Konica 7832 SERVICE HANDBOOK 7832fv1e
7832
SERVICE HANDBOOK
FIELD SERVICE
Dec. 2000
Ver. 1.0
KONICA CORPORATION
TECHNOLOGY SUPPORT CENTER
TOKYO JAPAN
KCS783210
INDEX (FIELD SERVICE)
DIS/REASSEMBLY,
ADJUSTMENT
SWITCHES ON PWBs,
TECH. REP. SETTINGS
TROUBLESHOOTING
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Safety Precautions for Inspection and Service
When performing inspection and service procedures, observe the following precautions to
prevent accidents and ensure utmost safety.
✽
Depending on the model, some of the precautions given in the following do not apply.
Different markings are used to denote specific meanings as detailed below.
Indicates a potentially hazardous situation which, if not avoided,
WARNING
CAUTION
The following graphic symbols are used to give instructions that need to be observed.
Used to call the service technician’s attention to what is graphically represented
inside the marking (including a warning).
Used to prohibit the service technician’s from doing what is graphically represented inside the marking.
Used to instruct the service technician’s to do what is graphically represented
inside the marking.
1. Always observe precautions.
• Parts requiring special attention in this product will include a label containing the
mark shown on the left plus precautionary notes. Be sure to observe the precautions.
• Be sure to observe the “Safety Information” given in the Operator’s Manual.
could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to
alert against unsafe practices.
WARNING
2. Before starting the procedures, be sure to unplug the power cord.
• This product contains a high-voltage unit and a circuit with a large current
capacity that may cause an electric shock or burn.
• The product also contains parts that can jerk suddenly and cause injury.
• If this product uses a laser, laser beam leakage may cause eye damage or
blindness.
3. Use the specified parts.
• For replacement parts, always use the genuine parts specified in the manufacturer’s parts manual. Installing a wrong or unauthorized part could cause dielectric breakdown, overload, or undermine safety devices resulting in possible
electric shock or fire.
• Replace a blown electrical fuse or thermal fuse with its corresponding genuine
part specified in the manufacturer’s parts manual. Installing a fuse of a different
make or rating could lead to a possible fire. If a thermal fuse blows frequently,
the temperature control system may have a problem and action must be taken
to eliminate the cause of the problem.
P-1
4. Handle the power cord with care and never use a multiple outlet.
• Do not break, crush or otherwise damage the power cord. Placing a heavy
object on the power cord, or pulling or bending it may damage it, resulting in a
possible fire or electric shock.
• Do not use a multiple outlet to which any other appliance or machine is connected.
• Be sure the power outlet meets or exceeds the specified capacity.
5. Be careful with the high-voltage parts.
• A part marked with the symbol shown on the left carries a high voltage. Touching it could result in an electric shock or burn. Be sure to unplug the power cord
before servicing this part or the parts near it.
6. Do not work with wet hands.
• Do not unplug or plug in the power cord, or perform any kind of service or
inspection with wet hands. Doing so could result in an electric shock.
7. Do not touch a high-temperature part.
• A part marked with the symbol shown on the left and other parts such as the
exposure lamp and fusing roller can be very hot while the machine is energized.
Touching them may result in a burn.
• Wait until these parts have cooled down before replacing them or any surrounding parts.
8. Maintain a grounded connection at all times. (This item may not apply in the USA.)
• Be sure to connect the ground wire to the ground terminal even when performing an inspection or repair. Without proper grounding, electrical leakage could
result in an electric shock or fire.
• Never connect the ground wire to a gas pipe, water pipe, telephone ground wire,
or a lightning conductor.
9. Do not remodel the product.
• Modifying this product in a manner not authorized by the manufacturer may
result in a fire or electric shock. If this product uses a laser, laser beam leakage
may cause eye damage or blindness.
10. Restore all parts and harnesses to their original positions.
• To promote safety and prevent product damage, make sure the harnesses are
returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being
crushed.
• To promote safety, make sure that all tubing and other insulating materials are
returned to their original positions. Make sure that floating components mounted
on the circuit boards are at their correct distance and position off the boards.
P-2
CAUTION
1. Precautions for Service Jobs
• A toothed washer and spring washer, if used originally, must be reinstalled.
Omitting them may result in contact failure which could cause an electric shock
or fire.
• When reassembling parts, make sure that the correct screws (size, type) are
used in the correct places. Using the wrong screw could lead to stripped
threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury.
• Take great care to avoid personal injury from possible burrs and sharp edges on
the parts, frames and chassis of the product.
• When moving the product or removing an option, use care not to injure your
back or allow your hands to be caught in mechanisms.
2. Precautions for Servicing with Covers and Parts Removed
• Wherever feasible, keep all parts and covers mounted when energizing the
product.
• If energizing the product with a cover removed is absolutely unavoidable, do not
touch any exposed live parts and use care not to allow your clothing to be
caught in the moving parts. Never leave a product in this condition unattended.
• Never place disassembled parts or a container of liquid on the product. Parts
falling into, or the liquid spilling inside, the mechanism could result in an electric
shock or fire.
• Never use a flammable spray near the product. This could result in a fire.
• Make sure the power cord is unplugged before removing or installing circuit
boards or plugging in or unplugging connectors.
• Always use the interlock switch actuating jig to actuate an interlock switch when
a cover is opened or removed. The use of folded paper or some other object
may damage the interlock switch mechanism, possibly resulting in an electric
shock, injury or blindness.
3. Precautions for the Working Environment
• The product must be placed on a flat, level surface that is stable and secure.
• Never place this product or its parts on an unsteady or tilting workbench when
servicing.
