Minolta Ep4000

1156SBG000AA
EP5000/EP4000 GENERAL, MECHANICAL/ ELECTRICAL
Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01
1149SBG000BA
CONTENTS
GENERAL
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 2. PRECAUTIONS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . G-4 3. PRECAUTIONS FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 4. HANDLING OF THE CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . G-6 5. SYSTEM OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
1156SBG000BA
MECHANICAL/ELECTRICAL
1. CROSS-SECTIONAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1 2. COPY PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-2 3. DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-4 4. SEQUENTIAL EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-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 SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-24 11-1. Exposure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-25 11-2. AE Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-26 11-3. Lamp Reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-27 11-4. Aperture Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-27 11-5. Scanner and 2nd/3rd Mirror Carriage Movement . . . . . . . . . . . M-28
CONTENTS
11-6. Lens Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-30 11-7. 4th/5th Mirrors Carriage Movement . . . . . . . . . . . . . . . . . . . . . . M-31 11-8. Original Glass Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-32 12. ORIGINAL SIZE DETECTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . M-33 12-1. Identification of Original Size Detecting Sensors . . . . . . . . . . . M-33 12-2. Original Size Detecting Operation . . . . . . . . . . . . . . . . . . . . . . . . M-33 12-3. Sensor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-34 12-4. Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-35 12-5. Original Size Detection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . M-36 13. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-37 13-1. 13-2. 13-3. 13-4. 13-5. 13-6. 13-7. 13-8. 13-9. Developing Unit Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . M-38 Magnet Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-39 Developing Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-40 Doctor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-41 ATDC Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-42 Sub Hopper Toner Replenishing Mechanism . . . . . . . . . . . . . . M-44 Sub Hopper Toner Empty Detection Control . . . . . . . . . . . . . . . M-45 Main Hopper Toner Replenishing Mechanism . . . . . . . . . . . . . . M-46 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 18-1. 18-2. 18-3. 18-4. 18-5. 18-6. 18-7. Drawer-in-Position Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-59 Drawer Paper Lifting/Lowering Mechanism/Control . . . . . . . . . M-60 Paper Level Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-65 Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-66 Universal Tray (2nd Drawer) Paper Size Detection . . . . . . . . . M-68 Paper Take-Up Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-71 Paper Take-Up Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-74
19. MULTI BYPASS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-76 19-1. Paper Take-Up Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-77 19-2. Paper Separating Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . M-78 19-3. Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-79
ii
CONTENTS
20. VERTICAL PAPER TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-80 21. SYNCHRONIZING ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-81 21-1. Synchronizing Roller Drive Mechanism . . . . . . . . . . . . . . . . . . . M-82 21-2. Paper Dust Remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-82 21-3. Synchronizing Roller 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. DEHUMIDIFYING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-96 26. MEMORY BACKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-97
iii
1151SBG000D
SAFETY INFORMATION
ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturers instructions. Denmark ADVARSEL! Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering. Udskiftning m kun ske med batteri af samme fabrikat og type. Levr det brugte batteri tilbage til leverandren. 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. Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren. Kassera anvnt batteri enligt fabrikantens instruktion. Finland VAROITUS Paristo voi rjht, jos se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hvit Kytetty paristo valmistajan ohjeiden mukaisesti.
1151SBG000CA
GENERAL
1156SBG0100A
1 SPECIFICATIONS
TYPE PHOTOCONDUCTOR COPYING SYSTEM PAPER FEEDING SYSTEM : Console (with Stationary Platen) : Organic Photoconductor : Electrostatic Dry Powdered Image Transfer to Plain Paper : 3-Way Feeding 1st Drawer: Fixed Paper Size Tray (500 sheets of paper, USA Area: 550 sheets of paper) 2nd Drawer: Universal Tray (500 sheets of paper, USA Area: 550 sheets of paper) Multi Bypass Table (50 sheets of paper)
EXPOSURE SYSTEM DEVELOPING SYSTEM CHARGING SYSTEM IMAGE TRANSFER SYSTEM PAPER SEPARATING SYSTEM FUSING SYSTEM PAPER DISCHARGING SYSTEM MAXIMUM ORIGINAL SIZE COPY MEDIUM
: Mirror Scanning, Slit Exposure : New Micro-Toning System : Comb Electrode DC Negative Corona with Scorotron System : Visible Image Transfer by means of a Single-Wire DC Negative Corona with Corotron System : Single-Wire AC Corona with Corotron System, plus Paper Separator Finger : Heat Roller : Charge Neutralizing Brush : Metric-A3L; Inch-11 17L (L: Lengthwise)
1st Drawer (Automatic feeding) Plain paper (60 to 90 g/m2) Medium Translucent paper Transparencies Thick paper (91 to 157 g/m2) Recycled paper Dimens sions Maximum (Width Length) Minimum (Width Length) f f 297 432 mm
2nd Drawer (Automatic feeding) f f 297 432 mm
Multi Bypass Table f f f f f 297 432 mm
140 182 mm
140 182 mm
100 140 mm
f: Permissible
: Not permissible
G-1
MULTIPLE COPIES WARMING-UP TIME FIRST COPY TIME
: 1 to 999 : 240 sec. or less with room temperature of 20C and rated power voltage : A4C or 8-1/2 11C: 3.7 sec. or less (in Full size Mode using 1st Drawer)
CONTINUOUS COPY SPEED (copies/min.): Fed from 1st Drawer
EP5000:
Zoom Ratio Area Size A3L A4L A4C B4L 1.000 28 37 50 31 Zoom Ratio Area Size 11 17 (L) 8-1/2 11 (L) 8-1/2 11 (C) 1.000 28 39 50
Metric
Inch
L: Lengthwise; C: Crosswise EP4000:

Zoom Ratio Area Size A3L A4L A4C B4L 1.000 26 34 40 29 Zoom Ratio Area Size 11 17 (L) 8-1/2 11 (L) 8-1/2 11 (C) 1.000 25 35 40
Metric
Inch
L: Lengthwise; C: Crosswise
ZOOM RATIOS
Area Mode Full Size Fixed Reduction Metric 1.000 0.816 0.707 0.500 1.154 1.414 2.000 Inch 1.000 0.785 0.733 0.647 0.500 1.214 1.294 1.545 2.000
Enlargement Variable
50% to 200% (in 0.1% increments)
LENS EXPOSURE LAMP FUSING TEMPERATURE
: Through Lens (F = 6, f = 190 mm) : Halogen Frost Tube Lamp : 200C
G-2
POWER/CURRENT CONSUMPTION (Copier Only)
EP5000:
Exposure Lamp (Rating) Fusing Heater Lamp (Rating) 115/120 V 950 W 220/240 V 1000 W Max. Power Consumption 1390 W 80 V 262 W 160 V 290 W 1450 W 1480 W 1410 W 1550 W
Voltage
115 V 120 V 127 V 220 V 240 V
EP4000:
Exposure Lamp (Rating) Fusing Heater Lamp (Rating) 115/120 V 900 W 220/240 V 950 W Max. Power Consumption 1250 W 80 V 262 W 160 V 290 W 1330 W 1400 W 1360 W 1500 W
Voltage
115 V 120 V 127 V 220 V 240 V
POWER REQUIREMENTS
: 115 V, 120 V, 127 V, 220-240 V; 50/60 Hz
ENVIRONMENTAL CONDITIONS
Temperature Humidity Ambient Illumination Levelness 10 to 30C with a fluctuation of 10C or less per hour 15 to 85% RH with a fluctuation of 10% RH or less per hour 3,000 lux or less 1 (1.75 mm/100 mm)
DIMENSIONS (Copier Only)
: Width .... 620 mm (24-1/2) Depth .... 740 mm (27) Height ... 960 mm (37-3/4) (including Original Cover and Paper Feed Cabinet) : EP5000: (with Paper Feed Cabinet) 123.5kg (272-1/4lbs) EP4000: (with Paper Feed Cabinet) 122.0kg (269lbs) *excluding the Copy Tray, starter, toner, and paper
WEIGHT
G-3
1149SBG0200A
2 PRECAUTIONS FOR INSTALLATION

J Installation Site
To ensure safety and utmost performance of the copier, the copier should NOT be used in a place: F Where it will be subjected to extremely high or low temperature or humidity. F Which is exposed to direct sunlight. F Which is in the direct air stream of an air conditioner, heater or ventilator. F Which puts the operator in the direct stream of exhaust from the copier. F Which has poor ventilation. F Where ammonia gas might be generated. F Which does not have a stable, level floor. F Where it will be subjected to sudden fluctuations in either temperature or humidity. If a cold room is quickly heated, condensation forms inside the copier, resulting in blank spots in the copy. F Which is near any kind of heating device. F Where it may be splashed with water. F Which is dirty or where it will receive undue vibration. F Which is near volatile flammables or curtains.
J 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 copier. F Make the following checks at frequent intervals: D Is the power plug abnormally hot? D Are there any cracks or scrapes in the cord? D Has the power plug been inserted fully into the outlet? D Does something, including the copier itself, ride on the power cord? F Ensure that the copier does not ride on the power cord or communications cable of other electrical equipment, and that it does not become wedged into or underneath the mechanism.
J Grounding
To prevent receiving electrical shocks in the case of electrical leakage, always ground the copier. F Connect the grounding wire to: D The ground terminal of the outlet. D A grounding contact which complies with the local electrical standards. F Never connect the grounding wire to a gas pipe, the grounding wire for a telephone, or a water pipe.
G-4
1149SBG0300A
3 PRECAUTIONS FOR USE

To ensure that the copier is used in an optimum condition, observe the following precautions. F Never place a heavy object on the copier or subject the copier to shocks. F Insert the power plug all the way into the outlet. F Do not attempt to remove any panel or cover which is secured while the copier is making copies. F Do not turn OFF the Power Switch while the copier is making copies. F Provide good ventilation when making a large number of copies continuously. F Never use flammable sprays near the copier. F If the copier becomes inordinately hot or produces abnormal noise, turn it OFF and unplug it. F Do not turn 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 clips, staples, or other small pieces of metal into the copier.
J Operating Environment
The operating environmental requirements of the copier are as follows. D Temperature: 10C to 30C with a fluctuation of 10C per hour D Humidity: 15% to 85% RH with a fluctuation of 10% RH per hour
J Power Requirements
The power source voltage requirements are as follows. D Voltage Fluctuation: AC115/120/127/220-240V "10% (Copying performance assured) )6%, 10% (Only AC 127V) 15% (Paper feeding performance assured) D Frequency Fluctuation: 50/60 Hz "0.3%
G-5
1151SBG0400A
4 HANDLING OF THE CONSUMABLES

Before using any consumables, always read the label on its container carefully. F Use the right toner. The applicable copier model name is indicated on the Toner Bottle. F Paper can to be easily damaged by dampness. To prevent absorption of moisture, store paper, which has been removed from its wrapper but not loaded into the Drawer, in a sealed plastic bag in a cool, dark 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 If your hands become soiled with toner, wash them with soap and water immediately. F Do not throw away any used consumables (PC Drum, starter, toner, etc.). They are to be collected. NOTE Do not burn, bury in the ground, or throw into the water any consumables (PC Drum, starter, toner, etc.).
G-6
1156SBG0500A
5 SYSTEM OPTIONS
9,10 1, 2
11
12 13
1138O525AA
1149M026AA
1136O061AA
1134O005AA
7, 8
4
1. 2. 3. 4. 5. 6. 7. Automatic Document Feeder AF-5 Duplexing Document Feeder AFR-13 Paper Feed Cabinet PF-105 Duplex Cabinet PF-5D Paper Feed Cabinet PF-205 Duplex Unit AD-9 10-Bin Sorter S-106 8. 9. 10. 11. 12. 13. 10-Bin Staple Sorter ST-104 20-Bin Sorter S-208 20-Bin Staple Sorter ST-211 Data Terminal Data Controller D-102 Large Capacity Cassette C-301
G-7
1151SBM000CA
MECHANICAL/ ELECTRICAL
1156SBM0100A
1 CROSS-SECTIONAL VIEW
1 2
9 10 11 12 13
14 15 16
30 29 28
17
18
19
20
27
26
25
24 23 22
21
1134M001AB
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
3rd Mirror 2nd Mirror 1st Mirror Exposure Lamp Ventilation Fan Motor Ozone Filter Lens Main Erase Lamp Cleaning Blade PC Drum Charge Corona PC Drum 6th Mirror Image Erase Lamp 4th Mirror 5th Mirror Sub Hopper Transport Roller
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Manual Bypass Take-Up Roll Upper Vertical Transport Roller Lower Vertical Transport Roller 2nd Drawer Paper Take-Up Roll 1st Drawer Paper Take-Up Roll Synchronizing Roller Image Transfer/Paper Separator Coronas Main Drive Motor Suction Belt Fusing Roller 1st Paper Exit Roller 2nd Paper Exit Roller Exit/Duplex Switching Guide
M-1
1156SBM0200A
2 COPY PROCESS
2 3 4 10 9 1 5
13
1. 2. 3. 4. 5. 6. 7. PC DRUM DRUM CHARGING IMAGE ERASE EXPOSURE DEVELOPING PAPER FEEDING IMAGE TRANSFER
12
11
8. 9. 10. 11. 12. 13.
8
PAPER SEPARATION CLEANING MAIN ERASE TRANSPORT FUSING PAPER EXIT
MULTI BYPASS TABLE
1. PC Drum
The PC Drum is an aluminum cylinder coated with a photosensitive semiconductor. It is used as the medium on which a visible developed image of the original is formed. (For more details, see 8. PC DRUM.)
2. Drum Charging
The PC Drum Charge Corona Unit is equipped with a Comb Electrode and a Scorotron Grid to deposit a uniform negative 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 an electrostatic latent image. (For more details, see 11. OPTICAL SECTION.)
5. Developing
Toner positively charged in the Developer Mixing Chamber is attracted onto the electrostatic latent image changing it to a visible, developed image. A DC negative bias voltage is applied to the Sleeve/Magnet Roller to prevent toner from being attracted onto those areas of the PC Drum which correspond to the background areas of the original. (For more details, see 13. DEVELOPMENT.)
M-2
6. Paper Feeding
Paper is fed either automatically from the 1st or 2nd Drawer, or manually via the Multi Bypass Table or Manual Bypass Table. Paper separation is accomplished by the torque limiter fitted to the Paper Separator Roll. (For more details, see 18. PAPER TAKE-UP/FEED SECTION.)
7. Image Transfer
The single-wire Image Transfer Corona Unit applies a DC negative corona emission to the underside of the paper, thereby attracting toner onto the surface of the paper. (For more details, see 14. IMAGE TRANSFER AND PAPER SEPARATION.)
8. Paper Separation
The single-wire Paper Separator Corona Unit applies an AC corona emission to the underside of the paper to neutralize 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 potential remaining on the surface of the PC Drum after cleaning. (For more details, see 17. MAIN ERASE LAMP.)
11. Transport
The paper is fed to the Fusing Unit by the Suction Belts. (For more details, see 22. PAPER TRANSPORT.)
12. Fusing
The developed image is permanently fused to the paper by a combination of heat and pressure applied by the Upper and Lower Fusing Rollers. (For more details, see 23. FUSING UNIT.)
13. Paper Exit

After the fusing process the paper is fed out by the Paper Exit Roller onto the Copy Tray. (For more details, see 24. EXIT UNIT.)
M-3
1156SBM0300A
DRIVE SYSTEM
The Main Drive Motor provides drive for the entire mechanism of the copier. To help minimize operating noise, timing belts and plastic gears are used in large numbers for the drive train parts.
2nd Paper Exit Roller Drive
Suction Unit Drive PC Drum Drive Developing Section Drive Manual Feed Paper Take-Up Clutch Upper Fusing Roller Drive Gear
Upper Vertical Transport Roller Drive
Toner Conveying Coil Drive (on PC Unit)
Main Drive Motor
Synchronizing Roller Clutch Paper Transport Clutch
Lower Vertical Transport Roller Drive

1136M002AA
M-4
1156SBM0400A
4 SEQUENTIAL EXPLANATION
* Figure in ( ) are the timer values for EP5000.
A The power cord is plugged into the outlet.
ON ON ON
DC Power Supply Unit PU1 outputs DC24V for dehumidifying heating. Drum Dehumidifying Heater H3 Paper Dehumidifying Heater H2 Only when Drum Dehumidifying Switch S3 and Paper Dehumidifying Switch S12 are ON
Power Switch S1 is turned ON.
OFF ON ON ON ON ON ON
H2 PU1 outputs DC24V and DC 5V. Power Supply Board PWB-C outputs DC 24V. (DC24V line: ON) Master Board PWB-A outputs DC4.7V and DC12V. Control panel display Suction Fan Motor M4 turns at half speed. Fusing Section Cooling Fan Motor M15 ON Approx. 1sec. Fusing Heater Lamp H1 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 165C. ON ON ON *1 ON Main Drive Motor M1 and Original Glass Cooling Fan Motor M5 start predrive. Ventilation Fan Motor M3 M4 turns at full speed. Developing Bias/Paper Separator Corona ON Image Erase Lamp LA2 Approx. 200msec. To on next page ON ON PC Drum Charge Corona/ Image Transfer Corona Main Erase Lamp LA3
Approx. 100msec.
M-5
After the lapse of 30sec. or 15sec. Approx. 5msec. *30sec. if the Upper Fusing Roller surface temperature is less than 165C when S1 is turned ON and 15sec. if the surface temperature is 165C or higher. PC Drum Charge Corona/Image Transfer Corona OFF LA2
OFF
Approx. 160msec. OFF
*2
Approx. 285msec.
M1/M5 OFF LA3 Approx. 150msec. (500msec.) Approx. 4850msec. (4500msec.) OFF Developing Bias/Paper Separator Corona M4 turns at half speed. M3
The Start Key is pressed.
The components are energized in order of *1 on the preceding page. Approx. *3 OFF ON ON ON Exposure Lamp LA1 *3 : Varies for different drawers.
Fusing Section Cooling Fan Motor M15 Paper Transport Clutch CL1 1st Drawer Paper Take-Up Motor M11
L
1st Drawer Vertical Transport Sensor PC63 is blocked ( Approx. 5msec. OFF M11
).
Paper Leading Edge Detecting Sensor PC55 is blocked ( Approx. 45msec. OFF CL1
).
D SCP Board PWB-F outputs a LOW BASE signal to Master Board PWB-A.
Approx. 75msec. (65msec.)
OFF
LA3...Leading edge erase
M-6
E PWB-F outputs a LOW TRON signal to PWB-A.
ON ON
CL1 Synchronizing Roller Clutch CL2 Approx. 170msec. ON Separator Solenoid SL1 Approx. 150msec. OFF SL1
F PWB-F outputs a LOW SCEND signal to PWB-A.
Approx. 200msec. ...The Scanner stops and starts a return motion. OFF LA1 Approx. 250msec.
H
SCAN signal:
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.
I
OFF
CL2
H
The Trailing edge of the paper moves past Paper Exit Switch S53 (ON:
).
The components are deenergized in order of *2 on the preceding page.
M-7
1149SBM0500A
5 WATCHDOG (CPU OVERRUN MONITOR) FUNCTION

The watchdog function monitors whether any of the CPUs mounted in the copier overrun. If this function detects that a CPU overruns, the copier automatically resets the CPU, thereby restarting the logic circuit and mechanism. Even if a copier CPU operates erratically due to electrical noise, therefore, the copier is able to recover from the faulty condition so that the number of visits made by the Technical Representative for CPU overrun can be minimized.
1156SBM0501A
5-1. Configuration
The copier has three printed-circuit boards each on which a CPU is mounted: *SCP Board PWB-F that controls the optical system, *Master Board PWB-A that controls the copier, Paper 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 of the CPUs in the Duplexing Document Feeder and Data Controller. *The Master CPU monitors the communications conditions of the CPUs in the Sorter and Staple Sorter. *The control boards for the Paper Feed Cabinet and Duplex Unit do not have a CPU in them. Instead, the Master CPU in the copier controls their operations.
Data Controller Control Board Duplexing Document Feeder Control Board (PWB-A)
Copier SCP Board PWB-F Sorter, Staple Sorter MSC Board PWB-B Control Board (PWB-A) Master Board PWB-A = Board on which a CPU is mounted
Paper Feed Cabinet, Duplex Unit Large Capacity Cassette
M-8
1149SBM0502A
5-2. Watchdog Function Post-Processing

The following processing is performed if a faulty condition is detected in the CPU. When the copier CPU is found faulty: D All CPUs including those of the options are reset and the system is restarted. If the CPU is found faulty during a copy cycle, the system attempts to feed 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 before resetting. The Watchdog Counter available from the Tech. Rep. mode allows the Technical Representative to check if any faulty condition has occurred in the CPU. For details, see SWITCHES ON PWBs.
M-9
1156SBM0600A
6 MALFUNCTION BYPASS FUNCTION

D When a malfunction occurs in the copier, the malfunction bypass function permits the copier to continue operating if that malfunction is one of the predefined candidates for an isolated malfunction and if it will not affect the current copying operation. But, if an isolated malfunction occurs anytime during the actual copy cycle, the copier considers it a normal malfunction. D If a copying function involving an isolated malfunction is selected, the message Selected mode cant be used. appears on the Touch Panel and the copier rejects that function. D When an isolated malfunction occurs, a tiny wrench indicator 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 malfunction, prompting a Tech. Rep. call. (The sixth malfunction is shown on the Touch Panel.) But, if all of the paper feed ports (except the manual feed port) show an isolated malfunction, the copier considers them a normal malfunction even though the isolated malfunction count may be less than five. The display also tells the condition when the image stabilization controls are not properly working. D For the details of the Isolated malfunction codes, see TROUBLESHOOTING for the copier and the specific SERVICE MANUAL for the options.
M-10
1149SBM0700A
7 IMAGE STABILIZATION SYSTEM

z The following image stabilization controls are provided to ensure stabilized copy image.
Item Initial Setting Quality Image density, gradation Purpose To make initial settings of grid voltage (Vg), optimum Exposure Lamp voltage, and AE Sensor gain. To compensate for any drop in image density due to a deteriorating PC Drum. To compensate for any drop in the intensity of LA1 light due to a contaminated optical system. To keep a given toner-to-carrier ratio of the developer in the Developer Mixing Chamber. To compensate for any drop in PC Drum surface potential when the copier is cool immediately after the Power switch is turned ON. To compensate for image density and gradation aggravated by a faulty AIDC Sensor. Control Sets the initial values for grid voltage correction, optimum Exposure Lamp voltage correction, and AE Sensor gain adjustment. Corrects the grid voltage through AIDC Sensor control. Corrects the optimum Exposure Lamp voltage through AIDC control. Provides toner replenishing control by means of the ATDC Sensor. (For details, see 13. DEVELOPMENT.) Corrects the grid voltage and optimum Exposure Lamp voltage through AIDC Sensor control. Corrects the grid voltage and optimum Exposure Lamp voltage according to the time through which the PC Drum has turned and the copier has run.
Regular correction
Image density
Gradation
Foggy background
Correction made immediately after Power Switch is turned ON Correction for Faulty AIDC Sensor
Image density, gradation
Image density, gradation
z The following is the block diagram of the image stabilization system.

Exposure Lamp LA1 Original Width Scale Original Glass Halftone Patch PU2 EE
PWB-A Image Erase Lamp LA3 Toner Replenishing HV1 CPU
ATDC AIDC
1136M003AA
M-11
1149SBM0701A
7-1. AlDC Sensor

To provide image stabilization control, this copier has AlDC Sensor PWB-G fitted to the Cleaning Unit of the Imaging Unit. The sensor is used to detect the toner density and background 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 PC Drum GND LED Power Supply
AIDC Sensor Image Transfer/Paper Separation Coronas

1149M005AA
Toner Density on PC Drum High Low
Light reflected Small Large
Output Voltage High Low
M-12
1156SBM0702A
7-2. Image Stabilization Control Processing Timing

D The image stabilization controls use the AIDC Sensor and AE Sensor as the basis, performing the following four major types of processing. The grid voltage, T/C, and optimum Exposure Lamp corrections are not, however, made if T/C falls outside the range of 4% to 8% at adjustment. AIDC Sensor adjustment Grid voltage and T/C correction D Processing Timing
Timing Item Processing Order ( ) Initial setting At the initial setup, or when the FF or F5 test operation is run after the PC Drum has been replaced. 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. During warming-up immediately after the Power Switch has been turned ON (*3) Upon completion of the copy cycle for every 75K copies made in terms of the number of intermittent copies, as it is equivalent to the time over which the PC Drum has turned after a faulty AIDC Sensor was detected. Processing (f: Performed; *: Not performed) f f (*1) f f f
Optimum Exposure Lamp voltage correction AE Sensor gain adjustment
Regular correction
Correction immediately after S1 is turned ON Correction for a faulty AIDC Sensor
f (*2)
f (*2)
*1: T/C is not corrected when an F5 test operation is run. *2: The grid voltage is increased by 30V and the optimum Exposure Lamp voltage by 1V. No T/C correction is made even when the grid voltage reaches its upper limit. *3: The correction sequence is canceled as regular correction starts.
M-13
1156SBM0703A
7-3. Details of Image Stabilization Controls

AIDC Sensor adjustment Grid voltage and T/C correction Optimum Exposure Lamp voltage correction AE Sensor gain adjustment
D The following is the details of each image stabilization control. -1 AIDC Sensor coarse adjustment This adjustment represents a coarse adjustment of the AIDC Sensor when the ordinary control of only the LED current cannot cover part-to-part variations in the AIDC Sensor (installation, circuit, deterioration, etc.). The surface of the PC Drum whose charges have been neutralized is exposed to light from the LED. The output current from the AIDC Sensor goes through the load resistance selected by a 4-bit analog switch and the 4-bit analog switch selects the load resistance so that the resultant voltage becomes 1V or less. -2 AIDC Sensor fine adjustment 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 AIDC Sensor Control Signal PJ11A-7A ON OFF WIRING DIAGRAM 1-I
Pulse output
Grid voltage and T/C correction The Image Erase Lamp produces a solid-black pattern on the surface of the PC Drum and the AIDC Sensor reads the pattern. The grid voltage is then varied so that the output from the AIDC Sensor remains at a given level or higher, which ensures that the toner-to-carrier ratio on the surface of the PC Drum becomes constant. If an even greater solid-black density is required when the upper control limit of the grid voltage has already been reached, the target control value of T/C is raised in 0.5% steps up to 7%, thus terminating the adjustment sequence.
Control Value
1 Step
Initial Value
Grid Voltage
550 to 790V
30V
550V
M-14
<Relation with Image Density> The Image Exposure function of Tech. Rep. Choice available from the Tech. Rep. mode enables fine-adjustments of the grid voltage (solid-black image density) to be made. It specifies how many volts the optimum grid voltage determined by the image stabilization control is to be increased or decreased. This fine-adjustment value remains the same even when the optimum grid voltage is later varied by the image stabilization control.
Controlled Part Grid voltage output from High Voltage Unit HV1 Control Signal PJ13A-1 ON OFF WIRING DIAGRAM 3-F
Pulse Output
Optimum Exposure Lamp voltage correction The Exposure Lamp is turned ON to illuminate the halftone patch on the back of the Original Width Scale, thereby producing a halftone pattern on the surface of the PC Drum. The Exposure Lamp voltage is then varied so that the output from the AIDC Sensor falls within the target range, thereby ensuring an optimum exposure level.
Control Value 1 Step Initial Value
Exposure Lamp voltage (100V Areas) Exposure Lamp voltage (200V Areas)
40 to 80V 80 to 160V
1V 2V
58V 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 stabilization control is to be increased or decreased. This fine-adjustment value remains the same even when the optimum Exposure Lamp voltage is later varied by the image stabilization control.
Controlled Part Exposure Lamp Regulator (PWB-J) REM Control Signal PJ8A-12 ON OFF WIRING DIAGRAM 45-H
Pulse output
AE Sensor gain adjustment The Exposure Lamp is turned ON to illuminate the blank sheet of paper placed on the Original Glass (when an F5 or FF operation is run) or the halftone patch on the back of the Original Width Scale (when the AE Sensor gain is adjusted in a sequence other than F5 or FF). The reflected light is then read by the AE Sensor and a gain adjustment of the AE Sensor is made to maintain an optimum Auto exposure level.
Controlled Part Control Signal PJ3A-2 ON OFF WIRING DIAGRAM 12-B
AE Sensor Board PWB-H
Pulse Output
M-15
1149SBM0800A
8 PC DRUM
The photoconductive drum used in this copier is the organic photoconductor (OPC) type. The drum is made up of two distinct, semiconductive materials on an aluminum alloy base. The outer of the two layers is called the Charge Transport Layer (CTL), while the inner layer is called the Charge Generating Layer (CGL). The PC Drum has its grounding point inside 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 from the copier. Further, use utmost care when handling the PC Drum to prevent it from being contaminated.
PC Drum Cross-Sectional View PC Drum CTL CGL Aluminum Cylinder
Gear
Shaft
Grounding Point
Grounding Plate
PC Drum Drive Coupling Gear
M-16
1156SBM0900A
DRUM CHARGING
The PC Drum Charge Corona has a Scorotron grid to deposit a negative DC charge evenly across the surface of the PC Drum. The grid voltage (VG) applied to the grid mesh is selected between 550V (initial value, variable according to image stabilization controls) in the normal mode and the value in the normal mode +90V in the Photo mode by the Constant-Voltage Circuit in High Voltage Unit HV1. 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 the shaft on which a Cleaning Rollar is mounted.
Holder
Comb Electrode
Spring
Holder
Grid Mesh
1151T03MCC
Control Signal PC Drum Charge Corona PWB-A PJ13A-2
ON L Normal Mode
OFF H
WIRING DIAGRAM 3-F
Control Signal Grid Voltage (VG) PWB-A PJ13A-1
Photo Mode
WIRING DIAGRAM 3-F
Pulse output
M-17
1156SBM0901A
9-1. Ozone Filter

D Ozone produced by the PC Drum Charge Corona is absorbed by the Ozone Filter located to the left of the PC Drum Charge Corona, as the air is drawn out of the copier by Ventilation Fan Motor M3.
Ventilation Fan Motor M3 Ozone Filter PC Drum Charge Corona
1134M004AA
Control Signal M3 PJ34A-1
ON H
OFF L
WIRING DIAGRAM 11-F
M-18
1156SBM1000A
10 IMAGE ERASE LAMP

To prevent a black band from occurring across both the leading and trailing edges, and along the front and rear edges, of the electrostatic 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 Exposure Image Erase Lamp LA3
1156M010AA
The position of LA3 can be adjusted using the adjusting screw at the front of the copier.
Copier Front Frame Adjusting Screw
Copier Rear Frame
LA3 Board
Compression Spring
1156M011AA
M-19
The 40 LEDs are grouped as follows and turned ON and OFF according to the paper size and zoom ratio. * In the full size mode, ON/OFF control is provided according to the paper size. * In any zoom ratio other than full size, the copier compares the number of LEDs that are turned ON according to the paper size with the number that are turned ON according to the zoom ratio 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. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 LED No. LED1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 LED 8 LED 9 LED 10 LED 11 LED 12 LED 13 LED 14 LED 15 LED 16 LED Group No. 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 LED No. LED 17 LED 18 LED 19 LED 20 LED 21 LED 22 LED 23 LED 24 LED 25 LED 26 LED 27 to 35 LED 36 LED 37 LED 38 LED 39 LED 40
*The bigger the number, the nearer the LED is to the front side of the copier.
M-20
LA2 LEDs ON/OFF Pattern

Zoom Ratio Paper Width (mm) X91 92 X 99 100 X 107 108 X 116 117 X 126 127 X 135 136 X 142 X0.522 0.523 X 0.550 0.551 X 0.576 0.577 X 0.610 0.611 X 0.642 0.643 X 0.672 0.673 X 0.698 0.699 X 0.728 0.729 X 0.758 0.759 X 0.776 0.777 X 0.806 0.807 X 0.830 0.831 X 0.854 0.855 X 0.882 0.883 X 0.914 0.915 X 0.938 0.939 X 0.964 0.965 X 0.990 0.991X 143 X 149 150 X 158 159 X 166 167 X 173 174 X 184 185 X 195 196 X 203 204 X 211 212 X 220 221 X 229 230 X 235 236 X 244 245 X 251 252 X 258 259 X 267 268 X 277 278 X 284 285 X 292 293 X 298 LED Group No.
0 f f f f f f f f f f f f f f f f f f f f f f f f f f 1 f f f f f f f f f f f f f f f f f f f f f f f f f 2 f f f f f f f f f f f f f f f f f f f f f f f f 3 f f f f f f f f f f f f f f f f f f f f f f f 4 5 6 f f f f f f f f f f f f f f f f f f f f 7 f f f f f f f f f f f f f f f f f f f 8 f f f f f f f f f f f f f f f f f f 9 f f f f f f f f f f f f f f f f f 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 31 f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f
f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f
f=
LED that turns ON
M-21
LA2 LEDs ON/OFF Pattern (Frame Erase, erase width 10mm)

Paper Width (mm) X105 106 X 113 114 X 121 122 X 130 131 X 140 141 X 149 150 X 156 157 X 164 165 X 172 173 X 180 181 X 188 189 X 198 199 X 208 209 X 217 218 X 225 226 X 234 235 X 243 244 X 249 250 X 258 259 X 265 266 X 272 273 X 281 282 X 291 292 X 298 299 X LED Group No.
0 f f f f f f f f f f f f f f f f f f f f f f f f f 1 f f f f f f f f f f f f f f f f f f f f f f f f f 2 f f f f f f f f f f f f f f f f f f f f f f f f 3 f f f f f f f f f f f f f f f f f f f f f f f 4 f f f f f f f f f f f f f f f f f f f f f f 5 f f f f f f f f f f f f f f f f f f f f f 6 f f f f f f f f f f f f f f f f f f f f 7 f f f f f f f f f f f f f f f f f f f 8 f f f f f f f f f f f f f f f f f f 9 f f f f f f f f f f f f f f f f f 10 f f f f f f f f f f f f f f f f 11 f f f f f f f f f f f f f f f 12 f f f f f f f f f f f f f f 13 f f f f f f f f f f f f f 14 f f f f f f f f f f f f 15 f f f f f f f f f f f 16 f f f f f f f f f f 17 f f f f f f f f f 18 f f f f f f f f 19 f f f f f f f 20 f f f f f f 21 f f f f f 22 f f f f 23 f f f 24 f f 25 f 26 27 30 f f f f f f f f f f f f f f f f f f f f f f f f f 31 f f f f f f f f f f f f f f f f f f f f f f f f f
f=
LED that turns ON
M-22
1151T20MCB
Control Signal LA3 PWB-A PJ9A-1~6
ON
OFF
WIRING DIAGRAM 4-L
Static ON/OFF Control
M-23
1156SBM1100A
11 OPTICAL SECTION
As the Scanner is moved by Scanner Motor M2, the light from Exposure Lamp LA1 is reflected off the original and guided through the six Mirrors onto the surface of the PC Drum to form the electrostatic latent image.
6 5 7 8 2 9
7 1 3
7 4
12 13 15 16
1156M012AA
10 11
14
18 17
1. 2. 3. 4. 5. 6. 7. 8.
Scanner Reference Position Sensor PC81 Original Glass Cooling Fan Motor M5 Scanner Lens Scanner Motor M2 Scanner Shaft Mirror Motor M7 4th/5th Mirrors Carriage
9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
4th Mirror 5th Mirror 6th Mirror Lens Motor M6 AE Sensor Board PWB-H Exposure Lamp LA1 1st Mirror 2nd Mirror 3rd Mirror 2nd/3rd Mirrors Carriage
M-24
1156SBM1101A
11-1. Exposure Lamp LA1

An AC halogen lamp is used as Exposure Lamp LA1. As the exposure level is adjusted on the control panel, the duty ratio of the pulse of AVR Remote from PWB-A changes to increase or decrease the LA1 voltage, thereby changing 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 Mode 1 Lamp Voltage Difference (V) Manual Level Priority Mode 2 Mode 3 9 8 7 6 5 Reference Reference Reference 4 3 2 1 8 5 2 1 8 6 4 2 8 7 6 3 +1 +2 +5 +8 +2 +4 +6 +8 +3 +6 +7 +8
Varies depending on the drawer.
1151T21MCB
Control Signal AVR Remote Signal (PWB-J) PWB-A PJ8A-13
ON L
OFF H
WIRING DIAGRAM 45-H
M-25
1156SBM1102A
11-2. AE Sensor
In the Auto Exposure Mode, the AE Sensor on AE Sensor Board PWB-H measures the intensity of the light reflected off the original, by sampling the black/white ratio of a 210-mm-wide area of the original being measured. According to this measurement, the 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) Intensity of Reflected Light PWB-H Output AVR Duty LA1 Voltage High Low High Increased Increased Control Signal PWB-H (AE Sensor) AVR Remote Signal (PWB-J) PWB-A PJ3A-2 PWB-A PJ8A-13 Low High Low Decreased Decreased ON OFF WIRING DIAGRAM 12-B 45-H
Pulse output L H
M-26
1156SBM1103A
11-3. Lamp Reflectors

The Main Reflector ensures that light from Exposure Lamp LA1 exposes all areas of the original. The Auxiliary Reflector functions to reflect light onto the areas that LA1 cannot illuminate when an original that does not lie flat on the Original Glass (such as a book) is being used. This 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
Auxiliary Reflector
Main Reflector Exposure Lamp LA1

1151M021AA
1156SBM1104A
11-4. Aperture Plates

Four Aperture Plates are moved to the front or rear to ensure even light distribution.
Aperture Plate
1139M035AA
M-27
1156SBM1105A
11-5. Scanner and 2nd/3rd Mirror Carriage Movement

The Scanner and 2nd/3rd Mirrors Carriage are moved by the Scanner Drive Cable fitted in the rear side of the copier. The Cable is driven by Scanner Motor M2. Both the Scanner and 2nd/3rd Mirrors Carriage slide along the Scanner Shaft at the rear side. While 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, M2 is energized to move them to the home position.
Scanner Motor M2
Scanner Reference Position Sensor PC81
Scanner Shaft
Rear
1st Mirrors Carriage
2nd Mirrors Carriage
Front
1156M013AA
M-28
The Scanner starts the scan motion as a Scan signal is output from PWB-A. At the start of a scan motion and other heavy load conditions, Scanner Motor M2 requires a large amount of current. The Current 1 or 2 signal from PWB-F is selected accordingly to vary the amount of current supplied to M2. *The Current signal selection timing is controlled by software.
L Current 1 Current 2 Current When the scan speed reaches a given level and during scan deceleration H H M1 L H M2>M1>L At scan start and during return deceleration. (*) At return start and during return motion. (*) M2 H L
Operation
* 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 width of the pulses applied to M2.
Control Signal M2 Scan Signal M2 Current Switching Signal 1 M2 Current Switching Signal 2 PWB-F Energized L Deenergized H WIRING DIAGRAM
PWB-F
H 22-B
PWB-F
Control Signal PC81 PWB-F
Blocked L
Unblocked H
WIRING DIAGRAM 18-E
M-29
1156SBM1106A
11-6. Lens Movement

The Lens is moved by the Lens Drive Cable which is driven by Lens Motor M6 (stepping motor). The motor drive pulses sent from PWB-F drive M5 to move the Lens a given distance, corresponding to the zoom ratio, from the reference position 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.
Lens Reference Position Sensor PC90 Lens Base Bracket Lens Shaft
Lens Aperture Cover
Spring
Cam
Lens Drive Cable Lens Motor M5

1156M014AB
Lens
Lens Aperture Cover

1136M013AA
Control Signal M6 PWB-F Control Signal PC90 PWB-F
Energized L Blocked L
Deenergized H Unblocked H
WIRING DIAGRAM 19-A WIRING DIAGRAM 18-D
M-30
1156SBM1107A
11-7. 4th/5th Mirrors Carriage Movement

The 4th/5th Mirrors Carriage is moved to vary the conjugate distance for a particular zoom ratio by driving the rack-and-pinion gears at the front and rear ends of the mirror 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 4th/5th Mirrors Carriage Mirror Motor M7
4th/5th Mirrors Guide Plate Mirror Reference Position Sensor PC86

1136M017AA
Control Signal M7 PWB-F Control Signal PC86 PWB-F
WIRING DIAGRAM 19-B WIRING DIAGRAM 18-C
M-31
1156SBM1108A
11-8. Original Glass Cooling Fan Optical Section Cooling Fan Motor M5 draws outside air into the copier and blows it against the 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.
Filter Original Glass
Rear of Copier
Front of Copier
Original Glass Cooling Fan Motor M5

1149M024AA
Control Signal M5 PWB-A PJ15A-5
Energized H
Deenergized L
WIRING DIAGRAM 21-H
M-32
1156SBM1200A
12 ORIGINAL SIZE DETECTING SENSORS

The five sensors fixed in the optical section receive the light reflected off the original to determine the size of the original in the Auto Paper and Auto Size mode. (The image density of the original, or OD, that can be detected is 0.6 or less.)
1156SBM1201A
12-1. Identification of Original Size Detecting Sensors

Original Size Detecting Board UN2
Original Size Detecting Sensor CD1 PC115
Original Size Detecting Sensor CD2 PC119
Original Cover Detecting Sensor PC111
Original Size Detecting Sensor FD3 PC118 Original Size Detecting Sensor FD2 PC117 Original Size Detecting Size Reset Switch S108
1156SBM1202A
Sensor FD1 PC116

1136M018AA
12-2. Original Size Detecting Operation

Each photo receiver of the original size detecting sensors (PC115 to 119) responds to reflected light of a given intensity with reference to the intensity of the light emitted by each LED. This allows the Original Size Detecting Board to determine whether or not there is an original within a set distance.
Original Original Glass
Set Distance Photo Receiver LED
1136M020AA
M-33
1156SBM1203A
12-3. Sensor Locations

