Specifications

ManualsBrandsSharp ManualsMusical InstrumentsVC-H670X

Summary of content (586 pages)

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SECTION 1 OVERALL MACHINE INFORMATION
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1 December 1990 1.
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1 December 1990 Automatic Reset: 1 minute standard setting; can also be set to 3 minutes or no auto reset. Paper Capacity: Cassettes: 500 sheets Paper tray: 250 sheets Manual feed table: 50 sheets Toner Replenishment: Black: Cartridge exchange (370g/cartridge) Color (red, blue, & green): Cartridge exchange (310g/cartridge) Copy Tray Capacity: 250 sheets (B4/8 1/2" x 14" and smaller) 100 sheets (A3/11" x 17") Power Source: 110V/ 60Hz/ 15A (for Taiwan) 115V/ 60Hz/ 15A (for N.A.
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1 December 1990 2. OPERATION PANEL — A4/A3 Version — C B A — LT/LDG Version — C B Section A: See page 1-4. Section B: See page 1-5 or 1-6. Section C: See page 1-7 or 1-8.
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1 December 1990 Section A — — LT/LDG Version — — A4/A3 Version — 1 2 7 3 1 2 3 4 4 5 5 7 6 6 1. Number Keys The number keys are used to enter the desired number of copies. They are also used to input the sizes of the original and the copy image when in size magnification mode. 4. Interrupt Indicator Lights when interrupt mode is selected. 2. Recall/Enter Key Press to display the number of copies entered. Also use to enter or change data when in size magnification mode. 6.
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1 December 1990 — Section B — — A4/A3 Version — 1 2 3 4 5 6 7 8 9 10 11 12 13 1 23 22 21 1. Magnification Ratio Indicator Shows the selected reproduction ratio and data for the Size Magnification mode. 2. Check Paper Size Indicator Lights when improper paper size is selected in the book original mode or the duplex mode. (Copying is impossible.) 14 15 20 19 18 17 16 7. Add Toner Indicator Blinks when it is time to change the toner cartridge.
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1 December 1990 — LT/LDG Version — 1 2 3 4 5 6 7 8 9 10 11 12 13 24 14 15 23 22 21 20 19 18 17 16 12. Wait Indicator Lights when that the machine is not ready to copy. 18. Misfeed Location Display Shows the location(s) of misfed paper. 13. Copy Counter Displays the number of copies entered. While copying, it shows the number of copies made. 19. Color Copy Indicator Lights if a color toner development unit is installed. 20.
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1 December 1990 — Section C — — A4/A3 Version — 5 4 6 7 3 8 2 9 1 13 12 11 10 5. Duplex Indicators Show which duplex copying mode is selected. 1. Sorter Key Press to select the sort or stack mode. The sort mode and stack mode are optional features requiring a sorter. 6. Auto Reduce/Enlarge Indicator Lights when in the auto reduce/enlarge mode. This mode is an optional feature requiring a document feeder. 2. Stack Indicator Lights when in the stack mode. 3.
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1 December 1990 — LT/LDG Version — 5 4 6 7 3 8 2 9 1 13 12 11 10 7. Auto Reduce/Enlarge Key Press to select the auto reduce/enlarge mode. This mode is an optional feature requiring a document feeder. 11. Size Magnification Indicators Lights when in the size magnification mode; shows when to enter the original size and copy size data. 8. Zoom Up Key Press to increase the reproduction ratio in 1% steps. 12. 2 Single Copies Key Press to select one of two 2 single copies modes.
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1 December 1990 1-9
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1 December 1990 3. COPY PROCESSES AROUND THE DRUM 2. EXPOSURE 1. DRUM CHARGE 3. ERASE 9. QUENCHING 4. DEVELOPMENT 8. CLEANING 5. PRE-TRANSFER LAMP (PTL) 7. PAPER SEPARATION 6.
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1 December 1990 1. DRUM CHARGE In the dark, the charge corona unit gives a uniform negative charge to the organic photoconductive (OPC) drum. The charge remains on the surface of the drum because the OPC drum has a high electrical resistance in the dark. 2. EXPOSURE An image of the original is reflected to the OPC drum surface via the optics assembly.
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1 December 1990 4.
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1 December 1990 5. MECHANICAL COMPONENT LAYOUT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 33 17 32 18 31 30 19 29 28 27 26 25 24 23 22 21 20 19. Separation Roller 20. Relay Rollers 21. Semi-circular Feed Rollers 22. Registration Rollers 23. Pre-transfer Lamp (PTL) 24. Transfer and Separation Corona Unit 25. Pick-off Pawls 26. Cleaning Brush 27. Cleaning Blade 28. Pressure Roller 29. Hot Roller 30. Duplex Turn Guide (Option) 31. Exit Rollers 32. Hot Roller Strippers 33.
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1 December 1990 6.
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1 December 1990 A Paper Feed Section BP3: Timing Belt Pulley G11: Registration CL Gear G4: Relay Gear 2nd Feed Station Registration CL G5: Relay Gear G12: Relay Roller CL Gear 1st Paper Feed CL G6: 1st Paper Feed CL Gear Relay Roller CL 1st Paper Feed CL G7: Relay Gear 1st Paper Feed Rollers G8: Paper Lift CL Gear Relay Roller G13: Relay Roller Gear G14: Relay Gear Registration Roller Paper Lift CL G9: Paper Lift Gear G10: Sector Gear 1-15 G15: 2nd Paper Feed CL Gear 2nd Paper Feed CL 2nd
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1 December 1990 7. ELECTRICAL COMPONENT LAYOUT 43 4 1 2 3 5 6 42 8 10 9 13 11 12 15 16 14 17 18 40 39 41 32 38 36 37 7 34 35 31 30 29 26 33 19 20 22 21 25 24 23 27 28 1. Scanner H.P. Sensor 2. Lens Motor 3. Lens H.P. Sensor 4. Exit Sensor 5. Scanner Motor 6. 2nd Paper Size SW-1 (SW4) 7. 2nd Paper Size SW-2 (SW5) 8. 2nd Paper Size SW-3 (SW6) 9. 2nd Paper Size SW-4 (SW7) 10. Main Motor 11. Development CL Sol. 12. 4th/5th Mirror H.P. Sensor 13. Toner Supply CL Sol. 14. Toner End Sensor 15.
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1 December 1990 49 50 48 51 47 52 46 53 45 44 62 54 61 55 60 56 59 57 58 44. Key Counter (Option) 45. Main Board 46. CC/Grid/Bias Power Pack 47. Optics Cooling Fan Motors 48. Optics Thermoswitch 49. Exposure Lamp 50. Operation Panel Board 51. Exhaust Blower Motor 52. Cover Safety SW 53. Main SW 54. Drum Anti-condensation Heater 55. Main DC Power Supply Board 56. Optional DC Power Supply Board (Option) 57. Optional Transformer (Option) 58. Main Transformer 59. AC Drive Board 60.
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1 December 1990 8. ELECTRICAL COMPONENT DESCRIPTIONS SYMBOL NAME FUNCTION INDEX NO. Motors 10 M1 Main Motor Drives all the main unit components except for the optics unit and fans. (115/220/240Vac) M2 Scanner Motor Drives the scanners (1st and 2nd). (dc stepper) 5 M3 Lens Motor Moves the lens position according to the selected magnification. (dc stepper) 2 M4 4th/5th Mirror Motor Move the 4th/5th mirror position according to the selected magnification.
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1 December 1990 SYMBOL NAME FUNCTION INDEX NO. Switches SW1 Main Switch Supplies power to the copier. 53 SW2 Cover Safety Switch Cuts the ac power line. 52 SW3 1st Paper Size Switch Determines what size paper is in the first cassette. 26 SW4 2nd Paper Size Switch-1 Determines what size paper is in the paper tray. 6 SW5 2nd Paper Size Switch-2 Determines what size paper is in the paper tray. 7 SW6 2nd Paper Size Switch-3 Determines what size paper is in the paper tray.
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1 December 1990 SYMBOL NAME FUNCTION INDEX NO. S11 Image Density (ID) Sensor Detects the density of the image on the drum to control the toner density. 32 S12 Development Unit Set Sensor Sensors whether or not the development unit is properly set. 18 Printed Circuit Board PCB1 Main Board Controls all copier functions both directly and through the other PCBs. 45 PCB2 AC Drive Board Drives all ac motors, the exposure lamp, fusing lamp, quenching lamp, exhaust blower motor.
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1 December 1990 SYMBOL NAME FUNCTION INDEX NO. Heaters H1 Drum Anticondensation Heater Prevents moisture around the drum. 54 H2 Optics Anti-condensation Heater Option Prevents moisture from forming on the optics. N/A CO1 Total Counter Keeps track of the total number of copies made. 33 CO2 Key Counter (Option) Used for control of authorized use. Copier will not operate until installed. 44 Counters Transformer TR1 Main Transformer Steps down the wall voltage to 26 Vac and 10 Vac.
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1 December 1990 9. OVERALL MACHINE CONTROL AC Power (115V or 220/240V) Cover Safety Switch Anti-condensation Heater -Drum -Optics Main Switch Operation Panel Board IC 123 CPU AC Drive Board Exhaust Blower Motor (L) Power Relay Fusing Lamp Fusing Lamp Drive Circuit Exposure Lamp Exposure Lamp Drive Circuit IC 124 I/O Main Motor Quenching Lamp Exhaust Blower Motor (H) Main Motor Relay IC 111 ROM IC 105 I/O Power Packs CC/Grid/Bias P.P. Charge Corona Grid Voltage Dev.
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1 December 1990 10.
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1 December 1990 The main dc power supply board converts the 10 volts ac input to +5 volts and a zero cross signal. There are two 26 volts ac inputs. The dc power supply board converts them to +24 volts and +30 volts. The +5 volts and +24 volts are supplied to both the copier main board and the sorter main board. The zero cross signal and +30 volts are supplied to the copier main board. The copier main board supplies dc powers to all copier dc components.
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1 December 1990 10.
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1 December 1990 10.
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SECTION 2 SECTIONAL DESCRIPTION
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1 December 1990 1. DRUM 1.1 OPC DRUM CHARACTERISTICS An OPC has the characteristics of: 1. Being able to accept a high negative electrical charge in the dark. (The electrical resistance of a photoconductor is high in the absence of light.) 2. Dissipating the electrical charge when exposed to light. (Exposure to light greatly increases the conductivity of a photoconductor.) 3. Dissipating an amount of charge in direct proportion to the intensity of the light.
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1 December 1990 1.2 DRUM UNIT [F] [H] [G] [B] [E] [C] [A] [C] [D] An organic photoconductor drum [A] is used on this model. A drum unit [B] is used to hold the drum to prevent stress on the drum. The drum unit consists of an OPC drum, ID sensor [C] and pick-off pawls [D]. When the drum is replaced, and/or the pick-off pawls and/or the ID sensor are cleaned, the drum unit must be removed from the copier as a unit.
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1 December 1990 1.3 HANDLING THE DRUM The organic photoconductor drum is comparatively more sensitive to light and ammonia gas than a selenium drum. 1. Never expose the drum to direct sunlight. 2. Never expose the drum to direct light of more than 1,000 Lux for more than a minute. 3. Never touch the drum surface with bare hands. When the drum surface is touched with a finger or becomes dirty, wipe with a dry cloth or clean with wet cotton. Wipe with a dry cloth after cleaning with wet cotton. 4.
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1 December 1990 2. DRUM CHARGE 2.1 OVERVIEW [C] [A] [C] [B] [A] This copier uses a single wire scorotron and a highly sensitive OPC drum [A]. The corona wire [B] generates a corona of negative ions when the CC/B/G power pack applies a high voltage. A stainless steel grid plate [C] makes the corona charge uniform. The drum coating receives a uniform negative charge as it rotates past the corona unit.
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1 December 1990 2.2 CHARGE CORONA WIRE CLEANER MECHANISM [B] [A] [D] [C] Pads [A] above and below the charge corona wire clean the wire as the charge unit is manually slid in and out. The cleaner pad bracket [B] rotates when the charge unit is fully extended and the bracket is pulled up against the rear block [C]. This moves the pads against the corona wire (see illustration). If the charge unit is not fully extended, the pads do not touch the corona wire.
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1 December 1990 2.3 CHARGE CORONA CIRCUIT CN112-8 CN1-1 CN112-7 CN1-2 CN112-6 CN1-3 CN112-5 CN1-4 CN112-4 CN1-5 CN112-3 CN1-6 VA [24] VC [5] CC Trig [ 24] Grid Trig (PWM) [ 0 0/5] Grid FB CN112-2 CN1-7 CN112-1 CN1-8 CC/Grid/Bias Power Pack (P1) TC Charge Corona Wire TG Grid TB Development Roller GND [0] Main Board (PCB 1) The main board supplies +24 volts to the CC/Grid/Bias power pack at CN1-1 as the power supply source. About 0.
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1 December 1990 2.4 GRID VOLTAGE CORRECTION There are two grid voltage correction factors. These correct for increases in the drum residual voltage (Vr). The first such factor, Vr correction, is done every 1,000 copies. Vr correction is based on the data of the drum counter (SP #69) and the Vr correction ratio (L) (SP #67). The second factor, Vp correction, corrects for changes in the photoconductor’s chargeability.
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1 December 1990 3. ID sensor pattern area Grid Voltage = –620 volts + Vp Correction Factor Drum Counter 0 to 999 (copies) 1,000 to 1,999 (copies) Over 2,000 (copies) Vp Correction Factor Black Color ±0 (volts) ±0 (volts) –20 (volts) ±0 (volts) –40 (volts) –20 (volts) 4.
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1 December 1990 3. OPTICS 3.1 OVERVIEW [C] [B] [A] [E] [D] [H] [I] [F] [J] [G] During the copy cycle, an image of the original is reflected onto the drum surface through the optics assembly as follows. Light Path: Exposure Lamp [A] → Original → First Mirror [B] → Second Mirror [C] → Third Mirror [D] → Lens [E] → Fourth Mirror [F] → Fifth Mirror [G] → Sixth Mirror [H] → Drum [I] The two optics cooling fans [J] draw cool air into the optics cavity.
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1 December 1990 3.2 SCANNER DRIVE [B] [D] [E] [F] [C] [A] [G] 3.2.1 1st and 2nd Scanner Drive Mechanism This model uses a stepping motor [A] to drive the scanners. Both ends of each scanner are driven to prevent skewing. The scanners have sliders [B], which ride on guide rails. The scanner home position is detected by the home position sensor [C]. The scanner return position is determined by counting the scanner motor drive pulses.
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1 December 1990 3.3 LENS DRIVE [C] [D] [E] [F] [B] [G] [A] : Reduction : Enlargement 3.3.1 Lens Drive The lens motor [A] (stepper motor) changes the lens [B] position through the lens drive wire [C] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and the drum surface. The rotation of the lens drive pulley moves the lens back and forth in discrete steps. The home position of the lens is detected by the home position sensor [D].
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1 December 1990 3.3.3 Lens Positioning [A] [C] Home Position (100%) (100% → 141/155%) [D] (141/155% → 71/65%) (71/65% → 93%) (93% → 71/65%) (71/65% → 141/155%) [B] (141/155% → 122/129%) (122/129% → 100%) (100% → 71/65%) (71/65% → 100%) Enlargement Side Reduction Side The lens home position sensor [A] informs the main board when the lens is at full size position (home position).
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1 December 1990 3.4 4TH AND 5TH MIRROR DRIVE [B] [A] Home Position (100%) (100% → 141/155%) (141/155% → 71/65%) (71/65% → 93%) (93% → 71/65%) (71/65% → 141/155%) (141/155% → 122/129%) (122/129% → 100%) (100% → 71/65%) (71/65% → 100%) 3.4.
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1 December 1990 3.5 STEPPER MOTOR CONTROL CIRCUIT Scanner H.P. Sensor (S1) Lens H.P. Sensor (S2) CN122-3 CN806-3 CN122-4 CN806-2 CN122-5 CN802-1 CN102-7 CN824-3 CN102-8 CN824-2 CN105-1 [0] GND VM [30] [ 5] CN105-2 Scanner H.P. A [ 30 0/30] CN105-3 [5] VC A [ 30 0/30] CN105-4 B [ 30 0/30] CN105-5 [0] GND B [ 30 0/30] CN105-6 [ 5] Lens H.P. VM [30] CN102-9 CN824-1 [5] VC VA[24] 4th/5th Mirror H.P.
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1 December 1990 The lens motor and the 4th/5th mirror motor move at a constant speed, but the scanner motor speed varies according to the reproduction ratio. The CPU changes the pulse rate (pulse per second) to adjust the speed for the selected reproduction ratio. HP sensors inform the main board when the first scanner, lens, and 4th/5th mirror assembly reach their respective home positions.
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1 December 1990 3.6 AUTOMATIC IMAGE DENSITY DETECTION [A] [C] [B] Sampled area 70 mm A B Light from the exposure lamp is reflected from the original and travels to the lens [A] via the mirrors. The auto ID sensor [B], a photodiode, is mounted on the upper front frame. The sensor cover [C] has a hole in it to allow light to fall directly onto the sensor.
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1 December 1990 3.7 EXPOSURE LAMP VOLTAGE CONTROL The main board controls the exposure lamp voltage through the ac drive board. The exposure lamp voltage is based on the base lamp voltage and various correction factors. The exposure lamp data setting determines the base lamp voltage. The following table gives the approximate lamp voltage for each data setting.
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1 December 1990 The exposure lamp voltage consists of the following 3 factors: Exposure lamp voltage = Base lamp voltage factor + Reproduction ratio correction factor + Drum wear correction factor 3.7.1 Base Lamp Voltage Factor In Manual Image Density Control Darker Manual ID Level Exposure Lamp Data Lighter 1 Vo –4 2 Vo ±0 3 Vo ±0 4 Vo ±0 5 Vo +4 6 Vo +8 7 Vo +12 The above table shows changes in the exposure lamp data in manual image density mode.
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1 December 1990 3.7.3 Reproduction Ratio Correction Factor Exposure Lamp Data +10 Lighter +5 +0 - 50 62 100 140 150 160 180 200 (%) Reproduction Ratio For the reduction and enlargement reproduction ratios the light path is longer than for the full size reproduction ratio. For this reason, the exposure lamp voltage is increased when reduction or enlargement is selected. The above chart shows the exposure lamp data at various reproduction ratios.
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1 December 1990 3.7.4 Drum Wear Correction Factor Exposure Lamp Data +10 (Max) SP #61 = 0 +5 SP #61 = 1 +0 0 10 20 30 40 50 60 70 80 90 100 110 (Hours) Main Motor On Time To compensate for OPC drum wear caused by contact with the cleaning brush, the exposure lamp voltage is increased at set intervals of main motor ON time. When SP mode #61 is set to 0, exposure lamp data is increased 1 at 10-hour intervals. When SP mode #61 is set to 1, the data is increased 1 at 20-hour intervals.
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1 December 1990 3.
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1 December 1990 3.9 SERVICE CALL CONDITIONS Service Code 11: Exposure Lamp Error The feedback signal becomes higher than 4.2 volts (r.m.s.) for 1.0 second when the exposure lamp is on, or it becomes higher than 1.0 volt (r.m.s) for 1.0 second when the exposure lamp is off. Service Code 12: Exposure Lamp Error The feedback signal falls below 0.5 volt (r.m.s.) for 1.0 second when the exposure lamp is on, or the exposure lamp stays on for longer than 10 seconds.
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1 December 1990 4. ERASE 4.1 OVERVIEW LE EL SE ES Lo Lc LE: Lead edge erase margin SE: Side erase margin 2.5 ±1.5 mm 2.0 ±2.0 mm on each side; total of both sides 4 mm or less LO: Original width LC: Charged width of drum EL: Lead edge erase ES: Side erase The erase lamp [A] consists of a line of LEDs extending across the full width of the drum [B]. The erase lamp has three functions: leading edge erase, side erase, and trail edge erase.
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1 December 1990 a b c d e f g h f e d c b a 4.1.1 Lead Edge Erase The entire line of LEDs turns on when the main motor turns on. They stay on until the erase margin slightly overlaps the lead edge of the original image area on the drum (Lead Edge Erase Margin). This prevents the toner density sensor pattern from being developed every copy cycle and the shadow of the original edge from being developed on the paper. At this point, side erase starts.
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1 December 1990 The following table shows which erase lamp LEDs turn on. Blocks On None a a–b a–c a–d a–e a–f a – f, g All Paper Size A3, A4 sideways 11" x 17", 11" x 8 1/2 B4 8 1/2" x 11", 8 1/2" x 5 1/2" A4 lengthwise B5 lengthwise A5 lengthwise, 5 1/2" x 8 1/2" Reproduction Ratio (%) 98 – 200 92 – 97 86 – 91 80 – 91 71 – 79 61 – 70 50 – 60 For ID sensor pattern For Vr correction 4.1.
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1 December 1990 5. DEVELOPMENT 5.1 OVERVIEW [B] [E] [C] [F] [A] [D] When the main motor turns on, the paddle roller [A] development roller [B] the auger [C], and the agitator [D] start turning. The paddle roller picks up developer in its paddles and transports it to the development roller. Internal permanent magnets in the development roller attract the developer to the development roller sleeve. The turning sleeve of the development roller then carries the developer past the doctor blade [E].
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1 December 1990 5.2 DRIVE MECHANISM [I] [G] [E] [H] [J] [B] [F] [A] [D] [C] When the main motor turns, the rotation is transmitted from the development drive gear [A] to the development roller gear [B] through the development clutch [C]. (The rotation is transmitted to the development drive gear when the development solenoid [D] is de-energized.) Then, the rotation is transmitted from the development roller gear to the paddle roller gear [E] through the idle gear [F].
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1 December 1990 5.3 CROSS-MIXING [F] [D] [A] [B] [E] [C] This copier uses a standard cross-mixing mechanism to keep the toner and developer evenly mixed. It also helps agitate the developer to prevent developer clumps from forming and helps create the triboelectric charge. The developer on the turning development roller is split into two parts by the doctor blade [A]. The part that stays on the development roller [B] forms the magnetic brush and develops the latent image on the drum.
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1 December 1990 5.4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROL Image density is controlled by changing two items: (1) the strength of the bias voltage applied to the development roller sleeve, and (2) the strength of the voltage applied to the exposure lamp. Applying a bias voltage to the development sleeve reduces the potential between the development roller and the drum, thereby reducing the amount of toner transferred. As the bias voltage becomes greater, the copy image becomes lighter.
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1 December 1990 5.4.2 Base Bias Voltage Factor In Automatic Image Density Control In automatic image density control mode, the base exposure lamp voltage is fixed to Vo. (See page 2-18 for more information.) Image density is controlled by changing only the base bias voltage. The base bias voltage depends on the background image density of the original, which is measured using the original ID sensor. (See page 2-18 for more information.) The CPU checks the voltage output from the automatic ID circuit.
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1 December 1990 5.4.3 Base Bias Voltage Adjustment Factor Base Bias Adjustment (Black toner: SP mode #37, Color Toner: SP mode #79) Image Density Normal Darkest Darker Lighter Lightest SP Data (SP mode #37 or #79) 0 1 2 3 4 Change of Base Bias Voltage ±0 volts +40 volts +20 volts –20 volts –40 volts The base bias voltage can be changed in SP mode #37 for black toner or #79 for color toner to adjust the image density level. The above table gives the base bias voltage for each SP mode setting.
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1 December 1990 5.5 DEVELOPMENT BIAS CIRCUIT CN112-8 CN1-1 CN112-7 CN1-2 CN112-6 CN1-3 CN112-5 CN1-4 CN112-4 CN1-5 CN112-3 CN1-6 VA [24] VC [5] Bias Trig (PWM) [ 0 0/5] Bias FB GND [0] CN112-2 CN1-7 CN112-1 CN1-8 CC/Grid/Bias Power Pack (P1) TC Charge Corona Wire TG Grid TB Development Roller Main Board (PCB 1) The main board supplies +24 volts to the CC/Grid/Bias power pack at CN1-1 as the power supply source.
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1 December 1990 5.6 DEVELOPMENT UNIT SET SENSOR [B] [A] When the development unit is removed from the copier, the development unit set sensor (S12) [A] sends a LOW signal to the main board and "U3" lights in the operation panel. When the development unit is properly set in the copier, the sensor is actuated by a projection [B] on the rear of the toner supply unit and "U3" turns off.
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1 December 1990 5.7 COLOR DEVELOPMENT UNIT DETECTION [A] [D] [A] [B] [C] [C] [D] Color Development Unit Detection Table SW 8-1 OFF ON OFF ON SW 8-2 OFF OFF ON ON Color Black Red Green Blue ON: LOW OFF: PULSE When a color development unit is installed in the copier, the color switch [A] is activated by screw [B] at the rear side of the development unit. The color switch has two microswitches (SW8-1 [C] and 8-2 [D]) inside.
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1 December 1990 6. TONER DENSITY DETECTION AND TONER SUPPLY 6.
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1 December 1990 6.2 ID SENSOR FUNCTION IN DETECT SUPPLY MODE Main Board I/D Sensor +5V B A C K E +24V CN118-2 CN110-2 TP 110 (PSE) SOL 1 CN110-3 C ID Sensor Output R IC111 ROM VR102 A CN110-1 ID Sensor LED CPU IC 105 I/O IC190 RAM CN118-1 Toner Supply CL Solenoid Vsg 4V Low Density (1/8 Vsg) High Density Vsp [BLACK] The image density sensor checks the density of the sensor pattern image once every 10 copy cycles.
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1 December 1990 6.3 FIXED SUPPLY MODE When the data of SP mode #30 is "1" (factory setting = "0") or a color development unit is installed, the fixed supply mode is selected. In this case, a fixed amount of toner is added every copy cycle depending on the selected toner supply ratio (SP mode #32 (black toner), SP mode #70 (color toner), the paper size in use, and the supply mode data. (See page 2-44 for more information.
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1 December 1990 6.4 ID SENSOR FUNCTION IN FIXED SUPPLY MODE 6.4.1 Black Development Unit In fixed supply mode, toner is supplied every copy cycle according to the fixed toner supply ratio data (SP mode), the paper size data and the color data. However, the toner supply clutch solenoid is de-energized to prevent over-toning when Vsp is lower than 1/8 Vsg. Vsg 4V Low Density 1/8 Vsg Vsp High Density [BLACK] 6.4.
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1 December 1990 6.5 ABNORMAL CONDITION IN TONER DENSITY DETECTION If the Vsg goes below 2.5 volts (Vsg abnormal) or Vsp goes above 2.5 volts (Vsp abnormal) 5 times in a row, the CPU determines that toner density detection is abnormal. The CPU changes from the detect supply mode to the fixed supply mode. At the same time either the Auto ID indicator or the selected manual ID level starts blinking, and the machine can be operated.
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1 December 1990 6.6.2 Vd Correction Factor (Only For Black Toner) After developer is replaced, the triboelectric charge sometimes changes as the new developer mixture is not stabilized in during the first 500 copies. The development bias for the ID sensor is adjusted automatically to compensate for these changes. The CPU calculates the threshold level for the Vd correction when the black developer initial setting procedure (SP mode #65) is completed.
