Service Manual
Service Manual
Service Manual
SERVICE MANUAL
GENERAL
1 SPECIFICATIONS
Type Photoconductor Copying System Paper Feeding System : Desk Top Copier with Stationary Platen : Organic Photoconductor : Electrostatic Dry Powdered Image Transfer to Plain Paper : 2-Way Feeding Paper Cassette (100 sheets) Manual Feed Table (1 sheet) : Mirror Scanning, Slit Exposure : Dual Component System : Single-Wire DC Negative Corona with Scorotron System : Visible Image Transfer by means of a Single-Wire DC Negative Corona with Corotron System
Paper Separating System : Natural Separation from the small-diameter PC Drum because of the inherent strength in paper, grounded discharge comb Ozone Removal Fusing System Paper Charge Neutralization Maximum Original Size Types of Originals : By means of Ozone Filter : Heat Rollers : Charge Neutralizing Brush : A4 lengthwise : Sheets, books, and three-dimensional objects weighing up to 3kg
Copy Paper Paper Cassette Plain Paper (60 to 90 g/m2) Copy Medium Recycled Paper (60 to 90 g/m2) Special Paper (OHP and others) Thick Paper (91 to 120 g/m2) Copy Paper Size O O A4L and A5C Manual Feed Table O O O O A4L to A6L
O: Permissible; L : Lengthwise;
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Multiple Copies Warming-up Time Auto Clear Time First Copy Time Continuous Copy Speed Magnification Ratio Lens Exposure Lamp Fusing Temperature
: 1 to 49 copies (Count-Down System) : 15 sec. or less when the ambient temperature is 23C and with rated power voltage : 60 2 sec. : 9 sec. or less (A4 Lengthwise) : 7 copies/min. or more (A4 Lengthwise) : x1.000 0.005 : Through Lens (F=8. f=160 mm) : Halogen Frost Tube Lamp : 185C (Standby and Multicopy Mode) 190C (Single Copy Mode)
Power/Current Consumption Exposure Lamp (Rating) 160V 215W Heater Lamp (Rating) 230V 950W Max. Power Consumption 1335W Max. Current Consumption 6.4A
: 230V, 50Hz
Humidity
Ambient Illumination
Levelness 1 (5.25mm/300mm)
15% to 85%RH with a fluctuation of 3000 lux or less 20%RH or less per hour
Dimensions
: Width ...... 478 mm 556 mm (Excluding Paper Cassette) Depth 285 mm ...... Height ..... : 19.3 kg (including Paper Cassette, Imaging Module, Starter and Toner) : Toner Bottle Starter Bottle Paper Cassette Installation Set
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2 SPACE REQUIREMEMTS
To ensure easy access and maintain high performance of the copier, the
following clearances must be provided, especially at the rear and left sides where there are exhaust ducts.
5cm
10cm 5cm
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NOTE Do not burn, bury in the ground, or throw into the water any consumables (PC Drum, starter, toner, etc.).
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6 SERVICE INSTRUCTIONS
Service Precautions When servicing the copier, observe the following precautions.
q Unplug the copier from the power outlet before attempting to
allow your clothing and shirt sleeves to be caught in the Timing Belt or other revolving parts. q Do not use flammable sprays near the copier while it is in operation. q Do not bring your watch near the Imaging Module. q Because there are two in-line fuses, even if one of these blows, there may still be a danger of electric shock. Precautions for Handling the PWBs with MOS ICs When handling the PWBs with MOS (Metal Oxide Semiconductor) ICs, observe the following precautions. During transportation and storage:
q The PWBs must not be indiscriminately removed from the protective
conductive bags.
q Do not store or place PWBs in a location exposed to direct sunlight. q When a PWB is removed from the copier, do not place it in a location
During replacement:
q When unplugging connectors from the PWB, make sure that the power
the IC pins or the printed pattern. Hold only onto the edges of the Board. q When plugging connectors to the PWB, be sure that the power cord has been unplugged. During checking:
q Avoid checking the IC directly with a tester. Check the connectors on
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Precautions for Handling the Imaging Module (IM) During transportation and storage:
q Use the specified package for transportation and storage of the IM. q Storage temperature for the IM is 20C to +40C. q Avoid leaving the IM in a car for a long time during hot weather.
During handling:
q When the IM has been removed from the copier, immediately store it in
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7 PARTS IDENTIFICATION
Control Panel
Fusing Unit
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8 CONTROL PANEL
1 2 4 5 6
1. Exposure Control Knob q Turn to set the exposure level. 2.Multi-Functional Display q Shows the following information: Warming-up state ... Blinking "1" Number of Copies set to be made ... "1" to "49" Paper Empty ... "P" Paper Jam..."PJ" Copier opened ... "U5" Trouble Code ... "C or E" and trouble Code number Function Mode ... "F" and function mode number Adjustment Mode For more ... "A" and adjustment mode number information, see the Function/Adjustment End of drum life Mode Section. ... Displays the PC Drum life... "du" / "Su"
Copy Counter
... Displays the number of copies made 3. Add Toner Indicator q Lights up when toner in the Toner Cartridge runs out, prompting the user to replace the Toner Cartridge with a new one.
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4. Up/Down Keys q Whether they are used with the Clear/Stop Key or not, the Up and Down Keys have the following four functions: Sets the number of copies to be made Press the Up Key ( + ) to increment the number of copies to be made by 1, with the exception that the number "49" changes to "1". Press the Down Key ( ) to decrement the number of copies to be made by 1, with the exception that the number "1" changes to "49". Displays the Copy Counter. Provisional processing for drum life For more information, see display (Credit Function) the Function/Adjustment Switches between the function and Mode Section. adjustment modes and selects the required mode. 5. Clear/Stop Key q When not used with the Up and Down Keys, the Clear/Stop Key has the following three functions: Stops a multi-copy process. By pressing this key during a multi-copy process, "1" appears on the Multi-Functional Display and the copier stops as soon as the paper comes out of the copier. After the copier has stopped, the Multi-Functional Display shows the remaining number of copies to be made. Clears the number of copies set The set number of copies to be made is reset to "1". Stops/clears the function/adjustment For more information, see the Function/Adjustment mode. Mode Section.
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MECHANICAL/ ELECTRICAL
1 CROSS-SECTIONAL VIEW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 28 17 18 19 20
27
26
25 24 23 22
21
4th Mirror 2nd Developer Mixing Screw 1st Developer Mixing Screw Sleeve/Magnet Roller PC Drum 6th Mirror Lens PC Drum Charge Corona Exposure Lamp 1st Mirror Erase Lamp Ozone Filter 2nd Mirror 3rd Mirror
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Scanner Cooling Fan Motor Upper Fusing Roller Paper Exit Switch Paper Exit Rolls Paper Exit Roller Lower Fusing Roller Cleaning Blade Image Transfer Corona Synchronizing Roller Paper Leading Edge Sensor Paper Feed Roller Paper Separator Pad Main Drive Motor 5th Mirror
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2 COPY PROCESS
2. PC DRUM CHARGE 3. EXPOSURE
9. ERASING
1. PC DRUM
4. DEVELOPING
7. CLEANING
EXIT
1. PC Drum The PC Drum is an aluminum cylinder coated with a photosensitive semiconductor. It is used as the medium on which a visible developed image of the original is formed. 2. PC Drum Charge The PC Drum Charge Corona Unit is equipped with a single wire and a Scorotron Grid. The negative corona emission from the wire is used to charge the surface of the PC Drum. The Scorotron Grid functions to control the potential of that charge and to ensure that the charge level is maintained evenly across the entire surface of the PC Drum. 3. Exposure Light from the Exposure Lamp striking the white and halftone areas of the original is reflected onto the PC Drum. The level of the negative charges on the surface of the PC Drum which are struck by light is reduced in accordance with the intensity of that light. Charges remaining on the surface of the PC Drum form the electrostatic latent image.
