Model Cor-C1 Machine Code: D197/D198/D199/D200/D201/D202 Field Service Manual July, 2014 Subject to change Important Safety Notices Safety Prevention of Physical Injury 1. Before disassembling or assembling parts of the machine and peripherals, make sure that the machine and peripheral power cords are unplugged. The plug should be near the machine and easily accessible. Note that some components of the machine and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off.
If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. If the [Start] key is pressed before the machine completes the warm-up period (the [Start] key starts blinking red and green), keep hands away from the mechanical and the electrical components as the machine starts making copies as soon as the warm-up period is completed. The inside and the metal parts of the fusing unit become extremely hot while the machine is operating. Be careful to avoid touching those components with your bare hands.
To prevent a fire or explosion, keep the machine away from flammable liquids, gases, and aerosols. Health Safety Conditions 1. Never operate the machine without the ozone filters installed. Always replace the ozone filters with the specified types at the proper intervals.
Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention. Observance of Electrical Safety Standards 1.
The machine and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. Safety and Ecological Notes for Disposal 1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame.
Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are non-toxic supplies. Dispose of replaced parts in accordance with local regulations. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box.
Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up. • The danger of explosion exists if a battery of this type is incorrectly replaced. Replace only with the same or an equivalent type recommended by the manufacturer. Discard used batteries in accordance with the manufacturer’s instructions.
Handling Toner • Work carefully when removing paper jams or replacing toner bottles or cartridges to avoid spilling toner on clothing or the hands. • If toner is inhaled, immediately gargle with large amounts of cold water and move to a well ventilated location. If there are signs of irritation or other problems, seek medical attention. • If toner gets on the skin, wash immediately with soap and cold running water.
• If toner gets into the eyes, flush the eyes with cold running water or eye wash. If there are signs of irritation or other problems, seek medical attention. • If toner is swallowed, drink a large amount of cold water to dilute the ingested toner. If there are signs of any problem, seek medical attention.
• If toner spills on clothing, wash the affected area immediately with soap and cold water. Never use hot water! Hot water can cause toner to set and permanently stain fabric. • Always store toner and developer supplies such as toner and developer packages, cartridges, and bottles (including used toner and empty bottles and cartridges) out of the reach of children. • Always store fresh toner supplies or empty bottles or cartridges in a cool, dry location that is not exposed to direct sunlight.
Laser Safety The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field.
Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required. 2 • Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. WARNING FOR LASER UNIT WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes.
CAUTION MARKING: Safety Precautions for This Machine Before moving the mainframe: • Disconnect all peripheral units (finisher, LCT, etc.) from the mainframe. • Pull the slide handles out of the mainframe and use them to lift the mainframe. 3 Symbols, Abbreviations and Trademarks This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations are as follows: Screw Shoulder screw Black screw (TCRU) Connector FFC (Flat Film Connector) Harness clamp Clip E-ring C-ring Timing belt Spring SEF Short Edge Feed LEF Long Edge Feed [A] Short Edge Feed (SEF) [B] Long Edge Feed (LEF) 4 Trademarks Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the United States and /or other countries.
PostScript® is a registered trademark of Adobe Systems, Incorporated. PCL® is a registered trademark of Hewlett-Packard Company. Ethernet® is a registered trademark of Xerox Corporation. PowerPC® is a registered trademark of International Business Machines Corporation.
Other product names used herein are for identification purposes only and may be trademarks of their respective companies. We disclaim any and all rights involved with those marks. 5 TABLE OF CONTENTS Important Safety Notices.1 Prevention of Physical Injury. 1 Health Safety Conditions.
1 Observance of Electrical Safety Standards.1 Safety and Ecological Notes for Disposal.2 Safety Precautions for This Machine.3 Symbols, Abbreviations and Trademarks. Product Information Product Overview. 33 Paper Feed Unit.34 Laser Unit/ PCDU. 36 Waste Toner Bottle.37 Duplex/Bypass Unit.38 Paper Exit/ Reverse Unit.42 Machine Codes and Peripherals Configuration.43 System Configuration and Options.
