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.
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.
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CHECKPOINTS WHEN PERFORMING ON-SITE SER- VICE Konica Minolta brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engi- neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
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WARNING: Power Plug and Cord • 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 (with plug and connector on each end) specified by KMBT.
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WARNING: Wiring • 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.
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CAUTION: Ventilation • 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 room b.
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WARNING: Work Performed with the product Powered • 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.
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WARNING: Safety Checkpoints • 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. •...
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WARNING: HANDLING OF CONSUMABLE • 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.
MEASURES TO TAKE IN CASE OF AN ACCIDENT 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.
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INDEX MAINTENANCE ADJUSTING/SETTING TROUBLESHOOTING...
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(6) Removal of the Inch/Metric Sensor/1 Assy (3rd area Only) ... 1-56 (7) Removal of the Flickerless Resistor (Only for 200 V area of Di1611) ..........1-56 5.2 Remounting of the EEPROM (U16) ............1-57 5.3 Installation of the Key Counter ..............1-58 6.
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1.1 Composition ..................... 2-1 1.1.1 Checking before starting work ............2-1 1.1.2 Checkpoints when conducting on-site service ....... 2-1 3. UTILITY MODE ....................2-5 3.1 Utility Mode Function Tree ............... 2-5 3.2 Utility Mode Setting Procedure ..............2-7 3.3 Setting in the Utility Mode ................ 2-7 3.3.1 MACHINE SETTING ..............
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(4) ID ADJUST ................2-22 (5) VG ADJUST ................2-23 (6) FUSER TEMP. Ad (PLAIN) ............ 2-23 (7) FUSER TEMP. Ad (THICK) ........... 2-24 (8) FUSER TEMP. Ad (OHP) ............2-25 (9) LEADING EDGE ERASE ............2-26 (11) TRAILING EDGE ERASE ............2-27 (12) VERTICAL EDGE ERASE .............
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(11) CUSTOMER ID ..............2-46 4.3.5 FUNCTION ..................2-46 (1) PAPER FEED TEST .............. 2-46 (2) PROCESS CHECK ..............2-46 (3) ATDC AUTO ADJUST ............2-46 (4) PRINT TEST PATTERN ............2-47 (5) ADF FEED TEST ..............2-47 (6) COPY ADF GLASS AREA ............. 2-47 (7) CCD MOVE TO HOME ............
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE SAFETY INFORMATION Laser Safety • This is a digital machine certified as a class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual.
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MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 the U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class I Laser product under Radiation Performance Stan- dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Finland, Sweden VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. LOUKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Laser Safety Label • A laser safety labels is attached to the outside of the machine as shown below. 4035D510CA Laser Caution Label • A laser caution label is attached to the inside of the machine as shown below.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Precautions for Handling the Laser Equipment • When laser protective goggles are to be used, select ones with a lens conforming to the above specifications. • When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC Drum, be sure first to turn the copier OFF.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE MAINTENANCE SCHEDULE PM Parts List Cycle (K=1,000) Ref. PM Parts Page Clean Replace ☞ 1-9 When a malfunction Paper Take-Up Roll 150k occurs ☞ 1-9 When a malfunction Paper Separator Roll Assy 150k...
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 NOTES • The contents of the maintenance schedule are subject to change without notice. • For part numbers, see Parts Manual and Parts Modification Notice. • Both for the copier and options, check the PM counter values for performing the service procedures.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Replacement and Cleaning of Parts 4.3.1 Paper Take-up/Transport Section Removal of the Paper Separator Roller Assy and Paper Take-Up Roller. 1. Slide out the Paper Feed Tray/1. 2. Remove two screws and the mounting bracket.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Cleaning of the Paper Separator Roller 1. Remove the Paper Separator Roller Assy. 2. Using a soft cloth dampened with alcohol, wipe the Paper Separator Roller clean of dirt. 4035D005AA Cleaning of the Paper Take-Up Roller 1.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Removal of the Paper Dust Remover Assy 1. Open the Right Door. 2. Remove the Imaging Unit. ☞ 1-15 3. Unhook the two tabs and remove the Paper Dust Remover Assy. 4035D008AB Cleaning of the Paper Dust Remover 1.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4. Using a soft cloth dampened with alcohol, wipe the Bypass Transport Roller clean of dirt. 4035D011AB 5. Using a soft cloth dampened with alcohol, wipe the Bypass Transport Roll clean of dirt.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Cleaning of the Lens 1. Remove the Original Glass. ☞ 1-25 2. Using a soft cloth dampened with alcohol, wipe the Lens clean of dirt. 4035D015AA Cleaning of the CCD Sensor 1. Remove the Original Glass.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Cleaning of the Scanner Rails/Bushings 1. Remove the Original Glass. ☞ 1-25 2. Using a soft cloth dampened with alcohol, wipe the Scanner rails and bushings clean of dirt. NOTE • After the Scanner rails and bushings have been cleaned, apply oil (copier lubricant A or FLOIL 947P).
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 4.3.4 Imaging Unit (IU) NOTE • When the developer is to be changed, it is necessary that toner in the Recycled Toner Recycling Duct and Toner Conveying Duct be fed into the Developer Mixing Chamber. To do that, remove the Toner Bottle and run “ATDC Auto Adjust”...
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MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 2. Remove two screws in the rear of the IU. 4035D023AA 3. Remove two screws at the front of the IU. 4035D024AA 4. Widen flaps on both ends (marked with A in the...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Removal of the PC Drum 1. Remove two screws and the pivot shaft. 4035D027AA 2. Remove the PC Drum. NOTES • Protect the PC Drum that has been removed with a protective cloth.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Removal of the PC Drum Charge Corona Assy 1. Remove the PC Drum. 2. Remove the Main Erase. 3. Turn the holder in the rear in the direction of the arrow to remove it from the side bracket.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Cleaning of the Ds Collars 1. Using a soft cloth dampened with alcohol, wipe the two Ds Collars clean of dirt. 4035D034AA Cleaning of the Developer Scattering Prevention Plate 1. Remove three screws and the Developer Scatter- ing Prevention Plate.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 <<How to Dump Developer>> • Dump developer on the surface of the Sleeve Roller by turning the gear in the direction of the arrow with the Developing Unit tilted as shown. NOTE • Turning the gear backward at this time could dam- age the Mylar for cleaning the ATDC Sensor.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 4. Unplug one connector, and remove one screw and the ATDC Sensor. 4035D041AA 5. Install the ATDC Sensor and the Developer Scattering Prevention Plate. 6. Assemble the Drum Assy to the Developing Assy to reconstruct the IU.
