Page 1 SECTION 1 OVERALL MACHINE INFORMATION...
Page 2: Specifications
6 January 1990 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: 5 cpm (A1/D sideways) Tray feed: 6 cpm (A1/D sideways)
Page 3 6 January 1990 Image Transfer: Single wire dc corona (negative charge) with pre-transfer lamp Paper Separation: Dual wire ac corona and pick-off pawls Cleaning: Cleaning blade Quenching: Photo quenching by LEDs Paper Feeding: Manual feed (auto sheet feeder optional) Image Fusing: Heat and pressure type, teflon (upper) and silicone rubber (lower) rollers Fusing Lamp:...
Page 4: Operator Controls
6 January 1990 2. OPERATOR CONTROLS 2.1 OPERATION PANEL 1. Manual Image Density 2. Lighter Copy Indicator Indicators There are 14 manual ID levels but Show the image density level only 7 manual ID LEDs. The Lighter selected by the Lighter and Darker Copy indicator lights when manual keys.
Page 5 6 January 1990 3. Wait Indicator 15. Copy Counter Indicates that the machine is not ready Displays the number of copies entered, to copy. the number of copies made, and service codes. 4. Select Paper Key Press to select manual feed or the auto 16.
Page 6: Indicator Panel
6 January 1990 2.2 INDICATOR PANEL 1. Insert Original Indicator Lights when the machine is ready for an original to be inserted. Turns off when an original is inserted. 2. Stop Key Press to stop the copier during a copy cycle (emergency stop). 3.
Page 7: Drum Processes
6 January 1990 3. DRUM PROCESSES 1. Charge In 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 high electrical resistance in the dark.
Page 8 6 January 1990 3. Development The 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 Lamp The pre-transfer lamp illuminates the drum prior to image transfer. This reduces the attraction between the toner and the drum, thus making image transfer easier.
Page 9: Mechanical Component Layout
6 January 1990 4. MECHANICAL COMPONENT LAYOUT 15 16 12 13 9 11 1. 1st Feed Detector 15. 2nd Original Transport 28. Hot Roller Detector 2. 2nd Feed Detector 29. Pressure Roller 16. Original Registration 3. Toner Cartridge 30. Transport Belt Rollers 4.
Page 10: Drive Layout
6 January 1990 5. DRIVE LAYOUT 1. Original Drive Belt 2 11. Toner Supply Clutch 21. Fusing Drive Chain 2. Rear Original Feed Rollers 12. Development Motor 22. Drum Drive Belt 3. Original Drive Clutch 13. Paper Feed Clutch 23. Feed/Fusing Drive Belt 1 4.
Page 11: Electrical Component Layout
6 January 1990 6. ELECTRICAL COMPONENT LAYOUT 6.1 MIDDLE AND UPPER SECTIONS 1-10...
Page 12 6 January 1990 6.2 LOWER AND FUSING SECTIONS 1-11...
Page 13 6 January 1990 1. Development Motor 23. Exhaust Fan 46. Fusing Lamp 2. Development Motor 24. Toner Overflow 47. Transfer/Separation Capacitor Sensor 3. Charge/Bias PP 25. Recycle Gate SOL 48. DC Power Supply 4. Lamp Regulator 26. Main Board 49. Hot Roller Thermistor 5.
Page 14: Electrical Component Descriptions
6 January 1990 7. ELECTRICAL COMPONENT DESCRIPTIONS SYMBOL NAME FUNCTION LOCATION Motors Main Motor Drives all mechanical components except the development unit and the fans. (100 Vac) Development Drives the development unit. (100 Vac) Motor Exhaust Fan Removes heat from around the fusing Motor unit.
Page 15 6 January 1990 SYMBOL NAME FUNCTION LOCATION SOL9 Original Stopper Moves the original stopper down to Solenoid prevent an original from being inserted. SOL10 Auto Feeder So- Turns the paper feed roller of the auto ---- lenoid 1 sheet feeder. SOL11 Auto Feeder So- turns the relay rollers of the auto sheet ----...
Page 16 6 January 1990 Original Exit De- Monitors movement of the original. tector Recycle Gate Detects whether the recycle gate is in Detector the up or down position. 1st Feed Detects when copy paper is inserted. Detector 2nd Feed Monitors copy paper movement Detector between the manual feed rollers and the registration rollers.
Page 17 6 January 1990 SYMBOL NAME FUNCTION LOCATION Lamps Exposure Lamp Provides light to reflect the original’s image onto the drum. Quenching Neutralizes any charge remaining on Lamp the drum surface after cleaning. Fusing Lamp Provides heat to the fusing unit. Pre-Transfer Reduces the charge on the drum Lamp (PTL)
Page 18 6 January 1990 SYMBOL NAME FUNCTION LOCATION Others Total Counter Keeps track of the total length of copies made. Noise Filter Filters electrical noise on the ac power input lines. Transformer Steps down the line voltage to 100 ---- Vac. Triac Provides ac power to the fusing lamp.
Page 19: Ac Power Distribution
6 January 1990 8. AC POWER DISTRIBUTION Interlock Switches Main Switch C.B SW3 SW4 SW2 (SW1) Trans- N. F fomer Anticonden- Neutral sation Heater T304 Thermofuse(x2) T306 Exhaust T307 T305 Fusing Lamp(L3) T309 T1 Controller 1 T310 G (PCB3) Triac Cooling T308 Lamp...
Page 20 6 January 1990 The preceding schematic shows how ac power is distributed in this machine. The ac power from the wall outlet passes through the noise filter, circuit breaker, and three interlock switches to the transformer and to ac controller AC controller 1 powers the fusing lamp with direct wall outlet ac power.
Page 21: Dc Power Supply
6 January 1990 9. DC POWER SUPPLY CN2-1 CN1-1 AC LINE C. GND CN2-2 DC5V CN2-3,4,5 A. GND CN2-6,7,8 CN1-3 DC24V AC NEUTRAL Above is a simplified schematic of the dc power supply. The dc power supply provides +5 volts (Vc) and +24 volts (Va) from CN2-2 and CN2-7 respectively to the main board.
Page 22: Detailed Section Descriptions
SECTION 2 DETAILED SECTION DESCRIPTIONS...
Page 23: Handling The Drum
6 January 1990 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 elec- trical resistance of the OPC drum is high in the absence of light.) •...
