konica minolta bizhub c6500 field service total manual

SERVICE MANUAL

2006.09

Ver. 1.0

Field Service

C6500C6500

iFIELD SERVICE TOTAL CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1IMPORTANT NOTICE ................................................................................................S-1DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1SAFETY WARNINGS .................................................................................................S-2

SAFETY INFORMATION ...............................................................................................S-13IMPORTANT NOTICE ..............................................................................................S-13INDICATION OF WARNING ON THE MACHINE .....................................................S-14

MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-16Legal restrictions on copying .......................................................................................... C-1Composition of the service manual ................................................................................. C-2Notation of the service manual ....................................................................................... C-3

bizhub PRO C6500OUTLINE ........................................................................................................................ 1

MAINTENANCE.............................................................................................................. 9

ADJUSTMENT/SETTING ........................................................................................... 227

TROUBLESHOOTING................................................................................................ 469

APPENDIX.................................................................................................................. 545

* For particulars, see the contents of the main body.

DF-609OUTLINE ........................................................................................................................ 1

MAINTENANCE.............................................................................................................. 3

ADJUSTMENT/SETTING ............................................................................................. 17

* For particulars, see the contents of DF-609.

PF-601/HT-504OUTLINE ........................................................................................................................ 1

MAINTENANCE.............................................................................................................. 3


* For particulars, see the contents of PF-601/HT-504.

LU-202/HT-503OUTLINE ........................................................................................................................ 1

MAINTENANCE.............................................................................................................. 3


* For particulars, see the contents of LU-202/HT-503.

RU-503/504OUTLINE ........................................................................................................................ 1

MAINTENANCE.............................................................................................................. 3

* For particulars, see the contents of RU-503/504.

ii

FD-501OUTLINE ........................................................................................................................ 1

MAINTENANCE ............................................................................................................. 5

ADJUSTMENT/SETTING............................................................................................. 49

* For particulars, see the contents of FD-501.

LS-501/502OUTLINE ........................................................................................................................ 1

MAINTENANCE ............................................................................................................. 5


* For particulars, see the contents of LS-501/502.

FS-503OUTLINE ........................................................................................................................ 1

MAINTENANCE ............................................................................................................. 5


* For particulars, see the contents of FS-503.

FS-607OUTLINE ........................................................................................................................ 1

MAINTENANCE ............................................................................................................. 5


* For particulars, see the contents of FS-607.

PI-502OUTLINE ........................................................................................................................ 1

MAINTENANCE ............................................................................................................. 3


* For particulars, see the contents of PI-502.

PK-512/513OUTLINE ........................................................................................................................ 1

MAINTENANCE ............................................................................................................. 3

ADJUSTMENT/SETTING............................................................................................... 9

* For particulars, see the contents of PK-512/513.

SD-501OUTLINE ........................................................................................................................ 1

MAINTENANCE ............................................................................................................. 9


* For particulars, see the contents of SD-501.

SAFETY AND IMPORTANT WARNING ITEMS

S-1

Read carefully the Safety and Important Warning Items described below to understand them before doing service work.

Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, Konica Minolta Business Technologies, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians.Changes may have been made to this product to improve its performance after this Service Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that the information contained in this Service Manual is complete and accurate.The user of this Service Manual must assume all risks of personal injury and/or damage to the product while servicing the product for which this Service Manual is intended.Therefore, this Service Manual must be carefully read before doing service work both in the course of technical training and even after that, for performing maintenance and control of the product properly.Keep this Service Manual also for future service.

In this Service Manual, each of three expressions " DANGER", " WARNING", and " CAUTION" is defined as follows together with a symbol mark to be used in a limited meaning.When servicing the product, the relevant works (disassembling, reassembling, adjustment, repair, maintenance, etc.) need to be conducted with utmost care.

Symbols used for safety and important warning items are defined as follows:


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/Earth


S-2

[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Konica Minolta brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network.Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For this reason, unauthorized modifications involve a high risk of degradation in performance and safety. Such modifications are therefore strictly prohibited. The points listed below are not exhaustive, but they illustrate the reason-ing behind this policy.

SAFETY WARNINGS

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 KMBT


S-3

[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 capac-ity, 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 240V


S-4

[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.

? V

kw


S-5

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-6

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-7

2. Installation Requirements

Prohibited Installation Places

WARNING Do not place the product near flammable materials or vol-

atile 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-8

3. Servicing

Inspection 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. Arisk 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-9

Safety Checkpoints

WARNING When taking a report of problems from a user, check each

part and repair properly.

