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Ricoh FT7770 Service Manual

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RICOH FT7770

S E R V I C E

M A N U A L

RICOH COMPANY, LTD.

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Summary of Contents for Ricoh FT7770

Page 1 RICOH FT7770 S E R V I C E M A N U A L RICOH COMPANY, LTD.
Page 2: Table Of Contents
TABLE OF CONTENTS SECTION 1: OVERALL MACHINE INFORMATION MAIN SPECIFICATIONS GUIDE TO COMPONENTS Copier Exterior Copier Interior Operation Panel 1-10 HOW TO USE THE GUIDANCE DISPLAY 1-14 DISPLAY CONTROL KEYS 1-15 THE COPY CYCLE 1-16 COPY PROCESSES AROUND THE DRUM 1-17 PAPER PATH 1-18...
Page 3 EXPOSURE Introduction 2-11 2-12 Exposure Lamp Unit Automatic Image Density Sensing 2-13 Lamp Regulator 2-14 Optics Cooling Fan 2-16 2-16 Anticondensation Heater SCANNER DRIVE Introduction 2-17 Scanner Motor Control 2-18 LENS AND MIRROR POSITIONG Lens Positioning 2-20 Second Scanner Shift 2-22 2-23 Lens/Mirror Position Initialization...
Page 4 PAPER FEED 2-61 Introduction 2-62 Feed Unit Mechanism 2-63 FER Operation 2-64 Paper Tray Drive Mechanism 2-65 Friction Roller Reverse Mechanism 2-66 Paper Volume Detection 2-67 Guide Posts and Paper Size Detection 2-68 Tray Lock and Positioning 2-69 Paper Size Board 2-70 220/240-Volt Paper Size Sensor 2-71...
Page 5 OTHER CIRCUITS Counters 2-103 Photosensor 2-105 Photointerrupters 2-106 Solenoids 2-107 Magnetic Clutches 2-108 Monitor Board 2-109 Operation Panel 2-110 AC Drive Board 2-111 Ozone Fan 2-112 Corona Cleaner 2-113 INSTALLATION SECTION 3: INSTALLATION REQUIREMENT Environment Minimum Space Requirement Machine Level Power Source INSTALLATION Unpacking...
Page 6 DRUM AND CHARGE Drum Replacement Drum Thermoswitch and Heater Replacement Charge Corona Wire and Cleaner Pad Replacement EXPOSURE Scanner Drive Wire Replacement 5-16 Lens Drive Wire Replacement 5-20 Exposure Lamp Unit Removal DEVELOPMENT 5-21 Development Unit Removal Developer Replacement 5-22 Development Roller and 5-23 Paddle Roller Removal...
Page 7 INVERTER Inverter Roller Clutch Disassembly and Adjustment 5-53 Return Pinch Roller Solenoid Adjustment 5-55 Inverter Gate Solenoid Adjustment 5-56 PAPER FEED Paper Feed Unit Removal 5-57 Pick-up Roller Replacement 5-58 Feed Roller Replacement 5-59 Friction Roller Replacement 5-60 Paper Tray Unit and Cover Removal 5-61 Paper Tray Drive Wire Replacement 5-62...
Page 8 ELECTRICAL DATA SECTION 6: MAIN BAORD SCHEMATIC 1 MAIN BAORD SCHEMATIC 2 MAIN BAORD SCHEMATIC 3 DC DRIVE BOARD SCHEMATIC SCANNER MOTOR CONTROL BOARD SCHEMATIC MAIN MOTOR CONTROL BOARD SCHEMATIC LENS/MIRROR MOTOR CONTROL BOARD SCHEMATIC POWER SUPPLY UNIT BLOCK DIAGRAM AC DRIVE BOARD SCHEMATIC 6-10 OPERATION PANEL-CPU BOARD SCHEMATIC...
Page 9 ELECTRICAL OPERATION Interface With Copier 7-24 Feed-in Sensor 7-25 Motor Control 7-26 7-27 Original Size Sensing DF Misfeed Check 7-29 Application Switch 7-30 Form Size Switch 7-31 CFF Feed Hole and Set Sensors 7-32 SERVICE TABLES Test Point Table 7-33 Variable Resistor Table 7-33 LED Table...
Page 10 MECHANICAL OPERATION Basic Operation Feed Unit Mechanism Tray Drive Mechanism Friction Roller Reverse Mechanism Paper Volume Detection Guide Plate and Paper Size Detection 8-10 Tray Lock and Positioning ELECTRICAL OPERATION Tray Motor Circuit 8-11 Paper Tray Heater 8-12 Tray Set Detection 8-12 INSTALLATION 8-13...
Page 11 INSTALLATION 9-21 Accessory Check 9-22 Installation Procedure SERVICE TABLES 9-25 Sorter Main Board 9-26 Sorter Interface Board REPLACEMENT AND ADJUSTMENT 9-27 Distribution Unit Removal 9-29 Transport Unit Removal 9-30 Transport Belt Replacement 9-33 Jam Sensor and Bin Copy Sensor Adjustment 9-34 50Hz/60Hz Modification 9-35...
Page 12 11-12 BASIC OPERATION MECHANICAL OPERATION Transport Section 11-13 Turn Gate Section 11-14 11-15 Distribution Section 11-16 Side Plate 11-18 Staple Unit 11-23 Misfeed Clearance Release Mechanism ELECTRICAL OPERATION 11-24 Bin/Jam sensor 11-25 Safety Switch 11-27 Service Call Conditions INSTALLATION 11-29 Accessory Check 11-30 Installation Procedure...
Page 13 BASIC OPERATION Job Sheet Reading 12-4 12-6 Menu Reader Indicator Lights 12-7 Processing Errors INSTALLATION Accessory Check 12-8 12-9 Installation Procedure REPLACEMENT AND ADJUSTMENT 12-11 Lower Transport Roller Replacement 12-12 MENU READER CONTROL BOARD SCHEMATIC SECTION 13: TROUBLESHOOTING 13-1 INTRODUCTION COPY QUALITY 13-2 White Spots...
Page 14 Original Jam 13-35 No Display 13-35 Abnormal Indication 13-36 SORTER Not Ready 13-37 False Jam 13-37 Jam in Sorter 13-38 Others 13-38 SERVICE CALL CONDITIONS SC - 1 Exposure 13-39 SC - 2 Drum Thermistor 13-41 13-42 SC - 3 Drum Heater SC - 4 13-43...
Page 15 SECTION 14: SORTER/STAPLER CONNECTOR UNIT 1. SPECIFICATIONS ........14-1 2.
Page 16 5.1 PM TABLE (Differences Between F21 and F22) ....... 15-9 5.2 VARIABLE RESISTORS .
Page 17: Overall Machine Information
SECTION 1 OVERALL MACHINE INFORMATION...
Page 18: Main Specifications
CONTENTS MAIN SPECIFICATIONS GUIDE TO COMPONENTS Copier Exterior Copier Interior Operation Panel 1-10 HOW TO USE THE GUIDANCE DISPLAY 1-14 DISPLAY CONTROL KEYS 1-15 THE COPY CYCLE 1-16 COPY PROCESSES AROUND THE DRUM 1-17 PAPER PATH 1-18 MECHANECAL COMPONENT LAYOUT 1-20 ELECTRICAL COMPONENT LAYOUT 1-22...
Page 19 30 April, ’89 MAIN SPECIFICATIONS - Item - - Specifications - Configuration: Console Copying Process: Dry electrostatic transfer system Original Feed: Automatic reversing document feeder (ARDF) Computer/Continuous form feeder (CFF) Original Size: Maximum A3, 11” x 17” Reproduction Ratios: 4 reductions, 3 enlargements, 1 option, zoom - 64% to 141% (1%/step) - A4 Version - 4R: 93%, 82%, 71%, and 65%...
Page 20 30 April, ’89 First Copy Time: 3.9 seconds (A4 or 8.5” x 11” fed from upper tray) Copy Number Input: 1 to 999 using number keys Operation Display: Guidance display LCD and indicator LCD Image Density Automatic Density Selection (ADS) + Manual Selection: Selection (7 Steps) Special Features:...
Page 21 30 April, ’89 24 codes (See the field manual for details) Self-diagnostic Codes: More than 50 programs can be controlled from the Service Programs: operation panel for efficient maintenance service. 115 V, 60 Hz, 20 A Power Requirements: 220 V, 50 Hz, 10 A 240 V, 50 Hz, 10 A Warm-up Copying Standby Off Power Consumption:...
Page 22: Guide To Components
30 April, ’89 1. GUIDE TO COMPONENTS 1-1. EXTERIOR...
Page 23 30 April, ’89 C o p i e r No. Name Function Main Switch Turns the machine on or off. Control Panel Operator controls and indicators for the main copier and sorter are located here. Exposure Glass Place originals here for copying. Left Door Provides access for supplying toner and removing misfeeds.
Page 24 30 April, ’89...
Page 25 30 April, ’89 Sorter – CS2065 (Option) 19. Sorter Bins Copies will be sorted or stacked here. 20. Proof Tray When not in sort or stack mode copies are delivered here. 21. Manual Feed Entrance Used to manually feed sheets to the sorter bins. (For job recovery, blank separators, etc.) Provides access for removing misfed paper from the 22.
Page 26: Copier Interior
30 April, ’89 1-2. COPIER INTERIOR...
Page 27 30 April, ’89 Function Name The top swings up for misfeed removal. 1. Top Unit Pull out to remove misfed paper from the fusing area. 2. Fusing Unit When copying thin originals with the document feeder, 3. Original Application set this switch to the right position. Switch When using the computer form feeder, select the com- 4.
Page 28: Operation Panel
30 April, ’89 1-3. OPERATION PANEL Keys * Letter/Legal Version Copy Face Down Key Set Timer Key Press to preset the power on/off time When this key is pressed, copies will for each day of the week. be delivered to the copy tray face down. Edit Image Key Staple Key Press to staple sorted copies.
Page 29 30 April, ’89 * A4/A3 Version Decimal Point Key Enlarge Key Press to make enlarged copies. Suc- Press to enter the decimal point when cessive key strokes change the ratio. entering the sizes of originals or copies while in size magnification mode. Display Control Keys Clear/Stop Key Press to make choices in the guidance...
Page 30 30 April, ’89 Indicators * Letter/Legal Version Auto Paper Selection Indicates that the copy paper matching the original size will be automatically selected. Original Recovery Counter (upper display) If a misfeed occurs while in ADF mode, this indicator shows how many originals must be reset before resuming copying. Load Staples Lights when the staple cartridge is empty.
Page 31 30 April, ’89 * A4/A3 Version Insert Key Counter Indicates that the key counter is not set correctly. The machine will not operate if the key counter is not properly set. Call Service Indicates that there are functional problems within the copier. Call your service representative.
Page 32: How To Use The Guidance Display
However, the added features do not mean added difficulty, because the FT7770 employs an ad- vanced guidance panel. The guidance panel displays all the information you need to operate the machine using a combination of text and animated graphic displays.
Page 33: Display Control Keys
30 April, ’89 Display Control Keys The number of control keys used in this machine is quite small when compared to the number of functions available. This is possible because the Guidance Display and the Display Control keys centralize and simplify all operator choices. In operation, a replica of the Display Con- The Display Control keys resemble the trol Keys is displayed on the guidance...
Page 34 30 April, ’89 1-16...
Page 36: Paper Path
30 April, ’89 PAPER PATH 1. Primary Paper Path 2. Copy Face Down Path 1-18...
Page 37 30 April, ’89 3. Duplex Copy Path 4. Image Overlay Path 1-19...
Page 38: Mechanical Component Layout
30 April, ’89 MECHANICAL COMPONENT LAYOUT (Front View) 15. Transport Belts Friction Roller Erase Lamp Unit 16. Return Rollers Feed Roller Exposure Glass Pull-out Rollers 17. Hot Roller Charge Corona Unit Vertical Transport Unit Drum Thermistor Unit 18. Inverter Rollers Vertical Transport Rollers 19.
Page 39: Electrical Component Layout
30 April, ’89 ELECTRICAL COMPONENT LAYOUT 1-22...
Page 40 30 April, ’89 Top Unit Safety Switch Duplex Side Plate Sensor Left Door Safty Switch Lower Tray Lift Sensor CPU PCB Lower Paper Feed Sensor ROM PCB Upper Paper Feed Sensor Lens Safety Sensor Duplex Paper Feed Clutch Right Door Safety Switch Duplex Entrance Sensor Left LCD PCB Ozone Fan Motor...
Page 41 30 April, ’89 67. Upper Paper Feed Clutch 83. Upper Paper End Sensor 68. Upper Tray Motor 84. Upper Paper Size PCB 69. Upper Paper Volume Sensor 85. Upper Tray Heater 70. Lower Paper Volume Sensor 86. Lower Paper Feed Clutch 87.
Page 42 30 April, ’89 116. Rush Current Relay (220/240 V) Scanner Motor Control PCB 117. Circuit Breaker Scanner H.P. Sensor 118. Noise Filter (220/240 V) Optics Thermoswitch (115V) 119. Noise Filter 100. Scanner Motor 120. AC Power Relay 101. Optics Cooling Fan Motor 121.
Page 43: Drive Layout
30 April, ’89 DRIVE LAYOUT (Rear View) Main Motor Inverter Drive Chain Main Drive Belt Inverter Roller Clutch Sprocket 20. Pull-out Roller Gear Fusing Pressure Drive Gear Vertical Transport Unit Fusing Pressure Drive Chain Vertical Transport Drive Chain Hot Roller Gear Vertical Transport Drive Gear Fusing Drive Gear Relay Gear...
Page 44: Electrical Component Descriptions
30 April, ’89 ELECTRICAL COMPONENT DESCRIPTIONS 1. Motors Charge Fan (M-13) 24-volt dc motor: Provides airflow to the charge corona to prevent uneven build up of positive ions. Charge Corona Wire 12-volt dc motor: Drives the charge corona wire cleaner. Cleaner (M-14) Hall effect motor: drives the development Development (M-4)
Page 45 30 April, ’89 3. Solenoids Cleaning (SOL-1) Brings the cleaning blade into contact with the drum. Raises and lowers the duplex bottom plate. Duplex Bottom Plate (SOL-8) Fork Gate (SOL-7) Varies the paper path in the duplex unit depending on paper size. Directs copies between the inverter guide Inverter Gate (SOL-4) plates.
Page 46 30 April, ’89 5. Sensors Duplex Entrance (S-14) 46 Jam detector. Duplex Paper (S-13) Determines whether or not there is paper in the duplex tray. Duplex Paper Feed Turns off the duplex paper feed clutch; (S-15) also, serves as a jam detector. Duplex Side Plate Determines the home position of the duplex (S-16)
Page 47 30 April, ’89 6. Power Packs Provides power for the development bias. Bias (P-4) Charge/PCC (P-2) Provides power for the charge and pre- cleaning coronas. Cleaning Bias (P-6) Provides power for the cleaning bias. PQC (P-5) Provides power for the pre-quenching corona.
Page 48 30 April, ’89 9. Printed Circuit Boards AC Drive (PCB-4) Controls several ac motors with SSRs. CPU (PCB-13) Controls all the operation panel PCBs. DC/AC Inverter (PCB-6) 12 Provides power for the LCD display. Development Motor Controls the speed of the development motor.
Page 49 30 April, ’89 11. Thermistors Bias (TH-2) Monitors the drum temperature for control of the development bias. Drum (TH-1) Monitors the drum temperature for control of the drum heater. Fusing (TH-3) Monitors the hot roller temperature for control of the fusing lamps. 12.
Page 50 30 April, ’89 14. Others Auto ID Cable (O-2) Optic fiber cable. A3/Ledger Counter (O-9)* 49 Keeps a count of the number of A3/Ledger copies made. Circuit Breaker (O-6) Guards against wall voltage surges. Steps 100 volts ac down to working voltage Development Trans.
Page 51: Overall Machine Control
30 April, ’89 OVERALL MACHINE CONTROL The following block diagram shows the direction of control signal flow within the copier. 1-34...
Page 52: Ac And Dc Power Distribution
30 April, ’89 AC AND DC POWER DISTRIBUTION 1-35...
Page 53: Detailed Section Description
SECTION 2 DETAILED SECTION DESCRIPTIONS...
Page 54: Drum
CONTENTS DRUM Selenium Drum Drum Thermistor Unit Drum Heater Circuit CHARGE Corona Unit Corona Unit Ventilation Wire Cleaner Charge Power Pack ERASE Introduction Side Erase and leading/Trailing Edge Erase 2-10 Erase Lamp Circuit EXPOSURE 2-11 Introduction 2-12 Exposure Lamp Unit 2-13 Automatic Image Density Sensing 2-14...
Page 55 April, ’89 CLEANIG 2-49 Introduction 2-50 Drive Mechanism 2-51 Cleaning Blade Pressure Mechanism 2-53 Used Toner Removal 2-55 Cleaning Solenoid Circuit 2-56 PCC Power Pack 2-57 Cleaning Bias Power Pack QUENCHING 2-58 Introduction 2-59 Pre-Quenching corona Circuit 2-60 Quenching Lamp Circuit PAPER FEED 2-61 Introduction...
Page 56 April, ’89 DUPLEX TRAY 2-94 Introduction 2-96 Drive Mechanism 2-96 Fork Gate 2-97 Paper Positioning 2-98 Bottom Plate Mechanism 2-99 Duplex Paper Feed 2-100 Duplex Motor Circuit TOP UNIT 2-101 Release Mechanism 2-102 Drum Support OTHER CIRCUITS 2-103 Counters 2-105 Photosensor 2-106 Photointerrupters...
Page 57 April, ’89 DRUM 1. Selenium Drum Selenium has the following important characteristics. 1. It can accept a high positive electrical charge in the dark. (The electri- cal resistance of selenium is high in the dark.) 2. It will dissipate the electrical charge on its surface when exposed to light.
Page 58 April, ’89 Drum Thermistor Unit The drum thermistor unit has two thermistors that detect the temperature of the drum surface. One (TH-1) is for the control of the drum heater, and the other (TH-2) is for bias compensation. Usually, these thermistors touch the drum surface. However, when the drum stay is removed, they are separated from the drum surface by a release mechanism.
Page 59 April, ’89 3. Drum Heater Circuit The main board monitors the temperature of the drum surface through TH-1. When the main board determines that the drum heater should be on, CN301- B15 goes LOW. This action energizes SSR10 on the ac drive board and 100 volts ac is applied to the drum heater.
Page 60 April, ’89 CHARGE 1. Corona Unit This copier uses a dual wire corotron and a highly sensitive selenium drum. The corona wires generate a corona of positive ions when the charge power pack applies a high positive voltage. The selenium surface of the drum receives a uniform positive charge (about +800 V) as it rotates past the corona unit.
Page 61 April, ’89 Corona Unit Ventilation The charge corona casing has three slots that allow air from the charge fan This airflow prevents an uneven build up to flow through the corona unit. of positive ions. The CPU turns on the charge fan by supplying a LOW signal at CN304-B18. The charge fan motor turns on 100 milliseconds before the main motor.
Page 62 30 April, ’89 Wire Cleaner Paper dust and/or toner particles on the charge corona wires may interfere with charging and cause low density bands on copies. The wire cleaner cor- rects this problem by automatically wiping the charge corona wires clean. Once every 5,000 copies, the wire cleaner is activated when the main switch is turned on.
Page 63 April, ’89 Charge Power Pack The circuit operation for the charge corona begins with the input of +24 volts to the power pack at CN232-6. This voltage powers the LEDs. This power Additionally, +24V enters the power pack at CN232-7. (VP) supply is used for the high voltage coronas.
Page 64: Introduction
April, ’89 ERASE 1. Introduction After passing the charge corona unit, the surface of the drum is covered with a uniform positive charge. However, the entire surface is not needed to produce the copy. To reduce toner consumption and reduce the load on the cleaning unit, the erase unit removes the charge potential from the areas that will not be used.
Page 65 30 April, ’89 2. Side Erase and Leading/Trailng Eage Erase - Side Erase - Side erase discharges the drum potential on both sides of the image area. It overlaps the image slightly on either side as shown in the figure. This prevents the edge of the original from being copied.
Page 66 30 April, ’89 Erase Lamp Circuit This copier uses 88 LEDs in the erase lamp unit. The large number of LEDs allows fine control of the side erase margins. Shift register drivers control the LEDs. Initially, the RESET signal (LOW ac- tive) turns off all the shift registers.
Page 67: Introduction
April, ’89 EXPOSURE 1. Introduction The optics assembly reflects an image of the original on the exposure glass onto the selenium drum to form a latent electrical image of the original during the copy cycle. - Optical Components - First Scanner: Exposure Lamp, Reflectors, and First Mirror Second Scanner: Second Mirror and Third Mirror Optical Cavity:...
Page 68: Exposure Lamp Unit
April, ’89 2. Exposure Lamp Unit (Rear View) These lamps are This copier uses six small halogen lamps for exposure. more shock-resistant than a single lamp; therefore, they are more suitable Each lamp is 35 watts/13.3 volts, and they are for high volume copying.
Page 69: Automatic Image Density Sensing
April, ’89 Automatic Image Density Sensing Light from the exposure lamp passes through a small hole in the reflector, reflects from the original, and is collected by the fiber optic cable. sampled strip is at the leading edge of the original and is 8 millimeters wide and 50 millimeters long, The fiber optic cable conducts the light to a sensor (photodiode) on the main beard.
Page 70: Lamp Regulator
April, ’89 Power to the exposure lamp control circuit (+24 volts) is input at CN228-10. Additionally 100 volts ac is input into the lamp regulator when RA102 is energized (main switch on, covers closed). To energize the exposure lamps, the main board supplies a LOW trigger at CN208-A3.
Page 71 April, ’89 Exposure CN228-4 Lamp Regulator Switch CN228-3 CN228-5 Output (RMS) Position CN228-6 70 volts Lower Middle 75.2 volts 79.75 volts Upper - Lamp Safety - Several safety circuits guard against exposure lamp circuit failure. SC 1 is caused by the following two status: 1.
Page 72: Optics Cooling Fan
30 April, ’89 5. Optics Cooling Fan prevent hot air from building up in the optics cavity, the cooling fan blows in cool air from outside. This fan is energized by two thermo- switches: TS1 and TS-3. TS-1 is un- der the exposure glass (115 volt units) or near the lens home position sensor (220/240 volt units), and TS-3 is be-...
Page 73: Introduction
April, ’89 SCANNER DRIVE 1. Introduction Scanner Guide Rod (Front) The scanner motor (servomotor) drives the first and second scanners at the Both scanners move to speed required for the selected reproduction ratio. maintain a constant focal length. The scanner motor drives the scanners by using two wires; one drives the front side and the other the rear side.
Page 74: Scanner Motor Control
30 April, ’89 Scanner Motor Control (B0 to B7). The main board controls the scanner speed with an 8 bit code The scanner motor control board reads the code and converts it to an analog signal (D/A converter). The analog signal is supplied through an in- verting amplifier to the driver circuit.
Page 75 30 April, ’89 - Main Board Input to Scanner Motor control Board - The main board CPU controls the scanner motor speed and is responsible for maintaining proper scanner speed and direction. The following is a descrip- tion of the signal lines that the main board CPU controls. PLL (Phase Lock Loop): The main board applies a reference clock pulse (REF CLK) to the scanner...
Page 76: Lens Positioning
April, ’89 LENS AND MIRROR POSITIONING The lens/mirror motor has two functions: It changes the lens position according to the selected reproduction ratio to achieve the correct optical distance between the lens and the drum surface. It changes the second scanner position to achieve the proper distance be- tween the exposure glass and the lens.
Page 77 April, ’89 To center the image on the copy paper, the lens also moves to the side (per- pendicular to the direction of paper movement) when the reproduction ratio A bearing on the bottom of the lens housing is engaged with is changed.
Page 78: Second Scanner Shift
April, ’89 Second Scanner Shift To keep the image focused on the drum, the second scanner (second and third mirrors) also has to move when the reproduction ratio is changed. When the lens motor turns on, the mirror shift cam starts turning. A bear- As the bearing rides up ing on the mirror shift bracket rides on this cam.
Page 79: Lens/Mirror Position Initialization
April, ’89 3. Lens/Mirror Position Initialization The CPU determines the location of the lens and controls its positioning through the lens home position sensor. This sensor is activated by a disk mounted on the lens/mirror drive pulley. The home position is initialized each time the lens passes the full size posi- tion, However, when moving from a reduction position to another reduction position or from an enlarge position to another enlarge position, the home...
Page 80: Introduction
April, ’89 DEVELOPMENT UNIT 1. Introduction When the development motor turns on, the paddle roller and development The paddle roller picks up developer and trans- roller sleeve start turning. ports it to the development roller. Then, the permanent magnets attract the developer onto the development sleeve and form it into a magnetic brush on the sleeve.
Page 81 30 April, ’89 The developer is agitated and mixed by the paddle roller and the crossmixing mechanism. Also, the developer agitator, just under the toner inlet, mixes fresh toner added by the toner supply roller with the developer spilling from the flow plate.
Page 82: Drive Mechanism
30 April, ’89 Drive Mechanism (Rear of Unit) (Front of Unit) The development motor turns an idle gear which drives the development roller gear. After that, the drive sequence shifts from the back of the unit to the front and then back again. The basic drive flow is as follows: *Development Roller Gear *Timing Belt...
Page 83: Cross Mixing
April, ’89 Cross Mixing The crossmixing mechanism has two functions: 1) it keeps the toner and de- veloper evenly mixed; and 2) it creates a triboelectric charge by mixing and agitating the developer. The developer that is attracted to the development roller at point A is split Part B (the magnetic brush) goes on to into two parts by the doctor blade.
Page 84: Knocking Solenoid
April, ’89 Knocking Solenoid The knocking solenoid vibrates the cover of the development unit to prevent toner from building up under the upper cover or the brush seal. It is ener- gized once each copy cycle. Actuation timing is shortly before scanner start timing;...
Page 85: Toner Density Control
April, ’89 5. Toner Density Control The CPU checks toner density by directly sensing the image density at the end of the first copy cycle after the main switch turns on, and at every fifth copy after that. On check cycles, a black sensor pattern is exposed after exposure of the original on the glass.
Page 86 30 April, ’89 - Toner Density Control - The image density sensor checks the density of the sensor pattern image once every 5 copy cycles. The CPU receives two voltage values directly from the sensor: the value for the bare drum (Vsg) and the value for the sen- sor pattern (Vsp) These two values are then compared to determine whether or not more toner should be added,...
Page 87 April, ’89 - Toner Supply - When the CPU energizes the toner supply clutch, the toner supply roller feeds toner to the developer tank for a set period of each copy cycle. This continues until the low toner density condition is recovered. This copier has two different ways of controlling the amount of toner sup- plied.
Page 88 April, ’89 Toner Supply Amount Supply Amount SP1O-3 in Detect Mode: SP1O-4 The factory setting is 30 %. - Toner End Detection - the image density sensor to detect a toner end condition. The CPU uses This method is effective in both detect and fixed supply modes. If the ratio of p to Vsg (Vsp/Vsg x 100) becomes greater than 18.8%, the toner cartridge.
Page 89: Image Density Control
April, ’89 6. Image Density Control Image density is controlled by changing the strength of the positive bias volt- age that is applied to the development roller sleeve by the bias power pack. Applying a bias voltage to the development sleeve reduces the potential be- tween the development roller and the drum, thereby reducing the amount of toner that is transferred to the drum.
Page 90 April, ’89 -Automatic Image Density Control (Auto ID)- -When the auto ID is on, the exposure lamp regulator voltage will be Increased volts due to lamp regulator This voltage 4 volts. cannot exceed 79.75 limitation. At the start of the copy cycle, the original sensing mechanism measures the background density of the original image.
Page 91 April, ’89 Bias Compensation Factors - As discussed previously, the bias base level (Vl or V2) is set either by the automatic image density system or by the operator through the image den- sity keys. The CPU increases the bias base level as necessary to compen- sate for the rest time between copy runs and the drum temperature, both of...
Page 92 ’89 April, Drum Temperature Compensation (V4): The increase in development bias between 15°C and 45°C When the switch on the bias power pack is on, the CPU monitors the drum temperature through a thermistor (TH-2), and it increases or decreases the bias voltage to compensate for temperature induced variations in drum sen- sitivity.
Page 93: Bias For Id Sensing
April, ’89 Bias for ID Sensing In order to develop the ID sensor pattern consistently, the CPU applies a fixed bias level to the development roller at the end of each copy cycle. The fixed base bias is 410 volts and it is affected by drum cavity tempera- ture and drum rest time.
Page 94: Bias Circuit
30 April, ’89 Bias Circuit The bias power Image density is controlled by varying the development bias. pack changes output level according to the data from the main board the bias thermistor. Output level controlled by the main board board commands the power pack to change the output level by six bits main (B0 to B4 and BP).
Page 95 April, ’89 (O2) B0 B1 B2 output (O1) output volts 0 volts 220 volts 10 volts 70 volts 130 volts 190 volts 250 volts output (O3) 310 volts 370 volts volts 30 volts 60 volts 90 volts TH-2 Resistance TH-2 provides the temperature compensation factor. The figure shows the variation in temperature compensation as the resistance of TH-2 changes.
Page 96: Development Drive Motor
April, ’89 Development Drive Motor This copier uses a Hall effect motor to drive the development unit. A sepa- rate development motor is used because the main motor's torque is insuffi- cient. Hall effect motors have the following characteristics: Good speed control (like a servomotor) o Quiet and compact.
Page 97 April, ’89 - Operation - To operate the development motor, the control circuit energizes drive coils U, V, and W by turning on drive transistors 1 to 6. (See figure A.) The The magnetic fields gen- coils are energized in sequence two at a time. erated by the coils cause the rotor, which is made of four permanent mag- nets, to turn.
Page 98: Image Transfer
April, ’89 TRANSFER AND SEPARATION 1. PTC (Pre-Transfer Corona) and PTL (Pre-Transfer Lamp) process requires a quick image this high speed of machine’s copy transfer. The PTC and the PTL help to achieve this goal by reducing the attraction between the toner and drum before the image transfer process and an ac charge to the drum.
Page 99: Paper Separation
April, ’89 3. Paper Separation To break the attraction between the paper and the drum, the separation corona applies an ac corona to the back side of the paper. The stiffness of the paper then causes it to separate from the drum. The transfer/separation corona unit is mounted at an angle to the drum to the drum just after completion of the image make the paper separate from...
Page 100: Tc/Sc Wire Cleaner
April, ’89 TC/SC Wire Cleaner If paper dust and /or toner particles get on the corona wires, they may make the T/S corona functions with corona discharging and interfere The wire cleaners correct this problem. inefficient. 5,000 copies, the wire cleaner is activated when the main switch Once every The hot roller temperature must be less than 100 ‘C for the is turned on.
Page 101: Pick-Off Pawls
April, ’89 Pick-off Pawls (Front View) The pick-off pawls aid the paper separation process. They ensure that thin, low-stiffness paper or curled paper separates from the drum. The pick-off pawls are not kept constantly in contact with the drum. Just after the registration clutch turns on, the CPU actuates the pick-off sole- noid.
Page 102: Ptc Power Pack And Ptl Stabilizer
30 April, ’89 PTC Power Pack and PTL Stabilizer The PTC power pack and the PTL stabilizer receive +24 volts (Vp) at CN325-4 is applied at and CN320-1 these are the power supply. volts ( V a ) Also, CN325-3 and CN320-2. pack and PTL The CPU drops CN202-A17 to 0 volts to actuate the PTC power...
Page 103 30 April, ’89 - Normal Operation - operation, +24 volts input to the Transfer/ To begin the circuit (VA) is at CN327-9. This voltage powers the LEDs and is in- Separation power pack as the triggers (Tl, T2, S1, S2). Additionally, when put to the main board the main switch is turned on, +24 volts input to the power pack at...
Page 104 April, ’89 Corona Current Shift - output Paper Application SW on, or duplex/image overlay cycle. Leading Edge S1 = CN208-B7, S2 = CN202-A16 Separation on Duplex Overlay 2nd Cycle: The decreased water content increases electrical resistivity of the paper. For this reason, the corona is more effective and less negative bias is needed.
Page 105: Introduction
30 April, ’89 CLEANING 1. Introduction The first step in the drum cleaning process is the application of the pre- cleaning corona (PCC). The pre-cleaning corona has both ac and dc com- ponents. The ac component makes drum cleaning more efficient by reducing the drum’s potential and weakening the electrical attraction between toner and the drum.
Page 106: Drive Mechanism
April, ’89 Drive Mechanism (Front View) The cleaning unit is driven by the drum flange gear. The force is trans- mitted to each part as follows: Drum Flange Gear --> Cleaning Unit Drive Gear (Dual Gear) --> --> Cleaning Brush Gear --> Toner Collection Coil Gear (Dual Gear) --> -->...
Page 107: Cleaning Blade Pressure Mechanism
April, ’89 3. Cleaning Blade Pressure Mechanism (Pressure Released) (Pressure Applied) When the main switch is turned on, the cleaning solenoid is energized. The cleaning solenoid then pulls the solenoid lever. Power is applied through the blade pressure spring. The roller on the opposite end of the solenoid lever turns the cleaning blade arm and rotates the cleaning blade against the drum.
Page 108 April, ’89 (pressure Released) (Pressure Applied) Manual cleaning blade off (MBOF)- order to check an efficiency of the cleaning blade, the cleaning blade can be released by SP 7-3, in the meantime, the copy can be made. Cleaning blade off timing (CBOF)- Paper dust or toner build up on the blade edge decreases the efficiency of the cleaning blade.
Page 109: Used Toner Removal
30 April, ’89 Used Toner Removal The toner that is cleaned from the drum settles in the trough of the clean- The toner collection coil transports this toner to the rear of the ing unit. A helical coil then moves the machine, where it enters a plastic tube.
Page 110 30 April, ’89 Toner Overload Detection: The toner sometimes builds up inside the collection and hardens, this pipe increases the load on the collection coil. One cause of this problem is the user failing to pullout and push in the shuller plate after replacing toner cartrige.