Page 24: Drum Drive
6 January 1990 1.3 DRUM DRIVE The OPC drum [A] is 80 millimeters in diameter and 970 millimeters long. It turns constantly when the main motor [B] is on. When the main motor turns on, drive is transmitted to the drum as follows: ⇒...
Page 25 6 January 1990 2. CHARGE 2.1 OVERVIEW Charge Grid 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].
Page 26: Charge Corona Circuit
6 January 1990 2.2 CHARGE CORONA CIRCUIT DC Power Charge / Bias PP CN1-1 24V Va CN1-2 CN107 Main Board -B14 DC/DC CN1-3 Converter Charge CN110 Grid Drive CN1-6 DC/DC Grid monitor CN1-10 Converter The main power supply board supplies +24 volts (Va) to the charge/bias power pack as the power supply source.
Page 27 6 January 1990 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]. During exposure, the original moves across the exposure glass at the same speed as the drum’s peripheral velocity. The platen roller [D] presses the original [E] flat against the exposure glass [F] just above the fiber optic array.
Page 28: Original Feed
6 January 1990 3.2 ORIGINAL FEED 3.2.1 Basic Operation When the original is inserted on the original table [A], it activates the original set detector [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], rear original feed rollers [D], and original registration rollers [E].
Page 29 6 January 1990 3.2.2 Drive Mechanism Drive power from the main motor is provided to the original transport mechanism from the original drive pulley through original drive belt 2 [A]. When the original drive clutch [B] is energized, original drive belt 3 [C] starts turning the front original feed rollers and the original registration rollers.
Page 30 6 January 1990 3.3 ORIGINAL STOPPER MECHANISM Originals should not be inserted during a copy cycle. To prevent originals from being inserted, the machine locks the feeler of the original set detector in the down position while copying. This is accomplished by the original stopper solenoid [A].
Page 31: Exposure Lamp Control
6 January 1990 3.4 EXPOSURE LAMP CONTROL [PCB4] CN1-1 [L1] CN3-1 LAMP Exp. Lamp CN3-2 CN1-2 REGULATOR CN2-1 CN3-4 CN3-5 CN2-2 Lamp OFF (+5V) Lamp ON (GND) CN2-2 T = 1.0 ms Duty = 15% to 100% The lamp regulator receives 100 volts ac at CN1-1 and CN1-2. It also receives +5 volts, which is used in the lamp regulator’s control circuit, from the main board at CN2-1.
Page 32 6 January 1990 3.5 MANUAL ID CONTROL VS ADS Light Sensor Output (Volts) 10 11 12 13 14 Manual ID Level Darker Lighter 3.5.1 Manual ID Control When in manual image density mode, the user can select one of 14 manual ID levels.
Page 33 6 January 1990 Vod/Vsd VS [V] ∼ 0.18 0.86 ∼ 0.19 0.46 1.74 ∼ 0.47 0.49 1.64 ∼ 0.50 0.53 1.54 ∼ 0.54 0.57 1.45 ∼ 0.58 0.61 1.37 ∼ 0.62 0.65 1.29 ∼ 0.66 0.69 1.21 ∼ 0.70 0.73 1.15 ∼...
Page 34 6 January 1990 3.6 AUTO DENSITY SENSOR (ADS) Center Line 10mm 18 mm Sampled Area 33.5 mm The ADS [A] measures the reflectivity of the original’s background. Based on the 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.
Page 35 6 January 1990 3.6.1 ADS Circuit R404 R401 C404 CN401-1 Vcc(+5V) CN401-3 ADS:OUT IC401 D401 ADS ADJUST IC401 CN401-5 C401 R402 R403 C402 CN401-2 C-GND C403 ADS RESET CN401-4 Vcc(+5V) CN401-6 LAMP401 CN401-7 SENSOR LAMP The ADS circuit is powered by +5 volts, which is provided at CN401-1 for the detection circuit and CN401-6 for the lamp.
Page 36 6 January 1990 3.7 LAMP HEATER This copier uses a fluorescent lamp [A] as the exposure light source. The output of the exposure lamp varies depending on the temperature; low temperatures especially degrade the light output. To prevent fluctuations in temperature from affecting the copy image, the lamp heater [B] keeps the °...
Page 37 6 January 1990 3.8 LAMP HEATER CONTROL CIRCUIT AC 100 V CN401 PCB5 PCB1 CN107 CN407 CN406-1 L. Heater ON CN406-2 CN408 CN407-4 Short Comparator Circuit CN407-3 Input Open The lamp thermistor, which is mounted together with the lamp heater, monitors the lamp temperature.
Page 38 6 January 1990 4. DEVELOPMENT 4.1 OVERVIEW When the main 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 permanent magnets in the development roller attract the developer to the development roller sleeve.
Page 39: Drive Mechanism
6 January 1990 4.2 DRIVE MECHANISM To reduce load on the main motor, the development unit uses a separate drive 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].
Page 40: Cross Mixing
6 January 1990 4.3 CROSS MIXING "Crossmixing" keeps the toner and carrier evenly mixed in the developer and evenly distributes the developer within the development unit. Crossmixing also agitates the developer to generate the necessary triboelectric charge on the toner and carrier particles. The arrows in the above illustration show the developer movement directions within the machine.
Page 41: Toner Density Control
6 January 1990 4.4 TONER DENSITY CONTROL ID Sensor Check Toner Sensor Check Toner ID sensor density normal? low? Toner supply solenoid ON Original longer than 1200 mm? Toner Toner sensor density normal? low? Toner supply Service Call solenoid ON indicator ON The flow chart above illustrates how the copier determines whether or not to add toner.
Page 42 6 January 1990 4.4.1 Image Density Sensor 0.2V Toner is supplied V SP No toner Voltage is supplied. Thres- hold Level Standard Intensity LED Light Intensity Weak Strong Toner density is detected by develop- ing the sensor pattern and by check- ing its reflectivity with the image density sensor (photosensor).
Page 43 6 January 1990 dition, 5.49 meters (=610 mm x 9) can be copied. After that, the toner end condition is reached. The Add Toner indicator will light and the machine will not operate. 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.
Page 44 6 January 1990 4.4.2 Toner Density Sensor Toner Density Sensor (S2) Main Board (PCB1) CN101-1 [24V] Va Control Analog Input [7.0V] (Control) Circuit Coils 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 upper and lower limits of toner density.
