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Ep5000/ep4000 General, Mechanical/ Electrical

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November 2018
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Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBG000AA EP5000/EP4000 GENERAL, MECHANICAL/ ELECTRICAL Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1149SBG000BA CONTENTS GENERAL 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 2. PRECAUTIONS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . G-4 3. PRECAUTIONS FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 4. HANDLING OF THE CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . G-6 5. SYSTEM OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7 1156SBG000BA MECHANICAL/ELECTRICAL 1. CROSS-SECTIONAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1 2. COPY PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-2 3. DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-4 4. SEQUENTIAL EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-5 5. WATCHDOG (CPU OVERRUN MONITOR) FUNCTION . . . . . . . . . . M-8 5-1. Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-8 5-2. Watchdog Function Post-Processing . . . . . . . . . . . . . . . . . . . . . . M-9 6. MALFUNCTION BYPASS FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . M-10 7. IMAGE STABILIZATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-11 7-1. AIDC Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-12 7-2. Image Stabilization Control Processing Timing . . . . . . . . . . . . . . M-13 7-3. Details of Image Stabilization Controls . . . . . . . . . . . . . . . . . . . . . M-14 8. PC DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-16 9. DRUM CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-17 9-1. Ozone Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-18 10. IMAGE ERASE LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-19 11. OPTICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-24 11-1. Exposure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-25 11-2. AE Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-26 11-3. Lamp Reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-27 11-4. Aperture Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-27 11-5. Scanner and 2nd/3rd Mirror Carriage Movement . . . . . . . . . . . M-28 i Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 CONTENTS 11-6. Lens Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-30 11-7. 4th/5th Mirrors Carriage Movement . . . . . . . . . . . . . . . . . . . . . . M-31 11-8. Original Glass Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-32 12. ORIGINAL SIZE DETECTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . M-33 12-1. Identification of Original Size Detecting Sensors . . . . . . . . . . . M-33 12-2. Original Size Detecting Operation . . . . . . . . . . . . . . . . . . . . . . . . M-33 12-3. Sensor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-34 12-4. Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-35 12-5. Original Size Detection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . M-36 13. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-37 13-1. 13-2. 13-3. 13-4. 13-5. 13-6. 13-7. 13-8. 13-9. Developing Unit Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . M-38 Magnet Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-39 Developing Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-40 Doctor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-41 ATDC Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-42 Sub Hopper Toner Replenishing Mechanism . . . . . . . . . . . . . . M-44 Sub Hopper Toner Empty Detection Control . . . . . . . . . . . . . . . M-45 Main Hopper Toner Replenishing Mechanism . . . . . . . . . . . . . . M-46 Swing Out/In the Main Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . M-47 14. IMAGE TRANSFER AND PAPER SEPARATION . . . . . . . . . . . . . . . . M-48 14-1. Ozone Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-49 15. PAPER SEPARATOR FINGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-50 16. CLEANING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-53 16-1. Spent Toner Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-54 16-2. Cleaning Bias (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-56 17. MAIN ERASE LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-57 18. PAPER TAKE-UP/FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-58 18-1. 18-2. 18-3. 18-4. 18-5. 18-6. 18-7. Drawer-in-Position Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-59 Drawer Paper Lifting/Lowering Mechanism/Control . . . . . . . . . M-60 Paper Level Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-65 Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-66 Universal Tray (2nd Drawer) Paper Size Detection . . . . . . . . . M-68 Paper Take-Up Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-71 Paper Take-Up Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-74 19. MULTI BYPASS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-76 19-1. Paper Take-Up Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-77 19-2. Paper Separating Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . M-78 19-3. Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-79 ii Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 CONTENTS 20. VERTICAL PAPER TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-80 21. SYNCHRONIZING ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-81 21-1. Synchronizing Roller Drive Mechanism . . . . . . . . . . . . . . . . . . . M-82 21-2. Paper Dust Remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-82 21-3. Synchronizing Roller Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-83 21-4. Prevention of Low Image Density on Copy . . . . . . . . . . . . . . . . M-84 22. PAPER TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-86 22-1. Suction Belt Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . M-87 23. FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-88 23-1. Fusing Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-89 23-2. Fusing Rollers Pressure Mechanism . . . . . . . . . . . . . . . . . . . . . M-90 23-3. Cleaning Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-91 23-4. Paper Separator Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-92 23-5. Fusing Section Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-93 24. EXIT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-94 24-1. Detection of Left Upper Door in Position . . . . . . . . . . . . . . . . . . M-95 25. DEHUMIDIFYING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-96 26. MEMORY BACKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-97 iii Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1151SBG000D SAFETY INFORMATION ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. Denmark ADVARSEL! Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering. Udskiftning må kun ske med batteri af samme fabrikat og type. Levér det brugte batteri tilbage til leverandøren. Norway ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri. Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten. Brukte batterier kasseres i henhold til fabrikantens instruksjoner. Sweden VARNING Explosionsfara vid felaktigt batteribyte. Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren. Kassera använt batteri enligt fabrikantens instruktion. Finland VAROITUS Paristo voi räjähtää, jos se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä Käytetty paristo valmistajan ohjeiden mukaisesti. Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1151SBG000CA GENERAL Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBG0100A 1 SPECIFICATIONS TYPE : Console (with Stationary Platen) PHOTOCONDUCTOR : Organic Photoconductor COPYING SYSTEM : Electrostatic Dry Powdered Image Transfer to Plain Paper PAPER FEEDING SYSTEM : 3-Way Feeding EXPOSURE SYSTEM : Mirror Scanning, Slit Exposure DEVELOPING SYSTEM : New Micro-Toning System CHARGING SYSTEM : Comb Electrode DC Negative Corona with Scorotron System IMAGE TRANSFER SYSTEM : Visible Image Transfer by means of a Single-Wire DC Negative Corona with Corotron System PAPER SEPARATING SYSTEM : Single-Wire AC Corona with Corotron System, plus Paper Separator Finger FUSING SYSTEM : Heat Roller PAPER DISCHARGING SYSTEM : Charge Neutralizing Brush MAXIMUM ORIGINAL SIZE : Metric-A3L; Inch-11” 1st Drawer: Fixed Paper Size Tray (500 sheets of paper, USA Area: 550 sheets of paper) 2nd Drawer: Universal Tray (500 sheets of paper, USA Area: 550 sheets of paper) Multi Bypass Table (50 sheets of paper) 17”L (L: Lengthwise) Dimens sions Medium COPY MEDIUM 1st Drawer (Automatic feeding) 2nd Drawer (Automatic feeding) Multi Bypass Table Plain paper (60 to 90 g/m2) f f f Translucent paper – – f Transparencies – – f Thick paper (91 to 157 g/m2) – – f Recycled paper f f f Maximum (Width Length) 297 432 mm 297 432 mm 297 432 mm Minimum (Width Length) 140 182 mm 140 182 mm 100 140 mm f: Permissible –: Not permissible G-1 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 MULTIPLE COPIES : 1 to 999 WARMING-UP TIME : 240 sec. or less with room temperature of 20°C and rated power voltage FIRST COPY TIME : A4C or 8-1/2” 11”C: 3.7 sec. or less (in Full size Mode using 1st Drawer) CONTINUOUS COPY SPEED (copies/min.): Fed from 1st Drawer EP5000: Zoom Ratio Area Size A3L A4L A4C B4L Metric Zoom Ratio 1.000 Area 28 37 50 31 Inch 1.000 Area Size 1.000 11” 17” (L) 8-1/2” 11” (L) 8-1/2” 11” (C) 28 39 50 L: Lengthwise; C: Crosswise EP4000: Zoom Ratio Area Size 26 34 40 29 A3L A4L A4C B4L Metric Zoom Ratio Size 1.000 11” 17” (L) 8-1/2” 11” (L) 8-1/2” 11” (C) Inch 25 35 40 L: Lengthwise; C: Crosswise ZOOM RATIOS Area Mode Fixed Variable Metric Inch Full Size 1.000 1.000 Reduction 0.816 0.707 0.500 0.785 0.733 0.647 0.500 Enlargement 1.154 1.414 2.000 1.214 1.294 1.545 2.000 50% to 200% (in 0.1% increments) LENS : Through Lens (F = 6, f = 190 mm) EXPOSURE LAMP : Halogen Frost Tube Lamp FUSING TEMPERATURE : 200°C G-2 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 POWER/CURRENT CONSUMPTION (Copier Only) EP5000: Voltage 115 V 120 V Exposure Lamp (Rating) Fusing Heater Lamp (Rating) 80 V 262 W 115/120 V 950 W 1390 W 127 V 220 V 240 V Max. Power Consumption 1450 W 1480 W 160 V 290 W 220/240 V 1000 W Exposure Lamp (Rating) Fusing Heater Lamp (Rating) 80 V 262 W 115/120 V 900 W 1410 W 1550 W EP4000: Voltage 115 V 120 V 1250 W 127 V 220 V 240 V POWER REQUIREMENTS Max. Power Consumption 1330 W 1400 W 160 V 290 W 220/240 V 950 W 1360 W 1500 W : 115 V, 120 V, 127 V, 220-240 V; 50/60 Hz ENVIRONMENTAL CONDITIONS Temperature 10 to 30°C with a fluctuation of 10°C or less per hour Humidity 15 to 85% RH with a fluctuation of 10% RH or less per hour Ambient Illumination 3,000 lux or less Levelness 1° (1.75 mm/100 mm) DIMENSIONS (Copier Only) : Width .... 620 mm (24-1/2”) Depth .... 740 mm (27”) Height ... 960 mm (37-3/4”) (including Original Cover and Paper Feed Cabinet) WEIGHT : EP5000: (with Paper Feed Cabinet) 123.5kg (272-1/4lbs) EP4000: (with Paper Feed Cabinet) 122.0kg (269lbs) *excluding the Copy Tray, starter, toner, and paper G-3 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1149SBG0200A 2 PRECAUTIONS FOR INSTALLATION J Installation Site To ensure safety and utmost performance of the copier, the copier should NOT be used in a place: F Where it will be subjected to extremely high or low temperature or humidity. F Which is exposed to direct sunlight. F Which is in the direct air stream of an air conditioner, heater or ventilator. F Which puts the operator in the direct stream of exhaust from the copier. F Which has poor ventilation. F Where ammonia gas might be generated. F Which does not have a stable, level floor. F Where it will be subjected to sudden fluctuations in either temperature or humidity. If a cold room is quickly heated, condensation forms inside the copier, resulting in blank spots in the copy. F Which is near any kind of heating device. F Where it may be splashed with water. F Which is dirty or where it will receive undue vibration. F Which is near volatile flammables or curtains. J Power Source Use an outlet with a capacity of 115/120/127V, 1480W or more, or 220-240V, 1550W or more. F If any other electrical equipment is sourced from the same power outlet, make sure that the capacity of the outlet is not exceeded. F Use a power source with little voltage fluctuation. F Never connect by means of a multiple socket any other appliances or machines to the outlet being used for the copier. F Make the following checks at frequent intervals: D Is the power plug abnormally hot? D Are there any cracks or scrapes in the cord? D Has the power plug been inserted fully into the outlet? D Does something, including the copier itself, ride on the power cord? F Ensure that the copier does not ride on the power cord or communications cable of other electrical equipment, and that it does not become wedged into or underneath the mechanism. J Grounding To prevent receiving electrical shocks in the case of electrical leakage, always ground the copier. F Connect the grounding wire to: D The ground terminal of the outlet. D A grounding contact which complies with the local electrical standards. F Never connect the grounding wire to a gas pipe, the grounding wire for a telephone, or a water pipe. G-4 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1149SBG0300A 3 PRECAUTIONS FOR USE To ensure that the copier is used in an optimum condition, observe the following precautions. F Never place a heavy object on the copier or subject the copier to shocks. F Insert the power plug all the way into the outlet. F Do not attempt to remove any panel or cover which is secured while the copier is making copies. F Do not turn OFF the Power Switch while the copier is making copies. F Provide good ventilation when making a large number of copies continuously. F Never use flammable sprays near the copier. F If the copier becomes inordinately hot or produces abnormal noise, turn it OFF and unplug it. F Do not turn ON the Power Switch at the same time when you plug the power cord into the outlet. F When unplugging the power cord, do not pull on the cord; hold the plug and pull it out. F Do not bring any magnetized object near the copier. F Do not place a vase or vessel containing water on the copier. F Be sure to turn OFF the Power Switch at the end of the workday or upon power failure. F Use care not to drop paper clips, staples, or other small pieces of metal into the copier. J Operating Environment The operating environmental requirements of the copier are as follows. D Temperature: 10°C to 30°C with a fluctuation of 10°C per hour D Humidity: 15% to 85% RH with a fluctuation of 10% RH per hour J Power Requirements The power source voltage requirements are as follows. D Voltage Fluctuation: AC115/120/127/220-240V "10% (Copying performance assured) )6%, –10% (Only AC 127V) –15% (Paper feeding performance assured) D Frequency Fluctuation: 50/60 Hz "0.3% G-5 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1151SBG0400A 4 HANDLING OF THE CONSUMABLES Before using any consumables, always read the label on its container carefully. F Use the right toner. The applicable copier model name is indicated on the Toner Bottle. F Paper can to be easily damaged by dampness. To prevent absorption of moisture, store paper, which has been removed from its wrapper but not loaded into the Drawer, in a sealed plastic bag in a cool, dark place. F Keep consumables out of the reach of children. F Do not touch the PC Drum with bare hands. F Store the paper, toner, and other consumables in a place free from direct sunlight and away from any heating apparatus. F The same sized paper is of two kinds, short grain and long grain. Short grain paper should only be fed through the copier crosswise, long grain paper should only be fed lengthwise. F If your hands become soiled with toner, wash them with soap and water immediately. F Do not throw away any used consumables (PC Drum, starter, toner, etc.). They are to be collected. NOTE Do not burn, bury in the ground, or throw into the water any consumables (PC Drum, starter, toner, etc.). G-6 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBG0500A 5 SYSTEM OPTIONS 9,10 1, 2 11 12 13 1138O525AA 1149M026AA 1134O005AA 1136O061AA 3 7, 8 5 6 4 1. 2. 3. 4. 5. 6. 7. Automatic Document Feeder AF-5 Duplexing Document Feeder AFR-13 Paper Feed Cabinet PF-105 Duplex Cabinet PF-5D Paper Feed Cabinet PF-205 Duplex Unit AD-9 10-Bin Sorter S-106 8. 9. 10. 11. 12. 13. G-7 10-Bin Staple Sorter ST-104 20-Bin Sorter S-208 20-Bin Staple Sorter ST-211 Data Terminal Data Controller D-102 Large Capacity Cassette C-301 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1151SBM000CA MECHANICAL/ ELECTRICAL Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM0100A 1 CROSS-SECTIONAL VIEW 1 2 4 3 5 6 7 8 9 10 11 12 13 14 15 16 17 30 29 18 28 19 20 27 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 26 3rd Mirror 2nd Mirror 1st Mirror Exposure Lamp Ventilation Fan Motor Ozone Filter Lens Main Erase Lamp Cleaning Blade PC Drum Charge Corona PC Drum 6th Mirror Image Erase Lamp 4th Mirror 5th Mirror Sub Hopper Transport Roller 25 24 23 22 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. M-1 21 1134M001AB Manual Bypass Take-Up Roll Upper Vertical Transport Roller Lower Vertical Transport Roller 2nd Drawer Paper Take-Up Roll 1st Drawer Paper Take-Up Roll Synchronizing Roller Image Transfer/Paper Separator Coronas Main Drive Motor Suction Belt Fusing Roller 1st Paper Exit Roller 2nd Paper Exit Roller Exit/Duplex Switching Guide Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM0200A 2 COPY PROCESS 2 3 4 10 9 13 1. 2. 3. 4. 5. 6. 7. PC DRUM DRUM CHARGING IMAGE ERASE EXPOSURE DEVELOPING PAPER FEEDING IMAGE TRANSFER 12 1 11 8. 9. 10. 11. 12. 13. 8 PAPER SEPARATION CLEANING MAIN ERASE TRANSPORT FUSING PAPER EXIT 5 MULTI BYPASS TABLE 7 6 1. PC Drum The PC Drum is an aluminum cylinder coated with a photosensitive semiconductor. It is used as the medium on which a visible developed image of the original is formed. (For more details, see “8. PC DRUM”.) 2. Drum Charging The PC Drum Charge Corona Unit is equipped with a Comb Electrode and a Scorotron Grid to deposit a uniform negative charge across the entire surface of the PC Drum. (For more details, see “9. DRUM CHARGING”.) 3. Image Erase Any areas of charge which are not to be developed are neutralized by lighting up LEDs. (For more details, see “10. IMAGE ERASE LAMP”.) 4. Exposure Light from the Exposure Lamp reflected off the original is guided to the surface of the PC Drum and reduces the level of the negative charges, thereby forming an electrostatic latent image. (For more details, see “11. OPTICAL SECTION”.) 5. Developing Toner positively charged in the Developer Mixing Chamber is attracted onto the electrostatic latent image changing it to a visible, developed image. A DC negative bias voltage is applied to the Sleeve/Magnet Roller to prevent toner from being attracted onto those areas of the PC Drum which correspond to the background areas of the original. (For more details, see “13. DEVELOPMENT”.) M-2 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 6. Paper Feeding Paper is fed either automatically from the 1st or 2nd Drawer, or manually via the Multi Bypass Table or Manual Bypass Table. Paper separation is accomplished by the torque limiter fitted to the Paper Separator Roll. (For more details, see “18. PAPER TAKE-UP/FEED SECTION”.) 7. Image Transfer The single-wire Image Transfer Corona Unit applies a DC negative corona emission to the underside of the paper, thereby attracting toner onto the surface of the paper. (For more details, see “14. IMAGE TRANSFER AND PAPER SEPARATION”.) 8. Paper Separation The single-wire Paper Separator Corona Unit applies an AC corona emission to the underside of the paper to neutralize the paper. In addition, mechanical paper separation is provided by the two PC Drum Paper Separator Fingers fitted to the Imaging Unit. (For more details, see “14. IMAGE TRANSFER AND PAPER SEPARATION”.) 9. Cleaning Residual toner on the surface of the PC Drum is scraped off by the Cleaning Blade. (For more details, see “16. CLEANING UNIT”.) 10. Main Erase Light from the Main Erase Lamp neutralizes any surface potential remaining on the surface of the PC Drum after cleaning. (For more details, see “17. MAIN ERASE LAMP”.) 11. Transport The paper is fed to the Fusing Unit by the Suction Belts. (For more details, see “22. PAPER TRANSPORT”.) 12. Fusing The developed image is permanently fused to the paper by a combination of heat and pressure applied by the Upper and Lower Fusing Rollers. (For more details, see “23. FUSING UNIT”.) 13. Paper Exit After the fusing process the paper is fed out by the Paper Exit Roller onto the Copy Tray. (For more details, see “24. EXIT UNIT”.) M-3 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM0300A 3 DRIVE SYSTEM The Main Drive Motor provides drive for the entire mechanism of the copier. To help minimize operating noise, timing belts and plastic gears are used in large numbers for the drive train parts. 2nd Paper Exit Roller Drive Suction Unit Drive PC Drum Drive Developing Section Drive Manual Feed Paper Take-Up Clutch Upper Fusing Roller Drive Gear Upper Vertical Transport Roller Drive Toner Conveying Coil Drive (on PC Unit) Main Drive Motor Synchronizing Roller Clutch Paper Transport Clutch Lower Vertical Transport Roller Drive 1136M002AA M-4 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM0400A 4 SEQUENTIAL EXPLANATION * Figure in ( ) are the timer values for EP5000. A The power cord is plugged into the outlet. ON DC Power Supply Unit PU1 outputs DC24V for dehumidifying heating. ON Drum Dehumidifying Heater H3 Paper Dehumidifying Heater H2 ON B Only when Drum Dehumidifying Switch S3 and Paper Dehumidifying Switch S12 are ON Power Switch S1 is turned ON. OFF H2 ON PU1 outputs DC24V and DC 5V. ON Power Supply Board PWB-C outputs DC 24V. (DC24V line: ON) ON Master Board PWB-A outputs DC4.7V and DC12V. ON Control panel display ON Suction Fan Motor M4 turns at half speed. ON Fusing Section Cooling Fan Motor M15 ON Approx. 1sec. Fusing Heater Lamp H1 The Lens is detected at the home position. The Mirror is detected at the home position. The Scanner makes its initial motion. The Lens is detected at the full size position. The Mirror is detected at the full size position. The surface temperature of the Upper Fusing Roller reaches 165°C. ON ON ON *1 ON Main Drive Motor M1 and Original Glass Cooling Fan Motor M5 start predrive. Ventilation Fan Motor M3 M4 turns at full speed. Developing Bias/Paper Separator Corona ON Image Erase Lamp LA2 Approx. 100msec. Approx. 200msec. To À on next page M-5 ON ON PC Drum Charge Corona/ Image Transfer Corona Main Erase Lamp LA3 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 À After the lapse of 30sec. or 15sec. *30sec. if the Upper Fusing Roller surface temperature is less than 165°C when S1 is turned ON and 15sec. if the surface temperature is 165°C or higher. OFF Approx. 5msec. PC Drum Charge Corona/Image Transfer Corona Approx. 160msec. *2 OFF LA2 OFF Approx. 285msec. M1/M5 OFF LA3 Approx. 150msec. (500msec.) OFF Developing Bias/Paper Separator Corona Approx. 4850msec. (4500msec.) C M4 turns at half speed. M3 The Start Key is pressed. The components are energized in order of *1 on the preceding page. Approx. *3 OFF ON ON ON Exposure Lamp LA1 Fusing Section Cooling Fan Motor M15 *3 : Varies for different drawers. Paper Transport Clutch CL1 1st Drawer Paper Take-Up Motor M11 1st Drawer Vertical Transport Sensor PC63 is blocked ( Approx. 5msec. OFF M11 Paper Leading Edge Detecting Sensor PC55 is blocked ( Approx. 45msec. OFF ). L L ). CL1 D SCP Board PWB-F outputs a LOW BASE signal to Master Board PWB-A. Approx. 75msec. (65msec.) OFF LA3...Leading edge erase M-6 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 E PWB-F outputs a LOW TRON signal to PWB-A. ON CL1 ON Synchronizing Roller Clutch CL2 ON Approx. 170msec. Separator Solenoid SL1 Approx. 150msec. OFF SL1 F PWB-F outputs a LOW SCEND signal to PWB-A. Approx. 200msec. SCAN signal: ...The Scanner stops and starts a return motion. OFF LA1 Approx. 250msec. H G The trailing edge of the paper moves past Transport Roller Sensor PC54 (unblocked: H ) OFF Approx. 5msec. CL1 H The trailing edge of the paper moves past Paper Leading Edge Detecting Sensor PC55 (unblocked: H Approx. 210msec. I ) OFF CL2 The Trailing edge of the paper moves past Paper Exit Switch S53 (ON: H The components are deenergized in order of *2 on the preceding page. M-7 ). Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1149SBM0500A 5 WATCHDOG (CPU OVERRUN MONITOR) FUNCTION The watchdog function monitors whether any of the CPUs mounted in the copier overrun. If this function detects that a CPU overruns, the copier automatically resets the CPU, thereby restarting the logic circuit and mechanism. Even if a copier CPU operates erratically due to electrical noise, therefore, the copier is able to recover from the faulty condition so that the number of visits made by the Technical Representative for CPU overrun can be minimized. 1156SBM0501A 5-1. Configuration The copier has three printed-circuit boards each on which a CPU is mounted: *SCP Board PWB-F that controls the optical system, *Master Board PWB-A that controls the copier, Paper Feed Cabinet and Duplex Unit, and *MSC Board PWB-B that controls the control panel and system. In addition to these, each of the control boards for the Data Controller, Duplexing Document Feeder, and Sorter/Staple Sorter is equipped with a CPU. The watchdog functions are summarized as follows: *Each of the copier CPUs monitors whether or not it overruns. *The MSC CPU monitors the communications conditions of the CPUs in the Duplexing Document Feeder and Data Controller. *The Master CPU monitors the communications conditions of the CPUs in the Sorter and Staple Sorter. *The control boards for the Paper Feed Cabinet and Duplex Unit do not have a CPU in them. Instead, the Master CPU in the copier controls their operations. Data Controller Duplexing Document Feeder Control Board Control Board (PWB-A) Copier SCP Board PWB-F Sorter, Staple Sorter MSC Board PWB-B Control Board (PWB-A) Master Board PWB-A = Board on which a CPU is mounted Paper Feed Cabinet, Duplex Unit Large Capacity Cassette M-8 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1149SBM0502A 5-2. Watchdog Function Post-Processing The following processing is performed if a faulty condition is detected in the CPU. When the copier CPU is found faulty: D All CPUs including those of the options are reset and the system is restarted. If the CPU is found faulty during a copy cycle, the system attempts to feed all sheets of paper out of the copier before resetting. (If paper is left inside the copier, the copier detects it as a misfeed as it is restarted.) When an option CPU is found faulty: D The option relays are turned OFF and ON and all options are then restarted. If the CPU is found faulty during a copy cycle, the copier stops the paper take-up sequence and feeds all sheets of paper out of the copier before resetting. The Watchdog Counter available from the Tech. Rep. mode allows the Technical Representative to check if any faulty condition has occurred in the CPU. For details, see SWITCHES ON PWBs. M-9 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM0600A 6 MALFUNCTION BYPASS FUNCTION D When a malfunction occurs in the copier, the malfunction bypass function permits the copier to continue operating if that malfunction is one of the predefined candidates for an isolated malfunction and if it will not affect the current copying operation. But, if an isolated malfunction occurs anytime during the actual copy cycle, the copier considers it a normal malfunction. D If a copying function involving an isolated malfunction is selected, the message “Selected mode can’t be used.” appears on the Touch Panel and the copier rejects that function. D When an isolated malfunction occurs, a tiny wrench “ ” indicator appears in the lower left corner of the Basic Screen. Access the “Machine Status” display by touching the wrench icon or via the Tech. Rep. mode to ascertain the trouble code. Then refer to the Troubleshooting Manual for details. D Trouble codes for up to five isolated malfunctions are shown on the “Machine Status” display. When a sixth isolated malfunction occurs, the copier considers it a normal malfunction, prompting a Tech. Rep. call. (The sixth malfunction is shown on the Touch Panel.) But, if all of the paper feed ports (except the manual feed port) show an isolated malfunction, the copier considers them a normal malfunction even though the isolated malfunction count may be less than five. The display also tells the condition when the image stabilization controls are not properly working. D For the details of the Isolated malfunction codes, see TROUBLESHOOTING for the copier and the specific SERVICE MANUAL for the options. M-10 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1149SBM0700A 7 IMAGE STABILIZATION SYSTEM z The following image stabilization controls are provided to ensure stabilized copy image. Item Quality Purpose Control Initial Setting Image density, gradation To make initial settings of grid voltage (Vg), optimum Exposure Lamp voltage, and AE Sensor gain. Sets the initial values for grid voltage correction, optimum Exposure Lamp voltage correction, and AE Sensor gain adjustment. Regular correction Image density To compensate for any drop in image density due to a deteriorating PC Drum. Corrects the grid voltage through AIDC Sensor control. Gradation To compensate for any drop in the intensity of LA1 light due to a contaminated optical system. Corrects the optimum Exposure Lamp voltage through AIDC control. Foggy background To keep a given toner-to-carrier ratio of the developer in the Developer Mixing Chamber. Provides toner replenishing control by means of the ATDC Sensor. (For details, see 13. DEVELOPMENT.) Correction made immediately after Power Switch is turned ON Image density, gradation To compensate for any drop in PC Drum surface potential when the copier is cool immediately after the Power switch is turned ON. Corrects the grid voltage and optimum Exposure Lamp voltage through AIDC Sensor control. Correction for Faulty AIDC Sensor Image density, gradation To compensate for image density and gradation aggravated by a faulty AIDC Sensor. Corrects the grid voltage and optimum Exposure Lamp voltage according to the time through which the PC Drum has turned and the copier has run. z The following is the block diagram of the image stabilization system. Exposure Lamp LA1 Original Width Scale Original Glass Halftone Patch PU2 EE PWB-A Toner Replenishing Image Erase Lamp LA3 CPU HV1 ATDC AIDC 1136M003AA M-11 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1149SBM0701A 7-1. AlDC Sensor To provide image stabilization control, this copier has AlDC Sensor PWB-G fitted to the Cleaning Unit of the Imaging Unit. The sensor is used to detect the toner density and background level on the PC Drum. Operation 1: The PWB-G LED projects approx. 950-nm infrared light onto the surface of the PC Drum. 2: The PWB-G phototransistor detects the amount of light reflected back. 3: The phototransistor outputs a voltage corresponding to the intensity of the light reflected back. Output GND PC Drum LED Power Supply AIDC Sensor Image Transfer/Paper Separation Coronas 1149M005AA Toner Density on PC Drum Light reflected Output Voltage High Small High Low Large Low M-12 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM0702A 7-2. Image Stabilization Control Processing Timing D The image stabilization controls use the AIDC Sensor and AE Sensor as the basis, performing the following four major types of processing. The grid voltage, T/C, and optimum Exposure Lamp corrections are not, however, made if T/C falls outside the range of 4% to 8% at adjustment. À AIDC Sensor adjustment Á Grid voltage and T/C correction Â Optimum Exposure Lamp voltage correction Ã AE Sensor gain adjustment D Processing Timing Processing (f: Performed; *: Not performed) Timing Item Processing Order ( ) À Á Â Ã Initial setting At the initial setup, or when the FF or F5 test operation is run after the PC Drum has been replaced. f f (*1) f f Regular correction Upon completion of the copy cycle for every 400 copies made in terms of the number of intermittent copies, as it is equivalent to the time over which the PC Drum turns. f f f f Correction immediately after S1 is turned ON During warming-up immediately after the Power Switch has been turned ON (*3) f f f f Correction for a faulty AIDC Sensor Upon completion of the copy cycle for every 75K copies made in terms of the number of intermittent copies, as it is equivalent to the time over which the PC Drum has turned after a faulty AIDC Sensor was detected. * f (*2) f (*2) f *1: T/C is not corrected when an F5 test operation is run. *2: The grid voltage is increased by 30V and the optimum Exposure Lamp voltage by 1V. No T/C correction is made even when the grid voltage reaches its upper limit. *3: The correction sequence is canceled as regular correction starts. M-13 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM0703A 7-3. Details of Image Stabilization Controls À AIDC Sensor adjustment Á Grid voltage and T/C correction Â Optimum Exposure Lamp voltage correction Ã AE Sensor gain adjustment D The following is the details of each image stabilization control. À-1 AIDC Sensor coarse adjustment This adjustment represents a coarse adjustment of the AIDC Sensor when the ordinary control of only the LED current cannot cover part-to-part variations in the AIDC Sensor (installation, circuit, deterioration, etc.). The surface of the PC Drum whose charges have been neutralized is exposed to light from the LED. The output current from the AIDC Sensor goes through the load resistance selected by a 4-bit analog switch and the 4-bit analog switch selects the load resistance so that the resultant voltage becomes 1V or less. À-2 AIDC Sensor fine adjustment If the AIDC Sensor is dirty with toner, it results in an error being produced in the sensor output voltage value, providing a false reference value. The surface of the PC Drum which has been erased is exposed to light from the LED. The LED current value is varied through pulse width control so that the output voltage from the AIDC Sensor becomes 1V. Á Controlled Part Control Signal AIDC Sensor PJ11A-7A ON OFF Pulse output WIRING DIAGRAM 1-I Grid voltage and T/C correction The Image Erase Lamp produces a solid-black pattern on the surface of the PC Drum and the AIDC Sensor reads the pattern. The grid voltage is then varied so that the output from the AIDC Sensor remains at a given level or higher, which ensures that the toner-to-carrier ratio on the surface of the PC Drum becomes constant. If an even greater solid-black density is required when the upper control limit of the grid voltage has already been reached, the target control value of T/C is raised in 0.5% steps up to 7%, thus terminating the adjustment sequence. Grid Voltage Control Value 1 Step Initial Value 550 to 790V 30V 550V M-14 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 The “Image Exposure” function of “Tech. Rep. Choice” available from the Tech. Rep. mode enables fine-adjustments of the grid voltage (solid-black image density) to be made. It specifies how many volts the optimum grid voltage determined by the image stabilization control is to be increased or decreased. This fine-adjustment value remains the same even when the optimum grid voltage is later varied by the image stabilization control. Controlled Part Control Signal Grid voltage output from High Voltage Unit HV1 PJ13A-1 Â ON OFF Pulse Output WIRING DIAGRAM 3-F Optimum Exposure Lamp voltage correction The Exposure Lamp is turned ON to illuminate the halftone patch on the back of the Original Width Scale, thereby producing a halftone pattern on the surface of the PC Drum. The Exposure Lamp voltage is then varied so that the output from the AIDC Sensor falls within the target range, thereby ensuring an optimum exposure level. Control Value 1 Step Initial Value Exposure Lamp voltage (100V Areas) 40 to 80V 1V 58V Exposure Lamp voltage (200V Areas) 80 to 160V 2V 116V The “manual exposure level” of Function F5 available from the Tech. Rep. mode enables fine-adjustments of the Exposure Lamp voltage (halftone image density) to be made. It specifies how many volts the optimum Exposure Lamp voltage determined by the image stabilization control is to be increased or decreased. This fine-adjustment value remains the same even when the optimum Exposure Lamp voltage is later varied by the image stabilization control. Controlled Part Control Signal Exposure Lamp Regulator (PWB-J) REM PJ8A-12 Ã ON OFF Pulse output WIRING DIAGRAM 45-H AE Sensor gain adjustment The Exposure Lamp is turned ON to illuminate the blank sheet of paper placed on the Original Glass (when an F5 or FF operation is run) or the halftone patch on the back of the Original Width Scale (when the AE Sensor gain is adjusted in a sequence other than F5 or FF). The reflected light is then read by the AE Sensor and a gain adjustment of the AE Sensor is made to maintain an optimum Auto exposure level. Controlled Part Control Signal AE Sensor Board PWB-H PJ3A-2 M-15 ON OFF Pulse Output WIRING DIAGRAM 12-B Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1149SBM0800A 8 PC DRUM The photoconductive drum used in this copier is the organic photoconductor (OPC) type. The drum is made up of two distinct, semiconductive materials on an aluminum alloy base. The outer of the two layers is called the Charge Transport Layer (CTL), while the inner layer is called the Charge Generating Layer (CGL). The PC Drum has its grounding point inside at the rear end. When the Imaging Unit is installed in the copier, the shaft on which the PC Drum Drive Coupling Gear is mounted contacts this grounding point. Handling Precautions This photoconductor exhibits greatest light fatigue after being exposed to light over an extended period of time. It must therefore be protected from light by a clean, soft cloth whenever the Imaging Unit has been removed from the copier. Further, use utmost care when handling the PC Drum to prevent it from being contaminated. PC Drum Cross-Sectional View PC Drum CTL CGL Aluminum Cylinder Gear Shaft Grounding Point Grounding Plate PC Drum Drive Coupling Gear M-16 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM0900A 9 DRUM CHARGING The PC Drum Charge Corona has a Scorotron grid to deposit a negative DC charge evenly across the surface of the PC Drum. The grid voltage (VG) applied to the grid mesh is selected between –550V (initial value, variable according to image stabilization controls) in the normal mode and the value in the normal mode +90V in the Photo mode by the Constant-Voltage Circuit in High Voltage Unit HV1. The Corona Unit has a Comb Electrode which minimizes the amount of ozone produced. The conventional wire type corona unit produces a large amount of ozone due to corona discharge in radial directions. The comb electrode type, on the other hand, discharges only toward the Grid Mesh, meaning a reduced amount of ozone is produced. The Comb Electrode can be cleaned by the user who pulls out to the front the shaft on which a Cleaning Rollar is mounted. Holder Comb Electrode Spring Holder Grid Mesh 1151T03MCC Control Signal PC Drum Charge Corona PWB-A PJ13A-2 Control Signal Grid Voltage (VG) PWB-A PJ13A-1 ON OFF WIRING DIAGRAM L H 3-F Normal Mode Photo Mode WIRING DIAGRAM Pulse output M-17 3-F Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM0901A 9-1. Ozone Filter D Ozone produced by the PC Drum Charge Corona is absorbed by the Ozone Filter located to the left of the PC Drum Charge Corona, as the air is drawn out of the copier by Ventilation Fan Motor M3. Ventilation Fan Motor M3 Ozone Filter PC Drum Charge Corona 1134M004AA Control Signal M3 PJ34A-1 ON OFF WIRING DIAGRAM H L 11-F M-18 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1000A 10 IMAGE ERASE LAMP To prevent a black band from occurring across both the leading and trailing edges, and along the front and rear edges, of the electrostatic latent image, 40 LEDs of Image Erase Lamp LA3 are turned ON before development takes place, thereby reducing to a minimum the unnecessary potential on the surface of the PC Drum. PC Drum Charge Corona Exposure Image Erase Lamp LA3 1156M010AA The position of LA3 can be adjusted using the adjusting screw at the front of the copier. Copier Front Frame Adjusting Screw Copier Rear Frame LA3 Board Compression Spring 1156M011AA M-19 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 The 40 LEDs are grouped as follows and turned ON and OFF according to the paper size and zoom ratio. * In the full size mode, ON/OFF control is provided according to the paper size. * In any zoom ratio other than full size, the copier compares the number of LEDs that are turned ON according to the paper size with the number that are turned ON according to the zoom ratio and uses the one that turns ON more LEDs. *The zoom ratio is used to provide ON/OFF control of the LEDs if paper size is not input in manual bypass copying, since the copier is unable to detect the paper size. LED Group No. LED No. LED Group No. LED No. 0 LED1 16 LED 17 1 LED 2 17 LED 18 2 LED 3 18 LED 19 3 LED 4 19 LED 20 4 LED 5 20 LED 21 5 LED 6 21 LED 22 6 LED 7 22 LED 23 7 LED 8 23 LED 24 8 LED 9 24 LED 25 9 LED 10 25 LED 26 10 LED 11 26 LED 27 to 35 11 LED 12 27 LED 36 12 LED 13 28 LED 37 13 LED 14 29 LED 38 14 LED 15 30 LED 39 15 LED 16 31 LED 40 *The bigger the number, the nearer the LED is to the front side of the copier. M-20 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 LA2 LEDs ON/OFF Pattern Zoom Ratio Paper Width (mm) LED Group No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 31 X91 f f f f f f f f f f f f f f f f f f f f f f f f f 92 X 99 f f f f f f f f f f f f f f f f f f f f f f f f f 100 X 107 f f f f f f f f f f f f f f f f f f f f f f f f 108 X 116 f f f f f f f f f f f f f f f f f f f f f f f 117 X 126 f f f f f f f f f f f f f f f f f f f f f f 127 X 135 f f f f f f f f f f f f f f f f f f f f f 136 X 142 f f f f f f f f f f f f f f f f f f f f X0.522 143 X 149 f f f f f f f f f f f f f f f f f f f 0.523 X 0.550 150 X 158 f f f f f f f f f f f f f f f f f f f 0.551 X 0.576 159 X 166 f f f f f f f f f f f f f f f f f f 0.577 X 0.610 167 X 173 f f f f f f f f f f f f f f f f 0.611 X 0.642 174 X 184 f f f f f f f f f f f f f f f 0.643 X 0.672 185 X 195 f f f f f f f f f f f f f f 0.673 X 0.698 196 X 203 f f f f f f f f f f f f f 0.699 X 0.728 204 X 211 f f f f f f f f f f f f 0.729 X 0.758 212 X 220 f f f f f f f f f f f 0.759 X 0.776 221 X 229 f f f f f f f f f f 0.777 X 0.806 230 X 235 f f f f f f f f f 0.807 X 0.830 236 X 244 f f f f f f f f 0.831 X 0.854 245 X 251 f f f f f f f 0.855 X 0.882 252 X 258 f f f f f f f 0.883 X 0.914 259 X 267 f f f f f f 0.915 X 0.938 268 X 277 f f f f 0.939 X 0.964 278 X 284 f f f 0.965 X 0.990 285 X 292 f f 0.991X 293 X 298 f f= f f f f f f f f f f f f f f f f f f f f f f f LED that turns ON M-21 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 LA2 LEDs ON/OFF Pattern (Frame Erase, erase width 10mm) Paper Width (mm) LED Group No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 X105 f f f f f f f f f f f f f f f f f f f f f f f f f f 106 X 113 f f f f f f f f f f f f f f f f f f f f f f f f f 114 X 121 f f f f f f f f f f f f f f f f f f f f f f f f 122 X 130 f f f f f f f f f f f f f f f f f f f f f f f 131 X 140 f f f f f f f f f f f f f f f f f f f f f f 141 X 149 f f f f f f f f f f f f f f f f f f f f f 150 X 156 f f f f f f f f f f f f f f f f f f f f 157 X 164 f f f f f f f f f f f f f f f f f f f 165 X 172 f f f f f f f f f f f f f f f f f f 173 X 180 f f f f f f f f f f f f f f f f f 181 X 188 f f f f f f f f f f f f f f f f 189 X 198 f f f f f f f f f f f f f f f 199 X 208 f f f f f f f f f f f f f f 209 X 217 f f f f f f f f f f f f f 218 X 225 f f f f f f f f f f f f 226 X 234 f f f f f f f f f f f 235 X 243 f f f f f f f f f f 244 X 249 f f f f f f f f f 250 X 258 f f f f f f f f 259 X 265 f f f f f f f 266 X 272 f f f f f f 273 X 281 f f f f f 282 X 291 f f f f 292 X 298 f f f 299 X f f f= LED that turns ON M-22 26 27 30 31 f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1151T20MCB Control Signal LA3 PWB-A PJ9A-1~6 ON OFF Static ON/OFF Control M-23 WIRING DIAGRAM 4-L Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1100A 11 OPTICAL SECTION As the Scanner is moved by Scanner Motor M2, the light from Exposure Lamp LA1 is reflected off the original and guided through the six Mirrors onto the surface of the PC Drum to form the electrostatic latent image. 6 5 7 8 2 9 7 7 1 4 3 10 12 13 15 11 14 16 18 1156M012AA 17 1. 2. 3. 4. 5. 6. 7. 8. Scanner Reference Position Sensor PC81 Original Glass Cooling Fan Motor M5 Scanner Lens Scanner Motor M2 Scanner Shaft Mirror Motor M7 4th/5th Mirrors Carriage 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. M-24 4th Mirror 5th Mirror 6th Mirror Lens Motor M6 AE Sensor Board PWB-H Exposure Lamp LA1 1st Mirror 2nd Mirror 3rd Mirror 2nd/3rd Mirrors Carriage Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1101A 11-1. Exposure Lamp LA1 An AC halogen lamp is used as Exposure Lamp LA1. As the exposure level is adjusted on the control panel, the duty ratio of the pulse of AVR Remote from PWB-A changes to increase or decrease the LA1 voltage, thereby changing the image density. In Photo mode, the voltages are varied on a level 3V (200V Areas: 6V) lower than the manual Exposure Lamp voltages. Manual EXP Setting Lamp Voltage Difference (V) “Manual Level Priority” 9 8 7 6 5 2 1 –8 –5 –2 –1 Reference +1 +2 +5 +8 Mode 2 –8 –6 –4 –2 Reference +2 +4 +6 +8 Mode 3 –8 –7 –6 –3 Reference +3 +6 +7 +8 Control Signal Signal (PWB-J) 3 Mode 1 Varies depending on the drawer. AVR Remote 4 PWB-A PJ8A-13 M-25 1151T21MCB ON OFF WIRING DIAGRAM L H 45-H Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1102A 11-2. AE Sensor In the Auto Exposure Mode, the AE Sensor on AE Sensor Board PWB-H measures the intensity of the light reflected off the original, by sampling the black/white ratio of a 210-mm-wide area of the original being measured. According to this measurement, the Exposure Lamp voltage is automatically increased or decreased so that copies of consistent quality are produced. The output from the AE Sensor is applied to PWB-A which, in turn, varies the duty ratio of the AVR Remote which varies the LA1 voltage accordingly. Original Density (B/W Ratio) High Low Intensity of Reflected Light Low High PWB-H Output High Low AVR Duty Increased Decreased LA1 Voltage Increased Decreased Control Signal PWB-H (AE Sensor) PWB-A PJ3A-2 AVR Remote Signal (PWB-J) PWB-A PJ8A-13 ON OFF Pulse output L M-26 H WIRING DIAGRAM 12-B 45-H Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1103A 11-3. Lamp Reflectors The Main Reflector ensures that light from Exposure Lamp LA1 exposes all areas of the original. The Auxiliary Reflector functions to reflect light onto the areas that LA1 cannot illuminate when an original that does not lie flat on the Original Glass (such as a book) is being used. This reduces shadows which would otherwise be transferred to the copy. The Main Reflector is of aluminum, while the Auxiliary Reflector is aluminum to which film has been deposited. The same film as that used on the Auxiliary Reflector is affixed to both ends of the frame to compensate for the reduced intensity of light around both ends of the Exposure Lamp. Auxiliary Reflector Auxiliary Reflector Main Reflector Exposure Lamp LA1 1151M021AA 1156SBM1104A 11-4. Aperture Plates Four Aperture Plates are moved to the front or rear to ensure even light distribution. Aperture Plate 1139M035AA M-27 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1105A 11-5. Scanner and 2nd/3rd Mirror Carriage Movement The Scanner and 2nd/3rd Mirrors Carriage are moved by the Scanner Drive Cable fitted in the rear side of the copier. The Cable is driven by Scanner Motor M2. Both the Scanner and 2nd/3rd Mirrors Carriage slide along the Scanner Shaft at the rear side. While at the front side, there is a Slide Bushing attached to the underside of each of the bodies and that Bushing slides over the Slide Rail. The speed of the Scanner and 2nd/3rd Mirrors Carriage varies with different zoom ratios. Scanner Reference Position Sensor PC81 detects the home position of the Scanner and 2nd/3rd Mirrors Carriage. If they are not at the home position when the copier is turned ON, M2 is energized to move them to the home position. Scanner Motor M2 Scanner Shaft Scanner Reference Position Sensor PC81 Rear 1st Mirrors Carriage 2nd Mirrors Carriage Front M-28 1156M013AA Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 The Scanner starts the scan motion as a Scan signal is output from PWB-A. At the start of a scan motion and other heavy load conditions, Scanner Motor M2 requires a large amount of current. The Current 1 or 2 signal from PWB-F is selected accordingly to vary the amount of current supplied to M2. *The Current signal selection timing is controlled by software. L M1 M2 Current 1 H L H Current 2 H H L Current M2>M1>L When the scan speed reaches a given level and during scan deceleration Operation At scan start and during return deceleration. (*) At return start and during return motion. (*) * M2 is used at scan start of a small zoom ratio. On receiving the Scan signal, Motor Drive Board PWB-F applies motor drive pulses, which are out-of-phase with each other, to M4. The motor speed is varied by changing the width of the pulses applied to M2. Control Signal Energized Deenergized PWB-F L H M2 Current Switching Signal 1 PWB-F L H M2 Current Switching Signal 2 PWB-F M2 Scan Signal 22-B Control Signal PC81 WIRING DIAGRAM PWB-F L H Blocked Unblocked WIRING DIAGRAM L H 18-E M-29 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1106A 11-6. Lens Movement The Lens is moved by the Lens Drive Cable which is driven by Lens Motor M6 (stepping motor). The motor drive pulses sent from PWB-F drive M5 to move the Lens a given distance, corresponding to the zoom ratio, from the reference position determined by Lens Reference Position Sensor PC90. There is a fixed-type Lens Aperture Cover provided at the rear of the Lens (on the 4th Mirror end). It limits the amount of light striking the surface of the PC Drum. Lens Reference Position Sensor PC90 Lens Base Bracket Lens Shaft Lens Aperture Cover Spring Cam Lens Drive Cable Lens Motor M5 1156M014AB Lens Lens Aperture Cover 1136M013AA Control Signal M6 PWB-F Control Signal PC90 PWB-F Energized Deenergized WIRING DIAGRAM L H 19-A Blocked Unblocked WIRING DIAGRAM L H 18-D M-30 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1107A 11-7. 