Develop D 2500iD Service Manual Download

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FrameMaker Ver.5.5E(PC) Di250 TROUBLESHOOTING
99.01.08

T-36

C0650, C0651

Step

Check Item

Result

Action

Is M5 energized?
Select the following functions in this
order: Tech. Rep. Mode

→

Move-

ment Check

→

Scanner. Then,

enter an appropriate value in “Abso-
lute Position” or “Relative Position”
and energize M5.

Check various parts for possible
overload and, if they are okay,
change M5, BCR, HGB, UN2, or
PWB-A, in that order.

Is “C0650” being displayed?

YES

Perform steps 3 and 4.

Perform steps 5 and 6.

Does the voltage across
CN11BCR-1 on BCR and GND
change from DC0V to DC5V when
step 1 is performed a second time
and PC12 is unblocked?

Change PC12.

Does the voltage across CN1BCR-
26 on BCR and GND change from
DC0V to DC5V when step 3 is per-
formed a second time?

YES

Change HGB, UN2, or PWB-A, in
that order.

Change BCR.

Does the voltage across
CN12BCR-1 on BCR and GND
change from DC5V to DC0V when
step 1 is performed a third time and
PC13 is unblocked?

Change PC13.

Does the voltage across CN1BCR-
27 on BCR and GND change from
DC0V to DC5V when step 5 is per-
formed a second time?

YES

Change HGB, UN2, or PWB-A, in
that order.

Change BCR.

Summary of Contents for D 2500iD

Page 1: ...Service Manual Digital Copier DEVELOP D 2500iD ...

Page 2: ...efore starting the procedures be sure to unplug the power cord 3 Use the specified parts WARNING CAUTION WARNING Parts requiring special attention in this product will include a label containing the mark shown on the left plus precautionary notes Be sure to observe the pre cautions Be sure to observe the Safety Information given in the Operator s Manual This product contains a high voltage unit an...

Page 3: ... part marked with the symbol shown on the left and other parts such as the exposure lamp and fusing roller can be very hot while the machine is energized Touching them may result in a burn Wait until these parts have cooled down before replacing them or any surround ing parts Be sure to connect the ground wire to the ground terminal even when perform ing an inspection or repair Without proper grou...

Page 4: ...embled parts or a container of liquid on the product Parts falling into or the liquid spilling inside the mechanism could result in an electric shock or fire Never use a flammable spray near the product This could result in a fire Make sure the power cord is unplugged before removing or installing circuit boards or plugging in or unplugging connectors Always use the interlock switch actuating jig ...

Page 5: ...ug the power cord before removing this cover If removing this cover while the power is ON is unavoidable be sure to wear pro tective laser goggles that meet specifications Make sure that no one enters the room when the machine is in this condition When handling the laser unit observe the Precautions for Handling Laser Equipment DANGER Invisible laser radiation when open AVOID DIRECT EXPOSURE TO BE...

Page 6: ...HAN DLING THE PWBs WITH MOS ICs applicable only to the products using MOS ICs The PC Drum is a very delicate component Observe the precautions given in HAN DLING OF THE PC DRUM because mishandling may result in serious image problems Note that replacement of a circuit board may call for readjustments or resetting of partic ular items or software installation After completing a service job perform ...

Page 7: ...sageés conformément aux instructions du fabricant Denmark ADVARSEL Lithiumbatteri Eksplosionsfare ved fejlagtig håndtering Udskiftning må kun ske med bat teri af samme fabrikat og type Levér det brugte batteri tilbage til leverandøren Norway ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten Brukte batterier ka...

Page 8: ...GENERAL D 2500iD ...

Page 9: ...i CONTENTS 1 SAFETY INFORMATION G 1 2 SPECIFICATIONS G 8 3 PRECAUTIONS FOR INSTALLATION G 10 4 PRECAUTIONS FOR USE G 11 5 HANDLING OF THE CONSUMABLES G 12 6 OTHER PRECAUTIONS G 12 7 SYSTEM OPTIONS G 13 ...

Page 10: ...T A FIELD SERVICE ITEM Therefore the print head unit should not be opened under any circumstances For United States CDRH regulation This copier is certified as a Class 1 Laser product under the Radiation Performance Standard 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 Radi...

Page 11: ... power of the laser diode is 5mW and the wavelength is 770 810nm ADVARSEL Usynlig laserstråling ved åbning når sikkerhedsafbrydere er ude af funktion Undgå udsættelse for stråling Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene LUOKAN 1 LASERLAITE VAROITUS Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittä...

Page 12: ...denne bruksanvisning kan brukeren utsettes för unsynlig laserstrålning som overskrider grensen for laser klass 1 Dette en halveder laser Maksimal effekt till laserdiode er 5mW og bφlgelengde er 770 810nm Model Serial No CLASS 1 LASER PRODUCT LASER KLASSE 1 PRODUKT MINOLTA CO LTD 2 Higashiakatsuchi Yawata cho Toyokawa shi Aichi ken 442 8585 Japan MANUFACTURED THIS PRODUCT COMPLIES WITH 21 CFR CHAPT...

Page 13: ...side the copy machine as shown below Please read the following for your own protection Opening the cover indicated by the Caution label may expose you to harmful laser radiation which could cause damage or loss of eyesight Do not open the cover when the power is on Caution 1166O234AA ...

Page 14: ...iftning må kun ske med batteri af samme fabrikat og type Levér det brugte batteri tilbage til leverandøren Norway only ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten Brukte batterier kasseres i henhold til fabrikantens instruksjoner Sweden only VARNING Explosionsfara vid felaktigt batteribyte Använd samma b...

Page 15: ...commended by the manufacturer Dispose of used IC Package according to the manufacturer s instructions Germany only VORSICHT Austausch nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen typ Entsorgung gebrauchter Batterien nach Angaben des Herstellers ...

Page 16: ... protect the eyes from possible exposure to the laser beam 5 Use only a Fuse of the indicated rating 3 During Operation 1 Keep your hands clothing etc well away from operating or rotating parts 2 Never touch the terminals of electrical parts or high voltage parts 3 This copier uses an invisible laser beam To prevent a laser beam leak the copier per forms a trial run to make sure the covers are in ...

Page 17: ...YSTEM Comb Electrode 1 DC Negative Corona with Scorotron System IMAGE TRANSFER Roller Image Transfer PAPER SEPARATING SYSTEM Paper Separator Fingers and Charge Neutralizing Plate FUSING SYSTEM Heat Roller PAPER DISCHARGING SYSTEM Charge Neutralizing Brush MAXIMUM ORIGINAL SIZE A3L 11 17 L Paper Source MP Cassette Manual Feed Tray Medium Plain paper 60 to 90 g m2 Transparencies Thick paper 91 to 15...

Page 18: ...ble 25 to 400 in 0 1 increments LENS Through Lens F 4 0 f 62 mm EXPOSURE LAMP Fluorescent Lamp FUSING TEMPERATURE 190 C Exposure Lamp Rating Fusing Roller Heater Lamp Rating Max Power Consump tion full system Max Current Con sumption full system 24V 20W 660W 850W 120V 8A 230V 4A POWER REQUIREMENTS 120V 230V 50 60Hz Temperature 10 to 32 C with a fluctuation of 10 C or less per hour Humidity 15 to 8...

Page 19: ...0V 8A or 220V to 240V 4A or more If any other electrical equipment is sourced from the same power outlet make sure that the capacity of the outlet is not exceeded 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 copier Make the following checks at frequent intervals Is the power plug abn...

Page 20: ...when you plug the power cord into the outlet When unplugging the power cord do not pull on the cord hold the plug and pull it out Do not bring any magnetized object near the copier Do not place a vase or vessel containing water on the copier Be sure to turn OFF the Power Switch at the end of the workday or upon power failure Use care not to drop paper clips staples or other small pieces of metal i...

Page 21: ...ash them with soap and water immediately Do not throw away any used consumables PC Drum starter toner etc They are to be collected NOTE Do not burn bury in the ground or throw into the water any consumables PC Drum starter toner etc 1170SBG0600A The Print Head Unit of this copier uses a laser diode that emits a laser beam Use the fol lowing precautions when performing service jobs at the users pre...

Page 22: ...00 5 Duplex Unit AD 10 6 Large Capacity Cabinet PF 106 7 Paper Feed Unit PF 108 8 Paper Feed Unit PF 110 9 Shift Tray OT 100 10 Job Tray JS 200 11 Mailbin Finisher FN 500 12 Finisher FN 100 1 3 11 2 5 1145M035AA 1166O015AA 1166O008AA 1166O014AA 1171G001AA 1166O009AA 1166O010AB 1166O012AA 1166O121AA 1166O120AA 12 10 4 7 8 9 6 4608D018AA 1166O011AA ...

Page 23: ...MECHANICAL ELECTRICAL D 2500iD ...

Page 24: ... 24 13 DEVELOPING UNIT M 25 13 1 Sleeve Magnet Roller M 26 13 2 Developing Bias M 27 13 3 ATDC Sensor M 28 13 4 Sub Hopper Toner Replenishing Mechanism M 29 13 5 Sub Hopper Toner Empty Detecting Mechanism M 30 13 6 Main Hopper Toner Replenishing Mechanism M 31 13 7 I C Cooling Fan Motor M 32 13 8 Ozone Fan Motor M 32 14 PAPER TAKE UP FEED SECTION M 33 14 1 MP Cassette Paper Lifting Plate M 33 14 2...

Page 25: ... 19 1 Drive Mechanism M 45 19 2 Fusing Rollers Pressure Mechanism M 45 19 3 Fusing Temperature Control M 46 19 4 CPM Control M 47 20 PAPER EXIT UNIT M 48 21 FUSING COOLING FAN MOTOR M 49 22 POWER UNIT COOLING FAN MOTOR M 50 ...

Page 26: ...PC3 11 Right Fusing Roller 12 Left Fusing Roller 13 Fusing Cooling Fan Motor M3 14 Image Transfer Roller 15 Synchronizing Roller 16 Synchronizing Roller Sensor PC2 17 Manual Feed Paper Take Up Sensor PC8 18 Manual Feed Paper Take Up Roll 19 Vertical Transport Roller 20 Paper Separator Pad 21 Paper Take Up Roll 22 Imaging Cartridge I C 23 PH Unit 1 2 5 6 7 8 9 10 11 12 13 14 15 16 17 21 22 1171M037...

Page 27: ...s the results to the MFB Board 5 MFB Board Compresses the image data received from the HGB Board stores it and uncom presses it 6 Laser Exposure The laser beam emitted from the LD laser diode strikes the surface of the PC Drum creating an electrostatic latent image 7 Development Negatively charged toner adheres to the latent image on the PC Drum surface creating a visible image 8 Paper Feed Feeds ...

Page 28: ...ual toner off the surface of the PC Drum and the toner is recycled back to the Developing Unit 12 Erase The PC Drum is exposed to light which effectively removes any residual charge from the drum surface 13 Fusing Heat and pressure applied by the Right and Left Fusing Rollers fuse toner on the paper 14 Paper Exit Feeds paper out of the copier ...

Page 29: ... the Scanner and 2nd 3rd Mirrors Carriage B I C Motor M1 Drives the I C Unit C Main Motor M2 Drives the Paper Take Up Roll Manual Feed Paper Take Up Roll Synchronizing Roller Image Transfer Roller and Fusing Unit 3 DRIVE SYSTEM 1171M024AB A B C ...

