RICOH Aficio 1015

Model K-C1
(Machine Code: B039/B040/B043)
SERVICE MANUAL
February 20th, 2001 Subject to change
!IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off. 4. If a job has started before the copier completes the warm-up or initializing period, keep hands away from the mechanical and electrical components because the starts making copies as soon as the warm-up period is completed. 5. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands. HEALTH SAFETY CONDITIONS Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention. OBSERVANCE OF ELECTRICAL SAFETY STANDARDS The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are non-toxic supplies.) 3. Dispose of replaced parts in accordance with local regulations.
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.
!WARNING
Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.
!WARNING FOR LASER UNIT

WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING:
Symbols and Abbreviations

This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations are as follows: ! " # SEF LEF See or Refer to Clip ring Screw Connector Short Edge Feed Long Edge Feed
TABLE OF CONTENTS
1 INSTALLATION ........................................................................... 1-1
1.1 INSTALLATION REQUIREMENTS ...........................................................1-1 1.1.1 ENVIRONMENT ...............................................................................1-1 1.1.2 MACHINE LEVEL .............................................................................1-2 1.1.3 MINIMUM SPACE REQUIREMENTS...............................................1-3 1.1.4 POWER REQUIREMENTS ..............................................................1-3 1.2 COPIER INSTALLATION ..........................................................................1-4 1.2.1 POWER SOCKETS FOR PERIPHERALS .......................................1-4 1.2.2 ACCESSORY CHECK......................................................................1-4 1.2.3 INSTALLATION PROCEDURE ........................................................1-5 1.3 PLATEN COVER INSTALLATION ............................................................1-8 1.3.1 ACCESSORY CHECK......................................................................1-8 1.3.2 INSTALLATION PROCEDURE ........................................................1-8 1.4 ARDF INSTALLATION ..............................................................................1-9 1.4.1 ACCESSORY CHECK......................................................................1-9 1.4.2 INSTALLATION PROCEDURE ........................................................1-9 1.5 ADF INSTALLATION...............................................................................1-11 1.5.1 ACCESSORY CHECK....................................................................1-11 1.5.2 INSTALLATION PROCEDURE ......................................................1-11 1.6 TWO-TRAY PAPER TRAY UNIT INSTALLATION ..................................1-13 1.6.1 ACCESSORY CHECK....................................................................1-13 1.6.2 INSTALLATION PROCEDURE ......................................................1-13 1.7 ONE-TRAY PAPER TRAY UNIT INSTALLATION...................................1-16 1.7.1 ACCESSORY CHECK....................................................................1-16 1.7.2 INSTALLATION PROCEDURE ......................................................1-16 1.8 IMB INSTALLATION................................................................................1-19 1.8.1 ACCESSORY CHECK....................................................................1-19 1.8.2 INSTALLATION PROCEDURE ......................................................1-19 1.9 DRAM INSTALLATION ...........................................................................1-20 1.10 ANTI-CONDENSATION HEATER INSTALLATION ..............................1-21 1.11 TRAY HEATERS ...................................................................................1-22 1.11.1 UPPER TRAY HEATER ...............................................................1-22 1.11.2 LOWER TRAY HEATER (TWO-TRAY MODEL ONLY)................1-23 1.11.3 TRAY HEATERS FOR THE OPTIONAL PAPER FEED UNITS ...1-24 1.12 KEY COUNTER INSTALLATION ..........................................................1-27
2 PREVENTIVE MAINTENANCE SCHEDULES ............................. 2-1

2.1 PM TABLES ..............................................................................................2-1 2.2 HOW TO CLEAR THE PM COUNTER......................................................2-3
3 REPLACEMENT AND ADJUSTMENT......................................... 3-1

3.1 GENERAL CAUTIONS..............................................................................3-1 3.1.1 PCU (PHOTOCONDUCTOR UNIT) .................................................3-1 3.1.2 TRANSFER ROLLER .......................................................................3-1 3.1.3 SCANNER UNIT...............................................................................3-1
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3.1.4 LASER UNIT ....................................................................................3-2 3.1.5 FUSING UNIT...................................................................................3-2 3.1.6 PAPER FEED...................................................................................3-2 3.1.7 IMPORTANT ....................................................................................3-2 3.2 SPECIAL TOOLS AND LUBRICANTS ......................................................3-2 3.3 EXTERIOR COVERS & OPERATION PANEL ..........................................3-3 3.3.1 REAR COVER..................................................................................3-3 3.3.2 REAR LOWER COVER (TWO-TRAY MODELS ONLY)...................3-3 3.3.3 COPY TRAY.....................................................................................3-4 3.3.4 LEFT UPPER COVER......................................................................3-4 3.3.5 FRONT UPPER LEFT COVER AND OPERATION PANEL .............3-4 3.3.6 RIGHT UPPER COVER ...................................................................3-4 3.3.7 TOP REAR COVER..........................................................................3-4 3.3.8 LEFT COVER ...................................................................................3-5 3.3.9 FRONT LONG COVER ....................................................................3-5 3.3.10 FRONT RIGHT COVER .................................................................3-6 3.3.11 RIGHT REAR COVER....................................................................3-6 3.3.12 RIGHT DOOR.................................................................................3-7 3.3.13 BY-PASS TRAY..............................................................................3-8 3.3.14 LEFT LOWER COVER (TWO-TRAY MODELS ONLY)..................3-9 3.3.15 RIGHT LOWER COVER (TWO-TRAY MODELS ONLY) ...............3-9 3.3.16 PLATEN COVER SENSOR............................................................3-9 3.4 SCANNER SECTION ..............................................................................3-10 3.4.1 EXPOSURE GLASS/DF EXPOSURE GLASS ...............................3-10 Exposure Glass ..................................................................................3-10 DF Exposure Glass.............................................................................3-10 3.4.2 LENS BLOCK .................................................................................3-11 3.4.3 EXPOSURE LAMP, LAMP STABILIZER BOARD ..........................3-11 3.4.4 ORIGINAL WIDTH SENSOR..........................................................3-12 3.4.5 ORIGINAL LENGTH SENSOR.......................................................3-12 Sensor Positions.................................................................................3-12 3.4.6 CHANGING THE ORIGINAL SENSOR POSITIONS (8K/16K) ......3-13 Procedure ...........................................................................................3-14 3.4.7 SCANNER MOTOR........................................................................3-15 3.4.8 SCANNER H.P. SENSOR ..............................................................3-15 3.4.9 ADJUSTMENT OF 2ND SCANNER POSITION.............................3-16 3.4.10 ADJUSTMENT OF 1ST AND 2ND SCANNER ALIGNMENT .......3-17 3.5 LASER UNIT ...........................................................................................3-18 3.5.1 LOCATION OF CAUTION DECAL ...............................................3-18 3.5.2 TONER SHIELD GLASS ................................................................3-19 3.5.3 LASER UNIT ..................................................................................3-19 3.5.4 LD UNIT..........................................................................................3-20 3.5.5 POLYGONAL MIRROR MOTOR....................................................3-20 3.5.6 LASER UNIT ALIGNMENT ADJUSTMENT....................................3-21 3.6 PCU SECTION ........................................................................................3-22 3.6.1 PCU ................................................................................................3-22 3.6.2 PICK-OFF PAWLS .........................................................................3-22 3.6.3 TONER DENSITY SENSOR ..........................................................3-22 3.6.4 OPC DRUM ....................................................................................3-23
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3.6.5 CHARGE ROLLER AND CLEANING BRUSH................................3-24 3.6.6 CLEANING BLADE.........................................................................3-24 3.6.7 DEVELOPER..................................................................................3-25 3.6.8 AFTER REPLACEMENT OR ADJUSTMENT.................................3-26 3.7 TONER SUPPLY MOTOR ......................................................................3-27 3.8 PAPER FEED SECTION.........................................................................3-28 3.8.1 PAPER FEED ROLLER..................................................................3-28 3.8.2 FRICTION PAD ..............................................................................3-28 3.8.3 PAPER END SENSOR...................................................................3-28 3.8.4 EXIT SENSOR ...............................................................................3-29 Non-duplex Models .............................................................................3-29 Duplex Models ....................................................................................3-29 3.8.5 BY-PASS FEED ROLLER AND BY-PASS PAPER END SENSOR ..................................................3-30 3.8.6 REGISTRATION ROLLER .............................................................3-31 3.8.7 BY-PASS PAPER SIZE SENSOR ..................................................3-32 3.8.8 REGISTRATION CLUTCH .............................................................3-32 3.8.9 REGISTRATION SENSOR.............................................................3-33 3.8.10 UPPER PAPER FEED CLUTCH AND BY-PASS FEED CLUTCH ............................................................3-33 3.8.11 RELAY CLUTCH ..........................................................................3-34 3.8.12 RELAY SENSOR..........................................................................3-34 3.8.13 LOWER PAPER FEED CLUTCH (TWO-TRAY MODELS ONLY) .....................................................3-34 3.8.14 VERTICAL TRANSPORT SENSOR (TWO-TRAY MODELS ONLY) .....................................................3-35 3.8.15 PAPER SIZE SWITCH .................................................................3-35 3.9 IMAGE TRANSFER.................................................................................3-36 3.9.1 IMAGE TRANSFER ROLLER ........................................................3-36 3.9.2 IMAGE DENSITY SENSOR ...........................................................3-36 3.10 FUSING .................................................................................................3-37 3.10.1 FUSING UNIT...............................................................................3-37 3.10.2 THERMISTOR..............................................................................3-37 3.10.3 FUSING LAMP .............................................................................3-38 3.10.4 HOT ROLLER...............................................................................3-38 3.10.5 THERMOFUSE AND THERMOSTAT ..........................................3-39 3.10.6 HOT ROLLER STRIPPER PAWLS ..............................................3-39 3.10.7 PRESSURE ROLLER AND BUSHINGS ......................................3-40 3.10.8 NIP BAND WIDTH ADJUSTMENT ...............................................3-41 3.11 DUPLEX UNIT (DUPLEX MODELS ONLY) ..........................................3-42 3.11.1 DUPLEX EXIT SENSOR ..............................................................3-42 3.11.2 DUPLEX ENTRANCE SENSOR ..................................................3-42 3.11.3 DUPLEX INVERTER SENSOR ....................................................3-42 3.11.4 DUPLEX TRANSPORT MOTOR ..................................................3-43 3.11.5 DUPLEX INVERTER MOTOR......................................................3-43 3.11.6 DUPLEX CONTROL BOARD .......................................................3-43 3.12 OTHER REPLACEMENTS....................................................................3-44 3.12.1 QUENCHING LAMP .....................................................................3-44 3.12.2 HIGH-VOLTAGE POWER SUPPLY BOARD ...............................3-44
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3.12.3 IMB (MEMORY BOARD) ..............................................................3-45 3.12.4 BICU (BASE-ENGINE IMAGE CONTROL UNIT) .........................3-45 3.12.5 IOB (I/O BOARD)..........................................................................3-46 3.12.6 MAIN MOTOR ..............................................................................3-46 3.12.7 REAR EXHAUST FAN..................................................................3-46 3.12.8 LEFT EXHAUST FAN...................................................................3-47 3.12.9 PSU (POWER SUPPLY UNIT).....................................................3-47 3.12.10 GEARBOX..................................................................................3-48 Replacement Procedure .....................................................................3-48 Gear Arrangement Within the Gearbox...............................................3-49 3.13 COPY ADJUSTMENTS: PRINTING/SCANNING ..................................3-50 3.13.1 PRINTING ....................................................................................3-50 Registration - Leading Edge/Side-to-Side...........................................3-50 Blank Margin.......................................................................................3-51 Main Scan Magnification.....................................................................3-51 3.13.2 SCANNING...................................................................................3-52 Registration: Platen Mode...................................................................3-52 Magnification.......................................................................................3-53 Standard White Density Adjustment ...................................................3-54 3.13.3 ADF IMAGE ADJUSTMENT.........................................................3-55 Registration and Blank Margin............................................................3-55 Sub-scan Magnification.......................................................................3-55
4 TROUBLESHOOTING ................................................................. 4-1

4.1 SERVICE CALL CONDITIONS .................................................................4-1 4.1.1 SUMMARY .......................................................................................4-1 4.1.2 SC CODE DESCRIPTIONS .............................................................4-2 4.2 ELECTRICAL COMPONENT DEFECTS ..................................................4-8 4.2.1 SENSORS ........................................................................................4-8 4.2.2 SWITCHES.......................................................................................4-9 4.3 BLOWN FUSE CONDITIONS .................................................................4-10 4.4 LED DISPLAY .........................................................................................4-10 4.4.1 BICU ...............................................................................................4-10 4.4.2 IOB .................................................................................................4-10
5 SERVICE TABLES....................................................................... 5-1

5.1 USING SERVICE PROGRAM MODES.....................................................5-1 Accessing SP Modes ............................................................................5-1 Accessing Copy Mode from within an SP Mode ...................................5-1 How to Select a Program Number ........................................................5-2 To Input a Value or Setting for an SP Mode .........................................5-2 5.1.1 SP MODE TABLES ..........................................................................5-3 SP1-XXX (Feed) ...................................................................................5-3 SP2-XXX (Drum)...................................................................................5-6 SP4-XXX (Scanner) ............................................................................5-11 SP5-XXX (Mode) ................................................................................5-17 SP6-XXX (Peripherals) .......................................................................5-24 SP7-XXX (Data Log)...........................................................................5-26 5.1.2 TEST PATTERN PRINTING (SP5-902) .........................................5-31
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5.1.3 INPUT CHECK (SP5-803) ..............................................................5-32 5.1.4 OUTPUT CHECK (SP5-804) ..........................................................5-36 Output Check Table ............................................................................5-36 5.1.5 COPY JAM HISTORY (SP7-903) ...................................................5-37 5.1.6 SMC PRINTING (SP5-992) ............................................................5-38 5.1.7 ORIGINAL JAM HISTORY DISPLAY (SP7-905) ............................5-38 5.1.8 MEMORY ALL CLEAR (SP5-801) ..................................................5-39 Using a Flash Memory Card ...............................................................5-39 Without Using a Flash Memory Card ..................................................5-40 5.1.9 PROGRAM UPLOAD/DOWNLOAD ...............................................5-41 Program Download (SP5-827)............................................................5-41 Program Upload (SP5-826) ................................................................5-42 5.1.10 NVRAM DATA UPLOAD/DOWNLOAD ........................................5-43 NVRAM Data Download (SP5-825) ....................................................5-43 NVRAM Data Upload (SP5-824).........................................................5-44 5.1.11 APS AND PLATEN/ADF COVER SENSOR OUTPUT DISPLAY (SP4-301) .....................................................5-45 5.1.12 ADF APS SENSOR OUTPUT DISPLAY (SP6-901) .....................5-46 5.1.13 SERIAL NUMBER INPUT (SP5-811) ...........................................5-47 5.1.14 ID SENSOR ERROR ANALYSIS (SP2-221) ................................5-48 5.2 USER TOOLS .........................................................................................5-49 5.2.1 HOW TO ENTER AND EXIT USER TOOLS ..................................5-49 5.2.2 USER TOOLS TABLE ....................................................................5-49 System Setting Table..........................................................................5-49 Copy Features Table ..........................................................................5-50
6 DETAILED SECTION DESCRIPTIONS ....................................... 6-1

6.1 OVERVIEW ...............................................................................................6-1 6.1.1 COMPONENT LAYOUT ...................................................................6-1 6.1.2 PAPER PATH...................................................................................6-3 6.1.3 DRIVE LAYOUT ...............................................................................6-4 6.2 BOARD STRUCTURE...............................................................................6-5 6.2.1 BLOCK DIAGRAM............................................................................6-5 1. BiCU (Base Engine and Image Control Unit) ....................................6-6 2. IOB (I/O Board).................................................................................6-6 3. SBU (Sensor Board Unit)..................................................................6-6 4. IMB (IMAC and Memory Board)........................................................6-6 6.3 COPY PROCESS OVERVIEW .................................................................6-7 6.4 SCANNING................................................................................................6-9 6.4.1 OVERVIEW ......................................................................................6-9 Lamp Stabilizer Fuse ............................................................................6-9 6.4.2 SCANNER DRIVE ..........................................................................6-10 6.4.3 ORIGINAL SIZE DETECTION IN PLATEN MODE.........................6-11 6.5 IMAGE PROCESSING ............................................................................6-13 6.5.1 OVERVIEW ....................................................................................6-13 6.5.2 SBU (SENSOR BOARD UNIT).......................................................6-14 6.5.3 AUTO IMAGE DENSITY (ADS) ......................................................6-15 In the SBU ..........................................................................................6-15 In the IPU............................................................................................6-15
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By Original Type .................................................................................6-15 6.5.4 IPU (IMAGE PROCESSING UNIT).................................................6-16 Overview.............................................................................................6-16 Image Processing Modes ...................................................................6-17 Image Processing Path.......................................................................6-18 Original Modes....................................................................................6-19 SP Modes for Each Image Processing Step .......................................6-19 Auto Shading ......................................................................................6-21 White Line Erase ................................................................................6-22 Black Line Erase .................................................................................6-22 Scanner Gamma () Correction ..........................................................6-23 Main Scan Magnification.....................................................................6-24 Mirroring for ADF Mode ......................................................................6-24 Filtering ...............................................................................................6-25 ID Gamma () Correction ....................................................................6-26 Gradation Processing .........................................................................6-27 6.5.5 IMB (MEMORY CONTROLLER AND DRAM) ................................6-28 6.5.6 VIDEO CONTROL UNIT (VCU)......................................................6-29 Fine Character and Image (FCI) .........................................................6-29 Printer Gamma Correction ..................................................................6-29 6.6 LASER EXPOSURE................................................................................6-30 6.6.1 OVERVIEW ....................................................................................6-30 6.6.2 AUTO POWER CONTROL (APC) ..................................................6-31 6.6.3 LD SAFETY SWITCH .....................................................................6-32 6.7 PHOTOCONDUCTOR UNIT (PCU) ........................................................6-33 6.7.1 OVERVIEW ....................................................................................6-33 6.7.2 DRIVE.............................................................................................6-34 6.8 DRUM CHARGE .....................................................................................6-35 6.8.1 OVERVIEW ....................................................................................6-35 6.8.2 CHARGE ROLLER VOLTAGE CORRECTION ..............................6-36 Correction for Environmental Conditions ............................................6-36 6.8.3 ID SENSOR PATTERN PRODUCTION TIMING............................6-37 6.8.4 DRUM CHARGE ROLLER CLEANING ..........................................6-38 6.9 DEVELOPMENT .....................................................................................6-39 6.9.1 OVERVIEW ....................................................................................6-39 6.9.2 DRIVE.............................................................................................6-40 6.9.3 DEVELOPER MIXING ....................................................................6-40 6.9.4 DEVELOPMENT BIAS ...................................................................6-41 6.9.5 TONER SUPPLY ............................................................................6-42 Toner Bottle Replenishment Mechanism ............................................6-42 Toner Supply Mechanism ...................................................................6-43 6.9.6 TONER DENSITY CONTROL ........................................................6-44 Overview.............................................................................................6-44 Toner Density Sensor Initial Setting....................................................6-46 Toner Concentration Measurement ....................................................6-46 Vsp/Vsg Detection ..............................................................................6-46 Toner Supply Reference Voltage (Vref) Determination.......................6-46 Toner Supply Determination ...............................................................6-46 Toner Supply Motor On Time Determinations.....................................6-47
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6.9.7 TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS...........6-48 ID Sensor............................................................................................6-48 TD Sensor...........................................................................................6-48 6.9.8 TONER NEAR END/END DETECTION AND RECOVERY............6-49 Toner Near End Detection ..................................................................6-49 Toner Near End Recovery ..................................................................6-49 Toner End Detection ...........................................................................6-49 Toner End Recovery ...........................................................................6-49 6.10 DRUM CLEANING AND TONER RECYCLING.....................................6-50 6.10.1 DRUM CLEANING........................................................................6-50 6.10.2 TONER RECYCLING ...................................................................6-50 6.11 PAPER FEED........................................................................................6-51 6.11.1 OVERVIEW ..................................................................................6-51 6.11.2 PAPER FEED DRIVE MECHANISM ............................................6-52 6.11.3 PAPER FEED AND SEPARATION MECHANISM........................6-52 6.11.4 PAPER LIFT MECHANISM ..........................................................6-53 6.11.5 PAPER END DETECTION ...........................................................6-53 6.11.6 PAPER SIZE DETECTION...........................................................6-54 Paper Tray ..........................................................................................6-54 By-pass Tray.......................................................................................6-55 6.11.7 SIDE FENCES..............................................................................6-56 6.11.8 PAPER REGISTRATION..............................................................6-56 6.12 IMAGE TRANSFER AND PAPER SEPARATION .................................6-57 6.12.1 OVERVIEW ..................................................................................6-57 6.12.2 IMAGE TRANSFER CURRENT TIMING......................................6-58 6.12.3 TRANSFER ROLLER CLEANING................................................6-59 6.12.4 PAPER SEPARATION MECHANISM...........................................6-59 6.13 IMAGE FUSING AND PAPER EXIT......................................................6-60 6.13.1 OVERVIEW ..................................................................................6-60 6.13.2 FUSING DRIVE AND RELEASE MECHANISM ...........................6-60 6.13.3 FUSING ENTRANCE GUIDE SHIFT............................................6-61 6.13.4 PRESSURE ROLLER...................................................................6-61 6.13.5 FUSING TEMPERATURE CONTROL..........................................6-62 Overview.............................................................................................6-62 Fusing Lamp Control...........................................................................6-64 Fusing Temperature Control for Thick Paper at the By-pass Tray......6-65 Pre-heat Mode (Fusing Idling) ............................................................6-65 To Prevent Offset when Making Multiple Copies on Small-width Paper..........................................................................6-65 Reduced Copy Speed with Narrow Paper ..........................................6-65 6.13.6 OVERHEAT PROTECTION .........................................................6-66 6.14 DUPLEX UNIT.......................................................................................6-67 6.14.1 OVERALL .....................................................................................6-67 6.14.2 DRIVE MECHANISM....................................................................6-68 6.14.3 BASIC OPERATION.....................................................................6-69 Larger than A4 Short-edge/LT Short-edge..........................................6-69 Up to A4 Short-edge/LT Short-edge ...................................................6-70 6.14.4 FEED IN AND EXIT MECHANISM ...............................................6-71 6.15 ENERGY SAVER MODES ....................................................................6-72
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6.15.1 OVERVIEW ..................................................................................6-72 6.15.2 LOW POWER MODE ...................................................................6-73 Entering Low Power Mode..................................................................6-73 What Happens in Low Power Mode....................................................6-73 Returning to Stand-by Mode ...............................................................6-74 6.15.3 NIGHT/OFF MODE.......................................................................6-74 Entering Night/Off Mode .....................................................................6-74 What Happens in Night/Off Mode .......................................................6-75 Returning to Stand-by Mode ...............................................................6-75
PERIPHERALS
AUTO REVERSE DOCUMENT FEEDER (B379) 1 OVERALL MACHINE INFORMATION ................................... B379-1
1.1 MECHANICAL COMPONENT LAYOUT ............................................ B379-1 1.2 ELECTRICAL COMPONENT LAYOUT.............................................. B379-2 1.3 DRIVE LAYOUT ................................................................................. B379-3
2 DETAILED SECTION DESCRIPTIONS ................................. B379-4

2.1 ORIGINAL SIZE DETECTION............................................................ B379-4 2.2 PICK-UP AND SEPARATION ............................................................ B379-6 2.3 ORIGINAL TRANSPORT AND EXIT.................................................. B379-7 2.3.1 SINGLE-SIDED ORIGINALS..................................................... B379-7 2.3.2 DOUBLE-SIDED ORIGINALS ................................................... B379-8 2.3.3 ORIGINAL TRAILING EDGE SENSOR..................................... B379-9 2.4 STAMP ............................................................................................. B379-10 2.5 TIMING CHARTS ............................................................................. B379-11 2.5.1 SINGLE-SIDED ORIGINAL MODE (A3).................................. B379-11 2.5.2 SINGLE-SIDED ORIGINAL MODE (A3, STAMP MODE)........ B379-12 2.5.3 DOUBLE-SIDED ORIGINAL MODE ........................................ B379-13 2.5.4 DOUBLE-SIDED ORIGINAL MODE (STAMP MODE)............. B379-14 2.6 JAM DETECTION............................................................................. B379-15 2.7 OVERALL ELECTRICAL CIRCUIT .................................................. B379-16 2.8 FREE RUN ....................................................................................... B379-17 Procedure .................................................................................... B379-17 One-sided Free Run Process ...................................................... B379-17 Two-sided Free Run Process ...................................................... B379-17
3 REPLACEMENT AND ADJUSTMENT................................. B379-18

3.1 3.2 3.3 3.4 3.5 DF EXIT TABLE AND COVER ......................................................... B379-18 ORIGINAL FEED UNIT .................................................................... B379-19 LEFT COVER ................................................................................... B379-20 PICK-UP ROLLER............................................................................ B379-21 FEED BELT ...................................................................................... B379-22
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3.6 3.7 3.8 3.9
SEPARATION ROLLER ................................................................... B379-23 ORIGINAL SET/ORIGINAL REVERSE SENSORS.......................... B379-24 ORIGINAL L/W SENSOR, TRAILING EDGE SENSOR ................... B379-25 FEED CLUTCH, PICK-UP SOL, TRANSPORT MOTOR, FEED MOTOR.................................................................................. B379-26 Exterior ........................................................................................ B379-26 DF Feed Clutch............................................................................ B379-26 Pick-up Solenoid .......................................................................... B379-26 Transport Motor ........................................................................... B379-26 DF Feed Motor............................................................................. B379-26 3.10 REGISTRATION SENSOR............................................................. B379-27 3.11 STAMP SOLENOID AND ORIGINAL EXIT SENSOR .................... B379-28
DOCUMENT FEEDER (B387) 1 OVERALL INFORMATION .................................................... B387-1

2 DETAILED SECTION DESCRIPTIONS ................................. B387-4

2.1 2.2 2.3 2.4 2.5 ORIGINAL SIZE DETECTION............................................................ B387-4 PICK-UP AND SEPARATION ............................................................ B387-6 ORIGINAL TRANSPORT AND EXIT MECHANISM ........................... B387-7 STAMP ............................................................................................... B387-8 TIMING CHARTS ............................................................................... B387-9 2.5.1 A3 .............................................................................................. B387-9 2.5.2 A3, STAMP MODE .................................................................. B387-10 2.6 JAM DETECTION............................................................................. B387-11 2.7 OVERALL ELECTRICAL CIRCUIT .................................................. B387-12 2.8 FREE RUN ....................................................................................... B387-13 Procedure .................................................................................... B387-13 Free Run Process ........................................................................ B387-13

3.1 EXTERIOR COVERS ....................................................................... B387-14 3.1.1 REAR COVER......................................................................... B387-14 3.1.2 ORIGINAL TABLE ................................................................... B387-14 3.1.3 FRONT COVER ...................................................................... B387-14 3.1.4 ORIGINAL ENTRANCE GUIDE .............................................. B387-14 3.1.5 DF FEED COVER.................................................................... B387-15 3.2 FEED UNIT....................................................................................... B387-15 3.3 SEPARATION ROLLER ................................................................... B387-15 3.4 PICK-UP ROLLER............................................................................ B387-16 3.5 FEED BELT ...................................................................................... B387-16 3.6 ORIGINAL SENSORS (WIDTH, LENGTH, TRAILING EDGE)......... B387-17 3.7 ORIGINAL SET SENSOR ................................................................ B387-18 3.8 TRANSPORT MOTOR ..................................................................... B387-18
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3.9 DF COVER OPEN SENSOR/FEED CLUTCH/ROM/ DF DRIVE BOARD ........................................................................... B387-19 Exterior ........................................................................................ B387-19 Feed Cover Open Sensor ............................................................ B387-19 Feed Clutch ................................................................................. B387-19 ROM ............................................................................................ B387-19 DF Drive Board ............................................................................ B387-19 3.10 REGISTRATION SENSOR............................................................. B387-21 3.11 PICK-UP SOLENOID ..................................................................... B387-21 3.12 STAMP SOLENOID........................................................................ B387-22
PAPER TRAY UNIT (B384) 1 OVERALL MACHINE INFORMATION ................................... B384-1

2 DETAILED DESCRIPTIONS .................................................. B384-4

2.1 2.2 2.3 2.4 PAPER FEED AND SEPARATION MECHANISM ............................. B384-4 PAPER LIFT MECHANISM ................................................................ B384-5 PAPER END DETECTION ................................................................. B384-7 PAPER HEIGHT DETECTION ........................................................... B384-8 PAPER SIZE DETECTION ............................................................ B384-9 2.5 SIDE AND END FENCES ................................................................ B384-10 Side Fences................................................................................. B384-10 End Fence ................................................................................... B384-10

3.1 FEED ROLLER REPLACEMENT..................................................... B384-11 3.2 TRAY MAIN BOARD REPLACEMENT ............................................ B384-12 3.3 TRAY MOTOR REPLACEMENT...................................................... B384-12 3.4 RELAY CLUTCH REPLACEMENT .................................................. B384-13 3.5 UPPER PAPER FEED CLUTCH REPLACEMENT .......................... B384-14 3.6 LOWER PAPER FEED CLUTCH REPLACEMENT ......................... B384-15 3.7 LIFT MOTOR REPLACEMENT ........................................................ B384-16 3.8 PAPER END SENSOR REPLACEMENT......................................... B384-17 3.9 VERTICAL TRANSPORT SENSOR REPLACEMENT ..................... B384-17 3.10 PAPER SIZE SWITCH REPLACEMENT ....................................... B384-18
PAPER TRAY UNIT (B385) 1 OVERALL MACHINE INFORMATION ................................... B385-1

2 DETAILED DESCRIPTIONS .................................................. B385-4

2.1 2.2 2.3 2.4 2.5 2.6 PAPER FEED AND SEPARATION .................................................... B385-4 PAPER LIFT MECHANISM ................................................................ B385-5 PAPER END DETECTION ................................................................. B385-7 PAPER HEIGHT DETECTION ........................................................... B385-8 PAPER SIZE DETECTION................................................................. B385-9 SIDE AND END FENCES ................................................................ B385-10 Side Fences................................................................................. B385-10 End Fence ................................................................................... B385-10

3.1 3.2 3.3 3.4 3.5 3.6 FEED ROLLER REPLACEMENT..................................................... B385-11 TRAY MAIN BOARD REPLACEMENT ............................................ B385-12 TRAY MOTOR REPLACEMENT...................................................... B385-13 LIFT MOTOR REPLACEMENT ........................................................ B385-14 PAPER END SENSOR REPLACEMENT......................................... B385-15 PAPER SIZE SWITCH REPLACEMENT ......................................... B385-15
SPECIFICATIONS.....................................................................SPEC-1
1. GENERAL SPECIFICATIONS............................................................. SPEC-1 Duplex Unit (B043 only) ................................................................ SPEC-4 2. MACHINE CONFIGURATION ............................................................. SPEC-5 3. OPTIONAL EQUIPMENT .................................................................... SPEC-6 ARDF ............................................................................................ SPEC-6 ADF............................................................................................... SPEC-7 ONE-TRAY PAPER TRAY UNIT .................................................. SPEC-8 TWO-TRAY PAPER TRAY UNIT.................................................. SPEC-9 16MB IMB (Copier Memory Unit)*................................................. SPEC-9
xi
20 February, 2001
INSTALLATION REQUIREMENTS
!CAUTION
Before installing options, please do the following: 1. If there is a fax unit in the machine, print out all messages stored in the memory, the lists of user programmed items, and the system parameter list. 2. If there is a printer option in the machine, print out all data in the printer buffer. 3. Turn off the main switch and disconnect the power cord, the telephone line, and the network cable.
1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT
Temperature and Humidity Chart
Humidity 80%
54% Operation range
15%
10C (50F)
27C 32C (80.6F) (89.6F)
Temperature
B039I502.WMF
1-1
Installation
1. INSTALLATION
20 February, 2001
1. Temperature Range: 10C to 32C (50F to 89.6F) 2. Humidity Range: 3. Ambient Illumination: 4. Ventilation: 5. Ambient Dust: 15% to 80% RH Less than 1,500 lux (do not expose to direct sunlight). Room air should turn over at least 30 m3/hr/person Less than 0.075 mg/m3 (2.0 x 10-6 oz/yd3)
6. Avoid areas exposed to sudden temperature changes: 1) Areas directly exposed to cool air from an air conditioner. 2) Areas directly exposed to heat from a heater. 7. Do not place the machine where it will be exposed to corrosive gases. 8. Do not install the machine at any location over 2,000 m (6,500 ft.) above sea level. 9. Place the copier on a strong and level base. (Inclination on any side should be no more than 5 mm.) 10. Do not place the machine where it may be subjected to strong vibrations.
1.1.2 MACHINE LEVEL

Front to back: Right to left: Within 5 mm (0.2") of level Within 5 mm (0.2") of level
1-2
20 February, 2001
1.1.3 MINIMUM SPACE REQUIREMENTS

Place the copier near the power source, providing clearance as shown: [C]
Installation
[B]
[D]
A: Front B: Left C: Rear D: Right [A]
> > > >
750 mm (29.6") 10 mm (0.4") 10 mm (0.4") 10 mm (0.4")
B039I145.WMF
NOTE: 1) The recommended 750 mm front space is sufficient to allow the paper tray to be pulled out. Additional front space is required to allow operators to stand at the front of the machine. 2) The recommended 10 mm right space is for installation only. Additional right space is required to allow operators to fix paper jams and use the by-pass tray.
1.1.4 POWER REQUIREMENTS
!CAUTION
1. Make sure that the wall outlet is near the copier and easily accessible. After completing installation, make sure the plug fits firmly into the outlet. 2. Avoid multi-wiring. 3. Be sure to ground the machine. 1. Input voltage: America, Taiwan:110 120 V, 50/60 Hz, 12 A Europe, Asia: 220 240 V, 50/60 Hz, 7 A
1-3
COPIER INSTALLATION
20 February, 2001
1.2 COPIER INSTALLATION

1.2.1 POWER SOCKETS FOR PERIPHERALS
!CAUTION
Rated voltage for peripherals Make sure to plug the cables into the correct sockets.
ADF/ARDF Rated voltage output connector for accessory Max. DC24 V
Paper Tray Unit Rated voltage output connector for accessory Max. DC24 V
B039I119.WMF
1.2.2 ACCESSORY CHECK

Check that you have the accessories indicated below.
No. 1 2 3 4 5 6 Description Operation Instructions - System Settings Operation Instructions - Copy Reference NECR - English (-10, -17) NECR - Multi Language (-19, -27, -29, -69) Model Nameplate (-10, -17, -22) Model Name Decal (-22) Qty 1 1 1 1 1 1
1-4
20 February, 2001
COPIER INSTALLATION
1.2.3 INSTALLATION PROCEDURE
!CAUTION
When installing the copier, make sure that the copier is unplugged. 1. Remove the strips of tape.
B039I102.WMF
2. Open the front door and remove the toner bottle holder [A].
[A]
B039I107.WMF
3. Open the right door, and remove the PCU (Photoconductor Unit) [B].
[B]
B039I108.WMF
1-5
Installation
COPIER INSTALLATION
20 February, 2001
4. Separate the PCU into two sections as shown (5 screws).
B039I114.WMF
5. Distribute one pack of developer [A] evenly across the width of the development unit, into all openings. NOTE: 1) To prevent foreign material from getting on the sleeve rollers, place a sheet of paper under the development unit. 2) Make sure not to spill the developer on the gears [B]. 3) If it is necessary to turn the gear [B] to distribute the developer, make sure to do so very minimally, otherwise the developer may spill. 6. Reassemble and reinstall the PCU. 7. Shake the toner bottle [C] several times. NOTE: Be sure not to remove the toner bottle cap [D] until after shaking. 8. Unscrew the bottle cap [D] and insert the bottle into the holder. NOTE: Do not touch the inner bottle cap [E]. 9. Reposition the holder and press down the holder lever to secure the bottle. [D] [E]
[A] [B]
B039I115.WMF
[C]
10. Pull out the paper tray and turn the B039I504.WMF paper size dial to the appropriate size. Adjust the end and side guides to match the paper size. NOTE: To move the side guides, first release the green lock on the rear side guide.
1-6
20 February, 2001
COPIER INSTALLATION
11. Install the optional ARDF, ADF, or platen cover ( 1.3/1.4/1.5). 12. Plug in the main power cord and turn on the main switch. Perform TD Sensor Initialization (SP2-214). 13. Select the correct display language using UP Mode (Language). 14. Load the paper in the paper tray and make a full size copy, and check if the side-to-side and leading edge registrations are correct. If they are not, adjust the registrations ( 3.13 Copy Adjustments: Printing/Scanning). 15. Initialize the electric total counter using SP7-825 in accordance with the type of service contract. NOTE: Select 1, then press the Original Type and OK keys at the same time. If the reset is successful, Action completed will appear on the LCD.
1-7
Installation
PLATEN COVER INSTALLATION
20 February, 2001
1.3 PLATEN COVER INSTALLATION

