Toshiba e-STUDIO4500c/5500c service manual

SERVICE MANUAL

MULTIFUNCTIONAL DIGITAL COLOR SYSTEMS

e-STUDIO4500c/5500c

File No. SME060023C0

R060621C2200-TTEC

Ver03_2007-04

Contents

Main TRADEMARKS 1. CONVENTIONS Conventions Used in this Manual Cautions, Notes, etc. Commonly Used Terms 2. GENERAL SAFETY INSTRUCTIONS 2.1 RESPONSIBILITIES OF THE SERVICE ENGINEER 2.1.1 SERVICE ENGINEER 2.1.2 REFERENCE MATERIAL FOR MAINTENANCE 2.2 BEFORE INSTALLATION, MAINTENANCE 2.2.1 SHIPPING AND MOVING THE MACHINE 2.2.2 POWER 2.2.3 INSTALLATION, DISASSEMBLY, AND ADJUSTMENTS 2.2.4 SPECIAL TOOLS 2.3 DURING MAINTENANCE 2.3.1 GENERAL 2.3.2 SAFETY DEVICES 2.3.3 ORGANIC CLEANERS 2.3.4 LITHIUM BATTERIES 2.3.5 OZONE FILTERS 2.3.6 POWER PLUG AND POWER CORD 2.4 AFTER INSTALLATION, SERVICING 2.4.1 DISPOSAL OF USED ITEMS 2.4.2 POINTS TO CONFIRM WITH OPERATORS 2.5 SPECIAL SAFETY INSTRUCTIONS FOR TONER 2.6 ACCIDENTAL PHYSICAL EXPOSURE 2.7 HANDLING AND STORING TONER 2.8 TONER DISPOSAL 2.8.1 SAFETY INSTRUCTIONS FOR THIS MACHINE LASER SAFETY Page 1. INSTALLATION...........................................................................1-1 Page 2. PREVENTIVE MAINTENANCE................................................... 2-1 3. REPLACEMENT AND ADJUSTMENT........................................3-1 Page Page Page 4. TROUBLESHOOTING.................................................................4-1 Page 5. SERVICE TABLES...................................................................... 5-1 Page Page Page Page Page 3. DETAILED DESCRIPTIONS................................................. B331-4 1. REPLACEMENT AND ADJUSTMENT................................. B473-1 2. DETAILS............................................................................... B473-7 2000/3000-SHEET FINISHER 1. 1. REPLACEMENT AND ADJUSTMENT............................ B700-1 1. 2. DETAILS........................................................................ B700-24 COVER INTERPOSER TRAY 1. REPLACEMENT AND ADJUSTMENT................................. B704-1 2. DETAILS............................................................................... B704-8 6. DETAILS............................................................................. B706-33 7. OVERALL MACHINE INFORMATION................................ B706-52 9-BIN MAILBOX 1. REPLACEMENT AND ADJUSTMENT................................. B762-1 2. DETAILS............................................................................... B762-4 SPECIFICATIONS.................................................................... SPEC-1 APPENDIX 1.1 INSTALLATION REQUIREMENTS 1.1.1 OPERATING ENVIRONMENT 1.1.2 MACHINE LEVEL 1.1.3 MINIMUM SPACE REQUIREMENTS 1.1.4 DIMENSIONS 1.1.5 POWER REQUIREMENTS 1.2 COPIER AND PERIPHERALS 1.3 COPIER e-STUDIO4500c/5500c 1.3.1 ACCESSORIES 1.3.2 INSTALLATION Tapes and packing material Page Page Page Shipping Retainer Removal Page Page Developer Cartridge Installation F R Page Page Page Page Reassemble the PCU Page Reattach the Face Plate Remove the Retainers in the Drawer Unit Page Page Reinstall the Toner Hopper STC (Soft Toner Cartridge) Installation Make the Machine Level Attach the PCU Stand Rack Attach Decals Initializing Developer and Toner Page Load the Paper Trays Make a Test Color Print ACC (Automatic Color Calibration) Adjustment Page Counter Display Setting Print an SMC Report Connect the Upper and Lower Tray Heaters 1.3.3 BREAKER SWITCH TEST PROCEDURE How to Test the Electrical Breaker Switch To return the switch to the ON position: 1.4 COPY TRAY (B756) 1.4.1 ACCESSORIES 1.4.2 INSTALLATION Page Page 1.5 A3/11" X 17" PAPER SIZE TRAY (B331) 1.5.1 ACCESSORIES 1.5.2 INSTALLATION Page Page Page Page 1.6 LCT (B473), LCT ADAPTER (B699) 1.6.1 ACCESSORIES LCT (B473) LCT Adapter (B699) 1.6.2 INSTALLATION Removing Tape and Accessories LCT Adapter (B699) Installation LCT Installation Page Page LCT (B473): Paper size change from A4 to 81/2" x 11" (LT) Page Page 1.7 81/2" X 14"/B4 PAPER SIZE TRAY (B474) 1.7.1 ACCESSORIES 1.7.2 INSTALLATION LCT Connected to the Machine Page Page 1.8 2000/3000 SHEET FINISHERS (B700/B701) 1.8.1 ACCESSORIES 1.8.2 INSTALLATION Removing Tapes and Packing Materials Page Docking the Finisher to the Copier Page Attaching the Trays B700 B701 Leveling the Finisher Support Tray Selecting the Staple Supply Name Enabling Booklet Binding (B700 Only) 1.9 PUNCH UNIT (B702) 1.9.1 ACCESSORIES 1.9.2 INSTALLATION Page Page 1.10 MAILBOX (B762) 1.10.1 ACCESSORIES 1.10.2 INSTALLATION Page Page 1.11 3000-SHEET FINISHER (B706), FINISHER ADAPTER (B698) 1.11.1 ACCESSORIES 3000-Sheet Finisher B706 Accessories Finisher Adapter Kit B698 Accessories 1.11.2 INSTALLATION Shipping tape and retainers Page Finisher Adapter B698 Installation Page Page Page Finisher Installation Page Page Selecting the Staple Supply Name Stopper Bracket (Co-packed with B698) Installation Page 1.12 PUNCH UNIT B531 1.12.1 ACCESSORIES 1.12.2 INSTALLATION Page Page Page 1.13 OUTPUT JOGGER UNIT (B703/B513) 1.13.1 ACCESSORIES 1.13.2 INSTALLATION Page 1.14 COVER INTERPOSER TRAY (B704) 1.14.1 ACCESSORIES 1.14.2 INSTALLATION Removing Tapes and Packing Materials Preparing the Finisher (B700/B701/B706) Attaching the Extensions for the B706 Page Page Attaching the Extensions for the B700/B701 Attaching the Interposer Tray (B700/B701/B706) Attaching the Corner Plates for the B706 NG OK Page Docking Finisher and Interposer to the Machine (B700/B701/B706) Page August 2006 MFP CONTROLLER OPTIONS 1-115 (Applications) 1.15 MFP CONTROLLER OPTIONS 1.15.1 OVERVIEW Board Slots SD Card Slots