Sharp VC-H670X Dokumentacja

— LT/LDG Version — 7. Auto Reduce/Enlarge Key Press to select the auto reduce/enlarge mode. This mode is an optional feature requiring a d

11.2 FUSING DRIVE RELEASE MECHANISM AND COVER SAFETY SWITCHThe fusing unit drive release mechanism automatically disengages the fusingunit drive gea

11.3 FUSING LAMP CONTROLWhen the main switch is turned on, the CPU starts sending a trigger pulse tothe fusing control circuit. The fusing control cir

11.4 FUSING LAMP CONTROL CIRCUITThe main board monitors the fusing temperature through a thermistor. It alsouses the zero cross signal generated by th

11.4.1 Phase Control ModeThe main board sends the fusing lamp trigger pulse (LOW active) [C] to theac drive board. PC402 activates TRC402, which provi

11.4.2 Overheat ProtectionIC121 and Q110 form an overheat protection circuit. When the fusing lamp iscontrolled within the normal range, pin 7 of IC12

11.5 SERVICE CALL CONDITIONSService Code 52: Fusing Warm-up Error The temperature detected by the thermistor does not reach 175 oC within 100 seco

SECTION 3 INSTALLATION

1. INSTALLATION REQUIREMENTS1.1 ENVIRONMENT 1. Temperature Range: 10oC to 30oC (50oF to 86oF) 2. Humidity Range: 15% to 90% RH 3. Ambient Illuminat

1.2 MACHINE LEVEL 1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of levelPlace the machine on a table

1.4 POWER REQUIREMENTS 1. Input voltage level:110V/60Hz : More than 15A (for Taiwan)115V/60Hz : More than 15A (for N.A.)220V/50Hz : More than 8A (for

1 December 19901-9

2. INSTALLATION PROCEDURE2.1 COPIER INSTALLATION 1. Remove the strips of tape [A] from the copier at the locations shown. 2. Open the front cover [B

4. Pull out the paper tray [E] and remove the foam block [F], tape, and silicagel [G]. 5. Open the platen cover and remove the optics lock pins [H]

7. Raise the development unit lock lever [A], pull out the development unit[B], and place it on a clean sheet of paper. 8. Remove the filter bracke

12. Lower the transport unit lever [A].13. Remove the drum protective sleeve [B].14. Remove the lock plate [C] from the cleaning blade release lever.N

17. Plug in the machine and turn on the main switch, then place a few sheetsof white paper (A3 or 11"x17") on the exposure glass and lower t

20. If an option (DF, Sorter, Duplex) is not installed on the machine, place acover sheet [A] from sheet [B] over the operation panel as shown.21. Loa

2.2 220/240V CONVERSIONNOTE: In areas where 240 volts is the standard, the connectors on the acdrive board must be repositioned as explained below. Th

2.3 CASSETTE MODIFICATION 1. Take off the cassette cover [A]. 2. Remove the side fences [B] (1 screw each) and the bottom plate [C]. 3. Reposition

2.4 KEY COUNTER HOLDER INSTALLATION (OPTION) 1.Make sure that the main switch is turned off. 2. Open the front cover and the manual feed table. 3.

2.5 OPTICS ANTI-CONDENSATION HEATER INSTALLATION (OPTION) 1. Make sure that the main switch is turned off. 2. Remove the rear cover. 3. Remove the

3. COPY PROCESSES AROUND THE DRUM4. DEVELOPMENT5. PRE-TRANSFER LAMP6. IMAGE TRANSFER7. PAPER3. ERASE2. EXPOSURE1. DRUM CHARGE9. QUENCHING8. CLEANINGSE

2.6 COLOR DEVELOPMENT UNIT INSTALLATION (OPTION)NOTE: The two tapping screws (M4 x6) are enclosed as accessories. 1. Screw the tapping screws [A] int

2. Remove the filter bracket [D] (2 screws). (The development unit handle isattached.) 3. Remove the toner supply unit [E] from the development uni

7. Shake the toner cartridge [A] well to distribute the toner evenly inside thecartridge. Then, install the cartridge as shown. 8. Turn on the main

2.7 DC POWER SUPPLY UNIT INSTALLATIONAccessory CheckCheck the quantity and condition of the accessories in the box according tothe following list: 1.

1. Make sure that the main switch is turned off and the power supply cord ofthe copier is unplugged. 2. Remove the rear cover [A] (4 screws). 3. I

4. Disconnect the connectors [A] from the main dc power supply unit [B] onthe copier. 5. Remove the main dc power supply unit (2 screws and 2 locki

10. Install the optional dc power supply unit [A] (2 screws and lockingsupport) as shown.11. To prevent damage to the ac harness [B] when installing t

14. Open the front cover and manual feed table; then, remove the right sidecover [A] (4 screws).15. Install the harness support bracket [B] (1 screw)

SECTION 4 SERVICE TABLES

1. SERVICE TABLES1.1 TEST POINTSCopier Main BoardNUMBER FUNCTIONTP101 GNDTP102 VCC (+5V)TP103 ADS (Auto Image Density Sensor)Adjust the voltage to 2.5

1. DRUM CHARGEIn the dark, the charge corona unit gives a uniform negative charge to the organicphotoconductive (OPC) drum. The charge remains on the

1.2 DIP SWITCHESCopier Main BoardDIP SWITCH NORMAL FUNCTION* 101-1 OFF Free run** 101-2 OFF Forced start (Ready temperature by-passed)Factory Use101-3

DF Main BoardDIP SWITCH 101 FUNCTION1234ON OFF OFF OFF * NormalON OFF OFF ON 1 sided free runOFF ON OFF ON 2 sided free runOFF OFF ON ON Solenoid test

Data Table (Jogger Position Adjustment)DIP SWITCH 700 (0:OFF, 1:ON) ADJUSTMENT VALUE12340000 -3.5mm1000 -3.0mm0100 -2.5mm1100 -2.0mm0010 -1.5mm1010 -1

1.3 VARIABLE RESISTORSCopier Main BoardNUMBER FUNCTIONVR101 Adjusts ADS Voltage (2.5 ± 0.1)VR102 Adjusts ID Sensor Voltage (4.0 ± 0.2)Power Pack (CC/G

DF Main BoardNUMBER FUNCTIONVR101 Factory UseVR102 Original leading edge registrationadjustment (One sided original mode)VR103 Original leading edge r

2. SERVICE PROGRAM MODE2.1 SERVICE PROGRAM MODE OPERATIONThe service program (SP) mode is used to check electrical data and changemodes or adjustment

Access Procedure 2 - DIP switch 101-4 1. Turn the main switch off. 2. Remove the rear cover and turn on DIP SW 101-4, then turn on the mainswitch. &q

2.1.3 Memory Clear Procedure<SP-98 "Clears all counters">Service Program SP-98 is used to clear all counters (copy counters, PMcounter

2.1.4 OthersIn the following 13 SP modes, copies can be made by pressing the Start key:SP Modes #5, #6, #8, #37, #41, #42, #43, #44, #47, #48, #5

2.2 SERVICE PROGRAM MODE TABLE * Copies can be made. (Refer to NOTE 1.)Mode No. Function Data FactorySettingComments*5: Exposure Lamp OFFExposure lamp

4. FUNCTIONAL OPERATION1 December 19901-12

Mode No. Function Data FactorySettingComments12: 220V/240VConversionSelects 220 or 240volts.0: 220V1: 240V0 If the rated voltageis 240V, this datamust

Mode No. Function Data FactorySettingComments25: Margin Adjustment in Duplex ModeSets the margin (5 mm) on the rightside of the reversepage.0: Yes1: N

Mode No. Function Data FactorySettingComments34: ADS Level Selects the imagedensity level inADS mode.0: Normal1: Darker2: Lighter0 Data #1:Increases b

Mode No. Function Data FactorySettingComments*48: Light Intensity AdjustmentAdjusts theexposure lampvoltage.100 – 150 100 –150Default = 126The exposur

Mode No. Function Data FactorySettingComments*55: Vsg & Vsp CheckDisplay the Vsgand Vsp readings.The Vsg reading isdisplayed while the"0"

Mode No. Function Data FactorySettingComments65: BlackDeveloperInitial SettingSets the data valuecorresponding tothe Vsp/Vsg ratiofor new blackdevelop

Mode No. Function Data FactorySettingComments73: Color CopyCounterThe Magnificationindicator displaysthe total number ofcolor copies (Red +Green + Blu

Mode No. Function Data FactorySettingComments82: Blue TonerDensity LevelDisplayDisplays the bluetoner density leveldetected by initialsetting (SP #10)

Mode No. Function Data FactorySettingComments100:First Station CopiesDisplays the totalnumber of copiesfed from the firstfeed station(cassette andmanu

Mode No. Function Data FactorySettingComments105:Duplex Copies Displays the totalnumber of copiesmade in duplexmode.0 The first threedigits are displa

5. MECHANICAL COMPONENT LAYOUT 512 346 78 9 10111213 14151617181920212224 23252627282932313033 1. Third Mirror 2. Second Mirror 3. First Mirror 4. Ex

Mode No. Function Data FactorySettingComments131:Number ofMisfeeds byLocationDisplay the totalnumber of papermisfeeds for eacharea. 0 "1" wi

NOTE 4: How to clear the PM counter1) Enter "89", then press the Enter key.2) Enter "1" to clear the PM counter, then press the En

2.3 SP-8 SENSOR/SWITCH DATA CHECK- How to check sensor/switch data - 1. Press "8", then press the Enter (#) key while pressing the Point ke

Input No. Sensor/Switch/Signal Data0 1 32 ADF ON Line ADF not installed ADF installed33 ADF Lift Sensor ADF closed ADF opened34 APS Sensors Refer to

2.4 SP-9 ELECTRICAL COMPONENT CHECK- How to turn electrical components on/off - 1. Enter "9", then press the Enter (#) key while pressing t

Output No. Electrical Component37 Erase Lamp39 Optics Cooling Fans40 Exposure Lamp + Optics Cooling Fans42 Charge Corona + Standard Grid + Transfer Co

2.5 MISFEED TABLE2.5.1 Number of PaperJams (SP Mode #131)The following explains how to access a record that gives the number of paperjams by copier lo

2.5.2 Paper Misfeed Location Indicator1. Initial MisfeedMisfeed location indicators turn on if paper is detected by sensors when themain switch is tur

3. Misfeed during copy cycle (Misfeed Location) 1. The misfeed location indicator turns on (and stays lit) to indicate thelocation of a misfeed detec

2. If a paper misfeed is detected by the registration sensor ONcheck during a multi-copy run, the misfeed location indicatorturns on after copies that

6. DRIVE LAYOUTG1: Main Motor Gear G20: Relay GearG2: Relay Gear G18: Relay Gear G21: Cleaning Drive Cleaning UnitG3: Timing Belt Drive Gear G19:

2.6 SERVICE CALL AND USER CODE TABLESERVICE CALL CODEE-CODE CONTENTS SP Mode No.(SC Counter)11 Exposure Lamp ErrorThe feed back signal beomes higher t

E-CODE CONTENT SP Mode No.(SC Counter)70 Toner Overflow Sensor ONWhen the toner overflow sensor is on, "E70" blinks in themagnification indi

3. SERVICE REMARKS3.1 GENERAL CAUTIONTo prevent physical injury, keep hands away from the mechanical drivecomponents in the following two cases:a. If

3.3 CHARGE CORONA 1. Clean the corona wire by sliding the corona unit in and out. (The cleanerpads come into contact with the corona wire when the co