Check that you have the accessories indicated below.
No. 1 Description Stepped Screw Qty 2
!CAUTION
Unplug the machine power cord before starting the following procedure. 1. Install the platen cover [A] (2 screws).
[A]
B039I120.WMF
1-8
20 February, 2001
ARDF INSTALLATION

Check the quantity and condition of the accessories against the following list.
No. 1 2 3 4 5 6 Description Scale Guide DF Exposure Glass Stud Screw Knob Screw Original Size Decal Screwdriver Tool Qty 1 1 2 2 2 1
2 5
B379I500.WMF

1. Remove the strips of tape.
B379I101.WMF
1-9
Installation
1.4 ARDF INSTALLATION
ARDF INSTALLATION
20 February, 2001
2. Remove the left scale [A] (2 screws). 3. Place the DF exposure glass [B] on the glass holder. NOTE: When installing the DF exposure glass, make sure that the white point [C] is face down. 4. Peel off the backing [D] of the double-sided tape attached to the rear side of the scale guide [E], then install it (2 screws removed in step 2). 5. Install the two stud screws [F]. 6. Mount the DF on the copier, then slide the DF to the front. 7. Secure the DF unit with two screws [G]. 8. Connect the cable [H] to the copier.
[C]
[D]
[E]
[B] [F] [A] [F]
B379I103.WMF
[G] [H]
B379I104.WMF
9. Attach the appropriate scale decal [I] as shown. 10. Turn the main power switch on. Then check if the document feeder works properly. 11. Make a full size copy, and check that the side-to-side and leading edge registrations are correct. If they are not, adjust the side-to-side and leading edge registrations. ( 3.13.3 ADF Image Adjustment)
[I]
B379I501.WMF
1-10
20 February, 2001
ADF INSTALLATION

No. 1 2 3 4 5 6 Description Scale Guide DF Exposure Glass Stud Screw Fixing Screw Original Size Decal Screwdriver Tool Qty 1 1 2 2 2 1
2 5
B387I500.WMF

1. Remove the strips of tape.
B387I151.WMF
1-11
Installation
1.5 ADF INSTALLATION
ADF INSTALLATION
20 February, 2001
2. Remove the left scale [A] (2 screws). 3. Place the DF exposure glass [B] on the glass holder. NOTE: When installing the DF exposure glass, make sure that the white point [C] is face down. 4. Peel off the backing [D] of the double-sided tape attached to the rear side of the scale guide [E], then install it (2 screws removed in step 2). 5. Install the two stud screws [F]. 6. Mount the DF on the copier, then slide the DF to the front. 7. Secure the DF unit with two screws [G]. 8. Connect the cable [H] to the copier.
[C]
[D]
[E]
[B] [F] [A] [F]
B387I103.WMF
[G] [H]
B387I104.WMF
9. Attach the appropriate scale decal [I] as shown. 10. Turn the main power switch on. Then check if the document feeder works properly. 11. Make a full size copy, and check that the side-to-side and leading edge registrations are correct. If they are not, adjust the side-to-side and leading edge registrations. ( 3.13.3 ADF Image Adjustment).
[I]
B387I501.WMF
1-12
20 February, 2001
TWO-TRAY PAPER TRAY UNIT INSTALLATION

No. 1 2 3 4 Description Screw M4x10 Unit Holder Adjuster Unit Holder Qty 10 4 1 2
B384I500.WMF
[A]
B384I158.WMF
B384I001.WMF
1. Remove the strips of tape. NOTE: After removing the tape that secures the peripheral components and cardboard to the paper tray, make sure that there is no tape and/or tape residue remaining on the tray. 2. Attach the adjuster [A] to the base plate, as shown. NOTE: If a table is installed, this step is unnecessary.
1-13
Installation
1.6 TWO-TRAY PAPER TRAY UNIT INSTALLATION
20 February, 2001
3. Remove the cover [A] (1 rivet).
[A]
B384I109.WMF
4. Set the copier on the paper tray unit. NOTE: When installing the copier, be careful not to pinch the connecting harness.
B384I117.WMF
5. One-tray copier model (B039): Remove the 1st tray cassette [B]. Two-tray copier models (B040/B043): Remove the 2nd tray cassette [B]. 6. Install the two screws [C]. 7. Reinstall the tray cassette. [B] [C]
B384I106.WMF
1-14
20 February, 2001
8. Install the two brackets [A] (1 stepped screw each). 9. Connect the connecting harness [B] to the copier. NOTE: There are cutouts in the plug on both sides. The left side has one cutout, and the right side has two. 10. Reinstall the cover removed in step 3 (1 rivet). [B]
B384I105.WMF
11. Install the four brackets [C] (2 screws each). NOTE: If a table is installed, this step is unnecessary.
[C]
B384I007.WMF
12. Rotate the adjuster [D] to fix the machine in place. NOTE: If a table is installed, this step is unnecessary. 13. Load the paper in the paper trays and make full size copies from each tray. Check if the side-toside and leading edge registrations are correct. If they are not, adjust the registrations ( 3.13 Copy Adjustments: Printing/ Scanning). [D]
B384I002.WMF
1-15
Installation
[A]
ONE-TRAY PAPER TRAY UNIT INSTALLATION
20 February, 2001
1.7 ONE-TRAY PAPER TRAY UNIT INSTALLATION

No. 1 2 3 Description Screw M4x10 Stepped Screw M4x10 Unit Holder Qty 2 2 2
B385I500.WMF
B385I159.WMF
1. Remove the strips of tape. NOTE: After removing the tape that secures the peripheral components and cardboard to the paper tray, make sure that there is no tape and/or tape residue remaining on the tray.
1-16
20 February, 2001
2. Remove the cover [A] (1 rivet).
[A]
B385I109.WMF
3. Set the copier on the paper tray unit. NOTE: When installing the copier, be careful not to pinch the connecting harness.
B385I112.WMF
4. One-tray copier model (B039): Remove the 1st tray cassette [B]. Two-tray copier models (B040/B043): Remove the 2nd tray cassette [B].
[B]
B385I120.WMF
1-17
Installation
20 February, 2001
5. Install the two screws [A]. 6. Reinstall the tray cassette.
[A]
B385I118.WMF
7. Install the two brackets [B]. (1 stepped screw each). 8. Connect the connecting harness [C] to the copier. NOTE: There are cutouts in the plug on both sides. The left side has one cutout, and the right side has two. 9. Reinstall the cover removed in step 2. 10. Load the paper in the paper tray and make full size copies from tray. Check if the side-to-side and leading edge registrations are correct. If they are not, adjust the registrations ( 3.13 Copy Adjustments: Printing/Scanning).
[B]
[C]
B385I105.WMF
1-18
20 February, 2001
IMB INSTALLATION

Click the quantity and condition of the accessory against the following list:
No. 1 Description Screw M3x6 Qty 3
[A]
[C]
B039I934.WMF
[B] [D]
B039I928.WMF
1. Remove the rear middle cover [A] (2 rivets). 2. Connect the connectors [B, C] and install the IMB [D] (3 screws). 3. Reinstall the rear middle cover.
1-19
Installation
1.8 IMB INSTALLATION
DRAM INSTALLATION
20 February, 2001
1.9 DRAM INSTALLATION
[A]
B039I934.WMF
[B]
B039R942.WMF
NOTE: The IMB must be installed before installing the DRAM. 1. Remove the rear middle cover [A] (2 rivets). 2. Install the DRAM [B]. 3. Reinstall the rear middle cover.
1-20
20 February, 2001
ANTI-CONDENSATION HEATER INSTALLATION
[A] [B]
[C] [E]
[D]
B039I127.WMF
1. Remove the exposure glass ( 3.4.1). 2. Remove the left cover ( 3.3.8). 3. Pass the connector [A] through the opening [B]. 4. Install the anti-condensation heater [C], as shown. 5. Join the connectors [A, D]. 6. Clamp the harness with the clamp [E]. 7. Reinstall the left cover and exposure glass.
1-21
Installation
1.10 ANTI-CONDENSATION HEATER INSTALLATION
TRAY HEATERS
20 February, 2001
1.11 TRAY HEATERS

1.11.1 UPPER TRAY HEATER
[B] [A]
B039I909.WMF
B039I020.WMF
[E]
[C] [D] [G]
B039I121.WMF
[F]
B039I126.WMF
1. Remove the 1st tray cassette [A]. 2. Remove the rear cover ( 3.3.1). 3. Remove the high voltage power supply board [B] with bracket (5 screws and 3 connectors). 4. Pass the connector [C] through the opening [D] and install the tray heater [E] (1 screw). 5. Install the relay cable [F], as shown. 6. Clamp the cable with the clamp [G]. 7. Reinstall the 1st tray cassette, power pack, and rear cover.
1-22
20 February, 2001
TRAY HEATERS
1.11.2 LOWER TRAY HEATER (TWO-TRAY MODEL ONLY)

Installation
B039I129.WMF
[A]
[G]
[B] [F]
B039I125.WMF
[E]
[C] [D]
B039I122.WMF
1. Remove the 2nd tray cassette [A]. 2. Remove the rear lower cover ( 3.3.2). 3. B043 model only: Remove the DCB [B] with bracket (4 screws and 3 connectors). 4. Pass the connector [C] through the opening [D] and install the tray heater [E] (1 screw). 5. Join the connectors [F, G]. 6. Reinstall the 2nd tray cassette, DCB, and rear lower cover.
1-23
TRAY HEATERS
20 February, 2001
1.11.3 TRAY HEATERS FOR THE OPTIONAL PAPER FEED UNITS

1. Remove the rear cover for the paper tray unit [A] (2 screws).
[A]
B039I202.WMF
2. Two-tray unit only: Remove the cable guide [B] (1 screw). 3. Install the clamps [C].
- One-tray paper feed unit -
[C]
B039I007.WMF
- Two-tray paper feed unit -
[B]
[C]
B039I004.WMF
1-24
20 February, 2001
TRAY HEATERS
4. Pass the connector [A] through the opening [B]. 5. Install the tray heater [C] (1 screw).
[B]
[A]
[C]
B039I009.WMF
[B]
[A]
[C]
B039I005.WMF
1-25
Installation
TRAY HEATERS
20 February, 2001
6. Clamp the cables [A], as shown. 7. Join the connectors [B]. 8. Two-tray unit only: Reinstall the cable guide. 9. One-tray copier model (B039): Remove the 1st tray cassette. Two-tray copier models (B040/B043): Remove the 2nd tray cassette.
[B] [A]
[C]
B039I008.WMF
[B] [B] [A]
B039I006.WMF
10. Remove the two screws [C] and install the two hexagonal socket screws [D]. 11. Reinstall the 1st tray and rear cover.
[D]
[C]
B039I003.WMF
1-26
20 February, 2001
KEY COUNTER INSTALLATION
[B] [C]
[D]
B039I128.WMF
[A]
[E]
[F]
B039I100.WMF
1. Remove the left cover ( 3.3.8). 2. Remove the rear cover ( 3.3.1). 3. Remove the cap [A] with nippers. 4. Punch out the small hole [B] using a screwdriver. 5. Hold the key counter plate nuts [C] on the inside of the key counter bracket [D] and insert the key counter holder [E]. 6. Secure the key counter holder to the bracket (2 screws). 7. Install the key counter cover [F] (2 screws).
1-27
Installation
1.12 KEY COUNTER INSTALLATION
KEY COUNTER INSTALLATION
20 February, 2001
[C] [F] [B]
[A]
B039I130.WMF
[K]
[L] [J] [I] [G]
B039I131.WMF
[E]
[D]
[H]
8. Clamp the relay cable [A] with the clamps [B], as shown. NOTE: The relay cable [A] is not included in the key counter bracket accessories. 9. Connect the connector [C] to CN306 on the IOB. 10. Reinstall the rear and left cover. NOTE: When reinstalling the left cover, pass the relay cable connector [D] through the opening [E]. 11. Install the stepped screw [F]. 12. Install the relay cable [G] and join the connectors [D, H]. 13. Join the connectors [I, J]. 14. Hook the key counter holder assembly [K] onto the stepped screw [F]. 15. Secure the key counter holder assembly with a screw [L]. 16. Change the value of SP5-113 to 1.
1-28
20 February, 2001
PM TABLES
2. PREVENTIVE MAINTENANCE SCHEDULES

2.1 PM TABLES
NOTE: 1) After carrying out PM, clear the PM counter (SP7-804). 2) PM intervals (60k, 80k, and 120K) indicate the number of prints. Key: AN: As necessary
EM OPTICS Reflector 1st mirror 2nd mirror 3rd mirror Scanner guide rails Platen cover Exposure glass Toner shield glass APS sensors DRUM AREA PCU Drum Developer Charge roller Cleaning brush (for charge roller) Cleaning blade (for OPC drum) Separation pawls Transfer roller ID sensor PAPER FEED Paper feed roller (in each feed tray) Friction pad (in each feed tray) Bottom-plate pad (in each feed tray) Paper feed roller (bypass tray) Friction pad (bypass tray) Bottom-plate pad (by-pass tray) Registration rollers Relay rollers C C C C C I C C C
C: Clean R: Replace L: Lubricate I: Inspect

60k 120k AN NOTE Optics cloth Optics cloth Optics cloth Optics cloth Do not use alcohol. Replace the platen sheet, if necessary. Blower brush or alcohol Blower brush or alcohol Blower brush Blower brush
C C C C C
I R R R R R R R C C Blower brush
C C C C C C C C
R R
C C C C C C C C
Clean with water or alcohol. Clean with water or alcohol. Clean with water or alcohol. Clean with water or alcohol. Clean with water or alcohol. Clean with water or alcohol. Clean with water or alcohol. Clean with water or alcohol.
2-1
Preventive Maintenance
PM TABLES
EM Paper feed guides Paper-dust Mylar FUSING UNIT Hot roller Pressure roller Hot roller bushings Pressure-roller bushing Hot roller stripper pawls Thermistor 60k C C 120k AN C C
20 February, 2001
NOTE Clean with water or alcohol. Clean with water or alcohol.
R R I R R C C C Dry cloth Dry cloth
80k ADF, ARDF Feed belt Separation roller Pick-up roller Stamp White plate DF exposure glass Platen cover R R R
AN C C C R C C C
NOTE Clean with water or alcohol. Clean with water or alcohol. Clean with water or alcohol. Replace when necessary. Clean with water or alcohol. Clean with water or alcohol. Clean with water or alcohol.
60k 120k AN NOTE PAPER TRAY UNIT (ONE-TRAY AND TWO-TRAY MODELS) Paper feed rollers R C Dry or damp cloth Bottom-plate pads C C Dry cloth Paper-feed guides C C Clean with water or alcohol. Friction pads R C Dry or damp cloth PAPER TRAY UNIT (TWO-TRAY MODEL ONLY) Relay clutch I Feed clutches I Relay roller C C Dry cloth
2-2
20 February, 2001
HOW TO CLEAR THE PM COUNTER
2.2 HOW TO CLEAR THE PM COUNTER

After PM, clear the PM counter (SP7-804). 1. Access SP mode 7-804.
Preventive Maintenance
2. Press the Original Type key and the OK or ! key at the same time to reset the counter. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!
2-3
20 February, 2001
GENERAL CAUTIONS
3. REPLACEMENT AND ADJUSTMENT

3.1 GENERAL CAUTIONS
Do not turn off the main switch while any of the electrical components are active. Doing so may result in damage to units (such as the PCU) as they are pulled out or replaced.
3.1.1 PCU (PHOTOCONDUCTOR UNIT)

Replacement Adjustment
The PCU consists of the OPC drum, charge roller, development unit, and cleaning components. Observe the following precautions when handling the PCU. 1. Never touch the drum surface with bare hands. If the drum surface is dirty or if you have accidentally touched it, wipe it with a dry cloth, or clean it with wet cotton and then wipe it dry with a cloth. 2. Never use alcohol to clean the drum. Alcohol will dissolve the drum surface. 3. Store the PCU in a cool dry place. 4. Do not expose the drum to corrosive gases (ammonia, etc.). 5. Do not shake a used PCU, as this may cause toner and developer to spill out. 6. Dispose of used PCU components in accordance with local regulations.
3.1.2 TRANSFER ROLLER

1. Never touch the surface of the transfer roller with bare hands. 2. Be careful not to scratch the transfer roller, as the surface is easily damaged.
3.1.3 SCANNER UNIT

1. Use alcohol or glass cleaner to clean the exposure and scanning glass. This will reduce the static charge on the glass. 2. Use a blower brush or a water-moistened cotton pad to clean the mirrors and lenses. 3. Take care not to bend or crease the exposure lamps ribbon cable. 4. Do not disassemble the lens unit. Doing so will throw the lens and copy image out of focus. 5. Do not turn any of the CCD positioning screws. Doing so will throw the CCD out of position.
3-1
SPECIAL TOOLS AND LUBRICANTS
20 February, 2001
3.1.4 LASER UNIT

1. Do not loosen or adjust the screws securing the LD drive board on the LD unit. Doing so will throw the LD unit out of adjustment. 2. Do not adjust the variable resistors on the LD unit. These are adjusted at the factory. 3. The polygonal mirror and F-theta lens are very sensitive to dust. 4. Do not touch the toner shield glass or the surface of the polygonal mirror with bare hands.
3.1.5 FUSING UNIT

1. After installing the fusing thermistor, make sure that it is in contact with the hot roller and that the roller can rotate freely. 2. Be careful to avoid damage to the hot roller stripper pawls and their tension springs. 3. Do not touch the fusing lamp and rollers with bare hands. 4. Make sure that the fusing lamp is positioned correctly and that it does not touch the inner surface of the hot roller.
3.1.6 PAPER FEED

1. Do not touch the surface of the paper feed rollers. 2. To avoid misfeeds, the side and end fences in each paper tray must be positioned correctly so as to align with the actual paper size.
3.1.7 IMPORTANT
1. After installing a new PCU, you must run SP2-214 to initialize the TD sensor. After starting initialization, be sure to wait for it to reach completion (wait for the motor to stop) before re-opening the front cover or turning off the main switch. 2. If the optional tray heater or optics anti-condensation heater is installed, keep the copier's power cord plugged in even while the main switch is off, so that the heater(s) remain energized.
3.2 SPECIAL TOOLS AND LUBRICANTS

Part Number A0069104 A2929500 A0299387 A2309352 A2579300 52039502 B0399099 G0219350 Description Scanner Positioning Pins (4 pins/set) Test Chart S5S (10 pcs/set) FLUKE 87 Digital Multimeter 4MB Flash Memory Card Grease Barrierta S552R Grease G-501 NVRAM Minus Counter Loop-back Connector Qty 1 set 1 set 1 1 1 1 1 1
3-2
20 February, 2001
EXTERIOR COVERS & OPERATION PANEL
3.3 EXTERIOR COVERS & OPERATION PANEL

3.3.1 REAR COVER
1. Unplug the DF cable [A]. 2. Rear cover [B] (! x 6)
[A]
[B]
B039R991.WMF
3.3.2 REAR LOWER COVER (TWO-TRAY MODELS ONLY)

1. Rear cover ( 3.3.1) or tray harness cover [C] (1 rivet). 2. Rear lower cover [D] (! x 2)
[D]
[C]
B039R123.WMF
3-3
20 February, 2001
3.3.3 COPY TRAY

1. Duplex models only: Inverter tray [A] 2. Copy tray [B] (! x 2) [A]
[B]
B039R152.WMF
3.3.4 LEFT UPPER COVER

1. Rear cover ( 3.3.1) 2. Left upper cover [C] (! x 2) [D] [C] [G]
[E] [F]
B039R002.WMF
3.3.5 FRONT UPPER LEFT COVER AND OPERATION PANEL

1. Front upper left cover [D] (! x 3) 2. Operation panel [E] (! x 3, " x 1)
3.3.6 RIGHT UPPER COVER

1. Right upper cover [F] (! x 1)
3.3.7 TOP REAR COVER

1. Platen cover or ARDF or ADF ( 1.2, 1.3, or 1.4) 2. Top rear cover [G] (! x 1)
3-4
20 February, 2001
3.3.8 LEFT COVER

1. Copy tray ( 3.3.3) 2. Rear cover ( 3.3.1) 3. Left cover [A] (! x 2)
[A]
B039R924.WMF
3.3.9 FRONT LONG COVER

1. Open the front door [B]. 2. Pull out the (top) paper tray. 3. Front long cover [C] (! x 4)
[C]
[B]
B039R929.WMF
3-5
20 February, 2001
3.3.10 FRONT RIGHT COVER

1. Open the front door [A]. 2. Front right cover [B] (! x 1)
[B]
[A]
B039R905.WMF
3.3.11 RIGHT REAR COVER

1. Right upper cover ( 3.3.6) 2. Right rear cover [C] (! x 1)
[C]
B039R914.WMF
3-6
20 February, 2001
3.3.12 RIGHT DOOR

[D]
[C]
[A] [B]
B039R915.WMF
1. Undo the strap [A] and lower the right door. NOTE: On non-duplex models (shown in the drawing above), hold the door open part way and push the strap toward the door so that it comes loose from the peg [B] on the door. On duplex models (not shown), unscrew the strap (! x 1) from the main unit. 2. Rear cover ( 3.3.1) 3. Right rear cover ( 3.3.11) 4. Open the 2 clamps [C] and disconnect the connectors [D]. NOTE: On non-duplex models (shown in the drawing above), disconnect 2 connectors. On duplex models, disconnect 3 connectors. 5. Pull the door off at an angle, so that it comes free of the hinges.
3-7
20 February, 2001
3.3.13 BY-PASS TRAY
[D]
[E] [A] [B] [C]

B039R803.WMF
1. Rear cover ( 3.3.1) 2. Right rear cover ( 3.3.11) 3. Open the two clamps (see [C] on preceding page) and disconnect the connector coming from the by-pass tray (5-pin connector with colored wires). Move the connector clear of the other wires, so that it will come out without snagging when you take off the by-pass tray. 4. Lower the right door. ( 3.3.12) 5. Open the wire harness on the inside of the right door (B043 model only). 6. Close the right door again temporarily (you do not need to refasten the strap). 7. Front-side clip ring [A], front-side pin [B], front-side tray holder arm [C], and rear-side clip ring [D] 8. By-pass tray [E]
3-8
20 February, 2001
3.3.14 LEFT LOWER COVER (TWO-TRAY MODELS ONLY)

1. Left lower cover [A] (! x 2)
[A]
B039R936.WMF
3.3.15 RIGHT LOWER COVER (TWO-TRAY MODELS ONLY)

1. Open the right lower cover [B]. 2. Right lower cover (1 rivet)
[B]
B039R937.WMF
3.3.16 PLATEN COVER SENSOR

1. Top rear cover ( 3.3.7) 2. Platen cover sensor [C] (" x 1) [C]
B039R013.WMF
3-9
SCANNER SECTION
20 February, 2001
3.4 SCANNER SECTION

3.4.1 EXPOSURE GLASS/DF EXPOSURE GLASS
[A]
[B]
[D]
[E] [C]
B039R001.WMF
Exposure Glass
1. Left scale [A] (! x 2) 2. Rear scale [B] (! x 3) 3. Exposure glass [C] NOTE: When reinstalling, be sure that the mark is at the rear left corner, and be sure to set the exposure glass so that its left edge is aligned flush against the small support ridge on the frame.
DF Exposure Glass
1. Left scale [A] 2. DF exposure glass [D] NOTE: When reinstalling, be sure that the mark [E] is facing down
3-10
20 February, 2001
SCANNER SECTION
3.4.2 LENS BLOCK

1. Exposure glass ( 3.4.1) 2. Lens cover [A] (! x 5) 3. Disconnect the flat cable [B]. 4. Lens block [C] (! x 4). NOTE: Do not loosen the paintlocked screws holding the lens unit in place. After installing the new lens block, do the copy adjustments ( 3.13). [C] [A]
[B]
B039R003.WMF
3.4.3 EXPOSURE LAMP, LAMP STABILIZER BOARD

1. Exposure glass ( 3.4.1) 2. Operation panel ( 3.3.5) 3. Slide the 1st scanner to a position where the front end of the lamp is clear of the metal lids. 4. Place your right hand under the [G] lamp stabilizer board [D] on the underside of the 1st scanner, to support the board when it drops. Press hook [E] with your left thumb to release the board. 5. Disconnect the lamp connector [F]. If you wish, you can now remove the lamp stabilizer board (by disconnecting the flat cable). 6. Remove the front reflector [G]. 7. Press on the plastic latch [H] and at the same time push the plastic end of the lamp toward the rear, so that the lamp snaps free. Remove the lamp together with the lamp cable. [H]
[E]
[D] [F]
B039R006.WMF
3-11
SCANNER SECTION
20 February, 2001
3.4.4 ORIGINAL WIDTH SENSOR

1. Exposure glass ( 3.4.1) 2. Original width sensor [A] (! x 1, " x 1) [A] [B]
B039R004.WMF
3.4.5 ORIGINAL LENGTH SENSOR

1. Exposure glass ( 3.4.1) 2. Lens block (3.4.2) 3. Original length sensor [B] (! x 1, " x 1)
Sensor Positions
[D]
[F] [C] [D] [C] [E] [F] [E]
B039R303.WMF
B039R304.WMF
Sensor positions vary according to region, as indicated below. [C], [D]: Europe, Asia, Taiwan [E], [F]: America [G], [H]: China
[G] [H] [G] [H]
B039R305.WMF
3-12
20 February, 2001
SCANNER SECTION
3.4.6 CHANGING THE ORIGINAL SENSOR POSITIONS (8K/16K)

This procedure is for China models only. To enable detection of the following original sizes, the original sensors must be moved from their factory-set positions to the locations indicated in the drawing below right. 8K SEF (270 x 390 mm) 16K SEF (195 x 270 mm) 16K LEF (270 x 195 mm) Once the sensors have been moved, they will detect paper sizes as follows.
Original Size 8K-SEF 16K-SEF 16K-LEF
Length Sensors L1 L2
Width Sensors W1 W2
: Original present : Original not present
3-13
SCANNER SECTION
20 February, 2001
Procedure
[B] [A]
B039R004.WMF
[D]
[C]
B039R012.WMF
1. Set the machine to detect 8K/16K originals as follows. If the machine is equipped with the platen cover: Access SP mode 5-955-1, and set the setting to 1 (=Yes). The machine will now detect 8K/16K rather than B4/B5. (B4-SEF 8K-SEF; B5-SEF 16K-SEF; B5-LEF 16K-LEF) If the machine is equipped with the ADF or ARDF: Access SP mode 5-955-2, and set the setting to 1 (=Yes). The machine will now detect 8K/16K rather than A3/A4/B4/B5. (A3-SEF/B4-SEF 8K-SEF; B5-SEF/A4-SEF 16KSEF; B5-LEF/A4-LEF 16K-LEF) Note that making either of the above settings will disable use of SP mode 5911. 2. Turn off the power, and remove the exposure glass ( 3.4.1). 3. Remove APS senosrs [A, B]. 4. Remove screws [C, D] at the new mount positions. 5. Mount the original width sensor into the new position (from where you removed screw [C]), and screw. 6. Mount the original length sensor into the new position (from where you removed screw [D]), and screw it. 7. Screw screws back into their original holes.
3-14
20 February, 2001
SCANNER SECTION
3.4.7 SCANNER MOTOR

1. Rear cover ( 3.3.1) 2. Right upper cover ( 3.3.6) 3. Rear scale and exposure glass ( 3.4.1) 4. Operation panel ( 3.3.5) 5. Top rear cover ( 3.3.7) 6. Detach the belt [A]. 7. Scanner motor [B] (! x 3, 1 spring, " x 1) NOTE: When reinstalling the motor: Fit the belt on first, then set the spring in place, and then screw in evenly, rotating from screw to screw so that the spring tension is correctly distributed. After installing the motor, do the copy adjustments ( 3.13).
[A]
[B]
B039R008.WMF
3.4.8 SCANNER H.P. SENSOR

1. Left upper cover ( 3.3.4) 2. Top rear cover ( 3.3.7) 3. Exposure glass ( 3.4.1) NOTE: If the machine is an A(R)DF model, remove both the DF exposure glass and the exposure glass. 4. Disconnect the scanner H.P. sensor connector [C]. 5. Scanner left lid [D] (! x 7) 6. Remove the sensor tape [E]. 7. Scanner H.P. sensor [F]
B039R005.WMF
[E]
[D]
[C] [F]
3-15
SCANNER SECTION
20 February, 2001
3.4.9 ADJUSTMENT OF 2ND SCANNER POSITION

Do this procedure after replacing a scanner belt. If you replaced the second scanner belts, go onto the next section (Adjustment of 1st and 2nd Scanner Alignment.) [A]
[C]
[B]
[C]
[B]
B039R011.WMF
1. Remove the A(R)DF or platen cover. 2. Remove the operation panel ( 3.3.5). 3. Remove the top rear cover ( 3.3.7). 4. Loosen the 2 screws [A] holding the 2nd scanner belt in place. 5. Slide the 2nd scanner so that the second hole from the right on each scanner arm is roughly aligned with the position guide holes [B] on the upper and lower mainframe rims. 6. Insert the positioning tools [C] into both sets of holes. NOTE: If the 1st scanner is preventing the pins from fitting in smoothly, loosen the 1st scanner securing screws and slide the 1st scanner out of the way ( 3.4.10, step 1). 7. Re-tighten the screws loosened in step 1 [A] and remove the positioning tools. 8. Go on to the next section, Adjustment of 1st and 2nd Scanner Alignment.
3-16
20 February, 2001
SCANNER SECTION
3.4.10 ADJUSTMENT OF 1ST AND 2ND SCANNER ALIGNMENT

For how to use this procedure, see the previous section, Adjustment of 2nd Scanner Position. [C] [D] [B]
[A] [C]
[B]
[A]
B039R007.WMF
1. Remove the A(R)DF or platen cover. 2. Remove the operation panel ( 3.3.5). 3. Remove the top rear cover ( 3.3.7). 4. Loosen the 2 screws [A] holding the 1st and 2nd scanner belts in place. 5. Slide the 1st and 2nd scanners so that all three of the following are aligned on both sides: The second hole from the right on each 2nd scanner arm The position guide holes on the upper and lower mainframe rims The 1st scanner position guide hole [B] 6. Insert the positioning tools [C] into both sets of holes. 7. Make sure that both the 1st and 2nd scanner belts are properly set in place on both sides [D]. 8. Re-tighten the screws loosened in step 1 [A] to clamp the scanner belts in place, then remove the positioning tools.
3-17
LASER UNIT
20 February, 2001
3.5 LASER UNIT !WARNING

Laser beam can seriously damage your eyes. Be absolutely sure that the main power switch is off and that the machine is unplugged before accessing the laser unit.
3.5.1 LOCATION OF CAUTION DECAL
B039R110.WMF
B039RLW.WMF
3-18
20 February, 2001
LASER UNIT
3.5.2 TONER SHIELD GLASS

1. Open the front door. 2. Lift the toner cartridge latch [A]. 3. Press the toner shield glass cover [B] to the left and pull it out. 4. Pull out the toner shield glass [C]. [B] [C]
B039R151.WMF
[A]
3.5.3 LASER UNIT

1. Toner shield glass. ( 3.5.2) 2. Copy tray ( 3.3.3) 3. Pull out the (upper) paper tray. 4. Front long cover ( 3.3.9) 5. Disconnect the harness [D, E]. 6. Laser unit [F] (! x 4) NOTE: The screw at the left front position [G] is longer than the others. [F]
B039R153.WMF
[E] [D] [G]
3-19
LASER UNIT
20 February, 2001
3.5.4 LD UNIT
1. Laser unit ( 3.5.3) 2. LD unit [A] (! x 1) NOTE: Do not screw the LD unit in too tightly when installing it.
[A]
B039R155.WMF
3.5.5 POLYGONAL MIRROR MOTOR

1. Laser unit ( 3.5.3) 2. Two rubber bushings [B] 3. Laser unit cover [C] (! x 1) 4. Polygonal mirror motor [D] (! x 4) 5. Do the copy adjustments ( 3.13). [D] [C]
[B]
B039R154.WMF
3-20
20 February, 2001
LASER UNIT
3.5.6 LASER UNIT ALIGNMENT ADJUSTMENT
!WARNING
Be absolutely sure to reinstall the copy exit tray before making printouts. The laser beam can seriously damage your eyes.
[A]
[B] [C]
B039R156.WMF
[D]
Turning the lever counter-clockwise alters the trim pattern as shown above
Turning clockwise alters the trim pattern as shown above

B039R890.WMF
1. Use SP5-902 to output a trim pattern (pattern 10). If the pattern is not even, adjust the alignment as follows. 2. Copy tray ( 3.3.3) 3. Loosen the four screws securing the laser unit ( 3.5.3). 4. If this is the first time this adjustment is being made: Remove the adjustmentlever screw [A] (securing the adjustment lever [B]) from its factory set position at [C], and loosely screw it in at the center of the long hole [D]. NOTE: If you have already adjusted the alignment at least once, the screw will already be in the long hole. If readjustment is necessary, just loosen the screw and continue as follows. 5. Rotate the lever clockwise or counterclockwise. This allows you to shift the corners of the pattern 0.4 mm with respect to the leading and trailing edges of the paper. Using trial and error, adjust until the trim pattern is even. 6. Tighten screw [A] at its new position. 7. Tighten the other three screws. 8. Reinstall the copy tray. 9. Print the trim pattern and check the result. If further adjustment is required, repeat this procedure.
3-21
PCU SECTION
20 February, 2001
3.6 PCU SECTION

3.6.1 PCU
1. Toner bottle holder ( 1.2.3, step 2) 2. Open the right door. 3. Press in on the latch, and pull out the PCU. ( 1.2.3, step 3) NOTE: Do not touch the OPC drum surface with bare hands. 4. Load new developer. ( 3.6.7) 5. After reinstalling, run SP2-214 to reinitialize the TD sensor. 6. Do steps 1 to 6 of the procedure in section 3.6.8.
3.6.2 PICK-OFF PAWLS

1. Take out the PCU ( 3.6.1) or open the right door. 2. Pull each pawl [A] out from the bottom. 3. Do the procedure in section 3.6.8. [A]
[B]
B039R205.WMF
3.6.3 TONER DENSITY SENSOR

1. PCU ( 3.6.1) 2. The toner density sensor [B] is taped to the bottom of the PCU. Pry it off with a regular screwdriver (! x 1). NOTE: Do not turn the PCU upside down, as doing so will cause toner and developer to spill out. 4. Do the procedure in section 3.6.8.
3-22
20 February, 2001
PCU SECTION
3.6.4 OPC DRUM

[B] [C] [E]
[A] [D] [G]

B039R201.WMF
[F]
B039R206.WMF
1. PCU ( 3.6.1) 2. Remove the front side piece [A] (! x 1) and rear side piece [B] (! x 2, 1 coupling), and separate the PCU top part (drum section) [C] from its bottom part (developer section) [D]. Carry out the remaining steps on the drum section. NOTE: To ensure that the left-side gears line up, be sure that the drum cover [E] is closed when reinserting the front side piece. 3. Pry out the drum retaining clip [F]. NOTE: Be sure to reinstall the clip in the same orientation (with the lip facing away from the drum shaft). 4. Pull out the front end of the OPC drum [G], and remove. 5. Do the procedure in section 3.6.8.
3-23
PCU SECTION
20 February, 2001
3.6.5 CHARGE ROLLER AND CLEANING BRUSH

[E] [D]
[B]
[A]
[C]
B039R204.WMF
1. OPC Drum ( 3.6.4) 2. Remove holding pin [A] and 1 stepped screw [B]. 3. Turn the gear [C] as necessary so that the rear end piece can come out. 4. Pull out the charge roller [D] and cleaning brush [E] as a single assembly (together with the plastic end pieces and springs). 5. Do the procedure in section 3.6.8.
3.6.6 CLEANING BLADE

1. Drum charge roller ( 3.6.5) 2. Cleaning blade [F] (! x 2) 3. Do the procedure in section 3.6.8. [F]
B039R207.WMF
3-24
20 February, 2001
PCU SECTION
3.6.7 DEVELOPER
[A]
[B]
[D] [E] [C]

B039R203.WMF
[F]
B039R202.WMF
1. PCU ( 3.6.1) 2. Tap the top of the PCU with a screwdriver at eight evenly spaced locations (two or three taps at each spot) so as knock the recycled toner down into the development section. 3. Set the PCU back into the mainframe. 4. Turn the main power on. Then open and close the door and wait for the machine to rotate the development roller for 10 seconds. Then open and close the door two more times, so that total rotation time is 30 seconds. 5. Remove the PCU again. 6. Separate the developer section from the OPC drum section ( 3.6.4, step 2). 7. Remove the top part [A] of the development unit (! x 5), then place your finger under the front-side flap [B] and push out so that the flap pops off the peg. 8. Set the coupling [C] back onto the shaft, tilt the development roller [D] upward as shown, and turn the coupling (and shaft) in the direction of the arrow [E] to remove developer from the roller. 9. Turn the bottom part [F] of the developer unit over and rotate the gears to remove the developer. 10. Load new developer. ( 1.2.3, step 5) 11. After reinstalling, run SP2-214 to reinitialize the TD sensor. NOTE: 1) Be sure that there is no toner or developer stuck on any of the gears. (Clean as necessary with a blower brush, etc.) 2) Be sure to replace the Mylar at the rear side in the correct position. (The Mylar protects the gears at the rear side from falling toner).
3-25
PCU SECTION
20 February, 2001
3.6.8 AFTER REPLACEMENT OR ADJUSTMENT