D The number and location of the Original Size Detecting Sensors vary depending on the marketing area as shown below. f: Standard F: Optional
Sensors Areas Metric Areas Inch Areas Hong Kong Area CD1 (PC115) CD2 (PC119) FD1 (PC116) FD2 (PC117) FD3 (PC118)
f f f
F F f
f F f
f 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.
Length (Inch) FD1 FD2 Letter C Letter L Legal FLS FD3 11 17
Width (Inch) Width (Metric)
A5L B5L A4L B4L, B5C A3L, A4C CD2 CD1
Invoice Legal, Letter L Letter C, 11 17 L: Lengthwise; B5C A4C, B5L A4L B4L A3L C: Crosswise A5L Original Size Detecting Board UN2 CN1 JP1 CN4 CN3 CN2
Length (Metric)
LED1
LED2
JP2
FD1 is mounted
Position of JP1
CD2 and FD3 are mounted
FD1 is not mounted
CD2 and FD3 are not mounted
Position of JP2
1136M022CA
M-34
1156SBM1204A
12-4. Size Detection

D Original Size Detecting Board UN2 reads the output data provided by the original size detecting sensors (PC115 to 119). By comparing the data from each sensor with the threshold level, it determines whether there is an original placed on the Original Glass. UN2 then determines the size of the original according to the combination of the data. Metric Area
FD1 Original Size A3L B4L A4L A5L A4C Letter L: 8-1/2 11 11 17 Legal: 8-1/2 14 FLS: 8-1/2 13 Letter C: 11 8-1/2 No Original Size Determined by UN2 A3L (A3L) B4L (B4L) A4L (A4L) A5L (A5L) A4C (A4C) Letter L (Letter L) 11 17 (A3L) Legal (A4L) FLS (A4L) Letter C (A4C) No Original LED 2 FD2 LED 1 LED 2 FD3 LED 1 LED 2 CD1 LED 1 LED 2 CD2 LED 1
f f f f f f f f f f F
FD1
f f f F F f f f f F F
f f f F F F f f f F F
FD2 LED1
f(f) f(f) F(F) F(F) F(F)
f(F) f(F) F(F) F(F) F(F)
f F F F f F f F F f F
f f F F f F f F F f F
f(f) F(F) F(F) F(F) f(f) F(F) F(f) F(F) F(F) F(f) F(F)
CD1
F(F) F(F) f(f) f(F) f(F) f(F) f(F) F(F) F(F) F(F) F(F) F(F)
FD3 LED1
Inch Area
Original Size 11 17 Legal: 8-1/2 14 Letter L: 8-1/2 11 Letter C: 11 8-1/2 FLS: 8-1/2 13 Invoice: 5-1/2 8-1/2 No Original Size Determined by UN2 11 17 (11 17) Legal (Legal) Letter L (Letter L) Letter C (Letter C) FLS (Legal) Invoice (No Original) No Original
LED2
LED2
LED2
LED1
LED2
f(f) f(f) f(f) f(f) f(f) f(F) F(F)
f f f F f F F
f f F F f F F
f(f) f(f) F(F) F(F) f(f) F(F) F(F)
f(f) f(f) F(F) F(F) F(f) F(F) F(F)
f F F f F F F
f F F f F F F
*f: Original Present F: Original Not Present *If no optional sensors are mounted, data is processed as indicated in ( ) and the original sizes determined by UN2 are as indicated in ( ). *UN2 does not use the data provided by LED1 of Original Size Detecting Sensor FD1 (PC116) and LED2 of CD2 (PC119) for the determination of the original size. *Any non-standard size is rounded off to the nearest standard size.
M-35
1156SBM1205A
12-5. Original Size Detection Timing

Master CPU on PWB-A affirms and resets the readings of the original size at the following timings. D Takes size readings: When the Original Cover is raised to an angle of 15 or 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 deactivated 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 PC111 PWB-A PJ17A-11 Control Signal S108 PWB-A PJ12A-1
Blocked L ON L
Unblocked H OFF H
WIRING DIAGRAM 21-G WIRING DIAGRAM 16-B
M-36
1156SBM1300A
13
DEVELOPING UNIT
D This copier employs the New Micro-Toning developing system. The toner fed up to the Sleeve/Magnet Roller is conveyed onto the points of development as the Sleeve/Magnet Roller turns, thereby forming a visible, developed toner image of the original.
7 8
10
15
14 13 12 11
1156M015AA
1. 2. 3. 4. 5. 6. 7. 8.
Toner Bottle Developer Scattering Prevention Mylar Developer Scattering Prevention Plate Doctor Blade Sub Hopper Toner Supply Roller Toner Bottle Home Position Sensor PC35 Toner Bottle Home Position Detecting Plate Main Hopper Toner Replenishing Motor M8
9. 10. 11. 12. 13. 14. 15.
Sub Hopper Toner Empty Detecting Lever Sub Hopper Toner Agitating Lever ATDC Sensor UN3 Developer Conveying/Agitating Screw Bucket Roller Magnet Sheet Sleeve/Magnet Roller
M-37
1156SBM1301A
13-1. Developing Unit Drive Mechanism

D Drive is transmitted from the copier to the Developing Unit by Coupling Gears 1 and 2 when they mesh. D Coupling Gear 2 is spring-loaded. If the protruding part 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 allowing 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 Gear 1.
Front
Coupling Gear 2
Coupling Gear 1 Main Drive Motor M1
Rear
1134M009AA
M-38
1156SBM1302A
13-2. Magnet Roller

The Magnet Roller of the Sleeve/Magnet Roller of this copier has the following magnetic characteristics. Pole S3 before poles N1 and N2 at which development takes place provides a very weak magnetic force. If developer is compacted and clogs at the Doctor Blade and, as a result, part of the surface of the Sleeve/Magnet Roller is not covered with developer, the nearby developer around S3 goes to those uncovered areas because of the weak magnetic force. This helps prevent white lines from occuring on the copy. The magnetic flux density is maximized to allow the bristle to stand high and upright at poles N1 and N2, at which development takes place. The positioning of these two like poles together helps 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. The Imaging Unit integrates the Developing Unit with the PC Drum into one body. Because of that, it is impossible to move the Developing Unit against the PC Drum, thereby providing a certain distance between the PC Drum and Sleeve/Magnet Roller. The Magnet Roller has therefore been made movable: the Bushing is pressed by compression springs thereby pressing the Positioning Collars on both ends of the Magnet Roller against the PC Drum. This ensures a given distance between the PC Drum and the Sleeve/Magnet Roller.
S2 S3 N4
N1
N2
S1
N3 Movable Bushing
Compression Spring Fixed Bushing PC Drum

1156M016AA
M-39
1156SBM1303A
13-3. Developing Bias

A negative voltage (Vb = Developing Bias voltage) is applied to the Sleeve Roller to prevent a foggy background on the copy. The amount of toner attracted onto the surface of the PC Drum depends on how much lower the PC Drum surface potential (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.
DS Collar Bias Connector Sleeve/Magnet Roller Front

1134M018AA
Bias Terminal
Varies depending on the drawer.

1151T01MCC
Control Signal Developing Bias PWB-A PJ13A-3
ON L
OFF H
WIRING DIAGRAM 3-F
M-40
1156SBM1304A
13-4. Doctor Blade

The Doctor Blade installed over the Sleeve/Magnet 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 Direction of Magnet Roller Movement
Magnet Roller
1156M017AA
M-41
1156SBM1305A
13-5. ATDC Sensor

The copier compares the toner-to-carrier ratio (T/C) of the developer in the Developer Mixing Chamber detected by ATDC Sensor UN3 during a copy cycle with the reference ratio (6%) and, if it finds a lower ratio than the reference, replenishes the supply of toner. The standard output voltage of the ATDC Sensor for the reference T/C (6%) is 2.5V. If the toner-to-carrier ratio becomes lower than 2.5% in a toner-empty condition, the copier inhibits the initiation of a new copy cycle (this feature can be enabled or disabled by a Tech. Rep. Choice mode). As soon as a ratio of 3% or more is recovered, the copier permits the initiation of a new copy cycle. If the Front Door is swung open and closed with a T/C ratio of less than 3%, the copier initiates an Auxiliary Toner Replenishing 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 setup mode, upon pressing the Start Key, the copier CPU reads the output value of the ATDC Sensor and adjusts the ATDC Sensor gain so that the output value becomes 2.5V. NOTE: If an F8 (or FF) operation is run at a time when the starter has not been changed, it can result in a wrong T/C reference value being set by the copier. Avoid casual use of F8. If the setting value has been cleared because of the RAM Board being replaced, use the Level History function of the Tech. Rep. mode to return the ATDC Ref. Value to the original value before the board was replaced.
Controlled Part UN3 Control Signal PJ11A-2B T/C Ratio 6.0(%) Standard Output Voltage 2.5(V) WIRING DIAGRAM 1-J
M-42
<Toner Replenishing Control by ATDC Sensor> The ATDC Sensor samples T/C for each copy and the copier compares the reading with the reference T/C (which is normally 6% but may 7% depending on the image stabilization control provided), energizing Sub Hopper Toner Replenishing Motor M9 as may be necessary to replenish toner in either of the following four modes.
Toner Replenishing Mode Large amount replenishing Conditions The ATDC Sensor reading is lower than reference T/C by 0.5% or more. Small amount replenishing The ATDC Sensor reading is lower than reference T/C by less than 0.5%. Fixed amount replenishing The ATDC Sensor reading is higher than reference T/C by less than 1%. No toner replenishing The ATDC Sensor reading is higher than reference T/C by 1% or more. Approx. 13mg Approx. 66 mg Amount Replenished * Approx. 133 mg
* The amount of toner replenished varies according to the paper size (given in the table are figures for A4). The copier is also provided with a function that, if T/C detected during a copy cycle is lower than the 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, disabled 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 Sensor, if it becomes defective, to the AIDC Sensor to continue providing the toner replenishing control. A pattern is produced on the surface of the PC Drum for each copy between two successive copies or after it has been fed out. The AIDC Sensor reads that pattern to detect the amount of toner sticking to it and the copier performs either of the following toner replenishing sequences depending on the output voltage of the AIDC Sensor. (Controlled target T/C: 6%; AIDC Sensor output voltage: DC4.25V)
Toner Replenishing Mode Large amount replenishing Small amount replenishing Fixed amount replenishing No toner replenishing AIDC Sensor Output Voltage Less than DC3.25V DC3.25V to less than 4.25V DC4.25V to less than 5.25V DC5.25V or more Amount Replenished * Approx. 129 mg Approx. 64 mg Approx. 13 mg
* The amount of toner replenished varies according to the paper size (given in the table are figures for A4).
M-43
1156SBM1306A
13-6. Sub Hopper Toner Replenishing Mechanism

Sub Hopper Toner Replenishing Motor M9 is energized for the toner replenishing 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 Supply Roller
Sub Hopper Toner Replenishing Motor M9
Bucket Roller
Sub Hopper Developer Conveying/ Agitating Screw
Sleeve/Magnet Roller Rear of Copier
Front of Copier
1134M014AA
Controlled Part M9
Control Signal PJ11A-2A
ON L
OFF H
WIRING DIAGRAM 2-H
M-44
1156SBM1307A
13-7. Sub Hopper Toner Empty Detection Control

D A toner-empty condition in the Sub Hopper is detected by the magnet fitted to the Sub Hopper Toner Empty Detecting Lever and Sub Hopper Toner Empty Switch S106. D The Sub Hopper Toner Empty Detecting Lever rides on the eccentric cam fitted to the rear of the Sub Hopper Toner Agitating Lever. It is moved up and down as the eccentric cam is turned by the drive transmitted from Main Drive Motor M1. D While the amount of toner in the Sub Hopper is 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 time S106 is actuated exceeds a predetermined value, the copier CPU determines that the Sub Hopper has run out of toner.
Magnet Sub Hopper Toner Empty Detecting Lever
Eccentric Cam Sub Hopper Toner Empty Switch S106 Toner Empty
1134M015AA
Toner Full
1134M016AA
1134M017AA
Controlled Part Sub Hopper Toner Empty Switch S106
Control Signal PJ11A-8B
ON L
OFF H
WIRING DIAGRAM 2-L
M-45
1156SBM1308A
13-8. Main Hopper Toner Replenishing Mechanism

D Toner is supplied from the Main Hopper to Sub Hopper as follows. When a toner empty condition is detected in the Sub Hopper, it energizes Main Hopper Toner Replenishing Motor M8 to turn the Toner Bottle. D The Home Position Detecting Plate fitted to the coupling and Toner Bottle Home Position Sensor PC35 ensure that the Toner Supply Port in the Toner Bottle is positioned at the top whenever the Toner Bottle is stopped.
Toner Bottle Toner Bottle Home Position Sensor PC35 Toner Bottle
Toner Supply Port
Toner Supply Hole
Toner Bottle Holder Home Position Detecting Plate
1136M034AA
Coupling
Main Hopper Toner Replenishing Motor M8
1156M018AB
Controlled Part M8 Controlled Part PC35
Control Signal PJ11A-4A Control Signal PJ11A-9B
ON L Blocked L
OFF H Unblocked H
WIRING DIAGRAM 2-H WIRING DIAGRAM 2-K
M-46
1156SBM1309A
13-9. Swinging Out/In the Main Hopper

D To replace an empty Toner Bottle, the user first needs to swing the Toner Bottle Holder out 40 to the front. There is a flat spring installed on the Sub Hopper Holder, which causes the Toner Bottle Holder to click out of, and into, the locked position. D The Holder pivots about the Toner Supply Port as it is swung out or in, which effectively prevents toner from spilling when the Holder is swung out or in. The Coupling is provided with a locking mechanism that prevents the Toner Bottle 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.
Flat Spring
Coupling Lock Lever
Front
Toner Bottle Holder
Rear
1136M089AA
<When the Toner Bottle Holder is Swung Out> D The Toner Bottle Holder pushes the flat spring down and moves over it until the flat spring then fits into the rear ^ notch. This locks the Toner Bottle Holder in position. At this time, the Coupling Lock Lever is free and the spring acts to lock the Coupling in position with the Lock Lever.
Coupling Toner Bottle
Coupling Lock Lever Front
Rear
Flat Spring
1136M035AA
M-47
1156SBM1400A
14 IMAGE TRANSFER AND PAPER SEPARATION

Image Transfer The Image Transfer Corona applies a DC negative corona emission to the underside of the paper thereby attracting the positively charged toner onto the surface of the paper to form a visible, developed image of the original. The Corona Unit is provided with a Corona Wire cleaning mechanism: the operator has only to pull out the Lever on which the Cleaner is mounted from the front of the copier, which cleans the Wire. Paper Separation The Paper Separator Corona showers the underside of the paper with both positive and negative charges so that the paper can be easily separated from 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 the image may be properly transferred onto the paper. The Image Transfer/Paper Separator Coronas Unit is grounded via a high capacity resistor, which improves its efficiency to discharge to the PC Drum side, thus reducing the output current from High Voltage Unit HV1.
PC Drum Image Transfer Corona Wire Guide Paper Separator Corona Wire Corona Housing Resistor Image Transfer/Paper Separator Coronas Unit Rail Pre-Image Transfer Guide Plate
Reisitor
Image Transfer Corona Wire Cleaner

1136M054AA
Cleaner Lever
Cleaner
M-48
1151T07MCD
Control Signal Image Transfer Corona Paper Separator Corona

1156SBM1401A
ON L
OFF H
WIRING DIAGRAM 3-F
PWB-A PJ13A-2
PWB-A PJ13A-3
3-F
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.
Duct
(Front of Copier)
To Ozone Filter
Image Transfer/Paper Separator Coronas

1136M056AA
M-49
1156SBM1500A
15 PAPER SEPARATOR FINGERS

After image transfer, an AC corona emission is applied to the underside of the paper by the Paper Separator Corona to neutralize the paper so that it can be easily separated from the PC Drum. To further ensure that the paper is positively separated from the PC Drum, there are two Paper Separator Fingers attached to the Imaging Unit. They physically 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 by Separator Solenoid SL1.
Separator Solenoid SL1 PC Drum Paper Separator Finger Shaft Swash Plate Cam Return Spring
PC Drum Paper Separator Finger Pivot Pawl (A) Finger Operating Lever
1136M064AA
M-50
<Paper Separator Finger Front-to-Back Moving Mechanism> The Paper Separator Fingers are also moved over a given distance to the front and rear so that they will contact wider areas of the surface of the PC Drum, thus preventing localized damage to the PC Drum surface. 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 Deenergized Ratchet Wheel Swash Cam
1136M066AA
1136M067AA
Pawl (A) pushes the Swash Cam downward to turn it one notch.
Paper Separator Finger Shaft
M-51
Control Signal SL1 PWB-A PJ11A-6A
Energized L
Deenergized H
WIRING DIAGRAM 2-I
M-52
1156SBM1600A
16 CLEANING UNIT
The Cleaning Blade is pressed tightly against the surface of the PC Drum and scrapes off any toner remaining on the surface after image transfer and paper separation have been completed.
PC Unit Cleaning Blade
Blade Tension Spring
Toner Conveying Coll PC Drum Paper Separator Finger

1134M027AA
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.
Eccentric Cam Timing Belt
Back
Blade Moving Pin Cleaning Blade Assy Mounting Bracket
Front
To Main Drive Motor M1
1134M028AA
M-53
1156SBM1601A
16-1. Spent Toner Collection (1) Toner Conveying/Collecting Mechanism

D The toner which has been scraped off the surface of the PC Drum by the Cleaning Blade is conveyed by the Toner Conveying Coil towards the rear of the copier and falls into the Toner Collecting Box at the back of the copier through the pipe. D The Toner Antispill Mylar is affixed under the Cleaning Blade to receive toner, thus preventing any toner from failing down onto the surface of the copy paper or the paper path.
Cleaning Blade Residual Toner Toner Conveying Coil
Toner Antispill Mylar
1136M061AA
Toner Conveying Coil Toner Conveying Coil Drive Gear (Copier) Toner Conveying Coil Drive Gear (PC Unit)
Spent Toner Flow
Pipe
1136M062AA
D The type of Toner Collecting Box and the method of detecting an installed box differ between the applicable marketing areas. See the following table.
Areas EP5000 All areas U.S.A., Canada, EP4000 and Europe Other areas Type of Box Large-Capacity Toner Collecting Box (in Cabinet) Large-Capacity Toner Collecting Box (in Cabinet) Standard Toner collecting Box (in copier) Box-in-Position Detection PC31 (in Cabinet)
PC31 (in Cabinet)
PC107 (in Copier)
M-54
(2) Detection of Toner Collecting Box in Position

D Provided inside the Paper Feed Cabinet (in the copier for EP4000 for the areas other than the U.S.A., Canada, and Europe) is a Toner 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.
Toner Pipe Pipe Toner Collecting Box
Toner
PWB-A
Cabinet
Toner Collecting Box Set Sensor
PC107 Actuator
Toner Collecting Box
Actuator
(EP4000, except U.S.A., Canada, and Europe)
1134M030AA
1134M037EA
Controlled Part PC107
Control Signal PWB-A PJ19A-9
Blocked L
Unblocked H
WIRING DIAGRAM 21-F
M-55
1156SBM1602A
16-2. Cleaning 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 Cleaning Bias HV1
ON L
OFF H
WIRING DIAGRAM 3-F
M-56
1156SBM1700A
17 MAIN ERASE LAMP

Main Erase Lamp LA2 is turned ON to neutralize any surface potential remaining on the surface of the PC Drum after cleaning.
Main Erase Lamp LA2 Main Erase Lamp Board
Filter
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 contamination.
1151T06MCD
Control Signal LA2 PWB-A PJ12A-3
ON H
OFF L
WIRING DIAGRAM 1-L
M-57
1156SBM1800A
18 PAPER TAKE-UP/FEED SECTION

The copier is equipped with two paper 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.
Paper Size Detecting Sensors Assy (CD) Paper Take-Up Unit Assy
Paper Take-Up Rolls Paper Size Detecting Switches Assy (FD)
1st Drawer (Fixed Paper Size Type)
2nd Drawer (Universal Paper Size Type)
1149M014AA
M-58
1156SBM1801A
18-1. Drawer-in-Position Detection

D When 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 Front

4425M003AA
Control Signal PC61 PC62 PWB-A PJ22A-2 PWB-A PJ22A-6
Blocked L L
Unblocked H H
WIRING DIAGRAM 25-P 25-P
M-59
1156SBM1802A
18-2. Drawer Paper Lifting/Lowering Mechanism/Control (1) Metric Areas

D The paper lifting mechanism raises the paper in the drawer so that the top of the paper stack is pressed against the Paper Take-Up Roll at a constant pressure. D When slid into the copier, the drawer presses the Drawer Set Lever which engages Lift-Up Motor Gear 1 with Paper Lifting Arm Gear 2. D At the same time, the Drawer 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.
Rear Gear 2 Gear 1 Paper Lifting Arm 1st/2nd Drawer Lift-Up Motor M13/14
Front
4425M004AA
When Drawer is Slid in

1st/2nd Drawer Lift -Up Sensor (PC65/66)
D The Paper Lifting Arm further raises the paper after the top sheet of paper is pressed against the Paper Take-Up Roll. As the light blocking plate blocks the Lift-Up Sensor (goes LOW), the Lift-Up Motor (M13/M14) stops.
4425M005AA
M-60
During Copying
D As sheets of paper are used, the Paper Take-Up Roll lowers accordingly, unblocking the Lift-Up Sensor (PC 65/66 goes HIGH).
4425M006AA
D The Lift-Up Motor (M13/14) starts running, raising the paper stack until the Lift-Up Sensor (PC65/66) is blocked (output goes LOW).
4425M005AA
D Energizing and deenergizing of the Lift-Up Motor keeps constant the pressure between the Paper Take-Up Roll and paper regardless of the height of the paper stack.
Control Signal PC65 PC66 PWB-A PJ21A-2A PWB-A PJ21A-2B Control Signal M13 M14 PWB-A PJ18A-5 PWB-A PJ18A-7 Blocked L L Energized L L Unblocked H H Deenergized H H WIRING DIAGRAM 25-N 32-K WIRING DIAGRAM 25-M 25-M
M-61
(2) Inch Areas <Paper Stack Lifting>

D When the Paper Descent Key (UN5/6) is pressed*1 after the drawer has been slid into the copier, it energizes the Lift-Up Motor (M13/14) and the motor starts turning forward. D The rotation of the motor is transmitted via a gear train to the worm gear and the Paper Lifting Arm mounted on the same shaft, raising the Paper Lifting Plate. This raises the paper stack. D When the top of the paper stack is pressed against the Paper Take-Up Roll and the paper stack is further raised, the light blocking plate of the Paper Take-Up Roll Assy blocks the Lift-Up Sensor (PC65/66). This deenergizes the Lift-Up 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 still available for use. *1: The Lift-Up Motor is energized at the following timings, in addition to the press of the Paper Descent Key (UN5/6). D Turning ON the Power Switch D Opening and closing the door D Operating the panel D Detecting a sheet of paper on the Multi Bypass Table D Detecting an original in the Duplexing Document Feeder D Raising and lowering the Original Cover, etc.
Paper Lifting Arm
Worm Gear 1st/2nd Drawer Paper Lift-Up Motor M13/14
1st/2nd Drawer Paper Descent Key UN5/6

1134M032EA
M-62
D Paper lifting timings are as follows
1st/2nd Drawer Lift-Up Sensor PC65/66
1136T63MCA
4425M005AA
During Copying
4425M006AA
1136T64MCA
4425M005AA
Control Signal UN5 UN6 PWB-A PJ24A-3 PWB-A PJ24A-4 Control Signal M13 M14 PWB-A PJ18A-5 PWB-A PJ18A-7
OFF L L Energized L L
ON H H Deenergized H H
WIRING DIAGRAM 41-I 41-M WIRING DIAGRAM 25-M (41-K) 25-M (41-O)
M-63
<Paper Stack Lowering/Drawer Lock>

z
Paper Stack Lowering D When the Paper Descent Key (UN5/6) is pressed or the drawer runs out of paper during a copy cycle, the Lift-Up Motor (M13/14) is energized to turn backward. D The rotation of the motor is transmitted via a gear train to the worm gear and Paper Lifting Arm mounted on the same shaft, lowering them. D When the Lower Limit Position Sensor (PC70/71) is blocked by the light blocking plate of the worm gear, it deenergizes the Lift-Up Motor (M13/14). This completes the paper stack lowering motion (at a paper-empty condition). D When the Paper Descent Key (UN5/6) is pressed, the Lift-Up Motor is deenergized when the Lower Limit Position Sensor (PC70/71) is unblocked after it has been blocked. This unlocks the drawer. (For more details, see Drawer Locking Mechanism that follows.)
1st/2nd Drawer Lower Limit Position Sensor PC70/71

z
Light Blocking Plate

1134M033EA
Drawer Locking Mechanism D The Lock Lever on the bottom of the drawer contacts the Drawer Guide Frame of the copier and slides over the frame. D The drawer is locked in the copier when the Lock Lever drops into the slot in the Drawer Guide Frame.

Drawer Guide Frame
1134M034EA
Lock Lever
When Drawer is Unlocked

Drawer Spring
1134M035ED
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 Lock Lever downward and unlock the drawer. D When the drawer is unlocked, the Drawer Spring in the rear of the drawer pushes the drawer out to the front approx. 70 mm. D Once the drawer is pushed out, the drawer Set Sensor (PC61/62) is unblocked. This reverses the Liftup Motor (M13/14) and briefly turns the worm gear upward until its light blocking plate reblocks the Lower Limit Position Sensor (PC70/71), returning the Lock Lever to the locking position.
M-64
1156SBM1803A
18-3. Paper Level Detection

D The amount of paper still available for use, or the paper level, of the 1st and 2nd Drawer is detected by 1st/2nd Drawer Lift-Up Motor Pulse Sensor PC67/68 and a pulse disk. D The pulse disk is mounted on the shaft of the intermediary gear that transmits drive from the Lift-Up Motor (M13/14). The speed of the pulse disk varies with different paper levels and the number of pulses detected by the Lift-Up Motor Pulse Sensor (PC67/68) is used to determine the paper level. D Counting of the number of pulses is started when the Lift-Up Motor (M13/14) is energized and continues until the output from the Lift-Up 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 accumulated. When the count reaches 50 sheets of paper, one segment of the paper level indicator on the Touch Panel goes out.
1st/2nd Drawer LiftUp Motor M13/14 *Paper Level Indicator
D 1 to 50 sheets
1134M058AA
1st/2nd Drawer Lift-Up Motor Pulse Sensor PC67/68 Pulse Disk
D 50 to 200 sheets
1134M059AA
D 200 to 350 sheets

1134M060AA
D 350 to 500 sheets

1134M061AA
D 500 sheets up
1134M020AA 1134M062AA
Blocked L L
Unblocked H H
WIRING DIAGRAM 32-I (41-K) 32-J (41-N)
M-65
1156SBM1804
18-4. Paper Empty Detection (1) Metric Areas

D A paper empty condition in the 1st and 2nd Drawers is detected by 1st Drawer Paper Empty Sensor PC101 and 2nd Drawer Paper Empty Sensor PC102, respectively, installed in the paper take-up area of each drawer. D When the drawer, with no paper loaded in it, is roughly slid out of the copier, the Paper Empty Lever can hit against the Paper Lifting Plate. To prevent this from occurring, the Paper Empty Lever is tilted in the direction of sliding.
Paper Lifting Plate Paper Empty Lever
4425M007AA
1st/2nd Drawer Paper Empty Sensor PC101/102
PC101/102 (blocked)
Paper Present
The paper stack raises the Paper Empty Lever which blocks PC101/102 (goes LOW).
4425M008AA
PC101/102 (unblocked)
Paper not Present

The light blocking plate of the Empty Lever clears PC101/102 which goes HIGH.
4425M009AA
Blocked L L
Unblocked H H
WIRING DIAGRAM 32-J 32-K
M-66
(2) Inch Areas

D A paper empty condition in the 1st and 2nd Drawers is detected by 1st Drawer Paper Empty Board PWB-E1 and 2nd Drawer Paper Empty Board PWB-E2, respectively, installed on the underside of the Paper Lifiting Plate. D The board is provided with a reflector type photosensor. When the drawer is loaded with paper, the photosensor is activated by the light reflected off the paper. The copier then detects 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 copier automatically selects that second paper source to ensure an uninterrupted copy cycle (Automatic Drawer Switching).
1st/2nd Drawer Paper Empty Board PWB-E1/E2
1134M036EA
Control Signal PWB-E1 PWB-E2 PWB-A PJ23A-9 PWB-A PJ23A-12
Blocked L L
Unblocked H H
WIRING DIAGRAM 42-L 42-P
M-67
1156SBM1805A
18-5. Universal Tray (2nd Drawer) Paper Size Detection

D The length (feeding direction) and width (crosswise direction) of the paper are independently detected and the copier determines the paper size by combining the two separate detections made. The Universal Tray 13x or 14x function of Tech. Rep. Choice must be set for the width (CD) of FLS (13 or 14 long in the feeding direction). 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 (deactivate) the paper size detecting switches (and sensors) to allow the copier to determine a particular paper size. Detection in the Feeding Direction
Paper Size Detecting Switch Assy (FD) S61/62 Cam Tray Frame
S63/64 Cam
Trailing Edge Stop

1149M015AA
Detection in the Crosswise Direction

Paper Size Detecting Sensor Assy (CD)
PC72 Lever
Sensor Blocking Lever
PC73 Lever Lever Driving Pin
Edge Guide
1149M016AA
M-68
D Paper Size Detecting Switches/Sensors

Length FD S63 S61 Width CD PC72
S64
D Details of Paper Size Detecting Switches/Sensors Operation and Detectable Paper Sizes
CD FD (mm) Paper Size Detecting Switches/Sensors Length (FD)
S61 A5L (Invoice B5L B5C A4L A4C B4L A3L Quarto C G.Letter L G.Letter C Folio* Letter L Letter C Legal* 11 14 L)*2 (5-1/2 8-1/2) * * * * * * 10 8 8 10-1/2 10-1/2 8 8-1/4 13 8-1/2 11 11 8-1/2 8-1/2 14 11 14 11 17 11 15 * 8 13 8-1/2 13 8-1/2 13 8-1/4 14 148 210 (140 216) 182 257 257 182 210 297 297 210 257 364 297 420 254 203 203 267 267 203 210 330 216 279 279 216 216 356 279 356 279 432 279 381 192 268 203 330 216 330 216 330 210 356 f f f * f * * f f f * f f * * * * f * * * * S62 * f * f * * * * f * f f * * * * * f f f f * S63 f * * * f * f f f f f f f * * f * f f f f * S64 */f * * f * * f * * * f f f f f f * * f f f f
S62
1149M017AA
PC73
1149M018AA
Paper Size Name
Inch Size
Width (CD)
PC72 f f * * f * f * * * * * * * * * * f * * * * PC73 f f * * * * * * * f * * f * f f f f * * * *
Ledger Comp Form Korean FLS L FLS* Hongkong FLS L* G.Legal L* Folio (Eu.)*
Switch operation f: Actuated; *: Deactuated Sensor operation f: Blocked; *: Unblocked *A Tech. Rep. Choice function must be set for the size in the crosswise direction. L: Lengthwise; C: Crosswise *2Metric Areas: A5L Inch Areas: Invoice L
M-69
Control Signal S61 S62 S63 S64 PWB-A PJ26A-2 PWB-A PJ26A-4 PWB-A PJ26A-7 PWB-A PJ26A-9 Control Signal PC72 PC73 PWB-A PJ25A-2 PWB-A PJ25A-5
Actuated L L L L Blocked L L
Deactuated H H H H Unblocked H H
WIRING DIAGRAM 25-J 25-I 25I 25-H WIRING DIAGRAM 25-K 25-J
M-70
1156SBM1806
18-6. Paper Take-Up Mechanism (1) Paper Take-Up Mechanism

D The paper take-up and feeding mechanism takes up paper from the drawer and feeds it to the Vertical Transport Roller. D The take-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.
1st Drawer Paper Take-Up Motor M11
Paper Take-Up Roll
2nd Drawer Paper Take-Up Motor M12
Paper Feed Roll Paper Separator Roll
Torque Limiter
4425M011AA
M-71
(2) Paper Separating Mechanism

D 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. D This is accomplished by the difference in friction coefficient between the first and second sheets of paper.
<Normal Feeding>
D When only one sheet of paper is fed, the friction coefficient on the top side of the paper is equal Feed Roll to that on the underside. D Driven by the Feed Roll, the paper drives the Paper Separator Roll. This causes the paper to be sent Separator Roll to the Vertical Transport Section. D The friction coefficient varies for different ambi4425M012AA ent conditions and types of paper being used, which often causes the Separator Roll to be staDriven or stationary tionary.
<Double Feeding>
Feed Roll
1st sheet of Paper 2nd sheet of Paper
4425M013AA
Separator Roll
Stopped
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 and second sheets of paper, the first sheet of paper is fed into the copier by the Feed Roll. Since the friction coefficient between the second sheet of paper and the Separator Roll is greater than that between the first and second sheet of paper, the Separator Roll is not driven and holds the second sheet of paper.
M-72
(3) Paper Pressure Releasing Mechanism

D If the drawer is pulled out while the paper is between the Feed Roll and the Separator Roll, the paper is left in the copier. Removal of the paper is difficult. With this copier, sliding out the drawer automatically disengages the paper and Paper TakeUp/Feed Roll. D The Paper Pressure Releasing Mechanism makes it easier to remove a sheet of paper 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>
Feed Roll Separator Roll Assy
<Drawer Slid Out>
Approx. 2mm
Drawer
Pressure Spring
4444M004AA
(4) Paper Take-Up Roll Retraction Mechanism

D When the drawer is slid out, the rear end of the drawer on the take-up side and the Pressure Release Lever push up the Paper Take-Up Roll/Feed Roll, freeing the paper from the Paper Take-Up Roll.
Paper Take-Up Roll/Feed Roll Assy Front
Pressure Release Lever

1134M021AA
Rear
M-73
1156SBM1807A
18-7. Drawer Paper Take-Up Control (1) Paper Take-Up Motor Control
D A stepping motor is used for the Paper Take-Up Motor (M11/12). Each motor is turned forward or backward by energizing its four internal coils using the pulse signals output from Master Board PWB-A.
Main Drive Motor M9 Paper Transport Clutch CL2 Vertical Transport Sensor PC63/PC64 1st/2nd Drawer Paper Take-Up Sensor PC55/56 1st/2nd Drawer Paper Take-Up Motor M11/12 1st sheet of paper take-up start 2nd sheet of paper take-up start
1134T14MCA
T1: 5 msec. (Paper take-up off timer) T2: 5 msec. (Paper take-up interval timer)
Control Signal PC51 PC55 PC56 PC63 PC64 PWB-A PJ19A-5 PWB-A PJ19A-2 PWB-A PJ21A-5A PWB-A PJ21A-8A PWB-A PJ21A-8B Control Signal M11 M12 PWB-A PJ16A-1 PWB-A PJ16A-2
Blocked L L L L L Energized
Unblocked H H H H H Deenergized
WIRING DIAGRAM 32-M 32-N 25-N 25-O 32-M WIRING DIAGRAM 25-K 25-L
Pulse output Pulse output
M-74
(2) Paper Take-Up Retry Control

D To minimize the occurrence of a paper misfeed due to a slippery Paper Take-Up Roll, the Paper Take-Up Motor (M11/12) is kept deenergized for a given period of time before it is energized again, if a sheet of paper fails to reach the Paper Take-Up Sensor (PC55/56) even after the lapse of a given period of time after the motor has first been energized (paper take-up retry control). D A misfeed results if the sheet of paper does not reach the Paper Take-Up Sensor even after three paper take-up sequences.
(3) Paper Take-Up Interval Control

D The Paper Feed Roll and Separator Roll may sometimes fail to separate the subsequent sheet of paper properly and the leading edge of that paper may be beyond the Feed and Separator Rolls inside the copier. If the next paper take-up sequence is started in this condition, the distance between the preceding and the current sheet of paper will become shorter than normal, resulting in a misfeed. D To maintain a given paper take-up interval, therefore, this copier provides the following control. If it takes the paper less than a specified time to block ([L]) PC55/56 after M11/12 has been energized, M11/12 is temporarily deenergized and, an appropriate period of time thereafter, it is energized again (paper take-up interval control).
(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 misfeed. It eliminates a paper misfeed that would otherwise result when two sheets of paper are taken up at once. D If the second sheet of paper is stationary blocking PC55/56 when the trailing edge of the first sheet of paper moves past Vertical Transport Sensor PC63/PC64, the copier determines that it is a double feed condition and provides double feed control. D If, however, the second sheet of paper has reached the Vertical Transport Roller, the double feed control is not provided since the paper is fed further into the copier by the Vertical Transport Roller. This could result in a paper misfeed or the second sheet of paper being fed through the copier with the first one.
Paper Path Position of Leading Edge of 2nd Sheet of Paper PC54 Detection Point PC63 Detection Point PC55 Detection Point Double Feed Control (Not Provided) (Provided) For Paper Feeding from 1st Drawer
PC64 Detection Point PC56 Detection Point
(Not Provided) (Provided)
For Paper Feeding from 2nd Drawer
1149M019AB
M-75
1156SBM1900A
19
MULTI BYPASS TABLE
Construction
The Multi Bypass Table fitted to the Right Door of the copier, is integrated into the copier. It is constructed as follows.
Lever Paper Empty Sensor Right Cover
Right Door Cover
Multi Bypass Table
Manual Feed Paper Take-Up Clutch Manual Feed Paper Take-Up Solenoid Paper Stoppers Manual Bypass Take-Up Roll
1136M045AA
Upper Transport Roller Manual Bypass Feed Roll
Paper Empty Sensor Manual Bypass Take-Up Roll
Multi Bypass Table Lower Transport Roller Paper Empty Sensor Actuator Paper Stopper Manual Bypass Separator Roll
1136M088AA
M-76
1156SBM1901A
19-1. Paper Take-Up Mechanism The Paper Take-Up Rolls are normally in their raised (retracted) position so that they will not hamper proper loading of paper. When the Start Key is pressed, Manual Feed Paper Take-Up Solenoid SL4 is deenergized causing the Paper Take-Up 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 Paper Take-Up Rolls.
In Standby
Lock Levers
Lever Rack Gear
Paper Take-Up Rolls
Manual Feed Paper TakeUp Solenoid SL4
Paper Stoppers At Take-Up
M-77
1151T12MCE
Control Signal CL3 SL4 SL4 PWB-A PJ15A-12 PWB-A PJ15A-9 PWB-A PJ15A-10
Energized L L L
Deenergized H H H
WIRING DIAGRAM 32-P 32-P
1156SBM1902A
19-2. 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. PAPER TAKE-UP/FEED SECTION.
M-78
1156SBM1903A
19-3. Paper Empty 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
Paper Take-Up Roll Paper Stopper Actuator
Control Signal PC51 PWB-A PJ15A-14
Blocked H
Unblocked L
WIRING DIAGRAM 32-O
M-79
1156SBM2000A
20 VERTICAL PAPER TRANSPORT

The sheet of paper taken up by the Paper Take-Up Roll from the Drawer is fed along the Paper Guide to the Vertical Transport Rollers. The paper fed by the Vertical Transport Rollers reaches the Transport Rollers and is then fed up to the Synchronizing Rollers. The Transport Rollers are turned and stopped by Paper Transport Clutch CL1. The Transport Rollers are coupled to the Vertical Transport Rollers by way of gears, meaning that the Vertical Transport Rollers are turned 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 clearing misfeeds. Right Upper Door Interlock Switch S22 detects whether or not this Cover is open.
Transport Rollers Right Upper Door Interlock Switch
Transport Roller Sensor PC51
Vertical Transport Rollers/Rolls
1156M019AA
<Control>
1151T10MCC
Control Signal CL1 PWB-A PJ14A-2 Control Signal S22 PWB-A PJ16A-2
Energized L ON L
Deenergized H OFF H
WIRING DIAGRAM 7-F WIRING DIAGRAM 21-I
M-80
1156SBM2100A
21
SYNCHRONIZING ROLLERS
D The Upper Synchronizing Roller is a metal roller covered with a polyvinyl chloride tubing. It is secured to the front and rear frames of the copier. D The Lower Synchronizing Roller, a rubber roller, is fitted to the Transport Assy. Pivoting about its rear end, the Lower Roller can be swung downward to facilitate clearing paper misfeeds.
Upper Synchronizing Roller Paper Dust Remover
Guide Plates Lower Synchronizing Roller

1136M050AA
Paper Leading Edge Detecting Sensor PC55
Upper Synchronizing Roller Lower Synchronizing Roller
Torsion Spring
1136M051AA
M-81
1156SBM2101A
21-1. Synchronizing Roller Drive Mechanism

D The Upper Synchronizing Roller receives drive from Main Drive Motor M1 via a gear train and timming belt. The Upper Roller drives the Lower one.
Upper Synchronizing Roller
Synchronizing Roller Clutch CL2 To Main Drive Motor M1
Timing Belt
1136M052AA
1156SBM2102A
21-2. Paper 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 transferred onto the Paper Dust Remover. The Paper Transport Rollers are also provided with a paper Dust Remover.
Upper Synchronizing Roller Paper Dust Remover
Lower Synchronizing Roller
1136M026AA
M-82
1156SBM2103A
21-3. Synchronizing Roller Control The Synchronizing Rollers are started as Synchronizing Roller Clutch CL2 is energized upon reception of a signal from PWB-A.
1151T11MCD
Control Signal CL2 PWB-A PJ14A-4 Control Signal PC55 PWB-A PJ19A-2
WIRING DIAGRAM 7-G WIRING DIAGRAM 32-N
M-83
1156SBM2104A
21-4. Prevention of Low Image Density on Copy During conditions of high humidity when the paper is damp, charges tend to flow from the Image Transfer Corona through the paper and guide plates to the ground. This results in low image density on the copies. To prevent this from occuring, a plastic spacer is installed between the copier frame and each guide plate around the Synchronizing Rollers so that it remains insulated. Instead of using the plastic spacer, an electrodeposition coating has been applied to some of those guide plates. If, however, the resistance with the ground is made infinity, 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.
Synchronizing Rollers Transport Rollers Varistor Upper Vertical Transport Rollers Manual Bypass Feed/Separator Rolls
Resistor
1136M053AA
No.
Guide Plate Name Upper Pre-Synch Guide Plate Lower Pre-Synch Guide Plate Upper Transport Roller Guide Plate Lower Transport Roller Guide Plate Manual Bypass Guide Plate Vertical Transport Guide Plate Pre-Image Transfer Guide Plate
Insulation Method Plastic Spacer Plastic Spacer None [Fitted to top of guide plate no. ] Plastic Spacer Electrodeposition Coating Plastic Spacer Fitted to plastic holder of Image Transfer/Paper Separator Coronas
M-84
Flat Spring A B C D E
Connection Between varistor-and-resistor and guide plate Between varistor-and-resistor and guide plate Between guide plates and Between guide plates and Between guide plates and
M-85
1156SBM2200A
22
PAPER TRANSPORT
D Suction Fan Motor M4 draws the paper onto the turning Suction Belts. It also pulls the paper down as it reaches the Pre-Fusing Guide 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.
Suction Fan Ozone Filter
Suction Drive Gear
Suction Belts
Transport Section Release Lever
1136M070AA
Controlled Part M4
Half Speed Rotation L
Full Speed Rotation H
WIRING DIAGRAM 21-G
M-86
1156SBM2201A
22-1. Suction Belt Drive Mechanism