Page 30: ...C The warming up cycle is completed Main Motor ON Power Unit Cooling Fan Motor turns at full speed Approx 20 sec Predrive stops OFF Power Unit Cooling Fan Motor turns at half speed Developing bias DC ON Approx 100 msec ON I C Motor Image transfer output voltage ON Approx 700 msec ON Image transfer output voltage Approx 400 msec ON Image transfer output voltage ON Image transfer output voltage Appr...

Page 31: ...speed Approx 700 msec ON Paper Take Up Solenoid E The Synchronizing Roller Sensor is activated Approx 110 msec OFF Paper Take Up Solenoid VSYNC signal ON approx 50 msec later ON Paper Take Up Solenoid Developing bias AC Synchronizing Clutch ON ON OFF Paper Take Up Solenoid Approx 90 msec Approx 160 msec ON Image transfer current value for printing F The Synchronizing Roller Sensor is deactivated A...

Page 32: ...Paper Exit Sensor is deactivated Approx 680 msec OFF Main Motor OFF Ozone Fan Motor The Power Unit Cooling Fan Motor turns at half speed Polygon Motor OFF Approx 10 sec OFF Fusing Cooling Fan Motor Approx 20 sec ...

Page 33: ...ier CPU operates erratically due to electrical noise therefore the copier is able to recover from the faulty condition so that the number of visits made by the Tech Rep for CPU overrun can be minimized Processing performed during watchdog function If a faulty condition is detected the copier resets the CPU and performs a restart sequence Since this sequence of operations is performed even during a...

Page 34: ...ratures The I C Thermistor is used to detect temperature and according to the detected tem perature Vg Vb is corrected PC Drum deterioration correction To compensate for degraded sensitivity caused by a deterio rating PC Drum Corrects Vg according to the period of time during which the PC Drum has turned 1171M028AA PC Drum Charge Corona PC Drum Revolution Counter I C Thermistor TH2 Grid Voltage Vg...

Page 35: ... employs an Imaging Cartridge I C in this manual that contains a PC Drum PC Drum Charge Corona Developing Unit and Cleaning Unit as one unit 7 IMAGING CARTRIDGE I C Toner Supply Port 1171M001AA 1171M002AA 1171M003AA ATDC Sensor E1 ...

Page 36: ...hether the I C is new or one which has been used previously The copier monitors the I C life by storing in memory the period of time during which the PC Drum has turned The data is cleared when a new I C is installed in the copier 7 1 I C Drive Mechanism Electrical Component Control Signal ON OFF M1 PJ16A 3 L H 7 2 Identification and Life of I C 1171M004AA PC Drum Drive Gear Hopper Drive Gear I C ...

Page 37: ... cloth or other protective covering to prevent exposure to light Grounding of the PC Drum The PC Drum ground point is located inside and at the front end of the I C as viewed from the front of the copier and in constant contact with the Drum Holding Shaft When the I C is installed in the copier the Drum Holding Shaft contacts the ground point This provides for assured grounding of the PC Drum thro...

Page 38: ...mesh is controlled by the constant voltage cir cuitry within the High Voltage Unit It is varied through image stabilization control To restrict ozone production the copier uses a PC Drum Charge Corona with a comb electrode 9 DRUM CHARGING Electrical Component Control Signal ON OFF Drum charging output PJ14A 3A L H 1171M006AB PC Drum PC Drum Charge Corona 1171M008AC Comb Electrode Grid Mesh ...

Page 39: ...ged by the Image Transfer Roller A voltage of 820V is applied to the Charge Neutralizing Sheet from the High Voltage Unit The Erase Lamp then illumi nates the surface of the PC Drum to further neutralize it The Erase Lamp consists of ten tungsten lamps 10 ERASE LAMP Electrical Component Control Signal All lamps ON Standby ON LA1 PJ11A 6A H L 1171M009AD Erase Lamp LA1 I C PC Drum 1171M010AD PC Drum...

Page 40: ...ecting Sensor 5 UN8 3 Original Cover Detecting Sensor PC14 4 Original Size Detecting Sensor 4 UN7 5 Exposure Lamp LA2 6 Original Size Detecting Sensor 6 UN9 7 Scanner Motor M5 8 HGB Board HGB 9 Original Size Detecting Sensor 1 UN4 10 Original Size Detecting Sensor 2 UN5 11 Original Size Detecting Sensor 3 UN6 12 Scanner Home Position Sensor 1 PC12 13 Size Reset Switch S5 14 CCD Board CCD 15 Lens 1...

Page 41: ...Auxiliary Reflector reduces this problem by reflecting light from the Exposure Lamp onto these areas of the original 2 Exposure Lamp A fluorescent lamp is used to illuminate the original 3 1st Mirror Directs the reflected light from the original to the 2nd Mirror 11 1 Exposure Section Construction and Function Electrical Component Control Signal ON OFF LA2 CN13BCR 1 L H 1167M089AA 2 Exposure Lamp ...

Page 42: ...A D conversion It further makes various corrections and outputs the resultant image data to the MFB Board over an optical cable 3 MFB Board This board compresses the image data received from the HGB Board stores it and uncompresses it The image memory has a standard capacity of 16MB and can be expanded up to 64MB optional 4 PH Emits a laser beam according to the image data provided by the MFB Boar...

Page 43: ...ize Detection Electrical Component Control Signal Blocked Unblocked UN4 CN4BCR 4 L H UN5 CN5BCR 7 L H UN6 CN11HGB 4 L H UN7 CN6BCR 4 L H UN8 CN9HGB 1 L H UN9 CN8BCR 4 L H 1171M025AD Original Size Detecting Sensor 6 UN9 Original Size Detecting Sensor 1 UN4 Original Size Detecting Sensor 2 UN5 Original Size Detecting Sensor 3 UN6 Original Size Detecting Sensor 4 UN7 Original Size Detecting Sensor 5 ...

Page 44: ...tification Inch Areas Detected by sensor L Lengthwise C Crosswise NOTE UN6 UN8 and UN9 are options Original Size UN4 UN5 UN6 UN7 UN8 UN9 S1 S2 S3 S4 S5 S6 S7 S8 S9 11 17 A3L A4L A4C A5L B4L FLS Letter L Letter C Legal Original Size UN5 UN6 UN7 UN8 UN9 S2 S3 S4 S5 S6 S7 S8 S9 11 17 A3L A4L A4C B4L 5 1 2 8 1 2 L FLS B5C Letter L Letter C Legal ...

Page 45: ...he Start key is pressed with the Original Cover Detecting Sensor activated or the Size Reset Switch deactuated Resets size readings When the Size Reset Switch is deactuated 11 4 Original Size Detection Timing Electrical Component Control Signal ON OFF S5 CN9BCR 2 L H Electrical Component Control Signal Unblocked Blocked PC14 CN10BCR 2 L H 1167M113AB Original Cover Detecting Sensor PC14 Size Reset ...

Page 46: ...nner when AF 7 is used 2nd 3rd Mirrors Carriage The 2nd and 3rd Mirrors are mounted to their holder at right angles to each other They direct the light reflected off the 1st Mirror through the lens to the CCD The 2nd 3rd Mirrors Carriage is also moved by the Scanner Drive Cables and pulleys driven by the Scanner Motor It travels at a speed half that of the Scanner thereby keep ing constant the opt...

Page 47: ...M 22 1170SBM1200A Based on the image data output from the MFB Board the LD laser diode is activated and the corresponding light strikes the surface of the PC Drum 12 PH SECTION 1171M035AB PH Unit ...

Page 48: ...2 1 PH Components 1 Polygon Motor M10 2 Cylindrical Lens 3 SOS Mirror 4 Collimator Lens 5 Laser Diode Board PWB B 6 SOS Sensor 7 f θ Lens Electrical Component Control Signal ON OFF M10 PJ8A 3 L H 1167M023AB 1 7 2 3 4 5 6 ...

Page 49: ...SOS signal determines the laser emission timing for each line in the main scanning direction A to B LD activation B to C LD OFF C to D Laser beam exposure area according to the image data 12 2 Laser Emission Timing SOS Signal 1167M024AC Polygon Mirror f θ Lens Polygon Motor M10 SOS Mirror Cylindrical Lens Collimator Lens Laser Diode Board PWB B PC Drum SOS Sensor 1171M038AA PC Drum SOS Mirror SOS ...

Page 50: ...ce of the PC Drum thus forming an electrostatic latent image 13 DEVELOPING UNIT 1 Spent Toner Recycling Coil 2 PC Drum Charge Corona 3 Spent Toner Feed Roller 2 4 Cleaning Blade 5 Spent Toner Feed Roller 1 6 PC Drum Paper Separator Finger 7 PC Drum Protective Shutter 8 PC Drum 9 Sleeve Magnet Roller 10 1st Toner Conveying Roller 11 ATDC Sensor E1 12 2nd Toner Conveying Roller 13 3rd Toner Conveyin...

Page 51: ... low to ensure that the developer remaining on the surface of the Sleeve Roller is smoothly recy cled They also prevent developer from scattering N3 The developer brush is formed by this pole and its height is moderated before the brush is regulated by the Doctor Blade S2a This pole ensures that the developer is conveyed to the point of development over the wide interval between N3 and N1 S2b If d...

Page 52: ...o wear it becomes more sensitive to the increase in the amount of toner As a countermeasure against this problem the developing bias voltage is automatically switched according to the PC Drum temperature thereby stabilizing the image quality level 13 2 Developing Bias Electrical Component Control Signal ON OFF Vb PJ14A 1A L H 1171M012AB PC Drum Sleeve Magnet Roller Developing Bias Contact Terminal...

Page 53: ...eration of the Sub Hopper Toner Replenishing Motor 3 Toner Empty Control T C Recovery Mode When the control is passed onto the T C recovery mode the Sub Hopper Toner Replen ishing Motor is energized to replenish the supply of toner into the Developing Unit and if T C is recovered to a level of 14 or higher 2 32V or less within 150 sec it resets the toner empty condition 13 3 ATDC Sensor T C Ratio ...

Page 54: ...y turning the Sub Hop per Toner Replenishing Motor for the period of time controlled by the ATDC output volt age T C 13 4 Sub Hopper Toner Replenishing Mechanism Electrical Component Control Signal ON OFF M7 PJ11A 8A DC24V L 1171M013AC Sub Hopper Sub Hopper Toner Replenishing Motor M7 ...

Page 55: ...et Lever rests on the toner keeping the Sub Hopper Toner Empty Switch deac tuated even when the Sub Hopper Toner Agitating Lever turns As toner is consumed the Magnet Lever lowers to eventually actuate the Sub Hopper Toner Empty Switch at which timing the copier detects a toner empty condition in the Sub Hopper 13 5 Sub Hopper Toner Empty Detecting Mechanism Electrical Component Control Signal ON ...

Page 56: ...whenever the bottle is stopped The Toner Bottle Cover Sensor detects whether the Toner Bottle Cover is open If the cover is open the copier does not authorize the initiation of a new copy cycle If the cover is opened during a copy cycle the copier interrupts the cycle 13 6 Main Hopper Toner Replenishing Mechanism Electrical Component Control Signal ON OFF M6 PJ11A 4A DC24V L Electrical Component C...