54 Guidance for Those Who are Familiar with The Predecessor Product. 56 Differences between Similar Models.57 Differences between D146 Series. Installation Installation Requirements. 61 Minimum Space Requirements.
63 Main Machine Installation.65 Important Notice on Security Issues. 65 Password Setting Procedure.66 Installation Flow Chart. 73 Tapes and Retainers.77 Paper Exit Tray Stopper. 87 Check Image Quality / Settings.
87 Checking the copy image with the test chart.88 Moving the Machine. 89 Transporting the Machine. 89 Paper Feed Unit PB3210/ PB3220. 90 Paper Feed Unit PB3150.96 LCIT PB3170/ PB3230.
102 Changing the paper size. 110 Changing the Paper Size. 117 Caster Table Type M3.119 For Installing Directly under the Main Machine.120 For Installing under PB3150.121 Platen Cover PN2000 (D700).129 When feeding thin paper.136 Attaching the SPDF. 136 Attaching the Sub IPU.139 Adjust SP Settings.144 Bridge Unit BU3070.
146 1 Bin Tray BN3110.151 Internal Shift Tray SH3070.160 Side Tray Type M3. 165 Booklet Finisher SR3170 / Finisher SR3160.170 Adjustment after Installing the Finisher.178 How to Check and Adjust the Side-to-Side Registration.179 Punch Unit PU3060.182 Booklet Finisher SR3150 / Finisher SR3140.196 Adjustment after Installing Finisher. 203 How to Check and Adjust the Side-to-Side Registration. 203 Punch Unit PU3050.206 Internal Finisher SR3180.223 Staple Setting as an Initial Setting.
235 Internal Finisher SR3130.237 Punch Unit PU3040.248 Smart Operation Panel Type M3.255 Anti-Condensation Heater Type M12.261 Anti-Condensation Heater (Scanner).261 Anti-Condensation Heater (PCU).273 Anti-Condensation Heater for Trays.278 Anti-Condensation Heater for Paper Feed Tray (Main Unit). 278 Anti-Condensation Heater for Paper Feed Unit PB3210 / PB3220. 286 Anti-Condensation Heater for Paper Feed Unit PB3150.289 Anti-Condensation Heater for LCIT PB3170/ PB3230.291 Card Reader Bracket Type 3352.296 Key Counter Bracket Type M3.300 10 Optional Counter Interface Unit Type M12.305 Smart Card Reader Built-in Unit Type M12. 319 List of Slots.319 Printer/Scanner Unit Type M12.321 IEEE 1284 Interface Board Type A.11a/g/n Interface Unit Type M2.
327 User Tool Settings for IEEE 802.330 SP Mode Settings for IEEE 802.331 Bluetooth Interface Unit Type D.333 File Format Converter Type E. 335 USB Device Server Option Type M12.337 Interface Board Surface.338 What Do the LED Indications Mean?.341 Notes for Energy Save Mode Setting. 342 IP Address Setting.342 Copy Data Security Unit Type G. 345 User Tool Setting.348 Hard Disk Drive Option Type M12.
350 SD Card Option.352 SD Card Slots. 352 List of Slots Used. 352 SD Card Appli Move.355 OCR Unit Type M2. 359 Browser Unit Type M12.361 To update EXJS.
363 When checking the version of EXJS. 365 Browser unit uninstallation procedure. 366 Browser default setting. 366 SD card for NetWare printing Type M12.367 PostScript3 Unit Type M12.
369 XPS Direct Print Option Type M12.371 IPDS Unit Type M12. 373 External Keyboard Bracket Type M3 (D739-10).376 Data Overwrite Security Unit Type I (D362). 381 Before You Begin the Procedure. 381 Seal Check and Removal.
385 Security Function Installation. 385 Data Overwrite Security. 386 Before You Begin the Procedure. 386 Using Auto Erase Memory.388 Before You Begin the Procedure:.