• Provide good ventilation at regular intervals if a service job must be done in a
confined space for a long period of time.
• Avoid dusty locations and places exposed to oil or steam.
• Avoid working positions that may block the ventilation ports of the product.
4. Precautions for Handling Batteries (Lithium, Nickel-Cadmium, etc.)
• Replace a rundown battery with the same type as specified in the manufacturer’s parts manual.
• Before installing a new battery, make sure of the correct polarity of the installation or the battery could burst.
• Dispose of used batteries according to the local regulations. Never dispose of
them at the user’s premises or attempt to try to discharge one.
P-3
5. Precautions for the Laser Beam (Only for Products Employing a Laser)
• Removing the cover marked with the following caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure
to unplug the power cord before removing this cover.
• If removing this cover while the power is ON is unavoidable, be sure to wear
protective laser goggles that meet specifications.
• Make sure that no one enters the room when the machine is in this condition.
• When handling the laser unit, observe the “Precautions for Handling Laser
Equipment.”
1167P001AA
DANGER
Invisible laser radiation when open.
AVOID DIRECT EXPOSURE
TO BEAM
0947-7127-01
1144D270AA
Other Precautions
• When handling circuit boards, observe the “HANDLING of PWBs”.
• The PC Drum is a very delicate component. Observe the precautions given in “HANDLING OF THE PC DRUM” because mishandling may result in serious image problems.
• Note that replacement of a circuit board may call for readjustments or resetting of particular items, or software installation.
P-4
Used Batteries Precautions
ALL Areas
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturer’s instructions.
Germany
Explosionsgefahr bei unsachgemäßem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen ähnlichen Typ.
Entsorgung gebrauchter batterien nach Angaben des Herstellers.
France
Ily a danger d’explosion s’ily a remplacement incorrec de la batterie.
Remplacer uniquement avec une batterie du meme type ou d’un type équivalent recommande par le constructueur.
Mettre au rebut les batteries usageés conformément aux instructions du fabricant.
Denmark
Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering Udskiftning må kun ske med batteri af samme fabrikat og type.
Levér det brugte batteri tilbage til leverandøren.
Norway
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
CAUTION
VORSICHT!
ATTENTION
ADVARSEL!
ADVARSEL
Sweden
Explosionsfara vid felaktigt batteribyte.
Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren.
Kassera använt batteri enligt fabrikantens instruktion.
Finland
Paristo voi räjähtää, los se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä Käytetty paristo
valmistajan ohjeiden mukaisesti.
VARNING
VAROlTUS
P-5
Precautions for Service
When performing inspection and service procedures, observe the following precautions to
prevent mishandling of the machine and its parts.
✽
Depending on the model, some of the precautions given in the following do not apply.
Precautions Before Service
• When the user is using a word processor or personal computer from a wall outlet of the
same line, take necessary steps to prevent the circuit breaker from opening due to overloads.
• Never disturb the LAN by breaking or making a network connection, altering termination,
installing or removing networking hardware or software, or shutting down networked
devices without the knowledge and express permission of the network administrator or
the shop supervisor.
How to Use this Book
1. DIS/REASSEMBLY, ADJUSTMENT
• To reassemble the product, reverse the order of disassembly unless otherwise specified.
2. TROUBLESHOOTING
• If a component on a PWB or any other functional unit including a motor is defective, the
text only instructs you to replace the whole PWB or functional unit and does not give
troubleshooting procedures applicable within the defective unit.
• All troubleshooting procedures contained herein assume that there are no breaks in the
harnesses and cords and all connectors are plugged into the right positions.
• The procedures preclude possible malfunctions due to noise and other external causes.
Precautions for Service
• Check the area surrounding the service site for any signs of damage, wear or need of
repair.
• Keep all disassembled parts in good order and keep tools under control so that none will
be lost or damaged.
• After completing a service job, perform a safety check. Make sure that all parts, wiring
and screws are returned to their original positions.
• Do not pull out the toner hopper while the toner bottle is turning. This could result in a
damaged motor or locking mechanism.
• If the product is to be run with the front door open, make sure that the toner hopper is in
the locked position.
• Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit
containing these sensors is to be cleaned, first remove the sensors from the unit.
P-6
Precautions for Dis/Reassembly
• Be sure to unplug the copier from the outlet before attempting to service the copier.
• The basic rule is not to operate the copier anytime during disassembly. If it is absolutely
necessary to run the copier with its covers removed, use care not to allow your clothing
to be caught in revolving parts such as the timing belt and gears.
• Before attempting to replace parts and unplug connectors, make sure that the power
cord of the copier has been unplugged from the wall outlet.
• Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the
Interlock Switch with the covers left open or removed.
• While the product is energized, do not unplug or plug connectors into the circuit boards
or harnesses.
• Never use flammable sprays near the copier.
• A used battery should be disposed of according to the local regulations and never be dis-
carded casually or left unattended at the user’s premises.
• When reassembling parts, make sure that the correct screws (size, type) and toothed
washer are used in the correct places.
• If it becomes necessary to replace the thermal fuse or any other fuse mounted on a
board, be sure to use one of the rating marked on the blown fuse. Always note the rating
marked on the fuse, as the rating and mounting site or number used are subject to
change without notice.
Precautions for Circuit Inspection
• Never create a closed circuit across connector pins except those specified in the text and
on the printed circuit.
• When creating a closed circuit and measuring a voltage across connector pins specified
in the text, be sure to use the GND wire.
P-7
Handling of PWBs
1. During Transportation/Storage:
• During transportation or when in storage, new P.W. Boards must not be indiscriminately
removed from their protective conductive bags.
