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ORDER NO.

OED9909380B8

FP-7818/7824/7830/7835/7845/7850 Service Manual

Service Manual Parts Manual
Plain Paper Copier

FP-7818/7824/7830 FP-7835/7845/7850 Staple Sorter FA-S620/660 System Console FA-DS72/82

© 1999 Matsushita Graphic Communication Systems, Inc. All rights reserved. Unauthorized copying and distribution is a violation of law.

WARNING
This service information is designed for experienced repair technicians only and is not designed for use by the general public. It does not contain warnings or cautions to advise non-technical individuals of potential dangers in attempting to service a product. Products powered by electricity should be serviced or repaired only by experienced professional technicians. Any attempt to service or repair the product or products dealt with in this service information by anyone else could result serious injury or death.

For U.S.A
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment on a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his/her own expense. Any unauthorized changes or modifications to this equipment would void the users authority to operate this device.

For U.S.A
This manual was developed and is supplied to authorized servicing dealers by Panasonic Document Imaging Co. for the sole purpose of providing information necessary for the equipment’s proper support. It is intended that this information be confidential and may not reproduced without prior written consent from Panasonic Document imaging Co. Panasonic Document imaging Co. reserves the right to change any information enclosed herein without prior notification. This manual was developed and is supplied to authorized servicing dealers by Panasonic Co. for the sole purpose of providing information necessary for the equipment’s proper support. It is intended that this information be confidential and may not be reproduced without prior written consent from Panasonic Co. Panasonic Co. reserves the right to change any information enclosed herein without prior notification.

This manual dose not contain descriptions of PCB Connector and Signal Information and Sub Assemblies Operation which are discribed and unchanged in the FP-7718/7722/7728/7735/7742/7750 service manual. For those items not covered in this manual, please refer to the FP-7718/7722/7728/7735/7742/7750 service manual or PCB repaire manual.

Contents / Index
Introduction Unpacking/ Installation Troubleshooting Preventive Maintenance Sub Assemblies Control Functions I. Introduction 1.1 Specification ..................................................................................... 1-1 1.2 Features ............................................................................................ 1-3 1.3 System Configuration ....................................................................... 1-4 1.4 Operation .......................................................................................... 1-6 (1) Special Effects Panel (FP-7818/7824/7830/7835) ...................... 1-7 (2) Communications Monitor (FP-7818/7824/7830/7835) ................ 1-8 1.5 Component Location ......................................................................... 1-9 (1) Inner view .................................................................................. 1-10 (2) Fan/Motor Location ................................................................... 1-11 (3) Sensor Location ........................................................................ 1-12 (4) Solenoid/Clutch/Discharge lamp Location ................................ 1-13 (5) PCB Location ............................................................................ 1-13 1.6 Copy Process ................................................................................. 1-14 1.7 Precautions on Set Up .................................................................... 1-15 1.8 Precautions with Consumables ...................................................... 1-16 II. New Function 2.1 Image Control Qualitative Reasoning Based Adaptive Controller ......... 2-1 2.2 Toner Density Control ....................................................................... 2-3 2.3 Trouble Avoidance Mechanism ........................................................ 2-5 2.4 Toner Recycling System ................................................................... 2-7 2.5 Re-try Control for Paper Misfeed ...................................................... 2-8 III. Sub Assemblies 3.1 Main Drive ......................................................................................... 3-1 (1) Detecting sheet bypass paper size ............................................. 3-2 (2) Developing .................................................................................. 3-3 (3) Supplying toner ........................................................................... 3-4 (4) Toner level detection ................................................................... 3-5 (5) Temperature control .................................................................... 3-6 (6) Automatic detection of original paper size .................................. 3-7 (7) Adjusting quantity of light of AE sensor ...................................... 3-7

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............................... 6-1 6................................................................................................... 5-1 (2) Service mode procedure ....................................4 Installation Procedure .................................. 5-2 (3) F4 mode ......................... 4-4 4................................................................................6 White Density Adjustment .......................................... 5-1 (1) Service mode functions ....................... 5-40 (3) Machine error .......... 5-58 VI..........................5 Adjustment ............. 4-14 (4) Fuser unit ...................... 6-1 6.......................................................................................... 4-2 4.......................................................... 4-7 (1) Multi-feed bypass ..................... 5-16 (5) F6 mode Adjustment and programming ............ 4-35 V......................................3 Cleaning Method ...........................4 Disassembly and Re-assembly .................... 5-43 5.......2 Self-diagnostics/Machine Malfunctions ..........................................2 Contents Check .............................................. 5-34 (2) Paper Jam ............................ 4-24 (6) Automatic duplex unit (ADU ) ............ 5-23 (6) F7 mode electronic counter ................................................. 6-10 ...............................3 User Preset Mode ........................................................... 4-1 4....... 5-29 (7) F8 mode copier operation adjustment ..................................................... 6-2 6............................................................ 6-1 6..........................................................................................................................................1 Service Mode ...IV................................3 Unpacking ............. 4-8 (2) Paper feed unit ....... Unpacking/Installation 6............... 5-34 (1) User error ..................................................................................................................... 5-31 (8) F9 Telephone# input ..............................................................................................................................................................................2 Maintenance chart ........................................................................................................................................................................ 4-11 (3) Developer unit .................... 4-32 (7) Main Body .. 4-19 (5) Optics unit .......................................... 5-4 (4) F5 mode Copier function programming ......................1 Precautions for Periodic Maintenance Service ....................... 1 Installation Requirements ............. 6-7 6.................................................................................................. Preventive Maintenance 4............................................................................. 5-33 5.. Troubleshooting 5..........................................

and Denmark SPECIALSÄKRING: ENDAST AV APPARATFABRINKANTEN LEVERERAD SÄKRING FåR ANVÄNDAS. For Holland NL Batterij niet weggooien. maar inleveren als KCA.Caution: Danger of explosion if battery is incorrectly replaced. For Sweden. VARNING! Explosionsfara vid felaktigt batteribyte. Dispose of used batteries according to the manufacturer’s instructions. Lever det brugte batteri tilbage til leverrandoren. Dispose of used batteries according to the manufacture's instructions. Använd samma batterityp eller ekvivalent typ som rekommenderas av apparattillverkaren. Kassera använt batteri enligt fabrikantens instruktion. CAUTION! Danger of explosion if battery is incorrectly replaced. ADVARSEL! Lithiumbatteri—Eksplosionsfare ved fejlagtig håndtering. Replace only with the same or equivalent recommended by the manufacturer. Udskiftning må kun ske med batteri af samme fabrikat og type. Replace only with the same or equivalent type recommended by the manufacturer. ii .

The wire which is coloured BLUE must be connected to the terminal in the plug which is marked with the letter N or coloured BLACK.For U. Fuse Fuse iii . How to replace the fuse. A 13 amp fuse is fitted in this plug.K. IMPORTANT: The wires in this mains lead are coloured in accordance with the following code: Green and Yellow Blue Brown :Earth :Neutral :Live As the colours of the wires in the main lead of this appliance may not correspond with the coloured markings identifying the terminals in your plug. Open the fuse compartment with a screwdriver and replace the fuse. FOR YOUR SAFETY PLEASE READ THE FOLLOWING TEXT CAREFULLY. Check for the ASTA mark or the BSI mark on the body of the fuse. A replacement fuse cover can be purchased from your local Panasonic Dealer. If the plug contains a removable fuse cover you must ensure that it is refitted when the fuse is replaced. This appliance is supplied with a moulded three pin mains plug for your safety and convenience. If you lose the fuse cover the plug must not be used until a replacement cover is obtained. If in any doubt please consult a qualified electrician. THERE IS A DANGER OF SEVERE ELECTRICAL SHOCK IF THE CUT OFF PLUG IS INSERTED INTO ANY 13 AMP SOCKET. WARNING: THIS APPLIANCE MUST BE EARTHED. The wire which is coloured BROWN must be connected to the terminal in the plug which is marked with the letter L or coloured RED. proceed as follows: The wire which is coloured GREEN-AND-YELLOW must be connected to the terminal in the plug which is marked by letter E or by the safety EARTH symbol “ ” or coloured GREEN or GREEN-AND-YELLOW. If a new plug is to be fitted please observe the wiring code as shown below. IF THE FITTED MOULDED PLUG IS UNSUITABLE FOR THE SOCKET OUTLET IN YOUR OFFICE THEN THE FUSE SHOULD BE REMOVED AND THE PLUG CUT OFF AND DISPOSED OF SAFELY. Should the fuse need to be replaced please ensure that the replacement fuse has a rating of 13 amps and that it is approved by ASTA or BSI to BS1362.

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Paper capacity 10.00 35 45 50 FP-7818 FP-7824 FP-7830 FP-7835 FP-7845 FP-7850 4.Copy process 3.0 30. 0. 0.Development process 4.2 4. Tracing paper (Through multi-feed bypass) 1-999 reset to 1 (1-99 reset to 1 : FP-7818) 1-1 Introduction Section I . 1.9 3.5 50 18 24.Continuous copying OHP.Paper weight Ledger/A3–Invoice/A5 Cassette : 550 sheets x 2 (550 sheets:FP-7818) Multi-feed bypass : 50 sheets Front loading universal paper cassette Multi-feed bypass tray 250 sheets Cassette Bypass : 16–24 lbs ( 60–90g/m2) : 15–30 lbs (55–130g/m2) 13.1 4.5 14 15.5 24.5 18 FP-7830 FP-7835 FP-7845 FP-7850 <PU> <PG> <PU> <PG> <PU> <PG> <PU> <PG> 15.22.0 24.00/20.First copy time (sec) letter/A4 size without Auto mode letter/A4 size with Auto mode 7.5/23 19.Introduction 1.Paper feed 11.5/27.50 : 50%-200% (1%step) 8.15 : 0.5 17.Special paper 14.00. 0.1 4.00 20/20.5/19.00 35 45 43/41.0 5.0 5. 1. 1.71.0 21. 1.0 30. 0.5/17.5/16.50 28.Copy size 9.41.Paper exit tray capacity 12.50/19.Copy speed (cpm) Ledger/A3 : Legal/B4.6 Enlargement(fixed) Reduction (fixed) Zoom : 2.FLS : Letter-R/A4R : Letter/A4 : Invoice/A5 : 6.50 23.Copy ratio Desk Top Electrostatic photographic method Two component magnetic brush Ledger(11"x17") / A3(297 x 420mm) FP-7818 FP-7824 12.0 5. 1 Specifications 1.73.Type 2.Maximum original size 5.87.1 2.8 6.00/23.Label paper.58.6 2.9 3.0 18.82.

6 lbs / 70 kg FP-7845 161 lbs / 73. 180 sec. 270 sec.7 kg 23.0" x 22.Optional accessories Temperature : 50–86F/10–30 °C Relative humidity : 30–80% i-ADF ADF Sorter FA-A888 FA-A505 FA-S280 (10bin sorter: FP-7818/7824/7830) FA-S575/S660/S680 (20bin sorter: except FP-7818) System console LCC FA-DS72: FP-7818/7824/7830/7835 FA-DS82: FP-7845/7850 FA-MA301 * Specifications are subject to change without notice.45 kW/1.6 lbs / 70 kg FP-7830 149.9" x 26. 19.Ambient conditions 24.1" / 606 x 661 x 479 mm : FP-7818) (PU) (PG) FP-7818 138.Power consumption FP-7850 approx. FP-7835 approx. 40 sec. Less than 1.Power source AC120V 60Hz / AC220 .Dimensions (W x D x H) 23. FP-7830 approx.6 lbs / 70 kg FP-7835 149.Fusing system 16. 1-2 .6 lbs / 64 kg FP-7824 149.0" x 18.5 kW 20.9" / 606 x 661 x 582 mm 22.5 lbs / 73.240V 50Hz 21. 75 sec.Warm up time Heat and Pressure Organic Photo Conductor(OPC) 7 step digital+Photo/Auto button FP-7818 approx.15. FP-7845 approx. FP-7824 approx. 50 sec.9" x 26. 75 sec.Photoreceptor 17.5 kg FP-7850 161.Weight (23.Exposure control 18.

lower power consumption.800 sheets : five drawers + multipler sheet bypass FP-7830/7835/7845 FP-7850 5.1. • Functional expansion through optional accessories Equipping with the system stand and LCC allows a high copy volume Maximum feed paper capacity FP-7818 2.250 sheets : four drawers + LCC + multiple sheet bypass ADF and sorter can be connected with the main system easily by using exterior connectors. • Standard Automatic Duplexing (FP-7850) An Automatic Duplex Unit is provided as standard. 2 Features • Introducing Qualitative Reasoning Based Adaptive Controller copy density control With Qualitative Reasoning Based Adaptive Controller used for copy density control. in addition to front paper loading (550 sheets) + Multiple sheet bypass (50 sheets). Introduction • User friendly operation The touch panel enables simple operation. (FP-7845/7850) • Enhancements in serviceability If a problem should occur the self diagnosis system will indicate which area is responsible. optimum copies are maintained for a long time in variable environmental conditions. • Environmental considerations Quieter operation. (FP-7830/7835/ 7845/7850) 1-3 .800 sheets : five drawers + LCC + multiple sheet bypass 5.250 sheets : four drawers + multiple sheert bypass FP-7824 2. a higher content of recyleable plastic and our new Qualitative Reasoning Based Adaptive Controller.

Storage tray. 3 System Configuration ADF i-ADF Main Unit 50 Sorter ADU 550 Paper drawer 550 System console 550 Cover Storage LCC 3000 <Commonality of accessories> Accessories FA-DS72 System FA-DS82 console LCC ( FA-MA301 ) Copier FP-7818 FP-7824 FP-7830 FP-7835 FP-7845 FP-7850 x x x 1 x x x x 2 Option x x x x x x 2 Option 2 Option 1 + ADU 1 + ADU Standard Standard x x x Number of drawer paper feed Auto Duplex unit (FA-MADM6) ADF ADF i-ADF FA-A505 FA-A888 10bin sorter FA-S280 Sorter 20bin sorter FA-S575 20bin staple sorter FA-S660/S680 Key: System Console FA-DS72: Storage tray. Cover ( 3 drawers drive mechanism ) 1-4 .Cover x 1 = OK x = N/A ( 2 drawers drive mechanism ) FA-DS82: 550 sheets paper drawer.1.

0 2 DS72 22 LED No No 1 210 No No 10K 10K 80K 50 No * 2 70 4. Presentation Job memory 40 4. please refer to this chart and the Field Service Manual for each model.) Paper feed cassette System stand Copy speed Control panel design Transfer corona cleaner Drum separation finger Fuser lamp Process speed ( mm/sec.0 2 DS72 35 180 2.[ Comparison of specifications ] FP-7818 FP-7824 FP-7830 FP-7835 FP-7845 FP-7850 Warm up time ( sec. ) Developer suction Fresh toner recycling Toner bottle life Waste toner bottle capacity PM cycle Department counter Cover.) First copy time ( sec. 1-5 Introduction .9 1+ADU DS82 42 210 2.0 2 DS72 28 70 4.8 1 DS72 18 LED No No 1 170 No No 10K 10K 80K 50 No * 2 50 4. Interleaving.9 1+ADU DS82 50 LCD display LCD display No No 1 210 No Yes 20K 120K 120K 100 No * 2 No No 1 210 No Yes 20K 120K 120K 100 No * 2 LCD touch panel LCD touch panel Yes Yes 2 340 Yes Yes 20K 120K 120K 300 Yes 5 Yes Yes 2 340 Yes Yes 20K 120K 120K 300 Yes 5 * Except OHP Interleaving This Service Manual is based on the FP-7850. To identify areas where the other models differ.

Job Memory Key Copy Size Keys Print Key 1-6 .1. 4 Operation • FP-7818/7824/7830/7835 Energy Saverkey Reset Key Interrupt Key Clear/Stop Key LEDGER LEGAL LETTER INVOICE 1 2 3 4 5 6 7 8 9 0 Recall Key Original Size Keys Special Effects Panel Communications Monitor To recall the number of copies selected during a copy run. Copy Size Keys Quantity Keys Print Key • FP-7845/7850 Energy Saver User Preset Key Touch Panel Display Interrupt Key Reset Key Manual Key Press to reset all features to initial power-on state. 1 2 3 4 5 6 7 8 9 0 Multi Size Key Original Size Keys Quantity Keys Ready Indicator Ready: Green LED Not ready: Red LED Copy Reservation: Flashing Clear/Stop Key Press to stop copy run or clear copy count in display.

1 Keys Multi-Size Feeding (Except FP-7818/7824) • Using i-ADF Original Count (Except FP-7818/7824) • Using i-ADF and ADU 2 in 1 mode Access User Preset OHP interleaving mode Zoom Margin Shift Mode No. 8 9 10 11 Keys Edge Mode Book Mode Memory In/Job programs Duplexing mode selection (Except FP-7818/7824) • Using ADU 2 3 4 5 6 7 12 2:1 Copy (Except FP-7818/7824) • Using i-ADF 13 2-Page copy/2 in 1 mode selection (2 in 1 : Except FP-7818/7824) 1-7 .(1) Special Effects Panel (FP-7818/7824/7830/7835) Introduction 1 2 3 4 123 OHP OHP 13 OHP OHP 5 6 2 1 7 8 2 M 12 1 2 9 M1 M2 11 10 No.

Keys Manual Key PHOTO/AUTO Exposure Control (DARK) No. 1 Indicator Adding Paper Toner Staple (Except FP-7818) Replacing Waste Toner Bottle Reduction Enlargement Service Call • Flashes for routine maintenance. • Lights steadily for duplex maintenance Paper Misfeed Copy Count Display Indicates number of copies. etc.(2) Communications Monitor (FP-7818/7824/7830/7835) 1 2 3 1 4 5 6 FP-7818/7824 % mm 7 FP-7830/7835 STAPLE SORT STACK 13 LEDGER LEGAL LETTER LETTER INVOICE 14 15 16 STAPLE SORT FP-7718 STACK 12 18 11 10 17 9 8 No. functions maintenance. Exposure Indicator Paper Size Indicator Paper Drawer/Tray Indicator (–) Paper misfeed location (•) Mode Select Indicator Staple Sort (Except FP-7818) Sort Group 8 9 10 11 12 2 3 4 5 6 No. 13 14 15 No.. zoom ratio and error code. 7 Indicator Message Display (FP-7830/7835) Indicates procedures. 16 17 18 Keys Exposure Control (LIGHT) Paper Drawer/Tray Mode Select Key 1-8 .

5 Component Location ( Outer view ) ADF Control Panel i-ADF Bypass Sorter FP-7818 Sorter System console FP-7824/7830/7835 LCC (Except FP-7824) LCD touch panel i-ADF Control panel Right cover Front panel Sorter Bypass Paper feed cover System console FP-7845/7850 LCC 1-9 Introduction .1.

4 mirror No.(1) Inner view 1 2 3 4 5 6 7 38 8 9 10 11 12 37 36 35 34 33 13 14 15 16 17 18 19 31 30 20 32 21 29 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 28 27 26 25 24 23 22 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Paper feed roller DFP roller Pick-up roller ADU Paper feed roller Corona cleaner Transfer/Separation corona Drum Transfer belt Pressure roller Fuser lamps Fuser separation finger (lower) Reverse roller Fuser separation finger (upper) Paper exit roller Paper exit sensor Heat roller Cleaning Web roller Full-speed unit home postion sensor Drum separation finger Half-speed unit Full-speed unit Lens Position sensor Thermistor AE Sensor Main motor Lens unit Charge corona No.6 mirror Slit glass No.5 mirror LED array Magnetic roller Registration roller Bypass pick-up roller Bypass paper feed roller Bypass DFP roller Middle roller 1-10 .

(2) Fan/Motor Location Introduction Optics fan Optics fan Mirror stepping motor Optics drive motor Lens stepping motor Developer cooling fan Toner bottle motor Dust collecting fan ADU drive motor (FP-7850) Exhaust fan Optics fan Main motor Suction/Ozone fan Lifting motor (lower stage) ADU paper length guide motor (FP-7850) ADU paper width guide motor (FP-7850) 1-11 .

(3)Sensor Location Mirror home position AE (Automatic original density sensor) Original size Exposure lamp home position Lens home position Paper exit Front cover open/close ADU paper pass 1 (FP-7850) ADU paper length (FP-7850) ADU paper pass 2 (FP-7850) ADU paper detection (FP-7850) ADU paper width (FP-7850) Platen cover angle Platen cover open/close Paper feed cover open/close Toner bottle home position Toner level Bypass paper size Bypass paper detection Total counter Waste toner bottle Middle roller paper pass (upper/lower stage) Bottom plate upper limit sensor (lower stage) Registration roller paper pass Paper level (lower stage) Paper detection (lower stage) Copy density Toner density ADU detection (FP-7850) 1-12 .

(4) Solenoid/Clutch/Discharge lamp Location Introduction 1-13 Separation solenoid Paper exit solenoid (FP-7850) Door switch Discharge lamp Registration roller clutch Middle roller clutch Paper feed clutch Bypass pick-up solenoid Power switch Paper feed clutch (lower stage) ADU clutch (FP-7850) Pick-up solenoid (lower stage) Recycle solenoid (5) PCB Location Control panel 3 LVPS (Low voltage power supply) Control panel CPU Control panel 4 HVPS (High voltage power supply) AC driver Main CPU Paper feed driver Automatic duplex unit driver (FP-7850) LED array .

1. 6 Copy Process –DC Charger Discharge lamp Blacking prevention Trimming Exposure Cleaning Developer Reduction Discharge Original Toner Separation Transfer Exit Fusing ADU Paper feed Primary Charge: Charge corona Drum Image Exposure: Illumination Developing: Latent charge image(–) Toner (+) Drum surface approximately-800V DC Transfer/Separation Latent image Toner Latent charge image Magnetic roller Fusing: Heat roller Fuser lamp Paper Cleaning: Cleaning blade Drum Paper Separation corona Transfer corona Pressure roller Discharge lamp: Discharge lamp 1-14 .

) • A ground terminal is provided on the back of the copier main body. 4) 5) Install the machine with enough space around it.1. The maximum power consumption is 1. and safe operation. 7 Precautions on Set Up Copy machine performance and the copy quality is subject to and dependant on environmental conditions.) Make sure the machine is properly grounded. low temperature or low humidity • The temperature or humidity varies suddenly • Being exposed to direct sunlight • Dusty space • Badly ventilated location • Exposed to chemical gases (such as ammonia gas) • Exposed to strong vibration • Directly exposed to direct wind (ex. Use an independent power supply of 120 V and 15 A (220-240V and 7A)or higher. To maintain good performance. observe the following precautions: Introduction 1) For safe operation and to avoid trouble do not install the system under the following conditions: • High temperature. high humidity. outlet of air conditioner) 2) 3) The weight of machine is 220lb(100 kg) or more with options. quality.45 kW. 4"/100 mm 14"/350mm 28"/700mm Exit tray Copier Multi sheet bypass 1-15 . (Do not ground to gas or water pipe. (Do not use a extension cord. It must be placed on a firm platform which is level.

• Stand the drum with the drum gear up for storage. 2) Do not mix foreign materials. water. • The machines are designed to use exclusive toner and developer for specific models. 8 Precautions with Consumables (1) Photoreceptor drum • Do not touch the surface (with the hand or anything else). When delivered by truck the temperature inside must be not higher than 104 F/40 C. because some containers may change the characteristics of the supply. the inside temperature can typically be 140 F/60 deg. (Under the sun in summer. • Do not place it in strong light (such as direct sunshine or at window). 3) Do not place into other containers. • Be careful not to expose them to rain or direct sunshine during transportation. Pay attention to the following items for storage and transport. Do not mix with toner and developer for other models.C or higher in a closed vehicle compartment. Toner and developer must not be placed into other containers. Be careful not to include foreign materials in the toner and developer. If you spilled toner or developer on a table or floor when adding toner or developer in the developer unit. (2) Toner Developer 1) Do not mix different types of toner and developer. discard what was dropped. • Store them in a dark and cool location (lower than 95 F/35 C) and out of direct sunshine. • Be careful not to smear with saliva. • Do not store the developer unit with the photo receptor drum installed without covering it with clean paper. Vinyl chloride potentially changes the characteristics of supplies because of migrating plasticizers.1.) 1-16 . • Do not expose it to chemical gas or vapor. oil and so on. • Do not place a where the temperature is high. Such supplies may damage the drum as well as cause other trouble with the image. 4) Precautions on storage and transport • Toner and developer additives are sensitive to temperature (high temperature in particular) and humidity (high humidity in particular).

If you have breathed in a lot of toner by mistake. Any toner on the skin should be washed off with soapy water. or beating. eye protection and so on before handling any solvents such as IPA. alcohol. store in a low humidity condition. and developer when pouring in the developer unit. • Toner stuck on clothing must be removed in a dry condition (by a vacuum cleaner. • Toner spilled must be cleaned with a vacuum cleaner. Therefore. Do not put supplies near heaters. • Any wasted consumables (photo receptor. . • Wear rubber gloves. inhaling it is undesirable even if a powder is simply dust. • If exposed to flames toner and developer will burn. 1-17 Introduction • There are normally no special problems with storage and transport in a cold climate but. Wiping off with benzine. developer and toner) should be recycled. rinse out your mouth with water completely. or thinner is not recommended because it may partially melt the components of toner even more. brush. Toner on skin does not cause any damage to health but. • Handle the toner gently when changing cartridges. Keep these supplies away from open flames. be careful not to inhale toner .) and then washed with soapy water. and then wiped with a cloth dampened with a neutral detergent and wrung out. resulting in a harder stain and spot.5) Safety and hygiene Toner has the property of easily being wind blown.

Section II Control Functions 2.These three values are compared with the ideal gamma curve stored in the copiers memory. the copy density sensor which is installed under the developer unit controls the image to stablize the copy image. the copy image may vary with time depending on the characteristics of drum and the environmental variations. copy quality is stabilized by the various compensations enabled by Qualitative Reasoning Based Adaptive Controller adjustment in image production. The copier detects the amount offset from the standard gamma curve (such as "a little background" or "light image") and calculates the variables for copy density control in accordance with Qualitative Reasoning Based Adaptive Controller. Control Functions 2-1 . solid area density and good reproduction of fine lines regardless of environmental changes and variation with time and copy volume. In this way it finds the optimum compensation values to tighten the gamma curve for maintaining peak copy quality. 1 Image Control Qualitative Reasoning Based Adaptive Controller • Even if the toner density is at it's standard level. medium density and black density) and has a direct effect on background. By means of this process. • Controlling the image During initialization after turning on the power. medium density (line pattern density patch) and black density developed on the drum surface. • The control of the gamma curve stabilizes copy quality by monitoring three points of copy quality (white density. the copy density sensor reads the white density. To prevent this change.

the system reads the patch marks and determines the best values of exposure and surface potential to establish the best gamma curve for optimum copy quality.000 sheets following execution of Qualitative Reasoning Based Adaptive Controller (But. and line pattern density and one for detection of black density. one for white density. The resultant value is used for sensor compensation. clean the sensor at the same time as the replacement of the drum. The system provides a measured amount of light and detects the reflected light. various components are adjusted according to characteristics of the gamma curve. • As the reference value of the white density changes. a) During initialization after turning on the power. • Qualitative Reasoning Based Adaptive Controller is applied at the following intervals. This becomes the reference value. While successively reasoning and learning the change of process characteristics regardless of environmental changes and the variations with time and the number of copies on the copier. every 200 sheets following the execution of F8-09 for the next 500 sheets) c) After turning on the power (up to 200 copies) d) After replacing the toner bottle (up to 200 copies) • Copy density detecting sensor Two sensors for detection of copy density are used.) • To correct for toner build up on the sensor. (Temperature and humidity sensors are not used.• Qualitative Reasoning Based Adaptive Controller Qualitative Reasoning Based Adaptive Controller is adaptive control on the basis of quantative reasoning theory. b) After every 1. Reference F mode F5-25: Qualitative Reasoning Based Adaptive Controller Operation ON/OFF F6-80: Automatic compensation value (read only) F6-81: Automatic compensation value (read only) F6-82: Automatic compensation value (read only) F6-28: White density reference value (set by Qualitative Reasoning Based Adaptive Controller) F6-29: Black density reference value (set by Qualitative Reasoning Based Adaptive Controller) 2-2 .

The operation flow is as shown below.5 V) Yes No CPU will adjust sensor gain control signal Memory number will be changed to new number in memory. F8-09 start CPU will check toner density sensor output. Control Functions The change in magnetic flux density in accordance with the amount of carrier <Change of toner density and change of TDC sensor output voltage> Amount of carrier passing TDC sensor Less Much Toner density condition Sensor output voltage High Low Lower than normal Higher than normal <Control> The following controls are necessary for normal control of toner density 1) Automatic adjustment of TDC sensor gain (during execution of F8-C09) (to attain the standard reference level). 2) Maintain the standard level by control of toner density during use. (F6-21 or F6-26) Toner density sensor output voltage will be adjusted to 2. 2 Toner Density Control To keep toner density(toner carrier ratio) in the developer unit constant. <Fundamentals> (magnetic power) in the developer (mixture of toner and carrier) is detected by the TDC sensor and is converted to a voltage to control the toner density.2. (2.5 V 2-3 . the TDC sensor (toner density sensor) which is installed under the developer unit detects the amount of carrier in the developer unit to control the toner density. <Explanation of the control system> 1) Automatic adjustment of TDC sensor gain Automatically adjust the reference through the TDC sensor by executing service mode F8-09.

