KONICA MINOLTA D 1531 Service Manual

DEVELOP

Service Manual

General

D 1531iD · D1831iD

4890 4A06 91100/DP/0102

INDEX (GENERAL)

GENERAL

MECHANICAL/ELECTRICAL

GENERAL

14413

CONTENTS

1. SPECIFICATION .............................................................................................G-1

2. PRECAUTIONS FOR INSTALLATION ............................................................G-5

2-1. Installation Site ........................................................................................G-5

2-2. Power Source ..........................................................................................G-5

2-3. Grounding ................................................................................................G-5

3. PRECAUTIONS FOR USE ..............................................................................G-6

3-1. To ensure that the copier is used in an optimum condition .....................G-6

3-2. Operating Environment ............................................................................G-6

3-3. Power Requirements ............................................................................... G-6

3-4. Note .........................................................................................................G-6

4. HANDLING OF CONSUMABLES ....................................................................G-7

5. OTHER PRECAUTIONS .................................................................................G-8

6. SYSTEM OPTIONS .........................................................................................G-9

i

1. SPECIFICATION

TYPE
ORIGINAL SCANNING SYSTEM
PHOTOCONDUCTOR
COPYING SYSTEM

RESOLUTION
PAPER FEEDING SYSTEM

EXPOSURE SYSTEM
DEVELOPING SYSTEM
CHARGING SYSTEM

IMAGE TRANSFER SYSTEM
PAPER SEPARATING SYSTEM

FUSING SYSTEM
PAPER DISCHARGING SYSTEM
MAX. ORIGINAL SIZE

COPY MEDIUM

Paper Source Drawer Manual Bypass

Plain Paper (60 to 90 g/m

Transparencies

Ty p e

Dimensions

MULTIPLE COPIES
WARMING-UP TIME
FIRST COPY TIME

CONTINUOUS COPY SPEED (copies/min)

Size

A4C
A4L
A3L
B4L
B5C

B5L
8-1/2 × 11C
8-1/2 × 11L

11 × 17L

8-1/2 × 14L

11 × 14

Thick Paper (91 to 157 g/m

Recycled Paper (60 to 90 g/m

Maximum (Width × Length) 297 × 432 mm 297 × 432 mm

Minimum (Width × Length) 90 × 140 mm 90 × 140 mm

:

Console/Desktop Type

:

CCD Line Sensor

:

Organic Photoconductor

:

Electrostatic Dry Powdered Image Transfer to Plain
Paper with a Laser

:

600 × 600 dpi

:

2-way system
Manual Bypass...Single

Drawer................250 Sheets

:

Mirror Scanning

:

MT-HG System

:

Comb Electrode (1) DC Negative Corona with
Scorotron System

:

Roller Image Transfer

:

Paper Separator Fingers and Charge Neutralizing
Plate

:

Heat Roller

:

Charge Neutralizing Brush

:

A3L, 11 × 17

Postcards

:

1 to 99

:

30 sec. or less (23, Rated Voltage)

:

7 sec. or less (A4C, Drawer, full size mode)

Di152 Di183

15
12

9
10
16
13
15
12

9
10
10

2

)

2

)

2

)

Speed

❍❍
❍❍
❍❍
❍❍
❍❍

18
14
10
12
20
15
18
14
10
12
12

G-1

ZOOM RATIOS

Metric Inch

Full Size 100 % 100 %

200 %

Fixed

Enlargement

Reduction

Variable 50 % to 200 % (in 1 % increments)

141 %
115 %

81 %
70 %
50 %

200 %
129 %
121 %

78 %
64 %
50 %

LENS
EXPOSURE LAMP

POWER/CURRENT CONSUMPTION (copier only)

Exposure Lamp

(Rating)

24 V

14.4 W

POWER REQUIREMENTS : 110 V, 120 V, 127 V, 220 V to 240 V, 50/60 Hz

ENVIRONMENTAL CONDITIONS

Temperature 10 to 30 °C with a fluctuation of 10 °C or less per hour

Humidity 15 to 85 % RH with a fluctuation of 10 % RH or less per hour

Ambient Illumination 3,000 lux or less

Levelness 1° (1.75 mm/100 mm)

COPIER DIMENSION

COPIER WEIGHT

Fusing Roller
Heater Lamp

::Through Lens

Fluorescent Lamp

(Rating)

900 W

::W...590 mm (23-1/4)

D....611 mm (24)

H....487 mm (19-1/4)

39 kg (86 lb)

Max. Power

Consumption

(full system)

110 V: 970 W
120 V: 1090 W
127 V: 1180 W
220 V: 990 W
230 V: 1050 W
240 V: 1120 W

Max. Current
Consumption

(full system)
110 V: 8.9 A

120 V: 9.1 A
127 V: 9.3 A
220 V: 4.5 A
230 V: 4.6 A
240 V: 4.7 A

G-2

Multiple Bypass (MB-5): option

TYPE
INSTALLATION

COPY PAPER TYPE

Plain Paper (60 to 90 g/m

Transparencies 20 sheets

Ty p e

Thick Paper (91 to 157 g/m

Recycled Paper (60 to 90 g/m

Dimensions

Size

Maximum (Width × Length) 297 × 432 mm

Minimum (Width × Length) 90 × 140 mm

A3L, B4L, FLS, A4L, A4C, B5L, B5C, A5C,11 × 17, 11 × 14, 8-1/2 × 14,
8-1/2 × 11L, 8-1/2 × 11C, 8-1/2 × 5-1/2

DOCUMENT ALIGNMENT
CAPACITY
POWER REQUIREMENTS
MAX. POWER CONSUMPTION
DIMENSIONS

WEIGHT
OPERATING ENVIRONMENT

::Multiple Bypass

Mounted on the copier

2

)

2

)

50 sheets

20 sheets

Postcards 20 sheets

2

)

Center

:
:

50 sheets (80 g/m

:

DC24 V, DC5 V (supplied from copier)

:

9 W or less

:

W...245 mm (9-3/4)

2

)

50 sheets

D....435 mm (17-1/4)

H....137 mm (5-1/2)

:

2.7 kg (6 lb)

:

Same as copier

G-3

Job Tray (JS-202): option

TYPE
INSTALLATION

::Multiple Bypass

Mounted on the copier

CAPACITY

Exit Tray

of the machine

1Stacking height up

Plain Paper (60 to 90 g/m

150 sheets (A4C/L)

2

75 sheets

)

(except A4C/L)

to 22 mm
100 sheets (A4C/L)
50 sheets
(except A4C/L)

Transparencies

Ty p e

Thick Paper (91 to 157 g/m

2

)

20 sheets 10 sheets

Postcards

Stacking height up to

Recycled Paper (60 to 90 g/m

150 sheets (A4C/L)

2

75 sheets

)

(except A4C/L)

22 mm
100 sheets (A4C/L)
50 sheets
(except A4C/L)

Dimensions

Maximum (Width × Length) 297 × 432 mm

Minimum (Width × Length) 90 × 140 mm 140 × 140 mm

Exit Tray by Application Mode

Application Mode

Exit Tray

of the machine

Job Tray

Fax and Copier Copier Fax

Printer and Copier Copier Printer

Fax, Copier and Printer Copier Fax and Printer

Job Tray

POWER REQUIREMENTS : DC24 V, DC5 V (supplied from copier)

Shifting Unit (OT-103): option

TYPE
INSTALLATION
POWER REQUIREMENTS

:

Multiple Bypass

:

Mounted on the copier

:

DC24 V, DC5 V (supplied from copier)

G-4

2. PRECAUTIONS FOR INSTALLATION

2-1. Installation Site

To ensure safety and utmost performance of the copier, the copier should NOT be used in a
place:

• Where it will be subjected to extremely high or low temperature or humidity.