A risk of product trouble, injury, and fire exists.

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.


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.


S-10

Do not remove the cover of the write unit. Do not supply power with the write unit shifted from the specified mount-ing position.

The laser light can enter your eye, leading to a risk of loss of eyesight.

When replacing a lithium battery, replace it with a new lith-ium battery specified in the Parts Guide Manual. Dispose of the used lithium battery using the method specified by local authority.

Improper replacement can cause explosion.

After replacing a part to which AC voltage is applied (e.g., optical lamp and fixing lamp), be sure to check the instal-lation state.


Check the interlock switch and actuator for loosening and check whether the interlock functions properly.

If the interlock does not function, you may receive an electric shock or be injured when you insert your hand in the product (e.g., for clearing paper jam).

Make sure the wiring cannot come into contact with sharp edges, burrs, or other pointed parts.


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


S-11

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.

Never throw the used cartridge and toner into fire.

You may be burned due to dust explosion.

Handling of Service Materials

CAUTION Unplug the power cord from the wall outlet.

Isopropyl alcohol and acetone are highly flammable and must be handled with care. A risk of fire exists.

Do not replace the cover or turn the product ON before any solvent remnants on the cleaned parts have fully evaporated.


Use only a small amount of cleaner at a time and take care not to spill any liquid. If this happens, immediately wipe it off.


When using any solvent, ventilate the room well.

Breathing large quantities of organic solvents can lead to discomfort.


S-12

4. Fuse

5. Used Batteries Precautions

FuseCAUTION

CAUTIONDouble pole / neutral fusing

ATTENTIONDouble ple / Fusible sur le neutre

Handling of batteriesCAUTION

ALL AreasCAUTION

Danger of explosion if battery is incorrectly replaced.Replace only with the same or equivalent type recommended by the manufacturer.Dispose of used batteries according to the manufacturers instructions.

GermanyVORSICHT!

Explosionsgefahr bei unsachgemem Austausch der Batterie.Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.Entsorgung gebrauchter Batterien nach Angaben des Herstellers.

FranceATTENTION

Il y a danger dexplosion sil y a remplacement incorrect de la batterie.Remplacer uniquement avec une batterie du mme type ou dun type quivalent recom-mand par le constructeur.Mettre au rebut les batteries usages conformment aux instructions du fabricant.

DenmarkADVARSEL!

Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering. Udskiftning m kun ske med batteri af samme fabrikat og type.Levr det brugte batteri tilbage til leverandren.

Finland, SwedenVAROlTUS

Paristo voi rjht, jos se on virheellisesti asennettu.Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hvit kytetty paristo valmistajan ohjeiden mukaisesti.

VARNINGExplosionsfara vid felaktigt batteribyte.Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-tillverkaren.Kassera anvnt batteri enligt fabrikantens instruktion.

NorwayADVARSEL

Eksplosjonsfare ved feilaktig skifte av batteri.Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.Brukte batterier kasseres i henhold til fabrikantens instruksjoner.

SAFETY INFORMATION

S-13

The 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 NOTICE

SAFETY INFORMATION

S-14

Caution 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.

INDICATION OF WARNING ON THE MACHINE

a03up0e001ca

SAFETY INFORMATION

S-15

CAUTION:

a03up0e002ca

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.

MEASURES TO TAKE IN CASE OF AN ACCIDENT

S-16

1. If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage.

2. If a report of a serious accident has been received from a customer, an on-site evalua-tion must be carried out quickly and KMBT must be notified.

3. To determine the cause of the accident, conditions and materials must be recorded through direct on-site checks, in accordance with instructions issued by KMBT.

4. For reports and measures concerning serious accidents, follow the regulations speci-fied by every distributor.

MEASURES TO TAKE IN CASE OF AN ACCIDENT

C-1

Legal restrictions on copyingCertain types of originals must never be copied with the purpose or intent to pass copies ofsuch originals off as the originals.The following is not a complete list, but is meant to be used as a guide to responsible copy-ing.

