Di 1611-2011

2004.
3
Ver. 1.0
Di1611/Di2011
SERVICE MANUAL
2004 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Printed in Japan
4034-7991-11
04030700
Use of this manual should be strictly supervised to
avoid disclosure of confidential information.
FIELD SERVICE
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P-1
Read carefully the Safety and Important Warning Items described below to understand
them before doing service work.
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, Konica Minolta Business Technologies, INC. (hereafter
called the KMBT) strongly recommends that all servicing be performed only by KMBT-
trained service technicians.
Changes may have been made to this product to improve its performance after this Service
Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that
the information contained in this Service Manual is complete and accurate.
The user of this Service Manual must assume all risks of personal injury and/or damage to
the product while servicing the product for which this Service Manual is intended.
Therefore, this Service Manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep this Service Manual also for future service.
In this Service Manual, each of three expressions DANGER, WARNING, and
CAUTION is defined as follows together with a symbol mark to be used in a limited
meaning.
When servicing the product, the relevant works (disassembling, reassembling, adjustment,
repair, maintenance, etc.) need to be conducted with utmost care.
Symbols used for safety and important warning items are defined as follows:
SAFETY AND IMPORTANT WARNING ITEMS
IMPORTANT NOTICE
DESCRIPTION ITEMS FOR DANGER,
WARNING AND CAUTION
DANGER : Action having a high possibility of suffering death or serious injury
WARNING: Action having a possibility of suffering death or serious injury
CAUTION : Action having a possibility of suffering a slight wound, medium
trouble, and property damage
:Precaution when servicing the product.
General precaution Electric hazard High temperature
:Prohibition when servicing the product.
General prohibition
Do not touch
with wet hand
Do not disassemble
:Direction when servicing the product.
General instruction Unplug Ground/ Earth
P-2
1. MODIFICATIONS NOT AUTHORIZED BY
KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Konica Minolta brand products are renowned for their high reliability. This reliability is
achieved through high-quality design and a solid service network.
Product design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving
at proper tolerances and safety factors. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. the points listed below are not exhaustive, but they illustrate the reason-
ing behind this policy.
SAFETY WARNINGS
DANGER: PROHIBITED ACTIONS
Using any cables or power cord not specified by KMBT.
Using any fuse or thermostat not specified by KMBT.
Safety will not be assured, leading to a risk of fire and
injury.
Disabling fuse functions or bridging fuse terminals with
wire, metal clips, solder or similar object.
Disabling relay functions (such as wedging paper between
relay contacts)
Disabling safety functions (interlocks, safety circuits, etc.)
Safety will not be assured, leading to a risk of fire and
injury.
Making any modification to the product unless instructed
by KMBT
P-3
2. CHECKPOINTS WHEN PERFORMING ON-SITE SER-
VICE
Konica Minolta brand products are extensively tested before shipping, to ensure that all
applicable safety standards are met, in order to protect the customer and customer engi-
neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical
equipment may be subject to parts wear and eventual failure. In order to maintain safety
and reliability, the CE must perform regular safety checks.
1. Power Supply
Using parts not specified by KMBT
WARNING: Wall Outlet
Check that mains voltage is as specified. Plug the power
cord into the dedicated wall outlet with a capacity greater
than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
If two or more power cords can be plugged into the wall
outlet, the total load must not exceed the rating of the wall
outlet.
If excessive current flows in the wall outlet, fire may
result.
WARNING: Power Plug and Cord
Make sure the power cord is plugged in the wall outlet
securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.
DANGER: PROHIBITED ACTIONS
P-4
Check whether the power cord is damaged. Check
whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord (with plug and connector on each
end) specified by KMBT. Using the damaged power cord
may result in fire or electric shock.
When using the power cord (inlet type) that came with this
product, be sure to observe the following precautions:
a. Make sure the connector is securely inserted in the inlet
on the rear panel of the product.
Secure the cord with a fixture properly.
b. If the power cord or sheath is damaged, replace with a
new power cord (with plugs on both ends) specified by
KMBT.
If the power cord (inlet type) is not connected to the
product securely, a contact problem may lead to
increased resistance, overheating, and risk of fire.
Check whether the power cord is not stepped on or
pinched by a table and so on.
Overheating may occur there, leading to a risk of fire.
Do not bundle or tie the power cord.
Overheating may occur there, leading to a risk of fire.
Check whether dust is collected around the power plug
and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.
Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.
WARNING: Power Plug and Cord
P-5
2. Installation Requirements
WARNING: Wiring
Never use multi-plug adapters to plug multiple power
cords in the same outlet.
If used, the risk of fire exists.
When an extension cord is required, use a specified one.
Current that can flow in the extension cord is limited, so
using a too long extension cord may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.
WARNING: Ground connection
Check whether the product is grounded properly.
If current leakage occurs in an ungrounded product, you
may suffer electric shock while operating the product.
Connect power plug to grounded wall outlet.
WARNING: Prohibited Installation Place
Do not place the product near flammable materials or vola-
tile materials that may catch fire.
A risk of fire exists.
Do not place the product in a place exposed to water such
as rain.
A risk of fire and electric shock exists.
WARNING: When not using product for a long time
When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
P-6
CAUTION: Ventilation
The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
CAUTION: Fixing
Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
CAUTION: Inspection before Servicing
Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure, using only the prescribed tools. Do not make any
adjustment not described in the documentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
Before conducting an inspection, be sure to disconnect the
power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.
The area around the fixing unit is hot.
You may get burnt.
P-7
WARNING: Work Performed with the product Powered
Take every care when making adjustments or performing
an operation check with the product powered.
If you make adjustments or perform an operation check
with the external cover detached, you may touch live or
high-voltage parts or you may be caught in moving gears
or the timing belt, leading to a risk of injury.
Take every care when servicing with the external cover
detached.
High-voltage exists around the drum unit. A risk of elec-
tric shock exists.
WARNING: Safety Checkpoints
Check the exterior and frame for edges, burrs, and other
damages.
The user or CE may be injured.
Do not allow any metal parts such as clips, staples, and
screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
Check wiring for squeezing and any other damage.
Current can leak, leading to a risk of electric shock or
fire.
Carefully remove all toner remnants and dust from electri-
cal parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.
Check high-voltage cables and sheaths for any damage.
fire.
Check electrode units such as a charging corona unit for
deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
P-8
Before disassembling or adjusting the write unit (P/H unit)
incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
Do not remove the cover of the write unit. Do not supply
power with the write unit shifted from the specified mount-
ing position.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
When replacing a lithium battery, replace it with a new lith-
ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.
After replacing a part to which AC voltage is applied (e.g.,
optical lamp and fixing lamp), be sure to check the installa-
tion state.
Check the interlock switch and actuator for loosening and
check whether the interlock functions properly.
If the interlock does not function, you may receive an
electric shock or be injured when you insert your hand in
the product (e.g., for clearing paper jam).
Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
fire.
Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
WARNING: Safety Checkpoints
P-9
WARNING: HANDLING OF CONSUMABLE
Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
CAUTION: HANDLING OF SERVICE MATERIALS
Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (ace-
tone-based) are highly flammable and must be handled
with care. A risk of fire exists.
Do not replace the cover or turn the product ON before
any solvent remnants on the cleaned parts have fully
evaporated.
Use only a small amount of cleaner at a time and take care
not to spill any liquid. If this happens, immediately wipe it
off.
When using any solvent, ventilate the room well.
Breathing large quantities of organic solvents can lead to
discomfort.
P-10
3. MEASURES TO TAKE IN CASE OF AN ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
4. CONCLUSION
1. Safety of users and customer engineers depends highly on accurate maintenance and
administration. Therefore, safety can be maintained by the appropriate daily service
work conducted by the customer engineer.
2. When performing service, each product on the site must be tested for safety. The cus-
tomer engineer must verify the safety of parts and ensure appropriate management of
the equipment.
INDEX
ADJUSTING/SETTING
MAINTENANCE
TROUBLESHOOTING
i
CONTENTS
MAINTENANCE
1. SAFETY INFORMATION ................................................................................. 1-1
1.1 Laser Safety ............................................................................................. 1-1
1.2 Internal Laser Radiation ........................................................................... 1-1
1.3 Laser Safety Label ................................................................................... 1-4
1.4 Laser Caution Label ................................................................................. 1-4
1.5 Precautions for Handling the Laser Equipment ........................................ 1-5
2. OTHER PRECAUTIONS .................................................................................. 1-5
3. SERVICE TOOLS ............................................................................................ 1-6
3.1 Jigs and Tools .......................................................................................... 1-6
4. MAINTENANCE SCHEDULE .......................................................................... 1-7
4.1 PM Parts List ............................................................................................ 1-7
4.2 Guidelines for Life-time Expected Values by Unit .................................... 1-8
4.3 Replacement and Cleaning of Parts ........................................................ 1-9
4.3.1 Paper Take-up/Transport Section ................................................. 1-9
(1) Removal of the Paper Separator Roller Assy and
Paper Take-Up Roller. ........................................................... 1-9
(2) Cleaning of the Paper Separator Roller ................................. 1-10
(3) Cleaning of the Paper Take-Up Roller ................................... 1-10
(4) Cleaning of the Upper/Lower Synchronizing Rollers ............. 1-10
(5) Removal of the Paper Dust Remover Assy ........................... 1-11
(6) Cleaning of the Paper Dust Remover .................................... 1-11
(7) Cleaning of the Bypass Transport Roller/Roll ........................ 1-11
4.3.2 IR Section ...................................................................................... 1-12
(1) Cleaning of the Original Glass and Original Scanning Glass . 1-12
(2) Cleaning of Mirrors ................................................................. 1-12
(3) Cleaning of the Lens .............................................................. 1-13
(4) Cleaning of the CCD Sensor .................................................. 1-13
(5) Cleaning of the Scanner Rails/Bushings ................................ 1-14
4.3.3 PH Section ..................................................................................... 1-14
(1) Cleaning of the PH Window ................................................... 1-14
4.3.4 Imaging Unit (IU) ........................................................................... 1-15
(1) Removal of the Imaging Unit (IU) ........................................... 1-15
(2) Disassembly of the IU ............................................................ 1-15
(3) Removal of the PC Drum ....................................................... 1-17
(4) Removal of the Ozone Filter .................................................. 1-17
(5) Removal of the PC Drum Charge Corona Assy ..................... 1-18
(6) Removal of the Cleaning Blade ............................................. 1-18
(7) Cleaning of the PC Drum Paper Separator Fingers ............... 1-18
(8) Cleaning of the Ds Collars ..................................................... 1-19
(9) Cleaning of the Developer Scattering Prevention Plate ......... 1-19
(10) Replacement of the Developer .............................................. 1-19
(11) Cleaning of the Pre-Image Transfer Guide Plate ................... 1-20
(12) Replacement of the ATDC Sensor ......................................... 1-20
(13) Application of Toner ............................................................... 1-21
4.3.5 IMAGE TRANSFER SECTION ...................................................... 1-23
(1) Removal of the Image Transfer Roller Assy .......................... 1-23
(2) Cleaning of the Pre-Image Transfer Lower Guide Plate ........ 1-23
ii
(3) Cleaning of the Charge Neutralizing Plate ............................. 1-23
4.3.6 FUSING SECTION ........................................................................ 1-24
(1) Removal of the Fusing Unit .................................................... 1-24
5. MISCELLANEOUS PARTS .............................................................................. 1-25
5.1 Disassembly and Reassembly ................................................................. 1-25
5.1.1 Identification and Removal Procedures of Doors, Covers,
and Exterior Parts .......................................................................... 1-25
(1) Copier .................................................................................... 1-25
5.1.2 Removal of Circuit Boards and Other Electric Components .......... 1-27
(1) Removal of the Master Board (PWB-A) ................................. 1-28
(2) Removal of the Control Board (PWB-C/C) ............................. 1-29
(3) Removal of the High Voltage Unit (HV1) ............................... 1-30
(4) Removal of the Power Supply Unit (PU1) .............................. 1-31
(5) Removal of the Paper Size Detecting Board (PWB-I) ............ 1-32
(6) Removal of the Heater Relay Board (PWB-RY):
200 V area only ...................................................................... 1-33
(7) Removal of the Pre-image Transfer Board (PWB-R2) ........... 1-33
5.1.3 Removal of Units ........................................................................... 1-34
(1) Removal of the Manual Bypass ............................................. 1-34
(2) Removal of the Manual Bypass (Duplex Unit): Di2011 Only . 1-34
(3) Removal of the Toner Hopper Unit ........................................ 1-34
(4) Removal of the PH Unit ......................................................... 1-35
(5) Disassembly of the Fusing Unit ............................................. 1-36
5.1.4 Disassembly of the IR Section ....................................................... 1-39
(1) Removal of the CCD Unit ....................................................... 1-39
(2) Installation of the CCD Unit .................................................... 1-40
(3) Removal of the Scanner, Exposure Lamp,
and Inverter Board (PU2) ....................................................... 1-40
(4) Removal of the Scanner Motor .............................................. 1-42
(5) Removal of the Scanner Drive Cables ................................... 1-43
(6) Winding of the Scanner Drive Cables .................................... 1-46
5.1.5 Disassembly of the Engine Section ............................................... 1-51
(1) Removal of the Main Motor .................................................... 1-51
(2) Removal of the Power Unit Cooling Fan Motor ...................... 1-51
(3) Removal of the Fusing Cooling Fan Motor ............................ 1-52
(4) Removal of the Paper Size Sensor Assy ............................... 1-53
(5) Removal of the Fusing Unit Interlock Switch ......................... 1-54
(6) Removal of the Inch/Metric Sensor/1 Assy (3rd area Only) ... 1-56
(7) Removal of the Flickerless Resistor
(Only for 200 V area of Di1611) ............................................. 1-56
5.2 Remounting of the EEPROM (U16) ......................................................... 1-57
5.3 Installation of the Key Counter ................................................................. 1-58
6. UPGRADING THE FIRMWARE ....................................................................... 1-60
6.1 Upgrading the Copier Firmware (PWB-C/C) ............................................ 1-60
6.1.1 Installing the Driver ........................................................................ 1-60
(1) Plug and Play Installation of the GDI Printer/TWAIN Driver .. 1-60
6.1.2 Procedure for Upgrading the GDI Firmware .................................. 1-62
6.1.3 Procedure when Upgrading the Firmware has failed .................... 1-64
ADJUSTING/SETTING
1. HOW TO USE THE ADJUSTMENT SECTION ................................................ 2-1
iii
1.1 Composition ............................................................................................. 2-1
1.1.1 Checking before starting work ....................................................... 2-1
1.1.2 Checkpoints when conducting on-site service ............................... 2-1
3. UTILITY MODE ................................................................................................ 2-5
3.1 Utility Mode Function Tree ....................................................................... 2-5
3.2 Utility Mode Setting Procedure ................................................................. 2-7
3.3 Setting in the Utility Mode ........................................................................ 2-7
3.3.1 MACHINE SETTING ..................................................................... 2-7
(1) AUTO PANEL RESET ........................................................... 2-7
(2) ENERGY SAVE MODE ......................................................... 2-7
(3) AUTO SHUT OFF .................................................................. 2-7
(4) DENSITY (ADF) ..................................................................... 2-8
(5) DENSITY (BOOK) .................................................................. 2-8
(6) PRINT DENSITY .................................................................... 2-8
(7) LCD CONTRAST ................................................................... 2-8
(8) LANGUAGE ........................................................................... 2-8
3.3.2 PAPER SOURCE SETUP ............................................................. 2-9
(1) INCH/METRIC ....................................................................... 2-9
(2) TRAY1 PAPER ...................................................................... 2-9
(3) PAPER TYPE ........................................................................ 2-9
3.3.3 USER MANAGEMENT .................................................................. 2-10
(1) DRUM DEHUMIDIFY ............................................................. 2-10
(2) TONER REPLENISHER ........................................................ 2-10
3.3.4 ADMIN. MANAGEMENT ............................................................... 2-11
(1) AUTO SHUT OFF .................................................................. 2-11
(2) COPY TRACK ........................................................................ 2-11
3.3.5 COPY SETTING 1 ......................................................................... 2-14
(1) PAPER PRIORITY ................................................................. 2-14
(2) DENSITY PRIORITY ............................................................. 2-14
(3) DENSITY LEVEL (A) ............................................................. 2-14
(4) DENSITY LEVEL (M) ............................................................. 2-14
(5) BINDING POS. ...................................................................... 2-14
(6) MARGIN SETTING ................................................................ 2-14
(7) ERASE SETTING .................................................................. 2-15
(8) SMALL ORIGINAL ................................................................. 2-15
3.3.6 COPY SETTING 2 ......................................................................... 2-15
(1) MIXED ORIGINAL ................................................................. 2-15
(2) COPY PRIORITY ................................................................... 2-15
(3) OUTPUT PRIORITY .............................................................. 2-15
(4) 4IN1 COPY ORDER .............................................................. 2-16
(5) CRISSCROSS MODE ........................................................... 2-16
(6) DUPLEX COPY ..................................................................... 2-16
4. SERVICE MODE .............................................................................................. 2-17
4.1 Service Mode Function Tree .................................................................... 2-17
4.2 Service Mode Function Setting Procedure ............................................... 2-20
4.3 Setting in the Service Mode ..................................................................... 2-21
4.3.1 SERVICES CHOICE ..................................................................... 2-21
(1) SHIPMENT DESTINATION ................................................... 2-21
(2) MAINTENANCE COUNTER .................................................. 2-22
(3) IU LIFE STOP MODE ............................................................ 2-22
iv
(4) ID ADJUST ............................................................................ 2-22
(5) VG ADJUST ........................................................................... 2-23
(6) FUSER TEMP. Ad (PLAIN) .................................................... 2-23
(7) FUSER TEMP. Ad (THICK) ................................................... 2-24
(8) FUSER TEMP. Ad (OHP) ...................................................... 2-25
(9) LEADING EDGE ERASE ....................................................... 2-26
(11) TRAILING EDGE ERASE ...................................................... 2-27
(12) VERTICAL EDGE ERASE ..................................................... 2-28
(13) LOOP ADJUST (TRAY1) ....................................................... 2-29
(14) LOOP ADJUST (TRAY2 TO TRAY5) .................................... 2-29
(15) LOOP ADJUST (DUPLEX): Di2011 Only .............................. 2-30
(16) LOOP ADJUST (BYPASS) .................................................... 2-30
(17) FLS PAPER SIZE .................................................................. 2-31
(18) CCD APS SIZE ...................................................................... 2-31
(19) GDI TIMEOUT ....................................................................... 2-31
4.3.2 ADJUST ......................................................................................... 2-32
(1) PRN MAIN REGIST ............................................................... 2-32
(2) PRN SUB REGIST ................................................................. 2-33
(3) CCD MAIN ZOOM ................................................................. 2-34
(4) CCD SUB ZOOM ................................................................... 2-35
(5) CCD MAIN REGIST ............................................................... 2-36
(6) CCD SUB REGIST ................................................................ 2-37
(7) ADF SUB ZOOM .................................................................... 2-38
(8) ADF MAIN REGIST ............................................................... 2-38
(9) ADF SUB REGIST1 ............................................................... 2-38
(10) ADF SUB REGIST2 ............................................................... 2-39
(11) ADF REG. LOOP1 ................................................................. 2-39
(12) ADF REG. LOOP2 ................................................................. 2-39
(13) ATDC GAIN ........................................................................... 2-39
(14) MODEL SETTING .................................................................. 2-40
4.3.3 COUNTER ..................................................................................... 2-40
(1) TOTAL COUNTER ................................................................. 2-40
(5) SIZE COUNTER .................................................................... 2-40
(6) PM COUNTER ....................................................................... 2-40
(8) SUPPLIES LIFE COUNT. ...................................................... 2-41