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MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 2. Using a brush, apply a light coat of toner to the surface of the PC Drum. 4021U008AB 3. Hold both ends of the PC Drum with your both hands and turn the PC Drum a half turn in the direction of the arrow.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 4.3.5 IMAGE TRANSFER SECTION Removal of the Image Transfer Roller Assy 1. Remove the Image Transfer Roller Assy. NOTES • Indentations or dirt on the surface of the Image Transfer Roller adversely affect the printed image.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.3.6 FUSING SECTION Removal of the Fusing Unit 1. Remove the Rear Cover and Rear Right Cover. ☞ 1-26 2. Unplug two connectors of the Fusing Unit. 4035D045AA 3. Open the Right Door.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE MISCELLANEOUS PARTS Disassembly and Reassembly 5.1.1 Identification and Removal Procedures of Doors, Covers, and Exterior Parts Copier 4035D047AB Part Name Removal Procedure Remove the Original Scanning Glass. → Remove one screw. → Remove the holding bracket. → Remove the Original Glass Original Glass.
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MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Part Name Removal Procedure Remove the Left Cover. → Remove the Paper Exit Tray. → Remove two screws. → Remove the Rear Inside 10 Rear Inside Cover Cover. Remove the Left Cover. → Remove two screws. →...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 5.1.2 Removal of Circuit Boards and Other Electric Components NOTES • When removing a circuit board or other electric component, refer to “PRECAUTIONS FOR HANDLING THE PWBs” and follow the corresponding removal procedures.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Removal of the Master Board (PWB-A) 1. Remove the Rear Cover. ☞ 1-26 2. Unplug all connectors from the Master Board. 4035D049AA 3. Remove four screws and the Master Board. 4035D050AA 1-28...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Removal of the Control Board (PWB-C/C) 1. Remove the Rear Cover and Upper Rear Cover. ☞ 1-26 2. Remove the Master Board. ☞ 1-28 3. Unplug all connectors from the Control Board. 4035D051AB 4.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Removal of the High Voltage Unit (HV1) 1. Remove the Rear Cover. ☞ 1-26 2. Remove the Master Board. ☞ 1-28 3. Unplug all connectors from the High Voltage Unit. 4035D054AA 4. Remove two screws and the High Voltage Unit.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Removal of the Power Supply Unit (PU1) 1. Remove the Left Cover, Rear Cover, and Upper Rear Cover. ☞ 1-25 2. Remove the Master Board. 3. Remove the Control Board. ☞ 1-29 4. Remove the harness from four wiring saddles and one edge cover.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Removal of the Paper Size Detecting Board (PWB-I) 1. Remove the Rear Cover. ☞ 1-26 2. Slide out the Paper Feed Tray/1. 3. Unhook two tabs and remove the holder. 4035D058AA 4. Remove the lever.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Removal of the Heater Relay Board (PWB-RY): 200 V area only 1. Remove the Front Cover and Left Cover. ☞ 1-25 2. Unplug two connectors and remove three PWB supports and the Heater Relay Board.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 5.1.3 Removal of Units Removal of the Manual Bypass 1. Remove the Rear Right Cover. ☞ 1-26 2. Open the Right Door. 3. Remove two screws, unplug one connector, and remove the Manual Bypass.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 4. Unplug two connectors. 4035D063AA 5. Remove the Toner Hopper Unit. 4035D064AA 6. Remove two screws and the Toner Replenishing Motor. 4035D065AA Removal of the PH Unit 1. Remove the Front Cover, Left Cover, Rear Cover, Paper Exit Tray, and Rear Inside Cover.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 3. Remove two cable holders of the flat cable. 4035D067AA 4. Remove the harness from one wiring saddle. 4035D068AA 5. Remove three screws (with springs) and the PH Unit. 4035D069AA Disassembly of the Fusing Unit <Removal of the Thermistor and Paper Separator Fingers>...
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 3. Remove the torsion coil spring and the Movable Guide Assy. 4035D145AA 4. Remove four shoulder screws, two washers, and the Pressure Roller Cover. 4035D071AB 5. Remove two bushings and the Pressure Roller.
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MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 6. Remove one screw. Then, slide the Paper Sepa- rator Finger Assy in the direction of the arrow and take it off. 4035D072AA 7. Remove one screw and the Thermistor. 4035D073AA 8. Unhook springs and remove the four Paper Sep- arator Fingers.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 5.1.4 Disassembly of the IR Section Removal of the CCD Unit 1. Remove the Original Glass. ☞ 1-25 2. Remove four screws and the CCD Unit Cover. 4035D016AA 3. Mark a line along the profile of the CCD Unit mounting bracket as shown on the left.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Installation of the CCD Unit 1. Position the CCD Unit along the marking line. Then, temporarily secure three screws at the center of each of the screw slots. 2. Adjust the position of the CCD Unit.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 4. Remove one flat cable and the Scanner Assy. 4035D080AA 5. Remove two screws, unplug one connector, and remove the Inverter Board. 4035D081AA 6. Remove two screws and the Exposure Lamp. 4035D082AA 1-41...
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Removal of the Scanner Motor 1. Remove the Right Rear Cover. ☞ 1-26 2. Remove the Scanner Motor harness from the five wiring saddles. 4035D083AA 3. Unplug one connector from the Control Board.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Removal of the Scanner Drive Cables 1. Remove the Left Cover, Front Cover, Rear Cover, Upper Rear Cover, Right Rear Cover, Original Glass, and Original Scanning Glass. ☞ 1-25 2. Loosen two screws (to which red paint has been applied) and remove the Scanner Assy.
