Service manual

ManualsBrandsSharp ManualsAll in One PrinterAR-650

This document has been published to be used for

after sales service only.

The contents are subject to change without notice.

Parts marked with “ “ are important for maintaining the safety of the set.

Be sure to replace these parts with specified ones for maintaining the safety and performance of the set.

SHARP CORPORATION

SERVICE MANUAL

DIGITAL COPIER

MODEL

AR-650

[ 1 ] SPECIFICATIONS•ACCESSORIES•OPTIONS•SUPPLIES . . . 1 - 1

[ 2 ] OUTLINE OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

[ 3 ] COPYING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1

[ 4 ] COPIER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

[ 5 ] DISPLAY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

[ 6 ] IMAGE PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

[ 7 ] SCANNER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1

[ 8 ] PRINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1

[ 9 ] PAPER FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1

[10] DRUM-RELATED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1

[11] TRANSFER/TRANSPORT UNIT. . . . . . . . . . . . . . . . . . . . . . . 11 - 1

[12] DEVELOPER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1

[13] CLEANER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 1

[14] FUSER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 1

[15] AUTOMATIC DUPLEXING UNIT (ADU) . . . . . . . . . . . . . . . . . 15 - 1

[16] AUTOMATIC DOCUMENT FEEDER (ADF) . . . . . . . . . . . . . . 16 - 1

[17] POWER SUPPLY UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 1

[18] PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 - 1

[19] UNPACKING AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . 19 - 1

CODE : 00ZAR650//F1E

CONTENTS

Summary of content (396 pages)