Page 111: Cleaning Solenoid Circuit
30 April, ’89 5. Cleaning Solenoid Circuit The CPU energizes the cleaning solenoid one second after the main switch is turned on. For ini- tial pressure application, the sole- noid is energized by +40 volts. To accomplish this, the CPU sends +3-volt signals to the dc drive board from CN206-A4 and CN202-A13.
Page 112: Pcc Power Pack
April, ’89 PCC Power Pack The circuit operation for the PCC begins when +24 volts (VA) is input to the charge/ PCC power pack at CN232-6. This voltage powers the LEDs. Addi- tionally, +24 volts (VP) is input at CN232-7, which enters the power pack This is the power source for the high when the main switch is turned on.
Page 113: Cleaning Bias Power Pack
April, ’89 Cleaning Bias Power Pack The cleaning bias (+300 volts) is applied to the bias roller. The bias roller helps keep the cleaning brush clean by attracting negatively charged toner from the cleaning brush. Circuit operation begins with the application of +24 volts (VP) to CN240-1. This is the power source for the high voltage cleaning bias.
Page 114: Introduction
30 April, ’89 QUENCHING 1. Introduction (Front View) Quenching involves two steps. First, the PQC applies a positive charge to the drum. This neutralizes any negative charge remaining on the drum from the pre-cleaning corona. Then, the quenching lamp neutralizes the positive charge.
Page 115: Pre-Quenching Corona Circuit
30 April, ’89 Pre-Quenching Corona Circuit begins with the application of +24 volts to CN850-1 (VP). Circuit operation This is the power source for the high voltage corona. Additionally, +24 volts (VA) for the trigger photocoupler is applied at CN850-3. When the Start key is pressed, the CPU energizes the cleaning bias power pack by supplying a LOW output at CN202-B9.
Page 116: Quenching Lamp Circuit
April, ’89 Quenching Lamp Circuit To turn on the quenching lamp, the CPU sends a +3-volt signal to the dc drive board from CN208-A4. The dc drive board then provides a LOW out- put at CN301-A19. This energizes a relay in the power supply unit. When the relay closes, 485 volts ac is applied to the quenching lamp.
Page 117: Paper Feed
30 April, ’89 PAPER FEED 1. Introduction Tray Heaters This machine feeds paper from two trays. The capacity of the upper tray is 1,000 sheets and that of the lower tray is 500 sheets. So a total of 1,500 sheets can be loaded at once. (An extra tray holding 2,200 sheets is avail- able as an option.) Paper is always loaded sideways, and is positioned at the left-front of the...
Page 118: Feed Unit Mechanism
30 April, ’89 Feed Unit Mechanism Paper is fed from both trays by the paper feed unit shown above. Feed roller drive is provided by a gear on the front end of the pull-out This gear is engaged with the feed unit drive gear and turns roller shaft.
Page 119 April, ’89 FFR Operation To correctly feed a single sheet of paper, this copier uses an FFR (Feed and Friction Roller) paper feed system consisting of three sets of rollers: the pick-up rollers, the feed roller, and the friction rollers. The pick-up rollers drive the paper to the feed and friction rollers;...
Page 120: Paper Tray Drive Mechanism
April, ’89 Paper Tray Drive Mechanism Paper Volume Sensor Drive from a reversible ac motor is transmitted through a worm gear to the drive pulley shaft. The tray wires have metal beads on them. These beads are inserted in slots at the ends of the tray support rods; so, when the wire pulley turns (counterclockwise, rear view), the beads on the wires drive the tray support rods and the tray moves upward.
Page 121: Friction Roller Reverse Mechanism
30 April, ’89 Friction Roller Reverse Mechanism The friction rollers turn opposite to the paper feed direction to return any paper in contact with then to the paper stack when the tray moves down. When the tray starts moving down, the tray drive wire turns the pulley gear, and two idle gears transmit rotation to the delay gears.
Page 122: Paper Volume Detection
April, ’89 6. Paper Volume Detection Each tray uses a pulse generator to determine the quantity of paper in the tray. The CPU determines how much paper is in the tray based on the num- ber of pulses received from the pulse generator between the time the tray starts moving up and the time the lift sensor turns off.
Page 123: Guide Posts And Paper Size Detection
April, ’89 Guide Posts and Paper Size Detection The operator can easily adjust the paper guide posts for any paper size by pressing in the stopper lever and sliding the guide posts to the desired posi- tion, The guide post bracket has an actuator plate mounted on its bottom. This plate activates four sensors (photointerrupters) mounted in a diagonal line across the paper size detection board.
Page 124: Tray Lock And Positioning
April, ’89 Lock and Positioning Tray (Front View) When the tray starts moving up, the lock lever drops behind the lock plate on the accuride support bracket, locking the tray in position to prevent the tray from being pulled out while in the up position. When the tray moves to the down position, the bottom plate of the tray pushes down a pin on the lock lever.
Page 125: Paper Size Board
April, ’89 Paper Size Board The paper size sensor board is located on the bottom of the paper tray. Paper size detection circuit operation begins with the application of +15 volts to the photointerrupters. For the photointerrupters that do not have a shutter present, the LEDs activate the phototransistors.
Page 126 April, ’89 10. 220/240-Volt Paper Size Sensor Machines that operate on 220/240 volts have an additional paper size sen- sor. This sensor (a Photointerrupter) detects the difference between 8" x 13" paper and 8½" x 13" paper. The sensor operates in the same way as the paper end sensor (a feeler in the bottom plate is pressed down by the paper).
Page 127: Tray Motor Circuit "2-71
April, ’89 11. Tray Motor Circuit To turn on a tray motor, the CPU sends a +3-volt signal from either CN208-A10 (CN208-B10) or CN208-A1l (CN208-B1l) to the dc drive board. The dc drive board then drops either the up or the down trigger line to 0 The SSR, volts, energizing the connected SSR on the ac drive board.
Page 128: Paper Tray Heaters
April, ’89 Paper Tray Heaters All the tray heaters, including that of the option tray, are controlled by the same circuit. - Main Switch OFF - When the main switch is off, 100 volts ac is applied to the tray heater If the humidity switch is on, the tray heaters stay on while the circuit.
Page 129: Tray Set Detection
30 April, ’89 Tray Set Detection When the tray is pulled out, the ground connection is broken, and the sig- nal at CN203-A15 (CN203-B16) changes from O volts to a 7-volt pulse. The CPU then turns off the paper size display. When the tray is set, CN203-A15 (CN203-B16) goes from a 7-volt pulse to o volts.
Page 130: Vertical Transport And Registration
April, ’89 VERTICAL TRANSPORT AND REGISTRATION 1. Introduction After paper feed, the pull-out rollers and relay rollers transport the paper to the registration rollers. The registration rollers correct paper skew and then feed the paper to the drum at the proper time for image transfer. - Pre-registration - the registration rollers cannot completely of the high copy speed,...
Page 131 April, ’89 - Registration Rollers - The registration rollers stop turning just before the paper arrives. The pull- out rollers and the relay rollers, which do not stop turning, force the paper against the registration rollers. Consequently, the paper starts buckling and the leading edge is set parallel to the registration rollers.
Page 132: Drive Mechanism
April, ’89 Drive Mechanism 2-76...
Page 133 April, ’89 registration roller are all The vertical transport unit, paper feed units, and the transport drive belt. driven by the main motor through Main Drive Belt The pick-up roller shaft has a knob to manually turn the vertical transport The vertical transport gear is unit rollers when removing misfed paper.
Page 134: Jam Check Timing
April, ’89 Jam Check Timing The above timing chart shows the jam check timing for A4 (8½" x 11") paper. The paper feed MC stops momentarily for pre-registration when the paper actuates the paper feed sensor. (This is true for all three feed trays.) The paper feed sensor also checks for misfeeds.
Page 135: Paper Transport
April, ’89 PAPER TRANSPORT 1. Introduction The transport belts deliver paper to the fusing unit after it is separated from the drum by the separation corona and the pick-off pawls. A vacuum fan holds the paper firmly against the belts to obtain enough friction be- tween the belts and the paper for secure transport.
Page 136: Vacuum Fan Circuit
30 April, ’89 Vacuum Fan Circuit The CPU turns the vacuum fan on at the same time as the main motor. To do so, the CPU supplies +3 volts at CN206-B5. This signal then goes to the dc drive board, causing the dc drive board to drop CN301-B19 to O volts. This actuates SSR8 on the ac drive board, and 100 volts ac is applied to the fan motor.
Page 137: Introduction
30 April, ’89 FUSING 1. Introduction The toner powder image is fused onto the copy paper by the hot roller and pressure roller. The hot roller has two internal fusing lamps (550 W/1,100 Both lamps turn on during initial warm-up, and as necessary to keep However, to limit the the hot roller at the operating temperature (185°C).
Page 138: Pressure Mechanism
30 April, ’89 hot roller and the pressure roller have stripper pawls to prevent Both the wrap-around jams. Related Service Call Conditions: See FIELD MANUAL for details. Thermistor Circuit Open SC 5: Low Hot Roller Temperature SC 6: SC 7: Hot Roller Overheating SC 8: Thermofuse Circuit Open...
Page 139: Oil Supply
30 April, ’89 supply 3. Oil Silicone oil is applied to the hot roller to help prevent toner and paper from the hot roller, and to make roller cleaning easier, sticking to A small pump (consisting of two one-way valves enclosed in a rubber sleeve, the oil pump lever, and the oil cam) pumps silicone oil from the oil bottle (1,000 cc capacity) to the oil sump.
Page 140: Oil End Sensor
April, ’89 Oil End Sensor - Basic Operation - The oil end sensor’s operation is based on the difference between the refrac- tive index of air and that of silicone oil. When the sensor is immersed in oil, the light from the LED bends only slightly at the interface of the oil and the sensor casing, and almost no light is reflected to the phototransis- tor.
Page 141: Drive Mechanism
April ’89 5. Drive Mechanism Main motor drive is provided to the fusing unit through the fusing drive belt, the fusing drive, pulley and the fusing drive gear. Fusing Drive Gear 2-85...
Page 142: Fusing Lamp Circuit
April, ’89 Fusing Lamp Circuit The resistance of TH-3 decreases as the temperature of the hot roller rises Therefore, temperature changes cause voltage changes at (and vice versa). The voltage at CN202-A4 is input to an A/D converter on the CN202-A4.
Page 143 30 April, ’89 After Copy Cycle Completion (main motor off): Both fusing lamps operate in the same manner as during warm-up. Lower Temperature Limit: If the hot roller surface temperature drops below 171°C (175°C if SP 4-2 is set) whiIe copying, the copier stops and both fusing lamps turn on. (This may happen during a long continuous copy run using A3 or 11”...
Page 144: Introduction
April, ’89 INVERTER 1. Introduction After the fusing unit, copies come to the inverter unit which chiefly con- sists of the three inverter rollers, the inverter gate, the junction gate, and the return rollers, This unit does the following jobs: Ordinary Copying: Copies pass through the unit straight to the exit rollers.
Page 145: Operation
’89 30 April, Operation Ordinary Copying To Duplex Tray - Ordinary Copying - Copies go straight through the inverter rollers to the exit rollers. The in- verter gate and the junction gate stay down out of the paper path. - Duplex Copying- The up and down inverter rollers separate.
Page 146 April, ’89 Overlay Copying Face Down Feed Out - Overlay Image Copying - The inverter gate stays down and the inverter rollers stay closed. But, the junction gate opens to direct copies to the duplex tray without turning them over. - Face Down Fee&out- The up and down inverter rollers separate.
Page 147: Inverter Rollers
April, ’89 Inverter Rollers (Front View) The inverter rollers are controlled by the inverter roller clutch (half-turn clutch) and the inverter roller solenoid. For ordinary copying and overlay image copying, the inverter roller solenoid stays off. For duplex copying and face down feed-out, the solenoid turns on, and it allows the inverter roller clutch to turn by 180°.
Page 148: Inversion
April, ’89 Inversion Return are inverted by the inverter gate and the return roller in the Copies pinch This is for the first side of duplex copying or inversion copying cycles. feed-out. The inverter gate is driven by the inverter gate face down return solenoid and...
Page 149: Junction Gate
30 April, ’89 5. Junction Gate Gate Spring Junction For ordinary copying and face down feed-out cycles, the junction gate sole- noid stays off and the junction gate stays closed. For duplex copying and overlay image cycles, the junction gate solenoid turns on and opens the junction gate.
Page 150: Duplex Tray
30 April, ’89 DUPLEX TRAY Introduction Feed Pick-up Diagonal Left Right Sponge Fork Gate Relay Rollers Roller Roller Roller Roller Cover Cover Bottom Plate Separation Rollers (Front View) Copies are fed to the duplex tray when in duplex copying or overlay copying mode.
Page 151: Drive Mechanism
April, ’89 Drive Mechanism Outer Drive Gear 2-95...
Page 152: Fork Gate
April, ’89 Fork Gate Gate Solenoid Fork The distance from the duplex tray relay rollers to the diagonal roller is greater than the width of A4 or 8½" x 11" paper. So, for these sizes or smaller sizes of paper, the fork gate solenoid turns on to allow the fork gate to drop down as shown by the arrow in the illustration.
Page 153: Paper Positioning
30 April, ’89 Paper Positioning When the Start key is pressed to start a duplex or overlay copy cycle, the side plate motor turns on and moves the rear side plate from the home posi- tion to a waiting position which is 10 mm away from the rear edge of stacked copies.
Page 154: Bottom Plate Mechanism
April, ’89 Bottom Plate Mechanism (Rear View) tray bottom plate usually contacts the pick-up rollers, but it The duplex drops down when the Start key is pressed for the first side copy. First, the bottom plate solenoid turns on and the bottom plate clutch turns 180°, caus- ing the bottom plate cam to push down the pressure arm lever.
Page 155: Duplex Paper Feed
April, ’89 6. Duplex Paper Feed (Rear View) The duplex paper feed mechanism is almost the same as that of the paper feed trays. Only the friction rollers and the pressure wires are different. The friction rollers are mounted on a one-way clutch. A crank mechanism turns the friction rollers slightly each time the bottom plate moves down.
Page 156: Duplex Motor Circuit
30 April, ’89 Duplex Motor Circuit Normally the duplex side plate stays in the home Position. When it is in that position, CN208-B14 of the main board receives 0 volts. When the side plate moves away from the home position, CN208-B14 changes to +15 volts. In duplex or image overlay mode, when the Start key is pressed for the front side copy, the dc drive board outputs pulses D1 through D4 to drive the duplex side plate motor (M-7).
Page 157: Top Unit
30 April, ’89 TOP UNIT 1. Release Mechanism The top unit is hinged at the rear corners and swings up to facilitate the The top unit is usually locked by the lock pins removal of jammed paper. and springs. When the release lever is lifted, the release wires pull the release plates which in turn pull the lock pins.
Page 158: Drum Support
’89 April, 2. Drum Support If the drum stay is removed while the top unit is up, the drum and drum shaft tend to drop down. To prevent misalignment of the drum shaft, a screw on the drum support plate supports the drum drive housing when the top unit is raised.
Page 159: Other Circuits
April, ’89 OTHER CIRCUITS 1. Counters Three counters can be used to keep track of the copies made. The total counter is installed at the factory, whereas the key counter and A3/LDG counters (optional) are installed by the service engineer. All three counters count up one when the paper feed clutch turns on.
Page 160 April, ’89 Total Counter - The CPU energizes the total counter by supplying +3 volts at CN201-A14. The de drive board then drops CN301-B12 to O volts. This energizes the counter and closes the internal contact. When the contact closes CN206-B1 goes HIGH and the CPU determines that the total counter has energized.
Page 161: Photosensor
April, ’89 2. Photosensors The following sensors are reflective photosensors that are used to detect paper moving through the copier. Sensor Symbol Connector Duplex Paper Feed S-15 CN202-B6 Lower Paper Feed S-11 CN202-A6 Pick-off S-17 CN202-A20 Registration S-18 CN202-B8 Upper Paper Feed S-5 CN202-B5 CN203-A8 Pre-registration Sensor S-26...
Page 162: Photointerrupters
April ’89 3. Photointerrupters Photointerrupters consist of a plastic encapsulated LED and phototransistor separated by an open slot. When the slot is empty, light from the LED ac- tivates the phototransistor and the sensor outputs a LOW signal. When an actuator plate enters the slot, light from the LED is blocked and the output becomes open.
Page 163: Solenoids
April, ’89 Sensor PCBs Connectors Lower Paper Size CN203-B2 All connectors at the CN203-B4 main board, CN203-B6 CN203-B8 Upper Paper Size CN203-A1 CN203-A3 CN203-A5 CN203-A7 4. Solenoids To energize a solenoid, the main board supplies +3 volts at CN-1. When the dc drive-board receives this signal at CN-2;...
Page 164: Magnetic Clutches
April, ’89 5. Magnetic Clutches To energize a magnetic clutch, the main board supplies +3 volts at CN-1. When the dc drive board receives this signal at CN-2, it drops CN-3 to 0 volts to turn on the solenoid. Name Symbol CN-1 CN-2 CN-3...
Page 165: Monitor Board
April, ’89 6. Monitor Board The main board applies timing pulses to the monitor LEDs from CN202-A3, - A2, and -B2. Each signal line has three segmented timing pulses referred to With no jam, the same signal is applied to CN203-A18, - as A, B and C.
Page 166: Operation Panel
30 April, ’89 Operation Panel The operation panel has five circuit boards: a ROM board, a CPU board, two LED boards, and the key board. ROM Board: These ROMs hold the guidance This board has 11 ROMs (32 kbyte each). display data.
Page 167: Ac Drive Board
April, ’89 8. AC Drive Board The ac drive board controls many of the ac motors used in this machine. The circuit operation begins when RA102 energizes. At that time, 100 volts ac is input into the ac drive board at CN313-1. Power is then distributed to all solid state relays (SSRs).
Page 168: Ozone Fan
April, ’89 Ozone Fan The CPU turns on the ozone fan when the main motor turns on by supplying Low to CN209-B5. This causes SSR8 to energize and 100 volts ac is applied to the ozone fan. The CPU keeps the ozone fan on for one minute-after the main motor turns off.
Page 169: Corona Cleaner
April, ’89 10. Corona Cleaner Motors The corona cleaners are driven by small dc motors in the corona endblocks. These cleaners have no sensors; instead, the end of travel is detected by monitoring the motor drive current. When a cleaner is stopped at an endblock, the drive current increases slightly.
Page 170 SECTION 3 INSTALLATION...
Page 171 CONTENTS INSTALLATION REQUIREMENT Environment Minimum Space Requirement Machine Level Power Source INSTALLATION Unpacking Accessory Check Installation Procedure 3-15 KEY COUNTER HOLDER INSTALLATION 3-16 A3/11” x 17” COUNTER INSTALLATION 3-17 MODIFYING MAIN TRANSFORMER VOLTAGE (220V to 240 V) 3-18 PREPARATION FOR TRANSPORTING THE COPIER...
Page 172: Environment
30 April, ’89 INSTALLATION REQUIREMENT 1. Environment Temperature Range 10°C to 30°C (50°F to 86°F) Humidity Range 15% to 90% RH Ambient Illumination Less than 1,500 lux (Do not expose to direct sun- light.) Ventilation Room air should turn over at least 3 times/hour. Ambient Dust Less than 0.15 mg/m (4 x 10...
Page 173: Minimum Space Requirement
30 April, ’89 2. Minimum Space Requirements • ACCESS TO COPIER • Place the copier near a power source, providing clearance as shown. Copier + LCT Copier Copier + Sorter + LCT Copier + Sorter Copier + Sorter Stapler + LCT Copier + Sorter Stapler...
Page 174: Machine Level
30 April, ’89 3. Machine Level Front to Back: Within 5 mm (0.2”) of level Right to Left: Within 5 mm (0.2”) of level Place the four leveling shoes [A] under the leveling feet [B] and screw the leveling feet up or down to level the machine. 4.
Page 175: Unpacking
30 April, ’89 INSTALLATION 1. Unpacking Cut the bands [A] binding the carton and remove the top carton [B]. Take out the accessories [C]. Remove the cushion blocks [D]. Open the vinyl bag. Take out the machine.
Page 176: Accessory Check
30 April, ’89 2. Accessory Check Make sure that each accessory listed in the NECR or in the following table is in the box. Also check the condition of each item: Q ’ t y DESCRIPTION Copy Tray Original Tray Screw - M4 x 8 mm Leveling Shoe Cushion Block...
Page 177: Installation Procedure
30 April, ’89 3. Installation Procedure Remove all external strips of tape and the two sponge door cushions [A]. Raise the DF transport unit and remove the cushion [B]. Remove the lower right cover [C] (3 screws) and the two studs [D] Reinstall the lower right cover.
Page 178 30 April, ’89 Open the top unit then remove the fusing knob [A] (1 screw: reverse thread), cover [B] (3 screws), and the oil bottle [C]. Remove the clamp [D] (3 screws) which secures the fusing unit and the duplex tray. Turn the duplex tray handle [E] to the horizontal position, pull out the duplex tray, and remove the two strips of tape [F] securing the duplex Open the duplex unit covers and carefully remove the strip...
Page 179 30 April, ’89 Remove the shipping retainers in the optics section as follows: Raise the DF transport unit, and remove the front cover [A] of the DF (2 screws). Remove the front top cover [B] (3 screws). Loosen the two rear scale screws [C], and remove the exposure glass fixing bracket [D] (1 screw).
Page 180 30 April, ’89 Open the top unit [A], and remove the drum cover [B] (2 screws). Remove the drum stay [C] by turning the knob counterclockwise. Disconnect the charge corona wire cleaner connector [D] and remove the charge corona unit [E]. Pull out the erase unit [F] and the drum thermistor [G].
Page 181 30 April, ’89 Caution: Do not leave the top unit open exposing an uncovered dram for long periods of time. Remove the drum protective sleeve [A] from the drum. Save the drum protective sleeve for future use. Pressing the drum shaft [B] to the left to prevent drum damage, reinstall the cleaning unit [C].
Page 182 30 April, ’89 Prepare the development unit as follows: Remove the development unit cover [A] (1 screw). Remove the development unit [B] by removing the development unit mounting screw [C] and place the unit on a sheet of paper. Remove the developer inlet cover [D]. Pour two kilograms of developer into the development unit.
Page 183 30 April, ’89 Caution: Always lower the top unit [A] before tightening the development unit mounting screw [B]. The slot [C] on the top unit fits over the positionig pin [D] on the development unit to correctly position the development unit. Close the top unit, and secure the development unit (1 screw).
Page 184 30 April, ’89 Remove the lower left cover [A] (2 screws), and move the jumper connector [B] on the main board from JPS-202 to JPS-201. -NOTE for European version machine- The european version machines do not have the language ROM PCB in the operation palel assembly. The language ROM PCB should be procured by the customer and then installed it as follows: Raise the top unit ond remove the upper front cover.
Page 185 30 April, ’89 Set up the following items according to the customer’s requirements. Refer to Section 3 for Service Program Mode. SP No. Item SP No. Item Beeper Off Max. Copy Quantity ID Reset Level Magnification Ratio Priority 20 min. Fusing Timer Optional Magnification Copy Counter ID Control Mode...
Page 186: Key Counter Holder Installation
30 April, ’89 KEY COUNTER HOLDER INSTALLATION Remove the upper front cover (2 screws). Remove the cover plate [A] and fixing plate [B] from the main switch bracket (2 screws). Hold the fixing plate on the inside of the key counter holder and insert the key counter holder [C].
Page 187: A3/11" X 17" Counter Installation
30 April, ’89 A3/11” x 17” COUNTER INSTALLATION Open the left door. Remove the development unit cover [A] (1 screw) and the jam indicator cover [B] (3 screws). Remove the jam indicator bracket [C] (2 screws). Disconnect the dummy connector from the A3/11” x 17” counter connec- tor [D].
Page 188: Modifying Main Transformer Voltage (220V To 240 V)
30 April, ’89 MODIFYING MAIN TRANSFORMER VOLTAGE (220V to 240 Remove the lower right cover (2 screws). Disconnect the input line [A] from the 220 V connector [B]. Disconnect the dummy connector [C] from the 240 V connector [D]. Connect the input line to the 240 V connector. Connect the dummy connector to the 220 V connector.
Page 189: Preparation For Transporting The Copier
30 April, ’89 PREPARATION FOR TRANSPORTING THE COPIER CAUTI0N: Before transporting the copier, be sure to prepare it as follows. The copier may be badly damaged if it is moved without proper preparation. Select the 100% magnification ratio. Remove the paper from the upper and lower paper trays. Turn off the main switch and unplug the copier.
Page 190 30 April, ’89 9. Remove the lower right cover and fix the paper trays with studs [A]. Reinstall the lower right cover. 10. Fix the DF, left front door, and right front door with strips of tape. 11. Remove the copy tray or sorter. 12.
Page 191 SECTION 4 SERVICE TABLES...
Page 192 CONTENS PM TABLE LUBRICATION PARTS 4-11 SERVICE TABLES 4-11 Test Points 4-12 Variable Resistors 4-12 Dip Switches 4-13 SERVICE REMARKS 4-18 SPECIAL TOOLS AND LUBRICANTS...
Page 193: Pm Table
April, ’89 PM TABLE Symbol key: C = Clean R = Replace L = Lubricate A = Add I = Inspect A. Optics NOTE EM 120K 240K 360K 480K 600K 1.2M Alcohol/water Mirrors, Lens silicon cloth Glass cleaner Exposure Glass dry cloth Alcohol/water Reflector...
Page 194 30 April, ’89 Symbol key: C = Clean R = Replace L = Lubricate A = Add I = Inspect Duplex Tray NOTE EM 120K 240K 360K 480K 600K 1.2M Feed Roller Alcohol/Water Friction Roller Alcohol/Water Pick-up Roller Alcohol/Water Mobil Temp. 78 Drive Gears Mobil Temp.
Page 195 30 April, ’89 C = Clean R = Replace L = Lubricate A = Add I = Inspect Symbol key: E. Transport Unit NOTE EM 120K 240K 360K 480K 600K 1.2M Blower brush Pick-off Sensor Alcohol/Water Transport Belt, Belt Rollers Mobil Temp.
Page 196 April, ’89 Symbol key: C = Clean R = Replace L = Lubricate A = Add I = Inspect Around Drum EM 120K 240K 360K 480K 600K 1.2M NOTE Drum Replace if Necessary Pick-off pawls PQC Wire Dry Cloth CC Wires Dry Cloth PTC Wire Dry Cloth...
Page 197 30 April, ’89 Symbol key: C = Clean R = Replace L = Lubricate A = Add I = Inspect Fusing Unit NOTE EM 120K 240K 360K 480K 600K 1.2M Replace as a set Hot Roller, Bearings, and Isolating Sleeves Replace as a set Pressure Roller, Bearings, and...
Page 198 30 April, ’89 Symbol key: C = Clean R = Replace L = Lubricate A = Add I = Inspect Cleaning Unit NOTE EM 120K 240K 360K 480K 600K 1.2M Cleaning Blade Clean Finger Blade Swing Pin Mobil Temp 78 Cleaning Brush Mobil Temp 78 Bevel Gears...
Page 199 April, ’89 Symbol key: C = Clean R = Replace L = Lubricate A = Add I = Inspect DF Unit EM 120K 240K 360K 480K 600K 1.2M NOTE DF Transport Belt Cleaner Belt Separation Water Tabs Pick-up Rollers Water Separation Water Rollers...
Page 200: Lubrication Parts
30 April, ’89 LUBRICATION PARTS Parts to be lubricated using Mobil Temp. 78 every 120K are circled below:...
Page 201 April, ’89...
Page 203: Service Tables
’89 April, SERVICE TABLES 1. Test Points - Main Board - Number Function TP201 Trigger for P.P. (PCC) TP202 Trigger for P.P. (PTC) TP203 T r i g g e r f o r P . P . ( T 2 ) T r i g g e r f o r P .
Page 204: Dip Switches
30 April, ’89 2. Variable Resisters - Main Board - Function Number VR201 Adjusts the ADS input VR202 Adjusts the image density sensor VR203 v o l t a g e - Scanner Motor Control Board - Function Number VR501 Factory adjustment VR502 Factory adjustment...
Page 205: Service Remarks
April, ’89 SERVICE REMARKS <Handling the Drum> Never touch the drum surface with bare hands. Store the drum in a cool dry place. Always wear gloves when cleaning the drum. Prime the drum with setting powder only when the cleaning blade, cleaning brush, and drum are replaced as a set.
Page 206 30 April, ’89 <Erase Lamp> 1. A narrower lead edge erase margin increases the possibility of fusing jams. At least, l.0mm of margin is necessary to prevent fusing jams. 2. After cleaning the erase lamp filter, discharge any static charge on the filter surface with a finger before replacing the unit.
Page 207 April, ’89 <Development Unit> 1. Do not force the development roller to turn opposite to the normal direction of rotation because the gears may be damaged. 2. Never loosen the paint-locked screws that secure the development unit positioning bracket. This bracket is positioned at the factory, using special tools.
Page 208 April, ’89 <Quenching Unit> 1. Clean the lamp filter with a clean damp cloth. <Paper Feed Section> 1. Lubricate the tray motor worm gear with Mobil Temp 78. 2. Clean all rollers in the paper feed section with water only. <Vertical Transport and Registration Section>...
Page 209 30 April, ’89 <Duplex Tray> 1. The rollers of the duplex tray are unique; do not mix them up with those of the two lower feed trays. <Top Unit> 1. Do not close the top unit under the following conditions: stay is not set.
Page 210: Special Tools And Lubricants
30 April, ’89 SPECIAL TOOLS AND LUBRICANTS Item D e s c r i p t i o n Part No. Q’ty Test Chart OS-UA3 -- 10 sheets 5446 9516 5446 9517 - - 1 0 0 s h e e t s Digital Thermometer 5420 9504 (HLC-60E)E...
Page 211 SECTION 5 REPLACEMENT AND ADJUSTMENT...
Page 212 CONTENTS EXTERIOR COMPOMENT REMOVAL Exposure Glass and Operation Panel Removal Top Plate Removal DRUM AND CHARGE Drum Replacement Drum Thermoswitch and Heater Replacement Charge Corona Wire and Cleaner Pad Replacement EXPOSURE Scanner Drive Wire Replacement Lens Drive Wire Replacement 5-16 Exposure Lamp Unit Removal 5-20 DEVELOPMENT...
Page 213 30 April, ’89 April, ’89 PAPER FEED 5-57 Paper Feed Unit Removal Pick-up Roller Replacement 5-58 5-59 Feed Roller Replacement 5-60 Friction Roller Replacement 5-61 Paper Tray Unit and Cover Removal Paper Tray Drive Wire Replacement 5-62 5-65 Vertical Transport Unit Removal DUPLEX TRAY Duplex Tray Removal 5-66...
Page 214: Exterior Compoment Removal
April, ’89 EXTERIOR COMPONENT REMOVAL 1. Exposure Glass and Operation Panel Removal 1. Remove the DF front cover [A] (2 screws) and the copier front top cover [B] (3 screws). Exposure Glass - 2. Loosen the two screws securing the rear scale [C], and remove the glass fixing plate [D] (1 screw).
Page 215: Top Plate Removal
30 April, ’89 2. Top Plate Removal Remove the DF transport unit and feed-in unit. (Refer to “DF Removal” in Section 5.) Remove the following parts: a) Right top cover (2 screws) b) Original tray screws) c) Upper front cover (2 screws) Remove the platen cover support bracket [A] (2 flat-head screws and 2 pan-head screws).
Page 216: Drum And Charge
April, ’89 DRUM AND CHARGE 1. Drum Replacement Open the top unit, and remove the drum cover [A] (2 screws). Remove the drum stay [B] by turning the knob counterclockwise. Remove the following parts: a) Erase unit [C] b) Charge corona unit [D] (1 connector) c) Drum thermistor [E] d) Quenching unit [F] (1 connector) e) Cleaning unit [G]...
Page 217: Drum Thermoswitch And Heater Replacement
30 April, ’89 2. Drum Thermoswitch and Heater Replacement Before starting, note the locating tabs and cutouts [A] on the front and rear drum heater flanges. Turn off the main switch. Remove the drum (refer to “Drum Replacement”); then, take out the drum guide.
Page 218: Charge Corona Wire And Cleaner Pad Replacement
April, ’89 3. Charge Corona Wire and Cleaner Pad Replacement Remove the drum cover and take out the charge corona unit (1 connec- tor). Remove the rear endblock cover [A]. (Be careful not to break off the side hooks). Remove the front endblock cover [B] (1 screw) and the corona wires [C]. Replace the cleaner pad [C-1].
Page 219: Scanner Drive Wire Replacement
30 April, ’89 EXPOSURE 1. Scanner Drive Wire Replacement Remove the DF transport unit and feed-in unit. (Refer to “DF Removal” in Section 5.) Remove the top plate. (Refer to “Top Plate Removal”.) Remove the pre-quenching corona power pack with bracket [A] (1 screw and 2 connectors) and the main switch (2 screws).
Page 220 30 April, ’89 Using a flat blade screwdriver, turn the front mirror shift pulley [ A ] counterclockwise and insert the stopper pin [B] into the hole. Turning the front mirror shift pulley counterclockwise, remove the mir- ror shift wire [C] and the magnification ratio adjusting ring [D]. Remove the wire holding plates [E] from both mirror shift pulleys (1 screw each).
Page 221 30 April, ’89 - Installation - Remove the stud [A] from the second scanner, and position the second scanner so that the hole [B] in the second scanner is aligned with the hole [C] in the scanner motor bracket. Secure the second scanner to the scanner motor bracket with an M4 screw.
Page 222 30 April, ’89 Insert the beads of the long (gray) [A] and short (black) [B] wires into the slots of the scanner drive pulley [C] as shown. (At this time the Allen screw [D] should be facing up.) Wrap the two wires side by side 3 times along the grooves of the scan- ner drive pulley.
