Hardware Profiles a av Ports COM amp LPT fe lt Sound video and game controllers H System devices a E Universal Serial Bus controllers OK Cancel Apply 4980D045AA 4980D046AA 6 Double c
28. lowered position detection mechanism e There is a magnet provided in the Document Feeder allowing the printer to detect the position of the Document Feeder whether the Document Feeder is raised or lowered e This magnet attracts the Original Cover Set Sensor provided on the printer side thus activating the sensor The printer will then detect the position of the Document Feeder Magnet Original Cover Set Sensor PS2 1892 M003 A Electrical Component Control Signal Blocked Unblocked WIRING DIAGRAM PS2 PWB O P7010 1 2 L H F 9 M 8 DIS REASSEMBLY ADJUSTMENT 1 MAINTENANCE SCHEDULE To ensure that the printer produces good printed pages and to extend its service life it is recommended that the maintenance jobs described in this schedule be carried out as instructed PM Parts Replace Ref Page in This Manual Paper Take Up Roll Pick Up Roller Regist Roller Exit Roller ts D 2 t D 3 D 4 D 4 Paper Separator Pad NOTES K 1 000 printed pages te D 5 As a rule the Drum Cartridge and Toner Cartridge are to be replaced by the user The contents of the Maintenance List are subject to change without notice For the part numbers see Parts Manual and Parts Modification Notice D 1 2 REPLACEMENT CLEANING OF PARTS 1 Cleaning of the Paper Take Up Roll 1 Open the Document Feeder Cover 2 Using a soft cloth wip
29. on the backside of the PH Unit A dirty window can cause an image problem 1 Window 4136D009AB D 17 3 4 Disassembly of the Image Reading Section 1 Removal of the Original cover set sensor 1 Remove the Original Cover 2 Remove the Control Panel we D 7 3 Remove the Original cover set sensor 4980D073AA 2 Removal of the Upper Cover Assy Original Glass 1 Remove the Original Cover 2 Remove the Control Panel ts D 7 3 Remove the six screws and remove the Upper Y Q Cover Assy Original Glass AAN LAK A gt f SE PA 3 Removal of the Scanner Motor 1 Remove the Original Cover 2 Remove the Upper Cover Assy Original Glass t D 18 3 Remove the Left Cover we D 7 4 Unplug one connector from the Scanner Motor 4980D007AA D 18 5 Remove the two screws and then remove the F 0 Scanner Motor Mounting Bracket iy lt I 4980D018AB 6 Remove the two screws and then remove the Scanner Motor 4980D019AA 4 Removal of the Scanner Assy 1 Remove the Original Cover 2 Remove the Upper Cover Assy Original Glass D 18 3 Remove the two screws and then remove the Flat Cable Holding Plate 4980D020AA 4 Unplug the flat cable 4980D021AA D 19
30. pulse M3 operation check PWB P MPJ6P 1 ww T 3 to 3 pulse E 9 to 10 G to H 5 to 6 T 14 2 C0210 H V abnormal lt Detection Timing gt Description e The Drum Charge Monitor Voltage HVC_MON signal falls outside a predetermined range at any time after the lapse of a predetermined period of time after the Power Switch has been turned ON e The Image Transfer Voltage Monitor signal T_MON_V and Image Transfer Current Monitor signal T_MON_I fall outside a corresponding predetermined range lt Troubleshooting Procedures gt Relevant Electric Parts Fusing Unit Controller Mechanical Control Board PWB P WIRING DIAGRAM Action Location Control Signal Electric Parts Replace Fusing Unit 2 Replace PWB P T 15 3 C0500 Fuser warm up error lt Detection Timing gt Description The voltage of the Thermistor remains low for a predetermined period of time when a warm up cycle is started The temperature detected by the Thermistor remains lower than a reference value for a predetermined period of time for the period of time that begins 5 sec after and ends 9 sec after the start of the warm up cycle where the temperature detected by the Ther mistor is 80 C or less The temperature detected by the Thermistor does not increase for a 3 sec period or more for the period of time that begins after the lapse of a predetermined period of time after the Fusing Roller Hea
31. screw and then remove the cover Remove the screw unplug the connector and then remove the Paper Feed Cassette Paper Take Up Solenoid D 6
32. the Rear Cover 4980D004AB 2 Disconnect all connectors and flat cables from the Controller Mechanical Control Board NOTE e Use utmost care not to snap off the flat cable 3 Remove six screws and the Controller Mechani cal Control Board 2 Removal of the Control Panel 1 Remove the Exit tray ts D 7 h amp 4136D047AA 2 Remove the Rubber cap then remove the three screws unplug one connector and one flat cable and then remove the Control Panel NOTE e Use utmost care not to snap off the flat cable D 10 3 Removal of the Interface Board 1 Remove the Rear Cover ws D 7 2 Unplug the three connectors on the Controller Mechanical Control Board 3 Remove the two screws and then remove the Left Rear Cover 4980U044AA 4 Remove the three screws and then remove the Circuit Board and Metal Bracket 5 Remove the two screws and then remove the Protective Metal Bracket for the Interface Board 6 Remove the seven screws and then remove the Interface Board 4980D066AA D 11 4 Removal of the Power Unit 1 Remove the Right Cover ts D 7 2 Remove the Left Cover ts D 7 3 Remove the Rear Cover ts D 7 4980D006AA 5 Remove the IR Unit sr D 15 4980D060AA 4980E008AA 4 U
33. to pre vent toner from sticking to the surface of the PC Drum 2nd Toner Blade PC Drum 1st Toner Blade Sleeve Roller Bias Seal Ao 4136M505AA Toner Blade Voltage Developing Terminal Voltage Terminal Toner Supply Roller Developing Lower Seal Bias Seal Terminal Developing Lower Seal Bias Seal Terminal dodasi Developing Voltage Terminal Toner Blade Voltage Terminal M 11 6 4 Detection ofToner Cartridge 1 Installation detection The Imaging Cartridge when loaded in position is detected as follows At the comple tion of a warm up cycle the IC chip built into the Toner Cartridge TC detection board detects electrically whether or not the cartridge is loaded in position 2 Interchangeability detection e The built in IC chip TC detection board detects the applicable marketing area of the Toner Cartridge when power is turned ON or when the Front Door is opened and closed TC Detection Board gt 4136M540AA 4136M537AB 3 Toner Near Empty and Toner Empty Detection e The Toner Empty Detection Sensor detects the amount of toner still available for use Toner Empty Detection Sensor TE1 4136M540AA M 12 The Toner Empty Detection Sensor has an LED and a reflecting light detection sensor built into it Light from the LED enters the toner detection window and is reflected off the Reflection Mirror located inside the Toner Cartridge The reflecting light detection sensor de
34. user s premises 2 PRECAUTIONS FOR DISASSEMBLY ADJUST MENTS 2 1 Parts That Must Not be Touched 1 Red Painted Screws Purpose of Application of Red Paint Red painted screws show that the assembly or unit secured can only be adjusted or set at the factory and shall not be readjusted set or removed in the field If it becomes unavoidably necessary to disassemble any of these assemblies and units disassembly may be done provided that the conditions permitting reassembly are met Note also that when two or more screws are used on the part in question only one repre sentative screw may be marked with red paint 2 Variable resistors on board Do not turn the variable resistors on boards for which no adjusting instructions are given in ADJUSTMENT 3 Other Screws not Marked with Red Paint Scanner Assy PH Unit er T 4980D054AA 4980D014AA 3 DISASSEMBLY REASSEMBLY 3 1 Identification of Exterior Parts and Removal Procedures for Them C49800003AC C49800057AB D 7 Name Removal Procedure Original Cover Open the Original Cover gt Pull it straight up Upper Cover Assy Original Glass Remove the Original Cover gt Remove the Control Panel gt Remove the six screws and remove the Upper Cover Assy Original Glass ss D 18 Control Panel Open the Original Cover Remove the three screws unplug the connector and the flat cable and remove
35. which the Toner Cartridge is mounted 2 Using a soft cloth wipe the surface of the Paper Take Up Roll clean of dirt 4980E006AA 2 Replacement of the Paper Take Up Roll 1 Remove the Imaging Cartridge ww E 5 2 Remove the Paper Take Up Roll 4980E007AA 3 Replacement of the Image Transfer Roller 1 Remove the Imaging Cartridge ww E 5 y z4 4136E018AA N 4136E019AB 4136E020AB 2 Place the levers of the bushings white on the right and left ends of the Image Transfer Roller toward this side and remove the Image Transfer Roller from the Image Transfer Roller holder 3 Pull out the bushings on the right and left ends and the gear from the Image Transfer Roller removed from its holder Install the bushings and the gear to the new Image Transfer Roller NOTES Do not touch or dirty with chemicals or toner the surface of the Image Transfer Roller as indenta tions in and dirt on the surface of the Image Trans fer Roller adversely affect the quality of the printed image e When handling the Image Transfer Roller hold onto the shaft and bushings of the roller Do not place a new Image Transfer Roller directly on the floor or other surface 4 Insert the new ImageTransfer Roller into the Image Transfer Roller holder and place the levers of the bushings into the original upward positions 3 REPLACEMENT OF UNITS 1 Repl
36. width of C in copy of the test pattern meets the specification If the width of C is out of specification adjust it according to the following procedure 5 Change the setting If the width of C in the test pattern is longer than the specified width Increase the set ting If the width of C in the test pattern is shorter than the specified width Decrease the setting If the shift cannot be adjusted to within the specification with a single adjustment perform the adjustment again to change the setting 6 Press the Yes key to apply the setting NOTE If the Stop key is pressed instead of the Yes key the main screen is displayed and the set ting returns to that before it was changed Place the test pattern on the Original Glass again make another test copy and check it D 39 5 MISCELLANEOUS 5 1 Removal of the Mechanical Counter Option 1 Remove the Right Cover tx D 7 2 Remove the Rear Cover ss D 7 3 Unplug one connector on the Controller Mechani cal Control Board 4 Remove the Relay Harness 4980D056AA 5 Remove the screw and then remove the Mechanical Counter 4137U003AA D 40 5 2 Updating the Firmware NOTES The TWAIN driver must already be installed on the host computer to be used for updat ing the firmware If the GDI printer or TWAIN driver is not installed follow the procedure described below to install the driver If the driver is alrea
37. 0 2 0 mm ADJUST menu ADF MAIN REGIST t 1 increment 0 5 mm NOTE Perform this adjustment after the Automatic Document Feeder sub scanning zoom ratio adjustment lt Adjustment Procedure gt 1 Print the test pattern 2 Enter the ADJUST menu in the Service mode 3 Load the test pattern into the Automatic Document Feeder and make a test copy NOTE The test pattern should be positioned vertically Use A4 L or Letter L paper loaded into Tray 1 to make the test copy 4 Fold the copy of the test pattern in half and then check if the fold aligns with the center line If they are not aligned adjust it according to the following procedure 5 Change the setting If Dis shorter Decrease the setting If E is shorter Increase the setting If the shift cannot be adjusted to within the specification with a single adjustment perform the adjustment again to change the setting 6 Press the Yes key to apply the setting NOTE If the Stop key is pressed instead of the Yes key the main screen is displayed and the set ting returns to that before it was changed Load the test pattern into the Automatic Document Feeder again make another test copy and check it D 14 8 Automatic Document Feeder Sub Scanning Registration Adjustment lt Reference gt e Adjust the width of F in the copy of the test pattern so that the following specification is met F E gt 1382D010
38. 5 Remove the Timing Belt and shaft and then e eI remove the Scanner Assy 4980D022AA 5 Removal of the Timing Belt 1 Remove the Original Cover 2 Remove the Upper Cover Assy Original Glass D 18 3 Remove the Scanner Assy D 19 4 Remove the C clip 5 Remove the washer 6 Remove the Timing Belt 4980D023AB D 20 3 5 Disassembly of the Main Drive Section 1 Removal of the Main Motor 1 Remove the Left Cover N 4136D010AB 2 Disconnect one connector 3 Remove two screws two washers and the Main Motor 2 Removal of the Paper Empty Sensors 1 Remove the Imaging Cartridge 2 Remove the Front Door NOTE The Imaging Cartridge is the Drum Cartridge to which the Toner Cartridge is mounted 3 Remove the Left and Right Covers ws D 7 4980D015AB 4980D016AB 4 Remove the four connectors from the Paper Take Up Upper Guide Assy 5 Unhook the two tabs and then remove the Paper Take Up Upper Guide Assy D 21 6 Unhook two tabs and remove the tray 4980D027AC 7 Remove the Multi purpose Tray Paper Empty Sensor 4980D028AB 8 Remove the Multiple Bypass Tray Paper Empty Sensor 4980D029AB 9 Remove the Toner Empty detection sensor 4980D030AA D 22 3 Removal of the Paper Take Up Solenoid 1 Remove the Left Cover ws E 8 2 Discon
39. AA Specification Mode Function Setting Range 90 to 110 1 increment 0 5 mm 20 3 0 mm ADJUST menu ADF SUB REGIST Perform this adjustment in the following cases After the Scanner Assy has been replaced After the printer s main scanning amp sub scanning registration adjustments and the scan ner s sub scanning zoom ratio adjustment have been performed lt Adjustment Procedure gt 1 Print the test pattern 2 Enter the ADJUST menu in the Service mode 3 Load the test pattern into the Automatic Document Feeder and make a test copy NOTE The test pattern should be positioned vertically Use A4 L or Letter L paper loaded into Tray 1 to make the test copy 4 Check that the width of F in copy of the test pattern meets the specification If the width of F is out of specification adjust it according to the following procedure 5 Change the setting If the width of F in the test pattern is longer than the specified width Increase the setting If the width of F in the test pattern is shorter than the specified width Decrease the setting If the shift cannot be adjusted to within the specification with a single adjustment perform the adjustment again to change the setting 6 Press the Yes key to apply the setting NOTE If the Stop key is pressed instead of the Yes key the main screen is displayed and the set ting returns to that before it was changed Load the test pat
40. AA lt Troubleshooting Procedures gt Check 4011T020AA Result Action Is the document damaged or dirty YES Replace the document Is the Original Pad dirty YES Clean it Does the Original Cover not lie flat YES If the Original Cover is deformed or the hinges are damaged replace the Original Cover Is the surface of the Original Glass dirty Clean it Are the Shading Sheet or back surface of the Original Glass dirty Clean them Are the mirror or lens dirty Clean them Replace the Scanner Assy Is the Exposure Lamp dirty Clean it Replace the Scanner Assy Are there no bent connector pins on the cables connecting the control boards are all connectors correctly plugged in and are no cables broken T 31 Correctly plug in the connectors Replace connection cables 7 Image reading system Uneven image lt Sample of Image Quality Problem gt 4011T528AA lt Troubleshooting Procedures gt Check Action Is the Scanner Motor drive being trans mitted Correct drive coupling mecha nisms Replace it Is the harness of the Exposure Lamp catching Correct it Is there enough slack in the Timing Belt Correct it Replace the Timing Belt Are the Scanner Rails scratched or dirty Clean them Are there no bent connector pins on the cables connecting the control boards are all connectors correctly
41. ALITY PROBLEMS 5 1 Troubleshooting Image Quality Problems e This chapter is divided into two parts Initial Checks and Troubleshooting for Specific Image Quality Problems e If an image quality problem occurs first go through the Initial Checks ana if the cause is still not identified continue to Troubleshooting for Specific Image Quality Problems 5 2 Initial Checks Determine if the failure is attributable to a basic cause or causes Section Check Result Action Installation The installation size complies with the NO Change the site requirements specified in PRECAU installation site TIONS FOR INSTALLATION con tained in the GENERAL section Paper The paper meets product specifica Instruct the user tions to use recom mended paper that meets prod uct specifications The paper is damp Change the paper Instruct the user on the correct methods for stor ing paper Original The document is not flat Correct the docu document ment Copies of a faint document written in Instruct the user light pencil etc are being made to use a docu ment with an appropriate image density Copies of a highly transparent docu Instruct the user ment OHP transparencies etc are on how to copy being made transparent docu ments The Original Glass is dirty or Clean or replace scratched the Original Glass PM parts relating to image formation Clean or replace