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SERVICE MANUAL CODE : 00ZAR650//F1E DIGITAL COPIER MODEL AR-650 CONTENTS [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] SPECIFICATIONS•ACCESSORIES•OPTIONS•SUPPLIES . . . 1 - 1 OUTLINE OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 COPYING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 COPIER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 DISPLAY UNIT . . . . . . . . . . . . .
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GENERAL PRECAUTIONS REGARDING THE INSTALLATION AND SERVICE FOR THE COPIER The installation and service should be done by a qualified service technician. 1. Transportation/Installation • When transporting/installing the copier, move it by the casters while lifting the stoppers. The copier is quite heavy and weighs approximately 250 kg (551 lb), therefore pay full attention when handling it. • Be sure to use a dedicated outlet with AC 115V or 120V/20A (220V, 230V, 240V/10A) or more for its power source.
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5. Disposition of Consumable Parts/Packing Materials • Regarding the recovery and disposal of the copier, supplies, consumable parts and packing materials, it is recommended to follow the relevant local regulations or rules. 6. When parts are disassembled, reassembly is basically the reverse of disassembly unless otherwise noted in this manual or other related documents. Be careful not to reassemble small parts such as screws, washers, pins, E-rings, toothed washers in the wrong places. 7.
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CONTENTS 1. SPECIFICATIONS • ACCESSORIES • OPTIONS • SUPPLIES ........................................... 1-1 1.1 1.2 Specifications ......................................................................................................................... 1-1 Accessories ............................................................................................................................ 1-12 1.3 Options ..............................................................................................
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.3 Relation between Copier Conditions and Operator's Actions ................................................ 5-6 5.4 Description of Operation ........................................................................................................ 5-7 5.4.1 Dot matrix LCD circuit ................................................................................................. 5-7 5.5 5.4.2 LED display circuit .............................................................................................
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8. PRINTING .............................................................................................................................. 8-1 8.1 Function Outline ..................................................................................................................... 8-1 8.2 Structure ................................................................................................................................ 8-3 8.3 8.4 Laser Diode ....................................................
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12.4 Motors ................................................................................................................................... 12-7 12.4.1 Developer motor (IC motor) drive .............................................................................. 12-7 12.4.2 Brush motor (toner motor (M14)) drive circuit ............................................................ 12-10 12.5 Auto-Toner Sensor Circuit ........................................................................................
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15.3.2 Duplex copy (re-feed) operation ................................................................................ 15-7 15.3.3 Reversal exit operation .............................................................................................. 15-9 15.4 Disassembly and Replacement ............................................................................................. 15-10 16. AUTOMATIC DOCUMENT FEEDER (ADF) ......................................................................... 16-1 16.
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16.10.4 Pulse motor drive circuit .......................................................................................... 16-42 16.10.5 Solenoid drive circuit ............................................................................................... 16-42 16.10.6 Reset circuit ............................................................................................................ 16-43 16.10.7 EEPROM circuit diagram ................................................................................
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1. SPECIFICATIONS • ACCESSORIES • OPTIONS • SUPPLIES 1.1 Specifications 1.
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2. Basic specifications A. Copy speed (1) Continuous copy Paper feed system Paper size A4,B5,A5-R,LT,ST-R A4-R,B5-R,LT-R B4,FOLIO,LG,COMP A3,LD LCF Cassette 65 X X X 65 51 44 38 Manual feed Size specified Size not specified 48 33 42 33 37 33 33 33 Note 1: The above specifications are for manual feed, single and continuous copy. Note 2: The state which is other than the toner supply mode. (2) First copy First copy time 3.
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D. Paper (1) Size Fixed size Cassette AB series: A3,A4,A4-R,A5-R,B4,B5,B5-R,FOLIO LT series: LD,LG,LT,LT-R,ST-R,COM AB series: A3,A4,A4-R,A5-R,B4,B5,B5-R,FOLIO LT series: LD,LG,LT,LT-R,ST-R,COM SFB LCF : A4,LT,B5 Note 1: Postcards cannot be used. Note 2: Name cards cannot be used. Note 3: Same surface copy cannot be used. Note 4: Envelopes cannot be used. Note 5: The paper width of fixed size is detected with the manual tray guide width. Note 6: The upper stage of B5 cassette cannot be used.
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E. Paper feed Paper feed means LCF Cassettes: 3 steps (Drawers of the copier) SFB LCF: 4,000 sheets (Load height: max. 415mm) Cassette: 500 sheets (Load height: max. 55mm) SFB: 100 sheets (Load height: max. 11mm) Note 1: 50 sheets for SFB duplex copy. Note 2: However, the cassette load height is displayed as 53mm. Note 3: however, the SFB load height is displayed as 10mm.
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(2) Selected magnification ratio a. AB series Paper Original A3 B4 FOLIO A4 B5 A5 A3 B4 FOLIO A4 B5 A5 100 115 127 141 163 200 86 100 110 122 141 173 71 82 100 100 115 141 71 82 90 100 115 141 61 71 78 86 100 122 50 57 63 71 82 100 b.LT series Paper Original LD COMP LG LT ST LD COMP LG LT ST 100 108 121 129 200 82 100 100 119 165 78 84 100 100 154 65 78 78 100 129 50 54 60 65 100 Note 1: The above numbers show magnification ratios.
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K. Charger wire cleaning Charger wire cleaning Available (Auto cleaning system) Note 1: The charging wire is cleaned. L. Special functions Interruption Pre-heat Available Available Key input is accepted during warming up and in the ready state. Note 1: Auto pre-heat function can be set in the adjustment mode. Note 2: By data input of the adjustment mode, time can be set in the increment of 5min (5 – 60min). Note 3: The fuser temperature in pre-heat can be set in the adjustment mode.
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Timer display Available Factory setup: Display provided Factory setup: ON Factory setup: Available Paper feed means which allow selection: (1) LCF (2) Cassette Auto sort Auto cassette selection Available Available Network printer Language selection Allows connection of network printer board (option). Available (3 languages) Note 1: Language selection of DSS display must be initialized. FROM update Available Note 1: Download from PC Performed serviceman.
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O. Operation panel Operation key Status display Message display Hard key Note 1: There are following 19 keys. Start 0 – 9 (10 keys) Clear Stop All clear Interruption Pre-heat HELP Copy Printer Displayed with the message display and LED. Note 1: There are following 6 LED’s. All clear Interruption Pre-heat Copy Printer Timer Graphic LCD with touch panel (with backlight) Note 1: Details of LCD Display dot: 320 x 240 (1/4 VGA) Display area: 115.7mm c 86.37mm P.
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T. Power source Power voltage, frequency Power consumption Power cord 100V-50/60Hz,115V-50/60Hz,220V-50/60Hz,230~240V-50/60Hz,240V-50Hz 2.0kW or less 2m Note 1: For 200 series, detachable. U. External view External dimensions Weight (1) Body: W920 X D742 X H1111 mm (2) Body + Finisher: W1735 X D742 X H1111 mm (3) Body + Finisher + DSSC: W1735 X D905 X H1111 mm Body only: 250 kg V.
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X. Automatic original feeder Automatic original feeder ADF conforming to duplex original (Standard provision) (1) Functions Functions Loaded originals are automatically separated and fed.
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Z. Reverse paper exit function Reverse paper exit Process speed Applicable paper Paper conditions Use conditions Available A4,B5,A5-R,LT,ST-R:65cpm A4-R,B5-R,LT-R:45cpm B4,LG:36cpm A3,LD:30cpm Size A3,B4,A4,A4-R,B5,B5-R,A5-R LD,LG,LT,LT-R,ST-R Weight 64~80g/m2 17~22 Lbs Curl level 5mm or less (Paper feed section) 20mm or less (Refeed section) In duplex paper exit of the first set in Single ➔ Duplex mode, with an odd number of the quantity of originals. 4 Picture and picture quality specifications A.
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1.2 Accessories Operation Manual Drum Operation Manual Pocket Original feed tray Maintenance management table (Card, sheet) Delivery installation contract (EU only) MSDS card (USA,UK only) Warranty for Australia Warranty registration (EU only) 1.
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No.
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2. OUTLINE OF THE MACHINE 2.1 Sectional Views and Electrical Parts Location Diagram 2.1.
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No. Name No.
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No. Name No.
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[B] Front Drive System 126 127 125 136 128 130 132 129 133 137 138 131 134 135 139 140 141 No. Name No.
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[C] Rear Drive System 150 149 148 146 145 147 204 206 205 208 156 153 152 155 154 157 159 158 160 207 176 163 151 200 175 177 209 162 199 198 167 178 197 201 203 202 161 169 168 164 196 195 165 194 174 193 173 172 171 170 166 192 179 191 180 181 190 182 189 183 184 186 185 188 187 2-5 OUTLINE
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No. Name No.
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2-7 Empty sensor Separation pad Feed cover switch Aligning sensor 4 5 6 7 Size sensor lever Empty sensor lever 3 9 Weight 2 Size sensor Pick-up roller 8 11 Name 1 No. 9 8 7 5 10 12 6 4 2 1 Transport belt Belt holding roller 18 Belt holding roller DF open switch 17 16 15 Belt drop roller Belt drive roller 13 14 Feed roller Aligning roller Timing sensor 17 12 11 10 No.
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2.1.
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[B] Scanner Unit (B-1) PC board 2 1 3 Scanner unit Rear side No.
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(B-2) DC electrical parts (except motors, PC boards) [A4 series] 1 2 Scanner unit Rear side No. 1 2 Name Automatic paper size detector (APS1-6) Home switch (HOME-SW) Symbol S1-6 S2 [LT series] 1 2 Scanner unit Rear side No.
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(B-3) Motors 3 4 2 1 Scanner unit Rear side No. 1 2 3 4 (B-4) Name Scanning motor (SCN-MOT) Document motor (DCM-MOT) Scanning optical system cooling fan motor (OPT-FAN-MOT) SLG PC board cooling fan motor (SLG-FAN-MOT) Symbol M1 M2 M3-1,-2 M4 AC electrical parts 5 6 4 2 1 3 Scanner unit 7 No.
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[C] Laser Unit (C-1) PC boards 2 3 4 4 1 Laser unit 4 Rear side 4 No. 1 2 3 4 (C-2) Name PLG PC board (PWA-F-PLG-300) Polygon mirror motor drive PC board (M/A-DRV-POL-300) Sensor PC board (PWA-F-SNS-300) Laser PC board (K-PWA-F-LDR-300) Symbol PLG POL SNS LDR Electrical parts (except motors, PC boards) 1 1 1 1 Laser unit Rear side No.
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(C-3) Motors 1 2 Laser unit Rear side No. 1 2 Name Symbol M5 M6 Polygon mirror motor (POL-MOT) Laser unit fan (LSU-FAN-MOT) [D] System Unit (D-1) PC boards System unit 4 1 2 3 Rear side 5 No.
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(D-2) Motor 1 System unit Rear side No. 1 Name Symbol M7 System fan motor (FAN-SYS) [E] ADU (E-1) PC board 1 Rear side ADU No.
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(E-2) DC electrical parts (except motors, PC boards) 8 7 5 9 10 6 4 3 11 12 2 1 13 Rear side ADU No.
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(E-3) Motors 1 2 Rear side ADU No.
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[F] Upper Unit (F-1) PC board 1 Upper unit No.
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(F-2) DC electrical parts (except motors, PC boards) 1 17 14 13 2 21 10 3 15 4 5 6 19 18 16 12 Upper unit 7 20 9 11 Rear side 8 No.
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(F-3) Motors 11 1 18 2 14 10 3 4 5 9 15 16 Rear side 13 7 Upper unit No.
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(F-4) AC electrical parts 1 8 6 7 2 9 Rear side Upper unit 5 4 3 No.
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[G] Lower Unit (G-1) PC boards 2 1 Rear side Lower unit No.
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(G-2) DC electrical parts (except motors, PC boards) 11 8 7 6 14 13 12 25 15 16 9 31 10 17 1 3 18 29 21 23 No.
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(G-3) Motors 6 1 2 Rear side 3 Lower unit 5 4 No.
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(G-4) AC electrical parts 4 2 6 3 5 1 Lower unit Rear side No.
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2.
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(2) Solenoids Symbol Name Function SOL1 GID-SOL (guide solenoid) SOL3 SOL3 (scraper solenoid) Drives the separation claw SOL4 GATE-SOL (gate solenoid) Drives the exit/ADU switching gate SOL5 MANUAL-SOL (manual Pick-up solenoid) Drives vertical movement of the manual Remarks pick-up roller (3) Electromagnetic spring clutches Symbol Name Function CL1 TR-CLT (ADU transport clutch) Drives the paper transport of the ADU CL2 REV-CLT (ADU reverse clutch) Exits the copy in reverse CL3 STK-
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Symbol Name Function S8 RGT-SW (aligning switch) Detects aligning position of the paper in the ADU S9 SID-SW (side switch) Detects the side guide position of the ADU S10 EXIT-SW (fuser exit switch) Detects exiting paper S11 TNR-HOP-SW (toner supply cover switch) Detects opening/closing of the toner Remarks supply cover S12 TNR-EMP-SW (toner empty switch) Detects a no toner state in the toner hopper S13 P-STP-SW (paper stop switch) Used for stopping the feed roller S14 DEV-SW (develope
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Symbol Name Function S40 T-DOWN-SW (LCF tray down switch) Detects the bottom position of the LCF tray S41 DOOR-SW (door switch) Used for ensuring safety S42 MAIN-SW (main switch) Remarks Used for switching the main power supply ON and OFF S43 S44 TR-TCH-SW (Transfer belt touch switch) Used for touching the transfer belt TR-SEP-SW Used for separating the transfer belt (Transfer belt estrangement switch) S45 EXIT-AC-SW (Exit door inter lock switch) Used for ensuring safety S46 HTR-SW (Fu
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Symbol Name Function MTB PWA-F-MTB-300 (mother board) Option board connecting HDD Hard disk (HDD) Stores image data LAN or SCSI LAN printer board or SCSI board NIC NIC board Remarks Printer Option Network interface card Option for LAN printer board ADU PWA-F-ADU-300 (ADU PC board) Controls the ADU MOT PWA-F-MOT-300 (motor control PC board) Drives the drum and transport belt LGC PWA-F-LGC-300 (logic PC board) Controls the entire copier LCF PWA-F-LCF-150 (LCF PC board) Displays LCF
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HDD LCD 2 - 30 7 8 9 PWA-DSP-300 4 5 6 1 0 2 CLR/STP 3 BT 8 Finisher IPC ADU LCF PFP PWA-F-SYS-300 LCD Controller VRAM NVRAM RTC PCI-Bus(33MHz) 32 PCI-Bus CODEC CLK SRAM Serial-I/F PFC ASIC PWA-F-MTB-300 LAN-Card (for Debug) ISA-Bus SCSI OSC (Optional Board) M-CPU Gate Array 64bit-RISC ASIC Serial-I/F NVRAM ROM SRAM PWA-F-LGC-300 Flash ROM.1 Flash ROM.
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2.4 Removal of Covers and PC Boards 2.4.1 Removal of covers [A] Right front cover (1) Open the right front cover. (2) Remove the screws on the hinges at both ends (2 screws for each). Hinge Right front cover [B] Left front cover (1) Open the right front cover, then open the left front cover. (2) Remove the top and bottom hinge brackets (2 screws for each). Hinge Left front cover [C] Lower front cover (1) Remove the intermediate and lower cassettes. (2) Remove the 3 screws.
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[E] Upper feed cover (1) Slide the LCF unit. (2) Remove the 2 screws. [F] Lower feed cover (1) Draw out the LCF, and remove the manual feed unit. (2) Remove the lower feed cover (3 screws, 1 connector, both sides hooks 4 pcs.). Hooks [G] Power switch cover (1) Slide the LCF unit. (2) Remove the 3 screws.
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[H] Rear top cover on paper (feed side) and toner bag cover (1) Remove feed-side rear cover (2 screws). Feed side upper rear cover Toner bag cover (2) Remove the 2 coin screws, open the toner bag cover and remove the upper hinge screw. (3) Remove the toner bag cover from the lower hinge. Toner bag cover [I] Upper exit cover, lower exit cover, PFP exit Upper exit cover cover, front exit cover and rear exit cover (1) Remove the upper exit cover (2 screws). (2) Remove the front exit cover (3 screws).
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[K] Rear top cover Rear top cover (1) Remove the ADF unit. (2) Remove the 2 screws. Original glass [L] Right top cover (1) Remove the rear cover. (2) Remove the 3 screws. Right top cover [M] Toner supply cover (1) Remove the right top cover. (2) Remove the two hinges (1 screw for each), and Toner supply cover remove the toner supply cover. Hinge [N] Middle inner cover (1) Open the right and left front covers. Left inner cover Middle inner cover Right inner cover (2) Remove the 3 screws.
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[Q] Belt transport unit right cover (1) Push down the jam release in the direction of the arrow, and draw out the belt transport unit Belt transport unit left cover Belt transport unit right cover towards you. (2) Remove the 2 screws. [R] Belt transport unit left cover (1) Remove the 2 screws. [S] PFP inner cover (1) Draw out the ADU unit. (2) Remove the 4 screws. PFP inner cover 2.4.
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Lamp regulator PC board [B] Motor drive PC board (PWA-F-MOT-300) (1) Remove the rear cover. SDV-PC board (2) Disconnect the 3 connectors. (3) Remove the lock supports (4 pcs.), then remove the motor drive PC board. [C] Lamp regulator PC board (PS-LRG-JU-300, PS-LRG-E-300) (1) Remove the rear cover. (2) Disconnect the 3 connectors. Locking support Motor driver PC board Locking support (3) Remove the 2 screws, then remove the lamp regulator PC board.
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(4) Remove the PC board fastener hook, and draw Hook out the developer bias transformer. Power inner cover [G] Switching power supply unit (1) Remove the front exit cover (3 screws). (2) Remove the rear exit cover (2 screws). (3) Remove the PFP exit cover (4 screws). (4) Remove the power supply inner cover (5 screws). (5) Disconnect the 9 connectors. (6) Remove the 4 screws, and remove the switching power supply unit.
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[H] System PC board (PWA-SYS) Connector (1) Remove the glass holder, original glass and left top cover. (2) Remove the indicator screw, and slide the indicator to remove the scanner section lens cover. (3) Disconnect the connector from the system PC board side of the harness connecting the scanner logic PC board and the system PC board, and remove the cover on the rear side. (4) Remove the system PC board side of the harness connecting the system PC board and the PLG PC board.
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[I] HDD (1) Remove the upper exit cover. Connector HDD (2) Remove the system electronics slot cover (15 screws). (3) Remove the screw and connector, and take out the HDD unit. (4) Remove the bracket (4 screws).
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3. COPYING PROCESS 3.1 Copying Process 2 Image processing Original exposure Scanning 3 4 Halogen lamp CCD 180 W 600 dpi, 7500-pixels Printing Semiconductor laser Pw = 4.
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3.2 Details of Copying Process (1) Photosensitive Drum The photosensitive drum has two layers, an outer and an inner layer. The outer layer is a semi-conductive layer. It uses an organic pho- Photoconductive layer Base toconductive carrier (OPC) material. The inner layer is Aluminum and is a conductive material. The resistance of the drum's semi-conductive Structure of the photosensitive drum outer layer changes depending on the strength of the incident light.
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(3) Scanning Scanning is the process of directing light at the original document. Part of the scanning proc- CCD board ess is the conversion of reflected light (from the original document) into electrical signals. Scanner control PC board The Charged Coupled Device (CCD) receives light from the optics area and converts them Image processor into electrical signals that are sent to the Image Processing System for further processing Logic PC board into digital signals.
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(5) Development Magnetic roller Drum Development is the process of converting the electrostatic latent image into “visible image.” The developing agent is “brushed” unto the surface of the photosensitive drum by means of magnetic roller(s). The developing agent, commonly called “developer,” is coated with toner (which has a minus/negative charge).
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terial. Toner, which has a minus (negative) charge, adheres to the carrier material and producing what is commonly referred to as “developer.” Toner is a material mainly made with plastic and carbon materials. Carrier is ferrite beads with a coating layer for the reason of the stabilization of the frictional charge with toner. Note: If the developer material is used for long periods (beyond its normal life span), toner will become stuck to the carrier.
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(6) Transfer/Separation The transfer process transfers the developed Drum image onto the surface of the copy paper. • Paper passing under the drum is held in contact to the belt by static electricity produced by the transfer belt. onto the paper. Transfer belt • Separation is accomplished shortly after transfer begins. Paper 1.