Page 45: Development Bias
6 January 1990 4.5 DEVELOPMENT BIAS 4.5.1 Basic Concept When the drum is exposed, most of the negative charge is eliminated from the areas where light strikes the drum. This leaves a negative charge pattern corresponding to the dark areas of the original. After exposure however, a small residual charge of about --100 volts (for white paper) remains in the exposed areas.
Page 46 6 January 1990 Lighter Normal Darker -300 -280 -260 -220 -260 -240 -180 -220 -200 -160 -200 -180 0.18 0.85 0.77 0.73 ADS Vod/Vsd Vod: Original Density Detecting Voltage (ADS out put voltage) Vsd: Standard Pattern (White Plate) Density Detecting Voltage 4.5.3 Auto Image Density Bias The above chart shows the development bias when in ADS mode.
Page 47 6 January 1990 4.6 IMAGE DENSITY SENSOR BIAS The ID sensor bias is similar to the development bias; however, it is applied only when developing the ID sensor pattern. Basically, the ID sensor bias is fixed. The normal ID bias level is --240 volts, but it can be changed using service program #18.
Page 48: Toner Supply
6 January 1990 4.7 TONER SUPPLY To allow a compact design, the toner supply mechanism is built into the toner cartridge. 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.
Page 49: Image Transfer And Paper Separation
6 January 1990 5. IMAGE TRANSFER AND PAPER SEPARATION 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.
Page 50: Pick-Off Mechanism
6 January 1990 5.4 PICK-OFF MECHANISM The pick-off pawl solenoid [A] is energized 12 pulses after the registration solenoid 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.
Page 51 6 January 1990 5.5 T/S CORONA CIRCUIT +24 (Va) [P2] [PCB1] CN1-1 CN107 -B12 T. Trig DC/DC -A13 Converter T. Sel -B13 -5.0 kV S. Trig DC/DC Converter -B11 DC/AC Not Used Inverter AC 4.0 kV DC -200 V CN1-2 A.
Page 52 6 January 1990 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 to the used toner tank.
Page 53 6 January 1990 6.2 COLLECTION OF USED TONER The toner collection coil moves used toner from the cleaning unit through the used 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.
Page 54: Toner Overflow Sensor
6 January 1990 6.3 TONER OVERFLOW SENSOR +5 (Vc) Main Board Toner Overflow Sensor 3] [PCB1] CN107 Freq. -B22 Detec- Rectifier tion The toner overflow sensor [A] signals the CPU when the toner collection bottle is full. A small tuning fork [B] is used as the sensing element of the toner overflow sensor.
Page 55 6 January 1990 7. QUENCHING +24 V Quenching Lamp [2] Main Board [PCB1] CN104 (-B9) After the drum is cleaned, light from the quenching lamp neutralizes any charge remaining on the drum. The quenching lamp turns on and off at the same time as the main motor.
Page 56: Paper Feed And Registration
6 January 1990 8. PAPER FEED AND REGISTRATION 8.1 OVERVIEW In this copier, paper is fed either manually or by the auto sheet feeder (option). For manual feed, the copy paper is inserted until it contacts the manual feed rollers [A]. At that time the paper turns on the 1st feed detector [B], which causes the main motor to turn on.
Page 57: Drive Mechanism
6 January 1990 8.2 DRIVE MECHANISM Drive power from the main motor is provided to the paper feed and registration 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].
Page 58: Paper Transport
6 January 1990 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.
Page 59: Fusing And Paper Exit
6 January 1990 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.
Page 60 6 January 1990 The hot roller strippers [F] separate the copy from the hot roller and direct it to the fusing exit rollers [G]. After the fusing exit rollers, the exit gate [H] directs the copy to either the upper or lower exit rollers [I and J]. When the exit gate solenoid is on, the exit gate directs the copy paper down through the lower copy exit path.
Page 61 6 January 1990 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 drive belts 1 [C] and 2 [D], the sprockets [E] and the fusing drive chain [F], to the hot roller sprocket [G].
Page 62 6 January 1990 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.
Page 63: Fusing Temperature Control
6 January 1990 10.3 FUSING TEMPERATURE CONTROL Overheat Protection AC115,220,240 AC Controller 1 [PCB3] T304 T306 IC107 1.3K CN301 Q101 PC301 CN107-A25 Drive Circuit RA301 CN107-A15 A.GND CN107-B25 T309 T310 T308 T307 T305 CN110-12 CN110-11 CN110-9 CN110-10 10.3.1 Fusing Circuit Operation The fusing lamp is powered by AC controller 1 and controlled by the main board.
Page 64 6 January 1990 10.3.2 Overheat Protection The 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 the voltage at pin 5 of IC107 increases.
Page 65: Temperature Control
6 January 1990 10.4 TEMPERATURE CONTROL Roller Temp. SP #28 SP #29 Pressure Roller Temp. The main board monitors the temperature of the hot roller through TH1 and the 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.
Page 66: Pulse Generator
6 January 1990 11. OTHERS 11.1 PULSE GENERATOR Main Board [PCB1] [S4] CN112-1 CN112-3 CN112-2 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.
Page 67: Operation Panel
6 January 1990 11.2 OPERATION PANEL MAIN BOARD (PCB1) OPERATION PANEL (PCB7) CN106 CN201 -A11 Scan1 -A13 Scan2 Matrix LED Matrix -B11 Scan3 -B13 Scan4 -A12 Scan5 CN106 -B15 CN202 -1 Key 1 -B16 Key 2 -A16 Key 3 Seg a Seg b Seg c Seg d...
Page 68 6 January 1990 11.3 SOLENOIDS Main Board [PCB1] CN-1 [ +24] CN-2 [+24] Va To energize a solenoid, the main board drops CN-1 from +24 volts to 0 volt. The following table gives the main board connector numbers for the sole- noids used in this machine.
Page 69 6 January 1990 11.4 PHOTOINTERRUPTORS Main Board (PCB1) Photointerrupter CN-1 [+5V] CN-3 CN-2 Actuator Plate Photo TR ON Photo TR OFF Output LOW Output OPEN Photointerruptors consist of a plastic encapsulated LED and a phototransistor separated by an open slot. When the slot is empty, light from the LED activates the phototransistor, and the sensor outputs a low (0 volt) signal.