4. Clean the following parts with a silicone cloth:Lens and 4th/5th Mirror Guide Rails1st Scanner Guide Plate 5. Clean the exposure glass with glas

3.6 TONER SUPPLY 1. Clean the image density sensor with a blower brush. 2. Do not touch the sensor pattern with bare hands. 3. Image density sensor

3.9 FUSING UNIT 1. Be careful not to damage the edges of the hot roller strippers or theirtension springs. 2. Do not touch the fusing lamp with bare

3.13 DUPLEXWhen lifting the duplex unit out of the duplex tray, hold both sides of theduplex unit frame.3.14 OTHERS 1. If the toner density in solid

4. SPECIAL TOOLS AND LUBRICANTSPart Number Description Q’tyA0069105 Drum Shoe Shaft 1A0489500 Doctor Gap Gauge (1 pc) 1A0069103 Scanner Wire Clamper (

5. PREVENTIVE MAINTENANCE SCHEDULEAfter performing preventive maintenance, do the following: 1. Set the lamp voltage with SP Mode No. 48. Make a cop

APaper Feed SectionBP3: Timing Belt PulleyG11: Registration CL Gear G4: Relay Gear 2nd Feed StationRegistration CL G5: Relay Gear G12: Relay

5.1 PM TABLE L = Lubricate R = Replace C = Clean I = InspectionEM 60K 120K 180K 240K NOTESA. OPTICS _____________________________________

EM 60K 120K 180K 240K NOTES7. Quenching lamp C C C C C Dry cloth, discharge anystatic before installation8. ID sensor C C C C C Blower bru

EM 60K 120K 180K 240K NOTESJ. SORTER _________________________________________________1. Bin guide/wheel L L L L Grease G501(ifnecessary)2. Roun

NOTE 3: When replacing the mainmotor, lubricate the gearusing Grease G501.NOTE 4: Replace the black and color developer at PM, refering to thefollowin

5.2 EXPLANATION OF REGULAR PMItem ExplanationOptics Unit Mirrors, Lens,Reflector, ExposureGlass, Platen CoverStains on any part of the optics unit res

Item ExplanationCleaning Unit Cleaning Blade A dirty or worn out cleaning blade will cause blacklines on copies and/or scratches on the drum. Theblade

SECTION 5REPLACEMENT AND ADJUSTMENT

1. EXTERIOR AND INNER COVERS 1.1 EXTERIOR COVER REMOVAL1.1.1 Front Cover 1. Open the front cover [A]. 2. Unhook the chain [B] from the front cover.

1.1.3 Left Lower Cover 1. Pull out the paper tray or the duplex tray [A]. 2. Remove the left lower cover [B] (3 screws).1.1.4 Left Upper Cover. 1.

1.1.5 Rear Cover Remove the rear cover [A] (4 screws).1.1.6 Upper Cover 1. Remove the platen cover. 2. Remove the platen cover pedestal [B] (4 screw

7. ELECTRICAL COMPONENT LAYOUT42434123567891011121514171819202122242325272629283330313437363841394013353216 1. Scanner H.P. Sensor 2. Lens Motor 3.

1.2 INNER COVER REMOVAL1.2.1 Right Inner Cover 1. Open and remove the front cover. 2. Remove the development unit. 3. Lower the turn guide lever [A]

2. OPTICS2.1 EXPOSURE GLASS REMOVAL 1. Take off the left scale [A] (2 short screws). 2. Grasp the left edge of the exposure glass [B] and lift up sl

2.2 1ST MIRROR REMOVAL 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Move the first scanner to the cu

- To install - 1. Insert the 1st mirror into the front side plate cutout. Then insert the rearside of the mirror into the rear spring plate.NOTE: Ma

2.3 2ND AND 3RD MIRROR REMOVAL 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Slide the 1st scanner 2/

- To reinstall - 1. Hold the rear spring plate [A] in position as shown. 2. Insert the 2nd mirror [B] into the front side plate cutout. 3. Positi

2.4 4TH AND 5TH MIRROR REPLACEMENT 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Remove the lens cove

2.5 EXPOSURE LAMP REPLACEMENTNOTE: Do not touch the reflector or the new exposure lamp with your barehands. Use a strip of paper as shown. (Oil marks

7. Remove the exposure lamp [A] from the rear spring plate by moving thelamp toward the front. 8. Install a new lamp. Use a strip of paper as shown

2.6 THERMOSWITCH REPLACEMENT 1. Turn off the main switch. 2. Remove the exposure glass (2 screws). 3. Slide the first scanner 150 mm to the right.

4950515253545556575859606162444546474844. Key Counter (Option)45. Main Board46. CC/Grid/Bias Power Pack47. Optics Cooling Fan Motors48. Optics Therm

2.7 SCANNER DRIVE WIRE REPLACEMENT2.7.1 Wire Removal 1. Remove the following covers and parts.Sorter (if installed) Document feeder (if installed)Fro

2.7.2 Wire Installation 1. Position the scanner drive pulley as shown with the Allen screws facingyou. 2. Put the bead at the end of the blue wire [

7. Put the bead of the blue wire [3] in slot [A] on the Allen screw side. 8. Put the bead of the silver wire [4] in slot [B]. 9. Wind the blue w

12. Manually move the first and second scanners to home position.13. Insert the four positioning pins [A] in the holes on the scanner guide railsto se

17. Attach blue wires [1 and 3] around the pulleys as shown.18. Attach wire [3] to the wire fixing plate [A], then hook one end of tensionspring [B] t

21. Adjust the tension in the second scanner wire.(1) Insert positioning pin [A] in the hole at the front end of the secondscanner.(2) Loosely insert

22. Adjust the first scanner wire clamps.(1) Loosen the front and rear first scanner wire clamps [A](2) Insert the front and rear positioning pins (2)

2.8 SCANNER MOTOR REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover and the upper cover. 3. Remove the CC/G/B power pack [A] (2 loc

2.9 LENS DRIVE MOTOR REPLACEMENT 1. Turn off the main switch. 2. Remove the exposure glass and the lens cover. 3. Move the scanner to the return si

- Lens Drive Wire Installation - 1. Hook the spring [A] to the sensor actuator bracket [B]. 2. Wind the lens drive wire [C] three and half times a

SECTION 1OVERALL MACHINE INFORMATION

8. ELECTRICAL COMPONENT DESCRIPTIONSSYMBOL NAME FUNCTION INDEXNO.MotorsM1 Main Motor Drives all the main unit components exceptfor the optics u

2.10 4TH/5TH MIRROR ASSEMBLY DRIVE MOTOR REPLACEMENT 1. Turn off the main switch. 2. Remove the exposure glass, upper cover, lens cover, and rear

2.11 EXPOSURE LAMP POSITION ADJUSTMENT (HORIZONTAL DIRECTION) 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Remo

3. DEVELOPMENT AND TONER SUPPLY3.1 TONER TANK REMOVAL 1. Take out the development unit. 2. Remove the filter bracket [A] (2 screws). 3. Remove the

3.2 DEVELOPER REPLACEMENT 1. Take out the development unit. 2. Set the development unit on a large sheet of paper [A]. 3. Remove the toner supply u

3.3 INLET SEAL REMOVAL 1. Take out the development unit. 2. Remove the inlet seal plate [A] by working a small blade screwdriveralong the edge of th

3.4 DEVELOPMENT ROLLER REPLACEMENT 1. Take out the development roller and remove the toner tank. (See TonerTank Removal.) 2. Empty the developer fro

3.5 DOCTOR GAP ADJUSTMENTNOTE: a) Use a doctor gap gauge (P/N #A0489500) to measure the doctorgap. This gauge has a "GO" [A] and a "NO

4. Clean all developer from the development roller [A] with a vacuumcleaner. Turn the roller to make sure that it is free of developer. 5. Loosen t

- Confirmation Procedure - 1. Carefully follow the procedure given here to correctly measure the doctorgap.(1) Insert the gauge [A] into the doctor g

3.6 TONER SUPPLY CLUTCH SOLENOID REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover and main board (all connectors and 5 locking sup-

SYMBOL NAME FUNCTION INDEXNO.SwitchesSW1 Main Switch Supplies power to the copier. 53SW2 Cover SafetySwitchCuts the ac power line. 52SW3 1st Pa

3.7 DEVELOPMENT DRIVE CLUTCH SOLENOID REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover and main board (all connectors and 5 locki

3.8 DEVELOPMENT DRIVE CLUTCH REPLACEMENT 1. Remove the following parts:• Front cover • Development unit• Cleaning unit • Charge corona unit• Drum uni

4. CLEANING4.1 CLEANING UNIT REMOVAL 1. Open the front cover. 2. Lower the transport unit [A]. 3. Place a sheet of paper [B] underneath the cleanin

4.2 CLEANING BLADE REPLACEMENT 1. Remove the cleaning unit [A]. (See Cleaning Unit Removal.) 2. Remove the cleaning blade [B] (1 screw). 3. While h

4.3 CLEANING BRUSH REPLACEMENT 1. Remove the cleaning blade [A]. (See Cleaning Blade Replacement.) 2. Remove the cleaning brush bracket screws (4);

4.4 BLADE SCRAPER REPLACEMENT 1. Remove the cleaning blade and brush. (See Cleaning Blade and BrushReplacement.) 2. While holding down the cleaning

4.5 TONER OVERFLOW SENSOR REPLACEMENT 1. Remove the cleaning unit. 2. Lower the transport unit. 3. Remove the toner overflow sensor bracket [A] from

4.6 USED TONER COLLECTION 1. Remove the cleaning unit. 2. Set the cleaning unit on a large sheet of paper [A]. 3. Remove the toner collection cover

4.7 ENTRANCE SEAL REPLACEMENT 1. Remove the cleaning unit and the following parts:• Cleaning Blade• Cleaning Brush 2. Remove the used toner. (See Us

5. PAPER FEED5.1 PAPER SIZE SWITCH REPLACEMENT 1. Turn off the main switch. 2. Remove the paper feed lower guide plate [A] (2 screws). 3. Remove th

SYMBOL NAME FUNCTION INDEXNO.S11Image Density(ID) SensorDetects the density of the image on thedrum to control the toner density.32S12 Developm

5.2 1ST PAPER END SENSOR AND PAPER LIFT SENSOR REPLACEMENT 1. Turn off the main switch. 2. Remove the manual feed table. (See Manual Feed Table Re

5.3 1ST FEED ROLLER, PICK-UP ROLLER, AND REVERSE ROLLER REPLACEMENT 1. Turn off the main switch. 2. Open the manual feed table. 3. Remove the scr

- To install - 1. Clean the rollers with a damp cloth. 2. Clean the clutch spring [A] of the reverse roller. 3. Lubricate the surface [B] of the o

5.4 2ND PAPER FEED ROLLER REPLACEMENT 1. Turn off the main switch. 2. Open and remove the front cover. 3. Pull out the paper tray or the duplex tra

5.5 PICK-UP ROLLER RELEASE SOLENOID AND MANUAL FEED TABLE SWITCH REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove t

5.6 1ST FEED ROLLER SPRING CLUTCH SOLENOID REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the main board (5 locking

5.7 PAPER LIFT CLUTCH SOLENOID ASSEMBLY REPLACEMENT 1. Turn off the main switch. 2. Remove the left and rear covers. 3. Remove the main board (5

- To install - 1. Install the actuator lever [A] on the stud pin [B]. 2. Set the collar [C] on the stud pin [B]. 3. Install the manual feed table d

5.8 RELAY ROLLER SPRING CLUTCH SOLENOID AND RIGHT COVER SWITCH REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the

5.9 REGISTRATION CLUTCH REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the main board (5 locking supports and all con

SYMBOL NAME FUNCTION INDEXNO.HeatersH1 Drum Anti-condensationHeaterPrevents moisture around the drum. 54H2 Optics Anti-con-densation HeaterOpti

5.10 2ND PAPER FEED CLUTCH SOLENOID REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the main board (5 locking supports

- To install -1. Set the solenoid on the shaft.2. Open the right cover [A] and the front cover.3. Rotate the shaft [B] so that the 2nd feed roller fac

5.11 2ND PAPER END SENSOR REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the sensor bracket [A] (1 screw). 4. Replac

5.12 2ND PAPER SIZE SWITCH REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the switch bracket [A] (1 screw). 4. Repla

5.13 REGISTRATION SENSOR AND ROLLER REPLACEMENT 1. Turn off the main switch. 2. Remove the following parts:• Front cover (See Exterior Cover Removal

- Registration Rollers - 8. Remove the front and rear bushings [A] (1 screw, pressure spring, and E-ring each) of the upper registration roller. 9.

