Model R-C4/R-C4.5 (Machine Code: B205/B209/D007/D008) SERVICE MANUAL

Transcription

1 Model R-C4/R-C4.5 (Machine Code: B205/B209/D007/D008) SERVICE MANUAL 21 July 2006 Subject to change

2 TABLE OF CONTENTS 1. INSTALLATION PROCEDURE INSTALLATION REQUIREMENTS ENVIRONMENT MACHINE LEVEL MINIMUM SPACE REQUIREMENTS POWER REQUIREMENTS COPIER INSTALLATION POWER SOCKETS FOR PERIPHERALS INSTALLATION FLOW CHART ACCESSORY CHECK INSTALLATION PROCEDURE Tapes and Retainers Developer Toner Bottle Emblem, Decals PAPER TRAY UNIT INSTALLATION ACCESSORY CHECK INSTALLATION PROCEDURE LCT INSTALLATION ACCESSORY CHECK INSTALLATION PROCEDURE ARDF INSTALLATION ACCESSORY CHECK INSTALLATION PROCEDURE INTERCHANGE UNIT INSTALLATION COMPONENT CHECK INSTALLATION PROCEDURE BIN TRAY UNIT INSTALLATION COMPONENT CHECK INSTALLATION PROCEDURE SHIFT TRAY COMPONENT CHECK INSTALLATION PROCEDURE BY-PASS FEED UNIT INSTALLATION COMPONENTS CHECK INSTALLATION PROCEDURE DUPLEX UNIT INSTALLATION ACCESSORY CHECK INSTALLATION PROCEDURE BRIDGE UNIT INSTALLATION ACCESSORY CHECK INSTALLATION PROCEDURE i

3 SHEET FINISHER INSTALLATION ACCESSORY CHECK INSTALLATION PROCEDURE SHEET FINISHER (B442) INSTALLATION ACCESSORY CHECK INSTALLATION PROCEDURE PLATEN COVER (B406) KEY COUNTER OPTICS ANTI-CONDENSATION HEATER TRAY HEATER TRAY HEATER (OPTIONAL PAPER TRAY UNIT) TRAY HEATER (OPTIONAL LCT) COPY DATA SECURITY UNIT (B770) HDD (B773) DATA OVERWRITE SECURITY UNIT (B735) Before You Begin Seal Check and Removal Installation PREVENTIVE MAINTENANCE SCHEDULE PM TABLE MAIN MOTOR DRIVE GEAR REPLACEMENT AND ADJUSTMENT SPECIAL TOOLS AND LUBRICANTS SPECIAL TOOLS LUBRICANTS GENERAL CAUTIONS PCU (PHOTOCONDUCTOR UNIT) TRANSFER ROLLER UNIT SCANNER UNIT LASER UNIT FUSING UNIT PAPER FEED OTHERS SCANNER UNIT EXPOSURE GLASS SCANNER EXTERIOR/OPERATION PANEL LENS BLOCK ASSEMBLY ORIGINAL SIZE SENSORS EXPOSURE LAMP SCANNER MOTOR/LAMP STABILIZER SCANNER WIRES LASER UNIT CAUTION DECAL LOCATIONS LASER UNIT POLYGON MIRROR MOTOR LD UNIT LASER SYNCHRONIZATION DETECTOR ii

4 3.7 PHOTOCONDUCTOR UNIT (PCU) PCU REMOVAL PICK-OFF PAWLS OPC DRUM CHARGE ROLLER, CLEANING ROLLER CLEANING BLADE DEVELOPER AFTER REPLACEMENT OF PCU COMPONENTS TRANSFER UNIT TRANSFER ROLLER UNIT IMAGE DENSITY SENSOR FUSING/EXIT FUSING UNIT THERMISTORS THERMOSTATS HOT ROLLER AND FUSING LAMP PRESSURE ROLLER/CLEANING ROLLER PAPER EXIT SENSOR/PAPER OVERFLOW SENSOR PAPER FEED FEED ROLLER: TRAY FEED ROLLER: TRAY PAPER END SENSOR PAPER TRAY LIFT MOTORS REGISTRATION CLUTCH PAPER FEED CLUTCHES Lower Paper Feed Clutch Upper Paper Feed Clutch RELAY CLUTCHES PAPER SIZE DETECTOR REGISTRATION SENSOR RELAY SENSORS Upper Relay Sensor Lower Relay Sensor DUST COLLECTION BOX PCBS AND OTHER ITEMS CONTROLLER BOARD NVRAM SBCU BOARD POWER PACK MAIN MOTOR PSU IPU HDD Important Notes About HDD Replacement iii