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(7) Fixing Toner is melted into the fibers of the paper with the application of heat and pressure. Method: Melting point of the toner is 100°C. Upper heat roller Paper ~110°C. ↓ Heat: The upper (heat) roller applies the required heat that melts the toner. plus Pressure: Pressure The pressure (lower) roller applies pressure that fixes the melted toner into the fibers of the paper.
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(9) Discharge This process electrically discharges any residual electrostatic charge left on the surface of the drum. If not removed, an uneven charge is placed on the drum surface that will affect the print quality of the next copy. Double imaging will occur. Method: A discharge LED array illuminates the entire surface of the drum. The drum becomes a conductor and all residual charges will be grounded. All electrostatic charges are removed at this time.
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3.3 Copying Process Conditions AR-650 Process 1. Drum AR-650DR, AR-650DM (OPC drum) (1) Sensitivity (1) Highly sensitized drum (2) Surface potential 2. Main charger *(2) -650 V (grid voltage -720 V) Scolotron system Variable grid output (input 0 to 255 is set up on control panel numerical keypad) 3. Exposure (1) Light control (1) Automatic exposure + 11-step LCD setting (2) Light source (2) Laser scan (Adjustment not needed) 4. Image density control Toner adhesion volume sensor 5.
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Process AR-650 11. Pre-cleaning discharge None 12. Cleaning (1) System (1) Blade system + brush (2) Recovered toner (2) Non-reusable 13. Fur brush bias Earth 14.
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4. COPIER OPERATION 4.1 Operation Outline Copier operation Operation during warm up and standby Automatic feed copying using PRINT key Copying operation Bypass-feed copying Interrupt copying 4.2 Description of Operation 4.2.1 Warming up (1) Initialize operation • The main switch is turned ON. • The heater lamp is turned ON. • Copy quantity indicator “1” and “WAIT WARMING UP” are displayed. • Fan • Initialization of the scanning optical system ~ The carriages move to their home positions and then stop.
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(3) When the heat roller temperature is sufficient for fixing, • The heater lamp is turned OFF. • Copy quantity indicator “1” and “READY” are displayed. 4.2.2 Standby (ready) • All keys on the control panel are operable. • When there is no key input for a set amount of time. ~ The copy quantity “1” is indicated, the reproduction ratio indicates “actual size”, and the exposure is set to automatic. 4.2.3 Automatic feed copying using the START key (1) The START key is pressed to ON.
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(7) Exit operation • The exit switch detects the passing of the paper’s trailing edge. • The main charger, developer bias and discharge lamp turns OFF. • Operation of the drum, transfer belt, fuser unit and developer unit stops. The fans return to standby mode rotation. • The copier displays “READY” and enters the standby mode.
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4.2.4 Bypass-feed copying (1) A sheet of paper is inserted through the bypass guide. • The manual feed switch is turned ON. ~ “READY FOR BYPASS FEEDING” is displayed. • Carriages move to their home positions. (2) The START key is pressed • “READY FOR BYPASS FEEDING” changes to “COPYING”. • The main charger, developer bias and discharge lamp turns ON, and the fans rotate at high speed. • The drum, transfer belt, fuser and developer unit are running.
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4.3 Fault Detection If a fault occurs in the copier, a symbol corresponding to the type of fault will be displayed in order to draw the attention of the operator. 4.3.1 Classification of faults A) Faults which can be cleared without resetting the door switch. (1) ADD PAPER (2) BYPASS MISFEED (3) ADD TONER (4) REPLACE TONER BAG B) Faults which cannot be cleared without resetting the door switch.
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[In the case of the Copier and LCF and the pedestal] (When the cassette is installed) By combining the operation of the tray motor and the condition of the tray-up switch and the empty switch, the CPU detects whether or not there is paper. • When the power is turned ON or when the LCF door is opened/closed (for the pedestal: when the power is turned ON or when the cassette is loaded) ~ The PFC (Paper Feed Controller) causes the LCF to initialize.
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A-2) BYPASS MISFEED ( ) • During sheet bypass copying  The manual pick-up solenoid has been turned ON   ↓   The paper stop switch-1 comes ON * If the paper stop switch-1 does not come ON within the specified time: (E12) ↓ BYPASS MISFEED ↓ The BYPASS MISFEED symbol is displayed ( ↓ ) Copying cannot be started ↓ Clearing method: Remove the paper from the sheet-bypass guide. The manual-feed switch goes OFF.
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• Trailing-edge jam detection by the exit switch : (E02) The aligning motor goes OFF. Aligning motor OFF Exit switch ON ↓ 1.132 sec* The exit switch goes OFF (detects paper exit) * When the exit switch does not go OFF even after 1.132 seconds: Timer ↓ The CLEAR PAPER symbol appears (E02), and 0 1.132sec CLEAR PAPER (E02) copying stops.
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B-2) ADD TONER ( ) Toner density has become low ↓ Toner empty detection: Auto-toner sensor ↓ Control circuit: f the ADD TONER symbol appears: copying is not possible Clearing method: Open the toner supply cover and supply toner from the toner cartridge. Toner supply operation: copying is possible B-3) REPLACE TONER BAG ( ) The toner bag becomes full of toner ↓ The toner bag tilts due to its own weight: the toner-full switch will be turned ON.
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4.4 Flow Charts 4.4.
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A Initialization of laser optical system T-FULL-SW ON? YES NO NO Toner empty? Main motor 6 sec. ON NO YES T-FULL-SW ON? Toner-full cancel operation YES Toner bag replacement Toner replenishment Initialization over? NO YES 20 sec.
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4.4.
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B Paper jam NG “E02” Exit switch check 2? OK Main charger OFF Discharge lamp OFF Developer bias OFF Drum motor OFF Transfer belt motor OFF Fuser motor OFF Developer motor OFF Drum rotation reversed Standby 4 - 13 COPIER OPERATION
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5. DISPLAY UNIT 5.1 Detailed Drawing of the Control Panel and the Display Panel The display unit consists of key switches and touch-panel switches for copier operation/selection of each mode, LEDs and an LCD displaying the copier state or messages. When the operator’s attention is needed, a graphic symbol lights or flashes and a message indicating that particular condition is displayed in the LCD panel.
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5.2 Items Shown on the Display Panel 5.2.1 Display during normal copying No. 1 Message WAIT WARMING UP Conditions of machine Being warmed up • Indicated after the main switch is switched ON up until the machine becomes capable of copying. 2 3 READY COPYING Notes • The number and reproduction ratio of copies are indicated, for example, as “0”, “100%” when the main switch comes ON. Capable of copying.
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5.2.2 No. 7 Display in the event of faulty conditions Message ADD PAPER Abnormal state & indication Indication of lack of paper. • Flashes when there is no paper in the cassette A in Fig. 5.2-2. Solution • Supply paper to the selected cassette. • Select another cassette. • Manual copying is possible. 8 ADD TONER Indication of lack of toner. • B in Fig. 5.2-2 is indicated when the toner in the toner hopper runs out.
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No. Message Abnormal state & indication 11 PAPER MISFEED IN BYPASS Bypass paper jamming • Indicated when paper jams at the bypass guide. A in Fig. 5.2-3. The machine is returned to normal conditions automatically by pulling the paper out from the bypass guide. 12 MISFEED IN COPIER Paper jammed in the machine. • Indicated when paper jams in the Press the HELP/INFO key and remove the paper jammed in the copier by machine. B in Fig. 5.2-3. 13 MISFEED IN COPIER Cassette paper misfeed.
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No. Message Abnormal state & indication Solution 17 CALL FOR SERVICE Some part of the mechanism, motors, switches or sensors is abnormal. A in Fig. 5.2-4. Turn OFF the machine, remove the cause of the fault and turn the machine back ON. 18 TIME FOR PERIODIC MAINTENANCE Indication of PM cycle. • Indicated when it is time for Maintenance and inspection by a qualified service technician. periodic maintenance and inspection. • Capable of copying. A Fig. 5.
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DISPLAY UNIT — — — — Manual feed jammed Toner bag replaced Paper jammed in the unit Serviceman call 5-6 — Pre-heating — — — — — — — — — — — — — — Digital keys — — — — — — Zoom keys — — — — — — Density key — — — — — — Paper size key * — — — — — — Cassette key — — — — — * Interrupt key Interrupt key is acceptable during copying operation, but not acceptable during original scanning operation.
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5.4 Description of Operation 5.4.1 Dot matrix LCD circuit (1) Structure (320 x 240) The DSP-LCD-230 is an STN black & white mode transmissive type LCD with a 320x240-dot display capacity. It includes a driver LSI, frame, print board, and lateral CFL backlighting.
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(3) LCD drive operation The following describes the drive operation to display the message “100% READY”. PWA-F-SYS-300 GA (scc) 1 1 3 SM CPU PROM 2 3 3 LCD controller 4 R A M 2 PROM. The PROM outputs the data for dis- 3 playing the message to the SM CPU. The SM CPU writes the data for LCD 4 display to RAM IC41.
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5.4.2 LED display circuit (1) Method of LED display The following description is based on the example of displaying “TIME” on the LED display. 5VL LDON0 Current "L" "L" 6 D16 G Q3 (TIME) LP1 R1 IC1(7932) When the signal LDON0 changes to “L” level, the transistor is turned ON. Also when pin 6 (D16) of IC1 changes to “L”, a current flows from 5VL via the transistor to LP1 (“TIME”) i.e. LP1 (“TIME”) is turned ON.
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5.5 Disassembly and Replacement [A] Control Panel (1) Open the control panel. (2) Remove the left, middle and right inner covers (3 screws for each). (3) Disconnect the connector inserted into the copier frame. (4) Remove the 3 screws fixing the control panel. (5) Remove the control panel upwards. (6) Disconnect the connector. (7) Remove the 5 locking supports and screw. (8) Disconnect the 7 connectors, and remove the PC board. (9) Remove the toothed screw and aluminum sheet (2 places).
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6. IMAGE PROCESSING 6.1 Introduction The following diagram shows the processes beginning at the Scanner section to the Printer section (where light is transferred to the photosensitive drum.) ASIC which is short for “Application Specific IC” is for a specific use.
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6.2 Image Processing Circuit 6.2.1 Overview Unlike existing analog copiers where reflected light is projected directly to the photosensitive drum, digital copiers project reflected light (from the original document) to the Charged Coupled Device (CCD). The CCD converts optical images into electrical signals which ultimately undergo shading correction which is nothing more than compensations for variance in the light source and the CCD unit.
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6.2.2 Configuration Figure A shown below represents the image processing section of this digital copier.
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6.3 SLG Board (PWA-F-SLG-300) 6.3.1 Features (1) The image processing ASICs are controlled by CPU on the SLG board (PWA-F-SLG-300). (2) The image processing functions of the SLG board implement the following functions: • High quality image processing • Image memory editing • Editing processing • Gamma correction • Tone processing • External output system interfacing 6.3.2 Functional description of the image processing circuit An ASIC mounted on the SLG PC board implement the functions described below.
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(B) Filtering This function is comprised of a low-pass filter circuit and a high-pass filter circuit. (a) Low-pass filter circuit This circuit eliminates image and electrical noise as well as restrict Moire. It provides an image that closely resembles the original document’s. It does this by averaging the differences between the targeted pixel and those adjacent to it.
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(2) Image memory editing Editing functions such as enlargement/reduction and mirror image copying are performed by using a line memory. The line memory is used for storing one line of pixel data in the primary scanning direction and is updated with new pixel data each time the next line is scanned. (a) Enlargement/reduction This function is accomplished by using line memory control in the portion of the operation.
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(4) Gamma correction processing This function is used to correct the input/output characteristics of the scanner/printer so that image signals are obtained which have input/output characteristics matching a particular copying mode. (5) Tone processing This function works to process tone so that faithful reproduction of halftone images such as photographs are accomplished. (6) External output system interface This function performs the output control of the output interface for the SYS board (PWA-F-SYS300).
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6.4 PLG Board (PWA-F-PLG-300) 6.4.1 Features (1) The image processing ASICs are controlled by CPUs mounted on the PLG board (PWA-F-PLG-300) and the LGC board (PWA-F-LGC-300). (2) The image processing functions of the PLG board work to accomplish the following: • Smoothing processing • External input system interface • Image area control • Laser related control 6.4.
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6.5 Scanner Light that is reflected from the original document’s surface is directed to the CCD where photovoltaic conversion occurs. During this operation, optical image data are converted into electrical signals which are then converted into digital signals by the A/D conversion portion of the image processing system. CCD Signal amplification A/D conversion Shading compensation To next stage (1) Photo-voltaic conversion A conversion from optical signals to electrical signals performed by the CCD.
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7. SCANNER 7.1 Functions During a scanning process, light is directed at the surface of the original document and then to the CCD via mirrors and the CCD lens and a slit. The CCD unit in which optical image data are converted to electrical signals accomplishes photovoltaic conversion. The resultant analog signals undergo A/D conversion, which ultimately become digital signals. These signals undergo compensation processes in order to produce the required image.
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7.2 Configuration The following describes the configuration of the optical system and the purpose of its components. (1) Original glass The original glass is where the original document is placed for scanning. The exposure lamp illuminates the original document. (2) Carriage 1 Carriage 1 is the optical assembly that has the exposure lamp and is used for scanning the original document. The illustration below shows some of the components that make up the assembly. Thermostat Mirror 1 Carriage 1 a.
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(3) Carriage 2 The Carriage 2 assembly directs light reflected from mirror 1 to the CCD assembly. It contains mirrors 2 and 3. The scanner motor drives this assembly. Its scanning speed as well as the distance that it travels is half that of carriage 1. Mirror 2 Mirror 3 Carriage 2 (4) Lens → CCD Light reflected from mirror 3 is projected to the CCD. The CCD is located at the focal point of a fixed lens.
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(6) Automatic original detection unit The automatic original detection unit (APS sensor) uses sensors located on the lens cover and on the base frame for detection of the size of the original without the process of scanning. (7) Original width indicator unit The original width indicator unit is for indicating the original width currently selected by the copier. The original size is displayed by the yellow lines on the indicator and carriage 1.
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7.3 Description of Operation 7.3.1 Scanning motor CRG-2 pulley 27 CRG-2 CRG-1 Carriage drive wire Scaning motor Motor pulley 3GT-Z24 Idle pulley 27 Idler pulley 27 Wire windup pulley/motor deceleration pulley 39.75/3GT-Z28 Optical System (rear side) Scanner motor drive is transferred to carriages 1 and 2 via the timing belt and the carriage drive wire. Initially, carriage 1 moves to the home position. The actuation of the “home switch” determines the home position of Carriage 1 assembly.
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7.4 Drive of the 5-Phase Stepping Motor 7.4.1 Features Up till now, 2-phase hybrid stepping motors having a step angle of 1.8 have been regarded as being the highest performing motors. Compared to these motors, however, 5-phase stepping motors have the following features: (1) A small step angle (full step: 0.72°, half-step: 0.36°) achieves a resolution 2.5 times that of conventional stepping motors. As 2.
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The stator comprises 10 main poles, with two main poles in apposition forming a single phase. The coil is wound so that the two opposite main poles are the same polarity (N or S). Assuming a rotor tooth pitch of τR, the stator teeth are arranged in such a way that the stator teeth on adjacent main poles shift by 0.6 τR with respect to the rotor teeth. This means that the stator teeth on adjacent main poles shift by (0.6-0.
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7.4.3 5-phase motor drive circuit (fixed current type) The drive circuit mainly comprises the following: • microstep drive controller (IC4) • driver (IC5) • current detection resistor (R2) VDD 2 R31 1/10W1M R26 2 1/10WO 10 [HCU045] R28 1 2 1/10WO R29 1 2 12 1/10WO R30 2 1 1/10W330 1 IC2 [VCC] [GND] 13 1 R32 1 1 [HCU045] 1 11 IC2 [VCC] 14 7 [GND] 2 1/10WO 14 7 X1 2 1 BM C14 1 2 68P/50 C18 1 2 68P/50 GND GND +36V VDD VDD GND PULSEM TP13 1 2 A1 R18 1/10W4.
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7.5 Exposure Control Circuit 7.5.1 Overview [A] The exposure control circuit is comprised of the following four blocks: (1) Lamp regulator This circuit applies voltage to the exposure lamp correspondent to the duty ratio of the PWM signal. (2) CCD sensor circuit This circuit reads the amount of light from the shading correction plate. This information is used to compare the light intensity reflected from the original document and the light from the shading correction plate.
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[B] The exposure control circuit has two functions: (1) Normal mode The duty ratio of the PWM signal is controlled at 55% (lamp voltage : 61.25V). (2) Check mode Through input from the digital keys, the PWM signal output is varied from 30% ~ 70% to allow the exposure to be set arbitrarily. 7.5.2 Lamp regulator function The figure below shows a typical characteristic diagram. Control is performed so that a voltage across the lamp voltage proportional to the duty ratio of PWM signal is produced.
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7.5.4 Lamp regulator circuit The lamp regulator circuit ensures that illumination from the exposure lamp is constant. Any tendencies for variances in illumination is monitored and controlled by a series of detection and comparison circuits. Its principle control is as follows: (1) AC115V (or 220/240V) power source is rectified to provide DC160V (or 310/340V) which is used as the power source for the exposure lamp.
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(5) When the lamp drive transistor (Tr1) is turned OFF, the counter electromotive force of T1 causes current to flow along: Primary winding of transformer T1 (P) → Freewheeling diode D1 → Exposure lamp (L) → Primary winding of tranformer T1 (P) This causes continuous current I3 to flow through the exposure lamp (L) regardless of the drive transistor (Tr1) being turned ON/OFF.
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7.6 Outline of Control 7.6.1 Photo-voltaic conversion The purpose of photo-voltaic conversion is to form electrical signals corresponding to the intensity of light reflected from the original. A CCD is used for photo-voltaic conversion. CCDs are single-chip photovoltaic conversion device in which several thousands of photosensing elements several microns square are arranged in a single line. This copier uses a CCD having 7,500 of these photosensing elements.
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7.7 Automatic Original-Size Detection Circuit This circuit detects the original size (standard sizes only) using reflection-type photosensors on the base frame and lens cover of the optical unit. 7.7.1 Principle of original-size detection The reflection-type photosensors are located on the base frame and lens cover of the optical unit. Each photosensor comprises an infrared light emitting diode (LED, light-emitting side) and a phototransistor (light-receiving side).
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A5-R B5-R A4-R A5 B5 B4 A3 [A4 Series] APS-4 A5-R B5-R A5 A4-R B4 B5 A5-R APS-5 APS-1 B5-R A5 APS-2 B5 APS-6 A4-R B4 APS-3 A3 A3 LG ST-R LT-R ST LD LT [LT Series] APS-3 ST-R ST-R APS-1 APS-4 ST LT-R LG ST LT-R LG APS-2 LT LD LT LD Fig. 7.
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(4) Original size is determined by a combination of the presence/absence of the original at the each locations stated in step (3). Combination charts for size determination of A4 series and LT series are shown below. [A4 Series] APS-1 APS-2 1 beam sensor (No.) APS-3 APS-4 APS-5 APS-6 A5 A5-R A4 A4-R A3 B5 B5-R B4 : Original presence blank : Original absence : Original presence or absence [LT Series] APS-1 1 beam sensor (No.
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Supplementary comments • Concerning the reflecting photointerruptor: The reflecting photointerruptor consists of an infrared diode and a phototransistor. It detects originals by use of pulse modulation. Original 8µsec 130µsec LED Phototransistor The light emitting diode (LED) is driven by pulses with a period of 130 msec. If a signal which has the same characteristics is received by the phototransistor, an original is determined to be present.