42. ANCE SCHEDULE cooocccnccccoccconcncnnncnnnccnnncannnnnnn nan ccnnnnnnn cnn nc rancnannnnnnes D 1 2 REPLACEMENT CLEANING OF PARTS nenennennnsnnnennnnennnennnnnnn D 2 1 Cleaning of the Paper Take Up Roll uersenseessernennennnnnneennn nennen D 2 2 Replacement of the Paper Take Up Roll uu uuesseessnnessennnnnnnnnnnn D 2 3 DISASSEMBLY REASSEMBLY uussessenssnensnennnnnnnnnnnnennnennnnnnnnnnnnannnnn D 3 3 1 Identification of Exterior Parts and Removal Procedures for Them D 3 3 2 Removal of Circuit Boards ooooocccncccincccocacoccconccnancnonnn conc nono conan conc cancnannnn D 4 1 Removal of the Paper Feed Cassette Control Board D 4 3 3 Disassembly iii ainia D 5 1 Removal of the Paper Feed Cassette Paper Take Up Unit D 5 2 Removal of the Paper Size Detecting Switch o oo D 5 3 Removal of the Paper Feed Cassette Paper Take Up Solenoid D 6 GENERAL 1 SPECIFICATIONS Name Type of paper Media sizes Paper capacity Registration Power source Power consumption Dimension Weight Environment 2nd Paper Feed Cassette Plain and recycled paper 60 to 90 g m 16 to 24 Ib A4 Land Letter L Maximum 500 sheets 80 g m 21 Ib Center DC 24 V DC 5 V supplied by main unit Less than 7 W W 401 mm 15 3 4 in x D 615 mm 24 1 4 in x H 138 mm 5 1 2 in 4 3 kg 9 1 2 Ib Same as the copier G 1 MECH
43. ANICAL ELECTRICAL 1 COMPONENTS LAYOUT PWB A CAS 4516M002AA swi Cassette type Detecting Switch SL2 2nd Drawer Take up solenoid PWB A CAS 2nd Drawer Control Board 1 1 Paper Take up Mechanism Because of no drive motor installed for the Paper Feed Cassette drive from the Main Motor M1 of the printer is transmitted to the cassette by way of a drive coupling gear for paper take up and transport e Except that the Paper Separator Fingers are used for paper separation the paper take up mechanism is the same as that for Tray 1 e The paper separation mechanism uses the Paper Separator Fingers provided in the cas sette and the elasticity the paper has in its own right It ensures that only one sheet of paper is taken up at one paper take up sequence The Paper Take up Solenoid is controlled from the printer side by way of the control board of the optional Paper Feed Cassette Paper Take up 2nd Drawer Control Coupling Gear Roller Board PWB A CAS 2nd Drawer Take up Se Solenoid SL 2 Electrical Component Control Signal WIRING DIAGRAM PWB A CAS MPJ22A CAS 2 41275024 E F 5 SL2 M 2 1 2 Paper Empty Detection e There is a Paper Empty Sensor provided on the 2nd Drawer Control Board It detects a paper empty condition of the cassette e When paper is loaded the actuator is raised and blocks the sensor e If there is no paper loaded the actuator drops in the hole in the Paper Lift
44. CHHHH 4980P550DA lt Procedure for cancelling a malfunction display gt Cancel the malfunction display by turning the machine off then on again 3 1 List of Malfunctions Malfunc tion Malfunction Name Description Code e The LOCK signal remains HIGH or LOW continuously for a predetermined period of time while the Cooling Fan Motor remains energized The Drum Charge Monitor Voltage HVC_MON signal Fuser fan motor error falls outside a predetermined range at any time after the lapse of a predetermined period of time after the Power Switch has been turned ON The Image Transfer Voltage Monitor signal T_MON_V and Image Transfer Current Monitor sig nal T_MON_1 fall outside a corresponding predeter mined range H V abnormal T 11 Malfunc tion Code Malfunction Name Description Fuser warm up error The voltage of the Thermistor remains low for a prede termined period of time when a warm up cycle is started The temperature detected by the Thermistor remains lower than a reference value for a predetermined period of time for the period of time that begins 5 sec after and ends 9 sec after the start of the warm up cycle where the temperature detected by the Ther mistor is 80 C or less The temperature detected by the Thermistor does not increase for a 3 sec period or more for the period of time that begins after the lapse of a predetermined p
45. CK signal remains ON for a continuous 5 sec period or more when the Polygon Motor remains deen ergized Communication with option error Communication could not be established with the Con troller Control Board within 5 seconds while printing 7 12 Malfunc tion Malfunction Name Code Description ROM checksum error C133D A malfunction occurred in the ROM C13F0 Laser error The laser output exceeds the upper limit value The laser output remains lower than the lower limit value C1468 EEPROM error An EEPROM not written with initial data was detected IR lamp malfunc tion C14A3 The luminosity level of the Exposure Lamp is not stabi lized within the predetermined period of time T 13 3 2 Malfunction Detection Timing and Troubleshooting Proce dures 1 C0045 Fuser fan motor error lt Detection Timing gt Description e The LOCK signal remains HIGH or LOW continuously for a predetermined period of time while the Cooling Fan Motor remains energized lt Troubleshooting Procedures gt Relevant Electric Parts Cooling Fan Motor M2 Controller Mechanical Control Board PWB P Power Unit PU1 WIRING DIAGRAM Action Ref Page Control Si Location eee Electric Parts Check the Motor connectors for connection and correct as neces sary Check the fan for possible over load and correct as necessary M2 operation check PWB P MPJ13P 1 to 3
46. DENSITY To specify the default print density The default setting is O The setting range is 3 to 3 LCD CON TRAST To specify the brightness of the display e The default setting is 0 The setting range is 1 to 2 LANGUAGE To specify the language of screens e The default setting is ENGLISH The language settings are divided into Type 1 and Type 2 The Type 1 languages are the standard lt Available Languages gt Type1 ENGLISH GERMAN FRENCH ITALIAN DANISH DUTCH SPANISH NORWEGIAN SWEDISH FINNISH TURKISH PORTUGUESE Type2 ENGLISH GERMAN FRENCH CZECH HUNGARIAN POLISH ROMANIAN LITHUANIAN SLOVAKIAN LAMP OFF TIME To specify the time until the Expo sure Lamp goes off e The default setting is MODE1 MODE1 When four hours have passed since the last opera tion was performed MODE2 When the machine enters Energy Save mode 2 Paper Source Setting e Various settings for the paper tray can be specified Function Purpose To specify the type and size of paper loaded into Tray1 Setting Details Precautions The default settings are PLAIN in addition to A4 L or LT lt Procedure gt 1 Select the paper type PLAIN OHP CARD ENVELOPE 2 Select the paper size A5 B5 A4 FLS 16K HL LT LG NOTE If OHP is selected as the paper type only A4 and LT are available as paper sizes 3 To specify a cus
47. ING EDGE ERASE TRAILING EDGE ERASE VERTICAL EDGE ERASE FLS PAPER SIZE GDI TIMEOUT TONER EMPTY STOP PRE ROTATION FUSER TEMP Ad Service s Choice PRN MAIN REGIST PRN SUB REGIST CCD MAIN ZOOM CCD SUB ZOOM ADJUST CCD MAIN REGIST CCD SUB REGIST ADF SUB ZOOM ADF MAIN REGIST ADF SUB REGIST Service Mode TOTAL COUNTER PM COUNTER I C COUNTER APPLICATION COUNTER COUNTER SCAN COUNTER PRINTER JAM COUNTER ADF JAM COUNTER TROUBLE COUNTER MAIN F W VER ENGINE F W VER DISPLAY 1 MAIN RAM SIZE SERIAL NO CUSTOMER ID TC TYPE H FUNCTION PAPER FEED TEST PRINT TEST PATTERN ADF FEED TEST COPY ADF GLASS AREA CCD MOVE TO HOME SCAN TEST Service Mode FIXED ZOOM FACTORY TEST PANEL BUZZER TEST RAM TEST CLEAR DATA MEMORY CLEAR PM COUNTER I C COUNTER APPLICATION COUNTER SCAN COUNTER PRINTER JAM COUNTER ADF JAM COUNTER TROUBLE COUNTER S 10 4 2 Service Mode Setting Procedure NOTE Be sure to keep the access procedure for the Service mode from any unauthorized per sons not involved with service operations lt Procedure gt 1 2 Press the Utility key Press the following keys in order to enter the Service mode Stop gt 0 gt 0 gt Stop gt 0 gt 1 The first Service mode screen appears
48. JAM CAUTION OPEN FRONT COVER 4980P502DA lt Procedure for cancelling the misfeed display gt 1 Open the appropriate covers remove the misfed paper and any remaining paper and then close the covers 2 Open then close the Front Door 2 3 Locations of Misfeed Detection Sensors a Exit Sensor PS1 Paper Take Up Switch S1 4980M005AA 2 4 Misfeed Detection Timing and Troubleshooting Procedures 1 Paper Take Up Transport Misfeed lt Detection Timing gt Type Description MP tray Pick up Jam 2nd tray Pick The Paper Take Up Switch does not turn on after the predetermined period of time has elapsed after paper take up began Bypass tray Pick up Jam The Exit Sensor is not blocked after the predetermined period of time has elapsed after the Paper Take Up Switch is turned on The Paper Take Up Switch is not turned off after the predetermined period of time has elapsed after the Paper Take Up Switch is turned on lt Troubleshooting Procedures gt Relevant Electrical Parts Paper Take Up Switch S1 Controller Mechanical Control Board PWB P Exit Sensor PS1 Paper Take Up Solenoid SL1 WIRING DIAGRAM Action Ref Page Location Control Signal Electric Parts Initial checks ws T 6 SL1 solenoid check ts T 2 PWB P M
49. JUSTMENT 1 SAFETY INFORMATION 1 1 Laser Safety e This is a digital machine certified as a class 1 laser product There is no possibility of danger from a laser provided the machine is serviced according to the instruction in this manual 1 2 Internal Laser Radiation Semiconductor laser Maximum power of the laser diode 15 mw Maximum average radiation power 36 903 uW Wavelength 770 800 nm Laser Aperture of the Print Head Unit e This product employs a Class 3b laser diode that emits an invisible laser beam The laser diode and the scanning polygon mirror are incorporated in the print head unit e The print head unit is NOT A FIELD SERVICE ITEM Therefore the print head unit should not be opened under any circumstances Laser Aperture of the Print Head Unit C49800053AB the U S A Canada CDRH Regulation This machine is certified as a Class Laser product under Radiation Performance Stan dard according to the Food Drug and Cosmetic Act of 1990 Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health CDRH of the U S Food and Drug Administration of the U S Department of Health and Human Services DHHS This means that the device does not produce hazardous laser radiation e The label shown to page D 4 indicates compliance with the CDRH regulations and must be attached to laser products ma
50. M uuusesserseensersennnnnnnnnnnnnnnennnnnnnnnn nennen nennen nennen nnnnsnnnnnenen M 2 9 ELECTRICAL PARTS LAYOUT 1 nennen M 3 3 1 Document Take up Mechanism uuurssesssensnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn M 4 1 Document Take up Mechanism usuersseessnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnn M 4 2 Document Separation Mechanism cecceseeceeseeeeeeteeeeeeeeeeeeeeeeaee M 5 3 2 Document Transport Exit Mechanism urserserserneennennnnnenn nennen nennen M 6 1 Document transport Mechanism u uursssennnensnnnnnnnnnnnnnnnnnnnnnnnnnnn M 6 2 Document exit MECHANISM uurssesnnersnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnn M 7 3 3 Miscellanous isinan a A AR NGA ai M 8 1 Document Feeder raised lowered position detection mechanism M 8 DIS REASSEMBLY ADJUSTMENT 1 MAINTENANCE SCHEDULE uunsenseersensennsnnnnnnnnsnnnnnnnnennnnnnnnnnnnnnnnnnnn nenn D 1 2 REPLACEMENT CLEANING OF PARTS cnnnnsersennsnrnnnnennnnnnennnnnnennnn nenn D 2 1 Cleaning of the Paper Take Up Roll uursenseessernenseennnnneennn nennen D 2 2 Replacement of the Paper Take Up Roll uu uuesssensnnensnnnnnnnnnnnen D 2 3 Cleaning of the Pick Up Roller uerserneersennnnnnnnnennennnnnennnnn nenn D 3 4 Removal of the Pick Up Roller oo ooocononconocacinccincnnarcnanacc rca ra nananno D 4 5 Cleaning of the Registration Rollers ooooonnonnnnnonicnnnncnnnncnnrencnno D 4 6 Cleaning o
51. OUNTER ADF JAM COUNTER TROUBLE COUNTER S 18 4 Display e Various information can be displayed Function Purpose Setting Details Precautions To display the version of the main firmware MAIN F W VER ENGINE F W VER To display the version of the engine firmware MAIN RAM SIZE To display the size of the main memory SERIAL NO To display the serial number of the main unit CUSTOMER ID To display the customer ID for the main unit TC TYPE Function 5 To display the type of Toner Cartridge that should be installed in the main unit e The service functions paper feed test and image printing can be checked and adjusted Function Purpose Setting Details Precautions PAPER FEED TEST To check the paper feeding in the paper take up transport sections without printing on the paper When a paper misfeed occurs lt Procedure gt 1 2 Select the paper tray Press the Start key to begin testing paper feeding Press the Stop key to stop testing paper feeding To print the test pattern for adjust ing the image If there is tilt or when registration or zoom ratio adjustments are performed lt Procedure gt 1 2 3 Select the paper tray Select the test pattern type Press the Start key to print the test pattern To print the test pattern for half tones and gradations When checking density and pitch irregularities When
52. PJ3P 2 1 6 to 7 S1 switch check es T 2 PWB P MPJ10P 2 PS1 sensor check we T 1 PWB P MPJ8P 3 Replace PWB P G 8 to 9 E to F 7 to 8 2 Fusing Exit Misfeed lt Detection Timing gt Type Description The Exit Sensor is not unblocked after the predetermined period of time has elapsed after the Paper Take Up Switch is turned on If all of the following conditions are met Fuser Jam Remains paper Jam 1 e The Front Door or Exit Cover is opened then closed Or the machine is turned on e The Paper Take Up Switch is turned on or the Exit Sensor is blocked The Exit Sensor is unblocked slower than the predetermined period of time after the Paper Take Up Switch is turned on Remains paper Jam 2 lt Troubleshooting Procedures gt Relevant Electric Parts Paper Take Up Switch S1 Controller Mechanical Control Board PWB Exit Sensor PS1 P WIRING DIAGRAM Location Electric Parts Action Ref Page Control Signal Initial check items us 1 6 S1 switch check ww T 2 PWB P MPJ10P 2 G 8 to 9 PS1 sensor check es T 1 PWB P MPJ8P 3 Eto F 7 to 8 Replace PWB P T 10 3 MALFUNCTIONS WARNING e The CPU performs a self diagnosis on the condition of the unit and if a malfunction is detected the warning appears alternately with the error code in the display CAUTION MACHINE TROUBLE t SERVICE CALL
53. Print the test pattern 2 Enter the ADJUST menu in the Service mode 3 Load the test pattern into the Automatic Document Feeder and make a test copy NOTE The test pattern should be positioned vertically Use A4 L or Letter L paper loaded into Tray 1 to make the test copy 4 If the length of C in the copy of the test pattern is not the same as the length of C in the test pattern adjust it according to the following procedure 5 Change the setting If the width of C in the test pattern is longer than the specified width Decrease the setting If the width of C in the test pattern is shorter than the specified width Increase the setting If the shift cannot be adjusted to within the specification with a single adjustment perform the adjustment again to change the setting 6 Press the Yes key to apply the setting D 12 NOTE If the Stop key is pressed instead of the Yes key the main screen is displayed and the set ting returns to that before it was changed Load the test pattern into the Automatic Document Feeder again make another test copy and check it D 13 7 Automatic Document Feeder Main Scanning Registration Adjustment lt Reference gt e Adjust the amount that widths D and E in the copy D of the test pattern are shifted so that the following specification is met E 1382D011AA Specification Mode Function Setting Range 90 to 110
54. Replace Thermostat TS1 Replace Fusing Unit Replace Controller Mechanical Control Board PWB P Replace Power Unit PU1 T 17 5 C0520 Fuser overheat lt Detection Timing gt Description e The temperature detected by the Thermistor remains higher than 235 C for a predeter mined period of time while the fusing temperature control is being provided lt Troubleshooting Procedures gt Relevant Electric Parts Fusing Unit Controller Mechanical Control Board PWB P Thermistor TH1 Thermostat TS1 Fusing Roller Heater Lamp H1 Power Unit PU1 WIRING DIAGRAM Action Location Control Signal Electric Parts Replace Thermistor TH1 Replace Fusing Roller Heater Lamp H1 Replace Thermostat TS1 Replace Fusing Unit Replace Controller Mechanical Control Board PWB P Replace Power Unit PU1 6 C0650 Scanner home sensor error lt Detection Timing gt Description e The Scanner Home Position Sensor is not detected within the predetermined period of time after the Scanner Motor has started turning lt Troubleshooting Procedures gt Relevant Electrical Components Scanner Motor M4 Controller Mechanical Control Board PWB P WIRING DIAGRAM Step Action Ref Page C ntrol Signal Location oniro signa Electric Parts 1 M4 operation check 2 Replace PWB P 1 18 7 1200 ASIC memory abnorm
