Service Manual

Di1811p_F.
book 1 ページ２００４年３月２日　火曜日　午後４時２３分
SERVICE MANUAL FIELD SERVICE
AF-12
2004.3
Ver. 1.0
Di1811p_F.book 3 ページ２００４年３月２日　火曜日　午後４時２３分
INDEX
MAINTENANCE
ADJUSTMENT/SETTING
TROUBLESHOOTING
Di1811p_F.book i ページ２００４年３月２日　火曜日　午後４時２３分
CONTENTS
MAINTENANCE
1. MAINTENANCE SCHEDULE .......................................................................... 1-1
1.1 PM Parts List ............................................................................................ 1-1
1.2 Replacement and Cleaning of Parts ........................................................ 1-2
(1) Cleaning of the Pick-up Roller/Take-up Roller ....................... 1-2
(2) Removal of the Pick-Up Roller/Take-Up Roller ...................... 1-2
(3) Removal of the Separator Roller ............................................ 1-3
(4) Cleaning of the Separator Roller ............................................ 1-4
(5) Cleaning of the Registration Roller/Rolls ............................... 1-4
(6) Cleaning of the Exit Roller/Rolls ............................................ 1-5
(7) Cleaning of the Transport Rolls ............................................. 1-6
(8) Cleaning of Length Size Sensor 2 ......................................... 1-6
2. MISCELLANEOUS PARTS .............................................................................. 1-7
2.1 Disassembly and Reassembly ................................................................. 1-7
2.1.1 Identification and Removal Procedures of Door, Covers, and
Exterior Parts ................................................................................. 1-7
2.1.2 Removal of Circuit Boards and Other Electric Components .......... 1-8
(1) Removal of the Interface Board (PWB/AF) ............................ 1-8
ADJUSTING/SETTING
1. SERVICE MODE .............................................................................................. 2-1
1.1 Service Mode Function Setting Procedure ............................................... 2-1
1.2 Setting in the Service Mode ..................................................................... 2-2
1.2.1 ADJUST ......................................................................................... 2-2
(1) ADF SUB ZOOM .................................................................... 2-2
(2) ADF MAIN REGIST ............................................................... 2-3
(3) ADF SUB REGIST1 ............................................................... 2-4
1.2.2 FUNCTION .................................................................................... 2-5
(1) ADF FEED TEST ................................................................... 2-5
(2) COPY ADF GLASS AREA ..................................................... 2-5
2. MECHANICAL ADJUSTMENTS ...................................................................... 2-6
2.1 ADF Height Adjustment ............................................................................ 2-6
2.2 ADF Leading Edge Skew Adjustment ...................................................... 2-7
TROUBLESHOOTING
3. INTRODUCTION .............................................................................................. 3-1
3.1 Electrical Components Check Procedure ................................................ 3-1
3.1.1 Sensor ........................................................................................... 3-1
3.1.2 Switch ............................................................................................ 3-2
3.1.3 Solenoid ......................................................................................... 3-2
3.1.4 Clutch ............................................................................................ 3-2
3.1.5 Motor ............................................................................................. 3-3
4. MISFEEDS ....................................................................................................... 3-4
4.1 Initial Checks ............................................................................................ 3-4
4.2 Paper Misfeed Detection .......................................................................... 3-4
4.2.1 Outline ........................................................................................... 3-4
4.3 Misfeed Display ........................................................................................ 3-5
4.4 Misfeed-Detecting Sensor Layout ............................................................ 3-6
i
Di1811p_F.book ii ページ２００４年３月２日　火曜日　午後４時２３分
4.5 Misfeed Detection Timing/Troubleshooting Procedures .......................... 3-7

4.5.1 Misfeed at the Document Take-up Section ................................... 3-7
4.5.2 Misfeed at the Document Transport Section ................................. 3-8
4.5.3 Misfeed at the Document Exit Section ........................................... 3-9
ii
MAINTENANCE
19971
Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE
1. MAINTENANCE SCHEDULE
1.1 PM Parts List
Cycle (K=1,000) Ref.
PM Parts
Clean Replace Page
Pick-Up Roller 30K 120K ☞ 1-2
Paper Take-Up Roller 30K 120K ☞ 1-2
Separator Roller 30K 120K ☞ 1-3
Registration Roller 30K – ☞ 1-4
Automatic Doc- Registration Roll 30K – ☞ 1-4
ument Feeder Exit Roller 30K – ☞ 1-5
Exit Roll 30K – ☞ 1-5
Transport Roll 30K – ☞ 1-6
Length Size ☞ 1-6
30K –
Detection Sensor 2 (PC7/AF)
NOTES
• The contents of the maintenance schedule are subject to change without notice.
• For part numbers, see Parts Manual and Parts Modification Notice.
• Both for the copier and options, check the PM counter values for performing the service
procedures.
1-1
MAINTENANCE Di1811p FIELD SERVICE Ver.1.0 Mar. 2004
1.2 Replacement and Cleaning of Parts

(1) Cleaning of the Pick-up Roller/Take-up Roller
1. Open the Upper Door.
2. Using a soft cloth dampened with alcohol, wipe

the Take-up Roller clean of dirt.
4688D017AB

the Pick-up Roller clean of dirt.
4688D018AB
(2) Removal of the Pick-Up Roller/Take-Up Roller

2. Open the Document Take-up Section Cover.
☞ 1-7
3. Snap off two C-clips.

4. Remove two bushings and the Pick-up Roller/
Take-up Roller Assy.
4688D019AA
1-2
5. Snap off one C-clip and remove one lever and the
holder.
4688D020AA
6. Snap off one C-clip and remove the Pick-up

Roller.
4688D021AA
7. Remove one pin, snap off one C-clip, and remove

the Take-up Roller.
4688D022AB
(3) Removal of the Separator Roller

2. Remove two screws and the Separator Section
Protective Cover.
4688D023AA
1-3
3. Unhook one spring and remove the Separator

Roller Assy.
4688D024AA
4. Remove the Separator Roller.
4688D025AA
(4) Cleaning of the Separator Roller
1. Remove the Separator Section Protective Cover.

the Separator Roller clean of dirt.
4688D026AA
(5) Cleaning of the Registration Roller/Rolls
1. Raise the Automatic Document Feeder.

the Registration Rolls clean of dirt.
4688D027AB
1-4
3. Remove the Rear Cover.

4. Remove the Document Feeding Tray.
☞ 1-7
5. Remove three screws and the Registration Roller
Cover.
4688D028AA
6. Remove two screws and the Sensor Assy.
4688D029AA

the Registration Roller clean of dirt.
4688D030AA
(6) Cleaning of the Exit Roller/Rolls

☞ 1-7
the Exit Roller/Rolls clean of dirt.
4688D031AA
1-5
(7) Cleaning of the Transport Rolls

☞ 1-7
3. Remove the Registration Roller Cover.
the Transport Rolls clean of dirt.
4688D032AA
(8) Cleaning of Length Size Sensor 2
1. Using a brush, whisk dust and dirt off the surface

of the sensor window.
4688D033AA
1-6
2. MISCELLANEOUS PARTS
2.1 Disassembly and Reassembly
2.1.1 Identification and Removal Procedures of Door, Covers, and Exterior Parts
4
3
4688D034AB
No. Part Name Removal Procedure

Document Take-up Open the Upper Door. → Remove two screws. →
1
Section Cover Remove the Document Take-up Section Cover.
Open the Upper Door. → Remove one screw and unhook
2 Rear Cover
six tabs. → Remove the Rear Cover.
Open the Upper Door. → Remove the Rear Cover. →
Document Feeding
3 Remove three screws and unplug two connectors. →
Tray
Remove the Document Feeding Tray.
Document Feeding Remove the Document Feeding Tray. → Remove four
4
Tray Cover screws. → Remove the Document Feeding Tray Cover.
1-7
2.1.2 Removal of Circuit Boards and Other Electric Components
NOTES
• When removing a circuit board or other electric component, refer to “PRECAUTIONS
FOR HANDLING THE PWBs” and follow the corresponding removal procedures.
• The removal procedures given in the following omit the removal of connectors and
screws securing the circuit board support or circuit board.
• Where it is absolutely necessary to touch the ICs and other electric components on the
board, be sure to ground your body.
PWB/AF
4688D036AA
Symbol Part Name Removal Procedure

PWB/AF Interface Board ☞ 1-8
(1) Removal of the Interface Board (PWB/AF)

☞ 1-7
3. Unplug all connectors from the Interface Board.

4. Remove two screws and the Interface Board.
4688D035AA
1-8
ADJUSTING/SETTING
19971
ADJUSTING/SETTING Di1811p FIELD SERVICE Ver.1.0 Mar. 2004
1. SERVICE MODE
1.1 Service Mode Function Setting Procedure
NOTE
• Care must be used to ensure that only the personnel who are involved in service jobs
know the procedure to enter the Service mode.
<Procedure>
1. Press the Utility key.
2. Press the following keys in this order.
3. Stop → 0 → 0 → Stop → 0 → 1
4. The Service mode menu screen will appear.
<Exiting the Mode>

• Press the Panel Reset key as many times as it is required to display the initial screen.
<Service Mode Function Setting Value Changing Procedure>

1. Select the desired item using [ ▲ / ▼ ] key.
2. Select the setting value using [ ▲ / ▼ ] key, [ < / > ] key, or the 10-Key Pad.
3. Validate the selection by pressing the [Yes] key.
4. To go back to previous screen, press the [No] key.
2-1
Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING
1.2 Setting in the Service Mode

1.2.1 ADJUST
(1) ADF SUB ZOOM
Function Purpose Setting Details/Precautions

Press the Start key to start a test
Test Copy To adjust variations in machining and copy cycle.
installation accuracy of different parts by
varying the scanning zoom ratio in the • The default setting is “100.”
Adjust sub scanning direction when the Auto-
matic Document Feeder is used. Setting range: 87 to 113
(1 step: 0.4%)
<Adjustment Standard>
• Ready the test chart that comes with the Automatic

Document Feeder.
• Adjust so that deviation between length A on the
test chart and that on the copy falls within the
specified range.
Reference line A: 400 mm Specifications

4035D513AA
400 ± 6.0 mm
<Adjustment Procedure>
1. Make a full-size copy of the test chart.
2. Measure the length of reference line A on the copy to determine if the deviation falls
within the specified range. If it falls outside the specified range, perform the following
steps to make an adjustment.
3. Enter Adjust of the Service mode.
4. Select “ADF Sub Zoom” and press the [Yes] key.
5. Using [ ▲ / ▼ ] key, select the appropriate setting value.
6. Press the [Yes] key to validate the setting value selected in step 5.
7. Make another full-size copy of the test chart to determine the amount of error in length
A on the copy.
Adjustment Instructions
If length A on the copy is longer than the specifications, decrease the setting value.
If length A on the copy is shorter than the specifications, increase the setting value.
If a single adjustment procedure does not successfully bring the deviation into the specified
range, repeat steps 3 through 7.
2-2
(2) ADF MAIN REGIST

To adjust variations in machining and Press the Start key to start a test
Test Copy
installation accuracy of different parts by copy cycle.
varying the scanning start position in the Setting range: 20 to 180
Adjust main scanning direction when the Auto- (1 step: 0.1 mm)
matic Document Feeder is used.
• Ready the test chart that comes with the optional
Reference line B
Automatic Document Feeder.
• Adjust so that the amount of error of width B on the
Width B
copy falls within the specified range.
Specifications
4035D513AA
20 ± 2.0 mm
2. Using a scale, measure the distance between reference line B on the copy and the top
edge of the copy (width B) and determine if the amount of error in width B falls within
the specified range. If it falls outside the specified range, perform the following steps to
make an adjustment.
4. Select “ADF Main Regist” and press the [Yes] key.
7. Make another full-size copy of the test chart to check for the amount of error in width B
on the copy.
If width B on the copy is longer than the specifications, decrease the setting value.
If width B on the copy is shorter than the specifications, increase the setting value.
If a single adjustment procedure does not successfully bring the amount of error into the
specified range, repeat steps 3 through 7.
2-3
(3) ADF SUB REGIST1

