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Minolta EP4000, General, Mechanical/Electrical

The Minolta EP4000 is a versatile photocopier suitable for general office use, boasting exceptional mechanical and electrical capabilities. Unlock the full potential of this machine by downloading the comprehensive user manual for free from 88.208.23.73:8080. Your go-to resource to maximize the benefits of your Minolta EP4000.

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Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT
97.04.01

iii

1156SBD000BA

CONTENTS

SERVICE INSTRUCTIONS

1

1-1. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTS

D-1

. . . . . . 

1-2. INSTRUCTIONS FOR HANDLING THE PWBs

WITH MOS ICs

D-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

1-3. HANDLING OF THE PC DRUM

D-3

. . . . . . . . . . . . . . . . . . . . . . . . . . 

1-4. PARTS WHICH MUST NOT BE TOUCHED

D-5

. . . . . . . . . . . . . . . . 

DISASSEMBLY/REASSEMBLY

2

2-1. DOORS, COVERS, AND EXTERIOR PARTS:

IDENTIFICATION AND REMOVAL PROCEDURES

D-6

. . . . . . . . . 

2-2. REMOVAL OF CIRCUIT BOARDS

D-8

. . . . . . . . . . . . . . . . . . . . . . . . 

2-3. PAPER TAKE-UP/TRANSPORT SECTIONS

D-10

. . . . . . . . . . . . . . . 

(1) Removal of the Paper Take-Up Unit

D-10

. . . . . . . . . . . . . . . . . . . . . 

(2) Removal of the Paper Take-Up Roll/Feed Roll Assy and

Separator Roll Assy

D-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

(3) Cleaning of the Paper Take-Up Roll, Feed Roll, 

and Separator Roll

D-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

(4) Cleaning of the Vertical Transport Rollers

D-17

. . . . . . . . . . . . . . . . 

(5) Removal of the Drawers

D-17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

(6) Removal of the Upper Synchronizing Roller

D-19

. . . . . . . . . . . . . . 

(7) Cleaning of the Upper and Lower Synchronizing

Rollers

D-20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

(8) Replacement of the Paper Dust Remover

D-20

. . . . . . . . . . . . . . . . 

(9) Cleaning of the Paper Dust Remover

D-21

. . . . . . . . . . . . . . . . . . . 

(10) Removal of the Suction Unit

D-22

. . . . . . . . . . . . . . . . . . . . . . . . . . 

(11) Disassembly of the Suction Unit

D-23

. . . . . . . . . . . . . . . . . . . . . . . 

(12) Disassembly of the Multi Bypass Unit

D-24

. . . . . . . . . . . . . . . . . . 

2-4. OPTICAL SECTION

D-28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

(1) Cleaning of the Original Glass

D-28

. . . . . . . . . . . . . . . . . . . . . . . . . . 

(2) Cleaning of the Scanner Shaft

D-28

. . . . . . . . . . . . . . . . . . . . . . . . . 

(3) Cleaning of the Scanner Rail

D-28

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

(4) Removal of the Scanner

D-29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

(5) Cleaning of the Exposure Lamp

D-29

. . . . . . . . . . . . . . . . . . . . . . . . 

(6) Removal of the Thermal Fuse

D-30

. . . . . . . . . . . . . . . . . . . . . . . . . . 

(7) Cleaning of the 1st, 2nd, and 3rd Mirrors

D-30

. . . . . . . . . . . . . . . . 

(8) Cleaning of the Lens and 4th and 5th Mirrors

D-31

. . . . . . . . . . . . . 

(9) Winding of the Lens Drive Cable

D-32

. . . . . . . . . . . . . . . . . . . . . . . 

(10) Removal of Scanner Motor M2

D-34

. . . . . . . . . . . . . . . . . . . . . . . . 

(11) Removal of the Scanner Drive Cable

D-35

. . . . . . . . . . . . . . . . . . 

(12) Winding of the Scanner Drive Cable

D-36

. . . . . . . . . . . . . . . . . . . 

(13) Cleaning of the 6th Mirror Protective Filter

D-37

. . . . . . . . . . . . . . 

(14) Cleaning of the Cooling Fan Filter

D-37

. . . . . . . . . . . . . . . . . . . . . 

Summary of Contents for EP4000

Page 1: ...Interleaf EP5000 EP4000 GENERAL MECHANICAL ELECTRICAL 97 04 01 EP5000 EP4000 GENERAL MECHANICAL ELECTRICAL 1156SBG000AA ...

Page 2: ...5 5 WATCHDOG CPU OVERRUN MONITOR FUNCTION M 8 5 1 Configuration M 8 5 2 Watchdog Function Post Processing M 9 6 MALFUNCTION BYPASS FUNCTION M 10 7 IMAGE STABILIZATION SYSTEM M 11 7 1 AIDC Sensor M 12 7 2 Image Stabilization Control Processing Timing M 13 7 3 Details of Image Stabilization Controls M 14 8 PC DRUM M 16 9 DRUM CHARGING M 17 9 1 Ozone Filter M 18 10 IMAGE ERASE LAMP M 19 11 OPTICAL SE...

Page 3: ...hanism M 44 13 7 Sub Hopper Toner Empty Detection Control M 45 13 8 Main Hopper Toner Replenishing Mechanism M 46 13 9 Swing Out In the Main Hopper M 47 14 IMAGE TRANSFER AND PAPER SEPARATION M 48 14 1 Ozone Filter M 49 15 PAPER SEPARATOR FINGERS M 50 16 CLEANING UNIT M 53 16 1 Spent Toner Collection M 54 16 2 Cleaning Bias Optional M 56 17 MAIN ERASE LAMP M 57 18 PAPER TAKE UP FEED SECTION M 58 1...

Page 4: ...Control M 83 21 4 Prevention of Low Image Density on Copy M 84 22 PAPER TRANSPORT M 86 22 1 Suction Belt Drive Mechanism M 87 23 FUSING UNIT M 88 23 1 Fusing Temperature Control M 89 23 2 Fusing Rollers Pressure Mechanism M 90 23 3 Cleaning Roller M 91 23 4 Paper Separator Fingers M 92 23 5 Fusing Section Cooling Fan M 93 24 EXIT UNIT M 94 24 1 Detection of Left Upper Door in Position M 95 25 DEHU...

Page 5: ...ér 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 kasseres i henhold til fabrikantens instruksjoner Sweden VARNING Explosionsfara vid felaktigt batteribyte Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverk...

Page 6: ...Interleaf EP5000 EP4000 GENERAL MECHANICAL ELECTRICAL 97 04 01 GENERAL 1151SBG000CA ...

Page 7: ...SYSTEM Comb Electrode DC Negative Corona with Scorotron System IMAGE TRANSFER Visible Image Transfer by means of a Single Wire DC SYSTEM Negative Corona with Corotron System PAPER SEPARATING Single Wire AC Corona with Corotron System plus SYSTEM Paper Separator Finger FUSING SYSTEM Heat Roller PAPER DISCHARGING Charge Neutralizing Brush SYSTEM MAXIMUM ORIGINAL Metric A3L Inch 11 17 L L Lengthwise ...

Page 8: ...L 28 37 50 31 Area Zoom Ratio Size 1 000 Inch 11 17 L 8 1 2 11 L 8 1 2 11 C 28 39 50 L Lengthwise C Crosswise EP4000 Area Zoom Ratio Size 1 000 Metric A3L A4L A4C B4L 26 34 40 29 Area Zoom Ratio Size 1 000 Inch 11 17 L 8 1 2 11 L 8 1 2 11 C 25 35 40 L Lengthwise C Crosswise ZOOM RATIOS Metric Inch Full Size 1 000 1 000 Fixed Reduction 0 816 0 707 0 500 0 785 0 733 0 647 0 500 Enlargement 1 154 1 4...

Page 9: ...127 V 262 W 900 W 1400 W 220 V 160 V 220 240 V 1360 W 240 V 290 W 950 W 1500 W POWER 115 V 120 V 127 V 220 240 V 50 60 Hz REQUIREMENTS ENVIRONMENTAL CONDITIONS Temperature 10 to 30 C with a fluctuation of 10 C or less per hour Humidity 15 to 85 RH with a fluctuation of 10 RH or less per hour Ambient Illumination 3 000 lux or less Levelness 1 1 75 mm 100 mm DIMENSIONS Width 620 mm 24 1 2 Copier Onl...

Page 10: ... Power Source Use an outlet with a capacity of 115 120 127V 1480W or more or 220 240V 1550W or more F If any other electrical equipment is sourced from the same power outlet make sure that the capacity of the outlet is not exceeded F Use a power source with little voltage fluctuation F Never connect by means of a multiple socket any other appliances or machines to the outlet being used for the cop...

Page 11: ...ON the Power Switch at the same time when you plug the power cord into the outlet F When unplugging the power cord do not pull on the cord hold the plug and pull it out F Do not bring any magnetized object near the copier F Do not place a vase or vessel containing water on the copier F Be sure to turn OFF the Power Switch at the end of the workday or upon power failure F Use care not to drop paper...

Page 12: ...ark place F Keep consumables out of the reach of children F Do not touch the PC Drum with bare hands F Store the paper toner and other consumables in a place free from direct sunlight and away from any heating apparatus F The same sized paper is of two kinds short grain and long grain Short grain paper should only be fed through the copier crosswise long grain paper should only be fed lengthwise F...

Page 13: ...1134O005AA 13 1 Automatic Document Feeder AF 5 2 Duplexing Document Feeder AFR 13 3 Paper Feed Cabinet PF 105 4 Duplex Cabinet PF 5D 5 Paper Feed Cabinet PF 205 6 Duplex Unit AD 9 7 10 Bin Sorter S 106 8 10 Bin Staple Sorter ST 104 9 20 Bin Sorter S 208 10 20 Bin Staple Sorter ST 211 11 Data Terminal 12 Data Controller D 102 13 Large Capacity Cassette C 301 ...

Page 14: ...Interleaf EP5000 EP4000 GENERAL MECHANICAL ELECTRICAL 97 04 01 MECHANICAL ELECTRICAL 1151SBM000CA ...

Page 15: ...9 Cleaning Blade 10 PC Drum Charge Corona 11 PC Drum 12 6th Mirror 13 Image Erase Lamp 14 4th Mirror 15 5th Mirror 16 Sub Hopper 17 Transport Roller 18 Manual Bypass Take Up Roll 19 Upper Vertical Transport Roller 20 Lower Vertical Transport Roller 21 2nd Drawer Paper Take Up Roll 22 1st Drawer Paper Take Up Roll 23 Synchronizing Roller 24 Image Transfer Paper Separa tor Coronas 25 Main Drive Moto...

Page 16: ...ive charge across the entire surface of the PC Drum For more details see 9 DRUM CHARGING 3 Image Erase Any areas of charge which are not to be developed are neutralized by lighting up LEDs For more details see 10 IMAGE ERASE LAMP 4 Exposure Light from the Exposure Lamp reflected off the original is guided to the surface of the PC Drum and reduces the level of the negative charges thereby forming a...

Page 17: ...the paper In addition mechanical paper separation is provided by the two PC Drum Paper Separator Fingers fitted to the Imaging Unit For more details see 14 IMAGE TRANSFER AND PAPER SEPARATION 9 Cleaning Residual toner on the surface of the PC Drum is scraped off by the Cleaning Blade For more details see 16 CLEANING UNIT 10 Main Erase Light from the Main Erase Lamp neutralizes any surface potentia...

Page 18: ...ts and plastic gears are used in large numbers for the drive train parts 1136M002AA 2nd Paper Exit Roller Drive Upper Fusing Roller Drive Gear Toner Conveying Coil Drive on PC Unit Main Drive Motor Synchronizing Roller Clutch Paper Transport Clutch Lower Vertical Transport Roller Drive Upper Vertical Transport Roller Drive Manual Feed Paper Take Up Clutch Developing Section Drive PC Drum Drive Suc...

Page 19: ...1 ON ON Power Supply Board PWB C outputs DC 24V DC24V line ON ON Master Board PWB A outputs DC4 7V and DC12V The Lens is detected at the home position The Mirror is detected at the home position The Scanner makes its initial motion The Lens is detected at the full size position The Mirror is detected at the full size position The surface temperature of the Upper Fusing Roller reaches 165 C ON Main...

Page 20: ...msec 500msec OFF Developing Bias Pa per Separator Corona Approx 4850msec 4500msec M4 turns at half speed M3 2 The components are energized in order of 1 on the preceding page Approx 3 ON Exposure Lamp LA1 OFF Fusing Section Cooling Fan Motor M15 ON Paper Transport Clutch CL1 ON 1st Drawer Paper Take Up Motor M11 1st Drawer Vertical Transport Sensor PC63 is blocked L Approx 5msec OFF M11 Paper Lead...

Page 21: ... Approx 200msec SCAN signal The Scanner stops and starts a return motion H Approx 250msec OFF LA1 G The trailing edge of the paper moves past Transport Roller Sensor PC54 unblocked H Approx 5msec OFF CL1 H The trailing edge of the paper moves past Paper Leading Edge Detecting Sensor PC55 unblocked H Approx 210msec OFF CL2 I The Trailing edge of the paper moves past Paper Exit Switch S53 ON H The c...

Page 22: ...er Feed Cabinet and Duplex Unit and MSC Board PWB B that controls the control panel and system In addition to these each of the control boards for the Data Controller Duplexing Document Feeder and Sorter Staple Sorter is equipped with a CPU The watchdog functions are summarized as follows Each of the copier CPUs monitors whether or not it overruns The MSC CPU monitors the communications conditions...

Page 23: ... all sheets of paper out of the copier before resetting If paper is left inside the copier the copier detects it as a misfeed as it is restarted When an option CPU is found faulty D The option relays are turned OFF and ON and all options are then restarted If the CPU is found faulty during a copy cycle the copier stops the paper take up sequence and feeds all sheets of paper out of the copier befo...

Page 24: ...tor appears in the lower left corner of the Basic Screen Access the Machine Status display by touching the wrench icon or via the Tech Rep mode to ascertain the trouble code Then refer to the Troubleshooting Manual for details D Trouble codes for up to five isolated malfunctions are shown on the Machine Status display When a sixth isolated malfunction occurs the copier considers it a normal malfun...

Page 25: ...ontrol Foggy background To keep a given toner to carrier ratio of the developer in the Developer Mixing Chamber Provides toner replenishing control by means of the ATDC Sensor For details see 13 DEVELOPMENT Correction made immediately after Power Switch is turned ON Image density gradation To compensate for any drop in PC Drum surface potential when the copier is cool immediately after the Power s...

Page 26: ...ound level on the PC Drum Operation 1 The PWB G LED projects approx 950 nm infrared light onto the surface of the PC Drum 2 The PWB G phototransistor detects the amount of light reflected back 3 The phototransistor outputs a voltage corresponding to the intensity of the light reflected back Output GND LED Power Supply PC Drum AIDC Sensor Image Transfer Paper Separation Coronas 1149M005AA Toner Den...

Page 27: ... after the PC Drum has been replaced f f 1 f f Regular correction Upon completion of the copy cycle for every 400 copies made in terms of the number of intermittent copies as it is equivalent to the time over which the PC Drum turns f f f f Correction im mediately after S1 is turned ON During warming up immediately after the Power Switch has been turned ON 3 f f f f Correction for a faulty AIDC Se...

Page 28: ...justment If the AIDC Sensor is dirty with toner it results in an error being produced in the sensor output voltage value providing a false reference value The surface of the PC Drum which has been erased is exposed to light from the LED The LED current value is varied through pulse width control so that the output voltage from the AIDC Sensor becomes 1V Controlled Part Control Signal ON OFF WIRING...

Page 29: ...al Value Exposure Lamp voltage 100V Areas 40 to 80V 1V 58V Exposure Lamp voltage 200V Areas 80 to 160V 2V 116V Relation with Manual Exposure Level of F5 The manual exposure level of Function F5 available from the Tech Rep mode enables fine adjustments of the Exposure Lamp voltage halftone image density to be made It specifies how many volts the optimum Exposure Lamp voltage determined by the image...

Page 30: ...de at the rear end When the Imaging Unit is installed in the copier the shaft on which the PC Drum Drive Coupling Gear is mounted contacts this grounding point Handling Precautions This photoconductor exhibits greatest light fatigue after being exposed to light over an extended period of time It must therefore be protected from light by a clean soft cloth whenever the Imaging Unit has been removed...

Page 31: ... The Corona Unit has a Comb Electrode which minimizes the amount of ozone produced The conventional wire type corona unit produces a large amount of ozone due to corona discharge in radial directions The comb electrode type on the other hand discharges only toward the Grid Mesh meaning a reduced amount of ozone is produced The Comb Electrode can be cleaned by the user who pulls out to the front th...

Page 32: ...duced by the PC Drum Charge Corona is absorbed by the Ozone Filter lo cated to the left of the PC Drum Charge Corona as the air is drawn out of the copier by Ventilation Fan Motor M3 1134M004AA Ventilation Fan Motor M3 Ozone Filter PC Drum Charge Corona Control Signal ON OFF WIRING DIAGRAM M3 PJ34A 1 H L 11 F ...

Page 33: ...trostatic latent image 40 LEDs of Image Erase Lamp LA3 are turned ON before development takes place thereby reducing to a minimum the unnecessary potential on the surface of the PC Drum PC Drum Charge Corona Image Erase Lamp LA3 Exposure 1156M010AA The position of LA3 can be adjusted using the adjusting screw at the front of the copier Copier Front Frame Adjusting Screw LA3 Board Compression Sprin...

Page 34: ...tio and uses the one that turns ON more LEDs The zoom ratio is used to provide ON OFF control of the LEDs if paper size is not input in manual bypass copying since the copier is unable to detect the paper size LED Group No LED No LED Group No LED No 0 LED1 16 LED 17 1 LED 2 17 LED 18 2 LED 3 18 LED 19 3 LED 4 19 LED 20 4 LED 5 20 LED 21 5 LED 6 21 LED 22 6 LED 7 22 LED 23 7 LED 8 23 LED 24 8 LED 9...

Page 35: ... f f f f f f f f f f f 0 523 X 0 550 150 X 158 f f f f f f f f f f f f f f f f f f f 0 551 X 0 576 159 X 166 f f f f f f f f f f f f f f f f f f 0 577 X 0 610 167 X 173 f f f f f f f f f f f f f f f f f 0 611 X 0 642 174 X 184 f f f f f f f f f f f f f f f f 0 643 X 0 672 185 X 195 f f f f f f f f f f f f f f f 0 673 X 0 698 196 X 203 f f f f f f f f f f f f f f 0 699 X 0 728 204 X 211 f f f f f f...

Page 36: ...f f f f f f f f f f f f f f f f f f f f f f f 150 X 156 f f f f f f f f f f f f f f f f f f f f f f 157 X 164 f f f f f f f f f f f f f f f f f f f f f 165 X 172 f f f f f f f f f f f f f f f f f f f f 173 X 180 f f f f f f f f f f f f f f f f f f f 181 X 188 f f f f f f f f f f f f f f f f f f 189 X 198 f f f f f f f f f f f f f f f f f 199 X 208 f f f f f f f f f f f f f f f f 209 X 217 f f f f ...

Page 37: ...Interleaf EP5000 EP4000 GENERAL MECHANICAL ELECTRICAL 97 04 01 M 23 1151T20MCB Control Signal ON OFF WIRING DIAGRAM LA3 PWB A PJ9A 1 6 Static ON OFF Control 4 L ...

Page 38: ... the PC Drum to form the electrostatic latent image 18 1 2 5 7 6 8 9 10 11 12 13 14 15 16 17 7 3 4 7 1156M012AA 1 Scanner Reference Position Sen sor PC81 2 Original Glass Cooling Fan Motor M5 3 Scanner 4 Lens 5 Scanner Motor M2 6 Scanner Shaft 7 Mirror Motor M7 8 4th 5th Mirrors Carriage 9 4th Mirror 10 5th Mirror 11 6th Mirror 12 Lens Motor M6 13 AE Sensor Board PWB H 14 Exposure Lamp LA1 15 1st ...

Page 39: ...r decrease the LA1 voltage thereby chang ing the image density In Photo mode the voltages are varied on a level 3V 200V Areas 6V lower than the manual Exposure Lamp voltages Manual EXP Setting 9 8 7 6 5 4 3 2 1 Mode 1 8 5 2 1 Reference 1 2 5 8 Lamp Voltage Manual Level Mode 2 8 6 4 2 Reference 2 4 6 8 Difference V Priority Mode 3 8 7 6 3 Reference 3 6 7 8 1151T21MCB Varies depending on the drawer ...

