Oki ES9160 User manual

OEL
Maintenance Manual
ES9160/ES9170
Revision 1
Rev Date Oki Data Corporation
1 2012-11-16
Name
ES9160/ES9170
Maintenance Manual
This document is “OKI DATA – CONFIDENTIAL”
Only persons and parties authorised by OKI DATA have
permissions to access this document.
This document should not be accessed by any parties
without the approval of OKI DATA.
Anyone who is found to be contradicting the above may be subject to legal action.

Trademarks
• The official name of Windows XP is Microsoft Windows XP Operating System.
• The official name of Windows Vista is Microsoft Windows Vista Operating System.
• The official name of Windows 7 is Microsoft Windows 7 Operating System.
• Microsoft, Windows, Windows NT, Windows Vista and the brand names and product names of other
Microsoft products are trademarks or registered trademarks of Microsoft Corporation in the U.S.
and/or other countries.
• Apple, AppleTalk, Macintosh, and Mac are trademarks of Apple Computer, Inc. in the U.S. and other
countries.
• PostScript is a trademark of Adobe Systems Incorporated.
• NOVELL, NetWare, and NDS are trademarks or registered trademarks of Novell, Inc.
• Mylar is a registered trademark of DuPont Teijin Films U.S. Limited Partnership.
• Molykote is a registered trademark of Dow Corning Corporation.
• FLOIL is a registered trademark of Kanto Kasei Ltd. CORPORATION.
• TopAccess is a trademark of Toshiba Tec Corporation.
• iCLASS is a trademark of HID Corporation.
• MIFARE is a trademark of Royal Philips Electronics.
• Other company names and product names in this manual are the trademarks of their respective
companies.
© 2012 OKI DATA CORPORATION All rights reserved
Under the copyright laws, this manual cannot be reproduced in any form without prior written permission
of OKI DATA CORPORATION.

GENERAL PRECAUTIONS REGARDING THE SERVICE FOR
ES9160 MFP / ES9170 MFP
The installation and service shall be done by a qualified service
technician.
1. Transportation/Installation
- When transporting/installing the equipment, employ two persons and be sure to hold the
positions as shown in the figure.
The equipment is quite heavy and weights approximately 61 kg (134.48 lb.), therefore pay full
attention when handling it.
- Be sure not to hold the movable parts or units (e.g. the control panel, ADU or RADF) when
transporting the equipment.
- Be sure to use a dedicated outlet with AC 115 V / 12 A, 220-240 V / 8 A for its power source.
- The equipment must be grounded for safety.
- Select a suitable place for installation. Avoid excessive heat, high humidity, dust, vibration and
direct sunlight.
- Provide proper ventilation since the equipment emits a slight amount of ozone.
- To insure adequate working space for the copying operation, keep a minimum clearance of 80
cm (32”) on the left, 80 cm (32”) on the right and 10 cm (4”) on the rear.
- The equipment shall be installed near the socket outlet and shall be accessible.
- Be sure to fix and plug in the power cable securely after the installation so that no one trips over
it.
- When the equipment is used after the option is removed, be sure to install the parts or the covers
which have been taken off so that the inside of the equipment is not exposed.

2. General Precautions at Service
- Be sure to turn the power OFF and unplug the power cable during service (except for the service
should be done with the power turned ON).
- Unplug the power cable and clean the area around the prongs of the plug and socket outlet once
a year or more. A fire may occur when dust lies on this area.
- When the parts are disassembled, reassembly is the reverse of disassembly unless otherwise
noted in this manual or other related documents. Be careful not to install small parts such as
screws, washers, pins, E-rings, star washers in the wrong places.
- Basically, the equipment should not be operated with any parts removed or disassembled.
- The PC board must be stored in an anti-electrostatic bag and handled carefully using a wristband
since the ICs on it may be damaged due to static electricity.
- Avoid expose to laser beam during service. This equipment uses a laser diode. Be sure not to
expose your eyes to the laser beam. Do not insert reflecting parts or tools such as a screwdriver
on the laser beam path. Remove all reflecting metals such as watches, rings, etc. before starting
service.
- Be sure not to touch high-temperature sections such as the exposure lamp, fuser unit, damp
heater and areas around them.
- Be sure not to touch high-voltage sections such as the chargers, transfer roller, developer, high-
voltage transformer, exposure lamp control inverter, inverter for the LCD backlight and power
supply unit. Especially, the board of these components should not be touched since the electric
charge may remain in the capacitors, etc. on them even after the power is turned OFF.
- Make sure that the equipment will not operate before touching potentially dangerous places (e.g.
rotating/operating sections such as gears, belts pulleys, fans and laser beam exit of the laser
optical unit).
- Be careful when removing the covers since there might be the parts with very sharp edges
underneath.
- When servicing the equipment with the power turned ON, be sure not to touch live sections and
rotating/operating sections. Avoid exposing your eyes to laser beam.
- Use designated jigs and tools.
- Use recommended measuring instruments or equivalents.
- Return the equipment to the original state and check the operation when the service is finished.
- Be very careful to treat the touch panel gently and never hit it. Breaking the surface could cause
malfunctions.
3. Important Service Parts for Safety
- The breaker, door switch, fuse, thermostat, thermofuse, thermistor, batteries, IC-RAMs including
lithium batteries, etc. are particularly important for safety. Be sure to handle/install them properly.
If these parts are short-circuited and their functions become ineffective, they may result in fatal
accidents such as burnout. Do not allow a short-circuit and do not use the parts not
recommended by OKI DATA CORPORATION.
Caution: Before using the wristband, unplug the power cable of the equipment and
make sure that there are no charged objects which are not insulated in the
vicinity.