Rotate bottle for 7 seconds: supply toner to reserve tank. This is not a final confirmation for proper TDC adjustment. not the developer unit.) Do not supply toner. 2-4 . 1. (Reference 1) Toner supply route Bottle Reserve tank (hopper) Developer unit (Reference 2) Forced toner supply Supply toner: supply for 4 seconds from reserve tank. control the timing of toner supply to the developer unit so that the output voltage is 2. (Toner is not supplied to developer unit.5V at all times to keep the toner density constant.2) Maintain standard toner density While checking the output voltage of the TDC sensor for every copy.) Note: Bottle rotation means toner is being added to the reserve tank.4 g) Rotate bottle for 7 seconds: supply toner to reserve tank. toner is not supplied. (Toner is not supplied to developer unit. Note) During bottle rotating. 1.1 g) Perform twice.5V? NO YES Supply toner: supply from reserve tank for 6 seconds (amount of toner supply: approx. (amount of toner supply: approx. Is the measured output voltage over 2. Check TDC sensor output voltage at copying (or mixing).

this mechanism allows regular copy operation without error conditions (service man call) (providing the malfunction does not affect the basic copying operation and the appropriate function is not selected). 2-5 Control Functions . "(EX-XX)" EX-XX (Error code) Appropriate function not selected Normal indication of copying User mode Service mode XXXXXX (Electronic counter value at malfunction) Note: Only 30 records can be stored.2. <Indication> Appropriate function selected The selected function is unavailable. Earliest records are replaced by new ones as space is required. 3 Trouble Avoidance Mechanism When some malfunction happens. repair is necessary. select others.

<Self-recovery item> Item Copier paper feed ( upper ) Copier Paper feed ( lower ) System stand paper feed ( upper ) System stand paper feed ( middle ) System stand paper feed ( lower ) System stand paper feed timing LCC Lift up LCC Lift down Duplex unit ( length ) Duplex unit ( width ) duplex unit ( sensor ) Stapler Sorter ADF ( motor ) ADF ( sensor ) Error code E2-01 E2-02 E2-03 E2-04 E2-05 E2-10 E2-06 E2-07 E6-03 E6-04 E6-05 E7-06 E7-07 E7-10 E7-11 Copier Accessories 2-6 .

This process is completed unnoticed by the end user during regular operation. Toner Recycling System allows us to maximize toner yield. but on a regular basis is switched to the "Refresh" mode. <Process> There are two methods of handling the mixture of materials found in the cleaning unit following the drum cleaning. there by removing all undesireable particles from the system. while avoiding the potential side effects of recycling used toner. In addition. This handling is normally in the "Recycle" mode. toner cleaned off of the drum needs to be returned to the developer for re-use. Toner Recycling System directs the recycle solenoid to switch from Recycle to Refresh Mode for the next 100 copies. 2-7 . the undesireable particles are removed from the developer unit. the copy process can damage some toner. 4 Toner Recycling System To maximize the number of copies which can be produced for each bottle. and forwarded to the waste toner bottle to be discarded. the system will initiate the Refresh Mode automatically.). During the "Refresh" mode. the cleaning unit is emptied into the waste toner bottle. During the refresh cycle. Recycle Mode Developer unit Drum Cleaning unit Refresh Mode Developer unit Drum Cleaning unit Waste toner bottle Note: Toner Recycling System also monitors TDC. other undesireable materials may be cleared from the drum surface and mixed with reControl Functions useable toner (such as paper dust. <Control> Every programmed copies (500/1000/1500/2000 as set by F5-65). etc. If the ratio becomes too high.2. Under normal circumstances.

500ms.2. The re-try control for misfeeds is executed for each paper feed unit. Re-try H Paper feed sensor L 2-8 . the paper feed clutch turns on again (re-try operation). Paper feed motor ON OFF Motor off 925ms. • When the paper does not reach the paper feed sensor within a specific time after two re-try operations. 5 Re-try Control for Paper Misfeed • Copy paper should pass the paper feed sensor within a specific time after the paper feed clutch turns on. To reduce paper misfeeds due to a slipping paper feed roller. ON Paper feed clutch OFF 2038ms. "jam" is indicated.

Section III Sub Assemblies 3. paper transport.1 Main Drive The driving mechanism of this machine is as follows. fuser unit and paper exit unit 3-1 Sub Assemblies Fuser unit . paper feed unit. Main motor Pulley 1 Pulley 2 Transport roller Magnetic roller Drum Registration roller Bypass unit Middle roller Paper feed unit Middle gear Middle roller Paper feed unit (Lower stage) Name of motor Main motor Driving method DC24V driving Driving unit • Rotation of photo receptor drum • Developer unit.

(1) Detecting sheet bypass paper size • The paper size for the sheet bypass is detected by a matrix of sheet bypass paper size sensors which are installed on the sheet bypass tray. • When setting the paper in the sheet bypass tray and adjusting the paper guide. S1/S2 Ledger/A3 Legal/B4 Letter/A4 Letter-R/A4R Invoice/A5 S4 Paper size detecting sensor S1 ON ON ON OFF OFF S2 OFF ON OFF ON OFF S4 ON ON OFF OFF OFF 3-2 . the matrix is as follows.

• N2 through S3:Attract the developer to the sleeve from the mixing mill.(2) Developing • The developer mixing unit contains developer which is a mixture of fine powder (non-magnetic toner) and fine ferrite carrier. The height of magnetic brush is controlled by the gap between the doctor blade and the sleeve surface.61 mm –250 V reference N2 S1 S2 N1 N2 S3 Reference: • The twin field magnet roller presents enhanced developing performance by a wider developing area which results from two pole peaks (S1 and S2 pole) facing the drum surface. • The sleeve is charged opposite of the drum and an electric field is formed. The toner becomes charged ( + ) and the carrier becomes charged ( – ). • The sleeve has applied ( – ) bias voltage. • S3 pole: Raise the head of developer and control the head height with the doctor blade. 650 g 4. • The developer is mixed by the transport screw and the mixing mill. • The drum with an electrostatic latent image (negative charge) is rotating clockwise and makes contact with the magnetic brush. • N2 through S1: Transfer the developer to the developing position. The developer is transfered counterclockwise in the rotating direction of the sleeve.8 mm 0. The distance between the drum and the sleeve is controlled with the spacer rings. and the magnetic brush is formed.0 % 0. 3-3 Sub Assemblies . • N1 through N2: Separate the developer from the sleeve. which prevents the drum from covering with toner. Amount of developer Initial toner density DSD BSD Developing bias voltage Approx. The positive toner is stuck on the electrostatic latent image on the drum. The developer is magnetically stuck on the aluminum sleeve of the magnet roller.

TDC sensor output Toner empty Hopper sensor motor High (Lower toner density) High Low (Higher toner density) Low Detect Reverse rotation Toner bottle — Toner supply Add toner roller Rotate — — — Supply toner to developer unit Supply toner to sub-hopper — — Non detect Forward rotation Rotate Detect Not detect Stop Stop — — • A toner supply by the toner supply roller (approx.4 g of toner of to the hopper. • Separating the developer mixing unit from the toner supply unit of toner hopper. 3-4 . the toner supply shutter is closed to prevent toner drop. 16 seconds) can supply 1. by turning the Toner Hopper Motor in either direction: Forward Direction: The bottle turns (via a spring clutch) to supply toner from the Toner Bottle to the Reserve Tank. Reverse Direction: The Toner Supply Roller turns (via a spring clutch) to supply toner from the Reserve Tank to the Developer Mixing Unit. This direction is controlled by the Toner Volume Sensor. This direction is controlled by the TDC Sensor. so toner addition is done in two stages.(3) Supplying toner The Toner Hopper Unit supplies toner to the Developer Mixing Unit via the Reserve Tank.

After lighting the no toner indication. 3-5 . the toner bottle shutter opens and is able to add toner to the hopper. The copier is disabled. Accordingly.(4) Toner level detection • When the toner level sensor in the toner hopper detects no toner remaining. The "Add toner" indication is cleared by replacing the toner bottle. the machine stops after 300 copies. The machine can be used after the user's key input. Detecting the toner bottle position Sub Assemblies • Insert the toner bottle in the hopper and turn to the specified position. and does not detect toner after continuously turning the toner bottle "Add toner" is displayed. • The bottle home position sensor which is mounted in the toner hopper detects the position of the toner bottle and the toner bottle stops turning at the specified position.

will be reduced (no change for process rate)to increase fusing time. To control the maximum power consumption. which heats the heat roller.(5) Temperature control The heat roller is provided with two halogen lamps (main heater lamp and sub heater lamp). the sub heater lamp turns ON during warming up and after release of pre-heat mode only in order to reduce the warming up time of fuser unit. the main motor turns on and the heat roller and the pressure roller rotate. the error E4-01 is indicated. the machine is ready. the number of copies per min. In this case. the operation of main heater lamp is inadequate. the main heater lamp and the sub heater lamp turns ON. Time Main motor Main lamp Sub lamp 3-6 . The main heater lamp turns ON during warming up and copying operation. Switch ON (°C) 190 175 Heat roller surface temperature Warm-up complete Print key ON Energy Energy Copy complete Saver ON Saver OFF 0 210 sec. c) Afterwards. the main motor turns off. the thermister detects the temperature of heat roller. When the temperature of the heat roller surface rises enough. The temperature control in the copying operation and the standby is done by the main heater lamp. b) At a specified temperature. (Note) • When the temperature of heat roller surface does not reach the specified value in the specified time from power ON. After all copy quality standards are set. The heat roller keeps the temperature to the specified value by turning on/off the main heater lamp. the machine speed will return to the regular number of copies per min. • Sequence a) When turning ON the power. • If when the power is turn ON in an absolutely frozen condition of fuser roller (a very cold morning) or copies are continuously made. When the heat roller temperature reaches the specified value.

the platen cover angle sensor turns on and four original size detection sensors operate simultaneously. 30 degrees to insert the original. the output of the AE sensor must be at a proper level. – Detect ( Original size detection matrix ) – No detect Sub Assemblies Original size detect sensor(1) AOS1 Ledger/A3 Legal/B4 Letter/A4 Letter-R/A4R Invoice/A5 No original Original size Original size Original size Detect sensor (2) detect semsor (3) detect semsor (4) AOS1 AOS2 AOS3 AOS4 AOS3 AOS2 AOS4 (7) Adjusting quantity of light of AE sensor • In pre-scan. and the original density is read by the AE sensor. Reference: Service mode for adjustment (for details refer to the "Field Service Manual") F6-01: Compensation of vertical copy ratio (compensating scanning speed of optics unit) F6-02: Compensation of full size focus F6-03: Compensation of horizontal copy ratio (compensating lens position) F6-05: Compensation of paper registration position (Compensating timing roller clutch turning on timing) F6-11: Compensation of quantity of exposure light for full size F6-12: Compensation of quantity of exposure light for photo mode F6-16: Compensation of quantity of light for AE sensor 3-7 . the original reflects the light of the exposure lamp voltage adding the above compensation value. • The automatic original size detecting operation is released when pressing "original size selector" key in the control panel.(6) Automatic detection of original paper size • Opening the platen cover by approx. the exposure lamp voltage is adjusted to be approx. when operating image density control (QuantamTM Technology). setting the original in ADF or selecting "0" for F5-52. Therefore. and the system memorizes the compensation value at that time. • The original size is read again by turning on the platen open/close detecting sensor when closing the platen cover. 2. • In pre-scan automatic exposure mode. The result corrects the exposure before copying. • The original size detection sensors consists of light emission unit and light reception unit. The light from the light emission unit is thrown on the original and the reflected light is received by the light reception unit to check the existence of the original.7V of AE sensor output when reading the standard density mark.

pull out the plug. It is essential to perform these service activities properly for customer satisfacation.B short-circuit.C. 4. • Reassemble parts in the reverse sequence of the disassembling unless otherwise noted. therefore.Section IV Preventive Maintenance The periodic maintenance service is performed by machine cleaning and parts replacements. you should discard the waste parts and papers. • After taking apart. • Using a vacuum cleaner for the cleaning of the TDC sensor could cause electrostatic damage. The purpose of this service is to maintain the machine performance and the copy quality. • Make sure to use the correct screw sizes.8 “Precautions with consumables”. • Before removing the equipment. the connectors on any P. Preventive Maintenance (1) Timing (2) Cleaning of roller • Rollers should be cleaned with water and cloth. • For the drum. • Perform the periodic maintenance service in accordance with the chart of periodic maintenance areas. • Do not let the lithium battery on P. 1 Precautions for Periodic Maintenance Service • You should get the customer's agreement for when and where the maintenance service is performed. comply with the precautions shown in 1. • When electricity is applied. use blower brush and cotton swab for the cleaning of these parts. • Let the customer know when you are finished. • Use IPA (isopropyl alcohol) if they are very dirty. When operating the machine with the cover removed. • After finishing the maintenance service. do not operate the machine. • Before using solvents such as IPA (isopropyl alcohol). before cleaning any units. disconnect the power plug. must not be connected or disconnected. and clean the surrounding area. but to avoid them. be careful so that clothes are not caught by moving components. • You should completely explain the philosophy maintenance service is not to repair problems. • Use toothed lock washer for the installation of ground wires to secure electrical continuity.C. • You should prepare the necessary replacement parts and tools for cleaning beforehand. put on rubber gloves and eye protection.B. 4-1 . • Replace blown fuses with the specified rated ones. remove the sensors beforehand. (3) Precautions for disassembly and adjustment • Before disassembling the machine. And.

000 copies X X X X Developer FQ-ZK20 (FP-7830/7835/7845/7850) Drum (FP-7818/7824) FQ-HK10 Drum FQ-HK20 (FP-7830/7835/7845/7850) Side seal (Front) FFPXG51H00 Side seal (Rear) Spacer ring (Front) (FP-7818/7824) Spacer ring (Front) (FP-7830/7835/7845/7850) Spacer ring (Rear) (FP-7818/7824) Spacer ring (Rear) (FP-7830/7835/7845/7850) Waste toner bottle (FP-7818/7824) Waste toner bottle (FP-7830/7835/7845/7850) Toner dispersion cover FFPXG50H00 FFPHQ0057 FFPHQ0061 FFPHQ0058 FFPHQ0062 FFPQA0164 FFPQA0165 FFPXG08H00 Magnetic roller stopper (Front) FFPXG06H00 (Except FP-7818/7824) Magnetic roller stopper (Rear) FFPXG07H00 (Except FP-7818/7824) Drum separation finger FFPLK0332 Corona FFPXG60H00 4-2 .000 copies Replace at 1.200.200.000 copies Item Paper feed unit Service Paper feed roller DFP Roller Pick-up roller Cleaning sheet (Except FP-7818/7824) Registration roller Registration roller bearing Middle roller Torque limiter (Bypass) Torque limiter (Copier) Developer unit Cleaning blade Wire Developer (FP-7818/7824) Part number FFPMA05411 FFPMA05411 FFPMA0542 FFPHK0951 FFPMA0539 FFPMQ0559 FFPMA05451 FFPXQ24H00 FFPXQ04H00 FFPHK0942 FFPXL05H00 FQ-ZK10 Q'ty per Maintenance cycle (x 1000) unit 2 2 2 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X X 80/120 160/240 240/360 320/480 400/600 X X X X Replace at 1.200.4.000 copies Replace at 1.080.000 copies Replace at 1.000 copies Replace at 1.000 copies FP-7830/7835/7845/7850: per 240.000 copies X X X X X X X X X X X X Replace at 10.080.2 Maintenance chart 1) Replacement Maintenance cycle FP-7818/7824 : per 80.

000 copies X X X X X X Replace at 1.Item Fuser unit Service Separation finger (Upper) Separation finger (Lower) Thermister Fuser lamp (850W) Part number FFPLK0331 FFPLK0231 FFPBL0015 H12V085WN2A Q'ty per Maintenance cycle (x 1000) unit 5 4 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 X X X X X X X X X X X X X X X X X X X X X X X Replace at 1.000 copies X X X X X X X 80/120 160/240 240/360 320/480 400/600 X Cleaning web FFPKM0316 (FP-7818/7824) Cleaning web FFPKM01343 (FP-7830/7835/7845/7850) Cleaning web pressure roller FFPMA0470 (Except FP-7818/7824) Heat roller (FP-7850) FFPMA0590 Heat roller (FP-7845) Heat roller (FP-7830/7835) Heat roller (FP-7818/7824) Heat roller bearing Heat roller gear Fuser entry guide (lower) Pressure roller (FP-7818/7824) Pressure roller (FP-7830/7835) Pressure roller (FP-7845/7850) Pressure roller bearing Heat-insulating bushing Optics unit Exposure lamp Dust protection filter A Dust protection filter B Filter A Filter B Main body Suction/Ozone filter Ozone filter 1 FFPMA0566 FFPMA0577 FFPMA0574 FFPMQ0572 FFPMF1057 FFPKF1308 FFPMA03582 FFPMA04181 FFPMA0565 FFPMQ0573 FFPJF0034 E08V025WN2A FFPJD00382 FFPJD00421 FFPGB0022 FFPGB0023 FFPHJ0039 FFPHJ0038 Ozone filter 5 FFPHJ0042 (FP-7830/7835/7845/7850) Ozone filter 7 FFPHJ00461 (FP-7818/7824) Dust protection filter FFPHJ0049 Discharge lamp Transfer/Separation corona Wire 1 Wire 2 Wire cleaner ADU Paper feed roller DFP roller F/R Mylar Storage roller Paper feed pad PQ24V10WMG2 FFPVL01H01 FFPXL04H00 FFPXL05H00 FFPXL01H00 FFPMA0558 FFPMA0559 FFPXD07J00 FFPMA0557 FFPKP00821 4-3 Preventive Maintenance .200.200.

4. 14 17 20 25 19 18 22 9 8 17 24 23 10 1 2 3 7 4 30 5 15 16 13 11 21 12 6 4-4 .3 Cleaning Method • Cleaning method for each PM service visit is shown below.

Use IPA. and rotate mag-roller 4~5 times counterclockwise. high voltage leak may occur. if toner is stuck on the rollers.Clean the lower developer frame by cloth with water. . Remove the toner dust on lower developer frame by brush or vacuum cleaner. . if the roller is very dirty. . (As little as possible.Pay attention when replacing corona wire (No sagging or kinking) .Lift the developer unit (mag-roll side) up 45.Use IPA.Do not use cleaning cotton.Don’t damage separation finger edge. 10 Lower developer frame Brush / Dust cover Vacuum cleaner / Cloth with water .Remove toner dust on separation finger. . .) . . . (to be continued) 16 Fuser heat roller / pressure roller Cloth 4-5 Preventive Maintenance Paper feed unit Developer unit Fuser unit Brush / IPA Cloth with water .If not replaced at PM cycle.Do not use cleaning cotton. 11 Transport belt 12 Transfer corona wire / Corona case/ Transfer guide plate 13 Fuser guide plate 14 Fuser thermister 15 Fuser separation finger (upper/lower) Cloth with water Cloth Cloth Cloth .Remove paper dust by brush deleted.Cleaning position 1 Sheet bypass paper transfer roller 2 Sheet bypass paper feed roller 3 Timing roller 4 Middle roller 5 Paper feed roller 6 Paper transfer roller 7 Cleaning sheet 8 Corona wire 9 Corona grid / Corona case Tool/solvent Cloth with water / IPA Work/precaution .Clean by cloth with water.

Clean with soft touch. IPA Blower brush Cloth with water Cloth/Blower brush IPA IPA Cloth Vacuum cleaner Cloth with water / Neutral detergent Cloth with water / IPA .1 ~ 6) Optics unit 4-6 18 Lens Tool/solvent Work/precaution Blower . brush / the mirror surface may get Glass damaged cleaning .Cleaning position 17 Mirror (No.Same as paper feed unit .Clean the dust on the sensor 19 Original size detecting sensor 20 Reflector 21 Copy density sensor 22 Discharge lamp filter 23 LED array 24 Slit glass 25 Platen glass 26 Platen mat 27 Ozone filter 28 Dust collection filter 29 Outer cover Main body Duplex unit 30 Paper feed roller .Clean with soft paper and IPA as paper with required. otherwise.

) Multi-feed bypass 4-6 Main body 4-30 Fuser Unit 4-17 Optics Unit 4-22 ADU 4-27 Paper feed Unit 4-9 Drum Unit Developer Unit 4-12 4-7 Preventive Maintenance . (For other models.4. 4 Disassembly and Re-assembly PM parts replacement procedure • The replacement procedure of PM parts is as shown below. The replacement cycle of PM parts is shown for the FP-7750/7742. refer to the correct Service Manual.

out of the slot and slide the magnet clutch in the arrow direction 2 . 4-8 . in order to avoid welded point damage.(1) Multi-feed bypass Item Part name 1 Pick up roller 2 Paper feed roller 3 DFP roller 4 Torque limiter 5 Registration roller 6 Registration roller bearing 7 Cleaning sheet Cycle 120K 120K 120K 1200K 1080K 1080K 5. push the hook 1 . 6 4 3 2 1 600K 7 Caution Magnet clutch Hook Hook “D” cut “D” cut Welded point (Front view) (Side view) Welded point When removing the magnet clutch.

Preventive Maintenance 4-9 (7)remove the paper feed roller. *Open the copier paper feed cover. 7 (2)Remove the paper stopper. (x 2) (2)Disconnect the harness.1) Replacement of the pick-up roller/paper feed roller 1 2 (1)Remove the screws and covers. (3)Remove the torque limiter. (4)Check the rotation of the torque limiter. Note: Remove right cover (2 screws). (4)Remove the touch ring. (2)Remove the DFP roller. (5)Remove the pick-up roller 6 1 3 2 4 (6)Remove the touch ring. (3)Remove the sensor lever. (3)Remove the bypass tray. SV103 2) Replacement of the DFP roller and torque limiter 3 *Conduct the procedure 1. (1)Press the DFP roller lower side then remove touch ring. 3 1 2 . 1 3 1 2 (1)Remove the touch ring.

3 2 4 5) Remove the drive gear. timing roller. 7 2 1) Remove the cleaning sheet under the lower timing roller. 3 4 3 5 5 4 a) Open the waste toner bottle cover and remove the bottle. clutch. Remove the paper guide plate (Two screws). 2 4 5 7 4) Remove the E rings (both sides). 5 1a 2 1b 2 1) Open the copier paper feed cover and disconnect the cover link. b) Disconnect the harness. 4-10 . 3) Clean the timing roller with IPA. 3) Remove the upper registration roller. 2) Remove the bypass unit (Two screws). b) Turn the toner hopper 180°. 2) Open the front cover. 1 6 1 1) Remove the top cover (Two screws). 2) Remove the tension spring (X 2). 7) Remove the Lower registration roller. 1 4) Re-install new cleaning sheets (x2). and E ring. 2a 3) Pull and turn the developer release knob.3) Replacement of the registration roller and cleaning sheet 1) Remove the right cover and rear cover. 6) Remove the bushing support plate and bushing (1 screw). 4) Remove the drum unit. 2) Remove the cleaning sheet on the top cover. 5) Remove the connector and developer unit. a) Remove the knob (One screw).

(2) Paper feed unit Item Part name 1 Paper feed roller 2 Pick-up roller 3 DFP roller 4 Torque limiter 5 Middle roller Cycle 120K 120K 120K 1200K 1080K 2 1 3 4 5 4-11 Preventive Maintenance .

2) Remove paper feed roller.1) Replacement of the paper feed roller and the Pick-up roller 1 1 1) Remove the right cover and rear cover. Note: Confirm the direction of the rollers before the installation. 2 2 1 1) Disconnect the harness of the paper feed unit. 3 2) Open the copier paper feed cover. 2 3 2 1 1) Remove the touch ring. 4) Remove the the pick-up roller. Note: Move the stopper to the larger hole and remove. 3) Remove the paper feed cover stopper. 3) Remove the bracket guide. 2) Remove the paper feed unit (4 screws). 4 3 4-12 .

4 2 4-13 Preventive Maintenance .2) Replacement of the DFP roller and the torque limiter 4 1) Conduct the procedure 1 and 2. Note: Confirm the direction of the torque limiter when re-installing it. 5) Remove the torque limiter. 3) Remove the touch ring and bushing. 2) Remove the lower roller cover (2 screws) 3) Remove the touch ring. [Fit the positioning pin (rear side)] 3) Replacement of the Middle roller 5 1 3 1) Conduct the procedure 1 and 2. 4) Slide and remove the middle roller. 2) Remove the E ring gear on middle roller. 4) Remove the DFP roller.

(3) Developer unit Item Part name 1 Cleaning blade 2 Drum 3 Blade side seal (F) 3 Blade side seal (R) 4 Corona 5 Developer 6 Spacer ring (F) 6 Spacer ring (R) 7 Toner dispersion prevention cover 8 Mag-roll stopper (F) 8 Mag-roll stopper (R) 9 Drum separation finger cycle 120K 120K 120K 120K 360K 120K 120K 120K 600K 600K 600K 360K 3 9 2 1 4 6 7 8 5 4-14 .

4–8 step 4) 1 2 3 1 2 5 4 1) Remove the drum unit solenoid cover (1 screw). 3) Remove the cleaning blade. 3) Pull and turn the developer release lever and release the developer unit. 3) Remove the drum fixing screw.Before replacing the cleaning blade. 2) Move the toner hopper to front side. 2) Disconnect the harness.After replacing the cleaning blade. 4 2 3 1) Remove the cleaning blade tension spring. 5) Remove the drum unit. 4-15 Preventive Maintenance 3 . Note: . (lightly and evenly) . 2) Remove the blade case (1 screw). put drum starting powder on the 1 drum surface and cleaning blade. (Refer to p. 4) Open the waste toner bottle cover and remove the bottle. 1 1) Press the tabs of the drum unit lid toward arrow mark to remove the lid.1) Replacement of the cleaning blade 1 2 1) Open the front cover. do not forget to reinstall the tension spring.

3) Remove the grid(3a). 3) Remove the front side screw on the drum shaft. Adjustment after replacing new drum a. mylar(3b) and corona wire(3c). 2) Remove the corona fixing screw and remove the charge corona assembly. d.4-13 step 4). 2 7 3b 3a 3b 3c 4-16 . Adjust copy quality. 3) Replace the drum. Clean the copy density sensor. Adjust F8-14. 2) Remove the drum cleaning blade tension spring (refer to P. Set F mode. Go back to normal mode. b. c. e. 1) Remove the side seal (Front and Rear). 5) Remove the drum.2) Replacement of the Drum / Side seal 5 5 1) Conduct the procedure 1 and 2 and take the drum unit out. 6 3) Replacement of the charge corona 1) Conduct the same procedure 1 and 2 and take the drum unit out. 4) Remove the drum shaft. 3 4 Note: Handle the case not the drum. 2) Clean the surface of drum unit frame then reinstall the side seal (Front and rear).

TDC sensor may be damaged by electrostatics. 5) Remove the developer unit duct cover and clean inside of duct cover. 5) Replacement of the spacer ring 1) Conduct the procedure 1 and 2 then remove the developer unit.Shake the developer bottle and pour it into the developer unit evenly. 7) Replace the spacer ring (Front and rear). 5 b. Set F mode. 3) Remove the C ring and gears on mag-roller. 2) Remove the bias terminal (2 screws). Note: Take note of the position of the bushing support plate and reinstall it in the same position after replacing the spacer ring. 6) Pour in the new developer Note: . 3) Dump the developer out of the unit. 4-17 9 7 1 5 2 3 . 6) Remove the spacer ring (Front). 4) Remove the spacer ring (Rear). .Pay attention when cleaning the TDC sensor with vacuum cleaner . Preventive Maintenance Adjustment after relacing new developer a. Write the contents of F6-21 and 26 on the memory sheet. 5) Remove the bushing support plate (1 screw). Set and run F8-09.4) Replacement of the developer 8 2 1) Conduct the procedure 1 and 2 2) Remove the developer unit and remove the mixer lid. 4) Vacuum any developer on mag-roller and inside of the unit. c.

1 10 (2)Remove the toner dispersion prevention cover. (6)Reassemble in reverse order. (2)Remove the touch ring. (3)Remove the magnetic roller stoppers 3 1 2 (front/rear) and replace the magnetic roller. (5)Push the A from under side and slide the separation finger then remove it. 5 5 4-18 . 4 A Note: Be careful when removing and reinstalling the drum finger that the two springs are not lost or damaged. (4)Remove the sensor PCB from under side. (1)Remove the screws (x 2). (3)Slide the sensor base to rear side then 2 1 3 11 put it down and pull out.6) Replacement of the toner dispersion prevention cover/magnetic roller stopper • Conduct procedure 1 and 2 then pull out the developer unit. 3 7) Replacement of the dust collecting filter • Conduct procedure 1 and 2 then pull out the drum unit (1)Disconnect the sensor harness.

(4) Fuser unit Item Part name 1 Cleaning web roller 2 Web pressure roller 3 Fuser lamp 4 Heat roller 5 Heat roller bearing 6 Insulating bushing 7 Heat roller gear 8 Thermistor 9 Separation finger (upper) 10 Separation finger (lower) 11 Pressure roller 12 Pressure roller bearing 13 Fuser entry guide Cycle 120K 1200K 240K 360K 600K 360K 600K 240K 480K 480K 480K 600K 1200K Preventive Maintenance 4-19 9 10 11 4 8 3 5 6 7 13 12 2 1 .

(2) Slide the web ass'y to the right and remove. 1 4a 3 5 4b 4b 5 1 2 (2) Swing the toner hopper to the right. (3)Open the paper exit unit. b) Slide out the hinge pins. (2) Install the new web as shown.1) Replacement of cleaning web/web pressure roller (1) Open the front cover. (4)Remove the fuser bracket (3 screws). (2) Open the two LWS (x 2). (3) Remove the fuser unit manual paper feed knob. (4) Make sure the take-up drive is working normally. a) Remove the band. 2 4 3 1 1 (1) Remove the web ass'y bracket screw (x 2). (5) Remove the fuser front cover (2 screws). (1 screw reverse threaded) (4) Remove the front cover. 2 1 (5) Carefully slide the fuser unit out of the front of the machine. 2 3 1 (1) Disconnect the fuser unit connector (x 2). 1 2 4-20 . 4 3 4 (1) Remove the bushings (2 screws) and rollers (x2). (3) Make sure to remove the slack in the supply roller.