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7.8 Disassembly and Replacement [A] Original glass (1) Remove the 2 screws and glass holder. Glass fix Note: During assembly, feed the mylar sheet under the original glass. (2) Tilt the original glass up at an angle ( 1 ), and remove in the direction of the arrow ( 2 ). 2 Glass 1 Automatic paper-size detector unit [B] Automatic paper size detector (1) Remove the original glass, and move the carriage to the feed side. (2) Remove the original width indicator unit.
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(4) Remove the APS cover (2 screws). APS cover (5) Remove the screw, disconnect the connector and remove the harness from the 3 clamps (base side). Then remove the automatic paper size detector. Clamp A4 series : 6 pcs. LT series : 4 pcs. [C] Exposure lamp (1) Move the carriage to the center. (2) Remove the reflector (Upper) (2 screws). (3) Loosen the front side screw fixing the holder. Carriage (4) Remove the exposure lamp from the blade.
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[E] Copy area indicator unit (1) Remove the rear cover. (2) Remove the top left cover. Indicator unit (3) Disconnect the connector from the relay harness. (4) Remove the 8 screws fixing the indicator unit, and then remove the indicator unit. (5) When removing the document motor, remove the 2 screws. Belt (6) When removing the belt, remove the 2 screws and the cover first. (7) When removing the shooting plate board, remove the 2 screws, leaf springs and glass first.
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[G] Optical fan (1) Remove the top left cover. (2) Remove the indicator unit, and disconnect the Optical fan 2 connectors. (3) Remove each of the 2 screws and the fan. [H] Carriage 1 (1) Remove the original glass. Connector (2) Remove the blindfold cover on the control panel and top rear cover. (3) Disconnect the power supply cable from the clamp, disconnect the connector, and remove the earth terminal (1 screw). Ground terminal (4) Move the carriage to the feed side.
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[J] Carriage 2 and carriage drive wire (1) Remove the original glass, top rear cover, top left cover, top right cover, control panel, PC Rear top frame board, 2 ADF brackets and top rear frame (9 screws). (2) Remove the top front frame (8 screws). Front top frame (3) Remove the 11 screws, 1 connector and the lens cover. Lens cover Connector (4) Remove the 4 screws, and disconnect the 7 connectors. Then, remove the scanner control PC board PC board (SLG board).
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(7) Remove the shaft cover (1 screw). (only on TWD, ASD, MJD destination models) (8) Remove the shaft and pulley assembly (1 stop ring), and remove the wire from the pulley. Notes: 1. When attaching the wire, make sure that the wire is hooked on as shown in the figure below. 2. When attaching the wire, refer to the Service Handbook. 3. When attaching carriage-1, carriage-2 and the wire, adjustment is necessary.
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[L] Lens unit Shield bracket (1) Remove the damp heater. (2) Remove the shield bracket (2 screws). (3) Remove the 5 screws, and disconnect the 2 connectors. (4) Draw out the lens unit upwards. FG clamp Notes: 1: When replacing the lens unit, do not touch the paint-locked screws (6 pcs.). (Front side) (Rear side) 2: Also, when handling the unit, take sufficient care not to hold the adjustment section and the lens.
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[M] Upper damp heater (1) Remove the lens cover. (2) Remove the 1 screw, disconnect the cable from the clamp, and disconnect the 2 relay connectors. Then, remove the upper damp heater. (3) Remove the screw fixing the damp heater for the mirror. Remove the clamp fixing the cable. (4) Remove the 2 screw fixing the cable bracket. (5) Disconnect the connector, and remove the cable. Then, remove the damp heater unit. [N] SLG board cooling fan (1) Remove the original glass and the lens cover.
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8. PRINTING 8.1 Function Outline The laser optical system functions to irradiate the photosensitive drum with a laser beam producing a latent image. The printer controller circuit generates the laser beam. The Laser drive board converts the image signals to light emissions that are ultimately sent to the laser diode for irradiation. The polygonal mirrors, the lenses, the reflective mirrors, as well as other optical elements, play a role in directing the laser beam to the photosensitive drum.
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Feed side Rear side Front side PLG PCboard Exit side Fig. 8.
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8.2 Structure (1) Laser Unit The laser unit comprises a laser diode, laser drive board, finite lens and aperture. 1 Laser diode and laser drive board The laser diode controls emission of laser beams based on the laser control (ON/OFF) signals from the laser drive board. 2 Finite lens The finite lens focus the laser beam on the surface of the photosensitive drum. 3 Aperture The aperture regulates the shape of the laser beam at the laser beam irradiation position.
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(3) Half mirror Half mirrors are used for combining and aligning to separate optical axes the laser beams that are emitted from the four laser units. The transmissivity and reflectivity of each half mirror are designed so that the laser power is the same at the point that the four laser beams are combined.
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Laser beams (4) Polygonal Mirror Motor Unit The polygonal mirror motor unit comprises a polygonal mirror and a polygonal mirror motor. Drum A 1 Polygonal mirror motor The polygonal mirror motor rotates the polygonal mirror at high speed as follows: During standby: 18608.1 rpm During copying (600 dpi): 18608.1 rpm 2 Polygonal mirror The laser beams emitted from the laser diodes are reflected by this mirror.
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(5) fθ lens 1 and 2 These lenses perform the following compensations on the laser light reflected by the polygonal mirror. 1 Equidistant scanning Wide The laser light reflected on the polygonal mirror is scanned at the same angle as the polygonal mirror is rotated at the same speed. That is, when the scan is completed, Narrow the dot-pitch on the drum becomes the wide spaces at both edges and the narrow Drum spaces in the center.
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(7) Laser drive board This drive board has the following functions: 1 APC control function (for compensating unevenness in the laser intensity caused by temperature) 2 Laser ON/OFF generating function 3 Function for generating synchronizing signals in the primary scanning direction (8) Reflection mirror The mirror reflects and guides laser light reflected by the polygonal mirror onto the drum.
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8.3 Laser Diode The laser used in this copier is an AlGaInPtype semiconductor laser. This laser outputs in the singlehorizontal mode, and its oscillation wavelength is about 685 nm. This semiconductor laser is powered by a +5VDC power supply, and its optical output is controlled to about 2.5 mW. Output of a PIN diode for monitoring light output built into the semiconductor laser is used for controlling this.
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8.4 Disassembly and Replacement [A] Laser light unit (1) Remove the FAX glass holder, original glass and left top cover. (2) Slide the carriage to the feed side, and remove the 2 fastening screws on the laser unit from the panel holes. (3) Remove the indicator screws, and remove the scanner section lens cover after sliding the indicator.
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(8) Disconnect the 4 connectors from the system board, and remove the 2 screws to draw out Connector the system electronics unit. (9) Disconnect the 2 connectors on the PLG board and realy connector of the harness from the Stay PLG board and remove the harness from the clamp. (10) Remove the unit positioning stay (2 screws). Clamp (11) Draw out the laser unit along the rail paying attention to where you are holding it.
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[B] PLG board (1) Disconnect the 4 connectors at section A (WHPLG-GLV) and section B (WH-PLG-LDR1 to 4- A 300). B (2) Turn the laser unit over to its motor side, remove the fixing screw on the PLG board, and E disconnect the connectors at section C (WHPLG-SNS1-300) and section D (WH-PLGPOL). Note: During this operation, prevent the connec- C D tor at section A from becoming disconnected.
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9. PAPER FEED SYSTEM 9.1 General 9.1.1 Functions This unit feeds paper which is set in the LCF, the cassette or the manual feed tray to the transfer position. The paper feed section is mainly comprises an aligning section, large capacity feeder (LCF) and paper feed pedestal (PFP).
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9.1.2 Motor drive circuit ■ Brush motor drive circuit • Feed motor (M32) (FED-MOT) : Driven by IC39 (LGC PC board: TA8428K) • Tray motor (M30) (TRAY-MOT) • Main cleaning motor (M11) (CLN-MOT) : Driven by IC37 (LGC PC board: TA8429H) : Driven by IC58 (LGC PC board: TA8428K) • Belt cam motor (M26) (TRB-CAM-MOT) : Driven by IC2 (LGC PC board: TA8428K) The block diagram of TA8428K is shown below.
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■ Pulse motor drive circuit (Constant voltage bipolar type) Aligning motor (M17) (RGT-MOT) is driven by 2SD1415A of Q2 to Q5 on the logic PC board. The circuit is shown below. A DC 24V ZDA A X ZDA QA B ZDB QA DA ZDB QB DA B QB DB DB 2SD1415 X 4/STA404A Construction of motor drive In the case of 2-phase excitation, AB, BA, AB, and BA will be successively excited. While transistors QA and QB are ON, current from the +24V stabilized power supply will flow into phases A and B.
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9.1.3 Detection of the remaining amount of paper ■ Paper-empty detection • When the LCF or the cassette has run out of paper, the LCF door is opened, or the cassette is removed, the “ADD PAPER” symbol ↓ lights on the display panel on the copier. ■ Detection principle • When the cassette is selected and after the START button is depressed, the tray is lifted to the feed position and makes contact with the feed rollers.
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9.2 Aligning Section 9.2.1 Introduction The aligning section aligns the leading edge of paper fed from the LCF, PFP and manual feed tray, and transports the paper to the transfer position. This section comprises an aligning roller, paper stop switch and its drive mechanisms (aligning motor). (1) Aligning roller Paper fed from the feed roller is held in contact against the aligning roller, which is at rest, to align the leading edge.
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9.2.3 Disassembly and replacement [A] Upper aligning roller Developer stay (1) Remove the aligning motor and developer stay front side and rear side 3 screws for each. (2) Remove the front E-ring, bearing and bush. (3) Slide the upper aligning to the rear, take off the rear bushing, and then remove the upper aligning roller. (4) When replacing the roller, also remove the 2 set screws, 2 E-rings, pulley, bearing, bush, Bush E-ring [Front side] gear and pin.
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[D] Lower brush (1) Remove the developer and the cleaner. After drawing out the transfer belt unit, remove the brush fixing screw. (2) Remove the lower brush in the direction of the arrow. Note: When assembling, insert the projection of the brush securely in the hole in the rear frame. [E] Aligning motor (1) Remove the flywheel. (2) Remove the waste toner transport pipe unit. (3) Remove the motor bracket (3 screws).
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[F] Paper-stop switch (1) Remove the aligning unit. (2) Remove the 2 screws and the bracket fixing the paper stop switch. (3) Disconnect the connector, remove the two hooks, and then the paper-stop switch. Aligning unit frame Actuator Note: When installing the switch bracket, install the switch bracket so that the positional relationship between the actuator and switch is as shown in the figure on the right. Switch Mounting switch [G] Aligning unit (1) Disconnect the connector on the rear side.
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(3) Slide the aligning unit to the front side and remove in the direction of the arrow. Note: When installing the aligning unit, prevent the two leaf springs from becoming bent.
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9.3 Large Capacity Feeder (LCF) 9.3.1 Introduction For making large volumes of copies, the large capacity feeder (LCF) is designed to stack about 4,000 sheets of copy paper. The LCF consists of the following three main parts: (1) Tray section 1 Elevator tray ................... The elevator tray is designed to transport the stacks of paper to the paper feed mechanism. The unit functions to keep the paper biased towards the feeding mechanism so that paper is always in contact with the feed rollers.
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3 Separation roller This roller is responsible for allowing only one copy paper to pass through during a paper feeding process. When more than one sheet of paper is present at the feed roller area, the tendency for more than one paper to feed through. The separation roller reverse-rotates and that action pushes the paper that is below the sheet that is to be fed, backwards thus not allowing it to be fed. Only the top paper is fed through.
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9.3.
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(2) Paper feeding section TB (Z105/P2) Manual pick-up roller TP20 Manual feed roller Manual pick-up solenoid Manual separation roller G20 TP30 TP20 G22 G30 LCF pick-up roller TP20 TP20 TB(Z57/P2) LCF feed roller TB(Z96/P2) TB(Z78/P3) TP20 LCF separation roller Rear side Feed motor G20 G20 TP10 TP20 G22 TP27 TB (Z110/P2) G30 TP78/G18 9 - 13 Notes : Forward rotation : Backward rotation G : Gear TP : Timing pulley TB : Timing belt Z : Number of teeth P : Pitch (mm) PAPER FEED SYSTEM
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9.3.3 Description of operation ■ Operation of elevator tray (1) When the LCF door is closed with the power ON, the tray motor rotates in a forward direction and the elevator tray rises. (2) When the paper rises it pushes the LCF pick-up roller to which the tray switch and the LCF empty switch are connected. When this happens, the motor turns OFF. (3) The LCF pick-up roller moves down 2 to 3 mm when 10 to 20 sheets are fed.
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■ Up-and-down movement of manual pick-up Manual pick-up roller roller When the manual pick-up solenoid is energized, the pick-up bracket is lowered and allows the Manual pick-up roller to also lower. When the manual pick-up solenoid is de-energized, the pick-up bracket is raised by the action of the solenoid’s spring that pulls back the lever and thus,the pick-up roller.
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■ LCF pick-up roller The LCF pickup roller remains lowered due to the force of gravity. The lower limit is fixed by the bracket. Bracket The tray height for the LCF is controlled by the trayup switch.
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(1) Manual feed • The manual feed switch detects the presence of paper in the manual feed tray. • The manual pick-up solenoid is turned ON and the manual pick-up roller is lowered. • The feed motor revolves in a backward* direction and the manual pick-up roller, manual feed roller, and manual separation roller rotate, and paper feeding is started. • The manual pick-up solenoid is turned OFF, the manual pick-up roller rises, the paper presses the paper-stop switch and is aligned at the aligning rollers.
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■ Paper separation function Since the paper cassettes do not have separation claws, a pair of rollers (feed roller and separation The direction of paper feeding Paper-feed roller roller) are used inside the machine, as shown in Fig. 9.3-1. The separation roller is connected to its shaft through a spring joint torque limiter. The feed roller Spring joint (torque limiter) is rotated in the direction of the arrow ( ) at the same timing as the pick-up roller by the feed motor.
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9.3.4 Disassembly and replacement (LCF LCF door section) [A] LCF door (1) Open the LCF door, take out the 3 screws holding the hinge, and remove the LCF door. Hinge [B] LCF feed cover (1) Remove the LCF door. (2) Remove the 5 screws. LCF feed cover [C] LCF unit (1) Open the right front cover and remove the LCF knob (2 screws). (2) Pull the LCF release lever to move the LCF unit toward the arrow in the figure. Note: Take care not to pinch your fingers.
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(4) Lift the LCF unit to remove it. LCF unit [D] LCF fornt cover (1) Remove the 4 screws and then remove the LCF front cover. Drive bracket [E] Elevator wire (1) Lower the elevator tray as for as possible, and turn the power switch OFF. (2) Remove the LCF front cover. (3) Remove the 2 screws and the lowest PFP paper feed guide. (4) Remove the 2 screws and drive bracket.
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(7) Remove the 4 clips (front and rear) fastening the elevator wire. LCF stay (8) Remove the 2 elevator wire clips each on the front and rear sides and the 4 elevator wires. Elevator wire clips Elevator wire Notes: Precautions when installing the elevator wires 1. Judging the elevator wires The longer of the 2 elevator wires is 1 (LCF door cover side), and the shorter is 2 the (LCF paper feed side). B A 2.
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3. Securing the elevator wire gears Insert elevator wire 1 into the gear groove followed by elevator wire 2 . Gear 4. Installing the gears Install so that the line formed by joining Flange the arrow marks is horizontal. If the arrow marks are out of alignment, this causes the elevator tray to be an angle. Horizontal Arrow marks [F] Tray motor (1) Disconnect the connector, take out the 3 screws, and then remove the tray motor unit. (2) Remove the 3 screws, and then take out tray motor.
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[H] Tray bottom switch (1) Raise the elevator tray, and stop at the middle. (2) Remove the 2 screws and the bottom switch unit. Bottom switch unit (3) Remove the and connector on the tray bottom switch from the tray bottom switch unit. You can Tray bottom switch Connector now remove the switch. [I] LCF switch/PFP upper paper-stop switch (1) Pull out the LCF unit. (2) Remove the handle of front side and guide lever (1 screw for each).
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(4) Disconnect the connector, take out the 2 screws, and then remove the LCF switch bracket. Take out the 2 screws, and then remove LCF switch. (5) Take out the 2 screws, and then remove the PFP upper paper-stop switch bracket. Disconnect the connector and take out the screw, and LCF switch then remove PFP upper paper-stop switch. PFP upper paper stop switch [J] Manual pick-up roller (1) Remove the clip and draw out the shaft from the holder arm by pressing down the manual pickup roller.
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Notes: Observe the following when assembling the pick-up roller, feed roller, and separation roller: 1. Mount the timing belt securely on the pulleys. 2. Mount the timing belt in the correct position. 3. Clips are to engage securely into the grooves in the shafts. 4. Check that there is no oil, on the timing Manual separation roller belt, pulley, or roller surfaces. Spring joint [M] LCF pick-up roller (1) Open the LCF door. Papar guide (2) Remove the clip and remove the weight from the front side.
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[P] Feed motor Feed motor (1) Remove the LCF unit out and remove the manual feed tray. (2) Disconnect the connector, remove the 3 screws and the timing belt from the pulley to remove the motor bracket. (3) Remove the feed motor (3 screws). [Q] Varistor (1) Draw out the LCF unit and remove the varistor (2 screws). Notes: 1. When assembling, attach the short lead directly to the paper guide. 2. Tighten the screws securely. [R] Manual pick-up solenoid (1) Draw out the LCF unit.
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(3) Disconnect the connector, take out the 2 screws, and then remove the manual pick-up Manual pick-up solenoid solenoid. Note: When assembling, fasten the screws diagonally as shown below. Solenoid Screws [S] Manual-feed switch (1) Remove the paper guide. (2) Disconnect the connector, take out the screw, Connector and then remove the switch bracket. (3) Release the 4 hooks from the switch bracket, and then remove the manual-feed switch.
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[U] LCF paper-start switch (1) Draw out the LCF unit and remove the manual feed tray unit. (2) Remove the paper guide (2 screws on the rear side). (3) Remove the screw, disconnect the connector and remove the switch bracket. (4) Unhook the 4 claws to remove the switches. [V] Manual feed tray unit (1) Draw out the LCF unit and disconnect the 2 connectors on the rear side. Connector (2) Remove the 2 screws fixing the manual feed tray unit.
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9.4 Paper Feed Pedestal (PFP) 9.4.1 Introduction The paper feed pedestal (PFP) consists of three front-loading cassettes, which can feed paper independently. The PFP consists of the following components. 1 Font-loading cassette ......... A cassette which allows paper to be loaded from the front. 2 Elevator mechanism ........... The paper in the cassette is loaded on top of the tray. The tray motor can raise tray so that the top sheet of paper in the tray is in the pick-up position. 3 Paper feed mechanism .
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PAPER FEED SYSTEM 9 - 30 Lower tray PFP lower tray-up switch PFP lower paper-empty switch Middle tray Middle elevator PFP middle tray-up switch PFP middle paper-empty switch Upper tray PFP middle pick-up roller MIddle feed clutch Upper elevator Upper feed clutch Lower elevator PFP lower pick-up roller PFP upper paper-start switch PFP upper separation roller PFP middle separation roller PFP middle paper-start switch PFP middle feed roller PFP lower aligning rollers PFP lower paper-stop switch
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9.4.3 General operation ■ Explanation of operation [A] From power-on to the ready state (1) When the copier power is switched ON, power is also supplied to the PFP. At this time, the PFP tray motors (M27), (M28) and (M29) are turned ON in the CCW direction causing each tray to start to rise. When the rising trays switch on the PFP tray-up switches (S30), (S34) and (S38) (L→H), the PFP tray motors (M27), (M28) and (M29) stop and the trays no longer move.
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(8) For multiple copying, paper is fed so as to keep the distance between the sheets of paper constant. Consequently when the previous sheet of paper is being aligned by the copier’s aligning roller, the next sheet is being fed into the transport mechanism by the PFP. When the preceding sheet is stopped, the next one is also stopped. When the preceding sheet restarts, the next one also restarts. This maintains a constant spacing between the sheets of paper.