Page 40: ... Exposure Lamp voltage is automatically increased or decreased so that copies of consistent quality are produced The output from the AE Sensor is applied to PWB A which in turn varies the duty ratio of the AVR Remote which varies the LA1 voltage accordingly Original Density B W Ratio High Low Intensity of Reflected Light Low High PWB H Output High Low AVR Duty Increased Decreased LA1 Voltage Incre...

Page 41: ...is reduces shadows which would otherwise be transferred to the copy The Main Reflector is of aluminum while the Auxiliary Reflector is aluminum to which film has been deposited The same film as that used on the Auxiliary Reflector is affixed to both ends of the frame to compensate for the reduced intensity of light around both ends of the Exposure Lamp Auxiliary Reflector Main Reflector Exposure L...

Page 42: ...le at the front side there is a Slide Bushing attached to the underside of each of the bodies and that Bushing slides over the Slide Rail The speed of the Scanner and 2nd 3rd Mirrors Carriage varies with different zoom ratios Scanner Reference Position Sensor PC81 detects the home position of the Scanner and 2nd 3rd Mirrors Carriage If they are not at the home position when the copier is turned ON...

Page 43: ... Current M2 M1 L Operation When the scan speed reaches a given level and dur ing scan deceleration At scan start and dur ing return decelera tion At return start and during return motion M2 is used at scan start of a small zoom ratio On receiving the Scan signal Motor Drive Board PWB F applies motor drive pulses which are out of phase with each other to M4 The motor speed is varied by changing the...

Page 44: ...tion determined by Lens Reference Position Sensor PC90 There is a fixed type Lens Aperture Cover provided at the rear of the Lens on the 4th Mirror end It limits the amount of light striking the surface of the PC Drum Shaft Lens Reference Position Sensor PC90 Lens Base Bracket Lens Aperture Cover Spring Lens Drive Cable Lens Motor M5 Lens Lens Aperture Cover Cam 1156M014AB 1136M013AA Lens Control ...

Page 45: ...r using Mirror Motor M7 stepping motor Mirror Reference Position Sensor PC86 is used to control the position of the 4th Mirror It ensures that the Mirror is located at the home position when the copier is turned ON Pinion Gear M7 Rack Gear Mirror Motor M7 4th 5th Mirrors Carriage 4th 5th Mirrors Guide Plate Mirror Reference Position Sensor PC86 1136M017AA Control Signal Energized Deenergized WIRIN...

Page 46: ...he Original Glass which is heated by lit Exposure Lamp LA1 The Filter at the intake port of the Fan prevents dust and dirt from entering the Optical Section of the copier M5 turns only while Main Drive Motor M1 is being energized Rear of Copier Filter Front of Copier Original Glass Original Glass Cooling Fan Motor M5 1149M024AA Control Signal Energized Deenergized WIRING DIAGRAM M5 PWB A PJ15A 5 H...

Page 47: ...Original Cover Detecting Sensor PC111 Original Size Detecting Sensor CD1 PC115 Original Size Detecting Sensor CD2 PC119 Size Reset Switch S108 Original Size Detecting Board UN2 Original Size Detecting Sensor FD2 PC117 Original Size Detecting Sensor FD3 PC118 1156SBM1202A 12 2 Original Size Detecting Operation Each photo receiver of the original size detecting sensors PC115 to 119 responds to refle...

Page 48: ...ng Area f f f f f NOTE If the optional sensors are installed set Jumper Connector JP2 on UN2 as illustrated below and run the F7 operation 1136M022CA FD1 A4C A5L B5C B5L A4L B4L A3L CN1 JP1 JP2 CN2 CN3 CN4 Original Size Detecting Board UN2 Length Metric LED1 LED2 Letter C Letter L FLS Legal FD2 FD3 11 17 Length Inch Width Metric A5L B5L A4L B4L B5C A3L A4C CD2 CD1 Width Inch Invoice Legal Letter L...

Page 49: ... f Legal 8 1 2 14 Legal A4L f f f f F f F F F F F FLS 8 1 2 13 FLS A4L f f f f F F F F F F F Letter C 11 8 1 2 Letter C A4C f F F F F F F f f F f No Original No Original F F F F F F F F F F F Inch Area FD1 FD2 FD3 CD1 Original Size Size Determined by UN2 LED2 LED1 LED2 LED1 LED2 LED1 LED2 11 17 11 17 11 17 f f f f f f f f f f Legal 8 1 2 14 Legal Legal f f f f f f f f F F Letter L 8 1 2 11 Letter ...

Page 50: ...r more PC111 is deactivated D Affirms size readings When the Original Cover is lowered to an angle of 15 or less PC111 is just activated or when the Start key is pressed with PC111 in the deacti vated state D Resets size readings When the Original Cover is raised S108 is deactuated Magnet Size Reset Switch S108 Original Cover Detecting Sensor PC111 Control Signal Blocked Unblocked WIRING DIAGRAM P...

Page 51: ...e of the original 1156M015AA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 Toner Bottle 2 Developer Scattering Prevention Mylar 3 Developer Scattering Prevention Plate 4 Doctor Blade 5 Sub Hopper Toner Supply Roller 6 Toner Bottle Home Position Sen sor PC35 7 Toner Bottle Home Position De tecting Plate 8 Main Hopper Toner Replenishing Motor M8 9 Sub Hopper Toner Empty Detect ing Lever 10 Sub Hopper Toner ...

Page 52: ...t of Coupling Gear 1 makes contact with that of Coupling Gear 2 when the Developing Unit is slid into the copier spring loaded Coupling Gear 2 is pushed back toward the rear of the copier allow ing the Developing Unit to be slid into position When drive is later transmitted to the Developing Unit Coupling Gar 2 is pushed to the front by the tension of the spring to mesh positively with Coupling Ge...

Page 53: ... agitate the developer for greater uniformity thus preventing white lines from occurring on the copy The Sleeve Roller onto which developer is attracted by the magnetic fields of force set up by the poles of the Magnet Roller turns to convey the developer toward the point of development This means that developer fresh from the Developer Mixing Chamber is always brought to the point of development ...

Page 54: ... Vi is than Vb i e the potential difference D When the potential difference is large a greater amount of toner is attracted D When the potential difference is small a smaller amount of toner is attracted Because the Magnet Roller of this copier is movable a flat spring is used as the Bias Terminal which follows the movement of the Magnet Roller Sleeve Magnet Roller Bias Connector 1151T01MCC Bias T...

Page 55: ...et Roller regulates the height of the developer brush on the surface of the Sleeve Roller The Blade is perpendicular to the direction of movement of the Magnet Roller to minimize variations in the distance between the Doctor Blade and Magnet Roller as the Magnet Roller moves Doctor Blade Directionof Magnet Roller Movement Magnet Roller 1156M017AA ...

Page 56: ... sequence The toner empty condition is canceled as soon as a T C ratio of 3 5 is reached and the copier completes the Auxiliary Toner Replenishing sequence when the target level is reached ATDC Sensor Automatic Adjustment An automatic adjustment of the ATDC Sensor is made in the F8 or FF Test Mode operation When F8 or FF is Run after Starter Has Been Changed Following the execution of the starter ...

Page 57: ...reference by 2 or more interrupts the copy cycle and performs a toner replenishing sequence and as soon as there is a gain of 1 against the T C reading resumes the copy cycle This function is however dis abled when a toner empty condition is detected and the ATDC Sensor is found faulty Toner Replenishing Control by AIDC Sensor This copier is equipped with a function that switches from the ATDC Sen...

Page 58: ...hing time which is calculated based on the ATDC Sensor output voltage T C ratio and the size of the paper being fed through the copier Sub Hopper Toner Replenishing Motor M9 Sub Hopper Toner Supply Roller Bucket Roller Developer Conveying Agitating Screw Sub Hopper Sleeve Magnet Roller Rear of Copier Front of Copier 1134M014AA Controlled Part Control Signal ON OFF WIRING DIAGRAM M9 PJ11A 2A L H 2 ...

Page 59: ...s higher than the predetermined level the Sub Hopper Toner Empty Detecting Lever rests on the toner and does not make the up and down motion S106 therefore remains deactuated D When the amount of toner in the Sub Hopper is lower than the predetermined level the Sub Hopper Toner Empty Detecting Lever moves up and down by the eccentric cam This result in S106 being actuated and deactuated When the t...

Page 60: ...te fitted to the coupling and Toner Bottle Home Position Sensor PC35 ensure that the Toner Supply Port in the Toner Bottle is posi tioned at the top whenever the Toner Bottle is stopped Toner Bottle Toner Bottle Coupling 1156M018AB 1136M034AA Toner Supply Port Toner Supply Hole Main Hopper Toner Replenishing Motor M8 Home Position Detecting Plate Toner Bottle Holder Toner Bottle Home Position Sens...

Page 61: ...tle from turning when it is removed or installed When the Toner Bottle Holder is in Position D Since the flat spring fits into the front notch of the Toner Bottle Holder the Holder is locked in position At this time the bottom of the Coupling Lock Lever is pushed in by a part of the Sub Hopper keeping the Coupling free Rear Front 1136M089AA Flat Spring Toner Bottle Holder Coupling Lock Lever When ...

Page 62: ... the PC Drum In addition two Paper Separator Fingers physically peel the paper off the surface of the PC Drum For details see PAPER SEPARATOR FINGERS The Image Transfer Paper Separator Coronas Unit is provided with a Pre Image Transfer Guide Plate that determines the angle at which the paper comes into contact with the PC Drum and keeps an optimum distance between the paper and the PC Drum so that...

Page 63: ...a PWB A PJ13A 3 L H 3 F 1156SBM1401A 14 1 Ozone Filter Ozone produced by the Image Transfer Paper Separator Coronas is absorbed by the Ozone Filter on the back of the copier It is absorbed from the air being drawn out of the copier through the Duct under the Suction Deck by Suction Fan Motor M4 1136M056AA Front of Copier To Ozone Filter Image Transfer Paper Separator Coronas Duct ...

Page 64: ...Separator Fingers attached to the Imaging Unit They physi cally peel the paper off the surface of the PC Drum To prevent the Paper Separator Fingers from damaging the surface of the PC Drum they are kept in the retracted position whenever they are not at work As illustrated below the Fingers are brought into contact with and retracted from the surface of the PC Drum by the Lever which is operated ...

Page 65: ...D The Swash Cam mounted on the Pivot Pin of the Finger Operating Lever is moved through steps by means of the Ratchet wheel and SL1 causing the Swash Cam to push the Finger Shaft D The lateral movement of the Paper Separator Fingers is 3 5 mm which is equivalent to 60 times energization of SL1 SL 1 Energized Pawl A is raised The Swash Plate is locked in position by Pawl B 1136M065AA SL 1 Deenergiz...

Page 66: ...Interleaf EP5000 EP4000 GENERAL MECHANICAL ELECTRICAL 97 04 01 M 52 Control Signal Energized Deenergized WIRING DIAGRAM SL1 PWB A PJ11A 6A L H 2 I ...

Page 67: ...ansfer and paper separation have been completed Blade Tension Spring Toner Conveying Coll PC Unit PC Drum Paper Separator Finger 1134M027AA Cleaning Blade The Cleaning Blade is moved back and forth to prevent the PC Drum from deteriorating and the Cleaning Blade from warping away from the surface of the PC Drum Timing Belt Eccentric Cam Blade Moving Pin Cleaning Blade Assy Mounting Bracket To Main...

Page 68: ... down onto the surface of the copy paper or the paper path Toner Conveying Coil 1136M061AA 1136M062AA Cleaning Blade Toner Conveying Coil Residual Toner Toner Antispill Mylar Spent Toner Flow Toner Conveying Coil Drive Gear Copier Toner Conveying Coil Drive Gear PC Unit Pipe D The type of Toner Collecting Box and the method of detecting an installed box differ between the applicable marketing area...

Page 69: ...Collecting Box Set Sensor If no box is installed the sensor causes a warning message to appear on the Touch Panel and the initiation of a new copy to be inhibited 1134M037EA 1134M030AA Toner Pipe Actuator Toner Collecting Box Cabinet EP4000 except U S A Canada and Europe PC107 Actuator Toner Collecting Box Pipe Toner PWB A Toner Collecting Box Set Sensor Controlled Part Control Signal Blocked Unbl...

Page 70: ...eaning Bias Optional Except the U S A Canada and Europe A Cleaning Bias Seal is optionally available that can be fitted to reduce damage to the PC Drum from acid paper Toner Antispill Mylar PC Drum Cleaning Bias Seal 1151T02MCD Control Signal ON OFF WIRING DIAGRAM Cleaning Bias HV1 L H 3 F ...

Page 71: ...l remaining on the surface of the PC Drum after cleaning Main Erase Lamp Board Filter Main Erase Lamp LA2 1136M069AA D Main Erase Lamp LA2 consists of ten tungsten filament lamps mounted side by side on a board A filter is installed between LA2 and the PC Drum to protect LA2 from con tamination 1151T06MCD Control Signal ON OFF WIRING DIAGRAM LA2 PWB A PJ12A 3 H L 1 L ...

Page 72: ...per drawers that slide out to the front of the copier The 1st Drawer is a fixed paper size type while the 2nd Drawer is a universal paper size type 1149M014AA Paper Size Detecting Sensors Assy CD Paper Size Detecting Switches Assy FD Paper Take Up Rolls Paper Take Up Unit Assy 2nd Drawer Universal Paper Size Type 1st Drawer Fixed Paper Size Type ...

Page 73: ...en the drawer is slid into the copier Drawer Set Detecting Lever A is pushed in the direction of the arrow which blocks the Drawer Set Sensor PC61 PC62 goes LOW Rear 1st 2nd Drawer Set Sensor PC61 62 4425M003AA Front Control Signal Blocked Unblocked WIRING DIAGRAM PC61 PWB A PJ22A 2 L H 25 P PC62 PWB A PJ22A 6 L H 25 P ...

Page 74: ...wer Set Sensor PC61 PC62 is blocked goes LOW and after 1 msec the Lift Up Motor M13 M14 starts turning causing the Paper Lifting Arm to raise the Paper Lifting Plate D When the drawer is slid out Lift Up Motor Gear 1 is disengaged from Paper Lifting Arm Gear 2 lowering the Paper Lifting Plate 1st 2nd Drawer Lift Up Motor M13 14 Paper Lifting Arm Gear 2 Gear 1 4425M004AA Rear Front When Drawer is S...

Page 75: ...e paper stack until the Lift Up Sensor PC65 66 is blocked output goes LOW During Copying D Energizing and deenergizing of the Lift Up Motor keeps constant the pressure be tween the Paper Take Up Roll and paper regardless of the height of the paper stack Control Signal Blocked Unblocked WIRING DIAGRAM PC65 PWB A PJ21A 2A L H 25 N PC66 PWB A PJ21A 2B L H 32 K Control Signal Energized Deenergized WIR...

Page 76: ... Motor and the paper stack raising motion is completed D As the paper is consumed and the top level of the paper stack lowers the Lift Up Sensor is unblocked Then the Lift Up Motor is energized again to raise the paper stack until the Lift Up Sensor is blocked again This means that a constant pressure is maintained between the paper and the Paper Take Up Roll regardless of the amount of paper stil...

Page 77: ... Lift Up Sensor PC65 66 4425M005AA 4425M006AA 4425M005AA 1136T63MCA 1136T64MCA During Copying When Drawer is Slid in Control Signal OFF ON WIRING DIAGRAM UN5 PWB A PJ24A 3 L H 41 I UN6 PWB A PJ24A 4 L H 41 M Control Signal Energized Deenergized WIRING DIAGRAM M13 PWB A PJ18A 5 L H 25 M 41 K M14 PWB A PJ18A 7 L H 25 M 41 O ...

Page 78: ... Blocking Plate 1134M033EA z Drawer Locking Mechanism Drawer Guide Frame Lock Lever 1134M034EA D Pressing the Paper Descent Key UN5 6 starts the paper lowering motion D The worm gear is turned downward until its light blocking plate has passed through and below the Lower Limit Position Sensor PC70 71 blocking and then unblocking it This is so the worm gear can reach down low enough to push the Loc...

Page 79: ...p Sensor PC65 66 goes LOW The total number of pulses is translated into the amount of paper which is shown on the Touch Panel as a graphic marker in units of 50 sheets of paper D As the paper is consumed and the top level of the paper stack lowers the Lift Up Motor is energized to raise the paper stack During this time the Lift Up Motor Pulse Sensor PC67 68 detects pulses and that pulse count is a...

Page 80: ...copier the Paper Empty Lever can hit against the Paper Lifting Plate To prevent this from oc curring the Paper Empty Lever is tilted in the direction of sliding Paper Lifting Plate Paper Empty Lever 1st 2nd Drawer Paper Empty Sensor PC101 102 4425M007AA PC101 102 blocked PC101 102 unblocked 4425M008AA 4425M009AA The paper stack raises the Paper Empty Lever which blocks PC101 102 goes LOW The light...

Page 81: ...that there is paper in the drawer D If no paper is loaded the copier detects that the drawer is paper empty and at the same time the Lift Up Motor M13 14 starts turning backward to lower the Paper Lifting Plate D When a paper empty condition is detected during a multi copy cycle and if there is another paper source including options loaded with paper of the same size and in the same direction the ...

Page 82: ...of FLS 13 or 14 long in the feeding direc tion D On the bottom of the tray is a lever fitted to the Trailing Edge Stop and another lever fitted to the Edge Guide These levers actuate activate and deactuate deacti vate the paper size detecting switches and sensors to allow the copier to deter mine a particular paper size Detection in the Feeding Direction Paper Size Detecting Switch Assy FD S61 62 ...

Page 83: ...f f f B4L 257 364 A3L 297 420 f f f Quarto C 10 8 254 203 f f G Letter L 8 10 1 2 203 267 f f f G Letter C 10 1 2 8 267 203 f f f Folio 8 1 4 13 210 330 f f f Letter L 8 1 2 11 216 279 f f f f Letter C 11 8 1 2 279 216 f f f f Legal 8 1 2 14 216 356 f 11 14 11 14 279 356 f f Ledger 11 17 279 432 f f f Comp Form 11 15 279 381 f Korean FLS L 192 268 f f f f f FLS 8 13 203 330 f f f Hongkong FLS L 8 ...

Page 84: ... 70 Control Signal Actuated Deactuated WIRING DIAGRAM S61 PWB A PJ26A 2 L H 25 J S62 PWB A PJ26A 4 L H 25 I S63 PWB A PJ26A 7 L H 25 I S64 PWB A PJ26A 9 L H 25 H Control Signal Blocked Unblocked WIRING DIAGRAM PC72 PWB A PJ25A 2 L H 25 K PC73 PWB A PJ25A 5 L H 25 J ...

Page 85: ...ake up mechanism is driven by 1st 2nd Drawer Paper Take Up Motor M11 12 D Each paper take up mechanism consists of a Paper Take Up Roll Feed Roll and Separator Roll with torque limiter D The Separator Roll is controlled by the torque limiter so that it will not transport more than one sheet of paper at a time Paper Feed Roll Paper Separator Roll Paper Take Up Roll Torque Limiter 2nd Drawer Paper T...

Page 86: ...tical Transport Section D The friction coefficient varies for different ambi ent conditions and types of paper being used which often causes the Separator Roll to be sta tionary Paper Feed Roll Separator Roll 4425M012AA Driven or stationary Double Feeding D Since the coefficient of friction between the top side of the first sheet of paper and the Feed Roll is greater than that between the first an...

Page 87: ...r held between the Feed Roll and Paper Separator Roll by just sliding out the drawer When the drawer is pulled out the pressure release rail pushes down the Separator Roll Assy disengaging the Feed Roll from the Separator Roll Drawer in Position Drawer Slid Out Feed Roll Separator Roll Assy Drawer Pressure Spring Approx 2mm 4444M004AA 4 Paper Take Up Roll Retraction Mechanism D When the drawer is ...

Page 88: ...t Clutch CL2 1st 2nd Drawer Paper Take Up Motor M11 12 1st 2nd Drawer Paper Take Up Sensor PC55 56 Vertical Transport Sensor PC63 PC64 1st sheet of paper take up start 2nd sheet of paper take up start T1 5 msec Paper take up off timer T2 5 msec Paper take up interval timer Control Signal Blocked Unblocked WIRING DIAGRAM PC51 PWB A PJ19A 5 L H 32 M PC55 PWB A PJ19A 2 L H 32 N PC56 PWB A PJ21A 5A L ...

Page 89: ...C55 56 after M11 12 has been energized M11 12 is temporarily deenergized and an ap propriate period of time thereafter it is energized again paper take up interval con trol 4 Double Feed Paper Take Up Control D Even if the Paper Take Up Roll takes up two sheets of paper at one time the double feed paper take up control uses the second sheet of paper for the next copy cycle without causing a paper ...