- To install (Lower Registration Roller) - 1. Set the ends of the lower registration roller shaft into the front and rearbushing holes [A]. 2. Insta

6. AROUND DRUM6.1 PTL BOARD REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the main board (5 locking supports and all

6.2 QUENCHING LAMP REPLACEMENT/CLEANING 1. Open the front cover and lower the transport unit. 2. Remove the following parts:• Development unit• Clea

6.3 ERASE LAMP REPLACEMENT 1. Open the front cover and lower the transport unit. 2. Remove the following parts:• Development unit• Cleaning unit• Ch

9. OVERALL MACHINE CONTROLThe above diagram shows the control system of this copier in block form. TheCPU (IC123) on the main board controls the timin

6.4 CHARGE CORONA WIRE REPLACEMENT 1. Remove the charge corona unit [A] together with the wire cleaner [B](1 screw). 2. Remove the wire cleaner from

6.5 CHARGE CORONA GRID REPLACEMENT 1. Remove the charge corona unit. 2. Remove the grid plate [A] (2 springs [B]).NOTE: a) Oils and chemicals from yo

6.6 TRANSFER/SEPARATION CORONA WIRE REPLACEMENT 1. Remove the transfer/separation (TC/SC) corona unit. 2. Remove the following parts:• TC/SC unit

6.7 ENTRANCE GUIDE PLATE HEIGHT ADJUSTMENTNOTE: Do not loosen or remove the entrance guide plate [A] except toreplace it. The entrance guide plate hei

6.8 DRUM REPLACEMENT 1. Lower the transport unit. 2. Remove the following units:• Development unit• Cleaning unit• Charge corona unit [A] and wire c

6. Remove the drum knob [A] and the bearing [B] and install them with thescrew [C] on the new OPC drum. Do not remove the protective sheetfrom the

6.9 ID SENSOR REPLACEMENT 1. Remove the drum unit, then remove the drum [A] from the unit. (SeeDrum Replacement.)NOTE: Cover the drum with the protec

6.10 PICK-OFF PAWL REPLACEMENTNOTE: Cover the drum with the protective sheet after removing it from thedrum unit. This prevents the drum from being ex

6.11 CORONA CURRENT ADJUSTMENTNOTE: The corona current varies with environmental conditions such ashumidity and atmospheric pressure. The corona curre

NOTE: Do steps 4 – 8 before adjusting the transfer corona current,separation corona current or charge wire height: 5. Remove the drum from the dru

10. AC POWER AND DC POWER DISTRIBUTIONWhen this copier is plugged in and the main switch is turned off, ac power issupplied via the ac drive board t

6.11.1CHARGE CORONA CURRENT ADJUSTMENT (SP Mode #9-2 )- Wire Height Adjustment -NOTE: If the OS-A3 test chart gray scale shows an uneven image after t

- Charge Corona Current Adjustment -ADJUSTMENT STANDARD Adjusting VR SP Mode No.DC –400 ± 2 µAVRC #9–2NOTE: Keep the high voltage wire terminal [A] a

6.11.2 GRID VOLTAGE ADJUSTMENT (SP Mode #9-2 )ADJUSTMENT STANDARD Adjusting VR SP Mode No.DC –920 ± 16 VVRG #9–2 1. Set the multimeter range to dc 15

6.11.3 TRANSFER CORONA CURRENT ADJUSTMENT (SP Mode #9-5 )ADJUSTMENT STANDARD Adjusting VR SP Mode No.DC –19.3 ± 0.5 µAVRT #9–5 1. Reinstall the TC/S

6.11.4 SEPARATION CORONA CURRENT ADJUSTMENT (SP Mode #9-8)ADJUSTMENT STANDARD Adjusting VR SP Mode No.AC 41.6 ± 1.3 µAVRD #9–8 1. Reinstall the TC

7. FUSING7.1 EXIT UNIT REMOVAL 1. Remove the copy receiving tray or slide the sorter in the left side if it is in-stalled. 2. Open the exit unit [A]

7.2 FUSING LAMP REPLACEMENT 1. Make sure that the main switch is turned off and the power supply cord isunplugged. 2. Open and remove the front cove

7.3 PRESSURE ROLLER REPLACEMENT 1. Remove the exit unit. (See Exit Unit Removal.) 2. If the duplex tray is installed, remove the turn guide plate [A

- To install - 1. Install the bushings on both the front and rear roller shafts (1 E-ring each). 2. After setting the pressure roller, install the r

7.4 HOT ROLLER REPLACEMENT 1. Remove the exit unit. (See Exit Unit Removal.) 2. Remove the fusing lamp. (See Fusing Lamp Replacement.) 3. If the du

The main dc power supply board converts the 10 volts ac input to +5 voltsand a zero cross signal. There are two 26 volts ac inputs. The dc powersupply

- To install - 1. Set the rear bearing [A] on the rear frame. 2. Insert the rear end of the hot roller shaft through the rear bearing. 3. Place gea

7.5 THERMISTOR AND THERMOFUSE REPLACEMENT 1. Turn off the main switch and unplug the power supply cord. 2. Open the front cover and remove the left

7.6 FUSING PRESSURE ADJUSTMENT<Fusing pressure adjustment combinations>Spring Position SettingA – a If poor fusing occursA – b Factory SettingB

7.7 FUSING EXIT SENSOR REPLACEMENT 1. Turn off the main switch. 2. Open the front cover and exit unit. 3. Remove the following parts:• Left inner c

8. OTHERS8.1 OPERATION PANEL REMOVAL 1. Open the front cover and remove the following covers:• Right and left inner covers• Right Cover• Rear Cover

8.2 OZONE FILTER REPLACEMENT 1. Open the exit unit. 2. Unhook the front and the rear support levers [A]. 3. Replace the ozone filter [B].[A][B]1 De

9. COPY QUALITY ADJUSTMENT- General Information -Image density is affected by the following factors: (1) Light Intensity (2) Bias Voltage (3) Toner D

9.1 LIGHT INTENSITY ADJUSTMENTWhen: Every CallPurpose: To maintain the correct light intensityAdjustmentStandard:Level 2 of the gray scale on the OS-A

9.2 UNEVEN EXPOSURE ADJUSTMENTWhen: The exposure is uneven.Purpose: To maintain even exposure.AdjustmentStandard:The side-to-side variation of the gra

9.3 BIAS VOLTAGE ADJUSTMENTWhen: 1. The image is blurred even though the imagedensity in black solid areas is acceptable. 2. Dirty background. The

10.1 AC POWER DISTRIBUTIONMain(PCB1)Board[24] VA[5] VC[0] GNDCN418-1CN418-3T407T404T403 T401T402CN108-1CN108-2CN107-1CN107-2CN107-3CN107-4CN107-5CN107

9.4 TONER DENSITY ADJUSTMENTWhen: Customer wants to change the overall imagedensity of the copies.Purpose: To change toner concentration insidedevelop

9.7 ID SENSOR (Vsg) ADJUSTMENT (SP MODE #54)When: 1. Check Vsg at every call, and adjust Vsg if it is out of adjustment standard.2. At replacemen

9.8 ADS (Auto Image Density Sensor) ADJUSTMENT When: 1. After light intensity adjustment2. When replacing the following parts: • Main board • AC d

9.9 VERTICAL MAGNIFICATION ADJUSTMENTWhen: The vertical magnification is not within theadjustment standard.Purpose: To maintain proper vertical magnif

9.11 FOCUS ADJUSTMENTWhen: The copy image is out of focus.After adjusting the horizontal magnificationPurpose: To maintain proper focusAdjustmentStand

9.12 ERASE MARGIN ADJUSTMENTWhen: The leading edge erase margin is not within theadjustment standard.Purpose: To maintain the correct leading erase ma

9.14 SIDE-TO-SIDE REGISTRATION ADJUSTMENTWhen: Side-to-side registration is not within theadjustment standard.Purpose: To maintain the proper side-to-

- Side Fence Adjustment (Duplex Unit) - 1. Pull the duplex unit [A] out. 2. Loosen the two screws [B]. 3. Set the side fences to the desired positi

- Lens Position Adjustment - 1. Turn off the main switch and remove the exposure glass. (See ExposureGlass Removal.) 2. Remove the lens housing cove

9.15 4TH/5TH MIRROR HEIGHT ADJUSTMENTWhen: Parallelogram (skewed) image appears.Purpose: To maintain the proper copy imageMeasure: Turn 4th/5th mirror

10.2 DC POWER DISTRIBUTION10VACCN100ON26VAC26VACCN417115V220/240VCN101CN107ToSorter()ToSorter()CN101-5CN102-1CN101-4CN107-4CN103-3ToSorter()CN101-3CN1

SECTION 6 TROUBLESHOOTING

1. COPY QUALITY1.1 BLANK COPY (WHITE COPY)- Phenomenon -White or almost white copy- Possible Causes - 1. Charge is not applied.• CC/G/B bias power pac

- Action - Is the charge and/or TC/SC corona unit correctly installed?Yes NoInstall the charge and/or TC/SC corona unit correctly.Do the charge corona

Does the development roller bias terminal contact the development rollershaft?Yes NoRepair or replace the terminal.Check the following points:• CN112-

1.2 DIRTY BACKGROUND- Phenomenon - 1. Dirty background at image density level 4 (manual setting) 2. When newspapers are copied, the background is di

- Action -Make a copy in reduction mode at manual image density level 4.Is the non-image area dirty?Yes NoIs the optics section dirty?No YesClean the

If the dirty background occurs only in ADS mode, do the following:• If the ADS voltage is not within 2.5 ±0.1 volts standard voltage, readjustthe ADS

1.3 UNEVEN IMAGE DENSITY- Phenomenon -Uneven image density appears on the copies.- Possible Cause - 1. Dirty optics 2. Uneven exposure lamp horizonta

1.4 VERTICAL BLACK BANDS - Phenomenon -Vertical black bands appear on the copy paper.- Possible Causes - 1. Dirty optics 2. Dust between the cleaning

1.5 VERTICAL BLACK LINES - Phenomenon -Thin black lines appear on the copy.- Possible Causes - 1. Scratched cleaning blade 2. Dirty or scratched exp

SECTION 2 SECTIONAL DESCRIPTION

1.6 VERTICAL WHITE LINES OR BANDS—1 (DULL OR BLURRED)- Phenomenon - Dull or blurred white lines appear on the copy.- Possible Causes - 1. Dirty or de