(9) APPLICATION COUNTER .................................................... 2-41
(10) SCAN COUNTER .................................................................. 2-41
(11) PAPER SIZE COUNTER ....................................................... 2-42
(12) MISFEED COUNTER ............................................................ 2-42
(13) TROUBLE COUNTER ........................................................... 2-43
4.3.4 DISPLAY ....................................................................................... 2-44
(1) TONER DENSITY LEVEL ...................................................... 2-44
(2) PROCESS CONTROL ........................................................... 2-44
(3) MAIN F/W VER. (PWB-C/C) .................................................. 2-45
(4) ENGINE F/W VER. (PWB-A) ................................................. 2-45
(5) PCL F/W VER. ....................................................................... 2-45
(6) NIC F/W VER. ........................................................................ 2-45
(7) ADF F/W VER. ....................................................................... 2-45
(8) MAIN RAM SIZE .................................................................... 2-45
(9) PCL RAM SIZE ...................................................................... 2-45
(10) SERIAL NO. ........................................................................... 2-45
v
(11) CUSTOMER ID ...................................................................... 2-46
4.3.5 FUNCTION .................................................................................... 2-46
(1) PAPER FEED TEST .............................................................. 2-46
(2) PROCESS CHECK ................................................................ 2-46
(3) ATDC AUTO ADJUST ........................................................... 2-46
(4) PRINT TEST PATTERN ........................................................ 2-47
(5) ADF FEED TEST ................................................................... 2-47
(6) COPY ADF GLASS AREA ..................................................... 2-47
(7) CCD MOVE TO HOME .......................................................... 2-48
(8) SCAN TEST ........................................................................... 2-48
(9) ADF WIDTH ADJ. (MAX) ....................................................... 2-48
(10) ADF WIDTH ADJ. (MIN) ........................................................ 2-48
(11) ADF SENSOR ADJUST ......................................................... 2-48
4.3.6 ADMIN. REGISTRATION .............................................................. 2-49
4.3.7 FIXED ZOOM CHANGE ................................................................ 2-50
(1) Japan ..................................................................................... 2-50
(2) Metric ..................................................................................... 2-50
(3) Inch ........................................................................................ 2-50
(4) China ...................................................................................... 2-50
(5) Latin America (Metric) ............................................................ 2-51
(6) Latin America (Inch) ............................................................... 2-51
(7) OEM1 US ............................................................................... 2-51
4.3.8 FACTORY TEST ........................................................................... 2-51
(1) PANEL BUZZER TEST .......................................................... 2-51
(2) RAM TEST ............................................................................. 2-51
4.3.9 CLEAR DATA ................................................................................ 2-52
(1) MEMORY CLEAR .................................................................. 2-52
(2) PM COUNTER ....................................................................... 2-52
(4) SUPPLIES LIFE COUNT. ...................................................... 2-52
(5) APPLICATION COUNTER .................................................... 2-52
(6) SCAN COUNTER .................................................................. 2-52
(7) PAPER SIZE COUNTER ....................................................... 2-53
(8) MISFEED COUNTER ............................................................ 2-53
(9) TROUBLE COUNTER ........................................................... 2-53
(10) ADF BACKUP CLEAR (Di2011 Only) .................................... 2-53
4.3.10SECURITY .................................................................................... 2-53
(1) TOTAL COUNTER COUNT ................................................... 2-53
(2) SIZE COUNTER COUNT ...................................................... 2-54
(3) PLUG-IN COUNTER COPY .................................................. 2-54
(4) MACHINE COUNTER ............................................................ 2-54
5. MECHANICAL ADJUSTMENTS ...................................................................... 2-55
5.1 Adjustment of the Position of the Scanner and 2nd/3rd Mirrors Carriage 2-55
5.2 CCD Unit Position Adjustment ................................................................. 2-57
5.3 Adjustment of the Gap between the Doctor Blade and
Sleeve Roller (Db Adjustment) ................................................................. 2-58
5.4 Manual Bypass (for the optional AD-17) CD Registration Adjustment ..... 2-60
TROUBLESHOOTING
1. INTRODUCTION .............................................................................................. 3-1
1.1 Electrical Components Check Procedure ................................................ 3-1
vi
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 Paper Misfeed Detection .......................................................................... 3-4
2.2.1 Outline ........................................................................................... 3-4
2.3 Misfeed Display ........................................................................................ 3-5
2.4 Misfeed-Detecting Sensor Layout ............................................................ 3-6
2.5 Misfeed Detection Timing/Troubleshooting Procedures .......................... 3-7
2.5.1 Misfeed at the Paper Feed Tray/1 Paper Take-up Section ........... 3-7
2.5.2 Misfeed at the Manual Bypass Paper Take-up Section ................. 3-8
2.5.3 Misfeed at the Multiple Bypass Paper Take-up Section
(When the optional Multiple Bypass MB-6 is mounted) ................. 3-9
2.5.4 Misfeed at the Paper Feed Unit Paper Take-up/Vertical
Transport Section (When the optional Paper Feed
Unit PF-126 is mounted) ................................................................ 3-10
2.5.5 Misfeed at the Paper Separating Section ...................................... 3-11
2.5.6 Misfeed at the Fusing/Exit Section ................................................ 3-12
2.5.7 Misfeed at the Document Take-up Section (When the optional
Automatic Document Feeder AF-12 is mounted) .......................... 3-13
2.5.8 Misfeed at the Document Transport Section (When the optional
2.5.9 Misfeed at the Document Exit Section (When the optional
3. MALFUNCTIONS ............................................................................................. 3-16
3.1 List of Malfunction Codes ......................................................................... 3-16
3.2 Resetting Procedure by Malfunction Code ............................................... 3-20
3.3 Malfunction Detection Timing and Troubleshooting Procedure ............... 3-21
(1) C0000 Main Motor malfunction .............................................. 3-21
(2) C0044 ADF Cooling Fan Failure
(When the optional Duplexing Document Feeder
AFR-19 is mounted) ............................................................... 3-22
(3) C0045 Fusing Cooling Fan Motor Malfunction ....................... 3-23
(4) C004E Power Supply Cooling Fan Motor Malfunction ........... 3-24
(5) C0070 Toner Replenishing Motor Malfunction ....................... 3-25
(6) C0210 Abnormal Image Transfer Voltage ............................. 3-26
(7) C0500 Warm-up Failure
C0501 Warm-up Failure 2 (Di2011 Only)
C0510 Fusing Failure (Abnormally Low Fusing Temperature)
C0511 Fusing Failure (Abnormally Low Fusing Temperature 2)
(Di2011 Only)
C0520 Fusing Failure (Abnormally High Fusing Temperature)
C0521 Fusing Failure (Abnormally High Fusing Temperature 2)
(Di2011 Only) ......................................................................... 3-27
(8) C0650 Faulty Scanner Home Position Sensor ...................... 3-30
(9) C0F32 Faulty ATDC Sensor
vii
C0F33 Improperly Adjusted ATDC Sensor ............................ 3-31
(10) C1038 Engine Connection Failure ......................................... 3-32
(11) C1200 Faulty ASIC/Memory .................................................. 3-33
(12) C1300 Polygon Motor Malfunction
C13F0 Faulty HSYNC ............................................................ 3-34
(13) C133B Communication with Option Error
C133D ROM Check Error ...................................................... 3-35
(14) C1468 Faulty EEPROM ......................................................... 3-35
(15) C14A3 IR Fluorescent Lamp Fault ......................................... 3-36
3.4 Miscellaneous Errors ................................................................................ 3-37
3.4.1 Flash ROM Error ........................................................................... 3-37
3.5 Power Source-Related Malfunctions ........................................................ 3-38
(1) The copier does not turn ON. ................................................. 3-38
4. IMAGE FAILURE ............................................................................................. 3-40
4.1 Image Failure Troubleshooting ................................................................ 3-40
4.2 Initial Checks ............................................................................................ 3-40
4.3 Identification of the Faulty System ........................................................... 3-41
4.4 Troubleshooting Procedures by Image Failure ........................................ 3-42
4.4.1 Image Reading Section: Blank copy .............................................. 3-42
4.4.2 Image Reading Section: black copy .............................................. 3-43
4.4.3 Image Reading Section: Low image density ................................. 3-44
4.4.4 Image Reading Section: Foggy background or rough image ........ 3-45
4.4.5 Image Reading Section: Black streaks or bands ........................... 3-46
4.4.6 Image Reading Section: Black spots ............................................. 3-47
4.4.7 Image Reading Section: Blank streaks or bands ........................... 3-48
4.4.8 Image Reading Section: Uneven image density ............................ 3-49
4.4.9 Image Reading Section: Gradation reproduction failure ................ 3-50
4.4.10Image Reading Section: Periodically uneven image ..................... 3-51
4.4.11Image Reading Section: Moire ...................................................... 3-52
4.4.12Printer Section: Blank copy ........................................................... 3-53
4.4.13Printer Section: Black copy ............................................................ 3-54
4.4.14Printer Section: Low image density ............................................... 3-55
4.4.15Printer Section: Foggy background or rough image ...................... 3-56
4.4.16Printer Section: Black streaks or bands ......................................... 3-57
4.4.17Printer Section: Black spots ........................................................... 3-58
4.4.18Printer Section: Blank streaks or bands ........................................ 3-59
4.4.19Printer Section: Void areas ............................................................ 3-60
4.4.20Printer Section: Smear on back ..................................................... 3-61
4.4.21Printer Section: Uneven image density ......................................... 3-62
4.4.22Printer Section: Gradation reproduction failure ............................. 3-63
4.4.23Printer Section: Periodically uneven image ................................... 3-64
MAINTENANCE
19971
1-1
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE
1. SAFETY INFORMATION
1.1 Laser Safety
This is a digital machine certified as a class 1 laser product. There is no possibility of
danger from a laser, provided the machine is serviced according to the instruction in this
manual.
1.2 Internal Laser Radiation
*:Laser Aperture of the Print Head Unit
This product employs a Class 3b laser diode that emits an invisible laser beam. The laser
diode and the scanning polygon mirror are incorporated in the print head unit.
The print head unit is NOT A FIELD SERVICE ITEM. Therefore, the print head unit
should not be opened under any circumstances.
Semiconductor laser
Maximum power of the laser diode 5 mW
Maximum average radiation power(*) 6.32 W
Wavelength 770-795 nm
Laser Aperture of
the Print Head Unit
4035D507AA
This figure shows the view inside the Right Door.
1-2
the U.S.A., Canada
(CDRH Regulation)
This machine is certified as a Class I Laser product under Radiation Performance Stan-
dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory
for Laser products marketed in the United States and is reported to the Center for
Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of
the U.S. Department of Health and Human Services (DHHS). This means that the device
does not produce hazardous laser radiation.
The label shown to page P-16 indicates compliance with the CDRH regulations and must
be attached to laser products marketed in the United States.
All Areas
Denmark
CAUTION
Use of controls, adjustments or performance of procedures other than those specified in
this manual may result in hazardous radiation exposure.
Semiconductor laser
CAUTION
Use of controls, adjustments or performance of procedures other than those specified in
this manual may result in hazardous radiation exposure.
Semiconductor laser
ADVARSEL
Usynlig Laserstrling ved bning, nr sikkerhedsafbrydere er ude af funktion. Undg
udsttelse for strling. Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene.
Halvlederlaser
Laserdiodens hjeste styrke 5 mW
Blgelngden 770-795 nm
1-3
Finland, Sweden
Norway
VARO!
Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttmlle lasersteilylle. l
katso steeseen.
LOUKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
VAROITUS!
Laitteen Kyttminen muulla kuin tss kyttohjeessa mainitulla tavalla saattaa altistaa
kyttjn turvallisuusluokan 1 ylittvlle nkymttmlle lasersteilylle.
Puolijohdelaser
Laserdiodin suurin teho 5 mW
Aallonpituus 770-795 nm
VARNING!
Om apparaten anvnds p annat stt n i denna bruksanvisning specificerats, kan anvn-
daren utsttas fr osynlig laserstrlning, som verskrider grnsen fr laserklass 1.
Halvledarlaser
Den maximala effekten fr laserdioden 5 mW
Vglngden 770-795 nm
VARNING!
Osynlig laserstrlning nr denna del r ppnad och sprren r urkopplad. Betrakta ej
strlen.
ADVERSEL
Dersom apparatet brukes p annen mte enn spesifisert i denne bruksanvisning, kan
brukeren utsettes for unsynlig laserstrling som overskrider grensen for laser klass 1.
Halvleder laser
Maksimal effekt till laserdiode 5 mW
Blgelengde 770-795 nm
1-4
1.3 Laser Safety Label
A laser safety labels is attached to the outside of the machine as shown below.
1.4 Laser Caution Label
A laser caution label is attached to the inside of the machine as shown below.
4035D510CA
4035D509AA
1-5
1.5 Precautions for Handling the Laser Equipment
When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.
When a disassembly job needs to be performed in the laser beam path, such as when
working around the printerhead and PC Drum, be sure first to turn the copier OFF.
If the job requires that the copier be left ON, take off your watch and ring and wear laser
protective goggles.
A highly reflective tool can be dangerous if it is brought into the laser beam path. Use
utmost care when handling tools on the users premises.
2. OTHER PRECAUTIONS
A fuse is installed in each of both L and N lines of the power source of this machine. If the
machine is brought to a stop as a result of the fuse on the N line having been blown for
some reason, there is still the power source voltage being applied to the primary circuit of
the machine. To prevent an electric shock, be sure to unplug the power cord of the
machine before attempting to service the machine.
CAUTION
Double pole / neutral fusing
ATTENTION
Double ple / fusible sur le neutre.
1-6
3. SERVICE TOOLS
3.1 Jigs and Tools
<Scanner/Mirrors Carriage Positioning Jigs> <Ds Collar Positioning Jigs>
<Db Gap Adjusting Jigs> <PC Positioning Jig>
<Gauge>
4035D134AA 4022D011AA
4022D012AA 4035D506AA
4035D600AA
1-7
4. MAINTENANCE SCHEDULE
4.1 PM Parts List
PM Parts
Cycle (K=1,000)
Ref.
Page
Clean Replace
Paper Take-Up/
Transport Sec-
tion
Paper Take-Up Roll
When a malfunction
occurs
150k
1-9
Paper Separator Roll Assy
When a malfunction
occurs
150k
1-9
Paper Dust Remover
When a malfunction
occurs
40k
1-11
Upper Synchronizing Roller
When a malfunction
occurs
1-10
Lower Synchronizing Roller
When a malfunction
occurs
1-10
Bypass Transport Roller/roll
When a malfunction
occurs
1-11
IR Section
Mirrors/Lens
When a malfunction
occurs
1-12
Scanner Rails/Bushing
When a malfunction
occurs
1-14
Original Glass 80k 1-12
PH Section PH Window
When a malfunction
occurs
1-14
Imaging Unit
Section
PC Drum
When a malfunction
occurs
40k
1-15
Cleaning Blade 40k 1-18
PC Drum Charge Corona Assy 40k 1-18
Developer (starter) 40k 1-19
Ds Collar 40k 1-19
Developer Scattering Preven-
tion Plate
40k
1-19
Pre-Image Transfer Guide Plate 40k 1-20
PC Drum Paper Separator Fin-
ger
40k
1-18
Ozone Filter 150k 1-17
Image Transfer
Section
Image Transfer Roller Assy 150k 1-23
Pre-Image Transfer Lower
Guide Plate
When a malfunction
occurs
1-23
Charge Neutralizing Plate
When a malfunction
occurs
1-23
Fusing Section Fusing Unit 150k 1-24
1-8
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.
2-22
4.2 Guidelines for Life-time Expected Values by Unit
K = 1,000 copies
1: The Service mode can be used to set either enable or disable the initiation of a new
copy/print cycle.
NOTE
The life value represents the number of copies made in the conditions specified in the
table shown below, or a value translated to a corresponding number of copies made. It
may therefore vary depending on the conditions, in which the copiers are used among
different users.
<Life Value Conditions>
Description Life Value
New Copy/Print
Cycle Inhibited
PC Drum
The distance traveled by the PC Drum is
converted to a corresponding number of
printed pages of A4 crosswise paper at
2P/J.
40K
Not inhibited *1
Cleaning Blade 40K
PC Drum Charge
Corona
40K
Developer 40K
Image Transfer
Assy
The number of sheets of paper fed out of
the copier is counted.
150K Not applicable
Paper Dust
Remover Assy
40K Not applicable
Fusing Unit 150K Not applicable
Copying type 2P/J
Paper size A4Y
Original density B/W 6%
1-9
4.3 Replacement and Cleaning of Parts
4.3.1 Paper Take-up/Transport Section
(1) Removal of the Paper Separator Roller Assy and Paper Take-Up Roller.
1. Slide out the Paper Feed Tray/1.
2. Remove two screws and the mounting bracket.
4035D001AB
3. Remove the Paper Separator Roller Assy.
4035D002AA
4. Press down the Paper Lifting Plate.
5. Snap off one C-clip from the Paper Take-up
Roller Assy.
6. Slide the Paper Take-up Roller Assy to the rear
and pull it off the bushing at the front.
4035D003AB
5
6
7. Snap off one C-clip and remove the Paper Take-
up Roller.
4035D004AA
1-10
(2) Cleaning of the Paper Separator Roller
(3) Cleaning of the Paper Take-Up Roller
(4) Cleaning of the Upper/Lower Synchronizing Rollers
1. Open the Right Door.
2. Remove the Imaging Unit.
1-15
2. Using a soft cloth dampened with alcohol, wipe
the Paper Separator Roller clean of dirt.
4035D005AA
the Paper Take-up Roller clean of dirt.
4035D006AA
the Upper and Lower Synchronizing Rollers clean
of dirt.
4035D007AA
1-11
(5) Removal of the Paper Dust Remover Assy
1-15
3. Unhook the two tabs and remove the Paper Dust Remover Assy.
(6) Cleaning of the Paper Dust Remover
(7) Cleaning of the Bypass Transport Roller/Roll
1. Remove the Rear Right Cover.
1-26
4035D008AB
1. Remove the Paper Dust Remover Assy.
2. Using a brush, whisk dust and dirt off the Paper
Dust Remover.
4035D009AA
3. Remove two screws, unplug one connector, and
remove the Manual Bypass Assy.
4532D008AC
1-12
4.3.2 IR Section
(1) Cleaning of the Original Glass and Original Scanning Glass
(2) Cleaning of Mirrors
the Bypass Transport Roller clean of dirt.
4035D011AB
the Bypass Transport Roll clean of dirt.
4532D015AA
the Original Glass and Original Scanning Glass
clean of dirt.
4035D013AA
1. Remove the Original Glass.
1-25
the mirrors clean of dirt.
4035D014AB
1-13
(3) Cleaning of the Lens
(4) Cleaning of the CCD Sensor
1-25
the Lens clean of dirt.
4035D015AA
1-25
2. Remove four screws and the CCD Unit Cover.
4035D016AA
3. Pulling the tabs on both sides of the Lens Cover,
remove the Lens Cover.
4035D017AA
the CCD Sensor clean of dirt.
4035D018AA
1-14
(5) Cleaning of the Scanner Rails/Bushings
4.3.3 PH Section
(1) Cleaning of the PH Window
1. Remove the Front Cover, Left Cover, and Exit Tray.
1-25
1-25
the Scanner rails and bushings clean of dirt.
NOTE
After the Scanner rails and bushings have been
cleaned, apply oil (copier lubricant A or FLOIL
947P).
4035D019AA
the PH window clean of dirt.
4035D020AA
1-15
4.3.4 Imaging Unit (IU)
NOTE
When the developer is to be changed, it is necessary that toner in the Recycled Toner
Recycling Duct and Toner Conveying Duct be fed into the Developer Mixing Chamber. To
do that, remove the Toner Bottle and run ATDC Auto Adjust twice.
2-46
(1) Removal of the Imaging Unit (IU)
1. Open the Front Door.
(2) Disassembly of the IU
3. Remove two screws and the IU.
Precautions for Installation of the IU
When installing the IU, use care not to damage the
PC Drum.
Before attempting to install the IU, be sure to fully
open the Right Door. Take care that, if the IU is
installed with the Right Door locked halfway, it may
interfere with the transfer roller.
When inserting the IU, do that slowly and, when
you are sure that the drum gear contacts the mat-
ing part, push the IU all the way into position. If this
step is done all at once, the drum gear could be
damaged.
4035D021AA
1. Remove one screw in the rear of the IU and
remove the harness cover.
4035D022AA
1-16
2. Remove two screws in the rear of the IU.
4035D023AA
3. Remove two screws at the front of the IU.
4035D024AA
4. Widen flaps on both ends (marked with A in the
photo on the left) of the Drum Assy in the direc-
tion of the arrow and turn to take off the Develop-
ing Assy.
4035D025AA
A
A
5. Unplug one connector of the Main Erase.
4035D026AA
1-17
(3) Removal of the PC Drum
(4) Removal of the Ozone Filter
1. Remove two screws and the pivot shaft.
4035D027AA
2. Remove the PC Drum.
NOTES
Protect the PC Drum that has been removed with a
protective cloth.
If the PC Drum has been replaced with a new one,
apply a coat of toner to the surface of the new PC
Drum.
1-21
4035D028AA
1. Remove two screws and the Main Erase.
4035D029AB
2. Remove the Ozone Filter.
4035D030AA
1-18
(5) Removal of the PC Drum Charge Corona Assy
(6) Removal of the Cleaning Blade
1. Remove the PC Drum Charge Corona Assy.
(7) Cleaning of the PC Drum Paper Separator Fingers
1. Remove the PC Drum.
2. Remove the Main Erase.
3. Turn the holder in the rear in the direction of the
arrow to remove it from the side bracket.
4. Slide out the PC Drum Charge Corona in the
direction of the arrow.
4035D031AB
4
3
2. Remove three screws and the Cleaning Blade.
NOTES
When securing the Cleaning Blade, tighten screws
in the order of one on one edge, one at the center,
and one on the other edge.
When the Cleaning Blade has been replaced,
apply a coat of toner to the surface of the PC
Drum.
1-21 4035D032AA
the five Paper Separator Fingers clean of dirt.
4035D033AA
1-19
(8) Cleaning of the Ds Collars
(9) Cleaning of the Developer Scattering Prevention Plate
(10) Replacement of the Developer
the two Ds Collars clean of dirt.
4035D034AA
1. Remove three screws and the Developer Scatter-
ing Prevention Plate.
Precautions for Installation of the Developer
Scattering Prevention Plate
When securing the Developer Scattering Preven-
tion Plate, tighten screws in the order of one on
one edge, one at the center, and one on the other
edge.
4035D035AA
2. Using a brush, whisk dust and dirt off the surface
of the Developer Scattering Prevention Plate.
4035D036AA
1. Dump the developer.
4035D037AA
1-20
(11) Cleaning of the Pre-Image Transfer Guide Plate
(12) Replacement of the ATDC Sensor
1. Separate the IU into the Drum Assy and Developing Assy.
1-15
2. Remove the Developer Scattering Prevention Plate.
3. Dump developer.
<<How to Dump Developer>>
Dump developer on the surface of the Sleeve
Roller by turning the gear in the direction of the
arrow with the Developing Unit tilted as shown.
NOTE
Turning the gear backward at this time could dam-
age the Mylar for cleaning the ATDC Sensor.
Dump developer until almost no developer sticks to
the Sleeve Roller.
4035D038AA
2. Pour one packet of developer.
NOTES
Shake the packet of developer well before pouring.
When the developer has been changed, make the
ATDC AUTO ADJUST and enter the adjustment
value on the Adjust Label.
2-46
4035D039AA
the Pre-image Transfer Upper Guide Plate clean
of dirt.
4035D040AB
1-21
5. Install the ATDC Sensor and the Developer Scattering Prevention Plate.
6. Assemble the Drum Assy to the Developing Assy to reconstruct the IU.
7. Install the IU in the copier and run ATDC Auto Adjust of the Service mode.
2-46
8. Enter the adjustment value on the Adjust Label.
(13) Application of Toner
NOTE
Perform these steps when the PC Drum and/or Cleaning Blade have been replaced.
4. Unplug one connector, and remove one screw
and the ATDC Sensor.
4035D041AA
1. With the IU divided into the Drum Assy and
Developing Assy, install the PC Positioning Jig in
the rear of the Developing Assy.
NOTE
Ready the PC Positioning Jig (Pivot Shaft) sepa-
rately. (See the Parts Manual.)
4035D511AA
<<Area to which toner is to be applied>>
4021U057AA
20-25 mm 10-15 mm
2
0
-
3
0

