RICOH fw830_sm
Transcript of RICOH fw830_sm
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IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,make sure that the copier power cord is unplugged.
2. The wall outlet should be near the copier and easily accessible.
3. Note that some components of the copier and the peripherals are
supplied with electrical voltage even if the main switch is turned off.
4. If any adjustment or operation check has to be made with exterior coversoff or open while the main switch is turned on, keep hands away from
electrified or mechanically driven components.
5. The inside and the metal parts of the fusing unit become extremely hotwhile the copier is operating. Be careful to avoid touching those
components with your bare hands.
HEALTH & SAFETY CONDITIONS
1. Never operate the copier without the ozone filters installed.
2. Always replace the ozone filters with the specified ones at the specified
intervals.
3. Toner and developer are non-toxic, but if you get either of them in your
eyes by accident, it may cause temporary eye discomfort. Try to remove
with eye drops or flush with water as first aid. If unsuccessful, get medicalattention.
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OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course
on those models.
2. The RAM board on the main control board has a lithium battery which can
explode if replaced incorrectly. Replace the battery only with an identical
one. The manufacturer recommends replacing the entire RAM board. Do
not recharge or burn this battery. Used batteries must be handled inaccordance with local regulations.
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Do not incinerate the toner cartridge or the used toner. Toner dust mayignite suddenly when exposed to open flame.
2. Dispose of used toner, developer, and organic photoconductors
according to local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries in order to dispose of them later, donot put more than 100 batteries per sealed box. Storing larger numbers or
not sealing them apart may lead to chemical reactions and heat build-up.
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SECTION 1
OVERALL MACHINE INFORMATION
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1. SPECIFICATIONS
Configuration: Table top
Copy Process: Electrostatic transfer system
Original Feed: Sheet feed
Original Size: Maximum: 914 x 3,600 mm
Minimum: 182 x 257 mm (B5 lengthwise)
Copy Size: Same as "Original Size"
Copying Speed: Manual feed: 6 cpm (A1/D sideways)
Sheet & Roll feed: 7 cpm (A1/D sideways)
First Copy: 19 seconds (A1 sideways)
Warm-up Time: Within 6.5 minutes (Room temperature 20oC)
Multi-Copy: 1 to 10 (A1/D or smaller)
1 to 5 (A0/E)
Automatic Reset: 2 minutes after copying is finished (can be setto 1, 3, 4, or 5 minutes or to no auto reset)
Photoconductor: Organic photoconductor drum
Drum Charge: Single-wire with grid plate (Negative Charge)
Reproduction Ratio: 1 : 1 (±0.5%)
Exposure System: Slit exposure via fiber optic array
Exposure Lamp: Fluorescent lamp (65 W)
Development: Dual-component dry toner system
Toner Replenishment: Cartridge system (750 g toner/cartridge)
Toner Consumption: 1,860 A1 or D copies per cartridge (6% original)
Development Bias: Negative
Toner Density Control: Pattern density detection by photosensor and
direct toner density detection by induction
sensor
Image Density Adjustment: Development bias control + exposure control
Auto Image Density
Control:
Development bias control and exposure control
31 December 1992 SPECIFICATIONS
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Image Transfer: Single wire dc corona (negative charge) withpre-transfer lamp
Paper Separation: Dual wire ac corona and pick-off pawls
Cleaning: Cleaning bladeQuenching: Photo quenching by LEDs
Paper Feeding: Manual feed (sheet and roll feeder optional)
Image Fusing: Heat and pressure type, teflon (upper) and
silicone rubber (lower) rollers
Fusing Lamp: Halogen lamp (115 V: 1,100 W, 220/240 V:
1,100 W)Self-diagnostic Codes: 14 codes, displayed in copy counter
Power Source: 115 V/60 Hz....15 A220 V/50 Hz....7 A
240 V/50 Hz....7 A
Power Consumption: Maximum: 1.47 kWWarm-up: 1.25 kW
Ready: 0.1 to 1.2 kWCopy cycle: 1.42 kW
Dimensions (W x D x H): 1,410 x 800 x 600 mm
55.51 x 31.50 x 23.62 in
Weight: 180 kg, 397 lb
Optional Equipment: Sheet feeder
Roll feeder
Roll feeder connector Paper spool
Table
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2. MACHINE CONFIGURATION
This copier can be equipped with optional equipment as show above.
1. Copier (A098)
2. Sheet Feeder (A453)
3. Roll Feeder (A454) and Connector (A384)
4. Roll Feeder (A454) and Sheet Feeder (A453)
3
2
4
1
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3. DRUM PROCESSES
1. ChargeIn the dark the charge corona unit applies a negative charge to the drum.
The grid plate ensures the charge is applied uniformly. The charge remains
on the surface of the drum because the photoconductive drum has a highelectrical resistance in the dark.
2. ExposureHigh intensity light from a fluorescent lamp is reflected from the moving
original through the fiber optic array. The charge on the drum surface is
dissipated in direct proportion to the intensity of the reflected light, thus
producing an electric latent image on the drum surface.
12
3
4
5 6
7
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3. DevelopmentThe magnetic developer brush on the development roller comes in contact
with the latent image on the drum surface. Toner particles are
electrostatically attracted to the negatively charged latent image areas.
4. Pre-Transfer LampThe pre-transfer lamp illuminates the drum prior to image transfer. Thisreduces the attraction between the toner and the drum, thus making image
transfer easier.
5. Image TransferCopy paper is fed to the drum surface, at the exact timing, to align the copy
paper and the developed image on the drum surface. Then a strong negative
charge is applied to the back side of the paper. The negative charge pulls
the toner particles from the drum surface onto the paper.
6. Paper SeparationA strong ac corona discharge is applied to the back side of the copy paper,
reducing the charge on the paper and breaking the electrostatic attraction
between the paper and the drum. Then, the stiffness of the copy papercauses it to separate from the drum. The pick-off pawls help to separate
paper which has low stiffness.
7. CleaningThe cleaning blade removes any toner remaining on the drum surface.
8. QuenchingThe light from the quenching lamp electrically neutralizes the surface of thedrum.
31 December 1992 DRUM PROCESSES
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4. MECHANICAL COMPONENT LAYOUT
25
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23
22
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20
19
1817
16
15
14
131211
108765
9
32136
3533
32
31
30
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28
27
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4
34
MECHANICAL COMPONENT LAYOUT 31 December 1992
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1. Front Original Feed Roller
2. Exposure Lamp
3. 1st Press Rollers
4. Fiber Optic Array
5. Platen Roller
6. Charge Corona Unit
7. Cleaning Blade
8. Original Registration
Rollers
9. 4th Press Rollers
10. Rear Table Lever
11. 2nd Press Rollers
12. Rear Original Feed Roller
13. 3rd Press Roller
14. Switch Back Gate
15. Hot Roller
16. Upper Exit Rollers
17. Exit Gate
18. Exit Rollers
19. Pressure Roller
20. Transport Belt
21. Pick-off Pawls
22. T/S Corona Unit
23. Paper Registration Rollers
24. Lower Copy Guide
25. Table
26. Roll Feeder
27. Manual Feed Rollers
28. Sheet Feeder
29. Manual Feed Table
30. Original Guides
31. Development Roller
32. Toner Cartridge
33. OPC Drum
34. Original Table
35. 5th Press Roller
36. Original Recycle Gate
31 December 1992 MECHANICAL COMPONENT LAYOUT
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5. DRIVE LAYOUT
1. Original Drive Belt 2
2. Rear Original Feed Rollers
3. Original Drive Clutch
4. Main Drive Motor
5. Original Registration
Rollers
6. Original Drive Belt 37. Platen Roller
8. Front Original Feed Rollers
9. Development Roller Gear
10. Auger Gear
11. Toner Supply Clutch
12. Development Motor
13. Paper Feed Clutch
14. Paper Feed Drive Chain
15. Development Drive Belt
16. Paddle Roller Gear
17. Registration Roller Clutch
18. Drum Drive Gear
19. Toner Collection Coil Gear
20. Feed/Fusing Drive Belt 2
21. Fusing Drive Chain
22. Drum Drive Belt
23. Feed/Fusing Drive Belt 1
24. Transport Roller Sprocket
25. Hot Roller Sprocket
26. Exit Roller Drive Chain
27. Lower Exit Roller Sprocket
28. Original Reverse DriveBelt 1
29. Upper Exit Roller Sprocket
30. Original Reverse Drive
Belt 2
31. Original Drive Belt 1
28
910
11
12
13
14
151617182023
24
25
31
27
8
7
6
54
3230
19
29
2122
26
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DRIVE LAYOUT 31 December 1992
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6. ELECTRICAL COMPONENT DESCRIPTIONS
Refer to the electrical component layout on the reverse side of the Point to
Point (Water proof paper) index numbers.
Name Function Index. No.
Motors
Main Drives all mechanical components except thedevelopment unit and the fans. (100 Vac)
5
Development Drives the development unit. (100 Vac) 1
Exhaust Fan Removes heat from around the fusing unit.
(100 Vac)
25
Cooling Fan Provides air flow to the optics cavity. (100 Vac) 6
Vacuum Fan Provides suction so that paper is held firmly
on the transport belts and rollers. (100 Vac)
68
Magnetic Clutches
Original
Forward Feed
Drives the original forward feed mechanism. 52
Registration Drives the registration rollers. 50
Original Re-
verse Feed
Drives the original reverse feed mechanism. 8
Solenoids
Toner Supply Turns on to supply toner to the development
unit.
46
Pattern Shutter On ID check cycles, this solenoid turns on to
move the pattern plate into the light path.
19
Exit Gate Controls the position of the exit gate. (When
ON, the paper exits downward; when OFF,
the paper exits upward.)
24
Pick-off Pawl Moves the pick-off pawls against the drum. 34
Paper Stopper Moves the paper stopper down to prevent
paper from being inserted.
40
Manual Feed Turns ON to engage the manual feed clutch. 48
Recycle Gate Controls the position of the recycle gate.(ON = recycle gate in down position,
OFF = recycle gate in up position.)
26
31 December 1992 ELECTRICAL COMPONENT DESCRIPTIONS
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Name Function Index. No.
Switch Back
Gate
Lifts the switch back gate to the up position. 9
Original Stopper Moves the original stopper down to prevent an
original from being inserted.
43
Switches
Main Supplies power to the copier. 65
Upper Safety Cuts ac 100 volt power when the upper unit is
opened.
27
Lower Safety Cuts ac 100 volt power when the middle unit
is opened.
67
Rear Safety Cuts ac 100 volt power when the paper exit
unit is opened.
22
Toner Cover Cuts power to the toner supply solenoid when
the toner cartridge cover is opened.
45
Sheet Feeder
Set
Prevents main motor operation when the
sheet feeder is not set.
64
Rear Feeder Detects when the rear feeder table is opened. 21
Sensors
Image Density Detects the image density of the test pattern
on the drum.
33
Toner Density Detects the density of toner in the developer. 36
Toner Overflow Detects when the used toner tank is full. 28
Pulse Generator Supplies timing pulses to the main board(photointerruptor).
23
Original Set Detects when an original is inserted. 41
1st OriginalTransport
Monitors movement of the original. 11
2nd Original
Transport
Monitors movement of the original. 14
Original Regis-tration
Detects when the original lead edge passesthe original registration rollers.
12
Light Detects the intensity of the exposure lamp
output.
4
Original En-trance
Detects when an original is inserted from therear feeder.
13
ELECTRICAL COMPONENT DESCRIPTIONS 31 December 1992
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Name Function Index. No.
Switch Back
Gate
Detects if the switch back gate moves to the
up position during the original switch back.
10
Original Exit Detects jams in the original exit section. 39
Recycle Gate Detects whether the recycle gate is in the up
or down position.
30
1st Feed Detects when copy paper is inserted. 38
2nd Feed Detects jams between the manual feed rollersand the registration rollers.
37
Registration Detects when copy paper arrives at the
registration rollers.
35
Transport Monitors paper movement between thetransfer/separation section and the fusing unit.
71
Fusing Exit Detects jams through the exit unit. 17
Upper Exit Detects jams through the upper exit guides. 16
Lower Exit Detects jams through the lower exit guides. 18
Printed Circuit Boards
Main Controls all copier functions both directly and
through other PCBs.
63
DC Power
Supply
Provides dc power for all components of the
machine.
55
AC Controller 1 Provides ac power to the fusing lamp and triac. 57
Lamp Regulator Provides ac power to the fusing lamp. 51
AC Controller 2 Provides ac power to the main motor and
development motor.
60
Indicator Panel Contains the paper and original insertion
indicators and the original feed stop key.
42
Operation Panel Control the operation panel display. 32
Auto Image
Density
Measures the reflectivity from the original’s
background.
15
Lamps
Exposure Provides light to reflect the original’s image
onto the drum.
29
Quenching Neutralizes any charge remaining on the drum
surface after cleaning.
20
31 December 1992 ELECTRICAL COMPONENT DESCRIPTIONS
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Name Function Index. No.
Fusing Provides heat to the fusing unit. 53
Pre-Transfer
(PTL)
Reduces the charge on the drum surface prior
to image transfer.
31
Power Packs
Charge/Bias/Grid
Power Pack
Provides high voltage power for the charge
corona, charge grid, and development bias.
49
Transfer/
Separation
Provides high voltage power for the transfer
corona and separation.
54
Thermistors
Hot Roller Monitors the hot roller’s surface temperature. 56
Pressure Roller Monitors the pressure roller’s surface
temperature.
58
Exposure Lamp Monitors the fluorescent lamp’s temperature. 44
ThermofusesFusing Protects against fusing overheat. (Two
thermofuses in parallel.)
59
Exposure Lamp Protects against exposure lamp overheat. 44
Heaters
Exposure Lamp Warms the scanning lamp. 44
Anticondensa-tion
Keeps moisture from forming inside the copier. 47
Others
Total Counter Keeps track of the total length of copies made. 66
Noise Filter Filters electrical noise on the ac power inputlines.
62
Transformer Steps down the line voltage to 100 Vac. 69
DevelopmentMotor Capacitor
Motor start capacitor. 2
Main Motor Ca-
pacitor
Motor start capacitor. 3
Circuit Breaker Guards against voltage surges in the input
power.
61
ELECTRICAL COMPONENT DESCRIPTIONS 31 December 1992
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Name Function Index. No.
Vacuum Fan
Motor Capacitor
Motor start capacitor. 70
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7. ORIGINAL AND PAPER PATH
Repeating Copy Except for A0/E, A1/D Lengthwise
B
A
A: Upper Copy Exit
B: Lower Copy Exit
ORIGINAL AND PAPER PATH 31 December 1992
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A0/E, A1/D Lengthwise Switching Back
y z | : Switching Back
31 December 1992 ORIGINAL AND PAPER PATH
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SECTION 2
DETAILED SECTIONDESCRIPTIONS
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1. DRUM
1.1 DRUM CHARACTERISTICS
The organic photoconductor (OPC) drum has the following characteristics:• It is able to accept a high negative electrical charge in the dark. (The
electrical resistance of the OPC drum is high in the absence of light.)
• The electric charge on the drum surface dissipates when the drum is
exposed to light. (The conductivity of the OPC drum is greatly enhancedby exposure to light.)
• Dissipating an amount of charge in direct proportion to the intensity of the
light. That is, where stronger light is directed to the photoconductorsurface, a smaller voltage remains.
The OPC drum used in this model has high sensitivity, good colorreproduction, and good reproduction of low contrast originals (pencil
originals, etc.)
31 December 1992 DRUM
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1.2 DRUM DRIVE
The OPC drum [A] is 80 millimeters in diameter and 970 millimeters long. Itturns constantly when the main motor [B] is on.
When the main motor turns on, drive is transmitted to the drum as follows:
main motor drive gear [C] ⇒ idle gear [D] ⇒ main drive pulley gear [E] ⇒drum drive belt [F] ⇒ drum drive gear [G] ⇒ drum flange [H] ⇒ drum
When the drum knob [I] is tightened, the right flange [J] presses firmly againstthe drum so that the drum is held tightly between the flanges. The drum and
flanges turn together when the main motor is on.
[A]
[H]
[J]
[I]
[C]
[D]
[E]
[B]
[G]
[F]
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2. CHARGE
2.1 OVERVIEW
This model uses a single wire corona unit [A] to charge the OPC (organic
photoconductor) drum [B]. The corona wire generates a corona of negative
ions when a high negative voltage is applied to it by the charge/grid power
pack [P1].
To make the negative corona uniform, a grid consisting of 8 wires is installedon the charge corona unit between the corona wire and the drum. This grid
drains off any charge in excess of –940 volts, thus preventing fluctuation ofthe charge potential.
[B]
[A]
P1
Charge
Grid
P1
31 December 1992 CHARGE
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2.2 CHARGE CORONA CIRCUIT
The DC power supply board supplies +24 volts (Va) to the charge/bias/gridpower pack as the power supply source. About 8 seconds after the copy
process starts, the CPU drops CN107-B14 from +24 volts to 0 volt. This
actuates the dc/dc converter within the power pack which applies a high
negative voltage of approximately –5.3 kV to the charge corona wire. Thecorona wire then generates a negative corona charge.
The grid limits the maximum corona charge to –940 volts. This ensures that
the charge does not fluctuate and an even charge is applied to the drumsurface. When developing the test pattern for the image density sensor, the
grid charge is –460 volts.
The copy grid voltage, and ID sensor grid voltage amounts can be adjusted
using service program modes #23 and #22, respectively.
The grid drive signal applied to CN1-6 is a pulse width modulated signal. Asthe width of the pulses applied increases, the strength of the grid charge also
increases. The main board monitors the grid charge at CN110-8 and controls
the width of the drive pulses based on this feedback.
Charge / Bias Grid PPCN1-1
CN1-2
CN1-3
CN1-6
CN1-10
DC Power-6
-B14
CN110
-8
GND
DC/DCMain Board
Charge
-1
CN107
CN2
24V Va
Grid Drive0/5
Grid monitor
Converter
DC/DC
Converter
24
0 2.5
Charge/Bias/Grid PP
CHARGE 31 December 1992
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3. EXPOSURE
3.1 OVERVIEW
Light from the exposure lamp [A] reflects off the original and through the fiber
optics [B] to the OPC drum [C]. The reflector plate [D] aides the exposure
lamp intensity for high original moving speed. During exposure, the originalmoves across the exposure glass at the same speed as the drum’s
peripheral velocity.
The platen roller [E] presses the original [F] flat against the exposure glass[G] just above the fiber optic array. This ensures that the image is properly
focused. (The original must be within 0.2 mm of the exposure glass surface.)
The exposure lamp is a 100 V, 65 W fluorescent lamp. This lamp has aheater which prevents a reduction in light output due to low temperatures.
The heater maintains the lamp’s temperature at 40oC
[A]
[B]
[C]
[E]
[D]
[G]
[F]
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3.2 ORIGINAL FEED
3.2.1 Basic Operation
When the original is inserted on the original table [A], it activates the original
set sensor [B]. The main motor then turns on. Two seconds later the original
feed clutch turns on to start turning the front original feed rollers [C], rearoriginal feed rollers [D], and original registration rollers [E]. The two second
delay allows time for the operator to align the lead edge of the original
against the first set of rollers to prevent skew.
The original is fed past the 1st and 2nd original transport sensor [F,G] and
around the rear original feed rollers to the original registration rollers. The
original feed clutch turns off 0.2 second after the original’s leading edgeactivates the original registration sensor [H]. The original remains at this
position until a sheet of copy paper is fed.
Just before the copy paper reaches the registration sensor, the original feedclutch turns on again and original feed resumes. The original passes
between the platen roller [I] and the exposure glass [J] and from there to thefront original feed rollers. The original’s image density is measured by the
ADS [K] at this time. The original’s image is reflected through the fiber opticarray to the drum as it passes between the platen roller and the exposure
glass.
If making a single copy, the original then exits the machine. However, ifmaking repeat copies, the recycle gate [L] directs the original around the front
original rollers to the upper part of the original transport mechanism. The
original transport cycle then repeats.
The maximum original length for repeat copying is 610 millimeters. If the
operator attempts repeat copying with an original longer than 610 millimeters,
it will automatically feed out after making a single copy.
[A]
[B] [C] [F] [I] [H] [G][D]
[E][K][J][L]
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The main CPU determines the original length for synchro cutting by countingthe generated pulses after the 1st original transport sensor detects the
leading edge of the original until the original set sensor detects the trailing
edge of the original.
Switching-back
The inserted original activates both the original set [A] and original exit [B]
sensors when the lever [C] is lifted and the entered number of copies is twoor more. The copier CPU then detects that the switching-back mode has
been entered.
In the switching back mode, the original is exposured by passing between the
platen roller and exposure glass. At the appropriate timing after the trailing
edge of the original passes through the 1st original transport sensor [D], thefront original feed [E], platen [F], original registration [G], and rear original
feed [H] rollers turn backwards and the switch back gate [I] is lifted to the up
position. The original is transported to the machines rear side. At theappropriate timing after the trailing edge of the original passes through theregistration sensor, the front original feed, platen, original registration, and
rear original feed rollers begin turning forward again. The original is exposed
in the exposure section. The copier repeats the switching-back operation untilthe entered number of the copies have been made.
After all the copies are made, the original exits the machine.
The copies exit from the lower copy exit way in the switching-back mode
because the rear feeder table is opened.
If the operator attempts inserting an original longer than 610 mm without
lifting up the rear feeder table lever, the original will automatically feed outafter being scanned once only.
[A]
[B]
[C][F]
[I]
[H][G][D][E]
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3.2.2 Drive Mechanism
Drive power from the main motor is transmitted to the relay pulley [A]. When
the original forward feed clutch [B] is energized, the rear original feed rollershaft [C] starts turning the original drive belt 3 [D] forward through the original
drive belt 2[E]. The front original feed rollers, the rear original feed rollers,
and the original registration rollers rotate in the original forward direction.
When the original reverse feed clutch [F] is energized, the rear original feed
roller shaft starts turning the original drive belt 3 backwards from the relay
pulley through the intermediate gear [G], reverse gear [H], original reversefeed clutch shaft [I], and the original reverse drive belt 1 and 2 [J, K]. The
front original feed rollers, the rear original feed rollers, and the originalregistration rollers rotate in the original reverse direction.