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1 December 1990 6.7 TONER SUPPLY AND AGITATOR DRIVE MECHANISM [H] [F] [J] [I] [E] [F] [G] [B] [A] [C] [D] The toner supply clutch gear [A] turns when the main motor is on. The transmission of this rotation to the toner supply drive gear [B] is controlled by the toner supply clutch [C]. When the toner supply clutch solenoid [D] energizes, the toner supply clutch engages and starts turning the toner supply drive gear. The toner supply drive gear turns the toner supply roller gear [E].
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1 December 1990 6.8 TONER SUPPLY AMOUNT This copier has two different ways of controlling the amount of toner supplied. Normally, the detect supply mode controls toner supply for the black development unit; however, a fixed supply mode also can be selected by SP mode #30. When the color development unit is installed, the fixed supply mode controls toner supply regardless of the setting of SP mode #30. 6.8.
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1 December 1990 ID Sensor Data Vsp/Vsg x100 (Vsp, if Vsg = 4.0 volts) (Toner Supply Ratio, if SP #31 = 0) Toner Supply Level 0 to 12.5 % (0 to 0.5 volts) No toner supply (0 %) 0 12.5 to 15.0 % (0.5 to 0.6 volts) 1 (3.75 %) 15 15.0 to 17.5 % (0.6 to 0.7 volts) 2 (7.5 %) 29 17.5 to 25.0 % (0.7 to 1.0 volts) 3 (15 %) 59 25.0 to 62.5 % (1.0 to 2.5 volts) (See note below.) 4 (30 %) 118 62.5 to more than 100 % (2.5 to 5.
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1 December 1990 6.8.2 Fixed Supply Mode (SP mode #30 = 1) The amount of toner supplied depends on the fixed toner supply ratio data, the paper size data and the color data. The toner supply clutch solenoid on time in each copy cycle is calculated as follows: Toner Supply Clutch Solenoid ON Time = T x P x 2 x C (pulses) Where: T = Fixed Toner Supply Ratio Data P = Paper Size Data C = Color Data For example: The data of SP mode #32 is set to "0". The toner supply ratio is 7.0% and the toner supply data = 2.
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1 December 1990 Fixed Toner Supply Ratio Data (Black Toner: SP mode #32) SP Data (SP mode #32) 0 1 2 3 Toner Supply Ratio Toner Supply Ratio Data 7.0 % 3.5 % 10.5 % 14.0 % 2 1 3 4 Fixed Toner Supply Ratio Data (Color Toner : SP mode #70) SP Data (SP mode #70) 0 1 2 3 Toner Supply Ratio Toner Supply Ratio Data 14.0 % 7 .0% 21.0 % 28.
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1 December 1990 6.9 TONER END DETECTION [E] [C] [D] [G] [F] [B] [A] The toner agitator gear [A] has a cam [B] (the toner end cam) on its inner surface, and it rotates only when toner is supplied. The cam follower on the end of the toner end lever [C] rides on the surface of the toner end cam (spring pressure). The opposite end of the toner end lever alternately presses and releases the toner end arm [D] as the cam turns.
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1 December 1990 If this condition is detected by the CPU two times consecutively, the Add Toner indicator starts blinking. After the indicator starts blinking, 50 copies can be made. If a new toner cartridge is not added within that 50 copy interval, the Add Toner indicator stops blinking (stays on) and copying is inhibited. If the main switch is turned off and on after this, only 1 copy can be made each time. The toner end condition is normally detected by the mechanism described here.
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1 December 1990 7. IMAGE TRANSFER AND PAPER SEPARATION [B] [F] [E] [D] [C] [A] 7.1 PRE-TRANSFER LAMP (PTL) After the latent image is developed but before the image is transferred to the copy paper, the drum surface is illuminated by the pre-transfer lamp [A]. This illumination reduces the negative potential on the drum surface [B]. This prevents the toner particles from being re-attracted to the negatively charged drum during the paper separation process.
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1 December 1990 7.3 PAPER SEPARATION After image transfer the copy must be separated from the drum. To break the attraction between the paper and the drum, the separation corona wire [D] applies an ac corona to the reverse side of the paper. The stiffness and weight of the paper causes it to separate from the drum. The negative charge on the paper (from the transfer corona) is not completely discharged until the paper is far enough from the drum that the toner will not be reattracted to the drum.
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1 December 1990 7.
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1 December 1990 8. DRUM CLEANING 8.1 OVERVIEW [E] [B] [C] [D] [A] [F] The cleaning brush [A] and cleaning blade [B] remove any toner remaining on the drum [C] after the image is transferred to the paper. The cleaning brush and drum move in opposite directions at their point of contact. The cleaning brush removes paper dust and nearly half of the toner from the drum surface to reduce the cleaning load placed on the blade. The cleaning blade removes the remaining toner.
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1 December 1990 8.2 DRIVE MECHANISM [G] [H] [D] [C] [F] [E] [B] [A] The rotation of the main motor is transmitted to the cleaning unit through the main motor gear [A], the relay gear [B], and the cleaning drive gear [C]. The gear [D] driven by the cleaning drive gear passes the rotation to the toner collection roller gear [E] and to the cleaning brush gear [F] through the idle gears [G]. The cleaning blade [H] is mounted in the center of the blade and is tilted to apply even pressure.
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1 December 1990 8.3 TONER OVERFLOW DETECTION [C] [B] [A] The toner overflow detection mechanism stops copier operation when the used toner tank gets full. When the tank gets full, the pressure of the used toner pushes up a movable plate [A] mounted in the top of the used toner tank. As this plate moves up, it raises the toner overflow actuator [B]. When the actuator moves into the toner overflow sensor [C], the CPU starts to blink "E70" on the operation panel.
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1 December 1990 9. QUENCHING [A] [B] In preparation for the next copy cycle, light from the quenching lamp (QL) [A] neutralizes any charge remaining on the drum [B]. The neon lamp is used for quenching and it is turned on whenever the main motor rotates.
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1 December 1990 10. PAPER FEED AND REGISTRATION 10.1 OVERVIEW [G] [C] [D] [A] [B] [E] [H] [I] [J] [F] This model has two paper feed stations. The first feed station is located on the right side of the copier and the second feed station is located inside the copier. The first feed station uses a cassette [A] which can load 500 sheets, and the second feed station uses a drawer type tray [B] which can load 250 sheets.
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1 December 1990 10.2 FRR FEED SYSTEM [B] [A] [C] This copier uses an FRR (Feed + Reverse Roller) paper feed system which utilizes three rollers. 10.2.1 Pick-up Roller The pick-up roller [A] is not in contact with the paper stack before it starts feeding paper. Shortly after the Start key is pressed, the pick-up roller drops down and feeds the top sheet between the feed [B] and the reverse rollers [C].
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1 December 1990 [B] [B] F2 F2 F3 F2 F1 F1 F3 [A] F1 F1 [A] The direction that the reverse roller [A] turns depends on the frictional forces acting on it. The slip clutch applies a constant clockwise force (F1). When there is a single sheet of paper being driven between the rollers, the force of friction between the feed roller [B] and the paper (F2) is greater then F1. So, the reverse roller turns counterclockwise.
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1 December 1990 10.3 1ST FEED STATION PAPER LIFT MECHANISM AND PAPER END DETECTION [H] [K] [J] [I] [G] [A] [F] [E] [B] [C] [D] 10.3.1 Paper Lift Mechanism When the cassette [A] is inserted into the copier, the cassette actuator pin [B] is pushed down by the cassette. The paper lift clutch unit [C] moves down and then the paper lift gear [D] engages with the sector gear [E]. Simultaneously, the paper size actuator [F] actuates the paper size switch [G].
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1 December 1990 If the paper has not been raised to the feed position, the CPU turns on the main motor and the paper lift clutch. The paper lift gear turns the sector gear and the bottom plate raises until the top sheet pushes up the paper lift sensor feeler [I]. When the paper lift sensor is de-actuated, the paper lift sensor sends a Low signal to the main board, and then the main motor and the paper lift clutch are turned off.
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1 December 1990 10.4 2ND FEED STATION PAPER LIFT MECHANISM AND PAPER END DETECTION [I] [H] [J] [G] [K] [F] [A] [D] [E] [B] [C] 10.4.1 Paper Lift Mechanism When the paper tray [A] is closed after the paper is loaded, the release shaft [B] is pushed by the rear frame [C] and releases the lock arm [D], which is mounted on the paper tray bottom plate.
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1 December 1990 10.5 PAPER SIZE DETECTION 10.5.1 1st Feed Station [A] SW3– 12345 [B] The paper size switch (SW3) [A] in the cassette entrance detects the paper size. The paper size switch has five microswitches (SW3-1 through 3-5) inside. The paper size switch is actuated by an actuator plate [B] on the rear of the cassette. Each paper size has its own unique combination of notches in the plate.
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1 December 1990 Paper Size Detection Table (1st Feed Station) Paper Size Universal A3 B4 A4 A4 B5 B5 (lengthwise) A5 (sideways) A5 (lengthwise) B6 (sideways) B6 (lengthwise) Return Post Card Post Card 11" x 17" 11" x 8 1/2" 11" x 15" 10" x 14" 8 1/2" x 14" 8 1/2" x 13" 8 1/2" x 11" 8 1/2" x 5 1/2" 8 1/4" x 13" (14") F (8" x 13") 8" x 10 1/2" 8" x 10" 5 1/2" x 8 1/2" No Cassette 1 0 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Switch 3 – 2 3 4 0 0 0 0 0 0 1 0 0 0 1 0 0 1 0 1 1 0 1 1 0 0 0 1 0 0 1 1
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1 December 1990 10.5.2 2nd Feed Station [E] [F] [A] [B] [C] [D] Four paper size switches (SW4 [A], SW5 [B], SW6 [C], and SW7 [D]) on the rear frame detect the paper size. The paper size switches are actuated by an actuator plate [E] on the rear of the paper tray. The paper end guide [F] is connected to the actuator plate. When the paper end guide is pushed against the paper stack loaded in the cassette, the actuator plate slides into position and actuates the appropriate paper size switch.
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1 December 1990 10.6 PAPER FEED DRIVE MECHANISM 10.6.1 1st Feed Station [H] [F] [A] [E] [G] [B] [C] [D] Through several gears and a timing belt, main motor rotation is transmitted to the relay gear [A] and then the 1st paper feed clutch gear [B]. The 1st paper feed clutch gear turns the reverse roller drive gear [C]. The paper feed timing is controlled by the 1st paper feed clutch [D]. The pick-up roller [E] is normally in contact with the paper stack.
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1 December 1990 10.6.2 2nd Feed Station [H] [D] [E] [C] [A] [F] [B] [G] Main motor rotation is transmitted to the relay roller clutch gear [A] through gears and a timing belt. The paper feed timing is controlled by the relay roller clutch [B] and the 2nd feed clutch [C]. The relay roller gear [D] transmits rotation to the 2nd feed clutch gear [E] through the relay gear [F] only when the relay roller clutch is on (when the relay clutch solenoid [G] is energized).
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1 December 1990 10.7 SLIP CLUTCH MECHANISM [D] [B] [A] [C] [E] [D]: Reverse Roller [E]: Slip Clutch Cover The slip clutch consists of two hubs connected by a drive spring [A]. The spring grips the input hub [B] loosely and grips the output hub [C] tightly. It will slip if the resistance to rotation is too great. The hubs and spring are precisely machined, and the output hub and spring slip when a single sheet of paper feeds between the feed roller and reverse roller.
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1 December 1990 10.8 MANUAL FEED TABLE [A] [C] [B] [D] The manual feed table [A] uses the same feed mechanism as the first feed station and a maximum of 50 sheets of standard weight paper can be loaded. When the manual feed table is opened, a release lever [B] activates the manual feed table switch (SW9) [C] and releases the paper lift-up clutch unit mechanically to drop down the cassette bottom plate.
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1 December 1990 10.9 PAPER REGISTRATION [A] [E] [F] [G] [C] [D] [T] [B] Main motor rotation is transmitted to the timing belt [A] through a series of gears. The timing belt rotate the relay gear [B] and then the registration roller clutch gear [C]. When the registration clutch [D] is energized, the rotation of the clutch gear is transmitted to the lower registration roller [E]. The registration rollers can be rotated by a knob in the front to ease misfed paper removal.
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1 December 1990 10.10 PAPER FEED AND MISFEED DETECTION TIMING Timing Pulse (4 m sec/pulse) 0 100 1500 2000 2500 3000 3500 4000 400 m sec Start Key Main Motor <1st Feed Station> 1750 100 1st Feed Clutch 1750 2273 (A4 S) 1877 2285 (LT S) 1877 Pick-up Roller Release Sol.
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1 December 1990 11. IMAGE FUSING 11.1 OVERVIEW [F] [E] [D] [H] [G] [A] [C] [B] After the image is transferred, the copy paper enters the fusing unit. There the image is fused to the copy paper by the process of heat and pressure through the use of a hot roller [A] and pressure roller [B]. The fusing lamp [C] located inside the hot roller is turned on and off to maintain the operating temperature of 185 oC.
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1 December 1990 11.2 FUSING DRIVE RELEASE MECHANISM AND COVER SAFETY SWITCH [B] [A] [A] [D] [C] The front cover is opened. [E] [E] [E] [D] [C] The exit cover is opened. [D] [C] The front cover and exit cover are opened. The fusing unit drive release mechanism automatically disengages the fusing unit drive gear [A] when the front cover [B] or the exit cover is opened. This allows the fusing unit drive gear to rotate freely so that misfed paper can be easily removed.
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1 December 1990 11.3 FUSING LAMP CONTROL Temp 186 oC 185 oC Ready 172 oC Room Temp On – Fusing Lamp Off – Time When the main switch is turned on, the CPU starts sending a trigger pulse to the fusing control circuit. The fusing control circuit then applies power to the fusing lamp. The power is applied until the CPU detects the ready temperature (172 oC) through the fusing thermistor. This should take less than 60 seconds.
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1 December 1990 11.
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1 December 1990 11.4.1 Phase Control Mode AC Power A Zero Cross B Trigger Low Temp C1 Fusing Lamp Power D1 Trigger High Temp C2 Fusing Lamp Power D2 The main board sends the fusing lamp trigger pulse (LOW active) [C] to the ac drive board. PC402 activates TRC402, which provides ac power to the fusing lamp at the trailing edge of each trigger pulses. The trigger pulse goes HIGH when the main board receives the zero cross signal.
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1 December 1990 11.4.2 Overheat Protection IC121 and Q110 form an overheat protection circuit. When the fusing lamp is controlled within the normal range, pin 7 of IC121 stays LOW; therefore, Q110 stays on, allowing PC402 to operate. If the hot roller temperature reaches 240 oC, the resistance of the thermistor becomes too low. At that time, pin 7 of IC121 becomes HIGH, turning off Q110 and stopping PC402. At the same time "E53" lights on the operation panel and the power relay (RA401) turns off.
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1 December 1990 11.5 SERVICE CALL CONDITIONS Service Code 52: Fusing Warm-up Error The temperature detected by the thermistor does not reach 175 oC within 100 seconds after the main switch is turned on. Service Code 53: Fusing Overheat The temperature detected by the thermistor becomes higher than 240 oC. Service Code 55: Fusing Thermistor Open The temperature detected by the thermistor does not reach 2 oC within 30 seconds after the main switch is turned on.
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SECTION 3 INSTALLATION
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1 December 1990 1. INSTALLATION REQUIREMENTS 1.1 ENVIRONMENT 1. Temperature Range: 10oC to 30oC (50oF to 86oF) 2. Humidity Range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 lux (do not exposure to direct sunlight) 4. Ventilation: Room of more than 30 m3. Room air should turn over at least 3 times/hour. 5. Ambient Dust: Less than 0.15 mg/m3 (4 x 10-3 oz/yd3) 6.
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1 December 1990 1.2 MACHINE LEVEL 1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of level Place the machine on a table and screw the leveling feet up or down in order to level the machine. Use a leveling gauge if necessary. 1.3 MINIMUM SPACE REQUIREMENTS 10 cm 30 cm 15 cm 60 cm 70 cm 30 cm 1. Front: 70 cm (27.6") 70 cm 60 cm 30 cm 2. Back: 10 cm (3.9") : 15 cm (6.0") (when the sorter is installed.) 3. Right: 80 cm (31.5") 4. Left: 30 cm (11.
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1 December 1990 1.4 POWER REQUIREMENTS 1. Input voltage level: 110V/60Hz : More than 15A (for Taiwan) 115V/60Hz : More than 15A (for N.A.) 220V/50Hz : More than 8A (for EU.) 220V/60Hz : More than 8A (for EU.) 240V/50Hz : More than 8A (for EU.) 2. Permissible voltage fluctuation: ±10% 3. Do not set anything on the power cord. NOTE: a) Be sure to ground the machine. (Do not connect the grounding wire to a gas pipe.) b) Make sure the plug is firmly inserted in the outlet. c) Avoid multi-wiring.
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1 December 1990 2. INSTALLATION PROCEDURE 2.1 COPIER INSTALLATION [A] [A] [A] [C] [B] [D] 1. Remove the strips of tape [A] from the copier at the locations shown. 2. Open the front cover [B], and remove the strips of tape [C]. 3. Remove the transport unit lock plate [D] (2 screws).
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1 December 1990 [G] [E] [F] [I] [J] [H] 4. Pull out the paper tray [E] and remove the foam block [F], tape, and silica gel [G]. 5. Open the platen cover and remove the optics lock pins [H]. 6. Remove the left scale [I] (2 screws) and the scanner lock plates [J]. NOTE: Save the lock pins [H] and lock plates [D and J] for future use.
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1 December 1990 [A] [A] [B] [C] [F] [E] [D] [G] 7. Raise the development unit lock lever [A], pull out the development unit [B], and place it on a clean sheet of paper. 8. Remove the filter bracket [C] (2 screws). (The development unit handle is attached.) 9. Remove the toner tank [D] from the development unit (3 screws). 10. Pour one pack of developer [E] into the development unit while turning the development roller knob [F] counterclockwise to distribute the developer. 11.
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1 December 1990 [B] [C] [A] [D] 12. Lower the transport unit lever [A]. 13. Remove the drum protective sleeve [B]. 14. Remove the lock plate [C] from the cleaning blade release lever. NOTE: Save the lock plate for future use. 15. Reinstall the development unit as shown. 16. Shake the toner cartridge [D] well to distribute the toner evenly inside the cartridge. Then, install the cartridge as shown above.
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1 December 1990 [A] [A] [B] 17. Plug in the machine and turn on the main switch, then place a few sheets of white paper (A3 or 11"x17") on the exposure glass and lower the platen cover. 18. Perform 220/240 Conversion (240V machine only), Black Developer Initial Setting, and the Toner End Check. To access the SP modes, press the following keys in the order given.
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1 December 1990 [A] [B] 20. If an option (DF, Sorter, Duplex) is not installed on the machine, place a cover sheet [A] from sheet [B] over the operation panel as shown. 21. Load paper into the cassette and/or paper tray and check the machine operation and copy quality.
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1 December 1990 2.2 220/240V CONVERSION [B] 240V 220V [A] 220V 240V [C] NOTE: In areas where 240 volts is the standard, the connectors on the ac drive board must be repositioned as explained below. This procedure is also done after step 1 of the copier installation procedure. 1) Remove the rear cover (4 screws). 2) Disconnect the short connector [A] (2P/White) on the ac drive board [B] from CN421 and reconnect it to CN 421 as shown in the illustration.
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1 December 1990 2.3 CASSETTE MODIFICATION [A] [B] [F] [D] [E] [C] 1. Take off the cassette cover [A]. 2. Remove the side fences [B] (1 screw each) and the bottom plate [C]. 3. Reposition the rear fence [D] in the desired paper size position (1 screw). NOTE: Paper size positions are shown on the inside of the cassette. 4. Reinstall the bottom plate. 5. Reinstall the side fences in the desired size positions. 6. Attach the proper paper size decals [E] on the cassette at the positions shown. 7.
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1 December 1990 2.4 KEY COUNTER HOLDER INSTALLATION (OPTION) [F] [B] [C] [E] [A] 1.Make sure that the main switch is turned off. 2. Open the front cover and the manual feed table. 3. Remove the right cover (4 screws). 4. Remove the key counter cover [A] (2 screws). 5. Connect the 4P connector [B] of the key counter holder to the key counter harness [C] through the key counter access hole. 6. Position the fixing plate [D] as shown in the illustration and insert the key counter holder. 7.
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1 December 1990 2.5 OPTICS ANTI-CONDENSATION HEATER INSTALLATION (OPTION) [A] [B] [C] 1. Make sure that the main switch is turned off. 2. Remove the rear cover. 3. Remove the exposure glass. (See Exposure Glass Removal.) 4. Install the optics heater [A] in the optics cavity as shown (2 screws). 5. Wire the heater harness [B] and connect the connector [C] as shown.
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1 December 1990 2.6 COLOR DEVELOPMENT UNIT INSTALLATION (OPTION) [A] [C] [B] [D] [F] [E] [G] [H] NOTE: The two tapping screws (M4 x6) are enclosed as accessories. 1. Screw the tapping screws [A] into the holes at the rear side of the development unit as shown. Refer to the following table to determine the correct combination of screws for each color.
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1 December 1990 2. Remove the filter bracket [D] (2 screws). (The development unit handle is attached.) 3. Remove the toner supply unit [E] from the development unit (3 screws). 4. Pour one pack of developer [F] into the development unit while turning the development roller knob [G] counterclockwise to distribute the developer. 5. Reinstall the toner supply unit and the filter bracket on the development unit. NOTE: Make sure that there is no gap [H] between the toner supply unit and the development unit.
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1 December 1990 [A] [A] 7. Shake the toner cartridge [A] well to distribute the toner evenly inside the cartridge. Then, install the cartridge as shown. 8. Turn on the main switch and place a few sheets of white paper (A3 or 11" x 17") on the exposure glass. Then, lower the platen cover. 9. Perform Color Developer Initial Setting and Toner Supply Unit Initial Setting. To access the SP modes, press the following keys in order given.
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1 December 1990 2.7 DC POWER SUPPLY UNIT INSTALLATION Accessory Check Check the quantity and condition of the accessories in the box according to the following list: 1. Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. DC Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Locking Support - Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.
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1 December 1990 [E] [C] [G] [B] [F] [A] [D] [C] [E] [D] 1. Make sure that the main switch is turned off and the power supply cord of the copier is unplugged. 2. Remove the rear cover [A] (4 screws). 3. Install the three locking supports (long) [B] on the main board [C] and install the interface board [D]. NOTE: 1. The smaller side [E] of the locking supports must be inserted through the main board as shown. 2.
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1 December 1990 [B] [A] [A] [E] [D] [C] 4. Disconnect the connectors [A] from the main dc power supply unit [B] on the copier. 5. Remove the main dc power supply unit (2 screws and 2 locking supports). 6. Install the locking support bracket [C] on the rear frame (1 screw) and install the locking support (short) [D] on it. 7. Install the dc power supply unit bracket [E] on the main dc power supply unit as shown. 8. Reinstall the main dc power supply unit. 9.
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1 December 1990 [A] CN100 [B] [E] CN418 220V 240V [G] [H] [D] [C] [F] 10. Install the optional dc power supply unit [A] (2 screws and locking support) as shown. 11. To prevent damage to the ac harness [B] when installing the optional transformer [C], reposition the harness as shown. 12. Install the optional transformer [C] (2 screws). 13.
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1 December 1990 [A] [B] 14. Open the front cover and manual feed table; then, remove the right side cover [A] (4 screws). 15. Install the harness support bracket [B] (1 screw) as shown.
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SECTION 4 SERVICE TABLES
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1 December 1990 1. SERVICE TABLES 1.1 TEST POINTS Copier Main Board NUMBER FUNCTION TP101 GND TP102 VCC (+5V) TP103 ADS (Auto Image Density Sensor) Adjust the voltage to 2.5 ± 0.1 using VR101.) TP104 GND TP105 AVSS (GND) TP106 GND TP107 HT (23oC 96kΩ) TP108 BIN (Development Bias Feed Back) TP109 GIN (Grid Voltage Feed Back) TP110 PSE (ID sensor voltage) Adjust the voltage to 4.0 ± 0.2 using VR102.
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1 December 1990 1.2 DIP SWITCHES Copier Main Board DIP SWITCH NORMAL FUNCTION * 101-1 OFF Free run ** 101-2 OFF Forced start (Ready temperature by-passed) Factory Use 101-3 OFF Clear counter and/or memory 101-4 OFF Service program mode access * When this switch is set to ON, the SP mode is disabled. Free run starts when the Start key is pressed. To stop the free run, press the C/S key.
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1 December 1990 DF Main Board DIP SWITCH 101 * FUNCTION 1 2 3 4 ON OFF OFF OFF * Normal ON OFF OFF ON 1 sided free run OFF ON OFF ON 2 sided free run OFF OFF ON ON Solenoid test: Switch101 - solenoids ON Switch102 - solenoids OFF ON ON OFF ON Motor test (lift switch must be ON) ON ON ON ON All indicators ON The factory setting of DIP switch 101 is as follows: 101-1 101-2 101-3 101-4 ON ON OFF OFF This is because the DF is used on several different models.
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1 December 1990 Data Table (Jogger Position Adjustment) DIP SWITCH 700 (0:OFF, 1:ON) ADJUSTMENT VALUE 1 2 3 4 0 0 0 0 -3.5mm 1 0 0 0 -3.0mm 0 1 0 0 -2.5mm 1 1 0 0 -2.0mm 0 0 1 0 -1.5mm 1 0 1 0 -1.0mm 0 1 1 0 -0.5mm 1 1 1 0 ±0 0 0 0 1 0.5mm 1 0 0 1 1.0mm 0 1 0 1 1.5mm 1 1 0 1 2.0mm 0 0 1 1 2.5mm 1 0 1 1 3.0mm 0 1 1 1 3.5mm 1 1 1 1 4.
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1 December 1990 1.3 VARIABLE RESISTORS Copier Main Board NUMBER FUNCTION VR101 Adjusts ADS Voltage (2.5 ± 0.1) VR102 Adjusts ID Sensor Voltage (4.0 ± 0.2) Power Pack (CC/Grid/Bias) NUMBER FUNCTION VRC Adjusts Main Charge Current VRG Adjusts Standard Grid Voltage VRB Adjusts Standard Dev.
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1 December 1990 DF Main Board NUMBER FUNCTION VR101 Factory Use VR102 Original leading edge registration adjustment (One sided original mode) VR103 Original leading edge registration adjustment (Two sided original mode) VR106 Factory Use 4-6
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1 December 1990 2. SERVICE PROGRAM MODE 2.1 SERVICE PROGRAM MODE OPERATION The service program (SP) mode is used to check electrical data and change modes or adjustment values. 2.1.1 Service Program Access Procedure There are two ways to access an SP mode. (1) By key operation (2) By turning on DIP switch 101-4 (on the main board) All SP modes except for #27, #98, and #99 can be accessed by key operation. When accessing SP modes 27, 98, and 99, DIP switch 101-4 must be on.
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1 December 1990 Access Procedure 2 - DIP switch 101-4 1. Turn the main switch off. 2. Remove the rear cover and turn on DIP SW 101-4, then turn on the main switch. "5" will blink in the copy counter and the ADS indicator or a Manual Image Density indicator LED will blink. 3. Using the numeric key board, enter the desired SP mode number. (SP mode numbers are given in the Service Program Mode table.) The SP program can also be selected with the zoom keys (+, –).