m
m
PC Drum
1-22
2. Using a brush, apply a light coat of toner to the
surface of the PC Drum.
4021U008AB
3. Hold both ends of the PC Drum with your both
hands and turn the PC Drum a half turn in the
direction of the arrow.
4021U009AA
1-23
4.3.5 IMAGE TRANSFER SECTION
(1) Removal of the Image Transfer Roller Assy
(2) Cleaning of the Pre-Image Transfer Lower Guide Plate
(3) Cleaning of the Charge Neutralizing Plate
1. Remove the Image Transfer Roller Assy.
NOTES
Indentations or dirt on the surface of the Image
Transfer Roller adversely affect the printed image.
Do not therefore touch or dirty with toner the sur-
face of the Image Transfer Roller.
When handling the Image Transfer Roller, hold
onto the shaft or bushings of the roller.
Do not place a new Image Transfer Roller directly
on the floor.
4035D042AB
the Pre-image Transfer Lower Guide Plate clean
of dirt.
4035D043AA
the Charge Neutralizing Plate clean of dirt.
NOTES
Use care not to allow the Image Transfer Roller to
be touched with alcohol.
Do not allow the soft cloth to be caught by the tip of
the Charge Neutralizing Plate.
4035D044AB
1-24
4.3.6 FUSING SECTION
(1) Removal of the Fusing Unit
1. Remove the Rear Cover and Rear Right Cover.
1-26
NOTE
When removing the Fusing Unit, take care not to confuse the types of screw.
2. Unplug two connectors of the Fusing Unit.
4035D045AA
4. Remove four screws and the Fusing Unit.
NOTE
When removing the Fusing Unit, make sure of the
correct type of screws that must be removed.
4035D046AA
4035D144AA
1-25
5. MISCELLANEOUS PARTS
5.1 Disassembly and Reassembly
5.1.1 Identification and Removal Procedures of Doors, Covers, and Exterior Parts
(1) Copier
No. Part Name Removal Procedure
1 Original Glass
Remove the Original Scanning Glass. Remove one
screw. Remove the holding bracket. Remove the
Original Glass.
2 Control Panel
Remove the Control Panel Left Cover. Remove two
screws. Remove one flat cable and unplug one con-
nector. Remove the Control Panel.
3 Control Panel Left Cover
Remove one screw. Remove the Control Panel Left
Cover.
4 Front Cover
Remove the Control Panel. Slide out the Paper Feed
Tray/1. Open the Front Door. Remove six screws.
Remove the Front Cover.
5 Paper Exit Cover
Remove the Front Cover. Remove one screw.
Remove the Paper Exit Cover.
6 Front Door
Open the Front Door. Snap off one C-clip. Slide the
Front Door to the right and pull it off.
7 Tray 1
Slide out Tray/1. Remove two screws. Remove the
fixing brackets on the right and left ends of Tray/1.
Remove Tray/1.
8 Left Cover
Remove the Front Cover. Remove five screws.
Remove the Left Cover.
9 Paper Exit Tray
Remove the Front Cover. Remove two screws.
Remove the Paper Exit Tray.
4035D047AB
1
10
9
6
2
8
4
5
7
3
11
1-26
10 Rear Inside Cover
Remove the Left Cover. Remove the Paper Exit Tray.
Remove two screws. Remove the Rear Inside
Cover.
11 Original Scanning Glass
Remove the Left Cover. Remove two screws.
Remove the Original Scanning Glass.
12 Left Rear Cover
Remove the Upper Rear Cover. Remove four screws.
Remove the Left Rear Cover.
13 Upper Rear Cover Remove four screws. Remove the Upper Rear Cover.
14 Rear Cover
Remove nine screws. Remove the Rear Cover.
NOTE
When the Rear Cover is to be installed, make sure of type
of screw.
(9735-0306-14 8 Screw, 9770-0308-14 1 Screw)
15 Right Rear Cover
Remove the Upper Rear Cover. Remove three screws.
Remove the Right Rear Cover.
16 Rear Right Cover Remove two screws. Remove the Rear Right Cover.
17 Right Cover
Remove the Upper Rear Cover. Remove the Front
Cover. Remove four screws. Remove the Right
Cover.
4035D048AB
17
13
15
12
14
16
1-27
5.1.2 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.
200V area Only
Symbol Part Name Removal Procedure
PWB-A Master Board 1-28
PWB-C/C Control Board 1-29
PWB-I Paper Size Detecting Board 1-32
PWB-J CCD Board 1-39
PWB-RY* Heater Relay Board 1-33
PWB-R2 Pre-Image Transfer Board 1-33
HV1 High Voltage Unit 1-30
PU1 Power Supply Unit 1-31
PU2 Inverter Board 1-40
UN4 Control Panel 1-25
PU1
HV1
PWB-A
4035D135CB
PWB-C/C
PWB-J
PWB-I
PU2
UN4
PWB-R2
PWB-RY
1-28
(1) Removal of the Master Board (PWB-A)
1. Remove the Rear Cover.
1-26
2. Unplug all connectors from the Master Board.
4035D049AA
3. Remove four screws and the Master Board.
4035D050AA
1-29
(2) Removal of the Control Board (PWB-C/C)
1. Remove the Rear Cover and Upper Rear Cover.
1-26
2. Remove the Master Board.
1-28
3. Unplug all connectors from the Control Board.
4035D051AB
4. Remove two screws and two holders.
4035D052AA
5. Remove six screws and the Control Board.
NOTE
Whenever the Control Board has been replaced,
be sure to remount the EEPROM.
1-57
4035D053AB
1-30
(3) Removal of the High Voltage Unit (HV1)
1-26
1-28
3. Unplug all connectors from the High Voltage Unit.
4035D054AA
4. Remove two screws and the High Voltage Unit.
4035D055AA
1-31
(4) Removal of the Power Supply Unit (PU1)
1. Remove the Left Cover, Rear Cover, and Upper Rear Cover.
1-25
3. Remove the Control Board.
1-29
4. Remove the harness from four wiring saddles
and one edge cover.
5. Remove four screws and protective cover 1.
4035D522AA
6. Remove eight screws and protective cover 2.
4035D056AB
7. Unplug all connectors from the Power Supply
Unit.
4035D057AB
8. Remove six screws and the Power Supply Unit.
4035D523AA
1-32
(5) Removal of the Paper Size Detecting Board (PWB-I)
1-26
3. Unhook two tabs and remove the holder.
4035D058AA
4. Remove the lever.
4035D059AA
5. Unplug one connector and remove the Paper
Size Detecting Board.
4035D060AA
1-33
(6) Removal of the Heater Relay Board (PWB-RY): 200 V area only
1. Remove the Front Cover and Left Cover.
1-25
(7) Removal of the Pre-image Transfer Board (PWB-R2)
2. Unplug two connectors and remove three PWB
supports and the Heater Relay Board.
4035D139AB
2. Remove two screws and the Pre-image Transfer
Board.
4035D061AA
1-34
5.1.3 Removal of Units
(1) Removal of the Manual Bypass
1-26
(2) Removal of the Manual Bypass (Duplex Unit): Di2011 Only
1-26
(3) Removal of the Toner Hopper Unit
1. Remove the Front Door, Front Cover, Left Cover, and Paper Exit Tray.
1-25
2. Remove the Toner Bottle.
remove the Manual Bypass.
4532D008AC
remove the Manual Bypass.
4035D143AA
3. Remove three screws and the unit cover.
4035D062AA
1-35
(4) Removal of the PH Unit
1. Remove the Front Cover, Left Cover, Rear Cover, Paper Exit Tray, and Rear Inside
Cover.
1-25
4. Unplug two connectors.
4035D063AA
5. Remove the Toner Hopper Unit.
4035D064AA
6. Remove two screws and the Toner Replenishing
Motor.
4035D065AA
2. Disconnect one flat cable and one connector
from the Master Board.
4035D066AA
1-36
(5) Disassembly of the Fusing Unit
<Removal of the Thermistor and Paper Separator Fingers>
1. Remove the Fusing Unit.
1-24
3. Remove two cable holders of the flat cable.
4035D067AA
4. Remove the harness from one wiring saddle.
4035D068AA
5. Remove three screws (with springs) and the PH
Unit.
4035D069AA
2. Remove the pressure springs on both ends of the
unit.
4035D070AA
1-37
3. Remove the torsion coil spring and the Movable
Guide Assy.
4035D145AA
4. Remove four shoulder screws, two washers, and
the Pressure Roller Cover.
4035D071AB
5. Remove two bushings and the Pressure Roller.
4035D142AA
Precautions for Installation of the Pressure Roller
Install the right and left bushings in the directions
shown in the photo on the left.
4035D521AA
1-38
6. Remove one screw. Then, slide the Paper Sepa-
rator Finger Assy in the direction of the arrow and
take it off.
4035D072AA
7. Remove one screw and the Thermistor.
4035D073AA
8. Unhook springs and remove the four Paper Sep-
arator Fingers.
4035D074AA
1-39
5.1.4 Disassembly of the IR Section
(1) Removal of the CCD Unit
1-25
2. Remove four screws and the CCD Unit Cover.
4035D016AA
3. Mark a line along the profile of the CCD Unit
mounting bracket as shown on the left.
4035D075AA
4. Unplug one connector.
4035D076AA
5. Remove three screws (to which green paint has
been applied) and the CCD Unit.
NOTE
When removing the CCD Unit, loosen or remove
only these specified screws.
4035D077AA
1-40
(2) Installation of the CCD Unit
(3) Removal of the Scanner, Exposure Lamp, and Inverter Board (PU2)
1. Remove the Original Glass and Original Scanning Glass.
1-25
2. Remove two screws (to which no red paint has been applied). Then, remove the Scan-
ner Assy from the Scanner Drive Cables.
NOTE
Removal of the Scanner Assy leaves the front and rear Scanner Drive Cables attached
with the fixing brackets.
1. Position the CCD Unit along the marking line.
Then, temporarily secure three screws at the
center of each of the screw slots.
2. Adjust the position of the CCD Unit.
2-57
4035D077AA
4035D078AC
3. Remove one screw and the cable holder.
4035D079AA
1-41
4. Remove one flat cable and the Scanner Assy.
4035D080AA
remove the Inverter Board.
4035D081AA
6. Remove two screws and the Exposure Lamp.
4035D082AA
1-42
(4) Removal of the Scanner Motor
1. Remove the Right Rear Cover.
1-26
2. Remove the Scanner Motor harness from the five
wiring saddles.
4035D083AA
3. Unplug one connector from the Control Board.
4035D084AA
4. Snap off one C-ring.
5. Loosen four screws and remove the Scanner
Motor harness from the gear case assy.
4035D533AA
6. Remove two screws and the Scanner Motor.
4035D534AA
1-43
(5) Removal of the Scanner Drive Cables
1. Remove the Left Cover, Front Cover, Rear Cover, Upper Rear Cover, Right Rear Cover,
Original Glass, and Original Scanning Glass.
1-25
2. Loosen two screws (to which red paint has been applied) and remove the Scanner
Assy.
NOTE
Loosen the two red painted screws to remove the Scanner Assy in this step, which differs
from the removal procedure for the Scanner Assy as a single unit.
4035D086AC
3. Unhook the springs from the cable hooks at the
front and rear.
4035D087AB
4. Remove the front cable from the cable pulley.
4035D088AA
1-44
5. Remove the rear cable from the cable pulley.
4035D089AA
6. Remove one screw from the front cable pulley.
4035D090AA
7. Remove one screw from the rear cable pulley.
4035D091AA
8. Snap off one C-ring from the front side of the Pul-
ley Assy.
4035D092AA
1-45
9. Snap off one C-ring from the rear side of the Pul-
ley Assy.
4035D093AA
10. Pull out the shaft and two bushings.
4035D094AB
11. Remove two screws from the rear side of the Pul-
ley Assy and remove the gear.
12. Remove the cable from the cable pulley.
4035D095AA
1-46
(6) Winding of the Scanner Drive Cables
<Overall View>
NOTES
The cables are color-coded and differ in type from each other: the front cable is silver,
while the rear cable is black.
Make sure that no part of the cable rides on the other.
4035D109AA Pulley A
Pulley B
Pulley C
Pulley D
Wire pulley 2
Wire pulley 1
1. Pass the cable (black) through wire pulley 2.
4035D110AA
Side B
Side A
2. Wind the cable on side B around wire pulley 2
four turns counterclockwise, starting with the slit
at the bottom in the rear left of the pulley.
4035D111AA
1-47
3. Wind the cable on side A around wire pulley 2
four turns clockwise, starting with the slit at the
top in the front left of the pulley.
4035D112AA
4. Affix tape to secure the cable to wire pulley 2.
4035D113AA
5. Pass the cable (silver) through wire pulley 1.
4035D114AA
Side B
Side A
6. Wind the cable on side A around wire pulley 1
four turns counterclockwise, starting with the slit
at the bottom in the front left of the pulley.
4035D115AA
7. Wind the cable on side B around wire pulley 1
four turns clockwise, starting with the slit at the
top in the rear left of the pulley.
4035D116AA
1-48
9. Use the two screws to secure the gear to wire pulley 2.
NOTE
Make sure that the cable pulley is doweled to the gear.
10. Mount the front and rear cable pulleys onto the shaft and install the shaft to the copier.
11. Fit two bushings and snap on two C-rings.
8. Affix tape to secure the cable to wire pulley 1.
4035D117AA
NOTE
Install the shaft as shown on the left.
4035D515AA
Rear Side
Front Side
12. Secure the front and rear cable pulleys to the
shaft using one screw each.
NOTE
The direction in which the screw is installed differs
between the front and rear. Note the correct direc-
tion.
4035D118AA
13. Wind the lower cable of wire pulley 1 around pul-
ley A.
4035D119AA
Pulley A
1-49
14. Wind the cable from pulley A around pulley B.
NOTE
Wind the cable around the outer groove in pulley B.
4035D119AA
Pulley A
Pulley B
15. Pass the cable from pulley B into the hole in the
IR frame.
4035D121AA
16. Wind the lower cable of wire pulley 2 around pul-
ley C.
4035D124AA
Pulley C
17. Wind the cable from pulley C around pulley D.
NOTE
Wind the cable around the outer groove in pulley D.
4035D125AA
Pulley C
Pulley D
18. Pass the cable from pulley D into the hole in the
IR frame.
4035D126AA
1-50
25. Temporarily secure the Scanner to the front and rear cables.
26. Adjust the position of the Scanner and the 2nd/3rd Mirrors Carriage.
2-55
19. Pass the leading edge of each of the front and
rear cables into the space between the IR frame
and copier frame.
20. Affix tape to temporarily secure the cables to the
copier frame.
4035D121AA
21. Wind the upper cable of wire pulley 1 around pul-
ley B and hook it onto the hook.
NOTE
Wind the cable around the inner groove in pulley B.
4035D123AA
22. Wind the upper cable of wire pulley 2 around pul-
ley D and hook it onto the hook.
NOTE
Wind the cable around the inner groove in pulley D.
4035D128AA
23. Peel off the pieces of tape that secure the front
and rear cable pulleys.
24. Peel off the tape used to temporarily secure the
cables to the copier frame. Hook a spring to the
leading edges of the front and rear cables.
4035D129AA
1-51
5.1.5 Disassembly of the Engine Section
(1) Removal of the Main Motor
1-26
(2) Removal of the Power Unit Cooling Fan Motor
1. Remove the Left Cover, Rear Cover, and Upper Rear Cover.
1-25
3. Remove the Control Board.
1-29
2. Remove four screws, unplug one connector, and
remove the Main Motor.
4035D096AB
4. Remove nine screws and the protective cover.
4035D524AA
remove the Power Unit Cooling Fan Motor.
4035D097AB
1-52
(3) Removal of the Fusing Cooling Fan Motor
1-26
3. Remove the Image Transfer Roller Assy.
1-23
4. Remove one screw and the Transport Unit Assy.
NOTE
Use care not to lose the two springs.
4035D098AC
5. Remove four screws and the Duct Assy.
4035D099AC
6. Remove seven screws and the mounting bracket.
4035D100AB
1-53
(4) Removal of the Paper Size Sensor Assy
1-26
remove the Fusing Cooling Fan Motor.
4035D101AA
3. Remove one screw.
4035D102AA
4. Unplug two connectors and remove the Paper
Size Sensor Assy.
4035D103AA
1-54
(5) Removal of the Fusing Unit Interlock Switch
1-26
4035D130AC
3. Remove two screws (to which red paint has been
applied).
4035D131AA
4. Unplug four connectors and remove the Fusing
Unit Interlock Switch Assy.
NOTE
When installing the Fusing Unit Interlock Switch
Assy, make sure that the connectors are con-
nected properly.
4035D132AA
5. Unhook two tabs and remove the Fusing Unit
Interlock Switch.
4035D138AA
1-55
<Fusing Unit Interlock Switch Reinstallation Procedure>
1. Fit the switch holder to the Fusing Unit Interlock Switch.
2. Connect the four connectors to the Fusing Unit Interlock Switch Assy.
4. With the right door closed, insert the gauge between the projection of lever and the top
surface of Fusing Unit Interlock Switch, and then secure the switch holder so that the
gap is 0.5 mm.
NOTES
Use the 0.5 mm thick portion of gauge.
Insert the gauge between the rear side (projection) of lever and the top surface of Fusing
Unit Interlock Switch.
for Di1611
5. Close the right door, and then use a tester to make sure that the Fusing Unit Interlock
Switch is conducting between 2A and 2B.
6. Open the right door, and then use a tester to make sure that the Fusing Unit Interlock
Switch is not conducting between 2A and 2B.
for Di2011
5. Close the right door, and then use a tester to make sure that the Fusing Unit Interlock
Switch is conducting between 2A and 2B, 3A and 3B.
6. Open the right door, and then use a tester to make sure that the Fusing Unit Interlock
Switch is not conducting between 2A and 2B, 3A and 3B.
NOTE
If there is any abnormality in conducting check, repeat adjustment again from step 4.
3. Temporarily secure the Fusing Unit Interlock
Switch using two screws (to which red paint has
been applied).
4035D131AA
Projection
4035D541AA
Di1611
Di2011
4035D540AA
4035D539AA
1-56
(6) Removal of the Inch/Metric Sensor/1 Assy (3rd area Only)
1-26
(7) Removal of the Flickerless Resistor (Only for 200 V area of Di1611)
1-26
1-28
2. Remove one screw, unplug one connector, and
remove the Inch/Metric Sensor/1 Assy.
4035D141AA
4. Remove one screw, unplug one connector, and
remove the Flickerless Resistor.
4035D140AA
1-57
5.2 Remounting of the EEPROM (U16)
NOTE
When the Control Board (PWB-C/C) is replaced with a new one, EEPROM (U16) must
be demounted from the old PWB-C/C and remounted on the new PWB-C/C.
Mount the EEPROM (U16) of the old PWB-C/C on the new PWB-C/C.
4035D514AA
NOTE
Note the alignment notch marked with A on the
EEPROM (U16) when mounting the IC.
1171D049AA
1-58
5.3 Installation of the Key Counter
1. Cut out the knockout from the Right Cover.
4623D001AA
2. Using two screws, secure the counter mounting
bracket.
4623D002AA
3. Connect the Key Counter Socket connector.
4623D003AA
4. Using two screws, secure the Key Counter
Socket.
4623D004AA
1-59
5. Using two screws, secure the Key Counter cover.
4623D005AA
6. Plug in the Key Counter.
NOTE
When the Key Counter is mounted, set Machine
Counter Copying of the Security mode to Dis-
abled.
2-54
4623D006AA
1-60
6. UPGRADING THE FIRMWARE
6.1 Upgrading the Copier Firmware (PWB-C/C)
6.1.1 Installing the Driver
NOTES
Since USB is used to upgrade the firmware, the host computer must be run on an OS of
Windows 98 or later.
The TWAIN driver must previously be installed in the host computer that is used to
upgrade the firmware.
If the TWAIN driver has not been installed, use the procedure below to install it.
If the TWAIN driver has already been installed, proceed with the section on Firmware
upgrading procedure to upgrade the firmware.
(1) Plug and Play Installation of the GDI Printer/TWAIN Driver
<For Windows XP>
1. Start the host computer.
2. Turn on the power switch of copier.
3. Use a USB cable to connect the copier to host computer.
4. In the Found New Hardware Wizard dialog box, choose Install from a list or specific
location (Advanced), and then click [Next].
5. Under Search for the best driver in these locations, choose Include this location in the
search, and then click [Browse].
6. Specify \(name of any given language)\WinXP in the folder in which the TWAIN driver
is stored, and then click [OK].
7. Click [Next] and then [Finish].
8. The Found New Hardware Wizard dialog box will appear again: Repeat steps 4~7 to
install all drivers.
<For Windows 2000>
1. Prepare the files necessary for upgrading the firmware, and copy them to PC.
The Found New Hardware Wizard dialog box will appear.
5. In the Install Hardware Device Printers dialog box, choose Search for a suitable driver
for my device (recommended), and then click [Next].
6. In the Locate Driver Files dialog box, choose Specify a location, and then click
[Next].
7. Click [Browse], specify \(name of any given language)\Win2000 in the folder in which
the TWAIN driver is stored, and then click [OK].
8. Click [OK]. Then, continue following the instructions in the dialog boxes that will appear
until the Completing the Found New Hardware Wizard dialog box appears.
1-61
9. Click [Finish].
10. The Found New Hardware Wizard dialog box will appear again: Repeat steps 4~8 to
<For Windows Me/98>
1. Prepare the files necessary for upgrading the firmware, and copy them to PC.
The Add New Hardware Wizard dialog box will appear.
5. With Windows Me, choose Specify the location of the driver (Advanced), and then
click [Next].
With Windows 98, click [Next]. Then, in the dialog box that will then appear, choose
Search for the best driver for your device (recommended), and then click [Next].
6. Choose Specify a location, and then click [Browse].
7. Specify \(name of any given language)\Win9X in the folder in which the TWAIN driver
is stored, and then click [OK].
8. Click [Next]. Then, continue following the instructions in the dialog boxes that will
appear until the Finish button appears.
9. Click [Finish].
10. The Add New Hardware Wizard dialog box will appear again: Repeat steps 4~8 to
1-62
6.1.2 Procedure for Upgrading the GDI Firmware
1. Turn ON the Power Switch of the copier.
3. Copy the Update Software folder and Update file to drive C. (Copy them into the
highest directory on drive C.)
4. Connect the copier to the host computer using a USB cable. (Wait until the hardware is
detected.)
5. Open Properties of My Computer. Then select System Properties/Hardware/Device
Manager/Imaging devices to check that the XXXXXXXXXXX (Model Name) icon has
been added.
6. Double-click the Update file in the Update Software folder.
The A3S/A4S Update F/W-VXXX screen will appear.
7. Click the [Browse] button. Then, select the Update file that has been copied onto drive
C in step 3.
4035D525CA 4035D526CA
4980D047AA
4035D531AA
1-63
8. Click the [Update] button to start the transfer of the firmware data. (Wait until data trans-
fer is completed.)
9. Check the Display for status of the firmware upgrading sequence.
NOTE
NEVER turn OFF and ON the Power Switch as long as the above screens are being dis-
played.
10. When the following message appears in the Display, it indicates that upgrading of the
firmware has been completed.
11. Click the [OK] button to quit A3S/A4S Update F/W-VXXX.
12. Turn OFF and ON the Power Switch of the copier.
4035D530CA
<PWB-C/C>
4980D051AB
4035D532AA
1-64
6.1.3 Procedure when Upgrading the Firmware has failed
NOTES
Perform upgrading using BIOS only when upgrading from PC using ordinary USB con-
nection has failed and the PC has not started properly.
You need the Fax board and BIOS ROMs (V17, V19) to perform this procedure.
1. Turn off the power switch of copier.
2. Disconnect the USB cable from the copier and host computer.
3. Remove the rear cover.
1-26
4. Disconnect jumper [CJ1] on the Control board (PWB-C/C) from 1-2 and connect it to 2-
3.
5. Disconnect jumper [FJ1] on the Fax board from 1-2 and connect it to 2-3.
4035D535AA
1-65
6. Disconnect jumper [FJ2] on the Fax board.
7. Install the BIOS ROMs (U17, U19) on the Fax board.
8. Attach the Fax board to Control board (PWB-C/C).
9. Turn on the power switch of copier. Following message will appear on message panel
and copier waits for file data.
10. Perform steps 4~12 in the firmware upgrading procedure to upgrade the firmware.
11. Turn power off.
4035D536AA
4035D537AA
4035D538AA
1-66
12. Remove the Fax board.
13. Disconnect jumper [CJ1] on the Control board (PWB-C/C) from 2-3 and connect it to 1-
2.
14. Disconnect jumper [FJ1] on the Fax board from 2-3 and connect it to 1-2.
15. Connect jumper [FJ2] to 1-2 on the Fax board.
ADJUSTING/SETTING
19971
2-1
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING
1. HOW TO USE THE ADJUSTMENT SECTION
1.1 Composition
This part Adjustment describes items to be adjusted and their method of adjustment that
are required by this machine and gives detailed explanations.
1.1.1 Checking before starting work
When conducting claims in the field, it is necessary to check in advance the following:
1. Are the power source and voltage secured in accordance with the specifications?
2. Is the power source properly grounded?
3. Is any equipment that consumes repeatedly a lot of electricity connected to the same
power source? (e.g.: Electric noise sources such as elevator and air conditioner)
4. Are environmental conditions suitable for the machine?
High temperature and high humidity, direct sunlight, ventilation, etc.
Levelness of the location on which the machine is installed.
5. Does the cause of poor images lie in the original itself?
6. Is density selected properly?
7. Is the original glass stained?
8. Is proper paper used for copy?
9. Are copy materials replaced with new ones at their life? (e.g.: Developer, drum, cleaning
blade, etc.)
10. Is toner filled?
1.1.2 Checkpoints when conducting on-site service
Due attention should be paid to the following when repairing the machine.
1. Turn OFF the Power Switch and unplug the power cord of the copier. If it is unavoidably
necessary to service the copier with its power turned ON, use utmost care not to be
caught in the Scanner Cables or gears.
2. The fixing section may be very hot. Be careful not to get burnt when handling it.
3. The developing unit is strongly magnetized. Be careful not to bring a watch and instru-
ment near to the unit.
4. Be careful not to damage the drum with a tool.
5. Be careful not to touch IC directly with bare hands.
2-2
2-3
Di1611/Di2011 FIELD SERVICE Ver. 1.0 Mar. 2004 ADJUSTING/SETTING
2. Adjustment Item List
This table shows the list of adjustment items when replacing a part. Items are numbered by the priority if there is any.
SERVICE MODE
Mechanical Others
NOTE
SERVICE'S CHOICE ADJUST
CLEAR
DATA
FUNCTION
I
D