Page 223 April, ’89 18. Route the short end of the scanner drive wire [A] over the pulleys in the following order. NOTE: Use the wire clamps [B] to prevent the wire from slipping off the pulleys. (1) Lower track clockwise. (2) Inner track clockwise. (2nd scanner drive pulley) (3) Counterclockwise.
Page 224 April, ’89 19. Route the long end of the scanner drive wire [A] over the pulleys in following order. Upper track clockwise. Lower track clockwise. Inner track counterclockwise. (2nd scanner drive pulley.) Clockwise. (Front mirror shift pulley.) Skip the tension pulley. Clockwise.
Page 225 April, ’89 Wrap both ends of the wire around the scanner wire drive pulley. Insert the beads [A] into the slots of the pulley. String the wire over the front and rear tension pulleys [B]. Reinstall the scanner motor (2 shoulder screws and 2 connectors) and tighten the Allen screw of the scanner drive pulley.
Page 226 April, ’89 Remove the scanner drive pulley pin, the scanner drive pulley clamp, and the pulley clamps. Remove the front and rear second scanner positioning clamps. Hook up the wire tension springs [A]. Tighten the front and rear scanner pulley brackets [B] (2 screws each). Slide the second scanner manually several times to ensure proper move- ment.
Page 227 30 April, ’89 Using a flat blade screwdriver, turn the mirror shift pulley [A] counterclockwise until the slot [B] is facing up. Insert the bead of the mirror shift wire [C] into the slot of the mirror shift pulley. Route the mirror shift wire as shown, and insert the magnification ratio adjusting ring [D] into the holder [E].
Page 228 April, ’89 Set the front and rear second scanner positioning clamps. Adjust the distance between the rear second scanner bracket [A] and the rear first scanner bracket [B] as shown. (Distance: 120 mm) This is also part of the coarse horizontal magnification adjustment. Tighten the front and rear drive wire clamps [C] on the first scanner (1 Allen screw each).
Page 229: Lens Drive Wire Replacement
30 April, ’89 2. Lens Drive Wire Replacement Remove the upper front cover. Remove the top front cover, exposure glass, original tray, and operation panel. Remove the lens housing cover (3 screws) and the drum cover (2 screws). Remove the main switch [A] (2 screws). Using a flat blade screwdriver, turn the front mirror shift pulley [B] counterclockwise.
Page 230 April, ’89 9. Remove the lens drive wire [A] from the wire clamp [B] (1 Allen screw). 10. Remove the lens drive unit [C] from the copier (3 screws and 3 connec- tors). 11. Release the lens drive wire tensioning mechanism [D] (2 screws). 12.
Page 231 April, ’89 Insert the cam positioning pin [A] into the hole and tighten it. This posi- tions the lens in the 100% reproduction setting. Insert the painted portion of the wire [B] into the slot [C] in the lens drive pulley [D] and secure it with a screw. NOTE: The lens drive wire joiner [E] should be on the bottom as shown.
Page 232 April, ’89 Reinstall the lens drive unit (3 screws and 3 connectors). CAUTION: The lens housing cover support bracket [A] must be under the scanner drive wire [B]. This wire sometimes gets caught when installing the lens drive unit. Clamp the harnesses with the three twist clamps, and connect the three connectors and the two terminals.
Page 233: Exposure Lamp Unit Removal
April, ’89 3. Exposure Lamp Unit Removal Remove the exposure glass. (Refer to “Exposure Glass Removal”.) Remove the rear scale [A] (2 screws). Disconnect the ribbon cable connector [B]. Remove the automatic density sensor (ADS) with bracket [C] (1 screw). Manually position the first scanner so that the access holes in the top plate align with the exposure lamp unit mounting screws [D] as shown.
Page 234: Development Unit Removal
30 April, ’89 DEVELOPMENT 1. Development Unit Removal Open the top unit, and remove the development unit cover [A] (1 screw). Remove the development unit [B] (1 screw, M4 x 10 [C]). CAUTION: Always lower the top unit before tightening the development unit mounting screw.
Page 235: Developer Replacement
April, ’89 2. Developer Replacement Remove the development unit cover (1 screw). Remove the developer exchange plate [A] (1 screw). Close the doors and use SP 1-1 (Tribo charge) for about 1 minute to dump the old developer. Turn off the main switch. Clean and reinstall the developer exchange plate.
Page 236: Development Roller And Paddle Roller Removal
April, ’89 3. Development Roller and Paddle Roller Removal Remove the developer. (Refer to “Developer Removal”.) Place the development unit on a clean sheet of paper with the develop- ment roller facing up. Remove the gear cover [A] (1 screw) and the upper cover [B] (4 screws, 1 connector).
Page 237 [B] . 6. Remove the development roller [A] and the paddle roller roller are in- 7. Reassemble when the development roller and the paddle stalled, do the following: - Position the development roller so that the magnet angle pin [C] fits into the flat surface [D] of the development roller shaft.
Page 238: Adjustment Of Development Roller Gaps
12 July ’86 ’89 April, 4. Adjustment of Development Roller Gaps The Flow ADJUSTMENT STANDARD: 1.75 mm ± 0.15 mm Gap - - The Pre-doctor Gap - ADJUSTMENT STANDARD: 1.6 mm ± 0.1 mm - The Doctor Gap - ADJUSTMENT STANDARD: 0.9 mm ± 0.1 mm 1.
Page 239 April, ’89 Remove the paddle roller [A] and loosen the pre-doctor plate (5 screws [B]). Insert a 1.60 mm thickness gauge [C] between the pre-doctor plate and the development roller [E] at the positions shown. Tighten the pre-doctor plate while pressing down the development roller and pressing the pre-doctor plate against the thickness gauge.
Page 240: Image Density Sensor Cleaning And Removal
April, ’89 5. Image Density Sensor Cleaning and Removal 2. Loosen the screw [A] securing the image density sensor unit [B]. 3. Pull the image density sensor unit to release it. - Cleaning - a) Clean the image density sensor using a dry cloth.
Page 241: Image Density Sensor Adjustment
April, ’89 6. Image Density Sensor Adjustment ADJUSTMENT STANDARD: 4.0±0.2 volts (Vsg) Clean the following parts: Lens and Mirrors Exposure Glass Toner Shield Glass Corona Wires Erase Lamp Quenching Lamp Image Density Sensor NOTE: Discharge any static electricity on the sensor after cleaning it. A clean finger will serve as a discharge medium.
Page 242: Transfer And Pick-Off
April, ’89 TRANSFER AND PICK-OFF 1. Transport Unit Removal 1. Slide out the fusing unit. 2. Remove the following parts: a) Development unit (Refer to “Development Unit Removal”.) b) Transport unit cover [A] (2 screws) c) Drum (Refer to “Drum Replacement”.) 3.
Page 243: Transfer Ozone Filter Replacement
’89 April, 2. Transfer Ozone Filter Replacement (Refer to “Transport Unit Removal”) Remove the transport unit. Remove the spring [A], and disconnect the 3P connector [B]. Remove the transport roller unit [C] (2 screws). and replace the transport ozone Remove the cover plate [D] (1 screw), filter [E].
Page 244: Pre-Transfer Corona Wire Replacement
April, ’89 3. Pre-transfer Corona Wire Replacement Remove the transport unit cover [A] (2 screws). Remove the pre-transfer corona unit [B] (1 screw and 2 connectors [C]. Remove the front endblock cover [D] (1 screw) and rear endblock cover [E]. (Be careful not to break off the side hooks.) Unhook the spring [F] and remove the old corona wire.
Page 245: Transfer/Separation Corona Wire And Cleaner Pad Replacement
30 April, ’89 4. Transfer/Separation Corona Wire and Cleaner Pad Replacement Slide out the fusing unit and remove the transport unit cover (2 screws). Slide out the transfer and separation corona unit (1 connector). Remove the front and rear paper guides [A]. Remove the front and rear endblock covers [B, C].
Page 246: Transport Belt Replacement
30 April, ’89 5. Transport Belt Replacement 1. Remove the transport unit from the copier. (Refer to “Transport Unit Removal”.) 2. Remove the transfer and separation corona unit [A] (1 connector). 3. Remove the transport belt unit [B] (2 screws, 1 spring, and 1 connec- tor).
Page 247: Registration Sensor Replacement
30 April, ’89 6. Registration and Pre-registration Sensors Replacement Remove the transport unit. (Refer to “Transport Unit Removal”.) Remove the PTC and PTL unit (1 screw and 2 connectors). Remove the registration roller cover [A] (4 screws). Remove the registration sensor [B] (2 screws and 1 connector). Remove the pre-registration sensor [C] (2 screws and 1 connector).
Page 248 April, ’89 7. Pick-off Pawl Unit Replacement and Pick-off Pawl Release Adjustment WARNING: Be careful not to cut yourself on the sharp edges of the pick-off pawls. - Pick-off Pawl Unit Replacement - 1. While holding the pick-off pawl shaft [A], pull the pick-off pawl release lever [B] to remove the assembly.
Page 249: Cleaning Blade And Brush Replacement
30 April, ’89 CLEANING 1. Cleaning Blade and Brush Replacement Remove the cleaning blade release spring [A]. While pressing the cleaning blade pressure lever [B] in the direction of the arrow, remove the cleaning blade mounting screw [C]. Remove the old cleaning blade [D]. Remove the brush spindle [E] (l screw) and take out the old cleaning brush [F].
Page 250: Pre-Cleaning Corona Wire Replacement
April, ’89 2. Pre-cleaning Corona Wire Replacement 1. Remove the front and rear endblock covers [A,B]. (Be careful not to break off the side hooks.) 2. Unhook the old wire [C] from the tension spring [D] and remove. 3. Clean the front and rear endblocks and the corona casing. 4.
Page 251: Toner Collection Coil Replacement
30 April, ’89 3. Toner Collection Coil Replacement Remove toner collection coil gear [A] (1 E-ring). Remove old coil [B]. 5-38...
Page 252: Cleaning Blade Pressure Adjustment
April, ’89 4. Cleaning Blade Pressure Adjustment Clearance A = 5.2 mm ± 0.4 mm ADJUSTMENT STANDARD: CAUTION: - This adjustment is rarely required. Check all other possible causes before performing this adjustment. - Improper adjustment of cleaning blade pressure can cause permanent damage to the drum.
Page 253: Blade Cleaner And Bias Roller Blade Replacement
30 April, ’89 5. Blade Cleaner and Bias Roller Blade Replacement - Blade Cleaner - 1. Remove the blade assembly [A] (4 screws). 2. Remove the old blade cleaner [B] (2 screws). 3. Install the new blade cleaner. (Make sure that the spring [C] is set properly.) - Bias Roller Blade - 1.
Page 254: Pre-Quenching Corona Wire Replacement
30 April, ’89 6. Pre-quenching Corona Wire Replacement Remove the drum cover (2 screws). Disconnect the high voltage cable [A] from the terminal. Remove the pre-quenching corona unit [B]. Remove the front and rear endblock covers [C] (1 screw on the rear Be careful not to break off the side hooks.
Page 255 April, ’89 FUSING WARNING: The fusing unit is heavy and maybe hot; be careful when handling the unit. - Removal - 1. Remove the fusing unit knob (1 reverse threaded screw) [A] and the fusing unit cover [B] (3 screws). 2.
Page 256: Hot Roller Stripper Replacement
April, ’89 2. Hot Roller Stripper Replacement Remove the fusing unit knob reverse threaded screw) and the [A] (1 fusing unit cover [B] (3 screws). Slide the fusing unit all the way out and open the inverter unit [C]. Unhook the two left cover springs (front and rear) [D], and remove the left cover [E].
Page 257: And Oil Supply Pad Replacement
April, ’89 3. Cleaning Blade, Metering Blade, and Oil Supply Pad Replacement Remove the fusing left cover. (Refer to “Hot Roller Stripper Replace- ment”.) Disconnect the oil tube [A] and remove the the oil supply unit [B] (2 Al- len screws). Unhook the pressure springs [C], rotate the cleaning blade assembly to the vertical position, and remove it.
Page 258 April, ’89 Replace the cleaning and metering blades [A] (5 screws each). Install the blades with the beveled side up. Prime the edges of the new blades with silicone oil. NOTE: The cleaning blade and the metering blad are the same. But, the meter- ing blade has two oil skimmers [B].
Page 259: Hot Roller Replacement
April, ’89 4. Hot Roller Replacement 1. Remove the oil supply unit. (Refer to “Cleaning Blade, Metering Blade, and Oil Supply Pad Replacement”.) 2. Pull and rotate the front lamp terminals [A] and remove the fusing lamps [B] . 3. Rotate the pressure cam shaft clockwise to release the pressure between the hot and pressure rollers, and remove the hot roller unit (5 screws and 4 correctors).
Page 260 April, ’89 4. Remove the following parts; Rear lamp terminal (1 screw) Hot roller gear (1 C-ring) Spring Parallel key Spacer [E] Front and rear hot roller bearings [F] (1 C-ring each) Isolating Sleeves [G]. Spacers [H] 5. Remove the hot roller [I]. CAUTION: - When installing a new hot roller, be careful not to damage the thermistor.
Page 261: Pressure Roller Replacement
April, ’89 5. Pressure Roller Replacement Remove the left fusing cover (Refer to “Hot Roller Stripper Replace- ment”.) Disconnect the oil tube [A] and remove the oil supply unit and hot roller unit as a set [B] (5 screws, 4 connectors, and 2 bushings). Rotate the pressure cam shaft [C] clockwise until it locks (about 90°) and remove the stopper pin [D] of the pressure roller stripper assembly.
Page 262: Thermistor And Thermofuse Replacement
April, ’89 6. Thermistor and Thermofuse Replacement (Refer to “Hot Roller Stripper Replace- 1. Remove the fusing left cover. ment”.) - Thermofuse Replacement - 2. Replace the thermofuse [A] (2 screws). - Thermistor Replacement - 2. Remove the fusing support bracket [B] (2 screws). 3.
Page 263: Fusing Pressure Adjustment
April, ’89 7. Fusing Pressure Adjustment ADJUSTMENT STANDARD: Nip Band Width: 8.5 ± 0.8 mm (The difference between front and rear measurements should be less than 0.4 mm.) Disconnect the sorter from the copier. Make a black copy (sky shot) using A3/LDG copy paper. As soon as the paper starts to exit, open the left door to stop the paper in the fusing unit.
Page 264 30 April, ’89 6. If the nip band width is not within specifications at both ends, ad- just it using the adjusting screw [A] (Clockwise = increase pressure, Counterclockwise = decrease pressure) NOTE: Loosen the lock nuts [B] before turning the adjusting screws. Retighten the nuts after adjusting.
Page 265: Hot Roller Temperature Adjustment
April, ’89 8. Hot Roller Temperature Adjustment ADJUSTMENT STANDARD: 181 to 188° C 1. Remove the oil supply unit. Reinstall the fusing left cover and set the fusing unit. Remove the lower left cover (2 screws) and disconnect the two main motor connectors [A].
Page 266: Fusing Unit Removal
April, ’89 INVERTER 1. Inverter Roller Clutch Disassembly and Adjustment - Disassembly - Remove the fusing unit. (Refer to “Fusing Unit Removal.”) Open the inverter unit and remove the inverter roller clutch assembly, which consists of the clutch [A], solenoid [B], and the bracket [C] (3 screws and 2 connectors).
Page 267 April, ’89 ADJUSTMENT STANDARD: 2.0 mm - Adjustment - If the inverter roller clutch hub [A] or clutch shaft [B] has been replaced, perform the following adjustment: Loosen the two Allen screws fixing the clutch hub and the clutch shaft. Insert a 0.2 mm thickness gauge [C] at the position shown.
Page 268: Return Pinch Roller Solenoid Adjustment
April, ’89 2. Return Pinch Roller Solenoid Adjustment 1.0 mm (Plunger at energized position) ADJUSTMENT STANDARD: 1.5 ± out and remove the inverter unit cover Pull the fusing unit all the way [A] (2 screws). Slowly push in the plunger [B] of the return pinch roller solenoid until the return pinch roller [C] touches the return drive roller [D].
Page 269: Inverter Gate Solenoid Adjustment
April, ’89 3. Inverter Gate Solenoid Adjustment ADJUSTMENT STANDARD: 0.2 to 1.0 mm [A] (2 Remove the fusing unit, and remove the inverter unit cover screws). (Refer to “Fusing Unit Removal”.) Remove the upper exit roller assembly [B] (2 screws). not, adjust Confirm if the stroke [C] of the plunger is 1.5 ±...
Page 270: Paper Feed
30 April, ’89 PAPER FEED 1. Paper Feed Unit Removal Slide out the upper, lower, and duplex paper trays. Remove the vertical transport cover [A] (1 screw). Remove the paper feed unit [B] (3 screws and 3 connectors). NOTE: When reinstalling the paper feed unit, make sure that the tab [C] of the paper feed unit is inserted into the slot of the paper feed guide plate 5-57...
Page 271: Pick-Up Roller Replacement
30 April, ’89 2. Pick-up Roller Replacement Remove the paper feed unit. (Refer to “Paper Feed Unit Removal”.) Remove the following parts: a) Lower feed unit guide plate [A] (2 screws) b) Tray lift sensor mounting bracket [B] (2 screws and 1 connector) guide plate [C] (2 screws) Upper feed unit Remove the pick-up rollers [D] (1 E-ring each).
Page 272: Feed Roller Replacement
30 April, ’89 3. Feed Roller Replacement Remove the following parts: a) Lower feed unit guide plate (2 screws) b) Tray lift sensor mounting bracket (2 screws and 1 connector) c) Upper feed unit guide plate (2 screws) Remove the two E-rings [A] from the feed shaft [B]. Loosen the two Allen screws on the feed shaft gears [C].
Page 273: Friction Roller Replacement
30 April, ’89 4. Friction Roller Replacement 1. Remove the paper feed unit. (Refer to “Paper Feed Unit Removal.”) 2. Remove the lower feed unit guide plate [A] (2 screws). 3. Remove the friction rollers [B] (2 E-rings, 2 Allen screws, and 2 bush- ings).
Page 274: Paper Tray Unit And Cover Removal
30 April, ’89 5. Paper Tray Unit and Cover Removal Lower the paper tray by pressing the tray button. Slide out the paper tray unit and remove the paper. Remove the paper tray unit (3 screws). Remove the following covers: a) Rear cover [A] (1 screw) b) Front top cover [B] and front exterior cover [C] (6 screws and 1 con-...
Page 275: Paper Tray Drive Wire Replacement
April, ’89 6. Paper Tray Drive Wire Replacement Remove the paper tray unit and remove the covers. (Refer to “Paper Tray Unit and Cover Removal.”) Remove the following parts: a) Tray motor [A] (2 screws and 2 connectors) b) Friction roller drive gear assembly [B] (3 screws) c) Wire tensioning springs [C] Loosen screws [D] (Front and rear).
Page 276 30 April, ’89 4. Rear Wire Replacement a. Insert the blue (upper tray)/yellow (lower tray) bead [A] of the new wire into the slot of the drive pulley [B] and wrap the wire around the drive pulley twice clockwise. b. String the wire over all pulleys, except the tension pulley [C]. c.
Page 277 30 April, ’89 Front Wire Replacement Insert the red (upper tray)/black (lower tray) bead [A] of a new wire into the slot of the drive pulley [B] and wrap the wire around the drive pulley twice counterclockwise. String the wire over all pulleys except, the tension pulley [C], wrap- ping the wire around the friction roller drive pulley [D] 5 times counterclockwise.
Page 278: Vertical Transport Unit Removal
30 April, ’89 7. Vertical Transport Unit Removal a) Duplex tray (Refer to “Duplex Tray Removal”.) b) Vertical transport cover (1 screw) c) Upper and lower trays (Refer to “Paper Tray Unit Removal”.) d) Drum guide [A] and drum guide holder [B] (1 screw) e) Harness cover [C] (1 screw), ozone fan cover [D] (1 screw), ozone fan with bracket [E] (1 screw and 1 connector).
Page 279: Duplex Tray
April, ’89 DUPLEX 1. Duplex Tray Removal Open the front doors and the top unit. and transport unit Slide out the fusing unit and remove the transfer cover (2 screws). the fusing unit. Remove the fusing unit cover (3 screws), and reset Pull the duplex tray all the way out.
Page 280: Paper Feed Roller Replacement And Adjustment
30 April, ’89 2. Paper Feed Roller Replacement and Adjustment (Refer to “Duplex Tray Removal”.) Remove the duplex tray. Unhook the pressure springs of the pick-up rollers [A], and remove the two upper feed guides [B] (2 screws each). Remove the bushing [C] for the feed roller shaft [D] from the front (1 E-ring).
Page 281: Pick-Up Roller Replacement
30 April, ’89 3. Pick-up Roller Replacement 1. Slide out the duplex tray. 2. Turn the duplex handle [A] to the horizontal position. 3. Remove the two old pick-up rollers [B] (1 E-ring each). CAUTION: When installing the pick-up rollers, ensure that the lettering on the bearing is facing toward the pick-up roller gear [C].
Page 282: Friction Roller Replacement
30 April, ’89 4. Friction Roller Replacement Remove the duplex tray. (Refer to “Duplex Tray Removal”.) Remove the duplex handle (1 screw) and the duplex tray cover (2 screws). Unhook the friction roller pressure spring [A]. Remove the friction roller assembly [B] (2 screws). Replace the friction rollers [C] (1 E-ring and 2 Allen screws).
Page 283: Bottom Plate Pressure Clutch Disassembly
30 April, ’89 5. Bottom Plate Pressure Clutch Disassembly Remove the duplex tray and the duplex tray rear top cover (2 screws, 3 twist clamps). (Refer to “Duplex Tray Removal”.) Remove the pressure arm [A] spring [B], (1 screw), and release the chain tensioner [C] (1 spring).
Page 284: Duplex Paper Sensor Adjustment
30 April, ’89 6. Duplex Paper Sensor Adjustment Open the front doors and pull the duplex tray all the way out. Leave the duplex handle in the vertical position. Remove the duplex tray handle (1 screw) and the duplex tray cover (2 screws).
Page 285: Duplex Side Plate Drive Wire Replacement
30 April, ’89 7. Duplex Side Plate Drive Wire Replacement Remove the duplex tray. (Refer to “Duplex Tray Removal.”) Place the duplex unit upside down. Remove the tension spring [A]. Remove the old drive wire [B]. Wrap the new wire around the drive pulley [C] 1.5 times as shown. Insert the beads [D] of the drive wire in the duplex side plate bracket Hook the tension spring to the eyelets of the drive wire.
Page 286: Copy Image
April, ’89 COPY IMAGE 1. Horizontal Magnification Adjustmcnt ADJUSTMENT STANDARD: ± 0.5% (100% Magnification Ratio) ± 1.0% (64%/141% Magnification Ratio) 1. Check that the scanner friction is 600 ± 150 grams. If it is incorrect, lubricate shafts and pulleys; also check the scanner clamp position. 2.
Page 287: Side-To-Side Registration Adjustment
30 April, ’89 2. Side-to-Side Registration Adjustment ADJUSTMENT STANDARD: 0 ± 2.0 mm NOTE: Adjust the lens side-to-side registration using the duplex tray; then, adjust registration for the upper and/or lower tray. Manually place a sheet of white paper on the exposure glass, select duplex or image overlay mode, and press the Start key.
Page 288: Uneven Exposure Adjustment
April, ’89 3. Uneven Exposure Adjustment CAUTION: Be careful not to damage the reflector or the fiber-optic cable. ADJUSTMENT STANDARD: The side-to-side variation of the gray scales of the test chart should be less than 1 level. Place the test chart on the exposure glass and make a copy. If the test copy is not within specifications, continue with this procedure.
Page 289: Light Intensity Adjustment
April, ’89 4. Light Intensity Adjustment ADJUSTMENT STANDARD: When the exposure switch is set at the darker position and the 2nd level of the density control is selected, level 0.2 on the standard test chart should be slightly visible on the copy and there should be no background on the copy.
Page 290: Auto Density Sensor Adjustment
30 April, ’89 5. Auto Density Sensor Adjustment ADJUSTMENT STANDARD: 1.55 ± 0.10V (Using the OS-UA3 test chart.) NOTE: Adjust light intensity before this adjustment. (Refer to “Light Intensity Adjustment.”) Lay the reverse side of a OS-UA3 test chart on the exposure glass. It is necessary to use the test chart (it must be clean), because color and surface finish of the original are critical for this adjustment.
Page 291: Corona Current Adjustment
April, ’89 CORONA CURRENT ADJUSTMENT Corona Current Adjustment Preparation a) Drum (Refer to “Drum Replacement”.) b) Transfer/separation corona unit c) Pre-transfer corona unit d) Development unit (Refer to “Development Unit Removal”.) e) Upper Seal [A] (2 screws) (Do not touch the brush.) f) Pick-off pawls g) Drum heater (Refer to “Drum Thermoswitch and Heater”.) h) Drum heater harness with the bracket [B] (1 screw and 1 connector)
Page 292 30 April, ’89 Mount the drum shoe [A] on the shaft and with the front edge 240 mm Route the wire out through the left side from the front of the shaft. of the machine. Reinstall all corona units. Install the drum stay and lower the top unit. Connect the positive lead of the digital multimeter to the red shoe lead [B].
Page 293: Charge Corona
30 April, ’89 2. Charge Corona OPTIMUM VALUE: dc 65.0±0.5µA Align the drum shoe [A] with the charge corona unit [B] as shown. Select the dc A range on the digital multimeter. Turn on the main switch and charge corona using SP 11-1. Confirm that the corona current at the front of the drum is the same as that at the rear of the drum.
Page 294: Pre-Transfer Corona
30 April, ’89 3. Pre-transfer Corona PTC ac = 43.0±2.0µA OPTIMUM VALUE: dc = -15.7±0.5µA Position the drum shoe [A] in the center and align it with the pre- transfer corona unit [B] as shown. Select the ac µA range on the digital multimeter. (When changing the range of the digital multimeter, make sure the copier’s main switch is off .) Turn on the main switch and the PTC corona using SP 11-3.
Page 295: Transfer Corona
30 April, ’89 4. Transfer Corona Tl: 14.0±0.5µA OPTIMUM VALUE: T2: 14.0±0.5µA Position the drum shoe [A] in the center and align it with the transfer corona unit [B] as shown. Select the dc µA range on the digital multimeter. Turn on the main switch and the transfer corona using SP 12-1.
Page 296: Separation Corona
30 April, ’89 5. Separation Corona ac = 45.0±2.0µA ac = 45.0±2.0µA OPTIMUM VALUE: dc = -3.0±0.5µA dc = -5.7±0.5µA 45.0±2.0µA D 2 a c = -2.0±0.5µA dc = NOTE: Adjust the ac current and then adjust the dc current, It is usually first necessary to repeat this adjustment two or three times, because adjustment of the dc component slightly changes the ac component and vice versa.
Page 297: Pre-Cleaning Corona
30 April, ’89 6. Pre-cleaning Corona 30.4±2.0µA OPTIMUM VALUE: ac = dc = -10.9±0.5µA NOTE: Adjust the ac discharge first and then adjust the de discharge. It is usually necessary to repeat this adjustment two or three times, because ad- justment of the dc component will cause a slight change in the ac component and vice versa.
Page 298: Pre-Quenching Corona
30 April, ’89 7. Pre-quenching Corona OPTIMUM VALUE: -7.4±2.0µA Position the drum shoe [A] in the center end align it with the pre- quenching corona unit [B] as shown. Turn on the main switch and the pre-quenching corona using SP 11-4. Adjust the pre-quenching corona current by turning VR1 on the pre- (Let the reading stabilize for 10 seconds.) quenching power pack [C].
Page 299: Service Program Mode
30 April, ’89 SERVICE PROGRAM MODE 1. Factory Settings SP 1 - All RESET SP 2 - All RESET SP 3 - All RESET SP 4 - All RESET SP 5 - All RESET SP 6 - AH RESET SP 7 - All RESET SP 8 - All RESET...
Page 300: How To Access Sp41 To Sp53
30 April, ’89 2. How to access SP41 to SP53 Turn off the main switch, open the right door, and remove the indicator cover [A] (3 screws). Disconnect the 2 pin short connector [B]. Reassemble and access the desired SP. 5-87...
Page 301: Service Program Functions
30 April, ’89 3. Service Program Functions NOTE: When in SP modes 1 though 12, the currently selected choice is shown in reverse video. To activate the function select SET. 1-1 Triboelectrification (TRIB) Turns on the Development motor to build up the static <Function>...
Page 302 30 April, ’89 2-1 Misfeed Sensor Off (JOFF) <Function> Disables all misfeed sensors except the pick-off sensor. This SP mode enables the user to temporarily use the machine until a faulty sensor is replaced. <Remark> The pick-off sensor stays on to avoid possible damage to the selenium drum.
Page 303 30 April, ’89 Copy Counter (CDWN) <Function> Switches the copy counter from a counting up to a count- ing down mode. SET: Counting-down RESET: Counting-up I.D. Control Mode (BIMO) <Function> Changes the standard (initial) mode of the image density (ID) control. SET: Manual ID Control...
Page 304 30 April, ’89 Corona Cleaner Manual Drive (MCON) <Function> Drives the corona cleaners in turn for corona cleaning and functional check. <Remark> This mode is automatically cleared after all the cleaners have been activated. This function is also automatically cleared when the S.P.
Page 305 30 April, ’89 <Remark> CRAM should be used only to initialize a new Ram. CRAM resets everything as follows: ==> All RESET SP 1 to 12 ==> Empty, nothing set SP 20 to 24 ==> Clock stops SP 25 Sp 26 to 53 ==>...
Page 306 April, ’89 Not Used (A2SA) <Function> No Function (only for Japanese version) <Note> Neither “Set” nor “Reset” effects machine operation. 8-2 Automatic Paper Selection (APS) <Function> Automatically enables the APS mode when originals are set in the DF feed-in unit. <Operation>...
Page 307 30 April, ’89 10-1 I.D. Threshold Level 1 (IDL1) 10-2 I.D. Threshold Level 2 (IDL2) <Function> Varies the toner density of the developer by shifting the threshold level of the image density sensor up or down. <Operation> The threshold level can be changed by setting various combinations of the memory frames as follows: I.D.
Page 308 April, ’89 11-1 Charge Corona On (CGC) 11-2 Pre-cleaning Corona On (PCC) 11-3 Pre-transfer Corona On (PTC) 11-4 Pre-quenching Corona On (PQC) 12-1 Transfer Corona On (TRC) 12-2 Separation Corona D1 On (SPC1) 12-3 Separation Corona D2 On (SPC2) 12-4 Separation Corona D3 On (SPC3) <Function>...
Page 309 30 April, ’89 24 Automatic Shut-off Timer <Function> Selects the automatic shut-off time from 30 minutes, 1 hour or 3 hours. All the functions, except the LED of the Timer <Operation> Release key, stop when the timer works. The machine can be reset by pressing the Timer Release key or by turning the power switch off and on.
Page 310 30 April, ’89 29 I.D. Sensor Output <Function> Displays the output voltage of the I.D. sensor for adjust- ment. 30 Leading Edge Separation Corona Off Timing <Function> (Factory use only) Must be center (8th position). 31 Scanner Brake Timing <Function> (Factory use only) Must be center (8th position).
Page 311 30 April, ’89 35 Exposure Lamp Voltage <Function> Varies the light intensity of the exposure lamp. <Remark> The input voltage of the lamp can be adjusted in 16 steps. One step corresponds to about 0.65 volts; therefore, the total change of the input voltage is 10 volts. Note: Do not adjust the potentiometers of the lamp regulator.
Page 312 April, ’89 43 Jam Counter 3 <Function> Displays the total number of paper misfeeds that have occurred in the following sections of the copier: 43-1 Large Capacity Tray (LCT) Automatic Document Feeder (ADF) 43-2 43-3 Sorter and Sorter Stapler 43-4 Duplex Exit 43-5...
Page 313 30 April, ’89 47 Duplex Counter <Function> Displays the number of duplex copies made. <Remark> The counter is automatically reset to 0 after the counter reaches 999,999 copies. The counter can be reset by pressing the left display control key. 48 Operating Time <Function>...
Page 314 SECTION 6 ELECTRICAL DATA...
Page 315: Main Baord Schematic 1
CONTENTS MAIN BAORD SCHEMATIC 1 MAIN BAORD SCHEMATIC 2 MAIN BAORD SCHEMATIC 3 DC DRIVE BOARD SCHEMATIC SCANNER MOTOR CONTROL BOARD SCHEMATIC MAIN MOTOR CONTROL BOARD SCHEMATIC LENS/MIRROR MOTOR CONTROL BOARD SCHEMATIC POWER SUPPLY UNIT BLOCK DIAGRAM AC DRIVE BOARD SCHEMATIC OPERATION PANEL-CPU BOARD SCHEMATIC 6-10...
Page 316 30 April, ’89...
Page 317 SECTION 7 DOCUMENT FEEDER...
Page 318: Mechanical Component Layout
CONTENTS SPECIFICATIONS MECHANICAL COMPONENT LAYOUT ELECTRICAL COMPONENT LAYOUT ELECTRICAL COMPONENT DESCRIPTIONS BASIC OPERATION Single-Sided Original Feed Two-Sided Original Feed Computer From Feed FEED-IN UNIT Original Feed-in 7-10 Drive Mechanism 7-12 Pressure Mylar Release 7-14 Separation of Originals 7-15 Relay Roller Pressure Release 7-16 TRANSPORT AND INVERSION UNIT Original Transport...
Page 319: Variable Resistors
April, ’89 SERVICE TABLES 7-33 Test Point Table 7-33 Variable Resistor Table 7-34 LED Table 7-35 DIP Switch Table 7-36 Blown Fuse Table 7-36 Switch Failure Table 7-37 Sensor Failure Table REPLACEMENT AND ADJUSTMENT 7-38 Separation Roller Replacement 7-39 Friction Tab Replacement 7-40 Pick-up Roller Replacement 7-43...
Page 320: Specifications
April, ’89 SPECIFICATIONS Operation Modes: ADF (Auto Document Feed) and SADF (Semi-Auto Document Feed) with auto-duplexing CFF (Computer Form Feed) Originals: <Size> ADF and SADF: A3 to A5 (11” x 17” to 5.5” x 8.5”) CFF: Length - 12”, 11”, or 8.5” Width - 15.
