Ricoh Company, Ltd.

Transcript

RICOH RICOH FT4460 RICOH COMPANY, LTD. Table of Contents OVERALL MACHINE INFORMATION 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1.1 MAIN COPIER, FT4460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 2. OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 3. COPY PROCESSES AROUND THE DRUM . . . . . . . . . . . . . . . . . . . . .1-9 4. FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 5. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11 5.1 PRIMARY PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 5.2 SlNGLE DUPLEX COPY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 5.3 MULTI DUPLEX COPY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 5.4 SINGLE OVERLAY COPY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15 5.5 MULTI OVERLAY COPY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16 6. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17 7. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . .1-18 8. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . .1-20 9. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . .1-22 10. AC AND DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . .1-27 11. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28 DETAILED SECTION DESCRIPTIONS 1. DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 1.1 OPC DRUM CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 1.2 HANDLING THE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 1.3 DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 2. DRUM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 2.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 2.2 CHARGE CORONA UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 2.3 CHARGE CORONA POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 2.4 CHARGE CORONA WIRE CLEANER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 3. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 3.2 SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 3.2.1 1st and 2nd Scanner Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 3.3 SCANNER MOTOR DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 3.4 LENS DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 3.4.1 Lens Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 3.4.2 Shading Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 3.5 LENS POSITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 3.6 3RD SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 3.6.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 3.6.2 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 3.7 STEPPER MOTOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14 3.8 RED ERASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 3.9 AUTOMATIC IMAGE DENSITY SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 3.10 AUTOMATIC ORIGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 3.11 EXPOSURE LAMP VOLTAGE CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 3.11.1 Manual Image Density Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 3.11.2 Size Magnification Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 3.11.3 Drum Sensitivity Correction (Vr Correction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 3.11.4 Drum Rotation Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 3.11.5 Photo Mode Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 3.11.6 ADS Correction (SP mode #34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 3.11.7 Red Erase Mode Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 3.11.8 Pre-scan Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 3.12 EXPOSURE LAMP CONTROL ClRCUlT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 3.13 SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 4. ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 4.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 4.1.1 Lead Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 4.1.2 Side Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 4.1.3 Special Mode Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 4.1.4 Trailing Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 4.2 ERASE LAMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 4.3 ERASE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 5. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .2-29 5.2 DEVELOPMENT UNIT CHANGE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 5.3 DEVELOPMENT UNIT SUPPORT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31 5.4 DRIVE MECHANISM (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32 5.5 DRIVE MECHANISM (Color) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33 5.6 AGITATOR MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 5.7 TONER SUPPLY AND AGITATOR DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . .2-35 5.8 TONER DENSITY DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36 5.9 TONER DENSITY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37 5.10 TONER END DETECTION (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38 5.10.1 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38 5.11 TONER END DETECTION (CoIor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39 5.11.1 Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39 5.12 ID SENSOR SUPPLY CONTROL (Black only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40 5.13 ID SENSOR TONER SUPPLY LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41 5.14 ID SENSOR SUPPLY CONTROL IN FIXED SUPPLY MODE . . . . . . . . . . . . . . . . . . . .2-42 5.15 TONER SUPPLY AMOUNT (FIXED SUPPLY MODE) . . . . . . . . . . . . . . . . . . . . . . . . .2-44 5.16 ID SENSOR ERROR DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45 5.17 DEVELOPMENT BlAS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46 5.17.1 Manual Bias Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46 5.17.2 Auto Image Density Bias Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46 5.18 BIAS CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47 5.18.1 Vr Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47 5.18.2 SP Mode Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47 5.19 ID SENSOR BlAS COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 5.19.1 Standard Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 5.19.2 Vp Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 5.19.3 Developer Counter Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49 5.19.4 Total lD Sensor Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49 6. IMAGE TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50 6.1 PRE-TRANSFER LAMP (PTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50 6.2 IMAGE TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50 6.3 PAPER SEPARATION AND TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51 6.3.1 Paper Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51 6.3.2 Paper Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51 6.4 PTL AND T/S CHARGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52 7. ID SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53 7.1 ID SENSOR IMAGE CORRECTION (Vr Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53 7.2 ID SENSOR PATTERN (Vsp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55 8. DRUM CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56 8.1 OVERVlEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56 8.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57 8.3 RELEASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58 8.4 TONER OVERFLOW DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59 9. PAPER FEED AND REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 9.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 9.2 FRR FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 9.2.1 Pick-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 9.2.2 Feed and Separation Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 9.3 FRICTION PAD FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62 9.4 PAPER LlFT MECHANlSM (1st Feed Station) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63 9.5 PAPER LIFT MECHANISM (2nd and 3rd Feed Stations) . . . . . . . . . . . . . . . . . . . . . . . .2-64 9.6 PAPER SIZE AND END DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65 9.7 PAPER FEED DRlVE MECHANlSM (FRR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66 9.8 PAPER FEED REGISTRATION DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . .2-67 9.9 MANUAL FEED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68 9.10 PAPER FEED TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69 9.11 SERVICE CALL CONDITlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70 10. IMAGE FUSING AND PAPER EXIT . . . . . . . . . . . . . . . . . . . . . . . . . .2-71 10.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71 10.2 FUSING DRIVE RELEASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72 10.3 FUSING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-73 10.3.1 Phase Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74 10.4 SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75 11. DUPLEX/OVERLAY MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76 11.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76 11.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77 11.3 JOGGER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78 11.4 SlNGLE DUPLEX/OVERLAY TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79 12. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80 12.1 PAPER MISFEED CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80 12.2 SERVICE CALL CONDlTIONS (Others) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82 13. COPIER TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-83 INSTALLATION 1. INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 1.1 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 1.2 MACHINE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 1.3 MINIMUM SPACE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 1.4 POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 1.5 COPIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 1.5.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 1.5.2 Removal Of Shipping Retainers And Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 1.5.3 For Areas Where The Voltage Is 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 1.5.4 Developer Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 1.5.5 Cassette Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 1.5.6 Key Counter Holder Installation (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 SERVICE TABLES 1. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 1.1 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 1.2 DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 1.3 VARIABLE RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 2. SERVICE REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 2.1 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 2.2 CHARGE CORONA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 2.3 OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 2.4 DEVELOPMENT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 2.5 TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 2.6 TRANSFER and SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 2.7 CLEANING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 2.8 FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 2.9 PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 2.10 DOCUMENT FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 2.11 SORTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 2.12 LARGE CAPACITY TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 2.13 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 3. SPECIAL TOOLS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . .4-10 4. SERVICE PROGRAM MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 4.1 DIP SWITCHES TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 4.1.1 DIP SW 1 (Operation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 4.2 SERVICE PROGRAM MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4.2.1 Service Program Access Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4.2.2 Change Adjustment Values or Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4.2.3 Memory Clear Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 4.2.4 Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 4.3 SERVICE PROGRAM MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 4.4 SERVICE PROGRAM SP-8 DATA INPUT GUIDE TABLE . . . . . . . . . . . . . . . . . . . . . . . .4-32 4.5 SERVICE PROGRAM SP-9 DATA OUTPUT GUIDE TABLE . . . . . . . . . . . . . . . . . . . . . .4-34 4.6 USER CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 4.6.1 User Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 4.6.2 User Code Counter Check (SP Mode #91) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 4.6.3 User Code Counter Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 4.7 MISFEED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38 4.7.1 Location of Jams/Number of Jams (SP Mode #131) . . . . . . . . . . . . . . . . . . . . . .4-38 4.7.2 Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40 5. PREVENTIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . .4-41 5.1 LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45 5.2 REPLACEMENT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46 5.3 ADJUSTMENT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47 5.4 EXPLANATION OF REGULAR PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48 REPLACEMENT AND ADJUSTMENT 1. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 1.1 EXPOSURE GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 1.2 1ST MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 1.3 2ND AND 3ND MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 1.4 4TH AND 5TH MlRRORS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 1.5 EXPOSURE LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 1.6 AUTO SIZE/ADS FIBER OPTIC CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .5-8 1.7 THERMOSWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 1.8 SCANNER DRIVE WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 1.8.1 Wire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 1.8.2 Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 1.9 SCANNER MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 1.10 LENS DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 1.11 3RD SCANNER DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 1.12 RED ERASE FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 1.13 EXPOSURE LAMP POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 1.14 EXPOSURE LAMP VOLTAGE ADJUSTMENT (SP Mode #48) . . . . . . . . . . . . . . . . . .5-22 1.15 ADS ADJUSTMENT (SP Mode #58) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23 1.16 ADS CORRECTION (SP Mode #56) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 1.17 APS VOLTAGE ADJUSTMENT (SP Modes #61 and #62) . . . . . . . . . . . . . . . . . . . . .5-25 1.18 APS LENGTH SENSOR ERROR CORRECTION (SP Modes #50 and #46) . . . . . . .5-26 1.19 VERTICAL MAGNIFICATION ADJUSTMENT 1 (SP Mode #43) . . . . . . . . . . . . . . . . .5-27 1.20 VERTICAL MAGNIFICATION ADJUSTMENT 2 (Overlay and Duplex) (SP Mode #45) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28 1.21 HORIZONTAL MAGNIFICATION ADJUSTMENT (SP Mode #44) . . . . . . . . . . . . . . .5-29 1.22 3RD SCANNER HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 2. DEVELOPMENT AND TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . .5-31 2.1 BLACK DEVELOPER REPLACEMENT (SP Mode #65) . . . . . . . . . . . . . . . . . . . . . . . . .5-31 2.2 BLACK DEVELOPMENT ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32 2.3 DOCTOR GAP ADJUSTMENT (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33 2.4 COLOR DEVELOPER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34 2.5 COLOR DEVELOPER CONDITIONING (SP Mode #10) . . . . . . . . . . . . . . . . . . . . . . . .5-35 2.6 COLOR DEVELOPMENT ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36 2.7 DOCTOR GAP ADJUSTMENT (Color) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-37 2.8 TONER SUPPLY CLUTCH CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-38 2.9 DEVELOPER SHIFT CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-39 2.10 DEVELOPMENT BIAS MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-40 2.10.1 Measurement (Beckman) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-40 2.10.2 Measurement (SP Mode #59) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-41 2.11 BLACK DEVELOPMENT BIAS ADJUSTMENT (SP Mode #37) . . . . . . . . . . . . . . . . .5-42 2.12 COLOR DEVELOPMENT BIAS ADJUSTMENT (SP Mode #79) . . . . . . . . . . . . . . . . .5-43 2.13 HIGHLIGHT COLOR DENSITY AMOUNT (SP Mode #86) . . . . . . . . . . . . . . . . . . . . .5-44 2.14 BLACK TONER SUPPLY ADJUSTMENT (SP Mode #30) . . . . . . . . . . . . . . . . . . . . . .5-45 2.15 BLACK TONER SUPPLY AMOUNT (ID Sensor Mode) (SP Mode #31) . . . . . . . . . . .5-46 2.16 BLACK TONER SUPPLY AMOUNT (Fixed Supply Mode) (SP Mode #32) . . . . . . . .5-47 2.17 COLOR TONER SUPPLY AMOUNT (SP Mode #70) . . . . . . . . . . . . . . . . . . . . . . . . . .5-48 3. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-49 3.1 CLEANING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-49 3.2 CLEANING BLADE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-50 3.3 CLEANING BRUSH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-51 3.4 BLADE SCRAPER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-52 3.5 TONER OVERFLOW SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-53 3.6 USED TONER COLLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-54 3.7 QUENCHING LAMP REPLACEMENT/CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-55 4. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-56 4.1 MANUAL FEED TABLE REMOVAL AND MANUAL FEED SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .5-56 4.1.1 Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-56 4.1.2 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-56 4.2 PAPER SIZE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-57 4.3 1ST FEED ROLLERS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-58 4.4 GRIP ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-60 4.5 2ND FEED ROLLER AND FRICTION PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . .5-61 4.6 3RD FEED ROLLER AND FRICTION PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . .5-62 4.7 FRICTION PAD PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-63 4.8 PRESSURE ARM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-64 4.9 FEED AND RELAY CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65 4.10 PAPER END SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-66 4.10.1 1st Feed Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-66 4.10.2 2nd and 3rd Feed Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-66 4.11 LIFT MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-67 4.12 REGISTRATION SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-68 4.13 REGISTRATION CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69 4.14 UPPER REGISTRATION ROLLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-70 4.15 LOWER REGISTRATION REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .5-71 4.16 REGISTRATION ADJUSTMENT (SP Mode #42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-72 4.17 UPPER RELAY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-73 4.18 LOWER RELAY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-74 5. TRANSPORT . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .5-75 5.1 TRANSPORT BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-75 5.2 DRUM HEATER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-77 6. DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78 6.1 CHARGE CORONA WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-78 6.2 CHARGE CORONA GRID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-79 6.3 CHARGE CORONA HElGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-80 6.4 TRANSFER/SEPARATION CORONA WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . .5-81 6.5 DRUM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-82 6.6 ID SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-85 6.7 ID SENSOR Vsg ADJUSTMENT (SP Mode #54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-86 6.8 SEPARATION PAWL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-87 6.9 CHARGE CORONA CURRENT ADJUSTMENT (SP Mode #9-2) . . . . . . . . . . . . . . . . .5-88 6.10 GRID VOLTAGE ADJUSTMENT (SP Mode #9-2 and 3) . . . . . . . . . . . . . . . . . . . . . . .5-89 6.11 DRUM CURRENT ADJUSTMENT (SP Mode #9-5 and 7) . . . . . . . . . . . . . . . . . . . . . .5-90 6.11.1 Transfer Current Measurement (SP Mode #9-5) . . . . . . . . . . . . . . . . . . . . . . . .5-91 6.11.2 Separation Corona Current Measurement (SP Mode #9-7) . . . . . . . . . . . . . . . .5-92 7. FUSlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 5-93 7.1 FUSING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-93 7.2 FUSlNG LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-94 7.3 HOT ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-95 7.4 PRESSURE ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-96 7.5 FUSING STRIPPER PAWL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-97 7.6 THERMAL FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-98 7.7 FUSING THERMISTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-99 7.8 FUSING TEMPERATURE CHECK (SP Mode #52) . . . . . . . . . . . . . . . . . . . . . . . . . . .5-100 7.9 FUSING TEMPERATURE ADJUSTMENT (SP Mode #49) . . . . . . . . . . . . . . . . . . . . .5-101 7.10 FUSING TEMPERATURE CONTROL SELECTION (Full Wave Control or Phase Control) (SP Mode #29) . . . . . . . . . . . . . .5-102 7.11 NIP WIDTH MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-103 7.12 FUSlNG PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-104 7.13 FUSING GUIDE PLATE HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-105 7.14 FUSlNG EXIT SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-106 8. TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-107 8.1 TRANSPORT GUIDE UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-107 8.2 RELAY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-108 8.3 INVERTER SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-109 8.4 DUPLEX/OVERLAY TRANSPORT MAGNETIC CLUTCH REPLACEMENT . . . . . . . . .5-110 9. JOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-111 9.1 JOGGER UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-111 9.2 JOGGER HOME POSITION SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . .5-112 9.3 JOGGER UNIT WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-113 9.4 JOGGER MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-115 9.5 JOGGER SOLENOID ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-116 10. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-117 10.1 OPERATION PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-117 MULTI DUPLEX/OVERLAY 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 2. COMPONENTS LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . .6-3 4. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 6. PAPER STACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 7. PAPER ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 8. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 9. ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 10. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 11. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11 12. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .6-14 12.1 PAPER FEED ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 12.2 FRICTION PAD REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .6-15 12.3 REPLACEMENT OF POSITIONING ROLLER AND ROUND BELT . . . . . . . . . . . . . . .6-16 12.4 JOGGER FENCE DRIVE WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 12.5 JOGGER HOME POSITION SENSOR ADJUSTMENT (SP Mode #8-13) . . . . . . . . . .6-19 12.6 CAM CLUTCH LUBRlCATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 12.7 POSITIONING ROLLER SOLENOID ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 12.8 PAPER EXIT/PAPER END SENSORS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .6-23 12.9 MULTI-DUPLEX SIDE TO SIDE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . .6-25 DOCUMENT FEEDER 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 2. COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . .7-3 4. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 6. POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 7. INTERFACE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 8. ORIGINAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 8.1 ORIGINAL PICK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 8.2 ORIGINAL SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 8.3 ORlGlNAL FEED-lN MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 8.4 ORlGlNAL SlZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 8.5 ORIGINAL INVERSION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16 8.6 ORlGlNAL FEED-OUT MECHANlSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18 8.7 BELT DRIVE MOTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19 8.8 FEED-OUT MOTOR ClRCUlT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20 8.9 INPUT AND OUTPUT ClRCUlTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21 9. LIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22 10. ORIGINAL MISFEED SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23 11. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25 12. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26 13. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .7-32 13.1 FEED-lN UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 13.1.1 Transport Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 13.1.2 Feed-in Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33 13.1.3 Pick-up Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 13.1.4 Feed-in Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 13.1.5 Pick-up Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36 13.1.6 Feed Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38 13.1.7 Feed-in Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39 13.1.8 Friction Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 13.1.9 Registration Sensor and Original Width Sensor Replacement . . . . . . . . . . . . . .7-41 13.1.10 Entrance Guide Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42 13.1.11 Belt Drive Motor Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43 13.2 FEED-OUT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44 13.2.1 Feed-out Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44 13.2.2 DF Main PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45 13.2.3 Inverter Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46 13.2.4 DF Leading Edge Registration Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47 14. SERVICE TABLES FOR DF MAIN PCB . . . . . . . . . . . . . . . . . . . . . . .7-49 14.1 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 14.2 VARIABLE RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 14.3 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 14.4 DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50 15. DF TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7-51 SORTER 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . .8-2 3. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . .8-3 4. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . .8-4 5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 5.1 CLEAR MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 5.2 SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 5.3 STACK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 6. EXAMPLE OF SORT MODE OPERATION . . . . . . . . . . . . . . . . . . . . . .8-6 7. BIN DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 8. BINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9 9. EXIT ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 10. ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 11. ELECTRICAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 12. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 13. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14 14. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .8-17 14.1 EXIT ROLLER AND O-RING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17 14.2 PAPER SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19 14.3 TIMING BELT TENSlON ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-20 EDITOR 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1 2. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . .9-2 3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . .9-3 4. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4 5. DETECTING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5 6. ERROR DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 6.1 INITIAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 6.2 PARITY ERROR (Communication Error) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 7. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 8. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9 8.1 EDITOR INSTALLATION (on Platen Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9 8.2 EDITOR INSTALLATION (on Editor Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12 9. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . .9-13 9.1 MAIN PCB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13 DATE PRINTER 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 2. OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 3. AUTOMATIC MAGNIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3 4. DATA PRINTING FUNCTION TABLE . . . . . . . . . . . . . . . . . . . . . . . . .10-4 5. TIME CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5 6. ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 7. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7 8. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 9. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .10-13 9.1 BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13 10. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 10.1 DIP SWITCH TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14 10.1.1 Standard Mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14 10.1.2 Special Mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14 10.2 DATE PRINTER PROGRAM MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16 LARGE CAPACITY TRAY 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . .11-2 3. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . .11-3 4. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . .11-4 5. MECHANICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5 5.1 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5 5.2 PICK-UP ROLLER MECHANlSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6 5.3 PAPER SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7 6. ELECTRICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8 6.1 DOWN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8 6.2 UP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8 7. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..11-9 8. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . .11-10 8.1 LCT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10 8.2 ADJUSTING SlDE REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15 9. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .11-17 9.1 TRAY WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-17 9.2 TRAY DOWN SENSOR AND POSITIONING SWITCH REPLACEMENT . . . . . . . . . . .11-19 9.3 PAPER SlZE SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-21 9.4 SIDE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-22 TROUBLESHOOTING 1. COPY QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1 1.1 BLANK COPY (WHITE COPY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1 1.2 DIRTY BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4 1.3 UNEVEN lMAGE DENSlTY - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7 1.4 UNEVEN lMAGE DENSlTY - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8 1.5 VERTlCAL BLACKBANDS - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-9 1.6 VERTICAL BLACKLINES - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10 1.7 VERTICAL WHITE LINES OR BANDS - 1 (Dull or Blurred) . . . . . . . . . . . . . . . . . . . . .12-11 1.8 VERTICAL WHITE LlNES - 2 (Half Tone Images) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12 1.9 VERTICAL WHITE LINES - 3 (Smeared Image) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 1.10 VERTICAL WHITE LINES OR BANDS - 4 (Thin, Distinct) . . . . . . . . . . . . . . . . . . . . .12-14 1.11 HORIZONTAL BLACK LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-15 1.12 JITTER - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-17 1.13 JITTER - 2 (lrregular) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-18 1.14 MARKS AT 251MM INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-19 1.15 SKEWED (OPTICAL) COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-20 1.16 BLACK SPOTS ON THE COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-21 1.17 TONER DENSITY TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-22 1.18 TONER DENSITY TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-24 1.19 UNFUSED COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-26 1.20 OPTlCS UNlT CONTROL FAlLURE - 1 (Initialization) . . . . . . . . . . . . . . . . . . . . . . . .12-28 1.21 OPTICS UNIT CONTROL FAILURE - 2 (Copy Cycle) . . . . . . . . . . . . . . . . . . . . . . . .12-29 1.22 SIDE REGISTRATION MALFUNCTION IN DUPLEX/OVERLAY COPY MODE . . . . .12-30 2. SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-32 2.1 CODE #11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-32 2.2 CODE #12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-33 2.3 CODE #21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-34 2.4 CODE #22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-34 2.5 CODE #23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-35 2.6 CODE #24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-35 2.7 CODES #25 AND #2E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-36 2.8 CODE #2A AND #2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-37 2.9 CODE #28 AND #29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-38 2.10 CODE #41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-39 2.11 CODE #53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-40 2.12 CODE #54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-40 2.13 CODE #55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-41 2.14 CODE #61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-41 2.15 CODE #81 AND #82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-42 2.16 CODE #91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-43 2.17 CODE #92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-43 2.18 CODE #93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-44 2.19 CODE #94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-44 2.20 CALL SERVlCE CONDITION #95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-45 3. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46 3.1 ID SENSOR MALFUNCTION (Color Copy Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-46 3.2 LOW lMAGE DENSITY (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-47 3.3 SORTER PAPER STACKING PROBLEM (A3/LDG Tracing Paper) . . . . . . . . . . . . . . .12-48 3.4 DIRTY BACKGROUND (Blue Development Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-48 3.5 PAPER CREASlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-49 4. ELECTRICAL COMPONENT DEFECTS . . . . . . . . . . . . . . . . . . . . . .12-50 4.1 PAPER END SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-50 4.2 MANUAL FEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-50 4.3 1ST CASSETTE LIFT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-50 4.4 REGlSTRATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-51 4.5 FUSING EXIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-51 4.6 INVERTOR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-51 4.7 INVERTER RELAY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-52 4.8 COLOR TONER END SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-52 4.9 PULSE GENERATOR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-52 4.10 1ST SCANNER HOME POSlTION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-53 4.11 LENS HOME POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-53 4.12 3RD SCANNER HOME POSITlON SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-53 4.13 FRONT COVER SAFETY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-54 4.14 THERMOFUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-54 4.15 FUSlNG THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-54 4.16 DC POWER SUPPLY FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-55 4.17 SHORT ClRCUIT lN DC 5V LlNE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-55 5. CAUTIONS FOR USERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-56 5.1 PICK-OFF PAWL TRACES (Overlay mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-56 5.2 CREASlNG DURING FUSING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-56 5.3 OHP MlSFEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-57 5.4 PHOTO MODE lD LEVEL SETTlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-57 5.5 INCOMPLETE IMAGE TRANSFER AT TRAILING EDGE . . . . . . . . . . . . . . . . . . . . . . .12-57 5.6 LOW IMAGE DENSITY WITH RED ORIGINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-58 5.7 LOW ID LEVEL WITH MULTIPLE SOLID COLOR COPIES . . . . . . . . . . . . . . . . . . . . .12-58 5.8 MODES CLEARED WHEN FRONT COVER OPENED . . . . . . . . . . . . . . . . . . . . . . . .12-58 5.9 INADEQUATE FUSING OF UNEVEN COPY SURFACE . . . . . . . . . . . . . . . . . . . . . . .12-59 5.10 GAP OR OVERLAPS IN OVERLAY COPYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-59 5.11 MULTIPLE PASSES THROUGH FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-59 5.12 PAPER EXlT ROLLER MARKS ON DIRECT IMAGE MASTERS (C & P) . . . . . . . . . .12-60 ELECTRICAL DATA PCB-1 COPIER: I/O CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . .13-1 PCB-2 COPIER: SYSTEM CONTROL BOARD . . . . . . . . . . . . . . . . . . .13-2 PCB-3 COPIER: DC POWER SUPPLY BOARD . . . . . . . . . . . . . . . . . . .13-3 PCB-4 COPIER: AD DRIVE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4 PCB-5 COPIER: PAPER FEED BOARD . . . . . . . . . . . . . . . . . . . . . . . . .13-5 PCB-6 DF: MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-6 PCB-7 LCT: MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 PCB-8 EDITOR: MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-8 PCB-9 DATE PRINTER: MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . .13-9 PCB-10 SORTER: CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . . .13-10 SECTION 1 OVERALL M A C H I N E INFORMATION CONTENTS .. 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1.1 MAIN COPIER, FT4460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 2. OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 3. COPY PROCESSES AROUND THE DRUM . . . . . . . . . . . . . . . . . . . .1-9 4. FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 5. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 1-11 5.1 PRIMARY PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-12 5.2 SlNGLE DUPLEX COPY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 5.3 MULTI DUPLEX COPY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 5.4 SINGLE OVERLAY COPY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15 5.5 MULTI OVERLAY COPY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16 6. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 7. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 1-18 8. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . 1-20 9. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . 1-22 10. AC AND DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . .1-27 11. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 28 February 1989 1. SPECIFICATIONS 1.1 MAIN COPIER, FT4460 Configuration: Desk top Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum A3/11”x17” Copy Paper Size: Maximum A3/11”x17” Minimum A6/5.5”x8.5” (DupIex/Overlay Copying) Maximum A3/11”x17” Minimum A5/5.5”x8.5” Copy Paper Weight: Cassette feed: 52 - 128 g/m² (14 - 34 lb) Manual feed: 52 - 157 g/m² (14 - 42 lb) Duplex/Overlay: 64 - 105 g/m² (17 - 28 lb) Reproduction Ratio: 4 Enlargement and 6 Reduction Enlargement Full Size Reduction LT/LDG Version A4/A3 Version 200% 155% 129% 121% 200% 141% 122% 115% 100% 100% 93% 85% 77% 74% 65% 50% 93% 82% 75% 71% 65% 50% Zoom: From 50% to 200% in 1% steps Copying Speed: 21 copies/minute (8½”x11” sideways) 20 copies/minute (A4 sideways) 12 copies/minute (A3/11”x17”) Warm Up Time: 120 seconds (20°C) 1-1 28 February 1989 First Copy Time: Black Copy: 7.9 seconds (A4/8.5” x11” sideways) 12.3 seconds (APS mode, A4/8.5” x11” sideways) Color Copy: 11.6 seconds (A4/8.5”x11” sideways) 12.8 seconds (APS mode, A4/8.5” x11” sideways) Copy Number Input: Ten keys, 1 to 999 (count up or count down) Manual Image Density Selection: 7 steps Automatic Reset: 1 minute standard setting; can also be set to 3 minutes or no auto reset. Paper Stock: Three universal cassettes (auto cassette shift) Manual feed table Large capacity (option) Toner Replenishment: Cartridge exchange Black: 310 g/cartridge Color: 60 g/cartridge (red, blue, & green) Copy Tray Capacity: 250 sheets B4/10”x14” 100 sheets A3/11”x17” Power Source: 110V/60Hz/15A 115V/60Hz/15A 220V/50Hz/8A 220V/60Hz/8A 240V/50Hz/8A Maximum Power Consumption: 110/115V: 1.3kw 220/240V: 1.5kw Dimensions: Copier only Full System Width 700 (27.6”) Depth Height 600 (23.7”) 443 mm (17.5”) 1610 (63.4”) 600 (23.7”) 1026 mm (40.4”) 1-2 28 February 1989 Weight: 110/115V version: Approximately 86kg(190 lb) 220/240V version: Approximately 88kg(194 lb) Optional Equipment: Document feeder (DF52) 20 bin sorter (CS2090) Large capacity tray (RT15) Color development unit (CU120) Editor board (RE12) Date printer (DP 100) Multi duplex/overlay unit (AD 500) Key counter 1-3 28 February 1989 2. OPERATION PANEL - Section A - LT/LDG Version - 1. Area Memory Indicator 10. Used Toner Bottle Indicator 2. Check Paper Size/Direction 11. Set Key Counter Indicator 3. Check Paper Size Indicator 12. Ready Indicator 4. Magnification Indicators 13. Wait Indicator 5. Paper Size Indicator 14. Manual Feed Indicator 6. Check Paper Path Indicator 15. Copy Counter 7. Close Cover Indicator 16. Call Service Indicator 8. Load Paper Indicator 17. Max indicator 9. Add Toner Indicator 1-4 28 February 1989 - A4/A3 Version - 18. Second Original Indicator 28. Auto Paper Select Key 19. Auto Image Density Indicator 29. Select Cassette Key 20. Manual Image Density Indicator 30 . Full Size Indicator 21. Auto Image Density Key 31 . Full Size Key 22. Manual Image Density Keys 32 . Enlarge Key 23. Misfeed Location Display 33 . Reduce Key 24. Color Toner Indicator 34 . Zoom Indicator 25. Color Copy Key 35 . Magnification Ratio Indicator 26. Color Copy Indicator 36 . Set Area Indicator 27. Auto Paper Select Indicator 1-5 28 February 1989 - Section B (Keys and Indicators for Special/Optional Functions) - LT/LDG Version - 1. Sorter Key 8. Margin Adjustment Key 2. Stack Indicator 9. Centering Indicator 3. Sort Indicator 10. Centering Key 4. Duplex Indicators 11. Size Magnification Indicators 5. Duplex Key 12. Size Magnification Key 6. Front Margin Adjustment Indicator 13. Auto Reduce/Enlarge Indicator 7. Back Margin Adjustment Indicator 1-6 28 February 1989 - A4/A3 Version - 14. Auto Reduce/Enlarge Key 21. Edit Image Key 15. Zoom Up Key 22. Edit Image Indicators 16. Zoom Down Key 23. Tone Key 17. Overlay Key 24. Photo Mode Indicator 18. Overlay Indicators 25. Red Erase Indicator 19. 2 Page Overlay Key 26. 2 Single Copies Key 20. 2 Page Overlay Indicators 27. 2 Single Copies Indicators 1-7 28 February 1989 - Section C - LT/LDG Version - - A4/A3 Version - 1. Number Keys 2. Recall/Enter Key 3. Program Indicator 4. Program Key 5. Interrupt Indicator 6. Interrupt Key 7. Clear Modes Key 8. Start Key 9. Clear/Stop Key 1-8 28 February 1989 3. COPY PROCESSES AROUND THE DRUM 28 February 1989 4. FUNCTIONAL OPERATION 1-10 28 February 1989 5. PAPER PATH The paper feed starts from one of the three paper feed stations. The copy paper then follows one of two paths inside the copier. The path followed depends on which mode the operator has selected. For copy processing, all sheets follow the same path from the paper feed mechanism through the fusing unit. After that, normal copies are delivered to the copy tray; however, duplex copies and overlay copies are diverted for further processing. The following discussion follows the route of a single sheet of paper through a duplex/overlay cycle. 1-11 28 February 1989 5.1 PRIMARY PAPER PATH 1. Paper Feed: If paper is fed from the first station, an FRR (Feed and Reverse Roller) mechanism separates one sheet of paper from the paper stack and feeds it to the registration rollers. The second and third stations use a friction pad for separation. In addition, if paper is fed from the third station, relay rollers move the paper to the registration rollers. The registration rollers are not turning at this time. The paper buckles slightly when the leading edge reaches the registration rollers. Buckling seats the sheet securely between the registration rollers and corrects any skew. 2. Registration: At the programmed time, the registration rollers start turning to feed the paper to the drum. 3. Image Transfer: The toner image on the drum surface is pulled from the drum onto the passing paper by the transfer corona. 4. Paper Separation: The electrostatic attraction between the paper and the drum is broken by the separating corona. The suction of the vacuum fan and the weight of the paper pulls the paper onto the transport belt. The transport belt moves the paper with the developed copy image to the fusing unit. 5. Fusing: The paper passes between two rollers which bond the toner image to the paper by applying heat and pressure. At this point the copy is complete, and the paper path splits two ways. Ordinary copies go directly through the exit rollers to the copy tray. However, duplex copies and overlay copies are diverted to the lower transport unit. 1-12 28 February 1989 5.2 SINGLE DUPLEX COPY PATH [F]: Duplex/Overlay Transport Gate [G]: Junction Gate [H]: Invertor Gate Duplex Paper Feed: The copy paper is fed down from the fusing unit to the lower section [A], where the paper’s leading edge passes through the inverter rollers. When the inverter sensor detects the paper’s trailing edge, the inverter rollers [B] reverse direction and the paper is fed to the jogger section [C]. When the paper enters the jogger section the jogger fences move up against the paper on both sides. Next, the transport rollers move the paper up through the vertical relay rollers [D] to the registration rollers [E]. From here on, the paper follows the same path as the first time, with the only difference being that the reverse side now faces up to receive the image. 1-13 28 February 1989 5.3 MULTI DUPLEX COPY PATH Multi Duplex Paper Feed: After the paper makes its first pass through the copier, the junction gate [A] directs the paper to the duplex tray where jogger fences [B] move up against the paper from both sides to correct its lateral position. The duplex feed mechanism then feeds the paper to the jogger section inside the copier. This time, however, the jogger fences there do not operate and the paper is fed directly to the registration rollers. After reaching the registration rollers, the sheet follows the same path as when the front side was copied, with the only difference being that the reverse side now faces up to receive the image. 1-14 28 February 1989 5.4 SINGLE OVERLAY COPY PATH Overlay Paper Feed: The copy paper is fed down from the fusing unit to the lower section [A] and sent directly to the jogger section [B]. When the paper enters the jogger section the jogger fences move up against the paper on both sides. Next, the transport rollers move the paper up through the vertical relay rollers [C] to the registration rollers [D]. From here the paper follows the same path as the first time, with the second image being placed on the same side. 1-15 28 February 1989 5.5 MULTI OVERLAY COPY PATH Multi Overlay Copy Feed: After the paper makes its first pass through the copier, the junction gate [A] directs the paper to the duplex tray, where jogger fences [B] move in from both sides to correct the lateral position of the paper. After this, the duplex feed mechanism feeds the paper. The inverter gate [C] guides the paper to the inverter rollers [D]. The inverter rollers turn until the trailing edge of the paper is detected by the inverter sensor [E]. The rollers then reverse direction and the paper is fed to the jogger section. This time, however, the jogger fences here do not operate and the paper is fed directly to the registration rollers. After the paper reaches the registration rollers, the sheet follows the same path as when the front side was copied. However, this time the front side faces up to make an overlay copy. 1-16 28 February 1989 6. DRIVE LAYOUT Gears Sprocket G1: Third Paper Feed Clutch Gear S1: Main Motor Sprocket G2: Second Paper Feed Clutch Gear TB1: Drum Drive Belt Timing Belt G3: First Paper Feed Clutch Gear Belt G4: Toner Supply Clutch Gear B1: Exit Roller Drive Belt G5: Development Unit Change Drive Gear Chains G6: Duplex/Overlay Transport Clutch Gear C2: Duplex/Overlay Drive Chain C1: Main Drive Chain G7: Registration Clutch Gear G8: Relay Clutch Gear 1-17 28 February 1989 7. MECHANICAL COMPONENT LAYOUT 28 February 1989 1. Exposure Lamp 23. Pre-Transfer Lamp 2. Cleaning Unit 24. Registration Roller 3. Ouenching Lamp 25. Transfer Corona 4. Lens 26. Separation Corona 5. Charge Corona 27. Pick-off Pawl 6. 6th Mirror 28. I.D.Sensor 7. Shield Glass 29. Cleaning Brush 8. Erase Unit 30. Cleaning Blade 9. Exposure Glass 31. Jogger Unit 10. Red Erase Unit 32. Transport Unit 11. 4th Mirror 33. Main Motor 12. 5th Mirror 34. Pressure Roller 13. Color Development Unit 35. lnverter Roller 14. OPC Drum 36. Inverter Gate 15. Manual Feed Table 37. Junction Gate 16. Black Toner Cartridge 38. Hot Roller 17. Black Development Unit 39. Hot Roller Stripper 18. Pick-up Roller 40. Duplex/Overlay Transport Gate 19. Feed Roller 41. Fusing Exhaust Fan 20. Separation Roller 42. 3rd Mirror 21. Feed Roller 43. 2rd Mirror 22. Friction Pad 44. 1st Mirror 1-19 28 February 1989 8. ELECTRICAL COMPONENT LAYOUT 1. Sorter Interface Board 2. Cooling Fan Motor 3. Scanner Drive Motor 4. Main Motor Capacitor 5. Development Drive MC 23. 24. 25. 26. 27. Key Counter (optional) 1st Cassette Paper End Sensor Registration Sensor Jogger Positioning SOL Jogger Motor 6. SC Power Pack 7. Toner Supply MC 8. AC Drive Board 9. Development Unit Change SOL 10. Manual Feed Sensor 28. Jogger H.P. Sensor 29. CC/TC Bias Power Pack 30. A3/LDG Counter (optional) 31. Total Counter 32. Red Erase SOL 11. 1st Paper Feed MC 12. 1st Lift Motor 13. 2nd Paper Feed MC 14. Paper Feed Board 15. 1st Pick-up SOL 33. System Control Board 34. Main SW 35. Front Cover Safety SW 36. Inverter Gate SOL 37. Noise Filter 16. 1st Cassette Lift Sensor 17. 2nd Cassette Paper End Sensor 18. 3rd Paper Feed MC 19. I/O Control Board 20. 3rd Cassette Paper End Sensor 21. Relay Roller MC 22. Registration MC 38. Duplex/Overlay Transport Gate SOL 39. Duplex/Overlay Transport MC 40. Pulse Generator Sensor 41. DC Power Supply Board 42. 1st Scanner H.P. Sensor 1-20 28 February 1989 43. 44. 45. 46. 47. 58. 59. 60. 61. 62. Erase Lamp Quenching Lamp Auto Density Sensor Original Length Sensor Thermal SW Drum Heater Lens H.P. Sensor Toner Overflow Sensor Lower Relay Sensor Vacuum Fan Motor 48. Exposure Lamp 49. Anti-Condensation Heater (Optional) 50. Fusing Exhaust Fan Motor 51. Fusing Lamp 63. Upper Relay Sensor 64. 3rd Paper Size Switches 65. 2nd Paper Size Switches 66. 1st Paper Size Switches 67. ID Sensor 52. Fusing Exit Sensor 53. Inverter Relay Sensor 54. Inverter Sensor 55. Main Motor 56. Main Transformer 57. Lens Drive Motor 68. 3rd Scanner H.P. Sensor 69. 3rd Scanner Drive Motor 70. Color Toner End Sensor 71. Original Width Sensor 72. Pre-Transfer Lamp 73. Color Toner DIP SW 1-21 28 February 1989 9. ELECTRICAL COMPONENT DESCRIPTIONS Index No. Name Function Symbol P to P Location Motors 55 Main Motor Drives all main unit components except optics unit and fans. (100 Vac) M1 H-5 50 Fusing Exhaust Fan Removes heat from around the fusing unit. (100 Vac) M2 H-4 2 Cooling Fan Prevents build up of hot air in the optics cavity. (100 Vac) M3 H-5 62 Vacuum Fan Provides suction so paper is held firmly on the transport belt. (100 Vac) M4 F-5 3 Scanner Drive Drives the scanner. (dc servo) M5 D-4 69 3rd Scanner Drive Positions the 3rd scanner. (dc stepper) M7 D-5 57 Lens Drive Positions the lens. M6 D-5 27 Jogger Drives the jogger plates to keep paper evenly stacked on the jogger tray. (dc stepper) M8 F-12 12 1st Lift Motor Lifts paper to the appropriate feed position. M9 F-5 Magnetic Clutches 22 Registration Drives the registration rollers. MC1 F-7 11 1st Paper Feed Starts paper feed from the first feed station. MC2 F-7 13 2nd Paper Feed Starts paper feed from the second feed station. MC3 F-8 18 3rd Paper Feed Starts paper feed from the 3rd feed station. MC4 F-8 7 Toner Supply Drives toner supply roller. MC5 F-8 21 Relay roller Drives the relay rollers for the 3rd cassette, cassette bank and the duplex/overlay paper path. MC6 F-8 5 Development Drive Drives black development or color development units MC7 F-6 39 Duplex/Overlay Transport Drives the rollers of the Duplex/Overlay section. MC8 F-11 15 1st Pick-up Starts paper feed from the 1st feed station. SOL1 F-4 1-22 28 February 1989 Index No. Name Function Symbol P to P Location 9 Development Unit Change Changes the position of the black development unit and color development unit. SOL2 F-4 32 Red Erase Changes the filter position. SOL3 F-5 38 Duplex/Overlay Transport Gate Directs copies to the Duplex/Overlay units. SOL4 F-11 36 Inverter Gate Directs copies to the Inverter Rollers. SOL5 F-12 26 Jogger Positioning Lifts the Jogger guide plates while copies are being jogged. SOL6 F-12 Switches 34 Main Supplies power to the copier. SW1 H-2 35 Front Cover Safety Cuts ac power line. SW2 H-2 73 Color Toner DIP Indicates which color development unit is installed. SW3 F-3 66 1st Paper Size Determines what size paper is in the first cassette. SW4 D-10 65 2nd Paper Size Determines what size paper is in the second cassette. SW5 D-10 64 3rd Paper Size Determines what size paper is in the third cassette. D-10 Sensors 40 Pulse Generator Supplies timing pulses to the system control board. S1 D-2 52 Fusing Exit Detects misfeeds. S2 D-6 60 Toner Overflow Detects when the used toner bottle is full. S3 F-3 70 Color Toner End Detects when it is time to add color toner. S4 F-3 25 Registration Detects misfeeds. S5 F-8 10 Manual Feed Detects when the manual feed table is open. S6 D-12 42 1st Scanner Home Position Informs the CPU when the scanner is at the home position. S7 D-4 68 3rd Scanner Home Position Informs the CPU when the 4th/5th mirror assembly is in the full size position. S9 D-4 59 Lens Home Position Informs the CPU when the lens is at the full size position. S8 D-5 1-23 28 February 1989 Name No. Function Symbol P to P Location 24 1st Cassette Paper End Informs the CPU when the first cassette runs out of paper. S10 D-11 17 2nd Cassette Paper End Informs the CPU when the second cassette runs out of paper. S11 D-11 20 3rd Cassette Paper End Informs the CPU when the third cassette runs out of paper. S12 D-11 28 Jogger Home Position Informs the CPU when the jogger plates are at the home position. S13 F-11 63 Upper Relay Detects misfeeds. S14 D-12 61 Lower Relay Detects misfeeds. S15 D-12 16 1st Cassette Lift Detects the correct feed height of the 1st cassette. S16 F-8 67 Image Density Detects the density of the image on the drum. S17 D-2 71 Original Width (OW) Used for determining paper size in the APS mode. S18 D-6 46 Original Length (OL) Used for determining paper size in the APS mode. S19 D-6 45 Auto Density (AD) Senses the background density of the original. S20 D-2 54 Inverter Detects trailing edge of copies for inverter roller reverse timing. Detects misfeeds. S21 F-10 53 Inverter Relay Detects misfeeds. S22 F-10 Monitors the fusing temperature. TH1 F-2 Thermistors - Fusing Power Packs 6 SC Power Pack Provides high voltage for the separation corona. P1 H-10 29 CC/TC/Bias Power Pack Provides high voltage for the charge corona, the development roller bias and the transfer corona. P2 G-9 Heaters 58 Drum Prevents moisture around the drum. H1 G-3 49 Anti-condensation (Option) Prevents moisture from forming on the optics. H2 G-3 1-24 28 February 1989 Index No. Name Function Symbol P to P Location Lamps 48 Exposure Applies high intensity light to the original for exposure. L1 H-5 51 Fusing Provides heat to the Hot Roller. L2 H-6 43 Erase Discharges the drum outside of the image area. Provides leading/trailing edge erase and editing functions. L3 D-3 44 Quenching Neutralizes any charge remaining on the drum surface after cleaning. L4 F-2 72 Pre-transfer Reduces charge on the drum surface before transfer. L5 F-2 Printed Circuit Boards 19 I/O Control Interfaces the copier functions to the System Control Board. Controls the speed of the scanner, the position of the lens, and the position of the mirrors and AC Drive Board. PCB1 E-2 33 System Control Controls all copier functions through other PCBs. PCB2 C-4 41 DC Power Supply Rectifies 100Vac input and outputs dc voltage. PCB3 G-2 8 AC Drive Drives all ac motors, the exposure lamp, and the fusing lamp. PCB4 G-5 14 Paper Feed Receives input from paper size and paper end sensors and sends that information to the I/O board. PCB5 C-9 Counters 31 Total Keeps track of the total number of copies made. CO1 D-3 30 A3/LDG Keeps track of the total number of A3/11 x 17 copies made. (option) CO2 D-3 23 Key Used for control of authorized use. Copier will not operate until installed. CO3 D-2 1-25 28 February 1989 Index No. Name Function Symbol P to P Location Others - Thermofuse Provides back-up overheat protection in TF the fusing unit. H-5 47 Thermal Switch Provides back-up overheat protection around the exposure lamp. TS H-5 37 Noise Filter Removes electrical noise. NF1 H-2 4 Main Motor Capacitor Start capacitor C H-5 56 Main Transformer Steps down the wall voltage to 100 Vac. TR1 H-3 1-26 28 February 1989 10. AC AND DC POWER DISTRIBUTION The ac power supply is filtered and distributed to the fusing lamp, drum heater, anticondensation heater (option), and main transformer. The transformer supplies 100 volts to the cooling fan, fusing fan, exposure lamp, main motor, and sorter (option). The dc power supply board receives 100 Vac from the main transformer. This voltage is rectified and regulated to 24 and 5 volts respectively. It is distributed to the ac drive board, I/O control board, system control board, ADF, and the power packs. Vpp is an isolated supply. The I/O control board and system control board supply voltage to the paper feed board, date printer (option), editor board (option), and the multi duplex/overlay unit (option). The LCT has a separate AC power supply, but receives VAA (24 Vdc) and VCC (5Vdc) from the paper feed board. 1-27 28 February 1989 11. OVERALL MACHINE CONTROL The following block diagram shows the flow of control signals within the The system control board is responsible for initiating all actions that take place in a copy cycle. The I/O control board interfaces the system control board to those components it does not directly control. 1-28 SECTION 2 DETAILED SECTION DESCRIPTIONS CONTENTS 1. DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 1.1 OPC DRUM CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 1.2 HANDLING THE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 1.3 DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 2. DRUM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 2.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 2.2 CHARGE CORONA UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 2.3 CHARGE CORONA POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 2.4 CHARGE CORONA WIRE CLEANER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 3. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 3.2 SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 3.2.1 1st and 2nd Scanner Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 3.3 SCANNER MOTOR DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 3.4 LENS DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 3.4.1 Lens Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 3.4.2 Shading Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 3.5 LENS POSlTIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 3.6 3RD SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 3.6.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 3.6.2 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 3.7 STEPPER MOTOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14 3.8 RED ERASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 3.9 AUTOMATlC lMAGE DENSITY SENSlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 3.10 AUTOMATIC ORIGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 3.11 EXPOSURE LAMP VOLTAGE CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 3.11.1 Manual Image Density Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 3.11.2 Size Magnification Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 3.11.3 Drum Sensitivity Correction (Vr Correction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 3.11.4 Drum Rotation Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 3.11.5 Photo Mode Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 3.11.6 ADS Correction (SP mode #34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 3.11.7 Red Erase Mode Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 3.11.8 Pre-scan Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 3.12 EXPOSURE LAMP CONTROL ClRCUlT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 3.13 SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 4. ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 4.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 4.1.1 Lead Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 4.1.2 Side Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 4.1.3 Special Mode Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 4.1.4 Trailing Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 4.2 ERASE LAMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 4.3 ERASE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 5. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 5.2 DEVELOPMENT UNIT CHANGE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 5.3 DEVELOPMENT UNIT SUPPORT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31 5.4 DRIVE MECHANISM (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32 5.5 DRIVE MECHANISM (Color) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33 5.6 AGITATOR MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 5.7 TONER SUPPLY AND AGITATOR DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . .2-35 5.8 TONER DENSITY DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36 5.9 TONER DENSITY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37 5.10 TONER END DETECTION (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38 5.10.1 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38 5.11 TONER END DETECTION (Color) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39 5.11.1 Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39 5.12 ID SENSOR SUPPLY CONTROL (Black only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40 5.13 ID SENSOR TONER SUPPLY LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41 5.14 ID SENSOR SUPPLY CONTROL IN FIXED SUPPLY MODE . . . . . . . . . . . . . . . . . . . .2-42 5.15 TONER SUPPLY AMOUNT (FIXED SUPPLY MODE) . . . . . . . . . . . . . . . . . . . . . . . . .2-44 5.16 ID SENSOR ERROR DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45 5.17 DEVELOPMENT BlAS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46 5.17.1 Manual bias control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46 5.17.2 Auto Image Density bias control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46 5.18 BIAS CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47 5.18.1 Vr Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47 5.18.2 SP Mode Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47 5.19 ID SENSOR BIAS COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 5.19.1 Standard Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 5.19.2 Vp Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 5.19.3 Developer Counter Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49 5.19.4 Total lD Sensor Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49 6. IMAGE TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50 6.1 PRE-TRANSFER LAMP (PTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50 6.2 IMAGE TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50 6.3 PAPER SEPARATION AND TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51 6.3.1 Paper Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51 6.3.2 Paper Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51 6.4 PTL AND T/S CHARGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52 7. ID SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53 7.1 ID SENSOR IMAGE CORRECTION (Vr Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53 7.2 ID SENSOR PATTERN (Vsp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55 8. DRUM CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56 8.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56 8.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57 8.3 RELEASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58 8.4 TONER OVERFLOW DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59 9. PAPER FEED AND REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . .2-60 9.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 9.2 FRR FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 9.2.1 Pick-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 9.2.2 Feed and Separation Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 9.3 FRICTION PAD FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62 9.4 PAPER LlFT MECHANlSM (1st Feed Station) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63 9.5 PAPER LlFT MECHANlSM (2nd and 3rd Feed Stations) . . . . . . . . . . . . . . . . . . . . . . . .2-64 9.6 PAPER SIZE AND END DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65 9.7 PAPER FEED DRIVE MECHANISM (FRR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66 9.8 PAPER FEED REGlSTRATION DRlVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . .2-67 9.9 MANUAL FEED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68 9.10 PAPER FEED TlMlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69 9.11 SERVlCE CALL CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70 10. IMAGE FUSING AND PAPER EXIT . . . . . . . . . . . . . . . . . . . . . . . . . .2-71 10.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71 10.2 FUSING DRIVE RELEASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72 10.3 FUSING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-73 10.3.1 Phase Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74 10.4 SERVlCE CALL CONDlTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75 11. DUPLEX/OVERLAY MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76 11.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76 11.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77 11.3 JOGGER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78 11.4 SlNGLE DUPLEX/OVERLAY TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79 12. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80 12.1 PAPER MISFEED CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80 12.2 SERVICE CALL CONDlTIONS (Others) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82 13. COPIER TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-83 28 February 1989 1. DRUM 1.1 OPC DRUM CHARACTERISTICS An OPC has the characteristics of: • Being able to accept a high negative electrical charge in the dark. (The electrical resistance of a photoconductor is high in the absence of light.) • Dissipating the electrical charge when exposed to light. (Exposure to light greatly increases the conductivity of a photoconductor.) • Dissipating an amount of charge in direct proportion to the intensity of the light. That is, where stronger light is directed to the photoconductor surface, a smaller voltage remains on the OPC. Being less sensitive to changes in temperature (when compared to selenium F type drums). This makes it unnecessary to monitor and control the drum temperature. 2-1 28 February 1989 1.2 HANDLING THE DRUM The organic photoconductor drum is comparatively more sensitive to light, and ammonia gas than a selenium drum. 1. Never expose the drum to direct sunlight. 2. Never expose the drum to direct light of more than 1000 Lux for more than a minute. 3. Never touch the drum surface with bare hands. When the drum surface is touched with a finger or becomes dirty, wipe with a dry cloth or clean with wet cotton. Wipe with a dry cloth after cleaning with wet cotton. 4. Never use alcohol to clean the drum; alcohol dissolves the drum surface. 5. Store the drum in a cool, dry place away from heat. 6. Take care not to scratch the drum as the drum layer is thin and is easily damaged. 7. Never expose the drum to corrosive gases such as ammonia gas. 8. Always keep the drum in the protective sheet when inserting or pulling the drum out of the copier. 9. Before inserting or pulling out the drum, remove all units around the drum. 2-2 28 February 1989 1.3 DRUM UNIT An 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. The drum unit consists of an OPC drum, ID sensor [C] and separation pawls [D]. The drum is driven by the main motor [H] through the drum drive belt [E] and the drum drive gear [F]. The separation pawls [D] are always in contact with the drum surface. The ID sensor is electrically connected to the ID sensor connector [G]. 2-3 28 February 1989 2. DRUM CHARGE 2.1 OVERVIEW This copier uses a single wire scorotron and a highly sensitive OPC drum. The corona wire [A] generates a corona of negative ions when the charge power pack applies a high voltage (-5.0 to -7.5 KV). The drum coating [B] receives a uniform negative charge as it rotates past the corona unit. A stainless steel grid plate [C] makes the corona charge uniform. The charge fan [D] provides a smooth flow of air to the interior of the charge corona unit to prevent an uneven build up of negative ions. (An uneven build up of negative ions could cause uneven image density.) 2-4 28 February 1989 2.2 CHARGE CORONA UNIT The charge corona unit consists of the charge corona wire [A], the grid mesh [B] and the charge wire cleaner [C]. The applied voltage of the charge corona wire is constant but the surface potential of the drum rises in proportion to the number of copies made. A voltage corresponding to the drum surface potential is applied to the grid [B] to achieve consistent copy quality. The amount of compensation is determined by the ID sensor (Vrp/Vsg). The flow of air around the charge corona wire [A] may deposit paper dust or toner particles on the corona wire. These particles may interfere with charging and cause low density bands on copies. The wire cleaner [C] cleans the corona wire when the operator slides the corona unit in and out. 2-5 21 April 1989 2.3 CHARGE CORONA POWER PACK The circuit operation for the charge corona begins with the input of 24 volts to the power pack at CN1-1. This power supply is used for the high voltage corona. The charge corona turns on 0.1 seconds after the Start key is pressed. A LOW signal from the I/O control board (at CN1-3) energizes the power pack. The OFF timing is the same as the scanner return timing. The grid voltage is also applied by the power pack. The voltage for the ID sensor grid is -560 volts. This ID sensor grid is applied from 0.1 to 0.59 seconds after the Start key is pressed. The voltage for the image grid changes depends on the combination of G0 G3 (Vrp/Vsg). 2-6 28 February 1989 2.4 CHARGE CORONA WIRE CLEANER MECHANISM Pads [A] above and below the charge corona wire clean the wire as the charge unit is manually slid in and out. The cleaner pad bracket [B] rotates when the charge unit is fully extended and the bracket is pulled up against the rear block [C]. This moves the pads against the corona wire (see illustration). The pads move away from the wire when the charge unit is fully inserted and the cleaning bracket is pushed against the front block [D]. 2-7 28 February 1989 3. OPTICS 3.1 OVERVIEW During the copy cycle, an image of the original is reflected onto the drum surface via the optics assembly as follows. Light Path: Exposure Lamp [A] –> 2nd Mirror [D] –> 4th Mirror [G] –> 6th Mirror [J] –> –> –> –> Original [B] –> 1st mirror [C] –> 3rd Mirror [E] –> Lens [F] 5th Mirror [H] –> Red erase [I] –> Drum [L] Toner shield glass [K] –> The cooling fan [M] removes warm air (heated by the exposure lamp) from the optics cavity. This blower operates during every copy cycle. The 1st scanner (lamp and 1st mirror), 2nd scanner (2nd and 3rd mirrors), 3rd scanner (4th and 5th mirrors), and the lens function together to achieve a wide range of reproduction ratios. The red erase unit [I] has a green filter and a red filter. The green filter is used in the normal copy mode. The red filter is used in the red erase copy mode. Auto density sensing (ADS) and auto original paper size sensing (APS) are done by optical fibers located on the 1st scanner unit. A thermoswitch (opens at 130°C)installed on the back of the exposure lamp reflector keeps temperatures at acceptable levels inside the optics assembly. 2-8 28 February 1989 3.2 SCANNER DRIVE 3.2.1 1st and 2nd Scanner Drive Mechanism This model uses a dc servo motor [A] to drive the scanners. Both ends of each scanner are driven to prevent skewing. The scanners have sliders [B], which ride on guide rails. The scanner home position is detected by the home position sensor [C]. The scanner return position is detected by counting the scanner motor drive pulses. The first scanner [D], which consists of the exposure lamp and the first mirror, is connected to the scanner drive wire by the wire clamps [E]. The second scanner [F], which consists of the second and third mirrors, is connected to the scanner drive wire by movable pulleys (the second scanner pulley [G]). The pulley moves the second scanner at half the velocity of the first scanner. This is to maintain the focal distance between the original and the lens during scanning. This relationship can be expressed as: V1r = 2(V2r) = VD/r where r = Reproduction ratio V1r = First scanner velocity (when the reproduction ratio is “r”) V2r = Second scanner velocity (when the reproduction ratio is “r”) = Drum peripheral velocity (120 mm/s) VD 2-9 28 February 1989 3.3 SCANNER MOTOR DRIVE The scanner drive motor is a servomotor. The I/O control PCB controls the speed of this servomotor. The I/O control PCB and the system control PCB communicate through a serial interface. At the programmed time, the system control PCB checks the drum speed by monitoring the pulses from the pulse generator. Based on this input, the I/O control PCB determines the proper speed for the scanner drive motor. The encoder on the servomotor is a photointerruptor that generates pulse signals. The I/O control PCB monitors the scanner speed by these pulse signals and uses this data to regulate the servomotor speed. The home position sensor informs the I/O control PCB when the first scanner is in the home position. 2-10 28 February 1989 3.4 LENS DRIVE : Reduction : Enlargement 3.4.1 Lens Drive The lens drive motor [A] (stepper motor) changes the lens [B] position through the lens drive wire [C] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and the drum surface. The rotation of the lens drive pulley moves the lens back and forth in discrete steps. The home position of the lens is detected by the home position sensor [D]. The I/O control PCB keeps track of the lens position based on the number of pulses sent to the lens drive motor. 3.4.2 Shading Mechanism The shading plates [E] are installed on the lens housing [F] and are slid open and shut by the shading cam [G]. This shading mechanism adjusts the horizontal light intensity, which becomes uneven in reduction mode, when the light at both edges is more intense. The shading plates close in reduction mode to even out the light intensity. 2-11 28 February 1989 3.5 LENS POSITIONING : Reduction : Enlargement The lens home position sensor [A] informs the I/O control PCB when the lens is at full size position (home position). The I/O control PCB determines the lens stop position in reduction and enlargement modes by counting the number of steps the motor makes with reference to the lens home position. When a new reproduction ratio is selected, the lens [B] moves directly to the selected magnification position. The lens home position is registered each time the lens starts from or passes through the lens home position sensor. As the lens moves from right to left (as viewed from the front), the sensor registers the home position. This occurs when the actuator plate [C] enters the lens home position sensor. A small vibration can be observed when the lens moves through home position from enlargement to reduction because the lens is going in the wrong direction to register. The lens overshoots the home position by only one pulse before going back to reference the home position. The lens always stops while moving from left to right to minimize the error caused by mechanical play in the drive gears [D]. 2-12 28 February 1989 3.6 3RD SCANNER DRIVE 3.6.1 Drive The 3rd scanner drive motor (stepper motor) changes the 3rd scanner position through the drive wire [A] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and drum surface. 3.6.2 Positioning The positioning mechanism is similar to that of lens positioning, as shown in the above positioning chart. The scanner always stops while moving from left to right (as viewed from the front). 2-13 28 February 1989 3.7 STEPPER MOTOR CONTROL Both the lens drive motor and the third scanner drive motor are stepper motors. The stators of these stepper motors have four coils (labeled A, B, and above), and the rotors are permanent magnets. Pulse signals energize the four coils as shown in the above illustration. The rotor turns in discrete steps. 2-14 28 February 1989 3.8 RED ERASE MECHANISM This model has a red erase function. In red erase mode, the red erase solenoid [A] is energized (ON) to move the red filter [B] into the optical path. (Normally, the green filter [C] is in the optical path.) The red filter allows only red to pass through, thus decreasing the contrast in light intensity between the red and white areas on the original. 2-15 23 May 1989 3.9 AUTOMATIC IMAGE DENSITY SENSING The input for the automatic image density circuit is via a fiber optic cable [A] mounted on the first scanner. Light from the exposure lamp [B] passes through a small hole in the reflector, reflects from the original, and is collected by the fiber optic cable. The sampled strip starts 18 millimeters from the leading edge of the original. The detecting length L of the ADS circuit is determined by the following equation in each copy mode: Black copy mode: L = Color copy mode: L = 88 mm Reproduction Ratio 44 mm Reproduction Ratio The highest voltage detected by the ADS is held (peak hold) and used for the bias voltage adjustment. The ADS system will change the developer bias to adjust the image density for optimum copy quality. This ADS system has three base levels (N,D,L) to allow the system more flexibility. SP Mode #34 switches the settings as follows: N: Normal (base levels) D: Dark (no exposure lamp change, bias increases 40V) L: Light (2V exposure lamp voltage increase, no bias increase) 2-16 28 February 1989 3.10 AUTOMATIC ORIGINAL SIZE DETECTION The original length sensor [A] and width sensor [B] on the first scanner detect the original size during pre-scanning. Length and width sensor data are combined as shown in the size detection table to determine the original size. The pre-scan speed is one half of the normal scan speed. 2-17 28 February 1989 3.11 EXPOSURE LAMP VOLTAGE CORRECTION 3.11.1 Manual Image Density Correction The I/O control PCB controls the exposure lamp voltage based on the manual image density level (selected using the operation panel image density key) and ADS base level. Lamp voltage at level 4 in manual image density mode can be set to 50 to 75 V using SP mode #48 (Standard 64 V). The following inputs will also change the lamp voltage to ensure consistent copy quality. Lamp voltage is varied by pressing the manual image density key on the control panel to adjust the image density. 3.11.2 Size Magnification Correction Lamp voltage is varied pressing the magnification key of the control panel to compensate for the change in the concentration of light on the drum. 2-18 28 February 1989 3.11.3 Drum Sensitivity Correction (Vr correction) As the OPC drum is used, residual voltage rises gradually in repeat copying due to characteristics of the drum. The lamp voltage is adjusted to keep copy quality consistent. 3.11.4 Drum Rotation Correction To compensate for fogging of the OPC drum surface by the cleaning brush, main motor “on” time is tracked and lamp voltage increased accordingly. 2-19 28 February 1989 3.11.5 Photo Mode Correction S P Mode #40 setting Data Correcting Voltage Normal N(0) -2V Lighter L(1) ±0V Darker D(2) -4V When photo mode is selected, the image density level can only be changed manually and the lamp voltage is shifted by -2V from the standard voltage in normal mode (V0). The amount of shift can be changed with SP mode #40. (Auto density cannot be used.) 3.11.6 ADS Correction (SP mode #34) Users can vary the voltage in ADS mode using SP mode #34. Normally this is a standard set voltage (V0). 