A
D
J
U
S
T
V
G

A
D
J
U
S
T
L
E
A
D
I
N
G

E
D
G
E

E
R
A
S
E
T
R
A
I
L
I
N
G

E
D
G
E

E
R
A
S
E
V
E
R
T
I
C
A
L

E
D
G
E

E
R
A
S
E
L
O
O
P

A
D
J
U
S
T

(
T
R
A
Y
1
)
F
U
S
E
R

T
E
M
P
C
C
D

A
P
S

S
I
Z
E
P
R
N

M
A
I
N

R
E
G
I
S
T
P
R
N

S
U
B

R
E
G
I
S
T
C
C
D

M
A
I
N

Z
O
O
M
C
C
D

S
U
B

Z
O
O
M
C
C
D

M
A
I
N

R
E
G
I
S
T
C
C
D

S
U
B

R
E
G
I
S
T
A
D
F

S
U
B

Z
O
O
M
A
D
F

M
A
I
N

R
E
G
I
S
T
A
D
F

S
U
B

R
E
G
I
S
T

1
A
D
F

S
U
B

R
E
G
I
S
T

2
P
M

C
O
U
N
T
E
R
S
U
P
P
L
I
E
S

L
I
F
E

C
O
U
N
T
.
P
A
P
E
R

F
E
E
D

T
E
S
T
A
T
D
C

A
U
T
O

A
D
J
U
S
T
P
R
I
N
T

T
E
S
T

P
A
T
T
E
R
N
A
D
F

F
E
E
D

T
E
S
T
S
C
A
N

T
E
S
T
F
o
c
u
s
-
P
o
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Paper Take-
Up/Transport
Section
Paper Take-up Roller
(Tray1)
Replace 3* 1 2 *Check when setting is chenged.
Paper Separator Roll Assy
(1st Tray)
Paper Dust Remover Assy
Replace 1
IR Section Scanner Rail/Bushing
Cleaning 2 1
Imaging Unit
Section
PC Drum
Replace 3* 4* 2 5 1 *Check when setting is chenged.
PC Drum Charge Corona
Assy
Developer
Replace 5* 3 1,4 6 2 *Check when setting is chenged.
Cleaning Blade
Replace 2 1
Image Transfer
Section
Image Transfer Roller Assy
Replace 1
Fusing Section Fusing Unit
Replace 2* 1 *Check when setting is chenged.
Copier Section Ozone Filter
Replace 1
P
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Electrical
Parts
CCD Assy
Replace 2 3 4 1
PWB-C/C Board
Replace 1 2
ATDC Sensor
Replace 4* 1,3 2
Others PH
Replace 11 12 13 1 2 3 4 5 6 7 8 9 10
Memory Clear
- 1 2
Scanner Drive Cable
Install 3 4 2 1
Original Size Sensor
Add 1
Ref. page
2-22 2-23 2-26 2-27 2-28 2-29 2-23 2-31 2-32 2-33 2-34 2-35 2-36 2-37 2-38 2-38 2-38 2-39 2-40 2-41 2-46 2-46 2-47 2-47 2-48 2-55 2-57 1-57 1-60 1-21 1-14 1-19
Service Item
Adjustment Setting Item
2-4
Di1611/Di2011 FIELD SERVICE Ver. 1.0 Mar. 2004 ADJUSTING/SETTING
NOTES: Before executing a Memory Clear, be sure to take notes of the settings and adjustment data of Utility, Tech. Rep., Security, and Adjust modes. After the Memory Clear has been executed, re-enter those data.
: The following data of Adjust are indicated at the factory on the Adjust Label located inside the Front Door (The other side of the Toner Replacement Label).
(PRN MAIN REGIST/PRN SUB REGIST/CCD MAIN ZOOM/CCD SUB ZOOM/CCD MAIN REGIST/CCD SUB REGIST)
: The ATDC value at the time of setting up of the PC Drum Unit is also entered on the Adjust Label at installation.
: The setting value after ATDC Adjustment is witten down in a Adjust Label.
SERVICE MODE
Mechanical Others
NOTE
SERVICE'S CHOICE ADJUST
CLEAR
DATA
FUNCTION
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P
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Pick-Up Roller Replace 1 2
Take-Up Roller Replace 1 2
Separator Roller Replace 1 2
A
F
-
1
2
P
M
Pick-Up Roller Replace 1 2
Take-Up Roller Replace 1 2
Separator Roller Replace 1 2
P
F
-
1
2
6
P
M
Take-Up Roller Replace 3* 1 2
M
B
-
6
P
M
Take-Up Roller Replace 3* 1 2
Separator Roller Assy Replace 3* 1 2
Ref. page 2-22 2-23 2-26 2-27 2-28 2-29 2-23 2-31 2-32 2-33 2-34 2-35 2-36 2-37 2-38 2-38 2-38 2-39 2-40 2-41 2-46 2-46 2-47 2-47 2-48 2-55 2-57 1-57 1-60 1-21 1-14 1-19
Service Item
Adjustment Setting Item
2-5
3. UTILITY MODE
Utility mode is used to make settings for the utility functions.
3.1 Utility Mode Function Tree
Utility
1. AUTO PANEL RESET
2. ENERGY SAVE MODE
3. AUTO SHUT OFF
4. DENSITY (ADF)
5. DENSITY (BOOK)
6. PRINT DENSITY
7. LCD CONTRAST
8. LANGUAGE
1. INCH/METRIC
2. TRAY1 PAPER
3. PAPER TYPE
PAPER SOURCE SETUP
1. DRUM DEHUMIDIFY
2. TONER REPLENISHER
ADMIN. MANAGEMENT
1. AUTO SHUT OFF
2. COPY TRACK
USER MANAGEMENT
MACHINE SETTING
2-6
Utility
COPY SETTING 1
1. PAPER PRIORITY
2. DENSITY PRIORITY
3. DENSITY LEVEL (A)
4. DENSITY LEVEL (M)
5. BINDING POS.
6. MARGIN SETTING
7. ERASE SETTING
8. SMALL ORIGINAL
COPY SETTING 2
1. MIXED ORIGINAL
2. COPY PRIORITY
3. OUTPUT PRIORITY
4. 4IN1 COPY ORDER
5. CRISSCROSS MODE
6. DUPLEX COPY
2-7
3.2 Utility Mode Setting Procedure
<Procedure>
1. Press the Utility key.
2. The Utility mode screen will appear.
<Exiting the Mode>
Press the Panel Reset key.
<Changing the Setting Values in Utility Mode Functions>
Select the appropriate item using [ / ] key, [ < / > ] key, or the 10-Key Pad.
Select the setting value using [ / ] key, [ < / > ] key, or the 10-Key Pad.
1. Validate the selected setting value using the [Yes] key.
2. To go back to the previous screen, press the [No] key.
3.3 Setting in the Utility Mode
3.3.1 MACHINE SETTING
MACHINE SETTING is used to set the operating environment.
(1) AUTO PANEL RESET
(2) ENERGY SAVE MODE
(3) AUTO SHUT OFF
Purpose Setting Details/Precautions
To set the time it takes the Auto Panel Reset function,
which resets the panel settings when the set period of
time elapses after a copy cycle has been completed or
the last key operated, to be activated.
The default setting is 1 min.
OFF
ON: 0.5 1 2 3 4 5
To set the time it takes the copier to enter the Energy
Saver mode after a copy cycle has been completed or
the last key operated.
The default setting is 15
min.
Setting range: 1 to 240 min.
To set the time it takes the Auto Shut OFF function,
which shuts down the copier when the set period of time
elapses after a copy cycle has been completed or the
last key operated, to be activated.
The default setting is OFF.
OFF
ON
Setting range: 15 to 240 min.
2-8
(4) DENSITY (ADF)
(5) DENSITY (BOOK)
(6) PRINT DENSITY
(7) LCD CONTRAST
(8) LANGUAGE
To set the reading image density level when the
Automatic Document Feeder is used.
NOTE
The low image density is set as the default
value to prevent a dirty copy from being pro-
duced.
The default setting is MODE1.
MODE1: To lower the image density to
prevent a dirty copy from
being produced.
MODE2: To produce a copy having an
image density equivalent to
that of the original.
To set the reading image density level when the
Original Glass is used.
The default setting is MODE1.
MODE1: To produce a copy having an
image density equivalent to
that of the original.
MODE2: To lower the image density to
prevent a dirty copy from
being produced.
To set the print density. The default setting is 0.
Setting range: -2 (LIGHT) to +2 (DARK)
To set the brightness of the LCD display. The default setting is 0.
To select the language displayed on the control
panel.
Select the desired language and
touch [OK] to set the language.
2-9
3.3.2 PAPER SOURCE SETUP
PAPER SOURCE SETUP is used to make the various settings for the paper source.
(1) INCH/METRIC
(2) TRAY1 PAPER
(3) PAPER TYPE
appears only when the AD-17 (Di2011 Only) is installed
To select the paper size type for each paper
source for automatic paper size detection.
The default setting is METRIC.
<Step>
1. Select the tray.
TRAY1 TRAY2
2. Select the appropriate paper size
type.
INCH METRIC
To set the type and size of the paper loaded in
Paper Feed Tray/1.
The default setting is PLAIN and
AUTO.
<Step>
1. Select the type of paper.
PLAIN OHP CARD ENVELOP
2. Set the paper size.
AUTO
SIZE INPUT
Setting range: 140 to 432 mm (X)
90 to 297 mm (Y)
To set the type of paper for the paper source. The default setting is PLAIN.
<Step>
1. Select the paper source.
TRAY1 TRAY2
BYPASS
2. Select the type of paper.
PLAIN RECYCLE SPECIAL
1-SIDE*
2-10
3.3.3 USER MANAGEMENT
(1) DRUM DEHUMIDIFY
(2) TONER REPLENISHER
To run a drum dry sequence.
The drum dry sequence is run when an image
problem occurs due to condensation formed
on the surface of the PC Drum as a result of a
sudden change in temperature or an increased
humidity.
<Step>
1. Select DRUM DEHUMIDIFY and
press the [Yes] key.
2. The drum dry sequence is automat-
ically terminated after the lapse of a
predetermined period of time and
the initial screen reappears.
To forcedly replenish the supply of toner when ID
drops as a result of a reduced T/C ratio after a
large number of copies have been made from an
original having a high image density, thereby
achieving the set T/C level.
When TONER REPLENISHER is
executed, the copier first detects the
current toner density. If it is found that
the density is lower than the refer-
ence value, supply of toner is replen-
ished and then toner is agitated. If
the density is found to be higher than
the reference value, the copier simply
agitates toner to complete the
sequence.
<Step>
1. Select TONER REPLENISHER
and press the [Yes] key.
2. The toner replenisher sequence is
automatically terminated after a
given period of time or when the
specified toner density is recovered.
Then, the initial screen reappears.
2-11
3.3.4 ADMIN. MANAGEMENT
ADMIN. MANAGEMENT is used to make various settings after the administrator number
set using the Service mode has been entered.
<Admin. Management Mode Setting Procedure>
2. Select ADMIN. MANAGEMENT.
3. Type the 6-digit administrator number and press the [Yes] key.
(1) AUTO SHUT OFF
(2) COPY TRACK
<COPY TRACK MODE>
To enable or disable the setting of Auto Shut
OFF.
The default setting is ENABLE.
DISABLE ENABLE
To select whether to turn ON or OFF the copy
track function.
The default setting is OFF (copy
track function is not used).

ON: Use the copy track function.
OFF: Not use the copy track function.
2-12
<ACCESS NO. REG.?>
To register a 3-digit (001 to 999) access number
used for the copy track function, or to change or
delete a previously set access number.
<Registration Procedure>
1. Type any access number from the
10-Key Pad.
2. Press the [Yes] key to validate the
entry of the access number.
3. To continue registering access
numbers, repeat steps 1 and 2. (Up
to 20 different accounts can be set.)
4. When the registration procedure is
completed, quit the function by
pressing the [No] key.
<Change/Delete Procedure>
1. Type the access number to be
changed or deleted from the 10-Key
Pad and press the [Yes] key.
2. When you are prompted to deter-
mine whether to retain the data or
not, press the [No] key.
3. Select EDIT or DELETE and
If EDIT is selected, a screen
appears allowing you to change the
access number. (To step 4)
If DELETE is selected, the current
access number is deleted.
4. Type the new access number from
the 10-Key Pad and press the [Yes]
key.
5. To continue changing or deleting
new access numbers, repeat steps
1 to 4.
6. When the EDIT/DELETE procedure
is completed, quit the function by
pressing the [No] key.
2-13
<COPY TRACK DATA?>
To display or clear the total count value of a
specific account.
To clear the total count values of all accounts
under control.
<Display/Clear Procedure>
1. Select DISPLAY and press the
[Yes] key.
2. Select the access number, for which
the count is to be checked, and
3. The total count value of the access
number selected will be displayed.
To clear the count value, press the
[No] key. (To step 4)
To quit the function without clearing
the count value, press the [Yes] key.
4. Press the [No] key to clear the
count value.
5. When the count value has been
cleared, quit the function by press-
ing the [Yes] key.
<All Clear Procedure>
1. Select CLEAR and press the [Yes]
key.
2. When you are prompted to confirm
if all count values are to be cleared,
2-14
3.3.5 COPY SETTING 1
COPY SETTING 1 is used to set the default values for different copy functions.
(1) PAPER PRIORITY
(2) DENSITY PRIORITY
(3) DENSITY LEVEL (A)
(4) DENSITY LEVEL (M)
(5) BINDING POS.
(6) MARGIN SETTING
To set the priority paper source. The default setting is 1ST.
1ST 2ND 3RD 4TH 5TH BYPASS
To set the priority image quality mode and den-
sity that are selected when the Power Switch is
turned ON or the Panel Reset key is pressed.
The default setting is TEXT/P and
AUTO.
Image quality mode: TEXT PHOTO
TEXT/P
Density: AUTO MANUAL
TEXT/P means TEXT/PHOTO.
To set the density level when the Auto density
is selected.
The default setting is 0.

To set the density level when the Manual den-
sity is selected.

To set the first page to be scanned when copies
are made from a book, whether it is on the left or
on the right.
LEFT RIGHT
To set the file margin width when making copies
with a file margin.
The default setting is 10 mm.