• Do not store or place P.W. Boards in a location exposed to direct sunlight and high temperature.
• When it becomes absolutely necessary to remove a Board from its conductive bag or
case, always place it on its conductive mat in an area as free as possible from static electricity.
• Do not touch the pins of the ICs with your bare hands.
• Protect the PWBs from any external force so that they are not bent or damaged.
2. During Inspection/Replacement:
• Avoid checking the IC directly with a multimeter; use connectors on the Board.
• Never create a closed circuit across IC pins with a metal tool.
• Before unplugging connectors from the P.W. Boards, make sure that the power cord has
been unplugged from the outlet.
• When removing a Board from its conductive bag or conductive case, do not touch the
pins of the ICs or the printed pattern. Place it in position by holding only the edges of the
Board.
• When touching the PWB, wear a wrist strap and connect its cord to a securely grounded
place whenever possible. If you cannot wear a wrist strap, touch a metal part to discharge static electricity before touching the PWB.
• Note that replacement of a PWB may call for readjustments or resetting of particular
items.
Handling of Other Parts
• The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy
disk, magnetic card, or CRT tube.
P-8
Handling of the PC Drum
✽
Only for Products Not Employing an Imaging Cartridge.
1. During Transportation/Storage:
• Use the specified carton whenever moving or storing the PC Drum.
• The storage temperature is in the range between –20°C and +40°C.
• In summer, avoid leaving the PC Drum in a car for a long time.
2. Handling:
• Ensure that the correct PC Drum is used.
• Whenever the PC Drum has been removed from the copier, store it in its carton or pro-
tect it with a Drum Cloth.
• The PC Drum exhibits greatest light fatigue after being exposed to strong light over an
extended period of time. Never, therefore, expose it to direct sunlight.
• Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter.
• Do not scratch the surface of the PC Drum.
• Do not apply chemicals to the surface of the PC Drum.
• Do not attempt to wipe clean the surface of the PC Drum.
If, however, the surface is contaminated with fingerprints, clean it using the following procedure.
1. Place the PC Drum into one half of its carton.
1076D001
1076D002
2. Gently wipe the residual toner off the surface of the
PC Drum with a dry, Dust-Free Cotton Pad.
A. Turn the PC Drum so that the area of its surface on
which the line of toner left by the Cleaning Blade is
present is facing straight up. Wipe the surface in
one continuous movement from the rear edge of
the PC Drum to the front edge and off the surface
of the PC Drum.
B. Turn the PC Drum slightly and wipe the newly
exposed surface area with a CLEAN face of the
Dust-Free Cotton Pad. Repeat this procedure until
the entire surface of the PC Drum has been thoroughly cleaned.
✽
At this time, always use a CLEAN face of the dry
Dust-Free Cotton Pad until no toner is evident on the
face of the Pad after wiping.
P-9
3. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters.
Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front
edge and off its surface one to two times.
✽
Never move the Pad back and forth.
1076D003
4. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the
entire surface of the PC Drum has been wiped.
Always OVERLAP the areas when wiping. Two
complete turns of the PC Drum would be appropriate for cleaning.
1076D004
NOTES
• Even when the PC Drum is only locally dirtied, wipe the entire surface.
• Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under
interior illumination.
• If dirt remains after cleaning, repeat the entire procedure from the beginning one more
time.
Handling of the Imaging Cartridge
✽
Only for Products Employing an Imaging Cartridge.
1. During Transportation/Storage:
• The storage temperature is in the range between –20°C and +40°C.
• In summer, avoid leaving the Imaging Cartridge in a car for a long time.
2. Handling:
• Store the Imaging Cartridge in a place that is not exposed to direct sunlight.
3. Precautionary Information on the PC Drum Inside the Imaging Cartridge:
• Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter.
• Do not scratch the surface of the PC Drum.
• Do not attempt to wipe clean the surface of the PC Drum.
P-10
DIS/REASSEMBLY,
ADJUSTMENT
10230
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CONTENTS
1. SERVICE INSTRUCTIONS .............................................................................D-1
1-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS ....................D-1
1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ...............D-1
1-3. PARTS WHICH MUST NOT BE TOUCHED ...........................................D-2
(1) Red Painted Screws ........................................................................D-2
(2) Variable Resistors on Board ............................................................D-2
(3) Other Screws ...................................................................................D-2
2. DISASSEMBLY AND REASSEMBLY .............................................................D-3
2-1. IDENTIFICATION AND REMOVAL OF EXTERIOR PARTS ...................D-3
2-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL
COMPONENTS .......................................................................................D-5
2-3. MAINTENANCE SCHEDULE ..................................................................D-7
2-4. REMOVAL OF UNITS .............................................................................D-10
(1) Removal of the Toner Hopper Unit ..................................................D-10
(2) Removal of the PC Unit ...................................................................D-11
(3) Removal of the Developing Unit ......................................................D-13
(4) Removal of the Fusing Unit and Transfer Unit ................................D-14
(5) Removal of the Multi Bypass Unit ....................................................D-15
(6) Removal of the Paper Take-Up Unit ................................................ D-16
(7) Removal of the Paper Exit Unit .......................................................D-17
(8) Removal of the IR Board Assy ........................................................D-18
(9) Removal of the PH Assy .................................................................. D-19
(10) Removal of the PHC Power Supply Board ...................................... D-20
2-5. PAPER TAKE-UP SECTION ................................................................... D-21
(1) Cleaning and Replacement of the Paper Take-Up Roll, Feed Roll,
Separator Roll, and Paper Dust Remover .......................................D-21
(2) Removal of the Synchronizing/Static Charge Roller Assy ............... D-23