Page 90: ...ed as follows Paper Empty Sensor 1136M045AA Lever Right Cover Right Door Cover Multi Bypass Table Manual Feed Paper Take Up Clutch Manual Feed Paper Take Up Solenoid Manual Bypass Take Up Roll Paper Stoppers Upper Transport Roller Manual Bypass Feed Roll Paper Empty Sensor Manual Bypass Take Up Roll Multi Bypass Table Paper Empty Sensor Actuator Paper Stopper Lower Transport Roller Manual Bypass S...

Page 91: ...p Rolls to press the paper stack downward and take up a sheet of paper Paper Stoppers are provided that block the leading edge of the paper stack as it is loaded on the Table preventing any portion of the leading edge of the paper from getting inside These Stoppers are unlocked at paper take up allowing paper into the copier Manual Feed Paper Take Up Clutch CL3 controls the turning and stop of the...

Page 92: ... Paper Separating Mechanism The paper separating mechanism ensures that only the top sheet of paper is fed in by separating the second sheet of paper from the top one This is accomplished by the Torque Limiter fitted to the Separator Roll shaft which stops the Separator Roll when there is a change in friction between the Feed and Separator Rolls For details of the paper separating mechanism see 18...

Page 93: ... Detection The Multi Bypass Table is equipped with Manual Feed Paper Empty Sensor PC51 which detects a sheet of paper at the manual bypass port Manual Feed Paper Empty Sensor PC51 Actuator Paper Stopper Paper Take Up Roll Control Signal Blocked Unblocked WIRING DIAGRAM PC51 PWB A PJ15A 14 H L 32 O ...

Page 94: ...and stopped in time with the Transport Rollers Transport Roller Sensor PC54 immediately after the Transport Rollers detects a sheet of paper fed from the Vertical Transport Section or Manual Bypass Table A Paper Dust Remover is fitted to one of the Transport Rollers collecting paper dust from the rollers The Cover for the Vertical Transport Section i e the Side Door can be opened and closed for cl...

Page 95: ... rear frames of the copier D The Lower Synchronizing Roller a rubber roller is fitted to the Transport Assy Pivot ing about its rear end the Lower Roller can be swung downward to facilitate clearing paper misfeeds Upper Synchronizing Roller Lower Synchronizing Roller 1136M050AA Paper Dust Remover Guide Plates Lower Synchronizing Roller Paper Leading Edge Detecting Sensor PC55 Upper Synchronizing R...

Page 96: ...r Dust Remover The Paper Dust Remover is installed so that it makes contact with the Upper Synchronizing Roller Since the Upper Synchronizing Roller is covered with a vinyl tubing triboelectric charging occurs as the Roller turns in contact with the Paper Dust Remover As paper is then fed between the Synchronizing Rollers the charges on the tubing attract paper dust from the paper The dust is then...

Page 97: ...oller Control The Synchronizing Rollers are started as Synchronizing Roller Clutch CL2 is energized upon reception of a signal from PWB A 1151T11MCD Control Signal Energized Deenergized WIRING DIAGRAM CL2 PWB A PJ14A 4 L H 7 G Control Signal Blocked Unblocked WIRING DIAGRAM PC55 PWB A PJ19A 2 L H 32 N ...

Page 98: ...ty the guide plate would build up charges and a spark could occur with other guide plates resulting in a malfunction To prevent this a resistor and a varistor are connected to the guide plates The guide plates are connected by flat springs as illustrated below Upper Vertical Transport Rollers 1136M053AA Varistor Resistor Manual Bypass Feed Separator Rolls Transport Rollers Synchronizing Rollers À ...

Page 99: ...L ELECTRICAL 97 04 01 M 85 Flat Spring Connection A Between varistor and resistor and guide plate Æ B Between varistor and resistor and guide plate Á C Between guide plates Á and à D Between guide plates Á and À E Between guide plates à and Å ...

Page 100: ...de Plate to ensure that the paper is smoothly fed into the Fusing Unit D As M4 turns ozone produced by the Image Transfer Paper Separator Coronas is absorbed by the Ozone Filter from the air being drawn out of the copier Ozone Filter 1136M070AA Suction Belts Transport Section Release Lever Suction Drive Gear Suction Fan Controlled Part Control Signal Half Speed Rotation Full Speed Rotation WIRING ...

Page 101: ...on Belt Drive Mechanism The Suction Belts are driven by Main Drive Motor M1 through a timing belt and gear train Suction Belt Drive Roller 1136M072AA Main Drive Motor Gear Suction Belt Suction Drive Gear Timing Belt Controlled Part Control Signal ON OFF WIRING DIAGRAM M1 PWB A PJ18A 9 L H 2 M ...

Page 102: ...r to the Upper Fusing Roller Drive Gear The Lower Fusing Roller and Cleaning Roller are driven by the respective Rollers in contact with them Pressure Spring Thermistor TH1 2 Fusing Heater Lamp H1 Upper Fusing Roller Lower Fusing Roller Fusing Thermoswitch TS1 Lower Fusing Paper Separator Finger 1156M020AA 1136M073AA Cleaning Roller 1st Paper Exit Roller Upper Fusing Paper Separator Finger Cleanin...

Page 103: ...0 C the tempera ture control at 200 C begins As soon as the copy cycle is completed control is again switched to 190 C TH1 is positioned at a point 30 5 mm from the paper path reference position there by preventing offset caused by low temperature and degraded fusing performance for small size paper The control temperature in the Energy Saving Mode is 155 C With EP5000 the control temperature is 1...

Page 104: ...d at a location 271 5 mm from the position of paper passage registration As soon as TH2 detects 225 C the 225 C control by TH2 is started 1156SBM2302A 23 2 Fusing Rollers Pressure Mechanism Pressure springs are fitted to the Pressure Holder for the Lower Fusing Roller on the front and rear ends When the pressure screws are tightened it moves the Pressure Holder upward thus allowing the Lower Fusin...

Page 105: ...leaning Roller is pressed up against the Upper Fusing Roller applying a coat of silicone oil to the surface of the roller At the same time it turns in the direction opposite that of the Upper Fusing Roller and with its brush removes toner and paper dust 1136M077AA Cleaning Roller Upper Fusing Roller Lower Fusing Roller ...

Page 106: ...l not be contaminated with toner D The tip of each Separator Finger is at all times pressed against the surface of the Upper Fusing Roller by a pressure spring 1136M078AA Upper Fusing Roller Upper Fusing Paper Separator Finger Rear Front zLower Fusing Paper Separator Fingers D The Lower Fusing Paper Separator Fingers are flat springs to enhance paper separat ing performance and ensure that the pap...

Page 107: ...ling Fan Motor M15 prevents the temperature in the optical section from being raised inordinately by the heat of the Fusing Unit in the standby state M15 remains energized while the copier is in the standby state and deenergized during a copy cycle M15 Fusing Unit 1156M022AA Control Signal ON OFF WIRING DIAGRAM M15 PWB A PJ10A 2 L H 3 D ...

Page 108: ...nal to energize Exit Duplex Switching Solenoid SL5 which switches the position of the Exit Duplex Switching Plate The Unit has Paper Exit Switch S53 built into it which detects a sheet of paper being fed out of the Unit For more details of switching control see the Service Manual for DUPLEXING UNIT 1139M082AA Exit Duplex Switching Plate Exit Duplex Switching Solenoid SL5 Paper Exit Roller Rolls Pa...

Page 109: ...opier body detects the Left Upper Door when closed The Exit Unit is fitted to the Left Upper Door D When the Left Upper Door is closed the rib on the Exit Unit pushes the Lever which activates S23 Left Upper Door 2nd Paper Exit Roller Drive Gear Left Upper Door Interlock Switch S23 Lever 1156M023AA Controlled Part Control Signal ON OFF WIRING DIAGRAM S23 PWB A PJ16A 4 L H 21 I ...

Page 110: ... under the Lower Synchronizing Roller to prevent the PC Drum from forming condensation Copier Base Frame Drum Dehumidifying Switch S3 Lower Synchronizing Roller Paper Dehumidifying Heater H2 Optional Paper Dehumidifying Switch S12 1136M004AA 1136M043AA Drum Dehumidifying Heater H3 Stan dard D H2 H3 ON OFF Conditions Dehumidifying Switch ON Power cord Plugged in Power Switch ON During a copy cycle ...

Page 111: ...BAT1 is mounted on PWB R to prevent the contents of memory from being lost when the power cord is unplugged or PWB R removed from the copier BAT1 requires a voltage of 2V or more to retain the contents of memory Important As we noted above the RAM stores critical data If PWB R has been replaced with a new one memory must first be cleared and then all settings be made again It should also be noted ...

Page 112: ...HANICAL ELECTRICAL 97 04 01 Copyright 1997 MINOLTA Co Ltd Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information MINOLTA Co Ltd 1156 7991 11 97046000 Printed in Japan 1156SBG000E ...

Page 113: ...Interleaf EP5000 EP4000 DIS REASSEMBLY ADJUSTMENT 97 04 01 EP5000 EP4000 DIS REASSEMBLY ADJUSTMENT 1156SBD000AA ...

Page 114: ...the machine be sure to unplug its power cord The machine contains a high voltage unit and a circuit with a large current capacity that may cause an electric shock or burn from sparking The machine also contains quick moving parts which could injure a person If the machine uses a laser a person can lose his her eyesight by a laser beam leak D Wherever feasible keep the covers and parts mounted when...

Page 115: ... user s premises Caution u Other Precautions u D While the machine is being energized do not unplug or plug in a connector on a PWB or relay harness D Sincethe Magnet Roller of the Imaging Unit generates a strong magnetic force do not bring a CRT watch floppy disk or magnetic card near it D Use of an air gun or vacuum generates static electricity which can cause the ATDCSensorandassociated parts t...

Page 116: ...Drawers D 17 6 Removal of the Upper Synchronizing Roller D 19 7 Cleaning of the Upper and Lower Synchronizing Rollers D 20 8 Replacement of the Paper Dust Remover D 20 9 Cleaning of the Paper Dust Remover D 21 10 Removal of the Suction Unit D 22 11 Disassembly of the Suction Unit D 23 12 Disassembly of the Multi Bypass Unit D 24 2 4 OPTICAL SECTION D 28 1 Cleaning of the Original Glass D 28 2 Clea...

Page 117: ...moval of the Ozone Filter PC Drum Charge Corona D 48 18 Removal of the Ozone Filter Image Transfer Paper Separator Coronas D 48 19 Removal of the Toner Collecting Box D 48 2 6 PC DRUM CHARGE CORONA AND IMAGE TRANSFER PAPER SEPARATOR CORONAS D 49 1 Removal of the PC Drum Charge Corona D 49 2 Cleaning of the PC Drum Charge Corona Housing D 49 3 Cleaning of the PC Drum Charge Corona Grid Mesh D 50 4 ...

Page 118: ...ST MODE D 67 3 6 ELECTRICAL IMAGE ADJUSTMENTS D 68 1 Initial Adjustment of Original Size Detecting Board D 68 2 ATDC Adjustment D 69 3 Adjustment of the Aperture Blades D 71 4 Adjustment of Exposure Level in the Auto Exposure Mode D 72 5 Adjustment of Optimum Exposure Setting in the Manual Exposure Mode D 73 6 Adjustment of Zoom Ratio in the Crosswise Direction D 75 7 Adjustment of Zoom Ratio in t...

Page 119: ...t of the Gap Between the Doctor Blade and Sleeve Roller D B Adjustment D 96 3 Adjustment of the PC Drum Paper Separator Finger Position D 97 4 Adjustment of Manual Feed Paper Take Up Solenoid SL4 D 98 5 Adjustment of Exit Duplex Solenoid SL5 D 99 MISCELLANEOUS 4 4 1 INSTALLATION OF THE PLUG IN COUNTER OPTION MOUNTING BRACKET D 100 4 2 ADJUSTMENT OF THE RIGHT DOOR D 101 ...

Page 120: ... the ATDC Sensor and other sensors as they can cause electrostatic destruction Use a blower brush and cloth If a unit containing these sensors is to be cleaned first remove the sensors from the unit D When handling the PWBs with MOS ICs observe Instructions for Handling the PWBs with MOS ICs D When handling the PC Drum observe precautions given in Handling of the PC Drum D Note that replacement of...

Page 121: ... ADJUSTMENT 97 04 01 D 2 Fuse Board PWB L 250V 3A 4 Power Supply Board PWB C 250V 3A 5 Power Supply Unit PU1 125V 8A Noise Filter Board PWB D 250V 15A Exposure Thermal Fuse TF1 110 C 10A Fuse Holder F3 250V 15A List of Fuses Used 1156D001CA ...

Page 122: ...ng connectors into the Board make sure that the power cord has been unplugged from the power outlet During Inspection D Avoid checking the IC directly with a multimeter use connectors on the Board D Never create a closed circuit across IC pins with a metal tool D When it is absolutely necessary to touch the ICs and other electrical components on the Board be sure to ground your body 1151SBD0103A 1...

Page 123: ... Wipe the surface in one contin uous movement from the rear edge of the PC Drum to the front edge and off the surface of the PC Drum b Rotate the PC Drum slightly and wipe the newly ex posedsurface area with a CLEAN face of the Dust Free Cotton Pad Repeat this procedure until the entire sur face of the PC Drum has been thoroughly cleaned At this time always use a CLEAN face of the dry Dust Free Co...

Page 124: ... which red paint is applied In addition be advised that if two or more screws are designated as those which must not be touched on a single part only one representative 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 ADJUST MENT 3 Other Screws Two screws on the Lower Pre Image Transfer Gu...

Page 125: ...EP5000 EP4000 DIS REASSEMBLY ADJUSTMENT 97 04 01 D 6 DISASSEMBLY REASSEMBLY 2 2 1 DOORS COVERS AND EXTERIOR PARTS IDENTIFICATION AND REMOVAL PROCEDURES 12 13 14 15 16 11 5 4 3 2 1 1156D002AA 1156D003AA 7 8 10 6 9 ...

Page 126: ...ne Rear Upper Cover Small mounting screw 6 Rear Upper Cover Raise No 12 Open No 14 Remove No 13 Re move No 5 Open No 8 Remove No 7 Remove one Rear Upper Cover mounting screw 7 Right Cover Open No 8 Open the Multi Bypass Table Remove four Right Cover mounting screws 8 Right Door Manual Bypass Unit Open No 8 Remove two cover mounting screws Remove the harness from one wiring saddle Unplug three conn...

Page 127: ...xt page D Replacement of a circuit board may call for readjustment or resetting of particular items D The removal procedures given on the next page omit the removal of connectors and screws securing the circuit board support or circuit board D Where it is absolutely necessary to touch the ICs and other electrical components on the board be sure to ground your body 1156D004AA PWB H PWB J UN2 PWB A ...

Page 128: ...P4000 Except U S A Canada and Europe Remove No 16 Remove the Toner Collecting Box Remove the Toner Pipe PWB M1 1st Drawer Flexible printed Circuit PWB M2 2nd Drawer Flexible printed Circuit Slide out the drawer PWB R RAM Board Remove No 16 UN1 Control Panel Swing down No 1 Remove No 2 UN2 Original Size Detecting Board Remove No 16 UN3 ATDC Sensor Swing down No 1 Remove the IU UN5 1st Drawer Paper ...

Page 129: ...2nd Drawers For the removal of the 1st and 2nd Drawers see p D 17 3 Remove two locking wiring saddles 4 Unplug one connector from Power Supply Board PWB C 5 Disconnect the hookup connector 1156D005AA 120V Areas 1 Remove the Right Door Right Cover and Rear Cover 2 Remove the 1st and 2nd Drawers For the removal of the 1st and 2nd Drawers see p D 18 3 Remove one locking wiring saddle 4 Disconnect the...

Page 130: ...tor Assy 7 Remove two screws each to free 1st Drawer Paper Take Up Motor M11 and 2nd Drawer paper Take Up Motor M12 For ease of understanding the illustration shows where the connectors and Paper Take Up Motors are removed 8 Remove two screws and the Paper Guide Plate 9 Remove two edge covers with locks 10 Unplug three hookup connectors 9 Remove two edge covers with locks 10 Unplug one hookup conn...

Page 131: ...Interleaf EP5000 EP4000 DIS REASSEMBLY ADJUSTMENT 97 04 01 D 12 1134D009AA 12 Remove five screws and the Paper Take Up Unit 1156D009AA 11 Pull the harness out to the front from the rear frame ...

Page 132: ...oll Assy and Separator Roll Assy 1 Remove the Right Door 2 Remove two screws and the Paper Guide Plate from each drawer 1134D011AA 3 Unhook the front and rear springs from the copier frame Remove the Paper Separator Roll Paper Guide Plate Assy by turning it about 90_ in the direction of the arrow 1156D010AA ...

Page 133: ...7 04 01 D 14 1156D011AA 5 Disassemble the Paper Separator Roll Assy 1156D012AA 4 Remove one screw and the Paper Separator Roll Assy Mounting Bracket from each drawer The illustration shows how the Paper Separator Roll Assy is removed from the 2nd Drawer ...

Page 134: ...nd Drawer 7 Remove the bushing from the front end of each Paper Take Up Roll Feed Roll Assy 8 Remove the rear bushing from the holder 9 Move the coupling holder of each Paper Take Up Roll Feed Roll Assy in the direction of the arrow to work it off the pinof the copier This allows the Paper Take UpRoll Feed Roll Assy to come out of the copier NOTE When reinstalling the Paper Take Up Roll Feed Roll ...

Page 135: ... pin for later use 3 Cleaning of the Paper Take Up Roll Feed Roll and Separator Roll 1 Remove each Paper Take Up Roll Feed Roll Assy 2 Remove each Paper Separator Roll Assy 3 Using a soft cloth dampened with alcohol wipe each roll clean of dirt 1156D019AA 1156D018AA Cleaning the Paper Take up Roll Feed Roll Cleaning the Paper Separator Roll ...

Page 136: ... are for the 1st Drawer the same procedure applies also to the 2nd Drawer Except 120V Areas 1156D020AA 1134D133AA 1134D143AA 1 Remove the Right Door Right Cover and Rear Cover 2 Using a soft cloth dampened with alcohol wipe each roller clean of dirt 1 Slide out the drawer and remove one screw and the right stopper 2 Remove one screw and the left stopper 3 Remove the drawer from the copier ...

Page 137: ...141CA 1 Turn ON Power Switch S1 2 Press the Paper Descent Key and then slide out the draw er 3 As with the metric areas remove the right and left stop pers 4 Remove one screw and the hookup connector cover 5 Remove one screw and the hookup connector mounting bracket 6 Unplug the hookup connector Remove the drawer ...

Page 138: ...er down 3 Remove the Rear Cover 4 Unplug the bias terminal from High Voltage Unit HV1 5 Unplug CN1 of HV1 6 Remove two screws to free HV1 7 Snap off one E ring to free Synchronizing Roller Clutch CL2 8 Snap off the E ring and remove the bushing from the rear end of the Upper Synchronizing Roller 9 Swing down the Front Door and slide out the IU 10 Snap off the E ring and remove the bushing from the...

Page 139: ... clean the Upper Synchronizing Roller 3 Swing down the Transport Section Release Lever 4 Using a brush or a soft cloth dampened with alcohol clean the Lower Synchronizing Roller 1 Swing down the Front Door and slide out the IU 2 Loosen the screw that secures the Paper Dust Remover Assy at the rear of the copier 3 Remove the screw that secures the Paper Dust Remover Assy at the front of the copier ...

Page 140: ...Interleaf EP5000 EP4000 DIS REASSEMBLY ADJUSTMENT 97 04 01 D 21 9 Cleaning of the Paper Dust Remover 1136D095AA 1 Remove the Paper Dust Remover Assy 2 Using a brush whisk dust off the Paper Dust Remover ...

Page 141: ...slide out the IU 3 Remove the Paper Dust Remover Assy 4 Remove the Fusing Unit 1156D029AA 1156D030AA 1156D031AA 5 Remove the motor cover 6 Unplug two connectors from the lower end of the Suction Unit 7 Swing the Transport Section Release Lever back to its original position 8 Pressingdown the Image Transfer PaperSeparatorCoro nas Unit pull it out of the copier ...

Page 142: ... the right NOTE Whenremoving and reinstalling the Suction Unit use care notto bend the ground plate located on the right in the rear NOTE When reinstalling the Suction Unit make sure that two positioning pins on the copier fit into the positioning holes in the Suction Unit 1 Remove the Suction Unit 2 Remove two screws and the duct 3 Remove four screws and the Suction Drive Unit NOTE When reinstall...

