Page 1 ORDER NO. OED9607318C1 Service Manual Plain Paper Copier FP-7742/7750 (Field Service) © 1996 Matsushita Electric Industrial Co., Ltd. All rights reserved. Unauthorized copying and distribution is a violation of law.
Page 2 This manual was developed and is supplied to authorized servicing dealers by Panasonic Communications & Systems 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 Communications &...
Page 4: Table Of Contents
Contents / Index I. Component Location 1.1 Inner View ..................1-1 1.2 Fan/Motor Location ................1-2 1.3 Sensor Location ................. 1-3 1.4 Solenoid/Clutch/Discharge Lamp Location ........1-4 1.5 PCB Location ..................1-5 II. Preventive Maintenance 2.1 Maintenance Chart ................2-1 III.
Page 5 6. Rear Jacket 6.1 Electrical Schematic Diagram (1) Schematic Diagram (2) Main CPU PCB (3) Control Panel PCB (4) Paper Feed Driver PCB (5) Automatic Duplex Unit Driver PCB (6) Low Voltage Power Supply PCB (7) AC Driver PCB (8) Automatic Original Density Sensor PCB (9) Copy Density Sensor PCB (10) LED Array PCB...
Page 6 Caution: Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions.
Page 7: Component Location
I. Component Location 1. 1 Inner View SV711 1. Fuser area cover 9. Manual paper feed knob 2. Toner bottle (Feed unit) 3. Drum unit 10. Paper transport handle 4. Developer unit 11. Transfer/Separation corona 5. Toner hopper unit and corona cleaner 6.
Page 8: Fan/Motor Location
1. 2 Fan/Motor Location Optics fan Mirror stepping motor Optics fan Optics drive motor Exhaust fan Lens stepping motor Developer Optics fan cooling fan Toner bottle Main motor motor Dust collecting Suction/Ozone ADU drive motor Lifting motor (lower stage) ADU paper length guide motor ADU paper width guide motor...
Page 9: Sensor Location
1. 3 Sensor Location Mirror home position Platen cover angle AE (Automatic original Platen cover density sensor) open/close Original size Paper feed cover open/close Exposure lamp Toner bottle home position home position Lens home Toner level position Bypass paper size Paper exit Front cover Bypass paper...
Page 10: Solenoid/Clutch/Discharge Lamp Location
1. 4 Solenoid/Clutch/Discharge lamp Location Discharge lamp Separation Registration roller clutch solenoid Middle roller clutch Paper exit Paper feed clutch solenoid Bypass pick-up solenoid Door switch Paper feed clutch (lower stage) ADU clutch Power switch Pick-up solenoid (lower stage) Recycle solenoid SV703...
Page 11: Pcb Location
1. 5 PCB Location Control panel 3 LVPS (Low voltage Control panel CPU power supply) Control panel 4 HVPS (High voltage power supply) AC driver LED array Main CPU Paper feed driver Automatic duplex unit driver SV704...
Page 12 II. Preventive Maintenance 2.1 Maintenance chart 1) Replacement Item Service Part number Q'ty per Maintenance cycle (x 1000) unit Paper Paper feed roller FFPMA0541 feed DFP Roller FFPMA0541 unit Pick-up roller FFPMA0542 Cleaning sheet FFPHK0951 Registration roller FFPMA0539 Replace at 1,080,000 copies Registration roller bearing FFPMQ0559 Replace at 1,080,000 copies...
Page 13 Fuser lamp (850W) H12V085WN2A Cleaning web FFPKM01343 Cleaning web pressure roller FFPMA0470 Replace at 1,200,000 copies Heat roller (FP-7750) FFPMA0564 Heat roller (FP-7742) FFPMA0566 Heat roller bearing FFPMQ0572 Heat roller gear FFPMF1057 Fuser entry guide (lower) FFPKF1308 Replace at 1,200,000 copies...
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Page 61: Troubleshooting
IV. Troubleshooting 4.1 Service Mode In Service mode, the technician can check for abnormalities in the copier so the copier can always operate normally. The input/output of major components in every section can be checked. To select the service mode The service mode is selected when USER PRESET, Multi-Copy key 3 and Original Size LEDGER keys are simultaneously pressed, then F1 will appear in the display.
Page 62: Service Mode Procedure
(2) Service mode procedure F1 appears in the display when the service mode is first turned ON. Multi- Copy Mode Item Function Remarks When the Print key is pressed, Display It stops when the Clear/Stop all displays light up. check key is pressed.