The Suction Belts are driven by Main Drive Motor M1 through a timing belt and gear train.
Suction Belt Suction Belt Drive Roller Suction Drive Gear
Timing Belt
Main Drive Motor Gear

Controlled Part M1 Control Signal PWB-A PJ18A-9 ON L OFF H
1136M072AA
WIRING DIAGRAM 2-M
M-87
1156SBM2300A
23 FUSING UNIT
The Upper Fusing Roller and Lower Fusing Roller together apply heat and pressure to the toner and paper to permanently fix the developed image to the paper. Drive for the Upper Fusing Roller is transmitted from the Main Drive Motor to the Upper Fusing Roller Drive Gear. The Lower Fusing Roller and Cleaning Roller are driven by the respective Rollers in contact with them.
Upper Fusing Paper Separator Finger 1st Paper Exit Roller Cleaning Roller Thermistor TH1/2 Fusing Thermoswitch TS1
Fusing Heater Lamp H1 Upper Fusing Roller Lower Fusing Roller
Pressure Spring
Lower Fusing Paper Separator Finger
1156M020AA
Cleaning Roller Upper Fusing Roller Cleaning Roller Drive Gear
Lower Fusing Roller
Main Drive Motor M1
Upper Fusing Roller Drive Gear
1136M073AA
M-88
1156SBM2301A
23-1. Fusing Temperature Control The Upper Fusing Roller is heated by Fusing Heater Lamp H1 which is an AC halogen lamp. Fusing Thermistor 1 TH1 and Thermistor 2 TH2 installed on the Upper Fusing Roller helps keep the optimum fusing temperature.
The fusing temperature is normally controlled at 200C during a copy cycle and at 190C in the standby state. To ensure good fusing performance even when the Lower Fusing Roller remains cool immediately after warmup in the early morning, the temperature is controlled as follows when the copier is turned ON. D Temperature is controlled at 200C for one hour after the copier has completed warming up, which is followed by a temperature control at 190C. If a copy cycle is started while the temperature is being controlled at 190C, the temperature control at 200C begins. As soon as the copy cycle is completed, control is again switched to 190C.
TH1 is positioned at a point 30.5 mm from the paper path reference position, thereby preventing offset caused by low temperature and degraded fusing performance for small-size paper. The control temperature in the Energy Saving Mode is 155C. With EP5000, the control temperature is 180C in the Energy Saving Mode. Fusing Thermoswitch TS1, installed above the Upper Fusing Roller, cuts off the power to the Fusing Unit if the temperature of the Upper Fusing Roller becomes excessively high. It eliminates the possibility of a fire that could occur when H1 remains ON due to a faulty temperature control circuit.
1 hour after Power Switch ON 200_C 190_C 180_C 165_C 155_C EP5000 Energy Saving Mode During Copy Cycle
In Standby State EP4000 Energy Saving Mode In Energy Saving Mode
During Predrive
Copy Cycle Completed
Copying Enabled
Copying Enabled
Copy Cycle Started
Energy Saving Mode ON
Energy Saving Mode OFF
Power Switch ON
1151M012CA
M-89
<Fusing Temperature Control During Continuous Small-Size Paper Feeding> When a number of sheets of small-size paper are fed through the copier continuously, the temperature of the rear end of the Fusing Rollers tends to rise, resulting in a hightemperature offset occurring. Fusing Thermistor TH2 is installed at a location 271.5 mm from the position of paper passage registration. As soon as TH2 detects 225C, the 225C 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 Fusing Roller to be pressed tightly up against the Upper Fusing Roller.
Upper Fusing Roller Rear
Front Pressure Screw Lower Fusing Roller Pressure Holder Pressure Spring
1136M075AA
M-90
1156SBM2303A
23-3. Oil Roller/Cleaning Roller

The Cleaning 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.
Cleaning Roller
Upper Fusing Roller
Lower Fusing Roller

1136M077AA
M-91
1156SBM2304A
23-4. Paper Separator Fingers

D Each of the two Fusing Rollers is provided with Paper Separator Fingers that strip the paper from the surface of the Rollers. z Upper Fusing Paper Separator Fingers D The Upper Fusing Paper Separator Fingers have been coated with teflon so that they will 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.
Upper Fusing Roller Rear Upper Fusing Paper Separator Finger
Front
1136M078AA
z Lower Fusing Paper Separator Fingers D The Lower Fusing Paper Separator Fingers are flat springs to enhance paper separating performance and ensure that the paper would not become wedged if a misfeed occurs.
Fusing Lower Guide/Lower Fusing Paper Separator Fingers Assy Lower Fusing Paper Separator Finger
Exit Unit
1156M021AA
M-92
1156SBM2305A
23-5. Fusing Section Cooling Fan Motor

Fusing Section Cooling 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
1156M022AA
Fusing Unit
Control Signal M15 PWB-A PJ10A-2
ON L
OFF H
WIRING DIAGRAM 3-D
M-93
1156SBM2400A
24
EXIT UNIT
Drive from the Fusing Unit is transmitted via a gear train to turn the 1st/2nd Paper Exit Rollers.
Left Door
Paper Exit Switch S53
Drive Gear
Exit/Duplex Solenoid SL5 1st Paper Exit Roller
Exit/Duplex Switching Plate
1136M081AA
Main Control Board PWB-A outputs a signal 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).
Paper Exit Switch S53
Paper Exit Roller/Rolls
Exit/Duplex Switching Plate
1139M082AA
Exit/Duplex Switching Solenoid SL5

Control Signal S53 PWB-A PJ14A-8 Control Signal SL5 PWB-A PJ14A-6 ON L Energized L OFF H Deenergized H WIRING DIAGRAM 3-D WIRING DIAGRAM 3-C
M-94
1156SBM2401A
24-1. Left Upper Door Interlock Switch S23

D Left Upper Door Interlock Switch S23 fitted to the copier 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.
Lever Left Upper Door
Left Upper Door Interlock Switch S23
2nd Paper Exit Roller Drive Gear
1156M023AA
Controlled Part S23
ON L
OFF H
WIRING DIAGRAM 21-I
M-95
1156SBM2500A
25
DEHUMIDIFYING SWITCH
To prevent image transfer efficiency from being reduced due to damp paper in highly humid weather, Paper Dehumidifying Heater H3 (Optional) is installed on the base frame of the copier under the 2nd Drawer. Drum Dehumidifying Heater H2 (Standard) is located under the Lower Synchronizing Roller to prevent the PC Drum from forming condensation.
Paper Dehumidifying Heater H2 (Optional) Lower Synchronizing Roller Drum Dehumidifying Heater H3 (Standard)
1136M043AA
1136M004AA
Copier Base Frame
Paper Dehumidifying Switch S12 Drum Dehumidifying Switch S3
D H2, H3 ON/OFF Conditions

Dehumidifying Switch ON Power cord Plugged in H2 H3 ON ON Power Switch ON OFF ON *During a copy cycle OFF OFF
*During a copy cycle: Refers to the period of time between when the Start Key is pressed and when Main Drive Motor M1 is deenergized.
M-96
1156SBM2600A
26 MEMORY BACKUP
IC1 (RAM) of RAM Board PWB-R connected to Main Control Board PWB-A stores the setting/adjustment values set in the Tech. Rep. Modes as well as the counter counts. Backup Battery 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 that PWB-R should not be replaced at the same time when PWB-A is replaced.
M-97
1156SBG000E
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
Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01
1156SBD000AA
EP5000/EP4000
DIS/REASSEMBLY, ADJUSTMENT
1151SBD0000A
u For the Utmost safety u
! Warning
D For replacement parts, use the genuine parts with their part numbers specified in the parts manual. Use of a wrong part could cause an overload or dielectric breakdown resulting in an electric shock or fire. D Replace a blown fuse or thermal fuse with the corresponding genuine part with its part number specified in the parts manual. Use of a fuse with a different rating or one with the same rating but of a different type can result in a fire. Especially when a thermal fuse blows frequently, the thermal control system is probably faulty. Be sure to take necessary action. D Before attempting to disassemble 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 energizing the machine. If it is absolutely necessary to energize the machine with its cover removed, do not touch an exposed part that is being charged and use care not to allow your clothing to be caught by a timing belt, gear, or other moving part. D Do not leave the machine unattended while it is being energized.
! Caution
D To actuate an interlock switch with a cover removed or opened, be sure to use the interlock switch actuating jig. Use of folded paper can damage the interlock switch mechanism.
! Caution
D A high voltage is being applied to the part marked with the symbol shown on the right. Touching it can cause an electric shock. Be sure to unplug the power cord when servicing this part or other parts near it. D When the machine is energized with any of its covers removed, never use a flammable spray near it, as a fire can result. D Make sure that correct screws (diameter and length of the screw, binding/tapping screws) are used in the correct places when assembling parts. If a wrong screw is used, a short insulating distance could result. It could also result in collapsed threads, which provides only a poor grounding connection, resulting in an electric shock. D A toothed washer and spring washer, if used originally, must be reinstalled. If they are left out, a contact failure results, causing an electric shock or fire. D Replace a lithium cell only with one having the part number specified in the parts manual. An explosion could result if the cell is installed with wrong polarity or a wrong cell is installed. Dispose of a used lithium cell according to the applicable local regulations. Never throw it away or abandon it on the users premises.
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 Since the 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 ATDC Sensor and associated parts to break down. Be sure therefore to use a blower brush or cloth to clean these parts. If a unit is to be cleaned, be sure to remove the sensors in advance. D MOS lCs are susceptible to static electricity. When handling a PWB loaded with MOS ICs, follow precautions given in INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs. D The PC Drum is highly delicate. When handling the PC Drum, follow the precautions given in HANDLING OF THE PC DRUM. D To reassemble, reverse the order of disassembly unless otherwise specified. D Note that replacement of a PWB may call for readjustments or resetting of particular items. CAUTION: DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURERS INSTRUCTIONS.
ADVARSEL!:Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering. Udskiftning m kun ske med batteri af samme fabrikat og type. Levr det brugle bafferi tilbage til leverandoren.
ii
1156SBD000BA
CONTENTS
1 SERVICE INSTRUCTIONS 1-1. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTS . . . . . . 1-2. INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. HANDLING OF THE PC DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. PARTS WHICH MUST NOT BE TOUCHED . . . . . . . . . . . . . . . . 2 DISASSEMBLY/REASSEMBLY 2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES . . . . . . . . . 2-2. REMOVAL OF CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . 2-3. PAPER TAKE-UP/TRANSPORT SECTIONS . . . . . . . . . . . . . . . (1) Removal of the Paper Take-Up Unit . . . . . . . . . . . . . . . . . . . . . (2) Removal of the Paper Take-Up Roll/Feed Roll Assy and Separator Roll Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) Cleaning of the Paper Take-Up Roll, Feed Roll, and Separator Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Cleaning of the Vertical Transport Rollers . . . . . . . . . . . . . . . . (5) Removal of the Drawers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6) Removal of the Upper Synchronizing Roller . . . . . . . . . . . . . . (7) Cleaning of the Upper and Lower Synchronizing Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (8) Replacement of the Paper Dust Remover . . . . . . . . . . . . . . . . (9) Cleaning of the Paper Dust Remover . . . . . . . . . . . . . . . . . . . (10) Removal of the Suction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . (11) Disassembly of the Suction Unit . . . . . . . . . . . . . . . . . . . . . . . (12) Disassembly of the Multi Bypass Unit . . . . . . . . . . . . . . . . . . 2-4. OPTICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Cleaning of the Original Glass . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Cleaning of the Scanner Shaft . . . . . . . . . . . . . . . . . . . . . . . . . (3) Cleaning of the Scanner Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Removal of the Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5) Cleaning of the Exposure Lamp . . . . . . . . . . . . . . . . . . . . . . . . (6) Removal of the Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . (7) Cleaning of the 1st, 2nd, and 3rd Mirrors . . . . . . . . . . . . . . . . (8) Cleaning of the Lens and 4th and 5th Mirrors . . . . . . . . . . . . . (9) Winding of the Lens Drive Cable . . . . . . . . . . . . . . . . . . . . . . . (10) Removal of Scanner Motor M2 . . . . . . . . . . . . . . . . . . . . . . . . (11) Removal of the Scanner Drive Cable . . . . . . . . . . . . . . . . . . (12) Winding of the Scanner Drive Cable . . . . . . . . . . . . . . . . . . . (13) Cleaning of the 6th Mirror Protective Filter . . . . . . . . . . . . . . (14) Cleaning of the Cooling Fan Filter . . . . . . . . . . . . . . . . . . . . . D-1 D-3 D-3 D-5
D-6 D-8 D-10 D-10 D-13 D-16 D-17 D-17 D-19 D-20 D-20 D-21 D-22 D-23 D-24 D-28 D-28 D-28 D-28 D-29 D-29 D-30 D-30 D-31 D-32 D-34 D-35 D-36 D-37 D-37
iii
CONTENTS
2-5. IMAGING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Removal of the Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Disassembly of the Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . (3) Replacement of the PC Drum . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Cleaning of the Developer Scattering Prevention Plate . . . . (5) Cleaning of the Ds Positioning Collars . . . . . . . . . . . . . . . . . . . (6) Cleaning of the Toner Antispill Trap . . . . . . . . . . . . . . . . . . . . . (7) Cleaning of the Cleaning Blade . . . . . . . . . . . . . . . . . . . . . . . . . (8) Replacement of the Cleaning Blade . . . . . . . . . . . . . . . . . . . . . (9) Replacement of the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . (10) Cleaning of the AIDC Sensor Board . . . . . . . . . . . . . . . . . . . (11) Cleaning of the PC Drum Paper Separator Fingers . . . . . . (12) Replacement and Cleaning of the Toner Antispill Seal and Cleaning of the Toner Antispill Plate . . . . . . . . . . . . . . . . . (13) Removal of Main Erase Lamp LA3 . . . . . . . . . . . . . . . . . . . . (14) Cleaning of the Main Erase Lamp Filter . . . . . . . . . . . . . . . . (15) Cleaning of Image Erase Lamp LA2 . . . . . . . . . . . . . . . . . . . (16) Replacement of Image Erase Lamp LA2 . . . . . . . . . . . . . . . (17) Removal of the Ozone Filter (PC Drum Charge Corona) . . . . . . . . . . . . . . . . . . . . . . . . . . . (18) Removal of the Ozone Filter (Image Transfer/Paper Separator Coronas) . . . . . . . . . . . . . (19) Removal of the Toner Collecting Box . . . . . . . . . . . . . . . . . . . 2-6. PC DRUM CHARGE CORONA AND IMAGE TRANSFER/PAPER SEPARATOR CORONAS . . . . . . (1) Removal of the PC Drum Charge Corona . . . . . . . . . . . . . . . . (2) Cleaning of the PC Drum Charge Corona Housing . . . . . . . . (3) Cleaning of the PC Drum Charge Corona Grid Mesh . . . . . . (4) Cleaning of the Comb Electrode . . . . . . . . . . . . . . . . . . . . . . . . (5) Removal of the Image Transfer/Paper Separator Coronas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6) Cleaning and Replacement of the Image Transfer Corona Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (7) Cleaning and Replacement of the Paper Separator Corona Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (8) Cleaning of the Image Transfer/Paper Separator Coronas Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (9) Cleaning of the Lower Pre-Image Transfer Guide Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Removal of the Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Disassembly of the Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . (3) Replacement and Cleaning of the Upper Fusing Paper Separator Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Cleaning of the Lower Fusing Paper Separator Fingers . . . . (5) Cleaning of the Fusing Unit Entrance Guide Plate . . . . . . . . . D-38 D-38 D-38 D-42 D-42 D-42 D-42 D-42 D-43 D-45 D-46 D-46 D-46 D-47 D-47 D-47 D-47 D-48 D-48 D-48 D-49 D-49 D-49 D-50 D-50 D-50 D-50 D-51 D-51 D-52 D-53 D-53 D-53 D-58 D-58 D-58
iv
CONTENTS
Cleaning of Fusing Front and Rear Thermistors TH1/2 . . . . Cleaning of Fusing Thermoswitch TS1 . . . . . . . . . . . . . . . . . . Replacement and Cleaning of the Cleaning Roller . . . . . . . . Replacement and Cleaning of the Upper Fusing Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (10) Replacement and Cleaning of the Lower Fusing Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8. EXIT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Removal of the Exit/Duplex Switching Unit . . . . . . . . . . . . . . . 3 ADJUSTMENT 3-1. JIGS AND TOOLS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. ADJUSTMENT REQUIREMENTS LIST . . . . . . . . . . . . . . . . . . . . 3-3. ADJUSTMENT OF SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment of Front Door Interlock Switch S21 . . . . . . . . . . . . . . 3-4. ADJUSTMENT OF BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . (1) Paper Take-Up Unit Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . (2) Developing Unit Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) Fusing Unit Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) I/U Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. ACCESSING THE TECH. REP. MODE AND ADJUST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. ELECTRICAL/IMAGE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . (1) Initial Adjustment of Original Size Detecting Board . . . . . . . . (2) ATDC Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) Adjustment of the Aperture Blades . . . . . . . . . . . . . . . . . . . . . . (4) Adjustment of Exposure Level in the Auto Exposure Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5) Adjustment of Optimum Exposure Setting in the Manual Exposure Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6) Adjustment of Zoom Ratio in the Crosswise Direction . . . . . (7) Adjustment of Zoom Ratio in the Feeding Direction . . . . . . . (8) Adjustment of Reference Position of the Multi Bypass Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (9) Adjustment of Reference Position of the 1st/2nd Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (10) Adjustment of the Leading Edge Registration . . . . . . . . . . . (1)Leading Edge Registration in Full Size Mode . . . . . . . . . (2)Leading Edge Registration in Enlargement Mode . . . . . (3)Leading Edge Registration in Reduction Mode . . . . . . . . (11) Adjustment of the Leading Edge Registration for Book Second Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (12) Adjustment of the Image Leading Edge Erase Width . . . . . (13) Adjustment of the Image Trailing Edge Erase Width . . . . . . (14) Adjustment of Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-62 D-63 D-64 D-65 D-66 D-66 D-66 D-66 D-66 D-67 D-68 D-68 D-69 D-71 D-72 D-73 D-75 D-77 D-79 D-80 D-81 D-81 D-83 D-85 D-87 D-89 D-91 D-93 (6) (7) (8) (9) D-58 D-59 D-59 D-59 D-60 D-61 D-61
CONTENTS
3-7. OTHER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Focus-Positioning of the Scanner and Mirrors Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller (D.B. Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . (3) Adjustment of the PC Drum Paper Separator Finger Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Adjustment of Manual Feed Paper Take-Up Solenoid SL4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5) Adjustment of Exit/Duplex Solenoid SL5 . . . . . . . . . . . . . . . . . 4 MISCELLANEOUS 4-1. INSTALLATION OF THE PLUG-IN COUNTER (OPTION) MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-100 4-2. ADJUSTMENT OF THE RIGHT DOOR . . . . . . . . . . . . . . . . . . . D-101 D-94 D-94 D-96 D-97 D-98 D-99
vi
1139SBD0100A
SERVICE INSTRUCTIONS
1151SBD0101B
1-1. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTS

Observe the following precautions whenever servicing the copier. D Be sure to unplug the copier from the outlet before attempting to service the copier. D The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears. D Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the Interlock Switch with the covers left open or removed. D Do not plug in or unplug print jacks on the Board or connect or disconnect the Board connectors while power is being supplied to the copier. D Do not use flammable spray around the copier in operation. D The Magnet Roller of the Imaging Unit generates strong magnetic force. Do not bring it near a cathode-ray tube or watch. D The lithium cell in RAM Board PWB-R can burst. At replacement, make sure of the correct polarity and do not change it or create a closed circuit. A used lithium cell should be disposed of according to the local regulations and never be discarded casually or left unattended at the users premises. D Do not use an air gun or vacuum cleaner for cleaning 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 a PWB may call for readjustments or resetting of particular items. D Use the right screw in the right place at reassembly. Note that some are longer and some are thicker than others. D A toothed washer is used with the screw that secures the ground wire to ensure positive conduction. Do not forget to insert this washer at reassembly. D To reassemble the copier, reverse the order of disassembly unless otherwise specified. D If it becomes necessary to replace the thermal fuse or any other fuse mounted on a board, be sure to use one of the rating marked on the blown fuse. Always note the rating marked on the fuse, as the rating and mounting site or number used are subject to change without notice. D Do not pull out the Toner Hopper while the Toner Bottle is turning, as a damaged Toner Replenishing Motor or locking mechanism could result. If the copier is to be run with the Front Door swung down, make sure that the Toner Hopper is in the locked position. CAUTION: DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISCARD USED BATTERIES ACCORDING TO THE MANUFACTURERS INSTRUCTIONS.
D-1
<List of Fuses Used>
Fuse Holder F3 250V 15A Fuse Board PWB-L 250V 3A (4) Exposure Thermal Fuse TF1 110C 10A
Power Supply Board PWB-C 250V 3A (5) Power Supply Unit PU1 125V 8A Noise Filter Board PWB-D 250V 15A
1156D001CA
D-2
1139SBD0102A
1-2. INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs

The following precautions must be observed when handling P.W. Boards with MOS (Metal Oxide Semiconductor) ICs. During Transportation/Storage: D During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. D Do not store or place P.W. Boards in a location exposed to direct sunlight. D When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static electricity. D Do not touch the pins of the ICs with your bare hands. During Replacement: D Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unplugged from the outlet. D When removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board. D Before plugging 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
1-3. HANDLING OF THE PC DRUM

During Transportation/Storage: D Use the specified carton whenever moving or storing the PC Drum. D The storage temperature is in the range between 20C and +40C. D In summer, avoid leaving the PC Drum in a car for a long time. Handling: D Ensure that the correct PC Drum is used. D Whenever the PC Drum has been removed from the copier, store it in its container or protect it with a Drum Cloth. D The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended period of time. Never, therefore, expose it to direct sunlight. D Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter. D Do not scratch the surface of the PC Drum. D Do not apply chemicals to the surface of the PC Drum. D Do not attempt to wipe clean the surface of the PC Drum.
D-3
If, however, the surface is contaminated with fingerprints, clean it using the following procedure. 1. Place the PC Drum into one half of its container.
2. Gently wipe the residual toner off the surface of the PC Drum with a dry, Dust-Free Cotton Pad. a) Rotate the PC Drum so that the area of its surface on which the line of toner left by the Cleaning Blade is present is facing straight up. Wipe the surface in one continuous 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 exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thoroughly cleaned. * At this time, always use a CLEAN face of the dry Dust-Free Cotton Pad until no toner is evident on the face of the Pad after wiping. 3. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front edge and off its surface one to two times. * Never move the Pad back and forth.
4. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped. Always OVERLAP the areas when wiping. Two complete turns of the PC Drum would be appropriate for cleaning.
NOTES D The Organic Photoconductor Drum is softer than CdS and Selenium Drums and is therefore susceptible to scratches. D Even when the PC Drum is only locally dirtied, wipe the entire surface. D Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interior illumination. D If dirt remains after cleaning, repeat the entire procedure from the beginning one more time.
D-4
1151SBD0104A
1-4. PARTS WHICH MUST NOT BE TOUCHED (1) Screws

Purpose of Application of Red Paint Red paint is applied to the screws which cannot be readjusted, set, or reinstalled in the field. The basic rule is not to remove or loosen the screws to 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 ADJUSTMENT.
(3) Other Screws

Two screws on the Lens Rail Two screws on the Lower Pre-Image Transfer Guide Plate
1136D068AA
1136D069AA
Two screws on the Mirror Motor Unit
1136D070AA
D-5
DISASSEMBLY/REASSEMBLY
REMOVAL PROCEDURES
2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND
5 4 3 2
1 7
11 10 9
1156D002AA
12
13 14
15
16
1156D003AA
D-6
No. 1 2
Part Name Front Door Control Panel
Removal Procedure Swing down No. 1. ! Remove two Front Door hinge shafts. Remove one belt mounting screw inside the Front Door. Raise No. 12. ! Swing down No. 1. ! Open No. 8. ! Remove No. 7. ! Swing down No. 14. ! Remove No. 13. ! Remove two control panel mounting screws. ! Remove two magnet attraction plate screws. ! Unplug one connector from MSC Board. ! Remove one connector. Raise No. 12. ! Remove two scale mounting screws. Note:When the Original Width Scale has been removed, use care not to lose two springs. Raise No. 12. ! Open No. 14. ! Remove No. 13. ! Remove the screw cover. ! Remove one Rear Upper Cover (Small) mounting screw. Raise No. 12. ! Open No. 14. ! Remove No. 13. ! Remove No. 5. ! Open No. 8 ! Remove No. 7. ! Remove one Rear Upper Cover mounting screw. Open No. 8. ! Open the Multi Bypass Table. ! Remove four Right Cover mounting screws. Open No. 8. ! Remove two cover mounting screws. ! Remove the harness from one wiring saddle. ! Unplug three connectors. ! Remove two Right Door mounting screws. Snap off the Counter Cover. (It is secured by catches at two places.) <Except 120V Areas> See p. D-17 <120V Areas> See p. D-18 Remove No. 12 by pulling up. Swing down No. 14. ! Remove six Upper Left Cover mounting screws. See p. D-61 Remove No. 13. ! Remove two Middle Left Cover mounting screws. Remove six Rear Cover mounting screws.
3 4 5
Original Width Scale Original Glass Rear Upper Cover (Small)
Rear Upper Cover
7 8
Right Cover Right Door (Manual Bypass Unit)
9 10 11 12 13 14 15 16
Counter Cover 2nd Drawer 1st Drawer Original Cover Upper Left Cover Left Door (Exit/Duplex Switching Unit) Middle Left Cover Rear Cover
D-7
2-2. REMOVAL OF CIRCUIT BOARDS

D When removing a circuit board, refer to PRECAUTIONS FOR HANDLING THE PWBs contained in SWITCHES ON PWBs and follow the corresponding removal procedures given on the next 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. PWB-A PWB-R UN1 PWB-F PWB-B PWB-I PWB-D PWB-L PWB-C HV1 PU1
PWB-H
PWB-J
UN2
PWB-G UN3
1156D004AA
D-8
Symbol PWB-A PWB-B PWB-C
Part Name Master Board MSC Board Power Supply Board Remove No. 16.
Removal Procedure Swing down No. 1. ! Remove the Circuit Board cover. Remove No. 16. ! Remove the Toner Pipe. <EP4000 Except U.S.A., Canada and Europe> Remove No. 16. ! Remove the Toner Collecting Box. Remove the Toner Pipe. Remove No. 16. Slide out the drawer. ! Remove the Holder. ! Remove the Paper Mounting Plate.
PWB-D PWB-E1 PWB-E2 PWB-F PWB-G
Noise Filter Board 1st Drawer Paper Empty Board 2nd Drawer Paper Empty Board SCP Board AIDC Sensor Board
Remove No. 16. Swing down No. 1. ! Remove the IU. ! Remove the PC Drum Charge Corona. ! Remove the PC Drum Paper Separator. Remove No. 3. ! Remove No. 4. Swing down No. 1. ! Remove the Circuit Board Cover. Remove No. 16. ! Remove PWB-A Mounting Bracket Assy. ! Remove the ADF Connector Unit. ! Remove the Exposure Lamp Regulator Cover. Remove No. 16. <EP4000 Except U.S.A., Canada and Europe> Remove No. 16. ! Remove the Toner Collecting Box. Remove the Toner Pipe.
PWB-H PWB-I PWB-J
AE Sensor Board Tech. Rep. Settings Switches Board Exposure Lamp Regulator Fuse Board
PWB-L
PWB-M1 PWB-M2 PWB-R UN1 UN2 UN3 UN5 UN6 PU1 HV1
1st Drawer Flexible printed Circuit 2nd Drawer Flexible printed Circuit RAM Board Control Panel Original Size Detecting Board ATDC Sensor 1st Drawer Paper Descent Key 2nd Drawer Paper Descent Key Power Supply Unit Hight Voltage Unit
Slide out the drawer.
Remove No. 16. Swing down No. 1 ! Remove No. 2. Remove No. 16. Swing down No. 1. ! Remove the IU. Slide out the drawer. ! Remove the Cassette Cover. ! Remove the Switch Cover. Remove No. 16. ! Remove the Power Supply Unit Cover. Remive No. 16. ! Remove the HV1 Cover.
z Readjustment/Resetting Involved in Replacement of PWB-G, PWB-R, UN2 and UN3 D When PWB-G is replaced: Adjust the exposure level in the Auto Exposure mode. (See p. D-72.) D When PWB-R (RAM Board) is replaced: Carry out Memory Clear and then make the Tech. Rep. Choice, Users Choice, and Adjust settings again. D When UN2 is replaced: Make the initial adjustment of the Original Size Detecting Board. (See p. D-68.) D When UN3 is replaced: Discard the developer which had been used until UN3 was replaced, recharge the Developing Unit with fresh starter, and adjust the ATDC. (See p. D-69.)
D-9
2-3. PAPER TAKE-UP/TRANSPORT SECTIONS (1) Removal of the Paper Take-Up Unit
<Except 120V Areas> 1. 2. 3. 4. 5. Remove the Right Door, Right Cover, and Rear Cover. Remove the 1st and 2nd Drawers. (For the removal of the 1st and 2nd Drawers, see p. D-17.) Remove two locking wiring saddles. Unplug one connector from Power Supply Board PWB-C. Disconnect the hookup connector.
1156D005AA
<120V Areas> 1. 2. 3. 4. Remove the Right Door, Right Cover, and Rear Cover. Remove the 1st and 2nd Drawers. (For the removal of the 1st and 2nd Drawers, see p. D-18.) Remove one locking wiring saddle. Disconnect the hookup connector.
1156D006CA
D-10
6.
Remove three screws to free the Paper Take-Up Connector Assy.
1156D007AA
7.
Remove two screws each to free 1st Drawer Paper TakeUp 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.
1134D006AA
8.
Remove two screws and the Paper Guide Plate.
1134D007AA
<Except 120V Areas> 9. Remove two edge covers with locks. 10. Unplug three hookup connectors.
1134D008AA
<120V Areas> 9. Remove two edge covers with locks. 10. Unplug one hookup connector.
1156D008CA
D-11
11. Pull the harness out to the front from the rear frame.
1134D009AA
12. Remove five screws and the Paper Take-Up Unit.
1156D009AA
D-12
(2) Removal of the Paper Take-Up Roll/Feed Roll Assy and Separator Roll Assy
1. 2. Remove the Right Door. 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
D-13
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.)
1156D011AA
5.
Disassemble the Paper Separator Roll Assy.
1156D012AA
D-14
6.
Remove two C-clips from each Paper Take-Up Roll/Feed Roll Assy. (The illustration is for the Paper Take-Up Roll/ Feed Roll Assy for the 2nd Drawer.)
1156D013AA
7. 8.
Remove the bushing from the front end of each Paper Take-Up Roll/Feed Roll Assy. Remove the rear bushing from the holder.
1156D014AA
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 pin of the copier. This allows the Paper Take-Up Roll /Feed Roll Assy to come out of the copier.
1156D015AA
NOTE When reinstalling the Paper Take-Up Roll/Feed Roll Assy, place it above the Pressure Release Lever.
1156D016AA
D-15
10. Disassemble the Paper Take-Up Roll/Feed Roll Assy.
*Keep the lock pin for later use.

1156D017AA
(3) Cleaning of the Paper Take-Up Roll, Feed Roll, and Separator Roll
1. 2. 3. Remove each Paper Take-Up Roll/Feed Roll Assy. Remove each Paper Separator Roll Assy. Using a soft cloth dampened with alcohol, wipe each roll clean of dirt.
Cleaning the Paper Take-up Roll/Feed Roll
Cleaning the Paper Separator Roll
1156D018AA
1156D019AA
D-16
(4) Cleaning of the Vertical Transport Rollers

1. 2. Remove the Right Door, Right Cover, and Rear Cover. Using a soft cloth dampened with alcohol, wipe each roller clean of dirt.
1134D016AA
(5) Removal of the Drawers

*Though the following steps and illustrations are for the 1st Drawer, the same procedure applies also to the 2nd Drawer. <Except 120V Areas> 1. Slide out the drawer and remove one screw and the right stopper.
1156D020AA
2.
Remove one screw and the left stopper.
1134D133AA
3.
Remove the drawer from the copier.
1134D143AA
D-17
<120V Areas> 1. 2. Turn ON Power Switch S1. Press the Paper Descent Key and then slide out the drawer.
1156D023AA
3. 4.
As with the metric areas, remove the right and left stoppers. Remove one screw and the hookup connector cover.
1134D139CA
5.
Remove one screw and the hookup connector mounting bracket.
1134D140CA
6.
Unplug the hookup connector. Remove the drawer.
1134D141CA
D-18
(6) Removal of the Upper Synchronizing Roller

1. 2. 3. 4. 5. Swing down the Front Door. Swing the Transport Section Release Lever down. Remove the Rear Cover. Unplug the bias terminal from High Voltage Unit HV1. Unplug CN1 of HV1.
1156D024AA
6.
Remove two screws to free HV1.
1156D025AA
7.
Snap off one E-ring to free Synchronizing Roller Clutch CL2.
1156D026AA
Rear
8.
Snap off the E-ring and remove the bushing from the rear end of the Upper Synchronizing Roller.
1156D027AA
9. Swing down the Front Door and slide out the IU. 10. Snap off the E-ring and remove the bushing from the front end of the Upper Synchronizing Roller.
Front
1134D025AA
D-19
11. Remove the Upper Synchronizing Roller.
1156D028AA
(7) Cleaning of the Upper and Lower Synchronizing Rollers

1. 2. Swing down the Front Door and slide out the IU. Using a brush or a soft cloth dampened with alcohol, clean the Upper Synchronizing Roller.
1136D092AA
3. 4.
Swing down the Transport Section Release Lever. Using a brush or a soft cloth dampened with alcohol, clean the Lower Synchronizing Roller.
1134D027AA
(8) Replacement of the Paper Dust Remover

1. 2. 3. 4. Swing down the Front Door and slide out the IU. Loosen the screw that secures the Paper Dust Remover Assy at the rear of the copier. Remove the screw that secures the Paper Dust Remover Assy at the front of the copier. Remove and replace the Paper Dust Remover Assy.
Rear
1136D093AA
5.
When only the Paper Dust Remover is to be replaced, affix the new one along the reference line as shown on the left.
1136D094AA
D-20
(9) Cleaning of the Paper Dust Remover

1. 2. Remove the Paper Dust Remover Assy. Using a brush, whisk dust off the Paper Dust Remover.
1136D095AA
D-21
(10) Removal of the Suction Unit

1. 2. 3. 4. Remove the 1st and 2nd Drawers. Swing down the Front Door and slide out the IU. Remove the Paper Dust Remover Assy. Remove the Fusing Unit. 5. Remove the motor cover.
1156D029AA
6.
Unplug two connectors from the lower end of the Suction Unit.
1156D030AA
7. 8.
Swing the Transport Section Release Lever back to its original position. Pressing down the Image Transfer/Paper Separator Coronas Unit, pull it out of the copier.
1156D031AA
D-22
9. Swing down the Transport Section Release Lever. 10. Holding up the Suction Unit, remove the compression coil.
1156D032AA
11. Remove the Suction Unit by sliding it to the right. NOTE When removing and reinstalling the Suction Unit, use care not to bend the ground plate located on the right in the rear.
1136D101AA
NOTE When reinstalling the Suction Unit, make sure that two positioning pins on the copier fit into the positioning holes in the Suction Unit.
1134D028AA
(11) Disassembly of the Suction Unit

1. 2. 3. Remove the Suction Unit. Remove two screws and the duct. Remove four screws and the Suction Drive Unit. NOTE When reinstalling the Suction Drive Unit, try to press it down against the Suction Base Plate.
1136D102AA
4.
Remove three driven rolls.
1136D103AA
D-23
5.
Remove three Suction Belts.
1136D104AA
6.
Remove the Suction Roller as shown on the left.
1136D105AA
(12) Disassembly of the Multi Bypass Unit

1. 2. 3. 4. Open the Right Door. Remove two screws and the cover. Remove the harness from one locking wiring saddle. Unplug three connectors.
1156D033AA
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.)
1156D034AA
6.
Remove four screws and the Separator Guide Plate Assy.
1156D035AA
D-24
7.
Remove the compression coil. NOTE When reinstalling the compression coil, place it so that its close-coiled end faces the Separator Unit.
Close-Coiled End
1136D107AA
8.
Remove one C-clip and the Separator Assy.
1136D108AA
9.
Remove one C-clip and the Separator Roll Assy.
1136D109AA
10. Remove the harness from the edge cover and cord clamp.
1136D110AA
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 adjustment procedure, see p. D-98.)
1156D036AA
D-25
12. Remove two set screws and the electromagnetic spring clutch.
1156D037AA
NOTES D When reinstalling the electromagnetic spring clutch, orient 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 recessed (up to 1 mm) from the end face of the Paper TakeUp Roll shaft. (The roll shaft should never protrude.) D There must be a gap of 1 mm or more at A when the Paper Take-Up Roll shaft is pushed in the direction of the arrow.
1136D114AA
0 to 1mm
A
1136D115AA
13. Snap off two C-clips and remove the Paper Take-Up Roll Assy.
1156D038AA
14. Snap off three C-clips and remove the Feed Roll.
1139D112AA
D-26
15. Snap off the C-clip and remove the Paper Take-Up Roll.
1139D113AA
D Cleaning of the Manual Bypass Paper Take-Up Roll Using a soft cloth dampened with alcohol, clean the PaperTake-Up Roll.
1136D117AA
D Cleaning of the Manual Bypass Feed Roll Using a soft cloth dampened with alcohol, clean the Feed Roll.
1136D118AA
D Cleaning of the Manual Bypass Separator Roll Using a soft cloth dampened with alcohol, clean the Separator Roll.
1156D039AA
D-27
2-4. OPTICAL SECTION (1) Cleaning of the Original Glass

Wipe clean the Original Glass with a soft cloth. NOTE The surface of the Original Glass is coated with conductive material. Do not use a wax-based detergent. An alcohol-dampened cloth may be used if the glass is seriously contaminated.
1136D120AA
(2) Cleaning of the Scanner Shaft

1. 2. Remove the Original Width Scale. Remove the Original Glass.
1136D121AA
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.
1156D040AA
(3) Cleaning of the Scanner Rail

Wipe clean the Scanner Rail (at the front of the copier) with a soft cloth. NOTE Apply a lubricating oil after cleaning the Scanner Rail.
1156D041AA
D-28
(4) Removal of the Scanner

1. Move the Scanner to the right side of the copier. Remove three screws to free the Scanner. NOTE Hold the Scanner at a point near the Scanner Shaft when moving it. To remove the Scanner, turn it counterclockwise.
1156D042AA
2. 3.
Unplug the Thermal Fuse terminal connector and remove the Thermal Fuse wire from three clamps. Unplug the Exposure Lamp terminal connector.
1156D043AA
4. 5. 6.
Turn over the Scanner and remove one screw, one washer, and the ground wire. Remove the tie band and harness. Remove the Scanner from the copier.
1156D044AA
(5) Cleaning of the Exposure Lamp

1. 2. Remove one screw and the Exposure Lamp terminal. 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 p. D-72.)
1156D045AA
3.
Using a soft cloth dampened with alcohol, clean the lamp by gently wiping its surface in one direction. NOTE When reinstalling the lamp, point the protruding navel of the lamp toward the opening in the Lamp Reflector so that the protruding navel will not hit against the Lamp Reflector.
1076D131
D-29
(6) Removal of the Thermal Fuse

1. 2. 3. 4. Unplug the Thermal Fuse connector. Remove the Thermal Fuse cord from three clamps. Remove one screw and Thermal Fuse cover. Remove two screws and the Thermal Fuse.
1156D046AA
(7) Cleaning of the 1st, 2nd, and 3rd Mirrors

1. Wipe clean the 1st Mirror with a soft cloth.
1156D047AA
2.
Wipe clean the 2nd Mirror with a soft cloth.
1136D130AA
3.
Wipe clean the 3rd Mirror with a soft cloth.
1136D131AA
D-30
(8) Cleaning of the Lens and 4th and 5th Mirrors