Page 143: ...ion Belts 6 Remove the Suction Roller as shown on the left 1 Open the Right Door 2 Remove two screws and the cover 3 Remove the harness from one locking wiring saddle 4 Unplug three connectors 5 Remove two screws and the Right Door NOTE The Right Door must be adjusted for correct position when it is reinstalled See p D 101 6 Remove four screws and the Separator Guide Plate Assy ...

Page 144: ... that its close coiled end faces the Separator Unit 8 Remove one C clip and the Separator Assy 9 Remove one C clip and the Separator Roll Assy 10 Remove the harness from the edge cover and cord clamp 11 Remove four screws and the Solenoid Mounting Bracket NOTE When the solenoid has been replaced or the solenoid mounting screws removed be sure to adjust the position of the solenoid For the adjustme...

Page 145: ...ri ent the Paper Take Up Roll shaft and the clutch as shown on the left D The end of the clutch must be flush with or slightly re cessed upto1mm fromtheendfaceofthePaperTake Up Roll shaft The roll shaft should never protrude D There must be a gap of 1 mm or more at A when the Pa per Take Up Roll shaft is pushed in the direction of the arrow 13 Snap off two C clips and remove the Paper Take Up Roll...

Page 146: ... the Manual Bypass Feed Roll 1136D118AA D Cleaning of the Manual Bypass Separator Roll 1156D039AA 15 Snap off the C clip and remove the Paper Take Up Roll Using a soft cloth dampened with alcohol clean the Paper Take Up Roll Using a soft cloth dampened with alcohol clean the Feed Roll Using a soft cloth dampened with alcohol clean the Separa tor Roll ...

Page 147: ...theOriginalGlassiscoatedwithconductive material Do not use a wax based detergent An alcohol dampened cloth may be used if the glass is se riously contaminated 1 Remove the Original Width Scale 2 Remove the Original Glass 3 Wipe clean the Scanner Shaft in the rear of the copier with a soft cloth NOTE Apply a lubricating oil after cleaning the Scanner Shaft Wipe clean the Scanner Rail at the front o...

Page 148: ...he Exposure Lamp terminal connector 4 Turn over the Scanner and remove one screw one wash er and the ground wire 5 Remove the tie band and harness 6 Remove the Scanner from the copier 1 Remove one screw and the Exposure Lamp terminal 2 Slide out the Exposure Lamp NOTE When the Exposure Lamp has been cleaned or replaced be sure to make the adjustment of exposure level in the Auto Exposure mode See ...

Page 149: ...rors 1156D047AA 1136D130AA 1136D131AA 1 Unplug the Thermal Fuse connector 2 Remove the Thermal Fuse cord from three clamps 3 Remove one screw and Thermal Fuse cover 4 Remove two screws and the Thermal Fuse 1 Wipe clean the 1st Mirror with a soft cloth 2 Wipe clean the 2nd Mirror with a soft cloth 3 Wipe clean the 3rd Mirror with a soft cloth ...

Page 150: ...ens and 4th and 5th Mirrors 1136D133AA 1136D132AA 1136D134AA 1 Remove the Original Glass 2 Remove two screws and the Optical Cover 3 Remove two screws and the Lens Cover 4 Gently dust off the surface of the Lens using a soft cloth 5 Wipe clean the 4th and 5th Mirrors with a soft cloth ...

Page 151: ...8AA 1 Hold the Cable Drive Gear with the bead at the bottom 2 Wind the longer length of the cable three and 1 2 turns clockwise around the Cable Drive Gear working from the back to the front side Then tape it 3 Wind the shorter length of the cable three and 1 2 turns counterclockwise around the Cable Drive Gear working from the front to back side Then tape it ...

Page 152: ...e 4 mm dia to position the gear 6 Wind the shorter length of the cable around pulley A 7 Secure the shorter length of the cable to the Cable Fixing Bracket NOTE Ensurea distance of 2 mm or less for the dimension shown on the left 8 Wind the longer length of the cable around pulley B 9 Hook the spring onto the longer length of the cable and pull the spring to hook it onto the shorter length of the ...

Page 153: ... 10 Removal of Scanner Motor M2 1156D048AA 1156D049AA 1 Remove the Right Cover Rear Cover and Rear Upper Cover 2 Remove four screws to free PWB F 3 Unplug one connector Then remove the edge cover with a lock and the harness 4 Remove four screws and Scanner Motor M2 ...

Page 154: ...Scanner Motor M2 1156D048AA 1156D050AA 1134D037AA 1134D038AA 6 Remove two screws to free the SCP Board PWB F mounting bracket The illustration shows where the SCP Board has been re moved for ease of understanding 7 RemovetwoscrewsandOriginalGlassCoolingFanMotor M5 8 Using a flat blade screwdriver loosen the right spring an chor to unhook the bead from the anchor thereby remov ing the cable 9 Move ...

Page 155: ...ng of the Scanner and Mirrors Carriage 2 Slide the Scanner by hand to check for cable tension before turning the copier ON 3 No part of the cable should ride on others when winding the cable around the Cable Drive Pulley Further no part in the cable should be bent or no part of the cable jacket frayed Wind the cable five turns around the Cable Drive Pulley 1156D054AA Wind Cable 5 Turns ...

Page 156: ...rew to free the Original Cover Detecting Sensor Assy 12 Remove four screws and the Scanner Drive Pulley mount ing bracket 13 Snap off one E ring and remove the Scanner Drive Pulley 1 Swing down the Front Door and slide out IU 2 Remove the Plate Spring 3 Remove the 6th Mirror Protective Filter 4 Using a soft cloth wipe clean the 6th Mirror Protective Fil ter 1 Remove six screws and the Rear Cover 2...

Page 157: ...t 1136D152AA 1156D056AA 1156D057AA 1 Swing down the Front Door 2 Swing the Transport Section Release Lever down 3 Loosen two screws that secure the IU 4 Slide out the IU 1 Remove the PC Drum Charge Corona by moving it to the rear 2 Loosen one screw and remove the stopper 3 Remove the PC Drum 4 Pull the Main Hopper to the front and unplug two Hopper Unit connectors ...

Page 158: ...ug one connector and remove three screws and the Sub Hopper 7 Remove two screws and the Developer Scattering Pre vention Plate NOTE Do not remove the Doctor Blade Assy as a changed Db could result NOTE Install the Developer Scattering Prevention Plate so that its seal is placed behind the side seals of the Developer Mixing Chamber 8 Dump the developer out of the Developing Unit ...

Page 159: ...and the Cleaning Blade NOTE When reinstalling the Cleaning Blade press the blade tightly up against the mounting bracket 10 Unplug one connector 11 Remove three screws and the PC Drum Paper Separator Finger Holder Assy NOTE When reinstalling the PC Drum Paper Separator Finger Holder Assy fit the collar of the assy onto the coupling holder in the rear ...

Page 160: ...sion Spring PWB G Assy PC Drum Paper Separator Fingers At removal and reinstallation use care not to damage the tip of the fingers Also use care not to get hurt by the tip of the fingers Hook the torsion spring properly After installation check that the Paper Separator Fingers oper ate smoothly Top View Bottom View 1156D063AA PC Drum Paper Separator Finger Installed ...

Page 161: ...opper 3 Remove and replace the PC Drum NOTE When the PC Drum has been replaced reset the count of PC Drum of Port Option counters of the Tech Rep mode and then make the adjustment of exposure level in the Auto Exposure mode For the adjustment of expo sure level in the Auto Exposure mode see p D 72 Using a brush whisk dust off the Developer Scattering Pre vention Plate Usingabrushorasoftclothdampen...

Page 162: ...ve and replace the Cleaning Blade 2 Remove the Toner Bottle from the IU Insert a brush through the toner port and into the toner 3 Apply toner to the entire surface of the new Cleaning Blade NOTE Be sure to apply toner to both end faces of the Cleaning Blade 4 Using the brush apply lubricant shipped with the Cleaning Blade to the two side seals shown ...

Page 163: ...he PC Drum when installing the drum 6 Fit the PC Drum stopper and tighten the screw 7 Apply a thin coat of toner to the surface of the PC Drum 8 Holding onto both ends of the PC Drum turn the PC Drum one complete turn in the forward direction 9 Holding onto both ends of the PC Drum turn the PC Drum 1 2 turns in the backward direction 10 Holding onto both ends of the PC Drum turn the PC Drum 1 2 tu...

Page 164: ... fresh starter evenly into the chamber NOTE Shake the packet of starter well before opening it NOTE When the starter has been replaced reset the count of Starter of the Port Option counters of the Tech Rep mode and then make the ATDC adjustment For the ATDC adjustment see p D 69 1134D051AA 1 Dump the developer out of the Developing Unit ...

Page 165: ...Using a brush or a soft cloth dampened with alcohol clean the AIDC Sensor Board 1 Remove the PC Drum Paper Separator Fingers Assy 2 Using a brush or a soft cloth dampened with alcohol clean the PC Drum Paper Separator Fingers 1 Remove the IU 2 Remove two screws the Toner Antispill Plate and Toner Antispill Seal 3 Replace the Toner Antispill Seal 4 Using a brush clean the Toner Antispill Seal 5 Usi...

Page 166: ...055AA 1 Swing down the Front Door 2 Unplug one connector 3 Remove one screw and Main Erase Lamp LA3 1 Swing down the Front Door 2 Remove the Main Erase Lamp Filter 3 Using a soft cloth dampened with alcohol wipe clean the Main Erase Lamp Filter 1 Swing down the Front Door 2 Remove the IU 3 Using a soft cloth dampened with alcohol wipe clean Image Erase Lamp LA2 1 Swing down the Front Door 2 Remove...

Page 167: ...onnectorintherearandremoveImageErase Lamp LA2 NOTE When Image Erase Lamp LA2 has been removed make the adjustment of edge erase For the adjustment of edge erase see p D 93 1 Swing down the Front Door 2 Swing out the Main Hopper 3 Slide out the Ozone Filter 1 Remove the Rear Cover 2 Remove one screw and the Filter Cover 3 Pull out the Ozone Filter 1 Remove the Rear Cover 2 Remove the Toner Collecti...

Page 168: ...ge Corona to the rear and pull it off 1 Remove the IU 2 Remove one screw and PC Drum charge Corona Unit 3 Press the Mesh Holder on the front of the Corona Unit in the direction of arrow A to remove the Grid Mesh 4 Remove the Cleaning Pad Cover 5 Remove the End Caps from the front and rear ends of the Unit 6 Remove the Comb Electrode NOTE Use care not to deform the Electrode When removing it first ...

Page 169: ... If the blower brush is not effective in cleaning the Grid use a soft cloth dampened with alcohol to clean serious con tamination Clean Comb Electrode using the Corona Unit Cleaning Lever 1 Swing down the Front Door 2 Pull out the Image Transfer Paper Separator Coronas 1 Swing down the Front Door 2 Clean the Image Transfer Corona Wire using the Corona Wire Cleaning Lever NOTE If the Image Transfer...

Page 170: ...ona wire with a new one 1 Remove four Paper Guides 2 Dampena soft cloth with alcohol hold it with a pair of twee zers and wipe the Paper Separator Corona Wire gently in one direction from the hook end to spring end 3 Replace the Paper Separator Corona Wire by using the same procedure as that for the Image Transfer Corona Wire 1 Remove four Paper Guides 2 Remove the Holder Covers at the front and r...

Page 171: ...EP5000 EP4000 DIS REASSEMBLY ADJUSTMENT 97 04 01 D 52 9 Cleaning of the Lower Pre Image Transfer Guide Plate 1136D206AA Using a soft cloth dampened with alcohol wipe clean the Lower Pre Image Transfer Guide Plate ...

Page 172: ... Open the Left Door 2 Swing down the Front Door 3 Remove one screw and the Fusing Unit 1 Remove two screws and the Front Cover 2 Unplug the connector of the Heater Lamp on the front 3 Remove three harness holders 4 Remove the Heater Lamp cord from the two edge covers 5 Remove two screws and the front lamp holder 6 Remove two screws and the cover NOTE At reinstallation position the cover between th...

Page 173: ...ng edge cov er 9 Remove three screws and the rear lamp holder 10 Remove the Heater Lamp cord from the wiring saddle 11 Remove the Heater Lamp 12 Remove four screws and the Upper Cover 13 Remove two screws and the Upper Fusing Paper Separa tor Finger mounting bracket NOTE When reinstalling the Upper Fusing Paper Separator Finger mounting bracket be sure that both ends of the bracket are in tight co...

Page 174: ... the two Thermistors 16 Remove one screw shoulder screw and the Harness Guide 17 Remove one screw and the Thermoswitch cord 18 Remove two screws and the Temperature Detector Assy NOTE When reinstalling the Temperature Detector Assy be sure that both ends of the assy are in tight contact with the frame 19 Remove the Gear 20 Remove two shoulder screws and the Fusing Unit En trance Guide Plate ...

Page 175: ...e Lower Exit Guide Assy Lower Fusing Roller Upper Fusing Roller Torsion Spring Shoulder Screw Shoulder Screw Torsion Spring Lower Exit Guide Assy 1156D086AA Front Rear Lower Exit Guide Assy Position À Installing the Lower Exit Guide Assy Á Lower Fusing Paper Separator Finger Contact Lower Fusing Roller No Clearance Allowed 1134D067AA ...

Page 176: ...installing the springs alternately tighten the bracket mounting screws until the brackets completely contact the ends of the Lower Exit Guide Assy 1156D087AA 1156D088AA 1156D089AA 1156D090AA 24 Remove the Lower Fusing Roller 25 Remove two extension springs 26 RemovetwoE rings thegear bushing andCleaningRoll er 27 Remove two E rings then two gears 28 Remove two screws the Upper Fusing Roller drive ...

Page 177: ...mount ing bracket 2 Remove five springs 3 Slide out the shaft to remove the Upper Fusing Paper Sep arator Fingers 4 Replace the fingers with new ones 5 Using a soft cloth dampened with alcohol or silicone oil wipe clean the Upper Fusing Paper Separator Fingers 1 Remove the Lower Exit Guide Assy 2 Using a soft cloth dampened with alcohol or silicone oil wipe clean the Lower Fusing Paper Separator F...

Page 178: ...233AA 1 Remove the Temperature Detector Assy 2 Using a soft cloth dampened with alcohol wipe clean the thermoswitch 1 Remove two screws and the Upper Cover 2 Remove the Cleaning Roller 3 Replace the Cleaning Roller with a new one 4 Using a brush whisk dust off the Cleaning Roller 1 Remove the Upper Fusing Roller 2 Replace the Upper Fusing Roller with a new one 3 Using a soft cloth dampened with al...

Page 179: ...1 D 60 10 Replacement and Cleaning of the Lower Fusing Roller 1156D088AA 1136D234AA 1 Remove the Lower Fusing Roller 2 Replace the Lower Fusing Roller with a new one 3 Using a soft cloth dampened with alcohol or silicone oil wipe clean the Lower Fusing Roller ...

Page 180: ...D095AA 1156D096AA 1156D097AA 4 Remove four screws to free the Sorter Connector Assy 5 Unplug two connectors 6 Remove one screw and the ground wire 7 Snap off the E ring from the shaft onto which the Exit Du plex Switching Unit is mounted 8 Work the harness indicated by the arrow off the wiring saddle 9 Remove one screw that holds the belt 10 Remove two screws and the mounting bracket 11 Remove the...

Page 181: ...Doctor Blade and Sleeve Roller use jigs number Ä and Å D When adjusting the position of the PC Drum Paper Separator Fingers use jigs number Ä and Æ ÀFront Door Interlock Switch Actuating Jig ÁPredrive Inhibit Switch Actuating Jig ÂScanner Positioning Jig ÃScanner Mirrors Carriage Positioning Jig ÄSleeve Magnet Roller Positioning Jig ÅD B Adjusting Jigs ÆPC Drum Paper Separator Finger Positioning J...

Page 182: ... 1 000 20 2 0 mm Multi Bypass Table D 79 1st Drawer reference Position 1 000 20 2 0 mm Drawer Positioning Plate D 80 2nd Drawer reference Position 1 000 20 2 0 mm Drawer Positioning Plate D 80 Leading edge registration full size 1 000 20 1 5 mm Control panel D 81 Leading edge registration enlargement 2 000 40 3 0 mm Control panel D 83 Leading edge registration reduction 0 500 10 1 5 mm Control pan...

Page 183: ...rrent flows between NO and COM when the actuator is closed COM Common Common contact for NC and NO Yellow NO Red COM Blue NC Red COM 1136D007AA 1136D008AA Requirement 0 1 mm to 0 5 mm Actuator Out of Adjustment When the actuator is closed D If the gap between the switch and actuator is too big current does not at times flow to NC or NO D If there is no gap between the switch and actuator the actua...

Page 184: ...he Front Door 2 Remove six screws and the Upper Left Cover 3 Remove three screws and the cover 4 Loosen two screws that secure Front Door Interlock Switch 5 Close the Front Door 6 Slowly move the switch to the front until the actuator is closed by the actuator stop on the Front Door Then tight en the two mounting screws D The switch is wired for the NO type ...

Page 185: ...y 1 Paper Take Up Unit Timing Belt 300 100 g Approx 3 mm 2 Developing Unit Timing Belt 350 100 g Approx 4 mm 3 Fusing Unit Timing Belt 350 100 g Approx 3 mm 4 IU Timing Belt 350 100 g Approx 5 mm Loosen two screws that secure the Tension Lever Move the Tension Lever in the direction of the arrow two to three times When the belt tension is correct tighten the two screws 1156D172AA 350 100 g 300 100...

Page 186: ...access the Tech Rep mode press the following keys in order Stop Key Stop Key 0 1 1156D134CA Press the keys in order of 1 2 3 and 4 1134D069AA z Accessing the Adjust Mode To access the Adjust mode press the following keys in order with the Tech Rep mode menu on the screen Stop Key Start Key 1156D138CA Press the keys in order of 1 and 2 1134D071AA ...

Page 187: ... 2 Call the Tech Rep mode menu to the screen 3 Touch Function to show the Function menu on the screen 4 Touch F7 Orig Sensor 5 Press the Start Key to let the copier make the initial adjustment of the Original Size Detecting Board 1156D142CA 1156D135CA NOTE While the copier is in the adjustment cycle the Start Key is lit up orange The key turns green as soon as the adjustment cycle is completed 6 A...

Page 188: ...C Adjust 6 Press the Start Key to let the copier make the ATDC adjustment It will run for about 3 minutes 1156D142CA 1156D139CA NOTES D While the copier is in the adjustment cycle the Start Key is lit up orange The key turns green as soon as the adjustment cycle is completed D Pressing the Start Key will automatically start the ATDC adjustment cycle Be sure to run this cycle only after the starter...

Page 189: ... to the Basic screen 1156D143CA 1156D168CA Enter This Value on the Adjust Label z Shouldthe F8 operation be run when the starter has not been replaced check that the ATDC Ref Level value on the Level History screen matches that written on the Adjust Label If they do not agree with each other change the ATDC Ref Level value on the screen so that it matches the value on the Adjust Label 1156D143CA T...

Page 190: ...urfaces of the Exposure Lamp and Main Erase Lamp are free of scratches and dirt 4 The Cleaning Blade is free of waviness 1 Make a copy under the following control panel settings Original A3 or A4 crosswise 11 17 or 11 8 1 2 crosswise Paper A3 or A4 crosswise 11 17 or 11 8 1 2 crosswise Magnification 100 ratio Exposure Manual setting convenient for check 2 Remove the Original Glass 3 Turn the copy ...

Page 191: ...Touch Panel Then stack about five blank sheets of A3 or 11 17 paper on the Original Glass and lower the Original Cover 1134D079AA 1156D140CA 2 Call the Tech Rep mode menu to the screen 3 Touch Function to show the Function menu on the screen 4 Touch F5 Optimum AE 5 Press the Start Key to let the copier adjust the exposure level in the Auto Exposure mode It will run for about 30 seconds 1156D142CA ...

Page 192: ...setting has been changed in this adjustment be sure to make the adjustment of exposure level in the Auto Exposure mode 1156D137CB 3 Call the Tech Rep mode menu to the screen 4 Touch Tech Rep Choice to show the Tech Rep Choice 1 menu on the screen 1156D141CA 1156D145CA 1 Place the Kodak Gray Scale lengthwise face down and at the center on the Original Glass Place a sheet of pure white A3 or 11 17 p...

Page 193: ...tion again D If the image density is low decrease the setting value D If the image density is high increase the setting value D If the image density does not fall within the specifications through one setting try another setting Setting Instructions 1156D150CA Touch This Key Twice Touch This Key if ID is High Touch This Key if ID is Low 1156D146CA NOTE Be sure to touch Enter before pressing the Pa...