(1)Remove the screws (x 4) (2)Remove the heat insulating cover. (5)Remove the heat roller. (Lift the thermostat and slide to the front. (4)Remove the roller pressure plates. 2a 2b 850 W (3)Remove the fuser lamps (x2). Note: Either loosen pressure screws (x 2) or install fuser shipping screws (x 2).) (3)Remove the screws (x 2). 1a 1b (2)Turn the fuser lamp covers. 2 6 3 2 (1)Remove the springs. 4-21 . check 1 the pressure roller for fit. • Replace the heat roller. bearing and 1 insulating bushing. 4 5 8 2 • Remove the heat roller gear. (850W) Reassemble the lamp with the rating indication in the rear. 1 550 W Note: The long one is the main fuser lamp.2) Replacement of the fuser lamp/heat roller/heat roller bearing/insulating bushing/ heat roller gear 1 5 1 • Conduct procedure 1and 2. Note: After reassembling and tightening the screws of the pressure springs. Preventive Maintenance 7 1 1 3 3 2 4 (1) (2) Remove the screws and take off the thermistor and thermostat blocks.

1 2 11 2 2 (1) Remove the separation finger (upper) spring. (3)Remove the duplex guide roller block and bracket together. (2)Remove the screws (x 2). (3)Remove the separation finger (upper) bracket. 3 (2)Remove the screws (x 2). • Replace the fingers (x 5). (2) Remove the separation finger (upper). 1 12 2 (1)Remove the screw (x1) and fuser exit cover pin then remove the exit cover. (3)(4) Remove the screw.3) Replacement of the thermistor 9 3 • Conduct procedure 5. 4 5 SV507 4) Replacement of the separation finger (upper/lower) 10 2 (1)Open the fuser exit cover. (5)Remove the thermistor. • Replace the thermistor. 1 2 4-22 .

• Remove the roller bearing. 2 (2)Turn the separation fingers and remove them (x 5). (1)Remove the screws (x 2).13 2 (1)Remove the spring (x 2). 1 1 SV506 5) Replacement of the pressure roller/roller bearing 14 3 • Remove the heat roller (refer to step 5 to 7). Mark the current height adjustment to use as a reference during re-assembly. • Remove the separation finger upper/lower brackets (refer to 10 and 12). 4-23 Preventive Maintenance 1 . 1 2 (2)Remove the entry guide. (3)Remove the pressure roller.

(5) Optics unit Item Part name 1 Exposure lamp 2 Filter A 2 Filter B 3 Optics filter 4 Full speed unit drive belt 5 Half speed unit drive belt 6 Optics drive belt T: As required Cycle 120K 120K 120K 120K T T T 2 1 3 4 5 6 2 4-24 .

2 2 1 (1)Remove the screws (x 3).1) Replacement of the exposure lamp 1 1 2 1 Remove upper covers (left/right). 1 2 4-25 Preventive Maintenance . (2)Remove the main reflector. (2)Remove the original guide. Remove the exposure lamp and replace it. (4)Move the full speed unit to the right. 2 3 4 SV601 3 1 (1)Remove the screws (x 2). (3)Remove the platen glass.

4-26 . Remove both left and right copier side covers. Replacement of the optics fan filter 4 • Conduct the procedure 1.2) Replacement of filter A and B. • Peel off the dust prevention filter and replace it with new one.

2 3 4-27 . platen glass and top rear cover (5 screws). 3 3 4 4 (4)Remove the rear cover (7 screws). Preventive Maintenance Remove the control panel ass’y. (2)Remove the right side control panel ass'y bracket (1 screw).3) Replacement of the optics motor belt/full-speed unit drive belt/half speed unit drive belt 5 4 4 (1)Remove the platen cover (or ADF/i-ADF if installed). (3) Remove the ground wire (1 screw). (3)Disconnect the lattice connectors of any options (System Console and LCC). (3)Remove the copier left and right covers 3 (4 screws). (2) Disconnect the 2 connectors. (2)Remove the copier front cover (refer to page 4-18 step 1). (2)Remove the original guide. 3 7 1 (1) Remove the 4 screws. (3)Remove the inner front cover (3 screws). 6 2 1 1 2 (1)Remove the copier top left and right covers (4 screws). 1 8 (1)Swing the toner hopper ass'y 180 1 degrees to the right.

2 (1)Disconnect the 2 connectors. 10 3 (1)Remove the ADF lattice connector bracket (5 screws). SV632 1 4-28 . (2)Remove the 2 screws. (1 screw). (4)Remove the optics drive motor (3 screws). (3)Remove the left ADF hinge receiving 2 1 5 4 SV630 1 bracket/key counter receptacle bracket (3 screws). 3 4 11 Remove the right hinge receiving bracket (2 screws). (2)Remove the optics motor tension spring. (5)Remove the optics drive motor belt. 12 2 Remove the optics cover.9 Remove the left side control panel ass’y bracket.

13 4 Move the full-speed unit to right until it stops. 14 2 (1)Remove the 2 screws on the full-speed 1 unit support (each side). (2) Remove the full-speed unit belt fixing plate (each side). 1 2 4-29 Preventive Maintenance . (2)Remove the four optics drive belt tension springs. 2 1 16 Remove the optics drive belts from the idler pulleys (4 belts). 2 15 1 (1)Loosen the four idler pulley brackets (2 screws each).

4-30 . 19 3 1 (1)Remove the E rings (each side). (2)Remove the bearings (each side).17 Disconnect the drive belts from both sides of the half-speed unit. we recommend 2 replacement of complete set of four. (3)Slide the optics drive shaft to the rear. due to the complexity of the process). 18 1 2 Loosen the hex screws and remove the E rings in the optics drive shaft pulleys (each side). (4)Replace the optics drive belts (when one requires replacement. and remove it.

3 (3) Tighten screws on the full-speed belt fixing plate. (2) Connect the half speed drive belts (each side).20 Connect the full-speed unit drive belt (1) Install the belt fixing plate on the full-speed unit drive belt (each side). loosen screw on the half-speed unit support plate and adjust the half-speed unit position. (each side) 1 21 Connect the half-speed unit drive belt (1) Move the half-speed unit to right until it stops. 2 Note: If the half-speed unit has not touched the stopper after the belt is connected. (2) Move the full-speed unit to right until it stops. 1 Stopper 4-31 Preventive Maintenance .

(6) Automatic duplex unit (ADU) Item Part name 1 Paper feed roller 2 Storage roller 3 F/R mylar 4 Paper feed pad 5 DFP roller Cycle 24K 48K 24K 24K 24K 2 1 4 3 5 4-32 .

Preventive Maintenance 3 1 4 4 1 (1) Remove the touch ring. (5) Remove the touch rings (x2). (2) Remove the upper cover (2 screws). 4 • Take off the F/R mylar (kit) and replace it. (3) Lift the transport guides (1 and 2). 4-33 . (3) Remove the touch rings from the guide plates. (2) Remove the stopper plate. (4) Disconnect the feed clutch connector. Note: Perform step 7 first. (7) Remove the paper feed roller shaft. (3) Replace the paper feed roller. (2) Remove all rollers by pulling in the arrow direction. (4) Replace the storage rollers.1) Replacement of the paper feed roller/storage roller/F/R mylar/feed roller pad 1 3 2 (1) Pull out the ADU until it stops. 2 6 6 (6) Move the bearing toward the feed rollers. 1 2 1 3 5 7 3 (1) Remove the screws (x 2).

(1)Remove the screws (x 2). 2) Replacement of the DFP roller • Conduct procedure 1. 1 1 4 4-34 . (2)Remove the DFP roller block. marked position is front side. (4)Remove the DFP roller. (2)Remove the bearing. 2 6 1 7 (1)Remove the touch rings (x 2). Note: When re-installing the DFP roller. • Peel off the paper feed pad and replace it. (3)Remove the roller shaft.5 • Conduct procedure 1 and 2.

(7) Main body Item Part name 1 Corona cleaner 2 Transfer wire 3 Separation wire 4 Ozone filter 5 Ozone filters 6 Dust collecting filter (Main body) 7 Transfer chager 8 Discharge lamp Cycle 120K 120K 120K 240K 240K 240K 360K 240K 4 7 3 1 2 5 8 6 4-35 Preventive Maintenance .

slide the wire cleaner felt to rear side until it stops. Note: When the transfer charger is installing. 1 4-36 .1) Replacement of the charger wire/wire cleaner felt 1 (1)Open the front cover. (3)Press down the transfer charger and draw it toward you. (2)Remove the charger cover. (1)Remove the paper guide. (2)Turn the transport lever and lower the transport unit. 2 3 2 2 • Remove the transfer corona. (1)Remove the corona wire spring. (3)Replace the transfer wire cleaner felt. 1 3 2 3 1 • Replace the transfer corona wire and the separation corona wire with new one. (2)Unfasten the corona wire.

(3)Remove the 1 screw. 3) Replacement of the dust collecting filter 5 2 • Remove the copier rear cover. • Open the front cover. 1 4) Replacement of the discharge lamp. (1)Remove the filter cover. (5)Remove the lamp holder. more if sorter-equipped).2) Remove the suction fan and the ozone filter to replace them with new ones. (2 screws. (6)Replace the discharge lamp (Filter and 3 screws). (2)Remove the dust collecting filter and replace it. • Remove the exit cover. (Left side) 3 Ozone filters 5 1 5 (3)Replace the filters. 4 (4)Disconnect the harness. (1)Remove the rear cover. Preventive Maintenance 4-37 • Re-assemble in the reverse. 3 (2)Turn the toner hopper 180°. (Rear side) 4 2 (2)Replace the ozone filter. • Remove the filter holder (1 screw). 6 (1)Open the front cover. • Replace the filters. .

For continuous copy operation.V. if the copier is left in the F mode and shut off. Various function settings (selected by code numbers) can be changed. The input/output of major components in every section can be checked. Input the telephone number. The functioning of Input/Output items (selected item numbers) is checked. then F4 will appear in the display. To select the service mode The service mode is selected when USER PRESET. 5-1 Troubleshooting (1) Service mode functions . Multi-Copy key 3 and Original Size A3 keys are simultaneously pressed. it will still be in the F mode. when the copier is turned ON again. (If copier is abnormal. then F1 will appear in the display. For single copy operation. NOTE: Message display is turned ON and OFF. NOTE: After servicing. Troubleshooting 5. Service mode F1 F2 F3 F4 F5 F6 F7 F8 F9 Item Display check Single sheet copying Continuous copying Input/Output check Copier function programming Adjustment and programming Electronic counter Copier operating adjustment Telephone number program Function Indicators and display check. Perform pseudo-operation of an item (selected by code numbers).) To reset the service mode The service mode is reset when USER PRESET and CLEAR/STOP keys are pressed simultaneously. same as above Reads or Resets the electronic counter. the technician can check for abnormalities in the copier so the copier can always operate normally.1 Service Mode In Service mode. The reset program must be used to reset the F mode.

2 sided copy mode. When in F3. When the Print key is pressed again. the ADF and Sorter can operate. 2 sided copy mode. When the Print key is pressed again. b. d. Duplex mode (1 sided original. In both F2 and F3. 3. a. 2. press the Clear/Stop key to stop the copy process. 2 sided copy) a. the second side is copied and fed to the copier exit tray. One sheet is copied normally when the Print key is pressed. Repeat procedures b) and c). 2 sided copy mode.(2) Service mode procedure F1 appears in the display when the service mode is first turned ON. For both F2 and F3 the total and electronic counter are disabled. 2. Mode F1 F2 MultiCopy key 1 2 Item Display check Single sheet copying Function When the Print key is pressed. Book original. c. (To be continued) Remarks It stops when the Clear/Stop key is pressed. b. 1. all displays light up. 2 sided copy or 2 sided original. 1. the second side is copied and fed to the copier exit tray. One sheet is copied when the Print key is pressed. The first side is copied and fed into the duplex unit tray. Select the 1 sided original 2 sided copy or 2 sided original. c. In F2 and F3 with paper in the drawer the misfeed circuit is enabled. 5-2 . d. If no paper is in drawer. Select the Book original. When the Print key is pressed again. the misfeed circuit is disabled. 5. 3. One sheet is copied and fed into the duplex unit tray. 4. One sheet is copied when the Print key is pressed.

the second side is copied and fed to the copier exit tray. When the Print key is pressed again. d. c. 2 sided copy mode. When the Print key is pressed again. 50 sheets are copied normally when the Print key is pressed. 2 sided copy) a. b. a. d. a. 2 sided original. Select the 1 sided original 2 sided copy or 2 sided original. 1.Mode MultiCopy key Item Function e. and fed into the duplex unit tray. b. a. Book original. 4. c. Select the 2 sided original. 50 sheets are copied normally when the Print key is pressed. 1 sided copy mode. b. 5-3 Troubleshooting . F3 3 Continuous copying 2. 1 sided copy mode. b. One sheet is copied normally when the Print key is pressed. 2 sided original. 1 sided copy mode. Repeat item b). 2 sided copy mode. Repeat item b). Duplex mode (1 sided original. 1 sided copy mode. c. c. 50 sheets are copied when the Print key is pressed. When the Print key is pressed again. Remarks Single sheet copying 4. Select the Book original. 3. 2 sided copy or 2 sided original. 2 sided copy mode. Multi copying is initiated by pressing the Print key. Repeat procedures b) and c). One sheet is copied and fed into the duplex unit tray. Repeat procedures b) and d). Select the 2 sided original. the second side is copied and fed to the copier exit tray.

(3) F4 mode
1) Input check. Set the copier to service mode and press Multi-Copy key “4”. Press Print key. Select desired code number with Multi-Copy key. Press Print key. Check arrow mark on the touch panel display. Press Clear/Stop and User Preset key to escape service mode.
Code Function Condition No. 00 a) Duplex unit tray detecting sensor Duplex unit tray is installed. b) Duplex unit detecting sensor 01 a) Registration roller paper pass sensor b) Mirror home position sensor c) Lens home position sensor d) Duplex unit paper width home position sensor e) Duplex unit paper length home position sensor 02 a) Copier front cover b) Developer unit detecting sensor c) +5V line error signal 03 Original size detection sensor Duplex unit is detected. Paper is not detected. Message display 6 5 4 3 2 1

7

0

Mirror unit in home position. Lens unit in home position. Paper guide (A) (for width) in home position. Paper guide (B) (for length) in home position. Cover closed. Developer unit is detected. +5V line is defective. Ledger/A3 Legal/B4-FLS Letter/A4 Letter R/A4R Invoice/A5

5-4

Code Function No. 04 a) Sheet bypass paper detecting sensor b) Sheet bypass paper size detection sensor

Condition 7 Paper is not detected.

Message display 6 5 4 3 2 1

0

Ledger/A3 Legal/B4-FLS Letter/A4 Letter R/A4R Invoice/A5 Platen is open. Platen is open more than 30 degrees. Cover closed. Motor is locked. +10V line is defective. Lamp is not lit. Lamp is not lit. Motor is locked. Motor is locked. High voltage leak is not detected. (Normal) High voltage leak is not detected. (Normal) Toner is empty When the toner bottle is not in the proper position. Paper is not detected. Total counter is not connected. Key counter is not installed.

c) Platen open/close sensor d) Platen angle sensor

e) Copier paper feed cover 05 a) Developer cooling fan motor b) +10V line error signal c) Discharge lamp error signal 1 d) Discharge lamp error signal 2 e) Dust collecting fan motor f) Suction fan motor g) High voltage leak detection (Separation corona) h) High voltage leak detection (Charge corona) 06 a) Toner level detection b) Toner bottle position sensor

c) Copier paper exit sensor d) Total counter e) Key counter

5-5

Troubleshooting

Code Function No. 07 a) Exhaust fan motor 1 b) Exhaust fan motor 2 c) Optics fan motor 1 d) Optics fan motor 2 e) Optics fan motor 3 f) Exhaust fan motor 3 08 a) Duplex unit paper pass sensor 1 b) Duplex unit paper pass sensor 2 c) Duplex unit paper detecting sensor

Condition 7 Motor is locked. Motor is locked. Motor is locked. Motor is locked. Motor is locked. Motor is locked. Paper is not detected.

Message display 6 5 4 3 2 1

0

Paper is detected.

Paper is not detected.

09

a) Paper detection sensor (Copier lower paper tray) b) Paper limit sensor 2 (Copier lower paper tray) c) Paper pass sensor (Copier lower paper tray) d) Paper level sensor 1 (Copier upper paper tray) e) Paper level sensor 2 (Copier lower paper tray) f) Paper limit sensor 2 (Copier upper paper tray) g) Paper detection sensor (Copier upper paper tray) h) Paper pass sensor (Copier upper paper tray)

Paper is not detected.

Paper is full.

Paper is not detected.

Paper is empty or tray is pulled out. Paper is empty or tray is pulled out. Paper is full.

Paper is not detected.

Paper is not detected.

10

Reserve

5-6

Code Function No. 11 a) System console motor signal b) System console paper feed cover sensor c) Paper detection sensor 3 (System console lower paper tray) d) Paper limit sensor 3 (System console lower paper tray) e) Paper pass sensor 3 (System console lower paper tray) 12 a) Paper detection sensor 2 (System console middle paper tray) b) Paper limit sensor 2 (System console middle paper tray) c) Paper pass sensor 2 (System console middle paper tray) d) Paper detection sensor 1 (System console upper paper tray) e) Paper limit sensor 1 (System console upper paper tray) f) Paper pass sensor 1 (System console upper paper tray) 13 a) Paper level sensor 1 (System console upper paper tray)

Condition 7 Motor is locked.

Message display 6 5 4 3 2 1

0

Cover is closed.

Paper is not detected.

Paper is over stocked.

Paper is not detected.

Paper is not detected.

Paper is over stocked.

Paper is not detected.

Paper is not detected.

Paper is over stocked.

Paper is not detected.

Paper is empty or paper tray is pulled out.

b) Paper level sensor 2 Paper is empty or paper tray (System console middle paper tray) is pulled out. c) Paper level sensor 3 (System console lower paper tray) Paper is empty or paper tray is pulled out.

d) System console detecting sensor System console is detected.

5-7

Troubleshooting

c) Timing sensor d) ADF open/close sensor e) Entry cover open/close sensor f) Exit cover open/close sensor 19 For FA-A888 a) Original size detection sensor Original is not detected.Code Function No. 14 a) LCC detecting sensor 1 b) LCC door open/close sensor c) LCC detecting sensor 2 d) LCC paper tray lower limit sensor e) LCC paper tray upper limit sensor f) LCC paper level sensor 15 a) Corona cleaner home position sensor b) Waste toner bottle full sensor 16. (When driving the transport belt) Original is detected. Door closed. Paper tray is beyond the upper limit. b) Original reverse detection sensor Original is not detected. Ledger/A3 Legal/B4-FLS Letter/A4 Letter R/A4R Invoice/A5 Original is detected. Original is detected. ADF is opened. Not used Signal is detected. Paper tray is beyond the lower limit. ADF is opened. Paper is full. b) Original detection sensor c) Original feed pass sensor d) Original exit pass sensor e) ADF open/close sensor For FA-A888 a) Registration roller pass sensor Original is not detected. Cover is closed. Original is detected.17 18 For FA-A505 a) Encoder sensor Condition 7 LCC is not installed. Cleaner in home position. b) Original detection sensor 5-8 . LCC is pulled out. Message display 6 5 4 3 2 1 0 Toner is full. Cover is closed.

e) Bin ass'y position sensor 1 f) Paper exit sensor g) Paper feed sensor For FA-S615 a) Bin lower limit switch Bin is placed less than lower limit. Paper is not detected.Code Function No. 23 For FA-S680 a) Bin home position switch b) Bin cam switch c) Tamper home position sensor Bin in home position Bin cam in home postion Tamper in home position 5-9 Troubleshooting . c) Cable safety switch d) Bin ass'y position sensor 2 Cable is not loose. (#1 bin) Paper is not detected. 20 For FA-S575 a) Motor clock sensor Condition 7 Signal is detected. Bin ass'y position is not placed correctly. Cam in home position. b) Paper transport cover open/close Cover opened. Bar in home position. Message display 6 5 4 3 2 1 0 b) Bin ass'y upper/lower limit switch Bin is beyond the upper limit or beyond the lower limit. Paper is not detected. Bin ass'y position is top Bin ass'y. Sorter is pulled out. Sorter is installed. Stapler is not installed. b) Bin cam home position sensor c) Tamper home position sensor d) Transfer motor clock sensor 21 For FA-S575 a) Sorter detection switch For FA-S615 a) Bin paper detecting sensor b) Paper detection sensor for JAM c) Stapler detection sensor 22 For FA-S680 a) Sorter interlock switch Clock signal is detected. Paper is not detected.

Stapler in staple position. Switch is not detected. Paper is detected.Code Function No. 24 For FA-S680 a) Bin paper detecting sensor b) Paper pass sensor c) Staple detecting sensor 25 For FA-S680 a) Stapler cam sensor b) Stapler swing home position sensor c) Staple position sensor d) Stapler safety switch Condition 7 Paper is detected. (Switch turns on) 5-10 . Stapler swing in home position. Staple is detected Message display 6 5 4 3 2 1 0 Cam in home position.

clutch operates. When CN203-6 is AC line level. solenoid operates. When CN107-6 is +24V. fan motor 2 rotates.) When CN5-4 is +24V. 40 Optics fan motor 2 (Except FP-7818) Exhaust fan motor 3 (Except FP-7818) Lift motor (FP-7818) Drum separator solenoid (FP-7845/7850) Paper feed solenoid (FP-7818) Total counter 41 42 * Accessory checks require the selected accessory to be ready (Cover closed. fan motor 2 rotates. count up by one. Lamp turns off after 2 seconds.2) Output check* Activate the door switch before executing output check. clutch operates. When CN8-7 is +24V. motor rotates. When CN203-4 is AC line level. lamp lights up. clutch operates. fan motor 4 rotates. When CN106-6 is +24V. When CN202-2 is AC line level. developer unit. When CN112-2 is +24V. fan motor 1 rotates. dust collecting fan rotates. fan motor 2 rotates. When CN5-6 is +24V. When CN111-20 is +24V. When CN8-2 is +24V. Press the Print key to start and press the Clear/Stop key to reset. 30 31 32 33 Registration roller clutch Main fuser lamp Sub fuser lamp Exposure lamp 34 Ozone/suction fan. discharge lamp and eraser lamp turn ON.) 5-11 Troubleshooting 35 Recycling solenoid (Except FP-7818) When CN7-11 is +24V. solenoid operates. etc. When CN8-1 is +24V. ozone/suction fan rotates. (HVPS. lamp lights up. developer cooling fan rotates. When CN5-2 is +24V. solenoid operates. Code Item 26 27 28 29 Timing roller clutch Sheet bypass paper feed solenoid Sheet bypass paper feed clutch Main motor Function When CN8-12 is +24V. lamp lights up. . When CN106-9 is +24V. When CN12-5 is +24V. When CN107-3 is +24V. When CN109-2 is +24V. developer unit cooling fan (Except FP-7818) and dust collecting fan 36 37 38 39 Paper exit selection solenoid (Except FP-7818/7824) Exhaust fan motor 1 Exhaust fan motor 2 Optics fan motor 1 and 4 When CN116-2 is +24V. When CN106-3 is +24V. fan motor 3 rotates. solenoid operates. solenoid operates. When CN106-12 is +24V. lift motor rotates. When CN102-2 is +24V.

When CN603-1 is +24V. clutch operates. motor rotates to second paper feed direction. 50 51 52 53 54 55 56 57 When CN610-4 is +24V. count up by one. 49 Lift motor 2 (Except FP-7818) Paper feed clutch 2 (Except FP-7818) Paper feed solenoid 2 (Except FP-7818) Duplex unit drive motor (Storage) Duplex unit drive motor (Paper feed) Lift motor 1 (System console upper) Paper feed clutch 1 (System console upper) Paper feed solenoid 1 Lift motor 2 (System console middle) When CN604-2 is +24V. When CN654-6 is +24V.) ADU clutch (When duplex unit is installed) (Except FP-7818) 47 48 Paper feed solenoid 1 (When duplex unit is not installed. motor rotates to storage direction.) When CN610-3 is +24V. motor rotates. When CN603-2 is +24V.) When CN609-3 is +24V.Code Item 43 44 45 Key counter Not used +24V output control Function When CN119-6 is +24V. motor rotates. lifting up (together with upper limit control. lifting up (together with upper limit control. motor rotates. lifting up (together with upper limit control.) (Except FP-7818) Paper feed clutch 1 (When duplex unit is not installed. solenoid operates.) 5-12 . When CN609-4 is +24V. +24V is supplied to +24V line. clutch operates. clutch operates. When CN604-2 is +24V. solenoid operates. motor rotates. 46 Lift motor 1 (When duplex unit is not installed.) ADU clutch (When duplex unit is installed) (Except FP-7818) When CN610-4 is +24V. When signal is sent from CPU CN1-6 to LVPS CN117-5. solenoid operates.) When CN610-3 is +24V. When CN654-3 is +24V. lifting up (together with upper limit control.

) 67 68-72 Not used 73 Transport belt motor forward rotation 1 (FA-A888/FA-A505) Transport belt motor forward rotation 2 (FA-A888) Transport belt motor forward rotation 3 (FA-A888) Transport belt motor reverse rotation (FA-A888/FA-A505) The transport belt rotates forward. clutch operates.) When CN608-3 is +24V. solenoid operates. motor rotates. lifting up (together with upper limit control. (Middle speed) 75 The transport belt rotates forward. (Low speed) 76 The transport belt rotates reverse. motor rotates. 63 64 65 66 When CN602-1 is +24V. When CN564-2 is +24V.Code Item 58 Paper feed clutch 2 (System console middle) Paper feed solenoid 2 (System console middle) Lift motor 3 (System console lower) Paper feed clutch 3 (System console lower) Paper feed solenoid 3 (System console lower) Option paper feed clutch Option paper feed drive motor LCC paper feed solenoid (Except FP-7818/7824) LCC paper feed tray lift (up) (Except FP-7818/7824) LCC paper feed tray lift (down) (Except FP-7818/7824) Function When CN609-3 is +24V. 59 When CN609-4 is +24V. 60 When CN605-2 is +24V. solenoid operates. clutch operates. clutch operates. When CN602-7 is +24V. lifting up (together with upper limit control. motor rotates. motor rotates. dropping down (together with upper limit control. solenoid operates. 5-13 Troubleshooting . (High speed) 74 The transport belt rotates forward. 61 62 When CN608-4 is +24V.) When CN563-2 is +24V. When CN563-1 is +24V.

The tamper moves to staple minimum size and return to the original position The stapler operates one time then resets. (Middle speed) The motor rotates forward. 90 91 92 5-14 . (Low speed) The solenoid operates. (Middle speed) The motor rotates reverse. (High speed) The motor rotates forward. The #1 bin position moves forward #20 bin position. 79 80 81 82 83 84 85 86 87 88 The solenoid operates. 78 The motor rotates reverse. (High speed) The motor rotates reverse. (Low speed) The motor rotates forward.Code Item 77 Paper feed motor forward rotation (FA-A888) Paper feed motor reverse rotation (FA-A888) Paper feed motor reverse rotation (FA-A888) Paper feed motor reverse rotation (FA-A888) Paper reverse/exit motor forward rotation (FA-A888) Paper reverse/exit motor forward rotation (FA-A888) Paper reverse/exit motor forward rotation (FA-A888) Wait plate and paper feed solenoid (FA-A888/FA-A505) Reverse solenoid (FA-A888) Not used Not used Transport/paper feed motor (Sorter) Bin movement for down direction (Sorter) Bin movement for up direction (Sorter) Tamper drive motor (only Staple Sorter) Staple motor (only Staple Sorter) Function The motor rotates forward. 89 The #20 bin position moves forward #1 bin position. The motor rotates.

Code Item 93 Staple ready indicator (LED) (only Staple Sorter) Stapler swing motor (only Staple Sorter) Function The ready indicator lights up. 5-15 Troubleshooting . 94 The swing motor drives in and out.