Page 70 6 January 1990 Name Symbol CN-1 CN-3 CN-2 Pulse Generator CN112-1 CN112-3 CN112-2 Original Set Detector CN105-B4 CN105-A5 CN105-B5 1st Original CN105-B2 CN105-A3 CN105-B3 Transport Detector 2nd Original CN105-A1 CN105-B1 CN105-A2 Transport Detector Original Exit CN106-A17 CN106-B17 CN106-B18 Detector Recycle Gate CN106-A17 CN106-B14 CN106-B18...
Page 71: Service Call Conditions
6 January 1990 12. SERVICE CALL CONDITIONS When functional problems occur within the copier, the Call Service indicator ) lights. At the same time, "E" and a code number blink alternatively in the copy counter display. CODE E1 (Abnormal Exposure Lamp) Code E1 blinks if the output voltage of the light sensor drops below 0.45 volts and this condition continues for 20 seconds or more after the exposure lamp on signal is output.
Page 72 6 January 1990 CODE EA (Ready Failure) Code EA blinks if the machine does not reach the ready condition (Ready indicator ON) within 14 minutes after the main switch is turned on. CODE Eb (Abnormal Drive) Code Eb blinks if the pulse generator does not generate pulses for 1 second after the main motor turns on.
Page 73: Installation
SECTION 3 INSTALLATION...
Page 74 6 January 1990 1. ENVIRONMENT 1. Temperature Range: C to 30 C (50 F to 86 2. Humidity range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 Lux (do not expo- sure to direct sunlight). 4. Ventilation: Room air should turn over at least 3 times/hour.
Page 75: Minimum Space Requirements
6 January 1990 1.1 MINIMUM SPACE REQUIREMENTS 600 mm 600 mm 600 mm 1000 mm 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)
Page 76: Power Source
6 January 1990 1.2 POWER SOURCE 1. Input Voltage Level: 115 V/60 Hz..12A 220 V/50 Hz..7A 240 V/50 Hz..7A ± 2. Permissible Voltage Fluctuation: 3. Permissible Extension Cord: At least 300 V, 30 A capacity and less than 5 m (5.5 yd) long. NOTE: a) Be sure to ground the machine.
Page 77: Accessory Check
6 January 1990 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.
Page 78: Installation Procedure
6 January 1990 3. INSTALLATION PROCEDURE 3.1 REMOVAL OF SHIPPING RETAINERS 1. Remove all strips of shipping tape and accessories. 2. Open the original feed unit [A] and re- move the two spac- ers [B] from the platen roller bear- ings, and remove the protective sheet from the exposure...
Page 79 6 January 1990 3. Loosen four screws and remove the right middle cover [C]. 4. Remove the screw [D] fixing the main board bracket [E] and open the board 90 degrees. 5. Remove the plate [F] (4 screws), fixing the right portion of the upper unit on the lower unit.
Page 80 6 January 1990 7. Remove the screw [G] fixing the left portion of the upper unit on the lower unit. 8. Press up the handle [A] and open the middle unit [B]. 9. Install the fixing plate [C] with the two screws.
Page 81: Mounting The Accessories
6 January 1990 3.2 MOUNTING THE ACCESSORIES 1. Mount the left inner cover bracket [A] with two screws. 2. Connect the two connectors [B] of the pick-off pawl unit [C] and fix the unit with two knob screws [D]. Make sure that the two po- sitioning pins of the main copier are in-...
Page 82 6 January 1990 4. Reset the cleaning blade by pulling the release lever [G] to- wards the front side. 5. Close the middle unit and open the re- tention unit. 6. Open the toner car- tridge cover [H]. 7. Place a level [I] in the space between the cartridge cover and the developer...
Page 83 6 January 1990 4. Turn on DIP SW 101-7 and 8 on the main board [C]. 5. Turn on the main switch [D]. 6. Pour of developer into the develop- ment unit evenly as shown. 7. Close the cartridge cover and the origi- nal feed unit.
Page 84: Supplying Toner
6 January 1990 3.4 SUPPLYING TONER 1. Set the toner car- tridge [A] as shown in the figure. 2. Remove the sealing tape [B] on the car- tridge and turn the knob [C] clockwise unit it stops. 3-11...
Page 85 6 January 1990 3.5 INITIAL CONDITIONING 1. Connect the power supply cord with the wall outlet (socket). 2. Turn on DIP SW 101-8. 3. Turn on the main switch. 4. Press the Lighter key [A] four times so that the fourth segment from the right of the copy density indicator...
Page 86 6 January 1990 3.6 MOUNTING THE COVERS 1. Press up the re- lease handle [D] and open the upper unit. 2. Install the right in- ner cover [E] and the bracket [F] on the lower unit. (Use 2 pan-head screws for the bracket.
Page 87 6 January 1990 3.7 MOUNTING GUIDES 1. Install the copy guide [A]. Use the two screws that are already in the cor- rect position on the top unit. 2. Set the two original guides [B] as shown in the figure. 3-14...
Page 88: Service Tables
SECTION 4 SERVICE TABLES...
Page 89: Preventive Maintenance Schedule
6 January 1990 1. PREVENTIVE MAINTENANCE SCHEDULE Symbol key: I = Inspect L = Lubricate R = Replace A = Adjust C = Clean A. Original Feed _________________________________________________ 3.6km 7.2km 10.8km 14.4km 18km Notes (6k) (12k) (18k) (24k) (30k) 1. Front original feed Clean with a roller damp cloth...
Page 90 6 January 1990 C. Development _________________________________________________ 3.6km 7.2km 10.8km 14.4km 18km Notes (6k) (12k) (18k) (24k) (30k) 1. Developer 2. Side seals Replace if damaged 3. Development filter D. Around Drum _________________________________________________ 3.6km 7.2km 10.8km 14.4km 18km Notes (6k) (12k) (18k) (24k) (30k)
Page 91 6 January 1990 Clean when necessary. F. Paper Feed __________________________________________________ 3.6km 7.2km 10.8km 14.4km 18km Notes (6k) (12k) (18k) (24k) (30k) 1. Transport belt Clean with a damp cloth 2. Manual feed rollers Clean with a damp cloth 3. Manual feed table Clean with a damp cloth 4.
Page 92 6 January 1990 H. Auto Sheet Feeder ____________________________________________ 3.6km 7.2km 10.8km 14.4km 18km Notes (6k) (12k) (18k) (24k) (30k) 1. Feed roller Replace at 40K (A1) if necessary. Clean with a damp cloth. 2. Friction pad Clean with a damp cloth. 3.