3.11.7 Red Erase Mode Correction The voltage is raised by +2V when red erase mode is selected. (V0 + 2V) 3.11.8 Pre-scan Correction The voltage is fixed to 68V during pre-scan when Auto Paper Select is selected. 2-20 28 February 1989 3.12 EXPOSURE LAMP CONTROL CIRCUIT AC power Zero cross Trigger pulse Lamp power Feedback signal The I/O control board sends lamp trigger pulses to the ac drive board from CN304-A19. PC401 activates TRC401, which provides ac power to the exposure lamp at the trailing edge of each trigger pulse. The voltage applied to the exposure lamp is also provided to the feedback circuit. The feedback circuit steps down (T401), rectifies (DB405), and smoothes (zener diodes and capacitors) the lamp voltage. The CPU monitors the lowest point of the smoothed wave (feedback signal). The lowest point of this signal is directly proportional to the actual lamp voltage. In case of overheating, the thermoswitch opens at 130°C and removes ac power to the exposure lamp. 2-21 28 February 1989 3.13 SERVICE CALL CONDITIONS Self Diagnostic Code 11: Code 11 is displayed if a lamp circuit malfunction is detected during standby (lamp ON), or if the lamp filament or thermal switch opens. Self Diagnostic Code 12: Exposure Lamp Malfunction Code 12 is displayed if the lamp circuit malfunctions (stays ON), or if the lamp filament or thermal switch opens for longer than 20 seconds during a copy cycle. Self Diagnostic Code 21: Scanner Malfunction Code 21 is displayed if the 1st scanner home position sensor is not actuated within 6 seconds (scanner does not return home). Self Diagnostic Code 22: Scanner Malfunction Code 22 is displayed if the 1st scanner home position sensor remains actuated (OFF) during the initialization. Self Diagnostic Code 23: Code 23 is displayed if the I/O control board does not receive the registration start signal within 4.9 seconds after the scanner starts. Self Diagnostic Code 24: No Scanner Home Position Signal Code 24 is displayed if the I/O control board does not detect the home position signal within 20 seconds after the scanner starts. (The scanner does not return to the home position.) 2-22 28 February 1989 Self Diagnostic Code 25: Code 25 is displayed if the scanner motor encoder pulse phase is not detected. Self Diagnostic Code 2E Scanner Motor Malfunction Code 2E is displayed if the scanner motor encoder pulse is not detected for more than 100m seconds. Self Diagnostic Codes 2A and 2B: Third Scanner Home Position At certain times (power ON, clear, auto-reset), the third scanner either moves to its home position or moves out and back. Code 2A is displayed if the third scanner home position sensor stays OFF longer than 2.3 seconds. Code 2B is displayed if the third scanner home position sensor stays ON longer than 2.3 seconds. Self Diagnostic Codes 28 and 29: Lens Home Position Check Code 28 is displayed if the lens home position sensor stays OFF (high). Code 29 is displayed if the scanner home position sensor stays ON (low). 2-23 28 February 1989 4. ERASE 4.1 OVERVIEW LE: Lead edge erase margin 2.5 ± 1.5 mm SE : Side erase margin 1.5 ± 1.5 mm on each side; total of both sides 4 mm or less Lo: Lc: EL: ES: Original width Charged width of drum Lead edge erase Side erase The erase lamp [A] consists of a line of 120 LEDs extending across the 300 mm width of the drum [C]. The function of the erase lamp is to prevent the toner from being attracted to the non-image part of the drum and to reduce the load on the cleaning unit. The erase function is divided into three major erase functions: lead edge erase, side erase, and editing mode erase. 2-24 28 February 1989 ERASE LAMP TIMING 4.1.1 Lead Edge Erase The entire line of LEDs turns on when the main motor turns on. They stay on until the erase margin slightly overlaps the lead edge of the original image area on the drum (Lead Edge Erase Margin). This prevents the toner density sensor pattern from being developed every copy cycle and the shadow of the original edge from being developed on the paper. The width of the lead edge erase margin can be adjusted using SP Mode #41. During image density detection cycles (once every ten cycles), a block of erase lamps turns off long enough for the sensor pattern to be developed. The entire line of LEDs turns on when the residual voltage is being detected (Vr. correction). 4.1.2 Side Erase Based on the paper size and the reproduction ratio, the LEDs turn on in pairs (one on either side) to discharge the drum potential on both sides. This reduces toner consumption and drum cleaning load. The side erase margin is overlapped to the size of the paper to prevent both sides of the original from being developed on the copy image. In A3 size, no erase lamps are turned on and side erase is done by the end block of the charge unit. (This does not apply to 11” x 17”, as it is narrower than A3 and does use the LEDs for side erase.) Erase lamp “on” timing depends on the combination of cassette data and the reproduction ratio data. In case of full size and enlargement copying, erase is made only by cassette data. In reduction, erase is made by cassette data and reproduction ratio data. 2-25 28 February 1989 EDGE ERASE MARGIN A3,A4 (DLT,LT) 4.5mm (5.5mm) B4,B5 4.5 (HLT,LG,LT”R”) 6.0 (4.0) 9.5mm (10.5mm) 14.5mm (15.5mm) 19.5mm (20.5mm) 9.5 14.5 19.5 11.0 (9.0) 16.0 (14.0) 21.0 (19.0) B5”R”, B6 4.5 9.5 14.5 19.5 A5”R”,A6 5.0 10.0 15.0 20.0 B6”R” 5.0 10.0 15.0 20.0 A6”R” (HLT”R”) 6.0 (6.0) 11.0 (11.0) 16.0 (16.0) 21.0 (21.0) Official Postcard 3.5 8.5 13.5 18.5 4.1.3 Special Mode Erase Erase is controlled by using 120 LEDs in 2.5 mm increments according to the cassette data in editing. In centering, the registration start timing and erase are controlled. The erase margins can be changed by SP Mode #39 (Center Erase) and SP Mode #38 (Erase Edge) in 5 mm steps. Center Erase Margin Standard = 20 mm Edge Erase Margin Standard = 10 mm 4.1.4 Trailing Edge Erase Normally, the erase lamps turn on after the trailing edge of the latent image has passed. Therefore, a trailing erase margin cannot be observed on the copy. Trailing edge erase ON timing is 0.04 seconds after charge corona OFF timing. During enlargement or reduction, the trailing erase ON timing changes according to the paper size and the reproduction ratio. NOTE: The erase margins do not precisely correspond to paper size and reproduction ratio as the erase lamps are 2.5 mm in size. 2-26 28 February 1989 4.2 ERASE LAMP CIRCUIT This copier uses 120 LEDs in the erase lamp unit. Shift register drivers control the LEDs. Initially, the RESET signal (LOW active) turns off all the shift registers. Then the system control PCB sends erase lamp data to the shift registers. After the RESET signal goes back to HIGH, the shift registers start accepting data. If the data line is HIGH at the time of the CLOCK pulse (rising edge), the shift register is set to turn the LED on; if it is LOW, the shift register is set to keep the LED off. The data in the shift registers is shifted right one position at the start of each clock cycle; so, it takes 120 CLOCK pulses to set the shift registers for all the LEDs. After all data bits have been sent, the main board sends the LATCH signal to turn on the erase lamp unit. The latch signal sets the shift registers which turn on all LEDs for which data bits have been set. 2-27 28 February 1989 4.3 ERASE TIMING Operation Timing T0: Start key ON. All erase lamps turn on, bias is applied. T1: T1 = T0 + 0.1 sec. Change corona outputs ID sensor grid voltage for 0.49 seconds. T2: T 2 = T0 + 0.63 sec. Some erase lamps switcn off to create the ID sensor pattern. Also, the development bias is changed to match the ID sensor pattern. For color, this happens at T0 + 0.65. For black, this happens at T0 + 0.9 seconds. T3: T3 = T0 + 0.81 sec. The erase lamps which were switched off turn on again, and there is full erase until T0 + 0.94 seconds. In order to create the Vr pattern, bias is reduced to 0V at T0 + 1.02 sec. T4: T4 = T0 + 1.14 sec. The ID sensor pattern bias switches to image bias. For color, at T0 + 1.14 + T4. For black, at T0 + 1.4. Vr pattern check is performed, the 0V bias rises to ID sensor pattern bias at T0 + 1.33 sec. T5: T5 = T0 + 1.88 sec. The ID sensor pattern is checked to correct the image density level or the VR pattern is checked to compensate for residual voltage on the drum. 2-28 28 February 1989 5. DEVELOPMENT 5.1 OVERVIEW The development section is composed of a black development unit [A] and a color development unit [B]. Normally, the black development roller is in contact with the drum [C]. When color copy mode is selected, the color development unit moves against the drum and the black development unit is pulled back. Both development units have a development roller [D], two paddle rollers [E], atoner supply roller [F] and a toner hopper [G]. The paddle rollers pick up developer in their paddles and transport it to the development roller. Internal permanent magnets in the development roller attract the developer to the development roller sleeve. The turning sleeve of the development roller then carries the developer past the doctor blade. The doctor blade trims the developer to the desired thickness and creates a backspill for the cross-mixing mechanism. The development roller continues to turn, carrying the developer to the drum. When the developer brush contacts the drum surface, the negatively charged areas of the drum surface attract and hold the positively charged toner. In this way, the latent image is developed. Negative bias is applied to the development roller to prevent toner from being attracted to non-image areas on the drum that may have a residual negative charge. Negative bias also controls image density. 2-29 28 February 1989 5.2 DEVELOPMENT UNIT CHANGE MECHANISM The development guide rails [A] are slid back and forth by the color development change shaft [B] The change shafts are turned by the development change cam [C] through the change lever [D]. The cam is driven by the main motor through gears and a drive chain. The development change solenoid [E] controls the spring clutch to set the cam position. 2-30 28 February 1989 5.3 DEVELOPMENT UNIT SUPPORT MECHANISM This model has a plate [A] that supports the development units. The plate is locked at a 45 degree angle for the color development unit, and at a 90 degree angle for the black development unit. The stopper [C] inside the inner cover can be released with a screwdriver to lower the support plate to the 90 degree angle. 2-31 28 February 1989 5.4 DRIVE MECHANISM (Black) The development unit drive is controlled by the development drive clutch [A] and the toner supply clutch [B]. The development drive clutch controls the rotation of the development roller [C] and the paddle rollers [D] through the drive gears. The toner supply clutch controls the rotation of the toner supply roller [E] and the agitator roller [F]. The paddle roller knob [G] contains a leaf spring and pawl which prevent the development roller from turning in the opposite direction. 2-32 28 February 1989 5.5 DRIVE MECHANISM (Color) The color development unit drive is controlled by the same magnetic clutches [A] and [B] as the black development unit. When color copy mode is selected, the black development unit gears are disengaged from the development drive gear [C] and the toner supply gear [D], and the color development unit gears engage with the gears [C] and [D]. The paddle roller knob [E] of the color development unit has the same mechanism as the black development unit. 2-33 28 February 1989 This copier uses a stsndard agitating mechanism to keep the toner and developer evenly mixed. It also helps agitate the developer to prevent clumps from forming and helps create the triboelectric charge. The developer on the rotating development roller is split into two parts by the doctor blade [A]. The part that stays on the development roller [B] forms the magnetic brush and develops the latent image on the drum. The rest of the developer slides down the backspill plate to the paddle roller [D]. The mixing vanes [E] move it slightly toward the rear (front: color development unit) of the unit. Part of the developer falls into the auger inlet and is transported to the front of the development unit (rear of the color unit) by the mixing auger [F]. 2-34 23 May 1989 5.7 TONER SUPPLY AND AGITATOR DRIVE MECHANISM The toner supply clutch [A] controls the rotation of the agitator [B] and toner supply roller [C]. The toner agitator prevents toner from clumping and rotates at the same speed as the toner supply roller. The black toner agitator is in the toner cartridge and the color development agitator is in the toner hopper. The black toner supply roller has 16 grooves [E]. Toner is caught in these grooves and trimmed by the toner supply shaft plate located on one side of the toner supply roller. This toner then enters to the development unit. The color toner supply roller has only 6 grooves. Operation is the same as in the black development unit. 2-35 23 May 1989 5.8 TONER DENSITY DETECTION In this model, the ID sensor normally does not perform a check at the first copy after power up. Instead, the previous value is stored in memory and the sensor pattern is checked every 10 copies even if the machine has been turned off and on several times. However, if the RAM is cleared (SP mode #99), or a new RAM is initialized, the ID sensor will check the pattern at the beginning of the 1st copy cycle. From then on it will check every 10 copies. During the check cycles, the sensor pattern is exposed prior to exposure of the original. The development bias is fixed for the development of the sensor pattern, but varies for the different colors (i.e., -260V: black, -320V: green & blue, -240V: red). The CPU notes the reflectivity of the pattern. If the reflectivity level is too strong, a low toner density condition is indicated and toner is added to the development unit. The toner is not added all at once. The CPU energizes the toner supply clutch to add a selected amount of toner each copy until the next toner detection cycle. 2-36 28 February 1989 5.9 TONER DENSITY CONTROL [COLOR] [BLACK] The image density sensor checks the density of the sensor pattern image once every 10 copy cycles (every 5 copy cycles in color copy mode). The CPU receives two voltage values directly from the sensor: the value for the bare drum (Vsg) and the value for the sensor pattern (Vsp). These two values are then compared to determine whether more toner should be added. This model has two modes: the ID sensor supply mode and the fixed supply mode. The ID sensor mode is used when the black development unit is in use. The fixed supply mode is used when the color develop unit is in use. The fixed supply mode can be selected when using the black development unit by SP Mode #30. 2-37 28 February 1989 5.10 TONER END DETECTION (Black) 5.10.1 Black When the black development unit is in use, the ID sensor detects toner end. The system control PCB detects toner end when Vsp is continuously detected at a level higher than 0.91V for more than five times. The Add Toner indicator then blinks. The process of the toner end detection is shown above. When Vsp is found higher than 0.91V, the detection mode changes from once every 10 to once ever 5 copies. Toner supply mode goes to 15% fixed supply. If at the second check Vsp is still above 0.91V, the toner supply mode moves up to 30%. If at the third check still Vsp is still above 0.91V, toner supply moves up again to 60%. If at the fourth check Vsp remains above 0.91V, toner supply stays at 60% for 5 move copy cycles. If at the fifth check Vsp remains above 0.91V, the “Add Toner” indicator starts blinking. 50 more copies can be made before the “Add Toner” indicator turns on continuously and the Start key turns red. When a new toner cartridge is added, the toner supply stays at 60% for 50 copies. The “Add Toner” indicator will go out. 2-38 28 February 1989 5.11 TONER END DETECTION (Color) 5.11.1 Color Toner end detection in the color development unit is performed by the piezoelectric sensor [A] in the development unit. Up to 50 additional copies can be made when the toner end condition is detected in both black and color copying modes. At the 51st copy after toner end is detected the Add Toner indicator will be ON continuously and the Start key will turn red (copying is disabled). 2-39 28 February 1989 5.12 ID SENSOR SUPPLY CONTROL (Black only) ID Sensor Level Name Rate (%) of Vsp/Vsg Toner Supply 0-0.50 0-12.5 Toner Supply stops Toner Supply Level 1 0.51-0.60 12.6-15.0 Toner Supply Level 2 0.61-0.70 15.1-17.5 Twice of(1) Toner Supply Level 3 0.71-0.90 17.6-22.5 Four Times of (1) Toner End Supply 0.91-2.49 22.6-62.4 Toner Density is High ID Sensor Error Vsp (V) 2.50 or mode a)Black ID Toner Mode Supply Rate (1) Toner Supply Rate Is Four Times Of(1) For 5 “Check” Cycles Then Toner End Condition Is Detected 62.5 or mode Goes to Fixed Supply Mode ID sensor Level is made on the ratio of Vsg and Vsp. SP Mode No.31 0 1 2 3 15% 7% 30% 60% Set Amount Toner Supply Rate Standard Using SP Mode #35, the ID sensor can be set to check the pattern every 10 copies or every 5 copies. Toner is supplied when Vsp is higher than 1/8 Vsg. The toner amount is determined by the selected paper size, the Vsp/Vsg ratio and the toner supply rate (as shown in the above table). The toner supply rate can be changed using SP mode #31. 2-40 28 February 1989 5.13 ID SENSOR TONER SUPPLY LEVEL The amount of toner supplied depends on the toner supply level data, toner supply ratio data, and the paper size. The toner supply clutch on time (in pulses) is calculated as follows: MC ON Time = l x T x P Where: I = ID Sensor Supply level Data T = Toner Supply Ratio Data P = Paper Size Data For example: Vsp = 0.65V which means that the ID sensor toner supply level is “2” and the data = 52 The toner supply ratio is 15% which means that the corresponding data = 2 Paper size is A4 so the paper size data = 1 The toner supply clutch turns on for 104 (52 x 2 x 1) pulses. One pulse is 2.259 milliseconds so the clutch on time is 235 milliseconds. 2-41 28 February 1989 5.14 ID SENSOR SUPPLY CONTROL IN FIXED SUPPLY MODE S set Toner Amount Supply P Mode 0 Rate 14 #70 1 % 7 % 2 2 1 % 3 2 8 % Standard Color: When a color development unit is used, the CPU automatically selects the fixed toner supply mode. SP Mode #70 determines the supply amount. The CPU calculates the threshold level for toner supply when the color developer conditioning (SP mode #10) procedure is completed. This level is determined by calculating the average of Vsp and Vsg. Since the fixed supply system is selected when in color toner mode, it is necessary to inhibit toner supply if the toner density becomes high to prevent over-toning. The CPU checks Vsp once in 5 copy cycles. If Vsp becomes lower than the threshold level, the CPU stops supplying toner. Toner supply resumes when Vsp rises above the threshold level again. If the color developer conditioning (SP mode #10) is not completed, the threshold level will automatically be set at 60% (2.4V) of Vsg. 2-42 28 February 1989 FIXED SP Set Toner SUPPLY mode 0 value supply Black rate toner S Up p l y level MODE No.32 1 2 7 % 3.5% 10.5% 2 1 3 3 14% 4 Black: Toner is supplied every copy cycle according to the supply mode selected by SP Mode #32. The toner supply clutch is de-energized when Vsp is lower than 1/8 Vsg in black copy mode (threshold voltage in color copy mode). The clutch ON timing of the fixed supply mode is determined by the input data of SP Mode #32 and the selected paper size. 2-43 28 February 1989 5.15 TONER SUPPLY AMOUNT (FIXED SUPPLY MODE) Paper Size Data Black/Color Toner Supply Level UNIVERSAL 26 Black Toner (# SP No. 32) A3 51 Supply Level B4 38 A4 26 A4R 26 B5 20 B5R 20 A5 13 A5R 13 P-MODE DATA 2 1 3 4 B6 10 Supply Level P-MODE DATA 10 2 1 3 4 DATA 0 DATA 1 DATA 2 DATA 3 7 11 x 17 49 11 x 8 1/2 24 11 x 15 42 10 x 14 38 8 I/2 x 14 33 8 1/2 x 13 29 8 1/2 x 11 24 8 1/2 x 5 1/2 13 8 1/4 x 14, 13 33 8 x 13 27 8 x 10 1/2 26 8 x 10 24 5 1/2 X8 1/2 12 7% 3.5% 10.5% 14% Color Toner (# SP No. 70) B6R POST CARD CONSTANT ADD DATA 0 DATA 1 DATA 2 DATA 3 CONSTANT ADD 14% 7% 21% 28% Supply Mode Data Black (Fixed Mode) Black (ID Sensor — > 1 Mode) R e d / G r e e n Color Blue R e d / G r e e n Photo Mode —> — > 1 2 — > 1 — > 3 Blue —> 1.5 Black — > 3 Paper Size Data x 2 Supply Level x Supply Mode = Toner Supply MC on Time (pulse) (1 pulse = 2.259 msec.) For example: - Paper size 11 x 8 1/2 - Supply level 4 –> data = 24 –> data = 3 - Supply mode photo, blue –> data = 1.5 The toner clutch on time will be: 24 x 2 x 3 x 1.5 = 216 pulses or 488 msec. 2-44 28 February 1989 5.16 ID SENSOR ERROR DETECTION 1. Vsg If Vsg is lower than 3.2V (color) or 2.5V (black), the toner supply stops. In color mode, if Vsg is low in 10 consecutive checks, the wrench mark and the color unit indicator are displayed on the operation panel. In black mode, if Vsg is low in 5 consecutive checks, the wrench mark in displayed. 2. Vsp If Vsp is higher than 3.2V (color) or 2.5V (black), the toner supply changes to 60% fixed supply mode. In color mode, if Vsp is high in 10 consecutive checks, the wrench mark and the color unit indicator are displayed. In black mode, if Vsp is high in 5 consecutive checks, the wrench mark is displayed. 3. With Vsp or Vsg error, clean the ID sensor and recheck Vsp or Vsg (SP #55). Adjust the voltage if it is not within the standard. In color mode, the color developer must also be replaced and conditioned (SP #10). NOTE: When SP #55 is used to check for a Vsg or Vsp error, a Vsg reading of 5.00V indicates a Vsp error and a Vsg reading of 0.00V indicates a Vsg error. 2-45 21 April 1989 5.17 DEVELOPMENT BIAS CONTROL This model has two bias voltage control modes: Manual control and ADS Control. There are also two bias voltage correction modes: Vr correction and SP mode. 5.17.1 Manual bias control (MANUAL I.D. LEVEL) The negative bias (-120 to -280V) corresponding to the selected image density level is applied to the development roller. 5.17.2 Auto Image Density bias control SP34 ADS Adjustment Data (0: Normal) (2: Lighter) K (SP57) = Reflected Light Voltage ADS Voltage (SP56) The negative bias corresponding to the detected background image voltage is applied to the development unit. The bias can be set two ways using SP Mode #34. 2-46 28 February 1989 5.18 BIAS CORRECTION 5.18.1 Vr Correction Vr CORRECTION With repeat copies, the residual potential on the OPC drum gradually affects the copy image density. With Vr correction, the residual potential is corrected using the ID sensor. 5.18.2 SP Mode Correction SP Set Value mode Code Density 2 4 0 1 0 +40V +20V - 2 0 V -40V N D D D L L L Standard Darkest Darker Bias Voltage No.37 3 Lighter Lightest –160V when manual ID level 4 Value is –200V. With SP correction, the voltage levels noted above can be applied using SP Mode #37. 2-47 21 April 1989 5.19 ID SENSOR BIAS COMPENSATION In order to ensure consistent operation of the ID sensor system, the bias for the development of the sensor pattern must be able to change (or be changed) to accommodate the following factors/conditions. (Numbers refer to the charts above) 5.19.1 Standard Bias I.D. Sensor Bias(Black) 0(N) -260(V) 1(L) -220 2(H) -280 3(HH) -300 SP Mode No.33 Initial Developer Conditioning: –340V I.D. Sensor Mode No.75 -320(V) -240(V) 0(N) SP Bias(Color) 1(L) -200 -280 2(H) -260 -340 3(HH) -280 -360 Initial Developer Conditioning: Red = –280V Blue/Green = -320V 1-1 and 1-2: ID sensor bias can be manually changed to accommodate customer copy quality preferences by changing the settings of SP Mode #33 for black developer and SP Mode #75 for color developer. During initial conditioning, only SP Mode #33 (black) and SP Mode #75 (color) can change the ID sensor bias. 5.19.2 Vp Correction 2000-2999 Copies Mode Then 3000 Copies OPC Counter 0-999 Copies 1000-1999 Copies Black + 0V + 20V + 40V + 80V Color + 0V + 0V + 20V + 20V Sensitivity on a new OPC drum’s surface will change with the first 3000 copies, so Vp is corrected as shown above. 2-48 28 February 1989 5.19.3 Developer Counter Correction Developer Counter Initial Correction Black Developer Counter Vsp Vsg (%) 0-499 Copies Mode Then 500 0 12-15 + 0V + 0V 1 0-7 -40V + 0V 2 8-11 -20V + 0V 3 16-21 + 0V +20V 4 22- + 0V +40V The developer counter correction (Vsp/Vsg) compensates for the change in the triboelectric charge as the new developer mixture (black only) is broken in. 5.19.4 Total ID Sensor Bias Initial Normal Copy Mode Developer Conditioning Black Color Note: The maximum of (2) + (3) is +40V The above table shows how to calculate the total bias for black or color developer using the information in tables (1) through (3). 2-49 28 February 1989 6. IMAGE TRANSFER 6.1 PRE-TRANSFER LAMP (PTL) After the latent image is developed but before the image is transferred to the copy paper [D], the drum surface is illuminated by the pre-transfer lamp [A]. This illumination reduces the negative potential on the drum surface [B]. This prevents the toner particles from being re-attracted to the negatively charged drum during the paper separation process. It also makes image transfer and paper separation easier. 6.2 IMAGE TRANSFER A high negative voltage (-5.6 kilovolts) is applied to the transfer corona wire [C], and the corona wire generates negative ions. These negative ions are applied to the copy paper [D], and the negative charge attracts the positively charged toner away from the drum and onto the paper. In addition, the paper is held against the drum by the positive counter charge on the drum. 2-50 28 February 1989 6.3 PAPER SEPARATION AND TRANSPORT After image transfer the copy must be separated from the drum. To break the attraction between the paper and the drum, the separation corona wire [D] applies an ac corona to the reverse side of the paper. The stiffness and weight of the paper causes it to separate from the drum [E]. The separation corona has a small dc bias but its effect is negligible. A dc bias is unnecessary because the separation corona is wide and diffuse. The negative charge on the paper (from the transfer corona) is not completely discharged until the paper is far enough from the drum that the toner will not be retracted to the drum. The two pick-off pawls [F] ensure that thin, low stiffness paper and upward curled paper separate completely. 6.3.2 Paper Transport The transport belts [G] are driven by the transport drive gear [H]. The gears are engaged when the transport unit is set. The vacuum fan located in the rear attracts the paper to the transport belt to ensure smooth paper transportation. 2-51 23 May 1989 6.4 PTL AND T/S CHARGE CIRCUIT The PTL is composed of 50 LEDs supplied by VPP. The PTL LEDs are wired in series. When the Start key is pressed, the I/O control PCB sends LOW signals to turn on the vacuum fan motor and the PTL. The I/O control PCB sends a LOW signal to turn on (T1) the transfer corona 0.7 seconds after the original leading edge signal (L.E.) and continues for a period corresponding to the paper length + 6.7mm. The separation corona is turned on (T2) 0.06 seconds after the transfer corona turns on. The trigger TC2 is only used for the second side of dupIex/overlay copies. This shifts the corona current to increase transfer efficiency. TC1 TC2 L H Single Sided Copy (or 1st side) H L Duplex/Overlay Copy 2nd side 2-52 7. ID SENSOR 7.1 ID SENSOR IMAGE CORRECTION (Vr Pattern) The ID sensor image correction system, detects residual voltage on the OPC drum, and corrects the image by changing the grid bias, development bias, and lamp voltage. The residual voltage is detected by comparing the Vsg and the Vrp. The Vrp pattern is created by applying a 0 voltage bias. Toner particles are attracted to the drum surface by the residual voltage. The Vrp pattern is checked for the first five copies after initialization. Thereafter, the pattern is checked for the first five copies of each 1,000 copy cycles. NOTE: Color copies and Toner Density Detection cycles will interrupt the Vr detection cycle. 2-53 28 February 1989 The grid bias and the development bias change by -40 volts in each specific ratio. The exposure voltage changes 1 volt in each specific ratio. 2-54 28 February 1989 7.2 ID SENSOR PATTERN (Vsp) The ID sensor pattern controls toner density. This pattern is transferred to the drum before creation of the latent image. The ID sensor illuminates the pattern and checks the reflectivity. The system control PCB detects variations in the light intensity (Vsp voltage) and controls the toner supply. This pattern is checked once every 10 copies. 2-55 28 February 1989 8. DRUM CLEANING 8.1 OVERVIEW The cleaning brush [A] and cleaning blade [B] remove any toner remaining on the drum [C] after the image is transferred to the paper. The cleaning brush and drum move in opposite directions at their point of contact. The cleaning brush removes paper dust and nearly half of the toner from the drum surface to reduce the cleaning load placed on the blade. The cleaning blade removes the remaining toner. The falling toner catches in the fibers of the cleaning brush and is carried inside the cleaning unit [D]. The toner collection roller [E] carries the used toner to the used toner tank. The light of the quenching lamp [F] neutralizes any charge remaining on the drum in preparation for the next copy cycle. 2-56 28 February 1989 8.2 DRIVE MECHANISM The cleaning brush [A] and the toner collection roller [B] are driven by the main motor through a chain and gears. The cleaning brush and the cleaning blade [C] are always touching the drum surface. The toner collection roller rotates at the same time as the cleaning brush to collect used toner. The cleaning blade is mounted in the center of the blade and is tilted to apply even pressure. 2-57 28 February 1989 8.3 RELEASE MECHANISM The cleaning guide rail [A] releases when the cleaning unit is removed. This prevents the drum [B] from being scratched by the cleaning unit [C]. The cleaning blade releases when the release knob [F] is pressed. This will clean the cleaning blade [D] using the blade scraper [E] which is installed under the cleaning blade. 2-58 28 February 1989 8.4 TONER OVERFLOW DETECTION The toner overflow sensor [A] sends the overflow signal to the I/O control PCB when the toner collection tank [C] is full. This sensor is a photo interrupter. A rubber sheet [B] under the toner overflow sensor is lifted up by the gradual collection of toner. Once full, the actuator moves into the photointerruptor. Up to 250 copies can be made after the CPU detects the overflow condition. 2-59 28 February 1989 9. PAPER FEED AND REGISTRATION 9.1 OVERVIEW This model has three paper feed stations [A][B][C]. Each cassette has a capacity of 250 sheets. As an option, a 1000 sheet large capacity tray [D] can be installed in the third paper feed station [C]. Paper can also be fed using the manual feed table [E] which utilizes the first feed station feed mechanism. The first feed station uses a FRR feed system. A grip roller [H] is installed in the first feed station to prevent skewing when using small sized paper. The second and third feed stations use a friction pad system. The third feed station uses a relay roller [F] and an auxiliary roller to help guide the paper to the registration roller. When the LCT is installed in the third paper feed station, the pick-up roller [G] will also be installed. 2-60 28 February 1989 9.2 FRR FEED SYSTEM 9.2.1 Pick-up Roller The pick-up roller [A] is in contact with the paper stack before it starts feeding paper. A few moments after the Start key has been pressed, the rotation of the pick-up roller feeds the top sheet to the feed [B] and separation [C] rollers. At almost the same time as the paper’s leading edge arrives at the feed roller, the pick-up roller lifts off the paper stack so that it does not interfere with the operation of the feed and separation rollers. The feed and separation rollers then take over the paper feed process. 9.2.2 Feed and Separation Rollers There is a one-way bearing inside the feed roller [B] so it can turn only in one direction. The separation roller [C], however, is driven through a slip clutch, which allows it to turn in either direction depending on the friction between the rollers. A spring keeps the separation roller in contact with the feed roller. The direction that the separation roller [C] turns depends on the frictional forces acting on it. The slip clutch applies a constant clockwise force (F1). When there is a single sheet of paper being driven between the rollers, the force of friction between the feed roller [B] and the paper (F2) is greater than (F1). So, the separation roller turns counterclockwise. If two or more sheets are fed between the rollers, the forward force on the second sheet (F3) becomes less than (F1) because the coefficient of friction between the two sheets is small. So, the separation roller starts turning clockwise and drives the second sheet back to the cassette. 2-61 28 February 1989 9.3 FRICTION PAD FEED SYSTEM When the feed roller [A] starts turning, it forces a single sheet of paper across the friction pad [B]. The roller stops turning when the paper reaches the registration rollers [C]. At that time the friction pad is pressing the paper up against the feed roller. So, when the registration rollers start turning, the friction of the moving paper as it is pulled from under the feed roller causes the feed roller to start turning again. As the trailing edge clears the leading edge of the paper stack, the feed roller catches on the next sheet and starts moving it forward. The feed roller stops turning when the trailing edge of the first sheet leaves the feed roller. The leading edge of the next sheet is then held ready for feeding between the friction pad and feed roller. Sometimes sheets of paper tend to stick together (perhaps due to static electricity or poorly cut edges). When this happens, two sheets may feed between the feed roller and friction pad. However, the coefficient of friction between the friction pad and lower sheet is much greater than that between the two sheets of paper; so, the top sheet slips through while the pad holds the lower sheet. The friction pad holder is mounted in one end of the plate with a swivel screw; so it automatically applies even pressure against the feed roller and the copy paper. The pressure spring on the other end of the swivel plate (reverse side) provides the pressure. After the cassette is removed, the pad pressure is released. 2-62 28 February 1989 9.4 PAPER LIFT MECHANISM (1st Feed Station) When the cassette [A] is inserted into the copier, the cassette actuator pin [B] is pushed down by the cassette. The lift motor unit then mechanically pivots clockwise at point [C] so that the lift gear [D] engages with the sector gear [E]. Simultaneously, the paper size actuator plate [F] actuates the paper size switches [G]. The I/O control PCB then detects that a cassette has been inserted and turns on the lift motor [H]. The lift motor raises the bottom plate [I] until the top sheet pushes up the pick-up roller [J]. When the paper pushes up the pick-up roller, the lift sensor [K] is actuated (OFF) and the l/O control PCB turns off the lift motor. As paper is fed into the copier, the level of the paper stack gets lower. If the level becomes too low, the lift sensor is de-actuated (ON) and the l/O control PCB energizes the lift motor until the top sheet raises the pick-up roller to actuate the lift sensor again. This ensures that the paper is always at the correct feed height. 2-63 28 February 1989 9.5 PAPER LIFT MECHANISM (2nd and 3rd Feed Stations) When a cassette is inserted into the copier, the curved release guides on the sides of the cassette press against the rollers on the release levers [A] and force the release levers down. The release levers rotate the cassette arm shaft [B], moving the cassette arm down and out of the way. When the cassette is fully seated, the release guides allow the release levers to move back up. The cassette arm [C] presses up the cassette bottom plate [D] until the paper contacts the paper feed roller. To prevent copy paper from multi-feeding or jamming, the spring [E] pressure is adjustable. 2-64 28 February 1989 9.6 PAPER SIZE AND END DETECTION Five microswitches in the cassette entrance detect each cassette is paper size. The paper size switches [A] are actuated by a plate on the front of the cassette. Each paper size has its own unique combination of notches in the actuator plate [B]. The CPU reads which microswitches have been actuated by the actuator plate to determine which size cassette has been inserted. When a cassette or the LCT runs out of paper, the paper end feeler [C] drops through a slot in the cassette (or LCT) bottom plate. The paper end actuator [D], which is on the same shaft as the paper end feeler, pivots into the detector (photointerruptor). The paper end sensor [E] then sends a pulse signal to the I/O control PCB, informing it that the cassette is empty. Then the Add Paper indicator turns on, the Start key turns red, and the machine stops after the copy is finished. 2-65 28 February 1989 9.7 PAPER FEED DRIVE MECHANISM (FRR) The feed roller is driven by the main chain [A] through the drive gear. The feed timing is controlled by the paper feed clutch [B]. The drive gear turns the pick-up roller [C] through an idle gear. The separation roller [G] and the grip roller [D] are driven by the main chain through the drive gear. These rollers are always rotating when the main motor is rotating. The pick up roller is normally in contact with the paper stack. The pick-up solenoid [E] raises the pick-up roller. When the leading edge of the paper passes between the feed roller [F] and separation roller [G], the pick-up roller is then lifted to its upper position out of the paper path. After the trailing edge of the paper passes under the pick-up roller, the pickup roller drops back onto the paper stack in preparation for the next copy cycle. 2-66 28 February 1989 9.8 PAPER FEED REGISTRATION DRIVE MECHANISM The main chain [A] turns the paper feed drive sprockets. These sprockets turn the second paper feed [B], third paper feed [C] and relay [F] magnetic clutches through the idle gears. The registration roller [D] is driven by the main chain and its ON/OFF timing is controlled by the magnetic clutch [E]. The relay rollers in the duplex/overlay feed station are driven by the gears on the relay roller. 2-67 28 February 1989 9.9 MANUAL FEED TABLE The manual feed mode allows multi-feeding without a cassette. (Maximum paper quantity is twenty sheets of normal weight paper.) This is accomplished by the manual feed table [A] and the rollers at the first feed station. When the manual feed table is opened, the manual feed sensor [B] sends a signal to the I/O control PCB. The I/O control PCB then shifts to manual feed mode. The lift motor assembly [C] is mechanically released by a release lever [E] when the manual feed table is opened. When the first cassette bottom plate drops, the actuator of the first cassette paper end sensor [D] will drop through a slot in the manual feed table. The I/O control board will then detect a paper end condition until paper is placed on the manual feed tray. 2-68 28 February 1989 9.10 PAPER FEED TIMING Each paper feed clutch start timing is almost the same (T1). Paper feed begins 0.1 seconds after the Start key is pressed. When the leading edge of the paper triggers the registration sensor (T2), the first and second paper feed clutches are turned OFF 0.07 seconds later. This buckles the paper in order to correct skewing. The third paper feed clutch will be turned off as soon as the leading edge of the copy paper is detected by the upper relay sensor. The relay clutch will drive the paper to the registration roller to create the buckle for paper fed from the 3rd paper feed station. After lead edge occurs*, the registration clutch is turned ON (T3) 0.7 seconds later to feed the paper to the copying unit. *After detection of the front end of the original (front of the original scale). 2-69 28 February 1989 9.11 SERVICE CALL CONDITION Self Diagnostic Code 41: First Cassette Lift Sensor The I/O control board will monitor the upper lift sensor while the lift motor is ON. If the output of the lift sensor stays low for 25 seconds after the lift motor starts turning, code 41 will be displayed. 2-70 28 February 1989 10. IMAGE FUSING AND PAPER EXIT 10.1 OVERVIEW Two fusing rollers, which apply heat and pressure, fuse the image to the copy paper. The hot roller [A] is made of teflon, and the pressure roller [B] is made of silicon rubber with a teflon sleeve. Pressure is constantly applied between the rollers. The fusing lamp [C], which is located at the hot roller axis, is turned on and off to maintain the operating temperature. The temperature control circuit monitors the hot roller surface temperature through a thermistor [D]. The thermofuse (169°C) [J] prevents the fusing temperature from exceeding 400 ± 50°C. This model uses an oilless hot roller system, and does not have a hot roller cleaning mechanism. The hot roller strippers [G] separate the copy from the hot roller and direct it to the fusing exit-rollers [H]. The lock position of the pressure lever tension springs [I] adjusts the roller pressure. 2-71 28 February 1989 10.2 FUSING DRIVE RELEASE MECHANISM The fusing unit drive release mechanism automatically disengages the fusing unit drive gear [A] when the front cover [B] is opened. This allows the fusing unit drive gear to rotate freely so that jammed paper can be easily removed. When the front cover is opened, the safety lever is released and the release shaft [D] rotates as shown above. This moves the release pin [E] upwards, thus disengaging the fusing unit drive gear from the hot roller gear. The leaf spring [F] forces the fusing unit drive gear downwards and keeps it engaged when the front cover is closed. 2-72 28 February 1989 10.3 FUSING CONTROL The I/O control PCB monitors the fusing temperature through a thermistor (TH1). It also uses the zero-cross signal generated by the ac drive PCB to accurately control the applied power. Normally, the voltage applied to the lamp is a full ac waveform. However, through SP Mode #29, fusing power can be phase controlled. (Normally, phase control is used only if the customer has a problem with electrical noise or interference.) When the main switch is turned on, the I/O control PCB outputs a trigger signal [C], which has the same timing as the zero-cross signal [B], to the ac drive PCB. This trigger signal allows maximum ac power to be applied to the fusing lamp. Then, when the operation temperature is reached, the CPU removes the trigger (HIGH) and the fusing lamp turns off. 2-73 28 February 1989 10.3.1 Phase Control In the phase control mode, the fusing lamp receives ac power constantly. The amount of power is regulated by the width of the trigger pulse. The wider the trigger pulse (C1), the more ac power the lamp receives (D1); therefore, the temperature increases. As the temperature rises, the LOW trigger pulse becomes narrower (C2) and less power is applied to the lamp (D2); therefore, the heating effect decreases. 2-74 28 February 1989 10.4 SERVICE CALL CONDITIONS Self Diagnostic Code 53: Fusing Thermistor Abnormal The I/O control PCB monitors the condition of the thermistor. Code 53 is displayed if the thermistor or its circuit is open for longer than 10 seconds. Self Diagnostic Code 54: Fusing Warm-up Failure Code 54 will be displayed if the hot roller does not reach the ready temperature within five minutes after the power is turned on. Self Diagnostic Code 55: Fusing Overheating The I/O control PCB monitors the condition of the thermistor. Code 55 is displayed if the resistance of the thermistor becomes too low (220 - 240°C). 2-75 28 February 1989 11. DUPLEX/OVERLAY MECHANISM 11.1 OVERVIEW This model has a duplex and overlay mechanism. Paper exiting from the fusing unit is sent to the duplex/overlay section through the duplex/overlay transport gate [A]. When overlay copy mode is selected (1), paper is sent to the jogger section [B] and is fed to the registration roller [C] again. When duplex copy mode is selected (2), paper is sent to the inverter section and then fed to the jogger section. The inverter gate [D] directs the paper into the inverter section. When 2 or moRe copies are set with the numeric keys, copies are fed to the multi-duplex tray (option) (3), and are fed to the jogger section in duplex copy mode and to the inverter section in overlay copy mode. 2-76 28 February 1989 11.2 DRIVE MECHANISM The relay rollers are driven by the main chain [A]. The transport gate, junction gate and inverter gate are opened and closed by solenoids [B][C]. The inverter gate solenoid [B] also switches the direction of roller rotation. The inverter roller drive gear is engaged with the “in” gear [D] in feed-in operation and the out gear [E] in feed-out operation. The inverter sensor [F] detects the trailing edge of the paper to change the direction of roller rotation. The inverter relay sensor [G] detects the paper feed timing. Both also are responsible for misfeed detection. 2-77 28 February 1989 The jogger mechanism aligns the paper in the duplex/overlay copy mode. The jogger motor [A] drives the jogger fences [B] to within 10 mm of the sides of the paper when the paper enters the jogger section. When paper is in the jogger section, it is stopped and the jogger fences are then driven against both sides of the paper. As the paper is being jogged, the guide plates [C] will be lifted by the jogger solenoid [D], preventing the rollers from interfering with the jogging process. NOTE: The jogging process performed when the size of paper is A4 (LT) lengthwise or less. No jogging is done with longer papers because the trail edge will be held in the inverter unit. The I/O control PCB will monitor the condition of the jogger home position sensor. If the I/O control PCB cannot establish the home position of the jogger, service code 81 or 82 will be indicated. 2-78 28 February 1989 11.4 SINGLE DUPLEX/OVERLAY TIMING Single Overlay Copy/Single Duplex Copy Mode T1: The jogger fences move to the home position when the start key is pressed. T2: The duplex/overlay transport clutch, the duplex/overlay transport solenoid, and the inverter gate solenoid (single overlay copy mode) are turned on when the fusing exit sensor detects the leading edge of the paper. The jogger fences move into position 10mm from the paper’s edge. T3: The inverter solenoid is de-energized 0.07 seconds after the inverter sensor detects the trailing edge of the paper. T4: The duplex/overlay transport clutch turns off to align the paper by the jogger fences 0.84 seconds after the inverter relay sensor detects the trailing edge of the paper. T5: The jogger motor moves the jogger fences into straighten the paper. At this time the positioning roller solenoid is energized to lift the positioning roller plates up out of the way. T6: The Duplex/Overlay transport clutch turns on, forwarding the paper to prepare for the next image cycle. 2-79 28 February 1989 12. OTHERS 12.1 PAPER MISFEED CHECK A: Registration Sensor Upper Relay Sensor Lower Relay Censor B: Fusing Sensor C: Inverter Relay Sensor D: Inverter Sensor This model uses six sensors to detect misfeed conditions inside the copier. Each sensor performs both ON and OFF detection as shown above. Four LEDs on the operation panel indicate which sensor detects a misfeed. Misfeeds are reset by the OFF/ON sequence of the front cover safety switch and/or the main switch. 2-80 28 February 1989 No paper feed: 1) 1st and 2nd feed station Checked by the registration sensor about 1.5 seconds after the 1st and 2nd feed MC is turned on. 2) 3rd feed station Checked by the upper relay sensor about 1.6 seconds after the 3rd feed MC is turned on. Paper does not reach the registration sensor: 1) 1st and 2nd feed station Same as no paper feed. 2) 3rd feed station Checked by the upper relay sensor about 1.7 seconds after the 3rd feed MC is turned on./ Paper does not reach the fusing exit sensor: 1) Checked about 3.5 seconds after the registration MC is turns on. Paper does not reach the inverter sensor: 1) Check about 2.3 seconds after the fusing exit sensor is turned on. Paper from inverter section does not reach the inverter relay sensor: 1) Checked about 7.9 seconds after the fusing exit sensor is turned on. Paper does not reach the inverter relay sensor in overlay mode: 1) Checked about 2.6 seconds after the fusing exit sensor is turned on. Paper does not reach the registration sensor in overlay (duplex) mode. 1) Checked about 10.7 (14.4) seconds after the fusing exit sensor is turned on. 2-81 28 February 1989 12.2 SERVICE CALL CONDITIONS (Others) Self Diagnostic Code 61: Functional Drive If the I/O control PCB does not receive pulses from the pulse generator for longer than two seconds, Code 61 will be displayed. Self Diagnostic Code 81: jogger Fails to Return to Home Position If the output of the jogger home position sensor remains low as the I/O control board is driving the fences outward, code 81 will be displayed. Self Diagnostic Code 82: jogge r Stays Home If the output of the jogger home position sensor remains high as the I/O control board is driving the fences inward, code 82 will be displayed. Self Diagnostic Code 91: No Total Counter The total counter is monitored by the system control PCB. If the total counter confirm signal remains either high or low constantly, Code 91 will be displayed. Self Diagnostic Code 93: System and I/O Control Communication Failure If the system control PCB and the I/O control PCB are unable to communicate, Code 93 will be displayed. Self Diagnostic Code 95: No Destination Signal If the system control board can not distinguish the destination code, Service Code 95 is displayed. Note: This would happen if the wrong version system control PCB were installed. 2-82 SECTION 3 CONTENTS INSTALLATION REQUIREMENTS 3-1 1.1 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 1.2 MACHINE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 1.3 MINIMUM SPACE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 1.4 POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 1.5 COPIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 1.5.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 1.5.2 Removal Of Shipping Retainers And Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 1.5.3 For Areas Where The Voltage Is 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 1.5.4 Developer Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 1.5.5 Cassette Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 1.5.6 Key Counter Holder Installation (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 28 February 1989 1. INSTALLATION REQUIREMENTS 1.1 ENVIRONMENT 1. Temperature Range: 10°C to 30°C (50°F to 86°F) 2. Humidity Range: 15% to 90% RH 3 . Ambient Illumination: Less than 1,500 Iux (do not exposure to direct sunlight) 3 4. Ventilation: Room of more than 30 m . Room air should turn over at least 3 times/hour. 3 -3 3 5 . Ambient Dust: Less than 0.15 mg/m (4 x 10 oz/yd ) 6 . If the installation place is air-conditioned or heated, place the machine as follows: a) Where it will not be subjected to sudden temperature changes. b) Where it will not be directly exposed to cool air from an air-conditioner in the summer. c) Where it will not be directly exposed to reflected heat from a space heater in winter. 7. Avoid placing the machine in an area filled with corrosive gas. 8. Avoid any places higher than 2,000 meters (6,500 feet) above sea level. 9. Place the machine on a strong and level base. 10. Avoid any area where the machine may be subjected to frequent strong vibration. 3-1 28 February 1989 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 level Place the machine on a table and screw the Ieveling feet up or down in order to level the machine. Use a leveling gauge if necessary. 1.3 MINIMUM SPACE REQUIREMENTS 1. Front: 70 cm (27.6”) 2. Back: 10 cm (3.9”) 3. Right: 80 cm (31.5”) 4. Left: 10 cm (3.9”) NOTE: Make sure there is at least 10 cm (3.9”) on the left of the duplex unit when it is opened out, in order to avoid damaging the unit. 28 February 1989 1.4 POWER REQUIREMENTS 1. Input voltage level: 110V/60Hz: More than 15A 115V/60Hz: More than 15A 220V/50Hz: More than 8A 220V/60Hz: More than 8A 240V/50Hz: More than 8A 2 . Permissible voltage fluctuation: ± 10% 3 . Permissible extension cord: At least 300V, 30A capacity and less than 5 meters (16.4 ft) long. 4. Do not set anything on the power cord. NOTE: a) Be sure to ground the machine. (Do not connect the grounding wire to a gas pipe.) b) Make sure the plug is firmly inserted in the outlet. c) Avoid multi-wiring. 3-3 28 February 1989 1.5 COPIER INSTALLATION 1.5.1 Accessory Check Check the quantity and condition of the accessories in the box according to the following list: 1. Installation Procedure . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . . . . . . .1 (115V - English only / 220V - Five Languages) 2. New Equipment Condition Report . . . . . . . . . . . . . . . . . . . . . . . . 1 3. Envelope for NECR (115V only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4. Cassette - Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5. Cassette - Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6. Copy Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7. Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 (115V - English only / 220V - Five Languages) 8. Original Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 9. Multilingual Decals (220V/240V only) . . . . . . . . . . . . . . . . . . . . 1 10. Editing Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11. Sorter Panel Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 1 12. Sorter Key Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 NOTE: No.11 and No.12 are used when installing the optional sorter. 1.5.2 Removal Of Shipping Retainers And Tape 1. Remove the strips of shipping tape [A] from the copier as shown. 3-4 21 April 1989 2. Open the copier front cover [B]. 3 . Remove the strips of tape [C] and the fixing plate [D] (2 screws) as shown. 4. Remove the yellow seal [E] from the toner tank. 5. Remove the clamp [F] from the cleaning unit. NOTE: Save the fixing plate [D] for future use. 3-5 28 February 1989 6. Remove the original scale [A] (2 screws). 7. Remove the 3 scanner lock plates [B]. 8. Remove the lens lock pin [C]. 9. Replace the original scale. NOTE: a) Save the scanner lock plates and lens lock pin for future use. b) If the copier is to be transported, install the scanner lock plates and lens lock pin after turning off the power switch in the full size mode. 10. Open the manual feed table [D] and remove the plastic cap [E] (1 screw). 11. Remove the lock plate [F] (1 screw) and remount the plastic cap. 12. Close the manual feed table. 3-6 28 February 1989 13. Push up the lock lever [A]; then, grasp the handle [B] of the color development unit and pull the color development unit out half way. Release the lock lever [A] and pull the color development unit out until it stops. 14. Grasp the holding band [C] and remove the color development unit while pushing up the lock lever [A]. Place it on a clean sheet of paper. NOTE: a) Do not place any metal objects such as screws near the development unit. b) Do not touch the surface of the entrance seal [D] or the development roller [E]. 15. Remove the development guide [F] (6 screws). 16. Pour one pack of 4460 type color developer [G] into the color development unit while turning the knob [H] counterclockwise to distribute the developer. NOTE: a) For easy pouring of the developer, make a small diagonal cut in the pack as shown. b) Pour in the color developer required by the customer. (Red, blue and green developer are available.) c) Wrap a cloth around the shaft of a magnetized screw driver to pick up spilled developer. d) Make sure there is no developer on the entrance seal. 17. Remount the development guide. 3-7 28 February 1989 NOTE: As the color development unit in the copier is originally set up for red toner, the following procedure is required when changing to an optional color development unit. 18. Set the DIP SW [A] as shown above so that the color indicated on the operation panel matches the color in the color development unit. 19. Stick the color decal [B] (red, blue, or green) on the toner tank as shown. The color decal should be the same color as the developer in the color development unit. 3-8 28 February 1989 20. Insert the screwdriver [A] into the hole in the right cover to lower the development unit supporter [B] to a horizontal position. 21. Move the development unit lock lever [C] to the right (to the lock position). 22. Move the release lever [D] to the right and pull out the black development unit [E]. Place the unit on a clean sheet of paper. 3-9 28 February 1989 23. Separate the toner tank [A] from the development unit [B] (3 screws). 24. Pour one pack of 4460 type black developer [C] into the development unit while turning the knob [D] counterclockwise to distribute the developer. 25. Remount the toner tank on the development unit. 26. Release the cleaning tank lever [E] and the transport unit lever [A1] [F]. CAUTION: To avoid damaging the pick-off pawls, remove the drum protection sheet by pulling the lower side as shown in the figure. 27. Remove the drum protective sheet [G]. 28. Reset the cleaning tank lever [E] and the transport unit lever [A1]. NOTE: Save the drum protective sheet for future use when servicing the copier. 3-10 28 February 1989 29. Install the black development unit [A]. CAUTION: When installing the development unit, be sure the development unit rail is placed directly on the development unit rail. NOTE: a) Shake the cartridge well to break up any clumps in the toner. b) Remove the strip of tape covering the toner cartridge 30. Install the toner cartridge [B] and remove the tape [C] from the toner supply hole. 3-11 28 February 1989 31. Insert the toner cartridge [A] completely and turn it counterclockwise. NOTE: Confirm that the toner cartridge gear is properly engaged by attempting to rotate the toner cartridge knob counterclockwise. When the toner cartridge gear is properly engaged, the toner cartridge knob will not rotate freely. 32. Insert the screwdriver [B] into the hole in the right inner cover and lift the supporter [C] to a 45° angle as shown in the illustration. 33. Push the development unit lock release lever [D]. 3-12 28 February 1989 34. Install the color development unit. Side it about 8 cm down the guide rails until you hear a click. CAUTION: When installing the color development unit, be sure the development unit rail is placed directly on the unit guide rail. 35. Add the color toner. Follow the instructions (“How to Add Toner”) on the inside of the front cover. NOTE: Instruct the customer how to add color toner at this time. 3-13 28 February 1989 1.5.3 For Areas Where The Voltage Is 240V 36. Remove the copier rear cover (2 screws), disconnect the red wire [A] from the 220V terminal [B], and connect this wire to the 240 volt terminal [C] as shown. Then reinstall the copier rear cover. 3-14 28 February 1989 1.5.4 Developer Conditioning Do the following after installing the developer and toner: A: Color developer conditioning B: Black developer conditioning 37. Plug in the machine and turn on the main switch. 38. After the warm up period is completed, press the keys in the following order: A: Color developer conditioning 1) Press the Clear Modes key. 2) Press the Clear / Stop key. 3) Press the Recall / Enter key. 4) Enter “10”. 5) Press the Recall / Enter key. 6) Close the platen cover and press the Start key. NOTE: Buzzer sounds after color developer conditioning (20 copy cycles) is completed. B: Black developer conditioning 1) Press the Clear Modes key. 2) Press the Clear / Stop key. 3) Press the Recall / Enter key. 4) Enter “65”. 5) Press the Recall / Enter key. 6) Close the platen cover and press the Start key. NOTE: Buzzer sounds after black developer conditioning (20 copy cycles) is completed. 3-15 28 February 1989 39. Install the receiving tray [A]. 40. Install the original holder [B] on the platen cover. Remove the vinyl sheets from the operation panel covers. 41. Load paper into the cassette and check machine operation and copy quality. 42. Fill out the New Equipment Condition Report. 3-16 28 February 1989 1.5.5 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 the rear fence [D] in the desired paper size position (1 screw). NOTE: Paper size positions are shown on the inside of the cassette. 4. Reinstall the bottom plate. 5. Reinstall the side fences in the desired size positions. 6 . Attach the proper paper size decals [E] on the cassette at the positions shown. 7. Insert the actuator plate [F] in the slot on the front of the cassette as shown. 3-17 28 February 1989 1.5.6 Key Counter Holder Installation (Option) 1. Open the front cover. 2. Remove the right cover [A] (6 screws). 3 . Remove the key counter cover [B] (2 screws). 4. Remove the right inner cover [C] and the stopper chain [D] (3 screws). To do so, lower the Development unit supporter (insert screwdriver in hole in right inner cover) and release the transfer unit lever [A1]. Hold down the A2 lever and pull off the cover. 5 . Remove the shorting plug [E] from the 4P key counter connector. 6 . Connect the 4P connector of the key counter holder [F] to the key counter harness through the key counter access hole. 7. Position the fixing plate [G] as shown in the illustration and insert the key counter holder. 8 . Align the holes in the fixing plate with the mounting holes of the key counter holder and secure the key counter holder (2 screws). NOTE: The fixing plate has three different hole sizes. Use the holes that match those on the counter that you are installing. 9. Reinstall all covers. 3-18 SERVICE T A B L E S CONTENTS 1. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 1.1 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 1.2 DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 1.3 VARIABLE RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 2. SERVICE REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 2.1 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 2.2 CHARGE CORONA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 2.3 OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 2.4 DEVELOPMENT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 2.5 TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 2.6 TRANSFER and SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 2.7 CLEANING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 2.8 FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 2.9 PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 2.10 DOCUMENT FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 2.11 SORTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 2.12 LARGE CAPACITY TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 2.13 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 3. SPECIAL TOOLS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . .4-10 4. SERVICE PROGRAM MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 4.1 DIP SWITCHES TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 4.1.1 DIP SW 1 (Operation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 4.2 SERVICE PROGRAM MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4.2.1 Service Program Access Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4.2.2 Change Adjustment Values or Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4.2.3 Memory Clear Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 4.2.4 Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 4.3 SERVICE PROGRAM MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 4.4 SERVICE PROGRAM SP-8 DATA INPUT GUIDE TABLE . . . . . . . . . . . . . . . . . . . . . . . .4-32 4.5 SERVICE PROGRAM SP-9 DATA OUTPUT GUIDE TABLE . . . . . . . . . . . . . . . . . . . . . .4-34 4.6 USER CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 4.6.1 User Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 4.6.2 User Code Counter Check (SP Mode #91) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 4.6.3 User Code Counter Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 4.7 MISFEED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38 4.7.1 Location of Jams/Number of Jams (SP Mode #131) . . . . . . . . . . . . . . . . . . . . . .4-38 4.7.2 Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40 5. PREVENTIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . .4-41 5.1 LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45 5.2 REPLACEMENT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46 5.3 ADJUSTMENT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47 5.4 EXPLANATION OF REGULAR PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48 28 February 1989 1. SERVICE TABLES 1.1 TEST POINTS 1. I/O Control Board NUMBER FUNCTION TP301 TP302 TP303 TP304 GND Bias Fusing Thermistor = 0.9V ADS (3.0 ± 0.1V) Voltage adjustment using VR101 Exposure Lamp Voltage (+) Original Width Sensor Output Voltage Original Length Sensor Output Voltage Scan (Factory Use Only) TP305 TP306 TP307 TP308 2. DF Main Board NUMBER FUNCTION TP101 TP102 TP103 TP104 TP105 TP106 TP107 Factory Use Only +5V GND Factory Use Only +12V +24VAA Factory Use Only 3. System Control Board NUMBER FUNCTION TP101 TP102 TP103 TP104 TP105 ADS Voltage (3.0 ± 0.1V) GND Vsg voltage (4 ± 0.2V) GND T.Test (Factory Use Only) 4-1 28 February 1989 1.2 DIP SWITCHES 1. System Control Board (Operation Board) DIP SWITCH 1-1 1-2 1-3 1-4 NORMAL FUNCTION OFF OFF OFF OFF Free run Forced start (Ready Temp. By-pass) Clear counter Service Program mode access 2. DF Main Board DIP SW 101 101-1 101-2 101-3 101-4 FUNCTION ON ON ON OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF ON OFF OFF ON ON ON ON ON ON ON OFF ON ON ON Normal mode 12 cpm (Not used) Normal mode 18 cpm (Factory setting) 1 sided free run (SW101 must be ON) 2 sided free run (SW101 must be ON) Solenoid test: SW101-solenoids ON SW102-solenoids OFF Motor test (lift switch must be ON) All indicators ON (lift switch must be ON) NOTE: a) When the main switch is turned on, the DPS 101 setting must be normal, in order that the initial sequence between the copier and DF can take place. b) When utilizing the free run modes, the lift switch must be ON (close the DF unit) and the original must be inserted. 1.3 VARIABLE RESISTORS 1. I/O Control FUNCTION VR301 VR302 Adjusts Original Width Voltage Adjusts Original Length Voltage 4-2 28 February 1989 2. System Control Board (Operation Board) NUMBER FUNCTION VR101 VR102 Adjusts APS voltage (3 ± 0.1V) Adjust Vsg (4 ± 0.2V) 3. Power Pack (CC/TC/Bias/Grid) NUMBER FUNCTION VR1 VR2 VR3 VR4 Adjusts Adjusts Adjusts Adjusts Main Charge Current Transfer Current standard grid voltage ID sensor grid voltage 4. Power Pack (SC) NUMBER FUNCTION VR DC VR AC Adjusts separation current (dc) Adjusts separation current (ac) 5. Power Supply Board NUMBER FUNCTION VR201 Adjusts dc voltage 6. DF Main Board NUMBER FUNCTION VR101 VR102 Belt drive motor speed adjustment Original leading edge registration adjustment (One-sided original mode) Original leading edge registration adjustment (Two-sided original mode) Factory use VR103 VR106 4-3 28 February 1989 2. SERVICE REMARKS 2.1 DRUM 1. Never touch the drum surface with bare hands. 2. Store the drum in a cool dry place. 3. Always wear gloves when cleaning the drum. 4. Never expose the drum to light for a long time. 5. Drum Initial Setting (SP No. 66) is necessary when a new drum is installed. NOTE: This is not necessary at installation of a new machine as the Drum Initial Setting is performed at the factory. 6 . Always keep the drum in the protective sheet when inserting or pulling the drum out of the copier to avoid exposing it to a bright light or direct sunlight. This will protect the drum from light fatigue. 7. Before inserting or pulling out the drum, the following should be performed to avoid drum damage: a) b) c) d) Release the cleaning unit release lever. Remove the black and color development units. Remove the charge corona unit. Release the transport unit. 8 . Before pulling out the drum, place a sheet of paper under the drum to catch any dropped toner. 2.2 CHARGE CORONA 1. Clean the corona wires with a dry cloth or by sliding the corona unit in and out. Do not use sandpaper or a solvent for wire cleaning. 2. Do not touch the corona wire with oily hands. Oil stains may cause white bands on copies. 3 . Make sure that the corona wires are correctly positioned between the cleaner pads, and there is no foreign material (iron filings, etc.) on the casing. 4. When adjusting the drum current, always make sure that the axis of the drum shoe is aligned with the corona wire. 4-4 28 February 1989 5. Clean the charge grid with a blower brush (not with a cloth). 6. The corona height should only be adjusted in the following cases: a) b) The front end block is replaced. The drum charge current is uneven. 2.3 OPTICS 1. Do not adjust the following parts: a) b) c) d) 1st Scanner Home Position Sensor 3rd Scanner Home Position Sensor Lens Home Position Sensor Lens and 3rd Scanner Guide Rod 2. The above sensors do not have a convenient adjusting procedure. When replacing the sensor, mark the position of the sensor bracket before removing it, and adjust the fine position of the sensor by checking the copy image (magnification and focus). 3. Do not bend or damage the lens/scanner support plate or the mylar strip. 4. Clean the following parts with a dry cloth: Lens and 3rd Scanner Guide Rod 1st Scanner Guide Plate 5. Clean the exposure glass with glass cleaner and a dry cloth to reduce the static charge in the glass. 6. Clean the mirrors with water or a silicone cloth only. 7. Do not touch the following parts with bare hands: Reflectors Exposure Lamp Mirror and Lens 8. Do not bend the ADS or APS cables sharply. 4-5 28 February 1989 9. After adjusting the light intensity (SP No.48), check and adjust the following items: a) b) ADS Voltage Adjustment (SP No.58) . . . . 3.0 ± 0.1V ADS Reference Voltage Memory (SP No.56) NOTE: When adjusting the ADS voltage, perform SP No.56 to store the auto ID reference voltage as a standard. c) Vsg Adjustment (SP No.54) . . . . 4.0 ± 0.2V 2.4 DEVELOPMENT UNIT 1. Be careful not to nick or scratch the development roller sleeve. 2. Place a sheet of paper under the development unit when it is out of the copier. 3 . Be careful not to bend the bias terminal. 4. Clean the drive gears and end magnets after removing used developer. 5. Be careful not to add black developer or toner into the color development unit; do not add color developer or toner into the black development unit. 6 . Developer conditioning is necessary when the developer mixture is replaced, or when color developer units are 1st exchanged. a) b) Black Developer Conditioning (SP No.65) Color Developer Conditioning (SP No.10) 7. After replacing blue developer, make five copies. This prevents background stains (caused by the low electric potential of new toner) from appearing on the copies. 2.5 TONER SUPPLY 1. The image density sensor should becleaned with a blower brush. 2. Do not touch the sensor pattern with bare hands. 4-6 28 February 1989 3. Image density sensor adjustment is required in the following cases: a) b) c) d) e) The ID sensor is replaced. The system control board is replaced. The drum has been replaced and Vsg is out of specification. Problems with toner supply have occurred and the ID sensor check shows Vsg to be out of specification. Exposure lamp voltage is changed. 2.6 TRANSFER and SEPARATION 1. Clean the corona wires with a dry cloth. 2. When adjusting the drum current, always make sure that the axis of the drum shoe is aligned with the corona wire. 2.7 CLEANING UNIT 1. When servicing, be careful not to damage the edge of the cleaning blade. 2. Do not touch the cleaning brush with your bare hands. 3 . Before pulling out the cleaning unit, place a sheet of paper under it to catch any toner that spills out. 4. When inserting the cleaning unit into the copier, be sure the cleaning unit rail is properly engaged with the unit guide rail on the copier. 2.8 FUSING UNIT 1. Be careful not to damage the edge of the hot roller strippers or their tension springs. 2. Do not touch the fusing lamp with bare hands. 3 . Make sure that the fusing lamp does not touch the inner surface of the hot roller. 4. When paper creasing occurs, adjust the position of the entrance guide plate or the fusing pressure. 2.9 PAPER FEED 1. When replacing the friction pad, make sure that the friction pad is below the surface of the front lip of the pad holder. 2. When reinstalling the support bracket after cleaning the registration sensor, make sure that the bracket is properly engaged with the groove of the registration clutch retainer. 4-7 28 February 1989 3. When replacing the friction pad, adjust the gap between the feed roller and the friction pad. 4. Do not touch the feed roller or the friction pad with oily hands. 5. If the copy paper stacked in the cassette binds against the side or back fences and the frequency of paper misfeeds increases when using a nonstandard paper, adjust the position of the side fences and/or the back fence of the cassette. For example: With an A4/LT (sideways) cassette, if the paper width is 297.5mm and 296mm is the proper width, no paper feeding will occur because there is too much friction. 6. A worn out registration roller causes paper to crease. It should be replaced. 2.10 DOCUMENT FEEDER 1. Do not bend the DF interface harness at a sharp angle. This damages the fiber optics cables. 2. When installing or reinstalling the document feeder, make sure that the document feeder is in the open position. 3. A buildup of static electricity on the exposure glass can cause originals to jam. Apply silicon oil to the glass to reduce the amount of friction. 2.11 SORTER 1. The sorter has two types of bins; one type is used for odd numbered bins and the other is used for even numbers. Be careful not to mix them up. 2. If bin operation is not smooth, lubricate the slot liners and transfer wheels using grease 501 or an equivalent type. 2.12 LARGE CAPACITY TRAY 1. Unplug the power supply cord of the LCT before servicing it. 2. Before placing the large capacity tray in the cassette holders, make sure that the paper position feeler is set properly. 4-8 28 February 1989 2.13 OTHERS 1. If the toner density of a solid area decreases, shift the ID sensor bias level to ‘2’ or ‘3’ using SP#33. 2 . When installing a new system control board, remove the RAM from the old main board. Reinstall the old RAM on the system control board if the old RAM is not faulty. 3 . When replacing a sensor, do not overtighten the screw. If the screw is overtightened, the sensor may be damaged. 4. If red portions of the original are not showing up on the copy and the customer requests this, increase the image density. (Press the manual image density key.) 5. Do not make more than one solid color copy at a time, otherwise the toner supply will run out quickly. Use the one-to-one copy process. 6 . In Photo mode, the image density level can not be increased by more than one gradation over that image density level used in normal mode. Shift the photo mode image density level using SP#40. 4-9 28 February 1989 3. SPECIAL TOOLS AND LUBRICANTS Part Number Description Q’ ty A006 9105 A006 9101 A006 9513 A006 9103 A006 9104 A008 9502 5205 9101 5206 9600 5203 9501 5442 9106 5447 9104 5420 9504 5420 9505 5420 9507 5447 9078 5420 9516 5420 9502 5442 9103 Drum Shoe Shaft Doctor Gap Gauge: Color Development Unit Doctor Gap Gauge: Black Development Unit Scanner Wire Clamper Scanner Positioning Pin (4pcs) Grease G-40M Gap Gauge - 0.1mm Sensor Checker Grease (Shinetsu Silicone G-501) Drum Shoe Shoe Adapter Digital Thermometer Digital Thermometer Probe Digital Multimeter Heat Resistant Grease (MT-78) Test Chart OS-A3 (10pcs/set) Test Chart OS-A3 (100pcs/set) Launa Oil 1 1 1 1 1 set 1 1 1 1 1 1 1 1 1 1 4-10 28 February 1989 4. SERVICE PROGRAM MODE 4.1 DIP SWITCHES TABLES 4.1.1 DIP SW 1 (Operation Panel) Description SW # 1* Free run 2 ** Forced start (Ready temperature bypass) 3 Clear counter (see CLEAR MEMORY PROCEDURE) 4 Service Program mode access * When ON, the SP mode is disabled. ** The copy quality and transport ability cannot be guaranteed until the fusing temperature reaches the standard level. 4-11 28 February 1989 4.2 SERVICE PROGRAM MODE OPERATION The service program mode is used to check electrical data and change modes or adjustment values. 4.2.1 Service Program Access Procedure 1. Turn the main switch off. 2 . Remove the key cover and the DIP switch cover on the Operation Panel and turn on DIP SW 1-4, then turn the main switch on. 3 . Using the numeric key board, enter the desired SP mode number according to the Service Program Mode Table. The SP program can also be selected with the zoom keys (+, –), in this case SP numbers are scanned through. After selecting an SP number, press the ENTER key (#). NOTE: To cancel an already entered program, press the clear key. If an invalid SP number is entered and the Enter key (#) is pressed, “0” is displayed in the copy counter. 4. To leave SP mode, turn the main switch OFF, set DIP SW1-4 to the off position, and turn the main switch on. 4.2.2 Change Adjustment Values or Modes 1. Follow steps 1-3 of the SP access procedure. 2. Factory setting value or mode will be displayed in the Magnification indicator. 3 . Enter the desired value or mode using the numeral keys according to the Service Program Mode table. 4. Turn off the main switch, set DIP SW1-4 to the off position, and turn the main switch on. The following procedure can also be used to access program numbers 10, 11, 15, 16, 17, 18, 19, 20, 21, 34, 36, 38, 39, 65, 66, 90, 91, 92, and 93. 1. Press the Clear Modes key. 2. Press the Clear/Stop key. 3. Press the Enter key, at this time the Copy Counter should blink. 4. Enter the desired number using the number keys or zoom keys. 4-12 28 February 1989 5. Press the Enter key. * Service program mode is cleared by pressing the Clear Modes key. * If an invalid SP number is entered and the Enter key is pressed, “0” is displayed in the copy counter. 4.2.3 Memory Clear Procedure Service Program SP-97 is used to clear all self-diagnostic counters and paper jam counters. To perform this clear function, the following procedure must be performed. 1. Turn main switch OFF. 2. Turn On DIP SW1-3 & 4 on the operation panel and turn the main switch ON . 3 . Select Service program SP-97 and press the “1” key on the key pad, then press the Enter key. At this point Service Programs SP-120 through 131 will be cleared, and default to “0”. 4. Turn off the main switch. 5. Turn DIP SW1-3 and 4 off. 6 . Turn the main switch ON to resume normal copier operation. Service Program SP-98 is used to clear all copy counters, self- diagnostic counters and jam counters at once. To perform this clear function, follow the same procedure as previously describe but using SP-98 instead. The following programs will be cleared: 1) SP-100 through SP-131 2) SP83, 84, and 85 (color copy counter) 3) SP-88 (PM counter) 4) All User Programs are cleared 4-13 28 February 1989 5) Secret Mode counters (1 - 20) are cleared This Service Program clears all service programs previously described as well as all adjustments and modes. All modes default to factory settings. 1. Turn the main switch OFF. 2. Turn on DIP SW1-3 and 4 on the operation board. 3 . Turn the main switch on. 4. Select SP-99 and press the “1” key on the key pad, then press the Enter key to perform the memory clear function. NOTE: The buzzer sounds five times when the memory clear function is performed. 5. Turn the main switch OFF and reset DIP SW1-3 and 4 to the OFF position, then turn the main ON to resume copier operation. 4.2.4 Others In the following 15 SP modes, it is possible to make a copy by pressing the Start key. SP mode numbers: 1, 5, 6, 8, 9, 11, 41, 42, 43, 44, 47, 48, 52, 55, and 59. 4-14 28 February 1989 4.3 SERVICE PROGRAM MODE TABLE *: Accessible through the key board (Sales/Customer Access Mode) Data Mode No. Factory Setting Comments 1 SP Mode Data Make copy of SP mode data sheet. Check the setting data of SP mode. 5 Exposure Lamp OFF Free Run Free run with exposure lamp OFF. Check function of machine. 6 Jam Detection OFF Copies are made without jam detection. 7 Call Service Indicator Indicates which section has problem. 8 Input Check Displays the input from sensors. For data, see the data input guide table. 9 Output Check Electrical component turns on. For data, see the data output guide table. *10 Color Developer Conditioning Used to condition the color developer. Buzzer sounds after color developer conditioning (20 cycle) is completed. *11 All Indicators ON Turns on all the indicators on the operation panel. *15 Auto Reset Time Selects auto reset of 1 or 3 minutes. 0: 1 min. 1: 3 min. 2: none 0 *16 Count Up/Down Selects count up or count down. 0: UP 1: DOWN 0 *17 Auto Cassette Shift Selects auto cassette shift mode. 0: YES 1: NO 0 Indicates data No. 1, 2, 3, 12, 13, 23 or 123. 1: PM cycle 2: ID sensor failure 3: Full toner 4-15 Copier automatically shifts to another cassette holding same size paper when paper runs out. 28 February 1989 Mode No. Function Data Factory Setting *18 Beeper Turns beeper ON or OFF. 0: ON 1: OFF 0 *19 Auto ID Priority Selects the priority of image density control when the main switch is turned on. 0: ADS 1: Manual 0 *20 Feed Station Priority Selects feed station priority at power on. 0: LCT 1: 1st 0 *21 APS Priority Selects APS or manual when the main switch is turned off. 0: Yes 1: No 0 22 SADF ShutOff Time Selects shut-off time for SADF mode. 0: 5 sec. 1: 60 sec. 0 23 ADF Free Size Enables originals of various sizes to be fed from the same stack. 0: No 1: Yes 0 24 White Frame for Edit Image Makes white frame on the border line when using “Black in Area” or “Color in Area” mode. 0: No 1: Yes 0 28 Sort Priority Sort Mode is automatically selected when more than 1 original is set on the DF table and the entered copy quantity is greater than 2 and less than 20. 0: Manual 1: Auto Sort 4-16 t 0 Comments When the LCT priority is selected and paper is not present on the LCT, 1st cassette takes priority of LCT. When the cassette is not inserted, its feed station is not selected. If No, CPM of A4 (LT) sideways in ADF mode (1 to 1 copy speed) becomes 18, due to pre-start feeding. If Yes, CPM of A4 (LT) sideways (1 to 1 copy speed) is 12. Sorter and DF must be installed on the machine. When in Duplex 1 sided original, 2 originals combine, and overlay mode, more than 2 originals must be set. 28 February 1989 Mode No. 29 Fusing Temperature Control Function Data Factory Setting Comments Selects fusing temperature control mode. 0: ON/OFF control 1: Phase control 30 Black Toner Supply Mode Selects black toner supply system. 