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ricoh ft5540/5550/5570 service manual ricoh company, ltd.

1. om cus iss ce 5 me ox or iis sur ig as om aes aes coop ms ag 163 19 co 163 164 ouo 18 IC TRANSISTOR RESISTOR SYMBOL n SYMBOL Be SYMBOL SYMBOL SYMBOL 1NDEX SYMBOL sy SYMBOL SYMBOL NO NO NO NO NO NO NO NO NO ico 191 zu 12130 a 133 133 1650 ue oun 193 omi 16100 132 128 10121 138 10131 4 133 133 1151 120 R101 173 R115 185 16102 130 127 16122 139 16132 136 10142 147 L 115 102 13 R16 185 iq 13 15 136 1 13 um 173 R117 185 145 10124 195 10134 142 10144 136 OSCILLATOR R104 171 R118 185 15 16135 149 10145 136 8105 180 R119 185 16106 140 1 116 136 16126 137 1C136 2 10146 34 NO NO R fee 136 1 117 136 10127 136 Gn 134 E T 4 16108 1
2. 12 11 TROUBLESHOOTING 1 2 1 9 1 SERVICE CALL CONDITIONS 13 1 DEFECTIVE SENSOR TABLE 13 8 5 BIN SORTER VoPECIFICATIONS seed ee hee E ous 14 1 MECHANICAL COMPONENT 14 2 DRIVE LAYOUT ieee wae oe ca 14 3 ELECTRICAL COMPONENT 14 4 ELECTRICAL COMPONENT DESCRIPTIONS 14 5 BASIC OPERATION totic ites bedi eee ernie 14 6 FUNCTIONAL AND ELECTRICAL DESCRIPTION 14 10 TA POWer SUP PIM aeuo a sas 14 10 Bin Gale Operation chet inosine wae a a 14 11 7 3 Relay Guide Plate Reset 14 12 7 4 Interface with the 14 13 SINS ONS aaa dettes tei ode 14 15 nlet Senso ae be es aa wana ne 14 16 Til CHECK c 52st ROC a Wane d 14 17 SINSTALEATION Ree tha ee 14 19 5 1 Accessory Check o dedecus s rere eS lente Bed ee tan a Ed 14 19 5 2 Installation sog uu vea RES a 14 20 SERVICE TABLES cerle RE kw xa Red 14 25 0 REPLACEMENT AND ADJUSTMENT
3. Philips Screw With Flat Washer M4x6 Co 1102 1625 Receptacl i 13 10 1102 1661 Receptacl i E 13 11 1102 1745 Receptacl 15 11 1102 1778 Connector 13 11 1102 1779 Connector 13 1 1102 1784 Connector 13 11 1102 1815 ector 15 108 1102 1815 ector 15 109 1102 1915 ector 17 110 Fastening Receptacle Fastening Receptacle Fastening Receptacle Fastening Receptacle Screw 1 1100 1241 Socket Mate N 15 103 a Screw 1 1100 1241 Socket Mate N 15 113 Philips F Screw 1 1100 1247 Terminal 15 104 Philips F Screw 1 1100 1247 Terminal 15 114 Philips Screw 1 1100 1249 Receptacle Terminal 13 102 Philips Screw 1 1100 1249 Receptacle Terminal 17 103 Philips H Screw 1 1100 1253 Pin Mate N Lock 13 103 Philips E Head Screw 1100 1327 Contact 13 104 Philips Head Screw 111 1100 1327 Contact 17 104 Philips Pan H Screw 106 1100 1404 Receptacle Sleeve 15 115 Tapping Screw M4x6 107 1101 0359 Terminal 3P 5 17 Tapping Screw 4 6 109 1102 0796 Connecting Sleeve 3 0mm 220V 15 105 Tapping Screw M4x8 108 1102 0895 Nylon Stud 5297 Tapping Screw M4x8 108 1102 1404 Receptacle Housing 15 106 Hexagon Headless Set Screw 5 5 109 1102 1404 Receptacle Housing 17 105 Hexagon Headless Set Screw 5 5 104 1102 1506 Pin Housing Mate N Lock 10P 13 105 Washer 6mm 110 1102 1507 nector 2E 15 116 Washer 8mm 115 1102 1514 nector 1
4. 10 21 7 5 Side Registration 10 23 2 5 K LCT 1 SPECIFICATIONS yao arg Cm Rae 11 1 2 ELECTRICAL COMPONENT 11 2 3 FUNCTIONAL AND ELECTRICAL OPERATION 11 3 3 1 TRAY 11 3 INSTALLATION 2 0 44 Fe aint sda E eSB EE CeO ee Bey inte xS 11 5 4 1 Accessory Ai xe ee bk Ree ERG Shee awe RA AER S RUE 11 5 4 2 Installation E DC 11 6 MENU READER A N S9PEGIFICATIONS 2 5 12 1 OVERALL MACHINE CONTROL 12 2 DATA FORMAT 12 3 BASIC 12 4 4 1 Job Sheet Reading RARE E RIAM 12 4 4 2 Menu Reader Indicator 0 5 12 6 4 3 Processing EITOES vu sve orsa da y horn ae we RUD WR UR ASIE REOR RR RR 12 7 INSTALLATION eh aa Sa eae 12 8 5 1 ACCESSORY CHECK wi guise eee ruat e E S E ee 12 8 5 2 INSTALLATION PROGEDURE ere moe 12 9 REPLACEMENT AND ADJUSTMENT 12 11 6 1 Lower Transport Roller
5. 5 33 4 9 Fusing Pressure 5 34 4 10 Hot Roller Temperature 5 35 4 11 Idling Period Selection 3 2 2 04 220644 REPERI ELEME LEER ce ees odes 5 35 IPAPER PEED ore ob Pe Te DE ed eee 5 36 5 1 Pick up Paper Feed and Separation Roller Replacement 5 36 5 2 Transport Unit Removal i4 se aa nal xh ry ER x gk re 5 37 SDUPLE ccna race method ctn ar px aU dE Md 5 39 6 2 Duplex Transport and Fork Gate Units 5 40 6 3 Jogger Unit 5 42 6 4 Duplex Pick up and Feed Roller Replacement 5 43 6 5 Duplex Separation Roller Replacement 5 44 6 6 Positioning and Entrance Actuator Rollers Replacement 5 45 6 7 Duplex Pick up Solenoid 5 46 6 8 Jogger Wire 5 47 COPYIIMAGE 1 3 oup neato we wea 5 49 7 1 Vertical Magnification 5 49 7 2 Horizontal Magnificallon ee x ee a ee 5 50 1 3 FOCUS Adjustment e ew oe
6. 5 59 8 2 Pre quenching Corona Wire 5 61 8 3 Transfer and Separation Corona Wires Replacement 5 62 8 4 Charge Cleaner Drive Wire 5 63 8 5 TC SC Cleaner Drive Wire 5 64 8 6 Drum Current Adjustment 5 65 8 7 Charge Corona Current Adjustment 5 67 8 8 Transfer Corona Current 5 68 8 9 Separation Corona Current 5 69 8 10 Pre Cleaning Corona Current 5 71 8 11 Pre Quenching Corona Current 5 72 92 OTHERS iarere 5 73 9 1 Power Supply Unit Removal 1 OPTICS 1 1 Exposure Glass Removal A es lt A B 1 Remove the left scale A 2 short screws 31 August 1989 2 Grasp the left edge of the exposure glass B and lift it up slightly Slide the other edge out from under the right glass holder Remove the exposure glass NOTE When reinstalling the exposure glass Make sure that the left edge of the glass is flush with the two tabs to the left on the scale plate Make sure that
7. 2 61 outer ig oe Ses HEAD es IHE ma rA ee A eS 2 61 9 2 PRE QUENCHING CORONA CIRCUIT 2 62 10 PAPER 2 63 TORO VE Ee ate 2 63 10 2 LIFT MECHANISM AND PAPER END DETECTION 2 64 10 3 ROLLER FUNCTION e dor aedes 2 66 10 4 SLIP CLUTCH MECHANISM 10 5 PAPER FEED DRIVE 10 6 MANUAL FEED acces DEAS T bard vU OE dE URP TOME 2 71 10 7 RELAY FEED AND REGISTRATION 2 72 10 8 SIZE SENSORS 2etuevewonneta reais 2 74 10 9 LIFT MOTOR CONTROL AND PAPER END DETECTION 2 15 11 PAPER TRANSPORT 2 77 S 1555 3 00 bs eine E T abe re ne 2 77 11 2 TRANSPORT UNIT RELEASE MECHANISM 2 78 12 IMAGE FUSING AND PAPER 2 79 Tte OVERVIEW eos otto ee tta uu Sas ee ee ae 2 79 12 2 FUSING DRIVE MEGHANISM s awe hae chis 2 80 12 3 ENTRANCE GUID Emea area E S 2 81 12 4 OIL SUPPLY AND CLEANING aan 2 82 12 5 OIL ENBASENSOR x x 2 vun Re ee a eves 2 83 12 5 FUSING EXIT ASSEMBLY S RR RS T27 EBSING CONTROL icm
8. 5 43 6 5 Duplex Separation Roller 5 44 6 6 Positioning and Entrance Actuator Rollers 5 45 6 7 Duplex Pick up Solenoid 5 46 6 8 Jogger Wire 5 47 2252 xo Sex 5 49 7 1 Vertical Magnification 5 5 49 7 0 Tortzontal Magnification wt 3 i ra aere Agee wx E 5 50 FOCUS ces EDS 5 51 7 4 Uneven Exposure 51 5 52 7 5 Light Intensity 5 5 53 7 6 ADS Reference Voltage 5 54 Ft ADS N Oltage AdJustmernt Winds es eevee thee 5 59 7 8 ADS Operation 5 56 Ease AGUSIMCN Or er ene xt Ie Etude 5 56 Registration E RR CREW utr ena 5 57 7 11 Side to Side Registration 5 58 5 59 8 1 Charge Corona Wire
9. Lr RF n C e c ds 1 Oo gt Q Q Q Q Q Q Q Q August 31 89 Page and Page and Parts No Description TD62308AP IC PST518A IC 519711 IC 5183011 17339 5182031 Ceramic Oscillator 10MHz Resistor 0 470HM 1 8W 5 Connector Connector Connector Connector Connector Connector Connector Connector Resistor 5100HM 5 1W Resistor 3900HM 1W Connector de Connector Connector 2P 11 1 1601 Resistor Array 10 Connector tal 1601 Variable istor 5KOHM Connector 2P 1121 1601 Variable istor 10 0 54 LSI Socket 42 1601 Variable istor 20 Fuse Holder 11 11 1601 Variable Resistor 100 lip 3N 1 1 Coil 800pH 2 5A lip 4N 1 1 Capacitor 1000 10V Capacitor 220pF 10V lip 1 1 Capacitor 50V iversal Bushing 2 4mm 1 1 Capaci 2 2 50V Fuse 1 PSI 1 1 Capaci 3 3pF 50V Fuse 3A 11 11 1 1 Capaci 4 7 50V DIP Switch 11 11 1 1 Capaci 470pF 50V Micro Switch 1 1 Capaci 1000 50V Push Switch 11 11 1 1 4700 50V Transistor 254683 1 Capaci 0 1 50V Transistor 2SB20 eT 1
10. C C C c e A A A Ae Philips ead Screw 136 August 31 89 te Page and fone 8 104 1 4 25 1 Tappi 4x8 27 1 ts No Description rage Ani Index No Screw Screw Screw Tappi 4 8 29 1 Screw Tappi 4 8 31 1 Screw Tappi x8 Tappi x8 Tappi x8 Tappi x8 Tappi x8 Tappi x8 Tappi x8 Tappi x8 Tappi x8 Tappi x8 Tappi x8 Tappi M4x8 ead Screw Head Screw 3x6 Head Screw 3x6 Head Screw 3x6 H Screw M4x8 Head Screw M4x8 Head Screw M4x6 M3x6 With Flat Washer M4x8 M4x10 Tappi 4x8 Tappi 4x8 Tappi 4 1 1 1 1 1 exagon exagon exagon exagon exagon Hexagon Hexagon Hexagon Hexagon Hexagon exagon 137 August 31 89 N Parts No Description Index No Hexagon Headless Set Screw M5x5 Q Q Hexagon Headless Set Screw M5x6 Socket Bolt M4x5 Hexagon Bolt M4x6 Spring Pin 2x6mm Parallel Pin M2x1 Parallel Pin M2x1 Spring Pin 3x10mn Spring
11. 2 108 15 1 DC POWER DISTRIBUTION tiie DEOR D aa AG RC CR 2 108 15 2 SAFETY SWITCH CIRCUITS PC C CAD Ru e E 2 109 15 3 AC COMPONENT 2 110 15 4 CORONA CLEANER 5 2 111 15 5 PULSE 2 112 15 6 MAGNETIC CLUTCH AND SOLENOID CONTROL 2 113 15 7 SENSOR 2 114 15 8 COUNTER CIRCUITS cR ORC 2 117 INSTALLATION 1 INSTALLATION REQUIREMENTS 3 1 1 1 ENVIRONMENT Racer SCC Cd di DR naci ca a aee End aa 3 1 1 2 MINIMUM SPACE 5 3 2 1 3 MACHINE LEVEL c his Steve are EE MP CE BN e END e fanc T i 3 3 14 POWER SOURCE Ca E RON OC Maid 2E EC ee 3 3 2 ACCESSORY 3 4 3 INSTALLATION PROCEDURE 3 5 3 1 COPIER INSTALLATION 5 5 adea Cae CR ORA atte 3 5 3 2 CASSETTE 3 15 3 3 KEY COUNTER HOLDER INSTALLATION 3 16 SERVICE TABLES 1 TABLE 99 Rn eee ree oe ure gu
12. 5 17 2 6 Toner Supply System 0 5 18 2 7 Toner Density 5 19 2 8 Fixed Supply Mode 5 19 2 9 Toner Amount 0 5 19 2 10 ID Pattern Bias Voltage 5 19 Me cp ves ae reece eaten we 5 20 3 1 Pick off Replacement 5 20 3 2 Cleaning Blade and Brush Replacement 5 22 3 3 Blade Cleaner and Bias Roller Blade Replacement 5 23 Rae S A or RR ce c we 5 24 4 1 Fusing Unit Removal fey os eee ee ERE yx A nk En 5 24 4 2 Oil Blade 5 25 4 3 Thermistor 1 5 26 4 4 Thermofuse 5 27 4 5 Hot Roller Stripper 5 28 4 6 Hot Roller 5 29 4 7 Pressure Roller 5 32 4 8 Entrance Guide Height
13. 9 17 8 3 Bin 9 18 8 4 Exit Roller Drive Motor Replacement 9 19 8 5 Lower Exit Roller Unit and Exit Sensor 9 20 1 1 SPECIFICATIONS SOROR AC CHR NOR OO 10 1 2 MECHANICAL COMPONENT LAYOUT 10 2 3 DRIVE LAYOUT AND DRIVE MECHANISM 10 3 4 ELECTRICAL COMPONENT 10 4 5 FUNCTIONAL AND ELECTRICAL DESCRIPTION 10 5 5 T THRAY OPERATION ete t tete LR ARR d 10 5 5 2 PAPER SIZE CHANGE AND 10 7 5 3 PAPER VOLUME DETECTION 10 8 5 4 COVER SAFETY SWITCH AR hee 10 9 6 INSTALLATION 4 545 4 Gwe rhe ean Ses 10 10 6 1 Accessory Check S bn ecd aed ee 10 10 6 2 Installation Procedure 10 11 7 REPLACEMENT AND 10 15 7 1 Tray Down Sensor and Positioning Switch Replacement 10 15 7 2 Paper Size Sensor Replacement 10 17 7 3 Tray Wire 10 18 7 4 Paper Volume Cord
14. 2 EXTERIOR 2 A045 A046 August 31 89 Q ty Per Index Assembly No A007 5862 ain Control Board Angle 01 0434 0060W Tapping Screw M4x6 007 1065 Upper Left Stay 1 02 0434 00801 Tapping Screw M4x8 A007 1066 Upper Right Stay 03 0720 00302 Retaining Ring M3 007 5005 Left Stay Transport Chamber 04 0720 0040E Retaining Ring 4 Q ty Per Part No Description Assembly Part No Description 4007 5006 Right Stay Transport Chamber 05 0801 1179 ips Screw With Toothed Washer 06 6019 Transport Spring 14 5027 Shutter Shaft A007 4381 nector Bracket 06 6014 nector Shotter Spring A007 4382 nector Shutter Plate A007 2125 Side Plate Behind Drum A007 5864 Fan Angle A007 2894 Cushion 8x15x30 A007 1068 Leaf Spring Transport Handle 5205 2893 Cushion Sector Gear 5206 2851 Right Fork Gate Guide A007 4370 Fusing Unit Rail A007 4376 Release Lever Fusing Unit CO co 5205 1170 Spring Fusing Release Lever AGO5 1003 Transport Handle Rod 5419 1057 Rubber Foot 5205 1853 Seal 14mm Mo Fr 11 3 OPTICS 1 A045 A046 August 31 89 12 3 OPTICS 1 Part No A045 A046 Q ty Per escription Assembly CO c C FSP C CO 1 O5 9 CO CO CO WwW CO WwW MR MN MB MH LH
15. Guide Upper Guide Plate Plate Spring 1 Insulating Mylar Antistatic Brush Upper Exit Roller c Bushing 4x7xl0mm Co mam Knob Cap Co Upper Guide Plate Transport Guide Roller Small Co A LED Sensor Type S Co Actuator One Turn Sensor Index P e ee 0 RES Pan Head Screw M3x12 Pan Head Screw M4x8 Pan Head Screw M4x10 Screw M4x8 Screw Flat Washer M3x6 Pan Head Screw M3x6 Pan Head Screw M3x14 Pan Head Screw M5x10 Screw 4 10 Head Tapping Screw M3x6 Head Tapping Screw M3x8 Ball Bearing 6 17 Clamp Philips Screw With Flat Washer M3x8 Microswitch Microswitch Retaining Ring M3 Retaining Ring M4 Tapping Screw With Flat Washer M4x8 gt CO C ho Lr Retaining Ring 6 Cable Clip Heat Sink Toothed Washer M4 P2 d Retaining Ring M8 Locking Support Fuse 0 5A mM o 1 Locking Support August 31 89 Index Aere Part No EE ae Pulley 18T Idle Pulley Bin Drive Tightener Bin Drive Belt Tension Spring Transport Motor DC24V Rubber Cushion 4 5x9 5x4 2mm Stepped Screw M3 Idle Pulley 6x34x11m
16. 10 8 SA COVER SAFETY SWITCH 10 9 6 1 10 10 O ACCESSO 10 10 6 2 Installation Procedure 55 ee Nee 10 11 7 REPLACEMENT AND ADJUSTMENT 10 15 7 1 Tray Down Sensor and Positioning Switch Replacement 10 15 7 2 Paper Size Sensor 10 17 io Trav Wire Replacement 5 10 18 7 4 Paper Volume Cord 10 21 7 5 Side Registration 10 23 1 SPECIFICATIONS Copy Paper Size Copy Paper Weight Tray Capacity Lift Time Power Source Power Consumption Dimensions W x D x H Weight 31 August 1989 B4 lengthwise 257 mm x 364 mm 4 lengthwise or sideways 210 mm x 297 mm B5 lengthwise or sideways 182 mm x 210 mm Legal lengthwise 82 x 14 Letter lengthwise or sideways 812 x 11 52 g to 105 g 14 Ib to 28 10 Approximately 1 000 sheets Maximum 12 seconds 50 Hz 10 seconds 60 Hz 220 V 50 Hz 0 15 240 V 50 Hz 0 15 A 115 V 60 Hz 0 3A Maximum 30 Watts 284 mm x 545 mm x 227 mm 12 kg 10 1 31 August 1989 2 MECHANICAL COMPONENT LAYOUT AM
17. 428 rigger 5 Bias 3135 ts 2156 CN101 A18 4 4 Front Cover Safety Switch The CPU sends bias trigger signal through the TC SC power pack to turn on the developer bias power pack The main board also monitors the selected image density level and the copier rest time and it sends a 4 bit bias output control signal to the bias power pack to control the bias output according to the image density level position and the 5 rest time See the table on the following page After receiving the 4 bit signal the power pack outputs the proper bias voltage This voltage 15 further compensated by the bias thermistor on the ID sensor board The bias voltage is displayed on the guidance display with SP mode 59 The displayed value does not include the compensation factor of the bias thermistor drum temperature compensation 2 36 31 August 1989 4 Bit Bias Control Signal BIT 4 BIT 3 BIT 2 BIT 1 Bias Output 0 0 0 0 260 0 0 0 290 0 0 0 320 0 0 350 0 0 0 380 0 0 410 0 0 440 0 470 0 0 0 500 0 0 530 0 0 560 0 590 0 0 620 0 650 0 680 710 NOTE 5 34 shifts the bias under all conditions There are three settings 0 60 and 120 5 7 RELATED SERVICE CALL CONDITIONS Code 31 Drum Thermistor Blown Definition Lights when the drum thermistor circuit is open Po
18. que e on op rH CO 418 0060D 0060W 0120W 0100W 0100W 4010W 0080W 0080 0160W 0040 0134 0060W Installation Procedure English Installation Procedure 5 Language DF Main Board Interface Harness Display Panel DF Cover Nut Plate Micro Switch Bracke Switch Bracket icro Switch Left Supporter Right Supporter Grip Plate Magnetic Catch Ass y Glip Cover Seal 15x30mm ip Scale LT LDG ip Scale A3 A4 iginal Exit Guide Shoulder Screw Scale Shoulder Screw M5 DF Fixing Plate Lift Switch Actuator Plate Left Hinge Right Hinge Display Board Display Board Bracket Original Table Guide Mylar Feed in Roller Cover DF Harness Bracket Interface Harness Bracket Rear Original Guide Original Feed Table LT LDG Original Feed Table A3 A4 Front Original Guide Truss Head Screw M4x6 lt Pan Head Screw M4x6 ilips Sunken Head Screw 4 12 ilips Pan Head Screw M4x10 ilips Pan Head Screw M5x10 111 5 Screw With Flat Washer M4x10 ing Screw M4x8 ilips Pan Head Screw M4x8 ilips Pan Head Screw 3 16 ining Ring M4 iversal Bushing 2 4mm Tapping Screw M4x6 August 31 89 Mylar Original Guides Cork Pad Gear 28T Wave Washer
19. Lift Sensor 2 CN2 1 dat 2 IK E vee CN2 2 As ip gt NE GNO CN2 3 176 1047 ol 8 SJ of 109 3 0102 z 100 RI24 51308 sh CH2 4 8134 3 mm RI25 100 CN109 5 NC C OI 100 13 5 4105 4 6 H IC 107 cues Ar Tr Sao 2 a CN109 8 Scan 1 IK a G3 08 2 Ren y CN109 9 pus tt CN109 10 PaPer End 2 470 lage 3 1 109 11 By Pass Mode RI38 cur 2 7 A lt 100 151588 IOK CN4 2 H P Sensor 109 12 GNO 1096105 p ec queis eom UPS 1 we ___ kg Down Key o o Hi N 2 B 5 e 6 4 t 5 F F560K Ic105 00 S RI3 RIIS 00 00 CN4 8 Positioning SW 116 T 3 100 777 d 1 CN406 8B Paper EIEH RIO Paper Lifted L 5 6K Vcc 12 1 wa esa rg 25215 SSSR 2 10 Lift 2 ET DE IK IK IC 101 GNO CN12 2 4 4 weer lt
20. eub ario eens eae 9 10 7 2 Installation PIOCedUle s 9 11 8 REPLACEMENT AND ADJUSTMENT 9 15 8 1 Bin Drive Belt 9 15 8 2 Bin Drive Motor 9 17 Reblacemellt tht anual I 9 18 8 4 Exit Roller Drive Motor 9 19 8 5 Lower Exit Roller Unit and Exit Sensor 9 20 1 SPECIFICATIONS Paper Size for Bins Paper Weight Number of Bins Bin Capacity Proof Tray Capacity Power Source Power Consumption Dimensions W x D x H Weight 31 August 1989 Maximum A3 11 x 17 Minimum 5 5 x 81 50 to 110 grams per square meter 14 to 28 Ib 20 bins proof tray Sort Mode 50 sheets A4 81 2 x 11 35 sheets A3 11 x 17 Stack Mode 35 sheets A4 872 x 11 20 sheets A3 11 x 17 150 sheets all sizes 100 volts 50 60 Hz 0 8 A from copier 80 W 450 x 508 x 503 millimeters 17 7 x 20 x 19 8 inches 21 kg 46 3 Ib 9 1 31 August 1989 2 BASIC OPERATION 2 1 CLEAR MODE When the main switch of the copier is turned on the sorter automatically assumes the clear mode It also changes to the clear mode if the sort or stack mode is recalled or if the interrupt key is
21. E zi Note Numbers circled within solenoid indicate sequence of solenoid operation The fork gate unit has five gates A through which copy paper passes to the duplex tray Two solenoids B C working together create any of five separate states for the fork gates See the figure Sol 1 C Sol 2 D Paper Size A3 DLT F ON OFF B4 LG G OFF ON A4 L LT L B5 L H gt ON 4 LT 5 gt A5 HLT Black arrows indicate initial movement 2 98 31 August 1989 14 3 DUPLEX STACKING Basic Operation Paper is stacked in the duplex tray which consists of the duplex delivery tray A and the jogger unit B The duplex delivery tray transports paper from the fork gate unit to the jogger unit The duplex delivery tray is ribbed to achieve precise stacking of paper in the duplex tray The jogger unit consists of a drive motor C jogger fences D duplex settlers E a positioning roller F and duplex stoppers G All these components work together to achieve proper stacking of paper in the duplex tray When the Start key is pressed the CPU reads the cassette paper size coding and the jogger fences are positioned 15 mm from either side of the copy paper As paper enters the duplex tray is positioned under the duplex settlers The positioning roller made of sponge rotates and pushes the paper up against the duplex stoppers t
22. etd us 8 17 14 REPLACEMENT AND ADJUSTMENT 8 25 14 1 DF Belt Drive Motor Speed 0 25 14 2 Inverter Turn Gate Solenoid 8 27 1 SPECIFICATIONS Original Size Original Weight Original Feed Modes Original Capacity Original Separation Original Transportation Original Stop System Copying Speed Power Source Power Consumption ARDF Dimensions W x D x H ARDF Weight 31 August 1989 ADF mode Maximum A3 11 x 17 Minimum A5 51 2 x 812 SADF mode Max A3 11 x 17 Min B6 5 x 8 lengthwise Maximum 130 grams 34 Ib Minimum 40 grams 11 Ib Automatic Feed ADF mode Manual Feed one by one SADF mode Maximum 50 sheets 80 gram 20 Ib FFR system One flat belt DC servomotor control system 50 cpm continuous copy 25 cpm single copy 24 volts and 5 volts from copier 20 Watts 976 x 522 x 104 millimeters 38 4 x 20 6 x 4 1 inches 12 kg 26 41 Ib 8 1 31 August 1989 2 BASIC OPERATION 2 1 INTERFACE comen Fiber Optics Board DF Main 34 Original Sensor gt 535 Original Entrance Sensor 537 Registration Sensor A i 38 Exit Sensor 5V Serial Interface 24V Feed Roller 829 ons TN RES Exit Rollers Registration Friction Roller Rollers
23. When the registration rollers start rotating the CPU simultaneously supplies a LOW signal at CN101 B5 This LOW signal energizes the pick off solenoid The CPU waits 610 milliseconds until the lead edge of the paper reaches the pick off area before turning off the pick off solenoid 24N CN101 B5 Y Pick off SOL 924 gt 2 53 31 August 1989 7 7 PRE TRANSFER LAMP AND QUENCHING LAMP CIRCUIT 24V Vp P GND V di 9 6 lt Front Door Safety Switch Main PCB TC SC P P Stabilizer D DC AC QL Inverter CN101 B20 AC Annu Alan IHI v p dts __ 414 TM pil When the main motor is energized the main board outputs LOW signal at CN101 B20 to energize the stabilizer power pack This LOW signal is routed through the TC SC power pack to the stabilizer The stabilizer has dc to ac inverter which changes 24 volts Vp to high voltage ac approximately 430 volts ac 2 54 31 August 1989 8 DRUM CLEANING 8 1 OPERATION TID Va AV Drum cleaning is accomplished by the pre cleaning corona PCC A cleaning brush B and cleaning blade C As the surface of the drum enters the cleaning unit the PCC applies an ac charge This loosens the toner on the drum In ea
24. pr NESS 2 1 Capacitor 50V Capaci 10 25V Capaci 25V Capaci 250V Capaci 1000gF 50V Do c Capaci 0 1 50V Resistor 14 V Resistor 1KOHM 1 4W e FP Pt e FP 1 h O O de gt BR gt B 25 MR20 MR20 A952 1 Menu Reader 952 2 Decal and Document 952 Parts Inde px eee eee wees 89 August 31 MENU READER A952 1 8107 1 MENU READER A952 August 31 89 ES EE mee eripi EET Cover LT 1 1 0312 5060M Philips Pan Head Screw M2 5x6 pper Cover A4 1 02 0704 00257 Toothed Washer M2 5 Indicator Decal English 3 0708 00258 Flat Washer M2 5 Indicator Decal Multi 1 04 0720 00208 Retaining Ring M2 Sheet Read Boards amp Motor 1 05 0720 00308 Retaining Ring M3 Leaf Spring 1 06 0801 1185 Philips Truss Head Screw M4x8 Shaft Upper Transport Roller 1 07 0985 2560B Tapping Screw M2 5x6 pper Transport Roller 1 08 0985 25808 Tapping Screw M2 5x8 Motor Control Board Menu Sheet Table LT Menu Sheet Table A4 Sheet Read Roller Bracket Sheet Read Roller Spring Sheet Re
25. 11 2 3 FUNCTIONAL AND ELECTRICAL OPERATION 11 3 SA TRAY OPERATION s ita heme I PENA 11 3 A INSTALLATION ae eel 11 5 4 WACCESSOrY 2o 4 2 Installation 11 6 1 SPECIFICATIONS Copy Paper Size Copy Paper Weight Tray Capacity Lift Time Power Source Power Consumption Dimensions W x D x H Weight 31 August 1989 B4 lengthwise 257 mm x 364 mm A4 lengthwise or sideways 210 mm x 297 mm B5 lengthwise or sideways 182 mm x 210 mm Legal lengthwise 8 7 x 14 Letter lengthwise or sideways 812 x 11 45 g to 105 g 14 Ib to 28 Ib Approximately 2500 sheets Maximum 33 seconds 50 Hz 28 seconds 60 Hz 220 V 50 Hz 0 3 240 V 50 Hz 0 3 115 V 60 Hz 0 6A Maximum 60 Watts 284 mm x 535 mm x 385 mm 115 V 15 kg 220 240 V 17 kg 11 1 31 August 1989 2 ELECTRICAL COMPONENT LAYOUT 2 al 1 ad 1 LCT HP Sensor 6 LCT Paper Size PCB 2 LCT Drive Motor 7 LCT Operator PCB 3 Motor Capacitor 8 Transformer 220 240 V 4 Cover Safety Switch 9 LCT Paper Volume Sensor 5 LCT Main PCB 10 Circuit Breaker 115 V 10 Fuse 220 240 V 11 2 31 August 1989 3 FUNCTIONAL AND ELECTRICAL OPERATION 3 1 TRAY OPERATION Overview The bottom plate A of the
26. 8 16 13 1 Accessory CHECK cae hs E a A E 8 16 13 2 Installation Procedure sosia AU 0A e Pre d 8 17 14 REPLACEMENT AND ADJUSTMENT 8 25 14 1 DF Belt Drive Motor Speed Adjustment 8 25 14 2 Inverter Turn Gate Solenoid 8 27 20 BIN SORTER SPECIFICA THONS ain a EI ca Se earned tu vetu dt i 9 1 2 BASIC OPERATION eius alae 9 2 2 CLEAR MODE s vd tt d E bis do ch rapa dard AR ade 9 2 2 2 SORT MODE 9 2 2 9 STACK MODE coo ax e ex a estne ud ees 9 2 2 4 EXAMPLE OF SORT MODE 9 3 3 BIN DRIVE MECHANISM 9 6 BIN HOME POSITION ae sone ek iie ano t x EROR Ro 9 7 PES cree Pa ura es ea 9 8 6 ELECTRICAL CONTROL 2 eu idee el ent Ganka tees peas ed ES 9 9 Ts INSTALLATION DR RC URS Reine RR Pees 9 10 7 Accessory CHECK 9 10 T 2 Installatiori Procedure wei o CR c 9 11 8 REPLACEMENT AND 5 9 15 8 1 Bin Drive Belt 9 15 8 2 Bin Drive Motor
27. Page and P De n arts No scriptio index No Resi Resi Resi Resi Resi Resi Resi Resi Thyristor TD62601P Resistor Resistor Resistor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor stor stor stor stor stor stor stor stor 400V 8 1000HM 1T 5 1 5T 5 2200HM 1W 0 68 35V 3 3pF 35V 4 7 25V 0 1 50V 0 01pF 1000 50 0 1 50 0 47pF 630VDC 1KOHM 1 4 5 10 1 4 10 1 4T 15KOHM 1 4T 1 4 1 4 1 4T 5 1 4T 55 August 31 89 DF51 A418 DF51 Location of 3 1 DET A418 2 ies ete te ee Pare ae garde 4 2 DF 418 ai 3 UE ee ae Se oy Sey 6 3 DF IE A418 sie oS ee eS 8 4 DF Main Board 418 10 5 DF Harness 418 12 Parts 16 August 31 89 LOCATION OF UNIT 3 DF Ill 2 DF Il 1 DF 1 DF A418 August 31 89 1 Index 4 Part No IEEE Mii ig gt u c N 1 Se MA CO Ww NY NYY n5 bh KY KH LK LY LY PLY e CO N DF Co 1
28. Seal Cooling Fan 117 August 31 89 ts N Description Page and 5 Index No Pa 16 1 7 C amp D Rail ushion Motor sensor Duct AAI ushion Lens 2 8 310 2 7 357 10 12 370 Transport Upper 1 ushion Fork Gate ushion Fork Gate ushion Junction Gate Transport Lower ushion Duplex Frame 3x7x484 3x5x30 3x4x122 ushion Duplex Frame t 2 CX ea Ex pao eie 4 ion Guide Rod CO c La ushion ide Rod C C Cushion Duplex Frame C C C Toner Collection ushion Lens 3x7x80 Heat Shielding Sheet Oil Tube 7 8mm Toner Collection Tank Blade Front Seal Cleaning Sleeve Oil Pump Tube 320mm 6 6 6 16 16 16 16 16 16 16 16 17 18 18 18 Blade Rear 12x10x318 11 16 2 Inner Outer 2x15x15 2x15x15 2 20 28 6 32 32 2 8 110 3 42 2 10 3 25 1 70 2 50 48 Side Seal Cleaning Rear PRR E EEE Side Seal Cleaning Front Brush Seal 6 7 144 Seal 5x6x40 Seal 4x5x84 Seal 5 10 64 1 4 5 25 1 4 4 40 gt 18T Gear 18T 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 5 L5 L5 L5 L5 L5 L5 L5 L5 L5 L5 5 L5 L5 L5
29. DOC oY 6n lt gt CO 1 Se Co Lr CONNECTOR 2 Lo DIODE CN451 106 0451 107 CM453 108 0453 CN454 103 0454 CN455 105 265 Ch456 102 0456 CN457 104 0457 CM58 101 0458 D459 0460 6 PRINT BOARD PAPER BANK A420 August 31 89 CAPACITOR ie dr pod B 1 110 113 SSR451 110 461 110 0471 Lee 110 1409 110 1419 110 110 D464 110 DATA 111 110 M65 110 0475 110 0466 110 46 110 467 110 110 0468 ito 110 0469 110 110 0470 110 14 6 PRINT BOARD PAPER BANK A420 Index A420 5270 Description Q ty Per Print Board Paper Bank Assembly 15 Part No August 31 89 Q ty Per Description Assembly 1102 1103 1103 1103 1103 1103 1103 1103 2113 1730 1731 1732 1734 1735 1736 1749 1028 0825 0423 1382 0998 Connector Connector Connector Connector Connector Connector Connector Connector 2P 8P 9P 14P 13P Solid State Relay Diode 155176 Diode 555006 10pF 50V 0 01 50V Capacitor Capacitor August 31 89 7 HARNESS LAYOUT A420 16 7 HA
30. imoer so R310 187 R320 173 0334 173 100 116 TP100 102 8100 153 20101 123 mu 173 1102 1 m mm ge 1 102 2003 124 R313 173 323 185 0347 ds 12103 102 R314 2 R324 O za Lo 315 13 RES im ms 173 i AE dig Liv i73 13 62 28 MAIN CONTROL BOARD A045 A046 August 31 89 Index Q ty Per pud Q ty Per 20 Assembly Main Control Board FT5550 5570 nector Main Control Board FT5540 11 ector Pin Contact Fiber Connector 11 nector 2P CPU Main Control Board TT Receptacle 14P Ram Board 11 nector 10P IC HN27512G25 FT5550 5570 11 1 in Header 6P 27512625 RDH 1103 1 ector 3P 27512625 5540 1103 1 nector 10P Fiber Connector 2 174135 1 11 1 nector 11 nector 14 nector 20P nector 50P LSI Socket 28P DIP Switch Transistor 2SC2712Y Transistor Array PU4310 60V3A Transistor Array 25 2883 iode 155181 iode DSA1A1 Transistor 2501006 iode 155184 1 Fe CO Do iode iode RD39P iode RD6 2 5 741500 HD74LS04FD HD74LS08FP LS32FP Ttl HD74LS107FP LS138FP IC 74LS11NS
31. 14 27 10 1 Sorter REMOVAL icm n docs kie ace Renn Oe 806208 14 27 10 2 Inlet sensor 14 28 10 3 Jam Sensor 14 29 10 4 Sponge Roller 14 30 10 5 DC Motor Replacement 42225 ieee seed 14 32 SECTION 1 OVERALL MACHINE INFORMATION Contents J SPECIFICATIONS 224 esas 1 1 GUIDE TO 5 1 4 2 1 INTERNAL EXTERNAL 2 2 OP ERATION PANEL 6888 win ana rim ROCA RR Den 1 6 2 3 INDICATOR SCREEN E hn Ono Y wae em CR 1 8 2 4 GUIDANCE DISPLAY xx EE 1 9 3 COPY PROCESSES AROUND THE DRUM 1 10 A GOPY CYCLES Sur ure 1 12 5 PAPER jaca cada desta Geos 1 13 6 DRIVE LAYOUT iussis xoci ete due oe eae SURE 1 16 7 MECHANICAL COMPONENT 1 17 8 ELECTRICAL COMPONENT LAYOUT 1 18 9 ELECTRICAL COMPONENT DESCRIPTIONS 1 23 10 OVERALL MACHINE CONTROL 1 28 11 AC AND DC POWER DISTRIBUTION 31 August 1989 1 SPECIFICATION
32. 2 77 TA OVERVIEW 2 77 11 2 TRANSPORT UNIT RELEASE MECHANISM 2 78 12 IMAGE FUSING AND PAPER 2 79 OVERVIEW oot ran No 2 79 12 2 FUSING DRIVE 8 2 80 12 3 ENTRANCE 2 81 12 4 OIL SUPPLY AND 2 82 12 5 OIL END 5 5 2 83 12 6 FUSING EXIT 5 2 84 12 7 FUSING 2 85 12 8 SERVICE CALL CONDITIONS i vs ss were aov n my rae 2 88 13 PAPER 2 90 13 1 OVERVIEW co rd 2 90 13 2 EXIT ROLLER DRIVE 2 91 14 DUPLEX 2 92 14 1 INVERSION 2 92 14 2 DUPLEX 2 96 14 3 DUPLEX STAGKING 2 5 aic cn WE CR Ene D 2 99 14 4 DUPLEX TRAY 5 5 5 2 103 14 5 DUPLEX PAPER FEED do RC e C JE ER e 2 104 14 6 RELATED SERVICE CALL 5 2 107 15 OTHER
33. LIO 40 _ p R36 915 LEDL 43 2K IX R RED R LED2 Ro xl for 5 1 er 5 A 2 Rae TR 30K te GRN R ri 100K GRN R44 ASOK 5 651 m mE T I OK T m a 1 R456 1 1 K 205 56K 43 R48 T 52 ____ 9 51 1 R53 54 15 25 a Ic5 6 T com a E 16 25 26 VSS Ics T HC3T3 _ 2784 27128 ce 9150 002 1 PO IFS 4 7102 2 5 One 4 03 032 A2 203152 4 804 oa 9 las 03p5 1 4 1305 052 6 pape 406 5 05 poas J 48 ig d 4 082 719 AB ALE E AB ero 21 VCC GND a 125 dr 2 A13 bus AID rd 27 28 25 MS 25 48 16 16 20 25V MAU x 5 5 MT 2 2 PCAHS SENSOR LED 2 5 LED pa 65 PAG 5 ___ 22 8 ERE 6 ZD RESET 41 80 MODE 10K 5128 5 JP 6 PB3 CNED 5 5 CNE 5v 6 10 pg
34. PRE RS 118 Page and D ri Gear Gear Gear Gear T Gap Left Gear 18T Gear 18T Gear 23T Gear 30T Gear 30T Helical Gear 29T Gear 30T Gear 17 Gear 39T Gear 24T Worm Gear 47T Gear 18T Gear 171 Gear 14T Drive Gear Pulley Gear Fusing Drive Cam Gear 34 21T Pulley Gear Cleaning Sprocket 16T 36T Idler Gear Toner Hopper Rear Gear Toner Cartridge Drive Gear 32T Gear 24 48T Sprocket 18T 50Hz Sprocket 15T 60Hz Sprocket 15T Sprocket 15T Sprocket 23T Pulley 42T 50Hz Pulley 35T 60Hz 119 ulley 24T Pulley 25T Pulley 20T Gear 36T Pulley 202 Idler Pulley Cleaner Drive Cleaner Drive Cleaner Idler Cleaner Idler Gear 25T Feed Roller Pulley Scanner Drive Pulley Pulley 36T 650Hz Pulley 30T 60Hz Platen Cover Ass y Exposure Glass LT Exposure Glass LT Exposure Glass A3 A4 Dust Proof Glass Lens 5 215 19 lst Mirror 2nd Mirror 3rd Mirror 4th Mirror 5th Mirror 6th Mirror Front Spring Plate 4th Mirror Rear Spring Plate 4th Mirror Front Spring Plate 5th Mirror Rear Spring Plate 5th Mirror Spring Plate 6th Mirror Front Spring Plate lst Mirror Rear Spring Plate lst Mirror Front Spring Plate 2nd Mirror August 31 Parts N D ription Pade aud arts No escriptio Index No 89 August
35. 4 17 4 SPECIAL TOOLS AND 5 4 18 5 SERVICE 5 4 19 5 1 Handling The 4 19 5 2 Chage Bc d a 4 19 hoes iin nd 4 19 54 OPIS 4 20 5 9 Developmen U 4 20 5 6 Transfer and Separation 4 21 9 4 Claiborne tae im 4 21 5 8 Pre transfer and Quenching 4 21 DO PUSING Aira data eae cain a a b 4 21 5 10 Paper Feed and 4 21 4 22 Eripe E o vr we 4 22 1 PM TABLE C Clean R Replace L Lubricate A Add Inspect A OPTICS Mirrors Lens Reflectors Toner Shield Glass Exposure Glass Platen Cover Exposure Lamp Scanner Guide Rods and Plate Guide Rod Felt ADS Sensor B PAPER FEED Paper Feed Rollers Pick up Rollers Separation Rollers Slip Clutch Registration Roller Lift Motor Worm Gear and Worm Wheel Paper Feed Guide Plate Registration Sensor Cassette Bottom Plate Pad Paper Dust Cleaner Relay Rollers C AROUND DRUM Corona Wires
36. Fiber Cable When automatic image density control is selected the exposure lamp voltage is set at position 4 Image density is controlled only by changing the bias voltage At the start of the copy cycle the original sensing mechanism measures the background density of the original image It does this by measuring the strength of the light reflected from a 48 mm strip This strip starts 12 mm from the leading edge of the original A fiber optic cable pipes the reflected light to a photodiode on the main board The photodiode 15 the input element of the auto ID circuit 2 31 31 August 1989 Leading edge of original Peak hold 400 Bias Voltage Auto V1 2 j volg 200 Ine oie c Forward scan 8 o 0 4 0 5 0 7 0 8 0 9 1 0 Auto ID Peak Hold Input Voltage The CPU checks the voltage output by the auto ID circuit This circuit has a peak hold function The peak hold voltage corresponds to the maximum reflectivity of the original Based on the peak hold voltage the CPU determines the proper bias base level and sends a 4 bit control signal to the power pack The power pack then applies the proper bias to the development roller SP 56 A new function has been added to enable the service engineers to quickly adjust for ADS sensor discrepancies All ADS sensor functions are related to an ADS sensor value of 3 0 volts for white paper Previously if this value was incorr
37. Stopper Lever 1 1162 Collar Inverter Solenoid A Bracket Inverter Gate Solenoid 3536 Exit Roller Co Spring Inverter Guide Plate 1 1152 Inverter Gate Q ty Per Q ty Per Part No T Description Assembly Assembly Guide Plat Inverter 1 0313 0060 Philips Pan Head Screw M3x6 Idle Roller 1 0742 3905 ll Bearing 5x13x4mm Antistatic Brush 0632 01008 Pin 2x10mm Step Screw 0741 3505 ll Bearing 5x10x4mm Idle Roller Arm 0314 00400 Philips Pan Head Screw M4x4 Spring Discharge Roller 0720 00308 Retaining Ring M3 Screw Duplex Guide Plate 0720 00502 Retaining Ring M5 Left Frame 0720 00402 Retaining Ring M4 Bushing 6mm 1105 0087 Clamp Upper Exit Roller 0741 3506 Ball Bearing 6x12x4mm Photosensor 0720 0070W Retaining Ring M7 0805 3291 l Bearing 8x1l6x5mm 0314 0060W Philips Pan Head Screw M4x6 0574 00402 Headless Set Screw M4x4 0633 01608 Pin 3xl mm 0742 3808 Ball Bearing 8xl6mm Belt Tightener Gear 19T Exit Roller Bracket Clamp Discharge Brush Spring Lever Revers Harness Cover 0720 0060E Ring 0313 0040W Philips Pan Head Screw M3x4 0720 0025 Retaining Ring M2 5 0632 01006 Pin 2x10mm 1105 0016 lon Clip 4N 0951 4006W Philips Screw With Flat Washer M4x6 0314 0100W Philips Pan Head Screw M4x10 0805 31
38. Q ty Per Q ty Per Part No Part No i 1 PESTRE Assembly Pick up Lower Guide Cushion Rising Gear 1 Cushion Lower Pick up Guide 1 Paper Feed Guide Paper Feed Stay 1 Paper Knob Lever Snap Ring Paper Knob Paper Feed Roller Paper End Feeler Gear 18T 1 Separation Guide 1 1 1 Pick up Roller Arm Lever Paper Knob 1 1 l 2 Bushing 8mm 1 Bushing Paper Feed Roller Paper End Actuator Bracket Gear 21T 1 Print Board Bracket Feed Guid Paper Feed Roller 1 Rear Paper Bank Harness Pick up Shaft 1 Print Board Paper Bank Feed Guide Shaft 1 Front Paper Bank Harness Lift Motor DC1 69W Sensor Type T Spring Lower Bracket Paper End Paper Lift Motor Bracket Photointerruptor Pack Cassette Sensor Arm Upper ED Sensor Bracket Coupled Gear 171 50 Coupled Gear 161 53 ED Sensor Type Pulley 19T Idler 5mm o 1 FSF c Paper Feed Spring Release Arm Tention Arm BR BD MH LY LY LY 1 Cassett Tention Arm Spring agnetic Clutch Collar 1 Volume Sensor Arm agnetic Clutch 1 Separation Roller Gear 40T Slip Clutch Cover Gear 20T 1 Output Hub Sector Gear 1 Cylind
39. us 154 127 154 166 180 SYMBOL INDEX sm INDEX cos us az 154 1 cus ise 151 14 c9 15 154 cuo 154 Eu 32 RESISTOR 464 rion ina naan ama rain 164 19 191 1140 104 01599 124 194 C150 154 UIT 1UIl f M far ee 1 SS Tm ua Nee A SIMBOL A a a ig a d n ig INDE u a 10101 10102 10102 12103 1104 12105 16106 10106 16107 1108 16 R101 161 R102 177 R103 169 13 105 167 mos 169 R107 172 R108 134 R109 167 R110 170 mn 19 161 161 157 157 159 uu mee om 8175 161 R185 157 SWITCH R176 161 R186 165 SYMBOL INDEX oum 1 15 me 157 165 me 15 smor um ue su 12 4 1 0 149 R111 8112 R113 RIL 815 R116 R117 R118 R119 R120 80101 180102 180103 180104 80105 180106 118 118 118 118 118 118 R121 R122 R123 R12
40. RXD ES 8 ROUT as 7 CK WIN ee 31 August 1989 7 piN2 9 2 R337 RIN2 1 rcon P 777 24v 7 24 PiltyH CNII3 8 24 po ae rene y Y lt R33 1015 4 af le 2 Fi m in qp eel Ls i 6 1 8 Large Capacity Tray Schematic 1 000 sheets 31 August 1989 U eri 3 a T13 1 Le it 4 C 15 ms t E IUNII tot Ira EC 220 CN3 2 19 5 115 Door Switch wpe 3 220 240 qd TIL 741500 d End 777 CN409 i M i x CN3 1 2 Vcc CN3 2 Sue 25 2 Size 2 4 3 409 4 Size 2 3 409 6 Size 21 6 Conse Size 2 1 Scan 2 CN1 7 wl el E CN3T Scan 2 Scan 2 e V V Y Scan ol ol R22 it 47K 0 02 104 25 1815 1 J 5
41. TOR 2 16 5 2 Sensor 12 3 4 5 Sensor M 5 N106 2 2 Us a hon ETE cos 2 a CN105 4 MC 5 7 Down Key 11 2 4 owes w l lll Hove E Goan deme CN106 6 NC s E CN106 7 NC de L 4 MER eae ee 7 CN108 9 GND D L Due e TOWEL LL Down Key Se _______ _1_____ gt CN408 2 Lift Motor 1 25 am CN408 3 VAA Volume 2 4 121 3 7 Volume 2 3 121 4 ume CN105 2 Lift Motor 1 CN105 3 NC 6 7 9 Large Capacity Tray Schematic 2 500 sheets 31 August 1989 he a 2o o 05V 0 E TET CN3 1 T13 7 155 240 a MR X oai Cover Safety amp Q Door Switch 14 115V 14 2 104 1C105 IC 103 220 240V 741 508 74 510 7 CN409 1 2 Size 25 Size 25 551011 3 5101 2 pe pum 2 gt 8 CN409 3 2 f Size 2 2 CN409 6 CN3 5 Size 2 2 2 2 1 Suez Kontas
42. The DF has its own CPU which controls all of the DF functions The DF CPU communicates with the copier through an interface board and serial interface bus Fiber optics are used for the serial interface bus because they are unaffected by electrical noise 8 2 31 August 1989 2 2 SINGLE SIDED ORIGINAL FEED D C X ey ee ee Feed in The DF CPU energizes the stopper and pick up solenoids and then turns on the feed in motor The feed A and friction rollers B separate and feed an original to the registration rollers C A short time after the original reaches the registration rollers the DF CPU turns on the belt motor and energizes the registration solenoid Original skew is corrected by the time lag The belt D then feeds the original to the exposure glass while the CPU counts the pulses of the belt motor encoder At the proper time the CPU stops the belt motor Feed out When the DF CPU receives the feed out signal from the copier it turns on the feed out motor When the exit sensor E is deactuated by the trailing edge of the original the CPU reduces the speed of the feed out motor to feed the original out completely This stacks the originals neatly 8 3 31 August 1989 2 3 TWO SIDED ORIGINAL FEED Feed in The operation in this mode is exactly the same as that in the single sided original feed mode until the registration so
43. 1709 irror Drive Pulley 80T 1 0016 4th Mirror 7039 Gear 24 48T 1 5004 Rear Spring Plate 4th Mirror 1 9 PP 1707 agnification Motor Bracket 1 5003 Front Spring Plate 4th Mirror 5215 Lens Home Sensor Harness 1 1722 Cam Plate Lens Shield 1706 agnification Drive Motor DC4 8W 1 1785 Harness Guide Exposure Lamp 1663 Stepping Motor Cover 1 1701 Rear Bracket 6th Mirror 1664 Seal Stepping Motor Cover 1 1001 Guide Rod Magnification 1716 Lens Drive Pulley 80T 1 1761 4th and 5th Mirror Bracket 0018 6th Mirror 5005 Front Spring Plate 5th Mirror 3497 Development Unit Rail 1 5006 Rear Spring Plate 5th Mirror 5007 Spring Plate 6th Mirror 0017 5th Mirror 1700 Front Bracket 6th Mirror 1770 Guide Bracket Lens Shield gt CODO 1 5927 DX 1853 Mylar Seal Base 1 5230 Photointerrupter L Type 1087 Seal 2 15 15 1 1776 Lens Home Sensor Bracket 0012 Shielding Mylar 30x30 1 5251 ED Sensor Type 1088 Seal 2 20 28 1781 Mirror Home Sensor Bracket Light Shielding Mylar Center 1805 Lens Tension Pulley 1729 Lens Fixing Plate 1 1811 Spring Lens Drive Wire Cushion Lens 1 2621 Snap Ring M6 Lens 5 215 19 1 1799 Lens Bracket Seal 2x8x110 1 1721 Lens Unit Base
44. 1 Remove the fusing unit Refer to Fusing Unit Removal 2 Remove the fusing unit cover 2 screws 3 Remove the fusing unit knob A 1 screw 4 Remove the oil pump mechanism B with the oil tank C 2 screws 1 connector 5 Move the pressure springs D to the desired position See the following table Position Nip Width Spring Pressure A a 7 2 mm 40 kg Normal Factory setting A b 6 7 mm 33 kg Thin B a 7 7 48 kg Thick B b 7 2mm 40 kg Normal 31 August 1989 4 10 Hot Roller Temperature Adjustment When Unfused copy with thick paper or paper curl with thin paper cannot be corrected by adjusting the fusing pressure Purpose To adjust for different paper thicknesses Target Well fused copies without Measure SP 49 from 175 to 190 C 10 C step How Changes hot roller operating temperature 1 Set SP 49 and press the number keys to change the number indicated while checking the copy quality 2 Set SP 52 to check the hot roller temperature 4 11 Idling Period Selection When The following cause unfused copies even after five minutes idling time 1 Thick copy paper 2 A drop of more than 5 in the power supply 3 Room temperature lower than 15 C Purpose To adjust for variations in paper thickness power supply or temperature Target Well fused copies without curl Measure SP 61 The idling period can be set at 5 10 or 15 minutes How Changes initial hot roller op
45. 7 2 3 ELECTRICAL COMPONENT LAYOUT 7 3 4 OVERVIEW exu uuo eR AERE SPEARS DELE EE eU 7 4 5 PAPER FEED CLUTCH ON 7 5 6 PAPER SIZE AND VOLUME SENSORS 7 6 7 LIFT MOTOR CONTROL AND PAPER END DETECTION 7 7 7 2 Paper End Detectloltz lace hed odes LE DUET PE Ee 7 8 Su INSTALLATION e ex tat ea 7 9 AC CESSON MOC LEE 7 9 8 2 Installation Procedure 7 10 1 SPECIFICATIONS Copy Paper Size Copy Paper Weight Paper Capacity Paper Feed System Power Source Power Consumption Dimensions Weight 31 August 1989 Maximum A3 or 11 x 17 Minimum 5 x 812 50 gto 110 g 14 Ib to 28 Ib Two universal cassettes holding about 500 sheets each Feed and reverse roller FRR 100 V 50 Hz 60 Hz 0 6 Maximum 60 W 745 mm x 447 mm x 612 mm W x D x H 30 4 18 27 25 19 kg 7 1 31 August 1989 2 MECHANICAL COMPONENT LAYOUT Third Relay Sensor Second Relay Sensor Second Relay Rollers Third Relay Rollers Paper Feed Roller Separation Roller Pick up Roller Fourth Cassette 3rd Cassette N o A 31 August 1989 3 ELECTRICAL COMPONENT LAYOUT Cassette Bank PCB 8rd Cassette Paper End Sen
46. 2 g o a E SEE 99 1 CNA09 109 Paper End 2 By pass 109 1 N N N NC Scan 1 H Scan 2 70 d CN4 1 CN109 11 By Pass ce 1 Di RIO GND 2 a CN4 3 GND Down 109 2 109 3 CN109 4 CN109 5 CN109 6 109 7 109 8 109 9 Uu 2 a 8 5 2 4 CN406 1 CN406 2 CN406 3 Volume 2 5 iil ajo njia N ane gx i E E Volume 2 4 Volume 2 3 Volume 2 2 Volume 2 1 CN406 7 Scan 2 CN406 8 Vcc CN406 9 GND Sensor 2 CN406 6 Paper End H H Paper Lifted L Y Lt sensor Ronis 2 gt 5 H P Sensor oom Kone 5 0 Bown 106 1 106 2 NC NC CN106 8 GND Lift Sensor 2 22 4 2 8 222 3 813 mim iw 2 2 2 CN106 10 Down Key NTIS rote vA eS CN105 2 ift M Volume 2 1 cni te CN105 4 N CN408 1 08 VAA ift Motor 1 ZN gt 2 lt gt 1 6 8 421 12 MENU READER PCB upper LL 9 R38 R39 ca TR 0 047u 56K
47. 2 11 3 5 LENS MIRROR 2 12 3 6 FOURTH AND FIFTH MIRROR ASSEMBLY 2 15 3 7 ORIGINAL SIZE DETECTION Se aes 2 17 3 8 RELATED SERVICE CALL CONDITIONS 2 17 A ERASE paie rio e nto ue 2 22 A OVERVIEW uS vov sad sss 2 22 4 2 LEAD EDGE AND TRAILING EDGE 2 23 A9 SIDEERASE eee ee ace Seabed Munus 2 23 44 EDGE ERASE FUNCTION 24220 399 835 ame baw wee 2 24 4 5 ERASE LAMP CIRCUIT 4s Seated dor Sema 2 25 5 DEVELOPMENT 554 tus fen bade eee e e eS 2 26 ecu seu cR SUPER 2 26 5 2 DEVELOPER EXCHANGE UNIT 2 2212 tr Een tenet ae eas ate ad aes 2 27 5 3 DRIVE MECHANISM te tie eee ia heh teed phe Sele hee eee a kits 2 28 54 IMAGE DENSITY CONTROL x 25 2 Be hates aas 2 30 5 6 BIAS CONTROL CIRCUIT s ETE 2 36 5 7 RELATED SERVICE CALL CONDITIONS 2 37 6 TONER DENSITY DETECTION AND TONER SUPPLY 2 38 TONER SUPPLY a eee Oe a ae 2 38 6 2 BOTTLE DRIVE MECHANISM eed cok ave eee ba eden 2 39 6 3 TONER DENSITY DETE
48. Decal Adding Toner Toner Supply Cover Toner Hopper Pipe Toner Hopper Pipe Cover Toner Shutter Toner Shutter Rack Bottle Release Lever Toner Hopper Pipe Cover Seal Toner Supply Shaft Lower Hopper Case Ass y Lower Hopper Case Upper Hopper Case Ass y Upper Hopper Case Toner Agitator Scraper Front Side Plate Ass y Toner Tank Front Side Plate Toner Tank Hopper Side Plate Hopper Side Plate Cam Wheel Toner Actuator Toner Ass y Rear Rear End End Rack Guide Bracket Cartridge Drive B racket Toner Hopper Casing Sheet Development Motor Bracket Helical Gear Joint Shaft Toner Supply Support Bracket Development Motor Tightener Bracket Development Support Solenoid Solenoid Bracket Development Bias Receptacle oner End Sensor Bracket oner End Sensor Cover Cooling Fan Cover Development Unit Rail Front Side Plate Cleaning Rear Side Plate Cleaning Cleaning Brush Drive Shaft Cleaning Brush Joint Upper Casing Cleaning Unit Seal Upper Casing Cleaning Blade Cleaner Lower Casing Ass y Cleaning Unit Lower Casing Cleaning Unit Outer Holder Beater Bar Inner Holder Beater Bar Cleaning Brush Holder Spring Brush Bias Roller Cleaning Blade Holder Pressure Arm Cleaning Blade Cleaning Grounding Plate Ger Support Bracket Cleaning Casing Blade Solenoid Bracket Clamp T amp S Coro
49. Fe CO Photointerrupter Pack 1 Guid Cassette Holder Rear Paper End Actuator 1 Guid Cassett Holder Front Bushing Volume Sensor Shaft Separation Guide Co Sector Gear Bushing Spacer 1x8x12mm Fixing Bracket 1 Spacer M6 gt Separation Roller Separation Fixed Bracket Slip Clutch Cover Hub 1 ical Spring 10 ion Shaft M6 Co re a3 Co Ww Ww Pressure Arm Shaft index Q ty Per Index M Q ty Per Part No Philips Pan Head Screw M3x5 Philips Pan Head Screw M4x8 Philips Pan Head Screw 4 10 Tapping Screw M4x8 Hexagon Headless Set Screw 4 5 Parallel Pin M2x10 Retaini Ring M3 Retaini ing Retaini ing g g g g 4 Retaining Ring M5 g g 6 g Retaining Rin Ball Bearing 6xl 9 DUPLEX SECTION 1 045 046 August 31 89 9 DUPLEX SECTION 1 A045 A046 August 31 89 ee Q ty Per Index Q ty Per Part N Part No Description Recently No BEES Gs Description Assembly Fork Gate j 1 Rear Side Frame Fork Gate Bushing 6 Fork Gate Lever Bushing 4x7x5mm Gate Solenoid Left Transport Roller 20mm First Gate Arm Transport Roller 16mm Second Gate Arm Entrance Guide Plat Fork Gate 1 Fork Gate Solenoid Inverter Return Roller 1 Gate Soleno
50. mer kx mw Cx oe 2 28 5A CROSSMIXING ed mt o e cR e QA le A 2 29 5 5 IMAGE DENSITY CONTROL teen e Cc RR 2 30 5 6 BIAS CONTROL CIRCUIT EGER 2 36 5 7 RELATED SERVICE CALL 5 2 37 TONER DENSITY DETECTION AND TONER SUPPLY 2 38 6 1 TONER UP PEN tet on c sah dia Ox a i ecu Rat eie de 2 38 6 2 BOTTLE DRIVE 5 2 39 6 3 TONER DENSITY 2 40 6 4 TONER DENSITY CONTROL xk Rn o ede ew n de e E eee RO eo 2 41 6 5 TONER SUPPLY 2 42 6 6 TONER END DETECTION R i ca Rem De ya 2 44 6 7 TONER OVERFLOW SENSOR 2 45 IMAGE TRANSFER AND PAPER SEPARATION 2 46 7 1 PRE TRANSFER LAMP 2 46 7 2 IMAGE TRANSFER a OR 2 47 7 3 PAPER SEPARATION 5555244 2 49 7 4 TRANSFER SEPARATION CORONA POWER 2 50 7 5 PICK OFF MECHANISM 52s oes nr RE x EC CREE RE ERE 2 52 7 0 PICK OFF TIMING 5 55 ce naw bam 2 53
51. t Ero Yo gt r3 FR 0 qo cC C2 1 Fe Co oO HI21 A421 RT21 Location of cd ok es wee 3 1 Exterior and Drive Section A421 4 2 Tray Section 421 6 3 Tray Main Board 421 8 4 Harness Layout 421 10 5 Main DC Harness 421 12 6 AC Harness 421 14 7 Tray DC Harness 421 16 8 A421 51A der ae ee eee 18 Parts 21 August 31 89 LOCATION OF UNIT 2 TRAY SECTION 1 EXTERIOR AND DRIVE SECTION August 31 89 1 EXTERIOR AND DRIVE SECTION A421 08 THA JS 1 EXTERIOR AND DRIVE SECTION A421 August 31 89 Index Q ty Per iia Q ty Per ipti 5 1 Capacitor 9 250V 1 21 2580 Front Cover 21 5200 1106 0336 Nylon Stud A421 2561 Tray Main Board Bracket Tray Drive Motor AC35V 1 Tray Drive Motor AC35W Timing Belt 120XL 037 Pulley 20T 5442 1372 Decal Power Source 220V 5446 8906 Decal English German 220V
52. 1 Philips E Screw M4x4 1 3506 Ball Beari Philips E Screw M4x6 1 3808 Ball Beari Philips E Screw M4x6 1 3905 11 1 Philips ead Screw 4x6 1 3145 Ball Bearin Philips F ead Screw 4x8 1 3145 Ball Bearing Philips F ead Screw 4x10 1 3291 Ball Bearing Philips Head Screw M4x10 1 4006W Philips Screw Wi Fl Philips Head Screw M5x10 1 4010W Philips Screw Wi Fl Philips Sunken Head Screw 4 12 1 3010W Tapping Screw Wi Fl Philips Truss Head Screw M4x6 1 4006W Tapping Screw 4 6 Tapping Screw M4x6 11 4008W Tapping Screw With Fl Tapping Screw M4x8 1 11 1089 Socket Mate N Lock Hexagon Headless Set Screw 11 1147 Socket Mate N Lock Hexagon Headless Set Screw 11 11 1169 Fastening Receptacle Hexagon Headless Set Screw 11 1190 Socket Mate N Lock 10mm 1 11 1240 Socket Mate N Lock 10mm 1 11 1327 Contact nm 1 11 1328 tact 3 12 1 ii 1348 in Contact 16mm 1 11 0328 ector Pin Contact 0958 ector 1089 Connector 3P in LN 1291 Connector 1350 Connector 5239 2P 1408 Receptacle Housing 1515 Connector P 1517 Connector 9 CO PO NH 1910 Connector 1912 Connector
53. _ Buc Mv qo m En wd E S Aum md pod p E TES WEN py eee 6 70 32 HARNESS LAYOUT FRONT VIEW A045 A046 August 31 89 Q ty Per Index EF Q ty Per Assembly No Part No Description Assembly In of ed Part No Description A045 5243 DC Harness T5570 A045 5267 DC Harness T5550 A046 5243 DC Harness T5540 2 A045 5451 AAC Harness 3 A045 5216 Lens Housi Harness 4 5217 ain Control Harness 5 0003 DC Motor Harness 6 5249 Paper Feed Unit Harness 7 5218 itch Harness 8 5251 Left Motor Harness 71 33 DC HARNESS A045 A046 33 CNS LJ 35 13 113 CN 135 129 us CNSS 17 125 2 CNIT 1106 Vil oa 107 Jm 7 4 99 229 48 144 only Duplex only Duplex only Mise Sy 132 ror 9 MCN NI eoe al jos 136 CN59 101 dnai Duplex Paar 4 120 157 n ur gt 10 28 15 39 T CNS2 CN53 He m 117 117 iG 152 CN32 24 113 117 131 147 72 33 DC HARNESS 045 046 August 31 89 Index ty P Q ty P Part No D Q ty Per Part No Description AS UA Assembly ae 045 5243 DC Harness 5570 045 5267 DC Harn
54. Neutralizes any charge remaining on the drum surface after cleaning Reduces charge on the drum surface before transfer Controls all copier functions both directly and through other PCBs 1 26 Optics Operation Panel Paper Feed AC Drive Timer COUNTERS Total A3 11 x 17 Key CIRCUIT BREAKERS Circuit Breaker TRANSFORMERS Main OTHERS Power Supply Unit Thermofuse AC Power Relay Noise Filter Main Motor Capacitor Development Motor Capacitor Paper Feed Capacitor 31 August 1989 Controls the speed of the scanner the position of the lens and the position of the mirrors Controls the LED matrix and monitors the key matrix Interfaces with overall paper feed receives input from paper size and paper end sensors Drives all ac motors the exposure lamp and the fusing lamp Controls weekly timer and timer functions Keeps track of the total number of copies made Keeps track of the total number of A3 11 x 17 copies made Option Used for control of authorized use Copier will not operate until installed Option Guards against voltage surges in the input power Steps down the wall voltage to 100 Vac Rectifies 100 Vac input and outputs dc voltages Provides back up overheat protection in the fusing unit Controls main power Removes electrical noise Start capacitor Start capacitor Start capacitor 1 27 31 August 1989 10 OVERALL MACHINE CONTROL
55. Paper Both 1 1 1 1 4 Both empty EX Paper End Sensor Cassette Bank PCB Paper Feed Control Main PCB oo N456 5 gt Cassette Bank PCB Paper Feed Control PCB Main PCB gt gt Lift Sensor CPU gt OFF High Ne OFF High ans ON Low The paper size sensor is also used as a cassette set sensor When the paper size actuator plate is inserted into the paper size sensor certain photointerruptors turn off 0 volts to 5 volts After receiving a 5 volt signal through the paper size data bus the CPU turns on the lift motor The CPU energizes the lift motor until the lift sensor is de actuated When the lift sensor is de actuated the photointerruptor is ON and its output drops from 5 volts to ground After receiving the 0 volt signal the CPU turns off the lift motor 7 7 31 August 1989 7 2 PAPER END DETECTION After the last sheet of paper from a cassette has been fed the Load Paper indicator lights Photointerruptors are used for the third and fourth paper end sensors When either one of the sensors is actuated the photointerruptor turns off 0 volts to 5 volts The CPU detects paper end by monitoring the output of these sensors As with the paper volume and paper size sensors the CPU uses the same scan pulses to monitor these sensors 7 8 31 August 1989 8 INSTALLATION 81 Acces
56. 13 Using the nylon clamp D secure the harness to the bottom plate 1 screw 11 10 14 Reinstall the toner collection bottle and the rear cover 15 Plug in the power supply cords of both the large capacity tray and the copier 16 Load paper into the tray 17 Turn on the main switch of the copier and check the tray operation 18 Fill out the NECR 11 11 31 August 1989 SECTION 12 MENU READER Contents MENU READER SPEGIFICATIONS Sa one OVERALL MACHINE CONTROL DATA FORMAT desde aen BASIC OPERATION 4 1 Job Sheet 4 2 Menu Reader Indicator Lights 4 3 Processing EOTS 4 vasco a rm ees INSTALLATION eoo tege vena veg dee es S JAGCESSORY CHECK restore EM XI M 5 2 INSTALLATION REPLACEMENT AND ADJUSTMENT 6 1 Lower Transport Roller 1 SPECIFICATIONS Item Job Sheet 1 Material 2 Size 3 Weight 4 Markers Job Sheet Feed Method Reading Time Power Source Dimensions W x D x H Weight 31 August 1989 Specification Paper 2 6 x 5 9 67 mm x 150 mm 22 105 to 43 105 83 g to 161 g Black pencil HB or higher HB B 28 etc Marker Black Ballpo
57. 131 132 133 134 135 136 137 138 139 Function Data Total Service Calls Displays the total number of times the Service Call indicator has turned on Service Call Breakdown Displays the total for each service call type using and keys Paper Jams Displays the total number of paper jams Feed Jams Displays the total number of entrance area paper jams Fuser Jams Displays the total number of fusing unit jams Inverter Jams Displays the total number of inverter unit jams Duplex Jams Displays the total number of duplex unit jams Duplex Misfeeds Displays the total number of duplex misfeeds Exit Jams Displays the total number of exit area jams Cassette Bank Jams Displays the total number of paper bank jams Sorter Jams Displays the total number of sorter jams DF Jams Displays the total number of DF jams 4 16 Comments Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 3 5 Language Code Table DIP 801 345 001 010 011 100 101 110 111 Destinations amp Paper Size PITNEY BOWES LT SP 12 0 English 1 French KALLE INFOTEC RICOH EUROPE RICOH ASIA No MIDDLE EAST M NASHUA SOUTH AMERIC
58. 1st and 2nd Lift Registration Condition Open Short Open Short Open Short Open Short Open Short Problem Paper End indicator stays on Paper End is not indicated and Start key stays green even when paper runs out The erase unit does not function properly is indicated when the A3 or 11 x 17 cassette 15 installed A4 sideways 15 indicated when the A4 lengthwise cassette is installed 8 5 x 11 is indicated when the 11 x 8 5 cassette is installed The erase unit does not function properly 4 lengthwise is indicated when the 4 sideways cassette is installed 11 x 8 5 15 indicated when the 8 5 x 11 cassette is installed Manual Feed is indicated when the manual feed table is closed Manual Feed 15 not indicated when the manual feed table is opened The SC 41 1st 42 2nd 43 3rd 44 4th is incremented 20 seconds after the cassette 15 installed The lift motor does not turn on and copying is inhibited when the cassette 15 installed When the Start key is pressed the copy paper is fed to the registration section where a misfeed occurs A lights on the Misfeed Location indicator A lights on the Misfeed Location indicator when the main switch is turned on 13 8 Name Fusing Exit Exit Toner End Pulse Generator ID Sensor Scanner Home Lens Home 4th 5th Mirror Condition Open Short Open Short
59. 2 Pusn 1 lever grasp Ine Pusn gown tne wo ievers 21 Remove mistes Dei removing tne musied paper fusing unit knob and pull the 109100 iront and rear 1 fusing unit carelul noi 10 tear pape 0 return ine fusing exit assembly unit out CAUTION Tne lusing unit Swing gown tne lusing exit touch rollers 10 ils Original position may be very so be carelul when the tusing into the touching it conie Ie I E23 Pull any ETA paper out ol the no pacer 15 in exil 0 ine tab While gt x the guide plate paper exit Quoi in the dwectian of the arrow out the misied paper 11 50 DECAL AND DOCUMENT m ETE Index Q ty Per 2 Q ty Per 22100 D Sheet Frenc A007 6350 Decal Misfeed Sheet German 26 007 6355 Decal Sensor Checker Sheet Spanish 1 27 007 1565 Decal DIP SW Sheet Italian 1 28 00 1071 Grip Decal Fusing Cover Adding Toner Manual Feed T Reset Drum Shaft Kn A2 Regist Sensor Handle A B3 High Temperature 220 240V SS Ln Decal High Temperature 115V Paper Level Thermofuse 8 1 2 x14 11 17 E E E E oco DB C FB W uction English LT uction English A4 uction
60. 2 Turn VR 1 A on the ID sensor PCB to adjust the Vsg voltage Turn clockwise to in crease the voltage At the same time check Vsg with SP 54 5 17 31 August 1989 2 6 Toner Supply System Checking When Toner is not being supplied in correct amounts Purpose To see if the ID sensor is causing the problem Target The Toner supply clutch turns on when Vsp is greater than one eigth of Vsg Measure SP 55 How Vsp and Vsg are displayed on the guidance display These readings change every ten copies VO is Vsg V1 is Vsp 1 Remove the rear cover 2 screws 2 Set SP 55 and read Vsg and Vsp 3 Divide the Vsg reading by eight While copying is in progress the toner supply clutch should turn on when Vsp is greater than one eighth of Vsg 4 While making twenty copies of an A3 LDG original verify that the toner supply clutch A turns on when Vsp is greater than one eigth of Vsg 5 18 31 August 1989 2 Toner Density Recovery When Purpose Target Measure How Vsp 15 extremely high toner density low To maintain correct toner density Vsp lt 0 5 volts SP 60 The copier runs and the toner supply clutch turns on 100 until Vsp falls below 0 5 volts Vsp and Vsg are displayed on the guidance display is Vsg V1 is Vsp 1 Set SP 60 then press the Enter key and the Start key 2 8 Fixed Supply Mode Selection When Purpose Target Measure How A problem wit
61. 7 7 PRE TRANSFER LAMP AND QUENCHING LAMP CIRCUIT 2 54 8 DRUM 2 55 8 1 2 55 8 2 PRE CLEANING CORONA AND BIAS 2 56 8 3 DRIVE 2 57 8 4 CLEANING 2 58 8 5 CLEANING SOLENOID CIRCUIT lesse ee 2 59 8 6 PRE CLEANING CORONA 2 60 9 QUENCHING rtr a RC e eds 2 61 9 1 OPERATION oce Ram NS wad Sud ros 2 61 9 2 PRE QUENCHING CORONA 2 62 PAPER FEED DR O RR 2 63 101 OVERVIEW cue uou Ve ires Me LE m LEE 2 63 10 2 LIFT MECHANISM AND PAPER END DETECTION 2 64 10 3 ROLLER FUNCTION costi Re mui 2 66 10 4 SLIP CLUTCH 2 68 10 5 PAPER FEED DRIVE t 2 69 10 7 RELAY FEED AND 5 2 72 10 8 PAPER SIZE 5 5 2 74 10 9 LIFT MOTOR CONTROL AND PAPER END DETECTION 2 75 11 PAPER
62. 8 Remove the fusing unit then remove the fusing unit cover E 2 screws 1 shoulder screw 9 Prime the oil supply pad F with silicon oil G Then fill the oil tank H with silicon oil 10 Manually operate the oil pump lever I to check the operation and the overall condition of the silicon oil supply assembly Then reassemble the fusing unit 3 8 31 August 1989 ss 2 t Psy A 11 European version only DAP 220 to 240 volts conversion TIRES go a Remove the support straps 1 screw each the front cover 2 knob screws and the left inner cover 4 screws b Disconnect the wire from the 220 volt terminal B and connect this wire to the 240 volt terminal C as shown Guidance ROM kit installation a Replace the three ROMs D IC 821 822 amp 823 on the operation panel with the ROMs of the guidance ROM kit b Reinstall the right inner and the front covers 3 9 31 August 1989 s sd R lt iY a ed D L K 12 Reinstall the fusing unit 13 Remove the image density sensor cover A 14 Pull down the toner bottle holder B lower the transport unit C and remove the drum inner cover D 1 screw 15 Put a sheet of paper E on the T S corona unit F 16 Remove the charge corona unit G 2 connectors and remove the drum stay H 1 brass screw reverse thread knob 17 Place a sheet of paper on the floor Raise the developmen
63. A 9 Index 1 Part No e 2 ee Head Screw M3x5 Index e Q ty Per Part No me part mo Assembly Pan Head Screw M4x8 Pan Head Screw 4 10 Pan Head Screw M4x20 Screw M4x10 ining Ring M2 5 ining Ring M5 ining Ring M6 ining Ring M5 Bearing 15x28x7mm 37 August 31 89 16 TRANSFER AND SEPARATION A045 A046 16 TRANSFER AND SEPARATION A045 A046 Part No Q ty Per Description Assembly 007 007 15 04 007 5215 5443 5053 007 007 007 007 5215 007 01 15 007 08 007 5053 06 007 AD02 01 03 008 007 007 007 008 AD02 AD02 A007 A007 AD02 3905 3907 1070 0007 3971 3942 2668 0447 3915 3911 3882 3974 3931 3901 1005 1071 5405 0017 5007 0223 6021 3939 2023 0011 2014 5321 3872 3868 3863 2091 2025 4003 9004 9003 2024 Drive Bushi Bushi Drive Leaf Conne Bushi Base Gear Seal Drum Suppo Fixed Bushi Trans Trans Front Gear Clean Motor Clean sport Guid Transport Belt sport Guide Plate Front Plat Rear Transport Upper Roller Transport Belt Transport Guide Roller ng ng M6 Roller Spring Transport ctor Bracket Transport Drive Shaft Bracket ng 8mm Plate Transport Unit 18T Transport Lower Heater rter Drive Roller
64. Bottom Plate Lever 11 1 ED Sensor Type T Bottom Plate Lever 1 1 ED Sensor Bushing Volume Sensor Shaft 11 1 ED Sensor Type Bushing Volume Sensor Shaft 1 1 ED Sensor Type Bushing Sector Gear 11 1 ED Sensor Type August 31 89 escription Page and 5 Index No M3x6 11 101 D Philips Pan Head Screw P Parts No Description Parts No Index No 0313 5205 5253 Photointerruptor Pack 5205 5253 Photointerruptor Pack 031 Philips Pan Head Screw 5205 5253 Photointerruptor Pack 031 Philips Pan Head Screw x6 5205 5321 Pick up Solenoid 031 Philips Pan Head Screw x6 5328 1304 Bushing 5x11x5mm 031 Philips Pan Head Screw x6 5403 2075 Stepped Screw 031 Philips Pan Head Screw x6 5415 1053 Caster 031 Philips Pan Head Screw x6 5424 1064 Screw Stand 031 Philips F ead Screw x8 5424 2625 Connector Spring 031 Philips E Screw x8 54 2668 54 2668 ushing 031 Philips ead Screw x8 ushing 1 031 Philips ead Screw x8 54 2676 54 2676 54 2678 Slip Clutch Cover 1 031 Philips ead Screw 4x12 54 2678 Slip Clutch Cover 1 031 Philips E ead Screw 5x8 54 2681 Snap Ring 031 Philips E Head Screw M5x8 utput Hub 1 031 Philips F ead Screw x10 B B 54 5832 Connector Guide Pin 031 Philips F ead Screw x10 0 0 utput Hub 031 Philips E ead Screw 4x10 54 2681 Snap Ring 1 Philips Head Screw M3x6 54 2693 Se
65. Rear End Block Charge Corona Spring Corona Wire Slider Drive Wire Rear Cover Charge Corona Cleaner Slider Cleaner Charge Corona Adjusting Screw Support Cleaner Sensor Feeler Spring Charge Corona Feeler Front End Block Charge Corona IL G 3P S3T2 E Photointerrupter Photointerruptor Harness Gear 56T Cleaner Drive Pulley Motor DC 5V 1 3W Support Pad Cleaner Motor Front Cover Charge Corona Dust Proof Glass Eraser Seal Agitator 2 11 75 Guide Plate 2x7x357 2x8x310 C amp D Rail Rail Drum Stay Support Bracket Q ty Per Assembly Upper Charge Corona Sheet 2 Side Charge Corona Sheet 2 41 No 01 August 31 89 Q ty Per Assembly lder Development Unit um Shaft Knob Decal Drum Shaft Knob um Stay Support Plate um Support Shaf Front Drum Flange n Flange Spring Stay Support Bracket Rear Flange Drum Guide Blower Fan Bracket Blower Blower Duct Quinching Lamp Receptacle PCC Receptacle Bias Receptacle ID Sensor Duct Seal Sensor Duct ain Corona Receptacle Drum Drive Pulley 112V QL Filter Development Unit Clamp Bushing 4mm ain Corona Wire 10pcs set Rear Cover PCC End Block Casing PQC Terminal Spring Front Cover FCC End Block Spring Corona Wire PCC PQC Corona Wire 10pcs set Ozone Filter 234x60x13 Ozone Filter B
66. When ON the SP mode is disabled DIP SW 100 Main Board SW 2 3 4 5 6 8 Description Factory use only must be off Factory use only must be off Disables the oil end sensor operation Not used RAM clear See CLEAR MEMORY PROCEDURE 2 4 User Code Table There are 20 user codes as follows 1 1101 1202 1303 1404 1505 1606 1707 1808 1909 2010 11 12 13 14 15 16 17 18 19 20 2111 2212 2313 2414 2515 2616 2 17 2818 2919 3020 31 August 1989 31 August 1989 2 5 Service Program SP 8 Data Input Guide Table INPUT SENSOR DATA Registration sensor 2 Fuser sensor 3 Exit sensor 4 Relay roller sensor 1 5 Relay roller sensor 2 6 Relay roller sensor 3 DATA 1 Paper present 8 Inverter entrance sensor 9 Inverter exit sensor DATA 0 Paper not present 10 Duplex entrance sensor present 11 Duplex paper sensor 12 Jogger home position DATA 0 Jogger at 15 Sorter inlet sensor 16 Sorter bin sensor DATA 0 Paper not present 17 Sorter home position sensor DATA 1 Bins at 18 Sorter door safety switch DATA 0 Sorter door closed 20 Toner end sensor DATA 1 Toner present 21 Total counter confirmation signal DATA 0 Confirmation signal LOW T C off 24 Pressure plate reed switch DATA 1 Pressure plate down 25 Paper bank set signal DATA 1 Paper bank installed 27 Duplex unit set signal DATA 1