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1 December 1990 2.1.3 Memory Clear Procedure Service Program SP-98 is used to clear all counters (copy counters, PM counter, self-diagnostic counters, misfeed counters). The procedure is as follows: 1. Turn off the main switch. 2. Turn on DIP SW101-3 & 4 on the main board and turn on the main switch. 3. Select Service program SP-98 and press the "1" key on the key pad, then press the Enter key. At this point all counters will be cleared to "0". 4. Turn off the main switch. 5.
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1 December 1990 2.1.
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1 December 1990 2.2 SERVICE PROGRAM MODE TABLE * Copies can be made. (Refer to NOTE 1.) Mode No. *5: Exposure Lamp OFF *6: Jam Detection Off Function Data Exposure lamp OFF Factory Setting Comments Use this mode for the scanner movement check. Turn on DIP switch 101-1, then press the Start key to start free run. Press the C/S key to stop free run. Press the Enter key in Ready mode to turn off this mode.
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1 December 1990 Mode No. Function Data Factory Setting 0 Comments 12: 220V/240V Conversion Selects 220 or 240 volts. 0: 220V 1: 240V 15: Auto Reset Time Selects auto reset of 1 or 3 minutes, or cancels this mode. 0: 1 min. 1: 3 min. 2: None 16: Count Up/Down Selects count up or count down. 0: Up 1: Down 0 17: Auto Feed Station Shift Selects auto feed station shift mode.
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1 December 1990 Mode No. Function Data Factory Setting Comments 0: Yes 1: No 0 Duplex must be installed on the machine. When 1 sided original mode is selected, the back margin (5 mm) is automatically added on the right side of the reverse page. 0: Normal 1: Double 0 25: Margin Sets the margin Adjustment (5 mm) on the right in Duplex Mode side of the reverse page. 27: A3 (DLT) Double Counter Selects single or double counter of the total counter in A3/DLT copies.
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1 December 1990 Mode No. 34: ADS Level Function Selects the image density level in ADS mode. Data 0: Normal 1: Darker 2: Lighter 35: Black Toner ID ID sensor check is 0: 10 copies Detection performed every 5 1: 5 copies copies or 10 copies. *37: Black Bias Adjustment Adjusts black bias output if the image density at level 4 cannot be adjusted in Light Intensity mode (SP 48). 0: 1: 2: 3: 4: V0 V0+40V V0+20V V0 - 20V V0 - 40V Factory Setting Comments 0 Data #1: Increases bias output (+40V).
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1 December 1990 Mode No. Function Data Adjusts the exposure lamp voltage. 100 – 150 49: Fusing Temperature Adjustment Adjusts fusing temperature. 175 – 190°C 51: Exposure Lamp Voltage Display Displays the exposure lamp voltage with a reference number. *52: Fusing Displays the fusing temperature. *48: Light Intensity Adjustment Temperature Display 54: Vsg Adjustment Factory Setting Comments 100 –150 The exposure lamp Default voltage is adjusted = 126 on the production line.
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1 December 1990 Mode No. *55: Vsg & Vsp Check Function Data Factory Setting Display the Vsg and Vsp readings. The Vsp and Vsg voltage readings are updated every 10 or 5 copies (ID sensor timing). The Vsg reading is displayed while the "0" key is held down. To stop this mode, press the C/S key. 56: ADS Voltage Adjustment Adjusts ADS. *59: Bias Voltage Displays bias voltage. Press the Start key to display the bias voltage. Press the C/S key to stop.
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1 December 1990 Mode No. 65: Black Developer Initial Setting Function Data Factory Setting Sets the data value corresponding to the Vsp/Vsg ratio for new black developer. Comments Initial setting must be done when new developer is installed. The CPU monitors Vsg and Vsp for copies 11 to 18 of the free run. Vsp is displayed on the magnification indicator. The copier automatically returns to normal mode after initial setting is completed.
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1 December 1990 Mode No. 73: Color Copy Counter Function Data Factory Setting The Magnification indicator displays the total number of color copies (Red + Green + Blue). Comments The first three digits are displayed in the magnification indicator when the Enter key is pressed. Press the "." key to display the second three digits. 74: Color Toner ID ID sensor check is 0: 5 copies Detection performed every 5 1: 10 copies copies or 10 copies. 0 Normally, "0" should be selected for color toner.
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1 December 1990 Mode No. Function Data 82: Blue Toner Density Level Display Displays the blue toner density level detected by initial setting (SP #10). 87: PM Interval Setting Sets the interval of the PM counter. 88: PM Counter Display The first three digits are displayed in the magnification indicator when the Enter key is pressed. Press the "." key to display the second three digits. 89: PM Counter Reset Resets the PM counter.
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1 December 1990 Mode No. Function Data Factory Setting Comments The first three digits are displayed in the magnification indicator when the Enter key is pressed. Press the "." key to display the second three digits. SP mode #102 is used only on the A054 copier. SP mode #103 and #104 are not used. 100:First Station Copies Displays the total number of copies fed from the first feed station (cassette and manual feed table).
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1 December 1990 Mode No. Function Data Factory Setting Comments 105:Duplex Copies Displays the total number of copies made in duplex mode. 0 106:DF Originals Displays the total number of originals fed from the DF. 0 120:Service Calls (total) Displays the total number of times the service call indicator has turned on. 0 The first three digits are displayed in the magnification indicator when the Enter key is pressed. Press the "." key to display the second three digits.
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1 December 1990 Mode No. Function 131:Number of Misfeeds by Location Data Display the total number of paper misfeeds for each area. Factory Setting Comments 0 "1" will be indicated in the copy counter when the Enter key is pressed.
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1 December 1990 NOTE 4: How to clear the PM counter 1) Enter "89", then press the Enter key. 2) Enter "1" to clear the PM counter, then press the Enter key.
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1 December 1990 2.3 SP-8 SENSOR/SWITCH DATA CHECK - How to check sensor/switch data 1. Press "8", then press the Enter (#) key while pressing the Point key. 2. With the numeral keys, enter the desired input number. The input numbers are given in the following table. 3. Press the Enter (#) key again. 4. Enter the number of copies and press the Start key. 5. The data (0 or 1) will be displayed in the magnification indicator. NOTE: Input No. The ON/OFF status can also be checked manually.
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1 December 1990 Input No. 32 33 34 Sensor/Switch/Signal ADF ON Line ADF Lift Sensor APS Sensors Data 0 1 ADF not installed ADF installed ADF closed ADF opened Refer to the following explanation Input No. 34 The A054 Copier has 7 different sensors for detecting the original length and width in APS mode. The platen cover position sensor (DF position sensor) and the platen cover closed sensor are used for the original size detection timing.
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1 December 1990 2.4 SP-9 ELECTRICAL COMPONENT CHECK - How to turn electrical components on/off 1. Enter "9", then press the Enter (#) key while pressing the Point key. 2. Enter the desired output number. (See the following table.) 3. Press the Start key to turn on the electrical component. 4. Press the Clear/Stop key to turn off the electrical component. CAUTION: To prevent the paper lift gear and sector gear from being damaged, remove the first cassette before turning on the lift clutch solenoid (No.
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1 December 1990 Output No.
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1 December 1990 2.5 MISFEED TABLE 2.5.1 Number of PaperJams (SP Mode #131) The following explains how to access a record that gives the number of paper jams by copier location. 1. Enter "131" with the numeric keys. 2. Press the Enter (#) key while pressing the Point key. 3. Select the desired FC code (Function Code). The FC code can also be selected with the "+" and "–" (zoom "up" and "down") keys. 4. Hold down the ".
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1 December 1990 2.5.2 Paper Misfeed Location Indicator F C B Upper Paper Tray E A D G 1. Initial Misfeed Lower Paper Tray (A054 Copier) Misfeed location indicators turn on if paper is detected by sensors when the main switch is turned or when the front cover/exit cover is closed. Sensors and indicators are listed below. ITEM NO.
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1 December 1990 3. Misfeed during copy cycle (Misfeed Location) 1. The misfeed location indicator turns on (and stays lit) to indicate the location of a misfeed detected by a sensor during the copy cycle. 2. The CPU determines the position of the copy leading edge by checking jam flags "0" through "15". The CPU then turns on the misfeed location indicator.
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1 December 1990 2. If a paper misfeed is detected by the registration sensor ON check during a multi-copy run, the misfeed location indicator turns on after copies that began the copy cycle before the paper jam are completely feed out from the copier. 3. If an original misfeed occurs in the DF, the misfeed indicator "F" blinks. NOTE2: The A054 copier has an additional feed station: the lower paper tray. When the lower paper tray is in use, the following apply: 1.
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1 December 1990 2.6 SERVICE CALL AND USER CODE TABLE SERVICE CALL CODE E-CODE 11 12 13 21 22 28 29 2A 2B 52 53 55 CONTENTS SP Mode No. (SC Counter) Exposure Lamp Error SP Mode #122 The feed back signal beomes higher than 4.2 volts (r.m.s) (Exposure for 1.0 second when the exposure lamp is on, or it Lamp) becomes higher than 1.0 volt (r.m.s) for 1.0 second when the exposure lamp is off. Exposure Lamp Error The feed back signal falls below 0.5 volt (r.m.s) for 1.
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1 December 1990 E-CODE CONTENT 70 Toner Overflow Sensor ON When the toner overflow sensor is on, "E70" blinks in the magnification indicator. Up to 250 copies additional can be made. After 250 copies are made, "E70" lights and copies cannot be made. Duplex and Copier Main Board Communication Error The copier main board does not receive any signal from the duplex main board. Interface Board Error The interface board is not connected when the duplex unit is installed.
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1 December 1990 3. SERVICE REMARKS 3.1 GENERAL CAUTION To prevent physical injury, keep hands away from the mechanical drive components in the following two cases: a. If the Start key is pressed before the copier finishes the warm-up cycle, (Ready indicator starts blinking) the copier starts making copies as soon as the warm-up cycle is completed. b. If the main switch is turned on while the first cassette is in the down position, the main motor starts rotating as soon as the warm-up period is completed.
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1 December 1990 3.3 CHARGE CORONA 1. Clean the corona wire by sliding the corona unit in and out. (The cleaner pads come into contact with the corona wire when the corona unit is slid all the way out.) The wire and casing can also be cleaned with alcohol or water. Do not use sandpaper or a solvent. 2. Do not touch the corona wire with oily hands. Oil stains may cause white bands on copies. 3.
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1 December 1990 4. Clean the following parts with a silicone cloth: Lens and 4th/5th Mirror Guide Rails 1st Scanner Guide Plate 5. Clean the exposure glass with glass cleaner and a dry cloth to reduce the amount of static electricity on the glass surface. 6. Only used water or a silicone cloth to clean the mirrors. 7. Do not touch the following parts with bare hands: Reflectors Exposure Lamp Mirrors and Lens 8. Do not bend the exposure lamp flat cables at sharp angles. 9.
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1 December 1990 3.6 TONER SUPPLY 1. Clean the image density sensor with a blower brush. 2. Do not touch the sensor pattern with bare hands. 3. Image density sensor adjustment is required in the following cases: a) When the ID sensor is replaced b) When the main board is replaced c) When the drum has been replaced and Vsg is out of specification d) When there have been problems with toner supply and the ID sensor check shows Vsg to be out of specification e) When the exposure lamp voltage is changed 4.
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1 December 1990 3.9 FUSING UNIT 1. Be careful not to damage the edges of the hot roller strippers or their tension springs. 2. Do not touch the fusing lamp with bare hands. 3. Make sure that the fusing lamp does not touch the hot roller. 3.10 PAPER FEED 1. Do not touch the pick-up, feed, and reverse rollers with oily hands. 2. Non-standard size copy paper may bind against the cassette side and/or back fences and misfeed. Reposition the fences.
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1 December 1990 3.13 DUPLEX When lifting the duplex unit out of the duplex tray, hold both sides of the duplex unit frame. 3.14 OTHERS 1. If the toner density in solid image areas decreases, shift the ID sensor bias level to ’2’ or ’3’ using SP#33. 2. If the RAM on the old main board is still usable, remove and place it on the new main board. Then, install the new main board to the copier. 3. After installing the new main board with the new RAM, clear the RAM memory using SP mode #99.
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1 December 1990 4. SPECIAL TOOLS AND LUBRICANTS Part Number Description Q’ty A0069105 Drum Shoe Shaft 1 A0489500 Doctor Gap Gauge (1 pc) 1 A0069103 Scanner Wire Clamper (Omega Clamp) 1 A0069104 Scanner Positioning Pin (4 pcs) A0089502 Grease G-40M 1 52059101 Gap Gauge - 0.
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1 December 1990 5. PREVENTIVE MAINTENANCE SCHEDULE After performing preventive maintenance, do the following: 1. Set the lamp voltage with SP Mode No. 48. Make a copy of the O-S-A3 test chart at manual image density level 4 to confirm that the lamp voltage is set correctly. (See Exposure Lamp Voltage Adjustment.) 2. Select SP Mode No.56 and set the ADS to 2.5 ± 0.1V by turning VR101. 3. Select SP Mode No.54 and set Vsg to 4.0 ± 0.2V by turning VR102. 4. Make a sample copy.
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1 December 1990 5.1 PM TABLE L = Lubricate R = Replace EM C = Clean I = Inspection 60K 120K 180K 240K NOTES A. OPTICS __________________________________________________ 1. Mirrors, lens, reflectors, toner shield glass C C C C C 2. Exposure glass 3. Platen cover sheet C C C R C R C R C R C C C C C C C C 4. Scanner guide rail 5. Magnification guide rail Silicone cloth, cotton pad with water, or blower brush NOTE: Clean 6th mirror with blower brush.
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1 December 1990 EM 60K 120K 180K 240K 7. Quenching lamp C C C C C 8. ID sensor 9. Erase lamp unit C C C C C C C C C C NOTES Dry cloth, discharge any static before installation Blower brush Dry cloth D. CLEANING UNIT___________________________________________ 1. Cleaning blade 2. Cleaning seal 3. Cleaning brush 4. Pick-off pawls 5.
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1 December 1990 EM 60K 120K 180K 240K NOTES J. SORTER _________________________________________________ 1. Bin guide/wheel L L L L 2. Round Belt 3. Guide plate C C C C C C C C Grease G501(if necessary) Alcohol Dry cloth K. DUPLEX _________________________________________________ 1. Feed roller 2. Friction roller 3. Bottom plate pad 4. Round belt 5. Spring clutch C C I R R R R L NOTE 1: Clean and lubricate the spring clutch of the reverse roller at every PM.
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1 December 1990 NOTE 3: When replacing the main motor, lubricate the gear using Grease G501. NOTE 4: Replace the black and color developer at PM, refering to the following supply yield table, if necessary. The yield is different for the black and color developer due to the carrier characteristics.
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1 December 1990 5.2 EXPLANATION OF REGULAR PM Item Mirrors, Lens, Reflector, Exposure Glass, Platen Cover Explanation Optics Unit Stains on any part of the optics unit result in a dirty background, black lines, or areas of decreased sharpness on the copy image. Periodic cleaning is required. The exposure glass and the platen cover must also be cleaned. If stains on the platen cover cannot be removed, it must be replaced. Exposure Lamp Deterioration of the exposure lamp affects the copy image.
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1 December 1990 Item Cleaning Unit Cleaning Blade Fusing Unit Duplex Unit ARDF Sorter Explanation A dirty or worn out cleaning blade will cause black lines on copies and/or scratches on the drum. The blade must be replaced or cleaned at regular intervals. Cleaning Brush A worn out cleaning brush will not clean effectively, resulting in a dirty background and damage to the cleaning blade. Replace at regular intervals.
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SECTION 5 REPLACEMENT AND ADJUSTMENT
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1 December 1990 1. EXTERIOR AND INNER COVERS 1.1 EXTERIOR COVER REMOVAL [D] [C] [A] [B] [E] [C] 1.1.1 Front Cover 1. Open the front cover [A]. 2. Unhook the chain [B] from the front cover. 3. Slide the front cover off the holding pins [C] (1 snap ring) and remove it. 1.1.2 Right Cover 1. Open the front cover and the manual feed table [D]. 2. Remove the right cover [E] (4 screws).
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1 December 1990 [C] [B] [A] 1.1.3 Left Lower Cover 1. Pull out the paper tray or the duplex tray [A]. 2. Remove the left lower cover [B] (3 screws). 1.1.4 Left Upper Cover. 1. Remove the left lower cover. 2. Open the exit unit. 3. Remove the left upper cover [C] (4 screws). NOTE: Remove the sorter if it is installed.
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1 December 1990 [B] [C] [A] 1.1.5 Rear Cover Remove the rear cover [A] (4 screws). 1.1.6 Upper Cover 1. Remove the platen cover. 2. Remove the platen cover pedestal [B] (4 screws). 3. Remove the upper cover [C] (6 screws). NOTE: Remove the DF if it is installed.
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1 December 1990 1.2 INNER COVER REMOVAL [G] [F] [E] [B] [C] [A] [D] 1.2.1 Right Inner Cover 1. Open and remove the front cover. 2. Remove the development unit. 3. Lower the turn guide lever [A]. 4. Remove the registration knob [B] and paper guide release lever [C] (1 screw each). NOTE: When reinstalling the release lever [C], make sure that the pin [D] on the lever is properly set in the paper guide. 5. Remove the right inner cover [E] (3 screws). 1.2.2 Left Inner Cover 1.
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1 December 1990 2. OPTICS 2.1 EXPOSURE GLASS REMOVAL [A] [B] [C] 1. Take off the left scale [A] (2 short screws). 2. Grasp the left edge of the exposure glass [B] and lift up slightly. Slide the other edge out from under the right glass holder [C]. Remove the exposure glass. NOTE: When reinstalling the exposure glass, make sure of the following: a) The left edge of the glass is flush with the tab to the left of the scale plate, and the right glass holder firmly secures the exposure glass.
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1 December 1990 2.2 1ST MIRROR REMOVAL [A] [B] [C] [D] [E] 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Move the first scanner to the cutout position (150 mm from the left scale). 4. Remove the reflector cover [A] (2 screws). 5. Remove the sub-reflector cover [B] (2 screws). 6. With your thumb, press down on the 1st scanner as shown to hold it in place.
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1 December 1990 [A] - To install 1. Insert the 1st mirror into the front side plate cutout. Then insert the rear side of the mirror into the rear spring plate. NOTE: Make sure when installing the mirror that the reflecting surface is on the upper side and the beveled edge [A] of the mirror is on the lower side. 2. Insert the front spring plate between the mirror and the front side plate cutout.
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1 December 1990 2.3 2ND AND 3RD MIRROR REMOVAL [C] [B] [A] 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Slide the 1st scanner 2/3 of the way to the right. 4. Press down on one side of the front spring plate [A] and pull it off the end of the mirror. 5. Carefully shift the 2nd mirror [B] towards the front of the machine to remove the rear spring plate [C]. 6. Lift the mirror out of the machine rear side first.
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1 December 1990 [A] [B] [C] OK NG [D] - To reinstall 1. Hold the rear spring plate [A] in position as shown. 2. Insert the 2nd mirror [B] into the front side plate cutout. 3. Position the rear end of the mirror under the rear spring plate in the rear side plate cutout. 4. Fit the front spring plate over the front end of the mirror. Make sure that the slot on each arm of the spring plate fits over the edge of the cutout as shown.
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1 December 1990 2.4 4TH AND 5TH MIRROR REPLACEMENT [A] [E] [F] [B] [D] [C] 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Remove the lens cover (2 screws). 4. Remove the 4th and 5th mirror assembly drive gear [A] (1 E-ring). 5. Slide the mirror assembly all the way to the right and remove it. 6. Replace the fourth [B] and fifth [C] mirrors. (The procedure for removing the mirrors from their brackets is the same as with the second and third mirrors.
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1 December 1990 2.5 EXPOSURE LAMP REPLACEMENT [F] [B] [A] [C] [D] [E] NOTE: Do not touch the reflector or the new exposure lamp with your bare hands. Use a strip of paper as shown. (Oil marks from fingers on the lamp or reflectors will be affected by heat from the lamp and will cause discoloration.) 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Move the first scanner to the cutout position at the rear frame [A]. (See illustration.) 4.
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1 December 1990 [B] [A] [C] [D] 7. Remove the exposure lamp [A] from the rear spring plate by moving the lamp toward the front. 8. Install a new lamp. Use a strip of paper as shown to hold the lamp. Set the rear terminal first. NOTE: a) Make sure that the lamp is set so that the terminal side of the exposure lamp routes through the rear side of the copier. b) Make sure that the insulators [B] are properly supported with the terminals [C].
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1 December 1990 2.6 THERMOSWITCH REPLACEMENT [C] [B] [A] 1. Turn off the main switch. 2. Remove the exposure glass (2 screws). 3. Slide the first scanner 150 mm to the right. 4. Remove the reflection plate cover (2 screws). 5. Remove the exposure lamp leads from the terminals [A] on both sides of the thermoswitch. 6. Remove the thermoswitch bracket [B] (1 screw). 7. Remove the thermoswitch [C] from the bracket (2 screws), and replace it.
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1 December 1990 2.7 SCANNER DRIVE WIRE REPLACEMENT 2.7.1 Wire Removal [C] [D] [F] [E] [B] [G] [A] 1. Remove the following covers and parts. Sorter (if installed) Front cover Left and right inner covers Left upper cover Right cover Operation panel TC/SC power pack Document feeder (if installed) Development unit Left lower cover Rear cover Upper cover Exposure glass 2. Loosen the screws securing the front and rear first scanner wire clamps [A]. 3. Remove the front and rear wire tightened springs [B].
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1 December 1990 2.7.2 Wire Installation [2] [1] [C] [A] [B] [1] [3] [2] [4] 1. Position the scanner drive pulley as shown with the Allen screws facing you. 2. Put the bead at the end of the blue wire [1] in slot [A] (opposite from the Allen screws). 3. Put the bead of the silver wire [2] in slot [B] on the Allen screw side. 4. Wind the blue wire [1] clockwise halfway around the pulley. Wind the silver wire [2] clockwise one complete turn around the pulley. 5.
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1 December 1990 [3] [A] [C] [E] [B] [4] [D] [D] [1] [3] [2] [4] 7. Put the bead of the blue wire [3] in slot [A] on the Allen screw side. 8. Put the bead of the silver wire [4] in slot [B]. 9. Wind the blue wire [3] clockwise one and a half times around the pulley. Wind the silver wire [4] once clockwise around the pulley. 10. Slide the omega clamp [C] down to secure all the wires as shown. NOTE: a) The blue and silver wires alternate on the pulley with the blue wire uppermost.
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1 December 1990 [A] [C] [4] [B] 4 5 [E] [2] [D] 3/7 6 [4] [2] 2 1 12. Manually move the first and second scanners to home position. 13. Insert the four positioning pins [A] in the holes on the scanner guide rails to secure the first and second scanners. 14. Loosen the wire tension bracket fixing screw [B] and the wire tension adjusting screws [C]. 15. Loosen the screw securing the front fixing plate [D]. Place wires [2] and [4] on the pulleys as shown. 16.
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1 December 1990 6-2 4 [C] [3] [B] [A] 3 [1] [1] [C] 6-1 1 [3] 2/5 17. Attach blue wires [1 and 3] around the pulleys as shown. 18. Attach wire [3] to the wire fixing plate [A], then hook one end of tension spring [B] to the fixing plate and the other end to the frame projection. 19. Tighten the first scanner clamps [C] and remove the four positioning pins and the omega clamp. 20. Perform free run (turn DIP switch 101-1 ON) for 10 minutes and make sure that the scanners operate smoothly.
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1 December 1990 [A] [B] [C] [D] [E] 21. Adjust the tension in the second scanner wire. (1) Insert positioning pin [A] in the hole at the front end of the second scanner. (2) Loosely insert positioning pin [B] in the hole at the rear end of the second scanner. (3) Loosen the two screws securing the wire tension bracket [C], then turn the 2nd scanner positioning screw [D] clockwise until the rear positioning pin drops and locks in position.
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1 December 1990 [A] 22. Adjust the first scanner wire clamps. (1) Loosen the front and rear first scanner wire clamps [A] (2) Insert the front and rear positioning pins (2). (3) Tighten the wire clamps. 23. Reassemble. NOTE: Always adjust the first scanner wire clamps after adjusting the tension in the second scanner wire.
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1 December 1990 2.8 SCANNER MOTOR REPLACEMENT [C] [D] [E] [B] 1mm [F] [A] [G] 1. Turn off the main switch. 2. Remove the rear cover and the upper cover. 3. Remove the CC/G/B power pack [A] (2 locking supports, 1 screw, and 4 connectors). 4. Remove the 6P connector [B] from the main board and remove the scanner motor harness from the harness clamps. 5. Secure the scanner wire with the omega clamp [C] so that it does not come off the pulley. (Use tape if no clamp is available.) 6.
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1 December 1990 2.9 LENS DRIVE MOTOR REPLACEMENT [D] [E] [B] [C] [A] 1. Turn off the main switch. 2. Remove the exposure glass and the lens cover. 3. Move the scanner to the return side. 4. Remove the tension spring and the lens drive wire [A]. Remove the rear cover and the CC/G/B power pack [B] (2 locking supports and 1 screw). 5. Remove the lens drive motor 6P connector [C]. 6. Remove the lens drive motor bracket [D] (2 screws). 7.
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1 December 1990 [A] [C] [B] [D] [E] [F] [G] [G] - Lens Drive Wire Installation 1. Hook the spring [A] to the sensor actuator bracket [B]. 2. Wind the lens drive wire [C] three and half times around the pulley [D]. 3. Unhook the spring [A] and place the bead [E] at the other end of the wire in slot [F] on the sensor actuator bracket. 4. Reattach the spring to the bracket. NOTE: a) Rotate the lens drive pulley and make sure that the scanner drive wire moves smoothly.
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1 December 1990 2.10 4TH/5TH MIRROR ASSEMBLY DRIVE MOTOR REPLACEMENT [A] [C] [B] 1. Turn off the main switch. 2. Remove the exposure glass, upper cover, lens cover, and rear cover. 3. Remove the main board. 4. Move the 4th/5th mirror assembly to the left (viewed from the front). 5. Remove the motor bracket [A] (2 screws). 6. Separate the 3rd scanner drive motor [B] from the bracket (2 screws) and replace it. NOTE: Position the motor harness [C] as shown when installing a new motor.
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1 December 1990 2.11 EXPOSURE LAMP POSITION ADJUSTMENT (HORIZONTAL DIRECTION) [A] [B] [D] [C] [E] [B] [F] [D] 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Move the first scanner to the cutout. 4. Position a scale [A] next to the sight hole [B] in the reflector cover to form a right angle for viewing alignment as shown. 5. Look at the lamp filament [C] through the sight hole in parallel with the scale.
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1 December 1990 3. DEVELOPMENT AND TONER SUPPLY 3.1 TONER TANK REMOVAL [A] [B] [C] 1. Take out the development unit. 2. Remove the filter bracket [A] (2 screws). 3. Remove the toner supply unit [B] (3 screws). NOTE: Make sure that there is no gap [C] between the toner supply unit and the development unit. (See illustration.