0: ID sensor 1: Fixed Supply 0 31 Black Toner supply Amount (ID Sensor Mode) Determines how much toner is supplied in ID sensor mode. 0: 15% 1: 7% 2: 30% 3: 60% 0 32 Black Toner Supply Amount (Fixed) Determines how much toner is supplied in fixed mode. 0: 7% 1: 3.5% 2: 10.5% 3: 14% 0 33 ID Sensor Bias (Black) Sets the bias voltage applied to the developer roller when sensing image density. 0: -260V 1: -220V 2: -280V 3: -300V 0 -260V = normal -220V = lighter -280V = darker -300V = darkest *34 ADS Adjustment (Bias shift) Adjusts the image density in ADS mode. 0: Normal 1: Darker 2: Lighter 0 1: Shifts bias output (+40V) 2: Shifts exposure lamp voltage (+2V) 35 Black Toner Supply Detection ID sensor check is performed every 5 copies or 10 copies. 0: 10 copies 1: 5 copies 0 This prevents low image density before toner end detection. *36 Margin Adjustment Selects the present margin adjustment value. 0: 5 mm 1: 10 mm 2: 15 mm 0 When using margin adjustment mode. 37 Black Bias Adjustment Adjusts black bias output if the Image density in level 4 can not be adjusted using Light Intensity Adjustment mode (SP 48). 0: Present Bias 1: Present Bias + (+40V) 2: Present Bias + (+20V) 3: Present Bias + (-20V) 4: Present Bias + (-40V) 0 0: Normal 1: Darkest 2: Darker 3: Lighter 4: Lightest NOTE: Present Bias = Standard Bias 4-17 After the selected mode is set and the main switch turns off/on, the fusing temperature control is changed. See SP31/SP32 for ratios. 28 February 1989 Mode No. Function Data Factory Setting *38 Edge erase Sets the width of margin erased. 0: 10 mm 1: 5 mm 2: 15 mm 3: 20 mm 0 *39 Center Erase Margin Sets the width of the center erase margin. 0: 20 mm 1: 10 mm 2: 15 mm 3: 25 mm 0 *40 Photo Mode Image Density Adjusts the image density in Photo mode 0: Expo. Lamp 0 Voltage = -2V Grid Voltage = -770V 1: Expo. Lamp Voltage = 0V Grid Voltage = -770V 2: Expo. Lamp Voltage = -4V Comments 0: Normal 1: Lighter 2: Lightest Grid Voltage = -560V 41 Lead Edge Erase Margin Adjustment Adjusts the lead edge margin. 0 - 15 8 0.8 mm per step. (max. -6.4 mm to +5.6 mm) 42 Registration Adjustment Adjusts registration. 0 - 15 8 0.8 mm per step. (max. -6.4 mm to +5.6 mm) 43 Vertical Magnification Adjustment Adjusts magnification in the paper travel direction. 0 - 15 8 44 Horizontal Magnification Adjustment Adjusts magnification perpendicular to the direction of paper travel. 0 - 15 8 0.2% per step (max. -1.6% to +1.4%) 0.2% per step (max. -1.6% to +1.6%) 45 First Image Magnification Correction Adjusts magnification of the first image to equal the second image when using Overlay or duplex mode. 0: +0.4% 1: No correction 2: +0.2% 3: +0.6% 4: +0.8% 5: +1.0% 6: +1.2% 7: +1.4% 8: +1.6% 9: +1.8% 10: +2.0% 0 4-18 28 February 1989 Mode No. Function Data Factory Setting Comments 46 Size DetecCorrects size detection Error Cor- tion. rection 0 - 15 8 1 mm per step. (Max. -8 mm to +7 mm) 47 Focus Adjustment Adjusts 4th/5th mirror position to correct focus. 0 - 14 8 0.48 mm per step. -1.72 mm to +2.88 mm NOTE: Adjust SP Mode #47 after adjust ing #43 & #44. 48 Light lntensity Adjustment Adjusts exposure lamp voltage. 50 - 75 Vac 64 To adjust voltage, enter lamp voltage with key pad in 1.0volt steps. 49 Fusing Temperature Adjustment Adjusts fusing temp. 175 - 190 degrees 185 175 to 190 degrees in 1 degree steps. 50 Original Length Detection Check Displays the length detected by the size detection sensor. Press # key to display. 51 Exposure Lamp Voltage Check Displays exposure lamp voltage. Press # key to display. Exposure lamp stays on for 10 seconds. Do not repeat more than 5 times to avoid overheating the optics cavity. 52 Fusing Temperature Displays the fusing temperature. Press “#” key to display. 54 Vsg Adjustment Adjusts Vsg 55 Vsg & Vsp Check Displays Vsg and Vsp. 4 ± 0.2V Adjust Vsg with VR102 on the operation board. Vsp & Vsg values updated every 10 copies. Press “#” key to display Vsp. Press “0” key to display Vsg. 4-19 28 February 1989 Mode No. Function Data Factory Setting Comments 56 ADS Reference Voltage Memory Automatically memorizes the auto ID reference voltage as a standard. Place more than 5 sheets of A3 (LDG) white paper on the exposure glass. NOTE: Do SP Mode #56 after adjusting #58. 57 ADS voltage value display original Displays K values. Press Start key to turn on. Press C/S to stop. Machine starts free run. K = SP #57/ SP #56 SP Mode #57: Reflected light voltage. 58 ADS Voltage Adjustment Displays ADS Voltage. Adjust the voltage using VR101 on the operation board so that it is 3 ± 0.1V. Press Start key to turn on. Press C/S key to stop. This is basic adjustment more than SP 56. NOTE: After adjust ing this mode, do SP Mode #56. 59 Bias Voltage Check (Black) Displays bias voltage. Press Start key to turn on. Press C/S key to stop. 61 APS Length Voltage Displays APS length voltage. Adjusts APS length voltage using VR302 on the I/O control PCB so that it is 2.8 ± 0.2V. Press Start key to turn on. Press C/S key to stop. 62 APS Width Voltage Displays width voltage. Adjusts APS width voltage using VR301 on the I/O control board so that it is 2.8 ± 0.2V. Press Start key to turn on. Press C/S key to stop. 4-20 28 February 1989 Mode No. Data Factory Setting Comments 64 Black Toner Density Level Check Displays the black toner density level in initial condition (SP65). *65 Black Developer Conditioning Used to condition the black developer. Buzzer sounds 5 times after black developer conditioning (20 cycle) is completed. *66 Drum Initial Setting Used to set new drum condition. Press # key to condition. Buzzer sounds 5 times after drum conditioning mode is completed. 67 Drum (Vr) Correction Ratio Displays L values (Vr correction ratio). 68 Drum Type Selects the Max. Vp value according to the type drum. Normally this should be “0”. 69 Vr Forced Detection Detects Vr value to be forced, and corrects the lamp, grid and bias voltages according to the Vr correction ratio. 70 Color Toner Supply Amount (Fixed Mode) Selects the color toner supply ratio. 0: 14% 1: 7% 2: 21% 3: 28% 0 71 Sorter Operation Enables sorter operation. 0: No 1: Sorter 0 0 1 2 3 4 Press “#” key to display the level (0 to 4). 0: 12 - 15 (Vsp/Vsg%) 1: 0 - 7 (Vsp/Vsg%) 2: 8 - 11 (Vsp/Vsg%) 3: 16 - 21 (Vsp/Vsg%) 4: 22 - (Vsp/Vsg%) 100 - 89 (0) 88 - 76 (1) 75 - 62 (2) 61 - 38 (3) 37 - 0 (4) 4-21 L = Vrp/Vsg x 100 28 February 1989 Mode No. Function 72 Multi Duplex/OverIay Operation Enables Multi Duplex/Overlay Operation. 73 Total Color Copy Count Shows the total number of color copies (Red + Green + Blue) in the Magnification Ratio Indicator. 74 Color Toner Supply Detection ID sensor check is performed every 5 copies or 10 copies. 0: 5 copies 1: 10 copies 75 ID Sensor Bias (Color Toner) Selects the bias voltage applied to the bias roller when sensing image density. Blue/Green: 0 (Normal Control) 0: -320V 1: -280V 2: -340V 3: -360V (Initial Control of SP Mode #10) 0: -320V 1: -320V 2: -320V 3: -320V Red: (Normal Control) 0: -240V 1: -200V 2: -260V 3: -280V (Initial Control of SP Mode #10) 0: -280V 1: -280V 2: -280V 3: -280V 0: Normal 1: Lighter 2: Darker 3: Darkest 76 Sorter Bin Capacity Sets the stack quantity limit. 0: No limit 1: Limit Sort Mode: Limit = 20 sheets/bin Stack Mode: Limit = 30 sheets/bin (A4/LT) = 10 sheets/bin (A3/DLT) Data 0: No 1: Multi Duplex/ Overlay Factory Setting 0 Comments Must be set to 1 to multi-duplex/overlay unit is installed. Press # key to display the first three digits in the Magnification indicator. Press “.” key to display the second three digits. 4-22 0 0 28 February 1989 Mode No. 77 ADF Odd Number Originals (Duplex/Overlay Mode) Function Sets the copier to eject the final copy if an odd number of originals are set. 79 Color Bias Ad- Adjusts color bias voltage so that the justment image density is the same as black copies. Data Factory Setting Comments 0: ON 1: OFF 0 When on, the final sheet is fed out; when off, it stays in the duplex tray. 0: Present Bias 1: Present Bias + (+40V) 2: Present Bias + (+20V) 3: Present Bias + (-20V) 4: Present Bias + (-40V) 0 1: Darkest 2: Dark 3: Light 4: Lightest NOTE: Present Bias = Normal Bias of SP Mode #37 80 ID Sensor Level (Red) Displays ID sensor level for red toner detected by SP Mode #10. Reference Value = 57 The value which was set in SP Mode #10 is displayed. ID sensor level = Vsp/Vsg x 100. 81 ID Sensor Level (Green) Displays ID sensor level for green toner detected by SP Mode #10. Reference Value = 60 The value which was set in SP Mode #10 is displayed. ID sensor level = Vsp/Vsg x 100. 82 ID Sensor Level (Blue) Displays ID sensor level for blue toner detected by SP Mode #10. Reference Value = 60 The value which was set in SP Mode #10 is displayed. ID sensor level = Vsp/Vsg x 100. 83 Color Copy Count (Red) Displays the total number of red copies. Press # key to display the first three digits in the Magnification indicator. Press “.” key to display the second three digits. 84 Color Copy Count (Green) Displays the total number of green copies Press # key to display the first three digits in the Magnification indicator. Press “.” key to display the second three digits. 4-23 28 February 1989 Mode No. Function Data Factory Setting Comments 85 Color Copy Count (Blue) Displays the total number of blue copies. *86 Highlight Color Density Adjustment Adjusts the density in Highlight Color mode. 1-7 4 87 PM Copy Count Sets the interval of the PM counter 0: No PM 1: 40K 2: 60K 3: 80K 4: 100K 0 88 PM Counter Check Displays contents of the PM counter. When the PM count is exceeded, the Service Call indicator blinks and Key Counter indicator lights. Press # Key to display the first three digits in the Magnification indicator. Press “.” key to display the second three digits. 89 PM Counter Reset Resets the PM counter Use after performing PM. *90 User Code Mode Selects user code mode. (Key counter shorting connector must be removed.) *91 User Code Counter Check Displays the contents of each user counter. Use “+” and “-” (“up” & “down”) keys to select user code. (The last two digits of user code are displayed in the copy counter.) *92 User Code Counter Reset Resets counters of all user codes. Press # key to display the first three digits in the Magnification indicator. Press “.” key to display the second three digits. 0: OFF 1: ON 0 1: Darker 4: Normal 7: Lighter If on, must enter a code to copy. See user code table. Reset after 60s or if C/S and Clear Modes pressed together. User counters count from 0 to 999999. Press # key to display the first three digits in the Magnification indicator. Press “.” key to display the second three digits. 0: No 1: Yes 4-24 To reset, press “1” then the “#” key. 28 February 1989 Mode No. Function Data *93 Maximum Copy Quantity Limits the maximum copy quantity that can be entered. 1 - 999 97 Clear S/C & Jam Count Clears the service call and jam counters. 0: No 1: Yes 98 Clear Counters Clears the following counters: - total copies - S/C & Jam counter - User Program - PM counter - Main Motor on Time - User Code Counter 0: No 1: Yes 99 Clear All Memory Clears all counters and returns all modes to factory setting. 0: No 1: Yes 100 Main Motor on time check Displays the total (accumulated) time that the main motor has operated. 4-25 Factory Setting Comments The magnification indicator blinks and the limit quantity is displayed. If you enter 10, the max. is 10. Otherwise, max. number is entered. 0 DIP SW1-3 and 4 on operation board must be on. DIP SW1-3 and 4 on operation board must be on. 0 DIP SW1-3 and 4 on the operation board must be ON. 0 Time in hours. Motor Count: Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. Drum Count: Press the “0” key to display the first three digits in the Magnification indicator. Press the “0” & “.” keys to display the second three digits. NOTE: This counter (Time in hours) can be cleared using SP#66. 28 February 1989 Mode No. Function Data Factory Setting Comments 101 Total Copies Displays the total number of copies. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 102 Duplex Copies Displays the total number of duplex copies made. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 103 DF Copies Displays the total number of copies made using the DF. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 104 Sort Copies Displays the total number of copies made using the sorter. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 105 Paper Bank Copies (Not used) Displays the total number of sheets fed from the paper bank unit (4th/5th feed station). 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 106 LCT Copies Displays the total number of sheets fed from the LCT. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 4-26 28 February 1989 Mode No. Function Data Factory Setting Comments 107 Overlay Copies Displays the total number of overlay copies mode. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 108 A3/11” x 17” Copies Displays the total number of A3 or 11” x 17” copies. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 109 A4/8-1/2” x 11” Copies Displays the total number of A4 or 8-1/2” x 11” copies. 0 This includes both sideways and length wise. 110 Optional Multi Duplex/Overlay Copies Displays the total number of sheets from the Multi Duplex/Overlay unit. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 111 Reduction Copies Displays the total number of reduction copies. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 112 Enlarged Copies Displays the total number of enlarged copies. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 4-27 28 February 1989 Mode No. Function Data Factory Setting Comments 114 Originals Copied Displays the total number of originals copied. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 115 Originals Copied Using DF Displays the total number of originals copied using the DF. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 116 B4 Copies Displays the total number of B4 copies. 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. 117 B5 Copies Displays the total number of B5 copies. 0 This includes both sideways and lengthwise. 120 Total Service Calls Displays the total number times that the service call indicator has turned on. 0 Press # key to display the total number times in the Magnification indicator (3 digits). 121 Service Call for Optics Displays the total number “Optics” service calls. 0 Press # key to display the total number “Optics” service calls in the Magnification indicator (3 digits). 122 Service Calls for Exposure Displays the total number of “Exposure” service calls. 0 Press # key to display the total number of “Exposure” service calls in the Magnification indicator (3 digits). 4-28 28 February 1989 Mode No. Function Data Factory Setting Comments 123 Service Calls for Drive Displays the total number of “Drive” service calls. 0 Press # key to display the total number of “Drive” service calls in the Magnification indicator (3 digits). 124 Service Calls for Fusing Displays the total number of “Fusing” service calls. 0 Press # key to display the total number of “Fusing” service calls in the Magnification indicator (3 digits). 125 Service Calls for Interface Communication Displays the total number of “Interface Communication” service calls. 0 Press # key to display the total number of “Interface Communication service calls in the Magnification indicator (3 digits). 130 Paper Jams Displays the total number of paper jams. 0 The first three digits are shown in the Magnification indicator. Press “.” to display the second 3 digits. 131 Location of Jams/Number of Jams Displays the total number of paper jams in the following area. Use “+” & “-” (“up & “down”) keys to select the following numbers. 1. Registration jams (This includes 1st/2nd feed station jams.) 0 Press the “#” key to display the first three digits in the Magnification indicator. Press the “.” key to display the second three digits. Enter the desired number using the numeral keys or zoom keys (“+” or “-” keys). See the jam location table. 2. 3rd feed station. 0 3. 4th feed station. (Not used) 0 4. 5th feed station. (Not used) 0 4-29 28 February 1989 Mode No. Data Function Factory Setting 5. Paper is not fed from the Multi Duplex/Overlay unit and the inverter relay sensor in the copier is not activated when making multi duplex copies. 0 6. The inverter sensor is not activated in the Multi Overlay mode. 0 7. Paper is not fed to the fusing unit. 0 8. Paper jams in the fusing unit. 0 9. Paper is not fed to the Sorter unit. 0 10. Paper jams in the Sorter unit. 0 11. Paper does not reach the paper exit sensor in the Multi Duplex/ Overlay unit. 0 12. Paper stays on the paper exit sensor in the Multi Duplex/ Overlay unit. 0 13. Paper does not reach the inverter sensor in the Single Duplex mode. 0 14. Paper stays on the inverter sensor in the Single Duplex mode. 0 4-30 Comments 28 February 1989 Mode No. Function Data Factory Setting 15. Paper does not reach the inverter relay sensor in the Single Duplex/Overlay mode. 0 16. Registration jam in overlay/duplex copies. 0 17. Paper stays on the inverter relay sensor in the Multi Duplex/Overlay mode 0 18. Inverter relay sensor is not activated when making multi overlay copies 0 19. Paper stays on the inverter sensor when in the Multi Overlay mode. 0 20. ADF jams. 0 4-31 Comments 28 February 1989 4.4 SERVICE PROGRAM SP-8 DATA INPUT GUIDE TABLE - How to use this table 1. After “8” is entered, press the Enter (#) key. 2. Enter the desired input number using the numeral keys according to the above table. 3. Press the Enter (#) key. 4. Enter the number of copies and press the Start key. 5. The data (0 or 1) will be displayed in the Magnification indicator. NOTE: It is possible to check the ON/OFF manually. Input No. Remarks Sensor / Switch / Signal 1 Registration Sensor (Copier) OFF ON ON: Paper is present OFF: Paper is not present 2 Fusing Exit Sensor (Copier) OFF ON ON: Paper is present OFF: Paper is not present 4 Upper Relay Sensor (Copier) OFF ON ON: Paper is present OFF: Paper is not present 5 Lower Relay Sensor (Copier) OFF ON ON: Paper is present OFF: Paper is not present *6 5th Relay Sensor (Paper Bank) OFF ON ON: Paper is present OFF: Paper is not present 8 lnverter Sensor (Copier) OFF ON ON: Paper is present OFF: Paper is not present 9 Inverter Relay Sensor (Copier) OFF ON ON: Paper is present OFF: Paper is not present 10 Paper Exit Sensor (Multi Duplex/Overlay) OFF ON ON: Paper is present OFF: Paper is not present 11 Paper End Sensor (Multi Duplex/Overlay) OFF ON ON: Paper is present OFF: Paper is not present * Not for use in this model. 4-32 28 February 1989 Input No. Remarks Sensor / Switch/ Signal 12 Jogger H.P. Sensor (Copier) OFF ON 13 Jogger H.P. Sensor (Multi Duplex/Overlay) OFF ON 15 Paper Sensor (Sorter) OFF ON ON: Paper is present OFF: Paper is not present 16 Wheel Sensor (Sorter) OFF ON ON: Sensor is activated 17 H.P. Sensor (Sorter) OFF ON ON: Sensor is activated 18 Cover Safety Switch (Sorter) Close Open Open: Switch is not activated 20 Color Toner End Sensor (Copier) OFF ON 21 Total Counter Confirmation (Copier) Low High Low: Counter OFF High: Counter ON 24 ADF Lift Switch (ADF) Close Open Open: Switch is not activated *25 Paper Bank ON line (Paper Bank) No Yes Yes: Paper Bank is installed 26 Editor ON line (Editor) No Yes Yes: Editor is installed 28 ADF ON line (ADF) No Yes Yes: ADF is installed 30 1st Cassette Lift Sensor OFF * Not for use in this model. 4-33 OFF: When the jogger fen ces are positioned at home positioned by hand ON: Sensor is activated 23 May 1989 4.5 SERVICE PROGRAM SP-9 DATA OUTPUT GUIDE TABLE - How to use this table 1. After “9” is entered, press the Enter (#) key. 2. Enter the desired output number using the numeral keys according to the table. 3 . Press the Start key to turn on the electrical component. 4. Press the Clear/Stop key to turn off the electrical component. CAUTION: To prevent the gear from being damaged, remove the first cassette when checking SP#27 (1st Lift Motor). Output No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 *19 20 21 22 *23 *24 Electrical Component Main Motor (Copier) Main Corona Charge + Standard Grid (Copier) Main Corona Charge + ID Sensor Grid (Copier) Main Corona Charge + VR Grid (Copier) Transfer Charge (Copier) Transfer Charge + Transfer Up Charge (Copier) Separation Charge (Copier) Black Development Unit Set Mode (Copier) NOTE 1 Color Development Unit Set Mode (Copier) NOTE 2 Development Drive MC (Copier) Toner Supply MC (Copier) PTL/QL (Copier) Red Erase Solenoid (Copier) Roller Drive Motor (Sorter) Wheel Drive Motor: Bin Up (Sorter) Wheel Drive Motor: Bin Down (Sorter) Registration MC (Copier) Relay Roller MC (Copier) 5th Gate MC (Paper Bank) 1st Paper Feed MC (Copier) 2nd Paper Feed MC (Copier) 3rd Paper Feed MC (Copier) 4th Paper Feed MC (Paper Bank) 5th Paper Feed MC (Paper Bank) * Not for use in this model. 4-34 28 February 1989 Output No. 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Electrical Component Duplex/Overlay Feed MC (Multi Duplex/Overlay) 1st Pick-up Solenoid (Copier) 1st Lift Motor (Copier) Duplex/Overlay Transport Solenoid (Copier) Junction Gate Solenoid (Multi Duplex/Overlay) Inverter Solenoid (Copier) Positioning Roller Solenoid (Copier) Duplex/Overlay Transport MC (Copier) Move the jogger side fences to the home position (Copier) Move the jogger side fences to the home position (Multi Duplex/Overlay) Positioning Roller Solenoid (Multi Duplex/Overlay) Cam Clutch Solenoid (Multi Duplex/Overlay) Eraser Lamps Main Corona + Standard Grid + Transfer + Separation Charge Main Corona + ID Sensor Grid + Transfer + Separation Charge NOTE: 1: Main motor, development drive motor, and toner supply clutch (for color toner) turn on and the development unit change solenoid is set. 2: Main motor, development drive motor, and toner supply clutch (for black toner) turn on and the development unit change solenoid is reset. 4-35 28 February 1989 4.6 USER CODE TABLE 4.6.1 User Codes There are 20 user codes as follows: No. 1 2 3 4 5 6 7 8 9 10 User Code 1101 1202 1303 1404 1505 1606 1707 1808 1909 2010 12 13 14 15 16 17 18 19 20 2212 2313 2414 2515 2616 2717 2818 2919 3020 - How to use “User Code” 1. Enter a user code (4 digits) using the numeral keys. 2. Press the Enter (#) key. 3. Press the Start key to make a copy. NOTE: The user code mode is reset after 60 seconds or if the Clear/Stop and Clear Modes keys are pressed together. 4-36 23 May 1989 4.6.2 User Code Counter Check (SP Mode #91) The contents of each user counter (20 codes) can be checked using the following procedure: 1. Select SP Mode #91 using the numeric keys. 2. Press the Enter (#) key. 3. Select the desired user code using the “+” and “-” (zoom “up” and “down”) keys. The last two digits (1 to 20) of the user codes are displayed in the copy counter. 4. Press the “.” key to display the second three digits in the Magnification indicator. In case the “.” key is not pressed, the first three digits are displayed in the Magnification indicator. 4.6.3 User Code Counter Reset The copy counters of all user codes can be cleared by the following procedure: 1. Select SP Mode #92 using the numeric keys. 2. Press the Enter (#) key. 3. Press the “1” key to reset all user code counters (20 codes). 4. Press the Enter (#) key. 4-37 21 April 1989 4.7 MISFEED TABLE 4.7.1 Location of Jams/Number of Jams (SP Mode #131) The number of jams in each area mentioned in the following table can be checked using the following procedure: 1. Enter “1 31” using the numeric keys. 2. Press the Enter (#) key. 3 . Select the desired FC code (Function Code) according to the table. The FC code can be selected with the “+” and “-” (zoom “up” and “down”) keys. 4. Press the “.” key to display the jam counter in the second three digits of the Magnification indicator. Release the “.” key to display the first three digits. FC Code 1 2 3 4 5 6 7 8 9 10 11 Jam Area / Detection Registration jams (This includes 1st/2nd feed station jams) (Registration Sensor not ON) 3rd feed station (Upper Relay Sensor not ON) 4th feed station (Not used) 5th feed station (Not used) Paper is not fed from the Multi Duplex/Overlay unit and the inverter relay sensor in the copier is not activated when making multi duplex copies. (Inverter Relay Sensor not ON) Inverter sensor is not activated in the Multi Overlay mode. (Inverter Sensor not ON) Paper is not fed to the fusing unit (Fusing Exit Sensor not ON) Paper jams in the fusing unit (Fusing Exit Sensor not OFF) Paper is not fed to the sorter unit (Paper Sensor not ON) Paper jams in the sorter unit (Paper Sensor not OFF) Paper does not reach the paper exit sensor in the Multi Duplex/Overlay unit. (Paper Exit Sensor not ON) 4-38 Sensor A B C E H H G G F 28 February 1989 FC Code 12 13 14 15 16 17 18 19 20 Jam Area / Detection Paper stays on the paper exit sensor in the Multi Duple/Overlay unit. (Paper Exit Sensor not OFF) Paper does not reach the inverter sensor in the Single Duplex mode. (Inverter Sensor not ON) Paper stays on the inverter sensor in the Single Duplex mode. (Inverter Sensor not OFF) Paper does not reach the inverter relay sensor in the Single Duplex/Overlay mode. (Inverter Sensor not ON) Registration jam in duplex/overlay copies. (Registration Sensor not ON) Paper stays on the inverter relay sensor in the Multi Duplex/Overlay mode. (Inverter Relay Sensor not OFF) Inverter relay sensor is not activated when making multi overlay copies. (Inverter Relay Sensor not ON in Multi Overlay mode) Paper stays on the inverter sensor in the Multi Overlay mode. (Inverter Sensor not OFF) ADF jams 4-39 Sensor F E E D A D D E l/J 28 February 1989 4.7.2 Sensor Location A: Registration Sensor (Copier) B: Upper Relay Sensor (Copier) C: Lower Relay Sensor (Copier) D: Inverter Relay Sensor (Copier) E: Inverter Sensor (Copier) F: Paper Exit Sensor (Multi D/O) G: Paper Sensor (Sorter) H: Fusing Exit Sensor (Copier) I: Registration Sensor (ADF) J: Exit Sensor (ADF) 4-40 28 February 1989 5. PREVENTIVE MAINTENANCE SCHEDULE After performing the preventive maintenance, do the following: 1. Make a copy of the O-S-A3 test chart at manual image density level 4 to set the lamp voltage (SP Mode No.48) and achieve the proper exposure lamp intensity (see Exposure Lamp Voltage Adjustment). 2. Adjust the ADS. Select SP Mode No.58 and turn VR101 to adjust the ADS to 3.0 ± 0.1V. 3 . Carry out ADS Memory Reference Voltage. (Press the start key in SP Mode No.56, and let the scanner run more than 5 times.) 4. Adjust the Vsg. Select SP Mode No.54 and turn VR102 to adjust Vsg to 4.0 ± 0.2V. 5. Select SP Mode No.1 and make a copy of the SP Mode Data Sheet. Fill out the copy of the sheet. Keep the copy for future reference. 6 . Make a sample copy. NOTE: 1) Do Drum Initial Setting (SP#66) after replacing the drum. 2) Do Black Developer Conditioning (SP#65) after replacing the black developer mixture. 3) Do Color Developer Conditioning (SP#10) after replacing the color developer mixture. 4-41 28 February 1989 Symbol keys: L = Lubricate R = Replace C = Clean I = Inspection EM 60K 120K 180K 240K A. OPTICS 1. Mirrors, lens, reflectors, toner shield glass 2. Exposure glass 3. Platen cover sheet C C C 4. Scanner guide rail 5. Magnification guide rod 6. ADS,APS sensor 7. Red erase filter B. PAPER FEED 1. Paper feed roller (1st, 2nd, 3rd) 2. Friction pad 3. Pick-up roller 4. Registration roller 5. Separation roller spring clutch (1st feed station) 6. Separation roller (1st feed station) 7. Paper feed guide plate 8. Registration sensor 9. Cassette bottom plate pad 10. 1st feed roller drive section C C C C NOTES Silicone cloth or water (cotton pad), blower brush C C C C C C C C C C C C C C NOTE: Clean 6th mirror with blower brush. Alcohol or water Alcohol or water (replace if necessary) Dry cloth Dry cloth C C C Silicone cloth Blower brush C C C C C C R R Water C C C R R C C R R C L L L L Water Water Alcohol (replace if necessary) Mobil temp 78 R Water C C C Alcohol Blower brush Alcohol or water L Grease G501. Refer to NOTE 3 C R C C C C C C L 4-42 C C C 21 April 1989 EM 60K 120K 180K 240K C. AROUND DRUM 1. Corona wires 2. Wire cleaner 3. Charge grid 4. End blocks and casing 5. Transfer guide plate 6. Pre-Transfer lamp NOTES C R R C C C C R R R C C C R R C C C C R R R C C C 7. Quenching lamp C C C C C 8. ID sensor 9. Erase lamp unit C C C C C C C C C C Blower brush Dry cloth Dry cloth Dry cloth, discharge any static before installation Dry cloth, discharge any static before installation Blower brush Dry cloth C C R C R C C Replace if necessary Replace if necessary Replace if necessary Replace if necessary Empty used toner Replace if necessary Refer to NOTE 7 D. CLEANING UNIT 1. Cleaning blade 2. Cleaning seal 3. Cleaning brush 4. Pick-off pawls 5. Used toner bottle E. DEVELOPMENT UNIT 1. Developer 2. Upper brush seal 3. Side seals 4. Development unit change clutch 5. Development drive gear C C C C R C R C C R R R R C C C C L C C C C L C C C R L 6. Development roller gears F. FUSING UNIT 1. Hot roller 2. Pressure roller 3. Stripper pawls 4. Fusing entrance and exit guides 5. Fusing drive gears 6. Fusing thermistor C L C C C C C C R R C C C C C C C C R I I 4-43 I Dry cloth Mobil temp 78. Refer to NOTE 1 Silicone grease G-40M. Refer to NOTE 6 Silicone grease G-40M Refer to NOTE 2 If necessary If necessary Suitable solvent, replace if necessary Suitable solvent Refer to NOTE 5 I Suitable solvent, clean if necessary 28 February 1989 EM 60K 120K 180K 240K G. OTHERS 1. Main drive chain 2. Ozone filter 3. Transport belt 4. Bushings 5. Drive roller in Jogger unit 6. Drum drive belt H. DOCUMENT FEEDER 1. Belt 2. Pick-up roller 3. Feed roller 4. Friction belt 5. Registration/Original width sensor 6. Spring clutch 7. Belt drive motor gears L R C R C L L R C R C L L I I I I C C C C C C R C C C R C C C R C C C R C I. LARGE CAPACITY TRAY 1. Pick-up roller C C 2. Feed roller J. SORTER 1. Bin guide/wheel 2. Round Belt 3. Guide plate K. MULTI DUPLEX/OVERLAY 1. Feed roller C C 2. Friction pad 3. Bottom plate pad 4. Round belt 5. Sponge roller 6. Spring clutch L R R NOTES Mobil temp 78, adjust if necessary. Refer to NOTE 8 Alcohol or water Spindle oil Mobil temp 78. Refer to NOTE 4 Adjust if necessary Belt cleaner, replace if necessary Water, replace if necessary Water, replace if necessary Water, replace if necessary Blower brush L L Mobil temp 78 Mobil temp 78 R R Water Water L C C L C C L C C L C C Grease G501 Alcohol Dry cloth C I I I I C l l l l C l l l l C I l I Replace if necessary Replace if necessary Replace if necessary Replace if necessary Alcohol, replace if necessary Mobil temp 78, lubricate if necessary 4-44 28 February 1989 5.1 LUBRICATION POINTS The location of the parts which should be lubricated at PM, are shown in the following figures: NOTE 1: 1. Development Unit Change Section * Use Mobil Temp 78 a) Clean the planetary gears [A] and the development unit change clutch spring [B] and drive gear [C]. Then, lubricate them with Mobil Temp 78 every 120K. NOTE 2: 1. Black Development Unit * Use Silicon Grease G-40M a) Clean the gears [A] located on the rear side of black development unit. Then, lubricate them with Silicon Grease G-40M every 120K. 2. Color Development Unit * Use Silicon Grease G-40M a) Clean the gears [A] located on the rear side of the color development unit. Then, lubricate them with Silicon Grease G-40M every 120K. 4-45 28 February 1989 NOTE 3: 1. 1st Feed Roller Drive Section * Grease G501 a) Clean the shaft [A] and the inside of the idle gears [B]. Then lubricate them with Grease G501 every 120K. NOTE 4: 1. Jogger Section * Mobil Temp 78 a) Remove the shaft holders [A]. b) Clean the positioning roller shafts [B] and shaft holders. Then, lubricate them with Mobil Temp 78 every 120K. 5.2 REPLACEMENT POINTS Replace the following parts at PM, if necessary, as shown in the following figures: NOTE 5: 1. Fusing Unit a) Replace the following three gears located on the rear side of the fusing unit every 180K, if necessary. A: Hot Roller Gear [P/N AB013132] B: Idle Gear [P/N AB013133] C: Exit Roller Gear [P/N AB013134] 4-46 28 February 1989 NOTE 6: 1 . Development Roller Drive Section a) Replace the development roller drive gear [A] every 240K, if necessary. Then, lubricate it with Silicon Grease G-40M. A: Development Roller Drive Gear [P/N AB013142] NOTE 7: Replace the black and color developer at PM, refering to the following supply yield table, if necessary. TYPE OF DEVELOPER TARGETED SUPPLY YIELD Black developer Red developer Blue developer Green developer 60K copies 20K copies 10K copies 10K copies 5.3 ADJUSTMENT POINTS NOTE 8: 1. If the tension sprocket [A] and the belt pulley [B] are aligned the chain is stretched approx. 10 mm, change the hook position of the tension spring [C] from lower [D] to upper [E] position at 240k copies (approximately). 4-47 28 February 1989 5.4 EXPLANATION OF REGULAR PM Item Optics Unit Paper Feed, Registration Transport Explanation Mirrors, Lens, Reflector, Exposure Glass, Platen Cover Stains on any part of the optics unit result in a dirty background, black lines, or areas of decreased sharpness on the copy image. Periodic cleaning is required. The exposure glass and the platen cover must also be cleaned. If stains on the platen cover cannot be removed, it must be replaced. Exposure Lamp Deterioration of the exposure lamp affects the copy image. Check the lamp at regular intervals and replace if discolored. Optical Fiber A dirty optical fiber receptor can result in insufficient image density. Clean at regular intervals. Paper Feed Roller, Pick-up Roller, Separation Roller This machine uses cassettes for paper feeding. If paper powder or dust adheres to the paper feed roller, paper may not feed correctly and/or skewing may result. Cleaning or replacement is required at regular intervals. Registration Roller A dirty registration roller can cause paper to register incorrectly, skew, or jam. Cleaning is required at regular intervals. Worm Gear Worm Wheel If the worm gear or worm wheel doesn’t turn smoothly, paper may not feed correctly or skewing may result. They must be lubricated at regular intervals. Transport Roller If the transport roller is dirty or if it slips, the back sides of the copy may become dirty. Clean the roller at regular intervals. 28 February 1989 Item Around Drum Cleaning Unit Explanation Charge Wires Dirty charge wires may cause uneven image density. They should be cleaned or replaced at regular intervals. End Blocks Toner tends to accumulate on the corona end blocks, and this can result in poor copy quality or even a high voltage leak. Clean end blocks at regular intervals. QL If toner accumulates on the QL, a dirty background or a repeating negative image may result. Regular cleaning and periodic replacement are recommended. PTL If paper dust or toner accumulates on the PTL, its efficiency may be reduced. This can cause the image to be reattracted to the drum during transfer, resulting in reduced image density. Clean the PTL at regular intervals. ID Sensor If paper dust or toner accumulates on the ID sensor, the image density will be insufficient. Clean this sensor at regular intervals. Erase Lamp If toner accumulates on the erase lamp, a dirty background may occur that becomes progressively worse in long copy runs. Clean this lamp at regular intervals. Cleaning Blade A dirty or worn out cleaning blade will cause black lines on copies and/or scratches on the drum. The blade must be replaced or cleaned at regular intervals. Cleaning Brush A worn out cleaning brush will not clean effectively, resulting in a dirty background and damage to the cleaning blade. Replace at regular intervals. 4-49 28 February 1989 Item Fusing Unit AD500 DF52 Explanation Thermistor If toner accumulates on the thermistor, fusing temperature control may not be accurate. Inspect the thermistor at regular intervals. Stripper Pawls Toner or dust adhering to the stripper pawls can cause a paper jam. Clean or replace the pawls at regular intervals. Fusing Entrance and Exit Guides Toner piling up on the guide plate will cause a dirty background on the copy. Clean the guide plate at regular intervals. Paper Feed Roller, Friction Pad Duplex feeding uses the friction pad system. Paper dust or oil may cause rollers to stick, resulting in paper feed failure or skewing of the copy image. Clean or replace at regular intervals. Transport Roller A transport roller that is dirty or slips may cause a dirty copy image or a paper jam. Clean the rollers at regular intervals. Positioning Roller Sponge rollers are used here. When they wear out, a paper jam may result in duplex/overlay copy mode. Replace sponge rollers at regular intervals. Round Belt The round belt transmits driving power to the positioning roller. When the belt wears out (breaks or stretches), a paper jam may occur. Replace the belt at regular intervals. Transport Belt A dirty transport belt can leave stains on copies. Clean or replace the belt at regular intervals. Pick-up Roller, Separation Roller, Friction Belt When dirty, these rollers and this belt can leave stains on the copy paper. Clean or replace these parts at regular intervals. 4-50 28 February 1989 Item CS2090 Bin Drive Wheel, Bin Guide Explanation Dust adhering to the bin drive wheel or bin guide may interfere with bin movement and result in uneven bin postitioning. Clean and lubricate at regular intervals. 4-51 REPLACEMENT AND CONTENTS 1. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 1.1 EXPOSURE GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 1.2 1ST MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 1.3 2ND AND 3ND MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 1.4 4TH AND 5TH MIRRORS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 1.5 EXPOSURE LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 1.6 AUTO SlZE/ADS FlBER OPTlC CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .5-8 1.7 THERMOSWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 1.8 SCANNER DRIVE WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 1.8.1 Wire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 1.8.2 Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 1.9 SCANNER MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 1.10 LENS DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 1.11 3RD SCANNER DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 1.12 RED ERASE FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 1.13 EXPOSURE LAMP POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 1.14 EXPOSURE LAMP VOLTAGE ADJUSTMENT (SP Mode #48) . . . . . . . . . . . . . . . . . .5-22 1.15 ADS ADJUSTMENT (SP Mode #58) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23 1.16 ADS CORRECTION (SP Mode #56) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 1.17 APS VOLTAGE ADJUSTMENT (SP Modes #61 and #62) . . . . . . . . . . . . . . . . . . . . .5-25 1.18 APS LENGTH SENSOR ERROR CORRECTION (SP Modes #50 and #46) . . . . . . .5-26 1.19 VERTICAL MAGNIFICATION ADJUSTMENT 1 (SP Mode #43) . . . . . . . . . . . . . . . . .5-27 1.20 VERTICAL MAGNIFICATION ADJUSTMENT (Overlay and Duplex) (SP Mde #45) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28 1.21 Horizontal MAGNIFICATION ADJUSTMENT (SP Mode #44) . . . . . . . . . . . . . . .5-29 1.22 3RD SCANNER HElGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 2. DEVELOPMENT AND TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . .5-31 2.1 BLACK DEVELOPER REPLACEMENT (SP Mode #65) . . . . . . . . . . . . . . . . . . . . . . . . .5-31 2.2 BLACK DEVELOPMENT ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32 2.3 DOCTOR GAP ADJUSTMENT (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33 2.4 COLOR DEVELOPER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34 2.5 COLOR DEVELOPER CONDITIONING (SP Mode #10) . . . . . . . . . . . . . . . . . . . . . . . .5-35 2.6 COLOR DEVELOPMENT ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36 2.7 DOCTOR GAP ADJUSTMENT (Color) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-37 2.8 TONER SUPPLY CLUTCH CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-38 2.9 DEVELOPER SHIFT CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-39 2.10 DEVELOPMENT BIAS MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-40 2.10.1 Measurement (Beckman) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-40 2.10.2 Measurement (SP Mode #59) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-41 2.11 BLACK DEVELOPMENT BlAS ADJUSTMENT (SP Mode #37) . . . . . . . . . . . . . . . . .5-42 2.12 COLOR DEVELOPMENT BIAS ADJUSTMENT (SP Mode #79) . . . . . . . . . . . . . . . . .5-43 2.13 HIGHLIGHT COLOR DENSITY AMOUNT (SP Mode #86) . . . . . . . . . . . . . . . . . . . . .5-44 2.14 BLACK TONER SUPPLY ADJUSTMENT (SP Mode #30) . . . . . . . . . . . . . . . . . . . . . .5-45 2.15 BLACK TONER SUPPLY AMOUNT (lD Sensor Mode) (SP Mode #31) . . . . . . . . . . .5-46 2.16 BLACK TONER SUPPLY AMOUNT (Fixed Supply Mode) (SP Mode #32) . . . . . . . .5-47 2.17 COLOR TONER SUPPLY AMOUNT (SP Mode #70) . . . . . . . . . . . . . . . . . . . . . . . . . .5-48 3. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-49 3.1 CLEANING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-49 3.2 CLEANING BLADE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-50 3.3 CLEANING BRUSH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-51 3.4 BLADE SCRAPER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-52 3.5 TONER OVERFLOW SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-53 3.6 USED TONER COLLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-54 3.7 QUENCHING LAMP REPLACEMENT/CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-55 4. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-56 4.1 MANUAL FEED TABLE REMOVAL AND MANUAL FEED SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .5-56 4.1.1 Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-56 4.1.2 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-56 4.2 PAPER SIZE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-57 4.3 1ST FEED ROLLERS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-58 4.4 GRIP ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-60 4.5 2ND FEED ROLLER AND FRICTION PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . .5-61 4.6 3RD FEED ROLLER AND FRICTION PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . .5-62 4.7 FRlCTION PAD PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-63 4.8 PRESSURE ARM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-64 4.9 FEED AND RELAY CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65 4.10 PAPER END SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-66 4.10.1 1st Feed Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-66 4.10.2 2nd and 3rd Feed Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-66 4.11 LIFT MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-67 4.12 REGlSTRATION SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-68 4.13 REGISTRATION CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69 4.14 UPPER REGISTRATION ROLLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-70 4.15 LOWER REGISTRATION REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-71 4.16 REGISTRATION ADJUSTMENT (SP Mode #42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-72 4.17 UPPER RELAY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-73 4.18 LOWER RELAY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-74 5. TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-75 5.1 TRANSPORT BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-75 5.2 DRUM HEATER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-77 6. DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-78 6.1 CHARGE CORONA WlRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-78 6.2 CHARGE CORONA GRID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-79 6.3 CHARGE CORONA HElGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-80 6.4 TRANSFER/SEPARATION CORONA WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . .5-81 6.5 DRUM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-82 6.6 ID SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-85 6.7 ID SENSOR Vsg ADJUSTMENT (SP Mode #54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-86 6.8 SEPARATION PAWL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-87 6.9 CHARGE CORONA CURRENT ADJUSTMENT (SP Mode #9-2) . . . . . . . . . . . . . . . . .5-88 6.10 GRlD VOLTAGE ADJUSTMENT (SP Mode #9-2 and 3) . . . . . . . . . . . . . . . . . . . . . . .5-89 6.11 DRUM CURRENT ADJUSTMENT (SP Mode #9-5 and 7) . . . . . . . . . . . . . . . . . . . . . .5-90 6.11.1 Transfer Current Measurement (SP Mode #9-5) . . . . . . . . . . . . . . . . . . . . . . . . .5-91 6.11.2 Separation Corona Current Measurement (SP Mode #9-7) . . . . . . . . . . . . . . . .5-92 7. FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93 .. 7.1 FUSING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-93 7.2 FUSlNG LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-94 7.3 HOT ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-95 7.4 PRESSURE ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-96 7.5 FUSING STRIPPER PAWL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-97 7.6 THERMAL FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-98 7.7 FUSING THERMISTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-99 7.8 FUSING TEMPERATURE CHECK (SP Mode #52) . . . . . . . . . . . . . . . . . . . . . . . . . . .5-100 7.9 FUSING TEMPERATURE ADJUSTMENT (SP Mode #49) . . . . . . . . . . . . . . . . . . . . .5-101 7.10 FUSING TEMPERATURE CONTROL SELECTION (Full Wave Control or Phase Control) (SP Mode #29) . . . . . . . . . . . . . .5-102 7.11 NIP WIDTH MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-103 7.12 FUSlNG PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-104 7.13 FUSING GUIDE PLATE HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-105 7.14 FUSING EXIT SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-106 8. TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-107 8.1 TRANSPORT GUIDE UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-107 8.2 RELAY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-108 8.3 INVERTER SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-109 8.4 DUPLEX/OVERLAY TRANSPORT MAGNETIC CLUTCH REPLACEMENT . . . . . . . . .5-110 9. JOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-111 9.1 JOGGER UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-111 9.2 JOGGER HOME POSITION SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . .5-112 9.3 JOGGER UNIT WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-113 9.4 JOGGER MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-115 9.5 JOGGER SOLENOID ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-116 10. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-117 10.1 OPERATION PANEL RENOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-117 28 February 1989 1. OPTICS 1.1 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 slightly. Slide the other edge out from under the right glass holder [C]. Remove the exposure glass. NOTE: When reinstalling the exposure glass, make sure that the left edge of the glass is flush with the tab to the left of the scale plate, and that the right glass holder firmly secures the exposure glass. 5-1 28 February 1989 1.2 1ST MIRROR REMOVAL 1. Turn off the main switch. 2. Remove the exposure glass. (See the Exposure Glass Removal section.) 3. Move the first scanner to the cutout position (150 mm from the left scale). 4. Remove the reflector cover [A] (2 screws). 5. Remove the sub-reflector cover [B] (2 screws). 6. Remove the front spring plate [C] using a small screwdriver to release the plate, then slide the plate towards the front of the machine. 7. Carefully pull the 1st mirror [D] towards the front of the machine and remove the rear spring plate [E]. 8. Lift the mirror out of the machine rear side first. 5-2 28 February 1989 - To install 9. Insert the 1st mirror into the front side plate cutout. Then place the rear spring plate and insert the rear side of the mirror into the rear spring plate. NOTE: Make sure when installing the mirror that the reflecting surface is on the upper side and the beveled edge [A] of the mirror is on the lower side. 10. Insert the rounded part [B] of the front plate spring between the mirror and the front side plate cutout. 11. Set the plate [C] by moving the plate spring in the direction of the arrow, until it latches into the side plate. 5-3 28 February 1989 1.3 2ND AND 3ND MIRROR REMOVAL NOTE: The 2nd mirror is usually removed to make 3rd mirror cleaning easier. 1. Turn off the main switch. 2. Remove the exposure glass. (See the Exposure Glass Removal section.) 3. Slide the 1st scanner 2/3 of the way to the right. 4. Remove the front spring plate [A] by pressing the top of the spring and moving the plate towards the front of the machine. 5. Carefully pull the 2nd mirror [B] towards the front of the machine to remove the rear spring plate [C]. 6. Lift the mirror out of the machine rear side first. 5-4 28 February 1989 - To Reinstall 7. Place the rear spring plate [A] in place and hold it. 8. Insert the 2nd mirror [B] into the front side plate cutout. 9. Insert the rear side of the mirror into the rear spring plate. 10. Locate the bottom of the front spring plate [C] and rotate the top of the spring into position. NOTE: Make sure when installing the mirrors that the reflecting surfaces [D] face the lens as shown. 5-5 28 February 1989 1.4 4TH AND 5TH MIRRORS REPLACEMENT 1. Remove the exposure glass. (See the Exposure Glass Removal section.) 2. Remove the lens cover (2 screws). 3. Remove the 2 fixing screws [A] from the third scanner [B]. 4. Slide the third scanner to the right. 5. Move the scanner in the direction of the arrow and remove it. 6. Replace the fourth [C] and fifth [D] mirrors. (The procedure for removing the mirrors from their brackets is the same as with the second and third mirrors.) NOTE: Make sure that the mirrors are installed in their original positions, as the fourth and fifth mirrors are different in size. • The fourth mirror is wider than the fifth mirror. • The fifth mirror has a beveled edge. 7. Reassemble all parts. NOTE: a) Make sure the mirrors are set correctly as shown. (Surfaces with numbers printed on them are not the reflecting surface.) b) The leaf springs hold the mirrors in place. Install them as shown in the illustration. c) Position the leaf spring [E] as shown by moving it in the direction of the arrow. 5-6 28 February 1989 1.5 EXPOSURE LAMP REPLACEMENT Do not touch the reflector or the new exposure lamp with your bare hands. Use a strip of paper as shown. (Oil marks from fingers on the lamp or reflectors will be affected by heat from the lamp and will cause discoloration.) 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal section.) 3. Move the first scanner to the cutout position at the rear frame [B] (see illustration). 4. Remove the reflector cover [A] (2 screws). 5. Wrap a strip of paper around the exposure lamp [B] as shown. 6. Press the release lever [C] on the rear terminal as shown and remove the lamp. 7. Install a new lamp using a strip of paper. Set the front terminal first. Make sure that the lamp is set so that the blister on the lamp surface is closer to the rear side of the copier. NOTE: The blister [D] on the lamp must point towards the reflector opening (left side of the copier) as shown. This positions the lamp with the frosted portion down. The clip [E] should be installed on the rear end of the exposure lamp as shown. 8. Reassemble the first scanner. 9. Check the exposure lamp position, light intensity and ADS sensor. (See Exposure Lamp Position, Light Intensity and ADS sensor Adjustments.) 5-7 28 February 1989 1.6 AUTO SIZE/ADS FIBER OPTIC CABLE REPLACEMENT 1. Turn off the main switch. 2. Remove the exposure glass. (See the Exposure Glass Removal section.) 3. Remove the reflector cover (2 screws). 4. Remove the exposure lamp lead [A] from the exposure lamp terminals [D]. 5. Remove the auto size sensor [B] (1 screw). 6. Remove the ADS sensor [C] (1 screw). 7. Remove the scanner harness [D] from the harness hold-down block [E] (1 screw). 8. Disconnect the optical cable connector [F]. 5-8 28 February 1989 9 . Open the front cover. 10. Remove the upper inner cover. 11. Remove the rear cover. 12 . Move the AC drive board [A] out of the way. 13 . Disconnect the fiber optic cable connectors [B] from the system control PCB [C] and the I/O control PCB [D]. 14. Replace the ADS fiber optic cable. 5-9 28 February 1989 1.7 THERMOSWITCH REPLACEMENT 1. Remove the exposure glass (2 screws). 2. Slide the first scanner 150 mm to the right. 3. Remove the reflection plate cover (2 screws). 4. Remove the exposure lamp leads from the terminals [A] on both sides of the thermoswitch. 5. Remove the thermoswitch bracket [B] (1 screw). 6. Remove the thermoswitch [C] from the bracket (2 screws), and replace it. 5-10 23 May 1989 1.8 SCANNER DRIVE WIRE REPLACEMENT 1.8.1 Wire Removal 1. Remove the following covers and parts. Control panel Sorter (if installed) Rear cover Upper inside cover Optics cooling fan cover [K] (2 screws) Contact glass ID sensor pattern plate [J] Upper cover Right cover Left cover 2. Loosen the front and rear first scanner wire clamp screws [A] . 3. Remove the front and rear wire tightener springs [B]. 4. Loosen the front and rear wire fixing plate screws [C]. 5. Remove the 1st scanner home position sensor connector [D] . 6. Remove the scanner wires [E] and [F] from the drive pulley. 7. Remove the scanner wire [H] from the left side plate 8. Remove the scanner wire [I] from the drive pulley. 9. Remove the drive pulley [G]. 5-11 28 February 1989 1. Position the blue wire [1] as shown in the figure (opposite the Allen screws) and wind it halfway around the pulley. (The upper half of the round ball at the end of the wire should be in the hole.) 2. Position the silver wire [2] in the hole on the Allen screw side. 3. Wind the blue wire six times and the silver wire six and a half times, as seen from the opposite side of the Allen screw. (Do not count the one half turn on the blue wire from step #1, and make sure to make the extra wrap on the silver wire.) 4. Position the blue wire [3] in the hole on the Allen screw side and wind it halfway around the pulley. 5. Position the silver wire [4]. 6. Wind the blue wire [3] one and a half times and the silver wire [4] once. NOTE: a) The blue and silver wires alternate on the pulley (blue uppermost). b) The wires are not wound on two of the grooves of the pulley as shown above. 7. Clamp wires onto pulley wires with the fixing jig [A]. 8. Set the scanner pulley on the shaft and tighten 2 Allen screws. NOTE: Maintain 1 mm of clearance as shown in the above figure. As the thickness of the scale is about 1 mm, put it between the pulley and the motor and tighten the Allen screws. 5-12 28 February 1989 9. Manually set the first and second scanners in their home position. 10. Set the four jig pins [A] to fix the first and second scanners. 11. Remove the sorter interface PCB bracket (not shown) and position to the side. 12. Loosen the fixing screw of the wire tension bracket [F] and loosen the wire tension adjusting screw. [M] 13. Position the silver scanner wires [2] and [4] at points [B] and [D] as shown in the illustration. NOTE: Temporarily remove the front fixing plate (1 screw), attach the silver wire [4] to the wire fixing plate [G], and set the spring [H]. Reinstall the fixing plate screw. 5-13 28 February 1989 14. Attach the blue wires [1] and [3]. NOTE: The blue wire [1] should be pulled towards the wire timing plate [G] and fixed to the spring [H]. 15. Tighten the first scanner wire clamps and remove the four jig pins and the fixing jig. 16. Perform Free Run (turn DIP switch 1-1 ON) for 10 minutes. This is done to make the wires operate more smoothly. 5-14 21 April 1989 17. Adjust the second scanner wire tension. (1) Set the jig pin [A] at the front of the second scanner. (2) Loosenly set the jig pin [B] at the rear of the second scanner. (3) Loosen the two fixing screws of the wire tension bracket [C] and turn the 2nd scanner positioning screw [D]. This screw is also used to position the 2nd scanner. Turn the adjusting screw [D] until the rear jig pin drops and is locked in position. (4) Clamp the two fixing screws of the wire tension bracket [C]. (5) Make sure the jig pin moves smoothly. If not, repeat step (3). (6) Clamp the fixing screws of the wire fixing plate [E] (front and rear). 18. Adjust the wire clamp position of the first scanner. (1) Loosen the wire clamps [F] of the first scanner. (2) Set the first scanner jig pins (2). (3) Tighten the wire clamps. 19. Reassemble all parts. NOTE: After adjusting the second scanner wire tension, make sure to adjust the wire clamp position of the first scanner. 5-15 28 February 1989 1.9 SCANNER MOTOR REPLACEMENT 1. Remove the rear cover and the upper cover. 2. Secure the wire with the fixing jig [A] so that it does not come off the pulley. (Use tape of no jigs are available.) 3. Remove the two screws holding the harness duct [B] at the front side of the scanner motor, and partially remove the harness duct. 4. Remove the two Allen screws of the scanner motor pulley and place it on the stud [D]. 5. Remove the 4P connector [E] and the 2P connector [F]. 6. Remove the four screws of the scanner motor [G] and replace the scanner motor. NOTE: Maintain 1 mm of clearance as shown in the above figure. As the thickness of the scale is about 1 mm, put it between the pulley and the motor and tighten the Allen screws. 5-16 28 February 1989 1.10 LENS DRIVE MOTOR REPLACEMENT 1. Remove the exposure glass and the lens cover. 2. Move the scanner to the return side. 3. Remove the tension spring and the lens drive wire [A]. 4. Remove the 6P connector of the lens drive motor [B]. 5. Remove the screws securing the lens drive motor and the bracket [C] (2 screws). 6. Separate the motor from the bracket (2 screws), and replace the motor. 7. Reassemble all parts. NOTE: a) Wind the lens drive wire [A] three and a half times around the pulley [D] as shown in the above figure and reassemble the unit. b) Position the lens drive motor harness so that it does not contact the second scanner or the shutter plate [E] of the lens home position sensor. 5-17 28 February 1989 1.11 3RD SCANNER DRIVE MOTOR REPLACEMENT 1. Remove the exposure glass, upper cover and lens cover. 2. Move the third scanner to the left (viewed from the front). 3. Remove the third scanner drive wire [A]. 4. Remove the 6P connector [B] of the third scanner drive motor. 5. Remove the motor and the bracket [C] (2 screws). 6. Separate the 3rd scanner drive motor [D] from the bracket [E] (2 screws) and replace it. NOTE: Wind the 3rd scanner drive wire [A] twice around the pulley [F]. 5-18 21 April 1989 1.12 RED ERASE FILTER REPLACEMENT 1. Open the front cover and remove the upper inner cover [A] (3 screws). 2. Remove the following units: Color development Black development Charge Corona Drum unit (Release cleaning unit and transfer unit) 3. Remove the color development lock lever [B]. (1 screw) 4. Remove the 2P connector of the red erase solenoid. 5. Remove the 6P connector of the erase lamp unit. 6. Remove the red erase unit (2 screws). 7. Push the plunger [C] of the red erase solenoid by half a stroke to make the lever [D] vertical, and pull out the red erase unit [H]. NOTE: Do not use alcohol to clean the filter. 8. Remove the spring [F], and replace the filter [G]. Set the spring in the notch as shown. NOTE: When inserting the red erase unit [H], lift the front side of the unit so that it fits under the bracket at the rear of the unit, as shown. 5-19 28 February 1989 1.13 EXPOSURE LAMP POSITION ADJUSTMENT 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal section.) 3. Move the first scanner to the cutout position. 4. Remove the front and rear terminal covers [A] (1 screw each). - Horizontal Adjustment 5. Position a scale [B] near the sight hole [C] of the reflector cover to form a right angle for viewing alignment as shown. 6. View the lamp filament [D] through the sight hole in parallel with the scale. The filament should be directly beneath the sight hole. NOTE: If the filament cannot be seen easily, use a penlight to illuminate the exposure lamp. 7. Turn adjusting screw [E] to correct the position of the filament. Loosen the screw: Filament moves to the left (F direction) Tighten the screw: Filament moves to the right (G direction) 5-20 28 February 1989 - Vertical Adjustment 8. Position a mirror [A] beside the rear sight hole [B] at a 45 degree angle as shown. NOTE: If you do not have a mirror, remove and use the 2nd mirror. 9. View the lamp filament [C] through the sight hole reflected on the mirror. The filament should be level with the sight hole. 10. To correct the position of the filament, turn the adjusting knob [E]. 11. Repeat steps 8 to 10 with the front sight hole. 5-21 28 February 1989 1.14 EXPOSURE LAMP VOLTAGE ADJUSTMENT (SP Mode #48) 1. Remove the DIP switch cover [A] from the control panel and turn DIP switches 1 - 4 ON. 2. Enter the lamp voltage setting mode with the numeric keys. (SP mode #48). 3. Set the OS-A3 chart and make a full-size copy at manual image density level 4. 4. Adjust the voltage with the numeric keys. ADJUSTMENT STANDARD: Level 2 of the gray scale on the OS-A3 chart should be just visible on the copy when the 4th level of the density control is selected. NOTE: a) After adjusting the exposure lamp voltage, adjust ADS. (See the next page.) b) Confirm that the exposure lamp output is set in the range of 50 to 75V. (Normally 64V.) 5-22 28 February 1989 1.15 ADS ADJUSTMENT (SP Mode #58) Standard Value: 3.0 ± 0.1V 1. Place a couple of sheets of A3 (LDG) size paper on the exposure glass. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3 . Enter ADS adjusting mode with the numeric keys. (SP mode #58) 4. Press the Start key. 5 . Use VR101 of the system control board to adjust the peak value displayed on the magnification display [B] to 3.0 ± 0.1V. NOTE: This adjustment should be performed in the following cases: a) When replacing the system control board, the optical fiber, and/or after adjusting the exposure lamp output. b) If the ADS value is out of standard when it is checked, perform the ADS adjustment. 5-23 28 February 1989 1.16 ADS CORRECTION (SP Mode #56) SP Mode #56 is used to store the ADS value in memory for ADS correction. This mode is used when the ADS value (3.0V) becomes slightly different. Adjustment is made as follows: 1. Place a few sheets of A3 (LDG) size paper on the exposure glass. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3 . Set to ADS reference voltage memory mode with the numeric keys (SP Mode #56). 4. Press the Start key. 5 . After three scans press the Clear/Stop key. NOTE: Be sure to reset the standard value memory using SP Mode #56 whenever SP #58 (ADS value) is changed. 5-24 28 February 1989 1.17 APS VOLTAGE ADJUSTMENT (SP Modes #61 & #62) Standard Value: 2.8 ± 0.1V 1. Place a few sheets of A3 (LDG) size paper on the exposure glass. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3. Enter the APS length voltage adjusting mode using the numeric keys (SP Mode #61). 4. Remove the rear cover. 5. Press the Start key and use VR302 (I/O control PCB) to adjust the peak value on the magnification display [B] to 2.8 ± 0.1V. 6. Press the Clear/Stop key. 7. Enter the APS width voltage adjusting mode using the numeric keys (SP Mode #62). 8. Press the Start key and use VR301 (I/O control PCB) to adjust the peak value on the magnification display [B] to 2.8 ± 0.1V. NOTE: Adjustment is required when the I/O control PCB and/or the system control board are replaced. 5-25 28 February 1989 1.18 APS LENGTH SENSOR ERROR CORRECTION (SP Modes #50 and #46) 1. Place a sheet of A3 (LDG) size paper on the exposure glass. 2. Remove the DIP SW cover [A] and turn DIP switch 1 - 4 ON. 3. Set the APS length sensor checking mode with the numeric keys (SP Mode #50). NOTE: A3 = 420mm and LDG = 432mm. 4. If the length is incorrect, set the APS length sensor error correcting mode (SP Mode #46) using the numeric keys. (The original length is displayed in “mm”.) 5. The setting value is displayed in the magnification indicator (blinking). 6. Change the value with the numeric keys and correct the error. • Width adjustments are in steps of 1mm. The mode standard setting is “8” and adjustment are made from “0” (-8mm) to “15“ (+7mm). 7. Set to APS length sensor checking mode again and confirm the original length. (Scan three times or more.) • Standard Value: Original length ± 3mm NOTE: Adjustment is required when the I/O control PCB and/or the scanner motor are replaced. 5-26 28 February 1989 1.19 VERTICAL MAGNIFICATION ADJUSTMENT 1 (SP Mode #43) NOTE: Vertical magnification adjustment is made after wire clamp position adjustment. 1. Check the measurement of the 100 mm vertical scale on a copy of the OSA3 test chart. If the measurement is incorrect, perform the following. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3. Enter the vertical magnification adjusting mode with the numeric keys (SP Mode #43). 4. The setting value is displayed in the magnification indicator (blinking). 5. Change the value with the numeric keys to adjust the magnification ratio. • In width adjustment “8” (± 0%) is the factory setting and one 1 step is 0.2%. Adjustment can be made in the range of “0” (-1.6%) to “15” (+1.4%). NOTE: Do not check the vertical magnification ratio until the copy paper has cooled down after fusing (approximately 3 minutes). 5-27 28 February 1989 1.20 VERTICAL MAGNIFICATION ADJUSTMENT 2 (Overlay and Duplex) SP Mode #45 1. Measure the 100mm vertical scale on the first side of a duplex (overlay) copy. If the measurement is incorrect, perform the following. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3. Enter the vertical magnification adjustment mode of overlay/dupIex with the numeric keys (SP Mode #45). 4. The setting value is displayed in the magnification indicator (blinking). 5. Change the value with the numeric keys and adjust the magnification ratio of the copy (1st side). NOTE: In width adjustment, the standard is “0” (+0.4%) and 1 step is +0.2%. Adjustment can be made in 11 steps of 0 to +2.0%. 0 = 0.4% 1 = 0% 2 = 0.2% 3 = 0.6% 4 = 0.8% 5 = 1.0% 6 = 1.2% 7 = 1.4% 8 = 1.6% 9 = 1.8% 10 = 2.0% NOTE: This adjustment is used to compensate for the change in the 1st image size after the 2nd pass through the fusing unit. 5-28 28 February 1989 1.21 HORIZONTAL MAGNIFICATION ADJUSTMENT (SP Mode #44) Horizontal magnification adjustment is made after wire clamp position adjustment. 1. Measure the 100mm horizontal scale on a copy of the OS-A3 test chart. If the measured value is incorrect, perform the following. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3. Enter the horizontal magnification adjusting mode with the numeric keys. 4. The setting value is displayed in the magnification indicator (blinking). 5. Adjust the value of the magnification ratio with the numeric keys. • In width adjustment, “8” (± 0%) is the factory setting and one step is 0.2%. Width adjustment can be made in the range of “0” (-1.6%) to “15” (+1.4%). Standard Value: Full size ± 0.5%. 5-29 28 February 1989 1.22 3RD SCANNER HEIGHT ADJUSTMENT CAUTION: Never perform this adjustment until you have positively verified that the source of the skewing is optical and not in the paper path . Adjust the height of the 3rd scanner only when a parallelogram (skewed) image appears. 1. Remove the exposure glass. 2. Remove the lens cover. (Two screws) 3. Open the front cover and remove the upper inner cover. (3 screws) 4. Remove the counter bracket [A]. (Two screws) 5. Put the screwdriver through the round hole [B] on the side plate, as shown in the figure. Adjust the eccentric cam [C] of the 3rd scanner to achieve the proper copy image. 5-30 28 February 1989 2. DEVELOPMENT AND TONER SUPPLY 2.1 BLACK DEVELOPER REPLACEMENT (SP Mode #65) 1. Take out the development unit. 2. Set the development unit on a large sheet of paper [A]. 3. Remove the toner tank [B] (3 screws). 4. Turn the paddle roller knob [C] counterclockwise. The developer will fall out onto the paper. 5. Turn the unit right-side up and pour in one bottle of 4460 type developer (1kg). 6. Reinstall the toner tank and set the development unit in the machine. 7. Remove the DIP switch cover [D] and turn DIP switch 1 - 4 ON. 8. Confirm that Vsg is 4 ± 0.2V and perform initial setting for the black toner density. Press the keys in the order as shown above (SP Mode #65). 9. After the 20th copy, the buzzer sounds five times indicating that the initial setting is completed. Turn DIP switch 1 - 4 OFF. 5-31 28 February 1989 2.2 BLACK DEVELOPMENT ROLLER REPLACEMENT 1. Remove the toner tank [A] (3 screws) and empty the black developer. During this procedure, keep the black developer away from foreign matters. 2. Remove the inlet seal plate [B] (1 screw). 3. Remove the black development unit positioning bracket [C] (2 screws). 4. Remove the black development roller drive gear [D] (C ring). 5. Remove the upper screws holding the bearing retainer [E] and loosen the lower screw. 6. Remove the black development upper unit [F] (3 screws). 7. Remove the bearing [G]. 8. Remove and replace the black development roller [H]. NOTE: a) When replacing the black development roller [H], use a blower brush to remove any carrier from the bearing [G], inlet seal plate [B], etc. b) When reassembling, insert the inlet seal [I] in the direction of the arrow. 5-32 28 February 1989 2.3 DOCTOR GAP ADJUSTMENT (Black) 1. Remove the toner tank (3 screws) and dump the black developer. 2. Remove the inlet seal plate [A]. (1 screw) 3. Remove any developer on the black development roller. 4. Loosen the four fixing screws [C], and adjust the doctor gap with the jig [B] (Part No. A006 9513). ADJUSTMENT STANDARD: 0.75 ± 0.07mm a) Before adjusting the doctor gap, remove the developer from the development roller. b) When reassembling the development unit, check and adjust the doctor gap if necessary. c) When reassembling, insert the inlet seal [J] in the direction of arrow. CAUTION: If the doctor gap is too wide, blocking of developer, noise, jittering, white lines, or carrier transfer (to drum and copies) may occur. 5-33 28 February 1989 2.4 COLOR DEVELOPER REPLACEMENT 1. Take out the development unit. 2. Set the development unit on a large sheet of paper [A] 3. Remove the toner tank [B] and the development guide (3 screws and 1 connector [E]), and turn the development unit over. NOTE: Be careful not to spill the used developer. 4. Turn the paddle roller knob [C] counterclockwise. The developer will fall out onto the paper. 5. Turn the unit right-side up and pour in one pack of 4460 type color developer (400g). 6. Reinstall the toner tank and set the development unit in the machine. 7. Make sure that the DIP switches are set correctly for the color of the toner. 5-34 28 February 1989 2.5 COLOR DEVELOPER CONDITIONING (SP Mode #10) NOTE: This procedure should be performed at installation and when color developer is replaced. Check that Vsg is 4 ± 0.2V before making the initial setting. 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Press the keys in the order shown above. 3. Press the Start key. 4. After the 20th copy, the beeper sounds five times indicating that the initial setting is completed. Turn DIP switch 1 - 4 OFF. 5-35 28 February 1989 2.6 COLOR DEVELOPMENT ROLLER REPLACEMENT 1. Remove the toner tank [A] (3 screws). 2. Remove the toner end connector [B], color setting switch connector [C], and color bias lead wire [D]. 3 . Peel off the side seals [E] and remove the color development rail [F]. 4. Remove the color development roller drive gear [G]. 5. Remove the bearing holder [H] (2 screws). 6 . Remove the mag angle adjustment plate [I] (1 screw). NOTE: Take note of the mag angle mounting position. 7. Remove the color development upper cover [J] (3 screws). 8. Remove the bearing [K]. 9. Replace the color development roller [L]. 10. Reassemble the unit. NOTE: When replacing the color development roller [L], use a blower brush to remove any carrier from the bearing [K], side seals [E], etc. 5-36 28 February 1989 2.7 DOCTOR GAP ADJUSTMENT (Color) 1. Perform steps 1 through 4 of the Color Development Roller Replacement section. 2. Remove any developer from the color development roller. 3. Loosen the fixing screws [A], and adjust the doctor gap with the jig [B] (Part No A006 9101). ADJUSTMENT STANDARD: 0.72 ± 0.07mm NOTE: a) Before adjusting the doctor gap, remove any developer from the development roller. b) When reassembling the development unit, check and adjust the doctor gap if necessary. CAUTION: If the doctor gap is too wide, blocking of developer, noise, jittering, white lines, or carrier transfer to drum and copies may occur. 5-37 28 February 1989 2.8 TONER SUPPLY CLUTCH CLEANING 1. Remove the rear cover (4 screws). 2. Lower the I/O control PCB [A]. 3. Remove the AC drive board [B] (1 screw and 3 connectors). 4. Remove the bracket [C] (2 screws). 5. Remove the screws securing the DC harness guide [D]. 6. Remove the bracket [E] (4 screws) by loosening the screw at the bottom of bracket [F] and rotating it 180° counterclockwise as shown. 7. Remove the 2P connector [H] (yellow) of the toner supply clutch. 8. Remove the toner supply clutch [I] and wipe the clutch face [J] with alcohol. (Remove 2 E-rings, 2 bearings and 1 C ring as shown.) 9. Reassemble the toner supply clutch bracket, etc. 5-38 21 April 1989 2.9 DEVELOPER SHIFT CLUTCH LUBRICATION 2. Lower the main PCB [A]. 3. Remove the AC drive board [B]. 4. Remove the bracket [C]. 5. Remove the manual feed sensor connector and paper feed relay board. 6. Remove the screws securing the DC harness guide [D]. 7. Remove the harness and the optical fiber [E] from the clamp hole, and remove the bracket [F] (4 screws). 8. Open the manual feed table, or it will interfere with the removal of the switching solenoid bracket [G]. 9. Remove the development unit change solenoid 2P connector [H] and remove the development unit change solenoid bracket [G] (3 screws). 10. Remove the development pressurizing spring [H]. 11. Release the tension [I] of the main chain [J]. 12. Remove the development switching drive gear [K], planetary gear [L] and sprocket [M]. CAUTION: Do not drop the planetary gear [L] inside the machine. 13. Lubricate clutch spring [N] with MT78 and reassemble. 5-39 28 February 1989 2.10 DEVELOPMENT BIAS MEASUREMENT 1. Place the SP mode data sheet on the exposure glass and turn DIP switch 1 - 4 ON. 2. Press the keys in the following order and make an A3 (DLT) size copy to confirm the bias set for the SP mode data sheet. “1” –> “#” Enter key –> Start key 3. Open the rear cover and lower the I/O control board [A] (1 screw). 4. Turn DIP switch 1 - 1 (free run) ON. 5. Set meter scale to 1500 Vdc. 6. Attach one lead of the meter to the retainer [B] and the other to the bottom of the chassis [C] as shown in the figure. 7. Press the Start key and measure the bias voltage. Voltage should be approximately -200 Vdc with the Manual ID level set to the center position (level 4). NOTE: The voltage measured by the multi-meter is the summation of the standard bias and the correction bias as shown in the following table. Black Development Bias = 1 + 2 + 4 Color Development Bias = 1 + 3 + 4 5-40 21 April 1989 2.10.2 Measurement (SP Mode #59) ADS setting Manual ID setting level — ADS adjustment mode (SP#34) is set to “0” or “2”. --- ADS adjustment mode (SP#34) is set to “1”. NOTE: A maximum of 10% error may occur in bias value in the measurement by Beckman or by monitor display. 1. Measurement by SP mode (bias voltage display): a) Remove DIP switch cover [A] and turn DIP switches 1 - 1 and 1 - 4 ON. b) Enter the bias voltage mode with the numeric keys. c) The voltage is displayed on the magnification ratio indicator. d) Press the Clear/Stop key and turn the DIP switches 1 - 1 and 1 - 4 OFF. 5-41 28 February 1989 2.11 BLACK DEVELOPMENT BIAS ADJUSTMENT (SP Mode #37) SP Mode #37 Set value Bias voltage Code Density Example: 0 1 2 3 0 +40V +20V -20V N DD D L Standard Darkest Darker Lighter 4 -40V LL Lightest When the bias value of the 4th setting is -200V and the setting value (SP #37) is “1”, the voltage becomes -160V. 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter the black bias adjustment mode with the numeric keys. 3. Numerals displayed in the magnification ratio indicator [B] blink. 4. Input a number from “0” to “4” with the numeric keys to adjust the bias voltage, then press the Enter key. 5. Turn DIP switch 1 - 4 OFF. 5-42 28 February 1989 2.12 COLOR DEVELOPMENT BIAS ADJUSTMENT (SP Mode #79) SP Mode #79 Set value Bias voltage Code Density Example: 0 1 2 4 3 +40V +20V -20V -40V 0 N DD Standard Darkest Dark Lighter Lightest When the bias value of the 4th setting is -200V and the setting value (SP #79) is “1”, the voltage becomes -160V. 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter the color development bias adjustment mode with the numeric keys. 3. Numerals displayed in the magnification ratio indicator [B] blink. 4. Input a number from “0” to “4” with numeric keys to adjust the bias voltage, then press the Enter key. 5. Turn DIP switch 1 - 4 OFF. 5-43 28 February 1989 2.13 HIGHLIGHT COLOR DENSITY AMOUNT (SP Mode #86) Normal Set Value = 4 (-200V) 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter the highlight color density adjustment mode with the numeric keys (SP Mode #86). 3. Numerals displayed in the magnification ratio indicator blink. 4. Input a number from “1” to “7” with the numeric keys to adjust the bias voltage, then press the Enter key. 5. Turn DIP switch 1 - 4 OFF. NOTE: Adjust the bias for each color (for each color development unit). 5-44 28 February 1989 2.14 BLACK TONER SUPPLY ADJUSTMENT (SP Mode #30) SP mode #30 1 0 Set value ID sensor mode Fixed supply mode Mode Normal Set Value = “0” (ID sensor mode) 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter the black toner supply mode with the numeric keys (SP Mode #30). 3. Numerals displayed in the magnification ratio indicator [B] blink. 4. For the ID sensor mode, input “0” with the numeric keys, then press the Enter key. For fixed supply mode, input “1” and press the Enter key. 5. Turn DIP switch 1 - 4 OFF. 5-45 28 February 1989 2.15 BLACK TONER SUPPLY AMOUNT (ID Sensor Mode) SP MODE #31 SP Mode #31 Set value Supply ratio 0 15% 1 7% 2 30% 3 60% Normal Supply Ratio: 15% 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter the black toner supply mode with the numeric keys. 3. Numerals displayed in the magnification ratio indicator [B] blink. 4. Input a number from “0” to “3” with the numeric keys to adjust the supply ratio. Then press the Enter key. 5. Turn DIP switch 1 - 4 OFF. 5-46 28 February 1989 2.16 BLACK TONER SUPPLY AMOUNT (Fixed Supply Mode) SP Mode #32 SP Mode #32 Set value Supply ratio 0 7% 1 2 3 3.5% 10.5% 14% Normal Supply Ratio: 7% 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter the black toner fixed supply mode with the numeric keys. 3. Numerals displayed in the magnification ratio indicator [B] blink. 4. Input a number from “0” to “3” with the numeric keys to adjust the toner supply ratio, then press the Enter key. 5. Turn DIP switch 1 - 4 OFF. 5-47 28 February 1989 2.17 COLOR TONER SUPPLY AMOUNT (SP Mode #70) SP Mode #70 Set Value Supply Ratio 0 14% 1 7% 2 21% 3 28% Normal Supply Ratio: 14% 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter the color toner supply amount mode with the numeric keys. 3. Numerals displayed in the magnification ratio indicator [B] blink. 4. Input a number from “0” to “3” with the numeric keys to adjust the supply ratio, then press the Enter key. 5. Turn DIP switch 1 - 4 OFF. NOTE: Adjust the color toner supply value for each color (for each color development unit). 5-48 28 February 1989 3. CLEANING 3.1 CLEANING UNIT REMOVAL 1. Open the front cover. 2. Lower the transport unit [A]. 3. Place some paper [B] underneath the cleaning unit [C]. 4. Turn the cleaning unit release lever 90°, and remove the cleaning unit. 5-49 28 February 1989 3.2 CLEANING BLADE REPLACEMENT 1. Remove the cleaning unit [A]. (See Cleaning Unit Removal.) 2. Remove the cleaning blade [B] (1 screw). 3. Install the new cleaning blade between blade brackets [C] and secure with the collar screw. NOTE: a) Do not touch the edge of a new cleaning blade, as it is damaged easily. b) After installing a new cleaning blade, make sure it swivels. 5-50 28 February 1989 3.3 CLEANING BRUSH REPLACEMENT 1. Remove the cleaning blade [A]. (See Cleaning Blade Replacement section). 2. Remove the 4 cleaning brush bracket screws, and remove the cleaning brush [C] together with the cleaning side brackets [B]. 3. Remove the E rings [D] on both sides and the rear-side gear [E], and replace the cleaning brush [C]. NOTE: a) Do not touch the cleaning brush surface. Handle only the shaft-ends. b) Do not bend or damage the inlet seal [F]. 5-51 28 February 1989 3.4 BLADE SCRAPER REPLACEMENT 1. Remove the cleaning blade and brush. (See Cleaning Brush Replacement section.) 2. Hold down the cleaning blade knob [A] and remove the blade scraper [B] (2 screws). 5-52 3.5 TONER OVERFLOW SENSOR REPLACEMENT 1. Remove the cleaning unit. 2 . Lower the transport unit [A]. 3 . Remove the toner overflow sensor bracket [B] from the duct bracket (1 screw). 4. Disconnect the connector [C] and remove the toner overflow sensor from the bracket [B] (1 screw). 5-53 28 February 1989 3.6 USED TONER COLLECTION 1. Slide out the cleaning unit [A] until the toner collection cap [B] is accessible. 2. Remove the toner collection cap [B], and check the toner quantity by inserting a screwdriver. 3. When the toner collection bottle is more than one half full, remove the cleaning unit and cover it tightly with a vinyl bag as shown. 4. Hold the bag over the opening and empty the toner. (Shake the unit if necessary.) 5-54 28 February 1989 3.7 QUENCHING LAMP REPLACEMENT/CLEANING 1. Open the front cover. 2. Pull out the QL [A]. 3. Wipe the surface of the QL with a cloth. 4. Reset (replace) the QL. NOTE: Do not use alcohol to clean the QL. 5-55 28 February 1989 4. PAPER FEED 4.1 MANUAL FEED TABLE REMOVAL AND MANUAL FEED SENSOR REPLACEMENT 4.1.1 Table 1. Lower the manual feed table [A]. 2. Remove the right cover (6 screws). 3. Remove the manual feed table in the direction of the arrow. 4.1.2 Sensor 1. Remove the right cover (6 screws). 2. Disconnect the sensor connector and remove the manual feed sensor [B] (1 screw). 