1. 2. 3. Remove the Original Glass. Remove two screws and the Optical Cover. Remove two screws and the Lens Cover.
1136D133AA
4.
Gently dust off the surface of the Lens using a soft cloth.
1136D132AA
5.
Wipe clean the 4th and 5th Mirrors with a soft cloth.
1136D134AA
D-31
(9) Winding of the Lens Drive Cable
Cable Drive Gear
B
1136D135AA
1.
Hold the Cable Drive Gear with the bead at the bottom.
1136D136AA
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.
1136D137AA
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.
1136D138AA
D-32
4. 5.
Pass the longer length of the cable through the hole in the light blocking plate. Slide the Cable Drive Gear onto its shaft and insert a wrench into the hole (4-mm dia.) to position the gear.
1136D139AA
6.
Wind the shorter length of the cable around pulley A.
A
1136D140AA
7.
Secure the shorter length of the cable to the Cable Fixing Bracket. NOTE
2mm or Less
Ensure a distance of 2 mm or less for the dimension shown on the left.
1136D141AA
8. 9.
Wind the longer length of the cable around pulley B. Hook the spring onto the longer length of the cable and pull the spring to hook it onto the shorter length of the cable. 10. Remove the wrench and peel off the two pieces of tape used in steps 2 and 3.
1136D142AA
D-33
(10) Removal of Scanner Motor M2

1. 2. Remove the Right Cover, Rear Cover, and Rear Upper Cover. Remove four screws to free PWB-F.
1156D048AA
3. 4.
Unplug one connector. Then, remove the edge cover with a lock and the harness. Remove four screws and Scanner Motor M2.
1156D049AA
D-34
(11) Removal of the Scanner Drive Cable

1. 2. 3. 4. 5. Remove the Original Cover. Remove the Right Cover, Rear Cover, Rear Upper Cover, and Upper Left Cover. Remove the Original Glass. Remove the Scanner. Remove Scanner Motor M2. 6. Remove two screws to free the SCP Board (PWB-F) mounting bracket. *The illustration shows where the SCP Board has been removed for ease of understanding.
1156D048AA
7.
Remove two screws and Original Glass Cooling Fan Motor M5.
1156D050AA
8.
Using a flat blade screwdriver, loosen the right spring anchor to unhook the bead from the anchor, thereby removing the cable.
1134D037AA
9.
Move the Scanner to the center and remove the Scanner Fixing Bracket.
1134D038AA
D-35
(12) Winding of the Scanner Drive Cable

z Important When the Scanner Drive Cable has been wound: 1) Perform the Focus-positioning 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.
Wind Cable 5 Turns.
1156D054AA
D-36
10. Remove the Scanner Drive Cable from the pulleys. 11. Remove one screw to free the Original Cover Detecting Sensor Assy. 12. Remove four screws and the Scanner Drive Pulley mounting bracket. 13. Snap off one E-ring and remove the Scanner Drive Pulley.
1156D051AA
(13) Cleaning of the 6th Mirror Protective Filter

1. 2. 3. Swing down the Front Door and slide out IU. Remove the Plate Spring. Remove the 6th Mirror Protective Filter.
1156D174AA
4.
Using a soft cloth, wipe clean the 6th Mirror Protective Filter.
1156D175AA
(14) Cleaning of the Cooling Fan Filter

1. 2. Remove six screws and the Rear Cover. Clean the Cooling Fan Filter using a brush or a vacuum cleaner.
1156D052AA
D-37
2-5. Imaging Unit (1) Removal of the Imaging Unit

1. 2. Swing down the Front Door. Swing the Transport Section Release Lever down.
1136D150AA
3. 4.
Loosen two screws that secure the IU. Slide out the IU.
1156D055AA
(2) Disassembly of the Imaging Unit

1. Remove the PC Drum Charge Corona by moving it to the rear.
1136D152AA
2. 3.
Loosen one screw and remove the stopper. Remove the PC Drum.
1156D056AA
4.
Pull the Main Hopper to the front and unplug two Hopper Unit connectors.
1156D057AA
D-38
5.
Remove three screws and the Main Hopper.
1136D155AA
6.
Unplug one connector and remove three screws and the Sub Hopper.
1156D058AA
7.
Remove two screws and the Developer Scattering Prevention Plate. NOTE Do not remove the Doctor Blade Assy, as a changed Db could result.
1156D059AA
Rear
NOTE Install the Developer Scattering Prevention Plate so that its seal is placed behind the side seals of the Developer Mixing Chamber.
Front
1156D060AA
8.
Dump the developer out of the Developing Unit.
1136D157AA
D-39
9.
Remove two screws and the Cleaning Blade.
1136D172AA
NOTE When reinstalling the Cleaning Blade, press the blade tightly up against the mounting bracket.
1136D173AA
10. Unplug one connector. 11. Remove three screws and the PC Drum Paper Separator Finger Holder Assy.
1156D061AA
Coupling Holder
NOTE When reinstalling the PC Drum Paper Separator Finger Holder Assy, fit the collar of the assy onto the coupling holder in the rear.
Collar
1134D047AA
D-40
12. Remove the PC Drum Paper Separator Fingers and AIDC Sensor Board PWB-G as shown below.
Assy
PWB-G
Torsion Spring
1156D062AA
* 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.
PC Drum Paper Separator Finger Installed
Top View
Bottom View
* Hook the torsion spring properly. After installation, check that the Paper Separator Fingers operate smoothly.
1156D063AA
D-41
(3) Replacement of the PC Drum

1. 2. 3. Slide out the IU. Loosen one screw and remove the stopper. 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 exposure level in the Auto Exposure mode, see p. D-72.)
1136U014AA
(4) Cleaning of the Developer Scattering Prevention Plate

Using a brush, whisk dust off the Developer Scattering Prevention Plate.
1136D050AA
(5) Cleaning of the Ds Positioning Collars

Using a brush or a soft cloth dampened with alcohol, clean the Ds Positioning Collars.
1136D177AA
(6) Cleaning of the Toner Antispill Trap

Using a brush or a vacuum cleaner, clean the Toner Antispill Trap.
1136D178AA
(7) Cleaning of the Cleaning Blade

Using a brush, whisk paper dust and toner off the Cleaning Blade.
1156D167AA
D-42
(8) Replacement of the Cleaning Blade

1. Remove and replace the Cleaning Blade.
1136D172AA
2.
Remove the Toner Bottle from the IU. Insert a brush through the toner port and into the toner.
1138D321AA
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.
1136U013AA
4.
Using the brush, apply lubricant shipped with the Cleaning Blade to the two side seals shown.
1136D303AA
D-43
5.
Install the PC Drum. NOTE Do not touch the surface of the PC Drum with bare hands. Hold onto both ends of the PC Drum when installing the drum.
1136U014AA
6.
Fit the PC Drum stopper and tighten the screw.
1156D064AA
7.
Apply a thin coat of toner to the surface of the PC Drum.
1156D065AA
8.
Holding onto both ends of the PC Drum, turn the PC Drum one complete turn in the forward direction.
1134U022AA
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 turns in the forward direction.
1156D066AA
D-44
(9) Replacement of the Starter

1. Dump the developer out of the Developing Unit.
1136D157AA
2.
Turning the Bucket Roller, pour 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
D-45
(10) Cleaning of the AIDC Sensor Board

1. 2. Remove the PC Drum Paper Separator Fingers Assy. Using a brush or a soft cloth dampened with alcohol, clean the AIDC Sensor Board.
1156D067AA
(11) Cleaning of the PC Drum Paper Separator Fingers

1. 2. Remove the PC Drum Paper Separator Fingers Assy. Using a brush or a soft cloth dampened with alcohol, clean the PC Drum Paper Separator Fingers.
1136D181AA
(12) Replacement and Cleaning of the Toner Antispill Seal and Cleaning of the Toner Antispill Plate
1. 2. 3. Remove the IU. Remove two screws, the Toner Antispill Plate, and Toner Antispill Seal. Replace the Toner Antispill Seal.
1136D182AA
4. 5.
Using a brush, clean the Toner Antispill Seal. Using a brush, clean the Toner Antispill Plate.
1134D052AA
NOTE When reinstalling the Toner Antispill Plate and Toner Antispill Seal, press them in the direction of the arrows.
1136D184AA
D-46
(13) Removal of Main Erase Lamp LA3

1. 2. 3. Swing down the Front Door. Unplug one connector. Remove one screw and Main Erase Lamp LA3.
1156D068AA
(14) Cleaning of the Main Erase Lamp Filter

1. 2. Swing down the Front Door. Remove the Main Erase Lamp Filter.
1136D186AA
3.
Using a soft cloth dampened with alcohol, wipe clean the Main Erase Lamp Filter.
1136D187AA
(15) Cleaning of Image Erase Lamp LA2

1. 2. 3. Swing down the Front Door. Remove the IU. Using a soft cloth dampened with alcohol, wipe clean Image Erase Lamp LA2.
1136D188AA
(16) Replacement of Image Erase Lamp LA2

1. 2. 3. Swing down the Front Door. Remove the IU. Remove one adjusting screw to free Image Erase Lamp LA2.
1134D055AA
D-47
4.
Unplug one connector in the rear and remove Image Erase 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.)
1134D056AA
(17) Removal of the Ozone Filter (PC Drum Charge Corona)

1. 2. 3. Swing down the Front Door. Swing out the Main Hopper. Slide out the Ozone Filter.
1134D057AA
(18) Removal of the Ozone Filter (Image Transfer/Paper Separator Coronas)

1. 2. 3. Remove the Rear Cover. Remove one screw and the Filter Cover. Pull out the Ozone Filter.
1136D189AA
(19) Removal of the Toner Collecting Box (Except the U.S.A., Canada, and Europe)
1. 2. Remove the Rear Cover. Remove the Toner Collecting Box. *For removal of the large capacity Toner Collecting Box, please refer to the instructions on the large capacity Box.
1136D087AA
D-48
26. PC DRUM CHARGE CORONA AND IMAGE TRANSFER/PAPER SEPARATOR CORONAS (1) Removal of the PC Drum Charge Corona
Move the PC Drum Charge Corona to the rear and pull it off.
1156D069AA
(2) Cleaning of the PC Drum Charge Corona Housing

1. 2. 3. Remove the IU. Remove one screw and PC Drum charge Corona Unit. Press the Mesh Holder on the front of the Corona Unit in the direction of arrow A to remove the Grid Mesh.
1156D070AA
4. 5.
Remove the Cleaning Pad Cover. Remove the End Caps from the front and rear ends of the Unit.
1156D071AA
6.
Remove the Comb Electrode. NOTE Use care not to deform the Electrode. When removing it, first snap off its spring end.
1139D176AA
7.
Using a soft cloth dampened with alcohol, wipe the Housing clean of dirt.
1139D177AA
D-49
(3) Cleaning of the PC Drum Charge Corona Grid Mesh

Blow all foreign matter off the Grid with a blower brush. NOTE If the blower brush is not effective in cleaning the Grid, use a soft cloth dampened with alcohol to clean serious contamination.
1139D178AA
(4) Cleaning of the Comb Electrode

Clean Comb Electrode using the Corona Unit Cleaning Lever.
1156D072AA
(5) Removal of the Image Transfer/Paper Separator Coronas

1. 2. Swing down the Front Door. Pull out the Image Transfer/Paper Separator Coronas.
1134D062AA
(6) Cleaning and Replacement of the Image Transfer Corona Wire

1. 2. Swing down the Front Door. Clean the Image Transfer Corona Wire using the Corona Wire Cleaning Lever.
1136D198AA
NOTE If the Image Transfer Corona Wire is seriously contaminated, dampen a soft cloth with alcohol, hold it with a pair of tweezers, and wipe the wire gently in one direction-from the hook end to the spring end.
1136D199AA
D-50
3.
Remove the Holder Covers at the front and rear.
1136D200AA
4. 5.
Remove the corona wire, first at the spring end. Replace the corona wire with a new one.
1136D201AA
(7) Cleaning and Replacement of the Paper Separator Corona Wire

1. Remove four Paper Guides.
1136D202AA
2.
3.
Dampen a soft cloth with alcohol, hold it with a pair of tweezers, and wipe the Paper Separator Corona Wire gently in one direction from the hook end to spring end. Replace the Paper Separator Corona Wire by using the same procedure as that for the Image Transfer Corona Wire.
1136D203AA
(8) Cleaning of the Image Transfer/Paper Separator Coronas Housing

1. 2. 3. 4. Remove four Paper Guides. Remove the Holder Covers at the front and rear. Remove the Image Transfer and Paper Separator Corona Wires first at the spring end. Using a soft cloth dampened with alcohol, wipe the housing clean of dirt.
1136D205AA
D-51
(9) Cleaning of the Lower Pre-Image Transfer Guide Plate

Using a soft cloth dampened with alcohol, wipe clean the Lower Pre-Image Transfer Guide Plate.
1136D206AA
D-52
27. FUSING UNIT (1) Removal of the Fusing Unit

1. 2. 3. Open the Left Door. Swing down the Front Door. Remove one screw and the Fusing Unit.
1156D073AA
(2) Disassembly of the Fusing Unit

1. Remove two screws and the Front Cover.
1156D074AA
2. 3. 4. 5.
Unplug the connector of the Heater Lamp on the front. Remove three harness holders. Remove the Heater Lamp cord from the two edge covers. Remove two screws and the front lamp holder.
1156D075AA
6.
Remove two screws and the cover.
1156D076AA
Cover Harness Cover
NOTE At reinstallation, position the cover between the Fusing Unit and harness cover.
Fusing Unit
1156D077AA
D-53
7. 8.
Remove one screw and the Heater Lamp cord in the rear. Remove the Heater Lamp cord from the locking edge cover.
1156D078AA
9. Remove three screws and the rear lamp holder. 10. Remove the Heater Lamp cord from the wiring saddle. 11. Remove the Heater Lamp.
1156D079AA
12. Remove four screws and the Upper Cover.
1156D080AA
13. Remove two screws and the Upper Fusing Paper Separator Finger mounting bracket.
1156D081AA
NOTE When reinstalling the Upper Fusing Paper Separator Finger mounting bracket, be sure that both ends of the bracket are in tight contact with the frame.
1136D213AA
D-54
14. Remove the harness from the Harness Guide. 15. Unplug the connectors of the two Thermistors.
1156D082AA
16. Remove one screw, shoulder screw, and the Harness Guide. 17. Remove one screw and the Thermoswitch cord.
1156D083AA
18. Remove two screws and the Temperature Detector Assy.
1156D084AA
NOTE When reinstalling the Temperature Detector Assy, be sure that both ends of the assy are in tight contact with the frame.
1136D217AA
19. Remove the Gear. 20. Remove two shoulder screws and the Fusing Unit Entrance Guide Plate.
1156D085AA
D-55
21. Remove the two torsion springs. 22. Remove two shoulder screws and the Lower Exit Guide Assy. Lower Fusing Roller Upper Fusing Roller Torsion Spring
Shoulder Screw Rear
Torsion Spring
Shoulder Screw
Front Lower Exit Guide Assy

1156D086AA
Lower Exit Guide Assy Position Installing the Lower Exit Guide Assy
Lower Fusing Roller Lower Fusing Paper Separator Finger Contact No Clearance Allowed.
1134D067AA
D-56
23. Loosen the screw that secures the spring bracket at the front and then unhook the spring at the top. Repeat the same step for the spring in the rear. NOTE When reinstalling the springs, alternately tighten the bracket mounting screws until the brackets completely contact the ends of the Lower Exit Guide Assy.
1156D087AA
24. Remove the Lower Fusing Roller.
1156D088AA
25. Remove two extension springs. 26. Remove two E-rings, the gear, bushing, and Cleaning Roller.
1156D089AA
27. Remove two E-rings, then two gears. 28. Remove two screws, the Upper Fusing Roller drive gear, and Upper Fusing Roller.
1156D090AA
D-57
(3) Replacement and Cleaning of the Upper Fusing Paper Separator Fingers
1. 2. 3. 4. Remove the Upper Fusing Paper Separator Finger mounting bracket. Remove five springs. Slide out the shaft to remove the Upper Fusing Paper Separator Fingers. Replace the fingers with new ones.
1156D091AA
5.
Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Upper Fusing Paper Separator Fingers.
1136D227AA
(4) Cleaning of the Lower Fusing Paper Separator Fingers

1. 2. Remove the Lower Exit Guide Assy. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Lower Fusing Paper Separator Fingers.
1136D228AA
(5) Cleaning of the Fusing Unit Entrance Guide Plate

Using a soft cloth dampened with alcohol, wipe clean the Fusing Unit Entrance Guide Plate.
1156D092AA
(6) Cleaning of Fusing Front and Rear Thermistors TH1/2

1. 2. Remove the Temperature Detector Assy. Using a soft cloth dampened with alcohol, wipe clean the two thermistors.
1156D093AA
D-58
(7) Cleaning of Fusing Thermoswitch TS1

1. 2. Remove the Temperature Detector Assy. Using a soft cloth dampened with alcohol, wipe clean the thermoswitch.
1156D094AA
(8) Replacement and Cleaning of the Cleaning Roller

1. 2. 3. Remove two screws and the Upper Cover. Remove the Cleaning Roller. Replace the Cleaning Roller with a new one.
1156D089AA
4.
Using a brush, whisk dust off the Cleaning Roller.
1136D232AA
(9) Replacement and Cleaning of the Upper Fusing Roller

1. 2. Remove the Upper Fusing Roller. Replace the Upper Fusing Roller with a new one.
1156D090AA
3.
Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Upper Fusing Roller.
1136D233AA
D-59
(10) Replacement and Cleaning of the Lower Fusing Roller

1. 2. Remove the Lower Fusing Roller. Replace the Lower Fusing Roller with a new one.
1156D088AA
3.
Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Lower Fusing Roller.
1136D234AA
D-60
1156SBD0208A
2-8. EXIT UNIT (1) Removal of the Exit/Duplex Switching Unit

1. Remove the Rear Cover. 2. Open the Left Door. 3. Remove the Upper Left Cover. 4. Remove four screws to free the Sorter Connector Assy.
1134D144AA
5. 6.
Unplug two connectors. Remove one screw and the ground wire.
1156D095AA
7. 8.
Snap off the E-ring from the shaft onto which the Exit/Duplex Switching Unit is mounted. Work the harness indicated by the arrow off the wiring saddle.
1156D096AA
9. Remove one screw that holds the belt. 10. Remove two screws and the mounting bracket. 11. Remove the Exit/Duplex Switching Unit.
1156D097AA
D-61
1156SBD0300A
ADJUSTMENT
1156SBD0301A
3-1. JIGS AND TOOLS USED

z Important D When adjusting the gap between the Doctor Blade and Sleeve Roller, use jigs number and . D When adjusting the positions of the Scanner and Mirrors Carriage, use jigs number and .
D When adjusting the position of the PC Drum Paper Separator Fingers, use jigs number and .
Front Door Interlock Switch

Actuating Jig
Predrive Inhibit Switch

Actuating Jig
1136D001AA
1136D005AA
Scanner Positioning Jig
Scanner/Mirrors
Carriage Positioning Jig
1136D002AA
1136D006AA
Sleeve/Magnet Roller
Positioning Jig
D.B. Adjusting Jigs
1136D003AA
PC Drum Paper
Separator Finger Positioning Jig
1136D004AA
D-62
1156SBD0302A
3-2. ADJUSTMENT REQUIREMENTS LIST

Adjustment Item Optimum exposure in the Manual Exposure mode Crosswise zoom ratio, full size Feeding direction zoom ratio, full size Multi Bypass Table reference Position 1st Drawer reference Position 2nd Drawer reference Position Leading edge registration, full size Leading edge registration, enlargement Leading edge registration, reduction Leading edge registration, book second page Image leading edge erase width Image trailing edge erase width Edge erase Requirements Kodak Gray Scale: no image of the 1st step, faint image of the 2nd step ( 1.000) 200 1.0 mm ( 1.000) 300 1.5 mm ( 1.000) 20 2.0 mm ( 1.000) 20 2.0 mm ( 1.000) 20 2.0 mm ( 1.000) 20 1.5 mm ( 2.000) 40 3.0 mm ( 0.500) 10 1.5 mm ( 1.000) 20 3.0 mm ( 1.000) 16.5 mm ( 1.000) 0.55.5 mm ( 1.000) 0.54.0 mm Adjusting Point Control panel Control panel Control panel Multi Bypass Table Drawer Positioning Plate Drawer Positioning Plate Control panel Control panel Control panel Control panel Control panel Control panel Edge Erase Adjusting Screw Ref. Page D-73 D-75 D-77 D-79 D-80 D-80 D-81 D-83 D-85 D-87 D-89 D-91 D-93
D-63
1151SBD0303A
3-3. ADJUSTMENT OF SWITCHES Microswitches

The following microswitches are used in various parts of this copier.
Blue (NC) Yellow (NO)
Red (COM)
1136D007AA
Red (COM)
1136D008AA
Wiring for the NO Type
Wiring for the NC Type
NC (Normally-Closed) NO (Normally-Open) COM (Common) Requirement
: Current flows between NC and COM when the actuator is open. : Current flows between NO and COM when the actuator is closed. : Common contact for NC and NO.
Actuator
The gap between the switch and actuator should be 0.1 to 0.5 mm when the actuator is closed.
0.1 mm to 0.5 mm
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 actuator is bent or the switch can be broken.
D-64
Adjustment of Front Door Interlock Switch S21

1. 2. Swing down the Front Door. Remove six screws and the Upper Left Cover.
1136D009AA
3. 4.
Remove three screws and the cover. Loosen two screws that secure Front Door Interlock Switch.
1136D010AA
5. 6.
Close the Front Door. Slowly move the switch to the front until the actuator is closed by the actuator stop on the Front Door. Then, tighten the two mounting screws. D The switch is wired for the NO type.
1156D098AA
D-65
3-4. ADJUSTMENT OF BELT TENSION

z Important
D Make sure that all gears are in positive mesh with each other and the belts snugly fit in the pulley grooves. D Each belt should flex a little when finger-pressed down on the location indicated by the arrow.
Belt (1) (2) (3) (4) Paper Take-Up Unit Timing Belt Developing Unit Timing Belt Fusing Unit Timing Belt IU Timing Belt
Tension 300 100 g 350 100 g 350 100 g 350 100 g
Deflection (Reference only) Approx. 3 mm Approx. 4 mm Approx. 3 mm 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.
Move lever 2 to 3 times, then tighten screws. Move lever 2 to 3 times, then tighten screws. 350 100 g
350 100 g
300 100 g 350 100 g Move lever 2 to 3 times, then tighten screws.
1156D172AA
D-66
3-5. ACCESSING THE TECH. REP. MODE AND ADJUST MODE

z Accessing the Tech. Rep. Mode To access the Tech. Rep. mode, press the following keys in order. Stop Key ! 0 ! Stop Key ! 1
1134D069AA 1156D134CA
Press the keys in order of [1], [2], [3], and [4].
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
1134D071AA
Press the keys in order of [1] and [2].
1156D138CA
D-67
1156SBD0306A
3-6. ELECTRICAL/IMAGE ADJUSTMENTS (1) Initial Adjustment of Original Size Detecting Board
z Important
D The following adjustment must be made when memory has been cleared, RAM Board PWB-R or Original Size Detecting Board UN2 replaced, or an Original Size Detecting Sensor replaced or added.
1.
Lower the Original Cover with no original placed on the Original Glass.
1136D017AA
2. 3. 4. 5.
Call the Tech. Rep. mode menu to the screen. Touch Touch Function to show the Function menu on the screen. .
F7 Orig. Sensor
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.
After the adjustment has been made, press the Panel Reset Key to return the copier to the Basic screen.
D-68
(2) ATDC Adjustment

z Important
Make this adjustment only after the starter has been replaced. 1. 2. Load the IU with fresh starter. Reinstall the IU in the copier.
1134D051AA
3. 4. 5. 6.
Call the Tech. Rep. mode menu to the screen. Touch Touch Function to show the Function menu on the screen. .
F8 ATDC Adjust
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 has been replaced.
D-69
7. Touch 8. Touch
Menu
on the screen to show the Tech. Rep. mode menu again. and enter the value for the ATDC Ref. Level on the Adjust Label affixed
Level History
inside the Front Door. 9. Then, press the Panel Reset Key to return the copier to the Basic screen.
1156D143CA
1156D168CA
Enter This Value on the Adjust Label. z Should the 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
1156D169CA
Touch the shift key A or " to change the value and touch Enter to validate the new setting.
D-70
(3) Adjustment of the Aperture Blades

z Requirement D There should be no dark or light bands running in the feeding direction on copies produced. (Adjust to obtain the mean image density for all areas.) z Important D If dark and light bands running in the feeding direction occur on copies, make this adjustment after checking the following. 1) The Drum Charge Corona Wire, Grid Mesh, and Image Transfer Corona Wire are free of dirt. 2) The surfaces of the Mirrors and Lens are free of dirt. 3) The surfaces 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 on the Copy Tray around as shown to reverse the leading and trailing edges and align it with the Aperture Blades.
4. Adjust to obtain the mean image density for all areas of the copy. NOTE To make the image darker, move the Aperture Blade toward the Auxiliary Reflector. To make the image lighter, move the Aperture Blade away from the Auxiliary Reflector.
D-71
(4) Adjustment of Exposure Level in the Auto Exposure Mode

z Important D Before starting the procedure, check that the Auto Exposure mode is selected on the Touch Panel. D For the adjustment, stack about five blank sheets of A3 or 11 and lower the Original Cover. D After this adjustment, be sure to check the optimum exposure setting in the Manual Exposure mode. 17 paper on the Original Glass
1.
Make sure that the Auto Exposure mode is selected on the 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. 3. 4. 5.
Call the Tech. Rep. mode menu to the screen. Touch Touch Function to show the Function menu on the screen. F5 Optimum & AE .
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
1156D144CA
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. 7.
After the adjustment, touch
Menu to return the copier to the Tech. Rep. menu.
Check the optimum exposure setting in the Manual Exposure mode. (See p. D-73.)
D-72
(5) Adjustment of Optimum Exposure Setting in the Manual Exposure Mode

z Requirement D Exposure Lamp voltage setting range in the Manual Exposure mode ... 44 to 56 D When the manual exposure setting is at the central indication, no image of step no. 1 of a Kodak Gray Scale should be produced on the copy, but a faint image of step no. 2 should be produced.
1136D300AA
z Important D This adjustment should be made only after completing the Adjustment of Exposure Level in the Auto Exposure Mode and Adjustment of the Aperture Blades. D If the setting has been changed in this adjustment, be sure to make the adjustment of exposure level in the Auto Exposure mode. 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 paper over it and then lower the Original Cover. Set the copier into the Manual Exposure mode and set the exposure setting to the central or fifth indication (EXP5). Make about 3 copies using A3 or 11 17 paper (so that the PC Drum sensitivity stabilizes). Then, check that the third copy meets the requirement given above. *If the image density is outside the specifications, make the following adjustment.
2.
1156D137CB
3. 4.
Call the Tech. Rep. mode menu to the screen. Touch Tech. Rep. Choice to show the Tech. Rep. Choice 1 menu on the screen.
1156D141CA
1156D145CA
D-73
5. Touch
Next
twice to show the Tech. Rep. Choice 3 menu on the screen.
6. Observing the image density of the sample copy, touch the shift key A or " to change the setting for Image Exposure. 7. Touch Enter to validate the setting. 8. Run the F5 operation again. Setting Instructions 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.
1156D146CA
1156D150CA
Touch This Key Twice.
Touch This Key if ID is High. Touch This Key if ID is Low.
NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid.
D-74
(6) Adjustment of Zoom Ratio in the Crosswise Direction (Adjust A1 = Lens Full Size Position)
z Requirement D This adjustment is made for the zoom ratio in the crosswise direction. D A scale is placed on the Original Glass to run parallel with the Scanner and the length of the scale on the copy is compared with that of the actual scale. The adjustment must be made so that the difference between the two dimensions falls within the following specifications. The difference should be within "0.5% of the actual length. For 200 mm, the allowance is 200 mm Zoom Ratio Full size ( 1.000) z Important This adjustment must be made before the Reference Position Adjustments. 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-wider paper. *If the scale is of plastic and transparent, place a blank sheet of paper over it. 0.005 = 1.0 mm. Adjusting Mode Adjust A1 + Lens Full Size Position Setting Range 43 to 58
Specifications 200 " 1.0mm
1134D136AA
2.
Allow the copy to stand for 5 minutes, then measure the length to determine the zoom ratio in the crosswise direction. (Make the check with the third copy.) Using the scale, measure the length of the scale on the copy to find any difference. *If the zoom ratio deviates from the specifications, go to the next step.
1134D124AA
D-75
3. 4.
Call the Adjust 1/2 menu to the screen. Touch the select key t or s to highlight A1 Lens Full Size Position.
1156D138CA
1156D154CA
5. 6.
Touch the shift key A or " to change the set value. Touch Enter to validate the setting.
Setting Instructions D If the scale on the copy 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 Value
1156D147CA
Touch This Key if Measurement is Shorter. Touch This Key if Measurement is Longer.
NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid.
D-76
(7) Adjustment of Zoom Ratio in the Feeding Direction (Adjust A3 = Feed Direction Mag. Ratio)
z Requirement D This adjustment is made for the zoom ratio in the feeding direction. D A scale is placed on the Original Glass perpendicularly to the Scanner and the length of the scale on the copy is compared with that of the actual scale. The adjustment must be made so that the difference between the two dimensions falls within the following specifications. The difference should be within "0.5% of the actual length. For 300 mm, the allowance is 300 mm Zoom Ratio Full size ( 1.000) z Important This adjustment must be made before the Adjustment of the Leading Edge Registration. 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 or 11 17 paper. *If the scale is of plastic and transparent, place a blank sheet of paper over it. 0.005 = 1.5 mm. Adjusting Mode Adjust A3 + Feed Direction Mag. Ratio Setting Range 46 to 54
Specifications 300 " 1.5mm
1134D137AA
2.
Allow the copy to stand for 3 minutes, then measure the length to determine the zoom ratio in the feeding direction. (Make the check with the third copy.) Using the scale, measure the length of the scale on the copy to find any difference. *If the zoom ratio deviates from the specifications, go to the next step.
1138D154AA
D-77
3. 4.
Call the Adjust 1/2 menu to the screen. Touch the select key t or s to highlight A3 Feed Direction Mag. Ratio.
1156D138CA
1156D151CA
5. 6.
Touch the shift key A or " to change the set value. Touch Enter to validate the setting.
Setting Instructions D If the scale on the copy 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.
1156D155CA
Touch This Key if Measurement is Shorter. Touch This Key if Measurement is Longer. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid.
D-78
(8) Adjustment of Reference Position of the Multi Bypass Table

z Requirement D Dimension A on the copy of the GTC-test chart should measure 20 mm " 2.0 mm in the full size ( 1.000) mode.
Dimension A
1134D196AB
z Important This adjustment should be made after the adjustment of zoom ratio in the crosswise direction. 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. Make three copies in the full size ( 1.000) mode using A3 or 11 17 paper fed from the Multi Bypass Table. Check 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.)
2. 3.
1136D030AA
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. Adjusting Instructions D If dimension A on the copy is shorter than 18 mm, move the table to the front of the copier. D If dimension A on the copy is longer than 22 mm, move the table to the rear of the copier. NOTE
1136D031AA
1156D099AA
When tightening the screws, hold the Multi Bypass Table from the underside with your hand and tighten screws in the order shown. When a Duplexing Document Feeder is mounted, it involves changing the Original Glass. This in turn results in the position of the Original Length Scale being slightly shifted to the rear. This can nonetheless be corrected with the Original Positioning Plate.
D-79
(9) Adjustment of Reference Position of the 1st/2nd Drawer

z Requirement D Dimension A on the copy of the GTC-test chart should measure 20 mm " 2.0 mm in the full size ( 1.000) mode.
Dimension A
1134D196AB
z Important This adjustment should be made after the adjustment of zoom ratio in the crosswise direction.
1.
2. 3.
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. Feeding three sheets of A3 or 11 17 paper from the 1st Drawer, make two full-size copies. Check if dimension A (from the edge up to the reference line) on the third copy is up to the specifications.
1136D030AA
4.
If dimension A deviates from the specifications, slide out the 1st Drawer. Then, loosen the three screws shown on the left and move the Drawer Positioning Plate to the front or rear as necessary. (Use the same procedure for the 2nd Drawer.)
1134D146AA
Adjusting Instructions D If dimension A on the copy is longer than 22 mm, move the Positioning Plate to the front of the copier. D If dimension A on the copy is shorter than 18 mm, move the Positioning Plate to the rear of the copier. 5. After the adjustment, loosen the four screws shown on the left and adjust the position (tilt) of the Drawer Cover.
1139U037AA
D-80
(10) Adjustment of the Leading Edge Registration

z Requirement Dimension A D Dimension A on the copy of the GTC-test chart should measure as follows at the respective zoom ratios.
1138D170AA
Zoom Ratio Full size ( 1.000) Enlargement ( 2.000) Reduction ( 0.500) z Important
Specifications 20 " 1.5mm 40 " 3.0mm 10 " 1.5mm
Adjusting Mode Adjust A4 + Lens Position Full Size Adjust A11 + Lens Position Enlargement Adjust A5 + Lens Position Reduction
Setting Range
40 to 60
This adjustment should be made after the adjustment of zoom ratio in the feeding direction.
(1) Leading Edge Registration in Full Size 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. Make three single copies on A3 or 11 17 paper in full size mode and check the third copy for leading edge registration. (If the registration is up to the specifications, go to the adjustment in the enlargement mode. If it deviates from the specifications, perform the following steps to make the adjustment of leading edge registration in the full size mode.)
2.
1136D033AA
D-81
3. 4.
Call the Adjust 1/2 menu to the screen. Touch the select key t or s to highlight A4 Scan Regist Full Size.
1156D138CA
1156D148CA
5. 6.
Touch the shift key A or " to change the setting value. Touch Enter to validate the setting.
Setting Instructions D If dimension A on 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.
1156D152CA
Touch This Key if Measurement is Longer. Touch This Key if Measurement is Shorter. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid.
D-82
(2) Leading Edge Registration in Enlargement Mode

z Important This adjustment should be made after the adjustment of leading edge registration in the full size mode.
1.
1136D034AA
After the 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 adjustment in the reduction mode. If it deviates from the specifications, perform the following steps to make the adjustment of leading edge registration in the enlargement mode.)
2. 3.
With the Adjust 1/2 menu on the screen, touch
Next
to show the Adjust 2/2 menu.
Touch the select key t or s to highlight A11 Scan Regist Enlargement.
1156D166CA
1156D156CA
D-83
4. 5.
1156D149CA
D-84
(3) Leading Edge Registration in Reduction Mode

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, perform the following steps to make the adjustment of leading edge registration in the reduction mode.)
1136D035AA
z Important This adjustment should be made after the adjustment of leading edge registration in the full size mode. 2. 3. Call the Adjust 1/2 menu to the screen. Touch the select key t or s to highlight A5 Scan Regist Reduction.
1156D138CA
1156D153CA
D-85
4. Touch the shift key A or " to change the setting value. 5. Touch Enter to validate the setting.
1156D157CA
D-86
(11) Adjustment of the Leading Edge Registration for Book Second Page
z Requirement D Dimension A on the copy of a test chart (A3 or 11 C. D Setting range: 45 to 55 17) as
shown on the left should measure 20 "3.0 mm and B equals
1136D036AA
z Important This adjustment should be made after the adjustment of the leading edge registration.
1.
Place the 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.
1136D037AA
2.
On the Basic screen, touch
Origi. " Copy
; then, select
Separation
1156D140CA
1156D158CA
3.
Select
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 specifications, perform the following steps to make the adjustment.)
1156D161CA
D-87
4.
With the Adjust 1/2 menu on the screen, touch light A6 Book B-Scan Regist.
Next
to show the Adjust 2/2 menu. Then, high-
1156D166CA
1156D163CA
5. Touch the shift key A or " to change the setting value. 6. Touch Enter to validate the setting.
Setting Instructions D If dimension 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.
1156D163CA
D-88
(12) Adjustment of the Image Leading Edge Erase Width

z Requirement Dimension A D The erase width, dimension A, on the copy of the GTCtest chart should measure 1.0 to 6.5 mm. D Setting range: 45 to 55
1134D135AA
z Important This adjustment should be made after the adjustment of the leading edge registration and adjustment of the leading edge registration for book second page. 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. Make three single copies on A3 or 11 17 paper in full size mode and check the third copy for leading edge erase width. (If the erase width deviates from the specifications, perform the following steps to make the adjustment of image leading edge erase width.)
2.
1136D040AA
3. 4.
With the Adjust 1/2 menu on the screen, touch Next
Touch the select key t or s to highlight A12 Leading Edge Erase Adjust.
1156D166CA
1156D159CA
D-89
5. 6.
Setting Instructions D If dimension A on the copy is longer than 6.5 mm, decrease the setting value. D If 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.
1156D162CA
D-90
(13) Adjustment of the Image Trailing Edge Erase Width

z Requirement 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.
Dimension A
1134D134AA
z Important D This adjustment should be made after the adjustment of the image leading edge erase width. D Before this adjustment can be made, Trailing Edge Erase on the Tech. Rep. Choice 2 screen must be set to Yes.
1.
2.
1136D042AA
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. Make three single copies on A3 or 11 17 paper in full size mode and check the third copy for trailing edge erase width. (If the erase width deviates from the specifications, perform the following steps to make the adjustment of image trailing edge erase width.)
3. 4.
With the Adjust 1/2 menu on the screen, touch
Next
Touch the select key t or s to highlight A13 Trailing Edge Erase Adjust.
1156D166CA
1156D164CA
D-91
5. 6.
Setting Instructions D If dimension A on the copy is longer than 5.5 mm, decrease the setting value. D If 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.
1156D160CA
D-92
(14) Adjustment of Edge Erase

z Requirement D Dimension A, which is the erase width from the front edge on the copy of the GTC-test chart, should be in the range between 0.5 mm and 4.0 mm.
1136D043AA
z Important This adjustment must be made after the adjustments of reference positions. 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. 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 81/2 11 crosswise paper.
2.
1136D044AA
3.
If the front edge erase width deviates from the specifications, adjust as necessary by turning the Edge Erase Adjusting Screw. Adjusting Instructions
D If dimension A on the copy (of the original width of 3.0 mm) is narrower than 0.5 mm, tighten the Adjusting Screw. D If dimension A on the copy (of the original width of 3.0 mm)
1134D114AA
is wider than 3.0 mm, loosen the Adjusting Screw.
D-93
3-7. OTHER ADJUSTMENTS (1) Focus-Positioning of the Scanner and Mirrors Carriage
z Requirement D With the Scanner positioned correctly with reference to the Scanner Drive Cable, there should be no gap between one end of the Scanner/Mirrors Carriage Positioning Jig and the Scanner, and between the other end of the jig and the Mirrors Carriage. The distance between the Scanner and Mirrors Carriage should be 83.5 mm. 1. 2. 3. Remove the Original Cover, Upper Rear Cover, and Original Glass. Slide the Scanner to a position at which the hole is aligned with the Scanner Positioning Screw. Insert a screwdriver into the hole and loosen the Scanner Positioning Screw. (This allows the Scanner Drive Cable to move independently of the Scanner.)
1134D138AA
Scanner Positioning Jig
4.
Align the rectangular hole in the upper copier frame with the U-groove in the Scanner. Insert the Scanner Positioning Jig.
1136D046AA
5.
Install the Scanner/Mirrors Carriage Positioning Jig between the Scanner and the Mirrors Carriage.
Scanner/Mirrors Carriage Positioning Jig 1136D047AA
6. 7. 83.5mm
Move the Mirrors Carriage in the direction of the arrow. Check that both ends of the Scanner/Mirrors Carriage Positioning Jig have no gap.
1136D048AA
D-94
8.
Tighten the Scanner Positioning Screw which was loosened in step 3.
1139D051AA
D-95
(2) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller (D.B. Adjustment)
z Requirement D The gap between the Doctor Blade and Sleeve Roller should be 0.53 " 0.05 mm. 1. 2. Remove the IU, PC Drum Charge Corona, and PC Drum. Remove two screws and the Developer Scattering Prevention Plate.
1136D049AA
3.
Using a brush, whisk developer off the surface of the Sleeve Roller.
1136D050AA
4.
Install the Sleeve/Magnet Roller Positioning Jig into the IU.
1136D051AA
5.
6.
Loosen three screws that secure the Doctor Blade. Insert the D.B. Adjusting Jigs between the Doctor Blade and Sleeve Roller. Press down the Doctor Blade until it positively contacts the D.B. Adjusting Jigs. Then, tighten the three screws to secure the Doctor Blade.
1136D052AA
D-96
(3) Adjustment of the PC Drum Paper Separator Finger Position

z Requirement D The gap between the PC Drum and Paper Separator Fingers should be 1.0 " 0.5 mm when Separator Solenoid SL1 is in the deenergized position. z Important D Use care not to deform the Separator Fingers during the adjustment procedure. 1. Attach the PC Drum Paper Separator Finger Positioning Jig to the IU.
1136D053AA
2.
Using an Allen wrench, adjust the position of one of the two Paper Separator Fingers. (Either one will do.) Adjusting Instructions 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
1136D054AA
1136D055AA
3.
After this adjustment, check that the other finger also meets the above requirement. NOTE If the fingers cannot be positioned correctly through steps 2 and 3, loosen the two solenoid mounting screws and adjust the position of the solenoid. Then, repeat steps 2 and 3.
1136D056AA
D-97
(4) Adjustment of Manual Feed Paper Take-Up Solenoid SL4

1. 2. Remove the SL4 mounting bracket. (For the removal steps, see p. D-25.) 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.
1134D119AA
3.
Loosen two screws that secure the SL4 and slide SL4 all the way in the direction of the arrow.
1134D120AA
4.
Slowly move the SL4 in the direction opposite that in step 3. When the two Stoppers just swing into the upright position, tighten the two SL4 mounting screws.
1134D121AA
D-98
(5) Adjustment of Exit/Duplex Solenoid SL5

z Requirement D With the lever in contact with the stopper (SL5 in the deenergized position), the gap between the plunger rubber washer and the solenoid should be 4.0 to 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. 1. 2. Open the Left Door. Loosen two screws that secure SL5.
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 screws.
1156D173AA
D-99
MISCELLANEOUS
1. 2. 3. 4. Open the Right Door. Remove two screws and the cover. Remove the harness from the locking wiring saddle. Unplug three connectors.
4-1. Installation of the Plug-In Counter (Option) Mounting Bracket
1156D033AA
5.
Remove two screws and the Right Door.
1156D034AA
6. 7.
Remove the Counter Cover. Remove four screws and the Right Cover.
1136D060AA
8. 9.
Remove the IU. Remove two screws and the cover.
1136D061AA
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 Plug-In Counter of System Input available from the Tech. Rep. mode.
1136D062AA
D-100
4-2. ADJUSTMENT OF THE RIGHT DOOR