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4. Developing
Carrier Toner
When carrier and toner are mixed together, the toner becomes positively charged triboelectrically. Being supplied by the Sleeve/Magnet Roller, the positively charged toner is attracted onto the electrostatic latent image changing it to a visible, developed image. A DC negative bias voltage is applied to the Sleeve/Magnet Roller to prevent toner from being attracted onto those areas of the PC Drum which correspond to the background areas of the original.
Sleeve/Magnet Roller
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5. Paper Feeding The Paper Cassette can accommodate up to 100 pieces of A4L or A5C paper. Manual feed copying is possible only for one sheet at a time. 6. Transfer In the image transfer process, a DC negative corona emission is applied to the underside of the paper thereby attracting the positively charged toner onto the surface of the paper to form a visible, developed image of the original.
7. Cleaning
Cleaning Blade
The residual toner left on the surface of the PC Drum after completion of image transfer is scraped off by the Cleaning Blade. Toner scraped off by the Cleaning Blade is collected by the Spent Toner Conveying Coil.
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8. Spent Toner Conveying Coil The Spent Toner Conveying Coil rotates to transfer toner to the Developing Unit through the Toner Recycling Coil. 9. Erasing
Erase Lamp LA2
Light from the Erase Lamp neutralizes any surface potential remaining on the surface of the PC Drum after cleaning.
10. Fusing The developed image is permanently fused to the paper by a combination of heat and pressure applied by the Upper and Lower Fusing Rollers.
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3 DRIVE SYSTEM
Main Belt Drive
3. Synchronizing Roller Drive 1. Optical System Drive 2. Developing Unit Drive 5. Fusing Unit Drive
4. PC Drum Drive
* This copier uses the Main Motor (M1) to drive most of the copy process
mechanisms. The driving force of the Main Motor is transmitted to those mechanisms mainly by the Main Belt Drive. The drive mechanisms are shown below. 1. Optical System Drive
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M-5
4. PC Drum Drive
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PC2
S53
S1 PC12
PC11 S1A
PC2 S53
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integrates a Toner Replenishing mechanism, Developing mechanism, PC Drum, PC Drum Charge Corona, Image Transfer Corona, Cleaning Unit, and Toner Recycling mechanism into one assembly. The life of the IM is 25,000 copies.
5-1. PC DRUM
30 mm
CGL CTL
260 mm
Aluminum Cylinder
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5-1-1. PC Drum
The OPC, or Organic Photoconductor Drum used in this copier is small in
diameter (30 mm), ensuring good paper separation. It consists of two distinct organic photoconductive layers on an aluminum alloy base: the outer layer is called the Carrier Transport Layer (CTL) and the inner the Carrier Generating Layer (CGL).
During the period of initial use, this Organic Photoconductor has a glossy,
wine-red surface. Since, however, the degree of hardness of this surface is rather low, faint lines corresponding to the edges of the paper will appear around the surface of the Drum after several tens of copies have been made. These lines will, however, in no way affect image quality.
This photoconductor exhibits greatest light fatigue after being exposed to
strong short and long wavelength light over an extended period of time. It is therefore necessary to protect the Drum with a Drum Cloth immediately after the IM has been removed from the copier. 5-1-2. PC Drum Drive
The PC Drum is driven from the Main Motor via the gears, belts and
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Grid which ensures that an even charge is deposited across the entire surface of the PC Drum.
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grounded or not.
After the Start Key is depressed, the Scanner moves from its home position
to its synchronizing position. When it has passed the Scanner Synchronizing Position Sensor once, the charge/transfer output (-7kVDC) of the High Voltage Unit switches on, causing the Drum Charge Corona Wire to start giving a corona emission to the PC Drum. At this point, the PC Drum is not yet charged since the Grid is grounded.
375 msec. after the charge/transfer output of the High Voltage Unit
switches on, the grid voltage output (-630VDC) of the High Voltage Unit switches on to start charging the PC Drum.
The Scanner then starts a scanning motion. 1.84 sec. after the Scanner
has blocked the light of the Scanner Home Position Sensor once, the grid voltage output of the High Voltage Unit switches off, completing the charging of the PC Drum. The charge/transfer output switches off 646 msec. after the Exposure Lamp goes off. Time Chart
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Corona is absorbed by the Ozone Filter located to the front of the IM from the air being drawn out of the copier by Scanner Cooling Fan Motor M2.
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5-3. DEVELOPMENT
4 1 2 3 5
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5-3-1. Developing Unit: Components and Their Functions 1. 2nd Developer Mixing Screw This Screw rotates to transport toner and starter onto the 1st Developer Mixing Screw. 2. 1st Developer Mixing Screw This screw rotates to supply toner and starter transported from the 2nd Developer Mixing Screw onto the Sleeve/Magnet Roller. 3. Doctor Blade This Blade regulates the height of the developer brush on the surface of the Sleeve Roller. 4. Sleeve/Magnet Roller The outer Sleeve Roller rotates, while the inner Magnet Roller remains stationary. As the Sleeve Roller rotates, it conveys the developer to the point of development where the toner is attracted onto the electrostatic latent image. 5. Toner Scattering Prevention Mylar This Mylar strip is in light contact with the surface of the PC Drum, thus effectively stopping any airborne toner and carrier from floating up into the copier. 6. Toner Recycling Coil This Coil rotates to carry the toner which has been scraped off the surface of the PC Drum by the Cleaning Blade to the 2nd Developer Mixing Screw. 7. ATDC Sensor This Sensor detects the toner-to-carrier ratio of the developer.
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Developer Chamber as follows. The starter and toner are fed through the Toner Supply Port from the Starter Cartridge and Toner Cartridge, respectively. The replenished toner merges with the developer and they are mixed and agitated as they are fed from the left to right end. The ATDC Sensor located under the 2nd Developer Mixing Screw near the left end of the Unit detects the ratio of toner and carrier composing the developer. The Partition between the 2nd and 1st Developer Mixing Screws prevents the developer being conveyed by the 2nd Developer Mixing Screw from entering the 1st Developer Mixing Screw before it has been conveyed all the way to the right end of the Unit. As the 1st Developer Mixing Screw rotates, the developer is, while being agitated, conveyed from the right end to the left. During that time, developer which is adhering to the Sleeve/Magnet Roller is carried to the point of development by the rotating Sleeve Roller. After development, residual toner on the surface of the PC Drum is scraped off by the Cleaning Blade and conveyed by the Spent Toner Conveying Coil onto the Toner Recycling Coil. At the left of the Unit, the toner is conveyed by the Toner Recycling Coil again onto the 2nd Developer Mixing Screw.
Right of Copier
2nd Developer Mixing Screw Toner Supply Port 1st Developer Mixing Screw Sleeve/Magnet Roller PC Drum
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of force set up by the poles of the Magnet Roller, rotates clockwise to convey the developer toward the point of development.
The amount of developer being conveyed toward the point of development
is strictly regulated by the height of the gap between the Doctor Blade and the surface of the Sleeve Roller. Developer which has passed through the gap is conveyed to the point of development. After development, the carrier and remaining toner are conveyed back into the Developer Chamber.
Positioning Collar
Sleeve/Magnet Roller
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toner from being attracted onto the non-image areas on the surface of the PC Drum. Bias voltage is ON, if Power Switch is ON.
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5-3-4. Function of Each Magnet N3B : This pole causes the developer brush on the surface of the Sleeve Roller to stand up straight so that its height will be regulated evenly by the Doctor Blade.