5-56 28 February 1989 4.2 PAPER SIZE SWITCH REPLACEMENT 1. Remove the size switch [A] from the paper feed station (1 screw). 2. Pull the connector harness as far as possible into the machine before disconnecting the switch or the new switch unit will be very difficult to install. 3. Disconnect the connector and replace the switch. 5-57 28 February 1989 4.3 1ST FEED ROLLERS REPLACEMENT 1. Remove the right cover and the manual feed table. (See the Manual Feed Table Removal section.) 2. Remove the following parts: Paper feed guide plate [A] (1 screw) Separation guide plate [B] (2 screws) 3. Remove the snap ring [C] from the pick-up roller shaft, and remove the pick-up roller [D]. NOTE: Do not bend the paper end actuator. 4. Remove the snap ring [C] from the paper feed roller shaft, and remove the paper feed roller [E]. 5. Remove the snap ring [C] from the reverse roller shaft, and remove the reverse roller [F]. 5-58 28 February 1989 6. Reinstall the new rollers as shown. NOTE: Do the following for cleaning/lubrication: a) Use a damp cloth to clean the rollers. b) Clean the clutch spring before lubricating it. c) Put Mobil Temp.78 in the three grease holes [G] in the drive hub [H]. 5-59 28 February 1989 4.4 GRIP ROLLER REPLACEMENT 1. Remove the first paper feed station pick-up roller, paper feed roller, and reverse roller. (See the 1st Feed Rollers Replacement section.) 2. Remove the holding spring plate [A] (1 collar screw). NOTE: Do not bend the spring plate [B] or the mylar strip [C]. 3. Remove the grip roller bracket [D] (1 screw). 4. Remove the grip roller [E] and replace it. NOTE: When removing the grip roller, take care not to move the rear-side bushing out of position. 5-60 28 February 1989 4.5 2ND FEED ROLLER AND FRICTION PAD REPLACEMENT 1. Remove the first separation guide plate [A] (2 screws). 2. Remove the paper feed roller bracket [B] (1 screw). CAUTION: Be careful not to drop the spacer [C], spring [D], or bushing [E]. 3. Remove the paper feed roller [F] from the shaft, and replace the roller. 4. To remove the friction pad assembly [G], press down on the bottom plate raising arm [H], and replace the friction pad [I] (1 screw). NOTE: a) Clean the bracket with solvent before attaching the new friction pad to its bracket with the 2-sided adhesive tape. b) When replacing the friction pad, make sure that the gap between the edge of the bracket and the surface of the pad is within 0.05 to 0.35 mm. c) After replacing the friction pad, adjust the friction pad pressure. 5-61 28 February 1989 4.6 3RD ROLLER AND FRICTION PAD REPLACEMENT 1. Remove the auxiliary roller assembly [A] (1 screw). 2. Remove the third feed roller [B] and the hub [C] from the shaft and replace the roller. NOTE: Do not apply grease to the bearings in the paper feed roller bracket or to the auxiliary roller assembly. This may cause the one-way clutch in the paper feed roller to slip. Be sure to wipe any grease off these parts with a cloth. 3. To remove the friction pad assembly [D], press down the bottom plate raising arm [E], and remove the friction pad (1 screw). NOTE: a) Clean the bracket with solvent before attaching the new friction pad to its bracket with 2-sided adhesive tape. b) When replacing the friction pad, make sure that the gap between the edge of the bracket and the surface of the pad is within 0.05 to 0.35 mm. c) After replacing the friction pad, adjust the friction pad pressure. 5-62 28 February 1989 4.7 FRICTION PAD PRESSURE ADJUSTMENT 1. Turn the eccentric cam [A] to adjust the clearance between the friction pad [B] and the paper feed roller [C] (0.8 ± 0.1 mm). NOTE: a) Put the 0.9 mm clearance gauge [D] between the roller and the pad. The clearance is correct when the gauge is slid left and right and there is a slight resistance. b) The clearance between the paper feed roller and the pad narrows as the longer grooved side of the eccentric cam nears the up position. Keep the longer grooved side to the left when the cam is in horizontal position. 2 . If the pressure cannot be adjusted by turning the eccentric cam, adjust the pressure by moving the friction pad bracket as explained below. 3. Remove the friction pad bracket fixing screw [E] and loosen the screw [F]. 4. Place the screw [E] in the center position [G] as shown. After adjusting the vertical position, tighten the screws. 5. Perform fine adjustment (step 1). 5-63 28 February 1989 4.8 PRESSURE ARM ADJUSTMENT [A]...250g [B]...380g : Normal Setting Position [C]...450g The pressure spring is normally at the [B] position (factory setting). In the following cases, change the position: 1. The friction coefficient is large and multiple feeding occurs. Increasing the friction pad pressure fails to correct the problem. Adjust the spring position to [A]. 2. When thick paper (90, 110 or 135 g/m2) is used, non feeding, poor registration and/or jams may occur. Adjust the spring position to [C]. 5-64 28 February 1989 4.9 FEED AND RELAY CLUTCH REPLACEMENT NOTE: No gap adjustment is required when installing a new paper feed clutch as the gear is provided as part of the assembly. 1. Remove the rear cover (2 screws). 2. Lower the I/O control board [A] (1 screw). 3. Release the upper limit sensor lever [C]. 4. Remove the E ring [D] holding the clutch and disconnect the 2P connector. 5. Slide the clutch off the shaft and replace it. 5-65 28 February 1989 4.10 PAPER END SENSOR REPLACEMENT 1. Remove the right cover (6 screws). 2. Remove the manual feed table. 3. Remove the paper feed guide plate [A]. 4. Disconnect the paper end sensor connector [B] and remove the paper end sensor bracket [C] (1 screw). 5. Replace the paper end sensor [D]. 4.10.2 2nd and 3rd Feed Stations 1. Remove the rear cover (2 screws). 2. Lower the I/O control PCB [E] (1 screw). 3. Remove the paper end sensor [F] (1 screw). 4. Disconnect the paper end sensor connector [G]. 5. Replace the paper end sensor [F]. 5-66 28 February 1989 4.11 LIFT MOTOR REPLACEMENT 1. Remove the rear and right covers (10 screws). 2. Disconnect the 3P connector (white) [A] of the manual feed sensor, and remove the paper feed control board [B] (1 screw). 3. Disconnect the 2P connector (white) [D] of the pick-up solenoid [C]. 4. Disconnect the 3P connector (brown) [E] of the 1st cassette lift sensor. 5. Remove the spring [F]. 6. Remove the pick-up solenoid bracket [G] (4 screws). 7. Remove the spring [H]. 8. Disconnect the 2P connector (green) [J] of the lift motor [I]. 9. Remove the E ring [L] holding the lift motor bracket [K]. 10. Separate the bracket from the lift motor [I] (2 screws). 5-67 28 February 1989 4.12 REGISTRATION SENSOR REPLACEMENT 1. Remove the following units and place them on a sheet of paper: • Color development unit • Black development unit • Charge corona unit (1 screw) • Drum unit (1 screw). 2. Remove the registration sensor bracket [A] (2 screws). 3. Disconnect the 3P connector [B]. 4. Remove and replace the registration sensor [C] (1 screw). 5-68 28 February 1989 4.13 REGISTRATION CLUTCH REPLACEMENT 1. Remove the rear cover (2 screws). 2. Lower the I/O control PCB (1 screw). 3. Disconnect the 2P connector (yellow) [A] of the registration clutch [B]. 4. Remove the connecting plate [C], and the registration clutch bracket [D] (3 screws). 5. Separate the registration clutch from the bracket (1 screw). 6. Remove the idle gear shaft assembly [E] and replace the registration clutch. NOTE: When reassembling, make sure that the positioning notch [F] on the clutch fits over the arm extending from the registration clutch bracket [G]. 5-69 28 February 1989 4.14 UPPER REGISTRATION ROLLER REMOVAL 1. Open the front cover. 2. Remove the rear cover and lower the I/O control PCB (1 screw). 3. Remove the drive gear [A] (2 Allen screws), then remove the E ring [B]. 4. Remove the E ring [D] and the bearing [E] from the front of the upper registration roller. 5. Remove the upper registration roller [F] (from the front side). 5-70 28 February 1989 4.15 LOWER RESISTRASION REPLACEMENT 1. Remove the transport unit. (See the Transport Belt Replacement section.) 2. Remove the spring [A] from the lower registration roller assembly [B]. 3. Remove the release lever [C] of the lower registration roller (1 screw). 4. Remove the bushing [D] (1 screw). 5. Remove the lower registration roller assembly. NOTE: When removing the lower registration assembly, make sure not to drop the bushing from the shaft (rear side). 6. Remove the spring [G] from both sides of the lower registration roller [H]. 7. Remove the E ring [I] and the bushing [J] from both ends of the roller. 8. Remove the E ring [K] and the collar [L] from both ends of the lower registration roller. 9. Replace the lower registration roller. 5-71 21 April 1989 4.16 REGISTRATION ADJUSTMENT (SP Mode #42) Standard Setting: 8 (0 ± 2.0 mm) 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter registration adjusting mode with the numeric keys as shown above. 3. The magnification indicator [C] shows the current registration setting (blinking). 4. Input a number from “0” to “15” with the numeric keys to adjust the registration. • Adjusting range from “0” (-6.4 mm) to “15” (+5.6mm) in 0.8mm steps. 1 step = 0.8 mm • Standard value = 0 ± 2 mm 5. Turn DIP switch 1 - 4 OFF. 5-72 28 February 1989 4.17 UPPER RELAY SENSOR REPLACEMENT 1. Remove the 1st separation guide plate (2 screws). 2. Remove the second paper feed roller (1 screw). 3. Remove the second feed station lower entrance guide plate (1 screw). 4. Remove the auxiliary roller assembly [A] (1 screw). 5. Remove the upper relay sensor bracket [B] (1 screw), and disconnect the connector. NOTE: Do not let the feeler [C] of the upper relay sensor [E] get caught in the roller [D]. 6. Replace the upper relay sensor [E]. 5-73 28 February 1989 4.18 LOWER RELAY SENSOR REPLACEMENT 1. Remove the third paper feed roller and friction pad assembly [A]. (See the 3rd Paper Feed Roller and Friction Pad Replacement section.) NOTE: Make a note of the positions of the slots on the eccentric cam [B]. Otherwise, friction pad pressure will require re-adjusting. 2. Remove the lower relay sensor bracket [C] and sensor (1 screw). 3. Disconnect the connector [D] and replace the lower relay sensor [E]. NOTE: Do not let the feeler [F] of the lower relay sensor get caught in the roller [G]. 5-74 28 February 1989 5. TRANSPORT 5.1 TRANSPORT BELT REPLACEMENT 1. Open the front cover and disconnect the 2P connector [A] on the rear side plate. 2. Lower the registration release lever [B] to lower the transfer unit [C]. 3 . Pull out the transfer/separation corona unit [D]. 4. Unhook the spring [E] connecting the transport unit to the rear pIate. 5. Remove the transport unit bracket [F] (2 screws). 5-75 23 May 1989 6. Remove the transport unit [A]. 7. Remove the following parts from the front side of the transport unit: E ring [B] step screw [C] bushing [D]. 8. Remove the following parts from the rear side of the transport roller: 3 E rings [E] transport drive gear [F] parallel pin [G] busing [H]. 9. Slide the transport belt assembly [I] to the rear side, then lift up the front and pull it out as shown. 10. Remove the transport rollers [J] as shown and replace the transport belts [K] . 5-76 28 February 1989 5.2 DRUM HEATER REPLACEMENT 1. Remove the transport unit. (See the Transport Belt Replacement section.) 2. Remove the drum heater [A] (one connector [B] and 1 screw [C]) and take out the heater. 5-77 28 February 1989 6. DRUM 6.1 CHARGE CORONA WIRE REPLACEMENT 1. Remove the charge corona. 2. Remove the front end block cover [A] (1 screw) and the rear end block cover [B]. 3. Unhook the spring from the corona wire [C] and replace the wire. NOTE: a) Do not touch the wire. Oils and chemicals on your hands will deteriorate the wire. b) Do not bend the wire. This will cause the wire coating to peel off. c) Do not damage the grid when replacing the charge wire. 5-78 28 February 1989 6.2 CHARGE CORONA GRID REPLACEMENT 1. Remove the charge corona unit. 2. Push in the front pawls [A] of the grid anchor (as shown) in order to remove the grid. NOTE: a) Oils and chemicals on your hands will deteriorate the grid. b) Do not bend the grid. This can result in an uneven charge. 5-79 28 February 1989 6.3 CHARGE CORONA HEIGHT ADJUSTMENT NOTE: Adjust the charge corona height after cleaning the optics section. Adjust the charge corona height to achieve even gradation [A] using an OSA3 test chart as following order. 1) Place the charge corona unit on a flat surface with the grid side [B] down. 2) Measure the height of the rear side of the corona wire [C]. 3) Adjust the front side to be eqal to the rear measurement. NOTE: Measurement should be approximately 9 mm. 5-80 28 February 1989 6.4 TRANSFER/SEPARATION CORONA WIRE REPLACEMENT 1. Remove the transfer/separation (T/S) corona unit. 2. Remove the following parts: T/S unit front end block cover [A] T/S unit rear end block cover [B] T/S unit paper guide [C]. NOTE: When replacing the T/S unit paper guide, verify that all three tabs are properly latched in place [D]. 3. Unhook the springs [E] from the wires. 4. Replace the transfer corona wire [F] and the separation corona wire [G]. 5. Check the position of the mylar strip [H]. NOTE: The transfer mylar is positioned by a jig at the factory. Adjustments are not normally necessary. 5-81 28 February 1989 6.5 DRUM REPLACEMENT 1. Remove the following units: color development unit black development unit cleaning unit charge corona unit [A]. 2. Remove the fixing screw [B] of the drum stay and pull out the drum unit [C] gently along the rail. NOTE: Take care when removing the drum unit not to strike the erase unit. [D] 3. Place the drum unit on a sheet of paper. Loosen the two screws [E] securing the bearing holder and rotate the holder as shown. 4. Remove the drum by holding the drum unit rail and pulling out and up on the drum knob. NOTE: a) When removing the drum, take care not to strike it against any objects. b) Be careful not to bend the bearing holder [F]. 5-82 28 February 1989 5. Remove the drum knob [A] and the bearing [B] and install them with the screw [C] on the new OPC drum. Do not remove the protective sheet from the new drum. 6. Set the OPC drum in the unit and put the bearing holder [D] back in place. Tighten the screws. NOTE: a) When setting the drum in the unit, be careful not to strike it against the rail. b) Do not bend the bearing holder. Make sure the bearing holder is in contact with the bearing [B], as they are both used to ground the unit. If they are not in contact, solid black copies may occur. c) Do not touch the drum surface. 7. Set the drum unit in the machine and remove the drum protective sheet. 8. Reinstall the other units around the drum unit. 5-83 28 February 1989 9. Remove the DIP switch cover [A] and turn switch 1 - 4 ON. 10. Press the numeric keys in the above sequence (SP Mode #66) in order to initialize the drum counter and measure the amount of residual voltage on the drum surface. NOTE: After the keys are pressed, and the beeper sounds five times. 11. Turn DIP switch 1 - 4 OFF. NOTE: The drum counter must be reset by SP Mode #66 whenever an OPC drum is replaced. 5-84 28 February 1989 6.6 ID SENSOR REPLACEMENT NOTE: Cover the drum with the protective sheet to prevent the drum from being exposed to light. 1. Remove the drum unit, then remove the drum [A] from the unit. (See the Drum Replacement section.) 2. Remove the ID sensor holder [B] (2 screws). 3. Peel the plastic strip off the back of the holders and remove the ID sensor PCB [C] from the holder. 4. Replace the PCB and put the plastic strip back in place. 5. Reinstall the sensor holder (2 screws). 5-85 28 February 1989 6.7 ID SENSOR Vsg ADJUSTMENT (SP Mode #54) 1. Clean the ID sensor (LED and photo transistor) with a blower brush. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3. Enter ID sensor Vsg adjustment mode with the numeric keys (SP Mode #54). 4. Adjust VR102 (ID) output to within 4.00 ± 0.2V using the magnification ratio display. NOTE: a) An incorrect adjustment of the ID sensor output may cause a toner density control error. b) Adjustment is required in the following cases: System control board replacement ID sensor removal and/or replacement Toner density control error (toner density is high or low) OPC drum replacement c) Do not adjust the VR on the ID sensor board. d) Do not use SP Mode #55 to adjust the voltage. (SP Modes #54 and #55 differ by up to 0.4V.) 5. Press the Clear/Stop key and turn DIP switch 1 - 4 OFF. 5-86 28 February 1989 6.8 SEPARATION PAWL REPLACEMENT NOTE: Cover the drum with the protective sheet before removing the drum unit. This prevents the drum from being exposed to light. 1. Remove the drum unit, then separate the drum [A] from the unit. (See the Drum Replacement section.) 2. Remove the separation pawl bracket [B] (2 screws). 3. Remove the screws [C] and the springs [D], then replace the separation pawls [E]. 5-87 23 May 1989 6.9 CHARGE CORONA CURRENT ADJUSTMENT (SP Mode #9-2) Standard Value: -400 ± 2µA 1. Turn off the main switch. 2. Remove the rear cover (4 screws). 3. Lower the I/O control board [A]. 4. Disconnect the charge corona terminal [M] from the CC/TC/Bias power pack. 5. Connect the multimeter leads as shown, and measure the main corona current. 6. Turn DIP switch 1 - 4 ON. 7. Turn on the main switch, and select SP Mode #9-2 as shown. 8. Adjust the charge corona current to -400 ± 2µA by turning VR1 on the CC/TC/Bias power pack. NOTE: To avoid possible shock hazard it is recommended to attach an aligator clip to the charge corona terminal [M] then secure positive meter lead with the other end of the clip. 5-88 21 April 1989 6.10 GRID VOLTAGE ADJUSTMENT (SP Mode #9-2 and 3) Standard value (V) Standard grid voltage ID sensor grid voltage Adjusting VR -920 ± 18V -560 ± 10V VR3 VR4 SP Mode #9-2 #9-3 1. Remove the rear cover and lower the I/O control board. 2. Set the multimeter range at DC 1500V and connect the probe to terminal [G] . 3. Turn ON DIP switch 1 - 4. Adjustment of standard grid voltage a) Turn on the main switch. b) Set SP Mode #9-2 as shown. c) Adjust VR3 of the CC/TC/Bias power pack to obtain the standard voltage. (Adjustment of ID sensor grid voltage) a) Set SP Mode #9-3 as shown. b) Adjust VR4 of the CC/TC/Bias power pack to obtain the standard voltage. Then, press the clear stop key. c) Turn OFF DIP switch 1 - 4. 5-89 21 April 1989 6.11 DRUM CURRENT ADJUSTMENT (SP Mode #9-5&7) Transfer DC - 18.0 ± 1.5 VR-2 Separation AC 44 ± 2.0 DC +1.5 ± 1.5 VR AC SC Power Pack VR DC } NOTE: The above values are measured with the Beckman 330 or 3030. 1. Turn off the main switch and remove the following parts: Charge corona unit Development units (black and color) Cleaning unit Drum unit. 2. Remove the paper guide from the transfer corona unit. 3. Clean the transfer/separation corona wires. 4. Turn on the front door safety switch. 5. Turn ON DIP switch 1 - 4. 6. Remove the drum from the drum unit. 7. Set the drum shoe [A] and connect the multimeter as follows: a) Slide the drum unit onto the drum unit guide rail. b) Put the drum shoe and the drum adaptor on the drum shaft (A006 9105) [B] and attach the drum knob. c) Set the drum shaft in the drum unit. d) Connect the drum shoe and multimeter leads as shown. 5-90 21 April 1989 6.11.1 Transfer Current Measurement (SP Mode #9-5) Standard Value: DC -18.0 ± 1.5µA 1. Put the drum shoe [A] on the center of the drum shaft with the curved surface facing the transfer corona wire [B]. 2. Set the range of the multimeter to DC200µA. 3. Make sure that the release lever of the transport unit is in the up position. 4. Turn on the main switch. 5. Enter SP Mode #9-5 as shown. 6. Adjust the VR-2 of the CC/TC/Bias power pack to obtain the standard value. 7. Press the Clear/Stop key and turn off the main switch. 5-91 21 April 1989 6.11.2 Separation Corona Current Measurement (SP Mode #9-7) Standard Value: AC 44 ± 2.0µA DC +1.5 ± 1.5µA NOTE: Turn off the main switch before changing the multimeter setting. 1. Shift the drum shoe [A] slightly to the left so that the distance between the stay of the pick-off pawl and the edge of the drum shoe is 10 mm (as shown). Then, lock the drum shoe in place. 2. Set the multimeter range to AC200µA. 3. Turn on the main switch. 4. Enter SP Mode 9-7 as shown: 5. Adjust the VR AC of the separation power pack to obtain the standard value. 6. Press the Clear/Stop key and turn off the main switch. 7. Set the multimeter range to DC200µA. 8. Turn on the main switch and enter SP Mode #9-7 as shown. 9. Adjust VR DC of the separation power pack to obtain the standard value. Press the Clear/Stop key. Repeat steps “4 to 9” and adjust the AC and DC currents to within the standard. 5-92 28 February 1989 7. FUSING 7.1 FUSING UNIT REMOVAL 1. Open the front cover. 2. Hold the fusing front cover [A] while pushing the release lever [B], and pull out the fusing unit until it stops. 3. Remove the fusing unit lock screws [C] (2 screws). 4. Remove the fusing unit completely. NOTE: Before completely removing the fusing unit, support the underneath of the fusing unit. 5-93 28 February 1989 7.2 FUSING LAMP REPLACEMENT 1. Remove the fusing unit. (See the Fusing Unit Removal section.) 2. Remove the fusing knob [A] by simply lifting the leaf spring with a screwdriver. 3. Remove the front cover [B] of the fusing unit (1 screw). 4. Pull out on the front lamp terminal [D] to remove the fusing lamp. Replace the fusing lamp. NOTE: After replacing the lamp, rotate it to make sure it does not contact the hot roller. 5-94 28 February 1989 7.3 HOT ROLLER REPLACEMENT 1. Remove the fusing lamp. (See the Fusing Lamp Replacement section.) 2. Press both “B2” release levers and lower the paper exit assembly [A]. 3. Remove the front and rear pressure springs [B]. 4. Remove the rear lamp terminal [C] (1 screw). 5. Remove the front and rear C rings [D], drive gear [E], front and rear collars [F], and front and rear fusing bearings [G]. Then, remove the hot roller [H] and replace it. NOTE: a) Peel off 3 cm (1 inch) from both ends of the protective sheet, and install the hot roller. b) Before setting the pressure springs, remove the rest of the protective sheet. 5-95 28 February 1989 7.4 PRESSURE ROLLER REPLACEMENT NOTE: Keep the protective sheet on the pressure roller until the hot roller is fully installed. Remove the sheet before setting the pressure springs. 1. Remove the hot roller. (See the Hot Roller Replacement section.) 2. Remove the fusing entrance guide [A] (2 screws). 3. Lift both ends of the pressure roller [B] and slide it along with its bushings [C] out the rear side of the unit. 4. Replace the pressure roller. 5-96 28 February 1989 7.5 FUSING STRIPPER PAWL REPLACEMENT 1. Lower the paper exit assembly [A]. 2. Remove the pawl spring [B]. 3. Loosen the step screw [C] and release the pawl spring [D]. 4. Loosen the screws holding the fusing pawl bracket [E] in place. 5. Remove the fusing stripper pawls [F] and replace them. 5-97 28 February 1989 7.6 THERMAL FUSE REPLACEMENT 1. Remove the fusing knob [A] and the fusing front cover [B]. (See the Fusing Lamp Replacement section.) 2 . Remove the fusing unit upper cover [C] (4 screws). 3 . Lower the paper exit assembly [D]. 4. Pull out the temperature fuse connector [E]. 5. Disconnect the fuse harness lead from the rear terminal [F] of the fusing lamp (1 screw). 6 . Remove the temperature fuse [G] (1 screw, 2 plate clamps). 7. Replace the temperature fuse. 5-98 28 February 1989 7.7 FUSING THERMISTOR REPLACEMENT 1. Remove the fusing knob [A] and the fusing front cover [B]. (See the Fusing Lamp Replacement section.) 2. Remove the fusing unit upper cover [C]. (See the Temperature Fuse Replacement section.) 2. Remove the upper paper entrance guide [D] (1 step screw, 1 flat seat screw). 3. Pull out the fusing thermistor connector [E]. 4. Remove the fusing thermistor [F] (1 screw). 5. Replace the fusing thermistor. 5-99 28 February 1989 7.8 FUSING TEMPERATURE CHECK (SP Mode #52) 1. Remove the DIP switch cover [A] and turn ON DIP switch 1 - 4. 2. Enter the fusing temperature check mode using the numeric keys (SP Mode #52). 3. The current temperature setting is indicated on the magnification indicator. 4. Turn OFF DIP switch 1 - 4. 5-100 28 February 1989 7.9 FUSING TEMPERATURE ADJUSTMENT (SP Mode #49) Normal Setting: 185°C The fusing temperature can be adjusted within the range of 175°C to 190°C (in 1°C steps) according to the following procedure: 1. Remove the DIP switch cover [A], and turn ON DIP switch 1 - 4. 2. Enter the fusing temperature adjustment mode using the numeric keys (SP Mode #49). 3. The current temperature setting blinks in the magnification display. Enter the new temperature setting with the numeric keys. 4. Turn OFF DIP switch 1 - 4. Adjustment is required in the following conditions: a) b) c) d) Fusing error has occurred Fusing thermistor replacement I/O control PCB replacement AC drive PCB replacement. 5-101 28 February 1989 7.10 FUSING TEMPERATURE CONTROL SELECTION (Full Wave Control or Phase Control) SP Mode #29 Normal Setting: Full Wave Control “0” 1. Remove the DIP switch cover [A], and turn ON DIP switch 1 - 4. 2. Enter the control mode using the numeric keys (SP Mode #29). 3. “0” blinks in the magnification indicator. 4. Enter “1” to select phase control mode: “0” = Full Wave Control “1” = Phase Control 5. Press the Enter key. 6. Turn OFF DIP switch 1 - 4. 7. Turn the main switch off, then on. 5-102 28 February 1989 7.11 NIP WIDTH MEASUREMENT 1st 2nd Center Front Back Specified Value 3.3 ± 0.3 mm Should be { equal to within 0.4mm } • Deviation between the front and back should not exceed 0.4 mm. 1. Perform free run for about 30 times to eliminate pressure roller distortion. 2. Make a sky shot copy A4 (LT size) sideways and turn off the main switch when the paper is passing through the fusing unit. 3. Wait 10 seconds, then turn the fusing unit roller knob clockwise one-half turn. NOTE: Before turning the fusing unit roller knob, make sure that the front cover safety switch is turned off. This releases the fusing unit drive gear. 4. Wait another 10 seconds, then gently pull out the copy paper of the fusing unit. 5. Measure the widths of the two dark lines at the center and note the average of the two widths. If the standard is not met, adjust the fusing pressure. NOTE: Make sure that the center widths are 3.3 ± 0.3 mm, and that the front and rear widths of each line do not vary more than 0.4 mm. If the front and rear are not equal, copies will wrinkle in duplex/overlay modes. 5-103 28 February 1989 7.12 FUSING PRESSURE ADJUSTMENT < Fusing pressure adjustment combinations > Hook settings A-a A-b B - a} B - b Nip Width 3.0 ± 0.3 mm 3.3 ± 0.3 mm ** 3.6 ± 0.3 mm ** Standard setting Three different nip widths can be selected. Adjust the width if poor fusing occurs or if the copy paper becomes creased. (See the Nip Width Measurement section.) 5-104 28 February 1989 7.13 FUSING GUIDE PLATE HEIGHT ADJUSTMENT Mounting positions A Factory C A + 1mm B A - 0.5mm Paper creasing in the fusing unit can also be corrected by adjusting the height of the fusing entrance guide plate [D]. 1. Remove the guide plate mounting screws from the A position and place them in the lower mounting plate holes. 2. Position guide plate (down for B position, up for C position) and tighten the screws. 5-105 28 February 1989 7.14 FUSING EXIT SENSOR REPLACEMENT 1. Remove the fusing knob and the fusing front cover. (See the Fusing Lamp Replacement section.) 2. Lower the fusing exit assembly [A]. 3. Remove the fusing exit sensor bracket [B] (1 screw). 4. Remove the exit sensor connector [C]. 5. Remove the fusing exit sensor [D] and replace it. 5-106 28 February 1989 8. TRANSPORT 8.1 TRANSPORT GUIDE UNIT REMOVAL 1. Remove the fusing unit. (See the Fusing Unit Removal section.) 2. Release the transport guide unit [A] and remove the collar screw [B]. 3. Pull out the transport guide unit. 5-107 28 February 1989 8.2 RELAY SENSOR REPLACEMENT 1. Open the front cover and remove the collar screw [A]. 2. Remove the inverter relay sensor connector [B] from the rear side plate and remove the reverse unit [C]. 3. Remove the collar screw [D]. 4. Remove the turn guide plate [E] from the reverse unit (4 screws). 5. Remove the inverter relay sensor [F] and replace it. 5-108 28 February 1989 8.3 INVERTER SENSOR REPLACEMENT NOTE: If the duplex unit is installed, press the release lever “E1” and slide the unit out until it stops. 1. Remove the left lower cover [A] (2 screws). 2. Remove the inverter sensor bracket [B] (1 screw). 3. Pull out the inverter sensor connector. 4. Remove the inverter sensor [C] from the bracket and replace it. 5-109 28 February 1989 8.4 DUPLEX/OVERLAY TRANSPORT MAGNETIC CLUTCH REPLACEMENT 1. Remove 2. Pull out the vacuum fan motor connector [A] and remove the vacuum fan motor [B] (3 screws). 3 . Pivot the DC power supply board [C] to the right (1 screw). 4. Remove the main transformer (1 screw, 1 connector). 5 . Remove the tension spring [D] and take the duplex/overlay drive chain [E] off its sprocket. 6. Disconnect the clutch connector [F] and remove the clutch [G] together with the clutch bracket [H] (3 screws). 7. Separate the clutch from the bracket (1 screw). 8 . Remove the E ring [I], sprocket [J], and bracket [H] and replace the clutch. 5-110 28 February 1989 9. JOGGER 9.1 JOGGER UNIT REMOVAL NOTE: Before removing the jogger unit, place a mark along the front edge of the bottom plate. This is so that the unit can be reinstalled in the same position, to maintain side-to-side registration. 1. Remove the rear cover (4 screws) and disconnect the three connectors [A] of the jogger unit. 2. Remove the front cover (2 screws) and the lower inner cover [B] (4 screws). If the multi-duplex unit is installed, remove the “E1” knob [C] in order to remove the inner cover (1 collar screw). 3. Mark the original position of the jogger unit [D] on the bottom plate [E]. 4. Remove two screws from the front of the jogger section. Lift “D1” lever [F] and pull out the jogger unit. NOTE: a) When reassembling, rotate the jogger section drive gear [G] and the tension gear [H] in order to check for backlash. Correct any backlash by shifting the jogger unit drive gear bracket. b) Make sure that the distance between the jogger side plate [I] and the front edge [J] of the copier is 62.4mm as shown. 5-111 28 February 1989 9.2 JOGGER HOME POSITION SENSOR REPLACEMENT 1. Remove the jogger unit. (See the Jogger Unit Removal section.) 2. Remove the screw [A] and disconnect the connector [B]. Then replace the jogger home position sensor [C]. NOTE: a) Access the screw [A] by inserting a screwdriver through the hole in the jogger unit bracket. b) Do not move the bracket [D] of the jogger home position sensor. This changes the home position. 5-112 28 February 1989 9.3 JOGGER UNIT WIRE REPLACEMENT - Removal 1. Remove the jogger unit. (See the Jogger Unit Removal section.) 2. Loosen the screws [A] securing the front and rear jogger fences (2 screws). 3. Remove the jogger unit lower cover [B] (1 screw). 4. Unhook the jogger wire tension spring [C] from the jogger wire. 5. Remove the jogger wire [D]. - Installation 6. Temporarily place the colored wire eyelet [E] over the anchorage point [F], and route the wire around the front idle pulley [G], and through the unit to the drive pulley [H]. 7. Wind the wire one and a half times around the drive pulley. 8. Hook the jogger wire tension spring to the jogger wire eyelets. 9. Reinstall the jogger unit lower cover. 5-113 10. Attach the rear jogger fence [A] to the jogger wire by placing the bead in the hole under the rear stop plate [B], and tighten the stop plate screw. 11. Position the rear logger fence to 11 ± 0.3 mm (home position) from the rear side plate [C]. 12. Position the front jogger fence [D] 10 mm from the front side plate [E], and tighten the side plate screw. NOTE: Make sure the front and rear jogger fences are 319 ± 1 mm apart. 5-114 28 February 1989 9.4 JOGGER MOTOR REPLACEMENT 1. Remove the jogger unit wire tension spring [A]. (See the Jogger Unit Wire Replacement section.) 2 . Disconnect the jogger motor connector [B] from the connector bracket. 3 . Remove the jogger motor assembly [C] (2 screws). 4. Separate the drive pulley [D] from the motor, and replace the motor. 5. Reassemble the unit and reposition the jogger fences. NOTE: Make sure that the top of the jogger drive pulley is flush with the end of the motor shaft. 5-115 28 February 1989 9.5 JOGGER SOLENOID ADJUSTMENT Adjust the position of the solenoid bracket [A] to satisfy the following conditions: When solenoid is OFF Press the solenoid plunger [B] and release it. Adjust the stroke [C] to 3 ± 0.3 mm. When solenoid is ON Make sure the clearance between the relay roller [D] and the transport roller [E] is at least 0.5 mm. 5-116 28 February 1989 10. OTHERS 10.1 OPERATION PANEL REMOVAL 1. Open the front cover and remove the inner cover [A] (3 screws). 2. Remove the operation panel [B] (4 screws, 6 connectors). 3. Replace the operation panel. NOTE: a) Remove the RAM IC from the old operation panel and install it in the new panel. b) If data stored in the RAM IC has been erased, re-input data in SP Mode. 5-117 SECTION 6 MULTI DUPLEX/ OVERLAY CONTENTS MULTI DUPLEX/OVERLAY 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 2. COMPONENTS LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . .6-3 4. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 6. PAPER STACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 7. PAPER ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 8. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 9. ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 10. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 11. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11 12. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .6-14 12.1 PAPER FEED ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 12.2 FRICTION PAD REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .6-15 12.3 REPLACEMENT OF POSITIONING ROLLER AND ROUND BELT . . . . . . . . . . . . . . .6-16 12.4 JOGGER FENCE DRIVE WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 12.5 JOGGER HOME POSITION SENSOR ADJUSTMENT (SP Mode #8-13) . . . . . . . . . .6-19 12.6 CAM CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 12.7 POSITIONING ROLLER SOLENOID ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 12.8 PAPER EXlT/PAPER END SENSORS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .6-23 12.9 MULTI-DUPLEX SIDE TO SIDE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . .6-25 28 February 1989 1. SPECIFICATIONS Power Source : +5 volts and +24 volts from the copier Power Consumption : 25 W Dimensions : (W x D x H) 520 mm x 540 mm x 180 mm 20.5” x 21.3” x 7.1” Weight : 12.5 Kg (49.5 lb) Paper Size : Min. A5/HLT (sideways) Max. A3/LDG Tray Capacity : Max. 50 sheets 6-1 28 February 1989 2. COMPONENTS LAYOUT - Mechanical Components - 1. Positioning Roller 4. Feed Roller 2. Positioning Roller Belt 5. Transport Rollers 3. Fork Gate Rollers - Electrical Components - 1. Jogger Motor (M10) 2. Duplex Feed Clutch (MC9) 3. Junction Gate Solenoid (SOL7) 4. Positioning Roller Solenoid (SOL8) 6-2 5. Cam Clutch Solenoid (SOL9) 6. Paper End Sensor (S23) 7. Paper Exit Sensor (S24) 8. Jogger Home Position Sensor (S25) 28 February 1989 3. ELECTRICAL COMPONENT DESCRIPTIONS Index No. Name Symbol P to P Location Drives the jogger fences that keep paper stacked evenly in the duplex tray. M10 D-7, C-7 Starts paper feed from the duplex tray. MC9 D-8, C-8 Function Motor 1 Jogger Magnetic Clutch 2 Duplex Feed Solenoids 3 Junction Gate Opens and closes the junction gate to change the paper path. SOL7 D-7, C-7 4 Positioning Roller Raises and lowers the positioning roller. SOL8 D-8, C-8 5 Cam Clutch Locks and releases the spring clutch to raise and lower the pressure plate. SOL9 D-7, C-7 Detects when paper is in the duplex unit. S23 D-6 Sensors Paper End 6 7 Paper Exit Detects when paper is being fed into the duplex tray. S24 D-6 8 Jogger Home Position Detects when jogger fences are in home position. S25 D-6 6-3 28 February 1989 4. OVERALL MACHINE CONTROL The copier I/O control PCB controls all operations in the duplex unit. 6-4 28 February 1989 5. BASIC OPERATION The optional duplex unit enables automatic multi-duplex/multi-overlay copying. With multi-duplex/multi-overlay copying, first side copies are directed by the duplex/overlay transport gate [A] and the junction gate [B] to the duplex tray [C]. The jogger fences [D] and the positioning roller [E] align the sheets of copy paper in the duplex tray. When multi-duplex copy mode is selected and the Start key is pressed, the copies in the duplex tray are fed through the lower transport section rollers to the registration rollers [F]. When multi-overlay copy mode is selected and the Start key is pressed, the copies in the duplex tray are inverted one at a time in the inverter section [G] and fed to the registration rollers. The copier provides the duplex unit power source. All duplex unit rollers are driven by the copier main motor. 6-5 28 February 1989 6. PAPER STACKING When the fusing exit sensor detects the leading edge of the first copy in multiduplex or multi-overlay mode, the duplex/overlay transport [A] and junction gate [B] solenoids are energized to direct the copy to the duplex tray. The duplex unit paper transport rollers are driven by the copier main motor through gears and the drive chain. The duplex/overlay transport clutch transmits the gear drive to the duplex unit. This clutch is energized and de-energized at the same time as the duplex/overlay transport gate solenoid. The paper exit sensor [C] in the duplex unit is used for timing and to check for paper misfeeds. 6-6 28 February 1989 7. PAPER ALIGNMENT The jogger fences [A] align copy paper laterally and the positioning roller [B] aligns paper in the feed direction. The jogger fences are driven by the stepper motor [C] in the duplex unit. The drive mechanism for the duplex unit jogger fences is the same as that for the copier jogger fences. When the fusing exit sensor detects the leading edge of the first sheet of copy paper, the front and rear fences move into position 10 mm away from the sides of the copy paper. These fences move up against the copy paper 0.7 seconds after the paper exit sensor detects the trailing edge of the copy paper. The fences then move back 10 mm from both sides of the paper. This operation is performed every time a sheet of copy paper is fed to the duplex tray. In duplex/overlay copy mode, the positioning roller solenoid [D] is energized to raise the roller when the Start key is pressed. This solenoid is de-energized to lower the roller when the jogger fences move against the paper sides. 6-7 28 February 1989 8. PAPER FEED The duplex unit paper feed mechanism uses the friction pad system. The cam clutch solenoid [A] is energized when the fusing exit sensor detects the leading edge of the paper. The cam clutch solenoid is de-energized 1.56 second after the paper exit sensor detects the trailing edge of the last copy. This raises the lift arm [B]. When the Start key is pressed, the positioning roller [C] starts rotating. The feed roller [D] starts rotating 0.19 second after the duplex feed clutch [F] is turned on. 6-8 28 February 1989 9. ELECTRICAL TIMING A4 Sideways 2copies Overlay Mode 1st Paper Feed Station T1: Just after the start key is pressed, the jogger motor starts to rotate to move the jogger fences into the home position. T2: When the fusing exit sensor detects the leading edge of the paper, the duplex/overlay transport M.C., the duplex/overlay transport gate solenoid and the cam clutch solenoid are turned on. T3: Timing pulse reset. T4: The positioning roller starts to rotate when the start key is pressed. 0.19 seconds after the pressing start key, the duplex/overlay transport M.C. and the duplex feed M.C. are turned on to feed the paper to the registration roller. 28 February 1989 10. ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: 1. Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 (115V - English only / 220V - Five Languages) 2. New Equipment Condition Report . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . Envelope for NECR (115V only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4. Receiving Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 5. Pan head Screws - M4 x 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 6 . Grounding Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 7. Multilingual Decal (220V/240V only) . . . . . . . . . . . . . . . . . . . . . . . 1 8 . English Decal (115V only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-10 28 February 1989 11. INSTALLATION PROCEDURE 1. Turn off the main switch and unplug the copier power cord. 2. Remove the strips of shipping tape [A]. 3. Remove the copier bottom left cover [B] (2 screws) and copier rear cover [C] (4 screws). 4. Open front cover. 5. Remove the 2 stopper screws [D]. Then remove the handle [E] and 2 collars [F] from the copier. 6 . Remove the shielding tape [G] from the inner cover. 7. Remove the plastic stopper tab [H] using pliers. 8. Install the front and rear acuride rails [I] of the multi duplex/overlay unit [J] as shown and secure them to the copier (2 screws each). NOTE: a) Use the M4 x 5 screws to secure the front and rear acuride rails to the copier. b) Make sure that the multi duplex/overlay unit moves smoothly by sliding back and forth several times with the release lever [K]. 6-11 21 April 1989 9. Remove the bracket [A] (1 screw) and mount the harness bracket [B] on the power cord bracket (1 screw). 10. Connect the harness connectors [C] (white - 10P, yellow - 6P). Then, put the connectors and the harness back under the transformer. Slide harness between the transformer and accuride bracket. 11. Fix the ground wire [D] to the bottom plate as shown (1 grounding screw). 12. Reinstall the copier rear cover (4 screws). 13. Install the receiving tray [E] (2 screws). 6-12 21 April 1989 14. Remove the dip switch cover [A] (1 screw). 15. Plug in the power cord of the copier and turn on the main switch. 16. Turn on DPS 1-4 under the operation panel. 17. Enter “72” in the copy counter using the numeral keys, then press the “#” key . 18. Enter “1” in the magnification ratio indicator using the numeral keys, then press the “#” key. 19. Turn off DPS 1-4 under the operation panel. 20. Reinstall the dip switch cover. 21. Stick the decal [B] on the front cover as shown. 22. Check the multi duplex/overlay operation and fill out the New Equipment Condition Report. 6-13 28 February 1989 12. REPLACEMENT AND ADJUSTMENT 12.1 PAPER FEED ROLLER REPLACEMENT 1. Slide the duplex unit to the left and remove the transparent cover. • Open the front cover and push lever E1 to the left. 2. Remove the rear cover [A] (5 screws) 3 . Remove the top cover [B] (collar screw). 4. Remove the transport guide plate [C] (4 screws) 5. Remove the snap ring [D] from the paper feed roller. 6 . Pull the paper feed clutch [E] and the shaft out for enough to remove the paper feed roller [F]. 7. Replace the roller. NOTE: a) Mount the paper feed roller so the bearing is towards the rear of the machine. b) Position the notch in the feed clutch on the holding bracket [G] properly. 6-14 28 February 1989 12.2 FRICTION PAD REPLACEMENT AND ADJUSTMENT (Bottom View) 1. Remove the duplex tray [A] from the multi-duplex unit (2 screws). 2. Remove the bottom cover [B] from the multi-duplex unit (1 screw). 3. Remove the eccentric cam set screw [C] from the friction pad assembly [D] . 4. Remove the friction pad assembly. 5. Peel off the friction pad [E] from the pad holder and replace it (see fig. 1). 6 . Verify the pad is installed correctly by checking it against fig. 2. 7. Install the assembly with the adjusting cam in the position shown above in fig. 3. 6-15 28 February 1989 12.3 REPLACEMENT OF POSITIONING ROLLER AND ROUND 1. Slide the duplex unit to the left and remove the a transparent cover. • Open the front cover and push lever “E1” to the left. 2 . Remove the duplex unit front and rear covers (3 front cover screws and 5 rear cover screws). 3 . Remove 6 snap rings [A] and remove the support shaft [B]. 4. Remove the snap ring [C]. Take out and replace the positioning roller [D]. 5. Remove the chain tension spring [E]. 6 . Remove the positioning roller drive sprocket [F] and bushing [G] (one E ring). 7. Remove the drive belt [H] as shown in the figure, by slipping it through the hole for bushing and replace it. NOTE: Do not drop the pin [I] from the drive sprocket. 6-16 28 February 1989 12.4 JOGGER FENCE DRIVE WIRE REPLACEMENT 1. Slide the duplex unit to the left. • Open the front cover and push lever “E1” to the left. 2. Remove the rear cover of the copier (4 screws) and disconnect the automatic duplex unit connectors [A] (10P and 6P), ground wire and bracket (1 screw). 3 . Remove the duplex unit front [B] and rear [C] covers (3 front cover screws and 5 rear cover screws), tray (2 screws) and transparent cover [D] from the automatic duplex unit. 4. Loosen the set screws [E] (2 front screws and 2 rear screws) from the rail bracket. 5. Disengage the automatic duplex unit from the rail and place it on a bench. 6 . Remove the bottom cover [F] (1 screw), move the jogger fence outward and remove the wire stop plates [G] (2 screws). 7. Remove the tray cam clutch solenoid [H]. 8 . Remove the cam clutch [I] (1 E-crip). 6-17 9. Remove the table jogger fence [A] (2 front screws and 1 middle screws). • Pull out the table to the left as shown. 10. Remove the tension spring [B] and jogger fence drive wire [C]. 11. Install the new jogger fence drive wire as follows 1. Place the wire [D] block in the fork as shown in fig. 1. 2. Wind the wire by 1.5 turns around the center of the jogger motor pulley [E] (from down to up). 3. Hook the wire to the upper groove of the intermediate pulley [F]. 4. Link the wire hooks together with the tension spring. 12. Reassemble the automatic duplex unit. 13. Adjust the jogger home position by referring to the next page. 6-18 28 February 1989 12.5 JOGGER HOME POSITION SENSOR ADJUSTMENT (SP MODE #8-13) 1. Remove the DIP switch cover [A] from the control panel and turn on the DIP switch 1-4. 2. Use the numeric keys on the control panel to select the check mode. 3 . Set the check item to the jogger home position sensor (#13). 6-19 28 February 1989 4. Move the rear jogger fence [B] so the position is approximately 10.5 ± 0.5 mm. 5. Loosen the adjusting screw [C] for jogger home position sensor [D], move the bracket inward [E] until the control paneI magnification indicator displays “0”, move it outward [F] until the magnification indicator just shows “1” and tighten the adjusting screw. 6. Loosen the front jogger fence wire set screw [G] and move the front jogger fence [H] until it is 10.5 ± 0.5 mm from the front side plate [I]. 7. Tighten the jogger wire set screw. (At this time the jogger rear fence will already be in the correct position.) Precautions: 1. Before the above-mentioned adjustment, ensure the silver ball on the jogger fence drive wire is properly attached to the jogger fence. 2. The above adjustment is correct from the factory. Do not use the adjusting screw for jogger home position sensor replacement. Should the jogger home position sensor need replacement, remove the sensor from the bracket and replace it without changing the bracket’s position. 6-20 28 February 1989 12.6 CAM CLUTCH LUBRICATION 1. Slide the duplex unit to the left. 2. Remove the front and rear covers from the duplex unit (3 screws front, 5 rear). 3. Remove the spring [A]. 4. Actuate the cam clutch solenoid [B] by hand and remove the cam clutch [C] (1 C-clip). 5. After cleaning the spring clutch [D], apply a light coating of Mobil Temp. 78 to it. 6-21 28 February 1989 12.7 POSITIONING ROLLER SOLENOID ADJUSTMENT 1. Slide the duplex unit to the left. 2. Remove the front cover from the automatic duplex unit (3 screws). 3. Actuate the positioning roller solenoid [A] by hand and check the gap between the positioning roller [B] and jogger fence table [C] (fig. 1). NOTE: For most paper applications, leave the pressure adjusting plate [D] at the factory position (as shown in fig. 2). If there is difficulty feeding thick paper, loosen the screw [E] and move the pressure adjusting plate in the arrow direction. 6-22 28 February 1989 12.8 PAPER EXIT/PAPER END SENSORS REPLACEMENT 1 . Slide the duplex unit to the left and remove the transparent cover. 2. Remove the front [A] and rear [B] covers (3 screws front, 5 rear). 3. Remove the upper cover [C]. • Loosen the collar screw from the rear plate. 4. Remove the transport guide plate [D] (4 screws). 5. Remove the snap ring from the paper feed roller and pull the feed roller drive shaft [E] out for enough to remove the paper feed roller. 6 . Loosen the set screws from the paper feed support plate [F] (2 screws each side, front and rear). NOTE: Loosen the harness [G] to turn the support plate easier. 7. Turn the paper feed support plate cover, so the sensors are visible. 6-23 28 February 1989 8. Replace the paper exit sensor [A]. 9. Replace the paper end sensor [B]. • Use of a long screwdriver facilitates the replacement. 10. Reverse the procedure to reassemble. 6-24 28 February 1989 12.9 MULTI-DUPLEX SIDE TO SIDE REGISTRATION ADJUSTMENT NOTE: Before performing this adjustment do the following: 1. Verify that side-to-side registration is off on the second side of multiple copy runs in duplex and overlay modes. 2. Perform the Jogger Home Sensor adjustment (page 6-19). Adjustment Procedure 1. Measure the error in registration. Example: When 2 or more multi-duplex copies are made, the second image is shifted 3 mm towards the front of the copy. 2. Loosen the jogger home position sensor adjusting screw [A] and move the home position sensor the same amount as measured to correct the error. Example: 3 mm towards the front of the machine. 3. Loosen the front jogger set screw [C] and move the front jogger twice the measured distance. Example: 6 mm towards the front of the machine. 4. Retighten the front jogger set screw. 6-25 CONTENTS DOCUMENT FEEDER 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 2. COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . .7-3 4. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 . 5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 6. POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 7. INTERFACE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 8. ORIGINAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 8.1 ORIGINAL PICK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 8.2 ORIGINAL SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 8.3 ORIGINAL FEED-IN MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 8.4 ORIGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 8.5 ORIGINAL INVERSION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16 8.6 ORIGINAL FEED-OUT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18 8.7 BELT DRIVE MOTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19 8.8 FEED-OUT MOTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20 8.9 INPUT AND OUTPUT ClRCUlTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21 9. LIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 10. ORIGINAL MISFEED SENSING . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 7-23 11. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25 12. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 13. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .7-32 13.1 FEED-IN UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 13.1.1 Transport Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 13.1.2 Feed-in Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33 13.1.3 Pick-up Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 13.1.4 Feed-in Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 13.1.5 Pick-up Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36 13.1.6 Feed Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38 13.1.7 Feed-in Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39 13.1.8 Friction Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 13.1.9 Registration Sensor and Original Width Sensor Replacement . . . . . . . . . . . . . .7-41 13.1.10 Entrance Guide Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42 13.1.11 Belt Drive Motor Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43 13.2 FEED-OUT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44 13.2.1 Feed-out Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44 13.2.2 DF Main PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45 13.2.3 Inverter Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46 13.2.4 DF Leading Edge Registration Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47 14. SERVICE TABLES FOR DF MAIN PCB . . . . . . . . . . . . . . . . . . . . . . .7-49 14.1 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 14.2 VARIABLE RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 14.3 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 14.4 DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50 15. DF TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51 28 February 1989 1. SPECIFICATIONS Original Size and Weight: - Thin original mode Maximum A3 / 11” x 17” Minimum B6 / 5½” x 8½” Weight 41 to 128 g/m2 (11 to 34 lb) - Thick original mode Maximum A3 / 11” x 17” Minimum B6 / 5½” x 8½” Weight 52 to 128 g/m2 (14 to 34 lb) - Auto reverse mode Maximum A3 / 11” x 17” B6 lengthwise / Minimum 5½” x 8½” lengthwise Weight 64 to 105 g/m2 (17 to 28 lb) Original Feed: Automatic feed – ADF mode Manual feed one by one – SADF mode Original Table Capacity: 30 sheets / 80 g/m2 (20 lb) Original Set: Face up. First sheet on top Original Transport: One flat belt Copy Speed: (1 to 1 Copy) ADF Free Size Mode OFF: 18 copies/minute for A4 / 8½” x 11” sideways ADF Free Size Mode ON: 12 copies/minute for A4 / 8½” x 11” sideways Power Consumption: 20 W Dimensions (W x D x H): 670 x 467 x 103 mm (26.4” x 18.4” x 4.1”) Weight: Approximately 8.6 kg (19.0 lb) 7-1 28 February 1989 2. COMPONENT LAYOUT - Mechanical Components - 6. Inverter Pawl 7. Inverter Roller 8. Transport Belt 9. Pick-up Roller 10. Feed Roller 1. Pulse Generator Disk 2. Friction Belt 3. Pick-up Lever 4. Original Table 5. Exit Roller - Electrical Components - 1. Original Set Sensor (S26) 2. Registration Sensor (S27) 3. Pulse Generator Sensor (S29) 4. Original Width Sensor (S28) 5. Pick-up Solenoid (SOL10) 6. Belt Drive Motor (M11) 7. Indicator Panel (PCB11) 7-2 8. 9. 10. 11. 12. 13. 14. Lift Switch (SW7) DF Main Board (PCB6) Feed-out Motor (M12) Inverter Solenoid (SOL12) Feed-out Sensor (S30) Original Select Switch (SW8) Feed-in Solenoid (SOL11) 28 February 1989 3. ELECTRICAL COMPONENT DESCRIPTIONS Index No. Name Function Symbol P to P Location Motors 6 Belt Drive Motor DC servomotor that drives the transport belt and feed-in system (pick-up roller, feed roller, pull-out roller and relay roller). M11 B-1 10 Feed-out Motor DC servomotor that drives the feed-out unit of the DF. M12 B-2 Energizes to press the pick-up lever against the stack of originals in preparation for original feed-in. SOL10 B-2 Solenoids Pick-up Solenoid 5 14 Feed-in Solenoid Turns on to engage the feed-in clutch so rotation is transmitted to the feed roller, pull-out rollers, and relay rollers. SOL11 B-2 11 Inverter Solenoid Energizes to invert the original when copying two sided originals. SOL12 B-2 Informs the CPU when the DF is lifted and also serves as the jam reset switch for the DF. SW7 B-4 Selects thick original mode or thin original mode. SW8 B-3 Switches Lift Switch 8 13 Original Select Switch Sensors 1 Original Set Sensor Informs copier System Control PCB that originals have been placed and causes the Insert Original indicator to turn off. S26 B-3 2 Registration Sensor Sets original stop timing and measures original length. S27 B-4 4 Original Width Sensor Determines the width of the originals. S28 B-4 3 Pulse Generator Sensor Generates pulses used to measure the original length. S29 B-3 12 Feed-out Sensor Checks for original misfeeds and sets original stop timing when in auto reverse mode. S30 B-4 7-3 28 February 1989 Index No. Symbol Name P to P Location Printed Circuit Boards 9 DF Main Board Controls all DF functions. PCB6 A-1 7 Indicator Panel Board Contains operator indicators. PCB11 B-3 7-4 28 February 1989 4. OVERALL MACHINE CONTROL Copier System Control Board RXD DF Main Board TXD CPU TXD RXD The DF CPU monitors the input signals from the sensors and switches, and directly controls the solenoids and the indicator LEDs. The belt drive motor and the inverter motor are controlled by the DF CPU through their respective driver ICs. Also, the DF CPU communicates with the copier using fiber optics. The exchanged signals are shown in the tables on the next page. 7-5 28 February 1989 1. DF –> Copier No. Signal Name 1 Original Set Definition Originals are set on the original table. Allows the copier to start copy sequence. The DF is lifted. 4 DF Misfeed Misfeed occurs in the DF. 2. Copier –> DF No. Signal Name Definition 1 Feed-in Requests the DF to feed-in the original. 2 Feed-out Requests the DF to feed-out the original. Requests the DF to invert the original. Shifts the DF to the auto feed mode. 5 Remove Original Attempting to use DF but the original from the previous copy run remains on the exposure glass. 7-6 23 May 1989 5. BASIC OPERATION 1. One-sided Original Feed When an original is inserted face up into the DF, the Insert Original indicator light turns off and the DF informs the copier CPU that originals have been set. When the Start key is pressed, the copier CPU sends the feed-in signal to the DF. On receipt of this signal, the DF energizes the pick-up solenoid, the feedin solenoid, and the belt drive motor in order to feed the bottom sheet of the original stack onto the exposure glass. The pick-up solenoid and the feed-in solenoid remain energized until the original leading edge reaches the DF registration sensor. The belt drive motor turns off shortly after the original’s trailing edge leaves the DF registration sensor. While feeding the original, the DF registration sensor and the paper width sensor check the original size. Just as the original trailing edge passes the DF registration sensor, the DF CPU sends the copy start signal to the copier. On receipt of this signal, the copier CPU starts the copy cycle. When the scanner reaches to the return position, the copier CPU sends the feed-out and the feed-in signals to the DF CPU in order to exchange the original with the next original. At this time, the scanner begins returning to the home position. When the scanner reaches the return position after scanning the last original, the copier CPU only sends the feed-out signal in order to feed-out the last original. 2. Two-sided Original Feed Unlike one-sided original feed, the back side of the original must be copied first to keep the originals and copies in the correct order. During original feed-in, the sequence is the same as for one-sided feed; however, a short time after the original trailing edge has passed the DF registration sensor, the DF CPU also energizes the inverter motor and the inverter solenoid. The belt drive motor continues to feed the original until the original leading edge passes the feed-out sensor. At this point the inverter mechanism inverts the original, in preparation for copying the back side. Then the belt drive motor reverses and the original is aligned against the left scale. The DF CPU sends the copy start signal a short time after the original trailing edge has passed the feed-out sensor. 7-7 28 February 1989 When the scanner reaches to the return position, the copier CPU sends the invert original signal to the DF CPU in order to make a copy of the front side. The original is inverted in the same way as for back side copying. 3. Semi-automatic Document Feed If a single original is inserted into the original table and copied, the DF shifts to the semi-automatic feed mode and lights the Auto Feed indicator. The Auto Feed indicator remains on for five seconds after the copier main motor stops. If another original is inserted within that five-second period, it is automatically fed and copied. 7-8 28 February 1989 6. POWER DISTRIBUTION The DF uses three dc power levels : +24 volts, +12 volts, and +5 volts. The line voltage is applied to the copier power supply board where it is stepped down and rectified to +24 volts and +5 volts. Then, those two dc voltages are supplied to the DF main board. The regulator IC on the DF main board further steps down the +24 volts to +12 volts. 7-9 28 February 1989 7. INTERFACE CIRCUIT Copier I/O Control PCB Copier System Control PCB DF Main Board The Copier System Control CPU and the DF CPU communicate via the fiber optics. The system control board changes the optical signals to electrical signals (and vice versa) for communication with the I/O control PCB. 7-10 28 February 1989 8. ORIGINAL FEED 8.1 ORIGINAL PICK-UP After setting the originals on the original table, the originals contact the feeler [A] of the original set sensor and cause the feeler to move out of the sensor. The DF then sends the original set signal to the copier CPU to inform it that the DF will be used. When the Start key is pressed, the pick-up solenoid [B] is energized. The original stack is then pressed between the pick-up lever [C] and pick-up roller [D]. The rotation of the pick-up roller advances the bottom original. 7-11 28 February 1989 8.2 ORIGINAL SEPARATION The feed roller [A] and the friction belt [B] are used to feed-in and separate the originals [C]. Only the bottom original is fed because the friction belt prevents any other originals from feeding. Original feed starts when the feed roller starts turning and advances the bottom original of the stack. The feed roller moves the original past the friction belt because the driving force of the feed roller is greater than the resistance of the friction belt. The friction belt prevents multiple feeds because the resistance of the friction belt is greater than the friction between original sheets. 7-12 28 February 1989 8.3 ORIGINAL FEED-IN MECHANISM The belt drive motor [A] drives the pick-up roller [B], the feed roller [C], the pull out roller [D], the relay roller [E], and transport belt [F] via a feed clutch and a gear train. The pick-up and feed-in solenoids are energized 100 milliseconds after the Start key of the copier is pressed. Then 100 milliseconds after the solenoids are energized, the belt drive motor starts turning. The pulse generator disc [G] turns whenever the belt drive motor is on. Slightly after the original trailing edge leaves the registration sensor [H], the relay rollers and the transport belt stop turning. 7-13 28 February 1989 This document feeder has two different ways of stopping original at the correct position on the exposure glass. They are called the “thin original mode” and the “thick original mode”. The mode used is determined by the original select switch [A]. - Original Select Switch 1. Thin Original Mode The original is stopped at the correct position on the exposure glass based on encoder pulse count. The belt drive motor stops shortly after the original trailing edge passes the DF registration sensor. (Exact timing depends on registration adjustment.) Thin original mode is selected at the factory. 2. Thick Original Mode When thick original mode is selected, the belt drive motor remains energized for an additional 30 encoder pulses as compared to thin original mode. Then, the belt drive motor pauses and reverses for 21 pulses. This forces the original against the left scale and thus aligns the edge of the original with the scale. After the exposure cycle is completed, the copier sends the feed-out signal to the DF CPU and the belt drive and feed out motors start turning. At this time, the copied original feeds out and the next original feeds in. 7-14 28 February 1989 8.4 ORIGINAL SIZE DETECTION The DF determines original size (both width and length) through the use of the original width sensor [A], registration sensor, and pulse generator sensor [B]. The original’s length is calculated by counting the number of pulses from the pulse generator while the registration sensor is on. The original width sensor is turned on when the original width is 204 mm (8”) or more. It is in the same position (front to back) as the original width sensor in the copier. Original size detection is necessary for the feed-in/feed-out timing of the DF. 7-15 28 February 1989 8.5 ORIGINAL INVERSION MECHANISM The two sided originals are inverted in the feed-out unit. 1) When the copier Start key is pressed, the two sided original is fed into the feed-in unit, passing over the DF registration sensor [A]. The feed-out motor [B] and the inverter solenoid [C] turn on 100 milliseconds after the original trailing edge passes the registration sensor. When the inverter solenoid turns on, the inverter pawls [D] rotate counterclockwise. 2) The original is passes over the exposure glass and feeds into the feed-out unit. 7-16 28 February 1989 3) The original is directed onto the exposure glass again by the inverter pawls. The belt drive motor now reverses 140 milliseconds after the feed out sensor [E] turns on. The transport belt then moves the original toward the left scale. Slightly before the original reaches the left scale, the belt drive motor drops to half speed. This is to prevent damaging the edge of the original against the left scale. When the original leading edge reaches the left scale, the belt drive motor stops. At the same time, the feed-out motor and the inverter solenoid turn off. 4) After the reverse side of the original is exposed, the belt drive motor, the feed-out motor, and the inverter solenoid turn on, and the original is fed into the inverter section. (This is the same as step “2)”.) 5) The original is fed onto the exposure glass again as in step 3 above. The front side of the original is then copied. 6) After the front side of the original has been exposed, the original is fed out from the DF. 7-17 28 February 1989 8.6 ORIGINAL FEED-OUT MECHANISM The exit rollers [A] are driven by the inverter motor [B]. When the document feeder receives the feed-out signal from the copier, the transport belt and the exit rollers start turning simultaneously. The transport belt carries the original to the inverter rollers [C] and the exit rollers finish feeding the original out. When the original trailing edge passes the feed-out sensor [D], the feed-out motor drops to half of its normal speed for 220 milliseconds and then stops. The lower speed prevents uneven stacking of originals. For A3 or ledger size originals, the feed-out motor speed does not change due to the length of the originals. 7-18 28 February 1989 8.7 BELT DRIVE MOTOR CIRCUIT A dc servomotor is used for the belt drive motor. The driver IC controls the speed of the belt drive motor. The CPU sends the speed data (programmed) to the driver IC. The driver IC sends the pulse-width-modulation (PWM) signal to the driver circuit, which sends the motor drive pulses. An encoder in the servomotor has two magnetic sensors that generate two pulse signals (phase A and B). The driver IC monitors the belt speed and direction by these pulse signals and uses this data to regulate the motor’s speed. 7-19 28 February 1989 8.8 FEED-OUT MOTOR CIRCUIT The DF CPU sends the speed data (high or low) to the driver IC and the motor drive circuit. The motor drive circuit creates the PWM signal and sends the motor drive pulses to the inverter motor. The frequency generator of the feed-out motor makes a very low voltage ac current which is fed back to the driver IC. The driver IC monitors the frequency of this ac current and based on the frequency, regulates the motor speed. 7-20 28 February 1989 8.9 INPUT AND OUTPUT CIRCUITS The above devices are directly controlled and monitored by the DF CPU. The solenoids and indicator panel are energized with +24 volts. The sensors and switches are energized with +12 volts or +5 volts. To energize a solenoid or indicator, the CPU drops the connected trigger line from +24 volts to LOW. The CPU monitors the input lines of the sensors and switch to determine when they are activated. 7-21 28 February 1989 9. LIFT MECHANISM When the document feeder is opened, the lift springs [D] provide enough force to ensure that the document feeder does not fall onto the exposure glass. When the document feeder is closed, points “A”, “B”, and “C” are aligned and no such force is provided to the document feeder. The lift switch [E] is actuated when the document feeder is closed. The copier then shifts to the document feeder mode. The lift switch also serves as the reset switch for document feeder misfeeds. When a book or thick (maximum thickness 60 mm) original is copied, the DF acts as a cover for the original as shown in the figure [F]. The lift switch is turned off during this condition, so the DF does not function. The tension of spring [G] returns the DF to the normal condition after copying a thick original. 7-22 28 February 1989 10. ORIGINAL MISFEED SENSING The registration sensor and the feed-out sensor are used for misfeed detection. 1. One sided original Registration Sensor Feed-out Sensor Belt Drive Motor Feed-out Motor If the registration sensor is not actuated within 685 milliseconds after the belt drive motor starts turning, the Original Misfeed indicator lights (ON check). If the registration sensor does not turn off within 1,250 milliseconds, the CPU determines that there has been an original misfeed (OFF check). The Original Misfeed indicator also lights if the feed-out sensor is not actuated within 1,250 milliseconds after the feed-out motor starts turning (ON check) or if the feedout sensor does not turn off within 1,250 milliseconds after the feed-out sensor is actuated (OFF check). 7-23 28 February 1989 2. Two sided original Registration Sensor (RS) Feed-out Sensor (FS) Inverter Solenoid Belt Drive Motor Feed-out Motor The registration ON/OFF check is same as for one-sided originals. The inverter motor and the inverter solenoid turn on 100 milliseconds after the registration sensor turns off. If the feed-out sensor is not actuated within 1,250 milliseconds after the feed-out motor starts turning, the Original Misfeed indicator lights (ON check). The Original Misfeed indicator also lights if the feed-out sensor does not turn off within 1,250 milliseconds after the belt drive motor reverses (OFF check). If a previous original remains on the exposure glass after manual copying and DF feed is attempted, the original misfeed indicator lights. When the DF is lifted and the previous original is removed, DF copying is permitted. 7-24 28 February 1989 11. ACCESSORY CHECK Check the accessories and their quantities according to the following list: 1. Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 pc (115V - English only / 220V Five Languages) 2. New Equipment Condition Report . . . . . . . . . . . . . . . . . . . . . . . .1 pc 3. Envelope for NECR (115V only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 pc 4. Original Feed Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 pc 5. Pan Head Screw - M4 x 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 pcs 6. Pan Head Screw with Washer - M4 x 3 . . . . . . . . . . . . . . . . . 2 pcs 7. Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 pc 8. Pan Head Screw - M5 x 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 pcs 9. Grounding Screw - M4 x 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 pc 10. Star Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 1 pc 11. Angle Stopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 1 pc 12. DF Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 pc 13. Lift Switch Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 pc 14. Shoulder Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 pcs 15. Test Sheet (A4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 pc 16. Spacer - 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 pcs 17. Spacer - 0.2 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 pcs 18. E Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 pc 19. Multilingual Decal for Jam Removal . . . . . . . . . . . . . . . . . . . . . .1 pc (220/240V only) 20. English Decal for Original Set (115V only) . . . . . . . . . . . .1 pc 21. Multilingual Decal for Original Set . . . . . . . . . . . . . . . . . . . . . . . . .1 pc (220/240V only) 7-25 28 February 1989 12. INSTALLATION PROCEDURE Install the document feeder before installing the optional sorter. This is to prevent damage to the sorter cover when installing the document feeder on the copier. 1. Unplug the power cord of the copier and turn off the main switch. 2. Remove the strips of shipping tape [A] and the red tag. (Pull the plastic spacer off the belt roller shaft.) 3. Remove the following parts: 1) Platen cover [B] (Push up the leaf spring [C] and slide the platen cover to the right). 2) Mounting stud [D] (2 pcs) 3) DF docking hole cap [E] (1 pc) 4) Rear cover [F] (4 screws) 5) Pan head screw [G] (4 screws) NOTE: Save the above parts for future use. (The platen cover is used as a mounting table for the optional editor board.) 4. Remove the ac drive board [I] (1 screw). NOTE: Do not disconnect the harnesses of the ac drive board. 7-26 28 February 1989 5. Secure the DF mounting bracket [A] (2 screws : M5 x 10) 6. Adjust the height of the DF mounting bracket [B] in the following order: 1) Set the E plate [C] (accessory) on the exposure glass [D] as illustrated and measure the clearance “a” between the DF mounting bracket [B] and the E plate tool [C] using a metal scale [E] NOTE: Make sure that the tool is placed on the exposure glass [D] and is not placed on the plastic cover in area [F]. 2) Adjust the height of the DF mounting bracket using the spacers [G] (0.2 mm and 0.5 mm) so that the clearance “a” is between 0 and 0.3 mm. NOTE: If the clearance “a” is incorrect, remove the DF mounting bracket and insert the proper spacer under the bracket. 7-27 28 February 1989 7. Install the bushing [A] into the harness hole of the DF mounting bracket. 8. Temporarily set the pins [B] of the document feeder into the left side holes of the DF mounting bracket and slide the document feeder to the left as viewed from the front of the machine. NOTE: When the optional sorter has already been installed on the copier, remove the rear sorter cover and disconnect the door safety switch connectors of the sorter. This is because the left side of the document feeder contacts the rear side sorter cover and the switch connectors when temporarily setting the document feeder on the DF mounting bracket. 9. Feed the DF harness [C] through the docking hole of the copier. CAUTION: During this step, avoid bending the fiber optics sharply as this will damage the fiber optics. 10. Lift the document feeder, then insert the document feeder pins [D] into the DF mounting holes on the right side (see illustration). 11. Secure the document feeder (2 screws [E]: M4 x 5). 12. Install the 2 shoulder screws [F] of the operation panel. 7-28 28 February 1989 13. Secure the DF ground wire [A] (1 ground screw and star washer). 14. Connect the fiber optics connector [B] (black connector) and dc harness 4P connector (white connector) [C]. 15. Reinstall the ac drive board [D] (1 screw). 16. Install the lift switch actuator [E] on the DF mounting bracket (1 screw : M4 x 6). 17. Install the angle stopper [F] (2 screws : M4 x 6). 18. Set the original table [G] as shown. 19. Reinstall the rear cover of the copier (4 screws). 7-29 28 February 1989 20. Adjust the height of the magnet catches [A] in the following order: 1) Remove the grip cover [B] (3 screws) of the document feeder. 2) Loosen the screws of the magnet catches (2 screws each). 3) Close the document feeder and tighten the screws of the magnet catches when the rubber stopper [C] contacts the exposure glass. 21. Reinstall the grip cover of the document feeder (3 screws). NOTE: Open and close the document feeder confirming secure connection of the magnet catches. 22. Confirm the original registration as follows: 1) Make a copy of the test sheet (accessory) in platen mode. 2) Set the original select switch of the document feeder to the thin mode and make a copy of the test sheet in ADF mode. 3) Compare the registration of the copy made in platen mode with that of ADF mode, and make sure that the difference is 0 ± 2.5 mm. If the difference is more than 2.5 mm, remove the ADF main PCB cover and adjust VR102 to change the original stopping timing. NOTE: Turning VR102 clockwise results in the original stopping later. 7-30 28 February 1989 4) Make a copy of the test sheet using the ADF two-sided original mode. NOTE: The position of the original select switch does not matter. 5) Compare the registration of the copy in the platen mode with that of the ADF two-sided original mode, and confirm that the difference is within 2.0 mm. If it is more than 2.0 mm, remove the ADF main PCB cover and adjust VR103 to change the original-stop timing. NOTE: a) The test sheet should stop against the left scale in the ADF two-sided original mode. b) Turning VR103 clockwise results in the original stopping later. 23 . Explain the function of the Free Size mode to the customer. When the Free Size mode (enables originals of various sizes to be fed from the same stack) is selected (by SP mode #23 [Data 1]) and the ADF mode is used, the APS mode is automatically selected. However, this can only be used if the originals have the same width. 24. Position the select switch to the thin mode (thick mode: heavier than 52 g/m 2 (14 lb)) and explain the function of this switch to the customer. 25. Place the Original Set decal [A] on the document feeder as shown. 26. Check the operation of the DF and copier system and fill out the New Equipment Condition Report. 7-31 28 February 1989 13. REPLACEMENT AND ADJUSTMENT 13.1 FEED-IN UNIT 13.1.1 Transport Belt Replacement 1. Turn off the main switch and remove the grip [A] (3 screws). 2. Remove the DF main PCB cover [B] (1 screw, 1 connector). 3. Open the entrance guide [C] and remove the transport belt assembly [D] (5 screws). 4. Remove the 2 tension springs [E] and pull off the transport belt [F]. NOTE: a) When installing the transport belt, make sure the belt lies between the belt guide spacers [G]. b) When installing the transport belt assembly, make sure the positioning pin correctly fits in the DF frame, and hold open the exit guide to prevent the mylar strip from becoming damaged. 7-32 28 February 1989 13.1.2 Feed-in Unit Removal 2. Remove the transport belt assembly. (See the Transport Belt Replacement section.) 3 . Remove the belt drive motor cover [A] (4 screws). 4. Remove the feed-in unit [B] (4 screws, 8 connectors). 7-33 28 February 1989 13.1.3 Pick-up Roller Replacement 1. Turn off the main switch. 2. Remove the feed-in unit. (See the Feed-in Unit Removal section.) 3. Remove the lower entrance guide [A] (2 screws). 4. Remove the original set sensor assembly [B] (1 screw, 1 connector). 5. Remove the pick-up roller [C] (3 E-rings, 1 bushing, 1 gear). NOTE: a) Be careful not to loose the pin [D]. b) When installing the roller, make sure the positioning pin is correctly inserted in the cut-out of the roller. c) When installing the gear, make sure the flat side of the gear is facing away from the roller. 7-34 28 February 1989 13.1.4 Feed-in Clutch Lubrication 1. Turn off the main switch. 2. Remove the original set sensor assembly. (See the Pick-up Roller Replacement section.) 3. Remove the feed-in solenoid lever spring [A]. 4. Remove the pick-up roller assembly [B] (2 E-rings, 2 bushings). 5. Disassemble and lubricate the feed clutch [C] (1 E-ring) with Mobil Temp. 78. NOTE: a) Be careful not to loose the pin [D]. b) When installing the feed clutch, make sure the positioning pin is correctly inserted in the cut-out of the clutch. 7-35 28 February 1989 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-in unit (see Feed-in Unit Removal section) without disconnecting the eight connectors. 4. Turn on the main switch. NOTE: When the main switch is turned on, the DPS101 setting on the DF main PCB must be as follows: 1 = ON 3 = OFF 2 = ON 4 = OFF This is so that the initial check sequence can take place. 7-36 28 February 1989 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 gauge [D] between the plunger and the solenoid. NOTE: Two sheets of paper (20 lb) can be used instead of a thickness gauge. 8. While holding the solenoid, press SW101 [E] on the DF main PCB to engage all DF solenoids. 9. Holding the solenoid securely, move it slowly towards the left, until the plunger is touching the thickness gauge (0.15 mm short of bottoming out). Just at this point, tighten the screw. NOTE: Make sure the pick-up lever is touching the pick-up roller during this adjustment. 10. Press SW102 [F] to turn off the solenoids. 11. Turn off DPS101-3 and 4, then turn on DPS101-1 and 2. 12. Turn off the main switch and reassemble the DF. 13. Check the original feed-in operation. 7-37 28 February 1989 13.1.6 Feed Roller Replacement 1. Turn off the main switch. 2. Remove the lower entrance guide. (See the Pick-up Roller Replacement section.) 3. Loosen the front bracket [A] (2 screws). 4. Release the feed roller shaft [B] from the front bracket (1 E-ring, 1 bearing). 5. Remove the feed roller [C] (3 E-rings, 1 side roller, 1 pull-out roller). NOTE: a) Take care not to lose the pins. b) When installing the feed roller, make sure the gear side of the roller faces the front (see illustration). c) When installing the side and pull-out rollers, make sure the pins are correctly inserted in the cut-outs of the rollers. 7-38 28 February 1989 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-in unit (see Feed-in Unit Removal section) without disconnetting the eight connectors. 4. Check that DPS101 is set for the normal mode (1 = ON, 2 = ON, 3 = OFF, 4 = OFF). 5. Turn on the main switch. 6. Turn off DPS101-1 and 2, then turn on DPS101-3 and 4 [B]. 7. Loosen the 2 screws securing the feed-in solenoid [C]. 8. Press SW101 on the DF main PCB (to engage all DF solenoids) and adjust the position of the solenoid until the gap [D] (see illustration) is within 1.0 - 2.0 mm. 9. Press SW102 on the DF main PCB to turn off all DF solenoids. 10. Turn off DPS101-3 and 4, then turn on DPS101-1 and 2. 7-39 28 February 1989 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 assembly [B] (1 screw). 4. Remove the friction belt [C] (2 springs, 1 pin). NOTE: a) When installing the friction belt assembly, make sure the friction roller [D] is set in the correct position (see illustration). b) If the seal cover becomes dirty or deformed, replace it with a new one. 7-40 28 February 1989 13.1.9 Registration Sensor and Original Width Sensor Replacement 1. Turn off the main switch and unplug the machine. 