Test Copy
sub scanning direction when the Auto- (1 step: 0.1 mm)
Adjust
NOTE
• This adjustment should be made after
the ADF Sub Zoom adjustment.
Reference line C
• Adjust so that the amount of error of length C on
the copy falls within the specified range.
Specifications
Length C 4035D513AA
20 ± 2.5 mm
2. Using a scale, measure the distance between reference line C on the copy and the
leading edge of the copy (length C) and determine if the amount of error in length C falls
4. Select “ADF Sub Regist” and press the [Yes] key.
7. Make another full-size copy of the test chart to check for the amount of error in length C
on the copy.
If length C on the copy is longer than the specifications, increase the setting value.
If length C on the copy is shorter than the specifications, decrease the setting value.
2-4
1.2.2 FUNCTION
(1) ADF FEED TEST
Purpose Setting Details/Precautions
• To check for correct paper passage of the <Step>
paper take-up and transport system in the 1. Load paper in the ADF.
Automatic (Duplexing) Document Feeder 2. Press the Start key to start the ADF feed
alone as a single unit. test.
• Here are the details of operation involved ✽ Press the Stop key to stop the ADF feed
in the paper passage motion. test.
• The Scanner does not make any
scan motion.
• Paper passage operation continues
until all pages of the document
loaded in the unit have been fed in.
✽ When a paper misfeed of originals occurs
(2) COPY ADF GLASS AREA

To check for scratches and dirt on the Origi- <Step>
nal Scanning Glass. 1. Place a gray chart (OD = 0.3) on the
Original Glass.
✽ When a dirty image occurs 2. Press the Start key to start the Copy
ADF Glass Area test.
3. The Scanner moves from its standby
position to a point 2 mm to the left of the
Original Scanning Glass.
4. The Scanner moves to the right to start a
scan motion.
5. The copier produces two copy samples
(in order to know dirt on the glass from
printer image noise).
2-5
2. MECHANICAL ADJUSTMENTS
2.1 ADF Height Adjustment
1. Turn one screw so that the spacer contacts the

glass at the scale position of the copier.
Turn the screw clockwise to raise the ADF.

Turn the screw counterclockwise to lower the ADF.
4688U031AA
Within 0.5 mm
4688U240AA
2-6
2.2 ADF Leading Edge Skew Adjustment
NOTE
• This adjustment is to be made when a tilted image occurs.
1. Prepare the test chart that comes with the ADF

(option).
4035D513AA
2. Load the test chart in the ADF and make five 1-

sided copies.
NOTE
• Load the test chart lengthwise.
4035D512AA
3. Align each copy sample as shown on the left and

check the deviation.
If the deviation falls outside the range specified
below, perform the following steps to make an
adjustment.
4688U001AB
Specifications
0 ± 3.0 mm
4. Loosen one screw.
4688U030AB
2-7
5. If the deviation is as shown on the left, move the

graduations of the ADF to the front.
4688U001AB
4688U206AA
6. If the deviation is as shown on the left, move the

graduations of the ADF to the rear.
4688U002AB
4688U207AA
7. Tighten the screw.
4688U030AB
2-8
TROUBLESHOOTING
19971
Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING
3. INTRODUCTION
• Information required for troubleshooting and steps that must be performed are described
in this chapter.
3.1 Electrical Components Check Procedure

• If a paper misfeed or malfunction occurs, perform the following operations to check the
condition of the electrical components.
3.1.1 Sensor
Step Check Result Action
1 Does the input signal of the control board change NO Replace the
when the sensor light is interrupted? (H → L, L → H) sensor.
YES Replace the
control board.
4025T520AA
4025T521AA
3-1
TROUBLESHOOTING Di1811p FIELD SERVICE Ver.1.0 Mar. 2004
3.1.2 Switch
1 Does the input signal (NO) of the control board change NO Replace the
from L to H when the switch is activated? switch.
YES Replace the
control board.
NO
Not Use
COM
4025T523AB
3.1.3 Solenoid
1 Does the output signal of the control board change NO Replace the
from H to L when the solenoid is activated? control board.
YES Replace the
solenoid.
1 2 1
2 1 2
4025T522AA
3.1.4 Clutch
from H to L when the clutch is activated? control board.
YES Replace the
clutch.
4025T528AA
3-2
3.1.5 Motor
1 Does the LOCK signal switch to H when the machine NO Replace the con-
goes into standby? trol board.
Replace the motor.
2 Does the REM signal of the master board change YES Replace the motor.
from H to L when the motor is turned on? NO Replace the con-
trol board.
GND 1
REM 2
LOCK3
4025T526AA

1 Does the input signal of the master board change YES Replace the motor.
from H to L when the motor is turned on?(The input NO Replace the con-
signal differs depending on the rotation direction.) trol board.
4025T525AA

1 Are the relay connector of the motor and the print jack YES Replace the motor
of the control board correctly connected? or the control
board.
NO Connect the con-
nector or the print
jack.
4025T527AA
3-3
4. MISFEEDS
4.1 Initial Checks
• When a paper misfeed occurs, first perform the following initial checks.
Check Item Action
Does paper meet product specifications? Replace paper.
Is the paper curled, wavy, or damp? Replace paper.
Instruct the user on the correct paper
storage procedures.
Is a foreign object present along the paper path, Clean or change the paper path.
or is the paper path deformed or worn?
Are the Paper Separator Fingers dirty, deformed, Clean or replace the defective Paper
or worn? Separator Finger.
Are rolls/rollers dirty, deformed, or worn? Clean or replace the defective roll/roller.
Are the Edge Guide and Trailing Edge Stop at the Set as necessary.
correct position to accommodate the paper?
Are the actuators operational and checked for Correct or replace the defective actua-
correct operation? tor.
4.2 Paper Misfeed Detection

4.2.1 Outline
• A paper misfeed is detected by detecting different states of signals (H, L) of several sen-
sors located near the paper take-up section and the Exit Paper Sensor. The copier
thereby determines whether there is paper left inside it.
• The timings of the rising and falling edges of the paper take-up-related sensors and the
Exit Paper Sensor are monitored to detect a misfeed of paper being fed through the
copier.
• The states (H, L) of the paper take-up-related sensors and the Exit Paper Sensor are
monitored to detect a sheet of paper left in the copier.
• All drives are brought to a stop when a sheet of paper misfed or left in the copier is
detected.
3-4
4.3 Misfeed Display

• When a paper misfeed occurs, the Error indicator lights up steadily and the Display gives
a corresponding message.
C4506P298CA
Display Message Misfeed/Paper Location Ref. Page

Document take-up section ☞ 3-7
OPEN DOC. FEED
Document transport section ☞ 3-8
COVER
Document exit section ☞ 3-9
<Display Resetting Procedure>

• Open the corresponding cover, clear the sheet of paper misfed, and close the cover.
3-5
4.4 Misfeed-Detecting Sensor Layout
5
4688T501AA
1: Registration Sensor (PC3/AF) 3: Paper Exit Sensor (PC5/AF)

2: Separator Sensor (PC4/AF)
3-6
4.5 Misfeed Detection Timing/Troubleshooting Procedures

4.5.1 Misfeed at the Document Take-up Section
<Detection Timing>
Type Description
Document • The Separator Sensor (PC4/AF) is not blocked even after the lapse of
take-up section a given period of time after the Main Motor (M1/AF) has been ener-
misfeed detec- gized.
tion
Document left • The Separator Sensor (PC4/AF) is blocked at timing when the Power
in the docu- Switch is turned ON, the cover is opened and closed, or a paper mis-
ment take-up feed or malfunction is reset.
section
<Action>
Relevant Electrical Components
Main Motor (M1/AF) Interface Board (PWB/AF)
Separator Sensor (PC4/AF)
WIRING DIAGRAM
Step Operations Ref. Page Location

Control signal (Electrical
Components)
1 Initial checks – – –
2 M1/AF operation check ☞ 3-3 – D-6 (AF-12)
3 PC4/AF sensor check ☞ 3-1 PWB/AF CN2/AF-9 (ON) I-4 (AF-12)
4 Replace PWB/AF – – –
3-7
4.5.2 Misfeed at the Document Transport Section
<Detection Timing>
Type Description
Document • The Registration Sensor (PC3/AF) is not blocked even after the lapse
transport sec- of a given period of time after the Main Motor (M1/AF) has been ener-
tion misfeed gized.
detection
Document left • The Registration Sensor (PC3/AF) is blocked at timing when the
in the docu- Power Switch is turned ON, the cover is opened and closed, or a
ment transport paper misfeed or malfunction is reset.
section
<Action>
Registration Sensor (PC3/AF)
WIRING DIAGRAM

Components)
3 PC3/AF sensor check ☞ 3-1 PWB/AF CN2/AF-6 (ON) H-4 (AF-12)
3-8
4.5.3 Misfeed at the Document Exit Section
<Detection Timing>
Type Description
Document exit • The Paper Exit Sensor (PC5/AF) is not blocked even after the lapse of
section mis- a given period of time after the Main Motor (M1/AF) has been ener-
feed detection gized.
Document left • The Paper Exit Sensor (PC5/AF) is blocked at timing when the Power
in the docu- Switch is turned ON, the cover is opened and closed, or a paper mis-
ment exit sec- feed or malfunction is reset.
tion
<Action>
Paper Exit Sensor (PC5/AF)
WIRING DIAGRAM

Components)
3 PC5/AF sensor check ☞ 3-1 PWB/AF CN2/AF-12 (ON) H-6 (AF-12)
3-9
AFR-19
2004.3
Ver. 1.0
INDEX
MAINTENANCE
ADJUSTMENT/SETTING
TROUBLESHOOTING
CONTENTS
MAINTENANCE
1.1 PM Parts List ............................................................................................ 1-1
(1) Removal of the Pickup Roller/Take-Up Roller ....................... 1-1
(2) Removal of the Separator Roll ............................................... 1-2
(3) Cleaning of the Roll ................................................................ 1-4
(4) Cleaning of the Roller ............................................................ 1-4
(5) Cleaning of the Scanning Guide ............................................ 1-5
(6) Cleaning of the Sensor Section ............................................. 1-6
2.1.1 Indentification and Removal Procedures of Doors, Covers, and Exterior
Parts 1-7
(1) Duplexing Document Feeder (AFR-19) ................................. 1-7
(1) Removal of the Main Control Board (PBA-CONT) ................. 1-8
(2) Removal of the Variable Resistor .......................................... 1-9
3. UPGRADING THE FIRMWARE ....................................................................... 1-11
3.1 Optional Duplexing Document Feeder (AFR-19)
Firmware Upgrade ................................................................................... 1-11
ADJUSTING/SETTING
1. SERVICE MODE .............................................................................................. 2-1
1.2.1 ADJUST ......................................................................................... 2-2
(1) ADF SUB ZOOM .................................................................... 2-2
(2) ADF MAIN REGIST ............................................................... 2-3
(3) ADF SUB REGIST1 ............................................................... 2-4
(4) ADF SUB REGIST2 ............................................................... 2-5
(5) ADF REG. LOOP1 ................................................................. 2-6
(6) ADF REG. LOOP2 ................................................................. 2-6
1.2.2 FUNCTION .................................................................................... 2-7
(1) ADF FEED TEST ................................................................... 2-7
(2) COPY ADF GLASS AREA ..................................................... 2-7
(3) ADF WIDTH ADJ. (MAX) ....................................................... 2-8
(6) ADF WIDTH ADJ. (MIN) ........................................................ 2-8
(6) ADF SENSOR ADJUST ......................................................... 2-8
1.2.3 CLEAR DATA ................................................................................ 2-9
(1) ADF BACKUP CLEAR ........................................................... 2-9
2.1 Checking for Skew Feed .......................................................................... 2-10
2.2 Adjusting Skew Feed ............................................................................... 2-11
2.3 Registration Check (full size copy, 2-sided original/2-sided copy) ........... 2-12
TROUBLESHOOTING
1. Introduction ...................................................................................................... 3-1
i
Di1811p_F.book ii ページ２００４年３月２日　火曜日　午後４時２３分
1.1.1 Sensor ........................................................................................... 3-1

1.1.2 Switch ............................................................................................ 3-2
1.1.3 Solenoid ......................................................................................... 3-2
1.1.4 Clutch ............................................................................................ 3-2
1.1.5 Motor ............................................................................................. 3-3
2. MISFEEDS ....................................................................................................... 3-4
2.1 Initial Checks ............................................................................................ 3-4
2.2.1 Outline ........................................................................................... 3-4
2.4.1 Paper Take-Up Misfeed ................................................................. 3-6
2.4.2 Transport Section Misfeed ............................................................. 3-7
2.4.3 Turnover Unit Misfeed ................................................................... 3-8
2.4.4 Paper Exit Section Misfeed ........................................................... 3-9
3. MALFUNCTIONS ............................................................................................. 3-10
3.1 Warning Detection Timing and Troubleshooting Procedure .................... 3-10
3.1.1 C0044: ADF Cooling Fan Failure .................................................. 3-10
4. Time Chart ....................................................................................................... 3-11
4.1 Single-sided document mode (A4C; 2-sheet feeding) ............................. 3-11
4.2 Double-sided document mode (A4C; 2-sheet feeding) ............................ 3-12
4.3 Fax (Fine) mode (A4C; 2-sheet feeding) .................................................. 3-14
4.4 Immediate fax transmission mode (A4C; 2-sheet feeding) ...................... 3-15
ii
MAINTENANCE
19971
1.1 PM Parts List
PM Parts
Clean Replace Page
Pickup Roller 50K 200K ☞ 1-1
Paper Take-Up Roll 50K 200K ☞ 1-1
Duplexing Doc- Separator Roll 50K 200K ☞ 1-2
ument Feeder Rollers and rolls 50K – ☞ 1-4
Scanning Guide 50K – ☞ 1-5
Reflective Sensor Section 50K – ☞ 1-6
NOTES
procedures.