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9 - 33 PAPER FEED SYSTEM Internal signals Signals at the copier side Signals at the PFD H L L H H L H PURGC PURGT PMRGC PMRGT PMFED PMFDC PFP PMTOP PMTRM ON OFF OFF ON ON OFF OFF ON ON OFF ON OFF ON OFF OFF ON OFF ON OFF ON OFF PSTP-SW ON (PRDY) (RSTART) (RQF) (CRUN) L 0 0.31 1.04 0.89 0.88 tray-up 0.88 brake 1.62 1.63 1.62 1.63 1.98 2.13 1.32 1.32 1.59 1.61 1.98 1.86 1.79 1.72 3.18 3.11 tray-down 2.81 3.05 2.68 2.61 2.43 2.80 3.
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Signals at the copier side Signals at the PFD PAPER FEED SYSTEM 9 - 34 Internal signals H L L H L H PURGC PURGT PMRGC PMRGT PMFED PMFDC PFP PMTOP PMTRM ON OFF OFF ON ON OFF OFF ON ON OFF ON OFF ON OFF OFF ON OFF ON OFF ON OFF PSTP-SW ON (PRDY) (RSTART) (RQF) (CRUN) L 0 0.33 1.07 1.07 0.90 tray-up 0.90 brake 1.66 1.67 1.66 1.67 2.01 2.16 2.35 1.35 1.35 1.62 1.65 2.49 2.46 2.86 2.74 2.67 3.08 3.23 3.16 3.69 3.62 tray-down 3.08 4.
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■ Abnormality detection [A] Jam detection (1) A paper misfeed in PFP is detected under the following conditions: 1 When the PFP paper-start switch (S28), (S32) or (S36) does not come ON within 1.6 seconds of the shart of paper feeding. 2 When the leading edge of the paper does not pass the PFP paper-stop switch within a constant time. (2) To clear a jam, slide the LCF unit, remove all paper from the transport mechanism and then close the front cover.
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*: Branch according to each level's PFP paper-empty switch (paper-empty detection).
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10 3 Paper feed standby PFP tray motor CCW ON PFP tray-up switch ON? Tray rises YES PFP tray motor OFF NO Have two seconds passed since the tray started to rise? YES All motors and clutches OFF Tray stops 7 NO "ADD PAPER" display Pedestal motor ON? 13 YES NO NO Have 0.3 seconds passed since the copier's CRUN signal become "H"? Have 0.
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C3 Was there a paper feed request? (Copier's RQF signal="H") Waiting for paper feeding NO Copying completed? (CRUN="L") PRDY signal goes to "L" (BUSY) YES Paper feeding completed Paper feeding Feed clutch ON PFP paper-start switch ON? Paper feeding starts Have 1.
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C4 (The ON/OFF signal for the copier's aligning motor) NO Is the copier's RSTART signal "L"? YES Aligning clutch ON PFP paper-stop switch OFF? NO YES Delay from the trailing edge of paper passing PFP paper-stop switch (PFP paper-stop switch off) until it has cleared the aligning roller.
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12 Paper feeding completed Aligning clutch ON Pedestal motor OFF PFP tray motor CW ON Tray lowers Copying started? (Copier's CRUN="H") YES PFP tray motor OFF NO NO 50 msec.
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9 Jam All motors and clutches OFF "CLEAR PAPER" flashing NO Door open? YES NO Door closed? YES PFP paper-stop switch ON? YES NO "CLEAR PAPER" goes OFF 6 9 - 41 PAPER FEED SYSTEM
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9.4.4 Configuration and drive system The paper feed pedestal (PFP) consists of the cassettes, pick-up rollers, feed rollers separation rollers, aligning rollers and their associated drive mechanisms. ● Feed motor system The PFP pick-up, PFP feed, PFP separation rollers in the cassettes and PFP aligning rollers are driven by the pedestal motor. ● Tray-up motor system Raises and lowers the trays.
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9.4.5 Explanation of operation ■ Cassette tray up-and down operation The previous paper feeding method was for the pick-up roller to lower itself on to the paper and feed at forward. With the paper feed pedestal, the paper-feed elevator mechanism raises the tray at the base of the cassette to the pick-up roller’s paper feed position to feed paper.
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• When gear 20 rotates in a CCW direction ( ), the spring loosens and gear 15 becomes free. • As gear 15 becomes free, gear 144 is pulled in a CCW direction ( elevator.
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■ PFP feed roller and PFP separation roller release operation The PFP feed roller and PFP separation roller have a releasing mechanism to enable jams to be cleared if a paper misfeed occurs with the leading edge of the paper not clear of the PFP feed roller. This releasing mechanism prevents the paper from ripping inside the copier which would otherwise happen if the cassette was removed to clear a jam with the paper held between the PFP feed roller and PFP separation roller.
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■ Cassette insertion operation When the cassette is inserted into the paper feed pedestal, the cassette latch pushes up the lever arm, lowering the PFP pick-up roller. (The roller does not lower itself onto the paper in the cassette.) Rear side PFP tray-up switch (S30) PFP paper-empty switch (S34) (S29) (S38) (S33) (S37) Pick-up arm Actuators Pick-up roller Cassette latch Lever arm Front side The cassette switches on the rear side detect whether a cassette is inserted or not.
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The PFP tray motor (M27), (M28) or (M29) turns ON and raises the cassette tray when the cassette switch detects that a cassette is installed. The pa- PFP tray-up switch PFP paper-empty switch per on the tray contacts with the PFP pick-up roller, which pushes up the roller. When the pick-up arm Actuator Pick-up roller is detected by the tray-up switch (S30), (S34) or (S38), the tray motor turns OFF and the tray stops. This position becomes the paper-feed position.
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■ Paper feed operation When the PRINT key is pressed on the control panel: • The PFP tray motor (M27), (M28) or (M29) corresponding to the selected cassette rotates to CCW direction raising the cassette tray until the paper on the tray contacts the PFP pick-up roller. At this point the tray stops.
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9.4.6 Disassembly and replacement [A] Cassettes (upper, middle, and lower) (1) Pull out the cassette, take out the 2 stopper screws, and then remove the cassette. * Repeat the procedure for the upper, middle and lower cassettes. Cassette [B] PFP feed unit (upper, middle, and lower) (1) Pull out the LCF unit. (2) Slightly draw out the cassettes corresponding to the feed units of each of the top, middle and lower cassettes from a loaded state. (3) Remove the 2 screws. (4) Pull out the PFP feed unit.
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[C] PFP pick-up roller (upper, middle, and PFP pick-up roller Preseparation roller guide lower) (1) Remove the PFP feed unit. Arms (2) Press the arm in the direction of allow ( ) to remove the PFP pick-up roller from the arm and then take off the PFP pick-up roller from the timing belt.
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(3) Slide the whole roller in the direction of arrow A, lift out one shaft and then remove the metalic roller. PFP aligning roller (metallic roller) Gear E-ring (4) When replacing the roller, remove the E-ring, gear, and pin. Pin Note: When assembling, be sure to keep to the mounting direction of the gear as shown below. Rubber roller Gear [F] E-ring PFP aligning roller (rubber roller) (upper and middle) Gear (1) Remove the metal roller. (2) Remove the spring, E-ring, and bushing on each end.
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(4) Take out the 4 screws each at the front and rear and remove the stay guide. Note: When removing the stay guide, pay atten- Stay guide tion to the harness fastening the guide. (5) Take out the screw, disconnect the connector and then remove the PFP paper-stop switch. PFP paper-stop switch Connector PFP paper-stop switch [H] PFP paper-start switch (upper, middle, and lower) PFP paper-start switch (1) Remove the stay guide.
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(3) Remove the switch cover (1 screw). Switch cover (4) Take out the screw, disconnect the connector and then remove PWA-F-PEM-700. PFP tray-up switch Connector PFP paper empty switch Note: When installing the PFP pick-up roller unit, remember to fit the spring in position. [J] Spring PFP upper aligning unit (1) Pull out the LCF unit. (2) Remove the 2 screws and pull the PFP upper aligning unit out to the paper feed side.
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[K] PFP upper aligning roller (metallic roller) (1) Remove the PFP upper aligning unit. (2) Remove the 3 E-rings, gear, pin, collar and PFP upper aligning roller (metal roller) bush. (3) Remove the E-ring and bush on the opposite end. Note: When assembling, pay attention to the mounting direction of the gear and collar.
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(5) Remove the 2 gear units (2 screws). Tray motor (6) Remove the PFP tray motor (3 screws). Motor fixing screws Gear units [N] Feed clutch/aligning clutch (upper, middle and lower) (1) Remove the rear cover. (2) Disconnect the connector. Spring PC board Bracket Aligning clutch Feed clutch (3) Loosen the setscrew holding the clutch. Pedestal motor [O] Pedestal motor (1) Remove the rear cover. (2) Disconnect the connector and then remove the 2 screws.
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[Q] PFP drive unit (1) Remove the rear cover. (2) Remove the harness from the 2 harness clamps and then the bracket (2 screws). (3) Remove the board (2 screws and 1 locking support). (4) Remove the spring from the waste toner transport pipe. (5) Disconnect the feed clutch, aligning clutch and PC board Spring Bracket Aligning clutch Feed clutch Pedestal motor Cassette switch connector cassette switch connectors (9 connectors). (6) Disconnect the pedestal motor connector.
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10. DRUM-RELATED SECTION 10.1 Construction Main charger Discharge LED Main charger wire cleaner Drum Transfer belt drive roller Transfer belt Recovery auger Transfer belt follower roller Lower damp heater Transfer belt cleaning brush Lower damp heater cover Transfer belt separation auxiliary roller In this section, the drum-related parts including the drum are described.
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10.2 Functions (1) Drum The drum comprises a drum-shaped, Aluminum base coated with an organic photosensitive element (photoconductor) film. The principle of “Photoconductivity” indicates that insulating properties of the material are evidenced in the dark. Likewise, its conductive properties are evidenced in the presence of light. (2) Main Charger The main charger is configured by stretching a special wire between two insulation blocks provided at both ends of a u-shaped metal bracket.
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10.3 Disassembly and Replacement Thermistor bracket Connector [A] Drum (1) Remove the cleaner unit (Refer to 13.3 [A].). (2) Disconnect the connector from the drum thermistor. Drum thermistor (3) Remove the thermistor bracket (1 screw). (4) Rotate the cam until it locks. (5) Remove the 2 drum shaft fixing screws. Cam (6) Draw out the drum shaft from the front side. (7) Remove the drum by lifting it up. Drum [B] How to replace the drum (1) Remove the drum. (2) Remove the 3 screws.
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(3) Remove the front flange. Front flange (4) Draw out the drum upwards. Drum [C] Main charger (1) Remove the middle inner cover. (2) Remove the screw, and draw out the main charger to the front side.
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[D] Charger wire • Main charger: 398mm long, 0.06mm dia., tungsten oxide wire Grid Grid cover Remove the grid cover Main charger Wire terminal (Small) Terminal (main charger) Charge wire Wire terminal (Large) Wire cleaner V-groove Charge wire Spring V-groove Terminal (1) Remove the grid cover, grid and terminal cover, and then remove the charger wire from the main charger. Installation Precautions 1.
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[E] Transfer charger wire cleaner (1) Remove the main charger wire. (2) Remove the wire cleaner (1 screw). Note: During assembly, make sure that the charger wire passes through the pads. Pad Wire cleaner Charger wire Wire cleaner [F] Main charger timing belt Tension pulley (1) Loosen the screw securing the tension pulley to remove the timing belt. Notes: 1.
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[G] Main charger guide unit Connector (1) Remove the center inner cover and the right inner cover. (2) Remove the main charger and cleaner. (3) Disconnect the connector, remove the screw and remove the main charger guide unit. [H] Main charger cleaning motor (1) Remove the main charger guide unit. Main charger cleaning motor Connector (2) Remove the connector, and remove the charger cleaning motor unit (2 screws). (3) Remove the motor (2 screws).
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[J] Discharge LED (1) Remove the stopper bracket (1 screw), and disconnect the connector. (2) Draw out the discharge LED. Connector [K] Ozone filter (1) Remove the upper exit cover. Ozone filter (2) Unlock the claw lock, turn the knob and draw out the ozone filter. (3) Remove the ozone filter from its holder. Ozone filter [L] Ozone filter unit (1) Disconnect the 2 connectors, remove the 2 screws, and remove the ozone filter unit.
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[M] Slot exhaust fan motor/exit fan motor (1) Remove the exhaust fan duct (2 screws). (2) Remove the slot exhaust fan duct (2 screws). (3) Remove each of the 2 screws. Note: When installing the slot exhaust fan motor and the exit fan motor, install in the direction shown in the figure. [N] Reversal Fan Motor (1) Open the exit door and draw out the ADU unit. (2) Remove the reversal fan motor bracket (2 screws, connector).
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(3) Remove the reversal fan motor from the bracket (2 screws). Note: Attach the reversal fan motor in the direction shown in the figure.
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11. TRANSFER/TRANSPORT UNIT 11.1 Construction This section describes the belt transport unit excluding the fuser unit.
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11.2 Description of Operation 1 While the copier is ready, the transfer belt stands by at a position separated from the photosensitive drum. 2 When printing is started, the transfer belt is controlled to rise, and is held in contact against the photosensitive drum. 3 Voltage from the high-voltage transformer unit is applied to the transfer belt via the power supply roller.
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11.3 Functions (1) Transfer belt unit The transfer belt is coated with a high-precision flat rubber belt and has electrical resistance. The transfer belt unit is divided into a belt support/power supply section and a cleaning mechanism. The belt support/power supply section supports the belt and rotates to supply power, and the cleaning mechanism scrapes of toner from the belt surface. (2) Transfer belt support/power supply mechanism As shown in Figure 1, the transfer belt is supported by four rollers.
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(8) Belt transport unit lock/unlock mechanism The belt transport unit is locked inside the copier. It is structured in such a way that it is locked when a paper jam is cleared, and can be drawn out towards you. The belt transport unit has a function for separating the transfer belt from the drum and a function for preventing erroneous operation of the handle when it is drawn out. • When the handle is rotated left when viewed from the front, the belt transport unit can be drawn out horizontally.
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11.4 Display and Replacement [A] Belt transport unit Grip (1) Rotate the handle to the left, and draw out the belt transport unit. (2) Remove the fuser unit (1 screw) (When the lower damp heater is attached, disconnect the rear connector.). (3) Remove the 2 stepped screws (blue). (4) Lift up the belt transport unit holding it by both grips.
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(4) Remove the 2 rear bearing bracket fastening screws and the 2 casing fastening screws. (5) Draw out the transfer belt unit upwards on the 1 front side. Notes: 1. During assembly, fasten the screws in order 1 , 2 and 3 . 3 2 2. When assembling the transfer belt unit, make sure that the front lever of the transfer belt unit fits under the cam on the front frame.
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(3) Rotate the drive roller in the direction of the arrow in the diagram. (4) Draw out the transfer belt. Notes: 1. Attach the belt so that the belt travels along the center of the inside of the housing. 2. Do not touch the belt surface directly with your hands. 3. The drive roller support bracket fastening screw on the front side is also used for connecting the earth lead. Pay attention to the direction of the terminal. 4.
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[E] Brush (1) Remove the transfer belt support/power supply mechanism from the transfer belt unit. 2 1 (2) Remove the short transport guide fastening screw, and slide the transport guide. Then, draw out the transport guide upwards. (3) Remove the front stop ring and the 3 gears. c b Note: a and c have claws. Remove in order a, b and then c. a (4) Remove the stop ring on the rear brush axis and pull out the bushing.
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[G] Transfer belt drive unit (1) Remove the main unit rear cover. (2) Disconnect the connector from the transfer belt motor. (3) Remove the 2 screws, and transfer belt drive unit. [H] Transfer belt contact/separation cam drive unit (1) Remove the main unit rear cover. (2) Remove the flywheel (3 screws). (3) Remove the toner transpor t auger unit (5 screws). (4) Disconnect the harness connector for the cam motor and sensor.
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[J] Mounting the lower damp heater (1) Remove the transfer belt unit. (2) Remove the transport guide (1 screw). (3) Attach the lower damp heater unit on the base of the belt transport unit (3 screws). (4) Attach the lower damp heater cover (2 screws). (5) Pass the damp heater harness through the M band on the belt transport unit, and attach locking supports (1 pc. to the rear frame and 2 pcs. to the base frame).
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12. DEVELOPER UNIT 12.
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12.2 Construction 12.2.1 Developer unit The developer unit consists of the lower and upper developer sleeves (magnetic rollers), leveler, autotoner sensor, supply/recovery paddle, separation auxiliary member, mixing unit, etc. The developer material is poured into the developer unit.
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(4) Lower and upper developer sleeves (magnetic rollers)/transport roller (magnetic roller) These parts are made of aluminum, with magnets positioned inside them. By using the magnetic force, the developer material is attracted (because the carrier is made of iron powder), forming magnetic lines of force shaped like a brush. Further, the magnets are secured, and only the sleeves around them rotate.
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12.2.2 Toner hopper unit When there is little toner left in the toner hopper, this status is detected and the “ADD TONER” symbol flashes. The principle is as follows. Toner hopper Sensor lever Magnetic sensor (Toner empty switch) Magnet 1 As shown in the left figure above, there is a sensor lever on the inside of the toner hopper. The lever is fitted with a magnet.
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12.
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Developer Unit Drive Motor shaft G10 Idle gear G48 P25 Idle gear P25 G25 Copier rear side drive Paddle Developer unit Drive input gear G27 Rear side Mixer 1 G24 Mixer 2 G45 Idle gear G24 Rear side gear G31 Lower and upper magnetic rollers G17 Idle gear G19 Transport roller G23 G45 Front side gear G18 DEVELOPER UNIT Idle gear G20 12 - 6 Front side
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12.4 Motors 12.4.
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[B] Developer motor drive FG pulse +24VA Wave shaping DEVCK Reference requency V-phase Phase comparator Difference Voltage detection circuit Speed comparator Difference Control signal DEVON Rotation control U-phase Excited phase switching unit W-phase A C B Developer motor (M13) Roter position detector A, B, C: Hall element (1) The LGC transmits control signals for the developer motor rotation (DEVON: motor rotation command).
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[C] Control signals (1) DEVCK signal (LGC→DEV-MOT:input) This signal is a reference clock signal for the developer motor to rotate at a fixed speed. The frequency of the reference clock is 821.2Hz. When the cycle of FG pulse deviation from the reference frequency is within ±6.25%, this state is specified as lock range (normal rotation). Also, at this time, the LED “LP1” light comes ON. (2) DEVON signal (LGC→DEV-MOT: input) This signal is the motor ON/OFF control signal.
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12.4.2 Brush motor (toner motor (M14)) drive circuit The toner motor is provided to supply toner for the developer unit. The toner motor is driven by transistor 2SD1415 (Q1 on the logic PC board), and its circuit is structured as follows. +24 VDD Gate array PH4 Q29 D1 Toner motor 142 TNRMT R213 Q1:2SD1415 IC48 R236 The motor winding is connected to the +24V at its (+) side and to the collector of Q40 at its (–) side.
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12.5 Auto-Toner Sensor Circuit 12.5.1 Brief description • Functions of auto-toner circuit. •  ~  • Detects the density of the toner in the developer material Density drops → toner supply. • •  • • Auto-toner sensor: Detects toner density. Control section: Control to maintain the toner in the developer material at a constant specific Detects that the toner in the toner hopper has been used up (toner-empty). • Configuration of auto-toner circuit. density.
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12.5.2 Operation of auto-toner sensor (1) Functions of auto-toner sensor. 1 Initialization function: -When the copier is set up or when the developer material is replacedAutomatic or semi-automatic adjustment is made so that the output of the auto-toner sensor (input value of the main CPU) will be 2.45 to 2.55V for the toner density of new developer material.
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-When the toner density is low  Iron powder (carrier) in the developer material ..... much    Toner in the developer material ............................. little →Magnetic resistance: small→detection output: large→auto-toner output VATS: large -When the toner density is high     Iron powder (carrier) in the developer material ..... little Toner in the developer material .............................