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MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 5. Remove the rear cable from the cable pulley. 4035D089AA 6. Remove one screw from the front cable pulley. 4035D090AA 7. Remove one screw from the rear cable pulley. 4035D091AA 8. Snap off one C-ring from the front side of the Pul- ley Assy.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 9. Snap off one C-ring from the rear side of the Pul- ley Assy. 4035D093AA 10. Pull out the shaft and two bushings. 4035D094AB 11. Remove two screws from the rear side of the Pul- ley Assy and remove the gear.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Winding of the Scanner Drive Cables <Overall View> Wire pulley 2 Wire pulley 1 Pulley D Pulley C Pulley B Pulley A 4035D109AA NOTES • The cables are color-coded and differ in type from each other: the front cable is silver, while the rear cable is black.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 3. Wind the cable on side A around wire pulley 2 four turns clockwise, starting with the slit at the top in the front left of the pulley. 4035D112AA 4. Affix tape to secure the cable to wire pulley 2.
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MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 8. Affix tape to secure the cable to wire pulley 1. 4035D117AA 9. Use the two screws to secure the gear to wire pulley 2. NOTE • Make sure that the cable pulley is doweled to the gear.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 14. Wind the cable from pulley A around pulley B. NOTE • Wind the cable around the outer groove in pulley B. Pulley B Pulley A 4035D119AA 15. Pass the cable from pulley B into the hole in the IR frame.
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MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 19. Pass the leading edge of each of the front and rear cables into the space between the IR frame and copier frame. 20. Affix tape to temporarily secure the cables to the copier frame.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 5.1.5 Disassembly of the Engine Section Removal of the Main Motor 1. Remove the Rear Cover. ☞ 1-26 2. Remove four screws, unplug one connector, and remove the Main Motor. 4035D096AB Removal of the Power Unit Cooling Fan Motor 1.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Removal of the Fusing Cooling Fan Motor 1. Remove the Rear Right Cover. ☞ 1-26 2. Open the Right Door. 3. Remove the Image Transfer Roller Assy. ☞ 1-23 4. Remove one screw and the Transport Unit Assy.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 7. Remove two screws, unplug one connector, and remove the Fusing Cooling Fan Motor. 4035D101AA Removal of the Paper Size Sensor Assy 1. Remove the Rear Cover. ☞ 1-26 2. Slide out the Paper Feed Tray/1.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Removal of the Fusing Unit Interlock Switch 1. Remove the Rear Cover. ☞ 1-26 2. Remove the harness from one wiring saddle. 4035D130AC 3. Remove two screws (to which red paint has been applied).
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE <Fusing Unit Interlock Switch Reinstallation Procedure> 1. Fit the switch holder to the Fusing Unit Interlock Switch. 2. Connect the four connectors to the Fusing Unit Interlock Switch Assy. 3. Temporarily secure the Fusing Unit Interlock Switch using two screws (to which red paint has been applied).
☞ 1-26 2. Remove one screw, unplug one connector, and remove the Inch/Metric Sensor/1 Assy. 4035D141AA Removal of the Flickerless Resistor (Only for 200 V area of Di1611) 1. Remove the Rear Cover. ☞ 1-26 2. Remove the Master Board.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE Remounting of the EEPROM (U16) NOTE • When the Control Board (PWB-C/C) is replaced with a new one, EEPROM (U16) must be demounted from the old PWB-C/C and remounted on the new PWB-C/C.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Installation of the Key Counter 1. Cut out the knockout from the Right Cover. 4623D001AA 2. Using two screws, secure the counter mounting bracket. 4623D002AA 3. Connect the Key Counter Socket connector. 4623D003AA 4.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 5. Using two screws, secure the Key Counter cover. 4623D005AA 6. Plug in the Key Counter. NOTE • When the Key Counter is mounted, set “Machine Counter Copying” of the Security mode to “Dis- abled.”...
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 UPGRADING THE FIRMWARE Upgrading the Copier Firmware (PWB-C/C) 6.1.1 Installing the Driver NOTES • Since USB is used to upgrade the firmware, the host computer must be run on an OS of Windows 98 or later.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 9. Click [Finish]. 10. The “Found New Hardware Wizard” dialog box will appear again: Repeat steps 4~8 to install all drivers. <For Windows Me/98> 1. Prepare the files necessary for upgrading the firmware, and copy them to PC.
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 6.1.2 Procedure for Upgrading the GDI Firmware 1. Turn ON the Power Switch of the copier. 2. Start the host computer. 3. Copy the “Update Software” folder and “Update” file to drive C. (Copy them into the highest directory on drive C.)
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 8. Click the [Update] button to start the transfer of the firmware data. (Wait until data trans- fer is completed.) 9. Check the Display for status of the firmware upgrading sequence. <PWB-C/C> 4035D530CA NOTE •...
MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 6.1.3 Procedure when Upgrading the Firmware has failed NOTES • Perform upgrading using BIOS only when upgrading from PC using ordinary USB con- nection has failed and the PC has not started properly.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE 6. Disconnect jumper [FJ2] on the Fax board. 4035D536AA 7. Install the BIOS ROMs (U17, U19) on the Fax board. 4035D537AA 8. Attach the Fax board to Control board (PWB-C/C). 9. Turn on the power switch of copier. Following message will appear on message panel and copier waits for file data.
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MAINTENANCE Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 12. Remove the Fax board. 13. Disconnect jumper [CJ1] on the Control board (PWB-C/C) from 2-3 and connect it to 1- 14. Disconnect jumper [FJ1] on the Fax board from 2-3 and connect it to 1-2.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 HOW TO USE THE ADJUSTMENT SECTION Composition This part “Adjustment” describes items to be adjusted and their method of adjustment that are required by this machine and gives detailed explanations. 1.1.1 Checking before starting work When conducting claims in the field, it is necessary to check in advance the following: 1.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING...
Di1611/Di2011 FIELD SERVICE Ver. 1.0 Mar. 2004 ADJUSTING/SETTING Adjustment Item List • This table shows the list of adjustment items when replacing a part. Items are numbered by the priority if there is any. SERVICE MODE Mechanical Others CLEAR SERVICE'S CHOICE...