Page 57: ...um Charge Corona is absorbed by the Ozone Filter from the air being drawn out of the copier by the Ozone Fan Motor 13 7 I C Cooling Fan Motor Electrical Component Control Signal ON OFF M9 PJ18A 10 DC24V L 13 8 Ozone Fan Motor Electrical Component Control Signal ON OFF M8 PJ11A 1A DC24V L 1171M032AB I C I C Cooling Fan Motor M9 1171M023AC I C Ozone Fan Motor M8 Ozone Filter ...

Page 58: ...lled in the MP Cassette is spring loaded to push the paper stack upward When the cassette is slid into the copier the lever located on the bottom of the cassette and used to lock down the Paper Lifting Plate is pushed and unlocked allowing the Paper Lifting Plate to push the paper stack upward 14 PAPER TAKE UP FEED SECTION 14 1 MP Cassette Paper Lifting Plate 1167M055AA Paper Size Detecting Board ...

Page 59: ...n the rear of the cassette blocks the Cassette Set Sensor and the copier determines that the MP Cas sette has been slid into position 14 2 MP Cassette in Position Detection Electrical Component Control Signal Unblocked Blocked PC6 PJ13A 5B H L Cassette Set Sensor PC6 Light Blocking Plate 1167M052AB ...

Page 60: ... blinking A paper empty condition results when about 50 more sheets of paper are used after the near empty condition has been detected Paper Empty Detection A paper empty condition is detected as the paper is consumed and when the Empty Lever lowers to eventually block the sensor L At this time the MP Cassette Paper Empty LED lights up steadily 14 3 MP Cassette Paper Empty Detection Electrical Com...

Page 61: ...ngs are necessary for any paper size other than the following 14 4 MP Cassette Paper Size Detection Paper Size Detecting Switches PWB I Paper Size 1 2 3 4 ON OFF OFF OFF A3L 11 17 L OFF OFF OFF OFF B4L 8 1 2 14 L OFF ON ON ON A4L ON ON ON ON B5L 8 1 2 11 L ON ON OFF OFF A4C A5L ON OFF OFF ON B5C OFF ON OFF OFF A5C ON ON ON OFF 8 1 2 11 C Electrical Component Control Signal ON OFF PWB I 1 PJ14A 1B ...

Page 62: ...ed to the Manual Paper Feed Take Up Clutch and by energizing this clutch the Manual Feed Paper Take Up Roll is turned 14 5 Paper Take Up Mechanism 14 6 Manual Bypass Tray Electrical Component Control Signal ON OFF M2 PJ16A 1 L H SL1 PJ13A 13B L H CL3 PJ4A 9A L H 1167M054AB 1167M038AB Main Motor M2 Paper Take Up Roll Paper Take Up Clutch Paper Take Up Solenoid SL1 Paper Separator Pad 1167M067AC Mai...

Page 63: ... Solenoid is energized a second time if a sheet of paper fails to reach the Synchronizing Roller Sensor within a given period of time after the solenoid has been energized first A paper take up misfeed results if the sheet of paper does not reach the Synchronizing Roller Sensor even after two paper take up sequences Electrical Component Control Signal Unblocked Blocked PC8 PJ4A 7B H L 14 7 Paper T...

Page 64: ...y the drive from the Main Motor transmitted to the Synchronizing Clutch The rollers are started when the Synchronizing Clutch is deenergized 15 SYNCHRONIZING ROLLERS 15 1 Synchronizing Roller Drive Mechanism Control Electrical Component Control Signal ON OFF M2 PJ16A 1 L H CL1 PJ13A 2A L H 1171M029AA Synchronizing Roller Main Motor M2 Synchronizing Clutch CL1 Right Synchronizing Roller Left Synchr...

Page 65: ...g to the surface of the PC Drum As the roller turns in contact with the Paper Dust Remover triboelectric charging occurs which attracts paper dust from the paper that passes between the two rollers and the dust is in turn transferred onto the Paper Dust Remover 15 2 Paper Dust Remover 1171M026AB Paper Dust Remover Synchronizing Roller Synchronizing Roller Sensor PC2 ...

Page 66: ...o of the original To prevent toner from sticking to the Image Transfer Roller an image transfer voltage of 975V is applied to the roller for cleaning Paper Separation To neutralize any charge left on the paper to which the image has been transferred the High Voltage Unit applies a voltage of 1200V via a ground plate to the Charge Neutraliz ing Plate 16 IMAGE TRANSFER AND PAPER SEPARATION Electrica...

Page 67: ...to the I C mechanically separate paper from the surface of the PC Drum to ensure good and positive paper separation 17 PC DRUM PAPER SEPARATOR FINGERS 1171M014AA PC Drum Paper Separator Fingers PC Drum Protective Shutter PC Drum 1167M053AC 8 5cm Paper Path Center 8 5cm ...

Page 68: ...sidual toner off the surface The waste toner is conveyed by Spent Toner Feed Roller 1 and 2 to the Spent Toner Recycling Duct and eventually back to the Developer Mixing Chamber 18 PC DRUM CLEANING 1171M015AA Cleaning Blade PC Drum 1171M016AA Toner Conveying Rollers Recycling Duct Spent Toner Feed Roller 1 Spent Toner Feed Roller 2 Spent Toner Recycling Coil ...

Page 69: ...essure applied at this time fixes the image perma nently to the paper 19 FUSING UNIT 1 Paper Exit Roller 2 Fusing Misfeed Clearing Lever 3 Paper Exit Sensor PC3 4 Pressure Spring 5 Right Fusing Roller 6 Fusing Roller Heater Lamp H1 7 Left Fusing Roller 8 Fusing Roller Thermostat TS1 9 Fusing Paper Separator Finger 1167M078AB 1 2 3 4 5 6 7 8 9 ...

Page 70: ...each other at all times and they are released only when servicing the copier or replacing parts The pressure between the two rollers is approx 12 kg The rollers can be released by moving the Fusing Misfeed Clearing Lever in the direction of the arrow 19 1 Drive Mechanism Electrical Component Control Signal ON OFF M2 PJ16A 1 L H 19 2 Fusing Rollers Pressure Mechanism 1167M057AB Right Fusing Roller ...

Page 71: ...rol the fusing temperature 19 3 Fusing Temperature Control Electrical Component Control Signal ON OFF H1 PJ16A 8 L H Electrical Component Control Signal Low Temp High Temp TH1 PJ16A 5 Analog input 1171M031AB 200 185 Warm Up Completed 200 C Approx 1 min Mode 1 Mode 2 Mode 3 Temperature Control During Standby State Approx 5 min 1171M030AB 200 190 Temperature Control During a Copy Cycle 210 175 Speci...

Page 72: ...heets of small size paper that are fed through is counted Timing The counter reaches 30 The plain special paper counter reaches N specified below If the control is in mode 1 or mode 2 when the counter starts counting N 30 If the control is in mode 3 when the counter starts counting N 100 Resetting If a period of 2 min or more elapses during which the counter does not count up after the counter has...

Page 73: ...e Neutralizing Brush touches the surface of the sheet of paper being fed out of the Fusing Unit to neutralize any static charge left on it This effectively prevents two sheets of paper fed out of the copier from sticking to each other due to static charge 20 PAPER EXIT UNIT Charge Neutralizing Brush Paper Exit Roller 1167M061AC ...

Page 74: ... motor also draws the paper after it has been separated from the PC Drum onto the transport guide to ensure that it is stably and smoothly fed into the Fusing Unit 21 FUSING COOLING FAN MOTOR Electrical Component Control Signal During Copy Cycle In Standby During Warm Up Full speed Half speed Stop M3 PJ13A 3A Pulse output L 1171M022AC Fusing Unit Fusing Cooling Fan Motor M3 I C ...

Page 75: ...Unit and the Polygon Motor in the PH from rising inordinately 22 POWER UNIT COOLING FAN MOTOR Electrical Component Control Signal While Main Motor is Turning In Standby Full speed Half speed M4 PJ6A 2 DC24V DC10V 1171M034AA Power Unit Cooling Fan Motor M4 Master Board PWB A Power Supply Unit 1 PU1 ...

Page 76: ...SWITCHES ON PWBs TECH REP SETTINGS 17196 D 2500iD ...

Page 77: ...ice Function Tree S 10 4 4 Settings in the User s Choice Mode S 11 5 TECH REP MODE S 16 5 1 Tech Rep Mode Menu Screen S 16 5 2 Tech Rep Mode Function Setting Procedure S 16 5 3 Tech Rep Mode Setting Tree S 17 5 4 Settings in the Tech Rep Mode S 18 1 Tech Rep Choice S 18 2 System Input S 22 3 Administrator Input S 23 4 Counter S 23 5 Function S 28 6 I O Check S 29 7 Movement Check S 30 8 RD Mode SM...

Page 78: ...not touch the parts and printed patterns on the PWBs with bare hands Whenever replacing the PWB make sure that the power cord of the copier has been unplugged When the power is on the connectors should never be plugged in or unplugged Use care not to strap the pins of an IC with a metal tool When touching the PWB wear a wrist strap and connect its cord to a securely grounded place whenever possibl...

Page 79: ...t mode 6 Display Contrast Knob Turn to vary the brightness of the Touch Panel 7 Panel Reset Key Clears all settings made on the control panel setting the copier back into the ini tial mode Cancels currently reserved jobs It does not clear the zoom ratios and job settings stored in memory and Interrupt mode 8 Clear Key Clears the number of copies setting zoom ratio and counter count Cancels the ima...

Page 80: ...opy or Basics 2 Message Display Shows the current copier status operat ing instructions caution warning mes sages and other data including the number of copies selected 3 Basic Function Keys Allows the user to select the finishing zoom ratio and copy paper 4 Function Display Shows graphic representations of the set tings currently made for Orig Copy and Finishing 5 Status Display Shows what is bei...

Page 81: ...ble occurs which can be corrected by the user Example Paper misfeed toner empty door open Warning Display A warning display is given when any fur ther copier operation will not be possible or only a defective copy will be produced because of erroneous or illegal panel set tings or other cause Example Unmatched paper size in Auto Paper Caution Display A caution display is given when though further ...

Page 82: ...TION OF SWITCHES AND OTHER PARTS ON PWBs 3 1 PWB Location 3 2 PWB A Master Board Symbol Name Description S1 Test Print Switch Used to run a test print cycle 1171S004AA PWB A UN1 UN2 PWB L S1 1167S002AA 1167S002AA ...

Page 83: ...ame Description S1 Low Speed Mode Selecting Switch Used to make longer the paper to paper intervals as a means of preventing the problem in which sheets of paper are fed out untidily when large size paper left to stand under high humidity condition is being used Keep this switch in the H position as it is only for special users 1167S018AA SW37 1167S018AA 1167S026AB SW1 SW1 H L 1167S026AB ...

Page 84: ...re not to close any other circuit 4 When the initial screen appears turn the Power Switch OFF 5 Open U6 NOTE When Forced RAM Clear has been performed make these adjustments and settings once again in this order 1 Marketing Area of Initial mode 2 Memory Clear of Initial mode 3 Other adjustments and settings as necessary 3 5 UN2 MFB Board Symbol Name Description U6 Forced Memory Clear Used when it i...

