Sharp VC-H670X Specifications

SECTION 1

OVERALL MACHINE

INFORMATION

1 December 1990

1. SPECIFICATIONS

Configuration:

Copy Process:

Originals:

Original Size:

Copy Paper Size:

(Duplex Copying)

Copy Paper Weight:

Reproduction Ratio:

Desk top

Dry electrostatic transfer system

Sheet/Book

Maximum A3/11"x17"

Maximum A3/11"x17"

Minimum A6/5 1/2 " x 8 1/2 " (lengthwise)

A4 and B5/8 1/2 " x 11" (sideways)

Cassette feed: 52 to 157 g/m

2

Paper tray feed: 64 to 90 g/m

2

(14 to 42 lb)

(17 to 22 Ib)

Manual feed: 52 to 157 g/m

2

(14 to 42 lb)

Duplex: 59 to 104 g/m

2

(16 to 27 lb)

2 Enlargement and 3 Reduction

Enlargement

Full size

Reduction

A4/A3 Version LT/LDG Version

141%

122%

100%

155%

129%

100%

93%

82%

71%

93%

74%

65%

Zoom:

Copying Speed:

Warm-Up Time:

First Copy Time:

Copy Number Input:

Manual Image Density

Selection:

From 50% to 200% in 1% steps

18 copies/minute (A4/8 1/2 " x 11" sideways)

10 copies/minute (A3/11" x 17")

60 seconds (at 20 o C)

5.9 seconds (A4/8 1/2 " x 11" sideways)

Ten keys, 1 to 99 (count up)

7 steps

1-1

1 December 1990

Automatic Reset:

Paper Capacity:

Toner Replenishment:

Copy Tray Capacity:

Power Source:

Power Consumption:

1 minute standard setting; can also be set to 3 minutes or no auto reset.

Cassettes: 500 sheets

Paper tray: 250 sheets

Manual feed table: 50 sheets

Black: Cartridge exchange (370g/cartridge)

Color (red, blue, & green): Cartridge exchange

(310g/cartridge)

250 sheets (B4/8 1/2 " x 14" and smaller)

100 sheets (A3/11" x 17")

110V/ 60Hz/ 15A (for Taiwan)

115V/ 60Hz/ 15A (for N.A.)

220V/ 50Hz/ 8A (for EU.)

220V/ 60Hz/ 8A (for EU.)

240V/ 50Hz/ 8A (for EU.)

(Refer to the serial number plate (rating plate) to determine the power source required by the machine.)

Maximum: 1.2 kw

Warm-up: 0.72 kw (average)

Ready: 0.16 kw (average)

Copy cycle: 0.81 kw (average)

Dimensions:

Copier only

Full system

Width

672 mm

(26.5")

1149 mm

(45.3")

Depth

600 mm

(23.7")

600 mm

(23.7")

Height

410 mm

(16.2")

513 mm

(20.2")

Weight: Copier only: 52 kg (114.7 Ib)

Full system: 71 kg (156.6 Ib)

Optional Equipment: Document feeder

10 bin sorter

Duplex unit

Color development unit

Key counter

Universal Cassette

•

Specifications are Subject to change without notice.

1-2

2. OPERATION PANEL

— A4/A3 Version —

C

— LT/LDG Version —

B A

C B

Section A:

Section B:

Section C:

See page 1-4.

See page 1-5 or 1-6.


1-3

A

1 December 1990

1 December 1990

Section A —


1 2 3

4

5


1 2 3

4

5

7 6 7 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

2. Recall/Enter Key

Press to display the number of

copies entered. Also use to

enter or change data when in

3. Clear Modes Key

Press to clear all previously

entered settings and modes.

4. Interrupt Indicator

Lights when interrupt mode is

selected.

5. Interrupt Key

Press to make interrupt copies

during a copy run.

6. Start Key

7. Clear/Stop Key

Press to cancel the copy

number entered. While copying,

1-4

1 December 1990

— Section B —


1 2 3 4 5 6 7 8 9 10

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

20 19 18 17 16

7. Add Toner Indicator

Blinks when it is time to change

the toner cartridge. When it is

cannot be used until a new

original mode or the duplex

mode. (Copying is impossible.)

3. Check Paper Size/Direction

Indicator

Blinks when the original size

does not match with the paper

size or direction. This indicator is

functional only with the document

feeder. (Copying is possible.)

4. Auto Paper Select Indicator

Lights when auto paper select

mode is selected. This mode is

an optional feature with the

8. Check Paper Path Indicator

Lights if there is a misfeed

within the machine.

9. Manual Feed Indicator

Lights when the manual feed

table is open.

10. Second Original Indicator

Lights when it is time to position

the second original on the

exposure glass when making

duplex copies.

— Light ON —

If copying has been completed,

press duplex key to cancel the

duplex mode and press start

5. Duplex Unit Indicator

Lights when the duplex unit is installed.

6. Load Paper Indicator

— Light Blinking —

Press start key to eject copies.

11. Ready Indicator

Lights when the machine is

ready to make copies.

paper tray in use runs out of

paper.

1-5

11

12

13

14

15

1 December 1990


1 2 3 4 5 6 7 8 9 10

24

11

12

13

14

15

23 22 21 20 19 18 17 16

12. Wait Indicator

Lights when that the machine is

not ready to copy.

13. Copy Counter

Displays the number of copies

entered. While copying, it shows

the number of copies made.

14. Auto Image Density Indicator

Lights when the copier is

refer to page 55.

15. Manual Image Density

Indicator

16. Auto Image Density Key

automatic image density mode.

17. Manual Image Density Keys

Use to cancel the automatic

image density mode and

manually select the image

18. Misfeed Location Display

paper.

19. Color Copy Indicator

Lights if a color toner

development unit is installed.

20. Select Paper Key

Press to select the cassette or

the paper tray for paper feed, or

press to cancel auto paper

document feeder is installed.

21. Full Size Key

Press to make copies the same

size as the originals.

22. Enlarge Key

Press to make enlarged copies.

23. Reduce Key

Press to make reduced copies.

24. Paper Size Indicator

Shows the size and direction of

the paper in use.

1-6

1 December 1990

— Section C —


5 4 6 7

3

2

8

9

1 13 12 11 10

1. Sorter Key

Press to select the sort or stack mode. The sort mode and stack mode are optional features requiring a sorter.

2. Stack Indicator

Lights when in the stack mode.

3. Sort Indicator

Lights when in the sort mode.

4. Duplex Key

Press to select one of three duplex modes. These modes are optional features requiring a duplex unit.

5. Duplex Indicators

Show which duplex copying mode is selected.

6. Auto Reduce/Enlarge Indicator

Lights when in the auto reduce/enlarge mode. This mode is an optional feature requiring a document feeder.

1-7

1 December 1990


5 4 6 7

3

2

8

9

1 13 12 11 10

7. Auto Reduce/Enlarge Key

mode is an optional feature

requiring a document feeder.

8. Zoom Up Key

Press to increase the

reproduction ratio in 1% steps.

9. Zoom Down Key

Press to reduce the

reproduction ratio in 1% steps.

10. Size Magnification Key

11. Size Magnification Indicators

Lights when in the size

when to enter the original size

and copy size data.

12. 2 Single Copies Key

Press to select one of two 2

single copies modes. The 2

Sided Original mode is an

document feeder.

13. 2 Single Copies Indicators

Show which the 2 single copies

1-8

1-9

1 December 1990

1 December 1990

3. COPY PROCESSES AROUND THE DRUM

1. DRUM CHARGE

9. QUENCHING

2. EXPOSURE

3. ERASE

4. DEVELOPMENT

8. CLEANING

7. PAPER

SEPARATION

5. PRE-TRANSFER LAMP

(PTL)

6. IMAGE TRANSFER

1-10

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. The charge on the drum surface is dissipated in direct proportion to the intensity of the reflected light, thus producing an electrical latent image on the drum surface.

3. ERASE

The erase lamp illuminates the areas of the charged drum surface that will not be used for the copy image. The resistance of the drum in the illuminated areas drops and the charge on those areas dissipates.

4. DEVELOPMENT

Positively charged toner is attracted to the negatively charged areas of the drum, thus developing the latent image. (The positive triboelectric charge is caused by friction between the carrier and toner particles.)

5. PRE-TRANSFER LAMP (PTL)

The PTL illuminates the drum to remove all negative charge from the exposed areas of the drum. This prevents the toner particles from being reattracted to the drum surface during paper separation and makes paper separation easier.

6. IMAGE TRANSFER

Paper is fed to the drum surface at the proper time so as to align the copy paper and the developed image on the drum surface. Then, a strong negative charge is applied to the back side of the copy paper, producing an electrical force which pulls the toner particles from the drum surface to the copy paper. At the same time, the copy paper is electrically attracted to the drum surface.

7. PAPER SEPARATION

A strong ac corona discharge is applied to the back side of the copy paper, reducing the negative charge on the copy paper and breaking the electrical attraction between the paper and the drum. Then, the stiffness of the copy paper causes it to separate from the drum surface. The pick-off pawls help to separate paper.

8. CLEANING

The cleaning brush removes most of the toner on the drum and loosens the remainder. Then the cleaning blade scrapes off the loosened toner.

9. QUENCHING

Light from the quenching lamp electrically neutralizes the surface of the drum.

1-11

1 December 1990

4. FUNCTIONAL OPERATION

1-12

33

32

31

30

1 December 1990

5. MECHANICAL COMPONENT LAYOUT

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15

16

17

18

19

29 28 27 26 25 24 23 22 21 20

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

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. Exhaust Blower

1-13

1 December 1990

6. DRIVE LAYOUT

G17 BP2 G16 TB1 G19 G18 G22 G23 G24

G5

G6

G7

G9

G8

G10

G4

BP3

G13 G12 G11 G14 G15 BP1 G3 G2 G1 G20 G21 G25 G29

G26

G27

G28

G1: Main Motor Gear

G2: Relay Gear

G3: Timing Belt Drive Gear

BP1: Timing Belt Pulley

TB1: Timing Belt

A

G20: Relay Gear

G21: Cleaning Drive Cleaning Unit G18: Relay Gear

G19: Drum Drive Gear G22: Relay Gear

Drum

Development

Section

Fusing and Exit Section

G23: Relay Gear

BP2: Timing Belt

Pulley

G24: Relay Gear

G25: Hot Roller Gear

G16: Development

G26: Relay Gear

G27: Relay Gear G29: Duplex Transport

Development CL

G17: Toner Supply CL Gear

G28: Exit Roller Gear

Development Unit

Toner Supply CL Toner Supply Unit

1-14

G11: Registration CL Gear

Registration CL

Registration Roller

1st Paper Feed CL

1st Paper Feed CL

1st Paper Feed Rollers

1 December 1990

A

Paper Feed Section


G4: Relay Gear

G5: Relay Gear

2nd Feed Station

G12: Relay Roller

CL Gear

G6: 1st Paper Feed CL Gear Relay Roller CL

G7: Relay Gear

G8: Paper Lift CL Gear

Relay Roller

G13: Relay Roller Gear

G14: Relay Gear

G15: 2nd Paper Feed

CL Gear Paper Lift CL

G9: Paper Lift Gear

G10: Sector Gear

2nd Paper Feed CL

2nd Paper Feed Roller

1-15

1 December 1990

7. ELECTRICAL COMPONENT LAYOUT

39

40

42

43

4

1

41

32

38

36

37

34

35

31

30

33

28

2

3

5

6

7

8 10

9

29 26

25

27

19

20

23

24

22

21

13

11

12

15

16

14

17

18

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)




10. Main Motor

11. Development CL Sol.

12. 4th/5th Mirror H.P. Sensor

13. Toner Supply CL Sol.

14. Toner End Sensor

15. 4th/5th Mirror Motor

16. Pick-up Roller Release Sol.

17. Manual Feed Table SW

18. Development Unit Set Sensor

19. Color Switch

20. Paper Lift CL Sol.

21. 1st Paper Feed CL Sol.

22. Relay Roller CL Sol.

23. Right Cover SW

24. Registration Clutch

25. 2nd Paper Feed CL Sol.

26. 1st Paper Size SW

27. 1st Paper End Sensor

28. 2nd Paper End Sensor

29. Cassette Lift Sensor

30. Registration Sensor


32. ID Sensor

33. Total Counter

34. Erase Lamp (EL)

35. Transfer and Separation Corona Unit


37. Fusing Lamp


39. Auto ID Sensor

40. Toner Overflow Sensor

41. Fusing Thermistor

42. Fusing Thermofuse

43. Tray Lock Sol.

1-16

45

46

44

1 December 1990

47

48

49

50

51

52

53

62

61

60

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

59

58

55

56

57

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. Main Motor Capacitor

61. TC/SC Power Pack

62. Interface Board (Option)

54

1-17

1 December 1990

8. ELECTRICAL COMPONENT DESCRIPTIONS

SYMBOL NAME FUNCTION

Motors

M1

M2

M3

M4

M5

M6

M7

Main Motor

Scanner Motor

Lens Motor

4th/5th Mirror Motor

Optics Cooling

Fan Motor-1

Optics Cooling

Fan Motor-2

Exhaust Blower

Motor

Drives all the main unit components except for the optics unit and fans.

(115/220/240Vac)

Drives the scanners (1st and 2nd). (dc stepper)

Moves the lens position according to the selected magnification. (dc stepper)

Move the 4th/5th mirror position according to the selected magnification. (dc stepper)

Prevents built up of hot air in the optics cavity. (24 Vdc)


Removes heat from around the fusing unit and blower the ozone built up around the charge section to the ozone filter.

Magnetic Clutch

MC1 Registration

Clutch

Drives the registration roller.

Solenoid

SOL1

SOL2

SOL3

SOL4

Toner Supply

Clutch Solenoid

1st Paper Feed

Clutch Solenoid

2nd Paper Feed

Clutch Solenoid

Pick-up Roller

Release Solenoid

SOL5

Drives the toner supply roller via the toner supply spring clutch.

Starts paper feed from the first paper station.

Starts paper feed from the 2nd paper station.

a) After the paper is fed, releases the pick-up roller from next paper. b) When the manual feed table is used, releases the pick-up roller from the table.

Lifts paper to the appropriate feed position.

SOL6

SOL7

SOL8

Paper Lift Clutch

Solenoid

Tray Lock Solenoid

Development

Clutch Solenoid

Relay Roller

Clutch Solenoid

Locks the paper tray/duplex unit.

Drives the development unit.

Drives the relay roller for the 2nd cassette station.

24

20

43

11

22

13

21

25

16

47

47

51

5

2

15

INDEX

NO.

10

1-18


Switches

SW1

SW2

SW3

SW4

SW5

SW6

SW7

SW8

Main Switch

Cover Safety

Switch

1st Paper Size

Switch

2nd Paper Size

Switch-1

2nd Paper Size

Switch-2

2nd Paper Size

Switch-3

2nd Paper Size

Switch-4

Color Switch

SW9

SW10

Manual Feed Table Switch

Right Cover

Switch

Sensor

S1

S2

S3

S4

S5

S6

S7

S8

S9

S10

Scanner Home

Position Sensor

Lens Home

Position Sensor

4th/5th Mirror

Home Position

Sensor

Registration

Sensor

Exit Sensor

1st Paper End

Sensor

2nd Paper End

Sensor

Toner End

Sensor

Toner Overflow

Sensor

Paper Lift

Sensor

Supplies power to the copier.

Cuts the ac power line.

Determines what size paper is in the first cassette.

Determines what size paper is in the paper tray.




Determines which color development unit is installed.

Detects when the manual feed table is open.

Detects when the right cover is open.

Informs the CPU when the 1st scanner is at the home position.

Informs the CPU when the lens is at the home position (full size position).

Informs the CPU when the 3rd scanner

(4th/5th mirrors assembly) is at the home position (full size position).

Detects misfeeds.

Detects misfeeds.

Informs CPU when the first cassette runs out of paper.

Informs CPU when the paper tray runs out of paper.

Detects when it is time to add toner.

Detects when the used toner tank is full.

Detects the correct feed height of the cassette.

1-19

1 December 1990

INDEX

NO.

6

7

8

53

52

26

9

19

17

23

28

18

40

29

30

4

27

1

3

12

1 December 1990


S11

S12

Image Density

(ID) Sensor

Development

Unit Set Sensor

Printed Circuit Board

PCB1 Main Board

Detects the density of the image on the drum to control the toner density.

Sensors whether or not the development unit is properly set.

PCB2

PCB3

PCB4

PCB5

AC Drive Board

Main DC Power

Supply Board

Auto Image

Density Sensor

(ADS)

Optional DC

Power Supply

Board

Interface Board

Controls all copier functions both directly and through the other PCBs.

Drives all ac motors, the exposure lamp, fusing lamp, quenching lamp, exhaust blower motor.

Rectifies 26 and 10 Vac input and outputs dc voltages.

Senses the background density of the original.

Rectifies 26 and 10 Vac input and outputs dc voltasges.

PCB6

PCB7

Power Packs

P1 CC/Grid/Bias

Power Pack

P2

Operation Panel

Board

TC/SC Power

Pack

Interfaces between the copier main board and all the optional equipment’s main board.

Informs the CPU of the selected modes and displays the situations on the panel.

Lamps

L1

L2

L3

L4

L5

Exposure Lamp Applies high intensity light to the original for exposure.

Provides heat to the hot roller.

Fusing Lamp

Quenching Lamp Neutralizes any charge remaining on the drum surface after cleaning.

Erase Lamp Discharge the drum outside of the image area. Provides leading/trailing edge erase.

Pre-transfer

Lamp

Reduces charge on the drum surface before transfer.

Provides high voltage for the charge corona, grid, and the development roller bias.

Provides high voltage for the transfer and separation corona.

46

61

49

37

38

34

31

INDEX

NO.

32

18

55

39

45

59

56

62

50

1-20

SYMBOL NAME

Heaters

H1

H2

Drum Anticondensation

Heater

Optics Anti-condensation Heater

Option

Counters

FUNCTION

Prevents moisture around the drum.

Prevents moisture from forming on the optics.

CO1

CO2

Total Counter

Key Counter

(Option)

Keeps track of the total number of copies made.

Used for control of authorized use. Copier will not operate until installed.

Transformer

TR1

TR2

Main Transformer Steps down the wall voltage to 26 Vac and

10 Vac.

Optional

Transformer

Steps down the wall voltage to 26 Vac and

10 Vac for the document feeder and duplex unit.

Others

TH

TF

TS

C

Fusing

Thermistor

Fusing

Thermofuse

Optics

Thermoswitch

Main Motor Capacitor

Monitors the fusing temperature.

Provides back-up overheat protection in the fusing unit.

Provides back-up overheat protection around the exposure lamp.

Start capacitor

1 December 1990

INDEX

NO.

54

N/A

41

42

48

60

33

44

58

57

1-21

1 December 1990

9. OVERALL MACHINE CONTROL

AC Power (115V or 220/240V)

Cover Safety Switch

Operation

Panel Board

Exhaust Blower Motor (L)

Fusing Lamp

Exposure Lamp

Main Motor

Quenching Lamp

Exhaust Blower Motor (H)

Main Switch

AC Drive Board

Power Relay

Fusing Lamp

Drive Circuit

Exposure Lamp

Drive Circuit

Main Motor Relay

Power Packs

CC/Grid/Bias P.P.

Charge Corona

Grid Voltage

Dev. Bias

TC/SC P.P.

Counters

Total Counter

Key Counter

IC 123

CPU

IC 105

I/O

IC 124

I/O

IC 111

ROM

Main Board

RAM

Board

Anti-condensation Heater

-Drum

-Optics

Sensors/Switches/Thermistor

Image Density Sensor

Registration Sensor

Cassette Lift Sensor

Exit Sensor

Auto ID Sensor

Scanner HP Sensor

Lens HP Sensor

4th/5th Mirror HP Sensor

Toner Overflow Sensor

Toner End Sensor

Color Switch

1st/2nd Paper Size Switches

1st/2nd Paper End Sensors

Right Cover Switch


Fusing Thermistor

Solenoids/Clutches

Pick-up Roller Release Sol.

Cassette Lift CL Sol.

1st/2nd Paper Feed CL Sol.

Relay Roller CL Sol.

Registration Clutch

Tray Lock Sol.

Development Drive CL Sol.

Toner Supply CL Sol.

Motors

Scanner Motor

Lens Motor

4th/5th Mirror

Optics Cooling Fan Motor

ARDF

Duplex

Sorter

Serial

Serial

Interface

Board

NOTE: The interface board is connected to the copier main board when the ARDF, duplex unit and/or sorter is installed.

The above diagram shows the control system of this copier in block form. The

CPU (IC123) on the main board controls the timing of all copier’s operation based on the CPU’s internal clock. The CPU monitors the input signals from all sensors and controls the dc components directly or through two I/O chips

(IC 105 and IC 124). It also controls ac components such as the fusing lamp, exposure lamp, main motor quenching lamp, and exhaust blower motor (High speed) directly via the ac drive board. The exhaust blower motor (Low speed) is controlled via the I/O chip (IC 124) and ac drive board. The charge corona, grid voltage and development bias are powered by the same power pack

(P1) but are controlled separately as shown above. The main board has a

RAM board for the service program mode and misfeed recovery. A battery backs up the power to the RAM board.

1-22

1 December 1990

10. AC POWER AND DC POWER

DISTRIBUTION


Main SW Anti-condensation Heater

-Drum

-Optics (Option)

Cover Safety SW

Fuse

Power Relay

(RA401)

24V (VA)

Scan

Signal

Operation Panel Board

5V (VC)

Sensors

Switches

Interface Board

Exhaust Blower

Motor (L)

Fusing Lamp

Exposure Lamp

Fusing Lamp

Drive Circuit

Exposure Lamp

Drive Circuit

24V (VA)

24V (VA)

RAM

PCB

24V (VA)

Solenoids

Clutches

Power Packs

Lens Motor


Optics Cooling Fan

Motors

30V (VM)

Scanner Motor

Main

Board

Main Motor

Quenching Lamp

Exhaust Blower

Motor (H)

Main Motor

Relay (RA402)

24V (VA)

AC Drive Board

Optional Transformer

26V AC 10V AC

FU100 (5V)

FU101 (24V)

Optional

DC Power Supply

Board

24V

(VA)

5V

(VC)

24V

(VA)

5V

(VC)

Main Transformer

10V AC 26V AC 26V AC

30V (VM)

Main DC Power Supply Board 24V (VA)

FU100 (5V)

FU101 (24V)

FU102 (30V)

5V (VC)

Zero

Cross

Interface

Board

ARDF Duplex ac power dc power

Sorter

24V (VA)

5V (VC)

When this copier is plugged in and the main switch is turned off, ac power is supplied via the ac drive board to the anti-condensation heater. When the front cover and/or the exit cover is open, the cover safety switch completely cuts off power to all ac and dc components. The RAM board has a back up power supply (dc battery) for the service program mode and misfeed job recovery.

When the main switch is turned on, the ac power supply to the anti-condensation heater is cut off and ac power is supplied to the ac drive board. The main transformer receives wall outlet ac power through the ac drive board and outputs 10 volts ac and 26 volts ac to the main dc power supply board.

1-23

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. All sensors, and switches plus the interface board operate on +5 volts. The scanner motor operates on +30 volts. All other dc components including the power relay (RA401) and the main motor relay (RA402) operate on +24 volts.

The ARDF and the duplex unit have a separate dc power supply.

When the main board receives power, it activates the power relay (RA401) which then supplies ac power to the fusing lamp drive circuit, and the exposure lamp drive circuit on the ac drive board. The exhaust blower motor begins rotating at low speed. The fusing lamp drive circuit receives a trigger signal from the main board and the fusing lamp lights. The exposure lamp does not turn on until the main board send a trigger pulse to the exposure lamp drive circuit.

When the Start key is pressed, the main board energizes the main motor relay (RA402). Then, the main motor and the quenching lamp turn on and the exhaust blower starts rotating at high speed.

When the main switch is turned off, power is cut off to the main board and to

RA401, and the drum and optional anticondensation heaters are turned on.

The exposure lamp and the fusing lamp power lines are completely disconnected from the line voltage.

1-24

1 December 1990

10.1 AC POWER DISTRIBUTION

Main SW

(SW1)

115V

220/240V

T404

Cover

Safety

SW (SW2)

T407

To DF and Duplex

[24] VA

[5] VC

[0] GND

Optional

DC Power

Supply

Board

(PCB5)

10V AC TR2 CN418-1

26V AC

CN418-3

CN417-3

CN417-1 To Sorter

[24] VA

[5] VC

[0] GND

CN103-1

CN103-2

CN103-3

TR1

ZERO

CROSS

[0] GND

[0] GND

[30] GND

[0] GND

[24] VA

[0] GND

[5] VC

CN108-1

CN108-2

CN107-1

CN107-2

CN107-3

CN107-4

CN107-5

CN107-6

CN100-1

CN100-2

CN100-3

CN100-4

CN100-5

CN100-6

CN102-2

CN102-1

CN101-1

CN101-2

CN101-3

CN101-4

CN101-5

CN101-6

26V AC

26V AC

10V AC

DC

Power

Supply

Board

(PCB3)

Main

Board

(PCB1)

CN122-7

CN122-6

CN122-10

CN401-8

CN401-9

CN401-5

CN122-14

CN122-9

CN401-1

CN401-6

Fuse

CN122-13

CN122-12

CN122-11

CN401-2

CN401-3

CN401-4

T403 T402 T401

CN411-1

RA402-1

CN411-2

Drum

Anti-condensation

Heater (H1)

RA401

AC

Drive

Board

(PCB2)

Noise Filter

Circuit

(220/240V

Only)

Exposure

Lamp Drive

Circuit CN421

(220/240V

Only)

Fusing

Lamp Drive

Circuit

RA402-2

CN420-3

CN420-2

Exhaust Blower Motor

CN419-1

Exposure Lamp

T405

Fusing

Lamp

Thermoswitch

Thermo-

(TS) fuse

169 C

(TF)

H L

M

(M7)

CN413-1

Main

Motor (M1)

CN415-1

M

(L2) (L1)

Quenching

Lamp

(L3)

CN415-2

CN413-2

T406

CN419-2

CN420-1

Power Relay

RA401

RA402

Main Motor Relay

1-25

1 December 1990

10.2 DC POWER DISTRIBUTION

CN417

-1

115V

220/240V

CN417

-3

DC Power Supply Board

CN100

-5

10VAC

CN100

-6

CN100

-3

26VAC

CN100

-4

CN100

-1

ON

FU100

D101

FU101

D100

ST100 R100 Q100

D102

IC100

+

C101

R101

R102

R104

+

C100

R105

R106

+

C103 C104

D103

R103

C112

C105 Q101

ST101 R107 Q102

D104

+

C108 C109 D105 C113

+

C110

IC101

+

C107

FU102

ST102

26VAC

CN100

-2

+

C110 R108 C111 C114

Main Board

CN101

-6

CN103

-2

CN102

-2

CN103

-1

CN101

-5

CN102

-1

CN101

-4

CN107

-6

(

To

Sorter

CN108

-1

(

To

Sorter

CN107

-5

CN108

-2

CN107

-4

)

[5]Vc

)

Zero

Cross

[0]GND

[0]GND

[24]VA

CN103

-3

(

To

Sorter

)

CN101

-3

CN101

-2

CN107

-3

CN107

-2

[0]GND

[30]VM

[24]VA

[5]VC

[30]VM

CN101

-1

CN107

-1

[0]GND

[0]GND

1-26

SECTION 2

SECTIONAL DESCRIPTION

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. That is, where stronger light is directed to the photoconductor surface, a smaller voltage remains on the OPC.

4. Being less sensitive to changes in temperature (when compared to selenium F type drums). This makes it unnecessary to monitor and control the drum temperature.

2-1

1 December 1990

1.2 DRUM UNIT

[B]

[G]

[F] [H]

[E]

[A]

[C]

[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.

The drum is driven by the main motor [H] through the main motor gear [E], a relay gear and the drum drive gear [F]. The pick-off pawls [D] are always in contact with the drum surface. The ID sensor is electrically connected to the

ID sensor connector [G].

2-2

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. Never use alcohol to clean the drum; alcohol dissolves the drum surface.

5. Store the drum in a cool, dry place away from heat.

6. Take care not to scratch the drum as the drum layer is thin and is easily damaged.

7. Never expose the drum to corrosive gases such as ammonia gas.

8. Always keep the drum in the protective sheet when inserting or pulling the drum unit out of the copier to avoid exposing it to bright light or direct sunlight. This will protect the drum from light fatigue.

9. Before inserting or pulling out the drum unit, the following should be performed to avoid damaging the drum: a) Remove the cleaning unit.

b) Remove the development unit.

c) Remove the charge corona unit.

d) Release the transport unit.

10. Before pulling out the drum unit, place a sheet of paper under the drum to catch any dropped toner.

11. Drum initial setting (SP #66) must be performed when a new drum is installed.

NOTE: This is not necessary at installation of a new machine as the drum initial setting is performed at the factory.

12. Dispose of the used drum according to local regulations.

2-3

1 December 1990

2. DRUM CHARGE

2.1 OVERVIEW

[C] [B]

[A]

[C]

[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.

The exhaust blower, located above the copy exit, causes a flow of air from the upper area of the development unit through the charge corona unit. This prevents uneven build-up of negative ions that can cause uneven image density. The exhaust blower runs at half speed when in the stand-by condition and runs at full speed while copying.

The exhaust blower has an ozone filter (active carbons) which adsorbs ozone

(O

3

) generated by the corona discharge. The ozone filter decreases in efficiency over time as it adsorbs ozone. The ozone filter should be replaced at every 60,000 copies.

The flow of air around the charge corona wire may deposit paper dust or toner particles on the corona wire. These particles may interfere with charging and cause low density bands on copies. The wire cleaner cleans the corona wire when the operator slides the corona unit in and out.

2-4

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.

The pads move away from the wire when the charge unit is fully inserted and the cleaning bracket is pushed against the front block [D].

After copier installation the key operator should be instructed how to use this mechanism when copies have white streaks.

2-5

1 December 1990

2.3 CHARGE CORONA CIRCUIT

VA [24]

VC [5]

CN112-8

CN112-7

CN112-6

CC Trig [ 24]

CN112-5

Grid Trig (PWM) [ 0 0/5]

CN112-4

CN112-3

Grid FB

GND [0]

CN112-2

CN112-1

CN1-1

CN1-2

CN1-3

CN1-4

CN1-5

CN1-6

CN1-7

CN1-8

CC/Grid/Bias

Power Pack

(P1)

TC

TG

TB

Main Board (PCB 1)

Charge

Corona Wire

Grid

Development

Roller

The main board supplies +24 volts to the CC/Grid/Bias power pack at CN1-1 as the power supply source. About 0.44 seconds after the Start key is pressed, the CPU drops CN1-3 from +24 volts to 0 volts. This energizes the charge corona circuit within the CC/Grid/Bias power pack, which applies a high negative voltage of approximately –5.6 kv to the charge corona wire.

The corona wire then generates a negative corona charge.

The grid limits the charge voltage to ensure that the charge does not fluctuate and an even charge is applied to the drum surface.

The grid trigger pulse applied to CN1-5 is a pulse width modulated signal

(PWM signal). This signal is not only a trigger signal; it also changes the voltage level of the grid. As the width of the pulse applied increases, the voltage of the grid also increases. The CPU monitors the grid voltage at

CN1-7 and controls the width of the grid trigger pulses based on this feedback.

2-6

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. (The chargeability of a new OPC drum may change after installation, but this stabilizes at around 2,000 copies.) Vp correction is based on the drum counter. The counter resets to "0" when drum initial setting (SP mode #66) is performed.

Both correction factors are applied to the copy process as follows:

1. Image area

Grid Voltage = –920 volts

+

L

100 to 89 (%)

88 to 76 (%)

75 to 62 (%)

61 to 45 (%)

44 to 0 (%)

Change of Grid Voltage

± 0 (volts)

–40 (volts)

–80 (volts)

–120 (volts)

–160 (volts)

L = Vrp/Vsg x 100 (Vr correction ratio)

Vrp: ID sensor output for Vr correction pattern

Vsg: ID sensor output for bare drum

2. Non-image area

Grid Voltage = 0 volts (Fixed)

2-7

1 December 1990

3. ID sensor pattern area

Grid Voltage = –620 volts

+

Drum Counter

0 to 999 (copies)

1,000 to 1,999 (copies)

Over 2,000 (copies)

4. Vr correction pattern area

±

Vp Correction Factor

Black

0 (volts)

–20 (volts)

–40 (volts)

Grid Voltage = –500 volts (Fixed)

Color

± 0 (volts)

± 0 (volts)

–20 (volts)

2-8

3. OPTICS

3.1 OVERVIEW

[C] [B] [A]

1 December 1990

[E] [H] [F] [J]

[D] [I] [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. The air flows from the right to the left in the optics cavity and exhausts through the vents in the left cover. These fans operate during the copy cycle.

This copier has six standard reproduction ratios: Three reduction ratios, two enlargement ratios, and full size. It also has a zoom function. The operator can change the reproduction ratio in one percent steps from 50% to 200%.

Stepper motors are used to change the positions of the lens and mirrors.

Separate motors are used because the wide range of reproduction ratios makes it mechanically difficult for one motor to position both the lens and mirrors. A stepper motor is also used to drive the scanner. This motor changes the scanner speed according to the reproduction ratio.

The thermoswitch opens at 130 o C and removes ac power to the exposure lamp to prevent overheating. The thermoswitch can be reset manually when the exposure lamp area cools.

2-9

1 December 1990

3.2 SCANNER DRIVE

[B]

[E]

[D]

[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.

The first scanner [D], which consists of the exposure lamp and the first mirror, is connected to the scanner drive wire by the wire clamps [E]. The second scanner [F], which consists of the second and third mirrors, is connected to the scanner drive wire by movable pulleys (the second scanner pulley [G]).

The pulley moves the second scanner at half the velocity of the first scanner.

This is to maintain the focal distance between the original and the lens during scanning. This relationship can be expressed as:

V1r = 2 (V2r) = VD/r

where r = Reproduction ratio

V1r = First scanner velocity (when the reproduction ratio

V2r

VD

is "r")

= Second scanner velocity (when the reproduction ratio

is "r")

= Drum peripheral velocity (120 mm/s)

2-10

1 December 1990

3.3 LENS DRIVE

[D]

[C]

[E]

[B] [F]

[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]. The main board keeps track of the lens position based on the number of pulses sent to the lens motor.

3.3.2 Shading Mechanism

The shading plates [E] are installed on the lens housing [F] and are slid open and shut by the shading cam [G]. This shading mechanism adjusts the horizontal light intensity, which becomes uneven in reduction mode, when the light at both edges is more intense. The shading plates close in reduction mode to even out the light intensity.

2-11

1 December 1990

3.3.3 Lens Positioning

[A] [C]

[D]

[B]

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%)

Enlargement Side Reduction Side

The lens home position sensor [A] informs the main board when the lens is at full size position (home position). The main board determines the lens stop position in reduction and enlargement modes by counting the number of steps the motor makes with reference to the lens home position. When a new reproduction ratio is selected, the lens [B] moves directly to the selected magnification position.

The lens home position is registered each time the lens starts from or passes through the lens home position sensor. As the lens moves from the enlargement side to the reduction side, the sensor registers the home position. This occurs when the actuator plate [C] enters the lens home position sensor.

A small vibration can be observed when the lens moves through home position from the reduction side to the enlargement side because the lens is going in the wrong direction to register the home position. The lens overshoots the home position by only one pulse before going back to register the home position.

The lens always stops while moving from left to right (as viewed from the front) to minimize the error caused by mechanical play in the drive gears [D].

2-12

3.4 4TH AND 5TH MIRROR DRIVE

[B]

1 December 1990

[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%)

3.4.1 Drive

The 4th/5th mirror drive motor (stepper motor) changes the 4th/5th mirror assembly position through the pinion gears [A] and the rack gear [B] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and drum surface.

3.4.2 Positioning

The positioning mechanism is similar to that of lens positioning, as shown in the above positioning chart. The scanner always stops while moving from right to left (as viewed from the front).

2-13

1 December 1990

3.5 STEPPER MOTOR CONTROL CIRCUIT

Scanner

H.P. Sensor

(S1)

CN122-3

CN122-4

CN122-5

Lens

H.P. Sensor

(S2)

CN102-7

CN102-8

CN102-9

4th/5th

Mirror

H.P. Sensor

(S3)

CN102-10

CN102-11

CN102-12

CN806-3

CN806-2

CN802-1

CN824-3

CN824-2

CN824-1

CN826-3

CN826-2

CN826-1

[0] GND VM [30]

[ 5]

Scanner H.P.

A [ 30 0/30]

[5] VC A [ 30 0/30]

CN105-1

CN105-2

CN105-3

CN105-4

B [ 30 0/30]

[0] GND B [ 30 0/30]

[ 5] Lens H.P.

VM [30]

[5] VC

VA[24]

CN105-5

CN105-6

CN102-1

CN102-2

[0] GND

A [ 24 0/24]

A [ 24 0/24]

CN102-3

[ 5] 4th/5th

Mirror H.P.

[5] VC

B [ 24 0/24]

B [ 24 0/24]

CN102-4

CN102-5

CN102-6

VA[24]

CN106-1

VA[24]

CN106-2

A [ 24 0/24]

CN106-3

A [ 24 0/24]

CN106-4

B [ 24 0/24]

CN106-5

B [ 24 0/24]

CN106-6

VA[24]

Main Board (PCB1)

4

3

2

1

CN825

6 1

5 2

3

4

5

6

Scanner

Motor

(M2)

Lens

Motor

(M3)

4th/5th

Mirror

Motor

(M4)

Step 1 2 3 4 5 6 7 8

Com.

1

Com.

6

A

B

A

B

ON

OFF

ON

OFF

ON

OFF

ON

OFF

2 3 4 5

A A B B

The scanner motor, the lens motor, and the 4th/5th mirror motor are all stepper motors. The scanner motor operates on +30 volts. Both the lens motor and the 4th/5th mirror motor operate on +24 volts. The stators of these stepper motors have four coils (labeled A, B, A, B above), and the rotor is made of permanent magnets. Pulse signals energize the four coils as shown in the above illustration. The rotors of these motors turn in discrete steps, and

48 steps are required for one revolution.

2-14

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. The main board determines the stop position by counting the number of steps the motor makes with reference to the home position.

2-15

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. Sampling starts 10 millimeters from the leading edge of the original and continued to 40 millimeters from the leading edge of original in full size mode.

The length A and B in each reproduction ratio are calculated as follows:

A=

10 mm

Reproduction Ratio (%) x100 B=

40 mm

Reproduction Ratio (%) x100

The photosensor circuit converts the light intensity to a voltage. The detected voltage is amplified and sent to the main PCB. The CPU stores the voltage of each sampled point in RAM. It then computes the image density of the original from the maximum sample voltage and changes the development bias accordingly. (See page 2-30 for details.) The exposure lamp voltage is constant regardless of the image density of the original. (See page 2-18 for details.)

2-16

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.

117

118

119

120

121

122

111

112

113

114

115

116

123

124

125

105

106

107

108

109

110

100

101

102

103

104

Exposure Lamp Data/Voltage Reference Table

Exposure

Lamp Data

65.0

65.6

66.2

66.8

67.3

67.9

61.6

62.2

62.8

63.3

63.9

64.5

Exposure Lamp Voltage

(Standard)

115V machine

57.1

57.6

220/240V machine

105.9

106.9

58.2

58.8

59.3

59.9

60.5

61.1

108.0

109.1

110.1

111.2

112.2

113.3

68.5

69.0

69.6

70.2

70.8

71.3

127.1

128.1

129.2

130.2

131.3

132.4

114.4

115.4

116.5

117.5

118.6

119.6

120.7

121.8

122.8

123.9

124.9

126.0

Exposure

Lamp Data

143

144

145

146

147

148

149

150

137

138

139

140

141

142

131

132

133

134

135

136

126

127

128

129

130

79.9

80.5

81.0

81.6

82.2

82.7

76.5

77.0

77.6

78.2

78.7

79.3

Exposure Lamp Voltage

(Standard)

115V machine

71.9

72.5

220/240V machine

133.4

134.5

73.0

73.6

74.2

74.7

75.3

75.9

135.5

136.6

137.6

138.7

139.8

140.8

83.3

83.9

84.4

85.0

85.6

154.6

155.6

156.7

157.8

158.8

141.9

142.9

144.0

145.1

146.1

147.2

148.2

149.3

150.4

151.4

152.5

153.5

NOTE: Exposure lamp rating: 100V machine: 85V/300W

2-17

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

Manual ID Level

Exposure Lamp Data

Darker Lighter

1 2 3 4 5 6 7

Vo –4 Vo

±

0 Vo

±

0 Vo

±

0 Vo +4 Vo +8 Vo +12

The above table shows changes in the exposure lamp data in manual image density mode.

SP mode #48 sets the exposure lamp data for level 4 (Vo) of manual image density mode. A value from 100 to 150 can be selected.

3.7.2 Base Lamp Voltage Factor In Auto Image Density Control

In auto ID mode, the CPU selects the level 4 (Vo) exposure lamp data regardless of the input from the auto image density sensor. When the auto image density level is set to lighter in SP mode #34, the exposure lamp data changes to that of manual ID level 5 as shown below. When the auto image density level is set to darker, the development bias shifts +40 volts. Only the development bias varies according to the input from the auto image density sensor. (See page 2-30).

Auto Image Density Level (SP mode #34)

Auto Image Density

Level

SP Data

(SP mode #34)

Exposure Lamp Data

Normal

Darker

Lighter

0

1

2

Same as level 4

(Vo

±

0)

Same as level 4

(Vo

±

0)

Same as level 5

(Vo +4)

Development Bias

Shift

±

0 volts

+40 volts

±

0 volts

2-18

1 December 1990

3.7.3 Reproduction Ratio Correction Factor

Exposure

Lamp

Data

+10

+5

Lighter

50 62 100 140 150 160

Reproduction Ratio

180 200 (%)

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.

2-19

1 December 1990

3.7.4 Drum Wear Correction Factor

Exposure

Lamp

Data

+10

(Max)

+5

SP #61 = 0

SP #61 = 1

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. The total increase cannot exceed 8.

2-20

1 December 1990

3.8 EXPOSURE LAMP CONTROL CIRCUIT

CN108-1

Main Board (PCB1)

B

Zero

Cross

TP111

(EXPO)

E

Feed back signal

CN122-7 CN401-8

0V

CN122-6 CN401-7

CPU

+24V CN122-13 CN401-2

C

24V

0V Trigger Pulse

CN122-10 CN401-5

R401

AC Drive Board (PCB2)

R404

ZD

401

ZD

402

VR401

R403

R404

D401

C401

ZD

403

ZD

404

R406

R411

DB401

TR401

T402

CN421

240V

220V

220V Only

CN419-1

Thermo-

SW (TS)

Exposure

Lamp

(L1)

D

CN419-2

PC401

TRC401

CR401

L401

L402

C411

T407

R413

A

AC115V

AC220V

AC240V

AC power

A

Zero cross

B

Trigger pulse

C

Lamp power

Feedback signal

D

E

Feedback

The main board sends lamp trigger pulses to the ac drive board from

CN122-10. PC401 activates TRC401, which provides ac power to the exposure lamp, at the trailing edge of each trigger pulse.

The voltage applied to the exposure lamp is also provided to the feedback circuit. The feedback circuit steps down (TR401), rectifies (DB401), and smoothes (zener diodes and capacitors) the lamp voltage. The CPU monitors the lowest point of the smoothed wave (feedback signal), which is directly proportional to the actual lamp voltage.

The CPU changes the timing of the trigger pulses in response to the feedback voltage. If the lamp voltage is too low, the CPU sends the trigger pulses earlier so that more ac power is applied to the exposure lamp. This feedback control is performed instantly; so, the lamp voltage is always stable even under fluctuating ac power conditions.

The voltage applied to the exposure lamp can be changed with SP mode #48

(Light Intensity Adjustment). The ADS voltage adjustment (SP mode #56) must be done whenever the light intensity adjustment is done.

2-21

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.

Service Code 13: Zero Cross Signal Error

The CPU does not receive the zero cross signal within 0.56 second.

Service Code 21: Scanner Home Position Error

The scanner home position sensor remains off (LOW) 8 seconds after the main switch is turned on.

Service Code 22: Scanner Home Position Error

The scanner home position sensor is still on (HIGH) 1.0 second after the scanner starts.

Service Code 28: Lens Home Position Error

The lens home position sensor remains off (LOW) 3.5 seconds after the lens moves to the home position.

Service Code 29: Lens Home Position Error

The lens home position sensor is still on (HIGH) 3.5 seconds after the lens leaves the home position.

Service Code 2A: 4th/5th Mirror Home Position Error

The 4th/5th mirror home position sensor is still on (HIGH) 2.5 seconds after the 4th/5th mirror assembly moves to the home position.

Service Code 2B: 4th/5th Mirror Home Position Error

The 4th/5th mirror home position sensor is still off (LOW) 2.5 seconds after the 4th/5th mirror assembly leaves the home position.

2-22

1 December 1990

4. ERASE

4.1 OVERVIEW

LE

EL

SE

ES

Lo

Lc

LE: Lead edge erase margin

SE: Side erase margin

LO: Original width

LC: Charged width of drum

EL: Lead edge erase

ES: Side erase

2.5 ± 1.5 mm

2.0 ± 2.0 mm on each side; total of both sides 4 mm or less

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. Trail edge erase begins after the trailing edge of the copy paper; therefore, the trailing edge of the copy will not be erased.

2-23

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. The width of the lead edge erase margin can be adjusted using SP mode #41.

During the image density detection cycle (once every ten copy cycles), a block of erase lamps (labeled "h" above) turns off long enough for the sensor pattern to be developed.

The entire line of LEDs turns on when the residual voltage on the OPC drum is being detected (Vr correction).

4.1.2 Side Erase

Based on the combination of copy paper size and the reproduction ratio data, the LEDs turn on in blocks (labeled "a" – "h" above). This reduces toner consumption and drum cleaning load.

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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

4.1.3 Trailing Edge Erase

The entire line of LEDs turns on again to erase the trailing edge after the latent image has passed. This prevents the trailing edge from appearing on the copy. The LEDs stay on to erase the leading edge of the latent image in the next copy cycle. After the final copy, the erase lamps turn off at the same time as the main motor.

2-25

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]. The doctor blade trims the developer to the desired thickness and creates backspill to the cross-mixing mechanism.

The development roller continues to turn, carrying the developer to the OPC drum. When the developer brush contacts the drum surface, the negatively charged areas of the drum surface attract and hold the positively charged toner. In this way, the latent image is developed.

The development roller is given a negative bias to prevent toner from being attracted to non-image areas on the drum that may have residual negative charge. The bias also controls image density.

After turning about 100 degrees more, the development roller releases the developer to the developer tank. The developer is agitated by the paddle roller, agitator [D], and the cross-mixing mechanism.

Rotation of the paddle roller and development roller tend to cause air pressure inside the unit to become higher than the air pressure around the development unit. A hole, fitted with a filter [F], has been added to the top of the unit to relieve air pressure and to minimize toner scattering.

2-26

1 December 1990

5.2 DRIVE MECHANISM

[I]

[G]

[E]

[H]

[J]

[A]

[D]

[F]

[B]

[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].

A gear [G] on the front end of the paddle roller shaft drives the auger gear [H] and the agitator gear [I]. The paddle roller shaft has a knob [J] on the front end so that it can be turned manually to exchange toner. The knob has a one-way clutch inside. The one-way clutch prevents the development roller from turning in the wrong direction.

The development clutch solenoid energizes each copy cycle after image development is completed. This stops the rollers, thereby reducing developer fatigue.

2-27

1 December 1990

5.3 CROSS-MIXING

[F]

[A]

[D]

[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. The part that is trimmed off by the doctor blade goes to the backspill plate [C].

As the developer slides down the backspill plate to the agitator [D], the mixing vanes [E] move it slightly toward the rear of the unit. Part of the developer falls into the auger inlet and is transported to the front of the unit by the auger

[F].

The agitator moves the developer slightly to the front as it turns, so the developer stays level in the development unit.

2-28

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. Similarly, increasing the voltage to the exposure lamp causes an increase in light intensity which also results in lighter copies.

The method of control is different depending on whether the image density is manually selected or the automatic ID mode is used.

The development bias applied to the development roller sleeve has the following three factors:

Development bias voltage = Base bias voltage factor

+

Base bias voltage adjustment factor

+

Vr correction factor

The base bias voltage for non-image areas is –200 volts (Fixed).

5.4.1 Base Bias Voltage Factor In Manual Image Density Control

Darker Lighter

Manual ID Level 1 2 3 4 5 6 7

Base Bias Voltage –120 –120 –160 –200 –200 –240 –280

Exposure Lamp Data Vo –4 Vo Vo Vo Vo +4 Vo+8 Vo+12

In manual ID control mode, the base bias voltage depends on the manually selected ID level. The voltage applied at each ID level is shown in the above table. The base exposure lamp voltage also varies depending on the manual

ID level as shown in the table. (See page 2-18 for more information.)

2-29

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. This circuit has a peak hold function. The peak hold voltage corresponds to the maximum reflectivity of the original. The CPU then determines the proper base bias level with reference to the peak hold voltage.

The following table gives the base bias voltages at each ADS output level.

When the automatic density level is set to darker by SP mode #34, the base bias voltage shifts +40 volts as shown in the following table.

K

Base Bias Voltage

Normal or Lighter

(SP mode #34 = 0 or 2)

Darker

(SP mode #34 = 1)

K TH1

TH1

>

K

≥

TH2

TH2

>

K

≥

TH3

TH3

>

K

–200 volts

–260 volts

–320 volts

–380 volts

ADS Output Voltage

(

Peak Hold Voltage

)

K

ADS Adjusted Voltage

(

SP #56

)

–160 volts

–220 volts

–280 volts

–340 volts

TH1 to 3: Threshold level (See the following table.)