1.7 VERTICAL WHITE LINES OR BANDS—2 (THIN, DISTINET)- Phenomenon - Vertical white lines appear on the copy.- Possible Causes - 1. Paper dust on the e

1.8 HORIZONTAL BLACK/WHITE LINES- Phenomenon - Black/white lines perpendicular to the paper feed direction appear on the copy image.- Possible Causes

1.9 JITTER- Phenomenon -Jitter appears on the copy.- Possible Causes - 1. Vibration in drive mechanism. 2. Scanner not moving smoothly.- Action -Doe

1.10 BLACK SPOTS ON THE COPY IMAGE- Phenomenon - 1. The grid voltage is not applied correctly.• Poor contact between charge corona casing and grid s

1.11 SKEWED (OPTICAL) COPY IMAGE- Phenomenon - The copy image is skewed (parallelogram shape).The sides of the copy image are straight, but the leadin

1.12 TONER DENSITY TOO HIGH- Phenomenon - 1. Dirty background appears on the copy. 2. The image density of black solid areas is too high. 3. Toner

Is the copier in fixed mode?No YesChange the data in SP Mode #30 from "1" to "0".Is the charge corona current correct?Yes NoReadju

1.13 TONER DENSITY TOO LOW- Phenomenon - 1. Light copy 2. Carrier is on the copy. 3. Light spots appear in black solid areas.- Possible Causes - 1

Is the data of SP Mode #30 "1"?No YesChange the data in SP Mode #30 from "1" to "0".Go to AIs the data of SP Mode #33

1. SPECIFICATIONSConfiguration:Desk topCopy Process: Dry electrostatic transfer systemOriginals: Sheet/BookOriginal Size: Maximum A3/11"x17"

1. DRUM1.1 OPC DRUM CHARACTERISTICSAn OPC has the characteristics of: 1. Being able to accept a high negative electrical charge in the dark. (Theelec

1.14 TONER SCATTERING- Phenomenon -Toner scatters from the development unit.- Possible Causes - 1. Toner density is too high. 2. Inlet seal on the d

1.15 UNFUSED COPY IMAGE- Phenomenon -Solid image rubs off easily.- Possible Causes - 1. Fusing pressure is too weak. 2. Fusing temperature is too lo

1.16 PAPER MISFEED- Phenomenon - 1. Misfeed location indicator turns on when the main switch is turned oneven if there is no paper in the copier. 2.

1.17 DF ORIGINAL MISFEED OR SKEW- Phenomenon -When the DF is in use, the original stops on the exposure glass or is skewedeven if the electrical compo

2. SERVICE CALL CONDITION2.1 CODE #11 — EXPOSURE LAMP ERROR- Definition -• The feedback signal becomes higher than 4.2 volts (r.m.s.) for 1.0 sec-ond

No OpenDo the cooling fans turn on?Yes NoCheck the voltage at CN103-1 and CN104-1 on the mainboard.0V 24VReplace the main board.Replace the cooling fa

2.2 CODE #12 — EXPOSURE LAMP ERROR- Definition -• The feedback signal falls below 0.5 volt (r.m.s.) for 1.0 second when theexposure lamp is on.• The e

2.3 CODE #13 — ZERO CROSS SIGNAL ERROR- Definition -The CPU does not receive the zero cross signal within 0.56 second.- Possible Causes -• Main board

2.4 CODE #21 — SCANNER HOME POSITION ERROR- Definition -The scanner home position sensor remains off (LOW) 8 seconds after themain switch is turned on

31V 34VReplace the main boardReplace the scanner motor.Check the continuity between CN806-2 and 3 on the scanner home posi-tion sensor.Not ContinuousC

1.2 DRUM UNITAn organic photoconductor drum [A] is used on this model.A drum unit [B] is used to hold the drum to prevent stress on the drum. Thedrum

2.5 CODE #22 — SCANNER HOME POSITION ERROR- Definition -The scanner home position sensor remains on (HIGH) 1.0 second after thescanner starts.- Possib

29V 34VReplace the main board.Replace the scanner motor.Check whether the scanner home position sensor circuit is open.Not OpenopenReplace the sensor.

2.6 CODE #28 — LENS HOME POSITION ERROR- Definition -The lens home position sensor remains off (LOW) 3.5 seconds after the lensmoves to the home posit

Check the continuity between CN824-2 and 3 on the lens home positionsensor.Not ContinuousContinuousReplace the sensor.Replace the main board.1 Decemb

2.7 CODE #29 — LENS HOME POSITION ERROR- Definition -The lens home position sensor is still on (HIGH) 3.5 seconds after the lensleaves the home positi

Check whether the lens home position sensor is open.Not OpenOpenReplace the sensor.Replace the main board.1 December 19906-35

2.8 CODE #2A — 4TH/5TH MIRROR HOME POSITION ERROR- Definition -The 4th/5th mirror home position sensor is still off (LOW) 2.5 seconds afterthe 4th/5th

Check the continuity between CN826-2 and 3 on the 4th/5th mirror homeposition sensor.Not ContinuousCountinuousReplace the sensor.Replace the main boa

2.9 CODE #2B — 4TH/5TH MIRROR HOME POSITION ERROR- Definition -The 4th/5th mirror home position sensor is still on (HIGH) 2.5 seconds afterthe 4th/5th

Check whether the 4th/5th mirror home position sensor is open.No OpenReplace the sensor.Replace the main board.1 December 19906-39

1.3 HANDLING THE DRUMThe organic photoconductor drum is comparatively more sensitive to lightand ammonia gas than a selenium drum. 1. Never expose th

2.10 CODE #52 — FUSING WARM-UP ERROR- Definition -The temperature detected by the thermistor does not reach 175oC within 100seconds after the main swi

Check the voltage at CN122-9 on the main board.0V 24VReplace the main board.Check the voltage at CN122-14 on the main board.24V 0VReplace the main boa

2.11 CODE #53 — FUSING OVERHEAT- Definition -The thermistor detects a temperature higher than 240oC.- Possible Causes -• Thermistor short• AC drive bo

2.12 CODE #55 — FUSING THERMISTOR OPEN- Definition -The thermistor does not detect 2oC within 30 seconds after the main switch isturned on.- Possible

Check the voltage at CN122-12 on the main board.0V 24VReplace the main board.Check the voltage at CN122-9 on the main board.0V 24VReplace the main boa

2.13 E70 (IN THE MAGNIFICATION INDICATOR) — TONER OVERFLOW SENSOR ON- Definition -Toner overflow sensor turns on- Possible Causes -• Toner overflow•

2.14 CODE #80 — DUPLEX AND COPIER BOARD COMMUNICATION ERROR- Definition -The copier main board does not receive any signal from the duplex mainboar

Check the voltage at CN101-4 on the optional dc power supply unit.24V 0VReplace the optional dc power supply unit.Check the voltage at CN205-4 on the

2.15 CODE #81 — INTERFACE BOARD ERROR- Definition -The interface board is not connected when the duplex unit is installed.- Possible Causes -• Interfa

2.16 CODE #82 — JOGGER HOME POSITION ERROR- Definition -The output of the jogger home position sensor stays LOW while the duplexmain board is driving

2. DRUM CHARGE2.1 OVERVIEWThis copier uses a single wire scorotron and a highly sensitive OPC drum [A].The corona wire [B] generates a corona of negat

2.17 CODE #83 — JOGGER HOME POSITION ERROR- Definition -The output of the jogger home position sensor remains HIGH as the duplexmain board is driving

2.18 ABNORMAL CONDITION IN TONER DENSITY DETECTION- Phenomenon -The Auto ID indicator or the selected manual ID level blinks. (No SC Code isindicated.

Is the Vsg less than 2.5V when checking TP110 on the main board by SPmode #54.No YesReadjust the Vsg to 4.0 0.2 volts.Check whether the ID sensor ha

3. ELECTRICAL COMPONENT DEFECTS3.1 SENSORComponent Condition SymptomScanner HomePosition Sensor(S1)OPEN(CN122-4 stays HIGH)SC code (E22) is displayed.

Paper Lift Sensor(S10)OPEN(CN125-2 stays HIGH)User Code #5 is displayed.SHORTED(CN125-2 stays LOW)The cassette bottom plate does notrise to the paper

3.2 SWITCH OR OTHER ELECTRICAL COMPONENTComponent Condition SymptomMain Switch(SW1)OPEN The copier does not turns on.SHORTED The copier does not turns

3.3 FUSEComponent Condition SymptomFU401(AC Drive Board)OPEN The copier does not turn on when themain switch is turned on.FU100 (5V)(Main DC PSU)OPEN

SECTION 8DOCUMENT FEEDER

1. SPECIFICATIONSOriginal Size and Weight: — Thin original mode — Maximum A3 / 11" x 17" Minimum B6 / 51/2" x 81/2" Weight 41

2. COMPONENT LAYOUT- Mechanical Components - 1. Pulse Generator Disk 6. Inverter Pawl 2. Friction Belt 7. Inverter Roller 3. Pick-up Lever

2.2 CHARGE CORONA WIRE CLEANER MECHANISMPads [A] above and below the charge corona wire clean the wire as thecharge unit is manually slid in and out.T

3. ELECTRICAL COMPONENT DESCRIPTIONSSymbol Name Function LocationMotorsM1 Belt Drive Motor DC servomotor that drives to the transportbelt and feed-in

4. OVERALL MACHINE CONTROLThe DF CPU monitors the input signals from the sensors and switches, andenergizes the solenoids and the indicator LEDs direc

1. DF → CopierNo. Signal Name Definition1 Original Set Originals are set on the original table2 Copy Start Allows the copier to start copy sequence3

5. BASIC OPERATION1. One-sided Original FeedWhen an original is inserted face up into the DF, the Insert Original indicatorlight goes out and the DF i

2. Two-sided Original FeedUnlike one-sided original feed, the back side of the original must be copiedfirst to keep the originals and copies in the co

6. POWER DISTRIBUTION The DF uses three DC power levels: +24 volts, +12 V, and +5 V.When the main switch is turned on, the optional transformer receiv

7. INTERFACE CIRCUITThe copier CPU and the DF CPU communicate via the interface board andfiber optics. The interface board changes the optical signals

8. ORIGINAL FEED8.1 ORIGINAL PICK-UPAfter setting the originals on the original table, the originals contact the feeler[A] of the original set sensor

8.2 ORIGINAL SEPARATION The feed roller [A] and the friction belt [B] are used to feed-in and separatethe originals [C]. Only the bottom original is

8.3 ORIGINAL FEED-IN MECHANISMThe belt drive motor [A] drives the pick-up roller [B], the feed roller [C], thepull out roller [D], the relay roller [E

2.3 CHARGE CORONA CIRCUITThe main board supplies +24 volts to the CC/Grid/Bias power pack at CN1-1as the power supply source. About 0.44 seconds after

This document feeder has two different ways of stopping originals at thecorrect position on the exposure glass. They are called the "thin origina

8.4 ORIGINAL SIZE DETECTIONThe DF determines original size (both width and length) through the use ofthe original width sensor [A], registration senso

8.5 ORIGINAL INVERSION MECHANISMThe two sided originals are inverted in the feed-out unit. 1) When the copier Start key is pressed, the two sided ori

2) The original passes over the exposure glass and feeds into the feed-outunit. 3) The original is directed onto the exposure glass again by the i

