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Fresa G024 Service Manual

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FRESA (G024)
SERVICE MANUAL
[Engine]

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Summary of Contents for Fresa G024

  • Page 1 FRESA (G024) SERVICE MANUAL [Engine]...

  • Page 2: Important Safety Notices

    ø IMPORTANT SAFETY NOTICES PHYSICAL INJURY PREVENTION 1. Before disassembling or assembling parts of the printer and peripherals, make sure that the power cord is unplugged. 2. The wall outlet should be near the printer and easily accessible. 3. Note that some printer components are supplied with electrical voltage even if the main switch is turned off.

  • Page 3: Laser Safety

    LASER SAFETY The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is only replaceable in the field by a qualified Customer Engineer.
  • Page 4 Trademarks Microsoft, Windows 98/95/3.1x, and Windows NT 4.0 are registered trademarks of Microsoft Corporation. Macintosh and AppleTalk are registered trademarks of Apple Computer, Inc. NetWare is a registered trademark of Novell, Inc. Ethernet is a registered trademark of Xerox Corporation. General Notice: Other product names used herein are for identification purposes only and may be trademarks of their respective companies.

  • Page 5: Overall Machine Information

    31 March, 1999 SPECIFICATIONS 1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS Configuration Desk top Print Process Dry electrostatic transfer system Resolution 600 dpi Paper Size Standard tray Short edge feed: A3, 11" x 17", 8 " x 14", Others* (B4 JIS, 8" x 13", "...
  • Page 6 SPECIFICATIONS 31 March, 1999 Power Supply 120 V, 60 Hz, 10 A 220 to 240 V, 50/60 Hz, 5.2 A Power Consumption Maximum: Less than 1200 W Average during printing: Less than 750 W Standby mode: Less than 150 W Energy saver mode: Less than 45 W Noise Emission Stand-by: Less than 43 dB...

  • Page 7: Mechanical Overview

    31 March, 1999 MECHANICAL OVERVIEW 1.2 MECHANICAL OVERVIEW 1.2.1 IMAGE FORMATION PROCESS OVERVIEW G024V151.WMF 1. OPC belt 7. Paper separation 2. Charge 8. Paper transfer (secondary transfer) 3. Exposure 9. Belt transfer (primary transfer) 4. Development 10. ID sensor 5. Transfer belt 11.
  • Page 8 MECHANICAL OVERVIEW 31 March, 1999 (1) OPC belt The OPC (organic photoconductor) belt is the central part of the machine. This is where the laser beam writes an image of the original. (2) Charge A negative corona discharge in darkness negatively charges the OPC belt. The grid ensures the even distribution of charge over the OPC belt.
  • Page 9 31 March, 1999 MECHANICAL OVERVIEW (11) OPC belt cleaning A cleaning brush applies lubricant to the OPC belt to improve cleaning. Then, a blade scrapes off the remaining toner on the OPC belt. (12) Quenching After cleaning, the entire surface of the OPC belt is exposed to light from a red LED.
  • Page 10 MECHANICAL OVERVIEW 31 March, 1999 1.2.2 TRANSFER An image is formed on the OPC belt in four colors, one color at a time. The resulting four images transfer to the transfer belt in the order of Y, C, M, then K. These four images form a full-color image on the transfer belt, then the image is finally transferred to the paper.
  • Page 11 31 March, 1999 MECHANICAL OVERVIEW 1.2.3 CHARGE CORONA UNIT VOLTAGES OPC belt G = –600 V Cleaning blade Charge grid C = –700 µA (About –5000 V) Quenching lamp G024V662.WMF Charge corona unit The charge corona wire receives a constant current (C) of – 700 µA (about – 5000 The charge grid voltage (G) varies depending on the process control results.
  • Page 12 MECHANICAL OVERVIEW 31 March, 1999 1.2.4 DEVELOPMENT UNIT BIAS VOLTAGES Each development unit contains a supply roller and a development roller. These rollers are conductive. The voltage applied to the supply roller (SB) depends on the process control results. The other voltages in turn all depend on SB, as described below.
  • Page 13 31 March, 1999 MECHANICAL OVERVIEW 1.2.5 TRANSFER BIAS VOLTAGES Paper transfer roller Paper TC– = –16 µA (About –1.1 kV) TC+ = +16 µA (About +1.8 kV) Transfer belt TB = 800 V Toner Bias roller G024V664.WMF OPC belt Primary transfer (from OPC belt to transfer belt) An 800-V bias voltage (TB) is applied to the bias roller.
  • Page 14 MAIN UNIT LAYOUT 31 March, 1999 1.3 MAIN UNIT LAYOUT G024V561.WMF 1. Optical housing unit 6. Fusing unit 2. Main control unit (MCU) 7. Paper transfer unit 3. High voltage supply unit 8. Photoconductor unit (PCU) 4. Controller board 9. Paper tray/paper feed mechanism 5.
  • Page 15 31 March, 1999 MAIN UNIT LAYOUT (1) Optical housing unit • Optical system: 6-sided polygon mirror, F-theta mirror, BTL • Resolution: 600 dpi • Modulation method: PM+PWM (2) MCU • CPU: XC68334 GFC16 • Engine system control • Process control •...

  • Page 16: Parts Layout

    PARTS LAYOUT 31 March, 1999 1.4 PARTS LAYOUT 1.4.1 MECHANICAL COMPONENT LAYOUT G024V561.WMF 1. Tray paper feed roller 13. Transfer belt cleaning unit 2. Paper tray 14. Transport fan 3. Charge corona unit 15. Paper transfer unit 4. Polygon mirror 16.

  • Page 17: Drive Layout

    31 March, 1999 PARTS LAYOUT 1.4.2 DRIVE LAYOUT G024V553.WMF 1. Main motor 8. Relay roller clutch 2. Fusing drive input gear 9. Pull-out clutch 3. Fusing drive gear 10. Paper feed clutch 4. Transfer belt toner collection drive 11. Paper feed drive gear gear 12.
  • Page 18 PARTS LAYOUT 31 March, 1999 G024V563.WMF 1. PCU pulley 2. PCU motor 3. OPC drive relay gear 4. OPC drive gear 1-14...
  • Page 19 31 March, 1999 PARTS LAYOUT 1.4.3 SENSORS G024V551A.WMF 1. Exit sensor 8. ID sensor 2. Oil end sensor 9. Pull-out sensor 3. Transfer belt H.P. sensor 10. By-pass paper end sensor 4. Transfer roller position sensor 11. Registration sensor 5. Used toner sensor 12.
  • Page 20 PARTS LAYOUT 31 March, 1999 1.4.4 SWITCHES G024V551.WMF 1. Main switch 2. Exit cover switch 3. Door safety switches 4. Paper size switch 5. PCU set switch 6. Charge corona unit set switch 7. Development toner magazine (DTM) cover switch 1-16...

  • Page 21: Motors, Clutches, And Solenoids

    31 March, 1999 PARTS LAYOUT 1.4.5 MOTORS, CLUTCHES, AND SOLENOIDS G024V552.WMF 1. Exhaust fan 10. Relay roller clutch 2. PCU motor 11. By-pass feed clutch 3. Transfer belt cleaning solenoid 12. Registration clutch 4. Main motor 13. Transfer roller clutch 5.
  • Page 22 PARTS LAYOUT 31 March, 1999 1.4.6 PCBS AND PSU G024V108.WMF 1. Power supply unit (PSU) 6. Laser synchronization detector board 2. Controller board 7. Quenching lamp 3. High voltage supply board 8. By-pass paper width detection board 4. Temperature/humidity sensor 9.
  • Page 23 31 March, 1999 PARTS LAYOUT 1.4.7 THERMISTORS, HEATERS, AND FUSES G024V111.WMF 1. Pressure roller thermistor 2. Pressure roller lamp 3. Hot roller thermofuse 4. Hot roller thermistor 5. Hot roller lamp 6. Pressure roller thermofuse 1-19...