67. m 3 00402 Retaining Ring M4 5 6 00602 Retaining Ring 3014 Nylon Washer 29 12 INVERTOR SECTION 1 A045 A046 August 31 89 os E 27 2 tA b v MT 4 o E M we A EN RR 2222 2 AE 7 n 222 2 543 Aa 99 lex AA op _ 27 wo Shy CREA tow Ste SSK A UO I SE oe on SBE x gt 30 33 30 34 12 ERE CO A Co N CO CO W CO W NH LH Mm c A po Fr INVERTOR SECTION 1 A045 A046 Index Q ty Per Part No _ Inverter Unit Vacuum Fan Duct Spring Anchor Upper Guide Inverter Unit Stepped Screw Spring Fusing Unit Stud Screw M3 Paper Entrance Feeler ED Sensor Type verter Entrance Sensor Bracket verter Guide Entrance Harness verter Return Roller Guide Plate Open and Shut Guide Holder Pressure Exit nm Spring Inverter Guide verter Guide verter Guide Plate verter Pressure Roller verter Pressure Shaft verter Pressure Arm Front verter Pressure Arm Rear Spring Driven Roller Bushing Inverter Unit Magnet Cushion Junction Gate Upper Guide Inverter Pressure Lowe
68. on the exposure glass 29 Set SP 10 for drum conditioning 30 After the warm up period is completed press the Start Key to start drum conditioning 100 is automatically displayed on the copy counter by SP 10 31 Set all appropriate SP modes as required 32 Turn off the main switch and DIP switch 801 8 Then reinstall the DIP switch cover and turn on the main switch 33 Load paper into the cassette then check the machine operation and the copy quality 34 Fill out the New Equipment Condition Report 3 14 31 August 1989 3 2 CASSETTE MODIFICATION 1 Remove the cassette cover 2 Remove the side fences 1 screw each and the bottom plate 3 Reposition the rear fence C 1 screw in the desired paper size position NOTE Paper size positions are shown on the inside of the cassette Reinstall the bottom plate Reinstall the side fences in the desired paper size position Attach the appropriate paper size decals D on the cassette at the positions shown Insert the desired actuator plate E in the slot on the front of the cassette as shown 3 15 31 August 1989 3 3 KEY COUNTER HOLDER INSTALLATION Remove the front cover 2 screws Remove the right inner cover 4 screws and right front cover 1 screws Remove the cover plate A and fixing plate B from the key counter bracket C Hold the fixing plate on the inside of the key counter bracket and insert the key counter bracket I
69. 007 5403 06 A420 A420 A420 A420 20 20 20 20 20 20 20 5251 5321 2743 2075 0082 2635 2636 2620 2631 2641 2810 2820 2598 1304 2530 2527 2526 0028 2565 2611 2350 2561 4252 1060 1061 1366 ED Sensor Stepped Pick up Release Release Release Lock Lever Tention Arm Inner Cover Front Inner Idler 5mm Bushing 5xllx5mm Idler Bracket Motor Bracket I5T 18T Feed Motor Pulley Paper Motor Stay Paper Paper Decal Decal Decal Decal Pressure Sol Bank Grip Bank Base Capacitor Bracket Paper Load Type T Pick up Sol enoid enoid Lever Screw Lever Spring Lever Bracket Lever Shaft Lever Bracket Knob Spring Front Side Fence Cover Front Side Fence Phili Phili Phili Phili Tappi Hexagon M4x6 M4x8 M4x10 M5x8 Pan Head Screw Pan Head Screw Pan Head Screw Pan Head Screw Screw M4x8 Headl M5x5 ss Set Screw Spring Pin 3xl0mm Bushi Retai Retai ng 4x5mm ning Ring M4 ning Ring M5 Tapping Screw M4x8 Tapping Screw With Flat Washer M4x10 8yF 220V Capacitor 4 3RD PAPER FEED SECTION A420 August 31 89 4 3RD PAPER FEED SECTION A420 August 31 89 Index Q ty Per Index Q ty Per Part No Part No eee Paper Feed Stay Paper End Actuator Bracket Upper Transport Gu
70. 3 Remove the copier rear cover J 2 screws and the plastic 4 Temporarily secure the two screws A pan head screws with washer M4 x 10 in the holes B on the upper cover and install the DF Then secure it with the lift switch actuator plate 3 pan head screws x 10 C 1 flat head screw x 10 D 8 18 31 August 1989 5 Remove the DF cover 4 screws and remove the shipping retainers 2 foam pads F 2 strips of tape 8 19 31 August 1989 6 Move the DF stoppers H to the ends as shown and tighten the Allen screws CAUTION When the DF cover is removed the DF unit tends to fly up easily 7 Install the original feed table A on the right side of the belt unit 4 pan head screws M4 x 6 Be sure to engage the 2 hooks B of the original table with the docking holes C of the belt unit 8 Install the original table cover 0 under the original table 3 pan head screws x 6 8 20 31 August 1989 A S 9 Pass the DF interface harness E through the hole in the harness bracket F and install the harness bushing G Then secure the harness bracket to the copier 1 tapping screw M4 x 8 10 Remove the fiber optics adapter I not needed for this installation and connect the optic cable J to CN112 K on the copier main board 11 Connect the free connector White L 12 Secure the ground wire M 1 gro
71. 5 4 COVER SAFETY SWITCH The cover safety switch monitors whether or not the top and side covers are closed If either cover 15 open the safety switch is de actuated Pins on the top and bottom actuator levers hold the safety switch actuator The top actuator lever is pushed down by the top cover while the bottom actuator lever is pushed in by the side cover Therefore the safety switch actuates only when both the top and side covers are closed 10 9 31 August 1989 6 INSTALLATION 6 1 1 Accessory Check Check the quantity and condition of the accessories in the box according to the following list 1 Bolt M4 x 12 2 Bolt M4 x 22 3 Nylon Clamp 4 Screw x 8 5 Multiple Language Decal 220 240V Only 6 NECR 7 Envelope NECR 115V Only 10 10 31 August 1989 6 2 Installation Procedure x NOTE The LCT can only be installed with the system table or the cassette bank 1 Remove the three strips of tape A 2 Open the side cover B and remove two strips of tape C on the top cover 3 Open the top cover 0 and remove the strip of tape E securing the stopper bar 4 Turn off the main switch of the copier and unplug the power supply cord 5 Remove the first and the second cassettes from the copier 10 11 31 August 1989 coo BEN 4 Fila 6 Remove the rear cover A 2 screws and remove the toner collection bottle B 7 Remove the handle
72. 76 Sorter Bin Indicates ihe mesa 0 No limit mode Capacity entry number 40 on the ad 2 stack guidance display stack mode and sort modes Limit 50 14 26 31 August 1989 10 REPLACEMENT AND ADJUSTMENT 10 1 Sorter Removal 1 Turn off the main switch 2 Remove all the bins 3 Remove the rear cover of the copier 4 screws 4 Open the sorter cover and remove the upper cover A of the sorter 3 screws 5 Remove the front B and rear covers C of the sorter 6 screws 6 Remove the copier main board shielding plate 2 screws 7 Disconnect the sorter harness from CN108 D on the copier main board E 8 Swing the copier main board to the left 2 screws and disconnect the red 2P connector F and the white 4P connector 9 Remove the ground wire H from the copier 1 screw 10 Loosen the screws front and rear one each securing the fixing brackets I and slide the brackets down 11 Remove the sorter from the copier 14 27 31 August 1989 10 2 Inlet sensor Replacement 1 Turn off the main switch 2 Remove the sorter from the copier See Sorter Removal 3 Disconnect the harness from the inlet sensor board installed under the lower relay guide plate A 4 Remove the inlet sensor bracket B with the inlet sensor C 2 screws 5 Remove the inlet sensor from the bracket 14 28 31 August 1989 10 3 Jam Sensor Replacement Upper Jam Sensor
73. Bracket Pick Pff Pawl Solenoid Clamp T amp S Corona Receptacle Bushing 6x8x4mm 6 47 Part No August 31 89 Q ty Per Assembly Description 0313 0314 0434 0720 0965 0060W 0080W 0080W 0040E 3006W ips Pan Head Screw M3x6 ips Pan Head Screw M4x8 ing Screw M4x8 ining Ring M4 ing Screw With Flat Washer M3x6 21 FUSING UNIT 1 A045 A046 2 8 d Ses gt RGN P M REC r ECA LIS PACE e a SEM a o CLE gt wo ae ee ASN B 5 B leu in i BEAL oo 3 4e a WA e TS a 5 4 48 21 FUSING UNIT 1 A045 A046 August 31 89 Index 0 Per me Part No Description Part No Q ty Per ER a Assembly ie Assembly Fusing Unit 115V Oil Tube 320mm using Unit 220V 1 Fusing Unit Knob tepped Screw Fusing Unit Cover Exit Guide Plate Heat Shielding Sheet Exit Guide Leaf Spring Heat Shield ube Clamp Leaf Spring Oil End Sensor Valve Oil Pump 11 End Sensor Oil Supply Bracket ing M6 Spring Oil Pump Actuator 1 High Temperature 220 240V Oil Pump Actuator 1 1 Decal High Temperature 115V Bushing 5 7 16 1 gt Gear 32T 1 1 Thermofuse Q leeve 011 Pum 1 ip
74. Displays the total accumulated time that the main motor has operated Total Copies Displays the total number of copies Duplex Copies Displays the total number of duplex copies made DF Copies Displays the total number of copies made using the DF Sort Copies Displays the total number of copies made using the sorter Cassette Bank Copies Displays the total number of sheets fed from the cassette bank unit LCT Copies ee the total number of sheets fed from the A3 11 x 17 Copies Displays the total number of or 11 x 17 copies A4 8 1 2 x 11 Copies Displays the total number of A4 or 8 1 2 x 11 copies Reduction Copies Displays the total number of reduction copies Enlarged Copies Displays the total number of enlarged copies Originals Copied Displays the total number of originals copied Originals Copied Using DF Displays the total number of originals copied using the DF 4 15 31 August 1989 Comments DIP SW 801 7 must be on DIP SW100 8 Main board and DIP SW 801 7 on the operation panel must be ON Factory setting 0 In hours Factory setting Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 31 August 1989 Mode No 120 121 130
75. Key Top Base A Key Top Base B Slide Rail Base Slide Cover LT Slide Cover A4 Decal DIP SW Decal DIP SW Stepping Motor Cover Seal Stepping Motor Cover Optics Right Frame Mounting Bracket Scale Exposure Glass Stay FT5540 Cooling Blower Bracket Optics Fan Filter Bracket Optics Fan Filter Front Bracket 6th Mirror Rear Bracket 6th Mirror Magnification Drive Motor DC4 8W Magnification Motor Bracket Mirror Drive Pulley 80T 122 ns Drive Pulley 80T s Unit Base Cam Plate Lens Shield Actuator Plate Lens Home Sensor Lens Fixing Plate Lens Shield Front Lens Shield Rear Shield Lens Lens Shielding Cover 4th and 5th Mirror Bracket Guide Bracket Lens Shield Lens Home Sensor Bracket Mirror Home Sensor Bracket Harness Guide Exposure Lamp Mirror Cover Lens Bracket Plate Lens Bracket Lens Bracket Scanner Home Sensor Bracket Scanner Sensor Bracket Scanner Motor Bracket Support Bracket Optics Frame Exposure Glass Stay FT5550 5570 Left Pulley Bracket Center Pulley Bracket Wire Clamp ide Rod Cleaner ide Rod Cleaner t Scanner flector Clamp in Reflector ulator Lamp Terminal Spacer Lamp Terminal Reflector Cover Front Cover Lamp Terminal August 31 Parts No Description P Index No 89 August 31 89 Page and No arts No Description Index
76. M4x6 Screw M3x6 Screw M3x4 2 5 et Screw M4x4 4 Nylon Clip 3N Ball Bearing 6x12x4mm Retaining Ring M7 Hexagon Headless Set Screw Tapping Screw With Flat Washer M4x8 3 DF A418 August 31 89 a a pred P Seton d 475 66 S e ds eT 4 Ae y CAT CAR o Qs ss eel arte 52 16 sT ieee 946 KYA 3I Hl d 22 gos 22 5 Sud er Lt 522 33 28 52 it a f S p7 HS io BE ES te 2 I ORE eb ESM ete Vid y LP WRT a ES Te E SEN gt SIT on EEE 772 3 13 E CU a 26 3 DF A418 August 31 89 Index Q ty Per Q ty Per Part No ipti P No ipti Assembly 5 ROUEN 1 409 1198 Rear Side Plate Exit Drive 5918 2289 Spring Exit Motor DC 9W A40 5511 Inverter Solenoid 2327 Release Lever 2355 Feed in Motor Bracket Spacer 10 16 1 6 591 Gear 461 1 591 Exit Drive Shaft 1 5918 2274 Timing Belt Tightener 2285 Tightener Stud Front Side Plate Exit Drive 1 591 Pulley 15T 1 521 3 5230 Photointerrupter L Type 2380 Sensor Bracket 1140 Exit Guide Plate 1147 Seal 10 1
77. Rb 2 4 2 OVERVIEW 2 4 22 WIRE CLEANER seins 2 5 2 3 CHARGE CORONA POWER 2 6 J OPTICS gt 2 7 2 7 3 2 EXPOSURE LAMP 1 2 9 3 3 SCANNER DRIVE ceiver REG GUERRA EAR C ER 2 10 3 4 SCANNER MOTOR 2 11 3 5 LENS MIRROR POSITIONING ur e ru Ia ur nn 2 12 3 6 FOURTH AND FIFTH MIRROR ASSEMBLY 2 15 3 7 ORIGINAL SIZE DETECTION 3 53 Rh e e eR ex E pare 2 17 3 8 RELATED SERVICE CALL 5 2 17 ERASE uuu dew ior ERE vaa add E laca 2 22 OVERVIEW exa p ER Rn ck 2 22 4 2 LEAD EDGE AND TRAILING EDGE ERASE 2 23 ASSIDEEBASE Ween Ree E DX 2 23 4 4 EDGE ERASE FUNCTION 4 553 tile 2 24 4 5 ERASE LAMP CIRCUIT ame 2 25 DEVELOPMENT staat CR 2 26 Dil mr 2 26 5 2 DEVELOPER EXCHANGE Ceo X aera e 2 27 5 3 DRIVE MECHANISM
78. Rectifier S4VB40 Transistor 2501773 Diode 06 Diode 12V Diode IC SN7406NS IC SN74LS00 IC HD74LS04FD IC HD74LS74AFP IC 5 741 527 5 5 741 5373 5 TC4050BF IC TD62308F UPD78C10GF PD71054GB gt co Se Co ic Oscillator 10MHz ic Oscillator 8MHz 47 10V 100MF 50V 3300PF 0 01 50V 0 1 25V 27PF 50V istor 1KOHM 1 8W 5 istor 1 2KOHM 1 8W 5 istor 2 2KOHM 1 8W istor 3 3KOHM 1 8W istor 4 7 1 8W istor 10 5 istor 27KOHM 1 8W 5 istor 1MOHM 1 8W 5 istor 1 2 5 1 2W Co CO co N 4 lt Co CO CO 01 TI nector 02 11 nector Pin Contact 03 11 nector 2 04 11 EI Connector 4P 05 11 nector 06 11 nector 12P 07 11 nector 12P 65 30 PAPER FEED CONTROL BOARD A045 A046 August 31 89 DIODE CONNECTOR RESISTOR ARRAY RESISTOR CAPACITOR Se ee a a SS SSS SSS Se SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX NO NO NO No No 10401 119 0401 17 0411 0421 117 CN401 107
79. ining Ring M6 11 11 Housing 3P ining Ring M6 13 11 1 Connector 3P Ball Bearing 8xl nm 11 1 Connector 3P Ball Bearing 8 1 nm 11 Jr Connector 2P Ball Bearing 6xl nm 11 11 Lil 1 Receptacle Housing 1P Ball Beari 6 1 nm 13 1 1 Connector 6x1 nm 13 11 11 1 Connector 2P RED Ball Beari Ball Beari 8x1 nm 11 11 11 1 Connector 3P Ball Beari 8x1 nm 13 11 Ti 1 Connector 3P Ball Bearin 8x1 nm 13 11 11 1 Receptacle Housing Ball Bearin 8x1 nm 1 11 1 Receptacle Housing Spacer M6 11 11 11 1 Connector 3P Spacer M6 1 11 1 Connector 3P Philips Screw With Flat Washer M4x6 1 11 i Connector 3P August 31 89 Page and Page and Parts No Description Vus g 1102 8P Connector 1 Connector 9P 1 Connector 101 1 Connector 121 1 Connector 11 Connector 141 11 Connector 141 1 Connector 11 Connector E 11 Connector 11 Connector 11 Connector 11 Connector 1 Connector 11 nector 11 nector 19 11 nector 15 10 nector 15 10 nector 10F 15 10 nector 125 15 1 nector 13P 15 10 Connector 14P 15 10 Connector 13P 15 1 Nylon Clip 4N 11 1 Nylon Clip 4N 13 11 Push Switch 1 Solid State Relay 15 1 Diode 155176 15 1 Diode 555006 15 1 Capacitor 10gF 50V 15 1 Capacitor 0 01 50V 15 1 Capacitor 8pF 220V 1
80. lightest 530 V dark Factory setting 0 Shifts all bias levels including ID pattern bias Factory setting 0 Use when separation problems occur 7 mm 10 msec 13 mm 10 msec Factory setting 0 31 August 1989 Mode No 39 41 42 43 44 45 47 48 49 51 52 53 Function Data Charge Wire Cleaner 0 ON Sets charge wire cleaner to on or off 1 OFF Lead Edge Erase Margin Adjustment 0 15 Adjusts the lead edge margin Registration Adjustment 0 15 Adjusts registration Vertical Magnification Adjustment 0 15 Adjusts magnification in direction of paper travel Horizontal Magnification Adjustment 0 15 Adjusts magnification perpendicular to the direction of paper travel Lens Tolerance Adjustment 0 15 Adjusts lens position to correct focus Focus 0 15 Adjusts 4th 5th mirror position to correct focus Light Intensity Adjustment 50 80 Adjusts exposure lamp voltage Vac Fusing Temperature Adjustment 175 190 Adjusts fusing temperature degrees Exposure Lamp Voltage Check Displays exposure lamp voltage Fusing Temperature Displays the fusing temperature Drum Temperature Displays the drum temperature 4 12 Comments Cleaner motor turns on every 5 copies at power up Factory setting 0 0 6 mm per step Max 4 8 mm to in mm Factory setting 0 6 mm per step Max 4 8 mm to mm Factory setting 0 8 to 0 7 Factory setting 8 0
81. lt 9 l 9 6 Z e N 2 lt l o 23 OPERATION PANEL 24 DRIVE SECTION 22 FUSING UNIT 2 LOCATION OF UNIT August 31 89 25 ELECTRICAL SECTIO 26 FLECTRICAL SECTION 27 ELECTRICAL SECTION 3 gt CS EES OSS CM est XL EN gt IR E NES 1 EXTERIOR 1 A045 A046 August 31 89 2104 oe us 422572 7 3 LOL b wm XT Ww M I 2 oy dfo x 35 _ RS m 7 36 T J 15 CSS _ di 46 AI 104 8 1 EXTERIOR 1 A045 A046 August 31 89 Index Q ty Per Index Q ty Per P N _ at o Rear Upper Cover Manual Feed Table Upper Cover Cap ADF Manual Feed Cover Left Scale LT 1 Side Fence Gear Left Scale A3 A4 1 ual Feed Table Support Receiving Tray 1 iction Pad B Left Cover 1 Cover Key Counter Cap Cover Left Sorter 1 Bottom Bracket Right Rear Cover Cap Left Cover L Bracket Right Rear Cover Cap Left Cover S Magnet By Pass Table Left Fro
82. where it drops onto the paddle roller H The amount of developer moved to the front by the mixing vanes and to the rear by the mixing auger 15 equal 2 29 31 August 1989 5 5 IMAGE DENSITY CONTROL Image density is controlled in two ways 1 by changing the strength of the bias voltage applied to the development roller sleeve and 2 by changing 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 which reduces the amount of toner transferred so the stronger the bias voltage the lighter the copy image Similarly increasing the voltage to the exposure lamp causes an increase in light intensity which also results in lighter copies The control method is different depending on whether the image density is selected manually or the automatic ID system 15 used Manual Image Density Control E eee gt LIGHT pee nr n oltage Vo 50 to 80 volts ac When image density is set manually the development bias base level and the exposure lamp voltage vary as shown in the above table The lamp voltage at ID level 4 Vo can be adjusted with SP mode 48 NOTE In Auto ID mode the lamp voltage remains at Vo no compensation is applied 2 30 31 August 1989 Auto Image Density Control Leading edge of original 12mm 48 mm og 2
83. 021 __ Optics PCB The scanner drive motor is a dc servomotor The CPU on the optics board controls the speed of this servomotor The main CPU and the optics CPU communicate through a serial interface bus TXD RXD After the main CPU sends the scanner start signal to the optics CPU the optics CPU receives the drum speed data from the main PCB pulse generator An encoder on the servomotor has two magnetic sensors that generate two pulse signals The optics CPU monitors the scanner speed and direction by these pulse signals Based on the drum speed and encoder data the optics CPU determines the proper speed for the scanner drive motor to obtain proper vertical magnification The optics CPU sends the speed data to the timer IC which controls the scanner motor circuit The home position sensor informs the optics board when the first scanner is in the home position 2 11 31 August 1989 3 5 LENS MIRROR POSITIONING Lens Drive The lens drive motor stepper motor A changes the lens position according to the selected reproduction ratio to provide the proper horizontal magnification between the lens and the drum s surface The output gear of the lens drive motor engages the gears B of the lens drive pulley The lens drive wire C is wrapped around the lens drive pulley and is connected to the lens drive bracket D The rotation of the lens drive pulley moves the lens back and forth in discrete steps 2 12
84. 1126 1373 2218 1353 2702 0271 0223 1351 5047 5048 5411 1352 1355 5253 1361 2555 7930 7968 ire Tightener ide Plate ord Bracket W 5 Clamp Stay ulley 20 Wire Rear Wire Tightener Drive Pulley Bushing 10mm P C B Bracket Transformer 115V 220V 240V 30W agnet Catch Ass y Fuse Holder Tray Control Board asher 4 5x24x2mm Paper Size Dial Dial Shaft Safety Switch Bracket Drive Shaft Rear Side Plate Drive Shaft Drive Motor Bracket Motor Harness 115V Motor Harness 220V Tray Drive Motor AC7 8W 115V Worm Gear M5x5 Paper Volume Detection Guide Photointerruptor Pack Pulley Trans Cover Power Supply Cord 115V Power Supply Cord 220V Part No August 31 89 Q ty Per Description Assembly Bk 5897 1277 5897 1279 5897 1274 5897 1359 1005 0016 5403 4335 5447 4980 0704 0040 0434 0060W 0314 00401 0720 00408 0555 0050 1105 0163 1204 1280 0314 0060W 1107 0487 1105 0008 1101 0359 0313 0140W 0807 5009 1106 0442 1208 1047 0951 3005 0720 0030E 0314 0100W 0720 0060 0315 00801 0930 0400 1105 0108 Lower Actuator Lever Safety Switch Actuator Upper Actuator Lever Shutter Paper Volume Sensor Terminal 115V Terminal 220V Toothed Washer Tapping Screw M4x6 Philips Pan Head Screw M4x4 Retaining Ring M4 Hexa
85. 13 16 1 163 ce 13 13 1 p 5er es E see ae Nr BJ LISSE 108 164 162 16 163 162 os o1 i6 CN106 101 C107 155 C117 157 C128 163 C138 163 C148 162 158 163 C168 163 cos 163 cume 162 163 163 162 163 cies 163 cuo 109 13 cus cio cuo 183 18 15 13 409 107 cuo 163 163 162 163 163 163 163 DIODE SYMBOL SYMBOL SYMBOL SYMBOL inex SYMBOL iori SYMBOL oe SYMBOL SYMBOL woe SYMBOL w am m ag as 1 coos 1 ems 19 i 163 162 163 163 C25 162 C29 158 0102 19 02 18 C4 16 162 195 163 163 C2 157 C23 158 ms 18 cis tet ga 18 5 com nu oma 163 163 163 162 com 163 0 no ug ous 12 a
86. 2 12 64 Seal 2 5 10 Transport Lock Shaft 39 57 Feed Roller Arm Shaft 21 27 Fusing Entrance Shaft 51 48 Separation Shaft 21 35 Separation Shaft 23 30 Blade Swing Pin 45 29 Front Position Pin 45 39 Positioning Stud End Block 45 25 Stopper Screw 55 43 Stud Platen Cover Mounting 9 8 Stepped Screw 25 10 Rear Position Pin 45 27 Shutter Shaft 123 Fusing Drive Shaft 55 28 Feeler Shaft 31 46 Shielding Myl Front Left 13 35 Shielding Myl Front Center 13 37 Shielding Myl Rear Left 13 34 Shielding Myl 30x30 17 22 Light Shieldi lar Front Left 13 36 Light Shielding lar Center 17 24 Light Shielding lar Lens 17 37 Lower Side Plate Seal Large Seal 6x12x7 Separator Seal Front Seal 3x27x39 Mylar Seal 57 34 Seal 2x16x20 37 52 Seal 3x7x55 37 36 Anti Static Brush Development Unit 37 8 8x8x278 35 61 Separator Seal Rear Seal 3 27 28 Seal 2 8 310 Seal 3x16x310 Seal 6x16x310 Seal 3x10x6 5 Right Development Seal Toner Hopper Entrance 35 10 PRE ERS SE EEE EERE Toner Hopper Pipe 35 11 Toner Shutter 35 8 3 16 57 21 42 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15
87. 2 3 31 August 1989 2 DRUM CHARGE 2 1 OVERVIEW A This copier uses a dual wire corotron unit and a highly sensitive selenium drum The corona wires A generate a flow of positive ions when the charge power pack applies a high positive voltage to the corona unit The drum coating B receives a uniform positive charge as it rotates past the corona unit The charge fan C provides a smooth flow of air to the interior of the charge corona unit D to prevent uneven build up of positive ions An uneven build up of positive ions could cause uneven image density 2 4 31 August 1989 2 2 WIRE CLEANER D Paper dust or toner particles on the corona wires A may interfere with charging The wire cleaner B corrects this problem by automatically wiping the charge corona wires clean Pads on the wire cleaner bracket clean the corona wires as the dc motor C drives the cleaner bracket from the home position to the rear end of the corona unit and then back again Operation of the wire cleaner is based on copy count A RAM counter keeps track of the number of copies made since the last time the wires were cleaned The CPU checks this counter each time the copier is turned on If the count is greater than 5 000 at that time the CPU turns on the cleaner motor to clean the corona wires Simultaneously it resets the counter to zero During a cleaning cycle the cleaner motor drives the wire cleaner toward the rear endblock Norm
88. 8 9 Separation Corona Current 5 69 8 10 Pre Cleaning Corona Current Adjustment 5 71 8 11 Pre Quenching Corona Current 5 72 ELECTRICAL DATA 1 Main PCB Schematic 1 6 1 Main PCB Schematic 2 6 3 2 Optics PCB Schematic 6 4 3 Paper Feed PCB Schematic 6 4 4 Timer PCB Schematic 6 4 5 TIMING GWAR s eoa ans te Ba doxes 6 5 6 20 Bin Sorter PCB Schematic 6 5 7 ARDF PCB 5 6 6 8 Large Capacity Tray PCB Schematic 1 000 Sheets 6 7 9 Large Capacity Tray PCB Schematic 2 500 Sheets 6 8 10 15 Bin Sorter PCB 6 9 11 15 Bin Sorter Timing Chart A4 Letter Mode 6 10 12 Menu Reader PCB Schematic 6 11 13 Menu Reader PCB Schematic lower 6 12 PAPER BANK bau 7 1 2 MECHANICAL COMPONENT LAYOUT 7 2 3 ELECTRICAL COMPONENT 7 3 A OVERVIEW des aed eee
89. Bushed Roller Chain 160P 1 08 0037 Bushing 6mm 5205 4527 Spring Exit 5304 1639 Bushing 8mm si re Gear 18T Sprocket 12T Slip Clutch Sprocket 23T Exit Sensor Bracket Exit Sensor Feeler Sensor Type 5 Sensor Harness Gear 18T Gear 27 18T Gap Left 1 Co PL CO Guide Plate Exit Inverter Unit FT5540 5570 Guide Plate Exit Inverter Unit FT5550 Inverter Roller 1 Phili Pan Head Screw Exit Guide Plate Upper 1 Phili Pan Head Screw Paper Exit Feeler 1 Phili Pan Head Screw Paper Exit Feeler Bracket 1 Phili Pan Head Screw Exit Roller 1 1 Screw M4x8 Upper Exit Roller 1 Retaining Ring M3 ED Sensor Type T 1 Retaining Ring 5 Harness Home Sensor Retaining Ring M6 Exit Guide Plate Upper 1 Ball Bearing 8 1 August 31 89 14 DEVELOPMENT 1 A045 A046 14 DEVELOPMENT 1 A045 A046 August 31 89 Index Q ty Per No 1061 Meet part Libo ds Assembly 34 15 1038 Seal 4x16x210 2 3 4 5 6 7 8 9 0 CO Ww gt MY h5 KY n5 HY YY LY LY c5 wpe Co Part No A007 A007 5205 5205 5205 01 01 007 007 15 A007 15 15 007 00
90. Connector Connector Connector Socket Mate N Lock 91 43 FUSING UNIT HARNESS AND GATE HARNESS A045 A046 TENET N 92 43 FUSING UNIT HARNESS AND GATE HARNESS A045 A046 Fusing Unit Harness Index No 1 2 ndex 5 Part 01 1100 0086 02 1100 1249 03 1100 1327 04 1100 1339 05 1100 1343 06 1102 1620 07 1102 1910 08 1102 1924 09 1102 110 1100 1253 11 1102 1859 August 31 89 Q ty Per Description Assembly lid Strand Receptacle Terminal ntact in Contact in Contact nnector nnector 2P nnector 2P nnector 12P n Mate N Lock nnector 4P 44 MAIN CONTROL HARNESS AND DC MOTOR HARNESS A045 A046 TEM ugus Ro gt 55 2 __ E N 44 MAIN CONTROL HARNESS AND DC MOTOR HARNESS A045 A046 August 31 89 Index Q ty Per Index TE Q ty Per Part No ipti Y Part No tere oe Assembly 01 1100 1259 007 5217 Main Control Harness Socket Mate N Lock 2 740 0003 DC Motor Harness 02 1102 1092 Connector 9P 03 1100 1328 Contact 04 1102 1952 Connector 2P 05 1102 1953 Connector 3P 06 1102 1967 Connector 6P spree i i AR 95 45 CL EANER SENSOR HARNESS AND GATE SOLENOID HARNESS A045 A046 A ugust 31 89 96 45 CLEA
91. Connector Connector Connector 3P Connector Connector Connector 3P Receptacle Housing 7P Connector Connector Receptacle Housing 3P Connector Connector 6P 73 1 px aq YD gt o Connector 87 1 Connector Receptacle Housing 13 4 1102 1 Connector Connector 85 1 1102 1 Connector P 75 1 01 10 03 102 105 108 104 109 106 99 102 101 112 103 106 99 107 75 125 81 111 93 111 101 104 97 109 79 107 73 142 1102 1 Connector Connector Connector 1102 1 Connector 1102 1 Connector nector nector 1102 1 Connector 1102 1 Connector U nector 1102 1 Connector nector 1102 1 Connector U nector 1102 1 Connector ector 1102 1 Connector U ector 1102 1 Connector U ector ector 1102 Connector 1102 1 Connector 6P U ector gt C Ww CO NO o CO ector 1102 1 Connector 2P 1102 1 Socket Housing 3P 1102 Connector 12P ector ector 1102 Connector 12 1102 Connector 2P ector ector ector 1102 Connector 2P 1102 Receptacle 14P 1102 Receptacle 32 1102 Connector 32P ector ector CO BSB 59 CO 9 9 WW CO CO ector 73 143 142 M Page and meses E Et
92. Duplex Pick up Roller Feed Roller Front Fram Duplex Feed Duplex Paper Actuator Dupelx Positioning Roller Feed Drive Belt Gear 30T Bushing 8x1l6x5mm Axle Feed Feed Feed Bushing 6x12x4mm Bushing 6x10x7mm Shoulder Screw Roller Arm Sh Roller Pulley Entrance Actuator Roller Plate Entrance Actuator Plate Roller Arm Stud Screw M3 Snap Ring Cushion Phili ips ips 105 ng ng Hexagon Spring Pin 3 10 Spring Pin 3x18m Retaining Ring Retaining Ring Retaining Ring Retaining Ring Ball Bearing Spac er Duplex Frame Head Screw Pan Head Screw Pan Head Screw Pan Head Screw Screw M4x6 Screw M4x8 Headless Set Screw M4x6 Philips Sunken Head Screw M3x6 1 5 20 20 Connector Bracket Duplex Pick up Solenoid Pick up Solenoid Bracket Pick up Solenoid Cover Actuator Shaft Solenoid Guide Roller Pressure Spring agnetic Clutch Duplex Feed uplex Feed Arm ear 30 uplex Spring Push Lock Push Lock Bracket Spacer 1x8x12mm Ball Bearing 8x20x13mm Gear 30T itioning Solenoid Lever lex Positioning Solenoid olenoid Bracket uplex Solenoid Bracket ear Frame Duplex Feed uide Pin August 31 Index Q ty Per Part No 89 Index Q ty P Part No M is peseription Assembly 11 DUPLEX SECTION 3 04
93. E to the machine ground 7 Deactuate the front safety switch 5 66 31 August 1989 8 7 Charge Corona Current Adjustment Optimum Adjustment Value DC 92 0 1 0 CAUTION Make sure that the main switch is turned off when you touch the drum shoe e m Reinstall the drum stay 1 screw and 1 knob and the charge corona unit Position the drum shoe so that the axis of the current sensing plate A is aligned with the charge corona wire B Select the dc 200 mA range on the digital multimeter To turn on the charge corona turn on the switching PCB dip switch corresponding to on the TC SC power pack PCB The silk screen printed on the TC SC power pack PCB is correct Adjust the corona current by turning VR C on the C B power pack Wait 30 seconds for the current to stabilize Confirm that the corona current at the front and the rear is the same by repeating the above procedure with the drum shoe in different positions If not adjust the wire height using the screw D on the front end block Remove the drum shoe and reassemble Check copy quality 5 67 31 August 1989 8 8 Transfer Corona Current Adjustment 4 d CZI A J E A D Optimum Adjusting Value DC 18 5 1 0 pA 1 Reinstall the TC SC corona unit and position the drum shoe at the center of the shaft so that the axis of the curr
94. H 1 screw 6 Remove the transport unit I with the bushing from the rear 9 38 31 August 1989 6 DUPLEX 6 1 Invertor Unit Removal 1 Turn off the main switch and remove the rear and left covers 6 screws 2 Remove two connectors A 3 Remove the invertor unit B 4 screws 5 39 31 August 1989 6 2 Duplex Transport and Fork Gate Units Removal 1 off the main switch and open the front cover 2 Remove the settler bar A lower inner cover B 2 screws and transport unit post C 2 screws Then remove the duplex delivery tray D 1 stud screw 3 Lower the transport unit and remove the duplex transport unit cover E 1 screw Then remove the duplex transport unit F 2 screws 4 Remove the rear cover 2 screws and remove the main board 2 screws leave connec tors inserted Then remove the connectors from the fork gate unit G 5 40 31 August 1989 5 Lower the fork gate unit G and press down the lever H on the bottom of the rear right corner of the fork gate unit Then pull the fork gate unit to the right and remove it NOTE When reinstalling the fork gate unit press down on the 1st amp 2nd fork gates with your fingers to avoid damaging the gates 5 41 31 August 1989 6 3 Jogger Unit Removal 1 Remove the rear cover 2 screws and the toner collection bottle 2 Lower the power pack bracket Refer to Transport Unit Removal
95. Holder Toner Tray ng 8mm port Lever Spring port Lever End Block Cover T amp C 56T er Drive Pulley DC SV 1 3W er Drive Wire Separation Separation Cleaner Slider Separation Corona Cleaner Suppo Rear Termi Trams Rear Separation Corona Wire rt Pad Cleaner Motor End Block Cover T amp C anl Spring T amp S 10pcs set fer Corona Wire 10pcs set End Block T amp S Index Q ty Per Le IE 1 0060W 0120W 0050W 0060W 0080W 0200W 0082W 0080W 0060W 0050 0060 4008W 4008W 3006A 0005 0430 Nylon Bushin Screw 3x12 4 5 4x6 4x8 4x20 Screw With Flat Washer M4x8 Pan Screw Pan Screw Pan Screw Pan Head Screw Pan Head Screw g Screw M4x8 Bolt 4 6 ining Ring 5 ining Ring M6 ips Screw With Flat Washer M4x8 ing Screw With Flat Washer M4x8 ips Polycarbonate Screw M3x6 Clap g 13mm 39 August 31 89 Q ty Per Tension Cleaner Spring Index No Part No Cleaner Idler Pulley Tension Bracket Wire Cleaner Paper Guide T amp S Corona T amp S Corona Guide Plate T amp S Corona Casing Plastic Ring 3x6xlmm 10pcs set Sensor Feeler Separation Corona End Block T amp C Front Suppert Cleaner Sensor Harness IL G 3P S3T2 E Photointerruptor P
96. LH CO 9 CO PO Fo wo TO Be CO 5442 5442 007 5215 AX52 5409 007 007 007 007 007 16 007 05 05 007 007 5442 007 5420 007 007 007 007 045 007 007 1 1 01 15 15 1704 1703 1860 1702 0005 1705 1870 1875 1873 1865 5009 5008 1848 1019 0013 1845 0012 0002 1851 1867 1705 1877 1682 1868 1892 1894 1880 5281 1890 1675 2021 2022 2002 0011 0009 ing Side 2 eflector Clamp Wing Center R lip Exposure Lamp Exposure Lamp 85V 160W Clamp Reflector Reflector Cover Rear Cover Lamp Terminal Front Cover Lamp Terminal Main Reflector Rear Spring Plate lst Mirror Front Spring Plate lst Mirror Guide Rod Cleaner Cushion Guide Rod lst Mirror Wire Clamp Scanner Drive Wire Guide Rod Scanner lst Scanner Insulator Lamp Terminal Exposure Lamp Terminal Release Exposure Lamp Termianl Fix Supporter Lamp Terminal Spacer Lamp Terminal Rear Cover Optical Fiber Rear Bracket Optical Fiber lst Scanner Slider Exposure Lamp Harness Harness Bracket Exposure Lamp ing Bracket Scale ure Glass LT FT5570 ure Glass A3 A4 ure Glass LT FT5540 Shielding Mylar Rear Left Shielding Mylar Front Left August 31 89 Index Q ty Per UE M
97. Menu Reader b7 b5 b4 63 b2 b DATA CONTENTS 0 Insert Sheet OK NG ORE a WIESEN 0 0 0 0 The contents of the reserve bytes are different in each market 12 3 31 August 1989 4 BASIC OPERATION 41 Job Sheet Reading A When a job sheet is inserted the sheet detection sensor A detects the leading edge of the job sheet The job sheet is then fed in by the upper and lower transport rollers B 12 4 31 August 1989 The mark detection sensor A detects the reference line D and reads the job sheet The mark detection sensor is composed of 4 photosensors The sensor on the right B detects the reference line and reference marks E and the other sensors C read the job sheet data The menu reader CPU monitors signals from the mark detection sensor and measures the time between each reference mark There are 25 reference marks along the sheet edge After the 25th reference mark is read the job sheet is fed out by the upper and lower transport rollers F The operation panel status changes after the job sheet is read and the job sheet information is sent to the copier CPU 12 5 31 August 1989 4 2 Menu Reader Indicator Lights Red Light A job sheet can be inserted 2 ON OFF A job sheet is being read or the copier Start key stays red A job sheet read error has occurred the menu reader stops reading Check the job sheet to 3
98. Part No Description Assembly 1 02 A411 5508 Sorter Main Board Connector Connector Connector Connector Solid State Relay 240V 3A Transistor 2SC372Y pPA2003C Diode 151588 Diode DSA1A1 Zener Diode D8 D D iode 555006 iode 0150 Photothyristor TLP5416 Thyristor 400V 8A IC TD62601P Resistor 1000HM 1T 5 Resistor 10HM 5T 55 Resistor 2200HM 1W co 1 c Capacitor 0 68pF 35V Capacitor 3 3pF 35V BD Capacitor 4 7pF 25 Capacitor 0 1 50V JT A Capacitor 0 01pF Capacitor 1000PF 50V Capacitor 0 1 50V Capacitor 0 47pF 630VDC Resistor 1KOHM 1 4 5 BD Resistor HM 1 4T istor 100 1 4 istor 1 4 istor 1 4 CO GE 65 istor 1 4T Co istor 1 4T istor 1 4T 5 Co August 31 89 4 SORTER HARNESS A411 4 SORTER HARNESS A411 August 31 89 Index Q ty Per De Q ty Per Part No ipti Part No Description Assembly r Description Assembly A411 5600 Sorter Harness 1100 1042 Socket Mate N Lock 2 A411 5610 Sorter Interface Harness 1100 1043 Pin Mate N Lock 1100 1168 Fastening Receptacle 1100 1169 Fastening Receptacle 1100 1239 Pin Mate N Lo
99. Photo transistor 1 Turn off the main switch 2 Open the sorter cover and remove the upper cover 3 screws 3 Disconnect the harness from the upper jam sensor board A 4 Remove the upper jam sensor board 2 screws Lower Jam Sensor LED 1 Turn off the main switch 2 Remove the interrupt bin and the 15th bin 3 Remove the antistatic brush B and the sensor cover C 2 screws 4 Disconnect the harness from the lower jam sensor board D 5 Remove the lower jam sensor board 2 screws 14 29 31 August 1989 10 4 Sponge Roller Replacement 1 Turn off the main switch 2 Remove the sorter from the copier See Sorter Removal 3 From the sorter rear side remove the motor drive pulley 1 Allen screw then remove the gear B of the sponge roller shaft 1 E ring and the parallel pin C Note sure not to lower the parallel pin 4 Remove the lower guide plate D with the upper guide plate E 2 screws each from the front and rear sides Note Be sure not to damage the inlet sensor when removing the guide plate One of the rear side screws is a flat head screw F 14 30 31 August 1989 5 From the sorter front side release the belt tightener bracket 1 screw 6 Remove the sponge roller drive pulley H 1 Allen screw 7 Remove the roller bearings I from the front and the rear of the roller shaft 8 Replace the sponge roller J 14 31 31 August 1989 1
100. Spacer 6x22x0 5mm Rack Rear Original Guide Rack Front Original Guide Rear Table Bracket Front Table Bracket Original Table Extender Extender Spring Plate Original Table Cover Decal Misfeed Removal Decal Jan Removal Decal DIP Switch Shoulder Screw M4 Spring Flip Scale Austatics Brush ight Hinge Spring Outer ight Hinge Spring Inner iber Optics Harness iber Connector R R Left Hinge Spring F F D isplay Panel Bracket Index NR Part No 728 um Q ty Per Assembly 2 DF Il A418 8 August 31 89 103 is eS er LAGE 2 E a 3e gt ue A ct 22 29 1 lt 03 48 20 3 4 798 Tod xe N x Pg BF 33 x E AS 4 406 103 2 77 45 E 225 ES 275 2 Dx p AP Gee T EE a 27 4 8 e m a E C 106 8 102 6 26 2 DF Il A418 Index Q ty Per 00 Index Q ty Per Assembly A418 2102 A418 2103 Registration Roller Paper Suze Sensor Photosensor Upper Feed in Guide Release Lever Shaft Rear Release Lever Upper Separation Roller Front Feed in Guide Snap Ring Pick up Roller Shaft Original Feed Roller Pulley 24T Timing Belt Bushing 6mm Feed Roller Shaft Separation Roller Pulley Bushing 8mm Pick up Ro
101. To prevent toner from scattering when the toner bottle is lowered a rack D and pinion E system closes the toner shutter F At the toner inlet section the toner agitator G has a spiral shape to move the toner to the toner tank cavity 2 39 31 August 1989 6 3 TONER DENSITY DETECTION e Se B RAN C Original Lead Edge Wy Dy D Original ms id E Full Erase F ID Check G Edge Erase copy cycle H Low Toner Condition Enough Toner Condition J Sensor Pattern Image The main CPU checks the image density of the sensor pattern at the beginning of the first copy cycle after the main switch is turned on and at every tenth copy cycle Alter the sensor pattern A is developed the image density sensor B a photosensor checks its reflectivity If the reflected light is too strong the CPU determines that the toner density is too low It then adds toner to the development unit Toner is not added all at once The CPU energizes the toner supply clutch to add a selected amount of toner over the next 10 cycles 2 40 31 August 1989 6 4 TONER DENSITY CONTROL 24V VA Image Density Sensor Main PCB 9 5vvo v 24 MC Toner Supply 8 Y CN103 12 Fm Clutch CN103 14 VRI LLL The image density sensor checks the density of the sensor pattern image once every 10 copy cycles The CPU receives two voltage values directly fro
102. gt c Exe pes pn CO CO CO WwW WwW gt gt 3 3 3 3 103 103 103 103 103 1103 1103 1103 103 tact nector nector nector nector nector nector nector nector nector nector nector nector Header ector ector ector ector ector ector ector ector ector ector ector ector ector ector ector ector ector ector ector ector ector 143 Connector 20P Connector 50P Relay Bracket LSI Socket 28P LSI Socket 28P lon Clip 3N lon Clip 3N Lon 3 lon Clip 3 3 2 lon Cli Wire Saddle Stud Harness Clamp Harness Clamp Harness Clamp ire Saddle ire Saddle ire Saddle lamp lamp Nylon Stud Cord Clamp 115V Locking Support ushing 13mm ord Clamp 115 40 B Bushing 9 9mm Fuse 3 15A 125V Circuit Breaker 115V F use 5A 125V ircuit Breaker 10 Power Supply Cord 115V Push Switch DIP Switch Switch Power Relay August 31 Page and ELS 0 No RF r3 pn t BP CO CO e e 99 89 August 31 89 T Page and Parts No escription index No HD74L
103. gt Sensors Toner Overflow ARDF Sorter RDH Finisher Exit Inverter Exit Duplex entrance Duplex Paper Jogger H P Toner End Oil image Density Solenoids Fork Gate Inverter Return Junction Gate Duplex Positioning ca Duplex Stopper Duplex Pick up Pick off Mal Cleaning Cooling Blower Motor Main Motor L AC Drive PCB gt Exposure Lamp Fusing Lamp E Motors Jogger Vacuum Fan Fusing Exhaust Charge Fan Cc Development Caniina WI Paper End Lift Registration Relay Manual Feed Fan Cleaner 5 Cleaner Paper Feed Counters PCB Total Solenoids Key Pick up A3 LDG Manual Feed Erase Lamps Power Packs CFL Stabilizer Magnetic Clutches Paper Feed gt Feed Relay Lift Motor 1 28 31 August 1989 11 AC AND DC POWER DISTRIBUTION AC Power Menu reader Fusing sn qu Main PCB Sorter 100VAC paper bank Power AC PCB Supply Operation PCB Logic circuits b Unit Paper feed PCB SSR ARDF RDH Paper bank PCB Anticondensation Clutches Drum heater Solenoids Counters 24N Relays Operation PCB 24 AC Drive Developer motor Power packs board Paper feed motor Main motor Co
104. pattern Vi Developer bias V0 Vsg V1 Vsp 0 5 min 1 10 min 2 15 min 0 NO 1 Sorter 2 Finisher 0 No 1 ARDF 2 RDH 0 No limit 1 Limit 0 Yes 1 No 31 August 1989 Comments Adjust Vsg with VR on the ID sensor board LED turns on 10 sec no drum rotation Vsp Vsg value updated every 10 copies Free run starts Auto ID adjusted automatically Machine starts free run K SP57 SP56 Without temperature compensation Use this mode to bring a low toner condition back to normal 100 is selected Factory setting 0 Factory setting 0 Factory setting 0 Limit 35 sheet bin Use with finisher Factory setting 0 When off the final sheet is fed out when on it stays in the tray Factory setting Also accessible by the customer using the key board 31 August 1989 Mode No 81 82 85 86 87 88 89 90 91 92 93 97 Function Weekly Timer Set Programs machine to turn on off each day of the week Automatic Shutoff Selects automatic shutoff time EM Call Phone Number Sets phone of service representative PM Counter Turns on PM counter PM Copy Count Sets PM counter interval PM Counter Check Displays contents of PM counter PM Counter Reset Resets PM counter User Code Mode Selects user code mode Key counter shorting connector must be removed User Code Counter Check Displays contents of ea
105. 1 A007 5366 Power Pack Harness 1264 Wire Terminal 1100 1 Pin Mate N Lock 1100 1 tact 1102 1 nector E 1102 nector 1102 1 nector E 1102 1 nector 1102 1 ector E 40 TRANSPORT UNIT HARNESS A045 A046 Arat 86 40 TRANSPORT UNIT HARNESS A045 A046 August 31 89 Q ty Per Index Q ty Per Assembly Assembly 01 1100 1253 007 5214 Transport Unit Harness Pin Mate N Lock Wire Terminal Contact Connector Connector 2P Connector 3P 41 SAFETY SWITCH HARNESS A045 A046 August 31 89 miim N 88 41 SAFETY SWITCH HARNESS A045 A046 Q ty Per Assembly Part No Description A007 5218 Safety Switch Harness 89 Part No August 31 89 Ee Q ty Per Description Assembly 1100 1100 1102 1102 1102 1172 1238 1402 1403 1404 Fastening Receptacle Pin Mate N Lock Receptacle Housing 1P Receptacle Housing Receptacle Housing Connector 6P 42 LIFT MOTOR HARNESS A045 A046 August 31 89 ioi 104 106 CN 407 CNS 101 07 v4 104 CN CNS 408 109 103 A D S 42 LIFT MOTOR HARNESS A045 A046 August 31 89 Q ty Per Index Q ty Per Part No Assembly Receptacle Terminal 045 5251 Left Motor Harness Contact Connector 10P ector P Connector
106. 1 1102 1 1102 1 1102 1 0277 1815 1172 1239 1241 1247 0796 1404 Fastening Receptacle Connector 3P Fastening Receptacle Pin Mate N Lock Socket Mate N Lock Terminal Receptacle Housing Receptacle Housing Connector 2P Connector Receptacle Receptacle Pin Mate N Lock Socket Mate N Lock Terminal Receptacle Housing Connector 2P Connector 1P Connector Receptacle Sleev 8 TRAY DC HARNESS 5897 August 31 89 sol ape lt gt A 80 8 TRAY DC HARNESS 5897 August 31 89 Q ty Per Index Oty Per 0 Assembly ule _ 5897 5043 Tray DC Harness Fastening Receptacle onnector Fastening Receptacle Socket Mate N Lock eceptacle Terminal Contact Connecting Sleeve 3 0mm 220V Receptacle Housing nector nector 3P Receptacle Housing 3P Receptacle Housing 7P Connector 7P 19 August 31 89 9 DECAL 5897 gt So Attention This machine is set for 220V 50Hz 9 DECAL 5897 August 31 89 sts Q ty Per TOR Q ty Per No Part No Description art No Description Assembly P Assembly A912 2582 1 Paper Siz 5897 1282 1 Operater Instruction A912 2594 1 512 A912 2595 1 Decrease Siz 5403 4335 1 Termina
107. 1 5442 3233 Spring Drive Wheel Main Drive Motor Bracket 06 0064 Tension Spring Main Drive Motor AC 39 5W 1 A007 1105 Support Plate Motor Shaft Pulley 30T 60Hz 007 1107 Support Plate Stud Pulley 36T 650Hz 1 5203 1852 Bushing 6x8x4mm Sprocket 15T 60Hz Sprocket 18T 50Hz Paper Feed Motor Timing Belt 200XL 1 coc CO Fe co LY Cleaning Drive Bracket Fusing Drive Spring 60Hz Co Fusing Drive Spring 50Hz Tension Lever Fusing Drive 27T gt Drive Unit Bracket Gear Fusing Drive Drive Shaft DO Bad Belt Tension Bracket 36T Belt 222PX Co Noo sion Spring Drum Drive 220 240V sion Spring Drum Drive 115V Index Q ty Per Index Part No Q ty Per Assenbly Assembly Pan Head Screw M4x6 1 2 Pan Head Screw M4x8 ilips Pan Head Screw M4x10 Tapping Screw M4x6 Tapping Screw M4x8 Headless Set Screw M4x5 Hexagon Headless Set Screw M5x5 Hexagon Headless Set Screw M5x6 Parallel Pin 3 14 Bushing 4x5 Retaining Ring M5 Retaining Ring M6 Ball Bearing 6x12x4mm Ball Bearing 8x1l6x5mm Philips Screw With Flat Washer M4x6 Philips Flange Screw M4x8 Capacitor 14MF 250V Retaining Ring M4 Harness Clamp Retaining Ring M4 CL AS soo 2
108. 1 8 1 2W 7468 Fuse Resistor 1000HM 1 2W 8185 Variable Resistor 2000HM 0 5W 0975 Noise Filter 0 1MF 1200HM 0976 Noise Filter 1200HM 0 1MF 0280 Capacitor 0 01MF 50V 0689 Capacitor 0 01MF 80 20 50V 1494 Capacitor 0 047MF 250V 0 0 CO 1 Fe WH gt Mo NM BM MW PY WB CO c5 1496 Capacitor 400V 047gF 125V 1542 Capacitor 0 22 AC250V 0218 Inductor 6660MF 11 4103 Resistor 10 1 4W 5 11 4223 istor 22KOHM 1 4W 5 11 4562 istor 5 6KOHM 1 4W 5 11 4820 istor 820HM 1 4W 5 11 6222 istor 2 2KOHM 1 2W 5 1203 istor 120KOHM 1 4W 1 1800 istor 1850HM 1 4W 4703 istor 4700HM 1 4W 1 8202 istor 82KOHM 1 4W 1 Bo o 1497 Capacitor CO c YP PY Mo FF J CO CO CO CO Oo Fe CO 101 1102 2113 Connector 2P 102 1103 0701 Connector 6P 69 32 HARNESS LAYOUT FRONT VIEW A045 A046 August 31 89 E EQ d Ru N Eu o N 2 MC wY SQN AX AE TN m EA C OL N 8 8 rub cre Hex gt HG Ww V A ww UA M ue 4r 20 ce A te ES gt gt 2 2 se V P Y A 50 05 gt EX7 eer i AP we
109. 1 Capaci 27PF 50V MP4503 1 1 Capaci 0 022pF 50V LED TLR 102A 11 11 1 1 Capaci 0 01 Photocoupler ON3111 Aeg 161 Resistor 1000H IC TC4040BP 11 1 161 Resistor 3300H IC TC4049BP 11 161 Resistor 1 5 I SN74LS373N at 1 Resistor 2 2 0 UPD7810G Last 161 istor 3 TG TD62304P 11 1 161 istor 4 7KOH August 31 89 Page and ipti Bae and Parts No Description oe Parts No Description Index No ndex No 1610 0071 Resistor 10 5 163 1610 0073 Resistor 12KOHM 1 8W 5 181 1610 0079 Resistor 22KOHM 1 8W 5 164 1610 0107 Resistor 1 8W 5 11 165 1610 0286 Capacitor 100PF 50V 5 11 166 1611 4103 Resistor 10KOHM 1 4T 5 11 167 1611 4229 Resistor 2 20HM 1 4W 5 11 168 1611 4272 Resistor 2 7 1 4 5 11 169 1611 4330 Resistor 3300HM 1 4T 5 11 170 1611 4393 Resistor 39KOHM 1 4T 5 11 171 1611 4472 Resistor 4 7 1 4T 5 11 172 1611 4563 Resistor 56KOHM 1 4T 5 11 173 22 PS220 A420 PS220 Location of 3 1 Vertical Transport A420 4 2 Exterior 420 6 3 Paper Feed Section 420 8 4 3rd Paper Feed Section A420 10 5 4th Paper Feed Section A420 12 6 Print Boar
110. 10E 1100 1253 Pi ate N Lock 1100 1253 i ate N Lock 1100 1253 Pi ate N Lock 1100 1253 Pi ate N Lock 1100 1253 Pi ate N Lock 1100 1253 Pi ate N Lock 1100 1253 Pi ate N Lock 1100 1253 i ate N Lock 1100 1259 Socket ate N Lock 1100 1259 Socket ate N Lock 1100 1259 Socket ate N Lock 1100 1259 Socket ate N Lock 1100 1264 Wire T inal 1100 1264 Wire Terminal 1100 1264 Wire T inal Connector 12F Terminal Socket Mate N Lock Socket Mate N Lock Socket Mate N Lock OV Positive Lock Receptacle c Fastening Receptacle lt gt FP O0 Ww OF W Fastening Receptacle Fastening Receptacle Fastening Receptacle Terminal Pin Lock Pin Lock Pin Lock Pin Lock 140 August 31 89 Parts N t Page and arts No escription index N nector 10P 91 103 Page and Une Wire Terminal Fastening Receptacle nector 12P 81 105 Fastening Receptacle Connector 65 104 Contact Contact nector 5P 73 123 nector 15 101 110 nector 2P 101 103 nector P 73 126 Contact tact Contact Contact Contact nector 97 107 nector P 73 127 Connector P 97 108 Contact Receptacl ousing 7355 Contact Receptacl ousing 75 116 Socket Contact Receptacl ousing 89 103 Contact Receptacl Housin 75 117 Contact Conta
111. 1102 1514 Connector 1102 1620 Connector 3P 102 1621 Receptacle Housing 3P 102 1623 Receptacle Housing 7P 102 1915 Connector 7P 102 1916 17 89 August 31 8 DECAL A421 ac B4 8 Hit i i 1 i 2 Sa _ M gt d o zor Zi amp or 55562 56845 900 fm ey 25259 ESE eee eu ZoomJgu 3 Md q 595 4 865 q 5552 999 lt SS SSNS GERNE 17 lt gt 2 99 2 4 ENEN Cw 0 E gt 0 gt 2ORO 5 g 52 5 6 lt E m S TES e S SS e TU SNS pe o 8 DECAL A421 August 31 89 Index Or Q ty Per Index EE Q ty Per Part No Description No Part No Description Assembly No Assembly Front Paper Size Decal ear Paper Size Decal Paper Siz Paper Siz Operater Instruction Terminal 115V Power Source 220V English German 220V u Co N Terminal 220V lt gt Installation Procedure English lt gt Installation Procedure 5 Language 19 PARTS INDEX Aug
112. 2 Open and remove the fusing exit assembly A 1 E ring and 1 connector 3 Remove the oil pan B 4 screws and 4 hooks 4 Remove the front pressure spring C and remove the front pressure lever D 1 E ring 5 Lift up the upper part of the fusing unit and remove the pressure roller E 6 Install the bearings on the new pressure roller and reassemble 5 32 31 August 1989 4 8 Entrance Guide Height Adjustment When Misfeeds with thick paper or paper creasing with thin paper occur Purpose To satisfy customer s applications exceptionally thick or thin paper Target No misfeeds and no creasing Measure Height Adjusting Lever Upper position Thin paper Lower Position Thick paper How Changes the angle of incidence of the paper when it contacts the hot roller surface 1 Pull the fusing unit all the way out 2 Move the height adjusting lever A to the rear to raise the fusing guide plate B or to the front to lower the plate The fusing guide plate can be raised or lowered 1 mm The upper position prevents creasing with thin paper and the lower position prevents misfeeds with thick paper 9 33 31 August 1989 4 9 Fusing Pressure Adjustment When Unfused copy with thick paper or paper curl with thin paper occurs Target Well fused copy without Measure Adjust the position of the fusing pressure spring three settings How Changes the distance between upper and lower fusing pressure levers
113. 31 89 and Parts No CON Doctor Blade VE Page and Parts wos NER Rear Spring Plate 2nd Mirror Front Spring Plate 3rd Mirror Development Roller Rear Spring Plate 3rd Mirror Toner Supply Shaft ft Scale LT ft Scale A3 A4 Back Spill Plate Development Anger Paddle Roller ide Rod Scanner ide Rod Scanner Toner Agitator ide Rod Magnification Toner Agitator Cleaning Unit Cleaning Brush Charge Corona Unit Toner Collection Coil T amp S Corona Unit Cleaning Brush Roller Receptacle PCC Hot Roller Receptacle Pressure Roller Bias Receptacle Ball Bearing 10x26x8 Bushing 20mm Oil Blade Main Corona Receptacle T amp S Corona Receptacle AD A A A A A A A A A A AE Oil Supply Pad Feed Roller Front End Block Charge Corona Rear End Block Charge Corona Cassette Cover Large Front Cover Charge Corona Cassette Cover Small Rear Cover Charge Corona Front End Block PCC Front Cover PCC End Block Transport Roller 20mm Upper Registration Roller Lower Registration Roller Upper Middle Roller Front Cover PCC End Block Rear End Block PCC Rear Cover PCC End Block Lower Middle Roller ir CO 1 CO 4 W NY Fr Transport Roller
114. 31 August 1989 Lens Positioning A Lens Drive Pulley B Lens Housing The lens home position sensor C informs the optics PCB when the lens D is at the full size position home position The optics PCB determines the lens stop position in reduction and enlargement modes by counting the number of steps from the home position When the reproduction ratio is changed the lens moves directly to the selected magnification position 2 13 31 August 1989 Operation Panel PCB TXD RXD Main PCB Home position is checked by moving the lens from the enlargement side towards the reduction side So when home position is checked a LOW to HIGH to LOW signal is present at CN305 9 of the optics board This occurs when the actuator blade enters and exits the lens home position sensor The lens only references home position when going to full size at power up when modes are cleared when full size is selected The lens always overshoots the selected magnification ratio position by 40 steps to eliminate mechanical play when going from enlargement to reduction Optics PCB Optics Driver T 24 24V VM Lens H P sensor CN305 9 CN305 8 Home Position 100 A Reduction L gt 40pis Enlargement 2 14 31 August 1989 3 6 FOURTH AND FIFTH MIRROR ASSEMBLY When the reproduction ratio is changed the stepper motor
115. 59 Feed in Motor Ass y DC24V 5918 3536 Exit Roller 9 69 Feed in Motor Bracket 5918 3562 Antistatic Brush 9 73 Pick up Solenoid Bracket 5918 3585 Upper Exit Roller 9 80 Pick up Lever 5918 5501 Stopper Solenoid 7 23 Stopper Lever 5918 5515 Pick up Solenoid 7 24 Stopper Lever 5918 5516 Release Solenoid 9 32 Stopper Bracket 5918 5525 Registration Solenoid 9 27 Pick up Control Shaft 5918 5631 Paper Suze Sensor 1 2 Sensor Bracket 5918 5722 Photosensor 1 3 Harness Bracket Ass y 5918 5722 Photosensor 9 81 Upper Feed in Guide 5918 5821 Registration Sensor Harness 7 4 Lower Feed in Guide 5936 2480 Magnetic Catch 5 11 Spring Plate 5936 2542 Turn Pulley 9 66 Middle Spring Plate 5936 5221 Heat Sink 11 5 Entrance Guide 5936 5501 Transport Drive Motor DC 21W 9 9 Paper Guide Mylar Paper Guide Mylar Seal 12x17x0 7mm Mylar Feed in Extender Spring Plate Decal Feed in Belt Unit Holder A Shoulder Screw M4 Unit Holder B M4 Release Bracket Drive Roller Roller Spring Floating Roller Floating Roller Belt Stopper Holder Floating Roller Belt Unit Stay 19 August 31 89 Page and Page and Parts No Description a Index No gt _ Index No Screw 1 0050 ining ee Screw M3x4 1 0060 4 Philips E Screw M3x6 1 0060 ining g g Philips Screw M3x6 00708 Philips Screw M3x8 1 00701 Philips Screw 16 1 3505 11
116. 8 to 0 7 Factory setting 8 0 8 to 0 7 Factory setting 8 0 215 mm per step 1 72 mm to 1 505 mm Factory setting 8 To adjust voltage enter lamp voltage with key pad in 0 5 volt steps Factory setting 65 Te to 190 21 in 1 egree steps Factory setting 185 Exposure lamp stays on for 10 seconds Do not repeat more than 5 times to avoid overheating the optics cavity Mode No 54 55 56 57 59 60 61 72 76 77 80 Function Vsg Adjustment Turns on ID sensor LED Vsg Vsp Check Displays Vsg and Vsp Auto ID Voltage Adjustment Automatically adjusts the auto ID reference voltage Auto ID Voltage Value Display Displays voltage and K values Press Start key to turn on Press C S to stop Bias Voltage Displays bias voltage Press Start key to turn on Press C S to stop Toner Density Recovery After the Start key is pressed the toner supply clutch turns on and free run starts Free run stops and constant supply is reset when Vsp becomes 1 8 Vsg Idling Period Selection Selects idling period at power up Sorter Finisher Operation Enables sorter or finisher operation ARDF RDH operation Enables ARDF or RDH operation Sorter Bin Capacity Sets the stack mode quantity limit Odd Number Duplex Op Sets the copler to eject the final copy i n odd number of originals are set Clock set Sets the machine clock 4 13 Data V0 ID
117. A N 4 ZZ NN 6 7 Stopper Bar 1 Top Cover 2 Rear Cover 8 Paper Size Dial 3 Side Post 9 Close Cover Indicator 10 Down Key 4 Tray Bottom Plate 11 Front Cover 5 Stopper Chain 6 Side Cover 10 2 31 August 1989 3 DRIVE LAYOUT AND DRIVE MECHANISM 1 Tray Drive Motor Reversible AC Motor 2 Tray Drive Wheel 3 Tray Drive Shaft 4 Wire Drive Pulley 10 3 5 Tray Wire 6 Lift Rods 7 Actuator Plate 8 Tray Down Sensor 9 Tray Bottom Plate 31 August 1989 4 ELECTRICAL COMPONENT LAYOUT 1 LCT Paper Size Sensor 7 LCT Paper Volume Sensor 2 LCT Operator PCB 8 Motor Capacitor 3 LCT HP Sensor 9 Circuit Breaker 115 V 4 Cover Safety Switch 9 Fuse 220 240 V 5 LCT Drive Motor 10 Positioning Switch 6 Main PCB 10 4 31 August 1989 5 FUNCTIONAL AND ELECTRICAL DESCRIPTION 5 1 TRAY OPERATION Overview The bottom plate A of the large capacity tray is raised and lowered by a wire and pulley mechanism This mechanism is driven by the tray motor B reversible ac motor Drive power is transmitted directly to the tray drive shaft via a worm gear and worm wheel C The tray wires have braces on them these braces hold the ends of the two lift rods D which support the tray bottom plate When the wire drive pulley turns clockwise the braces on the wires raise the lift rods and the tray bottom plate The bottom plate rises until the paper in the t
118. A045 A046 06 06 102 102 August 31 89 06 102 112 103 rrr CNAIT 108 09 103 80 37 PAPER FEED UNIT HARNESS A045 A046 August 31 89 Index T Q ty Per Index Q ty Per A045 5249 Paper Feed Unit Harness Socket Mate N Lock 14 1 Receptacle Terminal 11 1 Contact 11 1 Connector 12 11 1 Connector 3P 11 1 Receptacle Housing 11 1 Connector 3P 11 1 Connector 11 1 nector 10P 14 ector August 31 89 38 AC DRIVE BOARD HARNESS A045 A046 9NI 9 GOI sno Oll 82 4 38 AC DRIVE BOARD HARNESS A045 A046 Index Q ty Per Index Q ty Per Part No j n Part No ipti A007 5462 AC Drive Board Harness 1 01 1100 0863 Stud Pin 02 1100 0864 Housing AWG14 20 03 1100 1238 Pin Mate N Lock 04 1100 1239 Pin Mate N Lock 05 1100 1247 Terminal 06 1100 1327 tact 07 1102 0946 sing 08 1102 0977 nector 09 1102 1510 nector 0 1102 1512 nector 1 1102 1889 ector 2 1102 1910 ector 3 1102 1917 ector 83 August 31 89 39 POWER PACK HARNESS A045 A046 103 pu 105 min 2 84 39 POWER PACK HARNESS A045 A046 August 31 89 Index ty P Index Part No Description Q ty Per Part No i i Q ty Per Assembly No Assembly 01 1100
119. ADF or RDH Automatic reduction enlargement AMS with ADF 2 single copies mode Copies facing pages of a bound original with one press of the Start key 7 steps 1 minute standard setting can also be set to 3 minutes or no auto reset All functions canceled except cassette selection Quantity entered returns to 1 and reproduction ratio returns to full size Dual universal cassette feed 500 sheets each Manual feed table Large capacity tray LCT optional 1 000 or 2 500 sheets Two additional cassettes with cassette bank optional 500 sheets Feed and reverse roller Slit exposure moving optics Through lens F5 f 2 215 mm Halogen lamp 85 V 160 W control range 50 to 80 volts RMS Selenium drum F type Dual wire dc corona LED lamp unit 80 segments Magnetic brush roller Automatic voltage change The control board monitors the selected image density level drum temperature and rest time Cartridge exchange 330 g bottle 10 000 copies bottle 7 A4 1 2 Cleaning System Quenching System Image Transfer Paper Separation Image Fusing Fusing Lamp Oil Consumption Electronic Control System Copy Tray Capacity Self diagnostics Service Programs Power Source Power Consumption Dimensions Weight 31 August 1989 Blade and brush pre cleaning corona Photo quenching cold cathode tube and dc corona Single wire dc corona pre transfer lamp Dual wire a
120. Adjusting Start Lever 1794 Plate Lens Bracket c Lens Bracket Co jm Cushion Lens 3x7x80 Co Lens Shielding Cover Rear Shield Lens gt Front Lens Shield Lens Shield Co a Actuator Plate Lens Home Sensor Index 2 Part No D Pan Head Screw M3x6 Index Q ty Per Assembly n Pan Head Screw M4x10 ips Sunken Head Screw M4x8 ing Screw M4x6 ing Screw M4x10 ining Ring M4 ips Screw With Flat Washer ips Screw With Flat Washer ips Screw With Flat Washer ips Screw With Flat Washer lon Clip 3N 17 August 31 89 6 PLATEN COVER AND CASSETTE 045 046 18 6 PLATEN COVER AND CASSETTE A045 A046 Index Q ty Per Part No E Assembly CO u 9 2 3 4 5 6 7 8 8 9 9 0 BD BD LH YH MH LH LY OV Be CO PB F2 Platen Cover Ass y Rear Platen Cover Front Platen Cover Flex Hinge Platen Cover Platen Cover Pad Platen Cover Sheet Rubber Magnet Mounting Bracket Platen Cover Stud Platen Cover Mounting Platen Cover Hinge Ass y Pin 4x115mm late Magnet Platen Base ight Spring Platen Cover Left Spring Platen Cover Balancer Spring Arm Holder Slide Supporter Cassette Cover
121. August 1989 1 INSTALLATION REQUIREMENTS 1 1 ENVIRONMENT 1 Temperature Range 10 C to 30 C 50 F to 80 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 air should turn over at least 3 times hour 5 Ambient Dust Less than 0 15 mg m 4 x 103 2 3 6 Room size More than 10 m 13 4 yd 7 lf the place of installation is air conditioned or heated place the machine 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 c where it will not be directly exposed to reflected heat from a heater 8 Do not place the machine where it will be exposed to corrosive gasses 9 Do not install the machine at any location over 2 000 m 6 500 feet above sea level 10 Place the copier on a strong and level base 11 Do not place the machine where it may be subjected to strong vibrations 3 1 31 August 1989 1 2 MINIMUM SPACE REQUIREMENTS 10 cm 3 9 829 80 cm 31 5 70 cm 27 6 3 2 31 August 1989 1 3 MACHINE LEVEL 1 Front to Back Within 5 mm 0 2 of level 2 Right to Left Within 5 mm 0 2 of level 3 Screw the leveling feet A up or down to level the machine 1 4 POWER SOURCE 1 Input voltage Level 110 V 60 Hz 15A 115 V 60 Hz 15A 220 V 50 Hz 8A 240 V 50 Hz 8A 2 Permissible Voltage
122. August 1989 9 QUENCHING 9 1 OPERATION gt pre quenching corona A applies a positive corona 5 kilovolts to neutralize the negative charge remaining on the drum s surface from the pre cleaning corona Simultaneously the quenching lamp B neutralizes any remaining positive charge on the drum Both a lamp and a dc corona are required because the quenching lamp is less effective against negative charges than positive charges The quenching lamp also stabilizes the drum sensitivity from the first cycle by pre illuminating the drum This machine uses a cold cathode lamp sometimes called a cold fluorescent tube as the quenching lamp The cold cathode lamp ac 430 volts 1 3 watts consumes less power releases less heat and is brighter Also its effective light is in the most sensitive range of the drum A plastic filter prevents toner from being deposited on the lamp 2 61 31 August 1989 9 2 PRE QUENCHING CORONA CIRCUIT 5VDC Main PCB PQC Cleaning Bias P P CN101 B20 PQC QL v5 GND p Circuit operation begins with the application of 24 volts to CN1 1 on the PQC power pack This is the power source for the high voltage dc 5 kilovolts corona When the Start key is pressed the CPU energizes the PQC power pack through the TC SC power pack by supplying a LOW at CN101 B20 This turns on the LED and the phototransistor energizes the pre quenching
123. Bin Odd 2 3 4 5 6 7 8 9 0 Rear Hinge Lower Decal Misfeed Removal Collar 6 1mm Lower Mounting Stud Grounding Plate Bin Unit Mounting Stay Magnet August 31 89 2 MIDI SORTER A411 E N C lt A ae gt JA gt gt E 27 p yu lt gt A S A 7 NY 225 AS ad 22 2 22 SZ P ge 2 d 005 V 2 MIDI SORTER A411 Index Part No M Middle Stay Paper Stopper Lower Stay Paper Exit Sensor Bushing 6mm Pulley 18T Idle Pulley 6x22x11mm Lower Guide Plate Transport ower Exit Roller gt CO gt CO Lower Transport Roller Tightener Transport Drive Guide Plate Cover Cover Rear Helical Cam Sorter Harness Sorter Main Board Sorter Interface Harness Harness Bracket Helical Cam Bracket Magnet Upper Guide Plate O CO 1 A Co Rear Helical Cam Ass y Bin Motor AC31W 38W 115V Bin Motor AC31W 38W 220V 240V Pulley 18T Timing Belt 112MXL BS