A CD E Page 1.15.3 APPLICATIONS PROVIDED ON SD CARDS 1.15.4 HANDLING DIMMS AND SD CARDS DIMMs SD cards To install and remove an SD Card: 1.15.5 MERGING APPLICATIONS ON ONE SD CARD Merging Applications Undo Exec Storing SD Application Cards on Site 1.15.6 PRINTER/SCANNER UNIT GM-2100 (B737) Accessories Installation Page USB SP Settings 1.15.7 POSTSCRIPT3 UNIT TYPE 3260 (B761) Accessory Check 1.15.8 DATAOVERWRITESECURITY UNIT TYPE C (B735) Accessory Check Before You Begin Seal Check And Removal Installation Procedure Page 1.15.9 COPY CONNECTOR TYPE 3260 (B328) CN594 CN4 1.15.10 EFI PRINTER CONTROLLER (G815) 2. PREVENTIVE MAINTENANCE Page 2.2.2 PM PARTS SCREEN DETAILS All PM Parts list: Main Menu Number button submenu Parts list for PM yield indicator 2.3 PM TABLES 2.3.1 MAIN MACHINE Copier PM Parts August, 2006 PM TABLES 2-7 PM TABLES August, 2006 2-8 August, 2006 PM TABLES 2-9 PM TABLES August, 2006 2-10 ARDF PM Parts NOTE: The "K" number in the table below is the number of originals that have been fed. August, 2006 PM TABLES 2-11 2.3.2 2000/3000-SHEET BOOKLET FINISHER B700/B701 2.3.3 PUNCH B702 PUNCH 2.3.4 3000-SHEET FINISHER B706 FINISHER 2.3.6 COVER INTERPOSER TRAY B704 2.3.7 LCT B473 2.4 LUBRICATION POINTS 2.4.1 COPIER OPC, ITB Replacement Fusing Unit 3. REPLACEMENT AND ADJUSTMENT 3.1 GENERAL CAUTIONS 3.1.1 DRUM 3.1.2 PCU 3.1.3 TRANSFER BELT UNIT 3.1.4 SCANNER UNIT 3.1.5 LASER UNIT 3.1.6 DEVELOPMENT 3.1.7 CLEANING 3.1.8 FUSING UNIT 3.1.9 PAPER FEED 3.1.10 USED TONER (WASTE TONER) 3.2 COMMON REMOVAL PROCEDURES 3.2.1 ARDF 3.2.2 OPERATION PANEL, TOP COVERS 3.2.3 LEFT COVERS 3.2.4 FRONT DOOR 3.2.5 RIGHT COVERS 3.2.6 REAR COVERS 3.2.7 TONER HOPPER, FACE PLATE, PCU Removing Toner Hopper, Face plate, PCU Page Page F R Reinstalling PCU, Face plate, Toner Hopper Page Page 3.2.8 IMAGE TRANSFER UNIT Page 3.2.9 DRAWER UNIT Page 3.2.10 DUPLEX UNIT 3.2.11 OPENING AND LOCKING THE CONTROLLER BOX COVER 3.2.12 SD CARD STORAGE 3.3 SCANNER UNIT 3.3.1 EXPOSURE GLASS 3.3.2 LENS BLOCK, PAPER SIZE SENSORS 3.3.3 EXPOSURE LAMP 3.3.4 SCANNER MOTOR 3.3.5 SCANNER HP SENSOR 3.3.6 SCANNER INTERFACE BOARD (SIOB) Page Scanner Wire Reinstallation and Scanner Position Adjustment Page 3.4 LASER UNIT 3.4.1 CAUTION DECALS 3.4.2 POLYGON MOTOR 3.4.3 LASER UNIT Page Page Adjustments After Laser Unit Replacement SP Adjustments 3.4.4 LASER SYNCHRONIZATION DETECTOR 3.5 PCU (PHOTOCONDUCTOR UNITS) F 3.5.1 DEVELOPER REPLACEMENT R Page Page Page Page Page Page Page 3.5.2 DEVELOPMENT GEARS 3.5.3 CHARGE ROLLER UNIT 3.5.4 DRUM AND CLEANING BLADE Removing the OPC Drum Removing the Cleaning Blade Page 3.5.5 PCU CLEANING UNIT Page 3.5.6 TD SENSOR August, 2006 PCU (PHOTOCONDUCTOR UNITS) 3-57 3.5.7 AFTER REPLACING THE PCU COMPONENTS AND DEVELOPER Page 3.6 TONER SUPPLY UNIT 3.6.1 STC PORT CLEANING 3.6.2 CONNECTOR BOARD (CNB) 3.6.3 TONER PUMP 3.6.4 TONER END SENSOR 3.6.5 TONER HOPPER MOTOR 3.7 PAPER TRANSFER UNIT 3.7.1 RELAY SENSOR 3.7.2 DOUBLE-FEED DETECTION SENSOR, REGISTRATION SENSOR 3.7.3 PAPER TRANSFER UNIT Page 3.7.4 PAPER TRANSFER ROLLER, PAPER DISCHARGE PLATE 3.7.5 LUBRICANT BAR 3.7.6 CLEANING BLADE 3.7.7 PTR CLEANING BRUSH ROLLER 3.7.8 PAPER TRANSPORT BELT, SEPARATION POWER PACK 3.7.9 REGISTRATION MOTOR 3.7.10 DOUBLE-FEED DETECTION LED 3.8 IMAGE TRANSFER UNIT 3.8.1 ITB (Image Transfer Belt), BELT CLEANING UNIT Disassembly and ITB Replacement Page Reassembly of the Image Transfer Unit and Belt Cleaning Unit NG OK Dusting the ITB with Lubricant Powder Page 3.8.2 ITB CLEANING BLADE, DUST COLLECTION UNIT 3.8.3 ITB CLEANING ROLLER, SCRAPER BLADE 3.8.4 MUSIC AND ID SENSORS 3.8.5 IMAGE TRANSFER POWER PACK 3.8.6 BELT POSITION SENSORS 3.9 FUSING UNIT 3.9.1 FUSING BELT STRIPPERS 3.9.2 FUSING UNIT 3.9.3 FUSING EXIT SENSOR, ACCORDION JAM SENSOR 3.9.4 PRESSURE ROLLER THERMOSTATS, THERMISTOR 3.9.5 FUSING CLEANING UNIT 3.9.6 FUSING BELT THERMOSTATS 3.9.7 FUSING THERMISTORS, HEATING ROLLER TEMPERATURE SENSOR 3.9.8 FUSING BELT LUBRICATION ROLLER, CLEANING ROLLER 3.9.9 PRESSURE ROLLER CLEANING FELT ROLLER Page 3.9.10 HOT ROLLER, HEATING ROLLER FUSING LAMPS Page 3.9.11 PRESSURE ROLLER FUSING LAMP 3.9.12 HEATING ROLLER, FUSING BELT, HOT ROLLER Page Page 3.9.13 PRESSURE ROLLER 3.9.14 PRESSURE ROLLER STRIPPER 3.10 DUPLEX UNIT 3.10.1 DUPLEX INVERTER MOTOR 3.10.2 DUPLEX TRANSPORT MOTOR 3.10.3 DUPLEX UNIT SENSORS Duplex Entrance Sensor Transport Sensor 1, 2, Inverter Exit Sensor Page Transport Sensor 3 3.10.4 DUPLEX JOGGER MOTOR 3.10.5 DUPLEX JOGGER BELT 3.11 TANDEM TRAY (TRAY 1) 3.11.1 TANDEM TRAY Page 3.11.2 REAR FENCE RETURN SENSOR REPLACEMENT 3.11.3 REAR FENCE HP SENSOR REPLACEMENT 3.11.4 TANDEM RIGHT TRAY PAPER SENSOR REPLACEMENT 3.11.5 BOTTOM PLATE LIFT WIRE REPLACEMENT Page 3.11.6 TANDEM TRAY PAPER SIZE CHANGE Page Page 3.12 PAPER FEED (TRAYS 2, 3) 3.12.1 PICK-UP, FEED, SEPARATION ROLLERS 3.12.2 FEED UNIT Page 3.12.3 SEPARATION ROLLER PRESSURE ADJUSTMENT 3.12.4 PAPER END, TRAY LIFT, PAPER FEED SENSORS 3.12.5 VERTICAL TRANSPORT SENSOR 3.13 BYPASS UNIT 3.13.1 BYPASS PICK-UP, FEED, SEPARATION ROLLER 3.13.2 BYPASS AUTO PAPER SIZE DETECTION SWITCHES 3.13.3 BYPASS UNIT 3.13.4 BYPASS PAPER END SENSOR, FEED SENSOR 3.13.5 BYPASS FEED CLUTCH 3.14 BOARDS 3.14.1 CONTROLLER UNIT 3.14.2 CONTROLLER BOARD, 256 MB MEMORY, NVRAM 3.14.3 NVRAM REPLACEMENT Upload NVRAM Data SD Card Replace NVRAM Restore NVRAM Data to the New NVRAM 3.14.4 CONTROLLER BOX COVER, BICU, IOB Page 3.14.5 RDS BOARD, JUMPER 3.14.6 INTERFACE BOARD, MOTHER BOARD 3.14.7 HVPS, PFC BOARD 3.14.8 PSU 3.14.9 AC DRIVE BOARD 3.14.10 TRANSFER MOTOR, DRIVE, DRIVE MOTOR BOARDS 3.15 HDD