  • Page 24: System Block

    SYSTEM BLOCK 31 March, 1999 1.5 SYSTEM BLOCK 1.5.1 BLOCK DIAGRAM ID Sensor C P U D / A R O M N V R A M D R A M A D C Humidity Sensor P W M High Voltage Supply Board A S I C Pattern...

  • Page 25: Electrical Component List

    31 March, 1999 ELECTRICAL COMPONENT LIST 1.6 ELECTRICAL COMPONENT LIST 1.6.1 SENSORS Symbol Name Function Index No. Exit sensor Detects exiting paper. Oil end sensor Detects oil in the oil pan. Transfer belt H.P. Detects the marks on the transfer belt. sensor Transfer roller Detects when the transfer roller...
  • Page 26 ELECTRICAL COMPONENT LIST 31 March, 1999 1.6.3 MOTORS Symbol Name Function Diag. No. Main motor Drives the paper feed mechanisms, fusing unit, and development roller. PCU motor Drives the OPC belt and transfer belt. Revolver motor Drives the revolver (development). Polygon mirror Drives the polygon mirror.
  • Page 27 31 March, 1999 ELECTRICAL COMPONENT LIST 1.6.7 CIRCUIT BOARDS AND POWER SUPPLIES Symbol Name Function Diag. No. Power supply Supplies low-voltage power (5 VDC and 24 PCB1 unit (PSU) VDC) and ac power to the fusing unit. PCB8 Controller board Houses the controller, host interface, engine interface, and image generator.

  • Page 28: Detailed Section Descriptions

    31 March, 1999 PROCESS CONTROL 2. DETAILED SECTION DESCRIPTIONS 2.1 PROCESS CONTROL 2.1.1 OVERVIEW In this machine, process control adjusts the following two parameters, to compensate for changes in the environment, aging of the units, and differences between individual units after they are replaced. •...
  • Page 29 PROCESS CONTROL 31 March, 1999 2.1.2 ID SENSOR Diffused light detection curve Straight reflection detection curve Amount of attached toner (M/A, mg/cm G024D520.WMF The ID sensor consists of two separate sensors. For detecting the density of black toner patterns, there is a straight reflection sensor for K toner (this is the type of sensor normally used in black-and-white copiers), and for colored toner there is a diffused light sensor.

  • Page 30: Process Control Steps

    31 March, 1999 PROCESS CONTROL 2.1.3 PROCESS CONTROL STEPS Process control is done on seven separate occasions (see the 'Occasion' column in the table below). Process control consists of several steps. The steps that are done depend on which of the seven occasions has arisen. The steps that are done for each occasion are given in the 'Steps done' column of the following table.
  • Page 31 PROCESS CONTROL 31 March, 1999 Step 1: ID sensor calibration To calibrate the ID sensor, the light reflected from the bare transfer belt is measured. The LED current is adjusted until the sensor output is 2.5 V. The detector for black is used for the calibration. The LED current will be adjusted for color toner detection, based on the adjustment that was made during the calibration for the black toner detector.
  • Page 32 31 March, 1999 PROCESS CONTROL Step 4: Charge grid bias voltage adjustment Adjusting the development bias V controls the density of solid areas on the printout, and adjusting the charge grid bias V controls the density of low image density (highlight) areas. These two biases maintain a consistent γ for the engine. To adjust V , the machine makes another pattern on the transfer belt.
  • Page 33 PCU (PHOTOCONDUCTOR UNIT) 31 March, 1999 2.2 PCU (PHOTOCONDUCTOR UNIT) 2.2.1 OVERVIEW G024D151.WMF The PCU consists of an OPC section, a primary (belt) transfer section, and a used toner tank that collects the used toner from the OPC and belt transfer sections. 1.
  • Page 34 31 March, 1999 PCU (PHOTOCONDUCTOR UNIT) 2.2.2 COMPONENTS Section Component Overview The main motor (a brushless DC motor) Cleaning unit drives the used toner collection unit and the cleaning unit. Drive mechanism The PCU motor (an externally synchronized Belt drive brushless DC motor) drives the OPC belt and the transfer belt.

  • Page 35: Drive Mechanisms

    PCU (PHOTOCONDUCTOR UNIT) 31 March, 1999 2.2.3 DRIVE MECHANISMS Belt drive G024D602.WMF G024D194.WMF The PCU motor [A] drives the OPC belt drive roller [B] and transfer belt drive roller [C] via gears and two joints [D]. The OPC [E] and transfer [F] belts rotate at the same speed.
  • Page 36 31 March, 1999 PCU (PHOTOCONDUCTOR UNIT) Used toner collection drive G024D604.WMF The main motor drives the used toner collection process. There are two mechanisms, one for the transfer belt and one for the OPC. The pulley [A] drives the transfer belt toner collection auger [B] via gears. The paper feed drive gear [C] drives the OPC cleaning brush [D], OPC belt toner collection auger [E], and used toner collection auger [F] via a series of gears.
  • Page 37 PCU (PHOTOCONDUCTOR UNIT) 31 March, 1999 Transfer belt speed One revolution of the transfer belt (39.2 x 15 = 588) LT long edge feed two-image print A3 one-image print LT long edge feed one-image print Double-speed 376.8 revolution 506.8 Single-color black print 4 marks Unit: mm G024D517.WMF...
  • Page 38 31 March, 1999 PCU (PHOTOCONDUCTOR UNIT) 2.2.4 TRANSFER VOLTAGE SUPPLY G024D157.WMF The high voltage board [A] supplies the belt transfer voltage to the PCU through the connector [B], then the coil spring electrode [C] and finally the bias roller [D] to the transfer belt [E].

  • Page 39: Charge Corona Unit

    PCU (PHOTOCONDUCTOR UNIT) 31 March, 1999 2.2.5 CHARGE CORONA UNIT G024D605.WMF Electrode for the grid Electrode for the wire G024D607.WMF The charge corona unit [A] supplies a negative charge to the OPC using a single scorotron corona wire. The coil spring electrode [B] supplies the voltage as soon as the PCU motor starts.
  • Page 40 31 March, 1999 PCU (PHOTOCONDUCTOR UNIT) 2.2.6 OPC BELT G024D156.WMF G024D616.WMF The inner side of the OPC belt [A] is in continual contact with the grounding brush [B]. After primary transfer (from OPC to transfer belt), the cleaning brush [C] lubricates the OPC belt with zinc stearate, by using a spring to apply pressure to the lubricant bar [D].
  • Page 41 PCU (PHOTOCONDUCTOR UNIT) 31 March, 1999 2.2.7 PRIMARY TRANSFER Voltage application G024D155.WMF The primary transfer bias is applied to the transfer belt bias roller [A]. The default is +800 V. It changes according to environmental conditions (temperature and humidity measured by the sensors). The bias pulls the toner from the OPC belt to the transfer belt.
  • Page 42 31 March, 1999 PCU (PHOTOCONDUCTOR UNIT) Transfer belt cleaning G024D153.WMF G024D154.WMF When the cleaning brush [A] is moved into contact with the transfer belt [B], pressure from the contact turns the cleaning brush. The lubricant bar [C] uses its own weight to press against the cleaning brush, which applies lubricant to the transfer belt to improve transfer and cleaning.
  • Page 43 PCU (PHOTOCONDUCTOR UNIT) 31 March, 1999 2.2.8 USED TONER TANK G024D611.WMF G024D612.WMF The used toner tank [A] has a shutter mechanism [B]. When the used toner tank is placed in the PCU, a protrusion [C] on the PCU opens the shutter. When the tank is removed from the PCU, the spring (under tension) in the shutter cover pulls and closes the shutter.
  • Page 44 31 March, 1999 PCU (PHOTOCONDUCTOR UNIT) 2.2.9 PCU DETECTION G024D613.WMF The PCU set switch [A] is installed on the main unit (under the bottom center of the PCU). It detects the presence of a PCU. The used toner tank case presses the PCU set switch.