4. Cautionary Labels
- During servicing, be sure to check the rating plate and cautionary labels such as “Unplug the
power cable during service”, “CAUTION. HOT”, “CAUTION. HIGH VOLTAGE”, “CAUTION.
LASER BEAM”, etc. to see if there is any dirt on their surface and if they are properly stuck to the
equipment.
[1] Certification label (For U.S.A and Canada)
[2] Explanatory label
[3] Identification label (For U.S.A, Canada and EU)
[4] Warning for grounding wire
[5] Cautionary label for laser unit
[6] Warning for high temperature area (fuser unit)
5. Disposal of the Equipment, Supplies, Packing Materials, Used Batteries and IC-RAMs
including lithium batteries
- Regarding the recovery and disposal of the equipment, supplies, packing materials, used
batteries and IC-RAMs including lithium batteries, follow the relevant local regulations or rules.
[2]
[4]
[6] [6]
[3]
[1]
[5]

Caution:
Dispose of used batteries and IC-RAMs including lithium batteries according to this manual.
Attention:
Se débarrasser de batteries et IC-RAMs usés y compris les batteries en lithium selon ce manuel.
Vorsicht:
Entsorgung der gebrauchten Batterien und IC-RAMs (inclusive der Lithium-Batterie) nach diesem Handbuch.

ALLEGEMEINE SICHERHEITSMASSNAHMEN IN BEZUG
AUF DIE WARTUNG FÜR ES9160 MFP / ES9170 MFP
Die Installation und die Wartung sind von einem qualifizierten Service-
Techniker durchzuführen.
1. Transport/Installation
- Zum Transportieren/Installieren des Gerätes werden 2 Personen benötigt. Nur an den in der
Abbildung gezeigten Stellen tragen.
Das Gerät ist sehr schwer und wiegt etwa 61 kg; deshalb muss bei der Handhabung des Geräts
besonders aufgepasst werden.
- Beim Transportieren des Geräts nicht an den beweglichen Teilen oder Einheiten (z.B. das
Bedienungsfeld, die Duplexeinheit oder die automatische Dokumentenzuführung) halten.
- Eine spezielle Steckdose mit Stromversorgung von AC 115 V / 12 A, 220-240 V / 8 A als
Stromquelle verwenden.
- Das Gerät ist aus Sicherheitsgründen zu erden.
- Einen geeigneten Standort für die Installation wählen. Standorte mit zuviel Hitze, hoher
Luftfeuchtigkeit, Staub, Vibrieren und direkter Sonneneinstrahlung sind zu vermeiden.
- Für ausreichende Belüftung sorgen, da das Gerät etwas Ozon abgibt.
- Um einen optimalen Kopierbetrieb zu gewährleisten, muss ein Abstand von mindestens 80 cm
links, 80 cm rechts und 10 cm dahinter eingehalten werden.
- Das Gerät ist in der Nähe der Steckdose zu installieren; diese muss leicht zu erreichen sein.
- Nach der Installation muss das Netzkabel richtig hineingesteckt und befestigt werden, damit
niemand darüber stolpern kann.
- Falls der Auspackungsstandort und der Installationsstandort des Geräts verschieden sind, die
Bildqualitätsjustierung (automatische Gammajustierung) je nach der Temperatur und
Luftfeuchtigkeit des Installationsstandorts und der Papiersorte, die verwendet wird, durchführen.

2. Allgemeine Sicherheitsmassnahmen in bezug auf die Wartung
- Während der Wartung das Gerät ausschalten und das Netzkabel herausziehen (ausser Wartung,
die bei einem eingeschalteten Gerät, durchgeführt werden muss).
- Das Netzkabel herausziehen und den Bereich um die Steckerpole und die Steckdose die
Umgebung in der Nähe von den Steckerzacken und der Steckdose wenigstens einmal im Jahr
reinigen. Wenn Staub sich in dieser Gegend ansammelt, kann dies ein Feuer verursachen.
- Wenn die Teile auseinandergenommen werden, wenn nicht anders in diesem Handbuch usw
erklärt, ist das Zusammenbauen in umgekehrter Reihenfolge durchzuführen. Aufpassen, dass
kleine Teile wie Schrauben, Dichtungsringe, Bolzen, E-Ringe, Stern-Dichtungsringe,
Kabelbäume nicht an den verkehrten Stellen eingebaut werden.
- Grundsätzlich darf das Gerät mit enfernten oder auseinandergenommenen Teilen nicht in
Betrieb genommen werden.
- Das PC-Board muss in einer Anti-elektrostatischen Hülle gelagert werden. Nur Mit einer
Manschette bei Betätigung eines Armbandes anfassen, sonst könnte es sein, dass die
integrierten Schaltkreise durch statische Elektrizität beschädigt werden.
- Setzen Sie sich während der Wartungsarbeiten nicht dem Laserstrahl aus. Dieses Gerät ist mit
einer Laserdiode ausgestattet. Es ist unbedingt zu vermeiden, direkt in den Laserstrahl zu
blicken. Keine reflektierenden Teile oder Werkzeuge, wie z. B. Schraubendreher, in den Pfad des
Laserstrahls halten. Vor den Wartungsarbeiten sämtliche reflektierenden Metallgegenstände, wie
Uhren, Ringe usw., entfernen.
- Auf keinen Fall Hochtemperaturbereiche, wie die Belichtungslampe, die Fixiereinheit, die
Heizquelle und die umliegenden Bereiche, berühren.
- Auf keinen Fall Hochspannungsbereiche, wie die Ladeeinheiten, die Transferwalze, die
Entwicklereinheit, den Hochspannungstransformator, den Steuerumrichter für die
Belichtungslampe, den Umrichter für die LCD-Hintergrundbeleuchtung und das Netzgerät,
berühren. Insbesondere sollten die Platinen dieser Komponenten nicht berührt werden, da die
Kondensatoren usw. auch nach dem Ausschalten des Geräts noch elektrisch geladen sein
können.
- Vor dem Berühren potenziell gefährlicher Bereiche (z. B. drehbare oder betriebsrelevante
Bereiche, wie Zahnräder, Riemen, Riemenscheiben, Lüfter und die Laseraustrittsöffnung der
optischen Lasereinheit) sicherstellen, dass das Gerät sich nicht bedienen lässt.
- Beim Entfernen von Abdeckungen vorsichtig vorgehen, da sich darunter scharfkantige
Komponenten befinden können.
- Bei Wartungsarbeiten am eingeschalteten Gerät dürfen keine unter Strom stehenden, drehbaren
oder betriebsrelevanten Bereiche berührt werden. Nicht direkt in den Laserstrahl blicken.
- Ausschließlich vorgesehene Werkzeuge und Hilfsmittel verwenden.
- Empfohlene oder gleichwertige Messgeräte verwenden.
- Nach Abschluss der Wartungsarbeiten das Gerät in den ursprünglichen Zustand zurück
versetzen und den einwandfreien Betrieb überprüfen.
- Das berührungsempfindliche Bedienungsfeld stets vorsichtig handhaben und keinen Stößen
aussetzen. Wenn die Oberfläche beschädigt wird, kann dies zu Funktionsstörungen führen.
3. Sicherheitsrelevante Wartungsteile
- Der Leistungsschutzschalter, der Türschalter, die Sicherung, der Thermostat, die
Thermosicherung, der Thermistor, die IC-RAMs einschließlich der Lithiumakkus usw. sind
besonders sicherheitsrelevant. Sie müssen unbedingt korrekt gehandhabt und installiert werden.
Wenn diese Teile kurzgeschlossen und funktionsunfähig werden, kann dies zu
schwerwiegenden Schäden, wie einem Abbrand, führen. Kurzschlüsse sind zu vermeiden, und
es sind ausschließlich Teile zu verwenden, die von der OKI DATA CORPORATION. empfohlen
sind.
Vorsicht: Vor Benutzung der Manschette der Betätigung des Armbandes, das Netzkabel
des Gerätes herausziehen und prüfen, dass es in der Nähe keine geladenen
Gegenstände, die nicht isoliert sind, gibt.