5 3.12 COPY ADJUSTMENTS: PRINTING/SCANNING PRINTING Registration - Leading Edge/Side-to-Side Blank Margin Main Scan Magnification Parallelogram Image Adjustment SCANNING Registration: Platen Mode Magnification Standard White Density Adjustment ADF IMAGE ADJUSTMENT Registration Sub Scan Magnification TOUCH SCREEN CALIBRATION TROUBLESHOOTING SERVICE CALL CONDITIONS SUMMARY SC CODE DESCRIPTIONS SELF-DIAGNOSTIC MODE SELF-DIAGNOSTIC MODE AT POWER ON DETAILED SELF-DIAGNOSTIC MODE Executing Detailed Self-Diagnosis PAPER FEED TROUBLESHOOTING SKEWED IMAGE IMAGE PROBLEMS SKEWED, TRAPEZOID AND PARALLELOGRAM IMAGES Skewed Images Trapezoid Images Parallelogram Images CHECKING IMAGES WITH THE TRIMMING PATTERN CORRECTING THE IMAGES Correcting Skewed Images Correcting Trapezoid Images Correcting Parallelogram Images ELECTRICAL COMPONENT DEFECTS SENSORS SWITCHES BLOWN FUSE CONDITIONS iv

6 5. SERVICE TABLES SERVICE PROGRAM MODE SERVICE MODE LOCK/UNLOCK SERVICE PROGRAM MODE OPERATION Entering and Exiting SP mode SP Mode Button Summary Switching Between SP Mode and Copy Mode for Test Printing Selecting the Program Number SERVICE PROGRAM MODE TABLES SP1XXX: Feed SP2XXX: Drum SP4-XXX: Scanner SP5XXX: Mode SP6XXX: Peripherals SP7XXX: Data Log SP8-xxx: Data Log TEST PATTERN PRINTING (SP2902-3) INPUT CHECK Main Machine Input Check (SP5803) ARDF Input Check (SP6007) Finisher Input Check (SP6117) OUTPUT CHECK Main Machine Output Check (SP5804) ARDF Output Check (SP6008) Finisher Output Check (SP6118) SMC DATA LISTS (SP5990) MEMORY ALL CLEAR (SP5801) APS OUTPUT DISPLAY (SP4301) DF APS SENSOR OUTPUT DISPLAY (SP6901) NIP BAND WIDTH MEASUREMENT (SP1109) FIRMWARE UPDATE SOFTWARE RESET SYSTEM SETTINGS AND COPY SETTING RESET SYSTEM SETTING RESET COPIER SETTING RESET USER TOOLS HOW TO USE UP MODE UP Mode Initial Screen: User Tools/Counter Display System Settings Copier/Document Server Features Printer, Facsimile, Scanner Settings Inquiry Counter LEDS Controller SBCU v

7 5.7 DIP SWITCHES Controller SBCU USING THE DEBUG LOG SWITCHING ON AND SETTING UP SAVE DEBUG LOG RETRIEVING THE DEBUG LOG FROM THE HDD RECORDING ERRORS MANUALLY NEW DEBUG LOG CODES SP Copy SD Card-to-SD Card: Any Desired Key SP Create a File on HDD to Store a Log SP Create a File on SD Card to Store a Log DETAILS OVERVIEW MECHANICAL COMPONENTS PAPER PATH ELECTRICAL COMPONENT DESCRIPTIONS DRIVE LAYOUT BOARD STRUCTURE OVERVIEW CONTROLLER BOARD COPY PROCESS SCANNING OVERVIEW SCANNER DRIVE ORIGINAL SIZE DETECTION: PLATEN MODE IMAGE PROCESSING OVERVIEW SBU (SENSOR BOARD UNIT) AUTO IMAGE DENSITY ORIGINAL TYPE SETTINGS IPU (IMAGE PROCESSING UNIT) Overview Image Processing Path SP Modes for Each Image Processing Step Auto Shading Pre-Filtering Main Scan Magnification/Reduction Mirroring for ADF Mode Characteristic Detection Filtering Background Erase ID Gamma (g) Correction Gradation Processing Line width correction VIDEO CONTROL UNIT (GAVD) Fine Character and Image (FCI) vi