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1 December 1990 3.2 DEVELOPER REPLACEMENT [A] [B] 1. Take out the development unit. 2. Set the development unit on a large sheet of paper [A]. 3. Remove the toner supply unit (3 screws). (See Toner Supply Unit Removal.) 4. Turn the paddle roller knob [B] counterclockwise to empty developer onto the paper. NOTE: Dispose of the used toner according to local regulations. 5. Make sure that no developer remains on the development roller or in the development unit. 6.
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1 December 1990 3.3 INLET SEAL REMOVAL [A] [B] [C] 1. Take out the development unit. 2. Remove the inlet seal plate [A] by working a small blade screwdriver along the edge of the plate while pressing the stoppers [B] with one finger as shown. NOTE: a) Be careful not to damage the stoppers [B] when removing the inlet seal plate. b) The inlet seal plate must be replaced (i.e. a new plate must be installed) when it is removed to adjust the doctor gap or to replace the development roller.
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1 December 1990 3.4 DEVELOPMENT ROLLER REPLACEMENT [A] [D] [F] [E] [C] [B] 1. Take out the development roller and remove the toner tank. (See Toner Tank Removal.) 2. Empty the developer from the development unit onto a clean sheet of paper. Keep the developer clean for later use; do not allow it to be contaminated by foreign material. 3. Remove the development roller positioning bracket [A] (2 screws). 4. Remove the inlet seal plate. (See Inlet Seal Plate Removal.) 5.
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1 December 1990 3.5 DOCTOR GAP ADJUSTMENT [A] [B] NOTE: a) Use a doctor gap gauge (P/N #A0489500) to measure the doctor gap. This gauge has a "GO" [A] and a "NO GO" section [B]. b) Doctor gap adjustment is required whenever the development unit is disassembled or the doctor plate is replaced. CAUTION: Clean the development roller before starting the adjustment procedure. This prevents surface damage to the roller and ensures an accurate adjustment. ADJUSTMENT STANDARD: 0.6 ± 0.07 mm (0.024" ± 0.
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1 December 1990 20 mm 20 mm [A] [B] [C] 4. Clean all developer from the development roller [A] with a vacuum cleaner. Turn the roller to make sure that it is free of developer. 5. Loosen the doctor plate (4 screws). 6. Insert the"GO" gauge [B] in the doctor gap 20mm from the rear side of the development roller as shown. 7. Press down the doctor plate, and tighten the rear doctor plate screws [C]. 8. Repeat the adjustment procedure at the front side of the development roller. 9.
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1 December 1990 [A] - Confirmation Procedure 1. Carefully follow the procedure given here to correctly measure the doctor gap. (1) Insert the gauge [A] into the doctor gap 20mm from the front end of the development roller. (2) Check the doctor gap at three other points 20mm from the front end of the development roller, turning the roller 90° each time. (3) Repeat steps (1), (2), and (3) for the rear side of the development roller. 2. When the gap is 0.53 - 0.
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1 December 1990 3.6 TONER SUPPLY CLUTCH SOLENOID REPLACEMENT [D] [E] [C] [B] [A] 1. Turn off the main switch. 2. Remove the rear cover and main board (all connectors and 5 locking supports). 3. Remove the color switch harness [A] from the clamp [B]. 4. Remove the toner supply clutch solenoid bracket [C] (4 screws). 5. Replace the clutch solenoid [D] (2 E-rings, bushings, and 1 gear[E]).
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1 December 1990 3.7 DEVELOPMENT DRIVE CLUTCH SOLENOID REPLACEMENT [A] [B] 1. Turn off the main switch. 2. Remove the rear cover and main board (all connectors and 5 locking supports). 3. Remove the clutch solenoid bracket [A] (1 screw). 4. Replace the solenoid [B] (2 screws). NOTE: Reinstall the solenoid on the bracket [A] so that the harness is positioned on the upper side as shown.
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1 December 1990 3.8 DEVELOPMENT DRIVE CLUTCH REPLACEMENT [A] [G] [I] [B] [H] [E] [C] [F] [J] [D] 1. Remove the following parts: • • • • • • • • • Front cover Cleaning unit Drum unit Main board Development drive clutch solenoid Development unit Charge corona unit Rear cover Toner supply clutch solenoid 2. Remove the TC&SC power pack [A] (2 locking supports and screws). 3. Remove the timing belt tightener [B] (1 screw). 4. Remove the harnesses from the clamps [C] on the frames as shown. 5.
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1 December 1990 4. CLEANING 4.1 CLEANING UNIT REMOVAL [C] [D] [B] [A] 1. Open the front cover. 2. Lower the transport unit [A]. 3. Place a sheet of paper [B] underneath the cleaning unit [C]. 4. While holding down the cleaning blade release lever [D], remove the cleaning unit.
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1 December 1990 4.2 CLEANING BLADE REPLACEMENT [D] [A] [E] [C] [B] 1. Remove the cleaning unit [A]. (See Cleaning Unit Removal.) 2. Remove the cleaning blade [B] (1 screw). 3. While holding down the cleaning blade release lever [C], install the new cleaning blade between the blade bracket [D] and the blade scraper [E] (collar screw). NOTE: a) Do not touch the edge of a new cleaning blade, as it is damaged easily. b) After installing a new cleaning blade, make sure it swivels.
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1 December 1990 4.3 CLEANING BRUSH REPLACEMENT [E] [A] [C] [D] [⊗] [B] [⊗] [C] 1. Remove the cleaning blade [A]. (See Cleaning Blade Replacement.) 2. Remove the cleaning brush bracket screws (4); then, remove the cleaning brush [B] together with the cleaning side brackets [C] and gear [D]. 3. Remove the gear and the two E-rings, and replace the cleaning brush. NOTE: a) Do not touch the cleaning brush surface. Handle only the shaft-ends. b) Do not bend or damage the entrance seal [E].
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1 December 1990 4.4 BLADE SCRAPER REPLACEMENT [B] [A] 1. Remove the cleaning blade and brush. (See Cleaning Blade and Brush Replacement.) 2. While holding down the cleaning blade release lever [A], remove the blade scraper [B] (2 screws).
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1 December 1990 4.5 TONER OVERFLOW SENSOR REPLACEMENT [B] [A] [C] 1. Remove the cleaning unit. 2. Lower the transport unit. 3. Remove the toner overflow sensor bracket [A] from the duct bracket (1 screw). 4. Disconnect the connector [B] and remove the toner overflow sensor [C] from the bracket (1 screw).
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1 December 1990 4.6 USED TONER COLLECTION [B] [A] 1. Remove the cleaning unit. 2. Set the cleaning unit on a large sheet of paper [A]. 3. Remove the toner collection cover [B] (4 screws). 4. Pour the used toner slowly onto the paper sheet so that the toner does not scatter. 5. Place the paper sheet with the toner into a vinyl bag. NOTE: Dispose according to local regulations.
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1 December 1990 4.7 ENTRANCE SEAL REPLACEMENT [A] [B] [C] [I] [H] [D] [F] 2.5mm [E] 1. Remove the cleaning unit and the following parts: • Cleaning Blade • Cleaning Brush 2. Remove the used toner. (See Used Toner Collection.) [G] 3. Clean the cleaning unit with a vaccum cleaner. 4. Remove the entrance seal [A] together with the strip of 2-sided tape securing it to the lower casing. 5. Clean the lower casing [B] with alcohol; make sure that no tape remains on the casing surface. 6.
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1 December 1990 5. PAPER FEED 5.1 PAPER SIZE SWITCH REPLACEMENT [B] [A] 1. Turn off the main switch. 2. Remove the paper feed lower guide plate [A] (2 screws). 3. Remove the size switch [B] from the paper feed station (1 screw). 4. Pull the size switch out slightly and unhook the connector. Remove the size switch. NOTE: After connecting the new switch to the connector, take up slack in the switch harness by pulling on it from the rear side of the copier.
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1 December 1990 5.2 1ST PAPER END SENSOR AND PAPER LIFT SENSOR REPLACEMENT [D] [B] [C] [E] [F] [A] [G] 1. Turn off the main switch. 2. Remove the manual feed table. (See Manual Feed Table Removal.) 3. Remove the paper feed lower guide bracket [A] (2 screws). 4. Remove the paper feed upper guide bracket [B] (1 screw). 5. Remove the 1st paper end sensor bracket [C] (1 screw). 6. Replace the 1st paper end sensor [D] (1 connector). 7. Remove the paper lift sensor bracket [E] (1 screw). 8.
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1 December 1990 5.3 1ST FEED ROLLER, PICK-UP ROLLER, AND REVERSE ROLLER REPLACEMENT [B] [A] [H] [G] [D] [C] [E] [F] 1. Turn off the main switch. 2. Open the manual feed table. 3. Remove the screw [A] securing the paper lift sensor bracket [B]. 4. Close the manual feed table. 5. Slide the sensor bracket in the direction of the arrow. 6. Replace the pick-up roller [C] (1 small snap-ring). 7. Replace the feed roller [D] (1 snap-ring). 8. Remove the paper feed lower guide bracket [E] (2 screws). 9.
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1 December 1990 [D] [A] [C] [B] - To install 1. Clean the rollers with a damp cloth. 2. Clean the clutch spring [A] of the reverse roller. 3. Lubricate the surface [B] of the output hub [C] and input hub [D] with Mobil Temp. 78.
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1 December 1990 5.4 2ND PAPER FEED ROLLER REPLACEMENT [C] [A] [B] [D] [E] 1. Turn off the main switch. 2. Open and remove the front cover. 3. Pull out the paper tray or the duplex tray. 4. Remove the feed roller assembly [A] (2 screws). 5. Replace the feed roller [B] (1 screw each). NOTE: When reinstalling the feed roller assembly, make sure of the following: a) The feed rollers face up as shown. b) The pins [C] on the end of the drive shaft fit into the slots [D] on the end of the feed roller shaft.
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1 December 1990 5.5 PICK-UP ROLLER RELEASE SOLENOID AND MANUAL FEED TABLE SWITCH REPLACEMENT [C] [B] [A] [D] [E] [F] 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the main board (5 locking supports and all connectors). 4. Disconnect the connectors [A and B] of the solenoid and switch. 5. Remove the solenoid bracket [C] (1 screw). 6. Replace the solenoid [D] (3 screws) or switch [E].
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1 December 1990 5.6 1ST FEED ROLLER SPRING CLUTCH SOLENOID REPLACEMENT [C] [B] [A] 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the main board (5 locking supports and all connectors). 4. Remove the solenoid bracket [A] (1 screw). 5. Replace the solenoid [B] (1 screw). Press down on the stopper lever [C] while securing the solenoid bracket.
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1 December 1990 5.7 PAPER LIFT CLUTCH SOLENOID ASSEMBLY REPLACEMENT [C] [E] [J] [G] [H] [A] [I] [B] [F] [D] 1. Turn off the main switch. 2. Remove the left and rear covers. 3. Remove the main board (5 locking support and all connectors) and main board bracket [A] (1 screw). 4. Remove the sector gear [B] (1 screw). 5. Remove the pick-up roller release solenoid bracket [C]. (See Pick-up Roller Release Solenoid Replacement.) 6. Remove the 1st feed roller spring clutch solenoid bracket [D] (1 screw).
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1 December 1990 [E] [B] [D] [F] [A] [C] [G] - To install 1. Install the actuator lever [A] on the stud pin [B]. 2. Set the collar [C] on the stud pin [B]. 3. Install the manual feed table detection lever [D] on the stud pin [E]. 4. Place the gear [F] on the paper lift clutch solenoid assembly and install it on the stud pin [B] as shown. 5. With a pair of plyers, hook the spring [G] to the actuator lever. 6. Set the 2 E-rings and 2 springs.
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1 December 1990 5.8 RELAY ROLLER SPRING CLUTCH SOLENOID AND RIGHT COVER SWITCH REPLACEMENT [A] [C] [B] [E] [D] [F] 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the solenoid bracket [A] (2 screws). 4. Disconnect the connectors [B and C] of the solenoid and switch. 5. Replace the solenoid [D] (2 screws) or switch [E]. NOTE: When attaching the solenoid to its bracket, be sure to insert the two screws into the correct holes [F].
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1 December 1990 5.9 REGISTRATION CLUTCH REPLACEMENT [A] [B] 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the main board (5 locking supports and all connectors). 4. Remove the stopper bracket [A] (1 screw). 5. Replace the registration clutch [B]. NOTE: When reinstalling a new registration clutch, make sure that the stopper bracket locks the registration clutch as shown.
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1 December 1990 5.10 2ND PAPER FEED CLUTCH SOLENOID REPLACEMENT [A] [B] 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the main board (5 locking supports and all connectors). 4. Remove the small frame [A] (two E-rings, 3 screws, and 2 bushings). 5. Replace the 2nd paper feed clutch solenoid [B].
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1 December 1990 [D] [A] [B] [C] - To install 1. Set the solenoid on the shaft. 2. Open the right cover [A] and the front cover. 3. Rotate the shaft [B] so that the 2nd feed roller faces up as shown. 4. Install the small frame. NOTE: a) Make sure that the stopper [C] on the small frame fits into the slot on the solenoid as shown. b) Screw [D] has a washer.
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1 December 1990 5.11 2ND PAPER END SENSOR REPLACEMENT [C] [D] [A] [B] 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the sensor bracket [A] (1 screw). 4. Replace the sensor [B] (1 connector). NOTE: When reinstalling the sensor bracket, make sure that the paper end actuator [C] and paper end feeler release lever [D] are properly positioned as shown. If not, the feeler may be damaged when the paper tray is inserted.
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1 December 1990 5.12 2ND PAPER SIZE SWITCH REPLACEMENT [B] [A] 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the switch bracket [A] (1 screw). 4. Replace the switch [B] (1 connector).
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1 December 1990 5.13 REGISTRATION SENSOR AND ROLLER REPLACEMENT [B] [E] [C] [F] [A] [D] 1. Turn off the main switch. 2. Remove the following parts: • Front cover (See Exterior Cover Removal.) • Development unit • Right inner cover (See Interior Cover Removal.) • Cleaning unit (See Cleaning Unit Removal.) • Drum unit (See Drum Unit Removal.) • Rear cover (See Exterior Cover Removal.) • Main board • PTL board (See PTL Board Replacement) 3.
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1 December 1990 - Registration Rollers - [B] [A] [A] [D] [C] [E] [F] [C] 8. Remove the front and rear bushings [A] (1 screw, pressure spring, and Ering each) of the upper registration roller. 9. Replace the upper registration roller [B]. 10. Remove the 2 bushings [C] (1 E-ring each). 11. Remove the screw [D] securing the upper and lower guide plates [E]. 12. Remove the lower registration roller [F] together with the upper and lower guide plates; then, replace the lower registration roller.
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1 December 1990 - To install (Lower Registration Roller) - [E] [D] [F] [E] [C] [A] [B] [C] [A] 1. Set the ends of the lower registration roller shaft into the front and rear bushing holes [A]. 2. Install the lower guide plate [B] with the front and rear hooks [C] in the holes. 3. Insert the bushings, set the E-rings and tighten the screw [D] securing the lower guide plate. 4. Install the spring [E] on the upper guide plate and set the upper guide plate [F]. 5.
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1 December 1990 6. AROUND DRUM 6.1 PTL BOARD REPLACEMENT [A] [B] [C] [D] 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the main board (5 locking supports and all connectors). 4. Remove the TC/SC power pack [A] (2 locking supports and screws). 5. Remove the timing belt tightener [B] (1 screw). 6. Remove the PTL board stopper [C] (1 screw). 7. Replace the PTL board [D].
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1 December 1990 6.2 QUENCHING LAMP REPLACEMENT/CLEANING [F] [E] [D] [C] [A] [B] 1. Open the front cover and lower the transport unit. 2. Remove the following parts: • • • • • Development unit Cleaning unit Charge corona unit Drum unit Rear cover 3. Remove the TC/SC power pack [A] (2 screws, locking supports, and connectors). 4. Disconnect the connector [B] (CN415) from the ac drive board [C]. 5. Remove the quenching lamp [D] (1 screw). NOTE: a) Do not use alcohol to clean the QL.
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1 December 1990 6.3 ERASE LAMP REPLACEMENT [C] [D] [F] [B] [E] [A] 1. Open the front cover and lower the transport unit. 2. Remove the following parts: • • • • • Development unit Cleaning unit Charge corona unit Drum unit Rear cover 3. Remove the TC/SC power pack [A] (2 screws, locking supports, and connectors). 4. Disconnect the connector [B] (CN109) from the main board [C]. 5. Remove the erase lamp [D] (1 screw). NOTE: a) Do not use alcohol to clean the erase lamp.
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1 December 1990 6.4 CHARGE CORONA WIRE REPLACEMENT [F] [D] [G] [B] [C] [E] [A] 1. Remove the charge corona unit [A] together with the wire cleaner [B] (1 screw). 2. Remove the wire cleaner from the charge corona unit. 3. Remove the front end block cover [C] (1 screw) and the rear end block cover [D]. 4. Unhook the spring from the corona wire [E] and replace the wire. NOTE: a) Make sure that the damper ring [F] is properly positioned as shown. b) Do not handle a new corona wire with bare hands.
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1 December 1990 6.5 CHARGE CORONA GRID REPLACEMENT [B] [A] 1. Remove the charge corona unit. 2. Remove the grid plate [A] (2 springs [B]). NOTE: a) Oils and chemicals from your hands will deteriorate the grid. b) Do not bend the grid plate. This can result in an uneven charge.
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1 December 1990 6.6 TRANSFER/SEPARATION CORONA WIRE REPLACEMENT [C] [G] [B] [D] [A] [F] [E] [H] 1. Remove the transfer/separation (TC/SC) corona unit. 2. Remove the following parts: • TC/SC unit front end block cover [A] • TC/SC unit rear end block cover [B] • TC/SC unit paper guide [C]. NOTE: When reinstalling the TC/SC unit paper guide, verify that all three tabs [D] are properly latched in place. 3. Unhook the springs [E] from the wires. 4.
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1 December 1990 6.7 ENTRANCE GUIDE PLATE HEIGHT ADJUSTMENT [A] Gap "X" [B] [A] NOTE: Do not loosen or remove the entrance guide plate [A] except to replace it. The entrance guide plate height (gap between the leading edge of the entrance guide plate mylar and drum) is adjusted at the factory with special equipment. Before removing the entrance guide plate, mark its original position as shown. Position the new entrance guide plate so that the edge of the plate is aligned with the mark.
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1 December 1990 6.8 DRUM REPLACEMENT [A] [C] [B] 1. Lower the transport unit. [E] [D] 2. Remove the following units: • Development unit • Cleaning unit • Charge corona unit [A] and wire cleaner 3. Remove the fixing screw [B] securing the drum stay and pull out the drum unit [C] gently along the rail. 4. Place the drum unit on a sheet of paper. Loosen the two screws [D] securing the bearing holder and rotate the holder as shown. 5.
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1 December 1990 [B] [A] [C] [D] 6. Remove the drum knob [A] and the bearing [B] and install them with the screw [C] on the new OPC drum. Do not remove the protective sheet from the new drum. 7. Set the OPC drum in the unit and put the bearing holder [D] back in place. Tighten the screws. NOTE: a) When setting the drum in the unit, be careful not to strike it against the rail. b) Do not bend the bearing holder.
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1 December 1990 6.9 ID SENSOR REPLACEMENT [A] [B] [C] 1. Remove the drum unit, then remove the drum [A] from the unit. (See Drum Replacement.) NOTE: Cover the drum with the protective sheet to prevent the drum from being exposed to light. 2. Remove the ID sensor holder [B] (2 screws). 3. Replace the ID sensor board [C]. 4. Perform the ID sensor (Vsg) adjustment (SP mode #54).
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1 December 1990 6.10 PICK-OFF PAWL REPLACEMENT [E] [A] [C] [B] [D] NOTE: Cover the drum with the protective sheet after removing it from the drum unit. This prevents the drum from being exposed to light. 1. Remove the drum unit, then separate the drum [A] from the unit. (See the Drum Replacement section.) 2. Remove the pick-off pawl bracket [B] (2 screws). 3. Remove the screws [C] and the springs [D], then replace the pick-off pawls [E].
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1 December 1990 6.11 CORONA CURRENT ADJUSTMENT NOTE: The corona current varies with environmental conditions such as humidity and atmospheric pressure. The corona current is adjusted at the factory and is suitable under a wide range of environmental conditions. Corona current adjustment is necessary whenever the power packs are replaced; adjustment may also be necessary to correct problems with paper separation, toner transfer, or image density.
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1 December 1990 [B] [A] [D] [C] [F] [E] [E] NOTE: Do steps 4 – 8 before adjusting the transfer corona current, separation corona current or charge wire height: 5. Remove the drum from the drum unit. Cover the drum with a shielding sleeve. (See Drum Replacement.) 6. Remove the drum knob [A] and the bearing [B] from the drum, then install them on the drum shaft [C] (special tool: P/N #A0069105). 7. Set the drum shaft and drum shoe [D] on the drum unit as shown.
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1 December 1990 6.11.1CHARGE CORONA CURRENT ADJUSTMENT (SP Mode #9-2 ) [B] [A] [C] [Y] [X] [D] - Wire Height Adjustment NOTE: If the OS-A3 test chart gray scale shows an uneven image after the front end block of the charge corona unit is replaced, check and adjust the wire height as follows: 1. Set the drum shaft and drum shoe on the drum unit and install the drum unit in the machine. (See Drum Current Adjustment Preparation.) 2. Slide the the drum shoe [A] to the rear limit [X] as shown. 3.
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1 December 1990 [B] VRC [A] - Charge Corona Current Adjustment ADJUSTMENT STANDARD DC –400 ± 2 µA Adjusting VR SP Mode No. VRC #9–2 NOTE: Keep the high voltage wire terminal [A] away from the copier frame. Otherwise, electrical leakage may interfere with current measurement. 1. Turn off the main switch. 2. Disconnect the charge corona terminal [A] from the CC/G/B power pack [B]. 3. Select the dc 2mA range on the digital multimeter. 4.
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1 December 1990 6.11.2 GRID VOLTAGE ADJUSTMENT (SP Mode #9-2 ) [A] VRG ADJUSTMENT STANDARD DC –920 ± 16 V Adjusting VR SP Mode No. VRG #9–2 1. Set the multimeter range to dc 1500V and connect the multimeter leads as shown. 2. Turn on the main switch, front door safety switch, and grid using SP mode #9-2. 3. Adjust VRG of the CC/G/B power pack to –920 ± 16 V by turning VRG on the CC/G/B power pack [A]. 4. Press the Clear/Stop key and turn off the main switch.
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1 December 1990 6.11.3 TRANSFER CORONA CURRENT ADJUSTMENT (SP Mode #9-5 ) [A] [B] VRT [C] ADJUSTMENT STANDARD DC –19.3 ± 0.5 µA Adjusting VR SP Mode No. VRT #9–5 1. Reinstall the TC/SC corona unit and position the drum shoe [A] on the center of the shaft so that the axis of the current sensing plate [B] is aligned with the transfer corona wire as shown. 2. Select the dc 200 µA range on the digital multimeter. 3.
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1 December 1990 6.11.4 SEPARATION CORONA CURRENT ADJUSTMENT (SP Mode #9-8) [A] [B] VRD [C] ADJUSTMENT STANDARD AC 41.6 ± 1.3 µA Adjusting VR SP Mode No. VRD #9–8 1. Reinstall the TC/SC corona unit and position the drum shoe [A] on the center of the shaft so that the axis of the current sensing plate [B] is aligned with the separation corona wire as shown. NOTE: Make sure that the drum shoe does not touch the pick-off pawls. 2 Select the ac 200 µA range on the digital multimeter. 3.
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1 December 1990 7. FUSING 7.1 EXIT UNIT REMOVAL [C] [D] [F] [E] [B] [H] [G] [A] 1. Remove the copy receiving tray or slide the sorter in the left side if it is installed. 2. Open the exit unit [A]. 3. Remove the exit unit (2 screws and the rear holder [B]). NOTE: When reinstalling the exit unit, make sure of the following: a) The slot [C] in the rear holder fits over the projection [D] on the fusing unit rear frame and the holder pin [E] fits through the hole [F] as shown.
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1 December 1990 7.2 FUSING LAMP REPLACEMENT [F] [F] [E] [D] [B] [C] [A] 1. Make sure that the main switch is turned off and the power supply cord is unplugged. 2. Open and remove the front cover. 3. Remove the left inner cover. (See Interior Covers Removal.) 4. Disconnect the connector [A] at the front side. 5. Remove the front support bracket [B] (1 screw). 6. Remove the rear cover. 7. Remove the ac drive board [C] (all connectors, 4 locking supports, and 1 screw). 8.
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1 December 1990 7.3 PRESSURE ROLLER REPLACEMENT [C] [A] [E] [D] [D] [B] 1. Remove the exit unit. (See Exit Unit Removal.) 2. If the duplex tray is installed, remove the turn guide plate [A] (2 screws). If not, remove the fusing bottom plate [B] (2 screws). 3. Remove the exit paper guide [C] (1 screw). 4. Remove the rear cover and the ac drive board. (See Fusing Lamp Replacement.) 5. Remove the front and rear pressure springs [D]. 6. Replace the pressure roller [E] (2 bushings and E-rings).
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1 December 1990 [B] [A] [D] [C] [E] - To install 1. Install the bushings on both the front and rear roller shafts (1 E-ring each). 2. After setting the pressure roller, install the rear pressure spring [A] while sliding the bushing [B] up along with the rear frame as shown. 3. Slide the bushing up along with the front frame and pull the lower spring bracket [C] up as shown. 4. To hold the spring bracket, insert a screw driver into the cutout [D] on the front frame as shown. 5.
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1 December 1990 7.4 HOT ROLLER REPLACEMENT [A] [E] [D] [F] [B] [G] [H] [C] [A] 1. Remove the exit unit. (See Exit Unit Removal.) 2. Remove the fusing lamp. (See Fusing Lamp Replacement.) 3. If the duplex tray is installed, remove the turn guide plate (2 screws). If not, remove the fusing bottom plate (2 screws). 4. Remove the exit paper guide (1 screw). 5. Remove the front and rear pressure springs [A]. 6. Remove the C-ring [B] (front side). 7.
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1 December 1990 [D] [B] [A] [C] - To install 1. Set the rear bearing [A] on the rear frame. 2. Insert the rear end of the hot roller shaft through the rear bearing. 3. Place gear [B] on the rear end of the shaft. 4. Install the bearing stopper [C]. 5. Set the rear side C-ring [D] on the rear shaft. NOTE: a) Peel off 3 cm (1 inch) from both ends of the protective sheet before installing a new hot roller. b) Before setting the pressure springs, remove the rest of the protective sheet.
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1 December 1990 7.5 THERMISTOR AND THERMOFUSE REPLACEMENT [D] [C] [B] [G] [F] [A] [E] 1. Turn off the main switch and unplug the power supply cord. 2. Open the front cover and remove the left inner cover. 3. Lower the transport guide plate. 4. Disconnect the fusing lamp connector [A]. 5. Remove the rear cover and remove the ac drive board. (See Fusing Lamp Replacement.) 6. Disconnect the thermistor connector [B]. 7.