Page 194: ...allowance is 200 mm 0 005 1 0 mm Zoom Ratio Specifications Adjusting Mode Setting Range Full size 1 000 200 1 0mm Adjust A1 Lens Full Size Position 43 to 58 z Important This adjustment must be made before the Reference Position Adjustments 1134D136AA 1134D124AA 1 Place a scale in parallel with the Original Width Scale and make a copy Make three copies in full size 1 000 mode and using 200 mm or wi...

Page 195: ...ger than the actual scale decrease the setting value D 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 Setting Instructions Touch This Key if Measurement is Shorter Touch This Key if Measurement is Longer Setting Value 1156D147CA NOTE Be sure to touch Enter before...

Page 196: ...ce is 300 mm 0 005 1 5 mm Zoom Ratio Specifications Adjusting Mode Setting Range Full size 1 000 300 1 5mm Adjust A3 Feed Direction Mag Ratio 46 to 54 z Important This adjustment must be made before the Adjustment of the Leading Edge Registration 1134D137AA 1138D154AA 1 Place a scale in parallel with the Original Length Scale and make a copy Make three copies in the full size 1 000 mode using A3 o...

Page 197: ...y is longer than the actual scale decrease the setting value D 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 Setting Instructions Touch This Key if Measurement is Shorter Touch This Key if Measurement is Longer 1156D155CA NOTE Be sure to touch Enter before press...

Page 198: ...heck if dimension A from the edge up to the reference line on the copy is up to the specifications Make the check with the third copy 4 If dimension A deviates from the specifications loosen three screws that secure the Multi Bypass Table and move the table in the direction of the arrow as necessary D If dimension A on the copy is shorter than 18 mm move the table to the front of the copier D If d...

Page 199: ...should mea sure 20 mm 2 0 mm in the full size 1 000 mode 1 Place the GTC test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale Then lower the Original Cover 2 Feeding three sheets of A3 or 11 17 paper from the 1st Drawer make two full size copies 3 Check if dimension A from the edge up to the reference line on the third copy...

Page 200: ...on 1 Leading Edge Registration in Full Size Mode 1136D033AA D Dimension A on the copy of the GTC test chart should mea sure as follows at the respective zoom ratios 1 Place the GTC test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale Then lower the Original Cover 2 Make three single copies on A3 or 11 17 paper in full size ...

Page 201: ...n the copy is longer than 21 5 mm increase the setting value D If dimension A on the copy is shorter than 18 5 mm decrease the setting value If the measurement does not fall within the specifications through one setting try another setting Setting Instructions Touch This Key if Measurement is Shorter Touch This Key if Measurement is Longer 1156D152CA NOTE Be sure to touch Enter before pressing the...

Page 202: ...2 menu 3 Touch the select key t or s to highlight A11 Scan Regist Enlargement 1156D156CA 1156D166CA 1 Afterthe leading edge registration in the full size mode has been adjusted make three single copies on A3 or 11 17 paper at 2 000 and check the 3rd copy for leading edge registration If the registration is up to the specifications go to the ad justmentinthereductionmode Ifitdeviatesfromthespec ifi...

Page 203: ... dimension A on the copy is shorter than 37 0 mm decrease the setting value If the measurement does not fall within the specifications through one setting try another setting Setting Instructions Touch This Key if Measurement is Longer Touch This Key if Measurement is Shorter 1156D149CA NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen If this...

Page 204: ...1 2 menu to the screen 3 Touch the select key t or s to highlight A5 Scan Regist Reduction 1156D138CA 1156D153CA 1 After the leading edge registration in the enlargement mode has been adjusted make three single copies on A3 or 11 17 paper at 0 500 and check the 3rd copy for leading edge registration If the registration deviates from the specifications per form the following steps to make the adjus...

Page 205: ... dimension A on the copy is shorter than 8 5 mm decrease the setting value If the measurement does not fall within the specifications through one setting try another setting Setting Instructions Touch This Key if Measurement is Longer Touch This Key if Measurement is Shorter 1156D157CA NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen If this ...

Page 206: ... Book 1 and make three single copies on A4 crosswise paper at full size 1 000 mode Check the third copy for the leading edge registration If the dimensions deviate from the speci fications perform the following steps to make the adjustment 1156D161CA D Dimension A on the copy of a test chart A3 or 11 17 as shownon the left should measure 20 3 0 mm and Bequals C D Setting range 45 to 55 1 Place the...

Page 207: ...ion A on the copy is longer than 23 mm increase the setting value D If dimension A on the copy is shorter than 17 mm decrease the setting value If the measurement does not fall within the specifications through one setting try another setting Setting Instructions Touch This Key if Measurement is Longer Touch This Key if Measurement is Shorter 1156D163CA NOTE Be sure to touch Enter before pressing ...

Page 208: ...ct key t or s to highlight A12 Leading Edge Erase Adjust 1156D159CA 1156D166CA D The erase width dimension A on the copy of the GTC test chart should measure 1 0 to 6 5 mm D Setting range 45 to 55 1 Place the GTC test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale Then lower the Original Cover 2 Make three single copies on...

Page 209: ... dimension A on the copy is shorter than 1 0 mm increase the setting value If the measurement does not fall within the specifications through one setting try another setting Setting Instructions Touch This Key if Measurement is Longer Touch This Key if Measurement is Shorter 1156D162CA NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen If this ...

Page 210: ... menu 4 Touch the select key t or s to highlight A13 Trailing Edge Erase Adjust 1156D166CA 1156D164CA D The erase width dimension A on the copy of the GTC test chart should measure 0 5 to 5 5 mm D Setting range 42 to 58 1 Place the GTC test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale Then lower the Original Cover 2 Make...

Page 211: ... dimension A on the copy is shorter than 0 5 mm increase the setting value If the measurement does not fall within the specifications through one setting try another setting Setting Instructions Touch This Key if Measurement is Longer Touch This Key if Measurement is Shorter 1156D160CA NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen If this ...

Page 212: ...ss and align its rear left corner with the reference marker on the Original Width Scale Then lower the Original Cover 2 Make a single copy on A3 or 11 17 paper in full size mode If A3 or 11 17 paper is not available use A4 or 8 1 2 11 crosswise paper 3 If the front edge erase width deviates from the specifica tions adjust as necessary by turning the Edge Erase Ad justing Screw D If dimension A on ...

Page 213: ...age Positioning Jig 1136D047AA 1136D048AA 83 5mm 1 Remove the Original Cover Upper Rear Cover and Origi nal Glass 2 Slide the Scanner to a position at which the hole is aligned with the Scanner Positioning Screw 3 Insert a screwdriver into the hole and loosen the Scanner Positioning Screw This allows the Scanner Drive Cable to move independently of the Scanner 4 Align the rectangular hole in the u...

Page 214: ...Interleaf EP5000 EP4000 DIS REASSEMBLY ADJUSTMENT 97 04 01 D 95 1139D051AA 8 Tighten the Scanner Positioning Screw which was loos ened in step 3 ...

Page 215: ...e IU PC Drum Charge Corona and PC Drum 2 Remove two screws and the Developer Scattering Pre vention Plate 3 Using a brush whisk developer off the surface of the Sleeve Roller 4 InstalltheSleeve MagnetRollerPositioningJigintotheIU 5 Loosen three screws that secure the Doctor Blade Insert the D B Adjusting Jigs between the Doctor Blade and Sleeve Roller 6 Press down the Doctor Blade until it positiv...

Page 216: ...ger Positioning Jig to the IU 2 Usingan Allen wrench adjust the position of one of the two Paper Separator Fingers Either one will do D With the solenoid in the deenergized position the tip of the finger should be at a point between A and B preferably more on the B end D With the solenoid energized the tip of the finger should touch C A 41 5 mm B 40 5 mm C 40 0 mm Adjusting Instructions 3 After th...

Page 217: ...he two Stoppers just swing into the upright position tighten the two SL4 mounting screws 1134D121AA 1 Remove the SL4 mounting bracket For the removal steps see p D 25 2 Manually bring SL4 into the energized position plunger pushed in A click is heard when the solenoid is energized Then hold the plunger in position 3 Loosen two screws that secure the SL4 and slide SL4 all the way in the direction o...

Page 218: ... 4 5 mm z Important D After the adjustment move the plunger manually to check that it moves smoothly and the Switching Plate swings up and down properly 1134D122AA 3 Bring the lever into contact with the stopper Keeping that position move SL5 so that the gap between the plunger rubber washer and solenoid measures 4 0 to 4 5 mm When the specified dimension is reached tighten the two SL5 mounting sc...

Page 219: ...e the harness from the locking wiring saddle 4 Unplug three connectors 5 Remove two screws and the Right Door 6 Remove the Counter Cover 7 Remove four screws and the Right Cover 8 Remove the IU 9 Remove two screws and the cover 10 Connect the Plug In Counter connector 11 Secure the Plug In Counter Mounting Bracket with the two screws NOTE When the Plug In Counter is mounted be sure to turn ON the ...

Page 220: ...ustment 1156D100AA 1134D116AA 1134D117AA 1134D118AA 1 Mount the Right Door with two screws At this time only temporarily tighten these screws 2 Lightly close the Right Door so that the S22 actuator will not contact the frame 3 Due to its own weight the front end of the Right Door tends to hang lower Lifting the front end slightly tighten the two mounting screws 4 Open and close the Right Door two ...

Page 221: ...MBLY ADJUSTMENT 97 04 01 Copyright 1997 MINOLTA Co Ltd Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information MINOLTA CO LTD 1156 7992 11 97046000 Printed in Japan 1156SBD000EA ...

Page 222: ...Interleaf EP5000 EP4000 SWITCHES ON PWBs TECH REP SETTINGS 97 04 01 EP5000 EP4000 SWITCHES ON PWBs TECH REP SETTINGS 1156SBS000AA ...

Page 223: ...tings Switches Board PWB I S 5 USER S CHOICE MODE 4 S 7 4 1 User s Choice Selection Screen S 7 4 2 User s Choice Function Setting Procedure S 7 4 3 User s Choice Function Tree S 8 4 4 Settings in the User s Choice S 9 TECH REP MODE 5 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 Function Tree S 17 5 4 Settings in the Tech Rep Mode S 19 ...

Page 224: ...HES ON PWBs TECH REP SETTINGS 97 04 01 ii CONTENTS FACTORY SETTING 6 S 41 6 1 Factory Setting Menu Screen S 41 6 2 Factory Setting Function Setting Procedure S 41 6 3 Factory Setting Function Tree S 42 1 Function S 42 2 Adjust S 44 ...

Page 225: ...r bag never place it directly on an object that is easily charged with static electricity such as a carpet or plastic bag d Do not touch the parts and printed patterns on the PWBs with bare hands 1151SBS0102A 1 2 Precautions for Replacement and Inspection a Whenever replacing the PWB make sure that the power cord of the copier has been unplugged b When the power is on the connectors must not be pl...

Page 226: ... Track function the entry of the access number and the press of this key Access Mode will allow the user to make copies Å Energy Saver Key D Sets the copier into the Energy Saver mode Æ Interrupt Key D Sets the copier into or lets it leave the In terrupt mode Ç Panel Reset Key D Clears all control panel settings made pre viously initializing the copier Note It does not however clear the con tents ...

Page 227: ... à À Supplementary Function Keys D Selects the corresponding menu screen eitherAuxiliary Finishing or Orig Copy Á Message Display D Shows the current copier status operating instructions and other data including the number of copies selected and the amount of paper still available for use  Basic Function Keys D Allows the user to select the exposure lev el zoom ratio and copy paper à Function Dis...

Page 228: ...specific code Error Display D An error display is given when trouble occurs which can be corrected by the user Examples Paper misfeed toner empty door open 1149O387CA 1149O421CA Warning Display Caution Display 1149O422CA 1149O385CA D A warning display is given when any further copier operation will not be possible or only faulty results will come out due to erroneous panel settings or other cause ...

Page 229: ...sets a malfunction including those of the Exposure Lamp C04XX and fusing C05xx PJ2 Initialize Switch Forcibly resets a misfeed or malfunction that occurrs due to incorrect operation etc when it cannot be reset by opening and closing the Front Door or the press of S1 TP1 GND Test Point Ground terminal used for memory clear TP3 Memory Clear Test Point Initializes all data except the counts of electr...

Page 230: ...s shown on the Touch Panel then touch Enter NOTE D If an erratic operation or display occurs perform the clearing procedures in the order of PJ2 and TP3 D When memory clear has been performed make the necessary settings again List of Data Cleared by Switches and Points Clearing Method Data Cleared Front Door Open Close Trouble Reset Switch S1 Initialize Switch PJ2 Memory Clear Test Point TP3 Misfe...

Page 231: ...e 1 Press the User Mode key on the control panel and then touch the User s Choice key 2 Select the page number key that contains the desired function from among 1 6 through 6 6 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 NOTE The function selected is highlighted E...

Page 232: ...rity Expo Mode Priority Expo Level Priority Manual Expo Adjust Finishing Priority Auto Panel Reset Energy Saver Mode Drum Dehumidifier Counter Removal Intelligent Sort Confirmation Beep Original Thickness Smaller Originals Custom 2in1 Custom 2in1 Separation Custom Book Copy Special Paper Orig Copy Default Auto Power off Mode Original on Glass Administrator Mode 2 6 3 6 4 6 5 6 6 6 Manual feed expa...

Page 233: ...Select the language of the Touch Panel messages French Dutch Italian Spanish Portuguese Danish Norwegian Swedish Finnish Greek Metric Areas English German French Japanese Chinese Portuguese Inch Areas German Paper Priority Specify the paper source selected automatically 1st Drawer 2nd Drawer 3rd Drawer 4th Drawer LCT Copy Mode Priority Specify the default mode selected automatically when power is ...

Page 234: ...r Darker Normal Manual Expo Adjust Determine the default voltage curve EXP level in the Manual Exposure mode as optimized by the type of original Manual Exposure Voltages in Different Modes NOTE EXP 5 uses as reference the voltage value automatically adjusted by the F5 operation Mode 1 Mode 1 Halftone images photos Mode 2 Ordinary originals Mode 3 Originals with a colored back ground or faint text...

Page 235: ...FF the function that automatically switches be tweenSort and Non Sort according to the number of originals loaded in the docu ment feeder ON OFF NOTE This function is enabled when Mixed Orig Detection is turned OFF and the copier is in the Auto Paper or Auto Size mode Confirmation Beep Select whether to turn ON or OFF the beep that sounds each time a key on the control panel is pressed or that on ...

Page 236: ...m Inch areas 1 4 1 2 3 4 1 NOTE The erase width for the Top Edge and for the CD direction of the Frame is only 10mm for the metric areas and 1 2 for the inch areas Custom 2in1 Separation Make the settings for Paper Zoom Margin and Erase that are auto matically recalled when 2 in 1 separation copy is selected Position Right Edge Left Edge Frame Top Edge Center Frame Center Width Metric areas 5 10 1...

Page 237: ... erase Make the following selections only when Frame Center is selected Frame Metric areas 5 10 15 20 mm Inch areas 1 4 1 2 3 4 1 Center Metric areas 5 10 15 20 mm Inch areas 1 4 1 2 3 4 1 NOTE The erase width for the Top Edge and for the CD direction of the Frame is only 10mm for the metric areas and 1 2 for the inch areas X1 000 Zoom Fixed zoom ratios Special Paper Set up a drawer for special pa...

Page 238: ...means setting the time it takes the Auto Shut Off function to be activated that can range from 1 min to 240 min NOTE OFF is displayed when Enable is selected for Non Auto Shut off of the Administrator Mode function OFF 1 to 240 EP4000 90 min EP5000 60 min Original on Glass Select whether to turn ON or OFF the beep that sounds when you attempt to load an original in the document feeder with another...

Page 239: ...rom the 10 Key Pad 1 901 1000 Accounts The copy track data of the selected page is displayed Count Reset Clears the total counters of all accounts Total Displays the count of the Total Counter It can also be cleared with the Clear key NOTE The entry of an access number is not possible with 1 to 1000 corre sponding to the ID numbers Max Copy Sets Determine the number of copies or copy sets that can...

Page 240: ...O423CB 1149SBS0502A 5 2 Tech Rep Mode Function Setting Procedure Setting Procedure 1 Set the copier into the Tech Rep mode by pressing the following keys in this order 2 Select the particular Tech Rep mode function to be set 3 Make the necessary settings by following the instructions given sequentially on the screen NOTE The function selected is highlighted Exiting the Mode D Press the Panel Reset...

Page 241: ...Counter Maintenance Call Copy Kit Counter Toner Empty Stop Type of Vendor Tech Rep Choice 1 Auto Paper Config Leading Edge Erase Trailing Edge Erase Loop Adjust Drawer Loop Adjust Man Function Limit Tech Rep Choice 2 Image Exposure Simplex Duplex Bin Movement Universal Tray 13 x Universal Tray 14 x Automatic feeding adjust Stack Tech Rep Choice 3 Change Fixed Zoom Ratio Paper Size Input Marketing ...

Page 242: ...INGS 97 04 01 S 18 Tech Rep Mode I O Check RD Mode Accessory Test Level History IC Port Data Check Paper Path Sensors Check Memory Check Controller Board Check Panel Indication Check ADF Check Sorter Check Last Trouble Rom Version Machine Status Admin Mode ...

Page 243: ...the Stop key causes the copier to feed the paper out of it and stop operating another press of the Start key will resume the paper take up and feeding sequence F3 Exp Lamp Checks to see if the Exposure Lamp lights up properly It runs for 30 sec F5 Optimum AE Makes the following automatic adjustments Vg level Manual exposure level and AE Sensor optimum exposure level It runs for 30 sec Procedure 1 ...

Page 244: ... Select the conditions paper size and 2 sided copying by which the Total Counter count is increased NOTE See the Count up Table for details Mode 0 1 count per 1 copy cycle Mode 1 Multiple count up according to paper size and 2 sided copying Mode 2 Multiple count up according to paper size and 2 sided copying Count up Table Copying Size 1 Sided 2 Sided Sizes other than those set Set sizes Sizes oth...

Page 245: ... by selecting mode 1 or 2 When the count reaches the preset value the maintenance code M4 is displayed NO Disables the Copy Kit counter Mode 1 Copying not inhibited after the count reaches the preset value Mode 2 Copying inhibited after the count reaches the preset value Toner Empty Stop Select whether or not to inhibit copying when a toner empty condition is detected Enable Copy Disable Copy NOTE...

Page 246: ...ength approx 7 mm Display Description 51 52 53 Loop length approx 9 mm Loop length approx 11 mm Loop length approx 13 mm Loop Adjust Man Adjust the length of the loop before the Synchronizing Rollers to be formed in paper fed via the Multi Bypass Tray or a paper feeder option Display Description 47 48 49 50 Loop length approx 1 mm Loop length approx 3 mm Loop length approx 5 mm Loop length approx ...

Page 247: ...t Bins will automatically move upward after the last copy is ejected into the Bins OFF After the last copy the Sort Bins automatically move upward ON After the last copy the Sort Bins do not move upward Universal Tray 13 x Set the inch size of paper to be used in the Universal Tray 8 8 8 Universal Tray 14 x Set the inch size of paper to be used in the Universal Tray 8 8 Automatic feeding adjust Se...

Page 248: ...source for which the paper size is to be set on the Paper Size Input 1 2 screen 2 Then the Paper Size Input 2 2 screen appears Using the Y or B key select the paper size 3 Touch Enter to validate the paper size setting Marketing Area Select the marketing area to set the paper size and fixed zoom ratios MJ MC MH Other Areas Note Be sure to initialize the copier after the marketing area has been sel...

Page 249: ...ch Enter This clears all counts of the counter selected Tech Rep Mode Counter Touch Panel Display Operation Paper Shows the number of copies made on each paper size or type S0 stan dard paper S1 recycled paper S2 special paper S3 disabling 2 sided copying Paper 1 2 Paper Size A3 11 X 17 B4 11 X 14 A4 Legal B5 Letter A5 5 X8 FLS Paper Type S0 S1 S2 S3 Paper 2 2 Note For a paper size that can be loa...

Page 250: ...er of the copier Note 1 MCBJ System MCBJ Machine Only MCBJ ADF Note 2 A minus sign is appended when the denominator is 0 for each MCBJ Total Counter value divided by the sum of Jam Counter values Total Counter value divided by the sum of copier Jam Counter values No of originals fed through the ADF divided by the sum of ADF Jams Jam Counter 2 3 Display Description Display Description 5th Drawer No...