4. Warnetiketten
- Im Rahmen der Wartung unbedingt das Leistungsschild und die Etiketten mit Warnhinweisen
überprüfen [z. B. „Unplug the power cable during service“ („Netzkabel vor Beginn der
Wartungsarbeiten abziehen“), „CAUTION. HOT“ („VORSICHT, HEISS“), „CAUTION. HIGH
VOLTAGE“ („VORSICHT, HOCHSPANNUNG“), „CAUTION. LASER BEAM“ („VORSICHT,
LASER“) usw.], um sicherzustellen, dass sie nicht verschmutzt sind und korrekt am Gerät
angebracht sind.
[1] Klassifizierungsetikett
[2] Erklarungsetikett
[3] Erkennungsetikett
[4] Warnung fur Erdungskabel
[5] Laser-Warnetikett
[6] Warnung fur Bereiche mit hohen Temperaturen (Fixiereinheit)
5. Entsorgung des Geräts, der Verbrauchs- und Verpackungsmaterialien, alter Akkus und IC-
RAMs
- In Bezug auf die Entsorgung und Wiederverwertung des Geräts, der Verbrauchs- und
Verpackungsmaterialien, alter Akkus und IC-RAMs, einschließlich Lithiumakkus, sind die
einschlägigen nationalen oder regionalen Vorschriften zu befolgen.
[2]
[4]
[6] [6]
[3]
[1]
[5]

Caution:
Dispose of used batteries and IC-RAMs including lithium batteries according to this manual.
Attention:
Se débarrasser de batteries et IC-RAMs usés y compris les batteries en lithium selon ce manuel.
Vorsicht:
Entsorgung der gebrauchten Batterien und IC-RAMs (inclusive der Lithium-Batterie) nach diesem Handbuch.

• Laseremissionseinheit
Diese Einheit besteht aus der Laserdiode, dem Fokussierungsobjektiv, der Blende und dem
Zylinderobjektiv.
- Laserdiode
Diese Laserdiode zeichnet sich durch eine geringe Regeldifferenz, eine kleine Laservariation und
einen niedrigen Schwellenstrom aus.
Die Blende der Laseremissionseinheit ist unter dem Fokussierobjektiv angeordnet, um die Form der
Laserstrahlen in der primären und sekundären Scanrichtung festzulegen.
Die Laserdiode gibt Laserstrahlen als Reaktion auf die Signale der Laseremissionssteuerung (ein/
aus) von der Lasertreiber-PC-Platine (LDR) aus. Die durch das Fokussierobjektiv geführten
Laserstrahlen werden auf die Trommeloberfläche fokussiert.
- Vorsichtsmaßnahmen im Zusammenhang mit Lasern
Dieses Gerät enthält eine Laserdiode, die einen unsichtbaren Laserstrahl emittiert.
Da man diesen Laserstrahl nicht sehen kann, ist bei der Handhabung der Komponenten der
optischen Lasereinheit, bei der Durchführung von Arbeiten und bei der Justierung des Laserstrahls
äußerste Vorsicht geboten. Arbeiten dürfen niemals anhand anderer als den vorgeschriebenen
Anleitungen durchgeführt werden; andernfalls kann es zu einer Schädigung Exposition durch
Laserstrahlung kommen.
Die Lasereinheit ist vollständig mit einer Schutzabdeckung versiegelt. Solange ausschließlich die
Arbeitsschritte der vorgeschriebenen Anleitungen durchgeführt werden, tritt der Laserstrahl nicht
aus, und es besteht keine Gefahr, der Laserstrahlung ausgesetzt zu werden.
Das folgende Laser-Warnetikett ist an der Abdeckung vorne rechts angebracht.
• Warnhinweise:
- Setzen Sie sich während der Wartungsarbeiten nicht dem Laserstrahl aus.
Dieses Gerät ist mit einer Laserdiode ausgestattet. Es ist unbedingt zu vermeiden, direkt in den
Laserstrahl zu blicken. Keine reflektierenden Teile oder Werkzeuge, wie z. B. Schraubendreher,
in den Pfad des Laserstrahls halten. Vor den Wartungsarbeiten sämtliche reflektierenden
Metallgegenstände, wie Uhren, Ringe usw., entfernen.
- Bei Wartungsarbeiten am eingeschalteten Gerät dürfen keine unter Strom stehenden, drehbaren
oder betriebsrelevanten Bereiche berührt werden. Nicht direkt in den Laserstrahl blicken.
- Im Rahmen der Wartung unbedingt das Leistungsschild und die Etiketten mit Warnhinweisen
überprüfen [z. B. „Unplug the power cable during service“ („Netzkabel vor Beginn der
Wartungsarbeiten abziehen“), „CAUTION. HOT“ („VORSICHT, HEISS“), „CAUTION. HIGH
VOLTAGE“ („VORSICHT, HOCHSPANNUNG“), „CAUTION. LASER BEAM“ („VORSICHT,
LASER“) usw.], um sicherzustellen, dass sie nicht verschmutzt sind und korrekt am Gerät
angebracht sind.