(1) Removal of the Pickup Roller/Take-Up Roller
4344D507AA
2. Remove two screws and the cover.
4344D508AA
1-1
3. Remove two C-clips and remove the Pickup

Roller Assy.
4344D514AA
4. Remove two levers.

5. Remove five C rings.
6. Remove one arm.
7. Remove two Pickup Rollers.
4344D515AA
8. Remove one C-ring and remove the gear and

bushing.
9. Remove two pins.
10. Remove the Paper Take-Up Roll.
NOTE
• Use care not to lose the pin.
4344D516AA
(2) Removal of the Separator Roll
4344D507AA
2. Hold the arrow sections in the figure and remove

the cover.
4344D509AA
1-2
3. Remove the Paper Separator Roll Assy.
NOTE
• Use care not to lose the spring below the Separa-
tor Roller Assy.
4344D513AA
4. While opening up the holder, remove the shaft.
NOTE
• Opening the holder too much can break the holder.
4344D512AA
5. Remove the Separator Roller from the shaft.
4344D511AA
1-3
(3) Cleaning of the Roll

the roll.
4344D519AA
3. Lift up the Drawer.

the roll.
4344D520AA
5. Open the Duplexing Document Feeder.

the roll.
4344D521AA
(4) Cleaning of the Roller

the roller.
4344D522AA
3. Lift up the Drawer.

the roller.
4344D523AA
1-4
5. Remove the Front and Rear Cover.

6. Unplug eight connectors on the board.
4344D001AA
7. Remove the lever.
4344D002AA
8. Remove seven screws and the Paper Take-Up

Unit.
4344D003AA

the roller.
4344D004AA
(5) Cleaning of the Scanning Guide
1. Open the Duplexing Document Feeder.

the Scanning Guide clean of dirt.
4344D524AA
1-5
(6) Cleaning of the Sensor Section
1. Clean the sensor using a brush or other similar

tools.
4344D525AA
1-6
2.1.1 Indentification and Removal Procedures of Doors, Covers, and Exterior
Parts
(1) Duplexing Document Feeder (AFR-19)
6
5
7
4
3
2
1
4344D005AB

1 Document Exit Tray –
Document Feeding Remove the Document Feeding Tray. → Remove four
2
Tray Cover screws. → Remove the Document Feeding Tray Cover.
3 Document Edge Guide –
Raise the Duplexing Document Feeder. → Remove two
4 Front Cover
screws. → Remove the Front Cover.
5 Upper Door –
Document Take-up Open the Upper Door. → Remove two screws. →
6
Section Cover Remove the Document Take-up Section Cover.
Open the Upper Door. → Remove the Rear Cover. →
Document Feeding
7 Remove two screws and unplug one connector. →
Tray
Remove the Document Feeding Tray.
Open the Upper Door. → Remove two screws. → Unhook
8 Rear Cover
two tabs and remove the Rear Cover.
1-7
NOTES
PBA-CONT
4344D554AA

PBA-CONT Main Control Board ☞ 1-8
(1) Removal of the Main Control Board (PBA-CONT)

1. Turn OFF the Power Switch.
☞ 1-7
3. Unplug all connectors from the Main Control

Board.
4. Remove three screws and the Main Control
Board.
4344D531AA
<Reinstallation Procedure>
1. Reinstall all parts that have been removed by reversing the order of removal.
2. Turn ON the Power Switch.
NOTE
• Perform the following steps when the Main Control Board has been replaced.
3. Upgrade the firmware.
1-8
(2) Removal of the Variable Resistor

1. Turn OFF the power.
2. Remove the Original Feed Tray Rear Cover.
☞ 1-7
3. Unplug one connector.

4. Remove two screws and the mounting bracket.
4344D532AA
5. Remove the gear.
4344D533AA
6. Remove one nut and one washer and the Vari-

able Resistor.
4344D534AA
<Reinstallation Procedure>
1. Close the Side Edge Stop of the Original Feed

Tray.
NOTE
• Be sure to perform document width detection
adjustment after replacing the Variable Resistor
(PBA-VR).
4344D535AA
1-9
2. Use one nut to install the Variable Resistor.
NOTE
• Align the protrusion of the Variable Resistor and
the cutout of the mounting bracket.
4344D536AA
3. Turn the Variable Resistor counterclockwise until

it stops.
4344D537AA
4. Reinstall the gear that was removed at Removal

Procedure 5.
NOTE
• Note the mounting position of the gear and the
Variable Resistor.
4344D538AA
5. Use two screws to install the Variable Resistor.
NOTE
• Install the gear and rack gear by aligning the
arrows.
4344D539AA
6. Install the Original Feed Tray Rear Cover and turn ON the power.
NOTE
• Be sure to perform the following operation when the Variable Resistor is replaced.
7. Power cycle and check whether size detection operates normally.
1-10
3. UPGRADING THE FIRMWARE

3.1 Optional Duplexing Document Feeder (AFR-19)
Firmware Upgrade
1. Prepare the firmware upgrade EP-ROM.

2. Turn OFF the power and remove the Rear Cover.
4344D549AA
3. Insert the EP-ROM you prepared at step 1 to the

IC socket section of the Control Board.
NOTE
• Ensure that the EP-ROM is installed in the correct
direction.
4. Turn ON the power.

4344D550AA
5. Check the firmware update status at the Print

Lamp Display Section of the Duplexing Docu-
ment Feeder.
Updating : Green and red light up alternately.
Successful completion: Blinks in green.
Failure : Blinks in red.
Print Lamp Display Section
✽ If failure occurs, redo the procedure from step 3.
4344D551AA
6. After the firmware has been upgraded success-

fully, turn OFF the power and remove the EP-
ROM that was attached at step 3.
4344D552AA
1-11
7. Turn ON the power.

8. Display Tech. Rep. Mode.
9. Using the Display menu, check the ROM version
number of the ADFR.
10. Correct the version indication on the ROM label
on the Control Board using a pen or other similar
4344D553AA means.
11. Reinstall the Rear Cover.
1-12
ADJUSTING/SETTING
19971
1. SERVICE MODE
NOTE
<Procedure>
3. Stop → 0 → 0 → Stop → 0 → 1
<Exiting the Mode>


2-1

1.2.1 ADJUST
(1) ADF SUB ZOOM

Press the Start key to start a test
Test Copy To adjust variations in machining and copy cycle.
installation accuracy of different parts by
varying the scanning zoom ratio in the • The default setting is “100.”
Adjust sub scanning direction when the Auto-
matic Document Feeder is used. Setting range: 87 to 113
(1 step: 0.4%)
• Ready the test chart that comes with the Automatic

Document Feeder.
• Adjust so that deviation between length A on the
test chart and that on the copy falls within the
specified range.
Reference line A: 400 mm Specifications

4035D513AA
400 ± 6.0 mm
2. Measure the length of reference line A on the copy to determine if the deviation falls
4. Select “ADF Sub Zoom” and press the [Yes] key.
7. Make another full-size copy of the test chart to determine the amount of error in length
A on the copy.
If length A on the copy is longer than the specifications, decrease the setting value.
If length A on the copy is shorter than the specifications, increase the setting value.
If a single adjustment procedure does not successfully bring the deviation into the specified
range, repeat steps 3 through 7.
2-2
(2) ADF MAIN REGIST

Test Copy
Adjust main scanning direction when the Auto- (1 step: 0.1 mm)
Reference line B
• Adjust so that the amount of error of width B on the
Width B
copy falls within the specified range.
Specifications
4035D513AA
20 ± 2.0 mm
2. Using a scale, measure the distance between reference line B on the copy and the top
edge of the copy (width B) and determine if the amount of error in width B falls within
the specified range. If it falls outside the specified range, perform the following steps to
make an adjustment.
4. Select “ADF Main Regist” and press the [Yes] key.
7. Make another full-size copy of the test chart to check for the amount of error in width B
on the copy.
If width B on the copy is longer than the specifications, decrease the setting value.
If width B on the copy is shorter than the specifications, increase the setting value.
2-3
(3) ADF SUB REGIST1

Test Copy
Adjust NOTE
Reference line C • Ready the test chart that comes with the optional
Specifications
Length C 4035D513AA
20 ± 2.5 mm
on the copy.
If length C on the copy is longer than the specifications, increase the setting value.
If length C on the copy is shorter than the specifications, decrease the setting value.
2-4
(4) ADF SUB REGIST2

Test Copy
Adjust NOTE
Reference line C • Ready the test chart that comes with the optional
Specifications
Length C 4035D513AA
20 ± 2.5 mm
on the copy.
If length C on the copy is longer than the specifications, decrease the setting value.
If length C on the copy is shorter than the specifications, increase the setting value.
2-5
(5) ADF REG. LOOP1

To adjust the length of loop formed in the orig- • The default setting is “100.”
inal before the Registration Roller.
Setting range: 95 to 105
✽ When a skew feed, fold, or misfeed of the (1 step: 1.0 mm)
original occurs
2. Select “ADF Reg. Loop1” and press the [Yes] key.
3. Using [ ▲ / ▼ ] key, select the desired setting value.
• Try a different setting value until there is no skew, fold, or misfeed of the original.
(6) ADF REG. LOOP2

To adjust the length of loop formed in the orig- • The default setting is “100.”
inal before the Registration Roller.
Setting range: 95 to 105
✽ When a skew feed, fold, or misfeed of the (1 step: 1.0 mm)
original occurs
2. Select “ADF Reg. Loop2” and press the [Yes] key.
• Try a different setting value until there is no skew, fold, or misfeed of the original.
2-6
1.2.2 FUNCTION
(1) ADF FEED TEST
• To check for correct paper passage of the <Step>
paper take-up and transport system in the 1. Load paper in the ADF.
Automatic (Duplexing) Document Feeder 2. Press the Start key to start the ADF feed
alone as a single unit. test.
• Here are the details of operation involved ✽ Press the Stop key to stop the ADF feed
in the paper passage motion. test.
scan motion.
• Paper passage operation continues
until all pages of the document
loaded in the unit have been fed in.
✽ When a paper misfeed of originals occurs
(2) COPY ADF GLASS AREA

To check for scratches and dirt on the Origi- <Step>
nal Scanning Glass. 1. Place a gray chart (OD = 0.3) on the
Original Glass.
✽ When a dirty image occurs 2. Press the Start key to start the Copy
ADF Glass Area test.
3. The Scanner moves from its standby
position to a point 2 mm to the left of the
Original Scanning Glass.
4. The Scanner moves to the right to start a
scan motion.
5. The copier produces two copy samples
(in order to know dirt on the glass from
printer image noise).
2-7
(3) ADF WIDTH ADJ. (MAX)