55. Roller 1382E003AA 7 Cleaning of the Exit Roller 1 Open the Document Feeder Cover 2 While turning the Document Feed Knob in the direction shown in the illustration use a soft cloth i E _ to wipe clean the Exit Roller OL 1382E015AB D 4 8 1 Cleaning of the Paper Separator Pad Open the Document Feeder Cover UA 1382E005AA 9 1 2 Using a soft cloth wipe clean the surface of the Paper Separator Pad Removal of the Paper Separator Pad Open the Document Feeder Cover 1382E007AA 2 Remove the Paper Separator Cover 3 Loosen the two screws and then remove the Paper Separator Pad NOTE Be extremely careful not to lose the spring on the Paper Separator Pad 3 DISASSEMBLY REASSEMBLY 3 1 Names Removal of External Parts Name 1382D001AB Removal Procedure Document Feeder Cover Open the Document Feeder Cover gt Remove the two screws gt Remove the Document Feeder Cover Document Feeder Tray Open the Document Feeder Cover gt Remove the Rear Cover gt Remove the screw and then remove the Docu ment Feed Knob gt Remove the two screws Remove the Document Feeder Tray Rear Cover Remove the screw gt Remove the Rear Cover D 6 3 2 Removal of Circuit Boards NOTE When removing a circuit board refer to the precautions for handling printed circuit boards an
56. acement of the Toner Cartridge lt Removal Procedures gt VAHA mu Be 4136E007AC lt Installation Procedures gt 4136E008AA 1 Lift up the Exit Tray and remove it 2 Open the Front Door 3 Remove the Imaging Cartridge 4 Pull the lever of the Toner Cartridge in the direc tion shown in the illustration and disconnect the Toner Cartridge from the Drum Cartridge NOTE Ifthe Drum Cartridge is to be placed on a floor or similar place use care to prevent toner from scat tering around 1 Take out a newToner Cartridge and shake it in the horizontal direction sufficiently so that toner is agitated NOTE Placing the Toner Cartridge in an upright position or shaking it vigorously will spill toner 2 Remove the protective cover from the Toner Car tridge C41360049AC 3 Install the new Toner Cartridge to the Drum Car tridge NOTE Insert the Toner Cartridge along the guide provided on the Drum Cartridge side and make sure that the Toner Cartridge is not tilted when inserted 4136E009AC 4 Install the Imaging Cartridge in the printer NOTE Insert the Imaging Cartridge along the guide pro vided on the printer side Ensure that the Imaging Cartridge is not slid obliquely 5 Close the Front Door C49800029AC Precautions for Replacing the Toner Cartridge Different types of Toner Cartridges are available for
57. al lt Detection Timing gt Description e An error occurred while writing to or reading the SRAM on the Control Board PWB C lt Troubleshooting Procedures gt Relevant Electrical Components Controller Mechanical Control Board PWB P WIRING DIAGRAM Action Ref Page a Control Signal Location Electric Parts Turn the copier off then on again Check the connection of the memory on the PWB P and then correct it if necessary Replace PWB P 8 1300 Polygon mirror motor error lt Detection Timing gt Description The LOCK signal is not detected within a predetermined period of time that begins 1 sec after the Polygon Motor has been energized No new LOCK signal is detected for a 1 sec period that begins 1 5 sec after the first LOCK signal was detected The LOCK signal is not detected for a continuous 0 5 sec period in a state in which the Polygon Motor runs stably The LOCK signal remains ON for a continuous 5 sec period or more when the Polygon Motor remains deenergized lt Troubleshooting Procedures gt Relevant Electric Parts PH Unit Controller Mechanical Control Board PWB P Flat cable WIRING DIAGRAM Action Ref Page c isi Location Onirohelgine Electric Parts Check cables for connection and correct as necessary Replace PH Unit Replace PWB P 9 C133B Communication with option error lt Detection Timing gt Description
58. an cnn nan nn crac oran S 4 3 UTILITY MODE ci Er nie S 5 3 1 Utility Mode Function Tree ooonnnnoconoccnonnnnonaninnc nan cnnn cc non c cnn nann cr arc cnn nana S 5 3 2 Utility Mode Setting Procedure oooococconncniconccocnncnnoconcnnnncornnrncornnrc canon S 6 1 Machine Setting oooonconccncnnonoccnonnnocnncnnnncnononccnncnna cnn cnnn ran anonrnnnnnnnns S 6 2 Paper Source Setting urnnnsernennnernennnennennnnnnnnnnnnnennnnnnnnnennnennnn ran S 8 3 Copy Setting ra Hei ee Er Bi aes S 8 4 SERVICE MMODE covers net ei hair S 9 4 1 Service Mode Function Tree unmersenneersennennnennnnnennnnnnnnnnnnnnnnnnnnnnn nen S 9 4 2 Service Mode Setting Procedure unersenseensnnennnennennnennnnnnnnnnnnnnnnn nn S 11 4 3 Service Mode Functions 2un24ssersennnnnnnnnnnnnnennnnnennnnnnnnnnnnnnnennnnnennnnn S 12 1 Semice s CHOICE se eeccis icsacsccdeceescsceaccsncecednceunsducsesaneneaiacsancescndannaecdts S 12 2 Ad USE Her NAR S 14 EI A e E acedvnss aumento S 17 4 DIS S 19 A AA a e aaar A AO S 19 6 Fixed Zoom Change unnuersnssernennensnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnen S 21 2 A E NON S 22 8 Clear Data nannte S 22 5 SECURITY MODE ratarea an A R AOO a a eatin S 23 5 1 Security Mode Function Tree ooocoonccccinonnccnnnnnnncnnnonncnnnnn cnn cnn nona cn rrnncnnno S 23 5 2 Security Mode Setting Procedure ococcconccicnnnnnoconcnonccncnnncconnnrnconcnncrnncnn nos S 23 1 CS ECU rss ee
59. ands lt Sample of Image Quality Problem gt 4011T017AA lt Troubleshooting Procedures gt Check 4011T023AA Result Action Is the document damaged or dirty YES Replace the document Is the Original Pad dirty Does the Original Cover not lie flat YES Clean it If the Original Cover is deformed or the hinges are damaged replace the Original Cover Is the surface of the Original Glass dirty Clean it Are the Shading Sheet or back surface of the Original Glass dirty Clean them Are the mirror or lens dirty Clean them Replace the Scanner Assy Is the Exposure Lamp dirty Are there no bent connector pins on the cables connecting the control boards are all connectors correctly plugged in and are no cables broken T 29 Clean it Replace the Scanner Assy Correctly plug in the connectors Replace connection cables 5 Image reading system Black spots lt Sample of Image Quality Problem gt 4011T521AA lt Troubleshooting Procedures gt Check Result Action Is the document damaged or dirty YES Replace the document Is the Original Pad dirty YES Clean it Is the Original Glass dirty YES Clean it The problem has been eliminated after NO Replace the Scanner Assy performing step 3 T 30 6 Image reading system Blank streaks or bands lt Sample of Image Quality Problem gt 4011T015
60. aper after image transfer PC Drum Den Image Transfer Roller 41215034 PC Drum 4136M515AA M 24 12 FUSING UNIT 12 1 Overview e The toner image transferred onto the paper is securely fixed to the paper A heated roller system is used as the fusing system The paper to which the toner image has been transferred is fed between the Fusing Roller heated by the Fusing Roller Heater Lamp and the Pressure Roller This permanently fixes the toner image in the paper Fusing Paper Separator Finger Actuator Thermostat TS1 Exit Sensor PS1 f Thermistor TH1 _ EN Pressure Roller Fusing Roller Heater Lamp H1 Fusing Roller u Fusing Entrance Guide Plate 4136M520AA Electrical Parts Control Signal Blocked Unblocked WIRING DIAGRAM PS1 PWB P MPJ8P 3 L H F G 2 Electrical Parts Control Signal Low temp gt High temp WIRING DIAGRAM TH1 PWB P MPJ2P 1 Analog Input F 2 to 3 Electrical Parts Control Signal ON OFF WIRING DIAGRAM H1 PU 1 CN1PU 1 3 L H 1 7 M 25 12 2 Fusing Temperature Control 1 Temperature changes plain paper having a length of 186 mm or more Temperature detected by Thermistor Warm up A i i i 200 C l ee During print 5 l l l l cycle 600 dpi w I 0 l I I 0 l I z i i 2 l I l 1 l D l I I lt I Nn I I IL l l 130 C Y JAN h 7 l l In standby
61. art control is not provided s s s M 6 2 When the pre start control is provided ooniicccnnnnnicnnonnnanncnanananos M 7 5 2 Print End Sequence unsnnsursonsannnonnonnnennnnnonnnnnennnnnnnnnnonnennnnnennnnnen ran M 7 6 IC IMAGING CARTRIDGE SECTION uneessnnennnnnnennnennennnnnn nennen M 8 O aba othe eure heel E M 8 LIRA A a M 10 6 3 Developing System 2r2nsnnnennnernnnnnnnnnnnnnnnnnnnnnn nennen nennen nnnnnnnnnnnnn M 11 6 4 Detection of Toner Cartridge 22u222424nnnennennennnnnnnnnennennnnnnnnnnnnnnn nennen M 12 1 Installation detection o n nnnninninnnnnnonnnnnnnnonananancn nori r arrancan cnn M 12 2 Interchangeability detection o ononnnninnnnonncninninnaconacannccanarncnnnanan M 12 3 Toner Near Empty and Toner Empty Detection s M 12 Li DRUM CHARGE 0 AE ds M 14 1 Overview kein M 14 8 IR SEGTION zu ie M 15 8 1 Image Data Processing oocormornccnornnonanannnncnrnaranaracacononansacanacnoranonananonons M 15 8 2 Exposure Components Section unneensesneeneennennennnnnnnnnnnn nennen nennen nn na M 16 8 3 Scanner Drive Mechanism ursusssessernennnnnnennnnnnnnnnennnnnnnnennnnnnnnnnnen M 17 1 Scanner Drive Mechanism u uusserseensersennennnennennnnnnen nennen nenn M 17 8 4 Scanner Motor Drive Control uussunneessennennnennnnnennnnnnennnnnnn nennen M 17 9 PRINT HEAD PH sii e a M 18 YE CONSI AAA eae M 18 9 2 Laser Exposure Process
62. aution Label ococccnccnnnnicinnnncocnnrncocnnnrornnnornc nin rc coran nn D 4 1 5 Precautions for Handling the Laser Equipment oooocccncccnocanicccnononannananann D 5 PRECAUTIONS FOR DISASSEMBLY ADJUSTMENTS one D 6 2 1 Parts That Must Not be Touched nsss D 6 1 Red Painted Screws D 6 2 Variable resistors on board ee D 6 3 Other Screws not Marked with Red Paint oooooccccnnnnciinnncnnnnccincnnss D 6 DISASSEMBLY REASSEMBLY vichi ainan a R ARTA D 7 3 1 Identification of Exterior Parts and Removal Procedures for Them D 7 3 2 Removal of Circuit Boards and Other Electrical Components D 9 1 Removal of the Controller Mechanical Control Board D 10 2 Removal of the Control Panel 0 0 cceceeeeseeseeereeneeeeeeeeeeeeeeeeneeeeeeaes D 10 3 Removal of the Interface Board oooniccnnccnocanicccnonnnannnnann conca rara D 11 4 Removal of the Power Unit o occonccciocicicncnanananccinncnanc naar conocia rancnnnno D 12 5 Removal of the High Voltage Unit oo onnccnninininccnoninicncnacacinncinnananao D 14 3 3 Removal of Units ooooomoconannncnnoranononarscnrnacconononrnnccncnornc ona noncn coronas accnac s D 15 1 Removal of the IR Unit uesseessserssnessnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenn D 15 2 Removal of the PH Unit u uuresenssnessnnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn D 16 3 4 Disassembly of the Image R
63. checking reproducibility of gradations lt Procedure gt 1 2 3 Select the paper tray Select the test pattern type Press the Start key to print the test pattern ADF FEED TEST To check the paper feeding in the paper take up transport sections in the Automatic Document Feeder When a document misfeed occurs S 19 lt Procedure gt 1 Load paper into the Auto matic Document Feeder Press the Start key to begin testing paper feeding Press the Stop key to stop testing paper feeding Function Purpose Setting Details Precautions COPY ADF GLASS AREA To check for dirt in the scanning section of the Automatic Document Feeder If spots appear in the copies lt Procedure gt 1 Load A4 L or Letter L paper into Tray1 Press the Start key to start the COPY ADF GLASS AREA function Two copy samples are fed out Check that no spots appear in the copy samples Press the Stop key to stop the COPY ADF GLASS AREA function CCD MOVE TO HOME To move the scanner to its home position in order to secure the scanner When transporting the machine NOTE When transporting the machine be sure to move the scanner to its home position and secure it with the stopper at the bottom left of the IR SCAN TEST To check the lighting of the Expo sure Lamp and the movement of the scanner If the scanner malfunctions S 20 lt
64. d follow the corresponding removal procedures The following removal procedures omit the removal of the applicable component from connectors and circuit board supports When it is necessary to touch ICs and other electrical components on the circuit board be sure to first ground yourself PWB A ADF 1382D006AA Symbol Name Removal Procedure PWB A ADF Automatic Document Feeder Control Board D 7 1 Removal of the Automatic Document Feeder Control Board 1 Remove the screw unhook the six tabs and then remove the Rear Cover 1382D002AB D 7 1382D004AB 3 3 Disassembly Unplug all connectors connected to the circuit board Remove the two screws and then remove the Automatic Document Feeder Control Board 1 Removal of the Automatic Document Feeder Main Motor 1 Remove the Rear Cover ws D 6 1382D005AA Unplug the connector on the Automatic Docu ment Feeder Control Board Remove the two screws and then remove the Automatic Document Feeder Main Motor D 8 4 ADJUSTMENTS 4 1 Electrical Image Adjustment 1 Accessing the Service Mode 1 Press the Utility key 2 Press the following keys in order to enter the Service mode Stop gt 0 gt 0 gt Stop gt 0 gt 1 NOTE Be sure to keep the access procedure for the Service mode from any unauthorized per sons not involved with service operations 2 Accessing the
65. dy installed skip to Procedure for Updating the Firmware and update the firmware 1 Installing the GDI Printer TWAIN Driver Using Plug and Play lt For Windows XP gt 1 Start up the host computer and then insert the CD ROM into the CD ROM drive 2 Turn on the printer 3 4 Use a USB cable to connect the printer to the host computer In the Found New Hardware Wizard dialog box select Install from a list or specific location Advanced and then click the Next button Below Search for the best driver in these locations select Include this location in the search and then click the Browse button Specify Corresponding_language WinXP on the CD ROM and then click the OK button Click the Next button and then click the Finish button 8 When the Found New Hardware Wizard dialog box appears again repeat steps 4 through 7 to install all drivers lt For Windows 2000 gt PON Start up the host computer and then insert the CD ROM into the CD ROM drive Turn on the printer Use a USB cable to connect the printer to the host computer In the Install Hardware Device Drivers dialog box select Search for a suitable driver for my device recommended and then click the Next button In the Locate Driver Files dialog box select Specify a location and then click the Next button Click the Browse button specify Corresponding_languag
66. e Output Exposure Output Develop ing Output Reverse biag Image Transfer Unexposed area output Negative output Output Negative output 4980M013AA 2 When the pre start control is provided Startkey ON L Polygon Motor Main Motor Paper Take Up Solenoid S1 Drum Charge Output Output i Developing Output Drum charge DC Drum charge DC Reverse bias Image Unexposed area Transfer i Neaati iput E Output egative outpu 4980M017AB 5 2 Print End Sequence PS3 ON Polygon ON Motor Main Motor ON Drum Charge DC AG Output Laser Unexposed area ilj Substantially entire A 7 7 Output maton E 1 Suiface exp sure gt Unexposed area illumination Developing ION Charge Output NJ Reverse bias Image Negative Negative Transfer postive gt Output oe E ee TR OR BEE RR 4980M014AA M 7 6 IC IMAGING CARTRIDGE SECTION 6 1 Overview The illustration below shows the construction of the Toner Cartridge and the Developing Unit This printer adopts the single component FMT or Fine Micro Toning developing system The Toner Agitating Screw conveys toner in the Toner Cartridge onto the Toner Supply Roller The Toner Supply Roller t
67. e Mode 1 Mode 1 lasts for 5 min During this period the printing temperature is gradually decreased As the printing temperature is reduced down to a predetermined level mode 1 is completed and mode 2 starts e Mode 2 Mode 2 lasts for 208 sec e Mode 3 Mode 3 continues until the temperature control is interrupted by opening and closing the Front Door etc 4 Printing temperature by paper type in different temperature control modes Mode 0 Mode 1 Mode 2 Mode 3 Standby 200 C 130 C 130 C 130 C 186 mm or 200 C standard more 215 C gt 200 C set in Tech Rep Mode 1 Less than 186 mm 186 mm or more Plain paper 200 C gt 190 C 205 C gt 215 C Thick paper envelopes postcards Less than 186 mm OHP 185 C gt 175 C 1 Inferior fusing performance can at times result from plain paper having a length of 186 mm or more with the standard fusing temperature setting 200 C The FUSER TEMP Ad setting ofTech Rep Choice available from theTech Rep Mode can there fore be used to set a higher fusing temperature M 27 5 Fusing temperature protect control Fusing Unit AAA A A A dl E AT pol a Thermistor TH1 l ANIN 1 E a i 1 Comparative Ai i CAMA i Voltage l Fusing Roller i CPU Pa Heater Lamp amp l L Thermostat TS1 Comparator A A