8.6 ORIGINAL FEED-OUT MECHANISMThe exit rollers [A] are driven by the inverter motor [B]. When the documentfeeder receives the feed out signal from t

8.7 BELT DRIVE MOTOR CIRCUIT A dc servomotor is used as the belt drive motor. The driver IC controls thespeed of the belt drive motor. The CPU sends

8.8 FEED-OUT MOTOR CIRCUIT The DF CPU sends the speed data (high or low) to the driver IC and themotor drive circuit. The motor drive circuit creates

8.9 INPUT AND OUTPUT CIRCUITS The above devices are directly controlled and monitored by the CPU. Thesolenoids and indicator panel are energized with

9. LIFT MECHANISMWhen the document feeder is opened, the lift springs [D] provide enoughforce to ensure that the document feeder does not fall onto th

10. ORIGINAL MISFEED DETECTIONThe registration sensor and the feed-out sensor are used for misfeed checks.1. One sided original If the registration se

2.4 GRID VOLTAGE CORRECTIONThere are two grid voltage correction factors. These correct for increases inthe drum residual voltage (Vr). The first such

2. Two sided original The registration ON/OFF check is the same as for one-sided originals. Theinverter motor and the inverter solenoid turn on 100 mi

11. INSTALLATION PROCEDURE (for Machine Code: A048)11.1 ACCESSORY CHECKCheck the quantity and condition of the accessories in the box according toth

11.2 INSTALLATION PROCEDURE 1. Install the dc power supply unit. 2. Remove the following parts from the copier:1) Platen cover [A] (2 push-locks)2)

4. Secure the DF mounting bracket [A] (4 screws). 5. Adjust the height of the DF mounting bracket as explained below:1) Set the E plate [B] on

7. Mount the DF on the DF mounting bracket so that the holes in the DF arealigned with the pins on the mounting bracket, then slide the DF to the

13. Connect the optic cable connector (2P/Black) [A] to CN206 on the inter-face board.14. Connect the dc harness (4P/White) [B] to the optional harn

18. Adjust the height of the magnet catches as follows:1) Remove the grip cover [A] (3 screws).2) Loosen the screws of the magnet catches [B] (2 scr

5) Make a copy of the test sheet in DF two-sided original mode.NOTE: 1. The test sheet must be set facedown.2. The original select switch can be set a

12. PREPARATION FOR TRANSPORTATIONCAUTION: Before moving the document feeder, be sure to prepare it fortransportation as follows. The document feeder

13. REPLACEMENT AND ADJUSTMENT13.1 FEED-IN UNIT13.1.1 Transport Belt Replacement 1. Turn off the main switch and remove the grip [A] (3 screws). 2.

3. ID sensor pattern areaGrid Voltage = –620 volts+ Vp Correction FactorDrum CounterVp Correction FactorBlack Color0 to 999 (copies)1,000 to 1,999

4. Remove the 2 tension springs [A] and pull off the transport belt [B].NOTE: a) When installing the transport belt, make sure the belt lies between

13.1.2 Feed-in Unit Removal 1. Turn off the main switch. 2. Remove the transport belt assembly. (See Transport Belt Replacement.) 3. Remove the bel

13.1.3 Pick-up Roller Replacement* 1. Turn off the main switch. 2. Remove the feed-in unit. (See Feed-in Unit Removal.) 3. Remove the lower entrance

13.1.4 Feed-in Clutch Lubrication 1. Turn off the main switch. 2. Remove the original set sensor assembly. (See Pick-up Roller Replace-ment.) 3. Rem

13.1.5 Pick-up Solenoid Adjustment 1. Turn off the main switch. 2. Place several sheets of paper [A] over the exposure glass area. 3. Lower the feed

5. Turn off DPS101-1 and 2, then turn on DPS101-3 and 4 [B]. 6. Loosen the screw fixing the pick-up solenoid [C]. 7. Place the 0.15 mm thickness g

13.1.6 Feed Roller Replacement - 1. Turn off the main switch. 2. Remove the lower entrance guide. (See Pick-up Roller Replacement.) 3. Loosen the fr

13.1.7 Feed-in Solenoid Adjustment 1. Turn off the main switch. 2. Place several sheets of paper [A] over the exposure glass area. 3. Lower the feed

13.1.8 Friction Belt Replacement 1. Turn off the main switch. 2. Remove the seal cover [A] on top of the DF cover. 3. Remove the friction belt assem

13.2 FEED-OUT UNIT13.2.1 Feed-out Unit Removal 1. Turn off the main switch. 2. Remove the DF grip [A] (3 screws). 3. Remove the feed-out motor cover

3. OPTICS3.1 OVERVIEWDuring the copy cycle, an image of the original is reflected onto the drumsurface through the optics assembly as follows.Light Pa

13.2.2 Inverter Solenoid Adjustment 1. Turn off the main switch. 2. Place several sheets of paper [A] over the exposure glass area. 3. Lower the f

13.2.3 DF Leading Edge Registration Adjustment 1. Using the DF test chart, make a copy in the platen cover mode (A4 width). 2. Confirm that the or

4. If the difference is more than 2.5 mm, remove the DF main PCB cover (1screw) and adjust VR102 on the DF main PCB until the leading edge reg-istra

13.3 BELT DRIVE MOTOR SPEED ADJUSTMENTNOTE: The belt drive speed adjustment is required when the main board isreplaced. 1. Turn off the main switch.

SECTION 9 SORTER

1. SPECIFICATIONSNumber of Bins: 10 binsPaper Size for Bins: Maximum A3, 11" x 17"Minimum A6, 51/2" x 81/2"(Lengthwise)Paper Weig

2. COMPONENT LAYOUT— Mechanical Components —1234561. Bin2. Transfer Wheel 3. Exit Roller4. Upper Paper Guide5. Lower Paper Guide 6. Bin Guide1234675—

3. ELECTRICAL COMPONENT DESCRIPTIONSSymbol Name Function LocationMotorsM1 Roller Drive Motor DC motor that energizes to drive the lowerexit rollers.

4. OVERALL MACHINE CONTROLThe main DC power supply board provides +24 volts (VA) and +5 volts (VC)to the sorter main board. +24 volts powers the rolle

5. BASIC OPERATION- Clear Mode -When the main switch of the copier is turned on, the sorter automaticallyassumes the clear mode. In this mode, all cop

3.2 SCANNER DRIVE3.2.1 1st and 2nd Scanner Drive MechanismThis model uses a stepping motor [A] to drive the scanners. Both ends ofeach scanner are dri

6. EXIT ROLLER DRIVE6.1 ROLLER DRIVE MECHANISMF: Transfer WheelG: Bin Drive BeltH: Bin Drive Pulley I: Exit Roller PulleyJ: Upper Paper GuideK: Lower

6.2 ROLLER DRIVE CIRCUITTo turn on the roller drive motor, the interface board sends a drive signal tothe drive IC on the sorter main board. After rec

7. BIN DRIVE7.1 BIN DRIVE MECHANISMG : Exit RollerH : Upper Paper Guide I : Lower Paper GuideThe bin drive mechanism moves thebins up and dow

The home position switch [E] informsthe CPU when all the bins arelowered.To move the bins up, the bin drivemotor turns clockwise (as viewedfrom the fr

7.2 BIN DRIVE CIRCUITTo turn on the bin drive motor, the interface board sends drive signals to thedrive IC on the sorter main board. After receiving

8. MISFEED DETECTIONIn addition to being used for the exit roller and bin drive timing, the papersensor checks for a misfeed in the sorter. The copier

9. INSTALLATION PROCEDURE9.1 ACCESSORY CHECKCheck the quantity and condition of the accessories in the box according tothe following list:1. Magnet Ca

9.2 INSTALLATION PROCEDURE NOTE: Do not grasp the sorter by the top cover and stay as shown by [A].Hold both sides of the sorter as shown by [B]. Th

6. Install the sorter holder bracket [A] (3 screws) so that the two holes [B] onthe bracket align with the holes [C] on the copier frame as shown

12. Connect the sorter dc harness [A] (10P/Brown) to the optional harnessconnector [B]; then, connect the optional harness connector [C] to CN203on t

Automatic Reset: 1 minute standard setting; can also be set to 3minutes or no auto reset.Paper Capacity: Cassettes: 500 sheetsPaper tray: 250 sheetsMa

3.3 LENS DRIVE3.3.1 Lens DriveThe lens motor [A] (stepper motor) changes the lens [B] position through thelens drive wire [C] in accordance with the s

10. PREPARATION FOR TRANSPORTATIONCAUTION: When removing and transporting the sorter, be careful not tocarry it in a vertical position as the bins wil

11. ROLLER DRIVE BELT REPLACEMENT 1. Remove the front covers [A] (5 screws) and rear cover [B] (2 screws). 2. Lift off the top cover [C] and remove

12. BIN GUIDE LUBRICATION 1. Remove the lower paper guide. (See Roller Drive Belt Replacement sec-tion.) 2. Remove all bins [A] from the bin guides

SECTION 10 DUPLEX

1. SPECIFICATIONSCopy Paper Size: A4 and B5/8 1/2" x 11" (sideways)Paper Weight: 59 to 104 g/m2 (16 to 27 lb)Paper Stack: 50 sheetsDimension

2. COMPONENT LAYOUT— Mechanical Components — 1. Duplex Gate Roller 7. Paper Flattener 2. Duplex Gate 8. Duplex Feed Roller 3. Turn Guide Plate

3. ELECTRICAL COMPONENT DESCRIPTIONSYMBOL NAME FUNCTION INDEXNO.MotorsM1 Duplex Feed Mo-torStepper motor (24 Vdc) drives feed rollerand moves the bott

4. POWER DISTRIBUTION AND OVERALL MACHINE CONTROLWhen the main switch is turned on, the optional transformer receives walloutlet ac power through

5. BASIC OPERATION5.1 FIRST SIDE COPYWhen the registration clutch turns on, the duplex gate [A] rotates up to directthe copy to the duplex unit. The e

6. DRIVE MECHANISMDrive is transmitted from the duplex feed motor [A] to the duplex feed rollers[B] and the entrance rollers [C] through a series of g

3.3.3 Lens PositioningThe lens home position sensor [A] informs the main board when the lens is atfull size position (home position). The main board d

7. FIRST SIDE COPY7.1 FROM COPIER PAPER FEED SECTION TO DUPLEX ENTRANCE ROLLERWhen the copier 1st paper feed clutch turns on, the jogger motor turns

7.2 FROM DUPLEX ENTRANCE ROLLER TO DUPLEX TRAY300 milliseconds after the duplex gate solenoid energizes, the duplex paperfeed motor [A] starts turning

7.3 DUPLEX STACKING2,150 milliseconds after the duplex turn sensor is actuated by the leadingedge of the copy, the jogger motor [A] rotates to drive t

8. SECOND SIDE COPY2,350 milliseconds after the duplex turn sensor is actuated by the leadingedge of the final copy in the first side copy run, the du

9. DUPLEX PAPER FEED AND MISFEED DETECTION TIMINGThe duplex entrance sensor and the duplex turn sensor monitor themovement of the paper through the

10. SERVICE CALL CONDITIONSService Code 80: Duplex and Copier Main Board Communication Error The copier main board does not receive any signal from

11. DUPLEX UNIT INSTALLATION11.1 ACCESSORY CHECKCheck the quantity and condition of the accessories in the box according tothe following list:1. Turn

11.2 INSTALLATION PROCEDURE 1. Turn off the main switch and unplug the copier power supply cord. 2. Install the dc power supply unit. 3. Remove

