920_FS_ver 2.0.0 (1)

5.08

iceSERVICE MANUAL

200

Field Serv

Main body

PRO 920Ver. 2.0

SAFETY AND IMPORTANT WARNING ITEMSRead 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 using the copier. General

precautionElectric hazard High

temperature

:Prohibition when using the copier. General

prohibitionDo not touch with wet hand

Do not disassemble

:Direction when using the copier. General

instructionUnplug Ground/EarthS-1

SAFETY AND IMPORTANT WARNING ITEMS[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

Prohibited Actions

DANGER 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

Using parts not specified by KMBTS-2

SAFETY AND IMPORTANT WARNING ITEMS[2] POWER PLUG SELECTIONIn some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation of customer engineer (hereafter called the CE) to attach appropriate power plug or power cord set in order to connect the product to the supply.

Power Cord Set or Power Plug

WARNING Use power supply cord set which meets the following

criteria:- provided with a plug having configuration intended for

the connection to wall outlet appropriate for the prod-uct's rated voltage and current, and

- the plug has pin/terminal(s) for grounding, and- provided with three-conductor cable having enough cur-

rent capacity, and- the cord set meets regulatory requirements for the area.Use of inadequate cord set leads to fire or electric shock.

Attach power plug which meets the following criteria:- having configuration intended for the connection to wall

outlet appropriate for the product's rated voltage and current, and

- the plug has pin/terminal(s) for grounding, and- meets regulatory requirements for the area.Use of inadequate cord set leads to the product connect-ing to inadequate power supply (voltage, current capacity, grounding), and may result in fire or electric shock.

Conductors in the power cable must be connected to ter-minals of the plug according to the following order: Black or Brown: L (line) White or Light Blue: N (neutral) Green/Yellow: PE (earth)Wrong connection may cancel safeguards within the product, and results in fire or electric shock.

AC230V

AC208V 240VS-3

SAFETY AND IMPORTANT WARNING ITEMS[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICEKonica Minolta brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and 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

Connection to Power Supply

WARNING Check that mains voltage is as specified.

Connection to wrong voltage supply may result in fire or electric shock.

Connect power plug directly into wall outlet having same configuration as the plug.Use of an adapter leads to the product connecting to inadequate power supply (voltage, current capacity, grounding), and may result in fire or electric shock.If proper wall outlet is not available, advice the customer to contact qualified electrician for the installation.

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.

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.

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kwS-4

SAFETY AND IMPORTANT WARNING ITEMS 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.

Connection to Power Supply

WARNING

Power Plug and Cord

WARNING When using the power cord set (inlet type) that came with

this product, make sure the connector is securely inserted in the inlet of the product. When securing measure is provided, secure the cord with the fixture properly.If the power cord (inlet type) is not connected to the prod-uct 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.

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 or cord set (with plug and connec-tor on each end) specified by KMBT. Using the damaged power cord may result in fire or elec-tric shock.

Do not bundle or tie the power cord.Overheating may occur there, leading to a risk of fire.S-5

SAFETY AND IMPORTANT WARNING ITEMS 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.

Power Plug and Cord

WARNING

Wiring

WARNING 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.S-6

SAFETY AND IMPORTANT WARNING ITEMS2. Installation Requirements

Prohibited Installation Places

WARNING 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.

When not Using the Product for a long time

WARNING 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.

Ventilation

CAUTION 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 roomb. When taking a lot of copiesc. When using multiple products at the same time

Fixing

CAUTION Be sure to lock the caster stoppers.

In the case of an earthquake and so on, the product may slide, leading to a injury.S-7

SAFETY AND IMPORTANT WARNING ITEMSInspection before Servicing

CAUTION Before conducting an inspection, read all relevant docu-

mentation (service manual, technical notices, etc.) and proceed with the inspection following the prescribed pro-cedure in safety clothes, using only the prescribed tools. Do not make any adjustment not described in the docu-mentation.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.

Work Performed with the Product Powered On

WARNING 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.S-8

SAFETY AND IMPORTANT WARNING ITEMSSafety Checkpoints

WARNING 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.Current can leak, leading to a risk of electric shock or 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.

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.S-9

SAFETY AND IMPORTANT WARNING ITEMS 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.A risk of fire exists.

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.Current can leak, leading to a risk of electric shock or 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.

Safety Checkpoints

WARNING

Handling of Consumables

WARNING 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.S-10

SAFETY AND IMPORTANT WARNING ITEMS Never throw the used cartridge and toner into fire.You may be burned due to dust explosion.

Handling of Consumables

WARNING

Handling of Service Materials

CAUTION 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.A risk of fire exists.

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.A risk of fire exists.

When using any solvent, ventilate the room well.Breathing large quantities of organic solvents can lead to discomfort.S-11

SAFETY INFORMATIONThe Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin-istration implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products marketed in the United States.

This copier is certified as a "Class 1" laser product under the U.S.Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. Since radiation emit-ted inside this copier is completely confined within protective housings and external covers, the laser beam cannot escape during any phase of normal user operation.

SAFETY INFORMATIONIMPORTANT NOTICES-12

SAFETY INFORMATIONCaution labels shown below are attached in some areas on/in the machine.When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock.