Page 85: ...ns Cleared Power Switch OFF ON Side Cover open close Initial Mode Forced RAM Clear Memory Clear Total Clear Trouble Reset Misfeed display Malfunction display other than Fusing Malfunction display all including Fusing Erratic operation display User s Choice Tech Rep Mode Counter RD Mode Security Mode Adjust Mode ...

Page 86: ...ired function from among 1 5 through 5 5 shown at the bottom of the Touch Panel 3 Select the function to be set and make settings as required 4 After the settings are complete touch the Enter key to validate the settings The function selected is highlighted Exiting the Mode Touch Exit on the screen to go back to the Basic screen 4 USER S CHOICE MODE 4 1 User s Choice Selection Screen 4 2 User s Ch...

Page 87: ...al Copy Default Auto Paper Auto Size Tray Priority Special Paper 2 4 in 1 Booklet Copy Zoom Auto Panel Reset Energy Save Mode Plug In Counter ID Key Reset Auto Shutt Off LCD Back light Off 4 in 1 Copy Order Density Priority Default Level Copy Print Exposure Output Priority Intelligent Sorting Output Tray Small ID Original Scanner Dry ...

Page 88: ...r to recall the same image data Mixed Original Detection Select whether to let the system select by default ON the Mixed Original Detection mode or not OFF when power is turned ON or the Panel Reset key pressed Language Selected Select the language of the Touch Panel messages Highlighted ON OFF ON OFF Metric Areas Inch Areas GERMAN FRENCH FRENCH SPANISH DUTCH ITALIAN SPANISH JAPANESE PORTUGUESE DA...

Page 89: ...ically Manual Bypass Tray is not selectable Special Paper Set up a drawer for special paper loading 2 4 in 1 Booklet Copy Zoom Select whether to enable ON or disable OFF recalling a default zoom ratio for 2in1 4in1 or Booklet Creation The default zoom ratios are as follows when ON has been selected Highlighted 1 Sided 2 Sided 1 Sided 2 Sided 1 Sided 2 Sided 2 Sided 2 Sided 2 Sided 2 Sided 1 Sided ...

Page 90: ...unplugged Auto Shut Off Select whether to turn ON or OFF the Auto Shut Off function that shuts down the copier a given period of time after a copy cycle has been completed or the last key operated Selecting ON means set ting the time it takes the Auto Shut Off function to be activated that can range from 15 min to 240 min The option of No Reset becomes available on the screen if Yes is selected fo...

Page 91: ...he default exposure level in the Auto Exposure mode Manual Set the default exposure level in the Manual Exposure mode Auto Manual EXP 1 Lighter to EXP 9 Darker Print Exposure Set the image density level for printing Output Priority Select the default finishing type when the copier is equipped with a Sorter or Staple Sorter Highlighted 2 1 3 4 3 1 2 4 Manual Auto Photo Text Photo Text Lighter Darke...

Page 92: ...nisher the option of Copier and the tray designation keys 1 and 2 are not displayed Small ID Original Select whether to enable ON a copy cycle or not OFF when it is initiated with no original placed on the Original Glass or with an origi nal of a small size that is not detectable by the system smaller than A5 placed on the Original Glass Scanner Dry Set the time of day to run a Scanner drying cycl...

Page 93: ... the Utility menu screen press the following keys in this order 2 Select the particular Tech Rep mode function to be set 3 Make the necessary settings according to the function selected The function selected is highlighted Exiting the Mode Touch Exit on the screen to go back to the Basic screen 5 TECH REP MODE 5 1 Tech Rep Mode Menu Screen 5 2 Tech Rep Mode Function Setting Procedure Stop Key 0 0 ...

Page 94: ...n VG Adjust Original Stop Position Registration Loop Registration Zoom Adjust Paper Size Input Change Fixed Zoom Machine Configuration Technical Memo Permit Imaging Cartridge Original Size Detecting Option Paper Jam PM Trouble Device Maintenance ADF Paper Passage Scanner Exp Lamp Check Scan through ADF Scanner ADFR Output Option Printer F1 Paper Passage F2 HV Output Setting F7 1 Original Size Dete...

Page 95: ...e detected FLS Paper Set the size for FLS Simplex Duplex Select whether or not to enable the setting of 1 Sided 1 Sided under Original Copy Default available from User s Choice If Simplex Duplex is selected 1 Sided 1 Sided becomes available as an option Highlighted The measurement is rounded to the nearest standard inch or metric size Metric The measurement is rounded to the nearest standard metri...

Page 96: ...case by case basis Touching the key on the System Set menu selects or cancels this function Touch Panel Display Setting The default is Edge Erase Set the erase width on the leading trailing right and left edge of the image Loop Adjustment Set the loop length to be formed before the Synchronizing Rollers Highlighted Scanner Scanner Drum Disable ON Enables the functions other than Orig Copy and Auxi...

Page 97: ...a voltage value using the following equation ATDC Sensor Gain 5 1 2 2 setting value 256 V VG Adjust Set VG when a fog or void occurs in the image Touch Panel Display Setting The default is Original Stop Position Set the document stop position in each of the ADFR modes The minimum setting value is 6 only for 2 Sided Set Registration Loop Set the loop length to be formed in the original before the R...

Page 98: ...om Adjust Adjust the scanning zoom ratio in the main and sub scanning direc tions of the ADF Touch Panel Display Setting The default is IR Erasure Width Set the forced erasure width along the four edges of the paper to erase shadows which are otherwise produced by the Original Scales Highlighted 127 dot 127 dot Smaller Greater 0 0 990 1 010 Smaller Greater 1 000 Highlighted 3mm Smaller Greater 0mm...

Page 99: ...ad has been selected enter the FD and CD size of the paper from the 10 Key Pad 3 Touch END to validate the paper size setting Change Fixed Zoom Change a fixed zoom ratio to a desired value in the range between 0 250 and 4 000 Procedure 1 Touch the key of the fixed zoom ratio to be changed 2 Press the Clear key to clear the setting and enter the new ratio from the 10 Key Pad 3 Touch Input to valida...

Page 100: ...leared and END Two or more counters can be selected Tech Rep Mode Counter 3 Administrator Input Touch Panel Display Operation Administrator Input Set the administrator number used to open the Admin Management screen of Utility from the 10 Key Pad 1 to 8 digits 0 to 99999999 4 Counter Touch Panel Display Operation Paper Shows the number of sheets of paper used by the size and type Each counter may ...

Page 101: ...ical Transport Separator Fusing Duplex Entrance Duplex Feed LCC Feed No of misfeeds that occurred at the Manual Bypass Tray No of misfeeds that occurred at the paper take up transport section of the copier No of misfeeds that occurred at the paper separator section of the copier No of misfeeds that occurred at the Fusing Unit of the copier No of misfeeds that occurred at the turnover storage secti...

Page 102: ... of misfeeds that occurred at the document turnover and exit sections of the ADFR No of misfeeds that occurred at the SADF Display Description Printer Engine No of misfeeds that occurred due to illegal designation of FCU2 No of misfeeds that occurred due to communication error with engine VD fault Display Description I C Life Fusing Unit 1st Drawer 2nd Drawer 3rd Drawer 4th Drawer 5th Drawer No of...

Page 103: ...original with B W 5 Malfunction Code Location Malfunction Code Location C0000 C0010 C0045 C004C Main Motor I C Motor Cooling Fan Ventilation Fan C004E C0070 C0500 C0510 Cooling Fan Power Supply Toner Bottle Motor Fusing Warming up Fuser Low Temperature Malfunction Code Location Malfunction Code Location C0520 C0650 C0651 C0990 Fuser High Temperature Home Sensor Left Sensor LCC Transport Motor C099...

Page 104: ...ears in the Status Display When Call Indicated is selected for Maintenance Call available from Tech Rep Choice Setting a Count 1 Touch Maintenance Set and then press the Clear key to clear the count If the count is accidentally cleared pressing the inter rupt key will undo the clear operation 2 Enter the desired value from the 10 Key Pad Clearing a Count Touch Maintenance Count and then press the ...

Page 105: ...ess of the Start key will resume the test cycle F2 HV Output Setting Set the output of each HV This function is only for factory setting and should never be used in the field F7 1 Original Size Detecting Sensor Adjustment Automatically adjusts the Original Size Detecting Sensors Procedure 1 Stack five sheets of A3 or 11 17 paper on the Original Glass and lower the Original Cover 2 Press the Start ...

Page 106: ...m outputs a test pattern in the 2 sided mode Procedure 1 Touch the desired paper source key Touch Duplex for test pat tern output on paper fed from the Duplex Unit If the paper source is not loaded with paper an Add Paper mark appears at that source 2 Press the Start key to start the output sequence It continues until the paper source runs out of paper 3 Press the Stop key to halt the sequence 6 I...

Page 107: ...sage 2 Touch the desired mode key 3 Load originals in the ADF 4 Press the Start key to let the ADF start feeding originals Pressing of the Start key temporarily stops the ADF Another press will let the ADF resume the sequence The sequence is completed when there is no more originals in the ADF however it is possible to halt the sequence in mid operation by pressing the Stop key Scanner Drives the ...

Page 108: ...erminal 000000 is invalid TEL No Enter the 19 or less digit phone number of the modem connected to the Center personal computer from the 10 Key Pad In addition to the 10 Key Pad and Clear key use the following keys to enter the phone number Interrupt key For a pause 3 sec or more Pause key For a pause 3 sec or more P key For a pulse dialing P T key For a tone dialing T W key For a wait code waitin...

Page 109: ... the following functions Dial Mode Select the type of telephone line of the user Auto Receive Choose Yes or No for the auto reception function Select Yes if the line is dedicated to the Data Terminal Result Code Enter the result code for connection to the modem when the line is connected 0 to 999 Highlighted YES NO Pulse Tone NO YES ...

Page 110: ...r a machine that is not con nected to the system Procedure 1 Touch ROM Version to open the ROM Version screen 2 The screen shows the ROM version information of various machines configured in the system Display Description MSC MFB Board Message IC4 MFB Board Printer IC1 Master Board ADFR IC3 ADFR Board LCC IC7 LCC Board Finisher IC3 Finisher Job Tray Board IIF IIF2 Board ...

Page 111: ...a is updated when the ATDC Sensor Auto matic Adjustment F8 is completed ATDC Current Shows the current approximate ATDC Sensor T C setting in percent age Vg Current Displays the grid voltage as corrected through image stabilization and related functions Vb Current Displays the developing bias voltage as corrected through image sta bilization and related function Variable Range Increments 123 to 18...

Page 112: ... this order 3 Select the particular Security mode to be set 4 Make the necessary settings by following the instructions given sequentially on the screen The Function selected is highlighted Exiting the Mode Perform any one of the following steps to go back to the Basic screen Press the Panel Reset key and Touch Exit on the Tech Rep Mode screen Touch END on the Security Mode screen Then touch Exit ...

Page 113: ...opy Kit Counter Whether the initiation of a new copy cycle is inhibited or not when the current value exceeds the setting value depends on the setting made with Copy Kit Counter Counter Setting Procedure 1 Touch Set and press the Clear key to clear the current setting If the setting is accidentally cleared pressing of the Interrupt key will undo the clear operation 2 Enter the desired value from t...