Page 63 Multi- Copy Mode Item Function Remarks e. Repeat procedures b) and d). 4. 2 sided original, 1 sided copy Single mode. sheet a. Select the 2 sided original, 1 copying sided copy mode. b. One sheet is copied normally when the Print key is pressed. c.
Page 64: F4 Mode
(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...
Page 65 Code Function Condition Message display a) Sheet bypass paper detecting Paper is not detected. “ sensor b) Sheet bypass paper size Ledger/A3 “ « “ detection sensor Legal/B4-FLS “ “ “ Letter/A4 “ « « Letter R/A4R « “ « Invoice/A5 “...
Page 66 Code Function Condition Message display a) Exhaust fan motor 1 Motor is locked. “ b) Exhaust fan motor 2 Motor is locked. “ c) Optics fan motor 1 Motor is locked. “ d) Optics fan motor 2 Motor is locked. “...
Page 67 Code Function Condition Message display a) System console motor Motor is locked. “ signal b) System console paper feed Cover is closed. « cover sensor c) Paper detection sensor 3 Paper is not detected. “ (System console lower paper tray) d) Paper limit sensor 3 Paper is over stocked.
Page 68 Code Function Condition Message display a) LCC detecting sensor 1 LCC is not installed. “ b) LCC door open/close sensor Door closed. « c) LCC detecting sensor 2 LCC is pulled out. “ d) LCC paper tray lower limit Paper tray is beyond the “...
Page 69 Code Function Condition Message display For FA-S575 a) Motor clock sensor Signal is detected. “ b) Bin ass'y upper/lower limit switch Bin is beyond the upper « limit or beyond the lower limit. c) Cable safety switch Cable is not loose. “...
Page 70 Code Function Condition Message display For FA-S680 a) Bin paper detecting sensor Paper is detected. “ b) Paper pass sensor Paper is detected. “ c) Staple detecting sensor Staple is detected “ For FA-S680 a) Stapler cam sensor Cam in home position. “...
Page 71 2) Output check* Activate the door switch before executing output check. Press the Print key to start and press the Clear/Stop key to reset. Code Item Function Timing roller clutch When CN8-14 is +24V, clutch operates. Sheet bypass paper feed solenoid When CN5-6 is +24V, solenoid operates.
Page 72 Code Item Function Key counter When CN119-6 is +24V, count up by one. Not used +24V output control When signal is sent from CPU CN1-6 to LVPS CN117-5, +24V is supplied to +24V line. Lift motor 1 When CN603-1 is +24V, motor rotates, (When duplex unit is not installed.) lifting up (together with upper limit control.) Paper feed clutch 1...
Page 73 Code Item Function Paper feed clutch 2 When CN609-3 is +24V, clutch operates. (System console middle) Paper feed solenoid 2 When CN609-4 is +24V, solenoid operates. (System console middle) Lift motor 3 When CN605-1 is +24V, motor rotates, (System console lower) lifting up (together with upper limit control.) Paper feed clutch 3 When CN608-3 is +24V, clutch operates.
Page 74 Code Item Function Paper feed motor forward rotation The motor rotates forward. (FA-A888) Paper feed motor reverse rotation The motor rotates reverse. (FA-A888) (High speed) Paper feed motor reverse rotation The motor rotates reverse. (FA-A888) (Middle speed) Paper feed motor reverse rotation The motor rotates reverse.
Page 75 Code Item Function Staple ready indicator (LED) The ready indicator lights up. (only Staple Sorter) Stapler swing motor The swing motor drives in and out. (only Staple Sorter) 4-15...
Page 76: F5 Mode Copier Function Programming
(4) F5 mode Copier function programming Set the copler to service mode and press Multi-Copy key “5”. Press Print key. Select desired code number with touch panel display and touch the OK key. If you wish to select other code number, scroll the menu with arrow keys ( ' ¤). Select desired function with touch panel display and touch the OK key.
Page 77 Function (Factory setting) Auto off timer 0: No power saving 3 (FP-7750) 1: 30 m 2: 60 m 2 (FP-7742) 3: 1.5 hr 4: 3 hr 5: 4 hr Copy paper size setting 0: None 1: Ledger/A3 (copier paper tray upper)
Page 78 Code Item Function (Factory setting) 32–33 Not used Multi-feed default 0: off 1: on Sorter initial mode 0: Non sort 2: Staple sort setting 1: Sort 3: Group 36-37 Not used Duplex unit initial 0: Does not select mode setting 1: 1 sided to 2 sided 2: 2 sided to 2 sided 3: Book to 2 sided...