IMPORTANT: After replacing or adjusting any of the PCU components, please do the following procedure. It is not needed after replacing the PCU with a new one. 1. Take 5 sample copies. 2. If black dots (dropped toner) appear on any of the copies, continue as follows. (If all copies are clean, you don't need to carry out the following steps.) 3. Remove the PCU from the mainframe. 4. Tap the top of the PCU with a screwdriver at eight evenly spaced locations (two or three taps at each spot), to knock the recycled toner down into the development section. 5. Put the PCU back into the mainframe. 6. Turn the main power on. Then open and close the door and wait for the machine to rotate the development roller for 10 seconds. Then open and close the door two more times, so that total rotation time is 30 seconds. 7. Make some sky-shot copies (or solid black prints). If using A4/81/2" x 11" paper, make 4 copies/prints. If using A3/11" x 17" paper, make 2 copies/prints. To make solid black prints, use SP5-902 pattern 8. NOTE: Step 7 is required only after parts replacement or adjustment. There is no need to make sky-shot (or solid black) copies after replacing the developer.
3-26
20 February, 2001
TONER SUPPLY MOTOR
3.7 TONER SUPPLY MOTOR

1. Copy tray ( 3.3.3) 2. Open the front door. 3. Toner bottle holder ( 1.1.3, step 2) 4. Toner supply motor [A] (" x 1)
[A]
B039R917.WMF
3-27
PAPER FEED SECTION
20 February, 2001
3.8 PAPER FEED SECTION

3.8.1 PAPER FEED ROLLER
1. Pull out the appropriate paper tray. 2. Clip [A] 3. Push the shaft back through the opening, and tilt it up. NOTE: If the black plastic bushing [B] comes off, be sure to remount it when reinstalling the shaft. 4. Paper feed roller [C] [A] [B]
B039R702.WMF
[C]
3.8.2 FRICTION PAD

1. Pull the appropriate paper cassette out. 2. Clip [D] 3. Push the shaft back through the opening, so that the roller moves clear of the friction pad. 4. Friction pad [E] [D]
[E]
B039R703.WMF
3.8.3 PAPER END SENSOR

1. Pull the appropriate paper cassette out. 2. Paper end sensor [F] (" x 1)
[F]
3-28
B039R705.WMF
20 February, 2001
PAPER FEED SECTION
3.8.4 EXIT SENSOR

Non-duplex Models
1. Open the right door. 2. Front right cover ( 3.3.10) 3. Guide [A] (! x 2) 4. Exit sensor [B] (" x 1) [A]
[B]
B039R601.WMF
Duplex Models
1. Open the right door. 2. Front right cover ( 3.3.10) 3. Lower guide [C] (! x 2) 4. Upper guide [D] (! x 2) 5. Exit sensor [E] (" x 1) [E] [D]
[C]
B039R945.WMF
3-29
PAPER FEED SECTION
20 February, 2001
3.8.5 BY-PASS FEED ROLLER AND BY-PASS PAPER END SENSOR
[A]
[B]
[C]
B039R804.WMF
1. By-pass tray ( 3.3.13) NOTE: If you wish, you can just detach the tray and rest it on the ground without disconnecting the connector (but be careful to avoid placing too much load on the wires). 2. Sensor holder [A]. 3. By-pass paper end sensor [B] (" x 1) 4. By-pass feed roller [C]
3-30
20 February, 2001
PAPER FEED SECTION
3.8.6 REGISTRATION ROLLER

[D]
[F] [E]
[A]
[H] [B]
B039R951.WMF
[G]
[C]
B039R950.WMF
1. PCU ( 3.6.1) 2. Front long cover ( 3.3.9) 3. Right door ( 3.3.12) 4. Rear cover ( 3.3.1) 5. High-voltage power supply ( 3.12.2) 6. Registration clutch ( 3.8.8) 7. Unhook the springs [A] and [B] at the rear and front sides. 8. Guide [C] (! x 1, " x 1) 9. Bushing [D] (# x 1) 10. Gear [E] and bushing [F] (# x 1) 11. Registration roller [G] with the image transfer unit [H]
3-31
PAPER FEED SECTION
20 February, 2001
3.8.7 BY-PASS PAPER SIZE SWITCH

1. By-pass tray ( 3.3.13) 2. Tray lever [A] (! x 1, 1 pin) 3. Lift the upper tray [B] 4. By-pass paper size switch [C] (" x 1) NOTE: When reinstalling the switch: Move the paper guides to their middle position (about halfway between fully open and fully closed), and install the round gear so that the hole in the gear [D] aligns with the peg [E] on the sliding gear. [C] [A] [E] [D]
[B]
B039R704.WMF
3.8.8 REGISTRATION CLUTCH
[F]
B039R909.WMF
[G]
B039R911.WMF
1. Rear cover ( 3.3.1) 2. Bracket holding the high-voltage power supply board [F] (" x 5, all connectors) 3. Registration clutch [G] (! x 1, # x 1)
3-32
20 February, 2001
PAPER FEED SECTION
3.8.9 REGISTRATION SENSOR

1. Open the right door. 2. Registration sensor [A] (" x 1)
[A]
B039R920.WMF
3.8.10 UPPER PAPER FEED CLUTCH AND BY-PASS FEED CLUTCH

1. Rear cover ( 3.3.1) 2. Clutch cover [B] (# x 2, 2 bushings, ! x 2 ) [C] 3. Paper feed clutch [C] and bypass feed clutch [D] NOTE: When reinstalling, be sure that the rotationprevention tabs [E] on the clutches fit correctly into the corresponding openings on the clutch cover. [E]
[B]
[D]
B039R922.WMF
3-33
PAPER FEED SECTION
20 February, 2001
3.8.11 RELAY CLUTCH

1. Rear cover ( 3.3.1) 2. Relay clutch [A] (! x 1)
3.8.12 RELAY SENSOR

1. Relay clutch ( 3.8.11) 2. Sensor bracket [B] (" x 1) 3. Relay sensor [C] (! x 1)
[A]
B039R912.WMF
[C]
[B]
B039R923.WMF
3.8.13 LOWER PAPER FEED CLUTCH (TWO-TRAY MODELS ONLY)

1. Rear lower cover ( 3.3.2) 2. Clutch bracket [D] (" x 2) 3. Lower paper feed clutch [E] (# x 1, 1 bushing, ! x 1)
[D]
[E]
B039R940.WMF
3-34
20 February, 2001
PAPER FEED SECTION
3.8.14 VERTICAL TRANSPORT SENSOR (TWO-TRAY MODELS ONLY)

1. Open the right lower cover. 2. Metal plate [A] (! x 3) 3. Vertical transport sensor [B] (" x 1)
[B]
[A]
B039R938.WMF
3.8.15 PAPER SIZE SWITCH

1. Open the appropriate paper tray. 2. Switch cover [C] (! x 1) 3. Paper size switch [D] (" x 1)
[D]
[C]
B039R913.WMF
3-35
IMAGE TRANSFER
20 February, 2001
3.9 IMAGE TRANSFER

3.9.1 IMAGE TRANSFER ROLLER
1. Open the right door. 2. Pry open the plastic holders [A] at each end of the roller, and lift off the image transfer roller [B]. NOTE: 1) Leave the springs under the roller in their original position. When replacing the roller, be sure that the pegs [C] on the two square black pieces [D] are facing down into the springs. 2) Do not touch the transfer roller surface with bare hands. [C] [A] [B] [D]
B039R902.WMF
3.9.2 IMAGE DENSITY SENSOR

1. Open the right door. 2. Plastic cover [E] 3. Image transfer roller ( 3.9.1) 4. Push down on the notch [F] to free the sensor. 5. Image density sensor [G] (" x 1) [F] [G] [E]
B039R931.WMF
3-36
20 February, 2001
FUSING
3.10 FUSING
3.10.1 FUSING UNIT
!CAUTION
The fusing unit can become very hot. Be sure that it has cooled down sufficiently before handling it. 1. Turn off the main switch, and unplug the machine. 3. Open the right door. 4. Fusing unit [A] (! x 2, " x 2) NOTE: If you forget to connect the small connector when reinstalling, the copier will issue service call SC541. The color of connector [B] Blue: For 120 V machine Red: For 230 V machine [B]
B039R501.WMF
[A]
3.10.2 THERMISTOR
[C] 1. Fusing unit ( 3.10.1) 2. Thermistor [C] (! x 1, " x 1)
B039R502.WMF
3-37
2. Front right cover ( 3.3.10)
FUSING
20 February, 2001
3.10.3 FUSING LAMP
[A] [B] [D]
B039R503.WMF
[C] [F] 1. Fusing unit ( 3.10.1)
[E]
B039R504.WMF
2. Separate the fusing unit (! x 4) into two sections: the hot roller section [A], and the pressure roller section [B]. 3. Front metal holding plate [C] (! x 1) 4. Rear metal holding plate [D] (! x 1) 5. Remove the fusing lamp [E] from the hot roller section (! x 2). The color of connector [F] Blue: For 120 V machine Red: For 230 V machine
3.10.4 HOT ROLLER

1. Fusing lamp ( 3.10.3) 2. Hot roller [G] (2 C-rings, 1 gear, 2 bearings) NOTE: Before re-installing the hot roller, remove the hot roller stripper pawls ( 3.10.6) to avoid scratching the hot roller.
[G]
B039R505.WMF
3-38
20 February, 2001
FUSING
3.10.5 THERMOFUSE AND THERMOSTAT

1. Hot roller ( 3.10.4) 2. Thermofuse [A] (! x 2) 3. Thermostat [B] (! x 2) [B]
[A]
B039R507.WMF
3.10.6 HOT ROLLER STRIPPER PAWLS

1. Hot roller ( 3.10.4) 2. Metal holders [C] (1 holder for each pawl) 3. Hot roller stripper pawls [D] (1 spring for each pawl)
[D]
[C]
B039R506.WMF
3-39
FUSING
20 February, 2001
3.10.7 PRESSURE ROLLER AND BUSHINGS
[A]
[E]
[C]
[B] [D]
B039R508.WMF
1. Fusing unit ( 3.10.1) 2. Separate the fusing unit into two sections: the hot roller section and the pressure roller section ( 3.10.3, Step 2). Carry out the remaining steps on the pressure roller section. 3. Fusing entrance guide [A] (! x 2) 4. 2 springs [B] 5. 2 pressure arms [C] NOTE: Manipulate each arm so that it comes out through the slit in the casing. 6. 2 Bushings [D] 7. Pressure roller [E]
3-40
20 February, 2001
FUSING
3.10.8 NIP BAND WIDTH ADJUSTMENT

NOTE: 1) The fusing unit must be at operating temperature when this adjustment is carried out. 2) Place an OHP sheet on the by-pass feed table before starting this procedure. 3) Use only A4/LT LEF. (Other OHP sheet sizes may cause a paper jam.)
[A]
[C]
B039R302.WMF
[A]: Pressure roller [B]: Hot roller 1. Enter SP mode, and run SP1-109. 2. Press ". The machine feeds the OHP sheet into the fusing section, stops it there for 20 seconds, then ejects it to the copy tray. 3. Check that the nip band (the opaque stripe) across the ejected OHP sheet is symmetrical, with both ends slightly thicker than the center. NOTE: There is no standard value for the nip band on this machine. Make the adjustment based on the band's appearance. 4. If the band is not as described above, change the position of the spring hooks [C] (one on each side), and then check the band again. NOTE: The higher hook position produces greater tension.
3-41
[B]
DUPLEX UNIT (DUPLEX MODELS ONLY)
20 February, 2001
3.11 DUPLEX UNIT (DUPLEX MODELS ONLY)

3.11.1 DUPLEX EXIT SENSOR
1. Open the right door. 2. Sensor bracket [A] and bracket [B] (! x 1) 3. Duplex exit sensor [C] (" x 1) [C] [A] [B]
B039R801.WMF
3.11.2 DUPLEX ENTRANCE SENSOR

1. Open the right door. 2. Lift the duplex guide [D]. 3. Entrance sensor bracket [E] and bracket cover [F] (! x 2) 4. Duplex entrance sensor [G] [G] [F] [E] [D]
B039R802.WMF
3.11.3 DUPLEX INVERTER SENSOR

1. Open the right door. 2. Sensor bracket [H] (! x 1, " x 1) 3. Duplex inverter sensor [I] (! x 1) [H]
[I]
3-42
B039R944.WMF
20 February, 2001
DUPLEX UNIT (DUPLEX MODELS ONLY)
3.11.4 DUPLEX TRANSPORT MOTOR

1. Open the right door, detach the strap from the main body (! x 1), and lower the door. 2. Cover [A] (! x 1) 3. Open the two clamps securing the motor cable, and remove the motor bracket [B] (! x 3, " x 1). 4. Remove the duplex transport motor [C] (! x 2). [B]
B039R946.WMF
[A]
[C]
3.11.5 DUPLEX INVERTER MOTOR

1. Rear cover 2. Exhaust fan ( 3.12.7) 3. Duplex inverter motor [D] (! x 2, " x 1) [D]
B039R941.WMF
3.11.6 DUPLEX CONTROL BOARD

1. Rear lower cover (3.3.2) 2. Duplex control board [E] (! x 4 , all connectors) [E]
B039R132.WMF
3-43
OTHER REPLACEMENTS
20 February, 2001
3.12 OTHER REPLACEMENTS

3.12.1 QUENCHING LAMP
1. PCU ( 3.6.1) 2. Quenching lamp [A] (" x 1)
[A]
B039R921.WMF
3.12.2 HIGH-VOLTAGE POWER SUPPLY BOARD

1. Rear cover ( 3.3.1) 2. High-voltage power supply board [B] (! x 3, 2 standoffs, all connectors)
[B]
B039R959.WMF
3-44
20 February, 2001
OTHER REPLACEMENTS
3.12.3 IMB (MEMORY BOARD)

NOTE: The IMB is optional on B039 machines outside North America. It is included as standard equipment on all other models. 1. IMB (together with bracket) [A] (! x 3) NOTE: Be sure to remove the bracket together with the IMB. The IMB should never be taken off the bracket. (The IMB and bracket comprise a single service part.) [A]
B039R928.WMF
3.12.4 BiCU (BASE-ENGINE IMAGE CONTROL UNIT)

1. Rear cover ( 3.3.1) 2. IMB ( 3.12.3) 3. BiCU [B] (! x 6, all connectors, 1 ribbon cable) NOTE: Reinstall the NVRAM [C] from the old board into the socket on the new board. [B] [C]
B039R907.WMF
3-45
OTHER REPLACEMENTS
20 February, 2001
3.12.5 IOB (I/O BOARD)

1. BiCU (3.12.4) 2. IOB [A] (all connectors, ! x 6, 1 ribbon cable)
[A]
B039R910.WMF
3.12.6 MAIN MOTOR

1. Rear cover ( 3.3.1) 2. Main motor [B] (! x 4, " x 1)
[B]
B039R908.WMF
3.12.7 REAR EXHAUST FAN

1. Rear cover ( 3.3.1) 2. Rear exhaust fan [C] (! x 2 , " x 1)
[C]
B039R918.WMF
3-46
20 February, 2001
OTHER REPLACEMENTS
3.12.8 LEFT EXHAUST FAN

1. Rear cover ( 3.3.1) 2. Copy tray ( 3.3.3) 3. Left cover ( 3.3.8) 4. 5 screws [A] 5. Lift up [B], [C] and [D] together and pull the assembly toward the front side of the machine until the hooked harnesses [E] are accessible. 6. Harnesses [E] 7. Remove the [B] from the assembly. 8. Left exhaust fan [F] (! x 2, " x 1) [A]
B039R949.WMF
[E] [B]
[C] [A]
[D]
[F]
3.12.9 PSU (POWER SUPPLY UNIT)

1. Left cover ( 3.3.8) 2. PSU [G] (all connectors, ! x 6) [G]
B039R925.WMF
3-47
OTHER REPLACEMENTS
20 February, 2001
3.12.10 GEARBOX
Replacement Procedure
1. BiCU ( 3.12.4) 2. BiCU bracket [A] (! x 3) 3. Main motor ( 3.12.6) 4. Exhaust fan ( 3.12.7) 5. Remove the IOB with bracket ( 3.12.5) 6. Crosspiece [B] (! x 4) 7. Registration clutch ( 3.8.8) 8. Open the clamp [C] on the gearbox, and take out the wires. 9. Gearbox [E] (! x 5, 1 belt) NOTE: When reinstalling, set the belt onto the gearbox side first (at [F]), hold it taut, and fit the gearbox into place so that the belt fits over the corresponding gear on the main unit. Handle the gearbox carefully so that the gears don't fall out.
B039R919.WMF
[A]
B039R932.WMF
[B]
[F]
[C] [E] [D]

B039R916.WMF
3-48
20 February, 2001
OTHER REPLACEMENTS
Gear Arrangement Within the Gearbox
B039R933.WMF
The gears are numbered 1 to 12 in the order in which they are to be installed in the gear box. These numbers appear both on the gearbox and on the front (exposed) surface of each gear. If the gears fall out, start by finding gear number 1 and installing it onto location number 1 (setting it into place so that the side with the printed number remains visible). Then install the remaining gears (2 to 12) in the same way.
3-49
COPY ADJUSTMENTS: PRINTING/SCANNING
20 February, 2001
3.13 COPY ADJUSTMENTS: PRINTING/SCANNING

NOTE: 1) You need to perform these adjustment after executing a Memory All Clear, and after replacing or adjusting any of the following parts. First or second scanner Lens Block Scanner Motor Polygonal Mirror Motor Paper Tray Paper Side Fence 2) For detailed explanations about how to access and use the SP modes, see Section 5.
3.13.1 PRINTING
NOTE: 1) Make sure the paper is installed correctly in each paper tray before you start these adjustments. 2) Use the Trimming Area Pattern (SP5-902, No.10) to print the test pattern for the printing adjustments below. 3) Set SP 5-902 to 0 again after completing these printing adjustments.
Registration - Leading Edge/Side-to-Side

1. Check the leading edge registration for each paper feed station, and adjust each of these registrations using SP1-001. 2. Check the side-to-side registration for each paper feed station, and adjust these registrations using SP1-002. (Adjust the trays in order: the 1st tray first, then the 2nd tray, etc.)
Tray Any paper tray By-pass feed Duplex 1st tray 2nd tray 3rd tray (Optional PFU tray 1) 4th tray (Optional PFU tray 2) By-pass feed Duplex SP mode SP1-001-1 SP1-001-2 SP1-001-3 SP1-002-1 SP1-002-2 SP1-002-3 SP1-002-4 SP1-002-5 SP1-002-6
B039R558.WMF
Specification 2 1.5 mm
B A
2 1.5 mm
A: Leading Edge Registration B: Side-to-side Registration
3-50
20 February, 2001
Blank Margin NOTE: If the leading edge or side-to-side registration cannot be adjusted to within the specification, then adjust the leading-edge blank margin or the left-side blank margin.
1. Check the trailing edge and right side edge blank margins, and adjust them using the following SP modes.
Trailing edge Right edge Leading edge Left edge SP mode SP2-101-2 SP2-101-4 SP2-101-1 SP2-101-3 Specification 2 +2.5/1.5 mm 2 +2.5/1.5 mm 2 1.5 mm 2 1.5 mm
D C
A: Trailing Edge Blank Margin B: Right Edge Blank Margin C: Leading Edge Blank Margin D: Left Edge Blank Margin
A B
B039R559.WMF
Main Scan Magnification

1. Print the single-dot grid pattern (SP5-902-5). 2. Check the magnification (the grid size should be 2.7 x 2.7 mm), and if necessary use SP2-998 to adjust it. The specification is 100 1%.
3-51
20 February, 2001
3.13.2 SCANNING
NOTE: 1) Before doing the following scanner adjustments, check and adjust the printing leading-edge and side-to-side registrations and the printing blank margins (as described above). 2) Use an A3 test chart to perform the following adjustments.
Registration: Platen Mode

1. Place the test chart on the exposure glass and make a copy from one of the feed stations. 2. Check the leading edge and side-to-side registration, and adjust as necessary using the following SP modes.
Leading edge Side-to-side SP mode SP4-010 SP4-011 Specification 2 1.5 mm 2 1.5 mm
A: Leading edge registration B: Side-to-side registration
A250R515.WMF
3-52
20 February, 2001
Magnification
A B
B039R517.WMF
A: Main scan magnification B: Sub-scan magnification


1. Place the A3 test chart on the exposure glass and make a copy from one of the feed stations. 2. Check the magnification ratio. If necessary, adjust the magnification using the following SP mode.
Main Scan Magnification SP mode SP4-008 Specification 1.0%
Sub-scan Magnification
1. Place the OS-A3 test chart on the exposure glass and make a copy from one of the feed stations. 3. Check the magnification ratio. If necessary, adjust the magnification using the following SP mode.
Sub-scan magnification SP mode SP4-101 Specification 1.0%
3-53
20 February, 2001
Standard White Density Adjustment

This procedure adjusts the standard white density level. Carry out this adjustment after doing any of the following: After replacing the standard white plate. After replacing the NVRAM on the BiCU. (But note that you do not need to carry out this adjustment if you have replaced the BiCU itself but retained the previous NVRAM board [by moving it over onto the new BiCU].) After performing a memory all clear (SP5-801). Procedure: 1. Place 10 sheets of new A4/LT paper (sideways, LEF) or new A3/DLT paper on the exposure glass, and close the platen cover or the ADF. 2. Enter SP4-908 and select 1: YES. The machine automatically adjusts the standard white density.
3-54
20 February, 2001
3.13.3 ADF IMAGE ADJUSTMENT

Registration and Blank Margin
B
A: Leading edge registration B: Side-to-side registration

B039R516.WMF B039R515.WMF
NOTE: Make a temporary test chart as shown above, using A3/11" x 17" paper. 1. Place the temporary test chart on the ADF and make a copy from one of the feed stations. 2. Check the registrations, and adjust as necessary using the appropriate SP modes, as follows.
Side-to-side registration Leading edge registration Blank margin for the trailing edge
Side-to-side registration (Duplex: rear)
SP mode SP6-006-1 SP6-006-2 SP6-006-3 SP6-006-4
Sub-scan Magnification
A
B039R526.WMF
A: Sub-scan magnification
NOTE: Make a temporary test chart as shown above, using A3/11" x 17" paper. 1. Place the temporary test chart on the ADF and make a copy from one of the feed stations. 2. Check the registration, and if necessary adjust it using SP6-007. The specification is 1.0%.
3-55
20 February, 2001
SERVICE CALL CONDITIONS
4. TROUBLESHOOTING
4.1 SERVICE CALL CONDITIONS
4.1.1 SUMMARY
There are 2 levels of service call conditions.
Level Definition To prevent the machine from being damaged, the SC can only be reset by a service representative. The copier cannot be operated at all. The SC can be reset by turning the main power switch off and on. Reset Procedure Enter SP 5-810 (SC code reset) and select 1. Then hold down the Original type key and the OK or ! key at the same time (this does not require the main switch to be turned off and on). Turn the main power switch off and on.
NOTE: 1) If the problem concerns electrical circuit boards, first disconnect then reconnect the connectors before replacing the PCBs. 2) If the problem concerns a motor lock, first check the mechanical load before replacing motors or sensors.
4-1
Troubleshooting
20 February, 2001
4.1.2 SC CODE DESCRIPTIONS

No. Definition 101 B Symptom Exposure Lamp Error The standard white level was not detected properly when scanning the white plate. Possible Cause Exposure lamp defective Exposure lamp stabilizer defective Exposure lamp connector defective Dirty scanner mirror or scanner mirror out of position SBU board defective SBU connector defective Lens block out of position Incorrect position or width of white plate scanning ( SP4-015) Scanner home position sensor defective Scanner drive motor defective Scanner home position sensor connector defective Scanner drive motor connector defective IOB board defective Scanner home position sensor defective Scanner drive motor defective Scanner home position sensor connector defective Scanner drive motor connector defective IOB board defective Scanner home position sensor defective Scanner drive motor defective Scanner home position sensor connector defective Scanner drive motor connector defective IOB board defective Scanner home position sensor defective Scanner drive motor defective Scanner home position sensor connector defective Scanner drive motor connector defective IOB board defective
120
Scanner home position error 1 The scanner home position sensor does not detect the off condition during initialization or copying.
121
Scanner home position error 2 The scanner home position sensor does not detect the on condition during initialization or copying.
122
Scanner home position error 3 The scanner home position sensor detects the on condition while the scanner is returning to the home position.
123
Scanner home position error 4 The scanner home position sensor does not detect the on condition after the scanner returns to the home position.
4-2
20 February, 2001
No. Definition 130 B Symptom

Possible Cause
192
194
302
320
321
Communication Error between BiCU and SBU The BiCU board cannot detect the SBU The flat cable between the BiCU connect signal. board and the SBU has a poor connection The flat cable between the BiCU board and the SBU damaged BiCU board defective SBU defective Automatic SBU adjustment error During the automatic SBU adjustment, Exposure lamp defective the machine detects that the white level SBU auto adjustment was not done read from the white plate or paper is correctly ( 3.13 Copy adjustment out of range. ( SP4-908) printing/scanning Standard white density adjustment) SBU defective BiCU board defective Exposure lamp stabilizer defective SBU White Level Detection Error The automatic SBU adjustment failed Exposure lamp defective twenty times consecutively. Dirty white plate Incorrect position or width of white plate scanning ( SP4-015) BiCU board defective SBU board defective Charge roller current leak A current leak signal for the charge Charge roller damaged roller is detected. High voltage supply board defective Poor connection of the PCU Polygonal mirror motor error The polygon mirror motor does not Polygon mirror motor defective reach operating speed within 10 Poor connection between the seconds after the motor ON signal is polygonal mirror motor driver and the sent, or does not turn on within one of BiCU board the 200 ms check intervals during Damaged cable between BiCU/IOB operation. and polygonal mirror motor driver BiCU board defective No laser writing signal (F-GATE) error The laser writing signal (F-GATE) fails BiCU board defective to turn Low after the laser crosses 5 IMB board defective mm on the drum surface from the laser The fax controller or printer controller writing start position. has a poor connection Fax controller or printer controller defective
4-3
Troubleshooting

No. Definition 322 B Symptom Laser synchronization error The main scan synchronization detector board cannot detect the laser synchronization signal for more than 5 consecutive 100 ms intervals.
20 February, 2001
Possible Cause Poor connection between the LD unit and the BICU board Damaged cable between BiCU and LD unit LD unit out of position LD unit defective BiCU board defective TD sensor abnormal Poor connection of the PCU Poor connection of the PCU High voltage supply board defective ID sensor defective No developer Drum does not turn Development roller does not turn Poor connection of the PCU The voltage is not applied to charge roller High voltage supply board defective Poor connection of the PCU Transfer/separation unit set incorrectly Transfer roller damaged High voltage supply board defective Poor connection of the PCU Transfer/separation unit set incorrectly Transfer roller damaged
390
391
TD sensor error The TD sensor outputs less than 0.2 V or more than 4.0 V 10 times consecutively during copying. Development bias leak A development bias leak signal is detected. TD sensor initial setting error TD sensor initial setting is not performed correctly.
392
401
Transfer roller leak error 1 A current leak signal for the transfer roller is detected. A current feedback signal for the transfer roller is not detected. Transfer roller leak error 2 A current leak signal for the transfer roller is detected. A current feedback signal for the transfer roller is not detected.
402
500
503
Main motor lock A main motor lock signal is not Too much load on the drive detected for more than 7 consecutive mechanism checks (700 ms) after the main motor Main motor defective starts to rotate, or the lock signal is not detected for more than 7 consecutive checks during rotation after the last signal. Upper paper tray lift motor malfunction (optional paper tray units) The paper lift sensor fails to activate Paper lift sensor defective twice continuously after the tray lift Tray lift motor defective motor has been on for 18 seconds. Too much load on the drive mechanism Poor tray lift motor connection
4-4
20 February, 2001

Possible Cause
506
541
542
543
544
546
547
620
Lower paper tray lift motor malfunction (optional two-tray paper tray unit) The paper lift sensor fails to activate Paper lift sensor defective twice continuously after the tray lift Tray lift motor defective motor has been on for 18 seconds. Too much load on the drive mechanism Poor tray lift motor connection Paper feed motor lock (optional paper tray units) A motor lock signal is not detected for Paper feed motor defective more than 1.5 s or the lock signal is not Too much load on the drive detected for more than 1.0 s during mechanism rotation. Fusing thermostat/thermistor open The fusing temperature detected by the Fusing thermostat defective or out of position thermistor is below 10C for 5 seconds after the main power switch is turned Fusing thermistor defective or out of on. position Power supply board defective Fusing temperature warm-up error The fusing temperature does not reach Fusing thermistor defective or out of 80C within 30 seconds after the main position switch is turned on. Fusing lamp open Fusing thermostat open Fusing thermofuse open Power supply board defective Fusing overheat error Fusing thermistor defective A fusing temperature of over 230C is detected for 1 second by the fusing Power supply board defective thermistor. Fusing low temperature error A fusing temperature of lower than Fusing lamp open 100C is detected for 1 second by the Fusing thermistor defective fusing thermistor during operation or Power supply board defective stand-by mode. Fusing thermistor open Fusing thermostat open Unstable fusing temperature The fusing temperature does not rise Thermistor defective 3 C or more within 5 seconds after the Power supply unit defective fusing lamp has been on over 8 seconds. Zero cross signal malfunction Zero cross signals are not detected Power supply board defective within 5 seconds after the main power IOB defective switch is turned on, or are not detected BiCU defective within 1 second after operation begins. Communication error between IOB and ADF The IOB does not receive a response Poor connection between the IOB and from the ADF main board for 4 seconds ADF main board (DF connector) or more. ADF main board defective
IOB defective
4-5
Troubleshooting

20 February, 2001
Possible Cause
692
695
760
900
901
921
922
924
Communication error between BiCU and fax controller The BiCU board cannot communicate Poor connection between the BiCU with the fax controller. board and the fax controller BiCU board defective Fax controller defective Communication error between BiCU and printer controller The BiCU board cannot communicate Poor connection between the BiCU with the printer controller. board and the printer controller. BiCU board defective Printer controller defective Fax firmware error The fax program cannot be started. The fax firmware download has not ( Fax Service Manual) been completed correctly. Try again. ADF gate abnormal The ADF Gate signal line between the ADF main board defective ADF main board and the IOB is Input/output board defective disconnected. Poor connection (ADF Gate line) between the ADF main board and the IOB. Electrical total counter error The electrical total counter does not NVRAM defective work properly. Mechanical total counter The mechanical total counter does not Mechanical total counter defective work properly. IOB defective Disconnected mechanical total counter IMB memory controller error A memory control job is not completed IMB defective within a certain period. BiCU defective Poor connection between IMB and BiCU IMB DRAM error The machine detects a discrepancy in IMB defective the IMB DRAM write/read data during BiCU defective its write/read test (done at power off/on Poor connection between BiCU and and at recovery from low power or IMB night/off mode). Optional DRAM error The machine detects a discrepancy in Non-supported DRAM connected the Optional DRAM write/read data Poor connection between IMB and during its write/read test (done at power optional DRAM off/on and at recovery from low power Optional DRAM defective or night/off mode). IMB defective BiCU defective
4-6
20 February, 2001
No. Definition 925 B Symptom IMB non-connected error IMB is not connected. This SC only appears with B040 and B043 version machines.