S2A, S2B : These two poles cause the developer bristles on the surface of the Sleeve Roller to stand up straight so that their height will be regulated evenly by the Doctor Blade. N1 : This is the principal pole and its lines of magnetic flux at the point of development are perpendicular to the surface of the PC Drum. Therefore, when toner is attracted to the latent image, the carrier is firmly held onto the Sleeve Roller. The height between the N1 and S1 poles is held low to ensure that the developer is easily recycled. The developer is prevented from moving out toward the photoconductor by this pole and falls off the Sleeve Roller to be recycled toward the Screws. As the developer approaches the N-N pole, it falls into the 1st Developer Mixing Screw for recycling. The agitated developer is attracted onto the surface of the Sleeve Roller to form a developer brush.
S1 : N2 :
N-N : N3A :
Doctor Blade
PC Drum
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Holder.
When the CPU determines that the toner to carrier ratio as detected for
each copy by the ATDC Sensor has fallen below a predetermined level, Toner Replenishing Solenoid SL1 is energized.
When Toner Replenishing Solenoid SL1 is energized, the Pawl of the
Solenoid is disengaged from the Ratchet Wheel. This results in drive being transmitted to the Ratchet Wheel. This results in drive being transmitted to the Holder and the Toner Cartridge coupled to the Holder rotates one complete turn together with the Holder. As a result, toner is supplied through the Toner Supply Port and conveyed by the 2nd Developer Mixing Screw to the Developer Chamber.
1132M015
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predetermined level as a result of ATDC detection, the output of PJ3A-18 on PWB-A switches Low upon termination of the ATDC detection. This energizes the Toner Replenishing Solenoid (SL1) to replenish toner once.
If the CPU determines that the toner to carrier ratio is below the
predetermined level five or more consecutive times (copies), toner is replenished three times when the next copy is made.
The amount of toner replenished in each toner replenishing sequence is
30mg or more.
4811C03MCA
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sensor. The output of this sensor is used to control toner replenishment so that a stabilized toner to carrier ratio is maintained. This means that copies having a stabilized image density will be produced.
The ATDC Sensor is located on the bottom side of the Developing Unit
directly under the 2nd Developer Mixing Screw. The developer being conveyed by the 2nd Developer Mixing Screw passes over the top of the Sensor. As the toner in the developer is consumed during development, the amount of carrier increases. This change in the toner to carrier ratio results in a change in the magnetic flux. This in turn is converted to a corresponding voltage VC to be applied to the ATDC-Sensor and the value stored in the EEPROM.
The reference voltage of the ATDC Sensor is set so that the toner to carrier
ratio is maintained at 5.0%. By comparing the applied voltage with this reference value, the EEPROM determines the current toner to carrier ratio of the developer. For more information, see the Function/Adjustment Mode Section.
Carrier Toner
T/C 3%
T/C 4%
T/C 6%
T/C 7%
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after the scan is over, and is performed 16 times during 640 msec. at intervals of 20 msec.. If the ratio of toner to carrier is determined to be less than the set value eight or more times, the Toner Replenishing Solenoid (SL1) is energized to replenish toner.
Time Chart
4811T11M
4811C09M
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with the starter, the reference voltage of the ATDC Sensor must be adjusted when setting up the machine at the user. After this copier is switched on by the user and has then warmed up, the Micro Controler enters the ATDC automatic adjustment mode to adjust the control voltage VC of the ATDC Sensor after pressing the Copy Key.
When the IM has been changed, therefore, the EEPROM must also be
Whether developer has been supplied to the Developer Chamber is verified. For the verification procedure, the ATDC Sensor output voltage is detected as: 0.5V or higher Less than 0.5V Starter charge mode failure detected: E1 is shown.
repeat one times
Verification is made to see if the average of the voltage readings falls within the ATDC adjusting range
* This mode can be restarted even after "E2" has been displayed.
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adjusted to the 8% starter. After calculation the 5% toner to carrier ratio value will be stored in the EEPROM. This alignment is running automatically and adjusts the complete system (ATDC- Sensor and Logic Board).
4811C10M
must be built compactly, the conventional toner empty detecting mechanism using a reed switch and lever cannot be employed. The ATDC Sensor is therefore used to detect the toner- empty condition.
The ATDC Sensor detects the toner to carrier ratio of the developer each
time a copy is made. There is an ATDC Counter used that counts 14 consecutive copies made with a toner to carrier ratio less than the level set in the Adjustment mode. Unlike other copiers, this machine will allow you to make as many copies as you want after the Add Toner indicator starts blinking. Also, there is no toner end recovery sequence for this machine.
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of the sheet of paper passing under the PC Drum to effect transfer of the visible toner image from the surface of the PC Drum to the surface of the paper.
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5-5. SEPARATION
Paper
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Paper Transport Guide Plate Image Transfer Corona CH-2 Charge Neutralizing Comp
5-5-1. Separation
Paper being fed through the copier adheres to the surface of the PC Drum
because of the charge applied to its underside by Image Transfer Corona CH-2. This charge is neutralized by the Charge Neutralizing Comp to help the paper separate from the surface of the PC Drum easily. Further, the small diameter of the PC Drum (30 mm) aids separation because of the inherent strength in the paper.
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PC
1132M065
5-6-1. Construction of the Cleaning Unit 1. Cleaning Blade Scrapes any residual toner off the surface of the PC Drum. 2. Cleaning Blade Tension Spring Presses the Cleaning Blade tightly against the surface of the PC Drum. 3. Spent Toner Conveying Coil Rotates to convey the toner scraped off the surface of the PC Drum by the Cleaning Blade to the Toner Recycling Coil. 4. Toner Anti-Spill Mylar Prevents the toner scraped off the surface of the PC Drum by the Cleaning Blade from falling down onto the surface of the copy paper or the Paper Transport Guide Plate. 5. Toner Recycling Coil Recycles the toner scraped off the surface of the PC Drum to the Developing Unit.
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the illustration and is pressed against the surface of the PC Drum in opposition to the direction of rotation of the PC Drum.
Where the Cleaning Blade is Pressed Tightly up Against the Surface of the PC Drum:
Blade Holder Cleaning Blade Cleaning Blade Tension Spring
PC
1132M066
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employs a toner recycling mechanism which recycles the toner scraped off the surface of the PC Drum by the Cleaning Blade back to the Developer Chamber. Residual toner is scraped off the surface of the PC Drum by the Cleaning Blade. The toner is conveyed by the Spent Toner Conveying Coil to the Toner Recycling Coil. The spent toner fed to the Toner Recycling Coil is again conveyed onto the 2nd Developer Mixing Screw. The spent toner in the Developer Chamber, being mixed with fresh toner replenished from the Toner Cartridge, is conveyed onto the 1st Developer Mixing Screw and then onto the surface of the PC Drum by the Sleeve/Magnet Roller.
Cleaning Blade
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2 3
12
11
10
1. Paper Feed Rolls 2. Paper Feed Roller 3. Paper Take-Up Roller 4. Paper Leading Edge Sensor PC2 5. Upper Synchronizing Roller (at IM) 6. Lower Synchronizing Roller 7. Manual Sheet Feeder/Cassette Cover 8. Copy Tray 9. Paper Cassette 10. Paper Lift-Up Plate 11. Spring 12. Paper Separator Pad
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can be loaded. Note that when A5C paper is to be loaded, the A5C paper trailing edge stop plate must be raised.
Paper Lift-Up Plate Release Levers A5C Paper Trailing Edge Stop Plate Cassette Body Copy Tray
copier frame push the Latches which hold the Paper Lift-Up Plate Release Levers, unlocking the Paper Lift-Up Plate Release Levers. The spring forces the Paper Lift-Up Plate up, pressing the paper stack up against the Paper Feed Rolls and making the top sheet of paper ready to be fed.
When the Cassette is pulled out of the copier, the copier lower frame
causes the Paper Lift-Up Plate Release Levers to be raised and then locked so that paper can be replenished.