For North America and Taiwan:

INDICATION OF WARNING ON THE MACHINE

57gap0e001naS-13

SAFETY INFORMATIONFor Europe:

57gap0e002naS-14

SAFETY INFORMATIONFor other areas:

57gap0e003naS-15

SAFETY INFORMATION57gap0e004na

This product employs a Class 3B Laser Diode that emits an invisible laser beam. The cover should not be opened when the power is turned on.S-16

SAFETY INFORMATIONCAUTION:

57gap0e005na

You may be burned or injured if you touch any area that you are advised by any caution label to keep yourself away from. Do not remove caution labels. And also, when the caution label is peeled off or soiled and cannot be seen clearly, replace it with a new caution label.S-17

MEASURES TO TAKE IN CASE OF AN ACCIDENT1. 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. For reports and measures concerning serious accidents, follow the regulations given in "Serious Accident Report/Follow-up Procedures."

MEASURES TO TAKE IN CASE OF AN ACCIDENTS-18

C-1

Composition of the service manualThis service manual consists of the following sections and chapters:

This section gives, as information for the CE to get a full understanding of the product, arough outline of the object and role of each function, the relationship between the electricalsystem and the mechanical system, and the timing of operation of each part.

This section gives, as information required by the CE at the site (or at the customer'spremise), a rough outline of the service schedule and its details, maintenance steps, theobject and role of each adjustment, error codes and supplementary information.

The details of items with an asterisk "*" are described only in the service manual ofthe main body.

OUTLINE: System configuration, product specifications, unit configuration, and paper path

COMPOSITION/OPERATION: Configuration of each unit, explanation of the operatingsystem, and explanation of the control system

OUTLINE: System configuration, and product specificationsMAINTENANCE: Service schedule *, maintenance steps,

list of service tools and directions for use *, firmware version up method *, and removal/reinstallation methods of major parts

ADJUSTMENT/SETTING: Utility mode *, Tech. Rep. mode *, security and mechani-cal adjustment

TROUBLESHOOTING*: List of jam codes, their causes, operation when a jamoccurs and its release method, and list of error codes,their causes, operation when a warning is issued and esti-mated abnormal parts.

APPENDIX*: Parts layout drawings, connector layout drawings, timingchart, overall layout drawing

C-2

Notation of the service manualA. Product nameIn this manual, each of the products is described as follows:

B. Brand nameThe company names and product names mentioned in this manual are the brand name orthe registered trademark of each company.

C. Electrical parts and signalsThose listed by way of example below are not exhaustive, but only some instances amongmany.

(1) IC board: Standard printer(2) bizhub PRO 920: Main body(3) PS-502 PostScript3 Option: PS3 Option(4) Microsoft Windows 95: Windows 95

Microsoft Windows 98: Windows 98Microsoft Windows Me: Windows MeMicrosoft Windows NT 4.0: Windows NT 4.0 or Windows NTMicrosoft Windows 2000: Windows 2000Microsoft Windows XP: Windows XPWhen the description is made in combination of the OS's mentioned above:

Windows 95/98/MeWindows NT 4.0/2000Windows NT/2000/XPWindows 95/98/Me/NT/2000/XP

Classification Load symbol Ex. of signal name Description

Sensor PS

IN

Sensor detection signalPSDoor PS1SIG102 PS

Solenoid SD24V Power to drive the solenoidDRV

Drive signalSOL

Clutch CL24V Power to drive the clutchDRV

Drive signalSOL

C-3

Motor M

24V Power to drive the motorCONT Drive signalDRV1

Drive signals of two kindsDRV2D1D2

Motor M

_U

Drive signals (control signals) of three kinds

_V_WDRV1DRV2DRV3D1

Drive signals (control signals) of four kindsMotor, phases A and B control signals

D2D3D4DRV ADRV ADRV BDRV BA/AB/BABBBCLK, PLL PLL control signalLCK, Lock, LD PLL lock signalFR Forward/reverse rotation signalEM, Lock, LCK, LD Motor lock abnormalityBLK Drive brake signalP/S Power/stopS/S

Operating load start/stop signalSSCW/CCW, F/R Rotational direction switching signalENB Effective signalTEMP_ER Motor temperature abnormality detection signal

Fan FM

24V Power to drive the fan motorCONT, DRIVE Drive signalHL Speed control signal (2 speeds)EM, Lock, LCK, FEM Detection signal

Others TH1.S, ANG Analog signal


C-4

GroundSG, S.GND, S_GND Signal groundPG, P.GND Power ground

Serial com-munication

DCD Data carrier detectionSIN Serial inputSOUT Serial outputDTR Data terminal operation availableGND Signal ground (earth)DSR, DSET Data set readyRTS Transmission request signalCTS Consent transmission signalRI Ring indicatorTXD Serial transmission dataRXD Serial reception data


Revision historyAfter publication of this service manual, the parts and mechanism may be subject to change forimprovement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine.

When any change has been made to the descriptions in the service manual, a revised version will beissued with a revision mark added as required.

Revision mark: To indicate clearly a section revised, show to the left of the revised section.

A number within represents the number of times the revision has been made.

To indicate clearly a section revised, show in the lower outside section of the correspond-ing page. A number within represents the number of times the revision has been made.

NOTERevision marks shown in a page are restricted only to the latest ones with the old ones deleted.

When a page revised in Ver. 2.0 has been changed in Ver. 3.0: The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.

When a page revised in Ver. 2.0 has not been changed in Ver. 3.0: The revision marks for Ver. 2.0 are left as they are.