If the Right Door has been removed and reinstalled, the position of the actuator of Right Upper Door Interlock Switch S22 may deviate from the correct position. Hence, the necessity of the following adjustment. 1. Mount the Right Door with two screws. (At this time, only temporarily tighten these screws.)
1156D100AA
2.
Lightly close the Right Door so that the S22 actuator will not contact the frame.
1134D116AA
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.
1134D117AA
4.
Open and close the Right Door two to three times to check that the S22 actuator properly actuates and deactuates S22.
1134D118AA
D-101
1156SBD000EA

MINOLTA CO., LTD.
1156-7992-11 97046000 Printed in Japan
Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01
1156SBS000AA
EP5000/EP4000
SWITCHES ON PWBs, TECH. REP. SETTINGS
1156SBS000BA
CONTENTS
1 PRECAUTIONS FOR HANDLING THE PWBs . . . . . . . . . . . . . . . . . . . S-1 1-1. Precautions for Transportation and Storage . . . . . . . . . . . . . . . . S-1 1-2. Precautions for Replacement and Inspection . . . . . . . . . . . . . . . S-1 . . . . . . . . . . . . . . . . . S-2 2-1. Control Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2 2-2. Explanation of the Touch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3 . . . . . . . . . . . S-5 3-1. PWB-I Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5 3-2. Tech. Rep. Settings Switches Board PWB-I . . . . . . . . . . . . . . . . . S-5 .................................... Users Choice Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . Users Choice Function Setting Procedure . . . . . . . . . . . . . . . . . Users Choice Function Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings in the Users Choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7 S-7 S-7 S-8 S-9 S-16 S-16 S-16 S-17 S-19 S-19 S-20 S-24 S-25 S-32 S-34 S-34 S-35 S-37 S-39 S-40 S-40
CONTROL PANEL KEYS AND TOUCH PANEL
FUNCTIONS OF SWITCHES AND POINTS ON PWB-I
USERS CHOICE MODE 4-1. 4-2. 4-3. 4-4.
TECH. REP. MODE 5-1. 5-2. 5-3. 5-4.
......................................... Tech. Rep. Mode Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . Tech. Rep. Mode Function Setting Procedure . . . . . . . . . . . . . . . Tech. Rep. Mode Function Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings in the Tech. Rep. Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Tech. Rep. Choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. System Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. I/O Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. Last Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. ROM Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. RD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. Accessory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. Level History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. Machine Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. Admin. Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS
6 FACTORY SETTING ........................................ 6-1. Factory Setting Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Factory Setting Function Setting Procedure . . . . . . . . . . . . . . . . 6-3. Factory Setting Function Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-41 S-41 S-41 S-42 S-42 S-44
ii
1151SBS0100A
1 PRECAUTIONS FOR HANDLING THE PWBs

1151SBS0101A
1-1. Precautions for Transportation and Storage

a) Before transporting or storing the PWBs, put them in protective conductive cases or bags so that they are not subjected to high temperature (and they are not exposed to direct sunlight). b) Protect the PWBs from any external force so that they are not bent or damaged. c) Once the PWB has been removed from its conductive case or 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) b) c) d) Whenever replacing the PWB, make sure that the power cord of the copier has been unplugged. When the power is on, the connectors must not be plugged in or unplugged. Use care not to strap the pins of an IC with a metal tool. When touching the PWB, wear a wrist strap and connect its cord to a securely grounded place whenever possible. If you cannot wear a wrist strap, touch the metal part to discharge static electricity before touching the PWB.
S-1
1149SBS0200A
CONTROL PANEL KEYS AND TOUCH PANEL
* For more details, see the Operators Manual shipped with the copier.
1149SBS0201A
2-1. Control Panel Keys

1149O002EA
Display Contrast Knob D Varies the brightness of the Touch Panel. User Mode Key D Changes the screen to the User Mode setting screen. Touch Panel D Shows various screens and messages. 10-Key Pad D Numeric keypad used for entering the number of copies to be made, zoom ratio, access number, and the Tech. Rep. mode settings. Access Mode Key D When either 100 Accounts or 1000 Accounts has been selected for the Copy Track function, the entry of the access number and the press of this key (Access Mode) will allow the user to make copies. Energy Saver Key D Sets the copier into the Energy Saver mode. Interrupt Key D Sets the copier into, or lets it leave, the Interrupt mode.
Panel Reset Key D Clears all control panel settings made previously, initializing the copier. Note: It does not, however, clear the contents of the zoom and job program memory and the settings made immediately before the Interrupt mode. Clear Key D Clears the number-of-copies setting, zoom ratio, and counter count. Stop Key D Stops a copy cycle. Start Key D Starts a copy cycle. Mode Check Key D Shows the Mode Check screen on which the user can check the current copying settings. Job Recall Key D Selects the Job Recall screen which allows the user to recall or check a copy-job program previously stored in memory.
S-2
1149SBS0202A
2-2. Explanation of the Touch Panel

1149SBS020201A
1. Basic Screen
D The Basic screen is an initial screen that appears when the copier is turned ON, panel is reset, or when auto clear is activated.
1149O263CA
Supplementary Function Keys D Selects the corresponding menu screen, either Auxiliary, Finishing, or Orig. " Copy. 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 level, zoom ratio, and copy paper. Function Display D Shows graphic representations of the settings currently made for Orig. " Copy and Finishing.
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1149SBS020202A
2. Warning Screens
D The warning screen may be a malfunction display, error display, warning display, or a caution display. <Malfunction Display> D A malfunction display is given when trouble occurs which cannot be corrected by the user. Example: Malfunction that can be identified with a 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.
1149O421CA
1149O387CA
<Warning Display> 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. Example: Unmatched paper size in Auto Paper
<Caution Display> D A caution display is given when, though further copier operation will be possible, it could result in a malfunction. Example: Toner empty
1149O422CA
1149O385CA
S-4
1151SBS0300A
FUNCTIONS OF SWITCHES AND POINTS ON PWB-I
1151SBS0301A
3-1. PWB-I Location
1156S001AA
1156SBS0302A
3-2. Tech. Rep. Settings Switches Board PWB-I
1149S002BB
Symbol S1
Name Trouble Reset Switch Initialize Switch
Description Resets a malfunction including those of the Exposure Lamp (C04XX) and fusing (C05xx). 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. Ground terminal used for memory clear. Initializes all data except the counts of electronic counters, access numbers and administrator number for Copy Track, and RD mode functions.
PJ2
TP1 TP3
GND Test Point Memory Clear Test Point
S-5
<Clearing Procedures> D Initialize Points PJ2 1. Turn OFF the Power Switch. 2. With PJ2 closed, turn ON the Power Switch. 3. In approx. 5 sec. open PJ2. 4. Check that the message Initialize completed is shown on the Touch Panel, then touch Enter. D Memory Clear Test Point TP3 1. Turn OFF the Power Switch. 2. With the circuit across TP1 and 3 closed, turn ON the Power Switch. 3. In approx. 5 sec. open the circuit across TP1 and 3. 4. Check that the message Memory Clear completed is 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 Misfeed display Malfunction display (except Exposure Lamp and fusing system) Malfunction display (all including Exposure Lamp and fusing system) Erratic operation/display User mode Service mode F5/F7 setting values System Input Accessory Test Level History Adjust mode f : Cleared (initialized) Front Door Open/Close f f Trouble Reset Switch (S1) f f Initialize Switch (PJ2) f f Memory Clear Test Point (TP3) f f
* * * * * * * * * *: Not cleared:
f * * * * * * * *
f f * * * * * * *
f f f f f f f f f
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1149SBS0400A
USERS CHOICE MODE
D The Users Choice mode available through the User Mode menu is used to make various settings according to the users needs.
1149SBS0401A
4-1. Users Choice Selection Screen
1149O262DA
1149SBS0402A
4-2. Users Choice Function Setting Procedure

<Setting Procedure> 1. Press the User Mode key on the control panel and then touch the Users 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. <Exiting the Mode> Perform any one of the following steps to go back to the Basic screen. D Press the Panel Reset key on the control panel. D Touch Exit on the Touch Panel.
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1156SBS0403A
4-3. Users Choice Function Tree

Mixed Orig. Detection Language Selection 1/6 Paper Priority Copy Mode Priority Manual feed expansion Expo. Mode Priority Expo. Level Priority 2/6 Manual Expo. Adjust Finishing Priority Auto Panel Reset Energy Saver Mode Users Choice 3/6 Drum Dehumidifier Counter Removal Intelligent Sort Confirmation Beep 4/6 Original Thickness Smaller Originals Custom 2in1 Custom 2in1 Separation 5/6 Custom Book Copy Special Paper Orig. " Copy Default Auto Power-off Mode 6/6 Original on Glass Administrator Mode
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1156SBS0404A
4-4. Settings in the Users Choice

1156SBS040401A
[1/6]
Touch Panel Display Mixed Orig. Detection Setting (The default is Highlighted .)
Select whether to enable (ON) the Mixed Original Detection mode or not (OFF) when power is turned ON or the Panel Reset key pressed. ON OFF
Language Selection
Select the language of the Touch Panel messages. Metric Areas English Dutch Portuguese Swedish German Italian Danish Finnish French Spanish Norwegian Greek English Japanese Inch Areas German Chinese French Portuguese
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 turned ON or the Panel Reset key pressed. Auto Paper Auto Size Manual
Manual Feed Expansion
Select whether to use Manual feed expansion (ON) when using the Multi Bypass Tray or not (OFF) ON
OFF
S-9
1156SBS040402A
[2/6]
Touch Panel Display Expo. Mode Priority Setting (The default is Highlighted .)
Specify the default exposure mode selected automatically when power is turned ON or the Panel Reset key pressed. Auto Manual
Expo. Level Priority
Auto: Manual:
Select the default exposure level in the Auto Exposure mode. Set the default exposure level in the Manual Exposure mode. <Auto Exposure> Lighter Normal <Manual Exposure> Darker
Lighter
Normal
Darker
NOTE: EXP. 1 (Lighter) to EXP. 9 (Darker) Manual Expo. Adjust Determine the default voltage curve (EXP. level) in the Manual Exposure mode, as optimized by the type of original. Mode 1 Mode 2 Mode 3 Halftone images, photos Ordinary originals Originals with a colored background or faint texts
<Manual Exposure Voltages in Different Modes> Manual Exposure Voltage (V) EXP. Mode 1 Mode 2 Mode 3 1 +8 +8 +8 2 +5 +6 +7 3 +2 +4 +6 4 +1 +2 +3 5 0 0 0 6 1 2 3 7 2 4 6 8 5 6 7 9 8 8 8
NOTE: EXP. 5 uses as reference the voltage value automatically adjusted by the F5 operation. Finishing Priority Select the default finishing type when the copier is equipped with a Sorter or Staple Sorter. Non Sort Sort Group Sort Staple + Hole Punch
NOTE: Hole Punch can be combined with any one of the functions.
S-10
1156SBS040403A
[3/6]
Touch Panel Display Auto Panel Reset Setting (The default is Highlighted .)
Specify the default exposure mode selected automatically when power is turned ON or the Panel Reset key pressed. 30 sec. 3 min. 1 min. 5 min. 2 min. No Reset
Energy Saver Mode
Set the time it takes the copier to enter the Energy Saver mode after a copy cycle has been completed or the last key operated. Use the 10-Key Pad to set the time (1 to 240 min.). 1 to 240 (15 min.) OFF
NOTE: The OFF setting is available for European areas only. Drum Dehumidifier Select whether to allow the copier to enter the Drum Dehumidifier mode automatically after it has been turned ON, or not. ON Counter Removal OFF
Select whether to reset the panel or not when the Plug-In Counter is pulled out of the copier, a magnetic card is pulled out of the Data Controller, or the Access Mode key is pressed. ON OFF
1156SBS040404A
[4/6]
Touch Panel Display Intelligent Sort Setting (The default is Highlighted .)
Select whether to turn ON or OFF the function that automatically switches between Sort and Non-Sort according to the number of originals loaded in the document 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 the Touch Panel is touched. ON Original Thickness OFF
Select whether to allow (Thin) the user to make copies from thin originals in addition to the standard ones or not (Standard) using the document feeder. Standard The orginal is pressed against the Original Width Scale when stopped. Thin The original is not pressed against the Original Width Scale when stopped.
Smaller Originals
Select whether to enable (ON) a copy cycle or not (OFF) when it is initiated by pressing the Start key with an original of the smallest detectable size (metric areas: A5 or smaller; inch areas: Letter or smaller) placed on the Original Glass. ON OFF
The copy cycle is run using the paper A warning message is given and the loaded in the default paper source. copier inhibits the start of this copy cycle. NOTE: The default setting is OFF for the metric areas and ON for the inch areas.
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1156SBS040405A
[5/6]
Touch Panel Display Custom 2in1 Setting (The default is Highlighted .)
Make the settings for Paper, Zoom, Margin, and Erase that are automatically recalled when 2-in-1 copy is selected. Function Paper Description Auto Paper, sizes of paper loaded in drawers Initial Setting Auto Paper Metric areas: X0.707 Inch areas: X0.647
Zoom
Auto Size, fixed zoom ratios
Margin
Position: Right edge, left edge Mode: Shift-for-Margin, Margin-by-Reduction Width: Metric areas 5, 10, 15, 20 mm Inch areas 1/4, 1/2, 3/4, 1 Position: Right Edge, Left Edge, Frame, Top Edge, Center, Frame+Center Width: Metric areas 5, 10, 15, 20 mm Inch areas 1/4, 1/2, 3/4, 1
No margin
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
No erase
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 automatically recalled when 2-in-1 separation copy is selected. Function Paper Description Auto Paper, sizes of paper loaded in drawers Initial Setting 1st Drawer Metric areas: X1.414 Inch areas: X1.294
Zoom
Auto Size, fixed zoom ratios
Margin
Position: Right edge, left edge Mode: Shift-for-Margin, Margin-by-Reduction Width: Metric areas 5, 10, 15, 20 mm Inch areas 1/4, 1/2, 3/4, 1 Position: Right Edge, Left Edge, Frame, Top Edge, Center, Frame+Center Width: Metric areas 5, 10, 15, 20 mm Inch areas 1/4, 1/2, 3/4, 1
No margin
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
No erase
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.
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[5/6]
Touch Panel Display Custom Book Copy Setting (The default is Highlighted .)
Make the settings for Paper, Zoom, Margin, and Erase that are automatically recalled when Book copy is selected. Function Paper Zoom Description Sizes of paper loaded in drawers Fixed zoom ratios Position: Right edge, left edge Mode: Shift-for-Margin, Margin-by-Reduction Width: Metric areas 5, 10, 15, 20 mm Inch areas 1/4, 1/2, 3/4, 1 Position: Right Edge, Left Edge, Frame, Top Edge, Center, Frame+Center Width: Metric areas 5, 10, 15, 20 mm Inch areas 1/4, 1/2, 3/4, 1 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 No erase X1.000 Initial Setting
Margin
No margin
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. Special Paper Set up a drawer for special paper loading. Normal Recycled Insert Sheet Not for 2-Sided Initial setting: Normal (for all drawers)
Type of Paper Normal Recycled Insert Sheet Not for 2-Sided
Auto Paper f f NOTE 1 f NOTE 2
Automatic Drawer Switching (only of paper of the same type) f f f NOTE 2
f: Enabled : Disabled NOTE 1: A warning display is given and the copy cycle is started by pressing of the Start key. NOTE 2: Enabled only in the 1-sided copying mode.
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1156SBS040406A
[6/6]
Touch Panel Display Orig. " Copy Default Setting (The default is Highlighted .)
Select the type of Orig. " Copy setting selected automatically when the copier is turned ON or Panel Reset key pressed. If Duplex only is selected for Simplex/Duplex of the Tech. Rep. Choice function, neither 1 " 2 nor 1 " 2in1 are displayed. 1"1 1"2 1 " 2 in1 1 " 2-2 in1 2"2
NOTE: Some of the functions may not be displayed depending on the type of options the copier is equipped with. Auto Power-OFF Mode Select whether to turn ON or OFF the Auto Shut Off function that shuts down the copier a given period of time after a copy cycle has been completed or the last key operated. Selecting ON means setting the time it takes the Auto Shut Off function to be activated, that can range from 1 min. to 240 min. OFF 1 to 240 EP4000: 90 min. EP5000: 60 min.
NOTE: OFF is displayed when Enable is selected for Non-Auto Shut off of the Administrator Mode function. 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 one left on the glass. Beep ON Administrator Mode Copy Track Beep OFF
The entry of the Administrator # set using the Tech. Rep. mode permits the settings of the following functions. Select the number of accounts to be controlled. OFF 100 Accounts 1000 Accounts
Copy Track
This function is displayed when the above Copy Track setting is changed, prompting you to select whether to initialize (YES) the copy track data so far taken or not (NO) YES (initialize) NO (do not initialize)
Copy Track Data
When Count Reset is touched, it clears all data under control.
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[6/6]
Touch Panel Display 1/25 22/25 Setting (The default is Highlighted .)
<100 Accounts> The copy track data of the selected page is displayed (Account No., Total Counter, Size Counter, Limit, ID). Count Reset : Clears the total and size counters of all accounts. No. : Enter the set account number from the 10Key Pad. Total : Displays the count of the Total Counter. (It can also be cleared with the Clear key.) Size : Displays the count of the Size Counter. (It can also be cleared with the Clear key.) Limit : Enter the maximum number of copies that can be made from the 10-Key Pad. ID # : Enter the access number (0001 to 9999) from the 10-Key Pad. <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 corresponding to the ID numbers. Determine the number of copies or copy sets that can be set using the 10-Key Pad. Select whether to enable or disable the Auto Power-off Mode setting available from Users Choice. OFF Disable Enable OFF key is not displayed. OFF key is displayed.
1~ 901~
Max. Copy Sets Non-Auto Shut off
User Help * Displayed when a DT-103 is mounted.
<Transmission Procedure> 1. Using the B or Y key, select the user claim number and then, from the 10-Key Pad, enter the 3-digit user claim code (up to six entries are possible). 2. Touch Data Send to start the transmission.
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1149SBS0500A
5 TECH. REP. MODE

D This mode is used by the Tech. Rep. to set, check, adjust, and/or program various service functions.
1149SBS0501A
5-1. Tech. Rep. Mode Menu Screen
1149O423CB
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. Stop key ' 0 ' Stop key ' 1
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 key on the control panel.
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1156SBS0503A
5-3. Tech. Rep. Mode Function Tree
Function
F1 Paper Passage F3 Exp. Lamp F5 Optimum & AE F7 Orig. Sensor Developer
Paper Path Sensors
F8 ATDC Adjust FF F8+F5
Tech. Rep. Choice 1 Key Counter Size Counter Total Counter Maintenance Call Copy Kit Counter Toner Empty Stop Type of Vendor Tech. Rep. Choice 2 Auto Paper Config. Leading Edge Erase Trailing Edge Erase Loop Adjust (Drawer) Loop Adjust (Man) Function Limit Tech. Rep. Choice 3 Image Exposure Simplex/Duplex Bin Movement Universal Tray 13x Universal Tray 14x Automatic feeding adjust Stack
Tech. Rep. Mode
Tech. Rep. Choice
System Input
Change Fixed Zoom Ratio Paper Size Input Marketing Area Key Counter Telephone # Input
Counter
Paper Jam Retry Trouble Counter Reset
Maintenance Port/Option Consumables Auto CPU Reset
S-17
I/O Check
IC Port Data Check Paper Path Sensors Check Memory Check Controller Board Check Panel Indication Check
Last Trouble
Rom Version
Tech. Rep. Mode
RD Mode
Accessory Test
ADF Check Sorter Check
Level History
Machine Status
Admin. Mode
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1149SBS0504A
5-4. Settings in the Tech. Rep. Mode

1149SBS050401A
1. Function
D This function allows the Tech. Rep. to make the various functional tests and adjustments. <Setting Procedure> 1. Select the particular function to be run. 2. Press the Start key to start the test. 3. Press the Stop key to stop the test.
Tech. Rep. Mode " Function

Touch Panel Display F1 Paper Passage Operation A paper passage test is carried out to check for correct sensor operation without having to wait for the copier to complete warming up. <Procedure> 1. Before entering the Tech. Rep. Mode, select the paper feed source, then touch Paper Path Sensors. 2. Press the Start key. This starts a paper take-up and feeding sequence and the copier shows 1 or 0 depending on the condition of each sensor. NOTE: Pressing 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. Checks to see if the Exposure Lamp lights up properly. (It runs for 30 sec.) Makes the following automatic adjustments: Vg level, Manual exposure level and AE Sensor optimum exposure level. (It runs for 30 sec.) <Procedure> 1. Touching F5 automatically brings you to the next screen (AE level adjustment screen). 2. Using the A or " key, show the desired number (44 to 56) and press the Start key. This starts the automatic adjustment sequence. 3. Touch Test Copy to check for image. Makes an automatic adjustment of the Original Size Detecting Sensors. When Developer is pressed, F8 and FF functions are displayed and disappear when the corresponding operation has been completed. Runs the Developing Unit to agitate developer and makes an automatic adjustment of the ATDC Sensor level. (It runs for 5 min.) Runs the F8 and F5 operations.
F3 Exp. Lamp F5 Optimum & AE
F7 Orig. Sensor Developer F8 ATDC Adjust FF F8 + F5
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1156SBS050402A
2. Tech. Rep. Choice

D This function allows the Tech. Rep. to make various settings and adjustments.
Tech. Rep. Mode " Tech. Rep. Choice

Touch Panel Display Key Counter Operation Select the condition by which the Key Counter count is increased. # of Sheets NOTE: See the Count-up Table for details. Size Counter Select the size of the paper to be counted by the Size Counter. Metric Areas No Count A3/B4 A3 A3/B4/FLS Inch Areas No Count 11X17/LGR 11X17 11X17/11X14 Copy Cycle
NOTE: See the Count-up Table for details. Total Counter Select the conditions (paper size and 2-sided copying) by which the Total Counter count is increased. Mode 0 Mode 1 Mode 2 1 count per 1 copy cycle Multiple count-up according to paper size and 2-sided copying Multiple count-up according to paper size and 2-sided copying
NOTE: See the Count-up Table for details. <Count-up Table> Copying Size Total 0 Total (mechanical, electronic) Size (electronic) 2-Sided Total (electronic) 2-Sided Size (electronic)
Counting
1-Sided
Sizes other than those Set sizes set
2-Sided
Sizes other than those set Set sizes
Manual Bypass Mode
Mode 1 1 0 0 0 1 1 1 1 2 0 1 1
Mode 1 2 1 0 0 2 2 2 2 1 2 2 2 1 0
Mode 1 2 0 1 0 2 2 2 2 2 0 2 2 1 1 1 2
Mode 1 4 2 1 1 4 4 2 4 0 4 4 4 4 0
1 1 0 0 0 1 1
Key (me- copies chanical) Counting
copy cycles
0: No count 1: 1 count 2: 2 counts 4: 4 counts
S-20

Touch Panel Display Maintenance Call Operation Select whether to enable or disable the maintenance call reminder message that is displayed when the maintenance counter count reaches the preset value. NO YES
NOTE: Up to five maintenance counters may be set and the maintenance call reminder message is given when the count of any one of these five counters reaches the preset value, together with the display of maintenance code M1. Copy Kit Counter Select whether to enable or disable the Copy Kit counter; if the counter is to be enabled, select whether to allow or inhibit the start of a copy cycle when the count reaches the preset value. NO Mode 1 Mode 2 Disables the Copy Kit counter. Copying not inhibited after the count reaches the preset value. Copying inhibited after the count reaches the preset value.
NOTE: The Copy Kit counter is enabled by selecting mode 1 or 2. When the count reaches the preset value, the maintenance code M4 is displayed. Toner Empty Stop Select whether or not to inhibit copying when a toner-empty condition is detected. Enable Copy Disable Copy
NOTE: When Disable Copy is selected, copying is inhibited when a T/C of 2.5% or less is detected. Type of Vendor Make the display setting according to the type of optional vendor mounted on the copier. (Japan only) Key Counter Coin Vendor Card Vendor NOTE: Select Key Counter. No other setting should be made. Auto Paper Config. Select either Inch/Metric or Metric for rounding off the original size detected. Inch/Metric The measurement is rounded to the nearest standard inch or metric size. The measurement is rounded to the nearest standard metric size. Disables the Copy Kit counter.
Metric
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Touch Panel Display Leading Edge Erase Operation Select whether to enable (Yes) or disable (No) the leading edge erase. NO YES
Trailing Edge Erase
Select whether to enable (Yes) or disable (No) the trailing edge erase. NO YES
Loop Adjust (Drawer)
Adjust the length of the loop before the Synchronizing Rollers to be formed in paper fed from the copier drawer.
Display Description Loop length approx. 1 mm Loop length approx. 3 mm Loop length approx. 5 mm Loop length approx. 7 mm Display Description Loop length approx. 9 mm Loop length approx. 11 mm Loop length approx. 13 mm
47 48 49 50
51 52 53
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 Loop length approx. 1 mm Loop length approx. 3 mm Loop length approx. 5 mm Loop length approx. 7 mm Display Description Loop length approx. 9 mm Loop length approx. 11 mm Loop length approx. 13 mm
47 48 49 50
51 52 53
Function Limit
Select whether to limit (ON) the functions that can be set on the control panel or not (OFF). Functions that can be set are limited to the number of copies to be made, paper size, zoom ratio, and exposure level only. All functions can be set.
ON
OFF
S-22

Touch Panel Display Image Exposure Operation Vary the Vg voltage to set the desired image density.
Display Description Display Description
47 48 49 50 Simplex/Duplex
Vg Vg Vg Vg
90V 60V 30V " 0V
51 52 53 54
Vg Vg Vg Vg
+30V +60V +90V +120V
Select the copying mode types that can be selected in Orig. " Copy Default of Users Choice. Both Duplex only Permits selection of all copying modes. Permits selection of 2-sided copying modes only.
Bin Movement
Select whether or not the Sort Bins will automatically move upward after the last copy is ejected into the Bins. ON OFF After the last copy, the Sort Bins automatically move upward. After the last copy, the Sort Bins do not move upward.
Universal Tray 13x
Set the inch size of paper to be used in the Universal Tray. 8" 8 8
Universal Tray 14x
Set the inch size of paper to be used in the Universal Tray. 8" 8
Automatic feeding adjust
Select whether to display the number of originals that need to be returned when a jam occurs while using the ADF.
YES
NO
Stack
Select whether or not the Sorter automatically stacks the copy sets after the last copy is ejected into the Sort Bins when there are 20 or fewer copy sets made in non-staple mode. Mode 1 Mode 2 The copy sets are not stacked. The copy sets are stacked.
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1149SBS050403A
3. System Input
D This function allows the Tech. Rep. to change the fixed zoom ratios, set the paper size, define the marketing area, configure for the Key Counter, and input the telephone number.
Tech. Rep. Mode " System Input

Touch Panel Display Change Fixed Zoom Ratio Operation Change a fixed zoom ratio to a desired value in the range between X0.500 and X2.000. <Procedure> 1. Select the fixed zoom ratio to be changed and clear the setting by pressing the Clear key. Note: If a ratio is mistakenly cleared, pressing the Panel Reset key will recover the ratio. 2. Enter the new zoom ratio from the 10-Key Pad. 3. Touch Enter to validate the new setting. Set the size of the paper used in each paper source. <Procedure> 1. Select the paper 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. Select the marketing area to set the paper size and fixed zoom ratios. MJ MC MH Other Areas
Paper Size Input
Marketing Area
Note: Be sure to initialize the copier after the marketing area has been selected. Key Counter Select whether or not to inhibit copying if a Key Counter is not inserted when the copier is equipped with a Key Counter. ON OFF Inhibits copying if the Key Counter is not inserted. Permits copying even if the Key Counter is not inserted.
Note: Be sure to select ON when the copier is equipped with a Key Counter. Telephone # Input Input the telephone number that will appear on the Touch Panel when a malfunction occurs in the copier. <Procedure> 1. Enter the phone number (consisting of up to 19 digits) from the 10-Key Pad. Note: Use the Interrupt key to enter a hyphen . 2. Touch OK to validate the phone number setting.
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1156SBS050404A
4. Counter
D This function shows the counts of the various counters, thus aiding the Tech. Rep. in performing service jobs. <Setting Procedure> 1. Select Counter. 2. Select the desired counter function. 3. Clear or set the count according to the instructions given on the screen. <Clearing All Counts of a Counter Type at Once> 1. Touch the Counter Reset key. 2. Select the type of counter to be cleared all at once. 3. Touch Enter. This clears all counts of the counter selected.
Tech. Rep. Mode " Counter

Touch Panel Display Paper Operation Shows the number of copies made on each paper size or type (S0: standard paper; S1: recycled paper; S2: special paper; S3: disabling 2-sided copying). <Paper 1/2> Paper Size A3 B4 A4 B5 A5 11 X 17 11 X 14 Legal Letter 5X8 FLS <Paper 2/2> Paper Type S0 S1 S2 S3 Note: For a paper size that can be loaded both lengthwise and crosswise, the count represents the sum of both. (Ex.: A4 lengthwise/crosswise)
<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 operation.
S-25

Touch Panel Display Jam Operation Shows the number of misfeeds that have occurred in different parts of the copier system including MCBJ (system, copier only, ADF). <Jam Counter 1/3> Display
MCBJ (System) MCBJ (Machine Only) MCBJ (ADF) Manual Feed
Description
Misfeed occurrence rate of the entire system Misfeed occurrence rate of the copier only Misfeed occurrence rate of the ADF only No. of misfeeds that occurred at the Multi Bypass Tray
Display
1st Drawer
Description
No. of misfeeds that occurred at the 1st Drawer of the copier No. of misfeeds that occured at the 2nd Drawer of the copier No. of misfeeds that occurred at the 3rd Drawer of the copier No. of misfeeds that occurred at the 4th Drawer of the copier
2nd Drawer
3rd Drawer
4th Drawer
Note 1: MCBJ (System)
: Total Counter value divided by the sum of Jam Counter values MCBJ (Machine Only) : Total Counter value divided by the sum of copier Jam Counter values : No. of originals fed through the ADF divided MCBJ (ADF) by the sum of ADF Jams. Note 2: A minus sign is appended when the denominator is 0 for each MCBJ. <Jam Counter 2/3> Display
5th Drawer
Description
No. of misfeeds that occurred at the 5th Drawer of the copier
Display
Description
Vertical Trans.
Dup Entrance No. of misfeeds that occurred at the entrance of the Duplex Unit No. of misfeeds that No. of misfeeds that Dup Exit occurred at the transoccurred at the paper port section of the copitake-up section of the er Duplex Unit Sorter No. of misfeeds that occurred at the finishing option No. of misfeeds that occurred at the document take-up section of the ADF
Horizontal Trans.
No. of misfeeds that occurred at the paper separator section of the copier No. of misfeeds that occurred at the exit section of the copier
Exit Section
ADF Feed
S-26

Touch Panel Display Jam Display
ADF Transport ADF Reverse
Operation <Jam Counter 3/3> Description

No. of misfeeds that occurred at the transport section of the ADF No. of misfeeds that occurred at the turnover section of the ADF No. of misfeeds that occurred at the exit section of the ADF
Display
SADF Feed
Description
No. of misfeeds that occurred at the SADF No. of misfeeds that occurred at the LCT
LCT
ADF Exit
Stack
No. of misfeeds that occurred at the sorter stacking
<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 operation. Retry Shows the number of paper take-up retries carried out at different paper sources. Display 1st Drawer Description
No. of paper take-up retries at the 1st Drawer of the copier retries at the 2nd Drawer of the copier
Display 5th Drawer
Description
No. of paper take-up retries at the 5th Drawer of the copier No. of paper take-up retries at the Duplex Unit No. of paper take-up retries at the Multi Bypass Tray No. of paper take-up retries at the LCT
2nd Drawer No. of paper take-up
Dup
3rd Drawer
No. of paper take-up retries at the 3rd Drawer of the copier No. of paper take-up retries at the 4th Drawer of the copier
Manual Feed
4th Drawer
LCT
<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 operation. Trouble Shows the number of malfunctions that have occurred in different parts of the copier system. <Trouble Counter 1/6> Malfunction Code
C000X C0040 C0046/7 C004A/b
Location
Main Drive Motor Suction Fan Motor Fusing Cooling Fan Optical Cooling Fan
Malfunction Code
C004C/d C0070/1 C0072 C0200
Location
Ventilation Fan Main Hopper Motor Sub Hopper Motor PC Charge Corona
S-27

Touch Panel Display Trouble Malfunction Code
C03XX C04XX C050X C0510
Operation <Trouble 2/6> Location

Control Board/Harness Exposure Lamp Fuser Warm-Up Fuser Low Temp.
Malfunction Code
C0520 C0600 C0610 C0620
Location
Fuser High Temp. Scanner Drive Syst. Lens Drive System Mirror Drive System
<Trouble 3/6> Malfunction Code

C06FX C07XX C090X C091X
Location
Scanner Interface ADF 3rd Drawer 2nd Drawer
Malfunction Code
C092X C095X C0990 - 6 C0998 - F
Location
1st Drawer 4th Drawer LCC Main-Tray LCC Shift-Tray

C09CX C0E0X C0E20 C0F02
Location
LCT Main Erase Lamp Auxil. Erase Lamp Orig. Size Det. CPU
Malfunction Code
C0F10 C0F2X C0F3X C0F79
Location
EE Sensor AIDC Sensor ATDC Sensor Paper Empty Sensor

C0FE/FX C0b0X C0b10 - 3 C0b18 - d
Location
Original Sensor Sorter (Transport) Sorter (Paper Clamp) Original Guide Motor
Malfunction Code
C0b2X C0b3X C0b4X C0b5X
Location
Sorter (Staple Unit) Sorter (Guide) Sorter (Gate Motor) Sorter (Stapler)

C0b6X C0b7X C0d00
Location
Sorter (Bin Shift) Sorter (Punch) Front/Rear Guide
Malfunction Code
C0d20 C0d5X
Location
Dup Storage Dup Drive Motor
S-28

Touch Panel Display Maintenance Operation Five different values (counts) can be set for the Maintenance Counter. Each counter is increased by 1 each time a copy is made and, when the preset count is reached, the maintenance call reminder message and maintenance code M1 appear on the Touch Panel. Note: Whether the maintenance call reminder message is given or not depends on the setting made for Maintenance of Tech. Rep. Choice. Also, copying is not inhibited even when the reminder message appears. <Setting a 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. Port/option Shows the frequency of use of each of the different parts of the copier including options to serve as a guideline for the maintenance time for the Tech. Rep. <Port/Option 1/3> Display
Manual Feed
Description
No. of sheets of paper fed from the Multi Bypass Tray No. of sheets of paper fed from the 1st Drawer No. of sheets of paper fed from the 2nd Drawer
Display
3rd Drawer
Description
No. of sheets of paper fed from the 3rd Drawer No. of sheets of paper fed from the 4th Drawer No. of sheets of paper fed from the 5th Drawer
1st Drawer
4th Drawer
2nd Drawer
5th Drawer
<Port/Option 2/3> Display

ADF Entrance
Description
No. of sheets of paper fed through the ADF take-up section. No. of originals fed through the turnover unit of the ADF No. of sheets of paper fed from the Duplex Unit
Display
Sorter
Description
No. of sheets of paper fed out of the Sorter
ADF Reverse
Staple
No. of stapling sequences performed
DUP
Punch
No. of punching sequences performed
S-29

Touch Panel Display Port/option
Display PC Drum Developer Fusing Roller
Operation <Port/Option 3/3>

Description No. of revolutions of the PC Drum, as converted to the number of sheets of A4 crosswise paper fed through the copier No. of sheets of paper fed through No. of revolutions of the Fusing Roller, as converted to the number of sheets of A4 crosswise paper fed through the copier No. of sheets of paper fed through the LCT
LCT
S-30

Touch Panel Display Consumables Operation Enter the count of the Copy Kit counter. When the count, which is increased by 1 each time a copy is made, reaches the set count, the maintenance call reminder message, together with maintenance code M4, is displayed. Note: Whether the maintenance call reminder message is given or not depends on the setting made for Copy Kit Counter of Tech. Rep. Choice. D Toner collect Enter the count of the Toner Collect counter. When the count, which increases by 1 each time a copy is made, reaches the set count, the maintenance code M2 is displayed. After wards, the machine stops operating after 10k copies are made and the maintenance call reminder message is displayed. Note: The set count should be no more than 200k for U.S.A. areas, 180k for European areas. <Setting a 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 maintenance code, then press the clear key. Shows whether a CPU overrun has occurred in different CPU-mounted boards which are monitored by the watchdog function.
Display MSC/Panel Master SCP
Auto CPU Reset
Description
PWB-B PWB-A PWB-F
Display ADF
Description
Original System Opt.
Sorter Data Controller
Exit System Opt. D-102 (PWB-A)
Note: This counter does not count the number of CPU overruns which have occurred. 1 indicates that there was a CPU overrun, while 0 indicates there was no CPU overrun. <Clearing the 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.
S-31
1156SBS050405A
5. I/O Check
D This function is used to check the sensors and boards when a paper misfeed or malfunction occurs, thereby locating the fault.
Tech. Rep. Mode " I/O Check

Touch Panel Display IC Port Data Check Operation Shows the states of the I/O ports when the copier is in stand-by. With the output ports, the change of the data in the port allows an operation check of electrical components to be performed. NOTE For details, see TROUBLESHOOTING. Paper Path Sensors Check A sheet of paper is fed through the copier to switch the state of sensors along the paper path between 1 and 0, thereby determining whether the sensors are operational or faulty. <Procedure> 1. Select the paper path (paper source, copying mode, etc.) to be checked and enter this function. 2. Press the Start key to start the sensor check sequence. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Display 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 Sensor Name 1st Drawer Paper Take-up Sensor PC56 2nd Drawer Paper Take-up Sensor PC57 3rd Drawer Paper Take-up Sensor PC21 4th Drawer Paper Take-up Sensor PC29 1st Drawer Vertical Transport Sensor PC63 2nd Drawer Vertical Transport Sensor PC64 Vertical Transport Sensor 3 PC17 Vertical Transport Sensor 4 PC22 Transport Roller Sensor PC54 Paper Leading Edge Detecting Sensor PC55 Paper Exit Sensor S53 Duplex Unit Vertical Transport Sensor 1 PC30 Duplex Unit Turnover Path Sensor PC13 Duplex Unit Paper Entry Sensor PC14 Duplex Unit Paper Take-Up Sensor PC16 Non-Sort Exit Sensor PC1 Sort Exit Sensor PC2 Punch Registration Sensor PC10
Note: The sensor detects paper when 0 and no paper when 1.
S-32
Tech. Rep. Mode " I/O Check

Touch Panel Display Memory Check Operation Touching the Memory Check key causes the copier to automatically check the ROM/RAM on MSC Board PWB-B. Result Normal Display Memory check completed. Turn the main switch OFF, and then ON. ROM ERROR MESSAGE ROM ERROR Faulty RAM ERROR VRAM ERROR LCDTC ERROR Controller Board Check Change PWB-B. Change PWB-B. Change PWB-B. Action Turn OFF, then ON, the Power Switch. Change PWB-B (IC2B) Change PWB-B (IC2B)
Touching the Controller Board Check key causes the copier to perform a selfdiagnostics of Master Board PWB-A. Result Normal Display The highlighted Controller Board Check key is returned to normal display. Action 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 above sequence is repeated. (The LEDs should alternately light up and go out in said manner.) All ON Mode Check key Start key (orange) Energy Saver key Interrupt key
Start key (green)
3. A checkered pattern appears on the Touch Panel. 4. Select an individual grid. The grid should switch from white to black, or vice versa, when it is selected. If it works that way, the corresponding liquid crystal is considered to be operational. 5. Press the Panel Reset key to complete the procedure.
S-33
1149SBS050406A
6. Last Trouble Tech. Rep. Mode " Last Trouble

Touch Panel Display Last Trouble Operation Touching the Last Trouble key shows the various copying settings made when the last malfunction occurred, thereby providing a basis for determining the cause of the problem. Item No. of copies Copy paper Zoom ratio Image density Mixed Orig. Detection Orig. " copy Finishing Cover Page Insertion OHP Interleaving File Margin Erase Description No. of copies setting Auto Paper, paper size Auto Size, zoom ratio Auto Exposure, Manual Exp. setting On, off 1 " 1, 1 " 2, 2 " 2, etc. Non-Sort, Sort, Group, Sort Staple, Punch Cover (Front), Cover (Front & Back), Copied Cover, Non-Copied Cover Copied Inserts, Non-Copied Inserts Copied Interleaves, Non-Copied Interleaves Method, position, width Method, position, width
1156SBS050407A
7. ROM Version Tech. Rep. Mode " ROM Version

Touch Panel Display ROM Version Operation Shows the ROM versions of the following boards. Display MSC/Panel Master SCP ADF Sorter Data Controller IC2 IC2B IC2A IC1F PWB-B PWB-A PWB-F PWB-A of AFR-13, AF-5 PWB-A of S-208, ST-211, S-106, ST-104 D-102 board Description
S-34
1149SBS050408A
8. RD Mode Tech. Rep. Mode " RD Mode