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driven from the Main Motor. The rotation of the Paper Feed Rolls and Paper Take-Up Rolls are started and stopped by the Paper Feed Clutch (CL1).
When the Ratchet Wheel is secured by the Paper Feed Clutch (CL1), the
Kicker Spring contained in the Ratchet Wheel prevents the drive from the Main Motor from being transmitted to the Paper Feed Rolls and Paper Take-Up Rolls to stop them.
The Ratchet Wheel has the inner and outer ratchets which work differently
Main Belt Main Motor Main Belt Ratchet Wheel Kicker Spring Paper Feed Clutch CL1
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x Paper Feeding Cycle The following table shows the operations of the Rolls, Ratchet Wheel and
other parts in a paper feeding cycle. A temporary stop in the paper feeding cycle is made for the Paper Take-Up/Feed Mechanism to stand by for the start of the scan process (Synchronizing Roller rotation).
Step
Ratchet Wheel
Operation The inner ratchet of the Ratchet Wheel is locked to stop the Paper Feed Rolls and Paper Take-Up Rolls .
Home position
Feeding
The Paper Feed Clutch CL1 is energized, then de-energized once to disengage the inner ratchet. The Paper Feed Rolls and Paper Take-Up Rolls then rotate to feed the top sheet of paper. After the paper has reached the Synchronizing Rollers and formed a loop, the Paper Feed Clutch CL1 is energized to lock the outer ratchet, stopping the Paper Feed Rolls and Paper Take-Up Rolls. After the Synchronizing Rollers have started rotation, the Paper Feed Clutch CL1 is de-energized 450ms later, whereby the Paper Feed Rolls and Paper Take-Up Rolls resume rotating and are then stopped by the inner ratchet at the home position.
Temporary stop
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x Paper Feeding Control The Paper Feed Clutch (CL1) is energized when PJ3A-22 on PWB-A
switches Low, and is de-energized when the PJ3A-22 switches High. The Clutch is energized and de-energized in the following sequence: Depress the Start Key. The Paper Feed Clutch (CL1) is energized for 200 msec. to disengage the inner ratchet, thereby starting paper feeding. The leading edge of the paper reaches the Paper Leading Edge Sensor (PC2). The Paper Feed Clutch (CL1) is energized to engage the outer ratchet, whereby paper feeding is stopped until the start of a scan.
The Paper Feed Clutch (CL1) is de-energized to disengage the outer ratchet, resuming the paper feeding cycle. The inner ratchet causes the Paper Take-Up Rolls and Paper Feed Rolls to stop at the home position.
4811T12M
4811C05MCA
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Mechanism separates the top sheet of paper from the second one by means of the Paper Take-Up Rolls and Paper Separator Pads.
The Paper Separator Pads are applied to the Paper Separator Base which
is pressed up against the Paper Feed Rolls by the Spring. At the time of paper feeding, the Paper Take-Up Rolls rotate to produce frictional force to take up and feed only the top sheet. If several sheets of paper are going to be fed, the Paper Take-Up Rolls take up only the top one and the Paper Separator Pads prevent the other sheets from being fed.
paper is detected if no sheet of paper reaches the Paper Leading Edge Sensor PC2 from when the Paper Take-Up Rolls have started rotating until when the Scanner reaches the Scanner Synchronizing Position Sensor (PC12). "P" is displayed on the Control Panel to indicate paper empty detection.
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right side, in which the Manual Sheet Feeder slides. For manual feeding, push the Manual Sheet Feeder into the grooves. The Paper Lift-Up Plate Release Levers are then pushed down to stop paper feeding from the Cassette, enabling sheets of paper to be fed manually.
The manual paper feeding is under the same control as the cassette paper
feeding.
The Manual Sheet Feeder has the A5L and A6C Paper Trailing Edge Stop
Plates. When either of these paper types is to be fed manually, raise the corresponding Stop Plate.
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7 OPTICAL SECTION
7-1. Components
2 1 3 4
14 5 13
12 11 10 15 8 7
1. 2. 3. 4. 5.
4th Mirror Lens Carriage Shaft Return Spring Scanner Synchronizing Position Sensor (on PWB-A) 6. 2nd/3rd Mirrors Carriage Drive Cable 7. 3rd Mirror
8. 2nd Mirror 9. Scanner Home Position Sensor (on PWB-A) 10. Scanner 11. 1st Mirror 12. Exposure Lamp 13. Lens Holder 14. 5th Mirror 15. 6th Mirror
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7-2. Scanner
Original Glass 1
7 6
Light path
1. Auxiliary Reflector To prevent the emergence of a shadow on a copy, the Auxiliary Reflector reflects the light of the Exposure Lamp onto the original which does not make complete contact with the Original Glass surface, such as a book. 2. Intensity Correction Mirror The intensity of the light emitted by Exposure Lamp is slightly attenuated at the very ends, which is corrected by the Intensity Correction Mirrors fitted on the front and rear ends of the Scanner. 3. 1st Mirror The 1st Mirror reflects the light from the original surface to the 2nd/3rd Mirrors. 4. Exposure Lamp This copier uses a halogen frost lamp for the Exposure Lamp. The intensity of the light emitted by the Exposure Lamp varies symmetrically around the center of the Lamp, it is lower at the center and higher (about 15%) at the left and right side. 5. Exposure Lamp Thermal Fuse Exposure Lamp Thermal Fuse becomes electrically open if the temperature in the area surrounding the Main Reflector exceeds 139C thus cutting off the circuit to the Exposure Lamp. 6. Main Reflector The Main Reflector ensures that light from the Exposure Lamp exposes all areas of the original 7. Aperture Plate The Aperture Plate regulates the amount of the Exposure Lamp light striking the surface of the original, ensuring even light distribution.
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the gears, pulleys and belts. Without any clutches and the like in these transmission paths, the Scanner is designed to move horizontally as the Main Motor rotates. If the scanner is accidentally blocked, the torque limiter will be actuated to avoid damages of the scanner.(For the transmission of drive from the Main Motor, see Section 3. DRIVE SYSTEM.)
The Scanner Drive Plate is slotted to engage with the Drive Pin on the
Optical Drive Chain. As the Chain rotates, the Scanner moves horizontally along the Carriage Shaft to carry out a scan motion (return motion).
The Scanner Drive Plate has the Light Blocking Plate for the Scanner
Home Position Sensor and Scanner Synchronizing Position Sensor which are used to detect the position of the Scanner.
Scanner Scan direction
Carriage Shaft
Return direction
Main Belt
Scanner Home Position Sensor (on PWB-A) Scanner Synchronizing Position Sensor (on PWB-A) Original Scale
Scanner Scanner Drive Plate
Torque Limiter
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Synchronizing Position Sensor. These Optical Sensors are mounted on PWB-A and their lights are blocked by the Light Blocking Plate of the Scanner.
Paper feeding start, Synchronizing Roller rotation start and other timings
depend largely on the position of the Scanner which is designed to move horizontally as the Main Motor rotates, as described in the preceding section. Hence, the Optical Sensors are used to detect the position of the Scanner, thereby detecting reference signals for overall control of the copier.
q Scanner Home Position Sensor (PC11) Detects the home position of the Scanner. Also detects the reference signals for the following operations: Paper Synchronizing Clutch energization (for sheets of paper from the Main Motor ON Grid voltage output OFF Toner replenishing operation (for replenishing operation of three
motion.
Also detects the reference signals for the following operations: Exposure Lamp ON High Voltage Unit energization Grid voltage output ON Paper Synchronizing Clutch de-energization (Synchronizing Roller Toner replenishing operation (for replenishing operation of three
rotation start)
Scanner
PWB-A Scanner Home Position Sensor PC11 Scanner Synchronizing Position Sensor PC12
M-38
the angle of reflection of the light beam between the two Mirrors is 180.