8 6.6 LASER EXPOSURE OVERVIEW AUTO POWER CONTROL (APC) LD SAFETY SWITCH PHOTOCONDUCTOR UNIT (PCU) OVERVIEW DRIVE DRUM CHARGE OVERVIEW CHARGE ROLLER VOLTAGE CORRECTION Correction for Environmental Conditions ID SENSOR PATTERN PRODUCTION TIMING DRUM CHARGE ROLLER CLEANING DEVELOPMENT OVERVIEW DRIVE DEVELOPER MIXING DEVELOPMENT BIAS TONER SUPPLY Toner bottle replenishment mechanism Toner supply mechanism TONER DENSITY CONTROL Overview Toner density sensor initial setting Toner density measurement Vsp/Vsg detection Toner supply reference voltage (Vref) determination Toner supply determination Toner Supply Motor On Time Determinations TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS ID sensor TD Sensor TONER NEAR END/END DETECTION AND RECOVERY Toner Near End Detection Toner Near End Recovery Toner End Detection Toner End Recovery DRUM CLEANING AND TONER RECYCLING DRUM CLEANING TONER RECYCLING vii

9 6.11 PAPER FEED OVERVIEW PAPER FEED DRIVE MECHANISM PAPER FEED AND SEPARATION MECHANISM PAPER LIFT MECHANISM PAPER END DETECTION PAPER HEIGHT DETECTION FEED PRESSURE ADJUSTMENT FOR PAPER SIZE Overview Paper Size Thresholds Feed Pressure Adjustment Effect of the Amount of Remaining Paper PAPER SIZE DETECTION SPECIAL PAPER SETTING SIDE AND END FENCES Side Fences End Fence PAPER REGISTRATION IMAGE TRANSFER AND PAPER SEPARATION OVERVIEW IMAGE TRANSFER CURRENT TIMING TRANSFER ROLLER CLEANING PAPER SEPARATION MECHANISM IMAGE FUSING AND PAPER EXIT OVERVIEW FUSING DRIVE AND RELEASE MECHANISM FUSING ENTRANCE GUIDE SHIFT MECHANISM PRESSURE ROLLER CLEANING MECHANISM FUSING TEMPERATURE CONTROL Temperature Control Fusing Lamp Control OVERHEAT PROTECTION PAPER EXIT ENERGY SAVER MODES OVERVIEW ENERGY SAVER MODE Entering the energy saver mode What happens in energy saver mode Return to stand-by mode AUTO OFF MODE Entering off stand-by and off modes Off Stand-by mode Off Mode Returning to stand-by mode viii

10 7. OVERALL MACHINE INFORMATION SPECIFICATIONS MACHINE CONFIGURATION SYSTEM COMPONENTS OPTIONS TABLE Copier options Fax option Printer/scanner options ix

11 21 July 2006 SERVICE CALL CONDITIONS 4. TROUBLESHOOTING 4.1 SERVICE CALL CONDITIONS SUMMARY There are 4 levels of service call conditions. Level Definition Reset Procedure To prevent damage to the machine, the main Enter SP mode, and then turn A machine cannot be operated until the SC has the main power switch off and been reset by a service representative (see the on. note below). B C D SCs that disable only the features that use the defective item. Although these SCs are not shown to the user under normal conditions, they are displayed on the operation panel only when the defective feature is selected. The SC history is updated. The machine can be operated as usual. Turning the main switch off then on resets SCs displayed on the operation panel. These are redisplayed if the error occurs again. Turn the operation switch or main switch off and on. The SC will not be displayed. Only the SC history is updated. Turn the operation switch off and on. When a Level D SC code occurs When a Level D SC occurs, a screen opens on the operation panel to tell the operator: An error occurred The job in progress will be erased The machine will reboot automatically after approximately 30 seconds. The operator can wait until the machine reboots automatically or touch Reset on the screen to reset the machine immediately and go back to the copy screen. If the operator does not touch Reset The next message tells the operator that the machine will reset automatically and that the previous job was lost and must be started again. After reading the message, the operator touches Confirm on the screen. The next screen shows the number and title of the SC code, and stops until the operator turns the machine off and on. If the operator touches Reset If the operator touches "Reset" to bypass the 30-second interval for the machine to reboot, the machine reboots immediately and the operation panel displays the copy screen. Important Do not try to use the operation panel during an automatic reboot. If the Remote Service System is in use, the SC code is sent immediately to the Service Center Troubleshooting 4-1