4th/5th Mirrors Carriage Movement The 4th/5th Mirrors Carriage is moved to vary the conjugate distance for a particular zoom ratio by driving the rack-and-pinion gears at the front and rear ends of the mirror using Mirror Motor M7 (stepping motor). Mirror Reference Position Sensor PC86 is used to control the position of the 4th Mirror. It ensures that the Mirror is located at the home position when the copier is turned ON. Pinion Gear M7 Rack Gear 4th/5th Mirrors Carriage Mirror Motor M7 4th/5th Mirrors Guide Plate Mirror Reference Position Sensor PC86 1136M017AA Control Signal M7 PWB-F PC86 PWB-F Control Signal Energized Deenergized WIRING DIAGRAM L H 19-B Blocked Unblocked WIRING DIAGRAM L H 18-C M-31 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1108A 11-8. Original Glass Cooling Fan Optical Section Cooling Fan Motor M5 draws outside air into the copier and blows it against the Original Glass which is heated by lit Exposure Lamp LA1. The Filter at the intake port of the Fan prevents dust and dirt from entering the Optical Section of the copier. M5 turns only while Main Drive Motor M1 is being energized. Filter Original Glass Front of Copier Rear of Copier Original Glass Cooling Fan Motor M5 1149M024AA Control Signal M5 PWB-A PJ15A-5 Energized Deenergized WIRING DIAGRAM H L 21-H M-32 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1200A 12 ORIGINAL SIZE DETECTING SENSORS The five sensors fixed in the optical section receive the light reflected off the original to determine the size of the original in the Auto Paper and Auto Size mode. (The image density of the original, or OD, that can be detected is 0.6 or less.) 1156SBM1201A 12-1. Identification of Original Size Detecting Sensors Original Size Detecting Sensor CD1 PC115 Original Size Detecting Board UN2 Original Cover Detecting Sensor PC111 Original Size Detecting Sensor CD2 PC119 Original Size Detecting Sensor FD3 PC118 Original Size Detecting Sensor FD2 PC117 Original Size Detecting Sensor FD1 PC116 Size Reset Switch S108 1136M018AA 1156SBM1202A 12-2. Original Size Detecting Operation Each photo receiver of the original size detecting sensors (PC115 to 119) responds to reflected light of a given intensity with reference to the intensity of the light emitted by each LED. This allows the Original Size Detecting Board to determine whether or not there is an original within a set distance. Original Original Glass Set Distance Photo Receiver LED 1136M020AA M-33 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1203A 12-3. Sensor Locations D The number and location of the Original Size Detecting Sensors vary depending on the marketing area as shown below. f: Standard F: Optional Sensors Areas CD1 (PC115) CD2 (PC119) FD1 (PC116) FD2 (PC117) FD3 (PC118) f f f F F f f F f f f f F F f Metric Areas Inch Areas Hong Kong Area NOTE: If the optional sensors are installed, set Jumper Connector JP2 on UN2 as illustrated below and run the F7 operation. Length (Inch) FD1 FD2 Letter C Letter L Legal FLS FD3 11” 17” Width (Inch) Width (Metric) Invoice A5L B5L Legal, Letter L A4L B4L, B5C Letter C, 11” 17” A3L, A4C CD2 CD1 Length (Metric) L: Lengthwise; B5C A4C, B5L A4L B4L A3L C: Crosswise A5L Original Size Detecting Board UN2 CN4 CN1 JP1 LED1 JP2 LED2 CN3 CN2 FD1 is mounted FD1 is not mounted CD2 and FD3 are mounted CD2 and FD3 are not mounted Position of JP1 Position of JP2 1136M022CA M-34 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1204A 12-4. Size Detection D Original Size Detecting Board UN2 reads the output data provided by the original size detecting sensors (PC115 to 119). By comparing the data from each sensor with the threshold level, it determines whether there is an original placed on the Original Glass. UN2 then determines the size of the original according to the combination of the data. Metric Area FD1 Original Size Size Determined by UN2 FD2 FD3 CD1 CD2 LED 2 LED 1 LED 2 LED 1 LED 2 LED 1 LED 2 LED 1 f f f F F f f f F F f(f) f(f) F(F) F(F) F(F) f(F) f(F) F(F) F(F) F(F) f F F F f f f F F f f(f) F(F) F(F) F(F) f(f) A3L A3L (A3L) B4L B4L (B4L) A4L A4L (A4L) A5L A5L (A5L) A4C A4C (A4C) f f f f f Letter L: 8-1/2” 11” Letter L (Letter L) f f F F(F) F(F) F F F(F) 11” 17” 11” 17” (A3L) f f f f(f) f(F) f f F(f) Legal: 8-1/2” 14” Legal (A4L) f f f f(F) f(F) F F F(F) FLS: 8-1/2” 13” FLS (A4L) f f f f(F) F(F) F F F(F) Letter C: 11” 8-1/2” Letter C (A4C) f F F F(F) F(F) f f F(f) No Original No Original F F F F(F) F(F) F F F(F) Inch Area FD1 Original Size FD2 FD3 CD1 Size Determined by UN2 LED2 LED1 LED2 LED1 LED2 LED1 LED2 11” 17” 11” 17” (11” 17”) f(f) f f f(f) f(f) f f Legal: 8-1/2” 14” Legal (Legal) f(f) f f f(f) f(f) F F Letter L: 8-1/2” 11” Letter L (Letter L) f(f) f F F(F) F(F) F F Letter C: 11” 8-1/2” Letter C (Letter C) f(f) F F F(F) F(F) f f FLS: 8-1/2” 13” FLS (Legal) f(f) f f f(f) F(f) F F Invoice: 5-1/2” 8-1/2” Invoice (No Original) f(F) F F F(F) F(F) F F No Original No Original F(F) F F F(F) F(F) F F *f: Original Present F: Original Not Present *If no optional sensors are mounted, data is processed as indicated in ( ) and the original sizes determined by UN2 are as indicated in ( ). *UN2 does not use the data provided by LED1 of Original Size Detecting Sensor FD1 (PC116) and LED2 of CD2 (PC119) for the determination of the original size. *Any non-standard size is rounded off to the nearest standard size. M-35 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1205A 12-5. Original Size Detection Timing Master CPU on PWB-A affirms and resets the readings of the original size at the following timings. D Takes size readings: When the Original Cover is raised to an angle of 15° or more (PC111 is deactivated). D Affirms size readings: When the Original Cover is lowered to an angle of 15° or less (PC111 is just activated); or, when the Start key is pressed with PC111 in the deactivated state. D Resets size readings: When the Original Cover is raised (S108 is deactuated). Original Cover Detecting Sensor PC111 Magnet Size Reset Switch S108 Control Signal PC111 PWB-A PJ17A-11 Control Signal S108 PWB-A PJ12A-1 Blocked Unblocked WIRING DIAGRAM L H 21-G ON OFF WIRING DIAGRAM L H 16-B M-36 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1300A 13 DEVELOPING UNIT D This copier employs the New Micro-Toning developing system. The toner fed up to the Sleeve/Magnet Roller is conveyed onto the points of development as the Sleeve/Magnet Roller turns, thereby forming a visible, developed toner image of the original. 1 2 5 4 3 6 7 8 9 10 14 15 13 12 11 1156M015AA 1. 2. 3. 4. 5. 6. 7. 8. Toner Bottle Developer Scattering Prevention Mylar Developer Scattering Prevention Plate Doctor Blade Sub Hopper Toner Supply Roller Toner Bottle Home Position Sensor PC35 Toner Bottle Home Position Detecting Plate Main Hopper Toner Replenishing Motor M8 9. 10. 11. 12. 13. 14. 15. M-37 Sub Hopper Toner Empty Detecting Lever Sub Hopper Toner Agitating Lever ATDC Sensor UN3 Developer Conveying/Agitating Screw Bucket Roller Magnet Sheet Sleeve/Magnet Roller Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1301A 13-1. Developing Unit Drive Mechanism D Drive is transmitted from the copier to the Developing Unit by Coupling Gears 1 and 2 when they mesh. D Coupling Gear 2 is spring-loaded. If the protruding part of Coupling Gear 1 makes contact with that of Coupling Gear 2 when the Developing Unit is slid into the copier, spring-loaded Coupling Gear 2 is pushed back toward the rear of the copier allowing the Developing Unit to be slid into position. When drive is later transmitted to the Developing Unit, Coupling Gar 2 is pushed to the front by the tension of the spring to mesh positively with Coupling Gear 1. Front Coupling Gear 2 Coupling Gear 1 Main Drive Motor M1 Rear 1134M009AA M-38 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1302A 13-2. Magnet Roller The Magnet Roller of the Sleeve/Magnet Roller of this copier has the following magnetic characteristics. Pole S3 before poles N1 and N2 at which development takes place provides a very weak magnetic force. If developer is compacted and clogs at the Doctor Blade and, as a result, part of the surface of the Sleeve/Magnet Roller is not covered with developer, the nearby developer around S3 goes to those uncovered areas because of the weak magnetic force. This helps prevent white lines from occuring on the copy. The magnetic flux density is maximized to allow the bristle to stand high and upright at poles N1 and N2, at which development takes place. The positioning of these two like poles together helps agitate the developer for greater uniformity, thus preventing white lines from occurring on the copy. The Sleeve Roller, onto which developer is attracted by the magnetic fields of force set up by the poles of the Magnet Roller, turns to convey the developer toward the point of development. This means that developer fresh from the Developer Mixing Chamber is always brought to the point of development. The Imaging Unit integrates the Developing Unit with the PC Drum into one body. Because of that, it is impossible to move the Developing Unit against the PC Drum, thereby providing a certain distance between the PC Drum and Sleeve/Magnet Roller. The Magnet Roller has therefore been made movable: the Bushing is pressed by compression springs thereby pressing the Positioning Collars on both ends of the Magnet Roller against the PC Drum. This ensures a given distance between the PC Drum and the Sleeve/Magnet Roller. S2 S3 N1 N4 N2 S1 N3 Movable Bushing Compression Spring Fixed Bushing PC Drum M-39 1156M016AA Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1303A 13-3. Developing Bias A negative voltage (Vb = Developing Bias voltage) is applied to the Sleeve Roller to prevent a foggy background on the copy. The amount of toner attracted onto the surface of the PC Drum depends on how much lower the PC Drum surface potential (Vi) is than Vb (i.e., the potential difference). D When the potential difference is large, a greater amount of toner is attracted. D When the potential difference is small, a smaller amount of toner is attracted. Because the Magnet Roller of this copier is movable, a flat spring is used as the Bias Terminal which follows the movement of the Magnet Roller. DS Collar Bias Connector Sleeve/Magnet Roller Front Bias Terminal 1134M018AA Varies depending on the drawer. 1151T01MCC Control Signal Developing Bias PWB-A PJ13A-3 M-40 ON OFF WIRING DIAGRAM L H 3-F Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1304A 13-4. Doctor Blade The Doctor Blade installed over the Sleeve/Magnet Roller regulates the height of the developer brush on the surface of the Sleeve Roller. The Blade is perpendicular to the direction of movement of the Magnet Roller to minimize variations in the distance between the Doctor Blade and Magnet Roller as the Magnet Roller moves. Doctor Blade Direction of Magnet Roller Movement Magnet Roller 1156M017AA M-41 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1305A 13-5. ATDC Sensor The copier compares the toner-to-carrier ratio (T/C) of the developer in the Developer Mixing Chamber detected by ATDC Sensor UN3 during a copy cycle with the reference ratio (6%) and, if it finds a lower ratio than the reference, replenishes the supply of toner. The standard output voltage of the ATDC Sensor for the reference T/C (6%) is 2.5V. If the toner-to-carrier ratio becomes lower than 2.5% in a toner-empty condition, the copier inhibits the initiation of a new copy cycle (this feature can be enabled or disabled by a Tech. Rep. Choice mode). As soon as a ratio of 3% or more is recovered, the copier permits the initiation of a new copy cycle. If the Front Door is swung open and closed with a T/C ratio of less than 3%, the copier initiates an Auxiliary Toner Replenishing sequence. (The toner-empty condition is canceled as soon as a T/C ratio of 3.5% is reached and the copier completes the Auxiliary Toner Replenishing sequence when the target level is reached.) ATDC Sensor Automatic Adjustment An automatic adjustment of the ATDC Sensor is made in the F8 or FF Test Mode operation. *When F8 (or FF) is Run after Starter Has Been Changed: Following the execution of the starter setup mode, upon pressing the Start Key, the copier CPU reads the output value of the ATDC Sensor and adjusts the ATDC Sensor gain so that the output value becomes 2.5V. NOTE: If an F8 (or FF) operation is run at a time when the starter has not been changed, it can result in a wrong T/C reference value being set by the copier. Avoid casual use of F8. If the setting value has been cleared because of the RAM Board being replaced, use the “Level History” function of the Tech. Rep. mode to return the “ATDC Ref. Value” to the original value before the board was replaced. Controlled Part Control Signal T/C Ratio Standard Output Voltage WIRING DIAGRAM UN3 PJ11A-2B 6.0(%) 2.5(V) 1-J M-42 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 The ATDC Sensor samples T/C for each copy and the copier compares the reading with the reference T/C (which is normally 6% but may 7% depending on the image stabilization control provided), energizing Sub Hopper Toner Replenishing Motor M9 as may be necessary to replenish toner in either of the following four modes. Toner Replenishing Mode Large amount replenishing Conditions Amount Replenished * The ATDC Sensor reading is lower than Approx. 133 mg reference T/C by 0.5% or more. Small amount replenishing The ATDC Sensor reading is lower than Approx. 66 mg reference T/C by less than 0.5%. Fixed amount replenishing The ATDC Sensor reading is higher than Approx. 13mg reference T/C by less than 1%. No toner replenishing The ATDC Sensor reading is higher than reference T/C by 1% or more. * The amount of toner replenished varies according to the paper size (given in the table are figures for A4). The copier is also provided with a function that, if T/C detected during a copy cycle is lower than the reference by 2% or more, interrupts the copy cycle and performs a toner replenishing sequence and, as soon as there is a gain of 1% against the T/C reading, resumes the copy cycle. This function is, however, disabled when a toner-empty condition is detected and the ATDC Sensor is found faulty. This copier is equipped with a function that switches from the ATDC Sensor, if it becomes defective, to the AIDC Sensor to continue providing the toner replenishing control. A pattern is produced on the surface of the PC Drum for each copy between two successive copies or after it has been fed out. The AIDC Sensor reads that pattern to detect the amount of toner sticking to it and the copier performs either of the following toner replenishing sequences depending on the output voltage of the AIDC Sensor. (Controlled target T/C: 6%; AIDC Sensor output voltage: DC4.25V) Toner Replenishing Mode AIDC Sensor Output Voltage Amount Replenished * Large amount replenishing Less than DC3.25V Approx. 129 mg Small amount replenishing DC3.25V to less than 4.25V Approx. 64 mg Fixed amount replenishing DC4.25V to less than 5.25V Approx. 13 mg No toner replenishing DC5.25V or more * The amount of toner replenished varies according to the paper size (given in the table are figures for A4). M-43 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1306A 13-6. Sub Hopper Toner Replenishing Mechanism Sub Hopper Toner Replenishing Motor M9 is energized for the toner replenishing time which is calculated based on the ATDC Sensor output voltage (T/C ratio) and the size of the paper being fed through the copier. Sub Hopper Toner Supply Roller Sub Hopper Toner Replenishing Motor M9 Bucket Roller Sub Hopper Developer Conveying/ Agitating Screw Sleeve/Magnet Roller Rear of Copier Front of Copier 1134M014AA Controlled Part Control Signal ON OFF WIRING DIAGRAM M9 PJ11A-2A L H 2-H M-44 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1307A 13-7. Sub Hopper Toner Empty Detection Control D A toner-empty condition in the Sub Hopper is detected by the magnet fitted to the Sub Hopper Toner Empty Detecting Lever and Sub Hopper Toner Empty Switch S106. D The Sub Hopper Toner Empty Detecting Lever rides on the eccentric cam fitted to the rear of the Sub Hopper Toner Agitating Lever. It is moved up and down as the eccentric cam is turned by the drive transmitted from Main Drive Motor M1. D While the amount of toner in the Sub Hopper is higher than the predetermined level, the Sub Hopper Toner Empty Detecting Lever rests on the toner and does not make the up-and -down motion. S106 therefore remains deactuated. D When the amount of toner in the Sub Hopper is lower than the predetermined level, the Sub Hopper Toner Empty Detecting Lever moves up and down by the eccentric cam. This result in S106 being actuated and deactuated. When the time S106 is actuated exceeds a predetermined value, the copier CPU determines that the Sub Hopper has run out of toner. Sub Hopper Toner Empty Detecting Lever Magnet Eccentric Cam Sub Hopper Toner Empty Switch S106 1134M015AA Toner Empty Toner Full 1134M017AA 1134M016AA Controlled Part Control Signal ON OFF WIRING DIAGRAM Sub Hopper Toner Empty Switch S106 PJ11A-8B L H 2-L M-45 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1308A 13-8. Main Hopper Toner Replenishing Mechanism D Toner is supplied from the Main Hopper to Sub Hopper as follows. When a toner– empty condition is detected in the Sub Hopper, it energizes Main Hopper Toner Replenishing Motor M8 to turn the Toner Bottle. D The Home Position Detecting Plate fitted to the coupling and Toner Bottle Home Position Sensor PC35 ensure that the Toner Supply Port in the Toner Bottle is positioned at the top whenever the Toner Bottle is stopped. Toner Bottle Toner Bottle Toner Bottle Home Position Sensor PC35 Toner Supply Port Toner Supply Hole Toner Bottle Holder 1136M034AA Home Position Detecting Plate Main Hopper Toner Replenishing Motor M8 Coupling 1156M018AB Controlled Part Control Signal ON OFF WIRING DIAGRAM M8 PJ11A-4A L H 2-H Controlled Part Control Signal Blocked Unblocked WIRING DIAGRAM PC35 PJ11A-9B L H 2-K M-46 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1309A 13-9. Swinging Out/In the Main Hopper D To replace an empty Toner Bottle, the user first needs to swing the Toner Bottle Holder out 40° to the front. There is a flat spring installed on the Sub Hopper Holder, which causes the Toner Bottle Holder to click out of, and into, the locked position. D The Holder pivots about the Toner Supply Port as it is swung out or in, which effectively prevents toner from spilling when the Holder is swung out or in. The Coupling is provided with a locking mechanism that prevents the Toner Bottle from turning when it is removed or installed. D Since the flat spring fits into the front ^ notch of the Toner Bottle Holder, the Holder is locked in position. At this time, the bottom of the Coupling Lock Lever is pushed in by a part (*) of the Sub Hopper, keeping the Coupling free. Flat Spring Coupling Lock Lever Front Toner Bottle Holder 1136M089AA Rear D The Toner Bottle Holder pushes the flat spring down and moves over it until the flat spring then fits into the rear ^ notch. This locks the Toner Bottle Holder in position. At this time, the Coupling Lock Lever is free and the spring acts to lock the Coupling in position with the Lock Lever. Coupling Toner Bottle Coupling Lock Lever Front Rear Flat Spring M-47 1136M035AA Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1400A 14 IMAGE TRANSFER AND PAPER SEPARATION Image Transfer The Image Transfer Corona applies a DC negative corona emission to the underside of the paper thereby attracting the positively charged toner onto the surface of the paper to form a visible, developed image of the original. The Corona Unit is provided with a Corona Wire cleaning mechanism: the operator has only to pull out the Lever on which the Cleaner is mounted from the front of the copier, which cleans the Wire. Paper Separation The Paper Separator Corona showers the underside of the paper with both positive and negative charges so that the paper can be easily separated from the PC Drum. In addition, two Paper Separator Fingers physically peel the paper off the surface of the PC Drum. (For details, see PAPER SEPARATOR FINGERS.) The Image Transfer/Paper Separator Coronas Unit is provided with a Pre-Image Transfer Guide Plate that determines the angle at which the paper comes into contact with the PC Drum and keeps an optimum distance between the paper and the PC Drum so that the image may be properly transferred onto the paper. The Image Transfer/Paper Separator Coronas Unit is grounded via a high capacity resistor, which improves its efficiency to discharge to the PC Drum side, thus reducing the output current from High Voltage Unit HV1. PC Drum Image Transfer Corona Wire Pre-Image Transfer Guide Plate Guide Paper Separator Corona Wire Corona Housing Reisitor Resistor Image Transfer/Paper Separator Coronas Unit Rail Image Transfer Corona Wire Cleaner 1136M054AA Cleaner Lever Cleaner M-48 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1151T07MCD Control Signal Image Transfer Corona Paper Separator Corona ON OFF WIRING DIAGRAM PWB-A PJ13A-2 L H 3-F PWB-A PJ13A-3 L H 3-F 1156SBM1401A 14-1. Ozone Filter Ozone produced by the Image Transfer/Paper Separator Coronas is absorbed by the Ozone Filter on the back of the copier. It is absorbed from the air being drawn out of the copier through the Duct under the Suction Deck by Suction Fan Motor M4. Duct To Ozone Filter (Front of Copier) Image Transfer/Paper Separator Coronas 1136M056AA M-49 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1500A 15 PAPER SEPARATOR FINGERS After image transfer, an AC corona emission is applied to the underside of the paper by the Paper Separator Corona to neutralize the paper so that it can be easily separated from the PC Drum. To further ensure that the paper is positively separated from the PC Drum, there are two Paper Separator Fingers attached to the Imaging Unit. They physically peel the paper off the surface of the PC Drum. To prevent the Paper Separator Fingers from damaging the surface of the PC Drum, they are kept in the retracted position whenever they are not at work. As illustrated below, the Fingers are brought into contact with, and retracted from, the surface of the PC Drum by the Lever which is operated by Separator Solenoid SL1. Separator Solenoid SL1 PC Drum Paper Separator Finger Shaft Swash Plate Cam Return Spring PC Drum Paper Separator Finger Pivot Pawl (A) Finger Operating Lever 1136M064AA M-50 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 The Paper Separator Fingers are also moved over a given distance to the front and rear so that they will contact wider areas of the surface of the PC Drum, thus preventing localized damage to the PC Drum surface. D The Swash Cam mounted on the Pivot Pin of the Finger Operating Lever is moved through steps by means of the Ratchet wheel and SL1, causing the Swash Cam to push the Finger Shaft. D The lateral movement of the Paper Separator Fingers is 3.5 mm (which is equivalent to 60 times energization of SL1). SL 1 Energized Pawl (A) is raised. The Swash Plate is locked in position by Pawl (B). 1136M065AA SL 1 Deenergized Ratchet Wheel Swash Cam 1136M067AA 1136M066AA Pawl (A) pushes the Swash Cam downward to turn it one notch. Paper Separator Finger Shaft M-51 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 Control Signal SL1 PWB-A PJ11A-6A Energized Deenergized WIRING DIAGRAM L H 2-I M-52 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1600A 16 CLEANING UNIT The Cleaning Blade is pressed tightly against the surface of the PC Drum and scrapes off any toner remaining on the surface after image transfer and paper separation have been completed. PC Unit Cleaning Blade Blade Tension Spring Toner Conveying Coll PC Drum Paper Separator Finger 1134M027AA The Cleaning Blade is moved back and forth to prevent the PC Drum from deteriorating and the Cleaning Blade from warping away from the surface of the PC Drum. Eccentric Cam Timing Belt Back Blade Moving Pin Front Cleaning Blade Assy Mounting Bracket To Main Drive Motor M1 1134M028AA M-53 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1601A 16-1. Spent Toner Collection (1) Toner Conveying/Collecting Mechanism D The toner which has been scraped off the surface of the PC Drum by the Cleaning Blade is conveyed by the Toner Conveying Coil towards the rear of the copier and falls into the Toner Collecting Box at the back of the copier through the pipe. D The Toner Antispill Mylar is affixed under the Cleaning Blade to receive toner, thus preventing any toner from failing down onto the surface of the copy paper or the paper path. Cleaning Blade Residual Toner Toner Conveying Coil Toner Antispill Mylar 1136M061AA Toner Conveying Coil Toner Conveying Coil Drive Gear (Copier) Toner Conveying Coil Drive Gear (PC Unit) Spent Toner Flow Pipe 1136M062AA D The type of Toner Collecting Box and the method of detecting an installed box differ between the applicable marketing areas. See the following table. Areas EP5000 EP4000 All areas Type of Box Large-Capacity Toner Collecting Box (in Cabinet) U.S.A., Canada, Large-Capacity Toner and Europe Collecting Box (in Cabinet) Other areas Standard Toner collecting Box (in copier) M-54 Box-in-Position Detection PC31 (in Cabinet) PC31 (in Cabinet) PC107 (in Copier) Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 (2) Detection of Toner Collecting Box in Position D Provided inside the Paper Feed Cabinet (in the copier for EP4000 for the areas other than the U.S.A., Canada, and Europe) is a Toner Collecting Box Set Sensor. If no box is installed, the sensor causes a warning message to appear on the Touch Panel and the initiation of a new copy to be inhibited. Toner Toner PWB-A Pipe Pipe Toner Collecting Box Toner Collecting Box Set Sensor Cabinet Toner Collecting Box Actuator PC107 Actuator (EP4000, except U.S.A., Canada, and Europe) 1134M030AA Controlled Part PC107 Control Signal PWB-A PJ19A-9 1134M037EA Blocked Unblocked WIRING DIAGRAM L H 21-F M-55 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1602A 16-2. Cleaning Bias (Optional) * Except the U.S.A., Canada, and Europe A Cleaning Bias Seal is optionally available that can be fitted to reduce damage to the PC Drum from acid paper. Toner Antispill Mylar PC Drum Cleaning Bias Seal 1151T02MCD Control Signal Cleaning Bias HV1 M-56 ON OFF WIRING DIAGRAM L H 3-F Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1700A 17 MAIN ERASE LAMP Main Erase Lamp LA2 is turned ON to neutralize any surface potential remaining on the surface of the PC Drum after cleaning. Main Erase Lamp LA2 Main Erase Lamp Board Filter 1136M069AA D Main Erase Lamp LA2 consists of ten tungsten filament lamps mounted side-by-side on a board. A filter is installed between LA2 and the PC Drum to protect LA2 from contamination. 1151T06MCD Control Signal LA2 PWB-A PJ12A-3 ON OFF WIRING DIAGRAM H L 1-L M-57 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1800A 18 PAPER TAKE-UP/FEED SECTION The copier is equipped with two paper drawers that slide out to the front of the copier. The 1st Drawer is a fixed paper size type, while the 2nd Drawer is a universal paper size type. Paper Size Detecting Sensors Assy (CD) Paper Take-Up Unit Assy Paper Take-Up Rolls 1st Drawer (Fixed Paper Size Type) Paper Size Detecting Switches Assy (FD) 2nd Drawer (Universal Paper Size Type) 1149M014AA M-58 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1801A 18-1. Drawer-in-Position Detection D When the drawer is slid into the copier, Drawer Set Detecting Lever A is pushed in the direction of the arrow, which blocks the Drawer Set Sensor (PC61/PC62, goes LOW). Rear 1st/2nd Drawer Set Sensor PC61,62 Front 4425M003AA Blocked Unblocked WIRING DIAGRAM PC61 PWB-A PJ22A-2 Control Signal L H 25-P PC62 PWB-A PJ22A-6 L H 25-P M-59 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1802A 18-2. Drawer Paper Lifting/Lowering Mechanism/Control (1) Metric Areas D The paper lifting mechanism raises the paper in the drawer so that the top of the paper stack is pressed against the Paper Take-Up Roll at a constant pressure. D When slid into the copier, the drawer presses the Drawer Set Lever which engages Lift-Up Motor Gear 1 with Paper Lifting Arm Gear 2. D At the same time, the Drawer Set Sensor (PC61 /PC62) is blocked (goes LOW) and after 1 msec., the Lift-Up Motor (M13/M14) starts turning, causing the Paper Lifting Arm to raise the Paper Lifting Plate. D When the drawer is slid out, Lift-Up Motor Gear 1 is disengaged from Paper Lifting Arm Gear 2, lowering the Paper Lifting Plate. Rear Gear 2 Gear 1 Paper Lifting Arm 1st/2nd Drawer Lift-Up Motor M13/14 Front 4425M004AA When Drawer is Slid in 1st/2nd Drawer Lift -Up Sensor (PC65/66) D The Paper Lifting Arm further raises the paper after the top sheet of paper is pressed against the Paper Take-Up Roll. As the light blocking plate blocks the Lift-Up Sensor (goes LOW), the Lift-Up Motor (M13/M14) stops. 4425M005AA M-60 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 During Copying D As sheets of paper are used, the Paper Take-Up Roll lowers accordingly, unblocking the Lift-Up Sensor (PC 65/66 goes HIGH). 4425M006AA D The Lift-Up Motor (M13/14) starts running, raising the paper stack until the Lift-Up Sensor (PC65/66) is blocked (output goes LOW). 4425M005AA D Energizing and deenergizing of the Lift-Up Motor keeps constant the pressure between the Paper Take-Up Roll and paper regardless of the height of the paper stack. Blocked Unblocked WIRING DIAGRAM PC65 PWB-A PJ21A-2A Control Signal L H 25-N PC66 PWB-A PJ21A-2B L H 32-K Energized Deenergized WIRING DIAGRAM Control Signal M13 PWB-A PJ18A-5 L H 25-M M14 PWB-A PJ18A-7 L H 25-M M-61 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 (2) Inch Areas D When the Paper Descent Key (UN5/6) is pressed*1 after the drawer has been slid into the copier, it energizes the Lift-Up Motor (M13/14) and the motor starts turning forward. D The rotation of the motor is transmitted via a gear train to the worm gear and the Paper Lifting Arm mounted on the same shaft, raising the Paper Lifting Plate. This raises the paper stack. D When the top of the paper stack is pressed against the Paper Take-Up Roll and the paper stack is further raised, the light blocking plate of the Paper Take-Up Roll Assy blocks the Lift-Up Sensor (PC65/66). This deenergizes the Lift-Up Motor and the paper stack raising motion is completed. D As the paper is consumed and the top level of the paper stack lowers, the Lift-Up Sensor is unblocked. Then, the Lift-Up Motor is energized again to raise the paper stack until the Lift-Up Sensor is blocked again. This means that a constant pressure is maintained between the paper and the Paper Take-Up Roll regardless of the amount of paper still available for use. *1: The Lift-Up Motor is energized at the following timings, in addition to the press of the Paper Descent Key (UN5/6). D Turning ON the Power Switch D Opening and closing the door D Operating the panel D Detecting a sheet of paper on the Multi Bypass Table D Detecting an original in the Duplexing Document Feeder D Raising and lowering the Original Cover, etc. Paper Lifting Arm Worm Gear 1st/2nd Drawer Paper Lift-Up Motor M13/14 1st/2nd Drawer Paper Descent Key UN5/6 1134M032EA M-62 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 D Paper lifting timings are as follows 1st/2nd Drawer Lift-Up Sensor PC65/66 When Drawer is Slid in 4425M005AA 1136T63MCA During Copying 4425M006AA 1136T64MCA 4425M005AA OFF ON WIRING DIAGRAM UN5 PWB-A PJ24A-3 Control Signal L H 41-I UN6 PWB-A PJ24A-4 L H 41-M Energized Deenergized WIRING DIAGRAM Control Signal M13 PWB-A PJ18A-5 L H 25-M (41-K) M14 PWB-A PJ18A-7 L H 25-M (41-O) M-63 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 z Paper Stack Lowering D When the Paper Descent Key (UN5/6) is pressed or the drawer runs out of paper during a copy cycle, the Lift-Up Motor (M13/14) is energized to turn backward. D The rotation of the motor is transmitted via a gear train to the worm gear and Paper Lifting Arm mounted on the same shaft, lowering them. D When the Lower Limit Position Sensor (PC70/71) is blocked by the light blocking plate of the worm gear, it deenergizes the Lift-Up Motor (M13/14). This completes the paper stack lowering motion (at a paper-empty condition). D When the Paper Descent Key (UN5/6) is pressed, the Lift-Up Motor is deenergized when the Lower Limit Position Sensor (PC70/71) is unblocked after it has been blocked. This unlocks the drawer. (For more details, see ”Drawer Locking Mechanism” that follows.) Light Blocking Plate 1st/2nd Drawer Lower Limit Position Sensor PC70/71 z 1134M033EA Drawer Locking Mechanism When Drawer is Slid in Drawer Guide Frame D The Lock Lever on the bottom of the drawer contacts the Drawer Guide Frame of the copier and slides over the frame. D The drawer is locked in the copier when the Lock Lever drops into the slot in the Drawer Guide Frame. 1134M034EA Lock Lever When Drawer is Unlocked Drawer Spring 1134M035ED D Pressing the Paper Descent Key (UN5/6) starts the paper lowering motion. D The worm gear is turned downward until its light blocking plate has passed through and below the Lower Limit Position Sensor (PC70/71), blocking and then unblocking it. This is so the worm gear can reach down low enough to push the Lock Lever downward and unlock the drawer. D When the drawer is unlocked, the Drawer Spring in the rear of the drawer pushes the drawer out to the front approx. 70 mm. D Once the drawer is pushed out, the drawer Set Sensor (PC61/62) is unblocked. This reverses the Liftup Motor (M13/14) and briefly turns the worm gear upward until its light blocking plate reblocks the Lower Limit Position Sensor (PC70/71), returning the Lock Lever to the locking position. M-64 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1803A 18-3. Paper Level Detection D The amount of paper still available for use, or the paper level, of the 1st and 2nd Drawer is detected by 1st/2nd Drawer Lift-Up Motor Pulse Sensor PC67/68 and a pulse disk. D The pulse disk is mounted on the shaft of the intermediary gear that transmits drive from the Lift-Up Motor (M13/14). The speed of the pulse disk varies with different paper levels and the number of pulses detected by the Lift-Up Motor Pulse Sensor (PC67/68) is used to determine the paper level. D Counting of the number of pulses is started when the Lift-Up Motor (M13/14) is energized and continues until the output from the Lift-Up Sensor (PC65/66) goes LOW. The total number of pulses is translated into the amount of paper which is shown on the Touch Panel as a graphic marker in units of 50 sheets of paper. D As the paper is consumed and the top level of the paper stack lowers, the Lift-Up Motor is energized to raise the paper stack. During this time, the Lift-Up Motor Pulse Sensor (PC67/68) detects pulses and that pulse count is accumulated. When the count reaches 50 sheets of paper, one segment of the paper level indicator on the Touch Panel goes out. 1st/2nd Drawer LiftUp Motor M13/14 *Paper Level Indicator D 1 to 50 sheets 1134M058AA 1st/2nd Drawer Lift-Up Motor Pulse Sensor PC67/68 D 50 to 200 sheets 1134M059AA D 200 to 350 sheets Pulse Disk 1134M060AA D 350 to 500 sheets 1134M061AA D 500 sheets up 1134M020AA 1134M062AA Control Signal Blocked Unblocked WIRING DIAGRAM PC67 PWB-A PJ23A-2 L H 32-I (41-K) PC68 PWB-A PJ23A-5 L H 32-J (41-N) M-65 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1804 18-4. Paper Empty Detection (1) Metric Areas D A paper empty condition in the 1st and 2nd Drawers is detected by 1st Drawer Paper Empty Sensor PC101 and 2nd Drawer Paper Empty Sensor PC102, respectively, installed in the paper take-up area of each drawer. D When the drawer, with no paper loaded in it, is roughly slid out of the copier, the Paper Empty Lever can hit against the Paper Lifting Plate. To prevent this from occurring, the Paper Empty Lever is tilted in the direction of sliding. Paper Lifting Plate Paper Empty Lever 4425M007AA PC101/102 (blocked) 1st/2nd Drawer Paper Empty Sensor PC101/102 Paper Present The paper stack raises the Paper Empty Lever which blocks PC101/102 (goes LOW). 4425M008AA PC101/102 (unblocked) Paper not Present The light blocking plate of the Empty Lever clears PC101/102 which goes HIGH. 4425M009AA Blocked Unblocked WIRING DIAGRAM PC101 PWB-A PJ23A-9 Control Signal L H 32-J PC102 PWB-A PJ23A-12 L H 32-K M-66 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 (2) Inch Areas D A paper empty condition in the 1st and 2nd Drawers is detected by 1st Drawer Paper Empty Board PWB-E1 and 2nd Drawer Paper Empty Board PWB-E2, respectively, installed on the underside of the Paper Lifiting Plate. D The board is provided with a reflector type photosensor. When the drawer is loaded with paper, the photosensor is activated by the light reflected off the paper. The copier then detects that there is paper in the drawer. D If no paper is loaded, the copier detects that the drawer is paper-empty and, at the same time, the Lift-Up Motor (M13/14) starts turning backward to lower the Paper Lifting Plate. D When a paper-empty condition is detected during a multi-copy cycle and if there is another paper source (including options) loaded with paper of the same size and in the same direction, the copier automatically selects that second paper source to ensure an uninterrupted copy cycle (Automatic Drawer Switching). Control Signal 1st/2nd Drawer Paper Empty Board PWB-E1/E2 1134M036EA Blocked Unblocked WIRING DIAGRAM PWB-E1 PWB-A PJ23A-9 L H 42-L PWB-E2 PWB-A PJ23A-12 L H 42-P M-67 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1805A 18-5. Universal Tray (2nd Drawer) Paper Size Detection D The length (feeding direction) and width (crosswise direction) of the paper are independently detected and the copier determines the paper size by combining the two separate detections made. The “Universal Tray 13”x or 14x” function of “Tech. Rep. Choice” must be set for the width (CD) of FLS (13” or 14” long in the feeding direction). D On the bottom of the tray is a lever fitted to the Trailing Edge Stop and another lever fitted to the Edge Guide. These levers actuate (activate) and deactuate (deactivate) the paper size detecting switches (and sensors) to allow the copier to determine a particular paper size. Detection in the Feeding Direction Paper Size Detecting Switch Assy (FD) S61/62 Cam Tray Frame S63/64 Cam Trailing Edge Stop 1149M015AA Detection in the Crosswise Direction Paper Size Detecting Sensor Assy (CD) PC72 Lever Sensor Blocking Lever PC73 Lever Lever Driving Pin Edge Guide M-68 1149M016AA Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 D Paper Size Detecting Switches/Sensors Length FD Width CD S61 PC72 S63 S64 S62 1149M018AA PC73 1149M017AA D Details of Paper Size Detecting Switches/Sensors Operation and Detectable Paper Sizes Paper Size Name Inch Size Paper Size Detecting Switches/Sensors CD FD (mm) Length (FD) Width (CD) S61 S62 S63 S64 PC72 PC73 (5-1/2” 8-1/2”) 148 210 (140 216) f * f */f f f B5L * 182 257 f f * * f f B5C * 257 182 f * * * * * A4L * 210 297 * f * f * * A4C * 297 210 f * f * f * B4L * 257 364 * * * * * * A5L (Invoice L)*2 * 297 420 * * f f f * Quarto C 10” 8” 254 203 f * f * * * G.Letter L 8” 10-1/2” 203 267 f f f * * * G.Letter C 10-1/2” 8” 267 203 f * f * * f Folio* 8-1/4” 13” 210 330 * f f f * * Letter L 8-1/2” 11” 216 279 f f f f * * Letter C 11” 8-1/2” 279 216 f * f f * f Legal* 8-1/2” 14” 216 356 * * * f * * 14 11” 14” 279 356 * * * f * f Ledger 11” 17” 279 432 * * f f * f Comp Form 11” 15” 279 381 * * * * * f * 192 268 f f f * f f 8” 13” 203 330 * f f f * * Hongkong FLS L* 8-1/2” 13” 216 330 * f f f * * G.Legal L* 8-1/2” 13” 216 330 * f f f * * Folio (Eu.)* 8-1/4” 14” 210 356 * * * f * * A3L 11 Korean FLS L FLS* Switch operation f: Actuated; *: Deactuated Sensor operation f: Blocked; *: Unblocked *A Tech. Rep. Choice function must be set for the size in the crosswise direction. L: Lengthwise; C: Crosswise *2Metric Areas: A5L Inch Areas: Invoice L M-69 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 Actuated Deactuated WIRING DIAGRAM S61 PWB-A PJ26A-2 Control Signal L H 25-J S62 PWB-A PJ26A-4 L H 25-I S63 PWB-A PJ26A-7 L H 25–I S64 PWB-A PJ26A-9 L H 25-H Blocked Unblocked WIRING DIAGRAM PC72 PWB-A PJ25A-2 L H 25-K PC73 PWB-A PJ25A-5 L H 25-J Control Signal M-70 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1806 18-6. Paper Take-Up Mechanism (1) Paper Take-Up Mechanism D The paper take-up and feeding mechanism takes up paper from the drawer and feeds it to the Vertical Transport Roller. D The take-up mechanism is driven by 1st/2nd Drawer Paper Take-Up Motor M11/12. D Each paper take-up mechanism consists of a Paper Take-Up Roll, Feed Roll and Separator Roll with torque limiter. D The Separator Roll is controlled by the torque limiter so that it will not transport more than one sheet of paper at a time. 1st Drawer Paper Take-Up Motor M11 Paper Take-Up Roll 2nd Drawer Paper Take-Up Motor M12 Paper Feed Roll Paper Separator Roll Torque Limiter M-71 4425M011AA Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 (2) Paper Separating Mechanism D The paper separating mechanism ensures that only the top sheet of paper is fed in by separating the second sheet of paper from the top one. D This is accomplished by the difference in friction coefficient between the first and second sheets of paper. D When only one sheet of paper is fed, the friction coefficient on the top side of the paper is equal Feed Roll to that on the underside. D Driven by the Feed Roll, the paper drives the Paper Separator Roll. This causes the paper to be sent Separator Roll to the Vertical Transport Section. D The friction coefficient varies for different ambi4425M012AA ent conditions and types of paper being used, which often causes the Separator Roll to be staDriven or stationary tionary. Feed Roll 1st sheet of Paper 2nd sheet of Paper 4425M013AA Separator Roll Stopped D Since the coefficient of friction between the top side of the first sheet of paper and the Feed Roll is greater than that between the first and second sheets of paper, the first sheet of paper is fed into the copier by the Feed Roll. Since the friction coefficient between the second sheet of paper and the Separator Roll is greater than that between the first and second sheet of paper, the Separator Roll is not driven and holds the second sheet of paper. M-72 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 (3) Paper Pressure Releasing Mechanism D If the drawer is pulled out while the paper is between the Feed Roll and the Separator Roll, the paper is left in the copier. Removal of the paper is difficult. With this copier, sliding out the drawer automatically disengages the paper and Paper TakeUp/Feed Roll. D The Paper Pressure Releasing Mechanism makes it easier to remove a sheet of paper held between the Feed Roll and Paper Separator Roll by just sliding out the drawer. When the drawer is pulled out, the pressure release rail pushes down the Separator Roll Assy, disengaging the Feed Roll from the Separator Roll. Separator Roll Assy Feed Roll Approx. 