68. e Win2K on the CD ROM and then click the OK button Click the OK button and then continue following the instructions in the dialog boxes that appear until the Completing the Found New Hardware Wizard dialog box appears Click the Finish button When the Found New Hardware Wizard dialog box appears again repeat steps 4 through 8 to install all drivers D 41 lt For Windows Me 98 95 gt A N Start up the host computer and then insert the CD ROM into the CD ROM drive Turn on the printer Use a USB cable to connect the printer to the host computer In the Install Hardware Device Drivers dialog box click the Next button select Search for a suitable driver for my device recommended and then click the Next button again Select Specify a location and then click the Browse button Specify Corresponding_language Win9X on the CD ROM and then click the OK button Click the OK button and then continue following the instructions in the dialog boxes that appear until the Completing the Found New Hardware Wizard dialog box appears Click the Finish button When the Found New Hardware Wizard dialog box appears again repeat steps 4 through 8 to install all drivers D 42 5 3 Procedure for Updating the GDI Firmware Turn on the printer Start up the host computer Windows 98 or later Copy the Update Software folder and Update file to
69. e clean the surface of the Paper Take Up Roller 2 Replacement of the Paper Take Up Roll 1382E008AA 1 Open the Document Feeder Cover 2 Remove the two screws and then remove the Document Feeder Cover 3 Remove the screw and then remove the mount ing plate and spring NOTE Be extremely careful not to lose the spring 4 Remove the two Document Stoppers 5 Remove the Pick Up Roller Paper Take Up Roller Assy NOTE When installing the Pick Up Roller Paper Take Up Roller Assy make sure that the notch in the shaft of the Paper Take Up Roller is positioned on the top 1382E013AC 6 Remove the Paper Take Up Roller 1382E010AA 3 Cleaning of the Pick Up Roller 1 Open the Document Feeder Cover 2 Using a soft cloth wipe clean the surface of the Pick Up Roller 1382E001AA 4 Removal of the Pick Up Roller 1 Remove the Pick Up Roller Paper Take Up Roller Assy we D 2 2 Remove the Pick Up Roller 1382E011AA 5 Cleaning of the Registration Rollers 1 Open the Document Feeder Cover 2 While turning the Document Feed Knob in the direction shown in the illustration use a soft cloth to wipe clean the Registration Rollers 1382E014AB 6 Cleaning of the Transport Roller 1 Open the Document Feeder Cover 2 Using a soft cloth wipe clean the surface of the Transport
70. e following removal procedures omit the removal of the applicable component from connectors and circuit board supports e When it is necessary to touch ICs and other electrical components on the circuit board be sure to first ground yourself PWB A CAS 4516D002AA Symbol Name Removal Procedure PWB A CAS Paper Feed Cassette Control Board 1S D 4 1 Removal of the Paper Feed Cassette Control Board 1 Remove the Paper Feed Cassette Paper Take Up Unit ss D 5 Remove the screw and then remove the cover 3 Remove the two screws unplug the connector and then remove the Paper Feed Cassette Con trol Board 4136D005AA D 4 3 3 Disassembly 1 Removal of the Paper Feed Cassette Paper Take Up Unit 1 Raise the main unit to separate it from the Paper Feed Cassette 2 Unhook the two tabs and then remove the cover 4516D003AB 3 Remove the actuator 4 Remove the six screws unplug the two connec tors and then remove the Paper Feed Cassette Paper Take Up Unit 4516D004AA 2 Removal of the Paper Size Detecting Switch 1 Remove the Paper Feed Cassette Paper Take Up Unit 2 Unplug the connector and then remove the Paper Size Detecting Switch Nes LE 4136D037AA D 5 3 1 Removal of the Paper Feed Cassette Paper Take Up Solenoid Remove the Paper Feed Cassette Paper Take Up Unit 4136D038AA Remove the
71. e image area that is erased on both sides CD direction When the PH unit has been replaced Select the value for the width erased in the CD direction The default setting is 4mm Omm 1mm 2mm 3mm 4mm 5mm FLS PAPER SIZE GDI TIMEOUT To specify the paper size for foolscap When the FLS paper size has been changed Upon setup To specify the time for GDI timeout The default setting is 330 210 330 203 330 216 330 210 337 206 The default setting is 6 60 seconds 0 5sec 1 10sec 2 20sec 3 30sec 4 40sec 5 50sec 6 60sec TONER EMPTY STOP To select if copy operations are stopped when the toner becomes empty S 12 e The default setting is ON ON OFF e If OFF is selected opera tions are not stopped when the toner becomes empty Function Purpose Setting Details Precautions PRE ROTATION To select if the pre rotation opera tion for the Fusing Roller is per formed when the Start key is pressed The default setting is OFF ON OFF If OFF is selected the length of time until the first copy can be printed is shorter FUSER TEMP Ad To specify the fusing temperature when using plain paper more than 186 mm When a fusing failure has occurred S 13 The default setting is 0 O Standard 1 Higher 2 Adjust Function Purpose Setting Details Precauti
72. eading Section eessen D 18 1 Removal of the Original cover set sensor nunneersenseenserneeneen nennen D 18 2 Removal of the Upper Cover Assy Original Glass D 18 3 Removal of the Scanner Motor nneeerseeseersenneennen nn D 18 4 Removal of the Scanner Assy D 19 5 Removal of the Timing Belt ooo connninncnicnonacaniccninnnonananana nan cc nana nnnn D 20 3 5 Disassembly of the Main Drive Section oooococnnnicnnnnncnnonccccnnoncccnnrnnanano D 21 1 Removal of the Main Motor oonoccnniccnocinicncnnncnanccnnnnonananan aran c aran D 21 2 Removal of the Paper Empty Sensors esseci D 21 3 Removal of the Paper Take Up Solenoid s e D 23 4 Removal of the Paper Take Up Clutch Gear unernneeennennen D 24 5 Removal of the Torque Limiter oonoononnnnnccinnanncccnanncancnananonananancnnoo D 25 6 Disassembly of the Fusing Unit useeesseersenssnnnsnnnnnnnnnnnnnnnnnnnnnn D 26 ADJUSTMENTS uuruunseensennennnernennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennennnennennnen nn nnnnnn nen D 29 4 1 Electrical Image Adjustment 2 n2sersennennennnnnnnnennnnn nennen nennen D 29 1 Accessing the Service Mode 22424rsnernnnnennnnnnnnnnnnennnennen nennen D 29 2 Accessing the ADJUST Menu uununnsrseessnnnennennnennennnen nennen D 29 3 Printing a Test Pattern omommccnrncnnncnconannaronanncnnnanonanonocanroncasac n caso D 29 4 Margin Adjustment Leading Ed
73. en a service job needs to be performed in the laser beam path such as when working around the Print Head Unit or PC Drum be sure first to unplug the power cord of the printer from the outlet e If the service job requires that the power cord be left plugged in observe the following precautions 1 Take off your watch ring and any other reflective object and wear laser protective gog gles Keep users away from the job site 3 Do not bring a highly reflective tool into the laser beam path during the service job 6 PARTS IDENTIFICATION s o s oo 5 4 4980G001AA 1 Automatic Document Feeder AF 11 4 Paper Feed Cassette PF 125 2 Mechanical Counter 5 Main Unit D 16G 3 Expansion memory 32 5 32 MB 6 Original Cover OC 7 MECHANICAL E ELECTRICAL 1 on COMPONENTS LAYOUT IR Unit Exit Roller Fusing Unit Image Transfer Section M 1 4980M004AA Paper Take Up Roller Toner Cartridge Drum Cartridge Print Head PH Unit 2 COPY PROCESS 4980M018AC 1 PC Drum A photoconductive layer is formed on an aluminum tube and an electrostatic latent image is formed on this photoconductive layer 2 PC Drum Charging e Deposits a negative DC charge across the entire surface of the PC Drum 3 Photoelectric Conversion e The CCD Sensor converts the image data represented by light reflected off the original to a corresp
74. ens dirty YES Clean them Replace the Scanner Assy Is the Exposure Lamp dirty Are there no bent connector pins on the cables connecting the control boards are all connectors correctly plugged in and are no cables broken YES 1 27 Clean it Replace the Scanner Assy Correctly plug in the connectors Replace connection cables 3 Image reading system Foggy background or rough image lt Sample of Image Quality Problem gt 4011T004AA lt Troubleshooting Procedures gt Check Result Action Does sunlight or any other extraneous YES Protect the copier from extrane light enter the machine ous light Is the document damaged or dirty YES Replace the document Is the Original Pad dirty YES Clean it Does the Original Cover not lie flat YES If the Original Cover is deformed or the hinges are damaged replace the Original Cover Is the surface of the Original Glass dirty Clean it Are the Shading Sheet or back surface Clean them of the Original Glass dirty Are the mirror or lens dirty Clean them Replace the Scanner Assy Is the Exposure Lamp dirty Clean it Replace the Scanner Are there no bent connector pins on the Correctly plug in the connectors cables connecting the control boards Replace connection cables are all connectors correctly plugged in and are no cables broken 1 28 4 Image reading system Black streaks or b
75. eriod of time after the Fusing Roller Heater Lamp has been turned ON and ends when the lamp is turned OFF The Fusing Roller Heater Lamp remains ON for a 30 sec period or more except during the period through which the Main Motor remains energized Fuser temperature low The temperature detected by the Thermistor remains lower than the set temperature continuously for a pre determined period of time while the fusing temperature control is being provided The set temperatures are as follows 140 C during a print mode at 600 dpi 70 C during the standby mode Fuser overheat The temperature detected by the Thermistor remains higher than 235 C for a predetermined period of time while the fusing temperature control is being provided Scanner home sen sor error The Scanner Home Position Sensor is not detected within the predetermined period of time after the Scan ner Motor has started turning ASIC memory abnormal An error occurred while writing to or reading the SRAM on the Control Board PWB C Polygon mirror motor error The LOCK signal is not detected within a predeter mined period of time that begins 1 sec after the Poly gon Motor has been energized No new LOCK signal is detected for a 1 sec period that begins 1 5 sec after the first LOCK signal was detected The LOCK signal is not detected for a continuous 0 5 sec period in a state in which the Polygon Motor runs stably The LO
76. erminal in good NO Clean contact terminal or contact with the mating part check terminal position Is PH window dirty Clean Is the problem eliminated after checks have Replace High Voltage Unit been made up to step 3 HV1 Replace Controller Mechani cal Control Board PWB P 1 36 13 Printer system Blank streaks or bands lt Typical Faulty Images gt 4011T015AA 4011T020AA lt Troubleshooting Procedures gt Check Action Is Image Transfer Roller dented scratchy or Replace Image Transfer dirty Roller Is PC Drum scratchy or dirty Replace Drum Cartridge Is Fusing Roller scratchy or dirty Replace Fusing Unit Fusing Roller Is PH window dirty Clean Is the problem eliminated after checks have Replace Controller Mechani been made up to step 4 cal Control Board PWB P T 37 14 Printer system Black streaks or bands lt Typical Faulty Images gt 4011T017AA lt Troubleshooting Procedures gt Check 4011T023AA Result Action Is paper path dirty with toner YES Clean Is PC Drum scratchy or dirty YES Replace Drum Cartridge Is Fusing Roller scratchy or dirty YES Replace Fusing Unit Fusing Roller Is the problem eliminated after checks have been made up to step 3 15 Printer system Offset image NO lt Typical Faulty Image gt ABCDE Previous data ABCDE
77. f B is less than the width of A Decrease the setting If the shift cannot be adjusted to within the specification with a single adjustment perform the adjustment again to change the setting 5 Press the Yes key to apply the setting NOTE If the Stop key is pressed instead of the Yes key the main screen is displayed and the set ting returns to that before it was changed 6 Print a test pattern again and check it D 31 6 Printer s Sub Scanning Registration Adjustment lt Requirement gt e Adjust the width of C in the printed test pattern so le c that the following specification is met 4007D051AA Specification Mode Function Item Setting Range 87 to 113 20 2 5 mm ADJUST menu PRN SUB REGIST 1 increment 0 46 mm Perform this adjustment in the following cases After the PH Unit has been replaced After the printer s main scanning registration adjustment has been performed lt Adjustment Procedure gt 1 Print the test pattern 2 Check that the width of C in the test pattern meets the specification If the width of C is out of specification adjust it according to the following procedure 3 Enter the ADJUST menu in the Service mode 4 Change the setting If the width of C in the test pattern is longer than the specified width Increase the set ting If the width of C in the test pattern is shorter than the specified width Decrease the set
78. f the Transport Roller eeserneessenseensennenneennenneennn nenn D 4 7 Cleaning of the Exit Roller erennessersenneennennnnnnnnnnnennnnnnnennn nenn D 4 8 Cleaning of the Paper Separator Pad nuermeseessersensnnnnnnnnn nennen D 5 9 Removal of the Paper Separator Pad D 5 3 DISASSEMBLY REASSEMBLY eereeee D 6 3 1 Names Removal of External Parts D 6 3 2 Removal of Circuit Boards ooococccncnoccconooncocnnrncnnnarnnoncnnnonccnnnnnncnnnnnccnnnns D 7 1 Removal of the Automatic Document Feeder Control Board D 7 3 37 Disassembly Witt tia D 8 1 Removal of the Automatic Document Feeder Main Motor D 8 4 ADJUSTMENTS mai ei D 9 4 1 Electrical Image Adjustment c ooooccnccnncniccnnnnccnncnnoncncnorn cnn cnrnnrn cnn rnncnrcnn nn D 9 1 Accessing the Service Mode ooococcoccccccncconcconononcnnnorncnnnnrnnananrcrnnnnno D 9 2 Accessing the ADJUST Menu uenersennsersenneennnnnnnnnnnnnnnnnnn nenn D 9 3 Printing a Test Page nnseeenesnensesnennsonenusnnnsnensonasnasnenssnonnesnnenenne D 9 4 Height Adjustment omocconconicnnnrnoranoniononarncanncononarsncrncnnononaarocancoss D 10 5 Leading Edge Tilt Adjustment oononninnninnnnnnonnnnnnncnnananaccnnarncnrnannn D 11 6 Automatic Document Feeder Sub Scanning Zoom Ratio AdjustmentD 12 7 Automatic Document Feeder Main Scanning Registration Adjustment D 14 8 Automatic Document Feeder Sub Scanning Reg
79. g cases After the Scanner Assy has been replaced After the printer s main scanning amp sub scanning registration adjustments have been performed lt Adjustment Procedure gt 1 Print the test pattern 2 Enter the ADJUST menu in the Service mode 3 Place the test pattern on the Original Glass and make a test copy NOTES The test pattern should be positioned vertically Use A4 L or Letter L paper loaded into Tray1 to make the test copy 4 Check that the width of E in the copy of the test pattern meets the specification Calculation 1 Width of E in the document Width of E in the copy x 100 If the width of E is out of specification adjust it according to the following procedure 5 Change the setting If the width of E in the test pattern is longer than the specified width Decrease the set ting If the width of C in the test pattern is shorter than the specified width Increase the set ting If the shift cannot be adjusted to within the specification with a single adjustment perform the adjustment again to change the setting 6 Press the Yes key to apply the setting D 35 NOTE If the Stop key is pressed instead of the Yes key the main screen is displayed and the set ting returns to that before it was changed Place the test pattern on the Original Glass again make another test copy and check it D 36 9 Scanner s Main Scanning Registration Adjustment lt Requirement
80. ge Trailing Edge Both Sides D 30 5 Printers Main Scanning Registration Adjustment 6 Printers Sub Scanning Registration Adjustment 7 Scanner s Main Scanning Zoom Ratio Adjustment 8 Scanners Sub Scanning Zoom Ratio Adjustment 9 Scanners Main Scanning Registration Adjustment Zi 10 Scanner s Sub Scanning Registration Adjustment uee MISCELLANEOUS ccoo a 5 1 Removal of the Mechanical Counter Option sesser 5 2 Updating the Firmware omonnconncoonnorncnnnnconacraranananannaroncrnoncnranancncanacnos 1 Installing the GDI Printer TWAIN Driver Using Plug and Play D 41 5 3 Procedure for Updating the GDI Firmware ooonnonccncinnnncnnocicncncnncccnncnananos D 43 5 4 Remedy for a Failed Updating of the Firmware uunnenssnneenennennnnn D 45 5 5 Moving the EEPROM ueesnssessnnsensunnnennnennnnnnnnnnnnnnnnnnnnnnnnnnnnnennn nenn D 47 CONTROL PANEL SERVICE MODE DESCRIPTIONS 1 CONTROL PANEL DESCRIPTIONS u nunserseeseersennannnnnnennnnn nennen nennen nenn S 1 1 1 Names of Control Panel Parts and Their Functions uenee S 1 2 FUNCTIONS OF SWITCHES AND PARTS ON PWBS ncnseneesenennnnnns S 3 2 1 Circuit Board Locations iiini rhui eiia iai S 3 2 2 PWB P Controller Mechanical Control Board u nemrnenneneennennenn S 3 2 3 PWB IF Interface Board oocooncooncccoccnoncnnonananncnanc nao con