Page 251: ...identally cleared pressing the Interrupt key will undo the clear operation Display Description Display Description 1st Drawer No of paper take up retries at the 1st Draw er of the copier 5th Drawer No of paper take up retries at the 5th Draw er of the copier 2nd Drawer No of paper take up retries at the 2nd Drawer of the copier Dup No of paper take up retries at the Duplex Unit 3rd Drawer No of pa...

Page 252: ...on Code Location Malfunction Code Location C09CX C0E0X C0E20 C0F02 LCT Main Erase Lamp Auxil Erase Lamp Orig Size Det CPU C0F10 C0F2X C0F3X C0F79 EE Sensor AIDC Sensor ATDC Sensor Paper Empty Sensor Trouble 5 6 Clearing a Count Using the B or Y key highlight the count to be cleared then press the Clear key Note If a count is accidentally cleared pressing the Interrupt key will undo the clear opera...

Page 253: ...lly cleared pressing the Interrupt key will undo the clear operation Port option Shows the frequency of use of each of the different parts of the copier includ ing options to serve as a guideline for the maintenance time for the Tech Rep Port Option 1 3 Display Description Display Description Manual Feed No of sheets of paper fed from the Multi By pass Tray 3rd Drawer No of sheets of paper fed fro...

Page 254: ...crosswise paper fed through the copier Developer No of sheets of paper fed through Fusing Roller No of revolutions of the Fusing Roller as converted to the num ber of sheets of A4 crosswise paper fed through the copier Clearing a Count Using the B or Y key highlight the count to be cleared then press the Clear key Note If a count is accidentally cleared pressing the Interrupt key will undo the cle...

Page 255: ... Count 1 Using the B or Y key select the counter to be set 2 Enter the value from the 10 Key Pad Clearing the Set Value Count Using the B or Y key highlight the count to be cleared then press the Clear key Note If a count is accidentally cleared pressing the Interrupt key will undo the clear operation Resetting the Counter Using the B Y key select the counter corresponding to the displayed mainte ...

Page 256: ...unction 2 Press the Start key to start the sensor check sequence No Display Sensor Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1st Feed 2nd Feed 3rd Feed 4th Feed 1st Vertical 2nd Vertical 3rd Vertical 4th Vertical Trans Roller Leading Edge 1st Exit 2nd Exit Turnover Up Turnover Low Dup Entrance Dup Exit Non Sort Sort Punch Regist 1st Drawer Paper Take up Sensor PC56 2nd Drawer Paper Take...

Page 257: ...al The highlighted Controller Board Check key is returned to normal display None Faulty The malfunction code appears Change PWB A Panel Indication Check Checks the LEDs and Touch Panel on the control panel for correct operation Procedure 1 Touch the Panel Indication Check key 2 All LEDs light up and then each LED goes out in the following order When all LEDs go out they all light up again and the ...

Page 258: ...l Exp setting Image density On off Mixed Orig Detection 1 1 1 2 2 2 etc Orig copy Non Sort Sort Group Sort Staple Punch Finishing Cover Front Cover Front Back Copied Cover Non Copied Cover Cover Copied Inserts Non Copied Inserts Page Insertion Copied Interleaves Non Copied Interleaves OHP Interleaving Method position width File Margin Method position width Erase 1156SBS050407A 7 ROM Version Tech R...

Page 259: ... modem connected to the Center personal computer Note 1 When the office extension and outside line use different sys tems enter P for a pulse telephone line or T for a tone telephone line before the outside line number Note 2 The time it takes the private branch exchange PBX system to switch from the extension line to the outside line varies de pending on the type of PBX system used Set this time ...

Page 260: ... Data Save back to the PPC Initial Transmission Used to perform the initial transmission from the PPC to the Center to check for correct communication when the Data Terminal has been set up Call Completion Used by the Tech Rep to notify the Center that his her service job for the copier has been completed Counter Clear Used to clear the count of the spare counter set by the Center Procedure 1 Sele...

Page 261: ...ure 1 Select the operating mode to be checked and touch Next 2 Load the required number of originals into the Document Feed Tray and press the Start key Output Check Checks each of the motors and solenoids for operation M1 M2 M3 M4 M5 SL1 SL2 SL3 SL4 CL Procedure D Select the part to be checked and press the Start key Doc Stop Position Set Adjusts the document stop position in different operating ...

Page 262: ...per clamp motion occurs Paper Aligning Pressing the Start key causes a paper aligning motion to occur for the width of the paper currently selected for use Stack move Pressing the Start key begins a sequence in which paper is stacked in order starting with the paper loaded in the 1st Bin When Next is touched after any of the Sorter Check functions has been selected the Input Check screen appears W...

Page 263: ...ormance becomes poor due to the operating environment and the paper being used Level History 1 2 Display Variable Range Incre ments Description ATDC Ref Value ATDC Target Level ATDC Current Level 2 step 0 5 0 5 F8 adjusted value Target ATDC level Current ATDC level 2 to 254 1 0 to 9 0 1 0 to 9 0 Vg Default Level Vg Current Level 30 V 30 V Initial grid voltage setting Grid voltage correc tion value...

Page 264: ...e next isolated malfunction will be regarded as an ordinary one Malfunction Code Description C09XX Paper take up failure C0dXX Duplex Unit malfunction C0350 to 52 SP communication failure C0F2X Faulty AIDC Sensor C0FEX to FX Faulty Original Size Detecting Sensor C004d 45 Cooling Fan Motor malfunc tion Ventilation Fusing Section C0b3X 5X to 7X Sorter malfunction C0F7X Faulty Paper Empty Sensor Clea...

Page 265: ...ting Procedure 1 Set the copier into the Tech Rep mode by pressing the following keys in this order Stop key 0 Stop key 1 á á á 2 Enter the Factory Setting mode by pressing the following keys in this order Stop key Start key á 3 Select the particular Factory Setting function to be set 4 Make the necessary settings by following the instructions given sequentially on the screen NOTE The function sel...

Page 266: ...her than F2 F4 F6 F8 and FF See Tech Rep Mode F1 Paper Passage F3 Exp Lamp F5 Optimum AE F7 Orig Sensor Developer Paper Path Sensors F2 Drum Trans F4 HV Separator F6 Edit Ref Adj F8 ATDC Adjust FF F8 F5 1156SBS060301A 1 Function Factory Setting Function Touch Panel Display Operation F2 Drum Trans Checks the PC Drum Charge Corona and Image Transfer Corona for output Note For factory adjustment only...

Page 267: ...Replenishing Motor f f f Paper take up f f Scan f f f f Exposure Lamp f f f Main Erase Lamp f f f f f f f f Image Erase Lamp f f f f f f f Synchronizing Rollers f f PC Drum Paper Separator Fingers f f PC Drum Charge Corona and Image Transfer Corona f f f f f f Paper Separator Corona and developing bias f f f f f f f Misfeed detection f f Malfunction detection f f f f f f f f f f Energized Remains ...

Page 268: ...focal length adjustment Standard Long focal length adjust ment A1 Lens Full Size Position Adjusts the zoom ratio in the crosswise direction by varying the Lens full size position Setting 43 50 58 Description Reduction direction Enlargement direction A2 Mirror Full Size Position Corrects the optical path length of the Mirror with respect to the Lens focal length Setting 43 50 58 Description Reducti...

Page 269: ...50 55 Description 2 5mm Smaller 2 5mm Greater 0 A11 Scan Regist Enlargement Corrects the amount of offset along the leading edge in an enlargement mode by varying the Synchronizing Roller start timing Setting 40 50 60 Description 5 0mm Smaller 5 0mm Greater 0 A12 Leading Edge Erase Adjust Corrects the width of void image along the leading edge of the image by varying the Image Erase Lamp ON timing...

Page 270: ...Bs TECH REP SETTINGS 97 04 01 Copyright 1997 MINOLTA Co Ltd Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information MINOLTA CO LTD 1156 7997 11 97046000 Printed in Japan 1156SBS000EA ...

Page 271: ...Interleaf EP5000 EP4000 TROUBLESHOOTING 97 04 01 EP5000 EP4000 TROUBLESHOOTING 1156SBT000AA ...

Page 272: ...sport Separator Misfeed T 27 3 Multi Bypass Misfeed T 30 4 Fusing Exit misfeed T 32 5 PF 205 Paper Take Up Misfeed T 34 6 PF 105 Paper Take Up Misfeed T 36 7 AD 9 Vertical Transport Storage Misfeed T 38 8 AD 9 Paper Take Up Misfeed T 41 MALFUNCTIONS 4 4 1 Detection Timings Classified by Malfunction Codes T 43 4 2 Troubleshooting Procedures T 57 1 C0000 Main Drive Motor M1 s Failure to Turn T 57 C0...

Page 273: ...lure 11 C0610 Lens Motor M6 Malfunction T 75 C0620 Mirror Motor M7 malfunction 12 C0910 2nd Drawer Upward Motion Failure T 77 C0914 2nd Drawer Paper Lift Up Motor M14 s Failure to Turn C0920 1st Drawer Upward Motion Failure C0924 1st Drawer Paper Lift Up Motor M13 s Failure to Turn 13 C0900 3rd Drawer Upward Motion Failure T 79 C0904 3rd Drawer Paper Lift Up Motor M24 s Failure to Turn C0950 4th D...

Page 274: ... Home Position Detection Failure T 95 C0d20 Duplex Unit Gate Unit Home Position Detection Failure C0d50 Duplex Unit Drive Motor M31 s Failure to Turn C0d51 Duplex Unit Drive Motor M31 Turning at Abnormal Timing 22 C0E00 Main Erase Lamp LA2 s Failure to Turn ON T 97 C0E01 Main Erase Lamp LA2 Turning ON at Abnormal Timing 23 C0E20 Image Erase Lamp LA3 s Failure to Turn ON T 98 24 C0F02 Original Size...

Page 275: ...Interleaf EP5000 EP4000 TROUBLESHOOTING 97 04 01 iv 5 2 Initial Checks T 108 5 3 Troubleshooting Procedures Classified by Image Failure T 110 ...

Page 276: ...102A 1 2 How to Use This Book 1 If a component on a PWB or any other functional unit including a motor is defective the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defective unit 2 All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors ar...

Page 277: ...he text locate the I O port of thecontrolledpartwhichisprobably defective when a misfeed or malfunction occurs 2 Select the IC Port Data Check function of I O Check in the Tech Rep mode and access the screen which contains the port identified in step 1 above See SWITCHES ON PWBs TECH REP MODE 3 Change or check the input or output port data to determine whether the controlled part is operational an...

Page 278: ...ound that the H L input signal to PC56 is supplied from PWB A IC3A APB3 3 Select IC Port Check from the I O Check function in the Tech Rep mode and access the screen which includes the input ports of PWB A IC3A APB3 4 Check that the input port data of PWB A IC3A APB3 on the screen is H sensor being un blocked 5 Move the PC56 actuator to block the sensor 6 Return to the I O Check basic screen once ...

Page 279: ...ch Rep mode and access the screen which includes the output ports of PWB A IC5A BPA1 4 Check that the output port data of PWB A IC5A BPA1 on the screen is 1 CL3 is deener gized 5 Touch the CHANGE key on the screen to change the data from 1 to 0 causing CL3 to be energizedforapprox 5seconds ThisallowsyoutodeterminewhethertheClutchis operation al or faulty by checking for the Clutch sound Operationa...

Page 280: ...I O Port Check List Port Check Screens D The following screens are displayed in the standby mode but may not always be as shown below because some port data are undefined Copier PF 205 1156T021CA 1156T017CA 1156T018CA 1156T019CA 1156T020CA 1156T023CA 1156T022CA 1156T016CA ...

Page 281: ... PJ15A 4 Suction Fan Motor lock signal 3 8 IC4A BPC7 When locked When turned PJ15A 3 M5 Original Glass Cooling Fan Motor REM 3 8 IC4A BPC0 f OFF ON PJ15A 5 Original Glass Cooling Fan Motor lock signal 2 8 IC4A BPB5 When locked When turned PJ15A 7 M8 Main Hopper Toner Re plenishing Motor REM 3 8 IC4A BPC3 f OFF ON PJ11A 4A M9 Sub Hopper Toner Re plenishing Motor REM 3 8 IC5A APA2 f OFF ON PJ11A 2A ...

Page 282: ...A 4 CL3 Manual Feed Paper Take Up Clutch 3 8 IC5A BPA1 f OFF ON PJ15A 12 PC12 Duplex Unit Vertical Transport Sensor 3 8 IC5A BPB0 Paper not present Paper present PJ17A 8 PC35 Toner Bottle Home Position Sensor 3 8 IC4A BPC5 Un blocked Blocked PJ11A 9 PC51 Manual Feed Paper Empty Sensor 3 8 IC5A BPB1 Paper not present Paper present PJ15A 14 PC54 Transport Roller Sen sor 3 8 IC5A BPB6 Paper not prese...

Page 283: ...t Drawer Lower Limit Position Sen sor 1 8 IC3A BPA2 Not at lower limit At lower limit PJ24A 5 PC70 2nd Drawer Lower Limit Position Sen sor 1 8 IC3A BPA3 Not at lower limit At lower limit PJ24A 6 PC72 Paper Size Detect ing Sensor 5 2 8 IC3A BPB6 Size not detected Size de tected PJ25A 2 PC73 Paper Size Detect ing Sensor 6 2 8 IC3A BPB7 Size not detected Size de tected PJ25A 5 PC81 Scanner Reference ...

Page 284: ...ion 2 8 IC4A APC7 OFF ON PJ12A 5 S1 Power Switch 1 8 IC1A P53 OFF ON PJ4A 1 S21 Front Door Interlock Switch 1 8 IC1A P51 OFF ON PJ4A 4 S22 Right Upper Door Interlock Switch 3 8 IC5A BPB2 OFF ON PJ16A 2 S23 Left Upper Door Interlock Switch 3 8 IC5A BPC6 OFF ON PJ16A 4 S53 Paper Exit Switch 3 8 IC4A BPB2 Paper present Paper not present PJ20A 12 S61 Paper Size Detecting Switch 1 1 8 IC3A BPA6 Size ye...

Page 285: ...ics Panel Dis play CN PJ No Page H or 1 L or 0 UN5 1st Drawer Paper Descent Key 1 8 IC3A BPA0 OFF ON PJ24A 3 Manual Down Display 1 1 8 IC3A APC4 f OFF ON PJ24A 1 UN6 2nd Drawer Paper Descent Key 1 8 IC3A BPA1 OFF ON PJ24A 4 Manual Down Display 2 1 8 IC3A APC5 f OFF ON PJ24A 2 PWB G AIDC Sensor Board AIDC REM 2 8 IC4A APA4 f OFF ON ...

Page 286: ...J9A 2A 4th Drawer Paper Lift Up Motor 4 8 IC1A PA3 f OFF ON down PJ9A 1A PC11 Lower Left Door Sensor 4 8 IC2A PB1 Out of position In position PJ3A 2 PC13 Duplex Unit Turnover Path Sensor 4 8 IC2A PB0 Paper not present Paper present PJ3A 5 PC17 Vertical Transport Sensor 3 4 8 IC1A PC3 Paper not present Paper present PJ7A 5 PC18 Lower Right Door Sensor 4 8 IC1A PE2 Out of position In position PJ7A 2...

Page 287: ...8 IC1A PG2 Out of position In position PJ9A 2B PC26 4th Drawer Set Sensor 4 8 IC1A PF2 Out of position In position PJ9A 7A PC27 3rd Drawer Paper Lift Up Motor Pulse Sensor 4 8 IC1A PC1 Un blocked Blocked PJ9A 5B PC28 4th Drawer Paper Lift Up Motor Pulse Sensor 4 8 IC1A PD1 Un blocked Blocked PJ9A 4A PC29 4th Drawer Paper Take Up Sensor 4 8 IC2A PB3 Paper not present Paper present PJ8A 5 PC31 Large...

Page 288: ...ray Paper Empty Sensor 5 8 IC1A PD1 Paper not present Paper present PJ4A 4A PC2 Main Tray Lower Position Sensor 6 8 IC2A PC1 Not at lower limit At lower limit PJ4A 9A PC3 Shifter Home Position Sensor 6 8 IC2A PC0 Not at home At home PJ4A 8A PC4 Shifter Return Position Sensor 6 8 IC2A PD1 Not at returned position At returned position PJ4A 7A PC5 Elevator Motor Pulse Sensor 5 8 IC1A PF2 Un blocked B...

Page 289: ... 8 IC1A PE3 Paper not present Paper present PJ6A 9 PC22 Vertical Transport Sensor 4 5 8 IC1A PC2 Paper not present Paper present PJ6A 5 PC31 Large Capacity Toner Collecting Box Set Sensor 4 8 IC2A PC3 Out of position In position PJ2A 2 PC34 Shift Gate Position Sensor 5 8 IC1A PC1 Un blocked Blocked PJ4A 1B PC35 Lower Position Sensor 6 8 IC2A PB3 Not at lower limit At lower limit PJ4A 2A PWB E Main...

Page 290: ...tching Solenoid 7 8 IC1G PH1 f OFF ON PJ3G 5 SL32 Duplex Unit Rear Finger Solenoid 7 8 IC1G PH0 f OFF ON PJ3G 7 SL33 Duplex Unit Pick Up Solenoid 7 8 IC1G PB2 f OFF ON PJ2G 12 PC8 Duplex Gate Home Position Sensor 7 8 IC1G PE0 Not at home At home PJ7G 2 PC9 Front Rear Edge Guide Plate Home Position Sensor 7 8 IC1G PC3 Not at home At home PJ7G 5 PC14 Duplex Unit Paper Entry Sensor 7 8 IC1G PC1 Paper...

Page 291: ...oard 8 8 IC1A PG1 OFF ON CN2A 2 EMP SEN Paper Empty Sensor 8 8 IC1A PC1 Paper present Paper not present CN2A 5 KSEN Paper Feed Sensor 8 8 IC1A PG0 Paper present Paper not present CN2A 3 LEV SEN Paper Plate Raised Position Sensor 8 8 IC1A PC0 Not up per limit At up per limit CN2A 6 LOW SEN Paper Plate Lowered Position Sensor 8 8 IC1A PG3 Not at lower limit At lower limit CN3A 5 DSEN Cassette Door S...

Page 292: ...t Up Motor 6 8 IC1A PA3 f OFF ON up PJ9A 1A PC11 Lower Left Door Sensor 6 8 IC2A PB1 Out of position In position PJ3A 2 PC13 Duplex Unit Turn over Path Sensor 6 8 IC2A PB0 Paper not present Paper present PJ3A 5 PC17 Vertical Transport Sensor 3 6 8 IC1A PC3 Paper not present Paper present PJ7A 5 PC18 Lower Right Door Sensor 6 8 IC1A PE2 Out of position In position PJ7A 2 PC19 3rd Drawer Paper Lift ...

Page 293: ...6 8 IC1A PC1 Un blocked Blocked PJ9A 5B PC68 4th Drawer Paper Lift Up Motor Pulse Sensor 6 8 IC1A PD1 Un blocked Blocked PJ9A 4A PC69 3rd Drawer Lower Position Sensor 7 8 IC2A PD1 Not at lower limit At lower limit PJ4A 7A PC70 4th Drawer Lower Position Sensor 7 8 IC2A PC0 Not at lower limit At lower limit PJ4A 8A PWB E1 3rd Drawer Paper Empty Board 6 8 IC1A PC0 Paper not present Paper present PJ4A...

Page 294: ...ON PJ2G 12 PC8 Duplex Gate Home Position Sensor 7 8 IC1G PE0 Not at home At home PJ7G 2 PC9 Front Rear Edge Guide Plate Home Position Sensor 7 8 IC1G PC3 Not at home At home PJ7G 5 PC11 Lower Left Door Sensor 5 8 IC2A PB1 Out of position In position PJ3A 2 PC13 Duplex Unit Turnover Path Sensor 5 8 IC2A PB0 Paper not present Paper present PJ3A 5 PC14 Duplex Unit Paper Entry Sensor 7 8 IC1G PC1 Pape...

Page 295: ...ke up and transport T 22 Á Transport separator T 20 Â Fusing exit T 24 Ã Copier take up vertical transport T 17 18 Ã Ä Paper Feed Cabinet take up vertical transport T 25 to 28 Å Æ Duplex Unit vertical transport T 30 Ç 1st Drawer take up T 17 È 2nd Drawer take up T 17 É 3rd Drawer take up T 25 to 28 4th Drawer take up T 26 Duplex Unit take up T 32 33 Æ Duplex Unit storage T 31 ADF take up ADF trans...