Page 321: Mechanical Component Layout
April, ’89 MECHANICAL COMPONENT LAYOUT 11. Pick-up Rollers 1. Exit Roller 12. Separation Rollers 2. Turn Rollers 13. Lower Relay Rollers 3. Inverter Rollers 14. Entrance Belt Roller 4. Transport Belt 15. Pressure Roller 5. Upper Relay Rollers 16. Belt Drive Roller 6.
Page 322: Electrical Component Layout
April, ’89 ELECTRICAL COMPONENT LAYOUT 1. Exit Sensor 11. Pulse Generator 2. Inverter Entrance Sensor 12. Feed-in Motor 3. Inverter Registration Sensor 13. Indicator Board 4. Inverter Motor 14. One-turn Sensor 5. Inverter Gate Solenoid 15. Feed-in Safety Switch 6. Inverter Safety Switch 16.
Page 323: Electrical Component Descriptions
April, ’89 ELECTRICAL COMPONENT DESCRIPTIONS Motors Feed-in (M-l): Drives the feed-in unit. (dc servomotor) Belt (M-2): Drives the transport belt unit. (dc ser- vomotor) Drives the inverter unit and exit rollers. Inverter (M-3): (dc servomotor) Solenoid Inverter Gate (SOL-l): Opens and closes the inverter gate. Sensors Feed-in (S-l): Detects the leading edges of originals, and...
Page 324: Basic Operation
April, ’89 BASIC OPERATION 1. Single-Sided Original Feed - Feed-in - The feed-in motor turns in the reverse direction when the DF CPU receives the feed-in signal. The pick-up rollers then start driving the bottom original forward. The separation rollers and friction tabs allow only the bottom sheet to pass.
Page 325 April, ’89 - Feed-Out - When feeding the original out of the DF, the inverter gate solenoid stays off to keep the inverter gate pawls in the upper position. When the feed-out signal is received, the belt motor and the inverter motor turn on.
Page 326: Two-Sided Original Feed
April, ’89 2. Two-Sided Original Feed - Feed-in - The basic feed-in operation in this mode is exactly the same as that in the single sided original feed mode. - Inversion - After the first side of the original is copied, the inversion signal is supplied by the copier.
Page 327 30 April, ’89 - Feed-out - After the reverse side of the original is copied, the copier main board sends the inverter feed-out signal to the DF. The belt and inverter motors then turn on to feed out the original. At this time the inverter gate solenoid is still on;...
Page 328 30 April, ’89 3. Computer Form Feed When the first page of the computer form is placed on the exposure glass and the Start key is pressed, copying of the first page starts. Just before scanning of the first page is completed, the transport belt, pull-out roller, and exit roller start rotating forward.
Page 329: Feed-In Unit
30 April, ’89 FEED-IN UNIT 1. Original Feed-in When the main switch is turned on, the Insert Original indicator lights. It stays on until originals are inserted to the feed-in position. (The feed-in sensor detects the originals.) When originals are inserted, the ADF mode is automatically selected.
Page 330 April, ’89 When the original passes under the registration sensor, the CPU de-energizes the feed-in motor. The relay rollers then stop turning. In the SADF mode, when the first original is fed in by pressing the Start key, the Automatic Feed indicator lights. After that, originals are fed in automatically without any need to press the Start key again.
Page 331: Drive Mechanism
30 April, ’89 2. Drive Mechanism The feed-in drive mechanism consists of the feed-in motor, three gears con- taining one-way clutches, and several idle gears. The feed-in motor has a worm drive gear on its shaft which transmits torque to the three one-way gears.
Page 332 April, ’89 The feed-in motor turns in the reverse direction when it receives the feed- in signal from the copier. Then all the rollers turn to pick-up and feed a sheet of paper as follows. Worm Gear (Reverse Direction) 1st One-way Gear (B) 2nd One-way Gear 3rd One-way Gear (E) (Free) (D) Dual Idle Gear (K)
Page 333: Pressure Mylar Release
April, ’89 3. Pressure Mylar Release The pressure mylar presses the originals down against the pick-up rollers to provide the friction necessary for smooth feeding. When the copier is in stand-by mode, the pressure release cam presses up the pressure mylar lever to release the downward pressure and allow easy in- sertion of originals.
Page 334: Separation Of Originals
April, ’89 4. Separation of Originals The friction tabs and rollers separate the bottom original from the original stack and feed it to the relay rollers. First, the pick-up rollers drive the bottom original to the separation rollers. When the original reaches the separation rollers, it is driven both the The combined force is greater pick-up rollers and the separation rollers.
Page 335: Relay Roller Pressure Release
April, ’89 5. Relay Roller Pressure Release When the upper feed-in unit is raised to remove misfed originals, the relay roller pressure is released. Both arms of the upper feed-in unit have detents which allow the lower relay rollers to press against the upper relay rollers when the upper feed-in unit is down.
Page 336: Transport And Inversion Unit
30 April, ’89 TRANSPORT AND INVERSION UNIT 1. Original Transport The transport belt takes over original transport from the feed-in unit and moves the original to the proper position on the exposure glass for copying. The belt motor turns on when the one-turn sensor of the feed-in unit is ac- tivated.
Page 337: Transport Belt Drive Mechanism
April, ’89 2. Transport Belt Drive Mechanism The belt motor is a reversible servomotor. Its torque is transmitted to the transport belt as follows: Belt Motor Two Bevel Gears (A) Two Intermediate Gears (B) Timing Belt Drive Pulley (C) Timing Belt (D) Belt Drive Roller Pulley (E) Belt Drive Roller Transport Belt...
Page 338: Original Inversion And Feed-Out
30 April, ’89 3. Original Inversion and Feed-out at the same time as the belt motor. When in The inverter motor energizes the single-sided original feed mode, the pull-out and exit rollers deliver the original directly to the original tray. When the original passes under the exit sensor, the belt motor turns off.
Page 339: Inversion And Feed-Out Drive Mechanism
April, ’89 4. Inversion and Feed-out Drive Mechanism This drive mechanism consists of the two gears that contain one-way clutches, two timing belts, and several gears and pulleys. The torque of the inverter motor is transmitted to the two main drive gears (short and long) through the two bevel gears.
Page 340 30 April, ’89 When the inverter motor changes its direction of rotation, the pull-out rollers, turn rollers, and inverter rollers also reverse. However, the exit roller always turns in the same direction. - Forward Direction - Bevel Gear (A) Drive Gear (B) Drive Gear (C) Turn Roller Gear (D) One-way Gear (E)
Page 341: Lift Mechanism
30 April, ’89 5. Lift Mechanism A lift mechanism utilizing torsion springs is provided to make the transport and inversion unit easy for the operator to lift. The torsion springs are fixed to the middle of the belt unit, which can be lifted, and they are fixed at the outer ends to the base plate.
Page 342: Computer Form Feed
30 April, ’89 COMPUTER FORM FEED When the computer form is properly placed through the edge guides [A] onto the exposure glass, the CFF set sensor [B] is actuated. The CFF then is ready to operate. The ADF and Copy Face Down indicators light on when the DF transport unit is lowered and the lift switch is actuated.
Page 343: Electrical Operation
April, ’89 ELECTRICAL OPERATION 1. Interface With Copier The DF has its own CPU which controls all of the DF functions. The DF communicates with the copier through a serial interface bus. Fiber optics are used for the serial interface bus because they are unaffected by electri- cal noise.
Page 344: Feed-In Sensor
April, ’89 2. Feed-in Sensor When an original is inserted, the feed-in sensor (a photointerrupter) is ac- tivated and a LOW signal is applied to CN105-A12 on the DF main board. The DF main board then stops sending pulse signals to CN105-A7, thus turn- ing off the Insert Original indicator.
Page 345: Motor Control
April, ’89 3. Motor Control The document feeder has three servomotors, each of which is controlled by The DF CPU sends three signals its own motor control IC and driver IC. (SPEED DATA, START/STOP, and FORWARD/REVERSE) to each motor con- troller.
Page 346: Original Size Sensing
April, ’89 4. Original Size Sensing - Sensing Mechanism - The original size sensor board holds of five reflective photosensors an array (one registration sensor and four size sensors). Sensor No. Original Size SN1 or 2 A4(L), A4(S), A5(S), 8½ 11”(S) SN3 or 4 13”...
Page 347 April, ’89 - Auto Paper Selection (APS) - When the APS mode is selected, the copier receives original size data from the document feeder and chooses the paper size which matches the selected magnification ratio. - Auto Magnification Selection (AMS) - When the AMS mode is selected, the copier receives original size data from the document feeder.
Page 348: Df Misfeed Check
April, ’89 5. DF Misfeed Check The DF has four sensors for misfeed checks: the registration sensor, exit sen- sor, inverter entrance sensor, and inverter registration sensor. The DF CPU checks that each sensor has turned on or off within the specific periods shown above.
Page 349: Application Switch
April, ’89 6. Application Switch When the original application switch is turned on (Thick), CN104-1 receives a LOW signal and the DF CPU selects the original reverse mode. In this mode, the belt motor reverses to align the trailing edge of the original with the right scale.
Page 350: Form Size Switch
30 April, ’89 7. Form Size Switch In CFF mode when the Form Size Switch is turned on (8.5”), CN111-2 becomes LOW and the DF CPU selects the 8.5 inch (or 12 inch) form feed mode. (12 inch form feed is available by turning on the DIP SW 101-1 on the DF main board.
Page 351: Cff Feed Hole And Set Sensors
April, ’89 CFF Feed Hole and Set Sensors The circuit of the CFF feed hole and set sensors is shown above. When the computer form is detected by the CFF set sensor (Photo-transistor turns off), CN105-B8 on the DF main board becomes HIGH. When a feed hole is detected by a feed hole sensor (Photo-transistor turns on), the terminal on the DF main board (CN105-A16 or B17) becomes LOW.
Page 352: Service Tables
April, ’89 SERVICE TABLES 1. Test Point Table Number Specificat ion TP101 TP102 +24v TP103 +12V TPl04 TPl05 Registration sensor signal (Adjust using VR104) No original: Less than 3V With original: More than 9V TP106 Feed Hole sensor signal (Factory use only) 2.
Page 353: Led Table
April, ’89 3. LED Table Number Function LED101 Exit Sensor ON lights) (LED LED102 Inverter Entrance Sensor ON LED103 Inverter Registration Sensor ON LED104 Not Used LED105 Registration Sensor ON LED106 Feed-in Sensor ON LED107 Indicates status of the size sensors. Indicates status of the right feed hole sensor.
Page 354: Dip Switch Table
April, ’89 DIP Switch Table - : Don't care 7-35...
Page 355: Blown Fuse Table
April, ’89 Blown Fuse Table (All fuses are fast-acting and are on the motor control board.) Fuse Current Capacity Protects Machine Displays FU101 0.3A 12V line Original Misfeed indicator circuit turns on. FU102 Copier DF is off 6. Switch Failure Table Condition Machine Displays Name...
Page 356: Sensor Failure Table
April, ’89 Sensor Failure Table Machine Displays Condition Name One-turn Open When the main switch is turned on, the feed-in clutch energizes and Sensor cycles the one-turn disk for about 2 seconds; then, the Original Misfeed indicator lights. When feeding originals, the feed-in clutch rotates more than one turn (about 2 seconds) and originals may be torn.
Page 357: Replacement And Adjustment
April, ’89 REPLACEMENT AND ADJUSTMENT 1. Separation Roller Replacement Remove the DF front cover [A] (2 screws). Pull out the separation roller shaft [B]. Open the pressure unit [C], and remove the old separation rollers [D]. Install the new separation rollers. CAUTION: The marked side of the separation rollers should be towards the front.
Page 358: Friction Tab Replacement
30 April, ’89 Friction Tab Replacement 1. Open the pressure unit [A]. 2. Remove the friction tab unit [B] (1 shoulder screw) 3. Remove the old friction tab [C] (7 screws). Ensure that the paper entrance feeler [D] Install the new friction tab. is not restricted.
Page 359: Pick-Up Roller Replacement
30 April, ’89 3. Pick-Up Roller Replacement Removal - Remove the feed-in unit. (Refer to “DF Removal.”) Remove the two bushings [A] from the front of the pick-up rollers [B] (1 E-ring each). Remove the one-turn sensor [C] (1 screw). Remove the 2 screws securing the separation roller support bracket and slide it to the rear.
Page 360 April, ’89 Push the pick-up rollers to the rear and remove the four pins. Remove the cam [H], one-turn disk [1], first pick-up roller drive gear [J], and idle gears [K]. Be careful not to lose the pins. Push the second pick-up roller [L] to the front, and remove the second pick-up roller drive gear [M].
Page 361 30 April, ’89 - Reassembly - second pick-up roller drive gear [Al on the rear Place the plate, and insert the second pick-up roller [B] from the bottom. Install the idle gear [C]. Install the one-turn disk [D]. Align the flat surface of the second pick- [ E ] , s o t h a t t h e y ‘...
Page 362: Transport Unit Cover Removal
April, ’89 Transport Unit Cover Removal Open the inverter unit cover [A], Remove the screw securing the inverter unit cover brace wire Then, push the rear pin [C] towards the back of the machine, remove the inverter unit cover. Remove the transport unit upper cover [D] (4 screws). Raise the transport unit and remove four screws securing the lower cover [E].
Page 363 April, ’89 5. Feed Belt Replacement Lift up the transport unit. Push the stopper through the small hole [Al in the grip [B] and swing down the grip as shown. Swing up the stopper [Cl. Slide the grip to the left and remove it. Pull out and lower the belt unit [D].
Page 364: Inverter Entrance And Inverter Registration Sensor Replacement
30 April, ’89 Inverter Entrance and Inverter Registration Sensor Replacement Remove the transport unit covers. (Refer to “Transport Unit Cover Removal.”) Remove the inverter lower exit guide [A] (2 screws). Remove the bushing securing the inverter gate pawls [B] and lower them.
Page 365: Turn Roller Replacement
30 April, ’89 Turn Roller Replacement Remove the transport unit covers. (Refer to “Transport Unit Cover Removal.”) Release the inverter motor assembly [A] from the turn roller assembly (6 screws and 6 bushings). Remove the inverter lower exit guide (2 screws). Remove the front bearing [B] (1 E-ring).
Page 366: Transport Unit Cover Removal
30 April, ’89 8. Exit Roller/Pull-out Roller Replacement Remove the transport unit covers. (Refer to “Transport Unit Cover Removal.”) Remove the front bushing [A] of exit roller/pull-out roller (1 E-ring). Remove the exit roller [B]/pull-out roller [ C ] . [D/E] and bearing [F/G].
Page 367: Inverter Roller Replacement
30 April, ’89 9. Inverter Roller Replacement Remove the transport unit covers. (Refer to “Transport Unit Cover Removal.”) [A] (3 screws). Remove the side plate [B] (6 6 bushings, 5 Remove the inverter motor assembly screws, connectors and 1 ground screw). Remove the inverter safety switch [C] (2 screws).
Page 368 30 April, ’89 Remove the front bushing [E] (1 E-ring), Push the inverter roller shaft to the rear and remove the drive pulley lose [F] (1 pin). the pin.) (Do not Remove the inverter rollers [G]. NOTE: Every third inverter roller has a rubber surface. Install the new inverter rollers.
Page 369: Df Removal
30 Aprii, ’89 DF Removal [A] (2 screws) and the DF rear cover [B] (3 Remove the DF front cover screws). Remove the copier upper rear cover (2 screws). Lower the DF main board assembly [C] (2 screws) and disconnect the two fiber optic cables [D].
Page 370: Original Skew Adjustment
30 April, ’89 11. Original Skew Adjustment 1. Set the original application switch in the thin position. Open the DF main board plate (2 screws), and set the Dip SWs 101 and 102 as follows: (Free run mode for single sided originals.) Dip SW 101 Dip SW 102 1 2 3 4...
Page 371 April, ’89 12. Original Leading Edge Registration Adjustment Forward : 1.0 to 2.0 mm Adjustment Standard: 0.0 mm Reverse : NOTE: Before this adjustment, check the copier’s leading edge registration adjustment and original skew. Set the original application switch in the thin position. main board plate (2 screws), and Dip SWs 101 and 102 set the...
Page 372 April; ’89 13. Registration Sensor Level Adjustment sensor [B]. Make a solid copy [A] and place it under the registration TP101 (GND) TP105 Check the voltage between on the main board. Adjust the voltage with VR104 so that it is between 9 volts and 10 volts.
Page 373: Feed-In, Belt, And Inverter Motor
30 April, ’89 14. Feed-in, Belt, and Inverter Motor Speed Adjustment -Feed-in Motor- and turn off 101-1 Turn on DIP SW DIP SW 101-2, 3, and 4. off DIP SW 102-3. Turn on DIP SW 102-1, 2, and 4 and turn Adjust VR102 (Ml) so that LED108 turns on.
Page 374: Timing Chart 1
April, ’89 TIMING CHART 1 SINGLE SIDED ORIGINAL FEED MODE (A4 SIDEWISE/ADF MODE) 7-55...
Page 375: Timing Chart 2
TIMING CHART 2 2 SIDED FEED MODE (A4 SIDEWISE/ADF/REVERSE MODE) 7-56...
Page 376 SECTION 8 LARGE CAPACITY TRAY...
Page 377 CONTENTS SPECIFICATIONS MECHANICAL COMPONENT LAYOUT ELECTRICAL COMPONENT LAYOUT ELECTRICAL COMPONENT DESCRIPTIONS MECHANICAL OPERATION Basic Operation Feed Unit Mechanism Tray Drive Mechanism Friction Roller Reverse Mechanism Paper Volume Detection Guide Plate and Paper Size Detection Tray Lock and Positioning 8-10 ELECTRICAL OPERATION 8-11 Tray Motor Circuit Paper Tray Heater...
Page 378: Specifications
April, ’89 SPECIFICATIONS Paper Size: Legal (8½” x 14”), Letter (8½” x 11”), B4 (257 mm x 364 mm), A4 (210 mm x 297 mm), B5 (182 mm x 210 mm) Paper Weight: 60 g/m² - 90 g/m (16lb - 24lb) Approximately 2,200 sheets Tray Capacity: Power Source:...
Page 379: Mechanical Component Layout
April, ’89 MECHANICAL COMPONENT LAYOUT 5. Pull-out Rollers 1. Tray Drive Wire 6. Access Cover 2. Pick-up Rollers 7. Paper Entrance Guide 3. Friction Rollers 8. Paper Conveyor Unit 4. Paper Feed Roller...
Page 380: Electrical Component Layout
April, ’89 ELECTRICAL COMPONENT LAYOUT Tray Motor Tray Button Indicator Paper Volume Sensor Tray Button Switch Paper Size Sensor - Legal Paper Feed Sensor Paper Size Sensor - B4 Tray Lift Sensor Tray Heater Overrun Sensor Paper Size Sensor - Letter Paper End Sensor Paper Size Sensor - B5 Motor Capacitor...
Page 381: Electrical Component Descriptions
April, ’89 ELECTRICAL COMPONENT DESCRIPTIONS Motor Tray Motor (M-l): Moves the tray up and down. Magnetic Clutch Paper Feed (MC-l): Drives the paper feed rollers. Sensors Overrun (S-6): Senses when the tray is above the feed position. The tray moves down until the overrun sensor turns off.
Page 382: Mechanical Operation
April, ’89 MECHANICAL OPERATION 1. Basic Operation The large capacity tray (LCT) can hold about 2,200 sheets of paper. So, the addition of the (LCT) brings the total paper capacity of the system to 3,700 sheets. Paper is always loaded sideways and is positioned at the front of the tray. This places the paper path toward the front of the machine, making jam removal easy.
Page 383: Feed Unit Mechanism
April, ’89 2. Feed Unit Mechanism The paper feed unit is similar to that of the copier trays. A gear on the left side of the Feed roller drive is provided by the copier. This idle gear is copier engages with an idle gear on the paper feed unit. The first idle gear engages a spring loaded against the copier’s drive gear.
Page 384: Tray Drive Mechanism
April, ’89 3. Tray Drive Mechanism Drive from a reversible ac motor is transmitted through a timing belt and a worm gear to the drive pulley shaft. The tray wires have metal beads on them. These beads are inserted in slots at the ends of the tray support rods; so, when the wire pulley turns (clockwise, rear view), the beads on the wires drive the tray support rods and the tray moves upward.
Page 385: Friction Roller Reverse Mechanism
April, ’89 4. Friction Roller Reverse Mechanism Like the copier trays, the LCT has a delay mechanism to prevent damage to the copy paper when the tray starts moving down. The mechanism is the same as that of the copier trays. 5.
Page 386: Guide Plate And Paper Size Detection
April, ’89 6. Guide Plate and Paper Size Detection T h i s i s T h e r e a r f e n c e c a n b e m o v e d t o c h a n g e t h e p a p e r s i z e . accomplished by loosening the thumb screw and moving the rear fence to another slot.
Page 387: Tray Lock And Positioning
April, ’89 7. Tray Lock and Positioning When the tray starts moving up, the lock lever drops behind a lock plate on the accuride support bracket, locking the tray in position to prevent the tray from being pulled out while in the up position. When the tray moves to the down position, the bottom plate of the tray pushes down a pin on the lock lever.
Page 388: Tray Motor Circuit
April, ’89 CIRCUITS 1. Tray Motor Circuit To turn on the tray motor, the CPU sends a +3-volt signal from either CN208-A10 or CN208-A11 to the dc drive board. The dc drive board then changes either the up or the down trigger line to 0 volts, energizing the connected SSR on the ac drive board.
Page 389: Paper Tray Heater
April, ’89 2. Paper Tray Heater T h e t r a y h e a t e r i s the same in form and operation as the copier tray heaters. 3. Tray Set Detection When the tray is pulled out, the ground connection is broken, and the volts to a 9-volt pulse.
Page 390 April, ’89 INSTALLATION 1. Accessary Check Check the quantity and condition of the accessories in the box according to the New Equipment Condition Report (N.E.C.R) or the following list: (Remove all packing material.) DESCRIPTION Q’TY Paper Conveyor Unit Paper Entrance Guide Screw M4 x 6mm Paper Conveyor Drive Unit Screw w/washer M4 x 6mm...
Page 391: Installation Procedure
April, ’89 2. Installation Procedure Remove the four strips of tape [A] and remove the bubble wrap [B] from the harness bracket. Remove the stud [C] securing the paper tray. Remove the lower rear cover [D] (2 screws) and the lower left cover [E] (2 screws) from the copier.
Page 392 30 April, ’89 Position the paper conveyor drive unit [A] (2 positioning pins), and secure it (3 screws: M4 w/washer x 6mm). Install the two gears: 36T [B] and 31T [C]. Remove the cover plate [D] (2 screws). Couple the 3 connectors [E] of the option tray cables with those of the copier harness;...
Page 393 April, ’89 Open the top unit [ A ] , and remove the development unit cover [B] (1 screw). Position the paper conveyor unit [C] (2 positioning pins and 1 hook), and secure it (2 screws: M4 x 6mm). Reinstall the development unit cover. Stick the cushion [D] on the front top of the power supply unit shielding box.
Page 394 30 April, ’89 When docking the option tray [A] with the copier [B], make sure that the docking pins [C] are firmly seated in the notches [D] of the copier. Install the interlock plate [E] (2 screws: M5 x 8mm). Place the leveling shoes [F] under the option tray leveling feet [G], and screw down the feet to level the option tray.
Page 395 April, ’89 1. Undock the option tray from the copier. 2. Remove the upper cover [A] (4 screws). 3. Remove the paper feed unit [B] (5 screws). 8-18...
Page 396: Pick-Up Roller Replacement
30 April, ’89 2. Pick-up Roller Replacement Remove the upper cover (4 screws). Remove the lift and overrun sensor mounting bracket [A] (4 screws). Lift the pick-up roller assembly and remove the pick-up rollers [B] (1 E- ring each). Install new pick-up rollers, The pick-up roller has a one-way bearing. When replacing the pick-up roller, make sure that it can rotate freely in the direction of the arrow as shown.
Page 397: Paper Feed Unit Removal
30 April, ’89 3. Feed Roller Replacement Remove the paper feed unit. (Refer to “Paper Feed Unit Removal.”) Remove the tray lift and overrun sensors mounting bracket [A] (4 screws). Open the upper relay roller unit [B] and remove the upper plate [C]. Remove the two E-rings [D] from the feed shaft.
Page 398: Friction Roller Replacement
April, ’89 4. Friction Roller Replacement Remove the paper feed unit. (Refer to “Paper Feed Unit Removal.”) Open the upper relay roller unit [A]. Remove the paper feed sensor [B] (2 screws). Remove the exit guide [C] (2 screws). Slide out the lower guide plate [D] (4 screws). Replace the friction rollers [E] (2 E-ring and 2 screws).
Page 399: Paper Tray Unit Removal
April, ’89 5. Paper Tray Unit Removal Lower the paper tray. Slide out the paper tray unit and remove the paper. Remove the upper cover (4 screws) and the front top cover [A] (3 screws). Slide the front exterior cover [B] to the left and remove it (1 con- nector).
Page 400: Paper Tray Drive Wire Replacement
30 April, ’89 6. Paper Tray Drive Wire Replacement 1. Remove the paper tray unit. (Refer to “Paper Tray Removal.”) 2. Remove the following parts: and 2 connectors). a) Tray motor [A] (4 screws assembly [B] (3 screws). b) Friction roller drive gear c) Wire tensioning springs [C,D] (Front and rear).
Page 401 April, ’89 4. Rear Wire Replacement Remove the old wire. Insert the blue end bead [A] of the new wire into the slot of the drive pulley and wrap the wire twice around the drive pulley (counterclockwise). String the wire over all the pulleys, except the idle pulley [B], as shown.
Page 402 April, ’89 Front Wire Replacement Remove the old wire. Insert the red end bead [A] of the new wire into the slot of the the wire twice around the drive pulley drive pulley and wrap (clockwise). String the wire over all the pulleys, except the idle pulley [B], wrapping the wire around the friction roller drive pulley 5 times clockwise as shown.
Page 403 SECTION 9 SORTER...
Page 404: Accessory Check
CONTENTS SPECIFICATIONS MECHANICAL COMPONENT LAYOUT ELECTRICAL COMPONENT LAYOUT SORTER DRIVE ELECTRICAL COMPONENT DESCRIPTIONS MECHANICAL OPERATION Basic Operation 9-10 Transport Belt Mechanism 9-11 Turn Gate 9-12 Misfeed Clearance Release Mechanism 9-13 Manual Feed 9-14 Bin Gate Operation ELECTRICAL OPERATION 9-15 Interface with The Copier and AC Power 9-16 Timing Exit, and Manual Feed Sensors 9-17...
Page 405: Specifications
April, ’89 SPECIFICATIONS Console Configuration: Belt/Roller Paper Transport System: 20 + Proof Tray Number of Bins: Maximum A3 or 11” x 17” Paper Size: Minimum A5 or 5½” x 8½” -- 70 sheets/bin Sort Bin Capacity: Stack -- 50 sheets/bin 250 sheets Proof Tray Capacity: Inserted sheets counted by the copier...
Page 406: Mechanical Component Layout
April, ’89 MECHANICAL COMPONENT LAYOUT (Front View) Docking Pins 14. Anti-static Brush (Exit) Lower Entrance Guide Plate 15. Anti-static Brush (Bins) Upper Entrance Guide Plate 16. Proof Tray Lower Transport Belts 17. Exit Guide Plate Upper Transport Belts 18. First Bin Turn Guide 19.
Page 407: Electrical Component Layout
’89 April, ELECTRICAL COMPONENT LAYOUT Exit Sensor Sensor LED Board Manual Feed Sensor Distribution Drive Clutch Manual Feed solenoid Sensor Interface Board Bin solenoid (x 19) Timing Sensor Upper solenoid Board Front Door Safety Switch Lower solenoid Board (x 2 115 V Version) Fuse (x 3 220/240 V Version) Noise Filter...
Page 408: Sorter Drive
30 April, ’89 SORTER DRIVE The drive power distribution mechanism is shown in the illustration on the facing page. The drive train is as follows: Motor (1) 166XL Timing Belt (3) Main Drive Pulley (4) -------> 320XL Timing Belt (6) Belt/Exit Drive Pulley (7) Lower Belt Drive Gear (8) 34XL Timing Belt (10) Upper Belt Drive Gear (9) Exit Drive Pulley (11)
Page 409 April, ’89 - Dive Layout -...
Page 410: Electrical Component Descriptions
April, ’89 ELECTRICAL COMPONENT DESCRIPTIONS Motor Sorter (M-l): Drives the sorter. Clutch Drives the transport rollers. Distribution Drive (MC-l): Solenoids Bins (SOL-1 to -19): Directs the copy paper into the appropriate bin. Turn Gate (SOL-20): Directs the copy paper into the the sorter for sorting and stacking.
Page 411 April, ’89 Circuit Boards Lower Solenoid (PCB-1): Holds the lower bank of bin gate solenoids. Main (PCB-2): Controls all sorter functions. LEDs on this board light when bin jam Sensor Interface (PCB-3): sensors are activated. Sensor LED (PCB-4): Light source for bin jam sensors. Upper Solenoid (PCB-5): Holds the upper bank of bin gate solenoids.
Page 412: Mechanical Operation
April, ’89 MECHANICAL OPERATION 1. Basic Operation (Front View) Copies coming out of the copier pass through the entrance guides, and are delivered to the turn gate by the upper and lower transport belts. The turn gate directs the copies either to the sorter bins or to the proof tray.
Page 413 April, ’89 - Sort/Stack Mode - When copies activate the copier exit sensor, the distribution drive clutch turns on and starts turning the transport rollers. At the same time. the turn gate solenoid turns on and moves the turn gate up to direct copies to the sorter bins.
Page 414: Transport Belt Mechanism
30 April, ’89 2. Transport Belt Mechanism Lower Belt Lower Belt Tension Roller Inlet Roller (Front View) the turn gate by two sets Copies are transported from the copier exit to These belts are in contact of belts, upper and lower belts (6 belts each). with each other and move at the same speed.
Page 415: Turn Gate
30 April, ’89 3. Turn Gate (Rear View) When in the normal feed mode, the turn gate solenoid stays off, and the turn gate remains flat. Therefore, sheets can pass over the gate to the proof tray. When the turn gate solenoid turns on in the sort/stack/manual feed modes, the turn gate link rotates the gate lever, causing the turn gate to cut into the paper path to direct sheets down to the sorter bins.
Page 416: Misfeed Clearance Release Mechanism
April, ’89 4. Misfeed Clearance Release Mechanism (Front View) The roller panels of the upper and lower distribution units can be opened for easy removal of misfed paper. When the roller panel of the upper distribution unit is opened, it also opens the turn guides.
Page 417: Manual Feed
April, ’89 5. Manual Feed (Rear View) Manual feed is effective when the copier is in sort or stack mode. When a sheet of paper is inserted in the manual feed entrance, it presses down the feeler, and the manual feed sensor turns on. At the same time, the turn gate solenoid, the drive motor, the distribution drive clutch, and the appropriate bin solenoid all turn on.
Page 418: Bin Gate Operation
April, ’89 Bin Gate Operation (Rear View) The top 19 bins use the turn gate mechanism to direct paper into the sorter bins. When a solenoid is off, the return spring holds the bin gate out of the paper path, allowing the copy to pass to the lower bins. To direct paper into a bin, the bin solenoid turns on and rotates the bin The bin gate then moves into the paper path and gate lever clockwise.
Page 419: Electrical Operation
April, ’89 ELECTRICAL OPERATION 1. Interface with The Copier and AC Power The sorter the sorter functions. has its own CPU which controls all of communicates with the copier through a serial interface bus. The sorter Fiber optic cables are used for the serial interface bus because they are unaffected by electrical noise.
Page 420: Timing Exit, And Manual Feed Sensors
April, ’89 2. Timing, Exit, and Manual Feed Sensors Timing Sensor – – – Exit and Manual Feed Sensor – - Timing Sensor - The timing sensor is a reflective photosensor. When the paper reaches the timing sensor, the phototransistor turns on and applies HIGH to CN113-3. - Exit and Manual Feed Sensor - Exit sensor and manual feed sensor are photointerrupters and have the...
Page 421: Bin And Jam Sensors
30 April, ’89 3. Bin and Jam Sensors bin copy sensors (upper and lower) detect copy paper in the bins. The jam sensors (upper and lower) check that copy paper is fed to the bins and also count copies as they enter the bins. The circuit description for all four sensors is the same (except for connector numbers and pin numbers).
Page 422: Bin And Turn Gate Solenoids
30 April, ’89 4. Bin and Turn Gate Solenoids – Bin Solenoid – – Turn Gate Solenoid – - Bin Solenoids - The bin solenoids are powered by +24 volts. To energize one of the solenoids, the main board applies a HIGH signal to the appropriate driver IC (inverter).
Page 423: Safety Switches
April, ’89 5. Safety Switches When the top cover or front cover is opened, the respective safety switch At the same time, CN113- opens the 100 volt ac line to the sorter motor. 5 (top cover safety) or CN113-6 (front door safety) changes from 0 volts The sorter to +5 volts, informing the sorter’s CPU that a cover is open.
Page 424: Distribution Drive Clutch
April, ’89 6. Distribution Drive Clutch The main board turns on the distribution drive clutch by supplying a LOW signal at CN112-A13. On and off timing is the same as that of the turn gate solenoid. 9-20...
Page 425: Accessory Check
April, ’89 INSTALLATION 1. Accessory Check Check the quantity and condition of the accessories in the box according to the New Equipment Condition Report (N.E.C.R.) or the following list: DESCRIPTION Q’TY Proof Tray Tray Without Antistatic Brush Tray With Antistatic Brush Manual Feed Tray Screw (M4 x 8mm) Fixing Bracket...
Page 426: Installation Procedure
30 April, ’89 2. Installation Procedure CAUTION: Turn off the copier main switch. Remove all external strips of tape [A], styrofoam block and cut the two cable ties [B] securing the roller panel. Remove the bin number bracket [C] (2 screws and 2 ground screws) and the distribution unit support bracket [D] (7 screws).