The 2nd/3rd Mirrors Carriage moves during the scan motion at a speed half
of the Scanners, thereby keeping constant the conjugation distance between the Original Glass and the surface of PC Drum.
The 2nd/3rd Mirrors Carriage is held by the Carriage Shaft on one end and
is driven by the 2nd/3rd Mirrors Carriage Drive Cable and Return Spring.
When the Scanner moves in the scan direction, the 2nd/3rd Mirrors
Carriage Drive Cable is drawn by the Scanner and the 2nd/3rd Mirrors Carriage moves in the scan direction at a speed half of the Scanners.
When the Scanner moves in the return direction, the 2nd/3rd Mirrors
Carriage Drive Cable slackens and the 2nd/3rd Mirrors Carriage moves in the return direction by the force of the Return Spring.
Scanner
Return direction
M-39
reflected light has passed through the Lens, it strikes the 4th and 5th Mirrors and is reflected onto the 6th Mirror.
The 6th Mirror reflects the light from the 5th Mirror onto the PC Drum at the
2nd Mirror 4th Mirror 1st Mirror Lens 6th Mirror 5th Mirror PC Drum 3rd Mirror
of the light emitted by the Exposure Lamp varies symmetrically around the center of the Lamp.
Provided at the back side of the Lamp Main Reflector is a Thermal Fuse
that prevents the temperature surrounding the Lamp Main Reflector from going excessively high (141C, 10A).
Lamp Main Reflector
Silicone Tube
1132M070
M-40
the scan starting position, passes the Scanner Synchronizing Position Sensor (PC12) once.
The Lamp turns off 157 msec. after the grid voltage output of the High
4811T14M
turned into different positions, determines the Exposure Lamp voltage. Turn the Exposure Control Knob as required to set the exposure level. The exposure level is sent from PJ2B-2 to PWB-A. The exposure level entered into PJ3A-17 on PWB-A and is converted in a sinewave cutting pulse signal within PWB-A and outputted from PJ3A-21 to the Power Board PWB-D. The average voltage of the Exposure Lamp changes according to the signal level entered into PJ1D-2 on PWB-D to provide the proper Exposure Lamp light intensity.
4811C08CA
M-41
8 SYNCHRONIZING ROLLERS
8-1. Function of the Synchronizing Rollers
The Synchronizing Rollers make correction for any skewed sheet of paper
transferred by the Paper Feed/Take-Up Rolls. After this, the Synchronizing Rollers match the leading edge of an image on the PC Drum with that of the paper.
The Synchronizing Rollers are driven by the Main Motor via the Paper
Synchronizing Clutch. The Rollers rotate when the Paper Synchronizing Clutch (CL2) is de-energized, and stop when the Clutch is energized.
Paper
4811M037CA
1) As soon as the Start Key is depressed if a copy is to be made on the first sheet of paper; or
The rotation of the Synchronizing Rollers is stopped: 535 msec. after the Scanner, that has moved to the scan starting
position, has passed the Scanner Synchronizing Position Sensor (PC12) to the front. 1) 200 msec. after the Start key is depressed
4811C04MCA
M-42
Upper Synchronizing Roller. Since the Upper Synchronizing Roller is covered with an insulating tube, triboelectric charging occurs as the Roller rotates in contact with the Paper Dust Remover. As paper is then fed between the Synchronizing Rollers, the charges on the tube attract the paper dust from the paper. This dust is then transferred onto the Paper Dust Remover.
Paper Guide Plate Paper Dust Remover Upper Synchronizing Roller at Imaging Module Lower Synchronizing Roller at Base Plate
M-43
11 1. Fusing Roller Thermal Fuse TF1 (167C, 10A) 2. Upper Fusing Roller 3. Fusing Roller Heater Lamp H1 4. Fusing Roller Thermistor TH1 5. Paper Separator Finger 6. Paper Exit Switch S53
10 7. 8. 9. 10. 11. Paper Exit Rolls Paper Neutralizing Brush Paper Exit Roller Pressure Spring Lower Fusing Roller
halves. When the Upper Half of the copier is swung down into the locked position, it presses the Upper Fusing Unit so that the Upper and Lower Fusing Units are pressed together.
The Pressure Springs located under the left and right ends of the Lower
Fusing Roller Shaft exert an upward force on the Lower Fusing Roller. This results in an overall pressure of 9.5 kg being applied between the two Rollers.
Pressure Spring
1132M082
M-44
and enhance toner repellency and static-free performance. Because of its excellent toner repellency, the Roller can prevent the production of offsets with a small amount of silicone oil applied.
Teflon Coating Aluminum Cylinder
1132M083
PFA-Tube
no silicone oil is applied by roll or felt. The system is self cleaning
PFA tube
1132M084
65 mm
65 mm
M-45
Upper Fusing Roller detects the temperature of that surface and enters that temperature to PJ3A-2 on PWB-A.
In accordance with the analog voltage from the Fusing Roller Thermistor
(TH1), PWB-A outputs a signal from PJ3A-16 to PWB-D to keep the temperature of the Upper Fusing Roller at a predetermined value. This signal switches the Heater Lamp on/off to control the temperature.
This fusing temperature is designed to 185 C and possible to change in
o
adjustment mode. For more information, see the Function/Adjustment Mode Section.
The measuring circuit on PWB-A is preadjusted at each board and the
value documented at the A3-label on each board. In case of replacing PWB-A this value must be transferred to the EEPROM of the old PWB-A.
4811C07MCA
M-46
10 ERASE LAMP
10-1. Erase Lamp
The Erase Lamp (LA2) consists of an array of eight tungsten lamps
mounted on the PWB. It lights up to neutralize any residual potential on the surface of the cleaned PC Drum to enable even charging.
PC Drum Charge Corona
PC Drum
Cleaning Blade
of the Main Motor (M1). The Lamp is lit when 24VDC is output from PJ2A-1 on PWB-A.
4811C06MCA
M-47
7 Segment Display
Start Key
Down Key
4. Depress the Start Key to start the operation of the corresponding function mode. Depress the Clear/Stop Key to stop the operation. After the function mode has stopped, depress the Clear/Stop Key again to erase the function number and keep only " " displayed. 5. To return from the function mode to the normal mode, turn the POWER Switch OFF and back ON again, or swing open the Upper Half of the Copier.
S-1
This mode is used to pass sheets of paper to carry out a copy cycle.
Note that an image is not produced in this mode because the High Voltage Unit output is switched on but the grid output is off (grounded). The Copy Counters are not incremented, either.
In this function mode, the Paper Leading Edge Sensor (PC2), Paper Exit Switch (S53),
Scanner Home Position Sensor (PC11) and Scanner Synchronizing Position Sensor (PC12) can be checked. When any of the Sensors become active, the corresponding bar of the 7-Segment Display on the Control Panel is lit to indicate that the Sensor is normal. The relationships between the 7-Segment Display bars and the sensors are as follows:
Scanner Synchronizing Position Sensor (PC12) Paper Leading Edge Sensor (PC2) Scanner Home Position Sensor (PC11) Paper Exit Switch (S53)
In this mode, the charge/transfer output, grid output and bias output of the High Voltage Unit
are switched on for 20 seconds. This mode is only used in the factory to adjust the outputs of the High Voltage Unit. F3: Exposure Adjustment
In this mode, the Exposure Lamp (LA1) turns on for 20 seconds. This mode is used for the
adjustment of the maximum Lamp voltage. For details, see the Dis/Reassembly, Adjustment Part. F4: Paper Leading Edge Adjustment
This mode is used to vary the start timing of Synchronizing Roller rotation to match the
leading edge of paper with that of an image. For more information, see the Dis/Reassembly, Adjustment Section. F5: Missing Image Adjustment
This mode is used to vary the grid output timing of the High Voltage Unit (HV1) to adjust the
missing width at the leading edge of an image. For more information, see the Dis/Reassembly, Adjustment Section. F9: Continuous Running
This mode is used to perform a copy cycle without passing any sheet of paper. Note that the
High Voltage Unit outputs, Exposure Lamp ON and jam detection control operations are not performed in this mode. F : Display Test
" is being displayed on the Control Panel, depress the Start Key to enter this mode. The 7-Segment Display bars and Toner Empty LED are all lit, indicating that the Display is normal.