To maintain the correct image density, the lamp data is incremented when the reproduction ratio is changed and/or drum wear correction is done. This increment in the lamp data increases the intensity of light reflected from the original. Therefore, the ADS output voltage also changes.

In order to maintain a constant voltage for the same original when the lamp data is incremented, the threshold levels are shifted with each increment in the lamp data as shown in the following table.

Increase of lamp data

TH1

TH2

TH3

+0 +1 +2 +3 +4 +5 +6 +7 +8 +9

0.70

0.75

0.80

0.85

0.89

0.94

0.98

1.03

1.08

1.12

0.66

0.70

0.74

0.78

0.83

0.87

0.91

0.96

1.00

1.04

0.29

0.31

0.33

0.35

0.37

0.39

0.41

0.43

0.45

0.48

2-30

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. This adjustment should be done only when the exposure lamp voltage adjustment (SP mode #48) fails to achieve the desired image density.

5.4.4 Vr Correction Factor

As the OPC drum is used, drum residual voltage (Vr) gradually increases. Vr correction compensates for residual voltage on the drum. Vr correction is done every 1,000 copies based on the data of the drum counter (SP mode

#69) and the Vr correction ratio (L) (SP mode #67). The following chart shows how the bias voltage changes depending on the Vr correction ratio (L).

L

100 to 89 (%)

88 to 76 (%)

75 to 62 (%)

61 to 45 (%)

44 to 0 (%)

Change of Bias Voltage

± 0 (volts)

–40 (volts)

–80 (volts)

–120 (volts)

–160 (volts)

NOTE: L = Vrp/Vsg x100 (Vr Correction Ratio)

Vrp: ID sensor output for Vr correction pattern

Vsg: ID sensor output for bare drum

When the Vr correction is made every 1,000 copies, all blocks of erase lamps turn on and the development bias becomes 0 volts to develop the Vr correction pattern.

2-31

1 December 1990

5.5 DEVELOPMENT BIAS CIRCUIT

CN112-8

VA [24]

VC [5]

CN112-7

CN112-6

CN112-5

Bias Trig (PWM) [ 0 0/5]

CN112-4

CN112-3

Bias FB

CN112-2

CN112-1

GND [0]

CN1-1

CN1-2

CN1-3

CN1-4

CN1-5

CN1-6

CN1-7

CN1-8

CC/Grid/Bias

Power Pack

(P1)

TC

TG

TB

Main Board (PCB 1)

Charge

Corona Wire

Grid

Development

Roller

The main board supplies +24 volts to the CC/Grid/Bias power pack at CN1-1 as the power supply source. When the Start key is pressed, the CPU starts sending the bias trigger pulse to CN1-4. This energizes the development bias circuit within the CC/Grid/Bias power pack, which applies a high negative voltage to the development roller. The development bias is applied whenever the drum is rotating except when the Vr pattern is developed.

The bias trigger pulse applied to CN1-4 is a pulse width modulated signal

(PWM signal). This signal is also used to change the voltage level of the development roller. As the width of the trigger pulses increase, the voltage of the development roller also increases. The CPU monitors the development bias voltage at CN1-6 and controls the width of the bias trigger pulses based on this feedback.

2-32

5.6 DEVELOPMENT UNIT SET SENSOR

[B]

1 December 1990

[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.

2-33

1 December 1990

5.7 COLOR DEVELOPMENT UNIT DETECTION

[A] [D]

[C]

[B]

[C]

[A]

[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. The CPU receives a LOW signal from the microswitch activated by the screw and determines which color unit has been installed.

2-34

1 December 1990

6. TONER DENSITY DETECTION AND TONER

SUPPLY

6.1 DETECT SUPPLY MODE

Sensor

Pattern

Original Lead Edge

Original

A

ON

B

OFF

C

ON

D E

OFF

Leading Edge Erase

RAM Clear

1 2 3 4 5 6 7 8 9 10 11 12 13 14

ID Sensor

Pattern

20 21 22

Development

Bias

Toner Density Detection

1st

Toner Density Detection

2nd

Low Toner Density

Toner Supply Timing

Toner Density

Detection

3rd

Detection

Toner Add

Toner Supply Clutch ON

(10 times)

Detection

The CPU checks toner density by directly sensing the image density every 10 copy cycles (every 5 copies for the color development unit). If the RAM is cleared (SP mode #99), or a new RAM is installed, the CPU checks the image density at the beginning of the first copy cycle.

During the check cycles, the sensor pattern is exposed prior to exposure of the original. After the sensor pattern is developed, its reflectivity is checked by the image density sensor (a photosensor). The CPU notes the reflectivity.

If the reflected light is too strong, indicating a too low toner density condition, toner is added to the development unit.

The toner is not added all at once. The CPU energizes the toner supply clutch solenoid for the proper amount of time to add a selected amount of toner over the next 10 cycles.

When a color development unit is used, the CPU automatically selects fixed toner supply mode.

2-35

1 December 1990

6.2 ID SENSOR FUNCTION IN DETECT SUPPLY MODE

I/D Sensor

+5V

Main Board

+24V

B CN110-2 CN118-2

A C

TP 110

(PSE)

SOL 1

K

R

E

C CN110-3

ID Sensor Output

A CN110-1

ID Sensor LED

VR102

IC 105

I/O

IC111

ROM

IC190

RAM

CPU

CN118-1

Toner Supply

CL Solenoid

Vsg 4V

Low Density

Vsp

(1/8 Vsg)

High Density

[BLACK]

The image density sensor checks the density of the sensor pattern image once every 10 copy cycles. The CPU receives two voltage values directly from the sensor: the value for the bare drum (Vsg) and the value for the sensor pattern (Vsp). These two values are then compared to determine whether more toner should be added.

1. Vsp ≤ 1/8 Vsg .....No toner is added. (High density)

2. Vsp >1/8 Vsg .....Toner is added.(Low density)

When the image density is too low, the CPU activates the toner supply clutch solenoid to add toner over the next 10 copy cycles. The amount of toner added depends on the value of Vsp, the selected toner supply ratio (SP mode #31) and the paper size in use. (See page 2-42 for more information.)

When the data of SP mode #35 is set to "1" (factory setting = "0"), the CPU changes the interval of the ID check from every 10 copies to every 5 copies for the black development unit.

2-36

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.)

2-37

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

Vsp

[BLACK]

6.4.2 Color Development Unit

1/8 Vsg

High Density

When a color development unit is installed, the CPU automatically selects the fixed toner supply mode. The amount of toner supplied depends on the fixed toner supply ratio (SP mode #70), the paper size data and the kind of color data.

The CPU calculates the threshold level for toner supply when the color developer initial setting (SP mode #10) procedure is completed. This level is determined by calculating the average of Vsp/Vsg x 100 (%).

Since the fixed supply mode is selected when in color toner mode, it is necessary to inhibit toner supply if the toner density becomes high to prevent over-toning. The CPU checks Vsp once every 5 copy cycles. If Vsp becomes lower than the threshold level, the CPU stops supplying toner. Toner supply resumes when Vsp rises above the threshold level again.

Vsg 4V

Vsp

Low Density

Threshold Level

High Density

[COLOR]

The threshold level (a percentage) for each color can be monitored in SP mode #80 (Red), #81 (Green) and #82 (Blue).

2-38

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.

Abnormal Condition In Toner Density Detection

SP mode #55 Display

Vsp Vsg varies varies

0.00

5.00

Conditions

Vsg

≤

2.5 (Vsg Abnormal)

Vsp

≥

2.5 (Vsp Abnormal)

6.6 DEVELOPMENT BIAS FOR ID SENSOR

The development bias for the ID sensor consists of the following 2 factors:

Development bias voltage = Toner density adjustment factor

+

Vd correction factor

The development voltage for the Vr correction is 0 volts.

6.6.1 Toner Density Adjustment Factor

Toner Density Adjustment

(Black Toner: SP Mode #33, Color Toner: SP Mode #75)

Development Bias Voltage

Toner Density

SP Data

(SP mode

#33 or #75)

Normal

Low

High

0

1

2

Higher 3

Developer Initial Setting

Black Toner Red Toner

–260 volts

–220 volts

–280 volts

–300 volts

–340 volts

–240 volts

–200 volts

–260 volts

–280 volts

–280 volts

Blue Toner Green Toner

–300 volts

–260 volts

–320 volts

–340 volts

–240 volts

–320 volts

–280 volts

–340 volts

–360 volts

–240 volts

The development bias can be adjusted by SP mode #33 for black toner or

#75 for color toner to adjust the toner density level. The above chart shows the development bias voltage corresponding to setting of SP #33 or #75. This adjustment should be used only when the exposure lamp voltage adjustment

(SP mode #48) can not achieve the desired image density.

2-39

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. This threshold level is the average of Vsp/Vsg x 100 (%). The result of the calculation can be monitored by SP mode #64. The CPU has a software counter to count number of copies made with the developer. The counter resets to "0" when SP mode #65 is performed. The Vd correction is made based on the data of the counter and of SP mode #64. The following table gives the threshold levels for each data value of SP#64.

SP Data

(SP mode #64)

2

3

0

1

4

Vsp/Vsg x100 (%)

12 to 15

0 to 7

8 to 11

16 to 21

More than 22

Change of Development Bias Voltage

0 to 499 copies

±

0 volts

–40 volts

–20 volts

±

0 volts

±

0 volts

More than 500 copies

±

0 volts

±

0 volts

±

0 volts

+20 volts

+40 volts

2-40

1 December 1990

6.7 TONER SUPPLY AND AGITATOR DRIVE MECHANISM

[F] [H]

[J]

[I]

[E]

[F]

[G]

[C]

[A]

[D]

[B]

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]. Toner catches in the grooves on the toner supply roller [F]. Then, as the grooves turn past the pin hole plate [G], the toner drops into the development unit through the pin holes.

The toner agitator [H] mechanism, which is contained in the toner cartridge, prevents toner from blocking. The toner agitator gear [I] turns whenever the toner supply clutch solenoid is engaged. Rotation passes through the toner cartridge casing to the agitator junction [J].

2-41

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.

6.8.1 Detect Supply Mode (SP mode #30 = 0)

The amount of toner supplied depends on the ID sensor data, the detect toner supply ratio data, and the paper size. The toner supply clutch solenoid on time in each copy cycle is calculated as follows:

Toner Supply Clutch Solenoid ON Time = I x T x P (pulses)

Where : I = ID Sensor Data

T = Detect Toner Supply Ratio Data

P = Paper Size Data

For example: Vsp = 0.65 volts, which means the toner

The data of SP mode #31 is set to "0".

The toner supply ratio is 15 % and the toner

The paper size data = 1.

Toner Supply Clutch ON Time = I x T x P

= 29 x 2 x 1

= 232 (m sec.) (1 pulse = 4.0 m sec.)

2-42

1 December 1990

ID Sensor Data

Vsp/Vsg x100

(Vsp, if Vsg = 4.0 volts)

0 to 12.5 %

(0 to 0.5 volts)

12.5 to 15.0 %

(0.5 to 0.6 volts)

15.0 to 17.5 %

(0.6 to 0.7 volts)

17.5 to 25.0 %

(0.7 to 1.0 volts)

25.0 to 62.5 %

(1.0 to 2.5 volts)

(See note below.)

62.5 to more than 100 %

(2.5 to 5.0 volts)

Toner Supply Level

(Toner Supply Ratio, if SP #31 = 0)

No toner supply

(0 %)

1

(3.75 %)

2

(7.5 %)

3

(15 %)

4

(30 %)

Fixed supply mode

ID Sensor Data

0

15

29

59

118

N/A

NOTE: If this condition is detected two times consecutively, the toner supply ratio rises to 60% (ID Sensor Data = 236), which is double that at toner supply level 4.

Detect Toner Supply Ratio Data (SP mode #31)

SP Data

(SP mode #31)

0

1

2

3

Toner Supply Ratio

15 %

7 %

30 %

60 %

Paper Size Data

Paper Size

Paper Size

≤

A4 or LT

Paper Size > A4 or LT

Paper Size Data

1

2

Toner Supply Ratio Data

2

1

4

8

2-43

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

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.

Paper size is A4. The paper size data = 29.

Black toner is used. The color data = 1.

Toner Supply Clutch ON Time = T x P x 2 x C

= 2 x 29 x 2 x 1

= 464 (m sec.) (1 pulse = 4.0 m sec.)

2-44

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

7.0 %

3.5 %

10.5 %

14.0 %


3

4

2

1

Fixed Toner Supply Ratio Data (Color Toner : SP mode #70)

SP Data

(SP mode #70)

0

1

2

3

Toner Supply Ratio

14.0 %

7 .0%

21.0 %

28.0 %


3

4

2

1

Paper Size Data

Paper Size

A3

B4

A4

B5

A5

B6

11" X 17"

8 1/2" X 14"

8 1/2" X 11"

5 1/2" X 8 1/2"

Universal ( * )

Paper size not detected

Color Data

Color

Black

Red

Blue or Green

Paper Size Data

58

43

29

23

37

27

14

15

11

55

29

0

Color Data

1

2

1.2

2-45

1 December 1990

6.9 TONER END DETECTION

[E]

[C] [D]

[G]

[F]

[A] [B]

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. The toner end plate [E], which is in the toner hopper, is mounted on the same shaft as the toner end arm.

When there is sufficient toner in the hopper, the toner end plate is prevented from moving by the toner. Therefore, even when the toner end lever drops to the lowest position on the cam (releasing the toner end arm), the toner end arm does not move and the toner end sensor [F] is not activated.

When there is insufficient toner in the hopper, the toner end plate can move.

When the toner end lever releases the toner end arm, the toner end plate lowers and the actuator [G] on the toner end arm moves into the toner end sensor. The CPU receives a single pulse from the toner end sensor.

2-46

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. However, it can also be detected using the ID sensor. The Add Toner indicator will start blinking in the following cases:

Black Development Unit: If Vsp exceeds 1/4 Vsg 10 times in a row.

Color Development Unit: If Vsp/Vsg exceeds 1.1 x threshold level 10 times in a row. The threshold level is the average of Vsp x Vsg, which is calculated and stored in RAM when the color developer initial setting (SP mode #10) procedure is completed.

When Vsp exceeds 1/4 Vsg in the black development unit, the CPU checks toner density every 5 copy cycles instead of every 10 copy cycles.

When the toner cartridge is replaced and the front cover is closed, the CPU turns on the main motor, the development clutch solenoid, and the toner supply clutch solenoid for approximately 3 seconds to supply toner to the empty toner supply unit from the toner cartridge. A toner end check is also done during this 3 second period. The CPU performs this operation a maximum of 3 times (9 seconds) to clear the toner end condition.

6.10 TONER SUPPLY UNIT INITIAL SETTING (SP mode #63)

When a brand-new machine is installed or the toner supply unit is replaced with a new one, the toner supply unit initial setting (SP mode #63) must be performed to prevent the CPU from falsely detecting toner end.

When SP mode #63 is performed, the CPU turns on the main motor, the development clutch solenoid, and the toner supply clutch solenoid for approximately 3 seconds to supply toner to the empty toner supply unit from the toner cartridge. A toner end check is also done during this 3 second period. The CPU performs this operation a maximum of 3 times (9 seconds) to clear the toner end condition.

2-47

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. It also makes image transfer and paper separation easier.

7.2 IMAGE TRANSFER

A high negative voltage (–4.8 kilovolts) is applied to the transfer corona wire

[C], and the corona wire generates negative ions. These negative ions are applied to the copy paper, and the negative charge attracts the positively charged toner away from the drum and onto the paper. In addition, the paper is held against the drum by the positive counter charge on the drum.

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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. The two pick-off pawls [E] ensure that thin, low stiffness paper and upward curled paper separate completely.

The spurs [F] prevents the unfused toner on the paper from being smeared by the pick-off pawls.

2-49

1 December 1990

7.4 PRE-TRANSFER LAMP AND TRANSFER/SEPARATION

PTL (L5)

CN121-2

[24] VA VA [24]

CN126-5

CN126-4

TC2 Trig [ 24]

CN126-3

TC1 Trig [ 24]

CN126-2

SC Trig [ 24]

GND [0]

CN126-1

CN1-1

CN1-2

CN1-3

CN1-4

CN1-5

TC/SC

Power Pack

(P2)

Transfer Corona

Separation Corona

CN121-1

[ 24] PTL

Main Board

(PCB1)

When the Start key is pressed, the main board outputs Low signals to turn on the pre-transfer lamp (PTL) and the TC/SC power pack for the transfer and separation coronas.

The pre-transfer lamp is composed of 50 LEDs supplied by +24 volts.

The TC/SC power pack has a dc to dc converter and a dc to ac inverter. The dc to dc converter changes +24 volts to -4.8 kilovolts for the transfer corona.

The inverter changes +24 volts to the 5.0 kilovolts ac (500 Hz) for the separation corona.

The TC2 trigger is only used for the second side copies in duplex copy mode.

This shifts the corona current to increase transfer efficiency.

The separation corona circuit in the TC/SC power pack has a current leak detection circuit for safety. When this circuit detects that more than 2 milliampere is supplied to the separation corona, the separation corona turns off immediately. When the main switch is turned off and on, or the front cover or the exit cover is opened and closed, this condition is cleared.

2-50

8. DRUM CLEANING

8.1 OVERVIEW

[E] [B]

1 December 1990

[D]

[A]

[C]

[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. The falling toner catches in the fibers of the cleaning brush and is carried inside the cleaning unit. The toner collection roller [D] carries the used toner to the used toner tank. The light of the quenching lamp [E] neutralizes any charge remaining on the drum in preparation for the next copy cycle.

The cleaning blade releases when the release knob is pressed. This cleans the edge of the cleaning blade using the blade scraper [F], which is mounted under the cleaning blade.

2-51

1 December 1990

8.2 DRIVE MECHANISM

[G]

[H]

[D]

[F]

[E]

[A]

[C]

[B]

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.

2-52

8.3 TONER OVERFLOW DETECTION

[C]

[B]

[A]

1 December 1990

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. After the "E70" starts to blink, 250 copies can be made. Then, after 250 copies the "E70" stops blinking (stays on) and copying is inhibited.

2-53

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.

2-54

10. PAPER FEED AND REGISTRATION

10.1 OVERVIEW

[G]

1 December 1990

[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. Paper can also be fed using the manual feed table [C], which utilizes the feed mechanism of the first feed station.

The first feed station uses a FRR feed system. Rotation of the pick-up roller

[D] drives the top sheet of paper from the cassette to the feed and the reverse rollers. The feed [E] and reverse [F] rollers then take over the paper drive. If more than one sheet is fed by the pick-up roller, the reverse roller rotates in the opposite direction and prevents all but the top sheet from passing through to the registration rollers [G].

The second feed station uses the semicircular feed roller [H] and corner separator [I] system. The semicircular feed roller makes one rotation to drive the top sheet of paper to the relay rollers [J], which then feed the sheet to the registration rollers. The corner separator allows only one sheet to feed.

2-55

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]. At almost the same time that the paper’s leading edge arrives at the feed roller, the pick-up roller lifts off the paper stack so that it does not interfere with the operation of the feed and reverse rollers. The feed and reverse rollers then take over the paper feed process.

10.2.2 Feed and Reverse Rollers

There is a one-way bearing inside the feed roller so it can turn only in one direction. The reverse roller is driven in the opposite direction to the feed roller. The reverse roller, however, is driven through a slip clutch (torque limiter clutch) which allows it to turn in either direction depending on the friction between the rollers. A spring keeps the reverse roller in contact with the feed roller.

2-56

1 December 1990

F2

[B]

F2 F1

[A]

F1

[B]

F2

F3

F3

F1

[A]

F1

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.

If two or more sheets are fed between the rollers, the forward force on the second sheet (F3), becomes less than F1 because the coefficient of friction between the two sheets is small. So, the reverse roller starts turning clockwise and drives the second sheet back to the cassette.

2-57

1 December 1990

10.3 1ST FEED STATION PAPER LIFT MECHANISM AND

[H]

[I]

[K]

[J]

[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].

Under the following conditions, the CPU checks the paper lift sensor [H] to see if the paper is at the feed position:

1. When the Start key is pressed.

2. When the warm-up condition changes to the ready condition.

3. When the manual feed table is closed.

2-58

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.

If the tray lift sensor stays HIGH for 7 seconds after the paper lift clutch is turned on, "U5" lights in the operation panel.

As paper is fed into the copier, the level of paper stack gets lower. If the level becomes too low, the paper lift sensor is actuated and the CPU energizes the paper lift clutch until the top sheet raises the feeler to de-actuate the paper lift sensor again. This ensures that the paper is always at the correct feed height.

10.3.2 Paper End Detection

When the cassette runs out of paper, the paper end feeler [J] drops through a slot in the cassette bottom plate. As it drops, the paper end sensor [K] is actuated by the feeler. The paper end sensor then sends a HIGH signal to the main board. The Add Paper indicator then turns on. The Wait indicator keeps turning on and the machine stops after the copy cycle is finished.

2-59

1 December 1990

10.4 2ND FEED STATION PAPER LIFT MECHANISM AND

[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.

Once the lock arm is released, the bottom plate is raised by the pressure spring [E] and the top sheet pushes up the corner separator [F] and stops at the correct feed height.

10.4.2 Paper End Detection

When the paper tray runs out paper, the paper end feeler [G] drops through a slot in the tray bottom plate. The paper end actuator [H], which is on the same shaft as the paper end feeler, pivots into the paper end sensor [I]. The paper end sensor sends a HIGH signal to the main board and then the Add

Paper indicator turns on. The Wait indicator keeps turning on and the machine stops after the copy cycle is finished.

When the paper tray is pulled out, the release arm [J], which is spring loaded, rotates clockwise and lifts the paper end actuator and the paper end feeler.

This prevents the paper end feeler from being damaged by the paper tray.

When the paper tray is closed, the projection [K] on the paper tray pushes the release arm to release the paper end actuator and the paper end feeler.

2-60

10.5 PAPER SIZE DETECTION

10.5.1 1st Feed Station

1 December 1990

[A] SW3–

1 2 3 4 5

[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. The CPU receives a LOW signal from the microswitches activated by the actuator and determines which cassette was inserted.

2-61

1 December 1990

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

Paper Size Detection Table (1st Feed Station)

Paper Size

Switch 3 –

1 2 3 4 5

0 0 0 0 0

1 0 0 0 0

1 1 0 0 0

0 0 1 0 0

1 0 1 0 0

0 1 1 0 0

1 1 1 0 0

0 0 0 1 0

1 0 0 1 0

0 1 0 1 0

1 1 0 1 0

0 0 1 1 0

1 0 1 1 0

0 0 0 0 1

1 0 0 0 1

0 1 0 0 1

1 1 0 0 1

0 0 1 0 1

1 0 1 0 1

0 1 1 0 1

1 1 1 0 1

0 0 0 1 1

1 0 0 1 1

0 1 0 1 1

1 1 0 1 1

0 0 1 1 1

1 1 1 1 1

Size Indication

A3

B4

A4

A4

*

*

A5

A5

*

*

*

*

11 x 17

*

*

*

*

*

F

*

*

1/2 x 11

1/2 x 8 1/2

1/2 x 8 1/2

1/2 x 14

0: Low (ON)

1: High (OFF)

2-62

10.5.2 2nd Feed Station

[F]

1 December 1990

[E]

[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.

Paper Size Detection Table (2nd Feed Station)

Paper Size

A3

F (8" x 13")

A4 lengthwise

A4 sideways

8

8

1/2

1/2

B4

11" x 17"

11" x 8 1/2

" x 11"

" x 14"

"

Switch

4 5 6 7

0 1 1 1

1 0 1 1

1 0 0 1

1 1 0 1

0 0 1 1

0 1 1 1

1 1 1 0

1 1 0 1

1 0 1 1

0 0 0 0

Size Indication

A3

F

A4

A4

B4

11" x 17"

1/2 " x 11"

1/2 " x 11"

8 1/2 " x 14"

0: Low (ON)

1: High (OFF)

2-63

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. When the leading edge of the paper passes between the feed roller [F] and the reverse roller [G], the pick-up roller is then lifted up by the pick-up roller release solenoid [H]. After the trailing edge of the paper passes under the pick-up roller, the pick-up roller release solenoid is de-energized and the pick-up roller drops back onto the paper stack in preparation for the next copy cycle.

2-64

10.6.2 2nd Feed Station

1 December 1990

[H]

[D] [E]

[C]

[A]

[B]

[F]

[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).

Both the relay roller clutch and the 2nd paper feed clutch turn on at the same time to start paper feed. The 2nd feed clutch is energized for 500 milliseconds to transfer drive to the 2nd feed roller shaft and turns the 2nd feed rollers [H]. The 2nd feed rollers stop turning when the 2nd feed clutch gear completes one rotation. The relay roller clutch solenoid stays energized until the leading edge of the paper reaches the registration rollers.

2-65

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. At the same time the pick-up roller release solenoid turns on to release the pick-up roller and the paper end feeler [D] drops down into a slot in the manual feed table and the Add Paper indicator lights.

The manual feed table switch sends a LOW signal to the main board so that the Manual Feed indicator turns on and the pick-up roller is lifted up.

When paper is loaded onto the manual feed table, the paper end sensor is de-actuated and the Add Paper indicator turns off.

2-67

1 December 1990

10.9 PAPER REGISTRATION

[G]

[E]

[F]

[T]

[A]

[C]

[D]

[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.

The registration sensor [F], which is positioned just before the registration rollers [G], controls the paper feed stop timing. The 1st paper feed clutch stays on for 120 milliseconds and the relay roller clutch (2nd feed station) stays on 144 milliseconds after the leading edge of paper actuates the registration sensor. At the end of the period, the CPU turns off the 1st paper feed clutch or the relay roller clutch. This delay allows time for the paper to press against the registration rollers and buckle slightly to correct skew.

The CPU energizes the registration clutch 1.4 seconds after the Start key is pressed. The registration rollers then feed the paper to the image transfer section.

2-68

1 December 1990

10.10 PAPER FEED AND MISFEED DETECTION TIMING

Timing Pulse

(4 m sec/pulse)

0 100 1500 2000 2500 3000 3500

400 m sec

4000

Start Key

Main Motor

<1st Feed Station>

1st Feed Clutch

Pick-up Roller

Release Sol.

Registration

Sensor

Registration

Clutch

<2nd Feed Station>

Relay Roller

Clutch

2nd Feed Clutch

Registration

Sensor

Registration

Clutch

100

100 1433

1750 1750 1750

1877

120 m sec

J1

2010

2273 (A4 S) 1877

2285 (LT S)

120 m sec

2000 2000

J1

2010

2273 (A4 S) 1877

2285 (LT S)

120 m sec

J1

2010

2273 (A4 S)

2285 (LT S)

2000

500 m sec

1433

500 m sec

1433 1433

500 m sec

500 m sec

144 m sec

2000

J1 2010

144 m sec

2000

J1 2010

144 m sec

2000

J1 2010

Tray Lock Sol.

J2

2700

J3 J2

2700

Exit Sensor

2.75 sec (A4 sidewise)

2.80 sec (LT sidewise)

PAPER FEED AND MISFEED DETECTION TIMING

The registration sensor and the exit 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 two sensors for initial misfeed. During the copy cycle, the CPU performs three kinds of misfeed detection:

J1: Checks whether the registration sensor is actuated within 10 pulses (40 milliseconds) after the registration clutch turns on. (The Misfeed Location indicator "A" or "B" turns on.)

J2: Checks whether the exit sensor is actuated within 700 pulses (2.8

seconds) after the registration clutch turns on. (The Misfeed Location indicator "C" turns on.)

J3: Checks whether the copy paper has passed through the exit sensor 2.75

(A4 sideways) or 2.80 (Letter sideways) seconds after the exit sensor has been actuated. (The Misfeed Location indicator "D" turns on.)

2-69

1 December 1990

11. IMAGE FUSING

11.1 OVERVIEW

[F]

[H]

[G]

[E] [D]

[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 o

C. The CPU monitors the hot roller surface temperature through a thermistor [D] which is in contact with the hot roller’s surface. A thermofuse [E] protects the fusing unit from overheating.

The hot roller strippers [F] separate the copy paper from the hot roller and direct it to the exit rollers [G]. The exit sensor [H] monitors the progress of the copy paper through the fusing unit and acts as a misfeed detector while the exit rollers drive the copy paper to the copy tray. When the sorter is installed, the paper sensor on the sorter also functions as a misfeed detector.

2-70

1 December 1990

11.2 FUSING DRIVE RELEASE MECHANISM AND COVER

[B]

[A]

[A]

[E]

[E] [E]

[D]

[C]

[D]

[C]

[D]

[C]

The front cover is opened.

The exit cover is opened.

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.

When the front cover and/or the exit cover is opened, the actuator plate [C] pulls release wire [D] and the fusing unit drive gear is disengaged.

The actuator plate also releases the cover safety switch [E] removing all power from the copier and the optional peripherals.

2-71

1 December 1990

11.3 FUSING LAMP CONTROL

Temp

186 o C

185 o C

Ready 172 o C

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 o

C) through the fusing thermistor. This should take less than 60 seconds. Once the CPU detects the ready temperature, the CPU changes the timing of the fusing lamp on/off check (checks whether the fusing lamp should be turned on or off) from every 1 second to every 5 seconds.

During warm-up, the thermistor’s temperature lags behind the real hot roller’s temperature. As a result, when the thermistor senses the ready temperature, the hot roller is already at or near the operating temperature. At this time the

Ready indicator turns on.

After that, the trigger pulse is turned on constantly when thermistor detects a temperature less than 185 o

C, and is turned off when the thermistor detects

186 o

C.

If the fusing lamp (700W) is turned on or off when the exposure lamp is on, the power supplied to the exposure lamp will fluctuate, possibly degrading the copy image. To prevent this, the fusing lamp does not switch during scanning; it stays either on or off.

2-72

1 December 1990

11.4 FUSING LAMP CONTROL CIRCUIT

CN108-1

B

Zero

Cross

CPU

Main Board (PCB1)

+5V

TP107

(HT)

+5V

R127

+24V

R116

R118

IC121

5 8

6

4

7

R117

R125

R124

C162

CN122-1

Q110

CN122-2

CN122-14

Fusing

Thermistor

CN401-1

I/O

IC124

+24V

24V

0V

Trigger Pulse

C

CN122-10

CN122-12

CN122-13

CN401-6

CN401-3

CN401-2

AC Drive Board (PCB2)

PC402

T402

T405

R412

TRC402

D

Thermofuse

Fusing

Lamp

CR402

T406

A

AC115V

AC220V

AC240V

R414

RA401 T407

RA401

Power Relay

AC Power A

Zero Cross B

Trigger Pulse C

Lamp Power D

The main board monitors the fusing temperature through a thermistor. It also uses the zero cross signal generated by the dc power supply board to accurately control the applied power.

Normally, the voltage applied to the lamp is a full ac waveform. However, through SP mode #29, fusing power can be phase controlled. (Normally, phase control is used only if the customer has a problem with electrical noise or interference.)

When the main switch is turned on, the main board starts to output a trigger pulse [C], which has the same timing as the zero cross signal [B], to the ac drive board. This trigger pulse allows maximum ac power to be applied to the fusing lamp. When the operating temperature is reached, the CPU stops outputting the trigger pulse (trigger goes HIGH) and the fusing lamp turns off.

2-73

1 December 1990

11.4.1 Phase Control Mode

AC Power

Zero Cross

Trigger Low Temp C1

Fusing Lamp Power D1

A

B

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.

The amount of time that power is applied to the fusing lamp [D] depends on the temperature of the hot roller.

The trigger pulse (LOW part) is wider [C1] when the hot roller temperature is lower, and it is narrower [C2] when the hot roller is near the operating temperature.

2-74

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 o

C, 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.

Even if the thermistor overheat protection fails, a thermofuse is installed in series with the fusing lamp. If the thermofuse temperature reaches 169 o

C, the thermofuse opens, removing power from the fusing lamp.

2-75

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 C 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 o

C.

Service Code 55: Fusing Thermistor Open

The temperature detected by the thermistor does not reach

2 C within 30 seconds after the main switch is turned on.

When these service call conditions occure, for safety reason can not be cleared by turning off/on the main switch. The following procedure must be performed to clear these service call conditions:

1. Turn on the main switch.

2. Turn DIP switch 101-1 on and off.

3. Turn the main switch off and on.

NOTE: If the cause of the service call condition is not removed, the service code will be displayed again after this procedure.

2-76

SECTION 3

INSTALLATION

1 December 1990

1. INSTALLATION REQUIREMENTS

1.1 ENVIRONMENT

1. Temperature Range: 10 o

C to 30 o

C (50 o

F to 86 o

F)

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 m

3

. Room air should turn over at least

3 times/hour.

5. Ambient Dust: Less than 0.15 mg/m

3

(4 x 10

-3

oz/yd

3

)

6. If the installation place is air-conditioned or heated, place the machine as follows: a) Where it will not be subjected to sudden temperature changes.

b) Where it will not be directly exposed to cool air from an air-conditioner in the summer.

c) Where it will not be directly exposed to reflected heat from a space heater in winter.

7. Avoid placing the machine in an area filled with corrosive gas.

8. Avoid any places higher than 2,000 meters (6,500 feet) above sea level.

9. Place the machine on a strong and level base.

10. Avoid any area where the machine may be subjected to frequent strong vibration.

3-1

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 15 cm

30 cm 70 cm

60 cm

30 cm

70 cm

60 cm

1. Front: 70 cm (27.6")

2. Back: 10 cm (3.9")

: 15 cm (6.0")

30 cm

3. Right: 80 cm (31.5")

4. Left: 30 cm (11.8")

NOTE: Make sure there is at least 15 cm (6.0") clearance on the back side, in order to avoid damaging the sorter when it is opened.

3-2

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.)



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.

3-3

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).

3-4

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.

3-5

1 December 1990

[A]

[A]

[B]

[C]

[E]

[F]

[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. Reinstall the toner tank and the filter bracket on the development unit.

NOTE: Make sure that there is no gap [G] between the toner tank and the development unit.

3-6

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.

3-7

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.

(1)

(2)

(3)

Clear Mode key

Clear/Stop key

Access SP modes in the following sequence:

Step SP MODE

NUMBER

1 12 220/240

Conversion

2

3

65

63

Developer

Initial

Setting

Toner Supply

Unit Initial

Setting

PROCEDURE

This SP mode is only for 240 volt areas.

Enter "12" using the numeral keys. Then, press the Enter key while holding down the

Point key.

Finally, change the data from "0" to "1".

Enter "65" using the numeral keys and press the Enter key. "20" will be displayed in the copy counter. Press the Start key for initial setting.

Enter "63" using the numeral keys and press the Enter key while holding down the

Point key.

19. Place the outer decal (symbol explanation) [A] on the upper cover and install the receiving tray.

NOTE: If the DF is installed on the machine, place the outer decal [A] on the

DF [B] as shown.

3-8

[A]

[B]

1 December 1990

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.

3-9

1 December 1990

2.2 220/240V CONVERSION

240V

220V

[A]

220V

240V

[B]

[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.

3) Disconnect the transformer connector [C] (3P/White) on the ac drive board from CN417 and reconnect it to CN417 as shown in the illustration.

4) Reinstall the rear cover.

5) Change the data of SP mode #12 from "0" to "1". (Step 17 explains how to access the SP mode.)

3-10

1 December 1990

2.3 CASSETTE MODIFICATION

[B]

[A]

[D]

[E]

[F] [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. Insert the actuator plate [F] in the slot on the front of the cassette as shown.

3-11

1 December 1990

2.4 KEY COUNTER HOLDER INSTALLATION (OPTION)

[F]

[B]

[A]

[C] [E]

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. Align the holes in the fixing plate with the mounting holes of the key counter holder and secure the key counter holder (2 screws).

NOTE: The fixing plate has three different hole sizes. Use the holes that match those on the counter that you are installing.

8. Connect the other end of the key [E] counter harness to CN127 on the main board.

9. Cut off the jumper wire (JP103) [F] with a pair of pliers.

10. Reinstall all covers.

3-12

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.

3-13

1 December 1990

2.6 COLOR DEVELOPMENT UNIT INSTALLATION (OPTION)

[A]

[C] [B]

[F]

[G]

[E]

[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.

Screw Hole [B]

Screw Hole [C]

Red

Set

Not Set

Green

Not Set

Set

Blue

Set

Set

3-14

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.

6. Install the development unit as shown.

3-15

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.

(1)

(2)

(3)

Clear Mode key

Clear/Stop key

Enter key

Access SP modes in the following sequence:

Step SP MODE

NUMBER

1 10 Color

Developer

Initial

Setting

2 63 Toner Supply

Unit Initial

Setting

PROCEDURE

Enter "10" using the numeral keys and press the Enter key. "20" will be displayed in the copy counter. Press the Start key for initial setting.

Enter "63" using the numeral keys and press the Enter key while holding down the

Point key.

10. Make a copy and check the copy quality.

3-16

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. DC Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3. Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4. Locking Support - Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5. Locking Support - Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6. Locking Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7. DC Power Supply Unit Bracket . . . . . . . . . . . . . . . . . . . . . . 1

8. Harness Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9. DC Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10. Hexagon Head Tapping Screw - M3 x 6 . . . . . . . . . . . . . . . 6

11. Philips Pan Head Screw - M3 x 6 . . . . . . . . . . . . . . . . . . . . . 1

NOTE: Accessory Nos. 2 to 4 and 6 to 8 are not necessary to install the

Sorter. However, all accessories should be installed for future use.

3-17

1 December 1990

[E] [C]

[G]

[B]

[F]

[A] [D]

[C]

[D]

[E]

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. Be careful not to damage the main board when installing the locking supports and interface board.

3. After installing the interface board on the main board, confirm the following items to prevent erratic malfunction.

a. The heads [F] of three locking supports must correctly lock

the main board and interface board together as shown.

b. The connector [G] of the interface board must be

connected properly to the main board.

If erratic malfunction occurs, the memory of the RAM may be all set to zero. In this case, first you must clear all memory using SP Mode

#99. Then, readjust the data of SP Modes #41, #42, #43, #44, #47, and #48.

3-18

1 December 1990

[A]

[B]

[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. Re-connect the connectors [A] on the main dc power supply unit.

3-19

1 December 1990

[A]

CN100 [B]

[D]

[E]

CN418

220V 240V

[G] [H]

[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. Connect the connector [D] (3P/Black) of the transformer to CN418 on the ac drive board [E] and the connector [F] (4P/White) to CN 100 on the optional dc power supply unit.

NOTE: 1. The transformer connectors of the transformer are positioned differently for the 220V and 240V machines.

In 220V machines, connect the connector [G] to CN418 as shown.

In 240V machines, connect the connector [H] to CN418 as shown.

2. Connect the optional dc harness. (See the installation procedure for each option.)

3-20

[A]

1 December 1990

[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.

3-21

SECTION 4

SERVICE TABLES

1. SERVICE TABLES

1.1 TEST POINTS

Copier Main Board

NUMBER

TP101 GND

TP102 VCC (+5V)

FUNCTION

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 (23 o C 96k Ω )

TP108 BIN (Development Bias Feed Back)

TP109 GIN (Grid Voltage Feed Back)

TP110 PSE (ID sensor voltage)


VR102.

TP111 EXPO (Exposure Lamp Voltage)

TP112 GND

JP103 Key Counter (Cut this jumper wire when installing the key counter on the machine.)

DF Main Board

NUMBER

TP102 +5V

TP103 GND

TP104 Factory Use

TP105 +12V

TP106 +24V

TP107 Factory Use

FUNCTION

1 December 1990

4-1

1 December 1990

1.2 DIP SWITCHES


DIP SWITCH NORMAL

* 101-1 OFF

** 101-2 OFF

101-3

101-4

OFF

OFF

FUNCTION

Free run

Forced start (Ready temperature by-passed)

Factory Use

Clear counter and/or memory

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.

** The copy quality cannot be guaranteed if the fusing unit has not yet reached standard operating temperature.

To cancel this mode, turn off DIP SW 101-2, then turn the main switch on and off.

This mode must not be used in the field. The fusing and pressure rollers may be damaged when toner remaining on the rollers melts.

4-2

1 December 1990

DF Main Board

1

DIP SWITCH 101

2 3 4

ON OFF OFF OFF * Normal

ON OFF OFF ON 1 sided free run

FUNCTION

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. When the DF is used with this copier, DIP switch 101-2 must be turned off to increase the data transmission speed.

Duplex Main Board

DIP

SWITCH

700-1

700-2

700-3

700-4

700-5

700-6

700-7

700-8

FACTORY

SETTING

OFF

OFF

OFF

OFF

FUNCTION

Jogger Position Adjustment (0.5mm per step)

Refer to the Data Table on the next page.

4-3

1 December 1990

Data Table (Jogger Position Adjustment)

1

0

1

0

1

0

1

0

DIP SWITCH 700 (0:OFF, 1:ON) ADJUSTMENT VALUE

1

0

1

2

0

0

3

0

0

4

0

0

-3.5mm

-3.0mm

0

1

0

1

1

0

0

0

1

0

0

0

-2.5mm

-2.0mm

-1.5mm

1

0

1

0

1

1

0

0

1

0

1

1

0

1

1

1

1

0

0

0

0

1

1

1

1

0

0

0

1

1

1

1

1

1

1

1

-1.0mm

-0.5mm

±

0

0.5mm

1.0mm

1.5mm

2.0mm

2.5mm

3.0mm

3.5mm

4.0mm

4-4

1.3 VARIABLE RESISTORS


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

VRC

VRG

VRB

FUNCTION

Adjusts Main Charge Current

Adjusts Standard Grid Voltage

Adjusts Standard Dev. Bias

(Factory Use)

Power Pack (T&S)

NUMBER

VRT

VRD

FUNCTION

Adjusts Transfer Current

Adjusts Separation Current

AC Drive Board

NUMBER

VR401 Factory Use

FUNCTION

1 December 1990

4-5

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

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. All SP modes can be accessed by turning on DIP switch 101-4.

Access Procedure 1 - Key Operation


2. Press the Clear Modes key

3. Press the Clear/Stop key.

4. Press the Enter key. "5" will blink in the copy counter and the ADS indicator or one of the Manual Image Density indicator LEDs will blink.

5. Enter the desired SP mode number using the numeral keys. The SP mode numbers are given in the Service Program table. The SP mode number can also be selected with the zoom key (+, –).

NOTE: To cancel an SP mode number after entering it, press the

Clear/Stop key.

6. Press the Enter key while holding down the Point (".") key.

NOTE: a) If an invalid SP mode number is entered and the Enter key is pressed while pressing the Point key, the display on theoperation panel does not change.

b) With the following SP modes, press only the Enter key.

SP Mode numbers: #10, #11, #15, #17, #21, #34, #65, #66

7. To leave SP mode, press the Clear Modes key.

4-7

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 (+, –).

NOTE: To cancel an already entered program, press the Clear key.

4. Press the Enter key to view data.

NOTE: If an invalid SP number has been entered and the Enter key (#) is pressed, the display on theoperation panel does not change.

5. To leave SP mode, turn the main switch OFF, turn off DIP SW101-4, and turn the main switch on.

2.1.2 Change Adjustment Values or Modes

1. Follow steps 1-5 in access procedure 1 and steps 1-3 in access procedure 2.

2. The factory-set value or mode will be displayed in the Magnification indicator.

3. Enter the desired value or mode using the numeral keys. (SP mode numbers are given in the Service Program Mode table.)

4. To leave SP mode, press the Clear Modes key (access procedure 1) or turn off the main switch and DIP SW101-4 (access procedure 2).

4-8

1 December 1990

2.1.3 Memory Clear Procedure

<SP-98 "Clears all counters">

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".


5. Turn off DIP SW101-3 and 4.

6. Turn on the main switch to resume normal copier operation.

NOTE: When the counters are cleared, the Magnification indicator will blink 4 times.

<SP-99 "Clear all memory">

This Service Program clears all counters as well as all adjustments and modes. All modes return to factory settings, and all adjustments returns to factory settings or defaults.


2. Turn on DIP SW 101-3 and 4 on the main board.


4. Select SP-99 and press the "1" key on the key pad, then press the Enter key to clear the memory.

NOTE: When the memory is cleared, the Magnification indicator will blink

5 times.

5. Turn off both the main switch and DIP SW101-3 and 4, then turn on the main switch to resume copier operation.

4-9

1 December 1990

2.1.4 Others

In the following 13 SP modes, copies can be made by pressing the Start key:

SP Modes #5, #6, #8, #37, #41, #42, #43, #44, #47, #48,

#52, #55, and #59

4-10

1 December 1990

2.2 SERVICE PROGRAM MODE TABLE

*

Copies can be made. (Refer to NOTE 1.)

Mode No.

Function Data

*

5: Exposure

Lamp OFF

Exposure lamp OFF

*

6: Jam Detection

Off

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.

Copies are made without jam detection.

Press the Start key to make a copy.

Press the Enter key in Ready mode to turn off this mode.

8: Input Check Displays the input from sensors and switches.

9: Output Check Electrical components turns on.

10: Color

Developer

Initial Setting

Used to set the new color developer condition.

See comments

See comments

Factory

Setting

Comments

Use this mode for the scanner movement check.

To conserve toner, remove the development unit and disconnect

CN123 on the main board before turning on the main switch.

Use this mode to check whether the paper jam was caused by a jam sensor malfunction.

The copy counter increments when copies are made in this mode.

For data, see page

4-22.

For data, see page

4-23.

*

11: All Indicators

ON

Turns on all the indicators on the operation panel

Initial setting is required when new developer is installed.

After color developer conditioning (20 cycles) is completed, the copier automatically returns to normal mode.

To turn off the indicators, press the Enter key.

4-11

1 December 1990

Mode No.

12: 220V/240V

Conversion

Function

Selects 220 or 240 volts.

15: Auto Reset

Time

16: Count

Up/Down

17: Auto Feed

Station Shift

Selects auto reset of 1 or 3 minutes, or cancels this mode.

Selects count up or count down.

Selects auto feed station shift mode.

19: ADS Priority

20: APS Priority

(Copier)

21: APS Priority

(ADF)

Specifies whether the copier defaults to ADS or manual mode when the main switch is turned on.

Specifies whether the copier defaults to APS or manual mode when the main switch is turned on.

Specifies whether the copier defaults to APS or manual mode when the original is set on the DF.

22: SADF Shut-off

Time

Selects shut-off time for SADF mode.

23: ADF Free Size Enables originals of various sizes to be fed from the same size stack.

24: Factory Use

Data

0: 220V

1: 240V

0: 1 min.

1: 3 min.

2: None

0: Up

1: Down

0: Auto Shift

1: Manual

Factory

Setting

0

Comments

If the rated voltage is 240V, this data must be changed to "1". Refer to

NOTE 2.

0

0 Copier automatically shifts to the cassette or paper tray holding same size paper when paper runs out.

0: ADS

1: Manual

0

0: APS

1: Manual

0: APS

1: Manual

0: 5 sec.

1: 60 sec.

0: No

1: Yes

0

1

0

0

This mode is used only on the A054 copier.

DF must be installed on the machine.

4-12

1 December 1990

Mode No.

25: Margin

Adjustment in Duplex Mode

Function

Sets the margin

(5 mm) on the right side of the reverse page.

Data

0: Yes

1: No

27: A3 (DLT)

Double

Counter

28: Sort Priority

29: Fusing

Temperature

Control

Selects single or double counter of the total counter in

A3/DLT copies.

Sort Mode is automatically selected when more than1 original is set on the DF table and the entered copy quantity is greater than 1 and less than 21.

Selects fusing temperature control mode.

0: Normal

1: Double

0: Manual

1: Auto Sort

0: ON/OFF control

1: Phase control

30: Black Toner

Supply Mode

Selects black toner supply system.

0: Detect Mode

1: Fixed Mode

31: Black Toner

Supply Ratio

(Detect Mode)

32: Black Toner

Supply Ratio

(Fixed Mode)

33: ID Sensor Bias

(Black)

Determines how much toner is supplied in detect mode.

Determines how much toner is supplied in fixed mode.

Sets the bias voltage applied to the development roller for the image density check.

0: 15%

1: 7%

2: 30%

3: 60%

0: 7.0%

1: 3.5%

2: 10.5%

3: 14.0%

0: -260V

1: -220V

2: -280V

3: -300V

Factory

Setting

0

Comments

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

0

0

0

0

0

0

Sorter and DF must be installed on the machine.

When in duplex mode, more than 2 originals must be set.

After selecting the control mode and turning the main switch off/on, the fusing temperature control is changed.

See SP 31/SP32 for toner supply amount.

-260V = normal

-220V = lighter

-280V = darker

-300V = darkest

4-13

1 December 1990

*

Mode No.

34: ADS Level

Function

Selects the image density level in

ADS mode.

Adjusts registration.

Adjusts magnification in the paper travel direction.

Adjusts magnification perpendicular to the direction of paper travel.

Adjusts the 4th/5th mirror position to correct focus.

Data

0: Normal

1: Darker

2: Lighter

35: Black Toner ID

Detection

ID sensor check is performed every 5 copies or 10 copies.

0: 10 copies

1: 5 copies

*

37: Black Bias

Adjustment

*

41: Lead Edge

Erase Margin

Adjustment

*

42: Registration

Adjustment

*

43:Vertical

Magnification

Adjustment

*

44: Horizontal

Magnification

Adjustment

47: Focus

Adjustment

Adjusts black bias output if the image density at level 4 cannot be adjusted in Light Intensity mode (SP 48).

Adjusts the lead edge erase margin.

0: V

0

1: V

0

+40V

2: V

0

+20V

3: V

0

- 20V

4: V

0

- 40V

0 – 15

0 – 15

0 – 15

0 – 15

0 – 15

Factory

Setting

0

Comments

0

0

Data #1:

Increases bias output (+40V).

Lamp voltage is standard value.

Data #2:

Increases exposure lamp data (+4). Bias voltage is standard value.

If low image density occurs in the near end condition, change the data to "1".

V

0

= Standard Bias

0: Normal

1: Darkest

2: Darker

3: Lighter

4: Lightest

0 –15

Default = 8

0.5 mm per step.