UNIT Disposal of HDD Units Reinstallation 3.16 MOTORS 3.16.1 PCU MOTOR, DRUM MOTOR Page 3.16.2 PAPER TRANSFER MOTOR 3.16.3 IMAGE TRANSFER MOTOR 3.16.4 WASTE TONER TRANSPORT MOTOR, WASTE TONER DISTRIBUTION MOTOR 3.16.5 BOTTOM PLATE LIFT MOTOR (TRAYS 1, 2, 3) 3.16.6 ITB DRIVE MOTOR 3.17 AIR FILTERS 3.17.1 TONER HOPPER FILTER 3.17.2 OZONE FILTER, DUST FILTERS 3.17.3 SCANNER FILTER 3.18 ARDF 3.18.1 ARDF COVERS 3.18.2 ORIGINAL FEED UNIT 3.18.3 FEED BELT, PICK-UP ROLLER 3.18.4 BOTTOM PLATE POSITION SENSOR 3.18.5 INTERVAL, ORIGINAL WIDTH, SKEW CORRECTION, SEPARATION SENSORS 3.18.6 ORIGINAL LENGTH SENSORS 3.18.7 FEED COVER, ORIGINAL SET, BOTTOM PLATE, PICK-UP ROLLER HP, UPPER INVERTER SENSORS Page 3.18.8 ARDF POSITION SENSOR, APS START SENSOR 3.18.9 ORIGINAL REGISTRATION, EXIT SENSORS Page 3.18.10 ARDF SEPARATION ROLLER 3.18.11 ARDF TRANSPORT BELT Removing the ARDF Transport Belt Assembly Removing the Belt Page Reinstalling the Belt FRONT REAR Reattaching the White Cover 3.18.12 ARDF CONTROL BOARD 3.18.13 ARDF BOTTOM PLATE LIFT MOTOR 3.18.14 ARDF FEED MOTOR, ARDF TRANSPORT MOTOR 3.18.15 ARDF PICK-UP ROLLER LIFT MOTOR 3.19 IMAGE ADJUSTMENTS B 3.19.1 SCANNING Scanner sub-scan magnification Scanner leading edge and side-to-side registration Main scan dot position correction 3.19.2 ARDF ARDF side-to-side and leading edge registration B 3.19.3 REGISTRATION Image Area Leading Edge Side to Side Adjustment Standards Adjustment Procedure 3.19.4 COLOR REGISTRATION Forced MUSIC Adjustment Adjustment of Line Speed for Thick Paper Color Registration Test and Error Adjustment 3.19.5 SKEW ADJUSTMENT AFTER LASER UNIT REPLACEMENT Page 3.19.6 PRINTER GAMMA CORRECTION Copy Mode KCMY Color Balance Adjustment Adjustment Procedure August, 2006 IMAGE ADJUSTMENTS 3-187 - Photo Mode, Single Color - - Text (Letter) Mode, Full Color - IMAGE ADJUSTMENTS August, 2006 3-188 - Text (Letter) Mode, Single Color - Printer Mode IMAGE ADJUSTMENTS August, 2006 3-190 Adjustment Reference For Gamma Correction 3.20 TOUCH SCREEN CALIBRATION 4. TROUBLESHOOTING 4.1 PROGRAM DOWNLOAD 4.1.1 OVERVIEW 4.1.2 RECOVERY METHODS PROGRAM DOWNLOAD April, 2007 4.1.3 DOWNLOAD ERROR CODES April, 2007 PROGRAM DOWNLOAD 4-3 PROGRAM DOWNLOAD April, 2007 4-4 April, 2007 PROGRAM DOWNLOAD 4-5 4.1.4 IMPORTANT SP CODES Here is a list of important SP codes that you may need during troubleshooting. NOTE: For more information about these and other SP codes, see 4. Service Tables. 4.2 SPECIAL PROCEDURES 4.2.1 SP2181 030 (ALIGNMENT RESULT) ERRORS April, 2007 SPECIAL PROCEDURES 4-7 07/04 SPECIAL PROCEDURES April, 2007 4-8 Page 4.2.2 COLOR REGISTRATION ADJUSTMENT Color Registration Error Correction Page Color Skew Error Correction Overall Check Color Registration at the Left and Right Folds of the Test Pattern Page April, 2007 SPECIAL PROCEDURES 4-15 4.2.3 SP3812 001 (DevSetup Execute) ERRORS SPECIAL PROCEDURES April, 2007 4-16 4.2.4 PROCESS CONTROL TROUBLESHOOTING Summary of Process Control SC Codes Process Control Self-Check: SP3821 SPECIAL PROCEDURES April, 2007 4-18 April, 2007 SPECIAL PROCEDURES 4-19 SPECIAL PROCEDURES April, 2007 4-20 April, 2007 SPECIAL PROCEDURES 4-21 SPECIAL PROCEDURES April, 2007 4-22 4.2.5 COLOR ADJUSTMENT FOR CONNECTED COPIERS Page 4.3 SERVICE CALL CONDITIONS 4.3.1 SERVICE MODE LOCK/UNLOCK 4.3.2 SERIES SERVICE CALL CONDITIONS 4.3.3 SC CODE DESCRIPTIONS SERVICE CALL CONDITIONS April 2007 4-28 SC codes Group 1: Scanning April, 2007 SERVICE CALL CONDITIONS 4-29 SERVICE CALL CONDITIONS April 2007 4-30 SC codes Group 2: Exposure April, 2007 SERVICE CALL CONDITIONS 4-31 SERVICE CALL CONDITIONS April 2007 4-32 April, 2007 SERVICE CALL CONDITIONS 4-33 SERVICE CALL CONDITIONS April 2007 4-34 April, 2007 SERVICE CALL CONDITIONS 4-35 SERVICE CALL CONDITIONS April 2007 4-36 April, 2007 SERVICE CALL CONDITIONS 4-37 SC codes Group 3: Image Development - 1 SERVICE CALL CONDITIONS April 2007 4-38 April, 2007 SERVICE CALL CONDITIONS 4-39 SERVICE CALL CONDITIONS April 2007 4-40 April, 2007 SERVICE CALL CONDITIONS 4-41 Execute SP3820 001 to do auto process control manually. SERVICE CALL CONDITIONS April 2007 4-42 SC codes Group 4: Image Development - 2 April, 2007 SERVICE CALL CONDITIONS 4-43 SERVICE CALL CONDITIONS April 2007 4-44 Page SERVICE CALL CONDITIONS April 2007 4-46 April, 2007 SERVICE CALL CONDITIONS 4-47 SC codes Group 5: Paper Feed The lower limit sensor of the SERVICE CALL CONDITIONS April 2007 4-48 April, 2007 SERVICE CALL CONDITIONS 4-49 SERVICE CALL CONDITIONS April 2007 4-50 April, 2007 SERVICE CALL CONDITIONS 4-51 SERVICE CALL CONDITIONS April 2007 4-52 April, 2007 SERVICE CALL CONDITIONS 4-53 SERVICE CALL CONDITIONS April 2007 4-54 April, 2007 SERVICE CALL CONDITIONS 4-55 SC codes Group 6: Device Communication SERVICE CALL CONDITIONS April 2007 4-56 April, 2007 SERVICE CALL CONDITIONS 4-57 SERVICE CALL CONDITIONS April 2007 4-58 SC codes Group 7: Peripherals April, 2007 SERVICE CALL CONDITIONS 4-59 SERVICE CALL CONDITIONS April 2007 4-60 April, 2007 SERVICE CALL CONDITIONS 4-61 SERVICE CALL CONDITIONS April 2007 4-62 April, 2007 SERVICE CALL CONDITIONS 4-63 SERVICE CALL CONDITIONS April 2007 4-64 April, 2007 SERVICE CALL CONDITIONS 4-65 SC800: Overall System NOTE: report so you can read the error code. The error code is not displayed on the operation panel. SERVICE CALL CONDITIONS April 2007 NOTE: report so you can read the error code. The error code is not displayed on the operation panel. April, 2007 SERVICE CALL CONDITIONS 4-67 NOTE: SERVICE CALL CONDITIONS April 2007 4-68 April, 2007 SERVICE CALL CONDITIONS 4-69 SERVICE CALL CONDITIONS April 2007 4-70 SC April, 2007 SERVICE CALL CONDITIONS 4-71 SC900: Miscellaneous SERVICE CALL CONDITIONS April 2007 4-72 Here is a list of HDD status codes: Page SERVICE CALL CONDITIONS April 2007 4-74 April, 2007 SERVICE CALL CONDITIONS 4-75 4.3.4 ADDITIONAL SC CODES PRINTED IN SMC REPORTS SC No. Symptom Possible Cause 4.4 ADDITIONAL INFORMATIONS 4.4.1 TRAY PAPER SIZE SETTING 4.4.2 PAPER MISFEED (J098/J099) Page How to Change the Paper Thickness and Paper Type Settings: How to Change the "Paper Type Detect" or "Double Feed Detect" Setting: 4.4.3 PAPER FEED SKEW SYMPTOM: CAUSE: SOLUTION: HOW TO CHECK THE POSITION OF THE REAR REGISTRATION PRESSURE SPRING: Page Page NG position OK position 4.4.4 WHITE LINE IN SUB-SCAN DIRECTION ON SINGLE COLOR SOLID IMAGE. 