(3) Disassembly of the Synchronizing Roller Assy ...............................D-24
(4) Removal of the Drawer Lift-Up Motor Assy ..................................... D-26
(5) Disassembly of the Multi Bypass Unit .............................................D-26
2-6. FUSING/EXIT SECTION .........................................................................D-30
(1) Replacement of the Upper and Lower Fusing Roller Bushings and
Upper and Lower Fusing Rollers .....................................................D-30
(2) Replacement of the Oil Application Roller, Oil Supply Roller, Roller
Drive Gear, and Oil Regulating Blade .............................................D-34
(3) Adding Fuser Oil ..............................................................................D-37
(4) Replacement of the Cleaning Roller ................................................D-38
(5) Replacement of the Oil Collecting Blade and Oil Filter ....................D-39
(6) Cleaning of the Fusing Entrance Guide, Upper and Lower Fusing
Roller Thermistors, and Upper and Lower Fusing Roller
Thermostats ..................................................................................... D-40
(7) Disassembly of the Oil Pump Assy .................................................. D-41
(8) Replacement of the Exit Roller ........................................................D-44
2-7. DEVELOPING UNIT ................................................................................ D-45
(1) Replacement of the ATDC Sensor Window ....................................D-45
i
(2) Cleaning of the Ds Rolls, Toner Scattering Prevention Seal 1, and
Toner Scattering Prevention Plate ................................................... D-45
(3) Replacement of the Toner Collecting Box, Air Filter, and Ozone
Filter .............................................................................................D-45
(4) Removal of the Bk Developing Unit .................................................D-46
(5) Removal of the Y, M, and C Developing Units ................................D-47
(6) Disassembly of the Developing Unit ................................................D-48
(7) Cleaning along the Left Edge of the Developing Units .................... D-55
2-8. TONER HOPPER ....................................................................................D-56
(1) Cleaning of the Shutters ..................................................................D-56
(2) Disassembly of the Toner Hopper Unit ............................................ D-57
2-9. PARTS AROUND THE PC UNIT .............................................................D-64
(1) Removal of the PC Drum Charge Corona Assy and Pre-Cleaning
Charge Corona Assy .......................................................................D-64
(2) Cleaning and Replacement of the Pre-Cleaning Charge Corona .... D-64
(3) Cleaning and Replacement of the PC Drum Charge Corona Assy . D-65
(4) Replacement of the Ozone Filter (PC Drum Charge Corona) and
Cleaning of the Main Erase Lamp ...................................................D-66
(5) Disassembly of the PC Unit .............................................................D-67
(6) Cleaning of Toner Scattering Prevention Seal 2 and the Surface
Potential Detection Sensor .............................................................. D-68
(7) Removal of the PC Shaft Ground Plate ...........................................D-69
(8) Cleaning and Replacement of the Pre-Image Transfer Corona
Assy .............................................................................................D-70
2-10.OPTICAL SECTION ................................................................................D-71
(1) Cleaning of the Original Glass ......................................................... D-71
(2) Cleaning of the 1st to 3rd Mirrors, Slide Rails, and Lens Filter ....... D-71
(3) Disassembly of the Optical Section .................................................D-72
(4) Disassembly of the Scanner ............................................................ D-73
(5) Removal of the Scanner Drive Cables ............................................D-74
(6) Winding of Scanner Drive Cables .................................................... D-78
2-11.TRANSFER UNIT ....................................................................................D-79
(1) Replacement of the Ozone Filter .....................................................D-79
(2) Removal of the Paper Separator Corona ........................................D-79
(3) Cleaning of the Paper Separator Finger, Transfer Drum Ring, and
Separating Failure Detecting Sensor ...............................................D-80
(4) Disassembly of the Transfer Unit ....................................................D-80
(5) Cleaning and Replacement of the Paper Separator Corona Assy ..D-82
(6) Replacement of the Scraper Blade, Fur Brush Roller, and Fur Brush
Pressure Spring ...............................................................................D-82
(7) Cleaning of the Fur Brush Roller Assy ............................................D-84
(8) Removal of the Corona Units ..........................................................D-84
(9) Cleaning and Replacement of the Outer Charge Neutralizing
Corona Assy ....................................................................................D-85
(10) Cleaning and Replacement of the Inner Charge Neutralizing
Corona Assy ....................................................................................D-86
(11) Cleaning and Replacement of the Static Charge Corona Assy ....... D-86
ii
(12) Cleaning and Replacement of the Image Transfer Corona Assy .... D-87
(13) Replacement of the Transfer Film ................................................... D-88
(14) Installation of the Transfer Film .......................................................D-89
(15) Replacement of Backup Blade 1 and Backup Blade 2 ....................D-92
(16) Replacement of the Static Charge Roller Scraper ...........................D-93
3. ADJUSTMENTS ..............................................................................................D-94
3-1. JIGS AND TOOLS USED ........................................................................D-94
(1) Tools for Setting-up and PM ............................................................D-94
(2) Miscellaneous Jigs ..........................................................................D-95
3-2. ADJUSTMENT REQUIREMENTS FOR CLEANING/REPLACEMENT OF
EACH PART ............................................................................................D-96
3-3. ADJUSTMENT OF SWITCHES ...............................................................D-101
3-4. ADJUSTMENT OF SOLENOIDS .............................................................D-102