© 2012 OKI DATA CORPORATION All rights reserved ES9160 MFP / ES9170 MFP
CONTENTS
1
CONTENTS
1. FEATURES ...................................................................................................................1-1
1.1 Main Feature of ES9160 MFP / ES9170 MFP..................................................................1-1
2. SPECIFICATIONS / ACCESSORIES / OPTIONS / SUPPLIES ...................................2-1
2.1 Specifications....................................................................................................................2-1
2.1.1 General..............................................................................................................2-1
2.1.2 Copy ..................................................................................................................2-4
2.1.3 Print ...................................................................................................................2-7
2.1.4 Scan...................................................................................................................2-7
2.1.5 e-Filing...............................................................................................................2-7
2.1.6 Internet Fax........................................................................................................2-8
2.1.7 Network Fax.......................................................................................................2-9
2.2 Accessories.....................................................................................................................2-10
2.3 System List......................................................................................................................2-11
2.4 Supplies ..........................................................................................................................2-13
3. OUTLINE OF THE MACHINE.......................................................................................3-1
3.1 Sectional View...................................................................................................................3-1
3.2 Electric Parts Layout.........................................................................................................3-4
3.3 Symbols and Functions of Various Components............................................................3-11
3.3.1 Motors..............................................................................................................3-11
3.3.2 Sensors and switches......................................................................................3-11
3.3.3 Electromagnetic clutches.................................................................................3-13
3.3.4 Solenoids.........................................................................................................3-13
3.3.5 PC boards........................................................................................................3-13
3.3.6 Lamps and heaters..........................................................................................3-14
3.3.7 Thermistors and thermostats...........................................................................3-15
3.3.8 Transformer .....................................................................................................3-15
3.3.9 Others..............................................................................................................3-16
3.4 COPY PROCESS ...........................................................................................................3-17
3.4.1 General Description of Copying Process.........................................................3-17
3.5 GENERAL OPERATION.................................................................................................3-18
3.5.1 Overview of Operation.....................................................................................3-18
3.5.2 Description of Operation..................................................................................3-19
3.5.3 Detection of Abnormality..................................................................................3-22
3.6 CONTROL PANEL..........................................................................................................3-27
3.6.1 General Description.........................................................................................3-27
3.6.2 Description of Operation..................................................................................3-28
3.7 SCANNER.......................................................................................................................3-29
3.7.1 General Description.........................................................................................3-29
3.7.2 Construction.....................................................................................................3-30
3.7.3 Functions .........................................................................................................3-31
3.7.4 Description of Operation..................................................................................3-34
3.8 LASER OPTICAL UNIT...................................................................................................3-35
3.8.1 General Description.........................................................................................3-35
3.8.2 Laser precautions............................................................................................3-36
3.9 PAPER FEEDING SYSTEM...........................................................................................3-37
3.9.1 General Descriptions .......................................................................................3-37
3.9.2 Composition.....................................................................................................3-39
3.9.3 Functions .........................................................................................................3-40
3.9.4 Operation.........................................................................................................3-42
3.10 DRIVE SYSTEM .............................................................................................................3-48
3.10.1 General Description.........................................................................................3-48
3.10.2 Functions .........................................................................................................3-49
3.11 DRUM RELATED SECTION...........................................................................................3-50
3.11.1 Configuration ...................................................................................................3-50

3.11.2 Composition.....................................................................................................3-51
3.11.3 Functions .........................................................................................................3-52
3.12 DEVELOPMENT SYSTEM.............................................................................................3-54
3.12.1 Configuration ...................................................................................................3-54
3.12.2 Construction.....................................................................................................3-55
3.12.3 Functions .........................................................................................................3-56
3.13 FUSER UNIT...................................................................................................................3-58
3.13.1 General Description.........................................................................................3-58
3.13.2 Functions .........................................................................................................3-59
3.13.3 Operation.........................................................................................................3-60
3.13.4 Heater Control Circuit ......................................................................................3-61
3.14 PAPER EXIT SECTION/REVERSE SECTION...............................................................3-62
3.14.1 General Description.........................................................................................3-62
3.14.2 Functions .........................................................................................................3-63
3.14.3 Exit Motor / Reverse Motor / Offset Gate Motor Drive.....................................3-64
3.15 AUTOMATIC DUPLEXING UNIT (ADU).........................................................................3-66
3.15.1 General Description.........................................................................................3-66
3.15.2 Functions .........................................................................................................3-67
3.15.3 Description of Operations ................................................................................3-68
3.15.4 Drive of ADU....................................................................................................3-69
3.16 POWER SUPPLY UNIT..................................................................................................3-70
3.16.1 Construction.....................................................................................................3-70
3.16.2 Operation of DC Output Circuits......................................................................3-71
3.16.3 Output Channel................................................................................................3-73
3.16.4 Fuse.................................................................................................................3-75
4. DISASSEMBLY AND REPLACEMENT........................................................................4-1
4.1 Disassembly and Replacement of Covers........................................................................4-1
4.1.1 Front cover.........................................................................................................4-1
4.1.2 Front upper cover ..............................................................................................4-1
4.1.3 Front lower cover...............................................................................................4-2
4.1.4 Left upper cover.................................................................................................4-2
4.1.5 Right upper cover ..............................................................................................4-3
4.1.6 Rear cover.........................................................................................................4-3
4.1.7 Upper rear cover................................................................................................4-4
4.1.8 Left rear cover....................................................................................................4-4
4.1.9 Inner tray............................................................................................................4-4
4.1.10 Left cover...........................................................................................................4-5
4.1.11 Tray back cover .................................................................................................4-5
4.1.12 Connecting port cover........................................................................................4-5
4.1.13 Right rear cover-1 / Right rear cover-2 ..............................................................4-6
4.1.14 Right front cover ................................................................................................4-6
4.1.15 Left front cover...................................................................................................4-7
4.1.16 Paper exit cover.................................................................................................4-7
4.2 CONTROL PANEL............................................................................................................4-8
4.2.1 Control panel unit...............................................................................................4-8
4.2.2 Display board (DSP)........................................................................................4-10
4.2.3 KEY board (KEY).............................................................................................4-11
4.2.4 Touch panel (TCP) ..........................................................................................4-11
4.2.5 Control panel cover..........................................................................................4-12
4.3 SCANNER.......................................................................................................................4-13
4.3.1 Original glass...................................................................................................4-13
4.3.2 Lens cover.......................................................................................................4-13
4.3.3 Automatic original detection sensor (S1/S2/S3/S4/S5) ...................................4-14
4.3.4 Exposure lamp.................................................................................................4-15
4.3.5 Lens unit..........................................................................................................4-16
4.3.6 Scan motor (M1)..............................................................................................4-18
4.3.7 Carriage-1........................................................................................................4-19
4.3.8 LED driving PC board (LEDB).........................................................................4-22