81. gt After finishing the printer s main scanning amp sub scanning registration adjustments place the B printed test pattern on the Original Glass and make a copy of it A e Adjust the width of E in the copy of the test pattern so that the following specification is met 1382D011AA Specification Mode Function Item Setting Range 90 to 110 0 2 0 mm ADJUST menu CCD MAIN REGIST 1 increment 0 5 mm Perform this adjustment in the following cases e After the Scanner Assy has been replaced After the printer s main scanning amp sub scanning registration adjustments and the scan ner s main scanning zoom ratio adjustment have been performed lt Adjustment Procedure gt 1 Print the test pattern 2 Enter the ADJUST menu in the Service mode 3 Place the test pattern on the Original Glass and make a test copy NOTES The test pattern should be positioned vertically Use A4 L or Letter L paper loaded into Tray1 to make the test copy 4 Check the amount that widths A and B in the copy of the test pattern are shifted If the shift is out of specification adjust it according to the following procedure 5 Change the setting If the width of A is less than the width of B Increase the setting If the width of B is less than the width of A Decrease the setting If the shift cannot be adjusted to within the specification with a single adj
82. hook two tabs and remove the Paper Take Up Clutch Gear 4136D057AA 5 Removal of the Torque Limiter 1 Remove the Paper take up Clutch Gear wx D 24 2 Unhook three tabs and take apart the Paper Torque Limiter D Cawg Take Up Clutch Gear then remove the Torque GN Limiter vy Gear 4136D043AA Precautions for Installation of the Torque Limiter Coupling Gear has five dent for adjustment the Take up Roller position When Torque Lim iter is replaced adjust the set position of the Coupling Gear so that the Take up Roller becomes level The procedure is as follow 4136D044AA D 25 4136D060AA After setting replaced Paper Take Up Clutch Gear Torque Limiter to the shaft Rotate the Paper Take Up Clutch Gear by hand Need to be released Sole noid Flapper Look at the stop position of theTake Up Roller from Clutch Gear side 4136D046AA 4136D045AA 1 When the Roller is leant to clockwise move the coupling Gear to A direction 2 When the Roller is leant to counter clockwise move the coupling Gear to B direction 6 Disassembly of the Fusing Unit NOTE The Fusing Unit is extremely hot immediately after the Power Switch has been turned OFF Allow a sufficient time to let it cool down before starting the procedure to prevent burn 1 Remove the Fusing Unit D 8 Upper Fusing Roller section Lower Fusing y Roller sectio
83. hot Are there any cracks or scrapes in the cord x Has the power plug been inserted fully into the outlet Does something including the printer itself ride on the power cord Use an outlet with a capacity of 110 120 127V or 220 240V 3 PRECAUTIONS FOR USE 3 1 To Ensure the Printer is Used in an Optimum Condition Never place a heavy object on the printer or subject the printer to shocks e Insert the power plug all the way into the outlet Do not attempt to remove any panel or cover that is secured while the printer is in a print cycle e Do not turn OFF the printer while it is in a print cycle e Provide good ventilation if the printer is to be used for a long time in a narrow room Never use flammable sprays near the printer e If the printer becomes inordinately hot or produces abnormal noise immediately turn it OFF and unplug it Do not turn ON the power switch at the same time that you plug the power cord into the outlet e When unplugging the power cord do not pull on the cord hold the plug and pull it out Do nat bring any magnetized object near the printer e Do not place a vase or vessel containing water on the printer Be sure to turn OFF the power switch at the end of the workday or upon power failure e Use care not to drop paper clips staples or other small pieces of metal into the printer 3 2 Operating Environment The operating environmental requirements of the printer are as follows
84. ice mode SCAN COUNTER To display the number of scans made MONOCHROME Number of monochrome scans COLOR Number of color scans Scans made while making copies are not counted To clear the counter data use the functions on the CLEAR DATA menu of Ser vice mode PRINTER JAM COUNTER To display the number of misfeeds that occurred while printing S 17 To clear the counter data use the functions on the CLEAR DATA menu of Ser vice mode Function Purpose Setting Details Precautions To display the number of misfeeds To clear the counter data ADF JAM that occurred while using the Auto use the functions on the COUNTER matic Document Feeder CLEAR DATA menu of Ser vice mode To display the number of times C0045 Fuser fan error each error was detected C0210 Transfer voltage error C0500 Fuser Warm up error C0510 Fuser temperature low C0520 Fuser overheat C0650 Home sensor error Scanner motor error C1200 ASIC memory abnormal C1300 Polygon mirror motor error TROUBLE C133B Communication with COUNTER option error C133C Modem error C133D ROM checksum error C13F0 Laser error C1468 EEPROM error C14A3 IR lamp malfunction To clear the counter data use the functions on the CLEAR DATA menu of Ser vice mode NOTE The following counters continue counting even while operations are performed in Service mode e PM COUNTER e IC COUNTER PRINTER JAM C
85. ilm 4136M519AA 1 Drum Charge Brush 2 PC Drum 3 Ground 4 Charge Bias 4136M528AA M 14 8 IR SECTION 8 1 Image Data Processing 1 Photoelectric Conversion The CCD Sensor reads the light reflected off the original and converts the data to a cor responding analog signal 2 A D Conversion The analog signal output from the CCD Sensor is converted to a corresponding 8 bit dig ital signal 3 Shading Correction Corrected is an error that occurs due to variations in sensitivity of each CCD chip and the light distribution varying along the length of the Exposure Lamp 4 Gamma Correction The light reflection data read by the CCD Sensor is translated to corresponding image density data 5 Zoom Processing The synchronous timing of the input data write and output data read is varied to decrease reduction or increase enlargement the number of data readings thereby reducing or enlarging the image in the main and sub scanning direction 6 Background Level Detection The background of the original is detected to establish a threshold value between the background and the image data 7 Binarization The 8 bit image data is translated to one bit binary data 8 Data Buffer The binarized image data is amplified The data is transmitted to the PH Section M 15 8 2 Exposure Components Section CCD Lens 1 4980M019AA 1 E
86. ils Precautions To enable or disable copying depending on whether or not the Mechanical Counter is installed MACHINE COUNTER S 23 e The default setting is ENABLE ENABLE DISABLE NOTE e If ENABLE is selected copying is possible even if the Mechanical Counter is not installed TROUBLESHOOTING 1 INTRODUCTION e This chapter contains the items required or used when troubleshooting various printer problems 1 1 Electric Components Check Procedures e The following procedures can be used to check to see if an electric component is fully operational when a paper misfeed or a malfunction occurs in the printer 1 Sensors Check Result Action Does the input signal to the Controller Mechanical Control Board go from HIGH to LOW or vice versa when the sensor is blocked NO Replace the sensor Replace the Con troller Mechanical Control Board 4025T520AA 4025T521AA 2 Switches Check Action Replace the switch Does the input signal NO to the Controller Mechani cal Control Board go from LOW to HIGH when the switch is actuated Replace the Con troller Mechanical Control Board 4025T523AB 3 Solenoids Check Action Replace the Con Does the output signal from the Controller Mechani troller Mechanical cal Control Board go from HIGH to LOW when the Control Board solenoid is energized Replace
87. ing Plate thus unblocking the sensor When Paper is not Loaded When Paper is Loaded Paper Empty Sensor Actuator gt Q TS Actuator 4516M003AA 4136M542AA 1 3 Cassette Type Detection e The Paper Feed Cassette is provided with the Cassette Type Detection Switch e When the cassette is inserted into the printer the switch pusher provided on the right hand side of the cassette pushes the lever according to the paper size turning ON the switch e The Cassette Type Detection Switch consists of three switches The combination of these switches that turn either ON or OFF allows the printer to deter mine the cassette type paper size Cassette Type Detection Switch SW1 Lever OFF ye j z ON Co 4136M530AA Switch ___ _Switch Pusher Switch1 sees en Switch ___ Paper Feed Cassette 4136M531AA M 3 Cassette Type Detection Switch Conditions Cassette Type SwitchO Switch1 Switch2 OFF OFF ON OFF Electrical Component Control Signal ON OFF WIRING DIAGRAM PWB A CAS SWI MPJ23A CAS 1 2 4 D E 5 DIS REASSEMBLY ADJUSTMENT 1 MAINTENANCE SCHEDULE To ensure that the printer produces good printed pages and to extend its service life it is recommended that the maintenance jobs described in this schedule be carried out as instructed Replace P _ Ref Page Making one in This
88. istration AdjustmentD 15 TROUBLESHOOTING 1 INTRODUCTION nuussersensnersennnennnnnennnnnnnnnnnnennnnn nennen nennen nnnnnnnnnnnnnnnnenan T 1 1 1 Electric Components Check Procedures unnunneersenseernenneennnnnennen nennen T 1 1 S NSOIS nennen treten T 1 2 Clutches rain sie lasiert T 2 8 MOTOS seen id nenne Aid T 2 2 PAPER MISFEED enthaltene el T 4 2 1 Initial Cheek Items ee ana T 4 2 2 Paper Misfeed Displays oocooncornncnonoracnnncnconannarnnanccnoran ona nanrnc rn n non carcnss T 5 2 3 Locations of Misfeed Detection Sensors unserneessennenneennenneennnn nennen T 6 2 4 Misfeed Detection Timing and Troubleshooting Procedures T 7 1 The Original misfeeds 3 TIMING CHART GENERAL 1 SPECIFICATIONS Name Automatic Document Feeder Installation method Inserted at upper rear side of main unit Original type Plain paper 35 to 128 g m 9 to 34 Ib Detectable Original sizes A5 L B5 L A4 L Legal L Letter L Invoice L Custom size width 138 to 216 mm length 130 to 356 mm Paper capacity Maximum 50 sheets 80 g m 21 Ib Registration Center Original loading orientation Face up Productivity 12 sheets minute with plain A4 L or Letter L paper Original feeding Mode Standard mode Power source DC 24 V DC 5 V supplied by main unit Power consumption Less than 30 W Dimension gt W 497 mm 19 1 2 in x D 355 mm 14 in x
89. l Glass has been replaced Press the Start key to begin printing the test page The setting range is 90 to 110 1 increment 0 5 mm ADF SUB REGIST ADJUST To adjust for variations in the accu racy of all parts and their mounting accuracy by varying the scanning start position in the sub scanning direction when using the Automatic Document Feeder When the Upper Cover Assy Original Glass has been replaced Press the Start key to begin printing the test page The setting range is 90 to 110 1 increment 0 5 mm SERIAL NO To specify the 8 digit serial num ber Once the serial number is speci fied SERIAL NO does not appear in the ADJUST menu CUSTOMER ID To specify the customer ID e Once the customer ID is speci fied CUSTOMER ID does not appear in the ADJUST menu S 15 The default setting is 0 Develop 0 Develop 1 OEM1 2 Generic Function Purpose Setting Details Precautions To specify the type of Toner Car e The default setting differs tridge that should be installed in depending on the marketing the main unit area Once the type of Toner Cartridge Toner Cartridge Type Settin is specified TC TYPE on the eee 9 ADJUST menu cannot be set No Toner Cartridge 0 again Not Used A lt Types of Toner Cartridges gt B Not Used C Not Used Not Used Not Used Not Used Not U
90. l ll l i High temperature i AC Protect Signal 1 T2 FUSER_LAMP i T1 Q FUSER_LAMP_ Triac RY vat i Saree a tt eS te Datel WP Bits Sn ts ens BR Sh Controller Mechanical Control Board Power Unit 4980M015AB lt Soft protect gt e The comparator provided on the Controller Mechanical Control Board is used as means for detecting an abnormally high temperature through software approach If the temper ature detected by the Thermistor voltage value is greater than the comparative temper ature 235 C voltage value the triac relay is turned OFF to shut down the output of the Heater Lamp lt Hard protect gt Asaprotection should there be a software failure the Thermostat is used to shut down current to the Heater Lamp when the temperature of the Fusing Roller becomes inordi nately high WIRING DIAGRAM F 2 3 Electrical Component Control Signal PWB P MPJ2P 1 Low temp High temp Analog Input Electrical Component Control Signal WIRING DIAGRAM H1 PU 1 CN1PU 1 3 M 28 1 7 13 PAPER EXIT 13 1 Paper Exit Mechanism e The paper exit mechanism transports the paper that has been subjected to the fusing process onto the Exit Roller e The Exit Sensor detects not only a paper misfeed but also an open Upper Cover Exit Tray Exit Roll Face down Exit Exit Sensor PS1 SI OS Exit Roller y
91. lace the Con troller Mechanical Control Board N MA 4025T526AA Check Result Action Does the input signal to the Controller Mechanical YES Replace the motor Control Board go from HIGH to LOW when the motor Replace the Con is energized The input signal varies depending on NO _ troller Mechanical the direction of rotation Control Board 4025T525AA Action Replace the motor or the Controller Are the hookup connector of the motor and print jack Mechanical Control on the Controller Mechanical Control Board con Board nected properly Connect the con nector or the print jack properly l213lalslelrTelsholimeltg LIOI oO 4025T527AA 2 PAPER MISFEED 2 1 Initial Check Items e When a paper misfeed occurs in the printer first make the following initial checks Check Action Does the paper meet product specifications Replace paper Replace paper Is the paper curle avy or damp e paper curled wavy or damp Instruct user in correct paper storage Is the paper transport path deformed dirty or Clean the paper path and replace if obstructed with foreign matter necessary Clean the roller and replace if neces Is the roller dirty deformed or worn sary Are Edge Guides at correct position to accommo Slide the Edge Guides up against the date paper edges of the paper stack Does the actuator operate correctly whe
92. lick Update file in the Update Software folder The Develop Update F W V1 XX dialog box appears Update exe assonos7an 7 Click the Browse button and then select Update file which was copied onto drive C in step 3 Minolta Update FW VOOS x File path C bootfont bin Exit 4980D048AA D 43 8 Click the Update button The transfer of firmware data begins Wait until the transfer of data is finished 9 Check the firmware update status in the display PLEASE WAIT CHECK_SUM y ERASE FLASH ROM y FIRMWARE UPDATE AAA AA AAA OOOO 4980D050AB NOTE Do not turn the printer off or on while the screen shown above is displayed 10 Check that the following message appears in the display to indicate that the updating of the firmware is complete FIRMWARE UPDATE OK MACHINE POWER OFF ON sccooosiae 11 Click the OK button and then quit the Develop Update F W V1 XX application Minolta Update FAN x Transfer Successfully 4980D049AA 12 Turn the printer off then on again D 44 5 4 Remedy for a Failed Updating of the Firmware 1 Turn off the printer 2 Remove the USB cable connecting the printer to the host computer 3 Remove the Rear Cover ts D 7 4 Change the settings for jumper switches CJ1 and CJ2 on the Controller Mechanical Control Board from
93. mes in contact with the shaft of the front plate of the Imaging Cartridge When the Imaging Cartridge is loaded in the printer the set pin of the front plate of the Imaging Cartridge contacts a side plate on the printer side thereby providing grounding The potential on the surface of the PC Drum exposed to the laser beam is then grounded through the Ground Plate shaft and set pin to the frame of the printer PC Drum Front Plate Shaft Ground Plate 4136M514AB M 10 6 3 Developing System e The 1st Toner Blade located above the Sleeve Roller spreads a thin even coat of toner over the Sleeve Roller e A negative charge is applied to the 2nd Toner Blade which negatively charges the toner e The Sleeve Roller is negatively charged which retains the toner thereon The toner sticks to the area on the surface of the PC Drum that has been exposed to the laser beam e The Bias Seal on the underside of the Sleeve Roller separates toner which has not been attracted onto the surface of the PC Drum from the Sleeve Roller and returns it back to the Toner Hopper The same bias as that applied to the Sleeve Roller is applied to this Bias Seal thereby preventing toner from falling The developing bias automatically adjusts the print image density over a range of seven steps through feedback control A bias voltage reversed from the developing bias is applied before a print command is issued before predrive and during predrive