124. C on the bottom right side of the copier 2 stud screws then remove the second cassette lift arm D 2 screws NOTE Save this handle for later use when transporting the copier 8 Insert the tray into the second cassette position NOTE Make sure that the rib E fits into the groove F 9 Open the side and top covers and secure the tray with two bolts G Use the longer bolt for the rear side and the shorter bolt for the front side 10 12 31 August 1989 10 Disconnect CN406 A CN408 B and CN409 C on the feed control board 11 Connect the six tray harness connectors to the three free harness connectors and to the three connectors on the feed control board as follows TRAY CONTROL BOARD Female 4P CN408 Female 10P CN406 Female 12P CN409 TRAY FREE Male 4P 4p Male 10P 10P Male 12P 12P 12 Secure the harness to the copier table with the nylon clamp D 1 screw 10 13 31 August 1989 13 Reinstall the toner collection bottle and the rear cover 14 Plug in the power supply cords for both the large capacity tray andthe copier 15 Load paper into the tray 16 Turn on the main switch of the copier and check the tray operation 17 Fill out the New Equipment Condition Report 10 14 31 August 1989 7 REPLACEMENT AND ADJUSTMENT 7 1 Tray Down Sensor and Positioning Switch Replacement NO E Open the side cover and remove the front cover A 2 screws and 1 connector an
125. CPU then turns off the Add Paper indicator In manual feed mode the manual feed solenoid C lifts the pick up roller This solenoid has a longer stroke because the pick up roller must be lifted higher when the manual feed table is used 2 71 31 August 1989 10 7 RELAY FEED AND REGISTRATION 0 The relay rollers A and the registration rollers 8 feed paper from the second paper feed station to the transfer section From the first paper feed station paper is fed directly to the registration rollers and then on to the transfer section When feeding paper from the second cassette the relay rollers take over the paper feed until the paper reaches the registration rollers The paper feed motor C drives the relay rollers via the paper feed chain D gears and the relay roller clutch E Skew Correction The registration sensor F is positioned just before the registration rollers When the sensor detects the leading edge of the copy paper a timer starts 84 milliseconds first feed station 40 milliseconds second feed station At the end of the timing period the CPU turns off the first feed clutch or the relay feed clutch second feed station This delay allows time for the paper to press against the registration rollers and buckle slightly to correct skew 2 72 31 August 1989 A Registration The main motor A drives the registration rollers B via the main drive belt C gears and the registration clut
126. Capaci 27 50V 96 62 1 1451 0 1 50V 97 63 1 1454 0 01 50 64 1 1455 470 25V 65 1610 0035 Resistor 1000HM 1 8W 66 1610 0045 Resistor 2700HM 1 8W 67 1610 0047 istor 3300HM 1 8W 68 1610 0048 istor 3900HM 1 8W 69 1610 0049 istor 4700 70 1610 0053 istor 161 161 161 161 161 161 161 16 10 LO LO LO LO 11 11 11 Oo Do Do 1 4W 15 AW 51 1 4W 1 1 4W 15 bh Bo rn a E o 63 29 OPTICS BOARD A045 A046 CONNECTOR CAPACITOR DIODE SYMBOL SYMBOL SYMBOL SYMBOL NO NO NO 131 113 130 130 131 131 SYMBOL 12301 12302 12303 12304 12304 132 C305 131 131 131 133 SYMBOL NO 1C306 C307 C308 1C309 OSCILLATOR SYMBOL SYMBOL NO 05 301 126 05 302 127 RESISTOR SYMBOL NO 64 SYMBOL NO August 31 89 TRANSISTOR SYMBOL NO SYMBOL NO ZENER DIODE SYMBOL NO 20301 115 20302 114 29 OPTICS BOARD A045 A046 August 31 89 Index Q ty Per E Q ty Per Desc tion Part No Description Assembly ae ie Assembly 045 5180 Optics Board LSI Socket 28P Transistor 2SA1121C Transistor 25 2618 007 5182 Eprom Optical Control
127. Chat The lift spring A resists the weight of the belt unit making it easier to lift the belt unit When the belt unit is lifted the detent arm 6 turns on the lift switch At the same time the DF CPU sends a signal to the copier CPU This signal enables the copier to operate without the document feeder While the lift switch is on the DF modes are prohibited 8 13 31 August 1989 12 MISFEED CHECK ON CHECK NE OFF CHECK 1250ms Feed in Motor During single sided mode three sensors check for misfeeds the original entrance sensor A registration sensor B and exit sensor C After the feed in motor turns on the original activates the original entrance sensor The DF CPU checks to see if the original entrance sensor has been activated original entrance sensor ON check 475 ms after the feed in motor turns on Then 350 ms after the original entrance sensor is activated the DF CPU checks to see if the registration sensor has been activated registration sensor ON check The OFF check is carried out when the belt drive motor turns off The DF CPU checks to see if the registration sensor has been deactivated registration sensor OFF check There is no off check for the original entrance sensor The ON check for the exit sensor is performed 675 milliseconds after the feed out and belt drive motors are re energized The OFF check for the
128. Collection Tank 220 240V Toner Collection Tank 115V Oil Bottle Cap Transport Belt Timing Belt 228MXL Drive Belt ning Belt 345 Timing Belt 222 Timing Belt 699 ning Belt 200XL Scanner Drive Wire Jogger Fence Drive Wire Scanner Drive Wire Wire Duplex Stopper Solenoid Tension Cleaner Spring Tension Cleaner Spring Tightener Spring Pressure Spring Spring Inverter Pressure Release Pressure Spring Spring Inverter Pressur Front Spring Exit Roller Rear Spring Exit Roller Spring Fork Gate Lever Micro Switch Spring Tension Spring Drum Drive 220 240V Tension Spring Tension Spring Fusing Drive Spring 50Hz Fusing Drive Spring 60Hz Pick up Lever Spring Tension Spring Drum Drive 115V Page and Parts No Description Lue aes Pick up Lever Spring Upper Spring Wire Tightner Spring Duplex Stopper Cam Spring Spring Drum Flange Spring Feeler Spring Feeler Spring Paper Feed Separation Spring Paper Feed Separation Spring Spring Front Lamp Terminal Cleaning Blade Spring Toner Receiving Spring PQC Terminal Spring PQC Terminal Spring Spring Duplex Stopper Solenoid Spring Fork Gate Stopper Separation Pressure Spring Duplex Spring Spring Cleaning Blade Relay Roller Spring Spring Positioning Pin Spring Oil Pump Actuator Connector Shotter Spring Spring F
129. Des 7 4 5 PAPER FEED CLUTCH ON TIMING 7 5 6 PAPER SIZE AND VOLUME SENSORS 7 6 7 LIFT MOTOR CONTROL AND PAPER END DETECTION 7 7 7 1 MOTOR CONTROL 54242325 Re REV RS DERE EM NOx Ed 7 7 7 2 PAPER END 222225224555 do e 7 8 8 INSTALEATION ie ehh ed pe eee 7 9 8 1 Accessory Check MR 7 9 8 2 Installation Procedure 7 10 DOCUMENT FEEDER T SPECIFICATIONS a ek 8 1 2 BASIC OPERATION 8 2 ZTINTERFAGE hia 8 2 2 2 SINGLE SIDED ORIGINAL FEED cece cance ee eee es 8 3 2 3 TWO SIDED ORIGINAL FEED 8 4 3 FEED IN UNIT 8 5 4 SEPARATION MECHANISM 8 6 5 MISFEED 8 7 6 WEAR PREVENTION e ec ERROR RR 8 8 7 FRICTION ROLLER RELEASE MECHANISM 8 9 B HEGISTRATION odo ey ove ood e E 8 10 9 INVERTER MECHANISM 8 11 10 FEED OUT MECHANISM 8 12 11 LIFT MECHANISM 8 13 12 MISFEED CHECK 5 Ea RE 8 14 13 INSTALLATION
130. Drive One Turn Sensor Home Position Sensor Bracket Rear Helical Cam Bin Motor AC31W 38W 115V Bin Moto r AC31W 38W 220V 240V Transport Motor DC24V Sorter Main Board Sorter Main Board Protection Circuit Board Relay Ha rness Protection Board Sorter Harness Sorter Harness Sorter I Sorter I nterface Harness nterface Harness Grounding Wire Sorter C onnector Adapter Front Cover Decal Rear Cover Upper Cover Rear Hinge Lower Front Hinge Lower Hinge Upper Cover Right Cover Misfeed Removal ulti Lingual Decal Installation Procedure English Installation Procedure 5 Language Page and teste foo o mem fi Magnet Upper Guide Plate Transport Drive Belt Tension Spring Antistatic Brush Stepped Screw M4 Stepped Screw M3 Stud 28mm Rubber Cushi Pulley 18T 8 8 4 5x9 5x4 2mm Pulley Pulley Idle Pulley 6x22x11mm Idle Pulley 6x34x11mm ower Exit Roller Lower Transport Roller Bushing 6mm Sensor Type 5 Collar 6 1mm Insulating Mylar Stud 4 Bushing 4x7x10mm Lower Mounting Stud Mounting Stay Magnet Paper Exit Sensor Screw cn E Head Screw 3x12 Philips Head Screw 3x14 Philips Head Screw 4x6 Philips E Head Screw 4x8 Philips E Head Screw 4x8 Philips Head Screw M4x10 Philips Head Screw M5x10 Sunken
131. Drive Relay Roller Left Guide Plate Transport Right Guide Plate Transport Upper Relay Roller Rear Transport Bracket Vertical Transport Harness Gear 20T o Idle Gear Spring Idle Gear 36T BS Magnetic Clutch Vertical Transport lt gt Rear Side Fence Cap Transport Rear Side Fence Transport Co Magnetic Clutch Collar Magnetic Clutch Stopper Rubber Magnetic Clutch Stopper Co Spacer 1x8x12mm 2 EXTERIOR A420 August 31 89 _ 9 102 e Bia 10 o AN we 5 e We 26 103 aa ze e ddl C Sa gt 7 YA SB 4 Re SO LT eae SS 22 22 SSS 27 40 Ne c E Ro fh lt lt LP 2 SEES S BBE SSSA n 1 SEPA 2 EXTERIOR A420 August 31 89 Base Plate 420 3262 Joint Safety Switch Connector Angle 1 420 3721 Guide Holder Bracket 1 A420 4117 Stopper Guide Paper Bank Harness ide Rail Paper Bank et Catch Ass y Guide Guide Shaft Paper Feed Table Stopper Front Table Hinge Paper Ban
132. Duplex unit installed 30 Paper lift sensor 1 31 Paper lift sensor 2 DATA 1 Cassette lifted 32 Paper lift sensor 3 DATA 0 Cassette down 33 Paper lift sensor 4 For all sensors DATA is displayed in the guidance display 4 6 3 SERVICE PROGRAM MODE OPERATION 31 August 1989 The service program mode is used to check electrical data and change modes or adjustment values 3 1 Service Program Access 2 3 2 a Turn the main switch off Remove the DIP switch cover on the operation panel and turn on DIP SW 801 8 Then turn the main switch on NOTE At this point the guidance display will prompt PROGRAM No 5 Using the numeric key board enter the desired SP mode number according to the Service Program Mode Table The SP program can also be selected with the magnification keys in this case SP numbers are scanned through After selecting SP number press the ENTER key NOTE To cancel an already entered program press the Clear key Also if an invalid SP number is entered Press Clear key is displayed To abandon SP mode turn the main switch off set DIP SW 801 8 to the off position and turn the main switch on Change Adjustment Values or Modes Follow steps 1 3 of the preceding procedure Factory value settings or modes will be displayed in the guidance display Enter the desired value or mode using the numeral keys according
133. Function B 119 9 Size Function A Informs the sorter of the paper size Shorter than 300 mm or longer than or equal to 300 mm CN119 10 Exit Function A Informs the sorter when the copier exit sensor is activated CN119 11 Motor ON ou ut A Informs the sorter when the copier main motor is Function B Informs the sorter of the appropriate bin number by the combination of the binary states of these 4 signals The control line CN119 8 switches between HIGH and LOW When the control line is HIGH CN119 7 9 10 11 are used for Function A When the control line is LOW CN119 7 9 10 11 are used for Function B 14 14 31 August 1989 7 5 Jam Sensors Oscillatory Circuit Sorter Main Board 0 01u 0 01 2 0789 Sorter Main Board 24V m CN123 1 Ww OUT PUT CN123 2 GNO CN123 3 The jam sensor detects misfeeds of paper in the sorter The LED on the lower jam sensor board is turned on by a pulse signal which is supplied by an oscillator This pulse signal detection system has an advantage over a photointerruptor system because there is no noise from external light When there is no paper between the upper and the lower jam sensors the LED on the lower jam sensor board activates a photransistor PTr1 on the upper jam sensor board PTr1 turns on Q3 which causes IC1 pin 6 to have a higher voltage than pin 7 IC1 pin 1 then goes LOW IC2 pin 4 is then lower than pin 5 causing pin 2 of
134. Fusing Rail PTL Guide Plate Fusing Rail Bracket Base Plate Transport Unit Entrance Slider Transport Guide Plate Front Leaf Spring Transport Guide Plate Rear lider Knob Lever ann Ol C CO CO CO pe oe Leaf Spring Transport Entrance Drive Roller Fusing Entrance Cover Transport Duct Fusing Exit Frame Transport Fan Cover Lower Exit Guide Leaf Spring Micro Switch Upper Exit Guide Transport Lock Lever Fusing Exit Guide Plate Transport Lever Fusing Exit Sensor Feeler 126 M 5 ipti Page and arts No escription Index No Fusing Exit Sensor Bracket Fusing Unit Rail Release Lever Fusing Unit Connector Bracket Connector Shutter Plate Inverter Unit uide Plate Inverter Unit pper Guide Inverter Unit uide Plate Open and Shut uide Plate Holder G U Guide Holder Pressure G G Inverter Entrance Sensor Bracket Paper Entrance Feeler Guide Plate Exit Inverter Unit FT5540 5570 Exit Sensor Bracket Exit Sensor Feeler Exit Guide Plate Upper Exit Guide Plate Upper Paper Exit Feeler Bracket Paper Exit Feeler Jogger Unit Front Paper Stopper Guide Unit Rear Paper Stopper Guide Unit Duplex Transport Unit Fork Gate Unit Side Frame Inverter Unit Drive Gear Bracket Inverter Roller Inverter Pressure Arm Front Inverter Pressure Arm Rear Up
135. Head Screw M4x8 Philips Truss Head Screw M4x8 Philips Truss Head Screw M4x8 Tapping Screw M4x8 Tapping Screw M4x8 Tapping Screw M4x10 Hexagon Head Tapping Screw M3x6 Hexagon Head Tapping Screw M3x8 Toothed Washer M4 Retaining Ring M3 Retaining Ring M4 Retaining Ring M6 Retaining Ring M8 Ball Bearing 6x17x6mm Timing Belt 112MXL Timing Belt 1270P5M Philips Screw Flat Washer M3x6 Philips Screw With Flat Washer M3x8 Tapping Screw With Flat Washer M4x8 Tapping Screw With Flat Washer M4x8 Heat Sink Socket Mate N Lock Pin Mate N Lock Fastening Receptacle Fastening Receptacle Pin Mate N Lock Receptacle Terminal August 31 Page and Parts No EMEN NM c gt 1 89 Parts No Description page one Index No Contact Contact Connector 3F Connector 2P Connector 2P Receptacle Housing 1P Connector 2P Connector Connector nector nector nector nector nector nector nector nector nector nector Cable Clip Locking Support Locking Support Clamp Fuse 0 5A Microswitch Microswitch Solid State Relay 240V 3A Transistor 2SC372Y IC pPA2003C Diode 151588 Diode DSAIA1 Zener Diode D8 Diode 555006 Diode 015 Photothyristor TLP541G
136. Housing Receptacle Housing Connector Connector 3P Connector 12P Receptacle Housing Receptacle Housing Connector 4P Connector 12 13 6 AC HARNESS A421 6 AC HARNESS A421 August 31 89 T Q ty Per ndex M fat Q ty Per P P i art No Description Assembly No art No Description Assembly A421 5300 AC Harness 115V 1 01 1100 0277 Fastening Receptacle 2 A421 5310 AC Harness 220V 1 02 1100 1172 Fastening Receptacle 03 1100 1241 Socket Mate N Lock 04 1100 1247 inal 05 1102 0796 ecting Sleeve 3 0mm 220V 06 1102 1404 eptacle Housing 07 1102 1516 nector 08 1102 1815 nector 09 1102 1815 nector 0 1100 0885 Fastening Receptacle 1 1100 1172 Fastening Receptacle 2 1100 1239 Pin Mate N Lock 3 1100 1241 Socket Mate N Lock 4 1100 1247 inal 5 1100 1404 ptacle Sl 6 1102 1 ector 1102 1 ector 8 1102 1 ector 3P 9 1102 1 leeve 15 7 TRAY DC HARNESS A421 ere 108 103 104 2 S lioe N T 102 107 103 1110 1104 109 103 7 TRAY DC HARNESS A421 August 31 89 Index No Part No Description 2424444 Assembly Q ty Per Assembly Part No Description A421 5330 Tray DC Harness 1100 1192 Receptacle Housing 1100 1240 Socket Mate N Lock 1100 1249 Receptacle Terminal 1100 1327 Contact 1102 1404 Receptacle Housing
137. IC SN74LS373NS 1 TD62308F IC TD62304F IC UPD78C10GF een DO DR BH p Co c Co 3 Co Index To Q ty Per ndex Part No 5 pen Q ty Per escription Ro 15 136 1407 2187 SN74LSO7NS 1 137 1407 2218 IC SN74LS06NS 172 38 1407 2221 IC SN75157P 13 39 1407 2222 IC SN75158P 74 40 1407 2223 TPM82C51AF 2 75 41 1407 2228 151 TMP82C55AF 2 76 42 1407 2229 IC 555 77 43 1 2230 IC TD6F62303F 78 44 1 2231 IC TD62308AF 79 45 1 2232 IC 74HC157F 80 46 1 2823 MDP71051GB 3B4 81 47 1 3359 RF5C60 82 48 1 3360 IC MPD4711 83 49 1408 0456 AN6914S 84 50 1 0537 TL7705CPS 185 51 1 0561 TL092 86 52 1 0070 Ceramic Oscillator 10MHz 87 pi a bh bh E a Oy a an E an E n C oC CX rn o Ea 53 1 8138 Variable Resistor 0 75W 88 54 1 1375 Capacitor 0 22pF 50V 89 55 1 1378 Capacitor 50V 90 56 1 1381 Capacitor 4 7pF 50V 91 57 1 1382 Capacitor 10 50V 192 58 1 1383 Capacitor 22 50V 93 59 1 1385 Electrolytic CAP 47pF 20 50V 94 160 1 1386 Capaci 100MF 50V 95 61 1 0166
138. Instructions Spanish Reed Switch Operati Instructions English LT Front Cover FT5540 ain Control Board FT5540 ain Control Board FT5540 IC HN27512G25 FT5540 Lens Housing Harness Lens Housing Harness Lens Housing Harness DC Harness FT5570 DC Harness FT5570 DC Harness FT5570 DC Harness DC Harness FT5540 FT5540 Paper Feed Unit Harness DC Harness FT5540 Paper Feed Unit Harness Paper Feed Unit Harness Paper Feed Unit Harness Left Motor Harness Left Motor Harness Left Motor Harness DC Harness T5550 DC Harness T5550 114 Decal Oil Tank English Decal A2 Decal A2 Decal Regist Sensor Decal Regist Sensor Decal B3 Decal B3 Decal Handle Decal Handle Grip Decal Fusing Cover Grip Decal Fusing Cover Decal 8 1 2 x14 Decal 8 1 2 x14 Decal Decal Oe el Decal 8 1 2 x11R Decal 8 1 2 x11R Decal 8 1 2 x11 Decal 25 1 100 1 1 Decal A4R Decal A4R Decal 4 Decal 4 1 Manual Feed Decal Manual Feed Decal Manual Feed Decal Manual Feed Ozone Filter Ozone Filter 234x60x13 PTL Filter PTL Filter QL Filter Development Filter Page and In dex No 115 August 31 89 Page and NE Transport Fan Filter Inverter Unit Magnet Oil Tank Toner
139. Larg Cassette Cover Small Rear Side Fence Large Rear Side Fence Small Decal Paper Level Front Side Fence Large Front Side Fence Small Bottom Plate Large Bottom Plate Small Friction Pad B Rear Fence Cassette Body Large Cassette Body Small Decal B 1 2 x14 Decal LEX Decal 8 1 2 11 Decal 8 1 2 11 Part No August 31 89 Q ty Per Description Assembly 00 00 00 2007 2008 2009 2971 2979 2996 2997 2960 2962 2964 2847 1001 Decal Decal A4R Decal 4 Actuator 11 17 Actuator 11 8 1 2 Actuator 8 1 2 xllR Actuator 8 1 2 14 Actuator A3 Actuator A4R Actuator 45 Base Holder Original Holder ing Screw M4x10 Head Screw M4x8 ining Ring M4 ing Screw With Flat Washer M4x10 ing Screw With Flat Washer M4x12 7 PAPER FEED UNIT 1 A045 A046 August 31 89 i ul LEE 4 a EV E l FR 27 HELA 454 S gu CAM ES a 20 Index 7 PAPER FEED UNIT 1 045 046 Index Q ty Per Part No Stay Paper Feed Pick UP Shaft Paper Feed Shaft Upper Feed Guide Paper Feed Roller Paper Feed Roller Pick up Roller Paper Feed Roller Snap Ring End Shutter Upper Bushing Upper Bracket Paper End Photointerrupter L Type Photointer
140. No Transport Guide helt Page and Parts No Description Index No Rear Cover Lamp Terminal Exposure Lamp Terminal Fix Cushion Transport Guide lst Scanner Slider Paper Detect Feeler Transport Harness Bracket Exposure Lamp Transport Roller Sensor Shutter Rear Cover Optical Fiber Transport Roller Sensor Bracket Rear Bracket Optical Fiber Transport Upper Guide 2nd Scanner Guide Transport AID 2nd Scanner Slider Release Transport Guide Lever Scanner Guide Plate Cushion Transport Upper Guide Vacuum Fan Duct Front Platen Cover C amp D Rail Registration Registration Lower Guide Upper Feed Guide Upper Guide Upper Charge Corona Sheet Transport Middle Guide Side Charge Corona Sheet Transport Middle Guide Upper PTL Guide Separate Lower Guide DC Harness Bracket Separate Duplex Guide PTL Guide Cover Cushion Transport Middle PTL Guide Sheet Cushion Registration Upper Guide Density Sensor Bracket Pick up Guide Lower Density Sensor Connector Bracket Knob Transport Middle Guide Density Sensor Connector Bracket Lower Registration Guide Drum Stay Support Bracket Paper Bank Guide Duplex Side Plate Behind Drum Paper Bank AID 1 Duplex Paper Bank AID 2 Duplex Development Rear Holder Drum Stay Support Plate Separati uide Drum Stay Support Bracket Separati uide Drum Shaft Knob Bracket Fr
141. PTL After the latent image is developed but before the image is transferred to the copy paper the drum surface 15 illuminated by the pre transfer lamp A This illumination reduces the positive potential on the drum surface This 15 to prevent the toner particles transferred to the paper surface from being reattracted to the positively charged drum during the paper separation process It also makes image transfer and paper separation easier 2 46 31 August 1989 7 2 IMAGE TRANSFER The registration rollers A feed the copy paper through the transfer entrance guide to the transfer section A high positive voltage is applied to the transfer corona wire B and the corona wire generates positive ions These positive ions are applied to the reverse side of the paper and the paper is electrostatically attracted to the drum surface This is due to the relationship between the following three attractive forces A1 Paper and Toner The attraction between the positively charged paper C and the negatively charged toner A2 Paper and Drum Aluminum core The attraction between the positively charged paper and the negative countercharge on the aluminum core of the drum A3 Toner and Drum Selenium layer The attraction between the positively charged drum and the negatively charged toner 2 47 31 August 1989 Since the positive force applied to the reverse side of the paper by the transfer corona is much greater than the streng
142. Parts wos Description BAR _____ Friction Pad B 1 Terminal 115V lt gt 99 Trans Cover Decal Terminal 115V Lift Stay Power Supply Cord 220V Front Paper Guide Decal Power Source 220V Rear Paper Guide Decal Power Source 220V Gear 28T Idler Pulley 20 Gear 22T Tray Drive Motor AC7 8W 115V Decal Paper Size Decal Paper Size Paper Size Dial Front Cover Rear Cover Decal English French 115V Decal Increase Size Decal English French 115V 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 Decal Increase 517 Decal Decrease Size Decal Decrease Siz Operation Panel Key Top Cover Side Cover Front Guide Post Rear Guide Post Spring Plate Side Post Front Inner Cover Rear Inner Cover Spring Plate Rear Side Post Spring Plate Front Side Post Operation Board Tray Control Board Tray Control Board Bushing 8mm Bushing 10mm Magnet Catch Ass y Magnet Catch Ass y Magnet Catch Ass y LED Sensor Type S Photointerruptor Pack Photointerruptor Pack Oo gt co 1 English 1 En
143. SP31 4 25 Vsg _ ass ass oo Toner added as selected by SP32 1 8 Veg e gt gt Time SP 31 0 1 2 3 Toner Supply 30 15 45 60 Amount Note Vsg 4 0 volts 1 4 Vsg 1 0 volts 4 25 Vsg 0 64 volts 1 8 0 50 volts 3 8 Vsg 1 5 volts Fixed Supply Mode In the fixed supply mode SP 30 set to 1 a fixed amount of toner is added every copy as determined by the setting of SP 32 There is no overtoning detection mechanism SP 32 0 1 2 3 Toner Supply 7 4 119 1496 Amount 2 43 31 August 1989 6 6 TONER END DETECTION Sufficient Toner Condition L The toner detection mechanism actuates the toner end sensor A when the toner tank is almost empty 60 to 100 grams remaining In the first figure there is enough toner in the toner tank The toner resists the movement of the toner agitator B and the drive spring C stretches As a result the flat surface of the toner agitator cam D does not align with the flat section of the agitator gear E and the actuator is held in the toner end sensor slit The second figure shows what happens if there is not enough toner in the tank In this case the toner does not resist the movement of the agitator therefore the agitator gear spring forces the flat surface of the agitator drive cam to align with the flat surface of the toner agitator gear When the flat section comes to the actuator a spring pulls the actuator o
144. SYMBOL INDEX SYMBOL INDEX SYMBOL pn SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX M NM NO NU NM C100 BW C110 121 R100 123 R110 122 R120 122 131 122 C101 120 121 R101 124 111 123 RI21 127 032 127 C102 119 C113 120 R102 123 R112 123 R122 128 R133 122 C103 118 ci 120 R03 130 R13 123 123 124 R134 126 AB UM 0104 110 6110 149 KIUA 164 114 169 124 161 199 161 c5 190 11 mo rusl 122 R25 130 coe ug cur 123 124 R26 14 R38 14 cmo 120 cus 129 19 129 120 cug 118 08 123 125 R128 127 109 120 09 122 123 R130 123 s 3 TRAY MAIN BOARD A421 August 31 89 Index Q ty Per ND Q ty Per NUT Pa No Part Description Assembly rt No Description Assembly A421 5200 Tray Main Board 1103 1247 ector 3 1103 1729 ector 7 1103 1730 ector 8E 3 1 1 XI A N 1103 1739 ector 1103 1743 ector 1103 1757 ector 1047 lid State Relay 240V 3A 1400 0072 Transistor 25 372 1400 0135 Transistor 2SA1015 Y 1401 0825 Diode 155176 1407 0520 741 500 1407 0622
145. Shaft Rear Cover A008 1 Rear Lamp Terminal Ass y Left Cover A008 1 Front Lever Fusing Exit A008 Rear Lever Fusing Exit A008 1 otor DC 5V 1 3W A008 1 otor DC 5V 1 3W Upper Front Cap Decal Drum Shaft Knob Decal Drum Shaft Knob A008 Key Top Program A008 Key Top Clear Mode Decal Sheet German Decal Sheet French A008 Key Top Recall A008 Key Top 0 A008 Key Top A008 Key Top A008 Key Top A008 Key Top Decal Sheet Italian Decal Sheet Spanish PCC PQC Corona Wire 10pcs set PCC PQC Corona Wire 10pcs set Tramsfer Corona Wire 10pcs set Separation Corona Wire 10pcs set Hot Roller Stripper 6pcs set A008 Key Top A008 Key Top A008 Key Top A008 Key Top A008 Key Top Cleaning Unit Seal DG Gauge 0 76 2pcs set Cleaning Brush Set DG Gauge 0 71 0 86 1 CO 130 E isti Page and arts No escription Index No A008 A008 A008 A008 A008 A008 A008 A008 A008 A008 A008 A008 A008 A008 A008 A008 A009 A01 A01 A01 A01 A01 5640 5641 5642 5643 5644 5645 5646 5647 5648 5650 5651 5653 5658 9001 9501 9502 3689 3580 1281 165 166 167 710 103 0027 0223 0223 0223 Key Top C S Key Top ADS Key Top Lighter Key Top Darker Key Top Select Cassette Key Top Full Size Key Top Enlarge Key Top Reduce Key Top Auto Cassette Selection Key Top
146. Solenoid Lever 5206 Wire Clamp Plate A007 Jogger Fence Roller Duplex Stopper Solenoid Adjusting Plat Duplex Solenoid N AA16 1 Cushion Duplex Frame Bottom Frame Duplex Feed 5206 Spring Wire Duplex Stopper Solenoid Harness Pin By Pass Feed Table 007 1 Jogger Stay 5209 Puny Spring Duplex Stopper Cam A 05 1 Jogger Fence Drive Wir Paper Stopper Pulley 007 Home Sensor Harness Wire Clamp a A007 Jogger Motor Bracket Wire Duplex Stopper Solenoid 5350 Spring Pressure Arm 5919 Stepper Motor DC 4 8W A007 Jogger Motor Pulley Snap Ring Front Fram Duplex Feed Shoulder Screw Hing Index E ty Per Part No ipti y me 2010 E Co c 5205 LED Sensor Type T Co nan A007 Home Sensor Bracket 5053 Bushing M6 Co un Part 00501 Head Screw M3x5 0060W Pan Head Screw 4 00807 J Philips Pan Head Screw M4x8 01001 Philips Pan Head Screw 4 10 0060W Philips Sunken Head Screw M3x6 0060W Tapping Screw M4x6 0080W Tapping Screw M4x8 0040 Hexagon Headless Set Screw M4x4 0060 Headless Set Screw M4x6 0120 Spring Pin 3 12 00302 Retaining Ring 00502 Retaining Ring
147. T 5251 5251 5251 5251 5251 5251 5251 5251 5253 Photointerrupter Pack Page and P No D arts No escription Index No Bushing Paper Feed Roller Bushing Paper Feed Roller Sensor Type T Magnetic Clutch Collar Sensor Type T Cushion Sector Gear Bottom Plate Large Sensor Type T Sensor Type Front Side Fence Large Sensor Type Rear Side Fence Large Sensor Type Hf EL EH LH LJ gt C CU gt Rear Fence Actuator A3 Sensor Type Actuator A4R 5253 Photointerrupter Pack 5321 Pick up Solenoid 5405 Transformer 115V 6491 Rear Side Fence Small 6493 Front Side Fence Small 6570 Bottom Plate Small 9101 Gap Gauge Actuator 45 Actuator 11 17 Actuator 11 x8 1 2 Actuator 8 1 2 xllR Actuator 8 1 2 14 Bushing 6mm Gear 20T Upper Shaft 9111 Omega Clamp 9510 Drum Lower Shaft 9601 Switching Board Plate Spring Toner Supply Bracket 2557 Friction Pad Duplex Guide Plate Positioning Lug Toner Supply 2603 Separation Driven Shaft Seal Bottle Release Lever 2605 Separation Roller 2607 Spring Separation 2609 Gear 22T Cleaning Blade Cam Pick off Pawl Shaft 2626 Sensor Bracket Duplex Paper 2650 Bushing 8x12x7mm 2651 Ball Bearing 8x20x13mm 2677 Bushing 6x10x7mm Spring Set Screw 2680 Entrance Actuator Roller 2681 Axle Plate 26
148. Table A3 A4 Spring Inverter Guide Plate Decal DIP Switch DF Main Board DF Main Board IC MBM2764 30 Display Board Fiber Connector Interface Harness Fiber Optics Harness DF Main Harness Main Harness Grounding Wire Installation Procedure English Parts N D tion page aud arts Os escrip Index No A418 8615 A418 9001 Installation Procedure 5 Language Turn Roller Ring 8pcs set August 31 89 t Page and Parts No escription Front Frame Exit Roller Bracket Clamp Discharge Brush Turn Roller Shaft Pulley 50T Idle Roller Arm Guide Plat Inverter Spring Anchor Inverter Gate Spring Inverter Guide Plate Bracket Inverter Gate Solenoid ing Lever Revers lley 21T llar Inverter Solenoid Belt 83mm LT Exit Drive Shaft Spacer 1l0x16x1 6mm Rear Side Plate Exit Drive Gear 46T Exit Motor DC 9W Inverter Solenoid Fiber Connector Knob Cap Original Feed Belt Rack Front Original Guide Rack Rear Original Guide Right Frame Shoulder Screw Scal IC HCTL 3 Bushing 8mm Bushing 6mm Bushing 6mm Nut Plate Micro Switch Feed Clutch Spring Photointerrupter L Typ Spring Anchor Spring Detent Arm Knob Screw Step Screw Stepped Screw M4 Stepped Screw M4 Gear 28T Spacer 6x22x0 5mm Wave Washer Screw Duplex Guide Plate Screw Duplex Guide Pl
149. The wider the trigger pulse C1 the more c 40 wu Zero Cross V7 Low Temp lal of 77 Trigger High Temp Low Active 62 Fusing Lamp SY Power ac power the lamp receives D1 therefore the temperature increases As the temperature rises the LOW trigger pulse becomes narrower C2 and less power is applied to the lamp D2 therefore the heating effect decreases 2 86 31 August 1989 Fusing Warm up Cycle Fusing Temperature Below 100 C Start Key Red Start Key Green 7 Fusing idle time Tima hu 1 Time determined by SP81 Fusing Temperature Normal fusing unit operating temperature is 185 C however if the temperature at power up is below 100 C the CPU goes into the idle mode When the temperature reaches 175 C the idling cycle begins SP mode 61 selects the idling time During idling the control temperature is 200 C When the idling time is finished the control temperature is reduced to 185 C The Start key stays red during idling Service Program SP 61 selects the total warm up time as follows SP 61 Idle Time 0 5 minutes 10 minutes 2 15 minutes Fusing Temperature Above 100 C 200 185 3 Beeps 175 C Fusing Temperature Time _ the fusing temperature is above 100 C at power up then fusing idle is not needed and the fusing lamp stays on u
150. Transport Middle Guide Upper 2579 Spring Guide 2619 Transport Middle Guide 2626 Cushion Transport Middle 2632 Knob Transport Middle Guide Co Co alt fe e T Q ty Per Index uer Q ty Per Part No Part No r Description No Description Assembly 0313 00601 Phili Pan Head Screw M3x6 0314 00801 Phili Pan Head Screw M4x8 0314 01009 111 Pan Head Screw M4x10 0434 0080 Screw 4 8 0574 00505 Headless Set Screw 4 5 0720 0040 Retaining Ring M4 0720 00502 Retaining Ring M5 0720 00602 Retaining Ring M6 19 CLEANING UNIT 1 A045 A046 August 31 89 44 19 CLEANING UNIT 1 045 046 August 31 89 Q ty Per i Q ty Per Part No Part No Description Description Assembly p Assembly 000 2003 Cleaning Unit 2681 Snap Ring A007 9501 Cleaning Brush Set 1 1010 Gear 16T 012 3580 Bias Roller Blade 3707 Bushing 6x10x6mm A007 3583 Seal Upper Casing 3602 Cleaning Brush Holder A007 3582 Upper Casing Cleaning Unit 15 2006 Side Seal Cleaning Front A007 3584 Cleaning Blade Cleaner 1 14 3030 Front Position Pin AA15 1080 Seal 12x10x318 2016 Front End Block 06 3023 Cleaning Blade Spring 1 2017 Front Cover PCC End Block 5446 3619 Toner Receiving Pipe 1 9002 PCC PQC Colona Wire 10pcs set A007 3614 Spring Brush Bias Roller
151. Washer 4 8 5205 5321 Pi Solenoid 3008W Tapping Screw With Flat Washer M3x8 AA06 0082 Pi Lever Spring 1 1 11 0224 Relay Bracket 007 2738 Solenoid Upper Bracket 1 11 0005 Nylon Clip 3N A007 2748 Solenoid Lower Bracket 11 0196 007 2733 Feed Control Board Bracket 1 11 0197 A007 5190 Paper Feed Control Board 11 0363 Circuit Breaker 115V A007 2741 Support Bracket 2 Feed Control 1 11 0550 Circuit Breaker 10A A045 5216 Lens Housing Harness 1 1 1029 Power Relay A007 1129 Left ADF Bracket A045 5451 AC Harness CO C Be Co 06 0112 Pick up Lever Spring Upper 28 MAIN CONTROL BOARD A045 A046 August 31 89 CONNECTOR CAPACITOR iNDEX 1 inoex SYMBOL ba sten mer inex INDEX ono 106 1 eur 156 eom 162 ee 162 es 1 ce eu n2 6 coz mr cuz 63 az ee 1 18 c9 12 15 157 157 160 162 161 183 163 110 13 163 154 157 139 95 16 as 163 14 1 cus
152. Wire Cleaner Pad End Blocks and Casing Cleaner Drive Wire PTL Filter QL Filter ID Sensor Erase Lamp Unit M OO O TI C 80k 80k a3 80k 160k r r zo m C 160k 4 1 240 240 Dd Dd ID 240k 320k C L C 320k d D I 320k 55 31 August 1989 NOTE Alcohol Water Glass Cleaner Alcohol Water Replace if necessary Launa Oil Replace if necessary Blower Brush Only NOTE Damp Cloth Damp Cloth Damp Cloth Mobil Temp 78 Damp Cloth Mobil Temp 78 Damp Cloth Blower Brush Damp Cloth Damp Cloth NOTE Replace if necessary Alcohol Water Replace if necessary Dry Cloth Discharge Dry cloth Discharge Blower Brush Dry Cloth 31 August 1989 D CLEANING UNIT EM Cleaning Blade Cleaning Seals Cleaning Brush Bias Roller Bias Roller Blade Pick off Pawls DEVELOPMENT UNIT EM Developer Upper Brush Seal Development Unit Drive Gears Development Filter F FUSING UNIT EM Hot Roller Pressure Roller Stripper Pawls Oil Supply Pad Oil Blade Fusing Entrance amp Exit Guide Oil Sump Oil Tank A Gears G OTHERS EM Transport Ozone Filt
153. a sheet of paper under the development unit when it is out of the copier This prevents any small pieces of metal staples clips E rings etc from being attracted to the development roller and getting inside the unit 4 20 31 August 1989 5 6 Transfer and Separation Corona 1 Do not loosen the paint locked screws holding the entrance mylar guide of the transfer and separation corona unit 5 7 Cleaning Unit 1 2 3 4 Do not damage the cleaning blade edge Clean the blade with a soft clean cloth Do not touch the cleaning brush with oily hands Before pulling out the cleaning unit place a sheet of paper under it to catch toner falling from the entrance mylar seal Before adjusting the cleaning blade pressure check all other possible causes 5 8 Pre transfer and Quenching Unit Clean the lamp filters with a clean damp cloth 5 9 Fusing When removing the fusing unit keep it upright so that the silicone oil does not spill out After replacing the oil blade oil supply pad and hot roller prime the top of the oil blade with silicone oil Be careful not to damage the edge of the hot roller strippers or their tension springs Be careful not to bend the pressure roller strippers Do not touch the fusing lamp with bare hands Make sure that the fusing lamp does not come into contact with the inner surface of the hot roller Make sure that the oil end sensor is touching t
154. arness FT5540 Power Supply Cord Bracket August 31 89 Index Q ty Per Part No EUBZLN Assembly CO OR FF o Philips Pan Head Screw 3 10 Philips Pan Head Screw M4x6 Tapping Screw M4x6 Tapping Screw M4x8 Toothed Washer M8 Hexagon Nut M8 Philips Truss Head Screw M4x8 Tapping Screw With Flat Washer 4 8 Nylon Clip 3N Harness Clamp Noise Filter 115V Noise Filter 220 240V Capacitor 220V Capacitor 14 220V Cord Clamp Lisr 40 Cord Clamp 115V Fuse Resistor 1000HM 1 2W Nylon Stud Fuse 3 15A 125V Fuse 5A 125V 27 ELECTRICAL SECTION 3 A045 A046 August 31 89 60 27 ELECTRICAL SECTION 3 A045 A046 August 31 89 Index Q ty Per n Q ty Per Part No Description E Part No Description Assembly Assembly 007 1125 Right ADF Bracket 00501 Pan Head Screw M3x5 A007 5878 AC Harness Angle 0060W ili Pan Head Screw M4x6 A045 5251 Left Motor Harness 1 0100W ilips Pan Head Screw M4x10 A007 5852 Noise Filter Bracket 00600 Screw M4x6 A007 2740 upport Bracket 1 Feed Control 0080W Screw M4x8 A007 2749 Pick up Arm Manual Feed 1 0100 Screw 4 10 5205 5251 E ensor Type T 0050 ining Ring M5 AX11 0011 Pi Solenoid Manual Feed 1185 111 5 Truss Head Screw M4x8 A007 2742 Place 4008W Tapping Screw With Flat
155. cassette feed are not interchangeable 5 44 31 August 1989 6 6 Positioning and Entrance Actuator Rollers Replacement 1 Open the front cover 2 Remove the toner catch pan and the duplex paper actuator A 1 snap ring Positioning Roller 3 Remove the positioning roller B together with the drive belt C 1 snap ring NOTE When installing the new positioning roller make sure that the drive belt fits snugly in the grooves of the pulleys Entrance Actuator Roller 4 Remove the entrance actuator roller D together with its axle plate E 2 shoulder screws 5 Separate the actuator roller from the axle plate 1 E ring 5 45 31 August 1989 6 7 Duplex Pick up Solenoid Adjustment NN 1 Remove the jogger unit Refer to Jogger Unit Removal 2 Loosen the two screws to shift the duplex pick up solenoid bracket A fully to the left rear view 3 Insert a 1 5 mm thickness gauge B between the plunger and the solenoid Then push the plunger to the right 4 While rotating the duplex pick up roller C shift the duplex pick up solenoid bracket to the right until the roller can not be rotated Then secure the duplex pick up solenoid bracket 5 46 31 August 1989 6 8 Jogger Wire Replacement 1 Remove the jogger unit Refer to Jogger Unit Removal 2 Slide both the front and rear jogger fences A to align the screws B and holes C Then remove t
156. cover E 2 screws Then remove the power supply unit F Be careful not to damage any connectors 5 73 SECTION 6 ELECTRICAL DATA Contents ELECTRICAL DATA 1 Main PCB Schematic 1 6 1 Main PCB Schematic 2 6 3 2 Optics PCB Schematic _ 6 4 3 Paper Feed PCB Schematic 6 4 4 Timer PCB Schematic 6 4 UMNA GHAN a E E 6 5 6 20 Bin Sorter PCB Schematic 6 5 i ARDF PCB Schematic eee ead 6 6 8 Large Capacity Tray PCB Schematic 1 000 Sheets 6 7 9 Large Capacity Tray PCB Schematic 2 500 Sheets 6 8 10 15 Bin Sorter PCB Schematic 6 9 11 15 Bin Sorter Timing Chart A4 Letter Mode 6 10 12 Menu Reader PCB Schematic 6 11 13 Menu Reader PCB Schematic lower 6 12 1 Main PCB Schematic 1 Lig a PI I ISH aa CLK IC 150 zo MES 9 J CS 36 Lo C D 3 T PIleoH RS RESE NS C237 UU ZING PI em Mm PI 85 2 23 aa 3
157. ehe dete a er es 2 85 12 8 SERVICE CALL CONDITIONS Ru Rb tet Be d cec aeo e 2 88 13 PAPER EXIT 2 90 Is WOVER VIEW at ER rhe rae 2 90 13 2 EXIT ROLLER DRIVE MECHANISM mu ddd brutis mes 2 91 14 DUPE EX ib oo onc onde Scu 2 92 14A INVERSION um ees oboe ee eee ee ee wee 14 2 DUPLEX TRANSPOR T 30 3e PUR Rea ht ee en ee OS 2 96 14 3 DUPLEX STACKING canan es Bote 2 99 14 4 DUPLEX TRAY SENSORBS RE D ERR ACERO SS 2 103 14 5 DUPLEX PAPER FEED css 2 104 14 6 RELATED SERVICE CALL 5 2 107 15 OTHER CIRCUITS 2 108 15 1 DC POWER DISTRIBUTION tat ahd oad et ER eee 2 108 15 2 SAFETY SWITCH CIRCUITS 2 22 t ite qoo eau hoe Sota In Ban 2 109 15 3 COMPONENT GONTHBQONL irt ne REIN chase oa 2 110 15 4 CORONA CLEANER 5 2 111 15 5 PULSE GENERATOR 2 eno S s 2 112 15 6 MAGNETIC CLUTCH AND SOLENOID CONTROL 2 113 15 7 SENSOR OPERATION A 3222 bo TR tee Se one 2 114 15 9 COUNTER CIRGUITS wos
158. ete dades TER HORAE IS 2 117 31 August 1989 1 DRUM 1 1 SELENIUM DRUM CHARACTERISTICS Selenium has the following characteristics Accepts high positive electrical charge in the dark The electrical resistance of selenium is high in the absence of light e Dissipates the electrical charge when exposed to light Exposure to light greatly enhances the conductivity of selenium e Dissipates the electrical charge in direct proportion to the intensity of the light That is where stronger light is directed to the selenium surface a smaller voltage remains on the selenium The sensitivity of selenium changes slightly with variations in the surface temperature of the drum Under cool conditions the drum conductivity decreases This will result in background or excessive image density As a countermeasure the development bias is changed to compensate for temperature variations around the drum Also while the copier is off the drum heater warms the drum Drum sensitivity also depends on how long the drum has rested between copy runs The copiers CPU compensates for changes in drum sensitivity due to rest time by changing the development bias This prevents variations in image density at the beginning of copy runs The selenium drum used in this model has high sensitivity good color reproduction and good reproduction of low contrast originals pencil originals etc 1 2 HANDLING THE DRUM e Never touch the d
159. exit sensor is performed 1 250 ms after the exit sensor 15 activated 8 14 31 August 1989 During two sided original mode three sensors detect misfeeds The ON checks for the original entrance sensor and the registration sensor are the same as when in single sided mode The DF CPU checks if the original entrance sensor has been deactivated 1 250 milliseconds after the registration sensor is activated original sensor OFF check The DF CPU checks if the registration sensor has been deactivated 175 milliseconds after the original entrance sensor is deactivated When the original is inverted for the first time the ON check for the exit sensor is 1 250 milliseconds after the inverter gate solenoid turns on The OFF check for the exit sensor is 1 250 milliseconds after the belt drive motor reverses When the original is fed out the OFF check and ON check for the exit sensor are the same as in the single sided mode When a misfeed is detected the DF CPU stops the DF and sends a misfeed signal to the copier The misfeed condition is cancelled by deactuating the lift switch ON CHECK OFF CHECK Original Entrance Sensor 5 OHEAK cw waar errr OFF Registration Sensor 12 7 AIRS 250ms A OF ECK 475ms Inverter Gate Solenoid Feed in Motor _ Belt Drive Motor Omad reverse Feed out Motor NENNEN 0 15 31 August 1989 13 INSTALLATION 13 1 Accessory Check Check the quantity and condit
160. fusing uni noi 10 tear tne pape 0 very so be careful when assembly touching it no paper was found at step 2 take out tne paper cassette and remove any paper that remains in 21 remains in eU Ine 1220 entrance A Li Turn iever clockwise anc return the transport unit to the original position Alte removing tne misled paper return tne fusing exit assembly bark in its na position to 15 Shae tne lusing back into the copier Note misleed location indicator stays on after the front cover is clo Pull any misted paper out of the Ul uic paper exit OECD Press the lever to the lett and lower the fork gate unit Slaps wre enm cover Do not touch the selenium drum when Clearing misteeds ae P M aa lt in evil aueh iha tab While holding the guide plate puil i in CKN ine Guide pi up in the direction of the Out the misled paper numm aes P Remove any misled paper caught in To close the lork gate unit push up the fork gale unit lever 0 sed a misleed may st
161. harness A from the clamp B inserted in the rear side of the optics control PCB bracket C Then remove the optics control PCB with the bracket 8 connectors 3 screws 6 Loosen the first scanner wire clamp D 2 screws and remove the old wire Then slide the second scanner E all the way to the left rear view 9 0 31 August 1989 7 Hook one end of the wire A on the anchor B using the ring C 8 Route the scanner wire in the following order 1 Outer track counterclockwise 2 Below securing screws 3 Lower track counterclockwise 4 Lower track clockwise 5 From lower to upper 5 5 times counterclockwise 6 Lower track counterclockwise 7 Inner track counterclockwise 8 Inner track clockwise 9 Hook the wire to the anchor with the spring D and the ring E 5 6 31 August 1989 9 Thread the wire between the two pulleys A 10 Position the first and second scanners according to the adjustment table and secure the first scanner wire clamp rough adjustment of the horizontal magnification 11 Adjust the horizontal magnification using SP 44 Refer to Horizontal Magnification Adjust ment 12 Adjust the focus with SP 47 Refer to Focus Adjustment 13 Reassemble 5 7 31 August 1989 1 4 Fourth and fifth Mirror Drive Wire Replacement 0 1 Remove the exposure glass Refer to Exposure Glass Removal Then remove the top cover 9 screws the lens
162. housing cover 4 screws and the exposure harness guide plate A 2 screws 2 Remove the tension spring B and the old wire C 3 Route the wire in the following order 1 Hook one end of the wire D into the anchor point E on the fourth and fifth mirror assembly near the tension pulley 2 Wrap the wire clockwise around the tension pulley 3 From lower to upper wrap the wire 2 5 times clockwise around the drive pulley 4 Hook the other end of the wire F onto the fourth and fifth mirror assembly G 5 Hook up the tension spring and reassemble 5 8 31 August 1989 1 5 Lens Drive Wire Replacement 9 ___ Z gt IA 7 5 1 Remove the exposure glass Refer to Exposure Glass Removal Then remove the lens housing cover 4 screws 2 Remove the tension spring A and the old wire B 3 Route the wire in the following order 1 Hook one end of the wire C onto the front of the lens housing D 2 From lower to upper wrap the drive wire 2 5 times clockwise around the drive pulley 3 Wrap it clockwise around the tension pulley 4 Hook the other end of the wire E onto lens housing F 5 Hook up the tension spring and reassemble 5 9 31 August 1989 1 6 Scanner Harness Replacement Optics Cables amp Exposure Lamp 1 Remove the rear and left covers 2 screws each Then remove the exposure glass Refer to Exposure Glas
163. is displayed When SW 101 15 pressed 12 is displayed 6 Adjust the motor speed to 2 600 30 rom by turning VR 103 on the DF main board 7 Turn off the main switch return DIP SW 101 to the normal position and reassemble All switches are off 8 26 31 August 1989 14 2 Inverter Turn Gate Solenoid Adjustment Adjustment Standard 1 5 0 5 mm A E LTE x T m SR FI 1 Remove the DF upper cover 4 screws 2 Manually energize the inverter solenoid A 3 Loosen the screw B and adjust the position of the inverter solenoid to bring the gap D between the turn gate E and the guide plate F within the adjustment standard 4 Tighten the screw and install the DF upper cover 0 27 SECTION 9 20 BIN SORTER Contents 20 BIN SORTER T SPECIFICATIONS wits ih Ere eee A RES 9 1 2 BASIC OPERATION 45r ire eed EXC whe ees 9 2 2 9 2 2 2 St MOD stud Cad 9 2 MOG ur vea d e UR ED ARENA VR EY 9 2 2 4 Example of Sort Mode 9 3 3 BIN DRIVE MECHANISM 9 6 4 BIN HOME POSITION ii sania eee ewe 9 7 5 BINS veau awe EM IE cad ee a ae uae cea que 9 8 ELECTRICAL CONTROL eee ege e ir 9 9 Z INSTFAEEATION dive esate ase 9 10
164. lamp and fusing lamp The SSR board controls the developer motor and the paper feed motor AC hot is supplied from RA1 and contacts through each ac component AC neutral is applied to both the ac drive PCB and the SSR board In addition 24 volts Va is supplied to each terminal of the SSRs while the terminal returns to the main board To energize a component the main board supplies a LOW signal to the appropriate board which causes the SSR to turn on completing the ac circuit to the component To de energize the component the main board removes the LOW signal from the board turning it OFF 2 110 31 August 1989 15 4 CORONA CLEANER MOTORS Main PCB Svs 71 CN101 A1 REV Driver cc Charge Corona A5 101 1 FWD M Cleaner Motor s U 45 CN101 82 REV 2 4 sc N SC Corona Driver ay enorm FWD M Cleaner Notor lt lt lt ee BV Ve Puce T _______ Cleaner I 1 Small dc motors in the corona endblocks drive the corona cleaners When a cleaner motor is energized the CPU supplies forward drive for a period of 20 seconds after which time it reverses the polarity of the motor drive voltage to return the cleaner to the home position Home position front endblock is determined when the H P sensor turns off However if home
165. main drive chain A turns the duplex feed rollers The power is transferred through the drive sprocket gear positioning roller gear B and idle gear C to the gears driving the duplex feed roller 0 duplex separation roller E and pick up roller To feed paper from the duplex tray the CPU energizes the duplex feed clutch G providing drive to the duplex feed rollers This is similar to the mechanism used in the cassette paper feed except that the rollers are not interchangeable The one way clutches used in the duplex feed drive are oriented in the opposite direction Also the roller surfaces are serrated in a set direction so that paper is fed precisely 2 105 31 August 1989 Duplex Stopper and Pick up Roller Mechanism D B 65 The pick up roller bracket is lifted up by the rearmost duplex stopper A Both the duplex stopper and the pick up roller B are moved by solenoids When paper is being fed the duplex stopper solenoid C is energized and the stoppers are lowered The pick up roller bracket rotates downward and the pick up roller drops onto the copy paper The duplex pick up solenoid D is energized 160 milliseconds after the duplex feed clutch turns on Paper feed then begins The pick up roller stays in contact with the paper during paper feed 2 106 31 August 1989 14 6 RELATED SERVICE CALL CONDITIONS Code 81 Jogger Home Position Not Off Definition Lights if the jogger home s
166. mode PM by using VR 102 D on the DF main PCB PM DF Turn VR 102 clockwise PM DF Turn VR 102 counterclockwise k Co ntinue to repeat steps 4 and 4 until you achieve the same registration as in step py 8 23 31 August 1989 i Lm mu LJ v 16 Turn off the copier main switch and all the switches of the DIP SW 101 A on the DF main PCB 17 Reinstall all covers NOTE When reinstalling the DF cover make that the belt holders B do not ride on the ribs C of the DF cover 18 Turn on the copier main switch and check the operation of the DF and the copier system 19 Fill out the New Equipment Condition Report 0 24 31 August 1989 14 REPLACEMENT AND ADJUSTMENT 14 1 DF Belt Drive Motor Speed Adjustment 5102 5101 isi y B VRIO2 NOTE This adjustment should be done whenever the DF main board is replaced ADJUSTMENT STANDARD 2 600 30 rom 1 Turn off the main switch 2 Remove the DF cover 4 screws 2 collars 3 Lower the DF unit 4 Turn on DIP SW 101 1 2 and 4 A 5 Turn on the main switch The belt drive motor will start turning and the left two digits of the motor speed will be displayed in the original counter Press SW 101 B on the DF main board to display the second two digits of the motor speed 8 25 31 August 1989 Example Motor speed 2 612 rom When SW 101 15 not pressed 26
167. on The pick off lever B rotates counterclockwise rear view and pushes the pawl shaft pin C The pawl shaft D then rotates clockwise and the pick off pawls E touch the drum The pawl springs F hold the pick off pawls on the shaft and prevent them from touching the drum too strongly When the leading edge of the paper passes the pick off area and just before it reaches the fusing unit the pick off solenoid turns off The pick off shaft spring G then rotates the pick off lever and moves the pick off pawls away from the drum Side to Side Movement The pick off pawls do not always contact the drum in the same place but instead move slightly to the side on each copy cycle The pick off pawl shaft H the cam rider I are joined by a one way bearing J Each time the pick off pawl solenoid turns on the one way bearing causes the cam rider to turn together with the pick off pawl shaft As the cam rider turns it and the pawl shaft are forced to move laterally by a cam K When the pawl shaft rotates the pawls away from the drum however the cam rider does not turn Pawl lateral movement is 0 1 to 0 2 millimeter per copy cycle After moving about 8 millimeters the cam rider passes the lobe of the cam and the pawl shaft is returned to its start position by the pawl shaft spring G 2 52 31 August 1989 7 6 PICK OFF TIMING Registration Start Signal Y Resistration Clutch uunc
168. power pack Wait 30 seconds for the current to stabilize Remove the drum shoe and reassemble Check copy quality 9 71 31 August 1989 8 11 Pre Quenching Corona Current Adjustment Optimum Adjusting Value DC 17 0 2 0 LA 1 Disconnect the connector of the cleaning bias roller at the power pack as the on timing of the cleaning bias roller and the pre quenching corona are the same 2 Reinstall the PQC unit and position the drum shoe so that the axis of the current sensing plate A is aligned with the wire 3 Select the dc 200 uA range on the digital rnultimeter 4 To turn on the PQC turn on the switching PCB dip switch corresponding to PQC on the TC SC power pack PCB The silk screen printed on the TC SC power pack PCB is cor rect 5 Adjust the corona current by turning VR C on the PQC CB power pack Wait 30 seconds for the current to stabilize 6 Remove the drum shoe and reassemble 7 Check copy quality 5 72 31 August 1989 9 OTHERS 9 1 Power Supply Unit Removal 1 Turn off the main switch 2 Open the front cover and remove the left inner cover 4 screws Then disconnect the 2P white connector A from the power supply unit 3 Remove the rear cover 2 screws and the main board B 2 screws leave connectors in serted Then remove the 16P white connector C from the power supply unit 4 Pull out the transport handle D and remove the exit roller
169. pressed In the clear mode all copies are stacked on the proof tray Sorter operation starts when a sheet of copy paper actuates the copier exit sensor Simultaneously the roller drive motor and relay drive motor energize The motors de energize when the paper exits the copier and the paper sensor is deactuated The paper sensor signal goes through the interface board to the copier The wheel drive motor does not turn on when in the clear mode 2 2 SORT MODE After the sort mode is selected by pressing the Sorter key the wheel drive motor turns on to move the proof tray up When the first sheet of paper activates the paper exit sensor the roller drive motor turns on Shortly after the paper sensor turns off the wheel drive motor turns and advances the bins one step When the wheel sensor activates the wheel drive motor turns off 2 3 STACK MODE As in the sort mode the roller drive motor turns on when the first sheet of paper actuates the copier exit sensor All copies of the copy run are then fed to the first bin When the final copy passes the paper sensor the wheel drive motor turns on and advances the bins one step There are no limitations on the number of copies that can be entered up to the full 999 copy limit of the copier However the physical capacity of the bins is a good deal less See Bin Capacity in the specifications When all the bins have been used the wheel drive motor turns on and lowers all the bins includin
170. she eaten ate rq dus ee ees 14 16 e E 14 17 S INSTALLATION S s tein ve 14 19 9 ACCESSO Mage ee suing eae 14 19 8 2 Installation Procede 58 4 ford vt sera et lee RH RUE nee 14 20 9 SERVICE TABLES hehe Arce de cao 14 25 10 REPLACEMENT AND ADJUSTMENT 14 27 19 Soner Removals deser ULL USA XS AI aaa 14 27 10 2 Inlet sensor 14 28 10 3 Jam Sensor 14 29 10 4 Sponge Roller 14 30 10 5 DC Motor 14 32 1 SPECIFICATIONS Paper Size for Bins Copy Paper Weight Number of Bins Bin Capacity Top Bin Capacity Clear Mode Interrupt Bin Capacity Power Source Power Consumption Dimensions W x D x H Weight 31 August 1989 11 x 17 or Min 8 x 52 or 5 53 g to 90 14 Ibs to 24 Ibs 15 bins and 1 interrupt bin Sort 50 sheets bin Stack 40 sheets bin 150 sheets 100 sheets 100 V 60 Hz 115 V from copier 100 V 50 Hz 220 240 V from copier 45 W 499 mm x 535 mm x 600 mm 19 6 x 21 1 x 23 6 23 0 kg 50 7 I
171. sorter misfeed to the interrupt bin It also corrects the copier s Quantity Completed counter so that it displays only the number of copies actually in the top 15 bins After removing the misfed paper the misfeed condition is automatically cleared when the sorter cover is opened and closed 14 8 31 August 1989 Control 23Vac Main Board upply Unit FOAN 54 Sorter Safety CPU SW FG M EE The sorter has its own CPU which controls all the functions of the sorter The sorter CPU communicates with the copier through a parallel interface bus The sorter supplies 100 Vac to the transformer The transformer changes this 100 Vac to 23 Vac and it is then supplied to the dc power supply unit The copier also supplies 24 V to the jam sensor through the main board Input signals from the sensors and the safety switches are sent to the sorter CPU directly The sorter CPU operates the bin solenoids and the sorter drive motor This sorter uses a dc motor The motor speed is fixed by using a frequency generator FG The motor operates at high and low paper transport speeds 14 9 31 August 1989 7 FUNCTIONAL AND ELECTRICAL DESCRIPTION 7 1 Power Supply Main Board Power Supply Unit M a OUT 1 ict 100Vac 23Vac 2 From Copier i 1 24V Jam Sensor Upper When the 5 main power switch is turned o
172. that the platen cover is up or down Informs the CPU that there is no paper in the manual feed tray Detects misfeeds Detects misfeeds Detects whether paper has been raised to the proper paper feed position Detects whether paper has been raised to the proper paper feed position 1 25 31 August 1989 THERMISTORS Drum Bias Fusing POWER PACKS STABILIZER Power Pack T S Power Pack CC Bias Power Pack Q BR Power Pack PCC Lamp Stabilizer HEATERS Drum Anticondensation option LAMPS Exposure Fusing Erase Quenching Pre transfer PRINTED CIRCUIT BOARDS Main Monitors the temperature around the drum The CPU selects the bias compensation range based on its input Monitors the temperature around the drum and controls development bias compensation Monitors the fusing temperature and turns the fusing lamp on off Provides high voltage for the T S coronas Provides high voltage for the charge corona and the development roller bias Provides high voltage for the quenching corona and the cleaning bias roller Provides high voltage for the pre cleaning corona Provides high voltage for the quenching and pre transfer lamps Warms the drum when the main switch is off Prevents moisture from forming on the optics Applies high intensity light to the original for exposure Provides heat to the fusing unit Discharges the drum outside the image area Erases lead trail edge
173. the lower cover D from the sorter 2 screws 9 15 31 August 1989 Bd C 6 Remove the tension spring A 7 Remove the screws from the tension plate B When installing a new drive belt rotate the drive shaft bin pulleys C so that the flat surface on each pulley shaft is oriented in the same direction as prior to belt removal 8 Replace the bin drive belt D 9 16 31 August 1989 8 2 Bin Drive Motor Replacement 1 Remove the drive belt See the preceding procedure 2 Disconnect the 3p connector A from the sorter control board 3 Remove the helical wheel cover B 1 screw 4 Disconnect the 2p connectors C from the motor capacitor D and the connectors E from the overrun switch F 5 Remove the cable tie G 6 Loosen the 4 mounting screws of the bin drive motor I 7 Remove the bin drive motor 9 17 31 August 1989 8 3 Bin Replacement 1 Remove the front and the rear covers 2 screws each 2 Remove the helical wheel cover A 1 screw 3 Slightly move both helical wheels B away from the sorter after removing the 2 helical wheel bracket C fixing screws 4 Remove the upper cover D 2 screws each side 5 Lift up the bin unit E 6 Remove one of the screws from the upper shaft F 7 Remove the bin unit at an angle 9 18 31 August 1989 8 4 Exit Roller Drive Motor Replacement Remove the sorter u
174. the optics and select ADS mode Then set SP 56 2 Place three sheets of AS LDG white paper on the exposure glass and press the Enter key and then the Start key 3 Check if the ADS reference voltage VO is within specifications from 2 6 to 3 1 volts 4 After more than three scannings are finished press the Clear Stop key The ADS reference voltage is now newly stored NOTE If it is not within specifications perform ADS Voltage Adjustment 5 54 31 August 1989 7 7 ADS Voltage Adjustment When Purpose Target Measure How ADS voltage is not within specifications from 2 6 to 3 1 volts After replacement of either exposure lamp ac drive PCB main PCB or ADS sensor After Light Intensity Adjustment To maintain correct ADS mode operation ADS voltage 3 0 0 1 0 4 Voltage Adjustment VR 100 on the main PCB Set SP 56 The ADS output voltage on the main PCB can be changed The ADS voltage is displayed on the guidance display 1 Clean the optics and select ADS mode Then set SP 56 2 Place three sheets of A3 LDG white paper on the exposure glass and press the Enter key 3 Open the rear cover 2 screws and adjust the ADS sensor output voltage using VR 100 on the main PCB 5 55 31 August 1989 7 8 ADS Operation Checking When Problem with ADS mode occurs Purpose To check if ADS controls development bias voltage properly Target Darker original should incr
175. the right glass holder firmly secures the exposure glass 5 1 31 August 1989 1 2 Sixth Mirror Replacement 1 Remove the exposure glass Refer to Exposure Glass Removal 2 Remove the lens housing cover A 4 screws Then shift the lens housing B fully to the left and the 4th 5th mirror assembly C to the right 3 Remove the sliding plate D 4 screws and remove the plate springs E from both ends of the sixth mirror 1 screw each 5 2 31 August 1989 4 Remove the sixth mirror as follows 1 Slide the sixth mirror F to the right 2 Push it into the groove G at the rear 3 Swing the front end to the right 4 Pull it towards the front 5 Swing the rear end to the left 6 Push it towards the rear 7 Remove it from the front 5 Replace the sixth mirror While installing a new mirror do not touch its surface with bare hands 5 3 31 August 1989 1 3 Scanner Drive Wire Replacement 1 Remove the exposure glass Refer to Exposure Glass Removal Then remove the top cover 9 screws 2 Disconnect the following connectors from the power pack bracket C B Q CB SSR A Development Bias B White 11 C Charge Corona D Quenching E cleaning bias F and white 4P G Two white 3P H 3 Remove the power pack bracket C B Q CB SSR 2 screws 4 Remove the home position sensor with the bracket I 1 screw 5 4 31 August 1989 5 Remove the
176. the same time the pin on the leaf spring H drops into a notch the inside rim of the dial and the positioning switch becomes de actuated This signal allows the copier CPU to monitor data from the paper size sensor The paper size of the tray is then displayed on the indicator screen where the size of the lower cassette is usually displayed When the paper size dial is positioned at a non standard paper size the positioning switch is actuated At this time the Load Paper indicator lights and no paper size is displayed on the indicator screen 10 7 31 August 1989 5 3 PAPER VOLUME DETECTION A The paper volume detection system of the large capacity tray is similar to that of the cassettes Both systems use the same data bus signals and sensor type However the mechanism of detection and meaning of the display are different Unlike cassette volume detection the paper volume actuator plate A of the large capacity tray is not moved by the sector gear Instead the actuator plate is moved by the tray wire attached to the tray drive shaft B When the large capacity tray is full approximately 1 000 sheets the first four indicators are lit The indicators turn off one at a time each after approximately 225 sheets of paper have been fed The last indicator is the only one remaining lit when about 130 sheets remain in the tray This indicator turns off after the last sheet has been fed 10 8 31 August 1989
177. way out This mechanism makes paper loading and misfeed removal easy 2 Right Cover Misfed paper remaining in between the bank and copier can be removed by opening this cover 3 Slide Mechanism When the LCT is installed on the right side of the bank it is impossible to open the right cover for misfeed removal The slide mechanism however slides the paper supply unit to the left after pulling the paper supply unit all the way out for removal of misfed paper 4 Second Relay Roller Drive Mechanism This mechanism allows you to manually rotate the second relay roller to remove the misfed paper 7 4 31 August 1989 5 PAPER FEED CLUTCH ON TIMING 0 1 Pulse 1 9945msec Start Key _ _ 7 4th Paper Feed Clutch 925 1734 7 4 3rd Paper Feed Clutch 1145 1734 2nd Paper Feed Clutch 1528 7 7 1734 1st Paper Feed Clutch 1650 1734 The paper path length from each paper feed station to the registration rollers is different For this reason the paper feed magnetic clutch on timing for each paper feed station is different 7 9 31 August 1989 6 PAPER SIZE AND VOLUME SENSORS Cassette Bank PCB Paper Feed Control PCB Main PCB 1 3 1 1 M 461 13 102 5 3 e A 4 lt CN461 12 102 6 Lo 5 3 CN461 11 Paper Size 4 5V Ve 4 3 4 CN461 10 CN461 9 E CN102 Ag size ata bus CN102 A7 CN102 A8 191 B