• Where it will be subjected to sudden fluctuations in either temperature or humidity.

• Which is exposed to direct sunlight.

• Which is in the direct air stream of an air conditioner, heater, or ventilator.

• Which has poor ventilation or is dusty.

• Which does not have a stable, level floor or where it will receive undue vibration.

• Which is near any kind of heating device.

• Which is near volatile flammables (thinner, gasoline, etc.).

• Where it may be splashed with water.

• Which puts the operator in the direct stream of exhaust from the copier.

• Where ammonia gas might be generated.

2-2. Power Source

• If any other electrical equipment is sourced from the same power outlet, make sure that
the capacity of the outlet is not exceeded.

• Use a power source with little voltage fluctuation.

• Never connect by means of a multiple socket any other appliances or machines to the
outlet being used for the copier.

• Ensure that the copier does not ride on the power cord or communication cable of other
electrical equipment, and that it does not become wedged into or underneath the mecha­nism.

• Make the following checks at frequent intervals:

✽

Is the power plug abnormally hot?

✽

Are there any cracks or scrapes in the cord?

✽

Has the power plug been inserted fully into the outlet?

✽

Does something, including the copier itself, ride on the power cord?

Use an outlet with a capacity of 110 to 127 V, 15 A or more. 220 to 240 V, 10 A or more.

2-3. Grounding

• Always ground the copier to prevent receiving electrical shocks in the case of electrical
leakage.

• Connect the ground wire to the ground terminal of the outlet or a grounding contact which
complies with the local electrical standards.

• Never connect the ground wire to a gas pipe, the ground wire for a telephone, lightning
arrester, or a water pipe for fear of fire and electrical shock.

G-5

3. PRECAUTIONS FOR USE

3-1. To ensure that the copier is used in an optimum condition

• Never place a heavy object on the copier or subject the copier to shocks.

• Insert the power plug all the way into the outlet.

• Do not attempt to remove any panel or cover which is secured while the copier is making
copies.

• Do not turn OFF the copier while it is making copies.

• Provide good ventilation when making a large number of copies continuously.

• Never use flammable sprays near the copier.

• If the copier becomes inordinately hot or produces abnormal noise, turn it OFF and
unplug it.

• Do not turn ON the power switch at the same time when you plug the power cord into the
outlet.

• When unplugging the power cord, do not pull on the cord; hold the plug and pull it out.

• Do not bring any magnetized object near the copier.

• Do not place a vase or vessel containing water on the copier.

• Be sure to turn OFF the power switch at the end of the workday or upon power failure.

• Use care not to drop paper clips, staples, or other small pieces of metal into the copier.

3-2. Operating Environment

The operating environmental requirements of the copier are as follows.

• Temperature: 10 to 30 °C

• Humidity: 15 to 85 % RH

• Rate of temperature change: 10 °C/h

• Rate of humidity change: 10 % RH/h

3-3. Power Requirements

The power source voltage requirements are as follows.

• Voltage fluctuation: AC110 to 127 V/220 to 240 V ± 10 %

(copying performance assured)

• Frequency fluctuation: 50/60 Hz ± 0.3 %

+10 %/-15 % (paper feeding performance assured)

3-4. Note

• It is prohibited to copy paper and hard currencies, government securities, and municipal
bonds (even when they are stamped as “Sample”).

• For fear of infringement of copyright, it is also prohibited to copy copyrighted works,
including books, music, works of art, maps, drawings, motion pictures, and photos except
when the copy is to be used only personally.

G-6

4. HANDLING OF CONSUMABLES

Before using any consumables, always read the label on its container carefully.

• Paper can be easily damaged by dampness. To prevent absorption of moisture, store
paper, which has been removed from its wrapper but not loaded in the drawer, in a
sealed plastic bag in a cool, dark place.

• Keep consumables out of the reach of children.

• Do not touch the PC Drum with bare hands.

• The same sized paper is of two kinds, short grain and long grain. Short grain paper
should only be fed through the copier crosswise, long grain paper should only be fed
lengthwise.

• If your hands become soiled with toner, wash them with soap and water.

• Do not throw away any used consumables (PC Drum, starter, toner, etc.). They are to be
collected.

• Do not burn, bury in the ground, or throw into the water any consumables (PC Drum,
starter, toner, etc.).

• Do not store consumables in a place which:

✽

Is hot and humid.

✽

Is subject to direct sunlight.

✽

Has an open flame nearby.

G-7

5. OTHER PRECAUTIONS

Use the following precautions when performing service jobs for a copier that uses a laser.

• When a service job needs to be performed in the laser beam path, such as when working
around the printerhead or PC Drum, be sure first to unplug the power cord of the copier
from the outlet.

• If the job requires that the power cord be left plugged in, observe the following precau­tions.

1. Take off your watch, ring and any other reflective object and wear laser protective gog-

gles.

2. Keep users away from the job site.

3. Do not bring a highly reflective tool into the laser beam path during the service job.

G-8

6. SYSTEM OPTIONS

1

2

4021O009AA

3

1144M172AC

4021O010AA

7

4

4695U011AA

4021O013AB

6

4021O063AA

4021O012AA

5

1. Plug-In Counter

2. Original Cover OC-5

3. Automatic Document Feeder AF-10

4. Multiple Bypass MB-5

5. Copy Desk

6. Paper Feed Cabinet PF-120

7. Data Terminal DT-201

8. Job Tray JS-202
(Illustration none)

4021O014AA

9. Sifting Unit OT-103
(Illustration none)

10. Memory M16-4, M32-3
(Illustration none)

11. Mechanical Counter CNT1
(Illustration none)

G-9

MECHANICAL/

ELECTRICAL

14413

CONTENTS

1. CROSS SECTIONAL VIEW ............................................................................M-1

2. COPY PROCESS ............................................................................................M-2

3. DRIVE SYSTEM ..............................................................................................M-4

4. SEQUENTIAL EXPLANATION ........................................................................M-5

5. WATCHDOG FUNCTION (CPU OVERRUN MONITOR) ................................M-6

5-1. Watchdog Function Post-Processing .......................................................M-6

6. IMAGE STABILIZATION SYSTEM ..................................................................M-7

7. IMAGING UNIT (I/U) ........................................................................................M-8

7-1. Imaging Unit (IU) Drive Mechanism .........................................................M-9

8. PC DRUM SECTION .......................................................................................M-10

8-1. PC Drum Drive Mechanism .....................................................................M-10

8-2. Grounding of the PC Drum ......................................................................M-11

9. PC DRUM CHARGING SECTION ...................................................................M-12

10. IMAGE READING SECTION ...........................................................................M-13

10-1.Image Processing Process ......................................................................M-14

10-2.Exposure Components Section ...............................................................M-15

10-3.Scanner and Mirrors Carriage Movement Mechanism ............................M-16

(1) Scanner Movement Mechanism ......................................................M-16

(2) 2nd/3rd Mirrors Carriage Movement Mechanism ............................M-16

10-4.Scanner Motor Drive Control ...................................................................M-17

11. MEMORY STORAGE IMAGE PROCESSING SYSTEM .................................M-18

11-1.Laser Exposure Process .........................................................................M-19

12. DEVELOPING UNIT SECTION .......................................................................M-20

12-1.Developing Unit Drive Mechanism ..........................................................M-21

12-2.Sleeve/Magnet Roller ..............................................................................M-22