2mm Drawer Pressure Spring 4444M004AA (4) Paper Take-Up Roll Retraction Mechanism D When the drawer is slid out, the rear end of the drawer on the take-up side and the Pressure Release Lever push up the Paper Take-Up Roll/Feed Roll, freeing the paper from the Paper Take-Up Roll. Paper Take-Up Roll/Feed Roll Assy Front Pressure Release Lever 1134M021AA Rear M-73 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1807A 18-7. Drawer Paper Take-Up Control (1) Paper Take-Up Motor Control D A stepping motor is used for the Paper Take-Up Motor (M11/12). Each motor is turned forward or backward by energizing its four internal coils using the pulse signals output from Master Board PWB-A. Main Drive Motor M9 Paper Transport Clutch CL2 Vertical Transport Sensor PC63/PC64 1st/2nd Drawer Paper Take-Up Sensor PC55/56 1st/2nd Drawer Paper Take-Up Motor M11/12 1st sheet of paper take-up start 2nd sheet of paper take-up start 1134T14MCA T1: 5 msec. (Paper take-up off timer) T2: 5 msec. (Paper take-up interval timer) Blocked Unblocked WIRING DIAGRAM PC51 PWB-A PJ19A-5 Control Signal L H 32-M PC55 PWB-A PJ19A-2 L H 32-N PC56 PWB-A PJ21A-5A L H 25-N PC63 PWB-A PJ21A-8A L H 25-O PC64 PWB-A PJ21A-8B L H 32-M Energized Deenergized WIRING DIAGRAM Control Signal M11 PWB-A PJ16A-1 Pulse output 25-K M12 PWB-A PJ16A-2 Pulse output 25-L M-74 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 (2) Paper Take-Up Retry Control D To minimize the occurrence of a paper misfeed due to a slippery Paper Take-Up Roll, the Paper Take-Up Motor (M11/12) is kept deenergized for a given period of time before it is energized again, if a sheet of paper fails to reach the Paper Take-Up Sensor (PC55/56) even after the lapse of a given period of time after the motor has first been energized (paper take-up retry control). D A misfeed results if the sheet of paper does not reach the Paper Take-Up Sensor even after three paper take-up sequences. (3) Paper Take-Up Interval Control D The Paper Feed Roll and Separator Roll may sometimes fail to separate the subsequent sheet of paper properly and the leading edge of that paper may be beyond the Feed and Separator Rolls inside the copier. If the next paper take-up sequence is started in this condition, the distance between the preceding and the current sheet of paper will become shorter than normal, resulting in a misfeed. D To maintain a given paper take-up interval, therefore, this copier provides the following control. If it takes the paper less than a specified time to block ([L]) PC55/56 after M11/12 has been energized, M11/12 is temporarily deenergized and, an appropriate period of time thereafter, it is energized again (paper take-up interval control). (4) Double Feed Paper Take-Up Control D Even if the Paper Take-Up Roll takes up two sheets of paper at one time, the double feed paper take-up control uses the second sheet of paper for the next copy cycle without causing a paper misfeed. It eliminates a paper misfeed that would otherwise result when two sheets of paper are taken up at once. D If the second sheet of paper is stationary blocking PC55/56 when the trailing edge of the first sheet of paper moves past Vertical Transport Sensor PC63/PC64, the copier determines that it is a double feed condition and provides double feed control. D If, however, the second sheet of paper has reached the Vertical Transport Roller, the double feed control is not provided since the paper is fed further into the copier by the Vertical Transport Roller. This could result in a paper misfeed or the second sheet of paper being fed through the copier with the first one. Paper Path Position of Leading Edge of 2nd Sheet of Paper PC54 Detection Point Double Feed Control PC63 Detection Point (Not Provided) (Provided) PC55 Detection Point (Not Provided) PC64 Detection Point PC56 Detection Point (Provided) 1149M019AB M-75 For Paper Feeding from 1st Drawer For Paper Feeding from 2nd Drawer Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1900A 19 MULTI BYPASS TABLE Construction The Multi Bypass Table fitted to the Right Door of the copier, is integrated into the copier. It is constructed as follows. Right Cover Lever Paper Empty Sensor Right Door Cover Multi Bypass Table Manual Feed Paper Take-Up Clutch Manual Feed Paper Take-Up Solenoid Paper Stoppers Manual Bypass Take-Up Roll 1136M045AA Paper Empty Sensor Upper Transport Roller Manual Bypass Take-Up Roll Manual Bypass Feed Roll Multi Bypass Table Paper Empty Sensor Actuator Lower Transport Roller Paper Stopper Manual Bypass Separator Roll 1136M088AA M-76 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1901A 19-1. Paper Take-Up Mechanism The Paper Take-Up Rolls are normally in their raised (retracted) position so that they will not hamper proper loading of paper. When the Start Key is pressed, Manual Feed Paper Take-Up Solenoid SL4 is deenergized causing the Paper Take-Up Rolls to press the paper stack downward and take up a sheet of paper. Paper Stoppers are provided that block the leading edge of the paper stack as it is loaded on the Table, preventing any portion of the leading edge of the paper from getting inside. These Stoppers are unlocked at paper take-up, allowing paper into the copier. Manual Feed Paper Take-Up Clutch CL3 controls the turning and stop of the Paper Take-Up Rolls. In Standby Lock Levers Lever Rack Gear Paper Take-Up Rolls Manual Feed Paper TakeUp Solenoid SL4 Paper Stoppers At Take-Up M-77 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1151T12MCE Control Signal Energized Deenergized WIRING DIAGRAM 32-P CL3 PWB-A PJ15A-12 L H SL4 PWB-A PJ15A-9 L H SL4 PWB-A PJ15A-10 L H 32-P 1156SBM1902A 19-2. Paper Separating Mechanism The paper separating mechanism ensures that only the top sheet of paper is fed in by separating the second sheet of paper from the top one. This is accomplished by the Torque Limiter fitted to the Separator Roll shaft which stops the Separator Roll when there is a change in friction between the Feed and Separator Rolls. *For details of the paper separating mechanism, see ”18. PAPER TAKE-UP/FEED SECTION.” M-78 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM1903A 19-3. Paper Empty Detection The Multi Bypass Table is equipped with Manual Feed Paper Empty Sensor PC51 which detects a sheet of paper at the manual bypass port. Manual Feed Paper Empty Sensor PC51 Paper Take-Up Roll Paper Stopper Actuator Control Signal PC51 PWB-A PJ15A-14 Blocked Unblocked WIRING DIAGRAM H L 32-O M-79 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2000A 20 VERTICAL PAPER TRANSPORT The sheet of paper taken up by the Paper Take-Up Roll from the Drawer is fed along the Paper Guide to the Vertical Transport Rollers. The paper fed by the Vertical Transport Rollers reaches the Transport Rollers and is then fed up to the Synchronizing Rollers. The Transport Rollers are turned and stopped by Paper Transport Clutch CL1. The Transport Rollers are coupled to the Vertical Transport Rollers by way of gears, meaning that the Vertical Transport Rollers are turned and stopped in time with the Transport Rollers. Transport Roller Sensor PC54 immediately after the Transport Rollers detects a sheet of paper fed from the Vertical Transport Section or Manual Bypass Table. A Paper Dust Remover is fitted to one of the Transport Rollers, collecting paper dust from the rollers. The Cover for the Vertical Transport Section (i.e., the Side Door) can be opened and closed for clearing misfeeds. Right Upper Door Interlock Switch S22 detects whether or not this Cover is open. Right Upper Door Interlock Switch Transport Rollers Transport Roller Sensor PC51 Vertical Transport Rollers/Rolls 1156M019AA 1151T10MCC Control Signal CL1 PWB-A PJ14A-2 Control Signal S22 PWB-A PJ16A-2 Energized Deenergized WIRING DIAGRAM L H 7-F ON OFF WIRING DIAGRAM L H 21-I M-80 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2100A 21 SYNCHRONIZING ROLLERS D The Upper Synchronizing Roller is a metal roller covered with a polyvinyl chloride tubing. It is secured to the front and rear frames of the copier. D The Lower Synchronizing Roller, a rubber roller, is fitted to the Transport Assy. Pivoting about its rear end, the Lower Roller can be swung downward to facilitate clearing paper misfeeds. Upper Synchronizing Roller Paper Dust Remover Guide Plates Lower Synchronizing Roller 1136M050AA Paper Leading Edge Detecting Sensor PC55 Upper Synchronizing Roller Lower Synchronizing Roller Torsion Spring 1136M051AA M-81 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2101A 21-1. Synchronizing Roller Drive Mechanism D The Upper Synchronizing Roller receives drive from Main Drive Motor M1 via a gear train and timming belt. The Upper Roller drives the Lower one. Upper Synchronizing Roller Synchronizing Roller Clutch CL2 To Main Drive Motor M1 Timing Belt 1136M052AA 1156SBM2102A 21-2. Paper Dust Remover The Paper Dust Remover is installed so that it makes contact with the Upper Synchronizing Roller. Since the Upper Synchronizing Roller is covered with a vinyl tubing, triboelectric charging occurs as the Roller turns in contact with the Paper Dust Remover. As paper is then fed between the Synchronizing Rollers, the charges on the tubing attract paper dust from the paper. The dust is then transferred onto the Paper Dust Remover. The Paper Transport Rollers are also provided with a paper Dust Remover. Paper Dust Remover Upper Synchronizing Roller Lower Synchronizing Roller 1136M026AA M-82 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2103A 21-3. Synchronizing Roller Control The Synchronizing Rollers are started as Synchronizing Roller Clutch CL2 is energized upon reception of a signal from PWB-A. 1151T11MCD Control Signal CL2 PWB-A PJ14A-4 PC55 PWB-A PJ19A-2 Control Signal Energized Deenergized WIRING DIAGRAM L H 7-G Blocked Unblocked WIRING DIAGRAM L H 32-N M-83 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2104A 21-4. Prevention of Low Image Density on Copy During conditions of high humidity when the paper is damp, charges tend to flow from the Image Transfer Corona through the paper and guide plates to the ground. This results in low image density on the copies. To prevent this from occuring, a plastic spacer is installed between the copier frame and each guide plate around the Synchronizing Rollers so that it remains insulated. Instead of using the plastic spacer, an electrodeposition coating has been applied to some of those guide plates. If, however, the resistance with the ground is made infinity, the guide plate would build up charges and a spark could occur with other guide plates, resulting in a malfunction. To prevent this, a resistor and a varistor are connected to the guide plates. The guide plates are connected by flat springs as illustrated below. Synchronizing Rollers Æ À Â Manual Bypass Feed/Separator Rolls Transport Rollers Ä Á Varistor Ã Upper Vertical Transport Rollers Resistor Å 1136M053AA No. Guide Plate Name Insulation Method À Upper Pre-Synch Guide Plate Plastic Spacer Á Lower Pre-Synch Guide Plate Plastic Spacer Â Upper Transport Roller Guide Plate None [Fitted to top of guide plate no. Ã ] Ã Lower Transport Roller Guide Plate Plastic Spacer Ä Manual Bypass Guide Plate Electrodeposition Coating Å Vertical Transport Guide Plate Plastic Spacer Æ Pre-Image Transfer Guide Plate Fitted to plastic holder of Image Transfer/Paper Separator Coronas M-84 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 Flat Spring Connection A Between varistor-and-resistor and guide plate Æ B Between varistor-and-resistor and guide plate Á C Between guide plates Á and Ã D Between guide plates Á and À E Between guide plates Ã and Å M-85 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2200A 22 PAPER TRANSPORT D Suction Fan Motor M4 draws the paper onto the turning Suction Belts. It also pulls the paper down as it reaches the Pre-Fusing Guide Plate to ensure that the paper is smoothly fed into the Fusing Unit. D As M4 turns, ozone produced by the Image Transfer/Paper Separator Coronas is absorbed by the Ozone Filter from the air being drawn out of the copier. Suction Fan Ozone Filter Suction Belts Suction Drive Gear 1136M070AA Transport Section Release Lever Controlled Part Control Signal Half Speed Rotation Full Speed Rotation WIRING DIAGRAM M4 PWB-A PJ15A-4 L H 21-G M-86 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2201A 22-1. Suction Belt Drive Mechanism The Suction Belts are driven by Main Drive Motor M1 through a timing belt and gear train. Suction Belt Suction Belt Drive Roller Suction Drive Gear Timing Belt 1136M072AA Main Drive Motor Gear Controlled Part Control Signal ON OFF WIRING DIAGRAM M1 PWB-A PJ18A-9 L H 2-M M-87 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2300A 23 FUSING UNIT The Upper Fusing Roller and Lower Fusing Roller together apply heat and pressure to the toner and paper to permanently fix the developed image to the paper. Drive for the Upper Fusing Roller is transmitted from the Main Drive Motor to the Upper Fusing Roller Drive Gear. The Lower Fusing Roller and Cleaning Roller are driven by the respective Rollers in contact with them. Upper Fusing Paper Separator Finger Cleaning Roller Thermistor TH1/2 1st Paper Exit Roller Fusing Thermoswitch TS1 Fusing Heater Lamp H1 Upper Fusing Roller Pressure Spring Lower Fusing Roller Lower Fusing Paper Separator Finger 1156M020AA Cleaning Roller Upper Fusing Roller Cleaning Roller Drive Gear Lower Fusing Roller Main Drive Motor M1 Upper Fusing Roller Drive Gear 1136M073AA M-88 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2301A 23-1. Fusing Temperature Control The Upper Fusing Roller is heated by Fusing Heater Lamp H1 which is an AC halogen lamp. Fusing Thermistor 1 TH1 and Thermistor 2 TH2 installed on the Upper Fusing Roller helps keep the optimum fusing temperature. The fusing temperature is normally controlled at 200°C during a copy cycle and at 190°C in the standby state. To ensure good fusing performance even when the Lower Fusing Roller remains cool immediately after warm–up in the early morning, the temperature is controlled as follows when the copier is turned ON. D Temperature is controlled at 200°C for one hour after the copier has completed warming up, which is followed by a temperature control at 190°C. If a copy cycle is started while the temperature is being controlled at 190°C, the temperature control at 200°C begins. As soon as the copy cycle is completed, control is again switched to 190°C. TH1 is positioned at a point 30.5 mm from the paper path reference position, thereby preventing offset caused by low temperature and degraded fusing performance for small-size paper. The control temperature in the Energy Saving Mode is 155°C. With EP5000, the control temperature is 180°C in the Energy Saving Mode. Fusing Thermoswitch TS1, installed above the Upper Fusing Roller, cuts off the power to the Fusing Unit if the temperature of the Upper Fusing Roller becomes excessively high. It eliminates the possibility of a fire that could occur when H1 remains ON due to a faulty temperature control circuit. 1 hour after Power Switch ON 200_C 190_C 180_C 165_C 155_C EP5000 Energy Saving Mode During Copy Cycle In Standby State EP4000 Energy Saving Mode In Energy Saving Mode During Predrive Energy Saving Mode OFF Copying Enabled Energy Saving Mode ON Copy Cycle Completed Copy Cycle Started Copying Enabled Power Switch ON M-89 1151M012CA Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 When a number of sheets of small-size paper are fed through the copier continuously, the temperature of the rear end of the Fusing Rollers tends to rise, resulting in a hightemperature offset occurring. Fusing Thermistor TH2 is installed at a location 271.5 mm from the position of paper passage registration. As soon as TH2 detects 225°C, the 225°C control by TH2 is started. 1156SBM2302A 23-2. Fusing Rollers Pressure Mechanism Pressure springs are fitted to the Pressure Holder for the Lower Fusing Roller on the front and rear ends. When the pressure screws are tightened, it moves the Pressure Holder upward, thus allowing the Lower Fusing Roller to be pressed tightly up against the Upper Fusing Roller. Upper Fusing Roller Rear Front Pressure Screw Lower Fusing Roller Pressure Holder Pressure Spring M-90 1136M075AA Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2303A 23-3. Oil Roller/Cleaning Roller The Cleaning Roller is pressed up against the Upper Fusing Roller, applying a coat of silicone oil to the surface of the roller. At the same time, it turns in the direction opposite that of the Upper Fusing Roller and, with its brush, removes toner and paper dust. Cleaning Roller Upper Fusing Roller Lower Fusing Roller 1136M077AA M-91 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2304A 23-4. Paper Separator Fingers D Each of the two Fusing Rollers is provided with Paper Separator Fingers that strip the paper from the surface of the Rollers. z Upper Fusing Paper Separator Fingers D The Upper Fusing Paper Separator Fingers have been coated with teflon so that they will not be contaminated with toner. D The tip of each Separator Finger is at all times pressed against the surface of the Upper Fusing Roller by a pressure spring. Upper Fusing Roller Rear Upper Fusing Paper Separator Finger Front 1136M078AA z Lower Fusing Paper Separator Fingers D The Lower Fusing Paper Separator Fingers are flat springs to enhance paper separating performance and ensure that the paper would not become wedged if a misfeed occurs. Fusing Lower Guide/Lower Fusing Paper Separator Fingers Assy Lower Fusing Paper Separator Finger Exit Unit M-92 1156M021AA Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2305A 23-5. Fusing Section Cooling Fan Motor Fusing Section Cooling Fan Motor M15 prevents the temperature in the optical section from being raised inordinately by the heat of the Fusing Unit in the standby state. M15 remains energized while the copier is in the standby state and deenergized during a copy cycle. M15 1156M022AA Fusing Unit M15 Control Signal ON OFF WIRING DIAGRAM PWB-A PJ10A-2 L H 3-D M-93 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2400A 24 EXIT UNIT Drive from the Fusing Unit is transmitted via a gear train to turn the 1st/2nd Paper Exit Rollers. Left Door Drive Gear Paper Exit Switch S53 Exit/Duplex Switching Plate Exit/Duplex Solenoid SL5 1st Paper Exit Roller 1136M081AA Main Control Board PWB-A outputs a signal to energize Exit/Duplex Switching Solenoid SL5, which switches the position of the Exit/Duplex Switching Plate. The Unit has Paper Exit Switch S53 built into it which detects a sheet of paper being fed out of the Unit. (For more details of switching control, see the Service Manual for “DUPLEXING UNIT”). Paper Exit Switch S53 Paper Exit Roller/Rolls Exit/Duplex Switching Plate 1139M082AA Exit/Duplex Switching Solenoid SL5 S53 SL5 Control Signal ON OFF WIRING DIAGRAM PWB-A PJ14A-8 L H 3-D Control Signal Energized Deenergized WIRING DIAGRAM PWB-A PJ14A-6 L H 3-C M-94 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2401A 24-1. Left Upper Door Interlock Switch S23 D Left Upper Door Interlock Switch S23 fitted to the copier body detects the Left Upper Door when closed. The Exit Unit is fitted to the Left Upper Door. D When the Left Upper Door is closed, the rib on the Exit Unit pushes the Lever, which activates S23. Lever Left Upper Door Left Upper Door Interlock Switch S23 2nd Paper Exit Roller Drive Gear 1156M023AA Controlled Part Control Signal ON OFF WIRING DIAGRAM S23 PWB-A PJ16A-4 L H 21-I M-95 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2500A 25 DEHUMIDIFYING SWITCH To prevent image transfer efficiency from being reduced due to damp paper in highly humid weather, Paper Dehumidifying Heater H3 (Optional) is installed on the base frame of the copier under the 2nd Drawer. Drum Dehumidifying Heater H2 (Standard) is located under the Lower Synchronizing Roller to prevent the PC Drum from forming condensation. Lower Synchronizing Roller Paper Dehumidifying Heater H2 (Optional) Drum Dehumidifying Heater H3 (Standard) 1136M043AA Copier Base Frame 1136M004AA Paper Dehumidifying Switch S12 Drum Dehumidifying Switch S3 D H2, H3 ON/OFF Conditions Dehumidifying Switch ON Power cord Plugged in Power Switch ON *During a copy cycle H2 ON OFF OFF H3 ON ON OFF *During a copy cycle: Refers to the period of time between when the Start Key is pressed and when Main Drive Motor M1 is deenergized. M-96 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBM2600A 26 MEMORY BACKUP IC1 (RAM) of RAM Board PWB-R connected to Main Control Board PWB-A stores the setting/adjustment values set in the Tech. Rep. Modes as well as the counter counts. Backup Battery BAT1 is mounted on PWB-R to prevent the contents of memory from being lost when the power cord is unplugged or PWB-R removed from the copier. BAT1 requires a voltage of 2V or more to retain the contents of memory. Important As we noted above, the RAM stores critical data. If PWB-R has been replaced with a new one, memory must first be cleared and then all settings be made again. It should also be noted that PWB-R should not be replaced at the same time when PWB-A is replaced. M-97 Interleaf EP5000/EP4000 GENERAL, MECHANICAL/ELECTRICAL 97.04.01 1156SBG000E Copyright 1997 MINOLTA Co., Ltd. Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA Co., Ltd. 1156-7991-11 97046000 Printed in Japan Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1156SBD000AA EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1151SBD0000A u For the Utmost safety u ! Warning D For replacement parts, use the genuine parts with their part numbers specified in the parts manual. Use of a wrong part could cause an overload or dielectric breakdown resulting in an electric shock or fire. D Replace a blown fuse or thermal fuse with the corresponding genuine part with its part number specified in the parts manual. Use of a fuse with a different rating or one with the same rating but of a different type can result in a fire. Especially when a thermal fuse blows frequently, the thermal control system is probably faulty. Be sure to take necessary action. D Before attempting to disassemble the machine, be sure to unplug its power cord. The machine contains a high voltage unit and a circuit with a large current capacity that may cause an electric shock or burn from sparking. The machine also contains quick moving parts, which could injure a person. If the machine uses a laser, a person can lose his/her eyesight by a laser beam leak. D Wherever feasible, keep the covers and parts mounted when energizing the machine. If it is absolutely necessary to energize the machine with its cover removed, do not touch an exposed part that is being charged and use care not to allow your clothing to be caught by a timing belt, gear, or other moving part. D Do not leave the machine unattended while it is being energized. ! Caution D To actuate an interlock switch with a cover removed or opened, be sure to use the interlock switch actuating jig. Use of folded paper can damage the interlock switch mechanism. i Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 ! Caution D A high voltage is being applied to the part marked with the symbol shown on the right. Touching it can cause an electric shock. Be sure to unplug the power cord when servicing this part or other parts near it. D When the machine is energized with any of its covers removed, never use a flammable spray near it, as a fire can result. D Make sure that correct screws (diameter and length of the screw, binding/tapping screws) are used in the correct places when assembling parts. If a wrong screw is used, a short insulating distance could result. It could also result in collapsed threads, which provides only a poor grounding connection, resulting in an electric shock. D A toothed washer and spring washer, if used originally, must be reinstalled. If they are left out, a contact failure results, causing an electric shock or fire. D Replace a lithium cell only with one having the part number specified in the parts manual. An explosion could result if the cell is installed with wrong polarity or a wrong cell is installed. Dispose of a used lithium cell according to the applicable local regulations. Never throw it away or abandon it on the user’s premises. u Other Precautions u D While the machine is being energized, do not unplug or plug in a connector on a PWB or relay harness. D Since the Magnet Roller of the Imaging Unit generates a strong magnetic force, do not bring a CRT, watch, floppy disk, or magnetic card near it. D Use of an air gun or vacuum generates static electricity which can cause the ATDC Sensor and associated parts to break down. Be sure therefore to use a blower brush or cloth to clean these parts. If a unit is to be cleaned, be sure to remove the sensors in advance. D MOS lCs are susceptible to static electricity. When handling a PWB loaded with MOS ICs, follow precautions given in “INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs.” D The PC Drum is highly delicate. When handling the PC Drum, follow the precautions given in “HANDLING OF THE PC DRUM.” D To reassemble, reverse the order of disassembly unless otherwise specified. D Note that replacement of a PWB may call for readjustments or resetting of particular items. CAUTION: DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURER’S INSTRUCTIONS. ADVARSEL!:Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering. Udskiftning må kun ske med batteri af samme fabrikat og type. Levér det brugle bafferi tilbage til leverandoren. ii Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1156SBD000BA CONTENTS 1 SERVICE INSTRUCTIONS 1-1. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTS . . . . . . 1-2. INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. HANDLING OF THE PC DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. PARTS WHICH MUST NOT BE TOUCHED . . . . . . . . . . . . . . . . 2 D-1 D-3 D-3 D-5 DISASSEMBLY/REASSEMBLY 2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES . . . . . . . . . 2-2. REMOVAL OF CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . 2-3. PAPER TAKE-UP/TRANSPORT SECTIONS . . . . . . . . . . . . . . . (1) Removal of the Paper Take-Up Unit . . . . . . . . . . . . . . . . . . . . . (2) Removal of the Paper Take-Up Roll/Feed Roll Assy and Separator Roll Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) Cleaning of the Paper Take-Up Roll, Feed Roll, and Separator Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Cleaning of the Vertical Transport Rollers . . . . . . . . . . . . . . . . (5) Removal of the Drawers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6) Removal of the Upper Synchronizing Roller . . . . . . . . . . . . . . (7) Cleaning of the Upper and Lower Synchronizing Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (8) Replacement of the Paper Dust Remover . . . . . . . . . . . . . . . . (9) Cleaning of the Paper Dust Remover . . . . . . . . . . . . . . . . . . . (10) Removal of the Suction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . (11) Disassembly of the Suction Unit . . . . . . . . . . . . . . . . . . . . . . . (12) Disassembly of the Multi Bypass Unit . . . . . . . . . . . . . . . . . . 2-4. OPTICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Cleaning of the Original Glass . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Cleaning of the Scanner Shaft . . . . . . . . . . . . . . . . . . . . . . . . . (3) Cleaning of the Scanner Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Removal of the Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5) Cleaning of the Exposure Lamp . . . . . . . . . . . . . . . . . . . . . . . . (6) Removal of the Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . (7) Cleaning of the 1st, 2nd, and 3rd Mirrors . . . . . . . . . . . . . . . . (8) Cleaning of the Lens and 4th and 5th Mirrors . . . . . . . . . . . . . (9) Winding of the Lens Drive Cable . . . . . . . . . . . . . . . . . . . . . . . (10) Removal of Scanner Motor M2 . . . . . . . . . . . . . . . . . . . . . . . . (11) Removal of the Scanner Drive Cable . . . . . . . . . . . . . . . . . . (12) Winding of the Scanner Drive Cable . . . . . . . . . . . . . . . . . . . (13) Cleaning of the 6th Mirror Protective Filter . . . . . . . . . . . . . . (14) Cleaning of the Cooling Fan Filter . . . . . . . . . . . . . . . . . . . . . iii D-6 D-8 D-10 D-10 D-13 D-16 D-17 D-17 D-19 D-20 D-20 D-21 D-22 D-23 D-24 D-28 D-28 D-28 D-28 D-29 D-29 D-30 D-30 D-31 D-32 D-34 D-35 D-36 D-37 D-37 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 CONTENTS 2-5. IMAGING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Removal of the Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Disassembly of the Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . (3) Replacement of the PC Drum . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Cleaning of the Developer Scattering Prevention Plate . . . . (5) Cleaning of the Ds Positioning Collars . . . . . . . . . . . . . . . . . . . (6) Cleaning of the Toner Antispill Trap . . . . . . . . . . . . . . . . . . . . . (7) Cleaning of the Cleaning Blade . . . . . . . . . . . . . . . . . . . . . . . . . (8) Replacement of the Cleaning Blade . . . . . . . . . . . . . . . . . . . . . (9) Replacement of the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . (10) Cleaning of the AIDC Sensor Board . . . . . . . . . . . . . . . . . . . (11) Cleaning of the PC Drum Paper Separator Fingers . . . . . . (12) Replacement and Cleaning of the Toner Antispill Seal and Cleaning of the Toner Antispill Plate . . . . . . . . . . . . . . . . . (13) Removal of Main Erase Lamp LA3 . . . . . . . . . . . . . . . . . . . . (14) Cleaning of the Main Erase Lamp Filter . . . . . . . . . . . . . . . . (15) Cleaning of Image Erase Lamp LA2 . . . . . . . . . . . . . . . . . . . (16) Replacement of Image Erase Lamp LA2 . . . . . . . . . . . . . . . (17) Removal of the Ozone Filter (PC Drum Charge Corona) . . . . . . . . . . . . . . . . . . . . . . . . . . . (18) Removal of the Ozone Filter (Image Transfer/Paper Separator Coronas) . . . . . . . . . . . . . (19) Removal of the Toner Collecting Box . . . . . . . . . . . . . . . . . . . 2-6. PC DRUM CHARGE CORONA AND IMAGE TRANSFER/PAPER SEPARATOR CORONAS . . . . . . (1) Removal of the PC Drum Charge Corona . . . . . . . . . . . . . . . . (2) Cleaning of the PC Drum Charge Corona Housing . . . . . . . . (3) Cleaning of the PC Drum Charge Corona Grid Mesh . . . . . . (4) Cleaning of the Comb Electrode . . . . . . . . . . . . . . . . . . . . . . . . (5) Removal of the Image Transfer/Paper Separator Coronas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6) Cleaning and Replacement of the Image Transfer Corona Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (7) Cleaning and Replacement of the Paper Separator Corona Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (8) Cleaning of the Image Transfer/Paper Separator Coronas Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (9) Cleaning of the Lower Pre-Image Transfer Guide Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Removal of the Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Disassembly of the Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . (3) Replacement and Cleaning of the Upper Fusing Paper Separator Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Cleaning of the Lower Fusing Paper Separator Fingers . . . . (5) Cleaning of the Fusing Unit Entrance Guide Plate . . . . . . . . . iv D-38 D-38 D-38 D-42 D-42 D-42 D-42 D-42 D-43 D-45 D-46 D-46 D-46 D-47 D-47 D-47 D-47 D-48 D-48 D-48 D-49 D-49 D-49 D-50 D-50 D-50 D-50 D-51 D-51 D-52 D-53 D-53 D-53 D-58 D-58 D-58 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 CONTENTS (6) (7) (8) (9) Cleaning of Fusing Front and Rear Thermistors TH1/2 . . . . Cleaning of Fusing Thermoswitch TS1 . . . . . . . . . . . . . . . . . . Replacement and Cleaning of the Cleaning Roller . . . . . . . . Replacement and Cleaning of the Upper Fusing Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (10) Replacement and Cleaning of the Lower Fusing Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8. EXIT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Removal of the Exit/Duplex Switching Unit . . . . . . . . . . . . . . . D-58 D-59 D-59 D-59 D-60 D-61 D-61 3 ADJUSTMENT 3-1. JIGS AND TOOLS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. ADJUSTMENT REQUIREMENTS LIST . . . . . . . . . . . . . . . . . . . . 3-3. ADJUSTMENT OF SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment of Front Door Interlock Switch S21 . . . . . . . . . . . . . . 3-4. ADJUSTMENT OF BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . (1) Paper Take-Up Unit Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . (2) Developing Unit Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) Fusing Unit Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) I/U Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. ACCESSING THE TECH. REP. MODE AND ADJUST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. ELECTRICAL/IMAGE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . (1) Initial Adjustment of Original Size Detecting Board . . . . . . . . (2) ATDC Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) Adjustment of the Aperture Blades . . . . . . . . . . . . . . . . . . . . . . (4) Adjustment of Exposure Level in the Auto Exposure Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5) Adjustment of Optimum Exposure Setting in the Manual Exposure Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6) Adjustment of Zoom Ratio in the Crosswise Direction . . . . . (7) Adjustment of Zoom Ratio in the Feeding Direction . . . . . . . (8) Adjustment of Reference Position of the Multi Bypass Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (9) Adjustment of Reference Position of the 1st/2nd Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (10) Adjustment of the Leading Edge Registration . . . . . . . . . . . (1)Leading Edge Registration in Full Size Mode . . . . . . . . . (2)Leading Edge Registration in Enlargement Mode . . . . . (3)Leading Edge Registration in Reduction Mode . . . . . . . . (11) Adjustment of the Leading Edge Registration for Book Second Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (12) Adjustment of the Image Leading Edge Erase Width . . . . . (13) Adjustment of the Image Trailing Edge Erase Width . . . . . . (14) Adjustment of Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . v D-62 D-63 D-64 D-65 D-66 D-66 D-66 D-66 D-66 D-67 D-68 D-68 D-69 D-71 D-72 D-73 D-75 D-77 D-79 D-80 D-81 D-81 D-83 D-85 D-87 D-89 D-91 D-93 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 CONTENTS 3-7. OTHER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Focus-Positioning of the Scanner and Mirrors Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller (D.B. Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . (3) Adjustment of the PC Drum Paper Separator Finger Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4) Adjustment of Manual Feed Paper Take-Up Solenoid SL4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5) Adjustment of Exit/Duplex Solenoid SL5 . . . . . . . . . . . . . . . . . 4 D-94 D-94 D-96 D-97 D-98 D-99 MISCELLANEOUS 4-1. INSTALLATION OF THE PLUG-IN COUNTER (OPTION) MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-100 4-2. ADJUSTMENT OF THE RIGHT DOOR . . . . . . . . . . . . . . . . . . . D-101 vi Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1139SBD0100A 1 SERVICE INSTRUCTIONS 1151SBD0101B 1-1. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTS Observe the following precautions whenever servicing the copier. D Be sure to unplug the copier from the outlet before attempting to service the copier. D The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears. D Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the Interlock Switch with the covers left open or removed. D Do not plug in or unplug print jacks on the Board or connect or disconnect the Board connectors while power is being supplied to the copier. D Do not use flammable spray around the copier in operation. D The Magnet Roller of the Imaging Unit generates strong magnetic force. Do not bring it near a cathode-ray tube or watch. D The lithium cell in RAM Board PWB-R can burst. At replacement, make sure of the correct polarity and do not change it or create a closed circuit. A used lithium cell should be disposed of according to the local regulations and never be discarded casually or left unattended at the user’s premises. D Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit containing these sensors is to be cleaned, first remove the sensors from the unit. D When handling the PWBs with MOS ICs, observe “Instructions for Handling the PWBs with MOS ICs.” D When handling the PC Drum, observe precautions given in “Handling of the PC Drum.” D Note that replacement of a PWB may call for readjustments or resetting of particular items. D Use the right screw in the right place at reassembly. Note that some are longer and some are thicker than others. D A toothed washer is used with the screw that secures the ground wire to ensure positive conduction. Do not forget to insert this washer at reassembly. D To reassemble the copier, reverse the order of disassembly unless otherwise specified. D If it becomes necessary to replace the thermal fuse or any other fuse mounted on a board, be sure to use one of the rating marked on the blown fuse. Always note the rating marked on the fuse, as the rating and mounting site or number used are subject to change without notice. D Do not pull out the Toner Hopper while the Toner Bottle is turning, as a damaged Toner Replenishing Motor or locking mechanism could result. If the copier is to be run with the Front Door swung down, make sure that the Toner Hopper is in the locked position. CAUTION: DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISCARD USED BATTERIES ACCORDING TO THE MANUFACTURER’S INSTRUCTIONS. D-1 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 Fuse Holder F3 250V 15A Exposure Thermal Fuse Fuse Board TF1 110°C 10A PWB-L 250V 3A (4) Power Supply Board PWB-C 250V 3A (5) Power Supply Unit Noise Filter Board PU1 125V 8A PWB-D 250V 15A D-2 1156D001CA Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1139SBD0102A 1-2. INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs The following precautions must be observed when handling P.W. Boards with MOS (Metal Oxide Semiconductor) ICs. During Transportation/Storage: D During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. D Do not store or place P.W. Boards in a location exposed to direct sunlight. D When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static electricity. D Do not touch the pins of the ICs with your bare hands. During Replacement: D Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unplugged from the outlet. D When removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board. D Before plugging connectors into the Board, make sure that the power cord has been unplugged from the power outlet. During Inspection: D Avoid checking the IC directly with a multimeter; use connectors on the Board. D Never create a closed circuit across IC pins with a metal tool. D When it is absolutely necessary to touch the ICs and other electrical components on the Board, be sure to ground your body. 1151SBD0103A 1-3. HANDLING OF THE PC DRUM During Transportation/Storage: D Use the specified carton whenever moving or storing the PC Drum. D The storage temperature is in the range between –20°C and +40°C. D In summer, avoid leaving the PC Drum in a car for a long time. Handling: D Ensure that the correct PC Drum is used. D Whenever the PC Drum has been removed from the copier, store it in its container or protect it with a Drum Cloth. D The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended period of time. Never, therefore, expose it to direct sunlight. D Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter. D Do not scratch the surface of the PC Drum. D Do not apply chemicals to the surface of the PC Drum. D Do not attempt to wipe clean the surface of the PC Drum. D-3 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 If, however, the surface is contaminated with fingerprints, clean it using the following procedure. 1. Place the PC Drum into one half of its container. 2. Gently wipe the residual toner off the surface of the PC Drum with a dry, Dust-Free Cotton Pad. a) Rotate the PC Drum so that the area of its surface on which the line of toner left by the Cleaning Blade is present is facing straight up. Wipe the surface in one continuous movement from the rear edge of the PC Drum to the front edge and off the surface of the PC Drum. b) Rotate the PC Drum slightly and wipe the newly exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thoroughly cleaned. * At this time, always use a CLEAN face of the dry Dust-Free Cotton Pad until no toner is evident on the face of the Pad after wiping. 3. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front edge and off its surface one to two times. * Never move the Pad back and forth. 4. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped. Always OVERLAP the areas when wiping. Two complete turns of the PC Drum would be appropriate for cleaning. NOTES D The Organic Photoconductor Drum is softer than CdS and Selenium Drums and is therefore susceptible to scratches. D Even when the PC Drum is only locally dirtied, wipe the entire surface. D Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interior illumination. D If dirt remains after cleaning, repeat the entire procedure from the beginning one more time. D-4 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1151SBD0104A 1-4. PARTS WHICH MUST NOT BE TOUCHED (1) Screws Purpose of Application of Red Paint Red paint is applied to the screws which cannot be readjusted, set, or reinstalled in the field. The basic rule is not to remove or loosen the screws to which red paint is applied. In addition, be advised that, if two or more screws are designated as those which must not be touched on a single part, only one representative screw may be marked with red paint. (2) Variable Resistors on Board Do not turn the variable resistors on boards for which no adjusting instructions are given in “ADJUSTMENT.” (3) Other Screws Two screws on the Lower Pre-Image Transfer Guide Plate Two screws on the Lens Rail 1136D069AA 1136D068AA Two screws on the Mirror Motor Unit 1136D070AA D-5 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 2 DISASSEMBLY/REASSEMBLY 2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES 5 6 4 3 2 1 7 11 8 10 9 1156D002AA 12 13 14 15 16 1156D003AA D-6 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 No. Part Name Removal Procedure 1 Front Door Swing down No. 1. ! Remove two Front Door hinge shafts. Remove one belt mounting screw inside the Front Door. 2 Control Panel Raise No. 12. ! Swing down No. 1. ! Open No. 8. ! Remove No. 7. ! Swing down No. 14. ! Remove No. 13. ! Remove two control panel mounting screws. ! Remove two magnet attraction plate screws. ! Unplug one connector from MSC Board. ! Remove one connector. 3 Original Width Scale 4 Original Glass Raise No. 12. ! Remove two scale mounting screws. Note:When the Original Width Scale has been removed, use care not to lose two springs. 5 Rear Upper Cover (Small) Raise No. 12. ! Open No. 14. ! Remove No. 13. ! Remove the screw cover. ! Remove one Rear Upper Cover (Small) mounting screw. 6 Rear Upper Cover Raise No. 12. ! Open No. 14. ! Remove No. 13. ! Remove No. 5. ! Open No. 8 ! Remove No. 7. ! Remove one Rear Upper Cover mounting screw. 7 Right Cover Open No. 8. ! Open the Multi Bypass Table. ! Remove four Right Cover mounting screws. 8 Right Door (Manual Bypass Unit) Open No. 8. ! Remove two cover mounting screws. ! Remove the harness from one wiring saddle. ! Unplug three connectors. ! Remove two Right Door mounting screws. 9 Counter Cover Snap off the Counter Cover. (It is secured by catches at two places.) 10 2nd Drawer 11 1st Drawer See p. D-17 <120V Areas> See p. D-18 12 Original Cover Remove No. 12 by pulling up. 13 Upper Left Cover Swing down No. 14. ! Remove six Upper Left Cover mounting screws. 14 Left Door (Exit/Duplex Switching Unit) 15 Middle Left Cover Remove No. 13. ! Remove two Middle Left Cover mounting screws. 16 Rear Cover Remove six Rear Cover mounting screws. See p. D-61 D-7 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 2-2. REMOVAL OF CIRCUIT BOARDS D When removing a circuit board, refer to “PRECAUTIONS FOR HANDLING THE PWBs” contained in SWITCHES ON PWBs and follow the corresponding removal procedures given on the next page. D Replacement of a circuit board may call for readjustment or resetting of particular items. D The removal procedures given on the next page omit the removal of connectors and screws securing the circuit board support or circuit board. D Where it is absolutely necessary to touch the ICs and other electrical components on the board, be sure to ground your body. PWB-H PWB-J UN2 PWB-A PWB-R UN1 PWB-F PWB-B HV1 PWB-I PU1 PWB-D PWB-L PWB-C PWB-G 1156D004AA UN3 D-8 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 Symbol Part Name Removal Procedure PWB-A Master Board Remove No. 16. PWB-B MSC Board Swing down No. 1. ! Remove the Circuit Board cover. PWB-C Power Supply Board Remove No. 16. ! Remove the Toner Pipe. Remove No. 16. ! Remove the Toner Collecting Box. Remove the Toner Pipe. Remove No. 16. PWB-D Noise Filter Board PWB-E1 1st Drawer Paper Empty Board PWB-E2 2nd Drawer Paper Empty Board Slide out the drawer. ! Remove the Holder. ! Remove the Paper Mounting Plate. PWB-F SCP Board Remove No. 16. PWB-G AIDC Sensor Board Swing down No. 1. ! Remove the IU. ! Remove the PC Drum Charge Corona. ! Remove the PC Drum Paper Separator. PWB-H AE Sensor Board Remove No. 3. ! Remove No. 4. PWB-I Tech. Rep. Settings Switches Board Swing down No. 1. ! Remove the Circuit Board Cover. PWB-J Exposure Lamp Regulator Remove No. 16. ! Remove PWB-A Mounting Bracket Assy. ! Remove the ADF Connector Unit. ! Remove the Exposure Lamp Regulator Cover. PWB-L Fuse Board Remove No. 16. Remove No. 16. ! Remove the Toner Collecting Box. Remove the Toner Pipe. PWB-M1 1st Drawer Flexible printed Circuit PWB-M2 2nd Drawer Flexible printed Circuit PWB-R Slide out the drawer. RAM Board Remove No. 16. UN1 Control Panel Swing down No. 1 ! Remove No. 2. UN2 Original Size Detecting Board Remove No. 16. UN3 ATDC Sensor Swing down No. 1. ! Remove the IU. UN5 1st Drawer Paper Descent Key UN6 2nd Drawer Paper Descent Key PU1 Power Supply Unit Remove No. 16. ! Remove the Power Supply Unit Cover. HV1 Hight Voltage Unit Remive No. 16. ! Remove the HV1 Cover. Slide out the drawer. ! Remove the Cassette Cover. ! Remove the Switch Cover. z Readjustment/Resetting Involved in Replacement of PWB-G, PWB-R, UN2 and UN3 D When PWB-G is replaced: Adjust the exposure level in the Auto Exposure mode. (See p. D-72.) D When PWB-R (RAM Board) is replaced: Carry out Memory Clear and then make the Tech. Rep. Choice, User’s Choice, and Adjust settings again. D When UN2 is replaced: Make the initial adjustment of the Original Size Detecting Board. (See p. D-68.) D When UN3 is replaced: Discard the developer which had been used until UN3 was replaced, recharge the Developing Unit with fresh starter, and adjust the ATDC. (See p. D-69.) D-9 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 2-3. PAPER TAKE-UP/TRANSPORT SECTIONS (1) Removal of the Paper Take-Up Unit 1. 2. 3. 4. 5. Remove the Right Door, Right Cover, and Rear Cover. Remove the 1st and 2nd Drawers. (For the removal of the 1st and 2nd Drawers, see p. D-17.) Remove two locking wiring saddles. Unplug one connector from Power Supply Board PWB-C. Disconnect the hookup connector. 1156D005AA <120V Areas> 1. 2. 3. 4. Remove the Right Door, Right Cover, and Rear Cover. Remove the 1st and 2nd Drawers. (For the removal of the 1st and 2nd Drawers, see p. D-18.) Remove one locking wiring saddle. Disconnect the hookup connector. 1156D006CA D-10 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 6. Remove three screws to free the Paper Take-Up Connector Assy. 7. Remove two screws each to free 1st Drawer Paper TakeUp Motor M11 and 2nd Drawer paper Take-Up Motor M12. * For ease of understanding, the illustration shows where the connectors and Paper Take-Up Motors are removed. 1156D007AA 1134D006AA 8. Remove two screws and the Paper Guide Plate. 1134D007AA 9. Remove two edge covers with locks. 10. Unplug three hookup connectors. 1134D008AA <120V Areas> 9. Remove two edge covers with locks. 10. Unplug one hookup connector. 1156D008CA D-11 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 11. Pull the harness out to the front from the rear frame. 1134D009AA 12. Remove five screws and the Paper Take-Up Unit. 1156D009AA D-12 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (2) Removal of the Paper Take-Up Roll/Feed Roll Assy and Separator Roll Assy 1. 2. Remove the Right Door. Remove two screws and the Paper Guide Plate from each drawer. 1134D011AA 3. Unhook the front and rear springs from the copier frame. Remove the Paper Separator Roll/Paper Guide Plate Assy by turning it about 90_ in the direction of the arrow. 1156D010AA D-13 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 4. Remove one screw and the Paper Separator Roll Assy Mounting Bracket from each drawer. (The illustration shows how the Paper Separator Roll Assy is removed from the 2nd Drawer.) 1156D011AA 5. Disassemble the Paper Separator Roll Assy. 1156D012AA D-14 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 6. Remove two C-clips from each Paper Take-Up Roll/Feed Roll Assy. (The illustration is for the Paper Take-Up Roll/ Feed Roll Assy for the 2nd Drawer.) 7. Remove the bushing from the front end of each Paper Take-Up Roll/Feed Roll Assy. Remove the rear bushing from the holder. 1156D013AA 8. 1156D014AA 9. Move the coupling holder of each Paper Take-Up Roll/ Feed Roll Assy in the direction of the arrow to work it off the pin of the copier. This allows the Paper Take-Up Roll /Feed Roll Assy to come out of the copier. 1156D015AA NOTE When reinstalling the Paper Take-Up Roll/Feed Roll Assy, place it above the Pressure Release Lever. 1156D016AA D-15 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 10. Disassemble the Paper Take-Up Roll/Feed Roll Assy. *Keep the lock pin for later use. 1156D017AA (3) Cleaning of the Paper Take-Up Roll, Feed Roll, and Separator Roll 1. 2. 3. Remove each Paper Take-Up Roll/Feed Roll Assy. Remove each Paper Separator Roll Assy. Using a soft cloth dampened with alcohol, wipe each roll clean of dirt. Cleaning the Paper Take-up Roll/Feed Roll 1156D018AA D-16 Cleaning the Paper Separator Roll 1156D019AA Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (4) Cleaning of the Vertical Transport Rollers 1. 2. Remove the Right Door, Right Cover, and Rear Cover. Using a soft cloth dampened with alcohol, wipe each roller clean of dirt. 1134D016AA (5) Removal of the Drawers *Though the following steps and illustrations are for the 1st Drawer, the same procedure applies also to the 2nd Drawer. 1. Slide out the drawer and remove one screw and the right stopper. 2. Remove one screw and the left stopper. 3. Remove the drawer from the copier. 1156D020AA 1134D133AA 1134D143AA D-17 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 <120V Areas> 1. 2. Turn ON Power Switch S1. Press the Paper Descent Key and then slide out the drawer. 3. As with the metric areas, remove the right and left stoppers. Remove one screw and the hookup connector cover. 1156D023AA 4. 1134D139CA 5. Remove one screw and the hookup connector mounting bracket. 6. Unplug the hookup connector. Remove the drawer. 1134D140CA 1134D141CA D-18 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (6) Removal of the Upper Synchronizing Roller 1. 2. 3. 4. 5. Swing down the Front Door. Swing the Transport Section Release Lever down. Remove the Rear Cover. Unplug the bias terminal from High Voltage Unit HV1. Unplug CN1 of HV1. 6. Remove two screws to free HV1. 7. Snap off one E-ring to free Synchronizing Roller Clutch CL2. 8. Snap off the E-ring and remove the bushing from the rear end of the Upper Synchronizing Roller. 1156D024AA 1156D025AA 1156D026AA Rear 1156D027AA 9. Swing down the Front Door and slide out the IU. 10. Snap off the E-ring and remove the bushing from the front end of the Upper Synchronizing Roller. Front 1134D025AA D-19 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 11. Remove the Upper Synchronizing Roller. 1156D028AA (7) Cleaning of the Upper and Lower Synchronizing Rollers 1. 2. Swing down the Front Door and slide out the IU. Using a brush or a soft cloth dampened with alcohol, clean the Upper Synchronizing Roller. 3. 4. Swing down the Transport Section Release Lever. Using a brush or a soft cloth dampened with alcohol, clean the Lower Synchronizing Roller. 1136D092AA 1134D027AA (8) Replacement of the Paper Dust Remover 1. 2. Rear 3. 