(max. - 4.0 mm to

+3.5mm)

0 –15

Default = 8

0.5 mm per step.

(max. -4.0 mm to

+3.5mm)

0 –15

Default = 8

0.2% per step.

(max. -1.6% to

+1.4%)

0 –15

Default = 8

0.2% per step.

(max. -1.6% to

+1.4%)

0 –15

Default = 8

This mode must be done after vertical and horizontal magnification adjustment (SP

Mode #43 and 44).

4-14

1 December 1990

Mode No.

Function

*

48: Light Intensity

Adjustment

Adjusts the exposure lamp voltage.

Data

100 – 150

Factory

Setting

100 –150

Default

= 126

Comments

The exposure lamp voltage is adjusted on the production line. (The factory setting is different for each machine.

When clearing all memory, the data of this mode returns to "126".

49: Fusing

Temperature

Adjustment

Adjusts fusing temperature.

51: Exposure

Lamp Voltage

Display

Displays the exposure lamp voltage with a reference number.

175 – 190

°

C 185

°

C 175 to 190

°

C in

1

°

C steps.

If a number over

190 is input, the

CPU sets the temp. at 190

°

. If under 175, 175

°

is set.

The exposure lamp, main motor, and optics cooling fans turn on for 10 seconds when the

Enter key is pressed.

Press the C/S key to turn this mode off.

Do not repeat more than 5 times to avoid overheating the optics cavity.

*

52: Fusing

Temperature

Display

54: Vsg

Adjustment

Displays the fusing temperature.

Adjusts Vsg.

Adjust Vsg to 4.0

±

0.2 using VR102 on the main board.

The main motor and the ID sensor

LED turn on when the Enter key is pressed. The Vsg voltage is displayed on the magnification indicator.

4-15

1 December 1990

Mode No.

Function

*

55: Vsg & Vsp

Check

56: ADS Voltage

Adjustment

Display the Vsg and Vsp readings.

The Vsg reading is displayed while the

"0" key is held down.

To stop this mode, press the C/S key.

Adjusts ADS.

Data Factory

Setting

Comments

The Vsp and Vsg voltage readings are updated every

10 or 5 copies (ID sensor timing).

After adjusting the light intensity, place 6 or more sheets of A3 (LDG) white paper on the exposure glass and select this mode.

Adjust ADS voltage to 2.5

±

0.1 using

VR101 on the main board.

*

59: Bias Voltage

Check

61: Drum Wear

Compensation

Setting

Displays bias voltage. Press the

Start key to display the bias voltage.

Press the C/S key to stop.

Selects the drum wear compensation value.

0: 1/10h

1: 1/20h

62: ID Sensor Grid

Voltage Setting

Factory Use (The data must be "7".)

63: Toner Supply

Unit Initial

Setting

Used to supply toner from the toner cartridge to the toner hopper.

0

64: Black Toner

Density Level

Display

Displays the black toner density level detected by initial setting (SP #65)

2

3

0

1

4

3

Initial setting must be done when the machine is installed and when the toner supply unit is replaced.

Data Vsp/Vsg(%)

0 12 – 15

1

2

0 – 7

8 – 11

3

4

16 – 21

22 –

4-16

1 December 1990

Mode No.

65: Black

Developer

Initial Setting

66: Drum Initial

Setting

67: Vr Correction

Ratio

68: Vr Forced

Detection

69: OPC Counter

Function

Sets the data value corresponding to the Vsp/Vsg ratio for new black developer.

"20" is displayed on the copy counter when the

Enter key is held down.

Press the Start key to start the initial setting.

Vsg is displayed when the "0" key is held down.

Used to set new drum condition.

Displays L values

(Vr correction ratio).

Detects Vrp and perform Vr correction.

Shows the total number of copies made with the drum installed on the machine.

Data

70: Color Toner

Supply Ratio

(Fixed Mode)

Selects the color toner supply ratio.

71: Sorter

Operation

Enables sorter operation.

0: 14%

1: 7%

2: 21%

3: 28%

0: No

1: Sorter (1)

2: Sorter (2)

Factory

Setting

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.

Initial setting must be done when a new drum is installed.

The OPC counter is cleared.

L = Vrp/Vsg x 100

0

0

1. Turn off the DIP

SW 101-4 if it is

on.

2. Make 5 copies.

The first three digits are displayed in the magnification indicator when the


Press the "." key to display the second three digits.

This mode is available only when the color unit is installed.

NOTE 3

4-17

1 December 1990

Mode No.

Function Data Factory

Setting

Comments

73: Color Copy

Counter

The Magnification indicator displays the total number of color copies (Red +

Green + Blue).

74: Color Toner ID

Detection

75: ID Sensor Bias

(Color Toner)

ID sensor check is performed every 5 copies or 10 copies.

0: 5 copies

1: 10 copies

0

Selects the bias voltage applied to the bias roller when sensing image density.




Normally, "0" should be selected for color toner.

Data

2

3

0

1

Red

–240 V

–200 V

–260 V

–280 V

0: Normal 1: Lighter

2: Darker 3: Darkest

Blue

–300 V

–260 V

–320 V

–340 V

Green

–320 V

–280 V

–340 V

–360 V

76: Sorter Bin

Capacity

77: ADF Odd

Number

Originals

(Duplex Mode)

Sets the stack quantity limit.

Sets the copier to eject the final copy if an odd number of originals are set.

0: No Limit

1: Limit

0: On

1: Off

*

79: Color Bias

Adjustment

80: Red Toner

Density Level

Display

81: Green Toner

Density Level

Display

Adjusts color bias output if the image density at level 4 cannot be adjusted in Light Intensity mode (SP 48).

Displays the red toner density level detected by initial setting (SP #10).

Displays the green toner density level detected by initial setting (SP #10).

0: V

0

1: V

0

+40V

2: V

0

+20V

3: V

0

– 20V

4: V

0

– 40V

1

0 When on, the final sheet is fed out; when off, the sheet stays in the duplex tray.

V

0

= Standard Bias

0: Normal

1: Darkest

2: Darker

3: Lighter

4: Lightest

Toner Density Level

= Vsp/Vsg x 100

Toner Density Level

= Vsp/Vsg x 100

4-18

Mode No.

89: PM Counter

Reset

Function Data

82: Blue Toner

Density Level

Display

87: PM Interval

Setting

Displays the blue toner density level detected by initial setting (SP #10).

Sets the interval of the PM counter.

0: No PM

1: 40K

2: 60K

3: 80K

4: 100K

88: PM Counter

Display




Resets the PM counter.

1 (NOTE 4)

93: Maximum

Copy Quantity

Limits the maximum copy quantity that can be entered.

98: Clear Counters Clear the following counters:

•

Copy Counters

•

SC Counters

•

Jam Counters

•

PM Counter

99: Clear All

Memory

Clear all counters and returns all modes to the factory setting.

1 – 99

0: No

1: Yes

0: No

1: Yes

Factory

Setting

Comments

Toner Density Level

= Vsp/Vsg x 100

0

99

1 December 1990

Displays contents of the PM counter.

When the PM counter is exceeded, the

Magnification indicator blinks.

Use this mode after performing

PM.

DIP switches 101-3 and 4 on the main board must be on.

DIP switches 101-3 and 4 on the main board must be on.

4-19

1 December 1990

Mode No.

Function

100:First Station

Copies

101: Upper Paper

Tray

Copies

102: Lower Paper

Tray Copies

Displays the total number of copies fed from the first feed station

(cassette and manual feed table).

Displays the total number of copies fed from the upper paper tray.

Displays the total number of copies fed from the lower paper tray.

Data Factory

Setting

0

0

0

Comments




SP mode #102 is used only on the

A054 copier. SP mode #103 and

#104 are not used.

4-20

Mode No.

Function

105:Duplex Copies Displays the total number of copies made in duplex mode.

106:DF Originals Displays the total number of originals fed from the DF.

120:Service Calls

(total)

Displays the total number of times the service call indicator has turned on.

121:Optics Section

Service Calls

122:Exposure

Lamp Service

Calls

Displays the total number of service calls involving the optics section.

Displays the total number of service calls involving the exposure lamp.

123:

124:Fusing

Section

Service Calls

(E53 and 54)

Not used

Displays the total number of service calls involving the fusing unit.

125:Service Calls for Interface

Comunication

Displays the total number of

"Interface

Communication" service calls between the copier and duplex tray.

130:Misfeeds(total) Displays the total number of paper misfeeds.

Data

1 December 1990

Factory

Setting

0

0

0

Comments




0

0

0

0

0

4-21

1 December 1990

Mode No.

131:Number of

Misfeeds by

Location

Function

Display the total number of paper misfeeds for each area.

Data Factory

Setting

0

Comments

"1" will be indicated in the copy counter when the Enter key is pressed.

Press the Zoom keys ("+" or "–") to select the following numbers:

1: Paper Feed

2: Exit

3: Sorter

4: DF

5: Duplex

NOTE 1: After an SP mode is selected, the copier goes automatically into copy mode when data is changed (SP modes 37, 41-44, 47-48) or when the Enter key is pressed (SP modes 5, 6, 11, 52, 59, 79). To make a copy after changing data in SP mode, press the Start key.

If you do not wish to make a copy after changing data, press the

Enter key. "5" will blink in the copy counter and you can select another SP mode.

NOTE 2: Connectors CN418 and CN421 must be repositioned and the data in SP Mode #12 must be changed when the copier is installed in a

240V area.

NOTE 3: The following functions can be selected in SP Mode #71:

Data

0

1

2

Function

1. Sort/stack mode can only be selected when the

sorter is closed.

2. In Sort/stack mode, user code #4 is displayed

when the sorter is opened.

User code #4 is displayed whenever the sorter is opened.

1. In Sort/stack mode, user code #4 is displayed

when the sorter is opened.

2. Sort/stack mode can be selected even if the

sorter is open. User code #4 is displayed when

Sort/stack mode is selected.

4-22

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.

4-23

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: The ON/OFF status can also be checked manually.

Input No.

Sensor/Switch/Signal

1

2

3

4

5

6

9

10

11

14

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

Registration Sensor

Exit Sensor


0

Paper not detected

(HIGH)

Casssette lift arm down

(HIGH)

Paper end detected

(HIGH)

1st Paper End Sensor

2nd Paper End Sensor

3rd paper End Sensor

(used only on the A054

copier)

Manual Feed Table

Switch

Right Cover Switch (used

only on the A048 copier)

Right Cover Switch (used

only on the A054 copier)

Relay Sensor (used only

on the A054 copier)

Scanner HP Sensor

Lens HP Sensor


Toner End Sensor


Table closed (HIGH)

Cover closed (HIGH)

Paper not detected

(HIGH)

OFF (LOW)

Color 1 Switch

Color 2 Switch

ON (HIGH)

Used toner holder full

(HIGH)

Color development unit installed.

Duplex Entrance Sensor Paper not detected

Duplex Turn Sensor (HIGH)

Duplex Paper End Sensor

Duplex Jogger HP Sensor OFF (LOW)

Sorter Paper Sensor Paper not detected

(HIGH)

Sorter Wheel switch

Sorter HP Switch

Sorter Switch

Switch is off.

Switch is on.

Sorter opened

Data

1

Paper detected

(LOW)

Cassette lift arm up

(LOW)

Paper detected (LOW)

Table open (LOW)

Cover open (LOW)

Paper detected

(LOW)

ON (HIGH)

OFF (LOW)

Used toner holder not full

(LOW)

Black development unit installed.


ON (HIGH)


Switch is on.

Switch is off.

Sorter closed

4-24

1 December 1990

Input No.

Sensor/Switch/Signal

32

33

34

ADF ON Line

ADF Lift Sensor

APS Sensors

Data

0

ADF not installed

ADF closed ADF opened

Refer to the following explanation

1

ADF installed

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.

1) When an original length sensor or an original width sensor detects the

original, the manual image density indicator (7 LEDs) corresponding to the

sensor will light.

Original detected Original not detected

2) When the platen cover position sensor and/or the platen cover closed

switch are turned on, the point indicator in the magnification ratio indicator

Sensor/Switch ON

Optics Cavity

Sensor/switch OFF

Width Sensor

2

1

Length Sensor

1) Manual Image Density Indicator

3 4 5 6 7

2) Magnification Ratio Indicator

7 6 5 4 3 2 1

When platen cover

(DF) position sensor turns on, this point indicator will light.

When the platen cover closed switch turns on, the point indicator will light.

4-25

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. #27).

11

14

15

16

17

5

6

8

9

10

18

19

23

24

27

28

29

30

31

32

33

34

35

Output No.

1

2

3

4

Electrical Component

Main Motor (PTL and Quenching Lamp)

Charge Corona + Standard Grid

(Grid Voltage = –920 volts)

Charge Corona + ID Sensor Grid

(Grid Voltage = –660 volts + Vp Correction Factor)

Charge Corona + Vrp Grid

(Grid Voltage = –500 volts)

Transfer Corona (One sided copy)

Transfer Corona (Two sided copy)

Separation Corona

ID Sensor LED

Development Drive Clutch

Toner Supply Clutch Solenoid

Sorter DC Motor

Sorter Wheel Motor (Bin up)

Sorter Wheel Motor (Bin down)

Registration Clutch

1st Paper Feed Clutch Solenoid

Relay Roller Clutch Solenoid

2nd Paper Feed Clutch Solenoid

3rd Paper Feed Clutch Solenoid (used only on the A054 copier)

Cassette Lift Clutch Solenoid

Duplex Gate Solenoid (Paper tray must be inserted.)

Pick-up Roller Release Solenoid

Duplex Feed Motor (Stack) (Paper tray must be inserted.)

Duplex Feed Motor (Feed) (Paper tray must be inserted.)

Duplex Jogger Motor (Home Position) (Paper tray must be inserted.)

Duplex Jogger Motor (A4 size) (Paper tray must be inserted.)

Duplex Jogger Motor (B5 size) (Paper tray must be inserted.)

Duplex Jogger Motor (LT size) (Paper tray must be inserted.)

4-26

1 December 1990

Output No.

37

39

40

42

43

44

50 - 57

60 - 67

Electrical Component

Erase Lamp

Optics Cooling Fans

Exposure Lamp + Optics Cooling Fans

Charge Corona + Standard Grid + Transfer Corona + Separation Corona

Charge Corona + ID Sensor Grid + Transfer Corona + Separation Corona

Charge Corona + VR Grid + Transfer Corona + Separation Corona

Applies bias voltage in 40V steps starting at 120V

Applies grid voltage in 60V steps starting at 560V

NOTE: Disconnect the duplex entrance sensor connector before using SP

Mode #9-30 to check the duplex tray paper path. Otherwise,

RA401 on the ac drive board will turn on and off (the misfeed indicator blinks) whenever the entrance sensor is actuated by a paper sheet.

4-27

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 "." key to display the jam counter in the second three digits of the Magnification indicator.

Release the "." key to display the first three digits.

FC Code

1

2

3

4

5

Jam Area/Detection

Paper Misfeed Jam (Registration Sensor Not ON)

Exit Jam (Exit Sensor Not ON or OFF)

Sorter Jam (Sorter Paper Sensor Not ON or OFF)

DF Jam (DF Sensors Not ON or OFF)

Duplex Jam (Entrance Sensor Not ON, Turn Sensor not ON or

OFF in Stack Mode, Registration Sensor Not ON in Feed

Mode)

4-28

1 December 1990

2.5.2 Paper Misfeed Location Indicator

F

G D C B

Upper Paper Tray E A

Lower Paper Tray (A054 Copier)

1. Initial Misfeed

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.

SENSOR

1

MISFEED LOCATION

INDICATOR

B and C light

4

5

2

3

Registration

Sensor

Using cassette or manual feed table

Using upper or lower paper tray (NOTE 2)

Using duplex tray

Exit Sensor

Sorter Paper Sensor

Duplex Entrance Sensor

Duplex Turn Sensor

A and C light

A and C light

D lights

G lights

E lights

A lights

2. Misfeed during copy cycle (Misfeed Detection)

A paper misfeed indicator starts blinking to indicate that a paper jam has been detected during the copy cycle. Sensors and indicators are listed below.

ITEM NO.

SENSOR

1

MISFEED

LOCATION

INDICATOR

B blinks

2

5

6

3

4

7

8

9

Registration Sensor Not ON

(ON check jam)

Using cassette or manual feed table

Using upper or lower paper tray (NOTE 2)

Using duplex tray

Exit Sensor Not ON (ON check jam)

Sorter Paper Sensor Not ON (ON check jam)

Duplex Entrance Sensor Not ON (ON check jam)

Duplex Turn Sensor Not ON (ON check Jam)

Exit Sensor Not OFF (OFF check jam)

Sorter Entrance Sensor Not OFF (OFF check jam)

Duplex Turn Sensor Not OFF (OFF check jam)

Registration Sensor Not ON (ON check jam) (NOTE 2)

A blinks

A blinks and E lights

D blinks

G blinks

D blinks

E blinks

D blinks

G blinks

E blinks

C blinks

4-29

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.

Sorter

Paper

Sensor

JF

7

Exit

Sensor

JF

6

JF 8

Duplex

Turn Guide

JF

9

Duplex

Entrance

Sensor

JF: Jam Flag

Registraction

Roller

Registraction

Sensor

JF

0

JF 5

JF

1

JF

10

Duplex

Turn

Sensor

JF

11

Duplex Tray

Cassette

JF 2

Upper Paper Tray

Lower Paper Tray

Registraction

Sensor

JF 3

JF

15

Relay

Sensor

ITEM NO.

1

2

3

4

5

6

7

8

9

10

11

12

SENSOR

Misfeed location detected by sensor

Registration Sensor ON

Exit Sensor ON

Sorter Paper Sensor ON

Duplex Entrance Sensor ON

Duplex Turn Sensor ON

Relay Sensor ON (NOTE 2)

Misfeed location detected using jam flags

Jam Flag "0" ON

Jam Flag "5", "6", or "8" ON

Jam Flag "7" or "9" ON

Jam Flag "10" or "11" ON

Jam Flag "2", "3", or "15" ON (NOTE 2)

Jam Flag "1" ON

MISFEED

LOCATION

INDICATOR

C lights

D lights

G lights

E lights

E lights

A lights

B lights

C lights

D lights

E lights

A lights

E and A light

NOTE1: 1. If the misfeed location indicator is blinking and a misfed sheet is detected under the corresponding sensor, the indicator continues to blink. (Normally, the indicator stays lit to indicate the misfeed location.)

4-30

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. The misfeed location "A" and "C" indicators will light if the registration sensor turns ON during the check for an initial misfeed.

2. The misfeed location "A" indicator will blink if the relay sensor does not turn on during the copy cycle.

3. During the copy cycle, the misfeed location "C" indicator will blink if the registration sensor does not turn on after the relay sensor turns on.

4. The misfeed location "A" indicator will light if the relay sensor detects a paper misfeed.

5. Jam flags "3" and "15" have been added for the 2nd paper tray misfeed condition check.

4-31

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

Exposure Lamp Error

The feed back signal beomes 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.


The feed back 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.

Zero Cross Signal Error

The CPU does not receive the zero cross signal within

0.56 second.

Scanner Home Position Error



The scanner home position sensor still on (HIGH) 1.0

second after the scanner starts.

Lens Home Position Error

The lens home position sensor remains off (LOW) 3.5

seconds after the lens move to the home position.


The lens home position sensor is still on (HIGH) 3.5

seconds after the lens leaves the home position.

4th/5th Mirror Home Position Error

The 4th/5th mirror home position sensor is still on (HIGH)

2.5 seconds after the 4th/5th mirror assembly moves to the home position.


The 4th/5th mirror home position sensor is still off (LOW)

2.5 seconds after the 4th/5th mirror assembly leaves the home position.

Fusing Warm-up Error

The temperature detected by the thermistor does not reach 175 o C within 100 seconds after the main switch is turned on.

Fusing Overheat

The temperature detected by the thermistor becomes higher than 240 o C.

Fusing Thermistor Open


SP Mode No.

(SC Counter)

SP Mode #122

(Exposure

Lamp)

–

SP Mode #121

(Optics)

SP Mode #124

(Fusing

Section)

Refer to

NOTE b)

4-32

1 December 1990

E-CODE

70

80

81

82

83

CONTENT SP Mode No.

(SC Counter)

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.

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.



HIGH as the duplex main board is driving the jogger fences inward.

—

SP Mode #125

(Interface

Comunication)

^

NOTE: a) E-codes (E1 to E8) are displayed in the copy counter. To display the two digits, press the Enter key.

Example:

When the machine detects the E11 condition, E1 is displayed in the copy countrer. Hold down the Enter key, and "11" is displayed in the copy counter.

b) When the service call (E5) conditions occur, for safety reason they cannot be cleared by turning off/on the main switch. The following procedure must be performed to clear these service call conditions:



USER CODE

U-CODE

1

2

3

4

5

CONTENTS

Right Cover Open

Key Counter Not Set

Development Unit Not Set

Sorter Open

Cassette Lift Sensor Not ON (Cassette is not properly set.)

4-33

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.

3.2 DRUM

1. Never touch the drum surface with bare hands.

2. Store the drum in a cool dry place.

3. Always wear gloves when cleaning the drum.

4. Do not leave the drum exposed to light for long periods of time.

5. Drum Initial Setting (SP No. 66) must be done after installation of a new drum.

NOTE: Drum initial setting does not need to be done when a new machine is installed; this is done at the factory.

6. Always keep the drum in the protective sheet when inserting or pulling the drum out of the copier. This protects the drum from light, thus preventing drum fatigue.

7. Before inserting or pulling out the drum, do the following to prevent drum damage: a) Remove the cleaning unit.

b) Remove the development unit.

c) Remove the charge corona unit.

d) Lower the transport unit.

8. Before pulling out the drum, place a sheet of paper under the drum to catch any dropped toner.

9. Dispose of used drums according to local regulations.

4-32

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. Make sure that the corona wire is correctly positioned between the cleaner pads and that there is no foreign material (iron filings, etc.) on the casing.

4. When installing a new corona wire, be sure to place the damper ring in the front end block. (See Charge Corona Wire Replacement.)

5. When adjusting the drum current, always make sure that the axis of the drum shoe is aligned with the corona wire.

6. Clean the charge grid with a blower brush (not with a cloth).

7. The corona height should only be adjusted in the following two cases: a) When the front end block is replaced b) When the drum charge current is uneven

3.4 OPTICS

1.The following parts are very difficult to adjust. Do not adjust them.

a) 4th/5th Mirror Home Position Sensor b) Lens Home Position Sensor c) Lens and 4th/5th Mirror Guide Rails

2. Before removing a sensor bracket to replace a sensor, mark the position of the bracket. Check the copy image (magnification and focus) to determine the exact location of the sensor.

3. Do not bend or damage the lens/scanner support plate or the mylar strip.

4-33

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. After adjusting the light intensity (SP No.48), check and adjust the following items: a) b)

ADS Voltage (SP No.56)....2.5

±

0.1V

Vsg (SP No.54).... 4.0

±

0.2V

3.5 DEVELOPMENT UNIT

1. Be careful not to nick or scratch the development roller sleeve.

2. Place the development unit on a sheet of paper after removing it from the copier.

3. Be careful not to bend the bias terminals.

4. Clean the drive gears after removing used developer.

5. Never load black developer or toner into the color development unit; never load color developer or toner into the black development unit.

6. Developer initial setting is necessary when the developer is replaced, or when a new color development unit is installed.

a) Black Developer Initial Setting (SP No.65) b) Color Developer Initial Setting (SP No.10)

8. Dispose of used developer according to local regulations.

4-34

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. Toner supply unit initial setting (SP No.63) must be done when the machine is installed or the toner supply unit is replaced.

3.7 TRANSFER AND SEPARATION

1. Clean the corona wires and casing with alcohol or water.

2. When adjusting the drum current, always make sure that the axis of the drum shoe is aligned with the corona wire.

3.8 CLEANING UNIT

1. When servicing the cleaning unit, be careful not to damage the edge of the cleaning blade.

2. Do not touch the cleaning brush with bare hands.

3. Before pulling out the cleaning unit, place a sheet of paper under it to catch any toner that spills out.

4. When inserting the cleaning unit into the copier, be sure the cleaning unit rail is properly engaged with the unit guide rail on the copier.

5. Empty the used toner holder every service call.

6. Dispose of used toner according to local regulations.

4-35

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.

Example:

With an A4/LT (sideways) cassette, the proper paper width is

296mm. 297.5mm width paper binds against the cassette fences and does not feed correctly.

3. A worn out registration roller causes paper to crease. It should be replaced.

3.11 DOCUMENT FEEDER

1. Do not bend the DF interface harness at a sharp angle. This damages the fiber optics cables.

2. When installing or reinstalling the document feeder, make sure that the document feeder is in the open position.

3. A buildup of static electricity on the exposure glass can cause originals to jam. Apply silicon oil to the glass to reduce the amount of friction.

3.12 SORTER

1. The sorter has two types of bins, odd numbered and even numbered, which are installed in alternating sequence. Be sure to install them in the correct order.

2. If the bins do not operate smoothly, lubricate the slot liners and transfer wheels using grease 501 or an equivalent type.

4-36

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. (Do not clear RAM memory if you have placed the old RAM on the new main board.) Then, check and adjust the data of the following SP modes:

Customer Requests

SP Mode

Numbers

15, 16, 17, 19, 20, 21, 22,

23, 25, 27, 28, 29, 76, 77

Copy Quality/Type of

Machine

12, 30-35, 41-44, 47, 48, 54,

56, 70, 71, 74

4. When replacing a sensor, do not overtighten the screws. This may damage the sensor.

5. If a customer reports that red image areas on the original do not appear on the copy, increase the image density. (Press the Manual Image

Density key.)

4-37

1 December 1990

4. SPECIAL TOOLS AND LUBRICANTS

Part Number

A0069105 Drum Shoe Shaft

Description

A0489500 Doctor Gap Gauge (1 pc)

A0069103 Scanner Wire Clamper (Omega Clamp)

A0069104 Scanner Positioning Pin (4 pcs)

A0089502 Grease G-40M

52059101 Gap Gauge - 0.1mm

52069600 Sensor Checker

52039501 Grease (Shinetsu Silicone G-501)

54429106 Drum Shoe

54479104 Shoe Adapter

54209504 Digital Thermometer

54209505 Digital Thermometer Probe

54209507 Digital Multimeter

54479078 Heat Resistance Grease (MT-78)

54209516 Test Chart OS-A3 (10 pcs/set)

54209502 Test Chart OS-A3 (100 pcs/set)

1

1

1

1

1

1

1

Q’ty

1

1

1

1 set

1

1

1

4-38

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.

NOTE: 1) Drum Initial Setting (SP#66) must be done after the drum is replaced.

2) Black Developer Initial Setting (SP#65) must be done after black developer is replaced.

3) Color Developer Initial Setting (SP#10) must be done after color developer is replaced.

4-39

1 December 1990

5.1 PM TABLE

L = Lubricate R = Replace C = Clean I = Inspection

EM 60K 120K 180K 240K NOTES

A. OPTICS __________________________________________________

1. Mirrors, lens, reflectors, toner shield glass

2. Exposure glass

3. Platen cover sheet

4. Scanner guide rail

5. Magnification guide rail

C

C

C

C

C

R

C

C

C

C

R

C

C

C

C

R

C

C

C

C

R

C

C

Silicone cloth, cotton pad with water, or blower brush

NOTE: Clean 6th mirror

with blower brush.

Alcohol or water

Alcohol or water (replace if necessary)

Dry cloth

Dry cloth

B. PAPER FEED _____________________________________________

1. Paper feed roller (1st,

2nd, and 3rd)

2. Pick-up roller

3. Registration roller

C

C

C

C

L

R

R

C

C

L

C

C

L

R

R

C

C

L

Water

Water

Water (replace if necessary)

Water

Mobil temp 78

Refer To NOTE 1

4. Relay roller

5. Separation roller spring clutch (1st feed station)

6. Separation roller (1st feed station)

7. Paper feed guide plate

8. Cassette bottom plate pad

9. Paper tray bottom plate pad

10. Manual feed bottom plate pad


C

C

C

C

C

C

R

C

R

R

R

C

C

C

C

C

C

R

C

R

R

R

C

Water

Alcohol

Water

Water

Water

Blower brush

C. AROUND DRUM ___________________________________________

1. Corona wires

2. Wire cleaner

3. Charge grid

4. End blocks and casing

5. Transfer guide plate

6. Pre-Transfer lamp

C

C

C

C

C

C

R

R

C

C

C

C

R

R

R

C

C

C

R

R

C

C

C

C

R

R

R

Alcohol or water

Blower brush

Alcohol or water

Dry cloth

Dry cloth, discharge any static before installation

4-40

1 December 1990

7. Quenching lamp

8. ID sensor

9. Erase lamp unit

EM 60K 120K 180K 240K

C

C

C

C

C

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. Used toner bottle

C

C

C

C

C

R

C

R

C

C

C

C

C

R

C

R

C

C

Replace if necessary




Empty used toner

E. DEVELOPMENT UNIT ______________________________________

1. Developer R R R R Replace if necessary

Refer to NOTE 4

2. Upper brush seal

3. Side seals

C

C

C

C

C

C

C

C

F. FUSING UNIT _____________________________________________

1. Hot roller

2. Pressure roller

3. Stripper pawls

C

C

C

C

C

C

R

R

C

C

C

C

If necessary

If necessary

Suitable solvent, replace if necessary

Suitable solvent 4. Fusing entrance and exit guides

5. Fusing thermistor

C C C C

I I I I Suitable solvent, clean if necessary

G. OTHERS _________________________________________________

1. Ozone filter

2. Drive belt

3. Bushings

4. Exit Sensor

R

I

C

R

I

L

C

R

I

C

R

I

L

C


Spindle oil

Blower brush

H. DOCUMENT FEEDER ______________________________________

1. Transport Belt

2. Separation Belt

3. Pick-up Roller


5. Feed-in Clutch

C

C

L

C

R

C

C

R

R

C

C

C

R

C

C

R

R

C

C

Belt Cleaner

Do not touch friction face

Alcohol, replace if necessary

Alcohol

Mobil Temp. 78

4-41

1 December 1990

EM 60K 120K 180K 240K NOTES

J. SORTER _________________________________________________

1. Bin guide/wheel

2. Round Belt

3. Guide plate

L

C

C

L

C

C

L

C

C

L

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

R

R

R

R

L





Mobil temp 78, lubricate if necessary

Refer to NOTE 2

NOTE 1: Clean and lubricate the spring clutch of the reverse roller at every PM.

NOTE 2: Clean and lubricate the paper lift spring clutch of the duplex tray every 120K copies.

4-42

NOTE 3: When replacing the main motor, lubricate the gear using Grease G501.

1 December 1990

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.

DEVELOPER COLOR TARGETED SUPPLY YIELD

Black

Red

Blue

Green

60K copies

30K copies

30K copies

30K copies

4-43

1 December 1990

5.2 EXPLANATION OF REGULAR PM

Item

Optics Unit Mirrors, Lens,

Reflector, Exposure

Glass, Platen Cover

Exposure Lamp

Optical Fiber

Explanation

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.

Deterioration of the exposure lamp affects the copy image. Check the lamp at regular intervals and replace if discolored.

A dirty optical fiber receptor can result in insufficient image density. Clean at regular intervals.

Paper Feed,

Registration

Paper Feed Roller,

Pick-up Roller,

Separation Roller

Registration Roller

This machine uses cassettes for paper feeding. If paper powder or dust adheres to the paper feed roller and rollers are worn out, paper may not feed correctly and/or skewing may result. Cleaning or replacement is required at regular intervals.

A dirty registration roller can cause paper to register incorrectly, skew, or jam. Cleaning is required at regular intervals.

Transport Transfer Guide Plate If the transfer guide plate is dirty, the back sides of the copy may become dirty. Clean the plate at regular intervals.

Around Drum Charge Wires Dirty charge wires may cause uneven image density.

They should be cleaned or replaced at regular intervals.

End Blocks Toner tends to accumulate on the corona end blocks, and this can result in poor copy quality or even a high voltage leak. Clean end blocks at regular intervals.

QL

PTL

ID Sensor

Erase Lamp

If toner accumulates on the QL, a dirty background or a repeating negative image may result.

Clean the QL at regular intervals.

If paper dust or toner accumulates on the PTL, its efficiency may be reduced. This can cause toner to be reattracted to the drum during transfer, reducing image density. Clean the PTL at regular intervals.

If paper dust or toner accumulates on the ID sensor, the toner density cannot be controlled correctly. This results in light copy or overtoning. Clean this sensor at regular intervals.

If toner accumulates on the erase lamp, a dirty background may occur that becomes progressively worse in long copy runs. Clean this lamp at regular intervals.

4-44

1 December 1990

Fusing Unit

Duplex Unit

ARDF

Sorter

Item

Cleaning Unit Cleaning Blade

Cleaning Brush

Thermistor

Stripper Pawls

Fusing Entrance and

Exit Guides

Paper Feed and

Friction Rollers

Transport Roller

Round Belt

Transport Belt

Pick-up Roller,

Separation Roller,

Separation Belt

Bin Drive Wheel, Bin

Guide

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.

A worn out cleaning brush will not clean effectively, resulting in a dirty background and damage to the cleaning blade. Replace at regular intervals.

If toner accumulates on the thermistor, fusing temperature control may not be accurate. Inspect the thermistor at regular intervals.

Toner or dust adhering to the stripper pawls can cause a paper jam. Clean or replace the pawls at regular intervals.

Toner piling up on the guide plate will cause a dirty background on the copy. Clean the guide plate at regular intervals.

The duplex unit uses the feed and friction roller (FFR) system. If paper dust or dust adheres to the paper feed and friction rollers and if the rollers are worn out, paper may not feed correctly and/or skewing may result. Cleaning or replacement is required at regular intervals.

A transport roller that is dirty or slips may cause a dirty copy image or a paper jam. Clean the rollers at regular intervals.

The round belt transmits driving power to the turn guide roller. When the belt wears out (breaks or stretches), a paper jam may occur. Replace the belt at regular intervals.

A dirty transport belt can leave stains on copies.

Clean or replace the belt at regular intervals.

When dirty, these rollers and this belt can leave stains on the copy paper. Clean or replace these parts at regular intervals.

Dust adhering to the bin drive wheel or bin guide may interfere with bin movement and result in uneven bin positioning. Clean and lubricate if necessary.

4-45

SECTION 5

REPLACEMENT AND ADJUSTMENT

1 December 1990

1. EXTERIOR AND INNER COVERS

1.1 EXTERIOR COVER REMOVAL

[C]

[A]

[C]

[B]

[D]

[E]

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).

5-1

[C]

[B]

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.

[A]

5-2

1 December 1990

1 December 1990

[C]

[B]

[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.

5-3

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


2. Remove the fusing roller knob [F].

3. Remove the left inner cover [G] (3 screws).

5-4

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.

b) The red mark on the edge of the glass faces up. This side is smoother and it generates less static electricity when the DF is used.

5-5

2.2 1ST MIRROR REMOVAL

[B]

[D]

[C]

1 December 1990

[E]



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. Then, while holding down the scanner, press up on the front spring plate [C] with another finger and remove the plate with a pair of pliers.

Leave the rear spring plate [D] in position in the rear side plate cutout.

7. Carefully slide the 1st mirror [E] towards the front of the machine and lift the mirror out of the machine rear side first.

5-6

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.

5-7

2.3 2ND AND 3RD MIRROR REMOVAL

[C]

[B]

1 December 1990

[A]



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.

5-8

1 December 1990

[A]

[B]

OK

[C]

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.

NOTE: a) Make sure when installing the mirrors that the reflecting surfaces

[C] face the lens.

b) The front and rear spring plates are different. Make sure that each plate is placed in the correct position.

c) Position the spring plate [D] by moving it in the direction of the arrow.

5-9

2.4 4TH AND 5TH MIRROR REPLACEMENT

[A]

[E]

1 December 1990

[B]

[D]


[C]


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.)

NOTE: a) Make sure that the mirrors are installed in their original positions.

(The fourth mirror is larger than the fifth mirror.) b) The front and rear spring plates are different. Be sure to mount them in the correct positions.

c) Position the spring plates [D] as shown. Move them in the direction of the arrow.

d) When reinstalling the 4th and 5th mirror assembly, make sure that the hooks [E and F] are properly positioned as shown.

5-10

1 December 1990

2.5 EXPOSURE LAMP REPLACEMENT

[F]

[B]

[A]

[D]

[C]

[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.)



3. Move the first scanner to the cutout position at the rear frame [A]. (See illustration.)

4. Remove the reflector cover [B] (2 screws).

5. Disconnect the exposure lamp wires [C] [D] (1 terminal and 1 connector).

6. Press the release lever [E] on the front terminal while pressing the insulator [F] of the lamp as shown.

5-11

[A]

[B]

[C]

1 December 1990

[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].

c) Make sure that the blister [D] on the lamp points towards the reflector opening (left side of the copier) as shown.

d) Check the exposure lamp position, light intensity and ADS sensor adjustment. (See Exposure Lamp Position Adjustment, Light

Intensity Adjustment and ADS sensor Adjustment.)

5-12

1 December 1990

2.6 THERMOSWITCH REPLACEMENT

[C]

[B]

[A]


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.

5-13

2.7 SCANNER DRIVE WIRE REPLACEMENT

2.7.1 Wire Removal

1 December 1990

[C]

[D]

[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].

4. Loosen the screws securing the front and rear wire fixing plates [C].

5. Remove scanner wires [D] and [E] from the drive pulley.

6. Remove scanner wire [F] from the left side plate.

7. Remove scanner wire from the drive pulley [G].

8. Remove the drive pulley.

[F]

5-14

1 December 1990

2.7.2 Wire Installation

[2]

[B]

[1]

[A]

[1]

[2]

[C]

[3]

[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. Wind the blue and silver wires together five and a half times around the pulley. Make sure that the blue wire is wound six times and the silver wire is wound six and a half times in total.

6. Set the omega clamp [C] over the wires on the drive pulley as shown.

5-15

1 December 1990

[3]

[A]

[C]

[E]

[4] [B]

[D]

[D]

[1]

[2]

[3]

[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.

b) Wires are not wound around the two grooves shown in the illustration (rear view [D]).

c) Wires are wound around all the grooves shown in the illustration

(front view [E]).

11. Set the pulley on the drive shaft and tighten both Allen screws.

NOTE: Maintain 1 mm of clearance between the pulley and the bushing as shown above. Place the scale (1 mm thick) between the pulley and the bushing before tightening the Allen screws on the pulley.

5-16

1 December 1990

[A]

[C]

[4]

[B]

4

5

[E]

[D]

3/7

[2]

6

[4]

[2]

1

12. Manually move the first and second scanners to home position.

2

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. Hook the silver wire [4] onto the fixing plate and hook the wire tension spring [E] onto the fixing plate and the frame projection.

5-17

1 December 1990

6-2

[C]

4

[3]

[B]

[A]

3

[1]

[1]

1

6-1

[C]

[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.

5-18

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.

(4) Tighten the two screws securing the wire tension bracket [C].

(5) Make sure the positioning pin [B] slides in and out smoothly. If not, repeat step (3).

(6) Tighten the screws securing the front and rear wire fixing plates [E].

5-19

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.

5-20

1 December 1990

2.8 SCANNER MOTOR REPLACEMENT

[D]

[C]

[E]

[B]

1mm

[F]

[A]

[G]


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. Remove the two Allen screws [D] securing the scanner motor pulley and place it temporarily on bracket [E].

7. Remove the scanner motor bracket [F] (3 screws) and replace the scanner motor [G] (2 screws).

NOTE: Maintain 1mm of clearance between the pulley and the motor. Place the scale (1 mm thick) between the drive pulley and the motor bushing as shown in the above illustration and tighten the Allen screws.

5-21

1 December 1990

2.9 LENS DRIVE MOTOR REPLACEMENT

[D]

[E]

[B]

[C]

[A]


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. Remove the motor [E] from the bracket (2 screws), and replace the motor.

8. Reassemble.

5-22

1 December 1990

[D]

[C]

[B]

[A]

[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.

b) Position the motor harness [G] as shown when installing a new motor.

5-23

1 December 1990

2.10 4TH/5TH MIRROR ASSEMBLY DRIVE MOTOR

REPLACEMENT

[A]

[C]

[B]


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.

5-24

1 December 1990

2.11 EXPOSURE LAMP POSITION ADJUSTMENT

[A]

[C]

[E] [F]

[B]

[D]

[B]

[D]



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. The filament should be directly beneath the sight hole.

NOTE: If necessary, use a penlight to illuminate the exposure lamp.

6. Turn screw [D] to adjust the position of the filament.

Counterclockwise: Filament moves to the left (E direction).

Clockwise: Filament moves to the right (F direction).

5-25

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.)

5-26

1 December 1990

3.2 DEVELOPER REPLACEMENT

[A]

[B]


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. Pour one pack of developer into the development unit while turning the paddle roller knob.

7. Reinstall the toner tank and set the development unit in the machine.

8. Confirm using SP mode #54 that Vsg is 4 ± 0.2 volts .

If not, adjust Vsg. (See ID Sensor Adjustment.)

9. Perform initial setting for new black or color developer using the following

SP modes:

Black

SP Mode #65

Color

SP Mode #10

5-27

3.3 INLET SEAL REMOVAL

1 December 1990

[A]

[B]

[C]


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.

c) To install a new inlet seal plate, remove the covering from the

2-sided tape [C] and affix the inlet seal [D] to the development unit lower casing. Tuck both ends of the seal inside the lower casing as shown.

5-28

1 December 1990

3.4 DEVELOPMENT ROLLER REPLACEMENT

[D]

[A]

[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. Remove the development roller gear [B] (1 C-ring).

6. Remove the bearing retainer [C] (2 screws).

7. Remove the upper case [D] (3 screws).

8. Remove the development roller [E] with bearing [F].

9. Replace the development roller.

NOTE: a) When replacing the development roller, use a blower brush to remove any carrier from the bearing, inlet seal plate, etc.

b) After reassembling the development unit, make sure that the DG gap is within 0.6 ± 0.07 mm. (See Doctor Gap Adjustment.)

5-29

3.5 DOCTOR GAP ADJUSTMENT

[A]

[B]

1 December 1990

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" ± 0.003")

- Adjustment Procedure -

1. Take out the development unit and remove the toner supply unit. (See

Toner Supply Unit Removal.)

2. Remove the developer.

3. Remove the development roller positioning bracket and the inlet seal plate (See Inlet Seal Plate Removal.)

5-30

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. Check the doctor gap (procedure on next page).

5-31

[A]

1 December 1990

- 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 - 0.67 mm at three points on each side, the gap has been adjusted properly.

3. If the gap is out of specification at more than one point on either side, repeat the adjustment procedure.

5-32

1 December 1990

3.6 TONER SUPPLY CLUTCH SOLENOID REPLACEMENT

[D]

[E]

[C]

[B]

[A]


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]).

5-33

3.7 DEVELOPMENT DRIVE CLUTCH SOLENOID

REPLACEMENT

1 December 1990

[A]

[B]


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.

5-34

1 December 1990

3.8 DEVELOPMENT DRIVE CLUTCH REPLACEMENT

[G]

[I]

[B]

[H]

[A]

[C]

[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. Remove the big and small frames [D and E] (3 E-rings, bushings, and 6 screws).

Screws : 4 tapping screws and 2 screws with washer [F].

6. Remove the development drive gear [G] (1 E-ring) from the front side.

7. Replace the drive clutch [H] (1 E-ing and parallel pin).

NOTE: When reassembling, make sure of the following:

a) The timing belt fits correctly onto the sprockets.

b) Stopper [I] locks the registration clutch.

c) Stopper [J] locks the 2nd feed roller clutch solenoid.

d) The harnesses do not pass between the frames.

5-35

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.

5-36

1 December 1990

4.2 CLEANING BLADE REPLACEMENT

[A]

[D]

[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.

5-37

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].

c) These screws [

⊗

] are tapping screws. Do not tighten them too much as this will strip the resin threads.

5-38

1 December 1990

4.4 BLADE SCRAPER REPLACEMENT

[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).

[B]

5-39

4.5 TONER OVERFLOW SENSOR REPLACEMENT

1 December 1990

[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).

5-40

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.

5-41

1 December 1990

4.7 ENTRANCE SEAL REPLACEMENT

[A] [B]

[C]

[I]

[H]

[D]

2.5mm

[F]

[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. Place a new strip of 2-sided tape [C] on the lower casing surface. The lower edge [D] of the tape must be flush with the edge [E] of the projection as shown in the illustration.

7. Place the new entrance seal on the 2-sided tape. Extend the seal so that both edges [F] align with the edges [G] of the tape.

NOTE: a) The lower edge [H] of the entrance seal must be aligned with the edge [E] of the projection on the lower casing.

b) Make sure that there are no waves in the upper edge [I] of the entrance seal.

5-42

1 December 1990

5. PAPER FEED

5.1 PAPER SIZE SWITCH REPLACEMENT

[B]

[A]


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.

5-43

1 December 1990

5.2 1ST PAPER END SENSOR AND PAPER LIFT SENSOR

REPLACEMENT

[D]

[B]

[C]

[E]

[F]

[A]

[G]


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. Replace the paper lift sensor [F] (1 connector).

NOTE: When installing the paper feed upper guide plate, make sure that the hooks [G] fit into the holes as shown.

5-44

1 December 1990

5.3 1ST FEED ROLLER, PICK-UP ROLLER, AND REVERSE

[A] [B]

[G]

[H]

[D]

[C]

[E]

[F]


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. Replace the reverse roller [F] (1 small snap-ring).

NOTE: a) Snap-rings come in two sizes; the larger of the two is used on the feed roller.

b) Flat faces [G] and [H] of the feed roller and shaft must be aligned.

5-45

1 December 1990

[A]

[D]

[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.

5-46

1 December 1990

5.4 2ND PAPER FEED ROLLER REPLACEMENT

[A]

[C]

[D]

[B]

[E]



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.

c) Surface [E] of the bracket faces up.

5-47

1 December 1990

5.5 PICK-UP ROLLER RELEASE SOLENOID AND MANUAL

FEED TABLE SWITCH REPLACEMENT

[B]

[C]

[A]

[D]

[F]

[E]



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].

NOTE: Before replacing the plunger [F] (1 E-ring), first remove the paper lift clutch solenoid assembly. (See Paper Lift Clutch Solenoid Assembly

Replacement.)

5-48

1 December 1990

5.6 1ST FEED ROLLER SPRING CLUTCH SOLENOID

REPLACEMENT

[C]

[B]

[A]




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.

5-49

5.7 PAPER LIFT CLUTCH SOLENOID ASSEMBLY

REPLACEMENT

[C]

[E]

1 December 1990

[J]

[G]

[H]

[A]

[B]

[I] [F]

[D]


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).

(See 1st Feed Roller Spring Clutch Solenoid Replacement.)

7. Remove the 1st feed roller spring clutch [E] (1 E-ring).

8. Remove the paper lift assembly [F] together with the manual feed table detection lever [G] (3 E-rings and two springs).

9. Remove the spring [H] from the actuator lever [I].

10. Replace the paper lift clutch solenoid assembly [J] (spring, collar, and gear).

5-50

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.

5-51

1 December 1990

5.8 RELAY ROLLER SPRING CLUTCH SOLENOID AND

RIGHT COVER SWITCH REPLACEMENT

[A]

[C]

[B]

[D] [F]

[E]



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].

5-52

1 December 1990

5.9 REGISTRATION CLUTCH REPLACEMENT

[B]




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.

[A]

5-53

1 December 1990

5.10 2ND PAPER FEED CLUTCH SOLENOID REPLACEMENT

[A]

[B]




4. Remove the small frame [A] (two E-rings, 3 screws, and 2 bushings).

5. Replace the 2nd paper feed clutch solenoid [B].

5-54

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.

5-55

5.11 2ND PAPER END SENSOR REPLACEMENT

1 December 1990

[C] [D]

[A]

[B]



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.

5-56

1 December 1990

5.12 2ND PAPER SIZE SWITCH REPLACEMENT

[B]

[A]



3. Remove the switch bracket [A] (1 screw).

4. Replace the switch [B] (1 connector).

5-57

1 December 1990

5.13 REGISTRATION SENSOR AND ROLLER REPLACEMENT

[B]

[E]

[F]

[C]

[A]

[D]



• Front cover (See Exterior Cover Removal.)


• 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. Remove the 1st feed clutch [A] while pressing down on the stopper [B] lever of the solenoid (1 E-ring).

4. Remove the idle gear [C] (1 E-ring).

5. Remove the development lower guide plate [D] (2 screws each at front and rear frames).

- Sensor -

6. Remove the sensor bracket [E] (2 screws).

7. Replace the sensor [F] (1 connector).

5-58

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.

5-59

1 December 1990

- To install (Lower Registration Roller) -

[E]

[D]

[F]

[E]

[B]

[C]

[A]

[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. Hook the spring [E] to the lower guide plate using a paper clip as shown.

NOTE: Make sure of the following when installing the upper registration roller: a) The front and rear bushings are different. Make sure that they are in the correct position.

b) The pressure springs are positioned correctly in the bushings.

5-60

1 December 1990

6. AROUND DRUM

6.1 PTL BOARD REPLACEMENT

[C]

[B]

[A]

[D]




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].

5-61

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.



• Cleaning 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. This damages the resin in the

LED cover.

b) When reinstalling the quenching lamp, make sure that the positioning pin [E] on the lamp fits through the cutout [F] in the front side plate as shown.

5-62

1 December 1990

6.3 ERASE LAMP REPLACEMENT

[C]

[B]

[D]

[F]

[E]

[A]

1. Open the front cover and lower the transport unit.



• Cleaning 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. This damages the resin surface of he LED cover.

b) When reinstalling the erase lamp, make sure that the positioning pin [E] on the lamp fits through the cutout [F] in the front side plate as shown.