2. Remove the pick-up roller. (See the Pick-up Roller Replacement section.) 3. Remove the sensor holder plate [A] with the 2 sensors (2 screws). 4. Remove the registration sensor [B] and the original width sensor [C] (1 screw, 1 connector). NOTE: The registration sensor and the original sensor can be cleaned as follows: Open the DF and release the lower guide plate [D] of the feed-in unit by pushing the lever for misfeed removal. Then, clean the 2 sensors [E] from the cutout portion of the plastic guide plate [F]. Also, clean the black rubber seals [G] installed on the lower guide plate using a blower brush. 7-41 28 February 1989 13.1.10 Entrance Guide Plate Adjustment When the DF cover [A] or the entrance guide plate [B] is replaced, adjust the position of both the front and rear entrance guide plates as follows: 1. Adjust the clearance between the inner edge of the guide plates (see illustration) and the DF cover to 24.5 + 0.5 mm. 2. Adjust the clearance between the outer edge of the guide plates (see illustration) and the DF cover to 23.5 - 0.5 mm. 7-42 28 February 1989 13.1.11 Belt Drive Motor Speed Adjustment 1. With the main switch on, turn on DPS 101-4. 2. While holding the lift switch on manually, adjust the belt drive motor speed to within 2,570 to 2,630 rpm using VR101 [A], so that both the Insert Original indicator [B] and the Auto Feed indicator [C] go out. NOTE: a) When the Insert Original indicator lights, turn VR101 clockwise to reduce the motor speed. b) When the Auto Feed indicator lights, turn VR101 counter-clockwise to raise the motor speed. c) Confirm that both indicators remain off for approximately 5 seconds in order to steady the motor speed. d) This procedure must be performed when replacing the DF main PCB. 3. Turn off DPS 101-4. 7-43 28 February 1989 13.2 FEED-OUT UNIT 13.2.1 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 [B] (4 screws). 4. Remove the feed-out unit [C] (4 screws, 3 connectors). 7-44 28 February 1989 13.2.2 DF Main PCB Removal 1. Remove the DF angle stopper (2 screws) and stand the DF up vertically. 2. Remove the Df main PCB cover [A] (1 screw). 3. Disconnect the connector [B] of the original select switch. 4. Remove the lift and safety switch [C] (2 screws). 5. Remove the 3 screws securing the DF main PCB [D]. 6. Disconnect the optical fiber and connectors and remove the DF main PCB [D] . 7-45 28 February 1989 13.2.3 Inverter Solenoid Adjustment 1. Place several sheets of paper [A] over the exposure glass area. 2. Lower the feed-out unit (see Feed-out Unit Removal section) without disconnecting the three connectors. 3. With the main switch on, turn off DPS101-1 and 2, then turn on DPS101-3 and 4 [B]. 4. Loosen the screw securing the inverter solenoid [C]. 5. Press SW101 on the DF main PCB (to engage all DF solenoids), and adjust the position of the solenoid until the gap [D] (see illustration) is within 1.5 ± 0.5 mm. 6 . Press SW102 on the DF main PCB to turn off all DF solenoids. 7. Turn off DPS101-3 and 4, then turn on DPS101-1 and 2. 7-46 28 February 1989 13.2.4 DF Leading Edge Registration Adjustment 1. Using the DF test sheet (accessory), make a copy in the platen cover mode (A4/8½” x 11” width). 2. Confirm that the original select switch [A] is in the thin mode and again using the test sheet, make a copy in the DF mode (A4/8½” x 11” width). 3. Compare the leading edge registration of both copies, and check that the difference between the two copies is within 2.5 mm. 7-47 28 February 1989 4. If the difference is more than 2.5 mm, remove the DF main PCB cover (1 screw) and adjust VR102 on the DF main PCB [B] until the leading edge registration is within specification. NOTE: Turning VR102 clockwise results in stopping the original later (moving to the right). 5. Using the DF test sheet, make a copy in the DF two sided-original mode. (Insert the original face down.) 6. Compare the leading edge registration with that of the platen cover mode copy, and check that the difference between the two copies is within 2.0 mm. 7. If out of specification, adjust VR103 on the DF main PCB [B] until the leading edge registration is correct. NOTE: a) The test sheet stops pressed against the left scale in DF two-sided original mode. b) Turning VR103 clockwise results in the original stopping later (moving to the left) 7-48 28 February 1989 14. SERVICE TABLES FOR DF MAIN PCB 14.1 TEST POINTS NUMBER FUNCTION TP101 TP102 TP103 TP104 TP105 TP106 TP107 Factory use +5V GND Factory use +12V +24V Factory use 14.2 VARIABLE RESISTORS NUMBER VR101 VR102 VR103 VR106 FUNCTION Belt drive motor speed adjustment Original leading edge registration adjustment (one-sided original mode) Original leading edge registration adjustment (two-sided original mode) Factory use 14.3 LEDs NUMBER LED101 LED102 LED103 LED104 LED105 LED106 LED107 FUNCTION Lights when the registration sensor is activated Goes out when the original width sensor is activated Goes out when the feed-out sensor is activated Lights when the pulse generator sensor is activated Lights when the original set sensor is activated Lights when the lift sensor is turned on Goes out when the original select switch is turned on (when the thin original mode is selected) 7-49 28 February 1989 14.4 DIP SWITCHES DPS 101 -1 -2 -3 -4 1 0 0 0 Normal mode 12 cpm (Not used) 1 1 0 0 Normal mode 18 cpm (Factory Setting) 1 0 0 1 One-sided free run : SW101 - ON 0 1 0 1 Two-sided free run : SW101 - ON 0 0 1 1 Solenoid test : SW101 - solenoids ON SW102 - solenoids OFF 1 1 0 1 Motor test 1 1 1 1 All indicators ON FUNCTION 0: OFF 1: ON NOTE: a) When the main switch is turned on, the DPS101 setting must be normal, so that the initial sequence between the copier and the DF can take place. b) The lift switch must be turned on to use all functions except for the solenoid test mode. c) When utilizing the free run mode, the lift switch must be ON (close the DF unit), and the original(s) must be inserted since sensors detect the original as in normal mode. Then, actuate SW101 from the rear side of the DF (this is easier if the angle stopper is removed). 7-50 CONTENTS 2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . .8-2 3. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . .8-3 4. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . .8-4 5. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 5.1 CLEAR MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 5.2 SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 5.3 STACK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 6. EXAMPLE OF SORT MODE OPERATION . . . . . . . . . . . . . . . . . . . . .8-6 7. BIN DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 9. EXIT ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 10. ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 11. ELECTRICAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 12. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 13. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14 14. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .8-17 14.1 EXIT ROLLER AND O-RING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17 14.2 PAPER SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19 14.3 TIMING BELT TENSlON ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-20 28 February 1989 1. SPECIFICATIONS Paper Size for Bins: Maximum A3, 11” x 17” Minimum A5, 5½” x 8½” Paper Weight: 52 to 90 grams (14 to 24 lb) Number of Bins: 20 bins + proof tray Bin Capacity: Sort Mode: 30 sheets/A4 (8½” x 11”) 15 sheets/B4 (8½” x 14”) 10 sheets/A3 (11” x 17”) Stack Mode 30 sheets/A4 (8½” x 11”) 10 sheets/B4 (8½” x 14”) 10 sheets/A3 (11” x 17”) Proof Tray Capacity: 100 sheets (all sizes) Power Source: 100 V, 50/60 Hz, 0.6 A (from copier) Power Consumption: 60 W Dimensions: (W x D x H) 346 mm x 474 mm x 338 mm 13.6” x 18.7” x 13.3” Weight: 12.7 kg (28.3 lb) 8-1 28 February 1989 2. MECHANICAL COMPONENT LAYOUT 1. Exit Rollers 2. Bin Drive Wheel 3. Proof Tray 4. Bins 5. Roller Drive Belt 28 February 1989 3. ELECTRICAL COMPONENT LAYOUT 1. Paper Sensor (S31) 2. Wheel Drive Motor (M13) 3. Roller Drive Motor (M14) 4. Bin Home Position Sensor (S32) 5. Wheel Sensor (S33) 6. Sorter Control PCB (PCB10) 7. Cover Safety Switch (SW10) 8-3 28 February 1989 4. ELECTRICAL COMPONENT DESCRIPTIONS Index No. Name Function Symbol P to P Location Motors 2 Wheel Drive Motor Drives the wheel that changes the bin positions M13 H-7 3 Roller Drive Motor Drives all rollers in the sorter paper path M14 H-8 Sensors 1 Paper Sensor Misfeed detection for the sorter S31 H-8 4 Bin Home Position Sensor Detects when all bins are in the down position (home) S32 H-9 5 Wheel Sensor Detects each 1/2 turn of the wheel (1 bin changed for each 1/2 turn) S33 H-8 Detects when sorter cover is opened SW10 H-7 Controls all sorter functions. Communicates with I/O control PCB through the interface PCB PCB10 G-8 Switch 7 Cover Safety Switch Printed Circuit Board 6 Sorter Control 8-4 28 February 1989 5. BASIC OPERATION 5.1 CLEAR MODE When the main switch of the copier is turned on, the sorter automatically assumes the clear mode. It also changes to the clear mode if the sort or stack mode is recalled or if the interrupt key is pressed. In the clear mode, all copies are stacked on the proof tray. Sorter operation starts when a sheet of copy paper actuates the copier exit sensor. At this time the roller drive motor energizes. The roller drive motor deenergizes when the paper exits the copier and the paper sensor is deactuated. The paper sensor signal is sent to the copier through an interface board to check for paper misfeed. The wheel drive motor does not turn on when in the clear mode. 5.2 SORT MODE After the sort mode is selected by pressing the Sorter key, the wheel drive motor turns on to move the proof tray up. When the first sheet of paper activates the copier exit sensor, the roller drive motor turns on. Shortly after the paper sensor turns off (420 ms later), the wheel drive motor turns and advances the bins one step. When the wheel sensor is activated, the wheel drive motor turns off. 5.3 STACK MODE As in the sort mode, the roller drive motor turns on when the first sheet of paper actuates the copier exit sensor. All copies of the copy run are then fed to the first bin. When the final copy passes the paper sensor, the wheel drive motor turns on and advances the bins one step. There are no limits on the number of copies that can be entered up to the full 999 copy limit of the copier. However, the physical capacity of the bins is a good deal less. (See “Bin Capacity” in the specifications.) When all 20 bins have been used, the wheel drive motor turns on until all the bins have been lowered (including the proof tray). 8-5 28 February 1989 6. EXAMPLE OF SORT MODE OPERATION “3” copies entered/Start key pressed 3 times. - Start Key ON 1) The first copy feeds to the first bin. After the paper sensor turns off, the wheel drive motor turns on and moves the first bin up. 2) The same action as #1. 3) The third copy feeds to the third bin. The wheel drive motor does not turn on after the paper sensor turns off. (The sorter will stay at this position until auto-reset or until copying resumes.) - Start Key ON 4) The first copy is fed to the third bin. After the paper sensor turns off, the wheel drive motor turns on and moves the second bin down. 5) The same as #4. 6) The third copy is fed to the first bin. The wheel drive motor does not turn on after the paper sensor turns off. - Start Key ON 7) The first sequence (1, 2, and 3) is repeated. 8-6 28 February 1989 7. BIN DRIVE MECHANISM The bin drive mechanism moves the bins [A] up and down to receive copies under the direction of the copier CPU. The main components in this mechanism are the wheel drive motor [B], the two transfer wheels [C], the wheel sensor [D], and the bins themselves. Pins on either side of each bin are inserted into slots in the sorter side frame. The pins slide up and down in these slots. The bins rest on each other with the lower one resting on the lift bar [E]. The springs [F], on either end of the lift bar, lift it up forcing the bin pins against the transfer wheels. Plastic spacers [G] on the left end of the bins hold them apart. To move the bins up, the bin drive motor turns clockwise (as viewed from the front). A timing belt [H] turns the transfer wheels [I]. 8-7 28 February 1989 The transfer wheels have two slots in them 180 degrees apart. As the transfer wheels turn, these slots engage the pins of the bins and lift them up. Each time the transfer wheels turn 180 degrees, they raise one bin. The CPU counts the bins using the wheel sensor. A cylindrical actuator on the front transfer wheel turns the wheel sensor on and off. This actuator has two notches that are 180 degrees apart. The wheel sensor turns on each time one of the slots passes through the sensor. To move the bins down, the CPU reverses the bin drive motor and the above process reverses. The home position sensor [A] is located at the lower rear end of the sorter. When all the bins are lowered, the lift bar [B] presses down on the actuator [C], actuating the sensor. The CPU checks the sensor whenever the power is turned on. At this time, if the bins are not in the home position, the sensor will deactuate and inform the CPU to return the sorter to the home position. The mounting position is about 18.5 degrees off between the front transfer wheel [D], and the rear transfer wheel [E]. Therefore, the bin does not rise simultaneously on the front and rear. This avoids unusual noises and reduces the load. 8-8 28 February 1989 8. BINS The proof tray and the twenty bins are all basically the same. Formed out of thin flexible steel plate, they have spacers on the left end to hold them apart, and pins at the front and rear of the right end, which are inserted in guide slots in the sorter frame. On the right edge, the bins have stoppers [A] which prevent copies from sliding back into the sorter after they have been fed out. The pattern of these stoppers is different for even and odd numbered bins. Three leaf springs [B] on the underside of each bin hold the copies flat in the underlying bin. 8-9 28 February 1989 9. EXIT ROLLERS The exit roller shaft is hollow and is mounted on the transfer wheel shaft [A] (coaxial). When the copy actuates the copier’s exit sensor, the CPU sends a signal to the sorter to turn on the roller drive motor. The roller drive motor turns off at the same time as the copier main motor. 8-10 28 February 1989 10. ELECTRICAL TIMING T1: When a sheet of copy paper actuates the fusing exit sensor, the roller drive motor starts rotating. T2: 1.57 seconds after turning on the fusing exit sensor, the paper sensor turns ON. T3: 0.42 seconds after the paper sensor turns OFF, the wheel drive motor starts rotating and shifts the bin. T4: When the wheel sensor is actuated, the wheel drive motor turns OFF. T5: 0.42 seconds after the paper sensor turns OFF, the roller drive motor stops. 8-11 28 February 1989 11. ELECTRICAL CONTROL The copier I/O control PCB controls all the functions of the sorter through the interface board. The copier supplies 100 volts ac to the wheel drive motor and the SSRs. SSR 101 turns the wheel drive motor to move the bins up and SSR 102 is for the down operation. The copier supplies two dc power levels, +5 volts and +24 volts, for the dc components. Signals from the sensors and the safety switch are sent to the copier I/O control PCB through the interface board. The copier I/O control PCB operates motors and SSRs. 8-12 28 February 1989 12. ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: 1. Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 (115V - English only / 220V - Five Languages) 2. New Equipment Condition Report . . . . . . . . . . . . . . . . . . . . . . . . 1 3. Envelope for NECR (115V only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4. Thumb Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 5. Grounding Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 7. Multilingual Decal (220/240V only) . . . . . . . . . . . . . . . . . . . . . . . . 1 8-13 28 February 1989 13. INSTALLATION PROCEDURE NOTE: Install the sorter unit after the optional date printer and the document feeder have been installed. 1. Turn off the main switch and unplug the power supply cord of the copier. 2 . Remove the strips of shipping tape [A]. 3 . Remove the receiving tray [B] and rear cover [C] of the copier (4 screws). 4. Remove the 5 plastic caps [D]. 5 . Remove the front sorter cover [E] (2 screws) and rear sorter cover [F] (4 screws). 6 . Mount the sorter on the copier. Insert the two mounting studs into the docking holes, and pass the harness through the access hole. 7. Attach the sorter unit to the copier with the two thumb screws [G]. 8-14 28 February 1989 8. Connect the sorter ac harness [A] (free red 2P connector). 9. Connect the sorter dc harness [B] (white 4P connector). 10. Connect the sorter harness [C] (CN2, white 11P connector). 11. Secure the sorter ground wire [D] (1 screw and star washer). 12. Mount the sorter covers and copier rear cover. 13. Remove the sheet [E] on the left end of the operational panel, and insert the sorter key top [F] into the key hole. Then, stick on the sorter panel sheet [G]. NOTE: The sorter panel sheet and sorter key top are copier accessories. 8-15 28 February 1989 14. Remove the key cover [A] (1 screw). 15. Plug in the power cord of the copier and turn on the main switch. 16. Turn on DIP SW 1-4 under the operation panel. 17. Enter “71” in the copy counter using number keys, then press the “#” key. 18. Enter “1” in the magnification ratio indicator using number keys, then press the “#” key. 19. Turn off DIP SW 1-4 under the operation panel. 20. Install the key cover. 21. Check the sorter’s operation and fill out the New Equipment Condition Report. 8-16 28 February 1989 14. REPLACEMENT AND ADJUSTMENT 14.1 EXIT ROLLER AND O-RING REPLACEMENT 1. Remove the sorter from the copier and the sorter adapter from the sorter. 2. Remove the front and rear covers (2 screws each). 3. Remove the ground wire [A] of the upper guide plate [B] (1 screw). 4. Swing the guide plate up, then remove it by carefully pulling it up. 5. Remove the inner cover [C] (4 screws). 6. Unhook the front [D] and rear [E] pressure springs. 8-17 28 February 1989 7. Remove the wheel sensor assembly [A] (1 screw). 8. Remove the rear transfer wheel [B] (1 E-ring). NOTE: Be sure not to lose the pin [C] for the wheel. 9. Remove the pin and bushing [D]. 10. Loosen the four mounting screws [E] of the wheel drive motor [F]. 11. Lift the wheel drive motor and slip off the timing belt [G]. 12. Slide off the wheel drive shaft [H] and remove the exit roller [I] and O-ring [J] . CAUTION: Do not damage the paper sensor [K] when removing the exit roller. 13. Replace the exit roller and O-ring, then reassemble. NOTE: a) When reinstalling the wheel sensor assembly, be sure that the sensor does not touch the wheel. b) When remounting the wheel drive motor, adjust the timing belt tension. (See the section on Timing Belt Tension Adjustment.) 8-18 28 February 1989 14.2 PAPER SENSOR REPLACEMENT CAUTION: To avoid damaging the sensor, do not over-tighten the sensor mounting screw. 1. Remove the sorter from the copier. 2. Swing up the guide plate [A]. 3. Remove the inner cover [B] (4 screws). 4. Replace the paper sensor [C] (1 screw and 1 connector) and reassemble. 8-19 28 February 1989 14.3 TIMING BELT TENSION ADJUSTMENT ADJUSTMENT STANDARD: (deflection at 200 g (0.44 lb) pressure) 1. Remove the front cover. 2. Loosen the four mounting screws [A] of the wheel drive motor [B]. 3. Press the timing belt [C] with a tension gauge [D] as shown in the figure and adjust the tension by repositioning the wheel drive motor. 8-20 CONTENTS EDITOR 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1 2. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . .9-2 3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . . 9-3 4. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 5. DETECTING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 6. ERROR DETECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 6.1 INITIAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 6.2 PARITY ERROR (Communication Error) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 7. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8 8. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9 8.1 EDITOR INSTALLATION (on Platen Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9 8.2 EDITOR INSTALLATION (on EditorTable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12 9. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . .9-13 9.1 MAIN PCB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13 28 February 1989 1. SPECIFICATIONS Maximum Original Size: A3/LDG Error Tolerance: ± 2.5 mm Functions: Delete Area Mode Save Area Mode Erase Center Mode Erase Edge Mode Black in Area Mode Color in Area Mode Highlight Color Mode Centering Mode Size Size Magnification Mode Overlay Mode Dimensions: (W x D x H) 528 mm x 468 mm x 54 mm (20.8” x 18.5” x 2.2”) Weight: Approximately 2.6 Kg (5.8 lb) (including stylus and cable) Power Source: 5V 0.25A (from copier) Host Copier: FT4460 9-1 28 February 1989 2. ELECTRICAL COMPONENT LAYOUT 1. Main PCB (PCB9) 2. Stylus 3. Positioning Sheet 9-2 28 February 1989 3. ELECTRICAL COMPONENT DESCRIPTIONS PCBs Main Controls the Editor and drives the positioning sheet OTHERS Positioning Sheet Detects the stylus position Stylus Initializes detection of the position 9-3 28 February 1989 4. BASIC OPERATION There are resistors [A] (carbon sheets) in the positioning sheet aligned in the X and Y directions. When part of the positioning sheet is pressed with the stylus pen, voltage corresponding to the combination of the resistors is detected. The detected data is transmitted to the copier as the coordinate position. This detection method also applies to the mode selection pads [B]. 9-4 28 February 1989 5. DETECTING METHOD The positioning sheets consists of two carbon sheets for X and Y direction, and insulator dots located in-between the two carbon sheets. When the positioning sheet is pressed with the stylus pen, the switch in the stylus pen turns on and starts the detection of the coordinate point. Also, the upper carbon sheet contacts the lower carbon sheet at the coordinate point. Therefore, the voltage corresponding to the coordinate point is sent to the A/D converter. Coordinate Point in X Direction: The voltage of the coordinate point in the X direction is sent to the A/D converter through the Y line as the switching transistor T1 is turned ON and the voltage is applied to the X line. At this time, the switching transistor T2 should be OFF. Coordinate Point in Y Direction: By changing the ON/OFF position of the switching transistors T1 and T2, the voltage of the coordinate point in the Y direction is sent to the A/D converter through the X line. 9-5 The copier supplies +5 volts to the editor. The signals between the editor and the copier are as follows: CN No. Name Function Signal ----- 1 GND 2 Serial lnput: TXD (Copier to Editor) 3 GND 4 Serial Output: RXD (Editor to Copier) Coordinate data and mode selection data from editor. 5 Request (Editor to Copier) Request to receive data (Serial Input Signal) from copier. 6 Error (Editor to Copier) Request to receive data (Serial Input Signal) again from copier when Serial Input Signal is in error condition. 7 Reset (Copier to Editor) Resets the editor. 8 Editor Connection Connects to GND on Editor board. 9 / 10 +5V Status signal of copier ----- ----- 9-6 28 February 1989 6. ERROR DETECTION 6.1 INITIAL ERROR Short circuit and disconnection of the resistors in the positioning sheet is checked when the power is turned ON. If an error is found and coordinate data input is made with the stylus pen, the buzzer sounds for five seconds and the coordinate position at that time is not transmitted to the copier. 6.2 PARITY ERROR (Communication Error) When data transmitted from the editor or copier has an error, the serviceman call “SC94” is lit on the copier control panel. 9-7 28 February 1989 7. ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: 1. Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 (115V - English only / 220V - Five Languages) 2. New Equipment Condition Report . . . . . . . . . . . . . . . . . . . . . 1 3. Envelope for NECR(115V only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4. Grounding Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 5. Protective Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 6. Front Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 7. Rear Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 8. Sponge Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 9. Harness Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 10. Tie Wrap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 11. Pan Head Screw - M4 x 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12. Pan Head Screw - M4 x 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 13. Truss Screw - M4 x 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 14. Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 15. Multilingual Decals (220 / 240V only) . . . . . . . . . . . . . . . . . . . . 1 9-8 28 February 1989 8. INSTALLATION PROCEDURE 8.1 EDITOR INSTALLATION (on Platen Cover) 1. Turn off the main switch and unplug the machine. 2 . Remove the strips of shipping tape and check the condition of the stylus pen. 3 . Remove the platen cover [A] (lift up the leaf spring [B] and slide the platen cover to the right). 4. Close the hinge [C] of the platen cover and remove the original holder [D] from the platen cover. 5 . Apply the sponge plate [E] and the protective plates [F] as shown. 6 . Install the rear stoppers [G] to the right and left sides of the platen cover as shown (2 screws each: M4 x 6). 9-9 28 February 1989 7. Place the editor [A] on the platen cover from the operation side as shown and secure the right and left ends of the editor with the front stoppers [B] (1 screw each: truss screw - M4 x 8). 8 . Open the hinge [C] and reinstall the platen cover (with editor board) on the copier. 9 . Remove the copier rear cover [D] (4 screws). 10. Remove the docking hole cap [E] using pliers. 9-10 28 February 1989 11. Remove the ac drive board [A] (1 screw). 12. Connect the editor harness connector [B] (white, 10P). 13. Secure the 2 grounding wires [C] together (1 grounding screw). 14. Secure the editor harness with the harness clamp [D] (1 screw: M4 x 8), and the tie wrap [E]. NOTE: For 220/240V version: Place the editor harness as shown as it has a core [F]. 15. Reinstall the ac drive board (1 screw) and the copier rear cover (4 screws). 16. Check the editor operation and fill out the New Equipment Condition Report. 9-11 28 February 1989 8.2 EDITOR INSTALLATION (on Editor Table) 1. Remove the platen cover (2 screws) and set the editor on the platen cover (from the operation side). Refer to steps 2 to 7 on previous pages. 2. Reinstall the 2 studs [A], which were removed from the copier on the editor table [B]. 3 . Open the hinge [C] and install the platen cover (with editor) [D] on the editor table. Refer to steps 9 to 15 on previous pages. 4. Check the editor operation and fill out the New Equipment Condition Report. 9-12 28 February 1989 9. REPLACEMENT AND ADJUSTMENT 9.1 MAIN PCB REPLACEMENT CAUTION: Do not touch the DIP switch on the main PCB as it is factory preset. 1. Disconnect the editor connectors. 2. Remove the editor from the platen cover [A] (6 screws). 3. Remove the upper cover [B] (35 screws). NOTE: Carefully remove the upper cover as it is held down with double sided tape. 4. Remove the connectors [C]. 5. Remove the connector [D] and replace the main PCB [E] (9 screws). 9-13 SECTION 10 CONTENTS DATE PRINTER 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 2. OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 2 3. AUTOMATIC MAGNIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3 4. DATA PRINTING FUNCTION TABLE . . . . . . . . . . . . . . . . . . . . . . . .10-4 5. TIME CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5 6. ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 7. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 8. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 9. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . .10-13 9.1 BATTERY REPLACEMEN T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13 10. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14 10.1 DIP SWITCH TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14 10.1.1 Standard Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14 10.1.2 Special Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14 10.2 DATE PRINTER PROGRAM MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16 21 April 1989 1. SPECIFICATIONS Printer Display: ECD (Electro Chromic Display) 7 segments (6 digits and colon) Indicator Display: LCD (Liquid Crystal Display) 7 segments (6 digits and colon) Printing Position: Centered on leading edge of copy paper Battery: Lithium battery (3V) or dc power from copier Battery Life: More than two years Time Lag: ± 30 seconds/month (25 ± 10°C) Power Source: 3.0 V (Lithium battery) 5.0 V, 0.2 A (from copier) Dimensions: (W x D x H) 331 mm x 8.6 mm x 52.5 mm (131” x 0.34” x 2.1”) Weight: Approximately 120 g (0.27 lb) (including lithium battery) 10-1 28 February 1989 2. OUTLINE The Date Printer prints the date or time, centered on the leading edge of the copy paper. The electro chromic display (ECD) is located under the left scale, with the display portion face down on the exposure glass. When the Select key is pressed, the ECD displays the date or time (blinks). The displayed date or time is printed on the copy paper when the Start key is pressed. In date printer mode, the paper registration is advanced 15 mm to leave room on the leading edge for printing of the date or time. As a result, lead edge erase in date printer mode differs from the normal method. Also, 100% images cannot be made in date printer mode. Depending on the copy paper size, a magnification ratio from 90 to 97% is selected automatically. This leaves room on the leading edge for the printing of the date or time. 10-2 28 February 1989 3. AUTOMATIC MAGNIFICATION Date Printer Mode Full Size Mode 210 Reduction Rate (%) = 210 + 15 (A4 sideways) = 93% The following formula is used to automatically determine the copy magnification ratio. This depends on the paper size and paper feed direction. When the Start key is pressed, the reduction ratio is displayed on the magnification indicator. L Reduction ratio (%) = L + 15 NOTE: “L” = L e n g t h 10-3 28 February 1989 4. DATA PRINTING FUNCTION TABLE Printing select mode 1 Mode Name Clock display mode Time and date display (example) Hr. Min. Sec. 13 : 38 : 48 2 3 Date display mode 115V Version Month Day Year “1 18 88” Time display mode Hours Minutes “13 : 38” 220/240V Version Day Month Year “18 1 88” Select key Time and date display section Does not blink Blinks Blinks Printing Not enabled Enabled Enabled 115V Version “1 18 88” 220/240V Version “18 1 88” Printing example Hour: A 24 hour system is used to display minutes and seconds. Remarks 13 : 38 Year, month and A 24 hour system is day are displayed. used to display hours and minutes. See “NOTE”. NOTE: Depending on the DIP SW setting, the date is displayed as follows: 1) Month Day Year 1 18 88 2) Day 18 Month Year 1 88 3) Year 88 Month Day 1 18 10-4 28 February 1989 5. TIME CORRECTION Press the Set key to select the correction modes. Correct the data and time with the Select key. Set key pressing time Correction mode LCD Press Select key 1 (Seconds) 13 : 24 : “17” (Seconds blink) “00” seconds 2 (Minutes) 13 : “24” : 17 (Minutes blink) Minutes count up 3 (Hour) “13” : 25 : 05 (Hours blink) Hour counts up 4 (Day) 1 : “18” : 89 (Day blinks) Date counts up 5 (Month) “1” : 18 : 89 (Month blinks) Month counts up 6 (Year) 1 : 18 : “89” (Year blinks) Year counts up 7 Original condition 13 : 38 : 49 10-5 28 February 1989 6. ELECTRICAL TIMING CN No. Signal Name CN1-1 GND Function Ground line CN1-2 ECD Display Timing LOW to ECD Display ON HIGH to ECD Display OFF CN1-2 Print Mode When “Date” or “Time” is selected, a LOW signal is output Reset CN1-4 +5 (Vcc) CN1-5 Print Mode The mode is reset to the initial setting by the LOW signal 5 volt line SIG ECD Display Timing SIG Reset SIG NOTE: T1:When the Select key is pressed, and the “Date” or “Time” is displayed, the Print Mode signal becomes LOW. T2:When the scanner starts moving, the ECD timing signal becomes LOW to turn on ECD for approximately 1.5 seconds. T3:To initialize the Date Print mode, the reset signal (LOW) is sent from the copier and the “Time” indicator is lit. 10-6 28 February 1989 7. ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: 1. Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 (115V - English only / 220V - Five Languages) 10-7 28 February 1989 8. INSTALLATION PROCEDURE The date printer should be installed before the sorter (option), because the copier upper cover must be raised to install the date printer. 1. Turn off the copier main switch. 2. Remove the protective sheet [A] from the date printer. 3. Turn the date printer over and remove the lock pin [B] by pulling it in the direction of the arrow as shown. 4. Open the battery cover [C] and set the DIP SW for the desired sequence as shown below: 1) Month Day Year 1 18 88 2) Day 18 Month Year 1 88 Year Month Day 1 18 88 3) 10-8 28 February 1989 5. Remove the original scale [A] (2 collar screws). 6 . Remove the upper inner cover [B] (3 screws) and the operation panel [C] (4 screws). 7. Remove the 2 upper cover screws [D] in order to slightly lift up the upper cover. 8 . Install the date printer [E] (2 screws) and pass the harness [F] of the date printer to the operation panel side as shown. NOTE: To install the date printer, use the same two collar screws that were used with the original scale. 9. Secure the date printer harness to the harness clamp [G]. 10. Connect the harness connector [H] to the 5P connector on the control PCB under the operation panel. NOTE: Make sure that the harness is not in contact with the scanner wire and is not caught by the operation panel or the upper inner cover. 10-9 28 February 1989 11. Turn on the copier main switch. NOTE: If the date printer display is abnormal, reinstall the battery as follows: 1) Turn off the copier main switch. 2) Remove the date printer (2 collar screws). 3) Turn the date printer over and remove the lock pin [A] by pulling it in the direction of the arrow. 4) Open the battery cover [B] and remove the battery [C] by sliding it in the direction of the arrow. 5) Replace the battery. 10-10 28 February 1989 Select Key: - Press to select the date or time. - Press to correct the date or time in the correction mode. Set Key: - Press to enter the correction mode. 12. Set and adjust the time in the following order: then, press the Select Key to set “0” (second). Press the Set Key until the minute display blinks; then, press the Select Key to set the correct time (minute). Press the Set Key until the hour display blinks; then, 3) Hours press the Select Key to set the correct time (hour). Press the Set Key until the day display blinks; then, 4) Days press the Select Key to set the correct time (day). Press the Set Key until the month display blinks; then, 5) Month press the Select Key to set the correct time (month) Press the Set Key until the year display blinks; then, 6) Year press the Select Key to set the correct time (year). 7) Press the Set Key until the time display mode is on (not blinking) which means the time setting and adjusting is complete. 2) Minutes NOTE: When the second, minute, hour, day, month, or year displays blink, the Date Printer is still in correction mode. Make sure the entire display blinks for normal use. If the Set Key is pressed again, the correction mode is entered and the correction mode shifts in the following order each time the Set Key is pressed: position (Time display lights - not blinking) Correction mode: Press the Select Key to set the correct time when the display to be corrected is blinking. 10-11 28 February 1989 13. Do the following adjustments after installation. 1) Adjust the registration (Target: 0 ± 1 mm) using SP mode #42. 2) Place a metal scale (150 mm scale) on the exposure glass with the “0” mm side of the scale against the original scale. 3) Make 5 copies in full size mode. 4) Read the graduation of the leading edge on the copies. 5) Adjust the leading edge erase margin (Target: 2.5 ± 0.4 mm) using SP mode #41 (0.8 mm per step). 6) Check the copy quality using the date printer mode. NOTE: If the following problems appear, adjust the following items: a) No frame on the leading edge. Decrease the step number of SP #41 by one step. b) No frame on the trailing edge. Increase the step number of SP #41 by one step. c) Black line appears in front of the frame leading edge. Move the exposure glass to the left side. When a black line still appears after adjusting the exposure glass position, decrease the step number of SP Mode #42. 14. Instruct the customer as follows: 1) When using the date printer mode, the magnification modes can not be designated. The magnification of the copy automatically shifts between 90% and 97% according to the selected paper size to give enough space for the date / time copy to be printed, therefore 100% image cannot be made. Copy image Date display (Copied paper) 2) The date printer mode is canceled when the following modes are selected: 10-12 28 February 1989 9. REPLACEMENT AND ADJUSTMENT 9.1 BATTERY REPLACEMENT 1. Turn off the main switch. 2. Remove the date printer (2 screws), and turn it over. 3. Remove the lock pin [A] by pulling it in the direction of the arrow. 4. Place the date printer face down and remove the cover [B]. 5. Replace the battery [C]. NOTE: a) For easy removal, press the battery in the direction of the arrow. b) Use battery type : Matsushita BR2032. 10-13 28 February 1989 10. SERVICE TABLES 10.1 DIP SWITCH TABLES 10.1.1 Standard Mode: No. 1 2 DIP SW 3 4 5 Indicator Display x x 13 : 34 : 49 -----1 time on 1 OFF OFF OFF 2 OFF OFF OFF OFF OFF 87 5 16 OFF OFF OFF ON OFF 5 16 87 OFF OFF OFF OFF ON 16 5 87 3 OFF OFF OFF x x 13 34 Select SW 2 times on Remarks Initial setting Date Printing Mode: Year: Month : Day (100V) Month : Day : Year (115V) Day : Month : Year (220/240V) Time Print Mode (See “NOTE a”) NOTE: a) When the select switch is pressed three times, the indicator display returns to the initial setting. b) “x” = DIP SW ON/OFF position does not matter. 10.1.2 Special Mode: DIP SW 2 3 4 5 Indicator Display 1 ON OFF OFF x x 13 : 34 : 49 ------ 2 ON OFF OFF OFF OFF 87 5 16 1 time on ON OFF OFF ON OFF 5 16 87 ON OFF OFF OFF ON 16 5 87 No. 1 3 ON OFF OFF x x 13 34 4 ON OFF OFF x x - COPY - 5 ON OFF OFF x x PAGE : 25 6 ON OFF OFF x x 1 23 x x 87 5 16 7 x x ON Select SW 2 times on 3 times on 4 times on 5 times on ------ Remarks Initial setting Date Printing Mode: Year : Month : Day (100V) Month : Day : Year (115V) Day : Month : Year (220/240V) “Time” Print Mode “Copy” Print Mode “Page” Print Mode (See “NOTE b”) Special Print Mode (See “NOTE c”) ECD display turns 180 (See “NOTE d”) 10-14 28 February 1989 NOTE: a) “X” = DIP SW ON/OFF position does not matter. b) “PAGE” is printed on the copy paper and the number of pages is also printed on the side of “PAGE” and automatically shifts from 1 to 99. When the indicator display returns to the initial setting, the page number also returns to 1. c) When the select switch is pressed six times, the indicator display returns to the initial setting. The special pattern can be programmed into memory using the Program Mode (see next page). d) The indicator in the LCD located under the left scale turns 180 degrees. So, the “Date” and “Time” are printed opposite the standard mode. 10-15 21 April 1989 10.2 DATE PRINTER PROGRAM MODE The special pattern can be printed on the copy paper by programming the date printer in the following manner. A 1. Turn on DIP SW -1 and -2. F B a) Segment “A” of 6th digit blinks. E C D b) If the Select key is pressed, the segment “A” is lit and the next segment “F” blinks. If the Set key is pressed, the segment “A” is not lit and the segment “F” blinks. By the above procedure, the segments of each digit shift in the following order and allows programming of the special pattern to meet customer requirements. A –> F –> B –> G –> E –> C –> D c) After the 6th digit is completed, the segment “A” of the 5th digit blinks. Then, continue the above procedure until the 1st digit is completed. 2. Turn off DIP SW -2. (Special Mode must be selected.) 3 . Press the Select key five times to blink the special pattern. Then press the Start key to print it on the copy paper. 10-16 SECTION 11 LARGE C A P A C l T Y CONTENTS LARGE CAPACITY TRAY 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . .11-2 3. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . .11-3 4. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . .11-4 5. MECHANICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5 5.1 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5 5.2 PlCK-UP ROLLER MECHANlSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6 5.3 PAPER SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7 6. ELECTRICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8 6.1 DOWN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8 6.2 UP OPERATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8 7. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9 8. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10 8.1 LCT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10 8.2 ADJUSTING SlDE REGlSTRATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15 9. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .11-17 9.1 TRAY WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-17 9.2 TRAY DOWN SENSOR AND POSITIONING SWITCH REPLACEMENT . . . . . . . . . . .11-19 9.3 PAPER SIZE SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-21 9.4 SIDE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-22 28 February 1989 1. SPECIFICATIONS Copy Paper Size: B4 (lengthwise) A4 (lengthwise or sideways) B5 (lengthwise or sideways) 8½” x 14” (lengthwise) 8½” x 11” (lengthwise or sideways) Copy Paper Weight: 52 g to 93 g (14 Ib to 24 lb) Tray Capacity: 1,000 sheets (may vary slightly depending on paper weight) Lift Time: Maximum: Power Source: 220 V/60 Hz 220 V/50 Hz 240 V/50 Hz 115 V/60 Hz 110 V/60 Hz Power Consumption: Maximum 30 W Dimensions: (W x D x H) 410 mm x 545 mm x 220 mm 16.2” x 21.5” x 8.7” Weight: 12 kg (26.4 lb) 11-1 12 seconds (50 Hz) 10 seconds (60 Hz) 0.15 A 0.15 A 0.15 A 0.3 A 0.3 A 28 February 1989 2. MECHANICAL COMPONENT LAYOUT 1. Drive Wire 2. Drive Gears 3. Drive Pulley 4. Tray Wire 5. Lift Rods 11-2 28 February 1989 3. ELECTRICAL COMPONENT LAYOUT 1. LCT transformer (TR2) 2. LCT PCB (PCB7) 3. Ac fuse (220 V) 3. Circuit breaker (115V) (NF2) 4. LCT motor (M15) 5. LCT safety switch (SW11) 6. Tray down sensor (S34) 7. Positioning switch (SW12) 8. Paper size sensor (S35) 9. LCT operation panel (PCB12) 10. Paper end sensor (S36) 11. Upper limit sensor (S37) 11-3 28 February 1989 4. ELECTRICAL COMPONENT DESCRIPTIONS Index No. Name Function Symbol P to P Location Motor 4 LCT Motor Lifts and lowers the LCT bottom plate to bring paper to feed position and allow loading of paper. M15 A-10 A-10 Switches 5 LCT Safety Switch Disables LCT motor when covers are open. Detects when covers are opened. SW11 7 Positioning Switch Detects when paper size dial is in a standard paper size position. SW12 B-7 Detects when tray is completely down to stop tray motor. S34 Sensors Tray Down Sensor 6 B-10 8 Paper Size Sensor Determines what size paper is loaded into the LCT. S35 B-7 10 Paper End Sensor Detects paper end condition for LCT. S36 B-9 11 Upper Limit Sensor Detects the correct feed height of the stack of paper in the LCT. S37 B-9 Printed Circuit Boards 2 LCT PCB Controls LCT tray Iift interfaces LCT with copier. PCB7 A-7 to 10 9 LCT Operation Panel Contains the Down SW, Down indicator, and Open Cover indicator for the LCT. PCB12 B-9 Steps down wall voltage to 100 Vac for LCT. TR2 A-11 NF2 A-11 Transformer 1 LCT Transformer Circuit Breaker LCT Circuit Breaker Overload protection for LCT. 3 11-4 28 February 1989 5. MECHANICAL OPERATION 5.1 DRIVE MECHANISM A reversible ac motor [A] drives the LCT’s bottom plate up and down. The motor’s drive is transmitted directly to the tray drive shaft [B] via a worm gear and worm wheel. The tray wires [C] have braces on them; these braces hold the ends of the two lift rods which support the tray bottom plate. The braces on the wires raise the lift rods [D] and the tray bottom plate when the pulley turns counterclockwise, and they lower them when the pulley turns clockwise. 11-5 28 February 1989 5.2 PICK-UP ROLLER MECHANISM The pick-up roller [A] is driven by a drive gear [B] to initialize paper feed from the LCT. The paper end sensor [C] and the upper limit sensor [D] are incorporated in the LCT not the copier. The paper end sensor is used to detect paper end and the upper limit sensor detects when the tray has reached its upper limit when the tray is being raised. 11-6 28 February 1989 5.3 PAPER SIZE DETECTION The paper size dial controls side post positioning and paper size detection. When the paper size dial [A] is rotated, the cam groove [B] moves the size lever [C], which repositions the guide posts [D]. When the dial reaches a standard paper size, one of the actuator plates [E] enters the paper size sensor [F]. At the same time, the pin [G] on the leaf spring [H] drops into a notch on the inside rim of the dial and the positioning switch [I] deactuates. When the positioning switch opens, the scan signal is applied to the LCT paper size sensor. The paper size sensor then reads the pattern of the actuator plate and sends paper size data to the copier’s CPU. When the paper size dial is positioned at a non-standard paper size, the positioning switch is actuated (closed). In this case, the LCT cannot be used; the Load Paper indicator lights and no paper size is displayed on the operation panel. This prevents the skewing that would occur if the guide posts were not at the correct position. 11-7 28 February 1989 6. ELECTRICAL OPERATION 6.1 DOWN OPERATION The bottom plate moves down only when the Down key is pressed or paper end occurs. When the Down key is pressed, the flip-flop changes state (all outputs change from LOW to HIGH or vice versa). Then, three things happen simultaneously: (1) The gate circuit turns off, preventing size data from being sent to the copier; (2) The timer circuit turns on, causing the LED in the down key to blink; and (3) SSR1 turns on, energizing the drive motor to move the tray down. The down sensor is actuated when the bottom plate is fully lowered. This causes the flip-flop to change back to its original state, which turns off SSR1 and resets the timer circuit. The LED in the Down key stays continuously on. 6.2 UP OPERATION Opening and closing the upper or side LCT cover while the bottom plate is in the down position starts the up operation. This causes the gate circuit to send paper size data to the copier. At the same time the cover safety switch changes the state of the flip-flop and the flip-flop energizes SSR2, which turns on the drive motor to move the tray up. The drive motor stays on until the paper pushes up the pick-up roller. The actuator on the pick-up roller bracket then moves out of the upper limit sensor; this again changes the flip-flop’s state and the motor stops. The cover safety switch prevents operation if the cover is open by cutting off the ac 100 volt line. 11-8 28 February 1989 7. ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: 1. Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 (115V - English only / 220V - Five Languages) 2. New Equipment Condition Report . . . . . . . . . . . . . . . . . . . . . . . . 1 3. Envelope for NECR (115V only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4. Pick-up Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 5. Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 6. Screw (M4 x 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 7. Screw (M4 x 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 8. Grounding screw (M4 x 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 9. LCT Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 “A” type bracket: For 3rd paper feed station . . . . . . . . (2) of FT4460 “B” type bracket: (For other model) . . . . . . . . . . . . . . . . . . . . . (2) “C” type bracket: (For other model) . . . . . . . . . . . . . . . . . . . . . (2) 10. Harness Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 11. Caution Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 (115V - English and French, 220V/240V - English and German) 12. Multilingual Decals (220V/240V only) . . . . . . . . . . . . . . . . . . . . 5 11-9 28 February 1989 8. INSTALLATION PROCEDURE 8.1 LCT INSTALLATION 1. Turn off the copier main switch and unplug the copier power cord. 2. Remove the strips of shipping tape [A]. 3. Lift the copier and remove the cover plate [B] on the right side of the system table (2 screws), and then reposition the copier on the table. NOTE: If the system does not contain the special system table, move the copier to the right so that the Large Capacity Tray can overhang the end of the table as shown. 11-10 28 February 1989 4. Mount “A’’ type brackets [A] (2 screws each). NOTE: Use “A” type brackets when installing the LCT to the third paper feed station. 5 . Remove the copier rear cover [B] (4 screws). 6 . Open the manual feed table and the front cover, and remove the right cover [C] (6 screws). 7. Remove the 3rd cassette arm assembly [D] (4 screws). 8 . Move the sub roller unit [E] and the third feed roller [F] to the left (1 stud screw) as shown. CAUTION: Be careful not to peel off the mylar [G]. 9. Remove the nylon hub [H] and the snap ring [I]. 10. Reinstall the right cover. 11-11 28 February 1989 11. Press the pad positioning plate [A] down and unhook the spring [B] using a small screwdriver. 12. Place the large capacity tray [C] in the cassette holder on the third paper feed station. NOTE: Make sure that the rib of the tray side plate fits into the groove on the cassette holder. 13. Open the side and top covers and secure the tray to the third paper feed station (2 screws). 14. Install the pick-up roller assembly [D] and the gear [E] on the 3rd feed roller shaft. 15. Now move the sub roller unit [F] and the third feed roller [G] to the right and reinstall them (1 stud screw) while holding the friction pad down. CAUTION: Make sure that the paper position feeler [H] is positioned under the sensor actuator [I]. 11-12 21 April 1989 16. Remove the harness hole plate [A] (1 screw) and pass the tray harness through the harness hole [B]. 17. Disconnect CN508 and CN507 on the paper feed PCB [C]. 18. Connect the tray harness to the paper feed PCB [C] as follows: 3P red connector [D] to CN508 4P white connector [E] to CN510 7P white connector [F] to CN507 19. For 240 volt areas only: Remove the rear cover of the LCT (5 screws), disconnect the 220V connector [G] and connect the 240V connector [H] as shown, and then reinstall the rear cover of the LCT. 11-13 21 April 1989 20. Reinstall the rear cover of the copier. 21. Apply the caution decal [A] on the copier rear cover. 22. Plug in the machine and turn on the copier main switch. 23. Select Feed station priority at power on, using SP#20. Data 0 –> LCT priority Data 1 –> Cassette from 1st feed station 24. Check the LCT operation and fill out the New Equipment Condition Report. 11-14 28 February 1989 8.2 ADJUSTING SIDE REGISTRATION After installing the large capacity tray, confirm the side registration of the large capacity tray. The side-to-side registration of A4 sideways (LT sideways) copies should be the same as that of the first cassette. If the side registration is incorrect, adjust it as follows: 1. Load 2 or 3 sheets of paper on the tray [A] and position the paper size dial [B] to A4 sideways (LT sideways). NOTE: Do not move the paper size dial while adjusting the side registration. 2. Turn on the copier main switch and raise the tray to the paper feed position. 3 . Turn off the copier main switch. 4. Remove the front inner cover [C] (2 screws) using a stubby screwdriver. NOTE: Insert the chain [D] into the middle slot of the front inner cover as shown and remove the front inner cover while turning it. 5. Mark the current position of the side guide [E] on the plastic top cover using a pencil or tape. NOTE: Be careful not scratch the top cover. 11-15 28 February 1989 6. Loosen the shaft mounting plate [A] (1 screw). 7. Loosen the shaft bracket [B] (2 screws). CAUTION: Don’t remove the 2 screws. Be careful not to damage the heads of the screws as the screws are not visible. 8. Slide the front [C] and rear [D] side guide plates at the same time by making reference to the difference of the side registration on the copies and the mark on the top cover. (Adjusting range ± 4 mm.) CAUTION: Hold the gear 28T [E] so that the gear 28T [E] does not turn. 9. Mount the shaft bracket [B] (2 screws) and make copies to confirm the registration. NOTE: If there is still a side registration gap, readjust the position of the front [C] and rear [D] side guide plates. 10. Reinstall all parts. 11-16 28 February 1989 9. REPLACEMENT AND ADJUSTMENT 9.1 TRAY WIRE REPLACEMENT CAUTION: Unplug the tray power supply cord. - Front Wire 1. Remove the following parts: a) Front cover (2 screws and 1 connector) b) Nylon clamp holding the operation board harness (1 screw) - Rear Wire 1. Remove the LCT from the copier. 2. Remove the following parts: a) Rear cover (5 screws) b) Transformer assembly [A] with tray main board [B] (1 screw, 8 connectors, and 1 nylon clamp) c) Drive motor assembly [C] (2 screws and 1 connector) d) Ac power terminal [D] (2 screws and 1 ground wire) e) Safety switch assembly [E] (2 short screws) f) Safety switch actuator assembly [F] (2 E-rings) g) Shield plate [G] (4 screws) 11-17 28 February 1989 - Common Procedure for Front and Rear Wires NOTE: The wrapping directions for the front and rear wires are opposite. 1. Loosen the wire tightener [A] (1 screw). 2. Insert the bead [B] (unmarked) into the rear slot of the drive pulley. 3. Loop the wire around the drive pulley [C], as shown (one and a half turns). 4. Run the wire over WP1, WP2, WP3, and WP4 in turn while also placing the lift rod’s ends in the braces. 5. Insert the bead [D] (red) into the other slot of the drive pulley. 6. Loop the wire around the drive pulley, as shown (two and a half turns). 7. Hook the wire on the tightener pulley [E]. 8. Move the rods up and down manually to ensure that the drive wire does not overlap on the pulley. 9. Tighten the wire using the tightener (1 screw). 10. Reassemble. 11-18 28 February 1989 9.2 TRAY DOWN SENSOR AND POSITIONING SWITCH REPLACEMENT 1. Open the side cover (1 screw). 2. Remove the top cover and rear cover (5 screws). 3 . Remove the sensor bracket [A] (2 screws). (There is no need to disconnect the sensor connector.) 4. Remove the two post tops [B] (3 screws each). 5. Remove the tray bottom plate [C] (4 screws) taking care not to damage the 6 guide posts [D]. 6. Move the tray drive motor assembly [E] (2 screws) to the rear to disengage the tray drive shaft [F] from the wire drive pulley [G]. 11-19 28 February 1989 7. Raise the lift rods [A]. 8. Remove the front inner cover [B] (1 short and 1 long screw). 9. Replace the tray down sensor [C] (1 screw and connector). 10. Rotate the paper size dial to a smaller size, such as A4R, and remove the positioning switch bracket [D] (1 screw). 11. Replace the positioning switch (2 screws). 11-20 28 February 1989 9.3 PAPER SIZE SENSOR REPLACEMENT 1. Perform steps “1” to “8” of the Tray Down Sensor and Positioning Switch Replacement procedure. 2. Remove the front guide post [A] (1 screw and 1 hook). 3. Remove the paper size sensor bracket [B] (1 screw). 4. Replace the paper size sensor [C] (1 screw and 1 connector). NOTE: When installing the sensor bracket, make sure that the harness is positioned inside the sensor bracket. 11-21 28 February 1989 9.4 SIDE REGISTRATION ADJUSTMENT NOTE: Do not move the paper size dial while performing this adjustment. 1. Perform steps “1” to “8” of the Tray Down Sensor Replacement procedure. 2. Loosen the 2 screws securing the pinion bracket [A]. 3 . Loosen the screw securing the guide post lock plate [B]. 4. Move the pinion bracket while holding the pinion so that the pinion does not turn. (The front and rear guide posts must be equidistant from the center.) 5. Tighten the screws securing the pinion bracket. 6. Tighten the screws securing the guide post lock plates. 7. Confirm that the side registration is adjusted correctly and reassemble. 11-22 SECTION 12 CONTENTS TROUBLESHOOTING 1. COPY QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1 1.1 BLANK COPY (WHITE COPY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1 1.2 DIRTY BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4 1.3 UNEVEN IMAGE DENSITY - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7 1.4 UNEVEN lMAGE DENSlTY - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8 1.5 VERTICAL BLACK BANDS - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-9 1.6 VERTICAL BLACK LINES - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10 1.7 VERTICAL WHITE LINES OR BANDS - 1 (Dull or Blurred) . . . . . . . . . . . . . . . . . . . . .12-11 1.8 VERTlCAL WHlTE LlNES - 2 (Half Tone Images) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12 1.9 VERTlCAL WHlTE LlNES - 3 (Smeared Image) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 1.10 VERTICAL WHITE LINES OR BANDS - 4 (Thin, Distinct) . . . . . . . . . . . . . . . . . . . . .12-14 1.11 HORIZONTAL BLACK LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-15 1.12 JITTER - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-17 1.13 JITTER - 2 (Irregular) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-18 1.14 MARKS AT 251MM INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-19 1.15 SKEWED (OPTICAL) COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-20 1.16 BLACK SPOTS ON THE COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-21 1.17 TONER DENSITY TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-22 1.18 TONER DENSITY TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-24 1.19 UNFUSED COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-26 1.20 OPTICS UNIT CONTROL FAILURE - 1 (Initialization) . . . . . . . . . . . . . . . . . . . . . . . .12-28 1.21 OPTICS UNIT CONTROL FAILURE - 2 (Copy Cycle) . . . . . . . . . . . . . . . . . . . . . . . .12-29 1.22 SIDE REGISTRATION MALFUNCTION lN DUPLEX/OVERLAY COPY MODE . . . .12-30 2. SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-32 2.1 CODE #11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-32 2.2 CODE #12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-33 2.3 CODE #21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-34 2.4 CODE #22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-34 2.5 CODE #23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-35 2.6 CODE #24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-35 2.7 CODES #25 AND #2E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-36 2.8 CODE#2A AND #2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-37 2.9 CODE #28 AND #29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-38 2.10 CODE #41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-39 2.11 CODE #53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-40 2.12 CODE #54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-40 2.13 CODE #55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-41 2.14 CODE #61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-41 2.15 CODE #81 AND #82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-42 2.16 CODE #91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-43 2.17 CODE #92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-43 2.18 CODE #93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-44 2.19 CODE #94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-44 2.20 CALL SERVICE CONDITION #95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-45 3. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-46 3.1 ID SENSOR MALFUNCTION (Color Copy Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-46 3.2 LOW lMAGE DENSITY (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-47 3.3 SORTER PAPER STACKING PROBLEM (A3/LDG Tracing Paper) . . . . . . . . . . . . . . .12-48 3.4 DIRTY BACKGROUND (Blue Development Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-48 3.5 PAPER CREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-49 4. ELECTRICAL COMPONENT DEFECTS . . . . . . . . . . . . . . . . . . . . . . 12-50 4.1 PAPER END SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-50 4.2 MANUAL FEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-50 4.3 1ST CASSETTE LlFT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-50 4.4 REGISTRATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-51 4.5 FUSING EXIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-51 4.6 INVERTOR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-51 4.7 INVERTER RELAY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-52 4.8 COLOR TONER END SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-52 4.9 PULSE GENERATOR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-52 4.10 1ST SCANNER HOME POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-53 4.11 LENS HOME POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-53 4.12 3RD SCANNER HOME POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-53 4.13 FRONT COVER SAFETY SWlTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-54 4.14 THERMOFUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-54 4.15 FUSING THERMISTO R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-54 4.16 DC POWER SUPPLY FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-55 4.17 SHORT CIRCUIT lN DC 5V LlNE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-55 5. CAUTIONS FOR USERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-56 5.1 PICK-OFF PAWL TRACES (Overlay mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-56 5.2 CREASING DURING FUSING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-56 5.3 OHP MISFEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-57 5.4 PHOTO MODE lD LEVEL SETTlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-57 5.5 INCOMPLETE IMAGE TRANSFER AT TRAILING EDGE . . . . . . . . . . . . . . . . . . . . . . .12-57 5.6 LOW IMAGE DENSITY WITH RED ORIGINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-58 5.7 LOW ID LEVEL WITH MULTIPLE SOLID COLOR COPIES . . . . . . . . . . . . . . . . . . . . .12-58 5.8 MODES CLEARED WHEN FRONT COVER OPENED . . . . . . . . . . . . . . . . . . . . . . . .12-58 5.9 INADEQUATE FUSING OF UNEVEN COPY SURFACE . . . . . . . . . . . . . . . . . . . . . . .12-59 5.10 GAP OR OVERLAPS IN OVERLAY COPYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-59 5.11 MULTIPLE PASSES THROUGH FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-59 5.12 PAPER EXIT ROLLER MARKS ON DIRECT IMAGE MASTERS (C & P) . . . . . . . . . .12-60 28 February 1989 1. COPY QUALITY 1.1 BLANK COPY (WHITE COPY) - Phenomenon White or almost white copy - Possible Causes 1. Charge is not applied. This is the result of a CC/TC bias power pack (charge) failure, poor contact of the lead wire, a broken charge corona wire, or a leak in the insulator or endblock. 2. Copy image is not transferred to the paper. This is the result of a CC/TC bias power pack (transfer) failure, poor contact of the lead wire, poor contact of transfer/separation charger casings, a broken transfer charge wire, or a leak in the insulator or endblocks. 3 . Copy image grid gives no output. 4. Development roller does not turn due to binding caused by a broken drive gear. 5. Correct bias voltage is not applied. If the bias terminal is not connected properly, the development roller will be electrically grounded. As a result, the charge on the development roller will be equal to the drum surface level resulting in poor development (blank when copying solid black originals). 6 . The sensitivity of the drum has changed Exposure to fluorescent light or direct sunlight for long periods of time will destroy the ability of the drum to accept a charge. If there is no charge remaining on the drum surface, copies will be blank. Exposure to ammonia gas or fumes for long periods will also destroy the ability of the drum to accept a charge. 12-1 28 February 1989 - Actions - 1. 2. 3. No charge or transfer No grid output (1) Make sure that the charge corona unit and transfer corona unit have been installed correctly. (2) Check for a broken charge wire or a leak in the insulator or endblocks. Replace any defective parts. (3) Check the trigger signals at: CN302-A5 (Charge) 24V –> 0 (Low) CN302-B7 (Grid) 10V –> 0 CN302-B4 (Transfer) 24V –> 0 (CN302-A4 if second side of duplex/overlay) CN302-B1 (Bias) 0 –> 5V pulse If the voltage does not change, replace the I/O control board and/or the system control board. If the voltage changes correctly, replace the CC/TC bias power pack. (4) Check the voltage between pins 1 and 2 of CN1 (15p) on the power pack (with main power ON). If the voltage is +24V, replace the CC/TC bias power pack. If the voltage is 0V, check FU3 of the power supply unit. If FU3 is defective, replace it. If FU3 is OK, replace the DC power supply unit. 4. Check whether the development roller turns during the copy process. If it does not turn, take out the development unit and manually operate it to see the roller turning and detect any breakage of the gears. See if the development drive gear (on main body) is worn out. 5 . Check the development bias voltage during the copy process. If it is not at the correct level, check the contact of the bias terminal and then the output of CN302-B1. If a +5V pulse is applied, replace the CC/TC bias power pack If the voltage is 0V, replace the I/O control board. (See step 3.) 12-2 28 February 1989 6. (1) Leave the drum in darkness so that it regains sensitivity. However, if the drum cannot regain sensitivity due to excess exposure to fluorescent light or direct sunlight, it must be replaced. (2) If the surface integrity of the drum has been destroyed by ammonia, replace the drum, and instruct the user to move the copier away from the sourse of ammonia fumes. NOTES: 1. After replacing the drum, perform initialization (SP Mode No. 66). 2. To check the bias, turn on the front cover safety switch and measure the voltage between the development roller shaft and the sheath. 12-3 28 February 1989 1.2 DIRTY BACKGROUND - Phenomena 1. The background is dirty at image density level 4 (manual setting). 2 . When newspapers are copied, the background is dirty even at level 7. 3 . ADS copies have a dirty background. - Possible Causes 1. Dirty optics The optics fan brings in dust from outside the copier; this adheres to the exposure glass and mirrors. Dirty optics can sometimes be detected by increasing the magnification; this changes the position of the background pattern. (For details, see the paragraph on uneven inage density.) The following parts of the optics unit are most likely to become dirty: (1) Toner shield glass (toner) (2) Exposure glass and the mirrors 1 to 6. 2 . Toner density is too high. (For details, refer to the troubleshooting section.) If the toner density is too high, toner scatters inside the copier, getting on the toner shield glass, PTL, ID sensor, charge corona wire, and transfer corona wire. 3. The mylar strips or the side seals have been stripped off the development unit (side seals, inlet seals). If seals have been damaged or removed, toner will scatter. 4. The exposure lamp intensity is too weak. This may be caused by deterioration of the exposure lamp or low lamp regulator output voltage. 5. The doctor gap is too wide. If the doctor gap is too wide (standard value: black toner: 0.6 + 0.1 mm), the background will be dirty. With solid copies, the carrier may sometimes adhere to the drum. 6. Defective or deteriorated drum (1) The sensitivity of the drum is deteriorated. (2) The drum may not be properly grounded. The drum stay may be deformed and as a result have a poor connection with the bearing on the drum knob. 12-4 28 February 1989 7. In ADS Mode, VDE (reflected light from white original) is too high. 8. The ADS optical fiber is cut or bent. - Actions 1. Dirty optics. (1) Wipe the toner shield glass with a soft dry cloth. (2) Clean the exposure glass and mirrors 1 to 5. If necessary, clean the 6th mirror and both erase filters. In addition, clean the charge corona unit (charge wire, grid, casings), and set the lamp voltage to give proper exposure. 2. When the cover of the transfer corona end block is dirty, toner density increases; this results in scattering. (For details, see section 18). 3 . Check the mylar strip and side seals on the development unit. 4. Check the exposure lamp and replace if deteriorated. If the exposure lamp has no defects, adjust the exposure lamp voltage (SP Mode No. 48) and ADS (SP Mode No. 58). NOTE: Set the exposure lamp voltage so that level 2 of the OS-A-3 test chart is slightly visible at ID level 4 (manual ID selection). Then adjust the ADS. (1) Set ID level 4. (2) Adjust ADS to 3 ± 0.1V by turning VR101 in SP Mode No.56. (3) Set ADS standard memory in SP Mode No.56. Press the Start key in SP Mode No.56 and perform at least five scans. (Stop by pressing the Clear/Stop key.) 5. If the developer adheres to the copy image, perform the following. (Note that toner can also adhere to the image when the toner density is too low.) (1) Remove the developer from the development unit. (2) Adjust the doctor gap. (3) Put new developer in the development unit and condition the mixture (SP Mode No.65). 12-5 28 February 1989 6. Defective or deteriorated drum. (1) With a deteriorated drum, check the Vr correction level. NOTE: If the Vr correction rate is less than 37%, Vr correction is no longer effective and the drum must be replaced. (2) Correct the deformation of the drum holder. 7. Set the standard value (3V + 0.1V) for Vde with SP Mode No.58 and set the ADS memory value with SP Mode No.56. 8. Replace the ADS optical fiber and perform SP Mode No.58 and No.56. 12-6 28 February 1989 1.3 UNEVEN IMAGE DENSITY - 1 - Phenomena 1. Uneven image density appears on solid black copies. 2. Areas where the image density is uneven do not move when the reproduction ratio is changed. - Possible Cause Uneven charge on the drum (1) Dirty charge corona wires or grid (2) Uneven height of charge corona wires (3) Slack in the grid Uneven image density with a solid black copy is usually caused by a dirty transfer corona wire. Uneven image density with a halftone image is usually caused by a dirty charge corona wire. - Actions 1. Clean the charge corona wire and grid. 2. Check that the charge corona wire is not caught on the wire cleaner. If it is not, adjust the wire height at the front. The standard height is 9 mm from the grid. NOTE: For fine adjustment, adjust the drum current with the drum shoe. 3. Check the tension of the grid tension spring. 12-7 28 February 1989 1.4 UNEVEN IMAGE DENSITY - 2 - Phenomena 1. Uneven image density appears in the copy background, but not in the solid black area. 2. Areas where the image density is uneven move when the reproduction ratio is changed. - Possible Causes 1. The size of the dirty area can be used to determine which optics unit components are dirty. Refer to illustrations (1) and (2) below. (2) (1) Exposure Glass, Reflector 4th Mirror, 5th Mirror 1st Mirror, 2nd Mirror 6th Mirror, Red/Green Filter 3rd Toner Mirror Shield Glass NOTE: If the uneven area does not move when the reproduction ratio is changed, the problem is not with the optics unit. 2. Deterioration of the exposure lamp or an incorrectly aligned filament. - Actions 1. Clean the optics unit Clean the mirrors, lens, and reflector with a cloth. Clean the exposure glass with water or alcohol. Clean the toner shield glass with a dry cloth or one dipped in alcohol. Clean red erase filters with a blower brush (replace when fogged or scratched). 2. Check the exposure lamp. If the lamp is not discolored, adjust the exposure lamp position. (See the section on exposure lamp adjustment.) NOTE: After cleaning the mirrors or the exposure glass, adjust the ADS and the exposure lamp voltage to achieve the proper image. 12-8 28 February 1989 1.5 VERTICAL BLACK BANDS - 1 - Phenomenon Vertical black bands on the copy (paper feed direction). - Possible Causes 1. The inlet seal (mylar strip) on the development unit is defective; toner scatters and coats the toner shield glass. 2 . Optics unit components are dirty. 3. The cleaning brush bristles are crushed or contaminated with foreign substances. 4. The cleaning blade is dirty or damaged. 5. Toner density is too high. - Actions NOTE: See if the black bands shift when the reproduction ratio is changed. If so, the problem is in the optics unit. 1. Check and replace the inlet seal if defective; then, clean the toner shield glass. 2. Clean the optic unit components. 3 . Replace the cleaning brush. 4. Press the blade release lever two or three times to clean the edge of the cleaning blade. If this doesn’t correct the problem, replace the blade. 5. See section 1.16 (TONER DENSITY TOO HIGH). NOTE: A deteriorated exposure lamp can also cause black bands on the copy. A slack filament can cause dirty black bands. 12-9 28 February 1989 1.6 VERTICAL BLACK LINES - 2 - Phenomenon Thin black lines on the copy - Possible Causes 1. Scratched drum 2. Scratched hot roller 3. Dirty or scratched exposure glass. 4. Glue from labels sticks to the drum suface, causing toner build-up. 5. Scratched cleaning blade - Actions 1. Check the drum. Sometimes an accumulation of toner particles behind the development seal pushes it against the drum, scratching the drum surface. Adjust the doctor gap. 2 . Confirm that the line was caused by a scratched hot roller. This can be determined by stopping the copy on the transport unit and seeing if the same line appears. 3. Clean or replace the exposure glass. 4. Check the drum for toner buildup. Wipe the drum with a dry cloth. 5. Black lines of toner left on the drum are often caused by a scratched cleaning blade. Check the blade and, if damaged, replace both the blade cleaner and the blade. If this doesn’t correct the problem, replace the drum. (After replacing the drum, set SP Mode No.66 and make at least five copies.) 12-10 28 February 1989 1.7 VERTICAL WHITE LINES OR BANDS - 1 (Dull or Blurred) - Phenomenon Dull or blurred white lines appear on the copy. - Possible Causes 1. Dirty or deteriorated charge corona wire or burrs on the charge or transfer casings. White Line 2. Dirty or deformed grid. 3. The inlet seal on the development unit is damp or is contaminated with oil. - Actions 1. Clean the charge corona wire and/or transfer corona wire. Check the charge and transfer casings for burrs or other defects. Clean the charge corona cleaner, or, if seriously deformed (heat), replace the cleaner. 2. Clean or replace the grid. 3 . Replace the black or color development unit inlet seal. NOTE: A deteriorated charge wire may also cause thin, distinct white lines. 12-11 28 February 1989 1.8 VERTICAL WHITE LINES - 2 (Half Tone Images) - Phenomenon Blurred white lines appear on half tone images. - Possible Cause The light intensity of the exposure lamp is too strong. - Action Adjust the position of the exposure lamp. (See the section on exposure lamp position adjustment.) 12-12 28 February 1989 1.9 VERTICAL WHITE LINES - 3 (Smeared Image) - Phenomenon Objects rubbing against the image on the drum or paper surface (prior to fusing) cause fuzzy white lines on the copy image. - Possible Causes 1. Deformation of PTL filter 2. Deformation of ID sensor board 3. Deformation of transfer guide 4. Incorrectly positioned cleaning blade scraper - Action Check each of the items listed above. Repair, reposition, or replace the part causing the problem. 12-13 28 February 1989 1.10 VERTICAL WHITE LINES OR BANDS - 4 (Thin, Distinct) - Phenomenon Thin, distinct white lines - Possible Cause Scratched drum - Actions Replace the drum. Find out what caused the scratches on the drum and correct the problem. 1. Paper jam? 2. Pick-off pawls pushing too hard against the drum? 3 . Deformed ID sensor board? 4. Deformed transfer guide? 5. Foreign substances on cleaning brush? 6 . Blade cleaner positioned incorrectly? 12-14 28 February 1989 1.11 HORIZONTAL BLACK LINES - Phenomenon Black lines perpendicular to the paper feed direction appear on the copy image. - Possible Causes 1. Drum is scratched. 2. Hot roller is scratched. 3 . Blade presses so hard that toner sticks to the drum surface. For cause 1, 2 and 3, measure the distance between the horizontal black lines. If black lines appear at 251 mm intervals, the cause is a scratched drum or toner build up. If the black lines are at 125 mm intervals, the cause is a scratched hot roller. 4. If there are no scratches on the drum surface : (1) Due to insufficient cleaning, a sticky foreign substance may be attached to the blade, causing toner to attach to the drum suface when the drum stops. Things to look for: The black lines appear at the same location on copies from different single copy runs, regardless of the feed station that is used. Black lines appear regardless of color mode, paper size, or magnification ratio. Black lines do not appear in APS mode. (2) When the trailing edge of the paper is separated from the drum surface, a charge is transterred to the drum surface. The charged area is redeveloped in the cleaning unit and appears as a horizontal black line on the copy. Things to look for: Black lines appear beginning with the second copy in multicopy mode. • Black lines appear in a fixed location, regardless of paper size. • Black lines appear regardless of color mode, paper size, or magnification ratio. 12-15 28 February 1989 5. The development roller is shorted to ground. - Actions 1. 2. 3. Replace the drum or hot roller if scratched. 4. (1) a. Clean (dry cloth) or replace the drum. b. Clean or replace the cleaning blade. (2) a. Clean the cleaning blade and brush. b. If cleaning the blade or brush does not solve the problem or if the problem reoccurs, replace both the cleaning blade and brush. 5. Check the development bias. NOTE: After replacing the drum, perform SP Mode No.66. 12-16 28 February 1989 1.12 JITTER - 1 - Phenomenon Jitter appears at 94mm intervals on the copy. (The length of the interval is determined by the diameter of the optics unit drive pulley--30 mm.) - Possible Causes 1. Irregular rotation speed of scanner drive motor. 2. The optics drive pulley is defective, or it has burrs or scratches on its surface. - Actions 1. Replace the scanner drive motor. (See the section on scanner motor motor replacement.) 2. Replace the pulley. 12-17 28 February 1989 1.13 JITTER - 2 (Irregular) - Phenomenon Jitter appears at irregular intervals, especially with enlargement copies. - Possible Causes 1. There is a DC power surge in the +24V scanner drive line, and this changes the scanner drive motor speed. 2. Overload of the scanner caused by worn out sliders, an uneven slider unit guide rail surface, or incorrect adjustment of the drive wire tension. - Actions 1. Check the system control board, DC power supply, and scanner drive motor; replace if defective. 2. Check the sliding load on the scanner, the scanner drive wire tension, and the position of the wire clamps; adjust if necessary. Also, check the scanner sliders and replace if worn out. 12-18 28 February 1989 1.14 MARKS AT 251 MM INTERVALS - Phenomenon Imperfections in the copy image appear at 251 mm intervals. - Possible Causes 1. Scratches or areas of reduced sensitivity on the drum (Drum diameter: 80 mm). 2. If a positive image remains at 251 mm intervals, a dirty quenching lamp filter or a defective quenching lamp may be the problem. - Actions 1. Replace the drum. (Set SP Mode No. 66 to initialize the drum.) 2. Clean the quenching lamp filter and/or replace the quenching lamp. 12-19 28 February 1989 1.15 SKEWED (OPTICAL) COPY IMAGE - Phenomena 1. The copy image is skewed (parallelogram shape). 2. The sides of the copy image are straight, but the leading and trailing edges are skewed. (The image differs from the paper path type of skewing.) - Possible Causes 1. The 3rd scanner is not parallel with the 1st and 2nd scanners; this causes horizontal skewing of the copy image. 2. The mirrors shifted during transport of the copier. (They should have been locked into place before transport.) 3 . The 3rd scanner may have been bent at installation if the technician pressed the magnification key without first removing the 3rd scanner lock plate. 4. The front of the 3rd scanner is raised out of position, distorting the copy image. - Actions To correct the image, adjust the height of 3rd scanner (see scanner height adjustment) (Uneveness in height of 1st, 2nd, 3rd mirrors will cause similar images, but they are not adjustable and their heights are fixed. So, check that the scanner is placed correctly on the sliding rail, before taking action.) 12-20 28 February 1989 1.16 BLACK SPOTS ON THE COPY IMAGE - Phenomenon Black spots 2 to 3mm in diameter appear all over the copy image. - Possible Cause The grid voltage is not applied correctly. If the grid terminal does not properly contact its terminal, the grid will be insulated from all charges (floating). This hinders the flow of ions from the charge corona wire to the drum surface. (Ions must pass through the grid.) This results in a faint copy image or no image at all except for black spots where ions made it through the grid. - Action Make sure that the corona charger casings are correctly connected with grid voltage terminals. 12-21 28 February 1989 1.17 TONER DENSITY TOO HIGH - Phenomena Toner density is too high. (1) A dirty background appears on the copy. Also, a 1 mm thick vertical black line may appear. (2) The image density of the black solid area is too high. (3) Toner is built-up on the end block cover of the transfer/separating corona unit and also on the upper cover of the development unit. - Possible Causes 1. Exposure lamp voltage is too high. 2. ID sensor bias voltage is too high. 3. Charge corona current is too low. 4. ID sensor grid voltage is too low. 5. Toner supply clutch keeps on turning continuously. 