178. 0 5 DC Motor Replacement 1 Turn off the main switch 2 Remove the lower guide plate with the upper guide plate See Sponge Roller Replacement Steps 1 to 4 3 Disconnect the main board motor harness A and FG harness B then remove the motor harness C and FG harness D from the rear side plate E 4 Remove the dc motor from the rear side plate 4 screws 14 32 16 5897 RT16 Location 3 1 Exterior 5897 re aee x es SS 4 2 Paper Stock Section 5897 6 3 Drive Section 5897 8 4 Tray Control Board 5897 10 5 Harness Layout 5897 12 6 Main DC Harness 5897 14 7 Motor Harness 5897 16 8 Tray DC Harness 5897 18 9 Decal 5897 2 Se eis Oa hee 20 Parts 23 August 31 89 LOCATION OF UNIT E August 31 89 1 EXTERIOR 5897 EXTERIOR 5897 August 31 89 Index Q ty Per Q ty Per P Assembly den _ 2621 Top Cover Pan Head Screw M4x8 A912 2591 Front Cover Bolt 4 12 A91 A91 A91 5897 1272 Operation Board Mounting Bracket Nylon Clip 8N 2631 Side Cover Tapping Screw M4x8 2596 Operation Panel Key 0 Tapping Screw With Flat Washer M4x8 12 2 A91
179. 0742 3906 Ball Bearing 6mm 1 3966 Set Screw A007 3685 Ger Support Bracket Cleaning 3975 Cam 01 7027 Cam Gear 34 21T 1 3950 01 1011 Gear 14 1 3611 Front Pick off Guide Plate o IO GB e om CO CO CO Co PY vie Index WT Q ty Per m Q ty Per oe Assembly 70 A008 3612 ear Pick off Guide Plate 0 ips Pan Head Screw M3x6 71 A007 3631 leaning Blade Holder ips Pan Head Screw M4x8 72 06 3127 Spring Positioning Pin ips Pan Head Screw M4x12 ing Screw M4x8 ining Ring M2 5 ining Ring M3 ining Ring M4 ing 6x7 August 31 89 20 CLEANING UNIT AND TONER COLLECTION A045 A046 p 46 20 CLEANING UNIT AND TONER COLLECTION A045 A046 Index AER Q ty Per Assembly CO DB A A 9 N Pressure Lever Pick off Pawl Lever Spring Cleaning Blade Pick off Solenoid Pipe Toner Collection Receiver Spring Drum Return Arm Blade Solenoid Bracket Toner Collection Bracket Seal Toner Collection Leaf Spring Toner Collection Tank er Overflow Sensor sor Holder er Receiver Collection er Collection Tank 220 240V er Collection Tank 115V Cap Large Toner Collection Tank Seal Toner Collection Tank 2 Spring Blade Solenoid Right Bracket Toner Collection Left Bracket Toner Collection
180. 0MHz Ceramic Oscillator 10MHz Bo 144 August 31 89 Page and Parts No D ri n Capacitor 0 22MF AC250V Page and Parts No D r n Ceramic Oscillator 8MHz Resistor 1000HM 2W Capacitor 8 220V Resistor 1 8KOHM 1 2W Capacitor 14 220V Capacitor 14MF 250V Inductor 6660MF Resistor Array 4 7KOHM 1 8W Fuse Resistor 1000HM 1 2W Fuse Resistor 1000HM 1 2W Variable Resistor 30KOHM 0 75W Resistor 1000HM 1 8W Resistor 2700HM 1 8W Resistor 3300HM 1 81 Resistor 3900HM 1 8W Resistor 4700HM 1 8W Resistor 1KOHM 1 8W Resistor 1KOHM 1 8W Variable Resistor 2000HM 0 5W Noise Filter 115V Noise Filter 0 1MF 1200HM Noise Filter 1200HM 0 1MF Capaci 47pF 10V Capaci 0 22 50V Capaci 50V Capaci 4 7 50V Resistor 1 2K0 Resistor 1 5K0 Resistor 2 2K0 Capaci 10pF 50V Resistor 3 Capaci 10 50V Resistor 3 3KOH Capaci 2202 50V Resistor 4 7KOH Electrolytic CAP 47 20 50V Capaci 100 50 100MF 50V Capaci 27PF 50 1 0 01 50V 1 3300 1 0 01 80 20 50 1 0 01uF 50V Capaci 0 1 50V Capaci 0 01uF 50V Capaci 1 25V Capaci 0 01MF 50V Capaci 470 25V Capaci 0 047MF 250V Capaci 0 luF 400V Capa
181. 1 109 RAY401 120 R401 124 C401 122 1C402 119 0402 117 0412 17 0422 17 CN403 101 CN412 104 RAY402 120 R402 125 C402 122 1403 119 117 117 118 14 123 C43 121 17 MM cM 17 113 45 117 MI 117 05 118 CMIS 16 C405 122 0406 117 D416 2 0426 118 CM06 102 06 116 406 12 0407 117 MI 117 118 106 15 Lb 0408 ae 2 0418 117 SS CN408 110 9409 i1 1 0419 il 7 409 103 10 117 17 108 66 30 PAPER FEED CONTROL BOARD A045 A046 August 31 89 Index Q ty Per Index Q ty Per P ipti Part N art No Description Assembly No r Description Assembly A007 5190 Paper Feed Control Board EI Connector Connector 10 Connector 12 Connector ector lt gt Connector Connector Connector Connector Connector Connector Connector Connector Connector NO NO PO BB L3 1 NO CO CO Connector Do Connector 2 Diode 155176 Diode 5500G 75339 DB 9 Ln Resistor Array 4 7KOHM 1 8W Capacitor 10pF 50V Capacitor 0 01 50V Resistor 15KOHM 1 4T 5 Resistor 4 7KOHM 1 4T 5 R
182. 1 14 U Paper Feed Bracket Solenoid Upper Bracket 61 12 Cushion 8 15 30 Support Bracket 1 Feed Control 61 5 8x15x30 Support Bracket 2 Feed Control 61 16 Cushion 8x15x30 Shutter Plate 61 9 Seal 8x8x368 Solenoid Lower Bracket 61 13 Paper Feed Motor Bracket Pick up Arm Manual Feed 61 6 Chain Tightener Volume Sensor Shaft 21 48 Bushed Roller Guide Bracket Volume Sensor Shaft 23 60 Bushed Roller Chain 106 Bottom Plate Lever 21 49 Cassette Body Small Bottom Plate Lever 23 61 Cassette Body Large Bushing Volume Sensor Shaft 21 26 Development Unit Bushing Volume Sensor Shaft 23 205 Development Bottom Plate Ass y Sector Gear Bushing 21 25 Development Bottom Plate Sector Gear Bushing 23 03 Front Lower Side Plate Sector Gear 21 77 Seal Plate Lower Side Plate Sector Gear 23 54 Rear Lower Side Plate Paper Dust Scraper Bracket 43 66 Side Plate Bracket Dev Unit Paper Dust Scraper 43 65 Seal Plate Upper Side Plate Paper Dust Scraper Paper 43 23 Bearing Retainer Manual Feed Table 9 31 Adjusting Plate Magnet Angle 124 CM 5 arts escription Index No Idle Gear 17T Front Upper Side Plate Rear Upper Side Plate Seal Doctor Blade 1 Filter Bracket Development Unit Entrance Seal Retainer Guide Plate Anti Static Brush Guide Plate Development Unit Development Unit Clamp Development Unit Guide Toner Supply Unit Toner Supply Bracket Decal Adding Toner
183. 1 19 1071 Seal Blade Front 08 2006 Bushing Bias Roller 1 15 1085 Seal Outer 5413 3903 Pin Transfer Guide Plate 1 15 1083 Seal Inner A007 3642 Pressure Arm Cleaning Blade 3648 Stepped Screw 4 06 3024 Toner Receiving Spring 15 1082 Seal 11x16x2 5418 2116 Spacer Guard 1 3565 Cleaning Blade A009 3689 Actuator Pick off Pawl 1 3570 Cleaning Brush Drive Shaft 002 2019 Rear Cover PCC End Block 1 5001 Cleaning Brush Roller A007 3572 Cleaning Brush Joint 1 2006 Cleaning Brush A007 3561 Rear Side Plate Cleaning 3004 Toner Collection Coil 5442 3593 Seal Cleaning Balde Shaft 3624 Seal Cleaning Unit Casing 15 1078 Rubber Seal Cleaning 3558 Beater Bar 15 1079 Seal Blade Rear 1 3593 Outer Holder Beater Bar 15 2005 Side Seal Cleaning Rear 1 3594 Inner Holder Beater Bar o 1 06 3025 Terminal Spring 1 3591 Lower Casing Cleaning Unit Co 5442 2108 Spring Corona Wire 1 9006 Cleaning Unit Seal A AD02 2018 Rear End Block PCC 3590 Lower Casing Ass y Cleaning Unit gt 14 3032 Positioning Stud End Block 3904 Spring Pick off Pawl Slide A007 3655 Cleaning Grounding Plate 1 3981 Collar 14 3235 Rear Position Pin 1 3958 Pick off Pawl Shaft A007 3551 Front Side Plate Cleaning 3965 Spring 14 3029 Blade Swing Pin 1 5001 Pick off Pawl
184. 10 17 31 August 1989 7 3 Tray Wire Replacement AS Ft Paced Bost ie NR DNs Unplug the tray power supply cord Front Wire Remove the following parts Front cover 2 screws and 1 connector Nylon clamp A holding the operation board harness 1 screw Rear Wire Remove the following parts Rear cover 4 screws Transformer assembly B with tray main board C 1 screw 5 connectors and 1 nylon clamp Drive motor assembly 0 2 screws and 2 connectors Ac power terminal E 2 screws and safety switch assembly F 2 short screws Safety switch actuator assembly G 2 E rings 10 18 31 August 1989 Common Procedure for Front and Rear Wire 1 8 Bex E The front and rear wires run in opposite directions 1 5 6 re Loosen the wire tightener 1 screw 2 Insert the bead A unmarked into the slot on the drive pulley B 3 4 Run the wire over WP1 WP2 D WP3 E and WP4 in turn while also placing the lift Loop the wire one and a half turns around the drive pulley as shown rod s ends G in the braces H Insert the bead red I into the slot on the drive pulley Loop the wire two and a half turns around the drive pulley as shown Hang the wire on the tension pulley 10 19 31 August 1989 8 Move the rods up and down manually to
185. 106 164 104 22 10 MAIN PAPER BANK HARNESS A420 Index No Part No Description Q ty Per A420 5274 Harness Cassette Bank Assembly 23 Part No August 31 89 Q ty Per Description Assembly 1100 1100 1100 1100 1100 1100 1102 1102 1102 1102 1102 0864 1241 1264 1327 1340 1343 0946 1516 1922 1935 ousing AWG14 20 Socket Mate N Lock Fastening Receptacle Contact Contact Pin Contact Housing nector nector nector nector 11 REAR PAPER BANK HARNESS A420 August 31 89 MEN 10757 W 473 105 gt CN EN Ul NS e FLU NC a 104 ios 11 REAR PAPER BANK HARNESS A420 August 31 89 Index Q ty Per Q ty P Part No Descripti Part N Receptacle Terminal Contact Connector Receptacle Housing Connector nector nector 10 ector 12P 420 5275 Rear Paper Bank Harness 25 12 DECAL A420 August 31 89 12 DECAL A420 August 31 89 Index Q ty Per Index p NT Q ty Per art No 7 Assembly YO Decal Sheet 4LANGUAGE Decal Sheet Decal Decal Decal Decal E Decal E Installation Procedure English Installation Pr
186. 1120 iginal Feed Belt 3369 lt Drive Roller 1556 lt Stay 3382 lt Stopper 3381 Floating Roller 3383 Holder Floating Roller Timing Belt 83mm 1 591 Transport Drive Motor DC 21W 1 41 iddle Drive Shaft 1 41 Gear 19T 1 41 Timing Belt MM63 1 591 P P ulley 30T 1 591 ulley 21T 1 591 Motor Bracket 1 591 Spacer 6 5 1 1 591 Collar M6 5918 3380 Spring Floating Roller 1540 Shaft Floating Roller 3385 Belt Unit Stay 3125 Stud M4 Rubber Bushing M6 in Harness 591 lley 79 1 591 Belt P2M 208 o 1150 Spring Anchor lley 15T 5821 Grounding Wire lley 50T 1133 Front Frame gt 3395 Front Belt Unit Plate 3007 lt Unit Holder A 2298 pped Screw M4 3365 lt Release Bracket 3092 lt Unit Holder Clutch Lever gt Spring Detent Arm Solenoid Bracket Registration Solenoid LR y OO CO Solenoid Pin Stopper Lever 1 18 3370 lt Roller Co c Harness Bracket Ass y 1 1142 T Roller Shaft Co Feed in Motor Ass y DC24V 1 2542 T Pulley Co Release Solenoid 9001 Turn Roller Ring 8pcs set Co
187. 15 4093 5215 4211 5001 521 196 195 179 250 146 Fusing Unit Stopper Left Fusing Rail Hot Roller Heater 750W 115V Heater 800W 220V Fusing Side Frame Front Pressure Spring Pressure Lever Spring Front Lamp Terminal Front Lamp Terminal Bracket ushing 20mm using Unit Shaft using Shaft Collar ushing 8mm ire Clamp using Connector Bracket ear Bracket Lamp Terminal using Unit Harness Gear 27T Gear 171 Spring Fusing Drive Spacer M6 Fusing Side Frame Rear Thermofuse Thermofuse Bracket Upper Frame Decal Thermofuse Oil Supply Pad ump Holder ump Entrance Guide Plate Fusing Thermistor Thermistor Spring Index TE Q ty Per 01 02 03 04 05 06 07 08 09 d Pan Head Screw M3x6 Screw With Flat Washer 3 15 Pan Head Screw M4x6 Screw M4x8 Screw 4 14 Ring M3 ing M5 ing M6 g ing ing g Ring M7 ing Ring C M20 Bearing Ball Bearing 25x42x9mm Philips Screw With Flat Washer M3x5 Tapping Screw M4x10 51 Index No 38 Index No August 31 89 Q ty see ERE Thermister Mounting Frame Oil Blade Holder Oil Blade Ball Bearing 10x26x8 Spring Oil Blade Pressure Roller Lower Entrance Guide Plat Fusing Fusing Entrance Fusing Entrance Fusing Entrance Fusin
188. 153 1482 3587 1489 0060W 0060W 0040W 0120W 0060E I 0040C 0100W 0192 0106 0080W 0200W 0040E 0008 0050 3045 7071 Front Bracket Rear Bracket Friction Pad B Decal Paper Size Magnet Catch Ass y Rear Paper Guide Bracket Size Shaft Stopper Bar Knob Front Inner Cover Stopper Bar Mounting Stud Philips Pan Head Screw Tapping Screw M4x6 Philips Pan Head Screw Philips Pan Head Screw Retaining Ring M6 Toothed Washer M4 Philips Pan Head Screw icroswitch UL Harness Clamp Tapping Screw M4x8 Philips Pan Head Screw Retaining Ring M4 Nylon Clip 2N Hexagon Headless Set Screw M5x5 Washer Flat Washer 11 3 DRIVE SECTION 5897 August 31 89 2 2 6 y 5 104 X 79 105 275 090 74 ee 2 AN og kl Ese cil TJ l 02 E ms ay S Fu E 1 ITR 0 3 DRIVE SECTION 5897 Part No Q ty Per Description Assembly 5925 5925 5897 5925 5446 5925 5925 5925 5053 5925 5897 5054 1104 A912 5897 A912 5925 5897 5897 5925 5897 5446 1107 5053 5897 5897 5897 5446 5897 5897 5205 5897 A912 6769 5408 2251 2211 1125 2266 2620 2241 2253 2246 0419 2265 5520 0536 0323 5103 1472 2585 2235
189. 160k R R R 4 3 240k CD 240 240 320k 2222 22 22 320k R R R 320k R R R 31 August 1989 NOTE Damp Cloth Damp Cloth Damp Cloth Damp Cloth Mobil Temp 78 Damp Cloth Damp Cloth Damp Cloth NOTE Belt cleaner replace if necessary Water replace if necessary Water replace if necessary Water replace if necessary NOTE Water replace if necessary Water replace if necessary Water replace if necessary 31 August 1989 2 SERVICE TABLES 2 1 Test Points Main Board Number TP100 TP101 TP102 TP103 Scanner Control Number TP301 TP303 TP304 TP305 TP306 TP307 TP308 TP309 TP310 TP311 TP312 Function Image density sensor input voltage 24V 5V GND Function 24V Vm Factory Use Factory Use Factory Use Factory Use Factory Use Original Density Voltage Scanner Forward Signal Low Active Scanner Return Signal Low Active GND 5V Vc 2 2 Variable Resistors 10 Sensor Board VR VR 1 Main Board VR VR 100 Function LED Light Intensity Adjustment Function ADS Voltage Adjustment 4 4 2 3 DIP Switch Tables DIP SW 801 Operation Panel SW 1 N A Description Free run Not used Language code See language code table Not used Clear counter See CLEAR MEMORY PROCEDURE Service Program mode access
190. 16mm Rear Cover PCC End Block Front End Block T amp C Exit Roller Entrance Guide Plate Front End Block Cover T amp C verter Return Roller Rear End Block T amp S verter Roller Rear End Block Cover T amp C verter Pressure Roller Charge Corona Casing verter Return Roller T amp S Corona Casing verter Return Roller Adjusting Screw Junction Gate Terminal Spring T amp S Fork Gate Pawl Large Pick off Pawl A A A A A A A A A A A A A A A A A A A A A A A A A A A Fork Gate Pawl Small 120 Parts N Description Page and _ Index No Duplex Pick up Roller Duplex Positioning Roller ower Exit Roller Exit Roller Receiving Tray Original Holder Fusing Unit Knob Transport Handle Rod Fiber Connector Toner Density Sensor Paper Registration Sensor Paper Feed Motor Cooling Blower AC50HZ 20 5W 60Hz 18W Main Drive Motor AC 39 5W Development Motor AC 28W Cooling Fan Motor Blower Fan Exhaust Fan Motor Transport Fan Motor Scanner Motor DC 42W Duplex Positioning Solenoid Duplex Pick up Solenoid Pick up Solenoid Manual Feed agnetic Clutch Registration Paper Feed Clutch Paper Feed Clutch agnetic Clutch Toner Supply agnetic Clutch Duplex Feed Transport Magnetic Clutch Heater 750W 115V Heater 800W 220V PRE Transfer Lamp 430V 1 3W Eraser Quinching Lamp Exposure La
191. 2 Fork Gate SOL 1 Transport Unit Safety Switch Terminal Block Fork Gate Unit Safety Switch Noise Filter Circuit Breaker Power Relay 31 August 1989 92 SSR PCB 93 PQC Cleaning Bias Power Pack 94 CC Developer Bias Power Pack 95 PTL QL Stabilizer 96 Paper Feed PCB 97 Operation Panel PCB 1 22 98 TC SC Power Pack 99 Vacuum Fan Motor 100 PCC Power Pack 101 Main PCB 102 Timer PCB 103 Optics PCB 31 August 1989 9 ELECTRICAL COMPONENT DESCRIPTIONS NAME MOTORS Main Development Cooling Blower Fusing Exhaust Fan Cooling Blower Vacuum Fan Scanner Drive Lens Drive 4th Sth Mirror Drive Jogger Cleaner Motors Charge Fan Development 1st 2nd Lift Motors Paper Feed MAGNETIC CLUTCHES Registration 1st Paper Feed 2nd Paper Feed 1st Feed Relay Duplex Paper Feed Toner Supply FUNCTION Drives all main unit components except optics unit and fans blower 100 Vac Blows air to the development unit bottom plate Removes heat from around the fusing unit 100 Vac Prevents build up of hot air in the optics cavity 100 Vac Provides suction so paper is held firmly on the transport belt 100 Vac Drives the scanner dc servo Positions the lens dc stepper Positions the 4th 5th mirror assembly dc stepper Drives the jogger plates to keep paper evenly stacked on the duplex tray Clean charge and separation wires Ensures even charge on the surface of the drum Drive
192. 2 A045 A046 22 Duplex Section 1 045 046 24 Duplex Section 2 A045 A046 26 Duplex Section 045 046 28 Invertor Section 1 A045 A046 30 Invertor Section 2 A045 A046 32 Development 1 045 046 34 Development 2 045 046 36 Transfer and Separation 045 046 38 Drum Section 1 A045 A046 40 Drum Section 2 045 046 42 Cleaning Unit 1 045 046 44 Cleaning Unit and Toner Collection 045 046 46 Fusing Unit 1 045 046 48 Fusing Unit 2 045 046 50 Operation Panel 045 046 52 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Drive Section 045 046 54 Electrical Section 1 045 046 56 Electrical Section 2 A045 A046 58 Electrical Section 3 A045 A046 60 Main Control Board 045 046 62 Optics Board 045 046 64 Paper Feed Control Board 045 046 66 AC Drive Board A045 A046 68 Harness Layout Front View 045 046 70 DC Harness 045 046 72 AC Harness 045 046 74 Lens Housing Harness A045 A046 76 Lens Home Sensor Harness 045 046 78 Paper Feed Unit Harn
193. 2 After cleaning the erase lamp filter rub it lightly with your finger to discharge any static electricity on the filter surface 5 4 Optics 1 A small amount of launa oil should be used to lubricate the following parts a Scanner Guide Rods b Scanner Guide Rod Pads c Lens Housing Guide Rods Clean the exposure glass with glass cleaner and a dry cloth to reduce the amount of static electricity on the glass surface Do not touch the following parts with bare hands a Reflectors b Exposure lamps c Mirrors and lens Do not bend or crease the exposure lamp ribbon cable or the fiber cables The scanners are fragile so to move one manually push on the scanner guide bracket not the scanner Do not touch the mirror surface with your fingers When replacing a mirror make sure the surface faces the optical path Even when the lamps are off electricity continues to run through them Make sure that the power 15 off when working in this area Only use water or a silicon cloth to clean the mirrors and the lens 5 5 Development Unit 1 Do force the development roller to turn opposite to the normal direction of rotation be cause this may damage the gears Be careful not to nick or scratch the development roller sleeve made of aluminum Always check to make sure that there are no splits in the upper brush seal Any splits at this location will cause toner scattering Always keep
194. 2 2592 Rear Cover Bolt M4x22 2 2 2 5010 Operation Board Nylon Stud A912 2594 Decal Increase 517 A912 2595 Decal Decrease 517 1372 Decal Power Source 220V 8905 Decal English French 115V 8906 Decal English German 220V 1282 Decal Operater Instruction 2331 Holder Side Cover 0536 agnet Catch Ass y 2334 agnet Catch Plate 2 PAPER STOCK SECTION 5897 August 31 89 ee 02 SEE 2 44 lt gt d Y o 3 wu 2 PAPER STOCK SECTION 5897 Front Side Plate Side Guide Stopper Stopper Bar Spring Plate Stopper Bar Hook Stopper Chain Microswitch Mounting Bracket Stopper Bar Mounting Bracket Side Cover Plate Leaf Spring Size Lever Photointerruptor Pack Hook ED Sensor 5 Bottom Plate Stopper Chain Front Side Guide Sensor Mounting Bracket Gear 28T Bushing Rear Side Guide Rear Guide Post Front Guide Post Right Lift Rod Left Lift Stay Spring Plate Side Post Lift Stay Tray Bottom Plate Left Cover Rear Side Plate Side Guide Shaft Spring Plate Rear Side Post Spring Plate Front Side Post Front Paper Guide Rear Inner Cover Part No August 31 89 Q ty Per Description Assembly 5925 5925 A421 A912 5054 A912 5897 5897 A912 5897 2203 2204 2543 2582 0536 2576 4
195. 3 dX UF 25 ELECTRICAL SECTION 1 A045 A046 2 2 UU A MS 9 107 107 19 TES He _ pee m 2 10 o 781 ES OA RRA i 2 KS c NN 108 E 104 104 25 ELECTRICAL SECTION 1 A045 A046 August 31 89 Index Q ty Per ae Q ty Per Part No Part No n Power Pack PQC amp BR 15 0019 Mylar Seal Power Pack Bracket Ssr Board AC Drive Power Pack Charge 6 Bias Transport Fan Support Bracket CFL Stabilizer Power Pack Harness Transport Fan Cover Transport Fan Filter Ozone Filter Seal 3x7x484 Transport Fan Motor Power Pack PCC Transport Fan Bracket Grounding Wire Power Pack T amp S Total Counter 13 0060 Phili E ead Screw Counter Cover 13 03007 Phili ead Screw Total Counter Bracket 1 14 0080M Phili E ead Screw Safety Switch Lever 14 00801 Phili Head Screw 1 Co PP Main Power Switch Bracket 14 04501 Phili Head Screw Safety Switch Bracket 1 00607 Screw M4x6 Co Safety Switch Harness 1 0080W Screw M4x8 New Optics Board Bracket 1 1185 Phili Truss Head Screw M4x8 Op
196. 3300HM 1 4T 5 Resistor 39KOHM 1 4T 5 Resistor 4 7KOHM 1 4T 5 Resistor 56 1 4 55 4040 5183011 5182031 Resistor 0 470HM 1 8W 5 Capacitor 220pF 10V Capacitor 470pF 50V Capacitor 4700 50 Resistor 12KOHM 1 8W 5 11 5 DF HARNESS A418 August 31 89 5 DF HARNESS A418 August 31 89 Index Q ty P Index Part No ipti To sere Assembly No PEPR Ne 01 1100 1 U U 1 2 3 4 5 6 7 8 9 0 2 NY PL A418 5811 DF Main Harness Socket 1100 1 Socket 1100 1 Fastening 1100 1 Socket 1100 1 Socket 1100 1 Contact 1100 Contact 1100 1 Pin Contact 1102 1 Connector 3P 1102 Connector 1102 1 Connector 5239 2P 1102 1 Receptacle Housing 1102 151 nector 2P 1102 1 nector 1102 191 nector 2 1102 191 nector 1102 191 nector E 1102 1 nector E 1102 1 nector E 11 1 nector E 11 1 nector E nector 11 ector PARTS INDEX 5 t Page and Parts No escrip ion Index No C A ee gee feet tee coo ses EB 299 oe 9d Bar SPP Be pn Middle Drive Shaft Belt Un
197. 4 R125 R126 R127 R128 R129 R130 TEST POINT SYMBOL E SYMBOL SYMBOL INDEX 1 SYMBOL 1 SYMBOL ae 1 m SYMBOL E SYMBOL E SYMBOL INDEX 1 TP101 TP102 TP103 TP104 TP105 101 101 101 101 101 101 R131 R132 R133 R134 R135 R136 R137 R138 R139 R140 DIODE 0101 0102 0103 0104 9105 156 R141 158 8142 58 R143 R144 158 Ri45 163 R146 163 R147 161 R148 161 R149 161 R150 NOISE FILTER 165 8151 161 R161 161 161 R152 161 R162 161 161 R153 163 R163 161 161 R154 163 R164 157 161 155 158 165 161 161 rse 158 16 161 R157 161 R167 161 161 R158 161 R168 161 161 R159 161 R169 161 161 R160 161 R170 157 OSCILLATOR TRANSISTOR amp wir 3e a n u feet sre a 15 117 117 117 4 DF MAIN BOARD A418 August 31 89 nas Q ty Per Par A418 DF Main Board Index ME Q ty Per Assembly 01 1101 ector Pin Contact A409 Fiber Connector 5936 Heat Sink A418 2764 30 22 HCIL 3 02 1102 ector P 03 1103 ector P 04 1103 ector 05 1103 ector P 06 1103 nector P 07 1103 nector 08 1103 nector 2P 09 1104 LSI Socket 42 1104 Fuse Holder 1107 Fuse DIP Switch Push S
198. 45 ll Bearing 6x12x4mm 1105 0108 lon Clip 0633 0120E ing Pin M3x12 0313 0080W Philips Pan Head Screw M3x8 Grouding Plate Cushion 21x20x2 Mylar Seal 15x12x0 1 gt 1 9 F2 Paper Guide Mylar Belt Unit Stopper Spring Inverter Guide Plate P2 OC 4 DF MAIN BOARD A418 August 31 89 CAPACITOR VARIABLE RESISTOR CONNECTOR FUSE SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL p SYMBOL INDEX SYMBOL SYMBOL INDEX SYMBOL INDEX SYMBOL m NO NO NO NO NO NO NO NO B NO NO NO NO NO NO NO NO idl 15 C21 154 154 154 C151 Pu 136 103 cur cm m i M wo 136 eno 1 eus 154 c3 154 154 103 137 104 18 104 178 C114 143 C124 154 C134 154 154 VR104 139 CN104 107 110 105 179 cus 152 C5 154 135 154 cus 154 veins ous 15 HH _ di DIP SWITCH RESISTOR ARRAY c6 150 cue 152 14 154 cus 153 Eden 18 Tos
199. 4W 11 5 HARNESS LAYOUT 5897 DIA ANO fen PT 27029 1 A EU X X SQL 7 5 HARNESS LAYOUT 5897 August 31 89 Index Q ty Per Assembly Aem 5897 5042 Main DC Harness 5897 5047 Motor Harness 115V 5897 5048 Motor Harness 220V 5897 5043 Tray DC Harness 6 MAIN DC HARNESS 5897 CNS 03 7 04 5 105 114 lol 105 108 August 31 89 6 MAIN DC HARNESS 5897 August 31 89 Index Part No Description Q ty Per 5897 5042 Receptacle Housing Pin Mate N Lock Receptacle Terminal Mate N Lock tact nector Receptacle Housing Receptacle Housing Receptacle Housing Receptacle Housing Connector 4P Connector 12P Connector 12P Connector 3P Connector 7P 15 89 August 31 7 MOTOR HARNESS 5897 16 7 MOTOR HARNESS 5897 Index ee Q ty Per No Part No Description Assembly 5897 5047 Motor Harness 115V 2 5897 5048 Motor Harness 220V 17 Part No August 31 89 Q ty Per Description Assembly gt wo 1 DB LY Icom 1100 1102 1100 1100 1100 1100 1100 1102 1102 1 1102 1 1102 1 1102 1 1100 1100 1 1100 1 1100 1100 1 1102 1 1102
200. 5 046 August 31 89 7 p e 99 a q JE SE _ E be gt et MBL 5 d 5 ZA igh JS gt 4 55 5 22 2255 0 59 a ae 5 n 101 28 uS 11 DUPLEX SECTION 3 A045 A046 August 31 89 Index Q ty Per Assembly Bushing 6x18x5mm Q ty Per escription Assembly A007 Jogger Unit A007 1 Front Paper Stopper Guide Unit Rear Frame Duplex Unit A007 Paper Stopper Guide Unit ushion Fork Gate A007 Fenc Rear A007 Fence Sho 2 A007 Fence Sho 1 A007 Setter Mylar Rear 5206 Setter 5206 j Duplex Settler 5206 ushion Duplex Settler A007 uplex Settler Guide A007 uplex Guide Plate Middle uplex Stopper eparation Roller C D Snap Ring S 51 ip Clutch Cover Output Hub Spring Separation Input Hub Separation Driven Shaft Gear 23 Gear 221 a wo Cc CO 007 uplex Setter Mylar Front A007 ront Jogger Fence A007 uplex Guide Plate 5206 Friction Pad Duplex Guide Plate Paper Stopper Pulley Helical Gear 29T Separation Drive Shaft A007 i Vibration Pad Large Duplex Separation Arm A007 i Vibration Pad Small Separation Pressure Spring 5206 ing Pick up Roller Spring Duplex Stopper Solenoid A007 Guide Plate Jogger Fence Duplex Stopper
201. 51 1 118 141 10128 196 1C138 150 10148 143 152 R112 170 R122 185 1109 128 rem 133 169 127 148 osco 15 m3 170 15 a HEN 1 i ue ims iu imn SYMBOL SYMBOL es YMROI SYMBOL NO m5 185 m3 179 197 mo 113 um 15 me 367 027 m5 19 m5 15 166 1 m m 1 185 ma 19 167 1 m T 180 R183 191 R193 180 R203 192 R213 A ux 15 ma 180 ise 13 riea 167 rive igo aor 1 0 ros 16 R131 180 R145 180 R155 183 R165 167 R175 180 R185 191 R195 180 R205 190 R215 172 R132 180 rigs 180 piss 173 180 180 rse 194 172 mos 190 17 mo me ms 18 me 19 183 197 12 mv vell mi
202. 7 5054 5205 A007 A007 5205 A007 01 007 5403 15 A007 15 01 15 007 007 01 A007 A007 15 3051 3199 3314 3316 3317 5001 7033 3391 3256 1026 3271 1024 1025 3251 3290 0536 3374 3223 3230 3421 3286 1017 3281 2048 1039 3388 1030 3093 1040 3351 3350 2005 3176 3341 1028 Een Q ty Per Description Assembly Development Unit Toner Supply Unit Upper Hopper Case 2x3x53 2x3x45 2x16x53 2 16 45 Toner Agitator Gear 20T Upper Shaft Lower Shaft Gear 14T Gear Toner Cartridge Drive Cartridge Drive Bracket Seal Toner Supply Shaft Toner Hopper Pipe Cover Toner Supply Shaft Seal Toner Shutter Lower Hopper Case Ass y Toner Shutter Lower Hopper Case Toner Hopper Entrance Toner Hopper Casing Sheet Seal 4x12x211 Seal 2x15x308 Toner Hopper Pipe Toner Hopper Pipe Toner Hopper Pipe Cover Hopper Side Plate Ass y Rear Magnet Catch Ass y Seal Toner Hopper Positioning Lug Toner Supply Hopper Side Plat Seal 2x50x58 Toner Supply Bracket Toner Supply Cover Spacer 1x8x12mm Seal Bottle Release Lever Registration Drive Spring Bottle Release Lever Gear 16 Gear 15T Toner Shutter Rack Actuator Toner End Spring Drive Wheel Bushing 4mm Seal 2x51x60 Rack Guide Bracket Seal 2x11x75 Cam Wheel Toner End Gear 471 Idler Gea
203. 7 25v 10V T 16 Lm SGNO 5 19 ISV SOND 37 5 0 2 INT I AVREF 7 SH stop 1 1000P 1 4W l R55 A SS 22 9 4 lt JV 8 3 ET AGNO e OSCI C5 0 686 35 cL 9 13 MENU READER PCB lower 10 25377 ul lie EP Sle ae 2 lis CN3 iO XCN2 5 2 FILS a Te 220 37 FILI CENITE 3 R13 TRO Y POE 2 2 cs Mes 9 1 ud il 5 SGNO 24V 24V PGNO PGNO 202 R4 CED 50 S R2 9 e N 2 7 4 2 a o 2 o 4 CN3 8 4 2 o TRE 4 2 o V G RI Li 4 m ZUR TR2 14 FIL2 me 7r lt 6861 3 SECTION 7 PAPER BANK Contents PAPER BANK SPECIFICATIONS des eus Gre X A eee ese 7 1 2 MECHANICAL COMPONENT LAYOUT
204. 84 oulder Screw M3 2685 Entrance Actuator Plate 2686 ap Ring Collar ing Shaft Collar Upper Exit Roller Spring Exit Spring Exit 2686 ap Ring 2687 Stud Screw M3 ED Sensor Type S ED Sensor Type 5 132 Parts No Description Page and Index No 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5206 5207 5208 5209 5209 5209 5209 5209 5209 521 521 521 521 521 521 521 1 1 1 1 4 5 5 2687 2690 2695 2700 2712 2808 2826 2833 2840 2850 2851 2876 2877 2925 2926 2929 4388 4478 4478 9600 4405 4173 1694 1735 4149 4408 4470 5320 1374 1375 2285 2800 4122 1295 1297 Stud Screw M3 Duplex Paper Actuator Cover Duplex Paper Sensor Spring Pick up Roller Duplex Stopper Solenoid Anti Static Brush Duplex Transport Spring Gate Arm Gate Solenoid Bracket Fork Gate Holder Bracket Transfer Safety Switch Right Fork Gate Guide Spring Wire Wire Clamp Plate Duplex Setter Weight Duplex Settler Cushion Duplex Settler Spri Inverter Guide Spri Driven Roller Spri Driven Roller Sensor Checker Spring Fusing Unit Spring Stripper Guide Roller lst Scanner Pully Fusing Unit Shaft Gear 16T Upper Exit Roller Oil End Sensor Cap Left Cover L Cap Left Cover 5 Rear Flange Rear Platen Cover Str
205. 89 12 4 OIL SUPPLY AND CLEANING Silicone oil is applied to the hot roller to prevent toner and paper from sticking to the hot roller to reduce paper curl and to clean the roller A small one way valve pump moves the oil from the oil tank A capacity 360 cc to the oil supply pad B The oil pump lever C alternately presses and releases the rubber sleeve D between the valves as the oil cam E turns The oil supply pad then applies the oil to the hot roller as it turns The oil blade spreads the oil on the hot roller evenly Excess oil flows down the back of the oil supply pad to the oil sump F Oil flows out through a hole G in the bottom of the oil sump and returns to the oil tank The oil supply pad both distributes oil to the hot roller and removes toner and foreign matter from the hot roller surface 2 82 12 5 OIL END SENSOR Phototransistor LED Sensor Head 7 Polypropylene Silicone Ol Light Bottom of Tank Enough Level Vw ety Main Board 31 August 1989 Sensor Head P Polypropylene Silicone Oil UK LH o t lt lt lt lt Bottom of Oil Tank Ol la ve Al ke YY Le Vi 5V Y End Sensor qid Operation Panel b A LS Oil end detection is based on the difference between the index of r
206. 9 9 11 Copy Cycle Forward Scan 20 Scanner 268ms 32ms 2 Development 227 Bias ID Sensor Pattern For Image Selected Blas In order to develop the ID sensor pattern consistently the CPU applies a fixed base bias level to the development roller at the beginning of the first copy after power up and then once every ten copy cycles Fixed base bias is factory set at 500 volts dc adjusted by SP 33 Compensation for drum cavity temperature and drum rest time is added to the fixed base bias The CPU applies the ID sensor fixed base bias to the development roller about 32 milliseconds after the scanner starts forward scan Just after the sensor pattern is developed the CPU changes the bias output to the level selected by the ID keys or auto ID system The bias output remains at this level until the scanner starts the return scan Toner concentration can be increased or decreased by changing the ID fixed base bias Higher fixed base bias will cause the sensor pattern to be developed lighter The CPU then senses that the toner level is low and therefore adds more toner This results in darker copies as toner concentration is increased SP 33 0 2 3 ID fixed base bias 900 380 470 530 2 35 31 August 1989 5 6 BIAS CONTROL CIRCUIT 5V Vc Bias Thermistor 1 1 DC DC CN1 11 onverter ID Sensor Output Board LI B Bias 101 19 1 9
207. 92 ransport Guide l A007 Bushed Roller Guide Bracket 2597 ion Transport Guide 1 A007 1 agnetic Clutch Stopper 2754 ing Registration Roller AX20 Transport Magnetic Clutch 2612 ing A007 1 Pulley amp Gear 36T 45T 2577 Registration Knob 1 01 Drive Gear 4162 Screw Driven Guide Plate A007 1 Bushed Roller Chain 106P 2110 PTL Guide Sheet 1 01 Gear 30 2109 PTL Guide Cover AF02 Upper Middle Roller 2101 PTL Guide 1 A007 Separate Duplex Guide 2281 lar Seal Guide PTL Cover 1 A007 Separate Lower Guide c 3886 PTL Guide Plate A007 Cushion Transport Upper Guide 3885 PTL Guide Holder 007 Transport Upper Guide 0008 PRE Transfer Lamp 430V 1 3W 1 007 Guide Transport AID 2783 Paper Dust Scraper Paper 1 A007 Paper Bank AID 2 Duplex 0021 Upper Registration Roller A007 Paper Bank Guide Duplex 0022 Lower Registration Roller 1 007 Paper Bank AID 1 Duplex o 2631 Lower Registration Guide 1 5403 Stepped Screw 2614 Registration Lower Guide 5840 Stepped Screw c 1069 Seal 10x12x370 1 A007 Paper Dust Scraper 2616 Registration Upper Guide 007 Paper Dust Scraper Bracket Co Iw 2628 Cushion Registration Upper Guide 5205 Magnetic Clutch Collar Co Co 2620
208. 989 12 2 FUSING DRIVE MECHANISM The fusing drive gear A turns the release gear B which drives the hot roller gear C Rotation passes from the hot roller gear through two idle gears D to the exit roller drive gear E The pressure roller is driven by the friction between the two fusing rollers The release gear spring F allows the release gear to move in and out This prevents the gears from being damaged if they are not aligned correctly when the fusing unit is set Also by pulling on the fusing knob the operator can disengage the release gear and the fusing drive gear to turn the fusing rollers and remove misfeeds 2 80 31 August 1989 12 3 ENTRANCE GUIDE The entrance guide A for this machine is adjustable for thick or thin paper With thin paper set the entrance guide in the upper position This slightly lengthens the paper path which prevents the paper from creasing in the fusing unit With thick paper set the entrance guide in the lower position This is because thick paper does not bend as easily and is therefore less prone to creasing Also the lower setting allows more direct access to the gap between the fusing and pressure rollers This prevents thick paper from buckling against the fusing roller which can cause blurring at the leading edge of the copy The angle of the entrance guide can be adjusted using the knob B about 1 mm of play as shown by the arrows in the illustration 2 81 31 August 19
209. A LT RICOH USA LT SAVIN LT RICOH TAIWAN 4 NASHUA EUROPE 4 4 17 Function 0 English 1 French 0 English 1 French 0 English 1 French No Function No Function 31 August 1989 SP 13 No Function Original Option 0 Japanese 0 Swedish 1 English 1 English 2 French 2 Danish 3 German 3 Norwegian 4 Italian 4 Finnish 5 Spanish 5 Dutch No Function No Function No Function Same as Ricoh Europe NOTE When language selection is required turn off DIP 801 3 Original Option 0 Japanese 0 Swedish 1 English 1 English 2 French 2 Danish 3 German 3 Norwegian 4 Italian 4 Finnish 31 August 1989 4 SPECIAL TOOLS AND LUBRICANTS 4 18 Description Part No Q ty 1 Test Chart OS A3 10 sheets 5420 9516 100 sheets 5420 9502 2 Digital Thermometer HLC 60E 5420 9504 3 Digital Thermometer Probe HLC 60E 5420 9505 4 Digital Multimeter BECKMAN RMS 3030 5420 9507 5 Test Lead Kit BECKMAN 01241 5420 9508 6 Drum Shoe 5442 9106 7 Shoe Adaptor 5447 9104 8 Omega Clamp 5205 9111 2 9 Thickness Gauge 0 2 mm 5446 9140 10 Thickness Gauge 0 71 0 86 mm A007 9504 1 11 Setting Powder 5442 9101 12 Silicone 5420 9550 13 Launa 40 Oil 5442 9103 14 Grease MOBIL TEMP 78 400g 5447 9078 15 Silicone Grease G40M A008 9502 31 August 1989 5 SERVICE REMARKS 5 1 Handling The Drum Never touch the drum surface with bare hands 2 Store t
210. A moves the fourth and fifth mirror assembly B using the wire C and pulleys D This provides the proper focal distance between the original and the drum When the fourth and fifth mirror assembly is in the full size position the actuator E on the assembly actuates the fourth fifth mirror home position sensor F This signal goes to the optics CPU 2 15 31 August 1989 Fourth and Fifth Mirror Assembly Positioning 24 M GND Optics PCB Main S CN303 11 Mirror BV CN305 10 CN305 12 5 ba 1 Low Reduction Enlaraenent 9 lt Power up Power up Ferme Operation Panel Pwo Mirror Sensor 40pls 100 p Reduction Towards gt 40pis 14 Away from 1 100 Mag Ratio Home Position The mirror home position sensor informs the optics CPU when the fourth and fifth mirror assembly is at the home position The home position is determined by a LOW to HIGH to LOW change on CN305 12 of the optics board When a reproduction ratio is selected the operation panel PCB sends this information to the main board The main board then sends the appropriate trigger signals through the serial line to the optics board When moving away from the home position the mirror drive pulley turns clockwise and moves directly to the selected position Howeve
211. B is conductive and contacts both the drum and the bias roller C within the cleaning unit The bias roller has a positive dc voltage 300 volts applied to it This enables the cleaning brush to remove toner from the drum efficiently and deposit it in the cleaning unit 2 56 31 August 1989 8 3 DRIVE MECHANISM B The cleaning unit is driven by the main motor Mechanical drive is transmitted to each part as follows Main Motor A gt Registration Roller Drive Belt gt Gears gt Cleaning Brush 0 Toner Collection Coil E gt Bias Roller Gear F A groove cam G inside the toner collection coil gear moves the cleaning blade from side to side as long as mechanical drive is applied This loosens toner build up between the cleaning blade and the drum 2 57 31 August 1989 8 4 CLEANING BLADE A The cleaning pressure mechanism is shown above When the cleaning solenoid A is energized it turns the cleaning solenoid lever B clockwise rear view Due to the pull of the cleaning blade pressure spring C the pressure arm D also turns clockwise and pushes the cleaning blade lever E up The cleaning blade holder then rotates and the cleaning blade F presses against the drum Blade pressure is limited by the pressure spring I The cleaning blade is mounted on the blade bracket with a single swivel screw G at its exact center With this type of mounting the blade sets parallel a
212. Blinks OFF make sure it is marked correctly and insert it again Note The red light blinks for 6 seconds then it stays on A conversion error has occurred insert the job sheet again engs Note The green light blinks for 6 seconds then it stays on The RAM contents have been changed or the Blinks Blinks menu reader has failed to read the ROM contents Note Turn the main switch off and on 12 6 31 August 1989 4 3 Processing Errors Reference Line If the referrence line dows not reach the mark detection sensor within 2 6 seconds after the job sheet is fed in the job sheet is fed out Feeding out takes 1 6 seconds The red light blinks for 6 seconds then the job sheet can be reinserted Reference Mark If the mark detection sensor detects the reference line and then fails to detect a reference mark within 0 2 seconds or if it fails to detect a reference mark within 0 1 seconds the job sheet is fed out and the red light blinks for 6 seconds then the job sheet can be reinserted Note Occasionally the job sheet feeds out to the rear side of the menu reader after a failure to detect the reference mark number Marking When two or more selections are made for the same item the menu reader cannot process the job sheet and the red light blinks indicating an error Note 1 When an item is not marked on the job sheet the menu reader automatically reads as follows Item Indicator Copy Quan
213. CTION A ce BoP RUE 2 40 6 4 TONER DENSITY CONTROL ee oe 2 41 6 5 TONER SUPPLY AMOUNT s veces oa eee x HERR RR D PE oe eek 2 42 6 6 TONER END DETECTION PP Ute ea ee ar DR 2 44 6 7 TONER OVERFLOW SENSOR CIRCUIT 2 45 7 IMAGE TRANSFER AND PAPER SEPARATION 2 46 7 1 PRE TRANSFER LAMP E TL i onere o db dre i re Br Ba Bs Sat 2 46 Te MAGE TRANSFER 2226008 tof oe eee Deva RACE TR 2 47 7 3 PAPER SEPARATION E e T 2 49 7 4 TRANSFER SEPARATION CORONA POWER PACK 2 50 7 5 PICK OFF MECHANISM 5 2 52 7 6 PIGKOFF TIMING atri Rr Deu yew ta Ce ex 2 53 7 7 PRE TRANSFER LAMPAND QUENCHING LAMP CIRCUIT 2 54 8 DRUM 2 55 BSIUORERA DON 6 uet tet hy ea A Alo at al ere yon 2 55 8 2 PRE CLEANING CORONA AND BIAS ROLLER 2 56 8 3 DRIVE MECHANISM ou twos bebe Se sete ds 2 57 84 CLEANING BLADE eth ERE 2 58 8 5 CLEANING SOLENOID CIRCUIT sese RR Rem RE bakes 2 59 8 6 PRE CLEANING CORONA CIRCUIT 2 60 9
214. D and the exit drive chain E For safety purposes the lower exit roller is driven through a slip clutch F This slip clutch ensures that the roller turns when operating normally but it slips when excessive force exists between the lower and upper exit rollers 2 91 31 August 1989 14 DUPLEX 14 1 INVERSION C n MAN Z L I m or L INL HG fer N Pane 9 D Operation After passing through the fusing unit A copies come to the junction gate B The junction gate is controlled by the junction gate solenoid Single sided copies pass under the junction gate and go straight to the paper exit Duplex copies pass over the junction gate and enter the inverter unit C Once the copy is in the inverter unit the feed direction is reversed and the copy exits from the inverter unit via the fork gate unit D to the duplex tray 2 92 31 August 1989 Drive Mechanism The main motor A drives the inverter rollers B via the exit drive chain C The inverter rollers and the exit relay rollers D rotate in opposite directions 2 93 31 August 1989 Forward Drive aut When the copy s leading edge passes the fusing exit sensor the CPU energizes the junction gate solenoid A The exit relay rollers B feed the copy into the inverter unit The inve
215. Decal Fusing Cover il Tube 7 8mm 1 1 Oil Tank English il Bottle Cap 1 lder Screw 4 Tank Exit Roller Exit Roller Spring Rear Release Lever Stud Exit 55 Release Lever Rear Lever Fusing Exit 2 3 4 5 6 7 8 9 0 Front Lever Fusing Exit Spring Front Release Lever Hot Roller Stripper 6pcs set Exit Frame ips Pan Head Screw M4x6 ing Screw M3x6 a ED Sensor Type T 1 Philips Pan Head Screw M4x10 using Exit Sensor Bracket 1 Tapping Screw M4x8 using Exit Sensor Feeler 1 E ining Ring M3 e Exit Guide 1 ining Ring M4 in Exit E ining Ring 5 Co ing Plate Oil Supply Pad 1 ing 6x10x8mm ilicon Oil Nozzle 1 Philips Screw With Flat Washer M4x6 Co 22 FUSING UNIT 2 A045 A046 August 31 89 5 7 22 FUSING Part No UNIT 2 A045 A046 Q ty Per escription Assembly 007 4217 007 4212 01 1001 AX44 0008 AX44 0009 007 4161 06 0051 007 4171 06 3022 007 4273 03 2001 5209 4408 5209 4149 5205 4135 5053 0223 01 3076 11 5003 007 4192 5442 4201 007 5540 01 3060 01 3267 5442 4152 13 2024 007 4151 5215 5390 5203 5801 52
216. Detects the low oil condition Detects when the used toner bottle is full Detects when it is time to add toner Detects misfeeds Detects when the manual feed table is open Informs the CPU when the scanner is at the home position 1 24 Lens Home Ath 5th Mirror Home 1st Paper Size 1st Paper End 2nd Paper Size 2nd Paper End Scanner Overrun 1st Relay Jogger Home Duplex Paper Duplex Entrance Image Density Auto Density AD CC Cleaner Home Position SC Cleaner Home Position Platen Cover Manual Feed Paper End Fusing Exit Inverter Exit 1st Lift 2nd Lift 31 August 1989 Informs the CPU when the lens is at the full size position Informs the CPU when the 4th 5th mirror assembly is at the full size position Detects the paper size in the first cassette Informs the CPU when the first cassette runs out of paper Detects the paper size in the second cassette Informs the CPU when the second cassette runs out of paper Informs the CPU if the scanner overshoots the home position Detects misfeeds Informs the CPU when the jogger plates are at the home position Detects whether or not paper is on the duplex tray Misfeed detector Detects the density of the image on the drum Senses the background density of the original Informs the CPU when the charge wire cleaner has reached home position Informs the CPU when the separation wire cleaner has reached home position Informs the CPU
217. Do not touch the brush with bare hands as this may reduce its conductivity Make sure the notch of the cleaning brush F is fitted properly over the positioning pins G of the rear spindle 5 22 31 August 1989 3 3 Blade Cleaner and Bias Roller Blade Replacement 228 LAP EAA OO GE NEC 223 LN SS NSS SN Blade Cleaner 1 Remove the blade assembly A 2 screws 1 spring 2 Remove the old blade cleaner B 1 screw 3 Install the new blade cleaner Make sure that the springs C are set properly Bias Roller Blade 1 Remove the old bias roller blade D 2 screws 2 Install the new bias roller blade CAUTION When reassembling make sure the bias roller blade E is inserted unde the bias roller F 5 23 31 August 1989 4 FUSING 4 1 Fusing Unit Removal lt 77 B KIIS AS 1 Open the front cover 2 Push down the fusing unit release lever A and pull the fusing unit B all the way out 3 Move the fusing unit to the left to disengage the stopper C and remove the unit from the copier The base plate D of the fusing unit is hot do not touch it with bare hands 5 24 31 August 1989 4 2 Oil Blade Replacement No ee ee 1 Remove the fusing unit Refer to Fusing Unit Removal 2 Remove the fusing unit cover A 8 screws and remove the pressure plate B 2 screws 3 Remove the oil supply
218. E 154117 Retaining Ring M3 106 1102 1514 nector 1E 17 106 Retaining Ring M4 3 1102 1516 nector 15 107 Retaining Ring M6 1 1102 1516 nector E 15 118 Retaining Ring 6 107 1102 1620 nector 17 107 Rubber Shoe 110 1102 1621 Receptacl 3 106 Philips Truss Head Screw M4x8 112 1102 1621 Receptacl 1 E 17 108 Tapping Screw M4x8 13 1102 1623 Receptacl i 13 107 Knob Screw 101 1102 1623 Receptacl i F 17 109 8 3 9 4 5 1 Receptacle Housing Pin Mate N Lock Pin Mate N Lock H NO N FP FP c Lr Socket Mate N Lock 24 August 31 89 dt nector 1611 4103V i 10 1 4T 5 9 124 Connector 1611 4104V 100KOHM 1 4V 5 9 125 Connector 7P 1611 4380V 3800HM 1 4W 5 9 126 Receptacle Housing 1611 4472V 4 7KOHM 1 4 5 9 128 Connector 1611 4562V ist 5 6KOHM 1 4W 9 129 Connector 7P 1611 4564 ist 560KOHM 1 4W 9 130 Connector 1611 4680V ist 6800HM 1 4W 9 131 Connector 1611 4771V ist 4700HM 1 4W 9 127 nector Connector Fuse Holder Nylon Clip 4N Nylon Clip Nylon Stud Cord Clamp 220 240V Circuit Breaker 115V Push Switch Solid State Relay 240V 3A Transistor 2SC372Y Transistor 2SA1015 Y Diode 155176 HD74LS00 HD74LS10P IC TD62503P IC SN74LS06N TE LM555CN IG 7705
219. Fluctuation 10 3 Permissible Extension Cord None recommended NOTE Be sure to ground the machine Do not connect the grounding wire to a gas pipe Make sure the plug is firmly inserted in the outlet Use a dedicated power outlet Do not set anything on the power cord 3 3 31 August 1989 2 ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list USA Europe 1 Editing Sheet 0 0 2 Sort Stack Key Top inside the front cover 3 Sort Stack Key Cover 1FC inside the front cover 4 NECR 5 Cassette Large 6 Cassette Small 7 8 Paper Size Actuator Plate Paper Size Decal 9 Toner Catch Pan 10 Copy Tray 11 Original Holder 12 Operating Instructions English Five languages 0 13 Envelope NECR 14 Multiple Language Decal 0 15 Allen Screw M4 x 60 2 4 1 16 Washer M4 17 Screw Washer M4 x 6 18 Pippet inside the front cover 19 Key Cover Double Sided Original inside the front cover COO OO 3 4 31 August 1989 3 INSTALLATION PROCEDURE 3 1 COPIER INSTALLATION NOTE The platen cover and the original stacker are needed as options if the DF 15 not to be installed Also the copy tray is needed if the sorter is not to be installed When the RDH unit is installed on this copier Optional ROM Type A must be procured and installed in place of the
220. Front Door Switches 31 August 1989 100VAC Distrbution 100VAC to Power Supply When the front door is opened switches 1 2 3 and 4 open and cut ac power to the fusing lamp and all ac components Relay RA1 also controls ac distribution DC Safety Switches Operation Panel DC SAFETY CIRCUITS Power Packs ane 15 sec lamp Safety relay Safety switch Swe 24V VA Transport V2 gt 24 Fork Gat Diy 24 Safe 24 gt v 24 Thermofuse RA 1 b 104 10 CN102 B19 724 Main PCB Fork gate unit Transport unit Safety switch SW8 4 Front door ety switch Switches 7 8 and 9 the 15 second lamp safety relay and the fusing thermofuse will cause RA1 to de energize which interrupts ac power Relay RA1 controls ac distribution If switch 7 8 or 9 is open the Guidance Display indicates that a door is open However if the 15 second safety relay is energized or the thermofuse fails open circuit the Guidance Display will indicate a machine failure and display the appropriate Service Call Code number Safety switches 5 and 6 cut the 24 volts Vp from all power packs 2 109 31 August 1989 15 3 AC COMPONENT CONTROL RAI Door 100VAC H fomer Main Motor MOIOT Cooling 24 Fusing 24 The ac drive PCB controls the main motor cooling fan exposure
221. German struction French struction Italian lt struction Spanish ing Toner Manual Feed LT Manual Feed A3 A4 Misfeed Large Misfeed Small 111 PARTS INDEX August 31 89 Page and Parts No escription index No ness FT5550 D t Page and arts No escription Index No Front Cover FT5570 Front Cover FT5550 sure Lamp Harness Upper Cover Bracket arness Upper Cover Cap ADF arness Right Front Cover arness Operation Panel Ass y Operation Panel Sheet Duplex LT Operation Panel Ass y Operation Panel Sheet Sorter LT Operation Panel Ass y Operation Panel Sheet Finishing LT Instruction Card Holder Panel Sheet Auto Paper Select LT Instruction Card Holder Panel Sheet Enlarge Reduce LT Fixing Bracket Panel Sheet Auto Paper Select A4 Fixing Bracket Main Control Board FT5550 5570 Main Control Board FT5550 5570 IC HN27512G25 FT5550 5570 Panel Sheet Enlarge Reduce A4 Bracket Main Control Board Cover Main Control Board Operating Instructions English A4 Operation Panel Board Operating Instructions German LCD Board Operati Instructions French Optics Board Operati Instructions Italian Optics Board Operati
222. HD74LS10P 1407 0981 TD62503P S L c gt eo D co lt gt AS 1407 2028 N74LS06N 0124 555CN 0412 7705 0909 i lyF 50V 1363 i 10 25V 1366 i 4 25V 1336 i 1000gF 50V 1458 i 0 1 101V ist 1KOH 1KOH 10KOH 100 1 4V 5 3800HM 1 4W 5 4700HM 1 4W 5 4 7 1 4 5 5 6KOHM 1 4W 560KOHM 1 4W 6800HM 1 4W 5 AL OW GE n5 HY WB Ww gt r2 1 XO Zpxo en n August 31 89 4 HARNESS LAYOUT A421 X ANN amp 4 45 2 10 4 HARNESS LAYOUT A421 August 31 89 Index TE Q ty Per Part No Descri ption Part No Description Assembly Assembly Main DC Harness AC Harness 115 AC Harness 220V Tray DC Harness August 31 89 5 MAIN DC HARNESS A421 9 CN 109 es 12 5 MAIN DC HARNESS A421 August 31 89 Index Q ty Per Index Q ty Per N Part No Y art No Description Assembly No r Description Assembly A421 5340 Main DC Harness Mate N Lock Receptacle Terminal Mate N Lock tact Housing Mat Receptacle Housing Receptacle
223. Head Screw M4x8 ilips E Head Screw M4x10 ilips ken Head Screw M4x8 ing Screw M4x6 ing Screw M4x8 Hexagon Headless Set Screw M4x5 Parallel Pin M2x10 3 Retaining Rin Retaini Retaini g Retaining Rin g g in g g 4 ing M5 g 6 g Retaining Rin Ball Bearing 6x10x3mm Philips Screw With Flat Washer M4x8 8 PAPER FEED UNIT 2 A045 A046 August 31 89 8 PAPER FEED UNIT 2 A045 A046 August 31 89 Index Q ty Per Index Q ty Per Part No TU Assembly No pied 22000 Paper Feed Stay Sprocket 15T End Feeler 1 ear 20T End Actuator Bracket 1 Bushing Paper Feed Roller Paper Feed Clutch 8x15x30 1 Spring Pick UP Shaft 1 Spring si Paper Feed Shaft Upper 1 Coupled Gear 17T 50 Feed Guid Paper Feed Roller 1 Coupled Gear 16T 53 Cushion Lower Pick up Guide Cassette Sensor Arm Pick up Guide Lower Bracket Paper Lift Motor Bushing 8mm Lift Motor DC1 69W Paper Feed Roller Bracket 1 Sector Gear Cushion Upper Pick off Bracket Cushion Lower Pick off Bracket Paper Feed Roller 1 Paper Feed Separation Spring Pick up Roller 1 Paper Feed Stay Lower Snap Ring Volume Sensor Shaft Lower Bracket Paper End 1 Bottom Plate Lever Photointerrupter L Type 1 Paper Size Sensor Bracket 1
224. High Definition Lights if the 4th 5th mirror home position sensor remains actuated for 1 83 seconds after the mirror motor turns on Observations At power up the 4th 5th mirror drive rotates clockwise and the actuator leaves the home position sensor If the main switch is turned off and on the drive pulley continues to drive in a clockwise direction until the mirror motor emits a noise and stops at the extreme right Points to Check Confirm that the second scanner moves properly Check CN305 12 on the optics board Check the 4th 5th mirror section optics board and mirror drive motor 2 20 31 August 1989 Code 2D No Encoder Output Definition Lights durnig a copy cycle when the output frequency from the scanner motor encoder is not detected for 490 milliseconds after the scanner motor is energized or if the scanner home position sensor opens or shorts during a copy cycle Observation During a copy cycle the scanner first moves then stops The scanner does not move at all Points to Check Check the scanner drive motor the scanner home position sensor and CN306 2 3 on the optics board 2 21 31 August 1989 4 ERASE 41 OVERVIEW A Lead Edge Erase Margin Side Margins 2 2 mm each For full size copies the total of both side margins is less than 4 mm Lo Original Image Width Lc Charged Width on the Drum Lead Edge Erase Es Side Erase R Paper Lead Edge Registration 0 2 mm A R
225. IC2 to output HIGH This HIGH signal at CN123 2 informs the sorter main board that no paper is present When paper is entering a bin the phototransistor PTr1 turns off This causes the circuit to output a LOW signal to CN123 2 The sorter main board determines that paper is in the bins 14 15 31 August 1989 7 6 Inlet Sensor InletSensor Sorter Main Board 1 cae Sensor WIND Iie The inlet sensor is a photointerrupter When the photointerrupter is not blocked on the connected main board pin becomes 0 volts When the photointerrupter is blocked off it sends a high signal to the main board 14 16 31 August 1989 7 7 Misfeed Check 700 ms Copier Exit Sinsor 2 7 Inlet Sensor 2 Jam Sensor Reset Inlet Sensor Stat 7 350 ms Misfeed Check Timer 1 Reset T10PLS Inlet Sensor Start 7 1440 PLS Misfeed Check Timer 2 cna m MOM eRe 1 27 Misfeed Check Timer 1 B PLC Jam Sensor Misfeed Check Timer 2 The sorter has two sensors which are used to detect misfeeds in the sorter Also the exit sensor in the copier is used to check for misfeeds in the sorter The two sorter sensors each have two misfeed check timers After each misfeed check timer is set starts misfeed check is continuous for the timer period The timer must be reset within the timer period by the appropriate sensor going either ON or OFF as shown in the following ta
226. Index No Index No Timing Belt 120XL 037 Drive Shaft Drive Wire z Right Lift Rod Spring Left Lift Rod Rack Drive Shaft Magnet Catch Plate Worm Gear Fuse 250V 2A Gear 45T Operation Skin Pulley 10T Operation Board Pulley 20T Bushing 10mm Long 7mm Rack Drive Shaft Magnet Catch Ass y Tray Drive Motor LED Sensor 5 Tray Drive Motor Bushing 8mm Tape Decal Terminal 115V Harness Cover E Decal Terminal 115V Front Side Frame Power Supply Cord 220V Front AID Plate Stepped Screw M4 Magnet Collar Decal Power Source 220V Stopper Bar Decal Power Source 220V Spring Plate Stopper Bar Wave Washer Stopper Bar Knob Idler Pulley 20 Stopper Bar Mounting Stud gt Decal English German 220V Front Wire Tightener 1 English German 220V Rear Wire Tightener Decal Terminal 220V Chain Decal Terminal 220V Back Fence Operation Board Mounting Bracket Safety Switch Bracket Hook Clamp Stay Stopper Chain Sensor Bracket ylar 100x19mm Safety Switch Actuator Hook Top Actuator Lever Power Cord Bracket Bottom Actuator Lever Power Supply Cord 115V Drive Motor Bracket Motor Bracket Paper Detect Shaft Support Bracket Rear Support Plate August 31 89 Page and Page and Enders Nos
227. Lead Edge Blank Margin 3 5 2 5 mm The erase unit consists of a PCB with 10 registers and a row of 80 LEDs mounted in a plastic casing The LEDs emit light in the yellow green part of the spectrum The erase lamp performs the following functions lead edge erase side erase trail edge erase image density pattern g and the editing functions Trail edge erase begins after the trailing edge of the copy paper therefore the trailing edge will not appear on the copy 2 22 31 August 1989 4 2 LEAD EDGE AND TRAILING EDGE ERASE The entire bank of erase lamps turns on to erase the drum before and after the image area Leading edge erase overlaps the paper and the image slightly The leading edge margin helps prevent fusing jams by making it easier for the stripper pawls to separate the paper from the hot roller Trailing edge erase turns on about 2 mm after the trailing edge of the copy paper The width of the lead edge margin can be adjusted by SP mode 41 Mode No Function Data Factory Comments Setting 41 Lead Edge Adjusts the 0 15 8 0 6 mm per step Erase Margin lead edge max 4 8 mm to Adjustment margin 4 2 mm During image density detection cycles once every ten cycles the center block of erase lamps turns off long enough for the sensor pattern to be developed 9 4 3 SIDE ERASE Side erase overlaps the image slightly on either side The CPU calculates the side erase margins from the paper size and the selected reproducti
228. Magnetic Clutch Stopper Motor Stay Paper Bank Grip Release Lever Bracket Knob Lock Lever Release Lever Bracket Release Lever Shaft Tention Arm Spring Tention Arm Spring Front Side Fence Transport Rear Side Fence Transport Rear Side Fence Cap Transport Transport Sensor Bracket Left Guide Plate Transport Feeler Bracket Paper Sensor Feeler D Page and Parts No escription Index No Feeler Shaft Paper Sensor Upper Shutter Paper Sensor Right Guide Plate Transport Upper Drive Relay Roller Upper Relay Roller Gear 38T Transport Bracket Spring Magnetic Clutch Stopper Idle Gear Spring Front Transport Bracket Rear Transport Bracket Gear 18T Inner Cover Front Side Fence Front Inner Cover Front Side Fence Rear Inner Cover Rear Side Fence Pulley 19T Pulley 19T Base Plate Slide Rail Paper Bank k Table Guide nector Cover Bracket nector Bracket Sealed Plate Bracket Connector Sealed Plate Connector Angle Safety Switch Bracket Safety Switch Cover Clamp Bracket Harness Guard Bracket Guide Holder Bracket Safety Switch Joint Joint Safety Switch Paper Bank Door Left Table Cover Rear Cover Paper Bank Description Guide Bracket Paper Bank Positioning Bracket Frame Rail Paper Bank Cushion Paper Bank Small Cover Paper Bank Front Cover Front Table Hinge Magnet Catch Ass y Rear Cover Gri
229. N UM 38 No art No Description Light Shiel Shielding M Exposure Gl Exposure Gl Reed Switch Stepped Scr Small Screw Pan Pan Pan Pan Scr 194119 Mylar Front Left ylar Front Center ass Stay FT5550 5570 ass Stay FT5540 Cushion Exposure Glass Slider Lock M3 Head Screw Head Screw Head Screw Head Screw ew M4x8 4 OPTICS 2 A045 A046 EE AJl z E 102 26 2 G9 eA ey ZA 102 BES 24 a C Bee _ 102 eL VES EA gt gt Pre E D 024 7 O 35 4 OPTICS 2 045 046 August 31 89 Q ty Index Q ty Per 5 No Part No Description Assembly No art No Description Assembly 5205 2734 Magnet By Pass Table 0100W ili Pan Head Screw M4x10 A007 1670 ics Right Frame 1 0060W Screw M4x6 15 1087 1 2 15 15 0080W JT i Screw M4x8 A007 1691 ics Fan Filter Bracket 0060 Headless Set Screw M4x6 P A007 1694 ics Fan Flter 40101 111 Screw With Flat Washer M4x10 02 0029 ling Blower AC50Hz 20 5W 60Hz 1 0458 9 9mm 007 1686 ling Blower Bracket 03 2018 er Drive Pulley A007 1810 er Motor Bracket 06 0023 er Motor DC 42W 5215 5230 ointerrupter L Type A007 1806 ner Sensor Bracket A007 1836 Center Pulley Bracket 5442 1798 Hook Scanner Drive Wire 05 0014
230. NER SENSOR HARNESS AND GATE SOLENOID HARNESS A045 A046 August 31 89 fips Q ty Per Q ty Per Part No art No Description Description Assembly AZ40 0004 Photointerruptor Harness 1100 1327 Contact A007 5264 Gate Solenoid Harness 1100 1329 Socket Contact 1102 Connector 1102 1983 Socket Housing 3P 1100 1159 Socket Mate N Lock 1100 1253 Pin Mate N Lock 1102 1396 Connector 2P 1102 1398 Connector 2P 1102 1861 Connector 4 46 DUPLEX ENTRANCE HARNESS AND TONER END SENSOR HARNESS A045 A046 August 31 2 103 103 IN 102 89 CN3 2 105 104 106 107 luus 46 DUPLEX ENTRANCE HARNESS AND TONER END SENSOR HARNESS A045 A046 August 31 89 Index Q ty Per Index ers Q ty Per Part No Assembly Be ee a 1 01 1100 1253 007 5263 Entrance Harness Pin Mate N Lock A007 5204 End Sensor Harness TT 1 Connector 6P Connector 3P Pin Mate N Lock Socket Mate N Lock Connector 3P Connector 3P 47 DUPLEX STOPPER SOLENOID HARNESS INVERTER GUIDE ENTRANCE HARNESS August 31 89 AND LED SENSOR HARNESS A045 A046 103 104 eee L 2 105 06 108 CN2 3 jos 100 47 DUPLEX STOPPER SOLENOID HARNESS INVERTER GUIDE ENTRANCE HARNESS Auqust 31 89 AND LED SENSOR HARNESS A045 A046 g Q ty Per Assembly m P Part No D
231. No Description Index No Transfer Safety Switch Upper Paper Size Harness Transport Sensor Harness Inverter Guide Entrance Harness Inverter Guide Entrance Harness Home Sensor Harness Home Sensor Harness Harness Home Sensor Duplex Stopper Solenoid Harness Duplex Stopper Solenoid Harness Duplex Entrance Harness Duplex Entrance Harness Gate Solenoid Harness Gate Solenoid Harness ED Sensor Harness Sensor Harness Power Pack Harness Power Pack Harness Power Pack Charge amp Bias Drum Heater Ssr Board AC Drive AC Descent Harness 115V Harness AC Descent 220 240V Grounding Wire AC Drive Board Harness AC Drive Board Harness Fusing Unit Harness Fusing Unit Harness Mylar Seal Slide Cover Key Top Timer Key Top Interrupt Key Top Start Key Top Guidance Panel Sheet Zoom Panel Sheet LT 129 August 31 89 TR Page and Parts No escription Index No Single Side Panel Sheet LT Duplex Panel Sheet LT ADF Sheet LT Sorter Sheet LT Zoom Panel Sheet A3 Single Side Panel Sheet A3 Duplex Panel Sheet A3 ADF Sheet A4 Sorter Sheet A4 Operation Panel Sheet A3 Capacitor Bracket AC Drive Bracket Noise Filter Bracket Power Supply Cord Bracket Bracket Transformer Transport Fan Bracket Transport Fan Support Bracket Solenoid Cover Bracket Total Counter Bracket Main Control Boa
232. OARD PCB n This copier uses 80 LEDs in the erase lamp unit The large number of LEDs allows precise control of the side erase margins Shift register drivers control the LEDs Initially the ENABLE signal LOW active sets all shift registers to OFF Then the main board sends ERASE DATA to the shift registers from CN102 A17 After the ENABLE signal goes back to HIGH the shift registers start accepting data The data bit for LED 1 is set at each CLOCK pulse If the data line is HIGH at the time of the CLOCK pulse the shift register is set to turn the LED on if it is LOW the shift register is set to keep the LED off The data in the shift registers is shifted right one position each clock pulse so it takes 80 CLOCK pulses to set the shift registers for all the LEDs After all data bits have been sent the main board sends the LATCH signal to turn on the erase lamp unit Simultaneously the shift registers turn on all LEDs for which data bits have been set To turn off the erase lamp unit the ENABLE signal is reset to LOW 2 25 31 August 1989 5 DEVELOPMENT 5 1 OVERVIEW When the main motor sends a signal to the SSR PCB the development motor is energized When it turns on the paddle roller A and development roller B 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 deve
233. Oc a Nor RR Ra 5 51 7 4 Uneven Exposure 5 52 7 5 Light Intensity 5 53 7 6 ADS Reference Voltage 0 5 54 7 7 ADS Voltage 5 55 7 8 ADS Operation Checking 255252 eU ers 5 56 7 9 Erase arin roe abd an alo x R8 RR n 5 56 7 10 Registration 5 57 7 11 Side to Side Registration Adjustment 5 58 CORONA xx fc tense wre er are wre Boe cR E rk ee 5 59 8 1 Charge Corona Wire 5 59 8 2 Pre quenching Corona Wire Replacement 5 61 8 3 Transfer and Separation Corona Wires 5 62 8 4 Charge Cleaner Drive Wire 5 63 8 5 TC SC Cleaner Drive Wire 5 64 8 6 Drum Current Adjustment 5 65 8 7 Charge Corona Current 5 67 8 8 Transfer Corona Current 5 68