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1 December 1990 7.6 FUSING PRESSURE ADJUSTMENT A B b a A–a A–b B–a B–b Spring Position Setting If poor fusing occurs Factory Setting If paper creasing occurs The fusing pressure can be set at three different levels. Adjust the pressure spring position if poor fusing occurs or if the copy paper becomes creased. (See Pressure Roller Replacement.
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1 December 1990 7.7 FUSING EXIT SENSOR REPLACEMENT [A] [B] [C] 1. Turn off the main switch. 2. Open the front cover and exit unit. 3. Remove the following parts: • • • • Left inner cover Left lower and upper covers Rear cover AC drive board 4. Disconnect the exit sensor connector [A]. 5 Remove the exhaust blower motor bracket [B] (4 screws). 6. Replace the exit sensor [C].
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1 December 1990 8. OTHERS 8.1 OPERATION PANEL REMOVAL [A] [⊗] [⊗] [B] 1. Open the front cover and remove the following covers: • • • Right and left inner covers Right Cover Rear Cover 2. Disconnect the connectors from the main board (CN130 and CN131). 3. Remove the operation panel [A] (4 screws). 4. Remove the brackets [B] from the old operation panel and install them on the new operation panel. 5. Install the new operation panel on the machine. NOTE: The screws [⊗] are tapping screws.
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1 December 1990 8.2 OZONE FILTER REPLACEMENT [A] [B] 1. Open the exit unit. 2. Unhook the front and the rear support levers [A]. 3. Replace the ozone filter [B].
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1 December 1990 9. COPY QUALITY ADJUSTMENT - General Information Image density is affected by the following factors: (1) Light Intensity (2) Bias Voltage (3) Toner Density (4) Grid Voltage (5) Charge Corona Current The items listed above must be kept in balance to maintain correct image density. In the field, image density should be adjusted first by changing the exposure lamp voltage. If results are unsatisfactory, the bias voltage can be changed.
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1 December 1990 9.1 LIGHT INTENSITY ADJUSTMENT When: Purpose: Adjustment Standard: Measure: How: Every Call To maintain the correct light intensity Level 2 of the gray scale on the OS-A3 chart should be just visible on the copy when the 4th manual image density level is selected. SP Mode #48 Changes the ac drive board output voltage. 1. Turn off the main switch. 2. Clean the following parts: Item No.
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1 December 1990 9.2 UNEVEN EXPOSURE ADJUSTMENT When: Purpose: Adjustment Standard: Measure: How: The exposure is uneven. To maintain even exposure. The side-to-side variation of the gray scales on the test chart should be less than one level. Move the exposure adjustment plates. Changes the position of the adjustment plates to make the light intensity from the exposure lamp even across its length. [B] [A] NOTE: Do not adjust the charge corona wire height to correct the uneven image density on the copy.
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1 December 1990 9.3 BIAS VOLTAGE ADJUSTMENT When: Purpose: Measure: How: 1. The image is blurred even though the image density in black solid areas is acceptable. 2. Dirty background. The problem is not caused by excess toner and cannot be solved by adjusting light intensity. To improve the copy image SP Mode #37 Changes the bias voltage while the image area on the drum is being developed.
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1 December 1990 9.4 TONER DENSITY ADJUSTMENT When: Purpose: Measure: How: Customer wants to change the overall image density of the copies. To change toner concentration inside development unit. SP Mode #33 Changes the ID pattern bias voltage and either raises/lowers the toner supply threshold. 9.5 FIXED TONER SUPPLY MODE SELECTION When: Purpose: Measure: How: A problem with the ID sensing system cannot be corrected during a service call. (Detect supply mode does not function.
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1 December 1990 9.7 ID SENSOR (Vsg) ADJUSTMENT (SP MODE #54) When: Purpose: Adjustment Standard: Measure: How: 1. Check Vsg at every call, and adjust Vsg if it is out of adjustment standard. 2. At replacement of the following parts: • ID sensor • Main board • Drum 3. A toner supply problem occurs. To makes sure that ID sensor mode works correctly. Vsg = 4.0 ± 0.2 volts SP Mode #54 Changes the light intensity of the ID sensor LED. The Vsg voltage is displayed in the magnification indicator. VR102 1.
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1 December 1990 9.8 ADS (Auto Image Density Sensor) ADJUSTMENT When: Purpose: Adjustment Standard: Measure: How: 1. After light intensity adjustment 2. When replacing the following parts: • Main board • AC drive board. 3. ADS voltage is not within the adjustment standard. To maintain correct ADS mode operation ADS Voltage = 2.5 ± 0.1 volts SP Mode #56 Changes the main board ADS output voltage. The voltage reading is displayed in the magnification indicator. VR101 1.
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1 December 1990 9.9 VERTICAL MAGNIFICATION ADJUSTMENT When: Purpose: Adjustment Standard: Measure: How: The vertical magnification is not within the adjustment standard. To maintain proper vertical magnification Less than ± 0.5% difference between original and copy SP Mode #43 (0.2%/step, 16 steps) Changes the scanner speed compensation. 1. Place a 150 mm scale perpendicular to the left scale on the exposure glass. 2. Adjust the vertical magnification using SP Mode #43.
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1 December 1990 9.11 FOCUS ADJUSTMENT When: Purpose: Adjustment Standard: Measure: How: The copy image is out of focus. After adjusting the horizontal magnification To maintain proper focus Copy image in focus SP Mode #47 (16 steps) Adjusts the 4th/5th mirror assembly home position, changing the the distance between the original and the drum surface. 1. Make three A3/LDG copies with the test chart. 2. Adjust the focus using SP mode #47. Check the text on the copies.
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1 December 1990 9.12 ERASE MARGIN ADJUSTMENT When: Purpose: Adjustment Standard: Measure: How: The leading edge erase margin is not within the adjustment standard. To maintain the correct leading erase margin 2.5 ± 1.5 mm (0.1 ± 0.06") SP Mode #41 (0.5mm/step, 16 steps) Changes the erase lamp on period. 1. Place a 150 mm scale perpendicular to the left scale on the exposure glass. 2. Adjust the leading edge erase margin using SP mode #41. Make three copies and check the erase margin. 9.
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1 December 1990 9.14 SIDE-TO-SIDE REGISTRATION ADJUSTMENT When: Purpose: Adjustment Standard: Measure: How: Side-to-side registration is not within the adjustment standard. To maintain the proper side-to-side registration 0 ± 2 mm (0 ± 0.08") 1. Change the lens position. 2. Change the sIde fence position in the paper tray. Shifts the copy image. NOTE: a) When side-to-side registration is incorrect and only the paper tray or duplex unit is being used, adjust the side fence position.
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1 December 1990 [A] [C] [C] [B] - Side Fence Adjustment (Duplex Unit) 1. Pull the duplex unit [A] out. 2. Loosen the two screws [B]. 3. Set the side fences to the desired position [C].
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1 December 1990 [A] [C] [B] - Lens Position Adjustment 1. Turn off the main switch and remove the exposure glass. (See Exposure Glass Removal.) 2. Remove the lens housing cover (2 screws) and lens cover [A] (2 screws). 3. Loosen two screws [B] and shift the lens [C] from side-to-side to the adjust the registration. NOTE: Do not move the lens more than 2 mm (from the center position) in either direction (front/rear).
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1 December 1990 9.15 4TH/5TH MIRROR HEIGHT ADJUSTMENT When: Purpose: Measure: How: Parallelogram (skewed) image appears. To maintain the proper copy image Turn 4th/5th mirror height adjustment screw. Changes the 4th/5th mirror height CAUTION: Never perform this adjustment until you have positively verified that the source of the skewing is optical and not in the paper path. [A] 1. Turn off the main switch and remove the exposure glass. (See Exposure Glass Removal.) 2.
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SECTION 6 TROUBLESHOOTING
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1 December 1990 1. COPY QUALITY 1.1 BLANK COPY (WHITE COPY) - Phenomenon White or almost white copy - Possible Causes 1. Charge is not applied. • CC/G/B bias power pack (charge or grid) failure • Poor contact of power pack lead wires • Broken charge corona wire • Leak in insulator or endblock 2. Copy image is not transferred to the paper. • TC/SC power pack (transfer) failure • Poor contact of power pack lead wires • Poor contact of transfer corona wire • Leak in insulator or endblocks 3.
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1 December 1990 - Action Is the charge and/or TC/SC corona unit correctly installed? Yes No Install the charge and/or TC/SC corona unit correctly. Do the charge corona unit terminal and the springs of the TC/SC corona unit properly contact the receptacle terminals? Yes No Replace the defective parts. Are the charge and transfer corona wires broken? No Yes Replace the corona wires. Does leakage occur in the endblocks and/or receptacles? No Yes Replace the detective parts.
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1 December 1990 Does the development roller bias terminal contact the development roller shaft? Yes No Repair or replace the terminal. Check the following points: • CN112-6 (charge trigger line) and CN112-4 (Grid trigger line) (1) If the signal stays HIGH after the Start key is pressed, replace the main board. (2) If the charge corona does not turn on even if the signal changes to LOW, replace the CC/G/B power pack.
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1 December 1990 1.2 DIRTY BACKGROUND - Phenomenon 1. Dirty background at image density level 4 (manual setting) 2. When newspapers are copied, the background is dirty even at level 7. 3. ADS copies have a dirty background. - Possible Causes 1. Dirty optics 2. Toner scattering • • • High toner density The inlet seal of the development unit is stripped off. The doctor gap is too wide. 3. The exposure lamp is not bright enough. This may be caused by deterioration of the exposure lamp or low lamp voltage. 4.
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1 December 1990 - Action Make a copy in reduction mode at manual image density level 4. Is the non-image area dirty? Yes No Is the optics section dirty? No Yes Clean the optics and adjust the light intensity. Is the exposure lamp light intensity too weak due to deterioration? No Yes Replace the exposure lamp. Is the signal at CN112-5 LOW 1.4 seconds after the Start key is pressed? (No bias voltage is applied to the development roller.) No Yes Replace CC/G/B power pack. Replace the main board.
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1 December 1990 If the dirty background occurs only in ADS mode, do the following: • • • If the ADS voltage is not within 2.5 ±0.1 volts standard voltage, readjust the ADS voltage. If the signal at CN101-6 stays HIGH, check the harness and/or sensor, and replace defective parts. If the signal at CN101-5 stays LOW, replace the main board. NOTE: After the light intensity is adjusted, check and/or adjust the ADS voltage using SP mode #56.
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1 December 1990 1.3 UNEVEN IMAGE DENSITY - Phenomenon Uneven image density appears on the copies. - Possible Cause 1. Dirty optics 2. Uneven exposure lamp horizontal position. 3. Dirty corona wires or grid 4. Uneven height of charge corona wire. - Action Does the uneven image area shift when a reduction copy is made? No Yes Is the optics section dirty? No Yes Clean the optics.
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1 December 1990 1.4 VERTICAL BLACK BANDS - Phenomenon Vertical black bands appear on the copy paper. - Possible Causes 1. Dirty optics 2. Dust between the cleaning blade and drum 3. Edge of the cleaning blade deformed 4. Deformed cleaning brush 5. Deformed inlet seal on the development unit - Action Do the black bands shift when a reduction copy is made? No Yes Check and clean the optics section (including the toner shield glass).
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1 December 1990 1.5 VERTICAL BLACK LINES - Phenomenon Thin black lines appear on the copy. - Possible Causes 1. Scratched cleaning blade 2. Dirty or scratched exposure glass and/or dirty or scratched mirrors 3. Scratched or dirty drum 4. Scratched hot roller - Action Do the black lines shift when a reduction copy is made? No Yes Clean or replace the exposure glass or mirrors. Is the toner shield glass scratched? No Yes Replace the toner shield glass.
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1 December 1990 1.6 VERTICAL WHITE LINES OR BANDS—1 (DULL OR BLURRED) - Phenomenon Dull or blurred white lines appear on the copy. - Possible Causes 1. Dirty or deteriorated charge corona wire. 2. Dirty or deformed grid plate. 3. The inlet seal on the development unit is damp or is contaminated with oil. - Action Is the charge corona wire and/or grid plate dirty? No Yes Clean the charge corona wire and/or grid plate.
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1 December 1990 1.7 VERTICAL WHITE LINES OR BANDS—2 (THIN, DISTINET) - Phenomenon Vertical white lines appear on the copy. - Possible Causes 1. Paper dust on the edge of cleaning blade 2. Scratched drum 3. Scratched hot roller - Action Press the cleaning blade release lever down several times. Make a copy and if the white lines still occur, go to the next step. Make a copy and stop the machine when the paper reaches the transport section.
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1 December 1990 1.8 HORIZONTAL BLACK/WHITE LINES - Phenomenon Black/white lines perpendicular to the paper feed direction appear on the copy image. - Possible Causes 1. Drum is scratched. If black lines appear at 251mm intervals, the cause is a scratched drum or toner build up. 2. Hot roller is scratched. If black lines appear at 125mm intervals, the cause is a scratched hot roller. 3. Toner adhered to the drum surface.
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1 December 1990 1.9 JITTER - Phenomenon Jitter appears on the copy. - Possible Causes 1. Vibration in drive mechanism. 2. Scanner not moving smoothly. - Action Does the jitter interval change when a reduction copy is made? Yes No Check the drive belt, tension pulley, and drive gears. Replace the defective parts. Is the scanner wire tension correct? Yes No Readjust the scanner wire tension. Clean the scanner guide rails and check the scanner drive.
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1 December 1990 1.10 BLACK SPOTS ON THE COPY IMAGE - Phenomenon 1. The grid voltage is not applied correctly. • Poor contact between charge corona casing and grid spring • CC/G/B power pack defective • Main board defective - Action Is there a good electrical contact between the charge corona casing and the grid spring? Yes No Repair the poor contact and/or replace any parts if needed. Check the voltage at CN112-1 on the main board. 0V Not 0V Replace the main board. Replace the CC/G/B power pack.
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1 December 1990 1.11 SKEWED (OPTICAL) COPY IMAGE - Phenomenon - IMAGE The copy image is skewed (parallelogram shape). The sides of the copy image are straight, but the leading and trailing edges are skewed. (This differs from the paper path type of skewing.) - Possible Causes 1. 4th/5th mirror assembly is not parallel with the 1st and 2nd scanners. 2. Mirrors are in the wrong position 3. The stubs of the 4th/5th mirror assembly are off the rails.
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1 December 1990 1.12 TONER DENSITY TOO HIGH - Phenomenon 1. Dirty background appears on the copy. 2. The image density of black solid areas is too high. 3. Toner has built up on the endblock cover of the TC/SC corona unit and also on the upper cover of the development unit. - Possible Causes 1. Light intensity of the exposure lamp is too high. 2. Toner supply clutch keeps on turning continuously. 3. Copier is in fixed toner supply mode. 4. Main board defective 5.
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1 December 1990 Is the copier in fixed mode? No Yes Change the data in SP Mode #30 from "1" to "0". Is the charge corona current correct? Yes No Readjust the charge corona current. Is the grid voltage correct? Yes No Readjust the grid voltage. Check the data of SP Mode #33. If the data is greater than "2", readjust the data to "0".
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1 December 1990 1.13 TONER DENSITY TOO LOW - Phenomenon 1. Light copy 2. Carrier is on the copy. 3. Light spots appear in black solid areas. - Possible Causes 1. Light intensity of the exposure lamp is too low. 2. Toner supply clutch does not rotate. 3. Copier is in the fixed toner supply mode. 4. Main board is defective. 5. ID sensor voltage is too high. 6. Charge corona current is too high. 7. ID sensor grid voltage is too high.
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1 December 1990 Is the data of SP Mode #30 "1"? No Yes Change the data in SP Mode #30 from "1" to "0". Go to A Is the data of SP Mode #33 "1"? No Yes Change the data in SP Mode #33 from "1" to "0". Go to A Is the charge corona current correct? No Yes Readjust the charge corona current. Go to A Is the grid voltage correct? Yes No Readjust the grid voltage. A Clean the optics section and around the drum. Turn on DIP switch 101-1 on the main board.
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1 December 1990 1.14 TONER SCATTERING - Phenomenon Toner scatters from the development unit. - Possible Causes 1. Toner density is too high. 2. Inlet seal on the development unit is out of position. 3. Filter on the top of the development unit is dirty. 4. Developer deterioration 5. Doctor gap is too wide. - Action Is toner density too high? No Yes See section 1-11 (TONER DENSITY TOO HIGH). Is the inlet seal deformed? No Yes Replace the inlet seal plate.
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1 December 1990 1.15 UNFUSED COPY IMAGE - Phenomenon Solid image rubs off easily. - Possible Causes 1. Fusing pressure is too weak. 2. Fusing temperature is too low. 3. Thermistor malfunction - Action Adjust the position of the pressure springs to increase the fusing pressure. No good Increase fusing temperature using SP Mode #49. No good Check the thermistor. If the thermistor is malfunctioning, replace it.
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1 December 1990 1.16 PAPER MISFEED - Phenomenon 1. Misfeed location indicator turns on when the main switch is turned on even if there is no paper in the copier. 2. Misfeed location indicator always turns on at the same location when copies are made. - Possible Causes 1. Sensor is defective. 2. Mechanical and/or electrical malfunction - Action 1 (Initial Misfeed) Check which sensor is defective using the Initial Misfeed Table. (See page 4-33.) Replace the defective sensor.
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1 December 1990 1.17 DF ORIGINAL MISFEED OR SKEW - Phenomenon When the DF is in use, the original stops on the exposure glass or is skewed even if the electrical components are functioning normally. - Possible Causes 1. Exposure glass is upside-down. 2. Friction between the exposure glass and the feed belt - Action Is the red mark on the exposure glass facing up? Yes No Reinstall the exposure glass so that the red mark faces up. Clean the exposure glass surface with alcohol or water.
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1 December 1990 2. SERVICE CALL CONDITION 2.1 CODE #11 — EXPOSURE LAMP ERROR - Definition • The feedback signal becomes higher than 4.2 volts (r.m.s.) for 1.0 second when the exposure lamp is on. • The feedback signal becomes higher than 1.0 volt (r.m.s.) for 1.0 second when the exposure lamp is off. - Possible Causes • Exposure lamp open • Thermoswitch open • AC drive board defective • Main board defective • DC harness defective - Action Turn the main switch off and on.
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1 December 1990 No Open Do the cooling fans turn on? Yes No Check the voltage at CN103-1 and CN104-1 on the main board. 0V 24V Replace the main board. Replace the cooling fans. Is the exposure lamp harness defective? No Yes Replace the exposure lamp harness Is the voltage at TP111 on the main board higher than 4.2 volts in copy mode? No Yes Replace the ac drive board. Replace the main board.
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1 December 1990 2.2 CODE #12 — EXPOSURE LAMP ERROR - Definition • The feedback signal falls below 0.5 volt (r.m.s.) for 1.0 second when the exposure lamp is on. • The exposure stays on for longer than 10 seconds. - Possible Causes • AC drive board defective • Main board defective • DC harness defective - Action Turn the main switch off and on. Check the voltage at CN122-10 on the main board after the Start key is pressed. Less than 20V 24V Replace the main board.
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1 December 1990 2.3 CODE #13 — ZERO CROSS SIGNAL ERROR - Definition The CPU does not receive the zero cross signal within 0.56 second. - Possible Causes • Main board defective • DC power supply board • Zero cross line open - Action Turn the main switch off and on. Check the voltage at CN102-2 on the dc power supply unit. 0.6V 0V Replace the dc power supply board. Check the voltage at CN108-1 on the main board. 0.6V 0V Replace the dc harness. Replace the main board.
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1 December 1990 2.4 CODE #21 — SCANNER HOME POSITION ERROR - Definition The scanner home position sensor remains off (LOW) 8 seconds after the main switch is turned on. - Possible Causes • Scanner home position sensor short • Scanner motor defect • Main board defect • DC power supply unit defect - Action Turn the main switch off and on. Check the position of the 1st scanner sensor actuator.
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1 December 1990 31V 34V Replace the main board Replace the scanner motor. Check the continuity between CN806-2 and 3 on the scanner home position sensor. Not Continuous Continuous Replace the sensor. Replace the main board.
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1 December 1990 2.5 CODE #22 — SCANNER HOME POSITION ERROR - Definition The scanner home position sensor remains on (HIGH) 1.0 second after the scanner starts. - Possible Causes • Scanner home position sensor circuit open • Scanner motor defective • Main Motor defective • DC power supply unit defective - Action Turn the main switch off and on actuator position. Check the position of the 1st scanner sensor actuator.
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1 December 1990 29V 34V Replace the main board. Replace the scanner motor. Check whether the scanner home position sensor circuit is open. Not open Open Replace the sensor. Check whether the dc harness (signal line) is defective. No Defective Replace the dc harness. Replace the main board.
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1 December 1990 2.6 CODE #28 — LENS HOME POSITION ERROR - Definition The lens home position sensor remains off (LOW) 3.5 seconds after the lens moves to the home position. - Possible Causes • Lens home position sensor short • Lens drive motor defect • Main board defect - Action Turn the main switch off and on. Check the sensor actuator position on the lens assembly.
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1 December 1990 Check the continuity between CN824-2 and 3 on the lens home position sensor. No t Continuous Continuous Replace the sensor. Replace the main board.
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1 December 1990 2.7 CODE #29 — LENS HOME POSITION ERROR - Definition The lens home position sensor is still on (HIGH) 3.5 seconds after the lens leaves the home position. - Possible Causes • Lens home position sensor open • Lens drive motor defective • Main board defective - Action Turn the main switch off and on. Check the position of the lens assembly sensor actuator.
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1 December 1990 Check whether the lens home position sensor is open. Not Open Open Replace the sensor. Replace the main board.
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1 December 1990 2.8 CODE #2A — 4TH/5TH MIRROR HOME POSITION ERROR - Definition The 4th/5th mirror home position sensor is still off (LOW) 2.5 seconds after the 4th/5th mirror assembly moves to the home position. - Possible Causes • 4th/5th mirror home position sensor short • 4th/5th mirror motor defect • Main board defect - Action Turn the main switch off and on. Check the sensor actuator position on the 4th/5th mirror assembly.
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1 December 1990 Check the continuity between CN826-2 and 3 on the 4th/5th mirror home position sensor. Not Countinuous Continuous Replace the sensor. Replace the main board.
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1 December 1990 2.9 CODE #2B — 4TH/5TH MIRROR HOME POSITION ERROR - Definition The 4th/5th mirror home position sensor is still on (HIGH) 2.5 seconds after the 4th/5th mirror assembly leaves the home position. - Possible Causes • 4th/5th mirror home position sensor open • 4th/5th mirror motor defective • Main board defective - Action Turn the main switch off and on. Check the sensor actuator position on the 4th/5th mirror assembly.
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1 December 1990 Check whether the 4th/5th mirror home position sensor is open. No Open Replace the sensor. Replace the main board.
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1 December 1990 2.10 CODE #52 — FUSING WARM-UP ERROR - Definition The temperature detected by the thermistor does not reach 175oC within 100 seconds after the main switch is turned on. - Possible Causes • Thermistor position error • Fusing lamp open • Thermofuse open • AC drive board defective • Main board defective - Action Clear the service call condition. Does the fusing lamp turn on? Yes No Is the fusing lamp open? No Yes Replace the fusing lamp.
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1 December 1990 Check the voltage at CN122-9 on the main board. 0V 24V Replace the main board. Check the voltage at CN122-14 on the main board. 24V 0V Replace the main board. Does the thermistor properly contact the hot roller? Yes No Correctly position the thermistor. Does the voltage at TP107 on the main board increase after the main switch is turned on? Yes No Replace the thermistor. Replace the ac drive board.
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1 December 1990 2.11 CODE #53 — FUSING OVERHEAT - Definition The thermistor detects a temperature higher than 240oC. - Possible Causes • Thermistor short • AC drive board defect • Main board defect - Action Clear the service call condition. Check the voltage at TP107 on the main board. More than 3.45V Less than 3.45V Replace the main board. Has the thermistor shorted? No Yes Replace the thermistor. Check the voltage at CN122-9 on the main board. 24V 0V Replace the main board.
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1 December 1990 2.12 CODE #55 — FUSING THERMISTOR OPEN - Definition The thermistor does not detect 2oC within 30 seconds after the main switch is turned on. - Possible Causes • Thermistor open • Main board defective • Fusing lamp open • Thermofuse open - Action Is the thermistor open? No Yes Replace the thermistor. Clear the service call condition. Does the fusing lamp turn on? No Yes Replace the main board. Is the fusing lamp open? No Yes Replace the fusing lamp.
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1 December 1990 Check the voltage at CN122-12 on the main board. 0V 24V Replace the main board. Check the voltage at CN122-9 on the main board. 0V 24V Replace the main board. Check the voltage at CN122-14 on the main board. 24V 0V Replace the main board. Replace the ac drive board.
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1 December 1990 2.13 E70 (IN THE MAGNIFICATION INDICATOR) — TONER OVERFLOW SENSOR ON - Definition Toner overflow sensor turns on - Possible Causes • Toner overflow • Toner overflow sensor open • Main board defective - Action Is the used toner tank full? No Yes Dispose of the used toner. Check the voltage at CN101-2 on the main board. 0.9V 0V Replace the main board. Is the toner overflow sensor open? No Yes Replace the sensor. Replace the main board.
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1 December 1990 2.14 CODE #80 — DUPLEX AND COPIER BOARD COMMUNICATION ERROR - Definition The copier main board does not receive any signal from the duplex main board. - Possible Causes • Interface board defective • Copier main board defective • Duplex main board defective • Optional dc power supply unit defective • 2nd paper size switches shorted - Action Turn the main switch off and on Is the connector (CN205) on the interface board connected properly? Yes No Connect the connector (CN205) properly.
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1 December 1990 Check the voltage at CN101-4 on the optional dc power supply unit. 24V 0V Replace the optional dc power supply unit. Check the voltage at CN205-4 on the interface board. 6V 0V Replace the duplex main board. Check the voltage at CN205-3 on the interface board. 0V Replace the interface board and/or copier main board. Check whether the 2nd paper size switches have a short. No Short Replace the defective paper size switches. Replace the main board.
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1 December 1990 2.15 CODE #81 — INTERFACE BOARD ERROR - Definition The interface board is not connected when the duplex unit is installed. - Possible Causes • Interface board installed incorrectly • Interface board defective • Main board defective • 2nd paper size switch shorted - Action Turn the main switch off and on. Is the interface board installed properly? Yes No Install the interface board properly. Check the voltage at pin No.42 on IC203. Low High Replace the interface board.
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1 December 1990 2.16 CODE #82 — JOGGER HOME POSITION ERROR - Definition The output of the jogger home position sensor stays LOW while the duplex main board is driving the jogger fences outward. - Possible Causes • Jogger home position sensor shorted • Jogger motor defective • Duplex main board defective • Copier main board defective • Interface board defective - Action Turn the main switch off and on.
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1 December 1990 2.17 CODE #83 — JOGGER HOME POSITION ERROR - Definition The output of the jogger home position sensor remains HIGH as the duplex main board is driving the jogger fences inward. - Possible Causes • Jogger home position sensor open • Jogger motor defective • Duplex main board defective • Copier main board defective • Interface board defective - Action Turn the main switch off and on.