Personal checks Travelers checks Money orders Certificates of deposit Bonds or other certificates of indebtedness Stock certificates

Food stamps Postage stamps (canceled or uncanceled) Checks or drafts drawn by government agencies Internal revenue stamps (canceled or uncanceled) Passports Immigration papers Motor vehicle licenses and titles House and property titles and deeds

Identification cards, badges, or insignias Copyrighted works without permission of the copyright owner

In addition, it is prohibited under any circumstances to copy domestic or foreign currencies,or works of art without permission of the copyright owner. When in doubt about the nature of an original, consult with legal counsel.

DetailIn order to prohibit the illegal reproduction of certain originals, such as paper currency, thismachine is equipped with a counterfeit prevention feature.Due to the counterfeit prevention feature that this machine is equipped with, images maybe distorted.

C-2

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 specifications

MAINTENANCE: 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-3

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) bizhub PRO C6500: Main body

(2) Microsoft Windows 95: Windows 95

Microsoft Windows 98: Windows 98

Microsoft Windows Me: Windows Me

Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT

Microsoft Windows 2000: Windows 2000

Microsoft Windows XP: Windows XP

When the description is made in combination of the OS's mentioned above:

Windows 95/98/Me

Windows NT 4.0/2000

Windows NT/2000/XP

Windows 95/98/Me/NT/2000/XP

Classification Load symbol Ex. of signal name Description

Sensor PS

IN

Sensor detection signal

PS

Door PS1

SIG

102 PS

Solenoid SD

24V Power to drive the solenoid

DRVDrive signal

SOL

Clutch CL

24V Power to drive the clutch

DRVDrive signal

SOL

C-4

Motor M

24V Power to drive the motor

CONT Drive signal

DRV1

Drive signals of two kindsDRV2

D1

D2

Motor M

_U

Drive signals (control signals) of three kinds

_V

_W

DRV1

DRV2

DRV3

D1

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

D2

D3

D4

DRV A

DRV A

DRV B

DRV B

A

/A

B

/B

AB

BB

CLK, PLL PLL control signal

LCK, Lock, LD PLL lock signal

FR Forward/reverse rotation signal

EM, Lock, LCK, LD Motor lock abnormality

BLK Drive brake signal

P/S Power/stop

S/SOperating load start/stop signal

SS

CW/CCW, F/R Rotational direction switching signal

ENB Effective signal

TEMP_ER Motor temperature abnormality detection signal

Fan FM

24V Power to drive the fan motor

CONT, DRIVE Drive signal

HL Speed control signal (2 speeds)

EM, Lock, LCK, FEM Detection signal

Others TH1.S, ANG Analog signal


C-5

D. Paper feed directionWhen the direction in which paper is fed is in parallel with the longer side of paper, thepaper feed direction like this is referred to as the longitudinal feed.And the paper feed direction that is perpendicular to the longitudinal feed is referred to asthe transverse feed.When specifying the longitudinal feed, "S (abbreviation for Short Edge Feeding)" is addedto the paper size. For the transverse feed, no specific notation is employed.However, when only the longitudinal feed is specified for one and the same paper size withno specification made for the transverse feed, "S" is not added even when being fed longi-tudinally.

GroundSG, S.GND, S_GND Signal ground

PG, P.GND Power ground

Serial com-munication

DCD Data carrier detection

SIN Serial input

SOUT Serial output

DTR Data terminal operation available

GND Signal ground (earth)

DSR, DSET Data set ready

RTS Transmission request signal

CTS Consent transmission signal

RI Ring indicator

TXD Serial transmission data

RXD Serial reception data


Paper size Feed direction Notation

A4Transverse feed A4

Longitudinal feed A4S

A3 Longitudinal feed A3

C-6

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SERVICE MANUAL

2006.09

Ver. 1.0

Field Service

Main bodyC6500

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.