  • Page 45: Belt Mark Detection

    PCU (PHOTOCONDUCTOR UNIT) 31 March, 1999 2.2.11 BELT MARK DETECTION G024D614.WMF There are 15 belt marks [A] on the right edge of the transfer belt. The transfer belt home position sensor [B] (a reflective photosensor) on the front cover unit detects these marks to align the laser exposure start position in the sub-scan direction for the next image.
  • Page 46 31 March, 1999 PCU (PHOTOCONDUCTOR UNIT) 2.2.13 LUBRICANT APPLICATION MODE Lubricant application mode for a new PCU Lubricant application mode for a new PCU • Output a full-color A3 page using internal pattern #6. • Turn off the primary transfer bias. •...
  • Page 47 PCU (PHOTOCONDUCTOR UNIT) 31 March, 1999 Regular lubricant application mode Regular lubricant application mode Lubricant application counter = A Y e s Reset the counter. Drive the PCU motor and main motor. Turn off everything after 30 seconds. E n d G024D522.WMF Lubricant is applied to the OPC and transfer belts when the lubricant application counter reaches A (default: 100).

  • Page 48: Optical Unit

    31 March, 1999 OPTICAL UNIT 2.3 OPTICAL UNIT 2.3.1 OVERVIEW G024D501.WMF G024D502.WMF 1. Polygon Mirror 7. F-theta Mirror 2. Polygon Mirror Motor 8. BTL (Barrel Torroidal Lens) 3. 1st Mirror 9. Laser Synchronization Mirror 4. Cylindrical Lens 10. Laser Synchronization Detector Board 5.
  • Page 49 OPTICAL UNIT 31 March, 1999 2.3.2 COMPONENTS Section Component Overview Wavelength 780 nm, rated power 10 mW LD control board Drives the LD. LD unit Collimating lens Makes the laser beams parallel. Prevents the laser beams from expanding Aperture beyond the required beam diameter. Cylindrical lens Compensates for beam shape irregularities.
  • Page 50 31 March, 1999 OPTICAL UNIT 2.3.3 LD UNIT LD safety switch G N D +5V INT + 5 V + 2 4 V Power supply unit LD unit + 5 V Door safety switch To the paper exit cover switch LD safety Front cover switch...
  • Page 51 OPTICAL UNIT 31 March, 1999 Cylindrical lens The cylindrical lens concentrates the laser beam from the LD unit and forwards it to the polygon mirror. The cylindrical lens determines the beam diameter in the sub- scan direction. Polygon mirror Thick Thin G024D503.WMF The polygon mirror [A] is a combined unit consisting of a polygon mirror motor and...
  • Page 52 31 March, 1999 OPTICAL UNIT F-theta mirror Evenly spaced pixels G024D504.WMF The distance to the reflective face of the polygon mirror [A] is different at the center and at the edges of the OPC belt. The gaps between pixels are longer at the edges (the beam is sweeping across the belt more quickly).
  • Page 53 OPTICAL UNIT 31 March, 1999 Synchronization detection A mirror deflects the laser beam from the polygon mirror to the synchronization detection board. The detection board responses are sent to the MCU laser exposure controller as synchronization signals for LD exposure start position across the main scan.
  • Page 54 31 March, 1999 OPTICAL UNIT 2.3.4 APC (AUTO POWER CONTROL) Circuit + 5 V L D E R R L D O F F E M A Control signal G024D528.WMF The LD has a built-in photodiode to monitor the laser beam. The output signals from the photodiode are input to the LD control board, which contains a feedback circuit to keep the laser beam at a constant intensity.
  • Page 55 OPTICAL UNIT 31 March, 1999 2.3.6 LASER EXPOSURE TIMING Two-image output timing LGATE timing FGATE timing Laser exposure area Laser exposure area LGATE timing LSYNC LGATE FGATE timing START MARK PMSYNC FGATE G024D507.WMF The FGATE (for the sub-scan direction) and LGATE (for the main scan direction) signals determine the laser exposure timing.

  • Page 56: Development Unit

    31 March, 1999 DEVELOPMENT UNIT 2.4 DEVELOPMENT UNIT 2.4.1 OVERVIEW G024D169.WMF 1. Revolver motor 2. Revolver gear 3. Hopper 4. Development roller The development unit consists of independent Y, C, M, and K units (known as development toner magazines or DTMs) combined with a support unit. The development unit rotates clockwise (as seen from the left side of the printer) and develops images in the order of Y, C, M, and then K.
  • Page 57 DEVELOPMENT UNIT 31 March, 1999 2.4.2 COMPONENTS Section Component Overview The revolver motor turns the revolver unit. Revolver drive The MCU controls the rotational angle. Revolver Home position Detects when the revolver is at home sensor position. Four colors (Y, C, M, and K) The DTM set sensor detects the presence of DTM set sensor Toner supply...
  • Page 58 31 March, 1999 DEVELOPMENT UNIT 2.4.3 REVOLVER DRIVE G024D529.WMF G024D900.WMF degrees degrees degrees degrees degrees Development Development Development Development G024D513.WMF A gear transfers drive from the revolver motor [A] to the revolver gear [B] on the hopper. The support unit [C] has a protrusion for home position detection on the left side. The home position sensor [D] on the left side panel detects this protrusion.
  • Page 59 DEVELOPMENT UNIT 31 March, 1999 2.4.4 DEVELOPMENT UNIT DRIVE G024D162.WMF Gears and joints [A] transfer drive from the main motor [B] to the gears for the supply [C] and development [D] rollers. The joint only engages while the development drive solenoid [E] is on. 2-32...
  • Page 60 31 March, 1999 DEVELOPMENT UNIT 2.4.5 TONER AGITATION G024D167.WMF The rotation of the revolver agitates the toner inside the hopper. When the hopper is at the top, the toner is at the supply port (A) for the development roller. When the hopper turns towards the bottom, the toner falls from the toner supply port (B).

  • Page 61: Toner Transport

    DEVELOPMENT UNIT 31 March, 1999 2.4.6 TONER TRANSPORT G024D161.WMF The agitated toner passes from the hopper [A] to the supply and development rollers. The supply roller flicker [B] regulates the amount of toner applied to the supply roller. Then, the rotation of the supply roller [D] transports the toner to the development roller [C].

  • Page 62: Development Bias

    31 March, 1999 DEVELOPMENT UNIT 2.4.7 DEVELOPMENT BIAS G024D166.WMF G024D165.WMF Development roller bias: A Supply roller bias: B Development blade bias: Revolver revolution Development roller bias Supply roller bias Blade bias Blade AC bias Bias change-over G024D514.WMF The electrode [A] on the main unit side supplies the voltages. The electrode is connected only while development is in progress.
  • Page 63 DEVELOPMENT UNIT 31 March, 1999 2.4.8 DTM (DEVELOPMENT TONER MAGAZINE) DETECTION G024D164.WMF The DTM sensor [A] detects the presence of a DTM. The DTM sensor outputs an error detection signal when a toner bottle is not present or is incorrectly installed. Printing cannot start until this signal ceases (i.e., the error must be corrected).
  • Page 64 31 March, 1999 DEVELOPMENT UNIT 2.4.9 TONER NEAR-END DETECTION G024D163.WMF Reflecting Board Receive light Emits light G024D195.WMF Each toner hopper has a toner monitoring window [A] with two mirrors [B] at a 45- degree angle. The toner end sensor (a reflective photosensor) [C] detects the toner between the two mirrors.
  • Page 65 DEVELOPMENT UNIT 31 March, 1999 2.4.10 DEVELOPMENT TIMING LT, long edge feed, two-image print mode Belt mark Laser exposure C and M Revolver Development solenoid Development bias Change-over Change-over Belt transfer bias G024D515.WMF 2-38...