Possible Cause IMB is not connected Poor connection between BiCU and IMB IMB defective BiCU defective Poor connection between optional DRAM and IMB Optional DRAM defective IMB defective BiCU defective
926
Memory capacity error The machine detects a discrepancy between the memory capacity detected during the memory check at power on and the check at recovery from low power or night/off mode. NVRAM error The machine detects a discrepancy in the NVRAM write/read data when attempting to save actual data to the NVRAM (i.e. during actual use).
981
990
999
NVRAM defective Poor connection between BiCU and NVRAM NVRAM is not connected BiCU defective Communication error between BICU and IOB The BiCU board cannot communicate The connection between the BiCU with the IOB. board and the IOB is poor. BiCU board defective IOB defective Program version error An incorrect type of main software was The main software for another downloaded. machine was downloaded to this machine. Switch the machine off. Connect an IC card that has the correct firmware to the machine. Switch the machine on, and download the firmware (see section 5.1.9).
4-7
Troubleshooting
ELECTRICAL COMPONENT DEFECTS
20 February, 2001
4.2 ELECTRICAL COMPONENT DEFECTS

4.2.1 SENSORS
Component Registration CN 312-2 (IOB) Relay 312-5 (IOB) Upper Paper End Open 314-2 (IOB) Shorted Vertical Transport Open Shorted Condition Open Shorted Symptom The Paper Jam message will appear whenever a copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor. The Paper Jam message will appear whenever a copy is made except for 1st and by-pass tray feeding. The Paper Jam message appears even if there is no paper at the sensor. The Paper End indicator lights when the 1st paper tray is selected, even if there is paper in the tray. The Paper End indicator does not light when the 1st paper tray is selected, even if there is no paper in the tray. The Paper Jam message will appear whenever a copy is made from the 1st paper tray. The Paper Jam message will appear whenever a copy is made from an optional paper tray unit. The Paper Jam message appears even if there is no paper at the sensor. The Paper End indicator lights when the 2nd paper tray is selected, even if there is paper in the tray (B040/B043 models only). The Paper End indicator does not light when the 2nd paper tray is selected, even if there is no paper in the tray. The Paper Jam message will appear whenever a copy is made from the 2nd paper tray (B040/B043 models only). The Paper End indicator lights when the bypass tray is selected, even if there is paper in the tray. The Paper End indicator does not light when the bypass tray is selected, even if there is no paper in the tray. The Paper Jam message will appear whenever a copy is made from the bypass tray. The Paper Jam message will appear whenever a copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor. SC390 is displayed. The toner density control process is changed (see the note below the table).
316-2 (IOB)
Open Shorted Open
Lower Paper End
317-6 (IOB)
Shorted Shorted
By-pass Paper End 311-7 (IOB)
Open
Shorted Exit 331-2 (IOB) Toner Density Image Density 325-3 (IOB) 326-2 (IOB) Open Shorted Open Shorted Open Shorted
4-8
20 February, 2001
Component Scanner H.P. Platen Cover 304-5 (IOB) Original Width Original Length Duplex Entrance 222-2 (DCB) Duplex Exit 222-5 (DCB) Duplex Inverter 220-6 (DCB) Open Shorted Open Shorted Open Shorted CN 304-2 (IOB) Condition Open Shorted Open Shorted Open Shorted Open Shorted
ELECTRICAL COMPONENT DEFECTS

Symptom SC120 is displayed. APS and Auto Reduce/Enlarge do not function correctly. If the Start button is pressed with the platen cover or A(R)DF closed, Cannot detect original size is displayed. The CPU cannot detect the original size properly. APS and Auto Reduce/Enlarge do not function correctly. The CPU cannot detect the original size properly. APS and Auto Reduce/Enlarge do not function correctly. The Paper Jam message will appear whenever a duplex copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor. The Paper Jam message will appear whenever a duplex copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor. The Paper Jam message will appear whenever a duplex copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor.
305-3,4 (IOB) 305-8,9 (IOB)
NOTE: SC392 is activated when the CPU detects an ID sensor error during developer initialization (SP2-214). However, SC392 is not displayed on the LCD but simply logged in the SC log (SMC printout), unless the technician exits SP Mode as soon as the "Error!!!" message is displayed.
4.2.2 SWITCHES
Component Upper Paper Size Vertical Transport Door CN 315 1,2,4 (IOB) 316-5 (IOB) 3171,2,4 (IOB) 3111,2,4,5 (IOB) Condition Open Shorted Open Shorted Open Shorted Open Symptom The CPU cannot detect the proper paper size, and misfeeds may occur when a copy is made from the 1st paper tray. The Cover Open indicator is lit even if the vertical transport door is closed. The Cover Open indicator is not lit even if the vertical transport door is opened. The CPU cannot detect the proper paper size, and misfeeds may occur when a copy is made from the 2nd paper tray. The CPU misdetects or is not able to detect the size of the paper set in the bypass tray, causing possible misfeeds when feeding from this tray.
Lower Paper Size By-pass Paper Size
4-9
Troubleshooting
BLOWN FUSE CONDITIONS

Component Right Door CN 331-5 (IOB) Front/Right Cover Condition Open Shorted Open Shorted Open Shorted
20 February, 2001
Symptom The Cover Open indicator is lit even if the right door is closed. The Cover Open indicator is not lit even if the right door is open. The Cover Open indicator is lit even if doors are closed. The Cover Open indicator is not lit even if doors are open. The machine does not turn on. The machine does not turn off.
328-1 (IOB) 281-3,4 (PSU)
Main
4.3 BLOWN FUSE CONDITIONS

Rating 120 V 220 240 V Power Supply Board FU1 15 A/125 V FU2 6.3 A/250 V 3.15 A/250 V Fuse FU3 FU4 FU5 FU6 2 A/125 V 4 A/125 V 4 A/125 V 3.15 A/125 V 2 A/250 V 4 A/250 V 4 A/250 V 3.15 A/250 V Symptom when turning on the main switch No response. No response. Anti-condensation/Tray Heater does not turn on. Optional peripheral(s) are detected but do not function. The Cover Open indicator is lit then SC901 is displayed. LEDs are not lit and the LCD display does not function (backlight only).
4.4 LED DISPLAY

4.4.1 BiCU
Number LED 1 LED 2 Function Monitors the +5 V line for the CPU and the surrounding circuit. Usually, this LED is blinking. Monitors the +5 V line. Usually, this LED is lit.
4.4.2 IOB
Number LED301 Function Monitors the connection between the IOB and the BiCU. Usually, this LED is blinking.
4-10
20 February, 2001
USING SERVICE PROGRAM MODES
5. SERVICE TABLES
5.1 USING SERVICE PROGRAM MODES
Use the service program modes (SP modes) to check electrical data, change operating modes, and adjust values.
Accessing SP Modes How to Enter SP Mode

1. Key in the following sequence.
!"#$%
Hold the % key down for longer than 3 seconds. 2. The LCD displays a menu of the SP modes.
[Service P-Mode] No._ 1 Copy 2 Fax 3 Printer

B039M001.WMF
3. Press the number for the application mode you need. (For example, press 1 to select the copier application mode.) The selected SP mode display appears on the LCD, as shown.
SP B0395533A EU Class1 No.1 Feed

B039M002.WMF
How to Exit SP Mode

Press ! or Cancel key one or more times to return to the standby-mode display.
Accessing Copy Mode from within an SP Mode

1. Press the & key. 2. Select the appropriate copy mode and make trial copies. NOTE: The User Tools key LED is blinking at this time. 3. To return to SP mode, press the ! key.
5-1
Service Tables
NOTE: Installed applications appear on the menu as follows: 1.Copy, 2. Fax, 3. Printer, If an application is not installed, the corresponding item does not appear.
20 February, 2001
How to Select a Program Number
C1(1)Feed
C2 105
Fusing Temp Adjustment
B039M003.WMF
Each program number consists of two or three levels (classes). To select a program, you need to enter each class number in sequence. 1. Enter the first-class program number with the numeric keypad (or change the number using the Right or Left cursor key), and then press the ' key or the OK key. 2. Select the second-class program number with the numeric keypad (or Right or Left cursor key), and press ' or OK. 3. To select a third-class program (if there are any): select the second-class number and then use the Right or Left cursor key. 4. To return to the next higher class, press !. NOTE: 1) If the screen is not large enough to display information about all of the available selections, the screen displays a solid semicircle mark as shown below. The mark means that you can press the Darker key to view the contents for each selection. 2) An asterisk (*) to the right of mode name indicates that its value has been changed from the default.
SMC Printing (1 - 5) 0
B039M004.WMF
To Input a Value or Setting for an SP Mode

1. Enter the required program mode as explained above. 2. Enter the required setting using the numeric keys, and then press ' or the OK key. NOTE: 1) If you forget to press ' or OK, the previous value remains in effect. 2) If necessary, use the ! key to select + or before entering the value.
5-2
20 February, 2001
5.1.1 SP MODE TABLES

NOTE: In the Function/[Setting] column: The related pop-up screen name and function name (if any) appear in parenthesis following the function description. Comments are in italics. The setting range is enclosed in brackets, with the default setting written in bold. An asterisk (*) after the mode number means that this modes value is stored in the NVRAM. If you do a RAM reset, all these SP modes will be returned to their factory settings. DFU stands for Design/Factory Use only. Values marked DFU should not be changed. IAJ means that you should refer to "Replacement and Adjustment Copy Image Adjustments" for more information.
SP1-XXX (Feed)
1
001*
Mode Number/Name Leading Edge Registration 1 Paper tray 2 By-pass 3 Duplex
Function/[Setting] Adjusts the printing leading-edge registration from each paper feed station, using the Trimming Area Pattern (SP5902, No.10). [9.0 ~ 9.0 / 0.0 / 0.1 mm/step] IAJ Specification: 2 1.5 mm Use the ! key to select + or before entering the value. Adjusts the printing side-to-side registration from each paper feed station, using the Trimming Area Pattern (SP5902, No.10). Adjustments are supported for all 4 possible feed trays (including optional trays). [9.0 ~ 9.0 / 0.0 / 0.1 mm/step] IAJ Specification: 2 1.5 mm The SP1-002-1 setting is applied to all trays, not just the 1st Tray. Settings for trays 2 to 4 are offsets relative to the SP1-002-1 setting. For duplex copies, the value for the front side is determined by SP1-002-1 to -4, and the value for the rear side is determined by SP1-002-6. Use the ! key to select + or before entering the value. Adjusts the amount of buckle the paper feed clutch applies to the paper after the registration sensor is activated. A higher setting applies greater buckling. [0 ~ 10 / 5 / 1 mm/step] [0 ~ 20 / 6 / 1 mm/step]
002*
Side-to-Side Registration 1 1st tray 2 2nd tray 3 3rd tray 4 4th tray 5 By-pass feed 6 Duplex
003*
Paper Feed Timing 1 1st tray 2 2nd, 3rd, 4th trays 3 By-pass feed 4 Duplex
5-3
Service Tables
20 February, 2001
Function/[Setting]
1
007
Mode Number/Name By-pass Paper Size Display
Displays the by-pass paper width sensor output. Press ! to exit the display. 103* Fusing Idling Selects whether or not fusing idling is performed. [0 = No / 1 = Yes] Normally disabled in this machine. However, enable this mode if fusing is incomplete on the 1st and 2nd copies, which may occur if the room is cold. 6.13.5 Fusing Temperature Control Fusing Temperature Adjustment 1 Stand-by Adjusts the fusing temperature for standby mode. [160 ~ 190 / 175 / 1C/step] 2 Low power level 2 Adjusts the fusing temperature for low power level 2. [0 ~ 100 / 60 / 1C/step] Lower values cause the machine to take a longer time to reach the ready condition. Fusing Temperature Display Displays the fusing temperature. Press ! to exit the display. Fusing Soft Start Adjustment Adjusts the number of zero-cross cycles of the fusing 1 Stand-by lamp AC supply needed to bring the fusing lamp power to 100% while bringing the lamp up to the standby temperature. Increase this value if the machine is experiencing sudden power dropouts. [North Am.: 0 = 3 cycles / 1 = 10 cycles / 2 = 20 cycles] [EU/Asia: 0 = 3 cycles / 1 = 10 cycles / 2 = 20 cycles] 6.13.5 Fusing Temperature Control Adjusts the number of zero-cross cycles for the fusing 2 Copying lamp AC supply needed to gradually raise the fusing lamp power to 100% during printing. Increase this value if the machine is experiencing sudden power dropouts. [North Am.: 0 = 3 cycles / 1 = 10 cycles / 2 = 20 cycles] [EU/Asia: 0 = 3 cycles / 1 = 10 cycles / 2 = 20 cycles] 6.13.5 Fusing Temperature Control Fusing Soft Start Setting Selects whether the fusing temperature control cycle is 1 second or 3 seconds. [0 = 1 / 1= 3 s] Setting this item to 1 (3 s) reduces the power supply fluctuation that occurs when the fusing lamp switches on. 6.13.5 Fusing Temperature Control Fusing Nip Band Check Checks the fusing nip band. [1 = Start / 0= Stop] IAJ AC Frequency Display Displays the fusing lamp power control frequency (as detected by the zero cross signal generator). The displayed value is 1/5 the actual frequency: 10 = 50 Hz, 12 = 60 Hz.
105*
106
107*
108*
109
902
5-4
20 February, 2001

Function/[Setting] Adjusts the amount of extra push that the feed clutch gives to the paper after the skew has been corrected at registration. [0 ~ 10 / 6 / 1 mm/step] This feature helps the registration roller feed certain types of paper (such as thick paper). Increase the value if thick paper is jamming after feeding from the registration roller. [0 ~ 10 / 3 / 1 mm/step] Adjusts the reverse time for the upper and lower paper lift motors. [2 ~ +2 / 0 / 1/step] Detailed Descriptions Optional Paper Tray Unit
1
903*
Mode Number/Name Feed Clutch Boost 1 By-pass tray
908*
2 2nd, 3rd, 4th tray Paper Tray Adjustment 1 1st optional 2 2nd optional
5-5
Service Tables
20 February, 2001
SP2-XXX (Drum)
2
001*
Mode Number/Name
Function/[Setting]
101*
Charge Roller Bias Adjustment 1 Printing Adjusts the voltage applied to the charge roller when printing. [2100 ~ 1500 / 1700 / 1 V/step] The actually applied voltage changes automatically as charge roller voltage correction is carried out. The value you set here becomes the base value on which this correction is carried out. 2 ID sensor pattern Adjusts the voltage applied to the charge roller when generating the Vsdp ID sensor pattern (as part of charge roller voltage correction). [0 ~ 400 / 300 / 1 V/step] The actual charge-roller voltage is obtained by adding this value to the value of SP2-001-1. Erase Margin Adjustment 1 Leading edge Adjusts the leading edge erase margin. [0.0 ~ 9.0 / 3.0 / 0.1 mm/step] IAJ Specification: 2 1.5 mm 2 Trailing Adjusts the trailing edge erase margin. The rear trailing edge is this value plus 1.2 mm. [0.0 ~ 9.0 / 4.0 / 0.1 mm/step] IAJ Specification: 2 +2.5/1.5 mm 3 Left side Adjusts the left edge erase margin. The rear left edge is this value plus 0.3 mm. [0.0 ~ 9.0 / 2.0 / 0.1 mm/step] IAJ Specification: 2 1.5 mm Adjusts the right edge erase margin. The rear right edge is 4 Right side this value plus 0.3 mm. [0.0 ~ 9.0 / 2.0 / 0.1 mm/step] IAJ Specification: 2 +2.5/1.5 mm Development Bias Adjustment Adjusts the voltage applied to the development roller 1 Printing when printing. [1500 ~ 200 / 650 / 1 V/step] This can be adjusted as a temporary measure if faint copies are being produced due to an aging drum. 2 ID sensor pattern Adjusts the voltage applied to the development roller when generating the ID sensor pattern. [2 = LL (220 V) / -1 = L (260 V) / 0 = N (300 V) / 1 = H (340 V) / 2 = HH (380 V)] The actual voltage applied is this setting plus the value of SP2-201-1. The setting affects ID sensor pattern density, which in turn affects the toner supply.
201*
5-6
20 February, 2001

Function/[Setting] Sets the number of copy/print/fax pages that can be made after toner near-end has been detected. [0 = 50 pages / 1 = 20 pages] Reduce the number of pages if the user normally makes copies with a high image ratio.
2
213*
Mode Number/Name Outputs after Near End
214
Developer Initialization Initializes both the TD sensor toner supply target voltage and the TD sensor gain value. [0 = No / 1 = Yes] Carry this out after replacing the developer or the TD sensor. TD Sensor Output Value Display Displays: a) Vt: the current TD sensor output value and b) Vref: the target TD output value Vts (SP2-926) + correction for ID sensor output. The TD sensor output value changes every copy. If a > b, toner is supplied to the development unit. Press ! to exit the display.
220
221
ID Sensor Error Analysis Displays Vsg, Vsp, Vsdp, Vt, and ID sensor input value. Use these values to check the operational status of the ID sensor. [0 = No / 1 = Yes] This machine has no SC code for ID sensor errors. If imaging problems occur (such as dirty background), use this SP to determine whether the problem is with toner density control. You can use SP7-911 to check the number of ID sensor errors that have occurred. 5.1.14 ID Sensor Error Analysis
301*
Transfer Current 1 Normal paper
Thick/Special paper
Adjusts the current applied to the transfer roller when feeding from a paper tray. [2 = 4 A / 1 = 2 A / 0 = 0 A / 1 = 2 A / 2 = +4 A] Use a high setting if the user normally feeds relatively thick paper (within spec) from a paper tray. 6.12.2 Image Transfer Current Timing Adjusts the current applied to the transfer roller when feeding from the by-pass tray. [2 = 4 A / 1 = 2 A / 0 = 0 A / 1 = 2 A / 2 = +4 A] Use a high setting (a) if the user normally feeds relatively thick paper from the by-pass tray, or (b) if waste toner is re-attracted from the drum (which can occur when using transparencies). 6.12.2 Image Transfer Current Timing
5-7
Service Tables
20 February, 2001
Function/[Setting]
2
301* 3
Mode Number/Name Duplex
Cleaning
Adjusts the current applied to the transfer roller when carrying out a duplex job. [2 = 4 A / 1 = 2 A / 0 = 0 A / 1 = 2 A / 2 = +4 A] Use this SP if there is poor image transfer on the rear side of duplex copies. 6.12.2 Image Transfer Current Timing Adjusts the current applied to the transfer roller for roller cleaning. [10 ~ 0 / 1 / 1 A/step] Increase the current if toner remains on the roller after cleaning. (Remaining toner may cause dirty background on the rear side.) 6.12.2 Image Transfer Current Timing Initializes the developer and checks the TD sensor output (Vt). The machine mixes the developer for 2 minutes while reading and displaying the Vt value. The machine does not initialize the TD sensor output. [0 = No / 1 = Yes] If the machine has not been used for a long period of time, prints may have a dirty background. In this case, use this SP mode to mix the developer. After finishing, press the ! key to clear the Vt value from the screen.
802
Forced Developer Churning
906*
Tailing Correction 1 Shift value
Interval
Shifts the image writing position in intervals specified by SP2-906-2. [0.0 ~ 1.0 / 0.0 / 0.1 mm/step] When making many copies of an original that contains vertical lines (such as in tables), the paper may not separate correctly. This can cause tailing images (ghosts of the vertical lines continuing past the bottom of the table). This SP can be used to prevent this. Changes the interval for the image shift specified by SP2906-1. [1 ~ 10 / 1 / 1 page/step]
908
Forced Toner Supply Forces the toner bottle to supply toner to the toner supply unit. Press 1 to start. [0 = No / 1 = Yes] The machine continues to supply toner until the toner concentration in the development unit reaches the standard level, or for up to 2 minutes (whichever comes first). Polygon Mirror Motor Idling Time Selects the polygon mirror motor idling time. [0 = None / 1 = 15 s / 2 = 25 s] To increase the speed of the first copy, the mirror motor begins idling when the user sets an original, touches a key, or opens the platen cover or DF. If this setting is left at the default (15 s), the motor will stop if the user does nothing for 15s. If the setting is 0, the motor will not switch off during standby. (But note that regardless of the setting, the motor will switch off when the machine enters energy saver mode.)
915*
5-8
20 February, 2001

Function/[Setting] Selects the toner supply mode. [0 = Sensor 1 / 1 = Sensor 2 (DFU) / 2 = Fixed 1 (DFU) / 3 = Fixed 2] Under normal conditions this should be set to 0. You can temporarily change this to 3 if the TD sensor is defective. Do not set to 1 or 2, as these are for design use only. 6.9.6 Toner Density Control
2
921*
Mode Number/Name Toner Supply Mode
922*
Toner Supply Time Adjusts the toner supply motor ON time for Sensor 1 and Sensor 2 toner supply mode. Accordingly, this setting is effective only if SP2-921 is set to 0 or 1 [0.1 ~ 5.0 / 0.4 / 0.1 s/step] Raising this value increases the toner supply motor ON time. Set to a high value if the user tends to make many copies having high proportions of solid black image areas. 6.9.6 Toner Density Control
923*
Toner Recovery Time Adjusts the toner supply motor ON time used during toner recovery from Toner Near End or Toner End. This setting is effective only if SP2-921 is set to 0 [3 ~ 60 / 30 / 1 s/step] Since toner recovery is carried out in 3-second cycles, the input value should be a multiple of 3 (3, 6, 9...). 6.9.6 Toner Density Control
925*
Toner Supply Rate Adjusts the toner supply time for fixed toner supply mode. This setting is effective only if SP2-921 is set to 2 or 3. [0 ~ 7 / 0] t = 200ms, and settings are as follows 0=t 4 = 12t 1 = 2t 5 = 16t 2 = 4t 6 = on continuously 3 = 8t 7=0s Raising this value increases the toner supply motor ON time. Set to a high value if the user tends to make many copies having high proportions of solid black image areas. 6.9.6 Toner Density Control
926*
Standard Vt Adjusts Vts (the Vt value for new developer). The TD sensor output is adjusted to this value during the TD sensor initial setting process]. [0.00 ~ 5.00 / 2.40 / 0.01 V/step] DFU This SP is effective only when SP2-921 is 0, 1, or 2.
927*
ID Sensor Control Selects whether the ID sensor is or is not used for toner density control. [0 = No / 1 = Yes] This value should normally be left at 1. If the value is 0, dirty background may occur after long periods of non-use.
5-9
Service Tables
20 February, 2001
Function/[Setting]
2
928
Mode Number/Name Toner End Clear
Clears the toner end condition without adding new toner. Select 1 then press the ' key to clear the condition. [0 = No / 1 = Yes] Setting this to 1 will clear the following: Toner end indicator (goes out) Toner near-end counter Toner near-end level This function should generally not be used. If you clear the toner end condition without adding new toner, there is a risk that the drum may eventually begin to attract carrier after many more copies are made and toner runs out. This attracted carrier may damage the drum. 929* Vref Limits 1 Upper 2 995* Lower Adjust the upper Vref limit. [0.50 ~ 3.50 / 3.20 / 0.01V/step] DFU Adjust the lower Vref limit. [0.00 ~ 3.50 / 1.10 / 0.01V/step] DFU If the machine starts warm-up after this amount of time has passed since entering night/off mode (for example, to print an incoming fax), the machine makes an ID sensor pattern. [0 ~ 999 / 90 / 1 minute/step] Higher values increase the chance of dirty background. Lower values increase the frequency at which the machine makes ID sensor patterns, increasing the chance that the transfer roller (rear side of paper) will become dirty. 996* Transfer Roller Cleaning Selects whether the transfer roller is cleaned before each copy job. [0 = No / 1 = Yes] Set this to 1 if dirty background is appearing on the reverse side of the first page of copy jobs. Note that this will increase the time required to generate the first copy. If the setting is 0, the transfer roller is never cleaned. 6.12.3 Transfer Roller Cleaning 998* Main Scan Magnification Adjusts the magnification along the main scan direction, for all print modes (copy, fax, printing). [0.5 ~ +0.5 / 0.0 / 0.1%/step] IAJ Use the ! key to select + or before entering the value. The specification is 100 1.0%.
ID Sensor Detection Interval
5-10
20 February, 2001
SP4-XXX (Scanner)
4
008*
Mode Number/Name
Function/[Setting]
010*
011*
012*
013
Main Scan Magnification (Scanner) Adjusts the magnification along the main scan direction, for scanning. [1.0 ~ +1.0 / 0.0 / 0.1%/step] IAJ Use the ! key to select + or before entering the value The specification is 100 1.0% Main scan magnification is implemented in steps of 0.5. Accordingly, your input value should be a multiple of 0.5 (1.0, 0.5, 0, +0.5, or +1.0) Leading Edge Registration (Scanner) Adjusts the leading edge registration for scanning in platen mode. [5.0 ~ +5.0 / 0.0 / 0.1 mm/step] IAJ (): The image moves toward the leading edge. (+): The image moves toward the trailing edge Use the ! key to select + or before entering the value The specification is 2 1.5 mm. Side-to-side Registration (Scanner) Adjusts the side-to-side registration for scanning in platen mode. [10.0 ~ +6.0 / 0.0 / 0.1 mm/step] IAJ Increasing the value shifts the image to the right Use the ! key to select + or before entering the value The specification is 2 1.5 mm. Erase Margin Adjusts the scanning margin individually for each of the 1 Leading edge four edges. 2 Trailing edge [0 ~ 9.0 / 1.0 / 0.1 mm/step] IAJ 3 Left It is generally best to adjust the scanning margin as little 4 Right as possible, and use the printing margin for image adjustments. Scanner Free Run Performs a scanner free run with the exposure lamp on. [0 = No / 1 = Yes] After selecting 1, press OK or ' twice to start the run. Press % to stop.
5-11
Service Tables
20 February, 2001
Function/[Setting]
4
015*
Mode Number/Name White Plate Scanning 1 Start position
101*
301
303*
902*
903
904
Adjusts the scanning start position on the white plate for auto shading. [3.0 ~ +6.0 / 0.0 / 0.1 mm/step] The base value stored in the machine is 15.2 mm toward the white plate from the scanner H.P.. This SP setting specifies the offset from this base value. 2 Scanning length Adjusts the length of the white plate scan, in the main scan direction. The scan begins at the start position set above [in SP4-015-1] and extends for the specified length. [3.0 ~ +6.0 / 0.0 / 0.1 mm/step] The base value stored in the machine is 4.76 mm. This SP setting specifies the offset from this base value. Sub-Scan Magnification (Scanning) Adjusts the actual sub-scan direction scanning magnification. The higher the setting, the lower the scanner motor speed. [-0.9 ~ +0.9 / 0.0 / 0.1%/step] APS Data Display Displays the status of the APS sensors and platen/DF cover sensor. 5.1.11 APS and Platen/ADF Cover Sensor Output Display APS Small Size Original Selects whether or not the copier will consider the original to be A5 LEF when the APS sensors cannot detect its size. [0 = No (not detected) / 1 = Yes (A5 LEF)] If Yes is selected, paper sizes that cannot be detected by the APS sensors are regarded as A5 LEF. If No" is selected, Cannot detect original size will be displayed. Exposure Lamp ON Turns on the exposure lamp. [0 = No (Off) / 1 = Yes (On)] To turn off the exposure lamp, select 0. (The exposure lamp shuts off automatically after 30 seconds.) SBU Black Feedback Display Displays the black level feedback data in the SBU. 1 EVEN DFU 2 ODD SBU Black Level Adjustment This is the reference value for the EVEN channel black 1* EVEN target level used for black level adjustment at power-up. [0 ~ 255 / 0 / 1/step] DFU Use this mode to re-input the previous value after performing memory all clear (SP5-801). 2* ODD target This is the reference value for the ODD channel black level used for black level adjustment at power-up. [0 ~ 255 / 0 / 1/step] DFU Use this mode to re-input the previous value after performing memory all clear (SP5-801). 3 EVEN result Displays the value from the most recent EVEN channel black level adjustment. [0 ~ 255 / 0 / 1/step] DFU
5-12
20 February, 2001

Function/[Setting] Displays the value from the most recent ODD channel black level adjustment. [0 ~ 255 / 0 / 1/step] DFU Displays the number of times SBU black level adjustment was performed before the target values in 4-904-1 and 2 were reached. DFU Displays the value of the black level for the EVEN channel set at the factory. [0 ~ 255 / 0 / 1/step] DFU Displays the value of the black level for the ODD channel set at the factory. [0 ~ 255 / 0 / 1/step] DFU
4
904 4
Mode Number/Name ODD result
Number of attempts
6*
Factory setting - EVEN
7*
Factory setting - ODD
905
906
SBU White Level Adjustment 1* EVEN target This is the reference value for the EVEN channel white level used for white level adjustment at power-up. [0 ~ 255 / 0 / 1/step] DFU Use this mode to re-input the previous value after performing memory all clear (SP5-801). This is the reference value for the ODD channel white 2* ODD target level used for white level adjustment at power-up (set at the factory). [0 ~ 255 / 0 / 1/step] DFU Use this mode to re-input the previous value after performing memory all clear (SP5-801). Displays the value from the most recent EVEN channel 3 EVEN result white level adjustment. [0 ~ 255 / 0 / 1/step] DFU 4 ODD result Displays the value from the most recent ODD channel white level adjustment. [0 ~ 255 / 0 / 1/step] DFU 5 Number of attempts Displays the number of times SBU white level adjustment was performed before the target values in 4-904-1 and 2 were reached. DFU 6* Factory setting - EVEN Displays the value of the white level for the EVEN channel set at the factory. [0 ~ 255 / 0 / 1/step] DFU Displays the value of the white level for the ODD channel 7* Factory setting - ODD set at the factory. [0 ~ 255 / 0 / 1/step] DFU SBU White Level (EVEN/ODD) 1* Set value This is the reference value for the White Level EVEN/ODD adjustment carried out at power-up. [0 ~ 600 / 0 / 1/step] DFU Use this mode to re-input the previous value after performing memory all clear (SP5-801). Displays the value from the most recent EVEN/ODD SBU 2 Result White Level adjustment. DFU 3* Factory setting Displays the factory-set White Level EVEN/ODD setting. DFU
5-13
Service Tables
20 February, 2001
Function/[Setting]
4
907
Mode Number/Name
SBU Auto Adjustment Display 1* Set value This is the reference value for SBU Auto-Adjustment (white plate scanning). DFU Use this mode to re-input the previous value after performing memory all clear (SP5-801). Displays the value from the most recent SBU Auto2 Result Adjustment. DFU 3* Factory setting Displays the factory-set SBU Auto adjustment value. SBU Auto-Adjustment Performs auto scanner adjustment. [0 = No (normal operation) / 1 = Yes (start adjustment)] Use this SP mode after replacing the white plate. IAJ 3.13.2 Standard White Density Adjustment.
908
913*
DF Shading Interval Adjusts the interval used for shading processing in DF mode. [0 ~ 60 / 20 / 1s/step] Light and heat may affect the scanner response. Reduce this setting if copy quality indicates that the white level is drifting during DF copy jobs.
921*
Image Adjustment Selection Selects which mode the settings from SP4-922 to SP4928 will be applied to. [0~ 9 / 0] 0 = None 5 = Photo 3 10 = Special 5 1 = Text 1 6 = Special 1 2 =Text 2 7 = Special 2 3= Photo 1 8 = Special 3 4 = Photo 2 9 = Special 4 6.5.4 IPU
922*
Scanner Gamma Selection Selects text or photo as the priority output mode [0 = Text / 1 = Photo] This setting is applied to all image processing modes of SP4-921. 6.5.4 IPU
923*
Notch Selection Selects the value of the center ID adjustment notch for the ID adjustment LEDs. [1 = Light / 0 = Normal / +1 = Dark] Normally the center notch is 3 (range 1-5). If 1 is selected, each notch shifts down (becomes lighter). If +1 is selected, each notch shifts up (becomes darker). This setting is applied to all image processing modes of SP4-921. 6.5.4 IPU
5-14
20 February, 2001

Function/[Setting] Adjusts the clarity of line images and of solid-image edges. Higher settings provide greater clarity. [2 ~ 2 / 0 / 1/step] This setting is applied to all image processing modes of SP4-921. It is used for both MTF filtering and smoothing. 6.5.4 IPU Adjusts the clarity of solid image areas. Higher settings provide greater clarity. [2 ~ 2 / 0 / 1/step] This setting is only applied to Text 2 and Special 1 of SP4921. 6.5.4 IPU Adjusts the clarity of lines with low image density. Higher settings provide greater clarity. [2 ~ 2 / 0 / 1/step] This setting is only applied to Text 1, Text 2, Photo 2, Special 1, Special 2, and Special 5 of SP4-921. 6.5.4 IPU Adjusts the texture removal level. 0: The default value for each mode is used. Text 1, Special 2, and Special 5 have a default of 3 and Photo 1-3 have a default of 1. 1: No removal applied. 2 5: Removal applied at the level specified here. The higher the setting (level), the less clear the image will become (more texture removal). [0 ~ 5 / 0 / 1/step] This setting is only applied to Text 1, Photo 13, Special 2, and Special 5 of SP4-921. 6.5.4 IPU
4
925*
Mode Number/Name Sharpness Adjustment 1 Edge
Solid image
Low ID line
926*
Texture Removal
927*
Line Width Correction Adjusts the line width correction algorithm. Positive settings produce thicker lines; negative settings produce thinner lines. [2 ~ 2 / 0 / 1/step] This setting is only applied to Text 1, Text 2, Photo 2, Special 1, Special 2, and Special 5 of SP4-921. 6.5.4 IPU
928*
Independent Dot Erase Selects the dot erase level. Higher settings provide greater erasure. [2 ~ 2 / 0 / 1/step] This setting is only applied to Text 1, Text 2, Photo 2, Special 1, Special 2, and Special 5 of SP4-921. 6.5.4 IPU
5-15
Service Tables
20 February, 2001
Function/[Setting]
4
941*
Mode Number/Name White Line Erase
Selects the white line erase level. [0 ~ 5 / 2 / 1/step] None Weak Strong 0 1 2 3 4 5 This setting is effective only Photo 1, Photo 3, Special 3 or Special 4 mode. 0: White line erase is not used, and white level correction is used instead This setting is applied regardless of what mode has been selected in SP4-921. 6.5.4 IPU 942* Black Line Erase Selects the black line erase level. This setting is effective only when originals are scanned by the A(R)DF. [0 = No / 1 = Weak / 2 = Strong] This setting is applied regardless of what mode has been selected in SP4-921. 6.5.4 IPU 943* Positive/Negative 1 Text 2 Photo [0 = No / 1 = Yes] DFU
5-16
20 February, 2001
SP5-XXX (Mode)
5
001
Mode Number/Name All Indicators On
Function/[Setting] Blinks all indicators on the operation panel. Press OK or ! to cause all LEDs to begin blinking at a 3second cycle. After checking that LEDs are all blinking, press " or Cancel to exit.
104*
A3/DLT Double Count Selects whether the machine counts twice for each sheet of A3/11"x 17". [0 = No / 1 = Yes] If this is set to Yes is selected, the total (mechanical) counter and the current user counter will both increment by two for each A3/11" x 17" sheet.
113*
Optional Key Counter Enables/disables the optional key counter. [0: = None / 1 = Key Counter] You must set this value to 1 after installing the optional key counter.
116*
Key Counter Timing Selects whether the key counter increments at time of paper feed-in or at time of paper exit. [0 = Feed In / 1 = Exit]
120*
Key Counter Removal Reset Determines under which conditions the copy job settings are reset when the key counter is removed. With 0, the settings are cleared if the counter is removed at the end of a job or midway through a job. With 1, they are only cleared if the counter is removed at the end of a job. With 2, they are not cleared at all, under either condition. [0=Yes / 1=Standby only / 2=No] With duplex copies, the job settings are always preserved, regardless of the setting of this SP mode.
Service Tables
143*
DF 180 Image Rotation Selects whether images copied in DF mode are turned upside down (rotated 180 degrees). [0 = No / 1 = Yes] Select Yes when you want the image trailing edge at the papers leading edge (e.g., letter-headed copy paper).
401*
User Code Mode Enables/disables the User Code feature for copy mode. [0 = No / 1 = Yes] Changing this value causes the following User Tool setting to change accordingly: [3. Copier Features] [12. Key Operator Tools] [1. User Code Access]. If the customer forgets a user code, you can retrieve it as follows. 1) Change this SP value from 1 to 0. 2) Use [3. Copier Features] [12. Key Operator Tools] [3. Print Counter List] to print out the counter list. 3) The list will show all the user codes.
5-17
20 February, 2001
Function/[Setting]
5
501*
Mode Number/Name PM Alarm Mode 1 Interval
On/Off
Sets the base PM interval. [1 ~ 255 / 60 / 1K copies/step] The value stored in this SP is used when the value of SP5-501-2 is 1. Enables/disables the PM alarm for the total number of prints, copies, and faxes. [0 = No / 1 = Yes] Resets all software counters and returns all modes and adjustments to their defaults settings (except for some settings, such as SP5-811, SP5-907, SP5-916, and SP7003 5.1.8 Memory All Clear for a full list). [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the ! key at the same time to execute the clear. If the clear is successful, the display shows Action completed. If the clear fails, the display shows Error!!!. This SP mode should be used only after replacing the NVRAM or when the copier has malfunctioned due to damaged NVRAM. 5.1.8 Memory All Clear
801
Memory All Clear
802
Scanner/Printer Free Run Starts a free run of both the scanner and the printer. [0: = No / 1 = Yes] After selecting 1, press the OK key or ! key twice to start the run. Press " to stop the free run.
803
Input Check Displays the signals being received from sensors and switches. Press # to exit the program. 5.1.3 Input Check
804
Output Check Turns on electrical components individually for test purposes. 5.1.4 Output Check
807*
Display Language Group Selects the display language group. [0 = Standard / 1 = Option 1 / 2 = Option 2] The actual display language can be selected using User Tools: [6. Language]
809*
mm/inch Selection Selects whether the display shows values in mm or inches. [North Am.: 0 = inch / 1 = mm] [EU/Asia: 0 = mm / 1 = inch]
5-18
20 February, 2001

Function/[Setting] Resets all level-A service call conditions, such as fusing errors. (To reset SC 547, switch the machine off/on.) [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the ' key (or OK key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!. 4.1 Service Call Conditions
5
810
Mode Number/Name SC Code Reset
811*
Serial Number Input Used to input the machine serial number (normally done at the factory). This is the serial number printed on SMC reports. 5.1.13 Serial Number Input
812*
Service Telephone Number 1 Telephone
Facsimile
Use this to input the telephone number of the service representative. (The number is displayed when a service call condition occurs.) To input a dash, press !. To delete the current telephone number, press %. Use this to input the fax number printed on user counter reports. To input a dash, press !. To delete the current fax number, press %. Uploads SP and UP mode data (except for some items such as counters and the serial number) from the flash memory on the BiCU board to a flash memory card. [0 = No / 1 = Yes] This SP can be used when a flash memory card has been plugged into the machines card slot. 5.1.11 NVRAM Data Upload/Download
Service Tables
824
NVRAM Data Upload
825
NVRAM Data Download Downloads SP mode data from a flash memory card to the flash memory on the BiCU board. [0 = No / 1 = Yes] This SP can be used when a flash memory card has been plugged into the machines card slot. 5.1.11 NVRAM Data Upload/Download
826
Program Upload Uploads the system program from the flash memory on the BICU board to a flash memory card. [0 = No / 1 = Yes] This SP can be used when a flash memory card has been plugged into the machines card slot. 5.1.10 Program Upload/Download
5-19
20 February, 2001
Function/[Setting]
5
827
Mode Number/Name Program Download
Downloads the system program from a flash memory card to the flash memory on the BICU board. [0 = No / 1 = Yes] This SP can be used when a flash memory card has been plugged into the machines card slot. 5.1.9 Program Upload/Download 901 Printer Free Run Performs a printer free run. [0 = No / 1 = Yes] After selecting 1, press OK or ' twice to start the run. Press % to stop. 902 Test Pattern Print Prints a test pattern Press & to enter copy-mode display, then print out the pattern. 5.1.2 Test Pattern Printing 906* Exhaust-Fan Control Timer Inputs the fan control time. [30 ~ 120 / 30 / 1 s/step] The fan maintains normal speed for the specified time after occurrence of an SC or following entry into Warm-up mode, Low Power mode, or Night/Off mode. 907* Plug & Play Setting Selects the brand name and production name for the Plug and Play function (for Windows 95 and up). These names are registered in the NVRAM. If the NVRAM becomes defective, these names should be re-registered. Use the Right or Left cursor key to scroll through the list of brand names. To select a brand name, press the Original Type key and the OK (or ') key at the same time. The LCD displays an asterisk (*) next to the number of the currently selected brand name. After displaying any of the brand names, you can view the corresponding production name by pressing the Darker key. (If the production name is longer than 43 characters, hold down both the Darker and Lighter keys together to view the rest of the name). 908 Fax Download/Upload 1 Program download Download the fax system program from a flash memory card to the flash memory on the FCU board. Fax Service Manual Download fax setting data from a flash memory card to the SRAM on the FCU board. Fax Service Manual Download fax setting data from the SRAM on the FCU to a flash memory card. Fax Service Manual
SRAM data download
SRAM data upload
5-20
20 February, 2001