11

1

1

2006/09 1.0 Issue of the first edition

Date Service manual Ver. Revision mark Descriptions of revision

biz

hu

b P

RO

C6

50

0

CONTENTS

i

Field Service Ver1.0 Sep.2006

CONTENTS

bizhub PRO C6500

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

MAINTENANCE3. PERIODIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.2 Maintenance item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.1 Main body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.2.2 DF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.2.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.2.4 LU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.2.5 RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.2.6 FD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.2.7 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.2.8 PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.2.9 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3 Replacement parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.3.1 Periodically replacement parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.3.2 Spot replacement parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.4 Concept of parts life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.4.1 Life value of consumables and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.4.2 Conditions for life specifications values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.5 Maintenance procedure of the housing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.5.1 Replacing the Dust-proof filter /1 assy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.5.2 Replacing dust-proof filter /2 assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.6 Maintenance procedure of the photoconductor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.6.1 Process unit disassembly flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.6.2 Opening/closing toner supply section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333.6.3 Pulling out the process unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.6.4 Removing drum cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.7 Maintenance procedure of the charging section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.7.1 Replacing the charging corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.7.2 Replacing the charging dust-proof filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.8 Maintenance procedure of the intermediate transfer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.8.1 Removing/installing the transfer belt unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.8.2 Replacing the belt cleaning blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423.8.3 Replacing 1st transfer roller /Y, /M, /C and /K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433.8.4 Replacing the transfer belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443.8.5 Replacing the 2nd transfer roller /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463.8.6 Replacing the separation claw assy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473.8.7 Replacing the belt cleaner unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483.8.8 Replacing the toner collection sheet /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493.8.9 Replacing the 2nd transfer roller /Lw and the transfer earth plate assy . . . . . . . . . . . . . . . . . 50

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3.8.10 Replacing the belt separation claw solenoid (SD1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513.8.11 Replacing the separation discharging assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.9 Maintenance procedure of the developing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.9.1 Replacing the developer /Y, /M, /C, /K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533.9.2 Replacing the developing unit /C, /M, /Y, /K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.10 Maintenance procedure of the toner collection box assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573.10.1 Replacing the toner collection box assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.11 Maintenance procedure of the paper feeding section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583.11.1 Replacing the pick-up roller/paper feed roller rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583.11.2 Replacing the separation roller rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613.11.3 Replacing the paper feed clutch/pre-registration clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.12 Maintenance procedure of the bypass feed tray section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633.12.1 Replacing the pick-up roller/paper feed roller rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633.12.2 Replacing the separation roller rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653.12.3 Replacing the paper feed clutch/BP (MC6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.13 Maintenance procedure of the vertical conveyance section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683.13.1 Replacing the intermediate conveyance clutch /1 (MC13) . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.14 Maintenance procedure of the registration section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.14.1 Replacing the cleaning stay assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.14.2 Replacing the registration roller assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3.15 Maintenance procedure of the ADU section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753.15.1 Replacing the intermediate conveyance clutch/2 (MC4) and /3 (MC5) . . . . . . . . . . . . . . . . . . 753.15.2 Replacing the ADU conveyance clutch/1 (MC1), /2 (MC2), /3 (MC3),

and the ADU pre-registration clutch (MC18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773.16 Maintenance procedure of the reverse/paper exit section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.16.1 Replacing Reverse decurler roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 793.16.2 Replacing the paper exit decurler roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.17 Maintenance procedure of the fusing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 853.17.1 Removing/installing the fusing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 853.17.2 Replacing the fusing drive gear /B and the fusing duct 2 assy . . . . . . . . . . . . . . . . . . . . . . . . 873.17.3 Replacing the fusing drive gear/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 893.17.4 Replacing the fusing lamp /Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903.17.5 Replacing the fusing roller /2, fusing bearing, and fusing drive gear /O. . . . . . . . . . . . . . . . . . 923.17.6 Replacing the fusing belt, fusing roller /1, insulating sleeve /Up, fusing bearing /Up,

and belt regulation sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 953.17.7 Replacing the fusing heater lamp /4 (L5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 973.17.8 Replacing the fusing roller/Lw, fusing bearing/Lw, and insulating sleeve/Lw. . . . . . . . . . . . . . 993.17.9 Replacing the sensor mounting plate A assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013.17.10 Replacing the sensor stay B assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1023.17.11 Replacing the fusing paper exit roller /Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1043.17.12 Replacing the fusing regulation gear/A and the fusing limiter . . . . . . . . . . . . . . . . . . . . . . . . 106

3.18 Maintenance procedure of OT-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1083.18.1 Replacing the paper retainer roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1083.18.2 Replacing the paper exit roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1093.18.3 Replacing the paper exit driven roller/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4. SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1134.1 Service material list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1134.2 Jig list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1144.3 Mail remote notification system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

4.3.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1164.3.2 Operating environments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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4.3.3 Major functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1164.3.4 Initial setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1174.3.5 Usage of the mail remote notification system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.3.6 Mail sending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1215. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

5.1 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1235.1.1 Types of ISW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1235.1.2 Firmware data flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1245.1.3 Settings on the main body side while in ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