S-2
O : energized : deenergized
S-3
5. Depress the Start Key to start the operation of the corresponding adjustment mode and display the set value. 6. Depress the Up or Down Key to change the adjustment values.
* After changing the adjustment value with the Up/Down Key, depress the Start Key to write
the new adjustment value to the EEPROM, completing the adjustment. Depress the Clear/Stop Key to keep the old adjustment value stored intact without writing the new adjustment value to the EEPROM. 7. To return from the adjustment mode to the normal mode, turn the POWER ON/OFF Switch to OFF and back ON again, or swing open the Upper Half of the Copier.
S-4
Allows changing the ATDC set value (toner to carrier ratio) as indicated below:
7-Segment Display 1 2 3 4 5 Set Value (Toner to Carrier Ratio) 3% 3.5% 4% 4.5% 5% 7-Segment Display 6 7 8 9 Set Value (Toner to Carrier Ratio) 5.5% ( 6% 6.5% 7%
: Factory setting
Allows the set value of fusing temperature to be changed between 181C and 199C in
increments of 1C, as indicated below: 7-Segment Display 9 8 Set Temperature (C) 181C 182C 7-Segment Display 1 2 Set Temperature (C) 191C 192C
2 1 0
8 9
198C 199C
: Factory setting
Only used in the factory to set the reference value of the fusing temperature.
A4: Paper loop setting (Factory Use Only)
Only used in the factory to adjust the degree of a paper loop formed before the
Synchronizing Rollers. A5: ATDC reference voltage setting (Factory Use Only)
Only used in the factory to set the reference voltage of the ATDC Sensor.
S-6
2 OTHER INFORMATION
2-1. Copy Counters
This Copier has two Copy Counters: Total Copy Counter and IM Copy Counter, each of which
shows the number of copies made on the 7-Segment Display.
Each Counter is incremented when a sheet of paper leaves the Paper Exit Rollers after the
termination of the copy cycle. The Counter value is written to the EEPROM.
x Displaying the Copy Counter Values After the Copier has warmed up, depress the Up Key ( + ) and Clear/Stop Key at the same
time. This displays the counter types and corresponding count values in two digits in the following sequence:
Display example: The total number of copies made = 41344, the number of IM copies made= 16344
Normal display
S-7
This Copier has the Credit Function which allows copies to be made on a further 50 sheets of
paper for the time being if the drum life has been reached.
When the IM Counter reaches 25000 copies, the 7-Segment Display shows " machine is stopped, and the copy cycle is disabled.
", the
In the copy disabled state, depress the Clear/Stop Key and Down Key ( ) at the same time to enable copies to be made on 50 sheets of paper for the time being. At this time, the 7-Segment Display shows the set number of copies and " " alternately (Credit Function).
When the IM Counter reaches 25050 copies, the 7-Segment Display shows " machine is stopped completely, and the copy cycle is disabled.
", the
S-8
DIS/REASSEMBLY, ADJUSTMENT
1 SERVICE INSTRUCTIONS
1-1. Precautions for Disassembly/Adjustment
Observe the following precautions whenever servicing the copier.
Be sure to unplug the copier from the power outlet before attempting to service the copier. While power is being supplied to the copier, do not attempt to remove/install the print jacks If the copier is run with Its Covers removed, use care not to allow your clothing to be caught In Do not use flammable spray around the copier in operation. The Developing Unit generates strong magnetic force. Do not bring it near a cathode-ray tube When handling the P.W. Boards with MOS ICs, observe 1-2." Instructions for Handling the It should be noted that fuses are used with double-pole/neutral wires. If it becomes necessary to replace fuses and thermal fuses, be sure to use ones of the
following ratings. PWB-C F1 250 V T3.15 A F1 250 V T630 mA PWB-D F2 250 V T6.3 A # F3 250 V T6.3 A # TF1 141 C 10 A 250 V TF2 167 C 10 A 250 V PWBs with MOS ICs." or watch. revolving parts such as the Timing Belt. from/to the P.W. Boards or unplug/plug in the connectors.
D-1
1. All screws of IM
1132D007
1132D009
6. Distance between 1st and 2nd Slider by adjusting screw of drive cable
D-2
10. Paper feeding segment position by 1. Slit for kick spring 2. Fixing at slot in gear plate
2 DISASSEMBLY
2-1. Identification of Covers
Original Cover
Original Glass
Top Cover
Right Cover
Front Cover
Left Cover
Rear Cover
D-3
D-4
2. Close the Upper Half and remove two screws that secure the Front Cover.
3. Slide the Front Cover slightly forward,remove Operation Panel by pressing panel from the rear at upper center position and unplug the two Connectors of the Operation Panel., and remove the Front Cover.
Reassembling Procedure 1. Guide thew harness for the operation Panel through the hole for the panel in the Front Cover and press the Operation Panel inside the hole in the Front Cover. 2. Slide the Front Cover to the machine. Pay attention for not squeezing the harness of the Operation Panel between cover and optic frame (hold down harness).
D-5
2. Hold up the Imaging Module and disconnect the two fastened terminals (HV; right side) and one connector (left side; under toner bottle holder).
3. Slightly lift the Imaging Module, hold down the Securing Lever, slide the Imaging Module to the left and pull it out to the front.
D-6
NOTE Wear gloves to handle the Glass Tube of the Exposure Lamp.
4. Wipe the Lamp with a soft cloth dampened with alcohol.
1132D063
5. When reinstalling the Exposure Lamp, face the protrusion of the Lamp toward the Lamp Reflector Opening and make sure that the Lamp Terminal fits securely in the Terminal on the right of the Scanner. Check the light homogeneity and distribution on copy (refer to 3-1)
3. Unplug the two Connectors of the Exposure Lamp Thermal Fuse Holder.
D-7
4. Remove one screw and the Exposure Lamp Thermal Fuse Holder. * When the Exposure Lamp Thermal Fuse Holder cannot be removed easily, unplug the Connector of the right-hand side Exposure Lamp Terminal.
1132D057
5. Remove two screws from the Exposure Lamp Thermal Fuse Holder and remove the Exposure Lamp Thermal Fuse.
ATTENTION Make sure that thermofuse is in contact with the fuse holder and the lamp reflector.
1132D058
3. Remove the Original Cover, Top Cover and Original Glass. 4. Remove two screws and the Ozone Filter Cover.
5. Lift the left-hand side of the Ozone Filter and slide the Ozone Filter to the left to remove.
D-8
NOTE Any Mirror that has a thick coat of dust and/or dirt needs to be wiped with a soft cloth after it has been cleaned with the blower brush.
3. Switch on the copier and pull the cassette out. 4. Depress the Start Key. When the Scanner comes near the bottom of the Original Scale, turn off the Power Switch.
6. Dust the Lens and 4th Mirror with the blower brush.
NOTE The Lens or Mirror that has a thick coat of dust and/or dirt needs to be wiped with a soft cloth after it has been cleaned with the blower brush.
7. Swing up the Upper Half of the Unit and dust the 5th and 6th Mirrors with the blower brush.
NOTE Any Mirror that has a thick coat of dust and/or dirt needs to be wiped with a soft cloth after it has been cleaned with the blower brush.