Function/[Setting] Selects whether or not to back up the data written to the NV-RAM at power off (see conditions below). [0 = Disabled / 1 = Enabled] When enabled, this function creates a back up of the data if it has been 24 hours since the power was turned on or since the machine last wrote to the NV-RAM. The backup goes to a special back-up area inside the NVRAM.
5
909*
Mode Number/Name NV-RAM Auto Backup
911*
APS A4/LT LEF Priority Specifies whether the machine selects 81/2" x 11" LEF paper for A4 LEF originals (or vice versa for metric-based machines). [0 = No / 1 = Yes] On inch-based models: If this setting is Yes, the machine automatically selects 81/2" x 11" LEF if the APS sensors detect an A4 LEF original. On metric (mm) based models: If this setting is Yes, the machine automatically selects A4 LEF if the APS sensors detect an 81/2" x 11" LEF original. This SP is ineffective if the machine has been set up to detect Chinese paper sizes (SP5-955).
913
UP Mode Data Reset Resets the user tool settings. [0 = No / 1 = Yes] Note that the user codes, key operator code, and key operator printer counter value are not reset. After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!
914*
Printer Counter Display Selects whether the printer counter is displayed on the LCD ([1. Counter] in the user tools) and in the counter list printout. [0 = No / 1 = Yes] To display the printer counter on the LCD, press the Right cursor key once. To display the total counter, press it again.
916*
Language UK/TW Priority Selects the default display language. [0 = UK (Asia version) / 1 = TW (Taiwan version)] Asia and Taiwan versions only. This setting is not reset by Memory All Clear (SP5-801).
5-21
Service Tables
20 February, 2001
Function/[Setting]
5
930
Mode Number/Name Fax Forwarding Mode
Selects whether the machine will accept changeover to fax mode following occurrence of an SC error. [0 = No / 1 = Yes] When an SC occurs while there are received fax messages in the SAF memory, change the value to 1. Then access facsimile mode. Then forward the incoming data to another fax machine using the fax mode bit switches. 940* Image Rotation Enables/disables image rotation. [0 = Enabled / 1 = Disabled] This function is used for both rotate sort and rotate copy. 941* Duplex Blank Page Selects whether the blank page is made on the front side or back side when using duplex copy mode. [0 = Back Side / 1 = Front Side] 944* APS Mode Setting Enables/disables APS mode as the power-up default. [0: Disabled / 1 = Enabled] 950* By-pass LG Size Detection Selects whether the machine can detect LG paper in the by-pass tray. [0 = No / 1 = Yes] If No is selected, the machine detects LT instead of LG. 951* Interleave Count Setting Selects the interleave count used when interleave mode has been selected from User Tools [2. System Settings] [11. Print Priority]. [1 ~ 20 / 5 / 1 page/step] This determines what happens if there are jobs of different types waiting. If the setting is 5 (for example), interleave mode will print 5 pages of one job, then 5 pages of the next job, and so on. 952* By-pass Paper Type Reset Selects the operational default paper type for the by-pass tray. The machine returns to the value set here at power up and whenever ! is pressed. [0 = Thick / 1 = Plain / 2 = Selected] If the setting is 2, the paper type selected in the User Tools will be used.
5-22
20 February, 2001

Function/[Setting] Selects whether the machine will detect 8K/16K instead of B4/B5 in platen cover mode. [0 = No / 1 = Yes] For China models only To allow the machine to detect 8K/16K, first set this mode to Yes, then change the APS sensor positions as explained in Replacement & Adjustment Changing the Original Sensor Position. Note that SP5-911 (APS A4/LT LEF Priority) is not effective if this setting is Yes. If this setting is No (the default), the machine detects B4/B5 and not 8K/16K. 3.4.6 Changing the Original Sensor Position Selects whether or not the machine will detect 8K/16K instead of A3/A4/B4/B5 in ADF/ARDF mode. [0 = No / 1 = Yes] For China models only In this case, selecting Yes is sufficient to allow the machine to detect 8K/16K Note that SP5-911 (APS A4/LT LEF Priority) is not effective if this setting is Yes. If this setting is No (the default), the machine detects A3/A4/B4/B5 and not 8K/16K. 3.4.6 Changing the Original Sensor Position Selects the machine status list to be printed. See section 5.1.6 SMC Printing for details about how to print the list. [1 = SP / 2 = UP / 3 = Log / 4 = All / 5 = Big Font] Selection 5 is for printing reports to be sent by fax. B039 machines (outside North America) require optional 16MB memory to support this feature
Service Tables
5
955*
Mode Number/Name 8K/16K Detection 1 Platen cover
ADF/ARDF
992
SMC Printing
5-23
20 February, 2001
SP6-XXX (Peripherals)
6
006*
Mode Number/Name ADF Registration 1 Side-to-Side/Front
Function/[Setting] Adjusts the side-to-side registration for the front side of the original, for ADF mode. [7.0 ~ +9.5 / 0.0 / 0.1 mm/step] IAJ Use the ! key to select + or before entering the value. Adjusts the leading edge registration for ADF mode. [5.0 ~ +5.0 / 0.0 / 0.1 mm/step] IAJ 0.1 mm/step Use the ! key to select + or before entering the value. Adjusts the trailing edge erase margin for ADF mode. [3.0 ~ +3.0 / 1.0 / 0.1 mm/step] IAJ Use the ! key to select + or before entering the value. Adjusts the side-to-side registration for the rear side of duplex originals, for ADF mode. [7.0 ~ +9.5 / 0.0 / 0.5 mm/step] IAJ Use the ! key to select + or before entering the value. Adjusts the actual magnification ratio in the sub-scan direction, for ADF mode. [0.9 ~ +0.9 / 0.0 / 0.1%/step] IAJ Use the ! key to select + or before entering the value.
Leading edge
Trailing edge erase
Side-to-Side/Rear
007*
ADF Sub-scan Magnification
009
ADF Free Run Performs an ADF free run . [0 = No / 1 = Yes] After selecting 1, press OK or ' twice to start the run. Press % to stop.
010*
Stamp Position Adjustment Adjusts the stamp position in the sub-scan direction, for fax mode. [10 ~ +10 / 0 / 1mm/step]
901
ADF APS Data Display Displays the status of the ADF original size sensors. 5.1.12 ADF APS Original Sensor Output Display
905*
ARDF Skew Correction Enables/disables use of skew correction when the ARDF feeds the rear side of an original. [0 = No / 1 = Yes] ARDF Original Curl Adjustment Adjusts the amount of original buckle at the ARDF registration roller when the ARDF feeds the rear side of an original. [20 ~ +20 / 0 / 1 mm/step] This SP mode is effective only if SP6-905 is set to 1.
906*
5-24
20 February, 2001

Function/[Setting] Performs a free run for the ADF and printer using a special ROM. [0 = No / 1 = Yes] DFU
6
910
Mode Number/Name ADF/Printer Free Run
911*
Binding Hole Range Selects the diameter of the binding holes in the original that the sensors will ignore. If set at 0, this function is disabled. [0 ~ 20 / 12 / 1 mm/step] Original jams may occur when feeding originals with binding holes, because these holes may be detected by the sensors. Use this SP to avoid this problem. For example, setting this value to 12 mm will cause the sensors to ignore binding holes up to 12 mm in diameter.
5-25
Service Tables
20 February, 2001
SP7-XXX (Data Log)
7
001* 002*
Mode Number/Name Total Operation Time
Function/[Setting] Displays the total operation time (total drum rotation time).
Counter Original 1 Total 2 Copier 3 Fax
Displays the total number of scanned originals (total). Displays total number of scanned originals (copy mode only). Displays total number of scanned originals (fax mode only). Displays the total number of prints (total). Displays the total number of prints (copier mode). Displays the total number of prints (fax mode). Displays the total number of prints (printer mode). Displays the total number of prints (A3/DLT). Displays the total number of copies by paper size.
003*
101*
102*
Counter Print 1 Total 2 Copier 3 Fax 4 Printer 5 A3/DLT Counter Paper Size 1 A3 2 B4 3 A4 4 B5 5 DLT 6 LG 7 LT 8 HLT 9 Others Counter By-pass Print 1 Special
201*
204*
205* 211* 212*
Displays the total number of special paper prints fed from the by-pass tray. 2 Thick Displays the total number of thick paper prints fed from the by-pass tray. Counter - Total Scan (Non DF) Displays the total number of scanned originals (not from the DF). Counter - Printouts by Paper Tray Displays the total number of sheets fed from each paper 1 1st feed station. 2 2nd 3 3rd 4 4th 5 By-pass 6 Duplex Counter ADF Displays the total number of originals fed by the ADF. Display APS Working Time (Cumm.) Displays the accumulated APS working time. Display ID Sensor Working Time (Cumm.) Displays the accumulated ID sensor working time.
5-26
20 February, 2001

Function/[Setting] Displays the total number of copies by reproduction ratio or magnification mode.
7
301*
Mode Number/Name Counter Magnification 1 50% ~ 99% 2 Full size 3 101% ~ 200% 4 Auto reduce/enlarge 5 Fixed magnification Counter Mode 1 Text 2 Photo 3 Duplex - Printing 4 Duplex - Original 5 Combined 6 Series 7 Sort 8 ADF Counter Copy Qty 1 1 to 1 2 1 to 2 ~ 5 3 1 to 6 ~ 10 4 1 to 11 ~ 20 5 1 to 21 ~ 99 Counter SC Total Counter by each SC
304*
Displays the total number of copies by copy mode.
305*
Displays the total number of series copies.
401* 402*
Displays the total number of logged SC codes. Displays the total number of each type of logged SC code. [0 = No / 1 = Yes] 501* 502* 503* 504* Counter Total Jams Displays the total number of jams (copy paper + original). Counter Total Paper Jams Displays the total number of copy paper jams. Counter Total Original Jams Displays the total number of original jams, Total Jams by Location 1 A jams 2 B jams 3 Y jams 4 Z jams 5 1st 6 2nd 7 3rd 8 4th 9 By-pass 10 Duplex unit Displays the total number of copy paper jams by location.
Service Tables
5-27
20 February, 2001
Function/[Setting]
7
801
Mode Number/Name Memory/Version/PN 1 Main P/N 2 Main version 3 Fax P/N 4 Printer P/N 5 ADF ROM 6 Copier memory 7 # optional trays Display PM Counter
Displays the P/N and suffix of the copier firmware. Displays the version of the BiCU board Displays the P/N and suffix of the fax firmware. Displays the P/N and suffix of printer firmware. Displays the P/N and suffix of the ADF ROM. Displays the total amount of copier memory installed. Displays the number of optional paper trays currently installed. Displays the PM counter value (since the last PM).
803*
804
Reset PM Counter Resets the PM counter. [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!.
807
Reset SC/Jam Counters Resets the SC, paper, original, and total jam counter values. [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!.
808
Reset Counters Resets all counters except for the total print counters (SP7-003) and timer counter (SP7-991). [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!.
810
Reset Key Operator Code Resets the key operator code. [0 = No / 1=Yes] After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!. If the customer forgets the key operator code, clear it by using this SP mode and re-input the code using: [2. System Settings] [13. Key Operator Tools] [14. Program Key Operator Code].
5-28
20 February, 2001

Function/[Setting] Resets the electrical total counter. [0 = No / 1 = Yes] Usually, this is performed at installation. This SP mode is effective only once, while the counter still has a negative value. This SP mode cannot be used once the counter takes a positive value. After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset Is successful, the display shows Action completed. If the reset fails, the display shows Error!!!.
7
825
Mode Number/Name Reset Total Counter
901*
Display SC History Displays the last twenty SC codes that have occurred. [0 = No / 1 = Yes]
902
Clear SC History Clears the SC history. [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!.
903*
Display Paper Jam History Displays the paper jam history. [0 = No / 1 = Yes] Clears the copy jam history. [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!.
Service Tables
904
Clear - Copy Jam History
905*
Display - Original Jam History Displays the original jam history. [0 = No / 1 = Yes]
906
Clear - Original Jam History Clears the original jam history. [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!.
907
Reset - Timer Counter Resets the timer counter (SP7-991). [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!.
5-29
20 February, 2001
Function/[Setting]
7
908*
Mode Number/Name Display Developer Counter
911*
912
Display the total number of prints made since the last Developer Initialization (SP2-214). Note that this counter does not double count, even for A3 and 11" x 17". Developments are counted up at paper exit. Display - ID Sensor Error Counter Displays the total number of logged ID sensor errors. For the error analysis procedure, 5.1.14 ID Sensor Error Analysis. Reset - ID Sensor Error Counter Resets the ID sensor error counter. [0 = No / 1 = Yes] After selecting 1, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows Action completed. If the reset fails, the display shows Error!!!. Display - Timer Counter Displays the total ON time for the machine.
991*
5-30
20 February, 2001
5.1.2 TEST PATTERN PRINTING (SP5-902)

1. Input the class-3 number for the test pattern you need. 2. Press & to access the copy mode display. 3. Select the required copy features such as paper size, image density, and reproduction ratio. 4. Press & again to print the test pattern. 5. After checking the test pattern, press ! key to exit from copy mode. 6. Exit SP mode.
No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Test Pattern using VCU No Print Vertical Lines (single dot) Horizontal Lines (single dot) Vertical Lines (double dot) Horizontal Lines (double dot) Grid Pattern (single dot) Grid Pattern (double dot) Alternating Dot Pattern Solid Black Black Band Trimming Area Argyle Pattern Grayscales (Horizontal) Grayscales (Vertical) Grayscales (Vertical/Horizontal) Grayscales (Vertical/Horizontal Overlay) Grayscales with white lines (Horizontal) Grayscales with white lines (Vertical) Grayscales with white lines (Vertical/Horizontal) No. 31 32 33 34 35 36 37 38 39 40 41 42 43 Test Pattern using IPU Vertical Lines (single dot) Horizontal Lines (single dot) Vertical Lines (double dot) Horizontal Lines (double dot) Alternating Dot Pattern Grid Pattern (single dot) Vertical Stripes Grayscales (Horizontal) Grayscales (Vertical) ID Patch Cross Pattern Argyle Pattern Trimming Area
No. 51 52 53
Test Pattern using SBU Vertical Lines (double dot) Grid Pattern (single dot) 16 Grayscales
5-31
Service Tables
20 February, 2001
5.1.3 INPUT CHECK (SP5-803)
Input Check Code:

1. Access SP mode 5-803.
0
B039M005.WMF
2. Select the number that will access the switch or sensor you wish to check (see the table below). 3. Check the status of the sensor or switch. 4. If you wish to check the signal during a copy cycle, select the required copy modes, then press !. 5. The LCD panel will display 00H or 01H, as shown below.
In #01=00H
B039M006.WMF
The following table shows the meaning of each of the displayed values.
Number 0 1 2 3 4 5 6 15 16 17 18 19 20 21 22 23 24, 25 26 27 28 30 31 Description Not used Front/right cover safety switch Front/right cover safety switch - LD5V Right door switch Vertical transport door switch Tray cover switch (Optional paper tray unit) Not used Relay sensor Vertical transport sensor Vertical transport sensor (Optional paper tray unit) Registration sensor Exit sensor Duplex inverter sensor Duplex entrance sensor Duplex exit sensor Not used By-pass paper end sensor By-pass paper size switch Not used Upper paper end sensor Closed Closed Closed Closed Closed Reading 00H Opened Opened Opened Opened Opened 01H
Paper not detected. Paper not detected. Paper not detected. Paper not detected. Paper not detected. Paper not detected. Paper not detected. Paper not detected. Paper not detected. See Table 3. Paper not detected.
Paper detected. Paper detected. Paper detected. Paper detected. Paper detected. Paper detected. Paper detected. Paper detected. Paper detected.
Paper detected.
5-32
20 February, 2001
Number 32 33 34 35, 36 37 38 39 40 41 42 43 44 52 53 54 55 56, 57 58 59 61 62 6368 69 70 71 72 73 74, 75 76 77 78 79, 80 81 82 89 90 91 Description Lower paper end sensor Upper paper size switch Lower paper size switch Not used Upper paper end sensor (Optional paper tray unit) Lower paper end sensor (Optional paper tray unit) Upper paper size switch (Optional paper tray unit) Lower paper size switch (Optional paper tray unit) Upper paper height sensor (Optional paper tray unit) Lower paper height sensor (Optional paper tray unit) Upper lift sensor (Optional paper tray unit) Not used PCU set signal (a shorted connection in the TD sensor cable) Not used Paper tray unit type (Optional paper tray unit) Not used BiCU installed Not used Duplex unit installed Not used Lower lift sensor (Optional paper tray unit) Not used Main motor lock Polygonal mirror motor lock Paper feed motor lock (Optional paper tray unit) Not used Total (mech) counter installed Not used Key counter installed (Optional key counter) Not used Laser synchronization signal Not used DF position sensor (Optional ADF) Feed cover open sensor (Optional ADF)

Reading 00H 01H Paper not detected. Paper detected. See Table 1. See Table 1. Paper not detected. Paper not detected. See Table 2. See Table 2. See Table 4. See Table 4. Paper not at upper limit Not set Paper at upper limit Paper detected. Paper detected.
Set
Not installed Not installed Paper not at upper limit Off Off Off
Installed Installed Paper at upper limit
On On On
Not installed Not installed
Installed Installed
Not detected Closed Closed
Detected Opened Opened
5-33
Service Tables
See Table 5.

Number 92 93 94 95 96 97, 98 99 Description Original set sensor (Optional ADF) Registration sensor (Optional ADF) Original trailing edge sensor (Optional ADF) Optional exit sensor (Optional ADF) Original reverse sensor (Optional ADF) Not used Platen cover sensor
20 February, 2001
Reading 00H 01H Paper not detected. Paper detected. Paper not detected. Paper not detected. Paper not detected. Paper not detected. Paper detected. Paper detected. Paper detected. Paper detected.
Closed
Opened
Table 1: Paper Size Switch (Main Frame)
B039M999.WMF
Number
SW 1 0 0 0 0 1 1 1 1
SW 2 0 0 1 1 0 0 1 1
SW 3 0 1 0 1 0 1 0 1
SP Value 00H 04H 02H 06H 01H 05H 03H 07H
Paper Size inches mm 81/2" x 14" A5 LEF
33, 34
81/2" x 13" * (Asterisk)

A4 LEF 11" x 81/2" 81/2" x 11" A4 SEF 11" x 17" A3
1: Pushed
5-34
20 February, 2001
Table 2: Paper Size Switch (Optional Paper Tray Unit)
SW No. 1
4
B039M502.WMF
Number
39, 40
SW 1 0 0 0 0 0 1 1 1 1
SW 2 0 0 0 1 1 0 0 1 1
SW 3 0 1 1 0 1 0 1 0 1
SW 4 0 0 1 1 1 0 0 0 1
SP Value 00H 04H 0CH 0AH 0EH 01H 05H 03H 0FH
Paper Size A4 LEF A4 SEF 11" x 17" 11" x 81/2" 81/2" x 11" * (Asterisk) 81/2" x 14" A3
1: Pushed
Table 3: By-pass Paper Size Switch

Service Tables
Number
SP Value 06H 02H 03H 01H 08H 0CH 04H
27
Paper Size mm inches A3 11" x 17" A4 SEF 81/2" x 11" 8" x 13" A5 SEF 51/2" x 81/2"
Table 4: Paper Height Sensors

Number 41, 42 SP Value 00H 01H 02H 03H Paper Amount 100% 70 ~ 75% Near-end 25 ~ 30%
Table 5: Paper Tray Unit Set Sensor

Number 55 SP Value 00H 01H 02H Unit Installed None Paper tray unit (2 trays) Paper tray unit (1 tray)
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20 February, 2001
5.1.4 OUTPUT CHECK (SP5-804)
Output Check Code: 0
Data: 0
B039M007.WMF
CAUTION: To prevent mechanical or electrical damage, do not keep an electrical component on for a long time. 1. Access SP mode 5-804. 2. Select the SP number that corresponds to the component you wish to check (see the table below), then press OK or !. 3. Press 1, then press OK or the ! key to check that component. 4. To interrupt the test, re-enter SP mode 5-804 and enter a value of 0.
Output Check Table NOTE: Pull out the tray before performing output checks 28, 29, and 31.
Number 0 1 2 3 46 7 8 9 10 11 12 13 14 15 18 19 20 21 22 23 24, 25 26 27 28 Description Not used Main motor (Forward) Main motor (Reverse) Do not use Quenching lamp Not used Toner supply motor (Forward) Toner supply motor (Reverse) Do not use Exhaust fan (High Speed) Exhaust fan (Low Speed) Registration clutch By-pass feed clutch Upper paper feed clutch Lower paper feed clutch Not used Lower paper lift motor (Up) (Optional paper tray unit) Lower paper lift motor (Down) (Optional paper tray unit) Relay clutch Not used Relay clutch (Optional paper tray unit) Not used Upper paper feed clutch (Optional paper tray unit) Lower paper feed clutch (Optional paper tray unit) Paper feed motor (Optional paper tray unit) Number 29 30 31 32 39 40 41 42 43 44 45 46 50 51 52 Description Upper paper lift motor (Up) (Optional paper tray unit) Not used Upper paper lift motor (Down) (Optional paper tray unit) Not used Duplex inverter motor (Reverse) Duplex inverter motor (Forward) Duplex transport motor (Forward) Duplex inverter gate solenoid Duplex inverter motor (Hold) Duplex transport motor (Hold) Not used Polygonal mirror motor Polygonal mirror motor and laser diode Do not use Laser diode Do not use Not used DF transport motor (Optional ADF) DF feed motor (Optional ADF) DF feed clutch (Optional ADF) DF pick-up solenoid (Optional ADF) Stamp solenoid (Optional ADF) DF junction gate solenoid (Optional ADF) Not used
53 54 89 90 91 92 93 94 95 96 99
5-36
20 February, 2001
5.1.5 COPY JAM HISTORY (SP7-903)

After entering the SP mode, select 1 and press OK or !. The LCD panel displays the following message, 1 2 3 4 5
Jam No01 1001:06:58:43 122 B 2 A4" 1107645

B039M008.WMF
10
6 1. 2. 3. 4. 5. 6.
9 7. Jam location 8. Paper feed station 9. Paper size 10. Total counter value when the jam occurred
Jam history number Main motor operating time: Date Hour Minute Second Jam code (see the table below)
Jam Code 001 010 011 012 021 022 031 032 050 070 120 121 122 123 124 125 126 127 128 129
Meaning Jam at power on. Paper did not reach the registration sensor (from a paper tray). Paper did not reach the relay sensor. Paper caught at the relay sensor. Paper did not reach the vertical transport sensor. Paper caught at the vertical transport sensor. Paper did not reach the vertical transport sensor in the optional paper feed unit. Paper caught at the vertical transport sensor in the optional paper feed unit. Paper did not reach the registration sensor (from the by-pass tray). Paper caught at the registration sensor. Paper caught at the exit sensor (previous page). Paper did not reach the exit sensor. Paper caught at the exit sensor. Paper did not reach the duplex inverter sensor (from the registration roller). Paper did not reach the duplex inverter sensor (from the inverter tray). Paper caught at the duplex inverter sensor. Paper did not reach the duplex entrance sensor. Paper caught at the duplex entrance sensor. Paper did not reach the duplex exit sensor. Paper caught at the duplex exit sensor.
Service Tables
NOTE: The NVRAM can store data for up to 10 copy jams. If more than 10 copy jams occur, the oldest data is erased.
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20 February, 2001
5.1.6 SMC PRINTING (SP5-992)

NOTE: To use this feature on B039 models outside of North America, the optional 16MB must be installed. 1. Access SP mode 5-992 and select the number corresponding to the list that you wish to print. 2. Press ! to access the copy mode display. 3. Select the paper size. 4. Press ! again to print the list. 5. After printing the list, press " to exit from copy mode. 6. Exit SP mode.
5.1.7 ORIGINAL JAM HISTORY DISPLAY (SP7-905)

After entering the SP mode, select 1 and press OK or #. The following message is displayed. 1 2 3 4 5
Jam No01 1001:06:58:43 210 Org:A4$ 1107645

6 7
B039M009.WMF
1. 2. 3. 4. 5.
Jam history number Main motor operating time: Date Hour Minute Second
6. Jam code (see the table below) 7. Original size 8. Total counter value when the original jam occurred
Jam Code 210 211 212 213 214 215 216 218
Meaning Original does not reach the registration sensor. Original caught at the registration sensor. Original does not reach the original exit sensor. Original caught at the original exit sensor. Original does not reach the original reverse sensor. Original caught at the original reverse sensor. Short interval between originals. No original at the stamp.
NOTE: The NVRAM can store data for up to 10 original jams. If more than 10 original jams occur, the oldest data will be erased.
5-38
20 February, 2001
5.1.8 MEMORY ALL CLEAR (SP5-801)

NOTE: Memory All Clear mode resets all the settings and counters stored in the NVRAM to the defaults, except for the following: Electrical total counter values (SP7-003) Machine serial number (SP5-811) Plug & Play brand name and production name setting (SP5-907) Some SBU settings (SP4-904-6, SP4-904-7, SP4-905-6, SP4-905-7, SP4-906-3, SP4-907-3) Language UK/TW Priority (SP5-916) Asia and Taiwan versions only
Normally, this procedure should not be used. It is necessary only after replacing the NVRAM, or when the copier malfunctions because the NVRAM is damaged.
Using a Flash Memory Card

1. Upload the NVRAM data to a flash memory card ( 5.1.10 NVRAM Data Upload). 2. Print out all SMC data lists (SP5-992). NOTE: 1) For B039 models outside N. America, these lists cannot be printed without the IMB installed. Therefore, if it is not installed, write down all the data stored in NVRAM (all user tool settings, and all SP settings except for those listed above). 2) Be sure to print out all the lists. If the NVRAM data upload was not completed, it is necessary to change the SP mode settings by hand. 3. Access SP mode 5-801. 4. Press the Original Type key and the OK key (or !) key at the same time. If the operation is successful, the display shows Action completed. If the clear fails, the display shows Error!!!. 5. Turn the main switch off and back on. 6. Download the NVRAM data from a flash memory card ( 5.1.10 NVRAM Data Download).
5-39
Service Tables
20 February, 2001
Without Using a Flash Memory Card

If there is no flash memory card, follow the steps below. 1. Print out all SMC data lists (SP5-992). NOTE: For B039 models outside N. America, these lists cannot be printed without the IMB installed. Therefore, if it is not installed, write down all the data stored in NVRAM (all user tool settings, and all SP settings except for those listed above). 2. Access SP mode 5-801. 3. Press the Original Type key and the OK key (or !) key at the same time. If the operation is successful, the display shows Action completed. If the clear fails, the display shows Error!!!. 4. Turn the main switch off and back on. 5. Do the printer and scanner registration and magnification adjustments ( Replacement and Adjustment Copy Adjustments). 6. Refer to the SMC lists or the data you have written down, and re-enter any values that differ from the factory settings. In particular, the values for SP4-904, SP4-905, SP4-906, and SP4-907 must be re-entered. 7. Do the standard white level adjustment (SP4-908). 8. Initialize the TD sensor (SP 2-214). 9. Check the copy quality and the paper path, and do any necessary adjustments.
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20 February, 2001
5.1.9 PROGRAM UPLOAD/DOWNLOAD

The BiCU software for this machine is upgraded using a flash memory card. There are two program download procedures. SP5-826: Upload from the BiCU to a flash memory card. SP5-827: Download from a flash memory card to the BiCU.
Program Download (SP5-827)
[A]
[B]
B039M934.WMF B039M935.WMF
NOTE: Be sure to turn off the main switch before inserting or removing the flash memory. Installing or removing flash memory while the switch is still on may result in damage to the BiCU or to the memory. 1. Turn off the main switch. 2. Remove the rear middle cover [A] (2 rivets). 3. Insert the flash memory card [B] into the card slot. NOTE: Make sure that the printed A on the card is facing the outside of the machine. 4. Hold down the Operation Switch and turn on the main switch. 5. To start the download, press the 1 key and then press OK. 6. The machine erases the current software, then writes the new software to the BiCU. This takes about 60 seconds. If downloading fails, an error message appears, as indicated below. If this occurs, repeat the download procedure. 7. After finishing the software download, turn off the main switch and remove the memory card.
5-41
Service Tables
20 February, 2001
Display during writing.
Program Download Load status:2-161402

B039M010.WMF
Display when the download is complete.
Program Download End sum=2A74 0.29EU

B039M011.WMF
Display if writing has failed.
Program Download Loading error!!!

B039M012.WMF
NOTE: To view the current firmware version, check SP7-801-1.
Program Upload (SP5-826) NOTE: Be sure to turn off the main switch before inserting or removing the flash memory. Installing or removing flash memory while the switch is still on may result in damage to the BiCU or to the memory.
1. Turn off the main switch. 2. Insert a flash memory card into the card slot (see the previous page). NOTE: Make sure that the printed A on the card is facing the outside of the machine. 3. Turn on the main switch. 4. Access SP mode 5-826. 5. The machine erases the software on the card, then writes the new software to the flash memory card. This takes about 60 seconds. If uploading fails, an error message appears. If this occurs, repeat the upload procedure. 6. Turn off the main switch, then remove the memory card.
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20 February, 2001
5.1.10 NVRAM DATA UPLOAD/DOWNLOAD

The memory all clear procedure will reset all NVRAM settings back to their defaults. It is therefore necessary to upload the NVRAM data before starting the clear, and then to download the data back after completing the clear. SP5-824: Upload from the BiCU to a flash memory card. SP5-825: Download from a flash memory card to the BiCU.
NVRAM Data Download (SP5-825)
[A]
[B]
Service Tables
B039M934.WMF B039M935.WMF
NOTE: This procedure downloads all the settings stored in the NVRAM, except the following values. Electrical total counter values (SP7-003) Machine serial number (SP5-811, SP5-920, SP5-925) Plug & Play brand name and production name setting (SP5-907) Some SBU settings (SP4-904-6, SP4-904-7, SP4-905-6, SP4-905-7, SP4906-3, SP4-907-3) Language UK/TW Priority (SP5-916) Asia and Taiwan versions only NOTE: Be sure to turn off the main switch before inserting or removing the flash memory. Installing or removing flash memory while the switch is still on may result in damage to the BiCU or to the memory. 1. Turn off the main switch. 2. Remove the rear middle cover [A] (1 screw). 3. Insert the flash memory card [B] into the card slot. NOTE: Make sure that the printed A on the card is facing the outside of the machine. 4. Turn on the main switch. 5. Access SP mode 5-825.
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20 February, 2001
6. The machine erases the current settings, then writes the new settings onto the NVRAM on the BiCU board. This takes about 1 second. If downloading fails, an error message appears ( 5.1.9 Program Download). If the error message appears, repeat the download procedure. 7. Turn off the main switch, then remove the memory card.
NVRAM Data Upload (SP5-824)

1. Turn off the main switch. 2. Insert a flash memory card into the card slot. (See the previous page.) NOTE: Make sure that the printed A on the card is facing the outside of the machine. 3. Turn on the main switch. 4. Access SP mode 5-824. 5. The machine erases the settings on the card, then writes the machines settings to the flash memory card. This takes about 20 seconds. If uploading fails, an error message appears (see 5.1.9 Program Download). If the error message appears, repeat the upload procedure. 6. Turn off the main switch, then remove the memory card.
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20 February, 2001
5.1.11 APS AND PLATEN/DF POSITION SENSOR OUTPUT DISPLAY (SP4-301)
L1
L2
W1 W2
B039M512.WMF
1 0
2 0 0 1 1 0 0 0 0 L2 W2 L1 W1
3 A4 !
Service Tables
B039M513.WMF
1. Platen cover/DF position sensor status 2. APS sensor status 3. Paper size display
1 = Opened 1 = Paper detected
5-45
20 February, 2001
5.1.12 ADF APS SENSOR OUTPUT DISPLAY (SP6-901)
B039M600.WMF
W1 W2
Large 0 0
0 1
1 0
Small 1 1
1 0
2 0 0 1 0 1 1 0 W1 L1 W2 L2
3 11" x 17"*
B039M552.WMF
1. Original set sensor status 2. APS sensor status 3. Paper size display
W1 0 0 0 0 1 1 1 1 1 W2 0 0 1 1 1 0 0 1 1 L1 0 1 0 1 1 0 1 0 1 L2 0 1 0 0 1 0 1 0 0
1 = Paper detected 1 = Paper detected
Paper Size NA 10" x 14" 81/2" x 51/2" LEF 81/2" x 11" SEF 81/2" x 14" 11" x 81/2" LEF 11" x 17" 51/2" X 81/2" SEF EU/AA B5 LEF B4 A5 LEF A4 SEF 81/2" x 13" A4 LEF A3 A5 SEF B5 SEF
1: Detected
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20 February, 2001
5.1.13 SERIAL NUMBER INPUT (SP5-811)

Used to input the machines serial number (this is normally done at the factory). The numeric keypad has 12 buttons. Use the first 11 buttons " to +, ! and # to input the serial number (' is not used). Each button represents one digit of the serial number. Press consecutively to get the required letter/number. The first 4 buttons allow you to scroll through numbers 0 to 9 and A to Z. Buttons 5 to 11 only scroll through numbers 0 to 9.
"
1st digit
,
2nd digit
3rd digit
.
4th digit
/
5th digit
0
6th digit
$
7th digit
1
8th digit
+
9th digit
!
10th digit
#
11th digit
'
Not used
Service Tables
5-47
20 February, 2001
5.1.14 ID SENSOR ERROR ANALYSIS (SP2-221)
VG:3.84,VP:0.27,PW:139 VSDP:3.57,VT:2.09
B039M013.WMF
A defective ID sensor does not generate an SC condition, but does cause the image quality to become worse (e.g., dirty background on the copy). If these conditions occur, check the ID sensor output using this SP mode. 1. Vsg (VG in the display) Error Condition: Vsg < 2.5V or (Vsg Vsp) < 1.00V Possible causes: ID sensor defective ID sensor dirty Drum does not get charged 2. Vsp (VP in the display) Error Condition: Vsp > 2.5V or (Vsg Vsp) < 1.00V Possible causes: Toner density is very low ID sensor pattern is not created 3. Power (PW in the display) This is the power for the light source of the ID sensor. Error Condition: Vsg < 3.5V when maximum power (979) is applied Possible causes: ID sensor defective ID sensor dirty Drum does not get charged 4. Vsdp No Error Conditions 5. Vt Error Condition: Vt > 4.5V or Vt < 0.2V Possible causes: TD sensor defective
5-48
20 February, 2001
USER TOOLS
5.2 USER TOOLS

The User Tools are accessed by users and key operators and by sales and service staff. User Tools are used to input or change the copiers default settings.
5.2.1 HOW TO ENTER AND EXIT USER TOOLS

Press the User Tools button, then select the User Tools program. After finishing the User Tools program, press the User Tools button to exit.
5.2.2 USER TOOLS TABLE

System Setting Table
1. Function Priority 2. Copy Count Display 3. System Reset 4. Energy Saver Timer 5. Energy Saver Level 6. Auto Off Timer 7. AOF (Keep It On.) 8. Special Paper Size
2. System Settings
9. Paper Tray Priority 10. Auto Tray Switch 11. Print Priority 12. Display Contrast 13. Key Operators Tools
1. Show/Print Counter 2. Print Counter List 3. Key Operator Access 4. Program Key Operator Code 5. Restricted Access
1. Copier 2. Fax 3. Printer
5-49
Service Tables
1. Tray 1 2. Tray 2 3. Tray 3 4. Tray 4
USER TOOLS
20 February, 2001
Copy Features Table

1. APS Auto Reduce/Enlarge 2. Max. Copy Q'ty 3. Adjust Original Mode 4. Set Ratio 5. Copy Reset Timer 6. SADF Auto Reset 7. Rotate Sort Auto Continue 8. Orientation 9. Sort 10. Duplex Priority 11. Duplex Margin 12. Key Operator Tools
1. Text 2. Photo
3. Copier Features
1. User Code Access 2. Check Copy Counter 3. Print Counter List 4. Reset Counter 5. Clear all User Codes 6. Reset All Counters 7. Program User Code 8. Change User Code 9. Delete User Code
5-50
20 February, 2001
OVERVIEW
6. DETAILED SECTION DESCRIPTIONS

6.1 OVERVIEW
6.1.1 COMPONENT LAYOUT
10 11 12 13 14 15 16 17 18 19 20 21
39 38 37 36 35
22
Detailed Descriptions
34
23 24 25 33 32 31 30 29 28 27 26
B039D253.WMF
NOTE: The above illustration is the B043 model. B039: No duplex unit, one paper tray B040: No duplex unit, two paper trays
6-1
OVERVIEW
20 February, 2001
1. 2nd Mirror 2. Exposure Lamp 3. 1st Mirror 4. Exposure Glass 5. Original Width Sensors 6. Original Length Sensors 7. Lens Block 8. SBU 9. Inverter Roller 10. Scanner Motor 11. Duplex Inverter Sensor 12. Exit Sensor 13. Duplex Entrance Sensor 14. Hot Roller 15. Upper Transport Roller 16. Pressure Roller 17. OPC Drum 18. Middle Transport Roller 19. Image Density Sensor 20. Registration Roller
21. Registration Sensor 22. By-pass Tray 23. Lower Transport Roller 24. Upper Relay Roller 25. Relay Sensor 26. Lower Relay Roller 27. Vertical Transport Sensor 28. Paper Feed Roller 29. Paper End Sensor 30. Bottom Plate 31. PCU 32. Development Roller 33. WTL 34. Polygon Mirror Motor 35. Laser Unit 36. Toner Supply Bottle Holder 37. Exit Roller 38. 3rd Mirror 39. Scanner H.P. Sensor
6-2
20 February, 2001
OVERVIEW
6.1.2 PAPER PATH
B039D104.WMF
The B043 model has a duplex unit mounted on the right side of the machine. All models have a by-pass tray.
6-3
OVERVIEW
20 February, 2001
6.1.3 DRIVE LAYOUT
1
B039D107.WMF
2 3
10 9 8 7 6
B039D106.WMF
1. 2. 3. 4. 5.
Scanner Motor Main Motor Hot Roller OPC Drum Development Roller
6. Relay Clutch 7. Lower Paper Feed Clutch 8. By-pass Feed Clutch 9. Upper Paper Feed Clutch 10. Registration Clutch
6-4
20 February, 2001
BOARD STRUCTURE
6.2 BOARD STRUCTURE