5-63

6.4 CHARGE CORONA WIRE REPLACEMENT

[F]

[D]

[G]

[B]

1 December 1990

[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. Oil on the wire may cause uneven charge on the drum.

c) Do not rub the corona wires with rough material (sandpaper, etc.) as this will damage the corona wires.

d) When removing the end block covers, be careful not to break off the side hooks.

e) Do not use any solvents to clean the wires as this will cause uneven charge on the drum.

f) Do not damage the grid when replacing the charge wire.

g) When installing the charge corona unit, make sure that the wire is positioned between the cleaner pads [G].

5-64

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.

5-65

1 December 1990

6.6 TRANSFER/SEPARATION CORONA WIRE

REPLACEMENT

[C]

[G]

[D]

[A]

[F]

[E]

[B]

[H]

1. Remove the transfer/separation (TC/SC) corona unit.


•

•

•

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. Replace the transfer corona wire [F] and the separation corona wire [G].

NOTE: a) When installing the separation corona wire, make sure that the wire junction [H] is positioned inside the front endblock.

b) The transfer and separation corona wires must be in the grooves of the front and rear endblocks as shown.

c) Do not handle new corona wire with bare hands. Oil on the wire may cause an uneven charge on the drum.

d) Rubbing the corona wires with a rough material (sandpaper, etc.) will damage the corona wires.

e) When removing the end block covers, be careful not to break off the side hooks.

f) Do not use any solvents to clean the wires as this will cause uneven charge on the drum.

g) The transfer entrance guide is positioned with a special tool at the factory.

5-66

1 December 1990

6.7 ENTRANCE GUIDE PLATE HEIGHT ADJUSTMENT

[A]

Gap "X"

[A]

[B]

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.

If the original position of the entrance guide plate was not marked before the plate was loosened or removed, adjust its position as follows:

ADJUSTMENT STANDARD: GAP "X" Front 2.65

±

0.1 mm

Rear 3.25 0.1 mm

1. Set the gap "X" between the edge of the bracket [B] and the entrance guide plate adjustment standard using the thickness gauge as shown in the illustration. Then, tighten both the front and rear screws.

2. Make sure that the leading edge of the entrance guide plate mylar does not contact the drum after the TC/SC corona unit is installed.

5-67

1 December 1990

6.8 DRUM REPLACEMENT

[A]

[C]

[B]

1. Lower the transport unit.

[E]

2. Remove the following units:


•

•

Cleaning unit

Charge corona unit [A] and wire cleaner

[D]

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. Remove the drum by holding the drum unit rail and pulling out and up on the drum knob.

NOTE: a) When removing the drum, take care not to strike it against any objects.

b) Be careful not to bend the bearing holder [E].

5-68

1 December 1990

[C]

[B]

[A]

[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. Make sure the bearing holder is in contact with the bearing [B], as they are both used to ground the unit. If they are not in contact, solid black copies may occur.

c) Do not touch the drum surface.

8. Set the drum unit in the machine and remove the drum protective sheet.

9. Reinstall the other units around the drum unit.

10. To access the SP mode, press in sequence the Mode Clear key,

Clear/Stop key and the Enter key.

11. Reset the drum counter using SP mode #66.

NOTE: The drum counter must be reset by SP Mode #66 whenever an OPC drum is replaced.

12. Perform the ID sensor (Vsg) adjustment (SP mode #54).

5-69

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).

5-70

1 December 1990

6.10 PICK-OFF PAWL REPLACEMENT

[E]

[C]

[B]

[D]

[A]

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].

NOTE: When replacing the new pick-off pawls, make sure that the springs are positioned correctly as shown in the illustration.

5-71

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.

CAUTION: – Make sure that SP mode #9 is cleared before you change the range on the digital multimeter. If not, the multimeter may be damaged.

– High voltage is applied to the corona wires. Be careful.

- Preparation -

1. Turn off the main switch and remove the following parts:

• Development Unit

• Cleaning Unit

• Charge Corona Unit

• TC/SC Corona Unit

• Drum Unit

2. Clean or replace each corona wire and clean the corona units with water or alcohol.

3. Remove the rear cover (4 screws).

4. Disconnect CN123 on the main board.

5-72

1 December 1990

[B] [A]

[C]

[D]

[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.

NOTE: Be careful not to injure your hand on the edge of the pick-off pawls.

8. Reinstall the drum unit with the shaft rear end [E] positioned as shown in the illustration. Pass the harness [F] down into the development unit.

9. Connect the negative harness lead to the copier frame, then connect both multimeter leads as shown to the harness leads.

5-73

1 December 1990

6.11.1CHARGE CORONA CURRENT ADJUSTMENT (SP Mode #9-2 )

[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. Position the drum shoe so that the axis of the current sensing plate [B] is aligned with the charge corona wire as shown.

4. Reinstall the charge corona unit on the drum unit.

5. Select the dc 200

µ

A range on the digital multimeter [C].

6. Using SP mode #9–2, turn on the main switch, front door safety switch and the charge corona .

7. Note the reading. (Wait at least 30 seconds for the current to stabilize.)

8. Press the Clear/Stop key to turn off the charge corona, then move the drum shoe to the front limit [Y] as shown and repeat steps 3 to 7.

9. Adjust the front corona wire height by turning the adjusting screw [D] if the two readings are different.

10. Repeat steps 2 to 9 until the difference between the front and rear readings is no more than 4%.

5-74

1 December 1990

[B]

VRC

[A]

- Charge Corona Current Adjustment -

ADJUSTMENT STANDARD

DC –400

±

2

µ

A

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.


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. Connect the multimeter leads as shown, then measure the charge corona current.

5. Turn on the main switch, front door safety switch and the charge corona using SP mode #9–2.

6. Adjust the charge corona current to –400

±

2

µ

A by turning VRC on the

CC/G/B power pack [B].

7. Press the Clear/Stop key.

5-75

6.11.2 GRID VOLTAGE ADJUSTMENT (SP Mode #9-2 )

[A]

VRG

1 December 1990

ADJUSTMENT STANDARD

DC –920

±

16 V


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.

5-76

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

µ

A


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

µ

A range on the digital multimeter.

3. Turn on the main switch, front door safety switch, and transfer corona using SP mode #9–5.

4. Adjust the transfer corona current to dc –19.3

±

0.5

µ

A using VRT on the

TC/SC power pack [C].


5-77

6.11.4 SEPARATION CORONA CURRENT ADJUSTMENT

(SP Mode #9-8)

1 December 1990

[A]

[B]

VRD

[C]

ADJUSTMENT STANDARD

AC 41.6

±

1.3

µ

A


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

µ

A range on the digital multimeter.

3. Turn on the main switch, the front safety switch, and the separation corona using SP mode #9–8.

4. Adjust the separation corona current to ac 41.6

±

1.3

µ

A using VRD on the TC/SC power pack [C].


5-78

1 December 1990

7. FUSING

7.1 EXIT UNIT REMOVAL

[C]

[E]

[D]

[B]

[F]

[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.

b) The projection [G] on the front holder fits through the hole [H] in the fusing unit front frame.

5-79

7.2 FUSING LAMP REPLACEMENT

[F]

[E]

1 December 1990

[F]

[D]

[B]

[C]

[A]

1. Make sure that the main switch is turned off and the power supply cord is unplugged.


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).


7. Remove the ac drive board [C] (all connectors, 4 locking supports, and 1 screw).

8. Pull the fusing lamp [D] out the front end of the fusing roller.

NOTE: a) Do not touch the fusing lamp with bare hands.

b) Slide the new fusing lamp [E] into the fusing roller through the opening at the rear of the roller. (See the arrow in the illustration.) c) The connector housings used at the front and rear sides are different.

d) Make sure that the fusing lamp insulators [F] are properly set in the holders as shown.

5-80

1 December 1990

7.3 PRESSURE ROLLER REPLACEMENT

[A]

[D]

[C]

[E]

[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).

5-81

1 December 1990

[A]

[B]

[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. Install the front pressure spring [E].

5-82

1 December 1990

7.4 HOT ROLLER REPLACEMENT

[A]

[F]

[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. Remove the bearing stopper [C] (1 screw), and remove the bearing [D] and spacer [E].

8. Remove the rear C-ring [F].

9. Slide the hot roller out. The gear [G] will drop off the hot roller shaft.

10. Replace the hot roller (1 bearing [H]).

5-83

[E]

[D]

[B]

[D]

[B]

[A]

1 December 1990

[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.

c) Before reinstalling the pressure springs, refer to the installation procedure in the Pressure Roller Replacement Section.

5-84

1 December 1990

7.5 THERMISTOR AND THERMOFUSE REPLACEMENT

[D]

[C]

[B]

[G]

[F]

[E]

[A]

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. Open the exit unit and remove the cleaning unit and fusing unit cover [C]

(1 screw each).

8. Remove the left upper cover. (See Left Upper Cover Removal.)

9. Remove the safety switch actuator bracket [D] (1 screw).

10. Remove the upper fusing stay [E] as shown (2 screws).

11. Replace the thermistor [F] and/or thermofuse [G] (1 screw each).

NOTE: a) When reinstalling the stay [E], make sure that the front and rear hooks stay are inserted into the side frames as shown.

b) Make sure that each harness is properly wired as shown.

5-85

1 December 1990

7.6 FUSING PRESSURE ADJUSTMENT

A

B b a

<Fusing pressure adjustment combinations>

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.)

5-86

1 December 1990

7.7 FUSING EXIT SENSOR REPLACEMENT

[A]

[C]


2. Open the front cover and exit unit.


• 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].

[B]

5-87

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. Do not tighten them too much as this will strip the resin threads.

5-88

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].

5-89

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. Also, if requested from the customer, the overall image density can be changed by changing the toner density. Normally, this should be kept at the normal position (factory setting).

The grid voltage and charge corona current are carefully adjusted at the factory. Any adjustment out of the adjustment standard will result in overtoning, toner scattering, dirty background, or light image density problem.

The grid voltage and charge corona current adjustment should be done only when replacing the CC/G/B power pack or correct certain problems with image density after checking the other possible causes.

5-90

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.


2. Clean the following parts:

Item No. Section

(1)

(2)

(3)

(4)

Optics (mirrors, lens, reflectors, shield glass, exposure glass)

ID sensor

Corona wires (charge, transfer, and separation) and casing.

QL, PTL, Erase Lamp

Method

Damp cotton, silicine cloth, and blower brush

Blower brush

Alcohol or water

Dry Cloth

3. Set the OS-A3 chart and make a full size copy at manual image density level #4 (center).

NOTE: Make sure that the data in SP mode #37 is set to "0" (standard value).

4. Confirm that level 2 of the gray scale is just visible on the copy. If the image density is not correct, proceed to the following steps.

5. Enter the lamp voltage setting mode using the numeral keys (SP mode

#48).

6. Change the data with the numeral keys as follows:

If the image density is too dark: Increase the data number

If the image density is too light: Decrease the data number

7. Confirm that the image density is within the adjustment standard.

8. Perform the ADS adjustment. (See page 5-96.)

5-91

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.

When adjusting the wire height, use the drum shoe. (See Charge

Corona Current Adjustment.)

1. Clean the optics components and the charge corona wire.

2. Place a test chart on the expsure glass and make a A3/LDG copy.

3. If the side-to-side variations of the gray scales is not within the adjustment standard, turn off the main switch and remove the exposure glass.

(See Exposure Glass Removal.)

4. Position the adjusting plates [A] so that the copy image meets the adjustment standard. The leading edges of the three adjustment plates must be aligned [B] to avoid white streaks.

5-92

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.

SP Mode #37

Data 0

Bias Voltage [V] V 0

1

V 0 + 40

2

V 0 + 20

3

V 0 - 20

4

V 0 - 40

Image Density Normal Darkest Darker Lighter Lightest

NOTE: V 0 is the standard voltage applied to the development roller.

1. Make a copy after adjusting the light intensity.

2. If the image is blurred:

Decrease bias voltage by one step and readjust light intensity.

If the background is dirty:

Increase bias voltage by one step and readjust light intensity.

5-93

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.)

To leave Detect mode and manually turn on the toner supply system

SP Mode #30

Turns on the toner supply clutch every copy cycle.

9.6 TONER SUPPLY RATIO SELECTION

When:

Purpose:

Adjustment

Standard:

Measure:

How:

The factory setting for toner supply amount is not appropriate for the type of original in use.

To adjust the toner supply amount

Detect Mode

Fixed Mode

Detect Mode

Fixed Mode

: 15% (Factory Setting)

: 7% (Factory Setting)

: SP Mode #31

: SP Mode #32

Changes the toner supply clutch on period.

5-94

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. Turn off the main switch and clean the following parts:

Item No. Section

(1) Optics (mirrors, lens, reflectors, shield glass, exposure glass)

(2)

(3)

(4)

ID sensor

Corona wires (charge, transfer, and separation) and casing

QL, PTL, Erase Lamp

Method

Damp cotton, silicine cloth, and blower brush

Blower brush

Alcohol or water

Dry Cloth

2. Reinstall all the parts.

3. Place five sheets of A3 (LDG) paper on the exposure glass.

4. Check Vsg using SP mode #54. Adjust Vsg by turning VR102 (main board) if Vsg is out of adjustment standard.

5-95

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. Clean the optics (mirrors, lens, reflectors, shield glass, and exposure glass).

2. Place five sheets of A3 (LDG) paper on the exposure glass.

3. Select SP Mode #56 and press the Start key.

4. If the voltage is not within the adjustment standard, adjust it by turning

VR101 on the main board.

5-96

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. Make three copies to check the magnification.

9.10 HORIZONTAL MAGNIFICATION ADJUSTMENT

When:

Purpose:

Adjustment

Standard:

Measure:

How:

The horizontal magnification is not within the adjustment standard.

After loosening the first scanner wire clamps.

To maintain proper horizontal magnification.

Less than

±

0.5% difference between original and copy

1. Adjust the position of the first scanner wire

clamps (rough adjustment).

2. SP Mode #44 (0.2%/step, 16 steps)

(fine adjustment)

1. Changes the distance between the original and

the drum.

2. Changes the lens home position.

- Rough Adjustment -

1. Change the data of SP mode #44 to 8 (default value).

2. Position the scanner wire clamps using the scanner positioning pins.

(See Scanner Wire Installation.)

- Fine Adjustment -

3. Place a 150mm scale parallel to the left scale on the exposure glass.

4. Adjust the horizontal magnification using SP mode #44. Make three copies to check the magnification.

5-97

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.

5-98

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.


2. Adjust the leading edge erase margin using SP mode #41. Make three copies and check the erase margin.

9.13 REGISTRATION ADJUSTMENT

When:

Purpose:

Adjustment

Standard:

Measure:

How:

Registration is not within the adjustment standard.

To maintain proper registration

0

±

2 mm (0

±

0.08")

SP Mode #42 (0.5mm/step, 16 steps)

Changes the registration roller start timing.


2. Adjust the registration using SP mode #42. Make three copies and check the registration.

5-99

1 December 1990

9.14 SIDE-TO-SIDE REGISTRATION ADJUSTMENT

When:

Purpose:

Adjustment

Standard:

Measure:

Side-to-side registration is not within the adjustment standard.

To maintain the proper side-to-side registration

0

±

2 mm (0

±

0.08")

How:

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.

b) When side-to-side registration is incorrect for both the first paper feed station and the second paper feed station, adjust the lens position. Check the adjustment by making a copy from the first paper feed station. Then, make a copy from the paper tray feed station and adjust the paper tray or duplex unit side fences if necessary.

[B]

[C]

- Side Fence Adjustment (Paper Tray) -

1. Pull the paper tray out.

2. Move the side fences [A] to the A4 lengthwise position.

3. Loosen the five screws [B].

4. Set the side fences to the desired position [C].

5-100

[A]

1 December 1990

[C]

[A]

[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].

[C]

5-101

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). Otherwise, the lens may contact the lens unit rail while moving from home position to the selected reduction or enlargement position.

4. Make sure the lens moves smoothly when charging the magnification ratio.

5-102

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. Remove the lens housing cover (2 screws).

3. Adjust the 4th/5th mirror height by turning the screw [A]. Refer to the arrows in the illustration.

5-103

TROUBLESHOOTING

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. Development roller does not rotate.

• Broken drive gear

• Defective development clutch solenoid

4. The development roller is not properly grounded.

5. Poor drum sensitivity

• Drum exposed to fluorescent light or direct sunlight for long period of

• time.

Drum exposed to ammonia gas or fumes for long period of time.

6-1

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.

Are the development drive gears worn or broken?

No Yes

Replace the drive gears.

Does the development clutch solenoid turn on properly?

Yes No

Does the voltage at CN116-1 stay HIGH on the main board after the

Start key is pressed?

24V 0V

Replace the development clutch solenoid.

Replace the main board.

6-2

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.

• CN126-3 (Transfer trigger line)

(1) If the signal stays HIGH after the Start key is pressed, replace the main board.

(2) If the transfer corona does not turn on even if the signal changes to

LOW, replace the TC/SC power pack.

If there is no problem with the signal lines, replace the drum if the sensitivity does not recover even when the drum is not exposed to light.

6-3

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.


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. In ADS mode, Vde (reflected light from the original) is too high.

5. The ADS optical fiber is cut or bent.

6. The development bias is grounded.

6-4

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.


Is the cleaning blade and/or cleaning brush worn?

No Yes

Replace the cleaning blade and/or cleaning brush.

Are the erase quenching lamps and/or toner shield glass dirty?

No Yes

Clean the eraselamp, quenching lamp, and/or the toner shield glass.

If toner scattering occurs, see the toner scattering section of the manual.

6-5

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.

6-6

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.

If the filaments at both the front and rear ends of exposure lamp are not aligned with the holes on the reflector cover, adjust the exposure lamp position (horizontal direction) or adjust the wings (adjusting plates) on

the 1st scanner.

Is the erase lamp, quenching lamp, and/or toner shield glass dirty?

No Yes

Clean the erase lamp, quenching lamp, and/or toner shield glass.

Are the corona wires and/or grid plate dirty?

No Yes

Clean the corona wires, grid plate, and casings.

Adjust the charge corona wire height using a drum shoe.

6-7

1 December 1990

1.4 VERTICAL BLACK BANDS

- Phenomenon -

Vertical black bands appear on the copy paper.


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).

Press the blade release lever down two or three times to clean the edge of the the cleaning blade. If the black bands still appear, go to the next step.

Is the edge of the cleaning blade deformed?

No Yes

Replace the cleaning blade.

Is the cleaning brush deformed?

No Yes

Replace the cleaning brush.

If the inlet seal on the development unit is deformed, replace the inlet seal plate and the seal as a set.

6-8

1 December 1990

1.5 VERTICAL BLACK LINES

- Phenomenon -

Thin black lines appear on the copy.


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.

Is the edge of the cleaning blade scratched?

No Yes

Replace the cleaning blade.

Is the hot roller scratched?

No Yes

Check whether black lines appear on the copy by stopping the copy paper in the transport section. If no black lines appear, replace the hot roller.

Check whether the drum is scratched or toner is built-up on the drum.

• If toner is built-up on the drum, clean the drum with damp cloth.

• If the drum is scratched, replace the drum.

NOTE: When replacing the drum, perform drum initial setting using SP mode #66.

6-9

1 December 1990

1.6 VERTICAL WHITE LINES OR BANDS—1 (DULL OR BLURRED)

- Phenomenon -

Dull or blurred white lines appear on the copy.


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.

Is the inlet seal damp or contaminated with oil?

No Yes

Clean the inlet seal with a dry cloth. If the problem is not corrected, replace the inlet seal plate and the seal as a set.

Is the grid plate deformed?

No Yes

Replace the grid plate.

Replace the charge corona wire.

6-10

1 December 1990

1.7 VERTICAL WHITE LINES OR BANDS—2 (THIN, DISTINET)

- Phenomenon -

Vertical white lines appear on the copy.


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. Do white lines appear on the copy?

No Yes

Replace the drum if it is scratched.

Replace the hot roller if it is scratched.

NOTE: If the drum is scratched, find out what caused the scratches on the

•

•

•

• drum and correct the problem.

Paper Jam

Incorrect positioning of the pick-off pawls

Foreign substances on the cleaning brush and/or blade

Carrier leakage

When replacing the drum, perform the drum initial setting using SP mode #66.

6-11

1 December 1990

1.8 HORIZONTAL BLACK/WHITE LINES

- Phenomenon -

Black/white lines perpendicular to the paper feed direction appear on the copy image.


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.

Due to insufficient cleaning, foreign matter may be build up on the blade,

causing toner to stick to the drum surface when the drum stops.

- Action -

Is the drum scratched?

No Yes

Replace the drum.

Is the hot roller scratched?

No Yes

Replace the hot roller.

If toner adheres to the drum surface, clean the drum with water. Also clean or replace the cleaning blade and/or cleaning brush.

6-12

1.9 JITTER

- Phenomenon -

Jitter appears on the copy.


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.

1 December 1990

6-13

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 CC/G/B power pack.

6-14

1 December 1990

1.11 SKEWED (OPTICAL) COPY IMAGE

- Phenomenon -

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.)


IMAGE

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.

- Action -

Is each mirror positioned correctly on its scanner and on the 4th/5th mirror assembly?

Yes No

Reposition the mirror correctly. If the spring plates are defective, replace them.

Are the stubs of the 4th/5th mirror assembly off the rails?

No Yes

Put the mirror assembly stubs back on the rails.

Readjust the height of 4th/5th mirror assembly by turning the adjusting screw.

6-15

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.


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. ID sensor bias voltage (modules) is too low.

6. Charge corona current is too low.

7. ID sensor grid voltage is too low.

- Action -

Has an ID sensor abnormal condition occurred?

No Yes

See the ID Sensor Abnormal Condition section.

Clean the optics section and around the drum. Make a few sky shot copies and then readjust the light intensity and the ADS voltage.

Does the toner supply clutch solenoid turn even though there is sufficient toner in the development unit?

No Yes


24V 0V


Replace the toner supply clutch solenoid.

6-16

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".

6-17

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.


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.

- Action -

Does an ID sensor abnormal condition occur?

No Yes

See the ID Sensor Abnormal Condition section.

Does the toner supply clutch rotate?

Yes No

Check the voltage at CN118-1 on the main board

24V 0V

Replace the toner supply clutch solenoid.


Go to A

6-18

1 December 1990

Is the data of SP Mode #30 "1"?

No Yes


Go to A

Is the data of SP Mode #33 "1"?

No Yes


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. Place a few sheets of white paper on the exposure glass. Enter "99" using the numeral key and press the

Start key to start free run. Repeat free run until Vsp becomes lower than 1/8

Vsg using SP mode #55.

Adjust the light intensity, ADS voltage, and/or Vsg voltage.

6-19

1 December 1990

1.14 TONER SCATTERING

- Phenomenon -

Toner scatters from the development unit.


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.

Is the filter dirty with toner?

No Yes

Clean the filter with a vacuum cleaner.

Has the developer been used more than 60K?

No Yes

Replace the developer.

Check the doctor gap. If the doctor gap is wider than the adjustment standard, adjust the doctor gap.

6-20

1 December 1990

1.15 UNFUSED COPY IMAGE

- Phenomenon -

Solid image rubs off easily.


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.

6-21

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.


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. If no sensors are defective, replace the main board.

- Action 2 (Misfeed during copy cycle) -

Set jam Detection OFF mode (SP mode #6) to on and make a copy to see whether a misfeed occurs.

Misfeed No misfeed

Check which sensor is defective using the Misfeed During Copy

Cycle table. (See page 4-33.) If no sensors are not defective, replace the main board.

Check whether a mechanical or electrical malfunction occurs. Replace the defective parts.

6-22

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.


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. Pour a small amount of silicone oil on the exposure glass and wipe the exposure glass with a dry cloth to reduce the friction between the exposure glass and the feed belt.

6-23

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 sec-

• ond 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.


• Exposure lamp open

•

•

Thermoswitch open

AC drive board defective

•

•


DC harness defective

- Action -

Turn the main switch off and on.

Exposure lamp off?

Yes No


24V Less than 20V


Replace the ac drive board.

Is the exposure lamp circuit open?

No Open

Replace the exposure lamp.

Is the thermoswitch open or defective?

No Open Defective

Replace the thermoswitch.

6-24

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 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



6-25

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.


• AC drive board defective

•

•


DC harness defective

- Action -


Check the voltage at CN122-10 on the main board after the Start key is pressed.

Less than 20V

24V



More than

0.5V

Less than

0.5V



6-26

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.


• Main board defective

•

•

DC power supply board

Zero cross line open

- Action -


Check the voltage at CN102-2 on the dc power supply unit.

0.6V

0V

Replace the dc power supply board.


0.6V

0V

Replace the dc harness.


6-27

1 December 1990

2.4 CODE #21 — SCANNER HOME POSITION ERROR

- Definition -



• Scanner home position sensor short

•

•

•

Scanner motor defect

Main board defect

DC power supply unit defect

- Action -


Check the position of the 1st scanner sensor actuator.

Home Not Home

Does the scanner motor rotate when the main switch is turned on?

No Yes

Retighten the Allen screws on the scanner drive pulley.


34V 0V

Replace the dc power supply unit.

Check the voltage at CN105-1 and 6 on the main board.

34V 0V


Check the voltage at CN105-2 to 5 on the main board with the main switch on.

31V 34V

6-28

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.


6-29

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.


• 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.

Not Home

Home

Does the scanner motor rotate when turning on the main switch is turned on?

No Yes

Tighten the Allen screws on the scanner drive pulley.


34V 0V

Replace the dc power supply unit.


34V 0V



29V 34V

6-30

1 December 1990

29V 34V


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.


6-31

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.


• Lens home position sensor short

•

•

Lens drive motor defect

Main board defect

- Action -


Check the sensor actuator position on the lens assembly.

Home Not Home

Does the lens motor rotate when the main switch is turned on?

No Yes

Check the drive mechanism and repair or replace the defective parts.


24V 0V



17V 24V


Replace the lens motor.

6-32

1 December 1990

Check the continuity between CN824-2 and 3 on the lens home position sensor.

No t

Continuous

Continuous

Replace the sensor.


6-33

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.


• Lens home position sensor open

•

•

Lens drive motor defective


- Action -


Check the position of the lens assembly sensor actuator.

Not

Home

Home

Does the lens motor rotate when the main switch is turned on?

No Yes



24V 0V


Turn on the main switch and check the voltage at CN102-2 to 5 on the main board.

17V 24V


Replace the lens motor.

6-34

Check whether the lens home position sensor is open.

Not

Open

Open

Replace the sensor.


1 December 1990

6-35

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.


• 4th/5th mirror home position sensor short

•

•

4th/5th mirror motor defect

Main board defect

- Action -


Check the sensor actuator position on the 4th/5th mirror assembly.

Home Not Home

Does the 4th/5th mirror motor rotate when the main is turned on?

No Yes



24V 0V



17V 24V


Replace the 4th/5th mirror motor.

6-36

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.


6-37

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.


• 4th/5th mirror home position sensor open

•

•

4th/5th mirror motor defective


- Action -


Check the sensor actuator position on the 4th/5th mirror assembly.

Not

Home

Home

Does the 4th/5th mirror motor rotate when the main switch is turned on?

No Yes



24V 0V



17V 24V


Replace the 4th/5th mirror motor.

6-38

1 December 1990

Check whether the 4th/5th mirror home position sensor is open.

No Open

Replace the sensor.


6-39

1 December 1990

2.10 CODE #52 — FUSING WARM-UP ERROR

- Definition -



• Thermistor position error

•

•

•

•

Fusing lamp open

Thermofuse open

AC drive 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.

Is the thermofuse open?

No Yes

Replace the thermofuse.

If the ac harness is defective, replace it.


0V 24V


6-40

1 December 1990


0V 24V



24V 0V


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.


6-41

1 December 1990

2.11 CODE #53 — FUSING OVERHEAT

- Definition -

The thermistor detects a temperature higher than 240 o C.


• Thermistor short

•

•

AC drive board defect

Main board defect

- Action -


Check the voltage at TP107 on the main board.

More than

3.45V

Less than

3.45V


Has the thermistor shorted?

No Yes



24V 0V



6-42

1 December 1990

2.12 CODE #55 — FUSING THERMISTOR OPEN

- Definition -

The thermistor does not detect 2 o C within 30 seconds after the main switch is turned on.


• Thermistor open

•

•

•


Fusing lamp open

Thermofuse open

- Action -

Is the thermistor open?

No Yes



Does the fusing lamp turn on?

No Yes


Is the fusing lamp open?

No Yes

Replace the fusing lamp.

Is the thermofuse open?

No Yes

Replace the thermofuse.

Is the ac harness defective?

No Yes

Replace the ac harness.

6-43

1 December 1990


0V 24V



0V 24V



24V 0V



6-44

2.13 E70 (IN THE MAGNIFICATION INDICATOR)

— TONER OVERFLOW SENSOR ON

- Definition -

Toner overflow sensor turns on


• Toner overflow

•

•

Toner overflow sensor open


- Action -

Is the used toner tank full?

No Yes

Dispose of the used toner.


0.9V

0V


Is the toner overflow sensor open?

No Yes

Replace the sensor.


1 December 1990

6-45

1 December 1990

2.14 CODE #80 — DUPLEX AND COPIER BOARD COMMUNICATION

ERROR

- Definition -



• 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.

Is the connector (CN710) on the rear frame installed properly?

Yes No

Install the connector (CN710) on the frame properly.

Are the fuses (FU100 or FU101) on the optional dc power supply unit broken?

No Yes

Check the cause of the fuse damage and repair it, then replace the defective fuse.

Check the voltage at CN101-2 on the optional dc power supply unit.

5V 0V

Replace the optional dc power suppy unit.

6-46

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.


6-47

1 December 1990

2.15 CODE #81 — INTERFACE BOARD ERROR

- Definition -



• Interface board installed incorrectly

•

•

•

Interface board defective


2nd paper size switch shorted

- Action -


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.

Is this SC code (E81) displayed even if the duplex tray is not installed?

Yes No


Check whether the 2nd paper size switches have a short.

No Short

Replace the shorted 2nd paper size switches shorten.


6-48

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.


• Jogger home position sensor shorted

•

•

•

•

Jogger motor defective




- Action -


Do the side fences move when the main switch is turned on?

Yes No

Check the voltage at CN705-2 to 5 on the duplex main board.

14V 24V


Replace the jogger motor.

Is the jogger home position sensor shorted?

No Short

Replace the sensor.

Replace the duplex main board, copier main board and/or interface board.

6-49

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.


• Jogger home position sensor open

•

•

•

•

Jogger motor defective




- Action -


Do the side fences move when the main switch is turned on?

Yes No

Check the voltage at CN705-2 to 5 on the duplex main board.

14V 24V


Replace the jogger motor.

Is the jogger home position sensor open?

No Open

Replace the sensor.

Replace the duplex main board, copier main board and/or interface board.

6-50

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.


• 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.

5.00

0.00 (Vsg

≤

2.5 volts)

Is the copy image too light?

No Yes

Refer to Light Copy section.

Is the ID sensor circuit open?

No Yes

Replace the ID sensor and adjust the Vsg to 4.02

±

0.2 volts.

Replace the main board and adjust the Vsg to 4.02

±

0.2 volts.

Is the ID sensor surface dirty with toner?

No Yes

Clean the ID sensor with blower brush and/or damp cloth, then check and/or adjust the Vsg to 4.0

±

0.2 volts. If toner scattering occur, correct it. (Refer to Toner Scattering section.)

6-51

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.


6-52

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)

Toner Overflow

Sensor

(S9)

Condition

OPEN

(CN122-4 stays HIGH)

SHORTED

(CN122-4 stays LOW)

OPEN


SHORTED

(CN102-8 stays LOW)

OPEN


SHORTED

(CN102-11 stays LOW)

OPEN


SHORTED

(CN101-9 stays LOW)

OPEN


Exit Sensor

(S5)

SHORTED

(CN141-2 stays LOW)

Paper End Sensor

1st and 2nd

(S6 and S7)

Toner End Sensor

(S8)

OPEN

(1st: CN125-5 stays HIGH)

(2nd: CN139-4 stays

HIGH)

SHORTED

(1st: CN125-5 stays LOW)

(2nd: CN139-4 stays LOW)

OPEN


SHORTED

(CN114-2 stays LOW)

OPEN


SHORTED

(CN101-2 stays LOW)

Symptom

SC code (E22) is displayed.




SC code (E2A) is displayed.

SC code (E2B) is displayed.

"Check Paper Path" indicator

(location "A" or "B") blinks when a copy is made.


(location "A" or "B") lights when the main switch is turned on.


(location "D") blinks when a copy is made.


(location "D") lights when the main switch is turned on.

"Load Paper" indicator lights even when paper is in the cassette or tray.

"Load Paper" indicator lights even when the cassette or tray is empty.

The CPU detects toner end condition using Vsp/Vsg value.

If the ID sensor is defective, the CPU fails to detect toner end and the image density may become too low.

"E70" blinks in the magnification indicator even when used toner tank is not full.

"E70" does not blink.

6-53

1 December 1990

Paper Lift Sensor

(S10)

Component

Image Density

(ID Sensor)

(S11)

Development Unit

Set Sensor

(S12)

OPEN


SHORTED

(CN125-2 stays LOW)

Condition

OPEN


SHORTED

(CN110-3 stays LOW)

OPEN


SHORTED

(CN123-2 stays LOW)

User Code #5 is displayed.

The cassette bottom plate does not rise to the paper feed position.

Symptom

The CPU detects an ID sensor abnormal condition. The ADS or

Manual Image Density indicator starts blinking.

The CPU fails to detect User Code

#3 even when the development unit is not set.

User code #3 is displayed even when the development unit is set.

6-54

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)

OPEN

Condition

SHORTED

OPEN

SHORTED

OPEN

SHORTED

OPEN

(CN114-4 and/or 6 stays HIGH)

SHORTED

(CN114-4 and/or 6 stays LOW)

OPEN


Symptom

The copier does not turns on.

The copier does not turns off.

The copier does not tunrs on.

The copier does not turn off when the front or exit cover is opened.

The CPU cannot detect proper paper size, and misfeeds may occur when a copy is made.

The CPU cannot properly control the copy process system for the development unit (black or color).

This may cause an abnormal image

(dirty backfround, light copy, etc.)

Manual Feed

Table Switch

(SW9)

Right Cover Switch

(SW10)

SHORTED

(CN114-8 stays LOW)

OPEN


SHORTED

(CN117-2 stays LOW)

OPEN

The CPU does not detect manual feed mode even when the manual feed table is opened.

The "Manual Feed" indicator stays on even when the manual feed table is closed.

The CPU does not display User

Code #1 even when the right cover is opened.

User Code #1 is displayed even when the right cover is closed.

SC Code (E11) is displayed.

Exposure Lamp

(L1)

Fusing Lamp

(L2)

Fusing Thermistor

(TH)

Fusing Thermofuse

(TF)

Optics Thermoswitch

(TS)

OPEN

OPEN

OPEN

OPEN





6-55

1 December 1990

3.3 FUSE

Component

FU401

(AC Drive Board)

FU100 (5V)

(Main DC PSU)

FU101 (24V)

(Main DC PSU)

FU102 (30V)

(Main DC PSU)

OPEN

Condition

OPEN

OPEN

OPEN

OPEN

FU100 (5V)

(Optional DC PSU)

FU101 (24V)

(Optional DC PSU)

OPEN

Symptom

The copier does not turn on when the main switch is turned on.

The copier does not turn on even when the main switch is turned on.

SC Code #21 or #22 is displayed depending on the 1st scanner position.

SC Code #21 or #22 is displayed depending on the 1st scanner position.

Duplex Tray:

SC Code #80 is displayed.

ADF:

The feed-out motor starts rotating when the main switch is turned on.

Duplex Tray:

SC Code #80 is displayed.

ADF:

The ADF does not work.

6-56

DOCUMENT FEEDER

1 December 1990


Original Size and Weight:

Original Feed:

Original Table Capacity:

Original Set:

Original Transport:

Copy Speed:

Power Consumption:

Dimensions (W x D x H):

Weight:

— Thin original mode —

Maximum A3 11"

Minimum B6 5

1/2

" x 8

1/2

"

Weight 41 to 128 g/m

2

(11 to 34 lb)

— Thick original mode —

Maximum A3 11"

Minimum B6 5

1/2

" x 8

1/2

"

Weight 52 to 128 g/m

2

(14 to 34 lb)

— Auto reverse mode —

Maximum A3 11"

Weight

5

1/2

" x 8

1/2

" lengthwise

64 to 105 g/m

2

(17 to 28 lb)

Automatic feed — ADF mode

Manual feed one by one — SADF mode

30 sheets / 80 g/m

2

(20 lb)

Face up. First sheet on top

One flat belt

16 copies/minute for A4 / 8

1/2

" x 11" sideways

20 W

670 x 460 x 103 mm (26.4" x 18.1" x 4.1")

Approximately 8.8 kg (19.4 lb)

8-1

1 December 1990

2. COMPONENT LAYOUT

- Mechanical Components -

2 3 4

1

5 6

10 9 8

1. Pulse Generator Disk

2. Friction Belt

3. Pick-up Lever

4. Original Table

5. Exit Roller

- Electrical Components -

5

4

3

2

6

6. Inverter Pawl

7. Inverter Roller

8. Transport Belt

9. Pick-up Roller

10. Feed Roller

7

8

9

7

1

14

1. Original Set Sensor


3. Pulse Generator Sensor

4. Original Width Sensor

5. Pick-up Solenoid

6. Belt Drive Motor

7. Indicator Panel

13

11

12

8. Lift Switch

9. DF Main Board

10. Feed-out Motor

11. Inverter Solenoid

12. Feed-out Sensor

13. Original Select Switch

14. Feed-in Solenoid

8-2

10

1 December 1990


Symbol Name Function Location

Motors

M1

M2

Belt Drive Motor

Feed-out Motor

DC servomotor that drives to the transport belt and feed-in system (pick-up roller, feed roller, pull-out roller and relay roller).

DC servomotor that drives the feed-out unit of the DF.

Solenoids

SOL1

SOL2

SOL3

Pick-up Solenoid Energizes to press the pick-up lever against the stack of originals in preparation for original feed-in.

Feed-in Solenoid Turns on to engage the feed-in clutch so rotation is transmitted to the feed roller, pull-out rollers, and relay rollers.

Inverter Solenoid Energizes to invert the original when copying two sided originals.

Switches

SW1 Lift Switch

SW2 Original Select

Switch

Informs the CPU when the DF is lifted and also serves as the jam reset switch for the DF.

Selects thick original mode or thin original mode.

Sensors

S1

S2

S3

S4

S5

Original Set Sensor

Registration Sensor

Original Width

Sensor

Informs copier CPU that originals have been placed and causes the Insert Original indicator to go out.

Sets original stop timing and measures original length.

Determines the width of the originals.

Pulse Generator

Sensor

Generates pulses used to measure the original length.

Feed-out Sensor Checks for original misfeeds and sets original stop timing when in auto reverse mode.

Printed Circuit Boards

PCB1

PCB2

DF Main Board

Indicator Panel

Board

Controls all DF functions.

Contains operator indicators.

6

10

5

14

11

8

13

1

9

7

2

4

3

12

8-3

1 December 1990


Copier (PCB1)

Main Board

Interface (PCB6)

Board DF Main Board (PCB1)

TXD RXD

TXD RXD

CPU

ROM

Driver

IC

Driver

IC

Sensors

Switches

Solenoids

Indicators

Belt Drive

Motor

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. The exchanged signals are shown in the tables on the next page.

8-4

1 December 1990

1. DF → Copier

No.

Signal Name

1 Original Set

Definition

Originals are set on the original table

2

3

4

Copy Start

Lift Up

DF Misfeed

Allows the copier to start copy sequence

The DF is lifted

Misfeed occurs in the DF

2. Copier → DF

No.

Signal Name

1 Feed-in

Definition

Requests the DF to feed-in the original

2

3

4

5

Feed-out

Original Stay

Requests the DF to feed-out the original

Invert Original Requests the DF to invert the original

Auto Feed Shifts the DF to the auto feed mode

Attempt to use DF but the original from the previous copy run remains on the exposure glass

8-5

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. The pick-up solenoid and the feed-in solenoid remain energized until the original leading edge reaches the

DF registration sensor. The belt drive motor turns off shortly after the original’s trailing edge passes the DF registration sensor.

While feeding the original, the DF registration sensor and the paper width sensor check the original size.

Just when the original trailing edge has passed the DF registration sensor, the DF CPU sends the copy start signal to the copier. On receipt of the signal, the copier CPU carries out the original ID measurement while returning the scanner to the home position and starts the copy cycle.

When the scanner reaches the return position, the copier CPU sends the feed-out and the feed-in signals to the DF CPU in order to exchange the original with the next original. At this time, the scanner begins returning to the home position, but stays 100 mm away from the left scale until the next original is on the exposure glass. At this time the original ID measurement is taken.

When the scanner comes to the return position after scanning the last original, the copier CPU only sends the feed-out signal in order to feed-out the last original.

8-6

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. The belt drive motor continues to feed the original until the original leading edge passes the feed-out sensor. At this point the inverter mechanism inverts the original, in preparation for copying the back side. Then the belt drive motor reverses and the original is fed towards the left scale and is aligned against the scale. The DF CPU sends the copy start signal a short time after the original trailing edge has passed the feed-out sensor.

When the scanner reaches the return position, the copier CPU sends the invert original signal to the DF CPU in order to make a copy of the front side.

The original is inverted in the same way as for back side copying.

3. Semi-automatic Document Feed

If a single original is inserted into the original table and copied, the DF shifts to the semi-automatic feed mode and lights the Auto Feed indicator. The

Auto Feed indicator remains on for five seconds after the copier main motor stops. If another original is inserted within that five-second period, it is automatically fed and copied.

8-7

1 December 1990

6. POWER DISTRIBUTION

AC Drive Board

(PCB2)

115Vac

220/240Vac

Optional

Transformer

(TR2)

26Vac

Optional

DC Power

Supply Board

(PCB5)

+24V (VA)

+5V (VC)

10Vac

+24V +12V

Regulator

IC

5V

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. The optional dc power supply board then converts the 10 volts ac input to +5 volts dc and the 26 volts ac input to +24 volts. Then, thoes two dc voltsges are supplied to the DF main board.

The regulator IC on the DF main board further steps down the +24V to +12V.

8-8

1 December 1990

7. INTERFACE CIRCUIT

Copier Main Board (PCB1)

CPU

+5V

TXD

+5V

+5V

RXD

Interface Board (PCB6) DF Main Board (PCB1)

CN133-A14 CN201-A14

CN133-B14

CN106-4

CN201-B14

CN201-A3

CN201-B3

CN106-3

CN133-A1

CN133-B1

CN201-A1

CN201-B1

CN206

Fiber Optics

Fiber Optics

CN106

TXD

RXD

CPU

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).

8-9

1 December 1990

8. ORIGINAL FEED

8.1 ORIGINAL PICK-UP

[C]

[B]

[A]

[D]

[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]. The rotation of the pick-up roller advances the bottom original.

8-10

8.2 ORIGINAL SEPARATION

[B]

[A]

1 December 1990

[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. The feed roller moves the original past the friction belt because the driving force of the feed roller is greater than the resistance of the friction belt. The friction belt prevents multiple feeds because the resistance of the friction belt is greater than the friction between original sheets.

8-11

1 December 1990

8.3 ORIGINAL FEED-IN MECHANISM

[E]

[C]

[D]

[G]

[B]

[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. The pulse generator disc

[G] always turns when the belt drive motor is on.

Slightly after the original trailing edge passes the registration sensor, the relay rollers and the transport belt stop turning.

8-12

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. The belt drive motor stops shortly after the original trailing edge passes the DF registration sensor. (Exact timing depends on registration adjustment.) Thin original mode is selected at the factory.

2. Thick Original Mode

When thick original mode is selected, the belt drive motor remains energized for an additional 30 encoder pulses as compared to thin original mode. Then, the belt drive motor pauses and reverses for 21 pulses. This forces the original against the left scale and thus aligns the edge of the original with the scale.

After the exposure cycle is completed, the copier sends the feed-out signal to the DF CPU and the belt drive and feed out motors start turning. At this time, the copied original feeds out and the next original feeds in.

8-13

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.

8-14

8.5 ORIGINAL INVERSION MECHANISM

[D]

1 December 1990

[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.

8-15

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. This is to prevent damaging the edge of the original against the left scale.

When the original leading edge reaches the left scale, the belt drive motor stops. At the same time, the feed-out motor and the inverter solenoid turn off.

4) After the reverse side of the original is exposed, the belt drive motor, the feed-out motor, and the inverter solenoid turn on, and the original is fed into the inverter section. (This is the same as step 2 above.)

5) The original is fed onto the exposure glass again as in step 3 above. The front side of the original is then copied.

6) After the front side of the original has been exposed, the original is fed out from the DF.

8-16

8.6 ORIGINAL FEED-OUT MECHANISM

[A]

1 December 1990

[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.

When the original trailing edge passes the feed-out sensor [D], the feed-out motor drops to half of its normal speed for 220 milliseconds and then stops.

The lower speed prevents uneven stacking of originals. For A3 or double letter size originals, the feed-out motor speed does not change due to the length of the originals.

8-17

1 December 1990

8.7 BELT DRIVE MOTOR CIRCUIT

DF Main Board (PCB 1)

CPU

Speed

Data

ON/OFF

Driver

IC

PWM

Driver

Circuit

Forward/

Reverse

Phase A

Phase B

+5V

CN102-1

CN102-2

CN103-1

CN103-2

CN103-3

CN103-4

Belt Drive

Motor

Encoder

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. The driver IC sends the pulse-width-modulation (PWM) signal to the driver circuit, which sends the motor drive pulses.

An encoder in the servomotor has two magnetic sensors that generate two pulse signals (phase A and B). The driver IC monitors the belt speed and direction by these pulse signals and uses this data to regulate the motor’s speed.

8-18

1 December 1990

8.8 FEED-OUT MOTOR CIRCUIT

DF Main Board (PCB 1)

CN104-A2

CN104-A15

FG

AC Feedback

CPU

High/Low

Driver

IC

Voltage

Regulation

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.

The frequency generator of the feed-out motor makes a very low voltage ac current which is fed back to the driver IC. The driver IC monitors the frequency of this ac current and based on the frequency it regulates the motor speed.

8-19

1 December 1990

8.9 INPUT AND OUTPUT CIRCUITS

Original Set Sensor

P S

CN104-B1

CN104-B9

CN104-B15

Pulse Generator Sensor

P S

CN104-B2

CN104-A9

CN104-B17

Registration Sensor

P S

CN104-B11

CN104-B16

DF Main Board (PCB1)

+5V

[ 12]

+5V

[0-12]

[ 5]

[ 12]

CPU

+24V

[ 24]

+24V

[ 24]

Original Width Sensor

CN104-A11

P S [ 5] +24V

[0-24]

Feed-out Sensor

P S

CN104-A1

CN104-B10

CN104-A16

+5V

[ 5]

[0-24]

[0-24]

Original Select SW

[ 5]

P: Photoreceiver

S: Schmitt Trigger Circuit

Feed Out

Motor

[ 24]

GND

[ 24]

[ 24]

CN104-A10

CN104-A17

Lift SW (SW1)

CN104-B6

CN104-A3

Pick-up

SOL

CN104-A6

CN104-B14

Inverter

SOL

Indicator Panel

CN104-B5

CN104-A13

Insert Original

CN104-B12

Auto Feed

CN104-A4

Misfeed

Belt Drive

Motor

The above devices are directly controlled and monitored by the CPU. The solenoids and indicator panel are energized with +24 volts. The sensors and switches are energized with +12 volts or +5 volts.

To energize a solenoid or indicator, the CPU drops the connected trigger line from +24 volts to LOW. The CPU monitors the input lines of the sensors and switch to determine when they are activated.

8-20

1 December 1990

9. LIFT MECHANISM

[D]

[G]

[B]

[B]

[A]

[C]

[C]

[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. The lift switch also serves as the reset switch for document feeder misfeeds.

When a book or thick (maximum thickness 60 mm) original is copied, the DF acts as a cover for the original as shown in the figure [F]. The lift switch is turned off during this condition, so the DF does not function. The tension of spring [G] returns the DF to the normal condition after copying a thick original.

8-21

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

Belt Drive Motor

Feed-out Motor

ON check (1250 ms)

OFF check (1250 ms)

If the registration sensor is not actuated within 685 milliseconds after the belt drive motor starts turning, the Original Misfeed indicator lights (ON check).

If the registration sensor does not turn off within 1,250 milliseconds, the CPU determines that there has been an original misfeed (OFF check). The

Original Misfeed indicator also lights if the feed-out sensor is not actuated within 1,250 milliseconds after the feed-out motor starts turning (ON check) or if the feed-out sensor does not turn off within 1,250 milliseconds after the feed-out sensor is actuated (OFF check).

8-22

1 December 1990

2. Two sided original

Registration

Sensor (RS)

Feed-out

Sensor (FS)

Inverter Solenoid

RS ON check (685 ms)

RS OFF check (1250 ms)

100 ms FS OFF check (1250 ms)

FS ON check (1250 ms)

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. If the feed-out sensor is not actuated within

1,250 milliseconds after the feed-out motor starts turning, the Original

Misfeed indicator lights (ON check). The Original Misfeed indicator also lights if the feed-out sensor does not turn off within 1,250 milliseconds after the belt drive motor reverses (OFF check).

If a previous original remains on the exposure glass after manual copying and DF feed is attempted, the original misfeed indicator lights. When the DF is lifted and the previous original is removed, DF copying is permitted.