[D]
[C]
[K]
[J]
[F]
[I]
[H]
[G]
[B][E]
[A]
[G]
[H] [A]
[F]
[I]
[J]
[E]
[K]
[B][D]
[C]
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3.3 ORIGINAL STOPPER MECHANISM
Originals should not be inserted during a copy cycle. To prevent originalsfrom being inserted, the machine locks the feeler of the original set detector
in the down position while copying. This is accomplished by the originalstopper solenoid [A].
When the original stopper solenoid turns on, the stopper arm [B] rotates
against the feeler of the original set sensor. This locks the feeler in the down
position so that originals can only be inserted as far as the original set sensor.
[A]
[B]
31 December 1992 EXPOSURE
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3.4 EXPOSURE LAMP CONTROL
The lamp regulator receives 100 volts ac at CN1-1 and CN1-2. It alsoreceives +5 volts, which is used in the lamp regulator’s control circuit, from
the main board at CN2-1. The control signal, which is a pulse width
modulated (PWM) signal, is received at CN2-2. The PWM signal has a period
(T) of 1 millisecond and a duty of 15% to 100%.The basic light intensity level is determined either by the image density
selected from the operation panel (manual ID control) or by the original’s
background level as sensed by the ADS. The CPU uses the light sensor tomonitor the actual light intensity. The light sensor directly senses the lamp’s
light output and feeds a light intensity signal back to the main board. This
feedback allows the CPU to compensate for variations in light intensity due tothe lamp’s age or temperature.
[L1]CN3-1
CN3-2
CN3-4
CN3-5
CN1-1
CN1-2
CN2-1
CN2-2
+5V
PWM
Lamp OFF (+5V)
Lamp ON (GND)
T T = 1.0 ms
Duty = 15% to 100%
LAMP
REGULATOR
Exp. Lamp
[PCB4]
CN2-2
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3.5 MANUAL ID CONTROL VS ADS
Manual ID LevelLight Sensor
Output [V]Manual ID Level
Light SensorOutput [V]
1 0.74 14 1.21
2 0.80 15 1.253 0.81 16 1.29
4 0.82 17 1.33
5 0.84 18 1.37
6 0.86 19 1.41
7 0.90 20 1.45
8 0.94 21 1.50
9 0.99 22 1.54
10 1.05 23 1.59
11 1.10 24 1.64
12 1.15 25 1.69
13 1.18 26 1.74
3.5.1 Manual ID ControlWhen in manual image density mode, the user can select one of 26 manual
ID levels. For each level, the intensity of the light output by the exposurelamp (as measured by the light sensor) is fixed. This is shown in the abovetable. For manual ID levels 2 through 12, the development roller bias also
varies. (See the section on development bias.)
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3.5.2 ADS Control
Vod/Vsd VS [V] Vod/Vsd VS [V]
0 ~ 0.18 1.74 0.66 ~ 0.69 1.21
0.19 ~ 0.46 1.74 0.70 ~ 0.73 1.15
0.47 ~ 0.49 1.64 0.74 ~ 0.75 1.050.50 ~ 0.53 1.54 0.76 ~ 0.80 1.05
0.54 ~ 0.57 1.45 0.81 ~ 0.88 0.94
0.58 ~ 0.61 1.37 0.89 ~ 0.86
0.62 ~ 0.65 1.29
VS: Light Sensor Voltage
VOD: Original Density Detecting Voltage
VSD: Standard Pattern (White Plate) Density Detecting Voltage
When automatic image density sensing (ADS) is used, the exposure light
intensity varies depending on the background image density of the original.
The preceding table shows how the exposure light intensity changesdepending on the VOD/VSD ratio.
Use service program mode #10 to select the default ID setting. It can be set
to ADS or Manual ID level 7. The factory setting is ADS.NOTE: If the exposure lamp cannot output sufficient light, service call
condition "Exposure Lamp Abnormal" appears. However, copying is
still possible. Refer to the "SERVICE CALL CONDITIONS" table.
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3.6 AUTO DENSITY SENSOR (ADS)
The ADS [A] measures the reflectivity of the original’s background. Based onthe originals background image density, the CPU automatically adjusts the
development bias and exposure light intensity to achieve a good copy image.The ADS is located at the original registration rollers. It reads the reflectivityof the white plate [B] by emitting light from ADS (standard white), which is
located above the ADS, prior to the arrival of the original. This standard white
level (VSD) is used for comparison with the background level of the original
(VOD).
The ADS samples a 43.5 mm by 10 mm area near the leading edge of the
original. As shown in the above illustration, sampling starts 15 mm from the
leading edge.
The highest voltage detected by the ADS is held (peak hold) and used for the
exposure voltage adjustment.
33.5 mm
10mm
Center Line
Sampled Area
18 mm
20 mm
[A]
[B]
[B]
[A]
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3.6.1 ADS Circuit
The ADS circuit is powered by +5 volts, which is provided at CN401-1 for the
detection circuit and CN401-6 for the lamp. The CPU resets the ADS by
dropping CN401-4 to 0 volt. This discharges C403 to reset the peak hold
function. The resistance of PD401 varies with the strength of the light strikingit. The two op-amps amplify the effect of the change in PD401 and output the
ADS signal at CN401-3.
CN401-2 C-GND
R404
C404
IC401
D4016
5 7
C403
R403
2
3
8
1IC401
4
R401
R402
C402
C401
LAMP401
PD-401
Vcc(+5V)
CN401-3 ADS:OUT
CN401-5
CN401-4
Vcc(+5V)CN401-6
CN401-7 SENSOR LAMP
ADS ADJUST
ADS RESET
CN401-1
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3.7 LAMP HEATER
This copier uses a fluorescent lamp [A] as the exposure light source. Theoutput of the exposure lamp varies depending on the temperature; low
temperatures especially degrade the light output. To prevent fluctuations intemperature from affecting the copy image, the lamp heater [B] keeps the
lamp’s temperature at 40°C.
[A]
[B]
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3.8 LAMP HEATER CONTROL CIRCUIT
The lamp thermistor, which is mounted together with the lamp heater,monitors the lamp temperature. Based on the input from this thermistor at
CN107-B1, the CPU on the main board determines whether or not to turn onthe lamp heater. To turn on the lamp heater, the main PCB drops CN107-B2
to 0 volts. This turns on SSR401 on ac controller 2, which provides ac powerto the heater.
If the exposure lamp thermistor short circuits, the comparator circuit drops
CN107-B3 to LOW. The copier then stops operation, the Call ServiceIndicator (wrench mark) lights, and "E8" are alternately displayed in the Copy
Counter.
If the exposure lamp thermistor circuit becomes open, the comparator circuitchanges CN107-B4 from LOW to a 5 volt pulses. Then, service call condition
"Exposure Lamp Thermistor Open" appears. However, copying is still
possible. Refer to the "SERVICE CALL" Table.
CN107
-A2
-B2
-A1
-B3
-A3
-B1
-B4
CN407-2
-1
CN408
-3
-2
-1
-5
-4
Va
24
24SSR401
~
~+
AC 100 V
CN406-1
CN406-2
CN407-4
CN407-3TH3
H1
Comparator
Circuit
L. Heater ON
00/5
00/5
TH3Short
TH3Control
TH3Open
5Vc
GND
PCB1 PCB5CN401-2 -1
0/50
TF2
Main PCB AC Controller 2
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4. DEVELOPMENT
4.1 OVERVIEW
When the development motor 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 magnets in the developmentroller attract the developer to the development roller sleeve.
The turning sleeve of the development roller then carries the developer pastthe doctor blade [C]. The doctor blade trims the developer to the desired
thickness and creates backspill to the cross-mixing mechanism.
The development roller continues to turn, carrying the developer to the OPCdrum. When the developer brush contacts the drum surface, the negatively
charged areas of the drum surface attracts and holds the positively charged
toner. In this way, the latent image is developed.
Negative bias is applied to the development roller to prevent toner from beingattracted to non-image areas on the drum that may have residual positive
charge. The bias also controls image density.
After turning about 100 degrees more, the development roller releases the
developer into the developer tank. The developer is agitated by the paddle
roller and the cross-mixing mechanism.
Also, in this machine, rotation of the paddle roller and development roller tend
to cause air pressure inside the unit to become higher than the air pressurearound the development unit. Therefore, a hole fitted with a filter, has beenadded to the top of the unit to relieve air pressure and to minimize toner
scattering.
The toner density sensor [D] is mounted on the upper side of thedevelopment unit to detect the density of toner in the developer.
[C]
[A]
[B]
[D]
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4.2 DRIVE MECHANISM
To reduce load on the main motor, the development unit uses a separatedrive motor [A]. The development drive pulley turns the development drive
belt [B] which turns the development drive gear [C]. The development drive
gear turns the development roller gear [D] and the paddle roller gear [E]. The
auger gear [F] is engaged with the paddle roller gear. Thus, the developmentroller, paddle roller, and auger all turn when the development drive motor is
on.
The toner agitator gear [H] is also turned by an idle gear [G], which is
engaged with the auger gear. However the toner agitator does not turnunless the toner supply clutch [I] is engaged. It engages when the toner
supply solenoid turns on.
[F] [G][H] [I]
[E]
[A]
[B][C]
[D]
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4.3 CROSS MIXING
"Crossmixing" keeps the toner and carrier evenly mixed in the developer andevenly distributes the developer within the development unit. Crossmixing
also agitates the developer to generate the necessary triboelectric charge onthe toner and carrier particles.
The arrows in the above illustration show the developer movement directions
within the machine. The developer that is attracted to the development roller
[A] is split into two parts by the doctor blade [B]. One part (the magnetic
brush) goes on to develop the latent image on the drum. However, the otherpart is trimmed off by the doctor blade and directed to the backspill plate [C].
As the developer slides down the backspill plate to the paddle roller [D], part
of the developer falls into the auger inlets [E] and is transported to the leftside of the unit by the mixing auger [F], where it drops onto the paddle roller.
As the paddle roller rotates, its blades move the developer to the right. The
amount of developer moved to the right by the paddle roller is equal to the
amount moved to the left by the mixing auger.
[C]
[E] [F]
[A]
[D]
[B]
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4.4 TONER DENSITY CONTROL
The flow chart above illustrates how the copier determines whether or not toadd toner.
This copier uses a dual sensor system to control toner density. The primary
sensor is the ID sensor (image density sensor) which is installed on thepick-off pawl unit. This sensor is a photosensor and directly measures the
density of a test pattern on the drum. The test pattern is made by the pattern
plate interrupting the light path. This is done just before making the copy
when the main switch is turned on, and just before making the copy every
1220 mm. If the test pattern image density is too low, toner is added.
The secondary sensor is the toner sensor. It measures the ratio of toner to
carrier in the developer. This sensor is used only if the output of the IDsensor is abnormal or the original is longer than 1200 millimeters. (For very
long originals, it is possible for the toner density to change while the copy is
being made.)
ID Sensor
Check
Toner Sensor
Check
ID sensor
normal?
Toner
sensor
Tonerdensitylow?
Toner supply
solenoid ON
Toner supply
solenoid ON
Originallonger than1220 mm?
Service Call
indicator ON
Yes
No
No
Yes
No
Yes
No
YesAbnormal
Toner densitysensor
Low, Normal
Toner
density sensor
low?
Abnormal,High
Low, Normal, High
density
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4.4.1 Image Density Sensor
Toner density is detected by develop-ing the sensor pattern and by check-
ing its reflectivity with the image
density sensor (photosensor). Light
from the sensor’s LED reflects from
the drum and activates the phototran-
sistor. The output of the phototransis-
tor goes to CN102-12 of the main
board.An average reference voltage (Vsg) is
calculated from eight samples of bare
drum reflectivity. After that, an aver-
age voltage is calculated from eightsamples of sensor pattern reflectivity.
These two values are then compared
to determine whether toner should be
added or not as follows.
No toner supply condition: Vsp/Vsg < 0.125
Toner supply condition: Vsp/Vsg > 0.125
The ID sensor checks toner density every 1220 mm. If Vsp/Vsg becomes
greater than 0.125 (1/8), then it starts checking toner density every 610 mm.
Toner is
No toner
VSP
0
Thres-holdLevel
VSG
is supplied.
supplied
LED Light Intensity
Weak Strong
0.5
1.0
2.0
3.0
4.0
5.0
Voltage(V)
Standard Intensity
4.0 0.2V+_
SOL 1
CPU
ID Sensor [S2]
Main PCB [PCB1]
5
3
2
1
+5V +24 V
CN104-B10
CN102-14
-12
-15
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(If service program mode #21 is set to "1", the toner density will be checked
every 610 mm regardless of Vsp/Vsg.)
The toner supply amount (%) can be adjusted using service program mode
#17.
Using service program #34, Vsp, Vsg, and Vsp/Vsg can be displayed in the
copy counter.
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4.4.2 Toner Density Sensor
The toner density sensor works in conjunction with the ID sensor to control
the amount of toner in the developer mixture. It has three basic functions.
First, it controls the toner supply in case the toner density is greater than theupper limit and the toner density is less than the lower limit. It does not matter
what the ID sensor input is. If the amount of toner in the developer is greater
than the upper limit (in this case, the toner density sensor value, Vts, is less
than 2.4 V), toner supply is prohibited. Second, it checks toner density if an
original larger than 1220 mm is copied. Third, it takes over toner densitycontrol completely if the ID sensor becomes abnormal (=Vsp > 2.5 V or Vsg <
2.5 V).
The toner density sensor is powered by 24 volts from CN101-1 of the main
board. The sensor’s sensitivity is set by the control signal applied from
CN101-3. The input signal from the sensor is applied to CN101-2. This is ananalog signal. When the toner density is at the standard level, the analog
signal is approximately 2.1 volts.
Toner Density Sensor (S2) Main Board (PCB1)
Control
Circuit
1
2
3
4
CN101-1
-2
-3
-4
[24V] Va
GND
Coils
[7.0V] (Control)
Toner Density Sensor
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The active sensing element is a very small transformer with three coils. Wheniron ferrite (carrier) is near the sensing element, the inductance of the coils
changes, causing the current through the transformer to change. As the
amount of toner in the developer increases, the effect of the carrier particles
decreases and the voltage applied to CN101-2 decreases. Conversely, whenthe toner concentration drops due to use, the effect of the carrier on the
sensor coils increases and the voltage at CN101-2 also increases.
Service call "Ed" lights if the toner sensor output becomes less than 1.6 V or
more than 4.7 V.
Toner Density Sensor Output(= Vts) Toner Density Condition
Vts ≥4.7 Abnormal Service Call "Ed"
4.7 > Vts > 3.8Low
Toner density sensor control(Toner is supplied.)
3.8 ≥ Vts ≥ 2.4 Normal ID sensor control
2.4 > Vts > 1.6 High Toner density sensor control(No toner supply)
1.6 ≥ Vts Abnormal Service Call "Ed"
Upper limit 2.4 V
Lower limit 3.8 V
Toner End Condition
When the main PCB senses that Vsp/Vsg is 0.225 or more ten times in a row
under 2.4 ≤ Vts < 4.7 conditions, the toner near end condition is detected andthe add toner indicator start flashing.
When in the toner near end condition, 5.49 meters (=610 mm x 9) can be
copied. After that, the toner end condition is reached. The Add Tonerindicator will light and the machine will not operate.
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4.5 DEVELOPMENT BIAS
4.5.1 Basic ConceptWhen the drum is exposed, most of the negative charge is eliminated from
the areas where light strikes the drum. This leaves a negative charge patterncorresponding to the dark areas of the original. After exposure however, a
small residual charge of about –100 volts (for white paper) remains in theexposed areas. This residual charge could attract positively charged toner
from the development roller and result in dirty background on the copy.
The development bias prevents such dirty background. A negative bias a
little larger than the residual charge is applied to the development roller. This
prevents the positively charged toner from being attracted to the background
areas of the latent image.
4.5.2 Manual Image Density BiasWhen in manual image density mode, the development bias is applied as
shown by the above chart.
In addition to the development bias, the image density is also controlled by
varying the exposure light intensity. (See the exposure section.)
-120
-160
-180
-200
-240
-280
11 12 - 261 2 3 4 5 6 7 8 9 10
-260
-220
-140
-190
-170
Manual ID Setting
Bias
(Volts)
Manual ID Bias
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4.5.3 Auto Image Density BiasThe above chart shows the development bias when in ADS mode. The ADScan be switched to the "Darker" setting with service program mode #20.
In addition to the development bias, the image density is also controlled byvarying the exposure light intensity. (See the exposure section.)
4.5.4 Bias Adjustment
Using service program mode #19, the bias level can be increased ordecreased as shown in the above chart.
-280
-240
-200
-180
NormalADS
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
-180
-260
-220
-160
DarkerADS
ADS Vod/Vsd
Vod: Original Density Detecting Voltage (ADS out put voltage)
Vsd: Standard Pattern (White Plate) Density Detecting Voltage
0.88
0.80
LighterADS
-300
-260
-220
-200
0.75
Program Mode #19
1 2 3 40
BiasAdjustment
(Volts)
+20
0
-20
+40
-40
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4.6 IMAGE DENSITY SENSOR BIAS
The ID sensor bias is similar to the development bias; however, it is appliedonly when developing the ID sensor pattern.
Basically, the ID sensor bias is fixed. The normal ID bias level is –200 volts,but it can be changed using service program #18. The following table showsthe possible settings. You should clearly understand the effect of changing
the ID sensor bias. If the ID sensor bias is increased the sensor pattern will
become lighter. This will cause more toner to be added to the developer andthus copy images will become darker and toner consumption will increase. If
the ID sensor bias is decreased, lighter images and less toner consumption
will result.
Service Program #18Setting 0 1 2 3 4
ID Bias –200 –180 –240 –280 –320
Factory Setting
A developer counter correction is applied to the ID sensor bias tocompensate for changes in the triboelectric properties of the developer as a
new developer mixture is broken in. The following table shows this correction.
Notice that the correction depends on the average Vsp/Vsg ratio asmeasured during initial conditioning as well as on the developer counter. Byfactoring in the initial conditioning Vsp/Vsg ratio, this correction compensates
for slight variations between different lots of developer as well as for changes
in the developer during the break-in period. After the initial conditioning, the
copy counter will display the density level (dL).
Developer Counter Correction
dLInitial ConditioningVsp/Vsg (%)
Developer Counter (A3 lengthwise = 420 mm)0–499 Copies 500–999 Copies More than 1000
1 0–10 –40 V –20 V 0 V
2 10–15 –20 V 0 V 0 V
0 15–20 0 V 0 V 0 V
3 20–25 +20 V +20 V +20 V
4 >25 +40 V +40 V +40 V
NOTE: Perform the initial conditioning by SP#5 whenever the developermixture is replaced. As the developer counter returns to 0 at this
time, do not perform SP#5 when the drum is replaced. There is a
possibility of dLE being displayed. This means that there was on ID
sensor (Photo sensor) error during the initial conditioning. (dLE:
Vsp/Vsg > 50%, dLP: Vsp > 2.5 < Vsg)
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4.7 TONER SUPPLY
To allow a compact design, the toner supply mechanism is built into the tonercartridge. An agitator [A] in the toner cartridge turns when the toner supply
solenoid is on (toner supply spring clutch engaged). As the agitator rotates,
mylar strips [B] on the ends of the agitator force toner through small holes
(0.5 mm) in a plastic strip [C] along one side of the toner cartridge. The tonerparticles thus ejected from the cartridge fall into the development unit and are
mixed into the developer. The toner agitator turns at 120 rpm and the toner
supply rate is approximately 36 grams per minute.
When supplying toner, the CPU turns on the toner supply solenoid the length
of time required to supply the amount of toner specified by service program
#17.
[C]
[A]
[B]
[B]
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5. IMAGE TRANSFER AND PAPERSEPARATION
5.1 PRE-TRANSFER LAMP (PTL)After the latent image is developed but before the image is transferred to the
copy paper, the drum surface is illuminated by the pre-transfer lamp [A]. This
illumination reduces the negative potential on the drum surface. This
prevents the toner particles from being re-attracted to the negatively chargeddrum during the paper separation process. It also makes image transfer and
paper separation easier.
5.2 IMAGE TRANSFERThe registration rollers [B] feed the copy paper through the transfer entranceguides to the transfer section. A high negative voltage (about –5.0 kV) is
applied to the transfer corona wire [C], and the corona wire generates
negative ions. These negative ions are applied to the copy paper, and the
negative charge attracts the positive charged toner away from the drum and
onto the paper. In addition, the paper is held against the drum by the positivecounter charge on the drum.
5.3 PAPER SEPARATIONAfter image transfer, the copy must be separated from the drum. To break
the attraction between the paper and the drum, the separation corona wires[D] apply an ac corona (4.0 kV) to the reverse side of the paper. The stiffness
and weight of the paper causes it to separate from the drum.
The separation corona has a negative component of approximately –200volts. This negative component holds the toner on the paper to prevent it
from being reattracted to the drum during paper separation. The two pick-off
pawls [E] ensure that thin paper, paper with low stiffness, or upward curledpaper separates completely from the drum.
[A]
[B] [C] [D]
[E]
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5.4 PICK-OFF MECHANISM
The pick-off pawl solenoid [A] is energized 12 pulses after the registrationclutch turns on to feed the copy paper to the drum. The pick-off lever [B] then
rotates clockwise and pushes up the pawl holder [C]. This releases the two
pick-off pawls [D], allowing them to rotate against the drum.
Just after the leading edge of the copy paper passes the transport sensor,
the pick-off solenoid turns off again. The pick-off spring [E] then pushes down
the pawl holder, which moves the pick-off pawls away from the drum.
[A]
[B]
[C][D]
[E]
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5.5 T/S CORONA CIRCUIT
The T/S power pack is powered by +24 volts (Va) from the dc power supply.The dc/dc converters and dc/ac inverter change the +24 volts to the high
voltages used by the transfer and separation coronas.
The main board turns on the transfer corona by dropping CN107-B12 (T.Trig)
from 24 volts to 0 volt. This turns on the dc/dc converter, which applies a highvoltage of approximately –5.0 kV to the transfer corona wire. The main board
turns on the separation corona by dropping CN107-B13 (S.Trig) to 0 volt. The
dc/dc converter and dc/ac inverter circuits then apply approximately ac 4.0kV and –200 V to the separation corona wires.