Page 79 Code Item Function (Factory setting) Copier operation (After “U13” 0: Copier stops or copy cycle is inhibited. Toner bottle empty 1: Continuous copier operation detection) Auto paper tray selection 0: Manual 1: Auto 61–62 Not used U13 clear=After toner 0: When clearing U13, press any key. empty detection (Copier stops or copy cycle 1: Press RESET key and AUTO...
Page 80 Code Item Function (Factory setting) Paper tray selection 0: LCC > System (lower to upper) > Copier priority (lower to upper) > Sheet bypass (Left to Right) 1: Copier (upper to lower) > System (upper to lower) - LCC - Sheet bypass 2: LCC >...
Page 81 To Clear the Service Call indicator Re-input the F5-70 and F5-73. Sit the copier to service mode and press Multi-Copy key “5” Press Print key. Scroll the display menu until code number 70 is indicated with arrow keys ( ' ¤ ), then touch “70”...
Page 82: F6 Mode Adjustment And Programming
(5) F6 mode Adjustment and programming Set the copier to service mode and press Muiti-Copy key “6”. Press Print key. Select desired code number with touch panel display and touch the OK key. If you wish to select other code number, scroll the menu with arrow keys ( ' ¤). The display will indicate memorized number.
Page 83 (–25 to +9) Registration void of image After 05 and 06 are 0.425mm (FP-7750) (LED array synchronized adjusted, registration void 0.375mm (FP-7742) timer) is adjusted. (0 to +99) Trail edge timing of original After 06 is adjusted, black 0.425mm (FP-7750) image (Reduction) line is adjusted.
Page 84 Code Item Function Remarks Copy density rank Adjust copy density rank adjustment change for document (D mode light side) mode (Light side) Copy density rank Adjust copy density rank adjustment change for document (D mode dark side) mode (Dark side) Toner density sensor Adjustment of toner 19.5mV...
Page 85 F6-02. Registration void of image Adjustment of registration 0.425mm (FP-7750) (During use with ADF = NO void. 0.375mm (FP-7742) swing back condition) Registration void of image Adjustment of registration 0.425mm (FP-7750) (During use with ADF = NO void.
Page 86 Code Item Function Remarks Black density sensor Reference voltage for –99 to +99 reference voltage black density sensor compensation Black density sensor output Compensate value for –99 to +99 gain/compensation black density sensor output Copy density rank Adjust copy density rank adjustment change for photo mode (P mode light side)
Page 87: F7 Mode Electronic Counter
(6) F7 mode electronic counter Read procedure Set the copier to service mode and press Multi-Copy key “7”. Press Print key. Select the desired code number with Multi-Copy key. Indicates memorized count in the electric counter. Press Clear/Stop and User Preset key to escape service mode. Code Item Function...
Page 88 Code Item Function System console lower Total count of upper stage of optional system console. paper drawer count LCC count Total count of optional LCC (3000 sheet paper drawer) Copier upper paper drawer Total count of copies from upper paper drawer of the copier. count NOTE: When the duplex unit is installed to/upper stage of (When duplex unit is not...
Page 89: F8 Mode Copier Operation Adjustment
100% and 200% copies. Procedure: a) Position the Panasonic Test chart-53 on the platen glass. b) Press the Print key. Measurement input for adjusting the This function measures the registration that was copied original registration using "01".
Page 90 Code Item Function h) This adjustment may cause the factory setting of F6- 04 to change, so check the F6-04 setting once more. If it has changed, transfer the revised value the memory sheet. i) After completing this adjustment, check F6-05 once more.
Page 91 Code Item Function Not used Black density sensor reference level ( Factory use only / Need special fixtures ) adjustment ( Factory use only ) Black density sensor output gain This adjustment should be performed when installing adjustment the copier, cleaning/replace black density sensor or replacing the drum.
Page 92: Self-Diagnostics/Machine Malfunctions
4.2 Self-diagnostics/Machine Malfunctions The self-diagnostic functions detect troubles in important components of the copier. When any trouble occurs, the copier is stopped. User error NOTE: XXXX will appear in message display. Error Message Item See page code INSERT KEY Key counter failure (option) or 4-31 Access code number was not INPUT IDENTIFICATION...
Page 93: Code
Error Message Item See page code SORTER FULL-EMPTY If too many copies in bin or 4-33 PRESS MODE KEY too many bins selected. Remove copies and press the each sorter mode key on the touch panel. Not ready (Red LED flashes) Stand-by ---------- The ready indicator will lights...