5.2 ISWTrns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1265.2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1265.2.2 Installation of the ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1275.2.3 Usage of the ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1295.2.4 Error list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

5.3 USB memory ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1455.3.1 Usage of the USB memory ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1455.3.2 Main body error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

5.4 Internet ISW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1495.4.1 OUTLINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1495.4.2 Operating environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1495.4.3 Initial settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1495.4.4 Internet ISW using the Web Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1555.4.5 Internet ISW using the mail remote contact system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1565.4.6 Notes for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1575.4.7 Internet ISW using the operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1585.4.8 Authentication of the proxy server in the Internet ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

6. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1626.1 Items not allowed to be disassembled and adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

6.1.1 Scanner section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1626.1.2 Write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1646.1.3 Photoconductor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1666.1.4 Intermediate transfer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1676.1.5 Fusing unit section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

6.2 Disassembly/reassembly parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1696.3 Disassembly/reassembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

6.3.1 Removing/reinstalling rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1706.3.2 Removing/reinstalling left cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1706.3.3 Removing/installing right cover/Up1, /Up2, /Up3, /Lw1 and /Lw2 . . . . . . . . . . . . . . . . . . . 1716.3.4 Removing/reinstalling original glass assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1726.3.5 Removing/reinstalling upper cover/Fr, /Rt, and Lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1736.3.6 Removing/reinstalling upper cover/Rr1 and /Rr2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1746.3.7 Removing/installing main board unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1756.3.8 Removing/installing CCD unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1766.3.9 Removing/installing exposure unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1786.3.10 Removing/installing exposure lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1816.3.11 Removing scanner wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1826.3.12 Reinstalling the scanner wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1846.3.13 Removing/installing write unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1876.3.14 Removing/installing process unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1896.3.15 Removing/reinstalling image correction unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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6.3.16 Removing/installing belt collectin pipe,vertical conveyance pipe and horizontal conveyance pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

6.3.17 Removing/reinstalling ADU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2046.3.18 Replaceing the lock lever/1, /2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2066.3.19 Removing/reinstalling paper feed tray/1, /2 and /3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2086.3.20 Removing/reinstalling tray up/down wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2096.3.21 Removing/installing temperature sensor /1 (TEMS/1), thermostat /1 (TS1) and /2 (TS2) . . . . 2126.3.22 Removing/installing temperature sensor /2 (TEMS/2) and thermostat /3 (TS3) . . . . . . . . . . . 2156.3.23 Removing/reinstalling OT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

6.4 Commercially available parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2186.4.1 Installing the status indicator light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2186.4.2 Installing the key counter (KCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

ADJUSTMENT/SETTING7. HOW TO USE THE ADJUSTMENT/SETTING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

7.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2278. UTILITY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

8.1 List of utility mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2289. UTILITY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23210.SERVICE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

10.1 List of service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23410.2 Setting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

10.2.1 Start and exit service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23810.3 Machine adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

10.3.1 Restart Timing Adjustment (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23910.3.2 Centering Adjustment (Printer Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24010.3.3 FD-Mag. Adjustment (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24110.3.4 CD-Mag. Adjustment (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24210.3.5 Lead Edge Erase Adjustmet (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24310.3.6 Registration Loop Adj. (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24410.3.7 Pre-registration Adj. (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24510.3.8 Belt Line Speed Adj. (Printer Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24610.3.9 Writing Init. Pos. Memory (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24610.3.10 Color Registration Adj. (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24710.3.11 Color Registration/Manual (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24810.3.12 PFU DFeed Detect Adj. (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25110.3.13 CD Skew Adj. (Printer Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25110.3.14 Recall Standard Data (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25210.3.15 Restart Timing Adjustment (Scanner Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25310.3.16 Centering Adjustment (Scanner Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25410.3.17 FD-Mag. Adjustment (Scanner Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25510.3.18 Recall Standard Data (Scanner Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25610.3.19 Scanner smooth tone/color (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25710.3.20 Printer gamma adjustment (Quality Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25810.3.21 Sharpness adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26610.3.22 Contrast adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26610.3.23 Image Distinction Level (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26710.3.24 ACS adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27010.3.25 Density adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27110.3.26 Tone adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

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10.3.27 Recall standard data (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27710.3.28 Non-Image Area Erase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