Press Clear/Stop and User Preset key to escape service mode. Select desired function with touch panel display and touch the OK key. If you wish to select other code number. the desired code input will not be accepted. Select desired code number with touch panel display and touch the OK key.(4) F5 mode Copier function programming Set the copler to service mode and press Multi-Copy key “5”.) 0: Not detecting 1: Detecting 0 1 11 12 Copy reservation function Not used 1 5-16 . When the CANCEL key is touched. scroll the menu with arrow keys ( ).5 h 6: 4 h 1: 45 second 3: 2 minute 1: 30 m 2: 60 m 4: 2 h 5: 3 h 7: No energy saver timer 5: Spanish 6: Swedish 7: Finnish 8: Dutch 9: Portuguese (Factory setting) 1 (for American) 2 (for European) 0 (for European) 1 (for American) 2 0 (for American) 7 (for European) 1 2 3 Frequency desired Auto reset timer Energy saver timer 4–6 7 Not used Message display language change (Except FP-7818/7824) 0: Japanese 1: English 2: German 3: French 4: Italian 1 8 9 10 Not used Fuser lamp phase control Optics cooling fan control 0: Zero cross control 1: Phase control 0: Normal operation 1: Control mode (Fan operates when a predetermined amount of copies are made. Code 0 Item Country version Function 0: Japanese 1: North American 2: European/Others 0: 50 Hz 1: 60 Hz 0: None 2: 1 minute 0: 15 m 3: 1. Press Print key.

lower) Copy paper size setting (System console. * (for Qualitative Reasoning Based Adaptive Controller) 5-17 Troubleshooting . upper) Copy paper size setting (System console.Code 13 Item Auto off timer Function 0: No auto off timer 1: 30 m 2: 60 m 3: 1.5 hr 4: 3 hr 5: 4 hr (Factory setting) 0 (for European) 1 (for American FP-7818) 2 (for American FP-7824/7830/ 7835) 3 (for American FP-7845/7850) 1 14 Copy paper size setting (copier paper tray upper) Copy paper size setting (copier paper tray. middle) Copy paper size setting (System console. lower) Not used ADF (Automatic document feeder) Sorter 0: None 1: Ledger/A3 2: Legal/B4 3: Letter/A4 4: Letter . copy number is/not counted.R/A4R 5: Invoice/A5 same as F5-14 same as F5-14 same as F5-14 same as F5-14 15 16 17 18 19 20 1 0 0 0 0: Cancellation of ADF 1: ADF installation automatically discriminated 0: Cancellation of sorter 1: Sorter installation automatically discriminated 0: Cancellation of system console 1: System console installation automatically discriminated 0: Cancellation of LCC 1: LCC installation automatically discriminated 0: Not detecting 1: Detecting 0: Cancellation of duplex unit 1: Duplex unit installation automatically discriminated 0: Does not count up 1: Count up 1 21 1 22 System console 1 23 LCC (3000 sheet paper tray) Not used Copy density sensor read* Duplex unit 0 (FP-7818/7824) 1 (FP-7830/7835/ 7845/7850) 1 0 (FP-7818) 1 (FP-7824/7830/ 7835/7845/7850) 0 24 25 26 27 Total copy count (Except FP-7818) In case of mis-feed in second side copy for two side copy.

Not used Skyshot mode (Using ADF) ADF switch back Function 0: Does not count up 1: Count up (Factory setting) 0 29 30 31 0: not change registration void position 1: change registration void position 0: No 1: Yes 0: No 1: Yes 0: not operated 1: operated 0: off 0: Non sort 1: Sort 0: Yes 1: No 0: No 1: Yes 0: Does not select 1: 1 sided to 2 sided 2: 2 sided to 2 sided 3: Book to 2 sided 0: Single front 1: double 2: Single rear 0: Single 1: Ledger/A3 2: Ledger/Legal/A3/B4 0: At paper feed roller clutch (and sheet bypass solenoid) 1: At paper exit sensor 0: Not installed 1: Key counter installed 2: Departmental counter same as F5-41 0: Does not count up 1: Count up 0: No 1: Yes 1: on 2: Staple sort 3: Group 1 0 32 33 34 35 36 37 38 SADF function F2.Code 28 Item Total copy count (Except FP-7818) Checking double feed by comparison between in/out copies. cover mode) Hole punch default 0 0 0 1 (for American) 2 (for European) Hole punch indication change 0: 2 holes 1: 3 holes 2: 4 holes 5-18 . Key counter. and Electronic counter) Count up timing 0 0 0 0 0 1 0 39 0 40 1 41 1 42 Key counter and Departmental counter 0 43 44 45 46 Key counter count up timing Counter count up (Interleaving. ADF operation (in case of no originals) Multi-feed default Sorter initial mode setting Paper alignment function (Except sort mode) Countdown sorting function Duplex unit initial mode setting (Except FP-7818) Staple position default (FP-7845/7850) Double count (Total counter.

0: 500/100 2: 100/100 0: Blank 1: 1.Code 47-49 50 Item Not used Auto exposure default Function 0: Not detecting 1: Auto mode priority 2: Manual mode priority 0: Full size 1: Reduction (Factory setting) 2 51 52 2 in 1 mode copy ratio setting Auto original size detecting sensor 1 0: No detection . 1: Press RESET key and AUTO EXPOSURE key.Priority (Manual key LED lit) 0 (FP-7818/7824) 1: Detection .000/100 3: 300/100 4: No recycling 1: Copy 0: When clearing U13. press any key. waste toner bottle is full) 1: Continuous copier operation Copier operation (After “U13” 0: Copier stops or copy cycle is inhibited.Priority (Manual key LED off) 1 (FP-7830/7835/ 2: Manual key status LED lit/off held in 7845/7850) memory when power switch OFF 0: No auto shift 1: Auto shift 0: 100 % 2: 93 % 0: 5mm 2:15 mm 0: 5mm 2:15 mm 0: 15mm 2: 25 mm 1: 95 % 3: 91 % 1:10 mm 3: 20 mm 1:10 mm 3: 20 mm 1: 20 mm 3:30 mm 0 0 1 0 1 0 0 53 54 55 56 57 58 59 Auto shift (Duplexing) Reduction ratio (Margin mode) Margin value Initial setting Edge value Initial setting Book value Initial setting Copier operation (After “U14” 0: Copier stops or copy cycle is inhibited. Toner bottle empty 1: Continuous copier operation detection) Auto paper tray selection Not used U13 clear=After toner empty detection (Copier stops or copy cycle inhibited) Not used Toner recycling system operation cycle (Refresh cycle) (Except FP-7818/7824) Number of copies for operating timing of Refresh mode. 0: Manual 1: Auto 60 61–62 63 1 0 64 65 0 66 67 68 69 Interleave default Page Insertion mode initial setting (FP-7845/7850) Cover mode default (FP-7845/7850) Not used 0 0 1: Front copy 3: Front/back copy 0 0: Blank paper 1: Copied paper 0: Front blank 2: Front/back blank 5-19 Troubleshooting .

5K 2: 2.5K 4: 10K 5: 15K 7: 30K 8: 40K 10: 80K 11: 90K 13: 160K 0: No indication 1: Indication 0: Continuous copier operation 1: Copier stops or copy cycle is inhibited. M2 ON 0 74–79 80 0: LETTER R/A4R 2: LETTER/A4 4: INVOICE/B5R 0: B4 2: Foolscap 2 0: OFF 2: M2 ON 0: OFF 1: ON 81 82 83 84 0 0 1 0 0: LCC > System (lower to upper) > Copier (lower to upper) > Sheet bypass 1: Copier (upper to lower) > System (upper to lower) .Sheet bypass 2: LCC > Copier (upper to lower) > System (upper to lower) > Sheet bypass 0: None 1: Copier (upper) 2: Copier (lower) 3: System console (upper) 4: System console (middle) 5: System console (lower) 6: LCC 7: Sheet bypass same as F5-85 85 Auto selection prohibition paper tray setting (1) 0 86 87-89 90 91* 92* 93* Auto selection prohibition paper tray setting (2) Not used Beep sound (FP-7845/7850) Check size M1 Y Check size M1 X Check size M2 Y 0 0: None 1: Yes Width of paper parallel position to paper feed direction Length of paper vertical position to paper feed direction Width of paper parallel position to paper feed direction 1 160 70 220 5-20 .Code 70 Item Preventive maintenance Function 0: No call 1: 1.LCC . 0: 120k 1: 80k 3: 5K 6: 20K 9:60K 12: 120K (Factory setting) 10 (FP-7818/7824) 12 (FP-7830/7835/ 7845/7850) 71 72 Preventive maintenance (Duplex unit) Copier operation (After cleaning web roller counter is reached to 0) Cleaning web roller counter selection Not used Paper size selection priority B4/Foolscap size selection Sky shot mode Auto edge default Paper tray selection priority (Left to Right) 1 1 73 0 (FP-7830/7835/ 7845/7850) 1 (FP-7818/7824) 1: LEGAL/B4 3: LEDGER/A3 5: INVOICE/B5 1: Foolscap 1 3: LD 1: M1 ON 3: M1.

Code 94* 95 Item Check size M2 X Factory use size unit change Function Length of paper vertical position to paper feed direction 0: AB. 5-21 Troubleshooting . 93. Janpanese 1: inch 2: AB. European (Factory setting) 95 1 (for American) 2 (for European) 96-97 98 99 Not used Factory use paper size sensor 0: Yes change 1: No Not used 1 * F6-91~94. check size = (input value x 5) mm. Even number only. * F6-91.

Set the copier to service mode and press Multi-Copy key “5” Press Print key. the desired PM cycle will be not accepted. ). ). Press Clear/Stop and User Preset key to escape service mode.To Clear the Service Call indicator Re-input the F5-70 and F5-73. When the CANCEL key is touched. 5-22 . Touch desired PM cycle key and OK key. Touch desired PM cycle key and OK key. the desired PM cycle will be not accepted. Scroll the display menu until code number 73 is indicated with arrow keys ( then touch “73” key. When the CANCEL key is touched. Scroll the display menu until code number 70 is indicated with arrow keys ( then touch “70” key.

Adjustment of lens stop position by lens home position. scroll the menu with arrow keys ( ). Increase: Multi-Copy key or Up key of touch panel display Decease: Reset and Multi-Copy key or Down key of touch panel display The OK key is touched on the touch panel display. the memory number changed is now in memory. the content of F6-04mode is automatically changed from the factory setting. Press Clear/Stop and User Preset key to escape service mode. Remarks 01 Adjustment of ratio for parallel position. Select desired code number with touch panel display and touch the OK key. Code 00 Item 100% selection (Ratio of vertical and parallel position to the paper feed direction) (standard = 100%) Just 100% (Ratio of parallel position to the paper feed direction) 100% focus Just 100% (Ratio of vertical position to the paper feed direction) Original registration detecting timing (Reduction and Enlargement copying) Function Adjustment from 99. (S/S) Adjustment of original registration detection timing . (L/T) Adjustment of focus.(5) F6 mode Adjustment and programming Set the copier to service mode and press Muiti-Copy key “6”.10% (–9 to +9) (–50 to +50) (–50 to +50) (+): Enlargement (–): Reduction 0.10% (–9 to +9) (+): Enlargement (–): Reduction 0. 02 03 04 5-23 Troubleshooting . The display will indicate memorized number.1% to 100. Press Print key.2mm (–30 to +30) (+): Delayed (–): Advanced *If you adjust the content of F8-02 mode.9% 0. Input the new setting number with Multi-Copy key or Up/Down key. the desired code input will not be accepted. If you wish to select other code number. When the CANCEL key is touched.

425mm After 06 is adjusted.525mm (FP-7824/7830/7835) (0 to +99) 06 LED array synchronized timer for trimming function 07 Registration void of image (LED array synchronized timer) After 05 and 06 are adjusted.425mm (FP-7850/7818) 0.375mm (FP-7845) 0.4V (–9 to +9) 5-24 . 0.375mm (FP-7845) 0. 08 Trail edge timing of original image (Reduction) 0. synchronized timer is adjusted. In enlargement mode.525mm (FP-7824/7830/7835) (–20 to +20) 0.Code 05 Item Copy paper registration detecting timing Function Remarks 0.425mm *same as F6-04 After 04 is adjusted.525mm (FP-7824/7830/7835) (–9 to +30) same as F6-08 0. 0. black line is adjusted. (FP-7850/7818) (–) Advanced (+) Delayed 0.4V) 0.375mm (FP-7845) 0. the exposure voltage is adjusted in proportion to the difference between the reduction and 100% ratio.425mm (FP-7850/7818) 0. 0. the exposure voltage is adjusted in proportion to the difference between the enlargement and 100% ratio.4V (–99 to +99) 0.7V) Adjustment of overall exposure standard Adjustment of Photo mode exposure voltage In reduction mode. registration void is adjusted.525mm (FP-7824/7830/7835) (–30 to +20) (+): Delayed (–): Advanced After 04 is adjusted.525mm (FP-7824/7830/7835) (–9 to +9) 09 Trail edge timing of copy image (Enlargement) 10 11 12 13 Not used Exposure standard Photo mode exposure voltage change Zoom exposure (50% Reduction) (standard = 4.4V (–9 to +9) 14 Zoom exposure (200% Enlargement) (standard = 5.375mm (FP-7845) 0.425mm (FP-7850/7818) 0.375mm (FP-7845) 0.18V (–99 to +99) 0. delay (FP-7850/7818) time is adjusted from timing roller clutch ON.

28V (–99 to +99) –2.5mV (–10 to +10) –30 to +40 –99 to +99 (Except FP-7818/7824) 27 28 29 30 31 Adjustment of fuser temperature.033V (–49 to +54) Remarks 22–23 24 (–99 to +99) 25 (–99 to +99) 26 19. Adjustment of bias standard voltage Adjustment of toner density sensor gain.7 C (–15 to +15) (+): Lower (–): Raise 1% (–99 to +99) 32 Original density light peak of auto original density level The level is adjusted in proportion to the difference between the light peak and standard level. Adjustment of photo standard voltage.5V) Toner recycle switch judgment level White density adjustment* Black density adjustment* Not used Fuser temperature Function Adjustment of grid standard voltage. voltage Adjust copy density rank change for document mode (Light side) Adjust copy density rank change for document mode (Dark side) Adjustment of toner supply starting judgment voltage level.51V) Not used Copy density rank adjustment (D mode light side) Copy density rank adjustment (D mode dark side) Toner density sensor judgment voltage level (standard = 2. 0.65mm (A505) (–32 to +32) * (for Qualitative Reasoning Based Adaptive Controller) 5-25 Troubleshooting .28V (–99 to +99) –2. Adjustment of registration timing 33~35 36 Not used Registration of original for the automatic document feeder (1-side original feeding) 0.4mm (A888) 0.1V (–50 to +50) 0.5mV (–26 to +26) 19. Adjustment of toner density sensor judgment level (Recycle or collection) Adjustment of standard white density level* Adjustment of standard black density level* –2.Code 15-16 17 18 19 20 21 Item Not used Grid standard voltage (standard = –810V) Photo mode grid voltage (standard = –480V) Bias standard voltage (standard = –250V) Not used Toner density sensor gain voltage (standard = 6.

This must be adjusted if this focus changes after adjustment of F6-02.4mm (–32 to +32) Remarks with A888 38 39-40 41 Adjustment of judgment standard voltage.25ms. Adjustment for length of the loop formed before the copier timing roller.25ms.3mm (FP-7835/ 7830/7824/7818) same as F6-46 same as F6-46 42 Paper loop (ADU) same as F6-41 *When installed duplex unit.25ms.7mm (FP-7850/7845) 0. (–50 to +50) 43 Paper loop (Except FP-7818) (Copier paper tray lower) Paper loop (System console) 1.5mV (–99 to +99) 1.4mm (FP-7850/7845) 3. (–50 to +50) (–9 to +9) This must be adjusted if this focus changes after adjustment of F6-02.25ms. (–50 to +50) 44 Adjust the length of the loop formed before the registration roller of system console.4mm (FP-7835/ 7830/7824/7818) 0.7mm (FP-7845) 0. upper) Not used Reduction mode focus same as F6-46 same as F6-46 10.5mm (FP-7835/ 7830/7824) 0.25ms. (–50 to +50) 46 Paper feeding (ADU) Adjustment of registration timing 10.0ms.4mm (FP-7835/7830) 5. lower) Paper feeding (System console.4mm (FP-7818) 0. (–50 to +50) 47 48 49-50 52 Paper feeding (Copier paper tray.8mm (FP-7850) 0. (–50 to +50) 10. 19.0ms.Code 37 Item Registration of original for the automatic document feeder (2-side original feeding) Image density (black level) judgment standard voltage Not used Paper loop (Sheet bypass) Function Adjustment of registration timing 0.7mm (FP-7850/7845) 0.7mm (FP-7850/7845) 0. (–50 to +50) 45 Paper loop same as F6-41 LCC (Except FP-7818/7824) 1.4mm (FP-7835/ 7830/7824) 0.4mm (FP-7835/ 7830/7824/7818) 0.7mm (FP-7850/7845) 0. same as F6-41 1. second copy feeding. 53 Enlargement mode focus (–9 to +9) 5-26 .0ms. 1. (–40 to +40) 0.

Code 54 Item Registration void of image (During use with ADF = NO swing back condition) Function Adjustment of registration void.31mm (–12 to +12) Remarks 55 Original stop position (2 in 1 mode) (FA-A888) Original interval (2 in 1 mode) (FA-A888) Registration width guide standard position (Duplex) Registration length guide standard position (Duplex) Not used Not used Toner density sensor gain voltage Adjustment of original stop position from original guide plate Adjustment of original interval timing Adjustment of registration width guide position Adjustment of registration length guide position with A888 56 57 58 59 60-61 62 63 with A888 (Except FP-7818) (Except FP-7818) Adjustment of toner density sensor gain voltage.5mm –99 to +99 0.7mm (–16 to +8) 0.4mm (–32 to +32) 0.525mm (FP-7835/7830/7824) (0 to +99) 0.39mm (–10 to +10) 0. 0. 0.425mm (FP-7850/7818) 0.375mm (FP-7845) 0.033V (–5 to +5) 0 to 99 Limitation of maximum copy Selection of maximum number copy number of continuous copy mode Not used Black density sensor reference voltage compensation Black density sensor output gain/compensation Copy density rank adjustment (P mode light side) Copy density rank adjustment (P mode dark side) Not used LCD contrast adjustment Reference voltage adjustment for LCD contrast Coordinates compensation value (X1 point) Coordinates compensation value (Y1 point) Coordinates compensation value (X2 point) Coordinates compensation value (Y2 point) Reference voltage for black density sensor Compensate value for black density sensor output Adjust copy density rank change for photo mode (Light side) Adjust copy density rank change for photo mode (Dark side) 64 65 –99 to +99 66 –99 to +99 67 –99 to +99 68 –99 to +99 69 70 –46 to +18 60mV –50 to +50 0.5mm –50 to +50 –99 to +99 (FP-7850/7845) 71 72 73 74 Coordinates compensation for touch panel (X1) Coordinates compensation for touch panel (Y1) Coordinates compensation for touch panel (X2) Coordinates compensation for touch panel (Y2) (FP-7850/7845) (FP-7850/7845) (FP-7850/7845) (FP-7850/7845) 5-27 Troubleshooting .

Code 75-79 80 Item Not used Automatic compensation value (Read only) Exposure voltage Not used Automatic compensation value (Read only) Grid voltage Not used F5/F6 Initialization Function Set by Qualitative Reasoning Based Adaptive Controller Set by Qualitative Reasoning Based Adaptive Controller Return to factory setup –81 to +92 0.18V Remarks 81 82 –92 to +55 2.28V 83-98 99 Factory Use Only 5-28 .

23 24–25 26 Developer count Not used Fuser cleaning web count Possible number of copies until replacement of web roller. of specific department manager Function Identification code number for access counter of user choice mode 01 . the PM count is cleared.(6) F7 mode electronic counter Read procedure Set the copier to service mode and press Multi-Copy key “7”. Indicates memorized count in the electric counter. 38 Total count of upper stage of optional system console. Press Clear/Stop and User Preset key to escape service mode. Press Print key.32 Not used 33 34 35 36 ADF original feed total count Duplex unit copy total count Sheet bypass count Copier lower paper drawer count System console upper paper drawer count System console middle paper drawer count Total count of originals fed. Total elapsed copies since the last developer change. 27 . 5-29 Troubleshooting . Total count of copies from the lower drawer of the copier. Select the desired code number with Multi-Copy key.20 Not used 21 22 Total count Preventive maintenance total count Total count of all copies PM count of all copies. 37 Total count of upper stage of optional system console. Total count of sheet bypass paper fed. NOTE: When the service call indicator turns ON. Total count of duplex unit copies. Code 00 Item A code No.

42 . NOTE: When the duplex unit is installed to/upper stage of copier.) Function Total count of upper stage of optional system console.50 Not used 5-30 . this code No.Code 39 Item System console lower paper drawer count LCC count (3000 sheet paper drawer) Copier upper paper drawer count (When duplex unit is not installed. 05 does not count up. 40 Total count of optional LCC 41 Total count of copies from upper paper drawer of the copier.

Press Print key. Press Clear/Stop and User Preset key to escape service mode. b) Press the Print key. b) To return the optical system to the optics home position. Select the desired code number with Multi-Copy key.(7) F8 mode copier operation adjustment Set the copier to service mode and press Multi-Copy key “8”. d) Press the Print key. This function measures the registration that was copied using "01". Procedure: a) Press the Print key then this function moves the lamp to the position (approx. Procedure: a) Press the Print key. c) Multiply the average measured value obtained from these three copies by 10. then the resulting registration is memorized. Code 00 Item Exposure lamp replacement Function When replacing the exposure lamp. Adjust the selected mode according with instructed procedure. This function automatically makes six copies for checking the original registration. At this time. press the Clear/Stop key. Procedure: a) Position the Panasonic Test chart-53/54 on the platen glass. f) Same as c). the registration is calculated so the registration of both the 200% and 100% copy matches. b) Measure the registration on the three 200% copies that were made using "01". consisting of three 100% and 200% copies. 450mm from the optics home position) where it can be replaced. The original registration is corrected by input of the resulting measured value. 01 Original registration adjustment copy 5-31 Troubleshooting 02 Measurement input for adjusting the original registration . g) Press the Print key. then input the product using the Multi-Copy key. e) Measure the registration on the three 100% copies that were made using "01".

transfer the revised values to the memory sheet. only the most recent 30 are displayed. Procedure: a) Press the Print key to make copies. 30 machine error or paper jam codes stored in memory are displayed. i) After completing this adjustment. 5 codes per minute are displayed on the LCD. 10 Drum charge voltage checking 11 Original registration adjustment copy ( 2 ) 5-32 .Code 02 Item Function h) This adjustment may cause the factory setting of F604 to change. a) Press the Print key and the gain voltage and judgment level of the toner density sensor is automatically set in approx. If it has changed. b) Again. a) Press the Reset key. 03-05 06 Not used Machine error and Paper jam read a) Each time the Recall key is pressed. beginning with the code stored first. 07 Machine error and Paper jam code read (06) clear 08 Lock operation of mirror and lens 09 Automatic gain adjustment of toner density sensor This adjustment must always be performed when replacing new developer. b) Press the Print key. b) Press the Clear/Stop key to clear. b) When the mirror and lens unit are locked. NOTE: The lock operation is automatically reset when the Power switch is turned ON again. check F6-05 once more. a) Press the Print key then the mirror and lens unit move to locked position for transporting the copier. This function automatically makes 2 copies (both 100% and 200%) same as F8-01 mode. If they have changed. press the Reset key. A Message "Error code can be cleared with the Print key" is displayed on the LCD. so check the F6-04 setting once more. This function automatically confirms the drum bias voltage without paper of F3 mode because the LED array always lights up. so check F6-21 and 26 settings once more. any digit key input won't be accepted. b) This adjustment may cause the factory setting of F621 and 26 to change. NOTE: When stored codes more than 30. beginning with the code stored first. transfer the revised value the memory sheet. 2 minutes.

Press Clear/Stop and User Preset key to escape service mode. Number: Multi-Copy key Hyphen (–): Reset key Space: Interrupt key Carousal moving to left side: A5 key of Original size to right side: A5 key of Copy size The OK key is touched. Procedure : a) Press the Print key b) Adjustment value is automatically stored at F6-65 15 16 Not used LCD touch panel key input position adjustment ADU paper infeed positioning adjustment This adjustment is to compensate the LCD touch panel detecting position corresponding key input. This function automatically adjusts paper guide positioning. Touch INPUT key on the touch panel display. Press Print key.20 Not used (8) F9 Telephone# input Set the copier to service mode and press Multi-Copy key “9”. NOTE: Remove paper after this procedure. When “Print” is pressed. 17 18 . paper feeds into the ADU and stops. cleaning/replace black density sensor or replacing the drum. Input the telephone number. Troubleshooting 5-33 . the new telephone number is now in memory.Code 12 13 Item Not used Black density sensor reference level adjustment ( Factory use only ) Black density sensor output gain adjustment Function ( Factory use only / Need special fixtures ) 14 This adjustment should be performed when installing the copier.

User error NOTE: XXXX will appear in message display. Sorter with stapler Toner level detection Waste toner bottle full 4-34 4-34 U5 U6 U7 CLOSE DUPLEX UNIT CLOSE RIGHT SIDE PANEL CLOSE RIGHT SIDE PANEL 4-34 4-35 4-35 U10 U11 CLOSE ADF CLEAR SORTER BINS 4-35 4-35 U12 U13 U14 ADD STAPLES ADD TONER REPLACE WASTE TONER BOTTLE INSTALL DEVELOPER UNIT 4-36 4-36 4-36 U16 Developer unit is not installed 4-36 U17 — Sorter transport cover failure 4-36 U18 — Copy usage is upper limited. 1. Duplex unit failure Copier paper feed cover failure System console (option) paper feed cover failure ADF (option) failure Sorter copy paper removal NOTE: When clearing U11. all paper is removed from bins. Error Message code Uo INSERT KEY or INPUT IDENTIFICATION CODE XXX CLOSE FRONT PANEL CLOSE SORTER Item Key counter failure (option) or Access code number was not input See page 4-34 U1 U4 Front cover failure Sorter failure (option) Sorter won't close securely.2 Self-diagnostics/Machine Malfunctions The self-diagnostic functions detect troubles in important components of the copier. 4-36 5-34 . the copier is stopped.5. When any trouble occurs.

Not ready (Red LED lights) Auto off The ready indicator will flash and the other displays are turned OFF. Remove copies and press the each sorter mode key on the touch panel. See page 4-37 Not ready (Red LED flashes) Power saving The ready indicator will light and the other displays are turned OFF. To clear the Stand-by mode. To clear the Power saving mode.Error Message code oF SORTER FULL-EMPTY PRESS MODE KEY Item If too many copies in bin or too many bins selected. press the Print key. press the Print key. ---------- ---------- 5-35 Troubleshooting .

NO CN119-2. The sorter interlock switch is defective. 20. 4 of the CPU is defective. The key counter connection is defective. Is the front cover closed securely? YES Is DC24V detected on CN851-1. (Refer to sorter service manual. Does CN2-19. Is the duplex unit tray inserted securely? YES NO Insert the duplex unit tray securely.2 (of LVPS PCB) when the front cover is opened and closed? NO Close the front cover securely. The CN16 (of CPU PCB) is disconnected (3) U4: Sorter failure (option) *The copier does not indicate READY TO COPY when the sorter is installed.(1) U0: Key counter failure or Access code number was not input *The copier does not indicate READY TO COPY when the key is inserted. *Access code number was not input. Is the key inserted correctly? YES Is CN119-2 connected to CN-2? or Is CN119-4 contact to CN-4? YES NO Re-insert the key. Detected: Tray detecting sensor defective.) (4) U5: Duplex unit failure *The copier does not indicate READY TO COPY when the duplex unit is installed. NO The CN851 and CN205 (of AC driver PCB) connectors are defective. (2) U1: Front cover failure *The copier does not indicate READY TO COPY when the front cover is closed. Input access code number. 5-36 . Not detected: Check all DC5V lines. Is the sorter closed securely? YES Does J3-5 (output signal of Sorter CPU) change when the sorter interlock switch is turned ON and OFF? NO Close the sorter securely. 21 (output signal of CPU) change when duplex unit tray is removed and installed? NO Check DC5V of tray detecting sensor. NO Adjust the sorter interlock switch of sorter.

Not detected: Check DC5V line. Not detected: Check DC5V line. NO Close the paper feed cover securely. (6) U7: System console (option) paper feed cover failure *The copier does not indicate READY TO COPY when the system console paper feed cover is closed. Is the paper feed cover closed securely? YES Does CN611 (output signal of system console driver) change when the paper feed cover is opened and closed? YES System console drive PCB is defective. Any bin receives a double feed from the duplex unit. YES Is the ADF exit cover closed securely? YES Refer to the ADF Service Manual. (8) U11: Sorter copy paper removal *When the Staple Sort or Sort mode is selected: Copies are already in at least one bin. Is the ADF closed securely? YES NO Close the ADF securely.(5) U6: Copier paper feed cover failure *The copier does not indicate READY TO COPY when the copier paper feed cover is closed. Detected: Cover sensor is defective. Is the paper feed cover closed securely? YES Does CN5-7. Any bin receives more than 25 copies as a result of the use of the ADF. 11 (output signal of CPU) change when the paper feed cover is opened and closed? NO Close the paper feed cover securely. 9. 5-37 Troubleshooting Is the ADF entry cover closed securely? NO Close the entry cover securely. all paper must be removed from all bins. NOTE: To clear U11. Detected: Cover sensor is defective. (Refer to system console Service Manual) NO Check DC5V of the system console driver. NO Close the exit cover securely. . NO Check DC5V of the tray detecting sensor. Any bin receives a copy which is an unsuitable size for stapler use. (7) U10: ADF (option) failure *The copier does not indicate READY TO COPY when the original is placed onto the original feed tray.

Is the toner caked in the bottle? NO YES Shake the toner bottle well. NO: Check all DC5V lines. (or check the CN7 on CPU PCB connection) (13) U17: Sorter transport cover failure (FA-S680) The copier does not indicated READY TO COPY when the transport cover is closed. Does change voltage of sorter CPU PUB J4-2 (FCVRSW) when the cover open/close switch is turned on or off? YES Sorter CPU PUB is defective. NO Cover switch is defective. (14) U18: Copy usage is upper limited Please consult department key operator. Is the transport cover closed securely? YES NO Close the sorter transport cover securely. (12) U16: Developer unit failure Is the developer unit installed in the copier securely? NO Install the developer unit securely. (10) U13: Toner level detection *"U13" does not reset after replacing the toner bottle. (11) U14: Waste toner bottle full Is the waste toner bottle full? YES Replace the waste toner bottle. and a staple cartridge is not inserted. Is the output signal of the toner level detecting sensor approximately 4V? NO Check DC5V of CPU CN113-7. 5-38 . or Change the toner bottle. 8. YES: Toner level detecting sensor is defective. 9.(9) U12: Sorter with stapler *When the stapler mode is selected.