Page 296: ...ex Unit Paper Empty Sensor PC15 Paper Leading Edge Detecting Sensor PC54 3rd Drawer Paper Take up Sensor PC21 Transport Roller Sensor PC54 1st Drawer Paper Take Up Sensor PC56 2nd Drawer Vertical Transport Sensor PC64 2nd Drawer Paper Take Up Sensor PC57 Vertical Trans port Detection Sensor 3 PC17 Vertical Trans port Detection Sensor 4 PC22 Duplex Unit Paper Take up Sensor PC16 4th Drawer Paper Ta...

Page 297: ... up leading edge detection 1st Drawer Vertical Transport Sensor PC63 is not blocked L even after the lapse of approx 2 sec after PC56 has been blocked L 2nd Drawer Vertical Transport Sensor PC64 is not blocked L even after the lapse of approx 2 sec after PC57 has been blocked L Leading edge detection by Transport Roller Sensor PC54 is not blocked L even after the lapse of approx 1 3 sec after PC63...

Page 298: ...etection Timing Leading edge detection by Paper Exit Switch S53 S53 is not deactuated even after the lapse of approx 2 sec after the TRON signal has been input Trailing edge detection by S53 S53 is not actuated even after the lapse of approx 2 5 sec after PC55 has been unblocked H ...

Page 299: ... Relevant Electrical Parts D 2nd Drawer Paper Take Up Sensor PC57 D 1st Drawer Vertical Transport Sensor PC63 D 2nd Drawer Vertical Transport Sector PC64 D Transport Roller Sensor PC54 D 1st Drawer Paper Take Up Motor M11 D 2nd Drawer Paper Take Up Motor M12 D Paper Transport Clutch CL1 D Power Supply Board PWB C D Master Board PWB A 1156C01TAA ...

Page 300: ...M11 M12 or PWB C Paper is stationary at the Vertical Trans port Section 1 Are the Vertical Transport Rollers deformed worn or dirty with paper dust YES Clean or change the Verti cal Transport Rollers 2 Does PC63 operate proper ly Using the IC Port Data Check function make an in put port check on PWB A IC3A APB6 NO Check the PC63 actuator for operation and if it checks okay change PC63 3 Does PC64 ...

Page 301: ...r is stationary at the Vertical Trans port Section 7 Does CL1 operate proper ly Using the IC Port Data Check function set the data of PWB A IC4A BPA3 to 0 YES Check the drive transmis sion path Run the Controller Board YES Change PWB A 8 Check Is the malfunction code C0321 displayed NO Change CL1 ...

Page 302: ...eparator Misfeed Relevant Electrical Parts D Transport Roller Sensor PC54 D Paper Leading Edge Detecting Sensor PC55 D Paper Transport Clutch CL1 D Synchronizing Roller Clutch CL2 D Separator Solenoid SL1 D Suction Fan Motor M4 D High Voltage Unit HV1 D Master Board PWB A 1156C02TAA ...

Page 303: ...and if it checks okay change PC55 Paper is station ary near the PC 1 Is the Pre Image Transfer Guide Plate deformed or dirty YES Correct clean or change the guide plate Drum 2 Are the Image Transfer Paper Separator Corona wires deterio rated or dirty YES Clean or change the wires 3 Is the paper guide at the Paper Separator Corona deformed or dirty YES Clean or change the paper guide 4 Are the Sync...

Page 304: ... ary on the Suc 1 Do the Suction Belts turn when the Main Drive Motor runs NO Check the drive gears and timing belt tion Belts Does M4 operate properly Using the IC Port Data Check YES Check the Suction Belts 2 function set the data of PWB A IC4A BPC2 to 0 Does M4 then run at full speed NO Change M4 or PWB A ...

Page 305: ...OOTING 97 04 01 T 30 1156SBT030303A 3 Multi Bypass Misfeed Relevant Electrical Parts D Manual Feed Paper Empty Sensor PC51 D Manual Feed Paper Take Up Solenoid SL51 D Manual Feed Paper Take Up Clutch CL3 D Master Board PWB A 1156C03TAA ...

Page 306: ... waved or damp YES Change the paper Instruct the user in how to store the paper 3 Is the Manual Bypass Pa per Take Up Roll deformed worn or dirty with paper dust YES Clean or change the Manu al Bypass Paper Take Up Roll 4 Does SL51 operate proper ly Using the IC Port Data Check function set the data of PWB A IC5A BPA3 to 0 Does the roll then go down YES Check the drive transmis sion path Run the C...

Page 307: ...Interleaf EP5000 EP4000 TROUBLESHOOTING 97 04 01 T 32 1156SBT030304A 4 Fusing Exit Misfeed Relevant Electrical Parts D Paper Exit Switch S53 D Suction Fan Motor M4 D Master Board PWB A 1156C04TAA ...

Page 308: ...on Belts 3 of PWB A IC4A BPC2 to 0 Does M4 then turn at full speed NO Change M4 or PWB A Paper is stationary at the Fusing Roller 1 Are the Fusing Rollers dirty or scratched YES Clean or change the Fusing Rollers 2 Are the Fusing Roller Paper Separator Fingers de formed worn or dirty YES Clean correct or change the defective separator fin gers 3 Is the Cleaning Roller dirty or scratched YES Clean ...

Page 309: ...3rd Drawer Paper Take Up Sensor PC21 D 4th Drawer Paper Take Up Sensor PC29 D Vertical Transport Sensor 3 PC17 D Vertical Transport Sensor 4 PC22 D 3rd Drawer Paper Take Up Motor M22 D 4th Drawer Paper Take Up Motor M23 D Vertical Transport Drive Motor M21 D PF 205 Master Board PWB A D EP5000 EP4000 Master Board PWB A 1156C24TAA ...

Page 310: ... M21 2 Are the Vertical Transport Roll ers deformed worn or dirty with paper dust YES Clean or change the Ver tical Transport Rollers 3 Does PC17 operate properly Using the IC Port Data Check function make an input port check on PWB A 200 IC1A PC3 metric areas or PWB A MC IC1A PC3 inch areas NO Check the PC17 actuator for operation and if it op erates properly change PC17 4 Does PC22 operate prope...

Page 311: ...p Misfeed Relevant Electrical Parts D 3rd Drawer Paper Take Up Sensor PC21 D Vertical Transport Sensor 3 PC17 D Vertical Transport Sensor 4 PC22 D 3rd Drawer Paper Take Up Motor M22 D Vertical Transport Drive Motor M21 D PF 105 Master Board PWB A D EP5000 EP4000 Master Board PWB A 1156C26TAA ...

Page 312: ...cal Trans Is Vertical Transport Drive Motor M21 turning when the D Check the motor for over load D port Section 1 Start key is pressed NO D Change PWB A PF 105 or PWB A copier Change M21 2 Are the Vertical Transport Rollers deformed worn or dirty with paper dust YES Clean or change the Verti cal Transport Rollers 3 Does PC17 operate proper ly Using the IC Port Data Check function make an in put po...

Page 313: ...l Transport Sensor PC12 D Duplex Unit Turnover Path Sensor PC13 D Duplex Unit Paper Entry Sensor PC14 D Duplex Unit Paper Empty Sensor PC15 D Vertical Transport Sensor 3 PC17 D Exit Duplex Switching Solenoid SL5 D Duplex Unit Gate Switching Solenoid SL31 D Duplex Unit Drive Motor M31 D Duplex Unit Master Board PWB G D PF 205 105 Master Board PWB A D EP5000 EP4000 Master Board PWB A 1156C30TAA ...

Page 314: ...Data Check function set the data of PWB G Dup IC1G PB3 to 0 NO Check the gears belts and rollers Does PC12 operate proper YES Change PWB A 2 ly Using the IC Port Data Check function make an in put port check of PWB A IC5A BPB0 NO Check the PC12 actuator for operation and if it oper ates properly change PC12 Paper is stationary at the Duplex Unit Turnover Section 1 Do the Paddle Roller Slip Roller ...

Page 315: ...heck on PWB A Dup IC1G PC1 NO Check the PC14 actuator for operation and if it oper ates properly change PC14 Does SL31 operate proper ly YES Check the Gate Switching Lever for operation 3 Using the IC Port Data Check function set the data of PWB A Dup IC1G PH1 to 0 NO Change PWB G PWB A copier or PWB A PF 205 105 Change SL31 Paper is stationary at the storage sec tion Does PC15 operate proper ly U...

Page 316: ...ctrical Parts D Duplex Unit Paper Take Up Sensor PC16 D Vertical Transport Sensor 3 PC17 D Vertical Transport Drive Motor M21 D Duplex Unit Paper Take Up Clutch CL31 D Duplex Unit Pick Up Solenoid SL33 D Duplex Unit Master Board PWB G D PF 205 105 Master Board PWB A D EP5000 EP4000 Master Board PWB A 1156C31TAA ...

Page 317: ...ge the defec tive roll Paper is stationary at the Vertical Trans Is Vertical Transport Drive Motor M21 turning when a YES Check the motor for over load port Section 1 copy is taken up and fed into the copier from the Du plex Unit NO Change PWB A copier or PWB A PF 205 105 Change M21 2 Are the Vertical Transport Rollers deformed worn or dirty with paper dust YES Clean or change the defec tive rolle...

Page 318: ...e to turn The lock signal remains HIGH for a continu ous 2 0 sec or more period while M5 is ener gized C004b Original Glass Cooling Fan Motor M5 turning at abnormal timing The lock signal remains LOW for a continu ous 2 0 sec or more period while M5 is deen ergized C004c Ventilation Fan Motor M3 s failure to turn The lock signal remains HIGH for a continu ous 2 0 sec or more period while M3 is ene...

Page 319: ...N Code Description Master Board Port C0300 Port diagnosis cannot be started C0310 Drum Dehumidifying Heater H2 REM signal IC1A P45 C0311 Fusing Heater Lamp H1 REM signal IC1A P57 C0312 Exposure Lamp Regulator PWB J REM signal IC1A P61 C0313 AE Sensor Board PWB H PWM signal IC1A P60 C0314 Image Erase Lamp LA3 DATA IC1A P64 C0315 Image Erase Lamp LA3 MODE IC1A P65 C0316 Image Erase Lamp LA3 CLOCK IC...

Page 320: ...332 Sub Hopper Toner Replenishing Motor M9 IC5A APA2 C0333 2nd Drawer Paper Take Up Motor M12 ENABLE IC5A APA1 C0334 1st Drawer Paper Take Up Motor M11 ENABLE IC5A APA0 C0335 Manual Feed Paper Take Up Solenoid SL4 UP IC5A BPA2 C0336 Manual Feed Paper Take Up Solenoid SL4 DOWN IC5A BPA3 C0337 Manual Feed Paper Take Up Clutch CL3 IC5A BPA1 C0338 Warming up completion signal IC5A BPA7 C0339 During co...

Page 321: ... the lapse of a given period of time during warming up as detailed below D Ifthetemperatureis165_C or less when the Pow er Switch is turned ON From room temperature 105S 60S to 65_C 65_C 140_C 210S 110S EP4051 EP3051 140_C 170_C 220S 120S 170_C 200_C 145S 100S 170_C 190_C 145S 100S D If the temperature is more than 165_C when the Power Switch is turned ON EP4051 EP3051 A 200_C temperature control ...

Page 322: ...urning C06F0 SHOME signal failure Signal does not go LOW D When the Scanner is at a position other than home the SHOME signal does not go HIGH even after the lapse of 7 sec after the SCAN sig nal has gone LOW D The SHOME signal is HIGH even after the lapse of 5 sec after the BASE signal has gone from LOW to HIGH C06F1 SHOME signal failure Signal does not go HIGH The SHOME signal remains LOW even a...

Page 323: ...fail ure C0903 Inch Area 3rd Drawer upward motion failure C0904 3rd Drawer Lift Up Motor M24 s fail ure to turn C0906 Inch Area 3rd Drawer ejection failure C0950 4th Drawer upward motion failure See PF 205 Service Manual C0951 Inch Area 4th Drawer downward motion failure C0952 Inch Area 4th Drawer downward motion failure C0953 Inch Area 4th Drawer upward motion failure C0954 4th Drawer Lift Up Mot...

Page 324: ...M14 s failure to turn D PC68 detects no pulses even after the lapse of 500 msec after M14 has been energized D PC68 detects no pulses for the period of 200 msec while M14 is being energized C0916 2nd Drawer ejection failure D The 2nd Drawer is not ejected even after the lapse of 2 sec after PC70 has been blocked L C0920 1st Drawer upward motion failure D 1st Drawer Lift Up Sensor PC65 is not block...

Page 325: ...Motor M13 s failure to turn D PC67 detects no pulses even after the lapse of 500 msec after M13 has been energized D PC67 detects no pulses for the period of 200 msec while M13 is being energized C0926 1st Drawer ejection failure D The 1st Drawer is not ejected even after the lapse of 2 sec after PC69 has been blocked L ...

Page 326: ...ailure C0994 Elevator Motor M26 s failure to turn C0996 Main Tray ejection failure C0998 Shifter transfer failure See PF 105 Service Manual C0999 Shifter return failure C099A Shifter return failure C099b Shifter transfer failure C099C Shift Motor M27 s failure to turn C099E Shift Gate position detecting failure C099F Shift Gate position detecting failure C09C0 Elevator ascent fault See C 301 Servi...

Page 327: ...unc tion The output from PWB H remains approx 0 18V or less for a continuous 2 sec period with the Exposure Lamp OFF the Scanner at the home position and the Original Cover lowered C0F20 AIDC Sensor Board PWB G varia tion correction failure In the initial F5 or FF mode D The output from PWB G is 1V or more when the load resistance is made maximum by the 4 bit analog switch D Theoutput from PWB G i...

Page 328: ...lue of Level History drasti cally deviates from the value set in the FF mode D The UN3 output remains 0 5V or less or 4 2V or more for a consecutive 3 sec period 2 sec after Main Drive Motor M1 has been energized C0F79 D 3rd Drawer Paper Empty Sensor PC20 failure D Main Tray Paper Empty Board PWB E failure D Shift Tray Paper Empty Sensor PC1 failure See the PF 105 Service Manual D PaperEmpty Senso...

Page 329: ...g Sensors Ê and Ì failure d C0FE6 Original Size Detecting Sensors Ë and Ì failure A Ê Ë Ì ng Board C0FE7 Original Size Detecting Sensors Ê Ë and Ì failure B C D E Detecti C0FE8 Original Size Detecting Sensor Í failure A Í B Î inal Size C0FE9 Original Size Detecting Sensors Ê and Í failure Orig C0FEA Original Size Detecting Sensors Ë and Í failure Inch Areas D Ê PC116 option Ë PC117 Ì PC118 option ...

Page 330: ...B Í Î Board C0FF6 Original Size Detecting Sensors Ë Ì and Î failure Î tecting C0FF7 Original Size Detecting Sensors Ê Ë Ì and Î failure Size De C0FF8 Original Size Detecting Sensors Í and Î failure Inch Areas D Ê PC116 option Ë PC117 Ì PC118 option Í PC115 Î PC119 option riginal S C0FF9 Original Size Detecting Sensors Ê Í and Î failure Ê Ì O C0FFA Original Size Detecting Sensors Ë Í and Î failure ...

Page 331: ... the ST 210 S 207 ST 101 S 104 Ser C0b31 vice Manual C0b50 Stapling failure C0b51 C0b52 C0b53 C0b60 Bin motion failure See the ST 210 S 207 ST 101 S 104 Ser C0b61 vice Manual C0b62 C0b63 C0b64 C0b65 C0b70 Hole punching failure See the ST 210 S 207 Service Manual C0b71 C0b72 1156SBT040111A C0d Duplex Unit Malfunctions Code Description Detection Timing C0d00 Front Rear Edge Guide Plates home positio...

Page 332: ... 01 T 57 1156SBT0402A 4 2 Troubleshooting Procedures 1156SBT040201A 1 C0000 Main Drive Motor M1 s Failure to Turn C0001 Main Drive Motor M1 Turning at Abnormal Timing Relevant Electrical Parts D Main Drive Motor M1 D Master Board PWB A 1156C05TAA ...

Page 333: ... A IC4A BPA2 to 0 YES Change PWB A Perform the Controller Board Check YES Change PWB A 2 Is malfunction code C0327 dis played NO D Check the drive coupling D Change M1 uC0001 Step Check Item Result Action 1 Does M1 turn when the malfunction is reset YES Change PWB A 2 Is malfunction code C0001 displayed again YES Change PWB A ...

Page 334: ...Interleaf EP5000 EP4000 TROUBLESHOOTING 97 04 01 T 59 1156SBT040202A 2 C0040 Suction Fan Motor M4 s Failure to Turn Relevant Electrical Parts D Suction Fan Motor M4 D Master Board PWB A 1156C06TAA ...

Page 335: ...e data of PWB A IC4A BPC2 to 0 YES Change PWB A Perform the Controller Board Check YES Change PWB A 2 Is malfunction code C032B dis played NO D Change M4 uC0011 Step Check Item Result Action 1 Does M4 turn when the malfunction is reset YES Change PWB A 2 Is malfunction code C0011 displayed again YES Change PWB A ...

Page 336: ... T 61 1156SBT040203A 3 C0046 Fusing Section Cooling Fan Motor M15 s Failure to Turn C0047 Fusing Section Cooling Fan Motor M15 Turning at Abnormal Timing Relevant Electrical Parts D Fusing Section Cooling Fan Motor M15 D Master Board PWB A 1156C07TAA ...

Page 337: ...of PWB A IC4A APC2 to 0 YES Change PWB A Perform the Controller Board Check YES Change PWB A 2 Is malfunction code C0321 dis played NO D Change M15 uC0047 Step Check Item Result Action 1 Does M15 turn when the malfunction is reset YES Change PWB A or M15 2 Is malfunction code C0047 displayed again YES Change PWB A or M15 ...

Page 338: ... Failure to Turn C004b Original Glass Cooling Fan Motor M5 Turning at Abnormal Timing C004C Ventilation Fan Motor M3 s Failure to Turn C004d Ventilation Fan Motor M3 Turning at Abnormal Timing Relevant Electrical Parts D Original Glass Cooling Fan Motor M5 D Ventilation Fan Motor M3 D Master Board PWB A 1156C08TAA ...

Page 339: ...tion 1 Does M5 turn when the malfunction is reset YES Change PWB A 2 Is malfunction code C004b displayed again YES Change PWB A uC004C Step Check Item Result Action Does M3 turn YES Change PWB A 1 Set the data of PWB A IC4A BPC1 to 0 NO Change M3 uC004d Step Check Item Result Action 1 Does M3 turn when the malfunction is reset YES Change PWB A 2 Is malfunction code C004d displayed again YES Change...

Page 340: ...e to Turn C0071 Main Hopper Toner Replenishing Motor M8 Turning at Abnormal Timing C0072 Sub Hopper Toner Replenishing Motor M9 s Failure to Turn Relevant Electrical Parts D Main Hopper Toner Replenishing Motor M8 D Sub Hopper Toner Replenishing Motor M9 D Toner Bottle Home Position Sensor PC35 D Master Board PWB A 1156C09TAA ...

Page 341: ... NO Change PC35 Perform the Controller Board Check YES Change PWB A 3 Is malfunction code C032A dis played NO Change M8 uC0071 Step Check Item Result Action 1 Does M8 turn when the malfunction is reset YES Change PWB A 2 Is malfunction code C0071 displayed again YES Change PWB A uC0072 Step Check Item Result Action 1 Does M9 turn Set the data of PWB A IC5A APA2 to 0 YES Change PWB A Perform the Co...

Page 342: ...C Drum Charge Corona and Image Transfer Paper Separator Coronas are removed YES Go to step 4 2 Is C0200 displayed when the PC Drum Charge Corona is installed YES Clean or change the PC Drum Charge Corona 3 Is C0200 displayed when the Image Transfer Paper Separator Coronas unit is installed YES Clean or change the Image Transfer Paper Separator Coronas Is C0200 displayed even when the YES Change PW...

Page 343: ... Change Master Board PWB A uC0350 C0351 Step Action 1 Check the connections from PJ20A on PWB A to PJ13A on PF 205 105 PWB A 2 Change PWB A or PF 205 105 PWB A uC0352 Step Action 1 Check the connections from PJ20A on PWB A to PJ8G on Duplex Unit Master Board PWB G 2 Change PWB A PF 205 105 PWB A or Duplex Unit Master Board PWB G uC0353 C0357 Step Action 1 Check the connections from PJ20A on PWB A ...

Page 344: ...08A 8 C0400 Exposure Lamp LA1 s Failure to Turn ON C0410 Exposure Lamp LA1 Turning ON at Abnormal Timing Relevant Electrical Parts D Exposure Lamp LA1 D Exposure Thermal Fuse TF1 D Exposure Lamp Regulator PWB J D AE Sensor Board PWB H D Master Board PWB A 1156C11TAA ...