Page 427 30 April, ’89 Remove the lower rear cover (2 screws) from the copier. Remove the cover plate [A] from the copier (2 screws). Pass the sorter power cord [B] through the cover plate with the cord Then, install the cover plate inverted (2 screws). stopper [C].
Page 428: Sorter Main Board
April, ’89 Connect the fiber optic cables [A] to the cable terminals [B] on the sorter main board. CAUTION: When docking the sorter to the copier, open the copier to prevent damage to the sorter entrance guide plate. Dock the sorter with the copier. Make sure the docking pins [C] are seated Close the copier top firmly in the notches [D] in the copier frame.
Page 429: Sorter Main Board
April, ’89 SERVICE TABLES 1. Sorter Main Board - Test Point Table - Number Function +24V TP101 TP102 TP103 - LED Table - Number Function LED101 Exit Sensor ON LED102 Upper Entry Jam Sensor ON LED103 Upper Bin Copy Sensor ON LED104 Closed Front Door LED105...
Page 430: Sorter Interface Board
30 April, ’89 Fuse Table - Number Protection Input Voltage (8 Vac) FU101 FU102 Input Voltage (29 Vac) 2. Sorter Interface Board - Test Point Table - Number Specification +24V TP201 TP202 - VR Table - Number Function Upper Entry Jam Sensor Adjustment VR201 VR202 Lower Entry Jam Sensor Adjustment VR203 Upper Bin Copy Sensor Adjustment...
Page 431: Replacement And Adjustment
30 April, ’89 REPLACEMENT AND ADJUSTMENT Distribution Unit Removal Turn off the copier main switch and undock the sorter from the copier. Remove the bin number bracket [A] (2 screws and 2 ground screws) and the distribution unit support bracket [B] (7 screws). Remove all the bins [C].
Page 432 30 April, ’89 7. Remove the upper distribution unit [A] (4 screws). 8. Remove the lower distribution unit (7 screws and 2 connectors). 9. Check/adjust the transport roller drive belt tension. 7.0 ± 1.0 mm deflection at 200 g (upper) 6.0 ±...
Page 433: Transport Unit Removal
30 April, ’89 2. Transport Unit Removal Remove the upper distribution unit. Remove the following parts: a) Manual feed table [A] (2 screws) b) Front door safety switch bracket [B] (3 screws and 4 connectors) c) Top cover support bracket [C] (2 screws) d) Timing belt 320XL [D] CAUTION: Make sure the 4 connectors for the front door safety switch are installed as shown.
Page 434 30 April, ’89 Turn off the copier’s main switch and undock the sorter from the copier. CAUTION: During this procedure there will be three sets of springs removed. Do not mix up the sets; they are different. Remove the top cover (5 screws). Remove the manual feed cover [A]: a) One shoulder screw [B] b) Two pressure springs [C,D]...
Page 435 April, ’89 5. Loosen the Allen screw of the collar [A] and remove the top roller shaft [B] . 6. Remove the upper belt entrance roller shaft [C] in the same way. 7. Lift up the upper belt drive roller shaft [D] and remove it. 8.
Page 436 April, ’89 Loosen the Allen screw of the collar [A] and remove the lower belt entrance roller shaft [B]. Remove the lower belt tension roller shaft along with the pressure arms [C] (2 E-rings). Remove the inside idle roller shaft [D]. Remove the lower belt drive gear [E] (1 E-ring).
Page 437: Jam Sensor And Bin Copy Sensor Adjustment
April, ’89 4. Jam Sensor and Bin Copy Sensor Adjustment NOTE: When replacing the sensor interface board, the following adjustments must be performed: - Jam Sensor - Remove the rear cover (4 screws) and all paper from the bins. Turn on DIP SW201-1 on the sensor interface board. Adjust VR201 (Upper Jam Sensor) to the point where LED201 just turns off.
Page 438: Hz/60Hz Modification
30 April, ’89 5. 50Hz/60Hz Modification Loosen the belt tension bracket screw [A] and release the 166XL timing belt [B] from the main motor pulley. Loosen the two Allen screws and remove the main motor pulley [C]. Reverse the main motor pulley and install it so that it is flush with the end of the main motor shaft.
Page 439 SECTION 10 SORTER CONNECTER UNIT...
Page 440 CONTENTS SORTER CONNECTOR UNIT 10-1 SPECIFICATIONS 10-2 COMPONENT LAYOUT 10-2 MECHANICAL OPERATION ELECTRICAL OPERATION 10-3 Circuit 10-3 Main Board 10-4 DC Power Supply 10-5 Sensor Input Circuit 10-6 Bin Drive Circuit INSTALLATION 10-7 Accessory Check 10-8 Installation Procedure REPLACEMENT AND ADJUSTMENT 10-15 Tension Adjustment 50Hz/60Hz Modification (Sorter Connector Unit)
Page 441: Specifications
30 April, ’89 SPECIFICATIONS Paper Transport System: Rubber Rollers Copy Paper Weight: 52 to 93 g/m, 14 to 25 lb Paper Size: Maximum -- A3, 11” x 17” Minimum -- A5, 5.5” x 8.5” Power Requirement: 115 V, 60 Hz, 2 A 220 V, 50 Hz, 1 A 240 V, 50 Hz, 1 A Maximum Power Consumption:...
Page 442: Component Layout
30 April, ’89 COMPONENT LAYOUT First Cover Safety Switch Power Relay Motor Belt Fuse Second Cover Safety Switch 8. Turn Section Belt Vertical Drive Belt Horizontal Drive Belt Drive Motor MECHANICAL OPERATION Copy paper exits from the copier and enters the first sorter. If the first sorter is full, the paper exits through the 20th bin position and enters the sorter connector unit, which transports the copy to the second sorter.
Page 443: Electrical Operation
30 April, ’89 ELECTRICAL OPERATION 1. Circuit unit to the second AC power (100 volts) passes through the sorter connector fuse and a power sorter. The ac power circuit is protected by a 3 ampere relay. When the main switch of the copier is on, the first sorter provides +24 volts This energizes the power to the sorter connector unit and second sorter.
Page 444: Dc Power Supply
30 April, ’89 3. DC Power Supply The transformer supplies 29 volts ac and 8 volts ac to the second sorter main board. The +8 volt input is not used. The circuit shown above converts the 29 volt ac input to +24 volts. When +24 volts is supplied, LED 113 lights.
Page 445: Sensor Input Circuit
30 April, ’89 4. Sensor Input Circuit The sensor input circuit is basically the same as that of the first sorter. However, it needs only one LS151 CHIP (IC208) because the second sorter does not use a manual feed sensor. The +5 volt power for this circuit comes from the first sorter.
Page 446 The sorter uses a series of 3 shift registers to turn on all clutches and solenoids and the motor. The operation is similar to the erase lamp unit of the copier. Initially, all three shift registers are reset (CN201-11, CN202-11). The clock (CN201-2, CN202-2) then shifts the serial data (CN201-1, CN202-1) through the shift registers.
Page 447: Accessory Check
30 April, ’89 INSTALLATION 1. Accessory Check Check the quantity of the accessories in the box according to the following list: DESCRIPTION Q’ty Left Side Sorter Shield Front Side Sorter Shield Rear Fixing Bracket Front Fixing Bracket Screw M4 x 8mm Foot Shoe Docking Pin Second Sorter Main PCB...
Page 448: Installation Procedure
30 April, ’89 1. Installation Procedure Caution: Turn off the copier main switch - First Sorter Preparation - Remove the fixing bracket [A] (4 screws). Screw up the leveling feet [B], and remove the foot shoes [C]. Open the copier top unit, and secure the copier and the first sorter, being careful not to damage the fiber optics cable [D].
Page 449 30 April, ’89 Remove the bin number bracket [A] (2 screws, 2 ground screws), the distribution unit support bracket [B] (7 screws), and the base plate cover, [C] (3 screws). Replace the locking bracket [E] with the front fixing bracket [F] (4 (Do not clamp the ground wire with the front fixing bracket.) screws).
Page 450 30 April, ’89 - Sorter Connector Unit Preparation - Remove all the external strips of [A] and the two polystyrene covers [B] . Remove the upper [C] and lower [D] rear covers (5 screws). - Docking (Sorter connector unit & First sorter) - Loosen the screw [E] securing the locking bracket then, dock the sorter connector unit with the first sorter (2 screws).
Page 451 30 April, ’89 - Docking (First Sorter & Copier) - Connect the fiber optics cables [A] to the copier. (The cable with the brown making should be installed on the rear terminal.) Dock the first sorter with the copier. Make sure that the docking pin [B] is seated firmly in the notch on the copier.
Page 452 30 April, ’89 - Second Sorter Preparation - Unpack the sorter, install all the bins according to the installation procedure contained in the sorter carton. Replace the sorter main PCB [A] with the second sorter main PCB. [B] (4 connectors, 2 screws, 3 PCB mounting studs). Loosen the four screws [C], then, install the left side sorter shield [D].
Page 453 30 April, ’89 Connect the sorter connector unit interface harness [A] with CN201 (20P) on the second sorter main PCB [B]. Uncouple the second sorter 8P connectors (Green) [C], and connect them with the sorter connector unit 8P connectors (Green) [D]. Uncouple the second sorter 2P connectors (White) [E], and connect them with the sorter connector unit 2P connectors (White)[F].
Page 454 30 April, ’89 - Docking (Second sorter and Sorter connector unit) - Dock the second sorter [A] with the sorter connector unit [B] (2 docking pins). Place the foot shoes [C] under the second sorter leveling feet [D], and screw down the feet to level the second sorter. Loosen the three screws [E] and install the front side sorter shield [F] .
Page 455: Replacement And Adjustment
30 April, ’89 REPLACEMENT AND ADJUSTMENT 1. Tension Adjustment Horizontal Drive Belt Tension Standard: 5.0 ±1.0 mm deflection at 200g pressure Adjust with tightener [A]. Turn Section Belt Tension Standard: 5.0 ±1.0 mm deflection at 200g pressure Adjust with tightener [B]. Motor Belt Tension 6.0 ±1.0 mm deflection at 200g pressure Standard:...
Page 456: Hz/60Hz Modification (Sorter Connector Unit)
30 April, ’89 2. 50Hz/60Hz Modification (Sorter Connector Unit) Loosen the belt tension bracket screw [A]. Loosen the two Allen screws and remove the main motor pulley [B]. Reverse the main motor pulley and install it so that it is flush with the end of the main motor shaft.
Page 457 SECTION 11 SORTER STAPLER...
Page 458: Drive Layout
CONTECTS 11-1 SPECIFICATIONS COMPONENT LAYOUT 11-2 Mechanical Component Layout 11-3 Electrical Component Layout 11-5 Drive Layout 11-7 ELECTRICAL COMPONENT DESCRIPTIONS 11-11 OVERALL MACHINE CONTROL 11-12 BASIC OPERATION MECHANICAL OPERATION 11-13 Transport Section 11-14 Turn Gate Section 11-15 Distribution Section 11-16 Side Plate 11-18 Staple Unit...
Page 459: Main Baord Schematic 3
April, ’89 INSTALLATION Accessory Check 11-29 Installation Procedure 11-30 SERVICE TABLES Test Point Table 11-34 Variable Resister Table 11-34 LED Table 11-34 DIP Switch Table 11-34 REPLACEMENT AND ADJUSTMENT Stapler Removal 11-35 Staple Positioning Adjustment 11-37 Gripper Assembly Removal 11-38 Gripper Rubber Replacement 11-39 Gripper Solenoid Adjustment...
Page 460: Specifications
April, ’89 SPECIFICATIONS Console Configuration Roller Paper Transport System 20 + Proof Tray Number of bins Sort or Stack Mode: P a p e r S i z e Maximum A3 or 11” x 17” Minimum B6 or 5.5” x 8.5” Staple Mode: Maximum A3 or 11”...
Page 461: Mechanical Component Layout
April, ’89 COMPONENT LAYOUT 1. Mechanical Component Layout Entrance Roller Exit Sensor Feeler First Transport Rollers Proof Tray Timing Sensor Feeler Upper Bins Second Transport Rollers Lower Bins Third Transport Rollers Side Plate Fourth Transport Rollers Gripper Assembly Turn Gate Stapler Exit Rollers Distribution Roller...
Page 462: Electrical Component Layout
April, ’89 2. Electrical Component Layout Left Door Safety Switches (x2) Staple Unit Motor Top Cover Safety Switch Gripper Forward Sensor Indicator Board Gripper HP Sensor Right Door Safety Switches (x3) Gripper Motor Side Plate Motor Gripper Solenoid Side Plate HP Sensor Paper Sensor Jog Motor Staple End Sensor...
Page 463 April, ’89 DC Power Supply Board Exit Sensor Fuse Upper Bin/Jam Sensor Board Noise Filter (220, 240 volts only) Mmin Board Lower Bin/Jam Sensor Board Turn Gate Solenoid Sorter Stapler Motor Bin Solenoid Sensor LED Board Upper Solenoid Board Sorter Stapler Motor Capacitor Distribution Drive Clutch Timing Sensor Lower Solenoid Board...
Page 464: Drive Layout
30 April, ’89 3 Drive Layout shown in the illustration on the The drive power distribution mechanism is facing page. The drive train is as follows: Sorter Stapler Motor [10] Distribution Main Drive Clutch [8] Drive Pulley [9] Upper Lower Gear/Pulley [1] Distribution Distribution...
Page 465 April, ’89 11-6...
Page 466: Electrical Component Descriptions
April, ’89 ELECTRICAL COMPONENT DESCRIPTION Motors Sorter Stapler (Ml) Drives the rollers. (100 Vac) Side Plate Drive (M2) Drives the side plate side to side according to the paper size. (dc stepper) Staple Unit (M3) Drives the staple unit up or down to the appropriate bin.
Page 467 30 April, ’89 Switches Control the 100 volt ac, 24 volt dc, and Right Door Safety (SW1 to 3) 5 volt dc lines. Control the 100 volt ac line and provides Left Door Safety (SW 4 to 5) input to the main board on the status of the left cover.
Page 468 April, ’89 Sensors Exit Sensor (S1) Detects paper jams at the sorter exit. (Proof tray) Lower Bin Copy (S2) Detects whether copies are in the lower bins. Jam detector Lower Jam (S3) Upper Bin Copy (S4) Detects whether the copies are in the upper bins.
Page 469 April, ’89 Circuit Boards Lower Solenoid (PCB1) Interfaces between the lower bank of bin gate solenoids and the main board. Upper Solenoid (PCB2) Interfaces between the upper bank of bin gate solenoids and the main board. Sensor LED (PCB3) Light source for bin jam sensors. Main (PCB4) Controls all sorter stapler functions.
Page 470: Overall Machine Control
30 April, ’89 OVERALL MACHINE CONTROL The sorter stapler dc power supply board and the main board receives 100 volts ac from the copier where it is converted to +5 and +24 volts dc and supplied to the sorter stapler main board. The copier and sorter stapler main boards communicate via optical fibers (RXD The sorter stapler main board supplies +5 volts to each sensor, and TXD).
Page 471: Basic Operation
30 April, ’89 BASIC OPERATION - From copier exit section to turn gate section - The six rollers [A] start turning when the start key is pressed. Copies exiting the copier pass through the entrance guides [B] and are fed by the six rollers to the turn gate [C] section.
Page 472: Transport Section
30 April, ’89 MECHANICAL OPERATION 1. Transport Section - Overview - The transport section consists of the transport rollers and the guide plate. When the Start key is pressed, the sorter stapler motor turns on, and the six Copies are transported by the rollers rollers tabulated below start turning.
Page 473: Turn Gate Section
30 April, ’89 2. Turn Gate Section - Overview - The turn gate section consists of the turn gate [A], exit rollers, g u i d e plates, and proof tray [B]. - Turn gate in normal mode - In the normal feed mode, the turn gate solenoid [C] stays off and the turn gate remains flush with the proof tray guide plate, allowing sheets to pass over the gate to the proof tray.
Page 474: Distribution Section
30 April, ’89 3. Distribution Section - Summary - The distribution section has the distribution rollers, 21 bin gates, and the 21 bin gate solenoids. If only one sorter staler is installed on the the copier, the 21th bin gate is always opened and the 21th bin gate solenoid is not used.
Page 475: Side Plate
April, ’89 4. Side Plate - Overview - The side plate [A] is driven from side to side by the side plate drive motor The side plate also jogs (pivots), and this movement is [B] (stepper motor). driven by the jog motor (stepper motor). - Side plate drive mechanism - When the paper feed of the copier starts, the side plate drive motor turns on.
Page 476 April, ’89 - Jog mechanism - The jog motor [A] pivots the side plate [B] to square the paper stack via the cam [C], jog lever [D], the jog shaft [E]. - Jog HP sensor - When the main switch of the copier is turned on, the jog HP sensor [F] checks If not, the jog motor whether the side plate is at the jog home position.
Page 477: Staple Unit
April, ’89 5. Staple Unit - Overview - The staple unit consists of the grip assembly and the stapler. The staple unit is lowered from the home position, above the first bin, to the 20th bin The grip assembly grips the in order to staple the copies in each bin.
Page 478 April, ’89 - Grip Assembly - When the staple unit is lowered to a bin, the staple unit arm [A] makes contact with and pushes down on the bin front side plate [B]. The grip motor [C] (a dc brush motor) turns on and drives the gripper assembly spiral gear [D] via the timing belts [E].
Page 479 30 April, ’89 - Gripper Solenoid - When the grippers are at the home position, they are open. When the grippers move forward to the copies in the bins, the gripper solenoid [A] turns on and the grippers [B] are closed by the links [C]. The grippers grip the copies until stapling is completed.
Page 480 30 April, ’89 - Stapler motor - When the grippers reach the home position, the stapler motor turns on [A]. This moves the hammer [B] up and down via the cam [C], and link [D]. The motor also drives the stapler feed belt [E]. The motor turns off when the stapler HP sensor [F] is actuated.
Page 481 30 April, ’89 - Gripper push lever - The gripper push lever [A] pushes stapled copies [B] back to the bin. This is done as follows: The push spring [C] extends between one end [D] of the gripper push lever and pin [F] an anchor [E] on the push guide plate.
Page 482 30 April, ’89 To clear misfeeds in the sorter stapler, open the top cover, right door, and left door. - Top cover - To access the turn gate section, open the top cover [A]. The proof tray upper guide plate [B] will also open because it is connected to the cover by a link [C].
Page 483 30 April, ’89 ELECTRICAL OPERATION The bin copy sensors (upper and lower) detect copy paper in the bins. The jam sensors (upper and lower) check that copy paper is fed to the bins and also count copies as they enter the bins. The circuit description for all four sensors is the same (except for connector numbers and pin numbers).
Page 484: Safety Switch
30 April, ’89 2. safety Switch There are six safety switches, SW1 to 6, in the sorter stapler. SW1, a n d SW4 and 5 are for the left door. SW6 is for the 3 are for the right door. top cover.
Page 485 30 April, ’89 11-26...
Page 486: Service Call Conditions
30 April, ’89 3. Service call conditions There are two service call conditions for the sorter stapler although a numeric number is not provided. They are the staple inhibition and sort/stack inhibition. - Staple inhibition - Under this condition, only the staple mode is inhibited. The sort and stack modes can be used.
Page 487 30 April, ’89 - Sorter inhibition - Under this condition, the sorter and stapler modes cannot be used. “Service Call Sorter with Stapler” is displayed in the guidance display when either sort or staple mode is selected. However, the stack mode can still be used This inhibition occurs and also copies can be fed out to the proof tray.
Page 488: Accessory Check
30 April, ’89 INSTALLATION 1. Accessory Check Make sure that each accessory listed in the following table is in the box. Also check the condition of each item: Q’ty Description Proof Tray Fixing Plate Screw - M4 x 6 Leveling Shoe Grounding Screw with Tooth Washer Installation Procedure Multiple Language Decals (Europe)
Page 489: Installation Procedure
30 April, ’89 2. Installation Procedure Turn off the copier main switch and disconnect the power supply cord. Remove all external strips of tape and styrofoam blocks [A]. Open the left door [B] and remove the strips of tape [C] securing the guide plates.
Page 490 30 April, ’89 Remove the copier lower rear cover (2 screws) and the cover plate [A] (2 screws). Feed the sorter stapler power cord [B] through the opening in the cover plate until the cord stopper [C] reaches the opening. Then invert the opening faces down and install it (2 screws).
Page 491 30 April, ’89 Insert the leveling shoes [A] under the sorter stapler feet [B], and level the sorter stapler and align it with the copier by securing down the feet. Install the fixing plate [C] (2 screws: M4 x 6 mm). Plug in the power supply cord, and turn on the copier main switch.
Page 492 30 April, ’89 50Hz/60Hz Modification Loosen the belt tension bracket screw [A] and release the timing belt [B] from the sorter stapler motor pulley. Loosen the two Allen screws and remove the sorter stapler pulley [C]. Reverse the sorter stapler pulley and install it so that it is flush with the end of the sorter stapler motor shaft.
Page 493: Bin/Jam Sensor
30 April, ’89 SERVICE TABLE 1. Test Point Table Specification Number TP100 TP101 +24V TP102 2. Variable Resistor Table Number Function VR100 Adjusts the upper jam sensor threshold level. VR101 Adjusts the upper bin copy sensor threshold level. VR102 Adjusts the lower jam sensor threshold level. VR103 Adjusts the lower bin copy sensor threshold level.
Page 494 30 April, ’89 REPLACEMENT AND ADJUSTMENT stapler rear cover (2 Turn off the main switch, and remove the sorter screws). Turn on DIP switch 101-1 (lowers staple unit) on the sorter stapler main board, and turn on the main switch. The staple unit then lowers and stops when it reaches the 10th bin.
Page 495 April, ’89 Remove the following parts. Gear cover [A] (3 screws) Stapler lever [B] (2 screws) Cover [C] (2 screws) Bushing [D] Remove the stapler [E] (2 screws [F]). Remove the stapler knob [G] (1 Allen screw). 11-36...
Page 496: Stapler Removal
30 April, ’89 2. Staple Positioning Adjustment ADJUSTMENT STANDARD: 5±2 mm (0.2”±0.08”) [A] from the top-left corner of the paper. Perform steps 1 through 5 in “Stapler Removal”. - Front and Rear Adjustment - Loosen the two screws [B], and adjust the stapler position. - Right and Left Adjustment - Loosen the three screws [C], and adjust the stapler position.
Page 497: Gripper Assembly Removal
30 April, ’89 3. Gripper Assembly Removal Perform steps 1 through 5 in “Stapler Removal”. Disconnect connector 10P [A]. While supporting the gripper assembly [B], with one hand remove the 3 screws [C]. Pull the gripper assembly to the front and remove it. 11-38...
Page 498 April, ’89 4. Gripper Rubber Strip Replacement (Refer to “Gripper Assembly Removal”.) Remove gripper the assembly. Replace the rubbers strips [A] on the grippers. Note: 11-39...
Page 499: Gripper Solenoid Adjustment
April, ’89 5. Gripper Solenoid Adjustment ADJUSTMENT STANDARD: 3+0.5, -0.0 mm (0.11”+0.02”, -0.00”) Remove the gripper assembly. (Refer to “Gripper Assembly Removal”.) Manually rotate the timing belt [A] to move the grippers [B] forward. Manually close the grippers [C] and confirm if the gap [D] is within the adjustment standard.
Page 500 April, ’89 Open the left door and lift up the stapler release lever [A] to swing open the stapler [ B ] . Try using a screw driver [C] to remove the jammed staple. If the jammed staple is inaccessible with a screwdriver, unhook the springs [D] and open the stapler hammer cover [E].
Page 501: Side Plate Drive Belt Tension Adjustment
April, ’89 7. Staple Unit Drive Belt and Side Plate Drive Belt Tension Adjustment - Staple Unit Drive Belt - ADJUSTMENT STANDARD: 15 ± 1.0 mm (0.59” ± 0.04”) deflection of the belt when 250 grams of pressure is applied. Turn the screws [A] to adjust the tension on the stapler unit drive belt [B] .
Page 502 April, ’89 8. Tension Adjustment for Drive Belts A - F Move tension pulleys shown in the about illustration to adjust the tension on drive belts A - F. The following table gives the adjustment standard for each belt. Item Deflection Pressure A to E...
Page 503: Jam Sensor And Bin Copy Sensor Adjustment
April, ’89 9. Jam Sensor and Bin Copy Sensor Adjustment Note: After replacing the main board, the following adjustment must be performed. Turn off the main switch, then remove the rear cover (4 screws) and all paper from the bin. Turn on DIP SW 100-6 [A] on the sorter stapler main board and turn on the main switch.
Page 504: Timing Chart
April, ’89 ELECTRICAL OPERATION TIMING CHART 11-45...
Page 505: Sorter Stapler Main Board Block Diagram
April, ’89 SORTER STAPLER MAIN BOARD BLOCK DIAGRAM...
Page 506 SECTION 12 MENU READER...
Page 507 CONTENTS SPECIFICATIONS 12-1 OVERALL MACHINE CONTROL 12-2 DATA FORMAT 12-3 BASIC OPERATION Job Sheet Reading 12-4 Menu Reader Indicator Lights 12-6 Processing Errors 12-7 INSTALLATION Accessory Check 12-8 Installation Procedure 12-9 REPLACEMENT AND ADJUSTMENT Lower Transport Roller Replacement 12-11 MENU READER CONTROL BOARD SCHEMATIC 12-12...
Page 508: Specifications
30 April, ’89 SPECIFICATIONS - Item - - Specification - Job Sheet Material : Paper Size 2.6” x 5.9” (67mm x 150mm) Weight 22 lbs to 43 lbs (83g to 161g) ex) HB, B, 2B ---- Markers : Pencil (Black, HB or higher) Marker (Black) Ballpoint pen (Black) Job Sheet Feed Method :...
Page 509: Overall Machine Control
30 April, ’89 OVERALL MACHINE CONTROL 12-2...
Page 510: Data Format
30 April, ’89 DATA FORMAT The contents of the reserve bytes are different in each market. 12-3...
Page 511: Basic Operation
30 April, ’89 BASIC OPERATION 1. Job Sheet Reading When a job sheet is inserted, the sheet detection sensor [A] detects the leading edge of the job sheet. The job sheet is then fed in by the upper and lower transport rollers [B, C]. 12-4...
Page 512 30 April, ’89 The mark detection sensor [A] detects the reference line [D] and reads The mark detection sensor is composed of 4 the job sheet. The sensor on the right [B] detects the reference line photosensors. and reference marks [E], and the other sensors [C] read the job sheet data. The menu reader CPU monitors signals from the mark detection sensor and There are 25 reference measures the time between each reference mark.
Page 513: Menu Reader Indicator Lights
30 April, ’89 2. Menu Reader Indicator Lights Meaning Red Light Green Light A job sheet can be inserted. A job shhet is being read or the copier Start key stays red. A job sheet read error has occurred; the menu reader stops reading. Check the job sheet to make sure it is marked correctly and insert it again.
Page 514: Processing Errors
30 April, ’89 3. Processing Errors Reference Line If the reference line does not reach the mark detection sensor within 2.6 seconds after the job sheet is fed in, the job sheet is fed out. (Feeding out takes 1.6 seconds.) The red light blinks for 6 seconds;...
Page 515: Accessory Check
30 April, ’89 INSTALLATION 1. Accessory Check Make sure that each of the accessories listed below is in the box. Description Q’ty Installation Procedure Decal Sheet Ground Screw (M4 x 8 mm) NECR Envelope - NECR (115V machine only) 12-8...
Page 516: Installation Procedure
30 April, ’89 2. Installation Procedure and remove the lower left cover Turn off the main switch of the copier, Then, connect the 10P free connector [B] to CN217 on [A] (2 screws). the main PCB, and reinstall the lower left cover. Remove the lower rear cover (2 screws) and the cover plate [C] (2 screws).
Page 517 30 April, ’89 Reinstall the cover plate. Connect the 10P free connectors [A], and secure the grounding wire [B] (1 ground screw) as shown in the figure. Then reinstall the lower rear cover. Peel the backing off each strip of double-sided adhesive tape [C] and stick the menu reader on the DF.
Page 518: Replacement And Adjustment
30 April, ’89 REPLACEMENT AND ADJUSTMENT Lower Transport Roller Replacement Turn off the main switch. Remove the menu reader from the copier (3 strips of velcro tape). Remove the upper cover [A] (4 screws) and the reader unit [B] (2 screws, 10P connector). 12-11...
Page 519 30 April, ’89 Remove the control board [A] (4 screws, 2P connector) and the base plate [B] (2 screws, 4 lock tabs). Replace the lower transport roller [C] (3 E-rings, 2 bushes, 1 gear). 6. Reassemble. 12-12...
Page 520 30 April, ’89...
Page 521 30 April, ’89...
Page 522 SECTION 13 TROUBLESHOOTING...
Page 523: Horizontal White Lines (Bands)
CONTENS 13-1 INTRODUCTION COPY QUALITY 13-2 White Spots 13-3 Hat Image 13-4 Bllank Area 13-5 Wrinkled Copy 13-6 Unfused Copy 13-6 Horizontal White Lines (Bands) 13-7 J i t t e r 13-8 Hollwing Out 13-8 Fuzzy Copy 13-9 Vertical Black Lines (Bands) 13-11 Uneven Density 13-14...
Page 524 ’89 April, SERVICE CALL CONDITIONS 13-39 Exposure SC - 1 13-41 SC - 2 Drum Thermistor 13-42 Drum Heater SC - 3 13-43 Drum Overheat SC - 4 13-44 Fusing Thermistor SC - 5 13-44 Fusing Lamp SC - 6 13-45 Fusing Overheat SC - 7...
Page 525 30 April, ’89 INTRODUCTION This troubleshooting guide is compiled to help the field engineers solve some of the more common field problems. However, i t d o e s n o t c o v e r a l l potential problems.
Page 526: Copy Quality
30 April, ’89 COPY QUALITY 1) Firefly Spots spot in the center of the white spot? Is there a small black doctor gap (0.90 mm). Check and adjust the Is the image density too light? As toner may be sticking to the ends of the development roller: o Clean the ends of the development roller.
Page 527 30 April, ’89 Clean the transfer corona wire, and make sure the wire tension spring is the correct one. (Do not mix up the transfer and the separation wire springs.) Adjust the transfer corona current. Does the quenching lamp energize? Is there 485 volts ac between CN315-3 and CN315-4? Does CN222-8 drop from +24 volts to ground? o Check the connector and harness.
Page 528 April, ’89 Is the charge corona current correct? Adjust the charge corona current. Replace the developer. Blank Area (Patchy Image) Is the paper wrinkled? Adjust the transfer corona current. Refer to “Wrinkled Copy Section”. Are the PTC, transfer, and separation corona wires improperly installed? Clean the PTC, transfer, and separation corona wires and readjust the corona currents.
Page 529 30 April, ’89 Is there image in the wrinkled areas? feed and the transfer Check paper transport between paper corona unit, and correct or replace any defective parts. Check whether the screws securing the hot roller unit from the top are loose. Is the nip band width within specifications? Adjust the nip band.
Page 530 30 April, ’89 Unfused Copy 1) Image can be easily rubbed off. Sorter jams may occur. Condition 6 lights, refer to the Service Call If Service Call Section. Is the fusing temperature correct? Ready: 178°C Fusing Lamp ON: 182°C OFF: 185°C Readjust the fusing temperature.
Page 531: Jitter
30 April, ’89 1) Jitter at either 70 to 80 mm or 10 to 20 mm from the trailing edge. Tighten the screws securing the upper registration guide. Does jitter appear at the leading edge of copies? Does the interval of jitter change when making reduced copies? Readjust the...
Page 532: Hollowing Out
30 April, ’89 Hollowing Out 1) Center of bold letters or solid black areas is hollowed out. Is the paper damp? o Clean the PTC and T/S corona wires. o Check and readjust the transfer and separation corona currents. Replace the damp paper with fresh paper and turn on the tray heaters.
Page 533 30 April, ’89 Vertical White Lines (Bands) properly? Do the pick-off pawls swing pick-off pawls, and replace the Correct or replace the drum. Does the oscillator mechanism of the pick-off pawls work correctly? Correct or replace any defective parts. correct Is the gap between the drum and pick-off pawls (1 to 2 mm)?
Page 534 30 April, ’89 Clean, correct, and/or replace any parts which scratch the hot roller. If the hot roller strippers are badly stained with toner, check and readjust the fusing temperature. Then, replace the hot roller. Is the drum scratched? Follow troubleshooting section “Uneven Density 1) Uneven density appears in bands”? Are there any foreign substances around the drum that may cause leaking of the drum potential?
Page 535 30 April, ’89 Uneven Density 1) Image density gradually changes across the copy. Darker area has dirty background. making reduced Does the darker area follow the image when copies? Clean the charge corona wires. Are the charge corona wires incorrectly positioned in the wire cleaner and end block? Is the charge corona current uneven across the drum? Clean the transfer corona unit.
Page 536 30 April, ’89 2. Uneven density appears in bands. Does the darker area move with the image when making reduced copies? o Clean the charge corona wire. o Check and readjust the charge corona current. Note : Make sure it is even across the drum. o Check the charge ventilation fan, and correct it.
Page 537 30 April, ’89 Are the darker and lighter areas clearly contrasted (sharp boundaries)? Is the band interval 67mm? Does the lamp regulator output fluctuate? conductive foreign substances from Remove any around the development sleeve. Check and correct the DG, Pre-DG, and the flow gaps.
Page 538: Vertical Black Lines (Bands)
30 April, ’89 Vertical Black Lines (Bands) 1) Wavy Lines Is the cleaning blade damaged? Do the line(s) still exist after cleaning the edge of the blade? Check whether the edge of the blade cleaner is straight and the movement of the blade cleaner is smooth. If not, correct or replace any defective parts.