D-9
3. Unplug the three Connectors used for the Paper Exit Switch, Fusing Thermistor and Heater Lamp, and remove the Harness from the Wire Saddle.
4. Remove the Ground Wire of the Fusing Unit and the Ground Wire of the Pre-Fusing Guide Plate.
5. Unplug the two Connectors used for the Paper Synchronizing Clutch and Paper Take-Up Solenoid.
6. Unplug the four Connectors on the Power Board, the three Connectors of the Outlet and the one connector on the High Voltage Unit, and remove them from the Wire Saddle. 7. Remove the Power Board and High Voltage Unit.
D-10
9. Loosen the hexagon screw (Inbus 4 mm) on the Upper-Lower Half Coupling Shaft.
10. Hold to the front the gear meshing with the Main Motor Output Shaft and pull out the Drive Unit to the front to remove.
NOTE When reinstalling the Drive Unit, engage the Paper Feed Clutch Mounting Plate with the Adjusting Shaft of the Drive Unit.
NOTE When reinstalling the Drive Unit, engage the projection of the Paper Synchronizing Clutch with the Securing Portion of the Drive Unit.
D-11
NOTE Take care not to loose the steel balls, if disassembling the Torque Limiter.
2. Remove one screw and the Actuator of the Paper Leading Edge Sensor and the Guide Plate.
2-15-1. Removal of the Paper Take-Up Roll and Paper Feed Roll
1. Remove two screws and the Paper Feed Unit.
D-12
2. Remove the E-ring and slide the shaft with Paper Take-Up Rolls to the inside.
3. Remove the E-rings on both ends of the One-Way Gear and remove the One-Way Gear.
2. Remove while holder by clipping out at the top and than press the Counter Pressure Axle at one side down.
3. Remove pressure bracket from shaft by pulling. Remark: For assembling go back the same steps. The spring should be assembled when clipping in the holder.
D-13
1. Remove Power Plug and Cassette. 2. Lift-Up machine until its supported by the Rear Cover. Take care, not to push machine accidentally.
3. Press back the fork part 1 near the separation pad 2 . Press the separation pad upwards and pull the fork part to the front. 4. Now forcely pull the separation pad to the front side.
D-14
2. Remove one screw, the Actuator of the Paper Leading Edge Sensor, and the Guide Plate.
3. Unplug the connector for the paper synchronizing (timing) Clutch. 4. Loosen the PWB-D and shift the connector of the clutch back through the hole in the gear plate.
When reinstalling the Assy, use care not to mar the mylar. NOTE When reinstalling the Assy, securely engage the protrusions at the bushings of the Synchronizing Roller Assy with the holes in the Frame.
NOTE When reinstalling Assy engage the projection of the timing clutch with the scanning position of the Gear Drive Unit.
D-15
3. PC2 is located under the guide plate and must be clipped off from the cassette port of the vase plate.
NOTE The Fusing Unit may be removed without removing the Drive Unit. When the Drive Unit is not removed, the Fusing Unit cannot be reinstalled easily. At this time, reinstall the Fusing Unit securely using care not to damage the washer.
2. 3. 4. 5.
Remove screw of ground cable. Unplug connector for Heater Lamp. Unplug connectors for Thermistor and Exit Switch. Remove HV-Unit from gear plate.
6. Loosen axle with hexagon screw (3mm) at front of gear plate. 7. Pull off axle about 8mm.
D-16
8. Shift Fuser at right side. A: 10mm to the front B: 3mm upwards Then shift whole fusing unit. C: 3mm to the left
NOTE When assembling take care for the washer near double gear. 1. It is located between frame and gear. 2. When pressing in axle the washer may block
9. Remove one screw and the plastic part which retains the Fusing Unit Upper Cover. 10. Remove one screw and the Fusing Unit Upper Cover.
12. Remove one screw and the Fusing Roller Thermal Fuse Mounting Plate.
1132D040
D-17
13. Remove two screws and both Terminals of the Heater Lamp.
14. Remove two screws and the Left Fusing Unit Cover.
NOTE When reinstalling the Cover, make sure that the end of the Heater Lamp fits securely in the Bearing of the Cover.
1132D042
1132D043
1132D044
17. Snap off the C-ring and remove the gear and bearing.
1132D045
D-18
1132D046
1132D047
3. Remove one screw (axle) shown and shift the Guide Plate stopper upwards (also at the opposite side).
NOTE At this time, use care not to lose the plate nut.
D-19
3. Remove one screw shown and the sheet metal that holds the Switching Power Board.
5. Slightly lift up the motor cover with one hand and with the other lift the Switching Power Board and pull it out to the front to remove.
D-20
4. Slightly lift up the motor cover, slide the Main Motor to the right and pull it out to the front to remove.
D-21
2. Pull and simultaneously bent the PWB carefully until tip of the positioning pin.
3. Now slide the Erase Lamp to the left and remove the Connector on the Logic Board. 4. Slide the Erase Lamp to the right to remove.
NOTE At this time, use care not to break the Erase Lamp.
D-22
3. Unplug the three Connectors used for the Paper Exit Switch, Fusing Thermistor and Heater Lamp, and remove the Harness from the Wire Saddle.
4. Unplug the two Connectors used for the Paper Synchronizing Clutch and Paper Take-Up Solenoid.
5. Unplug the four Connectors on the Power Board, the three Connectors of the Outlet and the one connector on the High Voltage Unit, and remove them from the Wire Saddle. 6. Remove the Power Board and High Voltage Unit. 7. Exchange PWB and connect to the harness. 8. Adjust the maximum exposure voltage following 3-5. 9. Reassemble covers.
D-23
4. Unplug the two Connectors used for the Paper Synchronizing Clutch and Paper Take-Up Solenoid.
6. Unplug one Connector form the High Voltage Unit. 7. Remove the Power Board and High Voltage Unit. Remark: Adjustment not necessary. Part is preadjustted. 8. Loosen high voltage unit from holding pins. Pull power board slightly to the front at left upper corner and remove two high voltage cables from the cable channel behind the board.
NOTE When assembling take care for correct positioning/ squeeze of HV-cables to Imaging Module.
D-24
2. Exchange EEPROM from OLD to the NEW PWB-A. 3. Reassemble PWB-A and connect to harnesses and reinstall the Front Cover. OLD
NEW
A3 label
4. Plug in Power Cord and enter Adjusting Mode A3. Read value on A3-label of new PWB-A and put in this value to panel.
5. Enter the Function Mode. 5.1. Make Display Test F. 5.2. Make Passing Test F1. 6. Assemble Housing Covers. 7. Check Leading Edge Registration and Leading Edge Width following 3-3 and 3-4. It is not OK, change by using Function Mode F4/F5.
D-25
4. Remove screw 1 which fixes the turning roll for drive cable to the 2nd slider.
5. Pull upwards plastic part 1 at 1st slider at the right side which also secures the Auxiliary Reflector. 6. Remove the ring at cable end 2 from bracket of 1st slider.
7. Carefully mark the position of the cable holder which is fixed at the rear glass plate holder within 0.1mm.
NOTE The position of the rear cable holder is a important optical adjustment item.
Cable
D-26
3 ADJUSTMENT
3-1. Adjustment of the Image Density
Should uneven image density occur in the feeding direction, make the following checks first, then make the necessary adjustment.
Clean the PC Drum Charge Corona, Grid Mesh, and Image Transfer Corona Wire. Clean the Mirrors and Lens. Check that the protrusion in the Exposure Lamp faces upward. Check that the Cleaning Blade is in good condition.
1. Set the Exposure Control Knob to the center and make a copy on A4 paper.
3. Turn the copy around to reverse its leading and trailing edges, and place it on top of the copier so that its trailing edge faces the Aperture Plates.