12-3.Developing Bias .......................................................................................M-22

12-4.ATDC Sensor ..........................................................................................M-23

(1) ATDC Sensor Automatic Adjustment ..............................................M-23

12-5.Toner Replenishing Mechanism ..............................................................M-24

12-6.Toner Replenishing Control .....................................................................M-25

12-7.T/C Recovery Mode .................................................................................M-26

12-8.Toner Bottle Home Position Detection Mechanism .................................M-27

13. PAPER TAKE UP/FEED SECTION .................................................................M-28

13-1.Drawer In Position Detection ...................................................................M-29

13-2.Paper Empty Detection Mechanism ........................................................M-29

13-3.Paper Lifting Plate ...................................................................................M-30

13-4.Universal Tray Paper Size Detection Mechanism ...................................M-30

13-5.Paper Take Up Mechanism .....................................................................M-32

(1) Paper Separating Mechanism .........................................................M-32

13-6.Paper Take Up Control ............................................................................M-33

(1) Paper Take Up Retry Control ..........................................................M-33

14. MANUAL BYPASS SECTION ......................................................................... M-34

14-1.Paper Take Up Drive Mechanism ............................................................ M-34

14-2.Paper Detection Mechanism ...................................................................M-34

14-3.Manual Feed Take Up Control ................................................................M-35

15. MULTIPLE BYPASS SECTION .......................................................................M-36

i

15-1.Paper Take Up Drive Mechanism ............................................................ M-36

15-2.Paper Take-Up Mechanism ..................................................................... M-37

15-3.Paper Empty Detection Mechanism ........................................................M-38

15-4.Paper Take Up Control ............................................................................M-38

15-5.Paper Take Up Retry Control ..................................................................M-39

16. IMAGE TRANSFER AND PAPER SEPARATION SECTION ..........................M-40

17. PC DRUM CLEANING SECTION ....................................................................M-41

18. MAIN ERASE SECTION ..................................................................................M-42

19. FUSING UNIT SECTION .................................................................................M-43

19-1.Fusing Unit Drive Mechanism ..................................................................M-44

19-2.Fusing Rollers Pressure Mechanism ....................................................... M-44

19-3.Fusing Temperature Control ....................................................................M-45

19-4.CPM Control ............................................................................................M-45

20. JOB TRAY (JS-202): Option ............................................................................M-46

20-1.Tray Selecting Mechanism ......................................................................M-47

20-2.Tray-Full Detecting Mechanism ...............................................................M-48

20-3.Job Tray Paper Detecting Mechanism ....................................................M-48

21. SHIFTING UNIT (OT-103): Option ..................................................................M-49

21-1.Exit Position Shifting Mechanism ............................................................M-50

22. OTHER MECHANISM .....................................................................................M-52

22-1.Cooling Mechanism .................................................................................M-52

(1) Power Supply Section Cooling Mechanism .....................................M-52

(2) Fusing Section Cooling Mechanism ................................................M-53

ii

1. CROSS SECTIONAL VIEW

1

2

5

1. IR Section

2. Fusing Unit

3. Imaging Unit

3

4

4. Paper Take-Up/Feed Section

5. PH Section

4021M001AA

M-1

2. COPY PROCESS

4021M065CB

1. PC Drum

• Used as the medium on which a visible developed image of the original is formed.

2. Drum Charging

• A uniform negative DC charge is deposited across the entire surface of the PC Drum.

3. Photoelectric Conversion

• CCD converts the image data represented by light reflected off the original to a corre­sponding electrical signal which, in turn, is output to IR image-processing section.

4. IR Image-Processing

• The electrical signal is converted to an 8-bit digital image signal (A/D conversion) which,
in turn, goes through appropriate correction before being output to the PH Image Pro­cessing.

5. PH Image Processing

• After going through corrections, the digital image signal is converted to a corresponding
electrical signal (D/A conversion) that controls the intensity of the light from the laser
diode.

6. Laser Exposure

• The laser beam strikes the surface of the PC Drum, forming an electrostatic latent image.

7. Developing

• Toner negatively charged in the Developer Mixing Chamber is attracted onto the electro­static latent image changing it to a visible, developed image.

• An AC/DC negative bias voltage is applied to the Sleeve/Magnet Roller to prevent toner
from being attracted onto those areas of the PC Drum which correspond to the back­ground areas of the original.

8. Paper Feed

• Paper is fed from the drawer.

M-2

9. Bypass Paper Feed

• Feeds paper from the Manual Bypass Tray, one piece at a time.

• The optional Multiple Bypass Tray (MB-5), when mounted on the machine, permits con­tinuous paper feeding.

10. Image Transfer

• A DC positive charge is applied to the Image Transfer Roller to transfer the visible image
on the surface of the PC Drum onto the paper.Paper Separation.

11. Paper Separation

• The PC Drum Paper Separator Fingers remove paper from the surface of the PC Drum.

• The Charge Neutralizing Plate neutralizes any charge left on the paper.

12. Cleaning

• Residual toner on the surface of the PC Drum is scraped off.

• The toner is then recycled back to the Developing Unit.

13. Main Erase

• Light is directed to the surface of the PC Drum to neutralize any surface potential remain­ing there after cleaning.

14. Paper Transport

• The paper is fed to the Fusing Unit.

15. Fusing

• The developed image is permanently fused to the paper by a combination of heat and
pressure applied by the Right and Left Fusing Rollers.

16. Paper Exit

• The paper is fed out onto the Exit Tray.

• When the optional Job Tray (JS-202) is mounted, the specific tray into which paper is fed
is selected according to the application mode.

• The optional Shifting Unit (OT-103), when mounted, permits different finishing functions
set on the machine (Non-Sort, and Sort).

M-3

3. DRIVE SYSTEM

1

Paper Exit Roller Gear

Transport Roller Gear

Fusing Roller Gear

1. Scanner Motor M5

2. Main Motor M1

PC Drum

Synchronizing Roller Clutch

Paper Take-Up Roller Gear

2

4021M003AA

M-4

4. SEQUENTIAL EXPLANATION

4021M510CA

Power Switch ON Start Key ON

Polygon Motor M2

Predrive

150 ˚C Warm-up completed

Exposure Lamp LA2

Main Motor M1

Paper Take-Up Solenoid SL1

Synchronizing Roller Sensor PC1

Synchronizing Roller Clutch CL1

Developing Bias (VB) DC

Developing Bias (VB) AC

Image Transfer Bias (+)

Image Transfer Bias (–)

Exit Paper Sensor PC3

M-5

Full speed

Full speed

Speed reduction

Speed reduction

Power Supply Cooling

Fan Motor M4

Fusing Cooling Fan

Motor M3

5. WATCHDOG FUNCTION (CPU OVERRUN MONITOR)

• The watchdog function, or CPU overrun monitor function, monitors whether any of the
CPUs mounted in the copier overruns.

• If the function detects that a CPU overruns, the copier automatically resets the CPU,
thereby restarting the logic circuit and mechanism.

5-1. Watchdog Function Post-Processing

The following processing is performed if a faulty condition is detected in the CPU.
When the copier CPU is found faulty:

• All CPUs are reset and the system is restarted.

• If the CPU is found faulty during a copy cycle, the system attempts to feed all sheets of
paper out of the copier before restarting. (If paper is left inside the copier, the copier
detects it as a misfeed as it is restarted.)

M-6

6. IMAGE STABILIZATION SYSTEM

The following image stabilization controls are provided to ensure stabilized copy image.

Purpose Means Control

The Vg/Vb control voltage is varied to bring
Vg/Vb to an appropriate level according to
the following settings.

