'Field service' by dad - Page 1 of 271

D

i450/Di550

SERVICE MANUAL

[FIELD SERVICE]

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[FIELD SERVICE]

Safety Precautions for Inspection and Service

PRECAUTIONS FOR SERVICE

DIS/REASSEMBLY, ADJUSTMENT

1. SERVICE INSTRUCTIONS

1-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS

1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

1-3. PARTS WHICH MUST NOT BE TOUCHED

(1) Red painted Screws

(2) Variable Resistors on Board

(3) Other Screws

2. DISASSEMBLY/REASSEMBLY

2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES

2-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS

2-3. MAINTENANCE SCHEDULE

(1) 45-cpm copier

(2) 55-cpm copier

2-4. Removal of the Unit

(1) Removal of the Multi Bypass Unit

(2) Removal of the Suction Unit

(3) Removal of the Main Hopper Unit

(4) Removal of the IR Unit

(5) Removal of the PH Unit

(6) Removal of the Developing Unit

(7) Removal of the Sub Hopper Unit

(8) Removal of the Fusing Unit

(9) Removal of the Upper Left Door (Exit/Duplex Switching Unit)

2-5. PAPER TAKE-UP/TRANSPORT SECTION

(1) Removal of the Paper Take-Up Roll, Paper Feed Roll and Paper Separator Roll Assy.

(2) Cleaning of the Paper Take-Up Roll and Paper Feed Roll

(3) Cleaning of the Paper Separator Roll

(4) Removal of the Drawer Lift-Up Motor

(5) Removal of the Upper and Lower Transport Rollers

(6) Cleaning of the Upper Transport Roller

(7) Cleaning of the Lower Transport Roller

(8) Cleaning of the Vertical Transport Rollers

(9) Removal of the Synchronizing Roller

(10) Cleaning of the Upper Synchronizing Roller

(11) Removal of the Lower Synchronizing Roller

(12) Cleaning of the Lower Synchronizing Roller

(13) Removal of the Synchronizing Paper Dust Remover

(14) Removal of the Transport Paper Dust Remover

(15) Cleaning of the Paper Dust Remover

(16) Disassembly of the Suction Unit

(17) Disassembly of the Multi Bypass Unit

(18) Cleaning of the Multi Bypass Paper Take-Up Roll/Paper Feed Roll

(19) Cleaning of the Multi Bypass Paper Separator Roll Assy.

2-6. OPTICAL SECTION

(1) Cleaning of the Original Glass and EDH Glass

(2) Cleaning of the Mirrors

(3) Cleaning of the Lens

(4) Cleaning of the Scanner Rails/bushings

(5) Cleaning of the PH Glass

(6) Removal of the Scanner

(7) Removal of the Exposure Lamp

(8) Removal of the EDH Glass

(9) Removal of the Scanner Drive Cable

(10) Winding of the Scanner Drive Cable

2-7. DEVELOPING UNIT

(1) Remove of the Developing Unit

(2) Cleaning of the Developer Scattering Prevention Plate

(3) Cleaning of the DS Positioning Collars

(4) Cleaning of the Toner Antisocial Trap

(5) Replacement of the Cleaning Blade

(6) Replacement of the Developer

(7) Cleaning of the AIDC Sensor Board

(8) Cleaning of the PC Drum Paper Separator Fingers

(9) Removal of the Toner Antispill Seal

(10) Cleaning of the Toner Antispill Seal

(11) Removal of the Main Erase Lamp

(12) Cleaning of the Main Erase Lamp Filter

(13) Removal of the Ozone Filter (PC Drum Charge Corona)

(14) Removal of the Ozone Filter (Image Transfer/Paper Separator Coronas)