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ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver. 1.0 Mar. 2004 SERVICE MODE Mechanical Others Adjustment Setting Item CLEAR SERVICE'S CHOICE ADJUST FUNCTION DATA Service Item NOTE Check Items Pick-Up Roller Replace Take-Up Roller Replace Separator Roller Replace Pick-Up Roller Replace Take-Up Roller...
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 UTILITY MODE • Utility mode is used to make settings for the utility functions. Utility Mode Function Tree 1. AUTO PANEL RESET 2. ENERGY SAVE MODE 3. AUTO SHUT OFF 4. DENSITY (ADF) MACHINE SETTING 5.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING 1. PAPER PRIORITY 2. DENSITY PRIORITY 3. DENSITY LEVEL (A) 4. DENSITY LEVEL (M) COPY SETTING 1 5. BINDING POS. 6. MARGIN SETTING 7. ERASE SETTING 8. SMALL ORIGINAL Utility 1. MIXED ORIGINAL 2.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Utility Mode Setting Procedure <Procedure> 1. Press the Utility key. 2. The Utility mode screen will appear. <Exiting the Mode> • Press the Panel Reset key. <Changing the Setting Values in Utility Mode Functions>...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING DENSITY (ADF) Purpose Setting Details/Precautions To set the reading image density level when the • The default setting is “MODE1.” Automatic Document Feeder is used. MODE1: To lower the image density to prevent a dirty copy from NOTE being produced.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 3.3.2 PAPER SOURCE SETUP • PAPER SOURCE SETUP is used to make the various settings for the paper source. INCH/METRIC Purpose Setting Details/Precautions To select the paper size type for each paper • The default setting is “METRIC.”...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING 3.3.3 USER MANAGEMENT DRUM DEHUMIDIFY Purpose Setting Details/Precautions To run a drum dry sequence. <Step> 1. Select “DRUM DEHUMIDIFY” and ✽ The drum dry sequence is run when an image press the [Yes] key.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 3.3.4 ADMIN. MANAGEMENT • ADMIN. MANAGEMENT is used to make various settings after the administrator number set using the Service mode has been entered. <Admin. Management Mode Setting Procedure> 1. Press the Utility key.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING <ACCESS NO. REG.?> Purpose Setting Details/Precautions To register a 3-digit (001 to 999) access number <Registration Procedure> used for the copy track function, or to change or 1. Type any access number from the delete a previously set access number.
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ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 <COPY TRACK DATA?> Purpose Setting Details/Precautions • To display or clear the total count value of a <Display/Clear Procedure> specific account. 1. Select “DISPLAY” and press the • To clear the total count values of all accounts [Yes] key.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING 3.3.5 COPY SETTING 1 • COPY SETTING 1 is used to set the default values for different copy functions. PAPER PRIORITY Purpose Setting Details/Precautions To set the priority paper source. • The default setting is “1ST.”...
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ERASE SETTING Purpose Setting Details/Precautions To set the erase width when making erase cop- • The default setting is “LEFT” and “10 ies. mm.” <Step> 1. Select the erase position. LEFT UPPER FRAME 2.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING 4IN1 COPY ORDER Purpose Setting Details/Precautions To set the layout of copy images in 4in1 copies. • The default setting is “PATTERN1.” PATTERN1 PATTERN2 4035S501AA 4035S502AA CRISSCROSS MODE Purpose Setting Details/Precautions To select the crisscross function.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 SERVICE MODE • The Service mode is used to check, set, adjust, or register the various service functions. Service Mode Function Tree SHIPMENT DESTINATION MAINTENANCE COUNTER IU LIFE STOP MODE ID ADJUST VG ADJUST FUSER TEMP.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING TOTAL COUNTER SIZE COUNTER PM COUNTER MAINTENANCE COUNTER SUPPLIES LIFE COUNT. 3. COUNTER APPLICATION COUNTER SCAN COUNTER PAPER SIZE COUNTER MISFEED COUNTER TROUBLE COUNTER TONER DENSITY LEVEL PROCESS CONTROL MAIN F/W VER. ENGINE F/W VER.
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ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 REDUCTION2 REDUCTION1 7. FIXED ZOOM CHANGE EXPANSION1 EXPANSION2 PANEL BUZZER TEST 8. FACTORY TEST RAM TEST Service Mode MEMORY CLEAR PM COUNTER MAINTENANCE COUNTER SUPPLIES LIFE COUNT. 9. CLEAR DATA APPLICATION COUNTER SCAN COUNTER...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING Service Mode Function Setting Procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the Service mode. <Procedure> 1. Press the Utility key.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Setting in the Service Mode 4.3.1 SERVICE’S CHOICE • SERVICE’S CHOICE is used to make the various service settings. SHIPMENT DESTINATION Purpose Setting Details/Precautions To select the display of the fixed zoom ratios and •...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING MAINTENANCE COUNTER Purpose Setting Details/Precautions To enter an appropriate counter value (0 to • The default setting is “0.” 999999) as the tentative maintenance time. 0: Not counted Specify the setting on maintenance counter to “1”...
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 VG ADJUST Purpose Setting Details/Precautions To adjust image density by varying Vg with • The default setting is “0.” changing sensitivities as the PC Drum is used for Increase the setting value to eliminate an extended period of time.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING For Di2011 Mode selected in Service’s Choice Setting value Paper width Mode 1 Mode 3 Heater Lamp temperature (main/sub) 221 mm or more 200 ° C 220 mm or less 221 mm or more 190 °...
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 FUSER TEMP. Ad (OHP) Purpose Setting Details/Precautions To set the fusing temperature when OHP trans- • The default setting is “0.” parencies are used. Setting range: -1 to +1 ✽ When fusing failure occurs <Temperature table for adjusting fusing temperature for OHP transparencies>...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING LEADING EDGE ERASE Purpose Setting Details/Precautions To adjust the erase width on the leading edge • The default setting is “4 mm.” of the image by varying the laser emission timing. 0 mm 1 mm 2 mm 3 mm 4 mm 5 mm ✽...