Page 114: ...tion by which the Key Counter count is increased See the Count up Table for details Key Counter Set whether a Key Counter is plugged in ON or not OFF Vender Mode Select the medium to be used when the Key Counter or Vender is used This function is not valid if OFF is selected for Key Counter Highlighted No counting Mode 2 Counted and permits copying even when the Set value is reached Mode 3 Counted...

Page 115: ...han those set Set size Total Mode Mode Mode Mode 1 2 3 1 2 3 1 2 3 1 2 3 Total mechanical elec tronic 1 1 2 2 2 2 4 4 Size electronic 0 1 1 2 0 2 2 0 2 Sided Total electronic 0 0 1 1 2 1 1 4 2 Sided Size electronic 0 0 0 1 1 4 Total by account 1 1 2 2 2 2 4 4 Size by account 0 1 1 2 0 2 2 4 Key mechani cal Counting copies 1 1 2 2 1 2 2 1 4 4 Counting copy cycles 1 1 2 2 2 2 4 4 ...

Page 116: ...ing the following keys in this order 3 Select the particular Adjust mode function to be set 4 Make the necessary settings by following the instructions given sequentially on the screen The function selected is highlighted Exiting the Mode Perform any one of the following steps to go back to the Basic screen Press the Panel Reset key and Touch Exit on the Tech Rep Mode screen Touch END on the Adjus...

Page 117: ...lay Setting The default is Registration CD Adjust registration of the printer in the main scanning direction Adjust Duplex after adjustments have been completed for all drawers Registration FD Adjust registration of the printer in the sub scanning direction Adjust Printer IR Registration CD Registration FD Registration Zoom Adjust Highlighted 1st Drawer 4 0mm 4 0mm 2nd Drawer 3rd Drawer 4th Drawer...

Page 118: ...ired subfunction Tech Rep Mode Adjust 2 IR Touch Panel Display Setting The default is Registration Adjust registration of the Scanner in the main and sub scanning direc tions Zoom Adjust Adjust the scanning zoom ratio of the Scanner in the main and sub scanning directions Highlighted 127 dot 127 dot Smaller Greater 0 0 990 1 010 Smaller Greater 1 000 ...

Page 119: ...ngs by following the instructions given sequentially on the screen The function selected is highlighted Exiting the Mode Touch Exit on the Initial mode screen to go back to the Basic screen 8 INITIAL MODE 8 1 Initial Mode Menu Screen 8 2 Initial Mode Function Setting Procedure Warm Restart Switch ON Enter 3 from the 10 Key Pad when appears at the center on the left side of the screen while the sta...

Page 120: ... Track related data Marketing Area Selects the settings for the fixed zoom ratios paper sizes and others according to the marketing area Image Data Clear Clears the image data stored in file memory of the MFB Board FAX Set Clear Clears the fax related settings Two or more items can be selected Date Time Set Sets the time of day and date Trouble Reset Resets all malfunctions including the Fusing on...

Page 121: ...DIS REASSEMBLY ADJUSTMENT 18605 D 2500iD ...

Page 122: ...TICAL SECTION D 12 1 Removal of the IR Unit D 12 2 Removal of the PH Unit D 13 3 Removal of the CCD Unit D 15 4 Cleaning of the Scanner Rails Bushings D 15 5 Cleaning of the Mirrors D 16 6 Cleaning of the Lens D 16 7 Cleaning of the Original Glass D 16 8 Removal of the Scanner D 16 9 Removal of the Scanner Drive Cables D 18 10 Winding of the Scanner Drive Cables D 19 2 5 IMAGE TRANSFER SECTION D 2...

Page 123: ... 33 3 Loop Adjustment D 34 4 Edge Erase D 35 5 Registration CD Printer D 38 6 Registration FD Printer D 40 7 Registration IR D 42 8 Zoom Adjust IR D 46 9 IR Erasure Width D 50 3 6 OTHER ADJUSTMENTS D 51 4 MISCELLANEOUS D 53 4 1 INSTALLATION OF THE KEY COUNTER SOCKET OPTION D 53 4 2 REMOUNTING THE EEPROM IC3A D 54 ...

Page 124: ...t into the laser beam path Use utmost care when handling tools on the user s premises The printerhead is not maintainable in the field It is to be replaced as an assembly including the control board Never therefore attempt to remove the laser diode or adjust trimmers on the control board 1 SERVICE INSTRUCTIONS 1 1 IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS 1 2 PRECAUTIONS FOR HANDLING THE LASER ...

Page 125: ...on Avoid checking the IC directly with a multimeter use connectors on the Board Never create a closed circuit across IC pins with a metal tool When it is absolutely necessary to touch the ICs and other electrical components on the PW Board be sure to ground your body During Transportation Storage Use the specified carton whenever moving or storing the Imaging Cartridge The storage temperature is i...

Page 126: ...are used on the part in questions only one representa tive screw may be marked with red paint Do not turn the variable resistors on boards for which no adjusting instructions are given in ADJUSTMENT Although not marked with red paint the following screws must not be loosened or read justed 8 screws on the PH Unit Cover 1 5 PARTS WHICH MUST NOT BE TOUCHED 1 Red painted Screws 2 Variable Resistors o...

Page 127: ...DISASSEMBLY REASSEMBLY 2 1 DOORS COVERS AND EXTERIOR PARTS IDENTIFICATION AND REMOVAL PROCEDURES 1171D017AA 1171D019AB 12 13 14 15 1 2 3 4 5 11 16 17 6 7 8 9 10 18 19 20 21 22 23 24 25 26 27 28 29 30 32 33 31 ...

Page 128: ...e Pushing the tab on the right rail pull out the cassette 11 500 Sheet Cassette Slide out the 500 Sheet Cassette Pushing the tabs on both the right and left rails pull out the cassette 12 Upper Front Left Cover Remove No 4 Remove two screws that secure the Upper Front Left Cover 13 Left Cover Remove six screws that secure the Left Cover 14 Upper Cover Remove two screws that secure the Upper Cover ...

Page 129: ...wer Cover 28 500 Sheet Cas sette Side Cover Open the Side Cover Slide the Side Cover to the front and at the same time pull the rear side out of the frame 29 Manual Bypass Tray Remove No 26 Unplug one connector Remove three screws that secure the Manual Bypass Tray 30 Side Cover 31 Fusing Unit See D 26 32 Front Inside Cover Remove No 8 Remove No 31 Remove two screws that secure the Front Inside Co...

Page 130: ...s given in the following omit the removal of connectors and screws securing the circuit board support or circuit board Where it is absolutely necessary to touch the ICs and other electrical components on the board be sure to ground your body 2 2 REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPOMENTS BCR 1167D146CA INV PWB R PU2 HGB UN1 PWB L PWB I PWB A PU1 PWB R PWB R PWB H UN3 UN2 PWB A PWB N...

Page 131: ...Unit Remove two screws and two ground plates PWB R PWB R Pre Transfer Guide Plate Register Board 2 Open the Side Cover Remove the Imaging Car tridge Remove one screw and the PW Board Cover PWB R PU1 Power Supply Board 1 Remove the Harness Cover Remove the Rear Cover Remove the Left Cover Remove five screws and the Reinforcement Bracket Remove three screws and the PU1 Mounting Bracket Assy PU1 PU2 ...

Page 132: ...D 9 Symbol Part Name Removal Procedure UN2 MFB Board Remove the Upper Cover Remove nine screws and the MFB Box Cover UN2 UN3 Polygon Motor Drive Board Remove the PH Unit UN3 ...

Page 133: ...Lock the Paper Lifting Plate 3 Snap off one C clip of the Paper Take Up Roll Assy 4 Slide the Paper Take Up Roll Assy to the rear so that it can be pulled off the bushing at the front 1167D140AA 5 Snap off one C clip and remove and replace the Paper Take Up Roll 4108D035AA 1 Open the Side Cover 1171D021AA 2 Remove the Paper Dust Remover and replace it 1167D007AB ...

Page 134: ...leaning of the Side Cover 1 Open the Side Cover 1171D021AA 2 Remove the Paper Dust Remover 1167D007AB 3 Using a brush whisk dust and dirt off the Paper Dust Remover 1167D008AB Using a soft cloth dampened with alcohol wipe the Side Cover 1171D052AB ...

Page 135: ... Cover and Front Inside Cover 2 4 OPTICAL SECTION 1 Removal of the IR Unit 2 Remove one screw and the Motor Cover 1171D054AA 3 Remove the Shielding Plate U S A and Canada only 4 Remove one screw and the Harness Cover 1167D149DA 5 Unplug eight connectors of the HGB Board 1167D027AC 6 Remove three screws and the Harness Cover 7 Unplug one connector of the BCR Board 1167D032AC ...

Page 136: ...he PH Unit 8 Remove one screw and the Total Counter Mount ing Bracket Assy 9 Unplug one connector of the Control Panel 10 Remove two screws that secure the front end of the frame 1167D033AC 11 Remove five screws that secure the rear end of the frame 1167D059AC 12 Raise the rear end of the IR Unit and pull the unit out toward front 1171D053AA 1 Remove the Upper Cover Front Cover Left Cover and Rear...

Page 137: ... screws and the Reinforcement Bracket 6 Remove four screws and the handle 1167D062AC 7 Unplug all connectors 13 from Master Board PWB A 1167D029AC 8 Remove the harness from all cord clamps 12 on the PH Base Plate 1167D030AB 9 Remove four screws and the PH Unit 1167D012AA ...

Page 138: ...ove the CCD Unit as one unit 2 Whenever the CCD Unit has been replaced make the following adjustment FD of Zoom Adjust IR 3 Removal of the CCD Unit 4 Cleaning of the Scanner Rails Bushings 1 Remove the Original Glass 2 Remove four screws and the Cover 1167D014AB 1171D055AA 1 Remove the Original Glass 2 Using a soft cloth wipe clean the Scanner Rails and Bushings 1167D016AB ...

Page 139: ...leaning of the Original Glass 8 Removal of the Scanner 1 Remove the Original Glass 2 Wipe clean the Mirrors with a soft cloth 1167D017AC 1 Remove the CCD Unit 2 Wipe clean the Lens with a soft cloth 1167D018AB Wipe clean the Original Glass with a soft cloth 1171D050AA 3 Slide the Scanner to the position shown 1167D039AC ...

Page 140: ...the Exposure Lamp 5 Remove the flat cable of the Exposure Lamp 1167D037AC 6 Remove one screw and the Lamp Fixing Bracket 1167D035AD 7 Slide the Exposure Lamp to the front and remove it 1167D036AA Rear Front 8 Remove two screws and the Scanner 1167D049AB ...

Page 141: ...ng of the cable on the hook side one each at the front and in the rear 1167D044AB 5 Remove one screw and the Original Size Detection Sensor Inch Areas Option 1167D070AA 6 Snap off one E ring and remove one mounting screw from the front pulley and slide the pulley to the rear 1167D071AA 7 Snap off one E ring and remove one mounting screw from the rear pulley and slide the pulley to the front 1167D0...

Page 142: ...e in the pulley as shown Front 1167D051AC 2 Wind the hook end of the Scanner Drive Cable two turns counterclockwise from the rear side to the front 1167D052AD Cable on Hook End 3 Wind the bead end of the cable four turns clock wise from the front to the rear Then secure the cable with tape NOTE Make sure that no part of the cable rides on the other 1167D053AD Cable on Bead End ...