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2005/08 2.0 Addition of FS-509 and correction of an error in writing

2005/06 1.0 Issue of the first edition

Date Service manual Ver. Revision mark Descriptions of revision

CONTENTSField Service Ver2.0 Aug.2005

biz

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b P

RO

92

0CONTENTS

bizhub PRO 920

OUTLINE1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MAINTENANCE3. PERIODIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Life value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1.1 Life value of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1.2 Life value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.3 Maintenance item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.3.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.3.3 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.3.4 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.3.5 PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.3.6 PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.3.7 ZU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.3.8 TU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.3.9 RC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.4 Replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.4.1 Periodically replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.4.2 Spot replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.5 Maintenance procedure of the external section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313.5.1 Replacing the ozone filter /1 and /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313.5.2 Cleaning the dust-proof filter /1, /2 and /3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.5.3 Replacing the dust-proof filter /1, /2 and /3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.6 Maintenance procedure of the write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.6.1 Cleaning the dust-proof glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.7 Maintenance procedure of the photo conductor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.7.1 Removing/reinstalling the photo conductor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.7.2 Cleaning/removing the drum fixing couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.7.3 Replacing the drum temperature sensor (TH5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423.7.4 Cleaning the toner control sensor board (TCSB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433.7.5 Replacing the drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443.7.6 Replacing the drum claw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463.7.7 Replacing the drum fixing spring/drum positioning collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.8 Maintenance procedure of the charge section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493.8.1 Replacing the charge unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493.8.2 Replacing the charge control plate, charge wire, vibration-proof rubber,

charge cleaning unit and C-clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503.8.3 Cleaning/replacing the charge back plate and the erase lamp (EL) . . . . . . . . . . . . . . . . . . . . . . 54

3.9 Maintenance procedure of the transfer/separation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553.9.1 Replacing the transfer/separation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551 i

CONTENTS Field Service Ver2.0 Aug.2005b

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203.9.2 Replacing the transfer/separation wire, transfer cleaning assembly, separation cleaning assembly, vibration-proof rubber and the C-clip . . . . . . . . . . . . . . . . . . . . 56

3.9.3 Replacing the transfer exposure lamp (TSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593.10 Maintenance procedure of the developing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3.10.1 Replacing the suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603.10.2 Replacing the developing unit and the developing suction assembly. . . . . . . . . . . . . . . . . . . . . 603.10.3 Replacing the developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623.10.4 Cleaning the developing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643.10.5 Cleaning the developing bias contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.11 Maintenance procedure of the toner supply section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.11.1 Cleaning of the toner bottle section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.11.2 Replacing the toner supply sleeves /1 and /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.12 Maintenance procedure of the cleaning and toner recycle section . . . . . . . . . . . . . . . . . . . . . . . . . . . 693.12.1 Cleaning the cleaning/toner recycle section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693.12.2 Replacing the cleaning blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713.12.3 Replacing the toner guide brush assembly, scattering prevention felt,

seal plates /Fr and /Rr, and the toner seal plate assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753.12.4 Replacing the cleaning gear /A, /B and the guide plate assembly . . . . . . . . . . . . . . . . . . . . . . . 81

3.13 Maintenance procedure of the paper feed section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 853.13.1 Cleaning the paper dust removing brush (Tray 1, 2, 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 853.13.2 Replacing the feed roller/pick-up roller (Trays 1, 2, 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 863.13.3 Replacing the separation roller (Trays 1, 2, 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 893.13.4 Replacing the paper feed clutch (CL3, CL5, CL7)/pre-registration clutch (CL4, CL6, CL8)

(Trays 1, 2, 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923.13.5 Replacing the pre-registration roller (Trays 1, 2, 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 943.13.6 Replacing the feed input gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

3.14 Maintenance procedure of the bypass tray section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 993.14.1 Replacing the feed roller/pick-up roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 993.14.2 Replacing the separation roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.15 Maintenance procedure of the vertical conveyance section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1063.15.1 Cleaning the paper dust removing brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1063.15.2 Replacing the vertical conveyance clutch /1 (CL9) and /2 (CL10) . . . . . . . . . . . . . . . . . . . . . . 1083.15.3 Replacing the conveyance roller /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103.15.4 Replacing the vertical conveyance roller /2 and /3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103.15.5 Cleaning the vertical conveyance sensor (PS53)/loop sensor (PS54). . . . . . . . . . . . . . . . . . . . 111

3.16 Maintenance procedure of the ADU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1123.16.1 Cleaning the registration sensor (PS44) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1123.16.2 Replacing the registration clutch (CL1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1133.16.3 Removing/reinstalling the registration section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1153.16.4 Replacing the registration roller/registration bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1173.16.5 Replacing the loop roller/ADU exit roller/pre-registration roller/

ADU pre-registration bearing/ADU pre-registration clutch (CL2) . . . . . . . . . . . . . . . . . . . . . . . 1183.16.6 Replacing the ADU pre-registration loop roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1223.16.7 Replacing the ADU reverse roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1263.16.8 Replacing the ADU conveyance roller /1, /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1303.16.9 Replacing the paper reverse/exit roller, /2, /3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1343.16.10 Replacing the paper reverse/exit entrance roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1373.16.11 Replacing the reverse/exit switching gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1393.16.12 Replacing the sensor actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

3.17 Maintenance procedure of the fusing section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1493.17.1 Removing/reinstalling the fusing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149ii


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03.17.2 Opening/closing the fusing unit /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1513.17.3 Replacing the cleaning web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1523.17.4 Replacing the fusing heater lamp /1 (L2) and /2 (L3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