Normally, T.Sel is not used. However, if the user presses the Auto ImageDensity key for longer than 3 seconds, the CPU uses both T.Trig and T.Sel to
turn on the transfer corona. This increases the transfer corona current from
120 µA (the normal value) to 250 µA. The higher transfer current may be
useful under high humidity conditions (When the higher transfer coronacurrent is selected, the manual ID display function inverts.)
-5.0 kV
AC 4.0 kV
CN1-2
+24 (Va)
DC/DCConverter
DC/ACInverter
DC/DCConverter
-6 -B11
-5 -B13
-4 -A13
-3 -B1224
5
24
T. Trig
T. Sel
S. Trig
(Not Used)
CN107CN1
CN1-1
A. GND
DC -200 V
Main Board
S. Sel
Transfer/Separation
Power pack
5
T
S
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6. CLEANING
6.1 OVERVIEW
The cleaning blade [A] removes any toner remaining on the drum after the
image is transferred to the copy paper. The toner that is wiped off by the
cleaning blade drops onto the toner collection coil [B], which then moves it tothe used toner tank.
The cleaning blade pressure spring applies pressure to the exact center of
the cleaning blade so that pressure is evenly applied across the entire lengthof the cleaning blade. Blade pressure is applied constantly; however, the
blade pressure can be relieved manually for drum removal.
[A]
[B]
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6.2 COLLECTION OF USED TONER
The toner collection coil moves used toner from the cleaning unit through theused toner pipe [A] to the used toner tank [B]. The used toner tank can hold
about 800 grams of toner. On average, about 10,000 A2 sized copies can be
made before the used toner tank needs to be emptied. (This assumes 7%
originals and 80% transfer efficiency.) The toner overflow sensor [C] detectswhen the used toner tank is full.
The toner collection bottle is vibrated to prevent used toner from building up
in one place and activating the toner overflow sensor too early. The shaft of
the first set of transport rollers has a cam [D] on the end. This cam is incontact with a projection [E] of the used toner bottle. It turns when the main
motor is on and moves the used toner tank up and down as shown above
right.
[A] [C]
[B]
[E]
[D]
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6.3 TONER OVERFLOW SENSOR
The toner overflow sensor [A] signals the CPU when the toner collectionbottle is full.
A small tuning fork [B] is used as the sensing element of the toner overflow
sensor. This tuning fork is a damping element in a multivibrator circuit. Aslong as there is nothing in contact with the tuning fork, the vibrating frequency
of the circuit stays low and the transistor stays off.
When toner presses against the tuning fork, the resistance of thepiezoelectric elements that are in contact with the tuning fork changes and
the vibrating 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 CN107-B22.
When the CPU detects this LOW signal, it stops the copier and lights the
Toner Collection Bottle indicator.
[B]
[A]
+5 (Vc)
OSC
Freq.Detec- Rectifier
Tr.CN107-B22
Toner Overflow Sensor Main Board
tion
0/5 0
1
2
3
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7. QUENCHING
After the drum is cleaned by the cleaning blade, light from the quenching
lamp neutralizes any charge remaining on the drum. The quenching lampturns on and off at the same time as the main motor.
The quenching lamp consists of two PCBs containing 49 LEDs (light emitting
diodes) each. The LEDs output light in the 660 nm to 700 nm (red) range.The main board turns on the quenching lamp LEDs by dropping CN104-B8
and CN104-B9 to 0 volts. The two PCBs have identical circuits (shown
above).
[A]
[B]
24
Main Board
+24 V
Quenching Lamp
CN104
-B8
(-B9)
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8. PAPER FEED AND REGISTRATION
8.1 OVERVIEW
In this copier, paper is fed either manually [A], or by the sheet feeder [B]
(option), or roll feeder [C] (option).
For manual feed, the copy paper is inserted until it contacts the manual feed
rollers [D]. At that time the paper turns on the 1st feed sensor [E], which
causes the main motor to turn on. Two seconds after the main motor turnson, the manual feed solenoid turns on and the manual feed rollers start
turning to feed the paper to the registration rollers [F]. If using the auto sheet
feeder or roll feeder, copy paper feeds through the manual feed rollers
automatically after the original is inserted.
Just before the paper reaches the registration rollers it activates the
registration sensor [G]. The manual feed solenoid turns off 0.4 second after
that. The 0.4 second delay allows the leading edge of the paper to alignagainst the registration rollers (which are not turning at this time) to eliminate
skew.
The registration clutch turns on to feed the paper to the drum. It is energizedat the proper time to align the leading edge of the paper with the leading
edge of the developed image on the drum.
Fine and rough registration adjustments can be made using service program
modes #26 and #27 respectively.
[A]
[B]
[C]
[E] [D] [G] [F]
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8.2 DRIVE MECHANISM
Drive power from the main motor is provided to the paper feed andregistration drive mechanism from feed/fusing drive belt 2 [A] through the
manual feed/registration sprocket [B].
When the manual feed solenoid [C] is energized, the paper feed drive chain
[D] drives the manual feed roller [E]. Once the paper reaches the registrationsensor, the registration clutch [F] turns on, and the registration roller [G]
starts turning.
The manual feed/registration sprocket is in contact with the transport/fusing
sprocket [H] which drives the transport and fusing units.
[A]
[B]
[C]
[D]
[E]
[F]
[G]
[H]
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9. PAPER TRANSPORT
After separation from the drum, the copy paper rides on the transport belts
[A] and transport rollers [B] to the fusing unit.
Airflow directly from the vacuum fan [C] holds the paper firmly against the
belts so that there is enough friction between the paper and the belts for
smooth transportation of the paper. The transport belts and transport rollers
are directly driven by the fusing drive chain (no clutch or solenoid); so, theyturn constantly when the main motor is on.
[A]
[B]
[C]
[A]
[B] [C]
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10. FUSING AND PAPER EXIT
10.1 OVERVIEW
Two rollers fuse the image to the copy paper by applying heat and pressure.The hot roller [A] is made of carbon-teflon and the pressure roller [B] is made
of silicone rubber. Pressure is constantly applied by the pressure levers at
the ends of the fusing unit.
The fusing lamp [C], which is located at the hot roller axis, turns on and off to
maintain the operating temperature. The temperature control circuit (on themain board) monitors the surface temperature of the hot roller and the
pressure roller through thermistors [D and E respectively].
There are three operating temperature settings: normal, high, and low.
[A]
[B]
[C]
[D]
[E]
[F]
[G]
[H]
[I]
[J]
[K]
[L]
[M]
[N]
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The hot roller strippers [F] separate the copy from the hot roller and direct itto the fusing exit rollers [G]. After the fusing exit rollers, the exit gate [H]
directs the copy to either the upper rollers [I] or lower exit [J].
When the exit gate solenoid is on, the exit gate directs the copy paper down
through the lower copy exit path. If the exit gate solenoid is off, the papergoes through the upper copy exit path. The exit direction is selected using
the Copy Exit Way key.
Two thermofuses (wired parallel) [K] provide backup overheat protection.
(See the section on fusing temperature control.)
The fusing exit, upper exit, and lower exit sensors [L, M, N] are used for jam
detector.
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10.2 DRIVE MECHANISM
10.2.1 Fusing Drive
The hot roller is turned by the fusing drive chain as shown. The pressure
roller is friction driven by the hot roller. The fusing rollers turn constantly when
the main motor [A] is on, driven via the gears [B], through feed/fusing drivebelts 1 [C] and 2 [D], the sprockets [E] and the fusing drive chain [F], to the
hot roller sprocket [G].
[A]
[B]
[C]
[D]
[E]
[F]
[G]
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10.2.2 Exit Roller Drive
The upper [A] and lower [B] exit rollers are driven by the main motor [C] via a
set of gears [D]. Finally, the exit roller drive chain [E] drives the exit rollers
through a sprocket as shown above.
The exit rollers turn constantly when the main motor is on.
[A]
[B]
[C]
[D]
[E]
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10.3 FUSING TEMPERATURE CONTROL
10.3.1 Fusing Circuit OperationThe fusing lamp is powered by AC controller 1 and controlled by the main
board.
AC controller 1 receives direct wall voltage ac power (not stepped down) at
T304 and T306. It also receives +24 volts at CN301-5. The ac power isapplied to the drive circuit, the fusing lamp (L3), and the triac (TR). The dc
power drives PC301 and RA301.
To turn on the fusing lamp, the main board drops CN107-A15 to LOW. Thisactivates the photocoupler (PC301) which in turn energizes the drive circuit.
The drive circuit turns on the triac to complete the lamp circuit, thus turning
on the lamp.
RA301 guards against a failure of the +24 volt power supply. When +24 volts
is applied at CN301-5, RA301 is energized and its ac contacts stay open. If
the +24 volts power stops, the ac contacts of RA301 close, stopping the drive
circuit and turning off the fusing lamp (U.S.A. version only).
Overheat Protection
+
+24 +24
Q101
IC1071K
1.3K
6
5
7
CN107-A25
-5
CN107-A15
CN107-B25
CN301
A.GND
-6
-3
Drive Circuit
RA301
PC301
AC115,220,240
AC Controller 1T304 T306
TR
G
T309 T310 T308 T307 T305
CN110-12
CN110-11
CN110-9
CN110-10
TH2
TH1
L3
+5
CP
U
TF1
24
RA301
_
+5
RA301: U.S.A. version only
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10.3.2 Overheat ProtectionThe overheat protection circuit on the main board turns off the fusing lamp if
the temperature goes too high.
The input from TH1 goes to pin 5 of IC107 as well as to the CPU. As the
temperature of TH1 increases, its resistance decreases and therefore thevoltage at pin 5 of IC107 increases. If this voltage becomes greater than the
voltage at pin 6, the output at pin 7 becomes HIGH. Q101 then turns off and
cuts the +24 volt supply to ac controller 2. The fusing lamp then turns off. Theoverheat protection circuit becomes effective at about 220 degrees.
TF1 (2 thermofuses in parallel) provides overheat protection in case a shortbypasses the control and drive circuits. These two fuses will open if they
reach approximately 192 degrees.
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10.4 TEMPERATURE CONTROL
The main board monitors the temperature of the hot roller through TH1 andthe temperature of the pressure roller through TH2. The CPU determines
whether or not to turn on the fusing lamp based on the combination of the
input from these two thermistors. If the pressure roller is cool, the CPU keeps
the hot roller temperature high. However, if the pressure roller is hot, the CPUdecreases the operating temperature of the hot roller. The above graph
shows the relationship between the temperatures of the hot and pressure
rollers.
The operating temperature of the hot roller and pressure roller can be
adjusted using service programs #28 and #29. These programs are used to
compensate for variations in the response of different thermistors. Serviceprogram #28 adjusts the hot roller temperature and service program #29
adjusts the pressure roller temperature. Service program #28 shifts thetemperature in 1 degree increments (–4°C to +5°C). Service progtam #29
shifts the temperature in 2 degree increments (–8°C to +10°C). The fusingtemperature can be monitored using service program #32.
LOW
HIGH
NORMAL
75 80 120115110105100959085
200
155
195
190
185
180
175
170
165
160
Hot Roller
Temp. (°C)
Operating
temp. (Low)
Lower Limit(Low)
Pressure Roller Temp. (°C)
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The ready condition
When the hot roller temperature reaches the ready temperature, the copier
goes in to ready condition. Copying is possible. The ready temperature is any
where between 3° lower than the hot roller operating temperature.
When the mode of the fusing temperature is changed using the Fusing
Temperature key on the copier operation panel, the hot roller and pressure
roller start to rotate to change to the appropriate operating temperature.
Lower limit temperature
High mode: If the hot roller or pressure roller temperatures drop below the
ready condition temperature while copying, the copier stops and the fusing
lamp turns on until the temperatures return to the range of high mode. The
original will automatically feed out (normal mode).By changing SP mode #96, this limitation can be canceled. However, poor
fusing or a waved copy may occurs (forced copy mode).
Also, by changing SP mode #96, another program can be selected so that
the original stops in the original path and the copier automatically resumesthe copy run after the temperature returns to the high mode range (auto start
mode).
Low mode: Even if the hot roller temperature drops below the ready conditionof the low mode while copying, the copier dose not stop until the hot roller
temperature drops below the lowest temperature limit.
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11. OTHERS
11.1 PULSE GENERATOR
The CPU controls the timing of all machine operations based on the number
of pulses it receives from the pulse generator. Pulses are generated by
rotating a disk with slots in it within a photointerruptor. As the disk rotates,
light from the LED activates the phototransistor each time a notch comes
between them. The pulse interval is 3.125 milliseconds.
If no pulses are received for one second during the copy cycle, the machine
will stop and display "Eb" in the copy counter.
[S4]
Main Board [PCB1]
CPU
+5V
CN112-1
CN112-3
CN112-2
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11.2 OPERATION PANEL
The above illustration shows the copier’s operation panel circuit in block form.
The operation panel circuit is driven by six scan pulse lines. The copier uses
LEDs for display elements. To light any particular LED, the CPU drops theappropriate segment line to 0 volt at the same time that the scan lineconnected to the LED is being energized.
The CPU monitors the KEY lines (KEY1 to KEY3) to determine if a key has
been pressed. Each KEY line is used to monitor up to five keys on theoperation panel. A specific scan pulse appears at the appropriate KEY line
when a key on the operation panel is pressed.
CN106
-B15
-B16
-A16
-B7
-B6
-B5
-B4
-B3
-B2
-B1
-A1
CN202 -1 -2 -3 -4 -5 -6 -7 -9-8 -10 -11
CN106 CN201
-A11Scan1-1
-A13Scan2
-2
-B11Scan3
-3
-B13Scan4
-4
-A12Scan5
-5
Key
Matrix LED Matrix
MAIN BOARD OPERATION PANEL
Key 1
Key 2
Key 3Seg a
Seg b
Seg c
Seg d
Seg e
Seg f
Seg g
Seg h
seg b 2
seg c 2
seg d 2
seg e 2
seg f 2
seg g 2
seg h 2
seg a 2
-1 -2 -3 -4 -5 -6 -7 -8
-A2
-A3
-A4
-A5
-A7
-A8-B8
-A15
-6Scan6
OTHERS 31 December 1992
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SECTION 3
INSTALLATION
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1. ENVIRONMENT
1. Temperature Range: 10oC to 30oC (50oF to 86oF)
2. Humidity Range: 15% to 90% RH3. Ambient Illumination: Less than 1,500 Lux (do not expose
to direct sunlight).
4. Ventilation: Minimum space 20 m3
Room air should turn over at least
30 m3/hr/person.
5. Ambient Dust: Less than 0.15 mg/m3
(4 x 10-3 oz/yd3)
6. If the installation place is air-conditioned or heated, place the machine as
follows:
a) Where it will not be subjected to sudden temperature changes
from low to high, or vice versa.
b) Where it will not be directly exposed to cool air from an air
conditioner in the summer.
c) Where it will be directly exposed to reflected heat from a space
heater in the winter.
7. Avoid placing the machine in an area filled with corrosive gases.
8. Avoid any area higher than 2,000 m (6,500 ft) above sea level.
9. Place the machine on a strong and level base.
10. Avoid any area where the machine may be subjected to frequent strong
vibration.
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1.1 MINIMUM SPACE REQUIREMENTS
1. Front: 1,000 mm (39.5 in)
2. Back: 600 mm (24 in)
3. Right: 600 mm (24 in)
4. Left: 600 mm (24 in)
600 mm
600 mm600 mm
1000 mm
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1.2 POWER SOURCE
1. Input Voltage Level: 115 V/60 Hz
More than 15 A (for U.S.A. version)
220 V/230 V/240 V/50 HzMore than 7 A (for European version)
2. Permissible Voltage Fluctuation: ±10%
3. Do not set anything on the power cord.
NOTE: a) Make sure the plug is firmly inserted in the outlet.
b) Avoid multi-wiring.
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2. ACCESSORY CHECK
Check the accessories and their quantities according to the following list:
1. Copy Guide ............................................................................. 1 pc
2. Original Guide ......................................................................... 2 pcs
3. Left Inner Cover Bracket ......................................................... 1 pc
4. Pick-off Pawl Unit.................................................................... 1 pc
5. Right Inner Cover.................................................................... 1 pc
6. Left Inner Cover ...................................................................... 1 pc7. Inner Cover Bracket ................................................................ 1 pc
8. Pan-head Screw (M4 x 6) .......................................................12 pcs
9. Pan-head Screw (M4 x 8) ....................................................... 2 pcs
10. Flat-head Screw (M4 x 6) ....................................................... 3 pcs
11. Fixing Plate ............................................................................. 1 pc
12. Copy Exit Support ................................................................... 1 pc
13. Gear ....................................................................................... 1 pc
14. Spring...................................................................................... 1 pc
15. Bushing ................................................................................... 4 pcs
16. Plastic Cap.............................................................................. 2 pcs
17. Allen Screw ............................................................................. 1 pcs
1
2
4 5
6
7
8, 9
10
3
11
12
14 15
13
1716
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3. INSTALLATION PROCEDURE
1. Stick mylar sheets (large [A] and small [B]).
2. Install the copier on the table. Align the 2 pins [C] and 2 holes [D]. Fix the
rear side (1 screw and spacer each) and the front right side (2 bolts).
0 ~ 3 0 ± 3
0 ~ 3
0 ± 3
[B]
[A]
[C]
[D]
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3. Remove all stripsof shipping tape
and accessories.
4. Open the
original feed unit[A] and remove
the two spacers[B]. Remove the
protective sheet
from the
exposure glass.
5. Remove the right
middle cover [C](4 screws).
[A][B]
[B]
[C]
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6. Open the main board[A] (1 screw).
7. Remove the plate [B] (4
screws), fixing the right
portion of the upper unitto the lower unit. (Keep
two screws for
mounting the fixing
plate later.)
8. Remove the left middlecover [C] (4 screws).
[C]
[B]
[C]
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CAUTION: Make sure that the middle unit is closed completelybefore carrying out step 9. Otherwise, the middle unitcould open suddenly.
9. Remove the screw [A]
fixing the left portion of the
upper unit to the lower unit.
10. Lift up the handle [B] andopen the middle unit [C].
11. Install the fixing plate [D](2 screws). Then, reinstall
the main board bracket.
[A]
[C]
[B]
[D]
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12. Install the left innercover bracket [A] (2
screws).
13. Install the pick-off
pawl unit [B] (2
connectors [C], 2
knob screws [D], and2 positioning pins).
14. Remove the drum
protection sheet [E] by
turning the main motor
[F] counterclockwise.
Make sure that notape is left on thedrum.
[A]
[D]
[B] [C]
[F]
[E]
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15. Reset the cleaningblade by pulling the
release lever [A]
towards the front
side.Then close the
middle unit and
open the original
feed unit.
16. Open the tonercartridge cover [B], and
place a level [C] in the
space between the
cartridge cover and the
developer entrance.
Adjust the level of the
machine by turning thebolts on the 4 machine
feet.
17. Remove the spongeseal [D] from the
developer entrance.
[A]
[C][B]
[D]
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18. 220/230/240 V versionmachines only.
If the voltage of electrical
power supply from the wall
outlets is 230 V or 240 V,change the voltage as
follows:
a) Open the lower
registration guide plate [A](4 screws [B]) as shown.
b) Connect the input line
[C] to the appropriate
voltage (230 V or 240 V).
c) Reinstall the lowerregistration guide plate.
19. Turn on DIP SW 101-7and 8 on the main board
[C]. Then plug in the
power cord and turn on
the main switch [D].
20. Evenly pour 3 kg of
developer into the
development unit asshown.
Close the cartridge
cover and the originalfeed unit.
[A]
[B]
[C]
[C][D]
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21. Set the leading margin indicator [A] to 00 and the trailing margin indicator[B] to 01 as follows:
a) Press the margin key [C]. The leading margin indicator will blink.
b) Press the margin set key [D] to set the leading margin indicator to 00.
The trailing margin indicator will blink.c) Press the plus key [E] once to set the trailing margin indicator to 01.
22. Press the Copy Exit
Way key [F] to turnon the development
motor. Press the
Copy Exit Way keyagain after 2 or 3
seconds to turn themotor off.
23. Repeat step 22 until
all 3 kg of developer
has been loaded
into thedevelopment unit.
24. Turn off the main
switch and DIP SW101-7 and 8, and
unplug the power
cord.
25. Set the toner cartridge[G] as shown in the
figure.
[A]
[C] [B]
[D]
[F]
[E]
[G]
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26. Remove the sealingtape [A] on the cartridge
and turn the knob [B]
clockwise until it stops.
27. Lift up the release handle
[C] and open the middle
unit.
[B]
[A]
[C]
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28. Install the right innercover [A] and the
bracket [B] on the lower
unit. (Use 2 pan-head
screws for the bracket.Use 1 flat-head screw
and 3 pan-head screws
for the right inner cover.)
29. Install the left inner
cover [C] onto the lower
unit. (2 flat-head and 5pan-head screws)
30. Install the left middle
cover. (4 screws)
31. Install the copy guide[D] (2 screws).
[A]
[B]
[C]
[D]
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32. Set the two original guides[A].
33. Lower the lever [B] of therear table.
34. Install the copy exit
support [C], gear [D], andspring [E] as shown (4bushings, 1 Allen screw
[F]).
35. Install the 2 plastic caps[G].
36. Check the operation. If the
exit support levermovement seems heavy,
lower the fixing position of
the allen screw by around15 degrees.
[G]
[C]
[E]
[G]
[D][F]
[A]
[B]
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37. Stick 4 Velcro seals [A] tothe copier and table as
shown.
Set the 2 copy guidemylar strips [B] as shown.
[A]
[B]
[A]
[B]
[A]
[A]
[B]
0 ± 3
0 ± 3
0 ~ 3
0 ~ 3
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38. Plug in the power supplycord. Turn on DIP
SW101-8 on the main
board and turn on the
main switch.
39. Set the leadingmargin indicator [A] to
00 and the trailing
margin indicator [B] to05.
40. Set the copy counter
indicator [C] to 01
using the plus key.
Then, press the CopyExit Way key [D].
Turn off DIP SW101-8
to start initial
conditioning.Initial conditioning will
start, and stop
automatically when it is
completed.
41. Adjust the toner density
sensor voltage using SPmode #35.
42. Install the right middle
cover.
43. Check the copy quality
and copier operation.