8-23

1 December 1990

11. INSTALLATION PROCEDURE (for Machine

11.1 ACCESSORY CHECK


1. Original Table ........................................................................ 1

2. DF Mounting Bracket ............................................................. 1

3. Angle Stopper ........................................................................ 1

4. Lift Switch Actuator ................................................................ 1

5. E Plate ................................................................................... 1

6. Spacer - 0.5 mm .................................................................... 6

7. Spacer - 0.2 mm .................................................................... 4

8. DF Harness Bracket .............................................................. 1

9. Bushing .................................................................................. 1

10. Toothed Washer .................................................................... 1

11. Grounding Screw - M4 x 6 ..................................................... 1

12. Hexagon Head Screw - M4 x 10 ........................................... 4

13. Philips Screw with Flat Washer - M4 x 5 ............................... 4

14. Philips Pan Head Screw - M4 x 5 (round head) .................... 3

15. Philips Pan Head Screw - M4 x 5 (flat head) ......................... 2

16. Philips Pan Head Screw - M3 x 5 .......................................... 1

17. Stud Screw ............................................................................ 2

18. DF Test Chart ........................................................................ 1

NOTE 1. When the document feeder is installed on the copier, the DC power supply unit (option) is required.

2. When installing the DC power supply unit, please refer to the installation procedure enclosed with it.

8-24

11.2 INSTALLATION PROCEDURE

[D] [A]

1 December 1990

[B]

[C]

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.

8-25

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].

8-26

[B]

1 December 1990

[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. Place the bushing on the harness bracket [D] and secure the bracket to the harness support bracket [E] (2 screws).

8-27

1 December 1990

[E]

[B]

[C]

[G]

[A]

[D]

[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].

8-28

DIP SW101

1 December 1990

[A]

[C]

[D]

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.

20. Reinstall the grip cover (3 screws).

NOTE: Open and close the document feeder to confirm that the magnet catches are making good contact.

21. Plug in the copier and turn on the main switch.

22. Confirm the original registration as follows:

1) Make a copy of the test sheet in platen mode (A4 width).

2) Confirm that the original select switch is set to thin paper mode and

make a copy in DF mode (A4 width).

3) Compare the registration of the copy in platen mode with that of DF

mode, and confirm that the difference is within 2.5 mm.

4) If the difference is more than 2.5 mm, remove the DF main PCB cover

and adjust VR102 to change the original-stop timing.

NOTE: Turning VR102 clockwise results in the original stopping later.

8-29

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. The test sheet should stop pressed against the left scale in DF two-sided original mode.

2. Turning VR103 clockwise results in the original stopping later.

23. Reassemble the copier. (The DF harness fits in the cut-out on the rear cover as shown.)

24. Check the operation of the DF.

25. Position the original select switch to thin original mode (normal position) and explain the function of this switch to the customer.

8-30

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.

8-31

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).

8-32

[C]

1 December 1990

[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.

8-33

1 December 1990

13.1.2 Feed-in Unit Removal

[B]

[A]


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).

8-34

13.1.3 Pick-up Roller Replacement*

[D]

[C]

[A]

1 December 1990

[B]


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.

c) When installing the gear, make sure the flat side of the gear is facing away from the roller.

8-35

1 December 1990

13.1.4 Feed-in Clutch Lubrication

[B]

[A]

[D]

[C]


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].

b) When installing the feed clutch, make sure the positioning pin is correctly inserted in the cut-out of the clutch.

8-36

13.1.5 Pick-up Solenoid Adjustment

[B]

[C]

[D]

[F] [E]

1 December 1990

[A]


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.


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.

8-37

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.

NOTE: Make sure the pick-up lever is touching the pick-up roller during this adjustment.

10. Press SW 102 [F] to turn off the solenoids.

11. Turn off DPS101-3 and 4, then turn on DPS101-1 and 2.

12. Turn off the main switch and reassemble the DF.

13. Check the original feed-in operation.

8-38

13.1.6 Feed Roller Replacement -

[B]

[C]

1 December 1990

[A]


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.

b) When installing the feed roller, make sure the gear side of the roller faces the front (See illustration).

c) When installing the side and pull-out rollers, make sure the pins are correctly inserted in the cut-outs of the rollers.

8-39

1 December 1990

13.1.7 Feed-in Solenoid Adjustment

[B]

[C]

[A]

[D]



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).



7. Loosen the 2 screws securing the feed-in solenoid [C].

8. Press SW101 on the DF main PCB (to engage all DF solenoids) and adjust the position of the solenoid until the gap [D] (See illustration) is within

1.0 – 2.0 mm.

9. Press SW102 on the DF main PCB to turn off all DF solenoids.


8-40

13.1.8 Friction Belt Replacement

[A]

1 December 1990

[B]

[D]

[C]


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.

8-41

1 December 1990

13.2 FEED-OUT UNIT

13.2.1 Feed-out Unit Removal

[A]

[C]


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).

8-42

[B]

13.2.2 Inverter Solenoid Adjustment

[B]

1 December 1990

[A]

[C]

[D]



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).



7. Loosen the screw securing the inverter solenoid [C].

8. Press SW101 on the DF main PCB (to engage all DF solenoids), and adjust the position of the solenoid until the gap [D] (See illustration) is within

1.5

±

0.5 mm.

9. Press SW102 on the DF main PCB to turn off all DF solenoids.


8-43

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.

8-44

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. Compare the leading edge registration with that of the platen cover mode copy, and check that the difference between the two copies is within 2.00

mm.

7. If out of specification, adjust VR103 on the DF main PCB until the leading edge registration is correct.

NOTE: a) The test sheet stops pressed against the left scale in DF two-sided original mode.

b) Turning VR103 clockwise results in the original stopping later.

8-45

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.


2. Check that DIP switch 101 is set for the normal setting as follows:

101-1

ON

101-2

OFF

101-3

OFF

101-4

OFF

3. Turn on the main switch and DIP switch 101-2 and -4.

4. While turning on the lift switch manually, adjust the belt drive motor speed using VR 101 [A] so that both the Insert Original indicator [B] and Auto

Feed indicator [C] turn off.

NOTE: a) When the Insert Original indicator lights, turn VR 101 clockwise to reduce the motor speed.

b) When the Auto Feed indicator lights, turn VR 101 counterclockwise to increase the motor speed.

c) Confirm that both indicators remain off for approximately 5 seconds in order to stabilize the motor speed.

5. Turn off DIP switch 101-2 and -4.

NOTE: Do not use VR 106. This variable resistor is for adjusting feed-out motor speed. This is preset by the vendor.

8-46

SORTER

1 December 1990


Number of Bins:

Paper Size for Bins:

Paper Weight:

Bin Capacity:

10 bins

Maximum A3, 11" x 17"

Minimum A6,

1/2

"

(Lengthwise)

64 to 90 g/m

2

(17 to 24 lb)

Sort/Stack 20 sheets / A4, 8

1/2

" x11"

Mode 15 sheets / B4, 8

1/2

" x 14"

10 sheets / A3, 11" x 17"

100 sheets (all sizes) Top Bin Capacity:

(Non-Sort/Stack Mode)

Power Source:

Power Consumption:

Dimensions:

(W x D x H)

Weight:

+5 volts and +24 volts from the copier

7.7 W

440 mm x 391 mm x 367 mm

(17.3" x 15.4" x 14.4")

7.5 kg (16.5 lb).

9-1

1 December 1990


— Mechanical Components —

1

2

1. Bin

2. Transfer Wheel

3. Exit Roller

4. Upper Paper Guide

5. Lower Paper Guide

6. Bin Guide

— Electrical Components —

1

2

3

3 4

6 5

4

7

1. Sorter Main Board

2. Paper Sensor

3. Wheel Switch

4. Roller Drive Motor

9-2

6

5

5. Sorter Switch

6. Bin Drive Motor

7. Home Position Switch

1 December 1990


Symbol Name Function Location

Motors

M1

M2

Roller Drive Motor DC motor that energizes to drive the lower exit rollers.

Bin Drive Motor Reversible DC motor that energizes to move the bins up or down.

Switches

SW1

SW2

Wheel Switch

Sorter Switch

Detects the rotation of the transfer wheel and stops it in the correct position.

Reed switch that becomes activated when the sorter is in the proper position (aligned next to the copier). Also works as a jam reset switch for the sorter.

Informs the CPU that all the bins are lowered.

SW3 Home Position

Switch

Sensors

S1 Paper Sensor Serves as the misfeed sensor for the sorter and also sets exit roller and bin drive timing.


PCB1 Sorter Main Board Serves as the communication board between the copier main board and the sorter.

4

6

3

5

7

2

1

9-3

1 December 1990


Paper Sensor

Sorter Switch

Home Position Switch

Wheel Switch

Roller Drive Motor

Bin Drive Motor

Sorter Main Board (PCB1)

Data Select

IC

Scan Signal

Scan Output Signal

Copier Main Board (PCB1)

Interface

Board

(PCB6)

Drive IC

Sorter Drive Signal

+24V(VA)

+5V(VC)

+12V

Regulator

IC

+24V(VA)

26Vac

115Vac

+5V(VC)

Main DC

Power

Supply

Board

220/240Vac

10Vac

Main

Transformer

AC Drive

Board

The main DC power supply board provides +24 volts (V A ) and +5 volts (V C ) to the sorter main board. +24 volts powers the roller drive motor, and +5 volts powers all sensors and switches. Also, +24 volts is changed to +12 volts by the regulator IC, which powers the bin drive motor.

The copier main board controls the drive and checks the status of the sorter via the sorter main board and the interface board. The interface board sends the scan signals to the data selected IC on the main board according to the signal from the copier main board. After receiving the scan signals, the data select IC outputs the status of the sensor and switches as the scan output signal.

The interface board also sends the sorter drive signal to the drive IC on the sorter main board according to the signal from the copier main board. After receiving the drive signal, the drive IC turns on the appropriate motors.

9-4

1 December 1990


- 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. When the paper exits onto the sorter bin, the paper sensor is de-activated and the roller drive motor is then de-energized. The copier main board monitors the paper sensor through the sorter main board to check for paper misfeeds.

- Sort Mode -

Pressing the Sorter key once shifts the copier to the sort mode. In this mode, all copies of the first original are delivered to separate bins starting from the top. The copies of the second original are delivered to the same bins, but starting from the bottom. The copies of the third original start from the top and so on. The bin drive motor turns on to advance the bin one step, 250 milliseconds after the copy has gone through the paper sensor. If the Copy

Quantity, Clear/Stop, Book Copy, or Sorter key is pressed during the sort mode, all bins shift to the home position.

- Stack Mode -

Pressing the Sorter key twice shifts the copier to the stack mode. In this mode, all copies of the first original are delivered to the first bin, all copies of the second original are delivered to the second bin, and so on. The bin drive motor turns on to advance the bin one step, 250 milliseconds after the last copy of the original has gone through the paper sensor. If the Sorter key is pressed during stack mode, all bins shift to home position.

9-5

1 December 1990

6. EXIT ROLLER DRIVE

6.1 ROLLER DRIVE MECHANISM

[A]

[I]

[D]

[J]

[F] [K]

[L]

[C]

[H]

[G]

[B]

[H]

F:

G:

H:

I:

J:

K:

L:

[L]

Transfer Wheel

Bin Drive Belt

Bin Drive Pulley

Exit Roller Pulley

Upper Paper Guide

Lower Paper Guide

Roller Drive Motor Pulley

[E]

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. The exit rollers continue to rotate for 250 milliseconds after the copy paper has gone through the paper sensor [B].

The roller drive motor [C] rotates the lower exit roller via the roller drive belt

[D]. The shaft of the lower exit roller is a cylindrical cavity type which rotates around the transfer wheel shaft [E]. The paper sensor is positioned just in front of the exit rollers. The paper sensor detects misfeeds in the sorter.

9-6

1 December 1990

6.2 ROLLER DRIVE CIRCUIT


Paper Sensor

CN102-5

CN102-13

CN102-4

+5V

+5V

0V

Data

Select

IC

Scan Signal

Scan Output

CN101-3

CN101-4

CN2

CN203-1

CN203-2

Interface Board

(PCB6)

CN101-5

CN101-6

CN203-3

CN203-10

Roller

Drive

M

CN53-1

CN102-6

CN53-2

CN102-7

+24V

+24V

0V

Drive

IC

Drive Signal

Clock Pulse

CN101-7

CN101-8

CN101-9

CN203-4

CN203-5

CN203-6

To turn on the roller drive motor, the interface board sends a drive signal to the drive IC on the sorter main board. After receiving the drive signal, the drive IC drops CN102-7 from +24 to 0 volt to turn on the roller drive motor.

When the paper sensor is actuated, CN102-13 drops to LOW. The interface board outputs three scan signals to the data select IC. The status of the sensor changes the resulting scan output signal. Using the scan output signal, the copier main board determines the status of the sensor. For safety reasons, the CPU limits the operation time of the roller drive motor to 5 seconds.

9-7

1 December 1990

7. BIN DRIVE

7.1 BIN DRIVE MECHANISM

[D’]

[B’]

[E]

[G]

[C]

[D] [B] [F]

[A]

G : Exit Roller

H : Upper Paper Guide

I : 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.

Pins on either side of each bin are inserted into slots called bin guides

[D,D’]. The bins slide up and down in the bin guides. The bins sit on each other with the lower bin resting on the permanently-mounted 10th bin.

The upper and lower paper guides pivot up and down depending on the height of the bin to be picked up or released.

9-8

[B]

[E] [H]

[I]

The home position switch [E] informs the CPU when all the bins are lowered.

To move the bins up, the bin drive motor turns clockwise (as viewed from the front). A timing belt [F] turns the transfer wheels.

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.

To move the bins down, the CPU reverses the bin drive motor and the above processes reverses.

The CPU monitors the position of the bins through pulses generated by the wheel switch and the actuator cam

[J]. The actuator cam has two flat sides that are 180 degrees apart and is mounted behind the rear transfer wheel. A pulse is generated each time one of the lobes of the actuator cam passes the wheel switch.

[B]

1 December 1990

OFF

[J]

[C]

ON

OFF

9-9

1 December 1990

7.2 BIN DRIVE CIRCUIT

Home Position Switch

T51

CN102-11

T52 CN102-1

Wheel Switch

T53

CN102-12

T54 CN102-2

Bin

Drive

M


+5V

+5V

0V

0V

CN51-1

CN51-2

CN102-8

CN102-9

0V

Up

+12V

Down

0V

+12V

0V

0V

Data

Select

IC

Scan Signal

Scan Output

CN101-3

CN101-4

CN2

CN203-1

CN203-2

Interface Board

(PCB6)

CN101-5

CN203-3

CN101-6

CN203-10

Drive

IC

Drive Signal

Clock Pulse

CN101-7

CN101-8

CN101-9

CN203-4

CN203-5

CN203-6

To turn on the bin drive motor, the interface board sends drive signals to the drive IC on the sorter main board. After receiving the drive signals, the drive

IC either raises CN102-8 or CN102-9 to +12 volts. This turns on the bin drive motor which respectively moves a bin up or down. The main board monitors the output of both sorter switches through the data select IC through the interface board. When either the home position switch or wheel switch is actuated, CN102-11 or CN102-12 drops to LOW. The interface board outputs three scan signals to the data select IC. The status of the switches changes the resulting scan output signal. Using the scan output signal, the copier main board determines the status of the switch.

The CPU monitors the on-time of the bin drive motor to detect a malfunction of the bin drive motor. If the bin drive motor continues to rotate more than twelve seconds, the CPU stops machine operation.

9-10

1 December 1990

8. MISFEED DETECTION

Paper Sensor

J1

2942

2.75 sec ((A4 sidewise)


J2 J1

2942



J2

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). (J1: Paper Sensor ON Check)

Also, the copier CPU starts a timing cycle when the paper sensor is actuated.

Then, at 2.75 (A4 sidewise) or 2.80 (Letter sidewise) seconds, the CPU checks whether the copy paper has passed through the paper sensor. (J2:

Paper Sensor OFF Check)

In misfeed condition, the "Check Paper Path" and "Misfeed Location" indicators lights and copier operation is inhibited. To recover the sorter from the misfeed condition, the sorter has to be slide away from the copier, then, after misfed paper removal, returned to its original position.

9-11

1 December 1990

9. INSTALLATION PROCEDURE



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. Screw M4 x 8 .......................................................... 1

7. Snap Ring ............................................................... 1

NOTE: 1. If the sorter is installed on the copier, the DC Power Supply Unit

(option) is required.

2. When installing the optional DC Power Supply Unit, please refer to the installation procedure enclosed with it.

9-12


[B]

[A]

[C]

1 December 1990

[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. Install the magnet catch [G] on the exit unit [H] (2 screws).

9-13

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. Secure the sorter holder bracket and sorter harness bracket (2 screws).

11. Install the sorter holder bracket cover [F] (1 screw).

9-14

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. Turn on DIP switch 101-4 on the main board and turn on the main switch.

Then, change the SP Mode #71 data to "1" (sorter instruction).

17. Turn off the main switch and DIP switch 101-4.

18. Replace all covers and turn on the main switch.

19. Check the operation of the sorter.

9-15

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. Secure the bins with strips of tape as shown in the illustration.

3. Remove the sorter from the copier. (See the Installation Procedure

[Sorter] section.)

9-16

1 December 1990

11. ROLLER DRIVE BELT REPLACEMENT

[C]

[E] [D]

[F]

[B]

[H]

[A]

[J]

[I]

[G]

[K]

[L]

[M]

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. Lift the lower paper guide [F] out of position and turn it over to remove the roller drive belt [G].

NOTE: Be careful not to damage the sorter home position switch actuator

[H] when reassembling.

5. Remove transfer wheel [I], spacer [J], pin [K] and bushing [L] (1 C-ring).

6. Slide the wheel shaft [M] towards the front and remove the roller drive belt.

9-17

1 December 1990

12. BIN GUIDE LUBRICATION

A

B

C

B

C

B

A

B

C

C

B

C Grease 501

[A]

G rease 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.

9-18

DUPLEX

1 December 1990


Copy Paper Size:

Paper Weight:

Paper Stack:

Dimension

(W x D x H):

Weight:


59 to 104 g/m2 (16 to 27 lb)

50 sheets

516 x 529 x 90 mm

(20.4" x 20.9" x 3.6")

Approximately 5 kg (11 lb)

• Specifications are subject to change without notice.

10-1

1 December 1990


— Mechanical Components —

1

2

3

5

4

6 7

8

9

1. Duplex Gate Roller

2. Duplex Gate

3. Turn Guide Plate

4. Transport Roller

5. Entrance Roller

6. Paper End Feeler

— Electrical Components —

11 10

7. Paper Flattener

8. Duplex Feed Roller

9. Friction Roller

10. Duplex Bottom Plate

11. Jogger Fences

3

4

2

5

6

1

8

1. Main Board

2. Jogger Motor

3. Jogger HP Sensor

4. Duplex Gate Solenoid

7

5. Duplex Entrance Sensor

6. Duplex Paper End Sensor

7. Duplex Turn Sensor

8. Duplex Feed Motor

10-2

1 December 1990

3. ELECTRICAL COMPONENT DESCRIPTION


Motors

M1

M2

Duplex Feed Motor

Jogger Motor

Stepper motor (24 Vdc) drives feed roller and moves the bottom plate up and down.

Stepper motor (24 Vdc) drives the jogger fences to square the paper stack on the duplex tray.

Solenoids

SOL 1 Duplex Gate Solenoid

Printed Circuit Board

PCB1 Duplex Main

Board

Moves the duplex gate to direct copies to the duplex tray or to the paper exit.

Sensors

S1

S2

S3

S4

Duplex Entrance

Sensor

Duplex Turn Sensor

Duplex Paper

End Sensor

Jogger Home Position Sensor

Detects copy at the entrance.

Detects copy in the turn section.

Detects copy in the duplex tray.

Detects whether the jogger fences are at home position.

Controls all duplex unit functions.

4

1

6

3

5

7

8

2

INDEX

NO.

10-3

1 December 1990

4. POWER DISTRIBUTION AND OVERALL

MACHINE CONTROL

AC Power

115 Vac

220/240 Vac

Main Frame

AC Drive

Board

(PCB2)

AC Power

115 Vac

220/240 Vac

Optional

Transformer

(TR2)

26Vac

10 Vac

Optional

DC Power

Supply Board

(PCB5)

+24V

(VA)

+5V

(VC)

Interface

Board

(PCB6)

TxD

RxD

Reset Signal

+5V (VC)

Main Board

(PCB1)

RxD

Duplex Unit

+24V

(VA)

Motors

Solenoids

CPU

IC702

Sensors

+5V

(VC)

TxD

Main Board

(PCB1)

When the main switch is turned on, the optional transformer receives 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. The optional dc power supply board then converts the 10 volts ac input to +5 volts and the 26 volts ac input to +24 volts. Then, the +5 volts and +24 volts are supplied to the duplex unit main board. The interface board also provides +5 volts to the duplex unit main board and sends a reset signal to initialize the duplex unit CPU.

The duplex unit main board supplies dc power to all electrical components in the duplex unit. All motors and solenoid operate on +24 volts and all sensors operate on +5 volts.

The duplex unit has its own CPU which controls all functions in the duplex unit. The duplex unit CPU communicates with the copier through the interface board using a serial interface.

10-4

1 December 1990


[A]

[B] [C]

[G]

[F] [E] [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. After the final copy is delivered to the tray, the jogger fences remain against the paper stack.

5.3 SECOND SIDE COPY

Soon after the final copy is squared by the jogger fences, the duplex bottom plate raises up to the final position and the duplex feed rollers start rotating counterclockwise (front view) to feed the copy to the relay rollers [G]. Second side copying is then done with the copy following the second feed station paper path.

10-5

1 December 1990

6. DRIVE MECHANISM

[C]

[F]

[D]

[B]

[A]

[E]

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.

10-6

1 December 1990

7. FIRST SIDE COPY

7.1 FROM COPIER PAPER FEED SECTION TO DUPLEX

[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]. The duplex gate solenoid stays on until first side copying is finished.

The copy is then directed to the duplex turn guide, where it is fed by the transport rollers [C] to the entrance rollers [D]. The leading edge of the copy activates the duplex entrance sensor [E], which is monitored by the duplex

CPU to detect misfeeds.

10-7

1 December 1990

7.2 FROM DUPLEX ENTRANCE ROLLER TO DUPLEX TRAY

[G]

[H]

[B]

[F]

[B]

[E]

[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].

The tip of the flip mylar [E] moves to the left (front view) when the duplex feed rollers rotate to feed the copy into the duplex tray. The mylar presses the copy against the rollers, ensuring that the trailing edge of the copy clears the guide plate [F]. The paper flatteners [G] correct curl on the leading edge of the copies. The leading edge of the copy actuates the duplex turn sensor [H], which is monitored by the duplex CPU to detect misfeeds.

10-8

7.3 DUPLEX STACKING

[B]

1 December 1990

[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.

10-9

1 December 1990

8. SECOND SIDE COPY

[G]

[I] [J]

[C]

[B]

[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). At the same time the cam clutch [D] rotates clockwise

(front view), raising the duplex bottom plate [E].

The paper feed system, which consists of the duplex feed roller [B] and the friction roller [F], feeds only the top sheet of the stack copies to the relay rollers [G] in the copier. After that, the second side copies follow the second feed station paper path.

After the final copy leaves the duplex bottom plate, the paper end feeler [H] drops through a slot in the duplex bottom plate.The paper end actuator [I], which is on the same shaft as the paper end feeler, pivots into the duplex paper end sensor [J], sending a High signal to the main board to stop the next paper feeding cycle.

10-10

1 December 1990

9. DUPLEX PAPER FEED AND MISFEED

Timing Pulse

(4 m sec/pulse)

0 1750 2000 2500 3000 3500 4000 4500 5000

Start Key

Main Motor

1750 1750

1st Feed Clutch

Registration

Clutch 1750

2000 2000

50 m sec 50 m sec

Jogger Motor

Duplex Entrance

Sensor

Duplex Turn

Sensor

Duplex Gate

Sol.

Duplex Feed

Motor

2000

2075

J1

3110

J2

3425

J3

J1

3110

J2

3425

2100 m sec 2100 m sec

J3

200 m sec

450 m sec

The duplex entrance sensor and the duplex turn sensor monitor the movement of the paper through the paper path in duplex mode. If the duplex

CPU determines that a misfeed exists, the duplex CPU sends a misfeed signal to the copier CPU through the interface board, and the Check Paper

Path and the Misfeed Location indicators turn on. When the main switch is turned on, the CPU checks these two sensors for initial misfeed. During the first side copy cycle, the duplex CPU performs three kinds of misfeed detection:

J1: Checks whether the duplex entrance sensor is actuated within 1,110

pulses (about 4.4 seconds) after the registration clutch turns on. (The

Misfeed Location indicator "D" turns on.)

J2: Checks whether the duplex turn sensor is actuated within 1,315 pulses

(about 5.3 seconds) after the registration clutch turns on. (The Misfeed

Location indicator "E" turns on.)

J3: Checks whether the copy paper passes through the duplex entrance

sensor 525 pulses (2.1 seconds) after the duplex turn sensor has been

actuated. (The Misfeed Location indicator "E" turns on.)

In the second side copy cycle, the misfeed detection timing is same as the one in the second feed station copying.

5500

10-11

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

Service Code 81: Interface Board Error


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.

Service Code 83: Jogger Home Position Error

The output of the jogger home position sensor remains HIGH as the

duplex main board is driving the jogger fences inward.

10-12

1 December 1990

11. DUPLEX UNIT INSTALLATION



1. Turn Guide Plate ..................................................................... 1

2. Roller ....................................................................................... 3

3. Connector Bracket ................................................................... 1

4. Shoulder Screw ....................................................................... 2

5. Philips Pan Head Screw - M3 x 6 ............................................ 4

6. Tray Cover ............................................................................... 1

NOTE: 1. When the duplex unit is installed on the copier, the DC Power

Supply Unit (option) is required.

2. When installing the DC Power Supply Unit, please refer to the installation procedure enclosed with it.

10-13

[A]

1 December 1990


[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].

10-14

1 December 1990

[A]

[A]

[B]

[C] [B]

[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.

10-15

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).

10-16

1 December 1990

[B]

[C]

[A]

[D]

[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.

18. Reinstall all the brackets.

10-17

1 December 1990

[A]

[B]

[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.

NOTE: Explain to the customer how to install the tray cover.

10-18

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. Disconnect the sensor connector [H] from the jogger h. p. sensor.

8. Remove the duplex unit [I] (4 screws and grounding wire) from the tray.

NOTE: Hold both sides of the duplex unit frame when lifting the duplex unit out of the tray.

10-19

1 December 1990

[C]

[D]

[E]

[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.

b) The sensor harness [H] is clamped correctly and is not caught under the unit frame.

10-20

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).

10-21

1 December 1990

12.3 TURN SENSOR REPLACEMENT

[A]

[B]

[C]

[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).

10-22

12.4 FEED MOTOR REPLACEMENT

1 December 1990

[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.

10-23

1 December 1990

12.5 PAPER END SENSOR REPLACEMENT

[B]


2. Remove the paper end sensor bracket [A] (1 screw).

3. Disconnect the sensor connector [B].

4. Replace the sensor [C] (1 screw).

[C]

[A]

10-24

12.6 ENTRANCE SENSOR REPLACEMENT

1 December 1990

[C]

[[A]

[B]


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].

10-25

1 December 1990

12.7 GATE SOLENOID REPLACEMENT

[C]

[D]

[A]

[E]

[B]

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].

10-26

12.8 FRICTION ROLLER REPLACEMENT

1 December 1990

[A]

[B]

[C]

[D]


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.)

10-27

1 December 1990

12.9 FEED ROLLER REPLACEMENT

[F]

[G]

[M]

[G]

[G]

[C]

[A]

[L]

[K]

[J]

[I]

[H]

[B]


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).

7. Remove the E-ring [H] on the front side of the feed roller shaft [I].

8. Remove the feed roller shaft (2 bushings).

9. Remove the feed support roller [J], flatter [K], paper retainer [L]; then, replace the feed roller [M] (1 E-ring and parallel pin per roller).

10-28

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. Electrical adjustment and electrical component failure check

• All adjustment, sensor/switch check, and electrical component check except for the following adjustments can be performed by SP mode

(key operation).

a. ADS voltage (Variable resistor on the main board) b. ID sensor voltage (Variable resistor on the main board) c. Corona currents (Variable resistor on the power pack) d. Grid voltage (Variable resistor on the power pack)

3. Less mechanical adjustments

• There are only fem mechanical adjustments.

a. Doctor gap adjustment b. Scanner home position adjustment c. 4th/5th mirror home position adjustment d. Scanner drive pulley clearance adjustment e. Exposure lamp position adjustment

f. Entrance guide plate height adjustment g. Side-to-side registration adjustment

4. Less PM parts (consumable parts) in the fusing section

• The cleaning pad, oil supply pad and oil blade for the oil supply system are not necessary.

5. Replacement of feed rollers

• The replacement procedure for 1st feed rollers will be improved from production units. (See attached copy.)

6. Replacement of ozone filter

• The ozone filter can be replaced very easily. (See attached copy.)

7. Replacement of parts on the duplex unit

• The duplex unit can be removed from the copier as a module.

Therefore, access to the parts are easier.

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.

1 December 1990


Configuration:

Copy Process:

Originals:

Original Size:

Copy Paper Size:

(Duplex Copying)

Copy Paper Weight:

Reproduction Ratio:

Desk top

Dry electrostatic transfer system

Sheet/Book

Maximum A3/11"x17"

Maximum A3/11"x17"

Minimum A6/5 1/2 " x 8 1/2 " (lengthwise)


Cassette feed: 52 to 157 g/m

Paper tray feed: 64 to 90 g/m

2

2

(14 to 42 lb)

(17 to 22 Ib)

Manual feed: 52 to 157 g/m

2

(14 to 42 lb)

Duplex: 59 to 104 g/m

2

(16 to 27 lb)

2 Enlargement and 3 Reduction

Zoom:

Warm-Up Time:

First Copy Time:

Copy Number Input:

Manual Image Density

Selection:

Enlargement

Full size

Copying Speed:

Reduction

A4/A3 Version LT/LDG Version

141%

122%

100%

155%

129%

100%

93%

82%

71%

93%

74%

65%

From 50% to 200% in 1% steps

European version: 20 copies/minute

(A4 sideways)

11 copies/minute (A3)

Other versions: 21 copies/minute

(A4/8 1/2 " x 11" sideways)

11 copies/minute (A3)

60 seconds (at 20 o C)

5.9 seconds (A4/8 1/2 " x 11" sideways)

Ten keys, 1 to 99 (count up)

7 steps

11-1

1 December 1990

Automatic Reset:

Paper Capacity:

Toner Replenishment:

Copy Tray Capacity:

Power Source:

Power Consumption:

1 minute standard setting; can also be set to 3 minutes or no auto reset.

Cassette: 500 sheets

Paper tray: 250 sheets

Manual feed table: 50 sheets

Black: Cartridge exchange (370g/cartridge)

Color (red, blue, & green): Cartridge exchange

(310g/cartridge)

250 sheets (B4/8 1/2 " x 14" and smaller)

100 sheets (A3/11" x 17")

110V/ 60Hz/ 15A (for Taiwan)

115V/ 60Hz/ 15A (for N.A.)

220V/ 50Hz/ 8A (for EU.)

220V/ 60Hz/ 8A (for EU.)

240V/ 50Hz/ 8A (for EU.)

(Refer to the serial number plate (rating plate) to determine the power source required by the machine.)

Maximum: 1.3 kw

Warm-up: 0.72 kw (average)

Ready: 0.16 kw (average)

Copy cycle: 0.83 kw (average)

Dimensions:

Copier only

Full system

Width

672 mm

(26.5")

1149 mm

(45.3")

Depth

600 mm

(23.7")

600 mm

(23.7")

Height

530 mm

(20.9")

633 mm

(25.0")

Weight: Copier only: European version 69 kg (152.1lb)

Other versions 66 kg (145.5lb)

Full system: 86.5 (190.7lb)

Optional Equipment: Document feeder

10 bin sorter

Duplex unit (standard for European version)

Color development unit

Key counter

Universal cassette

•

Specifications are subject to change without notice.

11-2

2. OPERATION PANEL


C


B A

C B

Section A:

Section B:

Section C:

See page 11-4.



A

11-3

1 December 1990

1 December 1990

Section A —

— A4/A3 Version — — LT/LDG Version —

1 2 3 4 1 2 3 4

5

6

8 7 8 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

5. Interrupt Indicator

Lights when interrupt mode is

selected.

6. Interrupt Key

Press to make interrupt copies

during a copy run.

7. Start Key 2. Recall/Enter Key

Press to display the number of

enter or change data when in 8. Clear/Stop Key

Press to cancel the copy

number entered. While copying,

3. Program Key

Press to input or recall user

programs.

4. Clear Modes Key

Press to clear all previously

entered settings and modes.

5

6

11-4

3. FUNCTIONAL OPERATION

1 December 1990

11-5

33

32

31

30

1 December 1990

4. MECHANICAL COMPONENT LAYOUT

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15

16

17

18

19

29 28 27 26

1. Third Mirror

2. Second Mirror

3. First Mirror

4. Exposure Lamp

5. Ozone Filter

6. Cleaning Unit

7. Lens



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

25 24 23 22 21 20


20. Relay Rollers

21. Semi-circular Feed Rollers

22. Registration Rollers


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 (Standard

31. Exit Rollers

32. Hot Roller Strippers

33. Exhaust Blower

11-6

1 December 1990

5. DRIVE LAYOUT

G17 BP2 G16 TB1 G19 G18 G22 G23 G24

G11

G5

G6

G7

G26

G27

G9

G8

G10

G4

BP3

G12

BP4

G13

G14

TB2 G31 BP5 G32 G33 G15 BP1 G3 G2 G1 G20 G21 G25 G29

G28

G1: Main Motor Gear

G2: Relay Gear

G3: Timing Belt Drive Gear


TB1: Timing Belt

A

G20: Relay Gear

G21: Cleaning Drive G18: Relay Gear

G19: Drum Drive Gear G22: Relay Gear

Cleaing Unit

Drum

Development

Section

Fusing and Exit Section

G23: Relay Gear

G24: Relay Gear

G25: Hot Roller Gear BP2: Timing Belt

Pulley

G16: Development

CL Gear

Development CL

G17: Toner Supply CL Gear

G26: Relay Gear

G27: Relay Gear G29: Duplex Tranport

Gear (Standard

G28: Exit Roller Gear only for

Development Unit

Toner Supply CL Toner Supply Unit

11-7

1 December 1990

G11: Registration CL Gear

Registration CL

Registration Roller

1st Paper Feed CL

1st Paper Feed CL

1st Paper Feed Rollers

A

Paper Feed Section


G4: Relay Gear

G5: Relay Gear

G12: Relay Roller

CL Gear

Relay Roller CL

G6: 1st Paper Feed CL Gear

G7: Relay Gear

G8: Paper Lift CL Gear

Paper Lift CL

G9: Paper Lift Gear

G10: Sector Gear

2nd Feed Station

G13: Upper Relay Roller

Gear

G14: Relay Gear

G15: 2nd Paper Feed

CL Gear

2nd Paper Feed CL

2nd Paper Feed Roller

Upper Relay Roller

3rd Feed Station


TB2: Timing Belt

BP5: Timing Blet Pulley

Lower Relay Roller

G31: Lower Relay

Roller Gear

G33: 3rd Paper Feed

CL Gear

3rd Paper Feed CL

3rd Paper Feed Roller

11-8

1 December 1990

6. ELECTRICAL COMPONENT LAYOUT

1

2

36

34

35

3

4

5

6

7

8

33

32

31

30

29

28

27

26

25

24

23

22

1. Scanner H.P. Sensor

2. Scanner Motor

3. Main Motor

4. Development CL Sol.

5. Toner Supply CL Sol.

6. Toner End Sensor

7. Pick-up Roller Release Sol.

8. 4th/5th Mirror Motor

9. Manual Feed Table SW

10. Development Unit Set Sensor

11. Color Switch

12. 1st Paper Feed CL Sol.

13. Paper Lift CL Sol.

14. Registration Clutch

15. Relay Roller CL Sol.

16. Right Cover SW

17. 1st Paper End Sensor

18. 1st Paper Size SW

19. Paper Lift Sensor

20

19

18

17

16

15

9

10

11

12

13

14

21

20. Relay Sensor


22. Total Counter

23. Drum Anti-condensation Heater


25. Transfer and Separation

26. Erase Lamp (EL)

27. ID Sensor



30. Fusing Lamp

31. Fusing Thermister

32. Fusing Thermofuse

33. Auto ID Sensor

34. Toner Overflow Sensor

35. Exit Sensor

36. Lens Motor

11-9

1 December 1990

38

73

72

71

70

69

68

67

66

65

63

37

61

64

56

62

55

60

59

54

58

39

40

41

52

57

51

53

42

43

44

45

46

47

48

49

50

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


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. Upper Tray Lock Sol.

52. Lower Tray Lock Sol.





57. 3rd Paper Size SW-4 (SW14)




61. 2nd Paper End Sensor

62. 3rd Paper End Sensor

63. 2nd Paper Feed CL Sol.

64. 3rd Paper Feed CL Sol.

65. Main Motor Capacitor

66. AC Drive Board

67. Platen Cover Position Sensor

68. Lens H.P. Sensor

69. TC/SC Power Pack

70. Interface Board

71. Main Board

72. Key Counter (Option)

73. CC/Grid/Bias Power Pack

11-10

1 December 1990



Motors

M1

M2

M3

M4

M5

M6

M7

Main Motor

Scanner Motor

Lens Motor


Optics Cooling

Fan Motor-1

Optics Cooling

Fan Motor-2

Exhaust Blower

Motor

Drives all the main unit components except for the optics unit and fans.

(115/220/240Vac)

Drives the scanners (1st and 2nd). (dc stepper)

Moves the lens position according to the selected magnification. (dc stepper)

Move the 4th/5th mirror position according to the selected magnification. (dc stepper)



Removes heat from around the fusing unit and blower the ozone built up around the charge section to the ozone filter.

Magnetic Clutches

MC1 Registration

Clutch

Drives the registration roller.

Solenoids

SOL1

SOL2

SOL3

SOL4

Toner Supply

Clutch Solenoid

1st Paper Feed

Clutch Solenoid

2nd Paper Feed

Clutch Solenoid

Pick-up Roller

Release Solenoid

SOL5

Drives the toner supply roller via the toner supply spring clutch.

Starts paper feed from the first paper station.

Starts paper feed from the 2nd paper station.

a) After the paper is fed, releases the pick-up roller from next paper. b) When the manual feed table is used, releases the pick-up roller from the table.

Lifts paper to the appropriate feed position.

SOL6

SOL7

SOL8

Paper Lift Clutch

Solenoid

Upper Tray Lock

Solenoid

Development

Clutch Solenoid

Relay Roller

Clutch Solenoid

Locks the upper paper tray/duplex unit.

Drives the development unit.

Drives the relay roller for the 2nd cassette station.

14

13

51

4

15

63

7

5

12

8

38

38

47

2

36

INDEX

NO.

3

11-11

1 December 1990


SOL9

SOL10

Switches

SW1

SW2

SW3

SW4

SW5

SW6

SW7

SW8

3rd Paper Feed

Clutch Solenoid

Lower Tray Lock

Solenoid

Main Switch

Cover Safety

Switch

1st Paper Size

Switch

2nd Paper Size

Switch-1

2nd Paper Size

Switch-2

2nd Paper Size

Switch-3

2nd Paper Size

Switch-4

Color Switch

SW9

SW10

SW11

SW12

SW13

SW14

SW15


Right Cover

Switch

3rd Paper Size

Switch-1

3rd Paper Size

Switch-2

3rd Paper Size

Switch-3

3rd Paper Size

Switch-4

Platen Cover

Closed Switch

Sensors

S1

S2

Scanner Home

Position Sensor

Lens Home

Position Sensor

Starts paper feed from the 3rd paper station.

Locks the lower paper tray.

Supplies power to the copier.

Cuts the ac power line.

Determines what size paper is in the cassette.

Determines what size paper is in the upper paper tray.




Determines which color development unit is installed.

Detects when the manual feed table is open.

Detects when the right cover is open.

Determines what size paper is in the lower tray.




Detects when the platen cover or the document feeder is closed.

Informs the CPU when the 1st scanner is at the home position.

Informs the CPU when the lens is at the home position (full size position).

9

16

60

59

58

57

40

54

53

11

46

45

18

56

55

1

68

INDEX

NO.

64

52

11-12


S3

S4

S5

S6

S7

S8

S9

S10

S11

S12

S13

S14

S15

S16

S17

4th/5th Mirror

Home Position

Sensor

Registration

Sensor

Exit Sensor

1st Paper End

Sensor

2nd Paper End

Sensor

Toner End

Sensor

Toner Overflow

Sensor

Paper Lift

Sensor

Image Density

(ID) Sensor

Development

Unit Set Sensor

3rd Paper End

Sensor

Relay Sensor

Platen Cover Position Sensor

Original Width

Sensor

Original Length

Sensor


PCB1 Main Board

PCB2

PCB3

PCB4

AC Drive Board

Main DC Power

Supply Board

Auto Image

Density Sensor

(ADS)

Informs the CPU when the 3rd scanner

(4th/5th mirrors assembly) is at the home position (full size position).

Detects misfeeds.

Detects misfeeds.

Informs CPU when the cassette runs out of paper.

Informs CPU when the upper paper tray runs out of paper.

Detects when it is time to add toner.

Detects when the used toner tank is full.

Detects the correct feed height of the cassette.

Detects the density of the image on the drum to control the toner density.

Sensors whether or not the development unit is properly set.

Informs CPU when the lower paper tray runs out of paper.

Detects imsfeeds.

Detects when the platen cover is positioned about 10 cm (4") above the exposure glass.

Detects the original width.

Detects the original length.

Controls all copier functions both directly and through the other PCBs.

Drives all ac motors, the exposure lamp, fusing lamp, quenching lamp, exhaust blower motor.

Rectifies 26 and 10 Vac input and outputs dc voltages.

Senses the background density of the original.

1 December 1990

6

34

19

21

35

17

61

27

10

62

20

67

44

39

INDEX

NO.

37

71

65

48

33

11-13

1 December 1990


PCB5

PCB6

PCB7

Option DC

Power Supply

Board

Interface Board

Operation Panel

Board

Power Packs

P1 CC/Grid/Bias

Power Pack

Rectifies 26 and 10 Vac input and outputs dc voltasges.

Interfaces between the copier main board and all the optional equipment’s main board.

Informs the CPU of the selected modes and displays the situations on the panel.

Lamps

L1

L2

L3

L4

L5

Exposure Lamp Applies high intensity light to the original for exposure.

Provides heat to the hot roller.

Fusing Lamp

Quenching Lamp Neutralizes any charge remaining on the drum surface after cleaning.

Erase Lamp Discharge the drum outside of the image area. Provides leading/trailing edge erase.

Pre-transfer

Lamp

Reduces charge on the drum surface before transfer.

Provides high voltage for the charge corona, grid, and the development roller bias.

Provides high voltage for the transfer and separation corona.

P2 TC/SC Power

Pack

Heaters

H1

H2

Drum Anticondensation

Heater

Optics Anti-condensation Heater

Option

Prevents moisture around the drum.

Prevents moisture from forming on the optics.

Counters

CO1

CO2

Total Counter

Key Counter

(Option)

Keeps track of the total number of copies made.

Used for control of authorized use. Copier will not operate until installed.

Transformer

TR1 Main Transformer Steps down the wall voltage to 26 Vac and

10 Vac.

43

30

29

26

24

22

72

50

73

69

70

41

INDEX

NO.

49

23

N/A

11-14

SYMBOL NAME

Others

TH

TF

TS

C

Fusing

Thermistor

Fusing

Thermofuse

Optics

Thermoswitch


FUNCTION

Monitors the fusing temperature.

Provides back-up overheat protection in the fusing unit.

Provides back-up overheat protection around the exposure lamp.

Start capacitor

1 December 1990

INDEX

NO.

31

32

42

66

11-15

1 December 1990



Cover Safety Switch

Main Switch

Operation

Panel Board

Exhaust Blower Motor (L)

Fusing Lamp

Exposure Lamp

Main Motor

Quenching Lamp

Exhaust Blower Motor (H)

AC Drive Board

Power Relay

Fusing Lamp

Drive Circuit

Exposure Lamp

Drive Circuit

Main Motor Relay

Power Packs

CC/Grid/Bias P.P.

Charge Corona

Grid Voltage

Dev. Bias

TC/SC P.P.

Counters

Total Counter

Key Counter

ARDF

Duplex

Sorter

Serial

Serial

IC 123

CPU

IC 105

I/O

IC 124

I/O

IC 111

ROM

Main Board

RAM

Board

Interface

Board

Anti-condensation Heater

-Drum

-Optics

Sensors/Switches/Thermistor

Image Density Sensor

Registration Sensor


Exit Sensor

Auto ID Sensor

Scanner HP Sensor

Lens HP Sensor



Toner End Sensor

Color Switch

1st/2nd/3rd Paper Size Switches

1st/2nd/3rd Paper End Sensors

Right Cover Switch


Fusing Thermistor

Relay Sensor

Solenoids/Clutches


Cassette Lift CL Sol.

1st/2nd/3rd Paper Feed CL Sol.


Registration Clutch

Upper/Lower Tray Lock Sol.

Development Drive CL Sol.


Motors

Scanner Motor

Lens Motor

4th/5th Mirror

Optics Cooling Fan Motor

Platen Cover Closed Switch

Platen Cover/DF Position

Sensors


Original Length Sensor

The above diagram shows the control system of this copier in block form. The

CPU (IC123) on the main board controls the timing of all copier’s operation based on the CPU’s internal clock. The CPU monitors the input signals from all sensors and controls the dc components directly or through two I/O chips

(IC 105 and IC 124). It also controls ac components such as the fusing lamp, exposure lamp, main motor quenching lamp, and exhaust blower motor (High speed) directly via the ac drive board. The exhaust blower motor (Low speed) is controlled via the I/O chip (IC 124) and ac drive board. The charge corona, grid voltage and development bias are powered by the same power pack

(P1) but are controlled separately as shown above. The main board has a

RAM board for the service program mode and misfeed recovery. A battery backs up the power to the RAM board.

11-16

1 December 1990

9. AC POWER AND DC POWER DISTRIBUTION

Exhaust Blower

Motor (L)

Fusing Lamp

Exposure Lamp

Main Motor

Quenching Lamp

Exhaust Blower

Motor (H)


Main SW Anti-condensation Heater

-Drum

-Optics (Option)

Cover Safety SW

Fuse

Power Relay

(RA401)

Fusing Lamp

Drive Circuit

Exposure Lamp

Drive Circuit

Main Motor

Relay (RA402)

AC Drive Board

24V (VA)

Scan

Signal


5V (VC)

Sensors

Switches

Interface Board

24V (VA)

24V (VA)

24V (VA)

RAM

PCB

24V (VA)

Solenoids

Clutches

Power Packs

Lens Motor


Optics Cooling Fan

Motors

30V (VM)

Scanner Motor

Main

Board

26V AC

10V AC

FU100 (5V)

FU101 (24V)

Option

DC Power Supply

Board

24V

(VA)

5V

(VC)

24V

(VA)

5V

(VC)

Main Transformer

10V AC 26V AC 26V AC

30V (VM)

Main DC Power Supply Board 24V (VA)

FU100 (5V)

FU101 (24V)

FU102 (30V)

5V (VC)

Zero

Cross

Interface

Board

ARDF Duplex Sorter

24V (VA)

5V (VC) ac power dc power

When this copier is plugged in and the main switch is turned off, ac power is supplied via the ac drive board to the anti-condensation heater. When the front cover and/or the exit cover is open, the cover safety switch completely cuts off power to all ac and dc components. The RAM board has a back up power supply (dc battery) for the service program mode and misfeed job recovery.

When the main switch is turned on, the ac power supply to the anti-condensation heater is cut off and ac power is supplied to the ac drive board. The main transformer receives wall outlet ac power through the ac drive board and outputs 10 volts ac and 26 volts ac to the main dc power supply board and the option dc power supply board.

11-17

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. All sensors, and switches plus the interface board operate on +5 volts. The scanner motor operates on +30 volts. All other dc components including the power relay (RA401) and the main motor relay (RA402) operate on +24 volts.

The ARDF and the duplex unit have a separate dc power supply.

When the main board receives power, it activates the power relay (RA401) which then supplies ac power to the fusing lamp drive circuit, and the exposure lamp drive circuit on the ac drive board. The exhaust blower motor begins rotating at low speed. The fusing lamp drive circuit receives a trigger signal from the main board and the fusing lamp lights. The exposure lamp does not turn on until the main board send a trigger pulse to the exposure lamp drive circuit.

When the Start key is pressed, the main board energizes the main motor relay (RA402). Then, the main motor and the quenching lamp turn on and the exhaust blower starts rotating at high speed.

When the main switch is turned off, power is cut off to the main board and to

RA401, and the drum and optional anticondensation heaters are turned on.

The exposure lamp and the fusing lamp power lines are completely disconnected from the line voltage.