Page 93: Dip Switches
6 January 1990 2. TEST PINS, VRs, AND DIP SWITCHES 2.1 TEST PINS AND VARIABLE RESISTORS Function Original registration sensor ID sensor Toner density sensor Auto density sensor (ADS) Light sensor ---- Ground ---- Vc (+5 volts) ---- Va (+24 volts) 2.2 DIP SWITCHES Normal Free run (one A1 sideways feed cycle,...
Page 94: Service Tools
6 January 1990 3. SERVICE TOOLS 3.1 SERVICE PROGRAM MODE The service program mode allows you to select or adjust many machine and copy functions from the operation panel. 3.1.1 Access Procedure 1. Turn OFF the main switch 2. Turn ON DIP101-8 on the main board. 3.
Page 95 6 January 1990 Service Program Table Contd. Number ID Setting (1) Lead Edge Function Erase 20 mm Initial Conditioning Lighter Copy 0 ...Normal 15 mm 1 ...Initial Conditioning Auto 10 mm Image Density After set-up, turn off 5 mm DIP101-8 to start initial conditioning.
Page 96 6 January 1990 Service Program Table Contd. Number ID Setting (1) Lead Edge Function Erase 20 mm Default Paper Exit Lighter Copy 15 mm 0 ...Upper Exit Auto 10 mm Image Density 1 ...Lower Exit 5 mm 20 mm Auto Sheet Feeder Lighter Copy (ASF) 15 mm...
Page 97 6 January 1990 Service Program Table Contd. Number ID Setting (1) Lead Edge Function Erase 20 mm ID Sensing Interval Lighter Copy 0 ...1220 mm (Normal) 15 mm 1 ...610 mm Auto 10 mm Image Density 5 mm 20 mm ID Sensor Grid Lighter Copy Voltage Adjustment...
Page 98 6 January 1990 Service Program Table Contd. Number ID Setting (1) Lead Edge Function Erase 20 mm Coarse Registration Lighter Copy Adjustment 15 mm (1 mm/step) Auto 10 mm Image Density 0 ...0 mm 5 mm 1 ...--5 mm 2 ...--4 mm 3 ...--3 mm 4 ...--2 mm 5 ...--1 mm...
Page 99 6 January 1990 Service Program Table Contd. Number ID Setting (1) Lead Edge Function Erase 20 mm ID Sensor Vsg Lighter Copy Adjustment. Adjust 15 mm with VR104 and Auto 10 mm Image Density TP102. Adjust to 5 mm 4.0 ± 0 volts 20 mm ID Sensor Vsg/Vsp Lighter Copy...
Page 100 6 January 1990 Service Program Table Contd. Number ID Setting (1) Lead Edge Function Erase 20 mm Original Jams: Turn Lighter Copy Section 15 mm Auto 10 mm Image Density 5 mm 20 mm Original Jams: Lower Lighter Copy Transport 15 mm Auto 10 mm...
Page 101 6 January 1990 Service Program Table Contd. Number ID Setting (1) Lead Edge Function Erase 20 mm Paper Jams: Others Lighter Copy 15 mm Auto 10 mm Image Density 5 mm 20 mm Service Call Lighter Copy Condition E1 Display 15 mm E = Abnormal Auto...
Page 102 6 January 1990 3.2 INPUT TEST MODE The input test mode allows you to check the current sensor status from the operation panel. 3.2.1 Access Procedure 1. Turn OFF the main switch 2. Turn ON DIP101-6 and --8 on the main board. 3.
Page 103 6 January 1990 Input Test Table Contd. Number ID Setting (1) Lead Edge Sensor Erase 20 mm Lighter Copy Original Registration 15 mm Sensor Auto 10 mm Image Density 5 mm 20 mm Lighter Copy Original Exit Detector 15 mm (S9) Auto 10 mm...
Page 104 6 January 1990 Input Test Table Contd. Number ID Setting (1) Lead Edge Sensor Erase 20 mm Lighter Copy Upper Exit Sensor 15 mm (S16) Auto 10 mm Image Density 5 mm 20 mm Lighter Copy Lower Exit Sensor 15 mm (S17) Auto 10 mm...
Page 105 6 January 1990 Input Test Table Contd. Number ID Setting (1) Lead Edge Sensor Erase 20 mm Lighter Copy Thermistor (TH3) 15 mm Auto Open Signal 10 mm Image Density 5 mm 20 mm Lighter Copy Thermistor (TH3) 15 mm Short Signal Auto 10 mm...
Page 106: Output Test Mode
6 January 1990 3.3 OUTPUT TEST MODE The output test mode allows you to turn individual electrical components ON/OFF from the operation panel. 3.3.1 Access Procedure 1. Turn OFF the main switch 2. Turn ON DIP101-7 and --8 on the main board. 3.
Page 107 6 January 1990 Output Test Table Contd. Number ID Setting (1) Lead Edge Component Erase 20 mm Lighter Copy Recycle Gate 15 mm Solenoid (SOL8) Auto 10 mm Image Density 5 mm 20 mm Lighter Copy Original Feed Clutch 15 mm (MCI) Auto 10 mm...
Page 108 6 January 1990 Output Test Table Contd. 1 2 3 4 5 6 7 8 Number ID Setting (1) Lead Edge Component Erase 20 mm Lighter Copy Auto Feeder 15 mm Solenoid 1 (SOL10) Auto 10 mm Image Density 5 mm 20 mm Lighter Copy Auto Feeder...
Page 109 6 January 1990 Output Test Table Contd. Number ID Setting (1) Lead Edge Component Erase 20 mm Lighter Copy Exposure Lamp 15 mm Heater Auto 10 mm Image Density 5 mm 20 mm Lighter Copy Exposure Lamp Full 15 mm Duty ON Auto 10 mm...
Page 110 6 January 1990 Output Test Table Contd. Number ID Setting (1) Lead Edge Component Erase 20 mm Lighter Copy Exposure Lamp 15 mm (Manual ID level 8) Auto 10 mm Image Density 5 mm 20 mm Lighter Copy Exposure Lamp 15 mm (Manual ID level 9) Auto...