3.17.5 Replacing the fusing roller /Up, the bearing /Up, the heat insulating sleeve /Up and the fusing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

3.17.6 Replacing the fusing roller /Lw assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1573.17.7 Removing/reinstalling the fusing heat roller assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1593.17.8 Replacing the fusing cleaning sheet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1623.17.9 Replacing the fusing heater lamp /3 (L4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1633.17.10 Replacing the fusing heat roller, the heat roller bearing and the heat insulating sleeve /Lw . . . 1653.17.11 Replacing the fusing claw /Lw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1663.17.12 Replacing the fusing claw /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1673.17.13 Replacing the fusing actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1683.17.14 Replacing the thermistor /2 (TH2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1693.17.15 Removing/reinstalling the thermistor /1 (TH1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1713.17.16 Replacing the thermistor /4 (TH4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1733.17.17 Removing/reinstalling the thermistor /3 (TH3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1753.17.18 Removing/reinstalling the thermostat /1 (TS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1773.17.19 Removing/reinstalling the thermostat /2 (TS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1793.17.20 Replacing the web motor (M16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

3.18 Maintenance procedure of the paper exit section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1833.18.1 Cleaning the paper exit roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

4. SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1844.1 Service material list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1844.2 Jig list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1854.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1874.4 Mail remote notification system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

4.4.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1884.4.2 Operating environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1884.4.3 Major functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1884.4.4 Initial setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1894.4.5 Usage of the mail remote notification system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1934.4.6 Mail sending. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

4.5 Machine setting data Import/Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1954.5.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

5. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1975.1 ISW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

5.1.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1975.1.2 Firmware data flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1985.1.3 Types of the Transfer mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

5.2 ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1995.2.1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1995.2.2 Installation of the ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2005.2.3 Usage of the ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2025.2.4 Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

5.3 Internet ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2165.3.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2165.3.2 Operating environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2165.3.3 Initial setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2165.3.4 Internet ISW using the Web Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222iii


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205.3.5 Internet ISW using the mail remote notification system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2235.3.6 Notes for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2245.3.7 Internet ISW using the operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

5.3.8 Authentication of the proxy server in the Internet ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2266. OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

6.1 Items not allowed to be disassembled and adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2286.1.1 Scanner section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2286.1.2 Writing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2316.1.3 Developing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2336.1.4 Transfer/separation charge unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

6.2 List of parts to be disassembled and reassembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2366.3 Disassembling/assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

6.3.1 Removing/reinstalling the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2376.3.2 Removing/reinstalling the left cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2386.3.3 Removing/reinstalling the right cover /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2396.3.4 Removing/reinstalling the right cover /Lw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2396.3.5 Removing/reinstalling the front door /Rt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2406.3.6 Removing/reinstalling the front door /Lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2416.3.7 Removing/reinstalling the original glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2426.3.8 Removing/reinstalling the upper cover /Lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2436.3.9 Removing/reinstalling the upper cover /Rr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2436.3.10 Removing/reinstalling the operation panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2446.3.11 Recovery of the circuit breaker (CBR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2456.3.12 Removing/reinstalling the CCD unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2466.3.13 Replacing the exposure lamp (L1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2496.3.14 Removing/reinstalling the exposure unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2506.3.15 Stretching of the scanner wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2526.3.16 Removing/reinstalling the write unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2556.3.17 Removing/reinstalling the toner supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2576.3.18 Removing/reinstalling the paper feed tray 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2596.3.19 Removing/reinstalling the paper feed tray 1, 2 lift wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2616.3.20 Removing/reinstalling the paper feed tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2636.3.21 Removing/reinstalling the paper feed tray 3 lift wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2656.3.22 Removing/reinstalling the ADU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2676.3.23 Removing/reinstalling the paper exit section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2706.3.24 Setting the rank while in replacing the fusing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

ADJUSTMENT/SETTING7. HOW TO USE THE ADJUSTMENT/SETTING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

7.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2738. UTILITY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

8.1 List of utility mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2749. LIST OF ADJUSTMENT ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27610.TECH. REP. MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

10.1 List of Tech. Rep. mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27810.2 Setting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

10.2.1 Start and exit Tech. Rep. mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28110.3 Machine Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

10.3.1 Tray adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28210.3.2 Regist line speed adjustment (magnification adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283iv


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010.3.3 Printer FD-Mag (magnification adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28510.3.4 Printer CD-Mag (magnification adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28610.3.5 Scanner (Orig. Glass) FD-Mag (magnification adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

10.3.6 Scanner (ADF) FD-Mag (magnification adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28810.3.7 Printer top margin adjustment (timing adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28910.3.8 Printer regist loop adjustment (timing adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29010.3.9 Printer pre-regist (timing adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29110.3.10 Lead edge margin selection (timing adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29210.3.11 Top image (original glass) (timing adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29310.3.12 Top image (ADF) (timing adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29410.3.13 Scanner (ADF) regist loop adjustment (timing adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . 29510.3.14 Printer left margin (centering adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29610.3.15 Scanner (Orig. glass) left image (centering adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29710.3.16 Scanner (ADF) left image (centering adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29810.3.17 Distortion correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29910.3.18 Non image area erase check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30010.3.19 ADF density adj. (ADF adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30110.3.20 ADF original size adjustment (ADF adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30210.3.21 ADF sensor sensitivity adjustment (ADF adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30310.3.22 ADF incline offset adjustment (ADF adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30410.3.23 Recall standard data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