[A]
[B]
[D]
[C]
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SECTION 4
SERVICE TABLES
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1. PREVENTIVE MAINTENANCE SCHEDULE
1.1 PM TABLESymbol key: I = Inspect L = Lubricate R = Replace A = Adjust
C = Clean
A. Original Feed_________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Front original
feed roller
C C Water or alcohol
2. Rear originalfeed roller
C C Water or alcohol
3. Originalregistrationrollers
C C Water or alcohol
4. Platen roller C C C C C C Water or alcohol
5. Press rollers C C Water or alcohol
6. White plate C C C C C C Water or alcohol7. Auto image
density sensorC C C C C Blower brush
8. Original table C C C C C C Water or alcohol
B. Optics ______________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Fiberoptic array
Clean with lenspaperif necessary
2. Exposure lamp I I I I I Replace ifdamaged
3. Exposureglass
C C C C C C Water or alcohol
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C. Development_________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Developer R
2. Side seals I I I I I Replace ifdamaged
3. Developmentfilter
R R
4. Toner supplyclutch
L Mobil Temp. 78
D. Around Drum_________________________________________________EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Corona wires C C C C C C Blower brush, orif clean with adry cloth, don’texpand thecorona wires.
Replace at 20 K,(A1 sideways/ D size).
2. Wire cleanerpads
Replace at 20 K(A1 sideways/ D size).
3. Grid wires C C C C C C Dry cloth
4. Chargecoronaendblocks andcasing
C C C Dry cloth
5. T/S coronaendblocks andcasing
C C C C C C Dry cloth
6. Quenchinglamp
C C C C C C Dry cloth orblower brush
7. Pick-off pawls C C C C C Dry cloth
8. Pre-transfer
lamp
C C C C C C Dry cloth
9. ID sensor C C C C C Dry cloth orblower brush
10. Transferguide plate
C C C C C C Dry cloth
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E. Cleaning ____________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Cleaning blade C C C C C To prevent thecleaning bladeedge from beingdamaged, cleanit with your finger.Replace at 40 K(A1 sideways/ D size)
2. Cleaning seal I I I I I Replace ifdamaged
3. Used tonertank
I C C C C C Empty used toner
F. Paper Feed __________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Manual feed
rollers
C C C C C C Water
2. Manual feedtable
C C C C C C Water
3. Registrationrollers
C C C C C Water
4. Spring clutch L Mobil Temp. 78
5. Registrationroller brake
I I I I I Clean with adamp cloth ifnecessary
6. Manual feedguide
C C C C C Water
G. Transport ___________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/
D size
1. Transport belt C C C C C C Water
2. Transportguide plate
C C C C C C Water
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H. Fusing ______________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Hot roller Replace at 48K(A1 sideways/ D size).
2. Pressure roller Replace at 120K(A1 sideways/ D size).
3. Fusingthermistors
C Suitable solvent
4. Hot rollerstrippers C Suitable solvent
5. Fusing/exitguide plate
Suitable solventif necessary.
I. Others_______________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Timing belts I I I I I Adjust thetension ifnecessary.
2. Chains I L I L I Adjust thetension ifnecessary.Lubricate withMobil Temp. 78.
3. Gears I L I L I Mobil Temp. 78.
4. Ozone filters R R R R R
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J. Sheet Feeder_________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Feed roller C C C C C C WaterReplace at 40 K(A1 sideways/ D size).
2. Friction pad C C C C R C Water
3. Bottom platepad
Replace at 40 K(A1 sideways/ D size).
4. Relay rollers C C C C C Water5. Paper feed
guide plateClean with adamp cloth ifnecessary.
6. Spring clutch L Mobil Temp. 78
7. Teflon tape(2 tapes)
R
K. Roll Feeder __________________________________________________
EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Feed Roller C C C C C C Water
2. Exit Roller C C C C C C Water
L. Roll Feeder Connector _________________________________________EM 3.6km 7.2km 10.8km 14.4km 18km Notes
(6k) (12k) (18k) (24k) (30k) ( ) A1 sideways/ D size
1. Relay Rollers C C C C C
2. Spring Clutch L Mobil Temp. 78
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1.2 REGULAR PM PROCEDURE
Make a copy of OS-A1 chart at manual imagedensity level 7.
Clean the platen roller, white plate, auto image
density sensor, and original table by using
water, alcohol or blower brush.
Clean the front original feed roller, rear original
feed roller, original registration roller, and press
rollers by using water or alcohol.
1. Clean the exposure glass by using water oralcohol.
2. Inspect the exposure lamp.
3. Clean the fiber optics array with lens paper ifnecessary.
NOTE: After removing the drum, wrap it in
clean sheets of paper to protect it.
1. Clean the corona wires and grid wires with ablower brush or dry cloth.
Note: When using dry cloth, don’t expand thecorona wires.
2. Clean the T/S corona endblocks, casing, andthe transfer guide plate with dry cloth.
3. Clean the quenching lamp and pre-transferlamp with dry cloth or blower brush.
4. Clean the ID sensor with dry cloth or blower
brush.
5. Clean the pick-off pawls with dry cloth.
1. Make a Copy
2. Original Feed
(every 6 K)
3. Optics (every 6 K)
Original Feed
(every 12 K)
4. Around Drum
(every 6 K)
Every 6 K ( A1 sideways/D size)
Every 12 K (A1 sideways/D size)
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Clean the charge corona endblocks and casing
with dry cloth.
Replace the charge corona wires and wire
cleaner pads.
1. Empty used toner tank.
2. Inspect the cleaning seal.
3. Clean the cleaning blade with your finger.
Inspect the side seals.
5. Cleaning Unit
(every 6 K)
Around Drum(every 12 K)
6. Development Unit
(every 6 K)
Around Drum
(every 20 K)
Replace the cleaning
blade (every 40 K)
40 K
Replace the developmentfilter (every 12 K)
Lubricate the toner supply
clutch (every 18 K)
18 K
20 K
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1. Clean the manual feed rollers andregistration rollers with water.
2. Clean the manual feed table and manualfeed guide with water.
3. Inspect the registration roller brake.
Clean the transport belt and transport guideplate with water.
1. Clean the thermistors.
2. Clean the hot roller stripper.
120 K
7. Paper feed
(every 6 K)
8. Transport (every 6 K)
Lubricate the paperfeed clutch (every 18 K)
18 K
9. Fusing Unit
(every 18 K)
Replace the developer(every 30 K)
30 K
Replace the hot roller
(every 48 K)
Replace the pressureroller (every 120 K)
18 K
48 K
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1. Replace the ozone filter.
2. Inspect the timing belts, chains and gears.
Lubricate the chains and gears.
Clean the feed roller, friction pad and relay
rollers with water.
Lubricate the spring clutch.
Replace the friction pad and teflon tape (2 pcs).
Replace the feed roller and bottom plate pad.
Clean the feed roller and exit roller with water.
10. Others (every 6 K)
11. Sheet Feeder
(every 6 K)
Others (every 12 K)
Sheet Feeder(every 18 K)
Sheet Feeder(every 24 K)
18 K
24 K
Sheet Feeder
(every 40 K)
40 K
12. Roll Feeder
(every 6 K)
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Clean the relay rollers.
Lubricate the spring clutch.
1. Check the copy quality.
2. Adjust the light sensor voltage by turningVR102 on the main board.
3. Adjust the ADS reference voltage by SP#37.
4. Adjust the Vsg by SP#33.
13. Roll FeederConnector
(every 6 K)
Roll Feeder
Connector
(every 18 K)
14. Copy Quality
18 K
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2. SERVICE TABLES
2.1 TEST POINTS
Main Board
NUMBER FUNCTION
TP101 Original registration sensor
Adjusts the voltage to +2.6 ± 0.1 volts by VR101
TP102 ID sensor (Vsg)
Adjusts the voltage to +4.0 ± 0.1 volts by VR104
TP103 Toner density sensorAdjusts the voltage to +4.0 ± 0.1 volts by VR105
TP104 Auto image density sensor (ADS)
Adjusts the voltage to +3.0 ± 0.1 volts by VR103
TP105 Light sensor
Adjusts the voltage by VR102
TP106 GND
TP107 Vcc (+5 volts)
TP108 VAA (+24 volts)
2.2 VARIABLE RESISTORS
Main Board
NUMBER FUNCTIONVR101 Adjusts original registration sensor voltage
(+2.6 ± 0.1 volts)
VR102 Adjusts light sensor voltage
VR103 Adjusts ADS reference voltage (+3.0 ± 0.1 volts)
VR104 Adjusts Vsg (+4.0 ± 0.1 volts)
VR105 Adjusts toner density sensor voltage
(+4.0 ± 0.1 volts)
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Charge/Grid/Bias Power Pack
NUMBER FUNCTION
VR101 Adjusts charge corona current
VR102 Factory useVR201 Adjusts grid voltage
VR301 Adjusts development bias voltage
Transfer/Separation Power Pack
NUMBER FUNCTION
T1 Adjusts low (normal) transfer corona current
(T.Trig)
T2 Adjusts high transfer corona current (T.Sel)
D1 Adjusts ac current of separation corona
D2 Adjusts dc current of separation corona
D3 Not used
DC Power Supply Unit
NUMBER FUNCTION
VR Factory use (Adjusts 5 volts)
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2.3 DIP SWITCHES
Main Board
NUMBER OFF ON
DPS101-1 Normal Free run (A1 sideways/D size feed cycle)
DPS101-2 Normal Forced ready condition (no warm-up)
DPS101-3 Length counter(for total counter)
Copy counter (for total counter)
DPS101-4 *Millimeters **Inches
DPS101-5 Normal ***Clear counter memory
DPS101-6 Normal ***Input check
DPS101-7 Normal ***Output check
DPS101-8 Normal ***Service program mode (SP mode)
DPS102-1to
DPS102-6Not used
DPS102-7 50 Hz (paper feedmotor of the roll feeder)
60 Hz (paper feed motor of the roll feeder)
DPS102-8 Service call reset Service call reset
SW101 Normal Sends the reset signal to the main CPU
* Increments the total counter every meter of paper.
** Increments the total counter 100 inches of paper.
*** Refer to the Service Tools section for details.
Note: 1. DPS101-4 is effective only when the DPS101-3 is turned off
(length counter).
2. Do not change DPS101-3 and 101-4 positions from the
factory setting.3. If a main CPU malfunction occurs, turn on SW101 to
reset the main CPU.
4. In the free run mode (DPS101-1 ON), the copier automatically
operates without paper feeding after the original is inserted
and pulled out.
5. To clear the service call condition for fusing (E2, E3, E4, E5,
E6, E9 and EA), the position of DPS102-8 must be changedfrom OFF to ON or from ON to OFF before the main switch
is turned on.
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3. SERVICE TOOLS
3.1 SERVICE PROGRAM MODE
The service program (SP) mode is used to check electrical data and change
modes or adjustment values.
3.1.1 Access Procedure
1. Turn on the main switch.
2. Turn on DPS101-8 on the main board.
NOTE: The Call Service [A] and Add Toner [B] indicators will blink. This isto confirm that the correct mode has been selected.
ON
1 2 3 4 5 6 7 8
[D]
[H]
[C]
[G]
[J] [I]
[E]
[F]
[B][A]
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3. Enter the desired SP mode number as follows:a) Press the Margin key [C]. "00" will blink in the Leading Margin indicator
[D]. Enter the desired SP mode number using the Plus [E] or Minus [F]
key (The SP mode numbers are given in the Service Program Mode
Table).
b) Press the Margin Set key [G]. "00" will blink in the Trailing Margin
indicator [H]. Enter the desired SP mode number using the Plus or
Minus key (The SP mode numbers are given in the Service Program
Mode Table.)
Press the Margin Set key again. Then, the data will be displayed in the
Copy Counter indicator [I].
4. Enter the desired value or mode using the Plus or Minus key, and thenpress the Copy Exit Way key [J] (SP mode data are given in the Service
Program Mode Table).
NOTE: 1. The beeper will sound three times after a value or mode is
entered.
2. For some SP modes, you only need to press the Copy ExitWay key directly without pressing the Plus or Minus key.
(These SP modes are marked "#" in the Service ProgramMode Table.)
5. Input a new SP mode number as follows: (when changing to another
mode number)
a) Press the Margin key. A number will blink in the Leading Margin
indicator. Enter the desired SP mode number using the Plus or Minus
key.
NOTE: It is possible to input a new SP mode number when the
number in the Leading Margin indicator is blinking.
b) Press the Margin Set key. A number will blink in the Trailing Margin
indicator. Enter the desired SP mode number using the Plus key or
Minus key. Press the Margin Set key again.
NOTE: It is possible to input a new SP mode number when the
number in the Trailing Margin indicator is blinking.
6. To leave the SP mode, turn off the DSP101-8.
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3.1.2 Service Program Mode Table
1. In the Function column, comments are in italics.
2. In the data column, the default value is printed in bold letters.
3. A "#" after the mode number means that you only need to press the Copy
Exit Way key directly without pressing the Plus or Minus key to enter the
desired value or mode.
4. A "°" after the mode number means that the mode can be accessed by
Sales representatives.The access procedure is as follows:
1) While simultaneously pressing the Plus, Minus and Clear/Stop keys,
turn on the main switch.
NOTE: The Call Service and Add Toner indicators will blink. This is to
confirm that the correct mode has been selected.
2) Follow the steps 3 to 5 of the SP mode access procedure.
3) To leave this mode, turn off the main switch.
Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
1 00 01 Exposure Lamp OFF
When the main switch is turned off, thismode is automatically selected to default.
(0: Normal)
0: Normal1: Lamp OFF
Use this mode for removing the excess toner from the development unit.
2 00 02 Misfeed Detection OFF
Copies are made without misfeeddetection.When the main switch is turned off, thismode is automatically returned to thedefault. (0: Normal)
0: Normal1: Misfeed
detection OFF
Use this mode to check whether the paper misfeed was caused by a sensor malfunction.
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
3 00 03 Toner Density Sensor Control Cancel
Cancel the toner density sensor function.When the toner density sensor function iscanceled, ID sensor is only used to controlthe toner density in the development unit.
0: Normal
1: Toner densitysensorcontrol
canceled.
Use this mode when the toner density sensor does not function correctly.
5 00 05 Initial Conditioning
Sets the data value corresponding to theVsp/Vsg ratio of new developer.
Turn off DPS101-8 to start initialconditioning. The machine will stopautomatically after initial conditioning iscompleted. Press the Copy Exit Way key toreturn to normal mode.
0: Normal1: Initial
conditioning
Initial conditioning must be done whenever new developer is installed.The CPU monitors Vsg and Vsp for the developer counter correction during the initial conditioning.
The density level (0 ~4) will be displayed on the copy counter indicator.Density Level (dL) Vsp/Vsg X 100 (%)
0 0 10 1 10 15 2 15 20 3 20 25 4 > 25
NOTE: 1. If Vsp/Vsg X 100 is more than 50,
"E" is displayed (abnormal condition).2. If Vsp is more than 2.5 volts or the
Vsg is less than 2.5 volts, "P" is displayed (abnormal condition).
6
#°00 06 All Indicators ON
Turns on all the indicators on the operationpanel.
To turn off the indicators, press the Copy Exit Way key.
7
°00 07 Auto Reset Time
Selects auto reset time from 1 to 5 minutes,or cancels this mode.
0: 2 min1: 1 min
2: 3 min3: 4 min4: 5 min5: No auto reset
8
°00 08 Count Up/Down
Selects count up or count down.
0: Up1: Down
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
9
°
00 09 Key Tone ON/OFF
Selects key tone on or off.
0: ON
1: OFF
10
°01 00 Default ID Setting
Specifies whether the copier defaults toADS or manual ID level 7 when the mainswitch is turned on.
0: ADS1: Manual ID level 7
11
°01 01 Default Paper feed
Specifies whether the copier defaults tosheet feeder, synchro cut, preset cut, or
manual feed when the main switch isturned on.
0: Sheet feeder1: Synchro cut2: Preset cut: 11893: Preset cut: 841
4: Preset cut: 5945: Preset cut: 4206: Preset cut: 2977: Manual feed
12
°01 02 Default Paper Exit
Specifies whether the copier defaults toupper exit or lower exit.
0: Upper exit1: Lower exit
13 01 03 Pheripherals Installation
Enables peripheral operation.
0: Copier + SheetFeeder + RollFeeder
1: Copier + RollFeeder + RollFeeder Connector
2: Copier + SheetFeeder
3: Copier only
This SP mode must be done whenever pheripheral is installed.
15 01 05 Copy Paper/Original Waiting Time
After the original (copy paper) is inserted,the copier will wait for the set number ofminutes before feeding the original (copy
paper) out, if no copy paper (original) isinserted.
0: 2 minutes1: 1 minute2: 3 minutes3: 4 minutes4: 5 minutes
5: No limit
16 01 06 Factory Use
17 01 07 Toner Supply Amount
Determines how much toner is supplied.
0: 15%1: 7.5%2: 30%3: 60%
18 01 08 ID Sensor Bias Adjustment
Sets the bias voltage applied to the
development roller for the ID sensor pattern.
0: –200V1: –180V2: –240V
3: –280V4: –320VThe ID sensor bias voltage is also decreased or increased by the developer counter correction.The value for the developer counter correction is decided according to the Vsp/Vsg data obtained from initial conditioning.(SP#5)
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
19 01 09 Image Bias Adjustment
Adjust image bias output if the imagedensity at ID level 7 cannot be adjusted bythe light sensor adjustment. (VR102 on themain board)
0: Normal (V0)
1: Darkest(V0 + 40V)2: Darker
(V0 + 20V)3: Lighter
(V0 – 20V)4: Lightest
(V0 – 40V)
Vo is decided by the manual ID setting (level 1~ 26) or the background image density of the original in ADS mode.
20
°02 00 ADS Level
Selects the image density level in ADS
mode.
0: Normal1: Lighter2: Darker
Data 1(Lighter): Increases development bias by –20 volts Data 2 (Darker): Decreases development bias by +20 volts.
21 02 01 ID Sensor Detection Interval
ID sensor check is performed every 1220mm length of originals or 610 mm length oforiginals.
0: 1220 mmoriginals
1: 610 mmoriginals
If low image density occurs in the toner
near end condition, change the data to "1".22 02 02 ID Sensor Grid Voltage Adjustment
Adjust the ID sensor grid voltage if the IDsensor bias adjustment (SP#18) fails toachieve.
0: –460V1: –400V2: –440V3: –500V4: –540V5: –600V6: –640V
23 02 03 Image Grid Voltage Adjustment
Adjusts the image grid voltage if the lightsensor adjustment (VR102) and image biasadjustment (SP#19) fail to achieve.
0: –940V1: –860V2: –900V3: –980V4: –1020V
24 02 04 PTL OFF Timing
Adjusts the PTL off timing for the trailingedge of the copy paper.
0: –15 mm (fromtrailing edge ofthe copy paper)
1: Not OFF2: –30 mm3: –25 mm4: –20 mm5: –10 mm6: – 5 mm7: ± 0 mm8: + 5 mm9: +10 mm
If a blank image appears on the trailing edge of the copy paper, change the data.
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
25 02 05 Leading Edge Blank Margin Adjustment
Adjusts the leading edge blank margin(1 mm/step).
0: ± 0 mm
1: –5 mm2: –4 mm3: –3 mm4: –2 mm5: –1 mm6: +1 mm7: +2 mm8: +3 mm9: +4 mm
26 02 06 Fine Registration Adjustment–ManualFeed and Sheet Feeder
Adjusts registration for the manual feedand sheet feeder (0.25 mm/step).
0: ± 0 mm1: –1.0 mm
2: –0.75 mm3: –0.5 mm4: –0.25 mm5: +0.25 mm6: +0.5 mm7: +0.75 mm8: +1.0 mm
27 02 07 Rough Registration Adjustment–ManualFeed and Sheet Feeder
Adjusts registration for the manual feed
and sheet feeder (1 mm/step).
0: ± 0 mm1: –5 mm2: –4 mm3: –3 mm
4: –2 mm5: –1 mm6: +1 mm7: +2 mm8: +3 mm9: +4 mm
28 02 08 Hot Roller Temperature Adjustment
Increase or decrease the operatingtemperature of the hot roller (1°C/step).
0: ± 0°C1: –4°C2: –3°C3: –2°C4: –1°C
5: +1°C6: +2°C7: +3°C8: +4°C9: +5°C
29 02 09 Pressure Roller Temperature Adjustment
Increase or decrease the operatingtemperature of the pressureroller(2°C/step).
0: ± 0°C1: –8°C2: –6°C3: –4°C4: –2°C5: +2°C
6: +4°C7: +6°C8: +8°C9: +10°C
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
32
#
03 02 Fusing Temperature Display
Displays the hot roller and pressure rollertemperature.
"F"= Hot roller
Temperature"P"= PressurerollertemperatureDisplays the hot roller and pressure roller
temperature in the following order.1. "F" 2. Hot roller temperature
(100°C ~ 210°C)3. "P" 4. Pressure roller temperature
(50°C ~ 180°C)To stop the fusing temperature display,press the Copy Exit Way key.
Note: If the hot roller temperature is less than 100°C or pressure roller temperature is less than 50°C, "LLL" is displayed.If the hot roller temperature is more than 210°C or pressure roller temperature is more than 180°C, "HHH" is displayed.
33#
03 03 Vsg Adjustment
Adjusts Vsg.
"A"= Vsg
Adjusts Vsg to +4.0 ± 0.1 volts using VR104 on the main board.The main motor and ID sensor LED turn on when the Copy Exit Way key is pressed.After the adjustment is finished, press the Copy Exit Way key.
34#
03 04 Vsg & Vsp Display
Displays the latest Vsp, Vsg and Vsp/Vsg.
"A"= Vsp (volts)"C"= Vsg (volts)"F"= Vsp/Vsg
Displays the latest Vsp, Vsg and Vsp/Vsg in the following order.
1: "A=" 2: Vsp data (volts)3: "C=" 4: Vsg data (volts)5: "F=" 6: Vsp/Vsg data
To stop the display. Press the Copy Exit Way key.
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
35
#
03 05 Toner Density Sensor Adjustment
Adjusts toner density sensor voltage.
"A"= Toner
density sensorvoltage.
Adjusts toner density sensor voltage to +4.0 ± 0.1 volts using VR105 on the main board.This adjustment must be done only when the new developer is installed. After the adjustment is finished, press the Copy Exit Way key.
36#
03 06 Toner Density Sensor Voltage Display
Displays the latest toner density sensorvoltage.