4. Swing down the Front Door and slide out the IU. Loosen the screw that secures the Paper Dust Remover Assy at the rear of the copier. Remove the screw that secures the Paper Dust Remover Assy at the front of the copier. Remove and replace the Paper Dust Remover Assy. 1136D093AA 5. When only the Paper Dust Remover is to be replaced, affix the new one along the reference line as shown on the left. 1136D094AA D-20 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (9) Cleaning of the Paper Dust Remover 1. 2. Remove the Paper Dust Remover Assy. Using a brush, whisk dust off the Paper Dust Remover. 1136D095AA D-21 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (10) Removal of the Suction Unit 1. 2. 3. 4. Remove the 1st and 2nd Drawers. Swing down the Front Door and slide out the IU. Remove the Paper Dust Remover Assy. Remove the Fusing Unit. 5. Remove the motor cover. 6. Unplug two connectors from the lower end of the Suction Unit. 7. Swing the Transport Section Release Lever back to its original position. Pressing down the Image Transfer/Paper Separator Coronas Unit, pull it out of the copier. 1156D029AA 1156D030AA 8. 1156D031AA D-22 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 9. Swing down the Transport Section Release Lever. 10. Holding up the Suction Unit, remove the compression coil. 1156D032AA 11. Remove the Suction Unit by sliding it to the right. NOTE When removing and reinstalling the Suction Unit, use care not to bend the ground plate located on the right in the rear. 1136D101AA NOTE When reinstalling the Suction Unit, make sure that two positioning pins on the copier fit into the positioning holes in the Suction Unit. 1134D028AA (11) Disassembly of the Suction Unit 1. 2. 3. Remove the Suction Unit. Remove two screws and the duct. Remove four screws and the Suction Drive Unit. NOTE When reinstalling the Suction Drive Unit, try to press it down against the Suction Base Plate. 1136D102AA 4. Remove three driven rolls. 1136D103AA D-23 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 5. Remove three Suction Belts. 6. Remove the Suction Roller as shown on the left. 1136D104AA 1136D105AA (12) Disassembly of the Multi Bypass Unit 1. 2. 3. 4. Open the Right Door. Remove two screws and the cover. Remove the harness from one locking wiring saddle. Unplug three connectors. 5. Remove two screws and the Right Door. 1156D033AA NOTE The Right Door must be adjusted for correct position when it is reinstalled. (See p. D-101.) 1156D034AA 6. Remove four screws and the Separator Guide Plate Assy. 1156D035AA D-24 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 7. Remove the compression coil. NOTE When reinstalling the compression coil, place it so that its close-coiled end faces the Separator Unit. Close-Coiled End 1136D107AA 8. Remove one C-clip and the Separator Assy. 9. Remove one C-clip and the Separator Roll Assy. 1136D108AA 1136D109AA 10. Remove the harness from the edge cover and cord clamp. 1136D110AA 11. Remove four screws and the Solenoid Mounting Bracket. NOTE When the solenoid has been replaced or the solenoid mounting screws removed, be sure to adjust the position of the solenoid. (For the adjustment procedure, see p. D-98.) 1156D036AA D-25 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 12. Remove two set screws and the electromagnetic spring clutch. 1156D037AA NOTES 1136D114AA 0 to –1mm D When reinstalling the electromagnetic spring clutch, orient the Paper Take-Up Roll shaft and the clutch as shown on the left. D The end of the clutch must be flush with or slightly recessed (up to 1 mm) from the end face of the Paper TakeUp Roll shaft. (The roll shaft should never protrude.) D There must be a gap of 1 mm or more at A when the Paper Take-Up Roll shaft is pushed in the direction of the arrow. A 1136D115AA 13. Snap off two C-clips and remove the Paper Take-Up Roll Assy. 1156D038AA 14. Snap off three C-clips and remove the Feed Roll. 1139D112AA D-26 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 15. Snap off the C-clip and remove the Paper Take-Up Roll. 1139D113AA D Cleaning of the Manual Bypass Paper Take-Up Roll Using a soft cloth dampened with alcohol, clean the PaperTake-Up Roll. 1136D117AA D Cleaning of the Manual Bypass Feed Roll Using a soft cloth dampened with alcohol, clean the Feed Roll. 1136D118AA D Cleaning of the Manual Bypass Separator Roll Using a soft cloth dampened with alcohol, clean the Separator Roll. 1156D039AA D-27 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 2-4. OPTICAL SECTION (1) Cleaning of the Original Glass Wipe clean the Original Glass with a soft cloth. NOTE The surface of the Original Glass is coated with conductive material. Do not use a wax-based detergent. An alcohol-dampened cloth may be used if the glass is seriously contaminated. 1136D120AA (2) Cleaning of the Scanner Shaft 1. 2. Remove the Original Width Scale. Remove the Original Glass. 3. Wipe clean the Scanner Shaft (in the rear of the copier) with a soft cloth. 1136D121AA NOTE Apply a lubricating oil after cleaning the Scanner Shaft. 1156D040AA (3) Cleaning of the Scanner Rail Wipe clean the Scanner Rail (at the front of the copier) with a soft cloth. NOTE Apply a lubricating oil after cleaning the Scanner Rail. 1156D041AA D-28 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (4) Removal of the Scanner 1. Move the Scanner to the right side of the copier. Remove three screws to free the Scanner. NOTE Hold the Scanner at a point near the Scanner Shaft when moving it. To remove the Scanner, turn it counterclockwise. 1156D042AA 2. 3. Unplug the Thermal Fuse terminal connector and remove the Thermal Fuse wire from three clamps. Unplug the Exposure Lamp terminal connector. 1156D043AA 4. 5. 6. Turn over the Scanner and remove one screw, one washer, and the ground wire. Remove the tie band and harness. Remove the Scanner from the copier. 1156D044AA (5) Cleaning of the Exposure Lamp 1. 2. Remove one screw and the Exposure Lamp terminal. Slide out the Exposure Lamp. NOTE When the Exposure Lamp has been cleaned or replaced, be sure to make the “adjustment of exposure level in the Auto Exposure mode.” (See p. D-72.) 1156D045AA 3. Using a soft cloth dampened with alcohol, clean the lamp by gently wiping its surface in one direction. NOTE When reinstalling the lamp, point the protruding navel of the lamp toward the opening in the Lamp Reflector so that the protruding navel will not hit against the Lamp Reflector. 1076D131 D-29 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (6) Removal of the Thermal Fuse 1. 2. 3. 4. Unplug the Thermal Fuse connector. Remove the Thermal Fuse cord from three clamps. Remove one screw and Thermal Fuse cover. Remove two screws and the Thermal Fuse. 1156D046AA (7) Cleaning of the 1st, 2nd, and 3rd Mirrors 1. Wipe clean the 1st Mirror with a soft cloth. 2. Wipe clean the 2nd Mirror with a soft cloth. 3. Wipe clean the 3rd Mirror with a soft cloth. 1156D047AA 1136D130AA 1136D131AA D-30 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (8) Cleaning of the Lens and 4th and 5th Mirrors 1. 2. 3. Remove the Original Glass. Remove two screws and the Optical Cover. Remove two screws and the Lens Cover. 4. Gently dust off the surface of the Lens using a soft cloth. 5. Wipe clean the 4th and 5th Mirrors with a soft cloth. 1136D133AA 1136D132AA 1136D134AA D-31 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (9) Winding of the Lens Drive Cable A Cable Drive Gear B 1136D135AA 1. Hold the Cable Drive Gear with the bead at the bottom. 2. Wind the longer length of the cable three and 1/2 turns clockwise around the Cable Drive Gear, working from the back to the front side. Then tape it. 3. Wind the shorter length of the cable three and 1/2 turns counterclockwise around the Cable Drive Gear, working from the front to back side. Then tape it. 1136D136AA 1136D137AA 1136D138AA D-32 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 4. 5. Pass the longer length of the cable through the hole in the light blocking plate. Slide the Cable Drive Gear onto its shaft and insert a wrench into the hole (4-mm dia.) to position the gear. 1136D139AA 6. Wind the shorter length of the cable around pulley A. 7. Secure the shorter length of the cable to the Cable Fixing Bracket. A 1136D140AA NOTE Ensure a distance of 2 mm or less for the dimension shown on the left. 2mm or Less 1136D141AA 8. 9. Wind the longer length of the cable around pulley B. Hook the spring onto the longer length of the cable and pull the spring to hook it onto the shorter length of the cable. 10. Remove the wrench and peel off the two pieces of tape used in steps 2 and 3. B 1136D142AA D-33 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (10) Removal of Scanner Motor M2 1. 2. Remove the Right Cover, Rear Cover, and Rear Upper Cover. Remove four screws to free PWB-F. 1156D048AA 3. 4. Unplug one connector. Then, remove the edge cover with a lock and the harness. Remove four screws and Scanner Motor M2. 1156D049AA D-34 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (11) Removal of the Scanner Drive Cable 1. 2. 3. 4. 5. Remove the Original Cover. Remove the Right Cover, Rear Cover, Rear Upper Cover, and Upper Left Cover. Remove the Original Glass. Remove the Scanner. Remove Scanner Motor M2. 6. Remove two screws to free the SCP Board (PWB-F) mounting bracket. *The illustration shows where the SCP Board has been removed for ease of understanding. 1156D048AA 7. Remove two screws and Original Glass Cooling Fan Motor M5. 8. Using a flat blade screwdriver, loosen the right spring anchor to unhook the bead from the anchor, thereby removing the cable. 9. Move the Scanner to the center and remove the Scanner Fixing Bracket. 1156D050AA 1134D037AA 1134D038AA D-35 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (12) Winding of the Scanner Drive Cable z Important When the Scanner Drive Cable has been wound: 1) Perform the “Focus-positioning of the Scanner and Mirrors Carriage.” 2) Slide the Scanner by hand to check for cable tension before turning the copier ON. 3) No part of the cable should ride on others when winding the cable around the Cable Drive Pulley. Further, no part in the cable should be bent or no part of the cable jacket frayed. * Wind the cable five turns around the Cable Drive Pulley. Wind Cable 5 Turns. 1156D054AA D-36 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 10. Remove the Scanner Drive Cable from the pulleys. 11. Remove one screw to free the Original Cover Detecting Sensor Assy. 12. Remove four screws and the Scanner Drive Pulley mounting bracket. 13. Snap off one E-ring and remove the Scanner Drive Pulley. 1156D051AA (13) Cleaning of the 6th Mirror Protective Filter 1. 2. 3. Swing down the Front Door and slide out IU. Remove the Plate Spring. Remove the 6th Mirror Protective Filter. 4. Using a soft cloth, wipe clean the 6th Mirror Protective Filter. 1156D174AA 1156D175AA (14) Cleaning of the Cooling Fan Filter 1. 2. Remove six screws and the Rear Cover. Clean the Cooling Fan Filter using a brush or a vacuum cleaner. 1156D052AA D-37 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 2-5. Imaging Unit (1) Removal of the Imaging Unit 1. 2. Swing down the Front Door. Swing the Transport Section Release Lever down. 3. 4. Loosen two screws that secure the IU. Slide out the IU. 1136D150AA 1156D055AA (2) Disassembly of the Imaging Unit 1. Remove the PC Drum Charge Corona by moving it to the rear. 2. 3. Loosen one screw and remove the stopper. Remove the PC Drum. 4. Pull the Main Hopper to the front and unplug two Hopper Unit connectors. 1136D152AA 1156D056AA 1156D057AA D-38 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 5. Remove three screws and the Main Hopper. 6. Unplug one connector and remove three screws and the Sub Hopper. 7. Remove two screws and the Developer Scattering Prevention Plate. 1136D155AA 1156D058AA NOTE Do not remove the Doctor Blade Assy, as a changed Db could result. 1156D059AA NOTE Rear Install the Developer Scattering Prevention Plate so that its seal is placed behind the side seals of the Developer Mixing Chamber. Front 1156D060AA 8. Dump the developer out of the Developing Unit. 1136D157AA D-39 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 9. Remove two screws and the Cleaning Blade. 1136D172AA NOTE When reinstalling the Cleaning Blade, press the blade tightly up against the mounting bracket. 1136D173AA 10. Unplug one connector. 11. Remove three screws and the PC Drum Paper Separator Finger Holder Assy. 1156D061AA NOTE Coupling Holder When reinstalling the PC Drum Paper Separator Finger Holder Assy, fit the collar of the assy onto the coupling holder in the rear. Collar 1134D047AA D-40 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 12. Remove the PC Drum Paper Separator Fingers and AIDC Sensor Board PWB-G as shown below. Assy PWB-G Torsion Spring 1156D062AA * PC Drum Paper Separator Fingers At removal and reinstallation, use care not to damage the tip of the fingers. Also, use care not to get hurt by the tip of the fingers. PC Drum Paper Separator Finger Installed Top View Bottom View * Hook the torsion spring properly. After installation, check that the Paper Separator Fingers operate smoothly. 1156D063AA D-41 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (3) Replacement of the PC Drum 1. 2. 3. 1136U014AA Slide out the IU. Loosen one screw and remove the stopper. Remove and replace the PC Drum. NOTE When the PC Drum has been replaced, reset the count of “PC Drum” of “Port/Option” counters of the Tech. Rep. mode and then make the “adjustment of exposure level in the Auto Exposure mode.” (For the “adjustment of exposure level in the Auto Exposure mode,” see p. D-72.) (4) Cleaning of the Developer Scattering Prevention Plate Using a brush, whisk dust off the Developer Scattering Prevention Plate. 1136D050AA (5) Cleaning of the Ds Positioning Collars Using a brush or a soft cloth dampened with alcohol, clean the Ds Positioning Collars. 1136D177AA (6) Cleaning of the Toner Antispill Trap Using a brush or a vacuum cleaner, clean the Toner Antispill Trap. 1136D178AA (7) Cleaning of the Cleaning Blade Using a brush, whisk paper dust and toner off the Cleaning Blade. 1156D167AA D-42 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (8) Replacement of the Cleaning Blade 1. Remove and replace the Cleaning Blade. 2. Remove the Toner Bottle from the IU. Insert a brush through the toner port and into the toner. 3. Apply toner to the entire surface of the new Cleaning Blade. 1136D172AA 1138D321AA NOTE Be sure to apply toner to both end faces of the Cleaning Blade. 1136U013AA 4. Using the brush, apply lubricant shipped with the Cleaning Blade to the two side seals shown. 1136D303AA D-43 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 5. Install the PC Drum. NOTE Do not touch the surface of the PC Drum with bare hands. Hold onto both ends of the PC Drum when installing the drum. 1136U014AA 6. Fit the PC Drum stopper and tighten the screw. 7. Apply a thin coat of toner to the surface of the PC Drum. 8. Holding onto both ends of the PC Drum, turn the PC Drum one complete turn in the forward direction. 1156D064AA 1156D065AA 1134U022AA 9. Holding onto both ends of the PC Drum, turn the PC Drum 1/2 turns in the backward direction. 10. Holding onto both ends of the PC Drum, turn the PC Drum 1/2 turns in the forward direction. 1156D066AA D-44 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (9) Replacement of the Starter 1. Dump the developer out of the Developing Unit. 1136D157AA 2. Turning the Bucket Roller, pour fresh starter evenly into the chamber. NOTE Shake the packet of starter well before opening it. NOTE When the starter has been replaced, reset the count of “Starter” of the “Port/Option” counters of the Tech. Rep. mode and then make the ATDC adjustment. (For the ATDC adjustment, see p. D-69.) 1134D051AA D-45 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (10) Cleaning of the AIDC Sensor Board 1. 2. Remove the PC Drum Paper Separator Fingers Assy. Using a brush or a soft cloth dampened with alcohol, clean the AIDC Sensor Board. 1156D067AA (11) Cleaning of the PC Drum Paper Separator Fingers 1. 2. Remove the PC Drum Paper Separator Fingers Assy. Using a brush or a soft cloth dampened with alcohol, clean the PC Drum Paper Separator Fingers. 1136D181AA (12) Replacement and Cleaning of the Toner Antispill Seal and Cleaning of the Toner Antispill Plate 1. 2. 3. Remove the IU. Remove two screws, the Toner Antispill Plate, and Toner Antispill Seal. Replace the Toner Antispill Seal. 4. 5. Using a brush, clean the Toner Antispill Seal. Using a brush, clean the Toner Antispill Plate. 1136D182AA 1134D052AA NOTE When reinstalling the Toner Antispill Plate and Toner Antispill Seal, press them in the direction of the arrows. 1136D184AA D-46 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (13) Removal of Main Erase Lamp LA3 1. 2. 3. Swing down the Front Door. Unplug one connector. Remove one screw and Main Erase Lamp LA3. 1156D068AA (14) Cleaning of the Main Erase Lamp Filter 1. 2. Swing down the Front Door. Remove the Main Erase Lamp Filter. 3. Using a soft cloth dampened with alcohol, wipe clean the Main Erase Lamp Filter. 1136D186AA 1136D187AA (15) Cleaning of Image Erase Lamp LA2 1. 2. 3. Swing down the Front Door. Remove the IU. Using a soft cloth dampened with alcohol, wipe clean Image Erase Lamp LA2. 1136D188AA (16) Replacement of Image Erase Lamp LA2 1. 2. 3. Swing down the Front Door. Remove the IU. Remove one adjusting screw to free Image Erase Lamp LA2. 1134D055AA D-47 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 4. Unplug one connector in the rear and remove Image Erase Lamp LA2. NOTE When Image Erase Lamp LA2 has been removed, make the “adjustment of edge erase.” (For the adjustment of edge erase, see p. D-93.) 1134D056AA (17) Removal of the Ozone Filter (PC Drum Charge Corona) 1. 2. 3. Swing down the Front Door. Swing out the Main Hopper. Slide out the Ozone Filter. 1134D057AA (18) Removal of the Ozone Filter (Image Transfer/Paper Separator Coronas) 1. 2. 3. Remove the Rear Cover. Remove one screw and the Filter Cover. Pull out the Ozone Filter. 1136D189AA (19) Removal of the Toner Collecting Box (Except the U.S.A., Canada, and Europe) 1. 2. Remove the Rear Cover. Remove the Toner Collecting Box. *For removal of the large capacity Toner Collecting Box, please refer to the instructions on the large capacity Box. 1136D087AA D-48 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 2–6. PC DRUM CHARGE CORONA AND IMAGE TRANSFER/PAPER SEPARATOR CORONAS (1) Removal of the PC Drum Charge Corona Move the PC Drum Charge Corona to the rear and pull it off. 1156D069AA (2) Cleaning of the PC Drum Charge Corona Housing 1. 2. 3. Remove the IU. Remove one screw and PC Drum charge Corona Unit. Press the Mesh Holder on the front of the Corona Unit in the direction of arrow A to remove the Grid Mesh. 4. 5. Remove the Cleaning Pad Cover. Remove the End Caps from the front and rear ends of the Unit. 6. Remove the Comb Electrode. 1156D070AA 1156D071AA NOTE Use care not to deform the Electrode. When removing it, first snap off its spring end. 1139D176AA 7. Using a soft cloth dampened with alcohol, wipe the Housing clean of dirt. 1139D177AA D-49 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (3) Cleaning of the PC Drum Charge Corona Grid Mesh Blow all foreign matter off the Grid with a blower brush. NOTE If the blower brush is not effective in cleaning the Grid, use a soft cloth dampened with alcohol to clean serious contamination. 1139D178AA (4) Cleaning of the Comb Electrode Clean Comb Electrode using the Corona Unit Cleaning Lever. 1156D072AA (5) Removal of the Image Transfer/Paper Separator Coronas 1. 2. Swing down the Front Door. Pull out the Image Transfer/Paper Separator Coronas. 1134D062AA (6) Cleaning and Replacement of the Image Transfer Corona Wire 1. 2. Swing down the Front Door. Clean the Image Transfer Corona Wire using the Corona Wire Cleaning Lever. 1136D198AA NOTE If the Image Transfer Corona Wire is seriously contaminated, dampen a soft cloth with alcohol, hold it with a pair of tweezers, and wipe the wire gently in one direction-from the hook end to the spring end. 1136D199AA D-50 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 3. Remove the Holder Covers at the front and rear. 4. 5. Remove the corona wire, first at the spring end. Replace the corona wire with a new one. 1136D200AA 1136D201AA (7) Cleaning and Replacement of the Paper Separator Corona Wire 1. Remove four Paper Guides. 2. Dampen a soft cloth with alcohol, hold it with a pair of tweezers, and wipe the Paper Separator Corona Wire gently in one direction – from the hook end to spring end. Replace the Paper Separator Corona Wire by using the same procedure as that for the Image Transfer Corona Wire. 1136D202AA 3. 1136D203AA (8) Cleaning of the Image Transfer/Paper Separator Coronas Housing 1. 2. 3. 4. Remove four Paper Guides. Remove the Holder Covers at the front and rear. Remove the Image Transfer and Paper Separator Corona Wires – first at the spring end. Using a soft cloth dampened with alcohol, wipe the housing clean of dirt. 1136D205AA D-51 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (9) Cleaning of the Lower Pre-Image Transfer Guide Plate Using a soft cloth dampened with alcohol, wipe clean the Lower Pre-Image Transfer Guide Plate. 1136D206AA D-52 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 2–7. FUSING UNIT (1) Removal of the Fusing Unit 1. 2. 3. Open the Left Door. Swing down the Front Door. Remove one screw and the Fusing Unit. 1156D073AA (2) Disassembly of the Fusing Unit 1. Remove two screws and the Front Cover. 2. 3. 4. 5. Unplug the connector of the Heater Lamp on the front. Remove three harness holders. Remove the Heater Lamp cord from the two edge covers. Remove two screws and the front lamp holder. 6. Remove two screws and the cover. 1156D074AA 1156D075AA 1156D076AA Cover Harness Cover NOTE At reinstallation, position the cover between the Fusing Unit and harness cover. Fusing Unit 1156D077AA D-53 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 7. 8. Remove one screw and the Heater Lamp cord in the rear. Remove the Heater Lamp cord from the locking edge cover. 1156D078AA 9. Remove three screws and the rear lamp holder. 10. Remove the Heater Lamp cord from the wiring saddle. 11. Remove the Heater Lamp. 1156D079AA 12. Remove four screws and the Upper Cover. 1156D080AA 13. Remove two screws and the Upper Fusing Paper Separator Finger mounting bracket. 1156D081AA NOTE When reinstalling the Upper Fusing Paper Separator Finger mounting bracket, be sure that both ends of the bracket are in tight contact with the frame. 1136D213AA D-54 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 14. Remove the harness from the Harness Guide. 15. Unplug the connectors of the two Thermistors. 1156D082AA 16. Remove one screw, shoulder screw, and the Harness Guide. 17. Remove one screw and the Thermoswitch cord. 1156D083AA 18. Remove two screws and the Temperature Detector Assy. 1156D084AA NOTE When reinstalling the Temperature Detector Assy, be sure that both ends of the assy are in tight contact with the frame. 1136D217AA 19. Remove the Gear. 20. Remove two shoulder screws and the Fusing Unit Entrance Guide Plate. 1156D085AA D-55 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 21. Remove the two torsion springs. 22. Remove two shoulder screws and the Lower Exit Guide Assy. Shoulder Screw Lower Fusing Roller Rear Upper Fusing Roller Torsion Spring Torsion Spring Shoulder Screw Front Lower Exit Guide Assy 1156D086AA Lower Exit Guide Assy Position À Installing the Lower Exit Guide Assy Lower Fusing Roller Á Lower Fusing Paper Separator Finger Contact No Clearance Allowed. 1134D067AA D-56 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 23. Loosen the screw that secures the spring bracket at the front and then unhook the spring at the top. Repeat the same step for the spring in the rear. NOTE When reinstalling the springs, alternately tighten the bracket mounting screws until the brackets completely contact the ends of the Lower Exit Guide Assy. 1156D087AA 24. Remove the Lower Fusing Roller. 1156D088AA 25. Remove two extension springs. 26. Remove two E-rings, the gear, bushing, and Cleaning Roller. 1156D089AA 27. Remove two E-rings, then two gears. 28. Remove two screws, the Upper Fusing Roller drive gear, and Upper Fusing Roller. 1156D090AA D-57 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (3) Replacement and Cleaning of the Upper Fusing Paper Separator Fingers 1. 2. 3. 4. Remove the Upper Fusing Paper Separator Finger mounting bracket. Remove five springs. Slide out the shaft to remove the Upper Fusing Paper Separator Fingers. Replace the fingers with new ones. 1156D091AA 5. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Upper Fusing Paper Separator Fingers. 1136D227AA (4) Cleaning of the Lower Fusing Paper Separator Fingers 1. 2. Remove the Lower Exit Guide Assy. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Lower Fusing Paper Separator Fingers. 1136D228AA (5) Cleaning of the Fusing Unit Entrance Guide Plate Using a soft cloth dampened with alcohol, wipe clean the Fusing Unit Entrance Guide Plate. 1156D092AA (6) Cleaning of Fusing Front and Rear Thermistors TH1/2 1. 2. Remove the Temperature Detector Assy. Using a soft cloth dampened with alcohol, wipe clean the two thermistors. 1156D093AA D-58 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (7) Cleaning of Fusing Thermoswitch TS1 1. 2. Remove the Temperature Detector Assy. Using a soft cloth dampened with alcohol, wipe clean the thermoswitch. 1156D094AA (8) Replacement and Cleaning of the Cleaning Roller 1. 2. 3. Remove two screws and the Upper Cover. Remove the Cleaning Roller. Replace the Cleaning Roller with a new one. 4. Using a brush, whisk dust off the Cleaning Roller. 1156D089AA 1136D232AA (9) Replacement and Cleaning of the Upper Fusing Roller 1. 2. Remove the Upper Fusing Roller. Replace the Upper Fusing Roller with a new one. 3. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Upper Fusing Roller. 1156D090AA 1136D233AA D-59 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (10) Replacement and Cleaning of the Lower Fusing Roller 1. 2. Remove the Lower Fusing Roller. Replace the Lower Fusing Roller with a new one. 3. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Lower Fusing Roller. 1156D088AA 1136D234AA D-60 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1156SBD0208A 2-8. EXIT UNIT (1) Removal of the Exit/Duplex Switching Unit 1. Remove the Rear Cover. 2. Open the Left Door. 3. Remove the Upper Left Cover. 4. Remove four screws to free the Sorter Connector Assy. 5. 6. Unplug two connectors. Remove one screw and the ground wire. 7. Snap off the E-ring from the shaft onto which the Exit/Duplex Switching Unit is mounted. Work the harness indicated by the arrow off the wiring saddle. 1134D144AA 1156D095AA 8. 1156D096AA 9. Remove one screw that holds the belt. 10. Remove two screws and the mounting bracket. 11. Remove the Exit/Duplex Switching Unit. 1156D097AA D-61 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1156SBD0300A 3 ADJUSTMENT 1156SBD0301A 3-1. JIGS AND TOOLS USED z Important D When adjusting the positions of the Scanner and Mirrors Carriage, use jigs number Â and Ã. D When adjusting the gap between the Doctor Blade and Sleeve Roller, use jigs number Ä and Å. D When adjusting the position of the PC Drum Paper Separator Fingers, use jigs number Ä and Æ. À Front Door Interlock Switch Á Predrive Inhibit Switch Actuating Jig Actuating Jig 1136D005AA 1136D001AA Ã Scanner/Mirrors Â Scanner Positioning Jig Carriage Positioning Jig 1136D006AA 1136D002AA Ä Sleeve/Magnet Roller Å D.B. Adjusting Jigs Positioning Jig 1136D003AA Æ PC Drum Paper Separator Finger Positioning Jig 1136D004AA D-62 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1156SBD0302A 3-2. ADJUSTMENT REQUIREMENTS LIST Adjustment Item Requirements Adjusting Point Ref. Page Optimum exposure in the Manual Exposure mode Kodak Gray Scale: no image of the 1st step, faint image of the 2nd step Control panel D-73 Crosswise zoom ratio, full size ( 1.000) 200 ± 1.0 mm Control panel D-75 Feeding direction zoom ratio, full size ( 1.000) 300 ± 1.5 mm Control panel D-77 Multi Bypass Table reference Position ( 1.000) 20 ± 2.0 mm Multi Bypass Table D-79 1st Drawer reference Position ( 1.000) 20 ± 2.0 mm Drawer Positioning Plate D-80 2nd Drawer reference Position ( 1.000) 20 ± 2.0 mm Drawer Positioning Plate D-80 Leading edge registration, full size ( 1.000) 20 ± 1.5 mm Control panel D-81 Leading edge registration, enlargement ( 2.000) 40 ± 3.0 mm Control panel D-83 Leading edge registration, reduction ( 0.500) 10 ± 1.5 mm Control panel D-85 Leading edge registration, book second page ( 1.000) 20 ± 3.0 mm Control panel D-87 Image leading edge erase width ( 1.000) 16.5 mm Control panel D-89 Image trailing edge erase width ( 1.000) 0.55.5 mm Control panel D-91 Edge erase ( 1.000) 0.54.0 mm Edge Erase Adjusting Screw D-93 D-63 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1151SBD0303A 3-3. ADJUSTMENT OF SWITCHES Microswitches The following microswitches are used in various parts of this copier. Blue (NC) Yellow (NO) Red (COM) Red (COM) 1136D007AA 1136D008AA Wiring for the NO Type NC (Normally-Closed) Wiring for the NC Type : Current flows between NC and COM when the actuator is open. NO (Normally-Open) : Current flows between NO and COM when the actuator is closed. COM (Common) : Common contact for NC and NO. Requirement Actuator The gap between the switch and actuator should be 0.1 to 0.5 mm when the actuator is closed. 0.1 mm to 0.5 mm Out-of-Adjustment (When the actuator is closed) D If the gap between the switch and actuator is too big, current does not at times flow to NC or NO. D If there is no gap between the switch and actuator, the actuator is bent or the switch can be broken. D-64 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 Adjustment of Front Door Interlock Switch S21 1. 2. Swing down the Front Door. Remove six screws and the Upper Left Cover. 3. 4. Remove three screws and the cover. Loosen two screws that secure Front Door Interlock Switch. 5. 6. Close the Front Door. Slowly move the switch to the front until the actuator is closed by the actuator stop on the Front Door. Then, tighten the two mounting screws. 1136D009AA 1136D010AA D The switch is wired for the NO type. 1156D098AA D-65 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 3-4. ADJUSTMENT OF BELT TENSION z Important D Make sure that all gears are in positive mesh with each other and the belts snugly fit in the pulley grooves. D Each belt should flex a little when finger-pressed down on the location indicated by the arrow. Tension Deflection (Reference only) (1) Paper Take-Up Unit Timing Belt Belt 300 ± 100 g Approx. 3 mm (2) Developing Unit Timing Belt 350 ± 100 g Approx. 4 mm (3) Fusing Unit Timing Belt 350 ± 100 g Approx. 3 mm (4) IU Timing Belt 350 ± 100 g Approx. 5 mm Loosen two screws that secure the Tension Lever. Move the Tension Lever in the direction of the arrow two to three times. When the belt tension is correct, tighten the two screws. Move lever 2 to 3 times, then tighten screws. Move lever 2 to 3 times, then tighten screws. 350 ± 100 g 350 ± 100 g 300 ± 100 g 350 ± 100 g Move lever 2 to 3 times, then tighten screws. 1156D172AA D-66 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 3-5. ACCESSING THE TECH. REP. MODE AND ADJUST MODE z Accessing the Tech. Rep. Mode To access the Tech. Rep. mode, press the following keys in order. Stop Key ! “0” ! Stop Key ! “1” 1134D069AA 1156D134CA Press the keys in order of [1], [2], [3], and [4]. z Accessing the Adjust Mode To access the Adjust mode, press the following keys in order with the Tech. Rep. mode menu on the screen. Stop Key ! Start Key 1134D071AA Press the keys in order of [1] and [2]. 1156D138CA D-67 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1156SBD0306A 3-6. ELECTRICAL/IMAGE ADJUSTMENTS (1) Initial Adjustment of Original Size Detecting Board z Important D The following adjustment must be made when memory has been cleared, RAM Board PWB-R or Original Size Detecting Board UN2 replaced, or an Original Size Detecting Sensor replaced or added. 1. Lower the Original Cover with no original placed on the Original Glass. 1136D017AA 2. Call the Tech. Rep. mode menu to the screen. to show the Function menu on the screen. 3. Touch Function 4. Touch F7 Orig. Sensor 5. Press the Start Key to let the copier make the initial adjustment of the Original Size Detecting Board. . 1156D135CA 1156D142CA NOTE While the copier is in the adjustment cycle, the Start Key is lit up orange. The key turns green as soon as the adjustment cycle is completed. 6. After the adjustment has been made, press the Panel Reset Key to return the copier to the Basic screen. D-68 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (2) ATDC Adjustment z Important Make this adjustment only after the starter has been replaced. 1. 2. Load the IU with fresh starter. Reinstall the IU in the copier. 1134D051AA 3. Call the Tech. Rep. mode menu to the screen. to show the Function menu on the screen. 4. Touch Function 5. Touch F8 ATDC Adjust 6. Press the Start Key to let the copier make the ATDC adjustment. (It will run for about 3 minutes.) . 1156D142CA 1156D139CA NOTES D While the copier is in the adjustment cycle, the Start Key is lit up orange. The key turns green as soon as the adjustment cycle is completed. D Pressing the Start Key will automatically start the ATDC adjustment cycle. Be sure to run this cycle only after the starter has been replaced. D-69 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 7. Touch 8. Touch Menu on the screen to show the Tech. Rep. mode menu again. Level History and enter the value for the “ATDC Ref. Level” on the Adjust Label affixed inside the Front Door. 9. Then, press the Panel Reset Key to return the copier to the Basic screen. 1156D168CA 1156D143CA Enter This Value on the Adjust Label. z Should the F8 operation be run when the starter has not been replaced, check that the “ATDC Ref. Level” value on the “Level History” screen matches that written on the Adjust Label. If they do not agree with each other, change the “ATDC Ref. Level” value on the screen so that it matches the value on the Adjust Label. 1156D169CA 1156D143CA Touch the shift key A or " to change the value and touch Enter to validate the new setting. D-70 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (3) Adjustment of the Aperture Blades z Requirement D There should be no dark or light bands running in the feeding direction on copies produced. (Adjust to obtain the mean image density for all areas.) z Important D If dark and light bands running in the feeding direction occur on copies, make this adjustment after checking the following. 1) The Drum Charge Corona Wire, Grid Mesh, and Image Transfer Corona Wire are free of dirt. 2) The surfaces of the Mirrors and Lens are free of dirt. 3) The surfaces of the Exposure Lamp and Main Erase Lamp are free of scratches and dirt. 4) The Cleaning Blade is free of waviness. 1. Make a copy under the following control panel settings. Original : A3 or A4 crosswise, 11” 17” or 11” 8-1/2” crosswise Paper : A3 or A4 crosswise, 11” 17” or 11” 8-1/2” crosswise Magnification : 100 % ratio Exposure : Manual (setting convenient for check) 2. Remove the Original Glass. 3. Turn the copy on the Copy Tray around as shown to reverse the leading and trailing edges and align it with the Aperture Blades. 4. Adjust to obtain the mean image density for all areas of the copy. NOTE To make the image darker, move the Aperture Blade toward the Auxiliary Reflector. To make the image lighter, move the Aperture Blade away from the Auxiliary Reflector. D-71 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (4) Adjustment of Exposure Level in the Auto Exposure Mode z Important D Before starting the procedure, check that the Auto Exposure mode is selected on the Touch Panel. D For the adjustment, stack about five blank sheets of A3 or 11” 17” paper on the Original Glass and lower the Original Cover. D After this adjustment, be sure to check the optimum exposure setting in the Manual Exposure mode. 1. Make sure that the Auto Exposure mode is selected on the Touch Panel. Then, stack about five blank sheets of A3, or 11” 17”, paper on the Original Glass and lower the Original Cover. 1134D079AA 1156D140CA 2. Call the Tech. Rep. mode menu to the screen. 3. Touch Function to show the Function menu on the screen. 4. Touch F5 Optimum & AE 5. Press the Start Key to let the copier adjust the exposure level in the Auto Exposure mode. (It will run for about 30 seconds.) . 1156D142CA 1156D144CA While the copier is in the adjustment cycle, the Start Key is lit up orange. The key turns green as soon as the adjustment cycle is completed. 6. After the adjustment, touch 7. Check the optimum exposure setting in the Manual Exposure mode. (See p. D-73.) Menu to return the copier to the Tech. Rep. menu. D-72 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (5) Adjustment of Optimum Exposure Setting in the Manual Exposure Mode z Requirement D Exposure Lamp voltage setting range in the Manual Exposure mode ... 44 to 56 D When the manual exposure setting is at the central indication, no image of step no. 1 of a Kodak Gray Scale should be produced on the copy, but a faint image of step no. 2 should be produced. 1136D300AA z Important D This adjustment should be made only after completing the “Adjustment of Exposure Level in the Auto Exposure Mode” and “Adjustment of the Aperture Blades”. D If the setting has been changed in this adjustment, be sure to make the “adjustment of exposure level in the Auto Exposure mode”. 1. 2. 1156D137CB 3. Call the Tech. Rep. mode menu to the screen. 4. Touch Tech. Rep. Choice Place the Kodak Gray Scale lengthwise, face down, and at the center on the Original Glass. Place a sheet of pure white A3 or 11” 17” paper over it and then lower the Original Cover. Set the copier into the Manual Exposure mode and set the exposure setting to the central or fifth indication (EXP5). Make about 3 copies using A3 or 11” 17” paper (so that the PC Drum sensitivity stabilizes). Then, check that the third copy meets the requirement given above. *If the image density is outside the specifications, make the following adjustment. to show the “Tech. Rep. Choice 1” menu on the screen. 1156D141CA 1156D145CA D-73 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 5. Touch Next twice to show the “Tech. Rep. Choice 3” menu on the screen. 6. Observing the image density of the sample copy, touch the shift key A or " to change the setting for “Image Exposure”. 7. Touch Enter to validate the setting. 8. Run the F5 operation again. Setting Instructions D If the image density is low, decrease the setting value. D If the image density is high, increase the setting value. D If the image density does not fall within the specifications through one setting, try another setting. 1156D150CA 1156D146CA Touch This Key if ID is High. Touch This Key Twice. Touch This Key if ID is Low. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid. D-74 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (6) Adjustment of Zoom Ratio in the Crosswise Direction (“Adjust A1 = Lens Full Size Position”) z Requirement D This adjustment is made for the zoom ratio in the crosswise direction. D A scale is placed on the Original Glass to run parallel with the Scanner and the length of the scale on the copy is compared with that of the actual scale. The adjustment must be made so that the difference between the two dimensions falls within the following specifications. The difference should be within "0.5% of the actual length. For 200 mm, the allowance is 200 mm Zoom Ratio Full size ( 1.000) 0.005 = 1.0 mm. Specifications Adjusting Mode Setting Range 200 " 1.0mm Adjust A1 + Lens Full Size Position 43 to 58 z Important This adjustment must be made before the “Reference Position Adjustments”. 1. Place a scale in parallel with the Original Width Scale and make a copy. *Make three copies in full size ( 1.000) mode and using 200-mm-or-wider paper. *If the scale is of plastic and transparent, place a blank sheet of paper over it. 2. Allow the copy to stand for 5 minutes, then measure the length to determine the zoom ratio in the crosswise direction. (Make the check with the third copy.) Using the scale, measure the length of the scale on the copy to find any difference. *If the zoom ratio deviates from the specifications, go to the next step. 1134D136AA 1134D124AA D-75 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 3. Call the “Adjust 1/2” menu to the screen. 4. Touch the select key t or s to highlight “A1 Lens Full Size Position”. 1156D138CA 1156D154CA 5. Touch the shift key A or " to change the set value. 6. Touch Enter to validate the setting. Setting Instructions D If the scale on the copy is longer than the actual scale, decrease the setting value. D If the scale on the copy is shorter than the actual scale, increase the setting value. *If the measurement does not fall within the specifications through one setting, try another setting. Setting Value 1156D147CA Touch This Key if Measurement is Shorter. Touch This Key if Measurement is Longer. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid. D-76 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (7) Adjustment of Zoom Ratio in the Feeding Direction (“Adjust A3 = Feed Direction Mag. Ratio”) z Requirement D This adjustment is made for the zoom ratio in the feeding direction. D A scale is placed on the Original Glass perpendicularly to the Scanner and the length of the scale on the copy is compared with that of the actual scale. The adjustment must be made so that the difference between the two dimensions falls within the following specifications. The difference should be within "0.5% of the actual length. For 300 mm, the allowance is 300 mm Zoom Ratio Full size ( 1.000) 0.005 = 1.5 mm. Specifications Adjusting Mode Setting Range 300 " 1.5mm Adjust A3 + Feed Direction Mag. Ratio 46 to 54 z Important This adjustment must be made before the “Adjustment of the Leading Edge Registration”. 1. Place a scale in parallel with the Original Length Scale and make a copy. *Make three copies in the full size ( 1.000) mode using A3 or 11” 17” paper. *If the scale is of plastic and transparent, place a blank sheet of paper over it. 2. Allow the copy to stand for 3 minutes, then measure the length to determine the zoom ratio in the feeding direction. (Make the check with the third copy.) Using the scale, measure the length of the scale on the copy to find any difference. *If the zoom ratio deviates from the specifications, go to the next step. 1134D137AA 1138D154AA D-77 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 3. Call the “Adjust 1/2” menu to the screen. 4. Touch the select key t or s to highlight “A3 Feed Direction Mag. Ratio”. 1156D138CA 1156D151CA 5. Touch the shift key A or " to change the set value. 6. Touch Enter to validate the setting. Setting Instructions D If the scale on the copy is longer than the actual scale, decrease the setting value. D If the scale on the copy is shorter than the actual scale, increase the setting value. *If the measurement does not fall within the specifications through one setting, try another setting. 1156D155CA Touch This Key if Measurement is Shorter. Touch This Key if Measurement is Longer. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid. D-78 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (8) Adjustment of Reference Position of the Multi Bypass Table z Requirement D Dimension A on the copy of the GTC-test chart should measure 20 mm " 2.0 mm in the full size ( 1.000) mode. Dimension A 1134D196AB z Important This adjustment should be made after the “adjustment of zoom ratio in the crosswise direction”. 1. 2. 3. 1136D030AA 4. Place the GTC-test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale. Then, lower the Original Cover. Make three copies in the full size ( 1.000) mode using A3 or 11” 17” paper fed from the Multi Bypass Table. Check if dimension A (from the edge up to the reference line) on the copy is up to the specifications. (Make the check with the third copy.) If dimension A deviates from the specifications, loosen three screws that secure the Multi Bypass Table and move the table in the direction of the arrow as necessary. Adjusting Instructions D If dimension A on the copy is shorter than 18 mm, move the table to the front of the copier. 1136D031AA D If dimension A on the copy is longer than 22 mm, move the table to the rear of the copier. NOTE Â Á À 1156D099AA When tightening the screws, hold the Multi Bypass Table from the underside with your hand and tighten screws in the order shown. When a Duplexing Document Feeder is mounted, it involves changing the Original Glass. This in turn results in the position of the Original Length Scale being slightly shifted to the rear. This can nonetheless be corrected with the Original Positioning Plate. D-79 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (9) Adjustment of Reference Position of the 1st/2nd Drawer z Requirement D Dimension A on the copy of the GTC-test chart should measure 20 mm " 2.0 mm in the full size ( 1.000) mode. Dimension A 1134D196AB z Important This adjustment should be made after the “adjustment of zoom ratio in the crosswise direction”. 1. 2. 3. Place the GTC-test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale. Then, lower the Original Cover. Feeding three sheets of A3 or 11” 17” paper from the 1st Drawer, make two full-size copies. Check if dimension A (from the edge up to the reference line) on the third copy is up to the specifications. 1136D030AA 4. If dimension A deviates from the specifications, slide out the 1st Drawer. Then, loosen the three screws shown on the left and move the Drawer Positioning Plate to the front or rear as necessary. (Use the same procedure for the 2nd Drawer.) 1134D146AA Adjusting Instructions D If dimension A on the copy is longer than 22 mm, move the Positioning Plate to the front of the copier. D If dimension A on the copy is shorter than 18 mm, move the Positioning Plate to the rear of the copier. 5. After the adjustment, loosen the four screws shown on the left and adjust the position (tilt) of the Drawer Cover. 1139U037AA D-80 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (10) Adjustment of the Leading Edge Registration z Requirement D Dimension A on the copy of the GTC-test chart should mea- Dimension A sure as follows at the respective zoom ratios. 1138D170AA Zoom Ratio Specifications Adjusting Mode Full size ( 1.000) 20 " 1.5mm Adjust A4 + Lens Position Full Size Enlargement ( 2.000) 40 " 3.0mm Adjust A11 + Lens Position Enlargement Reduction ( 0.500) 10 " 1.5mm Adjust A5 + Lens Position Reduction Setting Range 40 to 60 z Important This adjustment should be made after the “adjustment of zoom ratio in the feeding direction”. (1) Leading Edge Registration in Full Size Mode 1. 2. 1136D033AA Place the GTC-test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale. Then, lower the Original Cover. Make three single copies on A3 or 11” 17” paper in full size mode and check the third copy for leading edge registration. (If the registration is up to the specifications, go to the adjustment in the enlargement mode. If it deviates from the specifications, perform the following steps to make the adjustment of leading edge registration in the full size mode.) D-81 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 3. Call the “Adjust 1/2” menu to the screen. 4. Touch the select key t or s to highlight “A4 Scan Regist Full Size”. 1156D148CA 1156D138CA 5. Touch the shift key A or " to change the setting value. 6. Touch Enter to validate the setting. Setting Instructions D If dimension A on the copy is longer than 21.5 mm, increase the setting value. D If dimension A on the copy is shorter than 18.5 mm, decrease the setting value. *If the measurement does not fall within the specifications through one setting, try another setting. 1156D152CA Touch This Key if Measurement is Longer. Touch This Key if Measurement is Shorter. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid. D-82 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (2) Leading Edge Registration in Enlargement Mode z Important This adjustment should be made after the “adjustment of leading edge registration in the full size mode”. 1. 1136D034AA After the leading edge registration in the full size mode has been adjusted, make three single copies on A3 or 11” 17” paper at 2.000 and check the 3rd copy for leading edge registration. (If the registration is up to the specifications, go to the adjustment in the reduction mode. If it deviates from the specifications, perform the following steps to make the adjustment of leading edge registration in the enlargement mode.) Next 2. With the “Adjust 1/2” menu on the screen, touch 3. Touch the select key t or s to highlight “A11 Scan Regist Enlargement”. 1156D166CA to show the “Adjust 2/2” menu. 1156D156CA D-83 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 4. Touch the shift key A or " to change the setting value. 