6 . Copier is in fixed toner supply mode (black development). In fixed toner supply mode, toner is supplied regardless of the actual usage. Consequently, excessive toner may be supplied depending on customer’s originals. 7. Toner supply ratio is greater than the actual usage. If the 45% supply in ID Mode is selected while 15% original is used, the amount of toner supplied at one time (1 copy) is twice the actual consumption. Selecting such a high supply ratio will cause toner scattering inside the copier. - Actions 1. Check the following items by making a copy of the SP Mode Data Sheet in SP Mode No.1. No.31 Black Toner Supply Amount (ID sensor mode) No.32 Black Toner Supply Amount (Fixed mode) No.33 Black Toner ID Sensor Bias Adjustment No.70 Color Toner Supply Amount (Fixed mode) No.75 Color Toner Sensor Bias Adjustment 12-22 28 February 1989 2. Check Vsg in SP Mode No.54 Adjust Vsg to 4 ± 0.2V by turning VR102 on the operation panel. NOTE: Though the Vsp level can be displayed by pressing the 0 key in SP Mode No.55, adjustments can only be made in SP Mode No.54. 3. Make a copy to see whether the toner supply clutch is on or off. (1) If toner is supplied while image density is too high: Check Vsp with SP Mode No.55. If Vsp is too high, check and adjust the ID sensor bias voltage, charge current, and ID sensor grid. If Vsp is too low, check the level of CN303-A13 on the I/O control board. L: Replace toner supply clutch. H: Replace I/O control board. - Considerations - System Control Board Does toner density decrease when Vsg is raised? (Example) If the toner density is too high (though Vsg is 4V) and Vsg is raised to about 5V, does toner density decrease? (Comments) When Vsg is raised (VR102), the intensity of light emitted by the ID sensor LED increases as does the intensity of light reflected from the ID sensor pattern (Vsp). There is no change in the ratio of Vsp to Vsg, so there is no change in the toner density. 12-23 28 February 1989 1.18 TONER DENSITY TOO LOW - Phenomena Toner density is too low. (1) Density of the solid black areas is too low. (2) Solid areas feel rough to the touch. (3) Carrier is on the copy. (4) Light spots appear on solid black copies. - Possible Causes 1. Vsg is low. When Vsg lower than 2.5V is detected five times in succession, the CPU changes the toner supply to fixed supply mode (black) and the service call indicator starts blinking. 2 . Charge corona current is too high. If the output of the ID sensor grid is increased, Vsp and the toner density decrease. 3. ID sensor bias voltage of is too low. 4. Exposure lamp voltage is too low. 5. Toner supply clutch is defective. Too many solid (dense) copies are being made. The amount of toner supplied is inadequate for the amount of toner that is required. - Actions 1. Check the following items by making a copy of the SP Mode Data Sheet in SP Mode No.1. No.31 Black Toner Supply Amount (ID sensor mode) No.32 Black Toner Supply Amount (Fixed mode) No.33 Black Toner ID Sensor Bias Adjustment No.70 Color Toner Supply Amount (Fixed mode) No.75 Color Toner Sensor Bias Adjustment 2. Check Vsg in SP Mode No.54 Set Vsg to +4 ± 0.2V by turning VR102 on the system control board. If Vsg cannot be adjusted higher than 2.5V, check for a dirty or defective ID sensor 12-24 28 February 1989 3. Make copies to check whether the toner supply clutch is on or off. (1) If toner is not supplied even though the image density is low: Check Vsp with SP Mode No.55 If Vsp is too low, check and adjust the ID sensor bias, charge corona current, and ID sensor grid voltage. If Vsp is too high, check the level of CN303-A13 on the I/O control board. L: Replace toner supply clutch. H: Replace I/O control board. (2) If Vsp does not decrease even though the toner supply clutch is on: Toner end is not detected (Color). –> Replace the toner end detector. Toner blocking in the toner tank –> Clean the inside of the toner hopper. Toner supply roller is clogged with toner. –> Clean the toner supply roller. 12-25 28 February 1989 1.19 UNFUSED CORY IMAGE - Phenomenon Solid image rubs off easily. - Possible Causes 1. Nip width is too narrow. 2. Fusing temperature is too low. 3. Thermistor malfunction - Actions 1. Adjust the position of the pressure spring in the fusing unit. Nip width Standard Value: Center = 3.3 mm Front Rear } Deviation between the front and the rear is within 0.3 mm. Check Position Feed Direction Nip Width 2. Replace the spring if the problem is not solved. Combinations of hooks Nip width 3.0 ± 0.3 mm 3.3 ± 0.3 mm * 3.6 ± 0.3 mm * Standard setting 12-26 28 February 1989 3. Confirm the temperature. (1) Enter SP Mode No.52 (2) Temperature is displayed in the size magnification indicator. (3) Check to see if temperature is 185 ± 5°C. (4) If the surface temperature is still low although 185 ± 5°C is displayed in the size magnification indicator, the problem is a thermistor malfunction. NOTE: Resistance and Voltage of Thermistor: Temperature Resistance Voltage between TP 303 and 301 4.7V (Approx.) 3.2V (Approx.) 0.9V (Approx.) 12-27 28 February 1989 1.20 OPTICS UNIT CONTROL FAILURE - 1 (Initialization) - Phenomenon When the main switch is turned on, the scanner moves all the way to the right (return position), strikes the copier frame, and stops. - Possible Cause A drop in the power supply voltage below the minimum specified level prevents the CPU from being reset. (The voltage in the Vcc line is low.) - Actions 1. Use a digital multimeter to measure the power supply voltage exactly when the main switch is turned on. (Do not take this measurement when the hot roller is hot.) 2. If the power supply voltage is lower than specified, find out why and correct the problem. NOTE: The shock from the scanner moving all the way to the right and striking the copier frame may break the gear inside the scanner motor, causing jitter to appear on the copy. 12-28 28 February 1989 1.21 OPTICS UNIT CONTROL FAILURE - 2 (Copy Cycle) - Phenomenon The scanner moves all the way to the right (return position) and strikes the copier frame. - Possible Causes 1. Scanner motor malfunction 2. I/O control board malfunction 3. Electrical noise caused by a high voltage leak from the charge corona may result in a program error that causes the scanner control failure. - Actions 1. Check the encoder output of the scanner drive motor on the I/O control board (CN301-B14 and CN301-B15) while slowly turning the scanner motor pulley. Each phase of the encoder should show a change of state (5V –> 0V –> 5V). 2. If each phase shows a change of state in the above check, replace the I/O control board. If there is no change of state (either phase), replace the scanner drive motor. 3 . Find out what caused the high voltage leak and correct the problem. 12-29 28 February 1989 1.22 SIDE REGISTRATION MALFUNCTION IN DUPLEX/ OVERLAY COPY MODE - Phenomenon - 1st copy image Duplex/overlay copy images do not register as specified. This usually occurs in duplex copy mode in the main body (FT4460) or in mulltiple overlay copy mode with the multi-duplex/overIay unit (option). - Possible Cause The jogger in the copier does not work in duplex/overlay mode with paper larger than A4/8½” x 11”, so the small skews caused at each transport stage are not corrected. - Action Replace and adjust the pressure springs for the duplex/overlay transport roller and the guide roller as listed below. Part #. 5205 4527 5206 4478 AA06 3041 Amount of Pressure (gf) 200 500 800 12-30 Correction Effect on Skew factory setting Approx. 1 mm Approx. 1.5 mm 28 February 1989 Duplex/overlay When the second copy image is shifted to the left of the position of the first copy image. Duplex/overlay transport roller Rear spring Front spring Duplex mode * in main body o x Duplex/overlay guide roller Rear spring Front spring x o Position of spring Overlay mode in main body o x o x x: No replacement o: Replace the spring When the second copy image is shifted to the right of the position of the first copy image. Duplex/overlay transport roller Rear spring Front spring Duplex mode * in main body x o Duplex/overlay guide roller Rear spring Front spring o x Position of spring Overlay mode in main body x o x o x: No replacement o: Replace the spring Side registration in multi-duplex copy mode can be adjusted in the same way as in single duplex mode as mentioned above. * The paper feed path in single duplex overlay copy mode is reverse that of multi-duplex overlay copy mode. When side-to-side registration is corrected in overlay mode, always check the side-to-side registration for image shift in duplex mode. This is because the image shift direction in duplex copy mode is the opposite that in overlay copy mode. 12-31 28 February 1989 2. SERVICE CALL CONDITIONS 2.1 CODE #11 - Phenomenon SC #11: The exposure lamp circuit is open (stand by). - Possible Causes 1. Exposure lamp circuit open 2. Optical thermoswitch open 3. I/O control board malfunction 4. System control board malfunction - Actions 1. Replace the exposure lamp. 2. Test the resistance across the optical thermoswitch. If there is no conductivity, replace the thermoswitch. 3 . Check the voltage at CN304-A19 (in standby condition). Replace AC drive board 24V: 14V pulse: Replace l/O control board or system control board NOTE: When a thermoswitch has opened due to excessively high temperatures, conductivity cannot be restored at temperatures above 0°C (32°F). 12-32 28 February 1989 2.2 CODE #12 - Phenomena SC #12: The exposure lamp circuit stays open longer than 20 seconds during a copy cycle. SC #12: The exposure lamp stays on longer than 20 seconds during a copy cycle. - Possible Causes 1. Exposure lamp circuit open 2. Optical thermoswitch open 3. Flat cable open 4. I/O control board or system control board malfunction - Actions 1. Check the conductivity in the exposure lamp filament. If there is no conductivity, replace the exposure lamp. 2. Check the conductivity in the optical thermoswitch. If there is no conductivity, replace the thermoswitch. 3. Remove CN402 from the AC drive board; then, while moving the scanner slowly from left to right, check the conductivity between CN402-1 and 4. If there is no conductivity, replace the flat cable. 4. During the copy cycle, check the voltage at CN304-A19 24V: Replace AC drive board 14V pulse: Replace I/O control board or system control board. 12-33 28 February 1989 2.3 CODE #21 - Phenomenon SC #21: 1st scannner not at home position - Possible Causes 1. Scanner home position sensor malfunction 2. I/O control board malfunction 3. System control board malfunction - Action Check CN301-B17 on the I/O control board with the scanner at the home position. 0V: Replace 1st scanner home position sensor. 5V: Replace I/O control board or system control board. 2.4 CODE #22 - Phenomenon SC #22: 1st scanner stays at home position. - Possible Causes 1. Scanner home position sensor malfunction 2. I/O control board malfunction 3. System control board malfunction - Action Move the 1st scanner away from the home position; then, check CN301-B17 on the I/O control board. 0V: Replace 1st scanner home position sensor. 5V: Replace I/O control board or system control board. 12-34 28 February 1989 2.5 CODE #23 - Phenomenon SC #23: The sytstem control board does not receive the lead edged signal (LE) until the scanner reaches the maximum return position. - Possible Causes 1. I/O control board malfunction 2. System control board malfunction 3. Scanner motor malfunction - Action Check CN301-B8 on the I/O control board during a copy cycle. 5V: Replace scanner drive motor or I/O control board. Voltage changes to 0V: Replace system control board. (See the note below.) NOTE: Normally, the lead edge signal drops from 5V to 0V just before the registration clutch turns on, then rises to 5V when the scanner reaches the “return” position. 2.6 CODE #24 - Phenomenon SC #24: The I/O control board does not receive the 1st scanner home position signal within 20 seconds after the scanner starts. - Possible Causes 1. I/O control board malfunction 2. System control board malfunction 3 . Optical scanner overload (binding) 4. The power supply unit is not supplying +24V. 5. The scanner wire is slipping. 12-35 28 February 1989 - Actions 1 . Replace the I/O control board. 2. Replace the system control board. 3 . Check the scanner drive load. 4. Check fuse FU2 on the dc power supply board. 5. Check the scanner wire. 2.7 CODES #25 AND #2E - Phenomena SC #25: The I/O control board cannot detect the scanner drive direction from encoder pulses. SC #2E: The encoder pulse is not detected within 100 msec. - Possible Causes 1. Scanner drive motor failure 2. I/O control board malfunction 3. Optical scanner overload (binding) 4. The dc power supply is not supplying +24V. 5. The scanner wire is slipping. - Actions 1. Check the encoder output of the scanner drive motor. If there is anything abnormal, replace the scanner drive motor. 2. Check CN301-B19 on the I/O control board: Check the encoder output voltage by turning the scanner drive motor. If the voltage level changes, replace the l/O control board. If the voltage level stays at 5V or 0V, replace the scanner drive motor. 3. Check the load on the optical scanner. 4. Check fuse FU2 on the dc power supply board. 5. Check the scanner wire. 12-36 21 April 1989 2.8 CODE #2A AND #2B - Phenomena SC #2A: 3rd scanner home position sensor output stays LOW. SC #2B: 3rd Scanner home position sensor output stays HIGH. - Possible Causes 1. 3rd scanner home position sensor failure 2. 3rd scanner drive motor malfunction 3. I/O control board malfunction 4. 3rd scanner drive wire slipped off pulley 5. Overload on 3rd scanner (binding) 6. DC power supply board not supplying +24V - Actions 1. Check the 3rd scanner home position sensor by measuring the voltage at CN301-B19 on the I/O control board while manually interrupting and uninterrupting the sensor (interrupted: 5V, not interrupted: 0V). If the voltage does not change, replace the 3rd scanner home position sensor. If the voltage does change, replace the 3rd scanner drive motor or the I/O control board. 2. If the 3rd scanner drive motor does not turn and nothing is binding the 3rd scanner, perform the following: Check the 3rd scanner drive motor by measuring the drive pulses at CN301-A2, B2, A1, B1 and re-intializing the copier. If the output remains constant at +24V, replace the I/O control board. If the output changes at each terminal, replace the 3rd scanner drive motor. If the output at each terminal remains constant at 0V, check CN301-A3, B3 if either or both read 0V, then replace the I/O control board. If the output at CN301-A3 and B3 is +24V, replace the 3rd scanner drive motor. 3. Reset the 3rd scanner drive wire. 4. Check the load on the 3rd scanner. 5. Check fuse FU2 on the dc power supply board. 12-37 28 February 1989 2.9 CODE #28 AND #29 - Phenomena SC #28: Lens home position sensor output stays HIGH SC #29: Lens home position sensor output stays LOW - Possible Causes 1. Lens home position sensor malfunction 2. Lens drive motor malfunction 3. I/O control board malfunction 4. Lens housing overload (binding) - Actions 1. Check the lens home position sensor by measuring the voltage at CN301-B18 on the I/O control board while manually interrupting and uninterrupting the sensor (interrupted: 5V, not interrupted: 0V). If the output does not change, replace the lens home position sensor. If the output does change, replace the lens drive motor or the I/O control board. 2. If the lens drive motor does not turn and nothing is blocking movement of the lens housing, perform the following: Check the lens drive motor by measuring the drive pulses at CN301-A5, B5, A4, and B4, and re-intialize the copier. If the output remains constant at +24V, replace the I/O control board. If the output changes at each terminal, replace the lens drive motor. If the output remains constant at 0V, check CN301 A6 and B6. If either is 0V, replace the l/O control board. If A6 and B6 are +24V, replace the lens drive motor. 3. Check the load on the lens housing. 12-38 28 February 1989 2.10 CODE #41 - Phenomenon SC #41: Upper lift sensor output stays HIGH for more than 25 seconds after the lift motor turns on. - Possible Causes 1. Cassette not inserted correctly. 2. Lift sensor malfunction 3. Lift motor malfunction 4. l/O control board malfunction 5. Paper size sensor malfunction - Action Check whether the bottom plate is lifted when the cassette is inserted. When the bottom plate is lifted: (1) Check CN303-A8 (lift sensor) on the l/O control board while manually interrupting and uninterrupting the sensor (interrupted: 5V, not interrupted: 0V). If the lift sensor voltage level remains the same, replace the lift sensor. If the Iift sensor voltage level changes, replace the lift motor or the l/O control board. When the bottom plate is not lifted: (1) If the lift motor is turning, see whether the gears are engaged and check the cassette lifting mechanism. (2) If the lift motor is not turning, check CN303-A20 (1st lift motor) on the l/O control board. If 0V when the cassette is inserted, replace the lift motor. If constant at 24V, replace the l/O control board. (3) If the paper size is not displayed on the operation panel, replace the paper size switch. 12-39 28 February 1989 2.11 CODE #53 - Phenomenon SC #53: Thermistor open longer than 10 seconds - Possible Causes 1. Fusing thermistor failure 2. Fusing unit not installed correctly 3. Fusing unit connector loose or defective - Actions 1. Replace the fusing thermistor. 2. Install the fusing unit correctly. 3. Insert correctly, repair, or replace the fusing unit connector. 2.12 CODE #54 - Phenomenon SC #54: Ready signal is not received within 5 minutes after main switch is turned on. - Possible Causes 1. Thermofuse blown 2. Fusing lamp open 3. I/O control board malfunction 4. AC drive board malfunction 5 . System control board malfunction - Actions 1. Check the thermofuse; if blown, replace it. 2. Check the fusing lamp; if blown, replace it. 3. Check CN304-B19 on the I/O control board when the fusing lamp is on: 0V: Replace AC drive. 24V: Replace I/O control board or system control board. 12-40 28 February 1989 2.13 CODE #55 - Phenomenon SC #55: Thermistor has shorted, or the fusing temperature is higher than 220 -240°C. - Possible Causes 1. Fusing thermistor malfunction 2. I/O control board malfunction 3. AC drive board malfunction - Action 1. Check the resistance of the fusing thermistor. If there are any gaps, replace it. (See note.) 2. With the fusing lamp on, check the voltage at CN304-B19 (fusing lamp) on the I/O control board. Replace AC drive board Constant at 0V: Constant at 24V: Replace I/O control board 2.14 CODE #61 - Phenomenon SC #61: Pulse generator signal not received for over 2 seconds - PossibIe Causes 1. Pulse generator malfunction 2. Main motor malfunction 3 . I/O main control board malfunction 4. System control board malfunction 5. Pulse generator disconnected 12-41 28 February 1989 - Actions 1. If the main motor turns: Check the voltage at CN101-A13 on the system control board while manually interrupting and uninterrupting the pulse generator sensor (interrupted: 5V, not interrupted: 0V). If the output does not change, replace the pulse generator sensor. If the output changes, replace the main motor or the ac drive board. 2, 3, 4. If the main motor does not turn: Check CN304-B20 (main motor) on I/O Control board after the start key is pressed. 24V: Replace the l/O control board or the system control board. 0V: Replace the main motor. 5. Connect the pulse generator sensor connector. 2.15 CODE #81 AND #82 - Phenomena SC #81: Jogger home position sensor output stays LOW SC #82: Jogger home position sensor output stays HIGH - Possible Causes 1. Jogger home position sensor malfunction 2. Jogger motor malfunction 3. I/O control board malfunction 4. Jogger fence overload 5. Jogger wire slipped off - Actions 1. Check the voltage at CN304-B8 (jogger home position sensor) on the l/O control board while manually interrupting and uninterrupting the sensor (interrupted: 5V, not interrupted: 0V). If the output does not change, replace the jogger home position sensor. If the output changes, replace the jogger motor or the l/O control board. 12-42 23 May 1989 2. If the jogger drive motor does not turn and nothing is binding the jogger assembly, do the following: Check the jogger drive motor by measuring the drive pulses at CN304-A29, A30, B29, and B30, and re-intialize the copier. If the outputs are constant at +24V, replace the I/O control board. If the outputs change, replace the jogger drive motor. If the outputs are constant at 0V, check CN304-B28; if it is 0V, replace the I/O control board. If it is +24V, replace the jogger drive motor. 3. Check the jogger fences for binding. 4. Set the jogger wire. 2.16 CODE #91 - Phenomenon SC # 91: When the total counter reed switch does not actuate. - Possible Cause 1. Total counter malfunction - Action 1. Replace the total counter. 2.17 CODE #92 - Phenomenon SC #92: When the read switch in the total counter has shorted - Possible Cause 1. Total counter malfunction - Action 1. Replace the total counter. 12-43 28 February 1989 2.18 CODE #93 - Phenomenon SC #93: System control board and I/O control board are disconnected. - Possible Causes 1. Poor connection of the harness connectors between the system control board and I/O control board. 2. I/O control board malfunction 3. System control board malfunction - Actions 1. Check the connections between the system control board and the I/O control board. System control board: CN101 I/O control board: CN301 2. Replace the I/O control board. 3. Replace the system control board 2.19 CODE #94 - Phenomenon SC #94: Communication failure between the editor main board and the system control board - Possible Causes 1. Poor connection of the harness connectors between the system control board and the editor main board 2. Editor main board malfunction 3. System control board malfunction 12-44 28 February 1989 - Actions 1. Check the connections between the system control board and the editor main board. System control board: CN101 Check the connector on the editor side: CN1. 2. Replace the editor main board. 3. Replace the system control board. 2.20 CALL SERVICE CONDITION #95 - Phenomenon SC #95: Destination codes are not unique. - Possible Cause System control board malfunction - Action Replace the system control board 12-45 28 February 1989 3. OTHERS 3.1 ID SENSOR MALFUNCTION (Color Copy Mode) - Phenomena 1. The ID sensor malfunctions in color copy mode. 2. The color copy indicator and the call service indicator blink on the operation panel. 3. Only the color copy indicator blinks. - Possible Cause The color developer is deteriorated. - Action Replace and initialize (SP Mode No.10) the color developer. When the values of Vsg and Vsp are detected correctly, the indicators will stop blinking. NOTES: 1. The call service indicator starts blinking when the corresponding color development unit is selected (color key pressed). 2. The color copy indicator starts blinking when the ID sensor malfunctions. 12-46 28 February 1989 3.2 LOW IMAGE DENSITY (Black) - Phenomena 1. Solid areas have uneven image density. - Possible Causes 1. Certain characteristics of the toner cause low image density with the first 100 to 500 copies after black toner is initialized. (The low ID level will be around 1.0; the standard ID level is 1.3.) 2. This problem may also occur after 4000 copies because the drum potential changes. - Action When over 4000 copies have been made, select H”2” or HH”3” for the black toner ID sensor bias (SP Mode No.33) to increase the toner density in the developer mixture. NOTES: 1. If this bias level is changed before 4000 copies are made, toner scattering from the development unit or dirty background on the copy may result. 2. Black toner image bias adjustment (SP Mode No.37) changes the image density level without increasing the toner density in the development unit. Do not perform this adjustment. 3. This problem with low image density is hardly noticeable with text-only originals. 28 February 1989 3.3 SORTER PAPER STACKING PROBLEM (A3/LDG Tracing Paper) - Phenomenon A3 (LDG) tracing paper copies do not always feed correctly into the sorter bins. - Possible Cause A3 (LDG) tracing paper is not very stiff. When stacked to feed in the short grain direction, sheets sometimes bend or curl so that they do not feed smoothly into the sorter inlet. - Action Stack A3 (LDG) paper in the long grain direction. 3.4 DIRTY BACKGROUND (Blue Development Unit) - Phenomenon 1. After developer is replaced, a dirty background may appear on the first few copies. 2. After replacing the toner cartridge, dirty background copy may appear on the first few copies with originals that have a small amount of black image. - Possible Causes 1. Blue toner is higher in fluidity (attracted more easily to the drum surface) than other toner colors when it is new. 2. The color development unit is smaller than that of other copiers; consequently, the triboelectric charge is weaker. - Actions 1 After installing a blue development unit or replacing blue developer, make about five blue copies. 2 If a dirty background appears at any other time, make three solid blue A4/LT size copies to decrease the toner density. NOTE: This dirty background is usually very faint, i.e. difficult to see. 12-48 28 February 1989 3.5 PAPER CREASING - Phenomenon Paper creasing on trailing edge of thin paper Creasing - Possible Cause The lower registration roller is greater in diameter in the center, and it tends to wear out the upper registration roller (made of rubber) at the point of contact. - Action Replace the upper registration roller. 12-49 23 May 1989 4. ELECTRICAL COMPONENT DEFECTS 4.1 PAPER END SENSOR - Conditions 1. Stays OFF (lnterrupted) 2. Stays ON (Not interrupted) - Phenomena 1. Paper End is displayed even though paper is still in the cassette. 2. Paper End is not detected; the Start key green light is on when the cassette is inserted and no paper in the cassette. 4.2 MANUAL FEED SENSOR - Conditions 1. Stays OFF (Interrupted) 2. Stays ON (Not interrupted) - Phenomena 1. The Manual Feed indicator is not displayed when the manual feed table is opened. 2. The Manual Feed indicator is displayed when the manual feed table is closed. 4.3 1ST CASSETTE LIFT SENSOR - Condition 1. Stays ON (Not interrupted) 2. Stays OFF (Interrupted) - Phenomena 1. Copies cannot be made because the 1st lift motor does not switch on when the cassette is inserted. (The Paper End indicator lights.) 2. Service Call code 41 is displayed 25 seconds after the cassette is inserted. 12-50 28 February 1989 4.4 REGISTRATION SENSOR - Conditions 1. Stays ON (Activated) 2. Stays OFF (Not activated) - Phenomena 1. The Check Paper Path indicator turns on and point A blinks on the Misfeed Location display when the main switch is turned on. 2. Paper stops at the registration rollers after the Start key is pressed. The Check Paper Path indicator is displayed and point A blinks on the Misfeed Location display. 4.5 FUSING EXIT SENSOR - Conditions 1. Stays ON (Not interrupted) 2. Stays OFF (Interrupted) - Phenomena 1. The Check Paper Path indicator turns on and point B blinks on the Misfeed Location display when the main switch is turned on. 2. When the Start key is pressed, the leading edge stops 10 cm after exiting the fusing unit. The Check Paper Path indicator turns on and point B blinks on the Misfeed Location display. 4.6 INVERTOR SENSOR - Conditions 1. Stays ON (not interrupted) 2. Stays OFF (interrupted) - Phenomena 1. The Check Paper Path indicator turns on and point D on the Misfeed Location display blinks when the main switch is turned on. 2. The leading edge stops about 12 cm beyond the inverter sensor when the Start key is pressed in duplex/overlay mode. The Check Paper Path indicator turns on and point D blinks on the Misfeed Location display. 12-51 28 February 1989 4.7 INVERTER RELAY SENSOR - Conditions 1. Stays ON (Not Interrupted) 2. Stays OFF (Interrupted) - Phenomena 1. The Check Paper Path indicator turns on and point “C” on the Misfeed Location display blinks when the Start key is pressed in duplex/overlay mode. 2 . Paper stops about 5 cm beyond the inverter relay sensor when the Start key is pressed in duplex/overlay mode. The Check Paper Path indicator turns on and point “C” blinks on the Misfeed Location display. 4.8 COLOR TONER END SENSOR - Conditions 1. Stays ON 2. Stays OFF - Phenomenon The sensor fails to detect that toner has run out. 4.9 PULSE GENERATOR SENSOR - Conditions Stays ON (Not interrupted) Stays OFF (Interrupted) - Phenomenon Service Call code 61 is displayed 1-2 seconds after the Start key is pressed. 12-52 28 February 1989 4.10 1ST SCANNER HOME POSITION SENSOR - Conditions 1. Stays ON (Not interrupted) 2. Stays OFF (Interrupted) - Phenomena 1. Service Call code 21 is displayed after the main switch is turned on. 2. Service Call code 22 is displayed when the Start key is pressed and the 1st scanner moves 14 cm from the home position. 4.11 LENS HOME POSITION SENSOR - Conditions 1. Stays OFF (Interrupted) 2. Stays ON (Not interrupted) - Phenomena 1. Service Call code 28 is displayed approximately 6 seconds after the main switch is turned on. 2. Service Call code 29 is displayed approximatedly 6 seconds after the main switch is turned on. 4.12 3RD SCANNER HOME POSITION SENSOR - Conditions 1. Stays ON (Not interrupted) 2. Stays OFF (Interrupted) - Phenomena 1. Service Call code 2A is displayed approximately 5.5 seconds after the main switch is turned on. 2. Service Call code 2B is displayed approximately 5.5 seconds after the main switch is turned on. 12-53 28 February 1989 4.13 FRONT COVER SAFETY SWITCH - Conditions 1. Stays ON (Actuated) 2. Stays OFF (Not actuated) - Phenomena 1. The indicators on the operation panel stay on even when the front cover is opened. 2. When the front cover is closed, indicators on the operation panel stay off and the copier cannot be used. NOTE: The copier becomes inoperable when the front cover is opened. 4.14 THERMOFUSE - Condition Open - Phenomenon 1. Service Call code 54 is displayed when the main switch is turned on. 4.15 FUSING THERMISTOR - Conditions 1. Open 2. Shorted - Phenomena 1. Service Call code 53 is displayed when the main switch is turned on. 2. Service Call code 55 is displayed when the main switch is turned on. 12-54 28 February 1989 4.16 DC POWER SUPPLY FUSES - Conditions 1. Fuse 1 open - no power supply output 2. Fuse 2 open - no +24 Vaa output 3. Fuse 3 open - no +24 Vpp output - Phenomena 1,2. Indicators on the operation panel stay off when the main switch is turned on. 3. Copies are blank. NOTE: Check the power pack if Fuse 3 blows after it is replaced. 4.17 SHORT CIRCUIT IN DC 5V LINE - Phenomenon Indicators on the operation panel stay off when the main switch is turned on. - Action Remove units that have 5V lines one at a time to determine which unit has the shorted line. (The operation panel indicators will turn on when the unit with the defective line is removed.) 12-55 28 February 1989 5. CAUTIONS FOR USERS Explain the following items to users in order to reduce the number of service calls. 5.1 PICK-OFF PAWL TRACES (Overlay mode) - Phenomenon Traces from the pick-of pawls appear on overlay copies in high humidity or low humidity. This happens frequently when thin A4 (LT) paper is fed in sideways (short grain direction). After the first side (front) of a sheet goes through the fusing process, the sheet curls. The sheet then contacts the pick-off pawls during overlay copying. - Explanation Instruct customer to insert the paper lengthwise (long grain direction) (A3R/Letter R). This will reduce the number of pawl marks. For duplex or overlay copying, use 64 to 105 g/m2 (17 - 28 lb) paper. 5.2 CREASING DURING FUSING PROCESS - Phenomenon Thin paper is creased during the fusing process. - Explanation Feeding paper in lengthwise (long grain direction) reduces the amount of creasing. If the customer is using paper lighter than 64 g/m² (17 lb), explain that paper between 64 to 105 g/m 2 (17 to 28 lb) gives better results. 12-56 28 February 1989 5.3 OHP MISFEEDS - Phenomenon Multi-sheet feeding and other types of misfeeds may occur depending upon how the sheets are cut or under certain environmental conditions. - Explanation Instruct users to make copies one sheet at a time from the manual feed table. 5.4 PHOTO MODE ID LEVEL SETTING - Phenomenon In photo mode, the image density cannot be more than one gradation lower on the gray scale than the image density in normal mode (Manual Level 4). - Explanation Select setting 1 or 2 in SP Mode No.40. 5.5 INCOMPLETE IMAGE TRANSFER AT TRAILING EDGE - Phenomenon The copy image may be faint (low image density) on the last 10 mm of the trailing edge. Low image density - Explanation The image is faint at the trailing edge because the attraction between the drum surface and the copy paper is weaker at this point. Instruct users to try feeding the original trailing edge first (reversed) or to use reduction mode so that none of the copy image is on the last 10 mm of the trailing edge. 12-57 28 February 1989 5.6 LOW IMAGE DENSITY WITH RED ORIGINALS - Phenomenon The image density is low in copies of red originals. - Explanation This copier uses an OPC drum, which has higher spectrosensitivity in red areas than a selinium (F type) drum. Instruct the user to make copies at manual image density level 2. 5.7 LOW ID LEVEL WITH MULTIPLE SOLID COLOR COPIES - Phenomenon Low image density occurs when multiple copies are made of color originals with heavy solid areas. - Explanation Explain that this rapidly depletes the color toner in the development unit. Instruct the user to limit the number of such copies in multi-copy runs. Or, if many copies are needed, instruct the user to do so one copy at a time; this is because the fixed supply mode is used to supply toner. 5.8 MODES CLEARED WHEN FRONT COVER OPENED - Phenomenon When the front cover is opened, the front cover safety switch is turned off and the DC power supply is shut off. This clears everything on the operation panel except in the case when the Toner End indicator or the Check Paper Path indicator is on. In this case, after the door is opened and closed, all the precious settings will be displayed on the operation panel. - Explanation Instruct the user not to open the front cover except to replace toner or clear paper misfeeds. 12-58 28 February 1989 5.9 INADEQUATE FUSING OF UNEVEN COPY SURFACE - Phenomenon The fusing unit, an oilless mechanism, uses a smooth teflon fusing roller. This roller sometimes misses indented areas on the paper surface. - Explanation Instruct the customer to use paper that has an even surface. 5.10 GAP OR OVERLAPS IN OVERLAY COPYING - Phenomenon Absolute precision is difficult to achieve when placing an overlay original on the exposure glass and/or inputting the designated area. In overlay mode, a small gap or overlaps of up to 5 mm/0.2” may appear between the designated area and the surrounding area. Horizontal gap - Explanation Instruct customers to leave some space free around the designated area. 5.11 MULTIPLE PASSES THROUGH FUSING UNIT - Phenomenon When paper is transported three or more times through the fusing unit, paper creasing or misfeeds often occur. - Explanation Instruct customers not to feed copies that have been through the duplex/overlay process once. 12-59 28 February 1989 5.12 PAPER EXIT ROLLER MARKS ON DIRECT IMAGE MASTERS (C & P) - Phenomenon Paper exit roller marks appear on copies of direct image masters used in offset printing. - Explanation Explain to the user that copies cannot be made of direct image masters. 12-60 SECTION ELECTRICAL 13 DATA RICOH FT4460 (A006) PARTS First Edition January 1989 CATALOG RICOH COMPANY, LTD. AD500 (A424) 1. Exterior (A424) . . . . . . . . . . . . . . . . . . . . . . . . 2 2. Jogger Section (A424) . . . . . . . . . . . . . . . . . . . 4 3. Transport Section (A424) . . . . . . . . . . . . . . . . 6 4. Duplex Harness (A424) . . . . . . . . . . . . . . . . . . 8 5. Relay Harness (A424) . . . . . . . . . . . . . . . . ...10 6. Decal & Document (A424) . . . . . . . . . . . . . ...12 Parts Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16 1. EXTERIOR (A424) Feb. 28, ’89 2 1. EXTERIOR (A424) Index No. Part No. Feb. 28, ’89 Index No. Q’ty Per Assembly Description Part No. Description 1 A416 2289 Duplex Tray Cover 1 101 0324 0080W 2 A424 2511 Decal - E2 1 102 0314 0050W Philips Pan Head Screw - M4x5 3 A424 2331 Upper Cover 1 103 0314 0080M Philips Pan Head Screw - M4x8 4 A424 2311 Rear Cover 1 104 0434 0082W 5 A424 5301 Relay Harness 1 105 0951 4010W Tapping Screw - M4x8 Philips Screw With Flat Washer - M4x10 6 A424 2280 Harness Bracket 1 106 0720 0030E Retaining Ring - M3 7 AA07 0002 Rail 2 107 0960 4006W Philips Flange Screw - M4x6 8 A424 2277 Support Plate 1 108 0344 0080W Philips Truss Head Screw - M4x8 9 AG05 1013 1 10 AA14 3043 Release Lever Shoulder Screw 11 A424 5802 Bracket - Harness - Duplex Unit 1 12 5403 2075 Stepped Screw 1 13 A424 2273 Release Link 1 14 A424 2275 Lever Bracket 1 15 A424 2502 Deca1 - Misfeed - LT 1 15 A424 2503 Decal - Misfeed - A4 1 16 AG05 1014 Slide Lever 1 17 A424 2522 Front Cover Decal - English 1 18 A424 2301 Front Cover 1 19 A424 2270 Support Plate 1 20 21 5205 2698 Relay Roller Spring 1 5919 2290 Duplex Tray Cover Holder 2 22 A424 2321 Duplex Tray 1 23 A424 5801 Harness Bracket 1 24 A424 2281 Cushion Stud 1 - M6x8 . 1 3 Philips Sunken Head Screw - M4x8 Q’ty Per Assembly 2. JOGGER SECTION (A424) Feb. 28, ’89 2. JOGGER SECTION (A424) Part No. I Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description Friction Pad Q’ty Per Assembly 1 1 5206 2686 Snap Ring 6 36 2 AA14 0117 Upper Guide Shaft 1 37 AG05 1017 Guide Plate Lever 1 3 5447 2681 Snap Ring 1 38 AF02 0052 Lower Transport Roller 1 4 A424 2171 Upper Jogger Guide 2 39 A424 2260 Guide Plate 1 5 A424 1104 Roller Shaft 1 40 5938 2598 Spring - Lower Transport Roller 2 6 5206 2671 Positioning Roller 1 41 5205 2697 Bushing - Upper Registration Roller 2 7 5919 2132 Positioning 1 42 A424 2127 Guide Plate 1 8 5919 2127 Positioning Roller Pulley 1 43 A424 1120 Junction Gate Solenoid 1 9 5053 0447 Bushing - M6 8 44 5403 2016 1 10 A424 2223 Roller 1 45 A424 2201 Tension Sprocket (11T) - Paper Feed . Gear Bracket 11 5403 2075 Stepped Screw 3 46 AB01 3160 Gear - 24T 1 12 A424 2160 Jogger Fence Table 1 47 AB01 3161 Gear - 28T 2 13 5206 2876 Spring - Wire 1 48 AA06 0013 Spring 1 14 5919 2172 Jogger Wire 1 49 A424 2246 Bracket 1 15 A424 2291 Lower Cover 1 50 AB02 3025 Sprocket - 18T 2 16 5442 1735 Pulley 1 51 AB01 7054 Gear - 17T 1 17 A424 2141 Stay 1 52 AB01 7055 Gear - 20T 1 18 AB01 3162 Gear - 28T 2 53 A424 2361 Bushed Roller Chain - 94P 1 19 AB01 3149 Gear - 20T 1 54 5919 2169 Wire Drive Pulley 1 20 5419 5714 Stepped Screw - M4 2 55 5919 2168 Jogger Motor Bracket 1 21 5887 4162 Screw - Driven Guide Plate 4 56 AX05 0021 Stepper Motor - DC4.8W 1 22 AA14 0095 Shaft 1 57 A424 2149 Sensor Bracket 1 23 AF02 0111 Fork Gate Roller 1 58 5215 5230 Photointerrupter - L-Type 1 24 A424 2126 Front Guide Plate 1 59 AA15 0096 Guide Sheet 1 25 A424 2137 Paper Support Guide 2 60 AB02 3003 Pulley - l1T 1 26 AF02 0050 Transport 1 61 5206 2877 Wire Clamp Plate 2 27 AA06 0090 Spring 2 62 5215 2713 Bottom Plate Pad 1 28 A424 1062 Paper Feed Tray 1 29 A424 2124 Guide Plate 1 30 5919 2105 Friction Pad Arm 1 31 AA13 2014 Spacer 1 32 5442 2645 Spring - Friction Pad 1 33 5442 2630 Arm - Friction Pad 1 34 5442 2642 Shoulder Screw - M3 1 35 A424 2146 Friction Pad Ass’y 1 Index No. Part No. Roller Arm Belt . Roller Description 101 0720 0040E 102 0314 0060W Philips Pan Head Screw - M4x6 103 0622 0140E Spring Pin - 2x14mm 104 0965 4008W Tapping Screw With Flat Washer - M4x8 105 0720 0030E Retaining Ring - M3 106 0720 0060E Retaining Ring - M6 107 0952 3012W Philips Screw - M3x12 108 0952 4008W Philips Screw - M4x8 109 0314 0050W Philips Pan Head Screw - M4x5 110 0574 0040E Hexagon Headless Set Screw - M4x4 111 0951 4010W Philips. Screw With Flat Washer - M4x10 112 0314 0120W Philips Pan Head Screw - M4x12 113 1105 0196 Harness Clamp 114 0434 0080W Tapping Screw - M4x8 Index No. Q’ty Per Assembly Retaining Ring - M4 5 AF03 3004 Part No. Description 1 Q’ty Per Assembly 3. TRANSPORT SECTION (A424) Feb. 28, ’89 6 3. TRANSPORT SECTION (A424) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description Q’ty Per Assembly 1 AA12 0005 Antistatic Brush 1 36 AW02 0010 Photointerruptor 1 2 A424 2102 Spring Plate 4 37 AW02 0011 Photointerruptor 1 3 AF02 0089 Exit Fork Gate Roller 1 38 A424 2117 1 4 A424 2103 Upper Guide Plate 1 39 5403 2075 1 5 AA14 0097 Pressure 1 40 AA14 0094 6 A424 2230 Pressure Arm 1 41 AX21 0010 Magnetic Clutch 1 7 5919 2218 Bushing - 4x7x10mm 4 42 A424 5302 Duplex Harness 1 8 AF02 0049 Fork Gate Roller 1 43 A424 2145 Clutch Bracket 1 9 AA02 0003 Slide Lever Magnet 2 44 AA06 0087 Spring 1 10 A424 2116 Lower Guide Plate 1 45 5919 2146 Pressure Lever 1 11 A424 1124 Pressure 1 46 5919 2147 Spring Hook 1 12 5919 2258 Spring - Feed-in Tray Clutch 1 13 5919 2262 Feed-in Tray Cam 1 14 5919 2264 Clutch Sleeve 1 15 AA06 6010 Spring Clutch 1 16 5919 2144 Feed-in Tray Lever 1 17 5919 2260 Gear - 58T 1 18 5304 1639 Bushing - 8mm 2 1 Retaining Ring - M3 Shaft Solenoid 1 19 A424 1128 Roller 20 AA06 0088 Spring 1 21 A424 2242 Spring Hook 1 22 A424 2252 Arm 1 23 A424 2255 Lever 2 101 0720 0030E 24 AA14 3045 Stud 1 102 0314 0050W Philips Pan Head Screw - M4x5 25 AA06 0089 Spring 1 103 0720 0060E Retaining Ring - M6 Solenoid 26 5410 1291 Pin - Return Lever 2 104 0964 4008W Tapping Screw With Flat Washer - M4x8 27 A424 1032 Upper Entrance Stay 1 105 1105 0010 Nylon Clip - 6N 28 AA14 0098 Shaft 1 106 0434 0060W Tapping Screw - M4x6 29 A424 2283 Rear Side Bracket 1 107 0720 0040E Retaining Ring - M4 30 AA06 0086 Spring 1 108 0443 0060W Hexagon Head Tapping Screw - M3x6 31 AA08 2009 Bushing - 8x12x8mm 2 109 0725 0120E Retaining Ring C - M12 32 5215 2619 Feed Roller 1 110 0951 3006W Philips Screw With Flat Washer - M3x6 33 5215 2618 Feed Roller Hub 1 111 0952 4008W Philips Screw - M4x8 34 5215 2621 Snap Ring - M6 1 112 0434 0080W Tapping Screw - M4x8 35 A424 2121 Support Bracket 1 113 0953 3006W Tapping Screw With Flat Washer - M3x6 7 4. DUPLEX HARNESS (A424) Feb. 28, ’89 4. DUPLEX HARNESS (A424) No. * Part No. A424 5302 Description Duplex Harness Feb. 28, ’89 Q’ty Per Assembly Index No. 1 9 Part No. Description 101 1102 1973 Connector - 6P 102 1102 1979 Connector - 6P 103 1100 1159 104 1100 1249 Socket - Mate-N-Lock Receptacle Terminal 105 1100 1259 Socket - Mate-N-Lock 106 1100 1327 Contact 107 1100 1328 Contact 108 1102 1091 Connector - 6P 109 1102 1397 Connector - 2P 110 1102 1398 Connector - 2P 111 1102 1620 Connector - 3P 112 1102 1910 Connector - 2P Connector - 3P 113 1102 1911 114 1102 1925 Connector - 3P 115 1102 1967 Connector - 6P Q’ty Per Assembly 5. RELAY HARNESS (A424) Feb. 28, ’89 10 5. RELAY HARNESS (A424) Index No. * Part No. A424 5301 Description Relay Harness Q’ty Per Assembly Index No. 1 . 11 Part No. Description 101 1100 1264 102 1100 1327 Contact 103 1100 1328 Contact 104 1102 1914 Connector - 6P 105 1102 1928 Connector - 6P 106 1102 1942 107 1102 1969 Connector - 6P Connector - 10P 108 1102 1979 Connector - 6P Wire Terminal Q’ty Per Assembly Feb. 28, ’89 6. DECAL & DOCUMENT (A424) 12 6. DECAL & DOCUMENT (A424) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly 1 A424 2502 1 1 A424 2503 1 2 A424 2511 3 A424 2522 Front Cover Decal - LT 1 4 A424 8610 Installation Procedure - English 1 4 A424 8615 Installation Procedure - 5 Language 1 1 . 13 Part No. Description Q’ty Per Assembly PARTS INDEX Feb. 28. ’89 Page and Index No. Description Parts No. Parts No. Description Page and Index No. A424 1032 Upper Entrance Stay 7-27 A424 2283 Rear Side Bracket 7-29 A424 1062 Paper Feed Tray 5-28 A424 2291 Lower Cover 5-15 A424 1104 Roller Shaft 5-5 A424 2301 Front Cover 3-18 A424 1120 A424 1124 Junction Gate Solenoid Pressure Solenoid 5-43 A424 2311 Rear Cover 3-4 7-11 A424 2321 Duplex Tray 3-22 A424 1128 Roller 7-19 A424 2331 Upper Cover 3-3 A424 2102 Spring Plate 7-2 A424 2361 Bushed Roller Chain - 94P 5-53 A424 2103 Upper Guide Plate 7-4 A424 2502 Decal - Misfeed - LT 13-1 A424 2116 Lower Guide Plate 7-10 A424 2502 Decal - Misfeed - LT 3-15 A424 2117 Lower Stay 7-38 A424 2503 Decal - Misfeed - A4 13-1 A424 2121 Support Bracket 7-35 A424 2503 Decal - Misfeed - A4 3-15 Solenoid 5-29 A424 2511 Decal - E2 13-2 5-24 A424 2511 Decal - E2 3-2 A424 2124 Guide Plate A424 2126 Front A424 2127 Guide Plate 5-42 A424 2522 Front Cover Decal - LT 13-3 A424 2137 Paper Support Guide 5-25 A424 2522 Front Cover Decal - English 3-17 Guide Plate . A424 2141 Stay 5-17 A424 5301 Relay Harness 11-* A424 2145 Clutch Bracket 7-43 A424 5301 Relay Harness 3-5 A424 2146 Friction Pad Ass’y 5-35 A424 5302 Duplex Harness 7-42 A424 2149 Sensor Bracket 5-57 A424 5302 Duplex Harness 9-* A424 2160 Jogger Fence Table 5-12 A424 5801 Harness Bracket 3-23 A424 2171 Upper Jogger Guide 5-4 A424 5802 3-11 A424 2201 Gear Bracket 5-45 A424 8610 Bracket - Harness - Duplex Unit Installation Procedure - English A424 2223 Roller Arm 5-10 A424 8615 Installation Procedure - 5 Language 13-4 A424 2230 Pressure Arm 7-6 A424 2242 Spring Hook 7-21 A424 2246 Bracket 5-49 A424 2252 Arm 7-22 A424 2255 Lever 7-23 A424 2260 Guide Plate 5-39 A424 2270 Support Plate 3-19 A424 2273 Release Link 3-13 A424 2275 Lever Bracket 3-14 A424 2277 Support Plate 3-8 A424 2280 Harness Bracket 3-6 A424 2281 Cushion Stud 3-24 16 13-4 Feb. 28, ’89 Description Parts No. Page and Description Parts No. Index No. Page and Index No. AA02 0003 Slide Lever Magnet 7-9 AG05 1014 Slide Lever 3-16 AA06 0013 Spring 5-48 AG05 1017 Guide Plate Lever 5-37 AA06 0086 Spring 7-30 AW02 0010 Photointerruptor 7-36 AA06 0087 Spring 7-44 AW02 0011 Photointerruptor 7-37 AA06 0088 Spring 7-20 AX05 0021 Stepper Motor - DC4.8W 5-56 AA06 0089 Spring 7-25 AX21 0010 Magnetic Clutch 7-41 AA06 0090 Spring 5-27 A416 2289 Duplex Tray Cover 3-1 AA06 6010 Spring Clutch 7-15 5053 0447 Bushing - M6 5-9 AA07 0002 Rail 3-7 5205 2697 Bushing - Upper Registration Roller 5-41 AA08 2009 Bushing - 8x12x8mm 7-31 5205 2698 Relay Roller Spring 3-20 AA12 0005 Antistatic 7-1 5206 2671 Positioning Roller 5-6 AA13 2014 Spacer 5-31 5206 2686 Snap Ring 5-1 AA14 0094 Shaft 7-40 5206 2876 Spring - Wire 5-13 AA14 0095 Shaft 5-22 5206 2877 Wire Clamp Plate 5-61 AA14 0097 Pressure 7-5 5215 2618 Feed Roller Hub 7-33 7-32 Brush Shaft AA14 0098 Shaft 7-28 5215 2619 Feed Roller AA14 0117 Upper Guide Shaft 5-2 5215 2621 Snap Ring - M6 7-34 AA14 3043 Shoulder Screw - M6x8 3-10 5215 2713 Bottom Plate Pad 5-62 5-58 AA14 3045 Stud 7-24 5215 5230 Photointerrupter - L-Type AA15 0096 Guide Sheet 5-59 5304 1639 Bushing - 8mm 7-18 AB01 3149 Gear - 20T 5-19 5403 2016 Tension Sprocket (11T) - Paper Feed 5-44 AB01 3160 Gear - 24T 5-46 5403 2075 Stepped Screw 3-12 AB01 3161 Gear - 28T 5-47 5403 2075 Stepped Screw 5-11 AB01 3162 Gear - 28T 5-18 5403 2075 Stepped Screw 7-39 AB01 7054 Gear - 17T 5-51 5410 1291 Pin - Return Lever 7-26 AB01 7055 Gear - 20T 5-52 5419 5714 Stepped Screw - M4 5-20 AB02 3003 Pulley - 11T 5-60 5442 1735 Pulley 5-16 AB02 3025 Sprocket - 18T 5-50 5442 2630 Arm - Friction Pad 5-33 AF02 0049 Fork Gate Roller 7-8 5442 2642 Shoulder Screw - M3 5-34 AF02 0050 Transport AF02 0052 Lower Transport Roller Roller 5-26 5442 2645 Spring - Friction Pad 5-32 5-38 5447 2681 Snap Ring 5-3 AF02 0089 Exit Fork Gate Roller 7-3 5887 4162 Screw - Driven Guide Plate 5-21 AF02 0111 Fork Gate Roller 5-23 5919 2105 Friction Pad Arm 5-30 AF03 3004 Friction Pad 5-36 5919 2127 Positioning Roller Pulley 5-8 AG05 1013 Release Lever 3-9 5919 2132 Positioning Roller Belt 5-7 17 Feb. 28, ’89 Description Parts No. Page and Index No. Parts No. Description Page and Index No. 5919 2144 Feed-in Tray Lever 7-16 0314 0050W Philips Pan Head Screw - M4x5 3-102 5919 2146 Pressure Lever 7-45 0314 0050W Philips Pan Head Screw - M4x5 5-109 5919 2147 Spring Hook 7-46 0314 0050W Philips Pan Head Screw - M4x5 7-102 5919 2168 Jogger Motor Bracket 5-55 0314 0060W Philips Pan Head Screw - M4x6 5-102 5919 2169 Wire Drive Pulley 5-54 0314 0080M Philips Pan Head Screw - M4x8 3-103 5919 2172 Jogger Wire 5-14 0314 0120W Philips Pan Head Screw - M4x12 5-112 5919 2218 Bushing - 4x7x10mm 7-7 0324 0080W Philips Sunken Head Screw - M4x8 3-101 5919 2258 Spring - Feed-in Tray Clutch 7-12 0344 0080W Philips Truss Head Screw - M4x8 3-108 5919 2260 Gear - 58T 7-17 0434 0060W Tapping Screw - M4x6 7-106 5919 2262 Feed-in Tray Cam 7-13 0434 0080W Tapping Screw - M4x8 5-114 5919 2264 Clutch Sleeve 7-14 0434 0080W Tapping Screw - M4x8 7-112 5919 2290 Duplex Tray Cover Holder 3-21 0434 0082W Tapping Screw - M4x8 3-104 5938 2598 Spring - Lower Transport Roller 5-40 0443 0060W Hexagon Head Tapping Screw - M3x6 7-108 0574 0040E Hexagon Headless Set Screw - M4x4 5-110 0622 0140E Spring Pin - 2x14mm 5-103 0720 0030E Retaining Ring - M3 3-106 0720 0030E Retaining Ring - M3 5-105 0720 0030E Retaining Ring - M3 7-101 0720 0040E Retaining Ring - M4 5-101 18 0720 0040E Retaining Ring - M4 7-107 0720 0060E Retaining Ring - M6 5-106 0720 0060E Retaining Ring - M6 7-103 0725 0120E Retaining Ring C - M12 7-109 0951 3006W Philips Screw With Flat Washer - M3x6 7-110 0951 4010W Philips Screw With Flat Washer - M4x10 3-105 0951 4010W Philips Screw With Flat Washer - M4x10 5-111 0952 3012W 5-107 0952 4008W Philips Screw - M3x12 Philips Screw - M4x8 0952 4008W Philips Screw - M4x8 7-111 0953 3006W Tapping Screw With Flat Washer - M3x6 7-113 5-108 0960 4006W Philips Flange Screw - M4x6 3-107 0964 4008W Tapping Screw With Flat Washer - M4x8 7-104 0965 4008W Tapping Screw With Flat Washer - M4x8 5-104 1100 1159 Socket - Mate-N-Lock 9-103 1100 1249 Receptacle Terminal 9-104 Feb. 28, ’89 Parts No. Description Page and Index No. 1100 1259 Socket - Mate-N-Lock 1100 1264 Wire Terminal 11-101 1100 1327 Con tact 11-102 1100 1327 Con tact 9-106 1100 1328 Contact 11-103 1100 1328 Contact 9-107 Parts No. 9-105 1102 1091 Connector - 6P 9-108 1102 1397 Connector - 2P 9-109 1102 1398 Connector - 2P 9-110 1102 1620 Connector - 3P 9-111 1102 1910 Connector - 2P 9-112 1102 1911 Connector - 3P 9-113 1102 1914 Connector - 6P 11-104 1102 1925 Connector - 3P 9-114 11-105 1102 1928 Connector - 6P 1102 1942 Connector - 6P 11-106 1102 1967 Connector - 6P 9-115 1102 1969 Connector - 10P 11-107 1102 1973 Connector - 6P 9-101 1102 1979 Connector - 6P 11-108 1102 1979 Connector - 6P 9-102 1105 0010 Nylon Clip - 6N 7-105 1105 0196 Harness Clamp 5-113 19 Description Page and Index No. PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of this parts on this machine. INDEX to PARTS CATALOG FT4460 CS2090 DF52 AD500 RE12 RT15 (A006) (A423) (A422) (A424) (A916) (A912) PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of this parts on this machine. INDEX to PARTS CATALOG Inverter Section 2 (A006) . . . . . . . . . . . . . . .. 40 1. Exterior (A006) . . . . . . . . . . . . . . . . . . . . . . . . . 2 20. 2. 21. Jogger Section (A006) . . . . . . . . . . . . . . . . ... 42 3. Operation Panel (A006) . . . . . . . . . . . . . . . . . . 4 Platen Cover & Cassette (A006) . . . . . . . . . . . . 6 4. Registration Section 1 (A006) . . . . . . . . . . . . . 8 5. Registration Section 2 (A006) . . . . . . . . . . . . . 10 Paper Feed Section 1 (A006) . . . . . . . . . . . . . 12 Paper Feed Section 2 (A006) . . . . . . . . . . . . . 14 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Drum Section (A006) . . . . . . . . . . . . . . . . . ... 16 Transport Section (A006) . . . . . . . . . . . . . . . . 18 Fusing Unit 1 (A006) . . . . . . . . . . . . . . . . ... 20 Fusing Unit 2 (A006) . . . . . . . . . . . . . . . . ... 22 Black Development Unit (A006) . . . . . . . . . . . 24 Color Development Unit (A006) . . . . . . . . . . . 26 Color Toner Supply Section (A006) . . . . . . . . . 28 Cleaning Unit (A006) . . . . . . . . . . . . . . . . . ... Optics Section 1 (A006) . . . . . . . . . . . . . . ... Optics Section 2 (A006) . . . . . . . . . . . . . . ... Paper Exit Section (A006) . . . . . . . . . . . . . ... Inverter Section 1 (A006) . . . . . . . . . . . . . . . . 30 32 34 36 38 22. Development Unit Change Section (A006) . . . . . . . . . . . . . . . . . . . . . . ... 44 23. Main Motor & Cleaning Release Section (A006) . . . . . . . . . . . . . . . . . . . . . . ... 46 Drive Section (A006) . . . . . . . . . . . . . . . . . ... 48 Electrical Section 1 (A006) . . . . . . . . . . . . . . . 50 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. Electrical Section 2 (A006) . . . . . . . . . . . . . . . 52 Frame (A006) . . . . . . . . . . . . . . . . . . . . . . ... 54 I/O Control Board (A006) . . . . . . . . . . . . . ... 56 Paper Feed Board (A006) . . . . . . . . . . . . . . ... 58 AC Drive Board (A006) . . . . . . . . . . . . . . . ... 60 AC Harness (A006) . . . . . . . . . . . . . . . . . . ... 62 DC Harness (A006) . . . . . . . . . . . . . . . . . . ... 64 Special Tool (A006) . . . . . . . . . . . . . . . . . . ... 66 Decal & Document (A006) . . . . . . . . . . . . . ... 68 Parts index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 74 Feb. 28, ’89 1. EXTERIOR (A006) 2 1. EXTERIOR (A006) Feb. 28, ’89 Q’ty Per Assembly 1 Index No. 31 AG06 0014 Right Hinge 1 Left Cover Cap - Sorter 1 32 5420 1515 Plate - Key Counter 1 A006 1329 Large Cap 2 33 A006 1352 Key Counter Cover 1 4 A006 1328 Small Cap 2 34 A006 1332 Right Cover 1 5 A006 1312 Left Cover - LT 1 35 A006 1348 Right Cover Cap 1 5 A006 1313 Left Cover - A4 1 AA02 1008 A006 1372 Lower Left Cover 1 AA00 2022 Magnet - Manual Feed Manual Feed Decal - LT 1 6 36 37 7 Decal - Unlock (115V) 1 37 AA00 2023 Manual Feed Decal - A4 1 8 A006 1398 A006 4493 Copy Guide - Receiving Tray 1 38 A006 2651 Manual Feed Table 1 9 A006 1315 Decal - Main SW - 115V 1 39 5447 2927 Friction Pad - B 1 9 A006 1316 Decal - Main SW - 220/240V 1 40 A006 2701 Manual Feed Guide 1 10 A006 2569 Magnet Support Plate 1 41 A006 2661 Manual Feed Cover 1 11 A007 8571 Editing Sheet - LT/LDG 1 42 A006 2698 Side Fence Gear 2 11 A007 8572 Editing Sheet - A4/A3 1 43 A006 2699 12 5442 1372 Decal - Power Source - 220V 1 44 5215 2687 Spacer - 5.1x20mm Gear - 16T 1 13 AA00 1052 Decal - Knob - Feed Roller 1 45 5215 2691 Brake 1 14 A006 5121 Left Bracket 1 46 5443 2713 Wave Washer 1 15 A006 5122 Middle Bracket 1 47 AA15 0063 Side Fence Sheet 4 16 A006 5123 Right Bracket 1 48 A006 2691 Rear Side Fence 1 17 5054 0536 Magnet Catch Ass’y 2 49 A006 2681 Front Side Fence 1 18 AA14 0140 Screw - M3x4.5 4 50 A006 2961 Decal - Manual Feed 1 19 A006 1384 Upper Inner Cover - LT 1 51 A917 5115 Battery Cover 1 19 A006 1394 Upper Inner Cover - A4 1 52 A006 1292 Rear Cover - 115V 1 20 A006 1294 Decal - Misfeed Removal 1 52 A006 1309 1 21 A006 1298 Decal - Adding Color Toner 1 53 A006 1266 Rear Cover - 220V/240V Decal - Scale - LT 22 A006 1299 Decal - Color Dev. Replacement 1 53 A006 1268 Decal - Scale - A4 1 23 A006 1304 Decal - Indications 1 54 A006 1396 1 24 A006 1303 Decal - Toner Replacement 1 55 A006 1387 Decal - Lock (115V) Decal - Release 25 A006 1272 Front Cover 1 56 A006 1267 ADF Cap 1 26 AG06 0018 Left Hinge 1 57 A006 1252 Upper Cover - LT 1 27 A006 1283 Front Cover Chain 1 57 A006 1253 Upper Cover - A4 1 28 A006 6033 Inner Cover Sheet 1 58 AC01 1006 Exposure Glass 1 29 A006 1368 Lower Inner Cover 1 59 5205 1768 Rubber Seal - Mirror 2 30 A006 1364 Right Inner Cover - LT 1 60 A006 1841 Exposure Glass Stay 1 30 A006 6012 Right Inner Cover - A4 1 61 AC04 1041 Left Original Scale - LT 1 Part No. Description Index No. 1 AG03 1004 Receiving Tray 2 A008 1307 3 Index No. Part No. Description Index No. Q’ty Per Assembly 61 AC04 1042 Left Original Scale - A4 1 62 A006 1840 Mounting Scale Bracket 1 63 A006 1379 Left Grip Cover 1 64 A006 1377 Right Grip Cover 1 65 AA14 3070 Shoulder Screw - M2x2 2 66 A006 8630 Sheet - SP Mode Table 1 101 0802 5094 Tapping Truss Head Screw - M4x8 102 0434 0080W Tapping Screw - M4x8 103 0965 4008W Tapping Screw With Flat Washer - M4x8 104 0323 0060W Philips Sunken Head Screw - M3x6 105 0434 0060W Tapping Screw - M4x6 106 0805 0073 Retaining Ring - M5 107 0433 0062W Hexagon Head Tapping Screw - M3x6 108 1206 0044 Lithium Battery 3 Part No. Part No. Description Description Q’ty Per Assembly 1 1 1 1 Q’ty Per Assembly 2. OPERATION PANEL (A006) Feb. 28, ’89 4 Feb. 28, ’89 2. OPERATION PANEL (A006) Index No. Part No. Description Q’ty Per Assembly 1 AG01 1095 Operation Panel Ass’y - LT 1 1 AG01 1101 Operation Panel Ass’y - A4 1 2 A006 5722 Left Cover - Clip 1 3 A006 5713 Left Cover - Smoke 1 4 A006 1266 Decal - Scale - LT 1 4 A006 1268 Decal - Scale - A4 1 5 A006 1397 Panel Sheet - Program 6 AA11 4099 Key Top No. 101 1 11 7 AA11 4100 Key Top - 8 A006 5732 Large Panel Sheet - LT 1 8 A006 5725 Large Panel Sheet - A4 1 9 A006 5734 Duplex Panel Sheet - LT 1 9 A006 5726 Duplex Panel Sheet - A4 1 10 A006 5733 Duplex/Sorter Panel Sheet - LT 10 A006 5727 Duplex/Sorter Panel Sheet - A4 (Accessory) 1 11 A006 5102 Right Panel Board 1 12 A006 5103 Left Panel Board 1 13 A006 5114 System Control Board - 115V 1 13 A006 5134 System Control Board - 220/240V 1 14 A006 5105 IC - UPD27C512 - 25 1 Duplex/Sorter (Accessory) 2 1 15 A008 5112 Ram Board 1 16 A006 5106 Operation Panel Board - 115V 1 16 A006 5107 Operation Panel Board - 220/240V 1 5 Part No. 0353 0060F Description Philips Truss Head Screw - M3x6 Q’ty Per Assembly 3. PLATEN COVER & CASSETTE (A006) Feb. 28, ’89 3. PLATEN COVER & CASSETTE (A006) Feb. 28, ’89 1 Index No. 24 AC00 1007 Platen Cover Ass’y 1 25 5215 2839 Balancer Spring 1 Side Fence - Front 1 26 5215 2834 Arm Holder 1 A008 2727 Side Fence - Rear 1 27 5215 2837 Shaft - 7x40 1 4 5215 2731 Rear Side Holder 1 28 5215 2842 Right Spring - Platen Cover 1 5 AA00 2010 2 29 5215 2843 Left Spring - Platen Cover 1 6 A008 2710 Decal - Paper Level Bottom Plate 1 30 5215 2846 Platen Base 1 7 5215 2713 Bottom Plate Pad 1 31 AG02 1001 Original Holder 1 8 5215 2720 Front Side Holder 1 32 5211 2800 Rear Platen Cover 1 9 AF01 7001 Rear Fence 1 33 A008 1666 Front Platen Cover 1 10 5205 2997 Actuator – 8-1/2x14 1 5448 2824 Flex Hinge - Platen Cover 2 10 5205 2971 Actuator - 11x17 1 34 35 5448 2803 Platen Cover Pad 1 10 5205 2979 Actuator - 8-1/2x11 1 10 5205 2996 Actuator - 8-1/2x11R 1 10 5205 2976 Actuator - 8”13” 1 10 5205 2960 Actuator - A3 1 Index No. 1 A008 2734 Large Cassette Cover 1 A008 2737 Small Cassette Cover 2 A008 2715 3 Part No. Description Q’ty Per Assembly Part No. Description 10 5205 2962 Actuator - A4R 1 10 5205 2964 Actuator - A4 1 11 AA00 2083 Decal Sheet - Large - LT 1 11 AA00 2080 Decal Sheet - Large - A4 1 11 AA00 2084 Decal Sheet - Small - LT 1 11 AA00 2079 Decal Sheet - Small - A4 1 12 AF01 0001 Large Cassette Body 1 12 AF01 0002 Small Cassette Body 1 13 A008 9501 Platen Cover Sheet (10 Sheets/set) 1 14 5215 2832 Platen Cover Hinge Ass’y 1 15 A008 1676 5442 1657 Mounting Bracket - Platen Cover Seal - 15x214x13mm 1 16 17 5215 1667 Platen Cover Stud 2 18 5215 2838 Rubber Magnet 1 19 5215 2845 1 101 0802 5131 Truss Head Screw - M4x8 20 5215 2840 Magnet Plate Pin - 4x115mm 3 102 0965 4012W Tapping Screw With Flat Washer - M4x12 21 5215 2847 Base Holder - Platen Cover 1 103 0414 0102W Tapping Screw - M4x10 22 5215 2836 Sleeve - 8x34 1 104 0805 0083 Retaining Ring - M4 23 5215 2844 Slide 2 105 0965 4010W Tapping Screw With Flat Washer - M4x10 Supporter 1 7 Q’ty Per Assembly 1 4. REGISTRATION SECTION 1 (A006) Feb. 28, ’89 8 4. REGISTRATION SECTION 1 (A006) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly 1 Part No. Description Q’ty Per Assembly 1 A006 3852 Pre-Transfer Lamp 36 5205 2681 Coupled Gear - 17T/50T 1 2 A006 3877 Transfer Guide 1 37 AA06 0075 Release Spring 1 3 AW01 0001 Photo Sensor 1 38 A006 2587 Solenoid Bracket 1 4 A006 5376 Registration Harness 1 39 5447 5430 Lift Motor - DC0.98W 1 5 A006 3872 Sensor Bracket 1 40 A006 2591 Registration Clutch Bracket 1 6 A006 2572 Paper End Actuator 1 41 5053 0447 7 A006 2549 Upper Registration Guide 1 42 AA15 0139 8 A006 2968 Rear Paper Feed Roller Guide 1 43 AA14 5031 Registration 9 5304 1639 Bushing - 8mm 3 44 AB01 3135 Gear - 18T 1 10 5442 2117 Shoulder Screw - Hinge 2 45 AB01 3118 Gear - 33T 1 11 AG05 1010 Release Knob 1 46 AB01 3117 Gear - 14T 1 12 AA06 0106 Spring - Pressure Arm 2 47 A006 2579 Paper Feed Guide Plate 1 13 A006 2767 Lower Pressure Arm 2 48 A006 2565 Paper End Feeler 1 14 5215 2662 Bushing 4 49 5443 2668 Bushing 2 Bushing - M6 1 Mylar Seal - Large 1 Clutch Shaft 1 15 AA06 0073 Release Spring 2 50 5216 5245 Photointerruptor - 16 AA14 3062 Shoulder Screw - M4 1 51 A006 2571 Paper End Sensor Bracket 1 17 A006 2639 Registration 1 52 A006 2560 Paper Feed Stay 1 18 AF02 0032 Upper Registration Roller 1 53 AX21 0008 Registration Clutch 1 19 A006 2813 Registration Support Plate 1 54 A006 2125 PTL Stopper Cover 1 20 A006 2851 Front Cassette Holder 1 55 A006 2133 PTL Stopper 1 21 A006 2861 Rear Cassette Holder 1 56 A006 2977 Seal - Guide Plate 2 Guide 22 A006 2756 Pressure 23 AA15 0057 Mylar Seal - Small 1 Bracket IL-G-3P-S3T2-E 1 24 A006 2755 Front Stay Bracket 1 101 0313 0080W Philips Pan Head Screw - M3x8 25 A006 2750 Pressure Shaft Stay 1 102 0313 0060W Philips Pan Head Screw - M3x6 26 A006 2760 Rear Stay Bracket 1 103 0313 0100W Philips Pan Head Screw - M3x10 27 A425 2581 Front Cassette Support Arm 2 104 0314 0080W Philips Pan Head Screw - M4x8 28 AA14 0082 Lower Cassette Bottom Shaft 2 105 0965 4008W Tapping Screw With Flat Washer - M4x8 29 A006 2766 Lower Cassette Bottom Arm 2 106 0951 4008W Philips Screw With Flat Washer - M4x8 30 A425 2583 2 107 0720 0060E Retaining Ring - M6 31 A006 2764 Rear Cassette Support Arm Pressure Shaft Stay 1 108 0720 0040E Retaining Ring - M4 32 5205 2680 Coupled Gear - 16T/53T 1 109 0574 0040E Hexagon Headless Set Screw - M4x4 33 5205 2667 Bracket - Paper Lift Motor 1 110 0574 0060E Hexagon Headless Set Screw - M4x6 34 A006 2581 Pressure Arm Bracket 1 111 0413 0062W Tapping Screw - M3x6 35 AA06 0074 Pressre Spring 1 112 0434 0080W Tapping Screw - M4x8 9 1 Feb. 28, ’89 5. REGISTRATION SECTION 2 (A006) 10 5. REGISTRATION SECTION 2 (A006) Feb. 28, ’89 Index No. 1 Q’ty Per Assembly Index No. AF02 0037 1 36 AA06 6023 Rear Release Spring 2 A006 2932 1 37 A006 2615 Rear Release Lever 1 3 AA06 6025 1 38 5053 0447 Bushing - M6 2 4 AA14 0085 5 5206 4478 6 5409 1855 7 AA08 0037 Bushing - 6mm 8 A006 1056 9 Part No. Description Part No. Description Q’ty Per Assembly 1 1 39 AA06 0076 Release Spring 1 2 40 A006 2620 Seal - 0.2x30x30mm 1 1 41 AA14 0243 Release Shaft 1 42 A006 2557 Pick-up Lever 1 Right Rear Support Plate 2 1 43 A006 2617 Transport Guide Plate 1 A006 2900 Exit Guide Plate 1 44 A006 2720 Rear Guide Holder 1 10 AF02 0035 Driven Roller 2 45 A006 2588 Cassette Release Arm 1 11 5205 2697 Bushing - Uppers Registration Roller 46 AA06 0071 Cassette Release Spring 1 12 AA06 3047 Roller 6 4 47 A006 2558 Paper Feed Solenoid Bracket 1 13 A006 2925 Front Guide Plate Lever 1 48 A006 1167 Rear Cover Angle 1 14 AA06 6024 Guide Plate Spring 1 49 5216 5245 Photointerruptor - 15 AG05 1005 Guide Plate Knob 1 50 A006 1166 ADF Harness Shielding Plate 1 16 A006 2538 Exit Guide Plate 1 51 A006 1078 Right Rear Support Bracket 1 17 A006 2383 Drum Guide Roller 1 52 A006 2564 Pick-up Solenoid 1 18 AG05 1054 Release Lever 1 - Drive Roller Spring IL-G-3P-S3T2-E 19 AA08 0025 Support Bushing 1 20 5442 2117 Shoulder Screw - Hinge 1 21 A006 1074 Key Counter Bracket 1 22 A006 2668 Front Guide Holder 1 101 0434 0080W Tapping Screw - M4x8 23 AG05 1009 Release Lever Knob 1 102 0323 0060W Philips Sunken Head Screw - M3x6 24 A006 2613 Front Release Lever 1 103 0314 0060W Philips Pan Head Screw - M4x6 25 AA16 1025 Transport Cushion 1 104 0965 3008W Tapping Screw With Flat Washer - M3x8 26 AA06 6022 Front Release Spring 1 105 0313 0060W Philips Pan Head Screw - M3x6 27 A006 2606 Bushing Holder 1 106 0314 0080W Philips Pan Head Screw - M4x8 28 5447 2630 Spring - Registration Roller 2 107 0443 0060W Hexagon Head Tapping Screw - M3x6 29 A006 2603 Front Side Plate 1 108 0720 0040E Retaining Ring - M4 30 AA13 2027 Lower Registration Roller Spacer 2 109 0720 0050E Retaining Ring - M5 31 AF02 1007 Lower Registration Roller 1 110 0720 0060E Retaining Ring - M6 32 AA13 2026 Side Plate Roller 6 111 0720 0030E Retaining Ring - M3 33 AA14 0080 Pick-off Pawl Shaft 1 112 0622 0120W Spring Pin - 2x12mm 34 A006 2605 Support Angle 2 113 1105 0201 Harness Clamp 35 A006 2611 Rear Side Plate 1 114 0802 5094 Tapping Truss Head Screw - M4x8 11 1 6. PAPER FEED SECTION 1 (A006) Feb. 28, ’89 12 6. PAPER FEED SECTION 1 (A006) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description 1 1 AB01 0015 Gear – 20T 1 36 A006 5336 2 AF02 0055 Grip Roller 1 37 AA08 3004 3 A006 2976 Front Roller Guide 1 38 AX20 0023 1 4 5447 2681 Snap Ring 3 39 A006 2576 2 5 AF03 1002 Paper Feed Roller 1 40 AA13 2024 1 6 5447 2723 Pick-up Roller 1 41 AB01 3114 7 AB01 3079 Gear - 21T 1 42 AA06 0069 Pick-up Spring 1 8 AB01 3169 Gear - 18T 1 43 AW50 0005 Paper Size Switch 1 9 A006 2551 Pick-up Roller Guide 1 44 A006 5356 Relay Sensor Harness 1 10 A006 2555 Paper Feed Bracket 1 45 A006 2982 Spacer - M6x9 2 11 AB01 0014 Gear - 18T 1 46 AB01 1023 Gear - Separation Arm 1 12 5203 4244 Bushing - 4x8x6mm 1 47 AA14 0076 Separation Drive Shaft 1 13 A006 2984 Roller Bracket 1 48 A006 2574 Separation Arm 1 14 5304 1639 Bushing - 8mm 6 49 A006 2577 Separation Driven Shaft 1 15 A006 2979 Rear Paper Feed Spacer 1 50 5887 4162 Screw - Driven Guide Plate 2 16 AB01 0016 Gear - 40T 1 51 5447 2693 Separation Roller 1 17 A006 2983 Spacer - M8x9 1 52 5447 2678 Slip Clutch Cover 1 18 AA14 0075 Paper Feed Shaft 1 53 5447 2676 Output Hub 1 19 A006 2980 Paper Feed Guide Plate 1 54 5447 2697 Cylindrical Spring 1 20 A006 2978 Front Paper Feed Spacer 1 55 5447 2695 Input Hub 1 21 5053 0447 Bushing - M6 2 56 AB01 1024 Gear - Separation Roller 1 22 Paper Feed Stay 1 57 A006 2915 Lower Entrance Guide Plate 1 23 A006 2527 A006 2793 Paper Feed Shaft Bracket 1 58 AW02 0009 Photointerruptor 1 24 AA06 3043 Shaft Bracket Spring 1 59 A006 2920 Lower Relay Sensor Bracket 1 25 AA13 2034 Spring Spacer 1 60 AA14 0078 Cassette Bottom Shaft 1 26 AA16 1026 Cushion 1 61 A006 2585 Cassette Bottom Lever 1 27 AA08 0028 Bushing - 8x12x7mm 2 62 A006 2575 Separation Guide Plate 1 28 AF03 1003 Paper Feed Roller 1 63 A006 2986 Mylar Seal - Paper Feed Stay 1 29 5215 2618 Feed Roller Hub 1 64 A006 1079 Solenoid Bracket Angle 1 30 5215 2621 Snap Ring - M6 1 65 A006 2586 Sector Gear 1 31 AA14 0083 Paper Feed Shaft 1 66 AX20 0022 Paper Feed Clutch 1 32 A006 2795 Paper End Feeler 1 67 A006 2951 Paper End Actuator 1 33 AA15 0051 Rear Roller Guide 1 68 5443 2668 Bushing 1 34 AA06 0070 Pressure 1 35 A006 2573 1st Paper Size Bracket Index No. Spring Part No. Description 101 0434 0080W Tapping Screw - M4x8 102 0964 4008W Tapping Screw With Flat Washer - M4x8 103 0314 0060W Philips Pan Head Screw - M4x6 104 0314 0200W Philips Pan Head Screw - M4x20 105 0720 0050E Retaining Ring -M5 106 0720 0040E Retaining Ring - M4 107 0720 0030E Retaining Ring - M3 108 109 0720 0060E 0700 0080W Retaining Ring - M6 Flat Washer - M8 110 0574 0040E Hexagon Headless Set Screw - M4x4 111 0622 0140E Spring Pin - 2x14mm 112 1105 0197 Wire Saddle 113 1105 0200 Clamp 114 0951 4008W Philips Screw With Flat Washer - M4x8 115 0805 3042 Ball Bearing - 6x10x3mm 1st Paper Feed Harness One-way Clutch - Feed Q’ty Per Assembly 1 1 1 Index No. Q’ty Per Assembly 13 Part No. Description Q’ty Per Assembly 7. PAPER FEED SECTION 2 (A006) Feb. 28, ’89 14 7. PAPER FEED SECTION 2 (A006) Index No. Part No. Description Feb. 28, ’89 Q’ty Per Assembly Index No. Part No. Description Q’ty Per Assembly 1 AW02 0008 Photointerruptor 1 36 A006 2811 2nd Paper Size Bracket 1 2 A006 2825 Upper Relay Sensor Bracket 1 37 A006 2950 Paper End Sensor Bracket 2 2 3 A006 2533 Guide Plate 1 38 5205 5250 L.E.D Sensor Type - S 4 AA14 0083 Paper Feed Shaft 1 39 A006 5357 3rd Paper Feed Harness 5 AF02 2013 Support Roller 2 40 A006 2812 Lower Entrance Guide Plate 6 5215 2621 Snap Ring - M6 2 41 A006 5337 2nd Paper Feed Harness 1 7 5304 1639 Bushing - 8mm 6 42 A006 2955 Magnetic Clutch Stopper 1 8 AF03 1003 Paper Feed Roller 1 43 5443 2668 Bushing 1 9 5215 2618 Feed Roller Hub 1 44 A006 2951 Paper End Actuator 1 10 AA08 0028 1 45 A006 2956 Harness Guide Plate 1 11 AA16 1026 Bushing - 8x12x7mm . Cushion 1 46 AB01 3110 Gear - 27T 2 12 A006 2797 Front Paper Feed Bracket 47 AB01 3116 Gear - 24T 1 13 AA08 2012 Bushing - M8 48 AB01 3115 Gear - 24T 1 14 AA14 8073 Support Roller Shaft 1 49 AB01 7042 Coupled Gear - 18T/36T 1 15 A006 2795 Paper End Feeler 1 50 AB01 3112 Gear - 22T 1 16 AF02 0033 Upper Drive Roller 1 51 AB01 3108 Gear - 36T 1 17 AF02 0034 Lower Drive Roller 1 52 AB01 3109 Gear - 39T 2 18 AF02 0036 Drive Roller 1 53 AB01 3111 Gear - 24T 1 19 5215 2644 Spring - Friction Pad 2 54 Friction Pad 2 20 5442 2642 Shoulder Screw - M3 2 55 AF03 3005 5446 4486 Support Guide Stud 1 21 22 A008 2555 A006 2808 Arm Pad Ass’y 2 3rd Paper Size Bracket 1 23 AW50 0005 Paper Size Switch 2 24 AA15 0056 Seal - 0.2x20x130mm 2 25 5215 2582 Spring 2 26 5215 2673 Fixing Pad Bracket 2 27 A006 2806 Pad Holder 2 28 AA13 2014 Spacer 2 29 AG05 0008 Feed Roller Knob 1 30 5053 0447 Bushing - M6 2 31 A006 2800 Paper Feed Bracket 2 32 5215 2579 Shaft 2 33 A006 2805 Lower Release Arm 2 34 A006 2535 Lower Entrance Guide Plate 1 35 AX20 0022 Paper Feed Clutch 2 Index No. 101 0951 4008W Philips Screw With Flat Washer - M4x8 102 0434 0080W Tapping Screw - M4x8 103 0313 0100W Philips Pan Head Screw - M3x10 104 0314 0080W Philips Pan Head Screw - M4x8 105 0314 0060W Philips Pan Head Screw - M4x6 106 0323 0080W Philips Sunken Head Screw - M3x8 107 0314 0100W Philips Pan Head Screw - M4x10 108 0720 0060E Retaining Ring - M6 109 0720 0030E Retaining Ring - M3 110 0720 0040E Retaining Ring - M4 111 0725 0100E Retaining Ring C - M10 112 0720 0025E Retaining Ring - M2.5 113 0622 0140E Spring Pin - 2x14mm 114 0964 4008W Tapping Screw With Flat Washer - M4x8 Part No. Description Index No. Q’ty Per Assembly 15 Part No. Description Q’ty Per Assembly 8. DRUM SECTION (A006) Feb. 28, ’89 16 8. DRUM SECTION (A006) Index No. Part No. Description Feb. 28, ’89 Q’ty Per Assembly Index No. Part No. Description Q’ty Per Assembly 1 A006 2117 Front Cover - Charge Corona 1 36 A006 2274 Pick-off Paul Shaft 2 AD02 3020 1 37 A006 2273 Pick-off Paul Bracket 1 3 A006 2055 Left Casing - Charge Corona Charge Corona Cleaner 1 38 AA06 3106 Pawl Spring 2 2 4 A006 2114 Grid Anchor 1 39 A006 9510 Drum 1 5 AA06 0141 Spring - Grid 2 40 A006 2278 Sensor Holder 1 6 AD02 2173 Front End Block - Charge Corona 1 41 A006 5222 ID Sensor Board 1 7 5442 2069 Plastic Screw - Main Corona 1 42 AA15 0073 Seal - Toner Density 2 8 A006 9001 Charge Corona Wire (10pcs/set) 1 43 A006 2280 Drum Guide 1 9 A006 2111 Charge Corona Grid 1 44 A006 2281 Rear Drum Side Plate 1 10 AD02 3021 Right Casing - Charge Corona 1 45 AB01 3142 Gear - 80T 1 11 AD02 2027 Rear End Block - Charge Corona 1 46 5434 7916 High Voltage Decal 2 12 5442 2110 Plug - Corona Unit 1 47 A006 5372 Drum Harness 1 13 5442 2108 Spring - Corona Wire 1 48 AD02 1015 Receptacle Housing 1 14 A006 2118 Rear Cover - Charge Corona 1 49 5442 2107 Hookless Spring 2 15 A006 2020 Charge Corona Unit 1 50 AD02 1013 Charge Corona Receptacle 1 16 A006 3871 Space Plate 1 51 AX21 0015 Development Drive Clutch 1 17 A006 2126 1 52 AB01 3144 Gear - 46T 1 18 A006 1850 Quenching Lamp Toner Shield Glass 1 53 5053 0447 Bushing - M6 2 19 AA14 3051 Shoulder Screw - M4 4 54 AB01 3143 Gear - 30T 1 20 A006 2071 Guide Casing 1 55 AA13 2074 Knob Collar 1 21 A006 2127 Charge Corona Rail - Left 1 56 A006 2386 Gear Box 1 22 A006 2128 Charge Corona Rail - Right 1 57 A006 3858 1 23 A006 2130 Spring Plate - Charge Corona 2 58 AB03 0022 QL Stopper Cover Pulley - 48T 24 A006 5332 Eraser Harness 1 59 AB01 3381 Gear - 44Z Ass’y 1 25 A006 5320 Eraser 1 60 AB01 2305 Gear Cover 1 26 A006 2259 Eraser Cushion 1 61 AA14 0086 Drum Shaft 1 27 A006 2268 Upper Left Drum Stay 1 62 A006 2132 QL Stopper 1 28 A006 2363 Right Drum Guide 1 63 A006 2129 Cleaning Unit Guide 1 29 A006 2269 Upper Right Drum Stay 1 64 A006 2387 Spacer - Magnetic Clutch 1 30 A006 2261 Front Drum Side Plate 1 31 A006 2258 Drum Support Plate 1 32 AG05 0031 Drum Shaft Knob 1 33 A006 2260 Drum Holder 1 34 A006 2271 Left Drum Stay 1 35 A006 2270 Pick-off Paul 2 Index No. Part No. Description 101 0413 0062W Tapping Screw - M3x6 102 0965 4008W Tapping Screw With Flat Washer - M4x8 103 0413 0082W Tapping Screw - M3x8 104 0313 0040W Philips Pan Head Screw - M3x4 105 0314 0100W Philips Pan Head Screw - M4x10 106 0314 0200W Philips Pan Head Screw - M4x20 107 0952 3006W Philips Screw - M3x6 108 0313 0060W Philips Pan Head Screw - M3x6 109 0314 0060W Philips Pan Head Screw - M4x6 110 0725 0170E Retaining Ring C - M17 111 0720 0060E Retaining Ring - M6 112 1105 0199 Clamp 113 0964 4008W Tapping Screw With Flat Washer - M4x8 114 0951 4006W Philips Screw With Flat Washer - M4x6 115 116 0315 0250W 0960 4010W Philips Pan Head Screw - M5x25 Philips Flange Screw - M4x10 117 0740 3008 Ball Bearing 118 0740 3017 Ball Bearing - M17 Q’ty Per Assembly Index No. Part No. Description 1 Q’ty Per Assembly 9. TRANSPORT SECTION (A006) Feb. 28, ’89 18 9. TRANSPORT SECTION (A006) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description Q’ty Per Assembly 1 AA15 1112 Seal - 3x7x105mm 1 33 A006 3859 Transfer Guide Plate 2 A006 3906 Upper Transport Cover 1 34 AD02 2167 Rear End Block 1 3 AA04 0009 Transport 4 35 AA06 3036 Terminal Spring 2 4 AF02 2005 Transport Drive Roller 1 36 AD02 2169 Rear End Block Cover 1 5 5053 0223 Bushing - 8mm 4 37 AD00 4036 T & S Corona Unit 1 6 A006 3907 Lower Transport Cover 1 38 A006 2625 Rear Transport Bracket 1 7 AF02 2006 Transport Driven Roller 4 39 A006 3855 Terminal Cover – Transfer 1 8 AA15 1113 Seal - 3x7x80mm 1 40 5434 7916 High Voltage Decal 1 9 A006 2631 Lower Transport Cover 1 10 A006 2628 Left Stay 1 11 A006 2635 Front Transport Gover 1 12 AA14 3043 Shoulder Screw - M6x8 1 13 A006 2633 Front Registration Roller Guide 1 14 A006 2623 Front Transport Bracket 1 15 A006 2629 Right Stay 1 Belt 16 AX40 0006 Drum Heater - 115V 1 16 AX40 0007 Drum Heater - 220/240V 1 17 A006 2634 Rear Registration Roller Guide 1 18 AB01 3165 Gear - 20T 1 19 AA08 2009 Bushing - 8x12x8mm 1 20 AA06 0072 Rear Transport Spring 1 21 AX05 0005 Fan - DC24V 1 22 AA0l 0004 1 23 A006 3931 Ozone Filter - 20x138x138mm Duct 24 AD02 1014 T & S Corona Receptacle 1 25 A006 3882 Paper Guide - T & S Corona 1 101 0965 4008W Tapping Screw With Flat Washer - M4x8 26 AD02 2166 Front End Block Cover 1 102 0964 4008W Tapping Screw With Flat Washer - M4x8 27 5442 2108 Spring - Corona Wire 2 103 0314 0080W Philips Pan Head Screw - M4x8 28 5442 9004 T & S Corona Wire (l0pcs/set) 104 0434 0080W Tapping Screw - M4x8 105 0622 0140E Spring Pin - 2x14mm 29 5442 9003 Main Corona Wire (l0pcs/set) 106 0725 0120E Retaining Ring C - M12 (Separation) 1 107 0314 0300W Philips Pan Head Screw - M4x30 30 AD02 2165 Front End Block 1 108 0413 0082W Tapping Screw - M3x8 31 A006 3854 T & S Corona Casing 1 109 0952 3006W Philips Screw - M3x6 32 A006 3875 T & S Corona Rail 1 110 0720 0060E Retaining Ring - M6 (Transfer) 1 1 19 1 10. FUSING UNIT 1 (A006) Feb. 28, ’89 20 10. FUSING UNIT 1 (A006) Feb. 28, ’89 Q’ty Per Assembly 1 Index No. 33 A006 4141 Upper Stay 1 Fusing Unit - 220/240V 1 34 5216 4145 Thermofuse Decal 1 AX44 0011 Heater - 750W - 115V 1 35 A006 5450 Thermofuse 1 1 AX44 0012 Heater - 750W - 220/240V 1 36 A006 5240 Thermistor 2 A006 4125 Rail Cover 1 37 A006 4133 Sheet - R a i l 3 A006 5375 Fusing Harness 1 38 A006 4131 Right Rail 1 4 A006 4080 Front Lamp Terminal 1 39 A006 4132 Left Rail 1 5 5216 5245 Photointerruptor - Index Part No. Description No. * A006 4051 Fusing Unit - 115V * A006 4053 1 IL-G-3P-S3T2-E A006 4091 Paper Exit Sensor Bracket 1 7 A006 4095 Harness Bracket 1 8 A006 4155 Front 9 A006 4168 Decal - Fusing Knob 1 10 A006 4165 Decal - B1 1 11 A006 4062 Fusing Knob Stopper 1 12 AG05 0009 Fusing Knob 13 AA00 0015 Decal - High . Description 1 1 Temperature 2 14 A006 4096 Pressure Arm 2 15 AA06 0217 Spring - Pressure Roller 2 16 A006 4167 Decal - B3 1 17 AE03 2002 Bushing - 25x30x9mm 2 18 AE03 0003 Bearing - 30x42x7mm 2 19 A006 4072 Front Side Plate 1 20 A006 4153 Lower Guide Plate 1 21 A006 4154 Lower Cover 1 22 A006 4151 Stay 1 23 AE02 0004 Pressure Roller 1 24 AE03 1001 Slide Bushing 2 101 0950 3006M Philips Screw With Lock Washer - M3x6 25 AE01 1002 Hot Roller 1 102 0434 0080W 0434 0082W Tapping Screw - M4x8 Tapping Screw - M4x8 Philips Screw With Flat Washer - M4x8 26 5840 1632 Stepped Screw 27 AB01 3132 Gear - 40T 3 1 103 104 0951 4008W 28 AB01 3133 Gear - 30T 1 105 0951 3005W Philips Screw With Flat Washer - M3x5 29 A006 4110 Rear Lamp Terminal 1 106 0720 0040E Retaining Ring - M4 30 A006 4101 Rear Side Plate 1 107 0720 0060E Retaining Ring - M6 31 A006 4145 Entrance 1 108 0725 0250E Retaining Ring C - M25 32 A006 4146 Upper Guide Plate 1 109 0314 0100W Philips Pan Head Screw - M4x10 Cover 21 Q’ty Per Assembly 1 - Fusing 1 6 Cover Part No. 1 11. FUSING UNIT 2 (A006) Feb. 28, ’89 22 Feb. 28, ’89 11. FUSING UNIT 2 (A006) Index No. Index No. 1 A006 4222 Upper Guide Plate 1 101 0314 0080W Philips Pan Head Screw - M4x8 2 5840 1632 Stepped Screw 2 102 0720 0050E Retaining Ring - M5 Part No. Description Q’ty Per Assembly Part No. Description 3 AF02 0043 Upper Fusing Exit Roller 1 103 0720 0030E Retaining Ring - M3 4 A006 4223 Lower Guide Plate 1 104 0622 0100E Spring Pin - 2x10mm 5 A006 4271 Fusing Exit Cover 1 105 0951 4008W Philips Screw With Flat Washer - M4x8 6 AF02 1016 Lower Fusing Exit Roller 5 7 A006 4224 Guide Plate Bracket 1 8 AA06 6033 Exit Lock Spring 1 9 A006 4241 Release Cover 1 10 AA14 3040 Lever Shaft 1 11 5424 4142 Bushing - Cleaning Roller 2 12 A006 4263 Paper Exit Shutter 1 13 A006 4261 Paper Exit Feeler 1 14 A006 4203 Feeler Holder 1 15 A006 4202 Fusing Exit Frame 1 16 AB01 3134 Gear - 15T 1 17 AA14 3039 Spring Holder 5 18 AA06 6026 Release Stripper Spring 5 19 AA06 0081 Stripper Spring 5 20 A006 4212 Upper Stripper Stay 2 21 A006 4213 Middle Upper Stripper Stay 1 22 A006 9002 Hot Roller Stripper (5pcs/set) 1 23 A006 4211 Stripper Stay 1 23 Q’ty Per Assembly Feb. 28, ’89 24 12. BLACK DEVELOPMENT UNIT (A006) Index No. Part No. Description Feb. 28, ’89 Q’ty Per Assembly Description Q’ty Per Assembly 1 A006 3143 Entrance Seal Plate 1 35 AD03 7011 Mixing Auger 2 A006 3112 Doctor Blade 1 36 AA15 2090 Seal- Mixing Auger 3 4 A006 3116 Development Unit Guide 1 37 AA15 0042 Seal- 20x30mm A006 3205 Development Pannel Plate 1 38 AA15 1101 Seal- 2x26x340mm 5 A006 3222 Front Development Side Plate 1 39 AA15 1102 Seal - 2x7x420mm 6 AA15 1186 Front Side Plate Seal 2 40 AA14 5050 Toner Supply Shaft 7 A006 3100 Development 1 41 AA15 1096 Seal - Supply Roller - Front 8 5429 3561 Ball Bearing - 10x26x8 1 42 AA15 1100 Seal - 2x28x320mm 9 AB01 3213 Gear - 27T 1 43 AA15 1104 Seal- Toner Supply Roller 2 10 A006 3113 Retainer 1 44 AA15 1148 Seal- Supply Roller - Rear 1 11 AA15 2013 Seal - Development Roller 2 45 AB01 0017 Gear - 18Z 1 12 AB01 3380 Gear - 19Z 1 46 AB01 0018 Gear - 34Z 13 A006 3223 Rear Development Side Plate 1 47 AD03 3002 Toner Supply Roller - Black 14 AB01 7046 Coupled Gear - 27T/34T 1 48 A006 3151 Upper Casing - Toner Supply Unit 1 15 5205 3103 Bushing - 6mm 4 49 A006 3158 Front Side Bracket 1 16 AB01 3136 Gear - 34T 1 50 A006 3168 Agitator Shaft 1 17 AD03 8004 Paddle Roller 1 51 A006 3171 Rear Side Bracket 1 18 AD03 8021 Light Paddle Roller 1 52 5215 3327 Shaft - Agitator Joint -Hopper (115V) Roller 1 19 A006 3335 Knob - Paddle 1 53 A006 3183 20 A006 3330 Development Knob 1 53 5215 3328 Joint - Hopper (220/240V) 21 A006 3221 Lower Casing 1 54 5215 3347 Spring - Gear 1 22 A006 3160 Slitter 1 55 A006 3190 Black Development Unit 1 23 AD03 6018 Mixing Vanes 1 24 A006 3154 Lower Casing - Toner Supply Unit 1 25 5215 3399 Seal - 50x19mm 2 26 A006 3155 Plate Nut 1 27 AA15 0031 Sea 1 - 25x55mm 1 28 A006 3138 Toner Supply Unit - 115V 1 28 A006 3148 Toner Supply Unit - 220/240V 1 29 5215 3394 Seal - 12x406mm 1 30 AA15 1099 Seal - 2x14x37mm 2 31 AA15 0060 Seal - 20x28mm 1 32 5215 3295 Hopper Filter 1 33 AB01 3157 Gear - 67T 1 34 AB01 3156 Gear - 27T 1 Index No. Part No. Description 101 0314 0080W Philips Pan Head Screw - M4x8 102 0314 0100W Philips Pan Head Screw - M4x10 103 0952 4016W Philips Screw - M4x16 104 0313 0060W Philips Pan Head Screw - M3x6 105 0413 0082W Tapping Screw - M3x8 106 0353 0050W Tapping Screw - M3x5 107 0314 0100B Philips Pan Head Screw - M4x10 108 0720 0040E Retaining Ring - M4 109 0725 0100E Retaining Ring C - M10 110 0720 0060E Retaining Ring - M6 111 112 0313 0050G Philips Pan Head Screw - M3x5 0720 0050E Retaining Ring - M5 113 0720 0020E Retaining Ring - M2 114 0807 4103 Spacer - 0.5mm 115 0951 4006W Philips Screw With Flat Washer - M4x6 Q’ty Per Assembly Index No. 25 Part No. Description Q’ty Per Assembly 13. COLOR DEVELOPMENT UNIT (A006) Feb. 28, ’89 Feb. 28, ’89 13. COLOR DEVELOPMENT UNIT (A006) Index Part No. Description Index Q’ty Per Part No. Description Q’ty Per Assembly Assembly No. 1 AA15 0156 Mylar Seal - 15x74mm 2 36 AA15 1201 Rear Side Seal 1 2 AA15 1379 Seal - Doctor Blade 1 37 AA15 1196 Seal - Rear Side Fence 1 3 A006 3312 Left Cover 1 38 A006 3026 Color Development Unit 1 4 A006 3340 Development Guide 1 No. 5 A006 3255 Doctor Blade - Color 1 6 AA15 1138 Seal - 2x4x20mm 2 7 A006 5335 Color Development Harness 1 8 AB01 3131 Gear - 16T 1 9 5205 3103 Bushing - 6mm 5 10 AA15 2018 Development Roller Seal 2 11 A006 3305 Rear Side Plate 1 12 AA15 1134 Rear Side Fence Seal 1 13 AA15 1132 Seal - 2x9x24mm 1 14 AB01 3119 Gear - 22T 1 15 A006 3322 Retainer 1 16 AD03 6005 Mixing Vanes 1 17 AD03 7002 Mixing Auger 18 A006 3251 Development 19 AB01 7075 Coupled Gear - 22T/27T 1 20 AB01 3130 Gear - 21T 1 21 AA15 2019 Seal - Mixing Auger 1 22 AA15 1131 Seal- 2x9x16mm 1 23 AA15 1133 Front Side Fence Seal 1 24 A006 3301 Front Side Plate 1 101 0344 0060W Philips Truss Head Screw - M4x6 25 AD03 8003 Paddle Roller 1 102 0314 0080W Philips Pan Head Screw - M4x8 26 AD03 8005 Right Paddle Roller 1 103 0960 3010W Philips Flange Screw - M3x10 27 AA15 1169 Front Side Seal 1 104 0950 3006M Philips Screw With Lock Washer - M3x6 28 A006 3335 Knob - Paddle 1 105 0413 0082W Tapping Screw - M3x8 29 A006 3330 Development Knob 1 106 0952 3020W Philips Screw - M3x20 30 A006 3320 Adjusting Plate 1 107 0951 3006W Philips Screw With Flat Washer - M3x6 31 A006 3310 Lower Casing 1 108 0720 0040E Retaining Ring - M4 32 AA15 1187 Front Casing Seal 1 109 0720 0025E Retaining Ring - M2.5 33 A006 5260 DIP SW Board 1 110 0727 0090E Retaining Ring C - M9 34 AA15 1139 Seal - 2x15x344mm 1 111 0313 0040W Philips Pan Head Screw - M3x4 35 AA15 