11-18

1 December 1990

9.1 AC POWER DISTRIBUTION

Main SW

(SW1)

115V

220/240V

T404

Cover

Safety

SW (SW2)

T407

To DF and Duplex

[24] VA

[5] VC

[0] GND

Option

DC Power

Supply

Board

(PCB5)

To Sorter

[24] VA

[5] VC

[0] GND

26V AC

26V AC

10V AC TR2

10V AC

26V AC

CN417-3

CN417-1

Main Transformer

(TR1)


(PCB3)

Fuse

ZERO

CROSS

[0] GND

[0] GND

[30] GND

[0] GND

[24] VA

[0] GND

[5] VC

CN108-1

CN108-2

CN107-1

CN107-2

CN107-3

CN107-4

CN107-5

CN107-6

Main

Board

(PCB1)

CN122-7

CN122-6

CN122-10

CN102-2

CN102-1

CN101-1

CN101-2

CN101-3

CN101-4

CN101-5

CN101-6

CN122-14

CN122-9

CN122-13

CN122-12

CN122-11

CN401-8

CN401-9

CN401-5

CN401-1

CN401-6

CN401-2

CN401-3

CN401-4

T403 T402 T401

CN411-1

RA402-1

CN411-2

Drum

Anti-condensation

Heater (H1)

RA401

AC

Drive

Board

(PCB2)

Noise Filter

Circuit

(220/240V

Only)

Exposure

Lamp Drive

Circuit CN421

(220/240V

Only)

Fusing

Lamp Drive

Circuit

RA402-2

CN420-3

CN420-2


CN419-1

Exposure Lamp

T405

Fusing

Lamp H

Thermoswitch

Thermofuse

(TS)

L

M

(M7)

(TF)

CN413-1

Main

Motor (M1)

CN415-1

M

(L2) (L1)

Quenching

Lamp

(L3)

CN415-2

CN413-2

T406

CN419-2

CN420-1

Power Relay

RA401

RA402

Main Motor Relay

11-19

1 December 1990

9.2 DC POWER DISTRIBUTION

CN417-1

115V

220/240V

CN417-3


CN100-5

26VAC

CN100-6

FU100

ON

ST100 R100 Q100

D100

R104

D102

R103

IC100

+ +

C100 C101

R105

R101

R102

R106

+

C103 C104

D103

C112

CN100-3

26VAC

FU101

CN100-4

ST101 R107 Q102

D104

+

C110

+

IC101 +

C108 C109

D105

C113

Main Board

CN101-6 CN107-6

[5] VC

CN103-2 (To Sorter)

CN102-2 CN108-1

CN103-1 (To Sorter)

Zero

Cross

CN101-5 CN107-5

[0] GND

[24] VA

CN102-1

CN101-4

CN108-2

CN107-4

CN103-3 (To Sorter)

[0] GND

[24] VA

[5] VC

CN100-1

10VAC

FU102

ST102

CN101-3 CN107-3

[0] GND

CN101-2 CN107-2

[30] VM

[30] VM

CN100-2

+

C110

R108

C111 C114

CN101-1 CN107-1

[0] GND

Option DC Power Supply Board

CN100-1

10VAC

CN100-2

FU100

ON

ST100 R100 Q100

D100 D100

+

C100

+

IC100

C101

+

R101

R102

C102 C103

D101

D104

D105

C108

CN101-2

CN102-2

[5] VC

[5] VC

To Duplex

To DF

CN102-1 [0] GND To DF

CN101-1

[0] GND To Duplex

[0] GND

CN100-3

26VAC

FU101

CN100-4

ST101 R103 Q101

D102

+

IC101

+

C104 C105

+

C106 C107

D103

C109

CN101-4 [24] VA

CN102-4 [24] VA

To Duplex

To DF

CN102-3 [0] GND

CN101-3

[0] GND

To DF

To Duplex

11-20

1 December 1990

10. ORIGINAL SIZE DETECTION IN PLATEN

MODE

[C]

[B]

[G]

[A]

[D]

[F]

[E]

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. The CPU checks the output signals twice as the platen cover (document feeder) is being closed.

The first check is done when the platen cover position sensor [D] turns on.

(When the document feeder is installed, the first check is done when the DF position sensor [G] on the document feeder turns on.) The platen cover position sensor is actuated when the platen cover (document feeder) is lowered to about 10 cm (4") above the exposure glass. At this time only the sensors located underneath the original receive the reflected light. These sensors output LOW signals.

11-21

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. At the second check, all sensors should output LOW signals because the platen cover sheet (document feeder belt) is white. This double check prevents original size detection errors that may occur if a black solid area on the original is positioned directly over a sensor.

When a copy with the platen cover (document feeder) open, the CPU checks the original size when the Print key is pressed.

The following illustration shows the location of the original width and length sensors. The table shows the sensor output (HIGH,

LOW) for each original size.

S16-2

S16-1

Original

Width

Sensors S17-1 S17-2 S17-3 S17-4 S17-5

Original Length Sensors

Sensors Original Width

Sensor


Original

Size

A3

B5 lengthwise or smaller

11" x 17"

B4

11" x 15"

10" x 14"

— 8 1/2" x 14"

A4 lengthwise 8 1/2" x 11"

8" x 10"

A5 lengthwise

5 1/2" x 8

1/2" or smaller

A4 lengthwise or smaller

11" x 8 1/2"

B5 sideways

A5 sideways or smaller

8 1/2" x 5

1/2"

8 1/2" x 5 1/2" or smaller

S16-1 S16-2 S17-1 S17-2 S17-3 S17-4 S17-5

0

0

1

1

1

1

0

0

1

0

0

0

0

0

1

0

0

0

0

0

0

0

0

1

0

1

1

0

0

0

0

1

1

1

1

1

0

0

0

1

1

1

1

1

1

0

0

0

1

1

1

1

1

1

0

1

1

1

1

1

1

1

1

0: LOW 1: HIGH

11-22

1 December 1990

11. PAPER FEED AND MISFEED DETECTION

TIMING

Timing Pulse

(4m sec/pulse)

Start Key

0

400ms

100

Main Motor

<1st Feed Station>

1st Feed Clutch

Pick-up Roller

Release Sol.

Registration

Sensor

Registration

Clutch

<2nd Feed Station>

Relay Roller

Clutch

2nd Feed Clutch

100

100

Registration

Sensor

Registration

Clutch

Upper

Tray Lock Sol.

<3rd Feed Station>

Relay Roller

Clutch

3rd Feed Clutch

100 1302

Relay Sensor

Registration

Sensor

Registration

Clutch

Upper

Tray Lock Sol.

1500

1433

1750

120ms

2500

1750

1877 2273 (A4S) 1877

J1

2010

2285 (LTS)

120ms

500ms

500ms

1587

JR

2000

2000

2010

500ms

2000

J1 2010

114ms

2000

2010

500ms

JR

1587

J1 2010

114ms

J2

3000

2010

500ms

114ms

2000

J1 2010

2010

500ms

2000

2700

1750

1587

JR

J1 2010

114ms

J3

3500

J2

2010

500ms

JR

1587

J1 2010

114ms

2000

2700

J1 2010

114ms

2000

2010

500ms

4000

2273 (A4S) 1877

J1

2010

2285 (LTS)

120ms

2273 (A4S)

J1

2285 (LTS)

2010

2000 2000

Exit Sensor



11-23

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. During the copy cycle, the CPU performs three kinds of misfeed detection:

J1: Checks whether the registration sensor is actuated within 10 pulses

(40 milliseconds) after the registration clutch turns on. (The Misfeed

Location indicator "A" or "B" turns on.)

J2: Checks whether the exit sensor is actuated within 700 pulses (2.8

seconds) after the registration clutch turns on. (The Misfeed Location indicator "C" turns on.)

J3: Checks whether the copy paper has passed through the exit sensor

2.75 (A4 sideways) or 2.80 (Letter sideways) seconds after the exit sensor has been actuated. (The Misfeed Location indicator "D" turns on.)

JR: Checks whether the relay sensor is actuated within 285 pulses (1.14

seconds) after the 3rd feed clutch turns on. (The Misfeed Location indicator "A" turns on.)

11-24

1 December 1990

12. DOCUMENT FEEDER

(Machine Code: A318)

12.1 SPECIFICATIONS

Original Size and Weight: — Thin original mode —

Maximum A3 11"

Minimum

Weight

B6 5 1/2 " x 8 1/2 "

41 to 128 g/m

2

(11 to 34 lb)

— Thick original mode —

Maximum

Minimum

Weight

A3 11"

B6 5 1/2 " x 8 1/2 "

52 to 128 g/m

— Auto reverse mode —

2

(14 to 34 lb)

Maximum

Minimum

A3 11"

Weight

5 1/2 " x 8 1/2 " lengthwise

64 to 105 g/m

2

(17 to 28 lb)

Original Feed: Automatic feed — ADF mode

Manual feed one by one — SADF mode

Original Table Capacity: 30 sheets / 80 g/m

2

(20 lb)

Original Set:

Original Transport:

Copy Speed:

Face up. First sheet on top

One flat belt

16 copies/minute for A4 / 8 1/2 " x 11" sideways

(A048 copier)

20 copies/minute for A4 / 8 1/2 " x 11" sideways

(A054 copier)

20 W Power Consumption:

Dimensions (W x D x H): 670 x 460 x 103 mm (26.4" x 18.1" x 4.1")

Weight: Approximately 8.8 kg (19.4 lb)

11-25

1 December 1990

12.2 COMPONENT LAYOUT

- Mechanical Components -

2 3 4

1

5 6

10 9

1. Pulse Generator Disk

2. Friction Belt

3. Pick-up Lever

4. Original Table

5. Exit Roller

- Electrical Components -

4

5

3

2

6

8

6. Inverter Pawl

7. Inverter Roller

8. Transport Belt

9. Pick-up Roller

10. Feed Roller

7

8

9

7

1

14

15

13

1. Original Set Sensor


3. Pulse Generator Sensor


5. Pick-up Solenoid

6. Belt Drive Motor

7. Indicator Panel

8. Lift Switch

12

11

9. DF Main Board

10. Feed-out Motor

11. Inverter Solenoid

12. Feed-out Sensor

13. Original Select Switch

14. Feed-in Solenoid

15. DF Position Sensor

11-26

10

12.3 ELECTRICAL COMPONENT DESCRIPTIONS

Function Symbol Name

Motors

M1 Belt Drive Motor

M2 Feed-out Motor

DC servomotor that drives to the transport belt and feed-in system (pick-up roller, feed roller, pull-out roller and relay roller).

DC servomotor that drives the feed-out unit of the DF.

Solenoids

SOL1

SOL2

SOL3

Pick-up Solenoid Energizes to press the pick-up lever against the stack of originals in preparation for original feed-in.

Feed-in Solenoid Turns on to engage the feed-in clutch so rotation is transmitted to the feed roller, pull-out rollers, and relay rollers.

Inverter Solenoid Energizes to invert the original when copying two sided originals.

Switches

SW1

SW2

Lift Switch

Original Select

Switch

Informs the CPU when the DF is lifted and also serves as the jam reset switch for the

DF.

Selects thick original mode or thin original mode.

Sensors

S1

S2

S3

S4

S5

Original Set

Sensor

Informs copier CPU that originals have been placed and causes the Insert Original indicator to go out.

Registration

Sensor

Original Width

Sensor

Pulse Generator

Sensor

Sets original stop timing and measures original length.

Determines the width of the originals.

Generates pulses used to measure the original length.

Feed-out Sensor Checks for original misfeeds and sets original stop timing when in auto reverse mode.

S6 DF Position

Sensor


PCB1

PCB2

DF Main Board

Indicator Panel

Board

Detects when the document feeder is positioned about 10 cm above exposure glass.

Controls all DF functions.

Contains operator indicators.

11-27

1 December 1990

Location

6

10

5

14

11

8

13

1

2

4

3

12

15

9

7

1 December 1990

12.4 POWER DISTRIBUTION

AC Drive Board

(PCB2)

115Vac

220/240Vac

Main

Transformer

(TR1)

26Vac

Option

DC Power

Supply Board

(PCB5)

+24V (VA)

+5V (VC)

10Vac

+24V +12V

Regulator

IC

5V

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. The option dc power supply board then converts the 10 volts ac input to +5 volts dc and the 26 volts ac input to +24 volts. Then, thoes two dc voltsges are supplied to the DF main board.

The regulator IC on the DF main board further steps down the +24V to +12V.

11-28

1 December 1990

13. DUPLEX UNIT POWER DISTRIBUTION

AND OVERALL MACHINE CONTROL

AC Power

115 Vac

220/240 Vac

Main Frame

AC Drive

Board

(PCB2)

AC Power

115 Vac

220/240 Vac

Main

Transformer

(TR1)

26Vac

10 Vac

Option

DC Power

Supply Board

(PCB5)

+24V

(VA)

+5V

(VC)

TxD

RxD

Interface

Board

(PCB6)

Reset Signal

+5V (VC)

Main Board

(PCB1)

Duplex Unit

+24V

(VA)

Motors

Solenoids

CPU

IC702

Sensors

+5V

(VC)

RxD

TxD

Main Board

(PCB1)

When the main switch is turned on, the main transformer receives 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. The option dc power supply board then converts the 10 volts ac input to +5 volts and the 26 volts ac input to +24 volts. Then, the +5 volts and +24 volts are supplied to the duplex unit main board. The interface board also provides +5 volts to the duplex unit main board and sends a reset signal to initialize the duplex unit CPU.

The duplex unit main board supplies dc power to all electrical components in the duplex unit. All motors and solenoid operate on +24 volts and all sensors operate on +5 volts.

The duplex unit has its own CPU which controls all functions in the duplex unit. The duplex unit CPU communicates with the copier through the interface board using a serial interface.

11-29

1 December 1990

14. INSTALLATION

14.1 INSTALLATION REQUIREMENTS

14.1.1 Environment

1. Temperature Range: 10 o

C to 30 o

C (50 o

F to 86 o

F)

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 m

3

. Room air should turn over at least

3 times/hour.

5. Ambient Dust: Less than 0.15 mg/m

3

(4 x 10

-3

oz/yd

3

)

6. The machine must not be subjected to sudden temperature changes. Do not install the machine where it will be directly exposed to cool air from an air conditioner or hot air from a heater.

7. Avoid placing the machine in an area filled with corrosive gas.

8. Do not install at any location over 2,000 meters (6,500 feet) above sea level.

9. Place the machine on a strong and level base.

10. Avoid any area where the machine may be subjected to frequent, strong vibrations.

11-30

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

10 cm 15 cm

30 cm

70 cm

60 cm

30 cm

70 cm

60 cm

30 cm

1. Front: 70 cm (27.6")

2. Back: 10 cm (3.9")

: 15 cm (6.0")

3. Right: 60 cm (31.5")

4. Left: 30 cm (11.8")

NOTE: Make sure there is at least 15 cm (6.0") clearance behind the copier so that the sorter will not be damaged when it is opened.

11-31

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.)




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.

11-32

1 December 1990


14.2.1 Introduction:

This section covers only those parts of the copier and option installation procedures that differ from the A048.

The following table shows which options can be used on the A048 and A054 copiers:

Document Feeder

A048 Copier

(A465)

(A318)

A054 Copier

(A318)

NOTE (1)

Sorter

Duplex Unit

(A490)

(A491)

(A490)

(A491)

NOTE (2)

Color Development Unit

DC Power Supply Unit

(A313)

(A494)

(A313)

NOTE (3)

( ) : Product Code

NOTE: (1) The A465 DF can be installed on the A054 copier; however, the

A465 DF does not have a DF positioning sensor, so APS mode will not function in platen mode.

(2) A054 copiers with the destination codes A054-26, -27 -46, and

-47 are equipped with a duplex unit as a standard feature.

(3) The dc power supply unit for the document feeder and duplex unit and the interface board are already installed on the A054 copier at the factory. The optional dc power supply unit (Unit code #A494) is not required.

(4) The installation procedures of the following options are the same as those of the A048 copier. Refer to each section of the A048 copier as follows:

1. Key Counter Holder

2. Optics Anti-condensation Heater

3. Color Development Unit

Refer to page 3-12.

Refer to page 3-13.

Refer to page 3-14 to16.

11-33

1 December 1990

14.2.2 Copier Installation

[D]

[A]

[F]

[A]

[A]

[H]

[C]

[B]

[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).

•

See page 3-10 for the 220/240 conversion procedure.

•

See page 3-11 for the cassette modification procedure.

11-34

14.3 DOCUMENT FEEDER INSTALLATION

14.3.1 Accessory Check

[B]

1 December 1990

[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.)


1. DF Position Sensor Actuator [A] . . . . . . . . . . . . . . . . . . . . . . 1 pc

2. Philips Pan Head Screw With Washer - M3 x 5 . . . . . . . . . . 1 pc

NOTE: For the other accessories, refer to the list on page 8-24.

11-35

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. Remove the CC/G/B power pack [G] (1 screw and 2 locking supports) and clamp the connector [H] as shown in the illustration; then, reinstall the CC/G/B power pack.

11-36

1 December 1990

[A]

[F] [E]

[G]

[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. Disconnect the platen cover position sensor connectors [E] [F], then connect connector [F] to the DF position sensor connector [G].

NOTE: If this procedure is not done, the APS mode will not function in platen mode.

11. Secure the grounding wire [H] to the right side plate.

12 Do steps 16 to 25 of the installation procedure for the A048 copier (page

8-28 to 30).

11-37

[B]

1 December 1990

14.4 SORTER INSTALLATION

[D]

[E]

[C]

[A]

[B]

NOTE: Refer to the list on page 9-12 to check the accessories.


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.


9-15).

14.5 DUPLEX UNIT INSTALLATION

NOTE: Refer to the list on page 10-13 to check the accessories.

1. Follow the A048 duplex unit installation procedure (pages 10-13 to 10-18).

NOTE: Steps 2, 13, 19, and 20 in the duplex unit installation procedure are not necessary with the A054 copier.

11-38

1 December 1990

15. 3RD PAPER FEED CLUTCH SOLENOID

REPLACEMENT


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. When the clutch solenoid is installed, make sure that the stopper

[G] on the bracket fits into the slot on the clutch solenoid as shown.

2. When the drive belt is installed, make sure that the belt stoppers

[H] of the drive pulleys are positioned correctly as shown. This is to prevent the drive belt from coming off the pulleys.

11-39

DOCUMENT FEEDER ELECTRICAL COMPONENTS AND CONNECTORS LAYOUT

1

2

3

4

5

6

7

8

9

14

15

13

Document Feeder Electrical Components

Index

No.

9

10

11

12

13

14

15

5

6

7

8

1

2

3

4

Original Set Sensor

Registration Sensor

Pulse Generator Sensor


Pick-up Solenoid

Belt Drive Motor

Indicator Panel

Lift Switch

DF Main Board

Feed-out Motor

Inverter Solenoid

Feed-out Sensor

Original Select Switch

Feed-in Solenoid

DF Position Sensor

Description

12

11

10

Symbol

S1

S2

S4

S3

SOL1

M1

PCB2

SW1

PCB1

M2

SOL3

S5

SW2

SOL2

S6

P to P

B15

B16

B16

B17

B19

B14

B18

B19

C14 –

C20

B15

B20

B17

B18

B20

F20

22

21

20

18

17

1

2

3

4

23

5

6

7

8

9

12

10

11

19

16

15

14

Document Feeder Connectors

Index

No.

CN No.

13

14

15

16

9

10

11

12

5

6

7

8

1

2

3

4

17

18

19

20

21

22

23

CN118

CN200

CN119

CN111

CN104

CN103

CN102

CN106

CN101

CN110

CN108

CN109

CN119

CN120

CN115

CN116

CN114

CN121

CN117

CN31

CN27

CN26

CN906

—

Indicator Panel

—

Belt Drive Motor

DF Main Board

DF Main Board

DF Main Board

DF Main Board

DF Main Board

Inverter Solenoid

Feed-out Motor

—

Feed-out Sensor

Original Select Switch

Feed-in Solenoid

—

Pick-up Solenoid

—

—


Regiastration Sensor

Original Set Sensor

DF Position Sensor

Component

13

PCB1

SOL3

M2

—

S5

SW2

SOL2

—

—

PCB2

—

M1

PCB1

PCB1

PCB1

PCB1

SOL1

—

—

S3

S2

S1

S6

Symbol Type P to P

B18

B18

B19

B21

B17

B20

B17

B18

B17

B18

B17

F20

C15 –

C21

C15 –

C21

C15 –

C21

B21

B16

B17

B19

B19

B15

C15 –

C21

C15 –

C21

5P/W

2P/R

4P/W

3P/W

3P/W

2P/W

2P/Y

3P/W

3P/R

4P/W

6P/W

6P/W

34P/B

4P/W

2P/W

2P/B

2P/R

3P/W

3P/Y

3P/B

3P/B

3P/W

3P/W

35

36

1

2

3

4

5

6

7

8

32

31

30

29

28

27

33

34

26

25

24

23

22 21

20

19

18

17

16

15

9

10

11

12

13

14

38

73

72

71

70

69

68

67

66

65

63

61

64

37

56

62

55

60 59

54 58

39

40

41

52

57

51

53

42

43

44

45

46

47

50

48

49

Copier Electrical Components

25

26

27

28

21

22

23

24

29

30

15

16

17

18

11

12

13

14

19

20

Index

No.

5

6

7

8

1

2

3

4

9

10

Description

Scanner H.P. Sensor

Scanner Motor

Main Motor

Development CL Sol.


Toner End Sensor



Manual Feed Table SW

Development Unit Set Sensor

Color Switch

1st Paper Feed CL Sol.

Paper Lift CL Sol.

Registration Clutch


Right Cover SW


1st Paper Size SW

Paper Lift Sensor

Relay Sensor

Registration Sensor

Total Counter

Drum Anti-condensation Heater

Pre-transfer Lamp (PTL)

Transfer and Separation Corona Unit

Erase Lamp (EL)

ID Sensor

Charge Corona Unit

Quenching Lamp (QL)

Fusing Lamp

35

36

37

38

31

32

33

34

39

40

Fusing Thermister

Fusing Thermofuse

Auto ID Sensor


Exit Sensor

Lens Motor

4th/5th Mirror H.P. Sensor

Optics Cooling Fan Motors


Platen Cover Closed SW

O5

O18

F4

G5

G7

H8

H4

G6

A8

A7

O8

O14

O15

O17

O16

O1

O3

O2

O5

O22

G5

B7

O9

O7

O7

O12

O10

O13

F21

H20

P to P

O9

O11

A7

O17

O18

O7

O15

O12

O4

O8

S4

CO1

H1

L5

—

L4

S11

—

L3

L2

SW8

SOL2

SOL5

MC1

SOL8

SW10

S6

SW3

S10

S14

TH1

TF

PCB4

S9

S5

M3

S3

M5

S17

SW15

Symbol

S1

M2

M1

SOL7

SOL1

S8

SOL4

M4

SW9

S12

65

66

67

68

61

62

63

64

69

70

55

56

57

58

51

52

53

54

59

60

Index

No.

45

46

47

48

41

42

43

44

49

50

Description


Optics Thermoswitch

Exposure Lamp


Cover Safety SW

Main SW


Main DC Power Supply Board


Main Transformer

Upper Tray Lock Sol.

Lower Tray Lock Sol.

2nd Paper Size SW-4

2nd Paper Size SW-3

2nd Paper Size SW-2

2nd Paper Size SW-1

3rd Paper Size SW-4

3rd Paper Size SW-3

3rd Paper Size SW-2

3rd Pape Size SW-1


3rd Paper End Sensor

2nd Paper Feed CL Sol.

3rd Paper Feed CL Sol.


AC Drive Board

Platen Cover Position Sensor

Lens H.P. Sensor

TC/SC Power Pack

Interface Board

71

72

73

Main Board

Key Counter (Option)

CC/Grid/Bias POwer Pack

S7

S13

SOL3

SOL9

C

PCB2

S15/S6

S2

P2

PCB6

SOL6

SOL10

SW7

SW6

SW5

SW4

SW14

SW13

SW12

SW11

PCB1

CO2

P1

Symbol

PCB7

TS

L1

S16

SW2

SW1

M7

PCB3

PCB5

TR1

P to P

G1 – G4

A9

A10

H21

B3, B4

C3

A6

F8

E8

E5

O4

O21

O14

O22

—

C10

E20

O10

H7

J16

O16

O23

O3

O3

O3

O2

O21

O20

O20

O20

K1

O18

H6

1

2

3

4

5

6

7

8

9

37 35 33 31

36 34 32

Main Board

(PCB1)

45

44

46

43

Interface Board

(PCB6)

42

10 13

40

19

41

38

39

30

29

28

27

26

24

25

23

22

21

11 12 14 15 16 17 18 20

96

95

94

93

92

91

90

89

88

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

71

64

65

66

67

68

69

70

87

86

85

84

83

82

81 80

79

78 77

76

75

74

73

72

137

136

135

134

133

132

131

130

129

97

98

128

127

99

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

124

123

126

125

Copier Connectors

35

36

37

38

31

32

33

34

39

40

25

26

27

28

21

22

23

24

29

30

15

16

17

18

11

12

13

14

19

20

Index

No.

CN No.

5

6

7

8

1

2

3

4

9

10

CN131

CN130

CN128

CN129

CN127

CN125

CN124

CN123

CN122

CN136

Component

Main Board (Operation Panel Board)

Main Board (Operation Panel Board)

Main Board (Pick-up Roller Release Solenoid)

Main Board (Total Counter)

Main Board (Key Counter)

Main Board (Paper Lift and 1st Paper End Sensors)

Main Board (Paper Lift Clutch Solenoid)

Main Board (Development Unit Set Sensor)

Main Board (Fusing Thermistor and Scanner HP Sensor)

Main Board (Open)

CN135

CN137

CN138

CN113

CN119

CN117

CN114

CN115

CN139

CN120

Main Board (3rd Paper Size Switches)

Main Board (Right Cover SW, 3rd Paper End Sensor, Relay

Sensor)

Main Board (3rd Paper Feed CL Sol.)

Main Board (Relay Roller Clutch Solenoid)

Main Board (1st Paper Feed Clutch Solenoid)

Main Board (Right Cover and 1st Paper Size Switches)

Main Board (Toner End Sensor, Color and Manual Feed Table SW)

Main Board (2nd Paper Size Switches)

Main Board (Upper Tray Lock Sol and 2nd Paper End Sensor)

Main Board (2nd Paper Feed Clutch)

Symbol

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

CN111

CN112

CN126

CN121

CN110

CN118

CN116

CN109

CN108

CN107

Main Board (Registration Clutch)

Main Board (CC/Grid/Bias Power Pack)

Main Board (TC/SC Power Pack)

Main Board (Pre-transfer Lamp)

Main Board (Image Density Sensor)

Main Board (Toner Supply Clutch Solenoid)

Main Board (Development Clutcfh Solenoid)

Main Board (Erase Lamp)

Main Board (Main DC Power Supply Board)

Main Board (Main DC Power Supply Board)

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

CN105

CN106

CN103

CN104

CN102

CN141

CN101

CN132

CN133

CN202

Main Board (Scanner Motor)

Main Board (4th/5th Mirror Motor)

Main Board (Optics Cooling Fan Motor –1)

Main Board (Optics Cooling Fan Motor –2)

Main Board (Lens Motor)

Main Board (Exit Sensor)

Main Board (Toner Overflow Sensor)

Main Board/RAM Board

Main Board

Interface Board (Open)

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB1

PCB6

41

42

43

44

45

CN203

CN207

CN208

CN205

CN209

Interface Board (Sorter)



Interface Board (Duplex)

Interface Board (Original Length/Width Sensors, Platen Cover

PCB6

PCB6

PCB6

PCB6

PCB6

46

47

48

49

50

CN206

CN1

CN1

TG

CN3

Interface Board (DF)

TC/SC Power Pack

CC/G/B Power Pack

CC/G/B Power Pack

Optics Anti-condensation Heater (Option)

PCB6

P2

P1

P1

H2

Type P to P

10P/C

12P/R

12P/B

4P/C

12P/B

2P/B

5P/W

8P/W

1P/–

2P/R

6P/T

6P/W

2P/W

2P/W

12P/W

3P/W

10P/W

24P/B

30P/B

20P/B

2P/B

8P/W

5P/W

2P/C

3P/W

2P/Y

2P/W

9P/W

2P/B

6P/W

9P/C

11P/C

2P/C

2P/W

2P/B

8P/W

8P/C

9P/W

5P/W

2P/W

15P/W

13P/W

2P/W

4P/B

4P/T

6P/W

2P/Y

4P/W

14P/W

5P/T

J3 – J4

J1 – J2

M15

M18

M19

M5 , M3

M15

M8

J5, M9

—

M19–M21

M1, M21,M22

M22

M16

M14

M1, M2

M7, M8, M4

M2 – M3

M16, M4

M14–M15

M11

M12

M13

M13

M12

M6

M7

—

J17

—

M17

J6

J7

J5

J4

M18

M17

J8

J10 – J11

J11 – J12

J12 – J13

—

—

J14 – J15

J20 – J22

J19

H7

H6

G6

E5

CN401

TS

TT

CN1

CN804

CN901

CN836

CN844

CN806

CN906

CN417

T405

T406

CN2

CN415

CN413

CN420

CN419

CN421

TC

95

96

97

98

91

92

93

94

99

100

85

86

87

88

81

82

83

84

89

90

Index

No.

55

56

57

58

51

52

53

54

59

60

CN No.

TB

CN102

CN102

T

T

CN4

T7

T6

T5

T4

Component

CC/G/B Power Pack



Optics Thermoswitch

Optics Thermoswitch

Exposure Lamp

Cover Safety Switch

Cover Safety Switch

Cover Safety Switch

Cover Safety Switch

T404

CN710

CN1

CN2

CN828

CN411

T401

T407

T402

CN418

T3

T1

T2

CN3

CN101

CN101

CN100

CN100

CN103

T403

75

76

77

78

71

72

73

74

79

80

65

66

67

68

61

62

63

64

69

70

Main Switch

Main Switch

Main Switch

Flat Cable for Exposure Lamp






AC Drive Board

AC Drive Board

Duplex Unit

Power Supply Cord

Sorter

Upper Tray Lock Solenoid (Relay Connector)

AC Drive Board

AC Drive Board

AC Drive Board

AC Drive Board

AC Drive Board (Open)

AC Drive Board

AC Drive Board

AC Drive Board

Drum Anti-condensation Heater

AC Drive Board

AC Drive Board

AC Drive Board

AC Drive Board

AC Drive Board (220/240V only)

CC/G/B Power Pack

AC Drive Board

TC/SC Power Pack

TC/SC Power Pack

Document Feeder

Key Counter (Relay Connector)

Relay Connector for Platen Cover/DF Position Sensor


Exit Sensor

Scanner HP Sensor

Platen Cover/DF Position Sensor

D3

C2

D2

B9 – B10

F8 – G8

E8 – F8

F7

E7

F8

C3

B3

E15 – F15

A3

E12 – E13

N16

E4

D3

B4

D3

E6

P to P

G6

E8

G8

A9

A9

B10

B3

B4

B4

B3

E9 – E10

G7

G7

E14

N19

G20

O7

O6

O9

F20

B8

B8

B6

B9

E5

B7

B9

E4

C9

G6

1P/R

8P/B

2P/W

10P/T

2P/W

2P/P

1P/W

1P/W

1P/B

3P/B

1P/–

1P/–

1P/–

2P/W

6P/W

4P/W

6P/W

4P/W

3P/W

1P/R

Type

1P/–

4P/W

2P/W

1P/–

1P/–

1P/W

1P/–

1P/–

1P/–

1P/–

9P/W

1P/–

1P/–

4P/W

4P/W

3P/B

3P/W

3P/W

3P/W

3P/W

3P/W

1P/Y

1P/Y

2P/R

2P/B

2P/B

3P/W

2P/Y

2P/W

1P/–

PCB2

—

—

—

SOL6

PCB2

PCB2

PCB2

PCB2

PCB2

SW1

SW1

SW1

—

PCB3

PCB5

PCB3

PCB5

PCB3

PCB2

Symbol

P1

PCB5

PCB3

TS

TS

L1

SW2

SW2

SW2

SW2

PCB2

P2

P2

—

CO2

—

S9

S5

S1

S6

PCB2

PCB2

PCB2

H1

PCB2

PCB2

PCB2

PCB2

PCB2

P1

131

132

133

134

135

136

137

121

122

123

124

125

126

127

128

129

130

111

112

113

114

115

116

117

118

119

120

Index

No.

CN No.

101

102

103

104

105

106

107

108

109

110

CN825

CN824

CN839

CN809

CN808

CN810

CN811

CN822

CN826

CN812

Component

Lens Motor (Relay Connector)

Lens HP Sensor

Relay Connector for Exit Sensor

2nd Paper Size Switch-1

Relay Connector for Fusing Thermistor



Relay Connector for Toner End Sensor



CN307

CN843

CN845

CN846

CN832

CN306

CN802

CN816

CN303

CN302

CN840

CN823

CN821

CN818

CN842

CN815

CN801

CN305

CN803

CN817

CN301

CN300

CN5

CN827

CN301

CN902

CN903

Toner End Sensor

Relay Connector for Development Unit Set Sensor

Color Switch


Development Unit Set Sensor


3rd Paper End Sensor

Relay Connector for 1st Paper End Sensor

Relay Connector for Paper LIft Sensor

Relay Connector for 1st Paper Size Switch

Right Cover Switch

1st Paper Size Switch


Paper Lift Sensor

Registration Sensor

Relay Connector for Relay Sensor

Total Counter (Relay Connector)

Relay Connector for Registration Sensor

3rd Paper Size Switch-4




Fusing Lamp

Relay Connector for Toner Overflow Sensor

Auto Image Density Sensor



Symbol

SW10

SW3

S6

S10

S4

—

CO1

—

SW14

SW13

SW12

SW11

L2

—

PCB4

S17

S16

S8

—

SW8

SW9

S12

S7

S13

—

—

—

M3

S2

—

SW4

—

SW5

SW6

—

S3

SW7

Type

O1

O2

O3

O5

O5

N22

N18

N5

O21

O20

O8

N8

O8

O4

O8

O4

O21

N3

N5

N2

P to P

N11 –

N12

O10

N6

O2

I5

O2

O3

N7

O10

O3

O20

O20

A7

N7

O9

F21

H21 – I21

2P/S

2P/W

1P/W

3P/W

4P/W

7P/W

4P/W

2P/W

6P/W

3P/W

3P/W

3P/W

3P/W

3P/B

3P/W

2P/B

2P/Y

3P/W

3P/S

3P/W

2P/W

3P/S

3P/W

3P/W

3P/W

3P/W

6P/W

6P/W

3P/W

3P/W

2P/B

2P/W

2P/B

2P/B

3P/W

3P/W

2P/B

CS110 (A490)

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) ............................................................ 8

5. DECAL AND DOCUMENT (A490) ........................................................... 10

Parts Index .................................................................................................. 12

1

1. EXTERIOR (A490) December 1, '90

2

1. EXTERIOR (A490)

Index

No.

Part No.

Description

1 A490 5610 Interface Harness

2 6801 5510 Sorter Main Board

3 A467 6161 Lower Cover

4 6802 5961 Strain Relief Plate

5 A490 3005 Sorter Bin - Top

6 6801 3145 Paper Stopper

7 A414 3151 Sorter Bin - Even

8 A414 3111 Sorter Bin - Odd

9 6801 6211 Top Stay

10 6769 2272 Antistatic Brush

11 A490 6001 Upper Cover

12 A490 7802 Misfeed Removal Decal

13 A490 6141 Hinge Cover

14 A490 5960 Sorter Bracket

15 A490 6131 Rear Cover

16 5447 2681 Snap Ring

17 A490 1020 Upper Hinge Bracket

18 A490 1021 Lower Hinge Bracket

19 6802 7125 Magnet - Sorter Mounting Base

20 A490 7511 Magnet Catch Bracket

21 A490 5951 Sensor Bracket

22 6802 5640 Reed Switch

23 6802 5839 Cord Clamp Rivet

24 6801 5600 Sorter Main Harness

25 6802 5838 Cord Clamp - M16

26 6802 3161 Antistatic Brush - Bin

27 AA14 0279 Frame Shaft

28 A490 1011 Sorter Frame

29 A490 6121 Front Support Cover

30 A490 6011 Front Cover

31 A490 7803 Arrow Decal

32 A490 3146 Front Mylar Seal - Top Bin

33 A490 3147 Rear Mylar Seal - Top Bin

34 6802 5971 Home Position Switch Cover

MB1 (Added)

Q'ty per

Assembly

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

4

1

2

1

1

1

1

1

1

1

2

2

December 1, '90

Index

No.

Part No.

Description

101 0313 0060W Philips Pan Head Screw - M3x6


0313 0140W Philips Pan Head Screw - M3x14 x/o MB1


104 0314 0080M Philips Pan Head Screw - M4x8



107 0324 0080Z Sunk Screw - 4x8

108 0354 0080F Screw - M4x8

109 0354 0100F Screw - M4x10

110 434 0060W Tapping Screw - M4x6

111 0700 0040B Flat Washer - M4 100 Pcs/Set

112 0704 0040C Toothed Washer - M4

113 0960 3006W Philips Flange Screw - M3x6

114 1005 0335 Earth Mark

115 1105 0087 Clamp

116 1106 0366 Cord Clamp

117 1107 0406 Fuse - 250V,0.5A

118 1107 0409 Fuse - 250V,1A

119 1204 1376 Microswitch


Q'ty per

Assembly

3

2. TRANSPORT (A490) December 1, '90

4

2. TRANSPORT (A490)

Index

No.

Part No.

Description

1 6802 5720 Grounding Wire

2 6802 5703 Grounding Wire

3 6802 2032 Antistatic Brush Angle

4 A490 2014 Antistatic Brush - Upper Guide

5 6801 2021 Upper Exit Roller

6 A490 2013 Upper Guide Plate

7 6802 2357 Exit Sensor Feeler

8 6802 2355 Exit Sensor Bracket

9 6801 5921 Harness Guidebracket

10 6801 5520 Exit Sensor Board

11 6801 5911 Insulating Sheet - Exit Sensor

12 A490 1011 Sorter Frame

13 6802 1025 Up-down Plate Guide

14 6802 1021 Front Slot Liner

15 6802 2239 Slot Roller

16 6802 2233 Transfer Wheel - A

17 6802 2317 Timing Belt - 80XL

18 6802 2217 Parallel Key

19 6802 2215 Bushing

20 6801 2123 Lower Exit Roller

21 6802 2213 Bin Drive Shaft

22 6802 2237 Transfer Wheel - B

23 6802 1023 Rear Slot Liner

24 6802 2117 Shaft - Lower Guide Plate

25 6801 5600 Sorter Main Harness

26 6802 2313 Timing Pulley - 12T

27 6802 2315 Drive Pulley Shaft

28 6802 5406 Bin Drive Motor

29 A423 5410 DC Motor - 24V 2.9W

30 6801 2331 Bracket - Roller Drive Motor

31 6801 2335 Roller Drive Pulley

32 6801 2322 Belt - M3 x 175

33 A467 2510 Guide Plate

34 6801 2115 Lower Guide Plate

December 1, '90

Q'ty per

Assembly

1

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

2

1

1

1

2

1

1

1

1

2

1

1

1

1

1

2

1

1

Index

No.

Part No.

Description

35 6802 5972 Wheel Switch Cover

MB1 (Added)

101

102

103

104

105

106

0313 0050W Philips Pan Head Screw - M3x5




0434 0060W Tapping Screw - M4x6

0720 0040E Retaining Ring - M4

0965 3008W Tapping Screw With Flat Washer - M3x8

107 0965 3010W Tapping Screw With Flat Washer - M3x10

108 0965 4008W Tapping Screw With Flat Washer - M4x8


Q'ty per

Assembly

1

5

3. SORTER MAIN BOARD (A490) December 1, '90

6

3. SORTER MAIN BOARD (A490)

Index

No.

Part No.

Description

* 6801 5510 Sorter Mian Board

Q'ty per

Assembly

1

Index

No.

Part No.

Description

101 1005 0799 Heat Sink - H0-220

102 1103 1690 Connector - 10P

103 1103 1732 Connector - 10P

104 1103 1735 Connector - 13P

105 1104 0307 Fuse Clip

106 1107 0406 Fuse - 250V,0.5A

107 1107 0409 Fuse - 250V,1A

108 1400 0072 Transistor - 2SC372Y

109 1400 0135 Transistor - 2SA1015-Y

110 1400 0212 Transistor - 2SB605

111 1401 0325 Transistor Array - PU4320

112 1401 0832 Diode - DSA1A1

113 1407 1607 IC - TD62603P

114 1407 1698 IC - TD62801P

115 1407 1807 IC - TC40H151P

116 1408 0306 IC - 78012AP

117 1408 0408 IC - PST518A

118 1601 7531 Fuse Resistor - 15 Ohm +-5%3W

119 1602 0934 RC Array - CR01-R

120 1604 1382 Capacitor - 10uF 50V

121 1604 1488 Capacitor - 35V,47MF

122 1606 1109 Capacitor - 50V,0.1MF

123 1606 1336 Capacitor - 10000pF -20% +80% 50V

124 1611 4102 Resistor - 1K Ohm 1/4T +-5%

125 1611 4121 Resistor - 120 Ohm 1/4T +-5%

126 1611 4153 Resistor - 15K Ohm 1/4T +-5%

127 1611 4222 Resistor - 2.2K Ohm 1/4T +-5%

128 1611 4472 Resistor - 4.7K Ohm +-5% 1/4W

129 1611 4473 Resistor - 47K Ohm 1/4T +-5%

130 1611 6222 Resistor - 2.2K Ohm 1/2T +-5%

December 1, '90

Q'ty per

Assembly

7

4. SORTER MAIN HARNESS (A490) December 1, '90

8

4. SORTER MAIN HARNESS (A490)

Index

No.

Part No.

Description

* 6801 5600 Sorter Main Harness

Q'ty per

Assembly

1

Index

No.

Part No.

Description

101 1100 0298 Solid Strand

102 1100 0505 Ground Terminal

103 1100 0861 Socket Terminal - Large

104 1100 1264 Wire Terminal

105 1100 1327 Contact

106 1100 1328 Contact

107 1102 0415 Connector Housing

108 1102 1921 Connector - 13P

109 1102 1964 Connector - 2P

110 6802 5817 Connector - 5P

111 6802 5823 Key - PK100C

December 1, '90

Q'ty per

Assembly

9

5. DECAL AND DOCUMENT (A490) December 1, '90

10

5. DECAL AND DOCUMENT (A490)

Index

No.

Part No.

Description

1 A490 7802 Misfeed Removal Decal

2 A490 7803 Arrow Decal

Q'ty per

Assembly

1

1

Index

No.

Part No.

Description

December 1, '90

Q'ty per

Assembly

11

PARTS INDEX

Part No.

A490 1011

A490 1011

A490 1020

A490 1021

A490 2013

A490 2014

A490 3005

A490 3146

A490 3147

A490 5610

A490 5951

A490 5960

A490 6001

A490 6011

A490 6121

A490 6131

A490 6141

A490 7511

A490 7802

A490 7802

A490 7803

A490 7803

Description

Sorter Frame

Sorter Frame

Upper Hinge Bracket

Lower Hinge Bracket

Upper Guide Plate

Antistatic Brush - Upper Guide

Sorter Bin - Top

Front Mylar Seal - Top Bin

Rear Mylar Seal - Top Bin

Interface Harness

Sensor Bracket

Sorter Bracket

Upper Cover

Front Cover

Front Support Cover

Rear Cover

Hinge Cover

Magnet Catch Bracket

Misfeed Removal Decal

Misfeed Removal Decal

Arrow Decal

Arrow Decal

Paper and

Index No.

3- 33

3- 1

3- 21

3- 14

3- 11

3- 30

3- 29

3- 15

3- 13

3- 28

5- 12

3- 17

3- 18

5- 6

5- 4

3- 5

3- 32

3- 20

3- 12

11- 1

3- 31

11- 2

13

Part No.

6801 2335

6801 3145

6801 5510

6801 5510

6801 5520

6801 5600

6801 5600

6801 5600

6801 5911

6801 5921

6801 6211

6802 1021

6802 1023

6802 1025

6802 2032

6802 2117

6802 2213

6802 2215

6802 2217

6802 2233

6802 2237

6802 2239

AA14 0279

A414 3111

A414 3151

A423 5410

A467 2510

A467 6161

5447 2681

6769 2272

6801 2021

6801 2115

6801 2123

6801 2322

6801 2331

Description

Frame Shaft

Sorter Bin - Odd

Sorter Bin - Even

DC Motor - 24V 2.9W

Guide Plate

Lower Cover

Snap Ring

Antistatic Brush

Upper Exit Roller

Lower Guide Plate

Lower Exit Roller

Belt - M3 x 175

Bracket - Roller Drive Motor

Roller Drive Pulley

Paper Stopper

Sorter Main Board

Sorter Mian Board

Exit Sensor Board

Sorter Main Harness

Sorter Main Harness

Sorter Main Harness

Insulating Sheet - Exit Sensor

Harness Guidebracket

Top Stay

Front Slot Liner

Rear Slot Liner

Up-down Plate Guide

Antistatic Brush Angle

Shaft - Lower Guide Plate

Bin Drive Shaft

Bushing

Parallel Key

Transfer Wheel - A

Transfer Wheel - B

Slot Roller

December 1, '90

Paper and

Index No.

5- 14

5- 23

5- 13

5- 3

5- 24

5- 21

5- 19

5- 18

5- 16

5- 22

5- 15

5- 31

3- 6

3- 2

7- *

5- 10

3- 24

5- 25

9- *

5- 11

5- 9

3- 9

3- 27

3- 8

3- 7

5- 29

5- 33

3- 3

3- 16

3- 10

5- 5

5- 34

5- 20

5- 32

5- 30

6802 2313

6802 2315

6802 2317

6802 2355

6802 2357

6802 3161

6802 5406

6802 5640

6802 5703

6802 5720

6802 5817

6802 5823

6802 5838

6802 5839

6802 5961

6802 5971

6802 5972

6802 7125

Timing Pulley - 12T

Drive Pulley Shaft

Timing Belt - 80XL

Exit Sensor Bracket

Exit Sensor Feeler

Antistatic Brush - Bin

Bin Drive Motor

Reed Switch

Grounding Wire

Grounding Wire

Connector - 5P

Key - PK100C

Cord Clamp - M16

Cord Clamp Rivet

Strain Relief Plate

Home Position Switch Cover MB1 (Added)

Wheel Switch Cover MB1 (Added)

Magnet - Sorter Mounting Base

5- 2

5- 1

9-110

9-111

3- 25

3- 23

3- 4

3- 34

5- 35

3- 19

5- 26

5- 27

5- 17

5- 8

5- 7

3- 26

5- 28

3- 22

14










0314 0080M Philips Pan Head Screw - M4x8



0324 0080Z Sunk Screw - 4x8

0354 0080F Screw - M4x8

0354 0100F Screw - M4x10



0700 0040B Flat Washer - M4 100 Pcs/Set

0704 0040C Toothed Washer - M4


0960 3006W Philips Flange Screw - M3x6




1005 0335

1005 0799

1100 0298

1100 0505

1100 0861

1100 1264

1100 1327

1100 1328

1102 0415

1102 1921

1102 1964

Earth Mark

Heat Sink - H0-220

Solid Strand

Ground Terminal

Socket Terminal - Large

Wire Terminal

Contact

Contact

Connector Housing

Connector - 13P

Connector - 2P

December 1, '90

3-114

7-101

9-101

9-102

9-103

9-104

9-105

9-106

9-107

9-108

9-109

3-108

3-109

3-110

5-104

3-111

3-112

5-105

3-113

5-106

5-107

5-108

5-101

3-101

3-102

5-102

3-102

5-102

3-120

3-103

5-103

3-104

3-105

3-106

3-107

Part No.

1400 0135

1400 0212

1401 0325

1401 0832

1407 1607

1407 1698

1407 1807

1408 0306

1408 0408

1601 7531

1602 0934

1604 1382

1604 1488

1606 1109

1606 1336

1611 4102

1611 4121

1611 4153

1611 4222

1611 4472

1611 4473

1611 6222

1103 1690

1103 1732

1103 1735

1104 0307

1105 0087

1106 0366

1107 0406

1107 0406

1107 0409

1107 0409

1204 1376

1204 1376

1400 0072

Description

Connector - 10P

Connector - 10P

Connector - 13P

Fuse Clip

Clamp

Cord Clamp

Fuse - 250V,0.5A

Fuse - 250V,0.5A

Fuse - 250V,1A

Fuse - 250V,1A

Microswitch

Microswitch

Transistor - 2SC372Y

Transistor - 2SA1015-Y

Transistor - 2SB605

Transistor Array - PU4320

Diode - DSA1A1

IC - TD62603P

IC - TD62801P

IC - TC40H151P

IC - 78012AP

IC - PST518A

Fuse Resistor - 15

Ω

±5%3W

RC Array - CR01-R

Capacitor - 10uF 50V

Capacitor - 35V,47MF

Capacitor - 50V,0.1MF

Capacitor - 10000pF -20% +80% 50V

Resistor - 1K

Ω

1/4T ±5%

Resistor - 120

Ω

1/4T ±5%

Resistor - 15K

Ω

1/4T ±5%

Resistor - 2.2K

Ω

1/4T ±5%

Resistor - 4.7K

Ω

±5% 1/4W

Resistor - 47K Ω 1/4T ±5%

Resistor - 2.2K

Ω

1/2T ±5%

Paper and

Index No.

7-120

7-121

7-122

7-123

7-124

7-125

7-126

7-127

7-128

7-129

7-130

7-109

7-110

7-111

7-112

7-113

7-114

7-115

7-116

7-117

7-118

7-119

7-102

7-103

7-104

7-105

3-115

3-116

3-117

7-106

3-118

7-107

3-119

5-109

7-108

15

Part No.

Description

December 1, '90

Paper and

Index No.

DF57 (A318)

PARTS CATALOG

INTRODUCTION



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. INDICATION BOARD (A318) ................................................................... 14

6. MAIN HARNESS (A318) .......................................................................... 16

7. INTERFACE HARNESS (A318) ............................................................... 18

Parts Index .................................................................................................. 20

1

1. EXTERIOR AND TRANSPORT SECTION (A318) December 1, '90

2

1. EXTERIOR AND TRANSPORT SECTION (A318)

Index

No.

Part No.