(1) Adjustment of the Transfer Drum Retract Solenoid .........................D-102
(2) Adjustment of the Static Charge Roller Solenoid ............................D-103
(3) Adjustment of the Paper Separator Finger Solenoid ....................... D-104
(4) Adjustment of the Internal Fur Brush Solenoid, Backup Brush
Solenoid, and Lifting Finger Solenoid ..............................................D-105
(5) Adjustment of the Manual Feed Paper Pick-Up Solenoid ...............D-106
(6) Adjustment of the Oil Roller Solenoid ..............................................D-107
3-5. ADJUSTMENT OF BELT TENSION ........................................................D-108
3-6. TOUCH PANEL CORRECTION MODE ..................................................D-110
3-7. SETTING MODE .....................................................................................D-111
(1) Manual Paper Width ........................................................................D-111
(2) OHP Speed ..................................................................................... D-112
(3) A6 Card Margin (4 × 6 Paper Margin) ............................................. D-112
3-8. MACHINE ADJUST MODE .....................................................................D-113
(1) Fuser Nip .........................................................................................D-113
(2) Fuser Speed ....................................................................................D-115
(3) Fuser Temp. ....................................................................................D-116
(4) AIDC Offset .....................................................................................D-117
(5) Transfer Output ...............................................................................D-117
(6) Jam Sensor .....................................................................................D-119
(7) Feed Motor Speed ...........................................................................D-120
(8) PRT Area ......................................................................................... D-122
(9) A6 Card Passage (4 × 6 Paper Passage) .......................................D-126
(10) Paper Loop ......................................................................................D-126
(11) IR Area ............................................................................................D-127
(12) Orig. Detect Sensor .........................................................................D-129
3-9. DEVELOPER CHANGE MODE ...............................................................D-130
(1) Developer Change (Developer Discharge → Developer Filling →
Developer Agitating) ........................................................................ D-130
(2) After Dev. (C/M/Y/Bk) Has Been Changed ......................................D-133
(3) Gradation Adjust ..............................................................................D-135
3-10.OTHER ADJUSTMENTS ........................................................................ D-137
(1) Adjustment of the AIDC Sensor Position .........................................D-137
(2) Focus-Positioning of the Scanner and 2nd/3rd Mirrors Carriage .... D-138
iii
(3) Adjustment of the Gap between the Doctor Blade and Sleeve Roller
(Db Adjustment) ...............................................................................D-139
(4) Adjustment of the Amount of Transfer Drum Retraction .................. D-140
(5) Adjustment of the Paper Separator Finger Roll Position .................D-141
(6) Adjustment of Clearance between the Transfer Drum Joint and
Paper Separator Guide ....................................................................D-142
(7) Adjustment of the Amount of Projection of Backup Blade 2 and 1 .. D-143
(8) Adjustment of Sprocket Unit Position ..............................................D-144
4. MISCELLANEOUS ..........................................................................................D-145
4-1. INSTALLATION OF THE PLUG-IN COUNTER MOUNTING BRACKET
(OPTION) .................................................................................................D-145
4-2. INSTALLATION OF THE ORIGINAL SIZE DETECTING SENSORS
(OPTION) .................................................................................................D-146
4-3. RAM PACK REPLACEMENT PROCEDURE ..........................................D-147
4-4. FLASH MEMORY ....................................................................................D-150
(1) Using a Single Memory Card ...........................................................D-150
(2) Using Two Memory Cards ...............................................................D-151
(3) Writing upon Replacement of IR Control Board/Master Board ........ D-152
(4) Action to be Taken When Data Transfer Fails .................................D-152
iv
1. SERVICE INSTRUCTIONS
1-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS
DC Power Supply 2 (PU2)
100 V AREA 125 V 6.3 A
200 V AREA 250 V 3.15 A
Engine Power Supply
Board (PWB-LE)
250V 3.15A (4 pcs.)
100 V AREA
DC Power Supply 1
(PU1)
125 V 12 A
250 V 3.15 A
250 V 6.3 A
200 V AREA
250 V 6.3 A
250 V 2 A
Circuit Breaker 1
(CB1) 15 A
1179D081CA
1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT
• The laser used in this copier is a semiconductor laser having the following specifications.
Max. power: 35 mW
Output wavelength: 675 to 695 nm
• When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.
• When a service job needs to be performed in the laser beam path, such as when working
around the PH or PC Drum, be sure first to turn OFF the copier.
• If the job requires that the copier be left ON, take off your watch and ring and wear laser
protective goggles.
• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use
utmost care when handling tools on the user’s premises.
• The PH is nonmaintainable in the field. It is to be replaced as an assembly including the
control board. NEVER, therefore, attempt to remove the laser diode or adjust trimmers
on the control board.
D-1
1-3. PARTS WHICH MUST NOT BE TOUCHED
(1) Red Painted Screws
Purpose of Application of Red Paint
Red painted screws show that the assembly or unit secured can only be adjusted or set at
the factory and shall not be readjusted, set, or removed in the field.
If it becomes unavoidably necessary to disassemble any of these assemblies and units,
disassembly may be done provided that the conditions permitting reassembly are met.
Note also that when two or more screws are used on the part in question, only one representative screw may be marked with red paint.
(2) Variable Resistors on Board
Do not turn the variable resistors on boards to which no adjusting instructions are given in
ADJUSTMENT.
(3) Other Screws
Although not marked with red paint, the following screws must not be loosened or readjusted.