4.4.5 DIRTY BLACK LINE IN CUB-SCAN DIRECTION OR DIRTY BACKGROUND Page Page Page APPENDIX: 4.4.6 EXPANDED SOFT TONER CARTRIDGE 4.4.7 SYSTEM STOP CONTROL DUE TO THE TEMPERATURE LIMITATION OVERVIEW: ACTION: 4.4.8 LOW POWER MODE TEMPERATURE Page 4.4.9 POOR FUSING ON 100g/m2 PAPER SYMPTOM: CAUSE: SOLUTION: ACTION: Final Solution: Middle Thickness Paper Mode Page Page Page April, 2007 ADDITIONAL INFORMATIONS 4-99 APPENDIX: Default settings of SP modes related to previous Temporary Solutions A, B and B+ 4.4.10 ABNORMAL SHIFT TRAY MOVEMENT OF SR842 (B706) WITH EFI PRINTER CONTROLLER (E-7000) 4.4.11 POOR FUSING ON 100g/m2 PAPER CAUSE and SOLUTION: Fusing Anti-glossy Streak Kit (P/N B1329713): Page 4.4.12 COPIER FIRMWARE UPDATE NOTICE WHEN COLOR CONTROLLER E-7000 IS INSTALLED REASON: PROCEDURE: Page 4.4.13 POOR FUSING ON 100g/m2 PAPER SYMPTOM: CAUSE: SOLUTION: Solution: Middle Thickness Paper Mode Page Page Page Page 4.4.14 NIP WIDTH ADJUSTMENT Important: MEASURING THE NIP WIDTH: NIP WIDTH SPECIFICATIONS: ADJUSTING THE NIP WIDTH: 5. SERVICE TABLES 5.1 SERVICE PROGRAM MODE 5.1.1 SERVICE PROGRAM MODE OPERATION Service Mode Lock/Unlock To Enter and Exit the Service Mode To Switch to the Copy Window for Test Printing Using the SP Mode Direct Entry Button Selection Entry SERVICE PROGRAM MODE April, 2007 5-4 SP Mode Button Summary Here is a short summary of the touch-panel buttons. (2)(1) (3) (4) (5) (6) (7) (8) (9) (10) SP Mode Print (SMC report print) 5.2 RESETS 5.2.1 MEMORY ALL CLEAR: SP5801 Page 5.2.2 SOFTWARE AND SETTING RESET Software Reset Resetting the User Tool Settings Resetting Copy/Document Server Features Only Resetting Scanner Features Only 5.3 TEST PATTERN PRINTING 5.3.1 PRINTING TEST PATTERN: SP2109 002 Test Pattern Table 5.3.2 IPU TEST PATTERNS: SP4417 5.4 FIRMWARE UPDATE 5.4.1 FIRMWARE UPDATE PROCEDURE Firmware Update Procedure Page Page Verifying the Firmware Update FIRMWARE UPDATE April, 2007 5-16 5.4.2 DOWNLOADING STAMP DATA 5.4.3 UPLOADING AND DOWNLOADING NVRAM DATA Uploading NVRAM Data to an SD card Downloading an SD Card to NVRAM SERVICE PROGRAM TABLES April, 2007 5-20 5.5 SERVICE PROGRAM TABLES 5.5.1 SERVICE TABLE KEY April, 2007 SERVICE PROGRAM TABLES 5-21 SERVICE PROGRAM TABLES April, 2007 5-22 5.5.2 COPIER SERVICE TABLES Group 1000 April, 2007 SERVICE PROGRAM TABLES 5-23 SERVICE PROGRAM TABLES April, 2007 5-24 April, 2007 SERVICE PROGRAM TABLES 5-25 SERVICE PROGRAM TABLES April, 2007 5-26 April, 2007 SERVICE PROGRAM TABLES 5-27 SERVICE PROGRAM TABLES April, 2007 5-28 April, 2007 SERVICE PROGRAM TABLES 5-29 SERVICE PROGRAM TABLES April, 2007 5-30 April, 2007 SERVICE PROGRAM TABLES 5-31 SERVICE PROGRAM TABLES April, 2007 5-32 April, 2007 SERVICE PROGRAM TABLES 5-33 Group 2000 SERVICE PROGRAM TABLES April, 2007 5-34 April, 2007 SERVICE PROGRAM TABLES 5-35 SERVICE PROGRAM TABLES April, 2007 5-36 April, 2007 SERVICE PROGRAM TABLES 5-37 07/04 SERVICE PROGRAM TABLES April, 2007 5-38 April, 2007 SERVICE PROGRAM TABLES 5-39 SERVICE PROGRAM TABLES April, 2007 5-40 April, 2007 SERVICE PROGRAM TABLES 5-41 SERVICE PROGRAM TABLES April, 2007 5-42 April, 2007 SERVICE PROGRAM TABLES 5-43 SERVICE PROGRAM TABLES April, 2007 5-44 April, 2007 SERVICE PROGRAM TABLES 5-45 SERVICE PROGRAM TABLES April, 2007 5-46 April, 2007 SERVICE PROGRAM TABLES 5-47 SERVICE PROGRAM TABLES April, 2007 5-48 April, 2007 SERVICE PROGRAM TABLES 5-49 SERVICE PROGRAM TABLES April, 2007 5-50 April, 2007 SERVICE PROGRAM TABLES 5-51 SERVICE PROGRAM TABLES April, 2007 5-52 April, 2007 SERVICE PROGRAM TABLES 5-53 ITB Side1:PTR Side1:SepDC Side1:SepAC SERVICE PROGRAM TABLES April, 2007 5-54 April, 2007 SERVICE PROGRAM TABLES 5-55 SERVICE PROGRAM TABLES April, 2007 5-56 April, 2007 SERVICE PROGRAM TABLES 5-57 SERVICE PROGRAM TABLES April, 2007 5-58 April, 2007 SERVICE PROGRAM TABLES 5-59 SERVICE PROGRAM TABLES April, 2007 5-60 April, 2007 SERVICE PROGRAM TABLES 5-61 SERVICE PROGRAM TABLES April, 2007 5-62 April, 2007 SERVICE PROGRAM TABLES 5-63 SERVICE PROGRAM TABLES April, 2007 5-64 April, 2007 SERVICE PROGRAM TABLES 5-65 SERVICE PROGRAM TABLES April, 2007 5-66 April, 2007 SERVICE PROGRAM TABLES 5-67 SERVICE PROGRAM TABLES April, 2007 5-68 April, 2007 SERVICE PROGRAM TABLES 5-69 SERVICE PROGRAM TABLES April, 2007 5-70 April, 2007 SERVICE PROGRAM TABLES 5-71 SERVICE PROGRAM TABLES April, 2007 5-72 April, 2007 SERVICE PROGRAM TABLES 5-73 SERVICE PROGRAM TABLES April, 2007 5-74 April, 2007 SERVICE PROGRAM TABLES 5-75 SERVICE PROGRAM TABLES April, 2007 5-76 April, 2007 SERVICE PROGRAM TABLES 5-77 SERVICE PROGRAM TABLES April, 2007 5-78 April, 2007 SERVICE PROGRAM TABLES 5-79 SERVICE PROGRAM TABLES April, 2007 5-80 Group 3000 April, 2007 SERVICE PROGRAM TABLES 5-81 SERVICE PROGRAM TABLES April, 2007 5-82 April, 2007 SERVICE PROGRAM