10.4 Process adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30610.4.1 Auto high voltage adjustment (high voltage adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30610.4.2 HV adjustment (Charge) (high voltage adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30610.4.3 HV adjustment (Transfer) (high voltage adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30610.4.4 HV adjustment (Separation AC) (high voltage adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30610.4.5 HV adjustment (Separation DC) (high voltage adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30610.4.6 HV adjustment (Charging grid voltage) (high voltage adjustment) . . . . . . . . . . . . . . . . . . . . . . 30610.4.7 HV adjustment (Bias of development DC) (high voltage adjustment) . . . . . . . . . . . . . . . . . . . . 30610.4.8 Transfer guide confirm (high voltage adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30610.4.9 Blade setting mode (drum peculiarity adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30710.4.10 Auto drum potential adjustment (drum peculiarity adjustment) . . . . . . . . . . . . . . . . . . . . . . . . 30810.4.11 Auto maximum density adjustment (drum peculiarity adjustment) . . . . . . . . . . . . . . . . . . . . . . 30910.4.12 Auto laser diameter adjustment (drum peculiarity adjustment) . . . . . . . . . . . . . . . . . . . . . . . . 31010.4.13 LD offset adjustment (drum peculiarity adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31110.4.14 Auto gamma adjustment (1dot) (drum peculiarity adjustment). . . . . . . . . . . . . . . . . . . . . . . . . 31210.4.15 LD1 bias adjustment (drum peculiarity adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31210.4.16 LD2 bias adjustment (drum peculiarity adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31210.4.17 Cartridge installation mode (drum peculiarity adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31310.4.18 Drum sensitivity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31310.4.19 User specified paper setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31310.4.20 Recall standard data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

10.5 Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31510.5.1 PM count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31510.5.2 Counter/Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31710.5.3 Preset parts life counter (parts life counter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33010.5.4 Optional parts life counter (parts life counter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

10.6 Machine Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33810.6.1 I/O check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33810.6.2 Input check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338v


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2010.6.3 Output check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34610.6.4 Operations in the I/O check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

10.7 List output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

10.7.1 List output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35810.8 Test mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

10.8.1 Test pattern output mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36010.8.2 Test pattern density setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36710.8.3 Running mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

10.9 System input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36910.9.1 Software switch setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36910.9.2 Telephone No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39010.9.3 Serial No. input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39010.9.4 Install date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39110.9.5 Size setting (Tray 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

10.10 Firmware version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39210.11 CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393

10.11.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39310.11.2 Setup procedure of the CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39310.11.3 List of combinations of E-Mail CS Remote Care and Mail remote notification system . . . . . . . 39610.11.4 Detailed setup procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39710.11.5 Software SW setting for CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40110.11.6 Mail address setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40910.11.7 Modem First Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41110.11.8 Receiving the initial connection mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41210.11.9 Setup confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41210.11.10 Maintenance call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41310.11.11 Center call from manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41310.11.12 Confirm communication log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41410.11.13 Initialization of RAM for CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41410.11.14 Error code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41510.11.15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

10.12 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41710.13 Finisher adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417

10.13.1 Fold & Staple stopper adj. (FS-604) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41710.13.2 Half hold stopper adjustment (FS-604) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41810.13.3 Cover sheet tray size adjustment (PI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41810.13.4 Trimming stopper adjustment (TU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41910.13.5 Punch kit vertical position adjustment (PK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42010.13.6 Punch kit horizontal position adjustment (PK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42110.13.7 Punch unit vertical position adjustment (ZU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42210.13.8 Punch unit horizontal position adjustment (ZU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42310.13.9 Punch registration loop adjustment (ZU/PK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42410.13.10 Z-fold position adjustment (ZU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42510.13.11 Letter fold adjustment (FS-604) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42610.13.12 2 positions stapling pitch adjustment (FS-604) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42710.13.13 Fold and staple pitch adjustment (FS-604) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

10.14 Administrator setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42910.14.1 Administrator authentication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42910.14.2 Administrator password setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429

10.15 CE Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430vi


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010.15.1 CE authentication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43010.15.2 CE password setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

10.16 IP HDD format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

11.MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43211.1 Mis-centering adjustment of the trays 1, 2 and 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

11.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43211.2 Paper feed roller pressure adjustment of the trays 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433

11.2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43311.3 Lift tray horizontal adjustment of the trays 1, 2 and 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434

11.3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43411.4 Skew adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

11.4.1 Pre-registration roller skew adjustment of the trays 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . 43511.4.2 ADU rear face skew adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

11.5 Separation pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43711.5.1 Separation pressure adjustment of the tray1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43711.5.2 Separation pressure adjustment of the bypass tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

11.6 Paper feed height adjustment of the trays 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43911.6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

11.7 Pick-up release amount adjustment of the trays 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44211.7.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442

TROUBLESHOOTING12.JAM CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445

12.1 Jam code list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44513.MALFUNCTION CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

13.1 Malfunction code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

APPENDIX14.PARTS LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

14.1 Main body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50514.1.1 Switch/sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50514.1.2 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51514.1.3 Boards and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526

14.2 DF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53314.3 LU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53814.4 FS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53914.5 PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54314.6 PK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

14.6.1 PK-503/PK-504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54414.6.2 PK-505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

14.7 ZU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54514.8 TU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547

15.CONNECTOR LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54915.1 Main body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549