234. Open Short Open Short Open Short Open Short Open Short Problem When the Start key is pressed in duplex mode paper is fed to the inverter section 80 mm after the leading edge of the paper passes the inverter exit sensor D on the Misfeed Location indicator lights D on the Misfeed Location indicator lights when the main switch is turned on When paper is stacked in the duplex tray in duplex mode D on the Misfeed Location indicator lights After completion of first side copying in duplex mode the paper is not fed from the duplex tray when the Start key is pressed to begin second side copying The copy paper in the duplex tray is not detected Instead the paper is fed from the normal paper feed station and is stacked in the duplex tray Second Side Copy is indicated when duplex mode is selected When the main switch is turned on the joggers move all the way in Six seconds later SC 82 is indicated When the main switch is turned on the joggers move all the way out Six seconds later SC 82 is indicated The copy image is too light The copy image is too dark Oil End is not indicated when oil runs out Oil End indicator stays on Toner Overflow is not indicated when the toner collection bottle is full Toner Overflow indicator stays on 13 10 Name 31 August 1989 Problem Condition Manual Feed Paper End CC Cleaner Home Position SC Cleaner Home Position Platen Co
235. Open Short Open Short Open Short Open Short Open Short Open Short 31 August 1989 Problem When the start key is pressed the copy paper is fed to the fusing rollers 100 mm after the leading edge passes through the fusing rollers on the Misfeed Location indicator lights B on the Misfeed Location indicator lights when the main switch is turned on When the start key is pressed the paper is fed through the fusing rollers 70 mm after the leading edge passes the exit sensor on the Misfeed Location indicator lights C on the Misfeed Location indicator lights when the main switch is turned on Toner end is not detected when toner runs out SC 61 is indicated 3 seconds after the Start key is pressed The wrench mark is indicated and toner supply switches to fixed supply mode When the main switch is turned on the scanner moves 180 mm and SC 22 is indicated When the main switch is turned on SC 22 is indicated SC 29 is indicated 3 seconds after the main switch 15 turned on SC 28 is indicated 3 7 seconds after the main switch is turned on SC 2B is indicated 3 seconds after the main switch 15 turned on SC 2A is indicated 0 3 seconds after the main switch 15 turned on 13 9 31 August 1989 Name Inverter Exit Duplex Entrance Duplex Paper Jogger Home Auto Density Oil End Toner Overflow Condition Open Short Open Short
236. Pin 12 Spring Pin 3x18mn Parallel Pin M3x1 Flat Washer M5 Toothed Washer M8 Bushing 4x5 Hexagon Nut M8 Retaining Rin Retaini in Retaini in Retaini Retaini Retaini Retaini Retaini Retaini Retaini Retaini Retaini Retaini Retaini CO CO CO CO CO WwW CO CO Retaini Retaini Retaini Retaini Retaini Retaini Z2 m ur ub um qus hone uuu d gu OW CO Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q QoQ Qa qa QB QQ oa QB QB a 138 August 31 89 P Page and ses nos NA Ball Bearing 15x28x7mm Page and Index No Parts No Description 0060E ini 0060E 00708 00708 00708 00708 01008 0120 0200 0050 0607 ing 6x7 3008 Ball Bearing 5 5 QQ QQ 51 108 g 55 1 21 1 23 1 35 1 51 1 dT 41 1 Nylon Washer Collar 6 5x20mm 5 5 5 5 Spacer 5 5 Spacer 6x13xlmm 5 QQ QQ 5 Philips Screw With ith ith ith ith ith ith ith ith it
237. R ell ee he PU as I ee BRI SYMBOL e SYMBOL p SYMBOL B SYMBOL NO NO NO NO NO NO NO NO D100 110 0100 108 C100 119 C110 121 D101 110 Q101 109 C101 120 111 121 D102 110 0102 108 118 C112 120 D103 110 0103 109 103 117 C113 120 D104 u m 114 10 0105 110 C105 117 C115 120 0106 110 C106 118 C116 120 D107 110 C107 120 C108 120 C109 120 puso e mr 7 52612 4 TRAY CONTROL BOARD 5897 August 31 89 ae Dake Ne Description 2 Es Part No Description 912 5103 Tray Control Board 01 1103144 SEDE 02 1103 1729 ector 03 1103 1730 ector 04 1103 1739 ector 05 1103 1743 ector P 06 1103 1757 ector P 07 1 1047 lid State Relay 240V 3A 08 1400 0072 sistor 2SC372Y 09 1400 0135 Transistor 2SA1015Y 0 1401 0825 Diode 155176 1 1407 0520 0741500 2 1407 0622 2741 51 0 3 1407 0981 D62503P 4 1407 2028 LSO6N 5 1408 0124 555CN 6 1408 0412 7705CP 7 1604 1363 itor 10 25V 8 1366 itor 47pF 25V 9 1378 itor 1MF 50V 20 1336 itor 1000eF 50V 21 1458 itor 50V 22 1611 4101V istor 1 14 V 5 23 1611 4102V istor 1 4W 5 24 1611 istor 10KOHM 1 4V 5 25 1611 istor 100KOHM 1 4V 5 26 1611 istor 4700HM 1 4W 5 21 1611 istor 4 7 1 4W 5 28 1611 5 6KOHM 1 4W 5 29 1611 560KOHM 1
238. R154 163 R164 157 1 104 7 16113 125 R105 167 R115 155 R125 160 R135 158 R145 161 R155 158 R165 161 16105 121 127 R106 169 R116 161 8126 160 R136 163 R146 161 R156 158 R166 161 12106 6 15 109 107 172 R117 164 R127 164 R137 163 R147 161 R157 161 R167 161 1 106 109 1216 128 R108 134 R118 155 R128 164 R138 161 R148 161 R158 161 R168 161 10107 174 16117 119 109 167 R119 161 R129 164 R139 161 R149 161 R159 161 R169 161 12108 129 R110 110 R120 161 R130 164 140 161 150 161 160 161 8170 157 LED TEST POINT DIODE NOISE FILTER OSCILLATOR TRANSISTOR SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL m SYMBOL SYMBOL INDEX SYMBOL INDEX SYMBOL NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO R171 157 R181 161 LED101 118 101 NF101 140 05 101 0101 14 172 157 R182 157 5 9 180102 118 102 101 0102 117 e 9102 115 R173 157 R183 157 LED103 118 TP103 101 0103 117 Soe R174 157 R184 157 LED104 118 TP104 101 0104 17 R175 161 R185 157 SWITCH LED105 118 TP105 101 0105 117 R176 161 R186 165 SYMBOL LED106 118 TP107 101 R177 157 R187 165 NO R178 57 R188 165 R179 157 R189 165 50101 113 R180 177 R190 181 54102 113 3 SORTER BOARD A411 August 31 89 NT ty Per Index ty P Part No Desc tion Q ty RN Q ty Per ripti Assembly No
239. RIGO RICOH 5540 5550 5570 SERVICE MANUAL RICOH COMPANY LTD Table of Contents OVERALL MACHINE INFORMATION ses x Meee Reider eat ade we 1 1 2 GUIDE TO 5 1 4 2 1 1 4 22 OPERATION 1 6 2 3 INDICATOR 1 8 2 4 GUIDANCE 1 9 3 COPY PROCESSES AROUND THE DRUM 1 10 4 COPY CY CEE ca er xo eae 1 12 5 PAPER PATH a crewed oe et eques ORE eve 1 13 5 DRIVE LAYOUT eek 1 16 7 MECHANICAL COMPONENT LAYOUT 1 17 8 ELECTRICAL COMPONENT LAYOUT 1 18 9 ELECTRICAL COMPONENT DESCRIPTIONS 1 23 10 OVERALL MACHINE CONTROL 1 28 11 AND DC POWER DISTRIBUTION 1 29 DETAILED SECTION DESCRIPTIONS uta 2 1 1 1 SELENIUM DRUM 5 2 1 1 2 HANDLING THE 2 1 1 3 DRUM HEATER 2 3 2 DRUM CHARGE
240. RNESS LAYOUT A420 August 31 89 Index Q ty Per Index verd Q ty Per Assembly Assembly A420 5273 Vertical Transport Harness A420 5276 Front Paper Bank Harness A420 5274 Main Paper Bank Harness A420 5275 Rear Paper Bank Harness 17 8 VERTICAL TRANSPORT HARNESS A420 August 31 89 103 b 43 109 106 106 Eum E 114 115 2 104 12 8 VERTICAL TRANSPORT HARNESS A420 Index No Part No Description Q ty Per A420 5273 ertical Transport Harness Assembly 19 August 31 89 Index Q ty Per Assembly Socket Mate N Lock Fastening Receptacle Pin Mate N Lock Receptacle Terminal Contact tact tact Contact nector 3P eptacle Housing 1P nector 2P RED nector 3P nector 14P nector 10P nector 8P ector 9 FRONT PAPER BANK HARNESS A420 Index Part ipti Q ty Per Assembly A420 5276 Front Paper Bank Harness Q ty Per Assembly Part No Description Socket Mate N Lock Receptacle Terminal Contact tact nector 3P nector 2P nector 3P eptacle Housing 7P nector 3P ector ector 13P ector BDO BD LH HH HH LH ector 21 10 MAIN PAPER BANK HARNESS A420 August 31 89 Te 102 CN 46 ids 104 92 CN 452 109 105
241. ROM originally installed on the copier main board See the RDH installation procedure The ROM that comes with the RDH unit as an accessory is only to be installed on the F30 A007 or F31 A01 9 European version The guidance ROM kit option is needed if one of the following optional languages is wanted on the guidance display Option ROM Standard ROM 0 Swedish 0 Japanese 1 English 1 English 2 Danish 2 French 3 Norwegian 3 German 4 Finnish 4 Italian 5 Dutch 5 Spanish The English in the optional and the standard ROMs is the same 3 5 31 August 1989 1 Remove all strips of tape and open the front cover 2 Remove the strips of tape as follows Non duplex model B Duplex model 3 Remove the transport unit support cushion 0 4 Remove the plastic wedge between the upper and lower registration rollers 3 6 31 August 1989 6 Remove the rear cover 4 screws the left cover A 2 screws and the scanner lock plate B 1 screw NOTE Reinstall the screw for future use Do not throw away the scanner lock plate it must be reinstalled before the copier is transported long distances 7 Remove the main PCB shielding plate 2 screws and move the jumper connector JPSW 191 on the timer PCB D from the upper printed OFF to the lower position Then reinstall the removed covers if no peripherals are to be installed 3 7 31 August 1989 E G
242. Roller D uU ZU ae 1 M LAA AUT mE QR ale GU me 7 ANS Drive Mechanism The duplex positioning roller A is driven by the main drive chain Power is transferred from the main drive chain to the positioning roller through the positioning roller gear B the positioning drive shaft C the positioning roller pulley D and the rubber belt Up and Down Mechanism The positioning roller release spring lifts the positioning roller 7 millimeters 0 29 above the jogger bottom plate and holds it in this position so that it does not interfere with the lateral stacking process When a sheet 15 fed into the duplex tray the positioning roller solenoid F energizes pulling the positioning roller down to fully advance the copy paper up to the duplex stopper 2 102 31 August 1989 14 4 DUPLEX TRAY SENSORS Duplex Entrance Sensor When paper enters the duplex tray the positioning roller bracket A is in the low position and the actuator roller B is resting on the jogger bottom plate When the paper passes under the actuator roller the friction of the paper turns the actuator roller This rotation moves the entrance actuator C up and down actuating the entrance sensor There are several slots in the entrance actuator C that activate the sensor D successively when the actuator roller rotates If there are more than two change
243. S Item Configuration Copying Process Original Original Size Reproduction Ratios Reproduction Ratio Change Warm Up Time Copy Paper Copying Speed First Copy Time Copy Number Input Specifications Desk top Dry electrostatic transfer system Book Sheet Maximum 11 x 17 5 reduction ratios 3 enlargement ratios zoom from 60 to 155 in 1 steps A4 Version 5R 93 82 75 71 and 65 115 122 and 141 Letter Version 5R 93 85 77 74 and 65 3E 121 129 and 155 Maximum 6 5 seconds Within 5 minutes Room Temp 20 C 68 F Size Maximum A3 11 x 17 Minimum 5 x 8 Weight war 52 52 g m to 157 g m 14 Ib to 42 Ib A4 L A5 S x 11 x Fag 22 438 38 4 F34 T F33 3 8 seconds A4 or 8 7 x 11 1st cassette F34 4 2 seconds A4 or 8 x 11 1st cassette Number keys 1 to 999 count up or count down 1 1 31 August 1989 Special Functions Manual Image Density Selection Automatic Reset Paper Feed Paper Feed System Exposure System Lens Light Source Photoconductor Charge System Erase Development System Development Toner Replenishment Toner Consumption Auto duplexing 8 modes e Margin adjustment 0 to 16 mm 5 8 on both sides Auto image density selection ADS Automatic paper selection APS with
244. S32FP IC HD74LS74AFP Ttl HD74LS107FP IC HD74LS138FP IC SN74LS27NS IC SN74LS11NS 5 5 Page and Parts No ETAT E Relay DC24V Transistor 25 1121 Transistor 25 2618 bh Transistor 28C2712Y Transistor Array PU4310 60V3A Transistor Array 25 2883 Rectifier S4VB40 Transistor 2501773 iode 155176 iode 155181 iode 05 1 1 ransistor 2SD1006 iode V06C IC N74LS373NS IC N74LS373NS IC TC4050BF IC TD62308F IC TD62308F IC TD62304F IC UPD78C10GF IC UPD78C10GF IC SN74LS07NS P 5 ise 5B GSS ak ER E Rr dee Oo r3 Do 99 Zener Diode 720 Diode 555006 Diode 555666 iode 155184 iode 12V lt gt D71054GB N74LSO6NS Ic SN75157P IC SN75158P IC TMP 82C51AF 2 LSI TMP82C55AF 2 IC NJM555 TD6F62303F IC TD62308AF IC 74HC157F 1C DP71051GB 3B4 IC RF5C60 IC MPD4711 IC 75339 1 HA17903E IC AN6914S TL7705CE TL092 iode iode iode RD39P iode RD6 2 IC TLP541G IC TG8D 600V 16A Bcr IC 5450 Rectifier 1J4B42 IC BCR8DM IC M51951M IC SN7406NS IC LS00 IC LS00 IC LSO4FD IC LSO4FD Ttl HD74LS08FP rmm Do 1 CO NYO Ceramic Oscillator 1
245. Scanner Drive Wire 05 0002 Guide Rod Scanner 007 1848 Guide Rod Cleaner 16 1019 Cushion Guide Rod A007 190 001 501 501 Rear Spring Plate 2nd Mirror 5205 1694 Adjusting Cam Start Lever A007 191 A007 192 2nd Scanner 2nd Mirror 1 4 0 Front Spring Plate 2nd Mirror 1 2nd Scanner Slider Scanner Guide Plate 001 501 15 3rd Mirror Rear Spring Plate 3rd Mirror 5 5 03 5012 Front Spring Plate 3rd Mirror 5 4 9 Seal 6x32x32 007 1815 Support Bracket Optics Frame A007 Scanner Home Sensor Bracket 5205 ED Sensor Type T A007 Left Pulley Bracket AA06 Spring Wire Tightner 5216 Stepped Screw Slider Lock 5 OPTICS 3 A045 A046 E ugust 31 32 12 dogs 107 2 A 2 We ts de VELAT 24 IM ees ESS ou c Ling SSS Ee oma E T 59 63 5 OPTICS 3 A045 A046 August 31 89 ee Q ty Per Q ty Per P art No Description Part No Description Assembly 1093 Seal 3x25x170 1 15 0015 j Shielding Mylar Lens 1791 Mirror Cover 1 AA15 2012 Seal 4x4x40 1092 1 3x42x270 1 1694 j Roller lst Scanner 1094 1 2 50 48 15 2009 Seal 4x5x84 2007 Brush Seal 6x7x144 1 15 2010 Seal 5 10 64 2008 Seal 5x6x40 1 15 2011 Seal 4x5x25
246. Stays Low Definition Lights if the lens is moving towards enlargement and the H P sensor stays at a LOW signal level for longer than 3 82 seconds Observations 1 The lens always moves toward enlargement at power up 2 The lens is to the right of the H P sensor and the lens motor does not turn on Points to Check Check if the lens is moving properly Check CN305 9 on the optics board Check the lens drive section optics board and lens drive motor Code 29 Lens Home Position Sensor Stays High Definition Lights if the lens is moving toward reduction at power up and the H P sensor stays at a high signal level longer than 3 82 seconds Observations 1 The lens always moves toward reduction at power up 2 The lens is to the left of the H P sensor and the lens motor does not turn on Points to Check Confirm that the lens is moving properly Check CN305 9 on the optics board Check the lens drive section optics board and lens drive motor 13 3 31 August 1989 Code 2A 4th 5th Mirror Home Position Sensor Stays Low Definition Lights if the 4th 5th mirror sensor does not actuate within 1 83 seconds after the mirror motor is turned on Observations At power up the 4th 5th mirror drive rotates counterclockwise past the home position sensor If the main switch is turned off and on the mirror motor emits noise and stays at the home position Points to Check Check if the 4th 5th mirror assembly is moving properl
247. Then remove the seven connectors A 2P black 2P white 2P yellow 3P black 6P black 3P white 3P red from the jogger unit 4 Remove the front cover 2 knob screws B and the lower inner cover C 2 screws 5 Remove the transport unit post D 2 screws Then remove the toner catch pan E and the settler bar 6 Remove the knob screws then remove the jogger unit F 2 screws NOTE When reinstalling the jogger unit insert it halfway then confirm from the rear that the gears mesh 5 42 31 August 1989 6 4 Duplex Pick up and Feed Roller Replacement 1 Open the front cover 2 thumb screws 2 Remove the toner catch pan the settler bar and the duplex paper actuator 1 snap ring 3 3 Remove the pick up roller A and the feed roller B 1 snap ring each CAUTION The duplex feed and cassette feed rollers are not Interchangeable The duplex feed roller must be installed with the beveled edge of the one way bearing to the front 5 43 31 August 1989 6 5 Duplex Separation Roller Replacement D K N OG ra AS y 2516 aT 1 Remove the jogger unit Refer to Jogger Unit Removal Then remove the separation roller cap A 2 Remove the separation roller B 1 snap ring and the slip clutch 3 Lubricate the slip clutch with Mobil Temp 78 4 Install a new separation roller CAUTION The rollers and slip clutch for the duplex and the rollers for the
248. Turn on the main switch and adjust the corona current by turning VR DC1 D on the TC SC power pack Wait 30 seconds for the current to stabilize Normal dc 01 8 D2 7 To turn on the separation corona turn on the switching PCB dip switches corresponding to D1 and D2 on the TC SC power pack PCB The silk screen printed on the TC SC power pack PCB is correct 8 Adjust the corona current by turning VR E on the TC SC power pack Wait 30 seconds for the current to stabilize 9 Remove the drum shoe and reassemble 10 Check copy quality 5 70 31 August 1989 8 10 Pre Cleaning Corona Current Adjustment Optimum Adjusting Values F O N AC 46 0 2 0 DC 24 1 0 uA Reinstall the cleaning unit and position the drum shoe at the center of the shaft so that the axis of the current sensing plate A is aligned with the PCC wire B Select the ac 200 range on the digital multimeter To turn on the PCC turn on the switching PCB dip switch corresponding to PCC on the TC SC power pack PCB The silk screen printed on the TC SC power pack PCB is cor rect Adjust the corona current by turning VR AC C on the PCC power pack Wait 30 seconds for the current to stabilize Turn off the main switch and select the dc 200 range on the digital multimeter Turn on the main switch and adjust the corona current by turning VR DC D on the PCC
249. U The main components in this mechanism are the bin drive motor A the helical wheels B the bin sensor and the bins C themselves Pins on either side of each bin fit into the slots of the bin holder D The pins slide up and down in these slots A timing belt turns both helical wheels The rear pulley has a slot which detects when the helical wheel has rotated 360 degrees The helical wheels lift and lower the bins They also lift the bin holder itself by lifting up the bottom bin The roller drive motor E drives the exit rollers F and the transport rollers G When the copy activates the 5 exit sensor the CPU sends a signal to the sorter to turn on the roller drive motor It turns off shortly after the paper exit sensor is deactivated 9 6 31 August 1989 4 BIN HOME POSITION E The bin home position sensor A is located on the sorter frame towards the front It is deactuated by the bin holder B when all bins are lowered The CPU detects the home position by monitoring this sensor when sort mode or stack mode is released Every time the helical wheel C turns 360 degrees the actuator of the bin sensor D also turns 360 degrees This provides the CPU with off timing for the bin drive motor 9 7 31 August 1989 5 BINS Rear View The proof tray A and the twenty bins are all basically the same Formed out of thin flexible steel plate they have spacers B on the left end to
250. W ied SOrteF Adapter MX 2 Multiple Language Decal 220 240V 1 Envelope 115V only Some older copiers may have incompatible EPROMs When the sorter cannot be enabled by setting SP71 check the EPROMs on the copier main board and the operation panel board If the copier uses the following EPROM part numbers they must be changed A007 5103 EPROM IC 103 on the main board A007 5145 EPROM IC 821 on the operation panel board A007 5146 EPROM IC 822 on the operation panel board A007 5147 EPROM IC 823 on the operation panel board The new EPROMs can be ordered a set A007 9502 15 bin Sorter ROM kit 14 19 31 August 1989 8 2 Installation Procedure A ARN N 0 Qa 2 lt HA Pu gt MIL 1 Remove the tape holding the upper cover A 2 Remove the two strips of tape holding the relay guide plates B and take out the cushion block C 3 Remove the shipping retainer D from the bottom of the vertical guide unit E 1 screw 4 Open the upper cover and remove the tape holding the vertical guide unit 5 Take out the two cushion blocks F holding the vertical guide unit and the shipping retainer 14 20 31 August 1989 B 6 Turn off the main switch of the copier 7 Remove the rear A and left covers B of the copier 6 scre
251. Zoom UP Key Top Zoom Down Key Top Key Top Point Main Corona Wire 10pcs set Platen Cover Sheet Silicone Grease G40M Actuator Pick off Pawl Bias Roller Blade Left Cover Option IC 272566 25 272566 25 272566 25 Fiber Connector 2 174135 1 27512625 Power Supply Cord 250V 10A 220 240V ushing 8mm ushi 8mm ushi 8mm mm ushi ushi B B B B B B B B B B QQ 131 Bushing M6 Magnet Catch Ass y Magnet Catch Ass y Registration Drive Spring Bushing 6x8x4mm Bushing 6x8x4mm Thermistor Spring Thermofuse Bracket Sprocket 24T Sprocket 12T Chain Tightener Spring Fusing Release Lever Adjusting Cam Start Lever Adjusting Cam Start Lever Seal 14mm Mylar Seal Base Spring Guide Gear 23T Paper End Actuator Bracket Paper Lift Motor Bracket Paper Lift Motor Cassette Sensor Arm Spring Spring Coupled Gear 161 53 Coupled Gear 161 53 Coupled Gear 171 50 Coupled Gear 171 50 Shaft Paper Guide Plate Spring Paper Guide Plate Bushing Upper Registration Roller Magnet By Pass Table Magnet By Pass Table Cushion Lower Pick up Guide Cassette Sensor Arm Upper August 31 89 iod Page and Parts No escription Index No August 31 89 Page and ED Sensor Type
252. a Us e ee 4 1 2 SERVICE TABLES 4 4 2 TeSt cisci var cs OR ROCCO RR 4 4 2 2 Variable HesiSlOlS soe drew cw Ten CR Aw a asi ear RM RC 4 4 2 3 DIP SWHCh Tables E ERE IO E ERES 4 5 24 User Code Table DA D Sue Eh saan ees 4 5 2 5 Service Program SP 8 Data Input Guide Table 4 6 3 SERVICE PROGRAM MODE OPERATION 4 7 3 1 Service Program 5 4 7 3 2 Change Adjustment Values or 4 7 3 3 Memory Clear RAS hasan ear deen eke dae tees 4 8 3 4 Service Program Mode Table 4 10 3 5 Language Code Table ton Rae Sek es eee EE ERR 4 17 4 SPECIAL TOOLS AND 4 18 5 SERVICE 2255522255525 4 19 5 1 Handling The o o e 4 19 5 2 Charge tent 4 19 33 Erase LOM Dik al aan we e ed 4 19 5 4 irene ie wesley memes 4 20 5 5 Development 4 20 5 6 Transfer and Separation 4 21 5 7 Glea
253. a e eo cs eo ae oso Cali ln et ee 5 24 Fusing Unit Reli oVal 5 24 4 2 Oll Blade Heplacelie bs adeo tot t rh e D t Eb te EAR CR 5 25 49 Thermistor ss que cem ope um eo R CUBE E 5 26 4 4 Thermofuse 5 27 4 5 Hot Roller Stripper 5 28 4 6 Hot Roller 5 29 4 7 Pressure Roller 5 32 4 8 Entrance Guide Height 5 33 4 9 FUSING Pressure 3s eee Me xe 5 34 4 10 Hot Roller Temperature 5 35 4 11 Idling Period 5 35 PAPER FEED ac aba T CR CRT CRURA GERUNT CR EET 5 36 5 1 Pick up Paper Feed and Separation Roller 5 36 9 2 Transporp Unit Removal 5 37 DUPLEX mca ee 5 39 6 1 Invertor Unit Removal udo Ron i RR NER CR e dio ot e P RECHT UR 5 39 6 2 Duplex Transport and Fork Gate Units 5 40 6 9 Jogger Unit Removal ceu ARRIERE 5 42 6 4 Duplex Pick up and Feed Roller
254. ad Roller Lower Transport Roller Gear 622 Gear 462 Bushing 2 Motor Bracket Motor Screw 2 Interface Harness Grounding Wire 115V Grounding Wire 220 240V Harness Clamp Shielding Plate 2 DECAL AND DOCUMENT A952 August 31 89 E When the red light is on check the 1 eA Anarvatinn nanai When the red and green lights are lt SEB blinking turn the copier off and 3 When the green light is blinking reinsert Tm the job shest into the Menu Reader MU When the red light is blinking confirm 4 that the job sheet is filled out correctly 7 co When the green light is on the Menu 9 Reader is ready gt 2 DECAL AND DOCUMENT A952 August 31 89 Q ty Per Index set Q ty Per Assembly No Part No Description Assembly Description A952 1003 Indicator Decal English A952 2001 Indicator Decal Multi PARTS INDEX August 31 89 Page and Page and E A952 1001 Upper Cover L 5060M Philips Pan Head Screw M2 5x6 A952 1003 Indicator Decal English 0025 Toothed Washer M2 5 A952 1 Indicator Decal English 0025B Flat Washer M2 5 A952 1 Upper Cover A4 0020B Retaining Ring M2 A952 11 Menu Sheet Table LT 0030B Retaining Ring M3 A952 11 Menu Sheet Table 4 1185 Philips Truss Head Screw M4x8 A952 11 Le
255. af Spring 2560B Tapping Screw M2 5x6 A952 1 Shaft Upper Transport Roller 2580B Tapping Screw M2 5x8 A952 1152 Upper Transport Roller A952 1160 Motor Control Board A952 Sheet Read Roller A952 1162 Bracket Sheet Read Roller A952 1163 Spring Sheet Read Roller A952 1171 Lower Transport Roller A952 1172 Gear 622 A952 1173 Gear 462 A952 1174 Bushing A952 1176 Motor Bracket A952 1177 Motor Screw A952 1203 Lower Cover A952 1204 Interface Harness A952 1205 Grounding Wire 115V A952 1207 Shielding Plate A952 1209 Grounding Wire 220 240V A952 1250 Velcro A952 1251 Harness Clamp A952 2001 Indicator Decal Multi A952 2001 Indicator Decal Multi A952 9500 Sheet Read Boards amp Motor e c
256. ally the cleaner reaches the rear endblock in about 10 seconds but the motor stays on for 20 seconds to ensure that the cleaner moves the full distance Then the motor reverses to drive the wire cleaner to the home position The motor turns off when the cleaner activates the home position sensor D If the home position sensor is not activated within 20 seconds after reverse drive is initiated the CPU stops the motor and adds 1 to the count stored in SP mode 121 SC85 and 86 Copies can still be made and there is no service call indication on the operation panel Note SC 85 gt The home position sensor does not turn ON SC 86 gt The home position sensor does not turn OFF 2 5 31 August 1989 2 3 CHARGE CORONA POWER PACK 5V DC P GND 4 1 24V Vp 9 Front Door Safety Sw X T e www wawy 527 Main PCB TC SC P P Charge W5 r CNi i CNi 5 Converter X CN101 A20 7 2 5 The circuit operation for the charge corona begins with the input of 5 volts Vc at CN2 3 This voltage powers the LED of the photocoupler Additionally 24 volts Vp enters the power pack at CN1 1 This power supply is used to produce the high voltage corona This voltage is interrupted if the front door safety switch opens The charge corona turns on 260 milliseconds before the lead edge of the copy is detected by the registration sensor A LOW signal from t
257. and atmospheric pressure The drum current should be checked and adjusted only when the corona power pack is replaced or the copy image is out of specification This is because each corona unit is adjusted to a range of environments in the factory CAUTION Make sure that the main switch is turned off when you change the range on the digital multimeter otherwise the multimeter may be damaged Make sure that the main switch is turned off when you touch the drum shoe ww w ww w w w wv Y V v 1 Turn off the main switch and remove the following parts Drum cover Charge corona unit T S corona unit cover T S corona unit T S corona paper guide Drum stay Pre quenching corona unit Cleaning unit Development unit Drum flange Drum cover it with the protective sleeve Drum guide A Rear cover 9 65 31 August 1989 2 Clean all corona units including the corona wires 3 Disconnect the connector A on the main motor so that the drum shaft does not rotate during adjustment 4 Plug a switching PCB B into CN3 of the TC SC power pack PCB C Confirm that the DIP switches face the paper feed control PCB 5 Install the drum shoe and adapter on the drum shaft with the lip to the rear Route the shoe lead wire out through the development unit opening 6 Connect the positive lead of the digital multimeter to the red lead D Connect the nega tive lead of the digital multimeter and the black lead
258. and code 21 is illuminated Observation The scanner is out of home position when the print key is pressed Points to Check Check that the scanner is moving properly Check CN306 2 and CN306 3 on the optics board Check the scanner drive wire and the scanner drive pulley screws 2 17 31 August 1989 Code 22 Scanner Home Position Sensor Stays High Definition Lights if the scanner home position sensor is open at power up Observation Scanner eventually moves to the extreme right as on off key is activated until code 2d is displayed Points to Check Check that the scanner is working properly Check CN305 3 on the optics board Code 24 No Home Position Signal Definition Lights if the main board does not receive the H P signal from the optics board within 20 seconds after the scanner return signal Observation Code 24 is displayed 20 seconds after power up Points to Check Check 106 5 and 6 on the main PCB Check CN304 4 and 5 on the optics board Code 25 Scanner Home Position Sensor Stays Low Definition Lights if the scanner home position sensor is shorted at power up Observation scanner moves to the extreme left at power up Points to Check Check CN305 3 on the optics board 2 18 31 August 1989 Code 28 Lens Home Position Sensor Stays Low Definition Lights if the lens is moving toward enlargement and the H P sensor stays at a LOW signal level for longer than 3 82 seconds Obser
259. ate Spring Discharge Roller Snap Ring Shaft Floating Roller Sensor Pad Shoulder Screw M5 Roller Cover Center Roller Original Feed Roller Timing Belt Spring Detent Arm Upper Separation Roller Lower Separation Roller Separation Roller Pulley Solenoid Pin Solenoid Pin Collar Spring Original Stopper Roller Relay Roller Shaft Mylar Original Guides Belt Stay Separation Roller Shaft Eccentric Cam Shaft August 31 89 Page and Page and Parts No D No NYO NBO NO WH MH HO NH Ln Eccentric Cam One Way Bearing Lever Adjusting Plate Feed in Stopper Registration Roller Gear 24T Pulley 25T Gear 24T Clutch Spring Clutch Sleeve Release Lever Shaft Front Release Lever Rear Release Lever Collar 6mm Pick up Roller Bracket Pick up Roller Shaft Pulley 24T Feed Roller Shaft Gear 45T Sensor Actuator Right Stay Feed in Sensor Feeler Pulley 15T Timing Belt Tightener Tightener Stud ing Pulley 79T Pulley 30T Timing Belt MM63 Timing Belt P2M 208 Gear 19T Gear 19T Solenoid Bracket Stopper Lever Release Lever August 31 89 Parts N D Mm Page and Page and TONS Parts Description Index No Clutch Lever 918 3394 Seal 15x30mm 5 13 Release Arm 5918 3395 Front Belt Unit Plate 9
260. ate Anti Static Brush 42 15 1042 Seal 3 5 142 Anti Static Brush Development Unit 43 15 1044 Seal 3x8x40 Entrance Seal Retainer 1 44 15 1045 Seal 3 5 41 Right Development Seal 1 45 15 1049 Seal 2 17 94 Seal Plat Upper Side Plat 46 A007 3075 Side Plate Bracket Dev Unit Seal 3x27x39 1 47 15 1050 Seal 2x12x64 Front Upper Side Plat 1 48 AA13 2020 Spacer 8 5x20x0 5mm Separator Seal Rear 1 49 01 3092 Gear 24T Bushing 6mm 50 A007 3126 Bearing Retainer Gear 25T 51 08 0015 Bushing 3x6x6mm Adjusting Plate Magnet Angle 1 52 AA15 1020 Seal 2x16x20 Development Anger 53 15 1058 Seal 3x27x28 Back Spill Plate 54 AA15 1055 Separator Seal Front Seal 6x16x310 1 55 A007 3151 Rear Upper Side Plat Seal 3 10 6 5 1 56 003 9003 Toner Agitator Seal Ring 1 53 AA15 1053 Seal 6x12x7 Holder Development Roller Bearing 1 58 A007 3055 Development Bottom Plate Development Roller 1 59 5894 2540 Arm Screw Gear 39T Idle Gear 17T chy 453 P2 n2 FR DRO BR PD o Bushing 6mm Seal 2x2x5 Lower Side Plate Seal Seal 2 5 10 Seal 2x5x28 Seal 2x5x10 Rubber Seal Paddle Roller Paddle Roller Seal Plate Lower Side Plat om wi Ww CO Co
261. auses relay RA1 to de energize removing power from the exposure lamp The copier stops and SC 12 is displayed Use SP mode 51 to display lamp voltage in the guidance display 31 August 1989 3 3 SCANNER DRIVE This model uses servomotor A to drive the first and second scanners This first scanner is attached to the scanner drive wire by the wire clamp D The second scanner is connected to the scanner drive wire by a movable pulley E the second scanner pulley The second scanner pulley moves the second scanner at half the velocity of the first scanner This maintains the focal distance between the original and the lens during scanning This relationship can be expressed as follows Vir 2 V2r VD r where r Reproduction Vir First Scanner Velocity when the Reproduction ratio is r V2r Second Scanner Velocity when the Reproduction ratio is r VD Drum Peripheral Velocity 300 mm s The first scanner wire clamp also actuates the home position sensor The CPU on the optics board controls both the registration and return timing 2 10 31 August 1989 3 4 SCANNER MOTOR CONTROL Scanner Home Sensor ra 24V VM M GND fe EA drive Driver Optlos CPU Timing Puise T R 2 RET Encoder 306 3 sie CN306 on Main PCB aia 305 1 3 2
262. be cleared 1 SP 100 through SP 139 2 SP 85 E M telephone number 3 SP 86 through SP 89 PM counter 4 All user programs 5 Secret Mode counters 1 20 lt SP 99 Clear all memory gt This service program clears all the service programs described above as well as all adjust ments and modes All modes default to factory settings 1 Turn the main switch off 2 Turn on DIP SW 801 7 and 8 on the operation board 3 Turn on DIP SW 100 8 on the main board 4 Turn the main switch on 5 Select SP 99 and press the 1 key on the key pad Then press the Enter key to clear the memory 6 Turn the main switch and the DIP switches off Then turn the main on to resume copier operation 4 9 31 August 1989 3 4 Service Program Mode Table Mode No 5 6 Function Data Exposure Lamp OFF Free Run Free run with exposure lamp OFF Jam Detection OFF Copies are made without jam detection Corona Wire Cleaner Function Operates CC SC cleaner motors Input Check Displays sensor input Drum conditioning Conditions a new drum All Indicators ON Turns on all operation panel indicators Language LT version only 0 E Selects language French or English 000908 4 version only 0 4 Selects language English French German Italian and Spanish 2 F 3 4 5 5 Auto Reset Time 0 1 min Selects 1 or 3 minute auto reset 1 3 min 2 none Count Up Down 0 UP Selects count up or cou
263. ber of A3 11 x 17 copies made optional 8 Registration Roller Knob Turn to remove misfed paper 9 Duplex Tray Stores the copies before reverse side copying 10 Toner Bottle Holder Swing down to replace the toner bottle 11 Transport Unit Release Lever Push down to lower the transport unit when removing misfed paper 12 Fusing Unit Release Lever Press down to slide out the fusing unit 13 Fork Gate Unit Lever Press down to lower the fork gate unit 14 Fusing Unit Knob Turn clockwise to remove misfed paper 15 Silicon Oil Bottle silicone oil to this bottle when the Add Oil indicator lights 1 5 31 August 1989 16 Front Cover Open this cover when the Misfeed Add Toner or Add Oil indicator lights 17 Exit Guide Plate Tab Raise this guide plate to gain access to the exit area 18 Copy Tray Completed copies are delivered here 19 Inverter Unit Inverts and feeds copies to the duplex tray 20 Main Switch Turns on the machine 21 Operation Panel The 5 keys and indicators are located here 22 Platen Cover Lower the platen cover over originals before copying 31 August 1989 2 2 OPERATION PANEL A4 A3 Version 123 4 567 8 ____ 1 Sorter Key Press to use the sorter Select sort or stack mode 2 Stack Indicator Lights when stack mode is selected 3 Sort Indicator Lights when sort mode is selected 4 2 Single Copies Key Press to make copies
264. ble If the timer is not reset within the timer period the sorter CPU determines that there has been a misfeed and it energizes the interrupt solenoid to allow the remaining copies to go to the interrupt pin 14 17 31 August 1989 Name Timer Reset Timer period Inlet Sensor Misfeed Check Copier s exit Inl nsor ON sensor ON et sensor O Inlet Sensor 110 pulses For paper shorter than Misfeed Check 300 mm 140 pulses For paper longer than or Inlet sensor ON Inlet sensor OFF equal to 300 mm oe 52 ime e sensor OFF B 50 pulses 3 OFF Check 1 Time control not pulse control is used for only this period because the pulse count for the period changes greatly due to the high and low paper transport speeds 2 A pulses depends on which bin the paper is going to For the first bin this period is 202 pulses 3 B pulses is the length of time that the inlet sensor is ON This period is uncertain because it depends both on the length of the paper and the amount of paper slippage 14 18 8 31 August 1989 INSTALLATION 8 1 Accessory Check Check the quantity and condition of the accessories in the es according to the following list Note Installation NEGR ae SINN 15 Hate ecce tae cone de SUC rename 2 Grounding Tooted SE
265. bly 1 screw Remove the support straps I 1 screws each the copier front cover 2 knob screws 7 Remove the right inner cover J 4 screws and install the relay roller drive assembly K 2 screws 8 Reinstall the right inner cover and the knob 9 Check the operation of the cassette bank and the copier system 10 Fill out the New Equipment Condition Report 7 13 SECTION 8 ARDF Contents DOCUMENT FEEDER 1 SPECIFICATIONS HA 8 1 2 BASIC OPERATION 8 2 ZN MMCHACO ET 8 2 2 2 Single sided Original 8 3 2 3 Two sided Original Feed E S 8 4 3 FEED IN UNIT MECHANISM 8 5 4 SEPARATION MECHANISM 8 6 5 MISFEED PREVENTION 8 7 6 WEAR PREVENTION 8 8 7 FRICTION ROLLER RELEASE MECHANISM 8 9 8 REGISTRATION 8 10 9 INVERTER 5 8 11 10 FEED OUT MECHANISM 8 12 11 LIFT MECHANISM arsit eae RE D ao a Ra ux 8 13 12 MISFEED CHECK 2 2288 b 8 14 T3 INSTALLATION 8 16 ACCESSON CIBC cam ou n ERE Du MD EU qu 8 16 19 2 Irstallation
266. bo yl s P is D is Qs xg E SYMBOL E ENDEX ii is fa R219 173 175 R60 16 123 ms 172 mo 172 172 m 165 m 12 172 m mu 12 12 mor 12 8201 172 R232 172 R242 168 R252 172 R262 173 R272 172 R282 172 292 172 R302 184 R222 172 172 19 R2353 180 1 173 112 172 R93 12 184 172 ex 12 ma rose 173 12 1 ex mo 1 R224 172 R235 173 R245 169 R255 172 R265 189 R275 172 R285 172 R295 172 R305 ee 16 mue 13 169 112 ros mos 172 12 ww 12 626 172 ex 173 ege rest m 16 172 mes 172 12 mor gs 15 ge e es vs ee m m 19 ins r0 ve meo mol ex poo 12 ee quc TEST PIN VARIABLE RESISTOR ZENER DIODE stu svuso
267. bs 14 1 31 August 1989 2 MECHANICAL COMPONENT LAYOUT 2 6 6 MW OBO M o 197 10 AGBS WU 1 iy 1 gt 4 Qr 7 us Om Li xl 14 13 12 11 10 9 8 7 6 1 Vertical Drive Rollers 2 Jam Sensor Photo Tr 8 Relay Guide Plates 9 Turn Gate 3 Pressure Rollers 10 Jam Sensor LED 4 Vertical Guide Unit 11 Bin Gates 5 Sorter Cover 6 Inlet Sensor 7 Sponge Roller 12 Bin Gate Solenoids 13 Interrupt Bin 14 Standard Bins 14 2 31 August 1989 3 DRIVE LAYOUT 1 Vertical Drive Rollers 15 rollers 4 Sponge Roller Pulley 2 Sorter Drive Motor 5 Drive Roller Timing Belt 3 Turn Gate Roller Pulley 14 3 31 August 1989 4 ELECTRICAL COMPONENT LAYOUT 1 2 X eT N 224 5 E X 8 7 6 1 Jam Sensor Photo Tr 6 Interrupt Bin Gate Solenoid 2 Sorter Cover Safety Switches 7 Sorter Main Board 3 Bin Gate Solenoids 8 Sorter Drive Motor 4 Inlet Sensor 9 Transformer 5 Jam Sensor LED 10 Power Supply Unit 14 4 31 August 1989 5 ELECTRICAL COMPONENT DESCRIPTIONS NAME Sorter Drive Motor Bin Gate Solenoids Interrupt Bin Gate Solenoid Sorter Cover Safety Switches Inlet Sensor Misfeed detector Jam Sensor PT Jam Sensor LED sorter Main Board Power Supply Unit Transformer FUNCTION Drives all the
268. c corona and pick off pawls Heat and pressure rollers Halogen lamp 750 W 80 000 copies per oil tank 360 cc 8 bit microprocessor 250 sheets all sizes 24 codes displayed in Guidance Display 100 programs controlled from the operation panel 110V 60Hz gt 15A 115V 60Hz gt 15A 220V 50Hz gt 8A 240V 50Hz gt 8A See the following table Numbers are in kilowatts per hour Warm up Copying Stand by Max Copier 1 0 1 8 0 18 1 5 See the following table The numbers are in millimeters with inches in parenthesis Width Depth Height Copier only with 750 763 mm 500 mm platen cover 29 5 30 0 19 7 Full System 1 575 mm 763 mm 1 065 mm 62 0 30 0 41 9 With DF Sorter LCT RT21 Paper Bank Menu Reader Duplex Model 115V 104 kg 228 5 16 220V 107 kg 235 4 Ib Non duplex Model 115V 96 kg 211 2 Ib 220V 99 kg 217 8 16 1 3 31 August 1989 2 GUIDE TO COMPONEN 2 1 INTERNAL EXTERNAL 1 Exposure Glass Position the original to be copied here 2 Manual Feed Table Open to manually feed the copy paper 3 Key Counter Holder Insert the key counter into this holder optional before copying 4 Toner Bottle Lever Turn counterclockwise to remove the toner bottle from its holder TS P2 1 4 5 Cassettes Hold the copy paper 6 Total Counter Shows the total number of copies made 7 A311 x 17 Counter Shows the total num
269. ch D The CPU energizes the registration clutch when it receives a registration start signal from the optics board The timing of this signal depends on the reproduction ratio editing functions and margin value The paper is fed at the same speed as the drum 300 mm s A paper dust cleaner is located at the center of the upper registration roller This is in line with the feed rollers where most paper dust is generated Image Shift If the margin adjustment mode is selected the CPU changes the on timing of the registration clutch 2 73 31 August 1989 10 8 PAPER SIZE SENSORS The CPU sends separate scan pulses SCAN 1 2 3 and 4 to the corresponding sensors in each cassette The output of this group of sensors for all cassettes can be monitored by one Feed Control PCB Output pulse example Cassette Cassette 1 2 1 102 8 12345 12348 2 102 8 3 102 8 4 102 a a 8 CN102 A9 UM No Notch High BV gt Notch low CN102 B8 Scan 1 Main PCB Paper size data bus data bus because the scan pulses are sequential This allows the CPU to determine which cassette the information comes from In the above diagram two example actuator plates are shown for paper size sensors 1 and 2 The actuator plates in cassette 1 and cassette 2 have notches in the fourth and second positions respec
270. ch user counter User Code Counter Reset Resets user s counters Use and keys to select the user code To reset press 1 then Maximum Copy Quantity Sets maximum enterable copy quantity Clear S C amp Jam count Clears service call and jam counters 4 14 Data 0 No 1 Yes 0 No 1 Yes Comments Also accessible by customer through keyboard Factory setting 0 Use decimal key for a space Factory setting 0 Factory setting 0 When the PM count is exceeded the Service Call indicator blinks Use after performing PM If ON a code must be entered to copy See user code table Reset after 60 sec or if C S and Clear modes pressed together Accessible through key board Factory setting 0 User counters count from 0 to 99999 Accessible through keyboard Accessible through keyboard The indicator blinks and the max quantity is displayed If 0 is entered max is 999 Otherwise max is number entered Factory setting 0 DIP SW 801 7 must be on Factory setting 0 Mode No 98 99 100 101 102 103 104 105 106 108 109 111 112 114 115 Function Data Clear Counters 0 No Clears the following counters total copies S C amp 1 Yes Jam Job Program PM counter Service Tel User Code Counter Clear All Memory 0 Clears all counters and returns all modes to 1 Yes factory setting Main Motor ON Time Check
271. ci 0 047 125V Capaci 27PF 50V Resistor 4 7 Resi 5 6 0 Resist 6 8KOH Resi 10KOH Resistor 10 Resistor 12 Resistor 15 Resistor 18 Resistor 22KOHM 1 8W 5 Resistor 27 1 8W 5 Resistor 33KOHM 1 8W Resistor 47KOHM 1 8W Resistor 56 1 8W Resistor 100 1 8W 5 Resistor 120KOHM gt a e rp one BP Hae o O o o o Resistor 270KOHM 1 8W 5 Resistor 1MOHM 1 8W 5 145 August 31 89 TP Page and 1610 0107 Resi 1 8W 5 65 141 1610 0108 Resi 1 2MOHM 1 8W 63 188 1610 0110 Resi 1 8KOHM 1 8W 63 189 1610 0113 Resi 3 3MOHM 1 8W 63 190 1611 4103 Resi 10KOHM 1 4W 69 129 1611 4151 Resi 1500HM 1 4W 63 191 1611 4153 Resi 15KOHM 1 4T 67 123 1611 4181 Resi 1800HM 1 4W 63 192 1611 4223 Resi 22KOHM 1 4W 69 130 1611 4472 Resi 4 7 1 4T 67 124 1611 4562 Resi 5 6KOHM 1 4W 69 131 611 4682 Resi 6 8 1 4T 61 125 6 4820 820HM 1 4W 63 193 1611 4820 1 820HM 1 4W 5 69 132 1611 6122 i 2 5 65 142 1611 6222 1 2KOHM 1 2W 69 133 1622 1003 i 1 4W 63 194 1622 1202 i 4 63 195 1622 1203 1 H 4W 15 69 134 1622 1800 i 1 4W 1 69 135 1622 4703 i 1 4W 1 69 136 1622 5231 i 5 23KOHM 1 4W 63 196 1622 8202
272. ck 1100 1249 Receptacle Terminal 1100 1327 tact 1100 1328 tact 1102 0512 nector 1102 0983 nector 2P 1102 1408 eptacle Housing 1102 1522 nector 2P 1102 1524 nector 2P 1102 1620 ector 1102 1911 ector 3P 1102 1919 ector 1102 1923 ector 1102 1934 ector 1102 1952 ector gt 1 WH FF 1102 1 ector 1102 1 ector 11 PARTS INDEX R escription Index No Side Stay Side Stay Knob Screw Lower Stay Middle Stay Upper Stay Base Cover Lower Guide Plate Transport Spacer 6 1x13x1 5mm Upper Guide Plate Transport Knob Cap Guide Plate Cover Grounding Wire Grounding Plate Antistatic Brush Relay Guide Plate Relay Guide Upper Exit Roller Plate Spring Guide Roller Small Tightener Transport Drive Paper Stopper Guide Upper Guide Plate Sorter Bin Odd Sorter Bin Even Bottom Bin Front Side Plate Bin Unit Rear Side Plate Bin Unit Stay Bin Unit Guide Pin Bin Guide Grounding Plate Bin Unit Antistatic Brush Grounding Plate Antistatic Brush Cushion Bin Front Helical Cam Ass y Rear Hel Helical August 31 89 Page and _ ical Cam Ass y Cam Bracket Tightener Bin Drive Belt Idle Pull Actuator Lever Harness Cover ey Bin
273. corona PQC The PQC turns off when the main motor is turned off 2 62 31 August 1989 10 PAPER FEED 10 1 OVERVIEW Paper feeds from either the first or second feed station A or from the manual feed table B The capacity of each cassette is 500 sheets One of the two optional large capacity trays 1 000 or 2 500 sheets can be installed in the second feed station Even more paper is provided with the cassette bank option The cassette bank can hold a third and a fourth cassette C These cassettes are the same as those of the first and second paper feed stations The maximum paper capacity with both the cassette bank and the 2 500 sheet large capacity tray installed is 4 000 sheets This copier uses three rollers for paper feed a pick up roller D a feed roller E and a separation roller F The bottom plate G inside the cassette is automatically lifted up when the cassette is inserted into the copier It stops when the paper stack pushes up the pick up roller Rotation of the pick up roller drives the top sheet of paper from the cassette to the feed and the separation rollers The feed and separation rollers then take over the paper drive If more than one sheet is fed by the pick up roller the separation roller rotates in the opposite direction and prevents all but the top sheet from passing through to the registration relay rollers The feed roller for the first paper feed station feeds the top sheet direct
274. ct Receptacle Housin 89 104 Receptacle Housin 73 128 Contact Receptacl Housin 75 118 Contact Receptacle Housin 89 105 nector Pin Contact Receptacle Housing 73 129 nector Pin Contact Connector nector Connector 2P 73 1 Connector 2P 73 1 nector 4P Housing 3P Housing 6P Black 73 1 Housing 3P Black 73 1 73 1 83 1 89 1 83 1 73 1 75 1 77 1 75 1 Housing Connector Connector Connector c Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector 73 1 on I NO N N PO FSF 9 WW BH gt W N N N rn O Ba 1 Connector Connector 141 August 31 89 Page and Parts No D 1102 191 83 112 Connector 2 Page and P No arts No Description indes No Connector 1102 191 1102 1102 1102 1102 1102 191 1102 191 1102 191 1102 191 1102 191 1102 191 Connector Connector Connector Connector Connector Connector Connector Connector
275. cycle is completed is stored in RAM The CPU references this time data in RAM to determine the proper rest time bias compensation level for the next copy cycle even after the main switch has been turned OFF and ON after a copy cycle For time data to be stored in RAM the jumper connector on the timer PCB must be in the ON position The copier increases the bias at the beginning of each copy run to prevent variations in the image density of the first few copies produced The amount of bias increase is shown in the above table If the drum temperature is less than 10 Celsius no rest time compensation is applied 2 33 31 August 1989 2 Drum Temperature Compensation The CC Bias power pack monitors drum temperature through a thermistor TH 1 and it increases or decreases the bias voltage to compensate for variations in drum sensitivity that are induced by temperature changes in the drum cavity At 30 Celcius base temperature no drum temperature compensation is performed For each 1 C rise in drum temperature the development bias is decreased 6V For each 1 C fall in drum temperature the development bias is increased 6V 2 34 31 August 1989 Bias For ID Sensing 1st Copy 11th Copy 1 0 Check I D Check Chec 400 2 Bias 200 260 260 260 260 260 260 260 4 Auto ID Rest Time 5 Min 100 Drum Temp 15 1 2 3 4 5 6 7 8
276. d Paper Bank A420 14 7 Harness Layout 420 16 8 Vertical Transport Harness A420 18 9 Front Paper Bank Harness A420 20 10 Main Paper Bank Harness A420 22 11 Rear Paper Bank Harness A420 24 12 Decal 420 26 Parts iv ne ee tw 29 August 31 89 LOCATION OF UNIT NS SAT UL 1 VERTICAL TRANSPORT A420 August 31 89 a AA y NAR d dU TT Edda 4 gt lt 33 Da 102 gees RET udi M X 1 VERTICAL TRANSPORT A420 August 31 89 Index Q ty Per Index Q ty Per P N Part No art No Description Assembly No Description Assembly Transport Knob Bracket Pan Head Screw M4x6 Bearing 8x16x5mm ili Pan Head Screw M4x8 26T il Pan Head Screw 4 12 30T 1 i Screw M4x8 Shaft 1 len Screw M4x4 Transport Roller Knob 1 E llel Pin Front Side Fence Transport Gear 18T 1 ining Ring Gear 38T 1 E ini Ring kza Bushing E ini Ring Relay Roller Spring E ini Ring Transport Bracket Spring Spacer M6 Front Transport Bracket Paper Sensor Feeler Feeler Shaft Paper Sensor Feeler Bracket Upper Shutter Paper Sensor ED Sensor Type Transport Sensor Bracket wo 1 c Upper
277. d Paper Size Sensor SC Cleaner Motor Duplex Stopper SOL SC Cleaner Home Position Sensor Duplex Paper Sensor 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 19 31 August 1989 Drum Heater Duplex Entrance Sensor Front Door Safety Switch Fusing Lamp Oil End Sensor Fusing Thermistor Main Switch AC Drive PCB Power Supply Unit Exit Sensor Exit Relay Sensor Inverter Exit Sensor Fusing Exit Sensor Thermofuse Fusing Exhaust Fan Motor Inverter Pressure SOL Junction Gate SOL Anticondensation Heater option Lens Drive Motor 31 August 1989 53 54 55 56 57 58 59 60 Main Motor Main Motor Capacitor Charge Fan Motor Pick off SOL Registration MC 1st Feed Relay MC Paper Feed Motor Toner Supply MC 1 20 61 62 63 64 65 66 67 68 Knocking Solenoid Development Motor Development Motor Capacitor Paper Feed Motor Capacitor Scanner Drive Motor 1st Paper Feed MC 1st Lift Sensor 1st Lift Motor 69 70 71 72 73 74 75 76 77 78 79 80 1st Pick up SOL Manual Feed SOL 2nd Paper Feed MC 2nd Lift Motor 1st Relay Sensor 2nd Lift Sensor 2nd Pick up SOL Duplex Paper Feed MC Duplex Positioning SOL Duplex Pick up SOL Jogger Motor Main Transformer 1 21 81 82 83 84 85 86 87 88 89 90 91 31 August 1989 Jogger Home Position Sensor Cleaning SOL Pulse Generator Fork Gate SOL
278. d the rear cover B 4 screws Remove the top cover Remove the stopper bar assembly C 2 screws 4 Remove the two 2 post tops D and the two paper guides E 1 long and 2 short screws each Remove the tray bottom plate F 4 screws Move the tray drive motor ass y G 2 screws to the rear to disengage the tray drive shaft H from the wire drive pulley I 10 15 31 August 1989 7 Loosen the front wire tightener A 1 screw 8 Remove the right lift rod B from the braces C front side first 9 Disengage the front end of the left lift rod D by raising it partway then lift it out from the top 10 Remove the inner cover E 2 short and 2 long screws 11 Replace the tray down sensor F 1 screw and 1 connector 12 Rotate the paper size dial to select a smaller paper size such as A4R and remove the positioning switch bracket G 1 screw 13 Replace the positioning switch H 2 screws NOTE When reassembling make sure that the ends with the holes I are at front 10 16 31 August 1989 7 2 Paper Size Sensor Replacement 1 Do steps 1 to 11 of tray down sensor and positioning switch replacement 2 Remove the front guide post A 1 screw 3 Remove the paper size sensor bracket B 4 Replace the paper size sensor C 1 screw NOTE When reinstalling the sensor bracket make sure that the harness D is positioned inside the sensor bracket
279. d the second cassettes from the copier 11 6 31 August 1989 6 Remove the rear cover 2 screws and remove the toner collection bottle F 7 Remove the handle G on the bottom right side of the copier 2 stud screws and remove the second cassette lift arm H 2 screws NOTE Save this handle for future use when transporting the copier 11 7 31 August 1989 8 DIP 101 8 If a customer requests a different paper size from that initially set change the position of the side posts accordingly A4 sideways does not need the front side post Then remove the front cover A and set Dip switch 101 B according to the paper size Dip switch table decal is stack on the rear of the front cover CAUTION Do not change the harness that runs between the LCT main board an LCT indicator panel 11 8 31 August 1989 9 Insert the tray into the second cassette position NOTE Make sure that the rib C fits into the groove D 10 Install the holder plates E 1 screw each 11 9 31 August 1989 0 11 Disconnect CN406 A CN408 and CN409 on the feed control board right rear corner of the copier 12 Connect the six tray harness connectors to the three free harness connectors and to the three connectors on the feed control board as follows TRAY CONTROL BOARD Female 4P CN408 Female 10P CN406 Female 12P CN409 TRAY FREE Male 4P 4P Male 10P 10P Male 12P 12P
280. der Lip lip lip Clamp lip lon Stud Cord Clamp Fuse Microswitch Push Switch Power Relay 3 7 nector 8E 3 7 7 using P P 2N 2N 8N Circuit Breaker 115V UL Solid State Relay 240V 3A e FP onn H OC c FPP gt August 31 89 Page and Sonde Page and Parts No Desc tion Receptacle Housing 15 1 1400 Transistor 2SC372Y Receptacle Housing 19 11 1400 Transistor 2SA1015Y Receptacle Housing 15 1 1401 Diode 1SS176 Receptacle Housing 15 11 1407 IC D74LS00 Receptacle Sleev 15 1 1407 D74LS10P 1407 IC D62503P 1407 IC LS06N 1408 IC 555CN 1408 IC 7705CP 1604 Capaci 10pF 25V 1604 Capaci 47pF 25V 1604 Capaci IMF 50V Capaci 1000gF 50V Capaci 0 luF 50V Resistor 1 14 V 5 Connector 4p Connector 12P Connector c A Connector Connector ector rA rn rn EX rA rA rn rn 1 a c rn c Connector Connector 3P rn c rn Connector 7P rn c um rm Receptacle Housing Resistor 1KOHM 1 4W 5 Resistor 10 1 4V 5 Resistor 100 1 4V 5 Resistor 4700HM 1 4W 5 Resist
281. drive motor stays on until the paper pushes up the pick up roller The actuator on the pick up roller bracket then moves out of the upper limit sensor this again changes the flip flop s state and the motor stops NOTE If JP 118 on the tray main board is removed the bottom plate moves up by opening and closing the cover before the bottom plate actuates the tray down sensor 10 6 31 August 1989 5 2 PAPER SIZE CHANGE AND DETECTION A Paper Size Change F Three paper guide posts A at the front and rear sides of the large capacity tray align the paper in the tray The two sets of guide posts are connected by a rack and pinion system which keeps the guide posts equidistant from the center of the tray The guide posts move as the paper size dial B turns As the dial is rotated the size lever tracks a cam groove C on the surface of the dial Movement of the size lever is transferred to the front post rack of the rack and pinion system Any movement of the front post rack D is transferred by the pinion to the rear post rack E Paper Size Detection The paper size detection system of the large capacity tray is similar to that of the cassette Both systems use the same data bus signals and type of sensor However the mechanism of paper size detection in the large capacity tray is different When the paper size dial is rotated to a standard paper size one of the actuator plates F enters the paper size sensor G At
282. e exposure glass Refer to 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 52 31 August 1989 7 5 Light Intensity Adjustment When Purpose Target Measure How Every call To maintain the correct light intensity second level of the standard test chart is slightly visible or there is no background on the copy when the second ID level is selected SP 48 Changes the lamp regulator output voltage 1 Clean the optics ID sensor and charge corona wires 2 Check adjust uneven exposure and horizontal magnification 3 Select the fourth manual ID level and make ten A3 LDG copies to stabilize drum sensitivity 4 Select the second manual ID level and make three A3 copies 5 Adjust the light intensity using SP 48 5 53 31 August 1989 7 6 ADS Reference Voltage Setting When Every call Purpose To maintain correct ADS mode operation Target ADS reference voltage from 2 6 to 3 1 volts Measure 56 How The main CPU automatically stores the reference voltage displayed in the guidance display V0 during SP 56 operation This voltage setting is valid only when the ADS reference voltage is from 2 6 to 3 1 volts This process saves time because the rear cover does not have to be removed to adjust the ADS reference voltage 1 Clean
283. e is pulled from the drum onto the passing paper by the transfer corona 1 13 31 August 1989 Paper Separation The electrostatic attraction between the paper and the drum is broken by the separating corona The suction of the vacuum fan and the weight of the paper pulls the paper onto the transport belt The transport belt moves the paper with the developed copy image to the fusing unit Fusing The paper passes between two rollers which bond the toner image to the paper by applying heat and pressure At this point the copy is complete and the paper path splits two ways Ordinary copies go directly through the exit rollers to the copy tray Duplex copies are diverted to the inverter unit 31 August 1989 2 DUPLEX COPY PATH Inverter Unit The junction gate directs the paper to the inverter unit which inverts the copy and sends it to the duplex transport unit Duplex Transport The duplex transport rollers move the copy to the right The appropriate fork gate is opened according to the paper size Then the copy is sent to the jogger unit through the duplex delivery tray Jogger Unit The copies are neatly stacked in the jogger unit to prepare them for duplex paper feed Duplex Paper Feed The copy is kept in the duplex tray until the operator sets the next original and presses the Start key Then the duplex feed mechanism feeds the copy up through the first relay rollers to the registration rollers After reaching the reg
284. e sheet of paper being driven between the rollers the force of friction between the feed roller B and the paper F1 is greater than F2 So the separation roller turns counterclockwise If two or more sheets are fed between the rollers the forward force on the second sheet F3 becomes less than F2 because the coefficient of friction between the two sheets is small So the separation roller starts turning clockwise and drives the second sheet back to the cassette 2 67 31 August 1989 10 4 SLIP CLUTCH MECHANISM C gerry 2 owe Sy SOS 09 4 D Separation Roller E Slip Clutch Cover The slip clutch has two hubs connected by drive spring A The spring grips the output hub tightly and grips the input hub loosely It will slip if the resistance to rotation is too great The hubs and spring are precisely machined and slip when resistance to rotation exceeds 1 A C 2 68 31 August 1989 10 5 PAPER FEED DRIVE Roller Drive Mechanism The pick up rollers A and the feed rollers B are driven by the paper feed motor C The main board sends a paper feed signal to the paper feed control board which then energizes the paper feed clutch D The clutch gear s rotation is then transferred to the feed roller shaft The pick up roller rotates in the same direction as the feed roller This is accomplished through an idle gear E The paper feed motor e
285. ean CN641 8 1 cN102 87 BEER Paper Size 4 SV CN461 7 CN102 B8 Not CN461 6 nay CN102 B10 used Ot gt t gt t gt t 9 era T UNGO1 4 1102 6711 ARAA Scand Comparator 102 5 Scan 3 CN102 Aa Scan 4 i CN102 A8 Scar The CPU sends separate scan pulses SCAN 3 4 to the corresponding sensors of the cassette bank The output of this group of sensors for all cassettes can be monitored by one data bus because the scan pulses are sequential allowing the CPU to determine which cassette information is being received In the above diagram two example actuator plates are shown The actuator plates in cassette 3 and cassette 4 paper size sensors in the cassette bank have notches in the fourth and second positions respectively Where there are notches the photointerruptors remain activated 0 volts Thus when scan line 3 is high bit 4 of the data bus remains LOW when scan line 4 is high bit 2 of the data bus remains LOW The CPU monitors the data bus at the appropriate time to determine the paper size in cassettes 3 and 4 of the cassette bank Signals from the volume sensors are sent to the copier main PCB through the cassette bank PCB and the paper feed control PCB however the copier operation panel will not indicate how much paper remains in the cassettes 7 6 31 August 1989 7 LIFT MOTOR CONTROL AND PAPER END DETECTION 7 1 LIFT MOTOR CONTROL Scan 4 1 1 4 4 4
286. ease the development bias voltage during ADS operation ADS Voltage Checking Measure Set SP 57 How ADS voltage is displayed on the guidance display V1 Also the number which is the actual ADS voltage divided by the reference ADS voltage fixed by SP 56 is displayed Development Bias Voltage Checking Measure SP 59 How The actual bias voltage is displayed on the guidance display V1 Also the ID sensor pattern development bias is displayed 1 Set the ADS reference voltage SP 56 2 f necessary adjust the ADS voltage 3 Place three sheets of A3 LDG white paper on the exposure glass and set SP 57 Then press the Enter key and the Start key 4 Write down the V1 amp K reading and set SP 59 First set ADS mode 5 Repeat steps 3 through 5 using any original but white paper on the exposure glass and confirm that V1 amp K decrease in SP 57 and V1 increases in SP 59 7 9 Erase Adjustment When The leading erase margin 15 not within specifications Purpose To maintain the correct leading erase margin Target 3 5 2 5mm Measure SP 41 0 6 mm step 15 steps changes the erase lamp on period 1 Place a 150 mm scale on the exposure glass and align it perpendicular to the left scale 2 Adjust the leading edge erase margin using SP 41 Make three copies with each adjust ment 5 56 31 August 1989 7 10 Registration Adjustment When Re
287. ect the ADS functions might not have worked properly and the variable resistor for the ADS sensor would have to be adjusted Now using SP 56 a correction factor can be stored in memory so that if the ADS sensor voltage is slightly out the variable resistor does not have to be adjusted See ADS Reference Voltage Setting 2 32 31 August 1989 Bias Compensation Factors As discussed previously the bias base level is set either by the automatic image density system or by the operator through the image density keys The CPU increases the base bias level as necessary to compensate for the rest time between copy runs and the drum temperature both of which affect drum sensitivity 1 Rest Time Compensation 10 20 Copies 2 3 4 5 6 10 Rest Time 0 3 min Same as previous copy 3 50 min 30 30 0 0 0 50 2 hr 30 30 30 0 0 gt 2hr 60 30 30 30 0 20 45 C Copies 2 3 4 5 6 10 Rest Time 0 10 sec Same as previous copy 10 sec 3 min 30 30 30 0 0 3 min 50 min 60 60 30 30 0 50 min 2 hr 90 60 60 30 30 gt 2hr 120 90 90 60 30 Note Figures are in Vdc The drum sensitivity often drops slightly over the first few cycles of a copy run This is because the light from the exposure lamp fatigues the drum slightly and it takes a few copies for the selenium to restabilize The amount that the sensitivity drops depends on the rest time between copy runs the longer the rest time the greater the change The time at which each copy
288. ected 2 Auto Paper Select Indicator Lights when auto paper select mode is selected 3 Auto Reduce Enlarge Indicator Lights when auto reduce enlarge mode is selected 4 Paper Size Indicator Shows the selected cassette and paper size 5 Empty Used Toner Indicator Lights when the used toner bottle is full simultaneously the Call Service indicator blinks 6 Add Toner Indicator Blinks when the copier needs toner 7 Add Oil Indicator Lights when the silicone oil level is low 8 Check Paper Path Indicator Lights if there are misfeeds 9 Load Paper Indicator Lights when the selected cassette runs out of paper 10 Copy Cycle Indicator Lights during a copy cycle 11 Ready Indicator Lights when the copier is ready to copy 1 8 Letter legal version 1 23 4 56 789 20 19 12 Wait Indicator Lights during warm up 13 Call Service Indicator Lights when the copier has a functional problem 14 Copy Counter Indicator Upper Displays the number of copies entered Lower While copying it shows the number of copies made If in count down mode it shows the number of copies to be made 15 Auto Image Density Indicator Lights when the copier is automatically controlling image density 16 Manual Feed Indicator Lights when the copier is automatically controlling image density 17 Manual Image Density Indicator Shows the selected image density 18 Misfeed Location Display Shows