Four screws on the 2nd/3rd Mirrors Carriage
D-2
1144D249AA
2. DISASSEMBLY AND REASSEMBLY
2-1. IDENTIFICATION AND REMOVAL OF EXTERIOR PARTS
4
3
2
1
5
10
20
9
8
11
6
7
1179D002AA
12
13
14
15
16
17
19
18
1179D003AA
D-3
No. Name Removal Procedure
1 Front Door Open and remove the Front Door.
Raise Original Cover. → Open 1. → Remove 4 and 13. →
Remove 12. → Remove two magnet catches. → Remove two
2 Control Panel
3 Original Glass
4 Right Upper Cover Remove two screws that secure the Upper Right Cover.
5 Upper Right Cover
6 Lower Right Cover
7 Lower Front Cover
8 Lower Drawer
9 Middle Drawer
10 Upper Drawer
11 Rear Upper Cover
Original Width
12
Scale
13 Left Upper Cover Remove two screws that secure the Left Upper Cover.
14 Upper Left Cover
15 Middle Left Cover Remove two screws that secure the Middle Left Cover.
Lower Front Left
16
Cover
17 Multi Bypass Unit☞ D-15
Lower Rear Left
18
Cover
19 Rear Cover
Toner Collecting
20
Box Cover
screws that secure the Control Panel.
✽
Reinstallation Tip:
Fit the Control Panel into the rectangular hole in the panel
mounting bracket.
Remove 13. → Remove 12.
✽
Reinstallation Tip:
Fit the Original Glass into the groove in the Original Scale and
fit the glass into the Glass Restriction Plate.
Remove 4. → Remove four screws that secure the Upper Right
Cover.
Remove 4 and 5. → Remove five screws that secure the Lower
Right Cover.
Slide out the Lower Drawer. → Remove two screws that secure
the Lower Front Cover.
Slide out the drawer. → Remove the stopper. → Pull out the
drawer while slightly lifting it.
Remove Original Cover. → Remove two Hinge Covers. →
Remove 4 and 13. → Remove 21. → Remove 20. → Remove 5
and 14. → Remove six screws that secure the Rear Upper Cover.
Remove 13. → Remove two screws that secure the Original
Width Scale.
Remove 13. → Remove 16. → Remove 15. → Remove six screws
that secure the Upper Left Cover.
Remove two screws that secure the Lower Front Left Cover.
Remove two screws that secure the Lower Rear Left Cover.
Remove 21. → Remove seven screws that secure the Rear
Cover.
Remove one screw that secures the Toner Collecting Box Cover.
D-4
2-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL
COMPONENTS
• When removing a PWB or other electrical component, refer to “PRECAUTIONS FOR
HANDLING THE PWBs” and follow the corresponding removal procedures.
• The removal procedures given in the following omit the removal of connectors and
screws securing the PWB support or PBW.
• Where it is absolutely necessary to touch the ICs and other electrical components on the
PWB, be sure to ground your body.
PU2
PWB-LE
PWB-ID
PWB-C
PU1
HV1
PWB-K
PWB-S2
UN22
UN23
PWB-O
PWB-Y
PWB-G
PWB-A
PWB-LP
PWB-JD
UN19
PWB-IM
UN27
PWB-P
HV3
PWB-W
HV2
HV4
PWB-M1
1179D082CA
NOTE
When PWB-IM (Master Board) has been replaced, never fail to remove and reinstall IC6
(RAM) on the board.
D-5
Symbol Name Removal Procedure
Remove the CCD Assy Cover. →
→
Remove 6 and 19. → Remove mounting
→
Remove 6 and 19. → Remove mounting
→
Remove cover. → PWB-M1
→
Remove Transfer Film. → PWB-O
→
PWB-A CCD Sensor Board
PWB-C IR Control Board
PWB-G SCP Board
PWB-ID Drive Board
PWB-IM Master Board
PWB-JD
PWB-K
PWB-LE
PWB-LP
PWB-M1
PWB-O
PH Control Board
(Digital)
Paper Take-Up
Board
Engine Power Supply Board
PHC Power Supply
Board
Automatic Adj.
Board
Paper Bonding Failure Detection Board 1Slide out Developing Unit.
Remove 13, 12, and 3.
Remove 5.
Board Assy.
Remove PWB-A with CCD Assy.
Remove 5.
Board Assy.
D-75
☞
D-74
☞
Remove 5.
Board Assy.
Remove 5.
Board Assy.
Remove 21 and 20.
bracket.
Remove 21 and 20.
bracket.
D-20
☞
Slide out Developing Unit.
Remove Shield Covers C and D. → Remove IR
→
PWB-A
→
Remove Shield Covers C and D. → Remove IR
→
Remove Shield Cover B. → PWB-C
→
Remove Shield Covers C and D. → Remove IR
→
Remove Shield Cover B. → PWB-IM
→
Remove Shield Covers C and D. → Remove IR
→
Remove Shield Cover B. → PWB-JD
→
PWB-K
→
PWB-LE
→
PWB-P
PWB-S2
PWB-W
PWB-Y
UN19
UN22
UN23 Humidity Sensor Remove 21 and 20.
UN27 Control Panel
PU1 DC Power Supply 1
PU2 DC Power Supply 2
HV1 High Voltage Unit 1 Remove 21 and 20.
HV2 High Voltage Unit 2
HV3 High Voltage Unit 3
HV4 High Voltage Unit 4
Paper Bonding Failure Detection Board
2
Tech. Rep. Setting
Switches Board
PC Drum Heater
Control Board
Failure Sensor Adj.
Board
Polygon Motor
Drive Board
Surface Potential
Detection Sensor
Slide out Developing Unit.
Remove 2.
Slide out PC Unit.
Slide out Transfer Unit.
Remove PWB Cover.
Remove 5.
Board Assy.
Remove 21 and 20.
Remove 2.
Remove 21 and 20.
mounting bracket.
D-74
☞
Slide out Transfer Unit.
Slide out Transfer Unit.
Slide out and remove Developing Unit.
Remove Developing Unit fixing bracket. → Remove Pre-
→
Image Transfer Corona Holder Assy.
Unit.