"A"= Tonerdensity sensor
voltage.
To stop the display, press the Copy Exit Way key.
37#
03 07 ADS Reference Voltage Adjustment
Adjusts ADS voltage for the white plate.
"A"= ADS voltagefor white plate.
Adjusts ADS voltage for the white plate to +3.0 ± 0.1 volts using VR103 on the main board.After the adjustment is finished, press the Copy Exit Way key.
38#
03 08 ADS Voltage Display
Displays the latest Vod (ADS voltage forthe original), Vsd (ADS voltage for thewhite plate) and Vod/Vsd.
"A" = Vod (volts)"B" = Vsd (volts)"F" = Vod/VsdDisplays the latest Vod, Vsd and Vod/Vsd
in the following order.1 = "A" 2 = Vod data (volts)
3 = "C" 4 = Vsd data (volts)5 = "F" 6 = "Vod/Vsd data
To stop the display, press the Copy Exit Way key.
39 03 09 Toner Density Sensor Voltage UpperLimit
Selects the upper limit voltage for the tonerdensity sensor.
0: 2.4 V (4.5 wt%)1: 2.6 V (4.0 wt%)2. 2.2 V (5.0 wt%)
40 04 00 Not Used (Domestic market only)
41 04 01 Maximum Copy Quantity
Limits the maximum copy quantity that canbe entered.
0: Up to 10 copies1: Up to 99 copies
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
42
#
04 02 Total Original Misfeeds
Displays the total number of originalmisfeeds (4 digits).
"J" = Total number
of originalmisfeeds.
To stop the display, press the Copy Exit Way key.
43#
04 03 Original misfeeds –Upper TransportSection Displays the number of original misfeedsin the upper transport section (4 digits).
"J" = Number oforiginalmisfeeds.
To stop the display, press the Copy Exit
Way key.44#
04 04 Original Misfeeds –Turn Section
Displays the number of original misfeeds inthe turn section (4 digits).
"J" = Number oforiginalmisfeeds.
To stop the display, press the Copy Exit Way key.
45#
04 05 Original Misfeeds –Lower TransportSection
Displays the number of original misfeeds inthe lower transport section (4 digits).
"J" = Number oforiginalmisfeeds.
To stop the display, press the Copy Exit Way key.
46#
04 06 Original Misfeeds –Rear TransportSection
Displays the number of original misfeeds inthe rear transport section (4 digits).
"J" = Number oforiginalmisfeeds.
To stop the display, press the Copy Exit Way key.
47#
04 07 Original Misfeeds –Recycle Gate/SwitchBack Gate
Displays the number of original misfeedswhen the recycle gate or switch back gatedoes not move properly (4 digits).
"J" = Number oforiginalmisfeeds.
To stop the display, press the Copy Exit Way key.
48#
04 08 Original Misfeeds –Others
Displays the number of original misfeeds inother sections (4 digits).
"J" = Number oforiginalmisfeeds.
To stop the display, press the Copy Exit Way key.
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
50
#
05 00 Total Paper Misfeeds
Displays the total number of papermisfeeds (4 digits).
"J" = Total number
of papermisfeeds.
To stop the display, press the Copy Exit Way key.
51#
05 01 Paper Misfeeds –Sheet Feeder
Displays the number of paper misfeeds inthe sheet feeder (4 digits).
"J" = Number ofpaper misfeeds.
To stop the display, press the Copy Exit Way key.
52#
05 02 Paper Misfeeds –Manual Feed andRegistration
Displays the number of paper misfeeds inthe manual feed and registration sections(4 digits).
"J" = Number ofpaper misfeeds.
To stop the display, press the Copy Exit Way key.
53#
05 03 Paper Misfeeds –Pick-off
Displays the number of paper misfeeds inthe pick-off section (4 digits).
"J" = Number ofpaper misfeeds.
To stop the display, press the Copy Exit Way key.
54#
05 04 Paper Misfeeds –Exit
Displays the number of paper misfeeds inthe exit section (4 digits).
"J" = Number ofpaper misfeeds.
To stop the display, press the Copy Exit Way key.
55
#
05 05 Paper Misfeeds –Others
Displays the number of paper misfeeds inother sections of the copier (4 digits).
"J" = Number of
paper misfeeds.
To stop the display, press the Copy Exit Way key.
56#
05 06 Paper Misfeeds –Roll Feeder
Displays the number of paper misfeeds inthe roll feeder (4 digits).
"J" = Number ofpaper misfeeds.
To stop the display, press the Copy Exit
Way key.
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
58
#
05 08 Exposure Lamp Abnormal Display
Displays when the voltage from the lightsensor is less than 0.45 volts for 20seconds.
"–" = Normal
"E" = Abnormal
When this condition occurs, the Call Service indicator does not light and copying is possible.To stop the display, press the Copy Exit Way key.
59#
05 09 Exposure Lamp Thermistor OpenDisplay
Displays when the resistance of theexposure lamp thermistor is more than 248Ω for 20 seconds.
"–" = Normal"E" = Abnormal
When this condition occurs, the Call Service indicator does not light and copying is possible.To stop the display, press the Copy Exit Way key.
61#
06 01 ID Sensor Abnormal Display
Displays when the Vsg is less than 2.5volts or Vsp is more than 2.5 volts.
"–" = Normal"E" = Abnormal
When this condition occurs, the Call Service indicator does not light and copying is possible.To stop the display, press the Copy Exit Way key.
62 06 02 Factory Use
63 06 03 Factory Use
64
#
06 04 Developer Counter
Shows the total millimeters of copies madewith the developer installed in the machine.
"dEu" = Millimeters
of copies(122 mm/ number)
This counter clears when the initial conditioning (SP#5) is performed after the new developer is installed.To stop the display, press the Copy Exit Way key.The maximum number is "4001".
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
65
#
06 05 Density Level Display
Shows the density level (0 ~ 4) after theinitial conditioning (SP#5) is performed.
"dL" = Density level
(0 ~4)
Density Level Vsp/Vsg x 100 0 0 –10 1 10 – 15 2 15 –20 3 20 –25 4 > 25
NOTE: 1. If the Vsp/Vsg X 100 is more than 50,
"E" is displayed (Abnormal condition).2.If the Vsp is more than 2.5 volts or the
Vsg is less than 2.5 volts, "P" is displayed (Abnormal condition).
To stop the display, press the Copy Exit Way key.
66#
06 06 Total Copy Counter
Displays the total number of copies made(6 digits)
" " = Number ofcopies
To stop the display, press the Copy Exit
Way key.67#
06 07 Total Length Counter –Meters
Displays the total meters of copies made(6 digits).
" " = Meters ofcopies(meter/ number)
To stop the display, press the Copy Exit Way key.
68 06 08 Total Length Counter –Inches
Displays the total inches of copies made(6 digits).
" " = Meters ofcopies(100 inches/
number)To stop the display, press the Copy Exit Way key.
69 06 09 Factory Use
70 07 00 Factory Use
71 07 01 Factory Use
72 07 02 Factory Use
73 07 03 Factory Use
75 07 05 Factory Use
76 07 06 Fine Cut Length Adjustment –Synchro
Cut Mode Adjusts the cut length of the synchro cutmode to match the original length (0.25mm/step).
0: ± 0 mm
1: –1.0 mm2: –0.75 mm3: –0.5 mm4: –0.25 mm5: +0.25 mm6: +0.5 mm7: +0.75 mm8: +1.0 mm
1
2
3
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
77 07 07 Rough Cut Length Adjustment
–Synchro Cut Mode Adjusts the cut length of the synchro cutmode to match the original length(1 mm/step).
0: ± 0 mm
1: –5 mm2: –4 mm3: –3 mm4: –2 mm5: –1 mm6: +1 mm7: +2 mm8: +3 mm9: +4 mm
78 07 08 Fine Registration Adjustment –RollFeeder
Adjusts registration of the roll feeder(0.25 mm/step).
0: ± 0 mm1: –1.0 mm
2: –0.75 mm3: –0.5 mm4: –0.25 mm5: +0.25 mm6: +0.5 mm7: +0.75 mm8: +1.0 mm
79 07 09 Rough Registration Adjustment –RollFeeder Adjusts registration of the roll feeder
(1 mm/step).
0: ± 0 mm1: –5 mm2: –4 mm3: –3 mm
4: –2 mm5: –1 mm6: +1 mm7: +2 mm8: +3 mm9: +4 mm
80 08 00 Cut Error Correction 1 –Preset Cut297 mm
Correct cut error for preset cut 297 mm.
Input "0" or "1" according to the decal onthe roll feeder right cover.
0: +1: –
This SP mode must be done when the roll feeder is installed.
81 08 01 Cut Error Correction 2 –Preset Cut297 mm
Correct cut error for preset cut 297 mm.
Input the number according to the decal onthe roll feeder right cover
(1 mm/step).
0 ~ 9
This SP mode must be done when the roll feeder is installed.
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
82 08 02 Cut Error Correction 3 –Preset Cut
297 mm
Correct cut error for preset cut 297 mm.
Input the number according to the decal onthe roll feeder right cover(0.1 mm/step).
0 ~ 9
This SP mode must be done when the roll feeder is installed.
83 08 03 Cut Error Correction 1 –Preset Cut1189 mm
Correct cut error for preset cut 1189 mm.
Input "0" or "1" according to the decal onthe roll feeder right cover.
0: +1: –
This SP mode must be done when the roll feeder is installed.
84 08 04 Cut Error Correction 2 –Preset Cut1189 mm
Correct cut error for preset cut 1189 mm.
Input the number according to the decal onthe roll feeder right cover(10 mm/step).
0 ~ 2
This SP mode must be done when the roll feeder is installed.
85 08 05 Cut Error Correction 3 –Preset Cut1189 mm
Correct cut error for preset cut 1189 mm.
Input the number according to the decal onthe roll feeder right cover(1 mm/step).
0 ~ 9
This SP mode must be done when the roll feeder is installed.
86 08 06 Paper Buckle Adjustment –Roll Feeder
Adjusts the amount of paper buckle in theroll feeder.
0: ± 0 mm (80 mm)1: – 20 mm2: – 16 mm3: – 12 mm4: – 8 mm5: – 4 mm6: + 4 mm7: + 8 mm8: + 12 mm9: + 14 mm
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Mode No.
Function DataNo. Leading
Margin
Indicator
Trailing
Margin
Indicator
92 09 02 Cut Error Correction 3 – Synchro Cut
297 mm Correct cut error for synchro cut 297 mm. Input the number according to the decal onthe roll feeder right cover(0.1 mm/step).
0 ~ 9
This SP mode must be done when the roll feeder is installed.
93 09 03 Cut Error Correction 1 –Synchro Cut1189 mm
Correct cut error for synchro cut 1189 mm. Input "0" or "1" according to the decal stuckon the roll feeder right cover.
0: +1: –
This SP mode must be done when the roll feeder is installed.
94 09 04 Cut Error Correction 2 –Synchro Cut1189 mm
Correct cut error for synchro cut 1189 mm.
Input the number according to the decal onthe roll feeder right cover(10 mm/step).
0 ~ 2
This SP mode must be done when the roll feeder is installed.
95 09 05 Cut Error Correction 3 –Synchro Cut1189 mm
Correct cut error for synchro cut 1189 mm.
Input the number according to the decal onthe roll feeder right cover(1 mm/step).
0 ~ 9
This SP mode must be done when the roll feeder is installed.
96 09 06 Fusing Lower Limit Temperature
Select 3 modes in case the fusingtemperature drops below the lower limittemperature.
0: Normal1: Forced Copy2: Auto Start
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3.2 INPUT CHECK MODE
The input check mode allows you to check the current status electrical
components (such as sensors, switches, etc.) from the operation panel.
3.2.1 Access Procedure
1. Turn on the main switch.
2. Turn on DPS101-6 and 101-8 on the main board
NOTE: The Call Service [A] and Misfeed [B] indicators will blink. This is to
confirm that the correct mode has been selected.
ON
1 2 3 4 5 6 7 8
[D]
[H]
[C]
[G]
[J][I]
[E]
[F]
[B][A]
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3. Enter the desired input check number as follows:
a) Press the Margin key [C]. "00" will blink in the Leading Margin indicator
[D]. Enter the desired input check number using the Plus [E] or Minus
[F] key.
(The input check numbers are given in the Input Check Mode Table.)
b) Press the Margin Set key [G]. "00" will blink in the Trailing Margin
indicator [H].
Enter the desired input check number using the Plus or Minus key.
(The input check numbers are given in the Input Check Mode Table.)
Then, the current electrical component status will be displayed in the
Upper Exit indicator [I] or Lower Exit indicator [J].
4. Input a new input check number as follows: (When changing to another
mode number)
a) Press the Margin key. A number will blink in the Leading Margin
indicator. Enter the desired input check number using the Plus or
Minus key.
NOTE: It is possible to input a new input check number when thenumber in the Leading Margin indicator is blinking.
b) Press the Margin Set key. A number will blink in the Trailing Margin
indicator. Enter the desired input number using the Plus or Minus key.
Press the Margin Set key again.
NOTE: It is possible to input a new input check number when the
number in the Trailing Margin indicator is blinking.
5. To leave input check mode, turn off DPS101-6 and 101-8.
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3.2.2 Input Check Mode Table
Input check No
Sensor/Switch/Signal
Status
No Leading
Margin
Indicator
Trailing
Margin
Indicator
Upper ExitIndicator
Lower ExitIndicator
0 00 00 Original Set Sensor Original detected Original notdetected1 00 01 1st Original Transport
Sensor
2 00 02 2nd Original TransportSensor
3 00 03 Original RegistrationSensor
4 00 04 Original Exit Sensor
5 00 05 Original Entrance
Sensor6 00 06 Recycle Gate Sensor Sensor not
actuatedSensor actuated
7 00 07 Switch Back GateSensor
8 00 08 Paper Entrance Sensor(Sheet Feeder)
Paper detected Paper notdetected
9 00 09 1st Feed Sensor
10 01 00 2nd Feed Sensor
11 01 01 Registration sensor
12 01 02 Transport Sensor13 01 03 Fusing Exit Sensor
14 01 04 Upper Exit Sensor
15 01 05 Lower Exit Sensor
16 01 06 Paper End Sensor(Sheet Feeder)
Paper detected Paper end
17 01 07 Sheet Feeder SetSwitch
Sheet feeder set Sheet feeder notset
18 01 08 Feed Pressure Switch(Sheet Feeder)
Feed pressurelever position 3
Feed pressurelever position
1 or 219 01 09 Leading Edge Sensor
(Roll Feeder)Paper detected Paper not
detected
20 02 00 Paper End Sensor(Roll Feeder)
Paper detected Paper end
21 02 01 Left Cutter Sensor(Roll Feeder)
Cutter detected Cutter notdetected
22 02 02 Right Cutter Sensor(Roll Feeder)
23 02 03 Set Switch
(Roll Feeder)
Roll feeder set Roll feeder not set
24 02 04 Door Safety Switch(Roll Feeder)
All roll feederdoors closed
One of the rollfeeder doors isopen
25 02 05 Rear Feeder Switch Rear originaltable not set
Rear originaltable set
29 02 09 Stop Key Stop key ispressed
Stop key is notpressed
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Input check No
Sensor/Switch/Signal
Status
No Leading
Margin
Indicator
Trailing
Margin
Indicator
Upper ExitIndicator
Lower ExitIndicator
30 03 00 Toner Overflow Sensor Used toner
overflow
Used toner not
overflowed31 03 01 Exposure Lamp Heater ON OFF
32 03 02 Exposure LampThermistor Open
Open Not open(Normal)
33 03 03 Exposure LampThermistor Short
Short Not short(Normal)
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3.3 OUTPUT CHECK MODE
The output check mode allows you to turn the current individual electrical
components ON/OFF from the operation panel.
3.3.1 Access Procedure
1. Turn on the main switch.
2. Turn on DPS101-7 and 101-8 on the main board.
NOTE: The Call Service [A] and Used Toner Tank [B] indicators will blink.
This is to confirm that the correct mode has been selected.
ON
1 2 3 4 5 6 7 8
[D]
[H]
[C]
[G]
[J]
[I]
[E]
[F]
[B]
[A]
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3. Enter the desired output check number as follows:a) Press the Margin key [C]. "00" will blink in the Leading Margin indicator
[D]. Enter the desired output check number using the Plus [E] or Minus
[F] key. (The output check numbers are given in the Output Check
Mode Table.)
b) Press the Margin Set key [G]. "00" will blink in the Trailing Margin
indicator [H]. Enter the desired output check number using the Plus or
Minus key. (The output check numbers are given in the Output Check
Mode Table.) Press the Margin Set key again.
4. Press the Copy Exit Way key [I] to turn the electrical components on and
off.
NOTE: When the selected component is ON, "1" is displayed in the CopyCounter indicator [J]. When it is OFF, "0" is displayed in the Copy
Counter indicator.
5. Input a new output check number as follows: (When changing to anothernumber)
a) Press the Margin key. A number will blink in the Leading Margin
indicator. Enter the desired output check number using the Plus or
Minus key.
NOTE: It is possible to input a new output check number when the
number in the Leading Margin indicator is blinking.
b) Press the Margin Set key. A number will blink in the Trailing Margin
indicator. Enter the desired output check number using the Plus or
Minus key. Press the Margin Set key again.
NOTE: It is possible to input a new output check number when the
number in the Trailing Margin indicator is blinking.
6. To leave output check mode, turn off the DPS-101-7 and 101-8.
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3.3.2 Output Check
Output Check No
Electrical ComponentNo LeadingMargin
Indicator
TrailingMargin
indicator
0 00 00 Main Motor
1 00 01 Development Motor
2 00 02 Original Stopper Solenoid
4 00 04 Recycle Gate Solenoid
5 00 05 Original Forward Feed Clutch
6 00 06 Manual Feed Solenoid
7 00 07 Paper Stopper Solenoid8 00 08 Registration Clutch
9 00 09 Pick-off Solenoid
10 01 00 Exit Gate Solenoid
11 01 01 Pattern Shutter Solenoid
12 01 02 Toner Supply Solenoid
13 01 03 Sheet Feeder Solenoid 1
14 01 04 Sheet Feeder Solenoid 2
15 01 05 Fusing Lamp
16 01 06 ID Sensor LED
17 01 07 Total Counter
18 01 08 ADS Lamp
19 01 09 ADS Sample Hold
20 02 00 Quenching Lamp
21 02 01 Pre-transfer Lamp
22 02 02 Exposure Lamp Heater
23 02 03 Exposure Lamp(ADS mode … Full duty)(Manual ID level … ID level 1 ~ 26)
24 02 04 Charge Corona
25 02 05 Transfer Corona (low current: T1)
26 02 06 Transfer Corona (high current:T2)
27 02 07 Separation Corona (AC current: D1)
28 02 08 Separation Corona (DC current: D2)
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Output Check No
Electrical ComponentNo LeadingMargin
Indicator
TrailingMargin
indicator
29 02 09 Development Bias (Levels 0 to 9)
30 03 00 Development Bias (Levels 10 to 19)
31 03 01 Development Bias (Levels 20 to 29)
Copy Counter Indicator Dev. Bias Voltage
0 0 volt
1 – 60 volts
2 – 60 volts
3 – 80 volts
4 –100 volts
5 –120 volts
6 –140 volts
7 –160 volts8 –180 volts
9 –200 volts
Copy Counter Indicator Dev. Bias Voltage
0 –220 volts
1 –240 volts
2 –260 volts
3 –280 volts
4 –300 volts
5 –320 volts
6 –340 volts
7 –360 volts
8 –380 volts
9 –400 volts
Copy Counter Indicator Dev. Bias Voltage
0 –420 volts
1 –440 volts
2 –460 volts
3 –480 volts
4 –500 volts
5 –520 volts
6 –540 volts
7 –560 volts8 –580 volts
9 –600 volts
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Output Check No
Electrical ComponentNo LeadingMargin
Indicator
TrailingMargin
indicator
32 03 02 Grid Voltage (Levels 0 to 9)
33 03 03 Grid Voltage (Levels 10 to 19)
34 03 04 Grid Voltage (Levels 20 to 29)
Copy Counter Indicator Grid Voltage
0 – 0 volts
1 –380 volts
2 –400 volts
3 –420 volts
4 –440 volts
5 –460 volts
6 –480 volts
7 –500 volts8 –520 volts
9 –540 volts
Copy Counter Indicator Grid Voltage
0 –560 volts
1 –600 volts
2 –620 volts
3 –640 volts
4 –660 volts
5 –680 volts
6 –700 volts
7 –720 volts
8 –740 volts
9 –760 volts
Copy Counter Indicator Grid Voltage
0 –780 volts
1 –800 volts
2 –820 volts
3 –840 volts
4 –860 volts
5 –880 volts
6 –900 volts
7 –920 volts
8 –940 volts
9 –960 volts
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Output Check No
Electrical ComponentNo LeadingMargin
Indicator
TrailingMargin
indicator
38 03 08 Paper Feed Motor (Roll Feeder)
39 03 09 Cutter Motor (Roll Feeder)
74 07 04 Original Reverse Feed Clutch
75 07 05 Switch Back Gate Solenoid
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3.4 MEMORY CLEAR MODE
3.4.1 Misfeed Counter Clear Procedure
NOTE: This procedure clears the following counters:
SP42 ~ SP48 (Original Misfeed Counters)
SP50 ~ SP56 (Paper Misfeed Counters)
1. Turn on the main switch.
2. Turn on DPS101-5 and 101-8 on the main board.
NOTE: The Call Service ( ), Misfeed ( ), Used Toner Tank ( ), and
Add Toner ( ) indicators will blink. This is to confirm that thecorrect mode has been selected.
3. Press the Plus or Minus key to display "5" in the Copy Counter indicator.
4. Press the Copy Exit Way key to clear.
5. Turn off DPS101-5 and 101-8.
3.4.2 All Memory Clear Procedure
CAUTION: All memory clear mode clears all the correction data forprocess control and software counters, and returns allthe modes to the default settings. Normally, this mode
should not be performed. This procedure is requiredonly when the copier malfunctions due to a damagedRAM or when replacing the RAM for any reason.
1. Turn on the main switch.
2. Turn on DPS101-5 and 101-8 on the main board.
NOTE: The Call Service ( ), Misfeed ( ), Used Toner Tank ( ) and
Add Toner ( ) indicators will blink. This is to confirm that thecorrect mode has been selected.