Description

1 A465 1337 Decal - Original Table - LT

1 A465 1338 Decal - Original Table - A4

2 A422 1335 Magnet - Original Table

3 A465 2025 Original Limit Decal

4 A422 1376 Rear Side Guide

5 5894 2747 Mylar - Original Guides

6 A422 1366 Front Side Guide

7 A422 1361 Rack - Side Guide

8 A422 1323 Original Table

9 5443 2712 Cork Pad

10 5443 2657 Gear - 28Z

11 5443 2713 Wave Washer

12 5443 2660 Spacer - 6x22x0.5mm

13 A465 2010 Misfeed Removal Decal - English

13 A465 2050 Misfeed Removal Decal - Multi

14 A422 1385 Original Exit Guide

15 A465 1125 Angle Stopper

16 A465 1398 Lift Switch Actuator

17 A437 1178 DF Harness Bracket

18 A318 1191 Mounting Bracket

18 A465 1195 Mounting Bracket

19 A422 1381 Shoulder Screw - M4

20 5936 2480 Magnet Catch Ass’y

21 A318 1135 Magnet Catch Bracket

22 5875 2088 Shoulder Screw - M4

23 AA14 3005 Stepped Screw - M4x2.5

24 A422 1108 Stopper

25 A422 1078 Bushing - 6x12x4mm

26 A318 1300 DF Upper Cover

27 A318 1100 Front Frame

28 A422 1185 Belt Guide - Front Left

29 A422 1187 Belt Guide - Front Right

30 5447 3655 Bushing - 4mm

31 A465 2017 Decal - DIP Switch

32 A437 1120 Bracket - Belt Tension Spring

Q'ty per

Assembly

1

1

1

1

8

1

1

2

2

6

2

1

1

1

1

2

2

1

1

1

1

1

1

2

1

6

1

1

1

1

1

1

1

1

1

3

Index

No.

Part No.

Description

33 A422 1112 Belt Tension Spring

34 A465 1127 Transport Belt

35 A422 1114 Driven Roller - Transport Belt

36 A422 1106 Stay

37 A465 1118 Belt Support Roller

38 5936 5348 Thin Original Feed Switch

39 A422 1107 Stay - Belt Support Roller

40 A497 1101 Belt Pressure Roller

41 A437 1115 Drive Roller - Transport Belt

42 A422 1188 Belt Guide - Rear Right

43 A422 1186 Belt Guide - Rear Left

44 A422 1103 Rear Frame

45 A422 1056 Gear - 19T

46 A318 1184 Feed-out Motor Cover

47 A437 1190 Grounding Plate

49 A318 1331 Grip Cover

50 A318 1498 Belt Drive Motor Cover

51 A422 1183 Main Board Cover

52 5936 7901 Decal - English

53 A465 1397 Spacer - 0.5mm

54 A465 1389 Spacer - 0.2mm

55 A465 1110 Magnet Catch Spacer

56 A422 1130 Reflector Plate

57 A422 1603 Seal - 2x8x14

58 A422 1604 Cushion - 8x15x25

59 A465 0656 Original Table Ass’y - LT

59 A465 0657 Original Table Ass’y - A4

60 A465 1179 DF Bracket

61 A497 1152 Magnet - APS

62 A318 1530 DF Halfway Sensor Actuator

63 A497 2025 Cushion - 5x5x3

64 A465 2031 Decal - Set

65 A422 1066 Stopper

December 1, '90

Q'ty per

Assembly

2

1

1

1

1

1

1

1

1

4

4

1

1

1

1

1

1

1

1

1

3

1

4

1

2

1

1

1

1

1

1

1

1

Index

No.

Part No.

Description




103 0951 4005W Philips Screw With Flat Washer - M4x5

104 0584 0103W Hexgon With Flange Screw - M4x10


106 0951 3006B Philips Screw with Flat Washer - M3x6

107 0344 0060W Philips Truss Head Screw - M4x6

108 0801 1185 Philips Truss Head Screw - M4x8

109 0720 0040E Retaining Ring - M4



112 0701 0060B Flat Washer - M6

114 0632 0100G Pin - 2x10mm

115 0344 0600D Philips Truss Head Screw - M4x6


117 0742 3906 Ball Bearing - 6mm

118 0741 3806 Ball Bearing - 6x13x5mm

119 1106 0222 Cord Clamp

120 1100 0340 Closed Terminal



Q'ty per

Assembly

Index

No.

Part No.

Description

Q'ty per

Assembly

4

2. FEED IN SECTION (A318) December 1, '90

5

2. FEED IN SECTION (A318)

Index

No.

Part No.

Description

1 A497 1077 Mylar - 18x306

3 A465 1057 Pull-out Bracket

4 5413 3903 Pin - Transfer Guide Plate

5 A422 1086 Pull-out Spring

6 A422 1063 Seal - 0.7x13x20

7 A422 1064 Hinge - Pull-out

8 5205 5250 LED Sensor Type - S

9 A422 1087 Shoulder Screw - M3x3

10 A422 5202 Harness - Pulse Generator

11 A437 1065 Lower Guide Plate

12 A422 1071 Pull-out Lever

13 A422 1068 Relay Roller

14 A422 1067 Relay Roller Shaft

15 A422 1080 Pulse Generator



18 A422 1040 Feed-in Solenoid Lever

19 AA14 3005 Stepped Screw - M4x2.5 MB5

20 5446 4577 Spring - Turn Plate MB5

21 A422 1074 Shoulder Screw - M4x2.5 MB5

22 A422 1075 Feed-in Unit Relese Lever MB5

23 5219 1957 Stepped Screw - M4 MB5

24 A422 1073 Release Spring

25 A422 1072 Front Side Plate

26 A422 5252 Solenoid - DC24V

27 A422 1047 Set Sensor Bracket

28 A422 5270 Photosensor

29 A422 5207 Harness - Registration

30 A422 5208 Harness - Paper Size

31 A422 1093 Sensor Bracket


33 A422 1078 Bushing - 6x12x4mm

34 A422 1051 Gear - 23T

35 A422 1044 Idle Shaft

36 A422 1503 Idle Shaft

Q'ty per

Assembly

2

4

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

1

1

1

1

2

2

2

1

1

1

6

Index

No.

Part No.

Description

37 A422 1042 Idle Gear - 22Z

38 A422 1046 Pick-up Roller

39 A422 1048 Pick-up Shaft

40 A422 1002 Clutch Boss

41 5918 2163 Clutch Spring

42 5918 2164 Clutch Sleeve

43 A422 1001 Gear - 24T

44 A422 1023 Feed Roller Shaft

45 A422 1045 Pull-out Roller

46 A318 1090 Side Roller

47 A422 1003 Feed Roller

48 A422 1041 Gear - 27T

49 A422 1025 Original Guide

50 A422 1602 Pick-up Lever Plate

51 A422 1600 Pick-up Lever

52 A422 1601 Pick-up Shaft

53 A422 1032 Lever - Pick-up Solenoid

54 A422 1031 Lever - Pick-up Spring

55 A422 1082 Pick-up Spring

56 A422 1033 Pick-up Solenoid Bracket

57 5894 2229 Solenoid Pin

58 A422 5255 Solenoid - DC24V (Invertor)

59 A422 1505 Gear - 57T

60 A422 1005 Clutch Pawl - Pick-up Roller

61 A422 1049 Gear - 27T

62 A422 1050 Gear - 29T

63 A318 1021 Side Plate

64 5894 2176 Spring - Detent Arm

65 A422 1291 Rear Guide Plate

66 A422 1290 Front Guide Plate

67 A422 1351 Seal - 0.5x37x71mm

68 A422 1352 Friction Belt Holder

69 A422 1354 Friction Belt

70 A422 1356 Pin - 3x26mm

71 A422 1355 Friction Belt Spring

December 1, '90

Q'ty per

Assembly

1

1

1

1

1

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

Index

No.

Part No.

Description

72 A422 1069 Friction Roller

73 A422 1295 Set Sensor Actuator

74 A422 1176 Set Sensor Actuator Bracket

75 A422 1390 Entrance Seal

76 A465 5260 Indication Board

77 A422 1177 Indication Bracket

78 A422 1504 Shaft/Gear - 16T

79 A422 1506 Gear - 25T

80 A318 1510 Rear Side Plate

81 A422 1507 Feed-in Motor Bracket

82 A422 1501 Gear - 20T

83 A422 5300 Feed-in Motor - DC10W

84 A422 5204 Feed-in Motor Harness

85 A497 1015 Gear - 45Z

86 A422 1396 Mylar - 0.125x14x45.5

87 A422 1603 Seal - 2x8x14

88 A422 5212 Grounding Wire

89 A465 1075 Shaft - 3x25

90 A465 1074 Pin - 4x77.5

91 A465 1073 Pin - 4x76.5

92 A465 1072 Lock Spring

93 A465 1068 Cushion - 2.5x14x43

94 A465 1077 Release Lever

95 A465 1076 Release Lever Knob

96 A465 1069 Harness Cover

97 A465 1080 Fixing Plate - Feed-in Unit

98 A465 1066 Mylar - 0.1x21x58

99 A465 1067 Mylar - 0.1x14.5x44

200 A465 1027 Guide Plate - Paper Feed

201 A465 1070 Lever Spring

202 A422 1022 Support Plate

Q'ty per

Assembly

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

Index

No.

Part No.

Description







106 0951 3004W Philips Screw with Flat Washer - M3x4



109 0720 0025E Retaining Ring - M2.5

110 0632 0100G Pin - 2x10mm

111 0632 0140G Parallel Pin

112 0632 0080G Parallel Key - 2x8mm

113 0573 0030E Hexagon Headless Set Screw - M3x3

114 0573 0060E Hexagon Headless Set Screw - M3x6

115 0354 0060W Philips Truss Head Screw - M4x6

116 1105 0199 Clamp

117 1105 0008 Nylon Clip - 2N

118 1105 0009 Nylon Clip - 5N

119 0741 3505 Ball Bearing - 5x10x4

120 0741 3506 Ball Bearing - 6x12x4 mm

121 0805 3383 Bushing - M5

122 0950 4006W Philips Screw With Lock Washer - M4x6



Q'ty per

Assembly

7

3. INVERTOR AND EXIT SECTION (A318) December 1, '90

8

3. INVERTOR AND EXIT SECTION (A318)

Index

No.

Part No.

Description

1 A465 1499 Right Hinge

2 A422 1121 Right Bracket - Right Hinge

3 A422 1120 Left Bracket - Right Hinge

4 A465 1393 Left Hinge

5 A318 1119 Left Hinge Bracket

6 A422 2030 Decal - Inverter Guide Plate



9 A465 5190 DF Main Board

10 A318 5220 Main Harness

11 A497 1500 I/F Harness Bracket

12 A497 2024 Paper Guide Mylar

13 A422 1225 Inverter Guide Plate


15 A409 1192 Pulley - 15T

16 A422 5270 Photosensor

17 A409 1195 Exit Drive Shaft

18 A422 1265 Gear - 46T

19 A422 1251 Bracket - Exit Sensor

20 A409 1197 Spacer - 10x16x1.6mm


22 A422 1232 Inverter Solenoid Bracket

23 5894 2229 Solenoid Pin

24 A422 5255 Solenoid - DC24V (Invertor)

25 A422 1235 Rear Lever

26 A422 5310 Feed-out Motor - DC10W

27 A409 1161 Pulley - 21T

28 5053 0447 Bushing - 6mm

29 A422 1226 Spring - Inverter Guide Plate

30 A409 1150 Spring Anchor

31 A422 1240 Upper Exit Roller

32 A422 1231 Inverter Gate Spring

33 A422 1234 Front Lever

34 A422 1078 Bushing - 6x12x4mm

35 5446 2824 Screw - Duplex Guide Plate

Q'ty per

Assembly

1

1

2

2

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

1

1

1

1

1

1

9

Index

No.

Part No.

Description

36 A422 1275 Front Side Plate - Feed-out

37 A422 1230 Inverter Pawls

38 A422 1210 Inverter Roller

39 A422 1216 Inverter Support Roller

40 A422 1276 Rear Side Plate - Feed-out

41 A422 1079 Bushing - 8x16x5mm

42 A422 1270 Timing Belt - 81xl

43 A409 1143 Pulley - 50T

44 A422 5203 Feed-out Sensor Harness

45 A422 1245 Upper Exit Roller Ass’y

46 A422 1218 Pressure Lever Shaft

47 A422 1217 Pressure Lever

48 A422 1219 Pressure Lever Spring

49 A422 1257 Antistatic Brush

50 A422 1255 Invertor Guide Plate

51 A422 1249 Upper Exit Roller

52 A465 1126 Grounding Plate

53 A465 5213 Grounding Wire

54 AW01 0010 Photosensor

55 5219 1957 Stepped Screw - M4

December 1, '90

Q'ty per

Assembly

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

4

1

1

1

Index

No.

Part No.

Description


101 0801 1185 Philips Truss Head Screw - M4x8











112 0720 0025E Retaining Ring - M2.5

113 0704 0040C Toothed Washer - M4

114 0632 0100G Pin - 2x10mm

115 0633 0120G Parallel Pin - 3x12

116 0632 0080G Parallel Key - 2x8mm

117 0701 0040B Flat Washer - M4

118 1105 0009 Nylon Clip - 5N

119 1105 0011 Nylon Clip - 8N

120 1106 0430 Bushing - 13mm

121 1105 0199 Clamp


123 1107 0413 Fuse - 3A 125V

124 0742 3905 Ball Bearing - 5x13x4mm

125 0741 3505 Ball Bearing - 5x10x4

126 0950 4006W Philips Screw With Lock Washer - M4x6

Q'ty per

Assembly

Index

No.

Part No.

Description

Q'ty per

Assembly

10

4. MAIN BOARD (A318) December 1, '90

11

4. MAIN BOARD (A318)

Index

No.

Part No.

Description

* A465 5190 DF Main Board

1 A422 5350 IC - HCTL-3

2 A465 5180 IC - D27128A-2

3 A465 5210 Fiber Connector - 2P

4 5936 5221 Heat Sink

Q'ty per

Assembly

1

1

1

1

1

12

Index

No.

Part No.

Description

101 1005 0843 Heat Sink - OSH2425SP

102 1101 0328 Connector Pin Contact

103 1102 0958 Connector - 2P

104 1102 2966 Connector - HIF3BA-34PA

105 1103 0881 Connector - 4P

106 1103 1726 Connector - 4P

107 1103 1729 Connector - 7P

108 1103 1878 Connector - 2P

110 1104 0271 LSI Socket - 28P

111 1104 0333 Fuse Holder

112 1107 0413 Fuse - 3A 125V

113 1204 0883 DIP Switch

114 1204 1385 Push Switch

115 1401 0282 Transistor - 2SB1020

116 1401 0329 Transistor Array - MP4503

117 1401 0832 Diode - DSA1A1

118 1403 0308 LED - TLR-102A

119 1403 0388 Photocoupler - ON3111

120 1407 0602 IC - TC4040BP

121 1407 0604 IC - TC4049BP

122 1407 1026 IC - SN74LS373N

123 1407 1334 IC - UPD7810G

124 1407 1348 IC - TD62304AP

125 1407 1535 IC - TD62308AP

126 1408 0076 IC - UPC14312H

127 1408 0408 IC - PST518A

128 1408 0521 IC - M51971L

129 1408 0578 IC - HA17339

130 1503 0070 Ceramic Oscillator - 10MHz

131 1600 0239 Resistor - 0.47 Ohm +-5% 1W

132 1600 0544 Resistor - 1k Ohm +-10% 1W

133 1600 0576 Resistor - 33 Ohm +-10% 5W

134 1601 1732 Resistor - 390 Ohm +-5% 1W

135 1601 7326 Resistor Array - 10k Ohm

136 1601 8145 Variable Resistor - 5k Ohm 0.5W

December 1, '90

Q'ty per

Assembly

Index

No.

Part No.

Description



139 1602 0953 Coil - 800uH 2.5A

140 1604 1358 Capacitor - 1000mF 10V

141 1604 1378 Capacitor - 1mF 50V

142 1604 1379 Capacitor - 2.2uF +-20% 50V

143 1604 1380 Capacitor - 3.3uF 50V

144 1604 1381 Capacitor - 4.7uF 50V

145 1604 1382 Capacitor - 10uF 50V

146 1604 1383 Capacitor - 22mF 50V

147 1604 1386 Capacitor - 100uF +-20% 50V

148 1604 1390 Capacitor - 1000mF 50V

150 1605 0141 Capacitor - 4700PF 50V

151 1606 0658 Capacitor - 0.1uF 50V

152 1606 1308 Capacitor - 27pF 50V

153 1606 1326 Capacitor - 100pF 50v +-10%

154 1606 1348 Capacitor - 0.022uF 50V

155 1606 1451 Capacitor - 0.1uF 50V

156 1606 1452 Capacitor - 0.01uF 50V

157 1610 0035 Resistor - 100 Ohm 1/8W +-5%

158 1610 0047 Resistor - 330 Ohm 1/8W +-5%

159 1610 0053 Resistor - 1k Ohm 1/8W +-5%

160 1610 0057 Resistor - 1.5k Ohm 1/8W +-5%

161 1610 0065 Resistor - 3.3K Ohm 1/8W +-5%

162 1610 0067 Resistor - 4.7k Ohm 1/8W +-5%

163 1610 0071 Resistor - 10k Ohm +-5% 1/8W

164 1610 0073 Resistor - 12K Ohm 1/8W +-5%

165 1610 0079 Resistor - 22k Ohm 1/8W +-5%

166 1610 0107 Resistor - 1M Ohm 1/8W +-5%

167 1610 0286 Capacitor - 100pF 50V +-10%

168 1611 4103 Resistor - 10k Ohm 1/4T +-5%

169 1611 4121 Resistor - 120 Ohm 1/4T +-5%

170 1611 4229 Resistor - 2.2 Ohm 1/4W +-5%

171 1611 4272 Resistor - 2.7k Ohm 1/4T +-5%

172 1611 4393 Resistor - 39k Ohm 1/4T +-5%

Q'ty per

Assembly

Index

No.

Part No.

Description

173 1611 4472 Resistor - 4.7k Ohm +-5% 1/4W

174 1611 4563 Resistor - 56k Ohm 1/4T +-5%

13

Q'ty per

Assembly

5. INDICATION BOARD (A318) December 1, '90

14

5. INDICATION BOARD (A318)

Index

No.

Part No.

* A465 5260 Indication Board

Description

Q'ty per

Assembly

1

Index

No.

Part No.

Description

101 1100 1306 Terminal

102 1100 1328 Contact

103 1102 1805 Connector - 4P

104 1102 1967 Connector - 6P

105 1403 0236 L.E.D. - MU02-520

106 1403 0237 L.E.D. - MU20-220

December 1, '90

Q'ty per

Assembly

15

6. MAIN HARNESS (A318) December 1, '90

16

6. MAIN HARNESS (A318)

Index

No.

Part No.

* A318 5220 Main Harness

Description

Q'ty per

Assembly

1

Index

No.

Part No.

Description

101 1100 0340 Closed Terminal

102 1100 1169 Fastening Receptacle

103 1100 1253 Pin - Mate-N-Lock

104 1100 1327 Contact

105 1100 1348 Pin Contact

106 1102 1408 Connector - 1P

107 1102 1756 Connector - 2P

108 1102 1910 Connector - 2P

109 1102 1911 Connector - 3P

110 1102 1912 Connector - 4P

111 1102 1914 Connector - 6P

112 1102 1924 Connector - 2P

113 1102 1925 Connector - 3P

114 1102 1938 Connector - 2P

115 1102 1939 Connector - 3P

116 1103 0659 Connector - 34P

119 1607 0116 Ferrite Core

December 1, '90

Q'ty per

Assembly

17

7. INTERFACE HARNESS (A318) December 1, '90

18

7. INTERFACE HARNESS (A318)

Index

No.

Part No.

Description

* A318 5205 Interface Harness

Q'ty per

Assembly

1

Index

No.

Part No.

Description

101 1100 0051 Connector

102 1100 1190 Socket - Mate-N-Lock


104 1102 1374 Connector - 4P

105 1102 1517 Connector - 4P

106 1102 1089 Connector - 3P


108 1102 2025 Pin Housing - 3P

109 1100 1330 Socket Contact

December 1, '90

Q'ty per

Assembly

19

PARTS INDEX

Part No.

A318 1021

A318 1090

A318 1100

A318 1119

A318 1135

A318 1184

A318 1191

A318 1300

A318 1331

A318 1498

A318 1510

A318 1530

A318 5205

A318 5205

A318 5220

A318 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.

3- 26

3- 49

3- 50

5- 80

3- 62

7- 7

15- *

7- 10

13- *

5- 63

5- 46

3- 27

7- 5

3- 21

3- 46

3- 18

21

Part No.

A422 1022

A422 1023

A422 1025

A422 1031

A422 1032

A422 1033

A422 1040

A422 1041

A422 1042

A422 1044

A422 1045

A422 1046

A422 1047

A422 1048

A422 1049

A422 1050

A422 1051

A422 1056

A422 1063

A422 1064

A422 1066

A422 1067

AA14 3005

AA14 3005

AW01 0010

A409 1143

A409 1150

A409 1161

A409 1192

A409 1195

A409 1197

A422 1001

A422 1002

A422 1003

A422 1005

Description

Stepped Screw - M4x2.5

Stepped Screw - M4x2.5 MB5

Photosensor

Pulley - 50T

Spring Anchor

Pulley - 21T

Pulley - 15T

Exit Drive Shaft

Spacer - 10x16x1.6mm

Gear - 24T

Clutch Boss

Feed Roller

Clutch Pawl - Pick-up Roller

Support Plate

Feed Roller Shaft

Original Guide

Lever - Pick-up Spring

Lever - Pick-up Solenoid

Pick-up Solenoid Bracket

Feed-in Solenoid Lever

Gear - 27T

Idle Gear - 22Z

Idle Shaft

Pull-out Roller

Pick-up Roller

Set Sensor Bracket

Pick-up Shaft

Gear - 27T

Gear - 29T

Gear - 23T

Gear - 19T

Seal - 0.7x13x20

Hinge - Pull-out

Stopper

Relay Roller Shaft

December 1, '90

Paper and

Index No.

5- 38

5- 27

5- 39

5- 61

5- 62

5- 34

3- 45

5- 6

5- 7

3- 65

5- 14

5-202

5- 44

5- 49

5- 54

5- 53

5- 56

5- 18

5- 48

5- 37

5- 35

5- 45

3- 23

5- 19

7- 54

7- 43

7- 30

7- 27

7- 15

7- 17

7- 20

5- 43

5- 40

5- 47

5- 60

A422 1086

A422 1087

A422 1093

A422 1103

A422 1106

A422 1107

A422 1108

A422 1112

A422 1114

A422 1120

A422 1121

A422 1130

A422 1176

A422 1177

A422 1183

A422 1185

A422 1186

A422 1187

A422 1188

A422 1210

A422 1216

A422 1217

A422 1068

A422 1069

A422 1071

A422 1072

A422 1073

A422 1074

A422 1075

A422 1078

A422 1078

A422 1078

A422 1079

A422 1080

A422 1082

Relay Roller

Friction Roller

Pull-out Lever

Front Side Plate

Release Spring

Shoulder Screw - M4x2.5 MB5

Feed-in Unit Relese Lever MB5

Bushing - 6x12x4mm

Bushing - 6x12x4mm

Bushing - 6x12x4mm

Bushing - 8x16x5mm

Pulse Generator

Pick-up Spring

Pull-out Spring

Shoulder Screw - M3x3

Sensor Bracket

Rear Frame

Stay

Stay - Belt Support Roller

Stopper

Belt Tension Spring

Driven Roller - Transport Belt

Left Bracket - Right Hinge

Right Bracket - Right Hinge

Reflector Plate

Set Sensor Actuator Bracket

Indication Bracket

Main Board Cover

Belt Guide - Front Left

Belt Guide - Rear Left

Belt Guide - Front Right

Belt Guide - Rear Right

Inverter Roller

Inverter Support Roller

Pressure Lever

3- 56

5- 74

5- 77

3- 51

3- 28

3- 43

3- 29

3- 42

7- 38

7- 39

7- 47

5- 5

5- 9

5- 31

3- 44

3- 36

3- 39

3- 24

3- 33

3- 35

7- 3

7- 2

5- 13

5- 72

5- 12

5- 25

5- 24

5- 21

5- 22

3- 25

5- 33

7- 34

7- 41

5- 15

5- 55

22

A422 1255

A422 1257

A422 1260

A422 1261

A422 1265

A422 1270

A422 1275

A422 1276

A422 1290

A422 1291

A422 1295

A422 1323

A422 1335

A422 1351

A422 1352

A422 1354

A422 1355

A422 1356

A422 1361

A422 1366

A422 1376

A422 1381

A422 1218

A422 1219

A422 1225

A422 1226

A422 1230

A422 1231

A422 1232

A422 1234

A422 1235

A422 1240

A422 1245

A422 1249

A422 1251

Pressure Lever Shaft

Pressure Lever Spring

Inverter Guide Plate

Spring - Inverter Guide Plate

Inverter Pawls

Inverter Gate Spring

Inverter Solenoid Bracket

Front Lever

Rear Lever

Upper Exit Roller

Upper Exit Roller Ass'y

Upper Exit Roller

Bracket - Exit Sensor

Invertor Guide Plate

Antistatic Brush

Front Side Plate

Rear Side Plate

Gear - 46T

Timing Belt - 81xl

Front Side Plate - Feed-out

Rear Side Plate - Feed-out

Front Guide Plate

Rear Guide Plate

Set Sensor Actuator

Original Table

Magnet - Original Table

Seal - 0.5x37x71mm

Friction Belt Holder

Friction Belt

Friction Belt Spring

Pin - 3x26mm

Rack - Side Guide

Front Side Guide

Rear Side Guide

Shoulder Screw - M4

December 1, '90

3- 8

3- 2

5- 67

5- 68

5- 69

5- 71

5- 70

3- 7

3- 6

3- 4

3- 19

7- 50

7- 49

7- 14

7- 21

7- 18

7- 42

7- 36

7- 40

5- 66

5- 65

5- 73

7- 46

7- 48

7- 13

7- 29

7- 37

7- 32

7- 22

7- 33

7- 25

7- 31

7- 45

7- 51

7- 19

Part No.

A422 1603

A422 1604

A422 2030

A422 5201

A422 5202

A422 5203

A422 5204

A422 5207

A422 5208

A422 5212

A422 5252

A422 5255

A422 5255

A422 5270

A422 5270

A422 5300

A422 5310

A422 5350

A437 1026

A437 1065

A437 1115

A437 1120

A422 1385

A422 1390

A422 1396

A422 1501

A422 1503

A422 1504

A422 1505

A422 1506

A422 1507

A422 1600

A422 1601

A422 1602

A422 1603

Description

Original Exit Guide

Entrance Seal

Mylar - 0.125x14x45.5

Gear - 20T

Idle Shaft

Shaft/Gear - 16T

Gear - 57T

Gear - 25T

Feed-in Motor Bracket

Pick-up Lever

Pick-up Shaft

Pick-up Lever Plate

Seal - 2x8x14

Seal - 2x8x14

Cushion - 8x15x25

Decal - Inverter Guide Plate

Interface Harness

Harness - Pulse Generator

Feed-out Sensor Harness

Feed-in Motor Harness

Harness - Registration

Harness - Paper Size

Grounding Wire

Solenoid - DC24V

Solenoid - DC24V (Invertor)

Solenoid - DC24V (Invertor)

Photosensor

Photosensor

Feed-in Motor - DC10W

Feed-out Motor - DC10W

IC - HCTL-3

Upper Guide Plate

Lower Guide Plate

Drive Roller - Transport Belt

Bracket - Belt Tension Spring

Paper and

Index No.

5- 58

7- 24

5- 28

7- 16

5- 83

7- 26

9- 1

5- 17

5- 11

3- 41

3- 32

5- 87

3- 58

7- 6

5- 16

5- 10

7- 44

5- 84

5- 29

5- 30

5- 88

5- 26

3- 14

5- 75

5- 86

5- 82

5- 36

5- 78

5- 59

5- 79

5- 81

5- 51

5- 52

5- 50

3- 57

23

Part No.

A465 1074

A465 1075

A465 1076

A465 1077

A465 1080

A465 1110

A465 1118

A465 1125

A465 1126

A465 1127

A465 1179

A465 1195

A465 1337

A465 1338

A465 1389

A465 1393

A465 1397

A465 1398

A465 1499

A465 2010

A465 2017

A465 2025

A437 1178

A437 1190

A465 0656

A465 0657

A465 1027

A465 1057

A465 1066

A465 1067

A465 1068

A465 1069

A465 1070

A465 1072

A465 1073

Description

DF Harness Bracket

Grounding Plate

Original Table Ass'y - LT

Original Table Ass'y - A4

Guide Plate - Paper Feed

Pull-out Bracket

Mylar - 0.1x21x58

Mylar - 0.1x14.5x44

Cushion - 2.5x14x43

Harness Cover

Lever Spring

Lock Spring

Pin - 4x76.5

Pin - 4x77.5

Shaft - 3x25

Release Lever Knob

Release Lever

Fixing Plate - Feed-in Unit

Magnet Catch Spacer

Belt Support Roller

Angle Stopper

Grounding Plate

Transport Belt

DF Bracket

Mounting Bracket

Decal - Original Table - LT

Decal - Original Table - A4

Spacer - 0.2mm

Left Hinge

Spacer - 0.5mm

Lift Switch Actuator

Right Hinge

Misfeed Removal Decal - English

Decal - DIP Switch

Original Limit Decal

December 1, '90

Paper and

Index No.

3- 18

3- 1

3- 1

3- 54

7- 4

3- 53

3- 16

7- 1

3- 13

3- 31

3- 3

5- 90

5- 89

5- 95

5- 94

5- 97

3- 55

3- 37

3- 15

7- 52

3- 34

3- 60

3- 17

3- 47

3- 59

3- 59

5-200

5- 3

5- 98

5- 99

5- 93

5- 96

5-201

5- 92

5- 91

Part No.

A497 1500

A497 2024

A497 2025

5053 0447

5205 5250

5219 1957

5219 1957

5413 3903

5443 2657

5443 2660

5443 2712

5443 2713

5446 2824

5446 4577

5447 3655

5875 2088

5875 2088

5875 2088

5894 2176

5894 2229

5894 2229

5894 2747

A465 2031

A465 2050

A465 5180

A465 5190

A465 5190

A465 5210

A465 5213

A465 5260

A465 5260

A497 1015

A497 1077

A497 1101

A497 1152

Description

Decal - Set

Misfeed Removal Decal - Multi

IC - D27128A-2

DF Main Board

DF Main Board

Fiber Connector - 2P

Grounding Wire

Indication Board

Indication Board

Gear - 45Z

Mylar - 18x306

Belt Pressure Roller

Magnet - APS

I/F Harness Bracket

Paper Guide Mylar

Cushion - 5x5x3

Bushing - 6mm

LED Sensor Type - S

Stepped Screw - M4 MB5

Stepped Screw - M4

Pin - Transfer Guide Plate

Gear - 28Z

Spacer - 6x22x0.5mm

Cork Pad

Wave Washer

Screw - Duplex Guide Plate

Spring - Turn Plate MB5

Bushing - 4mm

Shoulder Screw - M4

Shoulder Screw - M4

Shoulder Screw - M4

Spring - Detent Arm

Solenoid Pin

Solenoid Pin

Mylar - Original Guides

Paper and

Index No.

3- 11

7- 35

5- 20

3- 30

3- 22

5- 32

7- 8

5- 64

5- 57

7- 23

3- 5

7- 11

7- 12

3- 63

7- 28

5- 8

5- 23

7- 55

5- 4

3- 10

3- 12

3- 9

3- 64

3- 13

9- 2

7- 9

9- *

9- 3

7- 53

5- 76

11- *

5- 85

5- 1

3- 40

3- 61

24

Part No.

5918 2163

5918 2164

5936 2480

5936 5221

5936 5348

5936 7901

Description

Clutch Spring

Clutch Sleeve

Magnet Catch Ass'y

Heat Sink

Thin Original Feed Switch

Decal - English

December 1, '90

Paper and

Index No.

5- 41

5- 42

3- 20

9- 4

3- 38

3- 52

Part No.

Description














0344 0060W Philips Truss Head Screw - M4x6

0344 0600D Philips Truss Head Screw - M4x6


0354 0060W Philips Truss Head Screw - M4x6


0573 0030E Hexagon Headless Set Screw - M3x3

0573 0060E Hexagon Headless Set Screw - M3x6

0584 0103W Hexgon With Flange Screw - M4x10

0632 0080G Parallel Key - 2x8mm

0632 0080G Parallel Key - 2x8mm

0632 0100G Pin - 2x10mm

0632 0100G Pin - 2x10mm

0632 0100G Pin - 2x10mm

0632 0140G Parallel Pin

0633 0120G Parallel Pin - 3x12

0701 0040B Flat Washer - M4

0701 0060B Flat Washer - M6

0704 0040C Toothed Washer - M4

0720 0025E Retaining Ring - M2.5

0720 0025E Retaining Ring - M2.5



Paper and

Index No.

5-110

7-114

5-111

7-115

7-117

3-112

7-113

5-109

7-112

3-111

5-123

3-107

3-115

3-101

5-115

3-102

5-113

5-114

3-104

5-112

7-116

3-114

5-105

7-107

3-116

5-101

7-106

5-104

7-103

3-121

7-102

3-100

5-100

7-104

3-122

25

Part No.

Description








0741 3505 Ball Bearing - 5x10x4

0741 3505

0741 3506

0741 3806

0742 3905

0742 3906

Ball Bearing - 5x10x4

Ball Bearing - 6x12x4 mm

Ball Bearing - 6x13x5mm

Ball Bearing - 5x13x4mm

Ball Bearing - 6mm

0801 1185

0801 1185

Philips Truss Head Screw - M4x8

Philips Truss Head Screw - M4x8

0805 3383 Bushing - M5

0950 4006W Philips Screw With Lock Washer - M4x6

0950 4006W Philips Screw With Lock Washer - M4x6

0951 3004W Philips Screw with Flat Washer - M3x4

0951 3006B Philips Screw with Flat Washer - M3x6

0951 3006W Philips Screw With Flat Washer - M3x6








1005 0843

1100 0051

1100 0340

1100 0340

1100 1169

1100 1190

1100 1253

Heat Sink - OSH2425SP

Connector

Closed Terminal

Closed Terminal

Fastening Receptacle

Socket - Mate-N-Lock

Pin - Mate-N-Lock

December 1, '90

Paper and

Index No.

5-124

3-105

5-103

7-100

9-101

15-101

3-120

13-101

13-102

15-102

13-103

3-108

7-101

5-121

5-122

7-126

5-106

3-106

7-105

5-102

7-108

3-103

7-110

3-109

5-107

7-109

3-110

5-108

7-111

5-119

7-125

5-120

3-118

7-124

3-117

Part No.

1102 1756

1102 1805

1102 1910

1102 1911

1102 1912

1102 1914

1102 1924

1102 1925

1102 1938

1102 1939

1102 1967

1102 2025

1102 2966

1103 0659

1103 0881

1103 1726

1103 1729

1103 1878

1104 0271

1104 0333

1105 0008

1105 0009

1100 1259

1100 1306

1100 1327

1100 1328

1100 1330

1100 1348

1100 1447

1101 0328

1102 0958

1102 1089

1102 1374

1102 1408

1102 1517

Description


Terminal

Contact

Contact

Socket Contact

Pin Contact


Connector Pin Contact

Connector - 2P

Connector - 3P

Connector - 4P

Connector - 1P

Connector - 4P

Connector - 2P

Connector - 4P

Connector - 2P

Connector - 3P

Connector - 4P

Connector - 6P

Connector - 2P

Connector - 3P

Connector - 2P

Connector - 3P

Connector - 6P

Pin Housing - 3P

Connector - HIF3BA-34PA

Connector - 34P

Connector - 4P

Connector - 4P

Connector - 7P

Connector - 2P

LSI Socket - 28P

Fuse Holder

Nylon Clip - 2N

Nylon Clip - 5N

Paper and

Index No.

15-108

9-104

13-116

9-105

9-106

9-107

9-108

9-110

9-111

5-117

5-118

13-107

11-103

13-108

13-109

13-110

13-111

13-112

13-113

13-114

13-115

11-104

15-107

11-101

13-104

11-102

15-109

13-105

15-103

9-102

9-103

15-106

15-104

13-106

15-105

26

Part No.

1401 0832

1403 0236

1403 0237

1403 0308

1403 0388

1407 0602

1407 0604

1407 1026

1407 1334

1407 1348

1407 1535

1408 0076

1408 0408

1408 0521

1408 0578

1503 0070

1600 0239

1600 0544

1600 0576

1601 1732

1601 7326

1601 8145

1105 0009

1105 0011

1105 0199

1105 0199

1106 0222

1106 0430

1107 0413

1107 0413

1204 0883

1204 1319

1204 1385

1401 0282

1401 0329

Description

Nylon Clip - 5N

Nylon Clip - 8N

Clamp

Clamp

Cord Clamp

Bushing - 13mm

Fuse - 3A 125V

Fuse - 3A 125V

DIP Switch

Microswitch

Push Switch

Transistor - 2SB1020

Transistor Array - MP4503

Diode - DSA1A1

L.E.D. - MU02-520

L.E.D. - MU20-220

LED - TLR-102A

Photocoupler - ON3111

IC - TC4040BP

IC - TC4049BP

IC - SN74LS373N

IC - UPD7810G

IC - TD62304AP

IC - TD62308AP

IC - UPC14312H

IC - PST518A

IC - M51971L

IC - HA17339

Ceramic Oscillator - 10MHz

Resistor - 0.47

Ω

±5% 1W

Resistor - 1k

Ω

±10% 1W

Resistor - 33

Ω

±10% 5W

Resistor - 390

Ω

±5% 1W

Resistor Array - 10k Ω

Variable Resistor - 5k

Ω

0.5W

December 1, '90

Paper and

Index No.

9-126

9-127

9-128

9-129

9-130

9-131

9-132

9-133

9-134

9-135

9-136

9-117

11-105

11-106

9-118

9-119

9-120

9-121

9-122

9-123

9-124

9-125

7-118

7-119

5-116

7-121

3-119

7-120

7-123

9-112

9-113

7-122

9-114

9-115

9-116

Part No.

1606 0658

1606 1308

1606 1326

1606 1348

1606 1451

1606 1452

1607 0116

1610 0035

1610 0047

1610 0053

1610 0057

1610 0065

1610 0067

1610 0071

1610 0073

1610 0079

1610 0107

1610 0286

1611 4103

1611 4121

1611 4229

1611 4272

1601 8147

1601 8148

1602 0953

1604 1358

1604 1378

1604 1379

1604 1380

1604 1381

1604 1382

1604 1383

1604 1386

1604 1390

1605 0141

Description


Ω

0.5W


Ω

0.5W

Coil - 800uH 2.5A

Capacitor - 1000mF 10V

Capacitor - 1mF 50V

Capacitor - 2.2uF ±20% 50V

Capacitor - 3.3uF 50V




Capacitor - 100uF ±20% 50V


Capacitor - 4700PF 50V


Capacitor - 27pF 50V

Capacitor - 100pF 50v ±10%




Ferrite Core

Resistor - 100

Ω

1/8W ±5%

Resistor - 330

Ω

1/8W ±5%

Resistor - 1k

Ω

1/8W ±5%

Resistor - 1.5k Ω 1/8W ±5%

Resistor - 3.3K

Ω

1/8W ±5%

Resistor - 4.7k

Ω

1/8W ±5%

Resistor - 10k

Ω

±5% 1/8W

Resistor - 12K

Ω

1/8W ±5%

Resistor - 22k

Ω

1/8W ±5%

Resistor - 1M

Ω

1/8W ±5%

Capacitor - 100pF 50V ±10%

Resistor - 10k

Ω

1/4T ±5%

Resistor - 120

Ω

1/4T ±5%

Resistor - 2.2 Ω 1/4W ±5%

Resistor - 2.7k

Ω

1/4T ±5%

Paper and

Index No.

9-161

9-162

9-163

9-164

9-165

9-166

9-167

9-168

9-169

9-170

9-171

9-151

9-152

9-153

9-154

9-155

9-156

13-119

9-157

9-158

9-159

9-160

9-137

9-138

9-139

9-140

9-141

9-142

9-143

9-144

9-145

9-146

9-147

9-148

9-150

27

Part No.

1611 4393

1611 4472

1611 4563

Description

Resistor - 39k

Ω

1/4T ±5%

Resistor - 4.7k

Ω

±5% 1/4W

Resistor - 56k

Ω

1/4T ±5%

December 1, '90

Paper and

Index No.

9-172

9-173

9-174

P/N A0486684

FACTORY SETTING

SP MODE

NUMBER

41

42

43

44

47

48

FACTORY SETTING DATA

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

128 129 130 131 132 133 134 135 136

137 138 139 140 [ ]

SERIAL No.

TEST POINTS

Copier Main Board

NUMBER

TP101 GND

FUNCTION

TP102 VCC (+5V)

TP103 ADS (Auto Image Density Sensor)


VR101.)

TP104 GND

TP105 AVSS (GND)

TP106 GND

TP107 HT (23 o

C 96k Ω )

TP108 BIN (Development Bias Feed Back)

TP109 GIN (Grid Voltage Feed Back)

TP110 PSE (ID sensor voltage)


VR102.

TP111 EXPO (Exposure Lamp Voltage)

TP112 GND

JP103 Key Counter (Cut this jumper wire when installing the key counter on the machine.)

DF Main Board

NUMBER

TP102 +5V

TP103 GND

TP104 Factory Use

TP105 +12V

TP106 +24V

TP107 Factory Use

FUNCTION

DIP SWITCHES

Copier Main Board

NORMAL DIP

SWITCH

101-1

101-2

101-3

101-4

OFF Free Run

FUNCTION

OFF Forced Start (Ready temp.

by-passed) Factory Use

OFF Clear Counter and/or memory

OFF 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.)

All indicators ON

Duplex Main Board

DIP

SWITCH

FACTORY

SETTING

700-1

700-2

700-3

700-4

700-5

700-6

700-7

700-8

OFF

OFF

OFF

OFF

FUNCTION

Jogger Position Adjustment

(0.5mm per step)

Refer to the Data Table.

Factory Use

Data Table

0

1

0

1

0

1

0

1

0

1

0

1

DIP SWITCH 700 (0:OFF, 1:ON) ADJUSTMENT VALUE

1

0

1

0

1

2

0

0

1

1

3

0

0

0

0

4

0

0

0

0

-3.5mm

-3.0mm

-2.5mm

-2.0mm

0

0

1

1

0

0

1

1

0

0

1

1

1

1

1

1

0

0

0

0

1

1

1

1

0

0

0

0

1

1

1

1

1

1

1

1

-1.5mm

-1.0mm

-0.5mm

±

0

0.5mm

1.0mm

1.5mm

2.0mm

2.5mm

3.0mm

3.5mm

4.0mm

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

VRC

VRG

VRB

FUNCTION

Adjusts Main Charge Current

Adjusts Standard Grid Voltage

Adjusts Standard Dev. Bias

(Factory Use)

Power Pack (T&S)

NUMBER

VRT

VRD

FUNCTION

Adjusts Transfer Current

Adjusts Separation Current

AC Drive Board

NUMBER

VR401 Factory Use

FUNCTION

DF Main Board

NUMBER

VR101 Factory Use

FUNCTION

VR102 Original leading edge registration adjustment (One sided original mode)

VR103 Original leading edge registration adjustment (Two sided original mode)

VR106 Factory Use

SP MODE OVERVIEW

5

6

8

9

20

21

22

23

24

25

27

28

29

30

31

32

16

17

19

10

11

12

15

SP Mode Data

Movement Check

Exposure Lamp OFF

Jam Detection OFF

Input Check (Refer to Sensor/Switch Data Check Table)

-

-

When

Performed

EM

EM

EM

Output Check (Refer to Electrical Component Check Table) EM

Installation and/or Sales Demonstration

Color Developer Initial Setting -

All Indicators ON

220V/240V Conversion 0: 220V

1: 240V

-

User Requests

Auto Reset Time

Count Up/Down

Auto Feed Station Shift

ADS Priority

APS Priority (When turning on the main switch) (A054 copier only)

APS Priority (When the original is set on the

DF)

SADF Shut-off Time

0: 1 min.

1: 3 min.

2: None

0: Up

1: Down

0: Auto Shift

1: Manual

0: ADS

1: Manual

0: APS

1: Manual

0: APS

1: Manual

0: 5 sec.

1: 60 sec.

0: No 1: Yes ADF Free Size

Factory Used

Margin Adjustment in Duplex Mode

A3 (DLT) Double Counter

Sort Priority

Fusing Temperature Control

0: Yes 1: No

0: Normal

1: Double

0: Manual

1: Auto Sort

0: ON/OFF

1: Phase

Copy Quality Check and/or Adjustment

Black Toner Supply Mode

Black Toner Supply Ratio (Detect Mode)

Black Toner Supply Ratio (Fixed Mode)

0: Detect Mode

1: Fixed Mode

0: 15% 1: 7%

2: 30% 3: 60%

0: 7.0% 1 3.5%

2:10.5% 3: 14.0%

Replacement

-

Installation

-

-

-

-

-

-

-

-

-

-

-

EM or PM

EM or PM

EM or PM

51

52

54

55

56

41

42

43

44

47

48

49

59

61

62

63

64

65

66

67

68

69

70

71

33

34

35

37

73

SP Mode

ID Sensor Bias (Black)

Data

0:-260V 1:-220V

2:-280V 3:-300V

When

Performed

EM or PM

ADS Level

Black Toner ID Detection

Black Bias Adjustment

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 board)

Bias Voltage Check

Drum Wear Compensation Setting

ID Sensor Grid Voltage Setting

Toner Supply Unit Initial Setting

Black Toner Density Level Display

Black Developer Initial Setting

Drum Initial Setting

Vr Correction Ratio

Vr Forced Detection

OPC Counter

Options and Others

Color Toner Supply Ratio (Fixed Mode)

Sorter Operation

Color Copy Counter

0: Normal

1: Darker

2: Lighter

0: 10 copies

1: 5 copies

0: Normal

1: Darkest

2: Darker

3: Lighter

4: Lightest

0 – 15

0 – 15

0 – 15

0 – 15

0 – 15

100 – 150

175

°

C – 190

°

C

4.0

2.5

±

±

-

0.2 V

-

-

0.1 V

EM or PM

EM

EM and PM

EM

-

-

EM and PM

-

EM and PM

-

0: 1/10h

1: 1/20h

Factory Use (The data must be "7")

-

0 – 4

-

-

-

-

-

-

-

-

Installation

-

Replacement

-

-

-

0: 14% 1: 7%

2: 21% 3: 28%

0: No

1: Sorter (1)

2: Sorter (2)

-

EM or PM

Installation

EM or PM

74

75

76

77

79

80

81

82

87

88

89

93

98

99

100

101

102

105

106

120

121

122

123

124

125

130

131

SP Mode

Color Toner ID Detection

ID Sensor Bias (Color)

Sorter Bin Capacity

ADF Odd Number Originals (Duplex Mode)

Color Bias Adjustment

Red Toner Density Level Display

Green Toner Density Level Display

Blue Toner Density Level Display

PM Interval Setting

PM Counter Display

PM Counter Reset

Maximum Copy Quantity

Clear Mode

Clear Counters

Clear All Memory

Copy and Original Counters

First Station Copies

1st Paper Tray Copies

0: No

0: No

1: Yes

1: Yes

2nd Paper Tray Copies (A054 copier only)

Duplex Copies

DF Originals

Service Call Counters

Service Calls (Total)

Optics Section Service Calls

Exposure Lamp Service Calls

Not Used

Fusing Section Service Calls

Service Calls for Interface Communication

Misfeed Counters

Misfeeds (Total) -

Number of Misfeeds by Location

1: Paper Feed 2: Exit 3: Sorter 4: DF 5: Duplex

-

-

-

-

-

-

-

-

-

Data

0: 5 copies

1: 10 copies

0: Normal

1: Lighter

2: Darker

3: Darkest

0: No Limit

1: Limit

0: ON

1: OFF

0: Normal

1: Darkest

2: Darker

3: Lighter

4: Lightest

-

-

-

0: No PM

1: 40K

2: 60K

3: 80K

4: 100K

-

-

1 – 99

When

Performed

EM

EM or PM

EM

User

Request

EM or PM

EM

-

-

-

User

Request

-

-

EM or PM

EM

EM

EM

SERVICE CALL AND USER CODE TABLE

SERVICE CALL CODE

E-CODE

11

12

13

21

22

28

29

2A

2B

52

53

55

CONTENTS


The feed back signal beomes 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.


The feed back 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.

Zero Cross Signal Error

The CPU does not receive the zero cross signal within

0.56 second.




The scanner home position sensor still on (HIGH) 1.0

second after the scanner starts.


The lens home position sensor remains off (LOW) 3.5

seconds after the lens move to the home position.


The lens home position sensor is still on (HIGH) 3.5

seconds after the lens leaves the home position.


The 4th/5th mirror home position sensor is still on (HIGH)

2.5 seconds after the 4th/5th mirror assembly moves to the home position.


The 4th/5th mirror home position sensor is still off (LOW)

2.5 seconds after the 4th/5th mirror assembly leaves the home position.

Fusing Warm-up Error


Fusing Overheat

The temperature detected by the thermistor becomes higher than 240 o C.

Fusing Thermistor Open


SP Mode No.

(SC Counter)

SP Mode #122

(Exposure

Lamp)

–

SP Mode #121

(Optics)

SP Mode #124

(Fusing

Section)

Refer to

NOTE b)

E-CODE

70

80

81

82

83

CONTENTS SP Mode No.

(SC Counter)

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


Interface Board Error




LOW as the duplex main board is driving the jogger fences outward.



HIGH as the duplex main board is driving the jogger fences inward.

–

SP Mode #125

(Interface

Comunication)

NOTE: a) E-codes (E1 to E8) are displayed in the copy counter. To display the two digits, press the Enter key.

Example:

When the machine detects the E11 condition, E1 is displayed in the copy countrer. Hold down the Enter key, and "11" is displayed in the copy counter.

b) When the service call (E5) conditions occur, for safety reason they cannot be cleared by turning off/on the main switch. The following procedure must be performed to clear these service call conditions:




USER CODE

U-CODE

1

2

3

4

5

CONTENTS

Right Cover Open

Key Counter Not Set

Development Unit Not Set

Sorter Open

Cassette Lift Sensor Not ON (Cassette is not properly set.)