PWB-S2
→
Remove Shield Covers C and D. → Remove IR
→
Remove PH Upper Assy. → UN19
→
UN27
→
Remove cover. → HV4
→
D-6
Remove Transfer Film. → PWB-P
→
Remove PC Drum. → PWB-W
→
Remove Transfer Unit Cover. →
→
PWB-Y
→
Remove Toner Collecting Box. → UN22
→
Remove Toner Collecting Box. → UN23
→
Remove 6 and 19. → Remove Cover
→
Remove Cooling Fan Assy. → PU1
→
Remove mounting bracket. → HV1
→
Remove Transfer Unit Cover. → HV2
→
Remove Transfer Film. → HV3
→
Remove Drive Cover.
→
Remove Bk Developing
→
2-3. MAINTENANCE SCHEDULE
• To keep the copier in good operating condition and ensure an extended service life of the
copier, it is recommended that the maintenance jobs described in this schedule be carried out.
Maintenance
PM Parts
Paper Take-Up/Feed Roll Assy
Paper Separator Roll Assy
Synchronizing Roller 30 ––3
Transport Roller 30 ––2
Vertical Transport Roller 30 ––6
Paper Dust Remo ver (Transport
Roller)
Paper Take-Up/ Transport
Fusing Roller
(Upper)
(Lower) – 60 11ZT53440 1 –
Upper Fusing Roller Bushing
(Front)
(Rear) – 180 25TU75710 1 –
Lower Fusing Roller Bushing
(Front)
(Rear) – 180 25TU75710 1 –
Cleaning Roller – 15 25TU53200 1 –
Fusing Entrance Guide 15 ––1
Fusing Roller Thermistor
(Upper)
(Lower) 15 ––2
Fusing Roller Thermostat
(Upper)
Fusing/Exit
(Lower) 15 ––2
Oil Regulating Blade 15 60 11ZT54060 1
Oil Collecting Blade 15 120 11UM54360 1
Paper Separator Fingers 15 ––––
Fuser Oil (✽2) –––
Oil Application Roller – 120 25TU54110 1 –
Oil Supply Roller – 120 25TU54100 1 –
Oil Filter – 15 25TU53610 1 –
Roller Drive Gear – 120
Paper Exit Roller – 120 11ZT47200 1 –
Developer Bk –
Developer Y/M/C –
Ds Roll 30 ––8
Developing
Toner Scattering Prevention
Seal 1 (Y Developing Unit only)
✽
1: According to the Life Counter.
✽
2: Add oil at 15K (based on A4 paper) or when an oil-empty condition is detected.
Cycle (K)
Clean Replace
60
(✽1)
(✽1)
180
(✽1)
60
180
(✽1)
30 120 25TU40370 1
– 60 11ZT53010 1 –
– 180 25TU75730 1 –
– 180 25TU75730 1 –
15 ––2
15 ––2
30
(✽1)
30
(✽1)
30 ––1
Part No. Qty Tools Used Ref. Page
25TU-4010 3
25TU-4020 3
25TU77890 1
25TU77970 1
25TU77980 2
– 1 –
– 3 –
Cloth, alcohol
Brush, vacuum cleaner
Cloth, alcohol
–
Cloth, alcohol
☞ D-21
☞ D-21
☞
D-24
☞
D-21
☞ D-21
☞ D-21
☞
D-30
☞ D-30
☞
D-30
☞
D-30
☞ D-30
☞ D-30
☞ D-38
☞
D-40
☞ D-40
☞
D-40
☞
D-40
☞ D-40
☞
D-34
☞ D-39
☞
D-33
☞ D-37
☞ D-34
☞ D-34
☞ D-39
☞ D-34
☞ D-34
☞ D-34
☞ D-44
☞ D-130
☞ D-130
☞ D-45
☞ D-45
D-7
Maintenance
PM Parts
Toner Scattering Prevention
Plate (M/C/Bk)
Screw Assy Bushing
(Front)
(Rear) – 150 25TU75240 4 –
ATDC Sensor Window Y/M/C – 30 11ZT-3060 3 –
Air Filter – 60 25TU32120 1 –
Developing
Ozone Filter – (✽3) 25TU32110 1 –
Toner Collecting Box – (✽4) 11ZT-3210 1 –
Developing Unit Left Edge 15 ––4
Cycle (K)
Clean Replace
30 ––3
– 150 25TU75670 4 –
Part No. Qty Tools Used Ref. Page
Brush, vacuum cleaner
Cloth, vacuum cleaner
☞
☞
☞
☞
☞
☞
☞
☞
D-45
D-54
D-53
D-45
D-45
D-45
D-45
D-55
Shutter 60 ––4 Cloth
Hopper
PC Drum – 30 – 1 –
PC Drum Charge Corona Wire
Assy
Grid Mesh – 15 25TU25140 1 –
PC Drum Charge Corona
Housing
Ozone Filter (PC Drum Charge
Corona)
Cleaning Blade 15 25TU55400 1 –
Toner Antispill Seal 15 ––1
Pre-Cleaning Charge Corona
Wire
Pre-Cleaning Charge Corona
Housing
Main Erase Lamp 30 – 1
AIDC Sensor 15 – 1
Cleaner Side Seal
Parts around PC Unit
(Front)
(Rear) – 30 25TU55130 1 –
PC Bushing – 30 25TU55121 2 –
PC Drum Heater Terminal 30 ––1
Front Flange 30 120 25TU55240 1
Surface Potential Detection
Sensor
Toner Scattering Prevention
Seal 2 (under PC Drum Charge
Corona)
Slide Rail 30 ––4
Mirror (1st to 3rd) 15 ––3
Lens Filter 15 ––1
Optical
Original Glass 15 ––1
✽
3: 60K or 1 year
✽
4: At 75K or when a full Toner Collecting Box is detected