289. ed when more than 1 original is set on the DF table and the copy quantity is greater than 2 and less tnan 20 Toner Supply Mode Selects toner supply system Toner Supply Amount Detect Mode Determines how much toner is supplied in detect mode Toner Supply Amount Fixed and ep Determines how much toner is supplied in fixed and detect modes ID Sensor Bias Sets the bias voltage applied to the bias roller for image density sensing Bias shift Permanently shifts bias output Lead Edge Separation Corona timing Sets off timing of the lead edge separation corona 4 11 Data 0 Yes 1 No 4 sec 60 sec Yes C ARDF Yes NO Yes O c NO Yes Normal Sort Detect Fixed 3096 15 45 60 7 4 11 14 500 380 470 530 1 60 V 2 120 0 10 mm 1 7 mm 2 13mm 31 August 1989 Comments Factory setting 0 Factory setting 0 Possible in SADF mode Factory setting 0 Only if RDH ARDF is installed Factory setting 0 Finisher only Factory setting Finisher only Factory setting The first LED inside each paper boundary turns on Factory setting 0 Sorter and DF must be installed on the machine Factory setting 0 See SP31 SP32 for ratios Factory setting 0 Factory setting 0 Factory setting 0 500 V normal 470 V light 380 V
290. efraction of air and the index of refraction of silicone oil The index of refraction of silicone oil 1 40 is very near that of the sensor casing 1 49 so the oil casing interface has a very large critical angle As a result when oil covers the sensor light from the LED is only refracted slightly at the boundary between the casing and the oil The phototransistor stays off However the index of refraction of air is much lower 1 00 So the critical angle for the air casing interface is much less than that of the oil casing interface Light from the LED strikes the air casing interface at an angle greater than the critical angle So when oil runs out light from the LED reflects instead of refracting and activates the phototransistor This sends a LOW signal to the main board which lights the Add Oil indicator and stops copier operation The Start key turns red and displays Open Front Door and Add Oll on the guidance display 31 August 1989 12 6 FUSING EXIT ASSEMBLY The fusing exit assembly includes the fusing roller strippers A the lower fusing exit guide and the exit sensor C The hot roller strippers prevent copy paper from wrapping around the hot roller They slide between the paper and the roller and then direct the paper to the fusing exit rollers The lower fusing exit guide prevents the copy paper from wrapping around the pressure roller Although the lower fusing exit guide does not touch the press
291. ensor output stays LOW Observation Code 81 is displayed during the duplex mode copy cycle The jogger is vibrating Points to Check Check the voltage at CN104 B2 on the main PCB Check the jogger motor Code 82 Jogger Home Position Not On Definition Lights if the jogger home position sensor output stays HIGH Observation Code 82 is displayed during the duplex mode copy cycle The jogger is vibrating Points to Check Check the voltage at CN104 B2 on the main PCB Check the jogger motor 2 107 31 August 1989 15 OTHER CIRCUITS 100VAC p Neutral Control Overload Protection Power Supply Fuse Table Voltage Fuse Typical Symptoms Destination 24 Vi FU705 5A DF and Sorter inoperative Main board ARDF RDH 24 FU704 5A No display blank copies Operation panel Power packs 5 Vb Main board corona cleaner motors erase lamp unit LED power m 2 5 scanner lens mirror drive motors 24 Va FU702 3 15A Sorter motor on constantly Main board clutches solenoids counters relays ac PCB operation PCB paper feed PCB SSR PCB paper bank PCB 5 Logic circuits ARDF RDH 100 Vac 701 5 Dead machine 100 Vac input The outputs of Vb and Vc are protected by a built in safety circuit that will cause the output to open in the event of a short circuit The output voltage is restored when the short circuit is corrected 2 108 15 2 SAFETY SWITCH CIRCUITS AC Safety Circuits
292. ensure that the drive wire does not overlap on the pulley 9 Tighten the wire via the tension 1 screw 10 Reassemble 10 20 31 August 1989 7 4 Paper Volume Cord Replacement A G Unplug the tray and remove the rear cover 4 screws Remove the transformer assembly with the tray main board 1 screw 5 connectors and 1 nylon clamp Remove the drive motor assembly with the paper volume detection assembly 2 screws and 2 connectors Remove the drive motor worm gear 1 Allen screw Remove the washer A and the paper volume cord pulley B 1 screw Rotate the drive shaft C so that the slot D is vertical then secure the shaft with tape Insert both ends of the paper volume cord E into the slot F of the paper volume cord pul ley and run the cord as shown in the figure Insert the paper volume cord pulley and washer Partially tighten the screw 6 NOTE Align the slot of the paper volume string pulley with the slot of the drive shaft 10 21 31 August 1989 9 Pull the ends of the cord to stretch it before tightening the screw and cutting off the excess cord 10 Remove the tape on the drive shaft and turn the drive pin A 330 in the direction shown in the figure 11 Set the drive motor worm gear B on the motor shaft and make sure the angle of the drive pin is as shown in the figure C 12 Align the edge D of the paper volume senso
293. ent sensing plate A is aligned with the transfer corona wire B 2 Select the dc 200 range on the digital multimeter 3 To turn on the transfer corona turn on the switching PCB dip switch corresponding to T on the TC SC power pack PCB The silk screen printed on the TC SC power pack PCB is correct 4 Adjust the corona current by turning VR T C on the TC SC power pack Wait 30 seconds for the current to stabilize 5 Remove the drum shoe and reassemble 6 Check copy quality 5 68 31 August 1989 8 9 Separation Corona Current Adjustment OSS X gt Optimum Adjusting Values AC 57 0 2 0 uA D1 DC 8 0 1 0 leading edge D1 DC 2 5 1 0 normal D1 8 D2 1 Reinstall the TC SC corona unit and position the drum shoe at the center of the shaft so that the axis of the current sensing plate A is aligned with the separation corona wires B as shown AC current D1 2 Select the ac 200 uA range on the digital multimeter 3 To turn on the separation corona turn on the D1 DIP switch on the switching PCB on the TC SC power pack PCB The silk screen printed on the TC SC power pack PCB is cor rect 4 Adjust the corona current by turning VR C on the TC SC power pack Wait 30 seconds for the current to stabilize 9 69 31 August 1989 Leading edge dc D1 5 Turn off the main switch and select the dc 200 range on the digital multimeter 6
294. er E 6 Slide off the front pick off pawl F 1 screw 7 Slide off the rear pick off pawl G 1 positioning pin 8 Place the new pick off pawls on the shaft and position them with the positioning pins and pawl springs 5 20 31 August 1989 9 Assemble the pawl shaft assembly and slide it into the cleaning unit until the shaft touches the rear side plate NOTE When installing the cam holder and the cam rider align X and Y as shown in the figure Make sure that the end of the spring is in the small hole on the rear side plate 10 Install the pawl shaft pin 11 Push the spring collar A to the rear and rotate it twice as shown in the figure Set the col lar on the pin B NOTE Make sure that the end of the spring is correctly positioned in the groove of the collar 12 Reassemble 5 21 31 August 1989 3 2 Cleaning Blade and Brush Replacement v ZZE ZA 2266 225 _ 52 Pus Cleaning Blade D 1 Take out the cleaning unit 2 Replace the cleaning blade A 1 screw Be careful not to touch the edge of the new blade Apply setting powder or toner to the new blade s surface before installing 3 Reassemble After installing the blade make sure that the blade swivels Cleaning Brush 1 Remove the brush drive shaft B 1 snap ring and the brush shaft holder C together with the bushing D 1 screw 2 Replace the cleaning brush E
295. er Registration Roller Gears First Relay Roller Gears First Relay Rollers Drive Chains and Belts Transport Belt Vacuum Fan Filter Exit Relay Rollers Bushings 80k 2 80k 20 80k 20 gt 80k CO r 160k R R 160k R L R 160k R d 23 O D 2 gt 160k R 20 4 2 240k R R R 240k R L R 240k 20 2 gt 240k R 9 320k R R 320k R R 320k R 25 339 O gt gt 320k R r Clean or replace if necessary Clean if necessary Dry Cloth Clean if necessary NOTE Silicone Grease G40M NOTE Prime with oil when replacing Prime with oil when replacing Suitable solvent Mobil Temp 78 NOTE Mobil Temp 78 Mobil Temp 78 Damp Cloth Replace if necessary Damp Cloth Damp Cloth H DUPLEX Inverter Support Roller Inverter Pressure Roller Positioning Roller Drive Belt Positioning Roller Duplex Slip Clutch Duplex Pick up Roller Duplex Separation Roller Duplex Feed Roller DOCUMENT FEEDER Belt Pick up Roller Feed Roller Friction Roller J CASSETTE BANK Pick up Roller Feed Roller Friction Roller EM 6 OUO 00O00S 9 160k R L R R R 160k R R R
296. er Knob Screw 24 1 Harness Cover Philips Pan Head Screw M3x4 25 Tray Bottom Plate Retaining Ring M4 26 Set Angle 2 Hexagon Headless Set Screw M5x5 27 Rack Drive Shaft Philips Pan Head Screw 4 5 28 Tape 2 Retaining Ring M3 29 Paper Detect Shaft Retaining Ring 30 Spring 2 Tapping Screw M4x8 31 1 Size Post Rack l Tapping Screw M4x6 32 Support Bracket Rubber Shoe 33 1 Rear Paper Size Decal Philips Pan Head Screw M4x20 34 Front Wire Tightener Philips Pan Head Screw M4x4 35 1 Front Paper Size Decal Philips Screw With Flat Washer M4x6 3 TRAY MAIN BOARD A421 August 31 89 CONNECTER SSR TRANSISTOR DIODE INDEY INDEY SYMBOL INDEX SYMBOL INDEX VIMDUL I I ULA ND Nn NN WU Ww We v SU SV cmoo 105 SSRIO0 107 0100 108 0100 110 16100 15 CN101 104 59901 107 107 0101 109 D101 110 1C101 113 102 0102 108 0102 110 10102 CN103 103 0103 109 0103 110 16103 112 C04 101 110 10104 11 c05 16 D105 110 10105 1H 0106 110 C106 16 E CAPACITOR RESISTOR ee ee lt lt 4 Ip e T 1
297. er Tank Development Unit Manual Feed Table First Cassette Large Capacity Tray Transfer Separation Corona Unit Jogger Unit Fourth Cassette Cassette Bank Third Cassette Duplex Delivery Tray Fork Gate Unit Duplex Transport Unit Sorter 31 August 1989 8 ELECTRICAL COMPONENT LAYOUT 11 gt gt N M Fg 4 25 12 13 16 SK 18 ARIEL OWS lt A so SS SSS sere 9 54 40 WSS 1 Scanner Home Position Sensor 2 4th and 5th Mirror Drive Motor 3 Toner Overflow Sensor 4 Image Density Sensor PCB 5 Pre quenching Corona Wire 6 QL Quenching Lamp 7 Erase Lamp 1 18 n2 NS m Nm gt 8 Lens Home Position Sensor 9 Toner End Sensor 10 Exposure Lamp 11 Scanner Overrun Sensor 12 4th and 5th Mirror Home Position Sensor 13 Auto Density AD Sensor 14 Development Cooling Fan Motor 19 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Cooling Blower Motor Platen Cover Sensor CC Cleaner Home Position Sensor Key Counter Option Manual Feed Sensor CC Cleaner Motor 1st Cassette Paper End Sensor Manual Feed Paper End Sensor 1st Paper Size Sensor Registration Sensor Pre Transfer Lamp PTL 2nd Cassette Paper End Sensor Total Counter A3 LTG Counter Option 2n
298. erating temperature 1 Select idling period with SP 61 5 35 31 August 1989 5 PAPER FEED 5 1 Pick up Paper Feed and Separation Roller Replacement d A 22 6 3 Pick up and Feed Rollers 1 Remove the paper feed guide plate A 3 screws Then remove the snap ring B and replace the rollers C Separation Roller 1 Remove the snap ring D and remove the roller E 2 Slide the slip clutch F off the shaft Then clean and lubricate the clutch with Mobil Temp 78 CAUTION When reinstalling the spring between the inner G and outer H hubs make sure that the spring I does not contact the inner hub This is because the inner hub does not slip properly if the spring contacts the inner hub This may cause midfeeds 3 Reassemble 5 36 31 August 1989 5 2 Transport Unit Removal 2 Af 1 Remove the rear cover 2 screws and the toner collection bottle 2 Disconnect the connectors from the following components TC SC power pack A Two 1P White Quenching Stabilizer B Red 3P White PCC power pack C 1P White 3 Lower the power pack bracket D TC SC PCC Stabilizer 2 screws 4 Remove the vacuum fan duct E 1 screw disconnect the two white connectors 2P amp 6P F and remove the ground wire G 1 screw 5 37 31 August 1989 NEZ N 5 Remove the fusing and cleaning units Then remove the bushing
299. escription A em Part No Description A007 5262 Duplex Stopper Solenoid Harness 1100 1159 Socket Mate N Lock 1100 1253 Pin Mate N Lock 1102 1396 Connector 2 1102 1860 Connector 2 007 5260 Inverter Guide Entrance Harness A007 5265 LED Sensor Harness 1100 1249 Receptacle Terminal 1100 1253 Pin Mate N Lock 1102 1660 Receptacle Housing 1102 1786 Connector 3P 1100 1249 Receptacle Terminal 1102 1253 Connector 15 1102 1620 Connector 3P 1102 1814 Connector 101 89 August 31 48 TRANSPORT SENSOR HARNESS AND HOME SENSOR HARNESS A045 A046 N O ze 58 z 209 102 48 TRANSPORT SENSOR HARNESS AND HOME SENSOR HARNESS A045 A046 August 31 89 Q ty Per Part No Description Assembly 1100 1249 Receptacle Terminal 1102 1786 Connector 3P Index NE Q ty Per P No art No Description Assembly A007 5254 Transport Sensor Harness A007 5261 Home Sensor Harness 1100 1249 Receptacle Terminal 1100 1253 Pin Mate N Lock 1102 1620 Connector 3P 1102 1814 Connector 3P 103 49 SPECIAL TOOL A045 A046 o UN g 104 49 SPECIAL TOOL A045 A046 August 31 89 Index Q ty Per No Part No Description Assembly Q ty Per Description TIPET Assembly Setting Powder Li
300. esistor 6 8KOHM 1 4T 5 W Ph 31 AC DRIVE BOARD A045 A046 August 31 89 RA CONNECTOR L CAPACITOR TR RESISTOR ZENNER SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL NO NO NO NO NO NO NO NO C502 TR502 1 R522 132 C503 R523 132 C504 C505 115V 220V C506 1159 2207 Ic SYMBOL NO DIODE SYMBOL 08 SYMBOL 08501 115 2207 08502 1199 2207 08503 1159 2204 CR SYMBOL NO CR501 1150 2200 CR502 1159 2207 CR503 1159 2201 SYMBOL NO PC501 108 502 108 503 115 VR SYMBOL NO TRC SYMBOL 501 114 TRC502 113 TRC503 220V 08504 150 2207 CR505 1150 2200 68 31 AC DRIVE BOARD A045 A046 August 31 89 Index Q ty Per Index Ooty Per P N ae Assembly DS Ey AY11 0001 AC Drive Board 115V 1103 1724 Connector 2P AY11 0002 AC Drive Board 220 240V 1103 1731 1 5215 5222 Transformer 100V 25V 2 1208 1034 Relay DC24V 1402 0360 Zener Diode 720 1402 0467 Diode 55666 1405 0127 TLP541G 1405 0130 TG8D 1405 0148 iac 600V 16A Ber 1405 0151 TLP545J 0 0 0 1405 0152 Rectifier 1J4B42 1405 0156 IC BCR8DM 1405 0157 IC M51951M 1408 0233 IC HA17903PS 1600 1112 Resistor 1000HM 2W 2844 Resistor
301. ess A045 A046 80 AC Drive Board Harness A045 A046 82 Power Pack Harness A045 A046 84 Transport Unit Harness A045 A046 86 Safety Switch Harness 045 046 88 Lift Motor Harness A045 A046 90 Fusing Unit Harness and Gate Harness 045 046 92 Main Control Harness and DC Motor Harness 045 046 94 Cleaner Sensor Harness and Gate Solenoid Harness A045 A046 96 46 Duplex Entrance Harness and Toner End Sensor Harness A045 A046 98 47 Duplex Stopper Solenoid Harness Inverter Guide Entrance Harness and Led Sensor Harness A045 A046 100 48 Transport Sensor Harness and Home Sensor Harness A045 A046 102 49 Special Tool 045 046 104 50 Decal and Document A045 A046 106 Parts 113 August 31 89 LOCATION OF UNIT 2 EXTERIOR 2 3 OPTICS 1 EXTERIOR 1 1 SN 5 OPTICS 3 4 OPTICS 2 August 31 89 LOCATION OF UNIT 8 PAPER FEED UNIT 2 9 DUPLEX SECTION 1 7 PAPER FEED UNIT 1 August 31 89 LOCATION OF UNIT 15 DEVELOPMENT 2 gt O 13 INVERTOR SECTION 2 i 18 DRUM SECTION 2 17 DRUM SECTION 1 16 TRANSFER AND SEPARATION August 31 89 LOCATION OF UNIT gt 2 LL N gt
302. ess FT5550 A046 5243 DC Harness FT5540 5408 5160 Short Connector using 6P Black 3P Black Connector 11 1 Socket Mate N Lock 11 1 n Pin Mate N Lock 11 1 Receptacle Housing 8P Terminal LT 1 nector 3P Socket Mate N Lock 11 191 nector 2P Fastening Receptacle 11 191 nector ninal 1 11 191 nector Pin Mate N Lock 11 191 nector Socket Mate N Lock 11 191 nector Socket Mate N Lock 11 191 nector Termin TI 191 nector Lock 11 1 nector inal 11 1 nector ing Receptacle ET 1 nector Fastening Receptacle 11 1 nector Contact IT Receptacle 32P Pin Contact 11 Contact Connector 4P 11 Connector 50P gt 1 o Now Connector 11 Connector 20 34 AC HARNESS A045 A046 MINIS 5 1915 104 104 104 04 n PP 15 117 MM DIM Y i 106 5 102 H 122 122 13 m 74 i8 it August 31 89 34 AC HARNESS A045 A046 August 31 89 n Q ty Per Part No Description Assembly Assembly A045 5451 Harness 1 ANGE 20 13 Pin Mate N Lock 11 1 Positive Lock Receptacle 11 1 Fastening Receptacle 11 1 Fastening Receptacle 11 Socket Mate N Lock 11 1 Terminal 1 Pin Mate N Lock 1 11 1 Wire Terminal 1 Pin Contact ll 1 Pin Contac
303. f the scanner is not in the home position when the print key is pressed an excessive number of pulses from the encoder are received and code 21 15 illuminated Observation The scanner is out of home position when the print key is pressed Points to Check Check that the scanner is working properly Check CN306 2 and CN306 3 on the optics board If it is not working properly check the scanner drive wire and the scanner drive pulley Screws 13 1 31 August 1989 Code 22 Scanner Home Position Stays High Definition Lights if the scanner home position sensor is open at power up Observation The scanner eventually moves to the right as on off key is activated until code 2D is displayed Points to Check Check that the scanner is working properly Check CN305 3 on the optics board Code 24 No Home Position Signal Definition Lights if the main board does not receive the H P signal from the optics board within 20 seconds after the scanner return signal Observation Code 24 is displayed within 20 seconds after power up Points to Check Check CN106 5 and 6 on the main PCB Check CN304 4 and 5 on the optics board Code 25 Scanner Home Position Sensor Stays Low Definition Lights if the scanner home position sensor is shorted at power up Observation scanner moves to the extreme left at power up Points to Check Check CN305 3 on the optics board 13 2 31 August 1989 Code 28 Lens Home Position Sensor
304. from bound originals or two sided originals 5 2 Single Copies Indicator Lights when 2 single copies mode is selected 6 Margin Adjustment Indicator Lights when Margin Adjustment mode is selected 7 Margin Adjustment Key Press to create a margin on copies 8 Zoom Keys Press to alter the reproduction ratio in 1 steps 9 Guidance Indicator Lights when guidance mode is selected I E 40 33 32 3130 2928 2726 25 24 9 10 111213 141516 17 1888 23 22 21 20 19 18 10 Guidance Key Press to select guidance mode 11 Enter Key Press after entering data 12 Interrupt Indicator Lights when interrupt mode is selected 13 Interrupt Key Press to make interrupt copies during a copy run 14 Program Indicator Lights when the user program mode is selected 15 Program Key Press to enter or recall user programs 16 Timer Indicator Lights when the machine has been turned off by the weekly timer or automatic shut off timer 17 Timer Key Press to operate the copier after it has been turned off by the weekly timer or automatic shut off timer Letter Legal Version 31 August 1989 123 4 56 7 8 9 10 111213141516 17 NEN XH ERO UNE gt 988 me 2242 fo eee H 33 323130 2928 2726 25 24 18 Clear Modes Key Press to clear the co
305. g Entrance Oil Pan Stepped Screw lider Leaf Spring using Entrance Slider 5 Slider Knob Lever R R ight Fusing Rail ight Fusing Rail Bracket Front Lamp Terminal Ass y Rear Lamp Terminal Ass y Lamp Terminal Spacer Front Lamp Terminal Shaft Rear Lamp Terminal Inner Insulator Front Outer Insulator Rear Outer Insulator Front Lamp Terminal fete Per bly Q ty Per Assembly 89 August 31 23 OPERATION PANEL A045 A046 Q amp Q gt 28 7 52 23 OPERATION PANEL A045 A046 Part No Description Q ty Per Assembly A045 A045 A045 A045 A045 A007 A007 A007 A007 A007 A007 A007 1453 1452 1451 1531 1491 1313 1311 1312 1310 1294 6194 1531 Instruct Instructi Panel Ass y Panel Ass y Panel Ass y ion Card Holder ion Card Holder Panel Support Panel Bracket Panel Bracket Panel Bracket Plate Inner Front Slide Cover Upper Cover LT Bracket Left Center Right Ass y Index No 34 August 31 89 Q ty Per P No art No Description Assembly Key Top Key Top Key Top Key Top Key Top Key Top Key Top Point DIP SW HN27256G 25 HN27256G 25 272566 25 Decal Key Top Full Size Enlarge Reduce Zoom Down Auto Cassette Selection Zoom UP A007 A007 1535 Slide Cover A4 5728 Ke
306. g the proof tray Simultaneously the Max indicator blinks 9 2 31 August 1989 2 4 EXAMPLE OF SORT MODE OPERATION 3 copies entered and the Start key pressed 3 times In the illustrations the following call outs are used A Helical Wheel B Transfer Wheel C Exit Sensor D Paper E Bin Start Key ON 1 The first copy feeds to the first bin After the paper detector turns off the bin motor turns on and moves the first bin up 9 3 31 August 1989 3 The third copy feeds to the third bin The bin drive motor does not turn on after the paper sensor turns off The sorter will stay at this position until auto reset or until copying resumes NI PEE 2 4 L B D Start Key ON 4 The first copy goes to the third bin After the paper detector turns off the bin drive motor turns on and moves the second bin down 3 gt 4 a ww NS IAY 5 The same as 4 as ZN KKM XO I PANS NS 9 4 31 August 1989 6 The third copy goes to the first bin The bin motor does not turn on after the paper sensor turns off Start Key ON 7 The first sequence 1 2 and 3 starts again 9 5 31 August 1989 3 BIN DRIVE MECHANISM The bin drive mechanism moves the bins up and down to receive copies under the direction of the copier CP
307. ght Shielding Bag Drum Shoe Thermo Meter HLC Probe HLC 30 Digital Multimeter BECKMAN RMS3030 Test Lead Kit Silicone Oil Launa Oil Test Chart OS A3 10pcs set Heat Resisting Grease MT 78 Switching Board Omega Clamp Gap Gauge Sensor Checker DG Gauge 0 76 2pcs set Silicone Grease G40M DG Gauge 0 71 0 86 August 31 89 50 DECAL AND DOCUMENT A045 A046 5 4 GE 5 qr August 31 89 50 DECAL AND DOCUMENT A045 A046 182 C THERMAL CUTOF LJ 210 297 s 107 50 DECAL AND DOCUMENT A045 A046 21 22 t indicator blinks copies can be made ndicator stays lit copies cannot be made 275 FR Rey a 27 CS S ee Grasp the bottle holder Turn the lever on reverse Remove empty Toner and gently but firmly pull side of boltle holder down counterclockwise M Woe o am NV SIBI R777 y 7 ll lt 4 Alf TUN Place new Toner Bottle Turn lever clockwise until Grasp bottle holder handle in the holder it locks and pull up un
308. gistration is not within specifications Purpose To maintain proper registration Target 2 SP 42 0 6 mm step 15 steps changes the registration roller start timing 1 Place a 150 mm scale on the exposure glass and align it perpendicular to the left scale 2 Adjust the registration using SP 42 Make three copies for each adjustment 5 57 31 August 1989 7 11 Side to Side Registration Adjustment Adjustment Standard A B lt 3 0 mm 1 Turn off the main switch and remove the exposure glass Refer to Exposure Glass Removal 2 Remove the lens housing cover A 4 screws and the lens cover B 2 screws 3 Loosen 3 screws C and shift the lens D from side to side to adjust the registration l 5 58 31 August 1989 8 CORONA 8 1 Charge Corona Wire Replacement Ce B SKS 1 Remove the drum inner cover A 1 screw 2 Unplug the charge corona connectors B and take out the charge corona unit C 3 Remove the front D and rear E endblock covers front 3 screws 4 Remove the wire cleaner F 1 screw 5 Remove the rear endblock G 1 screw CAUTION The endblock may spring away from the corona unit so hold it firmly 5 59 31 August 1989 D 6 Unhook the tension spring A and take off the old corona wire B 7 Clean the endblock endblock covers and the corona unit casing with a blower brush and damp cloth 8 Hook the co
309. glish Decal Terminal Decal Terminal Front Bracket Rear Bracket Front Side Plate Front Side Plate Rear Side Plate Rear Side Plate Side Cover Plate Dial Shaft Drive Wire Drive Pulley Side Guide Shaft German 220V German 220V 220V Front Wire Tightener Rear Wire Tightener Side Guide Stopper Left Lift Stay Stopper Chain Hook P C B Bracket Power Cord Bracket Holder Side Cover 220V August 31 89 ciel Page and 031 M3x6 Descr 5925 2334 Magnet Catch Plate 5 15 3 00601 Philips Pan Head Screw 6769 7930 Power Supply Cord 115V 9 33 0313 0120W Philips Pan Head Screw M3x12 0313 0140W Philips Pan Head Screw M3x14 0313 02001 Philips Pan Head Screw M3x20 0314 0040W Philips Pan Head Screw 4 4 0314 0040W Philips Pan Head Screw 4 4 0314 0060W Philips Pan Head Screw 4x6 0314 00801 Philips Pan Head Screw 4x8 0314 01001 Philips Pan Head Screw 4 0314 01001 Philips Pan Head Screw 4 0315 00801 Philips Pan Head Screw 0060W Tapping Screw M4x6 00600 Tapping Screw M4x6 00800 Tapping Screw 4 8 0050 Hexagon Headless Set Screw M5x5 0050 Hexagon Headless Set Screw M5x5 0120W Hexagon Bolt 4 12 02201 Hexagon Bolt M4x22 0040C Toothed Washer M4 0040C Toothed Washer M4 0030 Retaining Ring M3 00401 Retaining 0040 Retaining Rin g ing M4 0060 Retai
310. gon Headless Set Screw M5x5 Nylon Stud Push Switch Philips Pan Head Screw M4x6 Circuit Breaker 115V Nylon Clip 2N Terminal 3P Philips Pan Head Screw M3x14 Washer 8 1x14x0 1mm Cord Clamp Power Relay Philips Screw With Flat Washer M3x5 Retaining Ring M3 Philips Pan Head Screw M4x10 Retaining Ring M6 Philips Pan Head Screw M5x8 Parallel Key Nylon Clip 4 TRAY CONTROL BOARD 5897 August 31 89 SSR CONNECTER IC RESISTOR SYMBOL INDEX AUS SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX SYMBOL INDEX NO NO NO NO NO NO ND NO NO NO NO NO NO SSR100 107 CN100 105 C100 115 R100 123 R110 122 R120 122 R131 122 SSRIOL 107 CN101 104 10101 113 R101 124 R111 123 R121 126 R132 126 CN102 102 10102 11 R102 123 112 123 R122 127 RI33 122 CN103 103 1 103 112 R103 129 R113 123 R123 124 R134 122 101 10104 11 R104 124 RIIA 123 R124 126 R135 126 CM105 106 12105 14 R105 129 R115 122 R125 122 R136 122 pee 12106 116 R106 123 16 124 1 124 R138 124 107 128 RI 128 R127 128 R108 123 R118 125 R128 126 R109 122 we 1 R119 123 R130 123 DIODE TRANSISTOR CAPACITO
311. h ith ith ith ith ith ith ith Philips Screw Philips Screw in Philips Screw in Philips Screw Philips Screw Philips Screw 3906 Ball Bearing 6mm Philips Screw 1179 Philips Screw With Toothed Washer Philips Screw 1185 Philips Truss Head Screw M4x8 Philips Screw 1185 Philips Truss Head Screw M4x8 Philips Screw 1385 Philips Truss Head Screw M4x8 Philips Screw c 5085 Tapping Screw M4x8 Philips Screw 5085 Tapping Screw M4x8 Philips Screw c 5086 Tapping Screw M4x10 Philips Screw 5094 Tapping Truss Head Screw M4x8 Philips Screw amp Ay cu du ce Philips Screw 5094 Tapping Truss Head Screw M4x8 5094 Tapping Truss Head Screw M4x8 Philips Flange Screw Philips Flange Screw ith ith ith ith ith ith ith ith ith ith ith 5094F Truss Tapping Screw M4T3x8 5131 Truss Head Screw M4x8 0017 Knob Screw M4x6 5 Screw Screw 0083 Retaining Ring M4 Screw 3042 Ball Bearing 6xl Screw 3042 ll Bearing 6 1 Screw 3101 11 Bearing 6 1 Screw 3145 ll Beari 6x1 3291 11 Beari 8 1 3291 11 Beari 8x1 3377 ll Bearing 25x 3399 Bushing 6x10x8mm Screw Screw Screw Screw Ej Hp dep god epos QQ Q
312. h 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 Fixed supply mode SP 30 Turns on the toner supply clutch every copy cycle 1 Set SP 30 to select fixed supply mode 2 9 Toner Amount Changing When Purpose Target Measure How The factory setting for toner supply amount 30 is not appropriate for the type of originals in use To adjust the toner supply amount Detect mode 30 factory setting 15 45 or 60 Fixed mode 7 4 11 or 14 Detect Mode SP 31 Fixed Mode SP 32 Changes the toner supply clutch on period 2 10 ID Pattern Bias Voltage Adjustment When Purpose Target Measure How Customer wants to change the overall image density of the copies To change toner concentration inside development unit Bias Voltage 500 factory setting 380 lightest 470 light 530 dark SP 33 Changes the ID pattern bias voltage and either raises lowers the toner supply threshold 5 19 31 August 1989 3 CLEANING 3 1 1 Pick off Pawl Replacement t A D s AD Qe Ir 1 Remove the pick off guide plates A 1 screw each 2 Remove the pawl shaft pin B from the pawl shaft C 3 Push the pawl shaft to the rear and slide the cam holder D off the front side plate 4 Remove the complete pawl shaft assembly 5 Slide off the cam holder and cam rid
313. harge 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 31 August 1989 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 DEVELOPMENT Negatively charged toner is attracted to the positively charged areas of the drum thus developing the latent image The negative triboelectric charge is caused by friction between the carrier and toner particles PRE TRANSFER LAMP PTL The PTL illuminates the drum to remove all positive 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 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 positive charge is applied to the back side of the copy paper providing 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 PAPER SEPARATION A strong ac corona discharge is applied to the back side of the copy paper reducing the positive charge on the copy paper and breaking the electrical attracti
314. he CPU CN101 A20 is sent to the CC B power pack through the TC SC power pack The OFF timing of the charge corona power pack varies according to the paper size being used 31 August 1989 3 OPTICS 3 1 OVERVIEW Jn During the copy cycle an image of the original is reflected onto the surface of the drum I the optics assembly The optics assembly consists of the following parts 1 First Scanner A Exposure lamp B 85V 160W First mirror AD Auto Density sensor C 2 Second Scanner 0 Second mirror Third mirror 3 Lens F5 f 215 mm E 4 Fourth and Fifth Mirror Assembly Fourth Mirror Fifth Mirror 5 Sixth Mirror G 6 Toner Shield Glass H 2 7 31 August 1989 This copier has nine standard reproduction ratios five reductions three enlargements and full size In addition it has a zoom function The reproduction ratio can be selected in one percent steps from 60 to 155 A servomotor drives the first and second scanners during the copy cycle This motor is controlled by the optics PCB which changes the motor speed depending on the reproduction ratio Two stepper motors change the position of the lens and the fourth and fifth mirror assembly to change the reproduction ratio The sixth mirror 15 fixed The fiber optic cable used for the auto density sensor ADS is mounted on the first scanner The ADS collects light reflected from the original in auto density se
315. he bottom of the oil tank 5 10 Paper Feed and Duplex 1 Grease the following parts periodically with Mobil Temp 78 to reduce noise and improve operation a Upper lower and duplex separation roller slip clutches b Upper and lower lift motor worm gears and worm wheels 4 21 31 August 1989 2 Be careful not to damage the forks when removing the fork gate unit 3 The rollers and the slip clutch for duplex and cassette feed are not interchangeable 4 Be sure that the duplex transport belts are matte side out when replacing them 5 When reinstalling the support bracket make sure that the bracket is properly engaged with the groove in the registration clutch stopper 5 11 Optional Equipment 1 Before servicing the document feeder and or sorter make sure that the main switch on the copier is off 2 Before servicing the large capacity tray unplug the tray s power supply cord 5 12 Handling PCBs ARNING The timer board has a lithium battery which can explode if handled incorrect ly Do not recharge disassemble or burn this battery Used timer boards must be handled in accordance with local regulations 4 22 SECTION 5 REPLACEMENT AND USTMENT Contents REPLACEMENT AND ADJUSTMENT T20PTIGS 7a ee rite diosa 5 1 1 1 Exposure Glass 22 2 2242 0 14 we cones eden 5 1 1 2 Sixth Mirror Replacement 5 2 1 3 Scanner Dri
316. he drum in a cool dry place 3 Always wear gloves when cleaning the drum 4 the drum with setting powder only when the cleaning blade cleaning brush and drum are replaced as a set Never expose the drum to light for a long time Always keep the drum the protective sleeve when inserting or pulling the drum out of the copier 7 Drum conditioning is necessary when a new drum is installed In addition it should be done at the following times a When image density is reduced due to overexposure of the drum b After cleaning the drum c When the drum is lightly scratched Before inserting or sliding out the drum the cleaning unit should be removed to avoid drum damage When pulling out the cleaning unit press the drum shaft slightly to the left 9 Return used drums to the distributor according to standard procedure 5 2 Charge Corona 1 Do not use emery paper to clean the corona wire this abrades the wire coating 2 Do not touch the corona wire with oily hands Oil stains may cause white bands on copies 3 The corona wire height should be adjusted only when a the front end block is replaced b the drum charge current is uneven 4 Make sure that the corona wires are correctly positioned between the cleaner pads 5 3 Erase Lamp 1 A narrower lead edge erase margin increases the possibility of fusing jams The margin should be at least 1 0 mm 4 19 31 August 1989
317. he screws 3 Unhook the spring D and remove the old wire E 5 47 31 August 1989 4 Turn over the jogger unit and place the eyelet F the one furthest from the ball on the anchor pin G Then route the wire as follows 1 Wrap the wire counterclockwise around the lower track of WP1 2 Wrap the wire counterclockwise from lower to upper around the jogger motor pulley I 5 Connect both ends of the wire with the spring J 6 ladjust the jogger home position Refer to the adjustment table 5 48 31 August 1989 7 COPY IMAGE 7 1 Vertical Magnification Adjustment When The vertical magnification is not within specifications Purpose To maintain correct vertical magnification Target 1 Measure SP 43 0 1 96 step 15 steps How Changes the scanner speed compensation 1 Place a 150 mm scale on the exposure glass and align it perpendicular to the left scale 2 Adjust the vertical magnification using SP 43 Make three copies each time 5 49 31 August 1989 7 2 Horizontal Magnification When The horizontal magnification is not within specifications After loosening the first scanner wire clamp Purpose To maintain proper horizontal magnification Target 0 5 Measure Adjust the position of the first scanner wire clamp rough adjustment How Changes the distance between the original and the drum surface Measure SP 44 0 4 95 step 15 steps fine adjustment How Changes the len
318. hing Unit uec parative hee oe eae Ea 4 21 5 8 Pre transfer and Quenching eee 4 21 5 9 FUSING aie dia eee 4 21 5 10 Paper Feed and 4 21 5 T1 Optional Equipment x oa oe NUI ERI SEES 4 22 5 12 Handling PCBS o cutis ub P EOS DENEN ME qeu 4 22 REPLACEMENT AND ADJUSTMENT T OPTICS Bees eat bare bouts 5 1 1 1 Exposure Glass 5 1 1 2 Sixth Mirror 5 2 1 3 Scanner Drive Wire Replacement 5 4 1 4 Fourth and fifth Mirror Drive Wire 5 8 1 5 Lens Drive Wire 5 9 1 6 Scanner Harness Replacement Optics Cables amp Exposure Lamp 5 10 DE VELOPMEN asado erede ae 5 12 2 1 Developer 5 12 2 2 Image Density Sensor 5 14 2 3 Toner Collection Bottle 5 15 2 4 Voltage ER t 5 16 2 5 Vsg Voltage
319. hold them apart and pins C at the front and rear of the right end which are inserted in guide slots in the bin holder D The bin holder is mounted in the sorter frame On the right edge the bins have stoppers E which prevent copies from sliding back into the sorter after they have been fed out The pattern of these stoppers is different for even and odd numbered bins 9 8 31 August 1989 6 ELECTRICAL CONTROL Copier Sorter Control PCB Overrun SW13 __________ 100Vac Down Bin Drive Motor SSR 101 SSR 102 24 gt Bin Up Bin Down Paper Sensor lt 5V gt en 4s A T Bin Sensor whee J 5 EN Cover Safety Cover The copier CPU controls all functions of the sorter The copier supplies 100 volts ac to the bin drive motor and SSRs SSR 101 turns on the wheel drive motor to move the bins up SSR 102 turns the bin drive motor in the opposite direction for the down operation Two dc power levels 5 volts and 24 volts are supplied from the copier and are used for the dc components Signals from the sensors and safety switch go to the copier CPU The copier CPU operates motors and the SSRs The midi sorter has an overrun switch which stops the bin drive motor if the bins move too low 31 August 1989 7 INSTALLATION 7 1 Accessory Check Check the quantity and conditi
320. hotointerrupter Spring Charge Wire PCC T amp S Corona Casing Seal 3x5x30 Seal 3x4x122 Iransport Duct Transfer Safety Switch Transport Switch Bracket T amp S Corona Receptacle Lock Lever Lock Shaft Sport Iransport Low Shaft Guide Transport Leaf Spring Micro Switch Feeler Spring Transport Unit Harness T amp S Corona Cover T amp S Corona Unit Feeler Holder Index n Q ty Per Assembly 17 DRUM SECTION 1 A045 A046 N E FREE 222 i WE 2 DE 4 104 He eet 2599 RS 5 e eI 104 38 La ea 90 At lt 7 August 31 89 47 BA E SP AA EA L 101 Sa ee AM 5 N ota 46 40 17 DRUM SECTION 1 A045 A046 Part No Q ty Per Description Assembly 00 01 AD02 A008 03 5442 06 AD02 5442 A008 AD02 A008 A008 AD02 A008 06 11 AD02 5216 740 01 03 008 008 AD02 ACO1 71 007 72 007 4003 1005 3008 2080 2015 2110 0045 2012 2108 2095 2014 2084 2085 4001 2090 3020 1001 2011 5245 0004 0011 2014 5321 2091 2013 5001 0010 3312 1030 2152 1068 1067 1065 2051 2121 2078 2079 Charge Corona Unit PTL Filter Charge Corona Casing Pulley Support Charge Corona Cleaner Idler Pulley Plug Corona Unit Tension Cleaner Spring
321. i 82 1 4W 1 69 137 1622 8661 i 8 6KOHM 1 4W 63 197 146 52080 411 CS2080 Location 3 1 Midi Sorter I 411 4 2 Midi Sorter Il 411 6 3 Sorter Board 411 8 4 Sorter Harness 411 10 Parts sce ee bie 13 August 31 89 LOCATION OF UNIT 1 MIDI SORTER August 31 89 1 MIDI SORTER 1 A411 55 be Cue R NR gt mee en ER gt A Ar 2 N 4 lt pr S I 1 MIDI SORTER A411 August 31 89 Index Q ty Per po Q ty Per Part No Y Part No y BE assembly ee Assembly Installation Procedure English Pan Head Screw M4x6 Installation Procedure 5 Language 1 1 Screw M4x8 ulti Lingual Decal 1 Philips Pan Head Screw M4x8 Upper Cover 1 Philips Truss Head Screw M4x8 Hing Upper Cover Philips Truss Head Screw M4x8 Front Hinge Lower Sunken Head Screw M4x8 Upper Stay 1 Tapping Screw With Flat Washer M4x8 Rear Cover Stud 28mm Right Cover Base Cover Front Cover Knob Screw Side Stay Bin Guide Guide Pin Rear Side Plate Bin Unit Bottom Bin Front Side Plate Bin Unit Stay Bin Unit Sorter Bin Even Sorter
322. id Bracket Timing Belt 228MXL 1 Fork Gate Solenoid Bracket Gear 25T Third Gate Arm Tension Spring Spring Fork Gate Actuator CO u C MA CO N Stepped Screw M3 1 Fork Gate Actuator ler Roller Spring Hot Roller Stripper lley 20T 1 Release Lever Fork Gate lley 25T Junction Gate Shaft Arm Tension Lever 1 Spring Stripper Transport Chamber 1 Fork Gate Setting Plate N Anti Static Brush Duplex 1 1 Cushion Fork Gate Guide Plate Fork Gate 1 Fork Gate Large Cover Transport Chamber 1 Fork Gate Pawl Small Fork Gate Cover 1 Fork Guide Roller Transport Spring Anti Static Brush Fork Gate 4 Fork Gate Knob Exit Roller Entrance Guide Plat ing Driven Roller Exit Guide Plate Fork Gate k Gate Stopper l Front Spring Exit Roller ing Fork Gate Stopper l Rear Spring Exit Roller Bushing 6mm Bushing Front Side Frame Fork Gate 1 Anti Static Brush Fork Gate Duplex Tray 1 Gate Solenoid Harness Knob Screw 1 Decal Handle Micro Switch Lever 1 Decal Reset Stepped Screw Spring Gate Arm Spring Fork Gate Lever Micro Switch Spring Fork Gate Holder Index Q ty Per Index Q ty Per P N Assembly No Philips Pan Head Screw M3x4 Philips Pan Head Screw M3x6 Tapping Screw M4x6 Tapping Screw M4x8 Hexagon Headless Set Screw M4x5 Hexagon Headless Se
323. idance display indicates Call for maintenance and the start key stays green 2 27 31 August 1989 5 3 DRIVE MECHANISM Ss SSSA V V Are A Development Drive Gear B Development Roller Gear C Idle Gear D Auger Gear The gears of the development unit and the toner agitator gear are driven by the development drive gear A when the development motor turns The rotation is transmitted as follows B The development drive gear and development roller gear are helical gears Helical gears more quiet than normal gears The teeth of the development drive gear are chamfered so that they smoothly engage with the development roller gear B when the unit 15 installed 2 28 31 August 1989 5 4 CROSSMIXING The crossmixing mechanism has two functions it keeps the toner and developer evenly mixed and it helps to agitate the developer The developer that is attracted to the development roller at point A is split into two parts by the doctor blade One part B the magnetic brush goes on to develop the latent image on the drum However the other part C is trimmed off by the doctor blade and directed to the backspill plate D As the developer slides down the backspill plate to the paddle roller it is moved slightly toward the front of the unit by the mixing vanes Part of the developer falls into the auger inlet and is transported to the rear of the unit by the mixing auger G
324. ide 1 Paper End Feeler Snap Ring Paper Sensor Feeler Pick up Roller 1 Separation Guide Paper Feed Roller 1 Separation Drive Shaft Gear 18T 1 Bushing Ball Bearing 8xl6x5mm Lower Feeler Bracket Paper Feed Roller Bracket Output Hub Gear 21T 1 Slip Clutch Cover gt Feed Guide Paper Feed Roller Cylindrical Spring Pick up Shaft 1 Input Hub Feed Guide Shaft Paper End Actuator Gear 20T 1 Pulley 19T Gear 20T 1 Timing Belt 184XL ushi Volume Sensor Arm ela ler Spring Shield Plate Paper Sensor B R Bushi M6 Holder Plate Transport Guide G ear T 1 Paper Size Sensor Bracket Bushi Paper Feed Roller 1 Upper Paper Feed Separation Stay CO C CO N Separation Drive Gear 1 Fixed Bracket Separation agnetic Clutch 1 Separation Arm agnetic Clutch Collar Gear 15T Gear 40T Gear 25T agnetic Clutch Transport Paper Feed Separation Spring Magnetic Clutch Stopper 1 Pressure Arm Shaft agnetic Clutch Stopper 1 Upper Relay Shaft 1 Sector Gear Paper Feed Guide Bushing Sector Gear Lower Transport Drive Roller Bushing Volume Sensor Shaft Right Paper Feed Guide c Feed Guide Upper 1 Lower Transport Roller Paper Feed Cover Up
325. ignal Not On Definition Lights if the idle signal is not received within 8 minutes after the power relay turns on Observation The fusing lamp does not turn on The ready beeper does not sound and code 54 is displayed 8 minutes after power is turned on Points to Check Check the power relay fusing lamp ac drive board and operation panel board To control effects of electrical noise from surrounding machines try JP100 Check for poor contact in the fusing unit connector Code 55 Fusing Overheat Definition Lights if the voltage at CN103 4 fusing thermistor drops below 0 53 V for 0 4 second Observation The fusing lamp stays on after the temperature rises above 220 C Points to Check Check the voltage at CN504 1 on the ac drive board for line voltage Check the resistance of the thermistor Disconnect the white thermistor connector on the front side of the fusing unit Reference value 1 10 kohms at 180 C 180 kohms at 10 C 2 89 31 August 1989 13 PAPER EXIT 13 1 OVERVIEW After fusing the copies are delivered to the copy tray through the fusing exit rollers A exit relay rollers B and the exit rollers C An anti static brush D removes static electricity from the copies as they leave the paper exit area This improves paper stacking 2 90 31 August 1989 13 2 EXIT ROLLER DRIVE MECHANISM The main motor A drives the exit relay rollers B and exit rollers C through the timing belt
326. ill be within the conier Be sure to remove all misted UR mms G N Check the inverter and remove any misied paper caught inside 89 109 50 DECAL AND DOCUMENT August 31 89 Removing the misleed indicator lights there a inside tne copier rasti 871 BL 7 FT Q 7 lt C1 2 22 Push gown the knob anc Remove misies paper oy turning the Return guide 10 115 originai paper was found at 2 lowes tne guide plate segisication knob counlercioCkwiss position wilh Ine lever out ine Daoer and and to pushing cown ins teyer temove any papet remains Ine teeo entrance It B is lit 2 A eun Turn tne lever duo Oo cou Counterclockwise Turn the ends CU Count counterclockwise Pull out the fusing umt out tne m knoo Gand rever clockwise anc J anc lower the unit Remove any misieo paper taking clockwise removing ihe not to tear pape original position If B is lit J 61 7 T tomi g is tusing unit gt EA qs _
327. ill stop and the guidance display will indicate that the sorter 15 full When the sorter bin capacity 15 set to limit by using service program mode 76 the guidance display will indicate that the maximum copy entry is 40 and the Quantity Entered counter will display 40 if the operator enters a number greater than 40 the maximum bin Capacity for stack mode 14 7 31 August 1989 Interrupt Mode If the Interrupt key is depressed during a multicopy run the sorter continues to place copies in the correct bins until that copy run is finished Which bin the copies go to depends on the mode sort stack or clear Then the operator depresses the Start key to make interrupt copies As each of the interrupt copies enters the sorter the sorter CPU energizes the interrupt solenoid A and the copies are directed to the interrupt bin When the interrupt mode is canceled the previous settings and modes are returned to resume the previous copy run that was interrupted Sorter Misfeed The sorter CPU starts the misfeed timing count when the inlet sensor turns on If the copy is not fed into the bin within a specified period different for each bin the sorter CPU will send a misfeed signal to the copier The copier will then light the Sorter Misfeed indicator and stop operation Any copies in the paper path at the time will be finished first The sorter CPU directs any copies that are being processed in the copier at the time of a
328. int pen Black Fed in and out automatically Approximately 2 5 seconds 24 volts and 5 volts from copier 4 4 x 6 5 x 1 8 112 mm x 165 mm x 45 mm 170 lbs 640 g 12 1 31 August 1989 2 OVERALL MACHINE CONTROL ROM Address Latch 15V 1 gt Signal Mark Amplification Detection s Sensor CPU 5V M LED LED Indicator Drive Sheet Detection Sensor E lu The menu reader is controlled by the copier 12 2 5 15V 24V Conversion Voltage Monitor External Reset Power Supply Copier 31 August 1989 3 DATA FORMAT Menu Reader gt Copier b6 1 63 62 DATA CONTENTS ol Copy Quantity x 1 Copy Quantity x 10 0 0 Copy Quantity x 100 Paper Size Reproduction Ratio 1 1 Reproduction Hatio 2 1 2 2 1 2 0 Duplex 0 Stack Sort 1 1 Sorter 0 0 0 Staple JjReevei 0 0 1 0 j Reserve2 2 Reserve2 2 Reserve2 1 o __ 2 0 1 0 1 Reserve 4 Reserve 4 IKE Size4 Sie 0 H Enlarge 3 Enlarge 2 100 Reduce 4 Reduce 3 0 MN SN RISK RBS cu dE IE EN Copier
329. ints to Check Check the resistance between CN36 3 and CN36 D on the ID sensor board Reference value 10 kohms at 25 C Check CN103 13 on the main PCB 2 37 31 August 1989 6 TONER DENSITY DETECTION AND TONER SUPPLY 6 1 TONER SUPPLY RR SSA m Pin 4 AE A V IA AA CR 919 N lt The toner supply drive gear A turns when the development motor is The toner supply clutch B applies the rotation from the toner supply drive gear to the toner supply roller gear C which drives the agitator gear D Toner catches in the grooves on the toner supply roller E Then as the grooves turn past the opening the toner drops into the development unit The teeth on both the toner supply drive gear and the toner supply roller gear are chamfered 2 38 31 August 1989 6 2 BOTTLE DRIVE MECHANISM 2 re y 1 77 1 gt a For easy access the toner bottle is just inside the front cover The bottle is positioned horizontally The bottle drive mechanism transports toner from the bottle to the toner tank A worm gear A on the front end of the toner supply roller B drives this mechanism When the toner supply roller turns the worm gear turns the toner bottle C via the worm wheel the bottle drive gear and the bottle gear The toner bottle has a spiral groove that helps move toner to the toner inlet
330. ion of the accessories in the box according to the following list Original Exit Guide Flip Scale Flip Scale Spring Original Table Original Table Cover Nylon Harness Bushing Harness Bracket Nylon Clamp 7 Lift Switch Actuator Plate 10 Test Chart A4 11 Toothed Washer 12 Ground Screw M4 x 8 13 Flathead Shoulder Screw M4 x 8 Magnet Catch 14 Flathead screw x 6 15 Pan Head Screw M4 x 6 16 Pan Head Screw with Washer M4 x 10 17 Pan Head Screw x 10 18 Flathead Screw M4 x 12 19 Tapping Screw M4 x 8 20 Multiple Language Decal 220 240V Only 21 22 Envelope 115V Only 23 ARDF Fixing Plate Not used for this installation 24 Pan Head Screw M5 x 8 4 Not used for this installation 1 4 09 O0 8 16 31 August 1989 13 2 Installation Procedure 1 Remove all the external strips of tape 2 Turn off the main switch of the copier and exchange the following parts Remove Install Left Scale Exit Guide C Flip Scale D Flip Scale Spring E Pan Head Screw x 6 F 2 Flathead Screw M4 x 6 G Pan Head Screw x 8 2 Flathead Shoulder Screw M4 x 8 I NOTE If the platen cover has been mounted on the machine remove the platen cover and the two stud screws 8 17 31 August 1989
331. ipper Spring Front Cover Hinge Right Front Cover Hinge Left 31 6 21 18 21 5 29 16 29 53 33 33 25 31 25 41 25 34 33 11 11 17 29 21 29 18 29 5 29 6 29 1 31 16 25 22 1 23 05 15 1559 25 49 14 39 29 23 51 14 51 13 49 15 49 40 9 7 9 8 41 45 19 1 49 23 9 12 9 13 133 August 31 89 Page and 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 125 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 19 15 Clip Exposure Lamp Lens Tension Pulley Spring Lens Drive Wire T amp S Corona Guide Plate Mylar Seal Guide PTL Cover Snap Ring M6 Bushing Gear 16T Side Fence Gear Brake Mounting Bracket Platen Cover Platen Cover Hinge Ass y Arm Holder Rubber Magnet Balancer Spring Pin 4x115mm Right Spring Platen Cover Left Spring Platen Cover Slide Supporter Plate Magnet Platen Base Base Holder Developer Knob Gear 441 Side Seal Doctor Blade Gear 25T Seal Ring Bushing 8mm Transport Guide Roller Upper Frame Oil Blade Holder Spring Oil Blade Oil Sump Holder Spring Plate Oil Supply Pad Decal Thermofuse 13 4 17 59 17 60 39 40 43 19 1 61 43 13 9 41 9 33 9 40 9 1 Page and einen Decal Thermofuse Decal Thermofuse Transformer 100V 25V Photointerrupter 1 Photointerrupter 1 Photointerrupter 1 Pho
332. istration rollers the sheet follows the same path as when the front side was copied However this time the reverse side faces up to receive the image 6 DRIVE LAYOUT 92 31 1989 EIS e Al 446 ob 1 Toner Supply Clutch 13 Exit Drive Chain 2 Development Drive Belt 14 Pulse Generator Drive Pulley 3 Development Drive Gear 15 Registration Roller Drive Belt 4 Development Motor 16 Cleaning Drive Gear 5 Drum Drive Pulley 17 Registration Clutch 6 Drum Drive Belt 18 Paper Feed Motor 7 Main Motor 19 Duplex Paper Feed Clutch 8 Fusing Duplex Drive Gears 20 Relay Roller Clutch 9 Main Drive Belt 21 Paper Feed Drive Chain 10 Exit Relay Roller Drive Sprocket 22 Second Paper Feed Clutch 11 Inverter Roller Drive Gear 23 First Paper Feed Clutch 12 Exit Roller Drive Gear 31 August 1989 7 MECHANICAL COMPONENT LAYOUT 12345678 9 101112131415 16 17 Inverter Unit Third Mirror Second Mirror First Mirror Exposure Lamp Fusing Unit Document Feeder Transport Unit Lens Cleaning Unit Quenching Unit Charge Corona Unit Drum Sixth Mirror Toner Shield Glass Erase Lamp Unit vest NEL 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 18 19 24 25 Fourth Mirror Fifth Mirror Ton
333. it Stopper Harness Cover Left Frame Exit Guide Plate Motor Bracket Front Side Plate Exit Drive Bracke Switch Bracket Collar M6 Rubber Bushing M6 Seal 10 1 Belt Tightener Spring Flip Scale Grip Plate Spacer 6 5 1 Spacer M4 5x1 DF Harness Bracket Idle Roller Mylar Seal 15 12 0 1 Original Exit Guide Austatics Brush Grouding Plate DF Cover Left Supporter ight Supporter lay Panel Cover lay Board Bracket ion 21x20x2 lay Panel Bracket Original Table Guide Origi Table Cover Front Original Guide Rear Original Guide Original Table Extender August 31 89 5 t Page and Parts No escription Index No neque ME E quM Wan vato Sea e sunt WIES NES Bee Dno le se Faas d cu Oc DS cud OO o Cork Pad Front Table Bracket Rear Table Bracket Right Hinge Right Hinge Spring Outer Right Hinge Spring Inner Left Hinge Left Hinge Spring Lift Switch Actuator Plate Interface Harness Bracket DF Fixing Plate Decal Misfeed Removal Decal Jan Removal Front Adjusting Plate Rear Adjusting Plate Rubber Seal 10x10x3 Front Feed in Guide Rear Feed in Guide Glip Scale LT LDG Flip Scale A3 A4 Original Feed Table LT LDG Original Feed
334. ith the spacer and the knob screw L front side only 9 13 31 August 1989 11 Secure the sorter ground wire A 1 screw A toothed washer B must also be installed with the European version 12 Connect the three connectors as follows Red 2P C to Red 2P free White 4P D to white 4P free White 12P E to CN108 on the main PCB 13 Reinstall the main PCB 2 screws 14 Install the sorter covers and copier rear cover 15 Peel off the cover F from the Sort Stack key panel left side of the operation panel 16 Install the Sort Stack key top G copier accessory and affix the Sort Stack key cover H copier accessory as shown 17 Set SP71 1 to enable the sorter Refer to the copier installation procedure 18 Check the sorter s operation and fill out the New Equipment Condition Report 9 14 31 August 1989 8 REPLACEMENT AND ADJUSTMENT 8 1 Bin Drive Belt Replacement When the duplex unit is not installed it is not necessary to perform steps 2 to 4 Note the orientation of the flat surface on each pulley shaft before removing the drive belt 1 Remove the sorter front A and rear B covers 2 screws each 2 Remove the rear cover of the copier 3 screws Then disconnect the sorter harness red 2p connector white 11p connector and white 4p connector and the sorter ground wire 3 Remove the knob screw C from the duplex unit 4 Remove the sorter unit from the machine 5 Remove
335. k Small Cover Paper Bank Front Cover Clamp Bracket Paper Bank Cushion Left Table Cover Guide Bracket Paper Bank Rear Cover Paper Bank Frame Rail Positioning Bracket Bank Table Guide Screw Stand Caster Sealed Plate Bracket 1 Philips Pan Head Screw M4x6 ector Sealed Plate 1 Philips Truss Head Screw M4x8 ess Guard Bracket 1 Philips Pan Head Screw M4x8 ector Guide Pin 1 Philips Head Screw M5x8 ector Spring 1 Philips Pan Head Screw M3x6 ector Bracket 1 Philips Truss Head Screw M4x6 nector Cover Bracket E Retaining Ring M4 Safety Switch Cover 1 Retaining Ring 5 Safety Switch Bracket j Retaining Ring 6 Safety Switch Joint Philips Screw With Flat Washer M4x6 Paper Bank Door 1 Connector 32 Decal Reset 1 Push Switch August 31 89 3 PAPER FEED SECTION A420 3 PAPER FEED SECTION A420 A420 2121 Rear Guide Cover A420 2111 A007 2877 A007 2878 A420 2830 A420 2145 A420 2161 A420 2148 A000 2702 August 31 89 Index Q ty Per Part No 228 Assembly A420 2331 Paper Feed Support Bracket Receiving Cassette Front Guide Cover Receiving Cassette Cushion Upper Pick off Bracket Cushion Lower Pick off Bracket Rear Inner Cover Rear Side Fence Solenoid Bracket Pressure Pick up Lever Pick up Solenoid Bracket Lift Sensor Bracket 5205 5205
336. kilogram of developer into the development unit while rotating the paddle roller knob to evenly distribute the developer 5 Reassemble 5 13 31 August 1989 2 2 Image Density Sensor Removal 1 Open the front cover 2 Remove the image density cover A 1 screw 3 Slide out the image density sensor 4 Clean or replace the sensor C 5 14 31 August 1989 2 3 Toner Collection Bottle Cleaning 1 Remove the toner collection bottle cover A 2 screws 2 Disconnect the toner overflow sensor connector B and remove the bottle C 3 Remove the stopper from the toner collection bottle to clean out the toner 5 15 31 August 1989 2 4 Vsg Voltage Checking When Every call especially if the drum is changed Purpose To confirm operation of ID sensor mode Target Vsg 4 00 0 20 volts Measure SP 54 How Vsg is displayed on the guidance display for ten seconds 1 Remove the ID sensor PCB Refer to ID Sensor Replacement 2 Clean the ID sensor 3 Reinstall the ID sensor PCB then check Vsg using SP 54 5 16 31 August 1989 2 5 Vsg Voltage Adjustment When Purpose Target Measure How Vsg 15 not within specifications After replacing either ID sensor PCB or main PCB To make sure that ID sensor mode works correctly Vsg 4 00 0 20 volts VR 1 on ID sensor PCB Changes light intensity of ID sensor LED 1 Do steps 1 and 2 of Vsg Voltage Checking
337. l 115V 5447 4980 1 Terminal 220V 5446 8905 1 English French 115V 5446 8906 1 English German 220V 5442 1372 1 Power Source 220V 5897 8610 Installation Procedure English 5897 8615 Installation Procedure 5 Language PARTS INDEX August 31 89 Nylon Clamp Stay Main DC Harness Safety Switch Bracket Main DC Harness Left Cover Tray DC Harness Operation Board Mounting Bracket Tray DC Harness Upper Actuator Lever otor Harness 115V Lower Actuator Lever otor Harness 115V Safety Switch Actuator otor Harness 115V Decal Operater Instruction otor Harness 220V Decal Operater Instruction otor Harness 220V Drive Motor Bracket otor Harness 220V Worm Gear 5 5 Transformer 115V 220V 240V 30W Drive Shaft Installation Procedure English Paper Volume Detection Guide Installation Procedure 5 Language Shutter Paper Volume Sensor Pulley Right Lift Rod Drive Shaft Bushing Washer 4 5x24x2mm Size Lever Stopper Bar Knob Stopper Bar Spring Plate Stopper Bar Stopper Bar Mounting Bracket Hook Stopper Bar Mounting Stud Stopper Chain Microswitch Mounting Bracket Sensor Mounting Bracket Bottom Plate Bracket Size Shaft Tray Bottom Plate Front Side Guide Rear Side Guide Leaf Spring August 31 89 soad Page and Page and
338. large capacity tray is raised and lowered by a wire and pulley mechanism This mechanism is driven by the tray motor B reversible ac motor Drive power 15 transmitted directly to the tray drive shaft C a worm gear and worm wheel The tray wires have braces on them these braces hold the ends of the two lift rods D which support the tray bottom plate When the wire drive pulley turns clockwise the braces on the wires raise the lift rods and the tray bottom plate The bottom plate rises until the paper in the tray pushes up the pick up roller actuating the lower lift sensor The tray bottom plate lowers when the tray drive motor turns the wire drive pulley counterclockwise It stops moving down when the actuator plate on the left lift rod actuates the tray down sensor 11 3 31 August 1989 Board Tray Main Board The Power Down Operation The bottom plate moves down either when the Down key is pressed or when paper runs out When either condition occurs the flip flop on the tray main board changes state all outputs change from LOW to HIGH or vice versa Then two things happen simultaneously 1 The timer circuit turns on causing the LED in the Down key to blink and 2 SSR100 turns on energizing the drive motor to move the tray down The tray down sensor is actuated when the bottom plate is fully lowered This causes the flip flop to change back to its original state which turns off SSR100 and reset
339. length of the original by counting pulses as the original passes under it The registration sensor is also a jam detector 8 10 31 August 1989 9 INVERTER MECHANISM In the two sided original mode the belt drive motor reverses 75 milliseconds after the leading edge of the original passes the exit sensor however the feed out motor A continues to turn forward Since the friction between the turn roller B and the original is greater than the friction between the DF belt C and the original the original continues to move forward through the inverter mechanism The belt drive motor and the feed out motor turn off 532 pulses after the trailing edge of the original passes the exit sensor This aligns the trailing edge of the original with the original scale 8 11 31 August 1989 10 FEED OUT MECHANISM C Exit Sensor un EN CEN Belt Drive Motor uM mE Feed out Motor When the DF CPU receives the feed out signal it energizes the belt drive and feed out A motors The feed out motor drives the exit rollers B through the timing belt C The DF CPU slows down the feed out motor when the trailing edge of the original passes the exit sensor The feed out motor continues to turn at this slower speed to feed the original to the original stacker This slow down exit function produces a neat stack of originals 0 12 31 August 1989 11 LIFT MECHANISM 7
340. lenoid turns on The original is then inverted in order to copy the reverse side of the original first The reverse side is copied first to stack the copies in the correct order Inversion To invert the original the CPU turns on the belt drive motor turns on the feed out motor and energizes the inverter gate solenoid The belt drive motor reverses 75 milliseconds after the leading edge of the original passes the exit sensor A but the feed out motor continues driving the orignal forward The belt drive motor turns off 532 pulses after the trailing edge of the original passes the exit sensor This ensures that the original stops at the correct position Feed out The basic operation in this mode is exactly the same as that in the single sided original feed mode 8 4 31 August 1989 3 FEED IN UNIT MECHANISM After an original is inserted into the feed in unit and the Start key is pressed the DF CPU energizes the pick up solenoid A This causes the pick up roller B to drop onto the original s At the same time the DF CPU energizes the original stopper solenoid C to retract the stopper claws D In ADF mode the original stopper claws stay underneath the original feed table until all the originals have been fed in In SADF mode the stopper claws rise for each original The DF CPU turns on the feed in motor E 200 ms after energizing the solenoids This starts turning the feed rollers F and the pick up roller
341. ller Bracket Center Roller Pick up Control Shaf Rear Feed in Guide Stopper Solenoid Pick up Solenoid Pick up Lever Spring Detent Arm Screw Duplex Guide Plate Stopper Bracket Solenoid Pin Pick up Solenoid Bracket Clutch Spring Spacer 4 5 1 Stopper Lever Pulley 25T Clutch Sleeve Front Adjusting Plate Rear Adjusting Plate Registration Sensor Harness Gear 24T Release Arm Eccentric Cam Gear 24T Gear 45T Decal Feed in One Way Bearing Lever Sensor Actuator Feed in Stopper Right Frame Feed in Sensor Feeler Right Stay Collar Separation Roller Shaft Lower Separation Roller Eccentric Cam Shaft Stepped Screw M4 Spring Anchor Knob Cap Collar 6mm Front Release Lever Adjusting Plate Feed Clutch Spring Lower Feed in Guide Seal 12x17x0 7mm Spring Plate iddle Spring Plate Knob Screw Entrance Guide Sensor Pad Paper Guide Mylar Roller Relay Roller Shaft Rubber Seal 10x10x3 Index No Part No Description ng Screw With Flat Washer M3x10 en g Screw M4x6 Pin 2x10mm Retaining Ring M6 Retaining Ring M3 Retaining Ring M5 Retaining Ring M2 5 Spring Original Stopper August 31 89 Index Q ty Per Q ty Per Assembly Philips Pan Head Philips Pan Head Phili Retai ps Pan Head ning Ring Hexagon Headless Retai ning Ring Screw
342. lling the transfer corona wire G confirm that the ring H is installed on the wire 5 62 31 August 1989 8 4 Charge Cleaner Drive Wire Replacement 1 Remove the corona wires Refer to Charge Corona Wire Replacement 2 Remove the drive wire tension springs A drive gear B and the old drive wire C 3 Wrap the new wire around the drive pulley one and one half times 0 4 Place the drive ring E over the post of the wire cleaner F 5 Slip the wire over the idle pulley G 6 Install the wire 7 Reassemble the corona unit NOTE Make sure that the corona wire is positioned between the cleaner pads Also check the wire cleaner movement using SP 7 Make sure that the spring that acts upon the home position sensor actuator is seated correctly 9 63 31 August 1989 8 5 TC SC Cleaner Drive Wire Replacement 1 Remove the TC SC wires Refer to Transfer and Separation Corona Wire Replacement 2 Remove the rear endblock A 1 screw while holding it firmly since it may spring away Then remove the drive pulley B 3 Remove the drive gear C and the pulley D from the front side Then replace the drive wire E 4 Reassemble NOTE Make sure that the spring that acts upon the home position sensor actuator is seated correctly 5 64 31 August 1989 8 6 Drum Current Adjustment Preparation NOTE drum current varies with environmental conditions such as humidity