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1 December 1990 2.18 ABNORMAL CONDITION IN TONER DENSITY DETECTION - Phenomenon The Auto ID indicator or the selected manual ID level blinks. (No SC Code is indicated.) - Definition If the Vsg goes below 2.5 volts or Vsp goes above 7.5 volts 5 times in a row. - Possible Causes • Incorrect Vsg voltage • Dirty ID sensor • Low toner density • ID sensor defect • Main board defect - Action Check the Vsg voltage displayed in the magnification indicator by SP Mode #55. 0.00 (Vsg ≤ 2.5 volts) 5.
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1 December 1990 Is the Vsg less than 2.5V when checking TP110 on the main board by SP mode #54. No Yes Readjust the Vsg to 4.0 0.2 volts. Check whether the ID sensor has a short. Not Short Short Replace the ID sensor. Replace the main board.
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1 December 1990 3. ELECTRICAL COMPONENT DEFECTS 3.1 SENSOR Component Scanner Home Position Sensor (S1) Lens Home Position Sensor (S2) 4th/5th Mirror Home Position Sensor (S3) Registration Sensor (S4) Exit Sensor (S5) Paper End Sensor 1st and 2nd (S6 and S7) Toner End Sensor (S8) Toner Overflow Sensor (S9) Condition Symptom OPEN (CN122-4 stays HIGH) SC code (E22) is displayed. SHORTED (CN122-4 stays LOW) SC code (E21) is displayed. OPEN (CN102-8 stays HIGH) SC code (E29) is displayed.
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1 December 1990 Paper Lift Sensor (S10) Component Image Density (ID Sensor) (S11) Development Unit Set Sensor (S12) OPEN (CN125-2 stays HIGH) User Code #5 is displayed. SHORTED (CN125-2 stays LOW) The cassette bottom plate does not rise to the paper feed position. Condition Symptom OPEN (CN110-3 stays HIGH) SHORTED (CN110-3 stays LOW) The CPU detects an ID sensor abnormal condition. The ADS or Manual Image Density indicator starts blinking.
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1 December 1990 3.2 SWITCH OR OTHER ELECTRICAL COMPONENT Component Main Switch (SW1) Cover Safety Switch (SW2) Paper Size Switch (1st and 2nd) (SW3 to 9) Color Switch (SW8) Condition Symptom OPEN The copier does not turns on. SHORTED The copier does not turns off. OPEN The copier does not tunrs on. SHORTED The copier does not turn off when the front or exit cover is opened. OPEN The CPU cannot detect proper paper size, and misfeeds may occur when a copy is made.
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1 December 1990 3.3 FUSE Component Condition Symptom FU401 (AC Drive Board) OPEN The copier does not turn on when the main switch is turned on. FU100 (5V) (Main DC PSU) OPEN The copier does not turn on even when the main switch is turned on. OPEN SC Code #21 or #22 is displayed depending on the 1st scanner position. OPEN SC Code #21 or #22 is displayed depending on the 1st scanner position. OPEN Duplex Tray: SC Code #80 is displayed.
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SECTION 8 DOCUMENT FEEDER
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1 December 1990 1.
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1 December 1990 2. COMPONENT LAYOUT - Mechanical Components 2 3 4 5 6 1 9 10 7 8 1. Pulse Generator Disk 2. Friction Belt 3. Pick-up Lever 4. Original Table 5. Exit Roller - Electrical Components - 6. Inverter Pawl 7. Inverter Roller 8. Transport Belt 9. Pick-up Roller 10. Feed Roller 6 7 5 8 4 3 9 2 1 10 14 11 13 12 1. Original Set Sensor 2. Registration Sensor 3. Pulse Generator Sensor 4. Original Width Sensor 5. Pick-up Solenoid 6. Belt Drive Motor 7. Indicator Panel 8. Lift Switch 9.
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1 December 1990 3. ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Location Motors M1 Belt Drive Motor DC servomotor that drives to the transport belt and feed-in system (pick-up roller, feed roller, pull-out roller and relay roller). M2 Feed-out Motor DC servomotor that drives the feed-out unit of the DF. 6 10 Solenoids 5 SOL1 Pick-up Solenoid Energizes to press the pick-up lever against the stack of originals in preparation for original feed-in.
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1 December 1990 4. OVERALL MACHINE CONTROL Copier (PCB1) Interface (PCB6) Board Main Board DF Main Board (PCB1) Sensors Switches RXD TXD Solenoids Indicators CPU TXD RXD ROM Driver IC Belt Drive Motor Driver IC Feed-out Motor The DF CPU monitors the input signals from the sensors and switches, and energizes the solenoids and the indicator LEDs directly. The belt drive motor and the inverter motor are controlled by the DF CPU through their respective driver ICs.
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1 December 1990 1. DF → Copier No. Signal Name Definition 1 Original Set Originals are set on the original table 2 Copy Start Allows the copier to start copy sequence 3 Lift Up The DF is lifted 4 DF Misfeed Misfeed occurs in the DF 2. Copier → DF No.
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1 December 1990 5. BASIC OPERATION 1. One-sided Original Feed When an original is inserted face up into the DF, the Insert Original indicator light goes out and the DF informs the copier CPU that originals have been set. When the Start key is pressed, the copier CPU sends the feed-in signal to the DF. On receipt of this signal, the DF energizes the pick-up solenoid, the feed-in solenoid, and the belt drive motor in order to feed-in the bottom sheet of the original stack onto the exposure glass.
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1 December 1990 2. Two-sided Original Feed Unlike one-sided original feed, the back side of the original must be copied first to keep the originals and copies in the correct order. During original feed-in, the sequence is the same as for one-sided feed; however, the DF CPU also energizes the inverter motor and the inverter solenoid a short time after the original trailing edge has passed the DF registration sensor.
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1 December 1990 6. POWER DISTRIBUTION +24V AC Drive Board (PCB2) 115Vac Optional Transformer (TR2) 26Vac Optional DC Power Supply Board (PCB5) +24V (VA) Regulator IC 5V +5V (VC) 220/240Vac +12V 10Vac DF Main Board (PCB1) The DF uses three DC power levels: +24 volts, +12 V, and +5 V. When the main switch is turned on, the optional transformer receives the wall outlet ac power through the ac drive board and outputs 10 volts ac and 26 volts ac to the optional dc power supply board.
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1 December 1990 7. INTERFACE CIRCUIT Copier Main Board (PCB1) +5V +5V Interface Board (PCB6) CN133-A14 CN201-A14 CN133-B14 CN201-B14 DF Main Board (PCB1) CN206 CN106-4 CN201-A3 CN106-3 CN201-B3 CN133-A1 CN201-A1 CN133-B1 CN201-B1 RXD Fiber Optics TXD CPU CPU +5V RXD Fiber Optics CN106 TXD The copier CPU and the DF CPU communicate via the interface board and fiber optics. The interface board changes the optical signals to electrical signals (and vice versa).
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1 December 1990 8. ORIGINAL FEED 8.1 ORIGINAL PICK-UP [B] [C] [D] [A] [A] After setting the originals on the original table, the originals contact the feeler [A] of the original set sensor and cause the feeler to move out of the sensor. The DF then sends the original set signal to the copier CPU to inform it that the DF will be used. When the Start key is pressed, the pick-up solenoid [B] is energized. The original stack is then pressed between the pick-up lever [C] and pick-up roller [D].
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1 December 1990 8.2 ORIGINAL SEPARATION [B] [A] [B] [C] [A] The feed roller [A] and the friction belt [B] are used to feed-in and separate the originals [C]. Only the bottom original is fed because the friction belt prevents any other originals from feeding. Original feed starts when the feed roller starts turning and advances the bottom original of the stack.
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1 December 1990 8.3 ORIGINAL FEED-IN MECHANISM [E] [C] [D] [G] [B] [A] [F] The belt drive motor [A] drives the pick-up roller [B], the feed roller [C], the pull out roller [D], the relay roller [E], and transport belt [F] via a feed clutch and a gear train. The pick-up and feed-in solenoids are energized 100 milliseconds after the Start key of the copier is pressed. Then 100 milliseconds after the solenoids are energized, the belt drive motor starts turning.
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1 December 1990 This document feeder has two different ways of stopping originals at the correct position on the exposure glass. They are called the "thin original mode" and the "thick original mode". The mode used is determined by the original select switch [A]. [A] - Original Select Switch 1. Thin Original Mode The original is stopped at the correct position on the exposure glass based on encoder pulse count.
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1 December 1990 8.4 ORIGINAL SIZE DETECTION [B] [A] The DF determines original size (both width and length) through the use of the original width sensor [A], registration sensor, and pulse generator sensor [B]. The original’s length is calculated by counting the number of pulses from the pulse generator while the registration sensor is on. Original size detection is necessary for the feed-in/feed-out timing of the DF.
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1 December 1990 8.5 ORIGINAL INVERSION MECHANISM [D] [C] [E] [B] 1) [D] [A] The two sided originals are inverted in the feed-out unit. 1) When the copier Start key is pressed, the two sided original is fed into the feed-in unit, passing over the DF registration sensor [A]. The feed-out motor [B] and the inverter solenoid [C] turn on 100 milliseconds after the original trailing edge passes the registration sensor. When the inverter solenoid turns on, the inverter pawls [D] rotate counterclockwise.
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1 December 1990 2) 4) 3) 5) 6) 2) The original passes over the exposure glass and feeds into the feed-out unit. 3) The original is directed onto the exposure glass again by the inverter pawls. The belt drive motor now reverses 140 milliseconds after the feed out sensor [E] turns on. The transport belt then moves the original toward the left scale. Slightly before the original reaches the left scale, the belt drive motor drops to half speed.
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1 December 1990 8.6 ORIGINAL FEED-OUT MECHANISM [A] [D] [C] [B] The exit rollers [A] are driven by the inverter motor [B]. When the document feeder receives the feed out signal from the copier, the transport belt and the exit rollers start turning simultaneously. The transport belt carries the original to the inverter rollers [C] and the exit rollers take over the original feed-out.
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1 December 1990 8.7 BELT DRIVE MOTOR CIRCUIT DF Main Board (PCB 1) Speed Data PWM Driver IC CN102-1 Driver Circuit Belt Drive Motor ON/OFF CN102-2 CPU Forward/ Reverse +5V CN103-1 Phase A CN103-2 Phase B CN103-3 Encoder CN103-4 A dc servomotor is used as the belt drive motor. The driver IC controls the speed of the belt drive motor. The CPU sends the speed data (programmed) to the driver IC.
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1 December 1990 8.8 FEED-OUT MOTOR CIRCUIT DF Main Board (PCB 1) CN104-A2 FG AC Feedback CN104-A15 Voltage Regulation CPU High/Low Driver IC Motor Drive Circuit CN104-B8 CN104-A12 Feed-out Motor ON/OFF The DF CPU sends the speed data (high or low) to the driver IC and the motor drive circuit. The motor drive circuit creates the PWM signal and sends the motor drive pulses to the feed-out motor.
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1 December 1990 8.
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1 December 1990 9. LIFT MECHANISM [A] [C] [D] [B] [G] [C] [A] [B] [F] [E] When the document feeder is opened, the lift springs [D] provide enough force to ensure that the document feeder does not fall onto the exposure glass. When the document feeder is closed, points "A", "B", and "C" are aligned and no such force is provided to the document feeder. The lift switch [E] is actuated when the document feeder is closed. The copier then shifts to the document feeder mode.
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1 December 1990 10. ORIGINAL MISFEED DETECTION The registration sensor and the feed-out sensor are used for misfeed checks. 1. One sided original Registration Sensor ON check (685 ms) OFF check (1250 ms) Feed-out Sensor ON check (1250 ms) OFF check (1250 ms) Belt Drive Motor Feed-out Motor If the registration sensor is not actuated within 685 milliseconds after the belt drive motor starts turning, the Original Misfeed indicator lights (ON check).
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1 December 1990 2. Two sided original Registration Sensor (RS) RS ON check (685 ms) Feed-out Sensor (FS) RS OFF check (1250 ms) FS OFF check (1250 ms) 100 ms FS ON check (1250 ms) Inverter Solenoid Belt Drive Motor Forward Reverse Feed-out Motor The registration ON/OFF check is the same as for one-sided originals. The inverter motor and the inverter solenoid turn on 100 milliseconds after the registration sensor turns off.
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1 December 1990 11. INSTALLATION PROCEDURE (for Machine Code: A048) 11.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: 1. Original Table ........................................................................ 1 2. DF Mounting Bracket ............................................................. 1 3. Angle Stopper ........................................................................ 1 4. Lift Switch Actuator ..............................
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1 December 1990 11.2 INSTALLATION PROCEDURE [A] [D] [B] 1. Install the dc power supply unit. 2. Remove the following parts from the copier: 1) Platen cover [A] (2 push-locks) 2) Platen cover pedestal [B] (4 screws) 3) 2 screws [C] for fixing the operation panel. 3. Remove the harness cap [D] on the rear cover with nippers.
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1 December 1990 [C] [A] [C] a [B] [D] 4. Secure the DF mounting bracket [A] (4 screws). 5. Adjust the height of the DF mounting bracket as explained below: 1) Set the E plate [B] on the exposure glass as shown and measure the clearance "a" between the DF mounting bracket and the E plate with a scale. 2) Remove the DF mounting bracket and insert spacers [C] until the clearance "a" is between 0 mm and 0.3 mm. 6. Remove the strip of tape [D].
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1 December 1990 [B] [A] [C] [D] [E] [D] 7. Mount the DF on the DF mounting bracket so that the holes in the DF are aligned with the pins on the mounting bracket, then slide the DF to the left as shown. 8. Secure the DF to the DF mounting bracket (4 screws). 9. Secure the 2 stud screws [A] as shown. 10. Install the lift switch actuator [B] (1 screw). 11. Place the bushing [C] on the DF harness as shown in the figure. 12.
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1 December 1990 [A] [E] [B] [C] [D] [G] [F] 13. Connect the optic cable connector (2P/Black) [A] to CN206 on the interface board. 14. Connect the dc harness (4P/White) [B] to the optional harness connector [C]; then, connect the optional harness connector [D] to CN102 on the dc power supply unit. 15. Secure the grounding wire [E] to the right side plate. 16. Install the angle stopper [F] (2 screws). 17. Install the original table [G].
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1 December 1990 DIP SW101 [A] [B] [D] [C] 18. Adjust the height of the magnet catches as follows: 1) Remove the grip cover [A] (3 screws). 2) Loosen the screws of the magnet catches [B] (2 screws for each catch). 3) Close the document feeder and tighten the screws of the magnet catches when the rubber stopper [C] contacts the exposure glass. 19. Remove the DF main PCB cover [D] and turn off DIP switch 101-2. NOTE: Make sure that DIP switch 101-1 is on and the other switches (101-2, 3, and 4) are off.
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1 December 1990 5) Make a copy of the test sheet in DF two-sided original mode. NOTE: 1. The test sheet must be set facedown. 2. The original select switch can be set at any position. 6) Compare the registration of the copy in platen mode with that of DF two-sided original mode, and confirm that the difference is within 2.0 mm. 7) If the difference is more than 2.0 mm, remove the DF main PCB cover and adjust VR103 to change the original-stop timing. NOTE: 1.
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1 December 1990 12. PREPARATION FOR TRANSPORTATION CAUTION: Before moving the document feeder, be sure to prepare it for transportation as follows. The document feeder may be badly damaged if it is moved without proper preparation. [A] [B] [B] 1. Remove the original table [A]. 2. Secure the document feeder with strips of tape [B] as shown in the illustration.
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1 December 1990 13. REPLACEMENT AND ADJUSTMENT 13.1 FEED-IN UNIT 13.1.1 Transport Belt Replacement [A] [D] [C] [B] 1. Turn off the main switch and remove the grip [A] (3 screws). 2. Remove the DF main PCB cover [B] (1 screw, 1 connector). 3. Open the entrance guide [C] and remove the transport belt assembly [D] (5 screws).
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1 December 1990 [C] [B] [A] 4. Remove the 2 tension springs [A] and pull off the transport belt [B]. NOTE: a) When installing the transport belt, make sure the belt lies between the belt guide spacers [C]. b) When installing the transport belt assembly, make sure the positioning pin correctly fits in the DF frame, and hold open the exit guide to prevent the mylar strip from becoming damaged.
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1 December 1990 13.1.2 Feed-in Unit Removal [B] [A] 1. Turn off the main switch. 2. Remove the transport belt assembly. (See Transport Belt Replacement.) 3. Remove the belt drive motor cover [A] (4 screws). 4. Remove the feed-in unit [B] (4 screws, 8 connectors).
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1 December 1990 13.1.3 Pick-up Roller Replacement* [A] [B] [C] [D] 1. Turn off the main switch. 2. Remove the feed-in unit. (See Feed-in Unit Removal.) 3. Remove the lower entrance guide [A] (2 screws). 4. Remove the original set sensor assembly [B] (1 screw, 1 connector). 5. Remove the pick-up roller [C] (3 E-rings, 1 bushing, 1 gear). NOTE: a) Be careful not to loose the pin [D]. b) When installing the roller, make sure the positioning pin is correctly inserted in the cut-out of the roller.
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1 December 1990 13.1.4 Feed-in Clutch Lubrication [B] [D] [C] [A] 1. Turn off the main switch. 2. Remove the original set sensor assembly. (See Pick-up Roller Replacement.) 3. Remove the feed-in solenoid lever spring [A]. 4. Remove the pick-up roller assembly [B] (2 E-rings, 2 bushings). 5. Disassemble and lubricate the feed clutch [C] (1 E-ring) with Mobil Temp. 78. NOTE: a) Be careful not to loose the pin [D].
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1 December 1990 13.1.5 Pick-up Solenoid Adjustment [B] [F] [E] [C] [D] [A] 1. Turn off the main switch. 2. Place several sheets of paper [A] over the exposure glass area. 3. Lower the feed-in unit (See Feed-in Unit Removal) without disconnecting the eight connectors. 4. Turn on the main switch. NOTE: When the main switch is turned on, the DPS101 setting on the DF main PCB must be as follows: 1 = ON 3 = OFF 2 = ON 4 = OFF This is so that the initial check sequence can take place.
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1 December 1990 5. Turn off DPS101-1 and 2, then turn on DPS101-3 and 4 [B]. 6. Loosen the screw fixing the pick-up solenoid [C]. 7. Place the 0.15 mm thickness gauge [D] between the plunger and the solenoid. 8 While holding the solenoid, press SW101 [E] on the DF main PCB to engage all DF solenoids. 9. Holding the solenoid securely, move it slowly towards the left, until the plunger is attracted to the solenoid. Just at this point, tighten the screw.
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1 December 1990 13.1.6 Feed Roller Replacement - [C] [A] [B] 1. Turn off the main switch. 2. Remove the lower entrance guide. (See Pick-up Roller Replacement.) 3. Loosen the front bracket [A] (2 screws). 4. Release the feed roller shaft [B] from the front bracket (1 E-ring, 1 bearing). 5. Remove the feed roller [C] (3 E-rings, 1 side roller, 1 pull-out roller). NOTE: a) Take care not to lose the pins.
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1 December 1990 13.1.7 Feed-in Solenoid Adjustment [B] [C] [A] [D] 1. Turn off the main switch. 2. Place several sheets of paper [A] over the exposure glass area. 3. Lower the feed-in unit (See Feed-in Unit Removal) without disconnecting the eight connectors. 4. Check that DPS101 is set for the normal mode (1 = ON, 2 = ON, 3 = OFF, 4 = OFF). 5. Turn on the main switch. 6. Turn off DPS101-1 and 2, then turn on DPS101-3 and 4 [B]. 7. Loosen the 2 screws securing the feed-in solenoid [C]. 8.
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1 December 1990 13.1.8 Friction Belt Replacement [A] [B] [D] [C] 1. Turn off the main switch. 2. Remove the seal cover [A] on top of the DF cover. 3. Remove the friction belt assembly [B] (1 screw). 4. Remove the friction belt [C] (2 springs, 1 pin). NOTE: a) When installing the friction belt assembly, make sure the friction roller [D] is set in the correct position (See illustration). b) If the seal cover becomes dirty or deformed, replace it with a new one.
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1 December 1990 13.2 FEED-OUT UNIT 13.2.1 Feed-out Unit Removal [A] [C] [B] 1. Turn off the main switch. 2. Remove the DF grip [A] (3 screws). 3. Remove the feed-out motor cover [B] (4 screws). 4. Remove the feed-out unit [C] (4 screws, 3 connectors).
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1 December 1990 13.2.2 Inverter Solenoid Adjustment [A] [B] [C] [D] 1. Turn off the main switch. 2. Place several sheets of paper [A] over the exposure glass area. 3. Lower the feed-out unit (See Feed-out Unit Removal) without disconnecting the three connectors. 4. Check that the DPS101 is set for the normal mode (1 = ON, 2 = ON, 3 = OFF, 4 = OFF). 5. Turn on the main switch. 6. Turn off DPS101-1 and 2, then turn on DPS101-3 and 4 [B]. 7. Loosen the screw securing the inverter solenoid [C]. 8.
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1 December 1990 13.2.3 DF Leading Edge Registration Adjustment [A] 1. Using the DF test chart, make a copy in the platen cover mode (A4 width). 2. Confirm that the original select switch [A] is in the thin mode and again using the test chart, make a copy in the DF mode (A4 width). 3. Compare the leading edge registration of both copies, and check that the difference between the two copies is within 2.5 mm.
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1 December 1990 4. If the difference is more than 2.5 mm, remove the DF main PCB cover (1 screw) and adjust VR102 on the DF main PCB until the leading edge registration is within specification. NOTE: Turning VR102 clockwise results in stopping the original later. 5. Using the DF test chart, make a copy in the DF two sided-original mode. (Insert the original face down.) 6.
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1 July 1991 13.3 BELT DRIVE MOTOR SPEED ADJUSTMENT Normal Setting [A] [B] [C] NOTE: The belt drive speed adjustment is required when the main board is replaced. 1. Turn off the main switch. 2. Check that DIP switch 101 is set for the normal setting as follows: 101-1 101-2 101-3 101-4 ON OFF OFF OFF 3. Turn on the main switch and DIP switch 101-2 and -4. 4.
PAGE 384
SECTION 9 SORTER
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1 December 1990 1. SPECIFICATIONS Number of Bins: 10 bins Paper Size for Bins: Maximum Minimum Paper Weight: 64 to 90 g/m2 (17 to 24 lb) Bin Capacity: Sort/Stack Mode Top Bin Capacity: (Non-Sort/Stack Mode) 100 sheets (all sizes) Power Source: +5 volts and +24 volts from the copier Power Consumption: 7.7 W Dimensions: (W x D x H) 440 mm x 391 mm x 367 mm (17.3" x 15.4" x 14.4") Weight: 7.5 kg (16.5 lb).
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1 December 1990 2. COMPONENT LAYOUT — Mechanical Components — 1 3 4 2 1. Bin 2. Transfer Wheel 3. Exit Roller 4. Upper Paper Guide 5. Lower Paper Guide 6. Bin Guide 6 5 — Electrical Components — 1 2 3 4 6 7 5 1. Sorter Main Board 2. Paper Sensor 3. Wheel Switch 4. Roller Drive Motor 5. Sorter Switch 6. Bin Drive Motor 7.
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1 December 1990 3. ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Location Motors M1 Roller Drive Motor DC motor that energizes to drive the lower exit rollers. 4 M2 Bin Drive Motor Reversible DC motor that energizes to move the bins up or down. 6 SW1 Wheel Switch Detects the rotation of the transfer wheel and stops it in the correct position. 3 SW2 Sorter Switch Reed switch that becomes activated when the sorter is in the proper position (aligned next to the copier).
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1 December 1990 4.
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1 December 1990 5. BASIC OPERATION - Clear Mode When the main switch of the copier is turned on, the sorter automatically assumes the clear mode. In this mode, all copies are stacked on the first bin. The sorter also assumes the clear mode when either the interrupt mode or the manual feed mode is selected. Sorter operation begins when a copy actuates the copier exit sensor. At this time, the roller drive motor energizes.
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1 December 1990 6. EXIT ROLLER DRIVE 6.1 ROLLER DRIVE MECHANISM [A] [I] [D] [J] [F] [K] [L] [C] [G] [H] [B] [L] F: G: H: I: J: K: L: [H] [E] Transfer Wheel Bin Drive Belt Bin Drive Pulley Exit Roller Pulley Upper Paper Guide Lower Paper Guide Roller Drive Motor Pulley The exit rollers [A] take over paper transport from the copier. When the copy paper actuates the copier exit sensor, the exit rollers start rotating.
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1 December 1990 6.
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1 December 1990 7. BIN DRIVE 7.1 BIN DRIVE MECHANISM [D’] [B’] [E] [G] [D] [B] [F] G: H: I: [A] [C] [E] [G] [H] Exit Roller Upper Paper Guide Lower Paper Guide The bin drive mechanism moves the bins up and down to receive copies under the direction of the copier CPU. The main components in this mechanism are the bin drive motor [A], two transfer wheels [B,B’], the wheel switch [C], and the bins themselves.
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1 December 1990 The home position switch [E] informs the CPU when all the bins are lowered. [B] To move the bins up, the bin drive motor turns clockwise (as viewed from the front). A timing belt [F] turns the transfer wheels. [J] [C] OFF The transfer wheels have two slots in them 180 degrees apart. As the transfer wheels turn, these slots engage the bins and lift them up. Each time the transfer wheels turn 180 degrees, they raise one bin.
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1 December 1990 7.
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1 December 1990 8. MISFEED DETECTION J1 J2 2942 J1 J2 2942 Paper Sensor 2.75 sec ((A4 sidewise) 2.80 sec (LT sidewise) 2.75 sec (A4 sidewise) 2.80 sec (LT sidewise) In addition to being used for the exit roller and bin drive timing, the paper sensor checks for a misfeed in the sorter. The copier CPU checks whether the paper sensor is actuated within 942 pulses (3.8 seconds) after the registration clutch turns on (at 2,000 pulses).
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1 December 1990 9. INSTALLATION PROCEDURE 9.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: 1. Magnet Catch ......................................................... 1 2. Sorter Holder Bracket ............................................. 1 3. Sorter Holder Bracket Cover .................................. 1 4. Philips Pan Head Screw - M4 x 8 ........................... 8 5. Philips Pan Head Screw - M4 x 8 ........................... 1 6.
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1 December 1990 9.2 INSTALLATION PROCEDURE [B] [A] [C] [F] [D] [H] [G] [E] NOTE: Do not grasp the sorter by the top cover and stay as shown by [A]. Hold both sides of the sorter as shown by [B]. This is to prevent anti-static brush [C] damage. 1. Turn off the main switch and unplug the power supply cord of the copier. 2. Remove the strips and styrofoam blocks [D]. 3. Remove the receiving tray [E]. 4. Remove the caps [F] on the upper left side cover with the pliers. 5.
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1 December 1990 [B] [C] [D] [A] [E] [F] 6. Install the sorter holder bracket [A] (3 screws) so that the two holes [B] on the bracket align with the holes [C] on the copier frame as shown. 7. Install the optional DC Power Supply Unit. (See the installation procedure enclosed with the unit.) 8. Install the sorter [D] on the sorter holder bracket (1 snap ring) as shown. 9. Install the sorter harness bracket [E] with the harness (1 screw). 10.