Page 539 30 April, ’89 3) Line or band appears at the rear edge of the copy (A3 or 11” x 17”) Set the toner shield glass properly. 4) Straight line(s) or band(s) Do the lines move with the image when making reduced copies? Start a copy cycle and stop it just before the paper reaches the fusing unit.
Page 540: Uneven Density
30 April, ’89 If the problem cannot be resolved by following trouble shooting “Uneven Density 2)Uneven density appears in bands”, clean the edge of the cleaning blade. Make sure the blade cleaner moves smoothly, and the cleaner edge is straight. Correct or replace the pick-off pawls, and replace the drum.
Page 541 30 April, ’89 7) Lines at irregular intervals Is toner clogged in the cleaning unit? Check the blade cleaner. - Is it straight? - Does it contact the cleaning blade properly? - Does it move correctly? Correct or replace any defective parts. Check the optics thermoswitch and the cleaning thermoswitch.
Page 542: Black Spots
30 April, ’89 Does the knocking solenoid energize properly? Does CN304-A12 drop from 24 volts to 0 volts each copy cycle? Replace the knocking solenoid. Replace the dc drive board. Clean the upper seal of the development unit. 2) Black spots at the leading edge. Is the separation corona wire properly installed? Clean the separation corona wire and T/S corona unit.
Page 543: Dirty Background
30 April, ’89 Dirty Background Note: When the problem occurs after the drum conditioning is performed, make several white copies or cycle the development unit for 2 minutes using SP 1-1. Make a reduction copy with A3/11” x 17” paper. Does the dirty background appear in the erased areas? o Clean the...
Page 544 30 April, ’89 Replace the dc drive board. o Check and readjust the charge corona current. o Perform developer mixing using SP 1-1. o Clean or replace the cleaning brush. Clean the edge of the cleaning blade. Check that the PCC wire is properly installed, and clean the wire.
Page 545 30 April, ’89 Is the cleaning blade defective? Adjust the cleaning blade pressure. Clean the cleaning wire, and replace the cleaning blade. 4) Dirty background after solid black copies. Is the quenching lamp defective? Is the PCC wire installed incorrectly? If the PCC corona current is incorrect, clean the wire and adjust the PCC corona current.
Page 546: Black Image
30 April, ’89 Black Image Check for condensation on any of the parts of the optics or the drum. Clean the optics and drum. Note: If the machine was cold before starting, this image may appear. Is there a faint image? wire (or unit) incorrectly installed? Is the charge corona Does the main board output the correct signal to the...
Page 547 30 April, ’89 Reset the charge corona wire (or unit). Does the density gradually drop when making copies? (Also, confirm that the development motor turns.) Is the transfer corona wire (unit) incorrectly installed? proper trigger Does the main board output the signal (CN208-A8 and CN202-A19 drop to ground)? Replace the main board.
Page 548 30 April, ’89 Does the image density change with ID selection? Is the development bias applied? Does the bias power pack receive the proper trigger signal from the main board? Replace the main board. Check for electrical continuity between the rear bias terminal and the development sleeve.
Page 549 30 April, ’89 Other possible causes: 1. Charge corona 2. Transfer corona 3. Development drive mechanism 13-25...
Page 550: Paper Jam/Misfeed Pick-Off Jam
30 April, ’89 PAPER JAM/MISFEED Pick-off Jam the main switch is turned on? Do jams occur when small size paper? Do jams occur only when using Is the paper separated from the drum by the pick-off pawls? (Or does it go to the cleaning area?) Is the gap between the pick-off pawls and the drum surface correct (1 to 2mm)? Adjust the gap.
Page 551: False Paper Jam
30 April, ’89 False Paper Jam 1) Continuous jam condition / Nothing wrong with other mechanical/electrical functions If the voltage between TP218 (TPTH) and ground on the main board is not in the normal range (+1.31V to +1.35V), readjust it using VR202 on the main board.
Page 552 April, ’89 2) Misfeed Does the bottom plate lift up? Does the bottom plate solenoid energize? Does CN301-A1 drop from +24 volts to ground? Replace the dc drive board. Replace the bottom plate solenoid. Clean and adjust the spring clutch. Does the duplex paper feed clutch energize? Does CN301-B5 drop from +24 volts to ground?
Page 553: Paper Feed Jam
30 April, ’89 Paper Feed Jam Does the main motor energize? Is fuse 301 (5A) of the main motor control board blown? Does CN301-B16 drop from +15 volts to ground? Replace the dc drive board. Are the drive voltages to the main motor correct? Replace the main motor drive board.
Page 554: Registration Jam
30 April, ’89 Registration Jam Check and replace the paper feed or registration sensors (short condition). Is fuse 102 (2A) on the sorter main board open circuit? o Check the exit roller drive mechanism o Check for paper curl o Check for some blockage in the paper path Replace the fuse.
Page 555 30 April, ’89 1) Accordion jam Clean or replace any parts heavily contaminated with toner, such as, hot roller strippers, oil pad, metering/cleaning blades, thermistor, hot roller, and pressure roller. Is silicone oil supplied properly? Check the silicone oil supply mechanism o 2 one-way valves o rubber sleeve o oil pump lever...
Page 556: Abnormal Indications
30 April, ’89 FUNCTIONAL PROBLEMS 1) The Please Wait indicator stays on after making duplex copies. Then duplex can not be selected. The rear side plate is not returning to the home position. Check for any mechanical restrictions which may limit side plate movement.
Page 557 30 April, ’89 5) Misfeed is displayed when the main SW is turned on and the covers are closed. Which misfeed indicator is Indicator 1: Replace the lower paper feed sensor. : Replace the upper paper feed sensor. : Replace the registration sensor.
Page 558: Please Wait Condition
30 April, ’89 Please Wait Condition 1) The Please Wait condition frequently occurs after a continuous copy run, especially in the morning. Check if the hot roller temperature is within specifications Ready: 182°C Fusing Lamp ON: 182°C OFF: 185°C Adjust temperature using SP 34. Set SP 4-2.
Page 559: Original Jam
30 April, ’89 Original Jam Is the feed-in motor energized when the main switch is turned Does the Misfeed indicator light when the main switch is turned on? Check the lift switch, feed-in safety switch, and the inverter unit safety switch. If the jam condition can not be reset, check the fuse 201 (3A), registration sensor, and exit sensor.
Page 560: Abnormal Indication
30 April, ’89 Abnormal Indication 1) Insert Original indicator stays on and can not be reset. o Check and replace the lift switch (short condition). o Check and replace the feed-in unit safety switch (short condition). o Check and replace the feed-in sensor (open condition). 2) Original Misfeed indicator stays on and can not be reset.
Page 561 30 April, ’89 SORTER no paper 1) Check Sorter indicator comes on, even when there is in the bins. Is the fuse (3A) located above the power cord open? sorter main board) open? fuse 101 (2A) (on the If the Check Sorter indicator comes on when selecting replace the bin sensor.
Page 562 30 April, ’89 Check the action of the following sensors: (All sensor signals change from 5 volts to ground.) Timing (CN113-3) Upper Jam (CN112-B8) (CN112-B7) Lower Jam Upper Bin Copy (CN112-A8) Lower Bin Copy (CN112-B9) Check and correct any defective parts. 1) Paper will not feed through the manual feed section.
Page 563 30 April, ’89 SERVICE CALL CONDITIONS Service Call 1 - Exposure o The exposure lamps light while in a waiting or an idling condition. o The circuit of the exposure lamps opens. Turn the main switch off and Do the exposure lamps light? Does SC 1 remain off? o Replace the exposure lamp if when the exposure lamp circuit is open.
Page 564 30 April, ’89 Does the input voltage on the main board (CN208-B20) go from LOW to HIGH (+12 volts)? Check and correct the harness and/or connector. Replace the main board. o Turn the main switch off o Disconnect CN228 on the lamp regulator. o Turn the main switch on.
Page 565 30 April, ’89 Service Call 2 - Drum Thermistor o The drum thermistor circuit opens. o Turn the main switch off. o Remove the drum thermistor unit. Is the drum thermistor open circuit? Set the drum thermistor unit. Disconnect CN202 on the main board. Is there an open circuit between CN231-A and CN231-B? o Connect CN202.
Page 566 30 April, ’89 Service Call 3 - Drum Heater o After the drum heater turns on, the drum temperature does not reach 20°C within 50 minutes. Is the drum heater open circuit (CN128-1, CN128-2)? Disconnect CN202. Is the drum thermistor an open circuit (CN202-B4, CN202-A1)? Does the input voltage of CN212-11 on the ac drive board go from HIGH (+24 volts) to LOW?
Page 567 30 April, ’89 Service Call 4 - Drum Overheat o The drum temperature exceeds 60°C for more than 3 seconds. Disconnect CN202 Is the drum thermistor a short circuit (CN202-B4, CN202-A1)? Is the output of CN201-A16 on the main board always HIGH (3 volts)? Is the output of CN301-B15 on the dc drive board always LOW?
Page 568 30 April, ’89 Service Call 5 - Fusing Thermistor o The fusing thermistor circuit opens. o Turn the main switch off. o Disconnect the fusing thermistor connector. Is the fusing thermistor an open circuit (CN353-1, CN353-2)? Disconnect CN202 on the main board. Is there an open circuit between CN202-A1 and CN202-A4? Replace the...
Page 569 30 April,’89 CN301-B14 (1,100W) or Is the output voltage between CN301-A15 (550W) and TP215 on the main board 0 volt? Check and correct the harness and connector. Is the input voltage between CN302-B14 (1,100W) or CN302-A15 (550W) and TP215 3V ? CN201-A15 (1,100W) Is the output voltage between or CN201-B15 (550W) and TP215...
Page 570 30 April, ’89 Is the voltage between CN302-B14 (1,100W) or CN302- A15 (550W) and TP215 0 volts? Replace the main board. Replace the dc drive board. Replace the fusing thermistor. Service Call 8 - Thermofuse o The CPU receives the thermofuse failure signal for more than 2 seconds.
Page 571 30 April, ’89 Service Call 9 - Scanner Motor Encoder When the Start key is pressed, the CPU does not receive the encode signal within 200 milliseconds. When the Start key is pressed and the scanner reaches the home position, the encode pulse count is not within specifications.
Page 572 30 April, ’89 Service Call 10 - Home Sensor When the Start key is pressed and the scanner motor has been activated, the scanner home sensor stays off for more than 2 seconds. When the Start key is pressed and the scanner motor has been activated, the CPU does not receive the scanner home position sensor ON signal.
Page 573 April, ’89 Service Call 11 - Scanner Velocity After the Start key is pressed and the scanner motor has been activated, the scanner does not reach the reference point within 0.2 seconds. The scanner reaches the reference point prior to the specified time.
Page 574 30 April, ’89 Service Call 12 - Scanner Return The scanner does not reach the following points within 1.0 second after the CPU outputs the “Return Signal”. a) Speed Down Point b) Braking Point c) Scanner Home Sensor The CPU continues to receive the encode pulses 1.0 second after the CPU outputs the “Return Signal”.
Page 575 30 April, ’89 High Voltage Leak Service Call 14 - o The charge, PCC, or TC/SC current is excessive. Note: If TC/SC current is excessive (leak occurs), an LED on the TC/SC power pack turns on. o Turn the main switch off. o Clean the charge, PCC, and TC/SC (wires, endblock, and casing).
Page 576 30 April, ’89 Service Call 15 - Lens Drive o If the CPU does not receive 1 pulse from the lens safety sensor for a 1% change in the reproduction ratio (lens motor rotates 180 degrees), the CPU returns the lens unit to the lens home position (1OO% position). While the lens unit is heading for the home position, if the CPU does not receive 1 pulse for 6 seconds, SC 15 turns on.
Page 577 Service Call 21 - Paper Feed Unit o The short circuit of the lift sensor connector from the upper or lower paper feed unit is open for more than 3 seconds. Disconnect CN203 on the main board. Is there a short circuit between CN203-B5 (connector) and TP215. Check and correct the harness and contact.
Page 578 ’89 April, Service Call 23 - Upper Tray o After the CPU sends the upper tray up signal or the upper tray down signal, the CPU does not receive any signal from the upper tray paper volume sensor within 3 seconds. When the main switch is turned on does the upper tray motor rotate?
Page 579 April, ’89 Service Call 24 - Lower Tray o After the CPU sends the lower tray up signal or the lower tray down signal, the CPU does not receive any signal from the lower tray paper volume sensor within 3 seconds. Turn the main switch on.
Page 580 30 April, ’89 Service Call 25 - Option Tray o After the CPU sends the option tray up signal or the option tray down signal, the CPU does not receive any signal from the option tray paper volume sensor within 3 seconds. Turn the main switch on.
Page 581 30 April, ’89 Service call Sorter with Stapler o Stapler Inhibition The staple unit motor takes more than 0.7 seconds (1.9 seconds in Staple Unit Lowering Mode; DIP SW 100-1 on) to lower the staple unit to the next bin. The staple unit motor takes more than 2.0 seconds to raise the staple unit to the next bin.
Page 582 30 April, ’89 Turn off the main switch, turn on Dip SW 1, and turn on the main switch. Does the staple unit lower properly? Can the staple unit be moved manually by turning the staple unit knob. o Correct the drive mechanism of the staple unit. Disconnect the staple unit motor connector.
Page 583 30 April, ’89 Does the side plate jog properly? Can the side plate be jogged manually. o Correct the drive mechanism of the side plate jog movement. Disconnect the jogger motor connector. Turn on the main switch and manually move the jogger motor shaft. Is the signal level of the jogger HP sensors correctly changed? o Replace the jogger HP sensor.
Page 584: Others
30 April, ’89 Condition Problem Component Lens Home Open The lens drives forward to find the home position, but never receives the home position pulse. It continues Position to drive forward until it locks. The Please Wait indicator turns on and “LENS DRIVE 15” is displayed. Short The lens drives backwards to get out of the home position, but never receives a high pulse, It continues to...
Page 585 30 April, ’89 Problem Component Condition “PAPER FEED 21” is displayed and the service call Upper/Lower Open cannot be reset. Tray Lift The tray motor does not turn off after moving up. Short Please Wait is displayed and the tray button flashes. After about 3 seconds, “PAPER FEED 23”...
Page 586 April, ’89 Component Condition Problem Duplex Open When the duplex tray is used, the side plate motor Side Plate drives the side as far as it can go. Possible jamming could occur when trying to feed. “There are copies in the duplex tray”...
Page 587 SECTION SORTER STAPLER CONNECTOR UNIT...
Page 588 CONTENTS SORTER STAPLER CONNECTOR UNIT 1. SPECIFICATIONS ........14-1 2.
Page 589: Specifications
1 August 1990 1. SPECIFICATIONS Paper Transport system: Rubber Rollers Copy Paper Weight: 52 to 93 g/m , 14 lb to 24 lb Paper Size: Maximum: A3, 11” x 17” Minimum: A5, 5½” x 8½” (Sideways) Power Requirements: 115V, 60 Hz, 2A 220V, 50 Hz, 1A 240V, 50 Hz, 1A Maximum Power...
Page 590: Component Layout
1 August 1990 2. COMPONENT LAYOUT S y m b o l P to P — Horizontal Drive Belt — Vertical Drive Belt Paper Exit Sensor Horizontal Cover Safety Switch — Turn Section Belt Vertical Cover Safety Switch Noise Filter D1,D2 AC Drive Motor —...
Page 591: Mechanical Operation
1 August 1990 3. MECHANICAL OPERATION Copy paper exits from the copier and enters the first sorter stapler unit. If the first sorter stapler unit is full, the paper exits through the 20th bin position and enters the sorter stapler connector unit, which transports the copy to the 2nd sorter stapler unit.
Page 592: Electrical Operation
1 August 1990 4. ELECTRICAL OPERATION - AC - AC power from the wall outlet passes through the sorter stapler connector unit to the sorter stapler connector motor and to the second sorter stapler. When the main switch of the copier is turned on, the copier provides AC power 100V to the first sorter stapler.
Page 593: Installation
1 August 1990 5. INSTALLATION 5.1 ACCESSORY CHECK Check the quantity of the accessories in the box according to the following list. Quantity Description 1. Stand Shoe ............... . . 2 2.
Page 594: Installation Procedure
1 August 1990 5.2 INSTALLATION PROCEDURE CAUTION: Turn off the copier main switch before starting installation. 5.2.1 First Sorter/Stapler Preparation If the Sorter/Stapler has been installed, start at step #1 on this page. If the Sorter/Stapler has not been installed, skip steps #1 - 4, and go next page. 1.
Page 595 1 August 1990 5. Remove the following parts from the sorter/stapler. - Front bin bracket [A] (3 screws) - Rear bin bracket [B] (3 screws) - Base plate cover [C] (2 screws) - Rear cover [D] (2 screws) 6. Remove the screw [E] securing the bottom bracket to the bin/jam sensor board.
Page 596 1 August 1990 7. Replace the shoulder screw [A] with the docking pin [B] which comes in the accessory box. Remove the front shoulder screw. 8. Remove the lowest two bins from the sorter/stapler. 9. Manually move the jogger unit [C] to the left. 10.
Page 597 1 August 1990 14. Remove all the external strips of tape from the connector unit and remove the upper [A] and two lower covers [B]. Remove the red shipping bracket (4 screws) on the back side of the S/S connector unit. 15.
Page 598 1 August 1990 16. Slide the connector unit [A] into the first sorter/stapler. While sliding it in, slightly lift the paper entrance section of the connector unit so that the bracket [B] meets the docking pin [C]. CAUTION: Be careful not to damage the side plate HP sensor. 17.
Page 599 1 August 1990 20. Route the interface cable from the connector unit to the first sorter/stapler main PCB [A]. NOTE: The wire clamps must be replaced with the bigger ones which come in the accessory box. 21. Connect the fiber cable to the Sorter/Stapler main PCB, and disconnect the 2P connector [B] on top of the Sorter/Stapler main PCB.
Page 600: Second Sorter/Stapler Preparation
1 August 1990 5.2.2 Second Sorter/Stapler Preparation 25. Remove the front left cover [A] (4 screws), two screws [B], and just loosen a screw [B’]. 26. Fix the front left shield cover bracket [C] to the sorter/stapler frame. 27. Reinstall the front left cover [A], and install the left shield cover [D] on the sorter/stapler.
Page 601 1 August 1990 Mount the second sorter/stapler power supply cord [A] on the connector unit. Make sure the cord stopper [B] is fixed to the cord bracket [C]. Secure the ground wire [D] to the connector unit rear plate [E], and stick the ground decal [F] beside it.
Page 602 1 August 1990 31. Connect the fiber optics cables [A] of the second sorter/stapler to the connector [B] mounted on the connector unit. 32. Connect the second sorter/stapler to the connector unit. Make sure that the docking pins [C] are in the correct position. 33.
Page 603 1 August 1990 34. Fix the rear covers [A] (7 screws). 35. Fix the rear fixing bracket [B] so that the rear docking pin of the second sorter/stapler does not come out of position. 36. Install the front bin bracket [C], rear bin bracket [D], and rear cover [E] of the first sorter/stapler.
Page 604 1 August 1990 5.3 50 Hz–60 Hz MODIFICATION 1. Loosen the belt tension bracket screw [A]. 2. Loosen the two Allen screws and remove the main motor pulley [B]. 3. Reverse the main motor pulley and install it so that it is flush with the end of the main motor shaft.
Page 605: Replacement And Adjustment
1 August 1990 6. REPLACEMENT AND ADJUSTMENT 6.1 TENSION ADJUSTMENT 1. Horizontal Drive Belt Tension Standard: 5.0 ± 1.0 mm deflection at 200g pressure Adjust with tightener [A]. 2. Turn Section Belt Tension Standard: 5.0 ± 1.0 mm deflection at 200g pressure Adjust with tightener [B].
Page 606 SECTION 15 RICOH FT7870 SERVICE MANUAL In this section, FT7060 is refferred to as the F20, FT7770 is refferred to as F21, and FT7870 is refferred to as the F22.
Page 607: Installation And Option Interchangeability
CONTENTS 1. SPECIFICATIONS (Compared with F21) ..... . 15-1 2. GUIDE TO COMPONENTS (Compared with F21) ....15-2 2.1 OPERATION PANEL .
Page 608 8.2 HOW TO RESET THE OPTICS AND FUSING SC ......15-17 8.3 ID SENSOR ABNORMAL RESET...
Page 609: Specifications (Compared With F21)
10 August 1990 1. SPECIFICATIONS (Compared with F21) Only the differences between F21 and F22 are written in the table. 15-1...
Page 610: Guide To Components (Compared With F21)
10 August 1990 2. GUIDE TO COMPONENTS (Compared with F21) This section does not cover minor differences such as the shape of covers, the color of parts, and key location. 2.1 OPERATION PANEL The shape and location of operation panel keys have changed. However, ex- cept for the Clear Modes key all functions remain the same.
Page 611: Electrical/Mechanical Component Layout
10 August 1990 2.2 ELECTRICAL/MECHANICAL COMPONENT LAYOUT Scanner Motor (M2) DC servomotor, power has been increasd for greater speed. The software has been changed. ROM PCB Variable resistors for VSG and ADS are Monitor PCB put on this PCB for easier operation. The software has been modified.
Page 612: Drive Layout
10 August 1990 2.3 DRIVE LAYOUT Location Description Function Drum Gear The helical gears are employed to maintain copy quality at higher speed. Drum Drive Gear Same as above. Drum Drive Belt The mini-pitch belts are employed to main- tain copy quality at higher speed. Main Motor Power has been increased for greater speed.
Page 613: Sectional Descriptions (Compared With F21)
10 August 1990 3. SECTIONAL DESCRIPTIONS (Compared with F21) 3 . 1 P R O C E S S The drum current, the rest time compensation and the toner end condition have been changed because of the higher speed (380 mm/s to 420 mm/s). 3.1.1 Drum Current The following drum currents has been increased by adjusting the current power packs;...
Page 614: Toner End Condition
10 August 1990 3.1.3 Toner End Condition If VSP becomes greater than 0.65 V twice consecutively, the CPU determines that it is time to replace the toner cartridge. In the F21 the limit was 0.75 V. The CPU does not detect the ratio of VSP and VSG;...
Page 615: Counter Measure For Toner Build Up
10 August 1990 3.2.2 Counter Measure for Toner Build Up To prevent toner buildup on the oil supply pad, the pressure of the cleaning blade [A] has been increased. Fusing cleaning 30 g 50 g blade pressure To increase the pressure, the screw [B] and the wire clamp [B] have been removed and a longer screw (M4 x 25.5) [C] and a washer [C] have been in- stalled.
Page 616: Installation And Option Interchangeability
10 August 1990 4. INSTALLATION AND OPTION INTERCHANGEABILITY 4.1 I N S T A L L A T I O N This is exactly the same as the installation procedure of the F21. Refer to the Installation section in the F21 service manual. 4.2 O P T I O N I N T E R C H A N G E A B I L I T Y Sorter Sorter...
Page 617: Service Table (Compared With F21)
10 August 1990 5. SERVICE TABLE (Compared with F21) 5.1 PM TABLE (Differences Between F21 and F22) Three PM parts have been modified, and the PM intervals have been changed as follows: 5.2 VARIABLE RESISTORS – Jam Indicator Board – Number Function VR1 (ADS)
Page 618: Service Remarks
10 August 1990 5.3 SERVICE REMARKS When the main switch is turned off and the power cord is plugged in, the fol- lowing parts are electrically charged, so be careful when servicing the machine. 15-10...
Page 619: Adjustments
10 August 1990 6. ADJUSTMENTS 6.1 IMAGE DENSITY SENSOR/AUTO DENSITY SENSOR A D J U S T M E N T The adjustment procedure is the same as in the F21. (See the F21 service manual, pages 5-28 and 5-77.) However the variable resistors used for adjustment (VSG, ADS) have been moved from the Main PCB to the jam indicator board.
Page 620: How To Access The Sp Mode
10 August 1990 6.3 HOW TO ACCESS THE SP MODE The 3 digit code has been changed as follows. 6.4 ADDITIONAL SP MODES 8½” x 11”/A4 lengthways copying SP3-2 CFA4: Europe, Asia, Middle East, Africa CFLT: North America <Function> 8½” x 11”/A4 lengthways copies can be made. <Operation>...
Page 621: Sp Mode Factory Settings
10 August 1990 6.5 SP MODE FACTORY SETTINGS The following settings have been changed from F21. SP1-2 (JADi) RESET RESET SP4-2 (LOWT) SP7-2 (ADF) RESET RESET SP8-2 (APS) 6.6 DRUM CURRENT ADJUSTMENT Some drum currents have been changed because of the higher speed. See the following tables.
Page 622 10 August 1990 - Drum Shoe (P/N 54469116) - Beckman Beckman 330B Beckman Beckman 330B Item 330/3030 Fluke 8062/ 330/3030 Fluke 8062/ 8062A 8062A Charge +67.5 ± 2µA +67.5 ± 2µA +74.0 ± 2µA +74.0 ± 2µA +48.0 ± 4µA +38.0 ±...
Page 623: Electrical Data
10 August 1990 7. ELECTRICAL DATA 7.1 TIMING CHART - F21 (A4/Letter Sideways) - 15-15...
Page 624 10 August 1990 - F22 (A4/Letter Sideways) -...
Page 625: Troubleshooting
10 August 1990 8. TROUBLESHOOTING 8.1 SERVICE CODES ) without service codes in the F21 as fol- There are 3 types of service call ( lows. only . ID sensor abnormal (see page 2-30 of the F21 service manual) . Charge/Transfer wire cleaner abnormal .
Page 626 CS2065 (A462)
Page 627 CS2065 (A462) Location of Unit ......3 1. Exteriro (A462) ......4 2.
Page 628 LOCATION OF UNIT April 30, ’89 TRANSPORT 2 EXTERIOR TRANSPORT 1 See page 4 See page 6 See page 8 DISTRIBUTION DRIVE SECTION See page 10 See page 12...
Page 629 1. EXTERIOR (A462) April 30, ’89...
Page 630 1. EXTERIOR (A462) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 5887 1110 Upper Cover Mounting Plate 5887 5782 Grounding Wire - Front Cover A462 1201 Upper Cover Timing Belt - 320XL 5887 2341 A462 3375 Manual Feed Table - LT...
Page 631 2. TRANSPORT 1 (A462) April 30, ’89...
Page 632: Transport 1 (A)
2. TRANSPORT 1 (A462) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5887 3253 Timing Belt - 134XL 0314 0060W Philips Pan Head Screw - M4x6 0314 0080W Philips Pan Head Screw - M4x8 5887 3252 Pulley - 21T 0720 0040E...
Page 633 April 30, ’89 3. TRANSPORT 2 (A462)
Page 634: Transport 2 (A)
April 30, ’89 3. TRANSPORT 2 (A462) Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5937 5705 Registration Sensor Harness 5887 3206 Stopper - Turn Pawl Solenoid 5937 4390 Driven Unit Guide 5887 3200 Turn Pawl Solenoid Stay - Side Plate AW02 0002...
Page 635 4. DISTRIBUTION (A462) April 30, ’89...
Page 636: Distribution (A)
4. DISTRIBUTION (A462) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 5937 4210 Driven Link Bracket 5887 4130 Vertical Drive Roller - A 5937 4200 Distribution Driven Unit 5887 4133 Exit Roller 5887 4162 Screw - Driven Guide Plate 5887 4140...
Page 637 5. DRIVE SECTION (A462) April 30, ’89...
Page 638 5. DRIVE SECTION (A462) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 5887 5780 Grounding Wire 5887 2136 Pulley - 40T 5887 2250 Pulley - 17T 5887 5530 Noise Filter - 115V Spring Anchor 5887 5531 Noise Filter - 220/240V...
Page 639 April 30, ’89 6. UPPER SOLENOID CONTROL BOARD (A462)
Page 640: Upper Solenoid Control Board (A)
6. UPPER SOLENOID CONTROL BOARD (A462) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 1102 1055 5887 5652 Upper Solenoid Control Board Connector - 2P 1102 1056 Connector - 4P 1103 0510 Connector - 10P 1103 0512 Connector - 12P...
Page 641 April 30, ’89 7. LOWER SOLENOID CONTROL BOARD (A462)
Page 642: Lower Solenoid Control Board (A)
7. LOWER SOLENOID CONTROL BOARD (A462) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 1102 1055 Connector - 2P Lower Solenoid Control Board 5887 5662 1102 1056 Connector - 4P 1103 0505 Connector - 3P 1103 0512 Connector - 12P 1401 0192...
Page 643 April 30, ’89 8. RECEIVER SENSOR BOARD (A462)
Page 644 8. RECEIVER SENSOR BOARD (A462) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly Connector - 4P 1102 1792 5937 5632 Receiver Sensor Board Transistor - 2SC372 1400 0045 1400 0236 Transistor - 2SK30A-GR 1400 0323 Transistor - PN108 1402 0481...
Page 645 April 30, ’89 9. LIGHT SENSOR BOARD (A462)
Page 646 April 30, ’89 9. LIGHT SENSOR BOARD (A462) Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly Connector - 3P 5887 5633 Light Sensor Board 1102 1791 Transistor - 2SA495GTMY 1400 0113 1400 0284 Transistor - 2SD789D 1403 0247 LED - LN51L IC - LM555CN...
Page 647 10. SORTER MAIN BOARD (A462) April 30, ’89...
Page 648: Sorter Main Board (A)
10. SORTER MAIN BOARD (A462) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 5918 5711 Fiber Output Connector 1407 1698 IC - TD62801P 5918 5712 Fiber Input Connector 1408 0383 IC - SI-3052V 5937 5613 IC - HN4827128G-25 1408 0408...
Page 649 11. MAIN SENSOR BOARD (A462) April 30, ’89...
Page 650: Main Sensor Board (A)
11. MAIN SENSOR BOARD (A462) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 1103 0515 Connector - 15P 5887 5612 Main Sensor Board 1204 0790 DIP Switch 1401 0611 Diode - 1S1588 1403 0308 LED - TLR-102A 1408 0099...
Page 651 April 30, ’89 12. HARNESS LAYOUT (A462)
Page 652 12. HARNESS LAYOUT (A462) Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5887 5625 Upper Sensor Harness 5887 5635 Middle Sensor Haness 5887 5701 Main Harness 5887 5710 Power Supply Harness 5887 5720 Transport Harness 5887 5730 Door Switch Harness 5887 5740...
Page 653 13. MAIN HARNESS (A462) April 30, ’89...
Page 654: Main Harness (A)
April 30, ’89 13. MAIN HARNESS (A462) Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 1100 1147 Socket - Mate-N-Lock 5887 5701 Main Harness Socket - Mate-N-Lock 1100 1159 1100 1182 Socket - Mate-N-Lock Connector - 4P 1102 1213 1102 1244...
Page 655 14. POWER SUPPLY HARNESS (A462) April 30, ’89...
Page 656: Power Supply Harness (A)
April 30, ’89 14. POWER SUPPLY HARNESS (A462) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 1100 1239 Pin - Mate-N-Lock 5887 5710 Power Supply Harness 1100 1042 Socket - Mate-N-Lock 1100 1147 Socket - Mate-N-Lock 1100 1155 Contact 1100 1159...
Page 657 15. DOOR SWITCH HARNESS (A462) April 30, ’89...
Page 658: Door Switch Harness (A)
15. DOOR SWITCH HARNESS (A462) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. D e s c r i p t i o n Assembly Assembly 5887 5730 Door Switch Harness 1100 1147 Socket - Mate-N-Lock 1100 1159 Socket - Mate-N-Lock 1100 1169...
Page 659 16. TRANSPORT HARNESS (A462) April 30, ’89...
Page 660 April 30, ’89 16. TRANSPORT HARNESS (A462) Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly Socket - Mate-N-Lock 1100 1147 5887 5720 Transport Harness Contact 1100 1155 Socket - Mate-N-Lock 1100 1159 1102 1286 Connector Connector - 10P 1102 1293 Connector - 2P...
Page 661 UPPER SENSOR, MIDDLE SENSOR AND CLUTCH HARNESSES (A462) April 30, ’89...
Page 662 April 30, ’89 17. UPPER SENSOR, MIDDLE SENSOR AND CLUTCH HARNESSES (A462) Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5887 5625 Upper Sensor Harness Socket - Mate-N-Lock 1100 1147 5887 5635 Middle Sensor Harness Fastening Receptacle 1100 1274...
Page 663 18. DECAL AND DOCUMENT (A462)
Page 664 18. DECAL AND DOCUMENT (A462) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A462 4510 Decal - Misfeed Removal 7 A462 4515 Decal - Misfeed Removal 7 - Multi A462 8610 Installation Procedure - English A462 8615 Installation Procedure - Multi...
Page 665 PARTS INDEX...
Page 666 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. AW02 0002 A462 1201 Upper Cover Photo Sensor A411 2531 Knob Cap A462 1205 Front Cover 5-18 9-62 A462 1216 A458 4147 Hand Grip Rear Cover 5-21 5053 0447...
Page 667 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5887 2138 Pulley - 14T 5887 3221 Lower Entrance Guide 9-46 13-24 5887 2150 Pulley - 17T 5887 3236 Lower Guide - Turn Pawl 13-28 9-40 5887 2170 Timing Belt - 82XL 5887 3245...
Page 668 April 30, ’89 Page and Page and Description Parts No. Description Parts No. Index No. Index No. 5887 4150 Bracket - Turn Solenoid 11-23 5887 5400 Drive Motor - AC35W/115V 13-15 5887 5420 5887 4155 Shaft Guide - Turn Driven 11-5 Drive Motor - AC35W/220/240V 13-15...
Page 669 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5937 3181 Bracket - Copy Timing Sensor 5887 5740 Clutch Harness 9-44 37-3 5937 3182 5887 5780 Grounding Wire 13-34 Safety Cover - Copy Timing Sensor 9-39 5937 3184 Spacer - Sensor...
Page 670 April 30, ’89 Page and Page and Description Parts No. Description Parts No. Index No. Index No. 0313 0040W Philips Pan Head Screw - M3x4 13-110 9-35 5937 5705 Registration Sensor Harness 0313 0040W Philips Pan Head Screw - M3x4 9-116 13-41 5937 5710...