Page 143: ...hook the bead onto the Adjust able Anchor 1167D056AC Pulley D Pulley C 6 Wind the hook end of the cable around pulley A and pulley B 1167D057AC Pulley B Pulley A 7 Fit the hook end of the cable into the groove in the Cable Guide and hook the spring 1167D074AA Cable Guide 8 Position the round bead of the Scanner Drive Cable in the pulley as shown Rear 1167D051AC ...

Page 144: ...ble with tape NOTE Make sure that no part of the cable rides on the other 1167D055AD Cable on Bead End 11 Slide the pulley toward the rear and install one mounting screw and one E ring 1167D075AA 12 Wind the bead end of the cable around pulley H and pulley G and hook the bead onto the Adjust able Anchor 1167D076AA Pulley H Pulley G 13 Wind the hook end of the cable around pulley E and pulley F 116...

Page 145: ...l the Original Glass and ADF Glass Assy 20 Perform the Focus Positioning of the Scanner and 2nd 3rd Mirrors Carriage For details see ADJUSTMENT NOTE Whenever the Scanner Drive Cables have been removed be sure to make the following adjustment CD of Zoom Adjust IR 14 Fit the hook end of the cable into the groove in the Cable Guide and hook the spring 1167D077AA Cable Guide ...

Page 146: ...Pre Image Transfer Guide Plate 1 Open the Side Cover 1167D006AD 2 Raise the Image Transfer Guide Plate 1167D061AA 3 Remove the Image Transfer Roller and replace it NOTE Do not touch the surface of the Image Transfer Roller directly with bare hands 4108D027AA 1 Open the Side Cover 1171D021AA ...

Page 147: ...D 24 2 Using a soft cloth dampened with alcohol wipe the Pre Image Transfer Guide Plate NOTE Make sure the alcohol does not touch the surface of the Image Transfer Roller 1167D010AA ...

Page 148: ...he Imaging Cartridge part of the way out 3 Then grasp the handle on top of the cartridge and pull the cartridge out NOTE When installing the Imaging Cartridge push it all the way into the machine If the cartridge is not properly installed the PC Drum protective shutter of the cartridge may not be opened or may even be damaged 1171D023AA ...

Page 149: ...ller Thermostat and Fusing Roller Heater Lamp Fuse 1 Open the Side Cover 1171D021AA 2 Remove the Front Cover 3 Unplug one connector at the front 1167D020AB 4 Open the Exit Cover and unplug two connectors in the rear 5 Close the Exit Cover and remove two screws and the Fusing Unit 1167D021AB 1 Open the Exit Cover 2 Remove one screw and the Fusing Front Cover 1171D036AA ...

Page 150: ...move two harnesses 6 Remove two screws and the Rear Cover 1171D038AA 7 Remove two screws and the rear Lamp Holder 1171D040AA 8 Remove one screw and the front Lamp Holder 9 Remove the Fusing Roller Heater Lamp 1171D042AA 10 Remove two screws and the Fusing Rear Guide Assy 11 Remove two pressure springs 1171D043AA ...

Page 151: ... Left Roller 1171D045AA NOTE When the Fusing Left Roller is removed it can cause the spring to come off the Separator Finger After the Fusing Left Roller has later been reinstalled be sure to hook the spring onto the Separator Finger 1171D046AA 17 Remove one screw and the Fusing Roller Ther mistor 18 Remove two screws and the Fusing Roller Heater Lamp Fuse 19 Remove two screws and the Fusing Rolle...

Page 152: ... Ref Page Touch Panel Adj Automatically adjusted Control Panel D 32 Original Size Detecting Sensor Adjustment D 33 Loop Adjustment D 34 Edge Erase Leading D 35 Trailing D 36 Right Left D 37 Registration CD Printer 10 2 0 mm D 38 Registration FD Printer D 40 Registration IR CD D 42 FD D 44 Zoom Adjust IR CD 200 1 0 mm D 46 FD 300 1 5 mm D 48 IR Erasure Width D 50 1167D108AA ...

Page 153: ...nd the Cover 1167D014AB 3 Loosen the two screws that secure the Scanner Motor Using a bar tension gage pull the motor to the right with a tension of 1000 g 50 g and at the same time tighten the mounting screws NOTE After the adjustment turn the timing belt to check that the belt teeth are in mesh with the pulley grooves 1167D109AB ...

Page 154: ... Zoom Adjust IR Adjustment Procedure 3 4 TEST PRINT 1 Check that Copy Track Mode of Copy Track under Admin Management available from Utility is OFF 1171D026CA 2 Select the paper source for the test print 1171D027CA 3 Press the Utility key on the control panel and touch User Management 1171D028CA 4 Touch Test Print to produce a test pattern 1171D029CA ...

Page 155: ...reen For details see SWITCHES ON PWBs TECH REP SETTINGS 2 Touch Touch Panel Adj 3 Touch on screen 1 NOTE At this time ensure that the very center of is touched using the tip of a ballpoint pen or similar device 4 Touch on screen 2 5 Touch on screen 3 6 Touch on screen 4 3 5 ELECTRICAL IMAGE ADJUSTMENT 1 Touch Panel Adj Initial Screen 1171D057CA 1171D058CA 1171D059CA 4 1 2 3 1171D056CA ...

Page 156: ... to the screen 3 Touch Function to call the Function menu 4 Touch F7 1 Original Size Detecting Sensor Adjustment 5 Press the Start key to run the Original Size Detecting Sensor Adjustment function NOTE The Start key remains lit up orange while this function is being run and lights up green as soon as the sequence is completed 2 Original Size Detecting Sensor Adjustment F7 1 1 Stack five sheets of ...

Page 157: ...lear the current setting 6 Enter the new setting value from the 10 Key Pad Setting Instructions Change the setting value as necessary until there are no variations in the amount of void image along the leading edge skewed feeding dog ear or misfeed 7 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key...

Page 158: ... the 10 Key Pad Setting Instructions To make the edge erase width smaller decrease the setting value To make the edge erase width greater increase the setting value 6 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key is used the previous setting remains valid 4 Edge Erase Adjust so that the erase wi...

Page 159: ...ue from the 10 Key Pad Setting Instructions To make the edge erase width smaller decrease the setting value To make the edge erase width greater increase the setting value 6 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key is used the previous setting remains valid Adjust so that the erase width on...

Page 160: ...e from the 10 Key Pad Setting Instructions To make the edge erase width smaller decrease the setting value To make the edge erase width greater increase the setting value 6 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key is used the previous setting remains valid Adjust so that the erase width on ...

Page 161: ...he test pattern meets the specifications 2 Sided Using the test pattern output as the original make an ordinary 2 sided copy Check to see if width A on the second side of the 2 sided copy meets the specifications If width A falls outside the specified range perform these steps to make the adjustment 5 Registration CD Printer Specification Adjust Mode Setting Range 1 Sided 10 2 0 mm 2 Sided 10 3 0 ...

Page 162: ...r than specifications make the setting value greater than the current one If a single adjustment procedure does not successfully bring width A into the specified range try another setting value 8 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key is used the previous setting remains valid 9 Perform t...

Page 163: ...r details see 3 4 TEST PRINT 2 Check to see if width A on the test pattern meets the specifications If width A falls outside the specified range perform these steps to make the adjustment 6 Registration FD Printer Specification Adjust Mode Setting Range 10 2 0 mm Registration FD 26 to 26 Adjust so that width A on the test pattern output falls within the following range 1171D007AA A ...

Page 164: ...urrent one If width A is narrower than specifications make the setting value greater than the current one If a single adjustment procedure does not successfully bring width A into the specified range try another setting value 8 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key is used the previous s...

Page 165: ...ace the test pattern output on the Original Glass and make a copy of it 3 Check to see if width A on the test pattern copy meets the specifications If width A falls outside the specified range perform these steps to make the adjustment 7 Registration IR Specification Adjust Mode Setting Range 10 2 0 mm Registration CD 127 to 127 Place the test pattern output after the adjustments of Registration C...

Page 166: ...han specifications make the setting value greater than the current one If a single adjustment procedure does not successfully bring width A into the specified range try another setting value 8 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key is used the previous setting remains valid Setting Value ...

Page 167: ...RINT 2 Place the test pattern output on the Original Glass and make a copy of it 3 Check to see if width A on the test pattern copy meets the specifications If width A falls outside the specified range perform these steps to make the adjustment Specification Adjust Mode Setting Range 10 2 0 mm Registration FD 127 to 127 Place the test pattern output after the adjustments of Registration CD and FD ...

Page 168: ...han specifications make the setting value greater than the current one If a single adjustment procedure does not successfully bring width A into the specified range try another setting value 8 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key is used the previous setting remains valid Setting Value ...

Page 169: ...IR Zoom Ratio Specification Adjust Mode Setting Range Full size 1 000 300 3 0 mm Zoom Adjust CD 0 990 to 1 010 1 Place a scale in parallel with the Original Width Scale and make a copy Note that the scale is per pendicular to the Original Length Scale Use the full size 1 000 mode and A3 or 11 17 paper If the scale is of plastic and transparent place a blank sheet of paper over it 1167D111AA 2 Meas...

Page 170: ...etting value If the scale on the copy is shorter than the actual scale increase the setting value If the measurement does not fall within the specifications through one setting try another setting 7 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key is used the previous setting remains valid 1171D035...

Page 171: ... Procedure Zoom Ratio Specification Adjust Mode Setting Range Full size 1 000 200 2 0 mm Zoom Adjust FD 0 990 to 1 010 1 Place a scale in parallel with the Original Length Scale and make a copy Use the full size X1 000 mode and paper with a width of 200 mm or more If the scale is of plastic and transparent place a blank sheet of paper over it 1167D112AA 2 Measure the length of the scale on the cop...

Page 172: ...etting value If the scale on the copy is shorter than the actual scale increase the setting value If the measurement does not fall within the specifications through one setting try another setting 7 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operating mode If the Panel Reset Key is used the previous setting remains valid 1171D035...

Page 173: ...es of the paper smaller decrease the setting value To make the erase width along four edges of the paper greater increase the setting value 6 Touch the END key to validate the setting value Caution Be sure to touch the END key before returning to normal operation mode If the Panel Reset Key is used the previous setting remains valid 9 IR Erasure Width Set so that the erase width along four edges o...

Page 174: ...between the Scanner Mirrors Carriage Positioning Jig and the 2nd 3rd Mirrors Carriage Adjustment Procedure 3 6 OTHER ADJUSTMENTS 1 Remove the Exposure Lamp For details see steps 1 through 7 8 Removal of the Scanner 2 4 OPTICAL SECTION 2 Temporarily loosen the set screws of the cable holding plate of the Scanner Drive Cable 1167D113AA 3 Fit the Scanner Mirrors Carriage Positioning Jigs in the space...

Page 175: ... Adjusting Screw 1 Temporarily loosen the set screws of the cable holding plate of the Scanner Drive Cable 1167D113AA 2 Obtain a distance of 13 mm between the 2nd 3rd Mirrors Carriage and rail 1167D117AC 13 mm 3 Secure the Scanner where it is located at a posi tion 21 mm from the right side face 4 Tighten the set screws of the cable holding plate 1167D118AC 21 mm NOTE If the Scanner does not run p...