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 (11) TRAILING EDGE ERASE Purpose Setting Details/Precautions To adjust the erase width on the trailing edge • The default setting is “4 mm.” of the image by varying the laser emission timing. 0 mm 1 mm 2 mm 3 mm 4 mm 5 mm ✽...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING (12) VERTICAL EDGE ERASE Purpose Setting Details/Precautions To adjust the erase width on both edges of the Select the erase width value in the CD image (in CD direction) by varying the laser direction.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 (13) LOOP ADJUST (TRAY1) Purpose Setting Details/Precautions To adjust the length of the loop formed in the Setting range: -3.9 to 3.9 mm paper before the Synchronizing Roller. (1 step: 0.6 mm) ✽ When a skew feed, fold, or misfeed of paper occurs ✽...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING (15) LOOP ADJUST (DUPLEX): Di2011 Only Purpose Setting Details/Precautions ✽ Refer to the option service manual (AD- To adjust the length of the loop formed in the paper before the Synchronizing Roller. 17) for details.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 (17) FLS PAPER SIZE Purpose Setting Details/Precautions To select the paper size for FLS. • The default setting is “330✽210.” ✽ When the FLS paper size is changed 330✽203 330✽210 ✽ At setup 330✽216...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING 4.3.2 ADJUST PRN MAIN REGIST Function Purpose Setting Details/Precautions To adjust by varying the starting position Press the Start key to start a test Test Copy of image writing in the main scanning copy cycle.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 PRN SUB REGIST Function Purpose Setting Details/Precautions To adjust by varying the starting position Press the Start key to start a test Test Copy of image writing in the sub scanning copy cycle.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING CCD MAIN ZOOM Function Purpose Setting Details/Precautions To adjust variations in machining and Press the Start key to start a test Test Copy installation accuracy of different IR parts copy cycle. by varying the scanning zoom ratio in the •...
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 CCD SUB ZOOM Function Purpose Setting Details/Precautions To adjust variations in machining and Press the Start key to start a test Test Copy installation accuracy of different IR parts copy cycle. by varying the scanning zoom ratio in the •...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING CCD MAIN REGIST Function Purpose Setting Details/Precautions To adjust variations in machining and Press the Start key to start a test Test Copy installation accuracy of different IR parts copy cycle. by varying the starting position of image Setting range: 20 to 180 scanning in the main scanning direction.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 CCD SUB REGIST Function Purpose Setting Details/Precautions To adjust variations in machining and Press the Start key to start a test Test Copy installation accuracy of different IR parts copy cycle. by varying the starting position of image Setting range: 60 to 140 scanning in the sub scanning direction.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING ADF SUB ZOOM ✽ appears only when the AF-12 or AFR-19 (Di2011 Only) is installed Function Purpose Setting Details/Precautions Test Copy To adjust variations in machining and ✽ Refer to the option service...
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 (10) ADF SUB REGIST2 ✽ appears only when the AFR-19 (Di2011 Only) is installed Function Purpose Setting Details/Precautions Test Copy To adjust variations in machining and ✽ Refer to the option service installation accuracy of different parts by manual (AFR-19) for details.
• The count should be cleared when the 4: TRAY3 (should not be used) corresponding PM part is replaced. 5: TRAY4 (should not be used only for Di1611) 6: TRAY5 (should not be used only for Di1611) 7: ADF (FEED)
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAINTENANCE COUNTER Purpose Setting Details/Precautions To display the count of the Maintenance • To clear the count, use “Clear Data” of the Counter. Service mode. When the counter reaches “0”, mainte- nance call M1 or the Tech. Rep. call will appear, according to the setting on maintenance counter of service choice.
2: TRAY1 ferent parts of the copier. 3: TRAY2 4: TRAY3 (should not be used only for Di1611) 5: TRAY4 (should not be used only for Di1611) 6: TRAY5 (should not be used only for Di1611) 7: PICK-UP/TSPT.
C0000: Main Motor malfunction ber of malfunctions detected C0044: ADF Cooling Fan failure according to the malfunction (should not be used only for Di1611) code. C0045: Fusing Cooling Fan Motor malfunction C004E: Power Unit Cooling Fan Motor malfunction C0070: Toner Replenishing Motor malfunction...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING 4.3.4 DISPLAY • DISPLAY displays various types of information. TONER DENSITY LEVEL Purpose To display the current output value of ATDC sensor. Refer to the following table for actual T/C values. ✽ Used to check the T/C ratio when the image density is defective.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MAIN F/W VER. (PWB-C/C) Purpose To display the main firmware version information. ENGINE F/W VER. (PWB-A) Purpose To display the engine firmware version information. PCL F/W VER. Purpose To display the PCL firmware version information.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING (11) CUSTOMER ID Purpose To display the customer ID of the copier. 4.3.5 FUNCTION • FUNCTION allows the various service functions (paper feed test, image printing) to be checked and adjustments to be made.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 PRINT TEST PATTERN Item Purpose Setting Details/Precautions To produce a test pattern for <Step> image adjustments. 1. Select the paper source. TRAY1 TRAY2 ✽ When skew, registration, or PATTERN 2. Select the type of test pat- zoom ratio has been adjusted tern.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING CCD MOVE TO HOME Purpose Setting Details/Precautions To move the Scanner to its home position • Pressing the Start key will move the Scan- and fix it at the home position. ner toward the left from its standby posi- tion.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.3.6 ADMIN. REGISTRATION • ADMINISTRATOR NUMBER REGISTRATION is used to register or change the adminis- trator number required when entering the Admin. Management function of the Utility mode. <Step> 1. Using the 10-Key Pad, type the 6-digit administrator number (000000 to 999999) to be registered or changed.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING 4.3.7 FIXED ZOOM CHANGE • FIXED ZOOM CHANGE is used to change the fixed zoom ratios. <Step> 1. Select the particular fixed zoom ratio to be changed. 2. Using the 10-Key Pad, enter the desired fixed zoom ratio.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Latin America (Metric) Setting name Default fixed zoom ratio Setting range REDUCTION2 51% to 70% REDUCTION1 71% to 99% EXPANSION1 115% 101% to 140% EXPANSION2 141% 141% to 199% Latin America (Inch) Setting name...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING 4.3.9 CLEAR DATA • CLEAR DATA is used to clear data of various types. MEMORY CLEAR Purpose Setting Details/Precautions To clear the setting values listed on the • Settings of the Utility mode right, resetting them to the default values.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 PAPER SIZE COUNTER Purpose To clear each of the counts of the Paper Size Counter. MISFEED COUNTER Purpose To clear each of the counts of the Misfeed Counter. TROUBLE COUNTER Purpose To clear each of the counts of the Trouble Counter.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING SIZE COUNTER COUNT Purpose Setting Details/Precautions To set the paper size to be counted. • The default setting is “1.” 0: Not counted 1: A3/LEDGER L 2: A3/B4/LEDGER L/LEGAL L/8K L 3: A3/B4/FLS/LEDGER L/LEGAL L/11 ×...