Page 671 April 30, ’89 Page and Page and Description Parts No. Description Parts No. Index No. Index No. 0575 0060E Hexagon Headless Set Screw - M5x6 0807 4064 Spacer - 6.2x9.5x0.2mm 9-107 11-117 0623 0180E Spring Pin - 3x18mm 0951 3006W Philips Screw With Flat Washer - M3x6 7-113 9-109...
Page 672 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1103 0505 1102 0983 Connector - 2P Connector - 3P 31-109 17-103 1103 0510 Connector - 10P 1102 0995 Connector - 2P 15-103 23-102 1102 1039 Connector - 4P...
Page 673 April 30, ’89 Page and Page and Description Parts No. Parts No. Description Index No. Index No. 1601 7370 Resistor Array - 1KOHM 1400 0045 Transistor - 2SC372 23-131 19-102 1601 7371 Resistor Array - 1.5KOHM 1400 0113 Transistor - 2SA495GTMY 23-132 21-102 1400 0236...
Page 674 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. Resistor - 470OHM 1/4T ±5% 1611 4471 19-113 1611 4472 Resistor - 4.7KOHM 1/4T ±5% 19-114 1611 4472 Resistor - 4.7KOHM 1/4T ±5% 23-146 1611 4472 Resistor - 4.7KOHM 1/4T ±5%...
Page 675 RICOH FT7770 P A R T S C A T A L O G RICOH COMPANY, LTD. First Edition April 1989...
Page 676 PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of this parts on this machine. INDEX to PARTS CATALOG FT7770 (A029) (A462) CS2065 (A463) RT25 (A469) ST20 SORTER CONNECTOR UNIT (5946) (A952) MR20 SORTER STAPLER (A310) CONNECTOR UNIT...
Page 677 (A029)
Page 678 FT7770 (A029) Location of Unit (A029) ..... 3 24. Cleaning Unit (A029) ....56 1.
Page 679 48. DF Main Board (A029) ....104 49. Original Size Sensor Board (A029) ..106 50.
Page 680 LOCATION OF UNIT April 30, ’89...
Page 681 LOCATION OF UNIT April 30, ’89 LOWER TRAY TRAY ACCURIDE PAPER FEED UNIT See page 22 See page 24 See page 26 DUPLEX TRAY 1 DUPLEX TRAY 2 DUPLEX TRAY 3 See page 32 See page 28 See page 30...
Page 682 April 30, ’89 15. VERTICAL TRANSPORT 2 VERTICAL TRANSPORT 1 DUPLEX TRAY 4 See page 38 See page 36 See page 34 DEVELOPMENT 2 DEVELOPMENT 1 VERTICAL TRANSPORT 3 See page 44 See page 42 See page 40...
Page 683 April 30, ’89 LOCATION OF UNIT TRANSFER AND SEPARATION 2 TRANSFER AND SEPARATION 1 DEVELOPMENT 3 See page 50 See page 48 See page 46 DRUM SECTION 2 24. CLEANING UNIT 22. DRUM SECTION 1 See page 56 See page 54 See page 52...
Page 684 LOCATION OF UNIT April 30, ’89 FUSING AND INVERTOR 1 FUSING AND INVERTOR 2 FUSING AND INVERTOR 3 See page 58 See page 60 See page 62 FUSING AND INVERTOR 4 DRIVE SECTION ELECTRICAL SECTION 1 See page 64 See page 66 See page 68...
Page 685 LOCATION OF UNIT April 30, ’89 ELECTRICAL SECTION 3 ELECTRICAL SECTION 2 33. OPERATION PANEL See page 74 See page 72 See page 70 36. TRANSPORT SECTION 1 – DF FEED – IN UNIT 1 – DF FEED – IN UNIT 2 – DF See page 80 See page 78 See page 76...
Page 686 LOCATION OF UNIT April 30, ’89...
Page 687 April 30, ’89 1. EXTERIOR (A029)
Page 688 1. EXTERIOR (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5446 1665 Rubber Pad - Exposure Glass A029 7015 Rear Lower Cover A029 1671 Main Table A029 7028 Left Door 5446 1669 Scanner Stopper 5219 1428...
Page 689 2. TOP UNIT MECHANISM (A029) April 30, ’89...
Page 690: Top Unit Mechanism (A)
2. TOP UNIT MECHANISM (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5446 1222 Left Lever - Lock Release 0720 0040E Retaining Ring - M4 5219 1210 0807 4005 Washer - 5.1x8x0.2mm Lock Release Wire Push Switch 5409 3030...
Page 691 3. OPTICS 1 (A029) April 30, ’89...
Page 692: Optics 1 (A)
3. OPTICS 1 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5219 5310 5446 1710 Mounting Screw - Exposure Bracket Scanner Therbo Motor - DC 37W 5219 1729 Exposure Adjusting Plate 5219 1762 Rear Guide Rod 5219 1693...
Page 693 4. OPTICS 2 (A029) April 30, ’89...
Page 694: Optics 2 (A)
4. OPTICS 2 (A029) April 30, ’89 Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5219 1871 Lens Shielding Cover A029 1832 Left Shielding Plate - Lens 5446 1710 Mounting Screw - Exposure Bracket 5446 1808 Lens Wire Clamp 5408 7501 Cleaning Lever Spring...
Page 695 5. OPTICS 3 (A029) April 30, ’89...
Page 696: Optics 3 (A)
5. OPTICS 3 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5219 1956 Right Cam - Lens Guide 5219 5330 Lens Drive Motor - DC 7.2W 5446 1866 Rear Pulley - Shift Mirror 5219 1947 Timing Belt - 60XL 5446 1855...
Page 697 6. UPPER TRAY (A029) April 30, ’89...
Page 698 6. UPPER TRAY (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 7063 Upper Cover - Paper Tray 1000 5446 2663 Spring - Lock Lever A029 2675 Lock Lever - 1000 A029 7062 Decal - Loading Paper 5446 2675...
Page 699 7. LOWER TRAY (A029) April 30, ’89...
Page 700: Lower Tray (A)
7. LOWER TRAY (A029) April 30, ’89 Index Q’ty Per Q’ty Per Part No. Description Description Assembly Assembly A029 7071 Upper Cover - Paper Tray 500 5446 2663 Spring - Lock Lever A029 7062 Decal - Loading Paper A029 2760 Lock Lever - 500 5446 2728 5446 2675...
Page 701 8. TRAY ACCURIDE (A029) April 30, ’89...
Page 702: Tray Accuride (A)
April 30, ’89 8. TRAY ACCURIDE (A029) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 0434 0080W Tapping Screw - M4x8 5446 2937 Upper Guide - Paper Feed Philips Pan Head Screw - M4x6 0314 0060W 5446 2586 Duplex Slide Guide...
Page 703 9. PAPER FEED UNIT (A029) April 30, ’89...
Page 704 9. PAPER FEED UNIT (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5219 5600 Photo Coupler 0314 0060W Philips Pan Head Screw - M4x6 5219 2923 Volume Sensor Bracket 0434 0080W Tapping Screw - M4x8 5446 2933 Pressure Spring - Paper Feed Rpller...
Page 705 10. DUPLEX TRAY 1 (A029) April 30, ’89...
Page 706: Duplex Tray 1 (A)
10. DUPLEX TRAY 1 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5446 6339 Upper Separation Guide 5219 6355 Bracket - Separation Roller 5219 6358 Separation Rller Guide 5219 6168 Upper Stay - Duplex Tray 5219 6224 5446 6345...
Page 707 April 30, ’89 11. DUPLEX TRAY 2 (A029)
Page 708 11. DUPLEX TRAY 2 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5219 6401 Left Cover - Duplex Tray 5219 5600 Photo Coupler 5429 3148 Spring - Release Lever 5219 6347 Sensor Bracket - Duplex Unit 5219 6408 Lift Shaft - Paper Holding Bar...
Page 709 12. DUPLEX TRAY 3 (A029) April 30, ’89...
Page 710: Duplex Tray 3 (A)
12. DUPLEX TRAY 3 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 4690 Separation Solenoid 0434 0080W Tapping Screw - M4x8 5446 6274 1105 0008 Nylon Clip - 2N Feeler Mounting Bracket 5446 6407 0720 0040E...
Page 711 13. DUPLEX TRAY 4 (A029) April 30, ’89...
Page 712 13. DUPLEX TRAY 4 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 7155 Decal - Misfeed Removal 5B 5219 6115 Spring - Fence Drive Wire 5446 6362 Antistatic Brush - Discharge Roller 5446 6364 Rear Plate - Discharge Roller 5446 6352...
Page 713 14. VERTICAL TRANSPORT 1 (A029) April 30, ’89...
Page 714: Vertical Transport 1 (A)
14. VERTICAL TRANSPORT 1 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5446 2971 Pressure Plate - Vertical Transport 0434 0080W Tapping Screw - M4x8 Spring - Vertical Transport Lever 5446 2972 0720 0080E Retaining Ring - M8...
Page 715 15. VERTICAL TRANSPORT 2 (A029) April 30, ’89...
Page 716: Vertical Transport 2 (A)
15. VERTICAL TRANSPORT 2 (A029) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 0720 0060E Retaining Ring - M6 5446 2761 Front Side Plate - Paper Feed 0805 3291 Ball Bearing - 8x16x5mm 5053 0223 Bushing - 8mm 0434 0080W...
Page 717 April 30, ’89 16. VERTICAL TRANSPORT 3 (A029)
Page 718: Vertical Transport 3 (A)
16. VERTICAL TRANSPORT 3 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5446 2813 Upper Guide Plate - Duplex 0434 0080W Tapping Screw - M4x8 5446 2822 Support Plate - Paper Sensor 1105 0008 Nylon Clip - 2N 5446 5240...
Page 719 17. DEVELOPMENT 1 (A029) April 30, ’89...
Page 720: Development 1 (A)
17. DEVELOPMENT 1 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 7088 Development Unit - 115V 5219 3091 Toner Supply Roller A029 7089 Development Unit - 220V 5446 3135 Cap - F Sensor A029 7084 Decal - Lock/Replace...
Page 721 April 30, ’89 18. DEVELOPMENT 2 (A029)
Page 722: Development 2 (A)
18. DEVELOPMENT 2 (A029) April 30, ’89 Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5446 3219 Insulating Mylar - Power Source 5446 3060 Seal - 2x3x466mm 5219 5480 5219 3062 Lower Casing - Developer Tank Power Pack - Bias 5219 5487 5219 3326...
Page 723 19. DEVELOPMENT 3 (A029) April 30, ’89...
Page 724: Development 3 (A)
19. DEVELOPMENT 3 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5446 3474 Mylar - Receptacle 0434 0080W Tapping Screw - M4x8 5446 3475 0314 0450W Philips Pan Head Screw - M4x45 Developer Receptacle 5446 3390 0951 4008W...
Page 725 20. TRANSFER AND SEPARATION 1 (A029) April 30, ’89...
Page 726: Transfer And Separation 1 (A)
April 30, ’89 20. TRANSFER AND SEPARATION 1 (A029) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly A029 3870 Guide Rail - T&S Charger A029 3950 Front End Block Cover - PTC AX50 0020 PTL Lamp A029 3932 PTC Casing...
Page 727 April 30, ’89 21. TRANSFER AND SEPARATION 2 (A029)
Page 728: Transfer And Separation 2 (A)
21. TRANSFER AND SEPARATION 2 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 3885 Regist Roller Cover A029 3860 Rear Plate - TC/SC Unit A029 2735 Knob - Registration Roller A029 5240 Front Regist Sensor Board...
Page 729 22. DRUM SECTION 1 (A029) April 30, ’89...
Page 730: Drum Section 1 (A)
22. DRUM SECTION 1 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 2175 Charge Corona Guide 5446 1885 Clamp - Toner Shield Glass 5219 2190 Frame - Drum 5446 1881 Toner Shield Glass 5446 1875 Seal - 11x11x528mm...
Page 731 23. DRUM SECTION 2 (A029) April 30, ’89...
Page 732: Drum Section 2 (A)
23. DRUM SECTION 2 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 0434 0080W Tapping Screw - M4x8 5219 2411 Drum Stay 5446 2415 Fixing Knob - Drum Screw 0314 0100W Philips Pan Head Screw - M4x10 5446 2423 0725 0200E...
Page 733 24. CLEANING UNIT (A029) April 30, ’89...
Page 734: Cleaning Unit (A)
24. CLEANING UNIT (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 3551 Cleaning Unit 5894 2275 Cam Spring 5446 3648 5446 3620 Spring - Toner Receiving Stepped Screw - M4 5219 3598 Cleaning Blade Holder 5446 3619...
Page 735 25. FUSING AND INVERTOR 1 (A029) April 30, ’89...
Page 736: Fusing And Lnvertor 1 (A)
25. FUSING AND lNVERTOR 1 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 7165 5446 4346 Oil Pan Fusing & Invertor Unit 5446 4326 Vinyl Tube - M3 5446 4264 Oil Connector Cap 5415 4310 Valve - Oil Pump...
Page 737 26. FUSING AND INVERTOR 2 (A029) April 30, ’89...
Page 738 26. FUSING AND INVERTOR 2 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly AA00 0038 5056 0181 Caution Decal - Hot Surface Stepped Screw - M4 5446 4236 Clamp - Hot Roller Stripper 5446 4190 Clamp - Oil Supply Felt AA00 1120...
Page 739 27. FUSING AND INVERTOR 3 (A029) April 30, ’89...
Page 740 27. FUSING AND INVERTOR 3 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 7137 Decal - Misfeed Removal 3B 5446 4853 Upper Roller - Paper Exit A029 7136 Invertor Unit Cover 5446 4852 Upper Guide - Paper Exit 5446 4830...
Page 741 28. FUSING AND INVERTOR 4 (A029) April 30, ’89...
Page 742 28. FUSING AND INVERTOR 4 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5446 4494 5219 4581 Turn Solenoid Rear Fusing Guide Sprocket - 17T 5446 4491 Fusing Transport Roller - Lower 5219 4573 5446 4393 5446 4458...
Page 743 29. DRIVE SECTION (A029) April 30, ’89...
Page 744 29. DRIVE SECTION (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5446 1101 Upper Cover - Belt Supporter 0951 4008W Philips Screw With Flat Washer - M4x8 0434 0080W 5446 2461 Drum Drive Bracket Tapping Screw - M4x8 5446 1116...
Page 745 30. ELECTRICAL SECTION 1 (A029) April 30, ’89...
Page 746: Electrical Section 1 (A)
30. ELECTRICAL SECTION 1 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 6210 Main Board - 115V 0951 4008W Philips Screw With Flat Washer - M4x8 A029 6220 Main Board - 220/240V 1107 0353 Fuse - 10A 5219 5640...
Page 747 31. ELECTRICAL SECTION 2 (A029) April 30, ’89...
Page 748: Electrical Section 2 (A)
31. ELECTRICAL SECTION 2 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5219 5671 DEV. Trans & Heater Relay Ass’y 5446 1100 Spring - Shielding Cover 5219 1077 Harness Shileding Plate 5219 5937 Bracket - Power Supply Cord - 115V 5219 5672...
Page 749 32. ELECTRICAL SECTION 3 (A029) April 30, ’89...
Page 750: Electrical Section 3 (A)
32. ELECTRICAL SECTION 3 (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5446 9550 Scanner Motor Control Board 5936 5314 Power Supply Harness 5219 1887 Pad - 4x6x166mm 5936 5312 Motor Harness 5219 1885 Right Shielding...
Page 751 33. OPERATION PANEL (A029) April 30, ’89...
Page 752 33. OPERATION PANEL (A029) April 30, ’89 Index Index Q’ty Per Part No. Part No. Description Description Assembly A029 6050 Operation Panel - LT A029 6060 Operation Panel - A4 A029 6055 LCD Board - 1 - LT A029 6063 LCD Board - 1 - A4 A029 5860 Operation Control Board...
Page 753 April 30, ’89 34. FEED–IN UNIT 1–DF (A029)
Page 754 34. FEED–IN UNIT 1–DF (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 7875 Top Copver - Separation Unit 5936 1159 Front Side Spring Holder 5936 1162 Relay Roller Spring 5886 1312 Frame Stopper Pin 5886 1315...
Page 755 35. FEED–IN UNIT 2–DF (A029) April 30, ’89...
Page 756: Feed–In Unit 2–Df (A)
35. FEED–IN UNIT 2–DF (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 7835 5936 1152 Shaft - Lower Pull-out Roller Left Cover - Separation Unit A029 6816 5936 9101 Separation Roller - 4pcs/set Original Size Sensor Board - LT A029 6817...
Page 757 36. TRANSPORT SECTION 1–DF (A029) April 30, ’89...
Page 758: Transport Section 1–Df (A)
36. TRANSPORT SECTION 1–DF (A029) April 30, ’89 Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5936 2240 Belt Stopper 5936 5501 Transport Drive Motor - DC 21W 5936 2470 Spring - Lift 5936 2309 Motor Bracket 5936 2438 Bushing - Press Roller...
Page 759 April 30, ’89 37. TRANSPORT SECTION 2–DF (A029)
Page 760 37. TRANSPORT SECTION 2–DF (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A029 6551 Original Invertor Cover 5886 2053 Transport Arm 5216 4198 Stepped Screw - Guide Plate 5886 2159 Side Frame 5936 2740 Wire - Invertor Cover...
Page 761 April 30, ’89 38. INVERTOR SECTION–DF (A029)
Page 762 38. INVERTOR SECTION–DF (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5866 1862 Antistatic Brush 5936 2532 Pulley - 16T 5936 2281 Exit Roller Guide 5936 2544 Pulley - 35T 5936 2255 Front Bracket - Antistatic Brush 5936 2545...
Page 764 39. MAIN BOARD (A029) April 30, ’89 Index Index Q’ty Per Part No. Description Part No. Description Assembly Connector - 26P A029 6220 Main Board - 220/240V 1103 0857 1103 1592 Connector - 36P A029 6210 Main Board - 115V Connector - 2P A029 6211 IC - HN27256G-25...
Page 766 40. DC DRIVE BOARD (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 1103 0621 Connector - 40P A029 5227 DC Drive Board 1103 0633 Connector - 6P 1103 0635 Connector - 10P 1103 1592 Connector - 36P 1400 0234...
Page 768: Scanner Motor Control Board (A)
April 30, ’89 41. SCANNER MOTOR CONTROL BOARD (A029) Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 1102 0903 Terminal - 4P 5446 9550 Scanner Motor Control Board Terminal - 5P 1102 0905 1102 0958 Connector - 2P 1102 0959 Terminal - 3P...
Page 770: Main Motor Control Pcb (A)
April 30, ’89 42. MAIN MOTOR CONTROL PCB (A029) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 1401 0612 Diode - 1S1585 5219 5634 Main Motor Control P.C.B. 1402 0110 Diode - 1.1A 200V 1402 0407 Zener Diode - HZ-6B3 1403 0069...
Page 771 April 30, ’89 43. AC DRIVE UNIT (A029)
Page 772: Ac Drive Unit (A)
43. AC DRIVE UNIT (A029) April 30, ’89 Index Index Q’ty Per Part No. Description Part No. Description Assembly 1102 1103 Pin Terminal - 11P 5446 5460 AC Drive Unit 1103 0604 Connector - 11P 1208 1028 Solid State Relay - G3L-102PL 1600 0563 Resistor - 7.5OHM 2T ±5%...
Page 773 44. LENS / MIRROR MOTOR PCB (A029) April 30, ’89...
Page 774 44. LENS / MIRROR MOTOR PCB (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5219 5323 Driver - Lens Drive 1103 1772 Pin Header - 6P 5219 5320 Lens/Mirror Motor P.C.B. 1103 1773 Pin Header - 7P 1401 0815...
Page 776: Operation Control Board (A)
45. OPERATION CONTROL BOARD (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 5860 Operation Control Board 1407 0710 IC - SN74LS107N 1407 0814 IC - SN74LS139N 1407 0838 IC - SN74LS266N 1407 0972 IC - HD74LS42P 1407 0974...
Page 778: Key Board (A)
46. KEY BOARD (A029) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 1204 1190 Key Board Switch A029 6053 Key Board 1204 1347 Push Switch 1401 0611 Diode - 1S1588 1403 0240 Packed LED 1611 4102 Resistor - 1KOHM 1/4T ±5% 1611 4111...
Page 779 47. ROM BOARD (A029) April 30, ’89...
Page 780: Rom Board (A)
47. ROM BOARD (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 6140 IC - HN27256G-25 - LT English A029 6148 IC - HN27256G-25 - LT English A472 6110 IC - HN27256G-25 - A4 English A472 6118 IC - HN27256G-25 - A4 English A472 6130...
Page 782: Df Main Board (A)
48. DF MAIN BOARD (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 0313 0060W Philips Pan Head Screw - M3x6 A029 6811 DF Main Board 1101 0328 Connector Pin Contact A029 6821 IC - MBM7C128-30 1102 0919...
Page 783 49. ORIGINAL SIZE SENSOR BOARD (A029) April 30, ’89...
Page 784: Original Size Sensor Board (A)
49. ORIGINAL SIZE SENSOR BOARD (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5886 5510 Photo Sensor 1103 1551 Connector - 8P A029 6816 Original Size Sensor Board - LT 1611 6681 Resistor - 680OHM 1/2W +5% A029 6817...
Page 785 50. HARNESS LAYOUT – FRONT VIEW (A029) April 30, ’89...
Page 786 50. HARNESS LAYOUT – FRONT VIEW (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A029 6310 DC Main Harness 5219 5658 AC Main Harness 5219 5681 Monitor Harness 5446 5165 Paper Feed Harness 5219 5514 Tray Harness - 115V...
Page 787 51. DC MAIN HARNESS (A029) April 30, ’89...
Page 788: Dc Main Harness (A)
April 30, ’89 51. DC MAIN HARNESS (A029) Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 1102 1323 Connector - 30P A029 6310 DC Main Harness 1100 0270 Fastening Receptacle 5442 5822 Connector Holder - Eraser Fastening Receptacle 1100 0290...
Page 789 52. AC MAIN HARNESS (A029) April 30, ’89...
Page 790 April 30, ’89 52. AC MAIN HARNESS (A029) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 1100 0275 Fastening Receptacle 5219 5658 AC Main Harness 1100 0284 Fastening Receptacle 5446 5834 Connector Holder - CFL Socket - Mate-N-Lock 1100 0882 Pin - Mate-N-Lock...
Page 791 53. MONITOR HARNESS (A029) April 30, ’89...
Page 792: Monitor Harness (A)
53. MONITOR HARNESS (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5219 5681 Monitor Harness 1100 1159 Socket - Mate-N-Lock 1100 1169 Fastening Receptacle 1100 1238 Pin - Mate-N-Lock 1100 1239 Pin - Mate-N-Lock 1100 1240 Socket - Mate-N-Lock...
Page 793 April 30, ’89 54. PAPER FEED HARNESS (A029)
Page 794: Paper Feed Harness (A)
54. PAPER FEED HARNESS (A029) Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5446 5165 Paper Feed Harness 1100 1159 Socket - Mate-N-Lock 1100 1238 Pin - Mate-N-Lock 1102 1306 Connector - 3P 1102 1307 Connector - 4P 1102 1308 Connector - 6P...
Page 795 55. TRAY HARNESS (A029) April 30, ’89...
Page 796: Tray Harness (A)
April 30, ’89 55. TRAY HARNESS (A029) Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 11OO 1204 Socket - Mate-N-Lock 5219 5514 Tray Harness - 115V Socket - Mate-N-Lock Tray Harness - 220/240V 1100 1259 Socket - Mate-N-Lock 1100 1264 Fastening Receptacle...
Page 797 56. DUPLEX UNIT HARNESS (A029) April 30, ’89 C N 4 3 4 C N 4 3 2 I l l...
Page 798: Duplex Unit Harness (A)
April 30, ’89 56. DUPLEX UNIT HARNESS (A029) Index Q’ty Per lndex Q’ty Per Part No. Description Part No. Description Assembly Assembly 1100 0270 Fastening Receptacle A029 5526 Duplex Unit Harness 1100 1159 Socket - Mate-N-Lock 1100 1259 Socket - Mate-N-Lock 1100 1264 Fastening Receptacle...
Page 799 57. TRANSFER AND SEPARATION HARNESS (A029) April 30, ’89...
Page 800: Transfer And Separation Harness (A)
57. TRANSFER AND SEPARATION HARNESS (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A029 5488 Transfer & Separation Harness Socket - Mate-N-Lock 1100 1042 Socket - Mate-N-Lock 1100 1159 1100 1240 Socket - Mate-N-Lock 1100 1266 Socket - Mate-N-Lock...
Page 801 58. FUSING UNIT HARNESS (A029) April 30, ’89...
Page 802: Fusing Unit Harness (A)
58. FUSING UNIT HARNESS (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A029 6301 Fusing Unit Harness 1100 0916 Pin - Mate-N-Lock 1100 1155 Contact 1100 1172 Fastening Receptacle 1100 1240 Socket - Mate-N-Lock 1100 1264 Fastening...
Page 803 April 30, ’89 59. INVERTOR AND FUSING LAMP HARNESS (A029)
Page 804 April 30, ’89 59. INVERTOR AND FUSING LAMP HARNESS (A029) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly Contact 1100 1155 A029 5456 Invertor Harness Socket - Mate-N-Lock 1100 1159 A029 5450 Fusing Lamp Harness Fastening Receptacle 1100 1169...
Page 805 60. OIL END SENSOR AND THERMOFUSE HARNESSES (A029) April 30, ’89...
Page 806 60. OIL END SENSOR AND THERMOFUSE HARNESSES (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5219 5468 1100 1238 Pin - Mate-N-Lock Oil End Sensor Harness 5219 5447 Thermofuse Harness 1100 1259 Socket - Mate-N-Lock 1102 1089...
Page 807 61. HARNESS LAYOUT – REAR VIEW (A029) April 30, ’89...
Page 808 61. HARNESS LAYOUT – REAR VIEW (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5219 5653 DC Main Harness 5219 5658 AC Main Harness 5219 5487 Development Unit Harness 5219 5603 AC Power Relay Harness - 115V 5219 5604 AC Power Relay Harness - 220/240V...
Page 809 62. DEVELOPMENT UNIT AND DC POWER RELAY HARNESSES (A029) April 30, ’89...
Page 810 62. DEVELOPMENT UNIT AND DC POWER RELAY HARNESSES (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5219 5487 Development Unit Harness 1100 1159 Socket - Mate-N-Lock 5219 5605 DC Power Relay Harness Socket - Mate-N-Lock 1100 1166 1100 1240...
Page 811 63. AC POWER RELAY HARNESS (A029) April 30, ’89...
Page 812: Ac Power Relay Harness (A)
63. AC POWER RELAY HARNESS (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5219 5603 AC Power Relay Harness - 115V 1100 0276 Fastening Receptacle 5219 5604 AC Power Relay Harness - 220/240V 1100 0916 Pin - Mate-N-Lock 1100 1042...
Page 813 64. UPPER LIMIT SENSOR, DEVELOPMENT AND OPERATION HARNESSES (A029) April 30, ’89...
Page 814 64. UPPER LIMIT SENSOR, DEVELOPMENT AND OPERATION HARNESSES (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5446 5196 Development Harness 1100 1190 Socket - Mate-N-Lock 5219 5661 Operation Harness 1100 1204 Socket - Mate-N-Lock 5219 5510 Upper Limit Sensor Harness...
Page 815 65. DC POWER RELAY HARNESS-220/240V (A029) April 30, ’89...
Page 816 65. DC POWER RELAY HARNESS–220/240V (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A029 6315 DC Power Relay Harness - 220/240V 1100 0300 Solid Strand 1100 1155 Contact 1100 1238 Pin - Mate-N-Lock 1100 1239 Pin - Mate-N-Lock...
Page 817 66. HARNESS LAYOUT–DF (A029) April 30, ’89...
Page 818: Harness Layout–Df (A)
66. HARNESS LAYOUT–DF (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A029 6827 Separation Harness 5936 5312 Motor Harness 5936 5313 Transport Unit Harness 5936 5314 Power Supply Harness 5936 5315 Invertor Entrance Relay Harness 5936 5327 Invertor Registration Harness...
Page 819 67. MOTOR HARNESS (A029) April 30, ’89...
Page 820: Motor Harness (A)
67. MOTOR HARNESS (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5936 5312 1100 1147 Socket - Mate-N-Lock Motor Harness 1100 1191 Terminal Socket - Mate-N-Lock 1100 1240 1102 1295 Connector - 12P 1102 1354 Connector - 6P...
Page 821 68. SEPARATION HARNESS (A029) April 30, ’89...
Page 822: Separation Harness (A)
68. SEPARATION HARNESS (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 1100 0086 Solid Strand A029 6827 Separation Harness 1100 1182 Socket - Mate-N-Lock 1100 1259 Socket - Mate-N-Lock 1100 1264 Fastening Receptacle 1100 1274...
Page 823 69. SEPARATION RELAY HARNESS (A029) April 30, ’89...
Page 824 69. SEPARATION RELAY HARNESS (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5936 5317 Separation Realy Harness 1100 0277 Fastening Receptacle 1100 1253 Pin - Mate-N-Lock 1100 1259 Socket - Mate-N-Lock 1102 0796 Insulating Sleeve 1102 1089...
Page 825 70. TRANSPORT HARNESS (A029) April 30, ’89...
Page 826 April 30, ’89 70. TRANSPORT HARNESS (A029) Q’ty Per Index Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 1100 0051 Connector 5936 5313 Transport Unit Harness 1100 1238 Pin - Mate-N-Lock Socket - Mate-N-Lock 1100 1240 Pin - Mate-N-Lock 1100 1253 1100 1259 Socket - Mate-N-Lock...
Page 827 71. INVERTOR REGISTRATION, INVERTOR ENTRANCE April 30, ’89 AND POWER SUPPLY HARNESSES (A029)
Page 828: And Power Supply Harnesses (A)
71. INVERTOR REGISTRATION, INVERTOR ENTRANCE AND POWER SUPPLY HARNESSES (A029) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5936 5327 Invertor Registration Harness 1100 1253 Pin - Mate-N-Lock 5936 5315 Invertor Entrance Relay Harness 1100 1259 Socket - Mate-N-Lock 5936 5314...
Page 829 72. SPECIAL TOOL (A029) April 30, ’89...
Page 830 72. SPECIAL TOOL (A029) April 30, ’89 Q’ty Per Index Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 5446 9116 Scanner Drive Pulley Pin 5446 9117 Stopper Pin 5446 9118 Cam Positioning Pin 5446 9119 Scanner Drive Pulley Clamp 5446 9122 Wire Clamp 5446 9140...
Page 832 73. DECAL AND DOCUMENT (A029) April 30, ’89...
Page 834 73. DECAL AND DOCUMENT (A029) April 30, ’89...
Page 835 73. DECAL AND DOCUMENT (A029) April 30, ’89...
Page 836 73. DECAL AND DOCUMENT (A029) April 30, ’89 Index Part No. Index Q’ty Per Q’ty Per Description Part No. Description Assembly Assembly A029 7902 Decal - CFF Original Size A029 8606 Operation Instruction - French (CAN) 5936 7901 Decal - English A029 8610 Installation Procedure - English AA00 1125...
Page 837 PARTS INDEX...
Page 838 April 30, ’89 Page and Page and Parts No. Description Description Parts No. Index No. Index No. A029 1671 A029 1071 Bracket - Menu Reader Harness 71-42 Main Table 11-2 A029 1682 Reflector A029 1076 Harness Bracket 71-40 11-74 71-25 A029 1831 Right Shielding Plate - Lens A029 1081...
Page 839 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. A029 3995 49-21 Front Guide - T&S Charger A029 2778 Rear Side Plate - Paper Feed 39-10 A029 3996 Rear Guide - T&S Charger 49-22 A029 2778 Rear Side Plate - Paper Feed...
Page 840 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. DC Drive Board 69-21 A029 5227 A029 6145 IC-HN27256G-25 - LT English 103-6 A029 5227 DC Drive Board 89-* A029 6146 IC-HN27256G-25 - LT English 103-7 A029 5240 Front Regist Sensor Board...
Page 841 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. A029 7058 Paper Tray - LT 23-31 A029 6662 Feed-in Table - A4 79-32 A029 7059 Paper Tray - A4 21-31 A029 6674 Side Guide 77-14 A029 7059...
Page 842 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. A029 7155 Decal - Misfeed Removal 5B A029 7895 Original Stopper Shaft 77-56 35-1 A029 7158 Inner Cover - Duplex Tray A029 7896 Magnet - CFF 77-57 29-19...
Page 843 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. AA00 0026 Decal - Large - 4 Languages 159-41 AA14 0196 Guide - Knoking Roller Shaft 63-70 AA00 0038 Caution Decal - Hot Surface AA14 0250 Shaft - Upper Separation Roller 159-25...
Page 844 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. AD02 2145 A472 6132 IC-HN27256G-25 - German Front End Block - PQC 103-3 53-69 A472 6133 IC-HN27256G-25 - German AD02 2146 Rear End Block - PQC 103-4 53-68 A472 6134...
Page 845 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5053 0223 Bushing - 8mm 5219 1084 Right Shielding Plate 47-11 33-13 5053 0223 5219 1084 Bushing - 8mm Right Shielding Plate 59-50 35-59 5053 0223 5219 1091...
Page 846 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5219 1703 5219 1856 Pressure Pulley Lever Sensor Head Clamp 15-46 19-15 5219 1858 5219 1704 Front Clamp - Auto ID Cable Front Spring - Wire Pressure 19-10 15-47 5219 1705...
Page 847 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5219 2411 Drum Stay Guide Plate - Vertical Transport 37-7 55-1 5219 2961 5219 2418 Separation Pawl Stopper 47-26 55-20 5219 2971 Mylar Seal - 0.1x25x442mm 5219 2460 Rear Side Plate 47-17...
Page 848 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5219 3565 Front Side Seal - Cleaning Unit 5219 3717 Seal - Toner Shielding 57-73 57-67 5219 3569 5219 3721 Spring - Toner Recovery Seal - 9x9x10mm 57-53 57-63...