– 15 11UM25090 1 –
15 ––1 Cloth, water
(✽3) 25TU25370 1 –
15 30 25TU55190 1
15 ––1
– 30 25TU55310 1 –
30 ––1 Airbrush
30 ––1 Cloth
Brush, vacuum cleaner
Cloth, water
Cloth, alcohol
Cloth, alcohol
Cloth, alcohol
☞ D-56
☞
D-67
☞
D-65
☞
D-65
☞ D-65
☞ D-66
☞
D-67
☞
D-67
☞
D-64
☞
D-64
☞ D-66
☞
D-46
☞ D-67
☞
D-67
☞
D-67
☞ D-66
☞ D-67
☞ D-68
☞ D-68
☞ D-71
☞ D-71
☞ D-71
☞ D-71
D-8
Maintenance
PM Parts
Window 1 (PH Upper Assy) 30 ––1
Window 2 (PH Upper Assy) 30 ––1
PH
Window 3 (PH Lower Assy) 30 ––1
Window 4 (PH Lower Assy) 30 ––1
Transfer Film –
Image Transfer Corona Wire 30 150 25TU21220 1
Image Transfer Cor ona Housing 30 ––1
Paper Separator Corona Assy 30 150 11UM-2600 1
Charge Neutralizing Corona
Assy (Inner)
(Outer) 30 150 11UM-2570 1
Static Charge Corona Wire 30 150 25TU21220 1
Static Charge Corona Housing 30 ––1
Paper Separator Finger 30 ––1
Transfer Drum Ring 30 ––2
Ozone Filter (Fusing, Image
Transfer)
Fur Brush Roller – 60 25TU46030 1 –
Fur Brush Roller Pressure
Spring
Fur Brush Roller Assy 30 ––1
Scraper Blade – 120 25TU45380 1 –
Sensor on Paper Bonding Fail-
ure Detection Board 1
Separating Failure Detecting
Sensor
Image Transfer
Sensor on Paper Bonding Failure Detection Board 2
Backup Blade 1 – 30 25TU21270 1 –
Static Charge Roller 15 ––1
Static Charge Roller Rubber
Roll
Static Charge Roller Scraper 15 150 25TU45380 1
Static Charge Roller Assy 15 ––1
Backup Blade 2 – 30 25TU21140 1 –
Oil Collecting Roller – 30 25TU27200 1 –
Static Charge Roller Clutch
Spring
Pre-Image Transfer Corona
Comb Electrode
Pre-Image Transfer Corona
Grid Mesh
Pre-Image Transfer Corona
Housing
✽
5: Perform “Jam Sensor” at the time of replacement.
✽
6: Apply heat-resistant grease (HP-500) at replacement.
Cycle (K)
Clean Replace
30
(✽5)
30 150 25TU-2580 1
– (✽3) 25TU32040 1 –
– 60 25TU46170 2 –
30 ––1
30 ––1
30 ––1
15 ––2
60
–
(✽6)
– 30 11ZT21020 1 –
15 30 11ZT21010
15 ––
Part No. Qty Tools Used Ref. Page
11UM20020 1 –
25TU20060 1 –
Brush, airbrush
Cloth, water
Cloth, alcohol
Brush, vacuum cleaner
Cloth
Cloth, alcohol
Brush, vacuum cleaner
Cloth, water
☞
D-19
☞
D-19
☞
D-19
☞
D-19
☞
D-88
☞
D-87
☞ D-87
☞ D-82
☞
D-86
☞ D-85
☞ D-86
☞
D-86
☞
D-80
☞ D-80
☞ D-79
☞ D-82
☞
D-82
☞
D-84
☞ D-82
☞
D-92
☞ D-80
☞
D-92
☞
D-92
☞
D-93
☞
D-93
☞
D-93
☞ D-93
☞ D-92
☞ D-80
☞ D-23
☞ D-70
☞ D-70
☞ D-70
NOTES
• K = 1,000 copies
• The contents of this maintenance schedule are subject to change without notice.
D-9
2-4. REMOVAL OF UNITS
• This copier provides maintainability of each mechanical unit to shorten downtime at the
user’s premises.
• Note that replacement of a unit may call for readjustments or resetting of particular items.
Paper Exit Unit
Toner Hopper Unit
Paper Take-Up Unit
PC Unit
Multi Bypass Unit
Developing Unit
(1) Removal of the Toner Hopper Unit
Transfer Unit
Fusing Unit
1179D005AA
1. Slide out the Guide Rails.
3. Loosen the shoulder screws.
4. Toner Hopper Unit
2. Toner Antispill Plate
1154D289AA
D-10
(2) Removal of the PC Unit
Remove the Toner Hopper Unit, unlock the Transfer Unit lever, and remove the Transfer Unit
Cover. Then, remove the PC Unit.
1. Developing Unit Cover
4. PC Front Frame Assy
B
5. Drum Holder
Fig. 2
3. PC Drum Charge Corona Assy
Fig. 1
While sliding the PC
Unit into the copier,
swing the drum in the
direction of the arrow
to avoid scratching it
on the Surface Potential Detection Sensor.
2. Slide out and then push down the
Developing Unit Pressure Lever.
6. PC Unit
Fig. 1
A
Fig. 2
At reinstallation, check that the Drum
Holder tabs fit into the slots. (If the
tabs do not fit in, turn the Drum
Holder.)
1154D291AA
1144D008AB
B
A
1154D290AA
1154D120AA
D-11
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