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1 December 1990 [E] [D] [C] [F] [B] [A] 12. Connect the sorter dc harness [A] (10P/Brown) to the optional harness connector [B]; then, connect the optional harness connector [C] to CN203 on the interface board [D]. 13. Connect the dc harness [E] (3P/White) to CN103 on the main dc power supply unit. 14. Secure the grounding wire [F] (1 screw and toothed washer) on the bottom plate as shown. 15. Plug in the copier power supply cord. 16.
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1 December 1990 10. PREPARATION FOR TRANSPORTATION CAUTION: When removing and transporting the sorter, be careful not to carry it in a vertical position as the bins will become dislocated. CAUTION: Before moving the sorter, be sure to prepare it for transportation as follows. The sorter may be badly damaged if it is moved without proper preparation. 1. If the bins are not at the home position, turn on the main switch of the copier to move the bins to the home position. 2.
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1 December 1990 11. ROLLER DRIVE BELT REPLACEMENT [C] [D] [E] [B] [F] [H] [A] [J] [I] [G] [K] [M] [L] 1. Remove the front covers [A] (5 screws) and rear cover [B] (2 screws). 2. Lift off the top cover [C] and remove the top stay [D]. NOTE: Be sure that the discharge brush on the top stay is facing the exit side of the sorter when reinstalling it. 3. Lift the upper paper guide [E] up and out of position. 4.
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1 December 1990 12. BIN GUIDE LUBRICATION A B A B C B C B C B C [A] Grease 501 C Grease 501 [B] [B] 1. Remove the lower paper guide. (See Roller Drive Belt Replacement section.) 2. Remove all bins [A] from the bin guides [B]. 3. Apply Grease 501 to the grooves of the bin guides. NOTE: There are three kinds of bins. Therefore, when installing the bins, be sure that they are installed in the correct order.
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SECTION 10 DUPLEX
PAGE 404
1 December 1990 1. SPECIFICATIONS Copy Paper Size: A4 and B5/8 1/2" x 11" (sideways) Paper Weight: 59 to 104 g/m2 (16 to 27 lb) Paper Stack: 50 sheets Dimension (W x D x H): 516 x 529 x 90 mm (20.4" x 20.9" x 3.6") Weight: Approximately 5 kg (11 lb) • Specifications are subject to change without notice.
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1 December 1990 2. COMPONENT LAYOUT — Mechanical Components — 1 2 8 3 5 7 6 4 9 11 1. Duplex Gate Roller 2. Duplex Gate 3. Turn Guide Plate 4. Transport Roller 5. Entrance Roller 6. Paper End Feeler 10 7. Paper Flattener 8. Duplex Feed Roller 9. Friction Roller 10. Duplex Bottom Plate 11. Jogger Fences — Electrical Components — 4 3 5 2 6 1 7 8 1. Main Board 2. Jogger Motor 3. Jogger HP Sensor 4. Duplex Gate Solenoid 5. Duplex Entrance Sensor 6. Duplex Paper End Sensor 7. Duplex Turn Sensor 8.
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1 December 1990 3. ELECTRICAL COMPONENT DESCRIPTION SYMBOL NAME FUNCTION INDEX NO. Motors M1 Duplex Feed Motor Stepper motor (24 Vdc) drives feed roller and moves the bottom plate up and down. 8 M2 Jogger Motor Stepper motor (24 Vdc) drives the jogger fences to square the paper stack on the duplex tray. 2 Duplex Gate Solenoid Moves the duplex gate to direct copies to the duplex tray or to the paper exit. 4 S1 Duplex Entrance Sensor Detects copy at the entrance.
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1 December 1990 4.
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1 December 1990 5. BASIC OPERATION [A] [G] [B] [F] [E] [C] [D] 5.1 FIRST SIDE COPY When the registration clutch turns on, the duplex gate [A] rotates up to direct the copy to the duplex unit. The entrance roller [B] and duplex feed roller [C] then start to rotate. At the same time, the duplex bottom plate [D] lowers. 5.2 DUPLEX STACKING After the copy is delivered to the duplex tray [E], the jogger fences [F] move inward to square the copy stack, then move back 10 mm.
PAGE 409
1 December 1990 6. DRIVE MECHANISM [B] [A] [C] [D] [E] [F] Drive is transmitted from the duplex feed motor [A] to the duplex feed rollers [B] and the entrance rollers [C] through a series of gears. A relay gear in the copier exit section transmits drive to the duplex gate rollers [D] through the duplex transport gear [E]. A rubber belt on the end of the duplex gate roller shaft drives the transport rollers [F]. The duplex feed motor also drives the duplex bottom plate up and down.
PAGE 410
1 December 1990 7. FIRST SIDE COPY 7.1 FROM COPIER PAPER FEED SECTION TO DUPLEX ENTRANCE ROLLER [B] [C] [D] [A] [E] When the copier 1st paper feed clutch turns on, the jogger motor turns on and drives the three jogger fences into position 10 mm from the edges of the copy paper. (This position is determined by cassette coding.) The registration clutch then turns on and the duplex gate solenoid [A] energizes to raise the duplex gate [B].
PAGE 411
1 December 1990 7.2 FROM DUPLEX ENTRANCE ROLLER TO DUPLEX TRAY [B] [H] [G] [F] [E] [B] [A] [D] [C] 300 milliseconds after the duplex gate solenoid energizes, the duplex paper feed motor [A] starts turning counterclockwise (front view). Gears drive the duplex feed rollers [B] clockwise and the cam clutch [C] counterclockwise (front view). The cam clutch rotation lowers the duplex bottom plate [D].
PAGE 412
1 December 1990 7.3 DUPLEX STACKING [B] [A] 2,150 milliseconds after the duplex turn sensor is actuated by the leading edge of the copy, the jogger motor [A] rotates to drive the jogger fences [B] inward to square the paper stack, then the fences move back 10 mm. After the last copy of the first side copying run enters the duplex tray, the fences remain against the stack.
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1 December 1990 8. SECOND SIDE COPY [B] [G] [I] [J] [C] [F] [A] [H] [E] [D] 2,350 milliseconds after the duplex turn sensor is actuated by the leading edge of the final copy in the first side copy run, the duplex feed motor [A] reverses direction and rotates clockwise (front view), rotating the duplex feed roller [B] counterclockwise (front view). This moves the flip mylar [C] back to the right (front view).
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1 December 1990 9. DUPLEX PAPER FEED AND MISFEED DETECTION TIMING Timing Pulse (4 m sec/pulse) 0 1750 2000 2500 3000 3500 4000 4500 5000 Start Key Main Motor 1750 1st Feed Clutch Registration Clutch 1750 2000 2000 50 m sec 1750 Jogger Motor 3110 3110 J1 Duplex Entrance Sensor Duplex Turn Sensor J1 3425 J2 J3 3425 J3 J2 2000 2100 m sec Duplex Gate Sol.
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1 December 1990 10. SERVICE CALL CONDITIONS Service Code 80: Duplex and Copier Main Board Communication Error The copier main board does not receive any signal from the duplex main board. Service Code 81: Interface Board Error The interface board is not connected when the duplex unit is installed. Service Code 82: Jogger Home Position Error The output of the jogger home position sensor remains LOW as the duplex main board is driving the jogger fences outward.
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1 December 1990 11. DUPLEX UNIT INSTALLATION 11.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: 1. Turn Guide Plate ..................................................................... 1 2. Roller ....................................................................................... 3 3. Connector Bracket ................................................................... 1 4. Shoulder Screw ................................................
PAGE 417
1 December 1990 11.2 INSTALLATION PROCEDURE [A] [B] [C] 1. Turn off the main switch and unplug the copier power supply cord. 2. Install the dc power supply unit. 3. Remove the strips and styrofoam blocks [A]. 4. Open the exit unit [B] and remove it (2 screws). 5. Remove the fusing bottom plate [C].
PAGE 418
1 December 1990 [A] [A] [B] [B] [C] [C] [D] [D] [E] 6. Remove the exit paper guide [A] (1 screw), and remove the stubs [B] with nippers and reinstall the exit paper guide. 7. Remove the upper paper guide [C] on the exit unit (2 screws) and remove the stubs [D] with nippers. 8. Install the three rollers [E] on the exit unit as shown. 9. Reinstall the upper paper guide plate [C] on the exit unit.
PAGE 419
1 December 1990 [A] [B] [C] [D] 10. While pushing up the duplex gate lever [A], install the turn guide plate [B] (2 screws). 11. Reinstall the exit unit (2 screws). 12. Remove the paper tray from the copier if it is installed. 13. Remove the power supply cord bracket [C] (2 screws). 14. Remove the tray lock solenoid bracket [D] (1 screw).
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1 December 1990 [A] [D] [C] [B] [E] 15. Remove the duplex connector cover plate [A] (2 screws). NOTE: The cover plate can be thrown away. 16. Secure the optional harness duplex connector (8P/Black) [B] to the connector bracket [C] (2 screws). NOTE: When installing the bracket, make sure that the cut-out [D] on the bracket faces up as shown. 17. Secure the connector bracket to the rear frame (2 shoulder screws). NOTE: Make sure that the duplex harness [E] does not interfere with lock solenoid movement.
PAGE 421
1 December 1990 [B] [A] [C] [D] [E] 19. Connect the optional harness connector (4P/Black) [A] to CN205 on the interface board [B]. 20. Connect the dc harness (4P/White) [C] to CN101 on the optional dc power supply unit. 21. Reinstall the rear cover (2 screws). 22. Insert the duplex unit into the copier. 23. Plug in the copier power supply cord and turn on the main switch. 24. Check the operation of the duplex unit. 25. Attach the tray cover [D] on the paper tray [E] as shown.
PAGE 422
1 December 1990 12. REPLACEMENT AND ADJUSTMENT 12.1 DUPLEX TRAY REMOVAL [C] [B] [A] [I] [F] [D] [E] [F] [H] [G] 1. Pull the duplex tray [A] out from the copier. 2. Remove the side inner cover [B] (3 screws). 3. Remove the front inner cover [C] (2 screws). 4. Unhook the pressure spring [D] from the paper lift arm [E] and the eccentric cam. 5. Remove the clamps [F] with a pair of plyers. 6. Disconnect CN702, CN704, and CN706 [G] from the main board. 7.
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1 December 1990 [C] [E] [D] [H] [B] [G] [A] [F] - Installation 1. When placing the duplex unit back into the tray, hold up the bottom plate [A] so that the mylar brackets [B] fit under it as shown. 2. Hook the pressure spring [C] to the eccentric cam [D] and the paper lift arm [E] as shown. NOTE: When installing the duplex unit, make sure of the following: a) Positioning pin [F] fits through hole [G] in the side plate.
PAGE 424
1 December 1990 12.2 JOGGER MOTOR AND JOGGER HOME POSITION SENSOR REPLACEMENT [D] [E] [B] [C] [A] 1. Remove the duplex tray. 2. Remove the front and side inner covers. - Jogger Motor Replacement 3. Disconnect CN705 [A] from the duplex main board. 4. Replace the jogger motor [B] (2 screws). - Jogger Home Position Sensor Replacement 3. Disconnect the sensor connector [C]. 4. Remove the sensor bracket [D] (1 screw). 5. Remove the sensor [E] from the bracket and replace it (1 screw).
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1 December 1990 12.3 TURN SENSOR REPLACEMENT [A] [C] [B] [D] 1. Remove the duplex tray. 2. Raise the upper and lower paper guides [A] all the way up. 3. Disconnect the turn sensor connector [B]. 4. While lifting the sensor actuator [C], remove the sensor [D] (1 screw).
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1 December 1990 12.4 FEED MOTOR REPLACEMENT [B] [C] [A] 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Remove the paper feed motor bracket [A] (2 screws). 3. Replace the feed motor [B] (2 screws). NOTE: When installing the paper feed motor, make sure that the bushing [C] is properly positioned between the bracket and the motor as shown.
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1 December 1990 12.5 PAPER END SENSOR REPLACEMENT [B] [C] [A] 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Remove the paper end sensor bracket [A] (1 screw). 3. Disconnect the sensor connector [B]. 4. Replace the sensor [C] (1 screw).
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1 December 1990 12.6 ENTRANCE SENSOR REPLACEMENT [C] [[A] [B] 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Turn over the duplex unit as shown. 3. Remove the entrance sensor bracket [A] (1 screw). 4. Disconnect the sensor connector [B]. 5. Replace the sensor [C].
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1 December 1990 12.7 GATE SOLENOID REPLACEMENT [D] [C] [A] [B] [E] 1.Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Replace the gate solenoid [A] (1 screw). NOTE: When installing a new solenoid, make sure of the following: a) Positioning pin [B] fits into the hole [C] on the gate solenoid actuator. b) Spring [D] is hooked to bracket [E].
PAGE 430
1 December 1990 12.8 FRICTION ROLLER REPLACEMENT [A] [B] [C] [D] 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Turn over the duplex unit as shown. 3. Unhook the springs [A] from the roller bracket [B]. 4. Remove the lock pin [C] and the roller assembly. 5. Remove the roller [D] (1 snap-ring and shaft) from the bracket and replace it. NOTE: This friction roller has a one-way clutch. Be sure to install the roller so that it rotates in the direction of the arrow. (See illustration.
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1 December 1990 12.9 FEED ROLLER REPLACEMENT [F] [G] [G] [M] [C] [G] [A] [L] [B] [K] [J] [I] [H] 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Remove the feed motor. (See Feed Motor Replacement.) 3. Remove the drive gear [A] (1 E-ring) and three idle gears [B] (1 parallel pin [C]). 4. Remove the E-ring [D] and the upper paper guide plate stopper [E] (1 shoulder screw). 5. Remove the upper and lower guide paper plates [F]. 6. Remove the paper end feeler shaft [G] (1 E-ring).
PAGE 432
POINTS OF MODEL E TYPE 1 SERVICEABILITY 1. Access to service program mode operation • There are two ways to access an SP mode. (1) By key operation (2) By turning on DIP SW101-4 on the main board • All the SP modes except for the following SP modes can be accessed simply by key operation. a. SP #27 A3 (DLT) Double Count b. SP #98 Clear Counters c. SP #99 Clear All Memory 2.
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SECTION 11 FT4421 SERVICE MANUAL In this section, the FT4418 is referred to as the A048 copier, and the FT4421 is referred to as the A054 Copier.
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1 December 1990 1.
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1 December 1990 Automatic Reset: 1 minute standard setting; can also be set to 3 minutes or no auto reset. Paper Capacity: Cassette: 500 sheets Paper tray: 250 sheets Manual feed table: 50 sheets Toner Replenishment: Black: Cartridge exchange (370g/cartridge) Color (red, blue, & green): Cartridge exchange (310g/cartridge) Copy Tray Capacity: 250 sheets (B4/8 1/2" x 14" and smaller) 100 sheets (A3/11" x 17") Power Source: 110V/ 60Hz/ 15A (for Taiwan) 115V/ 60Hz/ 15A (for N.A.
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1 December 1990 2. OPERATION PANEL — A4/A3 Version — C B A — LT/LDG Version — C B Section A: See page 11-4. Section B: See page 1-5 or 1-6. Section C: See page 1-7 or 1-8.
PAGE 437
1 December 1990 Section A — — A4/A3 Version — 1 2 8 — LT/LDG Version — 3 4 1 2 4 3 5 5 6 6 8 7 7 1. Number Keys The number keys are used to enter the desired number of copies. They are also used to input the sizes of the original and the copy image when in size magnification mode. 5. Interrupt Indicator Lights when interrupt mode is selected. 2. Recall/Enter Key Press to display the number of copies entered. Also use to enter or change data when in size magnification mode. 7.
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1 December 1990 3.
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1 December 1990 4. MECHANICAL COMPONENT LAYOUT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 33 32 17 18 31 30 19 29 28 27 26 25 1. Third Mirror 2. Second Mirror 3. First Mirror 4. Exposure Lamp 5. Ozone Filter 6. Cleaning Unit 7. Lens 8. Quenching Lamp (QL) 9. Charge Corona Unit 10. Sixth Mirror 11. Erase lamp (EL) 12. OPC Drum 13. Development Unit 14. Toner Supply Unit 15. Optics Cooling Fans 16. Feed Roller 17. Manual Feed Table 18. Pick-up Roller 24 23 11-6 21 20 22 19.
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1 December 1990 5.
PAGE 441
1 December 1990 A Paper Feed Section BP3: Timing Belt Pulley G11: Registration CL Gear G4: Relay Gear Registration CL G5: Relay Gear G12: Relay Roller CL Gear Relay Roller CL Registration Roller 1st Paper Feed CL G6: 1st Paper Feed CL Gear 1st Paper Feed CL G7: Relay Gear 1st Paper Feed Rollers G8: Paper Lift CL Gear Paper Lift CL G9: Paper Lift Gear G10: Sector Gear 2nd Feed Station Upper Relay Roller G13: Upper Relay Roller Gear 3rd Feed Station G14: Relay Gear BP4: Timing Belt Pulley G1
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1 December 1990 6. ELECTRICAL COMPONENT LAYOUT 1 2 36 3 35 4 5 34 6 7 8 33 32 9 31 10 11 12 13 14 30 29 28 27 26 17 25 24 20 23 22 19 15 16 18 21 20. Relay Sensor 21. Registration Sensor 22. Total Counter 23. Drum Anti-condensation Heater 24. Pre-transfer Lamp (PTL) 25. Transfer and Separation Corona Unit 26. Erase Lamp (EL) 27. ID Sensor 28. Charge Corona Unit 29. Quenching Lamp (QL) 30. Fusing Lamp 31. Fusing Thermister 32. Fusing Thermofuse 33. Auto ID Sensor 34.
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1 December 1990 39 40 38 41 37 42 73 43 44 72 45 71 46 70 69 47 68 67 66 65 63 48 49 61 50 64 56 53 62 55 60 59 54 51 57 52 58 37. 4th/5th Mirror H.P. Sensor 38. Optics Cooling Fan Motors 39. Original Length Sensor 40. Platen Cover Closed SW 41. Operation Panel Board 42. Optics Thermoswitch 43. Exposure Lamp 44. Original Width Sensor 45. Cover Safety SW 46. Main SW 47. Exhaust Blower Motor 48. Main DC Power Supply Board 49. Option DC Power Supply Board 50. Main Transformer 51.
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1 December 1990 7. ELECTRICAL COMPONENT DESCRIPTIONS SYMBOL NAME FUNCTION INDEX NO. Motors M1 Main Motor Drives all the main unit components except for the optics unit and fans. (115/220/240Vac) 3 M2 Scanner Motor Drives the scanners (1st and 2nd). (dc stepper) 2 M3 Lens Motor Moves the lens position according to the selected magnification. (dc stepper) M4 4th/5th Mirror Motor Move the 4th/5th mirror position according to the selected magnification.
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1 December 1990 SYMBOL NAME FUNCTION INDEX NO. SOL9 3rd Paper Feed Clutch Solenoid Starts paper feed from the 3rd paper station. 64 SOL10 Lower Tray Lock Solenoid Locks the lower paper tray. 52 Switches SW1 Main Switch Supplies power to the copier. 46 SW2 Cover Safety Switch Cuts the ac power line. 45 SW3 1st Paper Size Switch Determines what size paper is in the cassette. 18 SW4 2nd Paper Size Switch-1 Determines what size paper is in the upper paper tray.
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1 December 1990 SYMBOL NAME FUNCTION INDEX NO. S3 4th/5th Mirror Home Position Sensor Informs the CPU when the 3rd scanner (4th/5th mirrors assembly) is at the home position (full size position). 37 S4 Registration Sensor Detects misfeeds. 21 S5 Exit Sensor Detects misfeeds. 35 S6 1st Paper End Sensor Informs CPU when the cassette runs out of paper. 17 S7 2nd Paper End Sensor Informs CPU when the upper paper tray runs out of paper.
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1 December 1990 SYMBOL NAME FUNCTION INDEX NO. PCB5 Option DC Power Supply Board Rectifies 26 and 10 Vac input and outputs dc voltasges. 49 PCB6 Interface Board Interfaces between the copier main board and all the optional equipment’s main board. 70 PCB7 Operation Panel Board Informs the CPU of the selected modes and displays the situations on the panel. 41 L1 Exposure Lamp Applies high intensity light to the original for exposure. 43 L2 Fusing Lamp Provides heat to the hot roller.
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1 December 1990 SYMBOL NAME FUNCTION INDEX NO. Others TH Fusing Thermistor Monitors the fusing temperature. 31 TF Fusing Thermofuse Provides back-up overheat protection in the fusing unit. 32 TS Optics Thermoswitch Provides back-up overheat protection around the exposure lamp.
PAGE 449
1 December 1990 8. OVERALL MACHINE CONTROL AC Power (115V or 220/240V) Cover Safety Switch Anti-condensation Heater -Drum -Optics Main Switch Operation Panel Board IC 123 CPU AC Drive Board Exhaust Blower Motor (L) Power Relay Fusing Lamp Fusing Lamp Drive Circuit Exposure Lamp Exposure Lamp Drive Circuit IC 124 I/O Main Motor Quenching Lamp Exhaust Blower Motor (H) Main Motor Relay IC 111 ROM IC 105 I/O Power Packs CC/Grid/Bias P.P. Charge Corona Grid Voltage Dev.
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1 December 1990 9.
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1 December 1990 The main dc power supply board converts the 10 volts ac input to +5 volts and a zero cross signal. There are two 26 volts ac inputs. The dc power supply board converts them to +24 volts and +30 volts. The +5 volts and +24 volts are supplied to both the copier main board and the sorter main board. The zero cross signal and +30 volts are supplied to the copier main board. The copier main board supplies dc powers to all copier dc components.
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1 December 1990 9.
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1 December 1990 9.
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1 December 1990 10. ORIGINAL SIZE DETECTION IN PLATEN MODE [C] [B] [D] [G] [F] [A] An original width sensor [A] and an original length sensor [B] are under the exposure glass [C]. The original width sensor consists of two reflective photosensors. The original length sensor consists of four reflective photosensors. While the main switch is on, these sensors are active and the CPU receives their output signals through the interface board.
PAGE 455
1 December 1990 The second check is done when the platen cover closed switch [E] turns on. This is when the platen cover (document feeder) is completely closed. The platen cover closed switch is a lead switch. A magnet [F] mounted on the platen cover (document feeder) actuates the lead switch. The second check is necessary to confirm that the original size detected at the first check is correct.
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1 December 1990 11. PAPER FEED AND MISFEED DETECTION TIMING Timing Pulse 0 (4m sec/pulse) Start Key 100 1500 2000 2500 3000 3500 4000 400ms Main Motor <1st Feed Station> 1st Feed Clutch 1750 100 1750 1877 Pick-up Roller Release Sol.
PAGE 457
1 December 1990 The registration sensor, the exit sensor and the relay sensor monitor the movement of the paper through the paper path. If the CPU determines that a misfeed exists, the Check Paper Path and the Misfeed Location indicators turn on. When the main switch is turned on, the CPU checks these three sensors for initial misfeed.
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1 December 1990 12. DOCUMENT FEEDER (Machine Code: A318) 12.
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1 December 1990 12.2 COMPONENT LAYOUT - Mechanical Components 2 3 4 5 6 1 10 9 7 8 1. Pulse Generator Disk 2. Friction Belt 3. Pick-up Lever 4. Original Table 5. Exit Roller 6. Inverter Pawl 7. Inverter Roller 8. Transport Belt 9. Pick-up Roller 10. Feed Roller - Electrical Components 4 6 5 7 3 8 9 2 1 10 14 1. Original Set Sensor 2. Registration Sensor 3. Pulse Generator Sensor 4. Original Width Sensor 5. Pick-up Solenoid 6. Belt Drive Motor 7. Indicator Panel 8.
PAGE 460
1 December 1990 12.3 ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Location Motors M1 Belt Drive Motor DC servomotor that drives to the transport belt and feed-in system (pick-up roller, feed roller, pull-out roller and relay roller). 6 M2 Feed-out Motor DC servomotor that drives the feed-out unit of the DF. 10 5 Solenoids SOL1 Pick-up Solenoid Energizes to press the pick-up lever against the stack of originals in preparation for original feed-in.
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1 December 1990 12.4 POWER DISTRIBUTION +24V AC Drive Board (PCB2) 115Vac Main Transformer (TR1) 26Vac 220/240Vac Option DC Power Supply Board (PCB5) +24V (VA) +5V (VC) +12V Regulator IC 5V 10Vac DF Main Board (PCB1) The DF uses three DC power levels: +24 volts, +12 volts, and +5 volts. When the main switch is turned on, the main transformer receives the wall outlet ac power through the ac drive board and outputs 10 volts ac and 26 volts ac to the option dc power supply board.
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1 December 1990 13.
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1 December 1990 14. INSTALLATION 14.1 INSTALLATION REQUIREMENTS 14.1.1 Environment 1. Temperature Range: 10oC to 30oC (50oF to 86oF) 2. Humidity Range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 lux. (Do not expose to direct sunlight.) 4. Ventilation: Room of more than 30 m3. Room air should turn over at least 3 times/hour. 5. Ambient Dust: Less than 0.15 mg/m3 (4 x 10-3 oz/yd3) 6. The machine must not be subjected to sudden temperature changes.
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1 December 1990 14.1.2 Machine Level 1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of level Place the machine on a table and screw the leveling feet up or down in order to level the machine. Use a leveling gauge if necessary. 14.1.3 Minimum Space Requirements 15 cm 10 cm 30 cm 60 cm 70 cm 30 cm 60 cm 70 cm 30 cm 1. Front: 70 cm (27.6") 2. Back: 10 cm (3.9") : 15 cm (6.0") (when the sorter is installed.) 3. Right: 60 cm (31.5") 4. Left: 30 cm (11.
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1 December 1990 14.1.4 Power Requirements 1. Input voltage level: 110V/60Hz : More than 15A (for Taiwan) 115V/60Hz : More than 15A (for N.A.) 220V/50Hz : More than 8A (for EU.) 220V/60Hz : More than 8A (for EU.) 240V/50Hz : More than 8A (for EU.) 2. Permissible voltage fluctuation: ±10% 3. Do not set anything on the power cord. NOTE: a) Be sure to ground the machine. (Do not connect the grounding wire to a gas pipe.) b) Make sure the plug is firmly inserted in the outlet. c) Avoid multiwiring.
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1 December 1990 14.2 INSTALLATION PROCEDURE 14.2.1 Introduction: This section covers only those parts of the copier and option installation procedures that differ from the A048.
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1 December 1990 14.2.2 Copier Installation [A] [B] [A] [C] [A] [H] [D] [F] [F] [E] [D] [G] [E] 1. Remove 11 strips of tape [A] from the copier. 2. Open the front cover [B], and remove 2 strips of tape [C]. 3. Pull out the paper tray [D] and remove the foam blocks [E] (strips of tape) and the silica gel [F]. On machines equipped with the duplex unit [G], pull out the duplex unit and remove the 2 strips of tape [H]. 4. Do steps 5 to 21 of the A048 copier installation procedure (page 3-5 to 9).