15.1.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54915.2 DF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557

15.2.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55715.3 LU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55815.4 FS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55915.5 PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5611 vii


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2015.6 PK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56215.7 ZU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56315.8 TU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564

15.8.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56416.TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565

16.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56516.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56716.3 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56916.4 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570

16.4.1 FS-509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57016.4.2 FS-604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571

16.5 PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57516.6 PK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57616.7 ZU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57716.8 TU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578

17.OVERALL WIRING DIAGRAM17.1 Main body 1/417.2 Main body 2/417.3 Main body 3/417.4 Main body 4/417.5 DF17.6 LU17.7 FS17.8 PI17.9 PK-503/50417.10 PK-50517.11 ZU17.12 TU

18.PAPER SETTING18.1 Paper type setting according to the paper brand18.2 Relationship between the optimum paper type and the control according to the paper brand

(U.S.A. paper)18.3 Relationship between the optimum paper type and the control according to the paper brand

(European paper)18.4 Conversion table of paper weightviii 1

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1. SYSTEM CONFIGURATIONField Service Ver2.0 Aug.2005 OUTLINE1. SYSTEM CONFIGURATION

A. System configuration

[1] Main body [11] FS self-contained puncher (PK-504: Swedish)

[2] Double sided original auto feeder (DF-606) [12] FS self-contained puncher (PK-505)

[3] Large volume paper feed tray (LU-403) [13] TU connection kit (MK-707)

[4][5]

Large volume paper feed tray (LU-404)Z-folding puncher (ZU-601: Swedish)

[14] Fore-edge trimming with large capacity stacker (TU-501)

[6] Z-folding puncher (ZU-602) [15] Image controller (IC-203)

[7] Torque limiter separation type sheet feeder (PI-501)

[16][17]

PostScript kit (PS-503)Key counter

[8][9]

Flat stapling finisher (FS-509)Stitch-and-fold finisher (FS-604)

[18] Toner recycle cut kit (RC-501 (bizhub PRO 920))

[10] FS self contained puncher (PK-503)

57gat1e001nb

[4]

[3]

[15][18]

[16]

[17]

[7]

[12]

[11]

[10]

[13]

[14]

[9]

[7]

[12]

[11]

[10]

[8]

[5]

[6]

[1][2]1 1

1. SYSTEM CONFIGURATION Field Service Ver2.0 Aug.2005b

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20B. Configuration for optional device connection

Note For machines equipped with ZU-601/602, the function of PK-503/504/505 is not available when PI-

501 is not equipped. Any combination other than those listed below is not available.

*1 Paper fed from PI-501 cannot be punched.*2 Paper fed from PI-501 is punched by PK-503/504/505. And paper fed from those other than PI-501 is

punched by ZU-601/602.

No. Combinations for finishing AC power to be connected to

1 FS-509/604

2 FS-509/604 PI-501

3 FS-509/604 PK-504/505

4 FS-604 TU-501 + MK-707

5 FS-509/604 PI-501 PK-503/504/505

6 FS-604 PI-501 TU-501 + MK-707 External (TU-501)

7 FS-604 PK-503/504/505

TU-501 + MK-707 External (TU-501)

8 FS-604 PI-501 PK-503/504/505

TU-501 + MK-707 External (TU-501)

9 ZU-601/602 FS-509/604

10 ZU-601/602 FS-509/604 PI-501*1

11 ZU-602 FS-604 TU-501 + MK-707 External (TU-501)

12 ZU-601*2 FS-509/604 PI-501 PK-504*2

13 ZU-602*2 FS-509/604 PI-501 PK-503/505*2

14 ZU-602 FS-604 PI-501*1 TU-501 + MK-707 External (TU-501)

15 ZU-601*2 FS-604 PI-501 PK-504*2 TU-501 + MK-707

External (TU-501)

16 ZU-602*2 FS-604 PI-501 PK-503/505*2 TU-501 + MK-707

External (TU-501)2 1

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2. PRODUCT SPECIFICATIONSField Service Ver2.0 Aug.20052. PRODUCT SPECIFICATIONS

A. Type

*1 LU-403 and LU-404 are optional.

B. Functions

Type Console type (floor-mounted type)

Copying method Indirect electrostatic method

Original stand Fixed

Original alignment Left rear standard

Photo conductor OPC

Sensitizing method Laser writing

Paper feed trays Three trays (1,000 sheets x 1, 500 sheets x 2, 20 lb: 80 g/m2)Bypass feed (150 sheet x 1, 20 lb: 80 g/m2)LU-403 (4,000 sheet x 1, 20 lb: 80 g/m2) *1LU-404 (4,000 sheet x 1, 20 lb: 80 g/m2) *1

Original Sheet, book, solid object

Max. original size A3 or 11 x 17

Copy size Trays 1, 2 and 3 Inch: 11 x 17, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 8.5 x 13, 8.25 x 13, 8.125 x 13.25, 8 x 13, 5.5 x 8.5, A3, B4, A4, A4R, B5, B5R, A5, wide size paper (up to 314 x 445 mm)Regular Tab paperCustom size paper (182 x 140 mm, minimum)

Metric: A3, B4, A4, A4R, B5, B5R, A5, 11 x 17, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 8.5 x 13, 8.25 x 13, 8.125 x 13.25, 8 x 13, 5.5 x 8.5, wide size paper (up to 314 x 445 mm)Regular Tab paperCustom size paper (182 x 140 mm, minimum)