Page 94: Access Code Number Was Not Input
(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. Is the key inserted correctly? Re-insert the key. Is CN119-2 connected to CN-2? CN119-2, 4 of the CPU is defective. Is CN119-4 contact to CN-4? The key counter connection is defective.
Page 95: Copier Paper Feed Cover Failure
(5) U6: Copier paper feed cover failure *The copier does not indicate READY TO COPY when the copier paper feed cover is closed. Is the paper feed cover closed securely? Close the paper feed cover securely. Does CN5-7, 9, 11 (output signal of CPU) Check DC5V of the tray detecting sensor.
Page 96: Sorter With Stapler
(9) U12: Sorter with stapler *When the stapler mode is selected, and a staple cartridge is not inserted. (10) U13: Toner level detection *"U13" does not reset after replacing the toner bottle. Is the toner caked in the bottle? Shake the toner bottle well. Change the toner bottle.
Page 97 (15) oF: Sorter bin capacity failure *Too many copies in at least one bin or too many bins selected. Did the number of copies Remove copies and press the Sorter mode exceed the bin capacity? select key. SV725 4-37...
Page 98: Paper Jam
Paper Jam read Condition position code The registration roller paper pass sensor does not detect paper within a predetermined time after sheet bypass paper feed roller starts rotating. The copier upper paper feed unit paper pass sensor 1 does not detect paper within a predetermined time.
Page 99 read Condition position code 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. 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.
Page 100 read Condition position code 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. Transport operation for duplexing D, E The duplex unit paper pass sensor 1 is detecting paper within a predetermined time after sensor detected paper.
Page 101: Machine Error
Machine error The machine system will detect problems in important areas of the copier. When any problems occurs the copier stops. Error codes Biobum 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"...
Page 102 E3: Developer unit and Hopper unit error Code Function Refer page E3-01 Toner bottle motor rotation 4-45 E3-03 Toner density sensor gain 4-45 E3-10 High voltage power supply leak (1) 4-46 E3-11 High voltage power supply leak (2) 4-46 E3-20 Main motor rotation 4-46 E3-21...
Page 103 E7: Optional unit error *These errors are indicated when options are installed. Refer to Optional Unit Service Manual. Code Function Refer page E7-01 Sorter bin movement Sorter Service E7-03 Transport belt motor failure Manual E7-06 Stapler drive motor failure E7-07 Tamper drive motor failure E7-10 ADF main motor rotation...
Page 104 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. Does the lamp unit move when the power Lamp unit scanner motor connector is shorted switch is turned ON? or broken.
Page 105: E1-23 F8-02 Mis-Input
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. Does the mirror unit move when the Mirror stepping motor connector is shorted or power switch is turned ON? broken.
Page 106: E1-40 Optics Fan Motor (1) Rotation
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. Is DC24V, detected on CN 106-9, 12 or LVPS is defective. CN 107-3 (on LVPS PCB)? Connector is shorted or broken, Harness is defective.
Page 107: E2-06 Optional Lcc Lift Operation (Up)
E2-06: Optional LCC lift operation (UP) E2-07: Optional LCC lift operation (DOWN) When the lift motor drives up and down, the upper and lower limit switch are not detected within a predetermined time. Is lift motor sound detected? Check the upper limit sensor signal. Canged: CPU PCB is defective.
Page 108: E3-01 Toner Bottle Motor Rotation
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. Does the toner bottle motor rotate Bottle motor connector is shorted or broken in manual toner addition mode? Bottle motor drive mechanism is defective.
Page 109: High Voltage Power Supply Leak
E3-10: High voltage power supply leak (1) When a leak is detected from the high voltage power supply charge/transfer corona. Is the charge/transfer corona dirty? Clean the charge/transfer corona. Does the ground terminal float Tighten screw(s) on the ground terminal of from the copier frame? HVPS PCB or HVPS bracket.
Page 110: E3-21 Dust Collection Fan Motor Rotation
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, fan motor rotation signal is/not detected. Is DC24V detected on CN8-1, 2 or 7? Fan motor connector is shorted or broken. 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...
Page 111: E3-50 Transfer Cleaner Operation
E3-50: Transfer cleaner operation When the transfer cleaner motor drives, the transfer cleaner home position sensor is not ON/OFF within a predetermined time. Is the wire cleaner felt Does the wire cleaner felt connect to at the home position sensor? the corona rail slider? a) Turn the transport lever and lower the transport unit...