Page 345: ...alfunction code C0312 or C033B displayed YES Change PWB A 3 Disconnect CN7 Is there continuity across CN7 1 and 2 on LA1 side NO Change LA1 or TF1 Is the voltage across PJ3J 1 and 3 on YES Change PWB J 4 PWB J the source voltage NO Check the power supply line Is the voltage across PWB A PJ3A 2 and GND 3 9V or less when LA1 is off YES Change PWB A 5 the Scanner is at the home position and the Origi...

Page 346: ...ming up Failure C0510 Abnormally Low Fusing Temperature C0520 Abnormally High Fusing Temperature Relevant Electrical Parts D Fusing Heater Lamp H1 D Fusing Thermoswitch TS1 D Fusing Thermistor TH1 D Fusing Thermistor TH2 D Fusing Heater Lamp SSR SSR1 D Master Board PWB A 1156C12TAA ...

Page 347: ...er Board Check Is malfunction code C0311 displayed YES Change PWB A Check H1 for continuity Is there conti YES Change SSR1 6 nuity NO Change H1 or TS1 uC0520 Step Check Item Result Action 1 Does H1 remain lit after the copier has warmed up NO Go to step 4 2 Perform the Controller Board Check Is malfunction code C0311 displayed YES Change PWB A 3 Does H1 turn OFF NO Change SSR1 4 Is TH1 installed p...

Page 348: ...0 TROUBLESHOOTING 97 04 01 T 73 1156SBT040210A 10 C0600 Scanner Motor M2 Malfunction C06FX Signal Failure Relevant Electrical Parts D Scanner Motor M4 D Power Supply Unit PU1 D SCP Board PWB F D Master Board PWB A 1156C13TAA ...

Page 349: ... the voltage across PWB F PJ1F 2 and GND DC5V NO Check the connection of the DC5V line and if it is intact change PU1 Perform the Controller Board Check YES Change PWB A 3 Is malfunction code C031F or C0320 displayed NO Change PWB F or M2 uC06FX Step Check Item Result Action Are PWB A PJ8A and PWB F PJ2F YES Change PWB A or PWB F 1 connected securely NO Connect securely ...

Page 350: ...040211A 11 0610 Lens Motor M6 Malfunction 0620 Mirror Motor M7 Malfunction Relevant Electrical Parts D Mirror Reference Position Sensor PC86 D Lens Reference Position Sensor PC90 D Lens Motor M6 D Mirror Motor M7 D SCP Board PWB F D Master Board PWB A 1156C14TAA ...

Page 351: ...en PC90 is blocked NO Change PC90 Is the Lens drive defective YES Correct or change the defective part 3 NO Change PWB F or M6 uC0620 Step Check Item Result Action 1 Are all connectors on PWB F M7 and PC86 plugged in securely NO Plug them in securely 2 Does the voltage across PWB F PJ6F 2 and GND change from DC5V to DC0V when PC86 is blocked NO Change PC86 Is the Mirror drive defective YES Correct...

Page 352: ...ard Motion Failure C0924 1st Drawer Paper Lift Up Motor M13 s Failure to Turn Relevant Electrical Parts D 1st Drawer Lift Up Sensor PC65 D 2nd Drawer Lift Up Sensor PC66 D 1st Drawer Lift Up Motor Pulse Sensor PC67 D 2nd Drawer Lift Up Motor Pulse Sensor PC68 D 1st Drawer Paper Lift Up Motor M13 D 2nd Drawer Paper Lift Up Motor M14 D Master Board PWB A D Power Supply Board PWB C 1156C15TAA ...

Page 353: ... the Controller Board Check YES Change PWB A 2 Is malfunction code C032E dis played NO Replace PWB A Does the voltage across PWB C PJ9C 4 and GND change from DC0V YES Change M14 3 to DC24V when the 2nd Drawer is slid back into the copier NO Change PWB C Does the voltage across PWB A YES Change PWB A 4 PJ23A 5 and GND vary between DC0V and DC5V while M14 is turning NO Change PC68 uC0924 Step Check ...

Page 354: ...d Motion Failure C0954 4th Drawer Paper Lift Up Motor M25 s Failure to Turn Relevant Electrical Parts D 3rd Drawer Paper Lift Up Sensor PC19 D 4th Drawer Paper Lift Up Sensor PC23 D 3rd Drawer Paper Lift Up Motor Pulse Sensor PC27 D 4th Drawer Paper Lift Up Motor Pulse Sensor PC28 D 3rd Drawer Paper Lift Up Motor M24 D 4th Drawer Paper Lift Up Motor M25 D PF 205 Master Board PWB A 1156C25TAA ...

Page 355: ...slide it back into the copier Does M24 turn at this time NO Go to step 3 Does the voltage across PF 205 PWB A PJ9A 8B and GND change from YES Change M24 2 DC0V to DC24V when the 3rd Drawer is slid back into the copier NO Change PF 205 PWB A Does the voltage across PF 205 PWB YES Change PF 205 PWB A 3 A PJ9A 5B and GND vary between DC0V and DC5V while M24 is turning NO Change PC27 uC0954 Step Check...

Page 356: ...Inch Areas C0912 2nd Drawer Downward Motion Failure C0913 2nd Drawer Upward Motion Failure C0916 2nd Drawer Ejection Failure Relevant Electrical Parts D 2nd Drawer Lift Up Sensor PC66 D 2nd Drawer Lower Limit Position Sensor PC70 D 2nd Drawer Flexible Printed Circuit Board PWB M2 D Master Board PWB A 1156C35TAA ...

Page 357: ... Result Action Does PC70 operate properly Using the IC Port Data Check function YES Replace PWB A 1 make an input port check on PWB A IC3A BPA3 NO Replace PC70 or PWB M2 uC0916 Step Check Item Result Action 1 Remove the Right Door lift up the Lock Lever with a flat blade screwdriver to unlock and slide out the 2nd Drawer 2 Is the Lock Release Spring installed properly NO Reinstall or change 3 Are ...

Page 358: ...Inch Areas C0922 1st Drawer Downward Motion Failure C0923 1st Drawer Upward Motion Failure C0926 1st Drawer Ejection Failure Relevant Electrical Parts D 1st Drawer Lift Up Sensor PC65 D 1st Drawer Lower Limit Position Sensor PC69 D 1st Drawer Flexible Printed Circuit Board PWB M1 D Master Board PWB A 1156C36TAA ...

Page 359: ... Result Action Does PC69 operate properly Using the IC Port Data Check function YES Replace PWB A 1 make an input port check on PWB A IC3A BPA2 NO Replace PC69 or PWB M1 uC0926 Step Check Item Result Action 1 Remove the Right Door lift up the Lock Lever with a flat blade screwdriver to unlock and slide out the 1st Drawer 2 Is the Lock Release Spring installed properly NO Reinstall or change 3 Are ...

Page 360: ...h Areas C0902 3rd Drawer Downward Motion Failure C0903 3rd Drawer Upward Motion Failure C0906 3rd Drawer Ejection Failure Relevant Electrical Parts D 3rd Drawer Lift Up Sensor PC19 D 3rd Drawer Lower Limit Position Sensor PC69 D 3rd Drawer Flexible Printed Circuit Board PWB M1 D PF 205 Master Board PWB A 1156C37TAA ...

Page 361: ... Result Action Does PC69 operate properly Using the IC Port Data Check function YES Replace PWB A PF 205 1 make an input port check on PWB A MC IC2A PD1 NO Replace PC69 or PWB M1 uC0906 Step Check Item Result Action 1 Remove the Right Door lift up the Lock Lever with a flat blade screwdriver to unlock and slide out the 3rd Drawer 2 Is the Lock Release Spring installed properly NO Reinstall or chan...

Page 362: ...h Areas C0952 4th Drawer Downward Motion Failure C0953 4th Drawer Upward Motion Failure C0956 4th Drawer Ejection Failure Relevant Electrical Parts D 4th Drawer Lift Up Sensor PC23 D 4th Drawer Lower Limit Position Sensor PC70 D 4th Drawer Flexible Printed Circuit Board PWB M2 D PF 205 Master Board PWB A 1156C38TAA ...

Page 363: ... Result Action Does PC70 operate properly Using the IC Port Data Check function YES Replace PWB A PF 205 1 make an input port check on PWB A MC IC2A PC0 NO Replace PC70 or PWB M2 uC0956 Step Check Item Result Action 1 Remove the Right Door lift up the Lock Lever with a flat blade screwdriver to unlock and slide out the 4th Drawer 2 Is the Lock Release Spring installed properly NO Reinstall or chan...

Page 364: ...wnward Motion Failure C0993 Main Tray Upward Motion Failure C0994 Elevator Motor M26 s Failure to Turn Relevant Electrical Parts D Main Tray Lower Position Sensor PC2 D Elevator Motor Pulse Sensor PC5 D 3rd Drawer Paper Lift Up Sensor PC19 D Lower Limit Position Sensor PC35 D Cabinet Transport Board PWB H D PF 105 Master Board D Main Tray Elevator Motor M26 1156C27TAA ...

Page 365: ...B3 NO Change PWB H flat cable or PC35 Does PC2 operate properly Using the IC Port Data Check function YES Change PF 105 PWB A 2 make an input port check on PWB A 400 IC2A PC1 NO Change PC2 PWB H or flat cable uC0994 Step Check Item Result Action 1 Does M26 turn when the Paper De scent key is pressed YES Go to step 3 Does the voltage across PF 105 PWB A PJ4A 6B or PJ4A 7B and GND YES Change M26 PWB...

Page 366: ...lure C099A Shifter Return Failure C099b Shifter Transfer Failure C099C Shift Motor M27 s Failure to Turn Relevant Electrical Parts D Shifter Home Position Sensor PC3 D Shifter Return Position Sensor PC4 D Shift Motor Pulse Sensor PC6 D Paper Shift Motor M27 D Cabinet Transport Board PWB H D PF 105 Master Board PWB A 1156C28TAA ...

Page 367: ...Change PF 105 PWB A 1 make an input port check on PWB A 400 IC2A PC0 NO Change PC3 PWB H or flat cable uC099C Step Check Item Result Action 1 Does M27 turn when the 3rd Drawer is slid into the copier with a paper stack loaded in the Shift Tray YES Go to step 3 In step 1 does the voltage across YES Change M27 PWB H or flat cable 2 PF 105 PWB A PJ4A 5B and GND change from DC0V to DC24V NO Change PF ...

Page 368: ... Drawer Lock Release Failure C0F79 Paper Empty Sensor Failure Relevant Electrical Parts D Shift Tray Paper Empty Sensor PC1 D 3rd Drawer Paper Empty Sensor PC20 D Main Tray Paper Empty Board PWB E D 3rd Drawer Set Sensor PC7 D Shift Gate Position Detecting Sensor PC34 D 3rd Drawer Lock Solenoid SL41 D Cabinet Transport Board PWB H D PF 105 Master Board PWB A 1156C29TAA ...

Page 369: ...rly Using the IC Port Data Check function YES Change PF 105 PWB A 2 make an input port check on PWB A 400 IC1A PG2 NO Change PC7 PWB H or flat cable uC0F79 Step Check Item Result Action Does PC20 operate properly Using the IC Port Data Check function YES Change PF 105 PWB A 1 make an input port check on PWB A 400 IC1A PC0 NO Change PC20 PWB H or flat cable Does PWB E operate properly Using the IC ...

Page 370: ... Position Detection Failure C0d50 Duplex Unit Drive Motor M31 s Failure to Turn C0d51 Duplex Unit Drive Motor M31 Turning at Abnormal Timing Relevant Electrical Parts D Duplex Gate Home Position Sensor PC8 D Front Rear Edge Guide Plate Home Position Sensor PC9 D Duplex Unit Drive Motor M31 D Gate Motor M32 D Front Rear Edge Guide Drive Motor M33 D AD 9 Master Board PWB G 1149C24TAA ...

Page 371: ...ion Does M32 turn when the Gate Unit is YES Check for overload 1 moved to a position other than home and the Duplex Unit is slid in NO Change M32 or PWB G Does PC8 operate properly Using the IC Port Data Check function YES Change PWB G 2 make an input port check on PWB G Dup IC1G PE0 NO Change PC8 uC0d50 Step Check Item Result Action Does M31 turn Using the IC Port Data Check function YES Check th...

Page 372: ...56C22TAA uC0E00 Step Check Item Result Action 1 Perform the Controller Board Check Is malfunction code C0328 dis played YES Change PWB A Does the voltage across PWB A PJ12A 3 and GND change from DC0V YES Change LA2 2 to DC24V when the Start key is pressed NO Change PWB A uC0E01 Check the LA2 Failure Detection signal when LA2 is OFF YES Change PWB A 1 Using the IC Port Data Check function check tha...

Page 373: ...e to Turn ON Relevant Electrical Parts D Image Erase Lamp LA3 D Master Board PWB A 1156C23TAA Step Check Item Result Action 1 Perform the Controller Board Check Is malfunction code C0314 to C0317 displayed YES Change PWB A Is the voltage across PWB A PJ9A 1 YES Change LA3 2 and GND DC5V NO Check the 5V line ...

Page 374: ...ginal Size Detecting Sensor Failure Relevant Electrical Parts D Original Size Detecting Sensor CD1 PC115 D Original Size Detecting Sensor FD1 PC116 D Original Size Detecting Sensor FD2 PC117 D Original Size Detecting Sensor FD3 PC118 D Original Size Detecting Sensor CD2 PC119 D Orignal Size Detecting Board UN2 D Master Board PWB A 1156C16TAA ...

Page 375: ...ary between DC0V and DC5V NO Change UN2 uC0FE1 to C0FFF Step Check Item Result Action 1 Are the jumper connectors plugged correctly into J1 and J2 on UN2 NO Change the jumper connector posi tions 2 Is each Original Size Detecting Sensor installed in correct position NO Reinstall 3 Is the malfunction code displayed again after the Original Size Detecting Sen sor corresponding to the malfunction cod...

Page 376: ...ion Relevant Electrical Parts D AE Sensor Board PWB H D Master Board PWB A 1156C17TAA Step Check Item Result Action Is the voltage across PWB A PJ3A 3 and GND DC0 18V or less when the YES Change PWB H 1 Scanner is at the home position the Exposure Lamp is OFF and the Origi nal Cover is lowered NO Change PWB A ...

Page 377: ...ensor Board PWB G Exposure Correction Failure Relevant Electrical Parts D AIDC Sensor Board PWB G D Master Board PWB A 1156C18TAA Step Check Item Result Action 1 Is PWB A PJ11A plugged in securely NO Plug it in securely 2 Is CN35 plugged in securely NO Plug it in securely 3 Is PWB G installed in the correct posi tion NO Reinstall Is the photoreceiver or LED of PWB G YES Clean 4 dirty NO Change PWB...

Page 378: ...9TAA Step Check Item Result Action 1 Is the malfunction code C0F30 dis played YES Go to step 3 2 Is the value for ATDC Ref Value of Level History equal to the value given on the Adjust Label NO Enter the value given on the Adjust La bel 3 Is PWB A PJ11A plugged in securely NO Plug it in securely 4 Is CN35 plugged in securely NO Plug it in securely 5 Is UN3 installed in the correct position NO Rein...

Page 379: ...04 1156SBT0403A 4 3 Power Malfunctions 1156SBT040301A 1 Main Relay Does Not Turn ON Relevant Electrical Parts D Power Switch S1 D Main Relay RY1 D Power Supply Unit PU1 D Master Board PWB A D Power Supply Board PWB C D Noise Filter Board PWB D 1156C20TAA ...

Page 380: ...and if it is in tact change PU1 3 Is the voltage across PJ6C 1 on PWB C and GND DC24V when S1 is turned ON NO Check the wiring between PWB C and S1 and if it is intact change PWB C or S1 4 Is the voltage across PJ21 2 on PU1 and GND DC5V NO Check the wiring between PWB C and S1 and if it is intact change PWB C or S1 5 Is the wiring between PWB A PWB C and RY1 intact YES Change PWB A PWB C and RY1 ...

Page 381: ...ck Item Result Action 1 Is the voltage across PJ22 2 on PU1 and GND DC5V YES Check the wiring between PU1 and UN1 NO Change PU1 2 Is the voltage across PJ21 2 on PU1 and GND DC5V YES Check the wiring between PU1 and PWB B NO Change PU1 3 Is the voltage across PJ3C 1 on PWB C and GND DC24V YES Check the wiring between PWB C and UN1 NO Change PWB C Is the connection between PWB B and YES Change PWB ...

Page 382: ... is less than 4 when an F5 operation is run initial adjustment D Memory clear D PC Drum of Port Option counter is cleared D AIDC Sensor Board PWB G develops a malfunc tion Procedure Step Check Item Result Action 1 Is ATDC Current Level of Level His tory available from Tech Rep mode YES Run the auxiliary toner replenishing cycle and then an F5 operation less than 4 NO Run an F5 operation again ...

Page 383: ...he copier level 2 Copy paper D Is the recommended paper used èLoad recommended paper and make copies to see if the problem persists D Is the paper damp èLoad new paper and make copies to see if the problem persists 3 Original D Does the original used have a reddish background or is it written in light pencil èUse the Test Chart to check the image D Is the original transparent or are transparencies...

Page 384: ...ems registration focus AE level etc D Among the adjustment items given in DIS REASSEMBLY ADJUSTMENT is there any adjustment that may remedy the image failure 7 Controller Board Check D Is a malfunction code displayed when Controller Board Check in the Tech Rep mode is run ...

Page 385: ...9SBT0503A 5 3 Troubleshooting Procedures Classified by Image Failure Image Failure Samples 1 Blank copy 3 Low image density 2 Black copy 1149T012AA 4 Foggy background 6 Black spots 5 Black streaks or bands 7 Blank streaks or bands 8 Void areas 9 Smear on back ...

Page 386: ...o na wire normal NO Check and change if neces sary Is the wiring between High YES Change HV1 9 Voltage Unit HV1 and coro na wire normal NO Correct wiring Paper guide shorting 10 Is the paper guide shorted to the frame YES Connect the paper guide through the resistor to the frame 1149SBT050302A 2 Black copy Cause Step Check Item Result Action PC Drum grounding failure 1 Is the PC Drum properly grou...

Page 387: ...ring between High Voltage Unit HV1 and the YES Change HV1 5 PC Drum Charge Corona normal NO Correct the wiring Optical failure 6 Are the mirrors and lenses dirty or covered with con densation YES Clean the mirrors and lenses Image transfer fail ure 7 Is the Image Transfer Coro na dirty YES Clean the Image Transfer Corona or change the wire 8 Is the copy paper damp YES Change the copy paper and ins...

Page 388: ...ded NO Clean or change the PC Drum Ground Plate Developing failure 5 Is the Sleeve Roller abnor mally dirty YES Clean the Sleeve Roller Check the Developer Scat tering Prevention Seal to see if it is deformed or dirty 6 Is the developing bias con tact normal NO Clean or change the devel oping bias contact Main Erase Lamp failure 7 Does the Main Erase Lamp light up properly NO Replace the Main Eras...

Page 389: ...e Upper Fusing Roller 7 Are the Upper Paper Sepa rator Fingers dirty or de formed YES Clean or replace the Upper Paper Separator Fingers Optical failure 8 Are the mirrors and lenses dirty with foreign matter YES Clean the mirrors and lenses 1149SBT050306A 6 Black Spots Cause Step Check Item Result Action PC Drum failure 1 Is the PC Drum surface scratched or dirty with for eign matter YES Clean or ...

Page 390: ...fail ure 4 Is the Image Transfer Coro na wire dirty YES Clean or change the Image Transfer Corona 5 Is the Corona Wire Cleaner at the home position NO Check the corona wire cleaning mechanism Defective PC Drum Paper Separator Fingers 6 Are the PC Drum Paper Separator Fingers dirty or deformed YES Clean or replace the PC Drum Paper Separator Fin gers Image Erase Lamp lit at abnormal timing 7 Does t...

Page 391: ...ing 6 Is the paper guide shorted to the frame YES Connect the paper guide through the resistor to the frame Fusing failure 7 Is the Lower Fusing Roller scratched or deformed YES Replace the Lower Fusing Roller 1149SBT050309A 9 Smear on Back Cause Step Check Item Result Action Dirty Developing Unit 1 Is the bottom part of the Developing Unit dirty YES Clean and check the De veloper Scattering Preve...

Page 392: ...LESHOOTING 97 04 01 Copyright 1997 MINOLTA Co Ltd Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information MINOLTA CO LTD 1156 7998 11 97046000 Printed in Japan 1156SBT000EA ...

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