ON
1 2 3 4 5 6 7 8
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3. Press the Plus or Minus key to display "9" on the Copy Counter indicator.
4. Press the Copy Exit Way key to clear memory.
5. Turn off DPS101-5 and 101-8.
6. Clean the optics, sensors, and inside of the copier if necessary.
7. Replace the old developer with new one.
CAUTION: Since the developer counter (SP64) for the developercounter correction has been cleared, the old developercannot be used.
8. Perform the following SP modes in sequence.(1) SP#13: Pheripheral Installation (If pheripherals are installed)
(2) SP#80 ~ SP#85, SP#90 ~ SP#95: Cut Error Corrections (If the roll
feeder is installed)
(3) SP#5: Initial Conditioning
(4) SP#35: Toner Density Sensor Adjustment
(5) SP#33: Vsg Adjustment
(6) SP#37: ADS Reference Voltage Adjustment
(7) Light Sensor Adjustment (by using VR102 on the main board)
(8) SP#26 or SP#27: Registration AdjustmentManual Feed and Sheet
Feeder
(9) SP#78 or SP#79: Registration AdjustmentRoll Feeder (If the rollfeeder is installed)
(10) SP#76 or SP#77: Cut Length AdjustmentSynchro Cut Mode
(If the roll feeder is installed)
(11) SP#88 or SP#89: Cut Length AdjustmentPreset Cut Mode
(If the roll feeder is installed)
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4. JAM CODE LIST
When a document (original) jam or paper jam occurs, the cause of the jam is
displayed by using the following jam code.
4.1 ACCESS PROCEDURE
1. When a document jam or paper jam occurs, press and hold down the
Clear/Stop key.
2. Read the jam code (DJ001, PJ021, etc.)
NOTE: DJ = Document Jam, PJ = Paper Jam
4.2 DOCUMENT (ORIGINAL) JAM CODE
Code(DJ =)
Cause of JamSP Mode No
(Original Misfeed Counter)
00 No jam
01 Initial jam SP48 (Others)
02 An original is in the machine when the CallService indicator turns on.
16 2nd original transport sensor ON check SP43(Upper transport section)
17 2nd original transport sensor leading edge OFFcheck
18 Original registration sensor ON check SP45(Lower transport section)
19 Original registration sensor leading edge OFFcheck
20 Original is not fed within 6 seconds after theleading edge of the original is detected by originalset sensor. (When the original is fed from thefront original table.)
SP43(Upper transport section)
21 Original is not fed within 6 seconds after theleading edge of the original is detected by originalentrance sensor. (When the original is fed fromthe rear original table.)
SP46(Rear transport section)
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Code(DJ =)
Cause of JamSP Mode No
(Original Misfeed Counter)
22 Original is too small. (Minimum: B5 lengthwise) SP43(Upper transport section)
23 Original is pulled out from the rear original table
after the original registration sensor turns on butbefore the original registration rollers start turning.
24 Original is under the original set sensor when theoriginal stopper solenoid turns on. (When theoriginal is fed from the front original table.)
25 Original is under the original entrance sensorwhen the original stopper solenoid turns on.(When the original is fed from the rear originaltable.)
26 Original is pulled out from the front original tableafter the registration sensor turns on but beforethe original registration rollers start turning.
27 The 1st original transport sensor stays on whenthe 2nd original transport sensor trailing edgeOFF check. (When the original is fed from thefront original table.)
28 The original registration sensor stays on whenthe original exit sensor trailing edge OFF check.(When the original is fed from the rear originaltable.)
29 Original registration sensor ON check for theswitch back mode.
SP45(Lower transport section)
30 Original entrance sensor ON check for the switchback mode.
31 Switch back gate does not move to the upposition when the switch back gate solenoid turnson.
SP47(Recycle gate/switch backgate)
32 2nd original transport sensor trailing edge OFF
check.
SP43
(Upper transport section)33 1st original transport sensor leading/trailing edge
OFF check for repeat copy.
34 1st original transport sensor ON check for repeatcopy.
35 Original registration sensor trailing edge OFFcheck.
SP45(Lower transport section)
36 Original exit sensor ON check.
37 Original exit sensor leading/trailing edge OFFcheck.
38 Original is too long. (Maximum: 3.6 meters) SP44(Turn section)
39 Recycle gate does not return to the originalposition (up position) when the recycle gatesolenoid turns off.
SP47(Recycle gate/switch backgate)
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Code(DJ =)
Cause of JamSP Mode No
(Original Misfeed Counter)
40 Recycle gate does not move to down positionwhen the recycle gate solenoid turns on.
SP47(Recycle gate/switch backgate)
41 Switch back gate does not return to the originalposition (down position) when the switch backgate solenoid turns off.
42 Rear original table does not set when the switchback mode is selected.
SP48 (Others)
99 Original feed clutch stays on longer than 125seconds.
4.3 PAPER JAM CODE
Code(PJ =)
Cause of JamSP Mode No
(Paper Misfeed Counter)
00 No Jam
01 Initial Jam SP55 (Others)
02 Paper remains in the machine when the CallService indicator turns on.
16 Paper entrance sensor (Sheet feeder) ON check.(When the sheet feeder is used.)
SP51 (Sheet feeder)
17 Registration sensor leading edge OFF check. SP52(Manual feed andregistration)18 Registration sensor ON check.
20 2nd feed sensor leading edge OFF check.
21 Original is not set within 10 second after thepaper is set in the manual feed table.
22 Paper is pulled out after the registration sensorturns on but before the registration clutch turnson.
23 Paper entrance sensor (sheet feeder) stays onwhen the 2nd feed sensor trailing edge OFFcheck. (Multiple feed from the sheet feeder.)
SP51 (Sheet feeder)
24 2nd feed sensor stays on when the registrationsensor trailing edge OFF check.
SP53 (Pick-off)
25 2nd feed sensor ON check.
26 Registration sensor does not turn on when theregistration clutch turns on.
27 Paper entrance sensor (sheet feeder) ON check.(When the roll feeder is used.)
SP56 (Roll feeder)
28 Loading edge sensor (roll feeder) ON check.
30 Cutter abnormal condition
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Code(PJ =)
Cause of JamSP Mode No
(Paper Misfeed Counter)
31 Pulse generator (roll feeder) abnormal. SP56 (Roll feeder)
32 Upper exit sensor ON check. SP54 (Exit)
33 Upper exit sensor leading edge OFF check.
34 Lower exit sensor ON check.
35 Lower exit sensor leading edge OFF check.
36 Upper exit sensor trailing edge OFF check.
37 Lower exit sensor trailing edge OFF check.
38 Fusing exit sensor leading edge OFF check. SP53 (Pick-off)
39 Fusing exit sensor ON check.
40 Registration sensor trailing edge OFF check.
41 Fusing exit sensor trailing edge OFF check. SP54 (Exit)
42 Transport sensor ON check.
43 Transport sensor leading edge OFF check.
44 Paper is too long. (Maximum: 3.6 meters) SP53 (Pick-off)
99 Registration clutch stays on longer than 125seconds.
SP55 (Others)
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5. SPECIAL TOOLS AND LUBRICANTS
No DESCRIPTION PART NO. REMARKS
1 Digital Multimeter 54209507 BECKMAN RMS3030
2 Deluxe Test Lead
Accessory Kit
54209508 BECKMAN DL241
3 Grease – Mobil Temp.78 54479078 400 g/can
4 Current Measuring Drum A0239520
5 0.35 mm DG Gauge A0989105
6 0.5 mm DG Gauge A0989104
7 Test Chart OS-A1
(2 sheets/set)
A0239504
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6. SERVICE REMARKS
6.1 DRUM
The organic photoconductor drum is comparatively more sensitive to light
and ammonia gas than a selenium drum.
1. Never expose the drum to direct sunlight.
2. Never expose the drum to direct light of more than 1,000 Lux for more
than a minute.
3. Never touch the drum surface with bare hands. When the drum surface istouched with a finger or becomes dirty, wipe with a dry cloth or clean with
wet cotton. Wipe with a dry cloth after cleaning with wet cotton.
4. Never use alcohol to clean the drum; alcohol dissolves the drum surface.
5. Store the drum in a cool, dry place away from heat.
6. Take care not to scratch the drum as the drum layer is thin and is easily
damaged.7. Never expose the drum to corrosive gases such as ammonia gas.
8. Always keep the drum in the protective sheet when inserting or pulling the
drum unit out of the copier to avoid exposing it to bright light or direct sun-
light. This will protect the drum from light fatigue.
9. Before removing the drum, place a sheet of paper under the drum to
catch any falling toner.
10. Dispose of used drums according to local regulations.
11. Perform the following adjustment when a new drum is installed.1. Vsg adjustment (SP#33).
2. Light sensor adjustment (VR102 on the main board).
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6.2 CHARGE CORONA
1. Clean the charge corona wire by turning the gear of the wire cleaner padsclockwise until it stops, then turn the gear counterclockwise and the wire
cleaner pads move to the original position.The wire can also be cleaned with a blower brush. If the wire is cleaned
with a dry cloth, make sure that the wire does not become stretched. Donot use sand paper or a solvent.
2. Do not touch the corona wire and the grid wires with oily hands. Oil stainsmay cause uneven image density on copies.
3. Make sure that the corona wire is correctly positioned between the
cleaner pads and that there is no foreign material (iron filings, etc.) on thecasing.
4. When adjusting the charge corona current, always use the current meas-
uring drum.
5. Clean the grid wires with a dry cloth.
6.3 OPTICS
1. Clean the exposure glass with water or alcohol.
2. Clean the fiber optics array with lens paper or silicone cloth.
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6.4 DEVELOPMENT
1. Be careful not to nick or scratch the development roller.
2. Clean the drive gears after removing used developer.
3. Initial conditioning (SP#5) and toner density sensor voltage adjustment
(SP#35) are necessary when the developer is replaced.
4. Never loosen the paint locked screw securing the center of the toner car-tridge holder and the paint locked screw securing the doctor blade.
5. Dispose of used developer according to local regulations.
6.5 TONER SUPPLY
1. Clean the image density sensor with a dry cloth or a blower brush.
2. Vsg adjustment is required in the following cases:
a) When the image density sensor is replaced
b) When the main board is replaced
c) When the drum has been replaced and Vsg is out of specification
d) When there have been problems with toner supply and Vsg is out of
specification
6.6 TRANSFER AND SEPARATION
1. Clean the corona wires with a blower brush. If the wires are cleaned with
a dry cloth, make sure that the wire does not become stretched.
2. When adjusting the corona current, always use the drum currentmeasuring drum.
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6.12 OTHERS
1. When replacing the main board, if the RAM on the old main board is stillusable, remove and place it on the new main board. Then, install the new
main board in the copier.2. After installing the new main board with a new RAM, clear the RAM mem-
ory by performing the following procedure. (Do not clear RAM memory if
you have placed the old RAM on the new main board.)
1) Turn on the main switch.
2) Turn on the DPS101-5 and 101-8 on the main board.
NOTE: The Call Service ( ), Misfeed ( ), Used Toner Tank ( )
and Add Toner ( ) indicators will blink. This is to confirm
that the correct mode has been selected.
3) Press the Plus or Minus key to display "9" on the Copy Counter
indicator.
4) Press the Copy Exit Way key to clear.
5) Turn off the DPS101-5 and 101-8.
6) Clean the optics, sensors, and inside of the copier if necessary.
7) Replace the developer with new one.
CAUTION: Since the developer counter (SP64) for the developercounter correction has been cleared, the olddeveloper cannot be used.
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8) Perform the following SP modes in sequence.
(1) SP#13: Pheripherals Installation (If pheripherals are installed)
(2) SP#80 ~ SP#85, SP#90 ~ SP#95: Cut Error Corrections (If the roll
feeder is installed)
(3) SP#5: Initial Conditioning
(4) SP#35: Toner Density Sensor Adjustment
(5) SP#33: Vsg Adjustment
(6) SP#37: ADS Reference Voltage Adjustment
(7) Light Sensor Adjustment (by using VR102 on the main board)(8) SP#26 or SP#27: Registration Adjustment Manual Feed and Sheet
Feeder
(9) SP#78 or SP#79: Registration AdjustmentRoll Feeder
(If the roll feeder is installed)
(10) SP#76 or SP#77: Cut Length AdjustmentSynchro Cut Mode
(If the roll feeder is installed)
(11) SP#88 or SP#89: Cut Length AdjustmentPreset Cut Mode
(If the roll feeder is installed)
3. When replacing a sensor, do not overtighten the screws. This may dam-
age the sensor.
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SECTION 5
REPLACEMENT AND ADJUSTMENT
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1. EXTERIOR COVERS
1.1 LEFT SIDE COVER REMOVAL
1.1.1 Middle Left Cover1. Open the original feed unit [A].
2. Remove the middle left cover [B] (2 screws, loosen 2 screws [C]).
1.1.2 Top Left Cover
1. Open the original feed unit.
2. Remove the top left cover [D] (2 screws, loosen 2 screws [E]).
1.1.3 Front Left Cover1. Open the original feed unit, middle unit [F] and toner cartridge cover [G].
2. Remove the middle left cover (2 screws, loosen 2 screws).
3. Remove the front left cover [H] (4 screws, loosen 2 screws [I]).
1.1.4 Left Horizontal Cover1. Remove the front left cover. (See Front Left Cover Removal.)
2. Remove the left horizontal cover [J] (5 screws).
[A]
[D]
[C]
[E]
[B]
[C] [F]
[G]
[H]
[I]
[J]
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1.2 RIGHT SIDE COVER REMOVAL
1.2.1 Middle Right Cover1. Open the original feed unit [A].
2. Remove the middle right cover [B] (2 screws, loosen 2 screws [C]).
1.2.2 Top Right Cover1. Open the original feed unit.
2. Remove the top right cover [D] (2 screws, loosen 2 screws [E]).
1.2.3 Front Right Cover1. Open the original feed unit, middle unit [F] and toner cartridge cover [G].
2. Remove the middle right cover (2 screws, loosen 2 screws).
3. Remove the front right cover [H] (4 screws, loosen 2 screws [I]).
1.2.4 Right Horizontal Cover1. Remove the front right cover. (See Front Right Cover Removal.)
2. Open the main board bracket [J] (1 screw).
3. Remove the right horizontal cover [K] (5 screws).
[D]
[A]
[C]
[E]
[B]
[C]
[K]
[J]
[I]
[F]
[G]
[H]
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2. OPTICS
2.1 EXPOSURE GLASS REMOVAL
1. Open the original feed unit.
2. Remove the two exposure glass holders [A]. (2 hexagon head screwseach.)
3. Remove the exposure glass [B].
NOTE: When reinstalling the exposure glass, make sure that thebeveled edge [C] of the exposure glass must be positioned
upward as shown.
[A]
[B][A]
[C]
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2.2 FIBER OPTICS ARRAY REMOVAL/CLEANING
1. Remove the exposure glass. (See Exposure Glass Removal.)
2. Remove the light sensor board [A] (1screw and 1 connector).
3. Remove the two shoulder screws [B] and washers [C] securing the fiberoptics unit [D].
4. Rotate the fiber optics unit forward and lift it out of the machine.
5. Remove the pattern shutter solenoid unit [E] from the fiber optics unit
(2 screws and 1 connector).
NOTE: Do not miss the spring [F] on the unit.
6. Clean the fiber optics with a soft cloth.
[A][B]
[C]
[D]
[E]
[F]
[B]
[C]
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2.3 EXPOSURE LAMP/EXPOSURE LAMP HEATERREPLACEMENT
–To Remove–1. Remove the middle left cover, front left cover and left horizontal cover.
(See Left Horizontal Cover Removal.)
2. Remove the middle right cover. (See Middle Right Cover Removal.)
3. Close the middle unit.
4. Remove the exposure glass. (See Exposure Glass Removal.)
5. Remove the left lamp socket bracket [A] (1 screw and 1 shoulder screw).
6. Disconnect the 2P [B] and 3P [C] connectors.
7. Remove the left lamp holder [D] (2 screws).
8. Slide the exposure lamp [E] and exposure lamp heater [F] to the left and
remove them from the machine.
9. Remove the heater from the lamp.
[C]
[A]
[B]
[D]
[E] [F]
[F]
[E]
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–To Install–10. Place the exposure lamp heater [A] on the exposure lamp [B] as shown.
NOTE: The heater fits over the white part [C] of the lamp. Make sure
that the heater does not cover the lamp aperture [D].
11. Insert the exposure lamp together with the lamp heater through the
cutout, then connect the right lamp terminal [E] by pushing the lamp.NOTE: a) Do not touch the aperture on the exposure lamp.
b) Make sure that the aperture faces up and to the rear and that
the heater faces down and to the front.c) Make sure that the right lamp terminal fits into the socket [F].
12. Reinstall the left lamp holder [G] (2 screws) and left lamp socket bracket
[H] (2 screws).
NOTE: Make sure that the left lamp terminal fits into the socket.
13. Connect the 2P and 3P connectors and reassemble the machine.
14. Perform the light sensor adjustment. (See Light Sensor Adjustment.)
[B] [A]
[D]
[C]
[G]
[H]
[E]
[F]
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3. DRUM
3.1 DRUM REPLACEMENT
–To Remove–1. Open the middle unit and press the cleaning unit release lever [A] to the
rear.
2. Remove the pick-off pawl unit [B] with ID sensor [C] (2 knob screws and 2
connectors).
3. Remove the middle right cover. (See Middle Right Cover Removal.)
4. Open the main board bracket (1 screw).
5. Remove the ground screw [D] securing the cover plate [E].
6. Move the cover plate slightly to the right and remove it.
[A] [B][C]
[D][E]
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7. Support the drum [A] with your left hand and turn the drum lock knob [B]counterclockwise with your right hand.
NOTE: Never touch the drum surface with your bare hands. Use a sheet
of paper between your hand and the drum to avoid contact.
8. Remove and hold the drum with your hand.
NOTE: When removing the drum, take care not to strike it against any
objects.
[B]
[A]
[A]
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–To Install–1. Remove the left [A] and right [B] drum holders from the back side of the
main board bracket [C].
2. Disconnect the transfer [D] and separation [E] connectors.
3. Lift the T/S corona unit [F] and disconnect the ground wire connector [G].
4. Remove the T/S corona unit.
5. Place the left and right drum holders on the main frame as shown.
NOTE: "A" is written on the left drum holder and "B" is written on theright drum holder.
[C][B]
[A]
[D][E]
[F]
[G]
[A]
[B]
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6. Put the new drum [A] with the drum protective sheet [B] on the drumholders [C] as shown.
NOTE: The seals [D] on the drum protective sheet must be beneath thedrum.7. Close the middle unit [E] and turn the drum lock knob [F] clockwise until it
locks.
NOTE: To avoid drum damage, do not open the middle unit beforetightening the drum lock knob.
8. Open the middle unit.
9. Reinstall the T/S corona unit [G] (2 connectors and 1 ground wireconnector).
NOTE: When reinstalling the T/S corona unit, make sure that the four
edges [H] of the unit bottom plate are properly mounted on theleft [I] and right [J] support brackets of the copier frame, as
shown.
[E]
[F]
[C]
[D]
[C]
[B][A]
[H]
[I]
[G]
[H]
[J]
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10. Reinstall the cover plate [A] (1 ground screw).
NOTE: The right positioning pin [B] is inserted in the hole [C] while the
left positioning pins [D] are inserted in the holes [E].
11. Reinstall the pick-off pawl unit [F] (2 knob screws and 2 connectors).
NOTE: Make sure the two positioning pins [G] are inserted in the two
holes [H] of the pick-off pawl unit.12. Pull the cleaning unit release lever to the front side until it locks.
13. Remove the drum protective sheet.
14. Close the main board bracket (1 screw) and the middle unit.
15. Perform the Vsg adjustment by SP#33. (See Vsg Adjustment.)
NOTE: Initial conditioning (SP#5) is not necessary. (It is necessary only
when the developer is replaced.)
16. Perform the light sensor adjustment. (See Light Sensor Adjustment.)
[E]
[D]
[B]
[C]
[A]
[F]
[H]
[G]
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4. CORONA
4.1 CHARGE CORONA WIRE AND GRID WIREREPLACEMENT
1. Remove the drum. (See Drum Replacement.)
NOTE: Cover the drum with paper to prevent the drum from being
exposed to light.
2. Disconnect the ground lead [A] and remove the "+" shoulder screw [B]securing the right charge corona cover [C].
3. Remove the right charge corona cover.
4. Move the charge corona unit [D] slightly to the right. Then, take it out
downward through the drum opening.
[D]
[C][A]
[B]
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11. Reinstall the wire cleaner [A].
NOTE: Make sure that the corona wire [B] is positioned between the
cleaner pads [C].
12. Reinstall the endblock-covers and grid wire terminal.
13. Install 4 new grid wires [D] and grid holders [E].NOTE: 1) Make sure that the wires are correctly placed on the eight
slots [F] and in the eight holes [G].
2) Make sure that the wires are all straight and not crossed, as
shown.3) Handle the new wires by the ends only. Oil and chemicals
from your hands will deteriorate the wires.
4) Do not bend the wires. This can result in an uneven charge.
14. Reinstall the charge corona unit.
NOTE: Make sure that the charge corona unit is set properly, and the
grid wires and charge corona wire are positioned facing the drum
surface.
15. Reinstall all the units and covers.
[A]
[C] [B]
[C]
OK
NG
[G]
[F]
[D] [E]
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4.3 DRUM CURRENT ADJUSTMENT
NOTE: a) The drum currents vary with environmental conditions such ashumidity and atmospheric pressure. Generally it is not necessary
to adjust the drum currents because they have already been
adjusted for a wide range of environments at the factory.b) Drum current adjustment is necessary whenever the power packs
are replaced; adjustment may also be necessary to correct
problems with paper separation, incomplete toner transfer, or
image density.
c) Make sure that the main switch is turned off when you change therange on the digital multimeter. If it is not, the multimeter may be
damaged.
4.3.1 Preparation1. Turn off the main switch and remove the following parts:
• Left middle cover
• Right middle cover
• Pick-off pawl unit (See Drum Replacement)
• Cover plate (See Drum Replacement)
• Drum (See Drum Replacement)
2. Clean or replace each corona wire and clean the corona units.
NOTE: When the wire is cleaned with a dry cloth, make sure that the
wire does not become stretched.