Setting range: 0 to 20 mm
2-15
(7) ERASE SETTING
(8) SMALL ORIGINAL
3.3.6 COPY SETTING 2
COPY SETTING 2 is used to set the default values for different copy functions.
(1) MIXED ORIGINAL
(2) COPY PRIORITY
(3) OUTPUT PRIORITY
To set the erase width when making erase cop-
ies.
The default setting is LEFT and 10
mm.
<Step>
1. Select the erase position.
LEFT UPPER FRAME
2. Set the erase width.
Setting range: 5 to 20 mm
To set whether to enable or disable copying when
an original of a size smaller than the detectable
one is loaded in the Auto Paper mode.
DISABLE ENABLE
To set whether or not to select the Mixed Original
mode when the Power Switch is turned ON or
Panel Reset key is pressed.
The default setting is OFF.
ON OFF
To set the priority mode, either Auto Paper, Auto
Size, or Manual, selected when the Power Switch
is turned ON or Panel Reset key is pressed.
The default setting is APS.
APS AS MANUAL
To set the priority finishing function, either Non-
Sort, Sort, or Group.
The default setting is NON.
NON SORT GROUP
2-16
(4) 4IN1 COPY ORDER
(5) CRISSCROSS MODE
(6) DUPLEX COPY
appears only when the AD-17 (Di2011 Only) is installed
To set the layout of copy images in 4in1 copies. The default setting is PATTERN1.
To select the crisscross function. The default setting is ON.
ON OFF
To select whether to enable or disable 2-sided
copying.
This function should not be used.
4035S501AA
PATTERN1 PATTERN2
4035S502AA
2-17
4. SERVICE MODE
The Service mode is used to check, set, adjust, or register the various service functions.
4.1 Service Mode Function Tree
Displayed when options are mounted.
Service Mode
SHIPMENT DESTINATION
MAINTENANCE COUNTER
IU LIFE STOP MODE
ID ADJUST
VG ADJUST
FUSER TEMP. Ad (PLAIN)
FUSER TEMP. Ad (THICK)
FUSER TEMP. Ad (OHP)
LEADING EDGE ERASE
TRAILING EDGE ERASE
VERTICAL EDGE ERASE
LOOP ADJUST (TRAY1)
LOOP ADJUST (TRAY2 TO TRAY5)*
LOOP ADJUST (DUPLEX)
LOOP ADJUST (BYPASS)
FLS PAPER SIZE
CCD APS SIZE
GDI TIMEOUT
PRN MAIN REGIST
PRN SUB REGIST
CCD MAIN ZOOM
CCD SUB ZOOM
CCD MAIN REGIST
CCD SUB REGIST
ADF SUB ZOOM
ADF MAIN REGIST
ADF SUB REGIST1
ADF SUB REGIST2
ADF REG. LOOP 1
ADF REG. LOOP 2
ATDC GAIN
MODEL SETTING
2. ADJUST
1. SERVICES CHOICE
2-18
3. COUNTER
TOTAL COUNTER
SIZE COUNTER
PM COUNTER
MAINTENANCE COUNTER
SUPPLIES LIFE COUNT.
APPLICATION COUNTER
SCAN COUNTER
PAPER SIZE COUNTER
MISFEED COUNTER
TROUBLE COUNTER
PAPER FEED TEST
PROCESS CHECK
ATDC AUTO ADJUST
PRINT TEST PATTERN
ADF FEED TEST
COPY ADF GLASS AREA
CCD MOVE TO HOME
SCAN TEST
ADF WIDTH ADJ. (MAX)*
ADF WIDTH ADJ. (MIN)*
ADF SENSOR ADJUST*
TONER DENSITY LEVEL
PROCESS CONTROL
MAIN F/W VER.
ENGINE F/W VER.
PCL F/W VER.*
NIC F/W VER.*
ADF F/W VER.*
MAIN RAM SIZE
PCL RAM SIZE*
SERIAL NO.
CUSTOMER ID
4. DISPLAY
Service Mode
5. FUNCTION
6. ADMIN. REGISTRATION
2-19
REDUCTION2
REDUCTION1
EXPANSION1
EXPANSION2
7. FIXED ZOOM CHANGE
8. FACTORY TEST
PANEL BUZZER TEST
RAM TEST
9. CLEAR DATA
MEMORY CLEAR
PM COUNTER
MAINTENANCE COUNTER
SUPPLIES LIFE COUNT.
APPLICATION COUNTER
SCAN COUNTER
PAPER SIZE COUNTER
MISFEED COUNTER
TROUBLE COUNTER
ADF BACKUP CLEAR*
TOTAL COUNTER COUNT
SIZE COUNTER COUNT
PLUG-IN COUNTER COPY
MACHINE COUNTER
10. SECURITY
Service Mode
2-20
4.2 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>
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.
2-21
4.3 Setting in the Service Mode
4.3.1 SERVICES CHOICE
SERVICES CHOICE is used to make the various service settings.
(1) SHIPMENT DESTINATION
To select the display of the fixed zoom ratios and
paper sizes according to the applicable market-
ing area.
The default setting is METRIC

METRIC
INCH
JAPAN
CHINA
L. AMERICA (METRIC)
L. AMERICA (INCH)
2-22
(2) MAINTENANCE COUNTER
(3) IU LIFE STOP MODE
(4) ID ADJUST
To enter an appropriate counter value (0 to
999999) as the tentative maintenance time.
Specify the setting on maintenance counter to 1
or 2: If the maintenance life is reached, the
maintenance call (M1) or Tech. Rep. call [Call
Service (M1)] will appear.
0: Not counted
1: Counted (The maintenance call dis-
play is given when the counter
reaches 0.)
2: Counted (The Tech. Rep. call display
is given and the initiation of any new
copy cycle is inhibited when the
counter reaches 0.)
When 1 or 2 is selected, a screen
will then appear to allow the counter
value to be entered.
NOTE
The counter value is decremented
until it reaches -999999 even after it
has counted 0.
When the Supplies Life Count. reaches the life
value, the IU life will be detected. The mode
when the IU life is reached, is specified by this
setting.
The default setting is CONTINU-
OUS.
CONTINUOUS: Enables copying.
Maintenance call display is given.
STOP: Disables copying. Tech. Rep.
call display is given and the initiation of
any new copy cycle is inhibited.
NOTE
The counter value is decremented
until it reaches -999999 even after it
has counted 0. In this case, however,
no image quality is guaranteed.
To set the image density by varying Vg and Vb
on the engine side.
Used when the image density is high or low.

Setting range: -3 to +3
2-23
(5) VG ADJUST
(6) FUSER TEMP. Ad (PLAIN)
<Temperature table for adjusting fusing temperature for plain paper>
For Di1611
To adjust image density by varying Vg with
changing sensitivities as the PC Drum is used for
an extended period of time.
When image problems (fog, void) occur
When the PC Drum Unit has been replaced
Increase the setting value to eliminate
void.
Decrease the setting value to eliminate
fog.
To set the temperature of the Fusing Roller for
each type of paper, thereby making up for fusing
performance that changes with the operating
environment or type of paper.
When fusing failure occurs
When the type of paper is changed

Setting value
Paper width
Mode selected in Services Choice
Mode 1 Mode 3
CD FD Heater Lamp temperature
2
251 mm or more
361 mm or more 200 C 190 C
360 mm or less 200 C 190 C
250 mm or less 200 C 185 C
1
251 mm or more
361 mm or more 200 C 180 C
360 mm or less 200 C 180 C
250 mm or less 190 C 175 C
0
(default value)
251 mm or more
361 mm or more 190 C 170 C
360 mm or less 190 C 170 C
250 mm or less 180 C 165 C
-1
251 mm or more
361 mm or more 180 C 160 C
360 mm or less 180 C 160 C
250 mm or less 170 C 155 C
2-24
For Di2011
(7) FUSER TEMP. Ad (THICK)
<Temperature table for adjusting fusing temperature for special paper>
For Di1611
For Di2011
Setting value Paper width
Mode 1 Mode 3
Heater Lamp temperature (main/sub)
2
221 mm or more
200 C
220 mm or less
1
221 mm or more
190 C
220 mm or less
0
(default value)
221 mm or more
180 C
220 mm or less
-1
221 mm or more
170 C
220 mm or less
To set the fusing temperature when thick paper is
used.

Setting value
Paper width
Mode 1 Mode 3
CD Heater Lamp temperature
1
251 mm or more 210 C 200 C
250 mm or less 210 C 200 C
0 (default value)
251 mm or more 210 C 190 C
250 mm or less 200 C 190 C
-1
251 mm or more 200 C 180 C
250 mm or less 190 C 180 C
Setting value
Mode 1 Mode 3
1 210 C
0 (default value) 200 C
-1 190 C
2-25
(8) FUSER TEMP. Ad (OHP)
<Temperature table for adjusting fusing temperature for OHP transparencies>
For Di1611
For Di2011
To set the fusing temperature when OHP trans-
parencies are used.

Setting value
Paper width
Mode 1 Mode 3
CD Heater Lamp temperature
1
251 mm or more 180 C 175 C
250 mm or less 165 C 165 C
0 (default value)
251 mm or more 180 C 165 C
250 mm or less 155 C 155 C
-1
251 mm or more 170 C 155 C
250 mm or less 145 C 145 C
Setting value
Mode 1 Mode 3
1 175 C
0 (default value) 165 C
-1 155 C
2-26
(9) LEADING EDGE ERASE
<Adjustment Procedure>
1. Call Services Choice of Service Mode to the screen.
2. Select Leading Edge Erase and press the [Yes] key.
3. Using [ / ] key, select the desired setting value.
4. Press the [Yes] key to validate the setting value selected in step 3.
Adjustment Instructions
To make the erase width smaller, decrease the setting value.
To make the erase width greater, increase the setting value.
To adjust the erase width on the leading edge
of the image by varying the laser emission
timing.
When the PH Unit has been replaced

0 mm 1 mm 2 mm 3 mm 4 mm 5 mm
Set the erase width on the leading edge of the paper
(width A).
4035D516AA
A
2-27
(11) TRAILING EDGE ERASE
2. Select Trailing Edge Erase and press the [Yes] key.
To adjust the erase width on the trailing edge
of the image by varying the laser emission
timing.

Set the erase width on the trailing edge of the paper
(width B).
B
4035D517AA
2-28
(12) VERTICAL EDGE ERASE
2. Select Vertical Edge Erase and press the [Yes] key.
To adjust the erase width on both edges of the
image (in CD direction) by varying the laser
emission timing.
Select the erase width value in the CD
direction. (The default setting is 4 mm.)

Set the erase width on both edges of the paper
(width C).
C
4035D518AA
C
2-29
(13) LOOP ADJUST (TRAY1)
2. Select Loop Adjust (Tray1) 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.
(14) LOOP ADJUST (TRAY2 TO TRAY5)
To adjust the length of the loop formed in the
paper before the Synchronizing Roller.
When a skew feed, fold, or misfeed of paper
occurs
When variations in the amount of void on
the leading edge occurs
Setting range: -3.9 to 3.9 mm
(1 step: 0.6 mm)
paper before the Synchronizing Roller when
the optional Paper Feed Unit is used.
occurs
Refer to the option service manual (PF-
126) for details.
2-30
(15) LOOP ADJUST (DUPLEX): Di2011 Only
(16) LOOP ADJUST (BYPASS)
2. Select Loop Adjust (Bypass) 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.
paper before the Synchronizing Roller.
occurs
Refer to the option service manual (AD-
17) for details.
paper before the Synchronizing Roller when
the Manual Bypass is used.
occurs
Setting range: -3.9 to 3.9 mm
(1 step: 0.6 mm)
2-31
(17) FLS PAPER SIZE
(18) CCD APS SIZE
(19) GDI TIMEOUT
To select the paper size for FLS.
When the FLS paper size is changed
At setup
330203 330210
330216 330220
337206
To set the automatic paper size detection
function for CCD scan.
The default setting is PATTERN1.
PATTERN1 PATTERN2
To specify the time for timeout when data
from PC is interrupted during GDI printing.
0 (5 sec.), 1 (10 sec.), 2 (20 sec.),
3 (30 sec.), 4 (40 sec.), 5 (50 sec.),
6 (60 sec.)
2-32
4.3.2 ADJUST
(1) PRN MAIN REGIST
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. Check to see if width A on the test pattern falls within the specified range.
If width A falls outside the specified range, perform the following steps to make an
adjustment.
5. Select Adjust of PRN Main Regist.
6. Using [ / ] key, select the appropriate setting value.
If width A on the test pattern is longer than the specifications, decrease the setting value.
If width A on the test pattern is shorter than the specifications, increase the setting value.
If a single adjustment procedure does not successfully bring width A into the specified
range, repeat steps 5 through 7.
Function Purpose Setting Details/Precautions
Test Copy
To adjust by varying the starting position
of image writing in the main scanning
direction.
When the image on the copy deviates
in the CD direction
Press the Start key to start a test
copy cycle.
Adjust
Setting range: 60 to 140
(1 step: 0.1 mm)
Adjust so that width A on the test pattern produced
falls within the specified range.
Specifications
20 2.0 mm
4035D519AA
A
2-33
(2) PRN SUB REGIST
4. Check to see if width B on the test pattern falls within the specified range.
If width B falls outside the specified range, perform the following steps to make an
adjustment.
5. Select Adjust of PRN Sub Regist.
If width B on the test pattern is longer than the specifications, decrease the setting value.
If width B on the test pattern is shorter than the specifications, increase the setting value.
If a single adjustment procedure does not successfully bring width B into the specified
Test Copy
To adjust by varying the starting position
of image writing in the sub scanning
direction.
When the image on the copy deviates
in the FD direction
copy cycle.
Adjust
(1 step: 0.37 mm)
Adjust so that width B on the test pattern produced
falls within the specified range.
Specifications
10 1.5 mm
4035D520AA
B
2-34
(3) CCD MAIN ZOOM
Adjust so that the amount of error falls within 1.0% of the length to be measured.
Adjust so that the following specifications are met when the length of the scale is 200
mm.
Zoom Ratio/Specifications
Zoom Ratio: Full size ( 1.00)
Specifications: 200 2.0 mm
1. Place a scale on the Original Glass in parallel with the Original Width Scale and make a
copy.
3. Enter Adjust of the Service mode.
4. Select Adjust of CCD Main Zoom.
If the length on the copy is longer than the actual one, decrease the setting value.
If the length on the copy is shorter than the actual one, 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 6.
Test Copy
To adjust variations in machining and
installation accuracy of different IR parts
by varying the scanning zoom ratio in the
main scanning direction.
When the CCD Unit has been replaced
(After the CCD Unit has been adjusted
for correct position)
copy cycle.
Adjust

(1 step: 0.4%)
2. Measure the length of the scale on the copy. If the
amount of error falls outside the specified range,
perform the following steps to make an adjust-
ment.
4030D528AA
2-35
(4) CCD SUB ZOOM
mm.
1. Place a scale so that it is at right angles to the original width scale, and copy it.
3. Enter Adjust of the Service mode.
4. Select Adjust of CCD Sub Zoom.
If the length on the copy is longer than the actual one, decrease the setting value.
If the length on the copy is shorter than the actual one, 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 6.
Test Copy
by varying the scanning zoom ratio in the
sub scanning direction.
When the Scanner Drive Cables have
been replaced
copy cycle.
Adjust

(1 step: 0.4%)
ment.
4030D529AA
2-36
(5) CCD MAIN REGIST
4. Place the test pattern produced in step 3 on the Original Glass and make a copy of it.
5. Place the test pattern (original) on top of the copy and check for deviation in width A.
If the deviation in width A falls outside the specified range, perform the following steps
to make an adjustment.
6. Select Adjust of CCD Main Regist.
If the deviation is longer than the specifications, increase the setting value.
If the deviation is shorter than the specifications, decrease the setting value.
If a single adjustment procedure does not successfully bring the deviation into the specified
Test Copy
by varying the starting position of image
scanning in the main scanning direction.
(After PRN Main Regist, PRN Sub
Regist, and CCD Main Zoom have
been adjusted)
copy cycle.
Adjust
(1 step: 0.1 mm)
Adjust so that deviation between width A on the test
pattern produced and that on the copy produced falls
within the specified range.
Specifications
0 2.0 mm
4035D519AA
A
2-37
(6) CCD SUB REGIST
4. Place the test pattern produced in step 3 on the Original Glass and make a copy of it.
5. Place the test pattern (original) on top of the copy and check for deviation in width B.
If the deviation in width B falls outside the specified range, perform the following steps
to make an adjustment.
6. Select Adjust of CCD Sub Regist.
If the deviation is longer than the specifications, increase the setting value.
If the deviation is shorter than the specifications, decrease the setting value.
If a single adjustment procedure does not successfully bring the deviation into the specified
Test Copy
by varying the starting position of image
scanning in the sub scanning direction.
(After PRN Main Regist, PRN Sub
Regist, and CCD Main Zoom have
been adjusted)
copy cycle.
Adjust
(1 step: 0.1 mm)
Adjust so that deviation between width B on the test
pattern produced and that on the copy produced falls
within the specified range.
Specifications
0 1.5 mm
4035D520AA
B
2-38
(7) ADF SUB ZOOM
appears only when the AF-12 or AFR-19 (Di2011 Only) is installed
(8) ADF MAIN REGIST
(9) ADF SUB REGIST1
Test Copy To adjust variations in machining and
installation accuracy of different parts by
varying the scanning zoom ratio in the
sub scanning direction when the Auto-
matic Document Feeder is used.
Refer to the option service
manual (AF-12, AFR-19) for
details.
Adjust
varying the scanning start position in the
main scanning direction when the Auto-
details.
Adjust
NOTE
This adjustment should be made after
the ADF Sub Zoom adjustment.
details.
Adjust
2-39
(10) ADF SUB REGIST2
appears only when the AFR-19 (Di2011 Only) is installed
(11) ADF REG. LOOP1
(12) ADF REG. LOOP2
(13) ATDC GAIN
NOTE
This adjustment should be made after
the ADF Sub Zoom adjustment.
manual (AFR-19) for details.
Adjust
To adjust the length of loop formed in the orig-
inal before the Registration Roller.
When a skew feed, fold, or misfeed of the
original occurs
Refer to the option service manual
(AFR-19) for details.
To adjust the length of loop formed in the orig-
inal before the Registration Roller.
When a skew feed, fold, or misfeed of the
original occurs
Refer to the option service manual
(AFR-19) for details.
To manually adjust the ATDC Sensor voltage. The default setting is 155.

The adjusted value of the ATDC Auto
Adjust is the setting value.
2-40
(14) MODEL SETTING
4.3.3 COUNTER
COUNTER displays the counts of various counters.
(1) TOTAL COUNTER
(5) SIZE COUNTER
(6) PM COUNTER
NOTE
Never change this setting.
If it is changed, the Tech. Rep. call (C03FF)
will appear.