Touch Panel Display RD Mode ID Code Setting (The default is Highlighted .)
Make the initial settings of the copier for the Data Terminal. Entering a 7-digit ID code from the 10-Key Pad enables making the following settings. When the ID code is entered and transmitted after the initial settings have been made, it executes the transmission of MAINT. START to the Center. Used to make the initial settings and various transmissions. Enter the following data. Enter the 4-digit ID number of the Center which has been programmed in the Center personal computer. Enter the 6-digit ID number of the Data Terminal. Enter the 19-or-less-digit phone number of the modem connected to the Center personal computer. Note 1: When the office extension and outside line use different systems, 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 depending on the type of PBX system used. Set this time as follows. Fixed switching time: Enter the pause code (a single lasts 2 sec.). Varying switching time: Enter the wait code W. Settings of the following functions. Select the type of telephone line of the user. Pulse line Pulse Tone line Tone
Maintenance DT Setting CT-ID DT-ID TEL No.
Common DT Dial Mode
Auto Receive
Choose Yes or No for the auto reception function. YES NO
Note: Select Yes if the line is dedicated to the Data Terminal. Result Code Report Format Set the value according to the type of modem on the copier. Note: Dont use this function as long as 5 has been set for it. Japan only 10 BIT RAM Clear Reinitializes the Data Terminal. Maintenance NO
S-35
Tech. Rep. Mode " RD Mode

Touch Panel Display RD Mode Maintenance Data Save/Load Data Save Data Load Initial Transmission Setting ............................................................... ............................................................... Enables transmission of Data Save and Data Load. Transmits the command that saves the PPC RAM data to the Center. Transmits the command that loads the data sent by Data Save back to the PPC. 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. Used by the Tech. Rep. to notify the Center that his/her service job for the copier has been completed. Used to clear the count of the spare counter set by the Center. <Procedure> 1. Select the spare counter to be cleared. 2. Touch Call Completion which transmits a signal to the Center to clear the count of the specified counter.
Call Completion Counter Clear
S-36
1156SBS050409A
9. Accessory Test
D This function is used to make an operation check and adjustments to the ADF and Sorter or Staple Sorter.
Tech. Rep. Mode " Accessory Test

Touch Panel Display ADF Check Paper Passage & Input Check Setting (The default is Highlighted .)
Enables the operation check and adjustments to be performed for the document feeder. Makes a paper passage test in each operating mode of the ADF and checks the sensors along the paper path for operation. Step Feed Normal Empty Sensor ADF Entrance Sensor Register Sensor Exit Sensor Auto Feeder Empty Sensor 2in1 SADF Width Sensor A Width Sensor B Width Sensor C Exit Drawer Sensor Orig. Guide Home Sensor 2-Sided
Note: 1 paper present; 0 paper not present <Procedure> 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 SL1 M2 SL2 M3 SL3 M4 SL4 M5 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 modes of the ADF. 2in1 Space in between origs. 1-Sided Auto Feeder 2-Sided Regist Loop 2 in 1
Setting Stop Position
43 . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . . . . 58 7mm . . . . . . . . . . . 0mm . . . . . . . . . . . . . +8mm
Note: A greater setting value (+ direction) moves away from the Original Width Scale. (In 2in1 Space between origs., it is for greater distance between the documents.) <Procedure> 1. Select the operating mode to be checked and load the required number of originals into the Document Feed Tray. 2. Press the Start key. When the original is taken up and then stopped, raise the ADF and adjust the stop position using the A or " key; then, feed the original once again for a recheck.
S-37
Tech. Rep. Mode " Accessory Test

Touch Panel Display Sorter Check Transport Motor Setting Enables the following operation checks to be performed for the Sorter. Pressing the Start key energizes the Transport Motor to turn the various Transport Rollers. Note: The 10-Bin Sorter is not operated. Pressing the Start key energizes the Bin Moving Motor to move the bins up and down. Pressing the Start key runs a stapling sequence if paper is loaded in the 1st Bin. If no paper is loaded, only a paper clamp motion occurs. Pressing the Start key causes a paper aligning motion to occur for the width of the paper currently selected for use. 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. When that particular check operation is then run with this screen on the Touch Panel, either 1 or 0 is shown after each sensor according to its state. Paper Aligning Bar Home Bin Empty Paper Clamp Position Paper Clamp Home Staple Paper Detect Stapler Home Bin Home Position Staple unit FD move Staple Unit CD Constant Position Gate Unit constant Position Sort path constant Position
Bin Movement Stapling Paper Aligning Stack move
S-38
1156SBS050410A
10. Level History

D This function is used to show and set the various level histories which were changed according to the operating conditions of the copier and user requirements.
Tech. Rep. Mode " Level History

Touch Panel Display Level History Setting Touching the Level History key will show the various level histories as detailed below. Of all data displayed, only that for ATDC Ref. Value and Fuser Temp. Control can be changed. ATDC Ref. Value D Change this data when the RAM Board has been changed or a Developing Unit from another copier has been installed. Fuser Temp. Control D Change this data if fusing performance becomes poor due to the operating environment and the paper being used. <Level History 1/2> Display
ATDC Ref. Value ATDC Target Level ATDC Current Level Vg Default Level Vg Current Level
Variable Range
2 to 254 1.0 to 9.0 (%) 1.0 to 9.0 (%) 400 to 850 (V) 400 to 850 (V)
Increments
2 step 0.5 (%) 0.5 (%) 30 (V) 30 (V)
Description
F8 adjusted value Target ATDC level Current ATDC level Initial grid voltage setting Grid voltage correction value due to changes with time
<Level History 2/2> Display

Fuser Temp. Control Fuser Temp. Current
Variable Range
180 to 200 (C) 160 to 220 (C)
Increments
10 (C) 10 (C)
Description
Target fusing temperature Current fusing temperature Initial Exposure Lamp level setting Exposure Lamp level correction value due to changes with time Cumulative time of toner replenishing
Expo. Default Level Expo. Current Level
49 to 71 (V) 49 to 71 (V)
1 (V) 1 (V)
Toner Replenishing Time
0 to 1270 (mm)
10 steps
S-39
1156SBS050411A
11. Machine Status

D This function shows the codes of isolated malfunctions which are currently present. This screen is also accessible by touching the wrench mark shown at the bottom left corner of the Basic screen under normal operating conditions.
Tech. Rep. Mode " Machine Status

Touch Panel Display Machine Status Setting Of the malfunction codes listed below, those that have occurred are displayed, together with the functions that are disabled by these malfunctions. Up to five isolated malfunctions are shown. When a sixth isolated malfunction occurs, the copier considers it as an ordinary malfunction. Even if there are less than five isolated malfunctions, if there are isolated malfunctions occurring at all paper sources, the next isolated malfunction will be regarded as an ordinary one. Malfunction Code C004d/45 Description Cooling Fan Motor malfunction (Ventilation/Fusing Section) SP communication failure Paper take-up failure Duplex Unit malfunction Faulty AIDC Sensor Faulty Paper Empty Sensor Faulty Original Size Detecting Sensor Sorter malfunction
C0350 to 52 C09XX C0dXX C0F2X C0F7X C0FEX to FX
C0b3X / 5X to 7X
<Clearing Procedure> With the Machine Status screen on the Touch Panel, swing open and close the Front Door to clear all the isolated malfunctions.
1149SBS050412A
12. Admin. Mode

D This function is used to enter or change the administrator number, in addition to the functions set in the Administrator Mode available from Users Choice.
Tech. Rep. Mode " Admin. Mode

Touch Panel Display Copy Track Copy Track Data Max. Copy Sets User Help Administrator # Input From the 10-Key Pad, enter a 4-digit number (0000 to 9999) that serves as an ID number for opening the Admin. Mode of Users Choice. See Administrator Mode of Users Choice. Setting
S-40
1149SBS0600A
FACTORY SETTING
D Factory Setting is used to make adjustments at the factory.

1149SBS0601A
6-1. Factory Setting Menu Screen
1149O424CA
1149SBS0602A
6-2. Factory Setting Function Setting Procedure

<Setting Procedure> 1. Set the copier into the Tech. Rep. mode by pressing the following keys in this order. Stop key
Stop key
2. Enter the Factory Setting mode by pressing the following keys in this order. Stop key
Start key
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 selected is highlighted. <Exiting the Mode> D Press the Panel Reset key on the control panel.
S-41
1156SBS0603A
6-3. Factory Setting Function Tree

A0 A1 A2 A3 A4 A5 Adjust Adjust 1/2 Book B-Scan Regist Scan Regist Enlargement Leading Edge Erase Adjust Trailing Edge Erase Adjust Adjust 1/2 Lens Focus Lens Full Size Position Mirror Full Size Position Feed Direction Mag. Ratio Scan Regist Full Size Scan Regist Reduction
A6 A11 A12 A13
Factory Setting
Function
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
* See Tech. Rep. Mode for functions other than F2, F4, F6, F8, and FF.
Marketing Area
* See Tech. Rep. Mode.
1156SBS060301A
1. Function Factory Setting " Function

Touch Panel Display F2 Drum/Trans Operation Checks the PC Drum Charge Corona and Image Transfer Corona for output. Note: For factory adjustment only. F4 HV Separator Checks the Paper Separator Corona for output. Note: For factory adjustment only. F6 Edit Ref. Adj Pressing the Start key turns ON and OFF the Image Erase Lamp to make a checkered pattern on the paper for checking the lamp for correct operation and adjusting its position.
S-42
Components Energized in Function

Component Main Drive Motor Fan Motors Toner Replenishing Motor Paper take-up Scan Exposure Lamp Main Erase Lamp Image Erase Lamp Synchronizing Rollers PC Drum Paper Separator Fingers PC Drum Charge Corona and Image Transfer Corona Paper Separator Corona and developing bias Misfeed detection Malfunction detection F1 f f f f f f f f f f f f f F2 f f f f f F3 f f f f f f f f F4 f f f f f f F5 f f f f f f f f f f: Energized F6 f f f f f f f f f f f f f F7 f F8 f f f f f f f f FF f f f f f f f f
: Remains deenergized
S-43
1156SBS060302A
2. Adjust
D This function is used to adjust the optical system before shipment from the factory and must not be run except when the RAM Board has been replaced with a new one or memory cleared. Further, when the RAM Board has been changed or memory cleared, enter the factory settings indicated on the Adjust Mode label affixed to the inside of the Front Door.
Factory Setting " Adjust

Touch Panel Display A0 Lens Focus Operation Corrects the focal length of the Lens. (Match the grouping of the Lens being used.) Setting 49
Short focal length adjustment
50
51 Long focal length adjustment
Description
Standard
A1
Lens Full Size Position
Adjusts the zoom ratio in the crosswise direction by varying the Lens full size position. Setting Description 43 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 58 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 Description 43 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 58 Reduction direction Enlargement direction
A3
Feed Direction Mag. Ratio
Adjusts the zoom ratio in the feeding direction by varying the scan speed.
Setting
46 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 54
1.6% (Reduc- . . . . . . . . . 0% . . . . . . . . . . +1.6% (EnlargeDescription tion direction) ment direction)
A4
Scan Regist Full Size
Corrects the amount of offset along the leading edge in the full size mode by varying the Synchronizing Roller start timing. Setting Description 40 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 60
5.0mm . . . . . . . . . . . . . . "0 . . . . . . . . . . . . (Smaller) +5.0mm (Greater)
S-44
Factory Setting " Adjust

Touch Panel Display A5 Scan Regist Reduction Operation Corrects the amount of offset along the leading edge in a reduction mode by varying the Synchronizing Roller start timing. Setting Description A6 Book B-Scan Regist 40 . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . 60
Corrects registration in Book B-Scan by varying the Synchronizing Roller start timing. Setting Description 45 . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . 55
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 Description 40 . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . 60
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. Setting Description 45 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 55
5mm . . . . . . . . . . . . . . "0 . . . . . . . . . . . . (Smaller) +5mm (Greater)
A13 Trailing Edge Erase Adjust
Corrects the width of void image along the trailing edge of the image by varying the Image Erase Lamp ON timing. Setting Description 42 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 58
8mm . . . . . . . . . . . . . . "0 . . . . . . . . . . . . (Smaller) +8mm (Greater)
S-45
1156SBS000EA

MINOLTA CO., LTD.
1156-7997-11 97046000 Printed in Japan
Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01
1156SBT000AA
EP5000/EP4000
TROUBLESHOOTING
1156SBT000BA
CONTENTS
1 INTRODUCTION 1-1. General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 1-2. How to Use This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 1-3. Reading the Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1
I/O PORT CHECK 2-1. Controlled Parts Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-2 2-2. I/O Port Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-5
3 PAPER TRANSPORT FAILURE 3-1. Paper Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Misfeed Detection Types and Detection Timings . . . . . . . . . . . . . . . . 3-3. Misfeed Clearing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1) Copier Paper Take-Up Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2) Transport/Separator Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3) Multi Bypass Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4) Fusing/Exit misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5) PF-205 Paper Take-Up Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6) PF-105 Paper Take-Up Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7) AD-9 Vertical Transport/Storage Misfeed . . . . . . . . . . . . . . . . . . . . 8) AD-9 Paper Take-Up Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MALFUNCTIONS 4-1. Detection Timings Classified by Malfunction Codes . . . . . . . . . . . . . 4-2. Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1) C0000: Main Drive Motor M1s Failure to Turn . . . . . . . . . . . . . . . . C0001: Main Drive Motor M1 Turning at Abnormal Timing 2) C0040: Suction Fan Motor M4s Failure to Turn . . . . . . . . . . . . . . 3) C0046: Fusing Section Cooling Fan Motor M15s Failure to Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C0047: Fusing Section Cooling Fan Motor M15 Turning at Abnormal Timing T-43 T-57 T-57 T-59 T-61 T-20 T-22 T-24 T-24 T-27 T-30 T-32 T-34 T-36 T-38 T-41
4) C004A: Original Glass Cooling Fan Motor M5s Failure to Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C004b: Original Glass Cooling Fan Motor M5 Turning at Abnormal Timing C004C: Ventilation Fan Motor M3s Failure to Turn C004d: Ventilation Fan Motor M3 Turning at Abnormal Timing 5) C0070: Main Hopper Toner Replenishing Motor M8s Failure to Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C0071: Main Hopper Toner Replenishing Motor M8 Turning at Abnormal Timing C0072: Sub Hopper Toner Replenishing Motor M9s Failure to Turn 6) C0200 Corona Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7) C03##: Master Board/Harness Malfunctions . . . . . . . . . . . . . . . . . 8) C0400: Exposure Lamp LA1s Failure to Turn ON . . . . . . . . . . . . C0410: Exposure Lamp LA1 Turning ON at Abnormal Timing 9) C0500: Warming-up Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C0510: Abnormally Low Fusing Temperature C0520: Abnormally High Fusing Temperature 10) C0600: Scanner Motor M2 Malfunction . . . . . . . . . . . . . . . . . . . . . . C06FX: Signal Failure 11) C0610: Lens Motor M6 Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . C0620: Mirror Motor M7 malfunction 12) C0910: 2nd Drawer Upward Motion Failure . . . . . . . . . . . . . . . . . . C0914: 2nd Drawer Paper Lift-Up Motor M14s Failure to Turn C0920: 1st Drawer Upward Motion Failure C0924: 1st Drawer Paper Lift-Up Motor M13s Failure to Turn 13) C0900: 3rd Drawer Upward Motion Failure . . . . . . . . . . . . . . . . . . C0904: 3rd Drawer Paper Lift-Up Motor M24s Failure to Turn C0950: 4th Drawer Upward Motion Failure C0954: 4th Drawer Paper Lift-Up Motor M25s Failure to Turn 14) C0911: 2nd Drawer Upward Motion Failure (Inch Areas) . . . . . . . C0912: 2nd Drawer Downward Motion Failure C0913: 2nd Drawer Upward Motion Failure C0916: 2nd Drawer Ejection Failure 15) C0921: 1st Drawer Upward Motion Failure (Inch Areas) . . . . . . . C0922: 1st Drawer Downward Motion Failure C0923: 1st Drawer Upward Motion Failure C0926: 1st Drawer Ejection Failure 16) C0901: 3rd Drawer Upward Motion Failure (Inch Areas) . . . . . . . C0902: 3rd Drawer Downward Motion Failure C0903: 3rd Drawer Upward Motion Failure C0906: 3rd Drawer Ejection Failure 17) C0951: 4th Drawer Upward Motion Failure (Inch Areas) . . . . . . .
T-63
T-65
T-67 T-68 T-69 T-71
T-73 T-75 T-77
T-79
T-81
T-83
T-85
T-87
ii
C0952: 4th Drawer Downward Motion Failure C0953: 4th Drawer Upward Motion Failure C0956: 4th Drawer Ejection Failure 18) C0990: Main Tray Upward Motion Failure . . . . . . . . . . . . . . . . . . . T-89 C0991: Main Tray Downward Motion Failure C0992: Main Tray Downward Motion Failure C0993: Main Tray Upward Motion Failure C0994: Elevator Motor M26s Failure to Turn 19) C0998: Shifter Transfer Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-91 C0999: Shifter Return Failure C099A: Shifter Return Failure C099b: Shifter Transfer Failure C099C: Shift Motor M27s Failure to Turn 20) C099E: Shift Gate Position Detecting Failure . . . . . . . . . . . . . . . . . T-93 C099F: Shift Gate Position Detecting Failure C0996: 3rd Drawer Lock Release Failure C0F79: Paper Empty Sensor Failure 21) C0d00: Duplex Unit Front/Rear Edge Guide Plate Home Position Detection Failure . . . . . . . . . . . . . . . . . . . . T-95 C0d20: Duplex Unit Gate Unit Home Position Detection Failure C0d50: Duplex Unit Drive Motor M31s Failure to Turn C0d51: Duplex Unit Drive Motor M31 Turning at Abnormal Timing 22) C0E00: Main Erase Lamp LA2s Failure to Turn ON . . . . . . . . . . . T-97 C0E01: Main Erase Lamp LA2 Turning ON at Abnormal Timing 23) C0E20: Image Erase Lamp LA3s Failure to Turn ON . . . . . . . . . T-98 24) C0F02: Original Size Detecting Board UN2 Malfunction . . . . . . . T-99 25) C0F10: AE Sensor Board PWB-H Malfunction . . . . . . . . . . . . . . T-101 26) C0F20: AIDC Sensor Board PWB-G Variation Correction Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-102 C0F22: AIDC Sensor Board PWB-G Grid Voltage (Vg) Correction Failure C0F23: AIDC Sensor Board PWB-G Exposure Correction Failure 27) C0F30: ATDC Sensor UN3 Failure . . . . . . . . . . . . . . . . . . . . . . . . T-103 C0F31: ATDC Sensor UN3 Failure 4-3. Power Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-104 1) Main Relay Does Not Turn ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . T-104 2) Main Relay Turns ON But the Control Panel Gives No Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-106 4-4. Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-107 5 IMAGE FAILURE 5-1. Image Failure Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-108
iii
5-2. Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-108 5-3. Troubleshooting Procedures Classified by Image Failure . . . . . . . T-110
iv
1139SBT0100A
INTRODUCTION
1139SBT0101A
1-1. General Precautions

1. When servicing the copier with its covers removed, use utmost care to prevent your hands, clothing, and tools from being caught in revolving parts including the chains and gears. When servicing the copier with the Lower Rear Cover removed, be sure to install the jig. 2. Before attempting to replace parts and unplug connectors, make sure that the power cord of the copier has been unplugged from the wall outlet. 3. Never create a closed circuit across connector pins except those specified in the text and on the printed circuit. 4. When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the green wire (GND). 5. When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to overloads. 6. Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged.
1139SBT0102A
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 are plugged into the right positions. 3. For the removal procedures of covers and parts, see DIS/REASSEMBLY, ADJUSTMENT. 4. The troubleshooting procedures are given in the order of greater frequency of trouble or order of operation. 5. The procedures preclude possible malfunctions due to noise and other external causes.
1139SBT0103A
1-3. Reading the Text

1. The paper transport failure troubleshooting procedures are given according to the symptom. First identify the location where the paper is present and start the procedure for that particular location. For malfunction troubleshooting, start with step 1 and onward. 2. Make checks in numerical order of steps and, if an item is checked okay, go to the next step. Pattern 1 Step Check Item 1 2 Is...? Result YES Action Do this. Pattern 2 Step Check Item 1 Is...? Result YES NO 2 Action Do this. Check that.
Go to step 2 if you answered NO.
Go to step 2 if it checks okay.
T-1
1151SBT0200A
2 I/O PORT CHECK

1156SBT0201A
2-1. Controlled Parts Check Procedure

To allow the Tech. Rep. to easily and safely determine whether a particular controlled part is fully operational, this copier provides the following provision: checking the data of the I/O port of the board IC with the copier in the standby state (including a misfeed, malfunction, and closure failure condition) allows the Tech. Rep. to determine whether a signal is properly input to, and output from, a controlled part.
<Procedure> 1) On the circuit diagram accompanying the text, locate the I/O port of the controlled part which is probably 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 and signals are properly input and output. 4) If the controlled part does not operate properly after changing the output port data, select Controller Board Check of I/O Check in the Tech. Rep. mode and determine whether the board is responsible for that malfunction or not. Note: Only the output ports given on pages T-37 and 38 may be checked by Controller Board Check of I/O Check in the Tech. Rep. mode.
T-2
<Controlled Part Check Procedure by Changing Input Port Data>
Example: When a paper misfeed occurs in the paper take-up section of the copier, 1st Drawer Paper Take-Up Sensor PC56 is considered to be responsible for it. <Procedure> 1) Remove the sheet of paper misfed and reset the misfeed. 2) From the I/O port check list, it is found 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 unblocked). 5) Move the PC56 actuator to block the sensor. 6) Return to the I/O Check basic screen once, select IC Port Check again, choose the screen which includes the APB3 input port data, and make sure that the data has changed from H to L. L: PC56 is operational. H: PC56 is faulty.
T-3
<Controlled Part Check Procedure by Changing Output Port Data>
Example: When a manual paper misfeed occurs, Manual Feed Paper Take-Up Clutch CL3 is considered to be responsible for it. <Procedure> 1) Remove the sheet of paper misfed and reset the misfeed. 2) From the I/O port check list, it is found that the ON/OFF output signal of CL3 is supplied from PWB-A (IC5A) BPA1. 3) Select IC Port Check from the I/O Check function in the Tech. 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 deenergized). 5) Touch the CHANGE key on the screen to change the data from 1 to 0, causing CL3 to be energized for approx. 5 seconds. This allows you to determine whether the Clutch is operational or faulty by checking for the Clutch sound. Operational: Sound produced. Faulty: No sound produced.
6) If CL3 was not energized, make the Controller Board Check in the same mode (for some electrical parts only). 7) If the ON signal of CL51 is not output from PWB-A, the corresponding malfunction code is displayed. * For CL3, C0337 is displayed.
T-4
1156SBT0202A
2-2. 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)
1156T016CA
1156T020CA
1156T017CA
1156T021CA
1156T018CA
1156T022CA
1156T019CA
1156T023CA
T-5
<I/O Port Check List>

Copier *The shaded areas of the following table indicate that the output check cannot be made by touching the Change key. Display Page 2/8 2/8 3/8 3/8 2/8 Operation Characteristics/Panel Display H or 1 IC4A IC4A IC4A IC4A IC4A BPA2 BPB1 APC0 BPC1 BPB6 f f f f f f f f OFF When locked Stop OFF When locked Turned at high speed When locked OFF When locked OFF OFF Turn inhibited Turn inhibited OFF OFF OFF OFF OFF L or 0 ON When turned Scan cycle ON When turned Turned at low speed When turned ON When turned ON ON Turn permitted Turn permitted ON (up) ON (down) ON (up) ON (down) ON PJ18A-9 PJ18A-10 PJ8A-5 PJ34A-1 PJ34A-3
Symbol M1 M2 M3
Parts/Signal Name
IC No.
Port No.
I/O
CN/PJ No.
Main Drive Motor/REM Main Drive Motor/lock signal Scanner Motor/SCAN Ventilation Fan Motor/ REM Ventilation Fan Motor/ lock signal Suction Fan Motor/select signal Suction Fan Motor/lock signal Original Glass Cooling Fan Motor/REM Original Glass Cooling Fan Motor/lock signal Main Hopper Toner Replenishing Motor/REM Sub Hopper Toner Replenishing Motor/REM 1st Drawer Paper TakeUp Motor 2nd Drawer Paper TakeUp Motor 1st Drawer Paper Lift-Up Motor (UP) 1st Drawer Paper Lift-Up Motor (DOWN) 2nd Drawer Paper Lift-Up Motor (UP) 2nd Drawer Paper Lift-Up Motor (DOWN) Fusing Section Cooling Fan Motor/REM
M4
3/8
IC4A
BPC2
PJ15A-4
M5 M8 M9
3/8 3/8 2/8 3/8 3/8
IC4A IC4A IC4A IC4A IC5A
BPC7 BPC0 BPB5 BPC3 APA2
PJ15A-3 PJ15A-5 PJ15A-7 PJ11A-4A PJ11A-2A
M11
3/8
IC5A
APA0
PJ18A-1
M12
3/8
IC5A
APA1
f f f f f f
PJ18A-2
M13 M14 M15
3/8 3/8 3/8 3/8 3/8
APA4 APA5 APA6 APA7 APC2
PJ18A-5 PJ18A-6 PJ8A-7 PJ18A-8 PJ10A-1
T-6
Symbol
Parts/Signal Name
Display Page
IC No.
Port No.
I/O
Operation Characteristics/Panel Display H or 1 L or 0 When turned ON ON ON (up) ON (down) ON ON ON Paper present Blocked Paper present Paper present Paper present Paper present Paper present In position In position
CN/PJ No.
SL1 SL5
Fusing Section Cooling Fan Motor/lock signal Separator Solenoid Exit/Duplex Switching Solenoid Manual Feed Paper Take-Up Solenoid (UP) Manual Feed Paper Take-Up Solenoid (DOWN) Paper Transport Clutch Synchronizing Roller Clutch Manual Feed Paper Take-Up Clutch Duplex Unit Vertical Transport Sensor Toner Bottle Home Position Sensor Manual Feed Paper Empty Sensor Transport Roller Sensor Paper Leading Edge Detecting Sensor 1st Drawer Paper Take-Up Sensor 2nd Drawer Paper Take-Up Sensor 1st Drawer Set Sensor 2nd Drawer Set Sensor
3/8 2/8 2/8
IC4A IC4A IC4A
APB6 BPA0 BPA5
f f f
When locked OFF OFF
PJ10A-3 PJ11A-6A PJ14A-6
SL51
3/8
IC5A
BPA2
OFF
PJ15A-10
3/8
IC5A
BPA3
f f f f
OFF
PJ15A-9
CL1 CL2 CL3
2/8 2/8 3/8
IC4A IC4A IC5A
BPA3 BPA4 BPA1
OFF OFF OFF Paper not present Unblocked Paper not present Paper not present Paper not present Paper not present Paper not present Out of position Out of position
PJ14A-2 PJ14A-4 PJ15A-12
PC12
3/8
IC5A
BPB0
PJ17A-8
PC35
3/8
IC4A
BPC5
PJ11A-9
PC51
3/8
IC5A
BPB1
PJ15A-14
PC54
3/8
IC5A
BPB6
PJ19A-5
PC55
3/8
IC5A
BPB5
PJ19A-2
PC56
1/8
IC3A
APB3
PJ21A-5A
PC57
1/8
IC3A
APB4
PJ21A-5B
PC61 PC62
1/8 1/8
IC3A IC3A
BPA5 APB5
PJ22A-2 PJ22A-6
T-7
Symbol
Parts/Signal Name
Display Page
IC No.
Port No.
I/O
Operation Characteristics/Panel Display H or 1 L or 0 Paper present Paper present At upper limit At upper limit Blocked Blocked At lower limit At lower limit Size detected Size detected At home Paper present Paper present Lowered At home When counting In position
CN/PJ No.
PC63
1st Drawer Vertical Transport Sensor 2nd Drawer Vertical Transport Sensor 1st Drawer Lift-Up Sensor 2nd Drawer Lift-Up Sensor 1st Drawer Lift-Up Motor Pulse Sensor 2nd Drawer Lift-Up Motor Pulse Sensor 1st Drawer Lower Limit Position Sensor 2nd Drawer Lower Limit Position Sensor Paper Size Detecting Sensor 5 Paper Size Detecting Sensor 6 Scanner Reference Position Sensor 1st Drawer Paper Empty Sensor 2nd Drawer Paper Empty Sensor Original Cover Detecting Sensor Toner Hopper Home Position Sensor Total Counter/REM Total Counter/Set
1/8
IC3A
APB6
Paper not present Paper not present Not at upper limit Not at upper limit Unblocked Unblocked Not at lower limit Not at lower limit Size not detected Size not detected Not at home Paper not present Paper not present Raised Not at home Normally Out of position
PJ21A-8A
PC64
1/8
IC3A
APB7
PJ21A-8B
PC65
1/8
IC3A
APB1
PJ21A-2A
PC66
1/8
IC3A
APB2
PJ21A-2B
PC67 PC68
1/8 1/8
IC3A IC3A
APC0 APC1
PJ23A-2 PJ23A-5
PC69
1/8
IC3A
BPA2
PJ24A-5
PC70
1/8
IC3A
BPA3
PJ24A-6
PC72 PC73 PC81
2/8 2/8 2/8
IC3A IC3A IC4A
BPB6 BPB7 APC4
PJ25A-2 PJ25A-5 PJ8A-4
PC101
1/8
IC3A
APC2
PJ23A-9
PC102
1/8
IC3A
APC3
PJ23A-12
PC111 PC112 CNT1
2/8 3/8 1/8 2/8
IC4A IC5A IC1A IC4A
APB5 BPB7 P55 APB7
PJ12A-1 PJ11A-9B PJ13A-6
T-8
Symbol
Parts/Signal Name
Display Page
IC No.
Port No.
I/O
Operation Characteristics/Panel Display H or 1 L or 0 When counting In position ON OFF OFF ON ON ON ON ON ON ON Paper not present Size detected Size detected Size detected Size detected Toner empty
CN/PJ No.
CNT2
Plug-In Counter/REM
1/8
IC1A
P44
f f f f f f
Normally Out of position OFF ON ON OFF OFF OFF OFF OFF OFF OFF Paper present Size yet to be detected Size yet to be detected Size yet to be detected Size yet to be detected Toner still available
PJ28A-9
H1 H3 RY1 LA1 LA2 LA2 S1 S21 S22 S23
Plug-In Counter/Set Fusing Heater Lamp Paper Dehumidifying Heater Main Relay Exposure Lamp/AVR REM Main Erase Lamp/ REM Main Erase Lamp/ failure detection Power Switch Front Door Interlock Switch Right Upper Door Interlock Switch Left Upper Door Interlock Switch Paper Exit Switch
3/8 1/8 1/8 1/8 1/8 2/8 2/8 1/8 1/8 3/8 3/8
IC5A IC1A IC1A IC1A IC1A IC4A IC4A IC1A IC1A IC5A IC5A
BPC3 P57 P45 P46 P61 BPA1 APC7 P53 P51 BPB2 BPC6
PJ28A-7 PJ33A-2 PJ4A-5 PJ4A-3 PJ8A-13 PJ12A-3 PJ12A-5 PJ4A-1 PJ4A-4 PJ16A-2 PJ16A-4
S53
3/8
IC4A
BPB2
PJ20A-12
S61
Paper Size Detecting Switch 1 Paper Size Detecting Switch 2 Paper Size Detecting Switch 3 Paper Size Detecting Switch 4 Toner Empty Detecting Switch
1/8
IC3A
BPA6
PJ26A-2
S62
1/8
IC3A
BPA7
PJ26A-4
S63
2/8
IC3A
BPB4
PJ26A-7
S64
2/8
IC3A
BPB5
PJ26A-9
S106
3/8
IC1A
BPC6
PJ11A-8B
T-9
Symbol
Parts/Signal Name
Display Page
IC No.
Port No.
I/O
Operation Characteristics/Panel Display H or 1 L or 0 ON ON ON ON ON
CN/PJ No.
UN5 UN6 PWB-G
1st Drawer Paper Descent Key Manual Down Display 1 2nd Drawer Paper Descent Key
1/8 1/8 1/8 1/8 2/8
BPA0 APC4 BPA1 APC5 APA4
f f f
OFF OFF OFF OFF OFF
PJ24A-3 PJ24A-1 PJ24A-4 PJ24A-2
Manual Down Display 2 AIDC Sensor Board/ AIDC REM
T-10
PF-205 Display Page IC No. Port No. Operation Characteristics/Panel Display H or 1 M21 Vertical Transport Drive Motor 3rd Drawer Paper Take-Up Motor 4th Drawer Paper Take-Up Motor 3rd Drawer Paper Lift-Up Motor 3rd Drawer Paper Lift-Up Motor 4th Drawer Paper LiftUp Motor 4th Drawer Paper LiftUp Motor Lower Left Door Sensor Duplex Unit Turnover Path Sensor Vertical Transport Sensor 3 Lower Right Door Sensor 3rd Drawer Paper Lift-Up Sensor 3rd Drawer Paper Empty Sensor 3rd Drawer Paper Take-Up Sensor Vertical Transport Sensor 4 4th Drawer Paper LiftUp Sensor 4/8 IC1A PB3 f Turn inhibited Turn inhibited Turn inhibited OFF OFF Out of position Paper not present Paper not present Out of position Not at upper limit Paper not present Paper not present Paper not present Not at upper limit L or 0 Turn permitted Turn permitted Turn permitted ON (up) ON (down) ON (up) ON (down) In position Paper present Paper present In position At upper limit Paper present Paper present Paper present At upper limit PJ12A-1~ 4 PJ11A-1~ 4 PJ10A-1~ 4 PJ9A-8B PJ9A-7B PJ9A-2A PJ9A-1A PJ3A-2 CN/PJ No.
Symbol
Parts/Signal Name
I/O
M22
4/8
IC1A
PB1
M23
4/8
IC1A
PB0
f f f f f
M24 M25 PC11
4/8 4/8 4/8 4/8 4/8
PA0 PA1 PA2 PA3 PB1
PC13
4/8
IC2A
PB0
PJ3A-5
PC17
4/8
IC1A
PC3
PJ7A-5
PC18
4/8
IC1A
PE2
PJ7A-2
PC19
4/8
IC1A
PG3
PJ6A-12
PC20
4/8
IC1A
PC0
PJ6A-2
PC21
4/8
IC1A
PE3
PJ6A-9
PC22
4/8
IC1A
PC2
PJ6A-5
PC23
4/8
IC1A
PF3
PJ8A-8
T-11
Symbol
Parts/Signal Name
Display Page
IC No.
Port No.
I/O
Operation Characteristics/Panel Display H or 1 L or 0 Paper present In position In position
CN/PJ No.
PC24
4th Drawer Paper Empty Sensor 3rd Drawer Set Sensor 4th Drawer Set Sensor 3rd Drawer Paper Lift-Up Motor Pulse Sensor 4th Drawer Paper LiftUp Motor Pulse Sensor 4th Drawer Paper Take-Up Sensor Large Capacity Toner Collecting Box Set Sensor
4/8
IC1A
PD0
Paper not present Out of position Out of position Unblocked Unblocked Paper not present Paper not present
PJ8A-2
PC25 PC26
4/8 4/8
IC1A IC1A
PG2 PF2
PJ9A-2B PJ9A-7A
PC27
4/8
IC1A
PC1
Blocked
PJ9A-5B
PC28
4/8
IC1A
PD1
Blocked Paper present Paper present
PJ9A-4A
PC29
4/8
IC2A
PB3
PJ8A-5
PC31
4/8
IC2A
PC3
PJ2A-2
T-12
PF-105 Symbol Display Page IC No. Port No. Operation Characteristics/Panel Display H or 1 M21 Vertical Transport Drive Motor 3rd Drawer Paper Take-Up Motor Main Tray Elevator Motor Main Tray Elevator Motor Paper Shift Motor Paper Shift Motor Shift Gate Motor Shift Tray Paper Empty Sensor Main Tray Lower Position Sensor Shifter Home Position Sensor Shifter Return Position Sensor Elevator Motor Pulse Sensor Shift Motor Pulse Sensor 3rd Drawer Set Sensor Lower Left Door Sensor Duplex Unit Turnover Path Sensor Vertical Transport Sensor 3 Lower Right Door Sensor 5/8 IC1A PB3 f Turn inhibited Turn inhibited Up/stop Down/ stop Transfer/stop Return/ stop OFF Paper not present Not at lower limit Not at home Not at returned position Unblocked Unblocked Out of position Out of position Paper not present Paper not present Out of position L or 0 Turn permitted Turn permitted Down Up Return Transfer ON Paper present At lower limit At home At returned position Blocked Blocked In position In position Paper present Paper present In position PJ12A-1~4 CN/PJ No.
Parts/Signal Name
I/O
M22
5/8
IC1A
PB1
f f f f f f
PJ11A-1~4
M26 M27 M28 PC1
5/8 5/8 5/8 5/8 5/8 5/8
IC1A IC1A IC1A IC1A IC1A IC1A
PA2 PA3 PA0 PA1 PB2 PD1
PJ4A-6B PJ4A-7B PJ4A-4B PJ4A-5B PJ4A-2B PJ4A-4A
PC2
6/8
IC2A
PC1
PJ4A-9A
PC3
6/8
IC2A
PC0
PJ4A-8A
PC4
6/8
IC2A
PD1
PJ4A-7A
PC5 PC6 PC7 PC11
5/8 5/8 6/8 6/8
IC1A IC1A IC1A IC2A
PF2 PD0 PG2 PB1
PJ4A-5A PJ4A-3A PJ5A-2 PJ3A-2
PC13
6/8
IC2A
PB0
PJ3A-5
PC17
5/8
IC1A
PC3
PJ7A-5
PC18
5/8
IC1A
PE2
PJ7A-2
T-13
Symbol
Parts/Signal Name
Display Page
IC No.
Port No.
I/O
Operation Characteristics/Panel Display H or 1 L or 0 At upper limit Paper present Paper present Paper present In position
CN/PJ No.
PC19
3rd Drawer Paper Lift-Up Sensor 3rd Drawer Paper Empty Sensor 3rd Drawer Paper Take-Up Sensor Vertical Transport Sensor 4 Large Capacity Toner Collecting Box Set Sensor Shift Gate Position Sensor Lower Position Sensor Main Tray Paper Empty Board Drawer Paper Descent Key 3rd Drawer Lock Solenoid
6/8
IC1A
PG3
Not at upper limit Paper not present Paper not present Paper not present Out of position Unblocked Not at lower limit Paper not present OFF OFF
PJ6A-12
PC20
5/8
IC1A
PC0
PJ6A-2
PC21
5/8
IC1A
PE3
PJ6A-9
PC22
5/8
IC1A
PC2
PJ6A-5
PC31
4/8
IC2A
PC3
PJ2A-2
PC34
5/8
IC1A
PC1
Blocked At lower limit Paper present ON ON
PJ4A-1B
PC35
6/8
IC2A
PB3
PJ4A-2A
PWB-E
5/8
IC1A
PF3
PJ4A-6A
UN21 SL41
6/8 6/8
IC2A IC2A
PC2 PA1
PJ4A-10A PJ5A-5
T-14
AD-9 Display Page IC No. Port No. Operation Characteristics/Panel Display H or 1 M31 CL31 SL31 SL32 SL33 PC8 Duplex Unit Drive Motor Duplex Unit Drive Motor/lock signal Duplex Unit Paper Take-Up Clutch Duplex Unit Gate Switching Solenoid Duplex Unit Rear Finger Solenoid Duplex Unit Pick-Up Solenoid Duplex Gate Home Position Sensor Front/Rear Edge Guide Plate Home Position Sensor Duplex Unit Paper Entry Sensor Duplex Unit Paper Empty Sensor Duplex Unit Paper Take-Up Sensor 7/8 7/8 7/8 7/8 7/8 7/8 7/8 IC1G IC1G IC1G IC1G IC1G IC1G IC1G PB3 PE1 PA3 PH1 PH0 PB2 PE0 f f f f f OFF When locked OFF OFF OFF OFF Not at home Not at home Paper not present Paper not present Paper not present L or 0 ON When turned ON ON ON ON At home PJ6G-2 PJ6G-1 PJ2G-7 PJ3G-5 PJ3G-7 PJ2G-12 PJ7G-2 CN/PJ No.
Symbol
Parts/Signal Name
I/O
PC9
7/8
IC1G
PC3
At home
PJ7G-5
PC14
7/8
IC1G
PC1
Paper present Paper present Paper present
PJ3G-2
PC15
7/8
IC1G
PC2
PJ2A-4
PC16
7/8
IC1G
PC0
PJ2G-9
T-15
C-301 Display Page IC No. Port No. Operation Characteristics/Panel Display H or 1 HMOT PWB-B EMPSEN Elevator Motor Elevator Motor Paper Plate Descent Switch Board Paper Empty Sensor 8/8 8/8 8/8 IC1A IC1A IC1A PH0 PH1 PG1 f f Down/ stop Up/stop OFF Paper present Paper present Not upper limit Not at lower limit Out of position Out of position L or 0 Up Down ON Paper not present Paper not present At upper limit At lower limit In position In position CN5A-2 CN5A-1 CN2A-2 CN/PJ No.
Symbol
Parts/Signal Name
I/O
8/8
IC1A
PC1
CN2A-5
KSEN LEVSEN LOWSEN DSEN SETSEN
Paper Feed Sensor Paper Plate Raised Position Sensor Paper Plate Lowered Position Sensor Cassette Door Sensor Set Sensor
8/8
IC1A
PG0
CN2A-3
8/8
IC1A
PC0
CN2A-6
8/8
IC1A
PG3
CN3A-5
8/8 8/8
IC1A IC1A
PG2 PC2
CN3A-2 CN2A-4
T-16
PF205 : MC Display Page IC No. Port No. Operation Characteristics/Panel Display H or 1 M21 Vertical Transport Drive Motor 3rd Drawer Paper Take-Up Motor 4th Drawer Paper Take-Up Motor 3rd Drawer Paper Lift-Up Motor 3rd Drawer Paper Lift-Up Motor 4th Drawer Paper Lift-Up Motor 4th Drawer Paper Lift-Up Motor Lower Left Door Sensor Duplex Unit Turnover Path Sensor Vertical Transport Sensor 3 Lower Right Door Sensor 3rd Drawer Paper Lift-Up Sensor 3rd Drawer Paper Take-Up Sensor Vertical Transport Sensor 4 4th Drawer Paper Lift-Up Sensor 3rd Drawer Set Sensor 4th Drawer Set Sensor 6/8 IC1A PB3 f Turn inhibited Turn inhibited Turn inhibited OFF OFF OFF OFF Out of position Paper not present Paper not present Out of position Not at upper limit Paper not present Paper not present Not at upper limit Out of position Out of position L or 0 Turn permitted Turn permitted Turn permitted ON (up) ON (up) ON (up) ON (up) In position Paper present Paper present In position At upper limit Paper present Paper present At upper limit In position In position PJ12A-1~ 4 PJ11A-1~ 4 PJ10A-1~ 4 PJ9A-8B PJ9A-7B PJ9A-2A PJ9A-1A PJ3A-2 CN/PJ No.
Symbol
Parts/Signal Name
I/O
M22
6/8
IC1A
PB1
M23
6/8
IC1A
PB0
f f f f f
M24 M25 PC11
6/8 6/8 6/8 6/8 6/8
PA0 PA1 PA2 PA3 PB1
PC13
6/8
IC2A
PB0
PJ3A-5
PC17
6/8
IC1A
PC3
PJ7A-5
PC18
6/8
IC1A
PE2
PJ7A-2
PC19
6/8
IC1A
PG3
PJ6A-12
PC21
6/8
IC1A
PE3
PJ6A-9
PC22
6/8
IC1A
PC2
PJ6A-5
PC23
6/8
IC1A
PF3
PJ8A-8
PC25 PC26
6/8 6/8
IC1A IC1A
PG2 PF2
PJ9A-2B PJ9A-7A
T-17
Symbol
Parts/Signal Name
Display Page
IC No.
Port No.
I/O
Operation Characteristics/Panel Display H or 1 L or 0 Paper present In position
CN/PJ No.
PC29
4th Drawer Paper Take-Up Sensor Large Capacity Toner Collecting Box Set Sensor 3rd Drawer Paper Lift-Up Motor Pulse Sensor 4th Drawer Paper Lift-Up Motor Pulse Sensor 3rd Drawer Lower Position Sensor 4th Drawer Lower Position Sensor 3rd Drawer Paper Empty Board 4th Drawer Paper Empty Board 3rd Drawer Paper Descent Key 4th Drawer Paper Descent Key
6/8
IC2A
PB3
Paper not present Out of position Unblocked Unblocked Not at lower limit Not at lower limit Paper not present Paper not present OFF OFF
PJ8A-5
PC31
6/8
IC2A
PC3
PJ2A-2
PC67
6/8
IC1A
PC1
Blocked
PJ9A-5B
PC68
6/8
IC1A
PD1
Blocked At lower limit At lower limit Paper present Paper present ON ON
PJ9A-4A
PC69
7/8
IC2A
PD1
PJ4A-7A
PC70
7/8
IC2A
PC0
PJ4A-8A
PWB-E1
6/8
IC1A
PC0
PJ4A-4A
PWB-E2
6/8
IC1A
PD0
PJ4A-3A
UN5 UN6
7/8 7/8
IC2A IC2A
PC1 PC2
PJ4A-9A PJ4A-10A
T-18
PF-5D/AD-8 Display Page IC No. Port No. Operation Characteristics/Panel Display H or 1 M21 Vertical Transport Drive Motor Duplex Unit Drive Motor Duplex Unit Drive Motor/lock signal Duplex Unit Paper Take-Up Clutch Duplex Unit Gate Switching Solenoid Duplex Unit Rear Finger Solenoid Duplex Unit Pick-Up Solenoid Duplex Gate Home Position Sensor Front/Rear Edge Guide Plate Home Position Sensor Lower Left Door Sensor Duplex Unit Turnover Path Sensor Duplex Unit Paper Entry Sensor Duplex Unit Paper Empty Sensor Duplex Unit Paper Take-Up Sensor Vertical Transport Sensor 3 Lower Right Door Sensor Large Capacity Toner Collecting Box Set Sensor 4/8 IC1A PB3 f f f f f f Turn inhibited OFF When locked OFF OFF OFF OFF Not at home Not at home Out of position Paper not present Paper not present Paper not present Paper not present Paper not present Out of position Out of position L or 0 Turn permitted ON When turned ON ON ON ON At home PJ12A-1~ 4 PJ5G-2 PJ5G-1 PJ2G-7 PJ3G-5 PJ3G-7 PJ2G-12 PJ7G-2 CN/PJ No.
Symbol
Parts/Signal Name
I/O
M31 CL31 SL31 SL32 SL33 PC8
7/8 7/8 7/8 7/8 7/8 7/8 7/8
IC1G IC1G IC1G IC1G IC1G IC1G IC1G
PB3 PE1 PA3 PH1 PH0 FB2 PE0
PC9
7/8
IC1G
PC3
At home In position Paper present Paper present Paper present Paper present Paper present In position In position
PJ7G-5
PC11
5/8
IC2A
PB1
PJ3A-2
PC13
5/8
IC2A
PB0
PJ3A-5
PC14
7/8
IC1G
PC1
PJ3G-2
PC15
7/8
IC1G
PC2
PJ2G-4
PC16
7/8
IC1G
PC0
PJ2G-9
PC17
5/8
IC1A
PC3
PJ7A-5
PC18
5/8
IC1A
PE2
PJ7A-2
PC31
5/8
IC2A
PC3
PJ2A-2
T-19
1151SBT0300A
3 PAPER TRANSPORT FAILURE