6. Remove the exit paper guide [A] (1 screw), and remove the stubs [B] withnippers and reinstall the exit paper guide. 7. Remove the upper pap

10. While pushing up the duplex gate lever [A], install the turn guide plate [B](2 screws).11. Reinstall the exit unit (2 screws).12. Remove the pa

3.4 4TH AND 5TH MIRROR DRIVE3.4.1 DriveThe 4th/5th mirror drive motor (stepper motor) changes the 4th/5th mirrorassembly position through the pinion g

15. Remove the duplex connector cover plate [A] (2 screws).NOTE: The cover plate can be thrown away.16. Secure the optional harness duplex connecto

19. Connect the optional harness connector (4P/Black) [A] to CN205 on the in-terface board [B].20. Connect the dc harness (4P/White) [C] to CN101 on

12. REPLACEMENT AND ADJUSTMENT12.1 DUPLEX TRAY REMOVAL 1. Pull the duplex tray [A] out from the copier. 2. Remove the side inner cover [B] (3 screws

- Installation - 1. When placing the duplex unit back into the tray, hold up the bottom plate[A] so that the mylar brackets [B] fit under it as shown

12.2 JOGGER MOTOR AND JOGGER HOME POSITIONSENSOR REPLACEMENT 1. Remove the duplex tray. 2. Remove the front and side inner covers.- Jogger Motor Rep

12.3 TURN SENSOR REPLACEMENT 1. Remove the duplex tray. 2. Raise the upper and lower paper guides [A] all the way up. 3. Disconnect the turn sensor

12.4 FEED MOTOR REPLACEMENT 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Remove the paper feed motor bracket [A] (2 screws

12.5 PAPER END SENSOR REPLACEMENT 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Remove the paper end sensor bracket [A] (1

12.6 ENTRANCE SENSOR REPLACEMENT 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Turn over the duplex unit as shown. 3. Remo

12.7 GATE SOLENOID REPLACEMENT 1.Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Replace the gate solenoid [A] (1 screw).NOTE: W

3.5 STEPPER MOTOR CONTROL CIRCUITThe scanner motor, the lens motor, and the 4th/5th mirror motor are allstepper motors. The scanner motor operates on

12.8 FRICTION ROLLER REPLACEMENT 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Turn over the duplex unit as shown. 3. Unho

12.9 FEED ROLLER REPLACEMENT 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Remove the feed motor. (See Feed Motor Replaceme

POINTS OF MODEL E TYPE 1 SERVICEABILITY 1. Access to service program mode operation• There are two ways to access an SP mode.(1) By key operation(2)

SECTION 11FT4421 SERVICE MANUALIn this section, the FT4418 is referred to as the A048 copier, and theFT4421 is referred to as the A054 Copier.

1. SPECIFICATIONSConfiguration: Desk topCopy Process: Dry electrostatic transfer systemOriginals: Sheet/BookOriginal Size: Maximum A3/11"x17"

Automatic Reset: 1 minute standard setting; can also be set to 3minutes or no auto reset.Paper Capacity: Cassette: 500 sheetsPaper tray: 250 sheetsMan

2. OPERATION PANEL— A4/A3 Version — — LT/LDG Version — Section A: See page 11-4.Section B: See page 1-5 or 1-6.Section C: See page 1-7 or 1-8.C B ABCA

Section A — — A4/A3 Version —1. Number Keys The number keys are used to enter the desired number of copies. They are also used to inp

3. FUNCTIONAL OPERATION1 December 199011-5

4. MECHANICAL COMPONENT LAYOUT 1. Third Mirror 2. Second Mirror 3. First Mirror 4. Exposure Lamp 5. Ozone Filter 6. Cleaning Unit 7. Lens 8. Quen

The lens motor and the 4th/5th mirror motor move at a constant speed, butthe scanner motor speed varies according to the reproduction ratio. The CPUch

5. DRIVE LAYOUTG1: Main Motor Gear G20: Relay GearG2: Relay Gear G18: Relay Gear G21: Cleaning Drive Cleaing UnitG3: Timing Belt Drive Gear G19: Drum

APaper Feed SectionBP3: Timing Belt PulleyG11: Registration CL Gear G4: Relay Gear G12: Relay Roller CL GearRegistration CL G5: Relay Gear Re

6. ELECTRICAL COMPONENT LAYOUT 1. Scanner H.P. Sensor 2. Scanner Motor 3. Main Motor 4. Development CL Sol. 5. Toner Supply CL Sol. 6. Toner End

37. 4th/5th Mirror H.P. Sensor38. Optics Cooling Fan Motors39. Original Length Sensor40. Platen Cover Closed SW41. Operation Panel Board42. Optics Th

7. ELECTRICAL COMPONENT DESCRIPTIONSSYMBOL NAME FUNCTION INDEXNO.MotorsM1 Main Motor Drives all the main unit components exceptfor the optics u

SYMBOL NAME FUNCTION INDEXNO.SOL9 3rd Paper FeedClutch SolenoidStarts paper feed from the 3rd paperstation.64SOL10 Lower Tray LockSolenoidLocks

SYMBOL NAME FUNCTION INDEXNO.S3 4th/5th MirrorHome PositionSensorInforms the CPU when the 3rd scanner(4th/5th mirrors assembly) is at the homep

SYMBOL NAME FUNCTION INDEXNO.PCB5 Option DCPower SupplyBoardRectifies 26 and 10 Vac input and outputsdc voltasges.49PCB6 Interface Board Interf

SYMBOL NAME FUNCTION INDEXNO.OthersTH Fusing ThermistorMonitors the fusing temperature. 31TF Fusing ThermofuseProvides back-up overheat protect

8. OVERALL MACHINE CONTROLThe above diagram shows the control system of this copier in block form. TheCPU (IC123) on the main board controls the timin

3.6 AUTOMATIC IMAGE DENSITY DETECTIONLight from the exposure lamp is reflected from the original and travels to thelens [A] via the mirrors. The auto

9. AC POWER AND DC POWER DISTRIBUTIONWhen this copier is plugged in and the main switch is turned off, ac power issupplied via the ac drive board to t

The main dc power supply board converts the 10 volts ac input to +5 voltsand a zero cross signal. There are two 26 volts ac inputs. The dc powersupply

9.1 AC POWER DISTRIBUTIONMain(PCB1)Board[24] VA[5] VC[0] GNDCN417-3CN417-1T407T404T403 T401T402CN108-1CN108-2CN107-1CN107-2CN107-3CN107-4CN107-5CN107-

9.2 DC POWER DISTRIBUTIONCN417-1DC Power Supply BoardMain BoardCN101-6 CN107-6D100ONST100 R100Q100+C100+C101D102IC100R101R102C103 C104D103C112R103R104

10. ORIGINAL SIZE DETECTION IN PLATEN MODEAn original width sensor [A] and an original length sensor [B] are under theexposure glass [C]. The origina

The second check is done when the platen cover closed switch [E] turns on.This is when the platen cover (document feeder) is completely closed. Thepla

11. PAPER FEED AND MISFEED DETECTION TIMING1500 2000 2500 3000 3500 40000 100400ms1750 1750 17501877 18772273 (A4S) 2273 (A4S) 1877 2273 (A4S)2285 (L

The registration sensor, the exit sensor and the relay sensor monitor themovement of the paper through the paper path. If the CPU determines that amis

12. DOCUMENT FEEDER (Machine Code: A318)12.1 SPECIFICATIONSOriginal Size and Weight: — Thin original mode — Maximum A3 / 11" x 17" Minimum

12.2 COMPONENT LAYOUT- Electrical Components -12345678910- Mechanical Components - 1. Pulse Generator Disk 6. Inverter Pawl 2. Friction Belt 7.

3.7 EXPOSURE LAMP VOLTAGE CONTROLThe main board controls the exposure lamp voltage through the ac driveboard. The exposure lamp voltage is based on th

12.3 ELECTRICAL COMPONENT DESCRIPTIONSSymbol Name Function LocationMotorsM1 Belt Drive Motor DC servomotor that drives to the transportbelt and fe

12.4 POWER DISTRIBUTIONThe DF uses three DC power levels: +24 volts, +12 volts, and +5 volts.When the main switch is turned on, the main transformer r

13. DUPLEX UNIT POWER DISTRIBUTION AND OVERALL MACHINE CONTROLWhen the main switch is turned on, the main transformer receives wall outletac power

14. INSTALLATION14.1 INSTALLATION REQUIREMENTS14.1.1 Environment 1. Temperature Range: 10oC to 30oC (50oF to 86oF) 2. Humidity Range: 15% to 90% RH

14.1.2 Machine Level 1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of levelPlace the machine on a tab

14.1.4 Power Requirements 1. Input voltage level:110V/60Hz : More than 15A (for Taiwan)115V/60Hz : More than 15A (for N.A.)220V/50Hz : More than 8A (f

14.2 INSTALLATION PROCEDURE14.2.1 Introduction:This section covers only those parts of the copier and option installationprocedures that differ from t

14.2.2 Copier Installation 1. Remove 11 strips of tape [A] from the copier. 2. Open the front cover [B], and remove 2 strips of tape [C]. 3. Pull o

14.3 DOCUMENT FEEDER INSTALLATION14.3.1 Accessory CheckA DF position sensor actuator and a screw have been added as accessoriesfor the APS function in

14.3.2 Installation Procedure 1. Remove the following parts from the copier:1) Platen Cover [A] (2 push-locks)2) Platen Cover Pedestal [B] (4 screws)

The exposure lamp voltage consists of the following 3 factors:Exposure lamp voltage = Base lamp voltage factor +Reproduction ratio correction factor

5. Do steps 4 to 10 of the installation procedure for the A048 copier (page8-26 to 27). 6. Install the DF position sensor actuator [A] (1 screw).

14.4 SORTER INSTALLATIONNOTE: Refer to the list on page 9-12 to check the accessories. 1. Do steps 1 to 11 of the installation procedure for the A048

15. 3RD PAPER FEED CLUTCH SOLENOID REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover (7 screws). 3. Unhook the spring [A] from

DOCUMENT FEEDER ELECTRICAL COMPONENTS AND CONNECTORS LAYOUTDocument Feeder Electrical ComponentsIndex No.Description Symbol P to P 1 2 3 4 5 6 7 8 910

Document Feeder ConnectorsIndex No.CN No. Component Symbol Type P to P 1 2 3 4 5 6 7 8 91011121314151617181920212223CN118CN200CN119CN111CN104CN103CN10

363534333231302928272625242322 212019181716151413121110987654321

67686971707372666564636156625560595458525751535049484746454443424140383739

Copier Electrical ComponentsIndex No.Description Symbol P to P 1 2 3 4 5 6 7 8 910111213141516171819202122232425262728293031323334353637383940Scanner

Index No.Description Symbol P to P414243444546474849505152535455565758596061626364656667686970717273Operation Panel BoardOptics ThermoswitchExposure L

1234567891011 121314 15 16 18171920212224252627282931343032333523363741403839Main Board(PCB1)Interface Board(PCB6)42434445 46

3.7.3 Reproduction Ratio Correction FactorFor the reduction and enlargement reproduction ratios the light path is longerthan for the full size reprodu

4748495150525453555657585960616263646566676869707172739089888786858482818078777675748379969594939192

122121120119118117116115114113112111110109108107106105104103102101100999798123124125126127129130131132133134135136137128

Copier ConnectorsIndex No.CN No. Component Symbol Type P to P 1 2 3 4 5 6 7 8 910111213141516171819202122232425262728293031323334353637383940414243444

Index No.CN No. Component Symbol Type P to P51525354555657585960616263646566676869707172737475767778798081828384858687888990919293949596979899100TBCN1

Index No.CN No. Component Symbol Type P to P1011021031041051061071081091101111121131141151161171181191201211221231241251261271281291301311321331341351

CS110 (A490)

1PARTS CATALOGINTRODUCTIONThis chapter instructs you the numbers and names of these parts on this machine.INDEX to PARTS CATALOG1. EXTERIOR (A490) ...