Bypass feed Inch: 11 x 17, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 5.5 x 8.5, 5.5 x 8.5R, A3, B4, A4, A4R, B5, B5R, A5, A5R, B6R, wide size paper (up to 314 x 460 mm)Regular Tab paperCustom size paper (100 x 148 mm, minimum)

Metric: A3, B4, A4, A4R, B5, B5R, A5, A5R, B6R, 11 x 17, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 5.5 x 8.5, 5.5 x 8.5R, wide size paper (up to 314 x 460 mm)Regular Tab paperCustom size paper (100 x 148 mm, minimum)

ADU A3, B4, A4, A4R, B5, B5R, A5, B6R, 11 x 17, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 5.5 x 8.5, 5.5 x 8.5Rwide size paper (up to 314 x 460 mm)Custom size paper (100 x 140 mm, minimum)3

2. PRODUCT SPECIFICATIONS Field Service Ver2.0 Aug.2005b

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20C. Type of paper

*2 Recommended paperPlain paper Inch: Hammermill Tidal MP (75 g/m2)

Metric: Konica Minolta Profi (80 g/m2)Recycled paper Inch: Weyerhaueser Recycled Laser Copy (20lb)

Metric: Nautilaus (80 g/m2), Classic White (80 g/m2)*3 Recommended paper

Thick paper Inch: DomtarColor 65lb (176 g/m2), COUGAROOVER 65lb (176 g/m2), HM-Cover 65lb (176 g/m2), XeroxDisitalLaser 65lb (176 g/m2)

Metric: RDEREY200 (200 g/m2), RDEREY160 (160 g/m2), NEUOOLOROOPY (200 g/m2)XeroxColotech (200 g/m2), Xerox3R91798 (160 g/m2)

Thin paper Inch: Domter16lb, Docupaque16lbMetric: Clair Mail (60 g/m2)

Label paper Inch: AVERY 5160Metric: AVERY DSP24

OHP Inch: HP 92296TMetric: HP 92296T

*4 Label paper and blueprint master are loaded and fed one sheet at a time.

Magnification Fixed magnification Inch: x 1.000, x 2.000, x 1.545, x 1.294, x 1.214, x 0.785, x 0.772, x 0.647, x 0.500

Metric: x 1.000, x 2.000, x 1.414, x 1.224, x 1.154, x 0.866, x 0.816, x 0.707, x 0.500

Preset zoom setting 3 types

Zoom magnification x 0.250 to x 4.000 (at the step of 0.1%)

Vertical magnification x 0.250 to x 4.000 (at the step of 0.1%)

Horizontal magnifica-tion

x 0.250 to x 4.000 (at the step of 0.1%)

Warm-up time Less than 5 min. and 30 sec. (230V AC spec)

First copy out time Less than 3.1 sec.

Continuous copy speed 92 copies/min. (for A4/8.5 x 11)

Continuous copy count Up to 9,999 sheets

Original density selection Auto density selection, manual (9 steps), optional density (2 steps)

Resolution Scan 600 x 600 dpi

Write 600 x 600 dpi

Memory 256 MB (DRAM) + 10 GB (HDD)

Interface section RJ45 Ethernet, Serial port (RS232-C), Serial port (USB TypeB)

Plain paper *2 High quality paper, plain paper and recycled paper of 61 to 90 g/m2

Special paper *3 Bypass feed only

OHP film, label paper *4, blueprint master paper *4, Tab paper

All trays High quality paper of 50 to 60 g/m2 (thin paper)

High quality paper of 91 to 200 g/m2 (thick paper)4

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2. PRODUCT SPECIFICATIONSField Service Ver2.0 Aug.2005D. Maintenance

E. Machine data

F. Operating environment

Note The information herein may be subject to change for improvement without notice.

Maintenance Every 500,000 prints

Machine service life 30,000,000 prints or 5 years (whichever earlier)

Power source Inch: AC 208 to 240V 10%, 60 HzMetric: AC 230V 10%, 50 Hz

Maximum power consump-tion

Inch: 3,660 W or less (full option)Metric: 3,450 W or less (full option)

Weight Approx. 280 kg (including DF-606)

Dimensions Main body + DF-606 887 (W) x 780 (D) x 1,203 (H) mm

Main body + DF-606 + ZU-602 + LU-404 + FS-604 + MK-707 + TU-501

3,453 (W) x 780 (D) x 1,203 (H) mm

Temperature 10 to 30C

Humidity 10 to 80% RH (with no condensation)5

2. PRODUCT SPECIFICATIONS Field Service Ver2.0 Aug.2005b

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3. PERIODIC CHECKField Service Ver2.0 Aug.2005 MAINTENANCE3. PERIODIC CHECK

3.1 Life value

3.1.1 Life value of materials

3.1.2 Life valueThe life value is a value for the number of prints or a value for the drive time, whichever is earlier.The relationship between the driving time mentioned above and the actual number of prints has certain condi-tions. It is decided according to the amount of copy time and also idling time. Accordingly, the number of printscan vary substantially for the same amount of rotation time.

Reference: Relationship between the number of prints and the drive time250 hours drive at A4 continuous output of 9 sheets per job is equivalent to 1,000,000 prints.

Note Developer/drum replacement icon is generated only by print count or running time. The trigger

can be switched between print count and running time by setting of the DIPSW 15-7 in the Tech.Rep. mode.

Item No. of prints Driving time Definition of driving time

Drum 1,000,000 250h The time during which the drum is being driven. Idling time is included in this time period.