Purpose
To adjust the original size detection VR.
✽ When PBA-VR board is replaced
<Setting Details>
1. Display the Tech. Rep. mode.
2. Choose “ADF WIDTH ADJ. (MAX)” from “Functions”.
3. Align the original edge plane of the Side Edge

Stop of the Original Feed Tray to the outside ▼
mark.
4. Press the YES key to determine the maximum
value.
5. Power cycle and check whether size detection
4344D540AA operates normally.
(6) ADF WIDTH ADJ. (MIN)

Purpose
To adjust the original size detection VR.
✽ When PBA-VR board is replaced
<Setting Details>
1. Display the Tech. Rep. mode.
2. Choose “ADF WIDTH ADJ. (MIN)” from “Functions”.
3. Align the original edge plane of the Side Edge

Stop of the Original Feed Tray to the inside ▼
mark.
4. Press the YES key to determine the minimum
value.
5. Power cycle and check whether size detection
4344D541AA operates normally.
(6) ADF SENSOR ADJUST

To automatically adjust the detection level of 1. Display the Tech. Rep. mode.
original path sensor. 2. Choose “ADF WIDTH ADJUST” from
✽ When each sensor is replaced “Functions”.
✽ When original size detection error occurs 3. Press the YES key.
2-8
1.2.3 CLEAR DATA

(1) ADF BACKUP CLEAR
To clear the values adjusted with ADF SEN- 1. Press the YES key to clear settings
SOR ADJUST and the values adjusted with memorized in PBA-CONT.
Org. Width Detect.
2. The operation stops automatically.
✽ When PBA-CONT board has been 3. After clear the Backup data, adjust the
replaced. ADF WIDTH ADJ. (MAX), ADF WIDTH
✽ When PBA-VR board has been replaced.
ADJ. (MIN) and ADF SENSOR ADJUST.
2-9
2.1 Checking for Skew Feed
20 mm
1. Test chart (A3) of the attachment is prepared.
* Copy Paper
Inch area: 11 × 17
Metric area: A3
2. Plug in the power cord and turn ON the Power
Switch of the copier.
4688U042AB
3. Load the test chart in the Automatic Document

Feeder and make one 1-sided copy five consecu-
tive times.
4344U046AB
4. Fold each of the sample copies as illustrated and

check for any deviation.
Specifications: 0 ± 3.0 mm
* If the deviation does not fall within the specified range,

perform the following adjustment procedure.
4688U001AB
2-10
2.2 Adjusting Skew Feed
1. Loosen the screw shown and adjust the position

of the Automatic Document Feeder as detailed
below.
4344U022AA
2. If the deviation looks as illustrated, push the front

left side of the Automatic Document Feeder
toward the rear.
Move the hinge to the front.

4688U001AB
4344U028AA
3. If the deviation looks as illustrated, push the front

right side of the Automatic Document Feeder
toward the rear.
Move the hinge to the rear
4688U002AB
4344U010AA
4. After the adjustment procedure has been completed, tighten with a screwdriver the screw which has
been loosened in step 1
2-11
2.3 Registration Check (full size copy, 2-sided original/2-sided

copy)
1. Test chart (A3) of the attachment is prepared.

20 mm
20 mm
4344U053AA
2. Place the test chart in the Duplexing Document

Feeder.
3. Make a full size copy.
4344U048AB
4. Make a full size copy using the 2-sided original/2-sided

copy mode.
(Face down the test chart.)
4344U052AC
5. Check that the margins reproduced on the copy

A
meet the following specifications.
B
* In full size copy mode

Margin Registration Specifications:
Width A: 20 ± 2.5 mm
Width B: 20 ± 2.0 mm
4344U053AA * In 2-sided original mode

Margin Registration Specifications:
Width A: 20 ± 3.0 mm
If the margins reproduced on the copy fall outside the

specified range, make the “Registration Adjustment.”
2-12
TROUBLESHOOTING
19971
1. Introduction
in this chapter.
• If a paper misfeed or malfunction occurs, perform the following operation to check the
1.1.1 Sensor

Replace the sen-
NO
Does the input signal of the control board change sor.
1
when the sensor light is interrupted? (H → L, L → H) Replace the con-
YES
trol board.
4025T520AA
4025T521AA
3-1
1.1.2 Switch

Replace the
NO
Does the input signal (NO) of the control board change switch.
1
from L to H when the switch is turned on? Replace the con-
YES
trol board.
NO
Not Use
COM
4025T523AB
1.1.3 Solenoid

Replace the con-
NO
Does the output signal of the control board change trol board.
1
from H to L when the solenoid is activated? Replace the sole-
YES
noid.
1 2 1
2 1 2
4025T522AA
1.1.4 Clutch

Replace the con-
NO
Does the output signal of the control board change trol board.
1
from H to L when the clutch is activated? Replace the
YES
clutch.
4025T528AA
3-2
1.1.5 Motor

Replace the con-
Does the LOCK signal of the control board switch to
1 NO trol board.
H when the machine goes into standby?
Replace the motor.
YES Replace the motor.
Does the REM signal of the control board change
2 Replace the con-
from H to L when the motor is turned on? NO
trol board.
GND 1
REM 2
LOCK 3
4025T526AA

Does the input signal of the control board change from Replace the
YES
H to L when the motor is turned on? motor.
1
(Input signals differ according to the direction of rota- Replace the con-
tion) NO
trol board.
4025T525AA

Replace the
YES motor or the con-
Are the relay connector of the motor and the print jack trol board.
1
of the control board correctly connected? Connect the con-
NO nector or the print
jack.
4025T527AA
3-3
2. MISFEEDS
2.1 Initial Checks
Check Item Action

Replace paper.
Is the paper curled, wavy, or damp? Instruct the user on the correct paper stor-
age procedures.
Is a foreign object present along the paper Clean the paper path and replace if neces-
path, or is the paper path deformed or worn? sary.
Are the Paper Separator Fingers dirty, Clean or replace the defective Paper Sepa-
deformed, or worn? rator Finger.
Are the Edge Guide and Trailing Edge Stop
at the correct position to accommodate the Set as necessary.
paper?
Are the actuators operating correctly? Correct or change the defective actuator.

2.2.1 Outline
copier.
detected.
3-4
Registration Sensor (PC9-ADF)
Separator Sensor (PC6-ADF)
Original Detection Sensor

(PC8-ADF)
Exit/Turnover Sensor (PC10-ADF)
4344T502AA
3-5

2.4.1 Paper Take-Up Misfeed
<Detection Timing>;
Type Description
The Separator Sensor (PC6-ADF) is not blocked even after the
set period of time has elapsed after the Paper Take-Up Motor
Paper Take-Up Section (M1-ADF) is energized.
misfeed detection The Registration Sensor (PC9-ADF) is not blocked even after the
set period of time has elapsed after the Paper Take-Up Motor
(M1-ADF) is energized.
The Separator Sensor (PC6-ADF) is not blocked even after the
set period of time has elapsed after the Original Detection Sen-
Detection of paper sor (PC8-ADF) is blocked by the paper.
remaining in the Paper
Take-Up section The Registration Sensor (PC9-ADF) is not blocked even after the
set period of time has elapsed after the Original Detection Sen-
sor (PC8-ADF) is blocked by the paper.
<Action>
Paper Take-Up Motor (M1-ADF) Control Board (PBA-CONT)
Separator Sensor (PC6-ADF)
Original Detection Sensor (PC8-ADF)
WIRING DIAGRAM
Ref. Location
Step Operations
Page Control signal (Electrical
Components)
1 Initial checks ☞ 3-4 — —
2 PC6-ADF sensor check ☞ 3-1 PBA-CONT CN5CONT-11 G-2
5 M1-ADF operation check ☞ 3-3 — F-7
6 PBA-CONT replacement — — E-5
3-6
2.4.2 Transport Section Misfeed
<Detection Timing>;
Type Description
The Original Detection Sensor (PC8-ADF) is not blocked even
Transport Section mis-
after the set period of time has elapsed after the Registration
feed detection
Sensor (PC9-ADF) is blocked by the paper.
Detection of paper The Original Detection Sensor (PC8-ADF) is not unblocked even
remaining in the Trans- after the set period of time has elapsed after the Registration
port Section Sensor (PC9-ADF) is unblocked by the paper.
<Action>
Paper Take-Up Motor (M1-ADF) Control Board (PBA-CONT)
Transport Motor (M2-ADF)
WIRING DIAGRAM
Ref. Location
Step Operations
Components)
4 M1-ADF operation check ☞ 3-3 — F-7
5 M2-ADF operation check ☞ 3-3 — E-7
3-7
2.4.3 Turnover Unit Misfeed
<Detection Timing>;
Type Description
The Registration Sensor (PC9-ADF) is not blocked even after the
Turnover Unit misfeed
set period of time has elapsed after the Transport Motor (M2-
detection
ADF) is energized.
<Action>
Transport Motor (M2-ADF) Control Board (PBA-CONT)
WIRING DIAGRAM
Ref. Location
Step Operations
Components)
3-8
2.4.4 Paper Exit Section Misfeed
<Detection Timing>;
Type Description
The Exit/Turnover Sensor (PC10-ADF) is not blocked even after
Paper Exit Section mis-
the set period of time has elapsed after the Original Detection
feed detection
Sensor (PC8-ADF) is blocked by the paper.
Detection of paper The Exit/Turnover Sensor (PC10-ADF) is not unblocked even
remaining in the Trans- after the set period of time has elapsed after the Original Detec-
port Section tion Sensor (PC8-ADF) is unblocked by the paper.
<Action>
Transport Motor (M2-ADF) Control Board (PBA-CONT)
Exit/Turnover Sensor (PC10-ADF)
WIRING DIAGRAM
Ref. Location
Step Operations
Components)
3 PC10-ADF sensor check ☞ 3-1 PBA-CONT CN6CONT-9 H-2
3-9
3. MALFUNCTIONS
• The copier’s CPU performs a self-diagnostics function that, on detecting a malfunction,
gives the corresponding mulfunction code and maintenance call mark on the Touch
Panel.
4030T505CA
3.1 Warning Detection Timing and Troubleshooting Procedure

3.1.1 C0044: ADF Cooling Fan Failure
<Detection Timing>
Trouble
Description
Code
• The ADF Fan Motor Lock signal remains set to H for a set period of time
C0044
while the EDH Fan Motor is turning.
Action
Cooling Fan Motor (M3-ADF) Main Control Board (PBA-CONT)
WIRING DIAGRAM
Ref. Location
Step Operations
Components)
Check the motor connectors for
1 paper connection, and correct as — — —
necessary.
Check the fan for possible overload,
2 — — —
and correct as necessary.
PBA-CONT CN9
3 M3-ADF operation check. ☞ 3-3 E-5
CONT-2 (REM)
4 Replace PBA-CONT. — — —
3-10
4. Time Chart
4.1 Single-sided document mode (A4C; 2-sheet feeding)
4030T505CA
3-11
4.2 Double-sided document mode (A4C; 2-sheet feeding)
4344T506CA
3-12
4344T507CA
3-13
4.3 Fax (Fine) mode (A4C; 2-sheet feeding)
4344T508CA
3-14
4.4 Immediate fax transmission mode (A4C; 2-sheet feeding)
4344T509CA
3-15
3-16
AD-17
2004.3
Ver. 1.0
INDEX
MAINTENANCE
ADJUSTMENT/SETTING
TROUBLESHOOTING
CONTENTS
MAINTENANCE
1.1 PM Parts List ............................................................................................ 1-1
(1) Cleaning of the Duplex Unit Transport Rollers/Rolls .............. 1-2
(2) Cleaning of the Switch Back Unit Transport Roller/Roll ......... 1-2
(3) Cleaning of the Duplex Unit Ventilation Section .................... 1-3
(4) Cleaning of the Bypass Transport Roller/Rolls ...................... 1-3
2. MISCRELLANEOUS PARTS ........................................................................... 1-5
2.1.1 Identification and Removal Procedures of Doors, Covers, and
Exterior Parts 1-5
(1) Duplex Unit ............................................................................ 1-5
(1) Removal of the Control Board (PWB-A/AD) .......................... 1-7
ADJUSTING/SETTING
1. SERVICE MODE .............................................................................................. 2-1
1.2.1 SERVICE’S CHOICE ..................................................................... 2-2
(1) LOOP ADJUST (DUPLEX) .................................................... 2-2
TROUBLESHOOTING
1. INTRODUCTION .............................................................................................. 3-1
1.1.1 Sensor ........................................................................................... 3-1
1.1.2 Switch ............................................................................................ 3-2
1.1.3 Solenoid ......................................................................................... 3-2
1.1.4 Clutch ............................................................................................ 3-2
1.1.5 Motor ............................................................................................. 3-3
2. MISFEEDS ....................................................................................................... 3-4
2.1 Initial Checks ............................................................................................ 3-4
2.2.1 Outline ........................................................................................... 3-4
2.3 Misfeed Display ........................................................................................ 3-5
2.5.1 Duplex Reversal Housing Block .................................................... 3-7
i
MAINTENANCE
19971
1.1 PM Parts List
PM Parts
Clean Replace Page
Duplex Unit Transport Roller/ When a malfunction ☞ 1-2
–
Roll occurs
Switch Back Unit Transport When a malfunction ☞ 1-2
–
Roller/Roll occurs
Duplex Unit
When a malfunction ☞ 1-3
Ventilation Section –
occurs
Bypass Transport Roller/Roll –
occurs
NOTES
procedures.
1-1