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MECHANICAL ADJUSTMENTS Adjustment of the Position of the Scanner and 2nd/3rd Mir- rors Carriage NOTE • This adjustment is to be made when the Scanner Drive Cables has been replaced or rewound. <Adjustment Procedure>...
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING <Cross-sectional View> NOTE • When the Scanner Assy is secured to the Scanner Drive Cables using the fixing brackets, make sure that the cables are located as shown on the left. If the cables are not positioned properly, the Scan- ner Assy can move askew, resulting an image problem.
ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 CCD Unit Position Adjustment NOTE • This adjustment is to be made when the CCD Unit has been replaced. <Adjustment Standard> • Adjust so that the amount of error falls within ±1.0% of the length to be measured.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING Adjustment of the Gap between the Doctor Blade and Sleeve Roller (Db Adjustment) NOTE • This adjustment is to be made when an image problem (uneven density, low ID, gradation reproducibility failure, etc.) occurs.
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ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 7. Using a small piece of paper, remove developer from the shaded area on the surface of the Sleeve Roller and put it in the Developer Mixing Chamber. 8. Remove the developer left on the surface of the Sleeve Roller.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 ADJUSTING/SETTING Manual Bypass (for the optional AD-17) CD Registration Adjustment ✽ Di2011 Only NOTE • This adjustment is to be made when the PH Unit has been replaced. <Adjustment Procedure> 1. Load the Paper Feed Tray/1 with A4 crosswise paper.
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ADJUSTING/SETTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 9. Loosen two screws on the Manual Bypass and adjust the position of the Manual Bypass. Adjustment Instructions If width A on the copy is smaller than width A on the test pattern, move the Manual Bypass toward the rear of the copier.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING INTRODUCTION • Information required for troubleshooting and steps that must be performed are described in this chapter. Electrical Components Check Procedure • If a paper misfeed or malfunction occurs, perform the following operations to check the condition of the electrical components.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 1.1.2 Switch Step Check Result Action Does the input signal (NO) of the control board change Replace the from L to H when the switch is activated? switch. YES Replace the control board.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 1.1.5 Motor Step Check Result Action Does the LOCK signal switch to H when the machine Replace the con- goes into standby? trol board. Replace the motor. Does the REM signal of the master board change YES Replace the motor.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MISFEEDS Initial Checks • When a paper misfeed occurs, first perform the following initial checks. Check Item Action Does paper meet product specifications? Replace paper. Is the paper curled, wavy, or damp? Replace paper.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING Misfeed Display • When a paper misfeed occurs, the Error indicator lights up steadily and the Display gives a corresponding message. C4506P298CA 4980P502DA Display Message Misfeed/Paper Location Ref. Page Paper take-up section of the Paper Feed Tray/1 ☞...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Misfeed-Detecting Sensor Layout • When the optional AF-12, PF-126, and MB-6 are mounted 4035T501AA Exit Paper Sensor (PC3) Registration Sensor (PC3/AF) Synchronizing Roller Sensor (PC1) Separator Sensor (PC4/AF) Paper Set Sensor/Bypass (PC2) Paper Exit Sensor (PC5/AF)
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING Misfeed Detection Timing/Troubleshooting Procedures 2.5.1 Misfeed at the Paper Feed Tray/1 Paper Take-up Section <Detection Timing> Type Description Paper Take- • The leading edge of the paper does not unblock the Synchronizing Up Section...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 2.5.2 Misfeed at the Manual Bypass Paper Take-up Section <Detection Timing> Type Description Manual Bypass • The leading edge of the paper does not unblock the Synchronizing paper take-up Roller Sensor (PC1) even after the lapse of a given period of time section misfeed after the Paper Take-up Solenoid/Bypass (SL2) has been energized.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 2.5.3 Misfeed at the Multiple Bypass Paper Take-up Section (When the optional Multiple Bypass MB-6 is mounted) <Detection Timing> Type Description Paper take-up • The leading edge of the paper does not unblock the Synchronizing...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 2.5.4 Misfeed at the Paper Feed Unit Paper Take-up/Vertical Transport Section (When the optional Paper Feed Unit PF-126 is mounted) <Detection Timing> Type Description Paper take-up/ • The leading edge of the paper does not unblock the Synchronizing...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 2.5.5 Misfeed at the Paper Separating Section <Detection Timing> Type Description • The Exit Paper Sensor (PC3) is not blocked even after the lapse of a given period of time after the paper has unblocked the Synchronizing Roller Sensor (PC1).
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 2.5.6 Misfeed at the Fusing/Exit Section <Detection Timing> Type Description Fusing/exit sec- • The Exit Paper Sensor (PC3) is not unblocked even after the lapse of tion misfeed a given period of time after the Synchronizing Roller Sensor (PC1) has detection been blocked.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 2.5.7 Misfeed at the Document Take-up Section (When the optional Automatic Document Feeder AF-12 is mounted) <Detection Timing> Type Description Document • The Separator Sensor (PC4/AF) is not blocked even after the lapse of...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 2.5.8 Misfeed at the Document Transport Section (When the optional Automatic Document Feeder AF-12 is mounted) <Detection Timing> Type Description Document • The Registration Sensor (PC3/AF) is not blocked even after the lapse...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 2.5.9 Misfeed at the Document Exit Section (When the optional Automatic Docu- ment Feeder AF-12 is mounted) <Detection Timing> Type Description Document exit • The Paper Exit Sensor (PC5/AF) is not blocked even after the lapse of...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 MALFUNCTIONS • The copier’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the Touch Panel. 4980P550DA List of Malfunction Codes Malfunc-...