Page 111 6 January 1990 Output Test Table Contd. 1 2 3 4 5 6 Number ID Setting (1) Lead Edge Component Erase 20 mm Lighter Copy Transfer Corona 15 mm Trigger Auto 10 mm Image Density (T.Trig) 5 mm 20 mm Lighter Copy Separation Corona 15 mm...
Page 112 6 January 1990 Output Test Table Contd. Number ID Setting (1) Lead Edge Component Erase 20 mm Development Bias Lighter Copy Levels 10 to 19 15 mm 0 ...--220 V Auto 10 mm Image Density 1 ...--240 V 5 mm 2 ...--260 V 3 ...--280 V 4 ...--300 V...
Page 113 6 January 1990 Output Test Table Contd. Number ID Setting (1) Lead Edge Component Erase 20 mm Grid Voltage Lighter Copy Levels 10 to 19 15 mm 0 ...--560 V Auto 10 mm Image Density 1 ...--600 V 5 mm 2 ...--620 V 3 ...--640 V 4 ...--660 V...
Page 114 6 January 1990 3.4 MEMORY CLEAR MODE The memory clear mode allows you to clear the entire RAM or the following counters. (Certain contents which are set by SP mode will be returned to the original stage [factory setting].) 3.4.1 Access Procedure 1.
Page 115 6 January 1990 4. USER/SALES TOOLS Some of the service programs are also available for use by the user and/or sales staff. These programs are listed in the table below. Access Procedure 1. While simultaneously pressing the Plus, Minus, and C/S keys, turn on the Main Switch.
Page 116 6 January 1990 User/Sales Program Table Contd. Number ID Setting (1) Lead Edge Function Erase 20 mm Default Paper Feed Lighter Copy 15 mm 0 ...Auto Sheet Feeder Auto 10 mm Image Density 1 ...Manual Feed 5 mm 20 mm Default Paper Exit Lighter Copy 15 mm...
Page 117: Service Call Codes
6 January 1990 5. SERVICE CALL CODES Code No. Display(*) Function Conditions Exposure lamp abnormal SP#58 Light sensor <0.45 V for 20 seconds. Fusing thermofuse open Immediate Hot roller < 100 after 4 minutes. Hot roller thermistor open Immediate TH1 resistance 126.5 k Ω...
Page 118: Jam Code List
6 January 1990 6. JAM CODE LIST Access Procedure: 1. When a document jam or paper jam occurs, press and hold the Clear/Stop key. 2. Read the jam code (DJ 001, PJ 021, etc.). NOTE: DJ = Document (original) Jam, PJ = Paper Jam 6.1 DOCUMENT (ORIGINAL) JAMS CODE CAUSE OF JAM...
Page 119: Paper Jams
6 January 1990 Original exit detector leading/trailing edge OFF check. Original is too long. (Maximum: 4 meters) Recycle gate does not return to the original position (up position) when the recycle gate solenoid turns off. Recycle gate does not move to the down position when the recycle gate solenoid turns on.
Page 120 6 January 1990 Upper exit sensor leading edge OFF check. Lower exit sensor leading edge ON check. Lower exit sensor leading edge OFF check. Upper exit sensor trailing edge OFF check. Lower exit sensor trailing edge OFF check. Exit sensor leading edge OFF check. Exit sensor leading edge ON check.
Page 121: Special Tools And Lubricants
6 January 1990 7. SPECIAL TOOLS AND LUBRICANTS DESCRIPTION PART NO. REMARKS Digital Multimeter 54209507 BECKMAN RMS3030 Deluxe Test Lead 54209508 BECKMAN DL241 Accessory Kit Grease ---- Mobil 54479078 400 g/can Temp. 78 Current Measuring A0239520 Drum DG Gauge A0239101 Test Chart OS-A1 A0239503 (10 sheets/set)
Page 122: Replacement And Adjustment
SECTION 5 REPLACEMENT AND ADJUSTMENT...
Page 123: Left Side Cover Removal
6 January 1990 1. COVER REMOVAL 1.1 LEFT SIDE COVER REMOVAL 1. Middle Left Cover • Open the original feed unit [A]. • Remove the middle left cover [B] (4 screws). 2. Top Left Cover • Open the original feed unit. •...
Page 124: Right Side Cover Removal
6 January 1990 1.2 RIGHT SIDE COVER REMOVAL 1. Middle Right Cover • Open the original feed unit [A]. • Remove the middle right cover [B] (4 screws). 2. Top Right Cover • Open the original feed unit. • Remove the top right cover [C] (4 screws). 3.
Page 125 6 January 1990 2. OPTICS 2.1 OPTIC FIBER ARRAY REMOVAL/CLEANING 1. Open the upper unit; then, remove the exposure glass [A]. (4 hexagon head screws) 2. Remove the light sensor unit [B] (1 screw) and discon- nect the plug of the ID pattern shutter unit [C].
Page 126: Exposure Lamp Replacement
6 January 1990 2.2 EXPOSURE LAMP REPLACEMENT 1. Open the upper unit. 2. Remove the middle left and middle right covers. 3. Remove the expo- sure glass. (4 screws) 4. Remove the left lamp socket [A] (2 screws) and discon- nect the 2p [B] and 3p [C] connectors.
Page 127 6 January 1990 2.3 ADS SENSOR ADJUSTMENT ± ADJUSTMENT STANDARD: 3 0.1V 1. Open the upper unit and clean the white plate. 2. Remove the right middle cover. 3. Turn on DIP101-8. NOTE: Voltage can be veri- fied by attaching multimeter leads to TP104 (ADS OUT) and TP106 (GND).
Page 128: Light Sensor Adjustment
6 January 1990 2.4 ORIGINAL REGISTRATION ADJUSTMENT ± ADJUSTMENT STANDARD: DC 2.6 0.1V 1. Remove the middle right cover. 2. Turn on the main switch. 3. Connect the digital multimeter leads. • Attach the negative (common) lead to TP106 (ground) on the main PCB.
Page 129: Drum Replacement
6 January 1990 3. DRUM 3.1 DRUM REPLACEMENT 1. Open the middle unit and press the cleaning unit re- lease lever to the rear. 2. Remove the pick-off pawl unit. (2 knob screws, 2 connec- tors) 3. Loosen the four screws and remove the middle right cover.
Page 130 6 January 1990 8. Remove both left and right drum holders [D]. 9. Disconnect the transfer and separa- tion connectors from the T/S co- rona unit, and re- move the screw fixing the ground wire located on the back side of the T/S corona unit.