(1) Cleaning of the Duplex Unit Transport Rollers/Rolls
1. Open the Front Door of the Duplex Unit.

the Duplex Unit Transport Rollers/Rolls clean of
dirt.
4532D001AA
(2) Cleaning of the Switch Back Unit Transport Roller/Roll
1. Remove two screws and the Duplex Unit.
4532D002AA

the Switch Back Unit Transport Roller/Roll clean
of dirt.
4532D003AA
1-2
(3) Cleaning of the Duplex Unit Ventilation Section

the outside of the Duplex Unit Ventilation Section
clean of dirt.
4532D004AA
2. Open the Front Door of the Duplex Unit.

the inside of the Duplex Unit Ventilation Section
clean of dirt.
4532D005AB
(4) Cleaning of the Bypass Transport Roller/Rolls

1. Remove the Rear Right Cover.
☞ 1-5
2. Open the Right Door.
3. Remove two screws, unplug one connector, and

remove the Bypass Assy.
4532D013AB

the Bypass Transport Roller clean of dirt.
4532D010AA
1-3

the Bypass Transport Rolls clean of dirt.
4532D015AA
1-4
2. MISCRELLANEOUS PARTS
2.1.1 Identification and Removal Procedures of Doors, Covers, and Exterior Parts
(1) Duplex Unit
4532D006AB

Remove the Lower Right Cover. → Remove two screws.
1 Right Cover
→ Remove the Right Cover.
2 Lower Right Cover Remove one screw. → Remove the Lower Right Cover.
Remove the Right Cover. → Remove one screw, snap off
3 Front Door one C-clip, and remove one washer. → Slide the Front
Door to the left and take it off.
1-5
NOTES
PWB-A/AD
4532D007AA

PWB-A/AD Control Board ☞ 1-7
1-6
(1) Removal of the Control Board (PWB-A/AD)
1. Remove one screw and the Lower Right Cover.
4532D011AA
2. Remove two screws and the Right Cover.
4532D017AB
3. Remove two screws, unplug all connectors, and

remove the Control Board.
4532D018AA
1-7
ADJUSTING/SETTING
19971
1. SERVICE MODE
NOTE
<Procedure>
3. Stop → 0 → 0 → Stop → 0 → 1
<Exiting the Mode>


2-1

1.2.1 SERVICE’S CHOICE
(1) LOOP ADJUST (DUPLEX)
To adjust the length of the loop formed in the Setting range: -3.9 to 3.9 mm
paper before the Synchronizing Roller. (1 step: 0.6 mm)
✽ When a skew feed, fold, or misfeed of paper

occurs
✽ When variations in the amount of void on
the leading edge occurs
1. Call Service’s Choice of Service Mode to the screen.
2. Select “Loop Adjust (Duplex)” and press the [Yes] key.
• Try a different setting value until there are no variations in the amount of void on the lead-
ing edge, and paper skew, fold, or misfeed.
2-2
TROUBLESHOOTING
19971
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING
1. INTRODUCTION
in this chapter.

1.1.1 Sensor
YES Replace the
control board.
4025T520AA
4025T521AA
3-1
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004
1.1.2 Switch
YES Replace the
control board.
NO
Not Use
COM
4025T523AB
1.1.3 Solenoid
YES Replace the
solenoid.
1 2 1
2 1 2
4025T522AA
1.1.4 Clutch
YES Replace the
clutch.
4025T528AA
3-2
1.1.5 Motor
Replace the motor.
trol board.
GND 1
REM 2
LOCK3
4025T526AA

4025T525AA

board.
NO Connect the con-
nector or the print
jack.
4025T527AA
3-3
2. MISFEEDS
2.1 Initial Checks
Check Item Action
storage procedures.

2.2.1 Outline
copier.
detected.
3-4
2.3 Misfeed Display

4532T501CA

OPEN DUPLEX ☞ 3-7
Duplex Reversal Housing Block
COVER

3-5
4532T502CA
1: Duplex Unit Transport Sensor (PC2/AD)
3-6

2.5.1 Duplex Reversal Housing Block
<Detection Timing>
Type Description
Duplex Reversal Hous- • If the Duplex Unit Transfer Sensor does not turn on even when
ing Block a specified time elapses after the Exit Sensor turns off.
<Action>
Duplex Unit Transport Motor (M2/AD) Control Board (PWB-A/AD)
Duplex Unit Transport Sensor (PC2/AD)
WIRING DIAGRAM

Components)
F~G-7
2 M2/AD operation check ☞ 3-3 –
(AD-17)
PWB-A/AD PJ4A/AD-5 C~D-3~4
3 PC2/AD sensor check ☞ 3-1
(ON) (AD-17)
4 Replace PWB-A/AD – – –
3-7
PF-126
2004.3
Ver. 1.0
INDEX
MAINTENANCE
ADJUSTMENT/SETTING
TROUBLESHOOTING
CONTENTS
MAINTENANCE
1.1 PM Parts List ............................................................................................ 1-1
(1) Removal of the Paper Take-Up Rollers ................................. 1-1
(2) Cleaning of the Paper Take-up Rollers .................................. 1-2
(3) Cleaning of the Vertical Transport Roller/Rolls ...................... 1-2
(1) Identification and Removal Procedures of Doors, Covers,
and Exterior ............................................................................ 1-3
(1) Removal of the Control Board (PWB-A/PF) ........................... 1-4
(2) Removal of the Paper Size (FD) Detection Board
(PWB-I/PF) ............................................................................. 1-5
ADJUSTING/SETTING
1. SERVICE MODE .............................................................................................. 2-1
1.2.1 SERVICE’S CHOICE ..................................................................... 2-2
(1) LOOP ADJUST (TRAY2 TO TRAY5) .................................... 2-2
1.2.2 FUNCTION .................................................................................... 2-2
(1) PAPER FEED TEST .............................................................. 2-2
2.1 Paper Feed Unit CD Registration Adjustment .......................................... 2-3
TROUBLESHOOTING
1. INTRODUCTION .............................................................................................. 3-1
1.1.1 Sensor ........................................................................................... 3-1
1.1.2 Switch ............................................................................................ 3-2
1.1.3 Solenoid ......................................................................................... 3-2
1.1.4 Clutch ............................................................................................ 3-2
1.1.5 Motor ............................................................................................. 3-3
2. MISFEEDS ....................................................................................................... 3-4
2.1 Initial Checks ............................................................................................ 3-4
2.2.1 Outline ........................................................................................... 3-4
2.3 Misfeed Display ........................................................................................ 3-5
2.5.1 Misfeed at the Paper Feed Unit Paper Take-up/Vertical
Transport Section .......................................................................... 3-7
i
MAINTENANCE
19971
1.1 PM Parts List
PM Parts
Clean Replace Page
Paper Take-up Roller 150K
occurs
Paper Feed Unit
Vertical Transport Roller/Roll –
occurs
NOTES
procedures.

(1) Removal of the Paper Take-Up Rollers
1. Remove the Paper Feed Tray/1.
☞ 1-3
2. Remove the Paper Take-up Roller lock. Then,

slide and take off two Paper Take-up Rollers.
4686D011AB
Precautions for Installation of the Paper Take-up Roller

• Make sure that the Paper Take-up Roller lock is in position.
1-1
(2) Cleaning of the Paper Take-up Rollers
1. Remove the Paper Take-up Rollers.

the two Paper Take-up Rollers clean of dirt.
4686D012AA
(3) Cleaning of the Vertical Transport Roller/Rolls
1. Open the Paper Take-up Unit Right Door.

the Vertical Transport Roller/Rolls clean of dirt.
4686D013AA
1-2
(1) Identification and Removal Procedures of Doors, Covers, and Exterior
1 3
4686D014AB

Slide out the Paper Feed Unit. → Remove two screws. →
1 Paper Feed Unit Remove the fixing brackets on the right and left ends of
the unit. → Remove the Paper Feed Unit.
Paper Feed Unit Rear Remove one screw. → Remove the Paper Feed Unit Rear
2
Cover Cover.
Paper Feed Unit Right
3 –
Door
1-3
NOTES
PWB-I/PF
PWB-A/PF
4686D020AB

PWB-A/PF Control Board ☞ 1-4
Paper Size (FD) Detection
PWB-I/PF ☞ 1-5
Board
(1) Removal of the Control Board (PWB-A/PF)

1. Remove the Paper Feed Unit Rear Cover.
☞ 1-3
2. Unplug all connectors from the Control Board.

3. Remove two screws and the Control Board.
4686D015AB
1-4
(2) Removal of the Paper Size (FD) Detection Board (PWB-I/PF)

1. Slide out the Paper Feed Unit.
2. Remove the Paper Feed Unit Rear Cover.
☞ 1-3
4686D016AC
4. Remove two screws at the front.
4686D017AA
5. Remove two screws in the rear. Then, remove the

Paper Feed Unit from the copier.
4686D021AA
6. Remove two Paper Size (FD) Detection Board

Assy mounting screws.
4686D018AA
1-5
7. Unplug one connector and remove the lever and

Paper Size (FD) Detection Board.
4686D019AA
1-6
ADJUSTING/SETTING
19971
1. SERVICE MODE
NOTE
<Procedure>
3. Stop → 0 → 0 → Stop → 0 → 1
<Exiting the Mode>


2-1

(1) LOOP ADJUST (TRAY2 TO TRAY5)
paper before the Synchronizing Roller when (1 step: 0.6 mm)
the optional Paper Feed Unit is used.

occurs
2. Select “Loop Adjust (Tray2 to Tray5)” and press the [Yes] key.
1.2.2 FUNCTION
(1) PAPER FEED TEST
• To check for correct paper passage of <Step>
the paper take-up and transport sys- 1. Select the paper source.
tem by letting the copier consecutively TRAY1 TRAY2
take up and feed paper without involv- 2. Press the Start key to start the paper feed
ing actual printing action. test.
• Here are the details of operation ✽ Press the Stop key to stop the paper feed
involved in the paper passage motion. test.
scan motion.
• Paper is fed until the correspond-
ing paper source runs out of
paper.
• This test cannot be run while the
copier is warming up.
• This test cannot be run with the
Manual Bypass or Multiple Bypass
(option).
• No counters are activated.
✽ When a paper misfeed occurs
2-2
2.1 Paper Feed Unit CD Registration Adjustment
NOTE
• This adjustment is to be made when the PH Unit has been replaced.
1. Load the Paper Feed Unit with A4 crosswise paper.
2. Enter Function of the Service mode.
3. Select “Print Test Pattern” and then “Test Pattern1.” Then, press the Start key.
✽ This will produce a test pattern.
4. Check width A on the test pattern.