6.2.1 BLOCK DIAGRAM
LSD Options Printer
: Standard : Option
LD Unit Fax Unit
BiCU
SBU IMB (See Note) Optional DRAM
Paper Tray Unit
ADF/ ARDF
Operation Panel
IOB
PSU
Duplex (See Note)
Polygon Motor
Lamp Stabilizer
Sensors
Clutches
Motors
Thermistor
Xenon Lamp
B039D001.WMF
NOTE: 1) B039 models outside North America do not contain the IMB as a standard component. 2) Only B043 models contain the duplex unit.
6-5
High Voltage P.P
Fusing Lamp
BOARD STRUCTURE
20 February, 2001
1. BiCU (Base Engine and Image Control Unit)

The main board controls the following functions: Engine sequence Timing control for peripherals Image processing, video control Operation control Various application boards (fax, printer) Machine control, system control
2. IOB (I/O Board)

The IOB handles the following functions: Drive control for the sensors, motors, and clutches of the printer and scanner High voltage supply board control Serial interfaces with peripherals Fusing control
3. SBU (Sensor Board Unit)

The SBU deals with the analog signals from the CCD and converts them into digital signals.
4. IMB (IMAC and Memory Board)

The IMB stores the image data. ( 6.5.5 IMB)
6-6
20 February, 2001
COPY PROCESS OVERVIEW
6.3 COPY PROCESS OVERVIEW
1
B039D353.WMF
7 8 9 2 6
3 4
B039D251.WMF
1. EXPOSURE A xenon lamp exposes the original. Light reflected from the original passes to the CCD, where it is converted into an analog data signal. This data is converted to a digital signal, processed and stored in the memory. At the time of printing, the data is retrieved and sent to the laser diode. NOTE: For multi-copy runs, the original is scanned once only and stored to the memory. B039 models outside N. America do not have memory as a standard component, so cannot do multi-copying. 2. DRUM CHARGE In the dark, the charge roller gives a negative charge to the organic photoconductive (OPC) drum. The charge remains on the surface of the drum because the OPC layer has a high electrical resistance in the dark.
6-7
COPY PROCESS OVERVIEW
20 February, 2001
3. LASER EXPOSURE The processed data scanned from the original is retrieved from the memory and transferred to the drum by a laser beam, which forms an electrical latent image on the drum surface. The amount of charge remaining as a latent image on the drum depends on the laser beam intensity, which is controlled by the BiCU board.
4. DEVELOPMENT The magnetic developer brush on the development roller comes in contact with the latent image on the drum surface. Toner particles are electrostatically attached to the areas of the drum surface where the laser reduced the negative charge on the drum. 5. ID SENSOR The laser forms a sensor pattern on the drum surface. The ID sensor measures the reflectivity of the pattern. The output signal is one of the factors used for toner supply control. Also, the ID sensor measures the reflectivity of the drum surface. The output signal is used for charge roller voltage control.
6. IMAGE TRANSFER Paper is fed to the area between the drum surface and the transfer roller at the proper time for aligning the copy paper and the developed image on the drum surface. Then, the transfer roller applies a high positive charge to the reverse side of the paper. This positive charge pulls the toner particles from the drum surface onto the paper. At the same time, the paper is electrostatically attracted to the transfer roller. 7. PAPER SEPARATION Paper separates from the drum as a result of the electrostatic attraction between the paper and the transfer roller. The discharge plate (grounded) helps separate the paper from the drum.
8. CLEANING The cleaning blade removes any toner remaining on the drum surface after the image transfers to the paper.
9. QUENCHING The light from the quenching lamp electrically neutralizes the charge on the drum surface.
6-8
20 February, 2001
SCANNING
6.4 SCANNING
6.4.1 OVERVIEW
1 8 2 3 4 5
7 1. 2. 3. 4. Exposure Lamp 1st Scanner Exposure Glass Lens Block
6 5. 6. 7. 8.
B039D353.WMF
Scanner Motor Original Length Sensor Original Width Sensors Scanner H.P. Sensor
The original is illuminated by the exposure lamp (a xenon lamp). The image is reflected onto a CCD (charge coupled device) on the lens block via the 1st, 2nd, and 3rd mirrors, and through the lens on the lens block. The 1st scanner consists of the exposure lamp, a reflector, and the 1st mirror. A lamp stabilizer energizes the exposure lamp. The light reflected by the reflector is of almost equal intensity, to reduce shadows on pasted originals. An optics anti-condensation heater is available as an option. It can be installed on the left side of the scanner. It turns on whenever the power cord is plugged in.
Lamp Stabilizer Fuse
ICP1
B039D998.WMF
ICP1
Rating DC50 V/1.5 A
Manufacturer ROHM CO.,LTD
Type No. ICPN38
6-9
SCANNING
20 February, 2001
6.4.2 SCANNER DRIVE

[G] [I] [B] [A] [C]
[E]
[H] [F]
B039D014.WMF
[D]
A stepper motor drives the 1st and 2nd scanners [A,B]. The 1st scanner is driven by the scanner drive motor [C], drive gear through the timing belt [D], scanner drive pulley [E], scanner drive shaft [F], and two timing belts [G]. The 2nd scanner is driven through the 1st scanner and two timing belts [H]. - Book mode The IOB controls and operates the scanner drive motor. In full size mode, the 1st scanner speed is 89 mm/s during scanning. The 2nd scanner speed is half that of the 1st scanner. In reduction or enlargement mode, the scanning speed depends on the magnification ratio. The returning speed is always the same, whether in full size or magnification mode. The image length change in the sub scan direction is done by changing the scanner drive motor speed, and in the main scan direction it is done by image processing on the BiCU board. Magnification in the sub-scan direction can be adjusted by changing the scanner drive motor speed using SP4-101. Magnification in the main scan direction can be adjusted using SP4-008. - ADF mode The scanners are always kept at their home position (the scanner H.P. sensor [I] detects the 1st scanner) to scan the original. The ADF motor feeds the original through the ADF. In reduction/enlargement mode, the image length change in the sub-scan direction is done by changing the ADF motor speed. Magnification in the main scan direction is done in the BiCU board, like for book mode. Magnification in the sub-scan direction can be adjusted by changing the ADF motor speed using SP6-007. In the main scan direction, it can be adjusted with SP4-008, like for book mode.
6-10
20 February, 2001
SCANNING
6.4.3 ORIGINAL SIZE DETECTION IN PLATEN MODE
[C] [B] [A]
B039D012.WMF
While the main switch is on, these sensors are active and the original size data is always sent to the CPU. However, the CPU checks the data only when the platen cover sensor [C] is activated. This is when the platen is positioned about 15 cm above the exposure glass, for example while it is being closed. The CPU can recognize the original size from the combination of on/off signals from the APS sensors. If the copy is made with the platen fully open, the CPU decides the original size from the sensor outputs when the Start key is pressed.
6-11
In the optics cavity for original size detection, there are four reflective sensors. The original width sensors [A] detect the original width, and the original length sensors [B] detect the original length. These are the APS (Auto Paper Select) sensors. Each APS sensor is a reflective photosensor.
SCANNING
20 February, 2001
L1
L2
W1 W2
B039D006.WMF
Original Size A4/A3 LT/DLT version version A3 11" x 17" B4 8.5" x 14" 8.5" x 13" A4-SEF 8" x 13" A4-LEF 11" x 8.5" B5-LEF 8.5" x 11" A5-LEF 8.5" x 5.5"
Length Sensors L2 1 1 1 0 0 0 0 L1 1 1 1 1 0 0 0
Width Sensors W2 1 0 0 0 1 0 0 W1 1 1 0 0 1 1 0
SP4-301 display 11110000 11010000 11000000 01000000 00110000 00010000 00000000
NOTE: 0: High (no paper), 1: Low (paper present) The above table shows the outputs of the sensors for each original size. This original size detection method eliminates the necessity for a pre-scan and increases the machine's productivity. For other combinations, Cannot Detect Original Size will be indicated on the operation panel display (if SP4-303 is kept at the default setting). However, if the by-pass feeder is used, note that the machine assumes that the copy paper is short-edge first. For example, if A4 paper is placed long-edge first on the by-pass tray, the machine assumes it is A3 paper and scans the full A3 area for the first copy of each page of the original, disregarding the original size sensors. However, for each page, the data signal to the laser diode is stopped to match the copy paper length detected by the registration sensor. This means that copy time for the first page may be slower (because of the longer time required for scanning), but it will be normal for the rest of the job. Original size detection using the ADF is described in the manual for the ADF.
6-12
20 February, 2001
IMAGE PROCESSING
6.5 IMAGE PROCESSING

6.5.1 OVERVIEW
CCD
SBU
LSD VCU LD Driver FCI IPU
Memory Control IC
Optional DRAM DRAM
Drum
IMB
Fax Controller Printer Controller
LDD
BiCU
B039D002.WMF
The BiCU board can be divided into three image processing blocks: the IPU (Image Processing Unit), FCI (Fine Character Image), and VCU (Video Control Unit). IPU: Auto shading, filtering, magnification, scanner correction, ID correction VCU: Printer correction, LD print timing control and laser power PWM control FCI (inside the VCU): Smoothing NOTE: The IPU and VCU are contained in the same IC on the BiCU Finally, the BiCU board sends the video data to the LD drive board at the proper time. The IMB provides memory for the copier features (the B039 model outside N. America does not have the IMB as standard equipment). In addition, optional DRAM can be added to the IMB ( 6.5.5).
6-13
The CCD generates an analog video signal. The SBU (Sensor Board Unit) converts the analog signal to a 6-bit digital signal, then it sends the digital signal to the BiCU board.
IMAGE PROCESSING
20 February, 2001
6.5.2 SBU (SENSOR BOARD UNIT)
SBU
O
BiCU
A/D 1 Digital Processing 1
6 bit data
Analog Processing 1
CCD
IPU VCU Analog Processing 2 Analog Processing Circuit
A/D 2
Digital Processing 2
6 bit data
Digital Processing IC
B039D004.WMF
The CCD converts the light reflected from the original into an analog signal. The CCD line has 7,450 pixels and the resolution is 600 dpi (23.6 lines/mm). The CCD has two output lines, for odd and even pixels, to the analog processing circuit. The analog processing circuit performs the following operations on the signals from the CCD: 1. Z/C (Zero Clamp): Adjusts the black level reference for even pixels to match the odd pixels. 2. Signal Amplification: The analog signal is amplified by operational amplifiers. After the above processing, the analog signals are converted to 6-bit signals by the A/D converter. Each pixel will be assigned a value on a scale of 64 grades. Then, the digitized image data goes to the BiCU board.
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20 February, 2001
IMAGE PROCESSING
6.5.3 AUTO IMAGE DENSITY (ADS)
0.5mm 15mm
[A]
75mm
Sub scan direction

B039D007.WMF
In the SBU
ADS prevents the background of an original from appearing on copies. The copier scans the auto image density detection area [A] as shown in the diagram. This corresponds to a few mm at one end of the main scan line. As the scanner scans down the page, the IPU on the BiCU detects the peak white level for each scan line. The IPU determines the reference value for the A/D conversion for a particular scan line using the peak white level for that scan line. Then, the IPU sends the reference value data to the reference controller on the SBU. When an original with a gray background is scanned, the density of the gray area is the peak white level density. Therefore, the original background will not appear on copies. Because peak level data is taken for each scan line, ADS corrects for any changes in background density down the page. As with previous digital copiers, the user can select manual image density when selecting ADS, and the machine will use both settings when processing the original.
In the IPU
After the SBU process, the IPU board removes background noise resulting from the SBU-BiCU wiring by adjusting the white level.
By Original Type
ADS mode is only enabled when the user has selected: Text mode 1 or 2 (Normal or Sharp), Photo mode 2 (Text/Priority), or Special mode 1 or 2 (Unneeded background or Colored Text). This can be done using Adjust Original Mode (3) in User Tools (Copier Features).
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IMAGE PROCESSING
20 February, 2001
6.5.4 IPU (IMAGE PROCESSING UNIT)

Overview
BiCU
Fax Controller
SBU
Printer Controller
IPU
Memory Controller Optional DRAM
LSD
FCI
LDD
LD
VCU
DRAM
IMB
B039D005.WMF
The image data from the SBU goes to the IPU (Image Processing Unit) on the BiCU board, which carries out the following processes on the image data: 1. Auto shading 2. White/black line correction 3. Scanner gamma correction 4. Magnification (main scan) 5. Filtering (MTF and smoothing) 6. ID gamma correction 7. Binary picture processing 8. Error diffusion 9. Dithering 10. Video path control 11. Test pattern generation The image data then goes to the VCU. NOTE: The IPU and VCU are contained in the same IC (called KT-ONE) on the BiCU.
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20 February, 2001
IMAGE PROCESSING
Image Processing Modes

The user can select Text, Photo and Special original types. However, each of these original types has a range of different choices (such as sharp, photographs, etc), which are listed in the table below. All modes can be customized with a range of SP modes that can be adjusted to meet user requirements. The user can select the mode that best suits their original with the following user tool: Original Type: User Tools 3. Copier Features 3. Adjust Original Mode
Original Type Text Mode Normal Sharp Photo priority Text priority Special Photographs Unneeded background Targeted Original Type Normal text originals Newspapers, originals through which the rear side is moderately visible as faint text. Text/photo images which contain mainly photo areas Text/photo images which contain mainly text areas Actual photographs Originals through which the rear side is extremely visible (or have a colored background) with faint text. Also for originals with very grainy backgrounds (some newspapers) and faint text. Originals with colored text and lines. Photo images created by dither patterns (dots visible), such as newspaper photos normal resolution. Photo images created by dither patterns (dots visible), such as newspaper photos coarse resolution. Use instead of Normal Text if, e.g. an embedded white area causes Auto Image Density to initially remove the surrounding (darker) background but leave the rest. Use if the customer wishes to keep this background.
Photo
Colored text Normal Pixel Photo
Coarse Pixel Photo
Preserved Background (Normal Text)
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IMAGE PROCESSING
20 February, 2001
Image Processing Path

This diagram shows the various stages of image processing and where they are performed.
Image Correction ADS 6
SBU
Image Correction Auto Shading White/Black Line Erase Correction Scanner Gamma Correction Small Smoothing Filter 6 Magnification (Main Scan) 6 Filtering MTF Smoothing Independent Dot Erase Line Width Correction 6
ID Gamma Correction 6 Gradation Error Diffusion Dithering Binary Picture 1 Optional Printer Controller 8 Video Path Control 8 IPU 1 VCU BiCU 1 LD Unit
B039D003.WMF
Optional Fax Unit
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20 February, 2001
IMAGE PROCESSING
Original Modes
The machine has 10 original modes. There are two text modes, three photo modes, and five special modes. The original mode key on the operation panel has two settings, text and photo. With the default settings, the machine uses Normal Text (Text 1) when the Text indicator is lit, and uses Photo Priority (Photo 1) when the Photo indicator is lit. The customer can allocate different modes to the Text and Photo indicators with User Tools 3. Copier Features 3. Adjust Original Mode. Note that the Text indicator does not have to be allocated to a Text mode and the Photo key does not have to be allocated to a Photo mode. For example, the Text indicator can be allocated to Photo 3, and the Photo indicator can be allocated to Special 4. If the user wishes to customize one of the original modes, the technician can change the settings using SP4-922 to SP4-942. Refer to SP Modes for Each Image Processing Step. However, only one of the original modes can be customized at any one time.
SP Modes for Each Image Processing Step

The table on the next page shows which SP modes are used for each step of image processing. 4-921: Selects which original mode the settings from SP4-922 to SP4-928 will be applied to. 4-922: Selects the scanner curve. You can select either a curve for textbased originals (brings out text) or a curve for photo originals (better distinctions between shades of dark colors). 4-923: Selects the central notch position for the ID adjustment LEDs. 4-925-001: Adjusts the clarity of line images and the edges of solid images. Also determines the smoothing filter used when the user selects Special 3 or Special 4. 4-925-002: Adjusts the clarity of solid image areas. 4-925-003: Adjusts the clarity of low ID lines. 4-926: Adjusts the texture removal level. 4-927: Adjusts the line width. 4-928: Selects the dot erase level. 4-941: Selects the white line erase level. 4-942: Selects the black line erase level.
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NOTE: The gray area means the setting cannot be changed using SP mode.
Text Normal ADS ADS ADS Sharp Photo Priority Text Priority Photographs Unneeded Background Colored Text Normal Pixel Photo Coarse Pixel Photo Preserved Background Note Photo Special
SBU
ADS
Enabled Enabled Enabled (DF only) Text (Reflection Ratio ID Linear) Normal Normal Strong Strong Text (Reflection Ratio ID Linear) Weak Enabled (DF only) Enabled (DF only) Enabled Enabled Enabled Enabled SP4-941 SP4-942 SP4-922 Connected with MTF filter (Edge)
Shading Correction
Shading Line Correction
White Line Correction
IMAGE PROCESSING
Black Line Correction
Scanner Correction Weak
Text (Reflection Ratio ID Linear)
Small Smoothing Filter
Enabled Enabled (DF only) Enabled Enabled Enabled Enabled (DF only) Enabled (DF only) Enabled Enabled
Magnification Main Scan Magnification
Mirroring
Side-to-side Registration (Left Side)
Normal Normal Normal Normal Normal Normal Normal Weak Disabled Disabled Weak Strong Disabled Weak Thick Weak Disabled Normal Normal Strong Weak (All Area) Normal Strong Normal Weak (All Area) Normal SP4-925-001 SP4-925-002 SP4-925-003 SP4-925-001 SP4-928 SP4-927
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Normal Sharp Photo Priority Text Priority Photographs Sharp Normal Binary Error Difusion Binary Error Diffusion Enabled Enabled Enabled Enabled Enabled Enabled
Filtering
MTF Filter (Edge)
MTF Filter (Solid)
MTF Filter (Low ID)
Smoothing Filter
Independent Dot Erase
Line Width Correction
Normal Pixel Photo Dithering (105 Lines) Coarse Pixel Photo Dithering (53 Lines) Preserved Background Error Diffusion SP4-923
Graduation
ID Correction
SP4-926 (Error diffusion only)
Image Correction
Graduation
Error Diffusion
Enabled
Path Control
Video Path Control
VCU
FCI
Edge Correction
Enabled Enabled
20 February, 2001
B039D999.WMF
Printer Correction
20 February, 2001
IMAGE PROCESSING
Auto Shading Overview

There are two auto shading methods: black level correction and white level correction. Auto shading corrects errors in the signal level for each pixel. Unlike previous machines, white level correction is only done when SP4-941 is set to 0, and not by default. However, a process called White Line Erase Compensation is used instead; this process can be adjusted by changing the value of SP4-941 between 1 and 5 (the default setting is 2). Black level correction is always done.
Black Level Correction

The CPU reads the black dummy data from one end of the CCD signal (32 pixels at the end are blacked off) and takes the average of the black dummy data. Then, the IPU deletes the black level value from each image pixel.
White Level Correction

Previous machines used 8-bit data (256 gradations), but this machine uses 6-bit data (64 gradations). When white level correction is applied to 6-bit data, white lines are more easily generated. This is because the normal variations in CCD pixel response (which are very slight), when rounded off by white level correction, will show up much easier on the copy when the data is divided into 64 gradations. White level correction is only done when SP4-941 is set to 0 (this is not the default). This is the only setting that will compensate for extremely low (abnormal) pixel response. However, it was judged that under normal conditions, white lines were more likely to occur (due to the above reason) and have a larger effect on the copy. Before scanning the original, the machine reads a reference waveform from the white plate. The average of the white video level for each pixel is stored as the white shading data in the FIFO memory in the IPU (KT-ONE) chip. The video signal information for each pixel obtained during image scanning is corrected by the IPU (KT-ONE) chip. Auto shading is done before scanning for the first original as well as after scanning each page to prepare for the next page. If the image density or the original mode is changed during a copy run, auto shading is done before scanning the next original.
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IMAGE PROCESSING
20 February, 2001
White Line Erase

Since this machine does not apply white level correction as default, white lines are automatically minimized (the reason is explained above). However, with no white level correction, the images on the edges of the copy would always appear darker than those in the center. This is because the CCD elements on the edges receive less light. Therefore to compensate, SP4-941 can be used to control both the uniformity of the edge/center image density and to minimize white lines. However, it is a trade-off between the two: SP4-941 applies the correction only to the output from the central CCD elements only, keeping the output from the edge elements constant (as the standard). With a setting of 1, a large amount of correction is applied and the central areas are uniform with the edges. However white lines are relatively visible. With the maximum setting (5), no correction is applied and the central areas appear lighter than the edges (true to the original CCD data). However white lines are minimized. Note that if SP4-941 is set to 0, white line erase is not used, and white level correction is used instead.
Black Line Erase

In ADF mode, if extremely low CCD output is detected on the scanning line before the leading edge of original arrives there, this is attributed to abnormal black dots on the exposure glass. This low output is corrected using neighboring pixels. To adjust or switch off this correction, use SP4-942.
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20 February, 2001
IMAGE PROCESSING
Scanner Gamma () Correction

The CCD output is not proportional to the quantity of light received. Scanner correction corrects the CCD output so that grayscale data is proportional to the quantity of light received. The machine has two possible scanner gamma curves: Text and Photo. As the default setting, Text is used in all modes (SP4-922). When selecting Text, the machine does not use scanner correction. As a result, the output is darker than the image density on the original. The advantage of this is that the machine can bring out gradations in paler areas. The disadvantage is that the machine cannot bring out gradations in darker areas, i.e. differences in shades of dark colors are hard to distinguish. When selecting Photo, the machine uses scanner correction. One advantage of this is that the machine can bring out gradations in dark areas of photo image originals. The disadvantage is that it in some cases images come out lighter than the customer desires.
Text Output
Photo
Original Density
B039D008.WMF
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IMAGE PROCESSING
20 February, 2001

Changing the scanner speed enables enlargement and reduction along the sub scan direction. However, enlargement and reduction along the main scan direction is handled by the IPU (KT-ONE) chip. The processing for main scan enlargement/reduction is the same as in previous digital machines.
Mirroring for ADF Mode
[A]
B039D404.WMF
When making copies using the ADF, the magnification circuit creates a mirror image. This is because the scanning start position along the main scan direction in ADF mode is at the opposite corner of platen mode. In platen mode, the original is placed face down on the exposure glass. The main scan start position is at corner [A], and the scanner moves down the page. In ADF mode, the ADF feeds the leading edge of the original to the DF exposure glass. Therefore as mentioned above, the main scan start position will be at the opposite corner. To create the mirror image, the IPU stores each line in LIFO (Last In First Out) memory.
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20 February, 2001
IMAGE PROCESSING
Filtering Overview
There are several software filtering processes for enhancing the desired image qualities of the selected original mode. There are three MTF filters, a smoothing filter, independent dot erase, and line width correction. Each can be used only when certain modes are selected (details below) and are automatically applied. The strength levels for the MTF and smoothing filters are controlled by SP4-925. The levels for independent dot erase and line width correction are controlled by SP4-927 and 4-928, respectively. The MTF filters bring out sharpness. The three MTF filters are Edge, Solid Image and Low ID Line. Independent dot erase removes unwanted dots from the image. Line width correction adjusts the line width.
MTF Filter Adjustment - Edge

In order to determine whether a given dot is part of an edge or not, the IPU checks all surrounding dots (vertical, horizontal, and diagonal). If the IPU determines that the dot is part of an edge, the machine applies the MTF filter for edges, using the value set in SP4-925-001. The higher the setting, the sharper the image. However, this is only used when the customer uses Text 1, Text 2, Photo 1-3, Special 1, Special 2, or Special 5. The default value is 0 for each mode. However the actual strength of 0 differs from mode to mode.
MTF Filter Adjustment - Solid

If the IPU detects that the dot is not part of an edge, the machine applies the MTF filter for solid areas using the value set in SP4-925-002. The higher the setting, the sharper the image. However, this is only used when the customer uses Text 2 or Special 1. The default value is 0 for each mode. However the actual strength of 0 differs from mode to mode.
MTF Filter Adjustment - Low ID Line

The IPU also checks the image density of all dots. If a succession of low-density dots is detected, the machine interprets this as a low ID line and applies the MTF filter for low ID lines, using the value set in SP4-925-003. The higher the setting, the sharper the image. However, this is only used when the customer uses Text 1, Text 2, Photo 2, Special 1, Special 2, or Special 5. The default value is 0 for each mode. However the actual strength of 0 differs from mode to mode.
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IMAGE PROCESSING
20 February, 2001
Smoothing Filter Adjustment

The machine will apply the smoothing filter when the user selects Special 3 or 4 (Dithering), using the value in SP4-925-001. Note that this SP is also used when the machine applies the MTF Filter for Edges (see above). The higher the setting, the sharper the image. The default value is 0 for each mode. However, the actual strength of 0 differs from mode to mode.
Independent Dot Erase

When the user selects Text 1 and 2, Photo 2, and Special 1, 2, and 5 modes, independent dots are detected using a matrix and erased from the image. The detection level can be adjusted with SP4-928. The higher setting, the greater number of dots the machine will erase. The machine erases the dots regardless of their image density. However, note that dots in meshlike images may be mistakenly detected as independent dots.
Line Width Correction

When the user selects Text 1 and 2, Photo 2, Special 1, 2, and 5, the thickness of lines is adjusted using the setting of SP4-927. Note that the default for all modes except Special 2 is OFF. The higher the setting, the thicker the line. However note that Special 2 starts with a thickness value higher than normal line thickness, whereas the others begin at normal line thickness. So even if Special 2 is set to 2, the lines will still come out thicker than normal. Line width correction is done by the IPU (KT-ONE) chip.
ID Gamma () Correction
The machine automatically selects the most appropriate ID gamma correction based on the selected original type and the operation panel ID setting . Except for Special 1 and 2, each original mode has its own ID gamma correction type. Special 2 uses the same type as Text 1, and Special 1 uses the same type as Text 2. In all modes, ID gamma correction can be adjusted with SP4-923.
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20 February, 2001
IMAGE PROCESSING
Gradation Processing Overview

There are three types of gradation processing (listed below). Refer to the Default Image Processing Mode for Each Original Type section for more details on which processes are used for each original mode. Binary picture processing Error diffusion Dithering
Binary Picture Processing

The 6-bit image data is converted into 1-bit data (black and white image data). This is done when the user selects Text 2 or Special 1. The threshold for deciding whether a pixel is black or white cannot be adjusted.
Error Diffusion
Error diffusion reduces the difference in contrast between light and dark areas of a halftone image. Each pixel is corrected using the difference between it and the surrounding pixels. The corrected pixels are compared with an error diffusion matrix. Error diffusion is applied when the user selects Text 1, Photo 1-3 and Special 2 and 5. As the final step in error diffusion, a process called Texture Removal is applied to Text 1, Special 2, and Special 5 by default, but can also be applied to Photo 1-3 by changing the value of SP4-926.
Texture removal uses 64 threshold values in an 8 x 8 matrix. The value of SP4-926 controls the application of Texture Removal for each of the 5 modes listed above. The settings are as follows: 0: The default value for each mode is used. Text 1, Special 2, and Special 5 have a default of 3 (see below) and Photo 1-3 have a default of 1. 1: No removal applied. 2 5: Removal applied at the level specified here. The higher the setting (level), the less clear the image will become (more texture removal).
Dithering
Each pixel is compared with the threshold in a dither matrix. Several matrices are available to bring out half-tone areas in images such as newspaper-type photographs. Dithering is only used for Special 3 and Special 4.
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IMAGE PROCESSING
20 February, 2001
6.5.5 IMB (MEMORY CONTROLLER AND DRAM)

The functions of the these two IMB component devices are as follows: Memory Controller: Compression of the 1-bit image data Image rotation Image data transfer to the DRAM DRAM (16MB): Stores the compressed data Processing area
The data goes to the memory controller after binary picture/grayscale processing. The data is first compressed and then stored in the DRAM. For printing, the data from the DRAM goes back to the memory controller, where it is decompressed and goes through image editing (e.g., image rotation, repeat image). When the 16 and 32 MB memory is installed on the BiCU board, the memory capacity changes as follows: A4 size, Text mode (Number of pages)
A4 6% ITU-T#4 (12% black) 0 MB 0 0 16 MB 71 34 48 (16+32) MB 99 99
NOTE: The amount of standard memory depends on the model: B039: North America (16MB standard), Others (no standard memory). B040, B043: 16MB standard.
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20 February, 2001
IMAGE PROCESSING
6.5.6 VIDEO CONTROL UNIT (VCU)

Fine Character and Image (FCI)
The FCI performs image smoothing. This functions only affects binary picture processed images for certain original modes.
Main Scan Direction
4/4
3/4
2/4
1/4
Fig. A
Sub Scan Direction
Fig. B
Fig. C
B039D454.WMF
Usually, binary picture processing generates jagged edges on characters, as shown in the above illustration. These are reduced using edge smoothing. The FCI changes the laser pulse duration and position for certain pixels. Fig. A shows the four possible pulse durations, and Fig. B shows how the laser pulse can be in one of three positions within the pixel. Fig. C shows an example of how edge smoothing is used. FCI smoothing is only effective when Text 2 or Special 1 is selected. There is no SP adjustment for this.
Printer Gamma Correction

Printer correction corrects the data output from the IPU to the laser diode to account for the characteristics of the engine components (e.g. drum, laser diode, lenses). The machine chooses the most suitable gamma curve for the original type selected by the user. There is no SP adjustment for this.
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LASER EXPOSURE
20 February, 2001
6.6 LASER EXPOSURE

6.6.1 OVERVIEW
[K] [J] [I]
[A] [B] [C] [D]
[E] [H] [G] [F]

B039D101.WMF
[A]: [B]: [C]: [D]: [E]: [F]:
LD unit Synchronization detector lens Double toroidal lens Shield glass OPC drum 1st mirror
[G]: [H]: [I]: [J]: [K]:
2nd mirror F-theta lens Polygon mirror Cylindrical lens Synchronization detector mirror
The LD drive board controls both the laser output and laser synchronization mechanism. The machine cuts off the power supply to the LD drive board if the front or right cover is opened.
6-30
20 February, 2001
LASER EXPOSURE
6.6.2 AUTO POWER CONTROL (APC)
+5VLD 1 M61880 XLDENB Video Data (1 bit) LD
LD
PD
PD
APC_SH
+5VLD
XDETP
Sync Detector
GND
LD Drive Board
B039D013.WMF
The LD driver IC drives the laser diode. To prevent the intensity of the laser beam from changing because of the temperature, the machine monitors the current passing through the laser diode (LD). The machine adjusts the current to the laser diode by comparing it with the reference level from the reference circuit. This auto power control is done just after the machine is turned on and during printing. The laser diode power is adjusted on the production line. NOTE: Do not touch the variable resistors on the LD unit in the field.
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LASER EXPOSURE
20 February, 2001
6.6.3 LD SAFETY SWITCH
Front/Right Cover Safety Switches
REG +5VLD IOB
LDD: LDD Drive Board LD VCC PD
+24V
BiCU
Laser Beam Optical Path
PSU LD Driver IC OPC Drum
B039D906.WMF
To ensure technician and user safety and to prevent the laser beam from inadvertently switching on during servicing, there are safety switches at the front and right covers. When the front cover or the right cover is opened, the power supply to the laser diode is interrupted. The switches are installed on the +24V line coming from the power supply unit, then the +5VLD is generated from the +24V supply after it goes through the interlock switches.
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20 February, 2001
PHOTOCONDUCTOR UNIT (PCU)
6.7 PHOTOCONDUCTOR UNIT (PCU)

6.7.1 OVERVIEW
1 2 3 10 4 9
5 8
6
B039D203.WMF
1. 2. 3. 4. 5.
Cleaning Blade Toner Collection Coil Pick-off Pawl OPC Drum ID Sensor (see note)
6. Development Roller 7. Development Unit 8. Charge Roller 9. Charge Roller Cleaning Brush 10. Quenching Lamp (see note)
NOTE: The ID sensor and quenching lamp are not included in the PCU.
6-33
The PCU consists of the components shown in the above illustration. An organic photoconductor (OPC) drum (diameter: 30 mm) is used in this machine.
PHOTOCONDUCTOR UNIT (PCU)
20 February, 2001
6.7.2 DRIVE
[A]
[C]
[B]
B039D202.WMF
The main motor [A] drives the drum [B] through a series of gears and the drum drive shaft [C]. The main motor assembly includes a drive controller, which outputs a motor lock signal when the rotation speed is out of the specified range.
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20 February, 2001
DRUM CHARGE
6.8 DRUM CHARGE

6.8.1 OVERVIEW
[C] [D]
[A]
[B]
B039D205.WMF
The high voltage supply board gives a negative charge of 1700 V to the drum charge roller through the screw [C] and terminal plate [D]. This voltage can be changed using SP2-001-1.
6-35
This copier uses a drum charge roller to charge the drum. The drum charge roller [A] always contacts the surface of the drum [B] to give it a negative charge of 950 V.
DRUM CHARGE
20 February, 2001
6.8.2 CHARGE ROLLER VOLTAGE CORRECTION

Correction for Environmental Conditions
4.0 cm
+
1.5 cm 2 cm
ID Sensor Pattern
[B]
Sub Scan Direction
[A]
Charge Voltage On Laser Diode Drum Potential Off 950 V 650 V 600 V 350 V 150 V Vsg (4.00 V) Vsdp (3.70 V) 1700 V 1400 V
Development Bias
ID Sensor Output
Vsp (0.50 V)
t
B039D010.WMF
With a drum charge roller system, the voltage transferred from roller to drum varies with the temperature and humidity around the drum charge roller. The higher the temperature or humidity is the higher the applied voltage required. To compensate, the machine uses the ID sensor to measure the effects of current environmental conditions. For this measurement, the process control parameters are balanced so that any small change in drum potential caused by environmental effects is reflected in a change in the amount of toner transferred to the drum. This measurement is made immediately after the ID sensor pattern for toner density control. Immediately after making ID sensor pattern [A], the charge roller voltage stays the same, but the development bias goes up to 600 V; as a result the drum potential is reduced to 650 V. The laser diode is not switched on, and the drum potential is now slightly higher than the development bias, so a very small amount of toner transfers to the drum. The ID sensor measures the density of this pattern [B], and the output voltage is known as Vsdp. This voltage is compared with Vsg (read from the bare drum at the same time).
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20 February, 2001
DRUM CHARGE
If the humidity drops, the drum potential goes up (to a higher ve voltage) even if the charge roller voltage supply stays the same (efficiency of voltage transfer is higher with lower humidity). As a result, less toner is transferred to ID sensor pattern [B]. If the sensor output reaches a certain point, the drum charge voltage will be reduced. To determine whether to change the drum charge roller voltage, the machine compares Vsdp with Vsg. Vsdp/Vsg > 0.95 = Make the drum charge voltage less ve (smaller) by 50 V Vsdp/Vsg < 0.90 = Make the drum charge voltage more ve (larger) by 50 V
6.8.3 ID SENSOR PATTERN PRODUCTION TIMING

The ID sensor pattern is not made every page or every job. It is only made in the following conditions: During warm-up at power on If the machine starts warming up after a certain time (default: 90 minutes) has passed since entering night/off mode or low power mode. The 90-minute interval can be changed using SP2-995.
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DRUM CHARGE
20 February, 2001
6.8.4 DRUM CHARGE ROLLER CLEANING
[A] [B]
B039D201.WMF
Because the drum charge roller [A] always contacts the drum, it gets dirty easily. So, the cleaning brush [B] also contacts the drum charge roller all the time to clean the surface of the drum charge roller.
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20 February, 2001
DEVELOPMENT
6.9 DEVELOPMENT
6.9.1 OVERVIEW
4 1 2
3
B039D301.WMF
The development unit consists of the following parts. 1. Development roller 2. Mixing auger 2 3. TD sensor 4. Mixing auger 1 5. Doctor blade
This machine uses a single-roller development system. Two mixing augers mix the developer. The toner density (TD) sensor and image density (ID) sensor (see the illustration in the PCU section) are used to control the image density on the copy.
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DEVELOPMENT
20 February, 2001
6.9.2 DRIVE
The main motor [A] drives the development roller [B] and mixing augers [C] through a train of gears and the development drive shaft [D]. When the PCU is pushed in, the development drive shaft engages the development roller gear. The development drive gears (except for the gears in the development unit) are helical gears. These gears are quieter than normal gears. [A]
[B]
[D]
[C]
B039D304.WMF
6.9.3 DEVELOPER MIXING

The two mixing augers, [E, F] keep the developer evenly mixed. Mixing auger 2 [E] transports excess developer, scraped off the development roller [G] by the doctor blade [H], towards the front of the machine. Mixing auger 1 [F] returns the excess developer, along with new toner, to the rear of the mixing assembly. Here the developer is reapplied to the development roller. [H] [G] [E]
[F]
[E]
[F]
B039D302.WMF
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20 February, 2001
DEVELOPMENT
6.9.4 DEVELOPMENT BIAS
[B] [A]
B039D303.WMF
This machine uses a negative-positive development system, in which black areas of the latent image are at a low negative charge (about 154 50 V) and white areas are at a high negative charge (about 950 V). To attract negatively charged toner to the black areas of the latent image on the drum, the high voltage supply board applies a bias of 650 volts to the development rollers throughout the image development process. The bias is applied to the development roller shaft [A] through the drive shaft [B]. The development bias voltage (650 V) can be adjusted with SP2-201-1.
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DEVELOPMENT
20 February, 2001
6.9.5 TONER SUPPLY

Toner Bottle Replenishment Mechanism
[E] [F] [G]
[A]
[D]
[B]
[C]
B039D305.WMF
When a toner bottle is placed in the bottle holder unit [A] and the unit is pushed in completely, toner shutter [B] moves against the side [C] of the PCU. When the toner bottle holder lever [D] is put back in the original position, the cap [E] on the toner bottle is pulled away and kept in place by the chuck [F]. The toner supply mechanism transports toner from the bottle to the development unit. The toner bottle has a spiral groove [G] that helps move toner to the development unit. To add a new toner bottle, first lift the toner bottle holder. When this is done, the chuck releases the toner bottle cap into its proper position to prevent toner from scattering. Then, when the bottle holder unit is pulled out to add a new toner bottle, the toner shutter shuts to block the opening as a result of pressure from a spring.
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DEVELOPMENT
Toner Supply Mechanism
[A] [B]
[C]
[E]
B039D508.WMF
[D]
B039D306.WMF
The toner supply motor [A] drives the toner bottle [B] and the mylar blades [C]. First, the toner falls down into the toner bottle holder. The toner supply mylar blades transfer the toner to the slit [D]. When the PCU is installed in the machine, the shutter [E] above the PCU is opened by the toner bottle holder. Then the toner falls down into the development unit through the slit and the shutter.
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DEVELOPMENT
20 February, 2001
6.9.6 TONER DENSITY CONTROL

Overview
There are four modes for controlling toner supply as shown in the following tables, which can be changed with by SP2-921. The factory setting is sensor control 1 mode. Basically, the toner concentration in the developer is controlled using the standard TD sensor voltage (Vts), toner supply reference voltage (Vref), actual TD sensor output voltage (Vt), and ID sensor output data (Vsp/Vsg).
Toner Supply Motor On Time Calculation TD Sensor Output (Vt)
Vt Reference Voltage (Vref) New Vref Vt Reference Voltage Update Vref Update ID Sensor Output (Vsp/Vsg) TD Sensor Initial Setting (Vts)
B039D315.WMF
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20 February, 2001
DEVELOPMENT
The four toner density control modes are as follows.