Page 131 6 January 1990 11. Close the middle unit and tighten the drum lock knob. 12. Reinstall the cover plate and pick-off pawl unit. (Make sure the two positioning pins are inserted in the two holes of the pick-off pawl unit.) 13.
Page 132 6 January 1990 4. CORONA 4.1 CHARGE CORONA WIRE AND GRID WIRE REPLACEMENT NOTE: 1) Handle new corona wires and grid wires by the ends only. Oil from your hands will cause the wire to deteriorate rapidly, resulting in image problems and/or short corona wire life. 2) Avoid bending the new wires.
Page 133 6 January 1990 6. Install 4 new grid wires. Make sure that the wires are correctly seated in the eight slots in each endblock. 7. Slide a sheet of pa- per under the grid wires. Slide the sheet of paper from one end of the co- rona unit to the other while confirm-...
Page 134 6 January 1990 4.2 CHARGE GRID WIRE VOLTAGE ADJUSTMENT ± ADJUSTMENT STANDARD: -900 1. Turn off the main switch and take off the right middle cover (loosen 4 screws). 2. Turn on DIP101-7 and -8 (output mode) on the main board.
Page 135: Drum Current Adjustment
6 January 1990 4.3 DRUM CURRENT ADJUSTMENT NOTE: a) The drum currents vary with environmental conditions such as humidity and atmospheric pressure. Generally it is not necessary to adjust the drum currents because they have already been adjusted for a range of environments at the factory. b) Drum current adjustment may be required when there are problems with paper separation, incomplete toner transfer, and/or image density.
Page 136 6 January 1990 4.3.2 Charge Corona ± µ ADJUSTMENT STANDARD: DC -295 ± (Output current from charge power pack: 1.1 0.01 mA) 1. Disconnect the charge corona connector high voltage lead and connect it to the digital multimeter positive lead. 2.
Page 137 6 January 1990 4.3.3 Transfer Corona ± µ ADJUSTMENT STANDARD: T1: DC -150 µ T2: DC -250 + 5/-10 1. Generate the transfer corona (1) using output mode No.62. 2. Remove the lower rear cover. ± µ 3. Turn VR T1 (T.Trig) on the TS power pack to obtain DC -150 4.
Page 138: Doctor Gap Adjustment
6 January 1990 5. DEVELOPMENT 5.1 DOCTOR GAP ADJUSTMENT ± Adjustment Standard: 0.6 0.1 mm 1. Remove the expo- sure glass, expo- sure lamp, and the fiber optics array unit. 2. Remove the original exit guide [A] (4 screws). 3. Remove the seven guide roller sets [B] (two screws each).
Page 139 6 January 1990 4. Remove the toner sensor wire har- ness [C] from the cover plate clamp, and remove the two cover plates [D][E] (3 screws). 5. Remove the front exposure glass holder [F] (4 screws). 6. Measure the doctor gap with the DG gauge [G] and ad- just the gap by turn-...
Page 140 6 January 1990 5.2 PHOTOCONDUCTOR GAP ADJUSTMENT ADJUSTMENT STANDARD: 0.75 ± 0.1mm 1. Remove the doctor blade [A] (2 screws and 1 connector). 2. Remove the drum and mount a used drum in its place. 3. Take out the screw securing the main board [B] and swing the board...
Page 141 6 January 1990 6. Remove the front left cover; then, re- move the develop- ment motor [E] (5 screws). 7. Set the PG gauge to 0.75mm and loosen the adjustment screws [F][G] at both ends of the development roller. 8. Check the gap at both ends of the roller with the PG gauge. Set the gap to the adjustment standard and tighten the adjustment screws.
Page 142 6 January 1990 5.3 BIAS VOLTAGE ADJUSTMENT ± Adjustment Standard: -280V 1. Remove the middle left cover. 2. Connect the digital multimeter probes to the bias terminal and the ground. 3. Remove the middle right cover and turn on DIP switches 101-7 and 101-8.
Page 143 6 January 1990 5.4 ID SENSOR VOLTAGE ADJUSTMENT ± ADJUSTMENT STANDARD: 4 0.1V 1. Turn off the main switch and take off the middle right cover. (Loosen 4 screws.) 2. Turn on the main board DIP switch 101-8. 3. Turn on the main switch.
Page 144 6 January 1990 5.5 TONER DENSITY SENSOR VOLTAGE ADJUSTMENT ± ADJUSTMENT STANDARD: 4 0.1V 1. Turn off the main switch and take off the middle right cover. (Loosen 4 screws.) 2. Turn on the main board DIP switch 101-8. 3. Turn on the main switch.
Page 145 6 January 1990 5.6 DEVELOPMENT ROLLER REPLACEMENT 1. Remove the devel- oper. (See "DE- VELOPER REMOVAL".) 2. Remove the top left cover, middle left cover, and left horizontal cover. 3. Remove the top right cover, middle right cover, and right horizontal cover. 4.
Page 146 6 January 1990 9. Remove the mag- net adjustment plate [G] and the development roller adjustment gear [H] (2 screws, 1 spacer, 1 E ring, 1 bushing). 10. Remove the back- spill plates [I] (1 screw). 11. Remove the mixing auger [J] and the mixing separator casing [K] (4...
Page 147 6 January 1990 5.7 PADDLE ROLLER REPLACEMENT 1. Remove the development roller. (See "DEVELOPER ROLLER REPLACEMENT".) 2. Remove the paddle roller bearing [A] and drive gear [B]. 3. Remove the left and right paddle roller shafts [C] and [D] (2 E rings, 2 spacers, 2 bushings) and replace the paddle roller [E].
Page 148: Toner Supply Clutch Lubrication
6 January 1990 5.8 TONER SUPPLY CLUTCH LUBRICATION 1. Remove the C/B/G power pack unit [A] (3 screws, 3 bias leads) and the development motor unit [B] (5 screws). 2. Remove the toner supply clutch [C] (2 Allen screws) and take it apart. 3.
Page 149: Developer Removal
6 January 1990 5.9 DEVELOPER REMOVAL 1. Open the middle unit and lay a sheet of A2 paper (’C’ inch size) un- der the developer exit as shown [A]. 2. Activate the lower safety switch. 3. Remove the upper registration guide plate [B] (1 screw).