To stabilize image density. Vg/Vb control

To stabilize image transfer.

Image transfer
output control

• Tech. Rep. Choice: ID Adjustment

• Tech. Rep. Choice: VG Adjustment

• User's Choice: Print Density

• IU Life Counter

• Paper type
The image transfer output is varied to bring

the image transfer current to an appropriate
level according to the following conditions.

• Paper type

• Paper width

• B/W ratio of image

M-7

4021M066CA

7. IMAGING UNIT (I/U)

• The IU integrates the PC Drum, Developing Unit, PC Drum Charge Corona, and the PC
Drum Cleaning Mechanism, all in one body.

PC Drum

PC Drum Cleaning Mechanism

4021M006AB

PC Drum Charge Corona

Developing Unit

4021M007AB

M-8

7-1. Imaging Unit (IU) Drive Mechanism

• The IU is driven by the Main Motor.

Main Motor M1

4021M008AB

Elevtrical Component Control Signal

M1

PWB-A PJ7A-5 L L H
PWB-A PJ7A-7 H L H

Forward
Rotation

M-9

Backward

Rotation

OFF Wiring Diagram

17-G

8. PC DRUM SECTION

• The PC Drum consists of layers of semiconductive materials placed on an aluminum
alloy base, on which an electrostatic latent image is formed.

PC Drum

(PC Drum Cross-Section)

Charge Transport Layer

Charge Generation Layer

1167M007AA

8-1. PC Drum Drive Mechanism

• The PC Drum is rotated by drive from a motor.

PC Drum

Aluminum Base

1139M007AA

Main Motor M1

Elevtrical Component Control Signal

M1

PWB-A PJ7A-5 L H
PWB-A PJ7A-7 H H

Forward
Rotation

M-10

4021M009AA

OFF Wiring Diagram

17-G

8-2. Grounding of the PC Drum

• The potential on the surface of the PC Drum exposed to the light is grounded to the
frame.

PC Drum

Frame

Ground Plate

4021M010AA

M-11

9. PC DRUM CHARGING SECTION

• The PC Drum Charge Corona has a scorotron grid to deposit a charge evenly across the
surface of the PC Drum.

• The corona unit has a comb electrode that discharges only toward the grid mesh, thus
minimizing the amount of ozone produced.

Comb Electrobe

Grid Mesh

Elevtrical Component Control Signal ON OFF Wiring Diagram

HV1 PWB-A PJ8A-8 L H 5-C

4021M011AA

M-12

10. IMAGE READING SECTION

6

5

1. Scanner /Motor M5

2. CCD Board PWB-J

3. Size Reset Switch S10

1

4. Scanner

5. 2nd/3rd Mirrors Carriage

6. Scanner Home Position Sensor PC6

2

3

4

4021M012AB

M-13

10-1. Image Processing Process

1. Photoelectric Conversion

• Light reflected off the original is read by the CCD Sensor which converts the data to a
corresponding analog signal.

2. Analog-to-Digital Conversion

• The analog signal output from the CCD Sensor is converted to a corresponding 8-bit dig­ital signal.

3. Shading Correction

• An error is corrected that occurs due to variations in sensitivity of each CCD chip and the
light distribution varying along the length of the Exposure Lamp.

• The data obtained through actually illuminating the shading sheet with the Exposure
Lamp is compared with the shading sheet reading reference value (white = max. data
value) to make the necessary correction.

4. Zoom Processing

• The synchronous timing of the input data (read) and output data (read) is varied to
decrease (reduction) or increase (enlargement) the number of data readings, thereby
reducing or enlarging the image in the main scanning direction.

5. Data is sent to the PH.

M-14

10-2. Exposure Components Section

1

2

4021M013AA

3

1. Auxiliary Reflector

When a book or other bound original is copied, the paper in the area near the binding
generally fails to come flush against the glass, so that the copy of these areas is gener­ally too dark. The Auxiliary Reflector reduces this problem by reflecting light from the
Exposure Lamp onto these areas of the original.

2. Exposure Lamp LA2

A fluorescent lamp is used to illuminate the original.

3. 1st Mirror

Directs the light reflected off the original to the 2nd Mirror.

M-15

10-3. Scanner and Mirrors Carriage Movement Mechanism

(1) Scanner Movement Mechanism

• The Scanner is driven by the Scanner Motor.

(2) 2nd/3rd Mirrors Carriage Movement Mechanism

• The 2nd/3rd Mirrors Carriage moves at a speed half that of the Scanner, thereby keeping
constant the optical path length between the original and the CCD Board.

Scanner Motor M5

2nd/3rd Mirrors Carriage

CCD Board PWB-J

Scanner

4021M014AB

M-16

10-4. Scanner Motor Drive Control

• The speed at which the Scanner is moved is controlled by varying the period of the motor
drive pulse that is timed with the reference clock.

High Speed

Low Speed

Period

• The distance over which the Scanner travels is controlled by the number of motor drive
pulses that correspond to each paper size and zoom ratio.

Elevtrical Component Control Signal ON OFF Wiring Diagram

M5 PWB-C JP5C-1 to 4 Pulse output 11-B

M-17

11. MEMORY STORAGE IMAGE PROCESSING SYSTEM

• Based on the image data output from the IR, a laser light is projected onto the surface of
the PC Drum to form a corresponding latent image.

PH Unit

4021M015AA

M-18

11-1. Laser Exposure Process

1. The Start key is pressed.

2. The laser diode is forced to turn ON and the laser intensity is automatically adjusted.

3. The SOS Sensor Board is illuminated by the laser beam, which generates an SOS sig-

nal.

4. The SOS signal determines the laser emission timing for each main scanning line.

5. The surface of the PC Drum is illuminated by the laser beam corresponding to the

image data, which forms an electrostatic latent image.

Polygon Motor M2

LD Board PWB-B

SOS Mirror

PC Drum

SOS Board

PC Drum

SOS Mirror

DCBA

SOS
Sensor

4021M016AA

SOS Signal

1171M038AA

A to B: LD activation
B to C: LD OFF
C to D: Laser beam exposure area according to the image data

Elevtrical Component Control Signal ON OFF Wiring Diagram

M2 PWB-A PJ13A-3 L H 8-D

M-19

12. DEVELOPING UNIT SECTION

The Developing Unit agitates and triboelectrically charges toner so that it sticks to the elec­trostatic latent image formed on the surface of the PC Drum, then changing the image to a
visible, developed one.

1

14

13

1. Spent Toner Recycling Coil

2. PC Drum Charge Corona

3. Spent Toner Conveying Screw 2

4. Cleaning Blade

5. Spent Toner Conveying Screw 1

6. PC Drum Paper Separator Finger

7. PC Drum Protective Shutter

12

3

2

11

10

8. PC Drum

9. Sleeve/Magnet Roller

10. 1st Toner Conveying Roller

11. ATDC Sensor UN1

12. 2nd Toner Conveying Roller

13. 3rd Toner Conveying Roller

14. Spent Toner Recycling Duct

4

5

6

7

8

4021M017AA

9

M-20

12-1. Developing Unit Drive Mechanism

The rollers are driven through a gear train from the motor.

Sleeve/Magnet Roller

Main Motor M1

1st Toner Conveying Roller

2nd Toner Conveying Roller

4021M008AB

Elevtrical Component Control Signal

M1

PWB-A PJ7A-5 L H
PWB-A PJ7A-7 H H

Forward
Rotation

3rd Toner Conveying Roller

OFF Wiring Diagram

17-G

M-21

12-2. Sleeve/Magnet Roller

• The Sleeve/Magnet Roller, which consists of an outer sleeve roller and an inner magnet
roller, conveys developer to the point of development.