12 B205/B209/D007/D008 PARTS CATALOG MIU

13 B205/B209/D007/D008 TABLE OF CONTENTS B205/B209/D007/D008 PARTS LOCATION AND LIST LOCATION OF UNIT EXTERIOR 1 (B205/B209/D007/D008) EXTERIOR 2 (B205/B209/D007/D008) OPERATION PANEL (B205/B209/D007/D008) PLATEN COVER (OPTION B406) OPTICS SECTION 1 (B205/B209/D007/D008) OPTICS SECTION 2 (B205/B209/D007/D008) OPTICS SECTION 3 (B205/B209/D007/D008) LASER UNIT (B205/B209/D007/D008) TRANSFER UNIT (B205/B209/D007/D008) PAPER FEED SECTION 1 (B205/B209/D007/D008) PAPER FEED SECTION 2 (B205/B209/D007/D008) PAPER FEED SECTION 3 (B205/B209/D007/D008) TONER HOPPER UNIT (B205/B209/D007/D008) PAPER REGISTRATION (B205/B209/D007/D008) PAPER TRAY (B205/B209/D007/D008) PCU SECTION (B205/B209/D007/D008) FUSING UNIT 1 (B205/B209/D007/D008) FUSING UNIT 2 (B205/B209/D007/D008) PAPER EXIT (B205/B209/D007/D008) DRIVE SECTION 1 (B205/B209/D007/D008) DRIVE SECTION 2 (B205/B209/D007/D008) DRIVE SECTION 3 (B205/B209/D007/D008) DRIVE SECTION 4 (B205/B209/D007/D008) ELECTRICAL SECTION 1 (B205/B209/D007/D008) ELECTRICAL SECTION 2 (B205/B209/D007/D008) FRAME SECTION (B205/B209/D007/D008) SBCU BOARD (B205/B209/D007/D008) CONTROLLER BOARD (B205/B209/D007/D008) IPU BOARD (B205/B209/D007/D008) DECAL AND DOCUMENT (B205/B209/D007/D008) SPECIAL TOOLS (B205/B209/D007/D008) B205/B209/D007/D008 PARTS INDEX PARTS INDEX... 2 PAPER TRAY UNIT PS90 B390 PARTS LOCATION AND LIST 1.EXTERIOR (B390) PAPER TRAY (B390) PAPER FEED/TRANSFER (B390) ELECTRICAL SECTION1 1 (B390) ELECTRICAL SECTION1 2 (B390) ELECTRICAL SECTION1 3 (B390) DECALS AND DOCUMENTS (B390) PAPER TRAY UNIT PS90 B390 PARTS INDEX

14 LARGE CAPACITY TRAY PS500 B391 PARTS LOCATION AND LIST 1.EXTERIOR (B391) PAPER FEED SECTION (B391) TANDEM TRAY 1 (B391) TANDEM TRAY 2 (B391) TANDEM TRAY 3 (B391) DRIVE/ELECTRICAL SECTION (B391) DECALS AND DOCUMENTS (B391) LARGE CAPACITY TRAY PS500 B391 PARTS INDEX 1,000 SHEET FINISHER SR790 B408 PARTS LOCATION AND LIST 1.EXTERIOR (B408) TRANSPORT SECTION (B408) PAPER EXIT SECTION 1 (B408) PAPER EXIT SECTION 2 (B408) VERTICAL TRANSPORT (B408) STAPLE SECTION 1 (B408) STAPLE SECTION 2 (B408) STAPLE SECTION 3 (B408) SHIFT TRAY DRIVE (B408) DRIVE SECTION (B408) ELECTRICAL SECTION (B408) DECALS AND DOCUMENTS (B408) ,000 SHEET FINISHER SR790 B408 PARTS INDEX 1-BIN TRAY UNIT PT280 B413 PARTS LOCATION AND LIST 1.1 BIN TRAY (B413) BIN TRAY UNIT PT280 B413 PARTS INDEX DUPLEX UNIT AD420 B414 PARTS LOCATION AND LIST 1.DUPLEX UNIT 1 (B414) DUPLEX UNIT 2 (B414) DUPLEX UNIT 3 (B414)... 6 DUPLEX UNIT AD420 B414 PARTS INDEX BYPASS TRAY TYPE 1027 B415 PARTS LOCATION AND LIST 1.BYPASS TRAY 1 (B415) BYPASS TRAY 2 (B415)... 4 BYPASS TRAY TYPE 1027 B415 PARTS INDEX INTERCHANGE UNIT TYPE 1027 B416 PARTS LOCATION AND LIST 1.INTERCHANGE UNIT 1 (B416) INTERCHANGE UNIT 2 (B416)... 4 INTERCHANGE UNIT TYPE 1027 B416 PARTS INDEX