If width A falls outside the specified range, per-
form the following steps to make an adjustment.
A Specifications
20 ± 2.0 mm
4686D504AA
5. Slide out the Paper Feed Unit and loosen one

screw.
4686U025AB
6. If width A is greater than the specified range,

move the Edge Guide in the direction of the
arrow.
4686U088AB
7. If width A is smaller than the specified range,

move the Edge Guide in the direction of the
arrow.
8. After the adjustment has been made, produce a
new test pattern and check for deviation.
4686U089AB
2-3
9. After the adjustment has been properly made,

tighten the screw.
4686U025AB
2-4
TROUBLESHOOTING
19971
1. INTRODUCTION
in this chapter.

1.1.1 Sensor
YES Replace the
control board.
4025T520AA
4025T521AA
3-1
1.1.2 Switch
YES Replace the
control board.
NO
Not Use
COM
4025T523AB
1.1.3 Solenoid
YES Replace the
solenoid.
1 2 1
2 1 2
4025T522AA
1.1.4 Clutch
YES Replace the
clutch.
4025T528AA
3-2
1.1.5 Motor
Replace the motor.
trol board.
GND 1
REM 2
LOCK3
4025T526AA

4025T525AA

board.
NO Connect the con-
nector or the print
jack.
4025T527AA
3-3
2. MISFEEDS
2.1 Initial Checks
Check Item Action
storage procedures.

2.2.1 Outline
copier.
detected.
3-4
2.3 Misfeed Display

4686T502CA

OPEN 2nd SIDE Paper take-up/vertical transport section of the ☞ 3-7
COVER Paper Feed Unit

3-5

• When the optional AF-12, PF-126, and MB-6 are mounted
1
4686T501AA
1: Paper Take-Up Sensor (PC12/PF)
3-6

2.5.1 Misfeed at the Paper Feed Unit Paper Take-up/Vertical Transport Section
<Detection Timing>
Type Description
Paper take-up/ • The leading edge of the paper does not unblock the Synchronizing
vertical trans- Roller Sensor (PC1) even after the lapse of a given period of time
port section after the Paper Take-up Solenoid (SL11/PF) has been energized.
misfeed detec-
tion
• The Synchronizing Roller Sensor (PC1) is not blocked even after the
lapse of a given period of time after the paper has unblocked the Syn-
Size error
chronizing Roller Sensor (PC1).
detection
• The Synchronizing Roller Sensor (PC1) is blocked before the lapse of
a given period of time.
Paper left at the • The Paper Take-up Sensor (PC12/PF) is blocked at timing when the
paper take-up/ Power Switch is turned ON, the cover is opened and closed, or a
vertical trans- paper misfeed or malfunction is reset.
port section
<Action>
Synchronizing Roller Sensor (PC1) Paper Take-Up Sensor (PC12/PF)
Paper Take-Up Solenoid (SL11/PF) Master Board (PWB-A)
WIRING DIAGRAM

Components)
2 PC1 sensor check ☞ 3-1 PWB-A PJ17A-3 (ON) F-8
3 SL11/PF operation check ☞ 3-2 PWB-A/PF A-3 (PF-126)
PJ3A/PF-1A (ON)
4 PC12/PF sensor check ☞ 3-1 PWB-A/PF I-6 (PF-126)
PJ3A/PF-2B (ON)
5 Replace PWB-A – – –
3-7
MB-6
2004.3
Ver. 1.0
INDEX
MAINTENANCE
ADJUSTMENT/SETTING
TROUBLESHOOTING
CONTENTS
MAINTENANCE
1.1 PM Parts List ............................................................................................ 1-1
1.2 Replacement and Cleaning Parts ............................................................ 1-2
(1) Removal of the Separator Roller Assy ................................... 1-2
(2) Cleaning of the Separator Roller ............................................ 1-2
(3) Removal of the Paper Take-up Roller .................................... 1-2
(4) Cleaning of the Paper Take-up Roller .................................... 1-4
(5) Cleaning of the Bypass Transport Roller/Rolls ...................... 1-5
(1) Indentification and Removal Procedures of Doors, and
Exterior Parts ......................................................................... 1-6
2.1.1 Removal of Units ........................................................................... 1-7
(1) Removal of the Multiple Bypass ............................................. 1-7
2.1.2 Disassembly of the Optional Multiple Bypass (MB-6) .................... 1-9
(1) Removal and Disassembly of the Paper Take-up
Mechanical Clutch .................................................................. 1-9
ADJUSTING/SETTING
1. SERVICE MODE .............................................................................................. 2-1
1.2.1 SERVICE’S CHOICE ..................................................................... 2-2
(1) LOOP ADJUST (BYPASS) .................................................... 2-2
2.1 Multiple Bypass CD Registration Adjustment ........................................... 2-3
2.2 Multiple Bypass Mechanical Clutch Adjustment ....................................... 2-4
TROUBLESHOOTING
1. INTRODUCTION .............................................................................................. 3-1
1.1.1 Sensor ........................................................................................... 3-1
1.1.2 Switch ............................................................................................ 3-2
1.1.3 Solenoid ......................................................................................... 3-2
1.1.4 Clutch ............................................................................................ 3-2
1.1.5 Motor ............................................................................................. 3-3
2. MISFEEDS ....................................................................................................... 3-4
2.1 Initial Checks ............................................................................................ 3-4
2.2.1 Outline ........................................................................................... 3-4
2.3 Misfeed Display ........................................................................................ 3-5
2.5.1 Misfeed at the Multiple Bypass Paper Take-up Section ................ 3-7
i
MAINTENANCE
19971
1.1 PM Parts List
PM Parts
Clean Replace Page
Paper Take-up Roller 150K
occurs
Multiple Bypass Separator Roller Assy 150K
occurs
Manual Bypass Transport When a malfunction ☞ 1-5
–
Roller/Roll occurs
NOTES
procedures.
1-1
1.2 Replacement and Cleaning Parts

(1) Removal of the Separator Roller Assy

2. Remove the two screws and the Separator Roller
Assy.
4687D001AA
(2) Cleaning of the Separator Roller
1. Remove the Separator Roller Assy.

the Separator Roller clean of dirt.
4687D002AA
(3) Removal of the Paper Take-up Roller


3. Unplug two connectors.
4687D010AA
1-2
4. Remove two screws and the Upper Cover.
4687D011AB
5. Remove four screws and the Multiple Bypass.
4687D012AB
6. Remove two screws and the Lower Cover.
4687D003AA
7. Remove four screws, unplug one connector, and

remove the Paper Take-up Assy.
4687D004AB
1-3
8. Snap off three C-rings and slide the shaft to

remove one gear.
4687D005AB
9. Remove two bushings and the Paper Take-up

Roller Assy.
4687D006AB
10. Snap off one C-clip and two C-rings and remove
the Paper Take-up Roller.
4687D007AB
(4) Cleaning of the Paper Take-up Roller
1. Remove the Separator Roller Assy.

the Paper Take-up Roller Assy clean of dirt.
4687D008AA
1-4
(5) Cleaning of the Bypass Transport Roller/Rolls

3. Remove two screws and the Bypass Assy.
4035D010AA
the Bypass Transport Roller clean of dirt.
4035D011AA

the Bypass Transport Rolls clean of dirt.
4035D012AA
1-5
(1) Indentification and Removal Procedures of Doors, and Exterior Parts
4687D009AB

1 Upper Cover Remove two screws. → Remove the Upper Cover.
2 Lower Right Cover Remove one screw. → Remove the Lower Right Cover.
Remove the Upper Cover. → Remove two screws. →
3 Lower Cover
Remove the Lower Cover.
1-6
2.1.1 Removal of Units

(1) Removal of the Multiple Bypass
4687D010AA
4. Remove two screws and the Upper Cover.
4687D011AB
5. Remove four screws and the Multiple Bypass.
4687D012AB
<Multiple Bypass Installation Procedure>

1. Remove the Lower Right Cover, Upper Cover, and Lower Cover.
☞ 1-6
2. Install the Multiple Bypass and temporarily

tighten the four screws.
4687U054AA
1-7

4. Connect two connectors to the copier and secure
the harness using a wiring saddle.
4687U055AA
5. Install the positioning pin at the location shown

on the left.
6. Close the Right Door. Correctly position the Multi-
ple Bypass with reference to the positioning pin.
4687U012AA
7. Firmly tighten the four screws to fix the Multiple

Bypass in position.
8. Remove the positioning pin.
NOTE
• Save the positioning pin that has been removed.
4687U034AA
9. Loosen one screw shown.
4687U059AA
10. Make the lever contact the gear shaft.

11. Tighten the screw.
4687U060AA
12. Reinstall the Lower Cover, Upper Cover, and Lower Right Cover.
1-8
2.1.2 Disassembly of the Optional Multiple Bypass (MB-6)

(1) Removal and Disassembly of the Paper Take-up Mechanical Clutch
1. Remove the Multiple Bypass.
☞ 1-7
2. Remove the Lower Cover.
☞ 1-6
3. Remove four screws and the Paper Take-up

Roller Assy.
NOTE
• Use care not to lose the two springs.
4687D014AA
4. Remove the harness from the two wiring saddles.

5. Remove one screw, unplug one connector, and
remove the solenoid.
NOTE
• Do not remove the flapper from the solenoid.
4687D015AC
6. Snap off one E-ring and remove the Paper Take-

up Mechanical Clutch.
4687D016AA
7. Remove the collar.
4687D017AB
1-9
8. Remove the coupling.
4687D018AB
9. Remove the torque limiter from the gear.
4687D019AB
Precautions for Reassembly of the Paper Take-up Mechanical Clutch

• At reassembly, make sure that the protrusions on both ends of the torque limiter fit into
the center slit in the collar and coupling.
Torque Limiter Coupling
Slit
Slit Collar
4687D021AB
1-10
ADJUSTING/SETTING
19971
1. SERVICE MODE
NOTE
<Procedure>
3. Stop → 0 → 0 → Stop → 0 → 1
<Exiting the Mode>


2-1

(1) LOOP ADJUST (BYPASS)
paper before the Synchronizing Roller when (1 step: 0.6 mm)
the Manual Bypass is used.

occurs
2. Select “Loop Adjust (Bypass)” and press the [Yes] key.
2-2
2.1 Multiple Bypass CD Registration Adjustment
NOTE
• This adjustment is to be made when the PH Unit has been replaced.
1. Load the Paper Feed Tray/1 with A4 crosswise paper.
2. Enter Function of the Service mode.
3. Select “Print Test Pattern” and then “Test Pattern1.” Then, press the Start key.
✽ This will produce a test pattern.
4. Place the test pattern produced on the Original Glass.
5. Load A4 crosswise paper in the Multiple Bypass and make a test copy.
6. Check width A on the copy of the test pattern.

If width A falls outside the specified range, per-
form the following steps to make an adjustment.
A Specifications
20 ± 2.0 mm
4686D504AA
7. Turn the screw of the Multiple Bypass as neces-

sary to adjust the position of the Multiple Bypass
table.
If width A on the copy is smaller than width A on the
4687U035AA
test pattern, turn the screw clockwise.
If width A on the copy is greater than width A on the
test pattern, turn the screw counterclockwise.
8. Make another copy of the test pattern and check

for any error in width A.
2-3
2.2 Multiple Bypass Mechanical Clutch Adjustment

• The assembled position of the collar/coupling on the torque limiter of the Paper Take-up
Mechanical Clutch is varied so that the clutch operates properly.
NOTE
• This adjustment is to be made when a paper take-up failure occurs in the Multiple
Bypass.
1. Remove the Paper Take-up Mechanical Clutch.
☞ 1-9
2. Aligning protrusion A of the torque limiter with any one of the three slits in the coupling,
fit the coupling over the torque limiter.
3. Aligning protrusion B of the torque limiter with any one of the three slits in the collar, fit
the collar to the torque limiter.
Protrusion A Torque Limiter Coupling
Protrusion B Protrusion A
Slits
Slits Collar
Protrusion B 4687D021AB
4. Reinstall the Paper Take-up Mechanical Clutch and make copies using the Multiple
Bypass. If a paper take-up failure occurs again, repeat steps 1 through 3.
2-4
TROUBLESHOOTING
19971
1. INTRODUCTION
in this chapter.