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12.6 Disassembly and Replacement Connector [A] Developer unit (1) Remove the upper inner cover. (2) Tu r n t h e d eve l o p e r u n i t s l i d e l eve r counterclockwise. (3) Disconnect the 1 connector. Developer unit (4) Pull the developer unit toward the front. Developer unit [B] Developer material (1) Remove the developer unit. (2) Remove the top cover (2 screws). Top cover (3) Completely remove the old developer material while rotating the gear on the rear side plate.
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(4) Fill with new developer material. Developer material (5) Rotate the gear several times to distribute the developer material evenly. (6) Install the top cover. Note: When installing the top cover, position it securely on its hooks and be sure not catch Top cover the urethane seal.
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[C] Guide roller (1) Remove the developer unit. Handle (2) Remove the developer unit handles (2 screws). Guide roller (3) Remove the E-ring and then the spring. (4) Remove the 2 E-rings and both the front guide Upper guide roller (Gray) rollers from the magnetic roller shaft. Note: Pay attention to the color of the rollers when assembling the upper and lower guide rollers. E-ring E-ring Lower guide roller (Blue) Spring (5) Remove the E-ring and then the gear.
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[D] Developer magnetic roller Front side plate (1) Remove the developer material. (2) Remove the E-ring and then the spring. (3) Remove the front guide rollers. (4) Remove the front side plate (3 screws). (5) Remove the 2 fixing screws on the front magnetic roller holder. Magnetic roller holder (6) Remove the rear side plate (4 screws). Magnetic roller (7) Remove the 2 fixing screws on the rear magnetic roller holder.
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(10) Remove the 2 pushers. Pusher E-ring (11) Remove the 2 E-rings and 2 gears. (12) Remove the magnetic roller holders from the front and the rear sides. Magnet roller holder Gear E-ring (13) Remove the 2 seals the 4 shield bushes on both ends of the developer roller, scraper, and the Shield bush upper and lower magnetic rollers. Seal Scraper Seal Transport roller [E] Transport magnetic roller (1) Remove the upper and lower developer roller sub unit. (2) Remove the front gear and the E-ring.
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(3) Remove rear side screw, and then the transport roller and pole fixing bush. Pole fixing bush Transport roller (4) Remove the front side bearing and transport roller. [F] Leveler (1) Remove the top cover. Leveler (2) Remove the 2 screws and then the leveler. Note: When installing the leveler, both ends of the leveller must be contacting the protrusions on the front and rear side frames (2 screws). [G] Auto-toner sensor (1) Remove developer material.
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[H] Oil seal (mixer section) (1) Remove the rear side plate. Gear (2) Remove the 2 E-rings and 2 gears. E-ring (3) Remove the 2 screws and draw out the nozzle mixer. Nozzle mixer Bush (4) Remove the 2 E-rings and 2 bushes. E-ring (5) Remove the 2 oil seals from the nozzle mixer with the C-ring pliers. Nozzle mixer Oil seal (6) After removing the 2 bearings with the C-ring pliers, remove the 2 oil seals.
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Notes: Assembling the oil seal Developer unit frame (Nozzle mixer) Outside 1. Push the new oil seal in parallel to the mounting holes of the developer frame (or the nozzle mixer). * Pay attention to the direction that the oil seal is assembled (See figure on right). Grease Inside 2. Apply a uniform coating of grease to the inside surface of the oil seal. Oilseal • Amount: 2 large drops • Grease: Alvania No.2 3. Wipe off any surplus grease that oozes out from inside.
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(3) Remove the E-ring and then the rear paddle bush. (4) Remove the gear and then the E-ring. Paddle bush (rear side) (5) Remove the front paddle bush. E-ring Paddle bush (front side) E-ring (6) Remove each of the oil seals pressure-fitted into the paddle bushes on the front and rear Oil seal sides. Note: The oil seal installation follows the description in previous item [H].
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(4) Remove the oil pressure-fitted into the front side frame. Note: The oil seal installation follows the descrip- Oil seal tion in previous item [H]. [K] Toner hopper unit Connector (1) Remove the rear cover and right top cover. (2) Disconnect the connector. (3) Remove the 3 screws. Toner hopper unit (4) Press the toner hopper unit towards the rear side to release the hooks, and then lift the rear side up at an angle to remove.
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[L] Toner motor (1) Remove the toner hopper unit. Connector Toner motor (2) Disconnect the toner motor connector. (3) Remove the motor bracket (3 screws). Motor bracket (4) Remove the toner motor (2 screws). Toner motor [M] Toner-empty switch (1) Remove the toner hopper unit. Toner empty switch (2) Take out the screw, disconnect the connector, and remove the toner-empty switch. Connector [N] Toner-supply cover switch (1) Remove the switch cover (1 screw).
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(2) Disconnect the connector and remove the toner-supply cover switch. Toner-supply cover switch Connector [O] Toner-transport auger unit (1) Remove the upper feed cover. (2) Remove the developer unit. (3) Remove the toner hopper unit. (4) Draw out the large capacity feeder. (5) Remove the 2 screws. Toner transport auger unit [P] Developer motor (1) Remove the rear cover. Connector (2) Disconnect the developer bias connector and remove the duct (2 screws).
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(4) Remove the developer motor (2 screws). Developer motor [Q] Developer switch (1) Remove the right inner cover and the developer unit. Connector (2) Disconnect the connector and take off the harness from the harness clamp. (3) Remove the switch bracket (1 screw). (4) Disconnect the 2 connectors, and unscrew the screw and then remove the switch. Connector Developer switch [R] Toner filter unit (1) Remove the rear cover.
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[S] Laser fan unit (1) Remove the cover behind the hopper (2 screws). (2) Remove the 3 screws and disconnect the connector. Connector (3) Remove the 2 screws and the panel cover. (4) Draw out the fan. [T] Replacing toner filter (1) Remove the feed cover. (2) Remove the screw and the filter cover.
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(3) Draw out the toner filter.
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13. CLEANER UNIT 13.1 Construction The cleaner unit consists of a driver section, cleaning section, waste toner carry section, fur brush, toner adhesion amount sensor, separation claw, toner full switch and toner bag.
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Fur brush Main blade Toner adhesion amount sensor Drum thermistor Separation claw Recovery blade 13.2 Description of Functions (1) Main blade Scrapes off residual toner on the drum surface. The blade is pushed against the drum at a constant pressure by a weight. The main blade is separated from the drum by manually turning the lever. (2) Recovery blade Catches the toner after it is scraped off by the main blade.
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Toner transport auger Toner-full switch Spring Drum 1 2 Toner bag The weight of the toner pulls the toner bag down against the spring in direction of arrow 1 . Separation claw Paper When the toner bag drops the actuator also lowers in the direction of arrow 2 , turning the toner-full switch OFF. (7) Toner adhesion amount sensor Measures the relative reflectivity of the toner image on the drum to maintain the image density at an appropriate value.
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13.3 Drum Temperature Detection Circuit C5 +15 +15 R12 J60-1 TH R13 (Thermistor) R14 C10 R16 6– IC2 5+ 7 B R3 R11 E R2 R4 R5 2 – 3 +IC2 C2 1 J59-B1 DRM-TMP C9 R1 J60-2 Drum Temperature Detection Circuit (1) Temperature sensor In this detection circuit, the voltage obtained by R12, thermistor, R13 and R14 passes through the operation amplifier IC2 to be taken as input voltage B . Input voltage B is applied to pin No.
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13.4 Control for Maintaining Image Quality Using a Toner Adhesion Amount Sensor 13.4.1 Outline The toner adhesion amount sensor performs the following functions: • Controls the image formation conditions to an optimum state so that image density and line width can be maintained under varying environments and throughout the service life of the machine. • Detects the density of the test pattern developed on the drum.
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13.4.3 Outline of control Start of Control (Control is executed during the pre-run after the power is turned ON.) [1] The reference image formation conditions are set. [2] The sensor light source is adjusted. [6] [3] The test pattern is exposed. [4] The value of the toner adhesion amount sensor is read. [5] The result is judged. (Control judges whether or not the toner adhesion amount of the test pattern is within the permissible range.) When the result is judged as GOOD.
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13.4.4 Configuration • Toner adhesion amount sensor Emits light corresponding to the light intensity control voltage onto the drum, and outputs a voltage corresponding to the reflected light intensity of the drum or the toner image on the drum. • D/A converter Outputs the light source intensity control voltage. • Laser optical system Exposes the test pattern for forming the toner image. • A/D converter Converts the voltage values output from the sensor to digital values before they are read.
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13.5 Disassembly and Replacement Handle [A] Cleaner unit (1) Remove the main charger and the developer unit. (2) Disconnect the 2 connectors, and remove the Gear 2 screws. (3) Draw out the cleaner unit by holding the han- Cleaner unit dle. Notes: 1. The cleaner unit is heavy. Take care not to drop it. 2. When installing the cleaner unit, make sure that the cleaning unit gear is engaged with the gear on the rear of the toner auger motor pulley before you secure it. [B] Main blade (1) Remove the drum.
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[C] Recovery blade (1) Remove the recovery blade. Recovery blade Notes: 1. The recovery blade is secured by double-sided adhesive tape. Make sure that the tape is completely removed before Recovery blade securing the new blade. 2. When installing the recovery blade, press the edge of the recovery blade against the stepped section of the cleaner frame, A and fix at point A making sure that there is no gap.
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(2) Disconnect the sensor connector, and remove the 2 mounting screws. [F] Separation claw (1) Remove the cover (2 screws). Cover (2) Remove the E-ring, and remove the cam. Cam (3) Slide the separation claw unit to the front side to draw it out from the bushing on the rear side, and draw out the unit to the rear.
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(4) Remove the 3 screws, and draw out the 2 separation claws from the shaft together with the stopper and paper guide. Separation claw Stopper Paper guide [G] Drum thermistor (1) Disconnect the connector, and remove the Thermistor bracket Connector screw. (2) Cut the bundling band. Drum thermistor [H] Toner auger motor (1) Remove the cleaner unit. (2) Remove the left inner cover.
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[I] Scraper solenoid unit (1) Remove the rear cover, and disconnect the connector. (2) Remove the carry belt unit. Note: Take care not to scratch the transfer belt. (3) Remove the toner auger motor. (4) The solenoid unit can be removed when the 2 unit mounting screws on the rear frame are removed from the front side. (5) Remove the separation claw solenoid (2 screws, connect, bundling band). Note: During assembly, move the separation claw solenoid in the direction of the arrow, and secure.
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(2) Remove the motor bracket (3 screws, connector) and remove the harness from the clamp. Note: When installing the motor bracket, press in A clockwise (direction of arrow A ) and secure. (3) When replacing the motor, remove the 3 screws and remove the harness from the edge saddle. Note: When installing the motor, pay attention to the position of the harness with respect to the metal plate. [K] Toner bag Toner bag cover (1) Remove the 2 coin screws and open the toner bag. (2) Draw out the toner bag.
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[M] Toner transport auger unit (1) Remove the 5 screws securing the toner transport auger unit. (2) Disconnect the transport auger motor. [N] Toner transport motor (1) Remove the toner transport motor (2 screws). Note: Adjustment of the main blade, recovery blade and fur brush cleaner unit is not necessary.
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14. FUSER UNIT 14.1 General Description Cleaning roller 1 Cleaning roller 2 Upper heat roller Upper thermistor Upper separation claw Thermostat Heater lamp Heat roller guide Exit roller Exit switch Discharge brush Lower separation claw Lower thermistor Cleaning roller 3 Cleaning roller 4 Lower heat roller Fig. 14.1-1 Heat and pressure are applied to fuse the toner to the paper, which is separated from the drum after the transfer process.
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14.3 Functions (1) Heater lamp Two halogen lamps are provided inside the upper heat roller to heat the upper heat roller. The heater lamp stays fixed even when the upper heat roller is rotating. (2) Upper heat roller The upper heat roller is made of aluminum having comparatively good heat conducting properties. It is heated by the heater lamps. The upper heat roller is held in contact with the above-mentioned lower heat roller.
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(9) Exit roller After the paper is separated by the separation claw, the paper is output to the copy tray by the exit roller of the fuser and the exit roller of the reversal unit. (10) Exit switch This switch detects arrival of the leading edge or trailing edge of the transfer paper at the exit roller of the fuser. It is used for detecting paper jams in the fuser output section. (11) Upper heat roller No.
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14.4 Heater Control Circuit 14.4.1 Temperature detection unit To maintain the heat roller temperature, this unit detects the heat-roller temperature by thermistor-1, and then performs heater lamp ON/OFF control. • The thermistor is an electrical element whose resistance decreases as its detected temperature increases. If the thermistor is open-circuited, the control circuit erroneously determines that the fuser temperature is extremely low and continues to energize the heater lamp.
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Reference 1. A value other than 0, 1, 2, 3, 4, 5, 6, 7, 8 or 9 is never written in the Thermistor status counter. • At the power on, if the heater is not turned ON and the copier goes into C41 CALL SERVICE, check the Thermistor status counter to see if it is 2 or more. If it is 2 or more, be sure to check the thermistor and heater lamp, and after repair, reset the Thermistor status counter (08-code 400) to 0 and then turn ON the power switch.
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14.4.2 Detection of thermistor burnout * Since thermistor burnout detection circuits of the thermistor-1 and -2 are common, it is explained with the thermistor-1. • The input voltage is obtained by voltage dividing +5 R165, thermistor, R170 and R174. • The surface temperature of the heat roller R165 changes. → The thermistor resistance value changes Thermistor-1 HTRTHR170 Main Processor → The input voltage also changes • The main processor detects an abnormality → thermistor broken C125 R174 14.
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14.5 Heat-Roller Motor Drive 14.5.1 Outline of operation FG pulse +36A Wave shaping Phase comparator Difference V Reference requency (H-MOT-REF) Control signal Voltage detection circuit Speed comparator Difference HTR MOT HTR MOTL Rotation control Excited phase switching unit U W A B C Roter position detector Heat roller motor M/DC-HTR-300N U, V, W: Phase A, B, C: Hall element Fig. 14.
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14.5.2 Control signals (1) HMOT-REF signal (LGC → MOT:Input) This signal is a reference clock signal for the heat roller motor to rotate at a fixed speed. The frequency of the reference clock is 1247.6Hz. (2) HTRMOTL signal (LGC → MOT:Input) This signal switches low-speed heat-roller motor rotation ON/OFF. When the signal is “L”, the heat roller rotates at a low speed. (3) HTRMOT-ON signal (LGC → MOT:Input) This signal is the heat-roller motor ON/OFF control signal.
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14.6 Disassembly and Replacement [A] Fuser unit (1) Draw out the belt transport unit. Belt transport unit (2) Remove the screw. (3) Disconnect the connector from the rear side of the fuser unit (115V/230V). (4) Draw out the fuser unit to the front by about 6 mm, and lift up horizontally to remove. Note: The fuser unit must be held by holding the handles on the front and rear sides. * Replacement of parts on the fuser section is described assuming that the fuser unit has been removed.
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(4) Remove the shaft and 3-stage gear. (5) Remove the cleaning roller 1 and the cleaning roller 2. Front side Shaft Bush Cleaning roller 2 Bush E-ring Gear 22 E-ring E-ring Pin Bush Bush Cleaning roller 1 Rear side E-ring Front side [C] Upper thermistor and thermostat (1) Remove the front cover, rear cover and fuser unit guard. Clamp Thermostat bracket Drawer connector (2) Remove the drawer connector bracket (1 screw). (3) Disconnect the thermistor connector, and remove the 3 harness clamps.
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2. When removing the 2 upper thermistors and thermostats, prevent the heat rollers from becoming scratched (Wind paper onto the heat rollers as shown in the figure on the right.). Paper [D] Lower thermistor (1) Remove the harness cover (1 screw). (2) Remove the lower thermistor (1 screw). Lower thermistor Harness cover [E] Upper separation claw (1) Remove the jam release unit (1 screw on the front side).
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(2) Remove the upper separation claw unit (1 screw on the front side). Notes: 1. When fixing screws onto the shaft, make sure that the D cut section of the shaft fits into the D cut hole on the bracket. 2. The separation claw positions can be moved 3 mm each to the front and rear by the position of the E-ring on the shaft (Before the copier is shipped from the factory, the E-ring is at the center groove.). Before the copier is shipped from the factory, the E-ring is at the center groove.
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(2) Remove the spring and lower separation claw. (3) Cleaning roller 4 opens together with the lower separation claw unit. Cleaning roller 4 is attached to the lower separation claw unit via bushes and springs. Cleaning roller4 Lower separation claw Spring [G] 2 heater lamps (1) Remove the front lamp bracket (1 screw). Connector (2) Disconnect the 2 connectors from the front heater lamp. Lamp bracket (3) Remove the drawer connector bracket (1 Lamp bracket screw).
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2. The wattage of the 2 lamps is different. Make sure that the lamp having the correct wattage is attached by aligning the lamp with the holes on the heater lamp bracket. 3. Do not directly touch the glass sections of the lamps, and leave fingerprints or 6 7 other marks. 6 7 [H] Upper/lower heat roller and cleaning roller 3 (1) Remove the fuser unit guard and jam processing unit. (2) Draw out the 2 heater lamps. (3) Completely loosen the 2 screws fixing the pressure springs.
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(9) Remove the rear handle bracket (2 screws). (10) Remove the 2 rear screws and take out the Rear handle bracket (9) bearing. (9) (10) (10) Bearing (11) Slide the upper heat roller to remove as shown the arrow A . Notes: 1. Take care not to deform the lead spring on the upper thermistor. Paper A Upper heat roller 2. Wind paper onto the heat roller taking care not to scratch the heat roller. (12) Open the lower separation claw unit (2 screws). (13) Open the lower inlet guide unit (2 screws).
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Notes: Precautions during Replacement 1. Make sure on the front and rear sides that the bearing of the lower heat roller fits into the pressure lever. 2. Take care not to bump and scratch the surface of the heat roller against the bracket or other parts. 3. Take care not to scratch the thermistor. 4. Make sure that the screws of the pressure springs are firmly fastened (2 loca- Bearing Pressure lever tions).
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(2) Remove the 2 stop rings, screw, handle, gear and 2 pins. Then draw out the shaft to replace the exit roller. Gear Stop ring Gear Handle Stop ring Screw,spring Pin Handle Stop ring Stop ring Pin Bush Bush Pin Spring Screw Rear side [J] Front side Exit switch (1) Remove the front cover (2 screws). (2) Disconnect the connector. Claw (3) Release the claw from the bracket, and remove the exit switch. Connector [K] Heat roller motor (1) Remove the rear cover.
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(4) Disconnect the connector from the heat roller motor PC board. Heat roller motor PC board (5) Remove the motor (3 screws). Connector Heat roller motor [L] Heater fan motor (1) Remove the system electronics unit. Connector (2) Remove the screw and disconnect the 2 connectors, and then remove the heater fan duct in the direction of the arrow. (3) Remove the rear side cover. (4) Remove the connector cable bracket (2 screws). (5) Disconnect the motor connector.
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Heater fan (7) Remove the heater fan motor from the bracket (2 screws). Note: When assembling, the direction of the arrow on the blow out side of the heater fan motor must be as shown in the figure on the right. [M] SSR for the upper heater lamp (1) Remove the protective cover (3 screws). (2) Disconnect the 4 connectors, and remove each of the 2 screws to remove the SSR. Note: Wiring is as follows.
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15. AUTOMATIC DUPLEXING UNIT (ADU) 15.1 Introduction The Automatic Duplexing Unit (ADU) is a device for automatically making copies on both the front and rear sides of paper. The ADU also has a stack function that allows up to 60 copies to be made on both sides of the paper in a single operation. In other words, the stack function operates to make copies on the rear side for the number of sets specified when making multiple sets of copies, and stacking these sets. Up to 60 sheets can be stacked.
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Drum ADU/exit switching gate Aligning roller Fuser Exit roller ADU inlet/reversal roller Separation belt Stack section Holding gate Aligning roller Pick-up roller Transport roller Feed roller ADU 15 - 2 Transport guide