4.3.9 Installing the lamp harness..............................................................................4-23
4.3.10 Carriage wire / carriage-2 ................................................................................4-25
4.3.11 Platen sensor (S6) / Carriage home position sensor (S7) ...............................4-26
4.3.12 SLG board (SLG).............................................................................................4-26
4.4 LASER OPTICAL UNIT...................................................................................................4-27
4.4.1 Laser optical unit..............................................................................................4-27
4.5 PAPER FEEDING SYSTEM...........................................................................................4-29
4.5.1 Drawer .............................................................................................................4-29
4.5.2 Drawer feeding unit..........................................................................................4-29
4.5.3 Tray-up sensor (S16/S19) ...............................................................................4-30
4.5.4 Empty sensor (S17/S20)..................................................................................4-30
4.5.5 Paper stock sensor (S15/S18).........................................................................4-31
4.5.6 Separation roller .............................................................................................4-31
4.5.7 Feed roller .......................................................................................................4-32
4.5.8 Pickup roller ....................................................................................................4-32
4.5.9 Drawer feed clutch (CLT4/CLT5).....................................................................4-33
4.5.10 Bypass tray......................................................................................................4-34
4.5.11 Paper width detection PC board (SFB)............................................................4-35
4.5.12 Bypass feed unit ..............................................................................................4-36
4.5.13 Bypass separation pad ...................................................................................4-37
4.5.14 Bypass feed roller /Bypass feed clutch (CLT3)................................................4-37
4.5.15 Bypass paper sensor (S12) .............................................................................4-38
4.5.16 Registration guide............................................................................................4-39
4.5.17 Registration sensor (S22)................................................................................4-39
4.5.18 1st transport sensor (S21))..............................................................................4-40
4.5.19 Feed cover.......................................................................................................4-40
4.5.20 Transport roller ................................................................................................4-41
4.5.21 2nd transport sensor (S14)..............................................................................4-42
4.5.22 Feed cover opening/closing detection sensor (S13)........................................4-42
4.5.23 Flywheel...........................................................................................................4-42
4.5.24 Registration roller clutch (CLT2)......................................................................4-43
4.5.25 Upper tray-up motor (M11) ..............................................................................4-44
4.5.26 Upper drawer detection switch (SW6) .............................................................4-45
4.5.27 Hi-speed clutch (CLT6) / Low-speed clutch(CLT7)..........................................4-45
4.5.28 Lower drawer detection switch (SW7) .............................................................4-46
4.5.29 Lower tray-up motor (M12) ..............................................................................4-47
4.5.30 Registration roller (rubber)...............................................................................4-48
4.5.31 Registration roller (metal) ................................................................................4-49
4.6 DRIVE SYSTEM .............................................................................................................4-50
4.6.1 Main motor (M8) ..............................................................................................4-50
4.6.2 Toner motor (M4).............................................................................................4-50
4.6.3 Main motor drive unit.......................................................................................4-51
4.6.4 Process unit fan (M2).......................................................................................4-51
4.7 DRUM RELATED SECTION...........................................................................................4-52
4.7.1 Process unit.....................................................................................................4-52
4.7.2 Drum cleaner unit ............................................................................................4-52
4.7.3 Discharge LED.................................................................................................4-54
4.7.4 Main charger....................................................................................................4-55
4.7.5 Main charger grid ............................................................................................4-55
4.7.6 Main charger cleaner.......................................................................................4-56
4.7.7 Needle electrode ............................................................................................4-56
4.7.8 Drum ...............................................................................................................4-57
4.7.9 Drum cleaning blade .......................................................................................4-57
4.7.10 Drum separation finger ..................................................................................4-58
4.7.11 Recovery blade ...............................................................................................4-59
4.7.12 Ozone filter .....................................................................................................4-59
4.7.13 TRU fan (M9)...................................................................................................4-60
4.7.14 Transfer roller unit............................................................................................4-61