• The magnetic force of the magnet roller at the point of development is the strongest so
that the developer brush stands straight up to deliver the greatest amount of toner to the
point of development.

Sleeve/Magnet Roller

PC Drum

Sleeve/Magnet Roller

1171M027AA

4021M062AA

1st Toner Conveying Roller

12-3. Developing Bias

• Vb (-DC, AC) is applied to the Sleeve/Magnet Roller.

• Vb (-DC) is applied to prevent toner from sticking to the background of the image.

• Vb (AC) is applied to enhance good separation of toner from carrier.

• The amount of toner sticking to the surface of the PC Drum is varied according to the dif­ference in potential between the voltage (Vi) on the surface of the PC Drum and
Vb (-DC).

✽

Large difference = A greater amount of toner sticks.

✽

Small difference = A smaller amount of toner sticks.

PC Drum

Sleeve/Magnet Roller

Elevtrical Component Control Signal ON OFF Wiring Diagram

Vb (-DC) PWB-A PJ8A-9 L H

Vb (AC) PWB-A PJ8A-10 L H

Developing Bias Terminal

4021M018AB

6-B

M-22

12-4. ATDC Sensor

The ATDC Sensor detects the toner-to-carrier ratio (T/C) of the developer in the Developer
Mixing Chamber.

2nd Toner Conveying Roller

ATDC Sensor UN1

4021M019AA

(1) ATDC Sensor Automatic Adjustment

The reference value for the ATDC Sensor is automatically adjusted as detailed below using
the ATDC Sensor Automatic Adjustment mode.

With the copier set in the ATDC Sensor Automatic Adjustment mode, press the Start key.

The developer is mixed.

The ATDC Sensor converts the reference T/C (14 %) to a corresponding voltage
value and outputs it.

Does the output voltage fall within the range from 2.36 to 2.44 V?

YES NO

The voltage input to the ATDC Sensor from the
Master Board at this time is fixed as the reference
voltage.

The voltage input to the ATDC Sensor from
the Master Board is varied.

2.45 V or more: Decrease the voltage.

2.35 V or less: Increase the voltage.

M-23

12-5. Toner Replenishing Mechanism

• Toner is supplied from the Toner Bottle to the Developer Mixing Chamber.

1. The coupling is turned by the motor, which turns the Toner Bottle.

2. To regulate the amount of toner supplied from the Toner Bottle, there is a Metering

Chamber provided in the outer race of the coupling.

3. When the Toner Bottle turns, toner in the Metering Chamber drops.

4. Toner from the metering chamber is conveyed by the Toner Conveying Screw into the

Developer Mixing Chamber.

5. The Toner Conveying Screw is turned by the motor.

coupling

4021M022AA

Toner Bottle

Metering
Chamber

4021M020AB 4021M021AB

Toner Conveying Screw

Developer Mixing Chamber

Elevtrical Component Control Signal ON OFF Wiring Diagram

M6 PWB-A PJ19A-6 L H 4-B

4021M023AA

M-24

12-6. Toner Replenishing Control

• Replenishing of the supply of toner is determined based on the T/C ratio and B/W ratio.

• If T/C is 14 % or more, toner replenishing is not carried out regardless of the B/W value.

• If T/C is less than 14 %, toner replenishing is determined according to the B/W value.

• Toner is replenished until T/C becomes 14 %.

T/C ratio (%) B/W ratio toner replenishing
More than 14 — not supply

13.5 to 14 More than 2000 supply
13 to 13.5 More than 1000 supply

12.5 to 13 More than 500 supply
12 to 12.5 More than 500 supply

10 to 12 More than 0 supply

Less than 7 Proceeds to the T/C recovery mode

✽

The greater the value of B/W in the table, the higher the B/W ratio (high image density
original).

M-25

12-7. T/C Recovery Mode

The machine enters the T/C recover mode when a T/C of 10 % or less is detected.

Toner is replenished for 90 sec.

T/C is recovered by 1 % or more. T/C is not recovered by 1 % or more, or T/C

Toner is replenished for 60 sec.

T/C is recovered by 2 % or more, or is 12 % or more. T/C is not recovered by 2 % or

Toner is replenished for 30 sec. to complete the A toner-empty condition is detected.
T/C recovery mode.

A toner-empty-stop condition results and the initiation
of any new copy cycle is prohibited.

✽

A toner-empty condition is reset when the Front Cover is opened and closed after a T/C
of 10 % or more is detected with the supply of toner replenished.

✽

A toner-empty-stop condition is reset when the Front Cover is opened and closed after a
T/C of 8 % or more is detected with the supply of toner replenished. A toner-empty condi­tion results, however, if T/C falls within the range between 8 % and 10 % when the Front
Cover is opened and closed.

is less than 12 %.

more, or T/C is less than 12 %.

T/C is less than 8 %.

M-26

12-8. Toner Bottle Home Position Detection Mechanism

• The Toner Bottle is at its home position (where it remains stationary) when its Toner Sup­ply Port faces up. This position is detected by a sensor.

Toner Bottle Home Position Sensor PC7

Toner Supply Port

4021M024AA

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

PC7 PWB-A PJ19A-10 L H 4-B

M-27

13. PAPER TAKE UP/FEED SECTION

1

2

1. Paper Size Detecting Board PWB-I

2. Paper Size Detecting Sensor S11

3. Paper Empty Sensor PC4

3

4

5

6

4021M025AA

4. Paper Take-Up Roll

5. Separator Roll

6. Paper Lifting Plate

M-28

13-1. Drawer In Position Detection

• When the drawer is slid into the copier, the light blocking plate blocks the Set Sensor.
The copier then knows that the drawer has been slid in position.

Drawer Set Sensor PC5

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

PC5 PWB-A PJ15A-10 L H 1-I

4021M026AA

13-2. Paper Empty Detection Mechanism

• The Paper Empty Sensor detects a paper-empty condition in the drawer.

Paper Empty Sensor PC4

1167M073AD

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

PC4 PWB-A PJ6A-6 L H 1-I

M-29

13-3. Paper Lifting Plate

• The Paper Lifting Plate is locked into position when it is pressed down. It is unlocked
when the tray is slid into the unit.

• The Paper Lifting Plate is pushed upward by the Paper Lifting Springs at all times.

Paper Lifting Plate

Spring

4021M063AA

13-4. Universal Tray Paper Size Detection Mechanism

• Both the width (in the crosswise direction) and length (in the feeding direction) of the
paper are detected and the copier CPU determines the paper size based on the combi­nation of the two readings.

• The width (CD) of the paper is detected when the lever that is operatively connected to
the Edge Guide activates or deactivates the Paper Size (CD) Detection Sensor.

• The length (FD) of the paper is detected when the lever that is operatively connected to
the Trailing Edge Stop actuates or deactuates the switches on the Paper Size (FD)
Detection Board.