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15.2 Drive Holding gate Inlet/reversal roller Reverse rotation clutch Forward rotation clutch Drive motor Transport roller A Feed clutch Transport clutch Aligning clutch A Aligning roller Pick-up roller Separation belt Feed roller 15.2.1 ADU/exit switching gate drive When the gate solenoid turns ON, the link is pulled (arrow 1 ), the arm rotates (arrow 2 ), the gate opens, and the copied 3 paper is transported to the ADU stack section.
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15.2.2 Stack guide drive Paper side guide Paper trailing edge guide (1) Paper side guide The width guide motor operates in accordance with the size of the selected paper to move the paper side guide to the specified position. With each five sheets of paper stacked on the stack section, the width guide motor moves the side guide to the left and right to align the paper.
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15.2.4 Holding gate drive When the flapper solenoid turns ON, the projection on the spring clutch becomes disconnected and Holding gate rotates. When the flapper solenoid turns OFF, the projection on the spring clutch stopped by the flapper solenoid to stop rotation. Spring clutch Flapper solenoid 15.2.5 ADU pick-up roller, ADU feed roller and ADU separation belt drive Feed clutch • When the ADU feed clutch turns ON, the ADU feed roller and ADU pick-up roller rotates.
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15.3 Description of Operation 15.3.1 Paper stack operation ADU/exit switching gate Reversal sensor ADU inlet guide ADU inlet roller Pick-up roller Holding gate Side guide Stack section Empty switch When the double-sided copy mode is selected on the copier’s control panel, and the COPY button is pressed, the paper side guides and paper trailing end guide on the ADU stack section move to the positions corresponding to the selected paper size by respective motor drive.
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15.3.2 Duplex copy (re-feed) operation ADU/exit switching gate Exit roller Aligning roller Separation belt Holding gate ADU feed switch ADU aligning switch ADU aligning roller Position detection switch 1 Pick-up roller Position detection switch 2 ADU feed roller When the first sheet of paper is stacked, the pick-up roller located on the bottom side of the stack section rotates by the ADU feed clutch to feed paper out to the ADU feed roller section.
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1) The ADU feed switch detects the leading and trailing edges of the paper passing through the ADU feed roller. It is also used for detecting paper jams. 2) The ADU aligning switch detects the leading and trailing edges of the paper passing through the ADU aligning roller. It is also used for detecting paper jams. 3) The ADU position detection switch 1 and ADU position detection switch 2 switch detect the leading and trailing edges of the paper passing through the ADU transport roller.
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15.3.3 Reversal exit operation Reverse guide ADU/exit switching gate Exit roller Reversal gate Aligning roller Reversal switch Inlet/reversal roller Solenoid Reverse direction clutch ADU feed guide In the double-sided copy mode, the reversal exit operation is carried out when the second side is output if the following conditions are met: Conditions: The 1st of several copies of two or more odd-numbered originals made in the one-sided and double-sided modes using the ADF. Or, when one copy is made.
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15.4 Disassembly and Replacement [A] Removing the ADU covers [A-1] Removing the ADU front cover Stop ring Upper guide cover [A-2] (1) Draw out the ADU from the copier. (2) Remove the screw fixing the rotation knob, and [A-2] then remove the rotation knob. (3) Remove the 3 screws fixing the ADU front cover. (3) (3) (4) Remove the upper guide cover fastened by the stop ring. [A-2] Removing the ADU feed cover (1) Remove the 2 screws fixing the ADU feed cover.
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[C] Width guide motor and width guide switch (1) Remove the stack guide unit. (2) Disconnect the connector, and remove the 2 Length guide switch Width guide switch Position detection switch1 screws. (3) Remove the 2 screws fixing the width guide motor to remove the width guide motor. (4) Disconnect the connector, and release the switch claw from the bracket to remove the width guide switch.
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[F] Pick-up roller guide unit (1) Remove the stack guide unit. (2) Remove the 4 screws fixing the pick-up roller guide to remove the pick-up roller guide. [G] Pick-up roller (1) Remove the pick-up roller guide unit. (2) Remove the 3 clips fixing the pick-up roller, clutch and pick-up roller. [H] Transport clutch (1) Remove the ADU front cover. (2) Remove the stack guide unit. (3) Remove the pick-up roller guide unit. (4) Remove the 2 screws fixing the clutch guide and then the clutch guide.
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[I] Transport roller 2, 3, 4 2 3 4 (1) Remove the PC board. (2) Remove the front E-ring and bush. (3) Remove the rear E-ring, pulley pin and belt. (4) Remove the E-ring and bush and then the transport roller. The transport roller 2 and 3 are same parts. [J] Transport roller 1 (1) Remove the front clutch guide and the transport clutch. (2) Remove the front E-ring and bush. (3) Remove the 3 screws fixing the rear connector bracket, and then remove the connector bracket.
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[L] ADU drive unit (1) Disconnect the 2 connectors. (2) Remove the 5 screws fixing the ADU drive unit and then the ADU drive unit. [M] Feed clutch and aligning clutch (1) Remove the ADU drive unit. (2) Remove the bracket (2 screws). (3) Remove the 4 bushes. (4) Remove the E-ring, gear and pin. (5) Remove the feed clutch and the 2 set screws fixing the aligning clutch. Then, remove the feed clutch and aligning clutch.
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(7) Remove the rear E-ring, gear (black) and pin. (8) Remove the E-ring and bearing. (9) Remove the spring from the transport guide. (10) Slide the feed roller to the rear to remove. (11) Remove the spring and separation belt gear drive unit. (12) Remove the E-ring, pick-up gear drive unit and pin. [O] Aligning roller (1) Remove the ADU front cover. (2) Remove the stack guide unit. (3) Remove the pick-up roller guide unit. (4) Remove the ADU drive unit. (5) Remove the transport clutch guide.
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(7) Remove the rear E-ring, gear (white) and pin. (8) Remove the E-ring and bearing. (9) Slide the aligning roller to the rear to remove. [P] Feed switch (1) Remove the ADU feed cover. (2) Remove the screw fixing the feed switch bracket. (3) Disconnect the connector, and release the switch claw from the bracket to remove the feed switch. Feed switch [Q] Aligning switch (1) Remove the ADU feed cover. (2) Disconnect the connector, and release the switch claw from the bracket to remove the aligning switch.
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[R] ADU feed unit (1) Remove the ADU front cover. (2) Remove the ADU feed cover. (3) Remove the transport clutch holder. (4) Disconnect the 5 connectors, and release the harness from the feed unit. (5) Remove the 2 E-ring from the front side of the fulcrum shaft fixing the ADU feed unit. Color (black-black) (white-white) (white-black) (6) Remove the rear E-ring. (7) Remove the rear spring. (8) Draw out the fulcrum shaft to the front. (9) Remove the feeder unit by lifting it upwards.
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(3) Remove the 2 E-rings, 2 screws and bracket. (4) Remove the 2 E-rings and bush. (5) Remove each of the 2 set screws fixing the forward rotation clutch and reverse rotation clutch, and then remove forward rotation clutch and reverse rotation clutch. E-ring [T] Holding gate solenoid (1) Remove the ADU feed unit. (2) Remove the feed drive unit. (3) Remove the screw fixing the holding gate solenoid to remove the holding gate solenoid.
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[U] inlet/reversal roller (rubber roller, plastic roller) Transport guide-u (1) Remove the ADU feed unit. (2) Remove the feed drive unit. (3) Remove the E-ring, gear and pin. (4) Remove 2 screws for the transport guide-u. E-ring Pin (5) Remove the rear E-ring, and take out the bush. (6) Remove the transport guide-u (2 screws). E-ring Bush (7) Slide the inlet/reversal roller (rubber roller) to the front to remove. 2 1 (8) Remove the front springs and rear springs (2 each).
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(11) Slide the inlet/reversal roller (plastic roller) to the front, and take it out. 2 1 [V] Separation belt (1) Remove the ADU unit. (2) Remove the feed drive unit. (3) Remove the 4 screws fixing separation mounting bracket, and then the separation mounting bracket. Separation mounting bracket (4) Remove the E-ring, collar, gear, pin and bush. E-ring,collar,gear & pin (4) (5) Remove the 2 E-rings, bush and bracket.
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(7) Remove the 3 E-rings and collar. (8) Draw out the shaft to the rear side. (9) Replace the 4 separation belts. Collar [W] Pre-stack discharge brush (1) Remove the ADU feed cover. Discharge brush (2) Remove the 2 screws fixing the pre-stack discharge brush and then the pre-stack discharge brush. Sheet [X] Holding gate (1) Remove the ADU feed unit. (2) Remove the feed drive unit. (3) Remove the E-ring and clutch unit. (4) Remove the 2 front E-rings, each of the 2 gears and pins.
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(8) Slide the holding gate to the front and remove it. Holding gate [Y] ADU/exit switching gate (1) Open the exit unit. (2) Remove the spring from the arm, and the screw fixing the link to the arm. Note: When assembling, take care not to tighten the screw fixing the link to the arm too tight. (3) Remove the rear clip and bush. Clip (4) Slide the ADU/exit switching gate to the front and remove it.
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(5) Remove the E-ring, arm, pin and bush from the removed ADU/exit switching gate, and replace the gate. E-ring Arm Bush [Z] Gate solenoid (1) Remove the 4 screws fixing the exit cover, and then remove the exit cover. (2) Remove the screw fixing the link to the gate arm. (3) Disconnect the connector, and remove the 2 Gate solenoid screws fixing the gate solenoid. Then remove the gate solenoid. [AA] Reversal gate (1) Open the exit unit. Reversal gate (2) Remove the E-ring fixing the reversal gate.
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[AC] Transport (reversal) roller (1) Open the exit unit. (2) Remove the rear E-ring, gear, pin and bush. (3) Remove the E-ring, slide the transport (reversal) roller to the front, remove the bush from the frame, and then take out the transport (reversal) roller. Transport / reverse roller (4) Remove the E-ring from the transport (reversal) roller and bush, and replace the transport (reversal) roller. [AD] ADU drive motor (1) Remove the main unit rear cover. (2) Disconnect the connector.
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16. AUTOMATING DOCUMENT FEEDER (ADF) 16.1 Outline The ADF (Automatic Document Feeder) automatically feeds sheet originals onto the original glass, and outputs them to the tray after they have been copied. The figure below shows the configuration of the ADF. 1 Original feed section ................. This mechanism feeds originals one at a time onto the original glass. It comprises a pickup roller, feed roller, separation pad, aligning roller and other parts. 2 Original transport section ..........
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16.2 Construction 16.2.1 ADF construction Control section Original receiving tray Exit / Reverse section Transport section Original feeding tray Jam release cover Feeding section Document feeder unit consists of feeding section (includes the original feeding tray), transport section, reverse (includes exit) section and control section.
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16.2.2 Drive mechanism (1) Drive motor rotates CW (Front view) 8 7 6 Front side 5 Reverse motor Rear side 1 Transport motor 4 Lock 2 Stop 3 Feed motor Free 1 Pick-up roller rotates CCW. 2 Feed roller rotates CCW. 3 Aligning roller stops. 4 Weight goes down. 5 Transport belt rotates CW. 6 Exit roller rotates CW. 7 Reverse roller rotates CW. * 8 Flapper goes up at the duplexing mode and the following conditions. I.
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(2) Drive motor rotates CCW (Front view) 8 7 6 Front side 5 Reverse motor Rear side 1 Free Transport motor 4 Stop Stop 2 3 Feed motor Lock 1 Pick-up roller stops. 2 Feed roller stops. 3 Aligning roller rotates CCW. 4 Weight goes up. 5 Transport belt rotates CCW. 6 Exit roller rotates CCW. 7 Reverse roller rotates CCW.
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16.3 Description of Operations 16.3.1 Description of operation (1) Setting the original The original is set on the tray, and the empty sensor turns ON. The empty sensor detects that the original is set, and the original set signal is set. (2) Start of feed to aligning When the feed signal is received from the copier, the DF operation in progress signal is set.
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(3) Restart to end of initial alignment The feed motor starts to operate in the forward direction to rotate the aligning roller, transport of the original is started, and the initial alignment operation is restarted. After the timing sensor detects the leading edge of the original, the original is transported by a specified number of pulses. At the point that the original arrives at the initial alignment standby position, the feed motor stops, and the initial alignment operation is completed.
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(5) Aligning sensor OFF to timing sensor OFF At the point when the timing sensor turns OFF and the trailing edge of the original is detected, the feed motor stops. The number of drive pulses until the feed motor stops is set. (6) Setting the original at the exposure position (completion of feed) The original stops signal is set by the set timing of the original stop signal. After the timing sensor detects the trailing edge of the original, the original is transported for a specified number of pulses.
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(7) Start of initial alignment of next original to completion of initial alignment When there is an original on the tray at the point when feed is completed, the initial alignment signal is set, the feed motor starts to operate in the reverse direction, and initial alignment of the next original is started. If there is no original on the tray, operation from (8) is started. The same processes as (2) and (3) are carried out, initial alignment of the next original is completed, and the original stands by.
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(9) Start of original feed and exit to exit sensor ON When the original is output, the number of drive pulses up start of exit deceleration is set at the point when the exit sensor turns ON. When the output original is nipped by the exit roller by a specified amount or more when setting of the original to be fed is completed, the original is drawn out and output as it is. If the output original has not been nipped by the specified amount or more, the original is not drawn out and output.
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(12) Completion of exit At the point when the original is completely output onto the exit tray, the reversal motor stops, and exit is completed. (13) Start of exit of final original to completion of exit When the exit signal is received during exit of the final original, the DF operation in progress signal is set.
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16.3.2 Double-sided feed operation (1) Setting the original The original is set on the tray, the empty sensor turns ON, setting of the original is detected, and the original set signal is set. (2) Start of feed to aligning When the feed signal is received from the copier, the DF operation in progress signal is set. Then, the feed motor rotates in the reverse direction to rotate the feed roller, lower the weight plate and start initial alignment operation.
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(3) Restart of initial alignment to completion of initial alignment The feed motor starts to operate in the forward direction to rotate the aligning roller. Transport of the original starts, and the initial alignment operation is restarted.
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(5) Aligning sensor OFF to timing sensor OFF The feed motor stops at the point when the timing sensor turns OFF and the trailing edge of the original is detected. If exit operation is not carried out simultaneously or has already completed at this time, the reversal motor starts to rotate in the forward direction simultaneously to rotate the reversal roller. At the same time, the flapper solenoid turns ON to switch the reversal flapper over to the reversal side.
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(7) Start of reversal to flapper solenoid OFF After forward rotation transport is completed, the transport motor starts to rotate in the reverse direction and the reversal motor starts to rotate in the forward direction to rotate the transport belt and reversal roller to start reversal of the original. The original passes along the reversal path and is transported onto the original glass. The DF operation in progress signal is reset at the reset timing of the DF operation in progress signal.
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(9) Start of feed to completion of forward rotation transport When the feed signal is received, and the DF operation in progress signal is set, the reversal feed of the original that is set at the exposure position is started. First of all, the transport motor and reversal motor start operating in the forward direction to rotate the transport belt and reversal roller.
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(11) Setting the original at the exposure position (completion of No.2 side feed) The original is transported by a specified number of pulses after reversal starts. At the point where the original arrives at the exposure position, the transport motor and reversal motor stop, and feed is completed. The original is stopped in contact with the original stopper, and the rear side of the original is set.
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(14) Aligning sensor OFF to timing sensor OFF The feed motor stops at the point when the timing sensor turns OFF. When the 2nd original onwards is being fed, exit of exposed originals is carried out at the same time, and the original being fed must be made to stand by before the reversal section until exit is completed. For this reason, the number of drive pulses up to feed motor stop is set at the point when the timing sensor turns OFF to stop the original being fed before the reversal section.
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(17) Restart of forward rotation transport to completion of forward rotation transport After exit of the output original is completed, forward rotation transport of the original standing by before the reversal section is restarted. The transport motor and reversal motor start to rotate in the forward direction to rotate the transport belt and reversal roller. At the same time, the flapper solenoid turns ON to switch the reversal flapper to the reversal side.
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(20) Setting the original at the exposure position (completion of No.2 side feed) The same processes from (9) to (11) are carried out, and the top side of the original is set at the exposure position. If there is an original on the tray when feed is completed, initial alignment of the next original is started. * From here on, operation is repeated until all of the originals on the tray are fed.
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16.4 Description of Interface Signals The following 6 lines are used for sending and receiving signals between the copier and the ADF: REQ ......................... Communications request signal (copier to ADF) DF-REQ ................... Communications request signal (ADF to copier) DF-ACK .................... Communications request answer signal (copier to ADF) ACK .......................... Communications request answer signal (ADF to copier) TXD ..........................
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16.5 Detection of Paper Jam 16.5.1 Feed section jams [1] Aligning sensor non-arrival jam 1) Up to aligning sensor ON from start of feed from the tray in the one-sided and double-sided modes The number of pulses equivalent to 15X the distance from the original set position to the aligning sensor ON position is set as the jam pulse. This is set when feed from the tray is started.
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3) From restart of No.1 side transport to exit sensor ON in the double-sided mode The number of pulses equivalent to twice the distance from the leading edge position of the original being fed when the original being fed is paused on the original glass and standing by for exit of the output original to be completed during No.1 side transport in the double-sided mode is set as the jam pulse.
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16.6 Detection of Original Size 16.6.1 Original size detection method The number of drive pulses of the feed motor from start of transport of the original standing by at the initial alignment position up to when the trailing edge of the original being fed passes the aligning sensor is counted to detect the original size in the feed direction. At the same time, the original size in the width direction is judged by the size width sensor.
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16.7 Flow Charts 16.7.
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16.7.2 Operation control Operation control Initial alignment One-side feed control No.1 double-sided transport control No.
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16.7.
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16.7.
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16.7.5 No.1 double-sided transport control (double-sided transport of initially aligned original) No.1 double-sided transport started (double-sided transport of initially aligned original) Aligning sensor ON? No Original exiting? Aligning sensor nonarrival jam Timing sensor ON? No Timing sensor nonarrival jam No Setting of transport motor deceleration request by timing sensor OFF (deceleration started after specified pulse drive) Setting of jam pulse from start of No.
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16.7.6 No.2 double-sided transport control (double-sided transport of original on platen) No.2 double-sided transport START (double-sided transport of original on platen) Exit sensor OFF? Flapper solenoid ON (switchover to reversal direction) No Exit sensor accumulation jam Setting of jam pulse from start of No.
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16.7.
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16.7.