1188 Rear Casing Seal 1 112 0805 3415 Ball Bearing - M9 1 Roller 1 27 Feb. 28, ’89 14. COLOR TONER SUPPLY SECTION (A006) 28 14. COLOR TONER SUPPLY SECTION (A006) Index No. Part No. Description Feb. 28, ’89 Q’ty Per Assembly 1 Index No. Part No. I1 Description Q’ty Per Assembly 1 1 A006 3444 Stand Lever 36 AA15 1200 S e a l - 1x10x31mm 2 A006 3442 Lever Stopper 1 37 AA15 0068 Upper Casing Seal 1 3 A006 3443 Spring Plate 1 38 A006 3271 Decal - Red 1 4 A006 3434 Lever Bracket 1 38 A417 8551 Decal - Blue & Green (2pcs/set) 1 5 AA14 5046 Lever Shaft 2 39 A006 3027 Color Toner Supply Unit 1 6 5216 2676 Spring - Engage Gear Bracket 1 7 A006 3441 Stand Support Plate 1 8 AA15 1137 Seal - 3x6x318mm 1 9 AA15 1140 Seal - 2x10x50mm 1 10 A006 3380 Toner Supply Cover 1 11 A006 3383 Upper Casing Cover 1 12 AA15 1191 Seal - 2x40x45mm 1 13 A006 3349 Seal - 1x30x264mm 1 14 AA15 1141 Seal - 2x5x272mm 2 15 A006 3392 Upper Casing 1 16 AA15 2044 Seal - Toner Supply Cover 1 17 AB01 1022 Gear - 16T 1 18 AB01 7053 Coupled Gear - 32T/40T 1 19 AB01 1021 Gear - 15T 1 20 A006 3406 Rear Side Plate 1 21 AA15 1135 Seal - 2x13x44mm 2 22 AA15 1143 Rear Side Palte Seal 1 23 5215 3303 Seal - Toner Supply Roller 4 24 AA15 0032 Seal - 2x8x41mm 2 25 AD03 3003 Toner Supply Roller 1 26 AD03 9005 Agitator 1 27 AA15 1205 Seal - 2x5x318mm 1 28 AA15 1199 Seal - 1x10x39mm 1 29 A006 3400 Lower Casing 1 101 30 AA15 1130 Sensor Seal 1 102 0344 0060W 0413 0102W Philips Truss Head Screw - M4x6 Tapping screw - M3x10 31 A006 3386 Toner End Sensor 1 103 0313 0060W Philips Pan Head Screw - M3x6 32 A006 3385 Sensor Bracket 1 104 0323 0060W Philips Sunken Head Screw - M3x6 33 AA15 1142 Front Side Palte Seal 1 105 0323 0060B Philips Sunken Head Screw - M3x6 34 A006 3390 Front Side Plate 1 106 35 AG05 1051 Development Lever 1 107 0720 0040E 0434 0080W Retaining Ring - M4 Tapping screw - M4x8 29 15. CLEANING UNIT (A006) Feb. 28, ’89 30 Feb. 28, ’89 15. CLEANING UNIT (A006) Index No. Index No. * A006 3505 Cleaning Unit Q’ty Per Assembly 1 101 0413 0062W 1 5446 3135 Cap - F Sensor 1 102 0313 0050W Philips Pan Head Screw - M3x5 2 A006 3581 Upper Cleaning Casing 1 103 0720 0040E Retaining Ring - M4 3 A006 3579 Cap Seal 1 104 0313 0080W Philips Pan Head Screw - M3x8 4 A005 3585 Sensor Feeler - Toner Overflow 1 105 0413 0142W Tapping Screw - M3x14 5 A005 3587 Feeler 1 106 0413 0082W Tapping Screw - M3x8 6 A005 3586 Rubber Seal - Toner Collection 1 7 A006 3584 Toner Collection Hosing 1 8 AA15 1108 Casing Seal 1 9 A006 3585 Stay 1 10 AA15 2015 Toner Collection Seal 1 11 A006 3561 Frame 1 12 AA06 0099 Cleaning Blade Spring 2 13 AB01 7062 Coupled Gear - 17T/18T 1 14 AB01 7044 Coupled Gear - 18T/35T 1 15 A006 3563 Support Plate 1 16 AA14 3060 Shaft 1 17 AB01 1027 Gear - 19T 1 18 AB01 1026 Gear - 17T 1 19 AA08 0030 Bushing - M5 2 20 AA15 1106 Rear Blade Seal 1 21 AA15 1105 Front Blade Seal 1 22 A006 3560 Blade Cleaner 1 23 AG05 1059 Release Lever 1 24 A006 3552 Lower Cleaning Casing 1 25 A006 9003 Cleaning Seal 1 26 A006 3603 Front Brush Holder 27 AD04 2009 Cleaning Brush 28 A006 3604 Rear Brush Holder 29 AB01 1019 Gear - 12T 1 30 AA15 1109 Seal - M5 2 31 A006 3660 Toner Collection Roller 1 32 A006 3570 Cleaning Blade 1 33 A006 3556 Blade Bracket 1 34 5446 3648 Stepped Screw - M4 1 Part No. Description Supporter 1 31 Part No. Description Tapping Screw - M3x6 Q’ty Per Assembly 16. OPTICS SECTION 1 (A006) Feb. 28, ’89 32 16. OPTICS SECTION 1 (A006) Feb. 28, ’89 Q’ty Per Assembly Index No. Part No. Description Q’ty Per Assembly 1 5442 1704 Wing - Side 2 36 A006 1739 Scanner Sensor Bracket 1 2 5442 1703 Wing - Center 1 37 5205 5251 L.E.D Sensor Type - T 1 3 5442 1702 Small Screw - M3 4 38 5205 1768 Rubber Seal - Mirror 1 4 A006 1706 Support 1 39 AA15 0029 Seal - 0.2x15x140mm 1 5 A006 1710 Reflector Cover 1 40 5201 1775 Pulley 2 6 A006 1711 Lamp Terminal Rear Cover 1 41 AA05 0017 Scanner Drive Wire 1 7 A006 1712 Lamp Terminal Front Cover 1 42 5215 1924 3 8 5442 1710 1st Mirror 1 43 A006 1744 Cushion Wire Support Plate 2 9 5442 1711 Spring Plate - 1st Mirror 2 44 AA06 0083 Tension Wire Spring 2 10 5409 1705 Clamp - Reflector 2 45 A006 5333 Optics Fiber Cable 1 11 AX52 0008 Expossure Lamp - 85V/250W 1 46 A006 1731 Right Rear Pulley 1 12 5205 1696 Main - Reflector 1 47 A006 1737 Front Pulley 2 13 A006 1701 1st Scanner 1 48 AA05 0016 Scanner Drive Wire 1 14 A006 1708 Front Wire Clamp 1 49 A006 1733 Left Rear Pulley 1 15 A006 1705 Scanner Shoe 7 50 A006 5289 Exposure Lamp Harness 1 16 A007 1867 Insulator - Lamp Terminal 2 51 AA05 0018 Scanner Drive Wire 1 17 5442 1705 Rear Terminal - Exposure Lamp 1 52 A008 1840 Scanner Drive Wire Bracket 1 18 5420 1682 Supporter - Lamp Terminal 2 53 A006 1760 Lens Cover 19 A007 1868 Spacer - Lamp Terminal 2 54 A006 1709 Thermoswitch 20 AW11 0002 Thermoswitch 1 55 AA15 0072 Seal - 0.2x15x150mm 1 21 A006 5297 Reed Wire 1 56 57 AA15 1135 A006 1723 Seal - 2x13x44mm Spring Plate - Mirror 2 2 Reflector 22 5215 1700 Exposure Lamp Termianl - Fix 1 23 5215 1702 24 A006 1707 Clip - Exposure Lamp Rear Wire Clamp 1 25 A006 1721 Front Spring Plate 1 26 AC03 0019 2nd & 3rd Mirror 2 27 A006 1724 Rear Spring Plate 1 28 A006 1714 2nd Scanner 1 29 A006 1748 Optics Connector Bracket 1 30 A006 1747 Scanner Motor Support Plate 1 31 A006 1741 Motor Bracket 1 32 5361 2051 Capston : Drive Wire 1 33 AX06 0005 Scanner Drive Motor - DC24V/10W 1 34 AA05 0019 Scanner Drive Wire 1 35 A006 1745 Wire Adjusting Plate 1 Index No. Part No. Description 101 0951 4008W Philips Screw With Flat Washer - M4x8 102 0434 0060W Tapping Screw - M4x6 103 0313 0080W Philips Pan Head Screw - M3x8 104 0313 0120W Philips Pan Head Screw - M3x12 105 0964 4008W Tapping Screw With Flat Washer - M4x8 106 0434 0082W Tapping Screw - M4x8 107 0314 0250B Philips Pan Head Screw - M4x25 108 0314 0010W Philips Pan Head Screw - M4x10 109 0434 0080W Tapping Screw - M4x8 110 0720 0050E Retaining Ring - M5 111 0574 0050E Hexagon Headless Set Screw - M4x5 Philips Pan Head Screw - M3x4 112 0313 0040W 113 0313 0050W Philips Pan Head Screw - M3x5 114 0434 0060B Philips Tapping Screw - M4x6 1 Holder 1 1 Index No. Q’ty Per Assembly 33 Part No. Description Q’ty Per Assembly Feb. 28. '89 17. OPTICS SECTION 2 (A006) 34 17. OPTICS SECTION 2 (A006) Index No. Feb. 28, ’89 Q’ty Per Assembly Index No. 1 A006 1750 Lens Cover 1 35 5442 5329 Inlet Cooling Fan Meter 1 2 AA15 2014 Seal - 12x56mm 2 36 A006 5370 Optics Harness 1 3 5205 1794 Left Shield 1 37 A006 1828 Rear Optics Frame 1 4 A006 1752 Front 1 38 A006 1153 Lower Fan Bracket 1 5 5205 1793 Shielding - Guide 1 39 5205 5251 L.E.D Sensor Type - T 2 6 A006 1753 Lens Band 1 40 A006 1784 Sensor Bracket 1 7 AC02 0022 Lens - 8/180 1 41 AB00 0013 Mirror Drive Pulley 1 8 5419 5714 Stepped Screw - M4 2 42 AB00 0014 Gear - 48T 1 9 5442 1770 Cam - Optics Axis 2 43 A006 1767 1 10 A006 1749 Lens Bracket 1 44 A006 5279 Motor Bracket 3rd Scanner Drive Motor 11 A006 1756 Lens Bracket 1 45 5215 1811 12 A006 1755 Lens Shutter 1 46 Part No. Description Shielding Plate Part No. Description Q’ty Per Assembly 1 5215 1805 Spring - Lens Drive Wire Lens Tension Pulley 1 1 13 A006 1782 Mirror 1 47 AA14 3041 Guide Pin 1 14 AA05 0021 Mirror Drive Wire 1 48 A006 1792 Lens Cover Bracket 1 15 A006 1763 Mirror Carriage 1 49 A006 1786 Sensor Bracket 1 16 AC03 0020 4th Mirror 1 50 A006 1766 Adjusting Cam 2 17 5205 1853 Mylar Seal - Base 2 51 A006 1785 Sensor Bracket 1 18 A006 1788 Cam Plate - Lens Shield 1 52 A006 1817 Rear Scanner Slide Rail 1 19 AA01 0008 Sector Gear 1 53 A041 1823 Right Optics Stay 1 20 A006 5124 Optics Support Bracket 1 54 A006 1808 Guide Rod Bracket 1 21 A006 1769 Mirror Bracket Cover 1 55 AA15 0026 1 22 A006 1721 Front Spring Plate 2 56 AA15 0027 Seal - 0.2x10x295mm Seal - 10x87mm 23 A006 1798 Front Mirror Bracket 1 57 A006 1818 Front Scanner Slide Rail 1 24 A006 1762 Mirror Bracket 1 58 AC03 0022 6th Mirror 1 25 AC03 0021 5th Mirror 1 59 A006 1722 Spring Plate 2 Shutter 1 26 A006 1724 Rear Spring Plate 2 60 A006 1794 Mirror Bracket 1 27 AA14 0091 Guide Rod 1 61 A006 1866 Filter Bracket 1 28 A006 9514 Auti-Condensation Heater - 115V 1 62 A006 1871 Filter 1 28 A006 9515 Anti-Condensation Heater - 220V 1 63 A006 1862 Filter Holder 1 29 5215 5294 Lens Drive Motor - DC 6W 1 64 A006 1824 Left Optics Stay 1 30 A006 1757 Motor Bracket 1 65 A006 1870 Filter 1 31 5215 1813 Lens Drive Pulley 1 66 5408 3482 Clutch Spring 2 32 AA05 0020 Lens Drive Wire 1 67 A006 1827 Front Optics Stay 1 33 A006 1154 Motor Shielding Plate 1 68 A006 1684 Solenoid 1 34 A006 1152 Upper Fan Bracket 1 69 AA06 0098 Turn Spring 1 Index No. 70 AA01 0007 Sector Gear 101 0951 4008W Philips Screw With Flat Washer - M4x8 102 0314 0060W Philips Pan Head Screw - M4x6 103 0951 4012W Philips Screw With Flat Washer - M4x12 104 0434 0060W Tapping Screw - M4x6 105 0313 0060W Philips Pan Head Screw - M3x6 106 0324 0050W Philips Sunken Head Screw - M4x5 107 0314 0100W Philips Pan Head Screw - M4x10 108 0720 0030E Retaining Ring - M3 109 0720 0040E Retaining Ring - M4 110 1105 0197 Wire Saddle 111 1105 0199 Clamp 112 1105 0200 Clamp 113 0314 0060B Philips Pan Head Screw - M4x6 114 0434 0080W Tapping Screw - M4x8 115 0720 0060E Retaining Ring - M6 116 0951 3006W Philips Screw With Flat Washer - M3x6 Part No. Description Index No. Q’ty Per Assembly 1 35 Part No. Description Q’ty Per Assembly 18. PAPER EXIT SECTION (A006) Feb. 28, ’89 36 18. PAPER EXIT SECTION (A006) Index No. Feb. 28, ’89 1 A006 4471 Release Link 1 Index No. 36 AB01 3159 Gear - 30T Q’ty Per Assembly 1 2 A006 4470 Safety SW Arm 2 37 AB01 3218 Gear - 17T 1 3 A006 4472 Stopper Lever 1 38 A006 4301 Fusing Gear Bracket 1 4 5214 4128 Bushing - 14X8X6mm 2 39 5442 1924 Cushion - Exposure Glass 2 5 A006 4466 Decal - Exit 1 40 A006 4464 Stay - Lower Guide Plate 1 6 AX02 0033 Fan - AC100V/26W 1 41 AA14 3076 Stepped Screw - M4 3 7 AA14 0099 Release Shaft 1 8 A006 1146 Fan Stay 1 9 AA01 0005 Ozone Filter - 10x25x220mm 1 10 A006 1147 Ozone Filter Holder 2 Tapping Screw - M4x6 Part No. Description Q’ty Per Assembly 11 AA06 0118 Exit Spring 2 12 A006 4465 Upper Lever 1 13 A006 4455 Upper Guide Plate 1 14 AA12 0005 Antistatic Brush 1 15 5053 0447 Bushing - M6 4 Part No. Description 16 AF04 0007 Exit Drive Roller 1 17 AF02 2007 Exit Driven Roller 5 18 A006 4463 Lower Guide Plate 1 19 A006 4451 Duplex/Overlay Transport Gate 1 20 A006 4602 Entrance Guide Plate 1 21 A006 1098 Rear Support Plate 1 22 A006 1099 AC Power Supply Bracket 1 23 A006 4487 Inverter Gate Solenoid 1 24 A006 4480 Junction Gate Bracket 1 25 AB03 2019 Pulley 2 101 0434 0060W 26 AB01 3163 Gear - 30T 1 102 0434 0080W Tapping Screw - M4x8 27 A006 4483 Link 1 103 0414 0080W Tapping Screw - M4x8 28 A006 4486 Gate Solenoid 1 104 0965 4008W Tapping Screw With Flat Washer - M4x8 29 AA04 2003 Belt 1 105 0313 0050W Philips Pan Head Screw - M3x5 30 A006 4484 Junction Gate Lever 1 106 0720 0030E Retaining Ring - M3 31 AB01 3164 Gear - 17T 1 107 0720 0040E Retaining Ring - M4 32 AA06 0091 Junction Gate Spring 1 108 0720 0060E Retaining Ring - M6 33 AA06 0092 Release Spring 1 109 0622 0140E Spring Pin - 2x14mm 34 A006 4475 Release Lever 1 110 0622 0100E Spring Pin - 2x10mm 35 AA14 3074 Stepped Screw - M4x5 1 111 0802 5094 Tapping Truss Head Screw - M4x8 37 19. INVERTER SECTION 1 (A006) Feb. 28, ’89 38 19. INVERTER SECTION 1 (A006) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description Q’ty Per Assembly 1 36 A006 4606 Upper Guide 1 12 37 A006 4605 Upper Guide Plate 1 Duplex/Overlay Transport Clutch 1 38 A006 4607 Lower Guide 1 AA14 8049 Magnetic Clutch Shaft 1 39 A006 4671 Junction Gate Plate 1 5 5304 1639 Bushing - 8mm 2 40 A006 4672 Junction Gate Guide 1 6 A006 4695 Clutch Bracket 1 41 AF02 0045 Transport 1 7 AB02 3014 Sprocket - 22T 1 42 A006 4633 Inverter 8 5205 1105 Chain Tightener 1 43 AF02 0046 Inverter Roller 1 9 5409 1509 Ratchet Lever Spring 1 44 A006 4668 Inverter Guide Plate 1 10 A006 5371 Duplex Harness 1 45 A006 5329 Inverter 1 11 A006 4698 Bushed Roller Chain 1 46 A006 1100 Lower Left Stay 1 12 13 5442 1110 Sprocket - 20T 1 47 A006 4666 Sensor Bracket 1 AB01 3113 Gear - 32T 1 48 AW02 0010 Photointerruptor 1 14 A006 4892 Gear Arm 1 49 A006 4662 Bracket 1 15 AB01 7057 Sprocket - 16T 1 50 AB01 3154 Gear - 20T 1 16 A006 1102 Connector Holder 1 51 AA14 8048 Shaft 1 17 AB01 7080 Gear - 20T 2 52 AB01 7081 Coupled Gear - 16T/20T 1 18 AB01 3151 Gear - 20T 1 Tapping Screw With Flat Washer - M4x8 1 A006 4694 Inner Clutch Bracket 2 5053 0447 Bushing - M6 3 AX20 0024 4 Roller Gate Harness 19 AB01 3153 Gear - 20T 2 20 A006 4660 Support Plate 1 21 AA14 8047 Shaft 1 22 AA06 0085 Inverter Spring 1 23 AA06 0084 Junction Gate Spring 1 101 0964 4008W 24 A006 4618 Junction Gate Link 1 102 0951 4008W Philips Screw With Flat Washer - M4x8 25 A006 4614 Junction Gate Arm 1 103 0965 4008W Tapping Screw With Flat Washer - M4x8 26 A006 4641 Inverter Arm 1 104 0720 0050E Retaining Ring - M5 27 AB01 3150 Gear - 28T 1 105 0720 0060E Retaining Ring - M6 28 AB01 3152 Gear - 20T 1 106 0720 0040E Retaining Ring - M4 29 A006 4646 Gear Bracket 1 107 0720 0030E Retaining Ring - M3 30 AB01 3149 Gear - 20T 1 108 0622 0140E Spring Pin - 2x14mm 31 A006 4627 Rear Transport Bracket 1 109 0622 0100E Spring Pin - 2x10mm 32 5219 4560 Sprocket - 16T 1 110 1105 0199 Clamp 33 AF02 0066 Transport 1 111 1105 0196 Harness Clamp 34 A006 4616 Junction Gate 1 112 0964 4008W Tapping Screw With Flat Washer - M4x8 35 5442 2117 Shoulder Screw - Hinge 2 113 0434 0080W Tapping Screw - M4x8 Roller 39 1 20. INVERTER SECTION 2 (A006) Feb. 28, ’89 40 20. INVERTER SECTION 2 (A006) Index No. Feb. 28, ’89 Index No. Q’ty Per Assembly 1 101 0313 0060W Philips Pan Head Screw - M3x6 Slide Lever Magnet 2 102 0434 0082W Tapping Screw - M4x8 Photointerruptor 1 103 0965 4008W Tapping Screw With Flat Washer - M4x8 A006 5328 Relay Harness 1 104 0324 0060W Philips Sunken Head Screw - M4x6 5 A006 4685 Lower Guide Plate 1 105 0720 0040E Retaining Ring - M4 6 AF02 2004 Transport 3 106 0622 0140E Spring Pin - 2x14mm 7 A006 4609 Guide 1 107 Clamp 8 AA08 0037 Bushing - 6mm 8 108 1105 0199 0434 0080W 9 5205 4527 Spring - Exit 6 109 0802 5016 Tapping Screw - M3x5 10 A006 4626 Rear Lever 1 11 AA06 6032 Spring 12 AA14 0128 Transport 13 A006 4613 Lever 1 14 A006 4625 Transport Lever 1 15 AB01 3153 Gear - 20T 1 16 5053 0447 Bushing - M6 2 17 A006 4677 Rear Side Plate 1 18 5206 4478 Spring - Drive Roller 2 1 Part No. Description 1 A006 4689 Turn Guide Plate 2 AA02 0003 3 AW02 0011 4 Roller 1 Shaft 1 19 AF02 0047 Inverter Roller 20 AF02 0048 Transport 21 5442 2117 Shoulder Screw - Hinge 2 22 AG05 1015 Transport Lever 1 23 A006 4676 Front Side Plate 1 24 A006 4687 Upper Guide Plate 1 25 AG05 1016 Guide Plate Lever 1 26 AA14 3043 Shoulder Screw - M6x8 2 27 A006 4624 Lever Bracket 1 Roller 1 41 Part No. Description Tapping Screw - M4x8 Q’ty Per Assembly 21. JOGGER SECTION (A006) Feb. 28, ’89 42 Feb. 28, ’89 21. JOGGER SECTION (A006) Index No. Part No. Description Q’ty Per Assembly 1 Index No. Part No. Description Q’ty Per Assembly 1 A006 4835 Front Jogger Fence 36 A006 4810 Jogger Stay 1 2 AA16 2018 Jogger Fence Cushion 1 37 AF02 0039 Exit Jogger Roller 1 3 AA14 8040 Shaft 2 38 AB03 2030 Pulley 1 4 A006 4587 Front Paper Holder 1 39 5206 2684 Shoulder Screw - M3 2 5 AA15 0036 Jogger Fence Guide 2 40 AG05 1055 Jogger Knob 1 6 5442 2117 Shoulder Screw - Hinge 1 41 A006 4883 Exit Guide Plate 1 7 A006 4832 Jogger Fence Table 1 42 AA15 0055 Exit Guide 1 8 AA08 0029 Roller Holder 4 43 A006 4800 Front Jogger Frame 1 9 A006 4858 Roller Holder 2 44 A006 4805 Rear Jogger Frame 1 10 AF02 0040 Jogger Roller 2 11 A006 4880 Entrance 1 12 AA15 0025 Entrance Guide 1 13 A006 4590 Jogger Fence Support 2 1 Guide-Plate 14 A006 4885 Lower Jogger Guide 15 AA05 0015 Jogger Wire 1 16 5206 2877 Wire Clamp Plate 2 17 5206 2876 Spring - Wire 1 18 A006 4589 Rear Paper Holder 1 19 A006 4840 Rear Jogger Fence 1 20 AX05 0009 Stepping Motor - DC24V 1 21 AB03 2031 Pulley 1 22 A006 4825 Home Sensor Bracket 1 23 5205 5250 L.E.D Sensor Type - S 1 24 5206 5472 Harness - Jogger H.P. 1 101 0313 0060W Philips Pan Head Screw - M3x6 25 A006 4819 Motor Bracket 1 102 0960 4008W Philips Flange Screw - M4x8 26 A006 4873 Joined Link 1 103 0314 0100W Philips Pan Head Screw - M4x10 27 A006 4876 1 104 0314 0060W Philips Pan Head Screw - M4x6 28 A006 4592 Solenoid Bracket Jogger Positioning 1 105 0574 0050W Hexagon Headless Set Screw - M4x5 29 A006 4870 Arm 2 106 0720 0040E Retaining Ring - M4 30 5214 3105 Spring - Toner End Lever 1 107 0622 0100E Spring Pin - 2x10mm 31 AA04 2002 Belt 1 108 0323 0080W Philips Sunken Head Screw - M3x8 32 AB01 7056 Pulley - 20T 1 109 0965 3008W Tapping Screw With Flat Washer - M3x8 33 5053 0447 Bushing - M6 4 110 0720 0030E Retaining Ring - M3 34 AB03 2032 Pulley 2 111 0323 0050W Philips Sunken Head Screw - M3x5 35 AF02 0038 Entrance Jogger Roller 1 112 0443 0060W Hexagon Head Tapping Screw - M3x6 43 22. DEVELOPMENT UNIT CHANGE SECTION (A006) 44 Feb. 28, ’89 22. DEVELOPMENT UNIT CHANGE SECTION (A006) Index No. Part No. Description Q’ty Per Assembly 1 Feb. 28, ’89 Index No. 101 0951 3004W Part No. Description Philips Screw With Flat Washer - M3x4 1 A006 1831 Upper Right Shielding Plate 2 A006 3475 Solenoid Bracket 1 102 0314 0100W Philips Pan Head Screw - M4x10 3 5215 5230 Photointerrupter - L-Type 1 103 0720 0040E Retaining Ring - M4 4 A006 3473 Solenoid Link 1 104 0314 0080W Philips Pan Head Screw - M4x8 5 AX10 0006 Spring Solenoid 1 105 0313 0060W Philips Pan Head Screw - M3x6 6 AA05 1003 Pressure Wire 1 106 0314 0050B Philips Pan Head Screw - M4x5 7 AB04 5001 Clutch Lever 1 107 0720 0060E Retaining Ring - M6 8 AB04 1001 Gear - 28T 1 108 1105 0197 Wire Saddle 9 AB04 3001 Sleeve 1 109 1105 0199 10 AB04 4001 Spring 1 0950 4012W Clamp Screw - Spring Washer - M4x12 11 A006 3465 Cam 110 111 0434 0080W Tapping Screw - M4x8 12 A006 3480 Cam Lever . 1 1 13 5304 1639 Bushing - 8mm 14 5209 4096 Pressure 15 5446 2620 Idler Pulley - 20 16 A006 3483 Cam Lever 1 17 5413 1875 Knob Screw 2 18 A006 3421 Development Guide 1 19 A006 3490 Guide Support 2 1 Spring 4 1 1 20 AA14 0088 Shaft 21 A006 3060 Shaft 1 22 A006 3056 Shaft Arm 2 23 5918 3120 A006 3050 Stud - M4 Development Rail 2 24 25 A006 2589 Cassette Release Lever 1 26 A006 3426 Development 1 27 A006 3062 Development Lever 1 28 A006 3063 Development 1 29 5216 2676 Spring - Engage Gear Bracket 1 30 31 A006 1169 A006 1141 Front Right Support Plate Harness Stay 1 1 Stopper Stopper 1 45 Q’ty Per Assembly 23. MAIN MOTOR & CLEANING RELEASE SECTION (A006) Feb. 28, ’89 Feb. 28, ’89 23. MAIN MOTOR & CLEANING RELEASE SECTION (A006) Index No. Part No. Description Index No. Q’ty Per Assembly 1 Part No. Description 1 AA06 6027 Spring 101 0434 0080W Tapping Screw - M4x8 2 AA14 6297 Pin - 5x15mm 1 102 0964 4008W Tapping Screw With Flat Washer - M4x8 3 A006 4292 Fusing Unit Lever 1 103 0314 0060W Philips Pan Head Screw - M4x6 4 A006 1143 Fusing Unit Rail 1 104 0951 4006W Philips Screw With Flat Washer - M4x6 5 A006 2078 Charge Corona Duct 1 105 0315 0120W Philips Pan Head Screw - M5x12 6 5442 2146 Seal - 5x12x182mm 1 106 0434 0060W Tapping Screw - M4x6 7 A006 2080 Casing - Fan - Charge Corona 1 107 0314 0080W Philips Pan Head Screw - M4x8 8 5442 2143 Fan - Main Corona 1 108 0314 0080W Philips Pan Head Screw - M4x8 9 AX02 0034 Main Motor - 54W 1 109 0314 0120W Philips Pan Head Screw - M4x12 10 5205 1083 1 110 0720 0040E Retaining Ring - M4 1 111 0707 5050B Collar - M5 1 112 0575 0060E Hexagon Headless Set Screw - M5x6 10 5205 1084 Sprocket - 30T/50Hz Sprocket - 27T/60Hz 11 A006 5374 Fusing Support Harness 12 AA15 1110 Sea 1 - 5x45x59mm 1 113 0574 0060E Hexagon Headless Set Screw - M4x6 13 A006 2077 Blower Duct 1 114 0720 0030E Retaining Ring - M3 14 AA15 1111 Seal - 5x24x264mm 1 115 0803 0039 Stepped Screw - M3x2 15 A006 5334 Overflow Harness 1 116 1105 0196 Harness Clamp 16 AA16 1011 Cushion - 5x6x9mm 2 117 1105 0008 Nylon Clip - 2N 17 AA16 1002 Rubber Pad 4 118 0594 0080E Bolt - M4x8 18 A006 1132 Harness Guide Bracket 1 19 A006 2076 Duct Bracket 1 20 5205 5251 L.E.D Sensor Type - T 1 21 A006 3676 Sensor Shutter 1 22 A006 3675 Sensor Bracket 1 23 AA06 0131 Cleaning Pressure Spring 2 24 A006 3638 Release Guide 1 25 A006 3635 Release Lever 2 1 26 A006 3623 Release Bracket 27 A006 3628 Release Rail 1 28 A006 3926 Upper Transport Guide 1 29 A006 3619 Handle 1 30 5215 1102 31 AG05 1007 Spring - Main Drive Tightener Release Handle Bracket 1 1 47 Q’ty Per Assembly 24. DRIVE SECTION (A006) Feb. 28, ’89 48 24. DRIVE SECTION (A006) Index No. Part No. Description Feb. 28, ’89 Q’ty Per Assembly Index No. Part No. Description Q’ty Per Assembly 1 A006 3176 Toner Supply Support Plate 1 35 AA14 5034 Transport 2 5053 0447 Bushing - M6 4 36 A006 3918 Idle Gear Bracket 1 3 AA14 8044 Toner Supply Shaft 1 37 AB02 3026 Sprocket - 20T 1 4 A006 3175 Toner Supply Bracket 1 38 AB01 3166 Gear - 20T 1 5 AB01 3145 Gear - 44T 1 39 AB01 3167 Gear - 32T 1 6 AB01 7047 Gear - 20T 1 40 A006 3329 Agitator Holder 1 7 AX21 0009 Toner Supply Clutch 1 41 A006 3327 Development Holder 1 Shaft 1 8 AB01 3139 Gear - 19T 1 42 AB02 3024 Sprocket - 28T 1 9 AB01 3140 Gear - 17T 1 43 A006 3670 Drive Stay 1 10 AB01 3217 Gear - 16T 1 44 AA14 5033 Cleaning Shaft 1 11 AB01 7078 Coupled Gear - 18T/50T 1 45 AB01 1025 Gear - 17T 1 12 AB01 7076 Coupled Gear - 17T/18T 1 13 AB01 1020 Gear - 17T 1 14 AB02 3022 Sprocket - 28T 1 15 A006 3208 Bias Terminal 1 16 A006 1133 Board Angle 1 17 5442 1110 Sprocket - 20T 2 18 A006 1158 Power Supply Bracket 1 19 AA04 3007 Timing Belt - 230XL 1 20 A006 2329 Stay 1 21 AB03 0023 Pulley - 15T 1 22 AW02 0001 Photointerruptor 1 23 A006 2327 1 101 0951 4008W Philips Screw With Flat Washer - M4x8 24 5442 1111 Belt Tightener Spring -Main Drive Tightener (50Hz) 1 102 0960 4010W Philips Flange Screw - M4x10 24 5215 1102 Spring - Main Drive Tightener (60Hz) 1 103 0951 4006B Philips Screw With Flat Washer - M4x6 25 5215 1102 Spring - Main Drive Tightener 1 104 0434 0080W Tapping Screw - M4x8 26 A006 1134 Photointerruptor 1 105 0720 0060E Retaining Ring - M6 27 5205 1105 Chain Tightener 1 106 0720 0040E Retaining Ring - M4 28 AB01 3147 Coupled Gear - 15T/40T 1 0720 0050E Retaining Ring - M5 29 AB01 3148 Gear - 20T 1 107 108 0622 0140E Spring Pin - 2x14mm 30 AB01 3146 Gear - 45T 1 109 0807 4095 Washer 31 AB01 7051 Gear - 30T 1 110 1105 0199 Clamp 32 A041 1131 Fusing Guide Plate 1 111 0434 0060W Tapping Screw - M4x6 33 AB01 7049 Gear - 20T 1 112 0916 1226 Bushed Roller Chain 34 AB01 3155 Gear - 40T 1 Bracket 49 25. ELECTRICAL SECTION 1 (A006) Feb. 28, ’89 50 Feb. 28, ’89 25. ELECTRICAL SECTION 1 (A006) Index No. Part No. Description Index No. Q’ty Per Assembly 1 Part No. Description 1 A006 5321 Manual Feed Harness 101 0434 0080W Tapping Screw - M4x8 2 A006 5228 Paper Feed Board 1 102 0801 1185 Philips Truss Head Screw - M4x8 3 A006 5818 Paper Feed Board Bracket 1 103 0314 0100W Philips Pan Head Screw - M4x10 4 AZ31 0002 Power Pack - Separation 1 104 1105 0251 Clamp 5 A006 5382 DC Harness - 115V 1 105 1105 0160 Clamp 5 A006 5380 1 106 1105 0161 Locking Support 6 A006 5819 DC Harness - 220/240V Main Board Bracket 1 107 1105 0197 Wire Saddle 7 A006 5155 I/O Control Board 1 108 1105 0196 Clamp 8 A006 1164 Board Hinge 1 109 0964 4008W Tapping Screw With Flat Washer - M4x8 9 A006 1165 Board Hinge 1 110 1105 0229 Clamp 10 AZ32 0008 Power Pack - C/T/B/G 1 11 5408 5160 Short Connector 1 12 A000 5326 Print Board Sorter Adaptor 1 13 A006 5821 Board Bracket 1 14 A006 5352 Counter Harness 1 15 A006 5827 Counter Bracket 1 16 A006 5828 Counter Cover 1 17 5439 5246 Totalaizer Ass’y 1 18 A006 1163 Board Angle 1 19 A006 1156 Power Pack Bracket 1 20 5434 7916 High Voltage Decal 1 51 Q’ty Per Assembly 26. ELECTRICAL SECTION 2 (A006) Feb. 28, ’89 52 26. ELECTRICAL SECTION 2 (A006) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly 1 Part No. Description 1 A006 5820 AC Drive Board Bracket 101 0434 0080W Tapping Screw - M4x8 2 A006 5620 AC Drive Board - 220/240V 1 102 0801 1185 Philips Truss Head Screw - M4x8 2 A006 5520 AC Drive Board - 115V 1 103 0951 3006W Philips Screw With Flat Washer - M3x6 3 A006 5826 Bracket - Power Supply Board 1 104 0951 4006W 4 A006 5545 AC Support Harness - 115V 1 105 0964 4008W Tapping Screw With Flat Washer - M4x8 4 A006 5645 AC Support Harness - 220/240V 1 106 0314 0250W Philips Pan Head Screw - M4x25 5 5205 5494 Harness - Transformer - 220/240V 1 107 1105 0197 Wire Saddle 6 A006 5811 AC Power Supply Cord Bracket 1 108 1105 0200 Clamp 7 A006 5814 Harness Cover 1 109 1105 0160 Clamp 8 A006 5815 Transformer Bracket 1 110 1105 0183 Spacer 9 A006 5813 Power Supply Cord Bracket 1 111 0315 0080W Philips Pan Head Screw - M5x8 10 5403 4335 Decal - Terminal - 115V 1 112 0952 3006W Philips Screw - M3x6 11 5205 5405 Transformer - 115V 1 113 1606 1484 Capacitor - 16µF 220V (115V) 11 AZ14 0004 Transformer - 220/240V 1 113 1606 1485 Capacitor - 16µF 220V (220/240V) 12 A006 5822 Safety SW Bracket 1 114 1602 0923 Noise Filter - 115V 13 AZ23 0003 Power Supply Board 1 114 1602 0946 Noise Filter - 220/240V 14 A006 5824 Safety SW Lever 1 115 1104 0322 Fuse Holder (115V) 15 A006 5540 AC Harness 1 116 1107 0485 Fuse - 15A, 125V (115V) 16 A006 1160 Stay 1 116 1107 0486 Fuse - 8A, 250V (220/240V) 117 1204 1545 Main Switch 118 1204 1373 Push Switch 119 1101 0359 Terminal - 3P 120 0313 0160W Philips Pan Head Screw - M3x16 121 1107 0415 Fuse - 5A 122 1150 0003 Power Supply Cord (115V) 122 123 1150 0009 Power Supply Cord - 220/240V 0964 4010W Philips Screw With Flat Washer - M4x10 124 1106 0366 Cord Clamp - 115V 124 1106 0442 Cord Clamp - 220/240V 53 Philips Screw With Flat Washer - M4x6 Q’ty Per Assembly 27. FRAME (A006) Feb. 28, ’89 Feb. 28, ’89 27. FRAME (A006) Index No. Part No. Description Index Q’ty Per Assembly 1 No. I Part No. I Description 101 0314 0200W 1 102 1005 0383 Edging - B 1 103 1106 0493 Edging Rear Grip Arm 1 104 0434 0100W Tapping Screw - M4x10 Pin - 8x10mm 1 105 0434 0080W Tapping Screw - M4x8 Rear Grip Guide 1 A006 1061 Front Grip Guide 1 A006 1063 Harness Guide Bracket 1 9 A006 1056 Right Rear Support Plate 1 10 A006 1060 Small Shielding Plate 1 11 AH02 0001 Rubber Foot 6 12 A006 1057 Receive Plate 1 13 A006 1058 Jogger Support Plate 1 14 A006 1059 Large Shielding Plate 1 1 A006 1066 Left Grip 2 AA13 4013 Pin - 8x15mm 3 A006 1067 Front Grip Arm 4 A006 1068 5 AA13 2028 6 A006 1062 7 8 55 Philips Pan Head Screw - M4x20 Q’ty Per Assembly 28. I/O CONTROL BOARD (A006) Feb. 28, ’89 56 Feb. 28, ’89 28. I/O CONTROL BOARD (A006) Index No. Description Part No. Q’ty Per Assembly 1 Index No. Part No. Description * A006 5155 I/O Control Board 129 1407 2077 IC - SN74LS138NS 1 AW00 0003 Fiber Connector - Red 1 130 1407 2081 IC - SN74LS08NS 2 AW00 0004 Fiber Connector - White 1 131 1407 2187 IC - SN74LS07NS 3 A006 5153 Heat Sink 1 132 1407 2217 IC - MPD71054G 4 A006 5154 IC - MBM2764-25 1 133 1407 2230 IC - TD62303F 134 1407 2231 IC - TD62308AF 135 1407 2338 Cmos - IC - TC74HC4050F Ttl - IC - SN74LS241NS 101 0313 0060B Philips Pan Head Screw - M3x6 136 1407 2339 102 0314 0060W Philips Pan Head Screw - M4x6 137 1407 2340 IC - SN74LS126ANS 103 1002 0307 Jumper Wire 138 1407 2344 Transistor - TD62382F 104 1101 0328 Connector Pin Contact 139 1407 2345 Transistor - TD62305F 105 1102 0845 Contact - EI Connector 140 1407 2523 IC - TC74HC14F 106 1103 0347 Connector - 8P 141 1408 0516 IC - TLS27L4 107 1103 0734 Connector - 8P 142 1408 0598 IC - MB3773PF 108 1103 3019 Connector - 16P 143 1503 0070 Ceramic Oscillator - 10MHz 109 1103 3020 Connector - 20P 144 1503 0180 Ceramic Oscillator - 8MHz 110 1103 3024 Connector 145 1601 8349 Variable Resistor - 500KOHM 111 1103 3026 Connector 146 1604 1353 Capacitor - 47µF 10V 112 1104 0271 LSI Socket - 28P 147 1604 1354 Capacitor 148 1604 1386 Capacitor - 100MF 50V 149 1605 0304 Capacitor - 2200PF ±10% 50V 150 1606 1451 Capacitor - 0.1µF 50V 113 1401 0296 Transistor - 2SA1162Y 114 1401 0298 Transistor - 2SC2712Y 115 1401 0392 Transistor - 2SB1193 116 1401 0410 Transistor - 2SB1115YL 117 1401 0434 Transistor - 2SD1474P 118 1402 0688 Diode - 6.8V 1W 119 1402 0691 120 1402 0706 Diode - RD5.1M Diode - U1Z12 121 1402 0709 Diode - E11FS1 122 1407 1335 IC - RF5G02-005 123 1407 1599 IC - SN74LS153NS 124 1407 1720 IC - TC74HC02 125 1407 1880 IC - SN74LS04NS 126 1407 1882 IC - SN74LS373NS 127 1407 2052 IC - SN74LS74ANS 128 1407 2073 IC - UPD78C10GF 57 - 100MF 10V 151 1606 1452 Capacitor - 0.01µF 50V 152 1606 1455 Capacitor - 470PF 25V 153 1606 1520 Capacitor - 27PF 50V 154 1610 0039 Resistor - 150OHM l/8W ±5% 155 1610 0041 Resistor - 180OHM l/8W ±5% 156 1610 0053 Resistor - 1KOHM l/8W ±5% 157 1610 0064 Resistor - 3KOHM l/8W ±5% 158 1610 0065 Resistor - 3.3KOHM l/8W ±5% 159 1610 0067 Resistor - 4.7KOHM l/8W ±5% 160 1610 0071 Resistor - 10KOHM ±5% 161 1610 0107 Resistor - 1MOHM l/8W ±5% 162 1610 0119 Resistor - 10MOHM l/8W ±5% 163 1610 0511 Resistor - l/8W 5.23KOHM Q’ty Per Assembly 29. PAPER FEED BOARD (A006) Feb. 28, ’89 58 29. PAPER FEED BOARD (A006) Part No. Description A006 5228 Paper Feed Board 5205 5570 Jumper Wire Feb. 28, ’89 Index No. Q’ty Per Assembly 1 1 59 Part No. Description 101 1102 2365 102 1102 3254 Receptacle - 3P 103 1102 3255 Receptacle - 3P 104 1103 1559 Connector - 12P 105 1103 1726 Connector - 4P 106 1103 1727 Connector - 3P 107 1103 1729 Connector - 7P 108 1103 1731 Connector - 9P 109 1103 1733 Connector - 11P 110 1103 1739 Connector - 3P 111 1103 1745 Connector - 7P 112 1401 0825 Diode - 1SS176 113 1408 0200 IC - TA75339P 114 1601 7374 Resistor Array - 4.7KOHM 115 1604 1382 Capacitor - 10µF 50V 116 1606 0998 Capacitor - 0.01µF 50V 117 1611 4103 Resistor - 10KOHM l/4T ±5% Connector - 6P Q’ty Per Assembly 30. AC DRIVE BOARD (A006) Feb. 28, ’89 I 60 Feb. 28, ’89 30. AC DRIVE BOARD (A006) Index No. Part No. Description Index Q’ty Per Assembly No. Part No. Description 1 105 1402 0360 Zener Diode - HZ20 1 106 1402 0407 Zener Diode - HZ6B3 1 107 1402 0416 Zener Diode - HZ58 - 1 Jumper Wire 1 108 1402 0433 Zener Diode - HZ982 - 09 Holder 1 109 1402 0539 Zener Diode - HZ9C - 2 110 1402 0579 Diode - DSA1A4 111 1402 0716 Diode - 1S2471 112 1403 0521 Photocoupler - S21MD3 113 1405 0129 Rectifier - 1B4B42 114 1408 0233 IC - HA17903PS 115 1601 1148 Resistor - 1KOHM ±5% 1W 116 1601 7468 Fuse Resistor - 100OHM l/2W 117 1601 8138 Variable Risistor - 30KOHM 118 1602 0895 Noise Filter - 0.1µF 120OHM 119 1602 0920 Noise Kilter - 0.1µF 120OHM 120 1604 1378 Capacitor - 1MF 50V 121 1606 0689 Capacitor - 0.01µF 50V 122 1606 1400 Capacitor - 0.1µF 123 1606 1472 Capacitor - 0.1µF ±20% 124 1606 1497 Capacitor - 0.047µF 125V 125 1606 1542 Capacitor - 0.22MF AC250V 126 1607 0134 Choke Coil - 250MH 6A 127 1611 4103 Resistor - 10KOHM l/4T ±5% 128 1611 4124 Resistor - 120KOHM l/4T ±5% 129 1611 4153 130 1611 4223 131 1611 4242 Resistor - 15KOHM l/4T ±5% Resistor - 22KOHM l/4T ±5% Resistor - 2.4KOHM l/4T ±5% 132 1611 4333 133 1611 4474 134 1611 4562 Resistor - 5.6KOHM l/4T ±5% 135 1611 4820 Resistor - 82OHM l/4T ±5% * A006 5620 AC Drive Board - 220/240V * A006 5520 AC Drive Board - 115V 1 AZ10 0001 Transformer - 100,l15V/13V 2 6843 1222 3 A006 5805 Resistor - 33KOHM l/4T ±5% Resistor - 470KOHM l/4T ±5% 101 1102 1189 Pin Connector - 7P 136 1405 0156 IC - BCR8DM 102 1102 1194 Connector - 3P 137 1405 0182 Triac - BCR16DM8L (115V) 103 1103 1732 Connector - 10P 137 1405 0183 Triac - BCR16DM-12L (220/240V) 104 1208 1152 Relay 138 1405 0184 Triac - BCR10DM8L 61 Q’ty Per Assembly Feb. 28, ’89 31. AC HARNESS (A006) 62 Feb. 28, ’89 31. AC HARNESS (A006) Index No. * Part No. A006 5540 Description AC Harness Index No. Q’ty Per Assembly 1 63 Part No. Description 101 1102 1819 Positive Lock Housing 102 1102 1890 Housing - 7P 103 1100 0878 Connecting Cap 104 1100 0916 Pin - Mate-N-Lock 105 1100 1043 Pin - Mate-N-Lock 106 1100 1169 Fastening Receptacle 107 1100 1171 Fastening Receptacle 108 1100 1172 Fastening Receptacle 109 1100 1239 Pin - Mate-N-Lock 110 1100 1241 Socket - Mate-N-Lock 111 1100 1247 Terminal 112 1100 1310 Positive Lock Receptacle 113 1102 0512 Connector - 3P 114 1102 0782 Connector - 4P 115 1102 1023 Connector - SP Red 116 1102 1402 Receptacle Housing - 1P 117 1102 1403 Receptacle Housing 118 1102 1404 Receptacle Housing 119 1102 1408 Connector - 1P 120 1102 1507 Connector - 2P 121 1102 1515 Connector - 2P 122 1102 1516 Connector - 3P 123 1102 1532 Connector - 2P 124 1102 1815 Connector - 3P 125 1102 1817 Positive Lock Housing Q’ty Per Assembly Feb. 28, ’89 32. DC HARNESS (A006) Index No. Part No. Description * A006 5380 DC Harness - 220/240V * A006 5382 DC Harness - 115V Index No. Q’ty Per Assembly 1 1 Receptacle Part No. Description Connecting Sleeve 3.0mm 118 1102 0796 119 1102 1091 Connector - 6P 120 1102 1396 Connector - 2P 121 1102 1397 Connector - 2P 122 1102 1412 Receptacle Housing - 2P 123 1102 1423 Housing - 3P Black 124 1102 1509 Connector - 4P 125 1102 1515 Connector - 2P 126 1102 1620 Connector - 3P 127 1102 1740 Connector - 7P 128 1102 1831 Connector - 4P 129 1102 1882 Housing 130 1102 1910 Connector - 2P 131 1102 1911 Connector - 3P 132 1102 1912 Connector - 4P 133 1102 1913 Connector - 5P 134 1102 1914 Connector - 6P 135 1102 1916 Connector - 8P 136 1102 1918 Connector - 10P Connector - 11P 101 1100 0277 Fastening 102 1100 0340 Closed Terminal 137 1102 1919 103 1100 0342 Closed Terminal 138 1102 1923 Connector - 15P 104 1100 1159 Socket - Mate-N-Lock 139 1102 1924 Connector - 2P 105 1100 1239 Pin - Mate-N-Lock 140 1102 1928 Connector - 6P 106 1100 1240 Socket - Mate-N-Lock 141 1102 1932 Connector - 10P 107 1100 1247 Terminal 142 1102 1938 Connector - 2P 108 1100 1249 Receptacle Terminal 143 1102 1942 Connector - 6P 109 1100 1259 Socket - Mate-N-Lock 144 1102 1983 Socket Housing - 3P 110 1100 1301 Fastening 1102 2108 Connector 111 1100 1327 Contact 145 146 1102 2370 Connector - 6P 112 1100 1328 Contact 147 1103 0656 Connector - 16P 113 1100 1329 Socket Contact 148 1103 0658 Connector - 40P 114 1100 1342 Terminal 149 1103 0661 Connector 115 1100 1346 Pin Contact 150 1103 0663 Connector - 16P 116 1100 1348 Pin Contact 151 1104 0381 Holder 117 1100 1422 Contact 152 1107 0354 Fuse - 3.15A/125V Receptacle 65 Q’ty Per Assembly Feb. 28, ’89 33. SPECIAL TOOL (A006) 66 Feb. 28, ’89 33. SPECIAL TOOL (A006) Index No. 67 Part No. Description Q’ty Per Assembly 1 1 A006 9101 DG Gauge - Color Dev. 2 5205 9101 Gap Gauge 1 3 A006 9103 Omega Clamp 1 4 5203 9501 Grease - 501 1 5 5442 9106 Drum Shoe 1 6 5447 9104 Shoe Adaptor 1 7 5420 9504 Thermo Meter - HLC 1 8 5420 9505 Probe - HLC - 30 1 9 5420 9507 Digital Multimeter - BECKMAN 1 10 5447 9078 Heart Resisting Grease MT-78 1 11 5442 9103 Launa Oil 40 1 12 5446 9140 Thickness Gauge - 0.2mm 1 13 A006 9105 Drum Shaft 1 14 A006 9104 Adjusting Scanner Pin (4pcs/set) 1 15 A008 9502 Silicone Grease - G40M 1 16 A006 9513 DG Gauge - Black Dev. 1 17 Anti-Condensation Heater - 115V 1 17 A006 9514 A006 9515 Anti-Condensation Heater - 220V 1 18 5420 9516 Test Chart - OS-A3 (l0pcs/set) 1 34, DECAL & DOCUMENT (A006) Feb. 28, ’89 68 Feb. 28, ’89 34. DECAL & DOCUMENT (A006) 69 34. DECAL & DOCUMENT (A006) Feb. 28. ’89 70 34. DECAL & DOCUMENT (A006) Feb. 28, ’89 1 AA00 0015 Decal - High Temperature 1 Index No. 27 2 AA00 2010 Decal - Paper Level 1 28 A006 8610 Installation Procedure - English 3 AA00 2022 Manual Feed Decal - LT 1 3 AA00 2023 Manual Feed Decal - A4 1 28 A006 8615 Installation Procedure - 5 Language 4 A006 3271 Decal - Red 1 (Copier) 1 5 A006 1266 Decal - Scale - LT 1 28 A917 8610 Installation Procedure - English 1 5 A006 1268 Decal - Scale - A4 1 28 A917 8615 Installation Procedure - 5 Language 1 6 A006 1315 Decal -Main SW- 115V 1 28 A417 8616 Installation Procedure - Color Dev. 1 6 A006 1316 1 7 A006 1387 Decal - Main SW - 220/240V Decal - Release 8 A006 2961 Decal - Manual Feed 1 9 A006 4466 Decal - Exit 1 10 A006 1298 Decal - Adding Color Toner 1 11 A006 1299 Decal - Color Dev. Replacement 1 12 A006 1294 Decal - Misfeed Removal 1 13 A006 1303 Decal - Toner Replacement 1 14 A006 1304 Decal - Indications 1 15 AA00 1052 Decal - Knob - Feed Roller 1 16 A006 1398 Decal - Unlock 1 17 A006 1396 Decal - Lock 1 18 5403 4335 Decal - Terminal - 115V 1 19 5434 7916 High Voltage Decal 1 20 A006 4165 Decal - B1 1 21 A006 4167 Decal - B3 1 22 A006 4168 Decal - Fusing Knob 1 23 5216 4145 Thermofuse Decal 1 24 5442 1372 Decal - Power Source - 220V 1 25 AA00 2083 Decal Sheet - Large - LT 1 25 AA00 2080 Decal Sheet - Large - A4 1 26 AA00 2084 Decal Sheet - Small - LT 1 26 AA00 2079 Decal Sheet - Small - A4 1 27 A006 8600 Operating Instructions - English 1 27 A006 8601 Operating Instructions - German 1 27 A006 8602 1 27 A006 8603 Operating Instructions - French Operating Instructions - Italian Index No. Part No. Description Q’ty Per Assembly 1 1 Part No. Description A006 8604 Operating Instructions - Spanish (Copier) Q’ty Per Assembly 1 1 PARTS INDEX Feb. 28, ’89 Description Parts No. Page and Index No. Parts No. Description Page and Index No. A006 1056 Right Rear Support Plate 11-8 A006 1166 ADF Harness Shielding Plate A006 1056 Right Rear Support Plate 55-9 A006 1167 Rear Cover Angle 11-48 A006 1057 Receive Plate 55-12 A006 1169 Front Right Support Plate 45-30 11-50 A006 1058 Jogger Support Plate 55-13 A006 1252 Upper Cover - LT 3-57 A006 1059 Large Shielding Plate 55-14 A006 1253 Upper Cover - A4 3-57 A006 1060 Small Shielding Plate 55-10 A006 1266 Decal - Scale - LT 3-53 A006 1061 Front Grip Guide 55-7 A006 1266 Decal - Scale - LT 5-4 69-5 A006 1062 Rear Grip Guide 55-6 A006 1266 Decal - Scale - LT A006 1063 Harness Guide Bracket 55-8 A006 1267 ADF Cap 3-56 A006 1066 Left Grip 55-1 A006 1268 Decal - Scale - A4 3-53 A006 1067 Front Grip Arm 55-3 A006 1268 Decal - Scale - A4 5-4 A006 1068 Rear Grip Arm 55-4 A006 1268 Decal - Scale - A4 69-5 A006 1074 Key Counter Bracket 11-21 A006 1272 Front Cover 3-25 A006 1078 Right Rear Support Bracket 11-51 A006 1283 Front Cover Chain 3-27 A006 1079 Solenoid Bracket Angle 13-64 A006 1292 Rear Cover - 115V 3-52 A006 1098 Rear Support Plate 37-21 A006 1294 Decal - Misfeed Removal 3-20 A006 1099 AC Power Supply Bracket 37-22 A006 1294 69-12 A006 1100 Lower Left Stay 39-46 A006 1298 A006 1102 Connector Holder 39-16 A006 1298 Decal - Misfeed Removal Decal - Adding Color Toner Decal - Adding Color Toner A006 1132 Harness Guide Bracket 47-18 A006 1299 Decal - Color Dev. Replacement 3-22 49-16 A006 1299 Decal - Color Dev. Replacement 69-11 49-26 A006 1303 Decal - Toner Replacement 3-24 A006 1133 Board Angle A006 1134 Photointerruptor Bracket 3-21 69-10 A006 1141 Harness Stay 45-31 A006 1303 Decal - Toner Replacement 69-13 A006 1143 Fusing Unit Rail 47-4 A006 1304 3-23 A006 1146 Fan Stay 37-8 A006 1304 Decal - Indications Decal - Indications A006 1147 Ozone Filter Holder 37-10 A006 1309 A006 1152 Upper Fan Bracket 35-34 A006 1312 Rear Cover - 220V/240V Left Cover - LT 69-14 3-52 3-5 A006 1153 Lower Fan Bracket 35-38 A006 1313 Left Cover - A4 3-5 A006 1154 Motor Shielding Plate 35-33 A006 1315 Decal - Main SW- 115V 3-9 A006 1156 Power Pack Bracket 51-19 A006 1315 Decal - Main SW- 115V 69-6 A006 1158 Power Supply Bracket 49-18 A006 1316 Decal - Main SW - 220/240V 3-9 A006 1160 Stay 53-16 A006 1316 Decal - Main SW - 220/240V 69-6 A006 1163 Board Angle 51-18 A006 1328 Small Cap 3-4 A006 1164 Board Hinge 51-8 A006 1329 Large Cap 3-3 A006 1165 Board Hinge 51-9 A006 1332 Right Cover 3-34 74 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. A006 1348 Right Cover Cap 3-35 A006 1737 Front Pulley 33-47 A006 1352 Key Counter Cover 3-33 A006 1739 Scanner Sensor Bracket 33-36 A006 1364 Right Inner Cover - LT 3-30 A006 1741 Motor Bracket 33-31 A006 1368 Lower Inner Cover 3-29 A006 1744 Wire Support Plate 33-43 A006 1372 Lower Left Cover 3-6 A006 1745 Wire Adjusting Plate 33-35 A006 1377 Right Grip Cover 3-64 A006 1747 Scanner Motor Support Plate 33-30 A006 1379 Left Grip Cover 3-63 A006 1748 Optics Connector Bracket 33-29 A006 1384 Upper Inner Cover - LT 3-19 A006 1749 Lens Bracket 35-10 A006 1387 Decal - Release 3-55 A006 1750 Lens Cover A006 1387 Decal - Release 69-7 A006 1752 Front A006 1394 Upper Inner Cover - A4 3-19 A006 1753 Lens Band 35-6 A006 1396 Decal - Lock (115V) 3-54 A006 1755 Lens Shutter 35-12 35-11 Shielding 35-1 Plate 35-4 A006 1396 Decal - Lock 69-17 A006 1756 Lens Bracket A006 1397 Panel Sheet - Program 5-5 A006 1757 Motor Bracket 35-30 A006 1398 Decal -Unlock (115V) 3-7 A006 1760 Lens Cover 33-53 A006 1398 Decal - Unlock 69-16 A006 1762 Mirror Bracket 35-24 A006 1684 Solenoid 35-68 A006 1763 Mirror 35-15 A006 1701 1st Scanner 33-13 A006 1766 Adjusting Cam 35-50 A006 1705 Scanner Shoe 33-15 A006 1767 Motor Bracket 35-43 A006 1706 Support 33-4 A006 1769 Mirror Bracket Cover 35-21 A006 1707 Rear Wire Clamp 33-24 A006 1782 Mirror 35-13 A006 1708 Front Wire Clamp 33-14 A006 1784 Sensor Bracket 35-40 A006 1709 Thermoswitch 33-54 A006 1785 Sensor Bracket 35-51 A006 1710 Reflector Cover 33-5 A006 1786 Sensor Bracket 35-49 A006 1711 Lamp Terminal Rear Cover 33-6 A006 1788 Cam Plate - Lens Shield 35-18 Reflector Holder Carriage Shutter A006 1712 Lamp Terminal Front Cover 33-7 A006 1792 Lens Cover Bracket 35-48 A006 1714 2nd Scanner 33-28 A006 1794 Mirror Bracket 35-60 A006 1721 Front Spring Plate 33-25 A006 1798 Front Mirror Bracket 35-23 A006 1721 Front Spring Plate 35-22 A006 1808 Guide Rod Bracket 35-54 A006 1722 Spring Plate 35-59 A006 1817 Rear Scanner Slide Rail 35-52 A006 1723 Spring Plate - Mirror 33-57 A006 1818 Front Scanner Slide Rail 35-57 A006 1724 Rear Spring Plate 33-27 A006 1824 Left Optics Stay 35-64 35-67 A006 1724 Rear Spring Plate 35-26 A006 1827 Front Optics Stay A006 1731 Right Rear Pulley 33-46 A006 1828 Rear Optics Frame 35-37 A006 1733 Left Rear Pulley 33-49 A006 1831 Upper Right Shielding Plate 45-1 75 Feb. 28, ’89 Description Parts No. Page and Index No. Parts No. Description Page and Index No. A006 1840 Mounting Scale Bracket 3-62 A006 2274 Pick-off Pawl Shaft 17-36 A006 1841 Exposure Glass Stay 3-60 A006 2278 Sensor Holder 17-40 A006 1850 Toner Shield Glass 17-18 A006 2280 Drum Guide 17-43 A006 1862 Filter Holder 35-63 A006 2281 Rear Drum Side Plate 17-44 A006 1866 Filter Bracket 35-61 A006 2327 Belt Tightener 49-23 A006 1870 Filter 35-65 A006 2329 Stay 49-20 A006 1871 Filter 35-62 A006 2363 Right Drum Guide 17-28 A006 2020 Charge Corona Unit 17-15 A006 2383 Drum Guide Roller 11-17 A006 2055 Charge Corona Cleaner 17-3 A006 2386 Gear Box 17-56 A006 2071 Guide Casing 17-20 A006 2387 Spacer - Magnetic Clutch 17-64 13-22 A006 2076 Duct Bracket 47-19 A006 2527 Paper Feed Stay A006 2077 Blower Duct 47-13 A006 2533 Guide Plate 15-3 A006 2078 Charge Corona Duct 47-5 A006 2535 Lower Entrance Guide Plate 15-34 A006 2080 Casing - Fan - Charge Corona 47-7 A006 2538 Exit Guide Plate 11-16 A006 2111 Charge Corona Grid 17-9 A006 2549 Upper Registration Guide 9-7 A006 2114 Grid Anchor 17-4 A006 2551 Pick-up Roller Guide 13-9 A006 2117 Front Cover - Charge Corona 17-1 A006 2555 Paper Feed Bracket 13-10 11-42 A006 2118 Rear Cover - Charge Corona 17-14 A006 2557 Pick-up Lever A006 2125 PTL Stopper Cover 9-54 A006 2558 Paper Feed Solenoid Bracket 11-47 A006 2126 Quenching Lamp 17-17 A006 2560 Paper Feed Stay 9-52 A006 2127 Charge Corona Rail - Left 17-21 A006 2564 Pick-up Solenoid 11-52 A006 2128 Charge Corona Rail - Right 17-22 A006 2565 Paper End Feeler 9-48 A006 2129 Cleaning Unit Guide 17-63 A006 2569 Magnet Support Plate 3-10 A006 2130 Spring Plate - Charge Corona 17-23 A006 2571 Paper End Sensor Bracket 9-51 A006 2132 QL Stopper PTL Stopper 17-62 A006 2572 Paper End Actuator 9-6 A006 2133 9-55 A006 2573 1st Paper Size Bracket 13-35 A006 2258 Drum Support Plate 17-31 A006 2574 Separation 13-48 Arm A006 2259 Eraser Cushion 17-26 A006 2575 Separation Guide Plate 13-62 A006 2260 Drum Holder 17-33 A006 2576 Separation Support Plate 13-39 A006 2261 Front Drum Side Plate 17-30 A006 2577 Separation Driven Shaft 13-49 A006 2268 Upper Left Drum Stay 17-27 A006 2579 Paper Feed Guide Plate 9-47 Pressure Arm Bracket 9-34 A006 2269 Upper Right Drum Stay 17-29 A006 2581 A006 2270 Pick-off Pawl 17-35 A006 2585 Cassette Bottom Lever 13-61 A006 2271 Left Drum Stay 17-34 A006 2586 Sector Gear 13-65 A006 2273 Pick-off Pawl Bracket 17-37 A006 2587 Solenoid Bracket 9-38 76 Feb. 28, ’89 Parts No. Description Page and Index No. Description Parts No. Page and Index No. A006 2588 Cassette Release Arm 11-45 A006 2767 Lower Pressure Arm 9-13 A006 2589 Cassette Release Lever 45-25 A006 2793 Paper Feed Shaft Bracket 13-23 A006 2591 Registration 9-40 A006 2795 Paper End Feeler 13-32 A006 2603 Front Side Plate 11-29 A006 2795 Paper End Feeler 15-15 A006 2605 Support Angle 11-34 A006 2797 Front Paper Feed Bracket 15-12 A006 2606 Bushing Holder 11-27 A006 2800 Paper Feed Bracket 15-31 A006 2611 Rear Side Plate 11-35 A006 2805 Lower Release Arm 15-33 A006 2613 Front Release Lever 11-24 A006 2806 Pad Holder 15-27 A006 2615 Rear Release Lever 11-37 A006 2808 3rd Paper Size Bracket 15-22 A006 2617 Transport Guide Plate 11-43 A006 2811 2nd Paper Size Bracket 15-36 A006 2620 Seal - 0.2x30x30mm 11-40 A006 2812 Lower Entrance Guide Plate 15-40 A006 2623 Front Transport Bracket 19-14 A006 2813 Registration Support Plate 9-19 Clutch Bracket A006 2625 Rear Transport Bracket 19-38 A006 2825 Upper Relay Sensor Bracket 15-2 A006 2628 Left Stay 19-10 A006 2851 Front Cassette Holder 9-20 9-21 A006 2629 Right Stay 19-15 A006 2861 Rear Cassette Holder A006 2631 Lower Transport Cover 19-9 A006 2900 Exit Guide Plate 11-9 A006 2633 Front Registration Roller Guide 19-13 A006 2915 Lower Entrance Guide Plate 13-57 13-59 A006 2634 Rear Registration Roller Guide 19-17 A006 2920 Lower Relay Sensor Bracket A006 2635 Front Transport Cover 19-11 A006 2925 Front Guide Plate Lever 11-13 A006 2639 Registration 9-17 A006 2932 Rear Lever 11-2 Guide A006 2651 Manual Feed Table 3-38 A006 2950 Paper End Sensor Bracket 15-37 A006 2661 Manual Feed Cover 3-41 A006 2951 Paper End Actuator 13-67 A006 2668 Front Guide Holder 11-22 A006 2951 Paper End Actuator 15-44 A006 2681 Front Side Fence 3-49 A006 2955 Magnetic Clutch Stopper 15-42 A006 2691 Rear Side Fence 3-48 A006 2956 Harness Guide Plate 15-45 A006 2698 Side Fence Gear 3-42 A006 2961 Decal - Manual Feed 3-50 A006 2699 Spacer - 5.1x20mm Manual Feed Guide 3-43 A006 2961 Decal - Manual Feed 69-8 3-40 A006 2968 Rear Paper Feed Roller Guide 9-8 A006 2701 A006 2720 A006 2750 Rear Guide Holder 11-44 A006 2976 Front Roller Guide 13-3 Pressure Shaft Stay 9-25 A006 2977 Seal - Guide Plate 9-56 A006 2755 Front Stay Bracket 9-24 A006 2978 Front Paper Feed Spacer 13-20 A006 2756 Pressure Bracket 9-22 A006 2979 Rear Paper Feed Spacer 13-15 A006 2760 Rear Stay Bracket 9-26 A006 2980 Paper Feed Guide Plate 13-19 A006 2764 Pressure Shaft Stay 9-31 A006 2982 Spacer - M6x9 13-45 A006 2766 Lower Cassette Bottom Arm 9-29 A006 2983 Spacer - M8x9 13-17 77 Feb - 28, ’89 Description Parts No. Page and Index No. Parts No. Description Page and Index No. A006 2984 Roller Bracket 13-13 A006 3271 Decal - Red 69-4 A006 2986 Mylar Seal - Paper Feed Stay 13-63 A006 3301 Front Side Plate 27-24 A006 3026 Color Development Unit 27-38 A006 3305 Rear Side Plate 27-11 A006 3027 Color Toner Supply Unit 29-39 A006 3310 Lower Casing 27-31 A006 3050 Development Rail 45-24 A006 3312 Left Cover 27-3 A006 3056 Shaft Arm 45-22 A006 3320 Adjusting Plate 27-30 A006 3060 Shaft 45-21 A006 3322 Retainer 27-15 A006 3062 Development Lever 45-27 A006 3327 Development Holder 49-41 A006 3063 Development Stopper 45-28 A006 3329 Agitator Holder 49-40 A006 3100 Development Roller 25-7 A006 3330 Development Knob 25-20 A006 3112 Doctor Blade 25-2 A006 3330 Development Knob 27-29 A006 3113 Retainer 25-10 A006 3335 Knob - Paddle 25-19 A006 3116 Development Unit Guide 25-3 A006 3335 Knob - Paddle 27-28 A006 3138 Toner Supply Unit - 115V 25-28 A006 3340 Development Guide 27-4 A006 3143 Entrance Seal Plate 25-1 A006 3349 Seal - 1x30x264mm 29-13 29-10 A006 3148 Toner Supply Unit - 220/240V 25-28 A006 3380 Toner Supply Cover A006 3151 Upper Casing - Toner Supply Unit 25-48 A006 3383 Upper Casing Cover 29-11 A006 3154 Lower Casing - Toner Supply Unit 25-24 A006 3385 Sensor Bracket 29-32 A006 3155 Plate Nut 25-26 A006 3386 Toner End Sensor 29-31 A006 3158 Front Side Bracket 25-49 A006 3390 Front Side Plate 29-34 A006 3160 Slitter 25-22 A006 3392 Upper Casing 29-15 A006 3168 Agitator Shaft 25-50 A006 3400 Lower Casing 29-29 A006 3171 Rear Side Bracket 25-51 A006 3406 Rear Side Plate 29-20 A006 3175 Toner Supply Bracket 49-4 A006 3421 Development Guide 45-18 A006 3176 Toner Supply Support Plate 49-1 A006 3426 Development A006 3183 Joint - Hopper (115V) 25-53 A006 3434 Lever Bracket 29-4 A006 3190 Black Development Unit 25-55 A006 3441 Stand Support Plate 29-7 A006 3205 Development Pannel Plate 25-4 A006 3442 Lever Stopper 29-2 A006 3208 Bias Terminal 49-15 A006 3443 Spring Plate 29-3 A006 3221 Lower Casing 25-21 A006 3444 Stand Lever 29-1 A006 3222 Front Development Side Plate 25-5 A006 3465 Cam 45-11 A006 3223 Rear Development Side Plate 25-13 A006 3473 Solenoid Link 45-4 A006 3251 Development 27-18 A006 3475 Solenoid Bracket 45-2 A006 3255 Doctor Blade - Color 27-5 A006 3480 Cam Lever 45-12 A006 3271 Decal - Red 29-38 A006 3483 Cam Lever 45-16 Roller 78 Stopper 45-26 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. A006 3490 Guide Support 45-19 A006 3918 Idle Gear Bracket 49-36 A006 3505 Cleaning Unit 31-* A006 3926 Upper Transport Guide 47-28 A006 3552 Lower Cleaning Casing 31-24 A006 3931 Duct 19-23 A006 3556 Blade Bracket 31-33 A006 4051 Fusing Unit - 115V 21-* A006 3560 Blade Cleaner 31-22 A006 4053 Fusing Unit - 220/240V 21-* A006 3561 Frame 31-11 A006 4062 Fusing Knob Stopper 21-11 A006 3563 Support Plate 31-15 A006 4072 Front Side Plate 21-19 A006 3570 Cleaning Blade 31-32 A006 4080 Front Lamp Terminal 21-4 21-6 A006 3579 Cap Seal 31-3 A006 4091 Paper Exit Sensor Bracket A006 3581 Upper Cleaning Casing 31-2 A006 4095 Harness Bracket 21-7 A006 3584 Toner Collection Hosing 31-7 A006 4096 Pressure Arm 21-14 21-30 A006 3585 Stay 31-9 A006 4101 Rear Side Plate A006 3603 Front Brush Holder 31-26 A006 4110 Rear Lamp Terminal 21-29 A006 3604 Rear Brush Holder 31-28 A006 4125 Rail Cover 21-2 A006 3619 Handle 47-29 A006 4131 Right Rail 21-38 A006 3623 Release Bracket 47-26 A006 4132 Left Rail 21-39 21-37 Bracket A006 3628 Release Rail 47-27 A006 4133 Sheet - Rail - Fusing A006 3635 Release Lever 47-25 A006 4141 Upper Stay 21-33 A006 3638 Release Guide 47-24 A006 4145 Entrance Cover 21-31 A006 3660 Toner Collection Roller 31-31 A006 4146 Upper Guide Plate 21-32 A006 3670 Drive Stay 49-43 A006 4151 Stay 21-22 A006 3675 Sensor Bracket 47-22 A006 4153 Lower Guide Plate 21-20 A006 3676 Sensor Shutter 47-21 A006 4154 Lower Cover 21-21 A006 3852 Pre-Transfer Lamp 9-1 A006 4155 Front Cover 21-8 A006 3854 T & S Corona Casing 19-31 A006 4165 Decal - B1 21-10 A006 3855 Terminal Cover - Transfer 19-39 A006 4165 Decal - B1 69-20 A006 3858 QL Stopper Cover 17-57 A006 4167 Decal - B3 21-16 A006 3859 Transfer Guide Plate 19-33 A006 4167 Decal - B3 69-21 A006 3871 Space Plate 17-16 A006 4168 Sensor Bracket 9-5 A006 4168 Decal - Fusing Knob Decal - Fusing Knob 21-9 A006 3872 A006 3875 T & S Corona Rail 19-32 A006 4202 Fusing Exit Frame 23-15 A006 3877 Transfer Guide 9-2 A006 4203 Feeler Holder 23-14 A006 3882 19-25 A006 4211 Stripper Stay 23-23 A006 3906 Paper Guide - T & S Corona Upper Transport Cover 19-2 A006 4212 Upper Stripper Stay 23-20 A006 3907 Lower Transport Cover 19-6 A006 4213 Middle Upper Stripper Stay 23-21 79 69-22 Feb. 28. ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. A006 4222 Upper Guide Plate 23-1 A006 4613 Lever 41-13 A006 4223 Lower Guide Plate 23-4 A006 4614 Junction Gate Arm 39-25 A006 4224 Guide Plate Bracket 23-7 A006 4616 Junction Gate 39-34 A006 4241 Release Cover 23-9 A006 4618 Junction Gate Link 39-24 A006 4261 Paper Exit Feeler 23-13 A006 4624 Lever Bracket 41-27 A006 4263 Paper Exit Shutter 23-12 A006 4625 Transport Lever 41-14 A006 4271 Fusing Exit Cover 23-5 A006 4626 Rear Lever 41-10 A006 4292 Fusing Unit Lever 47-3 A006 4627 Rear Transport Bracket 39-31 A006 4301 Fusing Gear Bracket 37-38 A006 4633 Inverter 39-42 Gate A006 4451 Duplex/Overlay Transport Gate 37-19 A006 4641 Inverter Arm 39-26 A006 4455 Upper Guide Plate 37-13 A006 4646 Gear Bracket 39-29 A006 4463 Lower Guide Plate 37-18 A006 4660 Support Plate 39-20 A006 4464 Stay - Lower Guide Plate 37-40 A006 4662 Bracket 39-49 A006 4465 Upper Lever 37-12 A006 4666 Sensor Bracket 39-47 A006 4466 Decal - Exit 37-5 A006 4668 Inverter Guide Plate 39-44 A006 4466 Decal - Exit 69-9 A006 4671 Junction Gate Plate 39-39 A006 4470 Safety SW Arm 37-2 A006 4672 Junction Gate Guide 39-40 A006 4471 Release Link 37-1 A006 4676 Front Side Plate 41-23 A006 4472 Stopper Lever 37-3 A006 4677 Rear Side Plate 41-17 A006 4475 Release Lever 37-34 A006 4685 Lower Guide Plate 41-5 A006 4480 Junction Gate Bracket 37-24 A006 4687 Upper Guide Plate 41-24 A006 4483 Link 37-27 A006 4689 Turn Guide Plate 41-1 A006 4484 Junction Gate Lever 37-30 A006 4694 Inner Clutch Bracket 39-1 A006 4486 Gate Solenoid 37-28 A006 4695 Clutch Bracket 39-6 A006 4487 Inverter Gate Solenoid 37-23 A006 4698 Bushed Roller Chain 39-11 A006 4493 Copy Guide - Receiving Tray 3-8 A006 4800 Front Jogger Frame 43-43 A006 4587 Front Paper Holder 43-4 A006 4805 Rear Jogger Frame 43-44 A006 4589 Rear Paper Holder 43-18 A006 4810 Jogger Stay 43-36 A006 4590 Jogger Fence Support 43-13 A006 4819 Motor Bracket 43-25 A006 4592 Jogger Positioning 43-28 A006 4825 Home Sensor Bracket 43-22 A006 4602 Entrance Guide Plate 37-20 A006 4832 Jogger Fence Table 43-7 A006 4605 Upper Guide Plate 39-37 A006 4835 Front Jogger Fence 43-1 A006 4606 Upper Guide 39-36 A006 4840 Rear Jogger Fence 43-19 A006 4607 Lower Guide 39-38 A006 4858 Roller Holder 43-9 A006 4609 Guide 41-7 A006 4870 Arm 43-29 80 Feb. 28, ’89 Parts No. Description Page and Index No. Description Parts No. Page and Index No. A006 4873 Joined Link 43-26 A006 5334 Overflow Harness 47-15 A006 4876 Solenoid Bracket 43-27 A006 5335 Color Development Harness 27-7 A006 4880 Entrance Guide Plate 43-11 A006 5336 1st Paper Feed Harness 13-36 A006 4883 Exit Guide Plate 43-41 A006 5337 2nd Paper Feed Harness 15-41 A006 4885 Lower Jogger Guide 43-14 A006 5352 Counter Harness 51-14 13-44 A006 4892 Gear Arm 39-14 A006 5356 Relay Sensor Harness A006 5102 Right Panel Board 5-11 A006 5357 3rd Paper Feed Harness 15-39 A006 5103 Left Panel Board 5-12 A006 5370 Optics Harness 35-36 39-10 A006 5105 IC - UPD27C512 - 25 5-14 A006 5371 Duplex A006 5106 Operation Panel Board - 115V 5-16 A006 5372 Drum Harness 17-47 A006 5107 Operation Panel Board - 220/240V 5-16 A006 5374 Fusing Support Harness 47-11 21-3 Harness A006 5114 System Control Board - 115V 5-13 A006 5375 Fusing Harness A006 5121 Left Bracket 3-14 A006 5376 Registration Harness 9-4 A006 5122 Middle Bracket 3-15 A006 5380 DC Harness - 220/240V 51-5 65-* A006 5123 Right Bracket 3-16 A006 5380 DC Harness - 220/240V A006 5124 Optics Support Bracket 35-20 A006 5382 DC Harness - 115V 51-5 A006 5134 System Control Board - 220/240V 5-13 A006 5382 DC Harness - 115V 65-* A006 5153 Heat Sink 57-3 A006 5450 Thermofuse 21-35 A006 5154 IC - MBM2764-25 57-4 A006 5520 AC Drive Board - 115V 53-2 A006 5155 I/O Control Board 51-7 A006 5520 AC Drive Board - 115V 61-* A006 5155 I/O Control Board 57-* A006 5540 AC Harness 53-15 A006 5222 ID Sensor Board 17-41 A006 5540 AC Harness 63-* A006 5228 Paper Feed Board 51-2 A006 5545 AC Support Harness - 115V 53-4 A006 5228 Paper Feed Board 59-* A006 5620 AC Drive Board - 220/240V 53-2 A006 5240 Thermistor 21-36 A006 5620 AC Drive Board - 220/240V 61-* A006 5260 DIP SW Board 27-33 A006 5645 AC Support Harness - 220/240V 53-4 A006 5279 3rd Scanner Drive Motor 35-44 A006 5713 Left Cover - Smoke 5-3 A006 5289 Exposure Lamp Harness 33-50 A006 5722 Left Cover - Clip 5-2 A006 5297 Reed Wire 33-21 A006 5725 Large Panel Sheet - A4 5-8 5-9 A006 5320 Eraser 17-25 A006 5726 Duplex Panel Sheet - A4 A006 5321 Manual Feed Harness 51-1 A006 5727 Duplex/Sorter Panel Sheet - A4 A006 5328 Relay Harness 41-4 (Accessory) 5-10 A006 5329 Inverter 39-45 A006 5732 Large Panel Sheet - LT 5-8 A006 5733 Duplex/Sorter Panel Sheet - LT Harness A006 5332 Eraser Harness 17-24 A006 5333 Optics Fiber Cable 33-45 (Accessory) 81 5-10 Feb. 28, ’89 Description Parts No. Page and Index No. Parts No. Description Page and Index No. A006 5734 Duplex Panel Sheet - LT 5-9 A006 9513 DG Gauge - Black Dev. A006 5805 Holder 61-3 A006 9514 Auti-Condensation Heater - 115V 35-28 A006 5811 AC Power Supply Cord Bracket 53-6 A006 9514 Anti-Condensation Heater - 115V 67-17 A006 5813 Power Supply Cord Bracket 53-9 A006 9515 Anti-Condensation Heater - 220V 35-28 A006 5814 Harness Cover 53-7 A006 9515 Anti-Condensation Heater - 220V 67-17 A006 5815 Transformer Bracket 53-8 A006 5818 Paper Feed Board Bracket 51-3 A006 5819 Main Board Bracket 51-6 A006 5820 AC Drive Board Bracket 53-1 A006 5821 Board Bracket 51-13 A006 5822 Safety SW Bracket 53-12 A006 5824 Safety SW Lever 53-14 A006 5826 Bracket - Power Supply Board 53-3 A006 5827 Counter Bracket 51-15 A006 5828 Counter Cover 51-16 A006 6012 Right Inner Cover - A4 3-30 A006 6033 Inner Cover Sheet 3-28 A006 8600 Operating Instructions - English 69-27 A006 8601 Operating Instructions - German 69-27 A006 8602 Operating Instructions - French 69-27 A006 8603 Operating Instructions - Italian 69-27 A006 8604 Operating Instructions - Spanish 69-27 A006 8610 Installation Procedure - English A006 8615 Installation Procedure - 5 Language (Copier) 69-28 A006 8630 Sheet - SP Mode Table 3-66 A006 9001 Charge Corona Wire (10pcs/set) 17-8 A006 9002 Hot Roller Stripper (5pcs/set) 23-22 A006 9003 Cleaning Seal 31-25 A006 9101 DG Gauge - Color Dev. 67-1 A006 9103 Omega Clamp 67-3 A006 9104 Adjusting Scanner Pin (4pcs/set) 67-14 A006 9105 Drum Shaft 67-13 A006 9510 Drum 17-39 (Copier) 69-28 82 67-16 Feb. 28, ’89 Parts No. Description Page and Index No. Description Parts No. Page and Index No. AA00 0015 Decal - High Temperature 21-13 AA05 1003 Pressure Wire 45-6 AA00 0015 Decal - High Temperature 69-1 AA06 0069 Pick-up Spring 13-42 AA00 1052 Decal - Knob - Feed Roller 3-13 AA06 0070 Pressure AA00 1052 Decal - Knob - Feed Roller 69-15 AA06 0071 Cassette Release Spring Spring 13-34 11-46 AA00 2010 Decal - Paper Level 69-2 AA06 0072 Rear Transport Spring 19-20 AA00 2010 Decal - Paper Level 7-5 AA06 0073 Release Spring 9-15 AA00 2022 Manual Feed Decal - LT 3-37 AA06 0074 Pressre Spring 9-35 AA00 2022 Manual Feed Decal - LT 69-3 AA06 0075 Release Spring 9-37 AA00 2023 Manual Feed Decal - A4 3-37 AA06 0076 Release Spring 11-39 AA00 2023 Manual Feed Decal - A4 69-3 AA06 0081 Stripper Spring 23-19 33-44 AA00 2079 Decal Sheet - Small - A4 69-26 AA06 0083 Tension Wire Spring AA00 2079 Decal Sheet - Small - A4 7-11 AA06 0084 Junction Gate Spring 39-23 AA00 2080 Decal Sheet - Large - A4 69-25 AA06 0085 Inverter Spring 39-22 AA00 2080 Decal Sheet - Large - A4 7-11 AA06 0091 Junction Gate Spring 37-32 AA00 2083 Decal Sheet - Large - LT 69-25 AA06 0092 Release Spring 37-33 AA00 2083 Decal Sheet - Large - LT 7-11 AA06 0098 Turn Spring 35-69 AA00 2084 Decal Sheet - Small - LT 69-26 AA06 0099 Cleaning Blade Spring 31-12 AA00 2084 Decal Sheet - Small - LT 7-11 AA06 0106 Spring - Pressure Arm 9-12 AA01 0004 Ozone Filter - 20x138x138mm 19-22 AA06 0118 Exit Spring 37-11 AA0l 0005 Ozone Filter - 10x25x220mm 37-9 AA06 0131 Cleaning Pressure Spring 47-23 AA0l 0007 Sector Gear 35-70 AA06 0141 Spring - Grid 17-5 AA01 0008 Sector Gear 35-19 AA06 0217 Spring - Pressure Roller 21-15 AA02 0003 Slide Lever Magnet 41-2 AA06 3036 Terminal Spring 19-35 AA02 1008 Magnet - Manual Feed 3-36 AA06 3043 Shaft Bracket Spring 13-24 AA04 0009 Transport 19-3 AA06 3047 Roller Spring 11-12 AA04 2002 Belt 43-31 AA06 3106 Pawl Spring 17-38 AA04 2003 Belt 37-29 AA06 6022 Front Release Spring 11-26 AA04 3007 Timing Belt - 230XL 49-19 AA06 6023 Rear Release Spring 11-36 AA05 0015 Jogger Wire 43-15 AA06 6024 Guide Plate Spring 11-14 AA05 0016 Scanner Drive Wire 33-48 AA06 6025 Lever Spring 11-3 AA05 0017 Scanner Drive Wire 33-41 AA06 6026 Release Stripper Spring 23-18 AA05 0018 Scanner Drive Wire 33-51 AA06 6027 Spring 47-1 AA05 0019 Scanner Drive Wire 33-34 AA06 6032 Spring 41-11 AA05 0020 Lens Drive Wire 35-32 AA06 6033 Exit Lock Spring 23-8 AA05 0021 Mirror Drive Wire 35-14 AA08 0025 Support Bushing 11-19 Belt 83 Feb. 28, ’89 Parts No. Description Page and Index No. Description Parts No. Page and Index No. AA08 0028 Bushing - 8X12X7mm 13-27 AA14 3039 Spring Holder 23-17 AA08 0028 Bushing - 8X12X7mm 15-10 AA14 3040 Lever Shaft 23-10 AA08 0029 Roller Holder 43-8 AA14 3041 Guide Pin 35-47 AA08 0030 Bushing - M5 31-19 AA14 3043 Shoulder Screw - M6x8 19-12 AA08 0037 Bushing - 6mm 11-7 AA14 3043 Shoulder Screw - M6x8 41-26 AA08 0037 Bushing - 6mm 41-8 AA14 3051 Shoulder Screw - M4 17-19 AA08 2009 Bushing - 8x12x8mm 19-19 AA14 3060 Shaft 31-16 AA08 2012 Bushing - M8 15-13 AA14 3062 Shoulder Screw - M4 9-16 AA08 3004 One-way Clutch - Feed 13-37 AA14 3070 Shoulder Screw - M2x2 3-65 AA11 4099 Key Top 5-6 AA14 3074 Stepped Screw - M4x5 37-35 AA11 4100 Key Top - 5-7 AA14 3076 Stepped Screw - M4 AA12 0005 Antistatic Brush 37-14 AA14 5031 Registration AA13 2014 Spacer 15-28 AA14 5033 Cleaning Shaft 49-44 AA13 2024 Spacer - 1x6x10mm 13-40 AA14 5034 Transport 49-35 AA13 2026 Side Plate Roller 11-32 AA14 5046 Lever Shaft AA13 2027 Lower Registration Roller Spacer 11-30 AA14 5050 Toner Supply Shaft 25-40 AA13 2028 Pin - 8x10mm 55-5 AA14 6297 Pin - 5x15mm 47-2 Duplex/Sorter Clutch 37-41 Shaft Shaft 9-43 29-5 AA13 2034 Spring Spacer 13-25 AA14 8040 Shaft 43-3 AA13 2074 Knob Collar 17-55 AA14 8044 Toner Supply Shaft 49-3 AA13 4013 Pin - 8x15mm 55-2 AA14 8047 Shaft 39-21 AA14 0075 Paper Feed Shaft 13-18 AA14 8048 Shaft 39-51 AA14 0076 Separation Drive Shaft 13-47 AA14 8049 Magnetic Clutch Shaft 39-4 AA14 0078 Cassette Bottom Shaft 13-60 AA14 8073 Support Roller Shaft 15-14 AA14 0080 Pick-off Pawl Shaft 11-33 AA15 0025 43-12 AA14 0082 Lower Cassette Bottom Shaft 9-28 AA15 0026 Entrance Guide Seal - 0.2x10x295mm AA14 0083 Paper Feed Shaft 13-31 AA15 0027 Seal - 10x87mm 35-56 AA14 0083 Paper Feed Shaft 15-4 AA15 0029 Seal - 0.2x15x140mm 33-39 AA14 0085 Lever Shaft 11-4 AA15 0031 Sea 1 - 25x55mm 25-27 AA14 0086 Drum Shaft 17-61 AA15 0032 Seal - 2x8x41mm 29-24 AA14 0088 Shaft 45-20 AA15 0036 Jogger Fence Guide 43-5 25-37 35-55 AA14 0091 Guide Rod 35-27 AA15 0042 Seal - 20x30mm AA14 0099 Release Shaft 37-7 AA15 0051 Rear Roller Guide 13-33 AA14 0128 Transport 41-12 AA15 0055 Exit Guide 43-42 AA14 0140 Screw - M3x4.5 3-18 AA15 0056 Seal - 0.2x20x130mm 15-24 AA14 0243 Release Shaft 11-41 AA15 0057 Mylar Seal - Small 9-23 Shaft 84 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. AA15 0060 Seal - 20x28mm 25-31 AA15 1148 Seal - Supply Roller - Rear 25-44 AA15 0063 Side Fence Sheet 3-47 AA15 1169 Front Side Seal 27-27 AA15 0068 Upper Casing Seal 29-37 AA15 1186 Front Side Plate Seal 25-6 AA15 0072 Seal - 0.2x15x150mm 33-55 AA15 1187 Front Casing Seal 27-32 AA15 0073 Seal - Toner Density 17-42 AA15 1188 Rear Casing Seal 27-35 AA15 0139 Mylar Seal - Large 9-42 AA15 1191 Seal - 2x40x45mm 29-12 AA15 0156 Mylar Seal - 15x74mm 27-1 AA15 1196 Seal - Rear Side Fence 27-37 AA15 1096 Seal - Supply Roller - Front 25-41 AA15 1199 Seal - 1x10x39mm 29-28 AA15 1099 Seal - 2x14x37mm 25-30 AA15 1200 Seal - 1x10x31mm 29-36 AA15 1100 Seal - 2x28x320mm 25-42 AA15 1201 Rear Side Seal 27-36 AA15 1101 Seal - 2x26x340mm 25-38 AA15 1205 Seal - 2x5x318mm 29-27 AA15 1102 Seal - 2x7x420mm 25-39 AA15 1379 Seal - Doctor Blade 27-2 AA15 1104 Seal - Toner Supply Roller 25-43 AA15 2013 Seal - Development Roller 25-11 AA15 1105 Front Blade Seal 31-21 AA15 2014 Seal - 12x56mm 35-2 AA15 1106 Rear Blade Seal 31-20 AA15 2015 Toner Collection Seal 31-10 AA15 1108 Casing Seal 31-8 AA15 2018 Development Roller Seal 27-10 AA15 1109 Seal - M5 31-30 AA15 2019 Seal - Mixing Auger 27-21 AA15 1110 Seal - 5x45x59mm 47-12 AA15 2044 Seal - Toner Supply Cover 29-16 AA15 1111 Seal - 5x24x264mm 47-14 AA15 2090 Seal - Mixing Auger 25-36 AA15 1112 Seal - 3x7x105mm 19-1 AA16 1002 Rubber Pad 47-17 AA15 1113 Seal - 3x7x80mm 19-8 AA16 1011 Cushion - 5x6x9mm 47-16 AA15 1130 Sensor Seal 29-30 AA16 1025 Transport Cushion 11-25 AA15 1131 Seal- 2x9x16mm 27-22 AA16 1026 Cushion 13-26 AA15 1132 Seal - 2x9x24mm 27-13 AA16 1026 Cushion 15-11 AA15 1133 Front Side Fence Seal 27-23 AA16 2018 Jogger Fence Cushion 43-2 AA15 1134 Rear Side Fence Seal 27-12 AB00 0013 Mirror Drive Pulley 35-41 AA15 1135 Seal - 2x13x44mm 29-21 AB00 0014 Gear - 48T 35-42 AA15 1135 Seal - 2x13x44mm 33-56 AB01 0014 Gear - 18T 13-11 AA15 1137 Seal - 3x6x318mm 29-8 AB01 0015 Gear - 20T 13-1 AA15 1138 Seal - 2x4x20mm 27-6 AB01 0016 Gear - 40T 13-16 AA15 1139 Seal - 2x15x344mm 27-34 AB01 0017 Gear - 18Z 25-45 AA15 1140 Seal - 2x10x50mm 29-9 AB01 0018 Gear - 34Z 25-46 AA15 1141 Seal - 2x5x272mm 29-14 AB01 1019 Gear - 12T 31-29 AA15 1142 Front Side Palte Seal 29-33 AB01 1020 Gear - 17T 49-13 AA15 1143 Rear Side Palte Seal 29-22 AB01 1021 Gear - 15T 29-19 85 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. 29-17 AB01 3148 Gear - 20T 49-29 13-46 AB01 3149 Gear - 20T 39-30 13-56 AB01 3150 Gear - 28T 39-27 Gear - 17T 49-45 AB01 3151 Gear - 20T 39-18 AB01 1026 Gear - 17T 31-18 AB01 3152 Gear - 20T 39-28 AB01 1027 Gear - 19T 31-17 AB01 3153 Gear - 20T 39-19 AB01 2305 Gear Cover 17-60 AB01 3153 Gear - 20T 41-15 AB01 3079 Gear - 21T 13-7 AB01 3154 Gear - 20T 39-50 AB01 3108 Gear - 36T 15-51 AB01 3155 Gear - 40T 49-34 AB01 1022 Gear - 16T AB01 1023 Gear - Separation AB01 1024 Gear - Separation AB01 1025 Arm Roller AB01 3109 Gear - 39T 15-52 AB01 3156 Gear - 27T 25-34 AB01 3110 Gear - 27T 15-46 AB01 3157 Gear - 67T 25-33 AB01 3111 Gear - 24T 15-53 AB01 3159 Gear - 30T 37-36 AB01 3112 Gear - 22T 15-50 AB01 3163 Gear - 30T 37-26 AB01 3113 Gear - 32T 39-13 AB01 3164 Gear - 17T 37-31 AB01 3114 Gear - 20T 13-41 AB01 3165 Gear - 20T 19-18 AB01 3115 Gear - 24T 15-48 AB01 3166 Gear - 20T 49-38 AB01 3116 Gear - 24T 15-47 AB01 3167 Gear - 32T 49-39 AB01 3117 Gear - 14T 9-46 AB01 3169 Gear - 18T 13-8 AB01 3118 Gear - 33T 9-45 AB01 3213 Gear - 27T 25-9 AB01 3119 Gear - 22T 27-14 AB01 3217 Gear - 16T 49-10 AB01 3130 Gear - 21T 27-20 AB01 3218 Gear - 17T 37-37 AB01 3131 Gear - 16T 27-8 AB01 3380 Gear - 19Z 25-12 AB01 3132 Gear - 40T 21-27 AB01 3381 Gear - 44Z Ass’y 17-59 AB01 3133 Gear - 30T 21-28 AB01 7042 Coupled Gear - 18T/36T 15-49 . AB01 3134 Gear - 15T 23-16 AB01 7044 Coupled Gear - 18T/35T 31-14 AB01 3135 Gear - 18T 9-44 AB01 7046 Coupled Gear - 27T/34T 25-14 AB01 3136 Gear - 34T 25-16 AB01 7047 Gear - 20T 49-6 AB01 3139 Gear - 19T 49-8 AB01 7049 Gear - 20T 49-33 AB01 3140 Gear - 17T 49-9 AB01 7051 Gear - 30T 49-31 AB01 3142 Gear - 80T 17-45 AB01 7053 Coupled Gear - 32T/40T 29-18 AB01 3143 Gear - 30T 17-54 AB01 7056 Pulley - 20T 43-32 AB01 3144 Gear - 46T 17-52 AB01 7057 Sprocket - 16T 39-15 31-13 AB01 3145 Gear - 44T 49-5 AB01 7062 Coupled Gear - 17T/18T AB01 3146 Gear - 45T 49-30 AB01 7075 Coupled Gear - 22T/27T 27-19 AB01 3147 Coupled Gear - 15T/40T 49-28 AB01 7076 Coupled Gear - 17T/18T 49-12 86 Feb. 28, ’89 Page and Index No. Description Page and Index No. Parts No. Description AB01 7078 Coupled Gear - 18T/50T 49-11 AD02 2173 Front End Block - Charge Corona 17-6 AB01 7080 Gear - 20T 39-17 AD02 3020 Left Casing - Charge Corona 17-2 AB01 7081 Coupled Gear - 16T/20T 39-52 AD02 3021 Right Casing - Charge Corona 17-10 AB02 3014 Sprocket - 22T 39-7 AD03 3002 Toner Supply Roller - Black 25-47 AB02 3022 Sprocket - 28T 49-14 AD03 3003 Toner Supply Roller 29-25 AB02 3024 Sprocket - 28T 49-42 AD03 6005 Mixing Vanes 27-16 AB02 3026 Sprocket - 20T 49-37 AD03 6018 Mixing Vanes 25-23 AB03 0022 Pulley - 48T 17-58 AD03 7002 Mixing Auger 27-17 AB03 0023 Pulley - 15T 49-21 AD03 7011 Mixing Auger 25-35 AB03 2019 Pulley 37-25 AD03 8003 Paddle Roller 27-25 AB03 2030 Pulley 43-38 AD03 8004 Paddle Roller 25-17 AB03 2031 Pulley 43-21 AD03 8005 Right Paddle Roller 27-26 AB03 2032 Pulley 43-34 AD03 8021 Light Paddle Roller 25-18 AB04 1001 Gear - 28T 45-8 AD03 9005 Agitator 29-26 AB04 3001 Sleeve 45-9 AD04 2009 Cleaning Brush 31-27 AB04 4001 Spring 45-10 AE01 1002 Hot Roller 21-25 AB04 5001 Clutch Lever 45-7 AE02 0004 Pressure Roller 21-23 AC00 1007 Platen Cover Ass’y 7-24 AE03 0003 Bearing - 30x42x7mm 21-18 AC01 1006 Exposure Glass 3-58 AE03 1001 Slide Bushing 21-24 AC02 0022 Lens - 8/180 35-7 AE03 2002 Bushing - 25x30x9mm 21-17 AC03 0019 2nd & 3rd Mirror 33-26 AF01 0001 Large Cassette Body 7-12 AC03 0020 4th Mirror 35-16 AF01 0002 Small Cassette Body 7-12 AC03 0021 5th Mirror 35-25 AF01 7001 Rear Fence 7-9 AC03 0022 6th Mirror 35-58 AF02 0032 Upper Registration Roller 9-18 AC04 1041 Left Original Scale - LT 3-61 AF02 0033 Upper Drive Roller 15-16 AC04 1042 Left Original Scale - A4 3-61 AF02 0034 Lower Drive Roller 15-17 AD00 4036 T & S Corona Unit 19-37 AF02 0035 Driven Roller 11-10 AD02 1013 Charge Corona Receptacle 17-50 AF02 0036 Drive Roller 15-18 AD02 1014 T & S Corona Receptacle 19-24 AF02 0037 Driven Roller 11-1 Parts No. AD02 1015 Receptacle Housing 17-48 AF02 0038 Entrance Jogger Roller 43-35 AD02 2027 Rear End Block - Charge Corona 17-11 AF02 0039 Exit Jogger Roller 43-37 AD02 2165 Front End Block 19-30 AF02 0040 Jogger Roller 43-10 AD02 2166 Front End Block Cover 19-26 AF02 0043 Upper Fusing Exit Roller 23-3 AD02 2167 Rear End Block 19-34 AF02 0045 Transport 39-41 AD02 2169 Rear End Block Cover 19-36 AF02 0046 Inverter Roller 87 Roller 39-43 Feb. 28. ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. AF02 0047 Inverter Roller 41-19 AH02 0001 Rubber Foot 55-11 AF02 0048 Transport 41-20 AW00 0003 Fiber Connector - Red 57-1 AF02 0055 Grip Roller 13-2 AW00 0004 Fiber Connector - White 57-2 AF02 0066 Transport 39-33 AW01 0001 Photo Sensor 9-3 AF02 1007 Lower Registration Roller 11-31 AW02 0001 Photointerruptor 49-22 AF02 1016 Lower Fusing Exit Roller 23-6 AW02 0008 Photointerruptor 15-1 AF02 2004 Transport 41-6 AW02 0009 Photointerruptor 13-58 AF02 2005 Transport Drive Roller 19-4 AW02 0010 Photointerruptor 39-48 AF02 2006 Transport Driven Roller 19-7 AW02 0011 Photointerruptor 41-3 AF02 2007 Exit Driven Roller 37-17 AW11 0002 Thermoswitch 33-20 AF02 2013 Support Roller 15-5 AW50 0005 Paper Size Switch 13-43 AF03 1002 Paper Feed Roller 13-5 AW50 0005 Paper Size Switch 15-23 AF03 1003 Paper Feed Roller 13-28 AX02 0033 Fan - AC100V/26W 37-6 47-9 Roller Roller Roller AF03 1003 Paper Feed Roller 15-8 AX02 0034 Main Motor - 54W AF03 3005 Friction Pad 15-54 AX05 0005 Fan - DC24V 19-21 AF04 0007 Exit Drive Roller 37-16 AX05 0009 Stepping Motor - DC24V 43-20 AG01 1095 Operation Panel Ass’y - LT 5-1 AX06 0005 Scanner Drive Motor - DC24V/10W 33-33 AG01 1101 Operation Panel Ass’y - A4 5-1 AX10 0006 Spring Solenoid 45-5 AG02 1001 Original Holder 7-31 AX20 0022 Paper Feed Clutch 13-66 AG03 1004 Receiving Tray 3-1 AX20 0022 Paper Feed Clutch 15-35 AG05 0008 Feed Roller Knob 15-29 AX20 0023 Paper Feed Clutch 13-38 AG05 0009 Fusing Knob 21-12 AX20 0024 Duplex/Overlay Transport Clutch 39-3 AG05 0031 Drum Shaft Knob 17-32 AX21 0008 Registration Clutch 9-53 AG05 1005 Guide Plate Knob 11-15 AX21 0009 Toner Supply Clutch 49-7 AG05 1007 Release Handle 47-31 AX21 0015 Development Drive Clutch 17-51 AG05 1009 Release Lever Knob 11-23 AX40 0006 Drum Heater - 115V 19-16 AG05 1010 Release Knob 9-11 AX40 0007 Drum Heater - 220/240V 19-16 AG05 1015 Transport Lever 41-22 AX44 0011 Heater - 750W- 115V 21-1 AG05 1016 Guide Plate Lever 41-25 AX44 0012 Heater - 750W - 220/240V 21-1 AG05 1051 Development Lever 29-35 AX52 0008 Expossure Lamp - 85V/250W 33-11 AG05 1054 Release Lever 11-18 AZ10 0001 Transformer 61-1 AG05 1055 Jogger Knob 43-40 AZ14 0004 Transformer - 220/240V AG05 1059 Release Lever 31-23 AZ23 0003 Power Supply Board 53-13 AG06 0014 Right Hinge 3-31 AZ31 0002 Power Pack - Separation 51-4 AG06 0018 Left Hinge 3-26 AZ32 0008 Power Pack - C/T/B/G 51-10 88 - 100,115V/13V 53-11 Feb. 28, ’89 Parts No. Description Page and Index No. Parts No. I Description Page and A000 5326 Print Board Sorter Adaptor 51-12 5053 0447 Bushing - M6 A005 3585 Sensor Feeler - Toner Overflow 31-4 5053 0447 Bushing - M6 39-2 A005 3586 Rubber Seal - Toner Collection 31-6 5053 0447 Bushing - M6 41-16 A005 3587 Feeler 31-5 5053 0447 Bushing - M6 43-33 A007 1867 Insulator - Lamp Terminal 33-16 5053 0447 Bushing - M6 49-2 A007 1868 Spacer - Lamp Terminal 33-19 5053 0447 Bushing - M6 9-41 A007 8571 Editing Sheet - LT/LDG 3-11 5054 0536 Magnet Catch Ass’y 3-17 A007 8572 Editing Sheet - A4/A3 3-11 5201 1775 Pulley 33-40 A008 1307 Left Cover Cap - Sorter 3-2 5203 4244 Bushing - 4x8x6mm 13-12 A008 1666 Front Platen Cover 7-33 5203 9501 Grease - 501 67-4 A008 1676 Mounting Bracket - Platen Cover 7-15 5205 1083 Sprocket - 30T/50Hz 47-10 A008 1840 Scanner Drive Wire Bracket 33-52 5205 1084 Sprocket - 27T/60Hz 47-10 A008 2555 Arm Pad Ass’y 15-21 5205 1105 Chain Tightener 39-8 A008 2710 Bottom Plate 7-6 5205 1105 Chain Tightener 49-27 A008 2715 Side Fence - Front 7-2 5205 1696 Main - Reflector 33-12 A008 2727 Side Fence - Rear 7-3 5205 1768 Rubber Seal - Mirror 3-59 A008 2734 Large Cassette Cover 7-1 5205 1768 Rubber Seal - Mirror 33-38 A008 2737 Small Cassette Cover 7-1 5205 1793 Shielding - Guide 35-5 A008 5112 Ram Board 5-15 5205 1794 Left Shield 35-3 A008 9501 Platen Cover Sheet (10 Sheets/set) 7-13 5205 1853 Mylar Seal - Base 35-17 A008 9502 Silicone Grease - G40M 67-15 5205 2667 Bracket - Paper Lift Motor 9-33 A041 1131 Fusing Guide Plate 49-32 5205 2680 Coupled Gear - 16T/53T 9-32 A041 1823 Right Optics Stay 35-53 5205 2681 Coupled Gear - 17T/50T 9-36 A417 8551 Decal - Blue & Green (2pcs/set) 29-38 5205 2697 Bushing - Upper Registration Roller 11-11 A417 8616 Installation Procedure - Color Dev. 69-28 5205 2960 Actuator - A3 7-10 Supporter 37-15 A425 2581 Front Cassette Support Arm 9-27 5205 2962 Actuator - A4R 7-10 A425 2583 Rear Cassette Support Arm 9-30 5205 2964 Actuator - A4 7-10 A917 5115 Battery Cover 3-51 5205 2971 Actuator - 11x17 7-10 A917 8610 Installation Procedure - English 69-28 5205 2976 Actuator - 8”x13” 7-10 A917 8615 Installation Procedure - 5 Language 69-28 5205 2979 Actuator - 8-1/2x11 7-10 5053 0223 Bushing - 8mm 19-5 5205 2996 Actuator - 8-1/2x11R 7-10 5053 0447 Bushing - M6 11-38 5205 2997 Actuator - 8-1/2x14 7-10 5053 0447 Bushing - M6 13-21 5205 3103 Bushing - 6mm 25-15 5053 0447 Bushing - M6 15-30 5205 3103 Bushing - 6mm 27-9 5053 0447 Bushing - M6 17-53 5205 4527 Spring - Exit 41-9 89 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. 5205 5250 L.E.D Sensor Type - S 15-38 5215 2644 Spring - Friction Pad 15-19 5205 5250 L.E.D Sensor Type - S 43-23 5215 2662 Bushing 9-14 5205 5251 L.E.D Sensor Type - T 33-37 5215 2673 Fixing Pad Bracket 15-26 5205 5251 L.E.D Sensor Type - T 35-39 5215 2687 Gear - 16T 3-44 5205 5251 L.E.D Sensor Type - T 47-20 5215 2691 Brake 3-45 5205 5405 Transformer - 115V 53-11 5215 2713 Bottom Plate Pad 7-7 5205 5494 Harness - Transformer - 220/240V 53-5 5215 2720 Front Side Holder 7-8 5205 5570 Jumper Wire 59-1 5215 2731 Rear Side Holder 7-4 5205 9101 Gap Gauge 67-2 5215 2832 Platen Cover Hinge Ass’y 7-14 5206 2684 Shoulder Screw - M3 43-39 5215 2834 Arm Holder 7-26 5206 2876 Spring - Wire 43-17 5215 2836 Sleeve - 8x34 7-22 5206 2877 Wire Clamp Plate 43-16 5215 2837 Shaft - 7x40 7-27 5206 4478 Spring - Drive Roller 11-5 5215 2838 Rubber Magnet 7-18 5206 4478 Spring - Drive Roller 41-18 5215 2839 Balancer Spring 7-25 5206 5472 Harness - Jogger H.P. 43-24 5215 2840 Pin - 4x115mm 7-20 5209 4096 Pressure 45-14 5215 2842 Right Spring - Platen Cover 7-28 5211 2800 Rear Platen Cover 7-32 5215 2843 Left Spring - Platen Cover 7-29 5214 3105 Spring - Toner End Lever 43-30 5215 2844 Slide 5214 4128 Bushing - 14x8x6mm 37-4 5215 2845 Magnet Plate 5215 1102 Spring - Main Drive Tightener 47-30 5215 2846 Platen Base 7-30 5215 1102 Spring - Main Drive Tightener (60Hz) 49-24 5215 2847 Base Holder - Platen Cover 7-21 5215 1102 Spring - Main Drive Tightener 49-25 5215 3295 Hopper Filter 25-32 5215 1667 Platen Cover Stud 7-17 5215 3303 Seal - Toner Supply Roller 29-23 5215 1700 Exposure Lamp Termianl - Fix 33-22 5215 3327 Shaft - Agitator 25-52 5215 1702 Clip - Exposure Lamp 33-23 5215 3328 Joint - Hopper (220/240V) 25-53 5215 1805 Lens Tension Pulley 35-46 5215 3347 Spring - Gear 25-54 5215 1811 Spring - Lens Drive Wire 35-45 5215 3394 Seal - 12x406mm 25-29 Spring Supporter 7-23 7-19 5215 1813 Lens Drive Pulley 35-31 5215 3399 Seal - 50x19mm 25-25 5215 1924 Cushion 33-42 5215 5230 Photointerrupter - L-Type 45-3 5215 2579 Shaft 15-32 5215 5294 Lens Drive Motor - DC 6W 35-29 5215 2582 Spring 15-25 5216 2676 Spring - Engage Gear Bracket 29-6 5215 2618 Feed Roller Hub 13-29 5216 2676 Spring - Engage Gear Bracket 45-29 5215 2618 Feed Roller Hub 15-9 5216 4145 Thermofuse Decal 21-34 5215 2621 Snap Ring - M6 13-30 5216 4145 Thermofuse Decal 69-23 5215 2621 Snap Ring - M6 15-6 5216 5245 Photointerruptor - 90 IL-G-3P-S3T2-E 11-49 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. 