10.4 Process Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

10.4.1 1st transfer manual adj. (High Voltage Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28010.4.2 2nd transfer manual adj. (High Voltage Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28010.4.3 HV adj. (separation AC) (High Voltage Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28010.4.4 HV adj. (sepration DC) (High Voltage Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28010.4.5 Pre-transfer Guide HV check (High Voltage Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28010.4.6 Blade setting mode (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28010.4.7 Automatic drum potential (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28110.4.8 Auto gamma adjustment (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28110.4.9 LD bias adjustment (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28210.4.10 Automatic Developer Charge (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28410.4.11 Toner density sensor Init. (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28710.4.12 Initial drum rotation (Drum Peculiarity Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28710.4.13 Surface potential sensor (Sensor output check). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28810.4.14 Maximum density sensor (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28810.4.15 Gamma sensor output (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28810.4.16 Toner Density Sensor (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28810.4.17 Drum Surfase potential (Sensor output check). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28910.4.18 Humidity/Temperature (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28910.4.19 Toner Density Return Mode (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29010.4.20 Covered Margin Fine Adj. (Process Fine Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29110.4.21 Develop AC Bias Fine Adj. (Process Fine Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29210.4.22 Develop AC Frequency (Process Fine Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29310.4.23 Toner Density Fine Adj. (Process Fine Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29410.4.24 Drum Tiny Rotation Interval (Interval/Quantity Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29510.4.25 Auto. Refresh Interval (Interval/Quantity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29510.4.26 Toner Dens. Sensor Interval (Interval/Quantity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29610.4.27 Recall standard data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

10.5 System Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29710.5.1 Software SW Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29710.5.2 Telephone Number Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31210.5.3 M/C Serial Number Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31210.5.4 Setup Date Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

10.6 Counter/data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31410.6.1 Maintenance Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31410.6.2 Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31610.6.3 Count of special parts (Parts Counter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33510.6.4 Count of each parts (Parts Counter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

10.7 State Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34810.7.1 I/O Check Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34810.7.2 Input check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34910.7.3 Output check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36310.7.4 Adjustment when replacing multi feed detection board (PF). . . . . . . . . . . . . . . . . . . . . . . . . 38210.7.5 Adjustment when replacing multi feed detection board (PI) . . . . . . . . . . . . . . . . . . . . . . . . . 38410.7.6 Storing FD, SD, FS adjustment data into EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38610.7.7 Storing main body adjustment data into NVRAM board. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38710.7.8 Line memory check on image processing board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38810.7.9 Hard disk check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

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10.7.10 Replacement of the hard disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39010.8 ADF adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

10.8.1 ADF Original Size Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

10.8.2 ADF Orig. Stop Position Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39210.8.3 ADF Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39310.8.4 ADF Registration Loop Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

10.9 Finisher Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39510.9.1 Staple Center Position (Stapler Position Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39510.9.2 Paper Width (staple) (Stapler Position Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39610.9.3 Paper Width (straight) (Stapler Position Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39710.9.4 Paper Width Adjustment (Multi Folder (Punch) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39810.9.5 Hole-Punch Vertical Pos. (Multi Folder (Punch) Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39910.9.6 Half Fold Position Adj. (Multi Folder (Fold) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40010.9.7 Tri-Fold-in Pos. Adj. (Multi Folder (Fold) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40110.9.8 Tri-Fold-out Pos. adj. (Multi Folder (Fold) Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40210.9.9 Double Parallel Folds Pos. Adj. (Multi Folder (Fold) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40310.9.10 Z-Fold Position Adj. (Multi Folder (Fold) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40410.9.11 Gate Fold Position Adj. (Multi Folder (Fold) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40510.9.12 Fold Regist Loop Adj. (Multi Folder (Fold) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40610.9.13 Multi Folder (PI) Adj.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40610.9.14 Stacker Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40710.9.15 Staple Center Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40810.9.16 Staple Paper Width Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40910.9.17 Staple Pitch Adjustment (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41010.9.18 Half Fold Position Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41110.9.19 Tri-Fold Position Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41210.9.20 Fold Paper Width Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41310.9.21 Trimming Adjustment (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41410.9.22 Trimmer Receiver Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41510.9.23 Curl Reform Direction (RU Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41510.9.24 Recall Standard Data (Finisher Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41610.9.25 Saddle Stitcher Stopper Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41710.9.26 Half Fold Stopper Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41810.9.27 Vertical Position Adj. (Punch Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41910.9.28 Horizontal Position Adj. (Punch Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42010.9.29 Registration Adjustment (Punch Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42110.9.30 Paper Edge Detect Sensor Adj. (Punch Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42110.9.31 Tri-Fold Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42210.9.32 2 Pos. Staple Pitch Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42310.9.33 Paper Inserter Tray Size Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42410.9.34 Output quantity limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424