  • Page 66: Paper Transfer Unit

    31 March, 1999 PAPER TRANSFER UNIT 2.5 PAPER TRANSFER UNIT 2.5.1 OVERVIEW G024D422.WMF G024D426.WMF 1. Transfer roller casing 2. Transfer roller springs 3. Transfer roller 4. Antistatic brush 5. Transfer roller position sensor 6. Transfer roller clutch The paper transfer unit moves into contact and separates from the transfer belt during the printing process.
  • Page 67 PAPER TRANSFER UNIT 31 March, 1999 2.5.2 COMPONENTS Section Component Overview Charges the back side of the Transfer roller paper to attract toner from the transfer belt. Transfer Presses the transfer roller Spring against the transfer belt. Moves the paper transfer unit Transfer roller clutch into contact and away from the transfer belt.
  • Page 68 31 March, 1999 PAPER TRANSFER UNIT 2.5.3 CONTACT AND SEPARATION G024D159.WMF Registration clutch Transfer roller clutch Transfer bias 7 1 . 4 6 m m 3 1 . 5 m m G024D516.WMF The transfer roller contact/separation idler [A] and the transfer roller clutch [B] transfer drive from the main motor to the cam [C].
  • Page 69 PAPER TRANSFER UNIT 31 March, 1999 2.5.4 BIAS G024D427.WMF G024D157.WMF Normally, a constant current is applied to the transfer roller [A] axle. A conductive bearing [B] allows an electrical connection between the bias terminal [C] and the transfer roller axle. The current varies with paper type, size, and thickness as well as humidity.
  • Page 70 31 March, 1999 PAPER FEED/REGISTRATION UNIT 2.6 PAPER FEED/REGISTRATION UNIT 2.6.1 OVERVIEW G024D191.WMF 1. Friction pad 8. By-pass feed table 2. Paper size switch 9. By-pass paper width detection board 3. Tray paper feed roller 10. By-pass pick-up roller 4. Tray paper end sensor 11.
  • Page 71 PAPER FEED/REGISTRATION UNIT 31 March, 1999 2.6.2 COMPONENTS Section Main function Overview Paper feed/separation Friction pad separation method Paper tray bottom Paper tray bottom plate pressurized by a plate pressure spring Paper tray Paper end detection Detection by a feeler and photo-interrupter User-specified by a dial;...

  • Page 72: Standard Tray

    31 March, 1999 PAPER FEED/REGISTRATION UNIT 2.6.3 STANDARD TRAY Drive G024D192.WMF Drive from the main motor is transferred from the timing belt to the paper feed drive gear [A]. The paper feed drive gear drives the paper feed roller and pull-out roller via gears. These two rollers each have a clutch (paper pull-out: [B], feed: [C]) to transfer drive to the roller at the correct time.
  • Page 73 PAPER FEED/REGISTRATION UNIT 31 March, 1999 Paper feed/separation G024D406.WMF Mark detection Laser Exposure Paper feed clutch Pull-out clutch Pull-out sensor Relay roller clutch Registration sensor 27.88 Registration clutch G024D527.WMF Timing for black, LT, long edge feed The paper tray uses a friction pad [A]. A compressed spring [B] pushes the friction pad from the bottom, giving constant pressure to the sheet of paper against the paper feed roller [C].
  • Page 74 31 March, 1999 PAPER FEED/REGISTRATION UNIT Tray lift G024D402.WMF Springs under tension [A] connect the bottom plate [B] of the paper tray to the paper tray arm [C]. When the paper tray is placed in the main unit, the guide block [D] for the main unit base lifts the paper tray arm.
  • Page 75 PAPER FEED/REGISTRATION UNIT 31 March, 1999 Paper end detection G024D403.WMF The paper end sensor [A] is on the floor of the main unit. When there is no paper in the paper tray, the sensor actuator [B] falls into the notch in the bottom plate, causing the sensor to trip.
  • Page 76 31 March, 1999 PAPER FEED/REGISTRATION UNIT Paper size detection G024D404.WMF Paper size detection is based on the three paper size switches [A] on the main unit, which detect the setting of the paper size dial [B] on the paper tray. The paper size dial has grooves and ridges on the side facing the paper size switches.

  • Page 77: By-Pass Feed Table

    PAPER FEED/REGISTRATION UNIT 31 March, 1999 2.6.4 BY-PASS FEED TABLE Drive G024D407.WMF By-pass feed solenoid By-pass paper feed clutch Registration sensor Registration clutch G024D523.WMF Timing for black, LT, long edge feed Drive transfers from the paper feed drive gear [A] to the by-pass paper feed clutch [B] and the shaft [C].
  • Page 78 31 March, 1999 PAPER FEED/REGISTRATION UNIT Paper feed/separation G024D408.WMF The paper feed/separation mechanism for the by-pass feed table is based on the FRR method. A spring [A] pulls the pick-up roller [B] towards the paper. When the solenoid [C] is turned on, the pick-up roller lowers and feeds the top sheet of paper in.
  • Page 79 PAPER FEED/REGISTRATION UNIT 31 March, 1999 Paper size detection G024D410.WMF ã ã â â â â ã ã ã ã â G024D411. WMF â ã : Long edge feed : Short edge feed An electrode plate is connected to each of the two side fences [A]. The electrode plates short the patterns on the paper size detection board.
  • Page 80 31 March, 1999 PAPER FEED/REGISTRATION UNIT 2.6.5 REGISTRATION G024D414.WMF G024D413.WMF The registration sensor [A] detects the paper fed from the relay rollers. The paper then reaches the registration roller, and the relay roller clutch disengages, pausing the paper feed. The relay roller clutch [B] and registration clutch [C] engage simultaneously to restart paper feeding at the correct time to synchronize with the leading edge of the image on the transfer belt.
  • Page 81 TRANSPORT/FUSING/PAPER EXIT UNIT 31 March, 1999 2.7 TRANSPORT/FUSING/PAPER EXIT UNIT 2.7.1 OVERVIEW G024D182.WMF 1. Transport fan 9. Oil supply pad 2. Pressure roller thermistor 10. Oil supply sub-roller 3. Pressure adjustment screw 11. Oil blade 4. Exit rollers 12. Hot roller 5.
  • Page 82 31 March, 1999 TRANSPORT/FUSING/PAPER EXIT UNIT 2.7.2 COMPONENTS Section Component Overview The transport fan creates upward suction on the paper to hold the paper against the transport belt Transport fan so it moves smoothly to the entrance to the Transport fusing unit.

  • Page 83: Fusing Unit Drive

    TRANSPORT/FUSING/PAPER EXIT UNIT 31 March, 1999 2.7.3 FUSING UNIT DRIVE G024D303.WMF G024D182.WMF A gear train transfers drive from the main motor [A] to the fusing contact/separation gear [B]. Closing the front cover lowers the contact/separation lever [C] in direction [D]. This lifts the fusing contact/separation gear, which engages with the fusing drive gear [E].

  • Page 84: Paper Transport

    31 March, 1999 TRANSPORT/FUSING/PAPER EXIT UNIT 2.7.4 PAPER TRANSPORT Registration sensor Registration clutch 1 second later Transport fan Transfer roller clutch 1 0 1 . 8 9 m m G024D525.WMF G024D304.WMF The transport fan creates upward suction to hold the paper fed by the transfer roller against the transfer belt, which guides it to the fusing unit entrance guide plate.

  • Page 85: Temperature Control

    TRANSPORT/FUSING/PAPER EXIT UNIT 31 March, 1999 2.7.5 TEMPERATURE CONTROL G024D305.WMF The hot roller [A] and pressure roller [B] have independent thermistors [C] to monitor temperature. The hot roller fusing lamp is easier to heat or cool than the pressure roller fusing lamp, and may overheat quickly if left on.
  • Page 86 31 March, 1999 TRANSPORT/FUSING/PAPER EXIT UNIT Fusing unit SC codes SC No. Name Condition ° Pressure roller thermistor error The roller temperature has been at 0 C for five seconds. ° High pressure roller The roller temperature has been at 190 temperature for three seconds.

  • Page 87: Pressure Roller

    TRANSPORT/FUSING/PAPER EXIT UNIT 31 March, 1999 2.7.6 PRESSURE ROLLER G024D531.WMF The hot roller [A] is made of silicone. The pressure roller [B] is made of silicone covered with Teflon tubing. A compressed spring and a screw [C] press the pressure roller against the hot roller.
  • Page 88 31 March, 1999 TRANSPORT/FUSING/PAPER EXIT UNIT 2.7.7 OIL END DETECTION G024D307.WMF A photointerrupter [A] detects the presence of oil. When there is no oil, the beam from the LED passes through to the phototransistor. However, if oil is present, the beam from the LED is refracted away and does not reach the phototransistor.