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16.7.9 Operating status monitoring No (The second original onwards) Back side setting in progress? No (Front side setting progress) Double-sided mode? No (One-sided mode) No.2 double-sided transport started (double-sided transport of original on platen) No Double-sided mode? Initial alignment started No.
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Operating status monitoring Feed signal received? A B No First copy? Back side setting in progress? Initial alignment started No.
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ADF CW CCW OFF CW 16 - 34 Empty sensor Exit sensor Timing sensor Aligning sensor Reverse motor ON OFF ON OFF OFF ON OFF ON OFF ON CCW Transport motor OFF Feed motor PRE-FED ORG-STP DF-ACT 0 0 0 0 0 1.14 1.27 Exposure time 1.21 0.72 1.09 0.54 0.54 0.82 0.83 0.38 0.75 0.26 0.31 0.54 0.44 0.83 0.75 0.75 0 0 0 0 0 0.67 0.21 0.19 0.45 0.83 1.00 1.18 Exposure time differents with the machine type or the feed original mode. Exposure time 0.10 0.27 1.
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CW CCW OFF CW 16 - 35 Empty sensor Exit sensor Timing sensor Aligning sensor Reverse motor ON OFF ON OFF OFF ON OFF ON OFF ON CCW Transport motor OFF Feed motor PRE-FED ORG-STP DF-ACT ORG-OUT ORG-IN 0 0 0 0 0 0.54 0.54 0.54 0.37 0.26 0.31 0.44 0.92 1.44 1.31 1.38 0.89 1.26 0.99 0.99 1.00 0.92 0.92 Exposure time 0.34 0.14 0.97 Exposure time 0.69 0.55 0.38 0.36 0.45 0.45 0.46 0.37 0.37 0 0 0 0 0.97 0.97 0.69 0.55 0.45 0.25 0.
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ADF CW OFF CCW 16 - 36 ON OFF OFF ON OFF ON Timing sensor Exit sensor Empty sensor ON Reverse motor OFF OFF Flapper solenoid ON ON Aligning sensor OFF CW Transport motor OFF CCW Feed motor PRE-FED ORG-STP DF-ACT ORG-OUT ORG-IN 0 0 0 0 0 0.82 1.29 1.73 1.46 Exposure time 1.64 1.66 1.40 1.03 0.43 0.74 0.31 0.72 0.75 0.75 1.59 0.54 0.54 0.36 0.54 1.16 0.49 1.23 0 0 0 0 0 0 0.56 0.30 0.67 0.43 0.18 0 0.55 0.16 0 0 0 0 1.14 Exposure time 0.55 0.30 0.
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CW OFF CCW 16 - 37 ON OFF OFF ON OFF ON Timing sensor Exit sensor Empty sensor Reverse motor ON OFF OFF Flapper solenoid ON ON Aligning sensor OFF CW Transport motor OFF CCW Feed motor PRE-FED ORG-STP DF-ACT ORG-OUT ORG-IN 0 0 0 0 1.04 1.46 Exposure time 0.45 0.45 1.22 1.80 1.72 1.29 Exposure time 0.68 0.33 0.14 0.37 0.35 1.10 1.52 0.97 1.59 0.62 0.73 0.74 0.69 0 0.97 0.68 0.45 0.55 0.97 0.14 0 0 0.25 0 0 Exposure time 0.14 0.56 0 0 0.83 0.76 0 0.
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16.9 Descriptions of Symbols, Layout of Electrical Parts and Signal Block Diagrams 16.9.
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16.9.2 Electrical parts layout RCOVER TMOT FAN FMOT RMOT APSSW RSOL EXITS FCOVER EMPS SIZES2 SIZES1 REGS OPN TIM 16.9.
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16.10 Description of Circuits 16.10.1 Aligning sensor, timing sensor and exit sensor circuit diagrams This item describes the aligning sensor circuit. A description of the timing sensor and exit sensor circuits is omitted in this item as the aligning sensor, timing sensor and exit sensor share the same circuit configuration. +5V 1 Aligning sensor A 2 C 1 PT1 LED1 K 1 CN6.1 CN6.2 CN6.3 +5V 1 R43 2 +5V 2 *REGS 3 REGLED 1 NF2 3 2 C30 2 E 2 SGND E 3 1 B 24 1 R16 C31 R81 2 2 R84 7 + 6 IC5.
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16.10.2 +5V power circuit diagram D3 +24V CN2.1 CN2.2 DC24V PGND 1 1 R6 IC15 2 4 Vin Vo C43 1 + 1 CP1 1 GND 2 2 TP44 PGND 1 2 A K 1 + 1 K 1 C38 PGND 1 ZD2 2 2 TP26 +5V 1 +5V 2 C27 2 A 2 PGND SGND TP43 SGND 1 SGND This circuit generates the +5VDC voltage to be supplied to the CPU, logic IC and other components. +24VDC input from CN2 is converted to +5V by switching regulator IC15. ZD2, CP1 and D3 are used to protect IC15.
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16.10.4 Pulse motor drive circuit This item describes the feed motor drive circuit. As the feed motor, transport motor and reversal motor share the same circuit configuration, a description of the transport motor and reversal motor circuits is omitted in this item.
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16.10.6 Reset circuit A 2 2 2 5 1 VCC C20 C71 + 1 D1 RES +5V 24 CK *RES IC1 GND CT 3 K 1 1 8 1 2 CK *RES 1 2 R27 VREF R103 1 6 C70 2 VS 7 1 C5 2 + 1 SGND C4 2 SGND This circuit generates the CPU reset signal when the power is turned ON, and when the power voltage is momentarily interrupted or low. It has a watchdog timer for diagnosing CPU system operation. After the power is turned ON, pin 8 (*RES) of IC3 is normally High.
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16.10.7 EEPROM circuit diagram This circuit comprises an EEPROM for storing ADF data and other peripheral circuits. +5V E2PROM+5V A 1 +5V D11 1 K 2 R75 D10 D0 8 RA2.4 A 7 1 1 7 CS 5 CLK 3 DI 2 RA1.1 RA1.4 RA1.3 RA1.2 IC11 2 2 R74 4 DO 2 1 + 8 1 6 2 CLK NC1 4 3 DI NC2 7 5 CS C42 2 6 SGND RA2.3 3 RA2.2 RA2.1 1 K 2 1 4 6 SGND IC11 is memory for storing the adjustment values of reflection-type sensors.
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16.11 Description of I/O signals 16.11.1 REQ, ACK and TXD signals +5V 1 CN1.3 REQ DA3 K 3 2 3 TP23 IC2.1 R90 2 1 1 2 1 C46 R30 A 1 IC3.5 2 A Y 11 10 A Y REQ1 1 REQ1 2 SGND +5V 1 DA1 K 3 2 9 CN1.9 IC2.3 R92 2 1 ACK 1 C48 R32 A 1 5 2 A Y TP19 IC3.4 8 9 A Y 6 1 ACK2 ACK2 2 +5V SGND 1 CN1.7 TxD DA2 K 3 2 7 R91 TP21 IC2.2 2 1 2 R31 A 1 3 1 C47 IC3.1 2 1 A Y 4 A Y 1 DF-RxD 2 SGND This input circuit is for communicating with the copier body.
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16.11.3 Sensor input circuits +5V 1 +5V CN6.2 #REGS REGLED 1 NF2 1 R15 2 1 1 3 1 3 C30 2 SGND 1 B 1 R16 E 3 Timing sensor +5V #DTS CN6.6 DTSLED 1 NF4 1 R36 2 1 6 C32 2 SGND 1 B 1 10 + IC4.3 - 9 28 R18 E 3 CN7.6 CN7.7 NF2 +5V SGND 1 R64 2 C 2 1 010 B E 3 APS start SW #APS CN3.2 SGND 1 R29 2 2 1 + IC5.1 - 2 2 1 DTS TP33 1 1 DTS-AD 2 1 R86 1 2 R51 TP36 2 11 + 10 IC5.4 - 2 13 13 IC3.
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16.11.4 Pulse motor drive circuit diagram 1 +5V C24 TP2 TP3 TP4 TP5 1 1 R65 2 1 R97 2 MODE CLOCK 1 1 2 TP6 1 1 1 SGND 8 9 1 R98 2 1 R99 2 6 1 2 1 C9 C8 C11 1 1 C7 1 2 R73 B/A 2 12 1 2 1 11 C21 RESETB 7 R55 CWB 1 1 C69 2 + 2 10 C68 VDD A 5 MODE CLOCK AB 4 CWB 3 B RESETB 2 BB Vref 4 2 1 PM+24V SP ICB 1 1 1 1 C81 C80 C79 C78 GND 2 2 2 A 3 2 2 2 5 6 + 1 2 CN8.4 #A CN8.3 B CN8.2 #B CN8.1 PM+24V CN8.5 PM+24V CN8.
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16.11.6 Open switch input circuit diagram TP17 DC24V RY1 3 1 1 5 K 1 4 +24V 2 D2 ADF open SW CN6.7 DFSW CN6.8 DFSW1 7 A 2 8 1 R34 Feed cover SW CN5.4 DFSW1 CN5.5 DFSW2 2 4 5 1 C37 Exit cover SW CN7.1 DFSW2 CN7.2 PGND 2 1 2 PGND When all three reed switches turn ON, the relay coil is excited to supply +24V power to the drive circuit. The voltage of CN6 and CN7 becomes 0V when all three switches are ON.
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16.12 Disassembly and Replacement [A] Transport unit (1) Remove the 2 clips fastening the transport unit. (2) Push down the top of the transport unit (front side), and remove the rear side from the belt drive section. Belt Transportt unit Note: During assembly, insert the clips and fix the transport unit at the position shown in the figure. Clip [B] Transport belt (1) Remove the transport unit. (2) Loosen the screw (front) fastening the belt tension plate.
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(3) Rotate the belt tension plate to provide the transport belt with slack. (4) Remove the transport belt from the front side (Magnet catch side). Transport belt Notes: 1. During assembly, make sure that the Belt tension plate Frame edges of the transport belt are at the inside of the transport unit side frame. 2. After assembly is completed, make sure that the belt is carried in the center and does not drift to either side.
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Brush (1) Remove the 2 screws and brush fastening bracket. Brush [D] Original feeding tray (1) Loosen the two M4 screws, and slide the original feeding tray to the front to remove. Original feeding tray [E] Feed unit (1) Remove the original feeding tray. (2) Remove the rear cover. (3) Disconnect the 2 connectors and remove the Connector earth lead (1 screw) and harness band. (4) Remove the 2 screws, and slide the ADF unit to the rear side and light up to remove.
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(5) Turn the entire unit over, and remove the cover (3 screws: M4 x 8). Cover (6) Disconnect the 4 connectors from the PC board. (7) Open the jam release cover, and loosen the screw. Jam release cover (8) Remove the 6 screws and the feed unit.      Note: M4 x 12 ..... 4 pcs. M4 x 8 ....... 1 pc. A ADF M3 x 6 ....... 1 pc.
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Front side Rear side Feed unit [F] Feed motor (1) Loosen the tensioner fixing screw from the tim- Spring ing belt. Note: Do not remove the springs hanging on the belt tensioner. (2) Remove the motor connector, and 2 motor fixing screws. Note: During assembly, be sure to fasten the belt tensioner last of all. [G] Jam release cover (1) Remove the feed unit. (2) Remove the jam release cover by removing the 2 screws (front and rear sides).
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[H] Separation unit (1) Open the jam release cover. (2) Remove the 2 screws and leaf spring, then, re- Spring Separation unit Leaf spring move the unit. (3) Draw out the bracket holder making sure that the pressurizing springs do not become loose. [I] Front aligning plate Adjustment screw (1) Remove the feed unit. (2) Open the jam release cover. (3) Remove the 2 screws. Front aligning plate [J] Aligning roller (L) (1) Remove the feed unit. (2) Open the jam release cover.
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(3) Draw out the inlet guide while pushing the empty sensor upwards. Empty guide (4) Remove the 2 bracket fixing screws from the timing sensor and the bracket fixing screw from the size sensor, and disconnect the connectors from the sensors. Size sensor Timing sensor [L] Feed roller (1) Remove the feed unit. (2) Remove the inlet guide. (3) Remove the E-ring, bush and spring from the front side.
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Aligning roller (R) (2) Remove the inlet guide, and remove the timing sensor and size sensor. (3) Remove the pulley from the drive section (1 Ering). (4) Remove the 2 E-rings from the frame inside, and draw out the roller. Pulley [N] Transport motor (1) Remove the 2 screws and 1 connector. [O] Reversal unit (1) Remove the ADF unit. (2) Remove the transport unit and cover. (3) Disconnect the 2 connectors from PC board. (4) Remove the earth lead fastened to the hinge section.
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[P] Exit cover (1) Remove the reversal unit. (2) Remove the screws from the front and rear sides, and remove the cover. Exit cover [Q] Reversal motor Disconnect the connector and remove the 2 screws. [R] Reversal roller (1) Remove the reversal unit. (2) Remove the stay (2 screws). (3) Remove the E-rings from the front side.
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(4) Slide the reversal roller to the rear side, and remove the parallel pin. (5) Draw out the reversal roller while tilting it on its side from beneath the unit. Reverse roller [S] Exit sensor (1) Remove the stay (4 screws). Stay (2) Remove the sensor from the guide (1 screw). Exit sensor [T] PC board (1) Remove the ADF unit. (2) Remove the cover. (4) (3) Disconnect the 11 connectors. (4) Remove the 2 screws, and slide the PC board from the hooking section on the rear side to remove.
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[U] ADF fan motor (1) Remove the PC board. (2) Disconnect the connector and remove the Connector screw. (3) Remove the 2 screws.
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[V] Mylar sheet, etc. When replacing damaged mylar sheets, fix the new mylar sheet according to the reference positions shown below. Before you fix a new mylar sheet, first clean the fixing position with alcohol. After fixing the mylar sheet make sure that it is not rising up and the ends of the sheet are not peeling up. 1. Jump mylar sheet (feed guide) Feed guide A A Fixing reference: Clearance 0 to 0.5mm (when pushed up against this line) Jump mylar sheet 0 e anc lear e: c enc efer e) ng r Fixi -0.
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2. Mirror seal, feed cover mylar sheet * When fixing the mirror seal, do not scratch the mirror surface. a a b Mirror seal Feed cover mylar sheet Fixing reference: Clearance 0 to 0.5mm (when pushed up against this rib) b Fixing reference: Clearance 0 to 0.5mm (when pushed up against this rib) ren efe gr in e Fix .5mm fac ± 0 b end (ri Fi 0 xing to (w 0.
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3. Feed sheets 1, 2, 4, 5 Fixing reference 0 to -1 Feed sheet 2 0 Fixing reference (when pushed up against this indented section) Feed sheet 5 Fixing reference 0 to -1 0 Feed sheet 4 Sheets 4 and 5 must be fixed according to the rib contact reference in the direction of the arrows shown in the figure on the left. (Overlapping of ribs is not allowed. Clearance must be 0 to 2mm.
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4. Guide mylar sheets, mirror seals, mirror mylar sheets * When fixing the mirror seal, do not scratch the mirror surface. Fixing reference: Clearance 0 to 0.5mm * The opposite side must be fixed at the same Fixing reference. C C eet) r sh ±0.5mm a l y : ) de m ference erence (gui e ef r r g e n c Fixi end fa p (ste C-C cross-section 0 Mirror mylar sheet Guide mylar sheet (2 locations) B (mirror mylar sheet) Fixing reference: Clearance 0 to 0.
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5. Aligning mylar sheet (aligning plate) Aligning mylar Sheet Fix i 0 to ng re f (wh 0.5m erenc e: C the en pu m lea she cut ran -of d ce f se aga ctio ins t n) 0 ) (Al i pro gning tru s my (1 .2 +0ion) lar sh .5 ee t Aligning plate Fixing reference: Deviation 0 to -0.5mm (protrusion not allowed) (protrusion also not allowed on opposite face) 0 6. Weight mylar Sheet (weight holder) ce a le C e: ef m d r g .
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Fixing reference: Clearance 0 to 0.5mm (overlapping not allowed) A Fixing reference: Clearance 0 to 0.5mm (overlapping not allowed) A 16 - 65 Fixing reference: Clearance 0 to 0.5mm (overlapping not allowed) 7. Guide mylar sheet (2) Guide mylar sheet (2) (3 locations) nce nce: Cleara Fixing refere 0 to 0.
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0.5mm 8. Guide mylar sheet (3) Fixing reference: Arrow view Fix in order 1 , 2 and 3 so that mylar does not sag. 1 2 0 3 0 Guide mylar sheet (3) Fixing reference: 0 to 1 Sagging not allowed Make sure that edges of mylar guide do not deviate.
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9. Separation pad, separation mylar sheet Pad holder Separation pad, Separation mylar sheet Fixing reference: Clearance 0 to 0.5mm (overlapping not allowed) Separation pad A Separation pad Fixing reference: Clearance 0 to 0.3mm (overlapping not allowed) Paper path direction Separation pad Separation mylar sheet A Separation mylar sheet Fixing reference: Clearance 0 to 0.5mm (when pushed up against this line) * The paper path direction in the figure must be free from steps that may catch the paper.
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11. Reversal mirror seal * When fixing the reversal mirror seal, do not scratch the mirror surface. A A Fixing reference: (when pushed against indentation) Clearance 0 to 0.5mm (Overlapping not allowed) Reversal mirror seal ce: ren d e f re he on) ing us tati m Fix hen p nden 0.
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Fixing reference: Clearance 0 to 0.5mm (end face reference) Cushions Fixing reference: Clearance 0 to 0.5mm (end face reference) 12. Cushions Fixing reference: Clearance 0 to 0.
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Reversal roller mylar sheets (3 locations) ADF Reversal roller cushions (3 locations) 16 - 70 (Fix these cushions between the ribs so that they do not overlap the ribs.) (3 locations) (reversal roller mylar sheet) Fixing reference (when pushed against this line) (reversal roller cushion) Fixing reference: ± 0.5mm (Fix these cushions between the ribs so that they do not overlap the ribs.) (3 locations) (reversal roller cushion) Fixing reference (when pushed against this line) 13.
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14. Discharge brush Fixing reference: 0 to -0.5mm (hold end reference (line w/out crimp)) m m .5 e) 0 nc to 0 fere : e re nc re rimp e f tc re g /ou n i w x Fi ine (l Discharge brush (0.5) Hole A A 0 a The tip must be firmly pressed against the DF cover. (The tip must not protrude from the DF cover.) Section a: Insert into hole, and fix to rib.
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15. DF cover sheets 1, 2, 4, 5, 6 and 8 Each of the DF cover sheets must be fixed according to the rib contact reference in the direction of the arrows shown in the figure below. (Overlapping of ribs is not allowed. Clearance must be 0 to 2mm.) Firmly fix the DF cover sheets so that they do not rise up along the curve of the DF cover. DF cover sheet 2 (2 locations) (Overlapping of the gate not allowed.
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16. Tray sheet guides 0 0 Fixing reference: 0 to -0.5mm (end face rounded corner end reference) Fixing reference: 0 0.5mm (indentation end face reference) (indentation end face reference) Tray sheet guide Fixing reference: 0 0.5mm Fixing reference: 0 to -0.
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16.
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(2) PWA-F-SEN-794 16 - 75 ADF
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17. Gasket (transfer belt unit) FRAME-BELT-F Gasket Gasket Window Aligning Gap:0~1mm -0~1mm -0~1mm Must not protrude beyond the window Must not protrude beyond the edge of the frame 18. Discharge (Paper feeder area) [Attaching Position] Attach it to the two edge positions in GUIDE-ALGN-IN (A and B below). Note1. Insert the discharge brush between the FRM-FEED-794 and the GUIDE-ALGN-IN (rear side only). Note2.
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19. Shield mylar (DF cover) 0~1mm (2.4 ~ 2.5) Aligning with rib 0 ~ 1mm Aligning with rib Shield mylar COV-DF-794 20. Pad cushion Pad cushion 0~1mm Must not protrude beyond the bracket BKT-PAD-SPT-794 Pad cushion 0~1mm Must not protrude beyond the bracket Align and then attach (Gap = 0~0.
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21. Reverse section entrance mylar Unit: mm SHEET-RVS-M BELT +0.5 1 –0.5 0~0.5 MYLAR-RVS-M Not to protrude 0~1 0~1 MYLAR-RVS-M SHEET-RVS-M 22. Reverse section side mylar Rounded corner end +1 0 ~ 0.5 Not to become stuck on the rib 0 –1 MYLAR-RVS-U-R View MYLAR-RVS-U-F 0 ~ 0.
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17. POWER SUPPLY UNIT 17.1 Configuration The power supply unit comprises an AC filter and isolated DC output circuit. (1) AC filter This filter removes external electrical noise, and prevents leakage of electrical noise generated within the machine to the outside. (2) DC output circuit DC output is divided into the following two lines: : This power supply is used by the entire machine during image formation. 4 1 Main line voltages (+3.35V, +5.
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Exposure lamp load 5VA Heater lamp load F3 GNDA 24VA DGA 24VB Frequecy reactor F4 Breaker Main switch Live F5 F1 N.F Neutral N.F DGB 24VC DGC 24VD DGD Reg. Door switch F6 DGE 36VA DGA 36VB F7 DGB Switching power supply F8 DGC 36VD DGD Frequecy reactor 3.3VA~C GNDA~C(3.3V) 5.1VB,D,E,H,I F2 GNDB,D,E,H,I(5.1V) N.F 12VA~C Reg.
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Power supply sequence ON OFF AC input 700 ms or less Within 10 ms 3.2V or more +3.3V(MAIN) 3.2V or more 4.95V or more +5.1V(MAIN) 4.95V or more 10 ms~120 ms 20 ms or more 10 ms or more 20 ms or more 50 ms or more PWR-DN 0~200 ms 5 ms or more 0 ms or more 11.4V or more 0~200 ms 21.6V or more +12V(MAIN) 11.4V or more +24V(MAIN) 21.6V or more 4.95V or more +5.1V(DOOR) 4.95V or more 21.6V or more +24V(DOOR) 21.6V or more 34.2V or more +36V(DOOR) 34.
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18.
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(2) PWA-F-MTB-300 PC BOARD 18 - 2
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(3) PWA-F-LGC-300 18 - 3 PC BOARD
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(4) PWA-F-ADU-300 (5) PWA-F-MOT-300 PC BOARD 18 - 4
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(6) PWA-F-SLG-300 (7) PWA-F-SDV-300 18 - 5 PC BOARD
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(8) PWA-F-PLG-300 PC BOARD 18 - 6
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19.
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8)Remove the screws 12)Open the cover 1 2 9)Install the glass holder and the cover 13)Remove the lock screws 10)Remove the protectors 14)Pull out the transfer unit 1 2 11)Remove the protector UNPACKING AND INSTALLATION 15)Remove the lock screws 19 - 2
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16)Close the transfer unit 20)Remove the charger unit 1 2 21)Remove the drum unit 17)Remove the cover 1 1 1 2 1 2 2 3 18)Remove the protector 22)Remove the screw 19)Remove the developer unit 23)Remove the thermistor 1 2 3 19 - 3 UNPACKING AND INSTALLATION
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24Remove the drum shaft 28)Install the drum 1 2 25)Apply the starting powder for cleaning blade 29)Unlock the cleaner 26)Lock the cleaner 30)Rotate the drum manually 1 27)Apply the starting powder (UKOG-0123FCZZ) 31)Apply the starting powder for the drum for the drum UNPACKING AND INSTALLATION 2 19 - 4
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32)Rotate the drum manually 1 36)Remove the developer unit cover 2 33)Install the thermistor 37)Fill developer into the developer unit 34)Install the drum unit 3 2 2 1 38)Fix the cover 35)Install the charger unit 2 1 19 - 5 UNPACKING AND INSTALLATION
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43)Install the tray 39)Install the developer unit 3 2 1 40)Install the cover 44)Fix the machine position 2 2 2 1 41)Close the covers 45)Check the level 1 3 2 42)Remove the tape UNPACKING AND INSTALLATION 19 - 6
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46)Install the stocker (4) After a short time, the value in Zone “B” will automatically stop changing and, at the same time, the message will also change as shown below. 250% 200 LT ADJUST MODE 128 135 (5) In this status, check that the value in Zone “B” is in the range of 245~255 (auto-toner sensor output range of 2.45V~2.55V). (6) If the value in Zone “B” is in not in the range of 245~255, use the "Down / 'Up keys to adjust the value. (7) Press the SET key.
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50)Setting the date and time adjust the image center position. 1. Setting the Date and Time (1) Press the PROGRAM key to enter the program menu, and then press the DATE/TIME key. (2) Enter values for the year, month, date, day, hour and minute, and press the SET key. (The example on below is for 1999, April, 1st, Thursday, 10(a.m.) and 10(minutes).) Day Code No. Sunday 1 Monday 2 Tuesday 3 Wednesday 4 Thursday 5 Friday 6 Saturday 7 2.
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