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NOTE: Do steps 3 and 4 before adjusting the transfer corona current or
separation corona current.
3. Install the current measuring drum [A].
NOTE: 1) Position the connectors [B] to the right side as shown.
2) The harness leads should be positioned as close as possible
to the development roller [C] so that they are not in the way of
any corona units.4. Connect the five harness leads[D] of the current measuring drum to the
positive harness lead [E] of the multimeter [F], then connect the negativeharness lead [G] of the multimeter to the copier frame as shown.
5. Close the middle unit.
[A]
[B][C]
[G]
[F]
[E][D]
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4.3.2 Charge Corona Current Adjustment
ADJUSTMENT STANDARD Adjusting VR
DC 1.1 ± 0.01 mA VR101
1. Turn off the main switch.
2. Disconnect the Charge/Grid/Bias power pack connector [A] from the
charge corona terminal [B].3. Select the dc 2 mA range on the digital multimeter.
4. Connect the multimeter leads as shown.
5. Turn on the main switch.
6. Turn on DPS101-7 and 101-8 on the main board to enter the output
check mode.
7. Enter output check No 24. (See output Check Mode Access Procedure.)
8. Press the Copy Exit Way key to turn on the charge corona.
9. Enter output check No 34.
10. Press the Plus (+) key until "8" is displayed in the Copy Counter indicator.Then, press the Copy Exit Way key to apply the grid voltage (–940 volts).
11. Adjust the charge corona current to 1.1 ± 0.01 mA by turning VR101 on
the Charge/Grid/Bias power pack [C].
12. Turn off DPS101-7, 101-8 and the main switch.
[A]
[B]
[C]
VR101
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4.3.3 Transfer Corona Current Adjustment
ADJUSTMENT STANDARD Adjusting VR
Low (normal): DC –120 ± 5 µA T1
High: DC –250 + 5/–10 µA T2
1. Turn off the main switch.2. Remove the lower rear cover [A] (5 screws) and upper rear cover [B] (4
screws).
3. Select dc 200 µA on the digital multimeter.
4. Turn on the main switch.
5. Turn on DPS101-7 and 101-8 on the main board to enter the output
check mode.6. Enter output check No 25. (See Output Check Mode Access Procedure.)
7. Press the Copy Exit Way key to turn on the low (normal) transfer corona.
[A]
[B]
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8. Adjust the low (normal) transfer corona current to –120 ± 5 µA by turning
T1 on the Transfer/Separation power pack [A].
9. Turn off the main switch.
10. Select dc 2 mA on the digital multimeter.
11. Turn on the main switch.
12. Enter output check No 26.
13. Press the Copy Exit Way key to turn on the high transfer corona.14. Adjust the high transfer corona current to –250 + 5/–10 µA by turning T2
on the Transfer/Separation power pack.
15. Press the Copy Exit Way key and turn off DPS101-7, 101-8 and the main
switch.
[A]
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4.3.4 Separation Corona Current Adjustment
ADJUSTMENT STANDARD Adjusting VR
AC 220 ± 5 µA D1
DC –10 + 0.5 µA D2
1. Turn off the main switch.2. Remove the lower rear cover [A] (5 screws) and upper rear cover [B] (4
screws).
3. Select ac 2 mA on the digital multimeter.
4. Turn on the main switch.
5. Turn on DPS101-7 and 101-8 on the main board to enter the output
check mode.6. Enter output check No 27. (See Output Check Mode Access Procedure.)
7. Press the Copy Exit Way key to turn on the ac current of the separation
corona.
[A]
[B]
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8. Adjust the ac separation corona current to 220 ± 5 µA by turning D1 on
the Transfer/Separation power pack [A].
9. Turn off the main switch.
10. Select dc 200 µA on the digital multimeter.
11. Turn on the main switch.
12. Enter output check No 28.
13. Press the Copy Exit Way key to turn on the dc current of the separationcorona.
14. Adjust the dc separation corona current to –10 + 0.5 µA by turning D2 on
the Transfer/Separation power pack.
15. Press the Copy Exit Way key and turn off the DPS101-7, 101-8 and the
main switch.
[A]
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5. DEVELOPMENT
5.1 DEVELOPER REMOVAL
NOTE: When replacing the developer,make sure that the drum
is must be installed.
1. Remove the middle right cover. (See Middle Right Cover Removal.)
2. Open the main board bracket (1 knob screw).
3. Open the middle unit and lay a sheet of A2 paper (C size) [A] on the rightside of the paper entrance section as shown.
4. Remove the cover plate [B] (1 ground screw).
5. Activate the lower safety switch.
6. Close the main board bracket (1 knob screw).
7. Open the developer exit cover [C] (1 screw).
CAUTION: When opening the cover, the developer right away will fallon the paper.
[A]
[C]
[B]
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8. Turn on the main switch.
9. Turn on the DPS101-7 and 101-8 on the main board to enter the output
check mode.
10. Enter output check No.1 to turn on the development motor. (See Output
Check Mode Access Procedure.)
The development rollers will start turning and the remaining developer [A]
inside the development unit will pour out onto the paper [B]. After about15 minutes, nearly all of the developer will be out of the development unit.
NOTE: To remove all the developer, lift the left side [C] of the copier asshown.
11. Press the Copy Exit Way key to turn off the development motor.
12. Pour the old developer into a plastic bag for disposal.
13. Reinstall the all covers except the middle right cover.
14. Install the new developer.
NOTE: After installing the new developer, perform the Initial
Conditioning (SP#5) and Toner Density Sensor VoltageAdjustment (SP#35).
[B]
[A]
[C]
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5.2 TONER DENSITY SENSOR VOLTAGE ADJUSTMENT
ADJUSTMENT STANDARD Adjusting VR
4 ± 0.1 V VR105 SP#35
NOTE: This adjustment must be done only when the new developer is
installed.
1. Remove the middle right cover.
2. Turn on the main switch.
3. Turn on DPS-101-8 on the main board to enter the SP mode.
4. Select SP#35. (See Service Program Mode Access Procedure) and
press the Copy Exit Way key.
5. Adjust the toner density sensor voltage to 4 ± 0.1 V by turning VR105 on
the main board [A]. (The voltage will be displayed on the operation panel.)
6. Press the Copy Exit Way key and turn off DPS101-8 and the main switch.
[A]
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5.3 DEVELOPMENT FILTER REMOVAL
1. Open the middle unit.
2. Remove the middle right cover.
3. Open the main board bracket (1 screw).
4. Remove the development filter [A] (1 screw).
[A]
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5.4 DEVELOPER DISTRIBUTION ADJUSTMENT
NOTE: If uneven image density appears on copies or the service call
code "Ed" is displayed, this adjustment is required.1. Open the original feed unit.
2. Open the toner cartridge cover and take out the toner cartridge.
3. Check if that the developer moves to the right or left.
If yes, proceed with the following steps.
4. Adjust and correct the machine level.
5. Remove the original exit guide [A] (2 screws).
6. Turn the left [B] and right [C] eccentric cams clockwise or
counterclockwise.
If the developer moves to the right, turn the left and right eccentric cams
clockwise ("+" direction).
If the developer moves to the left, turn the left and right eccentric cams
counterclockwise ("– " direction).
7. Check the copy quality and machine condition.
[A]
[B]
[C]
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5.5 TONER DENSITY SENSOR REPLACEMENT
1. Open the middle unit.
2. Open the toner cartridge cover and take out the toner cartridge.
3. Remove the development filter. (See Development Filter Removal.)
4. Remove the original exit guide [A] (2 screws).
5. Remove the middle right cover.
6. Remove a screw [B] and push down the harness bracket [C].
7. Remove the toner cartridge holder [D] (Right......2 screws,
Left.........loosen 1 screw).
8. Remove the toner density sensor holder [E] (2 screws and 1 connector).
9. Remove the toner density sensor [F] from the holder.
NOTE: After replacing the toner density sensor, replace the developer,perform Initial Conditioning (SP#5) and Toner Density Sensor
Voltage Adjustment (SP#35).
[E]
[D]
[F]
[C]
[B]
[A]
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5.6 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT
ADJUSTMENT STANDARD Adjusting VR
DC –200 ± 2 V VR301
1. Remove the middle right and left cover.
2. Set the multimeter range to dc 1500 V and connect the multimeter leadsas shown.
3. Turn on the main switch.
4. Turn on DPS101-7 and 101-8 on the main board to enter the output
check mode.
5. Enter output check No. 29. (See Output Check Mode Access Procedure.)
6. Press the Plus (+) key until "9" is displayed in the Copy Counter indicator.
Then, press the Copy Exit Way key to apply the bias voltage.
7. Adjust the bias voltage to –200 ± 2 V by turning VR301 on theCharge/Bias/Grid power pack [A].
8. Press the Copy Exit Way key and turn off DPS101-7, 101-8, and the main
switch.
[A]
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5.7 TONER SUPPLY CLUTCH LUBRICATION
1. Remove the C/B/G power pack unit [A] (4 screws, 3 terminals, and 4
connectors) and the development motor unit [B] (5 screws).
2. Remove the toner supply clutch [C] (2 Allen screws) and take it apart.
3. Clean each part and apply grease.
[A]
[B]
[C]
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5.8 DOCTOR GAP ADJUSTMENTADJUSTMENT STANDARD Both ends.......0.5 ± 0.05 mm
Center............0.35 ± 0.05 mm
CAUTION: The doctor gap was adjusted at the factory using specialtools. Therefore, this adjustment is not normally requiredin the field. This adjustment is required only when thedevelopment roller, mixing auger or paddle roller is
replaced.
1. Remove the developer. (See Developer Replacement.)
2. Remove the exposure glass. (See Exposure Glass Removal.)
3. Remove the fiber optics array unit. (See Fiber Optics Array Removal.)
4. Remove the exposure lamp. (See Exposure Lamp Replacement.)
5. Open the toner cartridge cover.
6. Remove the original exit guide [A] (2 screws).
7. Remove the seven sets of guide rollers [B] (2 screws each).
8. Remove the toner density sensor harness [C] from the cover plate clamp
[D] and remove the upper [E] and lower [F] cover plates (3 screws).
[A] [B]
[C]
[D]
[E]
[F]
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9. Remove the front exposure glass holder [A] (4 screws).
NOTE: Do not loosen the two paint locked screws securing the holder.
10. Loosen the two screws [B] securing the doctor blade [C].11. Insert the 0.35 mm DG gauge [D] in the center position of the doctor gap.
12. Insert the 0.5 mm DG gauge [E] in the rear position of the doctor gap.
13. While pressing down the doctor blade directly between the two gauges,
tighten the rear screw [F].
14. Remove the 0.5 mm DG gauge and reinsert it in the front position of the
doctor gap.15. While pressing down the doctor blade directory between two gauges,
tighten the front screw [G].
16. Remove the two DG gauges and reassemble the machine.
[A]
[B]
[C]
[G]
[F][E]
[D]
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5.9 PHOTOCONDUCTOR GAP ADJUSTMENT
ADJUSTMENT STANDARD 1.0 ± 0.1 mm
CAUTION: The photoconductor gap was adjusted at the factory usingspecial tools. Therefore, this adjustment is not normallyrequired in the field. This adjustment is required only whenthe development roller, mixing auger or paddle roller isreplaced.
1. Follow steps1 to 9 of the Doctor Gap Adjustment.
2. Remove the doctor blade [A] (2 screws and 1 connector).3. Remove the drum and mount a used drum in its place.
NOTE: During this adjustment, the drum will be in contact with the
thickness gauge. Therefore, we recommend you use a used
drum for test.
4. Open the main board bracket [B] (1 screw).
NOTE: Mark the original position of the magnet adjusting plate [C]before removing the plate.
5. Remove the magnet adjusting plate [C] (2 screws).
6. Remove the lamp regulator/CBG power pack assembly [D] (4 screws, 3
terminals, and 4 connectors).
[A]
[C] [B]
[D]
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7. Remove the front left cover [A], and remove the development motor [B] (5
screws).
8. Loosen the adjustment screws [C][D] at both ends of the developmentroller [E].
9. Insert the 1.0 mm thickness gauge [F] between the drum and thedevelopment roller. Set the gap to the adjustment standard while turningthe front [G] and rear [H] positioning gears clockwise or counterclockwise
and tighten the adjustment screws.
10. Reinstall the all units and covers.
NOTE: After reinstalling the doctor blade, adjust the doctor gap.
[B][A]
[C]
[F]
[H]
[D][E]
[G]
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9. Remove the front exposure glass holder [A] (4 screws).
NOTE: Do not loosen the two paint locked screws securing the holder.
10. Remove the doctor blade [B] (2 screws and 1 connector).11. Take out the toner cartridge.
12. Remove a screw [C] and push down the harness bracket [D].
13. Remove the toner cartridge holder [E] (Right: 2 screws, Left: Loosen 1
screw).
[A]
[B]
[E][C][D]
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14. Remove the lamp regulator/CBG power pack assembly [A] (4 screws, 3terminals, and 4 connectors).
15. Remove the front left cover [B] and remove the development motor [C] (5screws).
16. Disconnect the bias terminal [D] (1 screw).
17. Remove the development drive gear [E], left positioning gear [F], left
positioning plate [G] and two bearings [H] (1 C-ring).
18. Remove the auger gear [I] (2 E-rings and 1 bushing).
[A]
[C]
[B]
[H]
[G][F]
[E]
[D]
[I]
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19. Open the main board bracket (1 screw).
NOTE: Mark the original position of the magnet adjusting plate [A]
before removing the plate.
20. Remove the magnet adjustment plate (2 screws).
21. Remove the right positioning gear [B] (1 screw and 1 spacer).
22. Remove a bushing [C] and E-ring [D].
23. Remove the three back spill plates [E] (1 screw).
24. Remove the mixing auger [F].
25. Remove the mixing separator casing [G] (4 screws).
[B]
[C]
[A]
[D]
[E]
[G][F]
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26. Peel off the side seal and pull out the development roller [A].
27. After replacing the development roller, put the side seal at the same
location on the new roller.
28. Adjust the doctor gap and the photoconductor gap. (See Doctor Gap
Adjustment and Photoconductor Gap Adjustment.)
[A]
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5.11 PADDLE ROLLER REPLACEMENT
1. Remove the development roller. (See Development Roller Replacement.)
2. Remove the paddle roller bearing [A] and drive gear [B].
3. Remove the right [C] paddle roller shaft (1 E-rings, 1 spacer, 1 bushing)and replace the paddle roller [D].
4. Adjust the doctor gap and photoconductor gap. (See Doctor Gap
Adjustment and Photoconductor Gap Adjustment.)
[A] [B]
[D] [C]
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6. CLEANING
6.1 CLEANING BLADE REPLACEMENT
1. Remove the drum. (See Drum Replacement.)
NOTE: Cover the drum with paper to prevent the drum from being exposed
to light.
2. Place a sheet of A1 size (D size) paper [A] on the paper transport section.
3. Pull up on the plate spring [B] and remove the cleaning blade [C].
4. Pull the cleaning blade release lever.
5. Install the new blade.
[A]
[C]
[B]
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6.2 USED TONER REMOVAL
1. Remove the middle right cover and open the main board [A] (1 screw).
2. Open the used toner tank cover [B] (1 screw).
3. Disconnect the toner overflow sensor connector [C].
4. Turn the toner collection lever [D] counterclockwise and pull out the used
toner tank [E].
5. Take off the toner collection cap [F] and pour the used toner into a plastic
bag.
6. Clean the toner overflow sensor [G] with a blower brush or equivalent.
[D]
[C][E]
[B]
[A]
[F][G]
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7. QUENCHING
7.1 QUENCHING LAMP CLEANING
1. Remove the charge corona unit. (See Charge Corona Wire Replacement.)
2. Clean the quenching lamp [A] with a blower brush [B].
[B]
[A]
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7.2 QUENCHING LAMP REPLACEMENT
1. Remove the middle left and middle right covers.2. Remove the left and right horizontal covers. (See Left and Right
Horizontal Cover Removal.)
3. Remove the cooling fan motor [A] (2 screws and 1 connector).
4. Remove the press roller plate [B] (4 screws).
5. Remove the 4th press rollers [C] (7 sets ....... 2 screws each).
6. Remove the quenching lamp unit [D] (4 screws).
7. Remove both quenching lamps from the quenching lamp bracket (4
screws each).
[C]
[D]
[A]
[B]
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8. PAPER FEED
8.1 PAPER FEED CLUTCH LUBRICATION
1. Open the middle unit.
2. Remove the left inner cover [A] (7 screws).
3. Remove the clutch collar [B] (Loosen 2 allen screws).
4. Remove the clutch sleeve [C] and spring clutch [D].
5. Clean and lubricate the spring clutch with Mobil Temp. 78.
[A]
[B]
[C][D]
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8.2 1ST/2ND FEED SENSOR REPLACEMENT
1. Remove the middle right cover.2. Remove the upper guide plate [A] (2 screws).
3. Remove the 1st feed sensor bracket [B] with the paper stopper solenoid[C] (2 screws and 2 connectors).
4. Remove the 1st feed sensor [D] from the bracket.
5. Remove the 2nd feed sensor bracket [E] (1 screw and 1 connector).
6. Remove the 2nd feed sensor [F] from the bracket.
[A]
[C]
[B][D]
[F] [E]
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8.3 REGISTRATION SENSOR REPLACEMENT
1. Remove the middle right cover.
2. Remove the cover plate [A] (1 screw).
3. Remove the registration sensor bracket [B] (2 screws and 1 connector).
4. Remove the sensor [C] from the bracket (2 screws).
[A]
[B]
[C]
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13. Open the exit guide unit [A].
14. Remove the left [B] and right [C] screws securing the exit guide unit.
15. Remove a ground screw [D].
16. Disconnect the two connectors [E].
17. Slide the exit guide unit to the left (rear view) and take it out from the
copier frame.
18. Loosen the screw [F] securing the tension sprocket [G] and remove the
paper exit drive chain [H].
19. Remove the two screws [I and J] securing the paper exit unit [K].
20. Remove a ground screw [L] and toothed washer [M].
[A]
[B]
[E]
[D]
[C]
[J]
[K]
[G]
[F][H]
[G] [F] [M] [L]
[I]
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21. Disconnect the two connectors [A] and remove the paper exit unit [B].
22. Remove the lower rear cover [C] (5 screws) and upper rear cover [D]
(4 screws).
23. Remove the small left [E] and right [F] covers (2 screws each).
24. Open the middle unit.
25. Loosen the two screws [G] securing the tension bracket [H].
26. Remove the screw [I] securing the fusing unit.
[A]
[B][E]
[C]
[D]
[F]
[H]
[G]
[I]
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27. Close the middle unit.
28. Remove the fusing drive chain [A] from the hot roller gear [B].
29. Remove the fusing lamp connector [C].
30. Remove the hot roller thermistor connector [D] and the pressure roller
thermistor connector [E].
31. Remove the two screws [F and G] securing the fusing unit [H].
32. Pull out the fusing unit.
[D]
[E]
[G]
[H]
[F] [C]
[A]
[B]
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9.2 FUSING LAMP REPLACEMENT
1. Remove the fusing unit. (See Fusing Unit Removal.)
2. Disconnect the lamp connector [A].
3. Remove the right lamp holder [B] (1 screw).
4. Remove the 2 wire clamps [C] from the left fusing frame (1 screw each).
5. Remove the left stopper [D] (1 screw).
6. Remove the harness cover [E] (2 screws).
7. Remove the left lamp holder [F] (1 screw).
8. Remove the lamp connector [G].
9. Slide out the fusing lamp [H].
10. Carefully slide in the new fusing lamp, lead wire first. Make sure that the
lead wire feeds straight into the hot roller.
[C]
[H]
[E]
[F]
[D]
[C]
[G]
[A]
[B]
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9.3 HOT ROLLER/PRESSURE ROLLER REPLACEMENT
1. Remove the fusing unit. (See Fusing Unit Removal.)
2. Remove the fusing lamp. (See Fusing Lamp Replacement.)
3. Remove the fusing upper cover [A] (4 screws) and the exit guide plate [B](4 screws).
4. Remove the left and right pressure springs [C,D].
5. Remove the entrance guide plate [E] (2 screws).
6. Remove the right stopper [F] (1 screw).
7. Remove two C rings [G], the gear [H], two bushings [I], and two bearings[J].
8. Slide the hot roller [K] to the right and pull it out.
9. Remove two stoppers [L] (1 screw each), then, remove the pressure roller
[M].
[J]
[F]
[J][I]
[G]
[H][K]
[C]
[G]
[I]
[D]
[A]
[B]
[M]
[L]
[L]
[E]
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9.5 HOT ROLLER/PRESSURE ROLLER THERMISTORREPLACEMENT
1. Remove the fusing unit. (See Fusing Unit Removal.)
2. Remove the fusing upper cover (4 screws).3. Take the hot roller thermistor wire out from the clamps [A] (3 clamps, 1
screw each) and remove the hot roller thermistor holder [B] (2 screws).
4. Remove the hot roller thermistor [C] from the holder (2 screws and 1
spring).
5. Remove the left and right pressure springs.
6. Remove the fusing unit lower cover [D] with the exit guide plate [E] (4screws, 1 wire clamp [F]).
7. Remove the pressure roller thermistor holder [G] (2 screws, 1 wire clamp
[H] and bushing [I]).
8. Remove the pressure roller thermistor [J] from the holder (2 screws and
1 spring).
[A] [A]
[B]
[C]
[G]
[H] [F] [I]
[J][D]
[E]
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9.6 FUSING PRESSURE DISTRIBUTION ADJUSTMENT
1. Remove the fusing unit. (See Fusing Unit Removal.)
2. Remove the hot roller and the pressure roller [A]. (See Hot
Roller/Pressure Roller Replacement.)
3. Slide the pressure roller shaft [B] out from the pressure roller.
4. Loosen the four Allen screws on each of the adjustment bearings [C,D].
5. Set the bearings in the desired positions and tighten the Allen screws.
[A]
[C][D] [B]
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10. COPY QUALITY ADJUSTMENT
– General Information –
Image density is affected by the following factors:
(1) Light Intensity
(2) Bias Voltage
(3) Toner Density
(4) Grid Voltage(5) Charge Corona Current
The items listed above must be kept in balance to maintain correct image
density.