Paper Size Detecting Board PWB-I

Paper Size Detecting Sensor S11

12 34

4011M009AA

M-30

Paper Size Detecting Board

PWB-I

SW1 SW2 SW3 SW4

— — — — — B4L, 8-1/2 × 14
— — — — Activated 11 × 14
— — — ON Activated A3L, 11 × 17
— — ON ON — A5L, 5-1/2 × 8-1/2 L
— — ON ON Activated A4C, 8-1/2 × 11 C
— ON — — — A5C, 5-1/2 × 8-1/2 C
— ON ON ON — A5L, 5-1/2 × 8-1/2 L

— ON ON ON Activated A4C, 8-1/2 × 11 C
ON — — — — FLS
ON ON — — — FLS
ON ON ON ON — A4L, 8-1/2 × 11 L

Elevtrical Component Control Signal ON OFF Wiring Diagram

PWB-I SW1 PWB-A PJ15A-1 L H
PWB-I SW2 PWB-A PJ15A-2 L H
PWB-I SW3 PWB-A PJ15A-3 L H
PWB-I SW4 PWB-A PJ15A-4 L H

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

S11 PWB-A PJ15A-7 H L 1-H

Paper Size Detecting

Sensor S11

Paper Size

2-H

M-31

13-5. Paper Take Up Mechanism

• Drive for the paper take-up sequence is transmitted via the Paper Take-Up Solenoid from
a motor.

Main Motor M1

Paper Take-Up Roll

Paper Take-Up Solenoid SL1

(1) Paper Separating Mechanism

• The coefficient of friction between the Paper Take-Up Roll and Separator Roll is effec­tively used to prevent double feed of paper.

When one sheet of paper is taken up:The coefficient of friction on the front side of the

When two or more sheets of paper are taken up:The coefficient of friction between the

Paper Take-Up Roll

sheet of paper taken up and fed through the space
between the Paper Take-Up Roll and Separator Roll
is the same as that on the backside of the sheet of
paper, allowing the paper to be properly fed into the
machine.

paper and the Separator Roll is greater
than that between the sheets of paper,
which allows only the top sheet of paper to
be fed into the machine.

Paper

Separator Roll

4021M060AB

4021M027AA

M-32

13-6. Paper Take Up Control

Start Key ON

Main Motor M1

Paper Take-Up
Solenoid SL1

Synchronizing Roller
Sensor PC1

Elevtrical Component Control Signal

M1

Elevtrical Component Control Signal ON OFF Wiring Diagram

SL1 PWB-A PJ5A-2 L H 1-I

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

PC1 PWB-A PJ6A-3 L H 1-F

(1) Paper Take Up Retry Control

• To minimize the occurrence of a paper misfeed, the paper take-up sequence is tempo­rarily halted if the paper fails to reach the Synchronizing Roller Sensor within a given
period of time after the sequence has been started. The paper take-up sequence is then
performed again. These paper take-up sequences are repeated a given number of times.

ON
OFF

ON
OFF

H
L

Forward

Rotation
PWB-A PJ7A-5 L H
PWB-A PJ7A-7 H H

4021M515CA

OFF Wiring Diagram

17-G

Paper Take-Up Retry 2

Paper Take-Up
Solenoid SL1

Synchronizing Roller
Sensor PC1

ON
OFF

H
L

M-33

No. of Paper Take-Up

Retry Sequences

1st Paper Take-Up

Retry Sequence

Successful paper take-up

4021M514CA

14. MANUAL BYPASS SECTION

14-1. Paper Take Up Drive Mechanism

• Drive for paper take-up from the Manual Bypass is transmitted from a motor via the Sole­noid.

Main Motor M1

Manual Feed Paper Sensor PC2

Manual Bypass Solenoid SL2

4021M028AA

14-2. Paper Detection Mechanism

• The Sensor detects a sheet of paper on the Manual Bypass.

<When Paper is not Present><When Paper is Present>

Manual Feed Paper Sensor PC2

Paper

M-34

4021M029AA4021M061AA

14-3. Manual Feed Take Up Control

Paper Set

Manual Feed
Paper Sensor PC2

Main Motor M1

Manual Bypass
Solenoid SL2

Elevtrical Component Control Signal

M1

Elevtrical Component Control Signal ON OFF Wiring Diagram

SL2 PWB-A PJ4A-2 L H 1-B

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

PC2 PWB-A PJ4A-5 L H 1-A

H
L

ON

OFF

ON

OFF

Paper drawing-in sequence completed

PWB-A PJ7A-5 L H
PWB-A PJ7A-7 H H

Start Key ON

Forward
Rotation

4021M511CA

OFF Wiring Diagram

17-G

M-35

15. MULTIPLE BYPASS SECTION

1

2

4021M031AA

1. Paper Take-Up Roll

2. Multiple Bypass Solenoid SL21

3

3. Multiple Bypass Paper Empty Sensor
PC21

15-1. Paper Take Up Drive Mechanism

• Drive for paper take-up from the Multiple Bypass is transmitted from a motor via the Sole­noid.

Main Motor M1

Multiple Bypass Solenoid SL21

Paper Take-Up Roll

4021M032AA

Multiple Bypass Paper Empty Sensor PC21

M-36

15-2. Paper Take-Up Mechanism

• The Paper Lifting Plate is raised to press the paper stack on the tray up against the
Paper Take-Up Roll.

• The Paper Lifting Plate is raised and lowered in time with a paper take-up sequence.

• The ascent and descent motion of the Paper Lifting Plate is accomplished when the drive
from the motor is transmitted to the cam through a solenoid to rotate the cam.

Drive from Main Motor

Paper Take-Up Roll

Cam

<Ascent/Descent Motion>
Main Motor (M1) is energized.
Paper Take-Up Roll is turned.

Multiple Bypass Solenoid (SL21): Energized

Cam: Rotates

Tray: Raised

Multiple Bypass Solenoid (SL21): Deenergized

Multiple Bypass Solenoid SL21

4021M033AA

Paper Take-Up Roll

Cam

Paper

Tr ay

Paper take-up

Multiple Bypass Solenoid (SL21): Energized

Cam: Rotates

Tray : Lo w e re d

Multiple Bypass Solenoid (SL21): Deenergized

M-37

4021M059AA

15-3. Paper Empty Detection Mechanism

• The Paper Empty Sensor detects a sheet of paper on the Multiple Bypass.

<When Paper is not Present><When Paper is Present>

Multiple Bypass Paper Empty Sensor PC21

Paper

4021M034AA

4021M035AA

15-4. Paper Take Up Control

Paper Set Start Key ON

ON

OFF

ON

OFF

H

L

4021M512CA

Forward
Rotation

OFF Wiring Diagram

17-G

Multiple Bypass Paper
Empty Sensor PC21

Main Motor M1

Multiple Bypass Solenoid
SL21

Elevtrical Component Control Signal

M1

Elevtrical Component Control Signal ON OFF Wiring Diagram

SL21 PWB-A PJ4A-2 L H 17-F

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

PC21 PWB-A PJ4A-5 L H 17-F

PWB-A PJ7A-5 L H
PWB-A PJ7A-7 H H

M-38

15-5. Paper Take Up Retry Control

• To minimize the occurrence of a paper misfeed, the paper take-up sequence is tempo­rarily halted if the paper fails to reach the Synchronizing Roller Sensor within a given
period of time after the sequence has been started. The paper take-up sequence is then
performed again. These paper take-up sequences are repeated a given number of times.

No. of Paper Take-Up

Retry Sequences

Paper Take-Up Retry 2

1st Paper Take-Up

Retry Sequence

Multiple Bypass
Solenoid SL21

Synchronizing
Roller Sensor PC1

ON
OFF

H
L

Successful paper take-up

4021M516CA

M-39

16. IMAGE TRANSFER AND PAPER SEPARATION SEC-

TION

✽

Image Transfer

• A positive charge is applied to the Image Transfer Roller to transfer the toner image
formed on the surface of the PC Drum onto the paper.

• The charge applied to the Image Transfer Roller is varied according to the following con­ditions to ensure that image transfer efficiency is stabilized.