  • Page 89: Oil Supply

    TRANSPORT/FUSING/PAPER EXIT UNIT 31 March, 1999 2.7.8 OIL SUPPLY G024D306.WMF Oil drips from the oil bottle [A] to the oil reservoir [B]. The oil is absorbed in the oil supply pad [C], fed to the oil supply roller [D] by the oil supply sub-roller [E], and supplied to the hot roller [F].
  • Page 90 31 March, 1999 TRANSPORT/FUSING/PAPER EXIT UNIT 2.7.9 CLEANING G024D313.WMF The cleaning roller [A] cleans the hot roller [B]. The cleaning roller picks up the toner or paper dust from the hot roller, and the scraper [C] removes them from the cleaning roller. The dust drops into the recess [D] behind the scraper.
  • Page 91 OPEN COVER DETECTION 31 March, 1999 2.8 OPEN COVER DETECTION 2.8.1 FRONT COVER OPEN/CLOSED DETECTION G024D101.WMF This feature ensures safety during maintenance and inspection with the front cover [A] opened. Opening or closing the front cover vertically moves the lever in contact with the actuators for the door safety switches [B].

  • Page 92: Video Data Processing

    31 March, 1999 VIDEO DATA PROCESSING 2.9 VIDEO DATA PROCESSING 2.9.1 FLOW CHART G a m m a compensation Gradation processing Controller VIDEO I/F Engine A M D G GAVD I/F H E M A G024D526.WMF 2.9.2 GAMMA COMPENSATION The controller receives either 8-bit RGB or 8-bit CMYK data from the driver (in the case of 8-bit RGB data, the controller has to convert this to 8-bit CMYK data before image processing can start).

  • Page 93: Gradation Processing

    VIDEO DATA PROCESSING 31 March, 1999 2.9.3 GRADATION PROCESSING The gamma-compensated data is dithered. The result of dithering depends on whether 1-bit or 2-bit mode was selected with the driver. After dithering, the data is converted to 4-bit and sent to the engine through the video interface.

  • Page 94: Installation Procedure

    31 March, 1999 ENVIRONMENT 3. INSTALLATION PROCEDURE 3.1 ENVIRONMENT Recommended temperature and humidity % R H R e c o m m e n d e d operation range Possible range 10ºC 15ºC 25ºC 27ºC 32ºC (50ºF) (59ºF) (77ºF) (80.6ºF) (89.6ºF) G024I502.WMF 10°C to 32°C (50°F to 89°F)

  • Page 95: Machine Level

    MACHINE LEVEL 31 March, 1999 3.2 MACHINE LEVEL 1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of level 3.3 MINIMUM SPACE REQUIREMENTS Place the printer near the power source, providing clearance as shown: G024I503.WMF A: More than 5 cm (2.0") B: More than 10 cm (4.0")

  • Page 96: Power Requirements

    31 March, 1999 POWER REQUIREMENTS 3.4 POWER REQUIREMENTS 1. Input voltage level: 85 – 138V, 60 ± 3 Hz: More than 12 A 187 – 276 V, 50/60 ± 3 Hz: More than 6 A 2. Permissible voltage fluctuation: 10% 3.
  • Page 97 MOVING 31 March, 1999 3.6 MOVING To move a previously installed laser printer, follow the instructions below. 1. The printer weighs about 62 kg. Always be sure two or more people move the printer. 2. Keep the printer horizontal during transportation. (Do not concentrate the load on any one part of the base.) 3.
  • Page 98 31 March, 1999 OVERVIEW 4. SP MODE 4.1 OVERVIEW This printer has two SP modes: 1) Engine SP mode 2) Controller SP mode The controller SP modes are described in the service manual for the controller. These two modes contain different functions. 4.2 ENGINE SP MODE 4.2.1 OVERVIEW Entering engine SP mode...
  • Page 99 ENGINE SP MODE 31 March, 1999 Outline of the engine SP mode functions The engine SP mode has the following menu items: Menu Item Function and application 1: Margin Independent vertical/horizontal registration adjustment for each tray, and for OHP mode 2: Parameter Independent adjustment of transfer bias and fusing temperature for normal paper, thick paper, and OHPs...
  • Page 100 31 March, 1999 ENGINE SP MODE LCD indications: Title Maintenance Arrow marks 1. Margin Selected item Title: The menu title is displayed to show the current menu level. Selected item: The currently selected item on the menu is displayed. Pressing the [ ] or [ ] key scrolls through the items at that level.
  • Page 101 ENGINE SP MODE 31 March, 1999 4.2.3 MARGIN (REGISTRATION AJDUSTMENT) The SP mode menu levels for registration adjustment are described below. Layer 1 Layer 2 Layer 3 Layer 4 Print: Std Tray 1 It can be printed Margin: Print from the optional Std.
  • Page 102 31 March, 1999 ENGINE SP MODE Follow the steps below to adjust registration in the “1. Margin” item of the engine SP mode menu: 1. From the Pattern Print menu, select the media type and paper tray. Then, print the registration adjustment pattern (4C overlay grid pattern). 2.

  • Page 103: Clear Memory

    ENGINE SP MODE 31 March, 1999 4.2.4 PARAMETER Use this menu to specify the paper transfer bias and fusing temperature for normal paper, thick paper, and OHPs. The paper transfer bias can be specified in 1% increments between 50% and 200%.

  • Page 104: Sensor Check

    31 March, 1999 ENGINE SP MODE 4.2.6 SENSOR CHECK Use this menu to check for sensor failures and status. Select the target sensor in the second level menu using the [ ] and [ ] arrow keys. Then, manually change the sensor status and check the corresponding output.
  • Page 105 ENGINE SP MODE 31 March, 1999 Sensor Name Sensor Status Name Display Transfer Roller Tfr Position Release Touch Position Sensor Pull-out Sensor P Feed-2nd Paper not detected Paper detected (Tray 2) Pull-out Sensor P Feed-3rd Paper not detected Paper detected (Tray 3) ID Sensor Temperature/Humidity...
  • Page 106 31 March, 1999 ENGINE SP MODE 4.2.7 NIP WIDTH Use this to re-adjust the fusing pressure, which is required when the pressure adjustment screw for the fusing unit is loosened. This function feeds a transparency from the by-pass feed tray, then stops and resumes feed through the fusing unit three times, and finally ejects the transparency.
  • Page 107 ENGINE SP MODE 31 March, 1999 4.2.9 PROCESS CTRL Use this menu either: • To execute process control after maintenance work that affects process conditions (ID sensor cleaning/replacement, bias electrode cleaning, MCU NV- RAM replacement) • To change the intervals for periodic process control and belt lubrication. There are four types of forced process control (these are listed below), and the parameters that are adjusted are different for each.

  • Page 108: Test Print

    31 March, 1999 ENGINE SP MODE 4.2.10 TEST PRINT Use this menu to check print quality. This function prints a pattern that is internally generated by the print engine and is not processed by the controller. To stop printing, press the [Escape] key. The following three patterns can be printed using this function: •...

  • Page 109: Image Adjust

    ENGINE SP MODE 31 March, 1999 4.2.12 IMAGE ADJUST Use this menu to adjust the reproduction ratio of images. With the top left corner as the reference point, adjustment can be done in steps of ± 0.1% within Layer 1 Layer 2 Layer 3 Layer 4...
  • Page 110 31 March, 1999 ENGINE SP MODE Name Display Operation Quenching lamp Quenching LED Operating until inputting PCU motor PCU Motor-slow Operating until inputting PCU Motor-normal Operating until inputting PCU Motor-fast Operating until inputting PCU Motor-reverse Operating until inputting Main motor Main Mtr-normal Operating until inputting Main Mtr-slow...