20ppm 18ppm 16ppm
To display the total count value of the
selected mode.
1. COPY
2. COPY DUPLEX
3. PRINT
4. PRINT DUPLEX
To display the count of the Size Counter. To clear the count, use Clear Data of the
Service mode.
To display the count of the number of
times each of different parts of the
copier has been used.
The count should be cleared when the
corresponding PM part is replaced.
1: BYPASS
2: TRAY1
3: TRAY2
4: TRAY3 (should not be used)
5: TRAY4 (should not be used only for Di1611)
7: ADF (FEED)
8: ADF (REVERSE) (should not be used only
for Di1611)
9: IR
10: OZONE
11: CLEANING
To clear the count, use Clear Data of the
Service mode.
2-41
(8) SUPPLIES LIFE COUNT.
(9) APPLICATION COUNTER
(10) SCAN COUNTER
To display the count of the Maintenance
Counter.
When the counter reaches 0, mainte-
nance call M1 or the Tech. Rep. call will
appear, according to the setting on
maintenance counter of service choice.
2-22
Service mode.
To display the count of the Supplies Life
Counter.
When the counter reaches 0, life 1 will
be detected and maintenance call M2
will appear.
The initial value is 40000, and the count-
down system is used.
Service mode.
sheets of paper used for each of differ-
ent applications.
COPY PRINT: Number of copies made
FAX RX PRINT: (Only when Fax is used)
REPORT PRINT: (Only when Fax is used)
PC PRINT: Number of printed pages produced
from PC
FAX TX PAGE: (Only when Fax is used)
MAIL TX PAGE: (Used only when SU-6 is
mounted)
Service mode.
To display the count of the Scan
Counter.
The number of scan motions carried out for
copying is not counted.
Service mode.
2-42
(11) PAPER SIZE COUNTER
(12) MISFEED COUNTER
sheets of paper used for each size and
type.
1: A3 2: B4
3: A4 L 4: A4 C
5: B5 6: A5
7: FLS 8: LEDGER
9: 11 14 10: LEGAL
11: LETTER L 12: LETTER C
13: INVOICE 14: OTHER
15: PLAIN PAPER 16: RECYCLE PAPER
17: SPECIAL PAPER
18: 1-SIDE PAPER (should not be used only for
Di1611)
19: OHP 20: THICK PAPER
21: ENVELOPE
Service mode.
paper misfeeds that have occurred at dif-
ferent parts of the copier.
1: BYPASS
2: TRAY1
3: TRAY2
7: PICK-UP/TSPT.
8: DUPLEX (ENTRANCE) (should not be used
only for Di1611)
9: DUPLEX (FEED) (should not be used only for
Di1611)
10: FUSER
11: SEPARATOR
12: ADF (PICK-UP)
13: ADF (TSPT.)
14: ADF (EXIT)
15: ADF (REVERSE) (should not be used only
for Di1611)
Service mode.
2-43
(13) TROUBLE COUNTER
To display the count of the num-
ber of malfunctions detected
according to the malfunction
code.
C0000: Main Motor malfunction
C0044: ADF Cooling Fan failure
(should not be used only for Di1611)
C0045: Fusing Cooling Fan Motor malfunction
C004E: Power Unit Cooling Fan Motor malfunction
C0070: Toner Replenishing Motor malfunction
C0210: Abnormal image transfer voltage
C0500: Warm-up failure
C0501: Warm-up failure 2
C0510: Fusing failure (abnormally low temperature)
C0511: Fusing failure (abnormally low temperature 2)
C0520: Fusing failure (abnormally high temperature)
C0521: Fusing failure (abnormally high temperature 2)
C0650: Faulty Scanner Home Position Sensor
C0B60: Bin Switching Motor malfunction
C0B80: Shift Motor malfunction
C0F32: Faulty ATDC Sensor
C0F33: Improperly adjusted ATDC Sensor
C1038: Engine connection failure
C1200: Faulty ASIC/memory
C1300: Polygon Motor malfunction
C133B: Communication with option error
C133C: Modem fault
C133D: ROM checksum error
C13F0: Faulty HSYNC
C1468: Faulty EEPROM
C14A3: IR fluorescent lamp fault
To clear the count, use Clear Data of the Service
mode.
2-44
4.3.4 DISPLAY
DISPLAY displays various types of information.
(1) TONER DENSITY LEVEL
(2) PROCESS CONTROL
Purpose
To display the current output value of ATDC sensor.
Refer to the following table for actual T/C values.
Used to check the T/C ratio when the image density is defective.
Display T/C
80 8.0%~8.4%
100 10.0%~10.4%
130 13.0%~13.4%
135 13.5%~13.9%
140 14.0%~14.4%
145 14.5%~14.9%
Purpose
To display the Vg and Vb values.
Display Vb (V) Vg (V)
-5 -300 -450
0 -400 -550
+5 -500 -650
2-45
(3) MAIN F/W VER. (PWB-C/C)
(4) ENGINE F/W VER. (PWB-A)
(5) PCL F/W VER.
(6) NIC F/W VER.
(7) ADF F/W VER.
(8) MAIN RAM SIZE
(9) PCL RAM SIZE
(10) SERIAL NO.
Purpose
To display the main firmware version information.
Purpose
To display the engine firmware version information.
Purpose
To display the PCL firmware version information.
Only when the optional Printer Controller (Pi2001e) is mounted
Purpose
To display the NIC firmware version information.
Only when the optional Network Interface Card (NC-6) is mounted
Purpose
To display the ADF firmware version information.
Only when the optional Duplexing Document Feeder (AFR-19) is mounted
Purpose
To display the main memory size.
Purpose
To display the PCL memory size.
Only when the optional Printer Controller (Pi2001e) is mounted
Purpose
To display the serial number of the copier.
2-46
(11) CUSTOMER ID
4.3.5 FUNCTION
FUNCTION allows the various service functions (paper feed test, image printing) to be
checked and adjustments to be made.
(1) PAPER FEED TEST
(2) PROCESS CHECK
(3) ATDC AUTO ADJUST
Purpose
To display the customer ID of the copier.
To check for correct paper passage of
the paper take-up and transport sys-
tem by letting the copier consecutively
take up and feed paper without involv-
ing actual printing action.
Here are the details of operation
involved in the paper passage motion.
The Scanner does not make any
scan motion.
Paper is fed until the correspond-
ing paper source runs out of
paper.
This test cannot be run with the
Manual Bypass or Multiple Bypass
(option).
No counters are activated.
When a paper misfeed occurs
<Step>
TRAY1 TRAY2
2. Press the Start key to start the paper feed
test.
Press the Stop key to stop the paper feed
test.
Purpose
HV output (for factory setting only) * Should not be used
To make an automatic adjustment of the
ATDC Sensor.
At setup
When developer has been changed
When IU has been replaced
<Step>
1. Press the [Yes] key to start the adjustment.
2. The adjustment sequence automatically
stops as soon as the adjustment is made.
The sequence may be interrupted using the
Stop key.
2-47
(4) PRINT TEST PATTERN
(5) ADF FEED TEST
(6) COPY ADF GLASS AREA
Item Purpose Setting Details/Precautions
PRINT
TEST
PATTERN
PATTERN
1
To produce a test pattern for
image adjustments.
When skew, registration, or
zoom ratio has been adjusted
<Step>
TRAY1 TRAY2
2. Select the type of test pat-
tern.
3. Press the Start key to let the
copier produce the test pat-
tern.
PATTERN
2
To produce halftone and grada-
tion test patterns.
When checking for uneven
density or uneven pitch
When checking for gradation
reproducibility
<Step>
TRAY1 TRAY2
2. Select the type of test pat-
tern.
3. Press the Start key to let the
copier produce the test pat-
tern.
To check for correct paper passage of the
paper take-up and transport system in the
Automatic (Duplexing) Document Feeder
alone as a single unit.
Here are the details of operation involved
in the paper passage motion.
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
Refer to the option service manual (AF-12,
AFR-19) for details.
To check for scratches and dirt on the Origi-
nal Scanning Glass.
When a dirty image occurs
Refer to the option service manual (AF-12,
AFR-19) for details.
2-48
(7) CCD MOVE TO HOME
(8) SCAN TEST
(9) ADF WIDTH ADJ. (MAX)
(10) ADF WIDTH ADJ. (MIN)
(11) ADF SENSOR ADJUST
To move the Scanner to its home position
and fix it at the home position.
When transporting the copier
Pressing the Start key will move the Scan-
ner toward the left from its standby posi-
tion.
<Step>
1. Press the Start key to move the Scanner
from the standby position to the home
position.
Pressing the Stop key will bring the Scan-
ner back to its original position.
To check that the Exposure Lamp turns ON
properly and the Scanner moves properly.
When the scan motion is faulty
<Step>
1. Press the Start key to start the scan test.
Pressing the Stop key will stop the scan
test.
To adjust the Original size detection VR.
When PBA-VR board is replace
When PBA-CONT board is replace
Refer to the option service manual (AFR-
19) for details.
To adjust the original size detection VR.
When the scan motion is faulty
When PBA-CONT board is replace
19) for details.
To automatically adjust the detection level
of original path sensor.
When each sensor is replaced
When original size detection error occurs
19) for details.
2-49
4.3.6 ADMIN. REGISTRATION
ADMINISTRATOR NUMBER REGISTRATION is used to register or change the adminis-
trator number required when entering the Admin. Management function of the Utility
mode.
<Step>
1. Using the 10-Key Pad, type the 6-digit administrator number (000000 to 999999) to be
registered or changed.
2. Press the [Yes] key to register the administrator number.
2-50
4.3.7 FIXED ZOOM CHANGE
FIXED ZOOM CHANGE is used to change the fixed zoom ratios.
<Step>
1. Select the particular fixed zoom ratio to be changed.
2. Using the 10-Key Pad, enter the desired fixed zoom ratio.
Default Values and Setting Range of Fixed Zoom Ratios
(1) Japan
(2) Metric
(3) Inch
(4) China
Setting name Default fixed zoom ratio Setting range
REDUCTION2 70% 51% to 70%
EXPANSION1 122% 101% to 140%
EXPANSION2 141% 141% to 199%
EXPANSION1 115% 101% to 140%
EXPANSION2 141% 141% to 199%
EXPANSION1 121% 101% to 128%
EXPANSION2 129% 129% to 199%
EXPANSION1 115% 101% to 140%
EXPANSION2 141% 141% to 199%
2-51
(5) Latin America (Metric)
(6) Latin America (Inch)
(7) OEM1 US
4.3.8 FACTORY TEST
(1) PANEL BUZZER TEST
(2) RAM TEST
EXPANSION1 115% 101% to 140%
EXPANSION2 141% 141% to 199%
EXPANSION1 121% 101% to 128%
EXPANSION2 129% 129% to 199%
EXPANSION1 129% 101% to 154%
EXPANSION2 155% 155% to 199%
To test LEDs and keys on control panel PANEL LED TEST
Make sure that all LEDs on control
panel light (for 5 seconds).
PANEL SWITCH TEST
Press the control keys and numeric
keys, and make sure that the names of
switches appear in the LCD display.
To release the test, press the panel
reset key twice: The initial screen will be
restored.
Write or read data to/from RAM memory to
make sure of normal operation.
1. Pressing the YES key will start the
check.
2. After approx. 30 seconds, RAM Chip
is OK will appear.
2-52
4.3.9 CLEAR DATA
CLEAR DATA is used to clear data of various types.
(1) MEMORY CLEAR
(2) PM COUNTER
(4) SUPPLIES LIFE COUNT.
(5) APPLICATION COUNTER
(6) SCAN COUNTER
To clear the setting values listed on the
right, resetting them to the default values.
Settings of the Utility mode
Settings of Services Choice of the Service
mode
Settings of Adjust of the Service mode
Setting of Administrator Number Registra-
tion of the Service mode
Settings of Fixed Zoom Change of the
Service mode
Settings of Security of the Service mode
Settings of copy programs
NOTE
After Memory Clear has been executed,
be sure to turn OFF and ON the Power
Switch.
Purpose
To clear each of the counts of the PM Counter.
Purpose
To clear the count of the Maintenance Counter.
Purpose
To clear the count of the Supplies Life Counter.
Purpose
To clear each of the counts of the Application Counter.
Purpose
To clear the count of the Scan Counter.
2-53
(7) PAPER SIZE COUNTER
(8) MISFEED COUNTER
(9) TROUBLE COUNTER
(10) ADF BACKUP CLEAR (Di2011 Only)
4.3.10 SECURITY
SECURITY is used to set the security functions.
<Security Function Setting Procedure>
1. Call the Service mode to the screen.
2. Press the following keys in this order:
Stop 9
3. The Security mode screen will appear.
(1) TOTAL COUNTER COUNT
Purpose
To clear each of the counts of the Paper Size Counter.
Purpose
To clear each of the counts of the Misfeed Counter.
Purpose
To clear each of the counts of the Trouble Counter.
To clear the values adjusted with ADF SEN-
SOR ADJUST and the values adjusted with
Org. Width Detect.
When PBA-CONT board has been
replaced.
When PBA-VR board has been replaced.
Refer to the option service manual (AFR-19) for
details.
To set the count-up method. The default setting is 0.
0: One count-up for each copy cycle (ordi-
nary mode)
1: Multiple count-up according to the
paper size and copy mode.
2: Multiple count-up according to the
paper size and copy mode.
2-54
(2) SIZE COUNTER COUNT
(3) PLUG-IN COUNTER COPY
(4) MACHINE COUNTER
<Count-up Table>
1: 1 count 2: 2 counts
To set the paper size to be counted. The default setting is 1.
0: Not counted
1: A3/LEDGER L
2: A3/B4/LEDGER L/LEGAL L/8K L
3: A3/B4/FLS/LEDGER L/LEGAL L/11
14 L/8K L
To select whether to enable or disable copy-
ing according to whether the Plug-in
Counter is mounted or not.
ENABLE DISABLE
To select whether to enable or disable copy-
ing according to whether the Machine
Counter is mounted or not.
The default setting is DISABLE.
ENABLE DISABLE
Size Counter Count Mode Size other than those set Set size
Total Counter Count Mode 0 1 2 0 1 2
Total Counter 1 1 2 2
Size Counter Not Count 1 1 2
2-55
5. MECHANICAL ADJUSTMENTS
5.1 Adjustment of the Position of the Scanner and 2nd/3rd Mir-
rors Carriage
NOTE
This adjustment is to be made when the Scanner Drive Cables has been replaced or
rewound.
4. Press the Scanner up against the jigs and tighten the fixing screws.
1-25
2. Fit the Scanner/Mirrors Carriage Positioning Jigs
in position. Then, press the 2nd/3rd Mirrors Car-
riage up against the jigs.
4035D106AA
3. Loosen the fixing screws and adjust as neces-
sary so that there is no clearance between the
2nd/3rd Mirrors Carriage and the jigs.
4035D107AA
4035D108AB
2-56
NOTE
When the Scanner Assy is secured to the Scanner
Drive Cables using the fixing brackets, make sure
that the cables are located as shown on the left.
If the cables are not positioned properly, the Scan-
ner Assy can move askew, resulting an image
problem.
4035D527AA
<Cross-sectional View>
Cable
2-57
5.2 CCD Unit Position Adjustment
NOTE
This adjustment is to be made when the CCD Unit has been replaced.
<Adjustment Standard>
mm.
1. Place a scale on the Original Glass in parallel with the Original Width Scale and make a
copy.
ment.
3. Loosen the three CCD Unit mounting screws
(painted in green), slide the CCD Unit to the right
or left, and secure it in position.
If the length on the copy is longer than the actual
one, move the CCD Unit to the right.
If the length on the copy is shorter than the actual
one, move the CCD Unit to the left.
If a single adjustment procedure does not success-
fully bring the amount of error into the specified
4035D528AA
2-58
5.3 Adjustment of the Gap between the Doctor Blade and
Sleeve Roller (Db Adjustment)
NOTE
This adjustment is to be made when an image problem (uneven density, low ID, gradation
reproducibility failure, etc.) occurs.
<Adjustment Standard>
The gap between the Doctor Blade and the Sleeve Roller should meet the following
specifications.
Specifications
0.39 0.04 mm (as set using the jigs)
2. Separate the Imaging Unit into the Drum Assy and Developing Assy.
3. Remove the PC Drum, Main Erase, PC Drum Charge Corona Assy, and Ozone Filter.
1-17
5. Remove the Developer Scattering Prevention Plate.
1-19
4. Install the Ds Collar Positioning Jigs.
NOTE
Ready one PC Positioning Jig (Pivot Shaft) sepa-
rately. (For details, see the Parts Manual.)
4022D018AC
6. Remove three screws and the Doctor Blade.
4022D019AB
2-59
11. Put the Developing Assy and Drum Assy together.
7. Using a small piece of paper, remove developer
from the shaded area on the surface of the
Sleeve Roller and put it in the Developer Mixing
Chamber.
8. Remove the developer left on the surface of the
Sleeve Roller.
4022D036AA
9. Temporarily secure the Doctor Blade using three
new screws.
NOTE
Whenever a Db adjustment is made, use new
screws (to which lock paint has been applied).
4022D020AA
10. Install the Db Gap Adjusting Jigs in a space
between the Sleeve Roller and Doctor Blade.
4022D021AB
12. Press the Doctor Blade tightly up against the Db
Gap Adjusting Jigs and tighten the screws in the
order of (1) at the front, (2) at the center, and (3)
in the rear.
NOTE
The Doctor Blade mounting screws have been
coated with lock paint and the job must be com-
pleted within 30 min. If the job extends more than
that time, change the screws for new ones.
4022D022AB
Front Rear
2-60
5.4 Manual Bypass (for the optional AD-17) CD Registration
Adjustment
Di2011 Only
NOTE
This adjustment is to be made when the PH Unit has been replaced.
4. Place the test pattern produced on the Original Glass.
5. Load A4 crosswise paper in the Manual 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.
Specifications
20 2.0 mm
A
4686D504AA
8. Remove two screws and the Manual Bypass
Cover.
4532U028AA
2-61
9. Loosen two screws on the Manual Bypass and
adjust the position of the Manual Bypass.
If width A on the copy is smaller than width A on the
test pattern, move the Manual Bypass toward the
rear of the copier.
If width A on the copy is greater than width A on the
test pattern, move the Manual Bypass toward the
front of the copier.
10. Make another copy of the test pattern and check
for any error in width A.
4532U029AA
TROUBLESHOOTING
19971
3-1
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING
1. INTRODUCTION
Information required for troubleshooting and steps that must be performed are described
in this chapter.
1.1 Electrical Components Check Procedure
If a paper misfeed or malfunction occurs, perform the following operations to check the
condition of the electrical components.
1.1.1 Sensor
Step Check Result Action
1 Does the input signal of the control board change
when the sensor light is interrupted? (H L, L H)
NO Replace the
sensor.
YES Replace the
control board.
4025T520AA
4025T521AA
3-2
1.1.2 Switch
1.1.3 Solenoid
1.1.4 Clutch
1 Does the input signal (NO) of the control board change
from L to H when the switch is activated?
NO Replace the
switch.
YES Replace the
control board.
1 Does the output signal of the control board change
from H to L when the solenoid is activated?
NO Replace the
control board.
YES Replace the
solenoid.
1 Does the output signal of the control board change
from H to L when the clutch is activated?
NO Replace the
control board.
YES Replace the
clutch.
Not Use
COM
NO
4025T523AB
1
2
2
1 2
1
4025T522AA
4025T528AA
3-3
1.1.5 Motor
1 Does the LOCK signal switch to H when the machine
goes into standby?
NO Replace the con-
trol board.
Replace the motor.
2 Does the REM signal of the master board change
from H to L when the motor is turned on?
YES Replace the motor.
NO Replace the con-
trol board.
1 Does the input signal of the master board change
from H to L when the motor is turned on?(The input
signal differs depending on the rotation direction.)
YES Replace the motor.
NO Replace the con-
trol board.
1 Are the relay connector of the motor and the print jack
of the control board correctly connected?
YES Replace the motor
or the control
board.
NO Connect the con-
nector or the print
jack.
GND
REM
LOCK
2
1
3
4025T526AA
4025T525AA
4025T527AA
3-4
2. MISFEEDS
2.1 Initial Checks
When a paper misfeed occurs, first perform the following initial checks.
2.2 Paper Misfeed Detection
2.2.1 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.
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,
or is the paper path deformed or worn?
Clean or change the paper path.
Are the Paper Separator Fingers dirty, deformed,
or worn?
Clean or replace the defective Paper
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
correct position to accommodate the paper?
Set as necessary.
Are the actuators operational and checked for
correct operation?
Correct or replace the defective actua-
tor.
3-5
2.3 Misfeed Display
When a paper misfeed occurs, the Error indicator lights up steadily and the Display gives
a corresponding message.
<Display Resetting Procedure>
Open the corresponding cover, clear the sheet of paper misfed, and close the cover.
Display Message Misfeed/Paper Location Ref. Page
OPEN 1st SIDE
COVER
Paper take-up section of the Paper Feed Tray/1
Paper take-up section of the Manual Bypass
Paper take-up section of the Multiple Bypass
Paper separating section
Fusing/paper exit section
3-7
3-8
3-9
3-11
3-12
OPEN 2nd SIDE
COVER
Paper take-up/vertical transport section of the
Paper Feed Unit
3-10
OPEN DOC. FEED
COVER
Document take-up section
Document transport section
Document exit section
3-13
3-14
3-15
4980P502DA C4506P298CA
3-6
2.4 Misfeed-Detecting Sensor Layout
When the optional AF-12, PF-126, and MB-6 are mounted
1: Exit Paper Sensor (PC3) 5: Registration Sensor (PC3/AF)
2: Synchronizing Roller Sensor (PC1) 6: Separator Sensor (PC4/AF)
3: Paper Set Sensor/Bypass (PC2) 7: Paper Exit Sensor (PC5/AF)
4: Paper Take-Up Sensor (PC12/PF)
1
2
5
6
7
3
4
4035T501AA
3-7
2.5 Misfeed Detection Timing/Troubleshooting Procedures
2.5.1 Misfeed at the Paper Feed Tray/1 Paper Take-up Section
<Detection Timing>
<Action>
Type Description
Paper Take-
Up Section
misfeed detec-
tion
The leading edge of the paper does not unblock the Synchronizing
Roller Sensor (PC1) even after the lapse of a given period of time after
the Paper Take-up Solenoid/1 (SL1) has been energized.
Size error
detection
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-
chronizing Roller Sensor (PC1).
The Synchronizing Roller Sensor (PC1) is blocked before the lapse of a
given period of time.
Relevant Electrical Components
Synchronizing Roller Sensor (PC1)
Paper Take-up Solenoid/1 (SL1)
Master Board (PWB-A)
Step Operations Ref. Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Initial checks
2 PC1 sensor check 3-1 PWB-A PJ17A-3 (ON) F-8
3 SL1 operation check 3-2 PWB-A PJ9A-2 (REM) H-5
4 Replace PWB-A
3-8
2.5.2 Misfeed at the Manual Bypass Paper Take-up Section
<Detection Timing>
<Action>
Type Description
Manual Bypass
paper take-up
section misfeed
detection
Roller Sensor (PC1) even after the lapse of a given period of time
after the Paper Take-up Solenoid/Bypass (SL2) has been energized.
Size error
detection
The Synchronizing Roller Sensor (PC1) is blocked before the lapse of
a given period of time.
Paper left at the
Manual Bypass
paper take-up
section
The Paper Set Sensor/Bypass (PC2) is blocked at timing when the
Power Switch is turned ON, the cover is opened and closed, or a
paper misfeed or malfunction is reset.
Paper Take-up Solenoid/Bypass
Paper Set Sensor/Bypass (PC2)
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Initial checks
3 SL2 operation check 3-2 PWB-A PJ12A-2 (REM) F-6
4 PC2 sensor check 3-1 PWB-A PJ12A-5 (ON) A-2
5 Replace PWB-A
3-9
2.5.3 Misfeed at the Multiple Bypass Paper Take-up Section (When the optional
Multiple Bypass MB-6 is mounted)
<Detection Timing>
<Action>
Type Description
Paper take-up
section mis-
feed detection
Roller Sensor (PC1) even after the lapse of a given period of time after
the Paper Take-up Solenoid (SL21/MB) has been energized.
Size error
detection
given period of time.
Paper Take-up Solenoid (SL21/MB)
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Initial checks
3 SL21/MB operation check 3-2 PWB-A PJ12A-2 (REM) D-16
4 Replace PWB-A
3-10
2.5.4 Misfeed at the Paper Feed Unit Paper Take-up/Vertical Transport Section
(When the optional Paper Feed Unit PF-126 is mounted)
<Detection Timing>
<Action>
Type Description
Paper take-up/
vertical trans-
port section
misfeed detec-
tion
Roller Sensor (PC1) even after the lapse of a given period of time
after the Paper Take-up Solenoid (SL11/PF) has been energized.
Size error
detection
The Synchronizing Roller Sensor (PC1) is blocked before the lapse of
a given period of time.
Paper left at the
paper take-up/
vertical trans-
port section
The Paper Take-up Sensor (PC12/PF) is blocked at timing when the
Paper Take-Up Solenoid (SL11/PF)
Paper Take-Up Sensor (PC12/PF)
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Initial checks
3 SL11/PF operation check 3-2 PWB-A/PF
PJ3A/PF-1A (ON)
A-3 (PF-126)
4 PC12/PF sensor check 3-1 PWB-A/PF
PJ3A/PF-2B (ON)
I-6 (PF-126)
5 Replace PWB-A
3-11
2.5.5 Misfeed at the Paper Separating Section
<Detection Timing>
<Action>
Type Description
Paper sepa-
rating section
misfeed detec-
tion
The Exit Paper Sensor (PC3) is not blocked even after the lapse of a
given period of time after the paper has unblocked the Synchronizing
Roller Sensor (PC1).
given period of time after the paper has unblocked the Synchronizing
Roller Sensor (PC1).
Paper left at
the paper sep-
arating section
The Synchronizing Roller Sensor (PC1) is unblocked at timing when
the Power Switch is turned ON, the cover is opened and closed, or a
Exit Paper Sensor (PC3)
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Initial checks
3 PC3 sensor check 3-1 PWB-A PJ15A-3 (ON) B-4
4 Replace PWB-A
3-12
2.5.6 Misfeed at the Fusing/Exit Section
<Detection Timing>
<Action>
Type Description
Fusing/exit sec-
tion misfeed
detection
The Exit Paper Sensor (PC3) is not unblocked even after the lapse of
a given period of time after the Synchronizing Roller Sensor (PC1) has
been blocked.
Paper left at the
fusing/exit sec-
tion
The Exit Paper Sensor (PC3) is blocked at timing when the Power
Switch is turned ON, the cover is opened and closed, or a paper mis-
feed or malfunction is reset.
Exit Paper Sensor
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Initial checks
3 PC3 sensor check 3-1 PWB-A PJ15A-3 (ON) B-4
4 Replace PWB-A
3-13
2.5.7 Misfeed at the Document Take-up Section (When the optional Automatic
Document Feeder AF-12 is mounted)
<Detection Timing>
<Action>
Type Description
Document
take-up section
misfeed detec-
tion
The Separator Sensor (PC4/AF) is not blocked even after the lapse of
a given period of time after the Main Motor (M1/AF) has been ener-
gized.
Document left
in the docu-
ment take-up
section
The Separator Sensor (PC4/AF) is blocked at timing when the Power
Main Motor (M1/AF)
Separator Sensor (PC4/AF)
Interface Board (PWB/AF)
WIRING DIAGRAM
Control signal
Location
(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
3-14
2.5.8 Misfeed at the Document Transport Section (When the optional Automatic
Document Feeder AF-12 is mounted)
<Detection Timing>
<Action>
Type Description
Document
transport sec-
tion misfeed
detection
The Registration Sensor (PC3/AF) is not blocked even after the lapse
of a given period of time after the Main Motor (M1/AF) has been ener-
gized.
Document left
in the docu-
ment transport
section
The Registration Sensor (PC3/AF) is blocked at timing when the
Main Motor (M1/AF)
Registration Sensor (PC3/AF)
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Initial checks
3 PC3/AF sensor check 3-1 PWB/AF CN2/AF-6 (ON) H-4 (AF-12)
4 Replace PWB/AF
3-15
2.5.9 Misfeed at the Document Exit Section (When the optional Automatic Docu-
ment Feeder AF-12 is mounted)
<Detection Timing>
<Action>
Type Description
Document exit
section mis-
feed detection
The Paper Exit Sensor (PC5/AF) is not blocked even after the lapse of
a given period of time after the Main Motor (M1/AF) has been ener-
gized.
Document left
in the docu-
ment exit sec-
tion
The Paper Exit Sensor (PC5/AF) is blocked at timing when the Power
Main Motor (M1/AF)
Paper Exit Sensor (PC5/AF)
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Initial checks
3 PC5/AF sensor check 3-1 PWB/AF CN2/AF-12 (ON) H-6 (AF-12)
4 Replace PWB/AF
3-16
3. MALFUNCTIONS
The copiers CPU performs a self-diagnostics function that, on detecting a malfunction,
gives the corresponding malfunction code and maintenance call mark on the Touch
Panel.
3.1 List of Malfunction Codes
Malfunc-
tion
Code
Malfunction Name Detection Timing
C0000
Main Motor mal-
function
The Main Motor (M1) Lock signal remains HIGH for a
continuous 1-sec. period at any time 1 sec. after the
Main Motor has started turning.
C0044
ADF Cooling Fan
Failure (Only when
the optional AFR-
19 is mounted)
Refer to the option service manual (AFR-19) for details.
C0045
Fusing Cooling Fan
Motor malfunction
The Fusing Cooling Fan Motor (M3) Lock signal remains
HIGH for a continuous 1-sec. period while the Fusing
Cooling Fan Motor is turning at full speed or decelerated
speed.
C004E
Power Supply Cool-
ing Fan Motor mal-
function
The Power Supply Cooling Fan Motor (M4) Lock signal
remains HIGH for a continuous 1-sec. period while the
Power Supply Cooling Fan Motor Remote signal
remains ON (for full-speed rotation) or OFF (for deceler-
ated-speed rotation).
C0070
Toner Replenish-
ing Motor malfunc-
tion
The Toner Bottle Home Position Sensor (PC7) outputs a
HIGH signal for a continuous 3.5-sec. period while the
Toner Bottle is turning.
The Toner Bottle Home Position Sensor (PC7) outputs a
LOW signal for a continuous 2-sec. period while the
Toner Bottle is turning.
C0210
Abnormal image
transfer voltage
The image transfer voltage remains more than 100 V
continuously for a given period of time while the PC
Drum remains stationary.
C03FF
Faulty Model Set-
ting
Model Setting of Adjust available from the Service
mode is incorrectly set.
4980P550DA
3-17
C0500 Warm-up failure
The surface temperature of the Fusing Roller does not
reach a given level even after the lapse of a given period
of time during a warm-up cycle.
From room temperature to 100C: 35 sec.
From 100C to 140C: 25 sec.
From 140C to the completion of
the warm-up cycle: 20 sec.
C0500
Warm-up failure
(for the model hav-
ing two Fusing
Roller Heater
Lamps)
Di2011 Only
The Fusing Roller Thermistor does not detect a prede-
termined temperature within 30 sec. after a warm-up
cycle has been started and thus the warm-up cycle is
not completed.
From 130C to 155C: 0.5 sec.
C0501
Warm-up failure 2
(for the model hav-
ing two Fusing
Roller Heater
Lamps)
Di2011 Only
The Fusing Roller Sub Thermistor does not detect a
predetermined temperature within 30 sec. after a warm-
up cycle has been started and thus the warm-up cycle is
not completed.
C0510
Fusing failure
(abnormally low
fusing temperature)
The temperature detected by the Fusing Roller Ther-
mistor remains lower than 120C (105C for the model
having two Fusing Roller Heater Lamps) for a given
period of time during the standby state.
mistor remains lower than 120C (105C for the model
having two Fusing Roller Heater Lamps) for a given
period of time during a print cycle.
C0511
Fusing failure
(abnormally low
fusing temperature
2)
Di2011 Only
The temperature detected by the Fusing Roller Sub
Thermistor remains lower than 105C for a given period
of time during the standby state.
Thermistor remains lower than 105C for a given period
of time during a print cycle.
C0520
Fusing failure
(abnormally high
fusing temperature)
mistor remains higher than 240C for a given period of
time.
Malfunc-
tion
Code
3-18
C0521
Fusing failure
(abnormally high
fusing temperature
2)
Di2011 Only
Thermistor remains higher than 240C for a given period
of time.
C0650
Faulty Scanner
Home Position
Sensor
The Scanner Home Position Sensor (PC10) does not go
from HIGH to LOW when the Scanner Motor (M5) is
energized for a given number of steps after the
sequence to bring the Scanner back to its home position
has been started at the end of a scan motion and during
re-shading.
The Scanner Home Position Sensor (PC10) does not go
from LOW to HIGH when the Scanner Motor (M5) is
energized for a given number of steps after a scan
motion has been started at the end of a Scanner Home
Position Sensor home check scan motion and during re-
shading.
C0B60
Bin Switching
Motor malfunction
(Only when the
optional JS-204 is
mounted)
Refer to the option service manual (JS-204) for details.
C0B80
Shift Motor mal-
function
(Only when the
optional OT-103 is
mounted)
Refer to the option service manual (OT-103) for details.
C0F32
Faulty ATDC Sen-
sor
The measurement taken by the ATDC Sensor (UN1) at
a time 2.0 sec. after the Main Motor (M1) has started
turning is less than 5% (greater than 4.63 V).
The measurement taken by the ATDC Sensor (UN1) at
a time 2.0 sec. after the Main Motor (M1) has started
turning is 19% or more (1.41 V or less).
C0F33
Improperly
adjusted ATDC
Sensor
The adjustment of the ATDC control voltage is not com-
pleted within 1 sec. after sampling has started of the
ATDC Sensor (UN1) as part of an operation of ATDC
Sensor Automatic Adjustment.
The ATDC Sensor control voltage falls outside the range
of 5.39 V to 8.15 V during an operation of ATDC Sensor
Automatic Adjustment.
Malfunc-
tion
Code
3-19
C1038
Engine connection
failure
Master Board (PWB-A) to Control Board (PWB-C/C) con-
nection failure
There is no acknowledge signal transmitted from the
Master Board (PWB-A) to Control Board (PWB-C/C) for
1.5 sec. or more.
An error command signal is transmitted from the Control
Board (PWB-C/C) to Master Board (PWB-A).
An error status signal is transmitted from the Master
Board (PWB-A) to Control Board (PWB-C/C).
C1200
Faulty ASIC/mem-
ory
ASIC/memory (for image and control) fault
A write or read error occurs with SRAM on the Control
Board (PWB-C/C).
C1300
Polygon Motor mal-
function
Startup failure
A LOW Polygon Motor (M2) Lock signal is not detected
within a given period of time that begins 1 sec. after the
Polygon Motor has started turning.
Lock signal fault: Unstable after the first Lock signal has
been detected
For a period of 1 sec. after the first LOW Polygon Motor
(M2) Lock signal (first Lock) has been detected, the next
LOW Polygon Motor Lock signal is not detected.
Lock signal fault: Lock signal out-of-timing
A LOW Polygon Motor (M2) Lock signal is not detected
for a continuous given period of time while the rotation
of the Polygon Motor remains stabilized.
Faulty Lock signal
A LOW Polygon Motor (M2) Lock signal is detected for a
given period of time or more when the Polygon Motor
remains deenergized.
C133B
Communication
with option error
It is not possible to communicate with the Printer Board
within a predetermined period of time during a print
cycle.
C133D ROM check error
An error is detected of the flash ROM chip on the Fax
Board when the Power Switch is turned ON.
C13F0 Faulty HSYNC
Laser scanning system malfunction
The SOS Sensor does not detect a rising edge of SOS
within a given period of time after the Polygon Motor
(M2) has started turning and a laser output has been
started.
The SOS Sensor detects no rising edges of SOS while
VIA (image area control) is ON.
C1468 Faulty EEPROM
EEPROM fault
Data cannot be written in EEPROM.
Data stored in EEPROM is wrong.
C14A3
IR fluorescent lamp
fault
The Exposure Lamp (LA2) of the Scanner fails to turn ON.
The intensity of the Exposure Lamp is a predetermined
value or less during shading and re-shading.
Malfunc-
tion
Code
3-20
3.2 Resetting Procedure by Malfunction Code
Code Description Procedure
C0000 Main Motor malfunction Turn OFF and ON the Power Switch.
C0044 ADF Cooling Fan Failure
C0045 Fusing Cooling Fan Motor malfunction
C004E
Power Supply Cooling Fan Motor mal-
function
C0070 Toner Replenishing Motor malfunction
C0210 Abnormal image transfer voltage
C03FF Faulty Model Setting
Make the correct setting for Model
Setting of Adjust available from the
Service mode.
2-39
C0500 Warm-up failure Turn ON the Power Switch with the
Stop key held down.
C0501 Warm-up failure 2
C0510
Fusing failure (abnormally low fusing
temperature)
C0511
Fusing failure (abnormally low fusing
temperature 2)
C0520
Fusing failure (abnormally high fusing
temperature)
C0521
Fusing failure (abnormally high fusing
temperature 2)
C0650 Faulty Scanner Home Position Sensor Turn OFF and ON the Power Switch.
C0B60 Bin Switching Motor malfunction
C0B80 Shift Motor malfunction
C0F32 Faulty ATDC Sensor
C0F33 Improperly adjusted ATDC Sensor
C1038 Engine connection failure
C1200 Faulty ASIC/memory
C1300 Polygon Motor malfunction
C133B Communication with option error
C133D ROM check error
C13F0 Faulty HSYNC
C1468 Faulty EEPROM
C14A3 IR fluorescent lamp fault
3-21
3.3 Malfunction Detection Timing and Troubleshooting Proce-
dure
(1) C0000 Main Motor malfunction
<Detection Timing>
<Action>
Trouble
Code
Description
C0000
The Main Motor (M1) Lock signal remains HIGH for a continuous 1-
sec. period at any time 1 sec. after the Main Motor has started turning.
Main Motor (M1) Master Board (PWB-A)
Power Supply Unit (PU1)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Check M1 connectors for proper con-
nection and correct as necessary.