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING Malfunc- tion Malfunction Name Detection Timing Code • The surface temperature of the Fusing Roller does not reach a given level even after the lapse of a given period of time during a warm-up cycle.
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TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Malfunc- tion Malfunction Name Detection Timing Code Fusing failure • The temperature detected by the Fusing Roller Sub (abnormally high Thermistor remains higher than 240°C for a given period fusing temperature of time.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING Malfunc- tion Malfunction Name Detection Timing Code Master Board (PWB-A) to Control Board (PWB-C/C) con- nection failure • There is no acknowledge signal transmitted from the Master Board (PWB-A) to Control Board (PWB-C/C) for...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Resetting Procedure by Malfunction Code Code Description Procedure C0000 Main Motor malfunction • Turn OFF and ON the Power Switch. C0044 ADF Cooling Fan Failure C0045 Fusing Cooling Fan Motor malfunction Power Supply Cooling Fan Motor mal-...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING Malfunction Detection Timing and Troubleshooting Proce- dure C0000 Main Motor malfunction <Detection Timing> Trouble Description Code • The Main Motor (M1) Lock signal remains HIGH for a continuous 1- C0000 sec. period at any time 1 sec. after the Main Motor has started turning.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 C0044 ADF Cooling Fan Failure (When the optional Duplexing Document Feeder AFR-19 is mounted) <Detection Timing> Trouble Description Code • The ADF Fan Motor Lock signal remains set to H for a set period of C0044 time while the EDH Fan Motor is turning.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING C0045 Fusing Cooling Fan Motor Malfunction <Detection Timing> Trouble Description Code • The Fusing Cooling Fan Motor (M3) Lock signal remains HIGH for a C0045 continuous 1-sec. period while the Fusing Cooling Fan Motor is turn- ing at full speed or decelerated speed.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 C004E Power Supply Cooling Fan Motor Malfunction <Detection Timing> Trouble Description Code • The Power Supply Cooling Fan Motor (M4) Lock signal remains HIGH for a continuous 1-sec. period while the Power Supply Cooling Fan...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING C0070 Toner Replenishing Motor Malfunction <Detection Timing> Trouble Description Code • The Toner Bottle Home Position Sensor (PC7) outputs a HIGH signal for a continuous 3.5-sec. period while the Toner Bottle is turning.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 C0210 Abnormal Image Transfer Voltage <Detection Timing> Trouble Description Code • The image transfer voltage remains more than 100 V for a continuous C0210 given period of time while the PC Drum remains stationary.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING C0500 Warm-up Failure C0501 Warm-up Failure 2 (Di2011 Only) C0510 Fusing Failure (Abnormally Low Fusing Temperature) C0511 Fusing Failure (Abnormally Low Fusing Temperature 2) (Di2011 Only) C0520 Fusing Failure (Abnormally High Fusing Temperature) C0521 Fusing Failure (Abnormally High Fusing Temperature 2) (Di2011 Only) <Detection Timing>...
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TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 <Detection Timing> Relevant Electrical Components Fusing Roller Heater Lamp (H1) Fusing Roller Thermostat (TS1) Fusing Roller Sub Heater Lamp (H2) Fusing Unit Interlock Switch (S2) Fusing Roller Thermistor Power Supply Unit (PU1) Fusing Roller Sub Thermistor (TH2)
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING WIRING DIAGRAM Ref. Location Step Operations Page Control signal (Electrical Components) Check the Fusing Roller Sub Thermistor (TH2) for operation. <Check procedure> Disconnect CN22 (4P) and check the – – resistance across CN22-2 and 3 on the Thermistor side.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 C0650 Faulty Scanner Home Position Sensor <Detection Timing> Trouble Description Code • The Scanner Home Position Sensor (PC10) does not go from HIGH to LOW when the Scanner Motor (M5) is energized for a given num-...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING C0F32 Faulty ATDC Sensor C0F33 Improperly Adjusted ATDC Sensor <Detection Timing> Trouble Description Code • The measurement taken by the ATDC Sensor (UN1) at a time 2.0 sec. after the Main Motor (M1) has started turning is less than 5% (greater than 4.63 V).
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 (10) C1038 Engine Connection Failure <Detection Timing> Trouble Code Description Master Board (PWB-A) to Control Board (PWB-C/C) connection failure • There is no acknowledge signal transmitted from the Master Board (PWB-A) to Control Board (PWB-C/C) for 1.5 sec. or more.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING (11) C1200 Faulty ASIC/Memory <Detection Timing> Trouble Description Code ASIC/memory (for image and control) fault C1200 • A write or read error occurs with SRAM on the Control Board (PWB-C/C). <Action> Relevant Electrical Components...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 (12) C1300 Polygon Motor Malfunction C13F0 Faulty HSYNC <Detection Timing> Trouble Description Code Startup failure • A LOW Polygon Motor (M2) Lock signal is not detected within a given period of time that begins 1 sec. after the Polygon Motor has started turning.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING (13) C133B Communication with Option Error C133D ROM Check Error <Detection Timing> Trouble Description Code • It is not possible to communicate with the Printer Board within a pre- C133B determined period of time during a print cycle.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 (15) C14A3 IR Fluorescent Lamp Fault <Detection Timing> Trouble Description Code The Exposure Lamp (LA2) of the Scanner fails to turn ON. C14A3 • The intensity of the Exposure Lamp is a predetermined value or less during shading and re-shading.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING Miscellaneous Errors 3.4.1 Flash ROM Error • The copier determines that there is an error if writing to the flash ROM fails during upgrading of the firmware. • When the Power Switch is turned ON, the Error indicator lights up steadily and a corre- sponding message appears on the Display.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 Power Source-Related Malfunctions The copier does not turn ON. Step Check Result Action A malfunction code appears when the • Go to step 2. Power Switch is turned ON. • Go to step 3.