15 BRIDGE UNIT TYPE 1027 B417 PARTS LOCATION AND LIST 1.BRIDGE UNIT 1 (B417) BRIDGE UNIT 2 (B417) BRIDGE UNIT 3 (B417)... 6 BRIDGE UNIT TYPE 1027 B417 PARTS INDEX 500 SHEET FINISHER SR820 B442 PARTS LOCATION AND LIST 1.Exterior (B442) Shift Tray (B442) Drive Section (B442) Paper Exit Section (B442) Paper Feed Section (B442) Frame/Electrical Section (B442) SHEET FINISHER SR820 B442 PARTS INDEX PARTS INDEX... 2 INTERNAL SHIFT SORT TRAY TYPE 1027 B459 PARTS LOCATION AND LIST 1.INTERNAL SHIFT SORT TRAY TYPE1027 (B459) 2 INTERNAL SHIFT SORT TRAY TYPE 1027 B459 PARTS INDEX FILE FORMAT CONVERTER TYPE B/C B609 PARTS LOCATION AND LIST 1.File Format Converter (B609)... 2 FILE FORMAT CONVERTER TYPE B/C B609 PARTS INDEX PARTS INDEX... 2 IEEE1824 INTERFACE UNIT TYPE A B679 PARTS LOCATION AND LIST 1.IEEE1284 Interface Board (B679)... 2 IEEE1824 INTERFACE UNIT TYPE A B679 PARTS INDEX PARTS INDEX... 2 FAX OPTION TYPE 3030 B766 PARTS LOCATION AND LIST 1.FAX OPTION (B766) GWFCU3 BOARD (B766)... 4 FAX OPTION TYPE 3030 B766 PARTS INDEX PARTS INDEX... 2 PRINTER/SCANNER UNIT TYPE 3030 B846/B767 PARTS LOCATION AND LIST 1.PRINTER UNIT/PRINTER SCANNER UNIT (B846/B767)... 2 PRINTER/SCANNER UNIT TYPE 3030 B846/B767 PARTS INDEX PARTS INDEX... 2

16 G3 INTERFACE UNIT TYPE 3030 B768 PARTS LOCATION AND LIST 1.G3 INTERFACE UNIT (B768) SG3 BOARD (B768)... 4 G3 INTERFACE UNIT TYPE 3030 B768 PARTS INDEX PARTS INDEX... 2 AUTO REVERSE DOCUMENT FEEDER DF83 B810 PARTS LOCATION AND LIST 1.ARDF 1 (B810) ARDF 2 (B810) ARDF 3 (B810) ARDF 4 (B810) ARDF 5 (B810) ARDF 6 (B810) ARDF 7 (B810) DECALS AND DOCUMENTS (B810) PRINTER/SCANNER UNIT TYPE 3010/PRINTER UNIT TYPE 3010 D310/D313 PARTS LOCATION AND LIST 1.Printer Unit/Printer Scanner Unit (D313/D310)... 2 PRINTER/SCANNER UNIT TYPE 3010/PRINTER UNIT TYPE 3010 D310/D313 PARTS INDEX PARTS INDEX... 2 IEEE802.11b INTERFACE UNIT TYPE H G813-PARTS LOCATION AND LIST 1.IEEE802.11b (G813)... 2 IEEE802.11b INTERFACE UNIT TYPE H G813-PARTS INDEX PARTS INDEX... 2 AUTO REVERSE DOCUMENT FEEDER DF83 B810 PARTS INDEX BLUETOOTH INTERFACE UNIT TYPE 3245 B826 PARTS LOCATION AND LIST 1.Bluetooth Interface Unit (B826)... 2 BLUETOOTH INTERFACE UNIT TYPE 3245 B826 PARTS INDEX

17 LOCATIONS OF UNITS 1. EXTERIOR 1 (B205/B209/D007/D008) 2. EXTERIOR 2 (B205/B209/D007/D008) 3. OPERATION PANEL (B205/B209/D007/D008) See Page 9 4. PLATEN COVER (OPTION B406) See Page OPTICS SECTION 1 (B205/B209/D007/D008) See Page OPTICS SECTION 2 (B205/B209/D007/D008) See Page 15 See Page 17 See Page 19 B205/B209/D007/D008 3 Parts Location and

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