5. Touch Enter to validate the setting. Setting Instructions D If dimension A on the copy is longer than 43.0 mm, increase the setting value. D If dimension A on the copy is shorter than 37.0 mm, decrease the setting value. *If the measurement does not fall within the specifications through one setting, try another setting. 1156D149CA Touch This Key if Measurement is Longer. Touch This Key if Measurement is Shorter. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid. D-84 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (3) Leading Edge Registration in Reduction Mode 1. After the leading edge registration in the enlargement mode has been adjusted, make three single copies on A3 or 11” 17” paper at 0.500 and check the 3rd copy for leading edge registration. (If the registration deviates from the specifications, perform the following steps to make the adjustment of leading edge registration in the reduction mode.) 1136D035AA z Important This adjustment should be made after the “adjustment of leading edge registration in the full size mode”. 2. Call the “Adjust 1/2” menu to the screen. 3. Touch the select key t or s to highlight “A5 Scan Regist Reduction”. 1156D138CA 1156D153CA D-85 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 4. Touch the shift key A or " to change the setting value. 5. Touch Enter to validate the setting. Setting Instructions D If dimension A on the copy is longer than 11.5 mm, increase the setting value. D If dimension A on the copy is shorter than 8.5 mm, decrease the setting value. *If the measurement does not fall within the specifications through one setting, try another setting. 1156D157CA Touch This Key if Measurement is Longer. Touch This Key if Measurement is Shorter. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid. D-86 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (11) Adjustment of the Leading Edge Registration for Book Second Page z Requirement D Dimension A on the copy of a test chart (A3 or 11” 17”) as shown on the left should measure 20 "3.0 mm and B equals C. D Setting range: 45 to 55 1136D036AA z Important This adjustment should be made after the “adjustment of the leading edge registration”. 1. Place the test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale. Then, lower the Original Cover. 1136D037AA 2. On the Basic screen, touch Origi. " Copy ; then, select Separation 1156D158CA 1156D140CA 3. Select Book "1 . and make three single copies on A4 crosswise paper at full size ( 1.000) mode. Check the third copy for the leading edge registration. (If the dimensions deviate from the specifications, perform the following steps to make the adjustment.) 1156D161CA D-87 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 4. With the “Adjust 1/2” menu on the screen, touch Next to show the “Adjust 2/2” menu. Then, high- light “A6 Book B-Scan Regist”. 1156D166CA 1156D163CA 5. Touch the shift key A or " to change the setting value. 6. Touch Enter to validate the setting. Setting Instructions D If dimension A on the copy is longer than 23 mm, increase the setting value. D If dimension A on the copy is shorter than 17 mm, decrease the setting value. *If the measurement does not fall within the specifications through one setting, try another setting. 1156D163CA Touch This Key if Measurement is Longer. Touch This Key if Measurement is Shorter. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid. D-88 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (12) Adjustment of the Image Leading Edge Erase Width z Requirement D The erase width, dimension A, on the copy of the GTC–test Dimension A chart should measure 1.0 to 6.5 mm. D Setting range: 45 to 55 1134D135AA z Important This adjustment should be made after the “adjustment of the leading edge registration” and “adjustment of the leading edge registration for book second page”. 1. 2. 1136D040AA Place the GTC-test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale. Then, lower the Original Cover. Make three single copies on A3 or 11” 17” paper in full size mode and check the third copy for leading edge erase width. (If the erase width deviates from the specifications, perform the following steps to make the adjustment of image leading edge erase width.) 3. With the “Adjust 1/2” menu on the screen, touch Next 4. Touch the select key t or s to highlight “A12 Leading Edge Erase Adjust”. 1156D166CA to show the “Adjust 2/2” menu. 1156D159CA D-89 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 5. Touch the shift key A or " to change the setting value. 6. Touch Enter to validate the setting. Setting Instructions D If dimension A on the copy is longer than 6.5 mm, decrease the setting value. D If dimension A on the copy is shorter than 1.0 mm, increase the setting value. *If the measurement does not fall within the specifications through one setting, try another setting. 1156D162CA Touch This Key if Measurement is Shorter. Touch This Key if Measurement is Longer. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid. D-90 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (13) Adjustment of the Image Trailing Edge Erase Width z Requirement D The erase width, dimension A, on the copy of the GTC-test chart should measure 0.5 to 5.5 mm. D Setting range: 42 to 58. Dimension A 1134D134AA z Important D This adjustment should be made after the “adjustment of the image leading edge erase width”. D Before this adjustment can be made, “Trailing Edge Erase” on the “Tech. Rep. Choice 2” screen must be set to “Yes”. 1. 2. 1136D042AA Place the GTC-test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale. Then, lower the Original Cover. Make three single copies on A3 or 11” 17” paper in full size mode and check the third copy for trailing edge erase width. (If the erase width deviates from the specifications, perform the following steps to make the adjustment of image trailing edge erase width.) Next 3. With the “Adjust 1/2” menu on the screen, touch 4. Touch the select key t or s to highlight “A13 Trailing Edge Erase Adjust”. to show the “Adjust 2/2” menu. 1156D164CA 1156D166CA D-91 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 5. Touch the shift key A or " to change the setting value. 6. Touch Enter to validate the setting. Setting Instructions D If dimension A on the copy is longer than 5.5 mm, decrease the setting value. D If dimension A on the copy is shorter than 0.5 mm, increase the setting value. *If the measurement does not fall within the specifications through one setting, try another setting. 1156D160CA Touch This Key if Measurement is Shorter. Touch This Key if Measurement is Longer. NOTE Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen. If this is not done, the old setting remains valid. D-92 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (14) Adjustment of Edge Erase z Requirement D Dimension A, which is the erase width from the front edge on the copy of the GTC-test chart, should be in the range between 0.5 mm and 4.0 mm. 1136D043AA z Important This adjustment must be made after the “adjustments of reference positions”. 1. 2. Place the GTC-test chart face down on the Original Glass and align its rear left corner with the reference marker on the Original Width Scale. Then, lower the Original Cover. Make a single copy on A3 or 11” 17” paper in full size mode. *If A3 or 11” 17” paper is not available, use A4 or 8–1/2” 11” crosswise paper. 1136D044AA 3. If the front edge erase width deviates from the specifications, adjust as necessary by turning the Edge Erase Adjusting Screw. Adjusting Instructions D If dimension A on the copy (of the original width of 3.0 mm) is narrower than 0.5 mm, tighten the Adjusting Screw. D If dimension A on the copy (of the original width of 3.0 mm) 1134D114AA is wider than 3.0 mm, loosen the Adjusting Screw. D-93 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 3-7. OTHER ADJUSTMENTS (1) Focus-Positioning of the Scanner and Mirrors Carriage z Requirement D With the Scanner positioned correctly with reference to the Scanner Drive Cable, there should be no gap between one end of the Scanner/Mirrors Carriage Positioning Jig and the Scanner, and between the other end of the jig and the Mirrors Carriage. The distance between the Scanner and Mirrors Carriage should be 83.5 mm. 1. 2. 3. Remove the Original Cover, Upper Rear Cover, and Original Glass. Slide the Scanner to a position at which the hole is aligned with the Scanner Positioning Screw. Insert a screwdriver into the hole and loosen the Scanner Positioning Screw. (This allows the Scanner Drive Cable to move independently of the Scanner.) 1134D138AA Scanner Positioning Jig 4. Align the rectangular hole in the upper copier frame with the U-groove in the Scanner. Insert the Scanner Positioning Jig. 5. Install the Scanner/Mirrors Carriage Positioning Jig between the Scanner and the Mirrors Carriage. 6. 7. Move the Mirrors Carriage in the direction of the arrow. Check that both ends of the Scanner/Mirrors Carriage Positioning Jig have no gap. 1136D046AA Scanner/Mirrors Carriage Positioning Jig 1136D047AA 83.5mm 1136D048AA D-94 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 8. Tighten the Scanner Positioning Screw which was loosened in step 3. 1139D051AA D-95 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (2) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller (D.B. Adjustment) z Requirement D The gap between the Doctor Blade and Sleeve Roller should be 0.53 " 0.05 mm. 1. 2. Remove the IU, PC Drum Charge Corona, and PC Drum. Remove two screws and the Developer Scattering Prevention Plate. 3. Using a brush, whisk developer off the surface of the Sleeve Roller. 4. Install the Sleeve/Magnet Roller Positioning Jig into the IU. 5. Loosen three screws that secure the Doctor Blade. Insert the D.B. Adjusting Jigs between the Doctor Blade and Sleeve Roller. Press down the Doctor Blade until it positively contacts the D.B. Adjusting Jigs. Then, tighten the three screws to secure the Doctor Blade. 1136D049AA 1136D050AA 1136D051AA 6. 1136D052AA D-96 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (3) Adjustment of the PC Drum Paper Separator Finger Position z Requirement D The gap between the PC Drum and Paper Separator Fingers should be 1.0 " 0.5 mm when Separator Solenoid SL1 is in the deenergized position. z Important D Use care not to deform the Separator Fingers during the adjustment procedure. 1. Attach the PC Drum Paper Separator Finger Positioning Jig to the IU. 2. Using an Allen wrench, adjust the position of one of the two Paper Separator Fingers. (Either one will do.) 1136D053AA Adjusting Instructions D With the solenoid in the deenergized position, the tip of the finger should be at a point between A and B, preferably more on the B end. D With the solenoid energized, the tip of the finger should touch C. A . . . . . . . 41.5 mm B . . . . . . . 40.5 mm C . . . . . . . 40.0 mm 1136D054AA 1136D055AA 3. After this adjustment, check that the other finger also meets the above requirement. NOTE If the fingers cannot be positioned correctly through steps 2 and 3, loosen the two solenoid mounting screws and adjust the position of the solenoid. Then, repeat steps 2 and 3. 1136D056AA D-97 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (4) Adjustment of Manual Feed Paper Take-Up Solenoid SL4 1. 2. Remove the SL4 mounting bracket. (For the removal steps, see p. D-25.) Manually bring SL4 into the energized position (plunger pushed in). * A click is heard when the solenoid is energized. Then, hold the plunger in position. 1134D119AA 3. Loosen two screws that secure the SL4 and slide SL4 all the way in the direction of the arrow. 1134D120AA 4. Slowly move the SL4 in the direction opposite that in step 3. When the two Stoppers just swing into the upright position, tighten the two SL4 mounting screws. 1134D121AA D-98 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 (5) Adjustment of Exit/Duplex Solenoid SL5 z Requirement D With the lever in contact with the stopper (SL5 in the deenergized position), the gap between the plunger rubber washer and the solenoid should be 4.0 to 4.5 mm. z Important D After the adjustment, move the plunger manually to check that it moves smoothly and the Switching Plate swings up and down properly. 1. 2. Open the Left Door. Loosen two screws that secure SL5. 1134D122AA 3. Bring the lever into contact with the stopper. Keeping that position, move SL5 so that the gap between the plunger rubber washer and solenoid measures 4.0 to 4.5 mm. When the specified dimension is reached, tighten the two SL5 mounting screws. 1156D173AA D-99 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 4 MISCELLANEOUS 4-1. Installation of the Plug-In Counter (Option) Mounting Bracket 1. 2. 3. 4. Open the Right Door. Remove two screws and the cover. Remove the harness from the locking wiring saddle. Unplug three connectors. 5. Remove two screws and the Right Door. 6. 7. Remove the Counter Cover. Remove four screws and the Right Cover. 8. 9. Remove the IU. Remove two screws and the cover. 1156D033AA 1156D034AA 1136D060AA 1136D061AA 10. Connect the Plug-In Counter connector. 11. Secure the Plug-In Counter Mounting Bracket with the two screws. NOTE When the Plug-In Counter is mounted, be sure to turn “ON” the “Plug-In Counter” of “System Input” available from the Tech. Rep. mode. 1136D062AA D-100 Interleaf EP5000/EP4000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 4-2. ADJUSTMENT OF THE RIGHT DOOR If the Right Door has been removed and reinstalled, the position of the actuator of Right Upper Door Interlock Switch S22 may deviate from the correct position. Hence, the necessity of the following adjustment. 1. Mount the Right Door with two screws. (At this time, only temporarily tighten these screws.) 2. Lightly close the Right Door so that the S22 actuator will not contact the frame. 3. Due to its own weight, the front end of the Right Door tends to hang lower. Lifting the front end slightly, tighten the two mounting screws. 4. Open and close the Right Door two to three times to check that the S22 actuator properly actuates and deactuates S22. 1156D100AA 1134D116AA 1134D117AA 1134D118AA D-101 Interleaf EP4000/EP5000 DIS/REASSEMBLY, ADJUSTMENT 97.04.01 1156SBD000EA Copyright 1997 MINOLTA Co., Ltd. Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA CO., LTD. 1156-7992-11 97046000 Printed in Japan Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS000AA EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS000BA CONTENTS 1 PRECAUTIONS FOR HANDLING THE PWBs 2 CONTROL PANEL KEYS AND TOUCH PANEL 3 FUNCTIONS OF SWITCHES AND POINTS ON PWB-I 4 USER’S CHOICE MODE . . . . . . . . . . . . . . . . . . . S-1 1-1. Precautions for Transportation and Storage . . . . . . . . . . . . . . . . S-1 1-2. Precautions for Replacement and Inspection . . . . . . . . . . . . . . . S-1 . . . . . . . . . . . . . . . . . S-2 2-1. Control Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2 2-2. Explanation of the Touch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3 . . . . . . . . . . . S-5 3-1. PWB-I Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5 3-2. Tech. Rep. Settings Switches Board PWB-I . . . . . . . . . . . . . . . . . S-5 4-1. 4-2. 4-3. 4-4. 5 .................................... User’s Choice Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . User’s Choice Function Setting Procedure . . . . . . . . . . . . . . . . . User’s Choice Function Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings in the User’s Choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECH. REP. MODE ......................................... Tech. Rep. Mode Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . Tech. Rep. Mode Function Setting Procedure . . . . . . . . . . . . . . . Tech. Rep. Mode Function Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings in the Tech. Rep. Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Tech. Rep. Choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. System Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. I/O Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. Last Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. ROM Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. RD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. Accessory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. Level History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. Machine Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. Admin. Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. 5-2. 5-3. 5-4. i S-7 S-7 S-7 S-8 S-9 S-16 S-16 S-16 S-17 S-19 S-19 S-20 S-24 S-25 S-32 S-34 S-34 S-35 S-37 S-39 S-40 S-40 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 CONTENTS 6 FACTORY SETTING ........................................ 6-1. Factory Setting Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Factory Setting Function Setting Procedure . . . . . . . . . . . . . . . . 6-3. Factory Setting Function Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii S-41 S-41 S-41 S-42 S-42 S-44 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1151SBS0100A 1 PRECAUTIONS FOR HANDLING THE PWBs 1151SBS0101A 1-1. Precautions for Transportation and Storage a) Before transporting or storing the PWBs, put them in protective conductive cases or bags so that they are not subjected to high temperature (and they are not exposed to direct sunlight). b) Protect the PWBs from any external force so that they are not bent or damaged. c) Once the PWB has been removed from its conductive case or bag, never place it directly on an object that is easily charged with static electricity (such as a carpet or plastic bag). d) Do not touch the parts and printed patterns on the PWBs with bare hands. 1151SBS0102A 1-2. Precautions for Replacement and Inspection a) b) c) d) Whenever replacing the PWB, make sure that the power cord of the copier has been unplugged. When the power is on, the connectors must not be plugged in or unplugged. Use care not to strap the pins of an IC with a metal tool. When touching the PWB, wear a wrist strap and connect its cord to a securely grounded place whenever possible. If you cannot wear a wrist strap, touch the metal part to discharge static electricity before touching the PWB. S-1 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS0200A 2 CONTROL PANEL KEYS AND TOUCH PANEL * For more details, see the “Operator’s Manual” shipped with the copier. 1149SBS0201A 2-1. Control Panel Keys À Á Â Ã Ä Å Æ Ç É È 1149O002EA Ç Panel Reset Key D Clears all control panel settings made previously, initializing the copier. Note: It does not, however, clear the contents of the zoom and job program memory and the settings made immediately before the Interrupt mode. À Display Contrast Knob D Varies the brightness of the Touch Panel. Á User Mode Key D Changes the screen to the User Mode setting screen. Â Touch Panel D Shows various screens and messages. È Clear Key D Clears the number-of-copies setting, zoom ratio, and counter count. Ã 10-Key Pad D Numeric keypad used for entering the number of copies to be made, zoom ratio, access number, and the Tech. Rep. mode settings. É Stop Key D Stops a copy cycle. Ä Access Mode Key D When either “100 Accounts” or “1000 Accounts” has been selected for the “Copy Track” function, the entry of the access number and the press of this key (Access Mode) will allow the user to make copies. Start Key D Starts a copy cycle. Mode Check Key D Shows the Mode Check screen on which the user can check the current copying settings. Å Energy Saver Key D Sets the copier into the Energy Saver mode. Job Recall Key D Selects the Job Recall screen which allows the user to recall or check a copy-job program previously stored in memory. Æ Interrupt Key D Sets the copier into, or lets it leave, the Interrupt mode. S-2 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS0202A 2-2. Explanation of the Touch Panel 1149SBS020201A 1. Basic Screen D The Basic screen is an initial screen that appears when the copier is turned ON, panel is reset, or when auto clear is activated. À Á Â 1149O263CA Ã À Supplementary Function Keys D Selects the corresponding menu screen, either Auxiliary, Finishing, or Orig. " Copy. Â Basic Function Keys D Allows the user to select the exposure level, zoom ratio, and copy paper. Á Message Display D Shows the current copier status, operating instructions, and other data including the number of copies selected and the amount of paper still available for use. Ã Function Display D Shows graphic representations of the settings currently made for Orig. " Copy and Finishing. S-3 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS020202A 2. Warning Screens D The warning screen may be a malfunction display, error display, warning display, or a caution display. D A malfunction display is given when trouble occurs which cannot be corrected by the user. Example: Malfunction that can be identified with a specific code. D An error display is given when trouble occurs which can be corrected by the user. Examples: Paper misfeed, toner empty, door open. 1149O421CA D A warning display is given when any further copier operation will not be possible, or only faulty results will come out, due to erroneous panel settings or other cause. Example: Unmatched paper size in Auto Paper 1149O387CA D A caution display is given when, though further copier operation will be possible, it could result in a malfunction. Example: Toner empty 1149O422CA 1149O385CA S-4 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1151SBS0300A 3 FUNCTIONS OF SWITCHES AND POINTS ON PWB-I 1151SBS0301A 3-1. PWB-I Location 1156S001AA 1156SBS0302A 3-2. Tech. Rep. Settings Switches Board PWB-I 1149S002BB Symbol S1 Name Resets a malfunction including those of the Exposure Lamp (C04XX) and fusing (C05xx). Initialize Switch Forcibly resets a misfeed or malfunction that occurrs due to incorrect operation, etc. when it cannot be reset by opening and closing the Front Door or the press of S1. GND Test Point Ground terminal used for memory clear. Memory Clear Test Point Initializes all data except the counts of electronic counters, access numbers and administrator number for Copy Track, and RD mode functions. PJ2 TP1 TP3 Description Trouble Reset Switch S-5 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 D Initialize Points PJ2 1. Turn OFF the Power Switch. 2. With PJ2 closed, turn ON the Power Switch. 3. In approx. 5 sec. open PJ2. 4. Check that the message “Initialize completed” is shown on the Touch Panel, then touch “Enter.” D Memory Clear Test Point TP3 1. Turn OFF the Power Switch. 2. With the circuit across TP1 and 3 closed, turn ON the Power Switch. 3. In approx. 5 sec. open the circuit across TP1 and 3. 4. Check that the message “Memory Clear completed” is shown on the Touch Panel, then touch “Enter.” NOTE D If an erratic operation or display occurs, perform the clearing procedures in the order of PJ2 and TP3. D When memory clear has been performed, make the necessary settings again. Front Door Open/Close Trouble Reset Switch (S1) Initialize Switch (PJ2) Memory Clear Test Point (TP3) Misfeed display f f f f Malfunction display (except Exposure Lamp and fusing system) f f f f Malfunction display (all including Exposure Lamp and fusing system) * f f f Erratic operation/display * * f f User mode * * * f Service mode * * * f F5/F7 setting values * * * f System Input * * * f Accessory Test * * * f Level History * * * f * * * f Clearing Method Data Cleared Adjust mode f : Cleared (initialized) *: Not cleared: S-6 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS0400A 4 USER’S CHOICE MODE D The User’s Choice mode available through the User Mode menu is used to make various settings according to the user’s needs. 1149SBS0401A 4-1. User’s Choice Selection Screen 1149O262DA 1149SBS0402A 4-2. User’s Choice Function Setting Procedure 1. Press the User Mode key on the control panel and then touch the “User’s Choice” key. 2. Select the page number key that contains the desired function from among 1/6 through 6/6 shown at the bottom of the Touch Panel. 3. Select the function to be set and make settings as required. 4. After the settings are complete, touch the “Enter” key to validate the settings. NOTE: The function selected is highlighted. Perform any one of the following steps to go back to the Basic screen. D Press the Panel Reset key on the control panel. D Touch “Exit” on the Touch Panel. S-7 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS0403A 4-3. User’s Choice Function Tree Mixed Orig. Detection Language Selection 1/6 Paper Priority Copy Mode Priority Manual feed expansion Expo. Mode Priority Expo. Level Priority 2/6 Manual Expo. Adjust Finishing Priority Auto Panel Reset Energy Saver Mode User’s Choice 3/6 Drum Dehumidifier Counter Removal Intelligent Sort Confirmation Beep 4/6 Original Thickness Smaller Originals Custom 2in1 Custom 2in1 Separation 5/6 Custom Book Copy Special Paper Orig. " Copy Default Auto Power-off Mode 6/6 Original on Glass Administrator Mode S-8 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS0404A 4-4. Settings in the User’s Choice 1156SBS040401A [1/6] Touch Panel Display Mixed Orig. Detection Highlighted .) Setting (The default is Select whether to enable (“ON”) the Mixed Original Detection mode or not (“OFF”) when power is turned ON or the Panel Reset key pressed. OFF ON Language Selection Select the language of the Touch Panel messages. –Metric Areas– Paper Priority –Inch Areas– English German French English German French Dutch Italian Spanish Japanese Chinese Portuguese Portuguese Danish Norwegian Swedish Finnish Greek Specify the paper source selected automatically. 1st Drawer 2nd Drawer 3rd Drawer 4th Drawer LCT Copy Mode Priority Specify the default mode selected automatically when power is turned ON or the Panel Reset key pressed. Auto Paper Manual Feed Expansion Auto Size Manual Select whether to use Manual feed expansion (“ON”) when using the Multi Bypass Tray or not (“OFF”) ON S-9 OFF Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS040402A [2/6] Touch Panel Display Expo. Mode Priority Highlighted .) Setting (The default is Specify the default exposure mode selected automatically when power is turned ON or the Panel Reset key pressed. Auto Expo. Level Priority Auto: Manual: Manual Select the default exposure level in the Auto Exposure mode. Set the default exposure level in the Manual Exposure mode. Lighter Normal Darker Lighter Darker Normal NOTE: EXP. 1 (Lighter) to EXP. 9 (Darker) Manual Expo. Adjust Determine the default voltage curve (EXP. level) in the Manual Exposure mode, as optimized by the type of original. Mode 1 Halftone images, photos Mode 2 Ordinary originals Mode 3 Originals with a colored background or faint texts Manual Exposure Voltage (V) EXP. 1 2 3 4 5 6 7 8 9 Mode 1 +8 +5 +2 +1 0 –1 –2 –5 –8 Mode 2 +8 +6 +4 +2 0 –2 –4 –6 –8 Mode 3 +8 +7 +6 +3 0 –3 –6 –7 –8 NOTE: EXP. 5 uses as reference the voltage value automatically adjusted by the F5 operation. Finishing Priority Select the default finishing type when the copier is equipped with a Sorter or Staple Sorter. Non Sort Group Sort Sort Staple S-10 + Hole Punch NOTE: Hole Punch can be combined with any one of the functions. Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS040403A [3/6] Touch Panel Display Auto Panel Reset Energy Saver Mode Setting (The default is Highlighted .) Specify the default exposure mode selected automatically when power is turned ON or the Panel Reset key pressed. 30 sec. 1 min. 2 min. 3 min. 5 min. No Reset Set the time it takes the copier to enter the Energy Saver mode after a copy cycle has been completed or the last key operated. Use the 10-Key Pad to set the time (1 to 240 min.). 1 to 240 (15 min.) OFF NOTE: The OFF setting is available for European areas only. Drum Dehumidifier Select whether to allow the copier to enter the Drum Dehumidifier mode automatically after it has been turned ON, or not. ON Counter Removal OFF Select whether to reset the panel or not when the Plug-In Counter is pulled out of the copier, a magnetic card is pulled out of the Data Controller, or the Access Mode key is pressed. ON OFF 1156SBS040404A [4/6] Touch Panel Display Intelligent Sort Setting (The default is Highlighted .) Select whether to turn “ON” or “OFF” the function that automatically switches between Sort and Non-Sort according to the number of originals loaded in the document feeder. ON OFF NOTE: This function is enabled when “Mixed Orig. Detection” is turned “OFF” and the copier is in the Auto Paper or Auto Size mode. Confirmation Beep Select whether to turn “ON” or “OFF” the beep that sounds each time a key on the control panel is pressed or that on the Touch Panel is touched. ON Original Thickness Select whether to allow (“Thin”) the user to make copies from thin originals in addition to the standard ones or not (“Standard”) using the document feeder. Standard The orginal is pressed against the Original Width Scale when stopped. Smaller Originals OFF Thin The original is not pressed against the Original Width Scale when stopped. Select whether to enable (“ON”) a copy cycle or not (“OFF”) when it is initiated by pressing the Start key with an original of the smallest detectable size (metric areas: A5 or smaller; inch areas: Letter or smaller) placed on the Original Glass. ON OFF The copy cycle is run using the paper A warning message is given and the loaded in the default paper source. copier inhibits the start of this copy cycle. NOTE: The default setting is OFF for the metric areas and ON for the inch areas. S-11 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS040405A [5/6] Touch Panel Display Custom 2in1 Setting (The default is Highlighted .) Make the settings for “Paper,” “Zoom,” “Margin,” and “Erase” that are automatically recalled when 2-in-1 copy is selected. Function Description Initial Setting Paper Auto Paper, sizes of paper loaded in drawers Auto Paper Zoom Auto Size, fixed zoom ratios Margin Position: Right edge, left edge Mode: Shift-for-Margin, Margin-by-Reduction Width: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” Metric areas: X0.707 Inch areas: X0.647 No margin Position: Right Edge, Left Edge, Frame, Top Edge, Center, Frame+Center Width: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” Erase Make the following selections only when Frame+Center is selected. Frame: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” Center: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” No erase NOTE: The erase width for the Top Edge and for the CD direction of the Frame is only 10mm for the metric areas and 1/2” for the inch areas. Custom 2in1 Separation Make the settings for “Paper,” “Zoom,” “Margin,” and “Erase” that are automatically recalled when 2-in-1 separation copy is selected. Function Description Initial Setting Paper Auto Paper, sizes of paper loaded in drawers 1st Drawer Zoom Auto Size, fixed zoom ratios Margin Position: Right edge, left edge Mode: Shift-for-Margin, Margin-by-Reduction Width: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” Metric areas: X1.414 Inch areas: X1.294 No margin Position: Right Edge, Left Edge, Frame, Top Edge, Center, Frame+Center Width: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” Erase Make the following selections only when Frame+Center is selected. Frame: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” Center: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” No erase NOTE: The erase width for the Top Edge and for the CD direction of the Frame is only 10mm for the metric areas and 1/2” for the inch areas. S-12 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 [5/6] Touch Panel Display Custom Book Copy Setting (The default is Highlighted .) Make the settings for “Paper,” “Zoom,” “Margin,” and “Erase” that are automatically recalled when Book copy is selected. Function Description Initial Setting Paper Sizes of paper loaded in drawers Zoom Fixed zoom ratios Margin Position: Right edge, left edge Mode: Shift-for-Margin, Margin-by-Reduction Width: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” X1.000 No margin Position: Right Edge, Left Edge, Frame, Top Edge, Center, Frame+Center Width: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” Erase Make the following selections only when Frame+Center is selected. Frame: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” Center: Metric areas – 5, 10, 15, 20 mm Inch areas – 1/4, 1/2, 3/4, 1” No erase NOTE: The erase width for the Top Edge and for the CD direction of the Frame is only 10mm for the metric areas and 1/2” for the inch areas. Special Paper Set up a drawer for special paper loading. Normal Insert Sheet Recycled Not for 2-Sided Initial setting: Normal (for all drawers) Auto Paper Automatic Drawer Switching (only of paper of the same type) Normal f f Recycled f NOTE 1 f Insert Sheet   Not for 2-Sided f NOTE 2 Type of Paper f NOTE 2 f: Enabled : Disabled NOTE 1: A warning display is given and the copy cycle is started by pressing of the Start key. NOTE 2: Enabled only in the 1-sided copying mode. S-13 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS040406A [6/6] Touch Panel Display Orig. " Copy Default Setting (The default is Highlighted .) Select the type of Orig. " Copy setting selected automatically when the copier is turned ON or Panel Reset key pressed. If ”Duplex only” is selected for “Simplex/Duplex” of the “Tech. Rep. Choice” function, neither 1 " 2 nor 1 " 2in1 are displayed. 1"1 1 " 2 in1 1"2 1 " 2-2 in1 2"2 NOTE: Some of the functions may not be displayed depending on the type of options the copier is equipped with. Auto Power-OFF Mode Select whether to turn ON or OFF the Auto Shut Off function that shuts down the copier a given period of time after a copy cycle has been completed or the last key operated. Selecting “ON” means setting the time it takes the Auto Shut Off function to be activated, that can range from 1 min. to 240 min. OFF 1 to 240 EP4000: 90 min. EP5000: 60 min. NOTE: “OFF” is displayed when “Enable” is selected for “Non-Auto Shut off” of the “Administrator Mode” function. Original on Glass Select whether to turn “ON” or “OFF” the beep that sounds when you attempt to load an original in the document feeder with another one left on the glass. Beep ON Administrator Mode Copy Track The entry of the “Administrator #” set using the Tech. Rep. mode permits the settings of the following functions. Select the number of accounts to be controlled. OFF Copy Track 100 Accounts 1000 Accounts This function is displayed when the above “Copy Track” setting is changed, prompting you to select whether to initialize (“YES”) the copy track data so far taken or not (“NO”) YES (initialize) Copy Track Data Beep OFF NO (do not initialize) When “Count Reset” is touched, it clears all data under control. S-14 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 [6/6] Touch Panel Display Setting (The default is Highlighted .) 1/25 ⋅ ⋅ ⋅ 22/25 <100 Accounts> The copy track data of the selected page is displayed (Account No., Total Counter, Size Counter, Limit, ID). “Count Reset” : Clears the total and size counters of all accounts. “No.” : Enter the set account number from the 10–Key Pad. “Total” : Displays the count of the Total Counter. (It can also be cleared with the Clear key.) “Size” : Displays the count of the Size Counter. (It can also be cleared with the Clear key.) “Limit” : Enter the maximum number of copies that can be made from the 10-Key Pad. “ID #” : Enter the access number (0001 to 9999) from the 10-Key Pad. 1~ ⋅ ⋅ ⋅ 901~ <1000 Accounts> The copy track data of the selected page is displayed. “Count Reset” : Clears the total counters of all accounts. “Total” : Displays the count of the Total Counter. (It can also be cleared with the Clear key.) NOTE: The entry of an access number is not possible, with 1 to 1000 corresponding to the ID numbers. Max. Copy Sets Determine the number of copies or copy sets that can be set using the 10-Key Pad. Non-Auto Shut off Select whether to enable or disable the Auto Power-off Mode setting available from User’s Choice. OFF Disable Enable User Help * Displayed when a DT-103 is mounted. “OFF” key is not displayed. “OFF” key is displayed. 1. Using the “ B or Y ” key, select the user claim number and then, from the 10-Key Pad, enter the 3-digit user claim code (up to six entries are possible). 2. Touch “Data Send” to start the transmission. S-15 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS0500A 5 TECH. REP. MODE D This mode is used by the Tech. Rep. to set, check, adjust, and/or program various service functions. 1149SBS0501A 5-1. Tech. Rep. Mode Menu Screen 1149O423CB 1149SBS0502A 5-2. Tech. Rep. Mode Function Setting Procedure 1. Set the copier into the Tech. Rep. mode by pressing the following keys in this order. Stop key ' 0 ' Stop key ' 1 2. Select the particular Tech. Rep. mode function to be set. 3. Make the necessary settings by following the instructions given sequentially on the screen. NOTE: The function selected is highlighted. D Press the Panel Reset key on the control panel. S-16 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS0503A 5-3. Tech. Rep. Mode Function Tree Function F1 Paper Passage F3 Exp. Lamp F5 Optimum & AE F7 Orig. Sensor Developer Paper Path Sensors F8 ATDC Adjust FF F8+F5 Tech. Rep. Choice 1 Key Counter Size Counter Total Counter Maintenance Call Copy Kit Counter Toner Empty Stop Type of Vendor Tech. Rep. Mode Tech. Rep. Choice Tech. Rep. Choice 2 Auto Paper Config. Leading Edge Erase Trailing Edge Erase Loop Adjust (Drawer) Loop Adjust (Man) Function Limit Tech. Rep. Choice 3 Image Exposure Simplex/Duplex Bin Movement Universal Tray 13”x Universal Tray 14”x Automatic feeding adjust Stack System Input Counter Change Fixed Zoom Ratio Paper Size Input Marketing Area Key Counter Telephone # Input Paper Jam Retry Trouble Counter Reset S-17 Maintenance Port/Option Consumables Auto CPU Reset Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 I/O Check IC Port Data Check Paper Path Sensors Check Memory Check Controller Board Check Panel Indication Check Last Trouble Rom Version Tech. Rep. Mode RD Mode Accessory Test ADF Check Sorter Check Level History Machine Status Admin. Mode S-18 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS0504A 5-4. Settings in the Tech. Rep. Mode 1149SBS050401A 1. Function D This function allows the Tech. Rep. to make the various functional tests and adjustments. 1. Select the particular function to be run. 2. Press the Start key to start the test. 3. Press the Stop key to stop the test. Tech. Rep. Mode " Function Touch Panel Display Operation F1 Paper Passage A paper passage test is carried out to check for correct sensor operation without having to wait for the copier to complete warming up. 1. Before entering the Tech. Rep. Mode, select the paper feed source, then touch “Paper Path Sensors.” 2. Press the Start key. This starts a paper take-up and feeding sequence and the copier shows “1” or “0” depending on the condition of each sensor. NOTE: Pressing the Stop key causes the copier to feed the paper out of it and stop operating; another press of the Start key will resume the paper take-up and feeding sequence. F3 Exp. Lamp Checks to see if the Exposure Lamp lights up properly. (It runs for 30 sec.) F5 Optimum & AE Makes the following automatic adjustments: Vg level, Manual exposure level and AE Sensor optimum exposure level. (It runs for 30 sec.) 1. Touching “F5” automatically brings you to the next screen (AE level adjustment screen). 2. Using the A or " key, show the desired number (44 to 56) and press the Start key. This starts the automatic adjustment sequence. 3. Touch “Test Copy” to check for image. F7 Orig. Sensor Makes an automatic adjustment of the Original Size Detecting Sensors. Developer When “Developer” is pressed, “F8” and “FF” functions are displayed and disappear when the corresponding operation has been completed. F8 ATDC Adjust Runs the Developing Unit to agitate developer and makes an automatic adjustment of the ATDC Sensor level. (It runs for 5 min.) FF F8 + F5 Runs the F8 and F5 operations. S-19 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS050402A 2. Tech. Rep. Choice D This function allows the Tech. Rep. to make various settings and adjustments. Tech. Rep. Mode " Tech. Rep. Choice Touch Panel Display Key Counter Operation Select the condition by which the Key Counter count is increased. # of Sheets Copy Cycle NOTE: See the Count-up Table for details. Size Counter Select the size of the paper to be counted by the Size Counter. Metric Areas Inch Areas No Count A3 No Count 11X17 A3/B4 A3/B4/FLS 11X17/LGR 11X17/11X14 NOTE: See the Count-up Table for details. Total Counter Select the conditions (paper size and 2-sided copying) by which the Total Counter count is increased. Mode 0 1 count per 1 copy cycle Mode 1 Multiple count-up according to paper size and 2-sided copying Mode 2 Multiple count-up according to paper size and 2-sided copying NOTE: See the Count-up Table for details. Copying Size 1-Sided 2-Sided Sizes other than those Set sizes set Total Mode 0 Mode Mode 1 2 0 1 2 2 2 2 2 4 4 1 Size (electronic) 0 1 1 2 0 2 2 0 0 2-Sided Total (electronic) 0 0 1 1 4 0 2-Sided Size (electronic) 0 0 1 1 4 0 1 4 4 1 2 4 4 1 1 2 0 1 1 2 2 1 1 2 2 1 2 2 0: No count 1: 1 count 2: 2 counts 4: 4 counts S-20 2 Mode 1 1 1 Mode 0 copy cycles 0 Manual Bypass 1 Counting 2 Set sizes Total (mechanical, electronic) Key (me- copies chanical) Counting 1 Sizes other than those set 2 0 1 2 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Tech. Rep. Choice Touch Panel Display Maintenance Call Operation Select whether to enable or disable the maintenance call reminder message that is displayed when the maintenance counter count reaches the preset value. NO YES NOTE: Up to five maintenance counters may be set and the maintenance call reminder message is given when the count of any one of these five counters reaches the preset value, together with the display of maintenance code “M1.” Copy Kit Counter Select whether to enable or disable the “Copy Kit” counter; if the counter is to be enabled, select whether to allow or inhibit the start of a copy cycle when the count reaches the preset value. NO Disables the Copy Kit counter. Mode 1 Copying not inhibited after the count reaches the preset value. Mode 2 Copying inhibited after the count reaches the preset value. NOTE: The Copy Kit counter is enabled by selecting mode 1 or 2. When the count reaches the preset value, the maintenance code “M4” is displayed. Toner Empty Stop Select whether or not to inhibit copying when a toner-empty condition is detected. Enable Copy Disable Copy NOTE: When “Disable Copy” is selected, copying is inhibited when a T/C of 2.5% or less is detected. Type of Vendor Make the display setting according to the type of optional vendor mounted on the copier. (Japan only) Key Counter Disables the Copy Kit counter. Coin Vendor Card Vendor NOTE: Select “Key Counter.” No other setting should be made. Auto Paper Config. Select either “Inch/Metric” or “Metric” for rounding off the original size detected. Inch/Metric The measurement is rounded to the nearest standard inch or metric size. Metric The measurement is rounded to the nearest standard metric size. S-21 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Tech. Rep. Choice Touch Panel Display Leading Edge Erase Operation Select whether to enable (“Yes”) or disable (“No”) the leading edge erase. YES NO Trailing Edge Erase Select whether to enable (“Yes”) or disable (“No”) the trailing edge erase. YES NO Loop Adjust (Drawer) Adjust the length of the loop before the Synchronizing Rollers to be formed in paper fed from the copier drawer. Display 47 48 49 50 Loop Adjust (Man) Description Loop length approx. 1 mm Loop length approx. 3 mm Loop length approx. 5 mm Loop length approx. 7 mm 51 52 53 Description Loop length approx. 9 mm Loop length approx. 11 mm Loop length approx. 13 mm Adjust the length of the loop before the Synchronizing Rollers to be formed in paper fed via the Multi Bypass Tray or a paper feeder option. Display 47 48 49 50 Function Limit Display Description Loop length approx. 1 mm Loop length approx. 3 mm Loop length approx. 5 mm Loop length approx. 7 mm Display 51 52 53 Description Loop length approx. 9 mm Loop length approx. 11 mm Loop length approx. 13 mm Select whether to limit (“ON”) the functions that can be set on the control panel or not (“OFF”). ON Functions that can be set are limited to the number of copies to be made, paper size, zoom ratio, and exposure level only. OFF All functions can be set. S-22 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Tech. Rep. Choice Touch Panel Display Image Exposure Operation Vary the Vg voltage to set the desired image density. Display Description Vg Vg Vg Vg 47 48 49 50 Simplex/Duplex Select whether or not the Sort Bins will automatically move upward after the last copy is ejected into the Bins. ON After the last copy, the Sort Bins automatically move upward. OFF After the last copy, the Sort Bins do not move upward. Set the inch size of paper to be used in the Universal Tray. 8¼” 8” Set the inch size of paper to be used in the Universal Tray. 8½" Automatic feeding adjust 8¼” Select whether to display the number of originals that need to be returned when a jam occurs while using the ADF. YES Stack +30V +60V +90V +120V Permits selection of 2-sided copying modes only. 8½" Universal Tray 14”x Vg Vg Vg Vg 51 52 53 54 Permits selection of all copying modes. Duplex only Universal Tray 13”x Description Select the copying mode types that can be selected in “Orig. " Copy Default” of User’s Choice. Both Bin Movement –90V –60V –30V " 0V Display NO Select whether or not the Sorter automatically stacks the copy sets after the last copy is ejected into the Sort Bins when there are 20 or fewer copy sets made in non-staple mode. Mode 1 The copy sets are not stacked. Mode 2 The copy sets are stacked. S-23 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS050403A 3. System Input D This function allows the Tech. Rep. to change the fixed zoom ratios, set the paper size, define the marketing area, configure for the Key Counter, and input the telephone number. Tech. Rep. Mode " System Input Touch Panel Display Operation Change Fixed Zoom Ratio Change a fixed zoom ratio to a desired value in the range between X0.500 and X2.000. 1. Select the fixed zoom ratio to be changed and clear the setting by pressing the Clear key. Note: If a ratio is mistakenly cleared, pressing the Panel Reset key will recover the ratio. 2. Enter the new zoom ratio from the 10-Key Pad. 3. Touch “Enter” to validate the new setting. Paper Size Input Set the size of the paper used in each paper source. 1. Select the paper source for which the paper size is to be set (on the Paper Size Input 1/2 screen). 2. Then, the Paper Size Input 2/2 screen appears. Using the Y or B key, select the paper size. 3. Touch “Enter” to validate the paper size setting. Marketing Area Select the marketing area to set the paper size and fixed zoom ratios. MJ MC MH Other Areas Note: Be sure to initialize the copier after the marketing area has been selected. Key Counter Select whether or not to inhibit copying if a Key Counter is not inserted when the copier is equipped with a Key Counter. ON Inhibits copying if the Key Counter is not inserted. OFF Permits copying even if the Key Counter is not inserted. Note: Be sure to select “ON” when the copier is equipped with a Key Counter. Telephone # Input Input the telephone number that will appear on the Touch Panel when a malfunction occurs in the copier. 1. Enter the phone number (consisting of up to 19 digits) from the 10-Key Pad. Note: Use the Interrupt key to enter a hyphen “–.” 2. Touch “OK” to validate the phone number setting. S-24 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS050404A 4. Counter D This function shows the counts of the various counters, thus aiding the Tech. Rep. in performing service jobs. 1. Select “Counter”. 2. Select the desired counter function. 3. Clear or set the count according to the instructions given on the screen. 