Mode Toner supply decision Toner control process Sensor control 1 (SP2-921, 0): Normally use this setting only Compare Vt with a reference voltage (Vts or Vref) Toner is supplied to the development unit when Vt is higher than the reference voltage (Vts or Vref). This mode keeps the Vref value for use with the next toner density control. Vts is used for the first toner density control after a new PCU has been installed, until it has been corrected with the ID sensor output. Vref is used after Vts has been corrected with the ID sensor output voltage (corrected during the first toner density control for a new PCU). Varies Performed
Toner supply amount Toner end detection
Mode Toner supply decision Toner control process Toner supply amount Toner end detection
Sensor control 2 (SP2-921, 1): For designers use only; do not use in the field Compare Vt with a reference voltage (Vts) This toner control process is the same as sensor control 1 mode. However, the reference voltage used is always Vts. Varies Performed
Fixed control 2 (SP2-921, 3): Use temporarily if the TD sensor needs to be replaced None Toner is supplied every printed page regardless of Vt. Fixed (SP2-925) Not performed
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Fixed control 1 (SP2-921, 2): For designers use only; do not use in the field Compare Vt with a reference voltage (Vts or Vref) This toner control process is the same as sensor control 1 mode. Fixed (SP2-925) Performed
DEVELOPMENT
20 February, 2001
Toner Density Sensor Initial Setting

The TD sensor initial setting (SP2-214: Developer Initialize) procedure must be done after replacing the developer. During TD sensor initial setting, the TD sensor is set so that the TD sensor output is the value of SP2-926 (default: 2.4 V). This value will be used as the standard reference voltage (Vts) of the TD sensor.
Toner Concentration Measurement

The toner concentration in the developer is detected once every copy cycle. The sensor output voltage (Vt) during the detection cycle is compared with the standard reference voltage (Vts) or the toner supply reference voltage (Vref).
Vsp/Vsg Detection
The ID sensor detects the following voltages. Vsg: The ID sensor output when checking the drum surface Vsp: The ID sensor output when checking the ID sensor pattern In this way, the reflectivity of both the drum surface and the pattern on the drum are checked, compensating for any variations in the reflectivity of the pattern on the drum or the reflectivity of the drum surface. The ID sensor pattern is made on the drum by the charge roller and laser diode. Vsp/Vsg is not detected every page or job; it is detected at the following times to decide Vref. During warm-up at power on If the machine starts warming up after a certain time (default: 90 minutes) has passed since entering night mode or low power mode The 90-minute interval can be changed using SP2-995.
Toner Supply Reference Voltage (Vref) Determination

The toner supply reference voltage (Vref) is used for toner supply determination (see below). Vref is determined using the following data: ID sensor output (Vsp/Vsg) (Vts or the current Vref) - Vt
Toner Supply Determination

The reference voltage (Vts or Vref) is the threshold voltage for determining whether or not to supply toner. If Vt becomes greater than the reference voltage, the machine supplies additional toner. This can be checked using SP2-220.
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DEVELOPMENT
Toner Supply Motor On Time Determinations

For fixed control mode, the toner supply motor on time is specified by the setting of SP2-925, and does not vary. The default setting is 200 ms for each copy. The toner supply motor on time for each value of SP2-925 is as follows.
Value of SP2-925 0 1 2 3 4 5 6 7 Motor On Time (t = 200 ms) t 2t 4t 8t 12t 16t Continuously Not supplied
For sensor control modes 1 and 2, the toner supply motor on time is decided by the following factors. Vt Vref or Vts TD sensor sensitivity (coefficient: S, value is 0.4) There are seven levels for toner supply motor on time as shown below.
Level 1 2 3 4 5 6 7 Decision (Vts or Vref) < Vt (Vts or Vref) + S/16 (Vts or Vref) < Vt (Vts or Vref) + S/8 (Vts or Vref) < Vt (Vts or Vref) + S/4 (Vts or Vref) < Vt (Vts or Vref) + S/2 (Vts or Vref) < Vt (Vts or Vref) + 4S/5 Vt (Vts or Vref) + 4S/16 (near-end) Vt (Vts or Vref) + S (toner end) Motor On Time (seconds) t (0.4) t x 2 (0.8) t x 4 (1.6) t x 8 (3.2) t x 16 (6.4) T (30); see note 3 T (30); see note 3
NOTE: 1) The value of t can be changed using SP2-922 (default: 0.4 second) 2) The value of T can be changed using SP2-923 (default: 30 seconds) 3) T (30) means that toner is supplied intermittently in a 1/3 duty cycle (1 s on, 2 s off) for 30 seconds
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DEVELOPMENT
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6.9.7 TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS

ID Sensor
Readings are abnormal if any of the following conditions occur: Vsg 2.5V Vsg < 3.5V when maximum power (979) is applied Vsp 2.5V (Vsg Vsp) < 1.0V Vt 4.5V or Vt 0.2V The above ID sensor values can be checked using SP2-221. When this is detected, the machine changes the value of Vref to 2.5 V then does the toner density control process (in a similar way to sensor control mode 2). No SC code is generated if the ID sensor is defective.
TD Sensor
The TD sensor output is checked every copy. If the readings from the TD sensor become abnormal, the machine changes the toner density control mode to fixed supply mode 2, and the toner supply amount per page is always 200 ms, regardless of the value of SP2-925. If the machine detects the TD sensor error condition 10 times consecutively, an SC code is generated (SC390) and the machine must be repaired.
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DEVELOPMENT
6.9.8 TONER NEAR END/END DETECTION AND RECOVERY

The toner near end and end conditions are detected using the Vt and Vref values, in a similar way to toner density control. This is done in all toner supply modes except for fixed mode 2, when toner end is not detected.
Toner Near End Detection

If Vt is at level 6 (see the table on the previous page) five times consecutively, the machine enters the toner near end condition and the toner end indicator starts blinking. Then the machine supplies toner for a certain time, which depends on the setting of SP2-923 (see the previous page).
Toner Near End Recovery

If the machine detects Vt < (Vref or Vts) + 4S/5 twice consecutively in any of the following situations, the machine clears the toner near end condition. While in the toner recovery cycle (supplying toner on and off for 30 ssee the previous page) after the machine has detected a toner near end condition. During copying in the toner near end condition. If the front cover is opened and closed for more than 10 seconds while a toner near end condition exists.
Toner End Detection

There are two situations for entering the toner end condition. When Vt is level 7 three times consecutively, the machine enters the toner end condition. When 50 copies have been made since entering the toner near end condition. The number of copies between toner near-end and toner end can be changed using SP2-213.
Toner End Recovery

While turning on the main switch, if the front cover is opened for 10 seconds or more and then closed while a Toner End condition exists (following toner bottle replacement), the machine clears the Toner End condition. The recovery procedure is the same as for toner near end. It takes about two minutes.
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DRUM CLEANING AND TONER RECYCLING
20 February, 2001
6.10 DRUM CLEANING AND TONER RECYCLING

6.10.1 DRUM CLEANING
The cleaning blade [A] removes any toner remaining on the drum after the image is transferred to the paper. This model uses a counter blade system. The cleaning blade scrapes off toner remaining on the drum. When toner builds up in the cleaning unit, toner at the top of the pile is removed by the toner collection coil [B]. To remove the toner and other particles that are accumulated at the edge of the cleaning blade, the drum turns in reverse for about 5 mm at the end of every copy job.
B039D203.WMF
[A]
[B]
6.10.2 TONER RECYCLING

Toner picked up by the toner collection coil [A], is transported to the opening [B] in the side of the PCU. Then, this toner falls into the development unit with new toner coming from the toner bottle and it is all mixed together by mixing auger 1 [C] and used again. [B] [A]
B039D204.WMF
[A]
[C]
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[B]
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20 February, 2001
PAPER FEED
6.11 PAPER FEED

6.11.1 OVERVIEW
5 6 7 8
B039D701.WMF
There are one or two paper trays, each of which can hold 250 sheets.
The paper tray feed stations use a friction pad system. To prevent paper from getting caught inside the machine when the tray is pulled out, the paper feed roller and shaft do not separate from the tray when the tray is pulled out. The two relay sensors are used for paper jam detection. The lower one detects jams when paper is fed up from the optional paper feed unit. The components of the paper feed station are as follows. 1. 2. 3. 4. Paper End Sensor Paper Feed Roller Registration Roller Paper Size Switch 5. 6. 7. 8. Upper Relay Roller Upper Relay Sensor Lower Relay Sensor Friction Pad
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6.11.2 PAPER FEED DRIVE MECHANISM

The main motor [A] drives the pick-up and feed mechanism of both the first and second paper trays. The paper feed clutches [B] transfer drive from this motor to the paper feed rollers [C]. When the paper feed clutch turns on, the feed roller starts to feed the paper. The paper feed clutch stays on until shortly after the registration sensor has been activated. [B] [A]
[C]
B039D707.WMF
6.11.3 PAPER FEED AND SEPARATION MECHANISM

The paper feed roller [A] drives the top sheet of paper from the paper tray to the copier. The friction pad [B] allows only one sheet to feed at a time. The friction pad applies pressure to the feed roller with a spring [C]. The friction pad pressure cannot be adjusted. [C]
B039D702.WMF
[A] [B]
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PAPER FEED
6.11.4 PAPER LIFT MECHANISM

When the paper tray [A] is closed, projection [B] on the copier frame pushes slider [C] (on the bottom part of the paper tray) off the bottom plate hook [D]. After the release slide comes off, compressed springs lift the bottom plate. [D]
[C] [B]
[A]
B039D703.WMF
6.11.5 PAPER END DETECTION

If there is any paper in the paper tray, the paper stack lifts the feeler, the paper end sensor [A] is deactivated. When the paper tray runs out of paper, the paper end feeler drops into the cutout [B] in the tray bottom plate and the paper end sensor is activated. When the paper tray is drawn out with no paper in the tray, the shape of the paper end feeler causes it to lift up.
B039D706.WMF
[A]
[B]
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PAPER FEED
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6.11.6 PAPER SIZE DETECTION

Paper Tray
SW Size A3, 11" x 17" A4 LEF A4 SEF, 81/2" x 11" A5 LEF, 81/2" x 14" 81/2" x 13" 11" x 81/2" * (Asterisk)
1
# #
2
#
3
# #
[A] [B]
B039D704.WMF
#: ON (Not pushed)
: OFF (Pushed)
There are three paper size microswitches [A] on the front right plate of the paper tray unit. The switches are actuated by a paper size actuator [B] behind the paper size indicator plate, which is on the front right of the tray. Each paper size has its own actuator, with a unique combination of notches. To determine which size has been installed, the CPU reads which microswitches the actuator has switched off. The CPU disables paper feed from a tray if the paper size cannot be detected. If the paper size actuator is broken, or if there is no tray installed, the Add Paper indicator will light. When the paper size actuator is at the * mark, the paper tray can be set up to accommodate one of a wider range of paper sizes by using User Tools. If the paper size for this position is changed without changing the User Tool setting, a paper jam will result.
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20 February, 2001
PAPER FEED
By-pass Tray
[A]
B039D710.WMF
The by-pass feed paper size switch [A] monitors the paper width. The side fence is connected to the terminal plate gear. When the side fences move to match the paper width, the circular terminal plate rotates over the wiring patterns on the rectangular part of the paper size switch. The patterns for each paper width in the paper size switch are unique.
North America
CN No. (IOB) CN311-1 CN311-2 CN311-3 (GND) CN311-4 CN311-5 11" x 17" ON/OFF OFF OFF OFF ON 81/2" x 11" OFF OFF OFF ON ON 51/2" x 81/2" OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF
Europe/Asia
CN No. (IOB) CN311-1 CN311-2 CN311-3 (GND) CN311-4 CN311-5 A3 ON/OFF OFF OFF OFF ON A4 SEF OFF OFF OFF ON ON 8" x 13" OFF OFF OFF ON OFF A5 SEF OFF ON/OFF OFF OFF OFF
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PAPER FEED
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6.11.7 SIDE FENCES

If the tray is full of paper and it is pushed in strongly, the fences may deform or bend. This may cause the paper to skew or the side-to-side registration to be incorrect. To correct this, each side fence has a stopper [A] attached to it. Each side fence can be secured with a screw, for customers who do not want to change the paper size. [A]
B039D705.WMF
6.11.8 PAPER REGISTRATION

The drive from the main motor [A] is transmitted to the registration roller through the registration clutch gear [B]. The registration sensor [C] is used for correcting paper skew and for detecting paper misfeeds. The cleaning mylar [D] contacts the registration roller. It removes paper dust from the registration roller so that this dust will not transfer into the development unit through the drum cleaning unit. The amount of paper buckle at the registration roller to correct skew can be adjusted with SP1-003. [D] [A]
[B]
[C]
B039D709.WMF
If jams frequently occur after registration, SP1-903 can be used to activate the relay clutch so that the relay roller assists the registration roller in feeding the paper along. When feeding from the by-pass tray, the by-pass feed clutch is activated, turning the by-pass feed roller. This feature may be needed when feeding thick paper, and cannot be used for the first paper feed tray.
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IMAGE TRANSFER AND PAPER SEPARATION
6.12 IMAGE TRANSFER AND PAPER SEPARATION

6.12.1 OVERVIEW
[B]
[C] [A]
[C]
[A]
B039D307.WMF B039D401.WMF
[D]
B039D308.WMF
The transfer roller [A] touches the surface of the drum [B]. The high voltage supply board supplies a positive current to the transfer roller, which attracts the toner from the drum onto the paper. The current depends on the paper width, paper type, and paper feed tray. The curvature of the drum and the discharge plate [C] help the paper to separate from the drum. The discharge plate is grounded. Drive from the drum through a gear [D] turns the transfer roller.
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6.12.2 IMAGE TRANSFER CURRENT TIMING

There are two transfer current levels: low and high. The image transfer procedure is as follows: 1. When the CPU receives the image writing start signal, the CPU instructs the high voltage supply board to supply +10A (low transfer current level) to the roller. This prevents any positively charged toner on the drum surface from transferring to the transfer roller. 2. At a certain time after the low transfer current has been supplied to the roller, high transfer current is applied to the roller to transfer the toner to the paper (see the table below). 3. After the trailing edge of the paper has passed through the roller, transfer current turns off. In multiple copy mode, the transfer current shifts again to the low transfer current. The high transfer current levels (default) are as shown in the following table. With SP2-301, the high transfer current level used for the paper feed trays, duplex tray, by-pass tray, and cleaning an be adjusted.
Paper Size A3/A4 LEF 11" x 17" B4/B5 LEF 81/2" x 11" A4 SEF B5 SEF A5/A6/B6/51/2" x 81/2" SEF Paper Tray/ By-pass Tray (Normal) 11 A 16 A 11 A 15 A 13 A 17 A 17 A By-pass Tray (Thick/OHP) 10 A 11 A 11 A 15 A 19 A 20 A 20 A By-pass Tray (Special/ Envelope) 12 A 13 A 13 A 13 A 25 A 25 A 25 A Duplex (2nd Side) 9 A 11 A 16 A 17 A 19 A 20 A 25 A
Be careful when increasing the transfer current. This may cause a ghosting effect, in which part of the image at the top of the page is repeated lower down the page at a lower density. In the worst case, it may also damage the OPC drum.
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6.12.3 TRANSFER ROLLER CLEANING

If the paper size is smaller than the image, or if a paper jam occurs during printing, toner may be transferred to the roller surface. To prevent the toner from transferring to the back side of the printouts, the transfer roller requires cleaning before the next printing run. During transfer roller cleaning, the high voltage supply unit supplies a negative cleaning voltage (about 1 kV) to the transfer roller. Any negatively charged toner on the transfer roller is then transferred back to the drum. Then a positive cleaning current (+10 A) is applied to the transfer roller to push back to the drum any positively charged toner on the transfer roller. The machine goes through the cleaning mode in the following conditions: Before starting the printing job (only if enabled with SP2-996; note that the default setting is off) Just after the power is switched on. After a copy jam has been cleared After 10 or more sheets of paper have been copied and the copy job has finished. Also, the transfer roller cleaning current can be adjusted using SP2-301-4.
6.12.4 PAPER SEPARATION MECHANISM

[A]
B039D307.WMF B039D401.WMF
The discharge plate [A] and the drum curvature of the drum help the paper to separate away from the drum. The discharge plate is grounded.
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IMAGE FUSING AND PAPER EXIT
20 February, 2001
6.13 IMAGE FUSING AND PAPER EXIT

6.13.1 OVERVIEW
The fusing unit and paper exit area consist of the following parts. 1. Paper exit roller 2. Exit sensor 3. Hot roller strippers 4. Pressure roller 5. Pressure spring 6. Fusing lamp 7. Thermistor 8. Hot roller 9. Thermofuse 10. Thermostat 1 2 3 4 10 9 8
B039D501.WMF
6.13.2 FUSING DRIVE AND RELEASE MECHANISM

The main motor [A] drives the fusing unit through a gear train and drives the paper exit rollers [B] through a timing belt [C]. The fusing unit release mechanism automatically disengages the fusing unit drive gear [D] when the right cover [E] is opened. This allows the fusing unit drive gear to rotate freely so that misfed paper can easily be removed. [C] [B] [A] [D]
[E]
B039D554.WMF
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20 February, 2001
6.13.3 FUSING ENTRANCE GUIDE SHIFT

The entrance guide [A] is adjustable for paper thickness to prevent creasing. The outer screw holes [B] on each side are used as the default setting. If creasing occurs frequently in the fusing unit, adjust the entrance guide to the right, by securing it with the inner holes [C]. This allows more direct access to the gap between the hot roller and the pressure roller. [A] [C]
[B]
[B]
B039D505.WMF
6.13.4 PRESSURE ROLLER

The pressure springs [A] constantly apply pressure between the hot roller [B] and the pressure roller [C]. Applied pressure can be changed by adjusting the position of the pressure springs. The spring is positioned at the end [D] as the default setting. [B]
[C]
[A]
[D]
B039D552.WMF
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6.13.5 FUSING TEMPERATURE CONTROL

Overview
[A]
B039D506.WMF
The fusing temperature is controlled using the fusing thermistor [A]. The CPU checks the output from the fusing thermistor once a second. The CPU compares the current and previous temperature, then decides the power-on ratio for the next second. To maintain the target temperature, the CPU controls the fusing lamp power-on ratio as shown in the following table (the temperature control algorithm only works with whole numbers). The fusing lamp works to maintain a target fusing temperature of 175C during copying.
Initializing
Sampling cycle: 1 second Soft start setting: 3 cycles
3C or less 100% 100% 100% 100% 100% Current minus Target 2C or +1C or 0C 1C +2C 50% 0% 0% 50% 0% 0% 50% 0% 0% 50% 0% 0% 50% 0% 0% +3C or more 0% 0% 0% 0% 0%
Previous minus Current 3C or less From 2C to 1C 0C From +1C to +2C +3C or more
Ratio (%): The proportion of time that the fusing lamp power is on
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Copying (North America Model)

Previous minus Current -3C or less From 2C to 1C 0C From +1C to +2C +3C or more
Copying (Europe Model)

Previous minus Current 3C or less From 2C to 1C 0C From +1C to +2C +3C or more 3C or less 100% 100% 100% 100% 100% Current minus Target 2C or +1C or 0C 1C +2C 100% 100% 0% 100% 100% 0% 100% 100% 0% 100% 100% 100% 100% 100% 100% +3C or more 0% 0% 0% 0% 0%
Standby
Sampling cycle: 1 second Soft start setting: 3 cycles (Europe model: 20 cycles)
Previous minus Current 3C or less From 2C to 1C 0C From +1C to +2C +3C or more
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20 February, 2001
Fusing Lamp Control

Turning on and off the fusing lamp power causes fluorescent light in the room to flicker. To reduce the flickering, use the following SP modes. Fusing temperature detection cycle (SP1-108) The CPU checks the output from the fusing thermistor once a second (default setting). The CPU compares the current and previous temperatures. Based on the result, it then decides how long the fusing lamp power should be on during the next one-second interval (also, if the current temperature is too high, the power will not be needed). Starting and stopping the fusing lamp power every second causes fluorescent lighting in the room to flicker. To reduce this flickering, use SP1-108 to change the cycle from 1 second to 3 seconds. Fusing soft-start (SP1-107) In addition, whenever the fusing lamp power switches on, full power is applied to the fusing lamp gradually, not all at once. This prevents the power in the room from dropping suddenly. This feature is known as Soft Start. The machine does this by gradually allowing more power to the fusing lamp over a number of zero-cross cycles of the ac supply. The diagram below shows full power being applied gradually over the duration of 3 zero-cross cycles. With SP1-107, this number can be set to 3, 10, or 20. Soft start occurs every time the fusing lamp power switches on (i.e., at some time during every second), not just at the start of the print job. NOTE: This SP mode is effective to counter flickering lights. However, generated noise increases if the setting is changed from the default. If a radio or a TV is close by the machine, the noise may have some effect on the image or sound.
B039D412.WMF
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20 February, 2001
Fusing Temperature Control for Thick Paper at the By-pass Tray

When thick paper mode is selected, the machine changes the target fusing temperature from 175C to 185C. When the by-pass tray is selected, the machine detects that the paper is thick. This setting can be changed with SP5-952.
Pre-heat Mode (Fusing Idling)

When the machine is powered on, or the front or right door is closed, the hot roller turns for 6 seconds. If the SP1-103 setting is 1 (Yes), when the fusing thermistor detects a temperature lower than 100C, the hot roller turns for 30 seconds (instead of for just 10 s) after the machine is powered on, or the right door is closed. This maintains conditions for fusing copies made on thick paper during cold weather conditions.
To Prevent Offset when Making Multiple Copies on Small-width Paper

This prevents the temperature at the ends of the hot roller from being higher than at the center. If the smallest copy paper width detected during a 40 seconds interval is less than 220 mm, the machine lowers the target fusing temperature by 10C. Then, during the next 80 seconds, if the smallest width detected is less than 220 mm again, the machine lowers the target temperature by another 5C.
Reduced Copy Speed with Narrow Paper

To ensure that images are properly fused onto paper 220 mm or less in width, the machine automatically reduces the copy speed under the following conditions: After 180 seconds of continuous copying When Thick or Special paper mode is used Paper is fed from the by-pass tray
Paper Size 81/2" x 11" SEF (216 x 279) 81/2" x 13" (216 x 356) A4 SEF (210 x 297) A5 LEF (210 x 148) B5 SEF (182 x 257) A5 SEF (148 x 210) 51/2" x 81/2" SEF (140 x 216) A6 SEF (105 x 148) Copy Speed Until 180 s 14 12 14 20.5 16 18 18 18 Copy Speed From 180 s 9.3 8.4 9.3 11.9 10.2 11 11 11
Copy speed is measured in copies/minute.
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6.13.6 OVERHEAT PROTECTION

If the hot roller temperature becomes greater than 230C for more than 1 second, the CPU cuts off the power to the fusing lamp. At this time, the LCD will display SC543. Even if the thermistor overheat protection fails, there is a thermostat in series with the common ground line of the fusing lamp. If the temperature of the thermostat reaches 180C, the thermostat opens, cutting the power to the fusing lamp, and printing stops. At the same time, SC544 or 546 is generated. After resetting the SC, when turning on the main switch, SC541 will appear. There is also a thermofuse to ensure overheat protection. If the temperature of the thermofuse reaches 172C, the thermofuse opens, cutting the power to the fusing lamp. The thermofuse is farther from the hot roller than the thermostat, so it opens later than the thermostat.
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DUPLEX UNIT
6.14 DUPLEX UNIT

6.14.1 OVERALL
8 1 2
3 7 4
B039D901.WMF
If the user selects duplex mode, the page is directed to the inverter tray, then reversed through the duplex unit, and back into the machine for printing the second side. 1. 2. 3. 4. Duplex Inverter Sensor Duplex Entrance Sensor Upper Transport Roller Middle Transport Roller 5. 6. 7. 8. Duplex Exit Sensor Lower Transport Roller Junction Gate Duplex Inverter Roller
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The printed page from the fusing unit goes straight through to the exit tray, or upward to the inverter section, depending on the position of the junction gate.
DUPLEX UNIT
20 February, 2001
6.14.2 DRIVE MECHANISM
1 2
5 6
B039D802.WMF
1. Duplex Inverter Roller 2. Duplex Inverter Motor 3. Upper Transport Roller
4. Duplex Transport Motor 5. Lower Transport Roller 6. Middle Transport Roller
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DUPLEX UNIT
6.14.3 BASIC OPERATION

To increase the productivity of the duplex unit, copies are printed as follows.
Larger than A4 Short-edge/LT Short-edge The paper feed path can hold only one sheet of copy paper at a time.
Example: 8 pages. The number [A] in the illustration shows the order of pages. The number [B] in the illustration shows the order of sheets of copy paper (if black, this indicates the second side).
2
1
&
'
B039D563.WMF
B039D560.WMF
6-69
DUPLEX UNIT
20 February, 2001
Up to A4 Short-edge/LT Short-edge
The paper feed path can hold two sheets of copy paper. Example: 8 pages. The number [A] in the illustration shows the order of pages. The number [B] in the illustration shows the order of sheets of copy paper (if black, this indicates the second side).
2
1
&
'
B039D562.WMF
B039D561.WMF
6-70
20 February, 2001
DUPLEX UNIT
6.14.4 FEED IN AND EXIT MECHANISM
[A]
[D]
B039D903.WMF
[C]
[B]
B039D902.WMF
During duplex copying, the inverter gate solenoid [A] switches on and the junction gate [B] switches over to direct the paper to the inverter. When the paper trailing edge reaches the duplex inverter sensor [C], the inverter roller [D] reverses its rotation direction and the paper goes to the duplex unit. The paper is then sent to the mainframe registration rollers to print the reverse side. If there are two or more copies being made with A4/81/2" x 11" SEF (or smaller), the next sheet waits at the registration sensor for the current sheet to exit the inverter.
6-71
ENERGY SAVER MODES
20 February, 2001
6.15 ENERGY SAVER MODES

6.15.1 OVERVIEW
System Reset Timer (UP: System 3-2) The machine returns to the preferred application mode (fax, printer, copier) that was selected with UP 2-1. Preferential Application (UP2-1) - Energy Saver Timer (UP: System 4) - Default: 15 min (NA), 1 min (Others) - Operation switch on - Off signal from PC
Low Power Mode

- Operation switch is pressed - An original is placed in the ADF - The platen cover or ADF is lifted - The machine receives a wakeup signal from a PC (Smart Net Monitor) - An error or SC condition occurs (Auto Off Timer) - (Energy Saver Timer)
Stand-by Mode
Auto Off Timer (UP: System 6) Defaul: 30 min
Preferential Application (UP2-1)
- Operation switch is pressed - An original is placed in the ADF - The platen cover or ADF is lifted - The machine receives a wakeup signal from a PC (Smart Net Monitor) - An error or SC condition occurs
Night/Off Mode
- Main Power Switch Off
If there is no fax or printer option, the main power switch is turned off immediately.
Main Power Off
Preferential Application (UP2-1)
- Main Power Switch On
B039D011.WMF
When the machine is not used, the energy saver function reduces power consumption by lowering the fusing temperature. This machine has two types of energy saver modes: 1) Low power mode 2) Night/off mode These modes are controlled by the following User Tools. Energy saver timer (Low power timer) Auto off timer Energy saver level Auto off disabling The way that the machine operates depends on the combination of equipment installed (i.e. copier only, fax and/or printer installed).
6-72
20 February, 2001
ENERGY SAVER MODES
6.15.2 LOW POWER MODE

Entering Low Power Mode
The machine enters low power mode when: The energy saver timer has expired following the last time engine components or sensors were active (e.g. end of a copy job, platen cover lifted, key pressed, etc). User Tools - System Settings - Energy Saver Timer The default setting is 15 min (NA), 1 min (Other) If the energy saver timer setting is longer than the auto off timer setting, the machine will not enter low power mode. It will enter night/off mode instead, when the auto off timer runs out after the end of the job.
What Happens in Low Power Mode

There are three low power modes: Low power mode level 1, 2, and 3. The user can select the level with a User Tool (System SettingsEnergy Saver Level).
Mode Low Power Mode Level 1 Low Power Mode Level 2 Low Power Mode Level 3 Operation Switch Off Off Off Fusing Temp. 105 C 60 C Room Temp. (Fusing lamp off) Approx. Recovery Time 10 s (NA) 12 s (Other) 15 s (NA) 18 s (Other) 20 s (N. America) 25 s (other) System +5V On On On
When the machine enters low power mode, the fusing lamp drops to a certain temperature and the operation panel indicators are turned off except for the main power LED. If the CPU receives the image print out command from an application (e.g. to print incoming fax data or to print data from a PC), the fusing temperature rises to print the data. However, the operation panel indicators stay off. The fusing temperature for level 2 low power mode can be changed with SP1-105 (the default setting is 60C).
6-73
NOTE: When there a fax or printer option is installed, low power mode level 3 is the same as night/off mode ( 6.15.3 Night/Off Mode). However, when no fax or printer is installed, power switches off in night/off mode (but not in low power mode).
ENERGY SAVER MODES
20 February, 2001
Returning to Stand-by Mode

If one of the following is done, the machine returns to standby mode: Operation switch is pressed An original is placed in the ADF The platen cover or ADF is lifted The machine receives the wake-up signal from a PC (Smart Net Monitor) An error or SC condition occurs
6.15.3 NIGHT/OFF MODE

The machines behaviour depends on whether a fax or printer option has been installed. If no optional fax and/or printer unit is installed, the main power switches off when the machine enters night/off mode. (This is the same as the Auto Off Mode used in previous models). If an optional fax and/or printer unit is installed, the main power does not switch off when the machine enters night/off mode. The machine enters a watching mode that is the same as low power mode level 3.
Entering Night/off Mode

The machine enters night/off mode when: The auto off timer has expired following the last time engine components or sensors were active (e.g. end of a copy job, platen cover lifted, key pressed, etc). User ToolsSystem SettingsAuto Off Timer The default setting is 30 min If the energy saver timer setting is greater than the auto off timer setting, the machine will enter night/off mode (rather than low power mode) when the auto off timer runs out after the end of the job.
6-74
20 February, 2001
ENERGY SAVER MODES
What Happens in Night/off Mode

When the machine enters night/off mode, the fusing lamp and the operation panel indicators are turned off except for the main power LED. If there is no fax or printer option, the main power switch is turned off immediately (this is the same as the Auto Off Mode in previous models).
Returning to Stand-by Mode

When no fax or printer option is installed, the main power switch must be turned on. When a fax and/or printer option is installed, the machine returns to stand-by mode in the same way as from the low power mode. The recovery time is about 20 s (NA/TWN) or 25 s (EU/ASIA).
Operation Switch Off Off Approx. Recovery Time 20 s (N. America) 25 s (other) 20 s (N. America) 25 s (other)
Mode With not fax/printer With fax/printer option
Fusing Temp. Room Temp. (Fusing lamp off) Room Temp. (Fusing lamp off)
System +5V Off On
6-75
20 February, 2001
SPECIFICATIONS
SPECIFICATIONS
1. GENERAL SPECIFICATIONS
Configuration: Copy Process: Originals: Original Size: Copy Paper Size: Desktop Dry electrostatic transfer system Sheet/Book Maximum A3/11" x 17" Maximum A3/11" x 17" Minimum A5 LEF/81/2" x 51/2" (Paper tray) A6 SEF/51/2" x 81/2" (Bypass) Custom sizes in the bypass tray: Width: 90 305 mm (3.5" 12.0") Length: 148 1,260 mm (5.8" 49.6") Paper Tray: 60 90 g/m2, 16 24 lb. Bypass: 52 162 g/m2, 14 43 lb. 3 enlargement and 4 reduction
A4/A3 Version 200% 141% 122% 100% 93% 82% 71% 50% LT/DLT Version 155% 129% 121% 100% 93% 78% 65% 50%
Copy Paper Weight:
Reproduction Ratios:
Enlargement Full Size Reduction
Zoom: Power Source:
50% to 200%, in 1% steps Taiwan 110 V, 50/60 Hz 12 A America 120 V, 50/60 Hz 12 A Europe, Asia 220 240 V, 50/60 Hz 7A
SPEC-1
Spec.
SPECIFICATIONS
20 February, 2001
Power Consumption:
Mainframe Only 120 V 220 ~ 240 V Maximum Copying Warm-up Standby Low Power Level 1 Low Power Level 2 Night/Off
Not above 1.1 kW Not above 480 W Not above 880 W Not above 125 W Not above 70 W Not above 40 W Not above 1W Not above 1.0 kW Not above 480 W Not above 780 W Not above 125 W Not above 70 W Not above 40 W Not above 1W
Full System 120 V 220 ~ 240 V

Not above 1.2 kW Not above 480 W Not above 890 W Not above 125 W Not above 80 W Not above 50 W N/A Not above 1.2 kW Not above 480 W Not above 790 W Not above 125 W Not above 80 W Not above 50 W N/A
NOTE: Full system - Maximum possible power consumption (any combination of mainframe and options), excluding optional heaters, key counter, fax unit, and printer controller. Noise Emission
Standby (Mainframe/Full system): Operating (Mainframe only): Operating (Full System): Sound Power Level Not above 39.6 dB(A) Not above 60.1 dB(A) Not above 62.9 dB(A) Sound Pressure Level Not above 28.2 dB(A) Not above 51.2 dB(A) Not above 53.6 dB(A)
NOTE: The above measurements were made in accordance with ISO 7779. Measurements were taken from the normal position of the operator. Dimensions (W x D x H) B039: 550 x 568 x 420 mm (21.7" x 22.4" x 16.5") B040: 550 x 568 x 518 mm (21.7" x 22.4" x 20.4") B043: 587 x 568 x 518 mm (23.1" x 22.4" x 20.4") NOTE: Measurement Conditions 1) With bypass feed table closed 2) Without the A(R)DF Weight B039: 35 kg (77 lb.) B040: 42 kg (92 lb.) B043: 45 kg (99 lb.) (Excluding A(R)DF, platen cover, toner, and developer)
SPEC-2
20 February, 2001
SPECIFICATIONS
Copying Speed in Multicopy Mode (copies/minute):