Lighter Darker
4. Adjust the Aperture Plates as necessary to correct any unevenness on the copies. * Slide the Aperture Plates to the front to make the image darker, and to the back to make it lighter.
D-27
2. Fold the copy in half and check to see if the fold matches the centerline of the copy.
3-1. If the copy looks as shown on the left, loosen the two screws securing the Original Scale and move it in the direction of the arrow.
3-2. If the copy looks as shown on the left, loosen the two screws securing the Original Scale and move it in the direction of the arrow.
NOTE Take care not to move original scale to the front or to the rear to avoid skewed image.
D-28
10 1.5 mm
2. Measure the distance between the leading edge and the line of the copy. (When this distance is 10 1.5 mm, no adjustment is required.)
3. After turning the Power Switch OFF, hold down the Up and Down Keys and turn the Power Switch ON to start up the function mode, and select the F4 mode. 4. Depress the Start Key and check the data. Standard value is 50. The factory setting is shown on a label at the top of the right cover which can be seen when opening machine.
5-1. If the measurement in step 2 is greater than 10 mm, choose the needed Correction Distance from the table below and add its step value to the data value given in step 4 using the Up/Down Key. 5-2. If the measurement in step 2 is less than 10 mm, choose the needed Correction distance from the table below and subtract its step value from the data value given in step 4 using the Up/Down Key. 6. Depress the Start Key to write the corrected data to the EEPROM. Check copy. If this is ok, correkt the value on the label. 7. Check leading edge erase width at last copies and correct following 3-4. Table for Conversion into the Correction Step (1 step/0.17 mm, correction range: 1 to 99) Step 1 2 3 4 5 6 7 8 9 10 Correction Distance 0.17 0.34 0.51 0.68 0.85 1.02 1.19 1.36 1.53 1.70 mm mm mm mm mm mm mm mm mm mm Step 11 12 13 14 15 16 17 18 19 20 Correction Distance 1.87 2.04 2.21 2.38 2.55 2.72 2.89 3.06 3.23 3.40 mm mm mm mm mm mm mm mm mm mm Step 21 22 23 24 25 26 27 28 29 30 Correction Distance 3.57 3.74 3.91 4.08 4.25 4.42 4.59 4.76 4.93 5.10 mm mm mm mm mm mm mm mm mm mm Step 31 32 33 34 35 97 98 Correction Distance 5.27 mm 5.44 mm 5.61 mm 5.78 mm 5.95 mm 16.49 mm 16.66 mm
D-29
3 2.5 mm
2. Measure the erase width at the leading edge of the copy. (When this width is 3 2.5 mm, no adjustment is required.)
3. After turning the Power Switch OFF, hold down the Up and Down Keys and turn the Power Switch ON to start up the function mode, and select the F5 mode. 4. Depress the Start Key and check the data. Standard value is 50. The factory setting is shown on a label at the top of the right cover which can be seen when opening machine.
5-1. If the measurement in step 2 is greater than 3 2.5 mm, choose the needed Correction Distance from the table below and subtract its step value from the data value given in step 4 using the Up/Down Key. 5-2. If the measurement in step 2 is less than 3 2.5 mm, choose the needed Correction Distance from the table below and add its step value from the data value given in step 4 using the Up/Down Key. 6. Depress the Start Key to write the corrected data to the EEPROM. Check copy. If this is ok, correkt the value on the label. Table for Conversion into the Correction Step (1 step/0.17 mm, correction range: 1 to 99) Step 1 2 3 4 5 6 7 8 9 10 Correction Distance 0.17 0.34 0.51 0.68 0.85 1.02 1.19 1.36 1.53 1.70 mm mm mm mm mm mm mm mm mm mm Step 11 12 13 14 15 16 17 18 19 20 Correction Distance 1.87 2.04 2.21 2.38 2.55 2.72 2.89 3.06 3.23 3.40 mm mm mm mm mm mm mm mm mm mm Step 21 22 23 24 25 26 27 28 29 30 Correction Distance 3.57 3.74 3.91 4.08 4.25 4.42 4.59 4.76 4.93 5.10 mm mm mm mm mm mm mm mm mm mm Step 31 32 33 34 35 97 98 Correction Distance 5.27 mm 5.44 mm 5.61 mm 5.78 mm 5.95 mm 16.49 mm 16.66 mm
D-30
3. Hold down the Up and Down Keys and turn the Power Switch to ON start up the function mode, and select the F3 mode.
4. Connect a RMS multimeter across Terminals 1 and 4 of PJ3D on the Power Board and depress the Start Key.
5. Turn Variable Resistor R7 on the Power Board to adjust the Exposure Lamp voltage to 147 (+2) V eff.
D-31
NOTE Do not forget to remove the sealing tape from the Starter Bottle.
D-33
IC3
Close machine. Display shows "UF". Starter filling must now be initiated by pressing the copy key. Wait approx. five minutes until display shows "1". Open machine and remove empty starter bottle. Shake toner bottle well, remove sealing tape and insert toner bottle. Close machine, unplug power cord and reassemble all covers. After plugging power cord in and switching power ON machine will be ready to copy.
D-34
TROUBLESHOOTING
General Precautions 1. When servicing this copier with its covers removed, use utmost care to prevent your hands, clothing, and tools from being caught in revolving parts. 2. Before attempting to replace parts and unplugging connectors, make sure that no power is being supplied from the copier. 3. When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the green wire (GND). 4. Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged. Reading the Text 1. If a component on a PWB or any other functional unit including a motor is defective, the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedure applicable within the defective unit. 2. The text assumes that there are no breaks in the harnesses and all connectors are plugged into the right positions.
E2
: - wrong starter detected after starter filling - ADTC sensor control voltage exceeded after starter filling - developing unit failure - ATDC sensor failure - PWB-A failure
C1 Scanner fan
: - scanner fan not connected, check "PJ1" on PWB-A - PWB-A failure : exposure lamp failure exposure lamp not connected power supply to exposure lamp interrupted connector "CN7" of exposure lamp harness not connected - connector "LA1-2" of exposure lamp harness not connected - connector "TB3-1" of exposure lamp harness not connected - malfunction of exposure lamp thermal fuse "TF1" - exposure lamp control circuit failure - PWB-A and/or PWB-D failure
C5 Warm-up malfunction : - temperatur in fusing unit does not achieve 185oC within 30 sec. after power on - connector "PJ3" on PWB-D not connected - connector "CN6" of fusing unit harness not connected - failure of fusing unit thermal fuse "TF1" - thermistor "TH1" short-circuited - thermistor "TH1" not connected, check "CN10" of harness - failure of fusing unit heater lamp - failure of power supply to fusing unit - malfunction in control circuit of fusing unit heater lamp - PWB-A and/or PWB-D failure
T-1
: - motor does not start when start key is pressed - scanner does not reach the two sensors within specified timing - motor not deactivated after end of copy cycle - connector "PJ2" on PWB-D not connected - motor power supply interrupted - motor failure - motor overheating error - motor control circuit failure - PWB-A and/or PWB-D failure
C7 Low-temperature error
: - after warm-up the fusing unit temperature falls below 138oC - connector "PJ3" on PWB-D not connected - failure of fusing unit thermal fuse "TF1" - thermistor "TH1" failure - failure of fusing unit heater lamp - power supply to fusing unit interrupted - malfunction in control circuit of fusing unit heater lamp - PWB-A and/or PWB-D failure
C8 Over-temperature error
: : -
fusing unit temperature is 220oC for 2 sec. thermistor "TH1" short-circuited failure in control circuit of fusing unit heater lamp PWB-A and/or PWB-D failure EEPROM not connected EEPROM not properly connected EEPROM failure error in EEPROM write/read routine PWB-A failure
T-2