1. Touch the “Counter Reset” key. 2. Select the type of counter to be cleared all at once. 3. Touch “Enter”. This clears all counts of the counter selected. Tech. Rep. Mode " Counter Touch Panel Display Paper Operation Shows the number of copies made on each paper size or type (S0: standard paper; S1: recycled paper; S2: special paper; S3: disabling 2-sided copying). Paper Size Paper Type A3 11 X 17 S0 B4 11 X 14 S1 A4 Legal S2 B5 Letter S3 A5 5½X8½ FLS Note: For a paper size that can be loaded both lengthwise and crosswise, the count represents the sum of both. (Ex.: A4 lengthwise/crosswise) Using the B or Y key, highlight the count to be cleared, then press the Clear key. Note: If a count is accidentally cleared, pressing the Interrupt key will undo the clear operation. S-25 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Counter Touch Panel Display Jam Operation Shows the number of misfeeds that have occurred in different parts of the copier system including MCBJ (system, copier only, ADF). Display Description Display Description MCBJ (System) Misfeed occurrence rate of the entire system 1st Drawer No. of misfeeds that occurred at the 1st Drawer of the copier MCBJ (Machine Only) Misfeed occurrence rate of the copier only 2nd Drawer No. of misfeeds that occured at the 2nd Drawer of the copier MCBJ (ADF) Misfeed occurrence rate of the ADF only 3rd Drawer No. of misfeeds that occurred at the 3rd Drawer of the copier Manual Feed No. of misfeeds that occurred at the Multi Bypass Tray 4th Drawer No. of misfeeds that occurred at the 4th Drawer of the copier Note 1: MCBJ (System) : Total Counter value divided by the sum of Jam Counter values MCBJ (Machine Only) : Total Counter value divided by the sum of copier Jam Counter values : No. of originals fed through the ADF divided MCBJ (ADF) by the sum of ADF Jams. Note 2: A minus sign “–” is appended when the denominator is “0” for each MCBJ. Display 5th Drawer Vertical Trans. Description Display Description Dup Entrance No. of misfeeds that occurred at the entrance of the Duplex Unit No. of misfeeds that No. of misfeeds that Dup Exit occurred at the transoccurred at the paper port section of the copitake-up section of the er Duplex Unit No. of misfeeds that occurred at the 5th Drawer of the copier Horizontal Trans. No. of misfeeds that occurred at the paper separator section of the copier Exit Section No. of misfeeds that occurred at the exit section of the copier S-26 Sorter ADF Feed No. of misfeeds that occurred at the finishing option No. of misfeeds that occurred at the document take-up section of the ADF Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Counter Touch Panel Display Operation Jam Display Description Display Description ADF Transport No. of misfeeds that occurred at the transport section of the ADF SADF Feed No. of misfeeds that occurred at the SADF ADF Reverse No. of misfeeds that occurred at the turnover section of the ADF LCT No. of misfeeds that occurred at the LCT ADF Exit No. of misfeeds that occurred at the exit section of the ADF Stack No. of misfeeds that occurred at the sorter stacking Using the B or Y key, highlight the count to be cleared, then press the Clear key. Note: If a count is accidentally cleared, pressing the Interrupt key will undo the clear operation. Retry Shows the number of paper take-up retries carried out at different paper sources. Display Description Display Description 1st Drawer No. of paper take-up retries at the 1st Drawer of the copier 5th Drawer No. of paper take-up retries at the 5th Drawer of the copier 2nd Drawer No. of paper take-up Dup retries at the 2nd Drawer of the copier No. of paper take-up retries at the Duplex Unit 3rd Drawer No. of paper take-up retries at the 3rd Drawer of the copier Manual Feed No. of paper take-up retries at the Multi Bypass Tray 4th Drawer No. of paper take-up retries at the 4th Drawer of the copier LCT No. of paper take-up retries at the LCT Using the B or Y key, highlight the count to be cleared, then press the Clear key. Note: If a count is accidentally cleared, pressing the Interrupt key will undo the clear operation. Trouble Shows the number of malfunctions that have occurred in different parts of the copier system. Malfunction Code C000X C0040 C0046/7 C004A/b Location Main Drive Motor Suction Fan Motor Fusing Cooling Fan Optical Cooling Fan S-27 Malfunction Code C004C/d C0070/1 C0072 C0200 Location Ventilation Fan Main Hopper Motor Sub Hopper Motor PC Charge Corona Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Counter Touch Panel Display Operation Trouble Malfunction Code C03XX C04XX C050X C0510 Location Control Board/Harness Exposure Lamp Fuser Warm-Up Fuser Low Temp. Malfunction Code C0520 C0600 C0610 C0620 Location Fuser High Temp. Scanner Drive Syst. Lens Drive System Mirror Drive System Malfunction Code C06FX C07XX C090X C091X Location Scanner Interface ADF 3rd Drawer 2nd Drawer Malfunction Code C092X C095X C0990 - 6 C0998 - F Location 1st Drawer 4th Drawer LCC Main-Tray LCC Shift-Tray Malfunction Code C09CX C0E0X C0E20 C0F02 Location LCT Main Erase Lamp Auxil. Erase Lamp Orig. Size Det. CPU Malfunction Code C0F10 C0F2X C0F3X C0F79 Location EE Sensor AIDC Sensor ATDC Sensor Paper Empty Sensor Malfunction Code C0FE/FX C0b0X C0b10 - 3 C0b18 - d Location Original Sensor Sorter (Transport) Sorter (Paper Clamp) Original Guide Motor Malfunction Code C0b2X C0b3X C0b4X C0b5X Location Sorter (Staple Unit) Sorter (Guide) Sorter (Gate Motor) Sorter (Stapler) Malfunction Code C0b6X C0b7X C0d00 Location Sorter (Bin Shift) Sorter (Punch) Front/Rear Guide Malfunction Code C0d20 C0d5X Location Dup Storage Dup Drive Motor Using the B or Y key, highlight the count to be cleared, then press the Clear key. Note: If a count is accidentally cleared, pressing the Interrupt key will undo the clear operation. S-28 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Counter Touch Panel Display Maintenance Operation Five different values (counts) can be set for the Maintenance Counter. Each counter is increased by 1 each time a copy is made and, when the preset count is reached, the maintenance call reminder message and maintenance code “M1” appear on the Touch Panel. Note: Whether the maintenance call reminder message is given or not depends on the setting made for “Maintenance” of “Tech. Rep. Choice.” Also, copying is not inhibited even when the reminder message appears. 1. Using the B or Y key, select the counter to be set. 2. Enter the value from the 10-Key Pad. Using the B or Y key, highlight the count to be cleared, then press the Clear key. Note: If a count is accidentally cleared, pressing the Interrupt key will undo the clear operation. Port/option Shows the frequency of use of each of the different parts of the copier including options to serve as a guideline for the maintenance time for the Tech. Rep. Display Description Display Description Manual Feed No. of sheets of paper fed from the Multi Bypass Tray 3rd Drawer No. of sheets of paper fed from the 3rd Drawer 1st Drawer No. of sheets of paper fed from the 1st Drawer 4th Drawer No. of sheets of paper fed from the 4th Drawer 2nd Drawer No. of sheets of paper fed from the 2nd Drawer 5th Drawer No. of sheets of paper fed from the 5th Drawer Display Description Display Description ADF Entrance No. of sheets of paper fed through the ADF take-up section. Sorter No. of sheets of paper fed out of the Sorter ADF Reverse No. of originals fed through the turnover unit of the ADF Staple No. of stapling sequences performed No. of sheets of paper fed from the Duplex Unit Punch No. of punching sequences performed DUP S-29 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Counter Touch Panel Display Operation Port/option Display Description PC Drum No. of revolutions of the PC Drum, as converted to the number of sheets of A4 crosswise paper fed through the copier Developer No. of sheets of paper fed through Fusing Roller LCT No. of revolutions of the Fusing Roller, as converted to the number of sheets of A4 crosswise paper fed through the copier No. of sheets of paper fed through the LCT Using the B or Y key, highlight the count to be cleared, then press the Clear key. Note: If a count is accidentally cleared, pressing the Interrupt key will undo the clear operation. S-30 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Counter Touch Panel Display Operation Consumables Enter the count of the Copy Kit counter. When the count, which is increased by 1 each time a copy is made, reaches the set count, the maintenance call reminder message, together with maintenance code “M4,” is displayed. Note: Whether the maintenance call reminder message is given or not depends on the setting made for “Copy Kit Counter” of “Tech. Rep. Choice.” D Toner collect Enter the count of the Toner Collect counter. When the count, which increases by 1 each time a copy is made, reaches the set count, the maintenance code “M2” is displayed. After wards, the machine stops operating after 10k copies are made and the maintenance call reminder message is displayed. Note: The set count should be no more than 200k for U.S.A. areas, 180k for European areas. 1. Using the B or Y key, select the counter to be set. 2. Enter the value from the 10-Key Pad. Using the B or Y key, highlight the count to be cleared, then press the Clear key. Note: If a count is accidentally cleared, pressing the Interrupt key will undo the clear operation. Using the B / Y key, select the counter corresponding to the displayed maintenance code, then press the clear key. Auto CPU Reset Shows whether a CPU overrun has occurred in different CPU-mounted boards which are monitored by the watchdog function. Display Description Display Description MSC/Panel PWB-B ADF Original System Opt. Master PWB-A Sorter Exit System Opt. SCP PWB-F Data Controller D-102 (PWB-A) Note: This counter does not count the number of CPU overruns which have occurred. “1” indicates that there was a CPU overrun, while “0” indicates there was no CPU overrun. Using the B or Y key, highlight the count to be cleared, then press the Clear key. Note: If a count is accidentally cleared, pressing the Interrupt key will undo the clear operation. S-31 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS050405A 5. I/O Check D This function is used to check the sensors and boards when a paper misfeed or malfunction occurs, thereby locating the fault. Tech. Rep. Mode " I/O Check Touch Panel Display IC Port Data Check Operation Shows the states of the I/O ports when the copier is in stand-by. With the output ports, the change of the data in the port allows an operation check of electrical components to be performed. NOTE For details, see TROUBLESHOOTING. Paper Path Sensors Check A sheet of paper is fed through the copier to switch the state of sensors along the paper path between 1 and 0, thereby determining whether the sensors are operational or faulty. 1. Select the paper path (paper source, copying mode, etc.) to be checked and enter this function. 2. Press the Start key to start the sensor check sequence. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Display 1st Feed 2nd Feed 3rd Feed 4th Feed 1st Vertical 2nd Vertical 3rd Vertical 4th Vertical Trans. Roller Leading Edge 1st Exit 2nd Exit Turnover Up Turnover Low Dup Entrance Dup Exit Non Sort Sort Punch Regist Sensor Name 1st Drawer Paper Take-up Sensor PC56 2nd Drawer Paper Take-up Sensor PC57 3rd Drawer Paper Take-up Sensor PC21 4th Drawer Paper Take-up Sensor PC29 1st Drawer Vertical Transport Sensor PC63 2nd Drawer Vertical Transport Sensor PC64 Vertical Transport Sensor 3 PC17 Vertical Transport Sensor 4 PC22 Transport Roller Sensor PC54 Paper Leading Edge Detecting Sensor PC55 Paper Exit Sensor S53 Duplex Unit Vertical Transport Sensor 1 PC30 Duplex Unit Turnover Path Sensor PC13 Duplex Unit Paper Entry Sensor PC14 Duplex Unit Paper Take-Up Sensor PC16 Non-Sort Exit Sensor PC1 Sort Exit Sensor PC2 Punch Registration Sensor PC10 Note: The sensor detects paper when “0” and no paper when “1”. S-32 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " I/O Check Touch Panel Display Memory Check Operation Touching the Memory Check key causes the copier to automatically check the ROM/RAM on MSC Board PWB-B. Result Display Normal “Memory check completed. Turn the main switch OFF, and then ON.” Turn OFF, then ON, the Power Switch. Action “ROM ERROR” Change PWB-B (IC2B) “MESSAGE ROM ERROR” Change PWB-B (IC2B) “RAM ERROR” Change PWB-B. “VRAM ERROR” Change PWB-B. “LCDTC ERROR” Change PWB-B. Faulty Controller Board Check Touching the Controller Board Check key causes the copier to perform a selfdiagnostics of Master Board PWB-A. Result Panel Indication Check Display Action None Normal The highlighted “Controller Board Check” key is returned to normal display. Faulty The malfunction code appears. Change PWB-A. Checks the LEDs and Touch Panel on the control panel for correct operation. 1. Touch the Panel Indication Check key. 2. All LEDs light up and then each LED goes out in the following order. When all LEDs go out, they all light up again and the above sequence is repeated. (The LEDs should alternately light up and go out in said manner.) All ON Mode Check key Start key (orange) Energy Saver key Interrupt key Start key (green) 3. A checkered pattern appears on the Touch Panel. 4. Select an individual grid. The grid should switch from white to black, or vice versa, when it is selected. If it works that way, the corresponding liquid crystal is considered to be operational. 5. Press the Panel Reset key to complete the procedure. S-33 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS050406A 6. Last Trouble Tech. Rep. Mode " Last Trouble Touch Panel Display Last Trouble Operation Touching the Last Trouble key shows the various copying settings made when the last malfunction occurred, thereby providing a basis for determining the cause of the problem. Item Description No. of copies No. of copies setting Copy paper Auto Paper, paper size Zoom ratio Auto Size, zoom ratio Image density Auto Exposure, Manual Exp. setting Mixed Orig. Detection On, off Orig. " copy 1 " 1, 1 " 2, 2 " 2, etc. Finishing Non-Sort, Sort, Group, Sort Staple, Punch Cover Cover (Front), Cover (Front & Back), Copied Cover, Non-Copied Cover Page Insertion Copied Inserts, Non-Copied Inserts OHP Interleaving Copied Interleaves, Non-Copied Interleaves File Margin Method, position, width Erase Method, position, width 1156SBS050407A 7. ROM Version Tech. Rep. Mode " ROM Version Touch Panel Display ROM Version Operation Shows the ROM versions of the following boards. Display Description MSC/Panel IC2B PWB-B Master IC2A PWB-A SCP IC1F PWB-F ADF PWB-A of AFR-13, AF-5 Sorter PWB-A of S-208, ST-211, S-106, ST-104 Data Controller IC2 S-34 D-102 board Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS050408A 8. RD Mode Tech. Rep. Mode " RD Mode Touch Panel Display Highlighted .) Setting (The default is RD Mode Make the initial settings of the copier for the Data Terminal. ID Code Entering a 7-digit ID code from the 10-Key Pad enables making the following settings. When the ID code is entered and transmitted after the initial settings have been made, it executes the transmission of MAINT. START to the Center. Maintenance Used to make the initial settings and various transmissions. DT Setting Enter the following data. CT-ID Enter the 4-digit ID number of the Center which has been programmed in the Center personal computer. DT-ID Enter the 6-digit ID number of the Data Terminal. TEL No. Enter the 19-or-less-digit phone number of the modem connected to the Center personal computer. Note 1: When the office extension and outside line use different systems, enter “P” for a “pulse” telephone line or “T” for a “tone” telephone line before the outside line number. Note 2: The time it takes the private branch exchange (PBX) system to switch from the extension line to the outside line varies depending on the type of PBX system used. Set this time as follows. Fixed switching time: Enter the pause code “–” (a single “–” lasts 2 sec.). Varying switching time: Enter the wait code “W.” Common DT Settings of the following functions. Dial Mode Auto Receive Select the type of telephone line of the user. Pulse line Tone line Pulse Tone Choose “Yes” or “No” for the auto reception function. YES NO Note: Select “Yes” if the line is dedicated to the Data Terminal. Result Code Set the value according to the type of modem on the copier. Note: Don’t use this function as long as “5” has been set for it. Report Format Japan only 10 BIT RAM Clear Reinitializes the Data Terminal. Maintenance S-35 NO Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " RD Mode Touch Panel Display RD Mode Maintenance Setting ............................................................... ............................................................... Data Save/Load Enables transmission of Data Save and Data Load. Data Save Transmits the command that saves the PPC RAM data to the Center. Data Load Transmits the command that loads the data sent by Data Save back to the PPC. Initial Transmission Used to perform the initial transmission from the PPC to the Center to check for correct communication when the Data Terminal has been set up. Call Completion Used by the Tech. Rep. to notify the Center that his/her service job for the copier has been completed. Counter Clear Used to clear the count of the spare counter set by the Center. 1. Select the spare counter to be cleared. 2. Touch “Call Completion” which transmits a signal to the Center to clear the count of the specified counter. S-36 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS050409A 9. Accessory Test D This function is used to make an operation check and adjustments to the ADF and Sorter or Staple Sorter. Tech. Rep. Mode " Accessory Test Touch Panel Display Setting (The default is Highlighted .) ADF Check Enables the operation check and adjustments to be performed for the document feeder. Paper Passage & Input Check Makes a paper passage test in each operating mode of the ADF and checks the sensors along the paper path for operation. Step Feed 2in1 Normal SADF Empty Sensor ADF Entrance Sensor Register Sensor Exit Sensor Auto Feeder Empty Sensor 2-Sided Width Sensor A Width Sensor B Width Sensor C Exit Drawer Sensor Orig. Guide Home Sensor Note: “1” – paper present; “0” – paper not present 1. Select the operating mode to be checked and touch “Next.” 2. Load the required number of originals into the Document Feed Tray and press the Start key. Output Check Checks each of the motors and solenoids for operation. M1 M2 M3 M4 M5 SL1 SL2 SL3 SL4 CL D Select the part to be checked and press the Start key. Doc. Stop Position Set Adjusts the document stop position in different operating modes of the ADF. 2in1 Space in between origs. 1-Sided Auto Feeder 2-Sided Regist Loop 2 in 1 Setting 43 . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . . . . 58 Stop Position –7mm . . . . . . . . . . . 0mm . . . . . . . . . . . . . +8mm Note: A greater setting value (+ direction) moves away from the Original Width Scale. (In “2in1 Space between origs.,” it is for greater distance between the documents.) 1. Select the operating mode to be checked and load the required number of originals into the Document Feed Tray. 2. Press the Start key. When the original is taken up and then stopped, raise the ADF and adjust the stop position using the A or " key; then, feed the original once again for a recheck. S-37 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Tech. Rep. Mode " Accessory Test Touch Panel Display Setting Sorter Check Enables the following operation checks to be performed for the Sorter. Transport Motor Pressing the Start key energizes the Transport Motor to turn the various Transport Rollers. Note: The 10-Bin Sorter is not operated. Bin Movement Pressing the Start key energizes the Bin Moving Motor to move the bins up and down. Stapling Pressing the Start key runs a stapling sequence if paper is loaded in the 1st Bin. If no paper is loaded, only a paper clamp motion occurs. Paper Aligning Pressing the Start key causes a paper aligning motion to occur for the width of the paper currently selected for use. Stack move Pressing the Start key begins a sequence in which paper is stacked in order starting with the paper loaded in the 1st Bin. When “Next” is touched after any of the Sorter Check functions has been selected, the “Input Check” screen appears. When that particular check operation is then run with this screen on the Touch Panel, either 1 or 0 is shown after each sensor according to its state. Paper Aligning Bar Home Bin Empty Paper Clamp Position Paper Clamp Home Staple Paper Detect S-38 Stapler Home Bin Home Position Staple unit FD move Staple Unit CD Constant Position Gate Unit constant Position Sort path constant Position Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS050410A 10. Level History D This function is used to show and set the various level histories which were changed according to the operating conditions of the copier and user requirements. Tech. Rep. Mode " Level History Touch Panel Display Level History Setting Touching the Level History key will show the various level histories as detailed below. Of all data displayed, only that for “ATDC Ref. Value” and “Fuser Temp. Control” can be changed. – ATDC Ref. Value – D Change this data when the RAM Board has been changed or a Developing Unit from another copier has been installed. – Fuser Temp. Control – D Change this data if fusing performance becomes poor due to the operating environment and the paper being used. Display Variable Range Increments Description ATDC Ref. Value ATDC Target Level ATDC Current Level 2 to 254 1.0 to 9.0 (%) 1.0 to 9.0 (%) 2 step 0.5 (%) 0.5 (%) F8 adjusted value Target ATDC level Current ATDC level Vg Default Level Vg Current Level 400 to 850 (V) 400 to 850 (V) 30 (V) 30 (V) Initial grid voltage setting Grid voltage correction value due to changes with time Display Variable Range Increments Fuser Temp. Control 180 to 200 (°C) 10 (°C) Fuser Temp. Current 160 to 220 (°C) 10 (°C) Expo. Default Level 49 to 71 (V) 1 (V) Expo. Current Level 49 to 71 (V) 1 (V) Toner Replenishing Time 0 to 1270 (mm) 10 steps S-39 Description Target fusing temperature Current fusing temperature Initial Exposure Lamp level setting Exposure Lamp level correction value due to changes with time Cumulative time of toner replenishing Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS050411A 11. Machine Status D This function shows the codes of isolated malfunctions which are currently present. This screen is also accessible by touching the wrench mark shown at the bottom left corner of the Basic screen under normal operating conditions. Tech. Rep. Mode " Machine Status Touch Panel Display Machine Status Setting Of the malfunction codes listed below, those that have occurred are displayed, together with the functions that are disabled by these malfunctions. Up to five isolated malfunctions are shown. When a sixth isolated malfunction occurs, the copier considers it as an ordinary malfunction. Even if there are less than five isolated malfunctions, if there are isolated malfunctions occurring at all paper sources, the next isolated malfunction will be regarded as an ordinary one. Malfunction Code Description C004d/45 Cooling Fan Motor malfunction (Ventilation/Fusing Section) C0350 to 52 SP communication failure C09XX Paper take-up failure C0dXX Duplex Unit malfunction C0F2X Faulty AIDC Sensor C0F7X Faulty Paper Empty Sensor C0FEX to FX Faulty Original Size Detecting Sensor C0b3X / 5X to 7X Sorter malfunction With the Machine Status screen on the Touch Panel, swing open and close the Front Door to clear all the isolated malfunctions. 1149SBS050412A 12. Admin. Mode D This function is used to enter or change the administrator number, in addition to the functions set in the “Administrator Mode” available from User’s Choice. Tech. Rep. Mode " Admin. Mode Touch Panel Display Setting Copy Track Copy Track Data See “Administrator Mode” of User’s Choice. Max. Copy Sets User Help Administrator # Input From the 10-Key Pad, enter a 4-digit number (0000 to 9999) that serves as an ID number for opening the “Admin. Mode” of User’s Choice. S-40 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1149SBS0600A 6 FACTORY SETTING D Factory Setting is used to make adjustments at the factory. 1149SBS0601A 6-1. Factory Setting Menu Screen 1149O424CA 1149SBS0602A 6-2. Factory Setting Function Setting Procedure 1. Set the copier into the Tech. Rep. mode by pressing the following keys in this order. Stop key á 0 á Stop key á 1 2. Enter the Factory Setting mode by pressing the following keys in this order. Stop key á Start key 3. Select the particular Factory Setting function to be set. 4. Make the necessary settings by following the instructions given sequentially on the screen. NOTE: The function selected is highlighted. D Press the Panel Reset key on the control panel. S-41 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS0603A 6-3. Factory Setting Function Tree A0 A1 A2 A3 A4 A5 Adjust 1/2 Lens Focus Lens Full Size Position Mirror Full Size Position Feed Direction Mag. Ratio Scan Regist Full Size Scan Regist Reduction A6 A11 A12 A13 Adjust 1/2 Book B-Scan Regist Scan Regist Enlargement Leading Edge Erase Adjust Trailing Edge Erase Adjust Adjust Factory Setting Function F1 Paper Passage F3 Exp. Lamp F5 Optimum & AE F7 Orig. Sensor Developer Paper Path Sensors F2 Drum/Trans F4 HV Separator F6 Edit Ref. Adj F8 ATDC Adjust FF F8+F5 * See “Tech. Rep. Mode” for functions other than F2, F4, F6, F8, and FF. Marketing Area * See “Tech. Rep. Mode.” 1156SBS060301A 1. Function Factory Setting " Function Touch Panel Display F2 Drum/Trans F4 HV Separator F6 Edit Ref. Adj Operation Checks the PC Drum Charge Corona and Image Transfer Corona for output. Note: For factory adjustment only. Checks the Paper Separator Corona for output. Note: For factory adjustment only. Pressing the Start key turns ON and OFF the Image Erase Lamp to make a checkered pattern on the paper for checking the lamp for correct operation and adjusting its position. S-42 Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 – Components Energized in “Function” – F1 F2 F3 F4 F5 F6 F7 F8 FF Main Drive Motor Component f f f f f f  f f Fan Motors f f f f f f  f f Toner Replenishing Motor      f  f f Paper take-up f     f    Scan f  f  f f    Exposure Lamp f  f  f     Main Erase Lamp f f f f f f  f f Image Erase Lamp f  f f f f  f f Synchronizing Rollers f     f    PC Drum Paper Separator Fingers f     f    PC Drum Charge Corona and Image Transfer Corona f f   f f  f f Paper Separator Corona and developing bias f  f f f f  f f Misfeed detection f     f    Malfunction detection f f f f f f f f f f: Energized S-43  : Remains deenergized Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS060302A 2. Adjust D This function is used to adjust the optical system before shipment from the factory and must not be run except when the RAM Board has been replaced with a new one or memory cleared. Further, when the RAM Board has been changed or memory cleared, enter the factory settings indicated on the Adjust Mode label affixed to the inside of the Front Door. Factory Setting " Adjust Touch Panel Display A0 A1 Lens Focus Lens Full Size Position Operation Corrects the focal length of the Lens. (Match the grouping of the Lens being used.) Setting 49 50 51 Description Short focal length adjustment Standard Long focal length adjustment Adjusts the zoom ratio in the crosswise direction by varying the Lens full size position. Setting Description A2 Mirror Full Size Position Description Feed Direction Mag. Ratio Reduction direction Enlargement direction Corrects the optical path length of the Mirror with respect to the Lens focal length. Setting A3 43 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 58 43 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 58 Reduction direction Enlargement direction Adjusts the zoom ratio in the feeding direction by varying the scan speed. Setting 46 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 54 –1.6% (Reduc- . . . . . . . . . 0% . . . . . . . . . . +1.6% (EnlargeDescription tion direction) ment direction) A4 Scan Regist Full Size Corrects the amount of offset along the leading edge in the full size mode by varying the Synchronizing Roller start timing. Setting Description 40 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 60 –5.0mm . . . . . . . . . . . . . . "0 . . . . . . . . . . . . (Smaller) S-44 +5.0mm (Greater) Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 Factory Setting " Adjust Touch Panel Display A5 Scan Regist Reduction Operation Corrects the amount of offset along the leading edge in a reduction mode by varying the Synchronizing Roller start timing. Setting Description A6 Book B-Scan Regist Description Description 45 . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . 55 –2.5mm . . . . . . . . . . . . . . "0 . . . . . . . . . . . . (Smaller) +2.5mm (Greater) 40 . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . 60 –5.0mm . . . . . . . . . . . . . . "0 . . . . . . . . . . . . (Smaller) +5.0mm (Greater) Corrects the width of void image along the leading edge of the image by varying the Image Erase Lamp ON timing. Setting Description A13 Trailing Edge Erase Adjust +5.0mm (Greater) Corrects the amount of offset along the leading edge in an enlargement mode by varying the Synchronizing Roller start timing. Setting A12 Leading Edge Erase Adjust –5.0mm . . . . . . . . . . . . . . "0 . . . . . . . . . . . . (Smaller) Corrects registration in Book B-Scan by varying the Synchronizing Roller start timing. Setting A11 Scan Regist Enlargement 40 . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . 60 45 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 55 –5mm . . . . . . . . . . . . . . "0 . . . . . . . . . . . . (Smaller) +5mm (Greater) Corrects the width of void image along the trailing edge of the image by varying the Image Erase Lamp ON timing. Setting Description 42 . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 58 –8mm . . . . . . . . . . . . . . "0 . . . . . . . . . . . . (Smaller) S-45 +8mm (Greater) Interleaf EP5000/EP4000 SWITCHES ON PWBs, TECH. REP. SETTINGS 97.04.01 1156SBS000EA Copyright 1997 MINOLTA Co., Ltd. Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA CO., LTD. 1156-7997-11 97046000 Printed in Japan Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT000AA EP5000/EP4000 TROUBLESHOOTING Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT000BA CONTENTS 1 INTRODUCTION 1-1. General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 1-2. How to Use This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 1-3. Reading the Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 2 I/O PORT CHECK 2-1. Controlled Parts Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-2 2-2. I/O Port Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-5 3 PAPER TRANSPORT FAILURE 3-1. Paper Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Misfeed Detection Types and Detection Timings . . . . . . . . . . . . . . . . 3-3. Misfeed Clearing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1) Copier Paper Take-Up Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2) Transport/Separator Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3) Multi Bypass Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4) Fusing/Exit misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5) PF-205 Paper Take-Up Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6) PF-105 Paper Take-Up Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7) AD-9 Vertical Transport/Storage Misfeed . . . . . . . . . . . . . . . . . . . . 8) AD-9 Paper Take-Up Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T-20 T-22 T-24 T-24 T-27 T-30 T-32 T-34 T-36 T-38 T-41 MALFUNCTIONS 4-1. Detection Timings Classified by Malfunction Codes . . . . . . . . . . . . . 4-2. Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1) C0000: Main Drive Motor M1’s Failure to Turn . . . . . . . . . . . . . . . . C0001: Main Drive Motor M1 Turning at Abnormal Timing 2) C0040: Suction Fan Motor M4’s Failure to Turn . . . . . . . . . . . . . . 3) C0046: Fusing Section Cooling Fan Motor M15’s Failure to Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C0047: Fusing Section Cooling Fan Motor M15 Turning at Abnormal Timing i T-43 T-57 T-57 T-59 T-61 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 4) C004A: Original Glass Cooling Fan Motor M5’s Failure to Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C004b: Original Glass Cooling Fan Motor M5 Turning at Abnormal Timing C004C: Ventilation Fan Motor M3’s Failure to Turn C004d: Ventilation Fan Motor M3 Turning at Abnormal Timing 5) C0070: Main Hopper Toner Replenishing Motor M8’s Failure to Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C0071: Main Hopper Toner Replenishing Motor M8 Turning at Abnormal Timing C0072: Sub Hopper Toner Replenishing Motor M9’s Failure to Turn 6) C0200 Corona Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7) C03##: Master Board/Harness Malfunctions . . . . . . . . . . . . . . . . . 8) C0400: Exposure Lamp LA1’s Failure to Turn ON . . . . . . . . . . . . C0410: Exposure Lamp LA1 Turning ON at Abnormal Timing 9) C0500: Warming-up Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C0510: Abnormally Low Fusing Temperature C0520: Abnormally High Fusing Temperature 10) C0600: Scanner Motor M2 Malfunction . . . . . . . . . . . . . . . . . . . . . . C06FX: Signal Failure 11) C0610: Lens Motor M6 Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . C0620: Mirror Motor M7 malfunction 12) C0910: 2nd Drawer Upward Motion Failure . . . . . . . . . . . . . . . . . . C0914: 2nd Drawer Paper Lift-Up Motor M14’s Failure to Turn C0920: 1st Drawer Upward Motion Failure C0924: 1st Drawer Paper Lift-Up Motor M13’s Failure to Turn 13) C0900: 3rd Drawer Upward Motion Failure . . . . . . . . . . . . . . . . . . C0904: 3rd Drawer Paper Lift-Up Motor M24’s Failure to Turn C0950: 4th Drawer Upward Motion Failure C0954: 4th Drawer Paper Lift-Up Motor M25’s Failure to Turn 14) C0911: 2nd Drawer Upward Motion Failure (Inch Areas) . . . . . . . C0912: 2nd Drawer Downward Motion Failure C0913: 2nd Drawer Upward Motion Failure C0916: 2nd Drawer Ejection Failure 15) C0921: 1st Drawer Upward Motion Failure (Inch Areas) . . . . . . . C0922: 1st Drawer Downward Motion Failure C0923: 1st Drawer Upward Motion Failure C0926: 1st Drawer Ejection Failure 16) C0901: 3rd Drawer Upward Motion Failure (Inch Areas) . . . . . . . C0902: 3rd Drawer Downward Motion Failure C0903: 3rd Drawer Upward Motion Failure C0906: 3rd Drawer Ejection Failure 17) C0951: 4th Drawer Upward Motion Failure (Inch Areas) . . . . . . . ii T-63 T-65 T-67 T-68 T-69 T-71 T-73 T-75 T-77 T-79 T-81 T-83 T-85 T-87 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 C0952: 4th Drawer Downward Motion Failure C0953: 4th Drawer Upward Motion Failure C0956: 4th Drawer Ejection Failure 18) C0990: Main Tray Upward Motion Failure . . . . . . . . . . . . . . . . . . . T-89 C0991: Main Tray Downward Motion Failure C0992: Main Tray Downward Motion Failure C0993: Main Tray Upward Motion Failure C0994: Elevator Motor M26’s Failure to Turn 19) C0998: Shifter Transfer Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-91 C0999: Shifter Return Failure C099A: Shifter Return Failure C099b: Shifter Transfer Failure C099C: Shift Motor M27’s Failure to Turn 20) C099E: Shift Gate Position Detecting Failure . . . . . . . . . . . . . . . . . T-93 C099F: Shift Gate Position Detecting Failure C0996: 3rd Drawer Lock Release Failure C0F79: Paper Empty Sensor Failure 21) C0d00: Duplex Unit Front/Rear Edge Guide Plate Home Position Detection Failure . . . . . . . . . . . . . . . . . . . . T-95 C0d20: Duplex Unit Gate Unit Home Position Detection Failure C0d50: Duplex Unit Drive Motor M31’s Failure to Turn C0d51: Duplex Unit Drive Motor M31 Turning at Abnormal Timing 22) C0E00: Main Erase Lamp LA2’s Failure to Turn ON . . . . . . . . . . . T-97 C0E01: Main Erase Lamp LA2 Turning ON at Abnormal Timing 23) C0E20: Image Erase Lamp LA3’s Failure to Turn ON . . . . . . . . . T-98 24) C0F02: Original Size Detecting Board UN2 Malfunction . . . . . . . T-99 25) C0F10: AE Sensor Board PWB-H Malfunction . . . . . . . . . . . . . . T-101 26) C0F20: AIDC Sensor Board PWB-G Variation Correction Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-102 C0F22: AIDC Sensor Board PWB-G Grid Voltage (Vg) Correction Failure C0F23: AIDC Sensor Board PWB-G Exposure Correction Failure 27) C0F30: ATDC Sensor UN3 Failure . . . . . . . . . . . . . . . . . . . . . . . . T-103 C0F31: ATDC Sensor UN3 Failure 4-3. Power Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-104 1) Main Relay Does Not Turn ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . T-104 2) Main Relay Turns ON But the Control Panel Gives No Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-106 4-4. Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-107 5 IMAGE FAILURE 5-1. Image Failure Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-108 iii Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 5-2. Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-108 5-3. Troubleshooting Procedures Classified by Image Failure . . . . . . . T-110 iv Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1139SBT0100A 1 INTRODUCTION 1139SBT0101A 1-1. General Precautions 1. When servicing the copier with its covers removed, use utmost care to prevent your hands, clothing, and tools from being caught in revolving parts including the chains and gears. When servicing the copier with the Lower Rear Cover removed, be sure to install the jig. 2. Before attempting to replace parts and unplug connectors, make sure that the power cord of the copier has been unplugged from the wall outlet. 3. Never create a closed circuit across connector pins except those specified in the text and on the printed circuit. 4. When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the green wire (GND). 5. When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to overloads. 6. Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged. 1139SBT0102A 1-2. How to Use This Book 1. If a component on a PWB or any other functional unit including a motor is defective, the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defective unit. 2. All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions. 3. For the removal procedures of covers and parts, see DIS/REASSEMBLY, ADJUSTMENT. 4. The troubleshooting procedures are given in the order of greater frequency of trouble or order of operation. 5. The procedures preclude possible malfunctions due to noise and other external causes. 1139SBT0103A 1-3. Reading the Text 1. The paper transport failure troubleshooting procedures are given according to the symptom. First identify the location where the paper is present and start the procedure for that particular location. For malfunction troubleshooting, start with step 1 and onward. 2. Make checks in numerical order of steps and, if an item is checked okay, go to the next step. Pattern 1 Pattern 2 Step Check Item 1 2 Is...? Result YES Action Do this. ↑ Go to step 2 if you answered NO. Step Check Item Result Is...? YES 1 NO 2 T-1 Action Do this. Check that. ↑ Go to step 2 if it checks okay. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1151SBT0200A 2 I/O PORT CHECK 1156SBT0201A 2-1. Controlled Parts Check Procedure To allow the Tech. Rep. to easily and safely determine whether a particular controlled part is fully operational, this copier provides the following provision: checking the data of the I/O port of the board IC with the copier in the standby state (including a misfeed, malfunction, and closure failure condition) allows the Tech. Rep. to determine whether a signal is properly input to, and output from, a controlled part. 1) On the circuit diagram accompanying the text, locate the I/O port of the controlled part which is probably defective when a misfeed or malfunction occurs. 2) Select the “IC Port Data Check” function of “I/O Check” in the Tech. Rep. mode and access the screen which contains the port identified in step 1 above. (See SWITCHES ON PWBs/TECH. REP. MODE.) 3) Change or check the input or output port data to determine whether the controlled part is operational and signals are properly input and output. 4) If the controlled part does not operate properly after changing the output port data, select “Controller Board Check” of “I/O Check” in the Tech. Rep. mode and determine whether the board is responsible for that malfunction or not. Note: Only the output ports given on pages T-37 and 38 may be checked by “Controller Board Check” of “I/O Check” in the Tech. Rep. mode. T-2 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Example: When a paper misfeed occurs in the paper take-up section of the copier, 1st Drawer Paper Take-Up Sensor PC56 is considered to be responsible for it. 1) Remove the sheet of paper misfed and reset the misfeed. 2) From the I/O port check list, it is found that the H/L input signal to PC56 is supplied from PWB-A (IC3A) APB3. 3) Select “IC Port Check” from the I/O Check function in the Tech. Rep. mode and access the screen which includes the input ports of PWB-A (IC3A) APB3. 4) Check that the input port data of PWB-A (IC3A) APB3 on the screen is “H” (sensor being unblocked). 5) Move the PC56 actuator to block the sensor. 6) Return to the “I/O Check” basic screen once, select “IC Port Check” again, choose the screen which includes the APB3 input port data, and make sure that the data has changed from “H” to “L”. L: PC56 is operational. T-3 H: PC56 is faulty. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Example: When a manual paper misfeed occurs, Manual Feed Paper Take-Up Clutch CL3 is considered to be responsible for it. 1) Remove the sheet of paper misfed and reset the misfeed. 2) From the I/O port check list, it is found that the ON/OFF output signal of CL3 is supplied from PWB-A (IC5A) BPA1. 3) Select “IC Port Check” from the I/O Check function in the Tech. Rep. mode and access the screen which includes the output ports of PWB-A (IC5A) BPA1. 4) Check that the output port data of PWB-A (IC5A) BPA1 on the screen is “1” (CL3 is deenergized). 5) Touch the “CHANGE” key on the screen to change the data from “1” to “0”, causing CL3 to be energized for approx. 5 seconds. This allows you to determine whether the Clutch is “operational or faulty” by checking for the Clutch sound. Operational: Sound produced. Faulty: No sound produced. 6) If CL3 was not energized, make the “Controller Board Check” in the same mode (for some electrical parts only). 