94. mporarily recovered and is made into even finer particles during the print end sequence before being recovered at the Developing Unit 13 Paper Transport e The paper is transported onto the Fusing Unit 14 Fusing e The developed image is permanently fused to the paper by a combination of heat and pressure applied by the Right and Left Fusing Rollers 15 Paper Exit e The paper is fed out onto the Exit Tray 3 PAPER PATH Exit Roller Exit Tray Fusing Roller Multiple Bypass Tray Tray 1 Paper Take Up Roll Image Transfer Roller 4980M005AA The system employs a two way paper supply system in which paper is fed from either Tray 1 or the Multiple Bypass Tray e When the optional Paper Feed Cassette is mounted the system offers a three way paper supply system e The paper taken up and fed in by the Paper Take Up Roll is transported through the printer by the Image Transfer Roller Fusing Roller and Exit Roller and fed out of the printer face down onto the Exit Tray DRIVE SYSTEM 4 4980M010AA 4 Main Motor Scanner Unit 1 5 Scanner Motor Image Transfer Roller 2 6 Fusing Roller 3 Paper Take up Roller M 5 5 5 1 1 OPERATING SEQUENCE Print Start Sequence When the pre start control is not provided Start key ON Polygon Motor Main Motor Paper Take Up Solenoid S1 DrumCharg
95. n checked Correct or replace the actuator Precautions for Clearing Misfeed e Reset the misfeed condition by opening and closing the Front Door after the misfeed has been cleared 2 2 Paper Misfeed Displays e The Error indicator lights up and a message appears in the display when a paper misfeed occurs lt Automatic Document Feeder Misfeed gt CAUTION ORIGINAL DOC JAM t CAUTION OPEN DOC FEED COVER C4506P298CA lt Procedure for canceling the misfeed display gt 1 Open the appropriate covers remove the misfed paper and any remaining paper and then close the covers 2 Open then close the Front Door 2 3 Locations of Misfeed Detection Sensors Paper Take Up Sensor PC2 Original Detection Sensor PC1 Leading Edge Detection Senspr PC1 4980T002AA 2 4 Misfeed Detection Timing and Troubleshooting Procedures 1 The Original misfeeds lt Detection Timing gt Description The Paper Take Up Sensor is not unblocked after the predeter mined period of time has elapsed after document feeding began The Paper Take Up Sensor is not blocked after the predeter mined period of time has elapsed after the Paper Take Up Sen sor is unblocked The Exit Sensor is not unblocked after the predetermined period of time has elapsed after the Paper Take Up Sensor is unblocked The Exit Sensor is not blocked after the predetermined period of time has elap
96. n 4136D021AA 2 Remove the two screws and then the Fusing Unit is divided into the Upper Fusing Roller sec tion and Lower Fusing Roller section D 26 Lower Fusing Roller section 4136D022AA Upper Fusing Roller ye section 4136D040AA 4136D023AB 4136D024AB 4136D033AA 3 Remove two bushings and the Pressure Roller Precautions for Installation of Bushings Make sure that the slits in the bushing are properly aligned with the rib of the Fusing Unit 4 Remove one screw and the terminal block 5 Pull out the Fusing Roller Heater Lamp NOTES Do not touch the surface of the glass of the Fusing Roller Heater Lamp with bare hands e When reinstalling the Fusing Roller Heater Lamp make sure that the side of the lamp having a volt age marking faces the gear side 6 Pull out the drive gear from the Fusing Roller 7 Pull out the Fusing Roller NOTE When removing and reinstalling the Fusing Roller keep the Fusing Roller Paper Separator Fingers in their raised position Use care not to damage the surface of the Fusing Roller 8 Remove the four Fusing Roller Paper Separator Fingers NOTE Use care not to lose the springs D 27 4980D068AA 9 Remove one screw and the Thermi
97. n donada S 23 TROUBLESHOOTING 1 INTRODUCTION coco T 1 1 1 Electric Components Check Procedures ooocococccoconoccccconcconcnnnconcnnnnnncnnno T 1 1 SOS iii Eis Rhein T 1 2 Switches Herner aaa Se ea T 2 3 SONAS zensiert de a i T 2 4 Motors incita A AAA td ESA T 3 1 2 Overall Control Configuration oooooonccicnnncnncnnnnoccncnnnccncnnrnrornnnncancnn cra T 5 2 PAPER MISFEED draa a a At T 6 2 1 Initial Check Items ooococconncnconicnccononcocnnrnnoccnnn non cnn corn corno T 6 2 2 Paper Misfeed Displays ooocoionnnnnconoccconncnncnnnnnc nac nno na rar corran anna cnn T 7 2 3 Locations of Misfeed Detection Sensors uensenseesnennenneennennennnnn nenne T 8 2 4 Misfeed Detection Timing and Troubleshooting Procedures T 9 1 Paper Take Up Transport Misfeed seses T 9 2 Fusing Exit Misfeed een T 10 3 MALFUNCTIONS WARNING cooccoccocccccncnncnnonnnnnancnnnn cnn cana nnnanann canaria nr nan car ninas T 11 3 1 List of Malfunctions ocomoonoononcononnnrnnaracaconenrnrnnnno ronca rnncrnancoronancncannonos T 11 3 2 Malfunction Detection Timing and Troubleshooting Procedures T 14 1 C0045 Fuser fan motor erfor nersesseerserseennennennennnnnnn we 1 14 2 0210 H V abnormal wee 1 15 3 C0500 Fuser warm up Error neneensennsennennnennnnnennnnnennn nennen nen T 16 4 C0510 Fuser temperature lOW uennessensennnennnnnennnnnennnen
98. nect one connector of the Paper Take Up Solenoid 4136D058AA 3 Remove one screw and the Paper Take Up Sole noid 4136D059AA Precautions for Installation of the Paper Take Up Solenoid 1 Mount the Paper Take Up Solenoid and tighten one screw 2 Turn the gear in the direction of the arrow shown below so that the flapper of the Paper Take Up Solenoid catches the stopper of the gear Stopper Gear NC N Flapper o o 4980D067AA D 23 4 Removal of the Paper Take Up Clutch Gear 1 Remove the Fusing Unit ws E 8 2 Remove the Power Unit we D 12 3 Remove the Paper Take Up Upper Guide Assy ws D 21 4 Disconnect one connector and remove the Cool ing Fan Motor 2 5 Disconnect one connector of the Main Motor we D 21 4980D074AA 6 Remove the Paper Lifting Plate Assy 7 Remove two springs 4980D057AA 8 Disconnect one connector and one flat cable from the Controller Mechanical Control Board NOTE e Use utmost care not to snap off the flat cable 9 Remove the Top Cover then remove four screws 4136D016AB and the PH Base Plate Assy 10 Disconnect one connector of the Paper Take Up a a 9 2 Jo a a 0 3 Solenoid a o 11 Remove three screws and the Left Frame U N y eee gt ys 4136D017AC D 24 12 Remove one screw and the Paper Take Up Sole noid 4136D018AA 13 Un
99. nnnnnnnnnennn T 17 5 C0520 Fuser overheat urseunsernennnensnnnennennnennennnnnnnnnnnnnnnennenen T 18 6 C0650 Scanner home sensor erfor unnenneessensennnennennnennennee nn T 18 7 1200 ASIC memory abnormal nerseensersenneennennnnnnnnennnennnn nennen T 19 8 1300 Polygon mirror motor erfor eeesenseersnnneennennenneennennnennen nenn T 19 9 C133B Communication with option error uunneessenseersennennennnenneenen T 20 10 C133D ROM checksum error ueeneessessensnernenennnnnnnnnnnennnnnnnnnen nen T 20 11 C13FO Laser error nunneersersnernnnensnnnnennnnnnennnnnnennnnnnn nennen nennen T 21 12 C1468 EEPROM error nersesssensennennnennennnnnnnnennnnnennn nennen nen T 21 13 C14A3 IR lamp malfunction enesserseeneersennnennennnennnnennnnn nennen nen T 22 4 MALFUNCTIONS RELATED TO POWER SUPPLY neseerserseersenseennennnennenn T 23 4 1 Power is not Turned ON uuursenssersennennnnnennnennennnnnnnnnnn nennen nnnnnnnnnnnnnnen T 23 5 IMAGE QUALITY PROBLEMS u nuneersennsnsnensennnennnnnnnnnennnnnnnnnnnnnnnnn nennen T 24 5 1 Troubleshooting Image Quality Problems wee 1 24 5 2 Initial Checks nennen we 1 24 5 3 Troubleshooting for Specific Image Quality Problems wee 1 25 1 Image reading system Blank or black prints 2 0 00 eee T 26 2 Image reading system Low image density uueneessenssnsnnnnnnennnnn T 27 3 Image reading system Foggy background or
100. nplug the two flat cables from the Controller Mechanical Control Board NOTE e Use utmost care not to snap off the flat cable 6 Remove the two screws and then remove the Left Rear Cover 7 Unplug one connector on the Controller Mechani cal Control Board 8 Remove the three screws and then remove the Circuit Board and Metal Bracket D 12 4980D009AB yo 4980D072AA 4980E001AC 9 Remove the three screws unhook the tab and then remove the Left Rear Frame 10 Remove the three screws from the Left Rear Frame 11 Remove the four screws and then remove the Metal Bracket 12 Remove the two screws unhook the tab and then remove the Left Rear Frame 13 Remove the Upper Left Cover 14 Remove the two screws and then remove the Upper Right Cover and Protective Metal Bracket NOTE The Protective Metal Bracket is tightened together with the Upper Right Cover D 13 15 Remove the two screws unplug the three con nectors and then remove the Fusing Unit Assy 4980E002AA 16 Remove three screws and the Power Switch stay 17 Remove the Power Switch 18 Remove four screws disconnect three connec tors and remove the Power Unit Assy 19 Remove four screws and the Power Unit 5 Removal of the High Voltage Unit 1 Remove the Power Unit Assy wx D 12 2 Remove one screw and the High Voltage Unit
101. ns and the SOS Mirror to eventually hit the SOS Sensor which generates an SOS signal e The SOS signal determines the laser emission timing for each line in the main scanning direction SOS Mirror G1 Lens Polygon Mirror Laser Unit SOS Sensor 4136M517AA M 20 9 4 Laser Emission Area 1 Main scanning direction e The print start position is determined by the main scanning print start signal HSYNC output from the Controller Mechanical Control Board and the width of the paper e The laser emission area is determined by the paper size 2 Sub scanning direction e The print start position is determined by the sub scanning print start signal TOD output from the Controller Mechanical Control Board and the length of the paper e The laser emission area is determined by the paper size VIDEO DUS i e VIDEO TOD 4980M016AB M 21 10 PAPER TAKE UP SECTION 10 1 Tray 1 1 Paper take up mechanism e When the Paper Take Up Solenoid is energized drive from the Main Motor is transmitted to the Paper Take Up Roll through the Paper Take Up Clutch turning the Paper Take Up Roll e Atthe same time the Depressing Cam turns so as to raise the Paper Lifting Plate Then the top sheet of paper loaded in the tray is taken up and fed into the printer e The actual length of paper is detected based on
102. of D in the copy of the test pattern meets the specification Calculation 1 Width of D in the document Width of D in the copy x 100 If the width of D is out of specification adjust it according to the following procedure 5 Change the setting If the width of D in the test pattern is longer than the specified width Decrease the setting If the width of C in the test pattern is shorter than the specified width Increase the set ting If the shift cannot be adjusted to within the specification with a single adjustment perform the adjustment again to change the setting 6 Press the Yes key to apply the setting D 33 NOTE If the Stop key is pressed instead of the Yes key the main screen is displayed and the set ting returns to that before it was changed Place the test pattern on the Original Glass again make another test copy and check it D 34 8 Scanner s Sub Scanning Zoom Ratio Adjustment lt Requirement gt After finishing the printer s main scanning amp sub scanning registration adjustments place the printed test pattern on the Original Glass and Qa make a copy of it E e Adjust the width of E in the copy of the test pattern so that the following specification is met 4007D053AA Zoom Ratio Full Size CCD SUB 95 to 105 100 N ADJUST menu ZOOM 1 increment 0 4 Specification Mode Function Item Setting Range Perform this adjustment in the followin
103. of paper This allows only the first sheet of paper to be transported by the Take up Roller Single Sheet Feeding Multiple Sheet Feeding gt 1382M009AA M 5 3 2 Document Transport Exit Mechanism 1 Document transport mechanism e The original that has been taken up blocks the Paper Take up Sensor The Transport Roller turns to transport the original up to the document scanning position of the printer e The AF Main Motor drives the Transport Roller through a gear train AF Main Motor M5 Paper Take up Sensor PC2 Transport Roller 1382M003AB Electrical Component Control Signal WIRING DIAGRAM PWB A AF M5 PAO1OA AF 1 4 Pulse output F G 2 3 Electrical Component Control Signal Blocked Unblocked WIRING DIAGRAM PWB A AF RGE PAO6A AF 1 M 6 2 Document exit mechanism e The Exit Roller turns to feed the original out of the Document Feeder During this sequence the original blocks the Leading Edge Detection Sensor and is fed onto the Document Exit Tray The AF Main Motor turns the Exit Roller through a gear train AF Main Motor M5 Leading Edge Detection Sensor PC3 Exit Roller 1382M004AC Electrical Component Control Signal WIRING DIAGRAM PWB A AF M5 PAO1OA AF 1 4 Pulse output F G 2 3 Electrical Component Control Signal Blocked Unblocked WIRING DIAGRAM PWB A AF gt PAO3A AF 1 M 7 3 3 Miscellaneous 1 Document Feeder raised
104. onding analog electric signal which in turn is output to the IR image process ing section 4 IR Image Processing The electric signal is converted to an 8 bit digital image signal A D conversion which in turn goes through appropriate correction processes before being output to the PH image processing section 5 PH Image Processing After going through correction processes the digital image signal is converted to a corre sponding electric signal D A conversion based on which control is provided for turning ON or OFF the laser 6 Laser Exposure The laser beam strikes the surface of the PC Drum forming an electrostatic latent image 7 Developing e Toner negatively charged in the Developer Mixing Chamber is attracted onto the electro static latent image changing it to a visible developed image A developing bias voltage Vb is applied to the Sleeve Roller to prevent toner from being attracted onto those areas of the PC Drum that correspond to the background areas of the original M 2 8 Paper Feed e Paper is fed from Tray 1 9 Bypass Paper Feed e Paper is fed from the Multiple Bypass Tray 10 Image Transfer e ADC positive charge is applied to the Image Transfer Roller to transfer the visible image on the surface of the PC Drum onto the paper 11 Paper Separation e The Charge Neutralizing Plate neutralizes any charge left on the paper 12 Recovery e The residual toner on the surface of the PC Drum is te
105. onds or less at full size and 600 dpi x 300 dpi with plain A4 L or Letter L paper If the Start key is pressed more than 3 seconds after open ing and closing the Original Cover or Auto Document Feeder after the engine has warmed up Zoom Ratios Metric Size English Size Full size x1 00 x1 00 x1 15 x1 29 Enlargement x1 41 x1 54 x2 00 x2 00 x0 81 x0 78 Reduction x0 70 x0 64 x0 50 x0 50 Variable Lens Exposure Lamp Fusing temperature x0 50 to x2 00 in x0 01 increments Through lens F 5 0 f 27 195 Cold Cathode Florescent Lamp 200 C Power Current Consumption main unit only Voltage Maximum power consumption 110 V 120 127 V 700 770 880 W 220 240 V Power source Main unit dimensions including Original Cover Main unit weight 740 830 W 110 V 120V 127 V 220 240 V 50 60 Hz Width 508 mm 20 inches Depth 608 mm 24 inches Height 408 mm 16 inches 14 9 kg 32 3 4 Ib 2 GDI Printer Function RAM Interfaces Printer Language Fonts Supported Operating Systems Web Browser Share with copier IEEE 1284 Parallel USB Revision 1 1 except for Windows 95 and Windows NT GDI Windows Windows XP SP1 or later Windows 2000 SP3 or later Windows NT Workstation Version 4 0 SP6a or later Win dows Me Windows 98 SP1 Windows 98 Second Edition Windows 95 OSR Internet Explorer 4 0 or later 2
106. ons PRN MAIN REGIST TEST COPY ADJUST To vary and adjust the print start position in the main scanning direction If the image on the copy devi ates in the CD direction When the PH unit has been replaced Press the Start key to begin printing the test page The setting range is 60 to 140 1 increment 0 1 mm ADJUST To vary and adjust the print start position in the sub scanning direc tion If the image on the copy devi ates in the FD direction When the PH unit has been replaced Press the Start key to begin printing the test page The setting range is 87 to 113 1 increment 0 46 mm ADJUST To adjust for variations in the accu racy of IR parts and their mounting accuracy by varying the scanning zoom ratio in the main scanning direction When the Timing Belt has been replaced When the Scanner Assy has been replaced Press the Start key to begin printing the test page The setting range is 95 to 105 1 increment 0 4 ADJUST To adjust for variations in the accu racy of IR parts and their mounting accuracy by varying the scanning zoom ratio in the sub scanning direction When the Scanner Assy has been replaced Press the Start key to begin printing the test page The setting range is 95 to 105 1 increment 0 4 CCD MAIN REGIST ADJUST To adjust for variations in the accu racy of IR parts and