Developer 1,000,000 250h The time during which the developing roller is being driven. Idling time is included in this time period.7

3. PERIODIC CHECK Field Service Ver2.0 Aug.2005b

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203.2 Schedule

Guarantee period (5 years or 30,000,000 prints)

Service item x 10,000 prints No. of executions0 25 50 75 10

012

515

017

520

022

525

027

530

0 xxxxxxxxxx

2800

2825

2850

2875

2900

2925

2950

2975

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Maintenance 1Every 500,000 prints

z z z z z z xxxzxxx z z z z 59 times

Maintenance 2Every 1,000,000 prints

z z z xxxzxxx z z 29 times


z z xxxzxxx z 19 times


z xxxzxxx 9 times


xxxzxxx 6 times


xxxzxxx 4 times


xxxzxxx 2 times


xxxzxxx 1 time

DF Maintenance 1

Every 500,000 printsz z z z z z xxxzxxx z z z z 59 times


z xxxzxxx z 15 times


xxxzxxx 6 times

FS



LU






z xxxzxxx 9 times

PI Maintenance 1





z xxxzxxx 9 times

PK Maintenance 1


ZU




z xxxzxxx 9 times

TU




xxxzxxx z 7 times8

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3. PERIODIC CHECKField Service Ver2.0 Aug.20053.3 Maintenance item

Caution For cleaning of the tools used, be sure to use a vacuum cleaner appropriate for cleaning toner.

Note For the replacement procedure of periodically replaced parts, see "3.5 Maintenance procedure of

the external section" to "3.17 Maintenance procedure of the fusing section."

3.3.1 Main bodyA. Maintenance 1 (Every 500,000 prints)

No. Unit classification

Description Quantity Implementation classification MaterialsTools usedCleaning Check Lubrication Replacement

1 Preparations Image check z 2 Fusing

sectionSeparation claw/Up, /Lw cleaning

z Drum cleaner/clean-ing pad

Cleaning web 55VA-524* Fixing cleaning web

counter reset (in Tech. Rep. mode)

1 z

3 Photo con-ductor sec-tion

Photo conductor sec-tion cleaning

z Drum cleaner/clean-ing pad/blower brush/vacuum cleaner

Drum claw 57GA2919*

3 z

4 Cleaning/toner recycle section

Cleaning unit cleaning z Cleaning pad/blower brush/vacuum cleaner

Cleaning blade 57GA5601* Blade set mode (in

Tech. Rep. mode)

2 z

5 Charge section

Charge unit cleaning(Charge back plate and its circumference, and erase lamp (EL))

z Drum cleaner/clean-ing pad/blower brush

Charge wire 55VA2509*

2 z

Vibration-proof rubber 55VA2527*

2 z

Charge control plate 57GA2508*

1 z

Charge cleaning unit 55VA-255*

2 z 9

3. PERIODIC CHECK Field Service Ver2.0 Aug.2005b

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205 Charge section

C-clip 45AA2040*

2 z

6 Developing section

Developing unit clean-ing

z Drum cleaner/clean-ing pad/blower brush/vacuum cleaner

Suction filter 57GA3108*

1 z

Developing bias con-tact cleaning

z

7 Transfer/sep-aration sec-tion

Transfer/separation unit cleaning

z Drum cleaner/clean-ing pad/blower brush

Transfer/separation wire 55VA2613*

3 z

Transfer cleaning assembly 56GA-276*

1 z

Separation cleaning assembly /1 56GA-277*

1 z

Separation cleaning assembly /2 56GA-278*

1 z

Vibration-proof rubber 56AA1783*

3 z

C-clip 45AA2040*

3 z

8 Registration section

Paper dust removing brush /1, /2 cleaning

z Cleaning pad/blower brush/vacuum cleaner

Cleaning of each sen-sor


9 ADU/paper reverse sec-tion

Cleaning of each roller/conveyance section/reverse/exit guide plate


10 Paper exit section

Cleaning of the paper exit roller


11 Paper feed section

Paper dust removing brush cleaning



z Blower brush

12 Bypass tray section


z Cleaning pad/blower brush


Description Quantity Implementation classification MaterialsTools usedCleaning Check Lubrication Replacement10

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3. PERIODIC CHECKField Service Ver2.0 Aug.2005B. Maintenance 2 (Every 1,000,000 prints)

13 Vertical con-veyance sec-tion

Cleaning of the paper dust removing brush


14 Scanner section

Cleaning of the origi-nal/slit glass


Cleaning of each mir-rors and lens




15 Write section Cleaning of the dust-proof glass

z Blower brush/clean-ing pad

16 Main body Exterior/machine inter-nal cleaning


Cleaning of the dust-proof filters /1, /2, /3

z Vacuum cleaner

17 Toner supply section

Toner bottle section cleaning

z Cleaning pad

18 Final check Check of W.U.T z Check of the image and the paper through (including the vertical magnification and tim-ing adjustment)

z

PM count reset z


Description Quantity Implementation classification MaterialsTools usedCleaning Check Lubrication Replacement

1 Paper feed section

Pick-up roller 55VA-464*

2 z Actual replacement count: 300,000 feeds

Feed roller 55VA-463*

2 z

Separation roller 55VA-463*

2 z

Pick-up roller 55VA-484*

1 z Actual replacement count: 500,000 feeds

Feed roller 55VA-483*

920_FS_ver 2.0.0 (1)

Documents