7) If the “ON” signal of CL51 is not output from PWB-A, the corresponding malfunction code is displayed. * For CL3, “C0337” is displayed. T-4 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT0202A 2-2. I/O Port Check List D The following screens are displayed in the standby mode but may not always be as shown below because some port data are undefined. (Copier+PF-205) 1156T016CA 1156T020CA 1156T017CA 1156T021CA 1156T018CA 1156T022CA 1156T019CA 1156T023CA T-5 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Copier Symbol *The shaded areas of the following table indicate that the output check cannot be made by touching the Change key. Parts/Signal Name Operation Characteristics/Panel Display Display Page IC No. Port No. I/O 2/8 IC4A BPA2 f OFF ON PJ18A-9 When turned PJ18A-10 H or 1 CN/PJ No. L or 0 M1 Main Drive Motor/REM ↑ Main Drive Motor/lock signal 2/8 IC4A BPB1  When locked M2 Scanner Motor/SCAN 3/8 IC4A APC0 f Stop Scan cycle PJ8A-5 M3 Ventilation Fan Motor/ REM 3/8 IC4A BPC1 f OFF ON PJ34A-1 ↑ Ventilation Fan Motor/ lock signal 2/8 IC4A BPB6  When locked When turned PJ34A-3 M4 Suction Fan Motor/select signal 3/8 IC4A BPC2 f Turned at high speed Turned at low speed PJ15A-4 ↑ Suction Fan Motor/lock signal 3/8 IC4A BPC7  When locked When turned PJ15A-3 M5 Original Glass Cooling Fan Motor/REM 3/8 IC4A BPC0 f OFF ON PJ15A-5 ↑ Original Glass Cooling Fan Motor/lock signal 2/8 IC4A BPB5  When locked When turned PJ15A-7 M8 Main Hopper Toner Replenishing Motor/REM 3/8 IC4A BPC3 f OFF ON PJ11A-4A M9 Sub Hopper Toner Replenishing Motor/REM 3/8 IC5A APA2 f OFF ON PJ11A-2A M11 1st Drawer Paper TakeUp Motor 3/8 IC5A APA0 f Turn inhibited Turn permitted PJ18A-1 M12 2nd Drawer Paper TakeUp Motor 3/8 IC5A APA1 f Turn inhibited Turn permitted PJ18A-2 M13 1st Drawer Paper Lift-Up Motor (UP) 3/8 IC5A APA4 f OFF ON (up) PJ18A-5 ↑ 1st Drawer Paper Lift-Up Motor (DOWN) 3/8 IC5A APA5 f OFF ON (down) PJ18A-6 2nd Drawer Paper Lift-Up Motor (UP) 3/8 IC5A APA6 f OFF ON (up) PJ8A-7 ↑ 2nd Drawer Paper Lift-Up Motor (DOWN) 3/8 IC5A APA7 f OFF ON (down) PJ18A-8 M15 Fusing Section Cooling Fan Motor/REM 3/8 IC4A APC2 f OFF ON PJ10A-1 M14 T-6 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Display Page IC No. Port No. Symbol Parts/Signal Name ↑ Fusing Section Cooling Fan Motor/lock signal 3/8 IC4A APB6 SL1 Separator Solenoid 2/8 IC4A SL5 Exit/Duplex Switching Solenoid 2/8 SL51 Manual Feed Paper Take-Up Solenoid (UP) ↑ I/O Operation Characteristics/Panel Display CN/PJ No. H or 1 L or 0  When locked When turned PJ10A-3 BPA0 f OFF ON PJ11A-6A IC4A BPA5 f OFF ON PJ14A-6 3/8 IC5A BPA2 f OFF ON (up) PJ15A-10 Manual Feed Paper Take-Up Solenoid (DOWN) 3/8 IC5A BPA3 f OFF ON (down) PJ15A-9 CL1 Paper Transport Clutch 2/8 IC4A BPA3 f OFF ON PJ14A-2 CL2 Synchronizing Roller Clutch 2/8 IC4A BPA4 f OFF ON PJ14A-4 CL3 Manual Feed Paper Take-Up Clutch 3/8 IC5A BPA1 f OFF ON PJ15A-12 PC12 Duplex Unit Vertical Transport Sensor 3/8 IC5A BPB0  Paper not present Paper present PJ17A-8 PC35 Toner Bottle Home Position Sensor 3/8 IC4A BPC5  Unblocked Blocked PJ11A-9 PC51 Manual Feed Paper Empty Sensor 3/8 IC5A BPB1  Paper not present Paper present PJ15A-14 PC54 Transport Roller Sensor 3/8 IC5A BPB6  Paper not present Paper present PJ19A-5 PC55 Paper Leading Edge Detecting Sensor 3/8 IC5A BPB5  Paper not present Paper present PJ19A-2 PC56 1st Drawer Paper Take-Up Sensor 1/8 IC3A APB3  Paper not present Paper present PJ21A-5A PC57 2nd Drawer Paper Take-Up Sensor 1/8 IC3A APB4  Paper not present Paper present PJ21A-5B PC61 1st Drawer Set Sensor 1/8 IC3A BPA5  Out of position In position PJ22A-2 PC62 2nd Drawer Set Sensor 1/8 IC3A APB5  Out of position In position PJ22A-6 T-7 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display CN/PJ No. H or 1 L or 0 Paper present PJ21A-8A PC63 1st Drawer Vertical Transport Sensor 1/8 IC3A APB6  Paper not present PC64 2nd Drawer Vertical Transport Sensor 1/8 IC3A APB7  Paper not present Paper present PJ21A-8B PC65 1st Drawer Lift-Up Sensor 1/8 IC3A APB1  Not at upper limit At upper limit PJ21A-2A PC66 2nd Drawer Lift-Up Sensor 1/8 IC3A APB2  Not at upper limit At upper limit PJ21A-2B PC67 1st Drawer Lift-Up Motor Pulse Sensor 1/8 IC3A APC0  Unblocked Blocked PJ23A-2 PC68 2nd Drawer Lift-Up Motor Pulse Sensor 1/8 IC3A APC1  Unblocked Blocked PJ23A-5 PC69 1st Drawer Lower Limit Position Sensor 1/8 IC3A BPA2  Not at lower limit At lower limit PJ24A-5 PC70 2nd Drawer Lower Limit Position Sensor 1/8 IC3A BPA3  Not at lower limit At lower limit PJ24A-6 PC72 Paper Size Detecting Sensor 5 2/8 IC3A BPB6  Size not detected Size detected PJ25A-2 PC73 Paper Size Detecting Sensor 6 2/8 IC3A BPB7  Size not detected Size detected PJ25A-5 PC81 Scanner Reference Position Sensor 2/8 IC4A APC4  Not at home At home PJ8A-4 PC101 1st Drawer Paper Empty Sensor 1/8 IC3A APC2  Paper not present Paper present PJ23A-9 PC102 2nd Drawer Paper Empty Sensor 1/8 IC3A APC3  Paper not present Paper present PJ23A-12 PC111 Original Cover Detecting Sensor 2/8 IC4A APB5  Raised Lowered PJ12A-1 PC112 Toner Hopper Home Position Sensor 3/8 IC5A BPB7  Not at home At home PJ11A-9B CNT1 Total Counter/REM 1/8 IC1A P55 f Normally When counting PJ13A-6 Total Counter/Set 2/8 IC4A APB7  Out of position In position – ↑ T-8 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display H or 1 L or 0 CN/PJ No. Plug-In Counter/REM 1/8 IC1A P44 f Normally When counting PJ28A-9 ↑ Plug-In Counter/Set 3/8 IC5A BPC3  Out of position In position PJ28A-7 H1 Fusing Heater Lamp 1/8 IC1A P57 f OFF ON PJ33A-2 H3 Paper Dehumidifying Heater 1/8 IC1A P45 f ON OFF PJ4A-5 RY1 Main Relay 1/8 IC1A P46 f ON OFF PJ4A-3 LA1 Exposure Lamp/AVR REM 1/8 IC1A P61 f OFF ON PJ8A-13 LA2 Main Erase Lamp/ REM 2/8 IC4A BPA1 f OFF ON PJ12A-3 LA2 Main Erase Lamp/ failure detection 2/8 IC4A APC7  OFF ON PJ12A-5 S1 Power Switch 1/8 IC1A P53  OFF ON PJ4A-1 S21 Front Door Interlock Switch 1/8 IC1A P51  OFF ON PJ4A-4 S22 Right Upper Door Interlock Switch 3/8 IC5A BPB2  OFF ON PJ16A-2 S23 Left Upper Door Interlock Switch 3/8 IC5A BPC6  OFF ON PJ16A-4 S53 Paper Exit Switch 3/8 IC4A BPB2  Paper present Paper not present PJ20A-12 S61 Paper Size Detecting Switch 1 1/8 IC3A BPA6  Size yet to be detected Size detected PJ26A-2 S62 Paper Size Detecting Switch 2 1/8 IC3A BPA7  Size yet to be detected Size detected PJ26A-4 S63 Paper Size Detecting Switch 3 2/8 IC3A BPB4  Size yet to be detected Size detected PJ26A-7 S64 Paper Size Detecting Switch 4 2/8 IC3A BPB5  Size yet to be detected Size detected PJ26A-9 S106 Toner Empty Detecting Switch 3/8 IC1A BPC6  Toner still available Toner empty PJ11A-8B CNT2 T-9 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symbol UN5 ↑ UN6 ↑ PWB-G Parts/Signal Name Display Page IC No. Port No. CN/PJ No. H or 1 L or 0  OFF ON PJ24A-3 APC4 f OFF ON PJ24A-1 IC3A BPA1  OFF ON PJ24A-4 1/8 IC3A APC5 f OFF ON PJ24A-2 2/8 IC4A APA4 f OFF ON – 1st Drawer Paper Descent Key 1/8 IC3A BPA0 Manual Down Display 1 1/8 IC3A Drawer Paper Descent Key 1/8 Manual Down Display 2 AIDC Sensor Board/ AIDC REM 2nd I/O Operation Characteristics/Panel Display T-10 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 PF-205 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display H or 1 L or 0 CN/PJ No. M21 Vertical Transport Drive Motor 4/8 IC1A PB3 f Turn inhibited Turn permitted PJ12A-1~ 4 M22 3rd Drawer Paper Take-Up Motor 4/8 IC1A PB1 f Turn inhibited Turn permitted PJ11A-1~ 4 M23 4th Drawer Paper Take-Up Motor 4/8 IC1A PB0 f Turn inhibited Turn permitted PJ10A-1~ 4 M24 3rd Drawer Paper Lift-Up Motor 4/8 IC1A PA0 f – ON (up) PJ9A-8B ↑ 3rd Drawer Paper Lift-Up Motor 4/8 IC1A PA1 f OFF ON (down) PJ9A-7B M25 4th Drawer Paper LiftUp Motor 4/8 IC1A PA2 f – ON (up) PJ9A-2A ↑ 4th Drawer Paper LiftUp Motor 4/8 IC1A PA3 f OFF ON (down) PJ9A-1A PC11 Lower Left Door Sensor 4/8 IC2A PB1  Out of position In position PJ3A-2 PC13 Duplex Unit Turnover Path Sensor 4/8 IC2A PB0  Paper not present Paper present PJ3A-5 PC17 Vertical Transport Sensor 3 4/8 IC1A PC3  Paper not present Paper present PJ7A-5 PC18 Lower Right Door Sensor 4/8 IC1A PE2  Out of position In position PJ7A-2 PC19 3rd Drawer Paper Lift-Up Sensor 4/8 IC1A PG3  Not at upper limit At upper limit PJ6A-12 PC20 3rd Drawer Paper Empty Sensor 4/8 IC1A PC0  Paper not present Paper present PJ6A-2 PC21 3rd Drawer Paper Take-Up Sensor 4/8 IC1A PE3  Paper not present Paper present PJ6A-9 PC22 Vertical Transport Sensor 4 4/8 IC1A PC2  Paper not present Paper present PJ6A-5 PC23 4th Drawer Paper LiftUp Sensor 4/8 IC1A PF3  Not at upper limit At upper limit PJ8A-8 T-11 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display CN/PJ No. H or 1 L or 0 Paper present PJ8A-2 PC24 4th Drawer Paper Empty Sensor 4/8 IC1A PD0  Paper not present PC25 3rd Drawer Set Sensor 4/8 IC1A PG2  Out of position In position PJ9A-2B PC26 4th Drawer Set Sensor 4/8 IC1A PF2  Out of position In position PJ9A-7A PC27 3rd Drawer Paper Lift-Up Motor Pulse Sensor 4/8 IC1A PC1  Unblocked Blocked PC28 4th Drawer Paper LiftUp Motor Pulse Sensor 4/8 IC1A PD1  Unblocked Blocked PC29 4th Drawer Paper Take-Up Sensor 4/8 IC2A PB3  Paper not present Paper present PJ8A-5 PC31 Large Capacity Toner Collecting Box Set Sensor 4/8 IC2A PC3  Paper not present Paper present PJ2A-2 T-12 PJ9A-5B PJ9A-4A Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 PF-105 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display H or 1 L or 0 CN/PJ No. M21 Vertical Transport Drive Motor 5/8 IC1A PB3 f Turn inhibited Turn permitted PJ12A-1~4 M22 3rd Drawer Paper Take-Up Motor 5/8 IC1A PB1 f Turn inhibited Turn permitted PJ11A-1~4 M26 Main Tray Elevator Motor 5/8 IC1A PA2 f Up/stop Down PJ4A-6B ↑ Main Tray Elevator Motor 5/8 IC1A PA3 f Down/ stop Up PJ4A-7B M27 Paper Shift Motor 5/8 IC1A PA0 f Transfer/stop Return PJ4A-4B ↑ Paper Shift Motor 5/8 IC1A PA1 f Return/ stop Transfer PJ4A-5B M28 Shift Gate Motor 5/8 IC1A PB2 f OFF ON PJ4A-2B PC1 Shift Tray Paper Empty Sensor 5/8 IC1A PD1  Paper not present Paper present PJ4A-4A PC2 Main Tray Lower Position Sensor 6/8 IC2A PC1  Not at lower limit At lower limit PJ4A-9A PC3 Shifter Home Position Sensor 6/8 IC2A PC0  Not at home At home PJ4A-8A PC4 Shifter Return Position Sensor 6/8 IC2A PD1  Not at returned position At returned position PJ4A-7A PC5 Elevator Motor Pulse Sensor 5/8 IC1A PF2  Unblocked Blocked PC6 Shift Motor Pulse Sensor 5/8 IC1A PD0  Unblocked Blocked PC7 3rd Drawer Set Sensor 6/8 IC1A PG2  Out of position In position PJ5A-2 PC11 Lower Left Door Sensor 6/8 IC2A PB1  Out of position In position PJ3A-2 PC13 Duplex Unit Turnover Path Sensor 6/8 IC2A PB0  Paper not present Paper present PJ3A-5 PC17 Vertical Transport Sensor 3 5/8 IC1A PC3  Paper not present Paper present PJ7A-5 PC18 Lower Right Door Sensor 5/8 IC1A PE2  Out of position In position PJ7A-2 T-13 PJ4A-5A PJ4A-3A Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display CN/PJ No. H or 1 L or 0 At upper limit PJ6A-12 PC19 3rd Drawer Paper Lift-Up Sensor 6/8 IC1A PG3  Not at upper limit PC20 3rd Drawer Paper Empty Sensor 5/8 IC1A PC0  Paper not present Paper present PJ6A-2 PC21 3rd Drawer Paper Take-Up Sensor 5/8 IC1A PE3  Paper not present Paper present PJ6A-9 PC22 Vertical Transport Sensor 4 5/8 IC1A PC2  Paper not present Paper present PJ6A-5 PC31 Large Capacity Toner Collecting Box Set Sensor 4/8 IC2A PC3  Out of position In position PJ2A-2 PC34 Shift Gate Position Sensor 5/8 IC1A PC1  Unblocked Blocked PC35 Lower Position Sensor 6/8 IC2A PB3  Not at lower limit At lower limit PJ4A-2A Main Tray Paper Empty Board 5/8 IC1A PF3  Paper not present Paper present PJ4A-6A UN21 Drawer Paper Descent Key 6/8 IC2A PC2  OFF ON PJ4A-10A SL41 3rd Drawer Lock Solenoid 6/8 IC2A PA1 f OFF ON PJ5A-5 PWB-E T-14 PJ4A-1B Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 AD-9 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display CN/PJ No. H or 1 L or 0 f OFF ON PJ6G-2 PE1  When locked When turned PJ6G-1 IC1G PA3 f OFF ON PJ2G-7 7/8 IC1G PH1 f OFF ON PJ3G-5 Duplex Unit Rear Finger Solenoid 7/8 IC1G PH0 f OFF ON PJ3G-7 SL33 Duplex Unit Pick-Up Solenoid 7/8 IC1G PB2 f OFF ON PJ2G-12 PC8 Duplex Gate Home Position Sensor 7/8 IC1G PE0  Not at home At home PJ7G-2 PC9 Front/Rear Edge Guide Plate Home Position Sensor 7/8 IC1G PC3  Not at home At home PJ7G-5 PC14 Duplex Unit Paper Entry Sensor 7/8 IC1G PC1  Paper not present Paper present PJ3G-2 PC15 Duplex Unit Paper Empty Sensor 7/8 IC1G PC2  Paper not present Paper present PJ2A-4 PC16 Duplex Unit Paper Take-Up Sensor 7/8 IC1G PC0  Paper not present Paper present PJ2G-9 M31 Duplex Unit Drive Motor 7/8 IC1G PB3 ↑ Duplex Unit Drive Motor/lock signal 7/8 IC1G CL31 Duplex Unit Paper Take-Up Clutch 7/8 SL31 Duplex Unit Gate Switching Solenoid SL32 T-15 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 C-301 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display CN/PJ No. H or 1 L or 0 Up CN5A-2 HMOT Elevator Motor 8/8 IC1A PH0 f Down/ stop ↑ Elevator Motor 8/8 IC1A PH1 f Up/stop Down CN5A-1 PWB-B Paper Plate Descent Switch Board 8/8 IC1A PG1  OFF ON CN2A-2 EMPSEN Paper Empty Sensor 8/8 IC1A PC1  Paper present Paper not present CN2A-5 KSEN Paper Feed Sensor 8/8 IC1A PG0  Paper present Paper not present CN2A-3 LEVSEN Paper Plate Raised Position Sensor 8/8 IC1A PC0  Not upper limit At upper limit CN2A-6 LOWSEN Paper Plate Lowered Position Sensor 8/8 IC1A PG3  Not at lower limit At lower limit CN3A-5 DSEN Cassette Door Sensor 8/8 IC1A PG2  Out of position In position CN3A-2 SETSEN Set Sensor 8/8 IC1A PC2  Out of position In position CN2A-4 T-16 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 PF205 : MC Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display H or 1 L or 0 CN/PJ No. M21 Vertical Transport Drive Motor 6/8 IC1A PB3 f Turn inhibited Turn permitted PJ12A-1~ 4 M22 3rd Drawer Paper Take-Up Motor 6/8 IC1A PB1 f Turn inhibited Turn permitted PJ11A-1~ 4 M23 4th Drawer Paper Take-Up Motor 6/8 IC1A PB0 f Turn inhibited Turn permitted PJ10A-1~ 4 M24 3rd Drawer Paper Lift-Up Motor 6/8 IC1A PA0 f OFF ON (up) PJ9A-8B ↑ 3rd Drawer Paper Lift-Up Motor 6/8 IC1A PA1 f OFF ON (up) PJ9A-7B M25 4th Drawer Paper Lift-Up Motor 6/8 IC1A PA2 f OFF ON (up) PJ9A-2A ↑ 4th Drawer Paper Lift-Up Motor 6/8 IC1A PA3 f OFF ON (up) PJ9A-1A PC11 Lower Left Door Sensor 6/8 IC2A PB1  Out of position In position PJ3A-2 PC13 Duplex Unit Turnover Path Sensor 6/8 IC2A PB0  Paper not present Paper present PJ3A-5 PC17 Vertical Transport Sensor 3 6/8 IC1A PC3  Paper not present Paper present PJ7A-5 PC18 Lower Right Door Sensor 6/8 IC1A PE2  Out of position In position PJ7A-2 PC19 3rd Drawer Paper Lift-Up Sensor 6/8 IC1A PG3  Not at upper limit At upper limit PJ6A-12 PC21 3rd Drawer Paper Take-Up Sensor 6/8 IC1A PE3  Paper not present Paper present PJ6A-9 PC22 Vertical Transport Sensor 4 6/8 IC1A PC2  Paper not present Paper present PJ6A-5 PC23 4th Drawer Paper Lift-Up Sensor 6/8 IC1A PF3  Not at upper limit At upper limit PJ8A-8 PC25 3rd Drawer Set Sensor 6/8 IC1A PG2  Out of position In position PJ9A-2B PC26 4th Drawer Set Sensor 6/8 IC1A PF2  Out of position In position PJ9A-7A T-17 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display CN/PJ No. H or 1 L or 0 Paper present PJ8A-5 PJ2A-2 PC29 4th Drawer Paper Take-Up Sensor 6/8 IC2A PB3  Paper not present PC31 Large Capacity Toner Collecting Box Set Sensor 6/8 IC2A PC3  Out of position In position PC67 3rd Drawer Paper Lift-Up Motor Pulse Sensor 6/8 IC1A PC1  Unblocked Blocked PC68 4th Drawer Paper Lift-Up Motor Pulse Sensor 6/8 IC1A PD1  Unblocked Blocked PJ9A-4A PC69 3rd Drawer Lower Position Sensor 7/8 IC2A PD1  Not at lower limit At lower limit PJ4A-7A PC70 4th Drawer Lower Position Sensor 7/8 IC2A PC0  Not at lower limit At lower limit PJ4A-8A PWB-E1 3rd Drawer Paper Empty Board 6/8 IC1A PC0  Paper not present Paper present PJ4A-4A PWB-E2 4th Drawer Paper Empty Board 6/8 IC1A PD0  Paper not present Paper present PJ4A-3A UN5 3rd Drawer Paper Descent Key 7/8 IC2A PC1  OFF ON PJ4A-9A UN6 4th Drawer Paper Descent Key 7/8 IC2A PC2  OFF ON PJ4A-10A T-18 PJ9A-5B Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 PF-5D/AD-8 Symbol Parts/Signal Name Display Page IC No. Port No. I/O Operation Characteristics/Panel Display H or 1 L or 0 CN/PJ No. M21 Vertical Transport Drive Motor 4/8 IC1A PB3 f Turn inhibited Turn permitted PJ12A-1~ 4 M31 Duplex Unit Drive Motor 7/8 IC1G PB3 f OFF ON PJ5G-2 ↑ Duplex Unit Drive Motor/lock signal 7/8 IC1G PE1  When locked When turned PJ5G-1 CL31 Duplex Unit Paper Take-Up Clutch 7/8 IC1G PA3 f OFF ON PJ2G-7 SL31 Duplex Unit Gate Switching Solenoid 7/8 IC1G PH1 f OFF ON PJ3G-5 SL32 Duplex Unit Rear Finger Solenoid 7/8 IC1G PH0 f OFF ON PJ3G-7 SL33 Duplex Unit Pick-Up Solenoid 7/8 IC1G FB2 f OFF ON PJ2G-12 PC8 Duplex Gate Home Position Sensor 7/8 IC1G PE0  Not at home At home PJ7G-2 PC9 Front/Rear Edge Guide Plate Home Position Sensor 7/8 IC1G PC3  Not at home At home PJ7G-5 PC11 Lower Left Door Sensor 5/8 IC2A PB1  Out of position In position PJ3A-2 PC13 Duplex Unit Turnover Path Sensor 5/8 IC2A PB0  Paper not present Paper present PJ3A-5 PC14 Duplex Unit Paper Entry Sensor 7/8 IC1G PC1  Paper not present Paper present PJ3G-2 PC15 Duplex Unit Paper Empty Sensor 7/8 IC1G PC2  Paper not present Paper present PJ2G-4 PC16 Duplex Unit Paper Take-Up Sensor 7/8 IC1G PC0  Paper not present Paper present PJ2G-9 PC17 Vertical Transport Sensor 3 5/8 IC1A PC3  Paper not present Paper present PJ7A-5 PC18 Lower Right Door Sensor 5/8 IC1A PE2  Out of position In position PJ7A-2 PC31 Large Capacity Toner Collecting Box Set Sensor 5/8 IC2A PC3  Out of position In position PJ2A-2 T-19 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1151SBT0300A 3 PAPER TRANSPORT FAILURE 1156SBT0301A 3-1. Paper Misfeed When a paper misfeed occurs, the Touch Panel shows the corresponding message, misfeed location and paper location. Blinking Light There is a misfeed at that location. Steady Light There might be a sheet of paper stopped at that location. 1149T002CA *When option is installed Blinking/Steady LED Misfeed/Paper Location Ref. Page À Multi Bypass take-up and transport T-22 Á Transport/separator T-20 Â Fusing/exit T-24 Ã Copier take-up/vertical transport T-17,18 Ã,Ä Paper Feed Cabinet take-up/vertical transport T-25 to 28 Å,Æ Duplex Unit vertical transport T-30 Ç 1st Drawer take-up T-17 È 2nd Drawer take-up T-17 É 3rd Drawer take-up T-25 to 28 4th Drawer take-up T-26 Duplex Unit take-up T-32,33 Duplex Unit storage T-31 Æ, * * ADF take-up – ADF transport – ADF turnover/exit – Sorter – LCC – When misfeed occurs in the copier Open and close the Front Door. When misfeed occurs in the option (except Duplex Unit) Raise and lower the option, or slide the option away from, and back up against, the copier. T-20 * * * * * * * * * Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 *When options (PF-205+AD-9) are installed Paper Exit Sensor (S53) Transport Roller Sensor (PC54) Paper Leading Edge Detecting Sensor (PC54) 1st Drawer Vertical Transport Sensor (PC63) 1st Drawer Paper Take-Up Sensor (PC56) 2nd Drawer Vertical Transport Sensor (PC64) *Duplex Unit Vertical Transport Sensor (PC12) 2nd Drawer Paper Take-Up Sensor (PC57) *Vertical Transport Detection Sensor 3 (PC17) *Vertical Transport Detection Sensor 4 (PC22) *Duplex Unit Paper Entry Sensor (PC14) *Duplex Unit Paper Take-up Sensor (PC16) *Duplex Unit Turnover Path Sensor (PC13) 1156T001AB *Duplex Unit Paper Empty Sensor (PC15) *3rd Drawer Paper Take-up Sensor (PC21) T-21 *4th Drawer Paper Take-up Sensor (PC29) Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT0302A 3-2. Misfeed Detection Types and Detection Timings D The following table lists the types of misfeed detection classified by the misfeed locations and their corresponding detection timings. Note: For the misfeed detection types and detection timings in the options, see the Service Manual for the options. Type Paper take-up failure detection Detection Timing 1st Drawer Paper Take-Up Sensor PC56 is not blocked (L) even after the lapse of approx. 2.2 sec. after 1st Drawer Paper Take-Up Motor M11 has been energized. 2nd Drawer Paper Take-Up Sensor PC57 is not blocked (L) even after the lapse of approx. 2.2 sec. after 2nd Drawer Paper Take-Up Motor M12 has been energized. Paper take-up trailing edge detection PC56 is not unblocked (H) even after the lapse of T (which varies for paper sizes) after it has been blocked (L). PC57 is not unblocked (H) even after the lapse of T (which varies for paper sizes) after it has been blocked (L). Paper take-up leading edge detection 1st Drawer Vertical Transport Sensor PC63 is not blocked (L) even after the lapse of approx. 2 sec. after PC56 has been blocked (L). 2nd Drawer Vertical Transport Sensor PC64 is not blocked (L) even after the lapse of approx. 2 sec. after PC57 has been blocked (L). Leading edge detection by Transport Roller Sensor PC54 PC54 is not blocked (L) even after the lapse of approx. 1.3 sec. after PC63 has been blocked (L). PC54 is not blocked (L) even after the lapse of approx. 1.7 sec. after PC64 has been blocked (L). Type Paper take-up failure detection Detection Timing PC54 is not blocked (L) even after the lapse of approx. 2.5 sec. after Manual Feed Paper Take-Up Clutch CL3 has been energized. Type Detection Timing Trailing edge detection by Transport Roller Sensor PC54 PC54 is not unblocked (H) even after the lapse of T (which varies for paper sizes) after the TRON signal has been input. Leading edge detection by Paper Leading Edge Detecting Sensor PC55 PC55 is not blocked (L) even after the lapse of approx. 1.2 sec. after PC54 has been blocked (L). Trailing edge detection by PC55 PC55 is not unblocked (H) even after the lapse of approx. 1.2 sec. after PC54 has been unblocked (H). T-22 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Type Detection Timing Leading edge detection by Paper Exit Switch S53 S53 is not deactuated even after the lapse of approx. 2 sec. after the TRON signal has been input. Trailing edge detection by S53 S53 is not actuated even after the lapse of approx. 2.5 sec. after PC55 has been unblocked (H). T-23 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT0303A 3-3. Misfeed Clearing Procedures 1156SBT030301A 1) Copier Paper Take-Up Misfeed Relevant Electrical Parts D 2nd Drawer Paper Take-Up Sensor PC57 D 1st Drawer Vertical Transport Sensor PC63 D 2nd Drawer Vertical Transport Sector PC64 D Transport Roller Sensor PC54 D 1st Drawer Paper Take-Up Motor M11 D 2nd Drawer Paper Take-Up Motor M12 D Paper Transport Clutch CL1 D Power Supply Board PWB–C D Master Board PWB-A 1156C01TAA T-24 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uCopier Paper Take-Up Misfeed Clearing Procedure Symptom D Paper is not taken up at all. D Paper is stationary before the Paper Take-Up Sensor. Paper is stationary at the Vertical Transport Section. Step Check Item 1 Does the paper being used meet product specifications? 2 Is the paper curled, waved, or damp? Result Action NO Instruct the user to use the paper that meets product specifications. YES Change the paper. Instruct the user in how to store the paper. Position the edge stop and guide to meet the paper size. 3 Is the Trailing Edge Stop or Edge Guide in good position? NO 4 Are the Paper Take-Up Roll and Separator Roll deformed, worn, or dirty with paper dust? YES Clean or change the Paper Take-Up Roll and/or Separator Roll. 5 Is the Paper Take-Up Motor (M11, M12) turning when the Start key is pressed? NO Check the motor for overload. Run the “Controller/Board Check.” Is either of the malfunction codes C032A and C032B displayed? YES Change PWB-A. 6 NO Change M11, M12, or PWB-C. YES Clean or change the Vertical Transport Rollers. 1 Are the Vertical Transport Rollers deformed, worn, or dirty with paper dust? 2 Does PC63 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB6. 3 Does PC64 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB7. 4 Does PC56 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB3. 5 Does PC57 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB4. 6 Does PC54 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC5A) BPB6. T-25 NO NO NO NO Check the PC63 actuator for operation and, if it checks okay, change PC63. Check the PC64 actuator for operation and, if it checks okay, change PC64. Check the PC56 actuator for operation and, if it checks okay, change PC56. Check the PC57 actuator for operation and, if it checks okay, change PC57. YES Change PWB-A. NO Check the PC54 actuator for operation and, if it checks okay, change PC54. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symptom Paper is stationary at the Vertical Transport Section Step Check Item 7 Does CL1 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPA3 to “0.” 8 Run the “Controller Board Check.” Is the malfunction code “C0321” displayed? T-26 Result Action Check the drive transmission path. YES YES Change PWB-A. NO Change CL1. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT030302A 2) Transport/Separator Misfeed Relevant Electrical Parts D Transport Roller Sensor PC54 D Paper Leading Edge Detecting Sensor PC55 D Paper Transport Clutch CL1 D Synchronizing Roller Clutch CL2 D Separator Solenoid SL1 D Suction Fan Motor M4 D High Voltage Unit HV1 D Master Board PWB-A 1156C02TAA T-27 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uTransport/Separator Misfeed Clearing Procedure Symptom Paper is stationary at the Synchronizing Roller. Step 1 2 Does CL2 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPA4 to “0.” 3 Run the “Controller Board Check.” Is the malfunction code “C0320” displayed? 4 Paper is stationary near the PC Drum. Is an adequate length of loop formed before the Synchronizing Roller? Result YES YES Action Change the paper. Instruct the user in how to store the paper. Check the drive transmission path. YES Change PWB-A. NO Change CL2. NO Adjust the loop length using the “Loop Adjust (Drawer)” function of “Tech. Rep. Choice.” YES Change PWB-A. NO Check the PC55 actuator for operation and, if it checks okay, change PC55. Correct, clean, or change the guide plate. 5 Does PC55 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC5A) BPB5. 1 Is the Pre-Image Transfer Guide Plate deformed or dirty? YES 2 Are the Image Transfer/Paper Separator Corona wires deteriorated or dirty? YES 3 Is the paper guide at the Paper Separator Corona deformed or dirty? YES Clean or change the paper guide. 4 Are the Synchronizing Rollers deformed, worn, or dirty with paper dust? YES Clean or change the Synchronizing Rollers. YES Change PWB-A. NO Change the Image Transfer/ Paper Separator Coronas Assy or HV1. Clean or change the Paper Separator Fingers. 5 Paper is wedged at the Paper Separator Fingers. Check Item Is the paper curled, waved or damp? Run the “Controller Board Check.” Is the malfunction code “C031D” or ”C031E” displayed? Clean or change the wires. 1 Are the Paper Separator Fingers deformed or dirty? YES 2 Does SL1 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPA0 to “0.” YES 3 Run the “Controller Board Check.” Is the malfunction code “C0324” displayed? T-28 Check the drive transmission path. YES Change PWB-A. NO Change SL1. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symptom Paper is stationary on the Suction Belts. Step Check Item 1 Do the Suction Belts turn when the Main Drive Motor runs? 2 Does M4 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPC2 to “0.” Does M4 then run at full speed? T-29 Result NO YES NO Action Check the drive gears and timing belt. Check the Suction Belts. Change M4 or PWB-A. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT030303A 3) Multi Bypass Misfeed Relevant Electrical Parts D Manual Feed Paper Empty Sensor PC51 D Manual Feed Paper Take-Up Solenoid SL51 D Manual Feed Paper Take-Up Clutch CL3 D Master Board PWB-A 1156C03TAA T-30 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uMulti Bypass Misfeed Clearing Procedure Symptom Step Check Item 1 Does PC51 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC5A) BPB1. Paper is not detected. Paper is not taken up at all. 1 2 Does the paper being used meet product specifications? Is the paper curled, waved, or damp? 3 Is the Manual Bypass Paper Take-Up Roll deformed, worn, or dirty with paper dust? 4 Does SL51 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC5A) BPA3 to “0.” Does the roll then go down? 5 Run the “Controller/Board Check.” Is the malfunction code ”C0336” displayed? 6 Does CL3 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC5A) BPA1 to “0.” 7 Run the “Controller/Board Check.” Is the malfunction code “C0337” displayed? T-31 Result YES NO Action Change PWB-A. Check the PC51 actuator for operation and, if it checks okay, change PC51. NO Instruct the user to use the paper that meets product specifications. YES Change the paper. Instruct the user in how to store the paper. YES Clean or change the Manual Bypass Paper Take-Up Roll. Check the drive transmission path. YES YES Change PWB-A. NO Change SL51. Check the drive transmission path. YES YES Change PWB-A. NO Change CL3. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT030304A 4) Fusing/Exit Misfeed Relevant Electrical Parts D Paper Exit Switch S53 D Suction Fan Motor M4 D Master Board PWB-A 1156C04TAA T-32 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uFusing/Exit Misfeed Clearing Procedure Symptom Paper is stationary before the Fusing Roller. Paper is stationary at the Fusing Roller. Step Check Item 1 Is the paper curled, waved, or damp? 2 Is the Fusing Guide Plate deformed or dirty? 3 Does M4 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPC2 to “0.” Does M4 then turn at full speed? Result Action YES Change the paper. Instruct the user in how to store the paper. YES Clean, correct, or change the Fusing Guide Plate. Check the Suction Belts. YES Change M4 or PWB-A. NO 1 Are the Fusing Rollers dirty or scratched? YES Clean or change the Fusing Rollers. 2 Are the Fusing Roller Paper Separator Fingers deformed, worn, or dirty? YES Clean, correct, or change the defective separator fingers. Is the Cleaning Roller dirty or scratched? YES Clean or change the Cleaning Roller. 3 Paper is stationary at the Exit Roller. 1 Does S53 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (IC5A) BPB3. T-33 YES NO Change PWB-A. Check the S53 actuator for operation and, if it checks okay, change S53. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT030305A 5) PF-205 Paper Take-Up Misfeed Relevant Electrical Parts D 3rd Drawer Paper Take-Up Sensor PC21 D 4th Drawer Paper Take-Up Sensor PC29 D Vertical Transport Sensor 3 PC17 D Vertical Transport Sensor 4 PC22 D 3rd Drawer Paper Take-Up Motor M22 D 4th Drawer Paper Take-Up Motor M23 D Vertical Transport Drive Motor M21 D PF-205 Master Board PWB-A D EP5000/EP4000 Master Board PWB-A 1156C24TAA T-34 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symptom D Paper is not taken up at all. D Paper is stationary before the Paper Take-Up Sensor. Step Result Action 1 NO Instruct the user to use the paper that meets product specifications. 2 Is the paper curled, waved, or damp? YES Change the paper. Instruct the user in how to store the paper. YES Clean or change the Paper Take-Up Roll and/or Separator Roll. NO D Check the motor for overload. D Change PWB-A (PF-205) or PWB-A (copier). Change M22 or M23. NO D Check the motor for overload. D Change PWB-A (PF-205) or PWB-A (copier). Change M21. 4 5 Paper is stationary at the Vertical Transport Section. Check Item Does the paper being used meet product specifications? 1 2 3 Are the Paper Take-Up Roll and Separator Roll deformed, worn, or dirty with paper dust? Is the Paper Take-Up Motor (M22, M23) turning when the Start key is pressed? Is Vertical Transport Drive Motor M21 turning when the Start key is pressed? Are the Vertical Transport Rollers deformed, worn, or dirty with paper dust? Does PC17 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) IC1A PC3 (metric areas) or PWB-A (MC) IC1A PC3 (inch areas). 4 Does PC22 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) IC1A PC2 (metric areas) or PWB-A (MC) IC1A PC2 (inch areas). 5 Does PC21 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) IC1A PE3 (metric areas) or PWB-A (MC) IC1A PE3 (inch areas). 6 Does PC29 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) IC1A PB3 (metric areas) or PWB-A (MC) IC1A PB3 (inch areas). T-35 YES NO NO NO Clean or change the Vertical Transport Rollers. Check the PC17 actuator for operation and, if it operates properly, change PC17. Check the PC22 actuator for operation and, if it operates properly, change PC22. Check the PC21 actuator for operation and, if it operates properly, change PC21. YES Change PWB-A (PF-205) or PWB-A (copier). NO Check the PC29 actuator for operation and, if it operates properly, change PC29. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT030306A 6) PF-105 Paper Take-Up Misfeed Relevant Electrical Parts D 3rd Drawer Paper Take-Up Sensor PC21 D Vertical Transport Sensor 3 PC17 D Vertical Transport Sensor 4 PC22 D 3rd Drawer Paper Take-Up Motor M22 D Vertical Transport Drive Motor M21 D PF-105 Master Board PWB-A D EP5000/EP4000 Master Board PWB-A 1156C26TAA T-36 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Symptom D Paper is not taken up at all. D Paper is stationary before the Paper Take-Up Sensor. Step Check Item 1 Does the paper being used meet product specifications? 2 4 Paper is stationary at the Vertical Transport Section. Is the paper curled, waved, or damp? Are the Paper Take-Up Roll and Separator Roll deformed, worn, or dirty with paper dust? 5 Is 3rd Drawer Paper TakeUp Motor M22 turning when the Start key is pressed? 1 Is Vertical Transport Drive Motor M21 turning when the Start key is pressed? 2 3 4 5 Are the Vertical Transport Rollers deformed, worn, or dirty with paper dust? Does PC17 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PC3. Does PC22 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PC2. Does PC21 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PE3. T-37 Result Action NO Instruct the user to use the paper that meets product specifications. YES Change the paper. Instruct the user in how to store the paper. YES Clean or change the Paper Take-up Roll and/or Separator Roll. NO D Check the motor for overload. D Change PWB-A (PF-105) or PWB-A (copier). Change M22. NO D Check the motor for overload. D Change PWB-A (PF-105) or PWB-A (copier). Change M21. YES NO NO Clean or change the Vertical Transport Rollers. Check the PC17 actuator for operation and, if it operates properly, change PC17. Check the PC22 actuator for operation and, if it operates properly, change PC22. YES Change PWB-A (PF-105) or PWB-A (copier). Change M21. NO Check the PC21 actuator for operation and, if it operates properly, change PC21. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT030307A 7) AD-9 Vertical Transport/Storage Misfeed Relevant Electrical Parts D Vertical Transport Sensor 3 PC17 D Duplex Unit Vertical Transport Sensor PC12 D Duplex Unit Turnover Path Sensor PC13 D Duplex Unit Paper Entry Sensor PC14 D Duplex Unit Paper Empty Sensor PC15 D Vertical Transport Sensor 3 PC17 D Exit/Duplex Switching Solenoid SL5 D Duplex Unit Gate Switching Solenoid SL31 D Duplex Unit Drive Motor M31 D Duplex Unit Master Board PWB-G D PF-205/105 Master Board PWB-A D EP5000/EP4000 Master Board PWB-A 1156C30TAA T-38 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uAD-9 Vertical Transport Misfeed Clearing Procedure Symptom Paper is stationary at the copier exit section. Paper is stationary at the Duplex Unit Vertical Transport Section. Step Check Item 1 Does SL5 operate properly? Using the IC Port Data Check function, set the data of PWB-A (IC4A) BPA5 to “0.” 2 Run the “Controller Board Check.” Is the malfunction code “C0324” displayed? 1 Do the Vertical Transport Roller and drive coupling operate properly when M31 is running? Using the IC Port Data Check function, set the data of PWB-G (Dup) (IC1G) PB3 to “0.” 2 Does PC12 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (IC5A) BPB0. Paper is stationary at the Duplex Unit Turnover Section. 1 Do the Paddle Roller, Slip Roller, and drive coupling operate properly when M31 is running? Using the IC Port Data Check function, set the data of PWB-G (Dup) (IC1G) PB3 to “0.” 2 Does PC13 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (200/400) (IC2A) PB0. T-39 Result Action Check the drive transmission path. YES YES Change PWB-A. NO Change SL51. Check the gears, belts, and rollers. NO YES Change PWB-A. NO Check the PC12 actuator for operation and, if it operates properly, change PC12. Check the gears, belts, and rollers. NO YES Change PWB-A (copier) or PWB-A (PF-205/105). NO Check the PC13 actuator for operation and, if it operates properly, change PC13. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uAD-9 Storage Misfeed Clearing Procedure Symptom The leading edge of the paper is stationary inside the Duplex Unit. Step 1 2 3 Paper is stationary at the storage section. 1 Check Item Is the Paper Guide Mylar dirty or deformed? Does PC14 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (Dup) (IC1G) PC1. Does SL31 operate properly? Using the IC Port Data Check function, set the data of PWB-A (Dup) (IC1G) PH1 to “0.” Does PC15 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (Dup) (IC1G) C2. T-40 Result YES Action Clean or change the mylar. YES Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). NO Check the PC14 actuator for operation and, if it operates properly, change PC14. YES Check the Gate Switching Lever for operation. NO Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). Change SL31. YES Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). NO Check the PC15 actuator for operation and, if it operates properly, change PC15. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT030308A 8) AD-9 Paper Take-Up Misfeed Relevant Electrical Parts D Duplex Unit Paper Take-Up Sensor PC16 D Vertical Transport Sensor 3 PC17 D Vertical Transport Drive Motor M21 D Duplex Unit Paper Take-Up Clutch CL31 D Duplex Unit Pick-Up Solenoid SL33 D Duplex Unit Master Board PWB-G D PF-205/105 Master Board PWB-A D EP5000/EP4000 Master Board PWB-A 1156C31TAA T-41 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uAD-9 Paper Take-Up Misfeed Clearing Procedure Symptom Step Check Item 1 Does SL33 operate properly? Using the IC Port Data Check function, set the data of PWB-A (Dup) (IC1G) PB2 to “0.” Paper is not taken up at all. 2 Paper is stationary at the Vertical Transport Section. Does CL33 operate properly? Using the IC Port Data Check function, set the data of PWB-A (Dup) (IC1G) PA3 to “0.” 3 Are the Take-Up Roll, Feed Roll, and Separator Roll deformed, worn, or dirty with paper dust? 1 Is Vertical Transport Drive Motor M21 turning when a copy is taken up and fed into the copier from the Duplex Unit? 2 Are the Vertical Transport Rollers deformed, worn, or dirty with paper dust? 3 Does PC17 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (200, 400) (IC1A) PC3. 4 Does PC16 operate properly? Using the IC Port Data Check function, make an input port check of PWB-A (Dup) (IC1G) PC0. T-42 Result Action YES Check the pick-up mechanism. NO Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). Change SL33. YES Check the drive transmission path. NO Change PWB-G, PWB-A (copier), or PWB-A (PF-205/105). Change CL31. YES Clean or change the defective roll. YES Check the motor for overload. NO Change PWB-A (copier) or PWB-A (PF-205/105). Change M21. YES Clean or change the defective roller. YES Change PWB-A (copier) or PWB-A (PF-205/105). NO Check the PC17 actuator for operation and, if it operates properly, change PC17. YES Change PWB-A (copier) or PWB-A (PF-205/105). NO Check the PC16 actuator for operation and, if it operates properly, change PC16. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1151SBT0400A 4 MALFUNCTIONS 1156SBT0401A 4-1. Detection Timings Classified by Malfunction Codes D The codes marked with an asterisk (*) are the candidates for isolated malfunctions. C00## Drive Malfunctions * Code 1156SBT040101A Description Detection Timing Main Drive Motor M1’s failure to turn The lock signal remains HIGH for a continuous 2.0-sec. or more period while M1 is energized. Main Drive Motor M1 turning at abnormal timing The lock signal remains LOW for a continuous 1.5-sec. or more period while M1 is deenergized. Suction Fan Motor M4’s failure to turn The lock signal remains HIGH for a continuous 1.0-sec. or more period while M4 is energized. C0046 Fusing Section Cooling Fan Motor M15’s failure to turn The lock signal remains HIGH for a continuous 2.0-sec. or more period while M15 is energized. C0047 Fusing Section Cooling Fan Motor M15 turning at abnormal timing The lock signal remains LOW for a continuous 2.0-sec. or more period while M15 is deenergized. C004A Original Glass Cooling Fan Motor M5’s failure to turn The lock signal remains HIGH for a continuous 2.0-sec. or more period while M5 is energized. C004b Original Glass Cooling Fan Motor M5 turning at abnormal timing The lock signal remains LOW for a continuous 2.0-sec. or more period while M5 is deenergized. C004c Ventilation Fan Motor M3’s failure to turn The lock signal remains HIGH for a continuous 2.0-sec. or more period while M3 is energized. C004d Ventilation Fan Motor M3 turning at abnormal timing The lock signal remains LOW for a continuous 2.0-sec. or more period while M3 is deenergized. Main Hopper Toner Replenishing Motor M8’s failure to turn D Toner Bottle Home Position Sensor PC35 does not go from HIGH to LOW within 12 sec. after M8 has been energized. D PC35 does not go LOW within 12 sec. after M8 has been energized and PC35 gone HIGH. Main Hopper Toner Replenishing Motor M8 turning at abnormal timing PC35 is HIGH 2 sec. after M8 has been deenergized. Sub Hopper Toner Replenishing Motor M9’s failure to turn When the current toner-to-carrier ratio is 2% lower than the SCH-90 setting and the Add Toner Indicator is not lit on the control panel, a toner replenishing sequence is carried out (M9 is turned); the toner-to-carrier ratio does not increase by 1% within 140 seconds or by 2% within 220 seconds. C0000 C0001 C0040 * * * C0070 C0071 C0072 T-43 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 C02## Corona Malfunction * 1156SBT040102A Code Description Detection Timing C0200 PC Drum Charge, Image Transfer, Paper Separator Corona malfunction The leak signal (SCD) turns ON after the PC Drum Charge and Image Transfer/Paper Separator Corona output has been turned ON. C03## Master Board/Harness Malfunctions 1156SBT040103A D The copier performs a self-diagnostic sequence to determine if the microprocessor outputs a signal to each of the IC ports on Master Board PWB-A properly. It is intended for detecting the following malfunctions (C03##). D Any malfunction is detected when “Controller Board Check” available from the “I/O Check” function of the Tech. Rep. mode is executed. D If the microprocessor fails to output any of these signals or if any of the electronic components on the board (driver IC, etc.) is faulty, the copier determines that there is a faulty condition existing and shows the corresponding malfunction code on the Touch Panel. D C0350, C0351, C0352, C0353, or C0357 is displayed when there is a communication fault between the copier and paper feeder option or Duplex Unit, and detected as an isolated malfunction when the Power Switch is turned ON. * Code Description Master Board Port C0300 Port diagnosis cannot be started. C0310 Drum Dehumidifying Heater H2 REM signal IC1A P45 — C0311 Fusing Heater Lamp H1 REM signal IC1A P57 C0312 Exposure Lamp Regulator PWB-J REM signal IC1A P61 C0313 AE Sensor Board PWB-H PWM signal IC1A P60 C0314 Image Erase Lamp LA3 DATA IC1A P64 C0315 Image Erase Lamp LA3 MODE IC1A P65 C0316 Image Erase Lamp LA3 CLOCK IC1A P66 C0317 Image Erase Lamp LA3 STROBE IC1A P67 C0318 Copy vendor count (during copy cycle) IC3A APA1 C0319 Copy vendor count (size) IC3A APA0 C031A 2nd Drawer Paper Take-Up Motor M12 energization IC3A φ1 C031B 1st Drawer Paper Take-Up Motor M11 energization IC3A φO C031C Original size detection IC4A APA7 C031D Original size detection, marketing area 2 IC4A APA6 C031E Original size detection, marketing area 1 IC4A APA5 C031F Scanner Motor M2 SCAN signal IC4A APC0 C0320 Scanner Motor M2 ENABLE signal IC4A APC1 C0321 Fusing Section Cooling Fan Motor M15 REM signal IC4A APC2 C0322 Separator/Developing Bias output REM signal IC4A BPA7 C0323 PC Drum Charge/Image Transfer output REM signal IC4A BPA6 C0324 Exit/Duplex Switching Solenoid SL5 IC4A BPA5 C0325 Synchronizing Roller Clutch CL2 IC4A BPA4 C0326 Paper Transport Clutch CL1 IC4A BPA3 C0327 Main Drive Motor M1 REM signal IC4A BPA2 C0328 Main Erase Lamp LA2 REM signal IC4A BPA1 C0329 Separator Solenoid SL1 REM signal IC4A BPA0 T-44 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 * Code Description Master Board Port C032A Main Hopper Toner Replenishing Motor M8 IC4A BPC3 C032B Suction Fan Motor M4 33/ Ventilation Fan Motor M3 IC4A BPC2 C032C Ventilation Fan Motor M3 IC4A BPC1 C032D 2nd Drawer Paper Lift-Up Motor M14 DOWN IC5A APA7 C032E 2nd Drawer Paper Lift-Up Motor M14 UP IC5A APA6 C032F 1st Drawer Paper Lift-Up Motor M13 DOWN IC5A APA5 C0330 1st Drawer Paper Lift-Up Motor M13 UP IC5A APA4 C0331 Separator bias switching IC5A APA3 C0332 Sub Hopper Toner Replenishing Motor M9 IC5A APA2 C0333 2nd Drawer Paper Take-Up Motor M12 ENABLE IC5A APA1 C0334 1st Drawer Paper Take-Up Motor M11 ENABLE IC5A APA0 C0335 Manual Feed Paper Take-Up Solenoid SL4 UP IC5A BPA2 C0336 Manual Feed Paper Take-Up Solenoid SL4 DOWN IC5A BPA3 C0337 Manual Feed Paper Take-Up Clutch CL3 IC5A BPA1 C0338 Warming-up completion signal IC5A BPA7 C0339 During copy cycle IC5A BPA6 C033A SSR2 REM signal (MH only) IC5A BPA5 C033B Exposure Lamp Regulator PWB-J PWM signal IC4A TOUT C033C Grid PWM signal IC5A TOUT C0350 Paper Feed Cabinet S/P-0 IC3 SO0 C0351 Paper Feed Cabinet S/P-1 IC3 SO1 C0352 Duplex Unit S/P-2 IC3 SO2 C0353 Large Capacity Cassette S/P-3 IC3 SO3 IC3 S13 C0357 T-45 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040104A C04## Exposure Lamp Malfunctions * Code Description Detection Timing C0400 Exposure Lamp LA1’s failure to turn ON The output from AE Sensor Board PWB-H does not become 4.0V or more for the period between when LA1 turns ON and the Scanner starts a scan motion and when the Image Leading Edge signal (BASE) turns ON. C0410 Exposure Lamp LA1 turning ON at abnormal timing With LA1 OFF, the output from PWB-H remains 3.9V or less for a continuous 3-sec. period at any timing while the Scanner is at the home position or the Original Cover is lowered. 1156SBT040105A C05## Fusing Malfunctions * Code C0500 Description Detection Timing The surface temperature of the Upper Fusing Roller does not reach a given level even after the lapse of a given period of time during warming-up as detailed below: Warming-up failure (Fusing Heater Lamp failure) D If the temperature is 165_C or less when the Power Switch is turned ON: EP4051 EP3051 From room temperature to 65_C 105S 60S 110S 65_C~140_C 210S 140_C~170_C 220S 120S *170_C~200_C 145S 100S *170_C~190_C 145S 100S D If the temperature is more than 165_C when the Power Switch is turned ON: EP4051 EP3051 *~200_C 200S 120S *~190_C 200S 120S *A 200_C temperature control is provided for the first 1 hour after the Power Switch has been turned ON and 190_C temperature control is provided thereafter. C0510 Abnormally low fusing temperature (Fusing Heater Lamp failure) The surface temperature of the Upper Fusing Roller remains 135°C or less for a continuous 5-sec. period or more after the copier has completed warming up. C0520 Abnormally high fusing temperature (Fusing Heater Lamp turning ON at abnormal timing) The surface temperature of the Upper Fusing Roller remains 230°C or more for a continuous 5-sec. period or more after the copier has completed warming up. T-46 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040106A C06## Optical Malfunctions * Code Description Detection Timing C0600 Scanner Motor M2 malfunction D When the Scanner is at a position other than home, Scanner Reference Position Sensor PC81 does not go from HIGH to LOW even after the lapse of 20 sec. after the Power Switch has been turned ON. D When the Scanner is at the home position, PC81 does not go from LOW to HIGH even after the lapse of 5 sec. after the Scanner has started a scan motion. D PC81 does not go from HIGH to LOW even after the lapse of 20 sec. after the Scanner has started a scan motion. C0610 Lens Motor M6 malfunction The output from Lens Reference Position Sensor PC90 does not go from HIGH to LOW, or vice versa, even after the lapse of 15 sec. after M6 has started turning. C0620 Mirror Motor M7 malfunction D The output from Mirror Reference Position Sensor PC86 does not go from HIGH to LOW even after the lapse of 10 sec. after M7 has started turning. D The output from PC86 does not go from LOW to HIGH even after the lapse of 3 sec. after M7 has started turning. C06F0 SHOME signal failure (Signal does not go LOW) D When the Scanner is at a position other than home, the SHOME signal does not go HIGH even after the lapse of 7 sec. after the SCAN signal has gone LOW. D The SHOME signal is HIGH even after the lapse of 5 sec. after the BASE signal has gone from LOW to HIGH. C06F1 SHOME signal failure (Signal does not go HIGH) The SHOME signal remains LOW even after the lapse of 7 sec. after it has gone LOW. C06F2 BASE signal failure (Signal does not go LOW) The BASE signal does not go LOW even after the lapse of 5 sec. after the SHOME signal has gone HIGH. C06F3 BASE signal failure (Signal does not go HIGH) The BASE signal remains LOW even after the lapse of 5 sec. after the SHOME signal has gone HIGH. C06F4 TRON signal failure (Signal does not go LOW) The TRON signal remains HIGH even after the lapse of 5 sec. after the BASE signal has gone LOW. C06F5 TRON signal failure (Signal does not go HIGH) The TRON signal remains LOW even after the lapse of 5 sec. after it has gone LOW. C06F6 SCEND signal failure (Signal does not go LOW) The SCEND signal remains HIGH even after the lapse of 5 sec. after the TRON signal has gone LOW. C06F7 SCEND signal failure (Signal does not go HIGH) The SCEND signal remains LOW even after the lapse of 5 sec. after it has gone LOW. T-47 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040107A C09## Paper Take-Up Malfunctions * Code Detection Timing 3rd Drawer upward motion failure C0901 (Inch Area) 3rd Drawer downward motion failure C0902 (Inch Area) 3rd Drawer downward motion failure C0903 (Inch Area) 3rd Drawer upward motion failure C0904 * Description C0900 C0906 (Inch Area) C0950 3rd Drawer Lift-Up Motor M24’s failure to turn 3rd Drawer ejection failure See PF-205 Service Manual. 4th Drawer upward motion failure C0951 (Inch Area) 4th Drawer downward motion failure C0952 (Inch Area) 4th Drawer downward motion failure C0953 (Inch Area) 4th Drawer upward motion failure C0954 C0956 (Inch Area) 4th Drawer Lift-Up Motor M25’s failure to turn 4th Drawer ejection failure T-48 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 * Code Description Detection Timing 2nd Drawer upward motion failure D 2nd Drawer Lift-Up Sensor PC66 is not blocked (L) even after the lapse of 5 sec. after 2nd Drawer Paper Lift-Up Motor M14 has been energized. D PC66 is not blocked (L) even if 2nd Drawer LiftUp Motor Pulse Sensor PC68 detects 75 pulses after M14 has been energized. 2nd Drawer downward motion failure D When PC66 is blocked (L), it is not unblocked (H) even after the lapse of 5 sec. after M14 has been energized. D PC66 is not unblocked (H) even if PC68 detects 10 pulses after M14 has been energized. 2nd Drawer downward motion failure D When PC66 is unblocked (H), 2nd Drawer Lower Limit Position Sensor PC70 is not blocked (L) even after the lapse of 5 sec. after M14 has been energized. D PC70 is not unblocked (H) even after the lapse of 1.5 sec. after it has been blocked (L). D PC70 is not blocked (L) even if PC68 detects 75 pulses after M14 has been energized. D PC70 is not blocked (L) even after the lapse of 2 sec. after M14 has been energized. 2nd Drawer upward motion failure D When PC70 is blocked (L), it is not unblocked (H) even after the lapse of 5 sec. after M14 has been energized. D PC70 is not unblocked (H) even after the lapse of 2 sec. after it has been blocked (L). 2nd Drawer Paper Lift–Up Motor M14’s failure to turn D PC68 detects no pulses even after the lapse of 500 msec. after M14 has been energized. D PC68 detects no pulses for the period of 200 msec. while M14 is being energized. 2nd Drawer ejection failure D The 2nd Drawer is not ejected even after the lapse of 2 sec. after PC70 has been blocked (L). 1st Drawer upward motion failure D 1st Drawer Lift-Up Sensor PC65 is not blocked (L) even after the lapse of 5 sec. after 1st Drawer Paper Lift-Up Motor M13 has been energized. D PC65 is not blocked (L) even if 1st Drawer LiftUp Motor Pulse Sensor PC67 detects 75 pulses after M13 has been energized. 1st Drawer downward motion failure D When PC65 is blocked (L), it is not unblocked (H) even after the lapse of 5 sec. after M13 has been energized. D PC65 is not unblocked (H) even if PC67 detects 10 pulses after M13 has been energized. 1st Drawer downward motion failure D When PC65 is unblocked (H), 1st Drawer Lower Limit Position Sensor PC69 is not blocked (L) even after the lapse of 5 sec. after M13 has been energized. D PC69 is not unblocked (H) even after the lapse of 1.5 sec. after it has been blocked (L). D PC69 is not blocked (L) even if PC67 detects 75 pulses after M13 has been energized. D PC69 is not blocked (L) even after the lapse of 2 sec. after M13 has been energized. 1st Drawer upward motion failure D When PC69 is blocked (L), it is not unblocked (H) even after the lapse of 5 sec. after M13 has been energized. D PC69 is not unblocked (H) even after the lapse of 2 sec. after it has been blocked (L). C0910 C0911 C0912 C0913 C0914 * C0916 C0920 C0921 C0922 C0923 T-49 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 * Code C0924 Description D PC67 detects no pulses even after the lapse of 500 msec. after M13 has been energized. D PC67 detects no pulses for the period of 200 msec. while M13 is being energized. 1st Drawer ejection failure D The 1st Drawer is not ejected even after the lapse of 2 sec. after PC69 has been blocked (L). * C0926 Detection Timing 1st Drawer Paper Lift–Up Motor M13’s failure to turn T-50 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 * * Code Description Detection Timing C0990 Main Tray upward motion failure C0991 Main Tray downward motion failure C0992 Main Tray downward motion failure C0993 Main Tray upward motion failure C0994 Elevator Motor M26’s failure to turn C0996 Main Tray ejection failure C0998 Shifter transfer failure C0999 Shifter return failure C099A Shifter return failure C099b Shifter transfer failure C099C Shift Motor M27’s failure to turn C099E Shift Gate position detecting failure See PF-105 Service Manual. C099F Shift Gate position detecting failure C09C0 Elevator ascent fault C09C2 Elevator descent fault See C-301 Service Manual. T-51 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040108A C0E## Erase Lamp Malfunctions * Code Description Detection Timing C0E00 Main Erase Lamp LA2’s failure to turn ON The LA2 Failure Detection signal remains HIGH for a continuous 1-sec. period while LA2 is ON. C0E01 Main Erase Lamp LA2 turning ON at abnormal timing The LA2 Failure Detection signal remains LOW for a continuous 1-sec. period while LA2 is OFF. Image Erase Lamp LA3’s failure to turn ON The LA3 gate array is faulty as found through a self-diagnostic sequence carried out immediately after Main Drive Motor M1 has been deenergized. C0E20 1156SBT040109A C0F## Sensor Malfunctions * * Code * * Detection Timing D Undefined data is input to the master CPU. D Under normal conditions: A fixed-cycle pulse signal (Busy) remains HIGH or LOW for 3 sec. or more. D When the Power Switch is ON: A fixed-cycle pulse signal (Busy) remains HIGH or LOW for 5 sec. or more. AE Sensor Board PWB-H malfunction The output from PWB-H remains approx. 