Page 176: ...Counter Mounting Bracket 1167D022AB 4 Route the harness of the Key Counter as shown 1167D025AB 5 Connect the Key Counter Socket connector 6 Using one screw and one screw and nut secure the counter socket 1167D023AB 7 Using two screws secure the Key Counter Cover NOTE When the Key Counter Socket is mounted set to ON the Key Counter available from the Security mode 1167D024AB ...

Page 177: ... one Because the EEPROM contains no data in this case make settings and readjustments as necessary 1 Remove the Master Board For details see 2 2 REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS 2 Demount the EEPROM IC3A from the new Master Board 3 Demount the EEPROM IC3A from the old Master Board and remount it onto the new Master Board 4 2 REMOUNTING THE EEPROM IC3A 1171D048AA New Master...

Page 178: ...TROUBLESHOOTING 14413 D 2500iD ...

Page 179: ...ke Up Misfeed AD 10 T 25 4 MALFUNCTION T 27 4 1 Detection Timing by Malfunction Code T 27 4 2 Troubleshooting Procedures by Malfunction Code T 30 1 C0000 M2 Malfunction C0010 M1 Malfunction C0045 M3 Malfunction C004C M8 Malfunction C004E M4 Malfunction C0070 M6 Malfunction T 30 2 C0500 Warming up Failure C0510 Abnormally Low Fusing Temperature C0520 Abnormally High Fusing Temperature T 33 3 C0650 ...

Page 180: ... 4 Foggy Background T 48 5 Black Streaks or Bands T 49 6 Black Spots T 49 7 Blank Streaks or Bands T 50 8 Void Areas T 50 9 Smear on Back T 51 10 Uneven Image Density T 51 11 Gradation Reproduction Failure T 51 12 Rough Image T 52 13 Periodically Uneven Image T 52 ...

Page 181: ... a motor is defective the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defective unit 2 All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions 3 For the removal procedures of covers and parts see DIS RE...

Page 182: ...n step 1 above See SWITCHES ON PWBs TECH REP MODE 3 Check the input port data to determine if a signal is probably input to the controlled part Controlled Part Check Procedure Through Checking Input Port Data Example When a paper misfeed occurs in the paper take up section of the copier Synchronizing Roller Sensor PC2 is considered to be responsible for it Procedure 1 Remove the sheet of paper mis...

Page 183: ... following screens are only typical and the input data shown does not necessarily represent the actual one IR Printer 2 2 I O Check List 1171T002CA 1171T030CA 1171T004CA Backup Next Backup Next 1171T006CA 1171T005CA Backup Next ...

Page 184: ...d IC1 PO3 PJ13A 2B PC4 Paper Empty Paper Empty Sensor Paper not present Paper present IC1 PO5 PJ14A 13A PWB I Size Detect Paper Size Detect ing Board Analog value IC1 P103 AN3 PJ14A 1B to PJ14A 4B S5 2nd Drawer Paper Near Empty Paper Near Empty Sensor Unblocked Blocked Cassette Main Board PWB A IC1 P12 PJ3A 11B S4 Paper Empty Paper Empty Sensor Paper not present Paper present IC1 P6 PJ3A 5B S2 Sid...

Page 185: ...r not present IC1 P5 PJ3A 2B S5 Paper Near Empty Paper Near Empty Sensor Unblocked Blocked IC1 P12 PJ3A 11B S4 Paper Empty Paper Empty Sensor Paper not present Paper present IC1 P6 PJ3A 5B S2 Side Cover Side Cover Set Sen sor When opened When closed IC1 P9 PJ3A 8B S1 Drawer Detect Cas sette Set Switch When PF 110 is used In position Out of position IC1 P10 PJ3A 9A When PF 108 is used In position 2...

Page 186: ...Sen sor Paper present Paper not present IC4 P24 INTP3 CN4A 11 PPS1 PPS1S Paper Empty Sen sor 1 Paper present Paper not present IC4 P25 INTP4 ASCK CN3A 2 RS1 Paper Near Empty 1 Paper Near Empty Sensor 1 Blocked Unblocked IC4 P75 ANI5 CN6A 1 RS2 Paper Near Empty 2 Paper Near Empty Sensor 2 Blocked Unblocked IC4 P76 ANI6 CN5A 5 PPS2 Paper Empty Paper Empty Sen sor 2 Paper present Paper not present IC...

Page 187: ... played IC1 P06 PJ11A 7B PC10 Toner Bottle Set Toner Bottle Home Position Sensor At home Not at home IC1 P40 PJ11A 2B PC2 Paper Pas sage Timing Roller Synchronizing Roller Sensor Paper present Paper not present IC1 P41 PJ13A 7A PC3 Exit Paper Exit Sensor Paper present Paper not present IC1 P77 PJ13A 12A M3 Drive Motor Detect Cool ing Fan Fusing Cooling Fan Motor LOCK When energized 1 and 0 alterna...

Page 188: ... transport 8 Finisher transport 1st Tray exit Elevator Tray exit 9 Mailbin transport 10 Finisher Tray 11 Separator Fusing Unit 3 12 Manual Bypass take up 2 13 Duplex turnover Duplex take up AD 10 6 14 1st Drawer take up 1 15 2nd Drawer transport 1 16 2nd Drawer take up 1 17 3rd Drawer transport PF 108 PF 110 PF 106 4 or 5 18 3rd Drawer take up PF 108 PF 110 PF 106 4 or 5 19 4th Drawer transport PF...

Page 189: ... and if it is intact replace the board Resetting the Display If the misfeed display is not reset by these procedures check the misfeed detecting sen sor at the paper location Misfeed in the copier Misfeed in the option Remove all sheets of paper misfed and left inside and then open and close the Side Cover Remove all sheets of paper misfed and left inside and then raise and lower or discon nect an...

Page 190: ... in the copier overview display In the above example there is a size error in the 2nd Drawer Resetting the Size Error Display Slide out the drawer then slide it back in or load paper in the Manual Bypass Tray Causes of a Size Error Wrong paper size settings have been made The user loads paper of a size different from what is set for the paper source Two or more sheets of paper are being taken up a...

Page 191: ...T 11 3 3 Misfeed Detection Sensor Layout Paper Exit Sensor PC3 1167T021AA Synchronizing Roller Sensor PC2 Manual Feed Paper Take Up Sensor PC8 ...

Page 192: ...olenoid SL1 has been energized for the second paper take up retry sequence 1 28 2nd Drawer paper take up PC2 is not unblocked H even after the lapse of T sec after SL1 has been energized for the first paper take up retry sequence 2 27 1st 2nd Drawer paper take up PC2 is unblocked H within T sec after SL1 has been energized 0 20 Type Detection Timing Timer Value T sec Bypass paper take up failure d...

Page 193: ...ased on the period of time between when Synchronizing Clutch CL1 is energized and when PC2 is blocked L the paper size detected is longer than the size data sent from the controller by 260 mm or more Size error detec tion The paper size detected based on the period of time between when CL1 is energized and when PC2 is blocked L is more than the size data sent from the controller by 20 mm or more P...

Page 194: ... 3 5 Misfeed Troubleshooting Procedures 1 Copier Take Up Misfeed Relevant Electrical Parts Paper Take Up Solenoid SL1 Synchronizing Roller Sensor PC2 Master Board PWB A Cassette Main Board PWB A 1171C10TAA ...

Page 195: ...ange from DC24V to DC0V when the Start key is pressed YES Check various parts for possi ble overload and if they are okay change SL1 NO Change PWB A 9 Is the Paper Separator Finger dirty or deformed YES Clean or change the Paper Separator Finger 10 Check CL2 for operation Does the voltage across CN9 1 on the PWB A side and GND change from DC24V to DC0V when the Start key is pressed NO Change PWB A...

Page 196: ...T 16 2 Manual Bypass Take Up Misfeed Relevant Electrical Parts Manual Feed Paper Take Up Clutch CL3 Synchronizing Roller Sensor PC2 Manual Feed Paper Take Up Sensor PC8 Master Board PWB A 1167C01TAA ...

Page 197: ... the Manual Feed Paper Take Up Roller or Roll 4 Is PC8 fully operational Check the input data using I O Check NO Check the PC8 actuator for operation and if it is intact change PC8 5 Check CL3 for operation Does the voltage across CN14 2 and GND change from DC24V to DC0V when the misfeed condition is reset YES Check various parts for possi ble overload and if they are okay change CL3 NO Change PWB...

Page 198: ...T 18 3 Separator Fusing Misfeed Relevant Electrical Parts Paper Exit Sensor PC3 Synchronizing Roller Sensor PC2 Synchronizing Clutch CL1 Master Board PWB A 1170C03TAB ...

Page 199: ...op near the PC Drum 1 Is the Pre Image Transfer Guide Plate dirty or deformed YES Clean or change the guide plate 2 Is the Image Transfer Roller deformed worn or dirty with paper dust YES Clean or change the Image Transfer Roller Paper is wedged at the PC Drum Paper Separator Fingers 1 Are the PC Drum Paper Sepa rator Fingers dirty or deformed YES Clean or change the separator fingers NO Check the...

Page 200: ...eed PF 108 PF 110 Relevant Electrical Parts Paper Take Up Solenoid SL1 Take Up Sensor S3 Synchronizing Roller Sensor PC2 Transport Clutch CL2 Master Board PWB A Cassette Main Board PWB A Cassette Main Board PWB A PF 108 PF 110 1171C11TAA ...

Page 201: ... Start key is pressed YES Check various parts for possible overload and if they are okay change SL1 or CL2 NO Change PWB A PF 108 PF 110 PWB A Cassette Main Board or PWB A in that order Paper is at a stop at the verti cal transport section Paper is at a stop near the Synchronizing Rollers 1 Is the Vertical Transport Roller deformed worn or dirty with paper dust YES Clean or change the Vertical Tra...

Page 202: ... Main Board PWB A PF 106 Cassette Main Board PWB A PF 108 PF 110 Cassette Main Board PWB A Master Board PWB A Symptom Step Check Item Result Action Paper is not taken up at all Paper is at a stop before the Paper Feed Separator Rolls 1 Does the paper being used meet the product specifica tions NO Instruct the user to use the paper that meets product specifications 2 Is the paper curled wavy or dam...

Page 203: ...or operation Does the voltage across CN7A 8 on PWB A PF 106 and GND change from DC24V to DC0V when step 6 is performed again NO Change PWB A PF 106 PWB A PF 108 PF 110 PWB A Cassette Main Board or PWB A in that order 9 IsS1fully operational Check the input data using I O Check Does the S1S input signal change from 0 to 1 when the drawer loaded with paper is slid into the copier YES Perform steps 1...

Page 204: ...106 PWB A PF 108 PF 110 PWB A Cassette Main Board or PWB A in that order 5 Check CL2 for operation Does the voltage across CN9 1 on PWB A and GND change from DC24V to DC0V when the Start key is pressed NO Change PWB A 6 If the 3rd Drawer is PF 106 Is PC2 fully operational Check the input data using I O Check YES Check various parts for possible overload and if they are okay change RCL CL2 or PWB A...