343. loper to the development roller sleeve The turning sleeve of the development roller then carries the developer past the doctor blade C The doctor blade trims the developer to the desired thickness and creates backspill to the crossmixing mechanism The development roller continues to turn carrying the developer to the selenium drum D When the developer brush contacts the drum surface the positively charged areas of the drum surface attract and hold the negatively charged toner In this way the latent image 15 developed The development roller is given a positive bias to prevent toner from being attracted to the non image areas on the drum that may have residual positive charge The bias controls image density After turning another 100 degrees the development roller releases the developer to the developer tank The developer is agitated by the paddle roller and the crossmixing mechanism The knocking solenoid vibrates the upper cover of the developer unit to prevent toner buildup 2 26 31 August 1989 5 2 DEVELOPER EXCHANGE UNIT NS lt a SS SSD ff SF The developer exchange plate A enables the removal of developer from the development unit The developer inlet cover B enables the addition of developer to the development unit without separating the toner tank from the development unit SP87 sets the PM cycle When a predetermined count is reached the service call indicator blinks the gu
344. ly to the registration rollers H The feed roller of the second feed station however feeds the top sheet to a set of relay rollers which then feed the sheet to the registration rollers 2 03 31 August 1989 10 2 LIFT MECHANISM AND PAPER END DETECTION When the cassette is inserted into the copier the cassette actuator pin A is pushed down by the cassette The lift motor unit then mechanically pivots clockwise at point B so that the lift gear C engages with the sector gear D Simultaneously the paper size actuator plate actuates the paper size sensor The CPU then detects that a cassette has been inserted and turns on the lift motor The lift motor raises the bottom plate until the top sheet pushes up the pick up roller When the paper pushes up the pick up roller E the lift sensor F is de actuated and the CPU turns off the lift motor When the lift motor has turned on the CPU allows 10 seconds for the lift sensor to deactuate lf the cassette is not inserted correctly the lift sensor will not deactuate If this occurs the operator panel will display Reload the Cassette This will increment both SP120 total service calls and SP121 service call breakdown Service codes for the cassettes are as follows 2 64 31 August 1989 As paper is fed into the copier the level of the paper stack gets lower If the level becomes too low the lift sensor is actuated and the CPU energizes the lift mo
345. m Transport Drive Belt Front Helical Cam Ass y Stepped Screw M4 Lever Home Position Sensor Spacer 6 1x13x1 5mm Cushion Bin Side Stay Timing Belt 1270P5M Relay Guide Plate uide ire late Antistatic Brush Brush ing Plate Antistatic Brush Sorter Connector Adapter Grounding Wire Protection Circuit Board Relay Harness Protection Board Index Q ty Per Assembly 3 SORTER BOARD A411 August 31 89 CAPACITOR VARIABLE RESISTOR CONNECTOR FUSE SYMBOL INDEX SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL NO NO NO NO 180 SYMBOL SYMBOL SYMBOL NO C101 141 Clit 145 C121 154 C131 154 154 C151 VR101 136 103 101 111 C102 149 C112 144 C122 154 C132 154 C142 134 136 CN102 102 110 C103 143 C113 142 C123 154 C133 154 C143 154 VR103 137 CN103 104 1102 182 C104 178 143 124 154 C134 154 C144 154 VR104 139 CN104 107 110 C105 179 115 152 C125 154 C135 154 C45 154 VR105 139 105 105 DIP SWITCH RESISTOR ARRAY C106 150 C116 152 C126 154 C136 154 C146 154 VR106 138 1 4 C107 148 C117 154 C127 154 C137 166 C147 180 SYMBOL SYMBOL NO NO NO 01 101 12 139 IC RESISTOR 1 109 123 134 161 156 165 161 161 16110 120 171 161 158 161 161 161 16111 129 173 160 158 161 163 161 12103 175 16112 124 R104 133 R114 168 R124 160 R134 158 R144 161
346. m the sensor the value for the bare drum Vsg and the value for the sensor pattern image Vsp These two values are then compared to determine whether or not more toner should be added 1 Vsp lt 1 8 of Vsg High image density no toner added 2 Vsp gt 1 8 of Vsg Low image density toner is added V VSG UR f 9 v um 5 Bare Sensor 5 R VSP E VSP m 20 nuca m 9 VSG VSP VSG drum pattern When the image density is too low Vsp gt 1 5 volts the CPU changes from the detect mode to fixed toner supply mode It will be recovered when VSP becomes less than 1 5 volts automatically Vsg becomes less than 2 5 volts the CPU determines that the sensed data is abnormal then it stops any further toner supply to the development tank However toner supply is re established if Vsg becomes greater than 2 5 volts In either case the service call indicator will blink SP mode 54 turns on the LED sensor manually VR1 on the ID sensor board adjusts the intensity of the sensor LED the voltage of SP mode 55 displays Vsp and Vsg voltage values 2 41 31 August 1989 6 5 TONER SUPPLY AMOUNT This copier has two different ways of controlling the amount of toner supplied Normally the detect supply mode system is used to control toner supply However a fixed supply s
347. mp 85V 160W 121 August 31 89 5 i Page and rts No escription Index No AC Drive Board 115V AC Drive Board 115V AC Drive Board 220 240V AC Drive Board 220 240V Transformer 220V 240V 100V 327VA DC Control Unit Power Pack PCC Power Pack T amp S Power Pack PQC amp BR DC Motor Harness DC Motor Harness DC Motor Harness Photointerruptor Harness Photointerruptor Harness Photointerruptor Harness CFL Stabilizer Lift Motor DC1 69W Lift Motor DC1 69W Upper Left Stay Upper Right Stay Leaf Spring Transport Handle ain Drive Motor Bracket Fusing Drive Unit Bracket Timing Belt Tension Bracket Tension Lever Fusing Drive Support Plate Motor Shaft Support Plate Stud Perforated Disk Photointerruptor Bracket Pulley amp Gear 36T 45 Pulley amp Gear 36T 45 Idle Pulley Bracket Tension Lever Drum Drive Right ADF Bracket ADF Support Bracket Page and Parts No Desc tion Left ADF Bracket Exit Cover Bushed Roller Chain 160P Front Cover Bracket Magnet Catch Plate Inner Cover Registration Sensor Operation Panel Bracket Right Operation Panel Bracket Left Operation Panel Bracket Center Operation Panel Support Bracket Bracket Right Front Cover Upper Bracket Right Rear Cover Bottom Bracket Right Rear Cover Lower Inner Cover FT5550 Band Front Cover
348. n the copier supplies 100 Vac to the inner transformer The transformer drops it to 23 Vac This 23 Vac is changed to 24 V Vs through the rectifier and the voltage regulator IC IC1 in the sorter power supply unit And also 23 Vac is changed to 30 V Vm through the rectifier only 24 V Vs is dropped to 5 V by IC2 in the sorter main board 24 V is then supplied to the solenoids and jam sensor LED 30 V Vm is supplied to the dc motor and 5 V is supplied to the CPU the other ICs and the inlet sensor 24 V Va is supplied from the copier to the sorter main board 24 V Va is supplied only to the upper jam sensor in order to prevent the sensor from misoperating because of a change of voltage 14 10 31 August 1989 7 2 Bin Gate Operation A Each bin gate shaft A is individually controlled by a solenoid Normally the bin gates B are held out of the paper path by the return spring To feed paper into a bin the sorter CPU energizes the appropriate solenoid The solenoid plunger D then rotates the bin gate lever E and opens the gate out into the paper path The curved inner face of the gate directs the paper into the bin After the paper passes into the bin the solenoid turns off and the return spring pulls the bin gate lever back to the closed position 14 11 31 August 1989 7 3 Relay Guide Plate Reset Mechanism This mechanism prevents the relay guide pla
349. na Receptacle Pick off Solenoid Pressure Lever August 31 89 P Page and D sas wo Description EA August 31 89 Page and Parts No Description Pa No 9 7 2 Pick off Pawl Lever Transport Switch Bracket Cleaning Drive Bracket Drive Roller Transport Belt Blade Solenoid Transport Drive Shaft Bracket Fusing Unit 115V Fusing Unit 220V Bracket Pick off Pawl Solenoid Cap Large Toner Collection Tank Sensor Holder Fusing Side Frame Rear Leaf Spring Toner Collection T Fusing Side Frame Front Toner Collection Bracket Pressure Lever Right Bracket Toner Collection Thermistor Mounting Frame Upper Entrance Guide Plate Fusing Left Bracket Toner Collection Toner Receiver Collection Fusing Connector Bracket Pipe Toner Collection Receiver Oil Sump Left Fusing Rail Ozone Filter Bracket Feeler Holder Fusing Unit Stopper Separation Corona Cleaner Oil Pan Paper Guide T amp S Corona Silicon Oil Nozzle Fusing Unit Cover Separation Cleaner Slider Tension Bracket Wire Cleaner Leaf Spring Heat Shield Cleaner Drive Wire Separation Oil Supply Bracket Sensor Feeler Separation Corona Oil Pump Actuator T amp S Corona Casing Leaf Spring Oil End Sensor Connector Bracket Lamp Terminal Bracket T amp S Corona Cover Entrance Guide Plate Fusing PTL Guide Holder
350. nd applies even pressure automatically Also since pressure is transmitted to the center a single pressure spring is used The blade scraper H is mounted in contact with the bottom side of the cleaning blade When pressure is applied to the cleaning blade it is forced forward and bends at its outer edge When pressure is released from the blade it snaps back to its original position Simultaneously the mylar of the blade scraper scrapes off the excess toner and paper dust from the edge of the blade This helps to maintain efficient cleaning The blade pressure is released when there is no key input for 15 minutes 15 seconds after a paper misfeed occurs or when the safety switches open Also the blade pressure is released for 1 second after every 100th copy The blade scraper also prevents toner from scattering inside the copier by keeping toner inside the cleaning unit 2 58 31 August 1989 8 5 CLEANING SOLENOID CIRCUIT 24V Va Cleaning 101 Solenoid v24 E SOL A 200msec YY Main Motor NESE e 77 777 HERRERA Paper Feed Motor Cleaning Solenoid RIEN I 15min When the Start key is pressed to start a copy cycle the CPU outputs a LOW signal at CN101 A3 to energize the cleaning solenoid The main motor and paper feed motor turn on 200 milliseconds later The CPU then de energizes the cleaning solenoid 15 minutes after the main motor is turned off This delay decreases the amount of t
351. nding wire 0 twice around the coil 0 and secure the wire to the cover plate E or the screw F on the left side rear view of the RDH 12 10 31 August 1989 6 REPLACEMENT AND ADJUSTMENT 6 1 Lower Transport Roller Replacement A B 1 Turn off the main switch 2 Remove the menu reader from the copier 3 strips of velcro tape 3 Remove the upper cover A 4 screws and the reader unit B 2 screws 10P connector 12 11 SECTION 13 TROUBLESHOOTING TROUBLESHOOTING 1 SERVICE CALL CONDITIONS 2 DEFECTIVE SENSOR TABLE Contents 31 August 1989 1 SERVICE CALL CONDITIONS Code 11 Exposure Lamp Malfunction Definition Lights if the lamp filament breaks or if the lamp turns on during ready or please wait modes Observation When the main switch is turned on call service code 11 is displayed Points to Check If the lamp is lit during the stand by mode check CN103 5 on the main PCB If it is not lit during copy cycle check CN501 6 on the ac drive board Check the exposure lamp Code 12 Lamp Relay Open Definition Lights if the lamp stays on longer than 15 seconds during a copy cycle Observation The lamp remains lit when the scanner returns to the home position Points to Check Check CN102 A20 CN101 A24 and CN103 5 on the main PCB Code 21 Scanner Home Position Not On Definition The scanner drive motor is energized until the scanner home position sensor is blocked I
352. nergized by the SSR PCB drives the separation rollers F via the paper feed drive chain G and gears 2 69 31 August 1989 Pick up Roller Up Down Movement The pick up roller is raised by a solenoid When the leading edge of the paper passes between the feed roller and separation roller the CPU energizes the solenoid and the pick up roller is lifted out of the paper path This copier has three pick up solenoids Two solenoids A are used for the first and second cassette paper feed The other solenoid B is used for manual paper feed The lift timing of the upper and lower pick up rollers is different After the trailing edge of the paper passes under the pick up roller the pick up roller drops onto the paper stack in preparation for the next copy cycle 2 70 31 August 1989 10 6 MANUAL FEED Detection In manual feed mode up to 20 sheets normal weight can be loaded on the manual feed table and fed into the copier without a cassette Manual feed mode uses the rollers of the first feed station When the manual feed table is opened the manual feed sensor A sends a low signal to the CPU The CPU then shifts to manual feed mode The actuator B of the first cassette paper end sensor stays in the same position but the CPU detects a paper end condition in the manual feed table and lights the Add Paper indicator When paper is inserted into the manual feed table the manual feed paper end sensor is actuated The
353. ni 6 0060 Retaining Ring 6 5094 Tapping Screw M4x8 3045 Washer 5009 Washer 8 1x14x0 1mm 7071 Flat Washer M11 0400 Parallel Key 3005 Philips Screw With Flat Washer M3x5 in g g g g 4008W Tapping Screw With Flat Washer M4x8 0016 String 0277 Fastening Receptacle 0277 Fastening Receptacle Parts No Description Index No Receptacle Housing Fastening Fastening Fastening Fastening Receptacle Receptacle Receptacle Receptacle August 31 89 Page and Receptacle Receptacl Receptacl Receptacl Receptacl Housing Housing Housing Housing Sleeve Pin Mate N Lock Pin Mate N Lock Pin Mate N Lock Socket Mate N Lock Socket Mate N Lock Socket Mate N Lock Terminal Terminal Receptacle Terminal Receptacle Terminal Mate N Lock tact tact Terminal 3P Connecting Sleeve 3 0mm 220V Nylon Stud Receptacle Housing Receptacle Housing Receptacle Housing Connector Connector 2P Connector 2P Connector Connector Connector Connector Connector 3P Connector 3P Receptacle Housing 3P Receptacle Housing 3P nector nector nector nector nector nector nector nector nector Receptacle Ho nector nector nector Connector ector l
354. nit from the copier Perform steps 2 to 4 of Bin Drive Belt Replace ment Remove the sorter front cover 2 screws Remove the roller drive belt A Remove the pulley B from the exit roller motor E ring Disconnect the motor connector C Remove the exit roller drive motor D 4 screws 9 19 31 August 1989 8 5 Lower Exit Roller Unit and Exit Sensor Replacement 1 Remove the sorter unit from the copier Perform steps 2 to 4 of Bin Drive Belt Replace ment 2 Open the upper safety cover A of the sorter A and pull the upper exit roller unit B up out of the guide rails as shown 3 Remove the rear C rail by releasing the hooks D on both sides as shown 9 20 31 August 1989 4 Remove the round belt 5 Remove the lower exit roller unit B from the sorter 4 screws 6 Remove the exit sensor C shown 1 screw 9 21 SECTION 10 1K LCT Contents 1K LCT 1 SPECIFICATIONS o3 10 1 2 MECHANICAL COMPONENT LAYOUT 10 2 3 DRIVE LAYOUT AND DRIVE MECHANISM 10 3 4 ELECTRICAL COMPONENT 0 10 4 5 FUNCTIONAL AND ELECTRICAL DESCRIPTION 10 5 RAY OPERATION ea 10 5 5 2 PAPER SIZE CHANGE AND 10 7 5 3 PAPER VOLUME DETEGTION
355. nsert the key counter holder D 5 Align the holes in the fixing plate with the mounting holes of the key counter holder and secure the key counter holder NOTE The fixing plate has three sets of holes Make sure to use the set that matches the holes on the counter 6 Remove the shorting plug E from the key counter connector F 7 Plug in the key counter harness C 8 Reassemble the copier Insert the key counter and check its operation NOTE Confirm that SP 90 Secret mode is set in No position 3 16 SECTION 4 SERVICE TABLES Contents SERVICE TABLES TI PM TABEE 2376313278858 o Gore Meads 4 1 2 SERVICE TABLES 2422952152255 e seh Rud dnd Sow De 4 4 2 1 TeSb Polla aeter EUH EEUU ER benny RUPTURE 4 4 2 2 RES S c xo tad e EE ELE eet eu Pact Ado 4 4 4 5 21056006 TADE DA emm 4 5 2 5 Service Program SP 8 Data Input Guide Table 4 6 3 SERVICE PROGRAM MODE OPERATION 4 7 3 1 Service Program 5 4 7 3 2 Change Adjustment Values or Modes 4 7 5 0 pe RA E ERRAT 4 8 3 4 Service Program Mode 4 10 3 9 Language Gode Table cry soa daa e
356. nsing mode 2 8 31 August 1989 3 2 EXPOSURE LAMP CONTROL 24VA RA1 mE Main PCB AC Drive PCB Y 501 9 Lamp Control CN503 1 oo _ Trigger Ros M t AC H 103 5 _ Monitor La Monitor 2 Zero m S B Aun CN103 11 CN501 1 Detect 0 a 15Sec 101 24 Safety 501 RA CN503 5 Timer 15 Second Safety Relay Lamp CN502 1 5 2 2 Satety 4 Relay CN102 20A SW8 Sw Thermofuse After the Start key is pressed the main PCB sends the exposure lamp trigger signal C to CN501 6 on the ac drive board The width of the lamp trigger pulse is based on the setting of SP mode 48 and on the zero cross signal B from the ac drive board This lamp trigger pulse activates the triac on the ac drive board which provides exposure lamp power D from the 100 volt ac line A The power supplied to the exposure lamp is also provided to the lamp monitor circuit which rectifies it and supplies it to the Sub CPU analog port E This allows fine tuning of the trigger pulse width and ensures accurate circuit operation The lamp monitor signal is also monitored by a timer circuit in the main board Should this signal stay active for longer than 15 seconds the main board energizes relay RA on the ac drive board This c
357. nt Cover 1 Brake Front Cover FT5570 1 Gear 16 Front Cover FT5550 1 Plate Nut Key Counter o Front Cover FT5540 1 Key Counter Bracket Band Front Cover Plate 12x220x1T Front Cover Hinge Right 1 1 Misfeed Large 5540 5570 Front Cover Hinge Left 1 1 Misfeed Small 5540 5570 Front Cover Bracket ii Misfeed FT5550 Left Inner Cover 1 1 Adding Toner Inner Cover Upper 1 A2 Cover Registration Sensor 1 1 Regist Sensor Inner Cover Lower FT5570 5540 1 1 Sensor Checker Inner Cover FT5550 1 Spring Plate Manual Feed Inner Cover 1 Lower Rear Cap Front Cover 1 Left Cover Option et Catch Ass y Upper Front Cap Bracket Right Front Cover Upper Cover Bracket ADF Manual Feed Table Holder Tonner Collection Rear Cover Rear Cover Rear Cover anual Feed Front anual Feed Rear ide Fence Manual Feed anual Feed LT anual Feed A3 A4 Index Q ty Per Index Q ty Per Assembly Nox Eu Ese Philips Sunken Head Screw M3x6 Tapping Screw M4x8 Tapping Screw M4x8 Tapping Truss Head Screw M4x8 Truss Tapping Screw M4T3x8 Knob Screw M4x6 5 ilips Flange Screw 4 5 ing Screw With Flat Washer M3x8 j Saddle ilips Screw With Flat Washer M4x8 Tapping Screw With Flat Washer M4x8 Tapping Screw M3x6 Tapping Screw M4x6 2 EXTERIOR 2 A045 A046 August 31 89
358. nt down 1 DOWN Auto Cassette Shift 0 YES Selects autocassette shift mode 1 NO Beeper 0 YES Turns beeper ON or OFF 1 NO Auto ID Priority 0 ADS Selects the priority of image density control when 1 Man the main switch is turned on Feed Station Priority 0 1st Selects feed station priority at power on em Comments No is displayed when 0 is selected Motor starts when Enter key is pressed Stops after 1 cycle For data see the input check table 100 will appear in the copy counter Press Start to activate DIP SW 801 3 4 5 must be set see DIP SW tables Factory setting 0 E DIP SW 801 3 4 5 must be set See DIP SW tables Factory setting 0 Copier automatically shifts to another cassette holding same size paper when paper runs out Factory setting 0 Factory setting 0 Factory setting 0 Factory setting 0 Mode No 21 22 23 24 25 26 27 28 30 32 33 34 3 Function APS Priority Selects APS or manual SADF Shut Off Time Selects shut off time for SADF mode Free Size Enables originals of various sizes to be fed from the same stack RDH ARDF priority Selects RDH or ARDF Staple limit Sets staple limit at 35 copies Shift stack Shift stack mode is automatically selected when staples run out Side erase Decreases side erase margins about 5mm each Sort Priority Sort Mode is automatically select
359. ntil the temperature reaches 185 C 2 87 31 August 1989 Hot Roller Temperature 220 240 C Upper Temperature Limit lf for any reason the hot roller temperature reaches the upper temperature limit the fusing thermistor resistance will become so low that the CPU detects a thermistor short resulting in a Call Service condition Code 53 This prevents the roller from being damaged 215 220 C Maximum overshoot must be less than this value 185 C Operating Temperature During the Ready condition the temperature is kept at this value 175 C Machine Idle Run At this temperature the caution beeper sounds five times After 2 seconds the machine starts to idle 12 8 SERVICE CALL CONDITIONS Code 52 Thermofuse Blown Definition Lights if the thermofuse circuit opens or the fusing unit is not set correctly Observation Code 52 18 displayed when the main switch is turned on Points to Check Confirm that CN102 B19 on the main board is 24 volts Confirm that the fusing unit is properly set Code 53 Thermistor Blown Definition Lights if the fusing thermistor opens Observation Code 53 is displayed when the main switch 15 turned on Points to Check Disconnect the white thermistor connector on the front side of the fusing unit Check the resistance of the thermistor at the white connector Reference value 1 10 kohms at 180 C 180 kohms at 10 C 2 88 31 August 1989 Code 54 Ready S
360. o correct paper skew The positioning roller is then lifted and the jogger fences move inwards to square the stack every time a sheet enters the duplex tray 2 99 31 August 1989 Jogger Drive Mechanism Both the front A and rear B fences of the jogger unit are attached to the same wire C The jogger drive pulley D is mounted on the jogger motor shaft When the jogger drive pulley turns both fences move the same distance in opposite directions The jogger home position sensor E informs the CPU when the jogger is at the home position In duplex mode when the Start key is pressed the jogger fences are driven outward by the stepper motor and the sensor actuator plate F slides through the slot of the jogger home position sensor to the reference home position After the home position is referenced the jogger fences move inward and the stop position is determined by the paper size cassette code 2 100 31 August 1989 Jogger Motor Circuit 24V Va mem n4 7 Wi UTD cl __ f Circuit JT NENNT Jagger exor 27 2 Ysvvo A Y gt EZ 2 _ 122 The jogger motor is a stepper motor It is controlled by phase signals from the main CPU on the main board as shown in the above block diagram With this motor step 15 1 80 One complete revolution equals 200 steps 2 101 31 August 1989 Duplex Positioning
361. ocedure 5 Language PARTS INDEX Page and Parts No 2 0 AEN rA BO PO PD A p BE Front Guide Cover Receiving Cassette Rear Guide Cover Receiving Cassette Paper Feed Stay Paper Feed Cover Upper Upper Paper Feed Separation Stay Upper Paper Feed Separation Stay Solenoid Bracket Pick up Solenoid Bracket Feed Guide Shaft Feed Guide Shaft Pick up Shaft Pick up Shaft Pressure Pick up Lever Arm Lever Paper Knob Release Arm Paper Feed Guide Release Cam Cassette Paper Knob Lever Paper Knob Paper Feed Spring Cushion Rising Gear Separation Drive Gear Separation Drive Gear Paper Feed Support Bracket Paper Bank Base Holder Plate Transport Guide Right Transport Guide Front Guide Spring Rear Guide Spring Paper Feed Guide Paper Feed Guide Upper Transport Guide Right Paper Feed Guide Lower Transport Drive Roller Lower Transport Roller August 31 89 Page and Parts No Description Bushing Bushing Paper Sensor Feeler Shield Plate Paper Sensor ED Sensor Bracket Lower Feeler Bracket Print Board Bracket Transport Shaft Upper Relay Shaft Tention Arm Pulley 15T 18T Motor Bracket Timing Belt 184XL Idler Bracket Idler 5mm Idler 5mm Capacitor Bracket agnetic Clutch Stopper Rubber Magnetic Clutch Stopper Rubber
362. oling fan Main PCB iamp Corona cleaner 5V VB Motor Erase unit bee The illustration on this page shows the electrical power distribution in block form AC power 115 220 volts is supplied from the wall outlet directly to the fusing lamp and the step down transformer The transformer supplies 100 volts ac to the power supply unit SSR board ac drive board and to one side of the fans motors heaters paper bank and sorter The power supply unit has four dc fuses and one ac fuse 1 29 SECTION 2 DETAILED SECTION DESCRIPTIONS Contents DETAILED SECTION DESCRIPTIONS 5 oes Bate Se ae Sh ee eee 2 1 1 1 SELENIUM DRUM CHARACTERISTICS 2 1 1 2 HANDLING THE DRUM dacs ow 2 1 1 3 DRUM HEATER CONTROL toca saan Rie qund EL C Bowes s 2 3 2 DRUM CHARGE 2 4 2 OVERVIEW ee V 2 4 2 2 WIRE CLEANER 2 aed ted a iad rubor d edd 2 5 2 3 CHARGE CORONA POWER 2 6 OPTICS A eee i es Got ab eas 2 7 S OVERVIEW orto te nee td tede cH 2 7 3 2 EXPOSURE LAMP CONTROL a e iex elena ee RU 2 9 39 3 SCANNER DRIVE eae ee eae 2 10 3 4 SCANNER MOTOR CONTROL oak
363. on Roller Decal A Holder Development Unit Spring Drive Wheel ing Drive Wheel Cleaning Balde Shaft g Pick off Pawl Slide Fusing Drive August 31 89 Page and ES Separation Roller Page and Rear Bracket Lamp Terminal Stud Exit Ass y Release Lever Separation Roller Spring Front Release Lever Input Hub Spring Rear Release Lever Input Hub Slip Clutch Input Hub Decal High Temperature 220 240V Cyrindrical Spring Decal High Temperature 220 240V Cyrindrical Spring Small Decal High Temperature 115V Gear 15T Small Decal High Temperature 115V Pick up Roller ing Powder Pick up Roller Light Shielding Bag Paper Feed Roller Launa Oil Paper Feed Roller Drum Shoe Stepped Screw Pin By Pass Feed Table Friction Pad B Bushing Bushing Bushing Friction Pad B Bushing Plate 12 220 1 Tube Clamp Noise Filter 220 240V Heat Resisting Grease MT 78 Plate Nut Key Counter Toner Receiving Pipe Platen Cover Pad Stepped Screw M4 Flex Hinge Platen Cover Bushing 6x10x6mm Stepped Screw Spring Charge Wire PCC Stepped Screw Spring Hot Roller Stripper Screw Driven Guide Output Hub Output Hub Output Hub Screw Driven Guide Screw Driven Guide Arm Screw Slip Clutch Cover Spring Drive Motor Tension Slip Clutch Cover Shoulder Sc
364. on 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 which has low stiffness PRE CLEANING The pre cleaning corona PCC applies an ac corona with a negative bias to the drum This removes the positive charge from the drum and makes the negative charge on the toner remaining on the drum even CLEANING The cleaning brush removes most of the toner on the drum and loosens the remainder Then the bias roller which has a positive potential attracts the toner particles from the cleaning brush to keep it clean Finally the cleaning blade scrapes off the loosened toner QUENCHING The pre quenching corona applies a positive corona charge to the selenium drum to eliminate any negative charge remaining from the pre cleaning corona Then light from the quenching lamp electrically neutralizes the drum 1 11 31 August 1989 4 COPY CYCLE Document Feeder i Feed out Unit Charge Corona Unit Power Pack C B Original Positioning Power Pack Pre Quenching Charge Unit Quenching Sensor Pattern Erase Lamp Unit Development Toner Density Detection PTL Lamp Stabilizer Ne Cold Cathode Tube Q PTL Copier PRS T Manual TETUR Feed Table Cleaning Pre Cleaning Corona Auto ID Senso
365. on of the accessories in the box according to the following list 1 Relay Guide 2 Knob Screw 3 Spacer 4 Stud 5 Grounding Screw 6 Toothed Washer 220 240V only 7 Multiple Language Decal 220 240V only 8 NECR 9 Envelope NECR 115V only NO 9 10 31 August 1989 7 2 Installation Procedure A 1 Remove the strips of tape A 2 Open the sorter top cover B and remove the side covers C 2 screws each Remove the shipping retainers D 2 screws each 31 August 1989 3 Exchange the relay guide E 1 screw with the relay guide F from the accessories 4 Remove the sorter cover G and discard Use a spanner to move the studs H to the upper position 5 Turn off the main switch and unplug the copier power supply cord 9 12 31 August 1989 JF N 4 FL 974 8 de code WAE 1 QEN k 6 Remove the receiving tray A and the rear cover B of the copier 2 screws Swing out the main board C 2 screws CAUTION Be careful not to damage the fiber optics cable 7 Remove the five plastic caps D from the left cover 8 Install the two studs E in the lower holes F 9 Mount the sorter on the copier Insert the two mounting studs G into the docking holes H and pass the harness 1 through the access hole J 10 Fix the sorter to the copier w
366. on ratio As the paper is fed to the center of the drum the LEDs for side erase turn on in pairs The erase lamp is not used for side erase with A3 or 11 x 17 paper For these paper sizes side erase occurs due to the end block covers of the charge corona The CPU adjusts the side erase margin to be as near as possible to the actual image size even when using the zoom function However since the erase lamp LEDs will not work in precise one millimeter intervals the side erase margin varies slightly depending on the reproduction ratio SP 27 decreases the side margins by 5 mm 2 23 31 August 1989 4 4 EDGE ERASE FUNCTION 5 10 mm 15mm 20 mm e rac 2 4 0 6 0 8 13 5mm 18 5mm _ 44 5 3 The edge erase function erases a border around the copy The border is adjustable in 4 steps using SP mode 38 These borders are approximately 5 10 15 and 20 millimeters wide but vary slightly according to paper size and the selected reproduction ratio The table shows the ON OFF condition of the erase lamp LEDs for the various paper sizes The factory setting is 10 millimeters 2 24 31 August 1989 4 5 ERASE LAMP CIRCUIT 215 ERASE UNIT B GND ar 5 SV VB i COND CN102 A16 CN37 5_ ACLOCK ENABLE E 102 18 ee REBASE DATA CN102 A17 MAIN B
367. oner scattering which occurs when the blade is released too frequently Key ON Cleanin Soleno vein A In cases where the copy cycle is initiated and the cleaning solenoid is already energized the CPU turns on the main motor and paper feed motor immediately Main Motor Cleaning gt 7 7 Solenoid 15sec 1sec The CPU counts the total number of copies made in both single and multiple copy runs After 100 copies the cleaning solenoid de energizes 15 seconds after the main motor stops It re energizes 1 second later The cleaning solenoid also de energizes 15 seconds after the front door is opened 2 59 31 August 1989 8 6 PRE CLEANING CORONA CIRCUIT 24V Vp P GND 4 lt Front Door Safety Switch Main PCB TC SC PCC Y VV VV Inverter E b The PCC power pack receives 24 volts Vp from the TC SC power pack energize the PCC power pack the main board supplies a LOW signal at CN101 A2 to the PCC power pack through the TC SC power pack which in turn applies a LOW signal at CN1 4 to energize the PCC power pack The PCC power pack energizes at the same time that the main motor turns on and de energizes 570 milliseconds after the registration sensor turns off Main Motor Registration 777 Sensor 7 Cla i i 570msec Ke i 2 60 31
368. ont Drum Flange Separati 1 G G Paper Feed Brace Upper F F Bracket Blower Duct Separati Bracket Blower Separati Arm Air Guide Plate Separati Arm 21 21 21 21 21 21 2 21 21 21 21 21 21 21 21 21 21 ID Sensor Duct Paper Size Sensor Bracket Drum Guide Paper Size Sensor Bracket Drum Drive Pulley 112V Paper Feed Stay Lower Registration Knob Bracket Paper Feed Roller 123 August 31 89 Parts No Description page one Index No Index No Parts No Description Feed Guide Paper Feed Roller 21 4 Manual Feed Cover Feed Guide Paper Feed Roller 23 8 Guide Manual Feed Front Stay Paper Feed oq Guide Manual Feed Rear Upper Magnetic Clutch Stopper 21 51 anual Feed Table Support Paper Feed Roller Bracket 23 12 Decal Manual Feed Table Lower Paper Feed Stay 23 1 Decal Side Fence Manual Feed Magnetic Clutch Stopper 43 48 anual Feed Table Holder Paper End Feeler 21 70 anual Feed Table Holder Paper End Feeler 23 2 anual Feed Sensor Bracket Paper End Actuator Bracket 21 66 Spring Plate Manual Feed Upper Bracket Paper End 21 14 Guide Cassette Holder Front Lower Bracket Paper End 23 18 Guide Cassette Holder Rear Paper End Shutter Upper 21 12 Cushion Upper Pick off Bracket Paper End Actuator Bracket 23 3 Cushion Lower Pick off Bracket Feed Control Board Bracket 6
369. ontacts the stopper plate E and the friction roller stops rotating At this point the separation mechanism will eliminate double feed When the trailing edge of the original passes the friction roller the spring F returns the lever to its original position without rotating the friction roller shaft 8 7 31 August 1989 6 WEAR PREVENTION The rear side of the feed roller shaft drive gear has an eccentric cam A This cam contacts the wear prevention lever B which is attached via a one way clutch to the friction roller shaft C This lever is free to rotate in the direction of the white arrow D As the feed roller drive gear rotates the high point of the cam pushes back the wear prevention lever in the direction of arrow D As the cam rotates to the low point a spring returns the wear prevention lever to its original position black arrow E When the wear prevention lever returns it rotates the friction roller shaft through the one way clutch Every time the feed roller shaft rotates once the friction roller shaft rotates a few degrees This prevents the friction roller from wearing unevenly too quickly 8 8 31 August 1989 7 FRICTION ROLLER RELEASE MECHANISM In the ADF mode when the original activates the original entrance sensor A the DF CPU energizes the roller release solenoid B This action rotates the roller release cam shaft C which has an eccentric cam D on each end to decrease the ove
370. or 4 7 1 4W 5 Resistor 5 6 1 4W 5 Resistor 560KOHM 1 4W Co Connector 3P rn nector rn ector Hi c a ector ector rn ector xn Gy OY lon Stud Cord Clamp Fuse Circuit Breaker 115V Microswitch UL Push Switch Solid State Relay 240V 3A Power Relay RICOH RICOH 5540 5550 5570 045 046 PARTS CATALOG COMPANY LTD PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of this parts on this machine INDEX to PARTS CATALOG FT5540 5550 5570 045 046 PS220 DF51 CS2080 CS1530 A455 RT16 21 MR20 Location of 3 1 CON B Q 11 12 13 14 15 16 17 18 19 20 21 22 23 Exterior 1 045 046 8 Exterior 2 045 046 10 Optics 1 045 046 12 Optics 2 045 046 14 Optics 3 045 046 16 Platen Cover and Cassette A045 A046 18 Paper Feed Unit 1 A045 A046 20 Paper Feed Unit
371. ork Gate Actuator Transport Spring Transport Spring Tension Spring Transport Lever Spring using Entrance Spring 6mm 5x7x16 Drive Roller F B Bushi 3x6x6mm B 5 ushi 8x16x5mm 116 August 31 89 Page and P N Desc tion arts No ripti Index No 12 12 12 13 13 13 13 13 13 13 13 13 13 13 13 14 14 14 14 6x12x4mm 4x7x5mm 6mm 6mm Bias Roller Bu B B B B 6mm B B B 6x18x5mm Holder Development Roller Bearing Charge Corona Feeler Rear Lamp Terminal Inner Insulator Front Outer Insulator Rear Outer Insulator Front Lamp Terminal Wire Clamp Anti Static Brush Fork Gate Anti Static Brush Fork Gate 4 Anti Static Brush Duplex Idle Pulley Spacer 8 5x20x0 5mm Spacer Spacer Spacer Spacer Spacer 1x8x12mm Spacer 1x8x12mm Spacer 1x8x12mm Spacer 1x8x12mm Spacer 1x8x12mm Spacer 1x8x12mm Pressure Arm Shaft Pressure Arm Shaft Pick UP Shaft Pick UP Shaft August 31 89 ae Page and Parts No escription Index No 3x28x308 2 15 308 2 11 75 2x11x75 Page and Description Index No Paper Feed Shaft Upper 91 3 Paper Feed Shaft Upper 23 1 Inverter Pressure Shaft 31 20 Drum Support Shaft 41 40 Toner Hopper 4x12x211 2x3x53 2x3x45 2x16x53 2xl6x45 4x16x210 2x51x60 3 72 172 2 50 58 3 5 142 3x8x40 3 5 41 2x2x5 2 5 10 2 5 28 2 17 94
372. orm Gear lamp Stay A421 2575 Decal Operater Instruction A912 2596 Operation Skin A421 2576 Decal Paper Siz 1106 0442 Cord Clamp 220 240V A403 1124 Spring Plate Stopper Bar ylon Clip ulley 10 ED Sensor Type 5 ensor Bracket 5714 Stepped Screw 4 N P Drive Motor Bracket L 5 ushing 8mm 0536 agnet Catch Ass y 1117 Front AID Plate 1118 agnet Collar 1245 agnet Catch Plate Gear 45T Drive Shaft Top Cover Rear Cover 5100 Paper Size Board 4335 Decal Terminal 115V 4980 Decal Terminal 220V 1182 otor Bracket Terminal 3P Fuse Holder Fuse 250V 2A Circuit Breaker 115V Side Cover Power Cord Bracket Power Supply Cord 115V Power Supply Cord 220V Bracket Cover Plate 115V Hook Stopper Chain Stopper Bar Stopper Bar Mounting Stud Wave Washer Stopper Bar Knob Operation Board Operation Board Mounting Bracket Nylon Stud Index ee Q ty Per Part No ipti M A Description Assembly No Part No Description Assembly 0140W Philips E Head Screw 0040W Philips E H Screw 0060W Philips F Head Screw 0080W Philips Head Screw 0100W Philips Head Screw 0120W Philips E Head Screw 0060W Tapping Screw M4x6 0080W Tapping Screw M4x8 0050E Hexagon Headless Set Scr 0060B Washer 6mm 00602 Retaining Ring M6 1185 Philips Trus
373. p Guide Grip Paper Feed Table Grip Guide Shaft Grip Stopper Transport Knob Bracket Gear 26T Knob Shaft Transport Roller Knob Gear 30T Stopper Guide Decal Decal E Decal Sheet 4LANGUAGE Decal Sheet Print Board Paper Bank Print Board Paper Bank Vertical Transport Harness Vertical Transport Harness Vertical Transport Harness ain Paper Bank Harness Harness Cassette Bank ain Paper Bank Harness Rear Paper Bank Harness Rear Paper Bank Harness Rear Paper Bank Harness Front Paper Bank Harness August 31 Page and Index No 89 August 31 89 du Page and o Page and A420 5276 Front Paper Bank Harness 17 2 1 A420 5276 Front Paper Bank Harness 21 1 1 Decal A420 8610 Installation Procedure English 27 5 Decal A420 8615 Installation Procedure 5 Language 27 5 1 Decal Decal Decal Decal Upper Guide Plate Magnet Pick up Lever Spring Paper Feed Separation Spring Paper Feed Separation Spring Spacer 1x6x10mm Spacer 1x6x10mm Spacer 1x8x12mm Spacer 1x8x12mm Pressure Arm Shaft Pressure Arm Shaft Separation Driven Shaft Gear 151 Gear 151 Gear 25T Gear 25T Gear 20T Gear 20T Gear 18T Gear 18T Gear 21T Gear 21T Idle Gear 40 Gear 40T Gear 20T Gear 20T Gear 20T Paper Feed Motor 32 August 31 89 M Page and te Page and P No arts No Desc
374. pad C 2 screws and 2 clamp plates and unhook the two tension springs D 4 Turn and remove the oil blade assembly E 5 Remove the three screws from the oil blade assembly and remove the oil blade F 6 Replace the oil blade 5 25 31 August 1989 4 3 Thermistor Replacement 1 Remove the oil blade Refer to Oil Blade Replacement 2 Unhook the thermistor spring A 3 Remove the thermistor wire B from the metal wire clamp C 1 screw and replace the thermistor 1 connector 4 Reassemble 9 26 31 August 1989 4 4 Thermofuse Replacement M EEA _ E E gt 1 Remove the fusing unit Refer to Fusing Unit Removal 2 Remove the fusing unit cover 3 screws 3 Remove the pressure plate A 2 screws and the thermofuse bracket B 1 screw 4 Remove the thermofuse lead wire C from the metal wire clamp D 1 screw 5 Replace the thermofuse 1 connector and reassemble 5 27 31 August 1989 4 5 Hot Roller Stripper Replacement B 1 Pull the fusing unit all the way out and open the fusing exit assembly A 2 Unhook the springs B and remove the hot roller strippers C 3 Replace the strippers and reassemble NOTE It is best to replace strippers and springs as a set 5 28 31 August 1989 4 6 Hot Roller Replacement D 1 Remove the oil blade Refer to Oil Blade Replacement 2 Remove any excess oil f
375. paration Roller Philips Truss Head Screw M4x6 54 2693 Separation Roller 1 Tapping Screw M4x8 54 2695 Input Hub 11 Tapping Screw M4x8 54 2695 Input Hub 1 Tapping Screw M4x8 54 2697 Cylindrical Spring 11 Tapping Screw M4x8 54 2697 Cylindrical Spring 1 Hexagon Set Screw M4x6 54 2723 Pick up Roller 11 Hexagon Set Screw M4x6 54 2723 Pick up Roller Allen Screw 4 4 54 2126 Paper Feed Roller 11 E Hexagon Headless Set Screw M5x5 54 2726 Paper Feed Roller Hexagon Headless Set Screw M4x5 Spring Pin 3x10mm Spring Pin 3x14mm Spring Pin 3x14mm Parallel Pin Spacer Washer Bushing 4x5mm August 31 89 Page and Page and Parts No Description Index EM ee Index No Tapping Screw With Flat Washer M4x10 Housing AWG14 20 Socket Mate N Lock Socket Mate N Lock Fastening Receptacle Pin Mate N Lock Socket Mate N Lock Receptacle Terminal Receptacle Terminal Receptacle Terminal pup puppe E Fastening Receptacle Contact Contact Contact Contact Contact Contact LN QQ Q Q QQ Q Q Q Q Q Q Q Q Q Q ad id an am ad d o8 DDD C DR in ips Truss Head Screw M4x8 11 1 Contact ing Screw M4x8 11 1 Contact ining Ring M5 jT 11 1 Pin Contact ining Ring M5 13 11 1 Pin Contact
376. per 1 Upper Guide Plate Magnet Co ED Sensor Volume Sensor Shaft Photointerruptor Pack Bottom Plate Lever A Lower Bracket Paper E 1 Right Transport Guide Co Separation Roller 1 Front Guide Spring Index Index Q ty P Part No Q ty og Assembly us zi d A420 2367 Rear Guide Spring 0060W Pan Head Screw M3x6 72 13 2024 Spacer 1x6x10mm 0060W iT Pan Head Screw M4x6 73 00 1059 Decal E2 0100W 111 Pan Head Screw M4x10 00800 j Screw M4x8 0060W Set Screw M4x6 0050E Headless Set Screw M4x5 01408 m 0030E 3 00408 1 1 4 00508 ini i 5 5 6 5 6 74 AA13 2025 Spacer 1x8x12mm 0050F 0060F 0050 ini ing 0060 ini ing 3042 Ball Bearing 6x10x3mm 3291 Ball Bearing 8x1l6x5mm 0016 Nylon Clip 4N 4116 Spacer M6 11 5 4TH PAPER FEED SECTION A420 August 31 89 APA Nae 78 Jen 4 V agence COL TI dd va d LEG mu gt Sh te o NF 21 a n pd NE Oe we ES aw ye V E OSS T LY Be 2 SALA gt lt gt 5 ols Ze A uu 2 SO eS lt SE e yox E TM 12 n 5 4TH PAPER FEED SECTION A420 August 31 89
377. per Guide Inverter Pressure Lower Guide Inverter Pressure Inverter Guide Plate Inverter Guide Junction Gate Lever 4 CO CO CO CO WwW CO CO Dp S pn 127 August 31 89 Parts No Description Index No Junction Gate Solenoid Junction Gate Solenoid Bracket Inverter Pressure Solenoid Pressure Solenoid Bracket Front Frame Duplex Feed Front Frame Duplex Feed Rear Frame Duplex Feed Rear Frame Duplex Unit Push Lock Push Lock Brac Fork Gate Knob Jogger Stay Jogger Motor Pulley Jogger Motor Bracket Home Sensor Bracket Duplex Guide Plate Jogger Fence Roller Duplex Guide Plate Middle Anti Vibration Pad Large Anti Vibration Pad Small Front Jogger Fence Jogger Fence Shoe 2 Jogger Fence Shoe 1 Jogger Fence Rear Guide Plate Jogger Fence Duplex Setter Mylar Front Duplex Setter Mylar Rear Low Shaft Guide Transport Duplex Settler Guide Duplex Stopper Solenoid Lever Duplex Stopper Paper Stopper Pulley Paper Stopper Pulley Adjusting Plate Duplex Solenoid Wire Clamp Page and D n Connector Bracket uplex Stay Pick up Arm uplex Feed Shaft eed Roller Arm uplex Feed Arm Positioning Solenoid Lever Sensor Harness Cover Entrance Actuator Sensor Cover Guide Pin Toner Catch Pan Seal 5x20x20 Bottom Frame Duplex Feed Duplex Separation A
378. photointerrupters Name Manual Feed Paper End Manual Feed 151 Cassette Paper End 2nd Cassette Paper End 1st Lift 2nd Lift Registration 1st Relay Toner Overflow Toner End Oil End CC Cleaner HP SC Cleaner HP CN CN411 9 Paper Feed PCB CN409 11 Paper Feed PCB CN409 9 Paper Feed PCB CN409 10 Paper Feed PCB CN407 3 Paper Feed PCB CN406 10 Paper Feed PCB CN417 3 Paper Feed PCB CN415 3 Paper Feed PCB CN103 7 Main PCB CN102 B25 Main PCB CN102 B12 Main PCB CN102 A2 Main PCB CN102 B4 Main PCB 2 114 31 August 1989 Fusing Exit CN102 A23 Main PCB Exit Sensor CN102 B23 Main PCB Exit Relay CN104 A9 Main PCB Invertor Exit Duplex Entrance Duplex Paper Jogger HP Scanner HP Scanner Overrun Lens HP 4th 5th Mirror CN104 B9 Main PCB CN104 A2 Main PCB CN104 B1 Main PCB CN104 B2 Main PCB CN305 3 Optics PCB CN305 6 Optics PCB CN305 9 Optics PCB CN305 12 Optics PCB 2 115 31 August 1989 Thermistors Resistance TH BERN Temp A thermistor is a semiconductor that converts a change in temperature into a change in resistance The character of this change is that resistance decreases when temperature increases and vice versa 2 116 31 August 1989 15 8 COUNTER CIRCUITS Main PCB 249 101 5 x Total Counter The CPU energizes the total counter by supplying a LOW signal at CN101 A12 This energizes the counter and clo
379. pier of previously entered settings and modes 19 Start Key Press to start copying 20 Clear Stop Key Press to cancel the copy number entered or to stop copying 21 Number Keys Use the number keys to enter the number of copies Also use to select user programs and input original size and copy size when in size magnification mode 22 Auto Image Density Key Press to select clear automatic image density mode 23 Image Density Keys Press to cancel automatic control and manually select the image density level 24 Select Cassette Key Press to select a cassette 25 Full Size Key Press to change reproduction ratio to 100 26 Enlarge Key Press to make enlarged copies 23 22 21 20 19 18 27 Reduce Key Press to make reduced copies 28 Auto Reduce Enlarge key Press to select automatic reduce enlarge mode 29 Auto Reduce Enlarge Indicator Lights when auto reduce enlarge mode is selected 30 Auto Paper Select Key Press to select automatic paper select mode 31 Auto Paper Select Indicator Lights when automatic paper select mode is selected 32 Duplex Key Press to select a duplex mode 33 Duplex Indicators Show selected duplex mode 31 August 1989 2 3 INDICATOR SCREEN A4 A3 Version 123 4 56 789 10111213 14 _ a Auge 2045 af LER Omm q ERU 20 19 18 17 16 15 1 Full Size Mode Indicator Lights when full size mode is sel
380. position is not reached within 20 seconds after the reverse drive turns on the CPU turns off the cleaner motor and adds 1 to the count stored in SP mode 120 and 121 The code for the charge cleaner motor is SC85 if the sensor stays low and SC86 if the sensor stays high the separation cleaner motor is SC87 and SC88 respectively Copies can still be made and no service call condition is displayed The cleaner motors are energized at power up if a count of more than 5 000 copies are registered in an internal counter since the last time the corona wires were cleaned When the cleaner motor actuates the counter resets to zero 2 111 31 August 1989 15 5 PULSE GENERATOR Main Board N A 102 2 O CN102 B3 7 AA VA N The main board CPU controls the timing of all machine operations The timing is based on how many pulses the CPU receives from the pulse generator Pulses are generated by the rotation of a notched disk within a photointerrupter As the disk rotates light from the LED activates the phototransistor each time a notch appears If no pulses are received for a 4 5 second interval while the main motor is on the CPU displays code SC 61 2 112 31 August 1989 15 6 MAGNETIC CLUTCH AND SOLENOID CONTROL Main PCB 243 Va To energize an electromagnetic device 24 vol
381. pping Screw M4x8 Key Top Base A Tapping Truss Head Screw M4x8 Tapping Screw With Flat Washer M4x8 Flat Head Screw DIP Switch Cover 24 DRIVE A045 A046 August 31 89 A T Rawle PAR MAD vi je 29 B CN INV t dt Vx 2 x C a o A FS PU mx es 6 6 eel 104 3 24 DRIVE SECTION 045 046 August 31 89 Index Q ty Per Index Q ty Per Assembly Noe Development Motor 28W 007 1117 le Pulley Bracket Pulley 35T 60Hz 1 03 0021 Idler Pulley Pulley 42T 50Hz 1 007 1114 Pulley amp Gear 36T 45T Helical Gear 1 01 7029 Pulley Gear Cleaning Joint Shaft Toner Supply 03 0020 Pulley 202 Cushion Motor A007 1123 Tension Lever Drum Drive Development Motor Bracket 04 3004 Timing Belt 699PX si Tightener Bracket 1 007 1108 Perforated Disk Idle Pulley 007 1112 Photointerruptor Bracket Timing Belt 345 1 5215 5230 Photointerrupter L Typ Pulley 24T 14 3033 Stopper Screw Magnetic Clutch Toner Supply 1 007 3461 Development Support Solenoid Support Bracket Development Motor 1 007 3466 Solenoid Bracket Paper Feed Motor Bracket
382. r image Transfer Transport Unit Fusing Unit Separation Corona I Transfer Corona Power Pack T S Duplex Duplex Stacking Transport lt gt 1 12 31 August 1989 5 PAPER PATH Paper feed starts from one of the four paper feed stations The copy paper then follows one of two paths inside the copier The path followed depends on which mode the operator has selected For copy processing all sheets follow the same path from the paper feed mechanism through the fusing unit After that normal copies are delivered to the copy tray however duplex copies are diverted for further processing The following discussion follows the route of a single sheet of paper through a duplex cycle 1 PRIMARY PAPER PATH ON 876 O SILLA Paper Feed An FRR Feed and Reverse Roller mechanism separates one sheet of paper from the paper stack and feeds it to the registration rollers If the paper is fed from the second third or fourth station relay rollers move the paper to the registration roller The registration rollers are not turning at this time The paper buckles slightly when the leading edge reaches the registration rollers Buckling seats the sheet securely between the registration rollers and corrects skew Registration At the programmed time the registration rollers start turning to feed the paper to the drum Image Transfer The toner image on the drum surfac
383. r when moving towards the home position pulley turns counterclockwise the mirror assembly overshoots the selected position by 40 steps by SP 47 and then returns to selected position This takes out any mechanical Play 2 16 31 August 1989 3 7 ORIGINAL SIZE DETECTION NOTE With the F33 34 original size detection is performed using the OL and OW sensors in the ARDF unit For more information see the ARDF options section 3 8 RELATED SERVICE CALL CONDITIONS Code 11 Exposure Lamp Malfunction Definition Lights if the lamp filament breaks or if the lamp turns on during ready or please wait modes Observation When the main switch is turned on call service code 11 is displayed Points to Check If the lamp is lit during the ready or please wait mode check CN103 5 on the main PCB If it is not lit during the copy cycle check CN501 6 on the main board Check the exposure lamp Code 12 Lamp Relay Open Definition Lights if the lamp stays on longer than 15 seconds during a copy cycle Observation The lamp remains lit when the scanner returns to the home position Points to Check Check CN102 A20 CN101 A24 and CN103 5 on the main PCB Code 221 Abnormal Encoder Pulse Definition The scanner drive motor is energized until the scanner home position sensor is blocked If the scanner is not in the home position when the print key is pressed an excessive number of pulses from the encoder are received
384. r Guide Inverter Pressure Junction Gate Bushing M6 Side Frame Inverter Unit Inverter Return Roller Bushing 8mm Drive Gear Bracket Inverter Roller August 31 89 Index Q ty Per Part No Assembly Gear 23T Pressure Solenoid Bracket Junction Gate Solenoid Bracket Spring Drive Motor Tension Spring Inverter Pressure Release Spring Inverter Pressure Cushion Duplex Frame Junction Gate Lever Inverter Pressure Solenoid Junction Gate Solenoid Screw Driven Guide Plate Feeler Shaft Guide Plate Holder Pan Head Screw 3x4 Pan Head Screw 3x4 Pan Head Screw 3x6 Pan Head Screw 4x6 Pan Head Screw 4x10 Screw M4x8 Headless Set Screw M4x6 Ring 2 5 ing 9 ing Ri M3 5 55 g ing Ring ing Screw With Flat Washer M3x6 ing Screw With Flat Washer M4x8 13 INVERTOR SECTION 2 A045 A046 August 31 89 P 2 ar 4 2 EM ue AY fi 26 35 m 7 RU Ep id Ru Ps T8 p mtm CUR mtra V ong lt 2 lo i 1077 CN Cw 2 32 4 AIN 12 7 Nus 08 07 15 14 13 INVERTOR SECTION 2 A045 A046 August 31 89 Index Q ty Per Index Q ty Per Assenbly 2 BOSE Guide Plate Inverter Unit 5206 2808 Anti Static Brush Duplex Transport
385. r Toner Hopper Rear Spacer M6 Worm Gear Seal 8x8x278 Seal 3x72x172 Guide Plate Development Unit Front Side Plat Toner Tank Toner Agitator Scraper Front Side Plate Ass y Toner Tank Plate Spring Toner Supply Bracket Development Filter Decal Adding Toner Filter Bracket Development Unit Upper Hopper Case Ass y Seal 3x28x308 5 e eid Stel 01 0314 0060W Philips Pan Head Screw M4x6 02 0314 0080W Philips Pan Head Screw M4x8 03 0344 0060D Philips Truss Head Screw M4x6 04 0622 0060E Spring Pin 2x6mm 05 0720 0030 Retaining Ring 06 0720 0040E Retaining Ring M4 07 0720 00502 Retaining Ring M5 08 0720 00702 Retaining Ring 7 09 0720 00602 Retaining Ring 6 10 0802 5085 Tapping Screw M4x8 11 0802 5086 Tapping Screw M4x10 12 0951 4008W Philips Screw With Flat Washer M4x8 35 15 DEVELOPMENT 2 A045 A046 pists 15 DEVELOPMENT 2 A045 A046 August 31 89 TU Q ty Per Index Q ty Per Part No r Description Assembly No Part No Description Assembly 3198 Development Unit Guide 1 15 1021 Seal 3 7 55 1060 Seal 3x16x310 1 37 007 3071 Rear Lower Side Plat 0001 Doctor Blade 1 38 A007 3061 Front Lower Side Plat 1059 Seal 2x8x310 39 5215 3101 Gear 441 Seal Doctor Blade 1 1 40 5215 3089 Developer Knob Side Seal Doctor Blade 41 A007 3054 Development Bottom Plate Ass y Guide Pl
386. r actuator plate with the bracket E as shown and secure the actuator plate with tape F 10 22 31 August 1989 7 5 Side Registration Adjustment ADJUSTMENT STANDARD A 297 to 299 5 mm 14 0 1mm The pinion bracket has 8 mm of play for side registration adjustment If the image is shifted to the front D move the pinion bracket in the direction of arrow E if the image 15 shifted to the rear F move the pinion in the direction of arrow 1 Rotate the paper size dial to A4 Do not move the paper size dial again while performing this adjustment 2 Raise the tray bottom plate A 3 Turn off the main switch 4 Remove the front inner cover B 2 screws 10 23 31 August 1989 5 Loosen the 2 screws securing the pinion bracket 6 Loosen the screw securing the guide post lock plate D 7 Move the pinion bracket while holding the pinion so that the pinion does not turn The front and rear guide posts must be equidistant from the center 8 Tighten the screws securing the pinion bracket 9 Tighten the screws securing the guide post lock plates 10 Confirm that the length between the guide posts E is within the standard value range 297 to 299 5 11 Confirm that the side registration is adjusted correctly and reassemble 10 24 SECTION 11 2 5K LCT Contents 2 5K LCT 1 SPECIFICATIONS 11 1 2 ELECTRICAL COMPONENT
387. racket High Voltage Decal m Q ty Per Part No 0350W 0050W 0080W 0060W 0080W 0060 0100 01208 40081 4012W 4006W 4008W 4008W 3006A Pan Head Screw M3x35 Pan Head Screw M4x5 Pan Head Screw M4x8 Screw M4x6 Screw M4x8 Headless Set Screw M4x6 ining Ring C M10 12 ining Ring C ilips Screw With Flat Wash ith ith Flat Wash ing Screw With Flat Wash lat Wash M W F 111 5 Screw With Flat Wash ilips Screw W F ilips Screw 111 5 Polycarbonate Screw M3x6 18 DRUM SECTION 2 045 046 August 31 89 v LN N YN Zh ANN B ME 85 VES s a LZ zu s t ABE Ng LA 18 DRUM SECTION 2 A045 A046 August 31 89 Q ty Per d Q ty Per Part No Description Tesem iy Part No Description Assembly 01 1005 PTL Filter 1 007 Development Rear Holder AW40 0005 Paper Registration Sensor 02 1 Sprocket 15 0003 Toner Density Sensor 1 A007 Chain Tightener 2606 Release Transport Guide Lever 1 A007 1 Density Sensor Connector Bracket 2691 Shaft Paper Guide Plate A007 1 Density Sensor Bracket 2694 Spring Paper Guide Plate 06 Tightener Spring 0024 Lower Middle Roller 1 20 1 agnetic Clutch Registration 3041 ller Spring AA13 Spacer 1x8x12mm 2697 i Upper Registration Roller A007 Development Bias Receptacle 25
388. ray pushes up the pick up roller actuating the lower lift sensor The tray bottom plate lowers when the tray drive motor turns the wire drive pulley counterclockwise It stops moving down when the actuator plate E on the left lift rod actuates the tray down sensor F 10 5 31 August 1989 Voc SV boe IN Positoning Switeh Co t Feed ontrol oard Scan 2 409 7 24V ndleator Bi TM Paper End eT fem CN409 1 Vec 5V Vo 5 AC Power Position Sensor roston Sensor Down Operation The bottom plate moves down either when the Down key is pressed or when paper runs out When either condition occurs the flip flop on the tray main board changes state all outputs change from LOW to HIGH or vice versa Then two things happen simultaneously 1 The timer circuit turns on causing the LED in the Down key to blink and 2 SSR100 turns on energizing the drive motor to move the tray down The tray down sensor is actuated when the bottom plate is fully lowered This causes the flip flop to change back to its original state which turns off SSR1 00 and resets the timer circuit The LED in the Down key stays on Up Operation Up operation is started by opening and closing the cover while the bottom plate is in the down position The cover safety switch changes the state of the flip flop to energize SSR101 which turns on the drive motor to move the tray up The
389. rd Angle Optics Board Bracket Fan Angle Power Pack Bracket Safety Switch Bracket Safety Switch Lever Key Counter Bracket Main Power Switch Bracket AC Harness Angle Counter Cover Rear Upper Cover Right Rear Cover Left Front Cover Lower Rear Cap Tonner Collection Rear Cover Inner Front Upper Cover Ass y August 31 89 Page and Parts No Description Index No Mm Page and Parts No Description Index No Left Inner Cover A008 1307 Cap Cover Left Sorter 9 6 Right Inner Cover A008 1354 Flat Head Screw DIP Switch Cover A008 2080 Pulley Support Charge Corona A008 2084 Cleaner Slider A008 2085 Cleaner Charge Corona Cover Transport Chamber Front Inner Cover Lower FT5570 5540 Front Inner Cover Upper A008 2090 Support Cleaner Sensor A008 2090 Support Cleaner Sensor A008 2091 Support Pad Cleaner Motor A008 2091 Support Pad Cleaner Motor A008 2095 Slider Drive Wire A008 3558 Beater Bar A008 Front Pick off Guide Plate A008 1 Rear Pick off Guide Plate Decal isfeed Large Decal isf Large FT5540 5570 Decal isf Small Decal isf Small FT5540 55701 Decal Decal isf FT5550 Decal ing Toner Decal ing Toner Decal Reset A008 Seal Cleaning Unit Casing Decal Reset A008 1 Front Lamp Terminal Ass y A008 1 Lamp Terminal Spacer Decal Sensor Checker Decal Sensor Checker A008 1 Front Lamp Terminal
390. release shaft B When the release lever C is pressed down the casters turn to the left and the transport unit moves down The front cover can be closed while the transport unit is lowered Whenever the transport unit is in the lowered position the transport unit safety switch D is actuated This causes the Close Cover indicator to remain lit and the Start key to stay red 2 78 31 August 1989 12 IMAGE FUSING AND PAPER EXIT 12 1 OVERVIEW The image is fused to the copy paper by two rollers which apply heat and pressure The hot roller A is made of teflon and the pressure roller B is made of silicone rubber but has a teflon tube coating Pressure is constantly applied between the rollers The fusing lamp which is located inside the hot roller is turned on and off to maintain the operating temperature The temperature control circuit monitors the hot roller surface temperature through a thermistor The oil supply pad C applies silicone oil to the hot roller The oil blade D then spreads the oil evenly across the hot roller The oil reduces the adhesion between paper and the hot roller reducing misfeeds reduces paper curl and helps to keep the roller clean by reducing the amount of toner transferred to the hot roller surface The oil supply pad also cleans the hot roller The hot roller strippers E separate the copy from the hot roller and direct it to the fusing exit rollers 2 79 31 August 1
391. rew 4 Slip Clutch Cover Actuator Shaft Stepper Motor DC 4 Snap Snap Snap a 1 1 1 wa A 1 1 1 1 1 DDD 9 CO CO NS NY NY NM MH ND LK NH Snap Ring R R R R g g ing Snap g 135 August 31 89 ioti Page and Index No 4 6 35 101 Descr Philips Pan Head Screw D ipti page oud Parts No Parts No escription indes Nos t 0314 031 Philips Pan Head Screw 031 Philips Pan Head Screw 031 Philips Pan Head Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 Philips ead Screw 031 031 031 031 031 031 031 031 031 031 031 031 031 Philips ead Screw Philips ead Screw Philips ead Screw Philips ead Screw 13 13 13 13 13 13 13 13 13 13 13 13 13 1 3 13 13 13 13 13 13 13 13 13 13 13 13 1 3 Philips E ead Screw Philips E ead Screw Philips E ead Screw Philips E ead Screw Philips E ead Screw Philips E ead Screw Philips E ead Screw Philips E ead Screw
392. rical Spring ushing Sector Gear Input Hub ushing Volume Sensor Shaft Separation Driven Shaft Co c pacer 1x6x10mm Pressure Arm Shaft B B 5 Bushing 6 15 Co Ww DRO Lr all Bearing 8xl6x5mm 1 Gear 25T ushing Paper Feed Roller 1 Separation Arm Co A Separation Drive Gear 1 Paper Feed Separation Spring Spring Fixed Bracket Separation ty Per Index Q ty Per Part No Q ty Part No Assembly Assembly 5205 5253 Photointerruptor Pack 0313 0060W Head Screw M3x6 0314 0060W A ead Screw M4x6 0314 0100W Philips E ead Screw M4x10 0434 0080W ing M4x8 0314 00801 Philips ead Screw M4x8 0700 0060 Spacer 0623 01408 ing Pin 3xl4mm 0805 3042 l Bearing 6x10x3mm 0720 00408 ini ing M4 0720 0050 ini ing M5 0805 3291 j 16x5mm 0720 0060 ini i 6 0805 0050 ini i 5 0805 0060 ini i 6 0805 3042 Bearing 6x10x3mm 0805 3291 Bearing 8xl6x5mm 1105 0016 Nylon Clip 4N 0534 0060W Set Screw 4 lt gt Xon Spo A007 2661 Paper Size Sensor Bracket c Co A420 2141 Upper Paper Feed Separation Stay A420 2511 Transport Shaft A420 2371 Paper Feed Guide A007 2752 Volume Sensor Shaft A007 2754 Bottom Plate Lever A007 2894 Cushion 8x15x30 5205 2644 Paper End Actuator c
393. ription Ind x N Parts No Description Nos Magnetic Clutch Bushing Sector Gear Magnetic Clutch Volume Sensor Arm Magnetic Clutch Transport Volume Sensor Arm Magnetic Clutch Vertical Transport Sector Gear Lift Sensor Bracket Sector Gear Lift Motor DC1 69W 1 Cushion Upper Pick off Bracket Feed Guide Upper 11 Cushion Lower Pick off Bracket Pick up Lower Guide Cushion 8x15x30 Separation Guide Tl Decal Paper Load Separation Guide 1 Decal Reset Fixed Bracket Separation 11 Bushing 8mm Fixed Bracket Separation 1 Bushing M6 Separation Arm 11 Bushing M6 Separation Arm 1 Separation Drive Shaft Paper Si Sensor Bracket 11 Paper End Actuator Paper Si Sensor Bracket 1 Paper End Actuator Paper Feed Roller Bracket Paper Lift Motor Bracket Feed Guide Paper Feed Roller 11 Spring Feed Guide Paper Feed Roller 1 Spring Paper Feed Stay Coupled Gear 16 Paper Feed Roller 1 Coupled Gear 17 Paper End Feeler 1 Relay Roller Spring Paper End Feeler 1 Relay Roller Spring Paper End Actuator Bracket 1 Cushion Lower Pick up Guide Lower Bracket Paper End 1 Cassette Sensor Arm Upper Lower Bracket Paper End 1 Bushing Paper Feed Roller Paper End Actuator Bracket 1 Bushing Paper Feed Roller Pressure Solenoid Lever Magnetic Clutch Collar Volume Sensor Shaft 11 Magnetic Clutch Collar Volume Sensor Shaft 1 etic Clutch Collar
394. rlap of the feed E and friction rollers F This prevents smearing of the originals due to the friction roller The overlap is 0 9 mm when the solenoid is off and 0 4 mm when it is on In the SADF mode it is not necessary to separate the originals so the DF CPU energizes the roller release solenoid and releases the friction roller before feeding the original 31 August 1989 8 REGISTRATION NOTE In the following discussion ADF timing is in parentheses The DF CPU stops the feed in motor 25 milliseconds after the leading edge of the original activates the original entrance sensor A The forward momentum of the original causes it to align against the registration roller B skew correction After a further 30 milliseconds the DF CPU energizes the belt drive motor C and the registration solenoid D Rotation of the belt drive motor is transmitted via the timing belts and F belt drive gear G registration clutch H and registration roller gear The DF CPU starts counting the belt motor pulses when the leading edge of the original activates the registration sensor When the pulse count reaches 1 844 pulses the original is at the proper position The DF CPU then stops the belt drive motor In Auto P S or Auto R E mode the ADF automatically determines the original size The original size 15 measured by a combination of the original width sensor J and the registration sensor The registration sensor measures the