0.18V or less for a continuous 2-sec. period, with the Exposure Lamp OFF, the Scanner at the home position, and the Original Cover lowered. AIDC Sensor Board PWB-G variation correction failure In the initial F5 or FF mode: D The output from PWB-G is 1V or more when the load resistance is made maximum by the 4-bit analog switch. D The output from PWB-G is less than 1V when the load resistance is made minimum by the 4-bit analog switch. D The output from PWB-G does not fall within the 0.9V-1.1V range when the intensity of PWB-G LED is varied. AIDC Sensor Board PWB-G grid voltage (Vg) correction failure In the initial F5 or FF mode: 1) Vg of 580V is output. 2) A solid black pattern is produced and the PWB-G output is sampled. 3) If the average is less than 4.3V, Vg is increased. AIDC Sensor Board PWB-G exposure correction failure In the initial F5 or FF mode: 1) The Exposure Lamp is turned ON with 58V. 2) A halftone pattern is produced and the PWB-G output is sampled. 3) If the average does not fall within the target range, the exposure level is varied. 4) The average does not fall within the target range even after steps 1) to 3) have been repeated 15 times. C0F02 C0F10 * Description Original Size Detecting Board UN2 malfunction C0F20 C0F22 C0F23 T-52 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 * * Code C0F30 Description Detection Timing ATDC Sensor UN3 adjustment failure The UN3 output does not fall within the target range in the F8 mode. ATDC Sensor UN3 failure D The “ATDC Ref. Value” of “Level History” drastically deviates from the value set in the FF mode. D The UN3 output remains 0.5V or less or 4.2V or more for a consecutive 3-sec. period 2 sec. after Main Drive Motor M1 has been energized. D 3rd Drawer Paper Empty Sensor PC20 failure D Main Tray Paper Empty Board PWB-E failure D Shift Tray Paper Empty Sensor PC1 failure See the PF-105 Service Manual. D Paper Empty Sensor EMPSEN failure See the C-301 Service Manual. C0F31 C0F79 T-53 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Original Size Detecting Board d* Code Description Sensor Layout C0FE1 Original Size Detecting Sensor Ê failure After having read the output data from PC115 to PC119, UN2 determines that there is a failure. C0FE2 Original Size Detecting Sensor Ë failure C0FE3 Original Size Detecting Sensors Ê and Ë failure C0FE4 Original Size Detecting Sensor Ì failure C0FE5 Original Size Detecting Sensors Ê and Ì failure C0FE6 Original Size Detecting Sensors Ë, and Ì failure C0FE7 Original Size Detecting Sensors Ê,Ë, and Ì failure C0FE8 Original Size Detecting Sensor Í failure C0FE9 Original Size Detecting Sensors Ê and Í failure C0FEA Original Size Detecting Sensors Ë and Í failure C0FEB Original Size Detecting Sensors Ê,Ë, and Í failure C0FEC Original Size Detecting Sensors Ì and Í failure C0FED Original Size Detecting Sensors Ê,Ì, and Í failure C0FEE Original Size Detecting Sensors Ë,Ì, and Í failure C0FEF Original Size Detecting Sensors Ê,Ë,Ì, and Í failure Metric Areas D Ê: PC116, Ë: PC117, Ì: PC118 (option), Í: PC115, Î: PC119 (option) D A to E: Sensor locations Ê A Ì Ë B C D E A B Í Î Inch Areas D Ê: PC116 (option), Ë: PC117, Ì: PC118 (option), Í: PC115, Î: PC119 (option) Ê A B A B Î T-54 Ì Ë Í C D E Original S Size Detecting Board * Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Code Description C0FF0 Original Size Detecting Sensor Î failure Sensor Layout C0FF1 Original Size Detecting Sensors Êand Î failure C0FF2 Original Size Detecting Sensors Ë and Î failure C0FF3 Original Size Detecting Sensors Ê,Ë, and Î failure C0FF4 Original Size Detecting Sensors Ì and Î failure C0FF5 Original Size Detecting Sensors Ê,Ì, and Î failure C0FF6 Original Size Detecting Sensors Ë,Ì, and Î failure C0FF7 Original Size Detecting Sensors Ê,Ë,Ì, and Î failure C0FF8 Original Size Detecting Sensors Í and Î failure C0FF9 Original Size Detecting Sensors Ê,Í, and Î failure C0FFA Original Size Detecting Sensors Ë,Í, and Î failure C0FFB Original Size Detecting Sensors Ê,Ë,Í, and Î failure C0FFC Original Size Detecting Sensors Ì,Í, and Î failure C0FFD Original Size Detecting Sensors Ê,Ì,Í, and Î failure C0FFE Original Size Detecting Sensors Ë,Ì,Í, and Î failure C0FFF Original Size Detecting Sensors Ê,Ë,Ì,Í, and Î failure (Metric Areas) Metric Areas D Ê: PC116, Ë: PC117, Ì: PC118 (option), Í PC115, Î Í: Î: PC119 (option) D A to E: Sensor locations Ê A Ì Ë B C D E A B Í Î Inch Areas D Ê: PC116 (option), Ë: PC117, Ì: PC118 (option), Í: PC115, Î: PC119 (option) Ê A B A B Î T-55 Ì Ë Í C D E Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040110A C0b## Staple Sorter/Sorter Malfunctions * Code Description C0b00 Transport drive malfunction See the ST-210/S-207 Service Manual. Detection Timing Paper Clamp Unit motion failure See the ST-210/S-207, ST-101/S-104 Service Manual. C0b01 C0b10 C0b11 C0b12 See the ST-210/S-207 Service Manual. C0b13 C0b30 Paper Aligning Mechanism drive failure C0b31 C0b50 See the ST-210/S-207, ST-101/S-104 Service Manual. Stapling failure C0b51 C0b52 C0b53 C0b60 * Bin motion failure See the ST-210/S-207, ST-101/S-104 Service Manual. Hole punching failure See the ST-210/S-207 Service Manual. C0b61 C0b62 C0b63 C0b64 C0b65 C0b70 C0b71 C0b72 1156SBT040111A C0d## Duplex Unit Malfunctions * Code Description Detection Timing C0d00 Front/Rear Edge Guide Plates home position detection failure C0d20 Gate Unit home position detection failure C0d50 Duplex Unit Drive Motor M31’s failure to turn C0d51 Duplex Unit Drive Motor M31 turning at abnormal timing T-56 See the AD-5 Service Manual. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT0402A 4-2. Troubleshooting Procedures 1156SBT040201A 1) C0000: Main Drive Motor M1’s Failure to Turn C0001: Main Drive Motor M1 Turning at Abnormal Timing Relevant Electrical Parts D Main Drive Motor M1 D Master Board PWB-A 1156C05TAA T-57 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0000 Step Check Item 1 Does M1 turn? Set the data of PWB-A (IC4A) BPA2 to “0.” 2 Result Perform the “Controller Board Check.” Is malfunction code “C0327” displayed? Action Change PWB-A. YES YES Change PWB-A. D Check the drive coupling. NO D Change M1. uC0001 Step Check Item Result 1 Does M1 turn when the malfunction is reset? YES 2 Is malfunction code “C0001” displayed again? YES T-58 Action Change PWB-A. Change PWB-A. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040202A 2) C0040: Suction Fan Motor M4’s Failure to Turn Relevant Electrical Parts D Suction Fan Motor M4 D Master Board PWB-A 1156C06TAA T-59 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0040 Step Check Item 1 Does M4 turn? Set the data of PWB-A (IC4A) BPC2 to “0.” Result 2 Perform the “Controller Board Check.” Is malfunction code “C032B” displayed? Action Change PWB-A. YES YES Change PWB-A. NO D Change M4. uC0011 Step Check Item Result 1 Does M4 turn when the malfunction is reset? YES 2 Is malfunction code “C0011” displayed again? YES T-60 Action Change PWB-A. Change PWB-A. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040203A 3) C0046: Fusing Section Cooling Fan Motor M15’s Failure to Turn C0047: Fusing Section Cooling Fan Motor M15 Turning at Abnormal Timing Relevant Electrical Parts D Fusing Section Cooling Fan Motor M15 D Master Board PWB-A 1156C07TAA T-61 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0046 Step Check Item 1 Does M15 turn? Set the data of PWB-A (IC4A) APC2 to “0.” Result 2 Perform the “Controller Board Check.” Is malfunction code “C0321” displayed? Action Change PWB-A. YES YES Change PWB-A. NO D Change M15. uC0047 Step Check Item 1 Does M15 turn when the malfunction is reset? Result YES 2 Is malfunction code “C0047” displayed again? YES T-62 Action Change PWB-A or M15 Change PWB-A or M15 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040204A 4) C004A: Original Glass Cooling Fan Motor M5’s Failure to Turn C004b: Original Glass Cooling Fan Motor M5 Turning at Abnormal Timing C004C: Ventilation Fan Motor M3’s Failure to Turn C004d: Ventilation Fan Motor M3 Turning at Abnormal Timing Relevant Electrical Parts D Original Glass Cooling Fan Motor M5 D Ventilation Fan Motor M3 D Master Board PWB-A 1156C08TAA T-63 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC004A Step Check Item Result YES Change PWB-A. 1 Does M5 turn? Set the data of PWB-A (IC4A) BPC0 to “0.” Action NO Change M5. uC004b Step Check Item Result 1 Does M5 turn when the malfunction is reset? YES 2 Is malfunction code “C004b” displayed again? YES Action Change PWB-A. Change PWB-A. uC004C Step Check Item 1 Does M3 turn? Set the data of PWB-A (IC4A) BPC1 to “0.” Result Action YES Change PWB-A. NO Change M3. uC004d Step Check Item Result 1 Does M3 turn when the malfunction is reset? YES 2 Is malfunction code “C004d” displayed again? YES T-64 Action Change PWB-A. Change PWB-A. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040205A 5) C0070: Main Hopper Toner Replenishing Motor M8’s Failure to Turn C0071: Main Hopper Toner Replenishing Motor M8 Turning at Abnormal Timing C0072: Sub Hopper Toner Replenishing Motor M9’s Failure to Turn Relevant Electrical Parts D Main Hopper Toner Replenishing Motor M8 D Sub Hopper Toner Replenishing Motor M9 D Toner Bottle Home Position Sensor PC35 D Master Board PWB-A 1156C09TAA T-65 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0070 Step Check Item Result 1 Turn the Toner Bottle a half turn by hand and close the Front Door. Does the Toner Bottle turn at this time? NO 2 Does PC35 operate properly? Make an input port check on PWB-A (IC4A) BPC5. NO 3 Perform the “Controller Board Check.” Is malfunction code “C032A” displayed? Action Go to step 3. Change PC35. YES Change PWB-A. NO Change M8. uC0071 Step Check Item Result 1 Does M8 turn when the malfunction is reset? YES 2 Is malfunction code “C0071” displayed again? YES Action Change PWB-A. Change PWB-A. uC0072 Step Check Item 1 Does M9 turn? Set the data of PWB-A (IC5A) APA2 to “0.” Result 2 Perform the “Controller Board Check.” Is malfunction code ”C0332” displayed? Action Change PWB-A. YES YES Change PWB-A. NO Change M9. T-66 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040206A 6) C0200: Corona Malfunctions Relevant Electrical Parts D High Voltage Unit HV1 D Master Board PWB-A 1156C10TAA Step Check Item 1 Is “C0200” displayed even when the PC Drum Charge Corona and Image Transfer/Paper Separator Coronas are removed? Result Action YES 2 Is “C0200” displayed when the PC Drum Charge Corona is installed? YES 3 Is “C0200” displayed when the Image Transfer/Paper Separator Coronas unit is installed? YES Clean or change the Image Transfer/ Paper Separator Coronas. Is “C0200” displayed even when the HV1 connector is unplugged? YES Change PWB-A. 4 NO Change HV1. Go to step 4. T-67 Clean or change the PC Drum Charge Corona. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040207A 7) C03##: Master Board/Harness Malfunctions Relevant Electrical Parts D Master Board PWB-A D PF-205/105 Master Board PWB-A D Duplex Unit Master Board PWB-G uC0300 to C033C Step 1 Action Change Master Board PWB-A. uC0350, C0351 Step Action 1 Check the connections from PJ20A on PWB-A to PJ13A on PF–205/105 PWB-A. 2 Change PWB-A or PF-205/105 PWB-A. uC0352 Step Action 1 Check the connections from PJ20A on PWB-A to PJ8G on Duplex Unit Master Board PWBG. 2 Change PWB-A, PF-205/105 PWB-A, or Duplex Unit Master Board PWB-G. uC0353, C0357 Step Action 1 Check the connections from PJ20A on PWB-A to CN1A on C-301 PWB-A. 2 Change PWB-A or C-301 PWB-A. T-68 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040208A 8) C0400: Exposure Lamp LA1’s Failure to Turn ON C0410: Exposure Lamp LA1 Turning ON at Abnormal Timing Relevant Electrical Parts D Exposure Lamp LA1 D Exposure Thermal Fuse TF1 D Exposure Lamp Regulator PWB-J D AE Sensor Board PWB-H D Master Board PWB-A 1156C11TAA T-69 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Step Check Item Result 1 Does the voltage across PWB-A PJ8A-13 and GND become DC0V (L) when the Start key is pressed? YES 2 Perform the “Controller Board Check.” Is malfunction code “C0312” or “C033B” displayed? YES 3 Disconnect CN7. Is there continuity across CN7-1 and -2 on LA1 side? NO 4 Is the voltage across PJ3J-1 and –3 on PWB-J the source voltage? 5 Is the voltage across PWB-A PJ3A-2 and GND 3.9V or less when LA1 is off, the Scanner is at the home position, and the Original Cover is lowered? Action Go to step 2. Change PWB-A. Change LA1 or TF1. YES Change PWB-J. NO Check the power supply line. YES NO T-70 Change PWB-A. Change PWB-H. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040209A 9) C0500: Warming-up Failure C0510: Abnormally Low Fusing Temperature C0520: Abnormally High Fusing Temperature Relevant Electrical Parts D Fusing Heater Lamp H1 D Fusing Thermoswitch TS1 D Fusing Thermistor TH1 D Fusing Thermistor TH2 D Fusing Heater Lamp SSR SSR1 D Master Board PWB-A 1156C12TAA T-71 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0500, C0510 Step Check Item Result Action 1 Does H1 light up when the Power Switch is turned ON? NO 2 Is TH1 installed properly? NO Reinstall TH1. 3 Is TH1 dirty? YES Clean or change TH1. 4 Measure resistance of TH1. Is is infinite? YES Change TH1. NO Change PWB-A. 5 Perform the “Controller Board Check.” Is malfunction code “C0311” displayed? 6 Check H1 for continuity. Is there continuity? YES Go to step 5. Change PWB-A. YES Change SSR1. NO Change H1 or TS1. uC0520 Step Check Item 1 Does H1 remain lit after the copier has warmed up? Result NO 2 Perform the “Controller Board Check.” Is malfunction code “C0311” displayed? YES 3 Does H1 turn OFF? NO Change SSR1. 4 Is TH1 installed properly? NO Reinstall TH1. 5 Is TH1 dirty? YES Clean or change TH1. 6 Measure resistance of TH1. Is is 0 Ω or close to 0? YES Change TH1 (TH2). NO Change PWB-A. T-72 Action Go to step 4. Change PWB-A. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040210A 10) C0600: Scanner Motor M2 Malfunction C06FX: Signal Failure Relevant Electrical Parts D Scanner Motor M4 D Power Supply Unit PU1 D SCP Board PWB-F D Master Board PWB-A 1156C13TAA T-73 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0600 Step Check Item Result Action 1 Are all connectors on PWB-F plugged in securely? Plug them in securely. NO 2 Is the voltage across PWB-F PJ1F-2 and GND DC5V? NO Check the connection of the DC5V line and, if it is intact, change PU1. Perform the “Controller Board Check.” Is malfunction code ”C031F” or “C0320” displayed? YES Change PWB-A. 3 NO Change PWB-F or M2. uC06FX Step 1 Check Item Are PWB-A PJ8A and PWB-F PJ2F connected securely? Result Action YES Change PWB-A or PWB-F. NO Connect securely. T-74 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040211A 11) 0610: Lens Motor M6 Malfunction 0620: Mirror Motor M7 Malfunction Relevant Electrical Parts D Mirror Reference Position Sensor PC86 D Lens Reference Position Sensor PC90 D Lens Motor M6 D Mirror Motor M7 D SCP Board PWB-F D Master Board PWB-A 1156C14TAA T-75 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0610 Step Check Item 1 Are all connectors on PWB-F, M6, and PC90 plugged in securely? Result NO 2 Does the voltage across PWB-F PJ6F-5 and GND change from DC5V to DC0V when PC90 is blocked? NO Is the Lens drive defective? YES Correct or change the defective part. NO Change PWB-F or M6. 3 Action Plug them in securely. Change PC90. uC0620 Step Check Item 1 Are all connectors on PWB-F, M7, and PC86 plugged in securely? NO 2 Does the voltage across PWB-F PJ6F-2 and GND change from DC5V to DC0V when PC86 is blocked? NO Is the Mirror drive defective? YES Correct or change the defective part. NO Change PWB-F or M7. 3 Result Action Plug them in securely. Change PC86. T-76 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040212A 12) C0910: 2nd Drawer Upward Motion Failure C0914: 2nd Drawer Paper Lift-Up Motor M14’s Failure to Turn C0920: 1st Drawer Upward Motion Failure C0924: 1st Drawer Paper Lift-Up Motor M13’s Failure to Turn Relevant Electrical Parts D 1st Drawer Lift-Up Sensor PC65 D 2nd Drawer Lift-Up Sensor PC66 D 1st Drawer Lift-Up Motor Pulse Sensor PC67 D 2nd Drawer Lift-Up Motor Pulse Sensor PC68 D 1st Drawer Paper Lift-Up Motor M13 D 2nd Drawer Paper Lift-Up Motor M14 D Master Board PWB-A D Power Supply Board PWB-C 1156C15TAA T-77 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0910 Step Check Item Result YES Change PWB-A. 1 Does PC66 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB2. Action NO Check the Paper Take-Up Roll for operation. If it is operational, change PC66. uC0920 Step Check Item Result YES Change PWB-A. 1 Does PC65 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB1. Action NO Check the Paper Take-Up Roll for operation. If it is operational, change PC65. uC0914 Step Check Item 1 Slide out the 2nd Drawer and slide it back into the copier. Does M14 turn at this time? 2 Perform the “Controller Board Check.” Is malfunction code “C032E” displayed? 3 4 Result Does the voltage across PWB-C PJ9C-4 and GND change from DC0V to DC24V when the 2nd Drawer is slid back into the copier? Does the voltage across PWB-A PJ23A-5 and GND vary between DC0V and DC5V while M14 is turning? Action Go to step 4. YES YES Change PWB-A. NO Replace PWB-A. YES NO Change M14. Change PWB-C. YES Change PWB-A. NO Change PC68. uC0924 Step Check Item 1 Slide out the 1st Drawer and slide it back into the copier. Does M13 turn at this time? YES 2 Perform the “Controller Board Check.” Is malfunction code “C033O” displayed? YES 3 Does the voltage across PWB-C PJ9C-2 and GND change from DC0V to DC24V when the 1st Drawer is slid back into the copier? 4 Result Does the voltage across PWB-A PJ23A-7 and GND vary between DC0V and DC5V while M13 is turning? Action Go to step 4. Change PWB-A. YES NO Change M13. Change PWB-C. YES Change PWB-A. NO Change PC67. T-78 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040213A 13) C0900: 3rd Drawer Upward Motion Failure C0904: 3rd Drawer Paper Lift-Up Motor M24’s Failure to Turn C0950: 4th Drawer Upward Motion Failure C0954: 4th Drawer Paper Lift-Up Motor M25’s Failure to Turn Relevant Electrical Parts D 3rd Drawer Paper Lift-Up Sensor PC19 D 4th Drawer Paper Lift-Up Sensor PC23 D 3rd Drawer Paper Lift-Up Motor Pulse Sensor PC27 D 4th Drawer Paper Lift-Up Motor Pulse Sensor PC28 D 3rd Drawer Paper Lift-Up Motor M24 D 4th Drawer Paper Lift-Up Motor M25 D PF-205 Master Board PWB-A 1156C25TAA T-79 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0950 Step Check Item Result YES Change PF-205 PWB-A. 1 Does PC19 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) (IC1A) PG3. Action NO Check the Paper Take-Up Roll for operation. If it is operational, change PC19. uC0900 Step Check Item Result YES Change PF–205 PWB-A. 1 Does PC23 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (200) (IC1A) PF3. Action NO Check the Paper Take-Up Roll for operation. If it is operational, change PC23. uC0904 Step Check Item 1 Slide out the 3rd Drawer and slide it back into the copier. Does M24 turn at this time? 2 Does the voltage across PF-205 PWBA PJ9A-8B and GND change from DC0V to DC24V when the 3rd Drawer is slid back into the copier? 3 Result Does the voltage across PF-205 PWBA PJ9A-5B and GND vary between DC0V and DC5V while M24 is turning? Action Go to step 3. NO YES NO Change M24. Change PF-205 PWB-A. YES Change PF-205 PWB-A. NO Change PC27. uC0954 Step Check Item 1 Slide out the 4th Drawer and slide it back into the copier. Does M25 turn at this time? 2 Does the voltage across PF-205 PWBA PJ9A-2A and GND change from DC0V to DC24V when the 4th Drawer is slid back into the copier? 3 Result Does the voltage across PF-205 PWBA PJ9A-4A and GND vary between DC0V and DC5V while M25 is turning? Action Go to step 3. NO YES NO Change M25. Change PF-205 PWB-A. YES Change PF-205 PWB-A. NO Change PC28. T-80 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040214A 14) C0911: 2nd Drawer Upward Motion Failure (Inch Areas) C0912: 2nd Drawer Downward Motion Failure C0913: 2nd Drawer Upward Motion Failure C0916: 2nd Drawer Ejection Failure Relevant Electrical Parts D 2nd Drawer Lift-Up Sensor PC66 D 2nd Drawer Lower Limit Position Sensor PC70 D 2nd Drawer Flexible Printed Circuit Board PWB-M2 D Master Board PWB-A 1156C35TAA T-81 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0911 Step Check Item 1 Does PC66 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB2. Result YES NO Action Replace PWB-A. Replace PC66 or PWB-M2. uC0912, C0913 Step Check Item 1 Does PC70 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) BPA3. Result YES NO Action Replace PWB-A. Replace PC70 or PWB-M2. uC0916 Step Check Item Result 1 Remove the Right Door, lift up the Lock Lever with a flat-blade screwdriver to unlock and slide out the 2nd Drawer. – 2 Is the Lock Release Spring installed properly? NO 3 Are the Lock Lever and Torsion Spring installed properly? NO T-82 Action Reinstall or change. Reinstall or change. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040215A 15) C0921: 1st Drawer Upward Motion Failure (Inch Areas) C0922: 1st Drawer Downward Motion Failure C0923: 1st Drawer Upward Motion Failure C0926: 1st Drawer Ejection Failure Relevant Electrical Parts D 1st Drawer Lift-Up Sensor PC65 D 1st Drawer Lower Limit Position Sensor PC69 D 1st Drawer Flexible Printed Circuit Board PWB-M1 D Master Board PWB-A 1156C36TAA T-83 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0921 Step Check Item 1 Does PC65 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) APB1. Result YES NO Action Replace PWB-A. Replace PC65 or PWB-M1. uC0922, C0923 Step Check Item 1 Does PC69 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (IC3A) BPA2. Result YES NO Action Replace PWB-A. Replace PC69 or PWB-M1. uC0926 Step Check Item Result 1 Remove the Right Door, lift up the Lock Lever with a flat-blade screwdriver to unlock and slide out the 1st Drawer. – 2 Is the Lock Release Spring installed properly? NO 3 Are the Lock Lever and Torsion Spring installed properly? NO T-84 Action Reinstall or change. Reinstall or change. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040216A 16) C0901: 3rd Drawer Upward Motion Failure (Inch Areas) C0902: 3rd Drawer Downward Motion Failure C0903: 3rd Drawer Upward Motion Failure C0906: 3rd Drawer Ejection Failure Relevant Electrical Parts D 3rd Drawer Lift-Up Sensor PC19 D 3rd Drawer Lower Limit Position Sensor PC69 D 3rd Drawer Flexible Printed Circuit Board PWB-M1 D PF-205 Master Board PWB-A 1156C37TAA T-85 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0901 Step Check Item 1 Does PC19 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (MC) (IC1A) PG3. Result YES NO Action Replace PWB-A (PF-205). Replace PC19 or PWB-M1. uC0902, C0903 Step Check Item 1 Does PC69 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (MC) (IC2A) PD1. Result YES NO Action Replace PWB-A (PF-205). Replace PC69 or PWB-M1. uC0906 Step Check Item Result 1 Remove the Right Door, lift up the Lock Lever with a flat-blade screwdriver to unlock and slide out the 3rd Drawer. – 2 Is the Lock Release Spring installed properly? NO 3 Are the Lock Lever and Torsion Spring installed properly? NO T-86 Action Reinstall or change. Reinstall or change. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040217A 17) C0951: 4th Drawer Upward Motion Failure (Inch Areas) C0952: 4th Drawer Downward Motion Failure C0953: 4th Drawer Upward Motion Failure C0956: 4th Drawer Ejection Failure Relevant Electrical Parts D 4th Drawer Lift-Up Sensor PC23 D 4th Drawer Lower Limit Position Sensor PC70 D 4th Drawer Flexible Printed Circuit Board PWB-M2 D PF-205 Master Board PWB-A 1156C38TAA T-87 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0951 Step Check Item 1 Does PC23 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (MC) (IC1A) PF3. Result YES NO Action Replace PWB-A (PF-205). Replace PC23 or PWB-M2. uC0952, C0953 Step Check Item 1 Does PC70 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (MC) (IC2A) PC0. Result YES NO Action Replace PWB-A (PF-205). Replace PC70 or PWB-M2. uC0956 Step Check Item Result 1 Remove the Right Door, lift up the Lock Lever with a flat-blade screwdriver to unlock and slide out the 4th Drawer. – 2 Is the Lock Release Spring installed properly? NO 3 Are the Lock Lever and Torsion Spring installed properly? NO T-88 Action Reinstall or change. Reinstall or change. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040218A 18) C0990: Main Tray Upward Motion Failure C0991: Main Tray Downward Motion Failure C0992: Main Tray Downward Motion Failure C0993: Main Tray Upward Motion Failure C0994: Elevator Motor M26’s Failure to Turn Relevant Electrical Parts D D D D Main Tray Lower Position Sensor PC2 Elevator Motor Pulse Sensor PC5 3rd Drawer Paper Lift-Up Sensor PC19 Lower Limit Position Sensor PC35 D Cabinet Transport Board PWB-H D PF-105 Master Board D Main Tray Elevator Motor M26 1156C27TAA T-89 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0990, C0991 Step Check Item Result YES Change PF-105 PWB-A. 1 Does PC19 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PG3. Action NO Check the Paper Take-Up Roll for operation and, if it is operational, change PC19. uC0992, C0993 Step Check Item 1 Does PC35 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC2A) PB3. 2 Result Does PC2 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC2A) PC1. YES NO YES NO Action Change PF-105 PWB-A. Change PWB-H, flat cable, or PC35. Change PF-105 PWB-A. Change PC2, PWB-H, or flat cable. uC0994 Step Check Item Result 1 Does M26 turn when the Paper Descent key is pressed? 2 Does the voltage across PF-105 PWBA PJ4A-6B or PJ4A-7B and GND change from DC0V to DC24V when the Tray is slid in or the Paper Descent key is pressed? 3 YES Does the voltage across PF-105 PWBA PJ4A-5A and GND vary between DC0V and DC5V while M26 is turning? YES NO Action Go to step 3. Change M26, PWB-H, or flat cable. Change PF-105 PWB-A. YES Change PF-105 PWB-A. NO Check the pulse disk and gear. Change PC5. T-90 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040219A 19) C0998: Shifter Transfer Failure C0999: Shifter Return Failure C099A: Shifter Return Failure C099b: Shifter Transfer Failure C099C: Shift Motor M27’s Failure to Turn Relevant Electrical Parts D Shifter Home Position Sensor PC3 D Shifter Return Position Sensor PC4 D Shift Motor Pulse Sensor PC6 D Paper Shift Motor M27 D Cabinet Transport Board PWB-H D PF-105 Master Board PWB-A 1156C28TAA T-91 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0998, C0999 Step Check Item 1 Does PC4 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC2A) PD1. Result YES NO Action Change PF-105 PWB-A. Change PC4, PWB-H, or flat cable. uC099A, C099b Step Check Item 1 Does PC3 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC2A) PC0. Result YES NO Action Change PF-105 PWB-A. Change PC3, PWB-H, or flat cable. uC099C Step Check Item 1 Does M27 turn when the 3rd Drawer is slid into the copier with a paper stack loaded in the Shift Tray? In step 1, does the voltage across PF-105 PWB-A PJ4A-5B and GND change from DC0V to DC24V? YES Change M27, PWB-H, or flat cable. 2 NO Change PF-105 PWB-A. Does the voltage across PF-105 PWBA PJ4A-3A and GND vary between DC0V and DC5V while M27 is turning? YES Change PF-105 PWB-A. NO Check the pulse disk and gear. Change PC6. 3 Result Action Go to step 3. YES T-92 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040220A 20) C099E: Shift Gate Position Detecting Failure C099F: Shift Gate Position Detecting Failure C0996: 3rd Drawer Lock Release Failure C0F79: Paper Empty Sensor Failure Relevant Electrical Parts D Shift Tray Paper Empty Sensor PC1 D 3rd Drawer Paper Empty Sensor PC20 D Main Tray Paper Empty Board PWB-E D 3rd Drawer Set Sensor PC7 D Shift Gate Position Detecting Sensor PC34 D 3rd Drawer Lock Solenoid SL41 D Cabinet Transport Board PWB-H D PF-105 Master Board PWB-A 1156C29TAA T-93 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC099E, C099F Step Check Item 1 Does PC34 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PC1. Result YES NO Action Change PF-105 PWB-A. Change PC34, PWB-H, or flat cable. uC0996 Step Check Item 1 Does SL41 operate properly? Using the IC Port Data Check function, set the data of PWB-A (400) (IC2A) PA1 to ”0.” 2 Result Does PC7 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PG2. YES NO YES NO Action Check the drawer lock mechanism. Change PF-105 PWB-A or SL41. Change PF-105 PWB-A. Change PC7, PWB-H, or flat cable. uC0F79 Step Check Item 1 Does PC20 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PC0. 2 3 Result Does PWB-E operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PF3. Does PC1 operate properly? Using the IC Port Data Check function, make an input port check on PWB-A (400) (IC1A) PD1. YES NO YES NO YES NO T-94 Action Change PF-105 PWB-A. Change PC20, PWB-H, or flat cable. Change PF-105 PWB-A. Change PWB-E, PWB-H, or flat cable. Change PF-105 PWB-A. Change PC1, PWB-H, or flat cable. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040221A 21) C0d00: Duplex Unit Front/Rear Edge Guide Plate Home Position Detection Failure C0d20: Duplex Unit Gate Unit Home Position Detection Failure C0d50: Duplex Unit Drive Motor M31’s Failure to Turn C0d51: Duplex Unit Drive Motor M31 Turning at Abnormal Timing Relevant Electrical Parts D Duplex Gate Home Position Sensor PC8 D Front/Rear Edge Guide Plate Home Position Sensor PC9 D Duplex Unit Drive Motor M31 D Gate Motor M32 D Front/Rear Edge Guide Drive Motor M33 D AD-9 Master Board PWB-G 1149C24TAA T-95 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0d00 Step 1 2 Check Item Result Does M33 turn when the Front/Rear Edge Guide Plates are moved to a position other than home and the Duplex Unit is slid in? Does PC9 operate properly? Using the IC Port Data Check function, make an input port check on PWB-G (Dup) (IC1G) PC3. YES NO YES NO Action Check for overload. Change M33 or PWB-G. Change PWB-G. Change PC9. uC0d20 Step Check Item Result 1 Does M32 turn when the Gate Unit is moved to a position other than home and the Duplex Unit is slid in? 2 Does PC8 operate properly? Using the IC Port Data Check function, make an input port check on PWB-G (Dup) (IC1G) PE0. Action YES Check for overload. NO Change M32 or PWB-G. YES NO Change PWB-G. Change PC8. uC0d50 Step Check Item 1 Does M31 turn? Using the IC Port Data Check function, set the data of PWB-A (Dup) (IC1G) PB3 to ”0.” Result YES NO Action Check the drive coupling. Change M31 or PWB-G. uC0d51 Step Check Item 1 Does M31 turn when the malfunction is reset? Result YES 2 Is malfunction code “C0011” displayed again? YES T-96 Action Change PWB-G Change PWB-G Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040222A 22) C0E00: Main Erase Lamp LA2’s Failure to Turn ON C0E01: Main Erase Lamp LA2 Turning ON at Abnormal Timing Relevant Electrical Parts D Main Erase Lamp LA2 D Master Board PWB-A 1156C22TAA uC0E00 Step Check Item Result 1 Perform the “Controller Board Check.” Is malfunction code “C0328” displayed? 2 Does the voltage across PWB-A PJ12A-3 and GND change from DC0V to DC24V when the Start key is pressed? Action Change PWB-A. YES YES NO Change LA2. Change PWB-A. uC0E01 1 Check the LA2 Failure Detection signal when LA2 is OFF. Using the IC Port Data Check function, check that the data of PWB-A (IC4A) APC7 is “H.” YES NO T-97 Change PWB-A. Change LA2. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040223A 23) C0E20: Image Erase Lamp LA3’s Failure to Turn ON Relevant Electrical Parts D Image Erase Lamp LA3 D Master Board PWB-A 1156C23TAA Step Check Item Result 1 Perform the “Controller Board Check.” Is malfunction code “C0314 to C0317” displayed? 2 Is the voltage across PWB-A PJ9A-1 and GND DC5V? Action Change PWB-A. YES YES Change LA3. NO Check the 5V line. T-98 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040224A 24) C0F02: Original Size Detecting Board UN2 Malfunction C0FE1 to C0FFF: Original Size Detecting Sensor Failure Relevant Electrical Parts D Original Size Detecting Sensor CD1 PC115 D Original Size Detecting Sensor FD1 PC116 D Original Size Detecting Sensor FD2 PC117 D Original Size Detecting Sensor FD3 PC118 D Original Size Detecting Sensor CD2 PC119 D Orignal Size Detecting Board UN2 D Master Board PWB-A 1156C16TAA T-99 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 uC0F02 Step Check Item 1 Are PJ62 on UN2 and PJ7A on PWB-A plugged in securely? Result 2 Does the voltage across PJ7A-6 on PWB-A and GND vary between DC0V and DC5V? NO Action Plug them in securely. YES Change PWB-A. NO Change UN2. uC0FE1 to C0FFF Step Check Item Result 1 Are the jumper connectors plugged correctly into J1 and J2 on UN2? NO 2 Is each Original Size Detecting Sensor installed in correct position? NO 3 Is the malfunction code displayed again after the Original Size Detecting Sensor corresponding to the malfunction code has been changed? YES Action Change the jumper connector positions. Reinstall. Change UN2 or PWB-A. T-100 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040225A 25) C0F10: AE Sensor Board PWB-H Malfunction Relevant Electrical Parts D AE Sensor Board PWB-H D Master Board PWB-A 1156C17TAA Step 1 Check Item Result Is the voltage across PWB-A PJ3A-3 and GND DC0.18V or less when the Scanner is at the home position, the Exposure Lamp is OFF, and the Original Cover is lowered? YES NO T-101 Action Change PWB-H. Change PWB-A. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040226A 26) C0F20: AIDC Sensor Board PWB-G Variation Correction Failure C0F22: AIDC Sensor Board PWB-G Grid Voltage (Vg) Correction Failure C0F23: AIDC Sensor Board PWB-G Exposure Correction Failure Relevant Electrical Parts D AIDC Sensor Board PWB-G D Master Board PWB-A 1156C18TAA Step Check Item Result 1 Is PWB-A PJ11A plugged in securely? NO Plug it in securely. Action 2 Is CN35 plugged in securely? NO Plug it in securely. 3 Is PWB-G installed in the correct position? NO 4 Is the photoreceiver or LED of PWB-G dirty? Reinstall. YES Clean. NO Change PWB-G or PWB-A. T-102 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040227A 27) C0F30: ATDC Sensor UN3 Failure C0F31: ATDC Sensor UN3 Failure Relevant Electrical Parts D ATDC Sensor UN3 D Master Board PWB-A 1156C19TAA Step Check Item Result Action 1 Is the malfunction code “C0F30” displayed? YES 2 Is the value for “ATDC Ref. Value” of “Level History” equal to the value given on the Adjust Label? NO Enter the value given on the Adjust Label. 3 Is PWB-A PJ11A plugged in securely? NO Plug it in securely. 4 Is CN35 plugged in securely? NO Plug it in securely. 5 Is UN3 installed in the correct position? NO Reinstall. T-103 Go to step 3. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT0403A 4-3. Power Malfunctions 1156SBT040301A 1) Main Relay Does Not Turn ON. Relevant Electrical Parts D Power Switch S1 D Main Relay RY1 D Power Supply Unit PU1 D Master Board PWB-A D Power Supply Board PWB-C D Noise Filter Board PWB-D 1156C20TAA T-104 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 Step Check Item 1 Is the source voltage applied to the circuit across PJ1-1 and -2 on PU1? Result NO 2 Is the voltage across PJ2-2 or -3 on PU1 and GND DC24V? NO Check the fuse on PU1 and, if it is intact, change PU1. 3 Is the voltage across PJ6C-1 on PWBC and GND DC24V when S1 is turned ON? NO Check the wiring between PWB-C and S1 and, if it is intact, change PWB-C or S1. NO Check the wiring between PWB-C and S1 and, if it is intact, change PWB-C or S1. YES Change PWB-A, PWB-C, and RY1, in that order. NO Correct the wiring or change the harness. 4 Is the voltage across PJ21-2 on PU1 and GND DC5V? 5 Is the wiring between PWB-A, PWB-C, and RY1 intact? T-105 Action Change PWB-D. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT040302A 2) Main Relay Turns ON But the Control Panel Gives No Display. Relevant Electrical Parts D Power Supply Unit PU1 D Control Panel UN1 D MSC Board PWB-B D Power Supply Board PWB-C 1156C21TAA Step Check Item Result 1 Is the voltage across PJ22-2 on PU1 and GND DC5V? 2 Is the voltage across PJ21-2 on PU1 and GND DC5V? 3 Is the voltage across PJ3C-1 on PWBC and GND DC24V? 4 Is the connection between PWB-B and UN1 normal? Action YES Check the wiring between PU1 and UN1. NO Change PU1. YES Check the wiring between PU1 and PWB-B. NO Change PU1. YES Check the wiring between PWB-C and UN1. NO Change PWB-C. YES Change PWB-B or UN1. NO Correct the wiring or change the harness. T-106 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT0404A 4-4. Miscellaneous D The message “Stabilizing Image Controller not run.” appears on the Touch Panel. Detection Timing Condition D Memory clear D “PC Drum” of “Port/Option” counter is cleared. D AIDC Sensor Board PWB-G develops a malfunction. T/C is less than 4% when an F5 operation is run (initial adjustment). Step 1 Check Item Result Is “ATDC Current Level” of “Level History” available from Tech. Rep. mode less than 4%? Action YES Run the auxiliary toner replenishing cycle and then an F5 operation. NO Run an F5 operation again. T-107 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1149SAT0500A 5 IMAGE FAILURE 1149SBT0501A 5-1. Image Failure Troubleshooting Image failures have many possible causes. For troubleshooting, it is necessary to determine whether a failure is attributable to a basic cause or any other cause. In this chapter, troubleshooting is divided into “initial checks” and “troubleshooting procedures classified by image failure”. If an image failure has occurred, first make the initial checks, then proceed to the corresponding image failure troubleshooting procedure. 1149SBT0502A 5-2. Initial Checks 1) Place of installation D Is the source voltage normal? Does the voltage vary greatly? D Is the copier installed in a hot, humid place or in a place where temperatures vary sharply? D Is the copier installed in a dusty place? D Is the copier subjected to direct sunlight? D Is the copier level? 2) Copy paper D Is the recommended paper used? èLoad recommended paper and make copies to see if the problem persists. D Is the paper damp? èLoad new paper and make copies to see if the problem persists. 3) Original D Does the original used have a reddish background or is it written in light pencil? èUse the Test Chart to check the image. D Is the original transparent or are transparencies being used? èCover with white paper and make a copy. D Are the Original Glass and ADF Transport Belt dirty or scratched? èIf dirty, clean with alcohol. If scratched, replace. 4) Adjust data and Level History data D Are the set values of “Adjust” and “Level History (ATDC Level)” in the Tech. Rep. mode equal to the value given on the Adjust Label inside the Front Door? èWhen installing the Developing Unit of another copier containing its own developer, input the ATDC Level value of that particular copier. 5) PM parts (supplies) D Have the PM parts (supplies), such as the PC Drum, Cleaning Blade, AIDC Sensor and corona wires, reached the end of their cleaning/replacement cycles? T-108 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 6) Adjustment items (registration, focus, AE level, etc.) D Among the adjustment items given in DIS/REASSEMBLY, ADJUSTMENT, is there any adjustment that may remedy the image failure? 7) Controller Board Check D Is a malfunction code displayed when “Controller Board Check” in the Tech. Rep. mode is run? T-109 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1149SBT0503A 5-3. Troubleshooting Procedures Classified by Image Failure 1) Blank copy 2) Black copy 3) Low image density 4) Foggy background 5) Black streaks or bands 6) Black spots 7) Blank streaks or bands 8) Void areas 9) Smear on back 1149T012AA T-110 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1149SBT050301A 1) Blank Copy Cause Charging failure Developing Unit out of position Step Check Item 1 Is the PC Drum Charge Corona installed correctly? NO 2 Are the Comb Electrode wire and grid mesh normal? NO 3 Is the wiring between High Voltage Unit HV1 and the PC Drum Charge Corona normal? YES NO Action Install correctly. Check and change if necessary. Change HV1. Correct the wiring. 4 Is the PC Unit in position? NO Reinstall the Unit. 5 Are the Ds Rolls in contact with the PC Drum? NO Reinstall the Developing Unit. Is the Developing Unit connector plugged in? NO 7 Is the drive transmission mechanism to the Developing Unit intact? NO 8 Is the Image Transfer Corona wire normal? NO Check and change if necessary. Is the wiring between High Voltage Unit HV1 and corona wire normal? YES Change HV1. 9 NO Correct wiring. YES Connect the paper guide through the resistor to the frame. 6 Image transfer failure Result Paper guide shorting 10 Is the paper guide shorted to the frame? Plug it in. Check and change any defective part. 1149SBT050302A 2) Black copy Cause PC Drum grounding failure Developing bias failure Step Result Action 1 NO Clean or change the PC Drum Ground Plate. 2 Is the developing bias contact normal? NO Clean or replace the developing bias contact. Is the developing bias harness intact? YES Change the High Voltage Unit for drum charging. 3 NO Change the harness. 4 Has condensation formed on the mirrors, lenses, or PC Drum? YES Clean the mirrors and lenses, and run the Drum Dehum. operation. 5 Are the mirrors installed properly? NO 6 Does the Exposure Lamp light up? NO Light path failure Exposure Lamp’s failure to turn ON Check Item Is the PC Drum properly grounded? T-111 Reinstall the mirrors. Take the action for malfunction code C0400. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1149SBT050303A 3) Low Image Density Cause PC Drum life PC Drum grounding failure Drum charge failure Step Result NO 2 Do the fan motors turn properly? (Ozone deterioration, temperature rise) NO 3 Is the PC Drum grounded properly? NO Clean or change the PC Drum Ground Plate. 4 Are the Comb Electrode and grid mesh normal? NO Check and change if necessary. 5 Is the wiring between High Voltage Unit HV1 and the PC Drum Charge Corona normal? YES NO Change the PC Drum. Troubleshoot the fan motors. Change HV1. Correct the wiring. 6 Are the mirrors and lenses dirty or covered with condensation? YES 7 Is the Image Transfer Corona dirty? YES Clean the Image Transfer Corona or change the wire. YES Change the copy paper and instruct the user in how to store paper and to keep the copier plugged in during the night. Is the copy paper damp? 8 Developing failure Action 1 Optical failure Image transfer failure Check Item Does the PC Drum have enough service life? Clean the mirrors and lenses. 9 Is Db adjusted properly? NO Make Db adjustment. 10 Are the Ds Rolls in contact with the PC Drum? NO Reinstall the Developing Unit. 11 Is the developing bias contact normal? NO Clean or Change the developing bias contact. T-112 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1149SBT050304A 4) Foggy background Cause Step Check Item 1 Is the Cleaning Blade dirty with foreign matter, paper dust, etc. or is it scratched? YES 2 Are the mirrors and lenses dirty? YES Clean the mirrors and lenses. YES Clean or replace the PC Drum. Change the Cleaning Blade if necessary. NO Clean or change the PC Drum Ground Plate. YES Clean the Sleeve Roller. Check the Developer Scattering Prevention Seal to see if it is deformed or dirty. Cleaning failure Optical failure PC Drum failure 3 4 Developing failure 5 Main Erase Lamp failure AIDC Sensor failure Is the PC Drum dirty with foreign matter, etc.? Is the PC Drum properly grounded? Is the Sleeve Roller abnormally dirty? Result Action Change the Cleaning Blade. 6 Is the developing bias contact normal? NO Clean or change the developing bias contact. 7 Does the Main Erase Lamp light up properly? NO Replace the Main Erase Lamp. 8 Is the Main Erase Lamp dirty? YES Clean the Main Erase Lamp. 9 Is the AIDC Sensor clean or installed properly? NO Clean or reinstall the AIDC Sensor and execute F5. YES Using care not to scratch, wipe the pattern with a dry soft cloth and run F5. 10 Is the AIDC halftone pattern dirty? T-113 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1149SBT050305A 5) Black Streaks or Bands Cause Step Uneven charging 1 Cleaning failure Optical failure YES Is the Cleaning Blade dirty with foreign matter, paper dust, etc., or is it scratched? YES 3 Does the Cleaning Blade make a correct lateral motion? NO 4 Fusing failure Result 2 PC Drum failure PC Drum Paper Separator Fingers Check Item Are the Comb Electrode and grid mesh dirty? Is the PC Drum surface dirty or scratched? YES 5 Are the PC Drum Paper Separator Fingers dirty, deformed or faulty in operation? YES 6 Is the Upper Fusing Roller dirty or scratched? YES 7 Are the Upper Paper Separator Fingers dirty or deformed? YES 8 Are the mirrors and lenses dirty with foreign matter? YES Action Clean or replace the PC Drum Charge Corona. Check the toner suction mechanism for operation. Change the Cleaning Blade. Check the Cleaning Blade for operation. Change the PC Drum. If necessary, change the Cleaning Blade. Clean or replace the PC Drum Paper Separator Fingers. Clean or replace the Upper Fusing Roller. Clean or replace the Upper Paper Separator Fingers. Clean the mirrors and lenses. 1149SBT050306A 6) Black Spots Cause Step PC Drum failure 1 Fusing failure 2 Developing failure Dirty PC Drum Paper Separator Fingers Check Item Is the PC Drum surface scratched or dirty with foreign matter? Is the Upper Fusing Roller dirty or scratched? Result Action YES Clean or change the PC Drum. Change the Cleaning Blade if necessary. YES Check the Fusing Thermistors. Clean or change the Upper Fusing Roller. 3 Is the amount of toner on the Sleeve Roller proper? YES 4 Is the toner-to-carrier ratio relatively high? YES Change the toner-to-carrier ratio. 5 Is the Db value normal? NO Make Db adjustment. 6 Is the Developer Scattering Prevention Seal deformed or dirty? YES Clean or change the Developer Scattering Prevention Seal. 7 Are the PC Drum Paper Separator Fingers dirty or deformed? YES Clean or change the PC Drum Paper Separator Fingers. T-114 Go to step 5. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1149SBT050307A 7) Blank Streaks or Bands Cause Step Plugged Db 1 Drum charge failure Image transfer failure Defective PC Drum Paper Separator Fingers Image Erase Lamp lit at abnormal timing Fusing failure Check Item Is Db plugged with foreign matter, caked toner, etc.? Result Action YES Remove foreign matter. If the problem persists, change the developer. Clean or change the PC Drum Charge Corona. 2 Are the Comb Electrode and grid mesh dirty? YES 3 Is the Drum Charge Corona Wire Cleaner at the home position? NO 4 Is the Image Transfer Corona wire dirty? YES Clean or change the Image Transfer Corona. 5 Is the Corona Wire Cleaner at the home position? NO Check the corona wire cleaning mechanism. 6 Are the PC Drum Paper Separator Fingers dirty or deformed? YES Clean or replace the PC Drum Paper Separator Fingers. 7 Does the Image Erase Lamp light up at abnormal timing? YES 8 Is the Upper Fusing Roller dirty or scratched? YES 9 Are the Upper Paper Separator Fingers dirty or scratched? YES T-115 Check the corona wire cleaning mechanism. Check the Image Erase Lamp. Clean or change the Upper Fusing Roller. Clean or change the Upper Paper Separator Fingers. Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1149SBT050308A 8) Void Areas Cause Image transfer failure Step Check Item 1 Is the Image Transfer Corona installed properly? NO 2 Is the Image Transfer Corona wire dirty? YES Clean or change the Image Transfer Corona wire. YES Change the copy paper and instruct the user in how to store paper and to keep the copier plugged in during the night. NO Check the Db value and amount of developer, and check the Bucket Roller for operation. Damp copy paper Is the image improved by loading new paper? 3 Small amount of toner supplied PC Drum condensation 4 Is toner uniformly attracted onto the Sleeve Roller? Action Reinstall. 5 Is the image improved by running Drum Dehum.? YES Run Drum Dehum. and instruct the user to take further action. 6 Is the paper guide shorted to the frame? YES Connect the paper guide through the resistor to the frame. YES Replace the Lower Fusing Roller. Paper guide shorting Fusing failure Result 7 Is the Lower Fusing Roller scratched or deformed? 1149SBT050309A 9) Smear on Back Cause Dirty Developing Unit Dirty Image Transfer Corona Dirty Suction Unit Dirty Fusing Unit Step 1 Check Item Is the bottom part of the Developing Unit dirty? Result Action YES Clean, and check the Developer Scattering Prevention Seal. 2 Is the Image Transfer Corona dirty? YES Clean the corona and check the Developing Unit. 3 Is the Pre-Image Transfer Guide Plate dirty? YES Clean the guide plate and check the Developing Unit. YES Clean the Suction Belts and check the Developing Unit. YES Clean the guide plate and check the Developing Unit. YES Clean or change the Upper and Lower Fusing Rollers and check the Fusing Roller cleaning mechanism. 4 5 6 Are the Suction Belts dirty? Is the Fusing Unit Entrance Guide Plate dirty? Are the Upper and Lower Fusing Rollers dirty? T-116 Interleaf EP5000/EP4000 TROUBLESHOOTING 97.04.01 1156SBT000EA Copyright 1997 MINOLTA Co., Ltd. Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA CO., LTD. 1156-7998-11 97046000 Printed in Japan

Ep5000/ep4000 General, Mechanical/ Electrical

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