1.1.1 Sensor
YES Replace the
control board.
4025T520AA
4025T521AA
3-1
1.1.2 Switch
YES Replace the
control board.
NO
Not Use
COM
4025T523AB
1.1.3 Solenoid
YES Replace the
solenoid.
1 2 1
2 1 2
4025T522AA
1.1.4 Clutch
YES Replace the
clutch.
4025T528AA
3-2
1.1.5 Motor
Replace the motor.
trol board.
GND 1
REM 2
LOCK3
4025T526AA

4025T525AA

board.
NO Connect the con-
nector or the print
jack.
4025T527AA
3-3
2. MISFEEDS
2.1 Initial Checks
Check Item Action
storage procedures.

2.2.1 Outline
copier.
detected.
3-4
2.3 Misfeed Display

4980P502DA

OPEN 1st SIDE ☞ 3-7
Paper take-up section of the Multiple Bypass
COVER

3-5

• When the optional AF-12, PF-126, and MB-6 are mounted
4687T501AA
1: Synchronizing Roller Sensor (PC1)
3-6

2.5.1 Misfeed at the Multiple Bypass Paper Take-up Section
<Detection Timing>
Type Description
Paper take-up • The leading edge of the paper does not unblock the Synchronizing
section mis- Roller Sensor (PC1) even after the lapse of a given period of time after
feed detection the Paper Take-up Solenoid (SL21/MB) has been energized.
• The Synchronizing Roller Sensor (PC1) is not blocked even after the
lapse of a given period of time after the paper has unblocked the Syn-
Size error
chronizing Roller Sensor (PC1).
detection
• The Synchronizing Roller Sensor (PC1) is blocked before the lapse of a
given period of time.
<Action>
Synchronizing Roller Sensor (PC1) Master Board (PWB-A)
Paper Take-up Solenoid (SL21/MB)
WIRING DIAGRAM

Components)
2 PC1 sensor check ☞ 3-1 PWB-A PJ17A-3 (ON) F-8
3 SL21/MB operation check ☞ 3-2 PWB-A PJ12A-2 (REM) D-16
4 Replace PWB-A – – –
3-7
JS-204
2004.3
Ver. 1.0
INDEX
MAINTENANCE
TROUBLESHOOTING
CONTENTS
MAINTENANCE
(1) Removal of the Control Board (PWB-A/JOB) ........................ 1-2
(2) Removal of the Paper Detecting Board (PWB-B/JOB) .......... 1-4
TROUBLESHOOTING
1. INTRODUCTION .............................................................................................. 2-1
1.1.1 Sensor ........................................................................................... 2-1
1.1.2 Switch ............................................................................................ 2-2
1.1.3 Solenoid ......................................................................................... 2-2
1.1.4 Clutch ............................................................................................ 2-2
1.1.5 Motor ............................................................................................. 2-3
2. MISFEEDS ....................................................................................................... 2-4
2.1 Initial Checks ............................................................................................ 2-4
3. MALFUNCTIONS ............................................................................................. 2-5
3.1 Resetting Procedure by Malfunction Code ............................................... 2-5
3.2 Malfunction Detection Timing and Troubleshooting Procedure ............... 2-6
(1) C0B60 Bin Switching Motor Malfunction ................................ 2-6
i
MAINTENANCE
19971
NOTES
PWB-A/JOB
PWB-B/JOB
4689D501AA

PWB-A/JOB Control Board ☞ 1-2
PWB-B/JOB Paper Detecting Board ☞ 1-4
1-1
(1) Removal of the Control Board (PWB-A/JOB)

1. Remove the control panel.
2. Remove the indicator lamp and one connector.
4689D001AA
3. Remove the Front Cover, Right Cover, and Paper Exit Cover.
4. Remove one screw, unplug one connector, and

remove the Total Counter.
4689D002AB
5. Remove one Sensor Assy mounting screw.
4689D003AA

7. Remove the harness from the edge cover and
remove the Sensor Assy.
4689D004AA
1-2
8. Disconnect the connector of the Bin Switching

Motor.
4689D005AA
9. Disconnect one connector from the copier.
4689D006AA
10. Remove two screws and the Control Board Assy.
4689D007AA
11. Unplug all connectors from the Control Board.
4689D008AA
1-3
12. Remove two screws, two PWB supports, and the

Control Board.
4689D009AA
(2) Removal of the Paper Detecting Board (PWB-B/JOB)

1. Remove the control panel.
4689D010AA
3. Holding onto both ends, remove the indicator

lamp cover.
4689D011AB
4. Press down one tab and remove the Paper

Detecting Board from the Front Cover.
4689D012AB
1-4
5. Remove one Paper Detecting Board Assy mount-

ing screw.
4689D013AA
6. Unplug one connector and remove the Paper

Detecting Board.
4689D014AA
1-5
TROUBLESHOOTING
19971
1. INTRODUCTION
in this chapter.

1.1.1 Sensor
YES Replace the
control board.
4025T520AA
4025T521AA
2-1
1.1.2 Switch
YES Replace the
control board.
NO
Not Use
COM
4025T523AB
1.1.3 Solenoid
YES Replace the
solenoid.
1 2 1
2 1 2
4025T522AA
1.1.4 Clutch
YES Replace the
clutch.
4025T528AA
2-2
1.1.5 Motor
Replace the motor.
trol board.
GND 1
REM 2
LOCK3
4025T526AA

4025T525AA

board.
NO Connect the con-
nector or the print
jack.
4025T527AA
2-3
2. MISFEEDS
2.1 Initial Checks
Check Item Action
storage procedures.
2-4
3. MALFUNCTIONS
gives the corresponding malfunction code and maintenance call mark on the Touch
Panel.
4980P550DA
3.1 Resetting Procedure by Malfunction Code
C0B60 Bin Switching Motor malfunction • Turn OFF and ON the Power Switch.
2-5
3.2 Malfunction Detection Timing and Troubleshooting Proce-

dure
(1) C0B60 Bin Switching Motor Malfunction
<Detection Timing>
Trouble
Description
Code
If the Upper Home Position Sensor is LOW during an initial operation:
• The Lower Home Position Sensor (PC33) is LOW when the Bin
Switching Motor (M1) starts turning forward.
• If the Lower Home Position Sensor (PC33) does not go LOW at a time
2.5 sec. after the Bin Switching Motor (M1) has started turning for-
ward, the Bin Switching Motor is kept deenergized for a given period
of time and then energized again to turn backward. The Upper Home
Position Sensor (PC32) does not go LOW after the motor has started
turning backward.
• The Upper Home Position Sensor (PC32) does not go HIGH at a time
1 sec. after the Bin Switching Motor (M1) has started turning forward.
• When the Lower Home Position Sensor (PC33) goes LOW, the Bin
Switching Motor (M1) starts turning backward. The Upper Home Posi-
tion Sensor (PC32) does not go LOW at a time 2.5 sec. after the
motor has started turning backward.
Switching Motor (M1) starts turning backward. The Lower Home Posi-
tion Sensor (PC33) does not go HIGH at a time 1 sec. after the motor
has started turning backward.
If the Lower Home Position Sensor is LOW during an initial operation:
• The Upper Home Position Sensor (PC32) does not go LOW at a time
C0B60
2.5 sec. after the Bin Switching Motor (M1) has started turning back-
ward.
• The Lower Home Position Sensor (PC33) does not go HIGH at a time
1 sec. after the Bin Switching Motor (M1) has started turning back-
ward.
If both the Upper Home Position Sensor and the Lower Home Position
Sensor are HIGH during an initial operation:
• If the Lower Home Position Sensor (PC33) does not go LOW at a time
2.5 sec. after the Bin Switching Motor (M1) has started turning for-
ward, the Bin Switching Motor is kept deenergized for a given period
of time and then energized again to turn backward. The Upper Home
Position Sensor (PC32) does not go LOW after the motor has started
turning backward.
Switching Motor (M1) starts turning backward. The Upper Home Posi-
tion Sensor (PC32) does not go LOW at a time 2.5 sec. after the
motor has started turning backward.
Switching Motor (M1) starts turning backward. The Lower Home Posi-
tion Sensor (PC33) does not go HIGH at a time 1 sec. after the motor
has started turning backward.
2-6
<Action>
Bin Switching Motor (M1/JOB) Control Board (PWB-A/JOB)
Upper Home Position Sensor (PC32/JOB) Master Board (PWB-A)
Lower Home Position Sensor (PC33/JOB)
WIRING DIAGRAM
Ref. Location
Step Operations
Components)
1 Check sensor connectors for proper
– – –
connection and correct as necessary.
2 Check M1/JOB connectors for proper
– – –
3 Check M1/JOB for correct drive cou-
– – –
pling and correct as necessary.
4 M1/JOB operation check ☞ 2-3 – A-16
5 PC32/JOB sensor check ☞ 2-1 PWB-A/JOB B-15
PJ4A/JOB-3 (ON)
6 PC33/JOB sensor check ☞ 2-1 PWB-A/JOB B-15
PJ4A/JOB-6 (ON)
7 Change PWB-A/JOB. – – –
8 Change PWB-A. – – –
2-7
OT-103
2004.3
Ver. 1.0
INDEX
MAINTENANCE
TROUBLESHOOTING
CONTENTS
MAINTENANCE
(1) Removal of the Control Board (PWB-A/OT) .......................... 1-2
TROUBLESHOOTING
1. INTRODUCTION .............................................................................................. 2-1
1.1.1 Sensor ........................................................................................... 2-1
1.1.2 Switch ............................................................................................ 2-2
1.1.3 Solenoid ......................................................................................... 2-2
1.1.4 Clutch ............................................................................................ 2-2
1.1.5 Motor ............................................................................................. 2-3
2. MALFUNCTIONS ............................................................................................. 2-4
2.1 Malfunction Detection Timing and Troubleshooting Procedure ............... 2-5
(1) C0B80 Shift Motor Malfunction .............................................. 2-5
i
MAINTENANCE
19971
NOTES
PWB-A/OT
4690D006AA

PWB-A/OT Control Board ☞ 1-2
1-1
(1) Removal of the Control Board (PWB-A/OT)

1. Remove the Front Cover, Right Cover, and Paper Exit Cover.
2. Unplug two connectors from the Shift Motor.
4690D001AB
3. Unplug one connector from the copier.
4690D002AA
4. Remove two screws and the Control Board Assy.
4690D003AB
4690D004AA
1-2
6. Remove two screws, two PWB supports, and the

Control Board.
4690D005AA
1-3
TROUBLESHOOTING
19971
1. INTRODUCTION
in this chapter.