395. rlier models the cleaning blade removed most of the toner but in this model the cleaning brush removes the bulk of the toner about 90 This is because the brush uses electric potential as well as mechanical action to remove the toner The cleaning brush has a positive charge that attracts the negative toner After picking up the toner the cleaning brush turns inside the cleaning unit Just inside the unit it brushes against a beater bar D The beater bar dislodges paper dust but is not effective in removing the negatively charged toner Next the cleaning brush brushes against the bias roller E The bias roller which has a charge of 300 volts attracts the toner from the cleaning brush The bias roller blade F scrapes the toner from the bias roller and the toner drops on the toner collection coil G The cleaning blade removes the remaining toner about 10 The toner collection coil transports the used toner to the rear of the machine where it falls into the used toner bottle 2 55 31 August 1989 8 2 PRE CLEANING CORONA AND BIAS ROLLER OF o LL 3C SG B The pre cleaning corona A applies a negative charge to the drum and toner remaining on the drum s surface using ac voltage with a negative dc bias A negative bias is used because toner more readily accepts a negative charge and a negative charge 15 more stable than a positive charge The cleaning brush
396. rm Separation Drive Shaft Pick up Solenoid Bracket Solenoid Guide Roller Pick up Solenoid Cover Solenoid Bracket Duplex Solenoid Bracket Transport Chamber Idler Roller Tension Lever Fork Gate Cover Front Side Frame Fork Gate Rear Side Frame Fork Gate Entrance Guide Plate Fork Gate Exit Guide Plate Fork Gate Fork Guide Roller Guide Plate Fork Gate First Gate Arm Second Gate Arm Third Gate Arm Junction Gate Shaft Arm Gate Solenoid Left 128 August 31 89 S Page and Parts No Description Index No Fork Gate Lever Fork Gate Actuator Release Lever Fork Gate Fork Gate Solenoid Bracket Micro Switch Lever Fork Gate Solenoid Fork Gate Setting Plate Fork Gate Stopper Duplex Tray Left Stay Transport Chamber Right Stay Transport Chamber Fixed Holder Toner Tray Guide Plate Exit Inverter Unit FT5550 CPU Main Control Board Ram Board LCD Power Supply Board Eprom Optical Control Paper Feed Control Board Paper Feed Control Board oner End Sensor Harness oner End Sensor Harness Gate Harness Gate Harness Transport Unit Harness Transport Unit Harness Lens Home Sensor Harness Lens Home Sensor Harness Main Control Harness Main Control Harness Main Control Harness Safety Switch Harness Safety Switch Harness Safety Switch Harness Transfer Safety Switch Parts
397. rom the oil sump area A and remove the oil sump 3 Remove the fusing unit knob B 1 screw 4 Remove the oil pump mechanism C with the oil tank 2 screws and the pressure plate D 2 screws 5 Rotate the front lamp terminal clockwise and remove the fusing lamp NOTE Do not touch the lamp with your hands because skin oil may discolor the lamp 5 29 31 August 1989 6 Swing down the fusing exit assembly and unhook the pressure springs E 7 Remove the gear F 1 E ring and remove the harness support bracket G 2 screws and 2 hooks Then remove the rear lamp terminal H 1 screw and 1 hook 8 Remove the thermistor bracket I 2 screws 9 30 31 August 1989 NS D Zam by NEZ MAP E PA H AN 4 KK NU oo 9 Remove the hot roller gear A and bearings B and collars C from both ends of the hot roller D 1 C ring each 10 Slide the hot roller slightly to the rear and remove the hot roller as shown 11 Tear the protective paper E from the ends of the new hot roller F and install the roller 12 After installing the new hot roller remove the remaining protective paper NOTE When reinstalling the fusing lamp make sure it does not touch the inside of the hot roller 5 31 31 August 1989 4 7 Pressure Roller Replacement RSS ye SSS 972 p 1 Perform steps 1 through 4 of Hot Roller Replacement
398. rona wire to the front anchor post 9 Hook the tension spring to the wire then hook it to the rear terminal The wire junction should be positioned inside the rear endblock D 10 Reassemble the charge corona unit NOTE Make sure that the corona wire E is positioned between the cleaner pads F Also check the wire cleaner movement with SP 7 Make sure that the spring that acts upon the home position sensor actuator is seated correctly 5 60 31 August 1989 8 2 Pre quenching Corona Wire Replacement 1 Remove the pre quenching corona unit 2 Remove the rear endblock cover A 3 Remove the front endblock cover B and take the old corona wire C off the front spring D 4 Pull the rear spring E out of the rear endblock F and remove the old quenching corona wire 5 Install a new corona wire 6 Reassemble the quenching corona unit 5 61 31 August 1989 8 3 Transfer and Separation Corona Wires Replacement _ MU I Q2 o BE OSS 1 Open the front cover and remove the TC SC unit cover A 2 screws Then disconnect the two cleaner motor connectors B 2 Lower the transport unit and slide out the TC SC unit C 3 Remove the paper guide D lifting it from the rear Then remove the cleaner cover E 1 screw 4 Remove the rear and front endblock covers F 2 screws from the front Then replace the wires CAUTION When insta
399. rter pressure rollers C are in the upper position at this time These rollers are driven via a gear train by the exit drive chain 0 2 94 31 August 1989 Reverse Drive After the 5 trailing edge passes the exit relay sensor A the CPU energizes the inverter return solenoid B which lowers the inverter pressure rollers C onto the inverter roller D Since the inverter rollers are always rotating reverse direction the feed direction is reversed The inverter roller drives the copy between the exit relay rollers and the fork gate entrance rollers E which then feed the copy to the duplex transport unit 2 95 31 August 1989 14 2 DUPLEX TRANSPORT Basic Operation After the copy is reversed in the inverter unit it comes to the duplex transport section The duplex transport unit A carries the copy from the inverter unit to the appropriate gate in the fork gate unit B The CPU opens the gate corresponding to the copy paper size The copy paper passes through the gate and is transported to the jogger unit C by the duplex delivery tray D 2 96 31 August 1989 Drive Mechanism The exit drive chain A powers the duplex transport rollers B Power is transferred from the chain through the exit relay roller gear C and two idle gears D to the drive gear E of the left duplex transport roller 2 97 31 August 1989 Fork Gate Mechanism Single Solenoid Activated 5012 SOL 1 TH
400. rum surface with bare hands e Store the drum in a cool dry place away from heat e When cleaning the drum always wear a pair of gloves Do not throw away cotton used for cleaning Bring it back to the service depot for disposal according to local regulations e Prime the drum with setting powder when the drum cleaning blade or cleaning brush are replaced Do this within one minute in a location not exposed to strong light 2 1 31 August 1989 Drum conditioning is necessary when a new drum is installed In addition it should be done at the following times 1 When image density is reduced due to overexposure of the drum 2 After cleaning the drum 3 When the oxide layer on the drum 15 lightly scratched When installing or removing the drum always keep it in the protective sleeve Before installing or removing the drum pull out the cleaning unit part way so that the pick off pawls do not scratch the drum surface Before placing the protective sleeve on the drum while it is in the copier always take out the development unit Otherwise the edge of the sleeve will scrape developer from the development roller 2 2 31 August 1989 1 3 DRUM HEATER CONTROL Main Switch AC Distribution Drum Heater UUUUU Anticondensation Heater Option The drum heater receives 100 volts ac only when the main switch is turned off When the main switch is turned on the 100 volt ac current stops flowing
401. rupter Pack ED Sensor Fixing Bracket Sector Gear Bushing Bushing Volume Sensor Shaft Paper Detect Feeler Transport Transport Roller Sensor Bracket Transport Roller Sensor Shutter Separation Roller Slip Clutch Cover Output Hub Cylindrical Spring Input Hub Separation Shaft Separation Fixed Bracket Gear 15 Gear 25T Pressure Arm Shaft oner End Sensor Harness oner End Sensor Cover Q ty Per Description Assembly Sector Gear August 31 89 Q ty Per Seal 3 16 57 Separation Arm Paper Feed Separation Spring Paper Feed Brace Upper Separation Guide Paper Size Sensor Bracket Volume Sensor Shaft Bottom Plate Lever Bushing Paper Feed Roller Upper Magnetic Clutch Stopper Paper Feed Clutch Spring Spring Coupled Gear 161 53 Coupled Gear 171 50 Cassette Sensor Arm Upper Bracket Paper Lift Motor Gear 20T Lift Motor DC1 69W Bushing M6 Seal 8x8x368 Cushion 8x15x30 Upper Paper Feed Bracket Manual Feed Sensor Bracket Paper End Actuator Bracket Cooling Fan Motor Seal Cooling Fan Cooling Fan Cover Paper End Feeler Upper Feed Guide Manual Feed Table Holder Spacer 1x8x12mm Spacer M6 Paper Feed Unit Harness Toner End Sensor Bracket Index Q ty Per Part No idi dd Assembly Screw 5 E Head Screw 3x28 ilips E Head Screw 4x6 ilips E
402. s 8 5 31 August 1989 4 SEPARATION MECHANISM He u1 Coefficient of friction between the feed rollers A and the original B u2 Coefficient of friction between the friction rollers C and the original Coefficient of friction between originals This model uses an FFR Feed and Friction Roller original feed system with three sets of rollers feed friction and pick up rollers The feed and friction rollers have grooves in them which interlock with one another The rollers interlock to decrease damage to the originals particularly pencil written originals from direct roller to roller pressure The pick up roller sometimes sends more than one original to the feed and friction rollers When this happens the friction rollers strip the extra original from the top original m1 is greater than m3 and m2 is greater than m3 Therefore the top original will slide past the friction rollers while lower originals stop 8 6 31 August 1989 5 MISFEED PREVENTION The front side of the friction roller A is attached to the misfeed prevention lever B via a one way clutch When the leading edge of an original C first contacts the feed D and friction rollers the friction roller is stationary As the leading edge is fed between these rollers the friction roller rotates counterclockwise a few degrees to help feed thick originals After the friction roller has rotated a few degrees the misfeed prevention lever c
403. s ON OFF ON or OFF ON OFF during the checking period the CPU determines that paper has entered the duplex tray Duplex Paper Sensor When there 15 copy paper in the duplex tray the paper actuator E is moved up and away from the duplex paper sensor which activates the photointerrupter 5V OV This informs the CPU that paper is in the duplex tray When the last sheet of paper has entered the duplex tray the CPU checks the suplex paper sensor signal and lights the second original instructions in the guidance display 2 103 31 August 1989 14 5 DUPLEX PAPER FEED A NS UN __ PM 0 Basic Operation Duplex paper feed uses an FRR Feed Reverse Roller paper feed system This is similar to the cassette feed system except that the duplex pick up roller A remains on the paper stack after feeding a sheet to the duplex feed roller B The cassette pick up roller lifts after paper feed starts This mechanism prevents the sheet below the top sheet from being pushed backwards by the duplex separation roller C The pick up roller slows down the next sheet rejected by the duplex separation roller so that it remains in position for feeding at the next copy cycle During duplex feed the duplex stopper D is moved under the duplex paper feed guide plate E and the duplex positioning roller F is lifted out of the way 2 104 31 August 1989 Duplex Feed Drive Mechanism The
404. s Head Screw 5094 Tapping Screw M4x8 0016 Nylon Clip 4N 0080E asher 8mm August 31 89 2 TRAY SECTION A421 7 7 j N pr 2 X i WS b Ji Veg ON N NE p 9 65 2 NN X ER RAE s VER Perte E 7 HK gt p d Pat x ro JE E 2 7 wi NS M 9 et SSS 5 vx 2 TRAY SECTION A421 August 31 89 1 Part No Description Part No Description ae 21 2530 Front Guide Rail 03 1187 Rear Support Plate 2 21 2525 ouple Bracket 2520 Actuator Paper Volume 3 21 2535 aper Size Stay 2521 Spring Paper Volume 4 2472554 Side Post Grip 1111 Front Side Frame 5 21 72531 Front Guide Rail 2515 Rear Side Frame 6 21 Side Post Grip 1147 Chain 7 03 Left Lift Rod 2259 Hook 8 21 Friction Rad 1148 Back Fence 9 21 Decal Paper Siz 2527 Front Paper Size Decal Left 0 21 Tray Bottom Plate 2528 Rear Paper Size Decal Left 11 1 Right Lift Rod 1511 ylar 100x19mm 2 Idler Pulley 20 8 2539 Hole Cover 3 Drive Wire 2 4 Rear Wire Tightener 5 Rack Drive Shaft Pulley 2 6 Bushing 10mm Long 7mm 2 7 Size Post Rack Spring Plate 3 8 Size Post Rack 9 1 Push Switch 20 Safety Switch Bracket 21 1 Top Actuator Lever 22 Safety Switch Actuator 23 1 Bottom Actuator Lev
405. s Removal 2 Open the front cover and remove the left inner cover Then disconnect the exposure lamp connector A white 2P connector and push the female half of the connector B through the frame into the optics cavity 3 Remove the front and rear lamp terminal covers C 1 screw each Then remove the reflector cover D 2 screws NOTE Do not touch the surface of the reflector 4 Disconnect the front and rear lamp terminals E Then remove the auto ID sensor with the bracket F 1 screw 5 10 31 August 1989 gt p Pd B IS 0 ll 5 Remove the fiber optics cable A with the exposure lamp harness B from the clamps in the optics cavity 4 screws 6 Disconnect the ADS cable C from the main PCB CN111 Then remove the cable from the clamp D on the back of the optics PCB bracket 7 Replace the scanner harness and reassemble 5 11 31 August 1989 2 DEVELOPMENT 2 1 Developer Replacement 1 Raise the development unit release lever A and take out the development unit Then place it on a sheet of paper 5 12 31 August 1989 2 Carefully remove the developer exchange plate B 2 screws CAUTION Developer pours out quickly 3 Rotate the paddle roller knob C counterclockwise to remove all the developer Then reinstall the developer exchange plate 4 Remove the developer inlet cover D 1 screw and pour one
406. s development unit Lift paper to the appropriate feed position Applies paper feed drive to the 1st and 2nd feed stations Drives the registration roller Starts paper feed from the first feed station Starts paper feed from the second feed station Drives the rollers of the copier relay unit Feeds paper from the duplex tray Drives toner supply roller 1 23 31 August 1989 SOLENOIDS Cleaning Pick off Junction Gate Duplex Positioning Manual Feed 1st and 2nd Fork Gate Duplex Pick up Duplex Positioning Inverter Pressure Duplex Stopper 15 2 Pick up SWITCHES Main Front Door Safety Transport Unit Safety Fork Gate Unit Safety SENSORS Pulse Generator Exit Oil End Toner Overflow Toner End Registration Manual Feed Scanner Home Moves the cleaning blade against the drum Moves the pick off pawls against the drum Energizes to direct copies to the duplex tray Raises and lowers the sponge roller Raises the pick up roller when paper is fed from the manual feed table In unison open and close the appropriate fork gates according to paper size Starts feed from duplex and aids the stopper solenoid Lowers positioning roller Controls the inverter pressure roller Stops copy in the jogger unit Starts paper feed from the cassettes Supplies power to the copier Cuts ac power line Cuts 24 volt lines Cuts 24 volt lines Supplies timing pulses to the main board Detects misfeeds
407. s home position Rough Adjustment 1 Set SP 44 and press number key 8 2 Turn off the main switch and position the first and second scanners as shown above Fine Adjustment 3 Place a 150 mm scale on the exposure glass parallel to the left scale 4 Adjust the horizontal magnification using SP 44 Make three copies each time 5 50 31 August 1989 7 3 Focus Adjustment When The copy image is out of focus After adjusting the horizontal magnification Target Copy image in focus Measure SP 47 0 1 per step 15 steps How Adjusts the fourth and fifth mirror assembly home position changing 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 45 Refer to the letter portion on the copies 5 51 31 August 1989 7 4 Uneven Exposure Adjustment When The exposure is uneven Purpose To maintain even exposure Target The side to side variation of the gray scales on the test chart should be less than one level Measure Exposure adjustment plate positioning How Changes the position of the adjustment plates to make the light intensity from the exposure lamp even across its length 1 Clean the optics and the charge corona wires 2 Place a test chart on the exposure glass and make three A3 LDG copies 3 If the side to side variations of the gray scales is not within specifications turn off the main switch and remove th
408. s the timer circuit The LED in the Down key stays on Up Operation Up operation is started by opening and closing the cover while the bottom plate is moving down or in the down position The cover safety switch changes the state of the flip flop to energize SSR101 which turns on the drive motor to move the tray up The drive motor stays on until the paper pushes up the pick up roller The actuator on the pick up roller bracket then moves out of the upper limit sensor this again changes the flip flop s state and the motor stops 31 August 1989 4 INSTALLATION 4 1 Accessory Check Check the quantity and condition of the accessories in the box according to the following list 1 Holder Plate 2 2 Nylon Clamp 3 Pan Head Screw M4 x 8 3 4 Multiple Language Decal 220 240V Only 5 Front Post A4 version only 6 Front A4 version only 7 8 9 0 Screw x 6 4 version only Knob screw A4 version only NECR Envelope NECR 115V Only 11 5 31 August 1989 4 2 Installation Procedure NOTE The LCT can only be installed with the system table or the cassette bank 1 Remove the three strips of tape A 2 Open the side cover and remove two strips of tape B on the top cover 3 Open the top cover and remove the strip of tape C securing the stopper bar D 4 Turn off the main switch of the copier and unplug the power supply cord 5 Remove the first an
409. s to 0 volts After receiving the 0 volt signal the CPU turns off the lift motor 2 75 31 August 1989 Paper End Detection After the last sheet of paper is fed from a cassette the Add Paper indicator lights The first and second paper end sensors use photointerruptors When a sensor is actuated the photointerrupter turns off 0 volts to 5 volts The CPU detects paper end by monitoring the output of these sensors The CPU uses scan pulses to monitor the output of these sensors and detect paper end or Manual Feed Paper End A Manual feed paper end sensor B Cassette paper end sensor The first paper end sensor consists of two photointerrupters which are in parallel The CPU detects a paper end condition by monitoring these two photointerrupters and the manual feed sensor 2 76 31 August 1989 11 PAPER TRANSPORT 11 1 OVERVIEW A c DET 2 __ gt 02 po eee When the copy paper separates from the drum it is advanced by the transport belt A to the fusing unit A vacuum fan B holds the paper firmly against the belt The gear C drives the transport belt There is no clutch so the gear turns whenever the main motor is on 2 77 31 August 1989 11 2 TRANSPORT UNIT RELEASE MECHANISM The transport unit can be lowered to remove misfeeds The transport unit is supported by two casters A which are mounted on the
410. ses the internal contact counter confirmation When the contact closes CN102 A25 goes HIGH 5 volts dc and the CPU determines that the counter has energized If the CPU does not receive a HIGH signal at CN102 A25 when the total counter is energized SC 91 is displayed Key Counter Option With this option the copier will not operate unless the key counter is inserted The operation of this counter is the same as the total counter however there is no service call condition provided if the confirmation signal is not received by the CPU 11 x 17 Counter Option This counter keeps count of all 11 x 17 copies made The operation is the same as for the other counters 2 117 SECTION 3 INSTALLATION Contents INSTALLATION 1 INSTALLATION 5 3 1 metu toos edv die 3 1 1 2 MINIMUM SPACE REQUIREMENTS 35 ru rh ette be be d 3 2 LS MACHINE LEVEL cusa RO SERE D 3 3 14 POWER SOURCE bbs EIS LES 3 3 2 ACCESSORY CHECK dentine de years 3 4 3 INSTALLATION PROCEDURE 3 5 9 4 COPIER INSTALLATION nega ea 3 5 3 2 CASSETTE MODIFICATION 3 15 3 3 KEY COUNTER HOLDER 3 16 31
411. sor 3rd Paper Volume Sensor Right Door Safety Switch 2nd Feed Relay MC 3rd Relay Sensor 3rd Paper Size Sensor 2nd Relay Sensor Cassette Bank Motor 3rd Lift Motor ard Lift Sensor 7 3 3rd Paper Feed MC 3rd Feed Relay MC 3rd Pick up SOL 4th Paper Feed MC 4th Lift Sensor 4th Pick up SOL 4th Lift Motor Cassette Bank Motor Capacitor 4th Paper Size Sensor 4th Paper Volume Sensor 4th Cassette Paper End Sensor 31 August 1989 4 OVERVIEW This unit adds two additional universal cassettes 500 sheets each which are the third and fourth cassettes to the copier Both the third and fourth paper feed stations have an FRR Feed and reverse roller mechanism which is similar to the feed system of the copier except for the following items 1 Both third and fourth cassette bottom plates can be lowered mechanically to load paper without removing the cassettes 2 The pick up paper feed and separation rollers are driven by the bank motor an ac motor via the third and fourth paper feed clutches and gears The second and third relay rollers transport paper to the registration rollers of the copier They are driven by the bank motor The second and third relay sensors monitor the paper feed timing To facilitate loading paper and removing misfed paper the following four mechanisms are included in the bank 1 Front Loading Mechanism The paper supply unit can be pulled all the
412. sorter s rollers Open and close the appropriate bin gates Opens and closes the interrupt bin gate Cut dc 5 volt and motor dc lines Misfeed detector light receiving element Misfeed detector light emitting element Controls all sorter functions Rectifies ac 23 volt input and outputs dc voltages Steps down the copier s ac 100 volt to ac 23 volt 14 5 31 August 1989 6 BASIC OPERATION Introduction Sorter operation begins when the Start key is depressed At that time the sorter drive motor turns on and the rollers start turning The sorter has two paper transport speeds When paper first enters the sorter it is transported at the slow speed of 325 mm s This is slightly faster than the copier transport speed When the trailing edge of the paper passes the exit sensor of the copier the sorter shifts to the high speed of 675 mm s The high speed not only decreases copy delivery time but also improves delivery to the bins preventing jams at the bin entrance due to paper pile Up After the trailing edge of the copy passes the jam sensor the sorter motor turns off at the same time as the copier main motor Clear Mode The copies pass from the copier exit through the relay guide plates to the turn gate The turn gate directs the paper to the vertical guide unit The vertical drive rollers then move the paper up until it reaches the turn guide The turn guide directs the paper to the first bin During transport of
413. sorter stack key cover E copier accessory 22 Set SP 71 2 to enable the sorter Refer to the copier installation procedure for SP access ing 23 Check the sorter s operation 14 24 31 August 1989 9 SERVICE TABLES 1 LEDs The 3 LEDs on the sorter main board indicate signals as follows LED NO Lights when sensor below is activated LED 100 Jam Sensor Upper Photo Tr LED 101 Inlet Sensor LED 102 Jam Sensor Lower LED 2 Dip Switch The dip switch on the sorter main board has three functions as follows ae dee SERES Paper Transport Test For paper shorter than 300 mm Paper Transport Test For paper shorter than 300 mm 1 OFF Note When using the paper transport test mode SP71 must be set to 0 14 25 31 August 1989 3 Service Program Mode Three sorter functions can be accessed from the copier by using the SP mode Refer to the copier manual s SERVICE PROGRAM MODE OPERATION for the SP access procedure Modeno Date 19099 Comments _ Setting Sort Mode is automatically selected when more than 1 0 Sorter and DF must 28 Sort Priority original is set on the DF be installed on the table and the entered copy quantity is from 2 to 15 Midi sorter 15 bin sorter F H Finisher 71 Sorter Finisher Enables sorter or finisher Operation operation Stops copying at the stack is sort mode bin capacity
414. sory Check Check the quantity and condition of the accessories in the box according to the following list 1 Relay Rollers Drive Ass y 2 Screw M4 x 8 6 3 Multiple Language Decal 220 240V only 4 5 Envelope 115V only 7 9 31 August 1989 8 2 Installation Procedure 1 Remove the external strips of tape A Remove the right cover 4 screws and the left cover 2 screws then remove the right and left retainers B 4 screws each and the front and rear retainers C 1 screw each from the paper feed unit 7 10 31 August 1989 ZL A 2 Pull the drawer D all the way out and remove the strips of tape E 3 Dock the copier to the cassette bank so that the pins of the copier F are inserted into the positioning holes G of the cassette bank Then secure the copier to the cassette bank 4 screws CAUTION Be careful not to crush the copier harness and the copier cassette bank 7 11 31 August 1989 W P Y T XG LULL 7 a 4 Remove the copier rear cover A 2 screws and the toner collection bottle B 5 Connect the 14P connector C of the cassette bank to CN413 on the paper feed control board D of the copier Connect the free connectors of the cassette bank to the free con nectors of the copier Red 2P E Red 8P F White 10 7 12 31 August 1989 6 Remove the knob H from the relay roller drive assem
415. stance between CN36 3 and CN36 D on the ID sensor board Reference value 10 kohms at 25 C Check CN103 13 on the main PCB Code 52 Thermofuse Blown Definition Lights if the thermofuse circuit becomes open or the fusing unit is not set correctly Observation Code 52 is displayed immediately after main switch is turned on Points to Check Confirm that 24 volts exists at CN102 B19 on the main board Confirm that the fusing unit is properly set 13 5 31 August 1989 Code 53 Thermistor Blown Definition Lights if the fusing thermistor is open Observation Code 53 is displayed immediately after the main switch is turned on Points to Check Disconnect the white thermistor connector on the front side of the fusing unit Check the resistance of the thermistor at the white connector Reference value 1 10 kohms at 180 C 180 kohms at 10 C Code 54 Ready Signal Not On Definition Lights if the idle signal is not received within 8 minutes after the power relay turns on Observation The fusing lamp does not turn on The ready beeper does not sound and code 54 is displayed 8 minutes after power is turned on Points to Check Check the power relay fusing lamp ac drive board and operation panel board To control effects of electrical noise from surrounding machines try JP100 Check for poor contact in the fusing unit connector Code 55 Fusing Overheat Definition Lights if the voltage at CN103 4 fusing thermi
416. stor drops below 0 53 V for 0 4 second Observation The fusing lamp stays on after the temperature rises above 220 C Points to Check Check the voltage at CN504 1 on the ac drive board for line voltage Check the resistance of the thermistor Disconnect the white thermistor connector on the front side of the fusing unit Reference value 1 10 kohms at 180 C 180 kohms at 10 C 13 6 31 August 1989 Code 81 Jogger Home Position Sensor Not Off Definition Lights if the jogger home sensor output stays LOW Observation Code 81 will be displayed during duplex mode copy cycles if there is vibrating noise from the jogger Points to Check Check the voltage at CN104 B2 on the main PCB Check the jogger motor Code 82 Jogger Home Position Sensor Not On Definition Lights if the jogger home position sensor output stays HIGH Observation Code 82 will be displayed during duplex mode copy cycles if there is vibrating noise from the jogger Points to Check Check the voltage at CN104 B2 on the main PCB Check the jogger motor Code 91 Total Counter Malfunction Definition Lights if the total counter is not set or is defective Observation Total counter does not click during copy cycle Points to Check Check the voltage at CN102 A25 on the main board Check the total counter 13 7 31 August 1989 2 DEFECTIVE SENSOR TABLE Name 151 and 2nd Paper End 151 and 2nd Paper Size Manual Feed
417. t T Connector 4P 11 Housing 11 Connector 2P 11 Receptacle Housing 1P 11 1 Receptacle Housing TI Receptacle Housing TI d Receptacle Housing TI 1 Connector 2 1 11 1 nector 11 1 nector TI 1 nector E 11 1 nector E 1 11 1 nector E 11 1 nector E 11 nector 14 nector 2 11 Pin Mate N Lock 75 U U U U U U Do t gt FP U NOU U August 31 89 35 LENS HOUSING HARNESS A045 A046 e ens 102 CN7 104 109 S 9 3 5 35 LENS HOUSING HARNESS A045 A046 August 31 89 Index Q ty Per Index TR Q ty Per Part No De EOD A045 5216 Lens Housing Harness 01 11 ocket Mate N Lock 02 11 1 inal 03 11 1 ector E 04 11 ector E 05 11 1 ector E 06 11 1 ector 07 11 1 ector E 08 11 1 ector E 09 1103 1431 ector 77 36 LENS HOME SENSOR HARNESS A045 A046 102 102 106 107 78 36 LENS HOME SENSOR HARNESS A045 A046 August 31 89 Index c Q ty Per Part Description py re A007 5215 Lens Home Sensor Harness 01 1100 1249 Receptacle Terminal 02 1100 1253 Mate N Lock 03 1100 1 Socket Mate N Lock 04 1102 1 Connector 6P 05 1102 1 Connector 06 1102 1 Connector 6P 07 1102 1 Connector 6P 79 37 PAPER FEED UNIT HARNESS
418. t Screw M4x6 Socket Bolt M4x5 Flat Washer M5 Retaining Ring M3 Retaining Ring M4 Retaining Ring M5 Tapping Truss Head Screw M4x8 Collar 6 5x20mm Spacer 6x13x1mm Tapping Screw With Flat Washer M3x6 Tapping Screw With Flat Washer M4x8 Philips Pan Head Screw M4x6 August 31 89 10 DUPLEX SECTION 2 A045 A046 26 10 DUPLEX SECTION 2 A045 A046 t Part No Description Assembly A007 4520 A007 4846 007 4841 A007 4843 5206 2626 5206 2695 5205 A007 4800 A007 5263 A007 4805 A007 4809 5206 2650 01 3105 5447 2706 5447 2681 AF03 0001 AF01 0003 A007 4700 5206 2690 AF03 1001 AA04 2001 01 3087 AA08 0020 5206 2680 5206 2681 5206 2685 A007 4820 AA14 0063 ABO3 2017 AA08 0021 5206 2677 5206 2684 5206 2687 5206 2686 AA16 1018 Co CO gt Co CO CO CO CO Ww NH MH NH YH LH HY PL PL 9 BD DW gt ps 22 Part 0040W 0060W 0080W 0100W 0060W 0080W 0060E 0100E 0180E 0025E 0040E 0050 0060 3101 4043 0060 Duplex Transport Unit Sensor Bracket Duplex Paper E Toner Catch Pan Sensor Harness Cover Entrance Actuator Sensor Cover Cov r Duplex Paper Sensor ED Sensor Type S ex Stay ex Entrance Harness ick up Arm uplex Feed Shaft ing 8 12 7 18T 15T Ring
419. t unit lock lever I remove the development unit and place it on the paper 3 10 31 August 1989 18 Remove the developer inlet cover J 1 screw 19 Pour one kilogram of developer into the development unit while turning the knob K counterclockwise to distribute the developer 20 Reinstall the developer inlet cover 3 11 31 August 1989 21 Pull out the drum protective sleeve from the drum NOTE Save the drum protective sleeve for future use when servicing the copier 22 Reinstall all removed parts and return them to their original position 23 Load the toner bottle onto the bottle holder Then rotate the lever B to fix the bottle and raise the holder C up to the bracket 24 Install the toner catch pan D on the jogger unit E 3 12 31 August 1989 KCB SRS EE 25 Install the platen cover A 2 M5 stud screws and the original holder Two sided tape as necessary 26 Remove the DIP switch cover C 1 screw and turn on DIP switch 801 8 D Then plug in the machine and turn on the main switch 27 Set the proper language in the guidance display using SP 12 LT Version or SP 13 A4 Version To access SP Service program mode enter 12 or 13 using the number keys Press the Recall Enter key 3 13 31 August 1989 28 Put five sheets of white paper A3 of 11 x 17
420. te A from being left up after paper has been removed from the sorter When the operator closes the sorter cover B the reset lever C is pushed down returning the relay guide plate to the horizontal position 14 12 31 August 1989 7 4 Interface with the Copier Sorter Main Board CN109 6 119 1 lt 1 V5 Exit CN108 on the DN Copier Main PCB CN109 9 CN119 5 CN109 10 CN119 9 Not Used lt V5 Sorter Connection Not Used lt V5 Ro3 Reset lt 1 Y5 Control lt 95 RD2 Size lt 75 RD1 Exit Y5 RDO Mot lt q The above interface is used for communication between the copier and the sorter There are 5 lines to send data to the copier and there are 6 lines to send data to the sorter The functions of these lines are as follows Table 1 Informs the copier when the copy paper is fed out to Cuno ea m sorter bin Informs the copier when the sorter r cover CN119 3 Informs the copier when occurs in the sorter 9 4 Pos __ O Not used CNi19 4 CN119 5 Sorter Informs the copier when the sorter is connected to the _ Connection copier 14 13 31 August 1989 Table 2 Data direction from copier to CN119 6 119 7 Reset Function A Informs the sorter when 5 71 is set to enable the CN1 19 8 Lets the sorter distinguish between Function A and
421. th of the positive ions on the drum surface 1 is greater than and A2 is greater than A3 1 gt gt Transfer occurs 2 gt 2 48 31 August 1989 7 3 PAPER SEPARATION A1 gt A2 gt A3 gt Separation occurs After image transfer the paper is fed to the separation section This process separates the paper from the drum while holding the toner on the paper surface Ac and dc currents are applied to the separation corona wire and the corona wire generates ions These positive ions are applied to the reverse side of the paper breaking the attractive forces A2 and A3 however A1 is not broken The paper separates from the drum taking the toner with it 2 49 31 August 1989 7 4 TRANSFER SEPARATION CORONA POWER PACK 24 9 Front Cover Safety O Z N ee TOSC CN2 7 T I Lael a Inverter s 6 2K Vac SC Shift CN101 B21 CN2 8 Trigger v5 and 465 Vde FAI A DC DC WINGS Front Cover Safety Switch Y Jp The power pack has dc to dc converter and a dc to ac inverter dc to dc converter changes 24 volts to 5 78 kilovolts dc for the transfer corona The inverter changes 24 volts Vp to 6 2 kilovolts ac with a slight negative dc bias for
422. the separation corona Both coronas turn on when the CPU applys a LOW at CN101 A21 The main board sends a LOW trigger signal to the TC SC power pack when the lead edge of the paper turns on the registration sensor The TC SC power pack turns off 328 milliseconds after the trailing edge of the copy paper deactuates the registration sensor Registration Sensor Eu 2 ee Wy 328msec 4 2 50 31 August 1989 The separation corona current is not always constant It has two levels a lead edge level and the normal level The normal separation corona current has an ac value of about 200 micro amperes with little dc component However at the leading edge the dc value is reduced from about 2 5 micro amperes to a dc component of about 8 micro amperes This helps the leading edge of the paper separate from the drum This is accomplished by the CPU supplying a LOW signal at CN101 21B to the TC SC power pack The above values for the drum currents are theoretical calculations for total drum current Normally the lead edge separation corona current is applied to the first 10 millimeters of the copy paper However you can select a margin of 7 or 13 millimeters using SP mode 37 37 Margin 0 10 mm 7 2 13 2 51 31 August 1989 7 5 PICK OFF MECHANISM Touch and Release Mechanism The pick off solenoid A energizes just after the registration rollers turn
423. the copies in this mode none of the bin gates are used Sort Mode When in sort mode the first sheet is placed in the first bin in the same way as when in clear mode The second and subsequent copies follow the same path but are directed to the bins in order from top to bottom second copy to second bin third to third bin and so on The appropriate bin gate solenoid turns on when the trailing edge of the previous sheet passes the jam sensor and turns off when the trailing edge of the paper passes the jam sensor If 16 or more is entered while in sort mode the guidance display will indicate that the maximum copy entry is 15 and the Quantity Entered counter will display 15 When the sorter bin capacity is set to limit by using service program mode 76 copying will stop at the maximum bin capacity for sort mode 50 sheets bin and the guidance display will indicate that the sorter is full Stack Mode When in stack mode all sheets of the first copy run go to the top bin just as in clear mode When the Start key is depressed again the entire second run is directed to the second bin Similarly the third run goes to the third bin and the fourth run to the fourth bin 14 6 31 August 1989 If the mode is not changed the sorter will continue in this way sending all copies from a single run to one bin and dropping down one bin each run until there are copies in all 15 bins Upon completion of the copy run to the 15th bin copying w
424. tics Board 4008W Tappi Screw With Flat Washer M4x8 o Bracket Main Control Board 1 11 0008 Main Control Board FT5550 5570 1 1 1105 0099 Main Control Board FT5540 0159 0197 0199 IS gt co Main Control Harness Exhaust Fan Motor lt gt Bracket Transformer Transformer 220V 240V 100V 327VA 0395 Locking Support 1280 Push Switch 1520 Switch 0200 Clamp 0080W Philips Pan Head Screw 5 8 Co Transformer 115V Co Cover Main Control Board CO 1 oO Se 9 LY High Voltage Decal 26 ELECTRICAL SECTION 2 A045 A046 M ID p lt SAC y gt x p v 108 PAE E 9725 CE 58 26 ELECTRICAL SECTION 2 A045 A046 Index Q ty Per Part No Assembly 1 DB NAY CO CO CO po YY 1 Paper Feed Unit Harness Upper Paper Size Harness Capacitor Bracket otor Harness Drive Board Harness Drive Board 115V Drive Board 220 240V Drive Bracket Control Unit Exit Cover ADF Support Bracket Solenoid Cover Bracket AC Descent Harness 115V Harness AC Descent 220 240V Power Supply Cord 115V Power Supply Cord 250V 10A 220 240V Gate Harness Harness Bracket ity Sensor Connector Bracket arness FT5570 arness FT5550
425. til holder meets magnetic catch 2 ISPITI IN Uy 77777 77777 WN 89 RS SS RAS SS SS APS SSS SS SS SSS SSS SS SSS SSS SSG SSS GSP shel SS 50 DECAL AND DOCUMENT A045 A046 Ee ES EE ES a a 2 3 2 GS 24 from fusing unit Removing misteed a a aown the knob anc lowe guide plate er Turn tne lever counterctockwise anc lower the transport unit aE mE Push gown tne lever orasp the Pusn ao 04250 fusing unit knob puli Ine tusing unit out CAUTION Tne fusing unit Swing down tne iusing exi PPN LLLA Remove misleg paper by turning the Return guide plate 10 ns original registration counterclockwis position with tne lever and to pushing dovan ine teye Nc MAY 1 Tum the mE Counterclockwise Full out tne tusing unit knob and Remove any paper taking turn Clockwise while removing care NE 10 lear n pape CEN ai EM e 224 Pusn gown tne fevers al Remove any mistes being rear Ine
426. tity Reproduction Ration 100 2 The job sheet may jam inside the menu reader if it is smaller than the specified size Caution Sensors were set at the factory and cannot be adjusted in the field 12 7 31 August 1989 5 INSTALLATION 5 1 ACCESSORY CHECK Make sure that each of the accessories listed below is in the box DecaShee 1 Decal Sheet 12 8 31 August 1989 5 2 INSTALLATION PROCEDURE uM A 2 B ds j ee L piss cg Pu i _ IC MA i 3 4 SS N S 18 gt Sul K 1 Peel the backing aff the ships of double bided adhesive tape A and stick the menu ready on the ARDF B RDH C or platen cover D as shown 2 Turn off the main switch of the copier and remove the rear cover 4 screws and the cover plate E 1 screw 3 Pass the harness F through the hole G Then plug in the connector H and secure the grounding wire I 1 grounding screw as shown 4 Pull the harness tight so that there is no slack between the menu reader J and the hole K Then place the extra portion L of the harness neatly inside the copier 12 9 31 August 1989 5 Remove the shield plate A 1 screw Then install the cord stopper B on the harness and use a pair of plyers to secure the stopper to the cover plate Reinstall the cover plate 1 screw 6 Wrap the grou
427. tively The photointerrupters corresponding to the notches remain active 0 volts Thus when scan line 1 is high bit 4 of the data bus remains LOW when scan line 2 is high bit 2 of the data bus remains LOW The CPU monitors the data bus at the appropriate time to determine the paper size in cassettes 1 and 2 2 74 31 August 1989 10 9 LIFT MOTOR CONTROL AND PAPER END DETECTION Lift Motor Control EX Paper End Sensor Paper Feed Control Main PCB Paper End av 1 CN102 A10 Scan Scan 4 4 4 Paper Both A Paper End 2 Paper End 1 gt Paper End 2 L mud i ARA BV pr Scan 2 WEEE Both empty Paper Feed Control PCB Main PCB Paper End p ty gt ni __ Scan ARP Paper ON Low Lift Sensor CPU GNO Paper Size zy sean ON Low N 7 Motor Lifted EO gt M The paper size sensor is also used as cassette set sensor When the paper size actuator plate is inserted into the paper size sensor one or more photointerrupters turn off 0 volts to 5 volts After receiving a 5 volt signal through the paper size data bus the CPU turns on the lift motor The CPU energizes the lift motor until the lift sensor is deactuated When the lift sensor is deactuated the photointerrupter is ON and its output drops from 5 volt
428. to the Service Program Mode table Turn off the main switch set DIP SW 801 8 to the off position and turn the main switch on The following procedure can be used instead of DIP SW 801 8 to access program num bers 80 81 90 91 and 92 1 2 Press the Mode Clear key Press the Clear Stop key 4 7 31 August 1989 3 Press the Enter key Simultaneously the guidance display prompts PROGRAM NO 80 4 Enter the desired number using the number keys or zoom keys 5 Press the Enter key Press the Clear Modes key to abandon SP mode 3 3 Memory Clear SP 97 Clears service counters and jam counters gt Service program SP 97 clears all self diagnostic counters and paper jam counters This func tion is used as follows 1 Turn the main switch off 2 Turn on DIP SW 801 7 and 8 on the operation panel and turn the main switch on 3 Select service program SP 97 and and press the 1 key on the key pad Then press the Enter key At this point service programs SP 120 through 139 clear and default to 0 4 Turn the main switch off 5 Turn DIP SW 801 7 and 8 off 6 Turn the main switch on to resume normal copier operation 4 8 31 August 1989 lt SP 98 Clears all counters gt Service program SP 98 clears all copy counters self diagnostic counters and jam counters The procedure for using this function is the same as with SP 97 only this time select SP 98 The following will
429. tointerrupter 1 Photointerrupter L T Thermistor Toner Overflow Sensor Total Counter Thermofuse Stepped Screw Slider Lock Stepped Screw Slider Lock Photointerrupter IL G 3P S3 Photointerrupter IL G 3P S3 Seal Agitator Rubber Seal Paddle Roller Plastic Ring 3x6xlmm 10pcs set ing 8mm ing 8mm ing 4mm B B Spring Pressure Arm B B ing 4mm Spring Anchor Stepped Screw Stepped Screw Short Connector Clamp Reflector Spring Drum Return Arm Knob Screw Stepped Screw Pin Transfer Guide Plate Decal Paper Level Decal Paper Level 134 August 31 89 Parts N D ription arts No escriptio Index No ho NY NY NY YH YH YH P5 MY NH NH NH Valve 011 Pump Spring Exit Spacer Guard Rubber Foot Supporter Lamp Terminal Thermo Meter HLC Probe HLC 30 Digital Multimeter BECKMAN RMS3030 Test Lead Kit Test Chart OS A3 10pcs set Silicone Oil Cover Key Counter Spring High Voltage Decal High Voltage Decal Sprocket 20T nall Screw Wing Center Wing Side Exposure Lamp Terminal Release Hook Scanner Drive Wire Cushion Exposure Glass Spring Corona Wi Spring Corona Wi Spring Corona Wi Plug Corona Unit Shoulder Screw Hinge Spring Registrati
430. tor until the top sheet raises the pick up roller to deactuate the lift sensor again This ensures that the paper is always at the correct feed height 2 65 31 August 1989 10 3 ROLLER FUNCTION A This copier uses an FRR Feed Reverse Roller paper feed system with three rollers Pick up Roller The pick up roller A rests on the paper stack until the start key is pressed A few moments after the Start key is pressed the pick up roller starts to rotate and feeds the top sheet between the feed roller B and the separation roller C When the paper s leading edge reaches 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 separation rollers Feed and Separation Rollers There is a one way bearing inside the feed roller so it can turn only in one direction The separation roller is driven in the opposite direction The separation roller however is driven through a slip clutch torque limiter clutch which allows it to turn in either direction depending 2 the friction between the rollers A spring keeps the separation roller in contact with the feed roller 2 66 31 August 1989 fant 6 we n CAN c AAN MONA The direction that the separation roller A turns depends on the frictional forces acting on it The slip clutch applies a constant clockwise force F2 When there is a singl
431. ts Va is supplied to one side of the component The main board then supplies a LOW trigger signal to the other side to turn the device on Magnetic Clutches Name 151 Paper Feed 2nd Paper Feed 1st Feed Relay Toner Supply Registration Duplex Paper Feed Solenoids Name Manual Feed 1st Pick up 2nd Pick up Pick off Cleaning Inverter Return Junction Gate Fork Gate SOL 1 Fork Gate SOL 2 Duplex Positioning Duplex Stopper Duplex Pick up Knocking CN CN405 2 Paper Feed PCB CN402 2 Paper Feed PCB CN416 2 Paper Feed PCB CN101 B8 Main PCB CN101 A11 Main PCB CN104 A8 Main PCB CN CN414 2 Paper Feed PCB CN404 2 Paper Feed PCB CN401 2 Paper Feed PCB CN101 B5 Main PCB CN101 A3 Main PCB CN104 B4 Main PCB CN104 A4 Main PCB CN104 B3 Main PCB CN104 A3 Main PCB CN104 B8 Main PCB CN104 A10 Main PCB CN104 A5 Main PCB CN101 A13 Main PCB 2 113 31 August 1989 15 7 SENSOR OPERATION Photointerrupters Internal Circult ALY AJY LE Photo Tr Photo Tr OFF Output LOW Output HIGH Photointerrupter sensors consist of a plastic encapsulated LED and phototransistor separated by an open slot When the slot is empty light from the LED activates the phototransistor and the sensor outputs a LOW signal When an actuator plate enters the slot light from the LED is blocked and the output becomes HIGH The following sensors are
432. und screw and toothed washer 13 Secure the harnesses with a clamp N 1 pan head screw x 6 and reinstall the rear cover 31 August 1989 14 Turn on the copier main switch and set SP 72 1 to enable ARDF operation Refer to the copier installation procedure for information on how to access a service program 15 Adjust the lead edge registration as follows a In platen mode use the flip scale to make a copy of the test chart b Keep this copy for reference and mark Platen Mode on the reverse side of it Front Side Original c Use the DF to make a copy of the test chart d Adjust the DF registration against the platen reference mode PM using VR 101 A on the DF PCB B PM DF Turn VR 101 counterclockwise PM DF Turn VR 101 clockwise e Continue to repeat steps c and d until you achieve the same registration as in step by 8 22 31 August 1989 DIP 101 W102 SW101 Um B Reverse Side Original f Turn off the copier main switch and set DIP SW 101 A on the DF main PCB as follows ON 101 3 4 OFF 101 1 2 g Turn on the copier main switch and set the test chart face up and with the leading edge to the right on the feed in table h Press switch 101 B on the DF main PCB twice i Press the Start key to make a copy then press switch 102 C to feed out the test chart j Adjust the DF registration against the platen reference
433. ure roller it catches the leading edge of the copy paper due to the face curl of the paper The face curl is caused by the pressure between the hot roller and silicone pressure roller 2 84 31 August 1989 12 7 FUSING CONTROL 24 Va Door CN1039 AC Drive PCB Switch M CN103 4 CN101 A14 0 0 1 AC H The main board monitors the fusing temperature through the fusing thermistor to control the fusing temperature It also uses the zero cross signal generated by the ac drive PCB to accurately control the applied power Normally the voltage applied to the lamp is a full ac waveform However by removing jumper JP100 on the main board fusing power is phase controlled Note phase control should only be used if the customer has a problem with electrical noise or interference Full AC Waveform 2 2 2 Q acin om Jd Ei bii EN 7 C When the main switch is turned on the main board outputs a trigger signal C to the ac drive PCB This trigger signal has the same frequency as the zero cross signal B The trigger signal allows maximum ac power D to be applied to the fusing lamp Then when the operating temperature is reached the CPU removes the trigger HIGH and the fusing lamp turns off 2 85 31 August 1989 Phase Control In the phase control mode the fusing lamp receives ac power constantly The amount of power is regulated by the width of the trigger pulse
434. ust 31 89 Page and Page and Parts No Description Index Index No Decal Paper Siz Paper Size Board Decal Paper Size Tray Main Board Tray Bottom Plate Tray Main Board AC Harness 115V AC Harness 115V Set Angle Front Paper Size Decal AC Harness 220V AC Harness 220V Front Paper Size Decal Rear Paper Size Decal Rear Paper Size Decal Tray DC Harness Rear Side Frame Tray DC Harness Actuator Paper Volume Main DC Harness Spring Paper Volume Main DC Harness Couple Bracket Installation Procedure English Ne 252 Cho e e Front Paper Size Decal Left Installation Procedure 5 Language Rear Paper Size Decal Left Front Guide Rail Front Guide Rail Paper Size Stay Hole Cover Tray Bottom Plate Friction Rad B Size Post Rack Side Post Grip Size Post Rack Size Post Rack Spring Plate Side Post Grip Tray Main Board Bracket Bracket Cover Plate 115V Decal Operater Instruction Decal Operater Instruction Decal Paper Size Decal Paper Size Front Cover Rear Cover Side Cover SONS M S S S SD S S S S S S S S S S SS SOS OS S M NS OS MO S pO p pp on op ng rn Cover August 31 89 Page and Page and Parts N Description Parts No Description
435. ut of the toner end sensor and the sensor sends a toner end signal to the CPU This starts the toner end run which allows 50 copies to be made before the Start key turns red 2 44 31 August 1989 6 7 TONER OVERFLOW SENSOR CIRCUIT GND 5 Y 1 LT rL Tr 03 7 i Freq OSC Detection Rectifier Main PCB Toner Overflow Sensor The toner overflow sensor signals the CPU when the toner collection bottle is full A tiny tuning fork is used as the sensing element for the toner overflow sensor This tuning fork is a damping element in a multivibrator circuit As long as there is nothing in contact with the tuning fork the oscillating frequency of the circuit stays LOW and the transistor stays off When toner presses against the tuning fork the resistance of the piezoelectric elements that are in contact with the tuning fork changes and the oscillating frequency increases The frequency detection circuit passes the higher frequency signal to the rectifier which activates the switching transistor The transistor sends a LOW signal to CN103 7 on the main board When the CPU receives this LOW signal it signals the copier to stop lights the Used Toner Bottle indicator and blinks the Service Call indicator Also a message instructing the customer to call for service is displayed on the guidance display 2 45 31 August 1989 7 IMAGE TRANSFER AND PAPER SEPARATION 7 1 PRE TRANSFER LAMP
436. vations The lens always moves toward enlargement at power up The lens is to the right of the H P sensor and the lens motor does not turn on Points to Check Check if the lens is moving properly Check CN305 9 on the optics board Check the lens drive section optics board and lens drive motor Code 29 Lens Home Position Sensor Stays High Definition Lights if the lens is moving toward reduction and the H P sensor stays at a high signal level longer than 3 82 seconds Observations The lens always moves toward reduction at power up The lens is to the left of the H P sensor and the lens motor does not turn on Points to Check Confirm that the lens is moving properly Check CN305 9 on the optics board Check the lens drive section optics board and lens drive motor 2 19 31 August 1989 Code 2A 4th 5th Mirror Home Position Sensor Stays Low Definition Lights when the 4th 5th mirror sensor home position sensor does not actuate within 1 83 seconds after the mirror motor turns on Observations At power up the 4th 5th mirror drive rotates counterclockwise past the home position sensor If the main switch is turned off and on the mirror motor emits a noise and stays at the home position Points to Check Confirm that the 4th 5th mirror assembly is moving properly Check CN305 12 on the optics board Check the 4th 5th mirror section optics board and mirror drive motor Code 2B 4th 5th Mirror Sensor Stays
437. ve Wire Replacement 5 4 1 4 Fourth and fifth Mirror Drive Wire Replacement 5 8 1 5 Lens Drive Wire Replacement s ec Rer EPEA ERAS ES 5 9 1 6 Scanner Harness Replacement Optics Cables amp Exposure Lamp 5 10 2 DEVELOPMENT rra RO RR RR RR AC 5 12 2 1 Developer 5 12 2 2 Image Density Sensor 5 14 2 3 Toner Collection Bottle Cleaning 5 15 2 4 Vs9 Voltage Checking hl t xe Le co eet ud 5 16 2 Voltage 5 17 2 6 Toner Supply System 5 18 2 7 Toner Density 5 19 2 8 Fixed Supply Mode 5 19 2 9 Toner Amount Ghangllg xcix ex toe etc npe ede DEO bea fes 5 19 2 10 ID Pattern Bias Voltage 5 19 S CLEANING oxi DEG epee eod 5 20 3 1 1 Pick off Pawl 5 20 3 2 Cleaning Blade and Brush 5 22 3 3 Blade Cleaner and Bias Roller Blade 5 23 4 FUSING att
438. ver Open Short Open Short Open Short Open Short Paper End indicator stays on Paper End 15 not indicated and the Start key stays green when paper runs out SC 85 is incremented SC 86 is incremented SC 87 is incremented SC 88 is incremented Remove Original is indicated after the original is removed The original counter SP 114 does not increment when the platen cover is raised to remove an original Remove Original is not indicated when an original is not removed after copying The original counter SP 114 does not increment when the platen cover is raised to remove an original 13 11 SECTION 14 15 BIN SORTER Contents 15 BIN SORTER 1 SPECIFICATIONS 3 33759 5555 14 1 2 MECHANICAL COMPONENT LAYOUT 14 2 3S DRIVE LAYOUT ies at to 14 3 4 ELECTRICAL COMPONENT LAYOUT 14 4 5 ELECTRICAL COMPONENT DESCRIPTIONS 14 5 6 BASIC OPERATION 14 6 7 FUNCTIONAL AND ELECTRICAL DESCRIPTION 14 10 TU ce E debate uet opto Ret E e ap dr d 14 10 Te Bit Gale Opel allON ands eset tod whe lee Pade 14 11 7 3 Relay Guide Plate Reset 14 12 7 4 Intertace with he sa bees eb ERE 14 13 LO Ja E 14 15 Tb
439. wa Screw 139 August 31 89 Page and arts No Index No 1100 1 Pin Mate N Lock Page and Parts No Description Index No 0965 4008W Tappi Screw 0965 4008W Tappi Screw 0965 40081 Tappi Screw With 0965 4010W Tappi Screw With 0965 4012W Tappi Screw With Flat Washer 0971 3006A Phili Polycarbonate Screw M3x6 0971 3006A Phili Polycarbonate Screw M3x6 1 0086 Solid Strand 844 Socket Mate N Lock 863 Stud Pin 864 Housing AWG14 20 864 Housing AWG14 20 916 Pin Mate N Lock 1043 Pin Mate N Lock ith ith Wi lat Washer Wi Wi Wi lat Washer 1100 1 Socket Mate N Lock lat Washer 1100 1 Socket Mate N Lock F F F F lat Washer 1100 1 Socket Mate N Lock 1100 1 Socket Mate N Lock 1100 1 Terminal 1100 1 1100 1100 1 1100 1 1100 1 1100 1 1100 1 1100 1 1100 1100 124 1100 124 1100 1253 Pi ate N Lock Terminal Terminal Terminal Receptacle Termi Receptacle Termi Receptacle Termi Receptacle Termi Receptacle Termi 1089 Socket Mate N Lock Receptacle Termi 1089 Socket Mate N Lock Receptacle Terminal 1091 EI Connector Receptacle Terminal 1094 Connector 9P 1100 1253 1 ate N Lock 1100 1253 Pi ate N Lock Connector 9P Connector
440. where to check inside the copier if there is a misfeed 19 Magnification Ratio Indicator Shows the selected reproduction ratio 20 Zoom Indicator Lights when zoom mode is selected 31 August 1989 2 4 GUIDANCE DISPLAY The Guidance Display shows information about keys and modes and it guides you through the procedures for operating the copier 2 _ ay 1 Em ae 5 _ sat D esi ____ 4 Ecc SERERE EE Information about keys and modes When you need information about keys or modes press the Guidance key and the key you want information about After starting copier operation you can get information about the current mode by pressing the Guidance key Guidance is not available for the following Keys Number keys Decimal key Start key Manual Image Density key Select Cassette key 1 9 31 August 1989 3 COPY PROCESSES AROUND THE DRUM EXPOSURE DRUM CHARGE QUENCHING CLEANING o IMAGE TRANSFER _ PAPER SEPARATION DRUM CHARGE In the dark the charge corona unit gives a uniform positive charge to the selenium drum The charge remains on the surface of the drum because the photoconductive selenium has electrical resistance in the dark EXPOSURE An image of the original is reflected to the selenium drum surface via the optics assembly The c
441. witch gt Transistor 254683 Transistor 25820 4503 TLR 102A oco CO Wwe Co Lr Photocoupler ON3111 IC TC4049BP SN74LS373N IC UPD7810G IC TD62304P IC TD62308AP 16 PST518A IC 519711 17339 p Mo DR A c gt BO Co Ceramic Oscillator 10MHz Resistor 5100HM 5 Resistor 3900HM istor Array 10 liable Resistor 5KOHM iable Resistor 10KOHM 0 5W liable Resistor 20KOHM iable Resistor 100 Coil 8001 2 5 A pem Q ty Per Assembly Index Q ty Per Part No ipti y Wwe part wo 2 Assembly 182 1107 0409 Fuse 1 itor 1000 10V itor 50V itor 2 2 50V itor 3 3pF 50V itor 4 7 50V itor 1000 50 itor 0 1 50V itor 27PF 50V itor 0 022 50V itor 0 012 50V Resistor 1000HM 1 8W 5 Resistor 3300HM 1 8W 5 Resistor 1 5 1 8W Resistor 2 2 1 8W istor 3 3KOHM 1 8W istor 4 7KOHM 1 8W istor 10 5 istor 22KOHM 1 8W 5 istor 1MOHM 1 8W 5 Capacitor 100PF 50V 5 Resistor 10 1 4 5 Resistor 2 20HM 1 4W 5 Resistor 2 7KOHM 1 4T 5 Resistor
442. ws 8 Remove the 5 plastic caps C from the docking holes 9 Remount the left cover 14 21 31 August 1989 10 Screw in the two mounting studs A then install the sorter adapter B with two screws C 11 Remove the upper cover D 3 screws 12 Remove the front E and rear covers F of the sorter 6 screws 14 22 31 August 1989 13 Mount the sorter on the copier through the docking holes A 14 Pass the sorter s harnesses through the rectangular docking hole 15 Remove the main board shielding plate 2 screws and swing the board C to the left 2 screws then connect the red 2P connector D to the red 2P free connector and the white 4P connector E to the white 4P free connector 16 Connect the harness from the sorter to CN108 F on the main board Secure the ground wire G as shown toothed washer H is also installed for the European version 17 Secure the sorter to the sorter adapter by fixing the brackets I while lifting them up 1 screw each 18 Remount the upper front and rear covers 14 23 31 August 1989 lt a 19 Install the interrupt bin A Then starting from bottom to top install the other bins B as shown Note sure that the bins lock in place when they are installed 20 Peel off the panel cover C at the left end of the operation panel 21 Install the sorter stack key top D copier accessory and stick down the
443. y Check CN305 12 on the optics board Check the 4th 5th mirror section optics board and mirror drive motor motor Code 2B 4th 5th Mirror Sensor Stays High Definition Lights if the 4th 5th mirror home position sensor remains actuated for 1 83 seconds after the mirror motor turns on Observations At power up the 4th 5th mirror drive rotates clockwise and the actuator leaves the home position sensor If the main switch is turned off and on the drive pulley continues to drive in a clockwise direction until the mirror motor emits a noise and stops at the extreme right Points to Check Confirm that the second scanner moves properly Check CN305 12 on the optics board Check the 4th 5th mirror section optics board and mirror drive motor 13 4 31 August 1989 Code 2D No Encoder Output Definition Lights during a copy cycle when the output frequency from the scanner motor encoder is not detected for 490 milliseconds after the scanner motor is energized of if the scanner home position sensor opens or shorts during a copy cycle Observation 1 During the copy cycle the scanner first moves then stops 2 The scanner does not move at all Points to Check Check the scanner drive motor the scanner home position sensor and CN306 2 3 on the optics board Code 31 Drum Thermistor Blown Definition Lights when the drum thermistor circuit is open Observation Copies are dirty Points to Check Check the resi
444. y Top A007 5729 Key Top A007 5730 Key Top 007 5731 Key Top A008 A008 A008 5629 Key Top A008 5630 Key Top A008 5631 Key Top A008 5632 Key Top A008 5633 Key Top A008 5634 Key Top A008 5635 Key Top A008 5636 Key Top A008 5637 Key Top A008 5638 Key Top A008 5639 Key Top A008 5640 Key Top C S A008 564 A008 564 ADF Sheet LT ADF Sheet A4 Sorter Sheet LT Sorter Sheet A4 Timer Interrupt Start Guidance Zoom Panel Sheet LT 5626 Key Top Program Zoom Panel Sheet A3 5627 Key Top Clear Mode 1 Sheet Enlarge Reduce LT Recall 1 1 Sheet 4 Sheet Auto Paper Select LT Sheet Auto Paper Select 4 Panel Sheet LT le Side ingle Side Panel Sheet A3 Duplex Panel Sheet LT Duplex Panel Sheet A3 Panel Sheet Sheet Sheet Sheet Sheet A3 Board Operation Panel Duplex LT Operati Panel Sorter LT Fo Operati Panel Finishing LT Operati Panel Key Top ADS Operati Panel Key Top Lighter Mylar Seal Slide Cover Darker LCD Power Supply Board LCD Board 1 2 A008 5643 Key Top 4 A008 564 Key T Select Cassette Q ty Per Assembly TES Q ty Per Part No Description Part No Description 007 1521 A007 1462 007 1461 0434 0434 0802 0965 008 Slide Rail Base 0060W 0080W 5094 4008W 1354 Tapping Screw M4x6 Key Top Base B Ta
445. ystem can also be selected using SP 30 SP 30 0 Toner supply mode Detect Fixed Toner supply starts 43 pulses after the exposure lamp turns off Toner is supplied at this time to prevent toner scattering on the copies The amount of toner added depends on the size of copy paper being used Exposure Lamp ON 2 Uy tort 43pls Toner Supply L YY Clutch 320msec 320msec 320msec 320msec ital gt 8 1 2 11 A4 Size 160msec 160 160 B 1 2x 11 A4 Size 15 30 i 4596 60 gt 160msec 2 42 31 August 1989 Detect Supply Mode In the detect supply mode SP 30 set to zero when a low toner image density condition is detected Vsp gt 1 8 toner is supplied during each copy cycle for the next ten copies as determined by SP 32 toner supply amount fixed and detect modes If Vsp becomes greater than 4 25 of Vsg the CPU adds toner as determined by SP 31 detect mode If Vsp becomes greater than 1 4 of Vsg Vsp gt 1 4 the toner supply amount changes to 60 regardless of those SP settings If Vsp becomes greater than 1 5 volts and the CPU detects this condition 3 times the wrench mark starts blinking on the operation panel board The toner supply amount in this condition remains 60 of the detect toner supply mode Vsp Voltage by 60 1 4 Vag lt lt a gt Toner added as selected by

ricoh ft5540/5550/5570 service manual ricoh company, ltd.

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