G F D C E A B 5-39 Troubleshooting . Did the number of copies exceed the bin capacity? YES Remove copies and press the Sorter mode select key.(15) oF: Sorter bin capacity failure *Too many copies in at least one bin or too many bins selected.

a) Paper feeding from the optional system console middle stage: The copier lower stage paper pass sensor 2 does not detect paper within a predetermined time after optional system console middle stage paper pass sensor 2 detected paper. b) Paper feeding from the optional system console lower stage: The copier lower stage paper pass sensor 2 does not detect paper within a predetermined time after optional system console lower stage paper pass sensor 3 detected paper. The copier lower paper feed unit paper pass sensor 2 does not detect paper within a predetermined time after copier lower stage paper feed roller starts rotating. B J09 B J10 J11 A A. The copier lower stage paper pass sensor 2 does not detect paper within a predetermined time after LCC pick-up roller starts rotating. a) Paper feeding from copier upper stage: b) Paper feeding from duplex unit: Jam position A Jam read code J00 J01 A A. Optional system console middle paper feed unit paper pass sensor 2 does not detect paper within a predetermined time after middle stage paper feed roller starts rotating. When the duplex unit is not installed: After copier upper stage paper feed roller starts rotating. Paper feeding from the optional system console upper stage: The copier lower stage paper pass sensor 2 does not detect paper within a predetermined time after optional system console upper stage paper pass sensor 1 detected paper. When the duplex unit is installed: After duplex unit paper feed roller starts rotating. E A J02 J03 B J04 B J05 B J06 A J07 A J08 A. Optional system console upper paper feed unit paper pass sensor 1 does not detect paper within a predetermined time after upper stage paper feed roller starts rotating. E 5-40 .2. Optional system console lower paper feed unit paper pass sensor 3 does not detect paper within a predetermined time after lower stage paper feed roller starts rotating. When optional LCC is installed. Not used The copier upper stage paper pass sensor 1 is detecting paper within a predetermined time. Paper Jam Condition The registration roller paper pass sensor does not detect paper within a predetermined time after sheet bypass paper feed roller starts rotating. Paper feeding from the copier lower paper tray or optional LCC or system console: The copier upper stage paper pass sensor 1 does not detect paper within a predetermined time after copier lower stage paper pass sensor detected paper. The copier upper paper feed unit paper pass sensor 1 does not detect paper within a predetermined time.

Optional system console upper paper pass sensor 1 is detecting paper. The paper exit sensor is detecting paper within a predetermined time after sensor detected paper. The paper exit sensor is detecting paper. Not used Paper feeding from sheet bypass: The registration roller paper pass sensor is detecting paper within a predetermined time after sensor detected paper. Not used The registration roller paper pass sensor is detecting paper. Not used Copier upper stage paper pass sensor 1 is detecting paper. Not used Jam position A J13 B J14 B J15 B J16 A J17 J18 A B A C C J31 J32 J33 J34-39 J40 J41 J42 J43-49 C C. a) The copier paper pass sensor 1 or 2 is detecting paper. Paper feeding from optional system console lower stage: Lower stage paper pass sensor 3 is detecting paper within a predetermined time after first detecting paper. Paper feeding from optional system console upper stage: Upper stage paper pass sensor 1 is detecting paper within a predetermined time after first detecting paper. Optional system console lower paper pass sensor 3 is detecting paper. Paper feeding from optional LCC: The copier lower stage paper pass sensor 2 is detecting paper within a predetermined time after first detecting paper. When fixed quantity paper passed on the registration roller paper pass sensor.Jam read code J12 Condition Paper feeding from copier lower stage: The copier lower stage paper pass sensor 2 is detecting paper within a predetermined time after first detecting paper. Copier lower stage paper pass sensor 2 is detecting paper. Optional system console middle paper pass sensor 2 is detecting paper. Not used The paper exit sensor does not detect paper within a predetermined time after registration roller starts rotating. D D D 5-41 Troubleshooting J19-20 J21 J22 J23 J24 J25 J26-29 J30 A A B B B . Paper feeding except from sheet bypass: The registration roller paper pass sensor is detecting paper within a predetermined time after registration roller starts rotating. Paper feeding from optional system console middle stage: Middle stage paper pass sensor 2 is detecting paper within a predetermined time after first detecting paper. b) Optional paper pass sensor 1 or 2 or 3 is detecting paper. Paper feeding except from sheet bypass: The registration roller paper pass sensor does not detect paper within a predetermined time after copier upper stage paper pass sensor 1 detected paper.

Transport operation for duplexing The duplex unit paper pass sensor 1 does not detect paper within a predetermined time after copier paper exit sensor detected paper. J51 Transport operation for duplexing The duplex unit paper pass sensor 1 is detecting paper within a predetermined time after sensor detected paper. J52 Transport operation for duplexing The duplex unit paper pass sensor 2 does not detect paper within a predetermined time after paper pass sensor 1 detected paper. J53 Transport operation for duplexing The duplex unit paper pass sensor 2 is detecting paper within a predetermined time after sensor detected paper. J54 The duplex unit paper pass sensor 1 is detecting paper. J55 The duplex unit paper pass sensor 2 is detecting paper. J56 The duplex unit paper detecting sensor does not detect paper after copies are fed into the duplex unit tray. J57-59 Not used J60 When the sorter is installed. a) The sorter entry paper pass sensor does not detect paper within a predetermined time after copier paper exit sensor detected paper. b) The sorter paper exit sensor does not detected paper within a predetermined time after sorter entry paper pass sensor detected paper. c) The sorter entry or exit paper pass sensor is detecting paper. d) For FA-S575 The sorter exit paper pass sensor does not detect paperwithin a predetermined time after sorter entry paper pass sensor detected paper. e) For FA-S575 The sorter exit paper pass sensor is detecting within a predetermined time after sensor detected paper. J70 When ADF is installed. a) The ADF entry paper pass sensor does not detect paper within a predetermined time after ADF paper feed roller starts rotating. b) The ADF entry paper pass sensor is detecting paper within a predetermined time after sensor detected paper. c) The ADF entry paper pass sensor is detecting paper before using ADF. J71 a) The ADF exit paper pass sensor does not detect paper within a predetermined time after ADF starts paper exit. b) The ADF exit paper pass sensor is detecting paper within a predetermined time after sensor detected paper. c) The ADF exit paper pass sensor is detecting paper before using ADF. J72 (FA-A888) a) The ADF exit paper pass sensor does not detect paper within a predetermined time after ADF starts reverse operation. b) The ADF exit paper pass sensor is detecting paper within a predetermined time after sensor detected paper.

Jam read code J50

Condition

Jam position D

D, E

D, E

D, E

D D

D, F F

F F

F

G G

G G G

5-42

3.

Machine error The machine system will detect problems in important areas of the copier. When any problems occurs the copier stops. Error codes indicate the mode number and code number which are alternately displayed in "Digit" display area of touch screen. When there is trouble in any part of the copier, the "MACHINE ERROR TURN

POWER SW OFF/ON" appears in the "Message" display. (1) Error code display functions
E1: Optical unit error Code E1-01 E1-20 E1-21 E1-23 E1-32 E1-40 E1-41 E1-43 Function Optical unit scan operating Lens ratio operating Mirror ratio operating F8-02 mis-input Auto original density detection Optics fan motor (1) rotation Optics fan motor (2) rotation Optics fan motor (4) rotation Refer page 5-46 5-46 5-47 5-47 5-47 5-48 5-48 5-48

E2: Paper feed unit error Code E2-01 E2-02 E2-03 E2-04 E2-05 E2-06 E2-07 E2-10 Function Lift motor rotation 1 (Copier upper tray) Lift motor rotation 2 (Copier lower tray) Lift motor rotation 3 (System console upper) Lift motor rotation 4 (system console middle) Lift motor rotation 5 (system console lower) Optional LCC lift operation (UP) Optional LCC lift operation (DOWN) System console motor rotation manual 5-49 5-48 Refer page

5-43

Troubleshooting

E3: Developer unit and Hopper unit error Code E3-01 E3-03 E3-10 E3-11 E3-20 E3-21 E3-22 E3-23 E3-30 E3-40 E3-50 Function Toner bottle motor rotation Toner density sensor gain High voltage power supply leak (1) High voltage power supply leak (2) Main motor rotation Dust collection fan motor rotation Exhaust fan motor rotation Suction fan motor rotation Discharge lamp Copy density sensor output detection Transfer cleaner operation Refer page 5-50 5-50 5-51 5-51 5-51 5-52 5-52 5-52 5-52 5-52 5-53

E4: Fuser unit error Code E4-01 E4-10 E4-11 E4-12 Function Fuser warm-up Exhaust fan motor (1) rotation Exhaust fan motor (2) rotation Exhaust fan motor (3) rotation Refer page 5-53 5-54 5-54 5-54

E5: System (+24V/+10V) error Code E5-01 E5-04 E5-10 E5-21 E5-22 E5-23 E5-41 E5-42 E5-50 Function Vp (+24V) line Vo (+10V) line +5V (for EPA) ADF communication abnormal Sorter communication abnormal Control panel communication abnormal Registration timing control circuit abnormal Total counter connection Communication error Refer page 5-54 5-55 5-55 5-55 5-55 5-55 5-56 5-56 5-56

E6: Duplex unit error Code E6-03 E6-04 E6-05 Function Paper length home position detecting sensor Paper width home position detecting sensor Paper detecting sensor Refer page 5-56 5-57 5-57

5-44

E7: Optional unit error *These errors are indicated when options are installed. Refer to Optional Unit Service Manual. Code E7-01 E7-03 E7-06 E7-07 E7-10 E7-11 Function Sorter bin movement Transport belt motor failure Stapler drive motor failure Tamper drive motor failure ADF main motor rotation ADF sensors output abnormal (registration and original exit/reverse sensor) ADF Service Manual Refer page Sorter Service Manual

5-45

Troubleshooting

. YES Is DC5V (output signal) detected on the home position sensor connector? NO CPU PCB is defective. Home position sensor mounting position is incorrect. Does the lens unit move when the power switch is turned ON? NO Lens stepping motor connector is defective. Is DC5V (output signal) detected on the lens position sensor connector CN-1 ? NO Is DC5V detected on the CN10-18 of CPU PCB? YES: Home position sensor connector is shorted or broken. Home position sensor is defective. Home position sensor connector is shorted or broken. CN115 or CN123 (of LVPS PCB) is shorted or broken.E1-01: Optical unit scan drive When the lamp unit scanner motor drives to the optics home position sensor and is not detected within a predetermined time. Is DC5V signal detected on the CN10-17 of CPU PCB? YES: Home position sensor connector is defective. change when the home position sensor is turned 5-46 CPU PCB is defective. CPU PCB is defective. Lens stepping motor is defective. Lamp mechanism drive mechanism is defective. YES CPU PCB is defective. Home position sensor mounting position is incorrect. change when the home position sensor is turned E1-20: Lens ratio drive When the lens stepping motor drives to the lens home position sensor and is not detected within a predetermined time. YES Does CN10-20 output signal of CPU PCB ON/OFF. Home position sensor is defective. CN114 or CN123 (of LVPS PCB) is shorted or broken. YES NO NO: Check all DC5V lines. NO NO: Check all DC5V lines. Does the lamp unit move when the power switch is turned ON? NO Lamp unit scanner motor connector is shorted or broken. YES Does CN10-19 (output signal of CPU PCB) ON/OFF. YES Lens drive mechanism is defective.

E1-21: Mirror ratio drive When the mirror stepping motor drives to the mirror home position sensor and is not detected within a predetermined time. CN-115 or CN-123 (of LVPS PCB) is shorted or broken. Is original density sensor dirty? NO Is DC10V signal detected on CN11-12 CPU PCB? NO PCB is defective. Original density sensor is defective. NO Check all DC5V lines. 5-47 Troubleshooting Measurement input for adjusting the Input the average measurement correctly. Is DC5V (output signal) detected on the Mirror position sensor connector CN-1 ? YES NO Is DC5V detected on the CN11-3 of the CPU PCB? YES: Home position sensor connector is shorted or broken. change when the home position sensor is turned YES CPU PCB is defective. E1-32: Auto original density detection When the auto original density signal is not detected. . Mirror stepping motor is defective. Home position sensor mounting position is incorrect. Mirror drive mechanism is defective. CPU PCB is defective. NO: Does CN11-2 (output signal of CPU PCB) ON/OFF. Home position sensor connector is shorted or broken. Does the mirror unit move when the power switch is turned ON? YES NO Mirror stepping motor connector is shorted or broken. or the auto original density can not be adjusted. YES Clean the original density sensor. E1-23: F8-02 mis-input original registration Adjust F8-01 and F8-02 again. YES Original density sensor connector is shorted or broken. Home position sensor is defective.

Is 0V CN106-9. Is DC24V. 12 or CN 107-3 (on LVPS PCB)? YES Connector is shorted or broken. Copier CPU PCB is defective. Does the lift motor lift the plate? NO YES Check level sensor signal(CN-2) when the plate rises. Lift motor is defective. detected on CN 106-9. * NOTE: X=1: Lift motor signal (Copier upper tray) X=2: Lift motor signal (Copier lower tray) X=3: Lift motor signal (System console upper) X=4: Lift motor signal (System console middle) X=5: Lift motor signal (System console lower) 5-48 . Does LUMX-2* changed "H" to "L" when the lift motor is turned ON? NO YES Lift motor drive mechanism is defective. A rotation signal is detected when the fan motor stops. Not changed: Check sensor lever. the level sensor is not turned ON within a predetermined time. E2-01: Lift motor rotation 1 (Copier upper tray) E2-02: Lift motor rotation 1 (Copier lower tray) E2-03: Lift motor rotation 1 (System console upper) E2-04: Lift motor rotation 1 (System console middle) E2-05: Lift motor rotation 1 (System console lower) When the lift motor is turned on. Level sensor is defective. NO LVPS is defective. Harness is defective.E1-40: Optics fan motor (1) rotation E1-41: Optics fan motor (2) rotation E1-43: Optics fan motor (4) rotation A lock signal is detected when the fan motor is rotating. Check DC5V of CN-1. 12 or CN107-3 (on LVPS PCB)? YES Fan is defective. NO LVPS is defective. Driver PCB is defective. Changed: CPU PCB defective. Fan is defective.

Locking mechanism of motor is defective. Changed: CPU PCB is defective. Is lift motor sound detected? NO YES Check the upper limit sensor signal. Does the main motor rotate by hand? YES Is DC24V detected on CN-1. Copier CPU PCB is defective. YES: Connector is shorted or broken. NO Check DC24V on CN602-3 and 4. E2-10: System console motor rotation When the system console main motor drives an abnormal signal is detected. 5-49 Troubleshooting . Not changed: Limit sensor is defective. Copier CPU PCB is defective. Canged: CPU PCB is defective. System console driver PCB is defective. the upper and lower limit switch are not detected within a predetermined time. Lift motor is defective. LCC driver PCB is defective. Does PLMCT6 change "H" to "L" when the lift motor is turned ON? NO YES Lift motor drive mechanism is defective. Does the CN602-7 signal change "H" to "L" when the main motor drives? NO YES Main motor is defective. NO: Check CN602-3 and 4 of system console driver PCB.E2-06: Optional LCC lift operation (UP) E2-07: Optional LCC lift operation (DOWN) When the lift motor drives up and down. Check the lower limit sensor signal. Not changed: Limit sensor is defective. 2 ? YES NO Main motor drive mechanism is defective.

CPU PCB is defective. Bottle motor home position sensor connector is shorted or broken. Is toner density level standard (3. NO Replace the developer material and re-adjust the toner density. Is DC24V detected on toner density sensor connector CN-2 ? YES Is the toner density sensor signal detected on CPU PCB CN7-8 ? YES NO Is DC24V detected on CPU PCB CN7-7 ? YES: Toner density sensor is defective. Does the toner bottle motor rotate in manual toner addition mode? YES NO Bottle motor connector is shorted or broken Bottle motor drive mechanism is defective. sensor is turned ON/OFF? YES NO NO Is DC5V detected on control panel CN401-13 ? YES: Bottle motor home position sensor connector is shorted or broken. CPU PCB is defective.5% +/-0. AC driver PCB is defective.5)? YES CPU PCB is defective. Is DC5V detected on the bottle home position sensor connector SN10-1 ? YES Does CN104-5 (signal of CPU PCB) or CN401-11 (of control panel CPU PCB) change when the toner bottle home position . NO: Toner density sensor connector is shorted or broken. toner density sensor standard signal level is not detected. NO: Check all DC5V lines. 5-50 . E3-03: Toner density sensor gain When the toner density gain is adjusted. Bottle motor is defective.E3-01: Toner bottle motor rotation When the toner bottle motor drives to the toner bottle position and the toner bottle home position sensor is not detected. NO Check DC24V of CPU PCB CN7-7. (between control panel CPU and main CPU PCB) CN401 is shorted or broken (on control panel CPU PCB). Sensor mounting position is incorrect Bottle motor home position sensor is defective. Harness is defective.

E3-20: Main motor rotation When the main motor is turned ON/OFF. Is the charge/transfer corona dirty? NO Does the ground terminal float from the copier frame? NO . Is the separation corona dirty? NO Does the ground terminal float from the copier frame? NO . YES Main motor connector is shorted or broken.E3-10: High voltage power supply leak (1) When a leak is detected from the high voltage power supply charge/transfer corona. 5-51 Troubleshooting . Does the main motor rotate during copier warm up? NO Is voltage detected at the LVPS CN852-1 ? YES LVPS is defective. CPU PCB is defective. YES Clean the charge/transfer corona. YES Clean the separation corona. NO Main motor is defective. CPU PCB is defective. YES Tighten screw(s) on the ground terminal of HVPS PCB or HVPS bracket. the signal is/not detected. CPU PCB is defective. YES Tighten screw(s) on the ground terminal of HVPS PCB or HVPS bracket. E3-11: High voltage power supply leak (2) When a leak is detected from the high voltage power supply separation corona.

fan motor rotation signal is/not detected.E3-21: Dust collection fan motor rotation E3-22: Exhaust fan motor rotation E3-23: Suction fan motor rotation When the fan motor is rotated or stopped. YES Clean the copy density sensor. NO Install the drum securely. E3-40: Copy density sensor output adjustment When the QRBAC* Function does operate. fan motor is defective E3-30: Discharge lamp When the discharge lamp does not turn ON. or the fan motor fails to rotate when the power switch is turned ON. CPU PCB is defective. Is the copy density sensor dirty? NO Does the copy density sensor connector insert securely? YES Is the drum installed securely? NO Does the LED array light? YES Is DC5V detected on CPU PCB CN7-3 ? (QRBAC* function) YES Is voltage detected on CPU PCB CN7-2 ? YES Check all DC5V lines. Is the discharge lamp ON? NO Is DC24V detected on discharge lamp connector CN-2? YES Discharge lamp terminal position is incorrect. 2 or 7? YES Fan motor connector is shorted or broken. YES CPU PCB CN14-1 and 2 are shorted. the white density output signal is not detected. 5-52 . Is DC24V detected on CN8-1. * QRBAC = Qualitative Reasoning Based Adaptive Controller. NO NO Check the LED array connector is connected correctly Check other DC5V line. NO Copy density sensor is defective. NO Re-insert the sensor connector securely. NO Check DC24V on CPU PCB CN14-2.

c) Slide the wire cleaner felt to rear side until it stops.E3-50: Transfer cleaner operation When the transfer cleaner motor drives.4M /77F. Fuser thermistor is defective. f) Check the wire cleaner felt is connected to the corona rail slider. YES Check operation Is DC5V detected on sensor CN-1? YES Does CN4-5 (output signal of control panel CPU PCB) change when the sensor is turned ON/OFF? NO Sensor is defective NO Sensor connector is shorted or broken. Is these continuity between CN-1 and 2 when the AC driver PCB CN203 is removed. . E4-01: Fuser warm-up When the fuser temperature does not reach the predetermined level Does fuser lamp turned ON after the power switch is turned on? NO YES Fuser thermistor is dirty. NO CNTH connector is shorted or broken. 1. Sensor position is incorrect. 5-53 Troubleshooting within a predetermined time. 25°C) . YES Is there some registrance between CNTH-1 and 2 approximately few M whenCPU PCB CN7 is removed. Fuser temperature is low (re-adjust F6-31) Fuser thermistor is defective. e) Turn the transport lever and raise the transport unit. (approx. Fuser thermostat is defective. d) Re-install the transfer charger. Is the wire cleaner felt at the home position sensor? YES NO Does the wire cleaner felt connect to the corona rail slider? NO a) Turn the transport lever and lower the transport unit b) Press down the transfer charger and draw it toward you. the transfer cleaner home position sensor is not ON/OFF within a predetermined time. Fuser lamp is defective. NO Fuser lamp connector is shorted or broken.

Is 0V CN106-3. E5-01: Vp (+24V) When the VCNT signal is "L". NO LVPS is defective.E4-10: Exhaust fan motor (1) rotation E4-11: Exhaust fan motor (2) rotation E4-12: Exhaust fan motor (3) rotation A lock signal is detected when the fanmotor is rotating. Harness is defective. NO LVPS is defective. NO The front cover open/close switch is defective. 6 or CN107-6 (on LVPS PCB)? YES Fan is defective. Fan is defective. The front cover is not closed correctly. Low voltage power supply PCB is defective. Is DC24V detected on CN106-3. Is DC24V detected on CN851-3 and 4 of the LVPS PCB? YES Is DC24V detected on CN205-1 and 2 of CPU PCB? YES Is DC24V detected on CN205-3 and 4 of the AC driver PCB? YES Connector is shorted or broken. DC24V outputs over approximately 18V/approximately. DC24V output is under approximately 18V or when the VCNT signal is "H". NO NO VCNT signal connector is defective or broken. Harness is defective. 6 or CN107-6 (on LVPS PCB)? YES Connector is shorted or broken. Connector is shorted or broken. Harness is defective. A rotation signal is detected when the fan motor stops. 5-54 .

NO Re-insert Sorter connector securely. NO Re-insert CN103 securely. NO Re-insert CN104 securely. IC9 or IC13) E5-10: +5V (for Power saving mode) When the power saving mode is operated on and DC5V power supply is not 0V.E5-04: Vo (+10V) line When the power switch is turned on. E5-22: Sorter communication abnormal When the communication signal between the sorter and copier is abnormal. E5-21: ADF communication abnormal When the communication signal between ADF and copier is abnormal. (Refer to Sorter Service Manual) Copier CPU PCB is defective. NO Re-insert ADF connector securely. 5-55 Troubleshooting . NO Re-insert CN401 securely. The E5-10 is indicated just moved power saving mode. (Refer to ADF Service Manual) Copier CPU PCB is defective. Is Sorter connector inserted securely? YES Sorter control PCB is defective. after normal communication between the control panel and the copier has occurred. Is CN103 connector of the CPU PCB inserted securely? YES Is CN104 connector of the LVPS PCB inserted securely? YES Is CN401 connector of the control panel CPU PCB inserted securely? YES Any PCB is defective. Is DC24V detected on between CPU PCB CN1-8 and 9? YES (IC16. Is ADF connector inserted securely? YES ADF control PCB is defective. E5-23: Control panel communication abnormal When the communication signal between the control panel and copier CPU become abnormal. DC10V is not detected.

E6-03: Paper length home position detecting sensor When the paper length motor drives to home position. IC5 on CPU PCB is defective. NO Check DC+24V line. 5-56 . Detected: Check sensor. Duplex unit control PCB is defective. paper feed driver. Main CPU (IC5). the optics scan and registration drive start driving or when the copier is operated. E5-42: Total counter connection When the total counter is disconnected. the optics scan and registration operating are not driven within a predetermined time.E5-41: Registration timing control circuit abnormal When the copier stops. Is the total counter connector inserted securely? YES Total counter is defective. Does the paper length motor rotate? NO YES Check paper length home position detecting sensor output PSLSN(CN-2) Changed: Duplex unit control PCB is defective. Not changed: Check DC+5V on CN-1. Not detected: Check DC+5V line. ADU driver or LCC driver is defective. E5-50: I/O Communication error When an abnormal communication is detected. paper length home position detecting sensor is not sensed within a predetermined time. Is DC+24V detected on CN653-4? YES Paper length motor is defective. NO Insert the total counter securely. Copier CPU PCB is defective.

Duplex unit control PCB is defective. Does the paper width motor rotate? NO YES Check paper width home position detecting sensor output PSWSN(CN-2) Changed: Duplex unit control PCB is defective. but it is not detected. Not detected: Check DC+5V line. paper width home position detecting sensor is not sensed within a predetermined time. Does CN-2(DXPESN) output level change when the duplex unit tray sensor is turned ON/OFF? YES Duplex unit control PCB is defective. Copier CPU PCB is defective. Not changed: Check DC+5V on CN-1. Is DC+24V detected on CN653-7? YES Paper width motor is defective. NO Check DC+24V line. Detected: Check sensor.E6-04: Paper width home position detecting sensor When the paper width motor drives to home position. E6-05: Paper detecting sensor When paper is in the duplex unit tray. 5-57 Troubleshooting . Detected: Check sensor. NO Check DC+5V on sensor. Not detected: Check DC+5V line.

5 h 6: 4 h 1: 45 seconds 3: 2 minute 1: 30 m 2: 60 m 4: 2 h 5: 3 h 7: No energy saver timer 2 0 5-58 . Auto reset timer 2: 1 minute Energy saver timer 0: None 2: 1 minute 0: 15 m 3: 1. LETTER 3: A3. please refer to the operating guide. and press Print key.3 User Preset Mode Regarding the operation procedure. Then press Recall key and input the changed copy usage. M2 ON (1) ON Press Print key and input the code number. please input ID number.5. A5 0: 5mm 2: 15mm 0: 5mm 2: 15mm 0: 15mm 2: 25mm 0: None 2: 93% 0: None sort 2: Sort 1: 10mm 3: 20mm 1: 10mm 3: 20mm 1: 20mm 3: 30mm 1: 95% 3: 91% 1: Staple sort 3: Group UP-02 UP-03 UP-04 UP-05 UP-06 UP-07 UP-08 UP-09 UP-10 UP-11 UP-12 Margin value default Edge value default Book value default Margin reduction default Sorter mode default Duplex mode default 2 in 1 copy ratio Auto edge default Check mode ON/OFF selection Manual toner addition Total copy usage of a specific department Changing the total copy usage of a specific department. 1 1 1 0 0 0 0 0 0 0: Does not select 1: 1 sided to 2 sided 2: 2 sided to 2 sided 3: Book to 2 sided 0: Full size 0: OFF 0: OFF 2: M2 ON (0) OFF 1: Reduction 1: ON 1: M1 ON 3: M1. Not used UP-13 to 18 UP-19 UP-20 to 34 UP-20 UP-21 Set key operator code (3digits) Before setting these modes. LETTER R 1: B4. Press Print key and input the code number. Code UP-00 Item Paper size (copier and System Console) Function Refer to example (Factory setting) Copier: Ledger/A3 System: Not setting 2 UP-01 Paper size priority 0: A4R. LEGAL 2: A4. LEDGER 4: INVOICE.

5 hr 4: 3 hr 5: 4 hr 0: Not detecting 1: Auto mode priority 2: Manual mode priority 0: Japanese 2: German 4: Italian 6: Swedish 8: Dutch 1: English 3: French 5: Spanish 7: Finnish 9: Portuguese (Factory setting) 1 UP-23 UP-24 Auto original density (When power ON) Message display language change 1 1 UP-25 Auto selection prohibition paper tray (1) 0: None 1: Copier (upper) 2: Copier (lower) (Except FP-7818) 3: System console (upper) 4: System console (middle) 5: System console (lower) 6: LCC (Except FP-7818/7824) 7: Sheet bypass 0 UP-26 UP-27 UP-28 UP-29 Auto selection prohibition paper tray (2) same as UP-25 Presentation/ OHP Interleaving mode initial setting Page Insertion mode initial setting Cover mode initial setting (0) Blank paper (1) Copied paper (0) Blank paper (1) Copied paper (0) Cover page: Blank paper (1) Cover page: Copied paper (2) Cover page: Copied paper Back cover: Blank paper (3) Cover page: Copied paper Back cover: Copied paper 0 0 0 0 UP-30 UP-31 UP-32 Not used Changing upper copy quantity (n = -99 to 0) Check width size in M1 memory (n = 1 to 60) Check length size in M1 memory (n = 1 to 41) Quantity = 999 + n x 10 + 1 Width = n x 5mm Length = n x 5mm 0 28 43 (American) 42 (Others) 28 43 (American) 42 (Others) UP-33 Check width size in M2 memory (n = 1 to 60) Check length size in M2 memory (n = 1 to 41) Width = n x 5mm Length = n x 5mm 5-59 Troubleshooting .Code UP-22 Item Auto off timer Function 0: No auto off timer 1: 30 m 2: 60 m 3: 1.

Press the Access key and input the code number. and press Print key. Then press Recall key and input the changed access number. Changing the access code number of a specific department.Code UP-34 Item Indicate the access code number of a specific department. Function Press the Access key and input the code number. (Factory setting) 5-60 .

1 Installation Requirements Make sure machine is properly leveled from left to right and from front to rear (use small carpenter level).VI. (Visual check) 6-1 Unpacking/ Installation . The mains plug on this equipment must be used to disconnect mains power.3 Unpacking Check the condition and contents of the box for any shipping damage and completeness before installation. Please ensure that the socket outlet is installed near the equipment and shall be easily accessible. 14"/ 350mm 4"/100mm 28"/ 700mm Exit tray Copier Multi-sheet bypass tray 6.2 Contents Check Contents 1 2 3 Copier Exit tray Document bag Check 6. Unpacking/Installation 6. The copier should be installed in a level and well-ventilated area. to minimize the ozone density in the air.