Page 150 6 January 1990 5. Turn on DIP SW 101-7 and 8; then, turn on the main switch. Press the Copy Exit Way key [A] to turn on the main motor. Press the Lighter key [B] once. 6. Press the Copy Exit Way key [A] to turn on the de- velopment motor.
Page 151: Used Toner Removal
6 January 1990 5.10 USED TONER REMOVAL 1. Remove the middle right cover and swing open the main board [A] (1 screw). 2. Open the used toner tank cover [B]. 3. Disconnect the toner overflow sensor connector and pull out the tank [C]. 4.
Page 152 6 January 1990 5. Clean the toner overflow sensor [E] with a blower brush or equiva- lent. 5-30...
Page 153: Cleaning Blade Replacement
6 January 1990 6. CLEANING 6.1 CLEANING BLADE REPLACEMENT 1. Open the middle unit and place a sheet of A1 size paper on the pa- per transport sec- tion. (See the illustration.) 2. Remove the pick- off pawl unit, regis- tration cover, and drum.
Page 154 6 January 1990 7. QUENCHING 7.1 CLEANING THE QUENCHING LAMP 1. Remove the charge corona unit. (Refer to the charge corona unit replacement proce- dure.) 2. Clean the quench- ing lamp with a blower brush. 5-32...
Page 155: Quenching Lamp Replacement
6 January 1990 7.2 QUENCHING LAMP REPLACEMENT 1. Remove the middle left and middle right covers. 2. Remove the left and right horizon- tal covers. 3. Remove the cool- ing fan [A]. (2 screws) 4. Remove the press roller plate [B]. (4 screws) 5.
Page 156: Paper Feed
6 January 1990 8. PAPER FEED 8.1 PAPER FEED CLUTCH/REGISTRATION CLUTCH LUBRICATION 1. Remove the middle left cover and the left inner cover. 2. Remove the paper feed clutch [A] and the registra- tion clutch [B]. 3. Take the clutches apart;...
Page 157 6 January 1990 8.2 1ST/2ND FEED DETECTOR REPLACEMENT 1. Remove the middle right cover. 2. Remove the upper guide plate. 3. Remove the 1st feed detector [A] and 2nd feed de- tector [B] assem- blies (1 screw and 1 connector each). 4.
Page 158: Registration Sensor Replacement
6 January 1990 8.3 REGISTRATION SENSOR REPLACEMENT 1. Remove the middle right cover. 2. Remove the regis- tration cover [A] (1 screw). 3. Remove the regis- tration sensor as- sembly [B] (2 screws); then, re- move the sensor (2 screws, 1 con- nector).
Page 159 6 January 1990 8.4 PAPER FEED ROLLER/REGISTRATION ROLLER REPLACEMENT 1. Remove the manual feed table [A] (1 screw), lower feed guide plate [B] (6 screws), and the lower registration guide plate [C] (4 screws). 2. Remove the paper feed clutch [D] (2 Allen screws) and the registration clutch [E] (1 Allen screw, 1 connector).
Page 160 6 January 1990 4. Remove the collar [H] (1 Allen screw) and bracket [I] (1 screw); then, remove and replace the registration roller [J] (1 E ring, 2 bushings, 1 spacer). 5-38...
Page 161: Fusing Unit Removal
6 January 1990 9. FUSING 9.1 FUSING UNIT REMOVAL 1. Open the middle unit and the origi- nal feed unit. 2. Remove the middle right, top right, and right horizon- tal covers. 3. Open the toner col- lection tank cover and take out the toner collection tank.
Page 162 6 January 1990 8. Remove the middle left cover, top left cover, left horizon- tal cover, left inner cover, and lower left cover [A] (6 screws). 9. Loosen the timing belt and remove the bracket [B] (5 screws). 10. Open the exit guide unit and re- move the left and right slider plate...
Page 163 6 January 1990 12. Remove the two screws [A,B] se- curing the paper exit unit. 13. Remove the ten- sion sprocket [C] and the paper exit unit drive chain [D]. 14. Disconnect the pa- per exit unit con- nectors and remove the paper exit unit [E].
Page 164 6 January 1990 15. Remove the fusing lamp cover [A] and disconnect the fusing lamp connector [B]. 16. Disconnect the two connectors [C] and remove screw [D]. 17. Remove screw [F], close the middle unit, and remove screw [E]. [F] [E] 18.
Page 165: Fusing Lamp Replacement
6 January 1990 9.2 FUSING LAMP REPLACEMENT 1. Remove the fusing unit from the cop- ier mainframe. 2. Disconnect the connector [A]; then, remove the lamp holder [B] (1 screw). 3. Remove the lamp holder [C] (2 screws), wire clamp [D] (1 screw), and har- ness cover [E] (2 screws).
Page 166 6 January 1990 9.3 FUSING ROLLER/PRESSURE ROLLER REPLACEMENT 1. Remove the fusing unit. 2. Remove the fusing lamp. 3. Remove the top cover [A] (4 screws) and the cleaning roller to- gether with its guide plate [B] (4 screws). 4. Remove the left and right pressure springs [C,D].
Page 167: Fusing Thermofuse Replacement
6 January 1990 9.4 FUSING THERMOFUSE REPLACEMENT 1. Remove the fusing unit. 2. Remove the fusing unit top cover. 3. Take the thermo- fuse wire out from the clamps (6 clamps, 1 screw each). 4. Remove the ther- mofuse holder [A] (1 screw).
Page 168 6 January 1990 9.5 HOT ROLLER/PRESSURE ROLLER THERMISTOR REPLACEMENT 1. Remove the fusing unit. 2. Remove the left and right pressure springs. 3. Remove the fusing unit top cover. 4. Take the hot roller thermistor wire out from the clamps (2 clamps, 1 screw each) and remove the hot roller ther-...
Page 169 6 January 1990 9.6 FUSING PRESSURE DISTRIBUTION ADJUSTMENT 1. Remove the fusing unit. 2. Remove the fusing roller and the pres- sure roller [A]. 3. Slide the pressure roller shaft [B] out from the pressure roller. 4. Loosen the four Al- len screws on each of the adjust- ment bearings...
Page 170: Cleaning The Cleaning Roller
6 January 1990 9.7 CLEANING THE CLEANING ROLLER 1. Remove the fusing unit. 2. Remove the clean- ing roller [A] to- gether with its guide plate (4 screws). 3. Wipe toner from the cleaning roller with a cloth and a cleaning solution.

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