  • Page 111: Highlight Adjustment

    ENGINE SP MODE 31 March, 1999 4.2.14 HIGHLIGHT ADJUSTMENT Use this menu to adjust the density in high-light (low ID) areas for each of Y, C, M, and K. This adjusts the grid bias. After adjusting this setting, do a forced process control (engine SP mode 7, Process Contrl –...

  • Page 112: Preventive Maintenance

    31 March, 1999 PM TASKSPM TASKSPM TASKS 5. PREVENTIVE MAINTENANCE 5.1 PM TASKS 5.1.1 REPLACEMENT Replace the PM parts every 100 K printouts as shown in the PM table on the next page. The fusing unit replacement interval is not determined in the same way. For details, see the note after the PM table.

  • Page 113: Main Unit

    PM TABLE 31 March, 1999 5.2 PM TABLE 5.2.1 MAIN UNIT C: Clean R: Replace I: Inspect item 100k Note Paper feed roller Alcohol or water Registration roller Alcohol or water Friction pad Water Bottom plate pad Water By-pass feed roller Alcohol or water Pull-out roller Alcohol or water...

  • Page 114: Replacement And Adjustment

    31 March, 1999 EXTERIOR 6. REPLACEMENT AND ADJUSTMENT 6.1 EXTERIOR 6.1.1 RIGHT COVER/OZONE FILTER COVER G024R151.WMF 1. Remove the ozone filter cover [A]. 2. Remove the ozone filter [B]. 3. Remove the right cover [C] (four screws).

  • Page 115: Left Cover

    EXTERIOR 31 March, 1999 6.1.2 LEFT COVER G024R152.WMF 1. Open the oil bottle cover [A]. Remove the left cover [B] (three screws).
  • Page 116 31 March, 1999 EXTERIOR 6.1.3 BOTTOM FRONT COVER G024R268.WMF 1. Open the front cover half way, and remove two snap rings [A]. 2. Carefully slide the hinge levers [B] out from the bottom front cover [C]. NOTE: The levers are spring loaded. 3.
  • Page 117 EXTERIOR 31 March, 1999 6.1.5 TOP COVER AND TOP REAR COVER G024R167.WMF G024R251.WMF 1. Open the oil bottle cover [A]. Remove the two screws holding the top cover [B], then slide and remove the top cover [B]. 2. Remove the top rear cover [C] (two screws).

  • Page 118: General Cautions

    31 March, 1999 INSIDE THE MAIN UNIT 6.2 INSIDE THE MAIN UNIT 6.2.1 GENERAL CAUTIONS G024R500.WMF CAUTION: When replacing the components inside the main unit, follow the instructions below. 1. When placing the PCU outside the printer, cover the photosensitive face with a sheet of paper or a similar material to avoid direct exposure to light.
  • Page 119 INSIDE THE MAIN UNIT 31 March, 1999 6.2.2 ID SENSOR G024R106.WMF 1. Remove the PCU. 2. Remove the ID sensor [A] (1 screw, 1 connector [B]). NOTE: Calibrate the new ID sensor after installing it. Follow the steps described in “Calibrating the ID sensor”...
  • Page 120 31 March, 1999 INSIDE THE MAIN UNIT 6.2.3 CALIBRATING THE ID SENSOR ID sensor calibration flowchart SP "9: ID Sensor PWM" Set 150 as PWM. SP "7: Process Ctrl" Execute "Color Bias." SP "8: Test Print" Print "Pattern 3." SP "9: ID Sensor PWM" D a r k : P W M →...
  • Page 121 INSIDE THE MAIN UNIT 31 March, 1999 6.2.4 PCU SET SWITCH/CHARGE CORONA UNIT SET SWITCH/PCU RESET SENSOR/ USED TONER SENSOR/QUENCHING LAMP G024R107A.WMF 1. Remove the PCU. 2. Remove the PCU set switch [A] (two hooks). Make sure to unplug the connector.
  • Page 122 31 March, 1999 INSIDE THE MAIN UNIT 6.2.5 PULL-OUT SENSOR/PAPER END SENSOR Pull-out sensor G024R275.WMF 1. Remove the PCU. 2. Remove the pull-out sensor [A] (four hooks, one connector [B]). Paper end sensor G024R900.WMF 1. Remove the paper end sensor bracket [C] (one screw). 2.
  • Page 123 INSIDE THE MAIN UNIT 31 March, 1999 6.2.6 OIL END SENSOR/EXIT COVER SWITCH G024R108B.WMF 1. Remove the fusing unit. (See Fusing Unit Removal.) 2. Remove the oil end sensor [A] (two hooks, one connector [B]). 3. Remove the exit cover switch bracket [C] (one screw, two connectors). 4.
  • Page 124 31 March, 1999 INSIDE THE MAIN UNIT 6.2.7 DOOR SAFETY SWITCH, PCU MOTOR, MAIN MOTOR G024R115.WMF G024R161.WMF G024R162.WMF 1. Remove the right cover. (See Right Cover Removal.) 2. Remove the door safety switch [A] (two screws, six connectors). 3. Remove the top flywheel [B] (three screws). 4.
  • Page 125 INSIDE THE MAIN UNIT 31 March, 1999 6.2.8 TRANSFER BELT CLEANING SOLENOID/DEVELOPMENT DRIVE SOLENOID G024R163A.WMF 1. Remove the right cover. (See Right Cover Removal.) 2. Remove the PCU motor. (See PCU Motor Removal.) 3. Remove the bottom flywheel [A] (three screws). 4.
  • Page 126 31 March, 1999 INSIDE THE MAIN UNIT 6.2.9 ADJUSTING THE DEVELOPMENT JOINT G024R518.WMF G024R516.WMF This is needed after replacing the development drive solenoid. 1. Remove the left cover. (See Left Cover Removal.) 2. Remove the right cover. (See Right Cover Removal.) 3.
  • Page 127 INSIDE THE MAIN UNIT 31 March, 1999 6.2.10 PCU DRIVE UNIT G024R111.WMF 1. Remove the right cover. (See Right Cover Removal.) 2. Loosen the tightener retaining screws [A] to release tension. 3. Remove the PCU joint drive unit [B] (four screws). NOTE: When installing the PCU drive unit, make sure that the arm is set in the constrictions of the two joints.
  • Page 128 31 March, 1999 INSIDE THE MAIN UNIT 6.2.11 REVOLVER MOTOR G024R901.WMF 1. Remove the right cover. (See Right Cover Removal.) 2. Remove the revolver motor unit [A] (three screws, one connector [B]). 6-15...
  • Page 129 INSIDE THE MAIN UNIT 31 March, 1999 6.2.12 DTM UNIT G024D164A.WMF 1. Turn off the printer. 2. Open the DTM cover [A] and remove the DTM unit [B]. Refer to the Quick Installation Guide and Operating Instructions. NOTE: 1) Be careful not to drop toner onto the floor. (Before placing the DTM unit on the floor, lay down a sheet of paper first.) 2) After installing a new DTM unit, remove the seal.
  • Page 130 31 March, 1999 LASER OPTICS SECTION 6.3 LASER OPTICS SECTION 6.3.1 LD UNIT G024R266.WMF G024R267.WMF 1. Remove the right cover. (See Right Cover Removal.) 2. Remove the left cover. (See Left Cover Removal.) 3. Lift the handle [A] to release the lock. Remove the Y, M, C, and K DTM units [B].
  • Page 131 LASER OPTICS SECTION 31 March, 1999 G024R258.WMF G024R259A.WMF 5. Remove the development top cover [A] (three screws). 6. Remove the development bottom cover [B] (two screws and 3 hooks). 7. Remove the LD unit [C] (two screws, one connector [D]). CAUTION: Do not loosen the painted screws [E].
  • Page 132 31 March, 1999 LASER OPTICS SECTION 6.3.2 OPTICAL HOUSING UNIT/POLYGON MIRROR MOTOR ø WARNING Turn off the main switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes. G024R269.WMF G024R270.WMF 1.
  • Page 133 LASER OPTICS SECTION 31 March, 1999 G024R522.WMF G024R504A.WMF CAUTN-V.WMF LASER-3.WMF 9. Remove the duct [E] for the exhaust fan (one screw). 10. Remove the optical housing unit [G] (four screws, two connectors [H]), lifting it in the direction of the arrow in the diagram. NOTE: When putting back the optical housing unit, check that the positioning boss on the housing bottom plate is in the hole in the main unit base.
  • Page 134 31 March, 1999 LASER OPTICS SECTION G024R263.WMF G024R506A.WMF 11. Remove the optical housing unit cover [I] (four screws and two hooks). NOTE: When removing or putting back the bracket, be careful not to touch the polygon mirror faces. 12. Remove the polygon mirror motor [J] (four screws). 6-21...