A4 LEF/ 11" x 81/2" Non-memory copy mode B039: Memory copy mode B039*: B040/B043: DF 1-to-1 B039*: B040/B043: 1-sided 2-sided 2-sided 2-sided B043: DF 1-to-1 (1-sided to 2-sided) B043: DF 1-to-1 (2-sided to 2-sided) B043: 15 15 18 15 15 B4 / 81/2" x 14" 9 10 12 10 10 A3 / 11" 17" 8 9 10 8 9
15
6 6
5 4
4 4
*Requires 16MB base memory, which is optional on all B039 models outside North America, and standard on all other models.
NOTE: Measurement Conditions: 1) Figures are for one-sided original to one-sided copy except where stated otherwise 2) Not APS mode 3) 100% size Warm-up Time: First Copy Time: NA models: Less than 20 seconds (at 20C [68F]) Others: Less than 25 seconds (at 20C [68F]) Not more than 6.9 seconds NOTE: Measurement Conditions 1) From the ready state, with the polygonal mirror motor spinning. 2) A4/LT copying 3) Not APS mode 4) 100%size 5) Paper feed from the upper tray Numeric keypad, 1 to 99 (increment, decrement) 5 steps Default is 60 seconds. Can be set from 10 to 999 seconds with user tools. Default is 30 minutes. Can be set from 1 to 240 minutes with user tools.
Manual Image Density: Automatic Reset: Automatic Shut-off:
SPEC-3
Spec.
Copy Number Input:
SPECIFICATIONS
20 February, 2001
Copy Paper Capacity:
Paper Tray: 250 sheets (B039) 250 sheets x 2 (B040/B043) Optional Paper Tray Unit: 500 sheets x 1, or 500 sheets x 2 Bypass Tray: 100 sheets (sheets up to 432 mm [17"] ) 10 sheets (sheets longer than 432 mm [17"]) 40 postcards 10 envelopes NOTE: Copy weight: 80 g/m2 (20 lb.)
Toner Replenishment: Optional Equipment:
Cartridge replacement (260 g/cartridge) Platen cover Auto document feeder Auto-reverse document feeder Paper tray unit (1 tray) Paper tray unit (2 trays) Tray heater Optics anti-condensation heater
Toner Yield: Copy-Tray Capacity Memory Capacity B039 (outside North America):
9k copies (A4 LEF, 6% full black, 1 to 2 copying, normal text mode) 250 sheets 0 standard; 16MB (IMB) and 32MB DIMM as options (max. 48MB) [Since the DIMM installs onto the IMB, the DIMM option requires the presence of the IMB option.]
B039 (North America), 16MB IMB standard; 32MB DIMM as option (max. 48MB) B040, B043
Duplex Unit (B043 only)

Copy Paper Size: Maximum A3/11" x 17" Minimum A5/81/2" x 11" 64 90 g/m2 (20 24 lb.)
Copy Paper Weight:
SPEC-4
20 February, 2001
SPECIFICATIONS
2. MACHINE CONFIGURATION
B039V501.WMF
Version Copier
Item Copier (1-tray model) Copier (2-tray non-duplex model) Copier (2-tray with duplex) Platen Cover (optional) ADF (optional) ARDF (optional) Paper Tray Unit 1 tray (optional) Paper Tray Unit 2 trays (optional) 16MB IMB memory board (for B039 models outside North America only [all other models include this as standard]) 32MB Memory (optional) Tray Heater (optional) Optics Anti-condensation Heater (optional) Fax Controller (optional) Handset (optional) Printer Controller (optional) NIB (optional) 32MB Memory (optional) 64MB Memory (optional) 128MB Memory (optional) PS2 (optional)
Machine Code B039 B040 B043 B406 B387 B379 B385 B384 B407 G578 B404 B433 B405 B430 G578 G579 G580 B431
Letter. C C C B B D D
Fax Unit Printer
A
Spec.
SPEC-5
SPECIFICATIONS
20 February, 2001
3. OPTIONAL EQUIPMENT
ARDF
Original Size: Standard sizes Single-sided mode: A3 to A5, 11" x 17" to 51/2" x 81/2" Double-sided mode: A3 to A5, 11" x 17" to 51/2" x 81/2" Non-standard sizes (Single-sided mode only) Max. width 297 mm Min. width 105 mm Max. length 1260 mm Min. length 128 mm Single-sided mode: 40 28 g/m2,10 34 lb. Double-sided mode: 52 105 g/m2,14 28 lb. 50 sheets (80 g/m2, 70 kg) Center FRR Roller transport From the top original 50 to 200% (Sub scan direction only) 24 and 5 Vdc from the copier 50 W 550 x 470 x 130 mm 10 kg
Original Weight: Table Capacity: Original Standard Position: Separation: Original Transport: Original Feed Order: Reproduction Range: Power Source: Power Consumption: Dimensions (W x D x H): Weight:
SPEC-6
20 February, 2001
SPECIFICATIONS
ADF
Original Size: Standard sizes (Single-sided mode only): A3 to A5, 11" x 17" to 51/2" x 81/2" Non-standard sizes (Single-sided mode only): Max. width 297 mm Min. width 105 mm Max. length 1,260 mm Min. length 128 mm 52 105 g/m2 (14 28 lb.) 30 sheets (80 g/m2, 22 lb.) Center FRR Roller transport From the top original 50 200% 24 and 5 Vdc from the copier 25 W 550 mm x 470 mm x 90 mm Not above 7 kg
Original Weight: Table Capacity: Original Standard Position: Separation: Original Transport: Original Feed Order: Reproduction Range: Power Source: Power Consumption: Dimensions (W x D x H): Weight:
SPEC-7
Spec.
SPECIFICATIONS
20 February, 2001
ONE-TRAY PAPER TRAY UNIT

Paper Size: Paper Weight: Tray Capacity: Paper Feed System: Paper Height Detection: Power Source: A5 to A3 51/2" x 81/2" SEF to 11" x 17" 60 105 g/m2, 16 28 lb. 500 sheets (80 g/m2, 20 lb. ) x 1 tray Feed roller and friction pad 4 steps (100%, 70%, 30%, Near end) 24 Vdc and 5Vdc (from the copier/printer): 120 Vac: 120 V version, from the copier/printer when the optional tray heater is installed 220 240 Vac: 230 V version, from the copier/printer when the optional tray heater is installed Max: 20 W (Copying/printing) 23 W (Optional Tray Heater On) Average: 13 W (Copying/printing) 15 W (Optional Tray Heater On) 12 kg (26.4 lb.) 550 mm x 520 mm x 134 mm
Power Consumption:
Weight: Size (W x D x H):
SPEC-8
20 February, 2001
SPECIFICATIONS
TWO-TRAY PAPER TRAY UNIT

Paper Size: Paper Weight: Tray Capacity: Paper Feed System: Paper Height Detection: Power Source: A5 to A3 51/2" x 81/2" SEF to 11" x 17" 60 105 g/m2, 16 28 lb. 500 sheets (80 g/m2, 20 lb.) x 2 trays Feed roller and friction pad 4 steps (100%, 70%, 30%, Near end) 24 Vdc, 5 Vdc (from the copier/printer) 120 Vac: 120 V version, from the copier/printer when the optional tray heater is installed 220 240 Vac: 230 V version, from the copier/printer when the optional tray heater is installed Max: 30 W (Copying/printing) 23 W (Optional Tray Heater On) Average: 17 W (Copying/printing) 15 W (Optional Tray Heater On) 25 kg (55 lb.) 550 mm x 520 mm x 271 mm
Power Consumption:
Weight: Size (W x D x H):
16MB IMB (Copier Memory Unit)*

Memory: 16MB (with slot for 32MB expansion DIMM)
*This component is included as standard on all models other than B039 machines sold outside of North America.
SPEC-9
Spec.
Fusing Thermostat
B039/B040/B043 POINT TO POINT CIRCUIT DIAGRAM

TS1 S1 S15 Duplex Entrance Sensor S16 Duplex Exit Sensor S2 GND [0] [!5] +5V [5] -4 -5 -6 GND [0] [!5] +5V [5] CN312-1 -2 -3 TF1 Power Supply Cord L2 Fusing Lamp Relay Sensor M8 TH1 Fusing Thermistor SW7 Main Switch Fusing Thermofuse Duplex Transport Motor [!5] [!5] GND [0] [!5] GND [0] [!5] CN314-1 S3 -2 CN315-1 -2 -3 -4 CN222-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 [0] GND [!5] [5] +5V [0] GND [!5] [5] +5V [24 0/24] A2 [24 0/24] /A2 [24 0/24] B2 [24 0/24] /B2 SW1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 <CN111>
Pin No. CN281-4 -3 -2 CN282-1 T281 T280
1
Registration Sensor Upper Paper Size Switch
2
Y2 -1 CN283-3 H1 -8 -4 M7 -9 -5 H3 S14 -10 -6 GND [0] SOL1 ["24] -9 Duplex Inverter Gate Solenoid -8
W1 W2
Y1 -2 AC-N AC-H Anti-condensationoptic Heater Upper Tray Heater [24 0/24] [24 0/24] [24 0/24] [24 0/24] Duplex Inverter Motor -5 -6 -7 Duplex Inverter Sensor CN220-1 -2 -3 -4
X2
X1
CN221-A8 -A7 -A6 -A5 -A4 -A3 -A2 -A1 -B7 -B6 -B5 -B4 -B3 -B2 -B1 -A9 CN324-A1 -A2 -A3 -A4 -A5 -A6 -A7 -A8 -B1 -B2 -B3 -B4 -B5 -B6 -B7 -B8 [!5] /DU_M2ON [!5] /DU_M1ON [24] +24V [24] +24V [!5] Unit Set [0] GND [0] GND [5] +5V [!5] /DU_RST [!5] /DU_EXITS [!5] /DU_ENTS [!5] /DU_REVS [!5] Sol. ON [!5] /DU_M1DR [!5] /DU_M2HOLD [!5] /DU_M1HOLD
+3.3V +3.3V +3.3V +3.3V GND GND /MID GND /MILSYNC GND /MOD GND /MLSYNC GND CK0 Signal H2 GND [0] [!5] +5V [5] GND [0] [!5] +24V [24] [!24] Pin No. Lower Tray Heater GND [0] ["5] +5V [5] 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Upper Paper End Sensor
S4
CN316-1 -2 -3 -4 -5 -6
Vertical Transport Sensor SW2 Vertical Transport Door Switch MC1 -7 Lower Paper Feed Clutch
Duplex Control Board (PCB9)
Power Supply Unit (PCB6)
GND [0] +24V [24]
+24V [24] +24V [24] GND [0] GND [0] +5V [5]
GND [0] GND[0] 12V [12] +3.3V [3.3] +5V [5]
Signal
GND ED7 ED5 ED3 ED1 GND GND EA5 EA3 EA1 GND /ERD GND /CS_IMAC GND
3
-11 CN287-1 CN284-6 -5 -4 -3 -2 -1 CN285-5 -6 -7 -9 -2 CN285-10 -11 -3 -4 -1 Pin No. -2 Signal 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 +3.3V +3.3V +3.3V +3.3V GND GND GND /MIFGATE /MILGATE GND GND /MFGATE /MSYNC GND GND CN310-1 -2 -3 -4 -5 Choke Coil (Eu only)
3
Lower Paper Size Switch GND [0] [!5] -5 S5 -6 Lower Paper End Sensor
SW3
[24] +24V [24] +24V [0] GND [0] GND [5]+5V
[!5] [!5] GND [0] [!5]
CN317-1 -2 -3 -4
4
Pin No. CN109-1 -2 -3 -4 -5 Signal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 GND ED6 ED4 ED2 ED0 GND EA6 EA4 EA2 EA0 GND /EHWR GND /RES_IMAC /CN_IMB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
SW4
CN307-1 -2 -3 -4 -5 -6
CN311-1 -2 -3 -4 -5 [!5] Zero Cross [!5] [!24] Fusing Lamp GND [0] [!24] Relay Trig. [!5] /MU_CN4 [0] GND [!5] /MU_CN3 [24] +24V [!24] Relay ON GND [0] [!5] +5V [5] -6 -7 -8
By-pass Paper Size Switch
S6
By-pass Paper End Sensor
<CN105>
<CN110>
<CN101>
<CN108>
Pin No.
Pin No.
Pin No.
Pin No.
IMB (PCB5)
CN111
CN701
5
GND /CN_SBU +5V +5V +5V +5V GND /LAMP_ERR +5V +5V /RDSYNC /SHGATE /OPBYNC GND GND GND D3 D4 D5 D6 D7 /CS_ICC A10 /RD A11 A9 A8 A13 A14 /EHLWR N.C. +5V N.C. A16 A15 Signal 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Pin No. Pin No. Pin No. Signal Signal GND TXD_PRN /CTSF RXDF /WKUP_PRN TXD_DWNL N.C. GND GND GND GND /OE_PRN N.C. /ARFGATE GND 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GND SDO2 SDO3 GND SDO4 SDO5 SDO6 SDO7 GND GND /SCK GND GND GND GND Signal Signal Signal /ARCLK /ARKD7 /ARKD5 /ARKD3 /ARKD1 GND GND GND /WRSYNC +5V +5V +5V GND GND /CN_PRN
M1
Signal SBU (PCB4) CN101 CN200 Pin No.
/I0BCNT2 GND GND IOA5 IOA3 IOA1 GND D15 D13 D11 D9 GND /IORD GND /CS_GATEX 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
MM_BK ["5] /MM_DR ["5] MM_ST [!5] /MM_RDY [!5] GND [0] GND [0] +24V [24] +24V [24]
CN333-1 -2 -3 -4 -5 -6 -7 -8
Main Motor
+24V [24] [!24] Signal
CN337-1 M2 -2 Rear Exhaust Fan Motor
GND GND GND /INT_ZERO AN7 AN5 AN3 AN1 GND SMO0 SMO2 SMO4 GND SMO8 GND
6
A12 A7 A6 A5 A4 A3 A2 A1 A0 D0 D1 D2 N.C. GND GND /CD1 D11 D12 D13 D14 Pin No. 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 SDE2 SDE3 GND SDE4 SDE5 SDE6 SDE7 GND /SSCAN /SLEAD GND DI_SBU DO_SBU CLK_SBU /DE_SBU D15 /CS_ICC N.C. N.C. N.C. A17 A18 A19 A20 A21 +5V N.C. A22 A23 GND N.C. /LWR N.C. N.C. /STBY Signal Signal Pin No. Pin No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 GND RXD_PRN RXRDYF TXDF /DWN_PRN /SLEEP N.C. GND GND GND GND N.C. N.C. /ARLSYNC /ARLGATE Signal
GND [0] Pin No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 +5VS GND IOA6 IOA4 IOA2 IOA0 GND D14 D12 D10 D8 GND /IOWR GND PMCLK Signal FB_HEAT [!5] +24V [24] [!24]
CN338-1 -2 CN308-1
X1 X2 M3
I/O Board (PCB1)
/BEEP /PWSW GND CLK_OPU GND DI_OPU DO_OPU +5V +5V
CN102-1 -2 -3 -4 -5 -6 -7 -8 -9
CN1-9 -8 -7 -6 -5 -4 -3 -2 -1
Operation Panel Board (PCB3)
-2
Left Exhaust Fan Motor
7
Pin No. 61 62 63 64 65 66 67 68 N.C. N.C. N.C. D8 D9 D10 /CD2 GND Signal Signal Pin No. 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 GND /ARKD6 /ARKD4 /ARKD2 /ARKD0 GND GND GND /FSYNC +5V +5V +5V GND GND GND
7
Exit Sensor Pin No. 46 47 48 49 50 GND GND 12V 12V GND Signal Pin No. 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 TM_RSV GND /RES_IOB /INT_GT AN6 AN4 AN2 AN0 GND SMO1 SMO3 SMO5 GND SMO9 /IOBCNT1 Signal GND [0] CN108 CN301 [!5] +24V [24] [!24] [!24] +24V [24] -4 -5 -6 L3 -7 -8 M4 -9 Toner Supply Motor SW5 Right Door Switch Quenching (LED) Lamp
S7
GND [0] [!5] +5V [5]
CN331-1 -2 -3
BiCU (PCB2)
<CN106>
Pin No.
8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Signal Pin No. GND GND TXDF RXDF RXRDYF /CTSF TXD_DWNL /DWNL_FCU TXD_FCU RXD_FCU /WKUP_FCU /SLEEP GND /OE_FCU GND /AWFGATE /AWLSYNC /AWLGATE GND /AWCLK GND /WRSYNC /FSYNC GND /AWKD7 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
S8
Lift Sensor
Lower Paper Hight 2 Sensor S1 M1 Lift Motor CN105-1 -2 -3 -4 [0] GND ["5] [5] +5V [!24] (+) Lower Paper Hight 1 Sensor Upper Paper Hight 2 Sensor S2 Paper Hight 2 Sensor
Set ["24] GND [0] Feed Back TDS +24V [24] S1 S2 S3 CN320-A1 -A2 -A3 -A4 S4 [!24] Lower PF MC (B384)
CN325-1 -2 -3 -4
CN1-1 -2 -3 -4
Toner Density (TD) Sensor
S9
Feed Back IDS PWMIDS ["5] [!24] Upper PF MC (B384) GND [0] [!24] Paper Feed Motor (B385) +5V [5] [!24] Relay MC (B384) [0/5] Scan B (B384/B385) Signal Upper Paper Hight 1 Sensor S3 Paper Hight 1 Sensor -A5 -A6 SW1 S4 Paper End Sensor Upper Paper Size Switch -A7 SW_TRG [0/5] Scan A (B384/B385) +24V [0/5] Set Bank (B384/B385) +24V [24] [0/5] Paper Height (B384/B385) [!24] -A8 SW1 Paper Size Switch SW2 Tray Cover Switch SW2 Lower Paper Size Switch -A9 -A10 Vertical Transport Sensor M2 Paper Feed Motor Lower Paper End Sensor -A11 S5 -A12 S6 -A13 [0/5] Lower Paper Size (B384) [0/5] Upper Paper Size (B384) [0/5] Paper Size (B385) Not Used [!24] Relay Clutch (B384) ["5] Lower Lift Sensor (B384) ["5] Upper Lift Sensor (B384) ["5] Lift Sensor (B385) [!24] +24 [24]
CN326-1 -2 -3 -4
Image Density (ID) Sensor
Tray Main Board (PCB1)
Paper Tray Unit 1 Trays (B385)
Paper Tray Unit 2 Trays (B384)
/AWKD6 /AWKD5 /AWKD4 /AWKD3 /AWKD2 /AWKD1 /AWKD0 GND GND /ARFGATE /ARLSYNC /ARLGATE GND /ARCLK GND /ARKD7 /ARKD6 /ARKD5 /ARKD4 /ARKD3 /ARKD2 /ARKD1 /ARKD0 GND /CN_FCU
9 10 " ! [ ] " ! SYMBOL TABLE Signal Direction on Active High Active Low Voltage 11 12
M1 DF Transport Motor CN106-1 -2 -3 -4 -5 -6 -7 CN107-1 SOL1 Stamp Solenoid DF Feed Clutch DF Pick-up Solenoid +24V +24V [0] GND [24 24/0] A [24 24/0] /A [24 24/0] B [24 24/0] /B +24V
CN327-1 -2 -3
Y1 Y2 CO1 Total Counter -4 +5VS SHOUT GND /LDD GND /LDENB /DETP CN107-1 CN220-7 -6 -2 -5 -3 -4 -4 -3 -5 -2 -6 -1 -7 Laser Diode Unit (PCB7) CN328-1 -2 SW6 Front/Right Cover Switch
10
M5
-5 CN102-1 -2 -3 -4 -5 -6 -7 -8 -9 CN103-1 -2 -3 -4 -5 -6 -7 CN101-1 -2 -3 -4 -5 -6
[!24] () [0] GND ["5] [5] +5V [0] GND ["5] [5] +5V [0] GND ["5] [5] +5V [!5] Size 1 [!5] Size 2 [0] GND [!5] Size 3 [!5] Size 4 [5] +5V [!5] [24 24/0] A [24] +24V [24 24/0] /A [24 24/0] B [24] +24V [24 24/0] /B
+24V [24] GND [0] ON [!5] Ready [!5] Clock Upper Paper End Sensor SW3
W1
CN303-1 -2 -3 -4 -5 -A14 S7 Tray Cover Switch H1 Optional Tray Heater

W2
CN320-A1 -A2 -A3 -A4 -A5 -A6 -A7 -A8 -A9 -A10 -A11 -A12 -A13 -A14 -A15 -B1 -B2 -B3 -B4 -B5 -B6 -B7 -B8 -B9 -B10 -B11 -B12 -B13 -B14 -B15
Polygonal Mirror Motor
["5] Lower Paper End Sensor (B384) ["5] Upper Paper End Sensor (B384) -A15 -B1 MC1 Upper Paper Feed Clutch Relay Clutch Lower Paper Feed Clutch M1 M2 SOL1 Stamp Solenoid DF Feed Clutch DF Transport Motor DF Feed Motor Paper Feed Motor MC2 MC3 M1 -2 -3 -4 -5 [!24] [24] +24V -B2 -B3 [!24] [24] +24V -B4 -B5 -B6 -B7 -B8 -B9 -B10 -B11 -B12 S8 -9 -10 MC1 [!24] Stamp +24V Lower Lift Sensor -B13
["5] Paper End Sensor (B385) [0] GND (B384/B385) [0] GND (B384/B385) [0] GND (B384/B385) [24] +24V (B384/B385) [24] +24V (B384/B385) [24] +24V (B384/B385) [0] GND (B384/B385) [5] +5V (B384/B385) [!5] Motor Rotate (B384) [0] GND (B385) [0] GND (B384/B385) [!5] Tray Motor (B384)
L1
CN103-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 CN104-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 CN102-1 -2 -3 -4 -5 -6 -7 -8 -9 CN110-1 -2 CN110-1
[0] GND ["5] [5] +5V [0] GND ["5] [5] +5V [0] GND ["5] [5] +5V [0] GND ["5] [5] +5V [!5] Size 2-1 [!5] Size 2-2 [0] GND [!5] Size 2-3 [!5] Size 2-4 [!5] Size 3-1 [!5] Size 3-2 [0] GND [!5] Size 3-3 [!5] Size 3-4 [0] GND [!5] [5] +5V [0] GND ["5] [5] +5V [0] GND ["5] [5] +5V [5] +5V ["5] [24] +24V
Lamp Stabilizer Board (PCB8)
Tray Main Board (PCB1)
GND [0] GND [0] Lamp ON [!24] +24V [24] +24V [24]
CN302-1 -2 -3 -4 -5
Exposure Lamp
11
S10
GND [0] ["5] +5V [5] GND [0] ["5] +5V [5]
CN304-1 -2 -3 -4 -5 -6
Scanner H.P. Sensor S11 S12 Platen Cover Sensor
12
Original Width Sensor
DF Drive Board (PCB1)
Sensor ON [!5] +5V [5] Width 1 [!5] Width 2 [!5] GND [0]
CN305-1 -2 -3 -4 -5
S13
CN240-1 -2 -3 -4 -5 -6 -7 CN270-1 2 -3 -4 -5 -6 -7 -8
+24V +24V [0] GND [24 24/0] A [24 24/0] /A [24 24/0] B [24 24/0] /B +24V +24V [0] GND [24 24/0] A [24 24/0] /A [24 24/0] B [24 24/0] /B +24
[!5] Lower Lift Motor () (B384)
Sensor ON [!5] +5V [5] Length 1 [!5] Length 2 [!5] GND [0] [!5] Lower Lift Motor (+) (B384)
Auto Reverse Document Feeder (B379)
-6 CN101-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 CN101-1 -2 -3 -4
-11 CN260-1
[!24] [!5] Motor ON [5] Speed [!5] Rotate [5] +5V [0] GND [24] +24V [24] +24V [24] +24V [24] +24V [0] GND [0] GND [0] GND [0] GND [0] GND ["5] [5] +5V [!24] (+)
-6 -7 -8 -9 -10
Original Length Sensor
DF Drive Board (PCB1)
Auto Document Feeder (B387)
13 14 15 16 K
13
[!24] DF Feed Cl. +24V SOL2 DF Pick-up Solenoid [!24] Stamp Sol. +24V MC1 SOL2 S1 -4 CN105-1 -2 [!24] DF Feed Cl. +24V [!24] DF Pick-up Junction Gate Solenoid Original Exit Sensor Registration Sensor Original Set Sensor Original Reverse Sensor S2 S3 Registration Sensor Original Set Sensor DF Position Sensor Feed Cover Open Sensor S4 S5 S6 S7 Original Width 2 Sensor Original Trailing Edge Sensor S8 S9 Original Length 2 Sensor Original Length 1 Sensor Original Width 1 Sensor DF Position Sensor Feed Cover Open Sensor Original Width Sensor Board -2 -3 -2 CN250-1 SOL3 S1 S2 S3 S4 S5 [!24] DF Pick-up +24V
Lower Lift Motor Upper Lift Sensor Upper Lift Motor
-B14 M2 S9 M3 H1 Optical Tray Heater -5 -6 -7 -8 -9 -10 [!24] () [0] GND ["5] [5] +5V [!24] (+) [!24] ()
W1 W2
M6
-B15
[!5] Upper Lift Motor () (B384) [!5] Lift Motor () (B385) [!5] Upper Lift Motor (+) (B384) [!5] Lift Motor (+) (B385)
+24V [24] +24V [24] A [0-24] /A [0-24] B [0-24] /B [0-24]
CN336-1 -2 -3 -4 -5 -6
Scanner Motor
+24V [24] [!24] +24V [24] [!24] +24V [24] S6 [!24] PCB2 +24V [24] [!24] S7 Original Length 1 Sensor
Power Pack -BCT/CL (PP1) MC2 MC3 Relay Clutch Upper Ppaer Feed Clutch MC4 By-pass Feed Clutch
14
CN102-1 -2 -3 -4 -5 -6 -7 -8 -9 -11 -12 -13
[0] GND ["5] Regist. +5V [0] GND [!5] Original Set +5V [0] GND [!5] DF Position +5V [0] GND [!5] Feed Cover Open +5V
CN334-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15
CN290-15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1
15
Registration Clutch
MC5
CN103-1 -2 -3 -4 -5 -6 -7 -8 -9
[0] GND [!5] Original W1 +5V [0] GND [!5] Original W2 +5V +5V [!5] Original TE [0] GND
S8
Original Length 2 Sensor
GND [0] Set [!5] +24V [24] Original Trailing Edge Sensor ON [!24] S9
CN306-1 -2 -3 CO2 -4 Key Counter
CN100-1 -2 -3 -4 -5 -6 -7 -8 CN101-3 -4 -5 -6 -7 -8 -9 CN104-1 -2 -3 -4 -5 -6 -7 -8 +5V [!5] Original L1 [0] GND [!5] LED1 +5V [!5] Original L2 [0] GND [!5] LED2
CN201-1 -2 -3 -4 -5 -6 -7 -8 CN130-3 -4 -5 -6 -7 -8 -9
CN101-8 -7 -6 -5 -4 -3 -2 -1 CN102-7 -6 -5 -4 -3 -2 -1
CN335-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15
PWM_B [0 0/5] Feed Back-B Feed Back-C PWM_C[0 0/5] PWM_TP[0 0/5] PWM_TM[0 0/5] Feed Back-T +5V [5] GND [0] +24V [24] +24V [24] [!24] [!24] [!24] [!24] ["5] DF_GATE +5V [0] GND [0] GND [0] GND +24V +24V +24V +5V +5V [0] GND [0] GND ["5] TXD [0] GND ["5] RXD
16
-2 CN220-1 -2 -3 -4 -5 -6 CN210-1 -2 -3 -4 -5 -6 -7 -8 -9 -11 -12 -13 CN230-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15
[!24] Junction Gate [0] GND ["5] Original Exit +5V [0] GND [!5] Original Reverse +5V [0] GND ["5] Regist. +5V [0] GND [!5] Original Set +5V [0] GND [!5] DF Position +5V [0] GND [!5] Feed Cover Open +5V [0] GND [!5] Original W1 [!5] Original W2 +5V [!5] Original L1 [0] GND [!5] LED1 +5V [!5] Original L2 [0] GND [!5] LED2 +5V [!5] Original TE [0] GND [!5] LED3
ELECTRICAL COMPONENT LAYOUT (B039/B040/B043)

3 4 5 6 11 23 10 7 22 8 9
B039V201.WMF
2 1
12 13 14
24 25 26 27 35 28
15 16 17 20 19 18 34 33 32 31 46 45 44 47 49
B039V203.WMF
29 30
21 36 37 38
B039V202.WMF
50 51
43 39
52
53 42 54 41 40
B039V204.WMF
48
B039V205.WMF B039V301.WMF
Symbol Sensors S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16
Description Registration Relay Upper Paper End Vertical Transport Lower Paper End By-pass Paper End Exit Toner Density (TD) Image Density (ID) Scanner H.P. Platen Cover Original Width Original Length Duplex Inverter Duplex Entrance Duplex Exit
Index No. 14 15 18 20 19 17 13 48 31 2 3 4 5 49 53 54
P-to-P A1 A1 A2 A3 A4 A5 A7 A8 A9 A11 A12 A12 A12 D3 F1 F1
Symbol SW2 SW3 SW4 SW5 SW6 SW7
Description Vertical Transport Door Lower Paper Size By-pass Paper Size Right Door Front/Right Cover Main
Index No. 21 22 16 12 34 35
P-to-P A3 A3 A4 A7 A10 I1
Symbol Description M7 Duplex Inverter M8 Duplex Transport Lamps L1 L2 L3
Index No. 50 52
P-to-P D3 F2
Exposure Fusing Quenching (LED)
1 46 32
A11 H1 A8
Symbol PCB3 PCB4 PCB5 PCB6 PCB7 PCB8 PCB9
Description Operation Panel Board (OPU) SBU IMB Power Supply Unit (PSU) Laser Diode Unit (LDU) Lamp Stabilizer Board Duplex Control Board (DCB)
Index No. 10 7 36 39 8 11 40
P-to-P C6 D6 D5 H3 I11 B11 E2
Magnetic Clutches MC1 Lower Paper Feed MC2 Relay MC3 Upper Paper Feed MC4 By-pass Feed MC5 Registration Motors M1 M2 M3 M4 M5 M6
30 29 27 28 26
A3 A14 A15 A15 A15
Counters CO1 Total CO2 Key (Option) Solenoids SOL1 Duplex Inverter Gate Solenoids PP1 PCBs PCB1 PCB2 Power Pack-BCT/CL
33
A9 A16
Heaters H1 Anti-condensation Optic (Option) H2 Upper Tray (Option) H3 Lower Tray (Option) Others TH1 TF1 TS1
F2 F3 F3
51
D3
Switches SW1 Upper Paper Size
23
A2
Main Rear Exhaust Fan Left Exhaust Fan Toner Supply Polygonal Mirror Scanner
25 43 38 24 9 6
A5 A6 A7 A8 A10 A13
42
B14
Fusing Thermistor Fusing Thermofuse Fusing Thermostat
47 44 45
H1 H1 H1
IO Board (IOB) BiCU
41 37
C6 D7
ELECTRICAL COMPONENT LAYOUT (B379)

2 3 4 5 6 7 8 14
1 17 16 15
13 12 10 11
B379D202.WMF
Symbol Name Motors M1 DF Feed M2 DF Transport Sensors S1 S2 S3 S4 S5 S6 S7 S8 S9
Index No. 10 11
P-to-P H12 H12
Original Exit Original Reverse Registration Original Set DF Position Feed Cover Open Original Length - 1 Original Length - 2 Original Trailing Edge
12 16 17 15 9 2 4 6 14
H14 H14 H14 H14 H15 H15 H15 H16 H16
Solenoids SOL1 Stamp SOL2 DF Pick-up SOL3 Junction Gate Magnetic Clutches MC1 DF Feed PCBs PCB1 PCB2
13 5 7
H13 H13 H13
H13
DF Drive Board Original Width Sensor Board
8 3
H12-16 H15

1 14 13 2 3 4 5 12 6
11 10 9 8 7
B387V101.WMF
Symbol Name Motors M1 DF Transport Sensors S1 S2 S3 S4 S5 S6 S7 S8 S9
Index No. 4
P-to-P J13
Registration Original Set DF Position Feed Cover Open Original Width 1 Original Width 2 Original Trailing Edge Original Length 1 Original Length 2
14 12 6 2 10 11 9 7 8
J14 J14 J14 J15 J15 J15 J15 J16 J16
Solenoids SOL1 Stamp SOL2 DF Pick-up Magnetic Clutches MC1 DF Feed PCBs PCB1
13 3
J13 J14
J13
DF Drive
I13-16

1 20 2 3 4 5 19 18 6 7 8 9 17 16 15 14 13
B384V102.WMF
10 11 12
Symbol Name Motors M1 Paper Feed M2 Lower Lift M3 Upper Lift Sensors S1 S2 S3 S4 S5 S6 S7 S8 S9
Index No. 20 18 3
P-to-P E12 E13 E13
Lower Paper Height 2 Lower Paper Height 1 Upper Paper Height 2 Upper Paper Height 1 Vertical Transport Lower Paper End Upper Paper End Lower Lift Upper Lift
10 11 4 5 12 14 13 19 2
E8 E9 E9 E9 E10 E10 E11 E13 E13
Switches SW1 Upper Paper Size SW2 Lower Paper Size SW3 Tray Cover Magnetic Clutches MC1 Upper Paper Feed MC2 Relay MC3 Lower Paper Feed PCBs PCB1 Others H1
16 15 8
E9 E10 E11
6 7 9
E11 E11 E12
Tray Main
D9-13
Optional Tray Heater
17
E14
1 2 3 4 5 6
7 10 9
B385V102.WMF
Symbol Name Motors M1 Lift M2 Paper Feed Sensors S1 S2 S3 S4
Index No. 3 6
P-to-P H9 H10
Lift Paper Height 2 Paper Height 1 Paper End
2 4 5 8
H9 H9 H9 H9
Switches SW1 Paper Size SW2 Tray Cover PCBs PCB1 Others H1
9 7
H10 H10
Tray Main
G9-10
Optional Tray Heater
10
H11

RICOH Aficio 1015

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Model K-C1

(Machine Code: B039/B040/B043)

February 20th, 2001 Subject to change

!IMPORTANT SAFETY NOTICES

!WARNING FOR LASER UNIT

Symbols and Abbreviations

2 PREVENTIVE MAINTENANCE SCHEDULES ............................. 2-1

3 REPLACEMENT AND ADJUSTMENT......................................... 3-1

4 TROUBLESHOOTING ................................................................. 4-1

5 SERVICE TABLES....................................................................... 5-1

6 DETAILED SECTION DESCRIPTIONS ....................................... 6-1

2 DETAILED SECTION DESCRIPTIONS ................................. B379-4

3 REPLACEMENT AND ADJUSTMENT................................. B379-18

3.6 3.7 3.8 3.9

DOCUMENT FEEDER (B387) 1 OVERALL INFORMATION .................................................... B387-1

2 DETAILED SECTION DESCRIPTIONS ................................. B387-4

3 REPLACEMENT AND ADJUSTMENT................................. B387-14

PAPER TRAY UNIT (B384) 1 OVERALL MACHINE INFORMATION ................................... B384-1

2 DETAILED DESCRIPTIONS .................................................. B384-4

3 REPLACEMENT AND ADJUSTMENT................................. B384-11

PAPER TRAY UNIT (B385) 1 OVERALL MACHINE INFORMATION ................................... B385-1

2 DETAILED DESCRIPTIONS .................................................. B385-4

3 REPLACEMENT AND ADJUSTMENT................................. B385-11

1.1 INSTALLATION REQUIREMENTS

54% Operation range

27C 32C (80.6F) (89.6F)

1.1.2 MACHINE LEVEL

1.1.3 MINIMUM SPACE REQUIREMENTS

A: Front B: Left C: Rear D: Right [A]

> > > >

750 mm (29.6") 10 mm (0.4") 10 mm (0.4") 10 mm (0.4")

1.1.4 POWER REQUIREMENTS

1.2 COPIER INSTALLATION

ADF/ARDF Rated voltage output connector for accessory Max. DC24 V

1.2.2 ACCESSORY CHECK

1.2.3 INSTALLATION PROCEDURE

4. Separate the PCU into two sections as shown (5 screws).

PLATEN COVER INSTALLATION

1.3 PLATEN COVER INSTALLATION

1.3.2 INSTALLATION PROCEDURE

1.4.1 ACCESSORY CHECK

1.4.2 INSTALLATION PROCEDURE

1.4 ARDF INSTALLATION

[B] [F] [A] [F]

1.5.1 ACCESSORY CHECK

1.5.2 INSTALLATION PROCEDURE

1.5 ADF INSTALLATION

[B] [F] [A] [F]

TWO-TRAY PAPER TRAY UNIT INSTALLATION

1.6.1 ACCESSORY CHECK

1.6.2 INSTALLATION PROCEDURE

1.6 TWO-TRAY PAPER TRAY UNIT INSTALLATION

TWO-TRAY PAPER TRAY UNIT INSTALLATION

3. Remove the cover [A] (1 rivet).

TWO-TRAY PAPER TRAY UNIT INSTALLATION

ONE-TRAY PAPER TRAY UNIT INSTALLATION

1.7 ONE-TRAY PAPER TRAY UNIT INSTALLATION

1.7.2 INSTALLATION PROCEDURE

ONE-TRAY PAPER TRAY UNIT INSTALLATION