4.7.15 Transfer roller .................................................................................................4-62
4.7.16 Separation needle............................................................................................4-62
4.7.17 Transfer unit.....................................................................................................4-63
4.7.18 Temperature/humidity sensor (S25) ................................................................4-63
4.8 DEVELOPMENT SYSTEM.............................................................................................4-64
4.8.1 Process unit.....................................................................................................4-64
4.8.2 Developer unit..................................................................................................4-65
4.8.3 Removing developer material .........................................................................4-65
4.8.4 Filling developer unit with developer material..................................................4-66
4.8.5 EPU memory board (EPU) ..............................................................................4-67
4.8.6 Auto-toner sensor (S8) ....................................................................................4-67
4.8.7 Drum thermistor (THMS4) ...............................................................................4-68
4.8.8 Guide roller / Developer sleeve .......................................................................4-68
4.8.9 Mixer................................................................................................................4-72
4.8.10 Replacement of oil seal ...................................................................................4-74
4.9 FUSER UNIT...................................................................................................................4-75
4.9.1 Fuser unit.........................................................................................................4-75
4.9.2 Fuser roller unit / Pressure roller unit...............................................................4-76
4.9.3 Separation finger .............................................................................................4-77
4.9.4 Fuser roller.......................................................................................................4-78
4.9.5 Heater lamp .....................................................................................................4-79
4.9.6 Center / Side / Edge thermistor (THMS1/THMS2/THMS3) .............................4-80
4.9.7 Fuser center / Fuser front thermostat (THMO1/THMO2).................................4-81
4.9.8 Pressure roller .................................................................................................4-84
4.9.9 Exit sensor (S9) ...............................................................................................4-86
4.9.10 Installation of the fuser unit fuse (service part)................................................4-87
4.10 PAPER EXIT SECTION/REVERSE SECTION...............................................................4-88
4.10.1 Reverse unit.....................................................................................................4-88
4.10.2 Paper exit unit..................................................................................................4-89
4.10.3 Exit motor (M10) ..............................................................................................4-90
4.10.4 Offset gate home position sensor (S24)..........................................................4-91
4.10.5 Exit roller..........................................................................................................4-91
4.10.6 Reverse motor (M14).......................................................................................4-92
4.10.7 Reverse gate solenoid (SOL1) ........................................................................4-93
4.10.8 Reverse sensor (S23)......................................................................................4-94
4.10.9 Offset gate motor (M13)...................................................................................4-95
4.10.10 Reverse roller ..................................................................................................4-95
4.10.11 Upper transport roller.......................................................................................4-96
4.11 AUTOMATIC DUPLEXING UNIT (ADU).........................................................................4-97
4.11.1 Automatic Duplexing Unit (ADU) .....................................................................4-97
4.11.2 ADU entrance sensor (S11).............................................................................4-98
4.11.3 ADU exit sensor (S10).....................................................................................4-99
4.11.4 ADU motor (M5).............................................................................................4-100
4.11.5 ADU opening / closing switch (SW5).............................................................4-101
4.11.6 ADU clutch (CLT1).........................................................................................4-102
4.11.7 ADU lower transport roller .............................................................................4-104
4.11.8 ADU upper transport roller.............................................................................4-104
4.12 Installation and Replacement of Options ......................................................................4-106
4.12.1 MR-3022 (Reversing Automatic Document Feeder (RADF)) ........................4-106
4.12.2 KD-1025 (Paper Feed Pedestal (PFP)).........................................................4-108
4.12.3 KD-1026 (Large Capacity Feeder (LCF)) ......................................................4-110
4.12.4 MJ-1032 (Finisher).........................................................................................4-112
4.12.5 MJ-1033 (Finisher).........................................................................................4-115
4.12.6 MJ-1101 (Finisher).........................................................................................4-117
4.12.7 MJ-1106 (Finisher).........................................................................................4-118
4.12.8 KN-2520 (Bridge unit)....................................................................................4-121
4.12.9 MJ-5006 (Job separator) ...............................................................................4-123
4.13 Damp Heater Kit (MF-4550U/E) Installation Procedure................................................4-125

4.13.1 Preparation ....................................................................................................4-125
4.13.2 Procedure ......................................................................................................4-125
5. SELF-DIAGNOSIS MODES..........................................................................................5-1
5.1 Overview...........................................................................................................................5-1
5.2 Service UI..........................................................................................................................5-5
5.2.1 Overview............................................................................................................5-5
5.2.2 Login procedure.................................................................................................5-5
5.2.3 [SERVICE MODE] Screen.................................................................................5-7
5.2.4 Setting/Changing password...............................................................................5-7
5.3 Input Check (Test Mode 03) .............................................................................................5-8
5.4 Output Check (Test Mode 03)...........................................................................................5-9
5.5 Test Print Mode (Test Mode 04) .....................................................................................5-10
5.6 Operation Procedure in Adjustment Mode (05)...............................................................5-11
5.7 Test print pattern in Adjustment Mode (05).....................................................................5-13
5.8 Operation Procedure in Setting Mode (08) .....................................................................5-14
5.9 Assist Mode (3C).............................................................................................................5-16
5.9.1 Functions .........................................................................................................5-16
5.9.2 Operating Procedure of Assist Mode...............................................................5-18
5.10 HDD Assist Mode (4C)....................................................................................................5-19
5.10.1 General description..........................................................................................5-19
5.10.2 Operation procedure........................................................................................5-19
5.10.3 Functions .........................................................................................................5-20
5.11 File System Recovery Mode (5C)...................................................................................5-23
5.11.1 Overview..........................................................................................................5-23
5.11.2 Operation procedure........................................................................................5-23
5.11.3 Functions .........................................................................................................5-24
5.12 SRAM Clear Mode (6C) ..................................................................................................5-28
5.12.1 General description..........................................................................................5-28
5.12.2 Operation procedure........................................................................................5-28
5.12.3 Functions .........................................................................................................5-29
5.13 List Print Mode (9S) ........................................................................................................5-30
5.13.1 Operation procedure........................................................................................5-30
5.13.2 List printing ......................................................................................................5-32
5.14 Pixel counter and its related code...................................................................................5-43
5.14.1 Outline .............................................................................................................5-43
5.15 PM support mode related code.......................................................................................5-52
6. SETTING / ADJUSTMENT............................................................................................6-1
6.1 Adjustment Order..............................................................................................................6-1
6.2 Adjustment of Auto-Toner Sensor.....................................................................................6-2
6.3 Image Dimensional Adjustment ........................................................................................6-4
6.3.1 General description............................................................................................6-4
6.3.2 Paper alignment at the registration roller...........................................................6-6
6.3.3 Printer related adjustment..................................................................................6-8
6.3.4 Scanner related adjustment.............................................................................6-14
6.4 Image Quality Adjustment (Copying Function)................................................................6-22
6.4.1 Automatic gamma adjustment .........................................................................6-22
6.4.2 Density adjustment ..........................................................................................6-23
6.4.3 Background adjustment...................................................................................6-24
6.4.4 Sharpness adjustment.....................................................................................6-24
6.4.5 Setting range correction...................................................................................6-25
6.4.6 Adjustment of smudged/faint text ....................................................................6-25
6.4.7 Gamma balance adjustment ...........................................................................6-26
6.4.8 Adjustment of image density............................................................................6-27
6.4.9 Background offsetting adjustment for RADF ...................................................6-28
6.4.10 Judgment threshold adjustment for blank originals .........................................6-29
6.4.11 Surrounding void amount adjustment..............................................................6-29
6.5 Image Quality Adjustment (Printing Function).................................................................6-30