107. or Laser G2 Lens 1st Mirror 2nd Mirror SOS Mirror 4136MO05AA w Polygon Mirror M 18 9 2 Laser Exposure Process e The laser beam light emitted from the Print Head is used to create an electrostatic latent image on the surface of the PC Drum e The following control is provided to correctly time image printing Print Head Unit Laser Diode Polygon Motor SOS Sensor 4136M006AB e When the printer receives a PRINT signal the Polygon Motor and the Main Motor start rotating and the paper is taken up and fed into the printer e The printing is started when the Controller Mechanical Control Board sends a VIDEO signal to the Print Head a given period of time after the leading edge of the paper actu ates the Paper Take Up Switch TOD signal e The print start position of a new line as shifted from the previous one is established by transmitting a VIDEO signal after the lapse of an appropriate period of time with refer ence to the SOS Sensor signal e The SOS Sensor provided in the PH ensures that the laser beam is emitted at the same timing for all lines in the main scanning direction M 19 9 3 Laser Emission Timing e When a READY signal is detected a given period of time after the print command has been issued the Controller Mechanical Control Board outputs a laser ON signal The laser ON signal makes a laser beam to be emitted and the laser beam travels to the Polygon Mirror G1 Le
108. owered in the standby state and raised when the document is taken up and fed in ing motion of the Pick up Roller the Paper Take up Clutch The Document Stopper is raised and lowered in synchronism with the raising and lower The Pick up Roller and Take up Roller turn to take up and feed the original properly The Pick up Roller transports the original up to the Take up Roller The AF Main Motor drives the Pick up Roller and Take up Roller through a gear train and AF Main Motor M5 Pick up Roller Original Detection Sensor PC1 Paper Take up Clutch CL1 Take up Roller Document Stopper Electrical Component Control Signal OFF 1382M001AC WIRING DIAGRAM PWB A AF Ms PA010A AF 1 4 oe F G 2 3 PWB A AF PAO7A AF 2 N F 2 3 Electrical Component Control Signal Blocked Unblocked WIRING DIAGRAM PWB A AF PAO2A AF 1 PC1 M 4 2 Document Separation Mechanism Double feeding of paper is prevented using coefficient of friction between the Take up Roller and Separator Pad Take up Roller 1382M002AB Separator Pad Single sheet feeding The coefficient of friction on the front side of the paper fed between the Take up Roller and Separator Pad is equal to that on the backside of the paper This allows the Take up Roller to transport the paper Multiple sheet feeding The coefficient of friction between the paper and Separator Pad is greater than that between sheets
109. plugged in and are no cables broken Correctly plug in the connectors Replace connection cables The problem has been eliminated after performing step 5 1 32 Replace the Scanner Assy Replace the IR Unit 8 Printer system Blank or black prints lt Typical Faulty Images gt 4011T035AA 4011T036AA lt Troubleshooting Procedures gt Check Action Is a printed page blank Check PH Unit connectors for proper connection Is the coupling of the drive mechanism of Check coupling of drive the Imaging Cartridge properly connected mechanism for connection and correct as necessary or replace Imaging Cartridge Drum Cartridge Toner Car tridge Is the drum charge voltage contact point or Check clean or correct con PC Drum ground contact point of the Imag tact point ing Cartridge properly connected Is the High Voltage Unit HV1 connector Connect it properly connected properly Is the problem eliminated when step 4 was Replace High Voltage Unit checked HV1 Replace Controller Mechani cal Control Board PWB P Replace PH Unit T 33 9 Printer system Blank spots lt Typical Faulty Image gt 4011T008AA lt Troubleshooting Procedures gt Result Action Is paper damp YES Replace paper for one just unwrapped Is the PC Drum scratchy YES Replace Drum Cartridge Is there foreign matter on paper path YES Remove foreign ma
110. ransports the toner to the Sleeve Roller The Resin Sleeve of the Sleeve Roller carries the toner onto the PC Drum to form a toner image on the latent image formed on the surface of the PC Drum Imaging Cartridge T C D C a PC Drum TiC O Toner Hopper Toner Agitating Screw sleeve Roller Toner Supply Roller 4136M504AA 2nd Toner Blade 1st Toner Blade 4136M529AA The Imaging Cartridge consists of a T C Toner Cartridge and a D C Drum Cartridge see the illustration below D C Drum Cartridge Imaging Cartridge 4136M511AA T C Toner Cartridge M 9 6 2 PC Drum e The PC Drum used in this printer is the organic photoconductor OPC type e The drum consists of two layers Charge Transport Layer CTL and the Charge Gener ating Layer CGL applied to an aluminum alloy base cylinder Handling Precautions The PC Drum of this type exhibits light fatigue after being exposed to light for a long time which results in ts sensitivity being changed Therefore always wrap the drum in the PC Drum Cloth or a soft cloth immediately after it has been removed from the printer Use utmost care to prevent the surface of the PC Drum from being dirtied CTL CGL Aluminum Cylinder 1167M007AA 1139M007AA e Grounding of the PC Drum The ground contact point Ground Plate for the PC Drum is located inside the PC Drum at its front side Itis at all ti
111. rketed in the United States CAUTION Use of controls adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure Semiconductor laser Maximum power of the laser diode 15 mW Wavelength 770 800 nm All Areas CAUTION Use of controls adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure Semiconductor laser Maximum power of the laser diode 15 mw Wavelength 770 800 nm Denmark ADVARSEL Usynlig Laserstraling ved abning nar sikkerhedsafbrydere er ude af funktion Undga uds ttelse for str ling Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene Halvlederlaser Laserdiodens hgjeste styrke 15 mw Bolgelaengden 770 800 nm Finland Sweden VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle Ala katso s teeseen LOUKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS Laitteen K ytt minen muulla kuin t ss k ytt ohjeessa mainitulla tavalla saattaa altistaa k ytt j n turvallisuusluokan 1 ylitt v lle n kym tt m lle lasers teilylle Puolijohdelaser Laserdiodin suurin teho 15 mW Aallonpituus 770 800 nm VARNING Om apparaten anv nds p annat s tt n i denna bruksanvisning specificerats kan anv ndaren uts ttas f r osynlig laserstr lning som verskrider gr nsen f r la
112. rough image T 28 4 Image reading system Black streaks or bands ee T 29 5 Image reading system Black Spots uuenneessnnennannnnnnnnnnnnnnnnnnnen T 30 6 Image reading system Blank streaks or bands n n T 31 7 Image reading system Uneven image uusnessennnnnnnnnnennnnnnnnnnnnnn T 32 8 Printer system Blank or black prints uesessensnennnnennnnnnnnennnnn T 33 9 Printer system Blank Spots uuunsseesssnnssnennnnennnnnnnnnnnnnnnnnennnnnnnnan T 34 10 Printer system Smears on back unserseessersenneennennennnennee nennen T 34 11 Printer system Low image density uunssesssnsnnnsnnnnnnnnnnnnnnnnnnnnnnn T 35 12 Printer system Foggy background uu2uuurssuesnnnsnnnnnnnnnnnnnnnnnnnnnnn T 36 13 Printer system Blank streaks or bands sneensennennnnnnnnnnnnnnnn T 37 14 Printer system Black streaks or bands u 2urnsunnnnnnnnnnnnnnnnn T 38 15 Printer system Offset image 16 Printer system Uneven image GENERAL 1 SPECIFICATIONS 1 Main Unit Type Desktop Original scanning system Scanning in main scanning direction with a 3 line color CCD sensor and scanning in sub scanning direction with unit scanning and sheet feed through system Photoconductor type OPC Organic Photoconductor Copying system Electrostatic dry Powdered image transfer to plain paper with laser Resolu
113. sed Not Used TC TYPE e ME Toner Cartridge 101 A e Others Toner Cartridge 101 B e MC Toner Cartridge 101 C o CO NI oJ O A j N 0 Precautions for making test copies with functions from the ADJUST menu e The test pattern should be positioned vertically e Use paper loaded into Tray1 to make the test copy S 16 Counter 3 e The counter values can be displayed Function TOTAL COUNTER PM COUNTER I C COUNTER Purpose To display the total number of pages used To display the number of times that PM parts are used To display the total number of times that the Drum Cartridge has been used Setting Details Precautions COPY Number of copies printed PRINT Number of computer printouts printed Test prints made in Service mode to check the operation are not counted To clear the counter data use the functions on the CLEAR DATA menu of Ser vice mode To clear the counter data use the functions on the CLEAR DATA menu of Ser vice mode APPLICATION COUNTER To display the number of pages used with each application COPY PRINT Number of cop ies printed FAX RX PRINT Not Used REPORT PRINT Not Used PC PRINT Number of com puter printouts printed FAX TX PAGE Not Used MAIL TX PAGE Not Used To clear the counter data use the functions on the CLEAR DATA menu of Ser v
114. sed after the Paper Take Up Sensor is blocked If all of the following conditions are met The Automatic Document Feeder is in standby The Document Feeder Cover is closed The Original Detection Sensor is blocked Either the Paper Take Up Sensor or the Leading Edge Detec tion Sensor or both sensors are blocked ADF remains paper jam lt Troubleshooting Procedures gt Relevant Electrical Parts Original Detection Sensor PC1 Automatic Document Feeder Control Board Paper Take Up Sensor PC2 PWB A ADF Leading Edge Detection Sensor PC3 WIRING DIAGRAM Action Ref Page Location Control Signal Electrical Component Initial checks PC1 sensor check PWB A ADF PAO2A ADF 1 C D 4 5 PC2 sensor check PWB A ADF PAO6A ADF 1 D E 4 5 PC3 sensor check PWB A ADF PAO3A ADF 1 6 7 Replace PWB A ADF TIMING CHART 3 abed puogas jo Bumuueos ysiul4 a ed puosas jo Buluueos ulbeg aBed 1811 Jo Buluueos ysiuly ebed s jo passed Bumuueos uibag Kay MAIS 330 NO 7 H dois uolye 01 p emioJ 330 NO H papeo euiBiio Bumuueos peul buo EId Josuas uUONWEIEA e6bp3 Bulpes7 SN JOJOW UIEN ACV H0 yamio dn syeL Jadey 19d JOSU9S uo01 99 2q jeulbuC sabed 7 py om Buipaay PF 125 Service Manual f CONTENTS GENERAL T SPECIFICATIONS ura ii G1 DIS REASSEMBLY ADJUSTMENT 1 MAINTEN
115. serklass 1 Halvledarlaser Den maximala effekten f r laserdioden 15 mW V gl ngden 770 800 nm VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Norway ADVERSEL Dersom apparatet brukes p annen m te enn spesifisert i denne bruksanvisning kan brukeren utsettes for unsynlig laserstr ling som overskrider grensen for laser klass 1 Halvleder laser Maksimal effekt till laserdiode 15 mW Bolgelengde 770 800 nm 1 3 Laser Safety Label e A laser safety labels is attached to the outside of the machine as shown below CLASS 1 LASER PRODUCT LASER KLASSE 1 PRODUKT E451 Ol AS PRODUCTO LASER DE CLASE 1 4980D070AB 1 4 Laser Caution Label A laser caution label is attached to the inside of the machine as shown below CEA AR AS EXPOSURE TO THE BEAM a 4980D061AA 1 5 Precautions for Handling the Laser Equipment e When laser protective goggles are to be used select ones with a lens conforming to the above specifications e When a disassembly job needs to be performed in the laser beam path such as when working around the printerhead and PC Drum be sure first to turn the copier OFF e If the job requires that the copier be left ON take off your watch and ring and wear laser protective goggles e A highly reflective tool can be dangerous if it is brought into the laser beam path Use utmost care when handling tools on the
116. stor NOTE When reinstalling the Thermistor route the har ness as shown in the illustration 10 Remove two screws and the Thermostat D 28 4 ADJUSTMENTS 4 1 Electrical Image Adjustment 1 Accessing the Service Mode 1 Press the Utility key 2 Press the following keys in order to enter the Service mode Stop gt 0 gt 0 gt Stop gt 0 gt 1 NOTE Be sure to keep the access procedure for the Service mode from any unauthorized per sons not involved with service operations 2 Accessing the ADJUST Menu 1 Enter the Service mode 2 Press the Zoom Select key to select the ADJUST menu 3 Printing a Test Pattern NOTES Print a test pattern when making the following adjustments Printers main scanning amp sub scanning registration adjustments Scanner s main scanning amp sub scanning registration adjustments Scanner s zoom ratio adjustment Enter the Service mode Press the Density Select key to select the function Select PRINT TEST PATTERN gt TEST PATTERN 1 Press the Start key to begin printing the test pattern Pr ONS D 29 4 Margin Adjustment Leading Edge Trailing Edge Both Sides lt Requirement gt A B e Specify the amount erased at the leading edge r width of A trailing edge width of B and both 4 sides width of C of the paper u Default setting 4 mm EC 4022D503AA Mode Function
117. t Sianal Location e Electric Parts Unplug then plug in the power cord and turn off the copier then turn it on again Check the connection of the EEPROM on the PWB P and then correct it if nec essary Replace PWB P Replace EEPROM 7 21 13 C14A3 IR lamp malfunction lt Detection Timing gt Description e The luminosity level of the Exposure Lamp is not stabilized within the predetermined period of time lt Troubleshooting Procedures gt Relevant Electric Parts IR Unit Controller Mechanical Control Board PWB P Check the connection of the connectors and then correct them if necessary Ref Page WIRING DIAGRAM Location Gontrot Signal Electric Parts Replace PWB P Replace the Scanner Assy T 22 4 MALFUNCTIONS RELATED TO POWER SUPPLY 4 1 Power is not Turned ON Relevant Electric Parts Controller Mechanical Control Board PWB P Power Unit PU1 Wiring Diagram Location Acton Check Is the power cord plugged Plug the power cord into the into the power outlet power outlet Is the power cord connected Plug the power cord into the properly to the printer printer Is the Power Switch turned Turn ON the Power Switch ON Are the fuses F101 and Replace Power Unit PU1 F102 on the Power Unit Replace Controller Mechan conducting ical Control Board PWB P T 23 5 IMAGE QU
118. tects this reflected light Toner Detection Window 4136M540AA When a Sufficient When There is only a Small Amount of Toner is Left Amount of Toner left Reflection Mirror Toner Agitating Blade Toner N Reflecting Light LED LED Detection Sensor 4980M011AA e The number of times at which the input voltage to the reflecting light detection sensor exceeds a predetermined period of time is counted When this count reaches a prede termined value a toner near empty or a toner empty condition is detected The toner near empty or toner empty condition is reset when the Front Door is opened and closed Electrical Component Control Signal Blocked Unblocked WIRING DIAGRAM M 13 7 DRUM CHARGE 1 Overview The PC Drum is charged with static electricity before laser exposure The Drum Charge Brush and the Pre charge Film are used for charging Since the Drum Charge Brush and the Pre charge Film directly deposit charge on the PC Drum they produce little ozone Further the charging voltage is low and the deposited charge is even and stable across the surface of the PC Drum The Pre charge Film supplies a preliminary charge to the PC Drum prior to charging by the Drum Charge Brush thereby increasing charging efficiency Drum en om II Paper Dust Remover Drum Cover Pre charge F
119. ter Lamp has been turned ON and ends when the lamp is turned OFF The Fusing Roller Heater Lamp remains ON for a 30 sec period or more except during the period through which the Main Motor remains energized lt Troubleshooting Procedures gt Relevant Electric Parts Fusing Unit Controller Mechanical Control Board PWB P Thermistor TH1 Thermostat TS1 Fusing Roller Heater Lamp H1 Power Unit PU1 WIRING DIAGRAM Action Location Control Signal Electric Parts Replace Thermistor TH1 Replace Fusing Roller Heater Lamp H1 Replace Thermostat TS1 Replace Fusing Unit Replace Controller Mechanical Control Board PWB P Replace Power Unit PU1 T16 4 C0510 Fuser temperature low lt Detection Timing gt Description The temperature detected by the Thermistor remains lower than the set temperature continuously for a predetermined period of time while the fusing temperature control is being provided The set temperatures are as follows 140 C during a print mode at 600 dpi 70 C during the standby mode lt Troubleshooting Procedures gt Relevant Electric Parts Fusing Unit Controller Mechanical Control Board PWB P Thermistor TH1 Thermostat TS1 Fusing Roller Heater Lamp H1 Power Unit PU1 WIRING DIAGRAM Action Location Control Signal Electric Parts Replace Thermistor TH1 Replace Fusing Roller Heater Lamp H1
120. tern into the Automatic Document Feeder again make another test copy and check it D 15 TROUBLESHOOTING 1 INTRODUCTION e This chapter contains the items required or used when troubleshooting various printer problems 1 1 Electric Components Check Procedures e The following procedures can be used to check to see if an electric component is fully operational when a paper misfeed or a malfunction occurs in the printer 1 Sensors Check Result Action NO Replace the sensor Does the input signal to the Controller Mechanical Control Board go from HIGH to LOW or vice versa when the sensor is blocked Replace the Con troller Mechanical Control Board 4025T520AA 4025T521AA 2 Clutches Check Result Action i Replace the Con Does the output signal of the Controller Mechanical NO troller Mechanical Control Board go from HIGH to LOW when the clutch Control Board is energized Replace the clutch 3 oc2av il 2 gt Nm HEHE m El 3 5 el 4025T528AA Motors Check Result Action Replace the Con troller Mechanical Control Board Replace the motor Is the LOCK signal of the Controller Mechanical Con trol Board HIGH when the printer is in the standby NO state Replace the motor Does the REM signal of the Controller Mechanical Control Board go from HIGH to LOW when the motor is energized Rep