(3) Remove the platen glass. Optical unit (1) Remove the original guide plate. 2. (1 piece) (8) Slide back the duplex unit tray.4 Installation Procedure • Remove the external packing/protection materials. 550 sheet paper drawer (1) Pull the 550 sheet paper drawer out fully. • Save the shipping materials for future use (Transport of copier) Location Shipping material/Procedure 1. (1 screw) (4) Check 1 (5) Reinstall the platen glass. (3 screws) (2) Remove the optical unit shipping brackets (front/rear) (1 screw each). (3) (4) Pull the duplex unit tray out fully. (2) Remove the waste toner bottle. (4) Remove the lens unit fixing bracket B. (5) Remove the paper guide shipping screws. (7) Remove the shipping styrofoam. (2 screws) (6) Raise the paper guide. (3) Remove the tape and duplex unit bracket. • Remove the shipping tape from the copier. (2) Remove the shipping styrofoam. 6-2 . (6) Reinstall the original guide plate. (1 piece) Styrofoam (5) (5) Duplex unit (3) Slide back the paper drawer.6. Duplex unit (1) Open the waste toner bottle cover. 3.

Location Shipping material/Procedure Paper transport unit (1) Open the front cover. then angle up to remove. (8) Remove the developer unit. (3) Remove the recycle solenoid cover. (2 screws) (4) Close the fuser exit guide plate. (2) Open the fuser exit guide plate. (5) Lower the paper transport.) Note: B e c a r e f u l t o a v o i d damaging the recycle and toner addition sponge seals. (1 screw) Waste toner bottle door Release lever (4) Open the waste toner bottle door. (5) Close the paper exit door. (6) Remove the drum unit. (Pull out until it stops. (2) Remove the shipping tape. (7) Disconnect the TDC connector. Unpacking/ Installation 6-3 Recycle solenoid cover 1 connector) . (1 screw. (180 degrees) (2) Turn the developer unit release lever clockwise. (3) Remove the fuser pressure release screws. (2) Tape Check 2 3 Fuser unit (1) Open the paper exit door. 4 TDC connector Toner bottle Hopper Developer unit (1) Swing open the toner bottle/ hopper.

Location Shipping material/Procedure Pour the developer into the unit (1) Remove the developer unit lid. (6) Close the front cover. Note: Pour in the entire bottle of developer. (2) Pour the developer evenly into the unit. (8) Close the waste toner bottle cover. Cleaning blade pressure release (1) Install the cleaning blade pressure spring to the pin. Rotate the mag-roller gear counterclockwise (up-ward) about 90 degrees in order to form magnet brush between shield plate and sleeve. (3) Reinstall the developer unit lid. if you push in the drum unit. (4)-1. (1 screw) (4) Swing back the toner bottle/hopper. (4)-3. Note: P l e a s e t a k e c a r e f o r Tonerrecycle Solenoid Harness. Check 5 Magnet brush Mag-roller Mag-roller gear Shield plate 6 Pin Spring 6-4 . Rotate the mag-roller gear clockwise (down-ward) several turns again to stabilize magnet brush. (5) Reinstall the developer unit. (5) Raise the paper transport. (8) Pull the developer unit release lever out until it stops and rotate it 90 degrees counterclockwise. (3) Reinstall the solenoid cover. (6) Reconnect the TDC connector. (4)-2. Rotate the mag-roller gear clockwise (down-ward) several turns in order to distribute developer evenly on the sleeve. after shaking it well. (2) Reconnect the solenoid connector. (7) Reinstall the drum unit. (7) Install the waste toner bottle. (9) Push the developer unit release lever back in until it stops.

Location

Shipping material/Procedure Turn the power switch ON TDC adjustment (1) Press the “User Preset”, “Ledger/ A3 of Original Size” and “3” keys simultaneously to enter the F mode. (2) Press the “8” key to enter the F8 mode. (3) Press the “Print” key. (4) Press the “0”, “9” keys to enter the F8 mode code “09”. (5) Press the “Print” key for automatic TDC sensor gain adjustment. (Wait approximately 2 minutes until the adjustment cycle stops.) (6) Write the contents of F6-21 and 26 on the memory sheet.

Check

7 8(a)

8(b)

Black density sensor output gain adjustment (1) Press the “1” and “4” to enter the F8 mode code “14”. (2) Press the “Print” key for automatic black density sensor output gain adjustment. memory sheet. (4) Press the “User Preset” and “Clear/Stop” keys simultaneously to escape from the F mode. Unpacking/ Installation
6-5

(3) Write the content of F6-65 on the

Location

Shipping material/Procedure Toner bottle insertion (1) Open the front cover. (2) Take a fresh bottle of toner and
Hopper

Check

9

shake it 10 to 15 times. (3) Swing the toner bottle hopper open 90 degrees. (4) Remove the toner bottle cap. (5) Insert the toner bottle into the hopper unit and turn it clockwise. Note: Make sure the arrows on the

Toner bottle

bottle and the hopper are aligned. (6) Close the front cover.

10
Paper guide (left)

Paper guides (front/rear)

Paper size setting (1) Pull the paper drawer out until it stops. (2) Position the paper guides (front/ rear) to the paper size required. If the size will remain fixed, install the screws to lock down the paper guides. (3) Position the paper guide (left) to the paper size required and install the paper guide screw. (4) Push in the paper tray. (5) Select F5-15. (6) Select the desired paper size. (7) Press the “User Preset” and "Clear/Stop" key simultaneously to escape from the F mode. (8) Take out and reinsert the indicator so the selected paper size is shown.

6-6

6.5 Adjustment
Location Shipping material/Procedure Exposure standard adjustment (1) Enter the F6 mode. (2) Confirm F6-11, 12, 17, 18 and 19 to “0”, and change as necessary. (3) Enter the F2 mode and set the exposure to the center position in the Document mode. (4) Make a copy of Test Chart 53/54 with gray scale (P/N FQ-SJ101). a) Gray scale “1” should not be visible. b) Gray scale “2” should be clearly visible. Note: Skip to step 11 if the density is in target. (5) Enter the F6-28 mode. (6) Enter the new content. Note: The “Reset” key is used to enter the “–” content. (+): Lighter side (–): Darker side (7) Press the “OK” key, then press the "Print" key. (8) Press the “Clear/Stop” key twice. (9) Enter the F2 mode. (10)Make a copy to confirm the adjustment Note: Repeat step 3 to 10 until the proper density is attained. (11)Press the “User Preset” and “Clear/Stop” keys simultaneously to escape from the F mode. Note: Dependent on customer requirement. Perform the above adjustment upon customer request.
6-7

Check

1

A 1 2 3

Not visible Clearly visible

Unpacking/ Installation

Location

Shipping material/Procedure Side to side adjustment

Check

2
Screw

1. Sheet bypass tray (1) L o o s e n a d j u s t i n g s c r e w s . (2 screws) (2) Move the adjusting plate to the front or rear accordingly. Note: After this adjustment is done, duplex side to side

Sheet by-pass tray

adjustment must be done. (Adjustment #3 below) 2. 550 sheet paper drawer

Adjusting plate screw storage Adjusting plate

(1) Pull the paper drawer out until it stops. (2) Loosen the paper drawer adjusting plate (2 screws), and move it to the front or rear as required. (3) Install new paper then adjust the paper width.

Paper size plate

(4) Remove the paper. (5) Retighten the paper drawer adjusting plate mounting screws. (6) Loosen paper size plate mounting screw and move the plate as necessary, then tighten the screw.

6-8

Location Shipping material/Procedure 3. (8) Press the “User Preset” key and “Clear/Stop” keys simultaneously to escape from the F mode. (+): Paper feed timing is (–): Paper feed timing is advanced (7) Press the “Print” key. (3) Press the “Print” key. (9) M a k e a c o p y c o n f i r m t h e adjustment. (2) Loosen the four screws of the front cover. 6-9 Unpacking/ Installation delayed . “Ledger/ A3 of Original Size” and “3” keys simultaneously to enter the mode. (6) Enter the new content. Note: Move the front cover evenly. Note: The “Reset” key is used to enter the “–” content. (3) Move the front cover as required. (left and right sides) Check 4. Side to side adjustment (Duplex) (1) Pull the duplex unit tray out until it stops. (2) Press the “6” key to enter the F6 mode. (4) Press the “0” and “5” keys to enter the F6 mode code “05”. (5) Press the “Print” key. Registration adjustment (1) Press the “User Preset”. then tighten the screws.

(4) Enter the new content according to the rank of sensor mark sheet.6. Note: Rank –2 –1 0 1 2 F6-C28 content –20 –10 0 10 20 6-10 . (2) Select the F6 mode. (3) Press “2” and “8” keys to enter F6 mode code “28” then press “Print” key.6 White Density Adjustment (When replacing the original guide for FA-A505) (1) Check the rank of sensor mark sheet back side of the original guide.

.....................................................................2 1.......................................................................................................................... Paper transport ........................................................................................................................................................ 3-1 3......................................... 2-1 2-1 2-3 2-5 2-8 III....................................... Stapler drive ............................. Tamper drive .............................................5 Construction ............... Introduction 1................................................................................. Component location ......... Operation panel ..................3 1......................................................................................2 Connector signals ............................................... Features .......................2 Disassembly/Assembly ............... Maintenance Trouble Shooting Unpacking/ Installation 3.......... Electrical 4........4 2........Contents I.............................1 2.2 2.......................................................................1 1.........5 1....................................................................................... 3-2 3........ External View ... 4-8 Electrical Maintenance Mechanism Introduction FA-S620/S660 Service Manual .............. 4-1 4.........................................1 Electrical parts operation .............................................................4 1............3 2...........6 Specifications ................ Bin drive . 3-10 IV........................................................................................................................ 1-1 1-1 1-2 1-2 1-3 1-4 II............................. Mechanism 2............................ Inner View ........1 Maintenance areas ................3 Adjustment ...........................................

............................................ 6-1 6................. Troubleshooting 5............................................2 Service mode ...................... 5-1 5.........1 Installation requirements .......................... 5-8 VI......2 Installation procedure .............................. 6-2 Supplements Electrical circuit diagram .... Unpacking/Installation 6...............................................................V....................1 Self-diagnosis/Machine malfunction .................

• Staple Mode: Copies discharged into bins will be stapled automatically (when using the ADF) • Group Mode: Copies of the same page will be grouped and stacked separately from copies of other pages. Legal/B4 paper) Copy Size Copy paper weight Manual staple capacity Dimensions(W x D x H) Weight 59 . S620: 25/Legal-B4.1. B4) copies can be made before "oF" appears---A4. Letter/A4. (This means a maximum of 600 (A4.24 lb / 64 .86 F / 15-30 °C (standard: 68 F / 20°C) 20-80% (standard: 60%) DC+24V (supplied from copier) Horizontal 20 bins Stack Sort Staple Group 30 (25) 50 (30.80g/m 2 2-50 copies (25 copies: A3/B4) (20lb / 80g/m 2 ) 17.1 Specifications Operating Conditions Ambient conditions Relative humidity Power source Installation condition Number of bins Bin Capacity (when recommended paper is used) • (Numbers in ( ) are for Ledger/A3.1 (After 75 copies enter the stack tray in excess of 100). A5: 30 X 20 A3.2 Features Following modes can be selected by pressing the key on the panel of the copier. • Sort Mode: Copies of multiple page documents will be sorted. 15/Ledger-A3) 30 (25) Specifications Ledger/A3. A5)/500 (A3. up to 30 (25) copies into each bin before shifting to the next bin.1" x 23. • Stack Mode: Copies will be received by other 20 bins starting from bin No. the balance of the copies requested are stacked into the sort bins. B4: 25 X 20 1.5" / 434 x 594 x 624 mm Approximately 44 lb / 20kg Less than 100 copies: 100 per pin More than 100 copies: 30 (25) per pin of 20 When more than 100 copies are selected. 15/Ledger-A3) 50 (30. 1-1 Introduction Section I Introduction . Legal/B4. starting from bin 1.3" x 23. Invoice/A5 16 . S620: 25/Legal-B4.

4 Inner View Bin unit Bin unit Roll Staple guide bar Feed roller Stapler unit Feed roller Stapler unit Staple guide bar Roll FA-S620 FA-S660 1-2 .1.3 External View Bin unit Bin unit Stapler unit Feed guide unit Stapler unit cover Feed guide unit Latch lever Latch Stapler unit cover Stapler unit FA-S620 FA-S660 1.

The indicator turns on in the absence of a staple cartridge. the process is discontinued. (The indicator turns on when stapling is ready. Name of key 1 Manual staple key 2 STAPLE RESUPPLY indicator Function Press “Manual Staple” at the start. The lamp blinks when the staple jam occurs in the stapler.1.) If the key is pressed during the stapling process.5 Operation Panel Staple Resupply Indicator Staple Key Manual No. Remarks When remaining staples after the stapling process are 1-3 Introduction . The lamp lights up when the staples in the stapler have exhausted.

6 Component Location (1) Sensors 12 3 4 12 6 1 2 3 4 5 10 9 6 7 8 11 7 8 FA-S620 FA-S660 5 9 No. 1 2 3 4 5 6 7 8 9 10 11 12 Name In-bin paper detecting sensor (TX) (S1) Bin lower limit sensor (PI4) Bin upper limit sonsor (PI5) Bin shift motor clock sensor (PI1) Reed cam sensor (PI2) Paper exit sensor (PS1) Staple guide bar home position sensor (PI3) In-bin paper detecting sensor (RX) (S2) Stapler home position sensor (PI8) Sorter interlock sensor (PI6 for FA-S660) Stapler unit cover sensor (PI7 for FA-S660) Stapling position detecting sensor (PL9 for FA-S660) 1-4 .1.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 Name Reed cam rotation detecting switch (SW3 for FA-S620) Bin shift motor (M1) Staple guide bar drive motor (M3) Feed motor (M2) Stapler swing motor (M4) Stapler swing home position detecting switch (MS4) Stapler unit cover detecting switch (MS2) Staple detecting switch (MS5) Cartridge detecting switch (MS6) Staple motor (M5) Staple key switch (SW) Stapler safety detecting switch (MS3 for FA-S660) In-bin obstacles detecting switch (MS7 for FA-S660) Sorter interlock switch (MS1 for FA-S660) 1-5 Introduction (2) Motors. Solenoids. PCBs . Swiches.11 1 2 10 11 12 13 2 10 4 14 8 8 3 9 7 6 5 4 9 7 FA-S620 6 FA-S660 5 3 No.

1 Construction •The staple sorter consists of the following four functional blocks. Transport speed is adjusted as follows: (a) Paper feed speed Speed of the paper passing between the paper exit sensor in the copier and the paper exit sensor (PS1). paper transport section.) (4) "Paper jam" in the sorter is detected by the paper transport sensors. (2) When the paper is detected by the paper exit sensor on the copier. Jams are detected when the sensors are not turned ON/OFF within a predetermined time.2 Paper transport The paper transport roller in the staple sorter is driven by the paper transport motor (M2) (+24V). (Paper exit speed depends on paper sizes. (1) When the "Print" key is pressed.the paper transport motor starts to rotate and transmits drive to the paper exit roller. tamper driving section and stapler driving section.Section II Mechanism 2. (Constant speed in all paper sizes) (b) Paper exit speed Speed of the paper passing between the paper exit sensor and the sorter bin. (3) The transport motor controls transport speed via pulse. 2-1 . bin driving section. the copier begins feeding paper. Paper exit speed of the first paper and the following papers may also be different. Mechanism 2.

Paper detecting signal PS1 Paper exit sensor M2 Feed motor drive switch Feed motor FA-S620 Feed motor Feed motor drive switch M2 Paper detecting signal PS1 Paper exit sensor FA-S660 2-2 Sorter controller PCB Sorter controller PCB .

which firmly secures each bin. thereby causing each bin up and down.2. Rolls (for each bin) engaged in the groove in the reed cam move up and down along the inclination provided in the reed cam. (1) Rolls are fitted to both sides of each bin. The rolls are engaged in the groove of the reed cam.the upper and lower limit switches(PI4 and PI5) (micro-switch) detect the abnormality and protect the machine against damage. (2) The rotating motion of the bin motor is transmitted to the reed cam (front/rear) through the bin drive belt. (3) The position of the cam is detected by the reed cam home position sensor (PI2). This is achieved by turning the reed cam home position sensor (PI2) ON each time the actuator on the reed cam (rear) completes a rotation. If any overdrive occurs. LED ON signal S1 PI5 PI1 PI4 Upper limit detecting signal Bin shift motor clock signal Lower limit detecting signal Bin shift motor drive signal M1 PS2 PI6 PI2 Reed cam rotation detecting signal FA-S620 Sorter controller circuit PCB 2-3 Mechanism .3 Bin drive Up and down movement of each bin in the sorter is achieved by the rotation of the bin motor (M1) located on the lower frame of the sorter.

Bin shift motor clock signal PI1 S1 PI5 PI4 LED ON signal Upper limit detecting signal Lower limit detecting signal Bin shift motor drive signal Sorter controller circuit PCB Level section Bin cam sensor M1 PI2 Reed cam rotation detecting signal FA-S660 Roll Bin Reed cam Roll 2-4 .

LED (S1) Bin unit Photo transistor (S2) 2. regardless of paper size. (1) The copier begins feeding paper when the "Print" key is pressed. 2-5 Mechanism . (2) The tampers are driven by the tamper motor (M3). while that of the tamper (rear) are determined by the paper size signal supplied from the copier.4 Tamper drive The tampers in the bin unit are driven by the tamper drive motor located on the lower frame of the sorter. The tampers jog each time a copy is fed into a bin and keeps the copies in each bin evenly stacked. (3) The tamper home position is detected by tamper home position sensor. The amount of motion of tamper (front) is constant. Copies discharged into each bin are stacked evenly by the movement of the tampers in the bin unit.

S1 LED signal Sorter controller circuit PCB In-bin paper detecting signal Guide bar home position detecting signal Guide bar swing motor drive signal Staple guide bar PI5 PI1 PI4 M1 S2 PI3 M3 PI2 FA-S620 PI1 S1 PI5 LED signal M1 PI2 M3 S2 PI3 Guide bar home position detecting signal In-bin paper detecting signal Guide bar swing motor drive signal FA-S660 2-6 Sorter controller circuit PCB Staple guide bar PI4 .

(5)When paper is detected by the paper exit sensor in the copier. the tamper moves to the preset copy size position to tap it into place. 2-7 Mechanism Staple guide bar home position detecting sensor Staple guide bar swing motor . the tamper motor rotates and positions the tamper at a prescribed distance (depending on paper size) from the selected copy size edge so the copy can be received easily into the bin. then the tamper moves out to the start position and waits for the next copy. A signal according to the copy size is output from the control panel and the tamper drive motor rotates appropriately to the start position for the selected copy size. After receiving a copy.Staple guide bar Staple guide bar Staple guide bar swing motor Staple guide bar swing motor drive signal Staple guide bar home position detecting signal Staple guide bar home position detecting signal Staple guide bar swing motor drive signal Sorter controller PCB Sorter controller PCB FA-S620 FA-S660 (4) The tamper (rear) home position is detected when the sensor detecting plate attached to the tamper support blocks the light from the tamper home position sensor on the bottom frame of the sorter.

manual stapling can be performed on copies placed into the bin tray by pressing the the "Staple" key. stapler swing position sensor. (1) The operational components in the stapler include the stapler swing motor. the swing motor (M4) returns the stapler back to it's home position.) d) Once the cam sensor (PS4) detects that the stapler drive has returned home. the staple detecting sensor (PS1) must detect staples in the staple cartridge. stapling position detecting sensor. b) The stapler swing motor (M4) drives the stapler to the stapling position as detected by the stapler swing sensor (PS3). (2) For stapling to begin. 2-8 ..d are repeated until the sensor bin paper sensor no longer detects paper in the bin assembly. and the sorters bin paper sensor (TX-1. RX-1) must detect paper in the bins. (If foreign objects are blocking the stapler or paper has been removed. (3) Stapler motion is detected by stapler swing position switch.2. and sends signals to the main unit. staple position sensor. (The cam connected to stapler drive gear turns the switch on and off) When stapling fails by staple jam etc. stapler drive motor. e) Step a . cartridge detecting sensor. In addition. staple detecting sensor. the swing motor drives the stapler back to the stapler swing home sensor (PS2).5 Stapler drive Copies discharged into the bins in the "Staple mode" can be stapled by stapler assembly automatically. c) The staple drive motor (M5) begins to drive. stapler safety switch. The stapling sequence is as follows: a) The bin motor (M1) correctly positions the bin assembly. the tampers tap the paper. and stapler. stapler drive motor returns to the initial position.

Staple motor Stapler motor drive signal M5 PI8 Staple detecting signal Cartridge detecting signal MS5 MS6 Stapler home position detecting signal Sorter controller circuit PCB Mechanism MS7 Stapler swing position detecting signal M4 Stapler unit swing motor drive signal FA-S620 Staple motor Stapler motor drive signal M5 PI9 PI8 MS5 MS6 Staple detecting signal Cartridge detecting signal Stapler home position detecting signal Sorter controller circuit PCB Stapling position detecting signal MS4 MS3 Stapler swing position detecting signal Stapler safety detecting signal Stapler swing motor M4 FA-S660 2-9 .

Bin shift home position/Lower limit sensor (PI5) Bin lower limit sensor (PI5) Bin upper limit sensor (PI4) Bin upper limit sensor (PI4) FA-S620 FA-S660 Staple position Home position Staple position Stapler position switch Stapler position switch Staple swing motor FA-S620 Staple swing motor Home position FA-S660 2-10 .

Stapling position Retracted position Stapling position Retracted position Mechanism Staple swing motor (M4) FA-S620 Stapler position switch (MS4) FA-S660 MS5 MS6 Copies Staple swing motor (M4) (M4) Stapler position switch Copies (MS4) (5) Staple detecting sensor detects the presence of staples. otherwise stays in the initial position. Stapler only swings when stapling. In case of no staples. the sensor sends signals to the main unit.(4) Staple swing motor swings stapler. Staple position sensor and stapler swing position sensors detect the staple position and initial position. Staple roller Staple detecting switch Cartridge detecting switch MS5 MS6 Staple Intermediate plate Spring Staple cartridge 2-11 .

Safety switch (FA-S660) Actuater 2-12 .(6) For FA-S660 If foreign objects like fingers are detected in the bin when stapling. actuater turns the stapler safety switch OFF and consequently stops stapling.

000 copies Cleaning Lubrication Maintenance — — Paper feed roller (upper/lower) Paper exit roller — Follow the cycle of main unit. Maintenance cycle Part name Stapler unit Replacement Per 200. — Bin/Roll Bin paper detecting sensor 3-1 .1 Maintenance areas • The following areas should be cleaned at the prescribed interval.Section III Maintenance 3.

3. 2 Remove the stapler unit. Rear cover Right cover Front cover 2 1 1 Remove the tie-wrap. 2 Disconnect the connector. and rear cover. (1 screw) 3 2 3 1 Rotate the stapler swing motor to move the stapler unit to the position indicated in the diagram.2 Disassembly/Assembly (1) Replacement of the stapler assembly (FA-S620) 1 Remove the front cover. 3 Remove the ground wire. (2 screws) 2 1 3-2 . right cover.

(2) Replacement of the stapler assembly (FA-S660) 1 Remove the front cover. 2 Remove the tie-wraps. Front cover 2 1 1 Remove the connector. (x2) 2 3 1 1 Remove the screws. (x2) 2 Remove the stapler unit. 1 3-3 Maintenance .

right cover. each 1 screw).(3) Replacement of the bin unit (FA-S620) 1 Remove the front cover. and rear cover. (3 screws) 1 2 3 1 1 Remove bin stoppers (front/rear. Rear cover Right cover Front cover 2 1 Disconnect the connectors of the sorter controller PCB. ( x 2) 2 Remove the bin cable. 3-4 .

(both front and rear at the same time) Maintenance 5 2 2 1 Remove the bin unit from the sorter and Staple guide bar place it on the work table. 3-5 . (4 screw) 3 Remove the staple guide bar. (1 screw) 3 2 6 Remove the bin. 2 Turn the reed cam in the direction of the arrow to remove the bin unit.(3) Replacement of the bin unit (FA-S620) (continued) 4 2 1 Remove the bin 1 Place the sorter sideways on the work table. 2 Remove the bin front cover.

(front side: 3 screws. (2 screws) 1 2 2 3 1 Remove two screws (front/rear). 3 Place the detached bin unit as shown. rear side: 4 screws) 3-6 . 3 1 4 2 3 3 3 3 Slide rail Replacing the bin from the upper side (See 8 for replacing the bin from the lower side) 1 Place the bin unit sideways on the work table. right cover. ( x 4) 2 Detach the signal code plate. (2 screws) 3 Remove the bin front cover and bin rear cover. and rear cover. 2 Signal code plate 1 Disconnect the connector of the sorter controller PCB. 2 Remove the slide rails (front/rear). 2 Lift the guide rail hitch.(4) Replacement of the bin unit (FA-S660) 1 Remove the front cover.

(screws x 2) 2 Guide bar holder 1 2 7 Bin roll stoper Bin Remove the bin roll stopper and bin roll then Remove the bins.(4) Replacement of the bin unit (FA-S660) (continued) 5 Bin upper cover Remove the bin upper unit cover. (1 screw) Screw Bin lower unit cover 3-7 Maintenance . 2 Remove the guide bar holder. 8 Replacing the bin from the lower side Remove the bin lower unit cover. (4 screws) Screw 6 1 Remove the spring.

2 1 11 Screw Guide bar holder cupper Remove the guide bar holder (upper). 1 Tie wrap) Connector 10 Sensor harness Remove the sensor harness as shown. (2 Connectors. Bin lower unit Screw 13 Remove the bins removing the bin roll stoppers.(4) Replacement of the bin unit (FA-S660) (continued) 9 Tie wrap Sensor harness Disconnect the sensor harness. Note: Pull out the guide bar holder separating it from the guide bar. 3-8 . (2 screws) 12 Screw Remove the bin lower unit.

3-9 Maintenance .Caution when reassembling the bin unit. and fit the bin into the reed cam rotating the clock plate of the shift motor 2 1 Make sure if the locking part of the bin roll stopper is not damaged. (FA-S660) 1 Put the bin unit on the reed cam from the upper side. 2 Make sure if the bin roll stopper is not omitted.

3 Adjustment LED SW1 SW3 (SW3: FA-S620) SW2 (SW1: FA-S660) ON 1 2 3 4 5 6 Sorter controller PCB 3-10 .3.

To adjust the staple position When disassembling sorter controller PCB. press the staple start/stop key again. By pressing the manual staple key again. 3-11 Maintenance .S2). 1 ON 1 2 3 4 5 6 1 ON 2 3 4 5 6 *1 2 3 4 5 6 1 2 3 4 5 6 ON 1 2 3 4 5 6 ON 1 2 3 4 5 *1 6 ON 1 2 3 4 5 6 ON 1 2 3 4 5 *1 6 (When A4 copy paper is used) (When A4 copy paper is used) ON 1 2 3 4 5 6 ON 1 2 3 4 5 *1 6 (When LTR copy paper is used) (When LTR copy paper is used) ON 1 2 3 4 5 6 ON 1 2 3 4 5 *1 6 By pressing the manual staple key. the guide bar operates. • By pressing the manual staple key. • By pressing the manual staple key ( ). the guide bar returns to the home position and stops. make sure to turn OFF all the swithces. When replacing sorter controller PCB and in-bin paper detecting sensor (S1. S2) adjustment mode is executed. Page No. the feed motor (M2) rotates in the forward direction (paper feed direction). ON 1 2 3 4 5 6 ON 1 2 3 4 5 *1 6 *1: After adjustment. When replacing sorter controller PCB. Each press causes the operation of A4-R B5 LT-R A4-R to be repeated. the in-bin paper dtecting sensor (S1. normal copy condition is set up. tamper bar home position sensor and the bin unit. • To adjust the swing range of tamper bar. Setting FA-S620 ON ON FA-S660 *1 Function By turning OFF all the switches. stapler home position sensor. and the stapler unit. To stop.(1) Dip switch function list Functions of the dip switch (SW1) on the sorter controller PCB are shown in the table below.

Check the installation condition of the sensor and repeat the procedure of step 3. SW1:FA-S660) 5 3-12 .(2) Adjustment of in-bin paper detecting sensor 1 Remove all the paper from the bin unit. 2 FA-S620 ON 1 2 3 4 5 6 Remove the right cover and set the dip switch on the sorter controller PCB as shown. 4 Check the lighting condition of the manual staple key. Blinking: Improper adjustment. (SW3: FA-S620. SW1:FA-S660) FA-S660 ON 1 2 3 4 5 6 3 Press the manual staple key. Turn OFF all the dip switch (SW3: FA-S620. • Turn OFF and ON the power switch of the copier. Kept ON: Adjustment completed.

(SW3: FA-S620. • SW1 (FA-S620). 2 ON 1 ON 1 2 2 FA-S620 3 4 5 6 Remove the right cover and set the dip switch on the sorter controller PCB as shown.(3) Adjustment of the tamper bar swing range 1 Remove all the paper from the bin unit. • SW2: The guide paper goes away from the copy paper. move the guide bar to touch the copy paper slightly. Bring paper into contact 4 Copy Pressing the push switches (SW2 and SW1/ SW3) on the sorter controller PCB. SW3 (FA-S660): The guide bar approaches to the copy paper. 3-13 . SW1:FA-S660) Maintenance (When using A4 copy paper) 3 4 5 6 (When using LTR copy paper) FA-S660 ON 1 ON 1 2 3 4 5 6 2 3 4 5 6 (When using A4 copy paper) (When using LTR copy paper) 3 A4/LTR Place the A4 or LTR copy paper (1 sheet) in the bin unit as shown.