TABLES 5-83 SERVICE PROGRAM TABLES April, 2007 5-84 April, 2007 SERVICE PROGRAM TABLES 5-85 SERVICE PROGRAM TABLES April, 2007 5-86 April, 2007 SERVICE PROGRAM TABLES 5-87 SERVICE PROGRAM TABLES April, 2007 5-88 April, 2007 SERVICE PROGRAM TABLES 5-89 After this SP is changed, process control must be executed manually with SERVICE PROGRAM TABLES April, 2007 5-90 April, 2007 SERVICE PROGRAM TABLES 5-91 SERVICE PROGRAM TABLES April, 2007 5-92 April, 2007 SERVICE PROGRAM TABLES 5-93 SERVICE PROGRAM TABLES April, 2007 5-94 April, 2007 SERVICE PROGRAM TABLES 5-95 You must do SP3820 to enable any values you change with SP3531 (Procon Use SP3561 to display the resuls of SP3820 execution. SERVICE PROGRAM TABLES April, 2007 5-96 Group 4000 April, 2007 SERVICE PROGRAM TABLES 5-97 SERVICE PROGRAM TABLES April, 2007 5-98 April, 2007 SERVICE PROGRAM TABLES 5-99 SERVICE PROGRAM TABLES April, 2007 5-100 April, 2007 SERVICE PROGRAM TABLES 5-101 SERVICE PROGRAM TABLES April, 2007 5-102 April, 2007 SERVICE PROGRAM TABLES 5-103 SERVICE PROGRAM TABLES April, 2007 5-104 April, 2007 SERVICE PROGRAM TABLES 5-105 SERVICE PROGRAM TABLES August, 2006 5-106 Group 5000 August, 2006 SERVICE PROGRAM TABLES 5-107 SERVICE PROGRAM TABLES August, 2006 5-108 August, 2006 SERVICE PROGRAM TABLES 5-109 SERVICE PROGRAM TABLES August, 2006 5-110 August, 2006 SERVICE PROGRAM TABLES 5-111 SERVICE PROGRAM TABLES August, 2006 5-112 August, 2006 SERVICE PROGRAM TABLES 5-113 SERVICE PROGRAM TABLES August, 2006 5-114 August, 2006 SERVICE PROGRAM TABLES 5-115 SERVICE PROGRAM TABLES August, 2006 5-116 August, 2006 SERVICE PROGRAM TABLES 5-117 SERVICE PROGRAM TABLES August, 2006 5-118 August, 2006 SERVICE PROGRAM TABLES 5-119 SERVICE PROGRAM TABLES August, 2006 5-120 August, 2006 SERVICE PROGRAM TABLES 5-121 SERVICE PROGRAM TABLES August, 2006 5-122 August, 2006 SERVICE PROGRAM TABLES 5-123 SERVICE PROGRAM TABLES August, 2006 5-124 August, 2006 SERVICE PROGRAM TABLES 5-125 SERVICE PROGRAM TABLES August, 2006 5-126 August, 2006 SERVICE PROGRAM TABLES 5-127 SERVICE PROGRAM TABLES August, 2006 5-128 August, 2006 SERVICE PROGRAM TABLES 5-129 SERVICE PROGRAM TABLES August, 2006 5-130 August, 2006 SERVICE PROGRAM TABLES 5-131 SERVICE PROGRAM TABLES August, 2006 5-132 Group 6000 August, 2006 SERVICE PROGRAM TABLES 5-133 SERVICE PROGRAM TABLES August, 2006 5-134 August, 2006 SERVICE PROGRAM TABLES 5-135 SERVICE PROGRAM TABLES August, 2006 5-136 August, 2006 SERVICE PROGRAM TABLES 5-137 SERVICE PROGRAM TABLES August, 2006 5-138 August, 2006 SERVICE PROGRAM TABLES 5-139 SERVICE PROGRAM TABLES August, 2006 5-140 August, 2006 SERVICE PROGRAM TABLES 5-141 Group 7000 SERVICE PROGRAM TABLES August, 2006 5-142 August, 2006 SERVICE PROGRAM TABLES 5-143 SERVICE PROGRAM TABLES August, 2006 5-144 August, 2006 SERVICE PROGRAM TABLES 5-145 SERVICE PROGRAM TABLES August, 2006 5-146 August, 2006 SERVICE PROGRAM TABLES 5-147 Page August, 2006 SERVICE PROGRAM TABLES 5-149 SERVICE PROGRAM TABLES August, 2006 5-150 Group 8000 SERVICE PROGRAM TABLES August, 2006 5-152 August, 2006 SERVICE PROGRAM TABLES 5-153 SERVICE PROGRAM TABLES August, 2006 5-154 Page Page Page SERVICE PROGRAM TABLES August, 2006 5-158 Page Page Page Page Page Page August, 2006 SERVICE PROGRAM TABLES 5-165 SERVICE PROGRAM TABLES August, 2006 5-166 Erase> Border Erase> Center Image Repeat Centering Positive/Negative August, 2006 SERVICE PROGRAM TABLES 5-167 Page August, 2006 SERVICE PROGRAM TABLES 5-169 Print jobs done with Web Image Monitor and Desk Top Binder are added to the L: count. SERVICE PROGRAM TABLES August, 2006 5-170 August, 2006 SERVICE PROGRAM TABLES 5-171 SERVICE PROGRAM TABLES August, 2006 5-172 These counters do not distinguish between LEF and SEF. August, 2006 SERVICE PROGRAM TABLES 5-173 During duplex printing, pages printed on both sides count as 1, Page Page Page August, 2006 SERVICE PROGRAM TABLES 5-177 SERVICE PROGRAM TABLES August, 2006 5-178 Page Page August, 2006 SERVICE PROGRAM TABLES 5-181 SERVICE PROGRAM TABLES August, 2006 5-182 August, 2006 SERVICE PROGRAM TABLES 5-183 SERVICE PROGRAM TABLES August, 2006 5-184 Page Group 9000 IMPOTANT: SERVICE PROGRAM TABLES August, 2006 5-188 5.5.3 PRINTER SERVICE TABLE Group 1 (Printer) Disp. Version August, 2006 SERVICE PROGRAM TABLES 5-189 5.5.4 SCANNER SERVICE TABLE Group 1 (Scanner) Group 2 (Scanner) August, 2006 COPIER INPUT/OUTPUT CHECK 5-191 5.6 COPIER INPUT/OUTPUT CHECK 5.6.1 COPIER INPUT CHECK: SP5803 Bit 7 6 5 4 3 2 1 0 Setting 1 1 0 0 1 0 1 0 003 Paper Feed 3 Paper Size Table: 002, 003 004 Paper Feed 4 Paper Height, Near End: 004 August, 2006 COPIER INPUT/OUTPUT CHECK 005: Paper Feed 5 006: Paper Feed 6 007: Paper Feed 7 008: Paper Feed 8 COPIER INPUT/OUTPUT CHECK August, 2006 009: Used Toner Trans 010: Paper Trans 1 011: Paper Trans 2 012: Paper Trans 3 013: Paper Trans 4 Paper Size Table: 013 (Trays 1 to 3, Bit 7 to 4) Paper Size Table: 013 (Bypass Tray Bit 3) 014: Drum Mtr Lock 015: PCU Motor Lock 016: Other Motor Lock 017: Fan System 1 018: Fan System 2 019: Fan System 3 020: Hi Volt SC1 (Drum Charge Power Pack) 021: Hi Volt SC2 (Development Bias Power Pack) 022: Hi Volt SC3 (Transfer Power Pack, Separation Power Pack) 023: Paper Transfer Bit Table: 023 024: Toner Supply 025: Fusing Temp Detect 026: Set Detection 027: Door 028: Peltier Unit 201: DIP Switches 5.6.2 COPIER OUTPUT CHECK: SP5804 NOTE: August, 2006 COPIER INPUT/OUTPUT CHECK 5-201 NOTE: ARDF INPUT/OUTPUT CHECK August, 2006 5-202 5.7 ARDF INPUT/OUTPUT CHECK 5.7.1 ADF INPUT CHECK: SP6007 Bit 7 6 5 4 3 2 1 0 Data 1 1 0 0 1 0 1 0 5.7.2 ADF OUTPUT CHECK: SP6008 FINISHER 1 (B700/B701) INPUT/OUTPUT CHECK August, 2006 5-204 5.8 FINISHER 1 (B700/B701) INPUT/OUTPUT CHECK 5.8.1 INPUT CHECK: FINISHER 1 (B700/B701) SP6121 August, 2006 FINISHER 1 (B700/B701) INPUT/OUTPUT CHECK 5-205 5.8.2 OUTPUT CHECK FINISHER 1: (B700/B701) SP6123 FINISHER 2 (B706) INPUT/OUTPUT CHECK August, 2006 5-206 5.9 FINISHER 2 (B706) INPUT/OUTPUT CHECK 5.9.1 INPUT CHECK FINISHER 2: (B706) SP6122 August, 2006 FINISHER 2 (B706) INPUT/OUTPUT CHECK 5-207 5.9.2 OUTPUT CHECK FINISHER 2 (B706) SP6125 5.10 USING THE DEBUG LOG 5.10.