PAGE 468
1 December 1990 14.3 DOCUMENT FEEDER INSTALLATION 14.3.1 Accessory Check [B] [A] A DF position sensor actuator and a screw have been added as accessories for the APS function in platen mode, Also, a dc harness (connector [B]) for the APS function has been added to the DF harness assembly. (When the A318 DF is installed on the A048 copier, the above accessories are not necessary and the connector [B] is not used.
PAGE 469
1 December 1990 14.3.2 Installation Procedure [E] [A] [B] [C] [D] [H] [G] [F] 1. Remove the following parts from the copier: 1) Platen Cover [A] (2 push-locks) 2) Platen Cover Pedestal [B] (4 screws) 3) The 2 screws [C] securing the operation panel 4) Rear Cover [D] (7 screws). 2. Remove the harness caps [E] on the rear cover with a pair of nippers. 3. Remove the platen cover position sensor [F] (1 screw). 4.
PAGE 470
1 December 1990 [A] [F] [E] [G] [B] [H] [C] [D] 5. Do steps 4 to 10 of the installation procedure for the A048 copier (page 8-26 to 27). 6. Install the DF position sensor actuator [A] (1 screw). 7. Do steps 11 and 12 of the installation procedure for the A048 copier (page 8-27). 8. Connect the optics cable connector (2P/Black) [B] to CN206 on the interface board. 9. Connect the DC harness (4P/White) [C] to the harness connector [D]. 10.
PAGE 471
1 December 1990 14.4 SORTER INSTALLATION [D] [E] [C] [B] [A] NOTE: Refer to the list on page 9-12 to check the accessories. 1. Do steps 1 to 11 of the installation procedure for the A048 copier (page 9-13 to 14). 2. Connect the sorter dc harness [A] (10P/Brown) to the harness connector [B]. 3, Secure the grounding wire [C] (1 screw, toothed washer [D], and spring washer [E]) to the rear frame as shown. 4. Do steps 15 to 19 of the installation procedure for the A048 copier (page 9-15). 14.
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1 December 1990 15. 3RD PAPER FEED CLUTCH SOLENOID REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover (7 screws). 3. Unhook the spring [A] from the tension pulley bracket [B]. 4. Remove the drive belt [C] from the drive pulley [D]; then remove the pulley (1 E-ring). 5. Re move the 3rd paper feed clutch solenoid bracket [E] (2 E-rings and bushings and 3 screws). 6. Replace the 3rd paper feed clutch solenoid [F] (1 connector). NOTE: 1.
PAGE 473
DOCUMENT FEEDER ELECTRICAL COMPONENTS AND CONNECTORS LAYOUT 6 5 7 4 8 3 1 9 2 10 14 15 11 13 12 Document Feeder Electrical Components Index No.
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1 2 3 4 17 5 18 21 23 6 20 7 8 9 22 10 11 12 19 16 13 15 14 Document Feeder Connectors Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 CN No.
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1 36 2 35 3 4 5 6 34 7 8 33 32 9 10 31 30 11 29 12 28 13 27 14 17 26 18 25 19 24 23 20 22 21 16 15
PAGE 476
39 40 38 41 37 42 43 73 44 72 45 71 46 70 47 69 68 67 48 66 65 63 61 49 64 50 56 62 55 53 60 59 51 54 58 57 52
PAGE 477
Copier Electrical Components Index No. Description Symbol P to P 1 2 3 4 5 6 7 8 9 10 Scanner H.P. Sensor Scanner Motor Main Motor Development CL Sol. Toner Supply CL Sol. Toner End Sensor Pick-up Roller Release Sol. 4th/5th Mirror Motor Manual Feed Table SW Development Unit Set Sensor S1 M2 M1 SOL7 SOL1 S8 SOL4 M4 SW9 S12 O9 O11 A7 O17 O18 O7 O15 O12 O4 O8 11 12 13 14 15 16 17 18 19 20 Color Switch 1st Paper Feed CL Sol. Paper Lift CL Sol. Registration Clutch Relay Roller CL Sol.
PAGE 478
Index No. Description Symbol P to P 41 42 43 44 45 46 47 48 49 50 Operation Panel Board Optics Thermoswitch Exposure Lamp Original Width Sensor Cover Safety SW Main SW Exhaust Blower Motor Main DC Power Supply Board Option DC Power Supply Board Main Transformer PCB7 TS L1 S16 SW2 SW1 M7 PCB3 PCB5 TR1 G1 – G4 A9 A10 H21 B3, B4 C3 A6 F8 E8 E5 51 52 53 54 55 56 57 58 59 60 Upper Tray Lock Sol. Lower Tray Lock Sol.
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37 35 33 31 36 34 32 1 30 38 29 2 Main Board (PCB1) 3 28 27 26 24 39 4 45 5 25 46 44 23 40 6 7 43 Interface Board (PCB6) 22 41 8 42 9 10 11 13 12 21 19 14 15 16 17 18 20
PAGE 480
49 50 51 52 53 54 48 55 56 57 58 59 60 47 61 62 63 96 64 65 95 66 94 67 68 93 69 92 91 70 90 89 71 88 72 87 86 85 73 84 83 82 81 80 79 74 78 77 76 75
PAGE 481
99 98 100 101 102 103 97 104 105 106 107 108 109 137 110 111 112 113 136 114 115 135 116 134 117 118 119 133 120 121 132 131 122 130 129 123 124 128 127 125 126
PAGE 482
Copier Connectors Index No. CN No.
PAGE 483
Index No. CN No.
PAGE 484
Index No. CN No.
PAGE 485
CS110 (A490)
PAGE 486
PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of these parts on this machine. INDEX to PARTS CATALOG 1. EXTERIOR (A490) ................................................................................... 2 2. TRANSPORT (A490) .................................................................................. 4 3. SORTER MAIN BOARD (A490) ................................................................ 6 4. SORTER MAIN HARNESS (A490) ............................................
PAGE 487
1.
PAGE 488
1. EXTERIOR (A490) Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Part No.
PAGE 489
2.
PAGE 490
2. TRANSPORT (A490) Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Part No.
PAGE 491
December 1, '90 3.
PAGE 492
December 1, '90 3. SORTER MAIN BOARD (A490) Index No. * Part No. 6801 5510 Description Sorter Mian Board Q'ty per Assembly Index No. 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 1 7 Part No.
PAGE 493
4.
PAGE 494
December 1, '90 4. SORTER MAIN HARNESS (A490) Index No. * Part No. 6801 5600 Description Sorter Main Harness Q'ty per Assembly Index No. 101 102 103 104 105 106 107 108 109 110 111 1 9 Part No.
PAGE 495
December 1, '90 5.
PAGE 496
5. DECAL AND DOCUMENT (A490) Index No. 1 2 Part No. A490 7802 A490 7803 Description Misfeed Removal Decal Arrow Decal December 1, '90 Q'ty per Assembly Index No. 1 1 11 Part No.
PAGE 497
PARTS INDEX
PAGE 498
December 1, '90 Part No.
PAGE 499
December 1, '90 Part No.
PAGE 500
December 1, '90 Part No. 1103 1103 1103 1104 1105 1106 1107 1107 1107 1107 1204 1204 1400 1400 1400 1401 1401 1407 1407 1407 1408 1408 1601 1602 1604 1604 1606 1606 1611 1611 1611 1611 1611 1611 1611 1690 1732 1735 0307 0087 0366 0406 0406 0409 0409 1376 1376 0072 0135 0212 0325 0832 1607 1698 1807 0306 0408 7531 0934 1382 1488 1109 1336 4102 4121 4153 4222 4472 4473 6222 Description Connector - 10P Connector - 10P Connector - 13P Fuse Clip Clamp Cord Clamp Fuse - 250V,0.5A Fuse - 250V,0.
PAGE 501
DF57 (A318)
PAGE 502
PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of these parts on this machine. INDEX to PARTS CATALOG 1. EXTERIOR AND TRANSPORT SECTION (A318) .................................... 2 2. FEED IN SECTION (A318) ........................................................................ 5 3. INVERTOR AND EXIT SECTION (A318) .................................................. 8 4. MAIN BOARD (A318) .............................................................................. 11 5.
PAGE 503
December 1, '90 1.
PAGE 504
1. EXTERIOR AND TRANSPORT SECTION (A318) Index No. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Part No.
PAGE 505
Index No. Part No. 100 101 102 103 104 105 106 107 108 109 110 111 112 114 115 116 117 118 119 120 121 122 0314 0060W 0353 0050W 0413 0082W 0951 4005W 0584 0103W 0951 4006W 0951 3006B 0344 0060W 0801 1185 0720 0040E 0720 0050E 0720 0030E 0701 0060B 0632 0100G 0344 0600D 0313 0050W 0742 3906 0741 3806 1106 0222 1100 0340 0314 0050W 0315 0100W Description Q'ty per Assembly Index No.
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2.
PAGE 507
December 1, '90 2. FEED IN SECTION (A318) Index No. 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Part No.
PAGE 508
Index No. 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 200 201 202 Part No.
PAGE 509
3.
PAGE 510
3. INVERTOR AND EXIT SECTION (A318) Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Part No.
PAGE 511
Index No. Part No. 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 0951 4006W 0801 1185 0314 0060M 0313 0140W 0314 0060W 0951 3006W 0313 0060W 0313 0040W 0951 3010W 0720 0040E 0720 0030E 0720 0060E 0720 0025E 0704 0040C 0632 0100G 0633 0120G 0632 0080G 0701 0040B 1105 0009 1105 0011 1106 0430 1105 0199 1204 1319 1107 0413 0742 3905 0741 3505 0950 4006W Description Q'ty per Assembly Index No.
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4.
PAGE 513
December 1, '90 4. MAIN BOARD (A318) Index No. * 1 2 3 4 Part No. A465 5190 A422 5350 A465 5180 A465 5210 5936 5221 Description DF Main Board IC - HCTL-3 IC - D27128A-2 Fiber Connector - 2P Heat Sink Q'ty per Assembly Index No. 1 1 1 1 1 101 102 103 104 105 106 107 108 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 12 Part No.
PAGE 514
Index No. 137 138 139 140 141 142 143 144 145 146 147 148 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 Part No.
PAGE 515
December 1, '90 5.
PAGE 516
December 1, '90 5. INDICATION BOARD (A318) Index No. * Part No. A465 5260 Description Indication Board Q'ty per Assembly Index No. 1 101 102 103 104 105 106 15 Part No. 1100 1100 1102 1102 1403 1403 1306 1328 1805 1967 0236 0237 Description Terminal Contact Connector - 4P Connector - 6P L.E.D. - MU02-520 L.E.D.
PAGE 517
6.
PAGE 518
6. MAIN HARNESS (A318) Index No. * Part No. A318 5220 December 1, '90 Description Main Harness Q'ty per Assembly Index No. 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 119 1 17 Part No.
PAGE 519
December 1, '90 7.
PAGE 520
7. INTERFACE HARNESS (A318) Index No. * Part No. A318 5205 Description Interface Harness December 1, '90 Q'ty per Assembly Index No. 101 102 103 104 105 106 107 108 109 1 19 Part No.
PAGE 521
PARTS INDEX
PAGE 522
December 1, '90 Part No. A318 A318 A318 A318 A318 A318 A318 A318 A318 A318 A318 A318 A318 A318 A318 A318 1021 1090 1100 1119 1135 1184 1191 1300 1331 1498 1510 1530 5205 5205 5220 5220 Description Side Plate Side Roller Front Frame Left Hinge Bracket Magnet Catch Bracket Feed-out Motor Cover Mounting Bracket DF Upper Cover Grip Cover Belt Drive Motor Cover Rear Side Plate DF Halfway Sensor Actuator Interface Harness Interface Harness Main Harness Main Harness Paper and Index No. Part No.
PAGE 523
December 1, '90 Part No. A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 1068 1069 1071 1072 1073 1074 1075 1078 1078 1078 1079 1080 1082 1086 1087 1093 1103 1106 1107 1108 1112 1114 1120 1121 1130 1176 1177 1183 1185 1186 1187 1188 1210 1216 1217 Description Relay Roller Friction Roller Pull-out Lever Front Side Plate Release Spring Shoulder Screw - M4x2.
PAGE 524
December 1, '90 Part No. A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A422 A437 A437 A437 A437 1385 1390 1396 1501 1503 1504 1505 1506 1507 1600 1601 1602 1603 1603 1604 2030 5201 5202 5203 5204 5207 5208 5212 5252 5255 5255 5270 5270 5300 5310 5350 1026 1065 1115 1120 Description Paper and Index No. Original Exit Guide Entrance Seal Mylar - 0.125x14x45.
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December 1, '90 Part No.
PAGE 526
December 1, '90 Part No.
PAGE 527
December 1, '90 Part No.
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December 1, '90 Part No. 1601 1601 1602 1604 1604 1604 1604 1604 1604 1604 1604 1604 1605 1606 1606 1606 1606 1606 1606 1607 1610 1610 1610 1610 1610 1610 1610 1610 1610 1610 1610 1611 1611 1611 1611 8147 8148 0953 1358 1378 1379 1380 1381 1382 1383 1386 1390 0141 0658 1308 1326 1348 1451 1452 0116 0035 0047 0053 0057 0065 0067 0071 0073 0079 0107 0286 4103 4121 4229 4272 Description Variable Resistor - 10k Ω 0.5W Variable Resistor - 20k Ω 0.5W Coil - 800uH 2.
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P/N A0486684 FACTORY SETTING SP MODE NUMBER 41 42 43 44 47 48 SERIAL No.
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TEST POINTS Copier Main Board NUMBER FUNCTION TP101 GND TP102 VCC (+5V) TP103 ADS (Auto Image Density Sensor) Adjust the voltage to 2.5 ± 0.1 using VR101.) TP104 GND TP105 AVSS (GND) TP106 GND TP107 HT (23oC 96kΩ) TP108 BIN (Development Bias Feed Back) TP109 GIN (Grid Voltage Feed Back) TP110 PSE (ID sensor voltage) Adjust the voltage to 4.0 ± 0.2 using VR102. TP111 EXPO (Exposure Lamp Voltage) TP112 GND JP103 Key Counter (Cut this jumper wire when installing the key counter on the machine.
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DIP SWITCHES Copier Main Board DIP SWITCH NORMAL 101-1 101-2 OFF OFF 101-3 101-4 OFF OFF FUNCTION Free Run Forced Start (Ready temp. by-passed) Factory Use Clear Counter and/or memory Service Program modes access DF Main Board DIP SWITCH 101 1 2 3 4 ON OFF OFF OFF ON OFF OFF ON OFF ON OFF ON OFF OFF ON ON ON ON OFF ON ON ON ON ON FUNCTION Normal 1 sided free run 2 sided free run Solenoid test: Switch101 - solenoids ON Switch102 - solenoids OFF Motor test (lift switch must be ON.
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Data Table DIP SWITCH 700 (0:OFF, 1:ON) 1 2 3 4 0 0 0 0 1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 0 1 0 1 0 0 1 1 0 1 1 1 0 0 0 0 1 1 0 0 1 0 1 0 1 1 1 0 1 0 0 1 1 1 0 1 1 0 1 1 1 1 1 1 1 ADJUSTMENT VALUE -3.5mm -3.0mm -2.5mm -2.0mm -1.5mm -1.0mm -0.5mm ±0 0.5mm 1.0mm 1.5mm 2.0mm 2.5mm 3.0mm 3.5mm 4.
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VARIABLE RESISTORS Copier Main Board NUMBER FUNCTION VR101 Adjusts ADS Voltage (2.5 ± 0.1) VR102 Adjusts ID Sensor Voltage (4.0 ± 0.2) Power Pack (CC/Grid/Bias) NUMBER FUNCTION VRC Adjusts Main Charge Current VRG Adjusts Standard Grid Voltage VRB Adjusts Standard Dev.
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SP MODE OVERVIEW SP Mode Data When Performed 5 6 8 Movement Check Exposure Lamp OFF Jam Detection OFF Input Check (Refer to Sensor/Switch Data Check Table) EM EM EM 9 Output Check (Refer to Electrical Component Check Table) EM 10 Installation and/or Sales Demonstration Color Developer Initial Setting 11 12 All Indicators ON 220V/240V Conversion 15 User Requests Auto Reset Time 16 Count Up/Down 17 Auto Feed Station Shift 19 ADS Priority 20 22 APS Priority (When turning on the main swit
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SP Mode 33 ID Sensor Bias (Black) 34 ADS Level 35 Black Toner ID Detection 37 Black Bias Adjustment 41 42 43 44 47 48 49 51 52 54 55 56 59 61 Lead Edge Erase Margin Adjustment Registration Adjustment Vertical Magnification Adjustment Horizontal Magnification Adjustment Focus Adjustment Light Intensity Adjustment Fusing Temperature Adjustment Exposure Lamp Voltage Display Fusing Temperature Display Vsg Adjustment (VR102 on the main board) Vsg & Vsp Check ADS Voltage Adjustment (VR101 on the main boa
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SP Mode 74 Color Toner ID Detection 75 ID Sensor Bias (Color) 76 Sorter Bin Capacity 77 ADF Odd Number Originals (Duplex Mode) 79 Color Bias Adjustment 80 81 82 87 Red Toner Density Level Display Green Toner Density Level Display Blue Toner Density Level Display PM Interval Setting 88 89 93 PM Counter Display PM Counter Reset Maximum Copy Quantity 98 99 100 101 102 105 106 120 121 122 123 124 125 130 131 Data 0: 1: 0: 1: 2: 3: 0: 1: 0: 1: 0: 1: 2: 3: 4: 0: 1: 2: 3: 4: 5 copies 10 copies Nor
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SERVICE CALL AND USER CODE TABLE SERVICE CALL CODE E-CODE 11 12 13 21 22 28 29 2A 2B 52 53 55 CONTENTS SP Mode No. (SC Counter) Exposure Lamp Error SP Mode #122 The feed back signal beomes higher than 4.2 volts (r.m.s) (Exposure for 1.0 second when the exposure lamp is on, or it Lamp) becomes higher than 1.0 volt (r.m.s) for 1.0 second when the exposure lamp is off. Exposure Lamp Error The feed back signal falls below 0.5 volt (r.m.s) for 1.
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E-CODE CONTENTS 70 Toner Overflow Sensor ON When the toner overflow sensor is on, "E70" blinks in the magnification indicator. Up to 250 copies additional can be made. After 250 copies are made, "E70" lights and copies cannot be made. Duplex and Copier Main Board Communication Error The copier main board does not receive any signal from the duplex main board. Interface Board Error The interface board is not connected when the duplex unit is installed.
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AD120 (A491)
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PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of these parts on this machine. INDEX to PARTS CATALOG 1. DUPLEX UNIT I (A491) ............................................................................. 2 2. DUPLEX UNIT II (A491) ............................................................................ 5 3. DUPLEX MAIN BOARD (A491) ................................................................. 7 4. DUPLEX HARNESS (A491) ...................................................
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1.
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1. DUPLEX UNIT I (A491) Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Part No.
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Index No. 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 Part No. 0313 0313 0314 0353 0353 0413 0632 0720 0720 0720 0720 0805 0951 0951 1105 0040B 0050W 0100W 0050W 0060F 0062W 0140E 0030E 0040E 0060E 0080E 3366 3005W 4006W 0199 Description Q'ty per Assembly Index No.
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December 1, '90 2.
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December 1, '90 2. DUPLEX UNIT II (A491) Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27 28 29 30 31 32 33 34 Part No.
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December 1, '90 3.
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3. DUPLEX MAIN BOARD (A491) Index No. * 1 101 102 103 104 105 106 107 108 109 Part No. Description A491 5101 A491 5105 Duplex Main Board IC - uPD7811H 1102 1102 1102 1103 1103 1103 1204 1400 1401 CT Header - 4P Connector - 6P Connector - 13P Pin Terminal - 4P Connector - 4P Pin Header - 6P DIP Switch Transistor - 2SC945 Diode - 1S1588 4203 4205 4497 0441 1770 1772 1482 0208 0815 December 1, '90 Q'ty per Assembly Index No.
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4.
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4. DUPLEX HARNESS (A491) Index No. * Part No. A491 5300 December 1, '90 Description Duplex Harness Q'ty per Assembly Index No. 101 102 103 104 105 106 1 10 Part No.
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5.
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December 1, '90 5. SENSOR HARNESS (A491) Index No. * Part No. A491 5301 Description Sensor Harness Q'ty per Assembly Index No. 101 102 103 104 105 106 1 12 Part No.
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6.
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6. DECAL AND DOCUMENT (A491) Index No. 1 1 2 Part No. A491 4910 A491 6060 A491 4915 Description Decal - Removing Misfed Paper Multi Decal - Removing Mifed Paper Dust Cover Decal December 1, '90 Q'ty per Assembly Index No. 1 1 1 14 Part No.
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PARTS INDEX
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December 1, '90 Part No.
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December 1, '90 Part No.
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December 1, '90 Part No.
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December 1, '90 Part No. 1611 1611 1611 1611 1611 1611 1611 1611 1611 1611 1611 1611 4102 4103 4105 4181 4223 4242 4332 4391 4472 4473 4511 4513 Description Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor - 1K W 1/4T ±5% 10K W 1/4T ±5% 1M W 1/4T ±5% 180 W 1/4T ±5% 22K W 1/4T ±5% 2.4K W 1/4T ±5% 3.3K W 1/4T ±5% 390 W 1/4T ±5% 4.7K W ±5% 1/4W 47K W 1/4T ±5% 510 W 1/4T ±5% 51K W 1/4T Paper and Index No. Part No.
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POWER SUPPLY UNIT (A494)
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PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of these parts on this machine. INDEX to PARTS CATALOG 1. POWER SUPPLY UNIT (A494) ................................................................. 2 2. INTERFACE BOARD (A494) ..................................................................... 4 3. DC DRIVE BOARD (A494) ........................................................................ 6 4. POWER SUPPLY UNIT HARNESS (A494) ...............................................
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1.
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1. POWER SUPPLY UNIT (A494) Index No. Part No. 1 2 3 3 4 4 A494 A494 A494 A494 A494 A494 5803 5101 5301 5310 5415 5416 5 6 7 7 A494 5801 A494 5802 AZ12 0014 AZ12 0015 Description Bracket - DF Power Supply Cord Interface Board Power Supply Unit Harness - 115V Power Supply Unit Harness - 220/240V DC Drive Board - 115V DC Drive Board - 220/240V MB2 (ADDED) Small P.S.U. Bracket Large P.S.U. Bracket Transformer - 115V Transformer - 220/240V Q'ty per Assembly Index No.
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2.
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2. INTERFACE BOARD (A494) Index No. " Part No. A494 5101 Description Interface Board Q'ty per Assembly Index No. 1 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 5 Part No.
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3.
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3. DC DRIVE BOARD (A494) Index No. * * Part No. A494 5415 A494 5416 Description DC Drive Board - 115V DC Drive Board - 220/240V Q'ty per Assembly Index No. 1 1 7 Part No.
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4.
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4. POWER SUPPLY UNIT HARNESS (A494) Index No. * * Part No. A494 5301 A494 5310 Description Power Supply Unit Harness - 115V Power Supply Unit Harness - 220/240V Q'ty per Assembly Index No. 1 1 101 102 103 104 105 106 107 108 109 110 111 112 9 Part No.
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PARTS INDEX 10
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Part No. A494 5101 A494 5101 1604 1382 A494 5301 A494 5301 A494 5310 A494 5310 A494 5415 A494 5415 A494 5416 A494 5416 A494 5801 A494 5802 A494 5803 Description Interface Board Interface Board Capacitor - 10uF 50V Power Supply Unit Harness - 115V Power Supply Unit Harness - 115V Power Supply Unit Harness - 220/240V Power Supply Unit Harness - 220/240V DC Drive Board - 115V DC Drive Board - 115V DC Drive Board - 220/240V MB2 (ADDED) DC Drive Board - 220/240V MB2 (ADDED) Small P.S.U. Bracket Large P.S.U.
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Part No.
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TABLE OF CONTENTS OVERALL MACHINE INFORMATION 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2. OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3. COPY PROCESSES AROUND THE DRUM. . . . . . . . . . . . . . . . . . . . . 1-10 4. FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 5. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . .
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3.3.2 Shading Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 3.3.3 Lens Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 3.4 4TH AND 5TH MIRROR DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 3.4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 3.4.
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6.3 FIXED SUPPLY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 6.4 ID SENSOR FUNCTION IN FIXED SUPPLY MODE . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 6.4.1 Black Development Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 6.4.2 Color Development Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 6.
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10.4.2 Paper End Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 10.5 PAPER SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 10.5.1 1st Feed Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 10.5.2 2nd Feed Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 10.
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SERVICE TABLES 1. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1.1 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1.2 DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 1.3 VARIABLE RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 2.
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4. SPECIAL TOOLS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 5. PREVENTIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . 4-39 5.1 PM TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 5.2 EXPLANATION OF REGULAR PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 REPLACEMENT AND ADJUSTMENT 1. EXTERIOR AND INNER COVERS . . . . . . . . . . . . . . . . . . . . .
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3.3 INLET SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 3.4 DEVELOPMENT ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 3.5 DOCTOR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 3.6 TONER SUPPLY CLUTCH SOLENOID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 5-33 3.7 DEVELOPMENT DRIVE CLUTCH SOLENOID REPLACEMENT. . . . . . . . . . . . . . . .
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6.4 CHARGE CORONA WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64 6.5 CHARGE CORONA GRID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65 6.6 TRANSFER/SEPARATION CORONA WIRE REPLACEMENT . . . . . . . . . . . . . . . . . 5-66 6.7 ENTRANCE GUIDE PLATE HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 5-67 6.8 DRUM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 6.
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9.11 FOCUS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98 9.12 ERASE MARGIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99 9.13 REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99 9.14 SIDE-TO-SIDE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100 9.15 4TH/5TH MIRROR HEIGHT ADJUSTMENT . . . . . . . . . . . . . .
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2.9 CODE #2B — 4TH/5TH MIRROR HOME POSITION ERROR . . . . . . . . . . . . . . . . . 6-38 2.10 CODE #52 — FUSING WARM-UP ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 2.11 CODE #53 — FUSING OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 2.12 CODE #55 — FUSING THERMISTOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 2.13 E70 (IN THE MAGNIFICATION INDICATOR) — TONER OVERFLOW SENSOR ON . . . . . . . . . . . . . . . . . . .
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5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 6. POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 7. INTERFACE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 8. ORIGINAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 8.1 ORIGINAL PICK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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14. DF MAIN BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47 15. DF TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48 SORTER 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 2. COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . .
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5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 5.1 FIRST SIDE COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 5.2 DUPLEX STACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 5.3 SECOND SIDE COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 6. DRIVE MECHANISM . . . . . . .
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COPIER ELECTRICAL COMPONENTS AND CONNECTORS LAYOUT DOCUMENT FEEDER ELECTRICAL COMPONENTS AND CONNECTORS LAYOUT SORTER ELECTRICAL COMPONENTS AND CONNECTORS LAYOUT DUPLEX ELECTRICAL COMPONENTS AND CONNECTORS LAYOUT FT4421 SERVICE MANUAL 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 2. OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 3. FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . .
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14.1.4 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32 14.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33 14.2.1 Introduction: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33 14.2.2 Copier Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34 14.