6.5.1 Adjustment of smudged/faint text ....................................................................6-30
6.5.2 Adjustment of image density............................................................................6-31
6.5.3 Gamma balance adjustment............................................................................6-32
6.6 Image Quality Adjustment (Scanning Function)..............................................................6-33
6.6.1 Gamma balance adjustment............................................................................6-33
6.6.2 Density adjustment ..........................................................................................6-34
6.6.3 Judgment threshold for ACS............................................................................6-35
6.6.4 Sharpness adjustment.....................................................................................6-35
6.6.5 Setting range correction...................................................................................6-36
6.6.6 Background adjustment...................................................................................6-37
6.6.7 Fine adjustment of black density .....................................................................6-38
6.6.8 RGB conversion method selection ..................................................................6-38
6.6.9 Adjustment of saturation..................................................................................6-38
6.6.10 Background processing offset adjustment.......................................................6-39
6.6.11 Adjustment of the capacity and image quality of SlimPDF ..............................6-40
6.7 Image Quality Adjustment (FAX Function)......................................................................6-41
6.7.1 Density adjustment ..........................................................................................6-41
6.7.2 Adjustment of image density............................................................................6-42
6.8 Adjustment of High-Voltage Transformer........................................................................6-43
6.8.1 Adjustment.......................................................................................................6-43
6.8.2 Precautions......................................................................................................6-49
6.9 Adjustment of the Scanner Section.................................................................................6-51
6.9.1 Carriages .........................................................................................................6-51
6.9.2 Lens unit..........................................................................................................6-55
6.10 Adjustment of the Paper Feeding System.......................................................................6-58
6.10.1 Sheet sideways deviation caused by paper feeding........................................6-58
6.11 Adjustment of Developer Unit .........................................................................................6-61
6.11.1 Doctor-to-sleeve gap .......................................................................................6-61
6.12 Adjustment of Dogleg......................................................................................................6-64
6.13 Adjustment of the RADF .................................................................................................6-66
6.13.1 Adjustment of RADF position...........................................................................6-66
6.13.2 Adjustment of RADF height .............................................................................6-70
6.13.3 Adjustment of skew..........................................................................................6-72
6.13.4 Adjustment of the leading edge position..........................................................6-75
6.13.5 Adjustment of horizontal position.....................................................................6-77
6.13.6 Adjustment of copy ratio ..................................................................................6-78
6.13.7 Adjustment of RADF opening/closing sensor..................................................6-79
6.14 Adjustment of the Finisher (MJ-1032).............................................................................6-80
6.14.1 Alignment position adjustment.........................................................................6-80
6.14.2 Stapling position adjustment............................................................................6-80
6.14.3 Punching position center adjustment...............................................................6-81
6.14.4 Punch hole position adjustment.......................................................................6-82
6.15 Adjustment of the Finisher (MJ-1033).............................................................................6-83
6.15.1 Saddle stitching position adjustment ...............................................................6-83
6.15.2 Saddle stitch folding position adjustment.........................................................6-83
6.15.3 Alignment position adjustment.........................................................................6-84
6.15.4 Stapling position adjustment............................................................................6-84
6.15.5 Punching position center adjustment...............................................................6-85
6.15.6 Punch hole position adjustment.......................................................................6-85
6.15.7 Saddle stitch alignment position adjustment....................................................6-86
6.15.8 Gripper arm exiting position adjustment ..........................................................6-86
6.15.9 Height/skew adjustment...................................................................................6-86
6.16 Adjustment of the Finisher (MJ-1101).............................................................................6-89
6.16.1 Adjusting the alignment position......................................................................6-89
6.16.2 Adjusting the stapling position .........................................................................6-91
6.16.3 B4-size recycled paper mode settings.............................................................6-93
6.16.4 Adjusting Paper Exit Speed.............................................................................6-95
6.17 Adjustment of the Finisher (MJ-1106)...........................................................................6-102