AD120 (A491)

PARTS CATALOG

INTRODUCTION



1. DUPLEX UNIT I (A491) ............................................................................. 2

2. DUPLEX UNIT II (A491) ............................................................................ 5

3. DUPLEX MAIN BOARD (A491) ................................................................. 7

4. DUPLEX HARNESS (A491) ...................................................................... 9

5. SENSOR HARNESS (A491) .................................................................... 11

6. DECAL AND DOCUMENT (A491) ........................................................... 13

Parts Index .................................................................................................. 15

1

1. DUPLEX UNIT I (A491) December 1, '90

2

1. DUPLEX UNIT I (A491)

Index

No.

Part No.

Description

1 AG05 1067 Paper Removal Handle

2 AF02 2032 Turn Driven Roller


4 AF02 2044 Large Driven Roller

5 AA14 3076 Stepped Screw - M4

6 A491 4740 Guide Plate Link

7 A491 4750 Lower Guide Plate

8 A491 4765 Paper Holding Bar

9 A491 4720 Duplex Stay

10 AF02 0153 Paper Transport Roller

11 A491 4715 Paper End Actuator

12 5304 1639 Bushing - 8mm

13 AF02 0156 Stack Roller

14 AF02 2045 Stack Roller Holder

15 AF03 1008 Feed Roller

16 A491 4825 Holder - Large Driven Roller

17 AA14 0292 Feed Roller Shaft

18 A491 4759 Guide Plate

19 AF02 5013 Junction Gate

20 A491 4789 Inverter Guide Plate

21 A491 4790 Mylar Seal - Inverter Guide Plate

22 A491 4770 Guide Plate Paper Feed

23 AA14 5119 Jog Plate Shaft

24 A491 4786 Jog Plate

25 A491 4783 Mylar Seal - 0.1x18x23

26 AW02 0023 Paper Entrance Sensor

27 A491 4785 Bracket - Paper Entrance Sensor

28 A491 5302 Intermediate Harness

29 AA06 0245 Separation Roller Spring

30 A491 4815 Separation Roller Bracket

31 A491 4780 Mylar Seal - 0.1x23.5x24

32 A491 4817 Guide Pin - Separation Roller

33 AF03 2003 Separation Roller

34 AA14 5117 Separation Roller Shaft

35 A491 4810 Separation Roller Holder

Q'ty per

Assembly

1

1

2

1

1

1

1

1

1

2

1

1

1

1

1

1

2

2

4

1

2

1

1

2

1

1

1

3

1

5

1

2

2

1

1

3

Index

No.

Part No.

Description

36 5447 2681 Snap Ring

37 A491 4625 Upper Left Cover

38 A491 4903 Upper Front Cover

39 A491 4910 Decal - Removing Misfed Paper

40 A491 4705 Stopper - Bottom Plate Clutch

41 AA08 0022 Bushing - 4x7x5mm

42 AB01 3425 Gear - 28Z

43 AB01 7162 Gear - 14Z/36Z

44 AB01 3426 Gear - 22Z

45 AB04 0008 Bottom Plate Clutch

46 A491 5205 Transport Motor - DC30V

47 A491 4700 Transport Motor Bracket

48 AB01 7163 Gear - 14Z/28Z

49 AB01 7161 Gear - 14Z/45Z

50 AB01 3424 Gear - 28Z

51 A491 4725 Junction Gate Hook

52 5442 3233 Spring - Drive Wheel


54 A491 4832 Fusing Gate Solenoid

A491 5220 x/o MB1

55 5443 2668 Bushing

56 AW02 0022 Photointerruptor

57 AA11 1010 Paper Entrance Feeler

58 A491 4710 Bracket - Paper End Sensor

59 AA11 1011 Paper End Feeler




63 A491 4761 Guide Plate Mylar - 0.188x12x25

64 A491 4831 Mylar Seal - 0.188x9x33

MB1 (Added)

December 1, '90

Q'ty per

Assembly

1

2

1

1

1

1

1

2

1

1

2

1

1

1

2

1

1

1

1

1

4

1

1

1

1

1

1

1

2

1

Index

No.

Part No.

Description

101 0313 0040B Philips Pan Head Screw - M3x4




105 0353 0060F Philips Truss Head Screw - M3x6


107 0632 0140E Parallel Pin - M2x14





112 0805 3366 Bushing - 6mm



115 1105 0199 Clamp

Q'ty per

Assembly

Index

No.

Part No.

Description

Q'ty per

Assembly

4

2. DUPLEX UNIT II (A491) December 1, '90

5

2. DUPLEX UNIT II (A491)

Index

No.

Part No.

Description

1 A491 5300 Duplex Harness

2 A491 5205 Transport Motor - DC30V

3 A491 5101 Duplex Main Board

4 A491 5301 Sensor Harness

5 A491 5210 Jog Motor - DC24V

6 A491 4660 Jog Sensor Bracket

7 AW02 0022 Photointerruptor

8 A491 4890 Harness Clamp Plate

9 AF01 7005 End Jog Fence

10 A491 4650 Jog Registration Plate

11 AF01 6026 Front Jog Fence

12 AF01 6027 Rear Jog Fence

13 AA14 3269 Guide Pin - M6

14 A491 4690 Bottom Plate Hook

15 AA06 0257 Spring - Bottom Plate Clutch

16 AA14 0291 Bottom Plate Shaft

17 A491 4695 Pressure Plate - Bottom Plate

18 AG07 0004 Magnet Catch Ass’y

19 A491 4685 Bottom Plate

20 AF01 3002 Bottom Plate Pad

21 A491 4611 Duplex Tray

22 AB01 7165 Gear - 16Z/22Z

23 A491 4640 Side Fence Rack

24 A491 4630 Bottom Cover

25 AB01 7164 Gear - 21Z/64Z

26 A491 4645 End Fence Rack

27 A491 4950 Front Cover (USA)

27 A491 4951 Front Cover (EU)

28 AF02 0155 Lower Turn Roller

29 AA08 0022 Bushing - 4x7x5mm

30 AB01 3427 Gear - 14Z


32 A491 4880 Fusing Gate Lever

33 A491 4860 Upper Turn Guide Plate

34 A491 4885 Turn Roller Pulley

Q'ty per

Assembly

1

2

1

4

1

1

2

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

6

1

1

1

1

1

1

1

1

2

1

1

6

Index

No.

Part No.

Description

35 AA04 2004 Turn Roller Drive Belt

36 AF02 0154 Upper Turn Roller

37 A491 4870 Lower Turn Guide Plate

38 AF02 2032 Turn Driven Roller

39 AA14 3070 Shoulder Screw - M2x2

40 A491 4835 Connector Bracket

41 A491 4634 Dust Cover

42 A491 4915 Dust Cover Decal

43 A491 4647 Cushion - Side Fence Rack

44 AA16 2035 Cushion - Paper Tray

MB2 (Added)

45 A491 4550 Turn Guide Plate A’ssy

46 A491 4686 Cushion - Tray Bottom Plate





105 0344 0080F Philips Truss Head Screw - M4x8


107 0434 0122W Pan Head Self-tapping Screw - M4x12



110 0805 0073 Retaining Ring - M5


December 1, '90

Q'ty per

Assembly

1

1

2

1

1

1

1

1

1

6

1

1

3. DUPLEX MAIN BOARD (A491) December 1, '90

7

3. DUPLEX MAIN BOARD (A491)

Index

No.

Part No.

Description

* A491 5101 Duplex Main Board

1 A491 5105 IC - uPD7811H

101 1102 4203 CT Header - 4P

102 1102 4205 Connector - 6P

103 1102 4497 Connector - 13P

104 1103 0441 Pin Terminal - 4P

105 1103 1770 Connector - 4P

106 1103 1772 Pin Header - 6P

107 1204 1482 DIP Switch

108 1400 0208 Transistor - 2SC945

109 1401 0815 Diode - 1S1588

Q'ty per

Assembly

1

1

8

Index

No.

Part No.

Description

110 1402 0277 Zener Diode - 1Z12

111 1402 0841 Diode - RK34

112 1407 1348 IC - TD62304AP

113 1407 1535 IC - TD62308AP

114 1407 3478 IC - SLA7024M

115 1408 0258 IC - AN6914

116 1503 0071 Oscillator - 12MHz

117 1600 1295 Resistor - 0.82

Ω

2W ±5%

118 1601 7354 Resistor Array - 10K

Ω

119 1601 7374 Resistor Array - 4.7K

Ω

120 1602 7032 Noise Filter - 2200pF 250V 7A

121 1604 1363 Capacitor - 10uF ±20% 25V

122 1604 1367 Capacitor - 100uF ±20% 25V

123 1604 1379 Capacitor - 2.2uF ±20% 50V

124 1604 1386 Capacitor - 100uF ±20% 50V

125 1606 1129 Capacitor - 30pF ±5% 50V

126 1606 1329 Capacitor - 330pF ±10% 50V

127 1606 1330 Capacitor - 470pF ±10% 50V

128 1606 1333 Capacitor - 2200pF -20% +80% 50V

129 1606 1336 Capacitor - 10000pF -20% +80% 50V

130 1606 1458 Capacitor - 0.1uF -20% +80% 50V

131 1611 4101 Resistor - 100

Ω

1/4T ±5%

132 1611 4102 Resistor - 1K

Ω

1/4T ±5%

133 1611 4103 Resistor - 10K Ω 1/4T ±5%

134 1611 4105 Resistor - 1M

Ω

1/4T ±5%

135 1611 4181 Resistor - 180

Ω

1/4T ±5%

136 1611 4223 Resistor - 22K

Ω

1/4T ±5%

137 1611 4242 Resistor - 2.4K

Ω

1/4T ±5%

138 1611 4332 Resistor - 3.3K

Ω

1/4T ±5%

139 1611 4391 Resistor - 390

Ω

1/4T ±5%

140 1611 4472 Resistor - 4.7K

Ω

±5% 1/4W

141 1611 4473 Resistor - 47K

Ω

1/4T ±5%

142 1611 4511 Resistor - 510

Ω

1/4T ±5%

143 1611 4513 Resistor - 51K Ω 1/4T

144 1604 1371 Capacitor - 1000uF 25V

December 1, '90

Q'ty per

Assembly

4. DUPLEX HARNESS (A491) December 1, '90

9

4. DUPLEX HARNESS (A491)

Index

No.

Part No.

* A491 5300 Duplex Harness

Description

Q'ty per

Assembly

1

Index

No.

Part No.

101 1100 1247 Terminal


103 1100 1534 Pin Contact

104 1102 1831 Connector - 4P

105 1102 1984 Connector - 4P

106 1102 4800 Connector - 8P

Description

December 1, '90

Q'ty per

Assembly

10

5. SENSOR HARNESS (A491) December 1, '90

11

5. SENSOR HARNESS (A491)

Index

No.

Part No.

* A491 5301 Sensor Harness

Description

Q'ty per

Assembly

1

Index

No.

Part No.

Description

101 1102 4213 Connector - 2P

102 1102 4214 CT Receptacle - 3P

103 1102 4215 Connector - 4P

104 1102 4473 CT Connector - 2P

105 1102 4484 Connector - 13P

106 1102 4559 Connector - 3P

December 1, '90

Q'ty per

Assembly

12

6. DECAL AND DOCUMENT (A491) December 1, '90

13

6. DECAL AND DOCUMENT (A491)

Index

No.

Part No.

Description

1 A491 4910 Decal - Removing Misfed Paper

1 A491 6060 Multi Decal - Removing Mifed Paper

2 A491 4915 Dust Cover Decal

Q'ty per

Assembly

1

1

1

Index

No.

Part No.

Description

December 1, '90

Q'ty per

Assembly

14

PARTS INDEX

Part No.

A491 4710

A491 4715

A491 4720

A491 4725

A491 4730

A491 4740

A491 4750

A491 4759

A491 4761

A491 4765

A491 4770

A491 4780

A491 4783

A491 4785

A491 4786

A491 4789

A491 4790

A491 4550

A491 4611

A491 4625

A491 4630

A491 4634

A491 4640

A491 4645

A491 4647

A491 4650

A491 4660

A491 4670

A491 4680

A491 4685

A491 4686

A491 4690

A491 4695

A491 4700

A491 4705

Description

Turn Guide Plate A'ssy

Duplex Tray

Upper Left Cover

Bottom Cover

Dust Cover

Side Fence Rack

End Fence Rack

Cushion - Side Fence Rack

Jog Registration Plate

Jog Sensor Bracket

Front Side Plate

Rear Side Plate

Bottom Plate

Cushion - Tray Bottom Plate

Bottom Plate Hook

Pressure Plate - Bottom Plate

Transport Motor Bracket

Stopper - Bottom Plate Clutch

Bracket - Paper End Sensor

Paper End Actuator

Duplex Stay

Junction Gate Hook

Upper Guide Plate

Guide Plate Link

Lower Guide Plate

Guide Plate

Guide Plate Mylar - 0.188x12x25

Paper Holding Bar

Guide Plate Paper Feed

Mylar Seal - 0.1x23.5x24

Mylar Seal - 0.1x18x23

Bracket - Paper Entrance Sensor

Jog Plate

Inverter Guide Plate

Mylar Seal - Inverter Guide Plate

3- 31

3- 25

3- 27

3- 24

3- 20

3- 21

3- 58

3- 11

3- 9

3- 51

3- 3

3- 6

3- 7

3- 18

3- 63

3- 8

3- 22

Paper and

Index No.

5- 45

5- 21

3- 37

5- 24

5- 41

5- 23

5- 26

5- 43

5- 10

5- 6

3- 53

3- 60

5- 19

5- 46

5- 14

5- 17

3- 47

3- 40

16

Part No.

A491 4910

A491 4910

A491 4915

A491 4915

A491 4950

A491 4951

A491 5101

A491 5101

A491 5105

A491 5205

A491 5205

A491 5210

A491 5220

A491 5300

A491 5300

A491 5301

A491 5301

A491 5302

A491 6060

A491 4810

A491 4815

A491 4817

A491 4825

A491 4831

A491 4832

A491 4835

A491 4860

A491 4870

A491 4880

A491 4885

A491 4890

A491 4903

Description

Separation Roller Holder

Separation Roller Bracket

Guide Pin - Separation Roller

Holder - Large Driven Roller

Mylar Seal - 0.188x9x33 MB1 (Added)

Fusing Gate Solenoid

Connector Bracket

Upper Turn Guide Plate

Lower Turn Guide Plate

Fusing Gate Lever

Turn Roller Pulley

Harness Clamp Plate

Upper Front Cover

Decal - Removing Misfed Paper

Decal - Removing Misfed Paper

Dust Cover Decal

Dust Cover Decal

Front Cover (USA)

Front Cover (EU)

Duplex Main Board

Duplex Main Board

IC - uPD7811H

Transport Motor - DC30V

Transport Motor - DC30V

Jog Motor - DC24V x/o MB1

Duplex Harness

Duplex Harness

Sensor Harness

Sensor Harness

Intermediate Harness

Multi Decal - Removing Mifed Paper

December 1, '90

Paper and

Index No.

5- 5

3- 54

5- 1

9- *

5- 4

11- *

3- 28

13- 1

3- 39

13- 1

5- 42

13- 2

5- 27

5- 27

5- 3

7- *

7- 1

3- 46

5- 2

3- 35

3- 30

3- 32

3- 16

3- 64

3- 54

5- 40

5- 33

5- 37

5-32•

5- 34

5- 8

3- 38

AA04 2004

AA06 0245

AA06 0257

AA08 0022

AA08 0022

AA11 1010

AA11 1011

AA14 0291

AA14 0292

AA14 3070

AA14 3076

AA14 3076

AA14 3076

AA14 3269

AA14 3287

AA14 5117

AA14 5119

AA16 2035

AB01 3424

AB01 3425

AB01 3426

AB01 3427

AB01 7161

AB01 7162

AB01 7163

AB01 7164

AB01 7165

AB04 0008

AF01 3002

AF01 6026

AF01 6027

AF01 7005

AF02 0153

AF02 0154

AF02 0155

Turn Roller Drive Belt

Separation Roller Spring

Spring - Bottom Plate Clutch

Bushing - 4x7x5mm

Bushing - 4x7x5mm

Paper Entrance Feeler

Paper End Feeler

Bottom Plate Shaft

Feed Roller Shaft

Shoulder Screw - M2x2

Stepped Screw - M4

Stepped Screw - M4

Stepped Screw - M4

Guide Pin - M6

Stepped Screw - M3

Separation Roller Shaft

Jog Plate Shaft

Cushion - Paper Tray MB2 (Added)

Gear - 28Z

Gear - 28Z

Gear - 22Z

Gear - 14Z

Gear - 14Z/45Z

Gear - 14Z/36Z

Gear - 14Z/28Z

Gear - 21Z/64Z

Gear - 16Z/22Z

Bottom Plate Clutch

Bottom Plate Pad

Front Jog Fence

Rear Jog Fence

End Jog Fence

Paper Transport Roller

Upper Turn Roller

Lower Turn Roller

3- 48

5- 25

5- 22

3- 45

5- 20

5- 11

5- 12

5- 9

3- 10

5- 36

5- 28

5- 13

3- 62

3- 34

3- 23

5- 44

3- 50

3- 42

3- 44

5- 30

3- 49

3- 43

5- 35

3- 29

5- 15

3- 41

5- 29

3- 57

3- 59

5- 16

3- 17

5- 39

3- 5

3- 61

5- 31

17

AF02 0156

AF02 2032

AF02 2032

AF02 2044

AF02 2045

AF02 5013

AF03 1008

AF03 2003

AG05 1067

AG07 0004

AW02 0022

AW02 0022

AW02 0023

5304 1639

5442 3233

5443 2668

5447 2681

Stack Roller

Turn Driven Roller

Turn Driven Roller

Large Driven Roller

Stack Roller Holder

Junction Gate

Feed Roller

Separation Roller

Paper Removal Handle

Magnet Catch Ass'y

Photointerruptor

Photointerruptor

Paper Entrance Sensor

Bushing - 8mm

Spring - Drive Wheel

Bushing

Snap Ring

December 1, '90

3- 1

5- 18

3- 56

5- 7

3- 26

3- 12

3- 52

3- 55

3- 36

3- 13

3- 2

5- 38

3- 4

3- 14

3- 19

3- 15

3- 33

Part No.

Description

0313 0040B Philips Pan Head Screw - M3x4







0344 0080F Philips Truss Head Screw - M4x8


0353 0060F Philips Truss Head Screw - M3x6



0434 0122W Pan Head Self-tapping Screw - M4x12

0632 0140E Parallel Pin - M2x14







0805 0073 Retaining Ring - M5

0805 3366 Bushing - 6mm




1100 1247 Terminal

1100 1329

1100 1534

Socket Contact

Pin Contact

1102 1831

1102 1984

1102 4203

1102 4205

1102 4213

1102 4214

1102 4215

Connector - 4P

Connector - 4P

CT Header - 4P

Connector - 6P

Connector - 2P

CT Receptacle - 3P

Connector - 4P

Paper and

Index No.

3-114

9-101

9-102

9-103

9-104

9-105

7-101

7-102

11-101

11-102

11-103

3-107

3-108

5-108

3-109

5-109

3-110

3-111

5-110

3-112

3-113

5-111

3-101

3-102

5-101

5-102

3-103

5-103

5-104

5-105

3-104

3-105

3-106

5-106

5-107

18

Part No.

1402 0841

1407 1348

1407 1535

1407 3478

1408 0258

1503 0071

1600 1295

1601 7354

1601 7374

1602 7032

1604 1363

1604 1367

1604 1371

1604 1379

1604 1386

1606 1129

1606 1329

1606 1330

1606 1333

1606 1336

1606 1458

1611 4101

1102 4473

1102 4484

1102 4497

1102 4559

1102 4800

1103 0441

1103 1770

1103 1772

1105 0199

1204 1482

1400 0208

1401 0815

1402 0277

Description

CT Connector - 2P

Connector - 13P

Connector - 13P

Connector - 3P

Connector - 8P

Pin Terminal - 4P

Connector - 4P

Pin Header - 6P

Clamp

DIP Switch

Transistor - 2SC945

Diode - 1S1588

Zener Diode - 1Z12

Diode - RK34

IC - TD62304AP

IC - TD62308AP

IC - SLA7024M

IC - AN6914

Oscillator - 12MHz

Resistor - 0.82 W 2W ± 5%

Resistor Array - 10K W

Resistor Array - 4.7K W

Noise Filter - 2200pF 250V 7A

Capacitor - 10uF

±

20% 25V

Capacitor - 100uF ± 20% 25V


Capacitor - 2.2uF ± 20% 50V

Capacitor - 100uF ± 20% 50V

Capacitor - 30pF ± 5% 50V



Capacitor - 2200pF -20% +80% 50V

Capacitor - 10000pF -20% +80% 50V

Capacitor - 0.1uF -20% +80% 50V

Resistor - 100 W 1/4T ± 5%

December 1, '90

Paper and

Index No.

7-122

7-144

7-123

7-124

7-125

7-126

7-127

7-128

7-129

7-130

7-131

7-111

7-112

7-113

7-114

7-115

7-116

7-117

7-118

7-119

7-120

7-121

11-104

11-105

7-103

11-106

9-106

7-104

7-105

7-106

3-115

7-107

7-108

7-109

7-110

Part No.

1611 4102

1611 4103

1611 4105

1611 4181

1611 4223

1611 4242

1611 4332

1611 4391

1611 4472

1611 4473

1611 4511

1611 4513

Description

Resistor - 1K W 1/4T ± 5%


Resistor - 1M W 1/4T ± 5%

Resistor - 180 W 1/4T ± 5%


Resistor - 2.4K W 1/4T ± 5%

Resistor - 3.3K W 1/4T ± 5%

Resistor - 390 W 1/4T ± 5%

Resistor - 4.7K W ± 5% 1/4W


Resistor - 510 W 1/4T ± 5%

Resistor - 51K W 1/4T

Paper and

Index No.

7-132

7-133

7-134

7-135

7-136

7-137

7-138

7-139

7-140

7-141

7-142

7-143

Part No.

Description

December 1, '90

Paper and

Index No.

19

POWER SUPPLY UNIT (A494)

PARTS CATALOG

INTRODUCTION



1. POWER SUPPLY UNIT (A494) ................................................................. 2

2. INTERFACE BOARD (A494) ..................................................................... 4

3. DC DRIVE BOARD (A494) ........................................................................ 6

4. POWER SUPPLY UNIT HARNESS (A494) ............................................... 8

Parts Index .................................................................................................. 10

1

June 30.'91

1. POWER SUPPLY UNIT (A494)

2

1. POWER SUPPLY UNIT (A494)

Index

No.

Part No.

Description

1 A494 5803 Bracket - DF Power Supply Cord

2 A494 5101 Interface Board

3 A494 5301 Power Supply Unit Harness - 115V

3 A494 5310 Power Supply Unit Harness - 220/240V

4 A494 5415 DC Drive Board - 115V

4 A494 5416 DC Drive Board - 220/240V

MB2 (ADDED)

5 A494 5801 Small P.S.U. Bracket

6 A494 5802 Large P.S.U. Bracket

7 AZ12 0014 Transformer - 115V

7 AZ12 0015 Transformer - 220/240V

Q'ty per

Assembly

1

1

1

1

1

1

1

1

1

1

Index

No.

Part No.

Description

101 0443 0060W Hexagon Head Tapping Screw - M3x6

102 1106 0389 Locking Support

103 1105 0159 PCB Stud

MB1 (ADDED)

Q'ty per

Assembly

3

2. INTERFACE BOARD (A494)

4

2. INTERFACE BOARD (A494)

Index

No.

Part No.

" A494 5101 Interface Board

Description

Q'ty per

Assembly

1

Index

No.

Part No.

Description

101 1102 2307 Connector - 20P

102 1102 5001 Connector - 30P

103 1102 5003 Connector - 2P

104 1103 1812 Pin Header - 4P

105 1103 1815 Pin Header - 7P

106 1103 1879 Connector - 3P

107 1103 3029 Connector - 2P

108 1403 0556 Photocoupler - TLP634

109 1407 2055 IC - TD62304F

110 1407 2187 IC - SN74LS07NS

111 1407 2341 IC - MPD71051G

112 1407 2344 Transistor Array - TD62382F

113 1407 2746 IC - CXD1095Q

114 1407 3532 IC - TC74HC4024AF

115 1408 0456 IC - AN6914S

116 1503 0339 Oscillator - 4.9152MHz

117 1604 1363 Capacitor - 10uF +-20% 25V

118 1604 1382 Capacitor - 10uF 50V

119 1606 1451 Capacitor - 0.1uF 50V

120 1606 1454 Capacitor - 0.01uF 25V

121 1606 1455 Capacitor - 470pF 25V

122 1610 0037 Resistor - 120 Ohm 1/8W +-5%

123 1610 0041 Resistor - 180 Ohm 1/8W +-5%

124 1610 0053 Resistor - 1K Ohm 1/8W +-5%

125 1610 0062 Resistor - 2.4 Ohm +-5% 1/8W

126 1610 0065 Resistor - 3.3K Ohm 1/8W +-5%

127 1610 0071 Resistor - 10K Ohm +-5% 1/8W

128 1610 0073 Resistor - 12K Ohm 1/8W +-5%

129 1611 4104 Resistor - 100K Ohm 1/4W +-5%

130 1611 4151 Resistor - 150 Ohm 1/4T +-5%

131 1607 0352 Inductor

Q'ty per

Assembly

5

3. DC DRIVE BOARD (A494)

6

3. DC DRIVE BOARD (A494)

Index

No.

Part No.

Description

* A494 5415 DC Drive Board - 115V

* A494 5416 DC Drive Board - 220/240V

Q'ty per

Assembly

1

1

Index

No.

Part No.

Description

101 1103 0441 Pin Terminal - 4P

102 1104 0351 Fuse Holder

103 1107 0354 Fuse - 3.15A/125V

103 1107 0457 Fuse - 3.15A/250V

MB2 (ADDED)

104 1107 0391 Fuse - 5A, 125V

104 11070459 Fuse - 5A, 250V

105 1402 0277 Zener Diode - 1Z12 (115V)

105 1402 0951 Zener Diode - 1Z12 (220/240V)

106 1402 0388 Diode - W03C

107 1402 0601 Rectifier - RBV-401

108 1405 0176 Rectifier - RBV-601

109 1408 0569 IC - NJM78M05F-A

110 1408 0753 IC - NJM78M24FA

111 1604 1378 Capacitor - 1MF 50V

112 1604 1382 Capacitor - 10uF 50V

113 1604 2238 Capacitor - 4700uF 25V

114 1604 2239 Capacitor - 4700uF 35V (115V)

114 1604 2289 Capacitor - 4700uF +-20% 50V (220/240V)

MB2 (ADDED)

115 1606 0996 Capacitor - 470pF 50V

116 1606 1396 Capacitor - 0.1uF 25V

117 1611 4220 Resistor - 22 Ohm 1/4T +-5%

118 1611 4689 Resistor - 6.8 Ohm 1/4T +-5%

119 1611 6102 Resistor - 1K Ohm 1/2T +-5%

Q'ty per

Assembly

7

4. POWER SUPPLY UNIT HARNESS (A494)

8

4. POWER SUPPLY UNIT HARNESS (A494)

Index

No.

Part No.

Description

* A494 5301 Power Supply Unit Harness - 115V

* A494 5310 Power Supply Unit Harness - 220/240V

Q'ty per

Assembly

1

1

Index

No.

Part No.

Description

101 1100 1239 Pin - Mate-N-Lock

102 1100 1247 Terminal



105 1100 1375 Pin - Mate-N-Lock

106 1102 1509 Connector - 4P

107 1102 1831 Connector - 4P

108 1102 1878 Connector - 3P

109 1102 1984 Socket Housing - 4P

110 1102 1990 Socket Housing - 10P

111 1102 2029 Pin Housing - 10P

112 1102 4801 Connector - 8P

Q'ty per

Assembly

9

PARTS INDEX

10

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


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. Bracket

Bracket - DF Power Supply Cord

Paper and

Index No.

3- 2

5- *

5-118

3- 3

9- *

3- 3

9- *

3- 4

7- *

3- 4

7- *

3- 5

3- 6

3- 1

Part No.

AZ12 0014

AZ12 0015

Description

Transformer -115V

Transformer -220/240V

Paper and

Index No.

3- 7

3- 7

11

Part No.

Description

04430060W Hexagon Head Tapping Screw - M3x6

1100 1239 Pin - Mate-N-Lock

1100 1247

1100 1329

1100 1330

1100 1375

Terminal

Socket Contact

Socket Contact

Pin - Mate-N-Lock

1102 1509

1102 1831

1102 1878

1102 1984

Connector - 4P

Connector - 4P

Connector - 3P

Socket Housing - 4P

1102 1990

1102 2029

1102 2307

1102 4801

1102 5001

1102 5003

1103 0441

1103 1812

1103 1815

1103 1879

1103 3029

1104 0351

1105 0159

1106 0389

1107 0354

Socket Housing -10P

Pin Housing - 10P

Connector - 20P

Connector - 8P

Connector - 30P

Connector - 2P

Pin Terminal - 4P

Pin Header - 4P

Pin Header - 7P

Connector -3P

Connector -2P

Fuse Holder

PCB Stud (ADDED)

Locking Support

Fuse - 3.15A/125V

1107 0391

1107 0457

1107 0459

1402 0277

1402 0388

1402 0601

1402 0951

1403 0556

1405 0176

1407 2055

Fuse - 5A, 125V

Fuse - 3.15A 250V MB2 (ADDED)

Fuse - 5A, 250V MB2 (ADDED)

Zener Diode - 1Z12 (115V)

Diode -W03C

Rectifier - RBV-401

Zener Diode - 1Z12 (220/240V)

Photocoupler - TLP634

Rectifier - RBV-601

IC - TD62304F

Paper and

Index No.

9-110

9-111

5-101

9-112

5-102

5-103

7-101

5-104

5-105

5-106

3-101

9-101

9-102

9-103

9-104

9-105

9-106

9-107

9-108

9-109

5-107

7-102

1- *

3-102

7-103

7-104

7-103

7-104

7-105

7-106

7-107

7-105

5-108

7-108

5-109

12

Part No.

1407 2187

1407 2341

1407 2344

1407 2746

1407 3532

1408 0456

1408 0569

1408 0753

1503 0339

1604 1363

1604 1378

1604 1382

1604 1382

1604 2238

1604 2239

1604 2289

1606 0996

1606 1396

1606 1451

1606 1454

1606 1455

1607 0352

1610 0037

1610 0041

1610 0053

1610 0062

1610 0065

1610 0071

1610 0073

1611 4104

1611 4151

1611 4680

16114689

16116102

Description

IC -SN74LS07NS

IC - MPD71051G

Transistor - TD62382F

IC - CXD1095Q

IC - TC74HC4024AF

IC - AN6914S

NJM78M05F-A

IC - NJM78M24FA

Oscillator - 4.9152MHz


Capacitor - 1MF 50V




Capacitor - 4700uF 35V (115V)

Capacitor - 4700uF +-20% 50V (220/240V)

MB2 (ADDED)

Capacitor -470pF 50V




Capacitor -470pF 25V

Inductor

Resistor - 120 Ohm 1/8W +-5%

Resistor - 180 Ohm 1/8W +-5%

Resistor - 1K Ohm 1/8W +-5%

Resistor - 2.4 Ohm +-5% 1/8W

Resistor - 3.3K Ohm 1/8W +-5%

Resistor - 10K Ohm +-5%

Resistor - 12K Ohm 1/8W +-5%

Resistor - 100K Ohm 1/4V +-5%

Resistor - 150 Ohm 1/4T +-5%

Resistor - 68 Ohm 1/4T +-5%

Resistor - 6.8 Ohm 1/4T +-5%

Resistor - 1K Ohm 1/2T +5%

Paper and

Index No.

5-110

5-111

5-112

5-113

5-114

5-115

7-109

7-110

5-116

5-117

7-111

5-118

7-112

7-113

7-114

7-114

5-124

5-125

5-126

5-127

5-128

5-129

5-130

7-117

7-118

7-119

7-115

7-116

5-119

5-120

5-121

5-131

5-122

5-123

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 . . . . . . . . . . . . . . . . . . . . . . . . 1-13

6. DRIVE LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . 1-17

8. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . 1-19

9. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

10. AC POWER AND DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . 1-24

10.1 AC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

10.2 DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

SECTIONAL DESCRIPTION

1. DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 OPC DRUM CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.2 DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

1.3 HANDLING THE DRUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2. DRUM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.2 CHARGE CORONA WIRE CLEANER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.3 CHARGE CORONA CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.4 GRID VOLTAGE CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

3. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

3.2 SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

3.2.1 1st and 2nd Scanner Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

3.3 LENS DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3.3.1 Lens Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

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

3.4.2 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

3.5 STEPPER MOTOR CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

3.6 AUTOMATIC IMAGE DENSITY SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

3.7 EXPOSURE LAMP VOLTAGE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

3.7.1 Base Lamp Voltage Factor In Manual Image Density Control . . . . . . . . . . . . . . . 2-18

3.7.2 Base Lamp Voltage Factor In Auto Image Density Control . . . . . . . . . . . . . . . . . 2-18

3.7.3 Reproduction Ratio Correction Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

3.7.4 Drum Wear Correction Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

3.8 EXPOSURE LAMP CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

3.9 SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

4. ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

4.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

4.1.1 Lead Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

4.1.2 Side Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

4.1.3 Trailing Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

5. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

5.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

5.3 CROSS-MIXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

5.4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROL . . . . . . . . . . . . . . . . . . . . 2-29

5.4.1 Base Bias Voltage Factor In Manual Image Density Control . . . . . . . . . . . . . . . . 2-29

5.4.2 Base Bias Voltage Factor In Automatic Image Density Control . . . . . . . . . . . . . . 2-30

5.4.3 Base Bias Voltage Adjustment Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

5.4.4 Vr Correction Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

5.5 DEVELOPMENT BIAS CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

5.6 DEVELOPMENT UNIT SET SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

5.7 COLOR DEVELOPMENT UNIT DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

6. TONER DENSITY DETECTION AND TONER SUPPLY . . . . . . . . . . . 2-35

6.1 DETECT SUPPLY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

6.2 ID SENSOR FUNCTION IN DETECT SUPPLY MODE. . . . . . . . . . . . . . . . . . . . . . . . 2-36

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

6.5 ABNORMAL CONDITION IN TONER DENSITY DETECTION . . . . . . . . . . . . . . . . . . 2-39

6.6 DEVELOPMENT BIAS FOR ID SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

6.6.1 Toner Density Adjustment Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

6.6.2 Vd Correction Factor (Only For Black Toner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

6.7 TONER SUPPLY AND AGITATOR DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . 2-41

6.8 TONER SUPPLY AMOUNT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

6.8.1 Detect Supply Mode (SP mode #30 = 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

6.8.2 Fixed Supply Mode (SP mode #30 = 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

6.9 TONER END DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

6.10 TONER SUPPLY UNIT INITIAL SETTING (SP mode #63) . . . . . . . . . . . . . . . . . . . 2-47

7. IMAGE TRANSFER AND PAPER SEPARATION . . . . . . . . . . . . . . . . 2-48

7.1 PRE-TRANSFER LAMP (PTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

7.2 IMAGE TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

7.3 PAPER SEPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

7.4 PRE-TRANSFER LAMP AND TRANSFER/SEPARATION CORONA CIRCUIT. . . . . 2-50

8. DRUM CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

8.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

8.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

8.3 TONER OVERFLOW DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

9. QUENCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

10. PAPER FEED AND REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

10.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

10.2 FRR FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

10.2.1 Pick-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

10.2.2 Feed and Reverse Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

10.3 1ST FEED STATION PAPER LIFT MECHANISM AND PAPER END DETECTION 2-58

10.3.1 Paper Lift Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

10.3.2 Paper End Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

10.4 2ND FEED STATION PAPER LIFT MECHANISM AND PAPER END DETECTION 2-60

10.4.1 Paper Lift Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

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

10.6 PAPER FEED DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

10.6.1 1st Feed Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

10.6.2 2nd Feed Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

10.7 SLIP CLUTCH MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

10.8 MANUAL FEED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

10.9 PAPER REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

10.10 PAPER FEED AND MISFEED DETECTION TIMING . . . . . . . . . . . . . . . . . . . . . . 2-69

11. IMAGE FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

11.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

11.2 FUSING DRIVE RELEASE MECHANISM AND COVER SAFETY SWITCH . . . . . . 2-71

11.3 FUSING LAMP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

11.4 FUSING LAMP CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

11.4.1 Phase Control Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

11.4.2 Overheat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

11.5 SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

INSTALLATION

1. INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.1 ENVIRONMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.2 MACHINE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.3 MINIMUM SPACE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.4 POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

2. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

2.1 COPIER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

2.2 220/240V CONVERSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

2.3 CASSETTE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

2.4 KEY COUNTER HOLDER INSTALLATION (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . 3-12

2.5 OPTICS ANTI-CONDENSATION HEATER INSTALLATION (OPTION) . . . . . . . . . . . 3-13

2.6 COLOR DEVELOPMENT UNIT INSTALLATION (OPTION) . . . . . . . . . . . . . . . . . . . . 3-14

2.7 DC POWER SUPPLY UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

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. SERVICE PROGRAM MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

2.1 SERVICE PROGRAM MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

2.1.1 Service Program Access Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

2.1.2 Change Adjustment Values or Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

2.1.3 Memory Clear Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

2.1.4 Others. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

2.2 SERVICE PROGRAM MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

2.3 SP-8 SENSOR/SWITCH DATA CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

2.4 SP-9 ELECTRICAL COMPONENT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

2.5 MISFEED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

2.5.1 Number of Paper Jams (SP Mode #131) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

2.5.2 Paper Misfeed Location Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

2.6 SERVICE CALL AND USER CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

3. SERVICE REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

3.1 GENERAL CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

3.2 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

3.3 CHARGE CORONA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

3.4 OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

3.5 DEVELOPMENT UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

3.6 TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

3.7 TRANSFER AND SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

3.8 CLEANING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

3.9 FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

3.10 PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

3-11 DOCUMENT FEEDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

3-12 SORTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

3-13 DUPLEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

3.14 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.1 EXTERIOR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.1.1 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.1.2 Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.1.3 Left Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

1.1.4 Left Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

1.1.5 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

1.1.6 Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

1.2 INNER COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

1.2.1 Right Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

1.2.2 Left Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

2. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

2.1 EXPOSURE GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

2.2 1ST MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

2.3 2ND AND 3RD MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

2.4 4TH AND 5TH MIRROR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

2.5 EXPOSURE LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

2.6 THERMOSWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

2.7 SCANNER DRIVE WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

2.7.1 Wire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

2.7.2 Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

2.8 SCANNER MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

2.9 LENS DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

2.10 4TH/5TH MIRROR ASSEMBLY DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . 5-24

2.11 EXPOSURE LAMP POSITION ADJUSTMENT (HORIZONTAL DIRECTION) . . . . . 5-25

3. DEVELOPMENT AND TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . 5-26

3.1 TONER TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

3.2 DEVELOPER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

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. . . . . . . . . . . . . . . . 5-34

3.8 DEVELOPMENT DRIVE CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

4. CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

4.1 CLEANING UNIT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

4.2 CLEANING BLADE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-378

4.3 CLEANING BRUSH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

4.4 BLADE SCRAPER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

4.5 TONER OVERFLOW SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

4.6 USED TONER COLLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

4.7 ENTRANCE SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5. PAPER FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

5.1 PAPER SIZE SWITCH REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

5.2 1ST PAPER END SENSOR AND PAPER LIFT SENSOR REPLACEMENT . . . . . . . 5-44

5.3 1ST FEED ROLLER, PICK-UP ROLLER, AND REVERSE ROLLER

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

5.4 2ND PAPER FEED ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5.5 PICK-UP ROLLER RELEASE SOLENOID AND MANUAL FEED TABLE SWITCH

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5.6 1ST FEED ROLLER SPRING CLUTCH SOLENOID REPLACEMENT . . . . . . . . . . . 5-49

5.7 PAPER LIFT CLUTCH SOLENOID ASSEMBLY REPLACEMENT. . . . . . . . . . . . . . . 5-50

5.8 RELAY ROLLER SPRING CLUTCH SOLENOID AND RIGHT COVER SWITCH

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5.9 REGISTRATION CLUTCH REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5.10 2ND PAPER FEED CLUTCH SOLENOID REPLACEMENT. . . . . . . . . . . . . . . . . . . 5-54

5-11 2ND PAPER END SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

5.12 2ND PAPER SIZE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

5.13 REGISTRATION SENSOR AND ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . 5-58

6. AROUND DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

6.1 PTL BOARD REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

6.2 QUENCHING LAMP REPLACEMENT/CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

6.3 ERASE LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

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

6.9 ID SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70

6.10 PICK-OFF PAWL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71

6.11 CORONA CURRENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72

6.11.1 Charge Corona Current Adjustment (SP Mode #9-2) . . . . . . . . . . . . . . . . . . . . 5-74

6.11.2 Grid Voltage Adjustment (SP Mode #9-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76

6.11.3 Transfer Corona Current Adjustment (SP Mode #9-5) . . . . . . . . . . . . . . . . . . . . 5-77

6.11.4 Separation Corona Current Adjustment (SP Mode #9-8) . . . . . . . . . . . . . . . . . . 5-78

7. FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79

7.1 EXIT UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79

7.2 FUSING LAMP REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80

7.3 PRESSURE ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81

7.4 HOT ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83

7.5 THERMISTOR AND THERMOFUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 5-85

7.6 FUSING PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86

7.7 FUSING EXIT SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87

8. OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

8.1 OPERATION PANEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

8.2 OZONE FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89

9. COPY QUALITY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90

9.1 LIGHT INTENSITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92

9.2 UNEVEN EXPOSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92

9.3 BIAS VOLTAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93

9.4 TONER DENSITY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94

9.5 FIXED TONER SUPPLY MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94

9.6 TONER SUPPLY RATIO SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94

9.7 ID SENSOR (Vsg) ADJUSTMENT (SP MODE #54) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

9.8 ADS (Auto Image Density Sensor) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

9.9 VERTICAL MAGNIFICATION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

9.10 HORIZONTAL MAGNIFICATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103

TROUBLESHOOTING

1. COPY QUALITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1.1 BLANK COPY (WHITE COPY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1.2 DIRTY BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

1.3 UNEVEN IMAGE DENSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

1.4 VERTICAL BLACK BANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

1.5 VERTICAL BLACK LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

1.6 VERTICAL WHITE LINES OR BANDS—1 (DULL OR BLURRED). . . . . . . . . . . . . . . 6-10

1.7 VERTICAL WHITE LINES OR BANDS—2 (THIN, DISTINET) . . . . . . . . . . . . . . . . . . 6-11

1.8 HORIZONTAL BLACK/WHITE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

1.9 JITTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

1.10 BLACK SPOTS ON THE COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

1.11 SKEWED (OPTICAL) COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

1.12 TONER DENSITY TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

1.13 TONER DENSITY TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

1.14 TONER SCATTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

1.15 UNFUSED COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

1.16 PAPER MISFEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

1.17 DF ORIGINAL MISFEED OR SKEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

2. SERVICE CALL CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

2.1 CODE #11 — EXPOSURE LAMP ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

2.2 CODE #12 — EXPOSURE LAMP ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

2.3 CODE #13 — ZERO CROSS SIGNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

2.4 CODE #21 — SCANNER HOME POSITION ERROR . . . . . . . . . . . . . . . . . . . . . . . . 6-28

2.5 CODE #22 — SCANNER HOME POSITION ERROR . . . . . . . . . . . . . . . . . . . . . . . . 6-30

2.6 CODE #28 — LENS HOME POSITION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

2.7 CODE #29 — LENS HOME POSITION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

2.8 CODE #2A — 4TH/5TH MIRROR HOME POSITION ERROR . . . . . . . . . . . . . . . . . 6-36

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

2.14 CODE #80 — DUPLEX AND COPIER BOARD COMMUNICATION ERROR . . . . 6-46

2.15 CODE #81 — INTERFACE BOARD ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

2.16 CODE #82 — JOGGER HOME POSITION ERROR . . . . . . . . . . . . . . . . . . . . . . . . 6-49

2.17 CODE #83 — JOGGER HOME POSITION ERROR . . . . . . . . . . . . . . . . . . . . . . . . 6-50

2.18 ABNORMAL CONDITION IN TONER DENSITY DETECTION . . . . . . . . . . . . . . . . 6-51

3. ELECTRICAL COMPONENT DEFECTS . . . . . . . . . . . . . . . . . . . . . . . 6-53

3.1 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

3.2 SWITCH OR OTHER ELECTRICAL COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

3.3 FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

COPIER ELECTRICAL DATA

1. COPIER MAIN BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

2. OPERATION PANEL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

3. AC DRIVE BOARD SCHEMATIC (220/240V). . . . . . . . . . . . . . . . . . . . . 7-3

4. AC DRIVE BOARD SCHEMATIC (115V) . . . . . . . . . . . . . . . . . . . . . . . . 7-4

5. INTERFACE PCB SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

6. MAIN DC POWER SUPPLY BOARD SCHEMATIC . . . . . . . . . . . . . . . . 7-6

7. AUTO IMAGE DENSITY SENSOR BOARD SCHEMATIC. . . . . . . . . . . 7-6

8. OPTIONAL DC POWER SUPPLY BOARD SCHEMATIC . . . . . . . . . . . 7-6

9. COPIER TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

DOCUMENT FEEDER (Machine Code: A465)

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

2. COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . . 8-3

4. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8.2 ORIGINAL SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8.3 ORIGINAL FEED-IN MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.4 ORIGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8.5 ORIGINAL INVERSION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

8.6 ORIGINAL FEED-OUT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

8.7 BELT DRIVE MOTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8.8 FEED-OUT MOTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

8.9 INPUT AND OUTPUT CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

9. LIFT MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

10. ORIGINAL MISFEED SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

11. INSTALLATION PROCEDURE (for Machine Code: A048) . . . . . . . . 8-24

11.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

11.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

12. PREPARATION FOR TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . 8-31

13. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

13.1 FEED-IN UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

13.1.1 Transport Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

13.1.2 Feed-in Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

13.1.3 Pick-up Roller Replacement* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

13.1.4 Feed-in Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

13.1.5 Pick-up Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

13.1.6 Feed Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

13.1.7 Feed-in Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

13.1.8 Friction Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

13.2 FEED-OUT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

13.2.1 Feed-out Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

13.2.2 Inverter Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

13.2.3 DF Leading Edge Registration Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44

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 . . . . . . . . . . . . . . . . . . . 9-3

4. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

6. EXIT ROLLER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

6.1 ROLLER DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

6.2 ROLLER DRIVE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

7. BIN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

7.1 BIN DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

7.2 BIN DRIVE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

8. MISFEED DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

9. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

10. PREPARATION FOR TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . 9-16

11. ROLLER DRIVE BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 9-17

12. BIN GUIDE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

13. SORTER MAIN BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

14. SORTER TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

DUPLEX

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

2. COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

3. ELECTRICAL COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . 10-3

4. POWER DISTRIBUTION AND OVERALL MACHINE CONTROL . . . . 10-4

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

7. FIRST SIDE COPY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

7.1 FROM COPIER PAPER FEED SECTION TO DUPLEX ENTRANCE ROLLER . . . . . 10-7

7.2 FROM DUPLEX ENTRANCE ROLLER TO DUPLEX TRAY . . . . . . . . . . . . . . . . . . . . 10-8

7.3 DUPLEX STACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

8. SECOND SIDE COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

9. DUPLEX PAPER FEED AND MISFEED DETECTION TIMING . . . . . 10-11

10. SERVICE CALL CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

11. DUPLEX UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

11.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

11.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

12. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 10-19

12.1 DUPLEX TRAY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

12.2 JOGGER MOTOR AND JOGGER HOME POSITION SENSOR REPLACEMENT 10-21

12.3 TURN SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

12.4 FEED MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23

12.5 PAPER END SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

12.6 ENTRANCE SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

12.7 GATE SOLENOID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

12.8 FRICTION ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27

12.9 FEED ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28

13. DUPLEX MAIN BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . 10-29

WATER PROOF SHEETS

POINT-TO-POINT DIAGRAM

TABLE OF ADJUSTMENTS

PM AND EM LOG

SERVICE PROGRAM MODE LOG

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

4. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . 11-6

5. DRIVE LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

6. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . 11-6

7. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . 11-11

8. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16

9. AC POWER AND DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . 11-17

9.1 AC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19

9.2 DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20

10. ORIGINAL SIZE DETECTION IN PLATEN MODE . . . . . . . . . . . . . . . 11-21

11. PAPER FEED AND MISFEED DETECTION TIMING . . . . . . . . . . . . . 11-23

12. DOCUMENT FEEDER (Machine Code: A318) . . . . . . . . . . . . . . . . . 11-25

12.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25

12.2 COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26

12.3 ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27

12.4 POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28

13. DUPLEX UNIT POWER DISTRIBUTION AND OVERALL

MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29

14. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30

14.1 INSTALLATION REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30

14.1.1 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30

14.1.2 Machine Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31

14.1.3 Minimum Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31

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

14.3 DOCUMENT FEEDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35

14.3.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35

14.3.2 Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36

14.4 SORTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38

14.5 DUPLEX UNIT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38

15. 3RD PAPER FEED CLUTCH SOLENOID REPLACEMENT . . . . . . . 11-39

16. ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40

16.1 COPIER MAIN BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41

16.2 OPERATION PANEL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42

16.3 AC DRIVE BOARD SCHEMATIC (220/240V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43

16.4 AC DRIVE BOARD SCHEMATIC (115V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44

16.5 INTERFACE PCB SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45

16.6 MAIN DC POWER SUPPLY BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . 11-46

16.7 AUTO IMAGE DENSITY SENSOR BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . 11-46

16.8 OPTION DC POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46

16.9 COPIER TIMING CHART (LT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-47

16.10 COPIER TIMING CHART (A4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48

WATER PROOF SHEETS

POINT - TO - POINT DIAGRAM

COPIER ELECTRICAL COMPONENTS AND CONNECTORS LAYOUT

DOCUMENT FEEDER ELECTRICAL COMPONENTS AND CONNECTORS LAYOUT