2 Check M1 for correct drive coupling
and correct as necessary.

3 M1 operation check. 3-3 I-14
4 Change PWB-A.
5 Change PU1.
3-22
(2) C0044 ADF Cooling Fan Failure
(When the optional Duplexing Document Feeder AFR-19 is mounted)
<Detection Timing>
<Action>
Trouble
Code
Description
C0044
The ADF Fan Motor Lock signal remains set to H for a set period of
time while the EDH Fan Motor is turning.
Cooling Fan Motor (M3-ADF) Main Control Board (PBA-CONT)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Check the motor connectors for
paper connection, and correct as
necessary.

2 Check the fan for possible overload,

3 M3-ADF operation check. 3-3 PBA-CONT
CN9CONT-2 (REM)
E-5 (AFR-19)
4 Replace PBA-CONT.
3-23
(3) C0045 Fusing Cooling Fan Motor Malfunction
<Detection Timing>
<Action>
Trouble
Code
Description
C0045
The Fusing Cooling Fan Motor (M3) Lock signal remains HIGH for a
continuous 1-sec. period while the Fusing Cooling Fan Motor is turn-
ing at full speed or decelerated speed.
Fusing Cooling Fan Motor (M3) Master Board (PWB-A)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)

2 Check the fan for possible overload

3 M3 operation check 3-3 PWB-A PJ22A-1
(REM)
C-2
4 Change PWB-A.
5 Change PU1.
3-24
(4) C004E Power Supply Cooling Fan Motor Malfunction
<Detection Timing>
<Action>
Trouble
Code
Description
C004E
The Power Supply Cooling Fan Motor (M4) Lock signal remains HIGH
for a continuous 1-sec. period while the Power Supply Cooling Fan
Motor Remote signal remains ON (for full-speed rotation) or OFF (for
decelerated-speed rotation).
Power Unit Cooling Fan Motor (M4) Master Board (PWB-A)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)

2 Check the fan for possible overload

3 M4 operation check 3-3 PU1 CN7PU1-1
(REM)
F-12
4 Change PWB-A.
5 Change PU1.
3-25
(5) C0070 Toner Replenishing Motor Malfunction
<Detection Timing>
<Action>
Trouble
Code
Description
C0070
The Toner Bottle Home Position Sensor (PC7) outputs a HIGH signal
for a continuous 3.5-sec. period while the Toner Bottle is turning.
The Toner Bottle Home Position Sensor (PC7) outputs a LOW signal
for a continuous 2-sec. period while the Toner Bottle is turning.
Toner Replenishing Motor (M6)
Toner Bottle Home Position Sensor (PC7)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)


3 M6 operation check 3-3 PWB-A PJ16A-1
(REM)
B-8
4 PC7 sensor check 3-1 PWB-A PJ16A-5
(ON)
B-8
5 Change PWB-A.
6 Change PU1.
3-26
(6) C0210 Abnormal Image Transfer Voltage
<Detection Timing>
<Action>
Trouble
Code
Description
C0210
The image transfer voltage remains more than 100 V for a continuous
given period of time while the PC Drum remains stationary.
Image Transfer Roller
High Voltage Unit (HV1)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Check the Image Transfer Roller for
installation.

2 Change HV1.
3 Change PWB-A.
3-27
(7) C0500 Warm-up Failure
C0501 Warm-up Failure 2 (Di2011 Only)
C0510 Fusing Failure (Abnormally Low Fusing Temperature)
C0511 Fusing Failure (Abnormally Low Fusing Temperature 2) (Di2011 Only)
C0520 Fusing Failure (Abnormally High Fusing Temperature)
C0521 Fusing Failure (Abnormally High Fusing Temperature 2) (Di2011 Only)
<Detection Timing>
Trouble
Code
Description
C0500
The surface temperature of the Fusing Roller does not reach a given level
even after the lapse of a given period of time during a warm-up cycle.
From 140C to the completion of the warm-up cycle: 20 sec.
C0500
The Fusing Roller Thermistor does not detect a predetermined tempera-
ture within 30 sec. after a warm-up cycle has been started and thus the
warm-up cycle is not completed.
C0501
The Fusing Roller Sub Thermistor does not detect a predetermined tem-
perature within 30 sec. after a warm-up cycle has been started and thus
the warm-up cycle is not completed.
C0510
The surface temperature of the Fusing Roller remains lower than 120C
(105C for the model having two Fusing Roller Heater Lamps) for a given
period of time during the standby state.
The surface temperature of the Fusing Roller remains lower than 120C
(105C for the model having two Fusing Roller Heater Lamps) for a given
period of time during a print cycle.
C0511
The temperature detected by the Fusing Roller Sub Thermistor remains
lower than 105C for a given period of time during the standby state.
lower than 105C for a given period of time during a print cycle.
C0520
The temperature detected by the Fusing Roller Thermistor remains higher
than 240C for a given period of time.
C0521
higher than 240C for a given period of time.
3-28
<Detection Timing>
Fusing Roller Heater Lamp (H1)
Fusing Roller Sub Heater Lamp (H2)
Fusing Roller Thermistor
Fusing Roller Sub Thermistor (TH2)
Fusing Roller Thermostat (TS1)
Fusing Unit Interlock Switch (S2)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Check that the Fusing Roller Heater
Lamp (H1) turns ON when the Power
Switch is turned ON and correct or
replace the lamp as necessary.

2 Check that the Fusing Roller Sub
Heater Lamp (H2) turns ON when the
Power Switch is turned ON and correct
or replace the lamp as necessary.

3 Check the Fusing Roller Thermostat
(TS1) for operation.
<Check procedure>
Check the resistance of TS1. TS1 is
open-circuited if its resistance is infinity.

F-2
4 Check the Fusing Unit Interlock Switch
(S2) for operation.
<Check procedure>
Check continuity across the following
terminals when S2 is ON.
Across S2-1A and S2-1B
Across S2-2A and S2-2B

E-16
5 Check the Fusing Roller Thermistor
(TH1) and Fusing Roller Sub Thermistor
(TH2) for installation and correct or
clean as necessary.

6 Check the Fusing Roller Thermistor
(TH1) for operation.
<Check procedure>
Disconnect CN15 (4P) and check the
resistance across CN15-2 and 3 on the
Thermistor side. TH1 is open-circuited if
the resistance is infinity.

D-2
3-29
7 Check the Fusing Roller Sub Thermistor
(TH2) for operation.
<Check procedure>
Disconnect CN22 (4P) and check the
resistance across CN22-2 and 3 on the
Thermistor side. TH2 is open-circuited if
the resistance is infinity.

D-2
8 Check the Fusing Roller Heater Lamp
(H1) for continuity and correct or replace
as necessary.

9 Check the Fusing Roller Sub Heater
Lamp (H2) for continuity and correct or
replace as necessary.

10 Change PU1.
11 Change PWB-A.
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
3-30
(8) C0650 Faulty Scanner Home Position Sensor
<Detection Timing>
<Action>
Trouble
Code
Description
C0650
The Scanner Home Position Sensor (PC10) does not go from HIGH
to LOW when the Scanner Motor (M5) is energized for a given num-
ber of steps after the sequence to bring the Scanner back to its home
position has been started at the end of a scan motion and during re-
shading.
The Scanner Home Position Sensor (PC10) does not go from LOW to
HIGH when the Scanner Motor (M5) is energized for a given number
of steps after a scan motion has been started at the end of a Scanner
Home Position Sensor home check scan motion and during re-shad-
ing.
Scanner Motor (M5)
Scanner Home Position Sensor (PC10)
Control Board (PWB-C/C)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)


3 M5 operation check 3-3 B-11
4 Scanner operation check
5 PC10 sensor check 3-1 PWB-C/C
P114C/C-3 (ON)
B-13
6 Change PWB-C/C.
3-31
(9) C0F32 Faulty ATDC Sensor
C0F33 Improperly Adjusted ATDC Sensor
<Detection Timing>
<Action>
Trouble
Code
Description
C0F32
The measurement taken by the ATDC Sensor (UN1) at a time 2.0 sec.
after the Main Motor (M1) has started turning is less than 5% (greater
than 4.63 V).
The measurement taken by the ATDC Sensor (UN1) at a time 2.0 sec.
after the Main Motor (M1) has started turning is 19% or more (1.41 V
or less).
C0F33
The adjustment of the ATDC control voltage is not completed within 1
sec. after sampling has started of the ATDC Sensor (UN1) as part of
an operation of ATDC Sensor Automatic Adjustment.
The ATDC Sensor control voltage falls outside the range of 5.39 V to
8.15 V during an operation of ATDC Sensor Automatic Adjustment.
ATDC Sensor (UN1) Master Board (PWB-A)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Check to see if developer is avail-
able.

2 Check the ATDC Sensor connectors
for proper connection and correct as
necessary.

3 Change UN1.
4 Run ATDC Auto Adjust. 2-46
5 Change PWB-A.
6 Change PU1.
3-32
(10) C1038 Engine Connection Failure
<Detection Timing>
<Action>
Trouble Code Description
C1038
Master Board (PWB-A) to Control Board (PWB-C/C) connection failure
There is no acknowledge signal transmitted from the Master Board
(PWB-A) to Control Board (PWB-C/C) for 1.5 sec. or more.
An error command signal is transmitted from the Control Board (PWB-
C/C) to Master Board (PWB-A).
An error status signal is transmitted from the Master Board (PWB-A)
to Control Board (PWB-C/C).
Master Board (PWB-A) Control Board (PWB-C/C)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Turn OFF and ON the Power Switch.
2 Check the PWB-A connectors for
proper connection and correct as
necessary.

3 Check the PWB-C/C connectors for
necessary.

4 Check for proper connection
between PWB-A and PWB-C/C and
correct as necessary.

5 Change PWB-A.
6 Change PWB-C/C.
3-33
(11) C1200 Faulty ASIC/Memory
<Detection Timing>
<Action>
Trouble
Code
Description
C1200
ASIC/memory (for image and control) fault
A write or read error occurs with SRAM on the Control Board (PWB-C/C).
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
2 Check memory on PWB-C/C for con-

3 Change PWB-C/C.
3-34
(12) C1300 Polygon Motor Malfunction
C13F0 Faulty HSYNC
<Detection Timing>
<Action>
Trouble
Code
Description
C1300
Startup failure
A LOW Polygon Motor (M2) Lock signal is not detected within a given
period of time that begins 1 sec. after the Polygon Motor has started
turning.
Lock signal fault: Unstable after the first Lock signal has been detected
For a period of 1 sec. after the first LOW Polygon Motor (M2) Lock
signal (first Lock) has been detected, the next LOW Polygon Motor
Lock signal is not detected.
Lock signal fault: Lock signal out-of-timing
A LOW Polygon Motor (M2) Lock signal is not detected for a continu-
ous given period of time while the rotation of the Polygon Motor
remains stabilized.
Faulty Lock signal
A LOW Polygon Motor (M2) Lock signal is detected for a given period
of time or more when the Polygon Motor remains deenergized.
C13F0
Laser scanning system malfunction
The SOS Sensor does not detect a rising edge of SOS within a given
period of time after the Polygon Motor (M2) has started turning and a
laser output has been started.
The SOS Sensor detects no rising edges of SOS while VIA (image
area control) is ON.
PH Unit Master Board (PWB-A)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
2 Check for proper connection
between the PH Unit and Master
Board and correct as necessary.