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG Page Page 5.10.2 RETRIEVING THE DEBUG LOG FROM THE HDD 5.10.3 RECORDING ERRORS MANUALLY 5.10.4 NEW DEBUG LOG CODES SP5857-015 Copy SD Card-to-SD Card: Any Desired Key SP5857-016 Create a File on HDD to Store a Log SP5857-017 Create a File on SD Card to Store a Log 5.11 USER TOOLS 5.11.1 OVERVIEW August, 2006 USER TOOLS 5-215 5.11.2 SYSTEM SETTINGS Key press: [User Tools]> "System Settings" System Settings Map USER TOOLS August, 2006 5-216 System Settings Map (Continued) August, 2006 USER TOOLS 5-217 System Settings Map (Continued) 5.11.3 MAINTENANCE Key press: [User Tools]> "Maintenance" Maintenance Map USER TOOLS August, 2006 5-218 5.11.4 COPIER/DOCUMENT SERVER FEATURES Key press: [User Tools]> "Copier/Document Server Features" Copier/Document Server Features Map August, 2006 USER TOOLS 5-219 Copier/Document Server Features Map (Continued) USER TOOLS August, 2006 5-220 Copier/Document Server Features Map (Continued) August, 2006 USER TOOLS 5-221 5.11.5 PRINTER FEATURES Key press: [User Tools]> "Printer Features" Printer Features Map USER TOOLS August, 2006 5-222 Printer Features Map (Continued) August, 2006 USER TOOLS 5-223 5.11.6 SCANNER FEATURES Key press: [User Tools]> "Scanner Features" Scanner Features Map USER TOOLS August, 2006 5-224 5.11.7 INQUIRY Key press: [User Tools]> "Inquiry" 5.11.8 COUNTER 6. DETAILS 6.1 GENERAL OVERVIEW 6.1.1 MAIN MACHINE Page 6.1.2 PAPER PATH: COVER INTERPOSER TRAY 6.1.3 PAPER PATH: 9-BIN MAILBOX 6.1.4 DRIVE LAYOUT Page 6.2.2 COMPONENT DESCRIPTIONS Page 6.2.3 CONTROLLER BOX VENTILATION 6.3 COPY PROCESS OVERVIEW K M C Y K Page 6.4 ARDF 6.4.1 OVERVIEW 6.4.2 ARDF ELECTRICAL COMPONENTS Components View 1: Sensors Components View 2: Motors, Sensors, Other ARDF Components View 3: Drive Motors 6.4.3 ORIGINAL SIZE DETECTION R ARDF August, 2006 6-18 Original Size Detection Table x x Page 6.4.4 PICK-UP ROLLER 6.4.5 BOTTOM PLATE LIFT 6.4.6 ORIGINAL FEED AND SEPARATION 6.4.7 ORIGINAL FEED AND SKEW CORRECTION 6.4.8 SLIP DETECTION 6.4.9 ORIGINAL TRANSPORT (ONE-SIDED) Page Page 6.4.11 ARDF JAM DETECTION Jam Detection Sensor Layout Jam Detection Table 6.5 SCANNER UNIT 6.5.1 OVERVIEW 6.5.2 ORIGINAL SIZE DETECTION Page Detection Timing 6.5.3 SCANNER DRIVE 6.5.4 SCANNER UNIT FANS AND ANTI-CONDENSATION HEATER 6.5.5 DUST DETECTION What Happens if Dust is Detected? How is the Dust Detected? The Effects of SP Mode Settings on Dust Detection IMAGE PROCESSING August, 2006 6-40 6.6 IMAGE PROCESSING LIBRA ORION DFID ARIES XDF_FGATE 6.6.2 SBU (SENSOR BOARD UNIT) SBU Operation Summary Storing Operation Settings SBU Test Mode 6.6.3 IPU (IMAGE PROCESSING UNIT) 6.7 LASER UNIT 6.7.1 OVERVIEW KMCY 6.7.2 LD UNIT Dual Beam Writing LD Safety Switches 6.7.3 OPTICAL PATHS K M C Y Optical Path 6.7.4 IMAGE POSITION CORRECTION (MUSIC) What does MUSIC do? When is MUSIC done? Location of the MUSIC Sensors How is MUSIC Done? Page 3rd Mirror Position Adjustment Exposure Unit Temperature Sensors 6.8 PHOTOCONDUCTOR UNITS (PCU) K 6.8.1 OVERVIEW OF TANDEM PCU M C Y 6.8.2 AROUND THE DRUM Drum Drive Drum Charge Drum Cleaning Drum Ventilation Page Ozone Ventilation 6.8.3 DEVELOPMENT UNIT Development Unit Operation Development, PCU Drive 6.9 TONER SUPPLY 6.9.1 OVERVIEW Page 6.9.2 TONER SUPPLY MECHANISM 6.9.3 TONER CARTRIDGE Page 6.9.4 TONER END SENSORS Toner near-end Toner end Toner End Recovery Page PCU (Y) PCU (C) PCU (M) PCU (K) ITB Unit PTR Unit 6.10.2 WASTE TONER UNIT MOTORS 6.10.3 WASTE TONER COLLECTION UNIT SENSORS Waste Toner Bottle Set Sensor Waste Toner Bottle Near-Full Sensor Waste Toner Bottle Full Sensor Waste Toner Lock Sensor Waste Toner Transport Motor 6.11 PROCESS CONTROL 6.11.1 OVERVIEW 6.11.2 COMPONENTS USED DURING PROCESS CONTROL Potential Sensor ID Sensors Page TD Sensor Temperature/Humidity Sensors PROCESS CONTROL August 2006 6-80 List of Process Control Acronyms August 2006 PROCESS CONTROL 6-81 Important SP Codes Related to Process Control 6.11.3 POTENTIAL CONTROL When is Potential Control Done? August 2006 PROCESS CONTROL 6-83 What is Done During Potential Control? B132D988.WMF Page Page 6.11.4 TONER SUPPLY CONTROL YC M K August 2006 PROCESS CONTROL 6-89 Toner Supply Operation Flow Page Interval Process Control (SP3042 001 Vtref Calibration Mode ON) Toner Supply Control Method: PID Control B132D921.WMF 6.12 IMAG E TRANSF ER AND PAPER TRANSFER 6.12.1 OVERVIEW Page Page 6.12.2 ITB DRIVE 6.12.3 ITB LIFT Page Page 6.12.5 PAPER TRANSFER AND SEPARATION 6.12.6 PTR CLEANING 6.12.7 ITB CLEANING 6.12.8 ITB SPEED CONTROL 6.12.9 ITB VENTILATION 6.13 PAPER FEED 6.13.1 OVERVIEW Page 6.13.2 DRIVE 6.13.3 TRAY AND PAPER LIFT MECHANISM TRAY 2,3 Bottom Plate Lift Lift Sensor 6.13.4 PAPER FEED AND SEPARATION MECHANISM Feed and Separation at Standby: No Paper Present Paper Feed and Separation Separation Roller Release Mechanism 6.13.5 PAPER NEAR-END AND PAPER END TRAYS 2 AND 3 6.13.6 PAPER SIZE DETECTION Tandem Tray (Tray 1) Universal Trays (Tray 2, 3) PAPER FEED August 2006 