1.1.1 Sensor
YES Replace the
control board.
4025T520AA
4025T521AA
2-1
1.1.2 Switch
YES Replace the
control board.
NO
Not Use
COM
4025T523AB
1.1.3 Solenoid
YES Replace the
solenoid.
1 2 1
2 1 2
4025T522AA
1.1.4 Clutch
YES Replace the
clutch.
4025T528AA
2-2
1.1.5 Motor
Replace the motor.
trol board.
GND 1
REM 2
LOCK3
4025T526AA

4025T525AA

board.
NO Connect the con-
nector or the print
jack.
4025T527AA
2-3
2. MALFUNCTIONS
gives the corresponding malfunction code and maintenance call mark on the Touch
Panel.
4980P550DA
2-4
2.1 Malfunction Detection Timing and Troubleshooting Proce-

dure
(1) C0B80 Shift Motor Malfunction
<Detection Timing>
Trouble
Description
Code
C0B80 • The Home Sensor (S31/OT) is LOW at a timing immediately before
the Shift Motor (M1/OT) starts turning backward.
• The Home Sensor (S31/OT) is LOW after the lapse of a given period
of time after the Shift Motor (M1/OT) has started turning backward.
<Action>
Shift Motor (M1/OT) Control Board (PWB-A/OT)
Home Sensor (PC31/OT) Master Board (PWB-A)
WIRING DIAGRAM
Ref. Location
Step Operations
Components)
1 Check PC31/OT connectors for
proper connection and correct as – – –
necessary.
2 Check M1/OT connectors for proper
– – –
3 Check M1/OT for correct drive cou-
– – –
pling and correct as necessary.
4 M1/OT operation check ☞ 2-3 – D-17
5 PC31/OT sensor check ☞ 2-1 PWB-A/OT D-18
PJ3A/OT-3 (ON)
6 Change PWB-A/OT. – – –
7 Change PWB-A. – – –
2-5
NC-6
2004.3
Ver. 1.0
INDEX
ELECTRICAL
DIS/REASSEMBLY,
Updating the Firmware
TROUBLESHOOTING
CONTENTS
ELECTRICAL
1. SPECIFICATIONS ........................................................................................... 1-1
2. Data Flow Diagram .......................................................................................... 1-1
2-1 Data Flow Diagram for Network GDI Printing .......................................... 1-1
2-2 Electrical Components ............................................................................. 1-2
1 Network Interface Card .................................................................. 1-2
2 LED status display list ................................................................... 1-3
DIS/REASSEMBLY,
1. Updating the Firmware ..................................................................................... 2-1
2. DISASSEMBLY/REASSEMBLY ...................................................................... 2-4
2.1 Removal of the Network Interface Card ................................................... 2-4
TROUBLESHOOTING
1. TROUBLESHOOTING ..................................................................................... 3-1
1.1 Troubleshooting Procedure Overview ...................................................... 3-1
1.2 Troubleshooting Procedure Chart ............................................................ 3-1
i
ELECTRICAL
19971
Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 ELECTRICAL
1. SPECIFICATIONS
Name : Network Interface Card (NC-6)

Interface : Ethernet 10/100Base T /TX (RJ-45)
TCP/IP Service ARP, BootP, DHCP, IPP, Ipr/lpd, Raw Socket,
HTTPd1.1, Telnetd, SLP, AutoIP
Netware Services : Bindery, NDS, PServer mode, NPrinter mode, NDPS
Frame Type (802.3, 802.2, 802.3 SNAP, Ethernet-ll,
Auto Detect)
2. Data Flow Diagram

2-1. Data Flow Diagram for Network GDI Printing
ADF
NCU
Sensors Network Control
Unit Board
CCD
Panel
Motor
DRV EEPROM PWB-C/C PWB-FAX

Flash Control Board Fax Control Board
ROM MODEM
CA
PWB-A (RISC)
Master Board
Flash
SRAM RTC
ROM
CCD Module
IA2
USB
CODEC
SO-DIMM
SDRAM
Socket
P1284
PCL
PCL Controller Board
ARM+NET PHY
RJ45
Flash
RISC SDRAM ROM
Flash
ROM SDRAM
HUB
PA
SDRAM DIMM
Socket
NIC
Network Interface Card Board
4508S502AA
1-1
ELECTRICAL Di1811p FIELD SERVICE Ver.1.0 Mar. 2004
2-2. Electrical Components

(1) Network Interface Card
Green LED
LED1
P401 LED2
U9 CN405
U11 U12
U13 U14
Orange LED
CN403
4508S501AA
P401 Hookup Connector (to Printer Controller Board)

U11 Internet Fax & Network Scan Kit
U9 EEPROM
U12 FlashROM
U13 SDRAM
U14 SDRAM
CN405 Network Interface
Green LED Network Interface Card status display.
Orange LED Network Interface Card status display.
P403 Hookup Connector (to PWB-C/C)
1-2
Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 ELECTRICAL
(2) LED status display list
LEDs Status
This is lit when the network cable is connected correctly. If
this LED is not lit, check the connection again, even if the
Green LED (Green) ON copier appears to be connected correctly. If this LED is not
lit when both ends are connected correctly, the network
cable may be damaged.
Orange LED (Orange) ON This LED blinks when data is being transfered.
1-3
DIS/REASSEMBLY,
19971
DIS/REASSEMBLY Di1811p FIELD SERVICE Ver.1.0 Mar. 2004
1. Updating the Firmware

1. Connect the Network Interface Card and PC with the network by using the RJ45 net-
work cables.
2. Start up the [MS-DOS prompt] or [Command prompt] of PC.
3. Input “ftp”, and then input the [IP address].
C:\>ftp XXX.XXX.XXX.XXX
NOTE
Confirm with the user's system administrator or network administrator on the IP address.
4. Press the “Enter” key.

5. Check that the following message is displayed, and that the PC has been connected
with the I-Fax/N-Scanner board.
Connected_to_XXX.XXX.XXX.XXX
220_NET+ARM_FTP_SERVER_1.0_ready
USER(XXX.XXX.XXX.XXX:(none)):
7. Check that the following message is displayed, and that you could log on to the I-Fax/N-
Scanner board through the PC.
230_User_none_logged_in.
8. Input “bin”. (Data transfer is switched to the binary mode.)
ftp>bin
10. The following messages is displayed.
200_Type_set_to_I.
11. Type "put” and then the location and name of the update file.
ftp>put X:\XXX.bin
12. Press the “Enter” key. (Wait to a while until data transfer is completed.)
13. Check that the following message is displayed, and data has been properly transferred
to the I-Fax/N-Scanner board from the PC.
200_PORT_command_OK
150_About_to_open_data_connection.
226_Transfer_complete.
ftp: xxxbytes_sent_in_xxxSeconds_xxKbytes/sec.
14. Type “get flash” and press the Enter key. (Wait to a while until data transfer is completed.)
ftp>get flash
15. The following messages will appear.
200_PORT_command_OK
150_About_to_open_data_connection.
226_Transfer_complete
ftp: xxxbytes_received_in_xxxSeconds_xxKbytes/sec.
2-1
Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 DIS/REASSEMBLY
16. Input “quit”, and then press the “Enter” key.

ftp>quit
221 Goodbye.
17. Input “type flash”.
C:\>type flash
18. Check that the firmware has been updated properly using the following messages that
should appear.
step 1: Command format is correct
step 2: Program’s header is right
spep 4: Flash ROM erase OK
spep 5: Flash ROM write OK
spep 6: Program complete
19. Input “exit”, and then press the “Enter” key.
C:\>exit
20. Check that you exit the [MS-DOS pronpt] or [ Command pronpt ] of PC.
21. Delete the “flash” file created in drive C of the PC.
22. Press the main power switch for the copier OFF/ON to restart the copier.
2-2
DIS/REASSEMBLY Di1811p FIELD SERVICE Ver.1.0 Mar. 2004
C:\>ftp XXX.XXX.XXX.XXX
Connected to XXX.XXX.XXX.XXX
220 NET+ARM FTP SERVER X.X ready
Connected to XXX.XXX.XXX.XXX
220 NET+ARM FTP SERVER X.X ready
USER(XXX.XXX.XXX.XXX:(none)):
230 User none logged in.
ftp>bin
200 Type set to I.
ftp>put X:\XXX.bin
200 PORT command OK.
150 About to open data connection.
226 Transfer complete
ftp: xxxbytes sent in xxxSeconds xxxKbytes/sec.
ftp>get flash
200 PORT command OK.
150 About to open data connection.
226 Transfer complete.
ftp: xxxbytes received in xxxSeconds xxxKbytes/sec.
ftp>quit
221 Goodbye
C:\>type flash
step 1 : Command format is correct
step 2 : Program’s header is right
step 4 : Flash ROM erase OK
step 5 : Flash ROM write OK
step 6 : Program complete
C:\>exit
2-3
Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 DIS/REASSEMBLY
2. DISASSEMBLY/REASSEMBLY
2.1 Removal of the Network Interface Card
1. Turn OFF the Power Switch and unplug the

power cord from the power outlet.
2. Remove the Rear Cover. (9 screws)
4048U006AB
3. Disconnect the Harness Assy furnished with the

kit to the connectors on the Printer Controller
Board and Network I/F Card.
P401
P301 NOTE
Skip this step if the Printer Controller Board is not
mounted.
4506U164AA
D. Remove the four screw, and the Network Inter-

face Card (unplug the hookup connector provided
on the backside of the Network I/F Card).
4506U153AA
2-4
TROUBLESHOOTING
19971
1. TROUBLESHOOTING
1.1 Troubleshooting Procedure Overview
• If the following symptoms occur when the machine is restarted after the Network Inter-
face Card has been mounted, check the board and connectors for proper connection. If
the symptom persists, replace the defective part or parts.
• If it is not possible to transfer data correctly with the various settings made on [NET-
WORK SETTING], the network or telephone line is probably defective.
Note
Network setting and line checks should be made by the network administrator (system
administrator).
1.2 Troubleshooting Procedure Chart

1. If network settings are not correct, check them by following the flowchart below.
Turn on the power switch
The machine does not start up YES

even if reset is repeated over and
over again.
Take necessary action according to the trouble shoot-
ing procedures for the machine.
NO
[NETWORK SETTING] is not dis- YES

played on the “Utility” screen.
• It takes several minutes for [NETWORK SET-

TING] to appear after the power switch has been
turned ON.
NO
• If it does not appear even after you wait for sev-
eral seconds, check the Network Interface Card
for proper connection. The symptom disappears
after the board has been properly reconnected.
NO
END Change the Network Interface Card.
3-1
Di1811p
Includes:
AF-12
AFR-19
AD-17
PF-126
MB-6
JS-204
OT-103
NC-6
© 2004 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Use of this manual should be strictly supervised to

4034-7994-11
2004.3
avoid disclosure of confidential information.
04030800 Ver. 1.0

Service Manual

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Service Manual

Загружено:

Авторское право:

Доступные форматы

Di1811p_F.

book 1 ページ ２００４年３月２日 火曜日 午後４時２３分

SERVICE MANUAL FIELD SERVICE

4.5 Misfeed Detection Timing/Troubleshooting Procedures .......................... 3-7

Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE

MAINTENANCE Di1811p FIELD SERVICE Ver.1.0 Mar. 2004

1.2 Replacement and Cleaning of Parts

2. Using a soft cloth dampened with alcohol, wipe

3. Using a soft cloth dampened with alcohol, wipe

(2) Removal of the Pick-Up Roller/Take-Up Roller

3. Snap off two C-clips.

Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE

6. Snap off one C-clip and remove the Pick-up

7. Remove one pin, snap off one C-clip, and remove

(3) Removal of the Separator Roller

1. Open the Upper Door.

MAINTENANCE Di1811p FIELD SERVICE Ver.1.0 Mar. 2004

3. Unhook one spring and remove the Separator

4. Remove the Separator Roller.

(4) Cleaning of the Separator Roller

1. Remove the Separator Section Protective Cover.

(5) Cleaning of the Registration Roller/Rolls

1. Raise the Automatic Document Feeder.

Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE

3. Remove the Rear Cover.

6. Remove two screws and the Sensor Assy.

7. Using a soft cloth dampened with alcohol, wipe

(6) Cleaning of the Exit Roller/Rolls

1. Remove the Rear Cover.

MAINTENANCE Di1811p FIELD SERVICE Ver.1.0 Mar. 2004

(7) Cleaning of the Transport Rolls

1. Remove the Rear Cover.

(8) Cleaning of Length Size Sensor 2

1. Using a brush, whisk dust and dirt off the surface

Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE

No. Part Name Removal Procedure

MAINTENANCE Di1811p FIELD SERVICE Ver.1.0 Mar. 2004

2.1.2 Removal of Circuit Boards and Other Electric Components

Symbol Part Name Removal Procedure

(1) Removal of the Interface Board (PWB/AF)

3. Unplug all connectors from the Interface Board.

ADJUSTING/SETTING Di1811p FIELD SERVICE Ver.1.0 Mar. 2004

<Exiting the Mode>

<Service Mode Function Setting Value Changing Procedure>

Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING

1.2 Setting in the Service Mode

Function Purpose Setting Details/Precautions

• Ready the test chart that comes with the Automatic

Reference line A: 400 mm Specifications

ADJUSTING/SETTING Di1811p FIELD SERVICE Ver.1.0 Mar. 2004

(2) ADF MAIN REGIST

Function Purpose Setting Details/Precautions

Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING

(3) ADF SUB REGIST1

Function Purpose Setting Details/Precautions

ADJUSTING/SETTING Di1811p FIELD SERVICE Ver.1.0 Mar. 2004

✽ When a paper misfeed of originals occurs

(2) COPY ADF GLASS AREA

Di1811p FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING

1. Turn one screw so that the spacer contacts the

Turn the screw clockwise to raise the ADF.

ADJUSTING/SETTING Di1811p FIELD SERVICE Ver.1.0 Mar. 2004

book 1 ページ２００４年３月２日　火曜日　午後４時２３分