10.10 Firmware version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42510.11 CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

10.11.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42610.11.2 Setup procedure of the CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42610.11.3 List of combinations of E-Mail CS Remote Care and Mail remote notification system. . . . . . 42810.11.4 Detailed setup procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42810.11.5 Software SW setting for CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43210.11.6 Mail address setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44010.11.7 Modem First Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

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10.11.8 Receiving the initial connection mail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44110.11.9 Setup confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44110.11.10 Maintenance call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442

10.11.11 Center call from manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44210.11.12 Confirm communication log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44310.11.13 Initialization of RAM for CS Remote Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44310.11.14 Malfunction code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44410.11.15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445

10.12 List output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44610.12.1 List Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

10.13 Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44710.13.1 Running Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44710.13.2 Test Pattern Output Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

10.14 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45810.15 CE/Administrator Security Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

10.15.1 List of CE/Administrator Security Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45910.15.2 Start and exit CE/Administrator Security Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45910.15.3 CE Authentication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46010.15.4 CE Auth. Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46010.15.5 Admin. Authentication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46110.15.6 Administrator Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461

10.16 Fee Collection Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46210.16.1 List of Fee Collection Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46210.16.2 Start and exit Fee Collection Setting Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46210.16.3 Coin Vendor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46210.16.4 Management Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462

11.MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46311.1 Adjusting the paper feed roller/BP pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46311.2 (Maximum) paper feed (bypass) height adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46411.3 Pick-up movement amount adjustment (bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46511.4 Mis-centering adjustment of the paper feed tray /1, /2 and /3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46611.5 Separation pressure adjustment of the paper feed tray/1, /2 and /3. . . . . . . . . . . . . . . . . . . . . . . . 467

TROUBLESHOOTING12.JAM CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469

12.1 Jam code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46913.MALFUNCTION CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487

13.1 Malfunction code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487

APPENDIX14.PARTS LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545

14.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54514.1.1 Switch/sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54514.1.2 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55714.1.3 Boards and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566

14.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57114.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57214.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57814.5 RU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58114.6 FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583

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14.7 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59114.8 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595

14.8.1 FS-503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595

14.8.2 FS-607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60014.9 PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60414.10 PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605

14.10.1 PK-512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60514.10.2 PK-513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606

14.11 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60715.CONNECTOR LAYOUT DRAWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620

15.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62015.1.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620

15.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63015.2.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630

15.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63115.3.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631

15.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63215.4.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632

15.5 RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63315.5.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633

15.6 FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63415.6.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634

15.7 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63815.7.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638

15.8 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64015.8.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640

15.9 PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64315.9.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643

15.10 PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64415.10.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644

15.11 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64515.11.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645

16.TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64716.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64716.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64916.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65116.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65216.5 FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65416.6 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66216.7 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666

16.7.1 FS-503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66616.7.2 FS-607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669

16.8 PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67316.9 PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674

16.9.1 PK-512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67416.9.2 PK-513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675

16.10 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67617.OVERALL WIRING DIAGRAM

17.1 Main body 1/1217.2 Main body 2/12

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17.3 Main body 3/1217.4 Main body 4/1217.5 Main body 5/12

17.6 Main body 6/1217.7 Main body 7/1217.8 Main body 8/1217.9 Main body 9/1217.10 Main body 10/1217.11 Main body 11/1217.12 Main body 12/1217.13 DF17.14 PF 1/417.15 PF 2/417.16 PF 3/417.17 PF 4/417.18 LU17.19 RU17.20 FD17.21 LS17.22 FS

17.22.1 FS-50317.22.2 FS-607

17.23 PI17.24 PK17.25 SD 1/417.26 SD 2/417.27 SD 3/417.28 SD 4/4

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1. SYSTEM CONFIGURATION

1


OUTLINE

1. SYSTEM CONFIGURATION

A. System configuration

[1] Main body [12] Saddle stitching staple finisher (FS-607)

[2] Dehumidifier fan heater (HT-503) [13] Punch kit (PK-512/513)

[3] Large capacity paper feed tray (LU-202) [14] Cover inserter (PI-502)

[4] Large cap

konica minolta bizhub c6500 field service total manual

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