(15) Removal of the Toner Collecting Bottle

2-8. PC DRUM CHARGE CORONA AND IMAGE TRANSFER/ PAPER SEPARATOR CORONAS

(1) Removal of the PC Drum Charge Corona

(2) Cleaning of the PC Drum Charge Corona Housing

(3) Cleaning of the PC Drum Charge Corona Grid Mesh

(4) Cleaning of the Comb Electrode

(5) Removal of the Image Transfer/Paper Separator Coronas

(6) Cleaning of the Image Transfer Corona Wire

(7) Removal of the Image Transfer Corona Wire

(8) Cleaning of the Paper Separator Corona Wire

(9) Removal of the Paper Separator Corona Wire

(10) Cleaning of the Image Transfer/Paper Separator Coronas Housing

(11) Cleaning of the Pre-Image Transfer Guide Plate

2-9. FUSING UNIT

(1) Disassembly of the Fusing Unit

(2) Removal of the Upper Fusing Paper Separator Fingers

(3) Cleaning of the Upper Fusing Paper Separator Fingers

(4) Cleaning of the Lower Fusing Paper Separator Fingers

(5) Cleaning of the Entrance Guide Plate

(6) Removal of the Upper Fusing Roller Thermistor

(7) Cleaning of the Upper Fusing Roller Thermistor

(8) Removal of the Lower Fusing Roller Thermistor

(9) Cleaning of the Lower Fusing Roller Thermistor

(10) Removal of the Upper Fusing Roller Thermostat

(11) Cleaning of the Upper Fusing Roller Thermostat

(12) Removal of the Web Roller

(13) Removal of the Web Pressure Roller

(14) Removal of the Misfeed Removal Knob Bushing

(15) Removal of the Fusing Unit Drive Coupling Gear

2-10. TURNOVER UNIT

(1) Cleaning of the Turnover Roller, Transport Rollers

3-1. ADJUSTMENT JIGS AND TOOLS USED

3-2. ADJUSTMENT REQUIREMENTS LIST

3-3. ADJUSTMENT OF SWITCHES

(1) Microswitches

(2) Adjustment of Front Door Interlock Switch

3-4. ADJUSTMENT OF BELT TENSION

(1) Adjustment of the Suction Drive Timing Belt

(2) Adjustment of the Developing Unit Drive Timing Belt

(3) Adjustment of the Scanner Motor Timing Belt

3-5. SOLENOID POSITION ADJUSTMENT

(1) Adjustment of Manual Feed Paper Pick-Up Solenoid

(2) Adjustment of Turnover Roller Retraction Solenoid

(3) Adjustment of Exit/Duplex Switching Solenoid

(4) Positioning of the PC Drum Paper Separator Fingers (Separator Finger Solenoid)

(5) Adjustment of Turnover Route Switching Solenoid

3-6. ACCESSING THE TECH. REP. MODE AND ADJUST MODE

(1) Accessing the Tech. Rep. Mode

(2) Accessing the Adjust Mode

3-7. ELECTRICAL/IMAGE ADJUSTMENT

(1) Touch Panel Adj.

(2) Orig. Size Adjust

(3) F8 ATDC Sensor

(4) F5 AIDC Sensor

(5) Registration (CD)

(6) Registration (FD)

(7) Lead Edge Erase

(8) Trail Edge Erase

(9) Loop Adjustment

(10) Erasure Width

(13) Scale (CD)

(14) Scale (FD)

3-8. OTHER ADJUSTMENTS

(1) Adjustment of the Reference Position of Each Drawer

(2) Adjustment of the Reference Position of the Multi Bypass Tray

(3) Adjustment of the Upper Right Door (Multi Bypass Unit)

(4) Adjustment of the Position of the Scanner and 2nd/3rd Mirrors Carriage

(5) Adjustment of the 2nd/3rd Mirrors Carriage Assy for Parallel Alignment

(6) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller (D.B. Adjustment)

4. MISCELLANEOUS

4-1. INSTALLATION OF THE KEY COUNTER SOCKET (OPTION)

4-2. MOUNTING THE ORIGINAL SIZE DETECTING SENSORS (OPTION)

4-3. FLASH MEMORY

(1) Rewriting the Master Board Data

(2) Rewriting the Image Processing Board Data

(3) Rewriting the ECC Board Data (option)

(4) Rewriting the Master Board, Image Processing Board, and ECC Board (Option) Simultaneously

4-4. REMOUNTING EEPROM

(1) Remounting EEPROM on the Master Board

(2) Remounting EEPROM on the Image Processing Board

SWITCHES ON PWBs, TECH. REP. SETTINGS

1. CONTROL PANEL KEYS AND TOUCH PANEL

1-1. Control Panel Keys

1-2. Explanation of the Touch Panel

(1) Basis Screen

(2) Warning Screens

2. FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs

2-1. PWB Location

2-2. PWB-S (Tech. Rep. Setting Switches Board)