  • Page 135: Fusing Section

    FUSING SECTION 31 March, 1999 6.4 FUSING SECTION 6.4.1 FUSING UNIT ø CAUTION 1. The fusing unit is hot. Handle with care. 2. Be careful not to spill silicone oil. 3. In the event of a fusing-related SC, replace the applicable components and execute “6: Reset SC”...
  • Page 136 31 March, 1999 FUSING SECTION 6.4.2 OIL SUPPLY UNIT, PRESSURE ROLLER LAMP, HOT ROLLER LAMP, PRESSURE ROLLER THERMOFUSE, PRESSURE ROLLER THERMISTOR G024R170.WMF G024R169A.WMF NOTE: If the pressure spring retaining screw has been turned while replacing the pressure or hot roller, adjust the nip width. See “Checking and Adjusting the Fusing Nip Width”...
  • Page 137 FUSING SECTION 31 March, 1999 G024R172.WMF G024R173.WMF 4. Remove the exit guide. (See Exit Sensor Removal.) 5. Remove the oil supply unit [A] (two screws). 6. Remove the holder [B] for the right fusing lamp terminals (three screws, three connectors). 6-24...
  • Page 138 31 March, 1999 FUSING SECTION G024R174.WMF G024R175.WMF 7. Remove the holder [A] for the left fusing lamp terminals (two screws, five connectors). 8. Extract the pressure roller lamp [B]. 9. Extract the hot roller lamp [C]. 6-25...
  • Page 139 FUSING SECTION 31 March, 1999 Reinstallation Make sure that the cables are connected to the correct places. G024R174.WMF G024R173.WMF • Pressure roller lamp connector [a], [A] • Hot roller lamp connector [b], [B] • Pressure roller thermofuse connector [c], [C] •...
  • Page 140 31 March, 1999 FUSING SECTION 6.4.3 OIL SUPPLY ROLLER, OIL SUPPLY SUB-ROLLER, BLADE G024R176.WMF 1. Remove the oil bottle [A]. NOTE: Oil tends to remain in the cap. Keep the oil bottle [A] lifted a little for a while, wait for the oil drips to stop, then move the oil bottle outside the printer.
  • Page 141 FUSING SECTION 31 March, 1999 G024R177.WMF G024R178.WMF 4. Remove the oil supply stay [A] (two screws). NOTE: When installing the oil supply stay, ensure that the notch fits over its counterpart. 5. Remove the oil supply sub-roller [B] (two E rings and two bearings). 6.
  • Page 142 31 March, 1999 FUSING SECTION 6.4.4 PAPER EXIT SENSOR, CLEANING ROLLER G024R309.WMF G024R171A.WMF G024R521.WMF 1. Open the exit top guide [A], and remove the exit bottom guide [B] (two screws). NOTE: When installing the exit bottom guide, put the paper exit feeler [C] under the guide notch [D] as shown in the diagram.
  • Page 143 FUSING SECTION 31 March, 1999 G024R179.WMF Paper exit sensor 3. Remove the paper exit sensor [A] (one screw and four hooks). Cleaning roller 4. Remove the cleaning roller [B] (two E rings, one gear, two springs, and two bearings). 6-30...
  • Page 144 31 March, 1999 FUSING SECTION 6.4.5 PRESSURE ROLLER, HOT ROLLER, HOT ROLLER THERMOFUSE, HOT ROLLER THERMISTOR G024R180.WMF G024R181.WMF 1. Remove the inlet guide plate [A] (two screws). NOTE: Put the two screws into the central screw holes [F] in the inlet guide plate when reinstalling it.
  • Page 145 FUSING SECTION 31 March, 1999 G024R182.WMF G024R183.WMF 6. Remove the hot roller [A] (two C rings, two bearings, and one gear). 7. Remove the inlet guide plate [B] (two screws). 8. Remove the hot roller thermistor [C] (one screw). 9. Remove the hot roller thermofuse [D] (one screw). 6-32...
  • Page 146 31 March, 1999 FUSING SECTION 6.4.6 CHECKING AND ADJUSTING THE FUSING NIP WIDTH 1 0 m m 1 0 m m Alteration belt G024R520.WMF NOTE: 1) Wait five minutes or longer after completion of warm-up before starting the steps below. 2) Put one transparency (long edge feed) in the by-pass feed table.
  • Page 147 FUSING SECTION 31 March, 1999 G024R314.WMF 4. If the average fails to meet the standard, turn the pressure screw [A]. (Black arrow direction: more nip width. White arrow direction: less nip width) Troubleshooting 1. Wrinkles Adjust the nip width to the upper limit of the standard (L: 6.7 mm, R: 7.1 mm). After adjustment, check that worm-like images do not appear.

  • Page 148: Electrical Wiring

    31 March, 1999 ELECTRICAL WIRING 6.5 ELECTRICAL WIRING 6.5.1 CONTROLLER BOARD, TEMPERATURE/HUMIDITY SENSOR NOTE: Before replacing the controller, print the list of settings whenever possible. In the event of NV-RAM damage, it is necessary to configure all settings according to the list. 1.

  • Page 149: Power Supply Unit

    ELECTRICAL WIRING 31 March, 1999 6.5.2 POWER SUPPLY UNIT ø WARNING To avoid the risk of electric shock, unplug the power cable before starting power supply unit replacement. 1. Remove the fusing unit (see Fusing Unit Removal) and the controller board (see Controller Board Removal).
  • Page 150 31 March, 1999 ELECTRICAL WIRING 4. Remove the power supply unit [C] (six screws, six connectors). G024R254.WMF 6-37...
  • Page 151 ELECTRICAL WIRING 31 March, 1999 6.5.3 HIGH VOLTAGE SUPPLY UNIT G024R255.WMF 1. Remove the right cover (see Right Cover Removal), left cover (see Left Cover Removal), controller board (see Controller Board Removal), and power supply unit (see Power Supply Unit Removal). 2.
  • Page 152 31 March, 1999 ELECTRICAL WIRING 6.5.4 MCU G024R256.WMF 1. Open the rear side panel (See High Voltage Supply Unit Removal). 2. Remove the MCU [A] (four screws, 18 connectors). NOTE: When replacing an MCU, remove the NVRAM chip (IC106) from the old board, install it on the new board, then install the new board.
  • Page 153 ELECTRICAL WIRING 31 March, 1999 6.5.5 UPGRADING THE MCU FIRMWARE NOTE: Turn off the printer before inserting or removing the IC card. (Otherwise the IC card may be damaged.) 1. Remove the left cover. (See Left Cover Removal.) 2. Remove the bracket to the bottom left of the revolver unit (one screw). 3.

  • Page 154: Paper Feed Section

    31 March, 1999 PAPER FEED SECTION 6.6 PAPER FEED SECTION 6.6.1 BY-PASS PAPER END SENSOR, REGISTRATION SENSOR G024R154.WMF 1. Remove the front cover. (See Front Cover Removal.) 2. Remove the paper end sensor bracket [A] (one screw). 3. Remove the by-pass paper end sensor [B] (one connector and four hooks). 4.