21. EXTERIOR (A490)December 1, '90

31. EXTERIOR (A490)1 A490 5610 Interface Harness 12 6801 5510 Sorter Main Board 13 A467 6161 Lower Cover 14 6802 5961 Strain Relief Plate 15 A490 3005

42. TRANSPORT (A490)December 1, '90

3.7.4 Drum Wear Correction FactorTo compensate for OPC drum wear caused by contact with the cleaningbrush, the exposure lamp voltage is increased at s

51 6802 5720 Grounding Wire 22 6802 5703 Grounding Wire 13 6802 2032 Antistatic Brush Angle 14 A490 2014 Antistatic Brush - Upper Guide 15 6801 2021 U

63. SORTER MAIN BOARD (A490)December 1, '90

7* 6801 5510 Sorter Mian Board 13. SORTER MAIN BOARD (A490)December 1, '90Q'ty perAssemblyIndexNo.Q'ty perAssemblyIndexNo.DescriptionPa

84. SORTER MAIN HARNESS (A490)December 1, '90

9* 6801 5600 Sorter Main Harness 14. SORTER MAIN HARNESS (A490)December 1, '90Q'ty perAssemblyIndexNo.Q'ty perAssemblyIndexNo.Descripti

105. DECAL AND DOCUMENT (A490)December 1, '90

111 A490 7802 Misfeed Removal Decal 12 A490 7803 Arrow Decal 15. DECAL AND DOCUMENT (A490)December 1, '90Q'ty perAssemblyIndexNo.Q'ty p

PARTS INDEX

13Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '90A490 1011 Sorter Frame 3- 28A490 1011 Sorter Frame 5-

14Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '90Part No.DescriptionDescriptionPaper andIndex No.Paper

2. OPERATION PANEL— A4/A3 Version — — LT/LDG Version — Section A: See page 1-4.Section B: See page 1-5 or 1-6.Section C: See page 1-7 or 1-8.BCAC B A1

3.8 EXPOSURE LAMP CONTROL CIRCUITThe main board sends lamp trigger pulses to the ac drive board fromCN122-10. PC401 activates TRC401, which provides a

15Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '901103 1690 Connector - 10P 7-1021103 1732 Connector - 1

DF57 (A318)

1PARTS CATALOGINTRODUCTIONThis chapter instructs you the numbers and names of these parts on this machine.INDEX to PARTS CATALOG1. EXTERIOR AND TRANSP

21. EXTERIOR AND TRANSPORT SECTION (A318)December 1, '90

31. EXTERIOR AND TRANSPORT SECTION (A318)December 1, '901 A465 1337 Decal - Original Table - LT 11 A465 1338 Decal - Original Table - A4 12 A422

4100 0314 0060W Philips Pan Head Screw - M4x6101 0353 0050W Tapping Screw - M3x5102 0413 0082W Tapping Screw - M3x8103 0951 4005W Philips Screw With F

52. FEED IN SECTION (A318)December 1, '90

61 A497 1077 Mylar - 18x306 13 A465 1057 Pull-out Bracket 14 5413 3903 Pin - Transfer Guide Plate 15 A422 1086 Pull-out Spring 26 A422 1063 Seal - 0.7

772 A422 1069 Friction Roller 173 A422 1295 Set Sensor Actuator 174 A422 1176 Set Sensor Actuator Bracket 175 A422 1390 Entrance Seal 176 A465 5260 In

83. INVERTOR AND EXIT SECTION (A318)December 1, '90

3.9 SERVICE CALL CONDITIONSService Code 11: Exposure Lamp ErrorThe feedback signal becomes higher than 4.2 volts (r.m.s.) for 1.0 second when the expo

91 A465 1499 Right Hinge 12 A422 1121 Right Bracket - Right Hinge 13 A422 1120 Left Bracket - Right Hinge 14 A465 1393 Left Hinge 15 A318 1119 Left Hi

10100 0951 4006W Philips Screw With Flat Washer - M4x6101 0801 1185 Philips Truss Head Screw - M4x8102 0314 0060M Philips Pan Head Screw - M4x6103 031

114. MAIN BOARD (A318)December 1, '90

12* A465 5190 DF Main Board 11 A422 5350 IC - HCTL-3 12 A465 5180 IC - D27128A-2 13 A465 5210 Fiber Connector - 2P 14 5936 5221 Heat Sink 1101 1005 08

13137 1601 8147 Variable Resistor - 10k Ohm 0.5W138 1601 8148 Variable Resistor - 20k Ohm 0.5W139 1602 0953 Coil - 800uH 2.5A140 1604 1358 Capacitor -

145. INDICATION BOARD (A318)December 1, '90

15* A465 5260 Indication Board 1 101 1100 1306 Terminal102 1100 1328 Contact103 1102 1805 Connector - 4P104 1102 1967 Connector - 6P105 1403 0236 L.E.

166. MAIN HARNESS (A318)December 1, '90

17* A318 5220 Main Harness 1December 1, '90Q'ty perAssemblyIndexNo.Q'ty perAssemblyIndexNo.DescriptionPart No.DescriptionPart No.101 11

187. INTERFACE HARNESS (A318)December 1, '90

4. ERASE4.1 OVERVIEWLE: Lead edge erase margin 2.5 ±1.5 mmSE: Side erase margin 2.0 ±2.0 mm on each side; total of both sides 4 mm or lessLO: Origin

19* A318 5205 Interface Harness 17. INTERFACE HARNESS (A318)December 1, '90Q'ty perAssemblyIndexNo.Q'ty perAssemblyIndexNo.DescriptionP

PARTS INDEX

21Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '90A318 1021 Side Plate 5- 63A318 1090 Side Roller 5- 46A

22Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '90Part No.DescriptionDescriptionPaper andIndex No.Paper

23Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '90A422 1385 Original Exit Guide 3- 14A422 1390 Entrance

24Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '90A465 2031 Decal - Set 3- 64A465 2050 Misfeed Removal D

25Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '900313 0040W Philips Pan Head Screw - M3x4 5-1050313 004

26Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '901100 1259 Socket - Mate-N-Lock 15-1071100 1306 Termina

27Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '901601 8147 Variable Resistor - 10k Ω 0.5W 9-1371601 814

FACTORY SETTINGSP MODENUMBERFACTORY SETTING DATA41 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1542 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1543 0 1 2 3 4 5 6 7 8 9

4.1.1 Lead Edge EraseThe entire line of LEDs turns on when the main motor turns on. They stay onuntil the erase margin slightly overlaps the lead edge

TEST POINTSCopier Main BoardNUMBER FUNCTIONTP101 GNDTP102 VCC (+5V)TP103 ADS (Auto Image Density Sensor)Adjust the voltage to 2.5 ± 0.1 usingVR101.)TP

DIP SWITCHESCopier Main BoardDIPSWITCHNORMAL FUNCTION101-1 OFF Free Run101-2 OFF Forced Start (Ready temp.by-passed) Factory Use101-3 OFF Clear Counte

Data TableDIP SWITCH 700 (0:OFF, 1:ON) ADJUSTMENT VALUE12340000 -3.5mm1000 -3.0mm0100 -2.5mm1100 -2.0mm0010 -1.5mm1010 -1.0mm0110 -0.5mm1110±00001 0.5

VARIABLE RESISTORSCopier Main BoardNUMBER FUNCTIONVR101 Adjusts ADS Voltage (2.5 ± 0.1)VR102 Adjusts ID Sensor Voltage (4.0 ± 0.2)Power Pack (CC/Grid/

SP MODE OVERVIEWSP Mode Data WhenPerformedMovement Check 5 Exposure Lamp OFF - EM 6 Jam Detection OFF - EM 8 Input Check (Refer to Sensor/Switch Da

SP Mode Data WhenPerformed33 ID Sensor Bias (Black) 0:-260V 1:-220V2:-280V 3:-300VEM or PM34 ADS Level 0: Normal1: Darker2: LighterEM or PM35 Black To

SP Mode Data WhenPerformed74 Color Toner ID Detection 0: 5 copies1: 10 copiesEM75 ID Sensor Bias (Color) 0: Normal1: Lighter2: Darker3: DarkestEM or

SERVICE CALL AND USER CODE TABLESERVICE CALL CODEE-CODE CONTENTS SP Mode No.(SC Counter)11 Exposure Lamp ErrorThe feed back signal beomes higher than

E-CODE CONTENTS SP Mode No.(SC Counter)70 Toner Overflow Sensor ONWhen the toner overflow sensor is on, "E70" blinks in themagnification ind

AD120 (A491)

The following table shows which erase lamp LEDs turn on.Blocks On Paper Size Reproduction Ratio (%)Noneaa – ba – ca – da – ea – fa – f, gAllA3, A4 sid

1PARTS CATALOGINTRODUCTIONThis chapter instructs you the numbers and names of these parts on this machine.INDEX to PARTS CATALOG1. DUPLEX UNIT I (A491

21. DUPLEX UNIT I (A491)December 1, '90

31. DUPLEX UNIT I (A491)December 1, '90Q'ty perAssemblyIndexNo.Q'ty perAssemblyIndexNo.DescriptionPart No.DescriptionPart No.1 AG05 106

4101 0313 0040B Philips Pan Head Screw - M3x4102 0313 0050W Philips Pan Head Screw - M3x5103 0314 0100W Philips Pan Head Screw - M4x10104 0353 0050W T

52. DUPLEX UNIT II (A491)December 1, '90

61 A491 5300 Duplex Harness 12 A491 5205 Transport Motor - DC30V 13 A491 5101 Duplex Main Board 14 A491 5301 Sensor Harness 15 A491 5210 Jog Motor - D

73. DUPLEX MAIN BOARD (A491)December 1, '90

8* A491 5101 Duplex Main Board 11 A491 5105 IC - uPD7811H 1101 1102 4203 CT Header - 4P102 1102 4205 Connector - 6P103 1102 4497 Connector - 13P104 11

94. DUPLEX HARNESS (A491)December 1, '90

10* A491 5300 Duplex Harness 14. DUPLEX HARNESS (A491)December 1, '90Q'ty perAssemblyIndexNo.Q'ty perAssemblyIndexNo.DescriptionPart No

5. DEVELOPMENT5.1 OVERVIEWWhen the main motor turns on, the paddle roller [A] development roller [B]the auger [C], and the agitator [D] start turning

115. SENSOR HARNESS (A491)December 1, '90

12* A491 5301 Sensor Harness 15. SENSOR HARNESS (A491)December 1, '90Q'ty perAssemblyIndexNo.Q'ty perAssemblyIndexNo.DescriptionPart No

136. DECAL AND DOCUMENT (A491)December 1, '90

141 A491 4910 Decal - Removing Misfed Paper 11 A491 6060 Multi Decal - Removing Mifed Paper 12 A491 4915 Dust Cover Decal 16. DECAL AND DOCUMENT (A491

PARTS INDEX

16Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '90A491 4550 Turn Guide Plate A'ssy 5- 45A491 4611 D

17Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '90Part No.DescriptionDescriptionPaper andIndex No.Paper

18Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '900313 0040B Philips Pan Head Screw - M3x4 3-1010313 005

19Part No.DescriptionDescriptionPaper andIndex No.Paper andIndex No.Part No.December 1, '901611 4102 Resistor - 1K W 1/4T ±5% 7-1321611 4103 Resi

POWER SUPPLY UNIT (A494)

5.2 DRIVE MECHANISMWhen the main motor turns, the rotation is transmitted from the developmentdrive gear [A] to the development roller gear [B] throug

1PARTS CATALOGINTRODUCTIONThis chapter instructs you the numbers and names of these parts on this machine.INDEX to PARTS CATALOGJune 30.'911. POW

21. POWER SUPPLY UNIT (A494)

31 A494 5803 Bracket - DF Power Supply Cord 12 A494 5101 Interface Board 13 A494 5301 Power Supply Unit Harness - 115V 13 A494 5310 Power Supply Unit

42. INTERFACE BOARD (A494)

5" A494 5101 Interface Board 1 101 1102 2307 Connector - 20P102 1102 5001 Connector - 30P103 1102 5003 Connector - 2P104 1103 1812 Pin Header - 4

63. DC DRIVE BOARD (A494)

7* A494 5415 DC Drive Board - 115V 1* A494 5416 DC Drive Board - 220/240V 13. DC DRIVE BOARD (A494)101 1103 0441 Pin Terminal - 4P102 1104 0351 Fuse H

84. POWER SUPPLY UNIT HARNESS (A494)

9* A494 5301 Power Supply Unit Harness - 115V 1* A494 5310 Power Supply Unit Harness - 220/240V 14. POWER SUPPLY UNIT HARNESS (A494)101 1100 1239 Pin

10PARTS INDEX

5.3 CROSS-MIXINGThis copier uses a standard cross-mixing mechanism to keep the toner anddeveloper evenly mixed. It also helps agitate the developer to

11A494 5101 Interface Board 3- 2A494 5101 Interface Board 5- *1604 1382 Capacitor - 10uF 50V 5-118A494 5301 Power Supply Unit Harness - 115V 3- 3A494

1204430060W Hexagon Head Tapping Screw - M3x6 3-1011100 1239 Pin - Mate-N-Lock 9-1011100 1247 Terminal 9-1021100 1329 Socket Contact 9-1031100 1330 So

TABLE OF CONTENTSOVERALL MACHINE INFORMATION 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.3.2 Shading Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113.3.3 Lens Positioning . . .

6.3 FIXED SUPPLY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-376.4 ID SENSOR FUNCTION IN F

10.4.2 Paper End Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6010.5 PAPER SIZE DETECTION .

SERVICE TABLES 1. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11.1 TEST POINTS . . . . . . .

4. SPECIAL TOOLS AND LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . 4-38 5. PREVENTIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . .

3.3 INLET SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-283.4 DEVELOPMENT ROLLER REPLA

6.4 CHARGE CORONA WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-646.5 CHARGE CORONA GRID REPLACEMENT. . . . . . .

5.4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROLImage density is controlled by changing two items: (1) the strength of the biasvoltage applied to the de

9.11 FOCUS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-989.12 ERASE MARGIN ADJUSTMENT

2.9 CODE #2B — 4TH/5TH MIRROR HOME POSITION ERROR . . . . . . . . . . . . . . . . . 6-382.10 CODE #52 — FUSING WARM-UP ERROR . . . . . . . . . . . .

5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 6. POWER DISTRIBUTION . . . . . . . . . .

14. DF MAIN BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4715. DF TIMING CHART . . . . . . . .

5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55.1 FIRST SIDE COPY . . . . . . . . . . . . .

COPIER ELECTRICAL COMPONENTS AND CONNECTORS LAYOUTDOCUMENT FEEDER ELECTRICAL COMPONENTS AND CONNECTORSLAYOUTSORTER ELECTRICAL COMPONENTS AND CONNECTOR

14.1.4 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3214.2 INSTALLATION PROCEDURE .

5.4.2 Base Bias Voltage Factor In Automatic Image Density ControlIn automatic image density control mode, the base exposure lamp voltage isfixed to Vo

Section A —1234567 — A4/A3 Version —1. Number Keys The number keys are used to enter the desired number of copies. They are also used to

5.4.3 Base Bias Voltage Adjustment FactorBase Bias Adjustment(Black toner: SP mode #37, Color Toner: SP mode #79)Image DensitySP Data (SP mode #37 or

5.5 DEVELOPMENT BIAS CIRCUITThe main board supplies +24 volts to the CC/Grid/Bias power pack at CN1-1as the power supply source. When the Start key i

5.6 DEVELOPMENT UNIT SET SENSORWhen the development unit is removed from the copier, the development unitset sensor (S12) [A] sends a LOW signal to t

5.7 COLOR DEVELOPMENT UNIT DETECTIONColor Development Unit Detection TableSW 8-1 SW 8-2 ColorOFFONOFFONOFFOFFONONBlackRedGreenBlueON: LOWOFF: PULSEWh

6. TONER DENSITY DETECTION AND TONER SUPPLY6.1 DETECT SUPPLY MODEThe CPU checks toner density by directly sensing the image density every 10copy cyc

6.2 ID SENSOR FUNCTION IN DETECT SUPPLY MODEThe image density sensor checks the density of the sensor pattern imageonce every 10 copy cycles. The CPU

6.3 FIXED SUPPLY MODEWhen the data of SP mode #30 is "1" (factory setting = "0") or a colordevelopment unit is installed, the fixe

6.4 ID SENSOR FUNCTION IN FIXED SUPPLY MODE6.4.1 Black Development UnitIn fixed supply mode, toner is supplied every copy cycle according to thefixed

6.5 ABNORMAL CONDITION IN TONER DENSITY DETECTIONIf the Vsg goes below 2.5 volts (Vsg abnormal) or Vsp goes above 2.5 volts(Vsp abnormal) 5 times in

6.6.2 Vd Correction Factor (Only For Black Toner)After developer is replaced, the triboelectric charge sometimes changes asthe new developer mixture i

— Section B — — A4/A3 Version —12 3 46 78 9 1011121314151617181920212223151. Magnification Ratio Indicator Shows the selected reproduction rati

6.7 TONER SUPPLY AND AGITATOR DRIVE MECHANISMThe toner supply clutch gear [A] turns when the main motor is on. Thetransmission of this rotation to the

6.8 TONER SUPPLY AMOUNTThis copier has two different ways of controlling the amount of toner supplied.Normally, the detect supply mode controls toner

ID Sensor DataVsp/Vsg x100(Vsp, if Vsg = 4.0 volts)Toner Supply Level(Toner Supply Ratio, if SP #31 = 0)ID Sensor Data0 to 12.5 %(0 to 0.5 volts)No to

6.8.2 Fixed Supply Mode (SP mode #30 = 1)The amount of toner supplied depends on the fixed toner supply ratio data,the paper size data and the color d

Fixed Toner Supply Ratio Data (Black Toner: SP mode #32)SP Data(SP mode #32)Toner Supply Ratio Toner Supply Ratio Data0 7.0 % 21 3.5 % 12 10.5 % 33 14

6.9 TONER END DETECTIONThe toner agitator gear [A] has a cam [B] (the toner end cam) on its innersurface, and it rotates only when toner is supplied.

If this condition is detected by the CPU two times consecutively, the AddToner indicator starts blinking.After the indicator starts blinking, 50 copie

7. IMAGE TRANSFER AND PAPER SEPARATION7.1 PRE-TRANSFER LAMP (PTL)After the latent image is developed but before the image is transferred to thecopy

7.3 PAPER SEPARATIONAfter image transfer the copy must be separated from the drum. To break theattraction between the paper and the drum, the separati

7.4 PRE-TRANSFER LAMP AND TRANSFER/SEPARATION CORONA CIRCUITWhen the Start key is pressed, the main board outputs Low signals to turn onthe pre-tran

— LT/LDG Version —12 3 46 78 9 101112131415161718192021222324512. Wait Indicator Lights when that the machine is not ready to copy.13. Copy Coun

8. DRUM CLEANING8.1 OVERVIEWThe cleaning brush [A] and cleaning blade [B] remove any toner remainingon the drum [C] after the image is transferred to

8.2 DRIVE MECHANISMThe rotation of the main motor is transmitted to the cleaning unit through themain motor gear [A], the relay gear [B], and the clea

8.3 TONER OVERFLOW DETECTIONThe toner overflow detection mechanism stops copier operation when theused toner tank gets full. When the tank gets full,

9. QUENCHINGIn preparation for the next copy cycle, light from the quenching lamp (QL) [A]neutralizes any charge remaining on the drum [B].The neon la

10. PAPER FEED AND REGISTRATION10.1 OVERVIEWThis model has two paper feed stations. The first feed station is located onthe right side of the copier a

10.2 FRR FEED SYSTEMThis copier uses an FRR (Feed + Reverse Roller) paper feed system whichutilizes three rollers.10.2.1 Pick-up RollerThe pick-up rol

The direction that the reverse roller [A] turns depends on the frictional forcesacting on it. The slip clutch applies a constant clockwise force (F1).

10.3 1ST FEED STATION PAPER LIFT MECHANISM AND PAPER END DETECTION10.3.1 Paper Lift MechanismWhen the cassette [A] is inserted into the copier, the

If the paper has not been raised to the feed position, the CPU turns on themain motor and the paper lift clutch. The paper lift gear turns the sector

10.4 2ND FEED STATION PAPER LIFT MECHANISM AND PAPER END DETECTION10.4.1 Paper Lift MechanismWhen the paper tray [A] is closed after the paper is lo

— Section C — — A4/A3 Version —5 4 6 78910111213132 1. Sorter KeyPress to select the sort or stackmode. The sort mode and stackmode are optional fe

10.5 PAPER SIZE DETECTION10.5.1 1st Feed StationThe paper size switch (SW3) [A] in the cassette entrance detects the papersize. The paper size switch

Paper Size Detection Table (1st Feed Station)Paper SizeSwitch 3 –Size Indication1 2 3 4 5Universal 0 0 0 0 0 *A3B4A4A4B5B5 (lengthwise)A5 (sideways) A

10.5.2 2nd Feed StationFour paper size switches (SW4 [A], SW5 [B], SW6 [C], and SW7 [D]) on therear frame detect the paper size. The paper size switch

10.6 PAPER FEED DRIVE MECHANISM10.6.1 1st Feed StationThrough several gears and a timing belt, main motor rotation is transmitted tothe relay gear [A]

10.6.2 2nd Feed StationMain motor rotation is transmitted to the relay roller clutch gear [A] throughgears and a timing belt. The paper feed timing is

10.7 SLIP CLUTCH MECHANISM[D]: Reverse Roller[E]: Slip Clutch CoverThe slip clutch consists of two hubs connected by a drive spring [A]. Thespring gri

10.8 MANUAL FEED TABLEThe manual feed table [A] uses the same feed mechanism as the first feedstation and a maximum of 50 sheets of standard weight p

10.9 PAPER REGISTRATIONMain motor rotation is transmitted to the timing belt [A] through a series ofgears. The timing belt rotate the relay gear [B] a

10.10 PAPER FEED AND MISFEED DETECTION TIMINGThe registration sensor and the exit sensor monitor the movement of thepaper through the paper path. If

11. IMAGE FUSING11.1 OVERVIEWAfter the image is transferred, the copy paper enters the fusing unit. Therethe image is fused to the copy paper by the p