Paper Type: The amount of charge is made less for OHP transparencies.
Paper width: The greater the paper width, the more the amount of charge.
B/W ratio of the image: The higher the B/W ratio, the more the amount of charge.

• A negative charge is applied to the Image Transfer Roller to return toner sticking to the
Image Transfer Roller to the PC Drum. It is performed in the following timings:

• A copy cycle is started and completed, The Power Switch is turned ON, A misfeed or a
malfunction is reset.

✽

Paper Separation

• The PC Drum Paper Separator Fingers mechanically separate paper from the surface of
the PC Drum to ensure good and positive paper separation.

• The Charge Neutralizing Plate is used to neutralize any charge left on the paper, to which
image has been transferred, thereby preventing discharge noise that occurs when paper
is separated.

PC Drum Paper Separator Fingers

PC Drum

Charge Neutralizing Plate

4021M037AA

Image Transfer Roller

Elevtrical Component Control Signal ON OFF Wiring Diagram

HV1 PWB-A PJ8A-8 L H 6-C

M-40

17. PC DRUM CLEANING SECTION

• The Cleaning Blade is used to scrape residual toner off the surface of the PC Drum.

• The spent toner is conveyed through the Recycling Duct and eventually back to the
Developer Mixing Chamber.

• To prevent paper dust from being compacted on the edge of the Cleaning Blade, the PC
Drum is turned backward (by turning the Main Motor backward) when the cumulative
time through which the PC Drum has turned reaches a predetermined value. When the
PC Drum is turned backward, a backlash in gears prevents drive from being transmitted
to other drive mechanisms.

Cumulative Time Through Which PC Drum

Has Been Driven

Approx. 330 sec 50 ms

PC Drum

4021M039AA

Spent Toner Recycling Coil

Spent Toner Recycling Duct

Cleaning Blade

PC Drum Backward

Rotation Time

Spent Toner Conveying Screw 1

Spent Toner Conveying Screw 2

M-41

4021M038AB

18. MAIN ERASE SECTION

• Any potential remaining on the surface of the PC Drum is neutralized by both light from
the Main Erase and a negative voltage applied by the Charge Neutralizing Sheet.

• A negative charge is applied to the Charge Neutralizing Sheet to neutralize a positive
charge on the surface of the PC Drum. The Main Erase then illuminates the surface of
the PC Drum to neutralize the charge left on it.

Main Erase LA1

Charge Neutralizing Sheet

PC Drum

4021M040AA

Elevtrical Component Control Signal ON OFF Wiring Diagram

LA1 PWB-A PJ7A-12 L H 4-A

M-42

19. FUSING UNIT SECTION

• The Fusing Unit fixes permanently the developed image to the paper by applying heat
and pressure to the toner and paper.

1

10

9

8

1. Paper Exit Roller

2. Transport Roller

3. Fusing Paper Separator Finger

4. Exit Paper Sensor PC3

5. Right Fusing Roller

2

3

7

6. Pressure Spring

7. Fusing Heater Lamp H1

8. Thermistor TH1

9. Thermoswitch TS1

10. Left Fusing Roller

4

5

4021M041AD

6

M-43

19-1. Fusing Unit Drive Mechanism

• The Fusing Unit is driven by a motor.

Left Fusing Roller

Main Motor M1

Right Fusing Roller

4021M042AA

19-2. Fusing Rollers Pressure Mechanism

• To ensure that there is a certain width of area of contact between the Right and Left Fus­ing Rollers, a pressure spring is used to press the Lower Fusing Roller up against the
Upper Fusing Roller.

Right Fusing Roller

Left Fusing Roller

4021M043AA

Pressure Spring

M-44

19-3. Fusing Temperature Control

• The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the
surface of the Fusing Roller.

• The Fusing Roller surface temperature is detected by using a thermistor that translates
the temperature to a corresponding electrical signal.

• If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater
Lamp is shut down.

<Temperature Control in Standby State>

(˚C)

200

190

180

Warm-up completed

170

155

30 sec.

or less

Mode 1

5 min

Mode 2

1 min

Mode 3

4021M513CA

Machine Condition or Paper Type Mode 1 Mode 2 Mode 3
Standby 180 °C 180 °C → 170 °C 170 °C
Plain paper (width 251 mm or more) 190 °C 190 °C → 170 °C 170 °C
Plain paper (width 250 mm or less) 160 °C 160 °C 160 °C
Thick paper (width 251 mm or more) 210 °C 210 °C → 190 °C 190 °C
Thick paper (width 250 mm or less) 200 °C 200 °C → 190 °C 190 °C
OHP transparencies (width 251 mm or more) 180 °C 180 °C → 165 °C 165 °C
OHP transparencies (width 250 mm or less) 155 °C 155 °C 155 °C

Elevtrical Component Control Signal ON OFF Wiring Diagram

H1 PWB-A PJ10A-7 L H 1-D

19-4. CPM Control

• If paper of a small size (width of 250 mm or less) or thick paper is used to run a multi­copy cycle, the temperature on the edges of the Fusing Rollers tends to run high, mean­ing that the temperature of the Fusing Rollers varies among different spots of the rollers.

• When the cumulative number of copies made through continuous copy cycles* exceeds
30, the paper take-up interval is made longer, thereby allowing the temperatures of the
Fusing Rollers at different spots to be uniform.

✽

Continuous copy cycle: Continuous copy cycles run with an interval of 2 min. or less
between cycles.

M-45

20. JOB TRAY (JS-202): Option

1

1. Job Tray

2. Main Board PWB-A

3. Paper Empty Sensor PC35

4. Full Detecting Sensor PC34

2

5. Upper Home Position Sensor PC32

6. Lower Home Position Sensor PC33

7. Paper Detecting Board PWB-B

8. Bin Switching Motor M1

3

4

6

5

4021M045AC

7

8

M-46

20-1. Tray Selecting Mechanism

• Paper is fed into either the Exit Tray of the machine or the Job Tray. Either is selected
according to the application mode (fax, copier, or printer).

• The specific tray in which paper is fed is selected by a motor and a sensor.

<When feeding paper into the Exit Tray: Copier>

Upper Home Sensor PC32: Activated

Paper

(M1: Backward Rotation)

<When feeding paper into the Job Tray: fax/printer>

Lower Home Sensor PC33: Activated

Paper

Bin Switching Motor M1

4021M046AB

Job Tray

4021M047AB

Elevtrical Component Control Signal ON OFF Wiring Diagram

M1 PWB-A PJ2A-1 to 4 Pulse output 16-A

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

PC32 PWB-A PJ4A-3 L H
PC33 PWB-A PJ4A-6 L H

16-B

M-47

20-2. Tray-Full Detecting Mechanism

• Tray-full detection is valid only when paper is fed into the Job Tray (Job Tray in the low­ered position).

• A tray-full condition is detected when the sensor is blocked for a continuous given period
of time (approx. 20 sec.).

Paper

Full Detecting Sensor PC34

Exit Roller

Job Tray

4021M049AA

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

PC34 PWB-A PJ4A-9 L H 16-C

20-3. Job Tray Paper Detecting Mechanism

• If paper is fed into the Job Tray when the machine is in a mode in which paper is fed into
the Exit Tray (Job Tray in the raise position), the indicator lamp on the Paper Detecting
Board lights to warn the user that there is paper in the Job Tray.

• A sensor is provided for detecting paper in the Job Tray.