121. the Control Panel ss D 10 Exit tray While pressing out one side remove the Exit tray Front Door Open the Front Door gt While pressing in one side remove the Front Door Bypass Tray Tray1 Hold down the main unit with one hand and pull Tray1 off toward you Left Cover Open the Front Door gt Remove the screw unhook the six tabs and remove the Left Cover Right Cover Rear Cover Open the Front Door Remove the two screws unhook the four tabs and remove the Right Cover Remove the five screws and remove the Rear Cover 3 2 Removal of Circuit Boards and Other Electrical Compo nents NOTES When removing a circuit board or other electric component refer to the precautions for handling PWBs and follow the corresponding removal procedures The removal procedures given in the following paragraphs omit the removal of the com ponent in question from a connector or a PWB support Where it is absolutely necessary to touch the ICs and other electric components on the board be sure to ground your body 4980D025AB PWB IF 4980D064AA Name Removal Procedures Controller Mechanical Control Board t D 10 Control Panel t D 10 Interface Board ws D 11 Power Unit ws D 12 High Voltage Unit ws D 14 1 Removal of the Controller Mechanical Control Board lt Removal Procedures gt 1 Remove
122. the functions to their default set All functions in the Services tings Choice menu of the Service mode All functions in the ADJUST menu of the Service mode except SERIAL NO CUSTOMER ID and TC TYPE MEMORY CLEAR All FIXED ZOOM settings in the Service mode All Security mode settings in the Service mode NOTE e After the MEMORY CLEAR function is performed turn the machine off then on again PM COUNTER To clear the PM COUNTER value I C COUNTER To clear the I C COUNTER value APPLICATION COUNTER SCAN COUNTER To clear the SCAN COUNTER value PRINTER JAM COUNTER ADF JAM COUNTER TROUBLE COUNTER To clear the APPLICATION COUNTER value To clear the PRINTER JAM COUNTER value To clear the ADF JAM COUNTER value To clear the TROUBLE COUNTER value S 22 5 SECURITY MODE e This mode is used to set various security functions 5 1 Security Mode Function Tree SECURITY MACHINE COUNTER 5 2 Security Mode Setting Procedure NOTE Be sure to keep the access procedure for the Security mode from any unauthorized per sons not involved with service operations lt Procedure gt 1 Display the Service mode screen we S 11 2 Press the Stop key then the 9 key 3 The Security mode screen appears lt Exiting Procedure gt e Press the Panel Reset key 1 Security Function Purpose Setting Deta
123. the period of time through which the Paper Take Up Switch remains actuated or through which the paper moves past the switch and the system speed It is then determined whether or not the actual length matches the paper length specified on the controller sA Paper Take Up Switch S1 SE i i i 5 o 1 Paper Take Up Roll Gear with se Depressing Cam S Tray 4980M006AA When Paper is Taken up 7 gr y I I 1 N A gt x O NN x S lt gt Paper Take Up Solenoid SL 1 Standby Tray Depressing Cam 4136M556AA M 22 4136M557AA Electrical Parts Control Signal WIRING DIAGRAM S1 PWB P MPJ10P 2 L F 3 SL1 PWB P MPJ3P 2 1 3 2 Double feed preventive mechanism e A fixed paper separator pad is used to prevent the second and subsequent sheets of paper from being taken up and fed in with the first one 3 Paper empty detection e There are the Multipurpose Tray Paper Empty Sensor PE1 and the Multiple Bypass Tray Paper Empty Sensor PE2 provided on the upper part ofTray 1 They function to detect paper loaded in Tray 1 and the Multiple Bypass Tray respectively e When there is a paper stack loaded in the tray the actuator is raised to block the Paper Empty Sensor e When paper runs out the actuator drops into the hole in the tray unblocking the Paper Empty Sensor Multipurpose Tray Paper Empty Sensor PE1
124. the sole noid oc2av ON 4025T522AA 4 Motors Check Result Action Is the LOCK signal of the Controller Mechanical Con trol Board HIGH when the printer is in the standby state NO Replace the Con troller Mechanical Control Board Replace the motor Does the REM signal of the Controller Mechanical Control Board go from HIGH to LOW when the motor is energized Replace the motor Replace the Con troller Mechanical Control Board oa k A Check 4025T526AA Result Action Does the input signal to the Controller Mechanical Control Board go from HIGH to LOW when the motor is energized The input signal varies depending on the direction of rotation YES Replace the motor NO Replace the Con troller Mechanical Control Board 4025T525AA Result Action Are the hookup connector of the motor and print jack on the Controller Mechanical Control Board con YES Replace the motor or the Controller Mechanical Control Board nected properly Connect the con nector or the print jack properly 4025T527AA 1 2 Overall Control Configuration e Understanding the overall control configuration will help perform the troubleshooting pro cedures for paper misfeeds malfunctions and image problems Automatic Docu Image Reading Control Panel ment Feeder IR Drive System PWB O
125. the test pattern into the Automatic Docu ment Feeder and then print five single sided cop ies NOTE The test pattern should be positioned vertically 1382U027AA 4 Measure the lengths a and b on the copies of the es test pattern and if there is a large shift adjust it a according to the following procedure Standard values of aandb 1 0 mm b k gt 1382D008AA lt lf A is longer than B gt Using a coin loosen the shoulder screw shown in the illustration and then slide the scale on the Automatic Document Feeder toward you I NOTE After finishing the adjustment be sure to tighten 1382U028AB the loosened shoulder screw D 11 lt If A is shorter than B gt Using a coin loosen the shoulder screw shown in the illustration and then slide the scale on the Automatic Document Feeder away from you NOTE After finishing the adjustment be sure to tighten the loosened shoulder screw we 1382U029AA 6 Automatic Document Feeder Sub Scanning Zoom Ratio Adjustment lt Reference gt Adjust the length of C in the copy of the test pat c tern so that the following specification is met 1382D009AA Zoom Ratio Specification Function Setting Range Full Size 7 95 to 105 100 200 0 5 mm ADJUST menu ADF SUB ZOOM 1 increment 0 4 lt Adjustment Procedure gt 1
126. their mounting accuracy by varying the scanning start position in the main scanning direction When the Upper Cover Assy Original Glass has been replaced When the Scanner Assy has been replaced S 14 Press the Start key to begin printing the test page The setting range is 90 to 110 1 increment 0 5 mm Function Purpose Setting Details Precautions CCD SUB REGIST TEST COPY ADJUST To adjust for variations in the accu racy of IR parts and their mounting accuracy by varying the scanning start position in the sub scanning direction When the Upper Cover Assy Original Glass has been replaced When the Scanner Assy has been replaced Press the Start key to begin printing the test page The setting range is 90 to 110 1 increment 0 5 mm ADJUST To adjust for variations in the accu racy of all parts and their mounting accuracy by varying the scanning zoom ratio in the sub scanning direction when using the Automatic Document Feeder When the Upper Cover Assy Original Glass has been replaced Press the Start key to begin printing the test page The setting range is 95 to 105 1 increment 0 4 ADJUST To adjust for variations in the accu racy of all parts and their mounting accuracy by varying the scanning start position in the main scanning direction when using the Automatic Document Feeder When the Upper Cover Assy Origina
127. ting If the shift cannot be adjusted to within the specification with a single adjustment perform the adjustment again to change the setting 5 Press the Yes key to apply the setting NOTE If the Stop key is pressed instead of the Yes key the main screen is displayed and the set ting returns to that before it was changed 6 Print a test pattern again and check it D 32 7 Scanner s Main Scanning Zoom Ratio Adjustment lt Requirement gt After finishing the printer s main scanning amp sub scanning registration adjustments place the printed test pattern on the Original Glass and a pa make a copy of it e Adjust the width of D in the copy of the test pattern so that the following specification is met 4007D052AA Zoom Ratio Full Size CCD MAIN 95 to 105 100 INN ADJUST MENU ZOOM 1 increment 0 4 Specification Mode Function Item Setting Range Perform this adjustment in the following cases After the Scanner Assy has been replaced After the printer s main scanning amp sub scanning registration adjustments have been performed lt Adjustment Procedure gt 1 Print the test pattern 2 Enter the ADJUST menu in the Service mode 3 Place the test pattern on the Original Glass and make a test copy NOTES The test pattern should be positioned vertically Use A4 L or Letter L paper loaded into Tray1 to make the test copy 4 Check that the width
128. tion 600 dpi x 600 dpi 600 dpi x 300 dpi Paper feed in system 2 Way system Tray1 and BypassTray 3 Way system is possible if optional PF 125 Tray2 is installed Exposure system Unit scanning slit exposure Developing system FMT single component developing Drum charging system Rotating brush with pre charge film Image transfer system Roller transfer Paper separation system Curvature separation Charge Neutralizing needle Fusing system Heat roller Max Original size Up to Legal size Copy Medium Paper source Bypass Tray Plain paper 60 to 90 g m o 16 to 24 Ib Recycled paper 60 to 90 g m o 16 to 24 Ib Special paper 91 to 163 g m 24 to 43 Ib O O Transparencies O O O O Label sheets Envelopes O O gt Maximum width x length 216x356 mm 216x356 mm Dimension A4 L Letter L Minimum width x length 105x148 mm 105x148 mm NOTE The dimension forTray2 is fixed at A4L or Letter L G 1 Continuous copy speed copies min Continuous print speed sheets min Warm up time First print time First copy time 12 copies minute at full size and 600 dpi x 300 dpi with ADF More than 16 sheets minute with plain A4 L or Letter L paper Less than 25 seconds at a room temperature of 23 C and at the rated voltage 16 seconds or less at full size and 600 dpi x 300 dpi with plain A4 L or Letter L paper 13 sec
129. tom paper size type in the size 3 TRAY SETTING Copy Setting To specify whether or not auto tray switching is enabled for each paper tray e The default setting is CON TINUOUS FIXED CONTINUOUS e The default settings for each copy function can be specified Function Purpose Setting Details Precautions PAPER PRIORITY To specify the paper tray that is given priority e The default setting is TRAY1 TRAY1 TRAY2 DENSITY PRI ORITY To specify the image density set ting that is selected when the machine is turned on or the Panel Reset key is pressed e The default setting is AUTO AUTO MANUAL PHOTO DENSITY LEVEL A To specify the default density level when the Auto setting is selected The default setting is NOR MAL 0 The setting range is 1 to 1 DENSITY LEVEL M To specify the default density level when manually setting the image density The default setting is NOR MAL 0 The setting range is 4 to 4 OUTPUT PRI ORITY RESOLUTION To specify the default finishing set ting To specify the scanning resolution The default setting is NON NON SORT The default setting is 600 x 300 600x300 600x600 4 SERVICE MODE This mode is used to check specify adjust and register service functions 4 1 Service Mode Function Tree SHIPMENT DESTINATION LEAD
130. tter Is Image Transfer Roller dirty or scratchy YES Replace Image Transfer 3 Roller Replace High Voltage Unit HV1 Replace Controller Mechani cal Control Board PWB P 10 Printer system Smears on back lt Typical Faulty Image gt ABCDE ABCDE 4011T009AA lt Troubleshooting Procedures gt Check Result Action Is there foreign matter on paper path YES Remove foreign matter Is Fusing Roller dirty or scratchy YES Replace Fusing Unit Fusing Roller Is Image Transfer Roller dirty or scratchy YES Replace Image Transfer Roller T 34 11 Printer system Low image density lt Typical Faulty Image gt 4011T003AA lt Troubleshooting Procedures gt Action Is paper damp Replace paper for one just unwrapped Is there toner left in Toner Cartridge Replace Toner Cartridge Is PC Drum faulty life Replace Drum Cartridge Is developing bias faulty Replace High Voltage Unit HV1 Replace Controller Mechani cal Control Board PWB P Is image transfer faulty T 35 Replace Image Transfer Roller Replace High Voltage Unit HV1 Replace Controller Mechani cal Control Board PWB P 12 Printer system Foggy background lt Typical Faulty Image gt 4011T004AA lt Troubleshooting Procedures gt Check Result Action Is PC Drum scratchy YES Replace Drum Cartridge Is developing bias contact t
131. ug one connector on the Controller Mechani cal Control Board 3 Remove the two screws and then remove the Left Rear Cover 4980U044AA 4 Remove the three screws and then remove the Circuit Board and Metal Bracket Remove the Upper Left Cover Remove the two screws and then remove the Upper Right Cover and Protective Metal Bracket NOTE The Protective Metal Bracket is tightened together with the Upper Right Cover 4980E001AC 7 Remove two screws unplug three connectors and remove the Fusing Unit NOTE The surfaces around the Fusing Unit are very hot Use utmost care not to touch any surfaces other than the Fusing Unit 4980E002AB 8 Remove the Fusing Unit 4980E003AA lt Installation Procedures gt 1 Connect connector A 2 Mount the Fusing Unit in the printer and secure it in position by tightening the two screws 3 Connect connectors B and C NOTE When installing the Fusing Unit route the harness as shown in the illustration and make sure that no part of the harness is wedged between the Fusing Unit and printer 4136E017AC NOTE When replacing a part comprising the Fusing Unit individually to correct an image prob lem or a defective part see D 26 Disassembly of the Fusing Unit of DIS REASSEM BLY ADJUSTMENT DIS REASSEMBLY AD
132. ustment perform the adjustment again to change the setting 6 Press the Yes key to apply the setting D 37 NOTE If the Stop key is pressed instead of the Yes key the main screen is displayed and the set ting returns to that before it was changed Place the test pattern on the Original Glass again make another test copy and check it D 38 10 Scanner s Sub Scanning Registration Adjustment lt Requirement gt After finishing the printer s main scanning amp sub se Cc scanning registration adjustments place the printed test pattern on the Original Glass and e make a copy of it e Adjust the width of C in the copy of the test pattern so that the following specification is met 4007DO51AA Specification Mode Function Item Setting Range 90 to 110 20 3 0 mm ADJUST menu CCD SUB REGIST 1 increment 0 5 mm Perform this adjustment in the following cases After the Scanner Assy has been replaced After the printer s main scanning amp sub scanning registration adjustments and the scan ner s sub scanning zoom ratio adjustment have been performed lt Adjustment Procedure gt 1 Print the test pattern 2 Enter the ADJUST menu in the Service mode 3 Place the test pattern on the Original Glass and make a test copy NOTES The test pattern should be positioned vertically Use A4 L or Letter L paper loaded into Tray1 to make the test copy 4 Check that the
133. xposure Lamp A CCFL lamp is used to illuminate the surface of the original 2 1st Mirror Reflects the light reflected off the surface of the original directing it to the 2nd Mirror 3 2nd Mirror Reflects the light reflected off the 1st Mirror directing it to the 3rd 5th Mirror 4 3rd 5th Mirror Reflects the light reflected off the 2nd Mirror directing it to the 4th Mirror Reflects the light reflected off the 4th Mirror directing it to the CCD through the Lens 5 4th Mirror Reflects the light reflected off the 3rd Mirror directing it to the 3rd 5th Mirror M 16 8 3 Scanner Drive Mechanism 1 Scanner Drive Mechanism e The Scanner Motor drives the Scanner Assy through the Timing Belt Scanner Motor M4 Scanner Assy Timing Belt 4980M002AA 8 4 Scanner Motor Drive Control e The speed at which the Scanner moves for scan and return motion is controlled by varying the period of the motor drive pulse that is timed with the reference clock Period gt e The number of motor drive pulses as determined according to the paper size and zoom ratio controls the amount of movement of the Scanner Electrical Component Control Signal ON OFF WIRING DIAGRAM M4 PWB P P105P 1 4 Pulse output B C 7 M 17 9 PRINT HEAD PH 9 1 Construction e The laser beam light emitted from the Print Head is used to scan the image as driven by the Polygon Motor SOS Sensor G1 Lens Semiconduct

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