(3) Adjustment of the tamper bar swing range (continued) 5 RemoCheck the lighting condition of the manual staple key. and repeat the procedure from the step 3. • Check the installation condition of the guide bar home position sensor. Blinking: Improper adjustment. ve all the paper from the bin unit. SW1:FA-S660) 6 (4) Adjustment of the staple position 1 Remove all the paper from the bin unit. Turn OFF all the dip switch (SW3: FA-S620. Kept ON: Adjustment completed. SW1:FA-S660) 6 2 3 4 5 FA-S660 ON 1 2 3 4 5 6 3-14 . 2 ON 1 FA-S620 Detach the right cover and set the dip switch on the sorter controller PCB as shown. (SW3: FA-S620.

5mm Press the push switch to check the staple position. Turn OFF all the dip switch (SW3: FA-S620. • The value of the adjustment is memorized. (SW1:FA-S620. • When the staple position is too inner. SW3:FA-S660) . SW3:FA-S660) • When the staple position is too outer. SW3:FA-S660) Press the manual staple key. (SW1:FA-S620. SW1:FA-S660). press the manual staple key to return the staple unit to the home position and readjust the staple position with the push switch. press the push switch (SW1/SW3) first then press the other (SW2) to adjust the staple position. (SW1:FA-S620.(4) Adjustment of the staple position (continued) 3 A4/LTR Place about 5 sheets of copy paper (A4 or LTR) into the top bin. 6 7 3-15 Maintenance 4 FA-S620 Pressing the push switch on the sorter controller PCB. SW1 SW2 SW3 ON 1 2 3 4 5 6 SW1 ON 1 2 3 4 Stapling forward FA-S660 SW3 SW2 5 6 Stapling forward 5 Feed direction Staple 6 ± 2. move the stapler unit to the staple position.

The bin unit stop position is detected by the lead cam home position sensor. Electrical The bin unit upper and lower limit sensors prevent the overrun of the bin unit. the 24V power supply is cut off by the stapler unit home position switch preventing the bin shift motor from rotating to avoid the bin unit and stapler from colliding with each other. which is controlled by the drive circuit so that the bin unit moves up and down.1 Electrical parts Operation (1) Bin motor control The circuit shows the bin shift motor control circuit diagram. When the stapler unit is not at the home position. Stapler unit home Load detecting Bin unit upper Bin unit shift homeposition/ position switch switch limit sensor lower limit sensor MS4 SW3 PI4 PI5 NO NO BMUP Q4 CPU BMDWN PWM Bin shift Bin shift motor motor clock sensor Drive circuit M1 PI1 Lead cam home position sonsor PI2 LCPD FA-S620 4-1 . A DC motor is used for the bin shift motor (M1).Section IV Electrical 4. The bin unit up/down speed is detected and controlled by the shift motor clock sensor.

Sorter controller circuit PCB Stapler unit home Bin unit upper Bin unit lower position switch limit sensor limit sensor MS4 PI4 PI5 NO +24V BMUP BMDWN Q1 CPU PWM Drive circuit Bin shift motor Shift motor clock sensor M1 PI1 Lead cam home position sonsor Current detection circuit PI2 LCHP NO MS7 FA-S660 Obstacle detection switch 4-2 .

A*. Sorter Controller PCB A FMTA Q19 Motor driver A* Feed motor M3 Q4 CPU FMTB B B* FA-S620 Sorter Controller PCB +24V Feed motor A FMTA FMTA* Q1 CPU FMTB FMTB* Q23 Motor driver A* M3 B B* FA-S660 4-3 Electrical . B.(2) Paper transport motor control A4-phase (FA-S660)/2-phase (FA-S620) control stepping motor is used for the feed motor. Q23: FA-S660). The feed speed is controlled by the number of pulses ofthe pulse signal A. and B* of the motor driver IC (Q19: FA-S620.

(3) Tamper drive motor control The guide bar swing motor is a 4-phase (FA-S660), 2-phase (FA-S620) control stepping motor. The sorter controller PCB sends drive pulses (GBMA, GBMA*, GBMB, and GBMB*/ GBMPA, GBMPA*, GBMPB, GBMPB*) to the motor driver. The motor driver controls the output timing of the pulse signal A, A*, B, and B* according to each signal, thereby switching ON and OFF the guide bar swing motor (M3) and its rotating direction. While the guide bar swing motor (M3) is at the hold condition, the output timing of the pulse signal A, A*, B, and B* is fixed. The fuse (ICP2/FA-S660) cuts off the power supply circuit to stop the guide bar swing motor (M3) when overcurrent flows to the circuit.
Sorter Controller Circuit PCB +24V Guide bar swing motor

A GBMPA GBMPA* Q1 CPU GBMPB GBMPB* Q30 Motor driver A*

M3

B B* PI3 Guide bar home position sensor

GBHP

FA-S620
Sorter Controller Circuit PCB +24V IPC2 A GBMA GBMA* Q1 CPU GBMB GBMB* Q34 Motor driver A* Guide bar drive motor

M3

B B* PI3 Guide bar home position sensor

GBHP

FA-S660

4-4

(4) Staple swing motor control Staple swing motor is a 4-phase (FA-S660)/2-phase (FA-S620) control stepping motor. By controlling the output of pulse signal A, A*, B, and B*, ON/OFF and the rotating direction of staple swing motor (M4) are switched. The stapler cover switch (MS2) and fuse (ICP3/FA-S660) are provided in the power supply circuit to the stapler unit swing motor (M4). The power supply circuit is opened respectively by the stapler cover switch (MS2) when the stapler cover is opened or by the fuse (ICP3/FA-S660) when overcurrent flows to the circuit, to stop staple swing motor (M4). The stapler home position switch (MS4) is provided in the power supply circuit to the bin shift motor. When the stapler unit is not at the home position, the switch cuts off the power supply to the bin shift motor to prevent the collision between bins and stapler.

Sorter Controller PCB Stapler unit swing motor

A SPSWPA Q18 Motor driver A*

M4

Q4 CPU

SPSWPB

B B* +24V Shift motor NO MS4

Q24

Stapler unit home position switch

FA-S620

4-5

Electrical

Stapler cover switch MS2 NO Sorter Controller PCB +24V ICP3 A SPSWHA SPSWHA* Q1 CPU SPSWHB SPSWHB* Q44 Motor driver A* B B* Staple swing motor

M4

Shift motor

NO

MS4

Q

Stapler unit home position switch

FA-S660

(5) Staple motor control A DC motor is used for the staple motor (M5). This circuit has major functions as follows: • Staple motor ON/OFF control • Staple motor rotating direction control • Staple motor overcurrent protection Stapler safety switches are provided in the power supply path down to the staple motor (M5). The stapler safety switch (MS3/FA-S660) cuts off the power supply to drive the staple motor (M5) when some object larger than about 5.5mm enters the stapler.

4-6

+24V

Q28

Q16

Q13

SPMCW

Stapler motor M5

Q27 Q10 +24V Q17

Q29

Q13

SPMCCW

Q26 Q10 Current detection circuit

FA-S620

Stapler safety switch NO +24V MS3

Sorter Control PCB

R156 Staple motor M5 Q49 Q47

R157 +5V R158 Q51 Q48 Q56 11 Q43 Q43 R164 Q52 Q54 R165 Q56 D32 +5V D33 Q55 R173 R163 +5V R161 12 R159 R160 +5V R162

SPMCW SPMCCW

Q50

Current detection circuit

FA-S660

4-7

Electrical

2 Connector signals (1) FA-S620 Connector No. Signal Name Connection Input/Output Rotates Function Lead cam rotation detecting siginal Lead cam rotation J1-2 DENDET detecting switch (SW3) J2-1 SPSWPB J2-2 SPSWPB* J2-4 SPSWPA J2-5 SPSWHA* J3-1 FMPA* J3-2 FMPA J3-3 FMPB* J3-4 FMPB J4-1 GBMPA J4-2 GBMPB J4-3 GBMPA* J4-4 GBMPB* J5-1 BMUP J5-2 BMDWN J7-1 JOI SW J8-2 SPUHP J8-5 STPOPN Bin shift motor (M1) Bin shift motor (M1) Sorter interlock switch (MS1) Stapler unit home position switch (MS4) Stapler unit cover switch (MS2) Staple guide bar drive motor (M3) Feed motor (M2) Stapler swing motor (M4) Pulse Stapler swing motor drive signal Pulse Feed motor drive signal Pulse Staple guide bar drive motor signal Up Bin shift motor drive signal (Bin goes up) Bin shift motor drive signal (Bin goes down) Sorter installation detecting signal Stapler unit home position detecting signal Stapler unit cover open/ close detecting signal Down Installed Home Close 4-8 .4.

Connector No. J9-1 J9-4 J9-8 Signal Name BUL BINHP BSMC Connection Bin unit upper limit sensor (PI4) Bin unit lower limit sensor (PI5) Bin unit drive motor clock sensor (MS-6) Input/Output Upper limit Function Bin unit upper limit detecting signal Bin unit lower limit detecting signal Bin unit drive motor clock signal Motor rotation signal 1 Motor rotation signal 2 Staple cartridge detecting signal Staple detecting signal Electrical Lower limit Pulse Staple motor J11-1.2 STTPMCW (M5) Staple motor J11-4.5 STTPMCCW (M5) Staple cartridge J11-6 STPCRT detecting switch (MS5) J11-8 SPEMP J11-9 SPLHP J12-3 STPOK J12-4 STEMP J13-1 SEJCT J15-1 LCPD J16-1 BINPA J16-5 GBHP J7-11 SELFP J7-12 IBUTU Staple detecting switch (MS6) Stapler unit home position sensor (PI8) Manual staple key Manual staple key Paper exit sensor Lead cam home position sensor (PI2) In-bin paper detecting sensor Guide bar home position sensor (P13) Stapling position detecting sensor (PI9) Stapler safety switch (MS3) Safe Pulse Pulse Staples No staples Staples No staples Home position Stapler unit home position detecting signal Stapling ready indication signal No staples indication signal Paper exit sensor signal Lead cam home position signal In-bin paper detecting sensor (light emitting unit) signal Guide bar home position detecting signal Stapling position detecting signal Stapler safety switch signal Stapling ready No staples Detects Home Light emitted Home position Stapling position Stapler unit cover J14-1 SPL COV switch (PI7) Close Stapler unit cover open/ close detecting signal 4-9 .

J3-1 J3-2 J4-2 J4-3 J4-6 J5-3 J5-5 J6-2 J6-4 J7-1 J7-2 J7-7 J7-8 J7-9 J7-11 J7-12 J8-1 J8-2 Signal Name SP LED HARI LED BIN LED PA CHE STYGHP SHIFT CLK CUMH SPLOPN SPUHP SPMCW SPMCCW SPEMP SP CART SPLHP SELFP IBUTU BMUP BMDWN Connection Manual staple key Manual staple key In-bin paper detecting sensor (light emitting unit)(S1) In-bin paper detecting sensor (light receiving unit)(S2) Guide bar home position sensor (P13) Bin unit drive motor clock sensor (PI1) Lead cam home position sensor (PI2) Stapler unit cover switch (MS2) Stapler unit home position switch (MS4) Staple motor (M5) Staple motor (M5) Staple detecting switch (MS5) Staple cartridge detecting switch (MS6) Stapler unit home position sensor (PI8) Stapling position detecting sensor (PI9) Stapler safety switch (MS3) Bin shift motor (M1) Bin shift motor (M1) Safe Input/Output Stapling ready Function Stapling ready indication signal No staples indication signal In-bin paper detecting sensor (light emitting unit) signal In-bin paper detecting sensor (light receiving unit) signal Guide bar home position detecting signal Bin unit drive motor clock signal Lead cam home position signal Stapler unit cover open/ close detecting signal Stapler unit home position detecting signal Motor rotation signal 1 Motor rotation signal 2 Staple detecting signal Staple cartridge detecting signal Stapler unit home position detecting signal Stapling position detecting signal Stapler safety switch signal No staples Light emitted Light received Home position Pulse Home Close Home Pluse Pluse Staples No staples Staples No staples Home position Stapling position Up Bin shift motor drive signal (Bin goes up) Bin shift motor drive signal (Bin goes down) Down 4-10 .(2) FA-S660 Connector No.

J8-3 J8-5 J8-6 J8-8 J9-1 J9-3 J9-4 J9-6 J10-2 J11-3 J11-6 Signal Name FMHA FMHB FMHA FMHB GBMA GBMB GBMA GBMB JOI SW BUL BLL Connection Input/Output Function Feed motor (M2) Pulse Feed motor drive signal Tamper bar drive motor (M3) Pulse Tamper bar drive motor signal Sorter interlock switch (MS1) Bin unit upper limit sensor (PI4) Bin unit lower limit sensor (PI5) Installed Sorter installation detecting signal Bin unit upper limit detecting signal Bin unit lower limit detecting signal Upper limit Lower limit J12-2 SPSWHB J12-3 SPSWHA J12-4 SPSWHB J12-5 SPSWHA J13-3 SOP Sorter interlock sensor (PI6) Installed Stapler swing motor (M4) Pulse Stapler swing motor drive signal Sorter installation detecting signal Stapler unit cover open/ close detecting signal Stapler unit cover J14-1 SPL COV switch (PI7) Close 4-11 Electrical .Connector No.

Take necessary measures depending on the message. When malfunctions occur.1 Self-diagnosis/Machine malfunction The self-diagnostic function detects machine malfunctions and indicates messages on the display depending on the trouble area. At the same time the message appears in the display. the +24V power supply is interrupted and the machine is stopped. 5. (1) Use error: Message appears on the copy number display Message "Close sorter" "Clear sorter bins" "Close staple cover of sorter" "Replace staple cartridge" "Sorter-full-Empty/Press mode key" Code U4 U11 U12 – oF Cause Sorter is not installed correctly Paper condition in the sorter is abnormal Stapler cover is not closed Staple cartridge is not detected Paper overflow in the sorter Page P5-2 P5-2 P5-2 P5-2 P5-3 5-1 Trouble Shooting .Section V Troubleshooting Remember that failure indications can be caused by defects in harnesses and/or connections.

(c) U12:Stapler unit cover trouble When the staple unit cover is not closed completely. "U11" is cleared when all the copies in the sort bin are removed. • Stapler unit cover switch NO failure.) are received. copies won't be stapled: • Pressing the manual staple key • Selecting the staple sort mode Note: The "Add staple" indication is an alarm. • Door switch improper fitting or failure • Install the sorter correctly NO 5-2 . All functions other than stapling are normal. • More than 50(30/Ledger.etc. Is the cover opened? NO YES Does the output from YJ6-2 (SPLOPN) change when opening and closing the cover? (d) Staple cartridge is not detected Under the following conditions.(a) U4:Sorter failure When the sorter is not installed correctly. • Sheets of paper of different width or sizes unsuitable for stapling(invoice. • Close the cover. A3) copies are received by the sort bin. Is the sorter installed correctly? NO YES Does the input of the connector (J71:S620/J3-1:S660) change when the door switch is turned ON/OFF? (b) U11:Sorter paper trouble Paper is in the sort bin when the staple sort mode or sort mode is selected.

(Maximum 10 occurrences including options. refer to the copier service manual "F8-06". at the same time. Trouble Shooting 5-3 . remove all the copied sheets.) • To recall paper jam codes. When paper is jammed. To clear "paper jam" indication. 8: S620/J7-7. the jam position indicator ( ) blinks. (2) Paper Jam Detection of Paper Jam • FA-S620/S660 copy paper transport condition is monitored by the sensors shown below. "paper jam" is memorized by code number (J60). 8: S660) change when the staple cartridge is in and out? NO • Staple detecting switch (MS5) failure---replace the sensor. • When the sorter paper feed sensor and the sorter paper exit sensor detect paper when the power switch is turned on. reset the sorter mode and select the sorter mode again. (a) Jam conditions • When the sorter paper feed sensor does not detect paper within a predetermined time after the paper exit sensor in the copier detects paper. • When the sorter paper exit sensor does not detect paper within a predetermined time after the paper feed sensor in the sorter detects paper.Does the output from (J11-6. To clear "oF". (e) oF: Paper detection trouble When the number of sorted copies received by a sorter bin exceeds the specified number of copies. remove the paper.

The staple unit home position sensor is not turned ON within a predetermined time after output of motor reverse drive signal. • The stapler unit home position sensor is not turned ON within a predetermined time after output of the motor drive signal.C. • The reed cam switch is not re-turned ON within a predetermined time after motor drive signal is output. (a) Sorter failure Error code E5-22 E7-01 Item Communication failure Bin motor failure Cause • Communication between the copier and the sorter is faulty.B. Next. the error code(Exx) appears in the message display of the copier and the machine will stop. • The motor clock signal is not detected within a predetermined time after the motor drive signal is output. release the sort mode and select the sort mode again. • Staple guide bar home position detecting sensor is not turned ON within a predetermined time after output of the motor drive signal. • The bin home position detecting switch is not turned OFF within a predetermined time after the bins are lifted up from the bin home position. E7-07 Stapler swing motor failure E7-07 Stapler drive motor failure E7-07 Staple guide bar drive motor failure 5-4 . • The stapler swing home position detecting sensor is not turned ON within a predetermined time after motor drive signal is output. can not control the machine or any trouble occurs. • To clear Exx.(3) Machine malfunctions • When the CPU P. • The stapler position detecting sensor is not turned ON within a predetermined time after motor drive signal is output.

• Check the sorter controller P. 2: S660) of the sorter controller CPU P.E5-22:Communication failure Is the sorter cord connected securely? YES NO • Check connector CNT3 of the copier.C.B. 10: S620/ J1. • Check connector (J6.B.C. failure. 2: S660) of the sorter controller P.B. approximately 24V? (J6/J1-2 0n the (+) side) NO 5-5 Trouble Shooting .C. Is the voltage between connector (J6-1. 2: S620/J1-1.

• Check DC+24V of the sorter controller CPU. NO • Check DC+24V of the sorter controller CPU. 5-6 . NO E7-07 Stapler swing motor failure Does the output of connector (J8-2: S620/ J7-1: S660) change when the stapler unit NO home position sensor is turned ON/OFF? YES Is DC+24V generated connector J12-1 (S660) with the rotation of stapler swing motor? YES Bin motor failure.E7-01Bin motor failure Does the output of (J1-2: S620/J5-5: S660) change when the reed cam home position sensor is turned ON/OFF? YES Is DC+24V generated between (J5-1 and 2: S620/J8-1 and 2: S660) with the rotation of bin motor? Lifting up: J5-1/J8-1: +24V Lifting down: J5-2/J8-2: +24V YES Bin motor failure. • Sensor is not mounted correctly or sensor failure. • Sensor is not mounted NO correctly or sensor failure.

NO • The switch is defective.C. 5: S620/J7-3.B. 5-7 . 4: S660) with the stapler drive motor? YES • Stapler drive motor failure.. NO E7-07: Staple guide bar drive motor failure Does the output of connector (J165:S620/J4-6:S660) change when the guide bar home position sensor is turned ON/OFF? YES • The guide bar home position sensor is defective. • Check DC +5V of the sorter controller P.E7-07: Stapler drive motor failure Does the output of connector (J8-2:S620/J6-4:S660) change when the switch is turned ON/OFF? YES Is +5V generated connector (J11-4.3.4.5 (S660)? NO • Check DC +24V of the sorter controller P.6 with the tamper drive motor and DC+24V generated on J9-2.C.. Trouble Shooting NO Is pulse input generated to J91.B.

Released by "Clear/Stop" key operation or at the end of operation. The #10/20 bin or other bin position moves to #1 bin position.2 Service mode (1) F4 mode 1) Input check Code No. b) Reed cam home position sensor Reed cam in home position. b) Staple detecting sensor Staple is detected. Code 88 89 90 91 92 93 94 Item Transport motor Bin movement (down direction) Bin movement (Up direction) Tamper drive motor Staple motor Staple ready indicator Staple action Function The motor is energized. (Switch turns ON) 2) Output check Started by "Copy start" key operation. c) Staple guide bar home Staple guide bar in position sensor home position. The indicator lights up once. The motor is energized once. b) Stapler safety switch Obstacles are not detected. a) Sorter interlock switch For FA-S620/S660 a) Bin unit drive motor clock sensor Bin in home position. 5-8 . 22 23 Function Condition Message display 7 6 5 4 3 2 1 0 24 25 For FA-S620/S660 Sorter is installed. For FA-S620/S660 a) Stapler unit home position sensor Unit in home position. The motor is energized once. For FA-S620/S660 a) Bin paper detecting sensor Paper is detected. The #1 bin or other bin position moves to #10/20 bin position. The tamper moves to the smallest size position.5.

(5) In areas of chemical fume concentration.1/1500mm 47. The performance of the sorter can be affected by the surrounding conditions. suggest that the customer move it to an appropriate place. (2) Check the following requirements before installing FA-S620/S660. (1) The sorter should not be installed under the following conditions: (1) Extremely high temperature/humidity. 6-1 . (6) In areas with excessive vibrations. FA-S620/S660 is a precision machine. (2) In areas exposed to direct sunlight. • System consoles: FA-DS72 FA-DS82 (3) Make sure the copier is operating normally before installing FA-S620/ S660. (7) Directly in air conditioning flow. (3) In areas of high dust concentration. Unpacking/ Installation 39"/100mm 59. (1) The space shown below is needed for installation.Section VI Unpacking/Installation 6. (4) In areas with poor ventilation.1 Installation requirements • The same as the copier. Note: If the copier is installed under the above conditions.2"/1200mm (2) Make sure that only accessories made by Panasonic are used.

6.2 Installation Procedure (FA-S620) (1) Unpacking Check the condition and contents of each box for any shipping damage and completeness before installation. Sorter receiving bracket (rear) (X1) Sorter receiving bracket (front) (X1) System console support bracket (X2) Rail mounting bracket (rear) (X1) Rail mounting bracket (front) (X1) Magnet catch (rear) (X1) Magnet catch (front) (X1) Rail assembly (X1) Paper guide (X1) Rail cover (X1) 6-2 . (Visual check) * Check the contents of the box.

A B C A B C A B C "Staple" label (A) (X1) "Staple" label (B) (X1) "Staple" label (C) (X1) <Screws> Rail assembly fixing (M4 X 25)(X2) (For FP-7824/7830) Rail assembly fixing (M4 X 16)(X2) (For FP-7818) Sorter fixing (M4 X 8)(X 2) Sorter receiving bracket fixing (M4 X 8)(X 1) Rail cover fixing (M4 X 8)(X3) System console support bracket fixing (M4 X 8)(X 4) Magnet catch fixing (M4 X 10)(X2) Paper guide fixing (M4 X 12)(X 2) Rail mounting bracket fixing (M4 X 8)(X4) 6-3 Unpacking/ Installation .

1 screw: included) (1) Pull out the upper cassette/ADU. remove the exit tray. (2) Remove the rail stopper. (3) Open the exit cover. Caution: Make sure the copier is unplugged before the installation. FP-7818: Remove the cassette. (7 screws) (3) When the ADU is installed: Remove the waste toner bottle then remove the right cover. (3 screws) (2) Remove the rear cover. 4 Left cover Check 1 2 3 1 2 (1) Remove the left cover. 3 2 1 Sorter receiving bracket (rear) 4 Rail stopper 1 2 3 6-4 . (2 screws) (1) Remove the upper cassette rail fixing screw. (1 screw) When the ADU is installed: Remove the both side rail stoppers (2 screws) (3) Remove the upper cassette/ADU. Procedures 1 to 7: for FP-7824/7830/7835 except FP-7818 Location Procedure (1) Open the front door. (2) When using the exit tray. (4) Open the upper cassette/ADU. (rear side X 1) (2) Install the sorter receiving bracket (rear).(2) Installation Remove all shipping materials before installation. (1 screw: just removed. together with the upper cassette rail.

(1 screw just removed) Sorter receiving bracket (front) 6 Re-install the upper cassette/ADU and rail stopper. 7 (1) Re-install the left cover and rear cover.Location Procedure Check 5 2 1 (1) Remove the upper cassette rail fixing screw. (front side X 1) (2) Install the sorter receiving bracket (front). together with the upper cassette rail. (front and rear. (3) When the ADU is installed: Re-install the waste toner bottle then re-install the right cover. M4 X 8) 6-5 . (2 screws) Unpacking/ Installation 8 9 Install the system console support brackets. 4 screws. Remove the system console left cover. (2) Close the exit door and front door.

2 screws. (2 positions.Location Procedure (1) Remove the pre-stamped holes (2 positions). M4 X 12) Paper guide 12 Install the magnet catches (front and rear sides). M4 X 10) Magnet catch (rear) Magnet catch (front) 13 Insert the rail assembly into the upper slits of copier left cover. M4 X 25) (For FP-7818: 2 screws. (2) Re-install the system console left cover. M4 X 16) FP-7818 FP-7824 /7830 6-6 . then fix the rail assembly. Check 10 1 1 11 Install the paper guide. (For FP-7824/7830: 2 screws. (2 screws.

sorter will be damaged. M4 X 8) Check 14 Rail mounting bracket (rear) Rail mounting bracket (front) 15 6-7 Unpacking/ Installation Pull out the rail assembly fully. Note: Holding the set the sorter with both hands as shown as the figure.Location Procedure Install the rail mounting bracket to underside of the sorter (front and rear side). . If hold the other parts. (4 screws. and install the sorter.

(3 screws.Location Procedure Fix the rail assembly to the sorter body (front and rear side). Refer to the installation procedure of FA-SH01. M4 X 8) 18 For FP-7818: Install the sorter mounting kit (FASH01). M4 X 8) Check 16 17 Install the rail cover. 19 Connect the lattice connector of the sorter to the copier. (2 screws. 6-8 .

Check 20 <Copier upper cover. 6-9 Unpacking/ Installation “Staple” label (C) A B C . (3) When sheets of paper are not stapled. 21 Operation check (1) Place some paper in the stapler position on the top bin and press the manual staple key. rear> “Staple” label (A) A B C <FA-A888> (When the ADF is installed) <FA-A888> Attach “Staple” label (B) provided on the main cover. (2) Remove the paper from the bin and check staple. “Staple” label (B) A B C <FA-A505> <FA-A505> Attach “Staple” label (C) provided on the main cover.Location Procedure Attach the “Staple” label (1) Open the platen cover (or ADF) (2) Attach “Staple” label (A) provided on the upper cover (rear). repeat steps (1) and (2).

(Visual check) * Check the contents of the box.6. Sorter receiving bracket (rear) (X1) Sorter receiving bracket (front) (X1) System console support bracket (X2) Spacer (X2) Connecting plate (X1) Latch receiving bracket (X1) Stabilizer (X1) Sorter mounting bracket (X1) Rail assembly (X1) Paper guide (X1) 6-10 .2 Installation Procedure (FA-S660) (1) Unpacking Check the condition and contents of each box for any shipping damage and completeness before installation.

A B C A B C "Staple" label (A) (X1) "Staple" label (B) (X1) <Screws> Rail assembly fixing (M4 x 33)(x 2) Sorter fixing (M4 x 8)(x 2) Sorter receiving bracket fixing (M4 x 8)(x 1) System console support bracket fixing (M4 x 8)(x 4) Latch receiving bracket fixing (M4 x 12)(x 2) Paper guide fixing (M4 x 12)(x 2) Upset prevention plate fixing (M4 x 14)(x 2) Sorter mounting bracket fixing (M4 x 12)(x 4) 6-11 Unpacking/ Installation .

Location Procedure (1) Open the front door. (3) Open the exit cover. Caution: Make sure the copier is unplugged before the installation. (3 screws) (2) Remove the rear cover. (1 screw: just removed. (7 screws) 3 Remove the power cord mounting bracket. remove the exit tray. (2) When using the exit tray. 1 screw: included) (3) Reinstall the power cord mounting bracket. (2 screws removed) Sorter receiving bracket (rear) 6-12 . Check 1 2 3 1 Left cover 2 (1) Remove the left cover. (rear side X 1) (2) Install the sorter receiving bracket (rear). (2 screws) Power cord mounting bracket 4 2 1 (1) Remove the lower cassette rail fixing screw.(2) Installation Remove all shipping materials before installation.

(2 screws just removed) 6 1 2 Sorter receiving bracket (front) 7 Re-install the lower cassette and rail stopper. (2 screws) 6-13 Unpacking/ Installation 8 (1) Re-install the left cover and rear cover. (1 screw) (3) Remove the lower cassette. together with the lower cassette rail.Location Procedure (1) Pull out the lower cassette. (2) Close the exit door and front door. . Check 5 Rail stopper 1 2 3 (1) Remove the lower cassette rail fixing screw. (2) Remove the rail stopper. (front side X 1) (2) Install the sorter receiving bracket (front). 9 Remove the system console left cover.

Location Procedure Install the system console support brackets. (2 screws. 4 screws. (2 screws. M4 X 12) Paper guide 13 Spacer Install the latch receiving bracket together with the spacer. 1 12 Install the paper guide. M4 X 12) Latch receiving bracket 6-14 . (front and rear. M4 X 8) Check 10 11 1 1 (1) Remove the pre-stamped holes (3 positions). (2) Re-install the system console left cover.

just removed) Check 14 Connecting plate 15 Install the floor stabilizer to the system console.Location Procedure (1) Remove 2screws of the rear cover (copier and system console). (2) Install the connecting plate to the rear cover (copier and system console). (2 screws. then fix the rail assembly. (2 screws. fall stabilizer 16 Insert the rail assembly into the lower slits of copier left cover. M4 X 14) Note: Put the floor stabilizer completely on the flower. M4 X 33) 6-15 Unpacking/ Installation . (2 screws.