388 Enable Encryption Setting. 388 Backing Up the Encryption Key. 390 Encryption Key Restoration.394 Operation Guidance for Users. Preventive Maintenance Preventive Maintenance Tables.399 Image Quality Standards.400 Magnification ratio error margin.
400 Magnification ratio error margin deviation.401 Pitch error margin. 402 Missing Image Area. 403 Paper Transfer Quality Standards. 404 PM Parts Settings.406 PM Parts Replacement Procedure.406 After Installing the New PM parts.
Replacement and Adjustment Notes on the Main Power Switch. 409 Characteristics of the Push Switch (DC Switch).412 Special Tools and Lubricants. 413 Cover Removal Order. 414 Cover Removal Order.419 Left Upper Cover.
419 Left Rear Cover. 421 Controller Rear Cover.422 14 Rear Left Cover. 423 Rear Right Cover. 423 Rear Lower Gap Cover.424 Rear Lower Cover.424 Scanner Rear Cover.425 Right Rear Cover.
425 Right Upper Cover. 427 Main Power Switch Cover. 430 Paper Exit Tray.430 Paper Exit Cover.430 Paper Exit Lower Cover.431 Upper Inner Cover. 432 Paper Exit Front Cover.
434 Toner Supply Housing. 437 Key Control Board. 442 Notes when replacing the LCD. 446 Scanner Upper Cover.
446 Scanner Right Cover.446 Scanner Front Cover.447 Scanner Left Cover.453 Original Size Sensors (APS). 455 Scanner HP Sensor.456 DF Position Sensor. 457 Adjusting the Scanner Wire.458 Scanner Wire Assembly (Front).461 Scanner Position Adjustment. 468 Scanner Wire Assembly (Rear).
472 Modifying the Scanner (contact/contactless) when using ARDF.475 Procedure for the ADF.475 Procedure for the Scanner. 478 Modifying the Scanner (contact/contactless) when using SPDF. 478 Procedure for the SPDF. 478 Procedure for the Scanner.
482 Caution Decal Location.482 Removing the Laser Unit. 482 Installing a New Laser Unit. 484 After Installing the New Laser Unit. 489 Before Replacing a PCU or Development Unit.489 PCU/Development Unit.491 Notes When Installing the Face Plates.
493 Installing a Development Unit.494 Charge Roller, Cleaning Roller. 495 Pick-off Pawls. 505 Development Mixing Auger Bearings. 506 Development Mixing Auger (L / R).511 Waste Toner Bottle.511 Toner Collection Full Sensor.
511 Recycling Shutter Solenoid.517 Transfer Roller Unit.520 Before Replacing the ID Sensor. 521 Transfer Unit Open/Close LED. 521 Temperature/Humidity Sensor.522 Fusing Entrance Sensor. 524 Transfer Unit Open/Close Sensor.526 Drum/Waste Toner Motor.
526 Fusing/Paper Exit Motor (D197/D199 Only).527 Paper Exit Motor (D200/D201/D202 Only).528 Paper Feed Motor. 528 Vertical Transport Motor.529 17 Transfer Roller Contact Motor. 530 Toner Supply Motor.535 Fusing Entrance Guide Plate.538 Cleaning the Fusing Entrance Guide Plate. 538 Fusing Exit Guide Plate.
539 Fusing Upper Cover. 539 Fusing Lower Cover.541 Heating Sleeve Belt Unit.543 To Clear SC544-02 or SC554-02. 544 Pressure Roller and Pressure Roller Bearings. 545 Adjustment before Replacing the Pressure Roller and Pressure Roller Bearings.
547 Fusing Roller Temperature Sensor.548 Pressure Roller Temperature Sensor.548 Notes When Reassembling the Fusing Unit.551 Paper Exit Unit. 551 Paper Exit Switching Solenoid.551 Paper Exit Sensor. 553 Paper Exit Full Sensor. 555 Fusing Exit Sensor.
558 Paper Feed Unit. 558 1st Paper Feed Unit. 558 18 2nd Paper Feed Unit. 559 Paper Dust Collection Unit.562 Pick-up Roller, Paper Feed Roller, Separation Roller, Torque Limiter.