(1) Clearing Procedures

(2) Data/Conditions Cleared by Reset Switches/Pins

3. UTILITY MODE

3-1. Utility Mode selection Screen

3-2. Utility Mode Function Tree

3-3. Settings in the Utility Mode

(1) User&s Choice Mode

(2) Administrator Mode

4. TECH. REP. MODE

4-1. Tech. Rep. Mode Menu Screen

4-2. Tech. Rep. Mode Function Setting Procedure

4-3. Tech. Rep. Mode Menu Function Tree

4-4. Setting in the Tech. Rep. Mode

(2) Tech. Rep. Choice

(3) System Input

(6) I.R. & EDH Check

(7) ROM Version

(9) Level History

(10) Admin. Mode

5. SECURITY MODE

5-1. Security Mode Menu Screen

5-2. Security Mode Setting Procedure

5-3. Settings in the Security Mode

6-1. Adjust Mode Menu Screen

6-2. Adjust Mode Setting Procedure

6-3. Adjust Mode Function Tree

6-4. Settings in the Adjust Mode

TROUBLESHOOTING

1. INTRODUCTION

1-1. Reading the Text

2-1. Controlled Parts Check Procedure

2-2. I/O Check List

3. PAPER TRANSPORT FAILURE

3-1. Paper Misfeed

3-2. Misfeed Detection Sensor Layout

3-3. Types of Misfeed Detection and Detection Timings

3-4. Misfeed Troubleshooting Procedures

(1) Copier Paper Take-Up Misfeed

(2) Multi Bypass Misfeed

(3) Transport/Separator Misfeed

(4) Fusing/Exit Misfeed

(5) PF-208 Paper Take-Up Misfeed

(6) PF-115 Paper Take-Up Misfeed

(7) Duplex Paper Take-Up Misfeed

4. MALFUNCTIONS

4-1. Detection Timing by Malfunction Code

4-2. Troubleshooting Procedures by Malfunction Code

(1) C0000: Fusing Motor&s failure to turn C0010: PC Drum Drive Motor&s failure to turn

(2) C0040: Suction Fan Motor&s failure to turn C004C: Ventilation Fan Motor&s failure to turn

(3) C0042: Fusing Unit Cooling Fan Motor&s failure to turn

(4) C0045: IR Cooling Fan Motor malfunction C0046: PH Cooling Fan Motor 1 malfunction C0047: PH C...

(5) C0049: Paper source option Vertical Transport Cooling Fan Motor malfunction

(6) C004E: Power Supply Unit Cooling Fan Motor 1&s failure to turn C004F: Power Supply Unit Cooli...

(7) C0072: Main Hopper Toner Replenishing Motor&s failure to turn C0090: Developing Unit Drive Mo...

(8) C0210: Image Transfer/Paper Separator Corona charge leak detected

(9) C0400: Exposure Lamp&s failure to turn ON C0420: Exposure Lamp turning ON at abnormal timing

(10) C0500: Warming-up failure C0510: Abnormally low fusing temperature C0520: Abnormally high fu...

(11) C0602: Cable unwound C0650: SHOME signal error

(12) C0910: 2nd Drawer Paper Lift-Up Sensor malfunction C0914: 2nd Drawer Lift-Up Motor&s failure...

(13) C0900: 3rd Drawer Paper Lift-Up Sensor malfunction C0904: 3rd Drawer Paper Lift-Up Motor&s f...

(14) C0990: Main Tray lifting motion failure C0994: Main Tray Elevator Motor&s failure to turn

(15) C0996: Main Tray lock release failure C0997: Shift Gate malfunction

(16) C0998: Shifter return failure C099C: Shift Motor&s failure to turn

(17) C0D50: Duplex Horizontal Transport Motor malfunction

(18) C0E00: Main Erase Lamp&s failure to turn ON

(19) C0F24: AIDC Sensor contamination correction failure

(20) C0F32: ATDC Sensor malfunction C0F33: Abnormally low T/C as detected by ATDC Sensor

(21) C10XX to C18XX

(22) Copier does not turn ON.

5. IMAGE FAILURE

5-1. Image Failure Troubleshooting

5-2. Initial Checks

5-3. Troubleshooting Procedures Classified by Image Failure

(3) Low image density

(4) Foggy background

(5) High image density

(6) Black streaks or bands

(7) Black spots

(8) Blank streaks or bands

(10) Smear on back

(11) Uneven image density

(12) Gradation reproduction failure

(13) Rough image

(14) Traces of PC Drum Paper Separator Fingers

(15) Void areas along leading edge

6. RESETTING THE MAINTENANCE CODE DISPLAY

6-1. Details of Maintenance Codes

6-2. Resetting the Maintenance Code Display

(1) Entering the Tech. Rep. Mode

(2) Resetting the Maintenance Code Display

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