(4 shoulder screws. M4 X 12) Check 17 Sorter mounting bracket 18 Pull out the rail assembly fully. If holding the other parts.Location Procedure Install the sorter mounting bracket to the sorter. and install the sorter. sorter will be damaged. 19 Fix the rail assembly (front/rear side). (2 screws. Note: Hold the sorter with both hands as shown in the figure. M4 X 8) (Rear side) (Front side) 6-16 .

Location Procedure Connect the lattice connector of the sorter to the copier. (2) Attach "Staple" label (A) provided on the upper cover (rear). (1) Open the platen cover (or ADF). (2) Remove the paper from the bin and check staple.(2). A B C Unpacking/ Installation Staple label (B) 22 Operation check (1) Place some paper in the stapler position on the top bin and press the manual staple key. repeat steps (1) . A B C Staple label (A) <FA-A888> (When the ADF is installed) <FA-A888> Attach "Staple" label (B) provided on the main cover. (3) When sheets of paper are not stapled. 6-17 . Check 20 21 (Copier upper rear cover) Attach the "Staple" label.

14 Front cover sensor CN206 3 LPFB1 4 LPFB2 5 VL GND DOSN VL 1 2 3 CN20 IADFRX ADFRX GND IADFTX ADFTX TESTID ADFOUT 1 2 3 4 5 6 7 CN3 F32OUT FENB OQLTH F32CLK OQLD LCCLD OQIN QMCLK VL GND ING OUT1 1 2 3 4 5 6 7 8 9 10 11 12 Middle roller clutch Pick-up solenoid CN601 CN6 1 Bypass paper feed clutch Registration roller clutch Bypass paper feed solenoid Paper feed cover sensor Bypass paper detecting sensor Registration roller paper pass sensor 3 1 HSSN2 2 3 1 HSSN1 2 3 Middle roller clutch Pick-up solenoid Bypass paper 3 size sensor (except FP-7818) 2 1 HSSN3 2 1 2 3 4 5 6 7 8 9 VL HSSN3 GND VL HSSN2 GND VL HSSN1 GND CN5 1 2 1 2 1 2 1 2 1 Paper pass sensor Paper limit sensor Paper detecting sensor Lifting motor Paper feed unit (Lower) (except FP-7818) POPSN 2 3 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Paper pass sensor Paper limit sensor Paper detecting sensor Lifting motor Paper feed unit (upper) (except FP-7818) HPESN 2 3 1 2 3 RRSN VP HFCR VP RRCR VP HFSOL VL VL QDOSN HPESN GND GND VL VL RRSN2 RRSN GND GND CN610 VP VP PFCR1 PUSOL1 VL VL PEWSN1 CRRSN1 GND GND VL VL LBSN1 PESN1 GND GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 PEW SN1 Paper level sensor 1 CRRSN 2 1 3 1 2 3 1 2 3 CN609 VP VP PFCR2 PUSOL2 VL VL PEWSN2 CRRSN2 GND GND VL VL LBSN2 PESN2 GND GND 1 2 CNT3 3 4 1 2 5 7 8 9 11 6 13 14 1 2 SCFL VP PGND PCCR CN21 ISTRX STRX GND ISTTX STTX 1 2 3 4 5 6 Sorter connector Devoloper FM cooling fan (For FP -7830/7835) Dust collecting FM fan (except FP-7818) Middle roller clutch 1 2 3 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 PGND VP F32OHT QLTH F32CLK QLD QIN FENB VL GND 1 2 3 Main CPU CN4 Paper feed driver 1 5 8 9 10 11 12 5 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 PEW SN2 Paper level sensor CN12 VP VP PGND PGND MMCNT MMLCK MMCLK CN9 HVLKC HVCNT GREF HVBCNT BREF HVLKD DTCNT PGND VP CN11 GND MHPSN VL GND PCSN VL GND PASN VL GND AESN VLC 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 12 11 10 9 8 7 6 5 4 3 2 1 1 2 1 2 3 4 CN1 CN2 M 1 2 1 2 1 CRRSN 2 2 3 1 2 3 1 2 3 LBSN 2 PESN 2 9 8 7 6 5 4 3 2 1 3 2 1 3 2 1 3 2 1 1 2 3 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 HVPS High voltage power supply LBSN 1 PESN 1 CN604 LUM2-1 1 LUM2-2 2 1 2 M MH PSN PCSN Copy density sensor CDSN 1 2 3 4 1 2 3 4 5 6 2 1 CN7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GND CDSN2 VCDS’ CDSN1 GOPSW1 TDREF’ VP TDSN GND GOPSW2 RCSOL PGND TH1 TH2 CN604 LUM1-1 1 LUM1-2 2 1 2 M Mirror home position sensor Platen cover open/close sensor Platen cover angle sensor AEsensor PASN Lom voltage power supply (for FP-7818) CN10 VL AOSS1 AOS1 GND VL AOSS2 AOS2 GND VL AOSS3 AOS3 GND VL AOSS4 AOS4 GND VL VL HPSN LHPSN GND GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 AESN AOSS1 CN109 1 LUM 2 PGND 1 GND 2 PESN 3 VL To thermistor Discharge lamp EL 1 2 3 CN14 1 ELP1 2 ELP2 3 VP 4 1 2 3 4 5 6 7 8 9 10 11 CRRSN VL PFCR VP CN110 CN111 GND PESN VL Recycle solenoid PFSOL (For FP -7830/7835) 1 2 3 4 AOSS2 AOSS3 3 PEWSN 2 1 1 2 3 2 1 3 2 1 3 CRRSN 2 1 PESN Paper level Sensor Paper detecting sensor Paper limit sensor Paper pass sensor Pick-up clutch RD terminal (Factory use) Lift motor 1 2 3 4 5 6 IRMRX RMRX GND IRMTX RMTX M LBSN CN22 1 2 AOSS4 HPSN 1 2 LHPSN 3 Lamp unit home position sensor Lens unit home position sensor Original size detecting sensor (For FP-7830/7835) Toner density sensor TDSN GND LBSN VL GND System console connector (option for FP-7818) Suction/ ozone fan FM 1 2 3 1 2 3 4 CN8 OZFM DDFM OZFL DDFL PGND PGND SCFM CN16 execptFP-7818 ADF connector CN1 CN13 CN15 1 5 8 9 10 11 12 7 2 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 15 14 13 12 11 10 9 CNT1 8 9 CNT2 1 2 23 26 27 25 13 28 22 21 1 2 3 4 5 6 7 8 9 10 8 7 6 5 4 3 2 1 CN852 1 PGND 2 VP 1 VP 2 3 PGND 1 2 3 4 5 6 7 1 2 3 4 1 BMBB 2 COM 3 BMB 4 BMA 5 BMAB 1 VLC 2 BPSN 3 GND 1 VLC 2 TFSN 3 GND 1 VTED 2 TED 3 GND GND GND BPSN TFSN VL VL 2 COM 1 BMA LCD LCDWR CPICLK EPASW VLC VLC VL GND GND GND CPOUT CPLD CPIN 6 5 4 3 TESN TFSN 7 8 9 10 11 12 13 14 Toner bottle motor (FP-7818/7824) 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 3 4 5 6 VL 7 LCDWR 8 7 8 Waste toner sensor SH/LD CLK2 DRSEL3 DRSEL2 DRSEL1 DRSEL0 LEDb0 LEDb1 CN402 CN403 CN404 LEDb2 LEDb3 LEDb4 LEDb5 LEDb6 GND GND VLC CKS CKL OE A QH M 1 2 3 4 5 6 Main motor . Use only manufacturer’s specified parts. When replace any of these components. 1 2 3 4 5 6 7 8 CN351 Control panel (2) Notice 1 2 3 4 5 6 CN353 In case of same signal name.Schematic Diagram (FP-7818/7824/7830/7835) ÆÆÆAC120/220-240V Line ÆÆÆDC+24V Line ÆÆÆDC+5V Line Important safety notice Componentes identified by head mark have special characteristtics important for safety. deleted it from one side of connector. 1 2 3 4 5 6 7 8 CN352 7 8 Toner bottle home position sensor Toner bottle motor (FP-7830/7835) Toner level sensor LCDWR DB0 DB1 DB2 DB3 DB4 DB5 DB6 DB7 FP-7830/7835 oniy CN354 GND VL VO RS R/W M BPSN 10 11 12 13 14 1 2 3 4 5 6 7 8 9 CPOCLK CPLTH CN401 BMBB COM BMB BMAB 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Key counter KC 1 2 3 4 5 6 CN112 VP 1 CT 2 TC DH 1 2 3 4 5 6 7 8 9 10 11 GND 12 VLO 13 VLO 14 15 Total counter Dehumidify heater Power switch MS ACHI ACI ACI ACH2 AC2 AC2 1 2 3 4 5 6 1 2 1 2 1 2 3 4 5 6 Control panel (1) 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 CN104 VL CPONT CPIN CPLD CPLTH CPICLK CPOCLK EPASW LCDWR GND GND CN119 VP KCT GND KCS VL KCTCNT CN113 BMBB COM BMB BMAB COM BMA TED VTED GND CN103 LDLTH LDOUT LDCLK GNG CN105 GND GND VLC VLC CN116 VP PCSOL VL PFOSN GND 1 2 3 4 1 2 3 4 1 2 3 4 5 8 7 6 5 4 3 2 1 CN901 LED array LDA 1 2 3 4 CN803 AC1 AC1 AC2 AC2 Low voltage power supply (LVPS) Optics motor Mirror Lens stepping stepping motor motor Exhaust fan 1 2 Optics fan 1 4 2 Exhaust fan 3 Thermostat Exposure lamp Thermostat Fuser lamp 1 2 1 2 3 4 CN201 AC1 AC1 AC2 AC2 1 2 BPSOL 1 2 3 1 2 3 4 5 6 7 8 9 1 2 3 4 5 M 1 2 3 4 5 6 7 8 9 10 11 M 1 2 3 4 5 M 1 2 3 4 5 PF OSN CN202 1 AC1 2 EXLP CN203 1 DSAC1 CN806 1 AC1 2 AC2 CN805 1 AC1 2 AC2 FM 3 2 1 FM FM 3 2 1 3 2 1 FM 3 2 1 FM 3 2 1 FM 3 2 1 CN115 LSMAB LSMA LSMB COM LSMBB CN114 LMBB COM LMB LMAB COM LMA MSMAB MSMA MSMB COM MSMBB CN106 PGND EXFL1 EXFM1 PGND EXFL2 EXFM2 PGND LPFL1 LPFM1 PGND LPFL4 LPFM1 2 FULP1 CN204 PSAC1 1 PSAC2 3 1 EC1 2 EC2 CN205 VP 1 2 3 VPC 4 CN107 PGND LPFL2 LPFM2 PGND EXFL3 LPFM2 CN ops Thermistor Choke coil AC driver 1 TH1 2 TH2 (Europe) CN123 VLC LMREF LMM1 LMM3 LMCLK LMCMB LMENB 8 LSMCBB 9 LSMCB 10 LSMCA 11 LSMCAB 12 MSMCBB 13 MSMCB 14 MSMCA 15 MSMCAB CPTRDY PPTRDY VP VP PGND PGND EPACNT VL GND GND VLC ZCRS LDLTH F640HT FENB CPLTH F64CLK CPCLK F64IN CPLD CPTX CPRX CN851 1 VP 2 3 4 VPC For FP-7830/7835 except FP-7818 CN124 BMCAB PGND BMCBB BMCB BMCA VL TEDSN TED GND CN125 VP BMBB BMB BMAB BMA Paper exit solenoid Paper exit sensor CN801 1 ACL CN802 2 ACN 1 2 3 4 5 6 7 8 9 1 2 3 4 5 BM driver 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 1 2 3 4 5 6 BMD CN117 CN101 CN854 CN855 1 VP 2 3 PGND CN856 VP VP PGND PGND 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 1 HTCNT1 2 HTCNT2 CPU CN7-13.

5V 5 0 LBSN 2 PESN 2 0 5 24 0 CN604 LUM2-1 1 LUM2-2 2 9 8 7 6 5 4 3 2 1 3 2 1 3 2 1 3 2 1 1 2 3 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 HVPS High voltage power supply 1 2 M 0 5 MH PSN 5 0 PCSN PGND VP PGND VP F32OUT QLTH F32CLK QLD DXIN DXMCA CDSN DXMCAB DXMCB DXMCBB PSLSN PSWSN FENB VL GND VL DXDPSN GND ADUSL OUT2 GND CN2 Copy density sensor 1 2 3 4 1 2 3 4 5 6 2 1 CN7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GND CDSN2 VCDS’ CDSN1 GOPSW1 0 to 5V TDREF’ VP TDSN GND GOPSW2 RCSOL 24 0 PGND TH1 5 to 2. When replace any of these components. Use only manufacturer’s specified parts. deleted it from one side of connector.7V TH2 Mirror home position sensor Platen cover open/close sensor Platen cover angle sensor AEsensor 0 5 0 5 5 0 0 5 PASN 0 to 5V 3 DX 2 1 OPSN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Toner density sensor Recycle solenoid PFSOL To thermistor TDSN ADU tray detecting sensor AESN CN10 VL AOSS1 AOS1 GND VL AOSS2 AOS2 GND VL AOSS3 AOS3 GND VL AOSS4 AOS4 GND VL VL HPSN LHPSN GND GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2 1 4 3 5 9 11 13 15 10 12 14 16 6 8 7 17 18 CN651 ADU driver 0 5 0 5 5 0 AOSS2 2 3 4 DXRRCR VP DXMA COM DXMAB DXMB COM DXMBB GND DXPSN2 VL DXWAB DXWA DXWB COM DXWBB PSWSN VL DXLAB DXLA DXLB COM DXLBB GND PSLSN VL CN654 CN653 CN655 CN652 GND DXPSN1 VL EL GND DXPESN VL Discharge lamp GND 1 2 3 CN14 1 ELP1 2 ELP2 3 VP 4 5 0 24 0 AOSS3 CN22 RD terminal (Factory use) 1 2 3 4 5 6 IRMRX RMRX GND IRMTX RMTX 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 6 7 8 1 2 3 4 5 6 7 AOSS4 11 1 2 1 3 5 7 9 5 4 3 2 1 5 4 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 Paper detecting sensor A Length guide motor DXLM Length guide sensor Width guide sensor Paper feed clutch B M Drive motor DXM M M Width guide motor DXLM PS LSN PS WSN DXP ESN DXP SN2 DXP SN1 0 5 HPSN Paper pass sensor 1 2 LHPSN 3 Lamp unit home position sensor Lens unit home position sensor Original size detecting sensor AOSS1 1 System console connector 1 2 3 4 CN8 OZFM DDFM OZFL DDFL PGND PGND SCFM 5 0 CN16 ADF connector Suction/ ozone fan FM 1 2 3 CN1 1 2 3 4 5 6 7 8 9 10 CN13 CN15 CN20 IADFRX ADFRX GND IADFTX ADFTX TESTID ADFOUT 1 2 3 4 5 6 7 Main CPU 1 5 8 9 10 11 12 7 2 8 7 6 5 4 3 2 1 CNT1 24 0 CN3 F32OUT FENB OQLTH F32CLK OQLD LCCLD OQIN QMCLK VL GND ING OUT1 1 2 3 4 5 6 7 8 9 10 11 12 CN852 1 PGND 2 VP 8 9 CNT2 1 2 23 26 27 25 13 28 22 21 1 VP 2 3 PGND VL GND GND VLC ZCRS CN205 VP 1 2 3 VPC 4 5 0 5 0 (Europe) 0 to 2. Control panel 4 CN475 10 1 2 3 4 5 6 7 8 9 M 1 2 3 4 5 1 2 3 Toner bottle home position sensor VLCD VEE UD3 UD2 UD1 UD0 Control panel 1 2 3 4 5 6 7 8 9 10 11 12 0 5 CN401 GND GND GND GND BPSN TFSN VLC VLC CPRX CPTX BPSN VLC VLC VP PGND VP PGND 1 VLC 2 GND 3 1 VLC 2 BPSN 3 GND 1 VLC 2 TFSN 3 GND BMBB COM BMB BMAB 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Key counter KC 1 2 3 4 5 6 15 14 13 12 11 10 9 8 7 6 BPSN 5 4 3 PGND 2 PGND 1 1 2 VP 1 VP 2 CN112 VP 1 CT 2 Total counter Dehumidify heater Power switch MS ACHI ACI ACI ACH2 AC2 AC2 1 2 3 4 5 6 TC DH 4 5 6 Control panel CPU 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 VP KCT GND KCS VL KCTCNT CN108 CN119 24 0 1 2 CN104 CN113 BMBB COM BMB BMAB COM BMA TED VTED GND VLC VLC VLC GND GND GND CPTX CPRX CN103 LDLTH LDOUT LDCLK GNG CN105 GND GND VLC VLC CN116 VP PCSOL VL PFOSN GND 1 2 3 4 1 2 3 4 1 2 3 4 5 8 7 6 5 4 3 2 1 CN901 LED array LDA 5 0 1 2 3 4 CN803 AC1 AC1 AC2 AC2 5 0 Low voltage power supply (LVPS) Optics motor Mirror Lens stepping stepping motor motor Exhaust fan 1 2 Optics fan 1 4 2 Exhaust fan 3 0 5 Thermostat Exposure lamp Thermostat Fuser lamp 1 Fuser lamp 2 Thermistor Choke coil AC driver 1 TH1 2 TH2 1 2 1 2 3 4 CN201 AC1 AC1 AC2 AC2 1 2 BPSOL 1 2 3 1 2 3 4 5 6 7 8 9 1 2 3 4 5 CN801 1 ACL CN802 2 ACN 24 0 M 1 2 3 4 5 6 7 8 9 10 11 M 1 2 3 4 5 M 1 2 3 4 5 PF OSN CN202 1 AC1 2 EXLP CN203 1 2 3 4 5 6 DSAC1 FM 3 2 1 FM FM 3 2 1 3 2 1 FM 3 2 1 FM 3 2 1 FM 3 2 1 CN114 LMBB COM LMB LMAB COM LMA CN115 LSMAB LSMA LSMB COM LSMBB MSMAB MSMA MSMB COM MSMBB CN106 PGND EXFL1 EXFM1 PGND EXFL2 EXFM2 PGND LPFL1 LPFM1 PGND LPFL4 LPFM1 PGND LPFL2 LPFM2 PGND EXFL3 LPFM2 CN107 DSAC1 FULP1 FULP2 CN204 PSAC1 1 PSAC2 3 CN805 1 AC1 2 AC2 CN851 1 VP 2 3 4 VPC CN806 1 AC1 2 3 AC2 GND DOSN VL 1 2 3 CN117 0 24 0 24 0 24 5 0 CN123 VLC LMREF LMM1 LMM3 LMCLK LMCMB LMENB 8 LSMCBB 9 LSMCB 10 LSMCA 11 LSMCAB 12 MSMCBB 13 MSMCB 14 MSMCA 15 MSMCAB CPTRDY PPTRDY VP VP PGND PGND EPACNT LDLTH F640HT FENB CPLTH F64CLK CPCLK F64IN CPLD CPTX CPRX CN101 CN854 CN855 1 VP 2 3 PGND CN856 VP VP PGND PGND 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 1 HTCNT1 2 HTCNT2 CPU CN7-13. Back light LCD 7 8 9 10 11 12 1 2 3 4 5 6 Corona cleaner motor Touch panel 1 2 3 4 Cleaner home position sensor CLSN Notice In case of same signal name.5V 1 EC1 2 EC2 CN124 BMCAB PGND BMCBB BMCB BMCA VL TEDSN TED GND CN125 VP BMBB BMB BMAB BMA Paper exit solenoid Paper exit sensor 1 2 3 4 5 6 7 8 9 1 2 3 4 5 BM driver Separation solenoid SPSOL 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 1 2 3 4 5 6 BMD F R 1 2 3 4 5 6 7 1 2 3 4 CN102 VP 1 SEPSOL 2 3 1 2 1 VTED 2 TED 3 GND 2 COM 1 BMA 6 5 4 3 TESN TFSN 5 0 5 0 CN450 7 8 9 10 11 12 1 2 3 4 5 6 DRV0 DRV1 DRV2 DRV3 MTR10 MTR11 MTR12 MTR13 LDDRV0 LDDRV1 GND GND CLMBB COM CLMB CLMA CLMAB VLC CLSN GND CN403 CN402 CN405 CN406 CN407 DRV3 DRV2 DRV1 DRV0 MTR20 MTR21 MTR22 MTR23 LDDRV2 GND 1 2 3 4 5 6 7 8 9 10 5 0 M BPSN Toner level sensor LCDAC 7 GND 8 VLC 9 CP 10 LP 11 PRM 12 CN351 INV1 1 2 INV2 3 1 2 3 4 5 6 X1 1 Y2 2 X2 3 Y1 4 1 2 3 4 5 6 7 8 Waste toner sensor Toner bottle motor .5 to 8.Schematic Diagram (FP-7845/7850) ÆÆÆAC120/220-240V Line ÆÆÆDC+24V Line ÆÆÆDC+5V Line Important safety notice Componentes identified by head mark have special characteristtics important for safety.14 Front cover sensor CN206 3 LPFB1 4 LPFB2 5 VL 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 15 14 13 12 11 10 9 Middle roller clutch Pick-up solenoid CN601 CN6 Bypass paper 3 size sensor 2 1 Bypass paper feed clutch Registration roller clutch Bypass paper feed solenoid Paper feed cover sensor Bypass paper detecting sensor Registration roller paper pass sensor 1 HSSN3 2 3 1 HSSN2 2 3 1 HSSN1 2 3 1 2 3 4 5 6 7 8 9 VL HSSN3 GND VL HSSN2 GND VL HSSN1 GND CN5 0 5 5 0 1 2 1 2 1 2 1 POPSN 2 3 1 24 0 Paper pass sensor Paper limit sensor Paper detecting sensor Lifting motor Paper feed unit (Lower) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 HPESN 2 3 1 RRSN 2 3 VP HFCR VP RRCR VP HFSOL VL VL QDOSN HPESN GND GND VL VL RRSN2 RRSN GND GND CN610 VP VP PFCR1 PUSDL1 VL VL PEWSN1 CRRSN1 GND GND VL VL LBSN1 PESN1 GND GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 1 2 CRRSN 1 3 ADU Paper pass sensor 24 0 0 5 5 0 0 5 0 5 CN609 VP VP PFCR2 PUSOL2 VL VL PEWSN2 CRRSN2 GND GND VL VL LBSN2 PESN2 GND GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 CNT3 24 0 3 4 1 2 5 7 8 9 11 6 13 14 Middle roller clutch 1 2 CN21 ISTRX STRX GND ISTTX STTX Sorter connector Dust collecting FM fan 1 2 3 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 PGND VP F32OHT QLTH F32CLK QLD QIN FENB VL GND Devoloper cooling fan FM 1 2 3 0 5 CN4 5 0 5 0 SCFL VP PGND PCCR 0 5 Paper feed driver 1 2 3 4 5 6 1 5 8 9 10 11 12 5 24 1 2 3 PEW SN2 Paper level sensor 5 0 0 5 CN12 VP VP PGND PGND MMCNT MMLCK MMCLK CN9 HVLKC HVCNT GREF HVBCNT BREF HVLKD DTCNT PGND VP CN11 GND MHPSN VL GND PCSN VL GND PASN VL GND AESN VLC 1 CRRSN 2 2 3 1 2 3 1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 12 11 10 9 8 7 6 5 4 3 2 1 1 2 1 2 3 4 CN1 CN2 M Main motor 5 0 0.

Schematic Diagram (FA-S620) Paper exit sensor +24V 9 8 7 6 5 4 3 2 1 12 11 10 FG1 to copier B J42 Sorter interlock 9825-4203 switch COM NO 2 J37 2 GND SEJCT +5V to copier 1 3 1 B B 3 1 3 +5V BUL J27 2 GND 3 1 2 J20 7 +5V BSMC GND 8 9 1 2 3 1 2 3 Bin unit drive motor clock sensor +5V BINHP GND 6 J9 5 4 3 1 2 Bin lower limit sensor 1 2 2 1 3 Bin upper limit sensor J6 J14 J13 J10 2 3 4 5 6 2 1 3 J7 2 5 J26 4 3 2 1 2 1 1 3 1 3 NC FG3 FG2 Stapler unit J40 Staple motor 1 1 1 MTR- 2 2 2 STTPMCW M5 3 3 3 4 4 4 MTR+ STTPMCCW 5 5 5 6 6 6 STPCRT MS5 7 7 7 MS6 8 8 8 SPEND PI8 9 9 9 10 10 10 +5V 11 1 Sorter Controller PCB (FA-S620) J5 2 3 11 11 GNG BMUP J22 172486-2 1 2 BMDWN 1 2 M1 Bin shift motor 12 12 12 SG 5V SPLHP J41 4 1 1 2 J1 1 DENDET +24V J29 NO COM Lead cam rotation detecting switch 2 3 3 STPOK J12 1 4 4 STEMP 3 2 2 J23 3 J15 1 2 +5V LCPD GND 3 1 2 3 1 2 J24 J2 A 2 3 4 5 1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 *B B *A A *B B J3 J8 J4 Manual staple key panel J16 1 FG4 7 5 6 4 1 2 3 2 J31 1 +5V GBHP GND 2 Bin unit BINPA GND 1 2 1 3 4 2 *A 1 In-bin paper detecting sensor (emitting) 5 6 SPSWPB GBMPA GBMPB GBMPA* GBMPB* 4 3 SPSWPB* M4 J34 2 3 1 4 5 2 FG5 3 1 2 Stapler swing motor J33 3 SPSWPA* +5V 1 SPSWPA 1 4 5 2 3 1 2 J30 1 2 J32 PHR-5 4 5 3 M3 2 Guide bar home position sensor 1 4 5 3 2 1 Vcc GND Vout C In-bin paper detecting sensor (receiving) 5 6 FMPA* 4 FMPA M2 1 FMPB* 3 FMPB Staple guide bar drive motor 2 Feed motor MS4 COM +24V NO SPUHP J25 +24V NO NC STPOPN Stapler unit home position switch Stapler unit cover switch NC MS2 COM .

Schematic Diagram (FA-S660) Stapler unit J7 J7 PS1 +5V M5 M – +5V COM MS6 COM MS5 +5V +5V NC NC +5V PI8 PD SPMCW 1 SPMCCW 2 +5V 3 +5V 4 GND 5 +5V 6 SPEMP 7 SPCART 8 SPLHP 9 GND 10 SELFP 11 +24V 12 IBUTU 13 J103 J103 1 1 2 2 NO MS3 COM 1 2 3 4 5 6 7 8 9 10 11 12 13 J102 1 2 3 4 5 6 7 8 9 10 11 J102 11 10 9 8 7 6 5 4 3 2 1 J201 J201 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 PI9 +5V Stapler safety switch Sorter Controller PCB (FA-S660) J3 J3 M4 M – J116 5 4 3 2 1 J116 5 4 3 2 1 J12 1 2 3 4 5 J12 1 2 3 4 5 +24V SPSWHB SPSWHA SPSWHB SPSWHA Manual staple key panel J11 1 2 3 4 5 6 +5V GND BUL +5V GND BLL J105 PI4 3 2 Bin unit upper limit sensor 1 Stapler swing motor Stapler unit cover sensor J205 3 2 1 J14 1 2 3 PI7 J14 1 SPL COV 2 GND 3 +5V J11 1 2 3 4 5 6 J106 PI5 3 2 Bin unit lower limit sensor 1 1 2 3 4 FMHB +24V FMHA FMHB +24V FMHA BMD WN BMUP +24V JOI SW GBMB +24V GBMA GBMB +24V GBMA +5V BIN LED PA CHE GND — STYGHP GND +5V J6 J6 J115 1 2 3 4 +24V SPLOPN +24V SPUHP VP PGND J115 8 7 6 5 4 3 2 1 2 1 1 2 3 4 5 6 7 8 J4 J4 6 5 4 3 2 1 1 2 3 4 5 6 7 8 J10 J10 8 7 6 5 4 3 2 1 2 1 J9 J9 6 5 4 3 2 1 J8 J8 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 1 2 J1 J1 1 2 J2 1110 9 8 7 6 5 4 3 2 1 J5 J5 6 5 4 3 2 1 J2 1110 9 8 7 6 5 4 3 2 1 NO NO J112 MS1 1 2 3 4 5 6 J110 6 5 4 3 2 1 2 1 J111 J111 2 1 M – M2 Feed motor M – M1 Bin shift motor J110 6 5 4 3 2 1 J112 COM 1 2 3 4 5 6 NC MS7 MS4 COM MS2 GND CUMH +5V SHIFT CU GND +5v NO COM NO G2 VP PGND 9 8 7 6 5 4 3 2 1 J13 1 2 3 J13 1 +5V 2 GND 3 SOP J107 PI6 3 2 Sorter interlock sensor 1 G1 1 2 3 1 2 3 Stapler unit home position switch COM Stapler unit cover open/close switch J114 J113 PI2 PI1 Reed cam home position sensor Bin unit drive motor clock sensor JS1 1 2 3 4 5 6 Copier 7 8 9 10 11 12 G3 J108 1 2 3 4 J108 4 3 2 1 LED In-bin paper detecting sensor (emitting) J203 1 1 2 2 M – M3 Staple guide bar drive motor J204 2 1 J109 1 2 3 PI3 1 2 3 Guide bar home position sensor 2 1 In-bin paper detecting sensor (receiving) LED SP LED HARI LED — GND 1 2 3 4 1 2 3 4 J104 1 2 3 4 J104 1 2 3 4 J202 1 2 3 4 J202 1 2 3 4 J301 1 2 3 4 SW LED .