Page 112: E4-10 Exhaust Fan Motor (1) Rotation
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. Is DC24V detected on CN106-3, 6 or LVPS is defective. CN107-6 (on LVPS PCB)? Connector is shorted or broken.
Page 113: E5-04 Vo (+10V) Line
E5-04: Vo (+10V) line When the power switch is turned on, DC10V is not detected. Is DC24V detected on between (IC16, IC9 or IC13) CPU PCB CN1-8 and 9? E5-10: +5V (for Power saving mode) When the power saving mode is operated on and DC5V power supply is not 0V, The E5-10 is indicated just moved power saving mode.
Page 114: E5-41 Registration Timing Control Circuit Abnormal
E5-41: Registration timing control circuit abnormal When the copier stops, the optics scan and registration drive start driving or when the copier is operated, the optics scan and registration operating are not driven within a predetermined time. IC5 on CPU PCB is defective. E5-42: Total counter connection When the total counter is disconnected.
Page 115: E6-04 Paper Width Home Position Detecting Sensor
E6-04: Paper width home position detecting sensor When the paper width motor drives to home position, paper width home position detecting sensor is not sensed within a predetermined time. Does the paper width motor rotate? Check paper width home position detecting sensor output PSWSN(CN-2) Changed: Duplex unit control PCB is defective.
Page 116: User Preset Mode
4.3 User Preset Mode Operation procedure: (1) Press the User Preset key on the control panel. (2) Select the User Preset Mode with LCD touch panel and touch the OK key according to the LCD message. (3) When the mode setting is completed, the LCD display will change to the initial menu.
Page 117 1 LETTER 2 INVOICE LEGAL 4 LEDGER 5 LETTER d) When the paper size setting is completed, touch the OK key. e) Touch the OK key on the LCD menu. The LCD menu will be changed to initial menu. Example: To enter or change pass codes Press User Preset key.
Page 118 2: 60 m 3: 1.5 h 4: 2 h 5: 3 h 6: 4 h UP-22 Auto off timer 0: No power saving 1: 30 m 2: 60 m (FP-7750) 3: 1.5 hr 4: 3 hr 5: 4 hr (FP-7742) 4-58...
Page 119 (Factory Code Item Function setting) UP-23 Auto original density 0: Not detecting 1: Auto mode priority (When power ON) 2: Manual mode priority UP-24 Message display 0: Japanese 1: English language change 2: German 3: French 4: Italian 5: Spanish 6: Swedish 7: Finnish 8: Dutch...
Page 120: Unpacking/Installation
V. Unpacking/Installation 5. 1 Installation Requirements Make sure machine is properly leveled from left to right and from front to rear (use small carpenter level). The mains plug on this equipment must be used to disconnect mains power. Please ensure that the socket outlet is installed near the equipment and shall be easily accessible.
Page 121: Installation Procedure
5.4 Installation Procedure • Remove the external packing/protection materials. • Remove the shipping tape from the copier. • Save the shipping materials for future use (Transport of copier) Location Shipping material/Procedure Check 1. Optical unit (1) Remove the original guide plate. (3 screws) (2) Remove the optical unit shipping brackets (front/rear) (1 screw...
Page 122 Location Shipping material/Procedure Check Paper transport unit (1) Open the front cover. (2) Remove the shipping tape. Tape Fuser unit (1) Open the paper exit door. (2) Open the fuser exit guide plate. (3) Remove the fuser pressure release screws. (2 screws) (4) Close the fuser exit guide plate.
Page 123 Location Shipping material/Procedure Check Pour the developer into the unit (1) Remove the developer unit lid. (2) Pour the developer evenly into the unit. Note: Pour in the entire bottle of developer, after shaking it well. (3) Reinstall the developer unit lid. (4) Reinstall the developer unit.
Page 124 Location Shipping material/Procedure Check 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”...
Page 125 Location Shipping material/Procedure Check Toner bottle insertion (1) Open the front cover. (2) Take a fresh bottle of toner and shake it 10 to 15 times. Hopper (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.
Page 126: Adjustment
5.5 Adjustment Location Shipping material/Procedure Check 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.
Page 127 Location Shipping material/Procedure Check Side to side adjustment 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.
Page 128 Location Shipping material/Procedure Check 3. Side to side adjustment (Duplex) (1) Pull the duplex unit tray out until it stops. (2) Loosen the four screws of the front cover. (3) Move the front cover as required, then tighten the screws. Note: Move the front cover evenly.

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