3 Change the PH Unit.
4 Change PWB-A.
3-35
(13) C133B Communication with Option Error
C133D ROM Check Error
<Detection Timing>
For detailed corrective action, see the Service Manual for Fax.
(14) C1468 Faulty EEPROM
<Detection Timing>
<Action>
Trouble
Code
Description
C133B
It is not possible to communicate with the Printer Board within a pre-
determined period of time during a print cycle.
C133D
An error is detected of the flash ROM chip on the Fax Board when the
Power Switch is turned ON.
Trouble
Code
Description
C1468
EEPROM fault
Data cannot be written in EEPROM.
Data stored in EEPROM is wrong.
Master Board (PWB-A) EEPROM (U16)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Turn OFF the Power Switch and
unplug the power cord. Then, plug in
the power cord and turn ON the
Power Switch again.

2 Check EEPROM (U16) on PWB-C/C
for proper connection and correct as
necessary.

3 Change PWB-A.
4 Change EEPROM. 1-57
3-36
(15) C14A3 IR Fluorescent Lamp Fault
<Detection Timing>
<Action>
Trouble
Code
Description
C14A3
The Exposure Lamp (LA2) of the Scanner fails to turn ON.
The intensity of the Exposure Lamp is a predetermined value or less
during shading and re-shading.
Exposure Lamp (LA2)
Inverter Board (PU2)
CCD Board (PWB-J)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Check that the Exposure Lamp (LA2)
turns ON when the Power Switch is
turned ON and correct or replace as
necessary.

2 Check connectors on PU2 for proper
connection and correct as necessary.

3 Check connectors on PWB-J for
necessary.

4 Change PWB-C/C.
3-37
3.4 Miscellaneous Errors
3.4.1 Flash ROM Error
The copier determines that there is an error if writing to the flash ROM fails during
upgrading of the firmware.
When the Power Switch is turned ON, the Error indicator lights up steadily and a corre-
sponding message appears on the Display.
If this error message appears, no operations can then be performed. It is not possible to
upgrade the firmware from a PC connected through USB connection, either.
<Action>
Master Board (PWB-A) Control Panel (UN4)
Control Board (PWB-C/C) EEPROM (U16)
Step Operations
Ref.
Page
WIRING DIAGRAM
Control signal
Location
(Electrical
Components)
1 Check the connection status of con-
nectors on each board (PWB-A,
PWB-C/C, UN4): If there is any
abnormality, correct it.

2 Identify the specific firmware that is
responsible for the error.

3 Perform upgrading of the firmware
through BIOS.
1-64

4 Unplug EEPROM (U16) from PWB-
C/C and then plug it back in.

5 Change PWB-C/C.
4035T506CA 4035T507CA 4035T508CA 4035T509CA
3-38
3.5 Power Source-Related Malfunctions
(1) The copier does not turn ON.
1 A malfunction code appears when the
YES Go to step 2.
NO Go to step 3.
2 The malfunction is temporarily reset
when the Power Switch is turned OFF
and ON with the Stop key held down.
YES Perform the troubleshoot-
ing procedure according
to the malfunction code.
3 Power supply voltage check
<Check Procedure>
Check voltage across pins of DC Power
Supply (PU1) when the Power Switch is
turned ON.
Voltage across CN1PU1-1 and
CN1PU1-2
AC0 V when the Power Switch is OFF
Rated AC voltage when the Power
Switch is turned ON
NO Check wall outlet for volt-
age.
Check power cord for
continuity.
Check Power Switch.
4 Check of output of DC24 V to Control
Board (copier: PWB-C)
<Check Procedure>
Check voltage across a Control Board
(copier: PWB-C) pin and GND when the
Voltage across P110C/C-1 and GND
DC0 V when the Power Switch is OFF
DC24 V when the Power Switch is
turned ON
NO Check Front Door Inter-
lock Switch (S3).
Check Right Door Inter-
lock Switch (S4).
Change DC power Sup-
ply (PU1).
5 Check of output of DC24 V to Master
Board (copier: PWB-A)
<Check Procedure>
Check voltage across a Master Board
(copier: PWB-A) pin and GND when the
Voltage across PJ2A-2 and GND
turned ON
NO Check Front Door Inter-
lock Switch (S3).
Check Right Door Inter-
lock Switch (S4).
ply (PU1).
3-39
6 Check of output of DC 5 V to Master
Board (copier: PWB-A)
<Check Procedure>
Check voltage across a Master Board
(copier: PWB-A) pin and GND when the
Voltage across PJ6A-9 and GND
turned ON
NO Change DC power Sup-
ply (PU1).
7 Check of output of DC5 V to control
panel (UN2)
<Check Procedure>
Check voltage across a Control Board
(copier: PWB-C) pin and GND when the
turned ON
NO Check Control Board
(copier: PWB-C).
Change Master Board
(copier: PWB-A).
ply (PU1).
YES Change Control Panel
(UN4).
3-40
4. IMAGE FAILURE
4.1 Image Failure Troubleshooting
In this chapter, troubleshooting is divided into initial checks and troubleshooting proce-
dures classified by image failures.
If any image failure has occurred, first make the initial checks, then proceed to the corre-
sponding image failure troubleshooting procedure.
4.2 Initial Checks
Determine if the failure is attributable to a basic cause or causes.
Section Step Check Result Action
Installation
site
1 The installation site com-
plies with the requirements
specified in PRECAUTIONS
FOR INSTALLATION con-
tained in GENERAL.
NO Change the installation
site.
Paper 2 Paper meets product specifi-
cations.
NO Change paper for one that
meets specifications.
Instruct user to use paper
that meets specifications
and is recommended.
3 Paper is damp. YES Change paper for one that
is dry.
Then, instruct user to use
paper that meets specifi-
cations and in how to
store paper.
Original 4 Original is placed correctly. NO Reposition original.
Instruct user in how to
place original correctly.
5 Original is written in light
pencil.
YES Change original.
Instruct user to use origi-
nal with appropriate image
density.
6 Original is transparent (OHP
transparencies, etc.).
YES Change original.
Instruct user to use origi-
nals that meet specifica-
tions.
7 Original Glass is dirty. YES Clean Original Glass.
8 Original Glass is scratchy. YES Change Original Glass.
PM parts 9 The PM parts relating to
image formation have
reached the end of cleaning/
replacement cycles.
YES Clean PM parts.
Change PM parts.
3-41
4.3 Identification of the Faulty System
Determine if the failure is attributable to an input system (IR) or output system (engine).
Check Result Action
Copy made at a reduced
ratio
Input system
(IR)
Output system
(printer)
1177T03YA
1177T04YA
Full-size Reduced
1177T05YA
Full-size Reduced
3-42
4.4 Troubleshooting Procedures by Image Failure
4.4.1 Image Reading Section: Blank copy
<Typical Faulty Images>
1 CCD Board (PWB-J) connector is loose. YES Reconnect.
2 Control Board (PWB-C) connector is loose. YES Reconnect.
NO Change Control
Board (PWB-C/C).
Change Master
Board (PWB-A).
4011T035AA
3-43
4.4.2 Image Reading Section: black copy
1 Exposure Lamp turns ON when the Power Switch
is turned ON.
NO Go to step 3.
2 Exposure Lamp is abnormally lit (flickers or abnor-
mally dark) when the Power Switch is turned ON.
NO Go to step 4.
3 Inverter Board (PU2) connector is loose. YES Reconnect.
NO Change Exposure
Lamp.
5 Control Board (PWB-C/C) connector is loose. YES Reconnect.
NO Change Inverter
Board (PU2).
Change CCD Unit.
Change Control
Board (PWB-C/C).
4011T036AA
3-44
4.4.3 Image Reading Section: Low image density
1 Shading sheet reading portion (the portion on the
backside of the Original Glass to which Original
Width Scale is affixed) is dirty.
YES Clean.
3 Control Board (PWB-C) connector is loose. YES Reconnect.
NO Change Control
Board (PWB-C/C).
Change Master
Board (PWB-A).
4011T003AA
3-45
4.4.4 Image Reading Section: Foggy background or rough image
1 Original Glass is dirty. YES Clean.
2 Scanner mirrors are dirty. YES Clean.
3 Exposure Lamp (LA2) is dirty. YES Clean.
4 CCD Unit lens and CCD surface are dirty.
<Check Procedure>
Remove lens cover to check for possible contami-
nation.
YES Clean.
mally dark) when the Start key is pressed.
NO Go to step 7.
6 Inverter Board (copier: PU2) connector is loose. YES Reconnect.
NO Change Exposure
Lamp (LA2).
7 CCD Board (copier: PWB-J) connector is loose. YES Reconnect.
NO Change Inverter
Board (PU2).
Change Control
Board (copier: PWB-
C).
4011T004AA
3-46
4.4.5 Image Reading Section: Black streaks or bands
1 Original Glass is dirty, scratchy, worn, or damaged. YES Clean or change.
YES Clean.
3 Scanner mirrors are dirty, scratchy, or damaged. YES Clean or change.
4 Exposure Lamp (LA2) is dirty. YES Clean or change.
5 CCD Unit lens and CCD surface are dirty or
scratchy.
<Check Procedure>
nation.
YES Clean or change.
NO Change CCD Unit.
Change Control
Board (PWB-C/C).
4011T017AA 4011T023AA
3-47
4.4.6 Image Reading Section: Black spots
1 Original Glass is dirty or scratchy. YES Clean.
NO Change CCD Unit.
Change Control
Board (PWB-C/C).
4011T521AA
3-48
4.4.7 Image Reading Section: Blank streaks or bands
YES Clean.
scratchy.
<Check Procedure>
nation.
NO Change CCD Unit.
Change Control
Board (PWB-C/C).
4011T015AA 4011T020AA
3-49
4.4.8 Image Reading Section: Uneven image density
YES Clean.
scratchy.
<Check Procedure>
nation.
mally dark) when the Power Switch is turned ON.
NO Go to step 8.
7 Inverter Board (PU2) connector CN1PU2 is loose. YES Reconnect.
NO Change Exposure
Lamp (LA2).
NO Change CCD Unit.
Change Control
Board (PWB-C/C).
4011T525AA
3-50
4.4.9 Image Reading Section: Gradation reproduction failure
YES Clean.
scratchy.
<Check Procedure>
nation.
mally dark) when the Start key is pressed.
NO Go to step 8.
7 Inverter Board (PU2) connector CN2PU2 is loose. YES Reconnect.
NO Change Exposure
Lamp (LA2).
NO Change CCD Unit.
Change Control
Board (copier: PWB-
C/C).
4011T526AA
3-51
4.4.10 Image Reading Section: Periodically uneven image
1 Scanner Motor (M5) is securely fastened using the
dedicated fixing screws.
NO Secure in position.
2 Scanner Motor (M5) drive mechanism is dirty or
damaged.
4 Scanner drive mechanism pulley is dirty with for-
eign matter, scratchy, deformed, worn, or dam-
aged.
YES Remove foreign
matter or change.
5 Scanner Drive Cables are wound incorrectly. YES Re-wind Scanner
Drive Cables.
6 Scanner rails and bushings are dirty with foreign
matter, scratchy, deformed, worn, or damaged.
7 Scanner moves smoothly.
<Check Procedure>
Gently move the Scanner by hand to check for
smooth operation.
NO Lubricate the Scan-
ner rails.
Reinstall Scanner.
NO Change CCD Unit.
Change Control
Board (PWB-C/C).
4011T528AA
3-52
4.4.11 Image Reading Section: Moire
1 Moire distortions recur even after the orientation of
original has been changed.
NO Change the original
mode (select one
other than that
resulted in moire).
2 Moire distortions recur even after the original mode
has been changed.
NO Change the original
image mode.
3 Moire distortions recur even when the zoom ratio is
changed.
NO Change the zoom
ratio setting.
4 The problem has been eliminated through the
checks of step up 3.
NO Adjust CCD Main
Zoom and CCD Sub
Zoom.
2-34
4011T040AA
3-53
4.4.12 Printer Section: Blank copy
1 Imaging Unit is installed correctly. NO Reinstall.
2 Connector between the Imaging Unit and copier is
dirty.
YES Clean.
3 PH Shutter (located along the laser path between
the PH Unit and PC Drum) is not in correct position
or malfunctions.
YES Correct or reinstall.
4 Connectors PJ12A and PJ13A in PH unit come off
or lift.
YES Reconnect.
5 Image Transfer Roller Assy is installed correctly. NO Reinstall.
6 Image transfer current contact is dirty, broken, or
bent.
YES Clean, correct, or
change.
7 Developing bias contact is dirty, broken, or bent. YES Clean, correct, or
change.
8 High Voltage Unit (HV1) connectors is loose. YES Reconnect.
9 The following voltage is supplied from the Master
Board (PWB-A).
<Check procedure>
Check that there is 24 V developing across the
Master Board pin and GND when the Power Switch
is turned ON (during a copy cycle or a standby
state).
YES Change IU.
Change PH Unit.
Change High Volt-
age Unit (HV1).
NO Change Master
Board (PWB-A).
4011T035AA
3-54
4.4.13 Printer Section: Black copy
1 PC Drum Charge Corona grid mesh and Comb
Electrode are loose.
YES Reinstall.
2 PC Drum Charge Corona contact is dirty, scratchy,
folded, bent, or damaged.
YES Correct or change.
3 Grid bias contact is dirty, folded, or bent. YES Clean, correct, or
change.
4 PC Drum ground contact is dirty, scratchy, bent, or
damaged.
change.
6 The PH Unit cable is loose. YES Reconnect.
Board (PWB-A).
<Check procedure>
Master Board pin and GND when the Power Switch
is turned ON (during a copy cycle or a standby
state).
YES Change IU.
Change PH Unit.
Change High Volt-
age Unit (HV1).
NO Change Master
Board (copier: PWB-
A).
4011T036AA
3-55
4.4.14 Printer Section: Low image density
1 The image changes when Toner Replenisher is
executed.
Toner Replenisher of Utility
YES Replenish the sup-
ply of toner using
Toner Replenisher.
2 The image changes when ID Adjust and VG
Adjust are executed.
YES Readjust. For
details, see
ADJUSTING/SET-
TING.
3 Image transfer current contact is dirty, folded, or
bent.
change.
4 Developing bias contact is dirty, folded, or bent. YES Clean, correct, or
change.
6 ATDC Sensor (UN1) is dirty with foreign matter
(such as paper dust) other than developer.
YES Clean.
7 The following voltages develop from the ATDC
Sensor (UN1).
<Check Procedure>
Check voltage across a Master Board pin and GND
when the Power Switch is turned ON.
DC5.39 V to 8.15 V across PJ10A-1 and GND
NO Change ATDC Sen-
sor (UN1) and then
change developer.
Board (PWB-A).
<Check procedure>
Master Board pin and GND when the Power
Switch is turned ON (during a copy cycle or a
standby state).
YES Change IU.
Change High Volt-
age Unit (HV1).
NO Change Master
Board (copier: PWB-
A).
4011T003AA
3-56
4.4.15 Printer Section: Foggy background or rough image
1 The image changes when ID Adjust and VG
Adjust are executed.
YES Readjust. For details,
see ADJUSTING/
SETTING.
2 PC Drum surface and the areas in contact with
Ds Collars are dirty with foreign matter, or
deformed or worn.
3 Main Erase (LA1) is dirty. YES Clean.
4 Grid bias contact is dirty, scratchy, deformed,
worn, or damaged.
change.
YES Clean.
Sensor (UN1).
<Check Procedure>
Check voltage across a Master Board pin and
GND when the Power Switch is turned ON.
NO Change ATDC Sensor
(UN1) and then
change developer.
Board (PWB-A).
<Check procedure>
Master Board pin and GND when the Power
Switch is turned ON (during a copy cycle or a
standby state).
YES Adjust Db. For details,
see ADJUSTING/
SETTING.
Change Eraser Lamp
(LA1).
Change PC Drum.
Change Imaging Unit.
Change High Voltage
Unit (HV1).
NO Change Master Board
(copier: PWB-A).
4011T004AA
3-57
4.4.16 Printer Section: Black streaks or bands
1 PC Drum is dirty or scratchy. YES Clean or change.
2 Foreign matter (such as paper dust) sticks to the
Cleaning Blade of IU or the blade curves upward.
YES Remove foreign
matter, correct, or
change.
3 DB of IU is plugged with foreign matter (such as
paper dust).
YES Remove foreign
matter.
Electrode are dirty, scratchy, deformed, damaged,
or out of position.
5 Fusing Roller is dirty or scratchy. YES Clean or change.
6 PH window of the PH Unit is dirty or scratchy. YES Clean or change.
NO Change IU.
4011T017AA 4011T023AA
3-58
4.4.17 Printer Section: Black spots
1 Toner is present along the paper path. YES Clean.
2 PC Drum is dirty or scratchy. YES Clean or change.
3 Tip of the PC Drum Paper Separator Finger is dirty,
scratchy, deformed, worn, or damaged.
4 Fusing Roller is dirty or scratchy. YES Clean or change.
5 Tip of the Fusing Paper Separator Finger is dirty,
scratchy, deformed, worn, or damaged.
YES Clean or change
Fusing Paper Sepa-
rator Fingers and
finger springs.
6 The image changes when VG Adjust is executed. YES Readjust. For
details, see
ADJUSTING/SET-
TING.
4011T521AA
3-59
4.4.18 Printer Section: Blank streaks or bands
1 PC Drum ground terminal is dirty, scratchy,
deformed, or damaged.
change.
paper dust).
YES Remove foreign
matter.
Electrode are dirty, scratchy, deformed, or dam-
aged.
change.
4 Post-fusing guide plate is dirty, scratchy, deformed,
worn, or damaged.
5 PH window of the PH Unit is dirty, scratchy, or dam-
aged.
NO Change IU.
4011T015AA 4011T020AA
3-60
4.4.19 Printer Section: Void areas
1 Foreign matter is present along the paper path. YES Remove foreign
matter.
2 Paper dust plugs up the Paper Dust Remover. YES Clean or change.
3 PC Drum Charge Corona, grid mesh, and Comb
Electrode are loose.
YES Reinstall.
4 PC Drum Charge Corona contact is dirty, scratchy,
deformed, worn, or damaged.
change.
5 Developing Roller is dirty, scratchy, deformed,
worn, or damaged.
6 Toner is even on Sleeve/Magnet Roller. NO Adjust Db. For
details, see
ADJUSTING/SET-
TING.
7 Developer is not even in the Developer Mixing
Chamber of IU.
YES Even out developer
in the Developer
Mixing Chamber.
paper dust).
YES Remove foreign
matter.
9 Image Transfer Roller is dirty, scratchy, deformed,
worn, or damaged.
change.
10 Image Transfer Roller Assy is installed correctly. NO Reinstall.
11 Charge Neutralizing Plate is dirty, scratchy, folded,
or bent.
change.
12 Fusing Roller is dirty, scratchy, deformed, or worn. YES Clean or change.
NO Change IU.
4011T008AA
3-61
4.4.20 Printer Section: Smear on back
1 Toner is spilled over area inside copier. YES Clean interior.
2 Toner is present along the paper path. YES Clean.
3 Fusing Pressure Roller is dirty, scratchy, or dam-
aged.
4 Image Transfer Roller is dirty. YES Clean or change.
5 Grid bias contact is dirty, scratchy, deformed, worn,
or damaged.
change.
NO Change High Volt-
age Unit (HV1).
Change Master
Board (PWB-A).
4011T009AA
3-62
4.4.21 Printer Section: Uneven image density
1 PC Drum ground plate is dirty, scratchy, deformed,
worn, or damaged.
change.
Electrode are dirty, scratchy, deformed, worn, dam-
aged, or loose.
change.
worn, or damaged.
4 Sleeve/Magnet Roller is dirty, scratchy, deformed,
worn, or damaged.
5 Toner is even on Sleeve/Magnet Roller. NO Adjust Db. For
details, see
ADJUSTING/SET-
TING.
6 Developer is not even in the Developer Mixing
Chamber of IU.
YES Even out developer
in the Developer
Mixing Chamber.
NO Change IU.
Change Master
Board (PWB-A).
4011T525AA
3-63
4.4.22 Printer Section: Gradation reproduction failure
1 PC Drum is dirty. YES Clean.
worn, or damaged.
3 The PH Unit cable is loose. YES Reconnect.
4 PH window of PH Unit is dirty. YES Clean.
YES Clean.
Sensor (UN1).
<Check Procedure>
Check voltage across a Master Board pin and GND
when the Power Switch is turned ON.
NO Change ATDC Sen-
sor (UN1) and
developer.
YES Change Master
Board (copier: PWB-
A).
4011T526AA
3-64
4.4.23 Printer Section: Periodically uneven image
1 IU is securely fastened using the dedicated fixing
screws.
2 PH Unit is securely fastened using the dedicated
fixing screws.
3 IU drive mechanism is dirty or damaged. YES Clean or change.
4 PC Drum surfaces in contact with Ds Collars and
drive mechanism are dirty, scratchy, deformed, or
worn.
5 Synchronizing Roller drive mechanism is dirty,
scratchy, deformed, or worn.
6 Fusing Unit drive mechanism is dirty, scratchy,
deformed, or worn.
NO Change Master
Board (PWB-A).
4011T528AA

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