Page 205: ...t Electrical Parts Paper Exit Sensor PC3 Duplex Unit Transport Sensor PI1 Synchronizing Roller Sensor PC2 Switchback Motor M1 Duplex Unit Transport Motor M2 Manual Feed Paper Take Up Clutch CL3 Master Board PWB A Duplex Main Board PWB A AD 10 1167C02TAA ...

Page 206: ...YES Clean or change the Duplex Unit Transport Roller or Roll 2 Is a torn piece of paper present on the paper path surface YES Remove the torn piece of paper 3 Is the Manual Feed Take Up Roller or Roll deformed worn or dirty with paper dust YES Clean or change the Manual Feed Take Up Roller or Roll 4 Check M2 for operation Does the voltage across PJ1A 3 on PWB A AD 10 and GND change from DC5V to DC...

Page 207: ...8 malfunction The Lock signal remains HIGH or LOW for a continuous 1 sec period or more while M8 remains energized C004E Power Unit Cooling Fan Motor M4 The Lock signal analog input voltage remains 0 4V or less for a continuous 0 5 sec period or more while M4 remains energized C0070 Main Hopper Toner Replenishing Motor M6 malfunction Toner Bottle Home Position Sensor PC10 remains blocked L for a c...

Page 208: ... when the Scanner moves 463 mm to the left after PC12 has been unblocked H C0990 LCC Lift Up Motor EMOT mal function PF 106 See option service manual C0991 Lift 1 ascent motion failure PF 106 C0995 LCC Transport Motor HMOT malfunction PF 106 C0999 Lift 2 ascent motion failure PF 106 C099D Communications error PF 106 C0B00 Transport Motor M1 drive mal function FN 100 FN 500 C0B0F Paper Entrance Swi...

Page 209: ...owever detected for 1 sec after the start Faulty Lock signal detection No Lock signals are detected for the 1 sec period which starts 1 sec after the first Lock First Lock The first Lock signal following 1 sec after the selection of start or half speed Out of timing Lock detection The Lock signal is not detected for a continuous 0 5 sec period while M10 is in the stabilized turning state after a L...

Page 210: ...lfunction C004C M8 Malfunction C004E M4 Malfunction C0070 M6 Malfunction Relevant Electrical Parts I C Motor M1 Main Motor M2 Fusing Cooling Fan Motor M3 Power Unit Cooling Fan Motor M4 Main Hopper Toner Replenishing Motor M6 Ozone Fan Motor M8 Toner Bottle Home Position Sensor PC10 Master Board PWB A 1167C03TAA ...

Page 211: ...heck various parts for possible overload 2 Check M1 for operation Does the voltage across PJ2 3 of M1 and GND change from DC5V to DC0V after the malfunction has been reset NO Change PWB A 3 Does the voltage across PJ2 4 of M1 and GND change from DC5V to DC0V after the malfunction has been reset YES Change PWB A NO Change M14 Step Check Item Result Action 1 Does M3 turn after the malfunction has be...

Page 212: ...eplaced with a new one YES Change PWB A Step Check Item Result Action 1 After the malfunction has been reset remove the Rear Lower Cover and block Toner Bottle Cover Sensor PC11 Then unlocking the Toner Bottle Lock Lever turn the Toner Bottle a half turn by hand Does the Toner Bottle turn when PC11 is unblocked H with the Toner Bottle Lock Lever kept unlocked YES Perform step 3 NO Check various pa...

Page 213: ...0520 Abnormally High Fusing Temperature Relevant Electrical Parts Fusing Roller Heater Lamp H1 Fusing Roller Thermistor TH1 Fusing Roller Thermostat TS1 Fusing Roller Heater Lamp Fuse TF1 Side Cover Interlock Switch 2 S3 Power Supply Unit 1 PU1 Master Board PWB A 1171C08TAB ...

Page 214: ...ty across 1A and 1B and across 2A and 2B of S3 when S3 is turned ON NO Change S3 4 Is the resistance of TH1 across CN5 2 and 3 on the Fusing Unit end infinity YES Change TH1 5 Is Fuse F2 on PU1 conducting YES Change PU1 or PWB A NO Change the fuse Step Check Item Result Action 1 Is TH1 installed properly NO Install TH1 correctly 2 Is TH1 dirty YES Clean or change TH1 3 Is the circuit across CN5 2 ...

Page 215: ...aulty PC12 C0651 Faulty PC13 Relevant Electrical Parts Scanner Home Position Sensor 1 PC12 Scanner Home Position Sensor 2 PC13 Scanner Motor M5 Master Board PWB A BCR Board BCR HGB Board HGB MFB Board UN2 1170C10TAB ...

Page 216: ...he voltage across CN11BCR 1 on BCR and GND change from DC0V to DC5V when step 1 is performed a second time and PC12 is unblocked NO Change PC12 4 Does the voltage across CN1BCR 26 on BCR and GND change from DC0V to DC5V when step 3 is per formed a second time YES Change HGB UN2 or PWB A in that order NO Change BCR 5 Does the voltage across CN12BCR 1 on BCR and GND change from DC5V to DC0V when ste...

Page 217: ...Lift 2 Ascent Motion Failure C099D Communications Error Relevant Electrical Parts LCC Lift Up Motor EMOT Lift Up Sensor 1 LS1 Lift Up Sensor 2 LS2 LCC Transport Motor HMOT LCC Main Board PWB A PF 106 Cassette Main Board PWB A PF 108 PF 110 Cassette Main Board PWB A Master Board PWB A 1171C13TAB ...

Page 218: ... PF 110 or PWB A Cas sette Main Board in that order NO Change LS1 3 Does EMOT turn when a drawer loaded with paper is slid into the copier YES Check gears and couplings for proper engagement and if they are okay change PWB A 4 Does the voltage across CN5A 1 on PWB A PF 106 and GND change from DC0V to DC24V when step 3 is performed again YES Check various parts for possible overload and if they are...

Page 219: ...loaded with paper is slid into the copier YES Check gears and couplings for proper engagement and if they are okay change PWB A 4 Does the voltage across CN5A 1 on PWB A PF 106 and GND change from DC0V to DC24V when step 3 is performed again YES Check various parts for possible overload and if they are okay change EMOT NO Change PWB A PF 106 PWB A PF 108 PF 110 PWB A Cas sette Main Board or PWB A ...

Page 220: ... I C with the same T C as that of a new one has been installed NO Change the I C with a new one 4 Is C0F32 or C0F33 displayed even when an I C with the same T C as that of a new one has been installed and an F8 operation run Be sure to record the ATDC control voltage setting value if an F8 opera tion is to be run YES Change PWB A install the old I C and return the ATDC control voltage setting to t...

Page 221: ...s sequen tially and turn OFF and ON the Power Switch When C133A is detected check the connector of the corresponding paper source unit and if it is intact change the PWB A of the unit C133B 1 Reset the malfunction and turn OFF and ON the Power Switch 2 If the same malfunction persists check the connection between the copier PWB A and Finisher PWB A 3 If the connection is made properly unplug the c...

Page 222: ...S1 is turned ON NO Change PU1 5 Does the voltage across the S2 connector yellow and GND change from DC0V to DC24V when S2 is turned ON NO Check S2 6 Is the voltage across PJ7PU1 9 on PU1 and GND DC3 3V NO Change PU1 7 Is the voltage across CN1PU2 1 on PU2 and GND DC24V NO Change PU1 8 Is the voltage across CN28UN2 8 on UN2 and GND DC 12V NO Change PU2 9 Is the voltage across CN28UN2 7 on UN2 and G...

Page 223: ... direct sunlight Is the copier level 2 Copy paper Is the recommended paper used Is the paper damp Does the paper size set in the paper source match the size of the paper loaded in it 3 Original Is the original written in light pencil Use the test chart to check the image Is the original transparent or are transparencies being used Place a blank sheet of paper over the original and make a copy Is t...

Page 224: ... output system engine Run F12 which can be selected as follows Tech Rep Mode Function If the test pattern output has the same problem as the copy image Check the output system If the test pattern output is normal Check the input system Make a copy at a different zoom ratio 1167T020AB Check the input system Reduction Full size Check the output system Original Original Full size Reduction ...

Page 225: ...re 1167T017AA 1 Blank copy 2 Black copy 3 Low image density 4 Foggy background 5 Black streaks or bands 6 Black spots 10 Uneven image density 11 Gradation reproduction failure 12 Rough image 13 Periodically uneven image 7 Blank streaks or bands 8 Void areas 9 Smear on back ...

Page 226: ...D HGB or UN2 in that order NO Reconnect 2 Black Copy Section Step Check Item Result Action Engine 1 Is the PC Drum charge voltage terminal in good condition NO Check and change as necessary 2 Is the grid voltage terminal in good condi tion NO Check and change as necessary 3 Is the developing bias terminal in good condition NO Check and change as necessary 4 Does ablack copy persist evenafter theI ...

Page 227: ...the I C has been replaced with a new one NO This completes the procedure 6 Does the image density become higher when the Image Density value is changed toward the plus side Image Density can be selected as follows Tech Rep Mode Tech Rep Choice Printer YES This completes the procedure 7 Does the image density become higher when the VG Adjust value is changed toward the plus side VG Adjust can be se...

Page 228: ...new one NO This completes the procedure 8 Does foggy background persist when the Image Density value is changed toward the minus side Image Density can be selected as follows Tech Rep Mode Tech Rep Choice Printer NO This completes the procedure 9 Does foggy background persist when the VG Adjust value is changed toward the minus side VG Adjust can be selected as follows Tech Rep Mode Tech Rep Choic...

Page 229: ...nect 3 Do the connections from HGB to UN2 remain intact YES Change CCD HGB or UN2 in that order NO Reconnect 6 Black Spots Section Step Check Item Result Action Engine 1 Is the PC Drum dirty YES Clean the PC Drum 2 Has toner spilled from the I C inside of the copier YES Clean the interior and change I C 3 Is the PC Drum charge voltage terminal in good condition NO Check and change as neces sary 4 ...

Page 230: ...act NO Reconnect 3 Do the connections from HGB to UN2 remain intact YES Change CCD HGB or UN2 in that order NO Reconnect 8 Void Areas Section Step Check Item Result Action Engine 1 Does the image get better when a copy is made with new paper loaded YES Change the paper Instruct the user on the storage of paper 2 Is the Image Transfer Roller installed correctly NO Install correctly 3 Is the Image T...

Page 231: ...th foreign mat ter YES Clean the Original Glass mir rors and lens 2 Is the Shading Sheet on the Orig inal Glass dirty YES Clean or change 3 Is the Exposure Lamp dirty or deteriorated YES Clean or change 4 Do the connections from CCD to HGB remain intact NO Reconnect 5 Do the connections from HGB to UN2 remain intact YES Change CCD HGB or UN2 in that order NO Reconnect 11 Gradation Reproduction Fai...

Page 232: ... with foreign mat ter YES Clean or change 3 Is the Synchronizing Roller drive gear cracked or dirty with foreign matter YES Clean or change 4 Is the Fusing Unit drive gear cracked or dirty with foreign mat ter YES Clean or change 5 Is the PH Assy secured properly YES Change the I C or PWB A NO Secure properly IR 1 Is the Scanner Motor drive gear cracked or dirty with foreign mat ter YES Clean or c...

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