Page 849 April 30, ’89 Page and Page and Description Parts No. Description Parts No. Index No. Index No. 5219 4748 Right Invertor Guide 59-66 5219 4272 Clamp - Oil Tube 63-23 5219 4765 Boss - Invertor 159-26 Roller 5219 4274 Decal 63-48 5219 4771 Front Left Arm - Invertor Roller...
Page 850 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5219 5475 Fusing Thermistor 5219 5605 DC Power Relay Harness 133-2 61-28 5219 5480 Power Pack - Bias 5219 5605 DC Power Relay Harness 71-16 45-3 5219 5487...
Page 851 April 30, ’89 Page and Page and Parts No. Description Description Parts No. Index No. Index No. 5219 5917 Side Cover - Vertical Transport 69-14 5219 6117 Hook - Fence Drive Wire 35-70 5219 5924 Jam Indicator Bracket 69-11 5219 6129 Front Side Plate - Duplex Tray 29-21 5219 5926...
Page 852 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5219 6408 5401 3731 Stepped Screw - M4 Lift Shaft - Paper Holding Bar 11-12 31-3 5219 6409 5401 3731 Stepped Screw - M4 Shaft Paper Holding Bar 71-21 31-9...
Page 853 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5413 1882 Stepped Screw 5424 4123 Spring - Solenoid 63-46 69-23 5413 2298 Stepped Screw - M4 5424 4307 Cam - Oil Pump 59-9 77-48 5413 2298...
Page 854 April 30, ’89 Page and Page and Parts No. Parts No. Description Description Index No. Index No. 5446 1087 5446 1453 Seal - 5x12x353mm Gas Spring - 15KG 11-73 13-18 5446 1466 5446 1088 Right Door Stopper Gas Spring Supporter 11-8 13-4 5446 1665...
Page 855 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5446 1808 Lens Wire Clamp 5446 2224 Corona Wire Hook 53-12 17-3 5446 1814 5446 2232 Pressure Roller Lever Thermistor Holder 53-15 17-24 5446 1816 Pressure Lever Shaft 5446 2242...
Page 856 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5446 2605 Base - Paper Tray 5446 2671 Drive Pulley - Paper Tray 23-18 23-51 5446 2675 5446 2620 Idler Pulley - 20 Paper Tray Shaft 21-37 21-19...
Page 857 April 30, ’89 Page and Page and Description Parts No. Parts No. Description Index No. Index No. 5446 2729 5446 2862 Gear - 36T 27-8 Gear - 50T 21-4 5446 2863 Screw - Separation Roller 5446 2729 Gear - 50T 27-9 23-4 5446 2741...
Page 858 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5446 3055 5446 3265 Spring Plate - Hopper A Gear - 40T 45-10 43-27 5446 3056 5446 3281 Gear - 31T Clamp Plate - Spring Plate 45-31 43-26 5446 3057...
Page 859 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5446 3584 Rear Seal - Drum Guide 5446 3853 Toner Catch Mylar 57-31 53-79 5446 3866 5446 3592 Seal - 1x9x9mm 57-10 T&S Connector Bracket 51-36 5446 3878 Registation...
Page 860 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5446 4138 Clamp - Left Heat Shield 5446 4346 Oil Pan 61-19 59-35 5446 4146 Oil Sump 5446 4354 Large Cushion - Oil Pan 21-67 61-14 5446 4156...
Page 861 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5446 4561 5446 4843 Invertor Harness Guide Gear & Sprocket - 14T/16T 63-53 65-33 5446 4567 5446 4852 Upper Guide - Paper Exit Sprocket - 22T 63-40 65-34...
Page 862 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5446 5458 Anticondensation Thermostat 5446 6188 Pulley - Drive Roller 31-30 19-52 5446 5460 AC Drive Unit 5446 6189 Gear - 22T 31-26 25-18 5446 5460 AC Drive Unit...
Page 863 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5446 6352 5446 9118 Front Side Plate - Entrance Guide Cam Positioning Pin 153-3 35-3 5446 6355 Rear Side Plate - Entrance Guide 5446 9119 Scanner Drive Pulley Clamp 153-4...
Page 864 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5886 1192 Mylar - Spring Plate 5886 2333 Seal - 5x15x24mm 77-11 81-17 5886 1197 Pad - 0.5x34x62mm 5886 3114 Roller Cover 77-16 83-22 5886 1306 Blade Pressure Pin...
Page 865 April 30, ’89 Page and Page and Parts No. Description Description Parts No. Index No. Index No. 5936 1210 Separation Blade Frame 77-34 Rear Frame - Transport Unit 85-41 5936 2202 5936 1216 Mylar - Entrance Guide 77-8 5936 2205 Left Side Shield - Transport 85-14 5936 1217...
Page 866 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5936 2460 5936 2308 Transmission Bracket - Belt Drive Original Feed Belt 81-33 81-28 5936 2309 5936 2470 Spring - Lift Motor Bracket 81-40 81-2 5936 2480...
Page 867 April 30, ’89 Page and Page and Parts No. Description Description Parts No. Index No. Index No. 5936 2602 Base Plate - Original Invertor 5936 5313 Transport Unit Harness 141-3 85-72 5936 2605 Invertor Exit Roller 85-71 5936 5313 Transport Unit Harness 149-1 5936 2611 Original Invertor Gate...
Page 868 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 0312 5040W Philips Pan Head Screw - M2.5x4 53-115 0313 0100W Philips Pan Head Screw - M3x10 45-103 0313 0040W Philips Pan Head Screw - M3x4 77-101 0313 0100W Philips Pan Head Screw - M3x10...
Page 869 April 30, ’89 Page and Page and Description Parts No. Description Parts No. Index No. Index No. 0314 0100W Philips Pan Head Screw - M4x10 31-110 0314 0060W Philips Pan Head Screw - M4x6 49-101 0314 0100W Philips Pan Head Screw - M4x10 35-105 0314 0060W Philips Pan Head Screw - M4x6...
Page 870 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 0323 0060W Philips Sunken Head Screw - M3x6 0353 0060F Philips Truss Head Screw - M3x6 81-107 79-131 0323 0060W Philips Sunken Head Screw - M3x6 0353 0060F Philips Truss Head Screw - M3x6 81-115...
Page 871 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 0632 0080 Parallel Pin - M2x8 85-130 0434 0080W Tapping Screw - M4x8 71-109 0632 0100 Parallel Pin - M2x10 79-125 0434 0080W Tapping Screw - M4x8 71-116 0632 0100...
Page 872 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 0720 0040E Retaining Ring - M4 0720 0030E Retaining Ring - M3 79-110 57-108 0720 0040E Retaining Ring - M4 0720 0030E Retaining Ring - M3 81-110 59-110 0720 0040E...
Page 873 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 0801 1239 Screw - Inner Cover 0720 0060E Retaining Ring - M6 29-105 79-112 0801 1239 Screw - Inner Cover 0720 0060E Retaining Ring - M6 43-101 81-112 0801 1239...
Page 874 April 30, ’89 Page and Page and Parts No. Parts No. Description Description Index No. Index No. 0951 3006W Philips Screw With Flat Washer - M3x6 57-106 0805 3307 Ball Bearing - 8x14x4mm 47-112 0951 3006W Philips Screw With Flat Washer - M3x6 0805 3370 65-104 Ball Bearing - 6x19x6mm...
Page 875 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 0951 4008W Philips Screw With Flat Washer - M4x8 111-102 73-111 1100 0270 Fastening Receptacle 0951 4008W Philips Screw With Flat Washer - M4x8 1100 0270 Fastening Receptacle...
Page 876 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1100 1238 Pin - Mate-N-Lock 1100 1159 Socket - Mate-N-Lock 123-103 149-102 1100 1239 Pin - Mate-N-Lock 1100 1159 Socket - Mate-N-Lock 111-112 127-103 1100 1239 Pin - Mate-N-Lock...
Page 877 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1100 1259 Socket - Mate-N-Lock 151-102 1101 0328 Connector Pin Contact 99-102 1101 0424 Terminal Plate - 4P 87-102 1100 1264 Fastening Receptacle 111-117 1100 1264 Fastening...
Page 878 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1102 1330 Connector - 3P 129-103 Connector - 2P 1102 1089 133-107 1102 1350 Connector - 5239-1P 1102 1089 Connector - 3P 137-115 111-137 1102 1351 Connector - 3P...
Page 879 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1102 1508 Connector - 3P 1102 1520 Connector - 12P 125-113 113-133 1102 1509 Connector - 4P 1102 1520 Connector - 12P 123-113 111-147 1102 1509 Connector - 4P...
Page 880 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1102 1732 1103 0635 Connector - 10P Connector - 34P 111-173 87-108 1102 1732 Connector - 34P 1103 0635 Connector - 10P 89-103 137-112 1103 0659 1102 1733...
Page 881 April 30, ’89 Page and Page and Description Parts No. Description Parts No. Index No. Index No. 1105 0005 Nylon Clip - 3N Cable Clip - 7mm 41-104 63-107 1105 0090 1105 0005 Nylon Clip - 3N 59-124 1105 0090 Cable Clip - 7mm 67-103 1105 0008...
Page 882 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1208 1111 Power Relay - AC 100V 1106 0442 Cord Stopper - 220/240V 71-118 71-115 1400 0072 Transistor - 2SC372Y 1106 0457 Cord Stopper - 115V 71-115 87-116 1400 0082...
Page 883 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1407 0639 IC - TC4009UBP 1401 0728 Zener Diode - Z1047 133-111 87-132 1407 0639 IC - TC4009UBP 1401 0728 Varistor - Z1047 139-111 91-122 1407 0640...
Page 884 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1408 0413 IC - TL092CP 1407 1332 IC - HD74LS11 87-145 87-153 1408 0459 IC - HA17393 1407 1333 IC - HD74LS245P 87-146 87-154 1408 0459 IC - HA17393...
Page 885 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1604 1366 Capacitor - 47µF ±20% 25V 1601 7374 Resistor Array - 4.7KOHM 87-165 99-138 1604 1378 Capacitor - 1MF 50V 1601 7374 Resistor Array - 4.7KOHM 87-178 99-135...
Page 886 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1611 4111 Resistor - 1OHM 1/4 1606 1330 Capacitor - 470PF 50V 87-184 101-106 1611 4124 Resistor - 120KOHM 1/4T ±5% 1606 1336 Capacitor - 10000PF 50V 87-185 91-155...
Page 887 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 91-175 1611 4333 1611 6271 Resistor - 270OHM 1/2T ±5% Resistor - 33KOHM 1/4T ±5% 99-147 1611 4334 1611 6561 Resistor - 560OHM 1/2W 89-133 Resistor - 330KOHM 1/4T ±5% 91-162...
Page 888 MR20 (A952)
Page 889 MR20 (A952) 1. Menu Reader (A952) ..... . 2 2. Decal and Document (A952) ....4 Parts Index .
Page 890 April 30, ’89 1. MENU READER (A952)
Page 891 1. MENU READER (A952) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A952 1001 Upper Cover - LT 0312 5060M Philips Pan Head Screw - M2.5x6 A952 1004 Upper Cover - A4 0704 0025J Toothed Washer - M2.5 A952 1003...
Page 892 2. DECAL AND DOCUMENT (A952) April 30, ’89...
Page 893 2. DECAL AND DOCUMENT (A952) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A952 8610 Installation Procedure - Engish A952 8615 Installation Procedure - Multi A952 1003 Indicator Decal - English A952 2001 Indicator Decal - Multi...
Page 894 PARTS INDEX...
Page 895 April 30, ’89 Page and Page and Parts No. Description Description Parts No. Index No. Index No. 0312 5060M Philips Pan Head Screw - M2.5x6 A952 1001 Upper Cover - LT 3-101 0704 0025J Toothed Washer - M2.5 3-102 A952 1003 Indicator Decal - English 0708 0025B Flat Washer - M2.5...
Page 896 (A463)
Page 897 RT25 (A463) Location of Unit ......3 1. Paper Conveyor Unit (A463) ....4 2.
Page 898 LOCATION OF UNIT April 30, ’89 PAPER CONVEYOR UNIT PAPER FEED UNIT EXTERIOR 1 See page 4 See page 6 See page 8 EXTERIOR 2 See page 10...
Page 899 1. PAPER CONVEYOR UNIT (A463) April 30, ’89...
Page 900 PAPER CONVEYOR UNIT (A463) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly Retaining Ring - M6 5938 2618 Stud - Lateral Transport Drive 0720 0060E 5938 2622 Gear - 36T 0742 3808 Ball Bearing - 8x16mm Retaining Ring - M6 5938 2625...
Page 901 2. PAPER FEED UNIT (A463) April 30, ’89...
Page 902 2. PAPER FEED UNIT (A463) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5938 2894 Transport Driven Roller 5938 2843 Paper Feed Frame 5866 1677 Belt Roller Gear - 17T 5938 2856 Transport Drive Roller 5938 2895 Guide Plate - Open Section...
Page 903 April 30, ’89 3. EXTERIOR 1 (A463)
Page 904 3. EXTERIOR 1 (A463) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5938 2822 Bracket - Lower Limit Sensor A463 2723 Front Cover - Large Capacity Tray A463 7004 Decal - Loading Paper A463 2732 Shutter 5938 2773...
Page 905 4. EXTERIOR 2 (A463) April 30, ’89...
Page 906 4. EXTERIOR 2 (A463) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 0720 0040E 5938 2751 Detent Bracket Retaining Ring - M4 5446 2566 Detent Arm 0314 0060W Philips Pan Head Screw - M4x6 0805 5003 Caster 5938 2757...
Page 907 5. HARNESS LAYOUT (A463) April 30, ’89...
Page 908 5. HARNESS LAYOUT (A463) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5938 5016 Option Tray Harness 5938 5008 Drawer Harness 5938 5009 Join Harness...
Page 909 6. OPTION TRAY HARNESSES (A463) April 30, ’89...
Page 910 6. OPTION TRAY HARNESSES (A463) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5938 5016 Option Tray Harness 1100 0082 Solid Strand 1100 1159 Socket - Mate-N-Lock 1100 1169 Fastening Receptacle 1100 1172 Fastening Receptacle...
Page 911 7. DRAWER AND JOIN HARNESSES (A463) April 30, ’89...
Page 912 7. DRAWER AND JOIN HARNESSES (A463) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 5938 5008 Drawer Harness 1100 0082 Solid Strand 5938 5009 Join Harness 1100 1089 Socket - Mate-N-Lock 1100 1204 Socket - Mate-N-Lock 1100 1241...
Page 913 8. DECAL AND DOCUMENT (A463) April 30, ’89...
Page 914 April 30, ’89 8. DECAL AND DOCUMENT (A463) Index Q’ty Per Index Q’ty Per Description Part No. Part No. Description Assembly Assembly A463 7004 Decal - Loading Paper A463 7012 Decal - Misfeed Removal 6-1 A463 7031 Decal - Paper Size - LT A463 7032 Decal - Paper Size - A4 A463 7035...
Page 915 PARTS INDEX...
Page 916 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. AB01 3032 Gear - 45T A463 2560 9-107 Paper Conveyer Unit 5-31 AG07 0004 Magnet Catch Ass’y A463 2716 11-25 Left Cover - Large Capacity Tray 11-13 A029 4677 Release Lever...
Page 917 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5446 2713 Gear - 16T/30T 5938 2599 Pressure Plate - Transport Roller 9-28 5-29 5446 2714 Gear - 16T/44T 5938 2600 Paper Conveyer Drive Unit 9-29 5-32 5446 2715...
Page 918 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5938 2889 5938 2806 Worm Gear Shaft Front Lock Lever 7-52 9-22 5938 2807 5938 2890 Rear Lock Lever Worm Gear 7-53 9-19 5938 2892 5938 2808 Pulley - 24T...
Page 919 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 0313 0050W Philips Pan Head Screw - M3x5 0805 3270 Ball Bearing - 8x16x5mm 7-105 11-116 0313 0050W 0805 5003 Philips Pan Head Screw - M3x5 Caster 11-103 9-123...
Page 920 April 30, ’89 Page and Page and Description Description Parts No. Parts No. Index No. Index No. 1102 1513 Connector - 15P 15-115 1102 1515 Connector - 2P 17-108 1102 1516 Connector - 3P 17-109 1102 1632 Connector - 4P 17-110 1102 1724 Connector - 24P...
Page 921 (5946)
Page 922 SORTER CONNECTOR UNIT (5946) Location of Unit ......3 1. Transport Section (5946) ....4 2.
Page 923 April 30, ’89 LOCATION OF UNIT VERTICAL TRANSPORT SECTION TRANSPORT SECTION See page 6 See page 4...
Page 924 April 30, ’89 1. TRANSPORT SECTION (5946)
Page 925 1. TRANSPORT SECTION (5946) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5887 4130 Vertical Drive Roller - A 5946 2489 Partition Plate - 62x210mm 5887 4131 Vertical Drive Roller - B 5946 2453 Mylar Seak - 0.125x54x55mm 5887 4132...
Page 926 2. VERTICAL TRANSPORT SECTION (5946) April 30, ’89...
Page 927 2. VERTICAL TRANSPORT SECTION (5946) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5946 4461 Rear Upper Cover - Vertical 5946 3651 Angle - Vertical Front Cover 5946 3655 Angle - Vertical Rear Cover 5946 4431 Front Bottom Cover - Vertical 5946 4451...
Page 928 3. MAIN BOARD – 2ND SORTER (5946) April 30, ’89...
Page 929 April 30, ’89 3. MAIN BOARD – 2ND SORTER (5946) Q’ty Per Index Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 5937 5604 IC - SI-3242P Connector - 8P 1102 0911 5946 5601 Main Board - 2nd Sorter 1102 0995 Connector - 2P 1102 1039...
Page 930 4. SAFETY SWITCH AND MOTOR HARNESSES (5946) April 30, ’89...
Page 931 4. SAFETY SWITCH AND MOTOR HARNESSES (5946) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5946 5200 Safety Switch Harness 1100 1159 Socket - Mate-N-Lock 5946 5220 Motor Harness 1100 1169 Fastening Receptacle 1100 1238...
Page 932 5. SORTER CONTROL AND FRONT DOOR SWITCH HARNESSES (5946) April 30, ’89...
Page 933 5. SORTER CONTROL AND FRONT DOOR SWITCH HARNESSES (5946) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5946 1152 Harness Fixing Plate 1100 1159 Socket - Mate-N-Lock 5946 5210 Sorter Control Harness 1100 1169 Fastening Receptacle...
Page 934 6. DECAL AND DUCUMENT (5946) April 30, ’89...
Page 935 6. DECAL AND DOCUMENT (5946) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly 5946 6211 Decal - English 5946 6221 Decal - English 5403 4335 Decal - Terminal - 115V 5447 4980 Decal - Terminal - 220/240V 5946 6225 Decal - Multilanguage...
Page 936 PARTS INDEX...
Page 937 April 30, ’89 Page and Page and Description Parts No. Description Parts No. Index No. Index No. 5946 1101 Bottom Plate 5946 3331 Drive Motor Stay 7-28 5-50 5946 1111 Base Fixing Bracket 5946 3351 Tightener Bracket 7-41 5-60 5946 1141 Front Positioning Angle 5946 3355 Washer - Tightener...
Page 938 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 5054 0536 5946 4471 Front Shielding Plate 7-40 Magnet Catch Ass’y 7-14 5056 0509 Nut Plate - Microswitch 5946 4481 7-37 Shielding Plate 5-10 5403 2075 Stepped Screw...
Page 939 April 30, ’89 Page and Page and Parts No. Description Description Parts No. Index No. Index No. 0313 0060W Philips Pan Head Screw - M3x6 5937 5604 IC - SI-3242P 5-110 0313 0060W Philips Pan Head Screw - M3x6 5937 5780 Grounding Wire 7-50 7-102...
Page 940 April 30, ’89 Page and Page and Parts No. Description Parts No. Description Index No. Index No. 1102 1507 1606 1382 Capacitor - 12µF (220/240V) Connector - 2P 11-107 5-116 1611 4102 1102 1515 Connector - 2P Resistor - 1KOHM 1/4T ±5% 11-108 9-125 1611 4103...
Page 941 SORTER STAPLER CONNECTOR UNIT (A310)
Page 942: Parts Catalog
PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of this parts on this machine. INDEX to PARTS CATALOG 1. Exterior (A310) ........2 2.
Page 943 1. EXTERIOR (A310) April 15, 1990...
Page 944 1. EXTERIOR (A310) April 15, 1990 Index Index Q’ty Per Q’ty Per Part No. Description Description Part No. Assembly Assembly A310 4460 A310 2690 Rear Upper Vertical Cover Connector Bracket 5946 4541 Pad - 5x20x480mm A310 4419 Rear Horizontal Cover A310 3655 Rear Vertical Cover Angle 5946 1111...
Page 945 2. HORIZONTAL TRANSPORT SECTION (A310) April 15, 1990...
Page 946 2. HORIZONTAL TRANSPORT SECTION (A310) April 15, 1990 Q’ty Per Index Q’ty Per lndex Part No. Description Part No. Description Assembly Assembly A310 5320 Safety Switch Harness 5887 4156 Spring - Driven Roller A310 5330 DC Harness 5887 4155 Shaft Guide - Turn Driven A310 5321 Safety Switch Harness - 220/240V A310 2479...
Page 947 3. VERTICAL TRANSPORT SECTION 1 (A310) April 15, 1990...
Page 948 3. VERTICAL TRANSPORT SECTION 1 (A310) April 15, 1990 lndex Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly A310 5320 Safety Switch Harness Power Supply Cord - 220/240V 5946 5231 A310 5330 DC Harness A310 4481 Shielding Cover - 2nd Sorter 5946 2631 Safety Switch Bracket...
Page 949 4. VERTICAL TRANSPORT SECTION 2 (A310) April 15, 1990...
Page 950 4. VERTICAL TRANSPORT SECTION 2 (A310) April 15, 1990 Q’ty Per lndex Index Q’ty Per Part No. Description Part No. Description Assembly Assembly Vertical Driven Roller 0313 0060W Philips Pan Head Screw - M3x6 5887 4132 5054 0536 Magnet Catch Ass’y 0314 0060W Philips Pan Head Screw - M4x6 0315 0080W Philips Pan Head Screw - M5x8 5887 4156...
Page 951 5. AC HARNESS (A310) April 15, 1990...
Page 952 5. AC HARNESS (A310) April 15, 1990 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A310 5311 AC Harness - 115V 1100 0082 Solid Strand A310 5312 AC Harness - 220/240V 1100 0885 Fastening Receptacle 1100 0916 Pin - Mate-N-Lok 1100 1169...
Page 953 6. SAFETY SWITCH HARNESS (A310) April 15, 1990...
Page 954 6. SAFETY SWITCH HARNESS (A310) April 15, 1990 Q’ty Per Index Q’ty Per Index Part No. Description Part No. Description Assembly Assembly 1100 1041 Pin - Mate-N-Lock A310 5320 Safety Switch Harness 1100 1042 Socket - Mate-N-Lock 1100 1169 Fastening Receptacle 1100 1241 Socket - Mate-N-Lock 1100 1247...
Page 955 7. DC HARNESS (A310) April 15, 1990...
Page 956 lndex Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A310 5330 DC Harness 1100 1155 Contact 1100 1159 Socket-Mate-N-Lock 1100 1169 Fastening Receptacle 1100 1259 Socket - Mate-N-Lock 1100 1327 Contact 1100 1330 Socket Contact 1102 1089 Connector - 3P 1102 1286...
Page 957 8. DC HARNESS (A310) April 15, 1990...
Page 958 8. DC HARNESS (A310) April 15, 1990 lndex Index Q’ty Per Q’ty Per Part No. Description Description Part No. Assembly Assembly A310 5332 DC Harness 1100 1329 Socket Contact 1102 1982 Socket Housing - 2P 1102 1986 Socket Housing - 6P 1102 1988 Socket Housing - 8P...
Page 959 9. DECAL AND DOCUMENT (A310) April 15, 1990...
Page 960 9. DECAL AND DOCUMENT (A310) Q’ty Per Index Index Q’ty Per Part No. Description Part No. Description Assembly Assembly A310 6211 Misfeed Removal Decal - English A310 6220 Misfeed Removal Decal - Multi...
Page 961 PARTS INDEX...
Page 962 April 15, 1990 Page and Page and Part No. Description Part No. Description Index No. Index No. A310 1101 Base Plate 3 - 2 6 A310 3431 Right Vertical Guide Plate 9 - 1 0 A310 1141 Front Positioning Angle 3 - 2 7 A310 3434 Sensor Bracket...
Page 963 April 15, 1990 Page and Page and Part No. Description Part No. Description Index No. Index No. A310 5330 DC Harness 9 - 1 2 AA02 0003 Slide Lever Magnet 5 - 1 6 A310 5330 DC Harness 1 5 - * AA04 3105 Timing Belt - 80XL 9 - 2 1...
Page 964 April 15, 1990 Page and Page and Part No. Description Part No. Description Index No. Index No. 5887 2136 Pulley - 40Z 9 - 2 3 5946 2641 Magnet Catch Bracket 3 - 1 2 5887 4120 Stay - Side Plate 5 - 3 2 Pad - 30x40x40mm 5946 2691...
Page 965 April 15, 1990 Page and Page and Part No. Description Part No. Description Index No. Index No. 0313 0060W Philips Pan Head Screw - M3x6 3-101 1005 0335 Earth Mark 7-110 0313 0060W Philips Pan Head Screw - M3x6 5-101 1100 0082 Solid Strand 11-101...
Page 966 April 15, 1990 Page and Page and Part No. Description Part No. Description Index No. Index No. 1102 1911 Connector - 3P 15-111 1102 1982 Socket Housing - 2P 17-102 1102 1986 Socket Housing - 6P 17-103 1102 1988 Socket Housing - 8P 17-104 1102 2045 Pin Housing - 2P...
Page 967 ST20 (A469)
Page 968 ST20 (A469) Location of Unit ......3 Harness Layout (A469) ....28 1.
Page 969 LOCATION OF UNIT April 30, ’89...
Page 970 LOCATION OF UNIT 7. STAPLER VERTICAL DRIVE See page 18...
Page 971 1. EXTERIOR (A469) April 30, ’89...
Page 972 April 30, ’89 1. EXTERIOR (A469) Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A469 1392 Bottom Cover A469 6071 Decal - Misfeed Removal 7 A469 1701 Right Cover A469 1314 Insulating Pad - 10x72x625mm 5887 4270 Antistatic Brush - Bin A469 1313...
Page 973 April 30, ’89 2. TRANSPORT (A469)
Page 974: Transport (A)
2. TRANSPORT (A469) April 30, ’89 Index Q’ty Per Q’ty Per Part No. Description Description Assembly Assembly 5442 4495 Slip Clutch A469 1398 Upper Cover - Gripper Solenoid AB01 7139 Gear - 26Z A469 1258 Upper Cover Mounting Plate AA04 3074 Timing Belt - 104XL A469 2139 Guide Plate - Distribution...
Page 975 3. UPPER DISTRIBUTION (A469) April 30, ’89...
Page 976: Upper Distribution (A)
3. UPPER DISTRIBUTION (A469) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly A469 3050 Front Side Plate - Distribution A469 3195 Tightener Pulley A469 3055 Rear Side Plate - Distribution A469 3210 Tightener Pulley - 10Z A469 3070 Stay Plate - Distribution...
Page 977 4. LOWER DISTRIBUTION (A469) April 30, ’89...
Page 978: Lower Distribution (A)
4. LOWER DISTRIBUTION (A469) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly 5887 4193 Pulley - 10Z A469 3300 Distribution Driven Unit A469 3340 Transport Roller - Driven Unit A469 3164 Bin Solenoid Lever 5937 4161 Cushion - Turn Lever...
Page 979 April 30, ’89 5. STAPLE UNIT (A469)
Page 980: Staple Unit (A)
5. STAPLE UNIT (A469) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A469 4301 Stapler Bracket A469 4442 Gripper Side Plate A010 5700 Sensor 5053 0447 Bushing - 6mm A469 4331 Joint Lever A469 4474 Shaft - Gripper Drive Guide...
Page 981 6. JOGGER (A469) April 30, ’89...
Page 982: Jogger (A)
6. JOGGER (A469) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly Upper Jog Cover A469 1396 A469 4221 Jog Lever A469 4156 Bracket - Side Plate Motor A469 4227 Mylar Seal - Exit Guide A469 4159 Idle Pulley A469 4228...
Page 983 April 30, ’89 7. STAPLER VERTICAL DRIVE (A469)
Page 984: Stapler Vertical Drive (A)
7. STAPLER VERTICAL DRIVE (A469) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A469 5442 Noise Filter Harness A469 1107 Hand Grip - Staple Unit A469 5465 Grounding Wire 5424 1064 Screw Stand A469 5450 AC Intermediate Harness...
Page 985 8. MAIN BOARD (A469) April 30, ’89...
Page 986 8. MAIN BOARD (A469) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 1101 0328 Connector Pin Contact A469 5100 Main Board 1103 0402 Pin Header - 26P A469 5102 IC - HN27256G-25 5918 5711 1103 0740 Connector - 6P...
Page 987 April 30, ’89 9. RECEIVER SENSOR BOARD (A469)
Page 988 9. RECEIVER SENSOR BOARD (A469) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly 5887 5623 Receiver Sensor Board 1102 1792 Connector - 4P 1400 0045 Transistor - 2SC372 1400 0236 Transistor - 2SK30A-GR 1400 0323 Transistor - PN108 1402 0481...
Page 989 10. LIGHT SENSOR BOARD (A469) April 30, ’89...
Page 990 10. LIGHT SENSOR BOARD (A469) April 30, ’89 Index Index Q’ty Per Part No. Part No. Description Description Assembly 5887 5633 Light Sensor Board 1102 1791 Connector - 3P 1400 0113 Transistor - 2SA495GTMY 1400 0284 Transistor - 2SD789D 1403 0247 LED - LN51L 1408 0124 IC - LM555CN...
Page 991 11. BIN SOLENOID BOARD (A469) April 30, ’89...
Page 992 April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Part No. Description Description Assembly Assembly A469 5130 Bin Solenoid Board 1103 1810 Pin Header - 2P (Brown) 1103 1819 Connector 1401 0832 Diode - DSA1A1...
Page 993 12. HARNESS LAYOUT (A469) April 30, ’89...
Page 994 April 30, ’89 12. HARNESS LAYOUT (A469) Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A469 5405 DC Harness A469 5400 AC Harness A469 5415 Stapler Harness A469 5420 Gripper Harness A469 5410 Jog Sensor Harness A469 5450 AC Intermediate Harness A469 5425...
Page 995 13. DC HARNESS (A469) April 30, ’89...
Page 996 13. DC HARNESS (A469) April 30, ’89 Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly Socket - Mate-N-Lock A469 5405 1100 1159 DC Harness Socket - Mate-N-Lock 1100 1241 1100 1247 Terminal 1100 1249 Receptacle Terminal 1100 1259 Socket - Mate-N-Lock...
Page 997 14. AC HARNESS (A469) April 30, ’89...
Page 998 14. AC HARNESS (A469) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly Pin - Mate-N-Lock 1100 1239 A469 5400 AC Harness 1100 1241 Socket - Mate-N-Lock Terminal 1100 1247 Connector - 2P 1102 1507 Connector - 2P 1102 1515 Connector - 3P...
Page 999 15. STAPLE HARNESS (A469) April 30, ’89...
Page 1000 15. STAPLE HARNESS (A469) April 30, ’89 Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly A469 5415 Stapler Harness 1100 1259 Socket - Mate-N-Lock 1100 1329 Socket Contact 1100 1330 Socket Contact 1102 1089 Connector - 3P 1102 1983 Socket Housing - 3P...
Page 1001 16. GRIPPER HARNESS (A469) April 30, ’89...
Page 1002: Gripper Harness (A)
16. GRIPPER HARNESS (A469) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A469 5420 Gripper Harness 1100 1329 Socket Contact 1102 1982 Socket Housing - 2P 1102 1983 Socket Housing - 3P 1102 1990 Socket Housing - 10P 1102 2010...
Page 1003 17. JOG SENSOR AND AC INTERMEDIATE HARNESSES (A469) April 30, ’89...
Page 1004 17. JOG SENSOR AND AC INTERMEDIATE HARNESSES (A469) April 30, ’89 Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A469 5450 AC Intermediate Harness 1100 0885 Fastening Receptacle A469 5410 Jog Sensor Harness 1100 1239 Pin - Mate-N-Lock 1100 1249 Receptacle...
Page 1005 April 30, ’89 18. RECEIVER SENSOR BOARD, LIGHT SENSOR BOARD AND PAPER SIZE SENSOR HARNESSES (A469)
Page 1006: Receiver Sensor Board, Light Sensor Board
18. RECEIVER SENSOR BOARD, LIGHT SENSOR BOARD April 30, ’89 AND PAPER SIZE SENSOR HARNESSES (A469) Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A469 5425 Paper Size Sensor Harness 1100 1259 Socket - Mate-N-Lock Fastening Receptacle A469 5430...
Page 1007 April 30, ’89 19. NOISE FILTER HARNESS (A469)
Page 1008: Noise Filter Harness (A)
19. NOISE FILTER HARNESS (A469) Index Index Q’ty Per Q’ty Per Part No. Description Part No. Description Assembly Assembly A469 5442 Noise Filter Harness 1100 0885 Fastening Receptacle 1100 1241 Socket - Mate-N-Lock 1100 1264 Fastening Receptacle 1102 1515 Connector - 2P 1102 1745 Receptacle Sleeve...
Page 1009 20. DECAL AND DOCUMENT (A469) April 30, ’89...
Page 1010 20. DECAL AND DOCUMENT (A469) Index Q’ty Per Index Q’ty Per Part No. Description Part No. Description Assembly Assembly A469 8610 Installation Procedure - English A469 8615 Installation Procedure - Multi A469 6059 Decal - Misfeed Removal 7 A469 6065 Decal - Staple Replacement A469 6071 Decal - Misfeed Removal 7...
Page 1011 PARTS INDEX...