6.17.1 Adjusting the Alignment Position...................................................................6-102
6.17.2 Adjusting the Stapling Position ......................................................................6-105
6.17.3 Stapling/folding position adjustment in saddle stitch unit...............................6-107
6.17.4 Saddle Stitch Skew Adjustment.....................................................................6-113
6.18 Adjustment of Hole punch unit (MJ-6007).....................................................................6-114
6.18.1 Destination setting of hole punch control PC board.......................................6-114
6.19 Adjustment of Hole punch unit (MJ-6008).....................................................................6-115
6.19.1 Sensor output adjustment .............................................................................6-115
6.19.2 Registration of the number of punch holes....................................................6-118
7. PREVENTIVE MAINTENANCE (PM)............................................................................7-1
7.1 General Description ..........................................................................................................7-1
7.2 PM Display........................................................................................................................7-1
7.2.1 General description............................................................................................7-1
7.2.2 PM display conditions........................................................................................7-1
7.2.3 PM display contents...........................................................................................7-3
7.2.4 Clearing counter ................................................................................................7-4
7.3 General Descriptions for PM Procedure ...........................................................................7-5
7.4 PM Support Mode (6S) .....................................................................................................7-6
7.4.1 General description............................................................................................7-6
7.4.2 Operational flow and operational screen ...........................................................7-6
7.4.3 Work flow of parts replacement .......................................................................7-11
7.5 EPU Replacement Mode (7S).........................................................................................7-12
7.5.1 General description..........................................................................................7-12
7.5.2 Operation flow..................................................................................................7-12
7.5.3 Counters to be cleared ....................................................................................7-14
7.5.4 Precautions......................................................................................................7-14
7.5.5 To allow the equipment to detect a recycled unit as a new one after replacement
7-15
7.6 Fuser Unit Status Detection Mode ..................................................................................7-16
7.6.1 General description..........................................................................................7-16
7.6.2 Operational flow...............................................................................................7-16
7.6.3 Counters to be cleared ....................................................................................7-16
7.6.4 Precautions......................................................................................................7-16
7.7 Preventive Maintenance Checklist..................................................................................7-17
7.7.1 Scanner ...........................................................................................................7-18
7.7.2 Laser optical unit..............................................................................................7-19
7.7.3 Paper feeding section......................................................................................7-20
7.7.4 Drum related section........................................................................................7-23
7.7.5 Developer section............................................................................................7-25
7.7.6 Fuser unit.........................................................................................................7-27
7.7.7 Paper exit section / Reverse section ...............................................................7-29
7.7.8 Automatic duplexing unit..................................................................................7-30
7.7.9 PFP (KD-1025) ................................................................................................7-31
7.7.10 LCF (KD-1026) ................................................................................................7-32
7.7.11 RADF (MR-3022).............................................................................................7-33
7.7.12 Finisher (MJ-1032) ..........................................................................................7-33
7.7.13 Finisher (MJ-1033) ..........................................................................................7-34
7.7.14 Finisher (MJ-1101)...........................................................................................7-35
7.7.15 Finisher (MJ-1106)...........................................................................................7-39
7.7.16 Hole punch unit (MJ-6103) ..............................................................................7-44
7.8 Precautions for Storing and Handling Supplies...............................................................7-45
7.8.1 Precautions for storing the supplies.................................................................7-45
7.8.2 Checking and cleaning of photoconductive drum............................................7-46
7.8.3 Checking and cleaning of drum cleaning blade...............................................7-47
7.8.4 Checking and cleaning of fuser roller and pressure roller ...............................7-47
7.8.5 Checking and replacing the transfer roller.......................................................7-48
7.9 PM KIT............................................................................................................................7-49
7.10 Maintenance Part List .....................................................................................................7-50

7.11 Grease List......................................................................................................................7-52
7.12 Operational Items in Overhauling....................................................................................7-52
8. ERROR CODE AND TROUBLESHOOTING................................................................8-1
8.1 General Descriptions.........................................................................................................8-1
8.2 Error Code List..................................................................................................................8-2
8.2.1 Jam....................................................................................................................8-2
8.2.2 Service call ......................................................................................................8-12
8.2.3 Error in Internet FAX / Scanning Function.......................................................8-19
8.2.4 Printer function error........................................................................................8-28
8.2.5 TopAccess related error ..................................................................................8-30
8.2.6 MFP access error ............................................................................................8-31
8.2.7 Maintenance error............................................................................................8-33
8.2.8 Network error...................................................................................................8-35
8.2.9 Error history .....................................................................................................8-38
8.3 Diagnosis and Prescription for Each Error Code ............................................................8-40
8.3.1 Check item.......................................................................................................8-40
8.3.2 Paper exit jam..................................................................................................8-41
8.3.3 Paper transport jam .........................................................................................8-42
8.3.4 Paper misfeeding.............................................................................................8-55
8.3.5 Cover open jam ...............................................................................................8-63
8.3.6 Other jam.........................................................................................................8-71
8.3.7 RADF jam ........................................................................................................8-76
8.3.8 Finisher jam .....................................................................................................8-82
8.3.9 Drive system related service call ...................................................................8-117
8.3.10 Paper feeding system related service call .....................................................8-118
8.3.11 Scanning system related service call.............................................................8-124
8.3.12 Process related service call...........................................................................8-127
8.3.13 Fuser unit related service call........................................................................8-130
8.3.14 Optional communication related service call .................................................8-133
8.3.15 Circuit related service call..............................................................................8-136
8.3.16 Communication related service call...............................................................8-138
8.3.17 RADF related service call ..............................................................................8-139
8.3.18 Laser optical unit related service call.............................................................8-139
8.3.19 Finisher related service call ...........................................................................8-140
8.3.20 Offset tray related service call .......................................................................8-176
8.3.21 Service call for others ....................................................................................8-177
8.3.22 Error in Internet FAX / Scanning Function.....................................................8-192
8.3.23 Printer function error......................................................................................8-225
8.3.24 TopAccess related error ................................................................................8-231
8.3.25 MFP access error ..........................................................................................8-233
8.3.26 Maintenance error..........................................................................................8-241
8.3.27 Network error.................................................................................................8-251
8.4 Troubleshooting for the Image......................................................................................8-261
8.4.1 Abnormality of image density / Gray balance................................................8-261
8.4.2 Background fogging.......................................................................................8-262
8.4.3 Moire/lack of sharpness.................................................................................8-263
8.4.4 Toner offset....................................................................................................8-264
8.4.5 Blurred image ................................................................................................8-265
8.4.6 Poor fusing.....................................................................................................8-266
8.4.7 Blank copy .....................................................................................................8-267
8.4.8 Solid copy ......................................................................................................8-268
8.4.9 White banding or white void(in the feeding direction)....................................8-269
8.4.10 White banding (at right angle with the feeding direction)...............................8-271
8.4.11 Skew (inclined image)....................................................................................8-272
8.4.12 Black banding (in the feeding direction).........................................................8-273
8.4.13 Black banding (at right angle with the feeding direction) ...............................8-274
8.4.14 White spots....................................................................................................8-275
8.4.15 Poor image transfer.......................................................................................8-276