1156SBT0301A
3-1. Paper Misfeed

When a paper misfeed occurs, the Touch Panel shows the corresponding message, misfeed location and paper location. Blinking Light There is a misfeed at that location. There might be a sheet of paper stopped at that location.
Steady Light
1149T002CA
*When option is installed Blinking/Steady LED Misfeed/Paper Location Multi Bypass take-up and transport Transport/separator Fusing/exit Copier take-up/vertical transport Paper Feed Cabinet take-up/vertical transport Duplex Unit vertical transport 1st Drawer take-up 2nd Drawer take-up 3rd Drawer take-up 4th Drawer take-up Duplex Unit take-up T-22 T-20 T-24 T-17,18 T-25 to 28 T-30 T-17 T-17 T-25 to 28 T-26 T-32,33 T-31 Ref. Page
, ,
* *
Duplex Unit storage ADF take-up ADF transport ADF turnover/exit Sorter LCC
* * * * * * * * *
<Display Resetting Method>

When misfeed occurs in the copier When misfeed occurs in the option (except Duplex Unit) Open and close the Front Door. Raise and lower the option, or slide the option away from, and back up against, the copier.
T-20
<Misfeed Detecting Sensor Layout>
*When options (PF-205+AD-9) are installed
Paper Exit Sensor (S53) Paper Leading Edge Detecting Sensor (PC54)
Transport Roller Sensor (PC54) 1st Drawer Vertical Transport Sensor (PC63) 1st Drawer Paper Take-Up Sensor (PC56) 2nd Drawer Vertical Transport Sensor (PC64)
*Duplex Unit Vertical Transport Sensor (PC12)
2nd Drawer Paper Take-Up Sensor (PC57)
*Vertical Transport Detection Sensor 3 (PC17) *Duplex Unit Paper Entry Sensor (PC14) *Vertical Transport Detection Sensor 4 (PC22) *Duplex Unit Paper Take-up Sensor (PC16)
*Duplex Unit Turnover Path Sensor (PC13)
1156T001AB
*Duplex Unit Paper Empty Sensor (PC15)
*3rd Drawer Paper Take-up Sensor (PC21)
*4th Drawer Paper Take-up Sensor (PC29)
T-21
1156SBT0302A
3-2. Misfeed Detection Types and Detection Timings

D The following table lists the types of misfeed detection classified by the misfeed locations and their corresponding detection timings. Note: For the misfeed detection types and detection timings in the options, see the Service Manual for the options.
<Copier Paper Take-up Misfeed>

Type Paper take-up failure detection Detection Timing 1st Drawer Paper Take-Up Sensor PC56 is not blocked (L) even after the lapse of approx. 2.2 sec. after 1st Drawer Paper Take-Up Motor M11 has been energized. 2nd Drawer Paper Take-Up Sensor PC57 is not blocked (L) even after the lapse of approx. 2.2 sec. after 2nd Drawer Paper Take-Up Motor M12 has been energized. Paper take-up trailing edge detection PC56 is not unblocked (H) even after the lapse of T (which varies for paper sizes) after it has been blocked (L). PC57 is not unblocked (H) even after the lapse of T (which varies for paper sizes) after it has been blocked (L). Paper take-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 PC54 is not blocked (L) even after the lapse of approx. 1.3 sec. after PC63 has been blocked (L). PC54 is not blocked (L) even after the lapse of approx. 1.7 sec. after PC64 has been blocked (L).
<Multi-Bypass Misfeed>
Type Paper take-up failure detection Detection Timing PC54 is not blocked (L) even after the lapse of approx. 2.5 sec. after Manual Feed Paper Take-Up Clutch CL3 has been energized.
<Transport/Separator Misfeed>
Type Trailing edge detection by Transport Roller Sensor PC54 Leading edge detection by Paper Leading Edge Detecting Sensor PC55 Trailing edge detection by PC55 Detection Timing PC54 is not unblocked (H) even after the lapse of T (which varies for paper sizes) after the TRON signal has been input. PC55 is not blocked (L) even after the lapse of approx. 1.2 sec. after PC54 has been blocked (L). PC55 is not unblocked (H) even after the lapse of approx. 1.2 sec. after PC54 has been unblocked (H).
T-22
<Fusing/Exit Misfeed>
Type Leading edge detection by Paper Exit Switch S53 Trailing edge detection by S53 Detection Timing S53 is not deactuated even after the lapse of approx. 2 sec. after the TRON signal has been input. S53 is not actuated even after the lapse of approx. 2.5 sec. after PC55 has been unblocked (H).
T-23
1156SBT0303A
3-3. Misfeed Clearing Procedures

1156SBT030301A
1) Copier Paper Take-Up Misfeed

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 PWBC D Master Board PWB-A
1156C01TAA
T-24
uCopier Paper Take-Up Misfeed Clearing Procedure

Symptom D Paper is not taken up at all. D Paper is stationary before the Paper Take-Up Sensor. Step 1 Check Item Does the paper being used meet product specifications? Is the paper curled, waved, or damp? Is the Trailing Edge Stop or Edge Guide in good position? Are the Paper Take-Up Roll and Separator Roll deformed, worn, or dirty with paper dust? Is the Paper Take-Up Motor (M11, M12) turning when the Start key is pressed? Run the Controller/Board Check. Is either of the malfunction codes C032A and C032B displayed? Are the Vertical Transport Rollers deformed, worn, or dirty with paper dust? Does PC63 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB6. Does PC64 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB7. Does PC56 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB3. Does PC57 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB4. Does PC54 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC5A) BPB6. Result NO Action Instruct the user to use the paper that meets product specifications. Change the paper. Instruct the user in how to store the paper. Position the edge stop and guide to meet the paper size. Clean or change the Paper Take-Up Roll and/or Separator Roll. Check the motor for overload. Change PWB-A. Change M11, M12, or PWB-C. Clean or change the Vertical Transport Rollers. Check the PC63 actuator for operation and, if it checks okay, change PC63.
YES
NO
YES
NO YES NO
Paper is stationary at the Vertical Transport Section.
YES
NO
NO
Check the PC64 actuator for operation and, if it checks okay, change PC64.
NO
NO
YES
Change PWB-A. Check the PC54 actuator for operation and, if it checks okay, change PC54.
NO
T-25
Symptom Paper is stationary at the Vertical Transport Section
Step
Check Item Does CL1 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPA3 to 0. Run the Controller Board Check. Is the malfunction code C0321 displayed?
Result
Action Check the drive transmission path.
YES
YES NO
Change PWB-A. Change CL1.
T-26
1156SBT030302A
2) Transport/Separator 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
T-27
uTransport/Separator Misfeed Clearing Procedure

Symptom Paper is stationary at the Synchronizing Roller. Step 1 Check Item Is the paper curled, waved or damp? Does CL2 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPA4 to 0. Run the Controller Board Check. Is the malfunction code C0320 displayed? Is an adequate length of loop formed before the Synchronizing Roller? Does PC55 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC5A) BPB5. Is the Pre-Image Transfer Guide Plate deformed or dirty? Are the Image Transfer/Paper Separator Corona wires deteriorated or dirty? Is the paper guide at the Paper Separator Corona deformed or dirty? Are the Synchronizing Rollers deformed, worn, or dirty with paper dust? Run the Controller Board Check. Is the malfunction code C031D or C031E displayed? Result YES Action Change the paper. Instruct the user in how to store the paper. Check the drive transmission path.
YES
YES NO
Change PWB-A. Change CL2. Adjust the loop length using the Loop Adjust (Drawer) function of Tech. Rep. Choice. Change PWB-A. Check the PC55 actuator for operation and, if it checks okay, change PC55. Correct, clean, or change the guide plate. Clean or change the wires.
NO
YES NO
Paper is stationary near the PC Drum.
YES
YES Clean or change the paper guide. Clean or change the Synchronizing Rollers. Change PWB-A. Change the Image Transfer/ Paper Separator Coronas Assy or HV1. Clean or change the Paper Separator Fingers. Check the drive transmission path.
YES
YES YES NO
Paper is wedged at the Paper Separator Fingers.
Are the Paper Separator Fingers deformed or dirty? Does SL1 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPA0 to 0. Run the Controller Board Check. Is the malfunction code C0324 displayed?
YES
YES
YES NO
Change PWB-A. Change SL1.
T-28
Symptom Paper is stationary on the Suction Belts.
Step 1
Check Item Do the Suction Belts turn when the Main Drive Motor runs? Does M4 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPC2 to 0. Does M4 then run at full speed?
Result NO YES
Action Check the drive gears and timing belt. Check the Suction Belts.
NO
Change M4 or PWB-A.
T-29
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
T-30
uMulti Bypass Misfeed Clearing Procedure

Symptom Paper is not detected. 1 Step Check Item Does PC51 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC5A) BPB1. Does the paper being used meet product specifications? Is the paper curled, waved, or damp? Is the Manual Bypass Paper Take-Up Roll deformed, worn, or dirty with paper dust? Does SL51 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC5A) BPA3 to 0. Does the roll then go down? Run the Controller/Board Check. Is the malfunction code C0336 displayed? Does CL3 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC5A) BPA1 to 0. Run the Controller/Board Check. Is the malfunction code C0337 displayed? Result YES Action Change PWB-A. Check the PC51 actuator for operation and, if it checks okay, change PC51. Instruct the user to use the paper that meets product specifications. Change the paper. Instruct the user in how to store the paper. Clean or change the Manual Bypass Paper Take-Up Roll. Check the drive transmission path. YES
NO
Paper is not taken up at all.
NO
YES
YES
YES NO
Change PWB-A. Change SL51. Check the drive transmission path.
YES
YES NO
Change PWB-A. Change CL3.
T-31
1156SBT030304A
4) Fusing/Exit Misfeed
Relevant Electrical Parts D Paper Exit Switch S53 D Suction Fan Motor M4 D Master Board PWB-A
1156C04TAA
T-32
uFusing/Exit Misfeed Clearing Procedure

Symptom Paper is stationary before the Fusing Roller. Step 1 Check Item Is the paper curled, waved, or damp? Is the Fusing Guide Plate deformed or dirty? Does M4 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPC2 to 0. Does M4 then turn at full speed? Are the Fusing Rollers dirty or scratched? Are the Fusing Roller Paper Separator Fingers deformed, worn, or dirty? Is the Cleaning Roller dirty or scratched? Does S53 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (IC5A) BPB3. Result YES Action Change the paper. Instruct the user in how to store the paper. Clean, correct, or change the Fusing Guide Plate. Check the Suction Belts. YES Change M4 or PWB-A. NO Clean or change the Fusing Rollers. Clean, correct, or change the defective separator fingers. Clean or change the Cleaning Roller. Change PWB-A. Check the S53 actuator for operation and, if it checks okay, change S53.
YES
Paper is stationary at the Fusing Roller.
YES
2 3 Paper is stationary at the Exit Roller. 1
YES
YES YES
NO
T-33
1156SBT030305A
5) PF-205 Paper Take-Up Misfeed

Relevant Electrical Parts D 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
T-34
Symptom D Paper is not taken up at all. D Paper is stationary before the Paper Take-Up Sensor.
Step 1
Check Item Does the paper being used meet product specifications? Is the paper curled, waved, or damp? Are the Paper Take-Up Roll and Separator Roll deformed, worn, or dirty with paper dust? Is the Paper Take-Up Motor (M22, M23) turning when the Start key is pressed?
Result NO
Action Instruct the user to use the paper that meets product specifications. Change the paper. Instruct the user in how to store the paper. Clean or change the Paper Take-Up Roll and/or Separator Roll. D Check the motor for overload. D Change PWB-A (PF-205) or PWB-A (copier). Change M22 or M23. D Check the motor for overload. D Change PWB-A (PF-205) or PWB-A (copier). Change M21. Clean or change the Vertical Transport Rollers. Check the PC17 actuator for operation and, if it operates properly, change PC17.
YES
YES
NO
Is Vertical Transport Drive Motor M21 turning when the Start key is pressed?
NO
Are the Vertical Transport Rollers deformed, worn, or dirty with paper dust? 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). Does PC22 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) IC1A PC2 (metric areas) or PWB-A (MC) IC1A PC2 (inch areas). Does PC21 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) IC1A PE3 (metric areas) or PWB-A (MC) IC1A PE3 (inch areas). Does PC29 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) IC1A PB3 (metric areas) or PWB-A (MC) IC1A PB3 (inch areas).
YES
NO
NO
Check the PC22 actuator for operation and, if it operates properly, change PC22.
NO
YES
Change PWB-A (PF-205) or PWB-A (copier). Check the PC29 actuator for operation and, if it operates properly, change PC29.
NO
T-35
1156SBT030306A
6) PF-105 Paper Take-Up 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
T-36
Symptom D Paper is not taken up at all. D Paper is stationary before the Paper Take-Up Sensor.
Step 1
Check Item Does the paper being used meet product specifications? Is the paper curled, waved, or damp? Are the Paper Take-Up Roll and Separator Roll deformed, worn, or dirty with paper dust? Is 3rd Drawer Paper TakeUp Motor M22 turning when the Start key is pressed?
Result NO
Action Instruct the user to use the paper that meets product specifications. Change the paper. Instruct the user in how to store the paper. Clean or change the Paper Take-up Roll and/or Separator Roll. D Check the motor for overload. D Change PWB-A (PF-105) or PWB-A (copier). Change M22. D Check the motor for overload. D Change PWB-A (PF-105) or PWB-A (copier). Change M21. Clean or change the Vertical Transport Rollers. Check the PC17 actuator for operation and, if it operates properly, change PC17.
YES
YES
NO
Is Vertical Transport Drive Motor M21 turning when the Start key is pressed?
NO
Are the Vertical Transport Rollers deformed, worn, or dirty with paper dust? Does PC17 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PC3. Does PC22 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PC2. Does PC21 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PE3.
YES
NO
NO
YES
Change PWB-A (PF-105) or PWB-A (copier). Change M21. Check the PC21 actuator for operation and, if it operates properly, change PC21.
NO
T-37
1156SBT030307A
7) AD-9 Vertical Transport/Storage Misfeed

Relevant Electrical Parts D Vertical Transport Sensor 3 PC17 D Duplex Unit Vertical 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
T-38
uAD-9 Vertical Transport Misfeed Clearing Procedure

Symptom Paper is stationary at the copier exit section. Step Check Item Does SL5 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPA5 to 0. Run the Controller Board Check. Is the malfunction code C0324 displayed? Do the Vertical Transport Roller and drive coupling operate properly when M31 is running? Using the IC Port Data Check function, set the data of PWB-G (Dup) (IC1G) PB3 to 0. Does PC12 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (IC5A) BPB0. Do the Paddle Roller, Slip Roller, and drive coupling operate properly when M31 is running? Using the IC Port Data Check function, set the data of PWB-G (Dup) (IC1G) PB3 to 0. Does PC13 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (200/400) (IC2A) PB0. Result Action Check the drive transmission path. YES
YES NO
Change PWB-A. Change SL51. Check the gears, belts, and rollers.
2 Paper is stationary at the Duplex Unit Vertical Transport Section.
NO
YES
Change PWB-A. Check the PC12 actuator for operation and, if it operates properly, change PC12. Check the gears, belts, and rollers.
NO
Paper is stationary at the Duplex Unit Turnover Section. 1
NO
YES
Change PWB-A (copier) or PWB-A (PF-205/105). Check the PC13 actuator for operation and, if it operates properly, change PC13.
NO
T-39
uAD-9 Storage Misfeed Clearing Procedure

Symptom The leading edge of the paper is stationary inside the Duplex Unit. Step 1 Check Item Is the Paper Guide Mylar dirty or deformed? Does PC14 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (Dup) (IC1G) PC1. Result YES Action Clean or change the mylar. Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). Check the PC14 actuator for operation and, if it operates properly, change PC14. Check the Gate Switching Lever for operation. Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). Change SL31. Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). Check the PC15 actuator for operation and, if it operates properly, change PC15.
YES
NO
Does SL31 operate properly? Using the IC Port Data Check function, set the data of PWB-A (Dup) (IC1G) PH1 to 0. Does PC15 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (Dup) (IC1G) C2.
YES
NO
Paper is stationary at the storage section. 1
YES
NO
T-40
1156SBT030308A
8) AD-9 Paper Take-Up Misfeed

Relevant Electrical 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
T-41
uAD-9 Paper Take-Up Misfeed Clearing Procedure

Symptom Paper is not taken up at all. 1 Step Check Item Does SL33 operate properly? Using the IC Port Data Check function, set the data of PWB-A (Dup) (IC1G) PB2 to 0. Does CL33 operate properly? Using the IC Port Data Check function, set the data of PWB-A (Dup) (IC1G) PA3 to 0. Are the Take-Up Roll, Feed Roll, and Separator Roll deformed, worn, or dirty with paper dust? Is Vertical Transport Drive Motor M21 turning when a copy is taken up and fed into the copier from the Duplex Unit? Are the Vertical Transport Rollers deformed, worn, or dirty with paper dust? Does PC17 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (200, 400) (IC1A) PC3. Does PC16 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (Dup) (IC1G) PC0. Result YES Action Check the pick-up mechanism. Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). Change SL33. Check the drive transmission path. Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). Change CL31. Clean or change the defective roll.
NO
YES
NO
YES
YES
Check the motor for overload. Change PWB-A (copier) or PWB-A (PF-205/105). Change M21. Clean or change the defective roller. Change PWB-A (copier) or PWB-A (PF-205/105). Check the PC17 actuator for operation and, if it operates properly, change PC17. Change PWB-A (copier) or PWB-A (PF-205/105). Check the PC16 actuator for operation and, if it operates properly, change PC16.
NO
YES
YES
NO
YES
NO
T-42
1151SBT0400A
4 MALFUNCTIONS
1156SBT0401A
4-1. Detection Timings Classified by Malfunction Codes

D The codes marked with an asterisk (*) are the candidates for isolated malfunctions.
C00## Drive Malfunctions

* Code C0000 Main Drive Motor M1 turning at abnormal timing Suction Fan Motor M4s failure to turn C0040 Fusing Section Cooling Fan Motor M15s failure to turn Fusing Section Cooling Fan Motor M15 turning at abnormal timing Original Glass Cooling Fan Motor M5s failure to turn Original Glass Cooling Fan Motor M5 turning at abnormal timing Ventilation Fan Motor M3s failure to turn Ventilation Fan Motor M3 turning at abnormal timing Main Hopper Toner Replenishing Motor M8s failure to turn C0070 Description Main Drive Motor M1s failure to turn
1156SBT040101A
Detection Timing The lock signal remains HIGH for a continuous 2.0-sec. or more period while M1 is energized. The lock signal remains LOW for a continuous 1.5-sec. or more period while M1 is deenergized. The lock signal remains HIGH for a continuous 1.0-sec. or more period while M4 is energized. The lock signal remains HIGH for a continuous 2.0-sec. or more period while M15 is energized. The lock signal remains LOW for a continuous 2.0-sec. or more period while M15 is deenergized. The lock signal remains HIGH for a continuous 2.0-sec. or more period while M5 is energized. The lock signal remains LOW for a continuous 2.0-sec. or more period while M5 is deenergized. The lock signal remains HIGH for a continuous 2.0-sec. or more period while M3 is energized. The lock signal remains LOW for a continuous 2.0-sec. or more period while M3 is deenergized. D Toner Bottle Home Position Sensor PC35 does not go from HIGH to LOW within 12 sec. after M8 has been energized. D PC35 does not go LOW within 12 sec. after M8 has been energized and PC35 gone HIGH. PC35 is HIGH 2 sec. after M8 has been deenergized. When the current toner-to-carrier ratio is 2% lower than the SCH-90 setting and the Add Toner Indicator is not lit on the control panel, a toner replenishing sequence is carried out (M9 is turned); the toner-to-carrier ratio does not increase by 1% within 140 seconds or by 2% within 220 seconds.
C0001
C0046
C0047
C004A
C004b
C004c
C004d
C0071
Main Hopper Toner Replenishing Motor M8 turning at abnormal timing Sub Hopper Toner Replenishing Motor M9s failure to turn
C0072
T-43
C02## Corona Malfunction

* Code C0200 Description PC Drum Charge, Image Transfer, Paper Separator Corona malfunction
1156SBT040102A
Detection Timing The leak signal (SCD) turns ON after the PC Drum Charge and Image Transfer/Paper Separator Corona output has been turned ON.
1156SBT040103A
C03## Master Board/Harness Malfunctions
D The copier performs a self-diagnostic sequence to determine if the microprocessor outputs a signal to each of the IC ports on Master Board PWB-A properly. It is intended for detecting the following malfunctions (C03##). D Any malfunction is detected when Controller Board Check available from the I/O Check function of the Tech. Rep. mode is executed. D If the microprocessor fails to output any of these signals or if any of the electronic components on the board (driver IC, etc.) is faulty, the copier determines that there is a faulty condition existing and shows the corresponding malfunction code on the Touch Panel. D C0350, C0351, C0352, C0353, or C0357 is displayed when there is a communication fault between the copier and paper feeder option or Duplex Unit, and detected as an isolated malfunction when the Power Switch is turned ON. * Code C0300 C0310 C0311 C0312 C0313 C0314 C0315 C0316 C0317 C0318 C0319 C031A C031B C031C C031D C031E C031F C0320 C0321 C0322 C0323 C0324 C0325 C0326 C0327 C0328 C0329 Description Port diagnosis cannot be started. Drum Dehumidifying Heater H2 REM signal Fusing Heater Lamp H1 REM signal Exposure Lamp Regulator PWB-J REM signal AE Sensor Board PWB-H PWM signal Image Erase Lamp LA3 DATA Image Erase Lamp LA3 MODE Image Erase Lamp LA3 CLOCK Image Erase Lamp LA3 STROBE Copy vendor count (during copy cycle) Copy vendor count (size) 2nd Drawer Paper Take-Up Motor M12 energization 1st Drawer Paper Take-Up Motor M11 energization Original size detection Original size detection, marketing area 2 Original size detection, marketing area 1 Scanner Motor M2 SCAN signal Scanner Motor M2 ENABLE signal Fusing Section Cooling Fan Motor M15 REM signal Separator/Developing Bias output REM signal PC Drum Charge/Image Transfer output REM signal Exit/Duplex Switching Solenoid SL5 Synchronizing Roller Clutch CL2 Paper Transport Clutch CL1 Main Drive Motor M1 REM signal Main Erase Lamp LA2 REM signal Separator Solenoid SL1 REM signal Master Board Port IC1A P45 IC1A P57 IC1A P61 IC1A P60 IC1A P64 IC1A P65 IC1A P66 IC1A P67 IC3A APA1 IC3A APA0 IC3A 1 IC3A O IC4A APA7 IC4A APA6 IC4A APA5 IC4A APC0 IC4A APC1 IC4A APC2 IC4A BPA7 IC4A BPA6 IC4A BPA5 IC4A BPA4 IC4A BPA3 IC4A BPA2 IC4A BPA1 IC4A BPA0
T-44
Code C032A C032B C032C C032D C032E C032F C0330 C0331 C0332 C0333 C0334 C0335 C0336 C0337 C0338 C0339 C033A C033B C033C C0350 C0351 C0352 C0353 C0357
Description Main Hopper Toner Replenishing Motor M8 Suction Fan Motor M4 33/ Ventilation Fan Motor M3 Ventilation Fan Motor M3 2nd Drawer Paper Lift-Up Motor M14 DOWN 2nd Drawer Paper Lift-Up Motor M14 UP 1st Drawer Paper Lift-Up Motor M13 DOWN 1st Drawer Paper Lift-Up Motor M13 UP Separator bias switching Sub Hopper Toner Replenishing Motor M9 2nd Drawer Paper Take-Up Motor M12 ENABLE 1st Drawer Paper Take-Up Motor M11 ENABLE Manual Feed Paper Take-Up Solenoid SL4 UP Manual Feed Paper Take-Up Solenoid SL4 DOWN Manual Feed Paper Take-Up Clutch CL3 Warming-up completion signal During copy cycle SSR2 REM signal (MH only) Exposure Lamp Regulator PWB-J PWM signal Grid PWM signal Paper Feed Cabinet S/P-0 Paper Feed Cabinet S/P-1 Duplex Unit S/P-2 Large Capacity Cassette S/P-3
Master Board Port IC4A BPC3 IC4A BPC2 IC4A BPC1 IC5A APA7 IC5A APA6 IC5A APA5 IC5A APA4 IC5A APA3 IC5A APA2 IC5A APA1 IC5A APA0 IC5A BPA2 IC5A BPA3 IC5A BPA1 IC5A BPA7 IC5A BPA6 IC5A BPA5 IC4A TOUT IC5A TOUT IC3 SO0 IC3 SO1 IC3 SO2 IC3 SO3 IC3 S13
T-45
1156SBT040104A
C04## Exposure Lamp Malfunctions

* Code C0400 Description Exposure Lamp LA1s failure to turn ON Detection Timing The output from AE Sensor Board PWB-H does not become 4.0V or more for the period between when LA1 turns ON and the Scanner starts a scan motion and when the Image Leading Edge signal (BASE) turns ON. With LA1 OFF, the output from PWB-H remains 3.9V or less for a continuous 3-sec. period at any timing while the Scanner is at the home position or the Original Cover is lowered.
C0410
Exposure Lamp LA1 turning ON at abnormal timing
1156SBT040105A
C05## Fusing Malfunctions

* Code C0500 Description Warming-up failure (Fusing Heater Lamp failure) Detection Timing The surface temperature of the Upper Fusing Roller does not reach a given level even after the lapse of a given period of time during warming-up as detailed below: D If the temperature is 165_C or less when the Power Switch is turned ON: EP4051 From room temperature to 65_C 65_C~140_C 140_C~170_C *170_C~200_C *170_C~190_C 105S 210S 220S 145S 145S EP3051 60S 110S 120S 100S 100S
D If the temperature is more than 165_C when the Power Switch is turned ON: EP4051 EP3051 *~200_C 200S 120S *~190_C 200S 120S *A 200_C temperature control is provided for the first 1 hour after the Power Switch has been turned ON and 190_C temperature control is provided thereafter. C0510 Abnormally low fusing temperature (Fusing Heater Lamp failure) The surface temperature of the Upper Fusing Roller remains 135C or less for a continuous 5-sec. period or more after the copier has completed warming up. The surface temperature of the Upper Fusing Roller remains 230C or more for a continuous 5-sec. period or more after the copier has completed warming up.
C0520
Abnormally high fusing temperature (Fusing Heater Lamp turning ON at abnormal timing)
T-46
1156SBT040106A
C06## Optical Malfunctions

* Code C0600 Description Scanner Motor M2 malfunction Detection Timing D When the Scanner is at a position other than home, Scanner Reference Position Sensor PC81 does not go from HIGH to LOW even after the lapse of 20 sec. after the Power Switch has been turned ON. D When the Scanner is at the home position, PC81 does not go from LOW to HIGH even after the lapse of 5 sec. after the Scanner has started a scan motion. D PC81 does not go from HIGH to LOW even after the lapse of 20 sec. after the Scanner has started a scan motion. The output from Lens Reference Position Sensor PC90 does not go from HIGH to LOW, or vice versa, even after the lapse of 15 sec. after M6 has started turning. D The output from Mirror Reference Position Sensor PC86 does not go from HIGH to LOW even after the lapse of 10 sec. after M7 has started turning. D The output from PC86 does not go from LOW to HIGH even after the lapse of 3 sec. after M7 has started turning. 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 signal 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. The SHOME signal remains LOW even after the lapse of 7 sec. after it has gone LOW. The BASE signal does not go LOW even after the lapse of 5 sec. after the SHOME signal has gone HIGH. The BASE signal remains LOW even after the lapse of 5 sec. after the SHOME signal has gone HIGH. The TRON signal remains HIGH even after the lapse of 5 sec. after the BASE signal has gone LOW. The TRON signal remains LOW even after the lapse of 5 sec. after it has gone LOW. The SCEND signal remains HIGH even after the lapse of 5 sec. after the TRON signal has gone LOW. The SCEND signal remains LOW even after the lapse of 5 sec. after it has gone LOW.
C0610
Lens Motor M6 malfunction
C0620
Mirror Motor M7 malfunction
C06F0
SHOME signal failure (Signal does not go LOW)
C06F1 C06F2
SHOME signal failure (Signal does not go HIGH) BASE signal failure (Signal does not go LOW) BASE signal failure (Signal does not go HIGH) TRON signal failure (Signal does not go LOW) TRON signal failure (Signal does not go HIGH) SCEND signal failure (Signal does not go LOW) SCEND signal failure (Signal does not go HIGH)
C06F3
C06F4
C06F5 C06F6
C06F7
T-47
1156SBT040107A
C09## Paper Take-Up Malfunctions

* Code C0900 C0901 (Inch Area) C0902 (Inch Area) C0903 (Inch Area) C0904 C0906 (Inch Area) C0950 C0951 (Inch Area) C0952 (Inch Area) C0953 (Inch Area) C0954 C0956 (Inch Area) Description 3rd Drawer upward motion failure 3rd Drawer downward motion failure 3rd Drawer downward motion failure 3rd Drawer upward motion failure 3rd Drawer Lift-Up Motor M24s failure to turn 3rd Drawer ejection failure See PF-205 Service Manual. 4th Drawer upward motion failure 4th Drawer downward motion failure 4th Drawer downward motion failure 4th Drawer upward motion failure 4th Drawer Lift-Up Motor M25s failure to turn 4th Drawer ejection failure Detection Timing
T-48
Code
Description 2nd Drawer upward motion failure
Detection Timing D 2nd Drawer Lift-Up Sensor PC66 is not blocked (L) even after the lapse of 5 sec. after 2nd Drawer Paper Lift-Up Motor M14 has been energized. D PC66 is not blocked (L) even if 2nd Drawer LiftUp Motor Pulse Sensor PC68 detects 75 pulses after M14 has been energized. D When PC66 is blocked (L), it is not unblocked (H) even after the lapse of 5 sec. after M14 has been energized. D PC66 is not unblocked (H) even if PC68 detects 10 pulses after M14 has been energized. D When PC66 is unblocked (H), 2nd Drawer Lower Limit Position Sensor PC70 is not blocked (L) even after the lapse of 5 sec. after M14 has been energized. D PC70 is not unblocked (H) even after the lapse of 1.5 sec. after it has been blocked (L). D PC70 is not blocked (L) even if PC68 detects 75 pulses after M14 has been energized. D PC70 is not blocked (L) even after the lapse of 2 sec. after M14 has been energized. D When PC70 is blocked (L), it is not unblocked (H) even after the lapse of 5 sec. after M14 has been energized. D PC70 is not unblocked (H) even after the lapse of 2 sec. after it has been blocked (L). 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. D The 2nd Drawer is not ejected even after the lapse of 2 sec. after PC70 has been blocked (L). D 1st Drawer Lift-Up Sensor PC65 is not blocked (L) even after the lapse of 5 sec. after 1st Drawer Paper Lift-Up Motor M13 has been energized. D PC65 is not blocked (L) even if 1st Drawer LiftUp Motor Pulse Sensor PC67 detects 75 pulses after M13 has been energized. D When PC65 is blocked (L), it is not unblocked (H) even after the lapse of 5 sec. after M13 has been energized. D PC65 is not unblocked (H) even if PC67 detects 10 pulses after M13 has been energized. D When PC65 is unblocked (H), 1st Drawer Lower Limit Position Sensor PC69 is not blocked (L) even after the lapse of 5 sec. after M13 has been energized. D PC69 is not unblocked (H) even after the lapse of 1.5 sec. after it has been blocked (L). D PC69 is not blocked (L) even if PC67 detects 75 pulses after M13 has been energized. D PC69 is not blocked (L) even after the lapse of 2 sec. after M13 has been energized. D When PC69 is blocked (L), it is not unblocked (H) even after the lapse of 5 sec. after M13 has been energized. D PC69 is not unblocked (H) even after the lapse of 2 sec. after it has been blocked (L).
C0910
C0911
2nd Drawer downward motion failure
2nd Drawer downward motion failure C0912
2nd Drawer upward motion failure C0913
C0914 * C0916
2nd Drawer Paper LiftUp Motor M14s failure to turn
2nd Drawer ejection failure 1st Drawer upward motion failure
C0920
1st Drawer downward motion failure C0921
1st Drawer downward motion failure
C0922
1st Drawer upward motion failure C0923
T-49
Code C0924
Description 1st Drawer Paper LiftUp Motor M13s failure to turn
Detection Timing 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. D The 1st Drawer is not ejected even after the lapse of 2 sec. after PC69 has been blocked (L).
* C0926 1st Drawer ejection failure
T-50
Code C0990 C0991 C0992 C0993 C0994 C0996 C0998
Description Main Tray upward motion failure Main Tray downward motion failure Main Tray downward motion failure Main Tray upward motion failure Elevator Motor M26s failure to turn Main Tray ejection failure Shifter transfer failure Shifter return failure Shifter return failure Shifter transfer failure Shift Motor M27s failure to turn Shift Gate position detecting failure Shift Gate position detecting failure Elevator ascent fault Elevator descent fault
Detection Timing
See PF-105 Service Manual.
C0999 C099A C099b C099C C099E C099F C09C0 C09C2
See C-301 Service Manual.
T-51
1156SBT040108A
C0E## Erase Lamp Malfunctions

* Code C0E00 C0E01 Description Main Erase Lamp LA2s failure to turn ON Main Erase Lamp LA2 turning ON at abnormal timing Image Erase Lamp LA3s failure to turn ON Detection Timing The LA2 Failure Detection signal remains HIGH for a continuous 1-sec. period while LA2 is ON. The LA2 Failure Detection signal remains LOW for a continuous 1-sec. period while LA2 is OFF. The LA3 gate array is faulty as found through a self-diagnostic sequence carried out immediately after Main Drive Motor M1 has been deenergized.
C0E20
1156SBT040109A
C0F## Sensor Malfunctions

* Code Description Original Size Detecting Board UN2 malfunction * C0F02 Detection Timing D Undefined data is input to the master CPU. D Under normal conditions: A fixed-cycle pulse signal (Busy) remains HIGH or LOW for 3 sec. or more. D When the Power Switch is ON: A fixed-cycle pulse signal (Busy) remains HIGH or LOW for 5 sec. or more. 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. 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 The output from PWB-G is less than 1V when the load resistance is made minimum by the 4-bit analog switch. D The output from PWB-G does not fall within the 0.9V-1.1V range when the intensity of PWB-G LED is varied. In the initial F5 or FF mode: 1) Vg of 580V is output. 2) A solid black pattern is produced and the PWB-G output is sampled. 3) If the average is less than 4.3V, Vg is increased. In the initial F5 or FF mode: 1) The Exposure Lamp is turned ON with 58V. 2) A halftone pattern is produced and the PWB-G output is sampled. 3) If the average does not fall within the target range, the exposure level is varied. 4) The average does not fall within the target range even after steps 1) to 3) have been repeated 15 times.
C0F10
AE Sensor Board PWB-H malfunction
AIDC Sensor Board PWB-G variation correction failure * C0F20
AIDC Sensor Board PWB-G grid voltage (Vg) correction failure * C0F22
AIDC Sensor Board PWB-G exposure correction failure
C0F23
T-52
* *
Code C0F30
Description ATDC Sensor UN3 adjustment failure ATDC Sensor UN3 failure
Detection Timing The UN3 output does not fall within the target range in the F8 mode. D The ATDC Ref. Value of Level History drastically 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. See the PF-105 Service Manual.
C0F31
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 D Paper Empty Sensor EMPSEN failure
See the C-301 Service Manual.
T-53
Code C0FE1
Description Original Size Detecting Sensor failure Original Size Detecting Sensor failure Original Size Detecting Sensors and failure Original Size Detecting Sensor failure Original Size Detecting Sensors and failure Original Size Detecting Sensors , and failure Original Size Detecting Sensors ,, and failure Original Size Detecting Sensor failure Original Size Detecting Sensors and failure Original Size Detecting Sensors and failure Original Size Detecting Sensors ,, and failure Original Size Detecting Sensors and failure Original Size Detecting Sensors ,, and failure B Original Size Detecting Sensors ,, and failure Original Size Detecting Sensors ,,, and failure A A
Sensor Layout <Detection Timing> After having read the output data from PC115 to PC119, UN2 determines that there is a failure.
C0FE2
C0FE3
C0FE4
<Sensor Layout> Metric Areas D : PC116, : PC117, : PC118 (option), : PC115, : PC119 (option) D A to E: Sensor locations
C0FE5
Original Size Detecting Board * d
C0FE6
B C D
C0FE7
C0FE8
A B
C0FE9
C0FEA
Inch Areas D : PC116 (option), : PC117, : PC118 (option), : PC115, : PC119 (option) B A C D
C0FEB
C0FEC
C0FED
C0FEE
C0FEF
T-54
Code C0FF0 C0FF1 C0FF2 C0FF3 C0FF4 C0FF5 Original S Size Detecting Board * C0FF6 C0FF7 C0FF8 C0FF9 C0FFA C0FFB C0FFC C0FFD C0FFE
Description Original Size Detecting Sensor failure Original Size Detecting Sensors and failure Original Size Detecting Sensors and failure Original Size Detecting Sensors ,, and failure Original Size Detecting Sensors and failure Original Size Detecting Sensors ,, and failure Original Size Detecting Sensors ,, and failure Original Size Detecting Sensors ,,, and failure Original Size Detecting Sensors and failure Original Size Detecting Sensors ,, and failure Original Size Detecting Sensors ,, and failure Original Size Detecting Sensors ,,, and failure Original Size Detecting Sensors ,, and failure Original Size Detecting Sensors ,,, and failure Original Size Detecting Sensors ,,, and failure Original Size Detecting Sensors ,,,, and failure (Metric Areas) B A A B A
Sensor Layout Metric Areas D : PC116, : PC117, : PC118 (option), PC115, PC119 (option) : : D A to E: Sensor locations
B C D
Inch Areas D : PC116 (option), : PC117, : PC118 (option), : PC115, : PC119 (option) B A C D
C0FFF
T-55
1156SBT040110A
C0b## Staple Sorter/Sorter Malfunctions