In the field, image density should be adjusted first by changing the lightintensity. (Adjust the light sensor voltage.) If results are unsatisfactory,the bias voltage can be changed. Also, if requested by the customer, theoverall image density can be changed by changing the toner density.Normally, this should be kept at the normal position (factory setting).
The grid voltage and charge corona current are carefully adjusted at the fac-tory. Any adjustment out of the adjustment standards will result in over toning,
toner scattering, dirty background, or light image density problems. The grid
voltage and charge corona current adjustment should be done only when re-
placing the Charge/Bias/Grid power pack, or to correct certain problems withimage density after checking all other possible causes.
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10.1 LIGHT SENSOR ADJUSTMENT
When:
1. Every Call
2. When replacing the following part• Exposure lamp • Light sensor
• Drum • RAM on the main board
Purpose: To maintain the correct light intensity.
Adjustment
Standard:
Level 2 (10%) of the 9 step gray scale on the OS-
A1 chart should be slightly visible when the 7th
manual image density level is selected.
Perform: Turn VR102 on the main board.
How: Change the light sensor voltage.
1. Turn off the main switch.
2. Clean the following parts:
Item No. Section Method
(1)Optics (Exposure glass, fiberoptics array)
Damp cotton and drysoft cloth
(2)ID sensor Dry cloth or blower
brush
(3)Corona wires (charge, transfer
and separation) and casing.
Dry cloth
(4)
QL, PTL Dry cloth or blower
brush
3. Remove the middle right cover.
4. Make several copies at manual image density level 7 with OS-A1 chart.
5. Confirm that level 2 (10%) of the 9 step gray scale is slightly visible on thecopy. If the copy image density is not correct, proceed with the following
step.6. Turn VR102 on the main board clockwise or counterclockwise.
If the image density is too dark: Turn VR102 clockwise.
If the image density is too light: Turn VR102 counterclockwise.
7. Confirm that image density is within the adjustment standard.
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10.2 IMAGE BIAS ADJUSTMENT
When:
1. The image is blurred even though the image
density in black solid areas is acceptable.
2. Dirty background, where the problem is notcaused by excess toner and cannot be solved
by adjusting the light sensor voltage.
Purpose: To improve the copy image.
Perform: SP #19
How:Change the development bias voltage for image
density control by SP #19.
Data (SP #19) 0 1 2 3 4
Change of biasvoltage (volts)
±0 +40 +20 – 20 – 40
Image Density Normal Darkest Darker Lighter Lightest
1. Make a copy after adjusting the light intensity.
2. If the image is blurred:
Decrease bias voltage by one step and readjust light intensity.
If the background is dirty:
Increase bias voltage by one step and readjust light intensity.
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10.3 TONER DENSITY ADJUSTMENT
When:Customer wants to change the overall image
density of the copies.
Purpose: To change toner concentration insidedevelopment unit.
Perform: SP #18
How:Change the development bias voltage for the ID
sensor pattern by SP #18
10.4 TONER SUPPLY RATIO SELECTION
When:The factory setting for toner supply amount is not
appropriate for the type of original in use.
Purpose: To adjust the toner supply amount.
AdjustmentStandard:
15% (Factory Setting)
Perform: SP #17
How:Change the toner supply solenoid on period bySP #17.
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10.5 ID SENSOR VOLTAGE (Vsg) ADJUSTMENT
When:
1. Check Vsg at every call, and adjust Vsg if it is not withinthe adjustment standard.
2. At replacement of the following parts: • ID sensor • Drum • RAM on the main board.3. A toner supply problem occurs.
Purpose: To make sure that the ID sensor works correctly.
Adjustment
Standard:
Vsg = 4.0 ± 0.1 volts
Perform: SP #33
How:Change the light intensity of the ID sensor LED by VR104.The Vsg voltage is displayed on the operation panel.
1. Turn off the main switch and clean the following parts:
Item No. Section Method
(1)Optics (exposure glass, fiber opticsarray)
Damp cotton and dry soft cloth
(2) ID sensor Dry cloth or blower brush
(3)Corona wires (charge, transfer, andseparation) and casing
Dry cloth
(4) QL, PTL, Dry cloth or blower brush
2. Remove the middle right cover.
3. Turn on the main switch.
4. Turn on DPS101-8 on the main board to enter the SP mode.
5. Select SP#33 (See Service Program Mode Access Procedure) and press
the Copy Exit Way key.
6. Check Vsg. Adjust Vsg by turning VR104 on the main board [A] if Vsg is
not within the adjustment standard.
[A]
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10.6 ADS (Auto Image Density Sensor) ADJUSTMENT
When: ADS voltage is not within the adjustment standard.
Purpose: To maintain correct ADS mode operation.
AdjustmentStandard:
ADS Reference Voltage = 3.0 ± 0.1 volts
Perform: SP #37
How:
Change the ADS reference voltage by VR103.
The voltage reading is displayed on the operationpanel.
1. Clean the white plate and auto image density sensor.
2. Remove the middle right cover.
3. Turn on the main switch.
4. Turn on DPS101-8 on the main board to enter the SP mode.
5. Select SP#37 (See Service Program Mode Access Procedure) and pressthe Copy Exit Way key.
6. If the voltage is not within the adjustment standard, adjust it by turning
VR103 on the main board [A].
[A]
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10.7 REGISTRATION ADJUSTMENT
10.7.1 Registration Adjustment for Manual Feed and Sheet Feeder
When: Registration is not within the adjustment standard.
Purpose: To maintain proper registration.
Adjustment Stand-ard:
0 ± 2 mm (0 ± 0.08")
Perform:SP #26 (0.25 mm/step, 9 steps) orSP #27 (1 mm/step, 10 steps)
How:Change the registration roller start timing by SP #26 or SP#27.
1. Adjust the original registration sensor voltage as follows:
ADJUSTMENT STANDARD +2.6 ± 0.1 V
1) Remove the middle right cover.
2) Set the multimeter range to dc 20 V and connect the multimeter leadsas shown.
3) Turn on the main switch.
4) Adjust the voltage by turning VR101 on the main board [A] if the
voltage is not within the adjustment standard.
2. Make several copies by using the manual feed or sheet feeder and check
the registration.
3. Adjust the registration using SP #26 if the registration is not within theadjustment standard.
4. If the registration is not within adjustment standard using SP #26, adjust
the registration using SP #27.
[A]
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10.7.2 Registration Adjustment for Roll Feeder.
When: Registration is not within the adjustment standard.
Purpose: To maintain proper registration.
Adjustment
Standard:0 ± 3 mm (0 ± 0.12")
Perform:SP #78 (0.25 mm/step, 9 steps) orSP #79 (1 mm/step, 10 steps)
How:Change the registration roller start timing by SP
#78 or SP #79.
1. Adjust the original registration sensor voltage. (See Step 1 of Registration
Adjustment for Manual Feed and Sheet Feeder.)
2. Make several copies by using the roll feeder and check the registration.
3. Adjust the registration using SP #78 if the registration is out of adjustment
standard.
4. If the registration is not within the adjustment standard using SP #78,
adjust the registration using SP #79.
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10.8 ORIGINAL SKEW ADJUSTMENT
When: Original skew is not within the adjustment standard
Purpose: To correct skew
Adjustment
Standard:
0 ± 2 mm (0 ± 0.08")/400 mm (15.7")..... A1 Sideways
(10 multi copies)
0 ± 2.5 mm (0 ± 0.10")/400 mm (15.7")... A0 Lengthwise
(5 multi copies)
Perform: Turn the eccentric cam clockwise or counterclockwise.
How: Change the rear turn guide plate position.
1. Make several copies and check the copy image.If a skew image occurs, proceed with the following steps.
2. Open the original feed unit.3. Remove the top left and right covers.
4. Set the rear original table [A] to the down position.
5. Remove the original feed rear cover [B] (3 screws).
[A]
[B]
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6. Loosen the screw [A] securing the tension bracket [B] and move the
bracket upward.
7. Loosen the four screws [C] securing the rear turn guide bracket [D].
8. Turn the eccentric cam [E] clockwise or counterclockwise.
9. Confirm that the copy image is within the adjustment standard.
[A]
[B]
[C]
[D]
[C]
[C]
[E]
x
y
x
y
Copy paper
Copy image
x
If copy image x occurs, turn the eccentric cam counterclockwise.
If copy image y occurs, turn the eccentric cam clockwise.
y
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11. OTHERS
11.1 LOWER OZONE FILTER REPLACEMENT
NOTE: If the sheet feed is not installed, skip step 1.
1. Open the sheet feeder unit [A] and remove the safety switch cover [B]
(2 screws).
2. Open the middle unit.
3. Remove the right inner cover [C] and support bracket [D] (5 screws).
4. Open the used toner tank cover [E] (1 screw).
5. Remove the lower right cover [F] (5 screws or 7 screws).
6. Replace the lower ozone filter [G].
[A]
[B]
[C]
[D]
[G][E]
[F]
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11.2 ORIGINAL ENTRANCE SENSOR AND SWITCH BACKGATE SENSOR
1. Open the original feed unit.
2. Remove the top right cover.
3. Set the rear original table [A] to the down position.
4. Remove the original feed rear cover [B] (3 screws).
5. Remove the original entrance sensor bracket [C] (2 screws and 1connector).
6. Remove the original entrance sensor [D] from the bracket (1 screw).
7. Remove the switch back gate sensor bracket [E] (1 screw and 1
connector).
8. Remove the switch back gate sensor [F] from the bracket (1 screw).
[A]
[B]
[C]
[D] [E] [F]
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SECTION 6
TROUBLESHOOTING
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1. TROUBLESHOOTING FOR COPY IMAGE
1.1 ABNORMAL COPY IMAGE
1.1.1 Low Image Density (Entire Copy Image)
Is toner supplied to the development unit?
Yes No
Toner the cartridge set properly?
Yes No
Set the toner cartridge properly or replace the cartridge if broken.
Toner density in the development tank may be too low.
⇒ Change ID sensor bias position from 0 to 2.
Is there sufficient toner in the cartridge?
Yes No
Toner supply amount may be low due to toner near end.
⇒ Replace the toner cartridge.
Toner supply system may not catch up with large black area on copy image.
⇒ Make white copies.
1.1.2 Low image density (partial copy image)
Partial void image?
Yes No
Transfer corona may leak or the development roller may not rotate.
⇒ Replace transfer corona end blocks or check the development drive section.
Charge corona may leak.
⇒ Replace charge corona end blocks.
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1.1.3 Uneven Copy Image
Developer level in the development unit?
Yes No
Developer may not be level in the development unit.
⇒ Check and correct the machine level.
Charge corona height may not be even.
⇒ Adjust the charge corona height and drum current if necessary.
1.1.4 Copy Image not Sharp
Is image density of solid areas too high?
Yes No
Is the light intensity setting proper?
Yes No
Adjust light intensity.
Jitter image?
Yes
Fix jitter problem.
Toner density may be high.
⇒ Change the ID sensor bias position from 0 to 1.
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1.2 DIRTY BACKGROUND
1.2.1 Dirty Background (entire Copy Image)
Is the original background pure white?
Yes No
Was ADS or Manual ID control selected?
ADS Manual
Is image density of solid areas high?
Yes No
Light intensity may be too low.
⇒ Clean the optics and adjust light intensity if necessary.
Toner density in the development unit may be too high.
⇒ Change the ID sensor bias position from 0 to 1.
ADS is not adjusted properly.
⇒ Adjust ADS.
Do dirty backgrounds still occur at lighter exposure setting?
Yes No
Light intensity may be too low.
⇒ Clean the optics and adjust light intensity if necessary.
Is the image density of solid areas high?
Yes No
Light intensity may be too low.
⇒ Clean optics and adjust light intensity if necessary.
Toner density in the development tank may be too high.
⇒ Change ID sensor bias position from 0 to 1.
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1.2.2 Partial Dirty Background
Does the dirty background area change position at each copy cycle?
Yes No
Is image density of solid areas high?
Yes No
Dirty optics or foreign material may obstruct the light path.
⇒ Clean optics and check the light path.
Cleaning function may not work properly.
⇒ Check and fix the cleaning unit.
Toner density in the development unit may be too high.
⇒ Change ID sensor bias position 0 to 1.
Does the dirty background area move if you reverse the ends of the drum?
Yes No
Drum sensitivity may not be even.
⇒ Replace the drum.
Light intensity may not be even.
⇒ Clean the optics and/or replace the fluorescent lamp.
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1.2.3 Dirty Background Band
Vertical band?
Yes No
Horizontal band?
Yes No
The fusing rollers may be dirty if background only appears at the copy leadingedge.
⇒ Clean or replace fusing rollers.
Lead from development unit if bands occur at 37 mm intervals.
⇒ Check and fix the development bias leakage.
Drum scratch if the bands are at 251 mm intervals.
⇒ Clean or replace the drum.
Is the edge of the dirty background band sharp?
Yes No
Charge corona grid may be dirty.
⇒ Clean charge corona unit.Exposure glass or fiber optics may be dirty.
⇒ Clean the exposure glass or fiber optics.
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1.2.4 Dirty Background Lines
Vertical lines?
Yes No
Horizontals?
Yes No
The fusing rollers may be dirty if lines appear only at the copy leading edge.
⇒ Clean and/or replace the fusing rollers.
Drum scratch if lines appear 251 mm interval.
⇒ Clean and replace the drum if necessary.
Do the lines appear when a plain white original is copied?
Yes No
Drum scratch.
⇒ Adjust light intensity. Replace the drum if lines are still visible.
Dirty exposure glass or cleaning blade damage.
⇒ Clean the exposure glass or replace the cleaning blade.
1.2.5 Random Dirty Background
Light dirty background?
Yes No
Toner may be falling from the cleaning unit or pick-off pawls.
⇒ Check and fix cleaning unit and pick-off pawls.
Is image density of solid areas high?
Yes No
Unknown.
⇒ Check around the drum.
Toner density in the development unit may be too high.
⇒ Change ID sensor bias position from 0 to 1.
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1.3.3 Partial Void Image
Paper wrinkling at void area?
Yes No
Does paper wrinkling still occur after replacing paper?
Yes No
Does paper wrinkling still occur when using manual feed?
Yes
Check and repair the paper feed and transfer section.
Paper has absorbed moisture.
⇒ Replace paper.
Paper wrinkling due to malfunction of the paper feed mechanism causes void area.
⇒ Check and repair the paper feed section.
1.3.4 Leading Edge Void Area
Do void areas appear only at the paper leading edge?
Yes
Transfer entrance mylar gap is too narrow.
⇒ Adjust transfer entrance mylar gap.
1.3.5 Trailing Edge Void Area
Do void arrears appear in line image areas as well as solid areas?
Yes No
PTL off timing is not set properly.
⇒ Change PTL off mode.
Transfer corona current is too high.
⇒ Clean the transfer corona unit and adjust the current if necessary.
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2. TROUBLESHOOTING SC CODES
2.1 SERVICE CALL (SC) CONDITION
2.1.1 SC Code E2 - Fusing Thermofuse Open
Definition:The temperature detected by the hot roller thermistor does not reach 100°C
within 4 minutes after the main switch is turned on.
<Points to check>• Fusing thermofuse
• Hot roller thermistor
• AC controller 1
2.1.2 SC Code E3 - Hot Roller Thermistor Open
Definition:The temperature detected by the hot roller thermistor does not reach 20°C
within 2 minutes after the main switch is turned on. (The resistance of the hot
roller thermistor is more than 126.5 KΩ.)
<Points to check>• Hot roller thermistor
• Main Board (CN110-11, CN110-12)
2.1.3 SC Code E4 - Hot Roller Thermistor Short
Definition:
The resistance of the hot roller thermistor is less than 0.1 KΩ within 2 minutesafter the main switch is turned on.
<Points to check>• Hot roller thermistor
• Main Board (CN110-12)
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2.1.4 SC Code E5 - Pressure Roller Thermistor Open
Definition:
The resistance of the pressure roller thermistor is more than 1 mΩ within 2minutes after the main switch is turned on.
<Points to check>• Pressure roller thermistor
• Main Board (CN110-9, CN110-10)
2.1.5 SC Code E6 - Pressure Roller Thermistor Short
Definition:
The resistance of the pressure roller thermistor is less than 0.5 KΩ within 2minutes after the main switch is turned on.
<Points to check>• Pressure roller thermistor
• Main Board (CN110-10)
2.1.6 SC Code E8 - Exposure Lamp Thermistor Short
Definition:
The resistance of the exposure lamp thermistor is less than 2.4 KΩ for 20 sec-
onds.
<Points to check>• Exposure lamp thermistor
• Exposure lamp heater
• AC controller 2 (CN407-4, CN407-3)
• Main Board (CN107-B3)
2.1.7 SC Code E9 - Fusing Overheat
Definition:The temperature detected by the hot roller thermistor becomes higher than220°C.
<Points to check>• Hot roller thermistor
• Fusing thermofuse
• AC controller 1 (T304/T306 for AC input voltage, T305/T307)
• Main Board (CN107-A25, CN107-A15)
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2.1.8 SC Code EA - Fusing Warm-up Error
Definition:The temperature detected by the hot roller thermistor does not reach the tar-get ready temperature within 12 minutes.
<Points to check>• Hot roller thermistor
• Fusing thermofuse
• AC controller 1 (T304/T306 for AC input voltage, T305/T307)
• Main Board (CN107-A25, CN107-A15)
2.1.9 SC Code Eb -Pulse Generator Abnormal
Definition:The main board does not receive a pulse from the pulse generator for 1 sec-
ond while the main motor is on.
<Points to check>• Connection of the pulse generator connector terminal
• Pulse generator disc (turning or not)
• Main board (CN112-1, CN112-3)
2.1.10 SC Code EC - Total Counter Abnormal
Definition:Total counter does not operate.
<Points to check>• Total counter and its connection
• Main board (CN107-A14, CN107-B19, CN107-A20)
2.1.11 SC Code Ed - Toner Density Sensor Abnormal
Definition:The toner density sensor voltage is less than 1.6 volts or more than 4.7 volts
for 1 minute.
<Points to check>• Toner density sensor
• Flow of the developer at the toner density sensor area
• Main board (CN101-1, CN101-2, CN101-3)
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2.1.12 SC Code No Code (SP58) - *Exposure Lamp Abnormal
Definition:The light sensor voltage is less than 0.45 volts for 20 seconds.
<Points to check>• Exposure lamp
• Light sensor
• Lamp Regulator (CN1-1/CN1-2 for AC input voltage, CN3-1/CN3-
2/CN3-4/CN3-5)
• Main board (CN107-A5 for PWM, CN102-7 for Light Sensor out)
2.1.13 SC Code No Code (SP59) - *Exposure Lamp Thermistor Open
Definition:
The resistance of the exposure lamp thermistor is more than 248 Ω for 20
seconds.
<Points to check>• Exposure lamp thermistor
• Exposure lamp heater
• AC controller 2
• Main board (CN107-B4, CN107-B1)
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2.1.14 SC Code No Code (SP61) - *ID Sensor Abnormal
Definition:Vsg goes below 2.5 volts or Vsp goes above 2.5 volts.
<Points to check>• ID sensor
• ID sensor pattern
• Toner supply mechanism
• Drum
• Developer
• Development bias
• Charge corona
• Erase lamp
• Main Board (CN102-15, CN102-12)
NOTE: 1. For the above three service call conditions (*), the CallService indicator does not light and copying is possible.
These codes can be displayed using SP58, SP59 or SP61.
For all other codes, the Call Service indicator turns on and
the machine stops.
2. When the service call conditions (E2, E3, E4, E5, E6, E9 andEA) occur, for safety reason they cannot be cleared by
turning the main switch off and on. The following proceduremust be performed to clear these service call conditions:
(1) Turn off the main switch.
(2) Change the position of DPS102-8 on the main board from
OFF to ON or from ON to OFF.
(3) Turn on the main switch.
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74
72
73
7675
79
85
84
83
82
80
81
86
87
8877
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90
89
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63
61
62
646566
6768
6970
71
5859
60
49
47
48
50
51
5253 54 55 56
57
32333435363738
3940
4142
43
44
45
46
1
23
4
56
8 9 10 11 12 1314
1516
1718
19
20
21
22
23
24
25
26
2728
2930
31
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Name Index. No. P to PLocation
Motors
Main 5 A9
Development 1 A10
Exhaust Fan 25 B7
Cooling Fan 6 B7
Vacuum Fan 68 B8
Paper Feed 77 K13
Cutter 83 K13
Magnetic Clutches
OriginalForward Feed
52 F17
Registration 50 F17
Original Reverse
Feed
8 E17
Solenoids
Toner Supply 46 G17
Pattern Shutter 19 G17
Exit Gate 24 G17
Pick-off Pawl 34 F17
Paper Stopper 40 F17
Manual Feed 48 E17
Recycle Gate 26 E17
Switch Back
Gate
9 E17
Original Stopper 43 D17
Sheet Feeder 1 72 I12
Sheet Feeder 2 73 I12
Paper Pull Out 89 K12
Switches
Main 65 A4
Upper Safety 27 A3
Lower Safety 67 A2
Name Index. No. P to PLocation
Rear Safety 22 A3
Toner Cover 45 G16
Sheet Feeder
Set
64 B9
Rear Feeder 21 I4
Feed Pressure 76 I10
Unit Set 81 K14
Upper Door
Safety
86 K14
Middle DoorSafety
84 K14
Lower Door
Safety
85 K14
Sensors
Image Density 33 G2
Toner Density 36 H2
Toner Overflow 28 H2
Pulse Generator 23 I5
Original Set 41 I5
1st Original
Transport
11 I5
2nd OriginalTransport 14 I6
Original Registra-
tion
12 I6
Light 4 C7
Original Entrance 13 I7
Switch Back
Gate
10 I8
Original Exit 39 I7
Recycle Gate 30 I7
1st Feed 38 I8
2nd Feed 37 I8
Registration 35 I9
Transport 71 I9
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Name Index. No. P to PLocation
Fusing Exit 17 I9
Upper Exit 16 I10
Lower Exit 18 I10
Paper Entrance 74 I11
Paper End 75 I11
Paper End 82 K14
Left Cutter 87 K16
Right Cutter 80 K15
Name Index. No. P to PLocation
Transfer/
Separation
54 F2
Thermistors
Hot Roller 56 B6
Pressure Roller 58 B5
Exposure Lamp 44 B9