5216 5245 Photointerruptor - IL-G-3P-S3T2-E 21-5 5442 1372 Decal - Power Source - 220V 69-24 5216 5245 Photointerruptor - IL-G-3P-S3T2-E 9-50 5442 1657 Seal - 15x214x13mm 7-16 5219 4560 Sprocket - 16T 39-32 5442 1702 Small Screw - M3 33-3 5304 1639 Bushing - 8mm 13-14 5442 1703 Wing - Center 33-2 5304 1639 Bushing - 8mm 15-7 5442 1704 Wing - Side 33-1 5304 1639 Bushing - 8mm 39-5 5442 1705 Rear Terminal - Exposure Lamp 33-17 5304 1639 Bushing - 8mm 45-13 5442 1710 1st Mirror 33-8 5304 1639 Bushing - 8mm 9-9 5442 1711 Spring Plate - 1st Mirror 33-9 5361 2051 Capston : Drive Wire 33-32 5442 1770 Cam - Optics Axis 35-9 5403 4335 Decal - Terminal - 115V 53-10 5442 1924 Cushion - Exposure Glass 37-39 5403 4335 Decal - Terminal - 115V 69-18 5442 2069 Plastic Screw - Main Corona 17-7 5408 3482 Clutch Spring 35-66 5442 2107 Hookless Spring 17-49 5408 5160 Short Connector 51-11 5442 2108 Spring - Corona Wire 17-13 5409 1509 Ratchet Lever Spring 39-9 5442 2108 Spring - Corona Wire 19-27 5409 1705 Clamp - Reflector 33-10 5442 2110 Plug - Corona Unit 17-12 5409 1855 Mounting Pin 11-6 5442 2117 Shoulder Screw - Hinge 11-20 5413 1875 Knob Screw 45-17 5442 2117 Shoulder Screw - Hinge 39-35 5419 5714 Stepped Screw - M4 35-8 5442 2117 Shoulder Screw - Hinge 41-21 5420 1515 Plate - Key Counter 3-32 5442 2117 Shoulder Screw - Hinge 43-6 5420 1682 Supporter - Lamp Terminal 33-18 5442 2117 Shoulder Screw - Hinge 9-10 5420 9504 Thermo Meter - HLC 67-7 5442 2143 Fan - Main Corona 47-8 5420 9505 Probe - HLC - 30 67-8 5442 2146 Seal - 5x12x182mm 47-6 5420 9507 Digital Multimeter - BECKMAN 67-9 5442 2642 Shoulder Screw - M3 15-20 5420 9516 Test Chart - OS-A3 (l0pcs/set) 67-18 5442 5329 Inlet Cooling Fan Meter 35-35 5424 4142 Bushing - Cleaning Roller 23-11 5442 9003 Main Corona Wire (10pcs/set) 5429 3561 Ball Bearing - 10x26x8 25-8 5434 7916 High Voltage Decal 17-46 5442 9004 T & S Corona Wire (10pcs/set) (Separation) 19-29 5434 7916 High Voltage Decal 19-40 5434 7916 High Voltage Decal 51-20 5442 9103 (Transfer) Launa Oil 40 67-11 19-28 5434 7916 High Voltage Decal 69-19 5442 9106 Drum Shoe 67-5 5439 5246 Totalaizer 51-17 5443 2668 Bushing 13-68 5442 1110 Sprocket - 20T 39-12 5443 2668 Bushing 15-43 5442 1110 Sprocket - 20T 49-17 5443 2668 Bushing 9-49 5442 1111 Spring - Main Drive Tightener (50Hz) 49-24 5443 2713 Wave Washer 3-46 5442 1372 Decal - Power Source - 220V 3-12 5446 2620 Idler Pulley - 20 45-15 Ass’y 91 Feb. 28, ’89 Parts No. Description Page and Index No. Parts No. Description Page and Index No. 5446 3135 Cap - F Sensor 31-1 0313 0040W Philips Pan Head Screw - M3x4 17-104 5446 3648 Stepped Screw - M4 31-34 0313 0040W Philips Pan Head Screw - M3x4 27-111 5446 4486 Support Guide Stud 15-55 0313 0040W Philips Pan Head Screw - M3x4 33-112 5446 9140 Thickness Gauge - 0.2mm 67-12 0313 0050G Philips Pan Head Screw - M3x5 25-111 5447 2630 Spring - Registration Roller 11-28 0313 0050W Philips Pan Head Screw - M3x5 31-102 5447 2676 Output Hub 13-53 0313 0050W Philips Pan Head Screw - M3x5 33-113 5447 2678 Slip Clutch Cover 13-52 0313 0050W Philips Pan Head Screw - M3x5 37-105 5447 2681 Snap Ring 13-4 0313 0060B Philips Pan Head Screw - M3x6 57-101 5447 2693 Separation 13-51 0313 0060W Philips Pan Head Screw - M3x6 11-105 5447 2695 Input Hub 13-55 0313 0060W Philips Pan Head Screw - M3x6 17-108 5447 2697 Cylindrical Spring 13-54 0313 0060W Philips Pan Head Screw - M3x6 25-104 5447 2723 Pick-up Roller 13-6 0313 0060W Philips Pan Head Screw - M3x6 29-103 5447 2927 Friction Pad - B 3-39 0313 0060W Philips Pan Head Screw - M3x6 35-105 5447 5430 Lift Motor - DC0.98W 9-39 0313 0060W Philips Pan Head Screw - M3x6 41-101 Roller 5447 9078 Heart Resisting Grease MT-78 67-10 0313 0060W Philips Pan Head Screw - M3x6 43-101 5447 9104 Shoe Adaptor 67-6 0313 0060W Philips Pan Head Screw - M3x6 45-105 5448 2803 Platen Cover Pad 7-35 0313 0060W Philips Pan Head Screw - M3x6 9-102 5448 2824 Flex Hinge - Platen Cover 7-34 0313 0080W Philips Pan Head Screw - M3x8 31-104 5840 1632 Stepped Screw 21-26 0313 0080W Philips Pan Head Screw - M3x8 33-103 5840 1632 Stepped Screw 23-2 0313 0080W Philips Pan Head Screw - M3x8 9-101 5887 4162 Screw - Driven Guide Plate 13-50 0313 0100W Philips Pan Head Screw - M3x10 15-103 5918 3120 Stud - M4 45-23 0313 0100W Philips Pan Head Screw - M3x10 9-103 6843 1222 Jumper Wire 61-2 0313 0120W Philips Pan Head Screw - M3x12 33-104 0313 0160W Philips Pan Head Screw - M3x16 53-120 0314 0010W Philips Pan Head Screw - M4x10 33-108 0314 0050B Philips Pan Head Screw - M4x5 45-106 0314 0060B Philips Pan Head Screw - M4x6 35-113 0314 0060W Philips Pan Head Screw - M4x6 11-103 0314 0060W Philips Pan Head Screw - M4x6 13-103 0314 0060W Philips Pan Head Screw - M4x6 15-105 0314 0060W Philips Pan Head Screw - M4x6 17-109 0314 0060W Philips Pan Head Screw - M4x6 35-102 0314 0060W Philips Pan Head Screw - M4x6 43-104 0314 0060W Philips Pan Head Screw - M4x6 47-103 0314 0060W Philips Pan Head Screw - M4x6 57-102 92 Feb. 28, ’89 Parts No. Description Page and Index No. Parts No. Description Page and Index No. 0314 0080W Philips Pan Head Screw - M4x8 11-106 0323 0080W Philips Sunken Head Screw - M3x8 43-108 0314 0080W Philips Pan Head Screw - M4x8 15-104 0324 0050W Philips Sunken Head Screw - M4x5 35-106 0314 0080W Philips Pan Head Screw - M4x8 19-103 0324 0060W Philips Sunken Head Screw - M4x6 41-104 0314 0080W Philips Pan Head Screw - M4x8 23-101 0344 0060W Philips Truss Head Screw - M4x6 27-101 0314 0080W Philips Pan Head Screw - M4x8 25-101 0344 0060W Philips Truss Head Screw - M4x6 29-101 0314 0080W Philips Pan Head Screw - M4x8 27-102 0353 0050W Tapping Screw - M3x5 25-106 0314 0080W Philips Pan Head Screw - M4x8 45-104 0353 0060F Philips Truss Head Screw - M3x6 5-101 0314 0080W Philips Pan Head Screw - M4x8 47-107 0413 0062W Tapping Screw - M3x6 17-101 0314 0080W Philips Pan Head Screw - M4x8 47-108 0413 0062W Tapping Screw - M3x6 31-101 9-111 0314 0080W Philips Pan Head Screw - M4x8 9-104 0413 0062W Tapping Screw - M3x6 0314 0100B Philips Pan Head Screw”- M4x10 25-107 0413 0082W Tapping Screw - M3x8 17-103 0314 0100W Philips Pan Head Screw - M4x10 15-107 0413 0082W Tapping Screw - M3x8 19-108 0314 0100W Philips Pan Head Screw - M4x10 17-105 0413 0082W Tapping Screw - M3x8 25-105 0314 0100W Philips Pan Head Screw - M4x10 21-109 0413 0082W Tapping Screw - M3x8 27-105 0314 0100W Philips Pan Head Screw - M4x10 25-102 0413 0082W Tapping Screw - M3x8 31-106 0314 0100W Philips Pan Head Screw - M4x10 35-107 0413 0102W Tapping Screw - M3x10 29-102 0314 0100W Philips Pan Head Screw - M4x10 43-103 0413 0142W Tapping Screw - M3x14 31-105 0314 0100W Philips Pan Head Screw - M4x10 45-102 0414 0080W Tapping Screw - M4x8 37-103 0314 0100W Philips Pan Head Screw - M4x10 51-103 0414 0102W Tapping Screw - M4x10 7-103 0314 0120W Philips Pan Head Screw - M4x12 47-109 0433 0062W Hexagon Head Tapping Screw - M3x6 3-107 0314 0200W Philips Pan Head Screw - M4x20 13-104 0434 0060B Philips Tapping Screw - M4x6 33-114 0314 0200W Philips Pan Head Screw - M4x20 17-106 0434 0060W Tapping Screw - M4x6 3-105 33-102 0314 0200W Philips Pan Head Screw - M4x20 55-101 0434 0060W Tapping Screw - M4x6 0314 0250B Philips Pan Head Screw - M4x25 33-107 0434 0060W Tapping Screw - M4x6 35-104 0314 0250W Philips Pan Head Screw - M4x25 53-106 0434 0060W Tapping Screw - M4x6 37-101 0314 0300W Philips Pan Head Screw - M4x30 19-107 0434 0060W Tapping Screw - M4x6 47-106 0315 0080W Philips Pan Head Screw - M5x8 53-111 0434 0060W Tapping Screw - M4x6 49-111 0315 0120W Philips Pan Head Screw - M5x12 47-105 0434 0080W Tapping Screw - M4x8 11-101 0315 0250W Philips Pan Head Screw - M5x25 17-115 0434 0080W Tapping Screw - M4x8 13-101 0323 0050W Philips Sunken Head Screw - M3x5 43-111 0434 0080W Tapping Screw - M4x8 15-102 0323 0060B Philips Sunken Head Screw - M3x6 29-105 0434 0080W Tapping Screw - M4x8 19-104 0323 0060W Philips Sunken Head Screw - M3x6 11-102 0434 0080W Tapping Screw - M4x8 21-102 0323 0060W Philips Sunken Head Screw - M3x6 29-104 0434 0080W Tapping Screw - M4x8 29-107 0323 0060W Philips Sunken Head Screw - M3x6 3-104 0434 0080W Tapping Screw - M4x8 3-102 0323 0080W Philips Sunken Head Screw - M3x8 15-106 0434 0080W Tapping Screw - M4x8 33-109 93 Feb. 28, ’89 Parts No. Description Page and Index No. Parts No. Description Page and Index No. 0434 0080W Tapping Screw - M4x8 35-114 0622 0140E Spring Pin - 2x14mm 41-106 0434 0080W Tapping Screw - M4x8 37-102 0622 0140E Spring Pin - 2x14mm 49-108 0434 0080W Tapping Screw - M4x8 39-113 0700 0080W Flat Washer - M8 13-109 0434 0080W Tapping Screw - M4x8 41-108 0707 5050B Collar - M5 47-111 0434 0080W Tapping Screw - M4x8 45-111 0720 0020E Retaining Ring - M2 25-113 0434 0080W Tapping Screw - M4x8 47-101 0720 0025E Retaining Ring - M2.5 15-112 0434 0080W Tapping Screw - M4x8 49-104 0720 0025E Retaining Ring - M2.5 27-109 0434 0080W Tapping Screw - M4x8 51-101 0720 0030E Retaining Ring - M3 11-111 0434 0080W Tapping Screw - M4x8 53-101 0720 0030E Retaining Ring - M3 13-107 0434 0080W Tapping Screw - M4x8 55-105 0720 0030E Retaining Ring - M3 15-109 0434 0080W Tapping Screw - M4x8 9-112 0720 0030E Retaining Ring - M3 23-103 0434 0082W Tapping Screw - M4x8 21-103 0720 0030E Retaining Ring - M3 35-108 0434 0082W Tapping Screw - M4x8 33-106 0720 0030E Retaining Ring - M3 37-106 0434 0082W Tapping Screw - M4x8 41-102 0720 0030E Retaining Ring - M3 39-107 0434 0100W Tapping Screw - M4x10 55-104 0720 0030E Retaining Ring - M3 43-110 0443 0060W Hexagon Head Tapping Screw - M3x6 11-107 0720 0030E Retaining Ring - M3 47-114 0443 0060W Hexagon Head Tapping Screw - M3x6 43-112 0720 0040E Retaining Ring - M4 11-108 0574 0040E Hexagon Headless Set Screw - M4x4 13-110 0720 0040E Retaining Ring - M4 13-106 0574 0040E Hexagon Headless Set Screw - M4x4 9-109 0720 0040E Retaining Ring - M4 15-110 0574 0050E Hexagon Headless Set Screw - M4x5 33-111 0720 0040E Retaining Ring - M4 21-106 0574 0050W Hexagon Headless Set Screw - M4x5 43-105 0720 0040E Retaining Ring - M4 25-108 0574 0060E Hexagon Headless Set Screw - M4x6 47-113 0720 0040E Retaining Ring - M4 27-108 0574 0060E Hexagon Headless Set Screw - M4x6 9-110 0720 0040E Retaining Ring - M4 29-106 0575 0060E Hexagon Headless Set Screw - M5x6 47-112 0720 0040E Retaining Ring - M4 31-103 0594 0080E Bolt - M4x8 47-118 0720 0040E Retaining Ring - M4 35-109 0622 0100E Spring Pin - 2x10mm 23-104 0720 0040E Retaining Ring - M4 37-107 0622 0100E Spring Pin - 2x10mm 37-110 0720 0040E Retaining Ring - M4 39-106 0622 0100E Spring Pin - 2x10mm 39-109 0720 0040E Retaining Ring - M4 41-105 0622 0100E Spring Pin - 2x10mm 43-107 0720 0040E Retaining Ring - M4 43-106 0622 0120W Spring Pin - 2x12mm 11-112 0720 0040E Retaining Ring - M4 45-103 0622 0140E Spring Pin - 2x14mm 13-111 0720 0040E Retaining Ring - M4 47-110 0622 0140E Spring Pin - 2x14mm 15-113 0720 0040E Retaining Ring - M4 49-106 0622 0140E Spring Pin - 2x14mm 19-105 0720 0040E Retaining Ring - M4 9-108 0622 0140E Spring Pin - 2x14mm 37-109 0720 0050E Retaining Ring - M5 11-109 0622 0140E Spring Pin - 2x14mm 39-108 0720 0050E Retaining Ring - M5 13-105 94 Feb. 28, ’89 Parts No. Description Page and Index No. Parts No. Description Page and Index No. 0720 0050E Retaining Ring -M5 23-102 0805 0083 Retaining Ring - M4 0720 0050E Retaining Ring - M5 25-112 0805 3042 Ball Bearing - 6x10x3mm 13-115 0720 0050E Retaining Ring - M5 33-110 0805 3415 0807 4095 Ball Bearing - M9 Washer 27-112 49-109 7-104 0720 0050E Retaining Ring - M5 39-104 0720 0050E Retaining Ring - M5 49-107 0807 4103 Spacer - 0.5mm 25-114 0720 0060E Retaining Ring - M6 11-110 0916 1226 Bushed Roller Chain 49-112 21-101 0720 0060E Retaining Ring - M6 13-108 0950 3006M Philips Screw With Lock Washer - M3x6 0720 0060E Retaining Ring - M6 15-108 0950 3006M Philips Screw With Lock Washer - M3x6 27-104 0720 0060E Retaining Ring - M6 17-111 0950 4012W Screw - Spring Washer - M4x12 45-110 0720 0060E Retaining Ring - M6 19-110 0951 3004W Philips Screw With Flat Washer - M3x4 45-101 0720 0060E Retaining Ring - M6 21-107 0951 3005W Philips Screw With Flat Washer - M3x5 21-105 0720 0060E Retaining Ring - M6 25-110 0951 3006W Philips Screw With Flat Washer - M3x6 27-107 35-116 0720 0060E Retaining Ring - M6 35-115 0951 3006W Philips Screw With Flat Washer - M3x6 0720 0060E Retaining Ring - M6 37-108 0951 3006W Philips Screw With Flat Washer - M3x6 53-103 0720 0060E Retaining Ring - M6 39-105 0951 4006B Philips Screw With Flat Washer - M4x6 49-103 0720 0060E Retaining Ring - M6 45-107 0951 4006W Philips Screw With Flat Washer - M4x6 17-114 0720 0060E Retaining Ring - M6 49-105 0951 4006W Philips Screw With Flat Washer - M4x6 25-115 0720 0060E Retaining Ring - M6 9-107 0951 4006W Philips Screw With Flat Washer - M4x6 47-104 0725 0100E Retaining Ring C - M10 15-111 0951 4006W Philips Screw With Flat Washer - M4x6 53-104 0725 0100E Retaining Ring C - M10 25-109 0951 4008W Philips Screw With Flat Washer - M4x8 13-114 0725 0120E Retaining Ring C - M12 19-106 0951 4008W Philips Screw With Flat Washer - M4x8 15-101 0725 0170E Retaining Ring C - M17 17-110 0951 4008W Philips Screw With Flat Washer - M4x8 21-104 0725 0250E Retaining Ring C - M25 21-108 0951 4008W Philips Screw With Flat Washer - M4x8 23-105 0727 0090E Retaining Ring C - M9 27-110 0951 4008W Philips Screw With Flat Washer - M4x8 33-101 0740 3008 Ball Bearing 17-117 0951 4008W Philips Screw With Flat Washer - M4x8 35-101 0740 3017 Ball Bearing - M17 17-118 0951 4008W Philips Screw With Flat Washer - M4x8 39-102 0801 1185 Philips Truss Head Screw - M4x8 51-102 0951 4008W Philips Screw With Flat Washer - M4x8 49-101 0801 1185 Philips Truss Head Screw - M4x8 53-102 0951 4008W Philips Screw With Flat Washer - M4x8 9-106 0802 5016 Tapping Screw - M3x5 41-109 0951 4012W Philips Screw With Flat Washer - M4x12 35-103 0802 5094 Tapping Truss Head Screw - M4x8 11-114 0952 3006W Philips Screw - M3x6 17-107 0802 5094 Tapping Truss Head Screw - M4x8 3-101 0952 3006W Philips Screw - M3x6 19-109 0802 5094 Tapping Truss Head Screw - M4x8 37-111 0952 3006W Philips Screw - M3x6 53-112 0802 5131 Truss Head Screw - M4x8 7-101 0952 3020W Philips Screw - M3x20 27-106 0803 0039 Stepped Screw - M3x2 47-115 0952 4016W Philips Screw - M4x16 25-103 0805 0073 Retaining Ring - M5 3-106 0960 3010W Philips Flange Screw - M3x10 27-103 95 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. 0960 4008W Philips Flange Screw - M4x8 43-102 1100 1171 Fastening Receptacle 63-107 0960 4010W Philips Flange Screw - M4x10 17-116 1100 1172 Fastening Receptacle 63-108 0960 4010W Philips Flange Screw - M4x10 49-102 1100 1239 Pin - Mate-N-Lock 63-109 0964 4008W Tapping Screw With Flat Washer - M4x8 13-102 1100 1239 Pin - Mate-N-Lock 65-105 0964 4008W Tapping Screw With Flat Washer - M4x8 15-114 1100 1240 Socket - Mate-N-Lock 65-106 0964 4008W Tapping Screw With Flat Washer - M4x8 17-113 1100 1241 Socket - Mate-N-Lock 63-110 0964 4008W Tapping Screw With Flat Washer - M4x8 19-102 1100 1247 Terminal 63-111 0964 4008W Tapping Screw With Flat Washer - M4x8 33-105 1100 1247 Terminal 65-107 0964 4008W Tapping Screw With Flat Washer - M4x8 39-101 1100 1249 Receptacle Terminal 65-108 0964 4008W Tapping Screw With Flat Washer - M4x8 39-112 1100 1259 Socket - Mate-N-Lock 65-109 0964 4008W Tapping Screw With Flat Washer - M4x8 47-102 1100 1301 Fastening 65-110 0964 4008W Tapping Screw With Flat Washer - M4x8 51-109 1100 1310 Positive Lock Receptacle 63-112 0964 4008W Tapping Screw With Flat Washer - M4x8 53-105 1100 1327 Contact 65-111 0964 4010W Philips Screw With Flat Washer - M4x10 53-123 1100 1328 Contact 65-112 0965 3008W Tapping Screw With Flat Washer - M3x8 11-104 1100 1329 Socket Contact 65-113 0965 3008W Tapping Screw With Flat Washer - M3x8 43-109 1100 1342 Terminal 65-114 0965 4008W Tapping Screw With Flat Washer - M4x8 17-102 1100 1346 Pin Contact 65-115 0965 4008W Tapping Screw With Flat Washer - M4x8 19-101 1100 1348 Pin Contact 65-116 0965 4008W Tapping Screw With Flat Washer - M4x8 3-103 1100 1422 Contact 65-117 0965 4008W Tapping Screw With Flat Washer - M4x8 37-104 1101 0328 Connector Pin Contact 57-104 0965 4008W Tapping Screw With Flat Washer - M4x8 39-103 1101 0359 Terminal - 3P 53-119 0965 4008W Tapping Screw With Flat Washer - M4x8 41-103 1102 0512 Connector - 3P 63-113 0965 4008W Tapping Screw With Flat Washer - M4x8 9-105 1102 0782 Connector - 4P 63-114 0965 4010W Tapping Screw With Flat Washer - M4x10 7-105 1102 0796 Connecting Sleeve 3.0mm 65-118 0965 4012W Tapping Screw With Flat Washer - M4x12 7-102 1102 0845 Contact - EI Connector 57-105 1002 0307 Jumper Wire 57-103 1102 1023 Connector - SP Red 63-115 1005 0383 Edging - B 55-102 1102 1091 Connector - 6P 65-119 1100 0277 Fastening 65-101 1102 1189 Pin Connector - 7P 61-101 Receptacle Receptacle 1100 0340 Closed Terminal 65-102 1102 1194 Connector - 3P 61-102 1100 0342 Closed Terminal 65-103 1102 1396 Connector - 2P 65-120 1100 0878 Connecting Cap 63-103 1102 1397 Connector - 2P 65-121 1100 0916 Pin - Mate-N-Lock 63-104 1102 1402 Receptacle Housing - 1P 63-116 1100 1043 Pin - Mate-N-Lock 63-105 1102 1403 Receptacle Housing 63-117 1100 1159 Socket - Mate-N-Lock 65-104 1102 1404 Receptacle Housing 63-118 1100 1169 Fastening 63-106 1102 1408 Connector - 1P 63-119 Receptacle 96 Feb. 28, ’89 Description Parts No. Page and Index No. Parts No. Description Page and Index No. 1102 1412 Receptacle Housing - 2P 65-122 1102 3255 Receptacle - 3P 59-103 1102 1423 Housing - 3P Black 65-123 1103 0347 Connector - 8P 57-106 1102 1507 Connector - 2P 63-120 1103 0656 Connector - 16P 65-147 1102 1509 Connector - 4P 65-124 1103 0658 Connector - 40P 65-148 1102 1515 Connector - 2P 63-121 1103 0661 Connector 65-149 1102 1515 Connector - 2P 65-125 1103 0663 Connector - 16P 65-150 1102 1516 Connector - 3P 63-122 1103 0734 Connector - 8P 57-107 1102 1532 Connector - 2P 63-123 1103 1559 Connector - 12P 59-104 1102 1620 Connector - 3P 65-126 1103 1726 Connector - 4P 59-105 1102 1740 Connector - 7P 65-127 1103 1727 Connector - 3P 59-106 1102 1815 Connector - 3P 63-124 1103 1729 Connector - 7P 59-107 1102 1817 Positive Lock Housing 63-125 1103 1731 Connector - 9P 59-108 1102 1819 Positive Lock Housing 63-101 1103 1732 Connector - 10P 61-103 1102 1831 Connector - 4P 65-128 1103 1733 Connector - 11P 59-109 1102 1882 Housing 65-129 1103 1739 Connector - 3P 59-110 1102 1890 Housing - 7P 63-102 1103 1745 Connector - 7P 59-111 1102 1910 Connector - 2P 65-130 1103 3019 Connector - 16P 57-108 1102 1911 Connector - 3P 65-131 1103 3020 Connector - 20P 57-109 1102 1912 Connector - 4P 65-132 1103 3024 Connector 57-110 1102 1913 Connector - 5P 65-133 1103 3026 Connector 57-111 1102 1914 Connector - 6P 65-134 1104 0271 LSI Socket - 28P 57-112 1102 1916 Connector - 8P 65-135 1104 0322 Fuse Holder (115V) 53-115 1102 1918 Connector - 10P 65-136 1104 0381 Holder 65-151 1102 1919 Connector - 11P 65-137 1105 0008 Nylon Clip - 2N 47-117 1102 1923 Connector - 15P 65-138 1105 0160 Clamp 51-105 1102 1924 Connector - 2P 65-139 1105 0160 Clamp 53-109 1102 1928 Connector - 6P 65-140 1105 0161 Locking Support 51-106 1102 1932 Connector - 10P 65-141 1105 0183 Spacer 53-110 1102 1938 Connector - 2P 65-142 1105 0196 Harness Clamp 39-111 1102 1942 Connector - 6P 65-143 1105 0196 Harness Clamp 47-116 51-108 1102 1983 Socket Housing - 3P 65-144 1105 0196 Clamp 1102 2108 Connector 65-145 1105 0197 Wire Saddle 13-112 1102 2365 Connector - 6P 59-101 1105 0197 Wire Saddle 35-110 1102 2370 Connector - 6P 65-146 1105 0197 Wire Saddle 45-108 1102 3254 Receptacle - 3P 59-102 1105 0197 Wire Saddle 51-107 97 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. 1105 0197 Wire Saddle 53-107 1402 0433 Zener Diode - HZ982 - 09 61-108 1105 0199 Clamp 17-112 1402 0539 Zener Diode - HZ9C - 2 61-109 1105 0199 Clamp 35-111 1402 0579 Diode - DSA1A4 61-110 1105 0199 Clamp 39-110 1402 0688 Diode - 6.8V 1W 57-118 1105 0199 Clamp 41-107 1402 0691 Diode - RD5.1M 57-119 1105 0199 Clamp 45-109 1402 0706 Diode - U1Z12 57-120 1105 0199 Clamp 49-110 1402 0709 Diode - E11FS1 57-121 1105 0200 Clamp 13-113 1402 0716 Diode - 1S2471 61-111 1105 0200 Clamp 35-112 1403 0521 Photocoupler - S21MD3 61-112 1105 0200 Clamp 53-108 1405 0129 Rectifier - 1B4B42 61-113 1105 0201 Harness Clamp 11-113 1405 0156 IC - BCR8DM 61-136 1105 0229 Clamp 51-110 1405 0182 Triac - BCR16DM8L (115V) 61-137 1105 0251 Clamp 51-104 1405 0183 Triac - BCR16DM-12L (220/240V) 61-137 1106 0366 Cord Clamp - 115V 53-124 1405 0184 Triac - BCR10DM8L 61-138 1106 0442 Cord Clamp - 220/240V 53-124 1407 1335 IC - RF5G02-005 57-122 1106 0493 Edging 55-103 1407 1599 IC - SN74LS153NS 57-123 1107 0354 Fuse - 3.15A/125V 65-152 1407 1720 IC - TC74HC02 57-124 1107 0415 Fuse - 5A 53-121 1407 1880 IC - SN74LS04NS 57-125 1107 0485 Fuse - 15A, 125V (115V) 53-116 1407 1882 IC - SN74LS373NS 57-126 1107 0486 Fuse - 8A, 250V (220/240V) 53-116 1407 2052 IC - SN74LS74ANS 57-127 1150 0003 Power Supply Cord (115V) 53-122 1407 2073 IC - UPD78C10GF 57-128 1150 0009 Power Supply Cord - 220/240V 53-122 1407 2077 IC - SN74LS138NS 57-129 1204 1373 Push Switch 53-118 1407 2081 IC - SN74LS08NS 57-130 1204 1545 Main Switch 53-117 1407 2187 IC - SN74LS07NS 57-131 1206 0044 Lithium Battery 3-108 1407 2217 IC - MPD71054G 57-132 1208 1152 Relay 61-104 1407 2230 IC - TD62303F 57-133 1401 0296 Transistor - 2SA1162Y 57-113 1407 2231 IC - TD62308AF 57-134 1401 0298 Transistor - 2SC2712Y 57-114 1407 2338 Cmos - IC - TC74HC4050F 57-135 1401 0392 Transistor - 2SB1193 57-115 1407 2339 Ttl - IC - SN74LS241NS 57-136 1401 0410 Transistor - 2SB1115YL 57-116 1407 2340 IC - SN74LS126ANS 57-137 1401 0434 Transistor - 2SD1474P 57-117 1407 2344 Transistor - TD62382F 57-138 1401 0825 Diode - 1SS176 59-112 1407 2345 57-139 1402 0360 Zener Diode - HZ20 61-105 1407 2523 Transistor - TD62305F IC - TC74HC14F 1402 0407 Zener Diode - HZ6B3 61-106 1408 0200 IC - TA75339P 59-113 1402 0416 Zener Diode - HZ58 - 1 61-107 1408 0233 IC - HA17903PS 61-114 98 57-140 Feb. 28, ’89 Parts No. Description Page and Index No. Parts No. Description Page and Index No. 1408 0516 IC - TLS27L4 57-141 1610 0064 Resistor - 3KOHM 1/8W ±5% 57-157 1408 0598 IC - MB3773PF 57-142 1610 0065 Resistor - 3.3KOHM l/8W ±5% 57-158 1503 0070 Ceramic Oscillator - 10MHz 57-143 1610 0067 Resistor - 4.7KOHM l/8W ±5% 57-159 1503 0180 Ceramic Oscillator - 8MHz 57-144 1610 0071 Resistor - 10KOHM ±5% 57-160 1601 1148 Resistor - 1KOHM ±5% 1W 61-115 1610 0107 Resistor - 1MOHM l/8W ±5% 57-161 1601 7374 Resistor Array - 4.7KOHM 59-114 1610 0119 Resistor - 10MOHM l/8W ±5% 57-162 1601 7468 Fuse Resistor - 100OHM 1/2W 61-116 1610 0511 Resistor - 1/8W 5.23KOHM 57-163 1601 8138 Variable Risistor - 30KOHM 61-117 1611 4103 Resistor - 10KOHM 1/4T ±5% 59-117 1601 8349 Variable Resistor - 500KOHM 57-145 1611 4103 Resistor - 10KOHM 1/4T ±5% 61-127 1602 0895 Noise Filter - 0.1µF 120OHM Noise Kilter - 0.1µF 120OHM 61-118 1611 4124 Resistor - 120KOHM 1/4T ±5% 61-128 1602 0920 61-119 1611 4153 Resistor - 15KOHM 1/4T ±5% 61-129 1602 0923 Noise Filter - 115V 53-114 1611 4223 Resistor - 22KOHM 1/4T ±5% 61-130 1602 0946 Noise Filter - 220/240V 53-114 1611 4242 Resistor - 2.4KOHM 1/4T ±5% 61-131 1604 1353 Capacitor - 47µF 10V 57-146 1611 4333 Resistor - 33KOHM 1/4T ±5% 61-132 1604 1354 Capacitor - 100MF 10V 57-147 1611 4474 Resistor - 470KOHM 1/4T ±5% 61-133 1604 1378 Capacitor - 1MF 50V 61-120 1611 4562 Resistor - 5.6KOHM 1/4T ±5% 61-134 1604 1382 Capacitor - 10µF 50V 59-115 1611 4820 Resistor - 82OHM 1/4T ±5% 61-135 1604 1386 Capacitor - 100MF 50V 57-148 1605 0304 Capacitor - 2200PF ±10% 50V 57-149 1606 0689 Capacitor - 0.01µF 50V 61-121 1606 0998 Capacitor - 0.01µF 50V 59-116 1606 1400 Capacitor - 0.1µF 61-122 1606 1451 Capacitor - 0.1µF 50V 57-150 1606 1452 Capacitor - 0.01µF 50V 57-151 1606 1455 Capacitor - 470PF 25V 57-152 1606 1472 Capacitor - 0.1µF ±20% 61-123 1606 1484 Capacitor - 16µF 220V (115V) 53-113 1606 1485 Capacitor - 16µF 220V (220/240V) 53-113 1606 1497 Capacitor - 0.047µF 125V 61-124 1606 1520 Capacitor - 27PF 50V 57-153 1606 1542 Capacitor - 0.22MF AC250V 61-125 1607 0134 Choke Coil - 250MH 6A 61-126 1610 0039 Resistor - 150OHM l/8W ±5% 57-154 1610 0041 Resistor - 57-155 1610 0053 Resistor - 1KOHM l/8W ±5% 180OHM l/8W ±5% 57-156 99 CS2090 (A423) 1. Sorter (A423) . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. Bin Motor Board (A423) . . . . . . . . .. .. . . . . 4 3. Sorter Harness (A423) . . . . . . . ... . . . . . . . . 6 4. Decal & Document (A423) . . . . . . . . . . . . . . . . 8 Parts Index . . . . . . . . . . . . . . . . . ...9.* 9 .9....9 . 12 1. SORTER (A423) Feb. 28, ’89 1. SORTER (A423) Index No. Feb. 28, ’89 Part No. Description Q’ty Per Assembly Index No. Part No. Description Q’ty Per Assembly 1 A414 6512 Jam Removal Decal 1 33 6803 4316 O-Ring 1 1 A414 6522 Multi-Lingual Decal 1 34 A423 1144 Base Roller 2 2 A423 6311 Upper Cover 1 35 A423 1143 Base Shaft 2 3 A423 6511 Upper Cover Hinge 2 36 6803 1161 Upper Mounting Stud 2 4 A423 1161 Upper 1 37 A423 1151 Stay 1 5 A414 3111 Sorter Bin - Odd 10 38 6802 5703 Grounding Wire 1 6 7 A414 3151 Sorter Bin - Even 10 39 A423 1145 Receive Plate 1 A423 3221 Sorter Bin - Bottom 1 40 6803 2261 Dumper - Upper Guide Plate 2 1 - Stay 8 6803 3316 Lift 1 41 6769 1128 Mounting Stay Magnet 9 A423 3513 Bin Support Shaft 1 42 A423 1131 Base Plate Bar . 10 AA12 1001 Antistatic Brush 1 43 6803 2111 Lower Guide Plate 1 11 A414 6521 Decal - Guide Plate 1 44 A423 2121 Entrance Guide Plate 1 12 6803 2241 Upper Exit Roller 1 45 6803 5430 Paper Exit Sensor 1 13 A423 2122 Upper Seal 1 46 6803 3414 Lever Stopper 1 14 A423 2124 Lower Rear Seal 1 47 6803 3413 Lever Spring 1 15 A423 2123 Lower Front Seal 1 48 6803 3411 Lever - Home Position Sensor 1 16 6803 2231 Bushing - 4x6x5mm 2 49 6803 3412 Stepped Screw - M4 1 17 6803 2221 Guide - Upper Guide Plate 2 50 5205 5250 L.E.D Sensor Type - S 2 18 A423 2531 Guide Plate Knob 1 51 A423 3425 Bracket - Half Turn Sensor 1 19 A423 2110 Upper Guide Plate 1 52 6803 3427 Holder - Half Turn Sensor 1 20 A423 3311 Left Spring 2 53 6769 5655 Angie - Cord Clamp (70) 2 21 5053 0447 Bushing - M6 2 54 A423 3327 Transfer Wheel 1 22 6803 3321 Front Transfer Wheel 1 55 6803 2273 Stepped Screw - M4 1 23 6803 4311 Timing Belt - 94XL 1 56 A423 2272 Guide Plate Arm 1 24 A423 3517 Bin Support Wire 2 57 A423 6211 Rear Cover 1 25 A423 6111 Front Cover 1 58 6803 5600 Main Harness 26 A423 3511 Bin Shaft Positioner 2 59 6803 5610 Interface 27 6803 2410 Lower Exit Roller 1 60 5403 2075 Stepped Screw 2 28 6803 3331 Transfer Wheel Shaft 1 61 5895 2165 Washer - 6x12 2 29 A423 5410 1 62 A423 2271 Guide Plate Lever 1 29 A414 5410 DC Motor - 24V 2.9W (115V) DC Motor - 24V 2.9W (220/240V) 1 63 A423 4434 Switch Sheet 1 30 6803 5400 Bin Motor - AC14/17W (115V) 1 64 6803 5500 Bin Motor Board 1 30 6803 5420 Bin Motor - 220/240V 1 65 A423 4436 Board Bracket 1 31 6803 4411 Cover Bracket 1 66 A423 4431 Switch Bracket 1 32 A423 4216 Pulley 1 67 A423 4433 Spring 1 Index No. Part No. Description Index No. Q’ty Per Assembly 68 A423 4432 Shoulder Screw - M2.5 1 69 A423 2311 Guide Plate 1 70 6803 4211 Pulley - 18T 1 71 6803 2415 Drive Pulley 1 101 0314 0060W Philips Pan Head Screw - M4x6 102 0720 0030E Retaining Ring - M3 103 0314 0080W Philips Pan Head Screw - M4x8 104 0434 0080W Tapping Screw - M4x8 105 0951 4010W Philips Screw With Flat Washer - M4x10 106 0315 0080W Philips Pan Head Screw - M5x8 107 0632 0140G Parallel Pin 108 0313 0060W Philips Pan Head Screw - M3x6 109 0720 0040E Retaining Ring - M4 110 0720 0060E Retaining Ring - M6 111 0344 0080D Philips Truss Head Screw - M4x8 112 0314 0080M Philips Pan Head Screw - M4x8 113 0965 3010W Tapping Screw With Flat Washer - M3x10 114 1606 0755 Capacitor - 10µF 220V (115V) 114 1606 1380 Capacitor - 10µF (220/240V) 115 1105 0196 Harness Clamp 116 0313 0120W Philips Pan Head Screw - M3x12 117 0314 0120W Philips Pan Head Screw - M4x12 118 1105 0091 Cable Clip - 16mm 119 1105 0193 Nylon Stud 120 1204 1318 Microswitch 121 0704 0040C Toothed Washer - M4 122 0701 0030B Flat Washer - M3 3 Part No. 1 Harness Description 1 Feb. 28, ’89 2. BIN MOTOR BOARD (A423) 4 2. BIN MOTOR BOARD (A423) Index No. * Part No. 6803 5500 Description Feb. 28, ’89 Index No. Q’ty Per Assembly 101 1 5 Part No. 1102 0995 Description Connector - 2P 102 1102 1194 Connector - 3P 103 1103 1695 Connector - 15P 104 1103 1748 Connector - 12P 105 1208 1024 Solid State Relay - 240V 2A 106 1401 0832 Diode - DSA1A1 Q’ty Per Assembly Feb. 28, ’89 3. SORTER HARNESS (A423) 6 3. SORTER HARNESS (A423) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description 1 6803 5600 Main Harness 1 101 1100 0051 Wire Terminal 2 6803 5610 Interface Harness 1 102 1100 1042 Socket - Mate-N-Lock 103 1100 1169 Fastening 104 1100 1238 Pin - Mate-N-Lock 105 1100 1239 Pin - Mate-N-Lock 106 1100 1249 Receptacle Terminal 107 1100 1264 Wire Terminal 108 1100 1327 Contact 109 1100 1328 Contact 110 1102 0512 Connector - 3P 111 1102 0983 Connector - 2P 112 1102 1408 Connector - 1P 113 1102 1508 Connector - 3P 114 1102 1524 Connector - 2P (RED) 115 1102 1620 Connector - 3P 116 1102 1911 Connector - 3P 117 1102 1919 Connector - 11P 118 1102 1923 Connector - 15P 119 1102 1934 Connector - 12P 120 1102 1952 Connector - 2P 121 1102 1964 Connector - 2P 122 1102 1966 Connector - 4P 7 Receptacle Q’ty Per Assembly 4. DECAL & DOCUMENT (A423) Feb. 28, '89 Feb. 28, ’89 4. DECAL & DOCUMENT (A423) Index No. Part No. Description Index Q’ty Per Assembly 1 A414 6512 Jam Removal Decal 1 1 A414 6522 Multi-Lingual Decal 1 2 A414 6521 Decal - Guide Plate 1 3 A423 8610 Installation Procedure - English 1 3 A423 8615 Installation Procedure - 5 Language 1 No. 9 Part No. Description Q’ty Per Assembly PARTS INDEX Feb. 28, ’89 Description Parts No. Page and Index No. Parts No. Description Page and Index No. A423 1131 Base Plate 3-42 AA12 1001 Antistatic Brush A423 1143 Base Shaft 3-35 A414 3111 Sorter Bin -Odd 3-5 A423 1144 Base Roller 3-34 A414 3151 Sorter Bin - Even 3-6 A423 1145 Receive Plate 3-39 A414 5410 DC Motor - 24V 2.9W (220/240V) 3-29 A423 1151 Stay 3-37 A414 6512 Jam Removal Decal 3-1 A423 1161 Upper Stay 3-4 A414 6512 Jam Removal Decal 9-1 A423 2110 Upper Guide Plate 3-19 A414 6521 A423 2121 Entrance Guide Plate 3-44 A414 6521 Decal - Guide Plate Decal - Guide Plate 9-2 A423 2122 Upper Seal 3-13 A423 2123 Lower Front Seal 3-15 A414 6522 A414 6522 Multi-Lingual Decal Multi-Lingual Decal 3-1 9-1 A423 2124 Lower Rear Seal 3-14 5053 0447 Bushing - M6 3-21 A423 2271 Guide Plate Lever 3-62 5205 5250 L.E.D Sensor Type - S 3-50 A423 2272 Guide 3-56 5403 2075 Stepped Screw 3-60 A423 2311 Guide Plate 3-69 5895 2165 Washer - 6x12 3-61 A423 2531 Guide Plate Knob 3-18 6769 1128 Mounting Stay Magnet 3-41 A423 3221 Sorter Bin - Bottom 3-7 6769 5655 Angie -Cord Clamp (70) 3-53 A423 3311 Left Spring 3-20 6802 5703 Grounding Wire 3-38 A423 3327 Transfer 3-54 6803 1161 Upper Mounting Stud 3-36 A423 3425 Bracket - Half Turn Sensor 3-51 6803 2111 Lower Guide Plate 3-43 A423 3511 Bin Shaft Positioner 3-26 6803 2221 3-17 3-12 Plate Arm Wheel A423 3513 Bin Support Shaft 3-9 6803 2231 Guide - Upper Guide Plate Bushing - 4X6X5mm A423 3517 Bin Support Wire 3-24 6803 2241 Upper Exit Roller 3-10 3-11 3-16 A423 4216 Pulley 3-32 6803 2261 Dumper - Upper Guide Plate 3-40 A423 4431 Switch Bracket 3-66 6803 2273 Stepped Screw - M4 3-55 A423 4432 Shoulder Screw - M2.5 3-68 6803 2410 Lower Exit Roller 3-27 A423 4433 Spring 3-67 6803 2415 Drive Pulley 3-71 A423 4434 A423 4436 Switch Sheet 3-63 6803 3316 Board Bracket 3-65 6803 3321 Lift Bar Front Transfer Wheel 3-8 3-22 A423 5410 DC Motor - 24V 2.9W (115V) 3-29 6803 3331 Transfer Wheel Shaft 3-28 A423 6111 Front Cover 3-25 6803 3411 Lever - Home Position Sensor 3-48 A423 6211 Rear Cover 3-57 6803 3412 Stepped Screw - M4 3-49 A423 6311 Upper Cover 3-2 6803 3413 Lever Spring 3-47 A423 6511 Upper Cover Hinge 3-3 6803 3414 Lever Stopper 3-46 A423 8610 Installation Procedure - English 9-3 6803 3427 Holder - Half Turn Sensor 3-52 A423 8615 Installation Procedure - 5 Language 9-3 6803 4211 Pulley - 18T 3-70 12 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. 6803 4311 Timing Belt - 94XL 3-23 0313 0060W Philips Pan Head Screw - M3x6 3-108 6803 4316 O-Ring 3-33 0313 0120W Philips Pan Head Screw - M3x12 3-116 6803 4411 Cover Bracket 3-31 0314 0060W Philips Pan Head Screw - M4x6 3-101 6803 5400 Bin Motor - AC14/17W (115V) 3-30 0314 0080M Philips Pan Head Screw - M4x8 3-112 6803 5420 Bin Motor - 220/240V 3-30 0314 0080W Philips Pan Head Screw - M4x8 3-103 6803 5430 Paper Exit Sensor 3-45 0314 0120W Philips Pan Head Screw - M4x12 3-117 6803 5500 Bin Motor Board 3-64 0315 0080W Philips Pan Head Screw - M5x8 3-106 6803 5500 Bin Motor Board 5-* 0344 0080D Philips Truss Head Screw - M4x8 3-111 6803 5600 Main Harness 3-58 0434 0080W 6803 5600 Main Harness 7-l 0632 0140G Tapping Screw - M4x8 Parallel Pin 3-107 6803 5610 Interface Harness 3-59 0701 0030B Flat Washer - M3 3-122 6803 5610 Interface 7-2 0704 0040C Toothed Washer - M4 3-121 Harness 13 3-104 0720 0030E Retaining Ring - M3 3-102 0720 0040E Retaining Ring - M4 3-109 0720 0060E Retaining Ring - M6 3-110 0951 4010W Philips Screw With Flat Washer - M4x10 3-105 0965 3010W Tapping Screw With Flat Washer - M3x10 3-113 1100 0051 Wire Terminal 7-101 1100 1042 Socket - Mate-N-Lock 7-102 1100 1169 Fastening 1100 1238 Pin - Mate-N-Lock 7-104 1100 1239 Pin - Mate-N-Lock 7-105 1100 1249 Receptacle Terminal 7-106 1100 1264 Wire Terminal 7-107 1100 1327 Contact 7-108 1100 1328 Contact 7-109 1102 0512 Connector - 3P 7-110 1102 0983 Connector - 2P 7-111 1102 0995 Connector - 2P 5-101 1102 1194 Connector - 3P 5-102 1102 1408 Connector - 1P 7-112 Receptacle 7-103 1102 1508 Connector - 3P 7-113 1102 1524 7-114 1102 1620 Connector - 2P (RED) Connector - 3P 1102 1911 Connector - 3P 7-116 7-115 Feb. 28, ’89 Description Parts No. Page and Index No. 1102 1919 Connector - 11P 7-117 1102 1923 Connector - 15P 7-118 1102 1934 Connector - 12P 7-119 1102 1952 Connector - 2P 7-120 1102 1964 Connector - 2P 7-121 1102 1966 Connector - 4P 7-122 1103 1695 Connector - 15P 5-103 1103 1748 Connector - 12P 5-104 1105 0091 Cable Clip - 16mm 3-118 1105 0193 Nylon Stud 3-119 1105 0196 Harness Clamp 3-115 1204 1318 Microswitch 3-120 1208 1024 Solid State Relay - 240V 2A 5-105 1401 0832 Diode - DSA1A1 5-106 1606 0755 Capacitor - 10µF 220V (115V) 3-114 1606 1380 Capacitor - 10µF (220/240V) 3-114 Parts No. 14 Description DF52 1. Exterior& Transport Section (A422) . . . . . . . . . 2 2. Feed–in Section (A422) . . . . . . . . . . . . . . . . . . 4 3. Invert & Exit Section (A422) . . . . . . . . . . . . . . . 6 4. DF Main Board (A422) . . . . . . . . . . . . . . . . . . . 8 5. Indication Board (A422) . . . . . . . . . . . . . . . ...10 6. DF Main Harness (A422) . . . . . . . . . . . . . . . ...12 7. Interface Harness (A422) . . . . . . . . . . . . . . . ...14 8. Decal & Document (A422) . . . . . . . . . . . . . . ...16 Parts Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20 1. EXTERIOR & TRANSPORT SECTION (A422) Feb. 28, ’89 2 EXTERIOR & TRANSPORT SECTION (A422) 1. Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description Q’ty Per Assembly 1 A465 1337 Decal - Original Table - LT 1 34 A422 1127 Transport Belt 1 1 A465 1338 Decal - Original Table - A4 1 35 A422 1114 Driven Roller - Transport Belt 1 2 A422 1335 Magnet - Original Table 1 36 A422 1106 Stay 1 3 A465 2025 Original Limit Decal 1 37 A465 1118 Belt Support Roller 4 4 A422 1376 Rear Side Guide 1 38 A422 1389 Spacer - 0.2mm 4 5 5894 2747 Mylar - Original Guides 6 39 A422 1107 Stay - Belt Support Roller 3 6 A422 1366 Front Side Guide 1 40 A422 1116 Belt Pressure Roller 1 7 A422 1361 Pack - Side Guide 2 41 A437 1115 Drive Roller - Transport Belt 1 8 A422 1320 Original Table 1 42 A422 1188 Belt Guide - Rear Right 1 1 43 A422 1186 Belt Guide - Rear Left 1 1 44 A422 1103 Rear Frame 1 Gear - 19T 1 9 5443 2712 Cork Pad 10 5443 2657 Gear - 11 5443 2713 Wave Washer 1 45 A422 1056 12 5443 2660 Spacer - 6x22x0.5mm 1 46 A422 1184 Feed-out Motor Cover 1 13 A422 2021 Decal - Misfeed Removal 1 47 A422 1603 Seal - 2x8x14 1 13 A422 2031 Decal - Misfeed - Multi-Language 1 48 A422 5211 Fiber Connector 1 14 A422 1385 Original Exit Guide 1 49 A465 1331 Grip Cover 1 15 A437 1125 Angle Stopper 1 50 A422 1500 Belt Drive Motor Cover 1 16 A437 1179 Lift Switch Actuator 1 51 A422 1183 Main Board Cover 1 17 A422 1395 Shaft 1 52 5936 7901 Decal - English 1 18 A422 1191 Mounting Bracket 1 53 5936 5348 Thin Original Feed Switch 1 19 A422 1380 Shoulder Screw - M4x12 2 54 A465 2017 Decal - DIP Switch 1 20 5936 2480 Magnet Catch Ass'y 2 55 A422 1130 Reflector Plate 1 21 A422 1135 Magnet Catch Bracket 1 56 A422 1604 Cushion - 8x15x25 1 22 5875 2088 Shoulder Screw - M4 6 23 AA14 3005 Stepped Screw - M4x2.5 2 24 A422 1108 Stopper 4 25 A422 1078 Bushing - 6x12x4mm 2 26 A465 2031 27 - 282 A465 1100 Decal - Set Front Frame 1 28 A422 1185 Belt Guide - Front Left 1 29 A422 1187 30 5447 3655 Bushing - 4mm 31 A422 1397 Spacer - 0.5mm 8 32 A437 1120 Bracket - Belt Tension Spring 2 33 A422 1112 Belt Tension Spring 2 Index No. 1 Belt Guide - Front Right Part No. Description 101 0353 0050W 102 0413 0082W Tapping Screw - M3x8 103 0951 4005W Philips Screw With Flat Washer - M4x5 104 0315 0l00W Philips Pan Head Screw - M5x10 105 0951 4006W Philips Screw With Flat Washer - M4x6 106 0741 3806 all Bearing - 6x13x5mm 107 0344 0060W Philips Truss Head Screw - M4x6 108 0801 1185 Philips Truss Head Screw - M4x8 109 0720 0040E Retaining Ring - M4 110 0720 0050E Retaining Ring - M5 111 0720 0030E 112 0701 0060B Flat Washer - M6 113 0314 0060W Philips Pan Head Screw - M4x6 114 0632 0100G Pin 2X10mm 115 0344 0060D Philips Truss Head Screw - M4x6 1 8 Index No. Q’ty Per Assembly Tapping Screw - M3x5 Retaining Ring - M3 116 1106 0279 Bushing 117 0742 3906 Ball Bearing - 6mm 3 Part No. Description Q’ty Per Assembly 2. FEED–IN SECTION (A422) Feb. 28, ’89 4 2. FEED-IN SECTION (A422) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description Q’ty Per Assembly 1 A437 1066 Guide Mylar 1 35 A422 1044 Idle Shaft 1 2 A465 1077 Release Lever 1 36 A422 1503 Idle Shaft 1 3 A465 1057 Pull-out 1 37 A422 1042 Idle Gear - 22Z 1 4 A465 1076 Release Lever Knob 1 38 A422 1046 Pick-up Roller 1 5 A422 1086 Pull-out Spring 2 39 A422 1048 Pick-up Shaft 1 6 A422 1063 Seal - 0.7x13x20 2 40 A422 1002 Clutch Boss 1 7 A422 1064 Hinge - Pull-out 1 41 5918 2163 Clutch Spring 1 Bracket 8 5205 5250 L.E.D Sensor Type - S 2 42 5918 2164 Clutch Sleeve 1 9 A422 1087 Shoulder Screw - M3x3 43 A422 1001 Gear - 24T 1 10 A422 5202 Harness - Pulse Generator 2 1 44 A422 1023 Feed Roller Shaft 1 11 A437 1065 Lower Guide Plate 1 45 A422 1045 Pull-out Roller 2 12 A422 1071 Pull-out Lever 2 46 A422 1090 Side Roller 2 13 A422 1068 Relay Roller 2 47 A422 1003 Feed Roller 1 14 A422 1067 Relay Roller Shaft 1 48 A422 1041 Gear - 27T 1 15 A422 1070 Pulse Generator 1 49 A422 1025 Original Guide 1 16 A422 5201 Interface Harness 1 50 A422 1602 Pick-up Lever Plate 1 17 A437 1026 Upper Guide Plate 1 51 A422 1600 Pick-up Lever 1 18 A422 1301 DF Upper Cover - 115V 1 52 A422 1601 Pick-up Shaft 1 18 A422 1302 DF Upper Cover - 220/240V 1 53 A422 1032 Lever - Pick-up Solenoid 1 19 5219 1957 Stepped Screw - M4 1 54 A422 1031 Lever - Pick-up Spring 1 20 A465 1068 Cushion - 2.5x14x43 1 55 A422 1082 Pick-up Spring 1 21 A465 1075 Shaft - 3x25 1 56 A422 1033 Pick-up Solenoid Bracket 1 22 A465 1074 Pin - 4x77. 5 1 57 5894 2229 Solenoid Pin 2 23 A465 1073 Pin - 4x76.5 1 58 A422 5255 Solenoid - DC24V 1 24 A465 1072 Lock Spring 2 59 A465 1067 Mylar - 0.1x14.5x44 1 25 A422 1072 Front Side P l a t e 1 60 A422 1005 Clutch Pawl - Pick-up Roller 1 26 A465 1069 Harness Cover 1 61 A422 1049 Gear - 27T 1 27 A422 1047 Set Sensor Bracket 1 62 A422 1050 Gear - 29T 1 28 A422 5270 Photosensor 2 63 A422 1021 Side Plate 1 29 A422 5207 Harness - Registration 1 64 5894 2176 Spring - Detent Arm 1 30 A422 5208 Harness - Paper Size 1 65 A422 1291 Rear Guide Plate 1 31 A422 1093 Sensor Bracket 1 66 A422 1290 Front Guide Plate 1 32 5875 2088 Shoulder Screw - M4 4 67 A422 1351 Seal - 0.5x37x71mm 1 33 A422 1078 Bushing - 6x12x4mm 4 68 A422 1352 Friction Belt Holder 1 34 A422 1051 Gear - 23T 1 69 A422 1354 Friction Belt 1 Q’ty Per Assembly Index No. Index No. Part No. Description Part No. Description 70 A422 1356 Pin - 3x26mm 1 101 0313 0060W 71 A422 1355 Friction Belt Spring 2 102 0951 3010W Philips Screw With Flat Washer - M3x10 72 A422 1069 Friction Roller 1 103 0951 4006W Philips Screw With Flat Washer - M4x6 73 A422 1295 Set Sensor Actuator 1 104 0313 0l00W Philips Pan Head Screw - M3x10 74 A422 1176 Set Sensor Actuator Bracket 1 105 0313 0040W Philips Pan Head Screw - M3x4 75 A422 1390 Entrance Seal 1 106 0951 3004W Philips Screw With Flat Washer - M3x4 76 A422 5260 Indication Board 1 107 0720 0040E Retaining Ring - M4 77 A422 1177 Indication 1 108 0720 0060E Retaining Ring - M6 78 A422 1504 Shaft/Gear - 16T 1 109 0720 0025E Retaining Ring - M2.5 79 A422 1506 Gear - 25T 1 110 0632 0100G Pin 2x10mm 80 A422 1510 Rear Side Plate 1 111 0632 0140G Parallel Pin 81 A422 1507 Feed-in Motor Bracket 1 112 0632 0080G Parallel Key - 2x8mm 82 A422 1501 Gear - 20T 1 113 0573 0030E Hexagon Headless Set Screw - M3x3 83 A422 5300 Feed-in Motor - DC10W 1 114 0573 0060E Hexagon Headless Set Screw - M3x6 84 A422 5204 Feed-in Motor Harness (115V) 1 115 0354 0060W Philips Truss Head Screw - M4x6 84 A422 5510 Feed-in Motor Harness (220/240V) 1 116 1105 0199 Clamp 85 A422 1502 Gear - 45T 1 117 1105 0008 Nylon Clip - 2N 86 A465 1066 Mylar - 0.1x21x58 1 118 1105 0009 Nylon Clip - 5N 87 A422 5252 Solenoid - DC24V 1 119 0951 4005W Philips Screw With Flat Washer - M4x5 88 A422 1040 1 120 0741 3506 Ball Bearing - 6x12x4mm 89 A422 1505 Feed-in Solenoid Lever Gear - 57T 1 121 0950 4006W Philips Screw With Lock Washer - M4x6 90 A465 1070 Lever Spring 1 122 0741 3505 Ball Bearing - 5x10x4mm 91 A422 1603 Seal - 2x8x14 1 123 0805 3383 Bushing - M5 92 A422 1022 Support Plate 1 93 A422 1396 Mylar - 0.125x14x45.5 1 124 125 0314 0060W 0720 0030E Philips Pan Head Screw - M4x6 Retaining Ring - M3 94 A465 1080 Fixing Plate - Feed-in Unit 1 95 A422 5212 Grouding Wire 1 96 A465 1027 Guide Plate - Paper Feed 2 Bracket 5 Philips Pan Head Screw - M3x6 Q’ty Per Assembly 3. INVERT & EXIT SECTION (A422) Feb. 28, ’89 3. INVERT & EXIT SECTION (A422) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly I Part No. I Description Q’ty Per Assembly 1 A422 1499 Right Hinge 1 36 A422 1275 Front Side Plate - Feed-out 1 2 A422 1121 Right Bracket - Right Hinge 1 37 A422 1230 Inverter Pawls 1 3 A422 1120 Left Bracket - Right Hinge 1 38 A422 1210 Inverter Roller 1 4 A422 1394 Left Hinge 1 39 A422 1216 Inverter Support Roller 1 5 A422 1119 Left Hinge Bracket 1 40 A422 1276 Rear Side Plate - Feed-out 1 6 A422 5550 Lift Switch (220/240V) 1 41 A422 1079 Bushing - 8x16x5mm 1 7 A422 5205 Interface Harness 1 42 A422 1270 Timing Belt - 81XL 1 8 A422 1249 Upper Exit Roller 4 43 A409 1143 Pulley - 50T 1 9 A422 5170 DF Main Board 1 44 A422 5203 Feed-out Sensor Harness 1 10 A422 5500 Main Harness 1 45 A422 1245 Upper Exit Roller Ass’y 1 11 A422 1175 Harness Bracket 1 46 A422 1218 Pressure Lever Shaft 1 12 5918 2623 Paper Guide Mylar 1 47 A422 1217 Pressure Lever 2 13 A422 1225 Inverter Guide Plate 1 48 A422 1219 Pressure Lever Spring 2 14 A422 1260 Front Side Plate 1 49 A422 1257 Antistatic Brush 1 15 A409 1192 Pulley - 15T 1 50 A422 1255 Inverter Guide Plate 1 16 A465 5213 Grounding Wire 1 51 A422 1251 Bracket - Exit Sensor 1 17 A409 1195 Exit Drive Shaft 1 52 A422 5270 Photosensor 1 18 A422 1265 Sear - 46T 1 53 5875 2088 Shoulder Screw - M4 4 54 A422 2030 Decal - Inverter Guide Plate 1 . 19 A465 1126 Grounding Plate 1 20 A409 1197 Spacer - 10x16xl.6mm 1 21 A422 1261 Rear Side Plate 1 22 A422 1232 Inverter Solenoid Bracket 1 23 5894 2229 Solenoid Pin 1 24 A422 5255 Solenoid - DC24V 1 25 A422 1235 Rear Lever 1 26 A422 5310 Feed-out Motor - DC10W 1 27 A409 1161 Pulley - 21T 1 28 5053 0447 Bushing - M6 2 29 A422 1226 Spring - Inverter Guide Plate 2 30 A409 1150 Spring Anchor 2 31 A422 1240 Upper Exit Roller 1 32 A422 1231 Inverter Gate Spring 1 33 A422 1234 Front Lever 1 34 A422 1078 Bushing - 6x12x4mm 1 35 5446 2824 Screw - Duplex Guide Plate 1 Index No. Part No. Description 101 0801 1185 Philips Truss Head Screw - M4x8 102 0314 0060M Philips Pan Head Screw - M4x6 103 0313 0140W Philips Pan Head Screw - M3x14 104 0314 0060W Philips Pan Head Screw - M4x6 105 0951 3006W Philips Screw With Flat Washer - M3x6 106 0313 0060W Philips Pan Head Screw - M3x6 107 0313 0040W Philips Pan Head Screw - M3x4 108 0951 3010W Philips Screw With Flat Washer - M3x10 109 0720 0040E Retaining Ring - M4 110 0720 0030E Retaining Ring - M3 111 0720 0060E Retaining Ring - M6 112 0720 0025E Retaining Ring - M2.5 113 0704 0040C Toothed Washer - M4 114 0632 0100G Pin 2X10mm 115 0633 0120G Parallel Pin - M3x12 116 0632 0080G Parallel Key - 2x8mm 117 0701 0040B Flat Washer - M4 118 1105 0009 Nylon Clip - 5N 119 1105 0011 Nylon Clip - 8N 120 1106 0430 Bushing - 13mm 121 1105 0199 Clamp 122 1204 1319 Micro Switch (115V) 122 1204 2136 Micro Switch (220/240V) 123 0950 4006W Philips Screw With Lock Washer - M4x6 124 0313 0300W Philips Pan Head Screw - M3x30 125 0710 0030W Hexagon Nut - M3 126 0742 3905 Ball Bearing - 5x13x4mm 127 0741 3505 Ball Bearing - 5x10x4mm 128 0951 4006W Philips Screw With Flat Washer - M4x6 129 1107 0413 Fuse - 3A 125V Index No. Q’ty Per Assembly 7 Part No. Description 8 Feb. 28, ’89 . 4. DF MAIN BOARD (A422) Index No. Part No. Description Q’ty Index No. Assembl Part No. 1102 0958 Description * A422 5170 DF Main Board 1 1 A422 5190 IC - MBM27C128-30 1 104 1102 2966 Connector - HIF3BA-34PA 2 A422 5210 Fiber Connector - 2P 1 105 1103 0881 Connector - 4P 3 A422 5350 IC - HCTL-3 1103 1726 Connector - 4P 5936 5221 Heat Sink 1 1 106 4 107 1103 1729 108 1103 1878 Connector - 7P . Connector - 2P - OSH2425SP 101 1005 0843 Heat Sink 102 1101 0328 Connector Pin Contact Index No. Part No. Description 138 1601 8148 Variable Resistor - 20KOHM 139 1602 0953 Coil - 800µH 2.5A 140 1604 1358 Capacitor - 1000MF 10V 141 1604 1378 Capacitor - lMF 50V 142 1604 1379 Capacitor - 2.2µF 50V 143 1604 1380 Capacitor - 3.3µF 50V 144 1604 1381 Capacitor - 4.7µF 50V 145 1604 1382 Capacitor - 10µF 50V 146 1604 1383 Capacitor - 22µF 50V 147 1604 1386 Capacitor - 100MF 50V 148 1604 1390 Capacitor - 1000MF 50V 149 1605 0141 Capacitor - 4700PF 50V 150 1606 0658 Capacitor - 0.1µF 50V 151 1606 1308 Capacitor - 27PF 50V 152 1606 1326 Capacitor- 100PF 50V ±10% 153 1606 1348 Capacitor - 0.022µF 50V 154 1606 1451 Capacitor - 0.lµF 50V 155 1606 1452 Capacitor - 0.01µF 50V 156 1610 0035 Resistor - 100OHM l/8W ±5% 157 1610 0047 Resistor - 330OHM l/8W ±5% 158 1610 0053 Resistor - 1KOHM l/8W ±5% 159 1610 0057 Resistor - 1.5KOHM l/8W ±5% 160 1610 0065 Resistor - 3.3KOHM l/8W ±5% 161 1610 0067 Resistor - 4.7KOHM l/8W ±5% 162 1610 0071 Resistor - 10KOHM ±5% 163 1610 0073 Resistor - 12KOHM l/8W ±5% 164 1610 0079 Resistor - 22KOHM l/8W ±5% 165 1610 0107 Resistor - 1MOHM l/8W ±5% 166 1610 0286 Capaciter - 100PF 50V ±10% 167 1611 4103 Resistor - 10KOHM l/4T ±5% 168 1611 4229 Resistor - 2.2OHM l/4W ±5% 169 1611 4272 Resistor - 2.7KOHM l/4T ±5% 170 1611 4393 Resistor - 39KOHM l/4T ±5% 171 1611 4472 Resistor - 4.7KOHM l/4W ±5% 172 1611 4563 Resistor - 56KOHM l/4T ±5% 109 1103 3029 Connector - 2P 110 1104 0271 LSI Socket - 28P 111 1104 0333 Fuse Holder 112 1107 0413 Fuse - 3A 125V 113 1204 0883 DIP Switch 114 1204 1385 Push Switch 115 1401 0282 Transistor - 2SB1020 116 1401 0329 IC - MP4503 117 1401 0832 Diode - DSA1A1 118 1403 0308 LED - TLR-102A 119 1403 0388 Photocoupler - ON3111 120 1407 0602 C-MOS,IC TC4040BP 121 1407 0604 IC - TC40498P 122 1407 1026 IC - SN74LS373N 123 1407 1334 IC - UPD7810G 124 1407 1348 IC - TD62304AP 125 1407 1535 IC - TD62308AP 126 1408 0076 IC - µPC14132H 127 1408 0408 IC - PST518A 128 1408 0521 IC - M51971L 129 130 1408 0578 IC - HA17339 1503 0070 Ceramic Oscillator - 10MHz 131 1600 0239 Resistor - 0.47 lW 132 1600 0544 Resistor - lKOHM lW ±l% 133 1600 0576 Resistor - 33OHM 5W 134 1601 1732 Resistor - 390OHM 1W ±5% 135 1601 7326 Resistor Array - 10KOHM 136 1601 8145 Variable Resistor - 5KOHM 137 1601 8147 Variable Resistor - 10KOHM 0.5W Index No. Q’ty Per Assembly 9 Part No. Q’ty Per Assembly Connector - 2P 103 Description Q’ty Per Assembly 5. INDICATION BOARD (A422) Feb. 28, ’89 10 5. INDICATION BOARD (A422) Index No. * Part No. A422 5260 Description Indication Board Index No. Q’ty Per Assembly 1 Description 101 1100 1306 Terminal 102 1100 1328 Contact 103 1102 1807 1102 1967 Connector - 6P 104 11 Part No. 105 1403 0236 106 1403 0328 Insulating Sleeve L.E.D. - MU02 - 520 L.E.D. - PY5551K Q’ty Per Assembly 6. DF MAIN HARNESS (A422) Feb. 28, ’89 12 6. DF MAIN HARNESS (A422) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description * A422 5200 Main Harness - 115V 1 101 1100 0340 Closed * A422 5500 Main Harness - 220/240V 1 102 1100 1169 Fastening Receptacle (115V) 102 1100 1172 Fastening Receptacle (220/240V) 103 1100 1253 Pin - Mate-N-Lock 104 1100 1327 Contact 105 1100 1348 Pin Contact 106 1102 1408 Connector - 1P (115V) 106 1102 1404 Receptacle 107 1102 1756 Connector - 2P 108 1102 1910 Connector - 2P 109 1102 1911 Connector - 3P 110 1102 1912 Connector - 4P 111 1102 1914 112 1102 1924 Connector - 6P Connector - 2P 113 1102 1925 Connector - 3P 114 1102 1938 Connector - 2P 115 1102 1939 Connector - 3P 116 1103 0659 Connector - 34P 13 Terminal Housing (220/240V) Q’ty Per Assembly 7. INTERFACE HARNESS (A422) Feb. 28, ’89 14 7. INTERFACE HARNESS (A422) Index No. Part No. Description * A422 5205 Interface Harness 1 A422 5211 Fiber Connector Q’ty Per Assembly 1 1 Index No. 1 Part No. I Description 101 1100 0051 Wire Terminal 102 1100 1190 Socket - Mate-N-Lock 103 1100 1447 Socket - Mate-N-Lock 104 1102 1374 Connector - 5265-4P 105 1102 1517 Connector - 4P Q'ty Per A s s e m b i y 8. DECAL & DOCUMENT (A422) Feb. 28, ’89 16 Feb. 28, ’89 8. DECAL & DOCUMENT (A422) Index No. Part No. Description Q’ty Per Assembly 1 5936 7901 Decal - English 1 2 A422 2021 Decal - Misfeed Removal 1 2 A422 2031 Decal - Misfeed - Multi-Language 1 3 A465 2017 Decal - DIP Switch 1 4 A465 2025 Original Limit Decal 1 5 A465 2031 Decal - Set 1 6 A465 1337 Decal -Original Table - LT 1 6 A465 1338 Decal - Original Table - A4 1 7 A422 2030 A422 8610 Decal - Inverter Guide Plate Installation Procedure - English 1 8 8 A422 8615 Installation Procedure - 5 Languages 1 Index No. 1 17 Part No. Description Q’ty Per Assembly PARTS INDEX Parts No. Page and Index No. Description Description Parts No Page and Index No. A422 1001 Gear - 24T 5-43 A422 1082 Pick-up Spring 5-55 A422 1002 Clutch Boss 5-40 A422 1086 Pull-out Spring 5-5 A422 1003 Feed 5-47 A422 1087 Shoulder Screw - M3x3 5-9 A422 1005 Clutch Pawl - Pick-up Roller 5-60 A422 1090 Side Roller 5-46 A422 1021 Side Plate 5-63 A422 1093 Sensor Bracket 5-31 A422 1022 Support Plate 5-92 A422 1103 Rear Frame 3-44 Roller A422 1023 Feed Roller Shaft 5-44 A422 1106 Stay 3-36 A422 1025 Original Guide 5-49 A422 1107 Stay - Belt Support Roller 3-39 A422 1031 Lever - Pick-up Spring 5-54 A422 1108 Stopper 3-24 A422 1032 Lever - Pick-up Solenoid 5-53 A422 1112 Belt Tension Spring 3-33 3-35 A422 1033 Pick-up Solenoid Bracket 5-56 A422 1114 Driven Roller - Transport Belt A422 1040 Feed-in Solenoid Lever 5-88 A422 1116 Belt Pressure Roller 3-40 5-48 A422 1119 Left Hinge Bracket 7-5 7-3 . A422 1041 Gear - 27T A422 1042 Idle Gear - 22Z 5-37 A422 1120 Left Bracket - Right Hinge A422 1044 Idle Shaft 5-35 A422 1121 Right Bracket - Right Hinge 7-2 A422 1045 Pull-out Roller 5-45 A422 1127 Transport 3-34 A422 1046 Pick-up Roller 5-38 A422 1130 Reflector Plate 3-55 A422 1047 Set Sensor Bracket 5-27 A422 1135 Magnet Catch Bracket 3-21 A422 1048 Pick-up Shaft 5-39 A422 1175 Harness Bracket 7-11 A422 1049 Gear - 27T 5-61 A422 1176 Set Sensor Actuator Bracket 5-74 A422 1050 Gear - 29T 5-62 A422 1177 Indication A422 1051 Gear - 23T 5-34 A422 1183 Main Board Cover 3-51 A422 1056 Gear - 19T 3-45 A422 1184 Feed-out Motor Cover 3-46 A422 1063 Seal - 0.7x13x20 5-6 A422 1185 Belt Guide - Front Left 3-28 A422 1064 Hinge - Pull-out 5-7 A422 1186 Belt Guide - Rear Left 3-43 A422 1067 Relay Roller Shaft 5-14 A422 1187 Relay Roller 5-13 A422 1188 Belt Guide - Front Right Belt Guide - Rear Right 3-29 A422 1068 A422 1069 Friction Roller 5-72 A422 1191 Mounting 3-18 A422 1070 Pulse Generator 5-15 A422 1210 Inverter Roller 7-38 A422 1071 Pull-out Lever 5-12 A422 1216 Inverter Support Roller 7-39 A422 1072 Front Side Plate 5-25 A422 1217 Pressure Lever 7-47 A422 1078 Bushing - 6X12X4mm 3-25 A422 1218 Pressure Lever Shaft 7-46 A422 1078 Bushing - 6X12X4mm 5-33 A422 1219 Pressure Lever Spring 7-48 A422 1078 Bushing - 6X12X4mm 7-34 A422 1225 Inverter Guide Plate 7-13 A422 1079 Bushing - 8X16X5mm 7-41 A422 1226 Spring - Inverter Guide Plate 7-29 20 Belt Bracket Bracket 5-77 3-42 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. A422 1230 Inverter Pawls 7-37 A422 1390 Entrance Seal 5-75 A422 1231 Inverter Gate Spring 7-32 A422 1394 Left Hinge 7-4 A422 1232 Inverter Solenoid Bracket 7-22 A422 1395 Shaft 3-17 A422 1234 Front Lever 7-33 A422 1396 Mylar - 0.125x14x45.5 5-93 A422 1235 Rear Lever 7-25 A422 1397 Spacer - 0.5mm 3-31 A422 1240 Upper Exit Roller 7-31 A422 1499 Right Hinge 7-1 A422 1245 Upper Exit Roller Ass’y 7-45 A422 1500 Belt Drive Motor Cover 3-50 A422 1249 Upper Exit Roller 7-8 A422 1501 Gear - 20T 5-82 A422 1251 Bracket - Exit Sensor 7-51 A422 1502 Gear - 45T 5-85 A422 1255 Inverter Guide Plate 7-50 A422 1503 Idle Shaft 5-36 A422 1257 Antistatic 7-49 A422 1504 Shaft/Gear - 16T 5-78 A422 1260 Front Side Plate 7-14 A422 1505 Gear - 57T 5-89 A422 1261 Rear Side Plate 7-21 A422 1506 Gear - 25T 5-79 A422 1265 Gear - 46T 7-18 A422 1507 Feed-in Motor Bracket 5-81 A422 1270 Timing Belt - 81XL 7-42 A422 1510 Rear Side Plate 5-80 Brush . A422 1275 Front Side Plate - Feed-out 7-36 A422 1600 Pick-up Lever 5-51 A422 1276 Rear Side Plate - Feed-out 7-40 A422 1601 Pick-up Shaft 5-52 A422 1290 Front Guide Plate 5-66 A422 1602 Pick-up Lever Plate 5-50 A422 1291 Rear Guide Plate 5-65 A422 1603 Seal - 2x8x14 3-47 A422 1295 Set Sensor Actuator 5-73 A422 1603 Seal - 2x8x14 5-91 A422 1301 DF Upper Cover - 115V 5-18 A422 1604 Cushion - 8x15x25 3-56 A422 1302 DF Upper Cover - 220/240V 5-18 A422 2021 Decal - Misfeed Removal 17-2 A422 1320 Original 3-8 A422 2021 Decal - Misfeed Removal 3-13 A422 1335 Magnet - Original Table 3-2 A422 2030 Decal - Inverter Guide Plate 17-7 A422 1351 5-67 A422 2030 Decal - Inverter Guide Plate 7-54 A422 1352 Sea 1 - 0.5x37x71mm Friction Belt Holder 5-68 A422 2031 Decal - Misfeed - Multi-Language 17-2 A422 1354 Friction Belt 5-69 A422 2031 Decal - Misfeed - Multi-Language 3-13 A422 1355 Friction Belt Spring 5-71 A422 5170 DF Main Board 7-9 A422 1356 Pin - 3x26mm 5-70 A422 5170 DF Main Board 9-* A422 1361 Pack - Side Guide 3-7 A422 5190 IC - MBM27C128-30 9-1 A422 1366 Front Side Guide 3-6 A422 5200 Main Harness - 115V 1 3-* A422 1376 Rear Side Guide 3-4 A422 5201 Interface 5-16 A422 1380 Shoulder Screw - M4x12 3-19 A422 5202 Harness - Pulse Generator 5-10 A422 1385 Original Exit Guide 3-14 A422 5203 Feed-out Sensor Harness 7-44 A422 1389 Spacer - 0.2mm 3-38 A422 5204 Feed-in Motor Harness (115V) 5-84 Table 21 Harness Feb. 28, ’89 Parts Page and Index No. Description No. Parts No. Description Page and Index No. A422 5205 Interface Harness 1 5-* AA14 3005 Stepped Screw - M4x2.5 3-23 A422 5205 Interface Harness 7-7 A409 1143 Pulley - 50T 7-43 A422 5207 Harness - Registration 5-29 A409 1150 Spring Anchor 7-30 A422 5208 Harness - Paper Size 5-30 A409 1161 Pulley - 21T 7-27 A422 5210 Fiber Connector – 2P 9-2 A409 1192 Pulley - 15T 7-15 A422 5211 Fiber Connector 15-1 A409 1195 Exit Drive Shaft 7-17 A422 5211 Fiber Connector 3-48 A409 1197 Spacer - l0x16xl.6mm 7-20 A422 5212 Grouding Wire 5-95 A437 1026 Upper Guide Plate 5-17 A422 5252 Solenoid - DC24V 5-87 A437 1065 Lower Guide Plate 5-11 A422 5255 Solenoid - DC24V 5-58 A437 1066 Guide Mylar 5-1 A422 5255 Solenoid - DC24V 7-24 A437 1115 Drive Roller - Transport Belt 3-41 A422 5260 Indication Board 11-* A437 1120 Bracket - Belt Tension Spring 3-32 A422 5260 Indication Board 5-76 A437 1125 Angle Stopper 3-15 A422 5270 Photosensor 5-28 A437 1179 Lift Switch Actuator 3-16 A422 5270 Photosensor 7-52 A465 1027 Guide Plate - Paper Feed 5-96 A422 5300 Feed-in Motor - DC10W 5-83 A465 1057 Pull-out 5-3 A422 5310 Feed-out Motor - DC10W 7-26 A465 1066 Mylar - 0.1x21x58 5-86 A422 5350 IC - HCTL-3 9-3 A465 1067 Mylar - 0.1x14.5x44 5-59 A422 5500 Main Harness - 220/240V 1 3-* A465 1068 Cushion - 2.5x14x43 5-20 A422 5500 7-10 A465 1069 Harness Cover 5-26 A422 5510 [sin Harness Feed-in Motor Harness (220/240V) 5-84 A465 1070 Lever Spring 5-90 A422 5550 Lift Switch (220/240V) 7-6 A465 1072 Lock Spring 5-24 A422 8610 Installation Procedure - English 17-8 A465 1073 Pin - 4x76. 5 5-23 A422 8615 Installation Procedure - 5 17-8 A465 1074 Pin - 4x77. 5 5-22 A465 1075 Shaft - 3x25 5-21 A465 1076 A465 1077 Release Lever Knob Release Lever 5-2 . Languages 22 Bracket 5-4 A465 1080 Fixing Plate - Feed-in Unit 5-94 A465 1100 Front Frame 3-27 A465 1118 Belt Support Roller 3-37 A465 1126 Grounding Plate 7-19 A465 1331 Grip Cover 3-49 A465 1337 Decal - Original Table - LT 17-6 A465 1337 Decal - Original Table - LT 3-1 A465 1338 Decal - Original Table - A4 17-6 Feb. 28, ’89 Parts No. Description Page and Index No. Description Parts No. Page and Index No. A465 1338 Decal - Original Table - A4 3-1 0313 0040W Philips Pan Head Screw - M3x4 5-105 A465 2017 Decal - DIP Switch 17-3 0313 0040W Philips Pan Head Screw - M3x4 7-107 A465 2017 Decal - DIP Switch 3-54 0313 0060W Philips Pan Head Screw - M3x6 5-101 A465 2025 Original Limit Decal 17-4 0313 0060W Philips Pan Head Screw - M3x6 7-106 A465 2025 Original Limit Decal 3-3 0313 0100W Philips Pan Head Screw - M3x10 5-104 A465 2031 Decal - Set 17-5 0313 0140W Philips Pan Head Screw - M3x14 7-103 A465 2031 Decal - Set 3-26 0313 0300W Philips Pan Head Screw - M3x30 7-124 A465 5213 Grounding Wire 7-16 0314 0060M Philips Pan Head Screw - M4x6 7-102 5053 0447 Bushing - M6 7-28 0314 0060W Philips Pan Head Screw - M4x6 3-113 5205 5250 L.E.D Sensor Type - S 5-8 0314 0060W Philips Pan Head Screw - M4x6 5-124 5219 1957 Stepped Screw - M4 5-19 0314 0060W Philips Pan Head Screw - M4x6 7-104 5443 2657 Gear - 28Z 3-10 0315 0010W Philips Pan Head Screw - M5x10 3-104 5443 2660 Spacer - 6x22x0.5mm 3-12 0344 0060D Philips Truss Head Screw - M4x6 3-115 5443 2712 Cork Pad 3-9 0344 0060W Philips Truss Head Screw - M4x6 3-107 5443 2713 Wave Washer 3-11 0353 0050W Tapping Screw - M3x5 3-101 5446 2824 Screw - Duplex Guide Plate Bushing - 4mm 7-35 0354 0060W Philips Truss Head Screw - M4x6 5-115 3-30 0413 0082W Tapping Screw - M3x8 3-102 5447 3655 - 5875 2088 Shoulder Screw - M4 3-22 0573 0030E Hexagon Headless Set Screw - M3x3 5-113 5875 2088 Shoulder Screw - M4 5-32 0573 0060E Hexagon Headless Set Screw - M3x6 5-114 5875 2088 Shoulder Screw - M4 7-53 0632 0080G Parallel Key - 2x8mm 5-112 5894 2176 Spring - Detent Arm 5-64 0632 0080G Parallel Key - 2x8mm 7-116 5894 2229 Solenoid Pin 5-57 0632 0100G Pin 2x10mm 3-114 5894 2229 5894 2747 Solenoid Pin 7-23 0632 0100G Pin 2X10mm 5-110 3-5 0632 0100G Pin 2x10mm 7-114 5918 2163 Mylar - Original Guides Clutch Spring 5-41 0632 0140G Parallel Pin 5-111 5918 2164 Clutch Sleeve 5-42 0633 0120G Parallel Pin - M3x12 7-115 5918 2623 Paper Guide Mylar 7-12 0701 0040B Flat Washer - M4 7-117 5936 2480 Magnet Catch Ass’y 3-20 0701 0060B Flat Washer - M6 3-112 5936 5221 Heat Sink 9-4 0704 0040C Toothed Washer - M4 7-113 5936 5348 Thin Original Feed Switch 3-53 0710 0030W Hexagon Nut - M3 7-125 5936 7901 Decal - English 17-1 0720 0025E Retaining Ring - M2.5 5-109 5936 7901 Decal - English 3-52 0720 0025E Retaining Ring - M2.5 7-112 0720 0030E Retaining Ring - M3 3-111 0720 0030E Retaining Ring - M3 5-125 0720 0030E Retaining Ring - M3 7-110 23 Feb. 28. ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. 0720 0040E Retaining Ring - M4 3-109 1100 1328 Con tact 11-102 0720 0040E Retaining Ring - M4 5-107 1100 1348 Pin Contact 13-105 0720 0040E Retaining Ring - M4 7-109 1100 1447 Socket - Mate-N-Lock 15-103 0720 0050E Retaining Ring - M5 3-110 1101 0328 Connector Pin Contact 9-102 0720 0060E Retaining Ring - M6 5-108 1102 0958 Connector - 2P 9-103 0720 0060E Retaining Ring - M6 7-111 1102 1374 Connector - 5265-4P 15-104 0741 3505 Ball Bearing - 5x10x4mm 5-122 1102 1404 Receptacle Housing (220/240V) 13-106 0741 3505 Ball Bearing - 5x10x4mm 7-127 1102 1408 Connector - 1P (115V) 13-106 0741 3506 Ball Bearing - 6x12x4mm 5-120 1102 1517 Connector - 4P 15-105 0741 3806 Ball Bearing - 6x13x5mm 3-106 1102 1756 Connector - 2P 13-107 0742 3905 Ball Bearing - 5x13x4mm 7-126 1102 1807 Insulating Sleeve 11-103 0742 3906 Ball Bearing - 6mm 3-117 1102 1910 Connector - 2P 13-108 0801 1185 Philips Truss Head Screw - M4x8 3-108 1102 1911 Connector - 3P 13-109 13-110 0801 1185 Philips Truss Head Screw - M4x8 7-101 1102 1912 Connector - 4P 0805 3383 Bushing - M5 5-123 1102 1914 Connector - 6P 13-111 0950 4006W Philips Screw With Lock Washer - M4x6 5-121 1102 1924 Connector - 2P 13-112 0950 4006W Philips Screw With Lock Washer - M4x6 7-123 1102 1925 Connector - 3P 13-113 0951 3004W Philips Screw With Flat Washer - M3x4 5-106 1102 1938 Connector - 2P 13-114 0951 3006W Philips Screw With Flat Washer - M3x6 7-105 1102 1939 Connector - 3P 13-115 0951 3010W Philips Screw With Flat Washer - M3x10 5-102 1102 1967 Connector - 6P 11-104 0951 3010W Philips Screw With Flat Washer - M3x10 7-108 1102 2966 Connector - HIF3BA-34PA 9-104 0951 4005W Philips Screw With Flat Washer - M4x5 3-103 1103 0659 Connector - 34P 13-116 0951 4005W Philips Screw With Flat Washer - M4x5 5-119 1103 0881 Connector - 4P 9-105 0951 4006W Philips Screw With Flat Washer - M4x6 3-105 1103 1726 Connector - 4P 9-106 0951 4006W Philips Screw With Flat Washer - M4x6 5-103 1103 1729 Connector - 7P 9-107 0951 4006W Philips Screw With Flat Washer - M4x6 7-128 1103 1878 Connector - 2P 9-108 1005 0843 Heat Sink 9-101 1103 3029 Connector - 2P 9-109 9-110 - OSH2425SP 1100 0051 Wire Terminal 15-101 1104 0271 LSI Socket - 28P 1100 0340 Closed Terminal 13-101 1104 0333 Fuse Holder 9-111 1100 1169 Fastening Receptacle (115V) 13-102 1105 0008 Nylon Clip - 2N 5-117 1100 1172 Fastening Receptacle (220/240V) 13-102 1105 0009 Nylon Clip - 5N 5-118 1100 1190 Socket - Mate-N-Lock 15-102 1105 0009 Nylon Clip - 5N 7-118 1100 1253 Pin - Mate-N-Lock 13-103 1105 0011 Nylon Clip - 8N 7-119 1100 1306 Terminal 11-101 1105 0199 Clamp 5-116 1100 1327 Contact 13-104 1105 0199 Clamp 7-121 24 Feb. 28, ’89 Parts No. Description Page and Index No. Page and Index No. Parts No. Description Capacitor - 1000MF 10V Capacitor - 1MF 50V 9-140 9-142 1106 0279 Bushing 3-116 1604 1358 1106 0430 Bushing - 13mm 7-120 1604 1378 1107 0413 Fuse - 3A 125V 7-129 1604 1379 1107 0413 Fuse - 3A 125V 9-112 1604 1380 Capacitor - 2.2µF 50V Capacitor - 3.3µF 50V 1204 0883 DIP Switch 9-113 1604 1381 Capacitor - 4.7µF 50V 9-144 1204 1319 Micro Switch (115V) 7-122 1604 1382 Capacitor - 10µF 50V 9-145 9-141 9-143 1204 1385 Push Switch 9-114 1604 1383 Capacitor - 22µF 50V 9-146 1204 2136 Micro Switch (220/240V) 7-122 1604 1386 1401 0282 Transistor - 2SB1020 9-115 1604 1390 Capacitor - 100MF 50V Capacitor - 1000MF 50V 9-148 9-147 1401 0329 IC - MP4503 9-116 1605 0141 Capacitor - 4700PF 50V 9-149 1401 0832 Diode - 9-117 1606 0658 Capacitor - 0.lµF 50V 9-150 1403 0236 11-105 1606 1308 Capacitor - 27PF 50V 9-151 1403 0308 L.E.D. - MU02 - 520 LED - TLR-102A 9-118 1606 1326 Capacitor- 100PF 50V ±10% 9-152 1403 0328 L.E.D. - PY5551K 11-106 1606 1348 Capacitor - 0.022µF 50V 9-153 1403 0388 Photocoupler - ON3111 9-119 1606 1451 Capacitor - 0.lµF 50V 9-154 1407 0602 C-MOS,IC TC4040BP 9-120 1606 1452 Capacitor - 0.0lµF 50V 9-155 1407 0604 IC - TC40498P 9-121 1610 0035 Resistor - 100OHM l/8W ±5% 9-156 1407 1026 IC - SN74LS373N 9-122 1610 0047 Resistor - 330OHM l/8W ±5% 9-157 1407 1334 IC - UPD7810G 9-123 1610 0053 Resistor - lKOHM l/8W ±5% 9-158 1407 1348 IC - TD62304AP 9-124 1610 0057 Resistor - 1.5KOHM l/8W ±5% 9-159 1407 1535 IC - TD62308AP 9-125 1610 0065 Resistor - 3.3KOHM l/8W ±5% 9-160 1408 0076 IC - µPC14132H 9-126 1610 0067 Resistor - 4.7KOHM l/8W ±5% 9-161 1408 0408 IC - PST518A 9-127 1610 0071 1408 0521 9-128 1610 0073 1408 0578 IC - M51971L IC - HA17339 9-129 1610 0079 1503 0070 Ceramic Oscillator - 10MHz 9-130 1610 0107 1600 0239 Resistor - 0.47 lW Resistor - lKOHM lW ±l% 9-131 1601 7326 Resistor - 33OHM 5W Resistor - 390OHM 1W ±5% Resistor Array - 10KOHM 1601 8145 Variable Resistor - 5KOHM 1600 0544 1600 0576 1601 1732 D S A 1 A 1 Resistor - 10KOHM ±5% Resistor - 12KOHM l/8W ±5% Resistor - 22KOHM l/8W ±5% 9-162 9-163 9-164 1610 0286 Resistor - lMOHM l/8W ±5% Capaciter - 100PF 50V ±10% 9-166 9-132 1611 4103 Resistor - 10KOHM l/4T ±5% 9-167 9-133 1611 4229 Resistor - 2.2OHM l/4W ± 5% 9-168 9-134 1611 4272 Resistor - 2.7KOHM l/4T ±5% 9-169 9-135 1611 4393 Resistor - 39KOHM l/4T ±5% 9-170 9-136 1611 4472 Resistor - 4.7KOHM l/4W ±5% 9-171 1611 4563 Resistor - 56KOHM l/4T ±5% 9-172 1601 8147 Variable Resistor - 10KOHM 0.5W 9-137 1601 8148 Variable Resistor - 20KOHM 9-138 1602 0953 Coi1 - 800µH 2.5A 9-139 25 9-165 RE12 (A916) 1. Editor Board (A916) . . . . . . . . . . . . . . . . 2 2. Decal & Cocument (A916) . . . ... ... 4 1. EDITOR BOARD (A916) Feb. 28, ’89 1. EDITOR BOARD (A916) Index No. Part No. Description Feb. 28, ’89 Index No. Q’ty Per Assembly Part No. Description 1 A916 1016 Original Cover - LT 1 101 0434 0060W Tapping Screw - M4x6 1 A916 1015 Original Cover - A4 1 102 0802 5094 Tapping Truss Head Screw - M4x8 2 A916 1002 Upper Cover 1 103 1607 0366 Ferrite Core 3 A916 5141 Operation Sheet - LT 1 3 A916 5142 Operation Sheet - A4 1 4 A916 1051 Front Stopper 2 5 A916 5100 Main Control Board 1 6 A916 1006 Lower Cover 1 7 A916 5120 Editor Harness 1 8 A916 5125 Harness Stopper 1 . 9 A916 5110 Pen 10 A916 1030 Pen Holder 11 A916 1054 Cushion 1 12 A916 1053 Support Stopper 2 13 A916 1052 Rear Stopper 2 14 A916 1023 1 14 A916 1022 Decal - operating Guide - LT Decal - Operating Guide - A3 1 1 1 3 Q’ty Per Assembly 2. DECAL & DOCUMENT (A916) Feb. 28,'89 4 2. DECAL & DOCUMENT (A916) Index No. Part No. Description Q’ty Per Assembly 1 A916 1023 Deca1 - Operating Guide - LT 1 1 A916 1022 Decal - Operating Guide - A4 1 2 A916 8600 Operating Instructions - English 1 2 A916 8605 A916 8610 Operating Instructions - 5 Language Installation Procedure - English 1 3 3 A916 8615 Installation Procedure - 5 Language 1 1 Index No. Part No. Description Q’ty Per Assembly PARTS INDEX Feb. 28, ’89 Description Parts No. Page and Index No. Parts No. Description Page and Index No. A916 1002 Upper Cover 3-2 0434 0060W Tapping Screw - M4x6 3-101 A916 1006 Lower Cover 3-6 0802 5094 Tapping Truss Head Screw - M4x8 3-102 A916 1015 Original Cover - A4 3-1 1607 0366 Ferrite Core 3-103 A916 1016 Original Cover - LT 3-1 A916 1022 Decal - Operating Guide - A3 3-14 A916 1022 Decal - Operating Guide - A4 5-1 A916 1023 Decal - Operating Guide - LT 3-14 A916 1023 Deca1 - Operating Guide - LT Pen Holder 5-1 A916 1030 A916 1051 Front Stopper 3-4 3-10 A916 1052 Rear Stopper A916 1053 Support Stopper A916 1054 Cushion 3-11 3-13 . 3-12 A916 5100 Main Control Board 3-5 A916 5110 Pen 3-9 A916 5120 Editor Harness 3-7 A916 5125 Harness Stopper 3-8 A916 5141 Operation Sheet - LT 3-3 A916 5142 Operation Sheet - A4 3-3 A916 8600 Operating Instructions - English 5-2 A916 8605 Operating Instructions - 5 Language 5-2 A916 8610 Installation Procedure - English 5-3 A916 8615 Installation Procedure - 5 Language 5-3 8 RT15 (A912) RT15 (A912) 1. LCT I (A912) . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. LCT II (A912) . . . . . . . . . . . . . . . . . . . . . . . . 4 3. LCT III (A912) . . . . . . . . . . . . . . . . . . . . . . . . 6 4. LCT Board (A912) . . . . . . . . . . . . . . . . . . . . . . 8 5. LCT Harness (A912) . . . . . . . . . . . . . . . . . ...10 6. Decal (A912) . . . . . . . . . . . . . . . . . . . . . . . ...12 Parts Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16 Feb. 28, ’89 1. LCT I (A912) 2 1. LCT I (A912) I ndex No. Part No. Feb. 28, ’89 Description Index No. Q’ty Per Assembly Part No. Description * A912 8610 Installation Procedure - 115V 1 101 0434 0060W Tapping Screw - M4x6 * A912 8615 Installation Procedure - 220V/240V 1 102 0434 0l00W Tapping Screw - M4x10 1 A912 2621 Top Cover 1 103 0802 5094 Tapping Truss Head Screw - M4x8 2 A912 2612 Rear Cover - 115V 1 104 2 Rear Cover - 220/240V 1 105 Tapping Screw With Flat Washer - M4x8 3 A912 2613 A912 2681 0314 0040W 0964 4008W Decal - English, French - 115V 1 106 0720 0030E 3 5446 8906 Decal - English, German - 220/240V 1 4 5442 1372 Decal - Power Source - 220V 1 5 A912 2631 Side Cover 1 6 A912 5010 Operation Board 1 7 5897 1272 Operation Board Mounting Bracket 1 8 A912 2610 Front Cover 1 9 A912 2598 Decal - Instructions 1 9 A912 4224 Multi - Lingual Decal - Ricoh 1 Philips Pan Head Screw - M4x4 Retaining Ring - M3 MB9 107 1102 0895 Nylon Stud MB9 MB9 10 A912 2596 Operation Skin 1 11 A912 2594 Decal - Increase Size 1 12 A912 2595 Decal - Decrease Size 1 13 A912 2546 Paper End Plate 1 14 AA14 8023 Feeler Shaft 1 15 A912 2547 Paper Position Feeler 1 16 AA06 6011 Spring - Paper Position Feeler 1 17 A912 2540 Sensor Bracket 1 18 A912 5202 Pick-up Harness 1 19 A912 2549 Harness Cover 1 20 5205 5250 L.E.D Sensor Type - S 2 21 ABO1 7034 Feed Gear - 30T 1 22 ABO1 3098 Idle Gear - 21T 1 23 A912 2520 Pick-up Roller - Holder 1 24 A912 2530 Pick-up Guide 1 25 A912 2528 Pick-up Roller 1 26 AA15 0007 Guide Seal - Pick-up 1 27 5447 2681 Snap Ring 1 28 5925 2334 Plate - Magnet Catch 1 3 Q’ty Per Assembly 4 Feb. 28, ’89 Index No. Part No. Description Index No. Q’ty Per Assembly Part No. Description Q’ty Per Assembly 1 A912 2573 Lift Stay 2 30 5205 5250 L.E.D Sensor Type - S 1 2 A912 3587 Front Inner Cover 1 31 5897 4103 Bracket - Shaft 1 A912 2587 x/o MB3 32 5897 1498 Harness Cover 2 1 A912 3575 Front Paper Guide 33 5925 2203 Front Bracket 1 A912 2575 X/X MB6 34 5897 4477 Leaf Spring 1 A912 3576 Rear Paper Guide 35 5925 2233 Side Cover Plate 1 A912 2576 X/X MB6 36 A912 2570 Rear Side plate 1 5 A912 2582 Decal - Paper Size 1 37 A912 2565 Front Mounting Bracket - Type B 1 6 5447 2927 Friction Pad - B 1 37 A912 2561 Front Mounting Bracket - Type C 1 7 A912 2580 Tray Bottom Plate 1 37 A912 2563 Front Mounting Bracket - Type A 1 8 A912 3551 Feed-in Guide 1 38 A912 2566 Rear Mounting Bracket - Type B 1 A912 2551 x/o MB3 38 A912 2562 Rear Mounting Bracket - Type C 1 5925 2211 Front Side Plate 1 38 A912 2564 Rear Mounting Bracket - Type A 1 10 5925 2255 Side Guide Stopper 1 39 5925 2258 Stopper Chain 1 11 A912 2647 Front Side Post Spring Plate 1 40 A912 2553 Pad - 14x38mm 1 12 5897 1455 Bushing 6 41 AA15 0008 Guide Seal - Paper Feed 1 13 5897 1451 Front Post Rack 1 42 A912 3588 Rear Inner Cover 1 14 A912 3640 Front Guide Post 1 A912 2588 x/o MB3 3 4 9 1 1 A912 2640 x/x MB3 43 A912 2646 Rear Side Post Spring Plate 1 15 5897 1457 Rear Post Rack 1 44 5897 4153 Bracket - Size Shaft 16 A912 3641 Rear Guide Post 1 45 A912 3577 Shoulder Screw - M3 1 4 MB6 A912 2641 x/x MB3 17 5925 2257 Left Lift Stay 18 5897 1372 Right Lift Rod 1 19 5925 2249 Side Guide Shaft 2 1 20 5925 2259 Hook 2 21 5925 2331 Holder - Side Cover 1 22 5925 2204 Rear Bracket 1 23 5897 1458 Side Post Spring Plate 2 24 5897 1493 Microswitch 1 25 5897 1497 Harness Cover 1 26 5897 1496 Sensor Mounting Bracket 1 27 5205 5253 Photointerruptor 1 28 5897 1473 Size Lever 1 29 5443 2657 Gear - 28Z 1 Index No. Part No. Mounting Bracket 1 Pack Description 101 0313 0060W Philips Pan Head Screw - M3x6 102 0313 0120W Philips Pan Head Screw - M3x12 103 0314 0100W Philips Pan Head Screw - M4x10 104 0314 0060W Philips Pan Head Screw - M4x6 105 0434 0060W Tapping Screw - M4x6 106 0951 3008W Philips Screw With Flat Washer - M3x8 107 0964 4008W Tapping Sciew With Flat Washer - M4x8 108 0314 0040W Philips Pan Head Screw - M4x4 109 0720 0040E Retaining Ring - M4 110 0720 0060E Retaining Ring - M6 111 1005 0383 Edging - B 112 1204 0192 Microswitch - UL Q’ty Per Assembly Parts No. 5 Description Page and Index No. 3. LCT Ill (A912) 106 116 Feb. 28, ’89 3. LCT Ill (A912) Index No. Part No. Feb. 28, ’89 Description I Q’ty Per Assembly Index No. Part No. Description Q’ty Per Assembly 1 5446 5411 Tray Drive Motor - AC 7/8W/l15V 1 32 5408 7968 1 5446 5412 Tray Drive Motor - AC 7/8W/220V 1 33 A912 2555 Trans Cover 1 2 5897 1352 Worm Gear - M5x5 1 34 A912 2556 Shield Plate 1 3 5897 1351 Drive Motor Bracket 1 35 5897 5520 Transformer - 115V, 220V, 240V/30W 1 4 5053 0223 Bushing - 8mm 2 36 5403 4335 1 5 5925 2239 Drive Gear Shaft 1 37 AZ02 0001 Decal - Terminal - 115V Grounding Inductor 6 5446 2702 Gear - 22T 1 38 5897 1514 Noise Filter Bracket - 220/240V 1 7 A912 2570 Rear Side Plate 1 39 5897 5555 Noise Filter Grounding Wire 1 8 5446 2620 Idler Pulley - 20 8 40 5925 5216 Noise Filter Harness 1 9 5925 2246 Drive Pulley . 2 10 5053 0419 Bushing - 10mm - Long - 7mm 2 11 5925 2241 Drive Wire 2 12 5897 1274 Top Actuator Lever 1 13 5897 1279 Safety Switch Actuator 1 14 5897 1277 Bottom Actuator Lever 1 15 5925 2253 Rear Wire Tightener 1 16 Ž17 5897 1126 Safety Switch Bracket 1 A912 5208 Safety Switch Harness 1 18 5925 5215 AC Harness 1 18 5925 5211 AC Harness - 115V X/X MB8 1 18 5925 5215 AC Harness - 220/240V 1 19 5925 2266 Power Cord Bracket 1 20 5925 2247 Drive Shaft 1 21 5925 2251 Front Wire Tightener 1 22 5925 2211 Front Side Plate 1 23 5897 1472 Washer - 4.5x24x2mm 1 24 5054 0536 Magnet Catch Ass’y 2 25 5925 2265 P.C.B Bracket 1 26 A912 5103 Tray Control Board 1 27 5925 5206 DC Harness 1 28 A912 2585 Paper Size Dial 1 29 5925 2235 Dial Shaft 1 30 5897 1125 Nylon Clamp Stay 1 31 A912 5205 Interface 1 32 6769 7930 Power SUPP lY Cord - 115V Harness Power Supply Cord - 220V 1 1 1 4 Part No. Description I 101 0315 0080W Philips Pan Head Screw - M5x8 102 0314 0100W Philips Pan Head Screw - M4x10 103 0314 0060W Philips Pan Head Screw - M4x6 104 0314 0050W Philips Pan Head Screw - M4x5 105 0434 0060W Tapping Screw - M4x6 106 0434 0080W Tapping Screw - M4x8 107 0964 4008W Tapping Screw With Flat Washer - M4x8 108 0801 1185 Philips Truss Head Screw - M4x8 109 0965 4010W Tapping Screw With Flat Washer - M4x10 110 0720 0030E Retaining Ring - M3 111 0720 0040E Retaining Ring - M4 112 0807 7071 Flat Washer - M11 113 0574 0050E Hexagon Headless Set Screw - M4x5 114 1005 0383 Edging - B 115 1105 0011 Nylon Clip - 8N 116 1105 0008 Nylon Clip - 2N 117 1106 0336 Nylon Stud 118 1105 0108 Nylon Clip 119 1104 0323 Fuse Holder 120 1101 0359 Terminal - 3P 121 1204 1280 Push Switch 122 1107 0271 Fuse - 3A 122 1107 0487 Circuit Breaker - 115V 123 0930 0400 Parallel Key 124 1602 0974 Noise Filter 125 1106 0442 Cord Clamp 126 0314 0120W Q’ty Per Assembly Parts No. MB1 Philips Pan Head Screw - M4x12 MB9 127 0720 0060E Retaining Ring - M6 MB9 128 0313 0060W Philips Pan Head Screw - M3x6 MB9 129 0313 0140W Philips Pan Head Screw - M3x14 MB9 7 Description Page and Index No. 4. LCT BOARD (A912) Index No. * Part No. A912 5103 Description Tray Control Board Feb. 28, ’89 Index No. Q’ty Per Assembly 1 Part No. Description 101 1103 1247 Connector - 3P 102 1103 1729 Connector - 7P 103 1103 1730 Connector - 8P 104 1103 1739 Connector - 3P 105 1103 1743 Connector - 7P 106 1103 1757 Connector – 7P 107 1208 1047 Solid State Pelay - 240V/3A 108 1400 0072 Transistor - 2SC372Y 109 1400 0135 Transistor - 25AS1015-Y 110 1401 0825 Diode - 1SS176 111 1407 0520 IC - HD74LS00 112 1407 0622 IC - HD74LSS10P 113 1407 0981 IC - TD62503P 114 1408 0124 115 1408 0412 IC - LM555CN IC - 7705CP 116 1604 0909 Capacitor - lµF 35V 117 1604 1363 Capacitor - 10µF 25V 118 1604 1366 Capacitor - 47µF 25V 119 1606 1336 Capacitor - 1000PF 50V 120 1606 1458 Capacitor - 0.1µF 50V 121 1611 4101V Resistor - lKOHM l/4V ±5% 122 1611 4102V Resistor - lKOHM l/4W ±5% 123 1611 4103V Resistor - 10KOHM l/4V ±5% 124 1611 4104V 125 1611 4471V Resistor - 100KOHM l/4W ±5% MB7 Resistor - 470OHM l/4W ±5% 126 1611 4472V Resistor - 4.7KOHM l/4W ±5% 127 1611 4562V Resistor - 5.6KOHM l/4W ±5% 128 1611 4564V Resistor - 560KOHM l/4W 129 1611 4361V Resistor - 360OHM l/4V MB5 130 1611 4681V Resistor - 680OHM l/4V MB5 9 Q’ty Per Assembly 5. LCT HARNESS (A912) Feb. 28, ’89 122 10 Feb. 28, ’89 5. LCT HARNESS (A912) Index No. Part No. Description Index Q’ty Per Assembly N O . I Description 1 102 1100 0885 Fastening Receptacle - 220/240V Pick-up Harness 1 103 1100 1169 Fastening Receptacle - 115V DC Harness 1 104 1100 1172 Fastening AC Harness 1 105 1100 1238 Pin - Mate-N-Lock 5925 5211 AC Harness - 115V X/XMB8 1 106 1100 1239 Pin - Mate-N-Lock 5925 5215 AC Harness - 220/240V 1 107 1100 1240 Socket - Mate-N-Lock A912 5208 Safety Switch Harness 1 108 1100 1241 109 1100 1247 Socket - Mate-N-Lock Terminal 110 1100 1249 Receptacle Terminal 111 1100 1327 Contact 112 1100 1328 Contact 113 1102 0796 Insulating Sleeve 3.0mm - 220V 114 1102 1404 Receptacle Housing 115 1102 1408 Connector – 1P - 115V 116 1102 1506 Connector - 1P 117 1102 1507 Connector - 2P 118 1102 1514 Connector - 1P 119 1102 1516 Connector - 3P 120 1102 1524 Connector – 2P (RED) 121 1102 1532 Connector - 2P 122 1102 1620 Connector - 3P 123 1102 1621 Receptacle Housing - 3P 124 1102 1623 Receptacle Housing - 7P 125 1102 1745 Receptacle Sleeve 126 1102 1786 Connector - 3P 127 1102 1815 Connector - 3P 128 1102 1911 Connector - 3P 129 1102 1912 Connector - 4P 130 1102 1915 Connector - 7P 131 1102 1916 Connector - 8P 132 1102 1925 Connector - 3P 133 1102 1929 Connector - 7P 134 1102 1943 Receptacle Housing 135 1102 1965 Connector - 3P 136 1102 1971 Connector - 3P 1 A912 5205 2 A912 5202 3 5925 5206 4 5925 5215 4 4 ●5 Interface Harness . 101 Part No. 1100 0277 Fastening Receptacle 11 Receptacle I Q’ty Per Assembly Feb. 28, ’89 12 6. DECAL (A912) Index No. 1 Part No. A912 2582 Feb. 28, ’89 Description Decal - Paper Size Q’ty Per Index Assembly No. 1 MB9 2 5403 4335 Decal - Terminal - 115V 1 MB9 3 A912 2594 Decal - Increase Size 1 Decal - Decrease Size 1 MB9 4 A912 2595 MB9 5 A912 2598 Decal - Instructions 1 MB9 6 A912 2681 Decal - English, French - 115V 2 MB9 7 A912 4224 Multi - Lingual Decal - Ricoh 1 MB9 8 5446 8906 Decal - English, German - 220/240V 1 MB9 9 5442 1372 Decal - Power Source - 220V 1 MB9 13 Part No. Description Q’ty Per Assembly PARTS INDEX Feb. 28, ’89 Parts No. Description Page and Index No. Description Parts No. Page and Index No. A912 2520 Pick-up Roller - Holder 3-23 A912 2610 Front Cover 3-8 A912 2528 Pick-up Roller 3-25 A912 2612 Rear Cover - 115V 3-2 A912 2530 Pick-up Guide 3-24 A912 2613 Rear Cover - 220/240V 3-2 A912 2540 Sensor Bracket 3-17 A912 2621 Top Cover 3-1 A912 2546 Paper End Plate 3-13 A912 2631 Side Cover 3-5 A912 2547 Paper Position Feeler 3-15 A912 2640 5-14 A912 2549 Harness Cover 3-19 A912 2641 x/x MB3 x/x MB3 A912 2551 x/o MB3 5-8 A912 2646 Rear Side Post Spring Plate 5-43 A912 2553 Pad - 14x38mm 5-40 A912 2647 Front Side Post Spring Plate 5-11 A912 2555 Trans Cover 7-33 A912 2681 Decal - English, French - 115V 13-6 A912 2556 Shield Plate 7-34 A912 2681 Deca1 - English, French - 115V 3-3 A912 2561 Front Mounting Bracket - Type C 5-37 A912 3551 Feed-in Guide 5-8 A912 2562 Rear Mounting Bracket - Type C 5-38 A912 3575 Front Paper Guide A912 2563 Front Mounting Bracket - Type A 5-37 A912 3576 Rear Paper Guide 5-16 5-3 “ 5-4 A912 2564 Rear Mounting Bracket - Type A 5-38 A912 3577 Shoulder Screw - M3 5-45 A912 2565 Front Mounting Bracket - Type B 5-37 A912 3587 Front Inner Cover 5-2 A912 2566 Rear Mounting Bracket - Type B 5-38 A912 3588 Rear Inner Cover 5-42 A912 2570 Rear Side Plate 5-36 A912 3640 Front Guide Post 5-14 A912 2570 Rear Side Plate 7-7 A912 3641 Rear Guide Post 5-16 A912 2573 Lift Stay 5-1 A912 4224 Multi - Lingual Decal - Ricoh 13-7 A912 2575 x/x MB6 5-3 A912 4224 Multi - Lingual Decal - Ricoh 3-9 A912 2576 X/X MB6 5-4 A912 5010 Operation Board 3-6 A912 2580 Tray Bottom Plate 5-7 A912 5103 Tray Control Board 7-26 A912 2582 13-1 A912 5103 Tray Control Board 9-* A912 2582 Decal - Paper Size Decal - Paper Size 5-5 A912 5202 Pick-up Harness 11-2 A912 2585 Paper Size Dial 7-28 A912 5202 Pick-up Harness 3-18 A912 2587 X/O MB3 5-2 A912 5205 Interface Harness 11-1 A912 2588 X/O MB3 5-42 A912 5205 Interface Harness A912 2594 Decal - Increase Size 13-3 A912 5208 Safety Switch Harness 7-31 11-Ž5 A912 2594 Decal - Increase Size 3-11 A912 5208 Safety Switch Harness 7-Ž17 A912 2595 13-4 A912 8610 Installation Procedure - 115V 3-* A912 2595 Decal - Decrease Size Decal - Decrease Size 3-12 A912 8615 Installation Procedure - 220V/240V 3-* A912 2596 Operation Skin 3-10 A912 2598 Decal - Instructions 13-5 A912 2598 Decal - Instructions 3-9 16 Feb. 28, ’89 Parts No. Description Page a n d Index No. Description Parts No. Page and Index No. AA06 6011 Spring - Paper Position Feeler 3-16 5897 1372 Right Lift Rod 5-18 AA14 8023 Feeler Shaft 3-14 5897 1451 Front Post Rack 5-13 AA15 0007 Guide Seal - Pick-up 3-26 5897 1455 Bushing 5-12 AA15 0008 Guide Seal - Paper Feed 5-41 5897 1457 Rear Post Rack 5-15 AB01 3098 Idle Gear - 21T 3-22 5897 1458 Side Post Spring Plate 5-23 AB01 7034 Feed Gear - 30T 3-21 5897 1472 Washer - 4.5x24x2mm 7-23 AZ02 0001 Grounding Inductor 7-37 5897 1473 Size Lever 5053 0223 Bushing - 8mm 7-4 5897 1493 Microswitch 5053 0419 Bushing - l0mm - Long - 7mm 7-10 5897 1496 Sensor Mounting Bracket 5-26 5054 0536 Magnet Catch Ass’y 7-24 5897 1497 Harness Cover 1 5-25 5205 5250 L.E.D Sensor Type - S 3-20 5897 1498 Harness Cover 2 5-32 5205 5250 L.E.D Sensor Type - S 5-30 5897 1514 Noise Filter Bracket - 220/240V 7-38 5205 5253 Photointerruptor 5-27 5897 4103 Bracket - Shaft 5-31 5403 4335 Deca1 - Terminal - 115V 13-2 5897 4153 Bracket - Size Shaft 5-44 5403 4335 Decal - Terminal - 115V 7-36 5897 4477 Leaf Spring 5-34 5408 7968 Power Supply Cord - 220V 7-32 5897 5520 Decal - Power Source - 220V 13-9 5897 5555 Transformer - 115V, 220V, 240V/30W Noise Filter Grounding Wire 7-35 5442 1372 5442 1372 Decal - Power Source - 220V 3-4 5925 2203 Front Bracket 5-33 5443 2657 Gear - 282 5-29 5925 2204 Rear Bracket 5-22 5446 2620 Idler Pulley - 20 7-8 5925 2211 Front Side Plate 5-9 5446 2702 Gear - 22T 7-6 5925 2211 Front Side Plate 7-22 5446 5411 Tray Drive Motor - AC 7/8W/l15V 7-1 5925 2233 Side Cover Plate 5-35 5446 5412 Tray Drive Motor - AC 7/8W/220V 7-1 5925 2235 Dial Shaft 7-29 5446 8906 Decal - English, German - 220/240V 13-8 5925 2239 Drive Gear Shaft 7-5 5446 8906 Decal - English, German - 220/240V 3-3 5925 2241 Drive Wire 7-11 5447 2681 Snap Ring 3-27 5925 2246 Drive Pulley 7-9 5447 2927 Friction Pad - B 5-6 5925 2247 Drive Shaft 7-20 5897 1125 Nylon Clamp Stay 7-30 5925 2249 Side Guide Shaft 5-19 5897 1126 Safety Switch Bracket 7-16 5925 2251 Front Wire Tightener 7-21 5897 1272 Operation Board Mounting Bracket 3-7 5925 2253 Rear Wire Tightener 7-15 5897 1274 Top Actuator Lever 7-12 5925 2255 Side Guide Stopper 5-10 5897 1277 Bottom Actuator Lever 7-14 5925 2257 Left Lift Stay 5-17 5897 1279 Safety Switch Actuator 7-13 5925 2258 Stopper Chain 5-39 5897 1351 Drive Motor Bracket 7-3 5925 2259 Hook 5-20 5897 1352 Worm Gear - M5x5 7-2 5925 2265 P.C.B Bracket 7-25 Pack 17 5-28 Mounting Bracket 5-24 7-39 Feb. 28, ’89 Description Parts No. Page and Index No. Description Parts No. Page and Index No. 5925 2266 Power Cord Bracket 7-19 0313 0060W Philips Pan Head Screw - M3x6 5-101 5925 2331 Holder - Side Cover 5-21 0313 0060W Philips Pan Head Screw - M3x6 7-128 5925 2334 Plate - Magnet Catch 3-28 0313 0120W Philips Pan Head Screw - M3x12 5-102 5925 5206 DC Harness 11-3 0313 0140W Philips Pan Head Screw - M3x14 7-129 5925 5206 DC Harness 7-27 0314 0040W Philips Pan Head Screw - M4x4 3-104 5925 5211 AC Harness - 115V X/X MB8 11-4 0314 0040W Philips Pan Head Screw - M4x4 5-108 5925 5211 AC Harness - 115V X/X MB8 7-18 0314 0050W Philips Pan Head Screw - M4x5 7-104 5925 5215 AC Harness 11-4 0314 0060W Philips Pan Head Screw - M4x6 5-104 5925 5215 AC Harness - 220/240V 11-4 0314 0060W Philips Pan Head Screw - M4x6 7-103 5925 5215 AC Harness 7-18 0314 0100W Philips Pan Head Screw - M4x10 5-103 5925 5215 AC Harness - 220/240V 7-18 0314 0100W Philips Pan Head Screw - M4x10 7-102 5925 5216 Noise Filter Harness 7-40 0314 0120W Philips Pan Head Screw - M4x12 7-126 6769 7930 Power Supply Cord - 115V . 7-32 0315 0080W Philips Pan Head Screw - M5x8 7-101 0434 0060W Tapping Screw - M4x6 3-101 0434 0060W Tapping Screw - M4x6 5-105 0434 0060W Tapping Screw - M4x6 7-105 0434 0080W Tapping Screw - M4x8 7-106 0434 0100W Tapping Screw - M4x10 3-102 0574 0050E Hexagon Headless Set Screw - M4x5 7-113 0720 0030E Retaining Ring - M3 3-106 0720 0030E Retaining Ring - M3 7-110 0720 0040E Retaining Ring - M4 5-109 0720 0040E Retaining Ring - M4 7-111 0720 0060E Retaining Ring - M6 5-110 0720 0060E Retaining Ring - M6 7-127 0801 1185 Philips Truss Head Screw - M4x8 7-108 0802 5094 Tapping Truss Head Screw - M4x8 3-103 0807 7071 Flat Washer - M11 7-112 0930 0400 Parallel Key 7-123 0951 3008W Philips Screw With Flat Washer - M3x8 5-106 0964 4008W Tapping Screw With Flat Washer - M4x8 3-105 0964 4008W Tapping Screw With Flat Washer - M4x8 5-107 0964 4008W Tapping Screw With Flat Washer - M4x8 7-107 0965 4010W Tapping Screw With Flat Washer - M4x10 7-109 1005 0383 Edging - B 5-111 18 Feb. 28, ’89 Parts No. Description Page and Index No. Parts No. Description Page and Index No. 1005 0383 Edging - B 7-114 1102 1929 Connector - 7P 1100 0277 Fastening Receptacle 11-101 1102 1943 Receptacle Housing 11-134 1100 0885 Fastening Receptacle - 220/240V 11-102 1102 1965 Connector - 3P 11-135 11-133 1100 1169 Fastening Receptacle - 115V 11-103 1102 1971 Connector - 3P 11-136 1100 1172 Fastening 11-104 1103 1247 Connector - 3P 9-101 Receptacle 1100 1238 Pin - Mate-N-Lock 11-105 1103 1729 Connector - 7P 9-102 1100 1239 Pin - Mate-N-Lock 11-106 1103 1730 Connector - 8P 9-103 1100 1240 Socket - Mate-N-Lock 11-107 1103 1739 Connector - 3P 9-104 1100 1241 Socket - Mate-N-Lock Terminal 11-108 1103 1743 Connector - 7P 9-105 11-109 1103 1757 Connector - 7P 9-106 1100 1249 Receptacle Terminal “ 11-110 1104 0323 Fuse Holder 1100 1327 Contact 11-111 1105 0008 Nylon 1100 1247 Clip - 2N 7-119 7-116 1100 1328 Cent act 11-112 1105 0011 Nylon Clip - 8N 7-115 1101 0359 Terminal - 3P 7-120 1105 0108 Nylon Clip 7-118 1102 0796 Insulating Sleeve 3.0mm - 220V 11-113 1106 0336 Nylon Stud 7-117 1102 0895 Nylon Stud 3-107 1106 0442 Cord Clamp 7-125 1102 1404 Receptacle Housing 11-114 1107 0271 Fuse - 3A 7-122 1102 1408 Connector - 1P - l15V 11-115 1107 0487 Circuit Breaker - 115V 7-122 1102 1506 Connector - 1P 11-116 1204 0192 Microswitch - UL 5-112 1102 1507 Connector - 2P 11-117 1204 1280 Push Switch 7-121 1102 1514 Connector - 1P 11-118 1208 1047 Solid State Pelay - 240V/3A 9-107 1102 1516 Connector - 3P 11-119 1400 0072 Transistor - 2SC372Y 9-108 1102 1524 Connector - 2P (RED) 11-120 1400 0135 1102 1532 Connector - 2P 11-121 1401 0825 Transistor - 25AS1015-Y Diode - 1SS176 9-110 9-109 1102 1620 Connector - 3P 11-122 1407 0520 IC - HD74LS00 9-111 1102 1621 Receptacle Housing - 3P 11-123 1407 0622 Ic - HD74LSS10P 9-112 1102 1623 Receptacle Housing - 7P 11-124 1407 0981 IC - TD62503P 9-113 1102 1745 Receptacle Sleeve 11-125 1408 0124 IC - LM555CN 9-114 1102 1786 Connector - 3P 11-126 1408 0412 IC - 7705CP 9-115 1102 1815 Connector - 3P 11-127 1602 0974 Noise Filter 7-124 1102 1911 Connector - 3P 11-128 1604 0909 Capacitor - lµF 35V 9-116 1102 1912 Connector - 4P 11-129 1604 1363 Capacitor - 10µF 25V 9-117 1102 1915 Connector - 7P 11-130 1604 1366 Capacitor - 47µF 25V 9-118 1102 1916 Connector - 8P 11-131 1606 1336 Capacitor - 1000PF 50V 9-119 1102 1925 Connector - 3P 11-132 1606 1458 Capacitor - 0.lµF 50V 9-120 19 Feb. 28, ’89 Parts No. Description Page and Index No. 1611 4101V Resistor - lKOHM l/4V ±5% 9-121 1611 4102V Resistor - IKOHM l/4W ±5% 9-122 1611 4103V Resistor - 10KOHM l/4V ±5% Resistor - 100KOHM l/4W ±5% MB7 9-123 9-129 1611 4471V Resistor - 360OHM l/4V Resistor - 470OHM l/4W ±5% 1611 4472V Resistor - 4.7KOHM l/4W ±5% 9-126 1611 4562V Resistor - 5.6KOHM l/4W ±5% 9-127 1611 4564V Resistor - 560KOHM l/4W 9-128 1611 4681V Resistor - 680OHM l/4v 9-130 1611 4104V 1611 4361V Parts No. 9-124 9-125 20 Description Page a n d Index No. CONTENTS ELECTRICAL DATA PCB-1 COPIER: I/O CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . .13-1 PCB-2 COPIER: SYSTEM CONTROL BOARD . . . . . . . . . . . . . . . . . . .13-2 PCB-3 COPIER: DC POWER SUPPLY BOARD . . . . . . . . . . . . . . . . . . .13-3 PCB-4 COPIER: AD DRIVE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4 PCB-5 COPIER: PAPER FEED BOARD . . . . . . . . . . . . . . . . . . . . . . . . .13-5 PCB-6 DF: MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-6 PCB-7 LCT: MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 PCB-8 EDITOR: MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-8 PCB-9 DATE PRINTER: MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . . 13-9 PCB-10 SORTER: CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . . .13-10