* Code C0b00 C0b01 C0b10 C0b11 C0b12 C0b13 C0b30 C0b31 C0b50 C0b51 C0b52 C0b53 C0b60 * C0b61 C0b62 C0b63 C0b64 C0b65 C0b70 C0b71 C0b72
1156SBT040111A
Description Transport drive malfunction
Detection Timing See the ST-210/S-207 Service Manual.
Paper Clamp Unit motion failure
See the ST-210/S-207, ST-101/S-104 Service Manual. See the ST-210/S-207 Service Manual.
Paper Aligning Mechanism drive failure
See the ST-210/S-207, ST-101/S-104 Service Manual.
Stapling failure
Bin motion failure
See the ST-210/S-207, ST-101/S-104 Service Manual.
Hole punching failure
See the ST-210/S-207 Service Manual.
C0d## Duplex Unit Malfunctions

* Code C0d00 C0d20 C0d50 C0d51 Description Front/Rear Edge Guide Plates home position detection failure Gate Unit home position detection failure Duplex Unit Drive Motor M31s failure to turn Duplex Unit Drive Motor M31 turning at abnormal timing Detection Timing See the AD-5 Service Manual.
T-56
1156SBT0402A
4-2. Troubleshooting Procedures

1156SBT040201A
1) C0000: Main Drive Motor M1s 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
T-57
uC0000
Step 1 Check Item Does M1 turn? Set the data of PWB-A (IC4A) BPA2 to 0. Perform the Controller Board Check. Is malfunction code C0327 displayed? Result YES YES NO D Change M1. Change PWB-A. D Check the drive coupling. Action Change PWB-A.
uC0001
Step 1 2 Check Item Does M1 turn when the malfunction is reset? Is malfunction code C0001 displayed again? Result YES YES Action Change PWB-A. Change PWB-A.
T-58
1156SBT040202A
2) C0040: Suction Fan Motor M4s Failure to Turn

Relevant Electrical Parts D Suction Fan Motor M4 D Master Board PWB-A
1156C06TAA
T-59
uC0040
Step 1 Check Item Does M4 turn? Set the data of PWB-A (IC4A) BPC2 to 0. Perform the Controller Board Check. Is malfunction code C032B displayed? Result YES YES NO Change PWB-A. D Change M4. Action Change PWB-A.
uC0011
T-60
1156SBT040203A
3) C0046: Fusing Section Cooling Fan Motor M15s 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
T-61
uC0046
Step 1 Check Item Does M15 turn? Set the data of PWB-A (IC4A) APC2 to 0. Perform the Controller Board Check. Is malfunction code C0321 displayed? Result YES YES NO Change PWB-A. D Change M15. Action Change PWB-A.
uC0047
Step 1 2 Check Item Does M15 turn when the malfunction is reset? Is malfunction code C0047 displayed again? Result YES YES Action Change PWB-A or M15 Change PWB-A or M15
T-62
1156SBT040204A
4) C004A: Original Glass Cooling Fan Motor M5s Failure to Turn C004b: Original Glass Cooling Fan Motor M5 Turning at Abnormal Timing C004C: Ventilation Fan Motor M3s 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
T-63
uC004A
Step 1 Check Item Does M5 turn? Set the data of PWB-A (IC4A) BPC0 to 0. Result YES NO Action Change PWB-A. Change M5.
uC004b
Step 1 2 Check Item Does M5 turn when the malfunction is reset? Is malfunction code C004b displayed again? Result YES YES Action Change PWB-A. Change PWB-A.
uC004C
Step 1 Check Item Does M3 turn? Set the data of PWB-A (IC4A) BPC1 to 0. Result YES NO Action Change PWB-A. Change M3.
uC004d
Step 1 2 Check Item Does M3 turn when the malfunction is reset? Is malfunction code C004d displayed again? Result YES YES Action Change PWB-A. Change PWB-A.
T-64
1156SBT040205A
5) C0070: Main Hopper Toner Replenishing Motor M8s Failure to Turn C0071: Main Hopper Toner Replenishing Motor M8 Turning at Abnormal Timing C0072: Sub Hopper Toner Replenishing Motor M9s 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
T-65
uC0070
Step 1 Check Item Turn the Toner Bottle a half turn by hand and close the Front Door. Does the Toner Bottle turn at this time? Does PC35 operate properly? Make an input port check on PWB-A (IC4A) BPC5. Perform the Controller Board Check. Is malfunction code C032A displayed? Result Go to step 3. NO Change PC35. NO YES NO Change PWB-A. Change M8. Action
uC0071
uC0072
Step 1 Check Item Does M9 turn? Set the data of PWB-A (IC5A) APA2 to 0. Perform the Controller Board Check. Is malfunction code C0332 displayed? Result YES YES NO Change PWB-A. Change M9. Action Change PWB-A.
T-66
1156SBT040206A
6) C0200: Corona Malfunctions

Relevant Electrical Parts D High Voltage Unit HV1 D Master Board PWB-A
1156C10TAA
Step
Check Item Is C0200 displayed even when the PC Drum Charge Corona and Image Transfer/Paper Separator Coronas are removed? Is C0200 displayed when the PC Drum Charge Corona is installed? Is C0200 displayed when the Image Transfer/Paper Separator Coronas unit is installed? Is C0200 displayed even when the HV1 connector is unplugged?
Result Go to step 4. YES
Action
YES
Clean or change the PC Drum Charge Corona. Clean or change the Image Transfer/ Paper Separator Coronas. Change PWB-A. Change HV1.
YES YES NO
T-67
1156SBT040207A
7) C03##: Master Board/Harness Malfunctions

Relevant Electrical Parts D Master Board PWB-A D PF-205/105 Master Board PWB-A D Duplex Unit Master Board PWB-G
uC0300 to C033C
Step 1 Change Master Board PWB-A. Action
uC0350, C0351
Step 1 2 Action Check the connections from PJ20A on PWB-A to PJ13A on PF205/105 PWB-A. Change PWB-A or PF-205/105 PWB-A.
uC0352
Step 1 2 Action Check the connections from PJ20A on PWB-A to PJ8G on Duplex Unit Master Board PWBG. Change PWB-A, PF-205/105 PWB-A, or Duplex Unit Master Board PWB-G.
uC0353, C0357
Step 1 2 Action Check the connections from PJ20A on PWB-A to CN1A on C-301 PWB-A. Change PWB-A or C-301 PWB-A.
T-68
1156SBT040208A
8) C0400: Exposure Lamp LA1s 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
T-69
Step 1
Check Item Does the voltage across PWB-A PJ8A-13 and GND become DC0V (L) when the Start key is pressed? Perform the Controller Board Check. Is malfunction code C0312 or C033B displayed? Disconnect CN7. Is there continuity across CN7-1 and -2 on LA1 side? Is the voltage across PJ3J-1 and 3 on PWB-J the source voltage? Is the voltage across PWB-A PJ3A-2 and GND 3.9V or less when LA1 is off, the Scanner is at the home position, and the Original Cover is lowered?
Result Go to step 2. YES
Action
Change PWB-A. YES Change LA1 or TF1. Change PWB-J. Check the power supply line. Change PWB-A. Change PWB-H.
3 4
NO YES NO YES NO
T-70
1156SBT040209A
9) C0500: Warming-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
T-71
uC0500, C0510
Step 1 2 3 4 5 Check Item Does H1 light up when the Power Switch is turned ON? Is TH1 installed properly? Is TH1 dirty? Measure resistance of TH1. Is is infinite? Perform the Controller Board Check. Is malfunction code C0311 displayed? Check H1 for continuity. Is there continuity? Result NO NO YES YES NO YES YES NO Go to step 5. Reinstall TH1. Clean or change TH1. Change TH1. Change PWB-A. Change PWB-A. Change SSR1. Change H1 or TS1. Action
uC0520
Step 1 2 3 4 5 6 Check Item Does H1 remain lit after the copier has warmed up? Perform the Controller Board Check. Is malfunction code C0311 displayed? Does H1 turn OFF? Is TH1 installed properly? Is TH1 dirty? Measure resistance of TH1. Is is 0 or close to 0? Result NO YES NO NO YES YES NO Go to step 4. Change PWB-A. Change SSR1. Reinstall TH1. Clean or change TH1. Change TH1 (TH2). Change PWB-A. Action
T-72
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
T-73
uC0600
Step 1 2 Check Item Are all connectors on PWB-F plugged in securely? Is the voltage across PWB-F PJ1F-2 and GND DC5V? Perform the Controller Board Check. Is malfunction code C031F or C0320 displayed? Result NO NO YES NO Action Plug them in securely. Check the connection of the DC5V line and, if it is intact, change PU1. Change PWB-A. Change PWB-F or M2.
uC06FX
Step 1 Check Item Are PWB-A PJ8A and PWB-F PJ2F connected securely? Result YES NO Action Change PWB-A or PWB-F. Connect securely.
T-74
1156SBT040211A
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
T-75
uC0610
Step 1 Check Item Are all connectors on PWB-F, M6, and PC90 plugged in securely? Does the voltage across PWB-F PJ6F-5 and GND change from DC5V to DC0V when PC90 is blocked? Is the Lens drive defective? 3 Result NO Action Plug them in securely. Change PC90. NO YES NO Correct or change the defective part. Change PWB-F or M6.
uC0620
Step 1 Check Item Are all connectors on PWB-F, M7, and PC86 plugged in securely? Does the voltage across PWB-F PJ6F-2 and GND change from DC5V to DC0V when PC86 is blocked? Is the Mirror drive defective? Result NO Action Plug them in securely. Change PC86. NO YES NO Correct or change the defective part. Change PWB-F or M7.
T-76
1156SBT040212A
12) C0910: 2nd Drawer Upward Motion Failure C0914: 2nd Drawer Paper Lift-Up Motor M14s Failure to Turn C0920: 1st Drawer Upward Motion Failure C0924: 1st Drawer Paper Lift-Up Motor M13s 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
T-77
uC0910
Step Check Item Does PC66 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB2. Result YES NO Action Change PWB-A. Check the Paper Take-Up Roll for operation. If it is operational, change PC66.
uC0920
Step Check Item Does PC65 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB1. Result YES NO Action Change PWB-A. Check the Paper Take-Up Roll for operation. If it is operational, change PC65.
uC0914
Step 1 Check Item Slide out the 2nd Drawer and slide it back into the copier. Does M14 turn at this time? Perform the Controller Board Check. Is malfunction code C032E displayed? Does the voltage across PWB-C PJ9C-4 and GND change from DC0V to DC24V when the 2nd Drawer is slid back into the copier? Does the voltage across PWB-A PJ23A-5 and GND vary between DC0V and DC5V while M14 is turning? Result Go to step 4. YES YES NO YES NO YES NO Change PWB-A. Replace PWB-A. Change M14. Change PWB-C. Change PWB-A. Change PC68. Action
uC0924
Step 1 Check Item Slide out the 1st Drawer and slide it back into the copier. Does M13 turn at this time? Perform the Controller Board Check. Is malfunction code C033O displayed? Does the voltage across PWB-C PJ9C-2 and GND change from DC0V to DC24V when the 1st Drawer is slid back into the copier? Does the voltage across PWB-A PJ23A-7 and GND vary between DC0V and DC5V while M13 is turning? Result Go to step 4. YES Change PWB-A. YES Change M13. Change PWB-C. Change PWB-A. Change PC67. Action
YES NO YES NO
T-78
1156SBT040213A
13) C0900: 3rd Drawer Upward Motion Failure C0904: 3rd Drawer Paper Lift-Up Motor M24s Failure to Turn C0950: 4th Drawer Upward Motion Failure C0954: 4th Drawer Paper Lift-Up Motor M25s 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
T-79
uC0950
Step Check Item Does PC19 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) (IC1A) PG3. Result YES NO Action Change PF-205 PWB-A. Check the Paper Take-Up Roll for operation. If it is operational, change PC19.
uC0900
Step Check Item Does PC23 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) (IC1A) PF3. Result YES NO Action Change PF205 PWB-A. Check the Paper Take-Up Roll for operation. If it is operational, change PC23.
uC0904
Step 1 Check Item Slide out the 3rd Drawer and slide it back into the copier. Does M24 turn at this time? Does the voltage across PF-205 PWBA PJ9A-8B and GND change from DC0V to DC24V when the 3rd Drawer is slid back into the copier? Does the voltage across PF-205 PWBA PJ9A-5B and GND vary between DC0V and DC5V while M24 is turning? Result Go to step 3. NO Change M24. Change PF-205 PWB-A. Change PF-205 PWB-A. Change PC27. Action
YES NO YES NO
uC0954
Step 1 Check Item Slide out the 4th Drawer and slide it back into the copier. Does M25 turn at this time? Does the voltage across PF-205 PWBA PJ9A-2A and GND change from DC0V to DC24V when the 4th Drawer is slid back into the copier? Does the voltage across PF-205 PWBA PJ9A-4A and GND vary between DC0V and DC5V while M25 is turning? Result Go to step 3. NO Change M25. Change PF-205 PWB-A. Change PF-205 PWB-A. Change PC28. Action
YES NO YES NO
T-80
1156SBT040214A
14) C0911: 2nd Drawer Upward Motion Failure (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
T-81
uC0911
Step Check Item Does PC66 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB2. Result YES NO Action Replace PWB-A. Replace PC66 or PWB-M2.
uC0912, C0913
Step Check Item Does PC70 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) BPA3. Result YES NO Action Replace PWB-A. Replace PC70 or PWB-M2.
uC0916
Step 1 Check Item Remove the Right Door, lift up the Lock Lever with a flat-blade screwdriver to unlock and slide out the 2nd Drawer. Is the Lock Release Spring installed properly? Are the Lock Lever and Torsion Spring installed properly? Result Reinstall or change. Reinstall or change. Action
2 3
NO NO
T-82
1156SBT040215A
15) C0921: 1st Drawer Upward Motion Failure (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
T-83
uC0921
Step Check Item Does PC65 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB1. Result YES NO Action Replace PWB-A. Replace PC65 or PWB-M1.
uC0922, C0923
Step Check Item Does PC69 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) BPA2. Result YES NO Action Replace PWB-A. Replace PC69 or PWB-M1.
uC0926
Step 1 Check Item Remove the Right Door, lift up the Lock Lever with a flat-blade screwdriver to unlock and slide out the 1st Drawer. Is the Lock Release Spring installed properly? Are the Lock Lever and Torsion Spring installed properly? Result Reinstall or change. Reinstall or change. Action
2 3
NO NO
T-84
1156SBT040216A
16) C0901: 3rd Drawer Upward Motion Failure (Inch 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
T-85
uC0901
Step Check Item Does PC19 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (MC) (IC1A) PG3. Result YES NO Action Replace PWB-A (PF-205). Replace PC19 or PWB-M1.
uC0902, C0903
Step Check Item Does PC69 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (MC) (IC2A) PD1. Result YES NO Action Replace PWB-A (PF-205). Replace PC69 or PWB-M1.
uC0906
Step 1 Check Item Remove the Right Door, lift up the Lock Lever with a flat-blade screwdriver to unlock and slide out the 3rd Drawer. Is the Lock Release Spring installed properly? Are the Lock Lever and Torsion Spring installed properly? Result Reinstall or change. Reinstall or change. Action
2 3
NO NO
T-86
1156SBT040217A
17) C0951: 4th Drawer Upward Motion Failure (Inch 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
T-87
uC0951
Step Check Item Does PC23 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (MC) (IC1A) PF3. Result YES NO Action Replace PWB-A (PF-205). Replace PC23 or PWB-M2.
uC0952, C0953
Step Check Item Does PC70 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (MC) (IC2A) PC0. Result YES NO Action Replace PWB-A (PF-205). Replace PC70 or PWB-M2.
uC0956
Step 1 Check Item Remove the Right Door, lift up the Lock Lever with a flat-blade screwdriver to unlock and slide out the 4th Drawer. Is the Lock Release Spring installed properly? Are the Lock Lever and Torsion Spring installed properly? Result Reinstall or change. Reinstall or change. Action
2 3
NO NO
T-88
1156SBT040218A
18) C0990: Main Tray Upward Motion Failure C0991: Main Tray Downward Motion Failure C0992: Main Tray Downward Motion Failure C0993: Main Tray Upward Motion Failure C0994: Elevator Motor M26s Failure to Turn
Relevant Electrical Parts D D D D Main Tray Lower Position Sensor PC2 Elevator Motor Pulse Sensor PC5 3rd Drawer Paper Lift-Up Sensor PC19 Lower Limit Position Sensor PC35 D Cabinet Transport Board PWB-H D PF-105 Master Board D Main Tray Elevator Motor M26
1156C27TAA
T-89
uC0990, C0991
Step Check Item Does PC19 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PG3. Result YES NO Action Change PF-105 PWB-A. Check the Paper Take-Up Roll for operation and, if it is operational, change PC19.
uC0992, C0993
Step Check Item Does PC35 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC2A) PB3. Does PC2 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC2A) PC1. Result YES NO YES NO Action Change PF-105 PWB-A. Change PWB-H, flat cable, or PC35. Change PF-105 PWB-A. Change PC2, PWB-H, or flat cable.
uC0994
Step 1 Check Item Does M26 turn when the Paper Descent key is pressed? Does the voltage across PF-105 PWBA PJ4A-6B or PJ4A-7B and GND change from DC0V to DC24V when the Tray is slid in or the Paper Descent key is pressed? Does the voltage across PF-105 PWBA PJ4A-5A and GND vary between DC0V and DC5V while M26 is turning? Result YES YES Go to step 3. Change M26, PWB-H, or flat cable. Action
NO YES NO
Change PF-105 PWB-A.
Change PF-105 PWB-A. Check the pulse disk and gear. Change PC5.
T-90
1156SBT040219A
19) C0998: Shifter Transfer Failure C0999: Shifter Return Failure C099A: Shifter Return Failure C099b: Shifter Transfer Failure C099C: Shift Motor M27s 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
T-91
uC0998, C0999
Step Check Item Does PC4 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC2A) PD1. Result YES NO Action Change PF-105 PWB-A. Change PC4, PWB-H, or flat cable.
uC099A, C099b
Step Check Item Does PC3 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC2A) PC0. Result YES NO Action Change PF-105 PWB-A. Change PC3, PWB-H, or flat cable.
uC099C
Step 1 Check Item Does M27 turn when the 3rd Drawer is slid into the copier with a paper stack loaded in the Shift Tray? In step 1, does the voltage across PF-105 PWB-A PJ4A-5B and GND change from DC0V to DC24V? Does the voltage across PF-105 PWBA PJ4A-3A and GND vary between DC0V and DC5V while M27 is turning? Result Go to step 3. YES YES NO YES NO Change M27, PWB-H, or flat cable. Change PF-105 PWB-A. Change PF-105 PWB-A. Check the pulse disk and gear. Change PC6. Action
T-92
1156SBT040220A
20) C099E: Shift Gate Position Detecting Failure C099F: Shift Gate Position Detecting Failure C0996: 3rd 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
T-93
uC099E, C099F
Step Check Item Does PC34 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PC1. Result YES NO Action Change PF-105 PWB-A. Change PC34, PWB-H, or flat cable.
uC0996
Step Check Item Does SL41 operate properly? Using the IC Port Data Check function, set the data of PWB-A (400) (IC2A) PA1 to 0. Does PC7 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PG2. Result YES NO YES NO Action Check the drawer lock mechanism. Change PF-105 PWB-A or SL41. Change PF-105 PWB-A. Change PC7, PWB-H, or flat cable.
uC0F79
Step Check Item Does PC20 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PC0. Does PWB-E operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PF3. Does PC1 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PD1. Result YES NO YES NO YES NO Action Change PF-105 PWB-A. Change PC20, PWB-H, or flat cable. Change PF-105 PWB-A. Change PWB-E, PWB-H, or flat cable. Change PF-105 PWB-A. Change PC1, PWB-H, or flat cable.
T-94
1156SBT040221A
21) C0d00: Duplex Unit Front/Rear Edge Guide Plate Home Position Detection Failure C0d20: Duplex Unit Gate Unit Home Position Detection Failure C0d50: Duplex Unit Drive Motor M31s 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
T-95
uC0d00
Step Check Item Does M33 turn when the Front/Rear Edge Guide Plates are moved to a position other than home and the Duplex Unit is slid in? Does PC9 operate properly? Using the IC Port Data Check function, make an input port check on PWB-G (Dup) (IC1G) PC3. Result YES NO YES NO Action Check for overload. Change M33 or PWB-G. Change PWB-G. Change PC9.
uC0d20
Step 1 Check Item Does M32 turn when the Gate Unit is moved to a position other than home and the Duplex Unit is slid in? Does PC8 operate properly? Using the IC Port Data Check function, make an input port check on PWB-G (Dup) (IC1G) PE0. Result YES NO YES NO Action Check for overload. Change M32 or PWB-G. Change PWB-G. Change PC8.
uC0d50
Step Check Item Does M31 turn? Using the IC Port Data Check function, set the data of PWB-A (Dup) (IC1G) PB3 to 0. Result YES NO Action Check the drive coupling. Change M31 or PWB-G.
uC0d51
Step 1 2 Check Item Does M31 turn when the malfunction is reset? Is malfunction code C0011 displayed again? Result YES YES Change PWB-G Change PWB-G Action
T-96
1156SBT040222A
22) C0E00: Main Erase Lamp LA2s Failure to Turn ON C0E01: Main Erase Lamp LA2 Turning ON at Abnormal Timing
Relevant Electrical Parts D Main Erase Lamp LA2 D Master Board PWB-A
1156C22TAA
uC0E00
Step 1 Check Item Perform the Controller Board Check. Is malfunction code C0328 displayed? Does the voltage across PWB-A PJ12A-3 and GND change from DC0V to DC24V when the Start key is pressed? Result YES Change LA2. Change PWB-A. Action Change PWB-A.
YES NO
uC0E01
Check the LA2 Failure Detection signal when LA2 is OFF. Using the IC Port Data Check function, check that the data of PWB-A (IC4A) APC7 is H. YES Change PWB-A.
NO
Change LA2.
T-97
1156SBT040223A
23) C0E20: Image Erase Lamp LA3s Failure to Turn ON

Relevant Electrical Parts D Image Erase Lamp LA3 D Master Board PWB-A
1156C23TAA
Step 1
Check Item Perform the Controller Board Check. Is malfunction code C0314 to C0317 displayed? Is the voltage across PWB-A PJ9A-1 and GND DC5V?
Result YES YES NO Change LA3.
Action Change PWB-A.
Check the 5V line.
T-98
1156SBT040224A
24) C0F02: Original Size Detecting Board UN2 Malfunction C0FE1 to C0FFF: Original 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
T-99
uC0F02
Step 1 Check Item Are PJ62 on UN2 and PJ7A on PWB-A plugged in securely? Does the voltage across PJ7A-6 on PWB-A and GND vary between DC0V and DC5V? Result NO YES NO Action Plug them in securely. Change PWB-A. Change UN2.
uC0FE1 to C0FFF
Step 1 2 Check Item Are the jumper connectors plugged correctly into J1 and J2 on UN2? Is each Original Size Detecting Sensor installed in correct position? Is the malfunction code displayed again after the Original Size Detecting Sensor corresponding to the malfunction code has been changed? Result NO NO Action Change the jumper connector positions. Reinstall. Change UN2 or PWB-A. YES
T-100
1156SBT040225A
25) C0F10: AE Sensor Board PWB-H Malfunction

Relevant Electrical Parts D AE Sensor Board PWB-H D Master Board PWB-A
1156C17TAA
Step
Check Item Is the voltage across PWB-A PJ3A-3 and GND DC0.18V or less when the Scanner is at the home position, the Exposure Lamp is OFF, and the Original Cover is lowered?
Result YES
Action Change PWB-H.
NO
Change PWB-A.
T-101
1156SBT040226A
26) C0F20: AIDC Sensor Board PWB-G Variation Correction Failure C0F22: AIDC Sensor Board PWB-G Grid Voltage (Vg) Correction Failure C0F23: AIDC Sensor Board PWB-G Exposure Correction Failure
Relevant Electrical Parts D AIDC Sensor Board PWB-G D Master Board PWB-A
1156C18TAA
Step 1 2 3 4
Check Item Is PWB-A PJ11A plugged in securely? Is CN35 plugged in securely? Is PWB-G installed in the correct position? Is the photoreceiver or LED of PWB-G dirty?
Result NO NO NO YES NO
Action Plug it in securely. Plug it in securely. Reinstall. Clean. Change PWB-G or PWB-A.
T-102
1156SBT040227A
27) C0F30: ATDC Sensor UN3 Failure C0F31: ATDC Sensor UN3 Failure
Relevant Electrical Parts D ATDC Sensor UN3 D Master Board PWB-A
1156C19TAA
Step 1
Check Item Is the malfunction code C0F30 displayed? Is the value for ATDC Ref. Value of Level History equal to the value given on the Adjust Label? Is PWB-A PJ11A plugged in securely? Is CN35 plugged in securely? Is UN3 installed in the correct position?
Result YES Go to step 3.
Action
2 3 4 5
NO NO NO NO
Enter the value given on the Adjust Label. Plug it in securely. Plug it in securely. Reinstall.
T-103
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
T-104
Step 1 2
Check Item Is the source voltage applied to the circuit across PJ1-1 and -2 on PU1? Is the voltage across PJ2-2 or -3 on PU1 and GND DC24V? Is the voltage across PJ6C-1 on PWBC and GND DC24V when S1 is turned ON? Is the voltage across PJ21-2 on PU1 and GND DC5V? Is the wiring between PWB-A, PWB-C, and RY1 intact?
Result NO NO
Action Change PWB-D. Check the fuse on PU1 and, if it is intact, change PU1. Check the wiring between PWB-C and S1 and, if it is intact, change PWB-C or S1. Check the wiring between PWB-C and S1 and, if it is intact, change PWB-C or S1. Change PWB-A, PWB-C, and RY1, in that order. Correct the wiring or change the harness.
NO
NO
YES NO
T-105
1156SBT040302A
2) Main Relay Turns ON But the Control Panel Gives No Display.

Relevant Electrical Parts D Power Supply Unit PU1 D Control Panel UN1 D MSC Board PWB-B D Power Supply Board PWB-C
1156C21TAA
Step 1
Check Item Is the voltage across PJ22-2 on PU1 and GND DC5V?
Result YES NO
Action Check the wiring between PU1 and UN1. Change PU1. Check the wiring between PU1 and PWB-B. Change PU1. Check the wiring between PWB-C and UN1. Change PWB-C. Change PWB-B or UN1. Correct the wiring or change the harness.
Is the voltage across PJ21-2 on PU1 and GND DC5V?
YES NO
Is the voltage across PJ3C-1 on PWBC and GND DC24V?
YES NO
Is the connection between PWB-B and UN1 normal?
YES NO
T-106
1156SBT0404A
4-4. Miscellaneous
D The message Stabilizing Image Controller not run. appears on the Touch Panel. Condition T/C is less than 4% when an F5 operation is run (initial adjustment). Detection Timing D Memory clear D PC Drum of Port/Option counter is cleared. D AIDC Sensor Board PWB-G develops a malfunction.
<Procedure> Step 1 Check Item Is ATDC Current Level of Level History available from Tech. Rep. mode less than 4%? Result YES NO Action Run the auxiliary toner replenishing cycle and then an F5 operation. Run an F5 operation again.
T-107
1149SAT0500A
IMAGE FAILURE
1149SBT0501A
5-1. Image Failure Troubleshooting

Image failures have many possible causes. For troubleshooting, it is necessary to determine whether a failure is attributable to a basic cause or any other cause. In this chapter, troubleshooting is divided into initial checks and troubleshooting procedures classified by image failure. If an image failure has occurred, first make the initial checks, then proceed to the corresponding image failure troubleshooting procedure.
1149SBT0502A
5-2. Initial Checks 1) Place of installation

D Is the source voltage normal? Does the voltage vary greatly? D Is the copier installed in a hot, humid place or in a place where temperatures vary sharply? D Is the copier installed in a dusty place? D Is the copier subjected to direct sunlight? D Is the copier level?
2) Copy paper
D Is the recommended paper used? Load recommended paper and make copies to see if the problem persists. D Is the paper damp? Load 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? Use the Test Chart to check the image. D Is the original transparent or are transparencies being used? Cover with white paper and make a copy. D Are the Original Glass and ADF Transport Belt dirty or scratched? If dirty, clean with alcohol. If scratched, replace.
4) Adjust data and Level History data

D Are the set values of Adjust and Level History (ATDC Level) in the Tech. Rep. mode equal to the value given on the Adjust Label inside the Front Door? When installing the Developing Unit of another copier containing its own developer, input the ATDC Level value of that particular copier.
5) PM parts (supplies)
D Have the PM parts (supplies), such as the PC Drum, Cleaning Blade, AIDC Sensor and corona wires, reached the end of their cleaning/replacement cycles?
T-108
6) Adjustment items (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?
T-109
1149SBT0503A
5-3. Troubleshooting Procedures Classified by Image Failure

<Image Failure Samples> 1) Blank copy 2) Black copy 3) Low image density
4) Foggy background
5) Black streaks or bands
6) Black spots
7) Blank streaks or bands
8) Void areas
9) Smear on back
1149T012AA
T-110
1149SBT050301A
1) Blank Copy
Cause Charging failure Step 1 2 Check Item Is the PC Drum Charge Corona installed correctly? Are the Comb Electrode wire and grid mesh normal? Is the wiring between High Voltage Unit HV1 and the PC Drum Charge Corona normal? Is the PC Unit in position? Are the Ds Rolls in contact with the PC Drum? Is the Developing Unit connector plugged in? Is the drive transmission mechanism to the Developing Unit intact? Is the Image Transfer Corona wire normal? Is the wiring between High Voltage Unit HV1 and corona wire normal? Is the paper guide shorted to the frame? Result NO NO YES NO NO NO NO Action Install correctly. Check and change if necessary. Change HV1. Correct the wiring. Reinstall the Unit. Reinstall the Developing Unit. Plug it in. Check and change any defective part. Check and change if necessary. Change HV1. Correct wiring. Connect the paper guide through the resistor to the frame.
Developing Unit out of position
4 5 6
7 Image transfer failure
NO
NO YES NO YES
9 Paper guide shorting 10
1149SBT050302A
2) Black copy
Cause PC Drum grounding failure Developing bias failure Step 1 2 Check Item Is the PC Drum properly grounded? Is the developing bias contact normal? Is the developing bias harness intact? Result NO NO YES NO Light path failure 4 Has condensation formed on the mirrors, lenses, or PC Drum? Are the mirrors installed properly? Does the Exposure Lamp light up? YES Action Clean or change the PC Drum Ground Plate. Clean or replace the developing bias contact. Change the High Voltage Unit for drum charging. Change the harness. Clean the mirrors and lenses, and run the Drum Dehum. operation. Reinstall the mirrors. Take the action for malfunction code C0400.
5 Exposure Lamps failure to turn ON 6
NO NO
T-111
1149SBT050303A
3) Low Image Density

Cause PC Drum life Step 1 Check Item Does the PC Drum have enough service life? Do the fan motors turn properly? (Ozone deterioration, temperature rise) Is the PC Drum grounded properly? Are the Comb Electrode and grid mesh normal? Is the wiring between High Voltage Unit HV1 and the PC Drum Charge Corona normal? Are the mirrors and lenses dirty or covered with condensation? Is the Image Transfer Corona dirty? Is the copy paper damp? 8 YES Result NO Action Change the PC Drum. Troubleshoot the fan motors. Clean or change the PC Drum Ground Plate. Check and change if necessary. Change HV1. Correct the wiring. Clean the mirrors and lenses. Clean the Image Transfer Corona or change the wire. Change the copy paper and instruct the user in how to store paper and to keep the copier plugged in during the night. Make Db adjustment. Reinstall the Developing Unit. Clean or Change the developing bias contact.
2 PC Drum grounding failure Drum charge failure
NO
3 4
NO NO YES NO
Optical failure 6 Image transfer failure
YES
YES
Developing failure
9 10 11
Is Db adjusted properly? Are the Ds Rolls in contact with the PC Drum? Is the developing bias contact normal?
NO NO NO
T-112
1149SBT050304A
4) Foggy background
Cause Cleaning failure 1 Optical failure PC Drum failure 3 Step Check Item Is the Cleaning Blade dirty with foreign matter, paper dust, etc. or is it scratched? Are the mirrors and lenses dirty? Is the PC Drum dirty with foreign matter, etc.? Is the PC Drum properly grounded? Is the Sleeve Roller abnormally dirty? Result YES Action Change the Cleaning Blade. Clean the mirrors and lenses. Clean or replace the PC Drum. Change the Cleaning Blade if necessary. Clean or change the PC Drum Ground Plate. Clean the Sleeve Roller. Check the Developer Scattering Prevention Seal to see if it is deformed or dirty. Clean or change the developing bias contact. Replace the Main Erase Lamp. Clean the Main Erase Lamp. Clean or reinstall the AIDC Sensor and execute F5. Using care not to scratch, wipe the pattern with a dry soft cloth and run F5.
YES
YES
4 Developing failure 5
NO
YES
6 Main Erase Lamp failure 7 8 AIDC Sensor failure 9
Is the developing bias contact normal? Does the Main Erase Lamp light up properly? Is the Main Erase Lamp dirty? Is the AIDC Sensor clean or installed properly? Is the AIDC halftone pattern dirty?
NO NO YES NO
10
YES
T-113
1149SBT050305A
5) Black Streaks or Bands

Cause Uneven charging 1 Step Check Item Are the Comb Electrode and grid mesh dirty? Result Action Clean or replace the PC Drum Charge Corona. Check the toner suction mechanism for operation. Change the Cleaning Blade.
YES
Cleaning failure 2
Is the Cleaning Blade dirty with foreign matter, paper dust, etc., or is it scratched? Does the Cleaning Blade make a correct lateral motion? Is the PC Drum surface dirty or scratched? Are the PC Drum Paper Separator Fingers dirty, deformed or faulty in operation? Is the Upper Fusing Roller dirty or scratched? Are the Upper Paper Separator Fingers dirty or deformed? Are the mirrors and lenses dirty with foreign matter?
YES
3 PC Drum failure 4 PC Drum Paper Separator Fingers
NO
Check the Cleaning Blade for operation. Change the PC Drum. If necessary, change the Cleaning Blade. Clean or replace the PC Drum Paper Separator Fingers. Clean or replace the Upper Fusing Roller. Clean or replace the Upper Paper Separator Fingers. Clean the mirrors and lenses.
YES
YES
Fusing failure
YES
7 Optical failure
YES
YES
1149SBT050306A
6) Black Spots
Cause PC Drum failure 1 Fusing failure 2 Developing failure Step Check Item Is the PC Drum surface scratched or dirty with foreign matter? Is the Upper Fusing Roller dirty or scratched? Is the amount of toner on the Sleeve Roller proper? Is the toner-to-carrier ratio relatively high? Is the Db value normal? Is the Developer Scattering Prevention Seal deformed or dirty? Are the PC Drum Paper Separator Fingers dirty or deformed? Result YES Action Clean or change the PC Drum. Change the Cleaning Blade if necessary. Check the Fusing Thermistors. Clean or change the Upper Fusing Roller. Go to step 5. Change the toner-to-carrier ratio. Make Db adjustment. Clean or change the Developer Scattering Prevention Seal. Clean or change the PC Drum Paper Separator Fingers.
YES
3 4 5 6
YES YES NO YES
Dirty PC Drum Paper Separator Fingers
YES
T-114
1149SBT050307A
7) Blank Streaks or Bands

Cause Plugged Db 1 Drum charge failure Step Check Item Is Db plugged with foreign matter, caked toner, etc.? Are the Comb Electrode and grid mesh dirty? Is the Drum Charge Corona Wire Cleaner at the home position? Is the Image Transfer Corona wire dirty? Is the Corona Wire Cleaner at the home position? Are the PC Drum Paper Separator Fingers dirty or deformed? Does the Image Erase Lamp light up at abnormal timing? Is the Upper Fusing Roller dirty or scratched? Are the Upper Paper Separator Fingers dirty or scratched? Result YES Action Remove foreign matter. If the problem persists, change the developer. Clean or change the PC Drum Charge Corona. Check the corona wire cleaning mechanism. Clean or change the Image Transfer Corona. Check the corona wire cleaning mechanism. Clean or replace the PC Drum Paper Separator Fingers. Check the Image Erase Lamp. Clean or change the Upper Fusing Roller. Clean or change the Upper Paper Separator Fingers.
YES
3 Image transfer failure
NO
4 5
YES NO
Defective PC Drum Paper Separator Fingers Image Erase Lamp lit at abnormal timing Fusing failure
YES
YES
YES
YES
T-115
1149SBT050308A
8) Void Areas
Cause Image transfer failure Step 1 2 Damp copy paper 3 Check Item Is the Image Transfer Corona installed properly? Is the Image Transfer Corona wire dirty? Is the image improved by loading new paper? YES Result NO YES Reinstall. Clean or change the Image Transfer Corona wire. Change the copy paper and instruct the user in how to store paper and to keep the copier plugged in during the night. Check the Db value and amount of developer, and check the Bucket Roller for operation. Run Drum Dehum. and instruct the user to take further action. Connect the paper guide through the resistor to the frame. Replace the Lower Fusing Roller. Action
Small amount of toner supplied
Is toner uniformly attracted onto the Sleeve Roller?
NO
PC Drum condensation Paper guide shorting
Is the image improved by running Drum Dehum.? Is the paper guide shorted to the frame? Is the Lower Fusing Roller scratched or deformed?
YES
6 Fusing failure
YES
YES
1149SBT050309A
9) Smear on Back
Cause Dirty Developing Unit Dirty Image Transfer Corona Step 1 Check Item Is the bottom part of the Developing Unit dirty? Is the Image Transfer Corona dirty? Is the Pre-Image Transfer Guide Plate dirty? Are the Suction Belts dirty? Is the Fusing Unit Entrance Guide Plate dirty? Are the Upper and Lower Fusing Rollers dirty? Result YES Action Clean, and check the Developer Scattering Prevention Seal. Clean the corona and check the Developing Unit. Clean the guide plate and check the Developing Unit. Clean the Suction Belts and check the Developing Unit. Clean the guide plate and check the Developing Unit. Clean or change the Upper and Lower Fusing Rollers and check the Fusing Roller cleaning mechanism.
2 3
YES YES YES YES
Dirty Suction Unit Dirty Fusing Unit
4 5
YES
T-116
1156SBT000EA

MINOLTA CO., LTD.
1156-7998-11 97046000 Printed in Japan

Minolta Ep4000

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1156SBG000AA

EP5000/EP4000 GENERAL, MECHANICAL/ ELECTRICAL

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

2nd Drawer (Automatic feeding) f f 297 432 mm

Multi Bypass Table f f f f f 297 432 mm

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

MULTIPLE COPIES WARMING-UP TIME FIRST COPY TIME

CONTINUOUS COPY SPEED (copies/min.): Fed from 1st Drawer

L: Lengthwise; C: Crosswise EP4000:

50% to 200% (in 0.1% increments)

LENS EXPOSURE LAMP FUSING TEMPERATURE

: Through Lens (F = 6, f = 190 mm) : Halogen Frost Tube Lamp : 200C

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

POWER/CURRENT CONSUMPTION (Copier Only)

115 V 120 V 127 V 220 V 240 V

115 V 120 V 127 V 220 V 240 V

: 115 V, 120 V, 127 V, 220-240 V; 50/60 Hz

DIMENSIONS (Copier Only)

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

2 PRECAUTIONS FOR INSTALLATION

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

3 PRECAUTIONS FOR USE

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

4 HANDLING OF THE CONSUMABLES

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

MULTI BYPASS TABLE

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

10. Main Erase

13. Paper Exit

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

2nd Paper Exit Roller Drive

Upper Vertical Transport Roller Drive

Toner Conveying Coil Drive (on PC Unit)

Main Drive Motor

Synchronizing Roller Clutch Paper Transport Clutch

Lower Vertical Transport Roller Drive

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

Power Switch S1 is turned ON.

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

Approx. 160msec. OFF

The Start Key is pressed.

Approx. 75msec. (65msec.)

LA3...Leading edge erase

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

E PWB-F outputs a LOW TRON signal to PWB-A.

F PWB-F outputs a LOW SCEND signal to PWB-A.

The components are deenergized in order of *2 on the preceding page.

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

5 WATCHDOG (CPU OVERRUN MONITOR) FUNCTION

Paper Feed Cabinet, Duplex Unit Large Capacity Cassette

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

5-2. Watchdog Function Post-Processing

Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01

6 MALFUNCTION BYPASS FUNCTION