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Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING Step Check Result Action Check of output of DC 5 V to Master • Change DC power Sup- Board (copier: PWB-A) ply (PU1). <Check Procedure> Check voltage across a Master Board (copier: PWB-A) pin and GND when the Power Switch is turned ON.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 IMAGE FAILURE Image Failure Troubleshooting • In this chapter, troubleshooting is divided into “initial checks” and “troubleshooting proce- dures classified by image failures.” • If any image failure has occurred, first make the initial checks, then proceed to the corre- sponding image failure troubleshooting procedure.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING Identification of the Faulty System • Determine if the failure is attributable to an input system (IR) or output system (engine). Check Result Action Full-size Reduced Copy made at a reduced ratio Input system...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.2 Image Reading Section: black copy <Typical Faulty Images> 4011T036AA Step Check Result Action Exposure Lamp turns ON when the Power Switch Go to step 3. is turned ON. Exposure Lamp is abnormally lit (flickers or abnor- Go to step 4.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.3 Image Reading Section: Low image density <Typical Faulty Images> 4011T003AA Step Check Result Action Shading sheet reading portion (the portion on the YES • Clean. backside of the Original Glass to which Original Width Scale is affixed) is dirty.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.4 Image Reading Section: Foggy background or rough image <Typical Faulty Images> 4011T004AA Step Check Result Action Original Glass is dirty. YES • Clean. Scanner mirrors are dirty. YES • Clean. Exposure Lamp (LA2) is dirty.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.5 Image Reading Section: Black streaks or bands <Typical Faulty Images> 4011T017AA 4011T023AA Step Check Result Action Original Glass is dirty, scratchy, worn, or damaged. YES • Clean or change. Shading sheet reading portion (the portion on the YES •...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.6 Image Reading Section: Black spots <Typical Faulty Images> 4011T521AA Step Check Result Action Original Glass is dirty or scratchy. YES • Clean. CCD Board (PWB-J) connector is loose. YES • Reconnect. Control Board (PWB-C/C) connector is loose.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.7 Image Reading Section: Blank streaks or bands <Typical Faulty Images> 4011T015AA 4011T020AA Step Check Result Action Original Glass is dirty, scratchy, worn, or damaged. YES • Clean or change. Shading sheet reading portion (the portion on the YES •...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.8 Image Reading Section: Uneven image density <Typical Faulty Images> 4011T525AA Step Check Result Action Original Glass is dirty, scratchy, worn, or damaged. YES • Clean or change. Shading sheet reading portion (the portion on the YES •...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.9 Image Reading Section: Gradation reproduction failure <Typical Faulty Images> 4011T526AA Step Check Result Action Original Glass is dirty, scratchy, worn, or damaged. YES • Clean or change. Shading sheet reading portion (the portion on the YES •...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.10 Image Reading Section: Periodically uneven image <Typical Faulty Images> 4011T528AA Step Check Result Action Scanner Motor (M5) is securely fastened using the • Secure in position. dedicated fixing screws. Scanner Motor (M5) drive mechanism is dirty or YES •...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.11 Image Reading Section: Moire <Typical Faulty Images> 4011T040AA Step Check Result Action Moire distortions recur even after the orientation of • Change the original original has been changed. mode (select one other than that resulted in moire).
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.12 Printer Section: Blank copy <Typical Faulty Images> 4011T035AA Step Check Result Action Imaging Unit is installed correctly. • Reinstall. Connector between the Imaging Unit and copier is YES • Clean. dirty. PH Shutter (located along the laser path between YES •...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.13 Printer Section: Black copy <Typical Faulty Images> 4011T036AA Step Check Result Action PC Drum Charge Corona grid mesh and Comb YES • Reinstall. Electrode are loose. PC Drum Charge Corona contact is dirty, scratchy, YES •...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.14 Printer Section: Low image density <Typical Faulty Images> 4011T003AA Step Check Result Action The image changes when “Toner Replenisher” is YES • Replenish the sup- executed. ply of toner using • “Toner Replenisher” of Utility Toner Replenisher.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.15 Printer Section: Foggy background or rough image <Typical Faulty Images> 4011T004AA Step Check Result Action The image changes when “ID Adjust” and “VG YES • Readjust. For details, Adjust” are executed. see ADJUSTING/ SETTING.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.16 Printer Section: Black streaks or bands <Typical Faulty Images> 4011T017AA 4011T023AA Step Check Result Action PC Drum is dirty or scratchy. YES • Clean or change. Foreign matter (such as paper dust) sticks to the YES •...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.17 Printer Section: Black spots <Typical Faulty Images> 4011T521AA Step Check Result Action Toner is present along the paper path. YES • Clean. PC Drum is dirty or scratchy. YES • Clean or change.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.18 Printer Section: Blank streaks or bands <Typical Faulty Images> 4011T015AA 4011T020AA Step Check Result Action PC Drum ground terminal is dirty, scratchy, YES • Clean, correct, or deformed, or damaged. change. DB of IU is plugged with foreign matter (such as YES •...
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.19 Printer Section: Void areas <Typical Faulty Images> 4011T008AA Step Check Result Action Foreign matter is present along the paper path. YES • Remove foreign matter. Paper dust plugs up the Paper Dust Remover.
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.20 Printer Section: Smear on back <Typical Faulty Images> 4011T009AA Step Check Result Action Toner is spilled over area inside copier. YES • Clean interior. Toner is present along the paper path. YES • Clean.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.21 Printer Section: Uneven image density <Typical Faulty Images> 4011T525AA Step Check Result Action PC Drum ground plate is dirty, scratchy, deformed, YES • Clean, correct, or worn, or damaged. change. PC Drum Charge Corona grid mesh and Comb YES •...
Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 TROUBLESHOOTING 4.4.22 Printer Section: Gradation reproduction failure <Typical Faulty Images> 4011T526AA Step Check Result Action PC Drum is dirty. YES • Clean. Image Transfer Roller is dirty, scratchy, deformed, YES • Clean or change.
TROUBLESHOOTING Di1611/Di2011 FIELD SERVICE Ver.1.0 Mar. 2004 4.4.23 Printer Section: Periodically uneven image <Typical Faulty Images> 4011T528AA Step Check Result Action IU is securely fastened using the dedicated fixing • Secure in position. screws. PH Unit is securely fastened using the dedicated •...
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