  • Page 155: Paper Width Detection Board

    PAPER FEED SECTION 31 March, 1999 6.6.2 PAPER WIDTH DETECTION BOARD G024R155.WMF G024R105.WMF G024R156.WMF 1. Remove the front cover. (See Front Cover Removal.) 2. Remove the by-pass feed table unit [A] (two snap rings, two hooks, one connector [B]). 3. Remove the auxiliary tray [C] (two hooks), from the cover [D] for the by-pass feed table.
  • Page 156 31 March, 1999 PAPER FEED SECTION 6.6.3 BY-PASS PAPER FEED ROLLER G024R157A.WMF G024R158.WMF 1. Remove the front cover. (See Front Cover Removal.) 2. Remove the paper end sensor bracket. (See By-pass Paper End Sensor Removal.) 3. Remove the pad bracket [A] (three screws). 4.

  • Page 157: Paper Feed Roller

    PAPER FEED SECTION 31 March, 1999 6.6.4 PAPER FEED ROLLER G024R408.WMF 1. Remove the paper feed tray. 2. Pull down the front bottom cover forward. Slide the lever [A] in the direction of the arrow in the diagram, and remove the paper feed roller [B]. 6-44...
  • Page 158 31 March, 1999 PAPER FEED SECTION 6.6.5 PCU HOLDER ø CAUTION Before removing the torsion springs [B] in the following procedure, make sure that the front cover is closed (to release pressure). If the springs are removed while pressure is applied to them, they may jump out and cause injury.
  • Page 159 PAPER FEED SECTION 31 March, 1999 6.6.6 TRANSFER ROLLER POSITION SENSOR, BY-PASS PAPER FEED CLUTCH, REGISTRATION CLUTCH, AND TRANSFER ROLLER CLUTCH G024R159.WMF 1. Remove the right inner cover [A] (three screws). 2. Remove the front cover. (See Front Cover Removal.) 6-46...
  • Page 160 31 March, 1999 PAPER FEED SECTION G024R519.WMF G024R160.WMF Transfer roller position sensor 3. Remove the transfer roller position sensor [A] (four hooks, one connector [B]). By-pass paper feed clutch 4. Remove the by-pass paper feed clutch [C] (one hook, one connector [D]). Registration clutch 5.

  • Page 161: Transfer Roller

    PAPER FEED SECTION 31 March, 1999 6.6.7 TRANSFER ROLLER G024R265.WMF 1. Remove the front cover. (See Front Cover Removal.) 2. Remove the right inner cover (three screws). See Transfer Roller Position Sensor Removal. 3. Remove the transfer roller [A] (three E rings, one gear, and two bearings). 6.6.8 REGISTRATION ROLLER IDLER G024R406.WMF 1.
  • Page 162 31 March, 1999 PAPER FEED SECTION 6.6.9 REGISTRATION CLUTCH AND REGISTRATION DRIVE ROLLER G024R407A.WMF 1. Remove the front cover (see Front Cover Removal) and registration roller idler (see Registration Roller Idler Removal). 2. Remove the registration clutch [A] (one hook, one connector [B]). NOTE: When putting back the registration clutch, put the stopper on the bent part of the bracket.
  • Page 163 PAPER FEED SECTION 31 March, 1999 6.6.10 TRAY PAPER FEED CLUTCH, PAPER SIZE SWITCH, AND PULL-OUT/RELAY ROLLER CLUTCH G024R273.WMF G024R274.WMF 1. Remove the front bottom cover (see Front Bottom Cover Removal) and the paper feed roller (see Paper Feed Roller Removal). 2.
  • Page 164 31 March, 1999 PAPER FEED SECTION Pull-out clutch G024R271.WMF 4. Remove the pull-out clutch bracket [A] (two screws). 5. Remove the pull-out clutch [B] (one bearing, one connector [C]). Relay roller clutch G024R272.WMF 6. Remove the relay roller clutch [D] (one hook, one connector [E]). 6-51...

  • Page 165: Troubleshooting

    31 March, 1999 SC TABLES 7. TROUBLESHOOTING 7.1 SC TABLES 7.1.1 TYPES OF SERVICE CALL For this printer engine, service calls and process control errors are classified into three types: TYPE 1: Safety warning and The printer stops immediately and the LCD displays immediate shutdown an SC error message.
  • Page 166 SC TABLES 31 March, 1999 7.1.2 SC ERROR LIST Type Name Occurrence conditions Detection conditions Cause Type 2 Optional tray The detection signal for Always monitored The optional tray unit error the 500 sheet paper tray unit connector has a unit is abnormal.
  • Page 167 31 March, 1999 SC TABLES Type Name Occurrence conditions Detection conditions Cause Type 2 Primary The PWM duty has been Detection starts 60 There is a transfer bias 50% or higher for 240 ms after control starts disconnection in the open for this component.
  • Page 168 SC TABLES 31 March, 1999 Type Name Occurrence conditions Detection conditions Cause Type 2 Laser diode LD error (abnormal laser LD, LD control error power output) board Type 2 Synchronizat Synchronization detection During polygon mirror Synchronization ion detection error of the optical unit motor revolution detection board, LD error...
  • Page 169 31 March, 1999 SC TABLES Type Name Occurrence conditions Detection conditions Cause Type 1 Hot roller When full-power No detection in the Hot roller thermistor, lamp full- operation occurs during event of a jam/door hot roller lamp power reheating, the main motor open, SC, unit connector, MCU operation...
  • Page 170 SC TABLES 31 March, 1999 7.1.3 PROCESS CONTROL ERROR LIST Detection Type Name Occurrence conditions Cause conditions Type 3 K ID sensor While the LED is off, the ID sensor (K) When the output error ID sensor output does not calibration meets the standard meet the standard...
  • Page 171 31 March, 1999 SC TABLES Detection Type Name Occurrence conditions Cause conditions The slope γM of the line Type 3 ID sensor K-DTM bias control Incorrect DTM pattern error installation, incorrect representing the PCU installation, relationship between the development bias DTM bias and attached error, MCU, LD control toner amount is not...
  • Page 172 USER ERROR LIST 31 March, 1999 7.2 USER ERROR LIST Operation after Detection Error Release method Remarks error conditions Add Toner: xx Printing can be Toner near-end Replace the DTM. When near-end is done. detection is enabled detected, closing the two seconds after front cover initiates the development...
  • Page 173 31 March, 1999 USER ERROR LIST Operation after Detection Error Release method Remarks error conditions Paper Size Printing is The specified paper Open the door. Error disabled. size for the by-pass feed table differs from that detected. Or the paper size in the tray differs from the paper size dial setting by ±40 mm.
  • Page 174 USER ERROR LIST 31 March, 1999 Operation after Detection Error Release method Remarks error conditions Reset Charger Printing is The charge corona Install the charge Correctly disabled. unit set switch does corona unit correctly. not detect the wire Return the wire cleaner for the cleaner to the home charge corona unit...
  • Page 175 31 March, 1999 USER ERROR LIST Release Detection conditions Remarks method Paper feed Paper Operation Paper feed clutch to Error feed after error Paper clutch to registration clutch to tray registration sensor (2 pull-out sensor (1 in double- sensor image mode Remove The paper feed jam...
  • Page 176 USER ERROR LIST 31 March, 1999 Operation Release Error Detection conditions Remarks after error method Remove the The transport Transport Printing is The exit sensor does not disabled. detect paper 3.14 seconds jammed paper jam counter after the registration clutch and close the increases by 1.
  • Page 177 ELECTRICAL COMPONENT LAYOUT SENSORS SWITCHES G024V551.WMF G024V551A.WMF Index No. Description Symbol P-to-P Main switch Exit cover switch Index No. Description Symbol P-to-P Door safety switches Exit sensor Paper size switch Oil end sensor PCU set switch Transfer belt H.P. sensor Charge corona unit set switch Transfer roller position sensor DTM cover switch...
  • Page 178 ì ë ê é è ç æ å )8ì 3&%ì 3RZHUý VXSSO\ý XQLW /ì +RWý UROOHU ëèí9 ODPS &1ìíëðì ì ì 7)ì 3RZHUýFRUG ìè$ +RWý UROOHU 7ìíê 7ìíì /,1( &1ìíëðë ë ë WKHUPRIXVH /ë 3UHVVXUHý UROOHU 3RZHUý UHOD\ ODPS &1ìíëðê ê...

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