6-112 Paper Size Switch Output 6.13.7 PAPER TRAY HEATERS 6.13.8 TANDEM TRAY TRAY 1 Connecting the Left and Right Sides of the Tray Paper Lift/Remaining Paper Detection Page Fence Drive Rear Fence Drive Tray Side-to-side Positioning 6.13.9 TRAY POSITIONING MECHANISM TRAYS 1 TO 3 6.13.10 BYPASS TRAY Bypass Feed and Separation Bypass Tray Paper End Detection Bypass Paper Size Detection Page 6.13.11 PAPER REGISTRATION Paper Registration Drive Jam Removal at Paper Registration 6.13.12 PAPER TYPE AND DOUBLE-FEED DETECTION Page Page 6.14 FUSING, PAPER EXIT 6.14.1 OVERVIEW Page 6.15 THERMISTORS, THERMOSTATS 6.15.1 FUSING UNIT DRIVE 6.15.2 LUBRICATION AND CLEANING Stripper Retraction 6.15.3 FUSING TEMPERATURE CONTROL Basic Temperature Control August 2006 THERMISTORS, THERMOSTATS 6-139 Temperature Control Graph This table shows how temperature control is done in the different operation modes. Correction for Machine Internal Temperature Copy Speed Reduction (CPM Down Mode) 6.15.4 FUSING UNIT VENTILATION 6.16 DUPLEX UNIT 6.16.1 OVERVIEW 6.16.2 DUPLEX DRIVE 6.16.3 INVERTER OPERATION Inverter Feed-in and Jogging Inverter Feed-out 6.16.4 DUPLEX TRAY FEED 6.16.5 DUPLEX INTERLEAVE FEED Page 6.16.6 DUPLEX UNIT VENTILATION 6.17 PAPER EXIT 6.17.2 DE-CURL MECHANISM 6.17.3 PAPER EXIT COOLING August 2006 PAPER EXIT 6-153 6.17.4 ENERGY SAVER MODES Low Power Mode Stand-by Mode Auto Off Mode (Sleep Mode, if printer/scanner installed) Page Page Page Page Page 2. REPLACEMENT AND ADJUSTMENT 2.1 BOTTOM PLATE LIFT WIRE REPLACEMENT Page 3. DETAILED DESCRIPTIONS 3.1 SECTIONAL DESCRIPTION LCT (LARGE CAPACITY TRAY) (Machine Code: B473) 1. REPLACEMENT AND ADJUSTMENT................................. B473-1 2. DETAILS............................................................................... B473-7 Page 1.1 EXTERNAL COVERS 1.2 PICK-UP/FEED/SEPARATION ROLLERS 1.3 PICK-UP SOLENOID 1.4 PAPER END SENSOR, UPPER COVER SWITCHES 1.5 TRAY MOTOR 1.6 PAPER STACK SENSOR 1.7 PAPER SIZE ADJUSTMENT 2.1.1 LCT MAIN COMPONENTS Page 2.1.2 LCT DRIVE LAYOUT 2.2 PAPER FEED AND SEPARATION 2.2.1 STARTING PAPER FEED 2.2.2 FEED AND SEPARATION 2.3 PAPER LIFT Page 2.4 PAPER HEIGHT DETECTION 2.5 PAPER END DETECTION Page 2000/3000-SHEET FINISHER (Machine Code: B700/B701) 1. REPLACEMENT AND ADJUSTMENT................................. B700-1 2. DETAILS............................................................................. B700-24 Page Page 1. REPLACEMENT AND ADJUSTMENT 1.1 BASIC PROCEDURES 1.1.1 COVERS 1.1.2 UPPER TRAY, END FENCE Page 1.2 UPPER TRAY LIMIT SENSOR, UPPER TRAY LIMIT SWITCH 1.3 POSITIONING ROLLER 1.4 PROOF TRAY EXIT SENSOR 1.5 UPPER TRAY PAPER HEIGHT SENSORS 1, 2 1.6 EXIT GUIDE PLATE, UPPER TRAY EXIT SENSOR 1.7 PROOF TRAY FULL SENSOR 1.8 FINISHER ENTRANCE SENSOR 1.9 PRE-STACK TRAY EXIT SENSOR 1.10 FOLD UNIT EXIT SENSOR 1.11 FOLD ADJUSTMENTS (B700 ONLY) 1.11.1 FOLDING HORIZONTAL SKEW ADJUSTMENT Page Page 1.11.2 FOLD VERTICAL SKEW ADJUSTMENT 1.12 CORNER STAPLER 1.13 FOLD UNIT Page 1.14 FOLD UNIT ENTRANCE SENSOR 1.15 STACK PRESENT SENSOR 1.16 BOOKLET STAPLER, BOOKLET STAPLER MOTOR 1.16.1 BOOKLET STAPLER 1.16.2 BOOKLET STAPLER MOTOR 2. DETAILS 2.1 GENERAL LAYOUT Page 2.2 ELECTRICAL COMPONENTS 2.2.1 UPPER AREA B700/B701 2.2.2 LOWER AREA B700/B701 2.2.3 PUNCH UNIT B702 2.2.4 STACKER/STAPLER - B700/B701 2.2.5 B700 FOLD UNIT B700 only August 2006 ELECTRICAL COMPONENTS B700-31 2.2.6 SUMMARY OF ELECTRICAL COMPONENTS No. Component Function Boards (PCB) Motors ELECTRICAL COMPONENTS August 2006 B700-32 No. Component Function Sensors August 2006 ELECTRICAL COMPONENTS B700-33 ELECTRICAL COMPONENTS August 2006 B700-34 August 2006 ELECTRICAL COMPONENTS B700-35 No. Component Function Solenoids Switches 2.3 DRIVE LAYOUT 2.4 JUNCTION GATES Proof Mode Shift Mode Staple Mode 2.5 PRE-STACKING Page 2.6 UPPER TRAY Tray Full 2.7 LOWER TRAY (B700 ONLY) Full 1 Full 2 Page 2.8 CORNER STAPLING 2.8.1 STACKING AND JOGGING Page 2.8.2 STAPLER MOVEMENT Page 2.8.3 CORNER STAPLING 2.9 BOOKLET STAPLING (B700 ONLY) 2.9.1 BOOKLET PRESSURE MECHANISM 2.9.2 BOOKLET STAPLING AND FOLDING 1 2 3 1 2 3 4 5 6 4 5 6 7 8 9 7 8 9 10 11 12 10 11 12 13 14 15 13 14 15 Booklet Stapling and Folding Mechanisms Page Page 2.10 UPPER TRAY OUTPUT 2.10.1 FEED OUT Page 2.10.2 FEED OUT STACKING 2.11 PUNCH UNIT B702 (FOR B700/B701) Using the result of the position calculation, the punch unit control board moves The feed rollers [G] feed the punched paper out of the punch unit and into the Page 2.11.2 PUNCH MECHANISMS Paper Position Detection Punch Unit Movement Punch Selection and Firing 2.11.3 PUNCH HOPPER MECHANISM August 2006 FINISHER JAM DETECTION B700-69 2.12 FINISHER JAM DETECTION FINISHER JAM DETECTION August 2006 B700-70 Page 1. REPLACEMENT AND ADJUSTMENT................................. B704-1 2. DETAILS............................................................................... B704-8 1.1 EXTERNAL COVERS 1.2 FEED UNIT AND PICK-UP ROLLER 1.3 FEED BELT 1.4 GUIDE PLATE ADJUSTMENT 1.5 MAIN BOARD 1.6 MOTOR REPLACEMENT 1.6.1 VERTICAL TRANSPORT MOTOR 1.6.2 BOTTOM PLATE LIFT MOTOR 1.6.3 FEED MOTOR, TRANSPORT MOTOR 2.1.1 MAIN LAYOUT 2.1.2 DRIVE LAYOUT OVERVIEW September 2006 B704-10 2.1.3 PAPER SIZE DETECTION 06/09 September 2006 OVERVIEW B704-11 The table below lists the sensor output for each paper size. 06/09 Page 2.1.4 PAPER PATH 2.2 PAPER FEED Power On Paper Separation and Feed Bottom Tray Lift Paper Near-end 3000-SHEET FINISHER (Machine Code: B706) Page 6. DETAILS............................................................................. B706-33 7. OVERALL MACHINE INFORMATION................................ B706-52 Page Page 2. PREVENTIVE MAINTENANCE 3. REPLACEMENT AND ADJUSTMENT 3.1 DOOR AND COVER REPLACEMENT Front Door Left Inner Cover Inner Cover Side Table and Upper Tray Left Covers Rear Cover and Top Cover Shift Tray 3.2 ROLLERS 3.2.1 SHIFT POSITIONING ROLLER 3.2.2 POSITIONING ROLLER 3.2.3 ALIGNMENT BRUSH ROLLER 3.3 STACK FEED-OUT BELT 3.4 JOGGER FENCE 3.5 SENSORS 3.5.1 STACK HEIGHT 1, 2 AND EXIT GUIDE OPEN SENSOR Stack Height Sensors 1 and 2 Exit Guide Open Sensor 3.5.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR Upper Tray Paper Limit Sensor Upper Tray Exit Sensor 3.5.3 SHIFT TRAY EXIT SENSOR 3.5.4 ENTRANCE AND STAPLER TRAY ENTRANCE SENSORS Entrance Sensor Stapler Tray Entrance Sensor 3.5.5 PRE-STACK PAPER SENSOR 3.5.6 STAPLE WASTE HOPPER SENSOR 3.5.7 STAPLER ROTATION HP AND STAPLER RETURN SENSORS 3.6 STAPLER 3.7 SHIFT TRAY MOTOR 3.7.1 STACKING ROLLE / ROLLER DRAG MOTORS, RETURN HP SENSOR Page Page 3.8 Z-FOLD JOGGER UNIT 3.8.1 Z-FOLD JOGGER UNIT COVER 3.8.2 Z-FOLD JOGGER UNIT 3.8.3 JOGGER TOP FENCE MOTOR Page 3.9 PUNCH UNIT (B531) 3.9.1 PUNCH POSITION ADJUSTMENT Front to Rear Adjustment Right to Left Adjustment 3.10 JOGGER UNIT (B513) 3.10.1 JOGGER UNIT 3.10.2 JOGGER UNIT PCB 3.10.3 JOGGER UNIT MOTOR 4. TROUBLESHOOTING 5. SERVICE TABLES 5.1 DIP SWITCHES 5.2 TEST POINTS 5.3 FUSES 6. DETAILS 6.1 TRAY AND STAPLER JUNCTION GATE 6.2 PAPER PRE-STACKING 6.3 JOGGER UNIT PAPER POSITIONING 6.4 STAPLER UNIT MOVEMENT Side-to-Side Rotation (1) Rotation (2) 6.5 STAPLER Page 6.6 FEED-OUT 6.7 PAPER EXIT STACKING 6.8 SHIFT TRAY 6.8.1 OVERVIEW Stand-by Mode 6.8.2 SHIFT TRAY UP/DOWN MOVEMENT Sort/Stack Mode (Shift Mode) Staple Mode 6.8.3 SHIFT TRAY LOWER LIMIT DETECTION 6.9 SHIFT TRAY SIDE-TO-SIDE MOVEMENT 6.10 STAPLING Z-FOLDED PAPER 6.11 JAM CONDITIONS 6.12 PUNCH UNIT (B531) 6.12.1 PUNCH UNIT DRIVE 6.12.2 PUNCH WASTE COLLECTION 6.13 JOGGER UNIT (B513) 6.13.1 JOGGER UNIT MECHANICAL LAYOUT 6.13.2 JOGGER UNIT DRIVE 7. OVERALL MACHINE INFORMATION 7.1 MECHANICAL COMPONENT LAYOUT September 2006 OVERALL MACHINE INFORMATION B706-53 7.2 ELECTRICAL COMPONENT DESCRIPTION OVERALL MACHINE INFORMATION September 2006 B706-54 Page 7.3 DRIVE LAYOUT 9-BIN MAILBOX (Machine Code: B762) 1. REPLACEMENT AND ADJUSTMENT................................. B762-1 2. DETAILS............................................................................... B762-4 Page 1.1 COVERS AND TRAYS 1.2 SENSORS 1.3 MAIN MOTOR AND CONTROL BOARD 2.1.1 MAIN COMPONENT LAYOUT 2.1.2 DRIVE LAYOUT 2.1.3 PAPER PATH 2.2 BASIC OPERATION 2.2.1 PAPER PATH 2.3 OVERFLOW DETECTION 2.3.1 OVERVIEW 2.3.2 DETECTION TIMING 2.4 PAPER MISFEED DETECTION TIMING 2.4.1 A4 SIDEWAYS (LEF) 1ST BIN TRAY 2.4.2 A4 SIDEWAYS (LEF) 2ND ~ 9TH BIN TRAY Page Page August, 2006 MainFrame Spec-1 SPECIFICATIONS 1. MAINFRAME 1.1 COPYING MainFrame August, 2006 Spec-2 August, 2006 MainFrame Spec-3 Paper Sizes Table Key MainFrame August, 2006 Spec-4 1.2 PRINTING August, 2006 MainFrame Spec-5 1.3 SCANNER ARDF August, 2006 Spec-6 2. ARDF 3. OPTIONAL PERIPHERALS 3.1 LARGE CAPACITY TRAY B473 3.2 8 X 14" / B4 PAPER SIZE TRAY B474 3.3 9-BIN MAILBOX B762 3.4 COVER INTERPOSER TRAY B704 August, 2006 Optional Peripherals Spec-9 3.5 3000-SHEET FINISHER B706 Note: *The capacity to be calculated with 80g/m2 or 20lb. Bond paper. Optional Peripherals August, 2006 Spec-10 3.6 PUNCH UNIT B531 August, 2006 Optional Peripherals Spec-11 3.7 3000-SHEET FINISHER B701 This finisher provides corner stapling only. Note: *The capacity to be calculated with 80g/m2 or 20lb. Bond paper. Optional Peripherals August, 2006 Spec-12 August, 2006 Optional Peripherals Spec-13 3.8 2000-SHEET FINISHER B700 Note: *The capacity to be calculated with 80g/m2 or 20lb. Bond paper. Optional Peripherals August, 2006 Spec-14 B700/B701 Paper Specifications August, 2006 Optional Peripherals Spec-15 3.9 PUNCH UNIT B702 3.10 A3/11" X 17" TRAY B331 3.11 COPY TRAY B756 4. MACHINE CONFIGURATION Machine Configuration August, 2006 Spec-18 4.1 ELECTRICAL COMPONENTS 4.1.1 COPIER August, 2006 Machine Configuration Spec-19 Machine Configuration August, 2006 Spec-20 August, 2006 Machine Configuration Spec-21 Machine Configuration August, 2006 Spec-22 August, 2006 Machine Configuration Spec-23 Machine Configuration August, 2006 Spec-24 August, 2006 Machine Configuration Spec-25 Machine Configuration August, 2006 Spec-26 August, 2006 Machine Configuration Spec-27 Machine Configuration August, 2006 Spec-28 August, 2006 Machine Configuration Spec-29 Machine Configuration August, 2006 Spec-30 August, 2006 Machine Configuration Spec-31 4.1.2 ARDF Machine Configuration August, 2006 Spec-32 APPENDIX Page Page Page Page e-STUDIO4500c/5500c ELECTRICAL COMPONENT LAYOUT (1/3) e-STUDIO4500c/5500c ELECTRICAL COMPONENT LAYOUT (2/3) e-STUDIO4500c/5500c ELECTRICAL COMPONENT LAYOUT (3/3) Page Page Page Page S22 Door Safety DC Line Pulse Signal PCB 1 Main Board S21 S20 S19 S18 S17 S16 S15 S14 S13 S12 S11 S10 CN300 Solenoid 7 Solenoid 5 M A G C A ( MA R 6 OC P 3000-SHEET FINISHER (B706) POINT TO POINT DIAGRAM SYMBOL TABLE Signal Direction Active High Active Low Voltage[ ] ADF ELECTRICAL COMPONENT LAYOUT 23 567 10 11 d 03 2000/3000 SHEET FINISHER (B700/B701) ELECTRICAL COMPONENT LAYOUT (1/2) 2000/3000 SHEET FINISHER (B700/B701) ELECTRICAL COMPONENT LAYOUT (2/2) OUTPUT JOGGER UNIT (B703) ELECTRICAL COMPONENT LAYOUT MAILBOX (B762) ELECTRICAL COMPONENT LAYOUT COVER INTERPOSER (B704) ELECTRICAL COMPONENT LAYOUT LCT (B473) ELECTRICAL COMPONENT LAYOUT 3000-SHEET FINISHER (B706) ELECTRICAL COMPONENT LAYOUT