<When Paper is Present>

Paper Empty Sensor PC35

Paper Detecting

Job Tray

Paper

<When Paper is not Present>

4021M051AA

Board PWB-B

4021M050AA

4021M052AA

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

PC35 PWB-A PJ3A-3 L H 18-A

M-48

21. SHIFTING UNIT (OT-103): Option

1

2

3

4021M053AB

1. Main Board PWB-A

2. Home Sensor S31

3. Shift Motor M1

M-49

21-1. Exit Position Shifting Mechanism

• Paper is fed into the Shifting Unit along a straight path or shifted from the reference
straight path position. This exit position shifting mechanism allows different finishing
functions offered by the machine (Non-Sort, Sort, and Group) to be effected.

<Straight Feeding>

• The paper that travels along a straight path is fed straight into the Shifting Unit without
being shifted sideways as the Exit Roller turns.

Exit Roller

Paper

4021M054AA

<Shifted Feeding>

• When the trailing edge of the paper transported to the exit section moves past the Fusing
Roller, the Shift Motor is energized to move the Transport Roller sideways.

• The paper is fed into the Shifting Unit as it is shifted sideways.

• The Exit Roller is moved sideways by turning the motor forward or backward.

• The Exit Roller is detected at its home position by a sensor.

Shift Motor M1

Paper

4021M055AA

Home Sensor S31

Exit Roller

4021M056AB

M-50

Elevtrical

Component

M1 PWB-A PJ2A-1 to 4 Pulse output 16-C

Elevtrical Component Control Signal Activated Deactivated Wiring Diagram

S31 PWB-A PJ3A-3 L H 17-D

Control Signal

Forward
Rotation

Backward

Rotation

OFF Wiring Diagram

M-51

22. OTHER MECHANISM

22-1. Cooling Mechanism

(1) Power Supply Section Cooling Mechanism

• A cooling fan motor draws air from the area around the Power Supply Unit to the outside
to prevent the Power Supply Unit temperature from running high.

• The cooling fan motor is turned at full speed when the Main Motor turns and at a speed
reduction during other timings, thereby making the machine quieter without sacrificing
cooling performance.

4021M057AA

Power Supply Cooling Fan Motor M4

Elevtrical Component Control Signal ON OFF Wiring Diagram

M4 PWB-A PJ19A-1

analog voltage

output

H 11-I

M-52

(2) Fusing Section Cooling Mechanism

• A fan motor draws air from the area around the Fusing Unit to the outside to prevent the
machine interior temperature from running high. In addition, the fan motor pulls paper
being transported up through suction force to help stabilize paper transport.

• Ozone produced from the PC Drum Charge Corona is absorbed by the Ozone Filter from
the air drawn by a fan motor to the outside.

• The fan motor is turned at full speed during a print cycle and at a speed reduction during
other timings, thereby making the machine quieter without sacrificing cooling perfor­mance.

Fusing Cooling Fan Motor M3

Ozone Filter

4021M058AB

Elevtrical Component Control Signal ON OFF Wiring Diagram

M3 PWB-A PJ10A-4

analog voltage

output

H1-C

M-53

DEVELOP

Copyright

2001 Develop

Printed in Germany

4890-4A06-91

DEVELOP

Service Manual

Field

D1531iD · D1831iD

INDEX (FIELD SERVICE)

SAFETY PRECAUTIONS FOR
INSPECTION AND SERVICE

DIS/REASSEMBLY,
ADJUSTMENT

SWITCHES ON PWBs,
TECH. REP. SETTINGS

TROUBLESHOOTING

1. 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.

1-1. Warning

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

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.

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.

P-1

3. Do not throw toner or the toner bottle into a fir.

• Do not throw toner or the toner bottle (Imaging Cartridge) into a fire. Toner
expelled from the fire may cause burns.

4. 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.

5. 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.

6. 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.

7. 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.

8. 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.

9. 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.

10. 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.

P-2

11. 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.

1-2. Caution

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.

P-3

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.

5. Precautions for the Laser Beam. (Only for Products Employing a Laser)

• Removing the cover marked with the 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.”

6. Precautions for storage the toner or imaging cartridge.

• Be sure to keep the toner or imaging cartridge out of the reach of children. Lick­ing the imaging cartridge or ingesting its contents is harmful to your health.

1-3. 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

1-4. 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 gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.

France

Il y a danger d’explosion s’il y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du même type ou d’un type équivalent recom­mandé par le constructeur.
Mettre au rebut les batteries usagées 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.

Finland, Sweden

Paristo voi räjähtää, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.

CAUTION

VORSICHT!

ATTENTION

ADVARSEL!

VAROlTUS

VARNING
Explosionsfara vid felaktigt batteribyte.
Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat­tillverkaren.
Kassera använt batteri enligt fabrikantens instruktion.

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.

ADVARSEL

P-5

1-5. 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.

1. 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.

2. How to Use this Book
< DIS/REASSEMBLY, ADJUSTMENT >

• To reassemble the product, reverse the order of disassembly unless otherwise specified.

< 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.

3. 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 sen-

sors, 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

4. 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.

5. 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

6. Handling of PWBs
< 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 tem-

perature.

• 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.

< 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.

7. 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

8. Handling of the PC Drum

✽

Only for Products Not Employing an Imaging Cartridge.

< 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.

< 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 protect

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, finger-

prints, 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.

A. Place the PC Drum into one half of its carton.

1076D001

1076D002

B. Gently wipe the residual toner off the surface of the

PC Drum with a dry, Dust-Free Cotton Pad.

• 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.

• 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

C. Soak a small amount of either ethyl alcohol or iso-

propyl 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

D. Using the SAME face of the Pad, repeat the proce-

dure 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.

9. Handling of the Imaging Cartridge

✽

Only for Products Employing an Imaging Cartridge.

< 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.

< Handling >

• Store the Imaging Cartridge in a place that is not exposed to direct sunlight.

< 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

CONTENTS

1. SAFETY INFORMATION .................................................................................D-1

1-1. LASER SAFETY ......................................................................................D-1

1-2. INTERNAL LASER RADIATION ..............................................................D-1

1-3. LASER SAFETY LABEL ..........................................................................D-4

1-4. LASER CAUTION LABEL ........................................................................D-4

1-5. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ...............D-4

2. SERVICE INSTRUCTIONS .............................................................................D-5

2-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS ....................D-5

2-2. PARTS WHICH MUST NOT BE TOUCHED ...........................................D-6

(1) Red Painted Screws ........................................................................D-6

(2) Variable Resistors on Board ............................................................D-6

3. DISASSEMBLY/REASSEMBLY ......................................................................D-7

3-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION

AND REMOVAL PROCEDURES ............................................................D-7

3-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL

COMPONENTS .......................................................................................D-9

(1) Removal of the Master Board ..........................................................D-10

(2) Removal of the Control Board .........................................................D-11

(3) Removal of the High Voltage Unit ...................................................D-11

(4) Removal of the DC Power Supply ...................................................D-13

3-3. MAINTENANCE SCHEDULE ..................................................................D-16

3-4. PAPER TAKE-UP/TRANSPORT SECTION ............................................D-18

(1) Removal of the Paper Separator Roll Assy and

Paper Take-Up Roll .........................................................................D-18

(2) Cleaning of the Paper Separator Roll ..............................................D-18

(3) Cleaning of the Paper Take-Up Roll ................................................D-18

(4) Cleaning of the Right and Left Synchronizing Rollers .....................D-19

(5) Removal of the Paper Dust Remover Assy .....................................D-19

(6) Cleaning of the Paper Dust Remover ..............................................D-20

(7) Cleaning of the Bypass Transport Roller .........................................D-20

3-5. OPTICAL SECTION ................................................................................D-21

(1) Cleaning of the Original Glass and ADF Glass ...............................D-21

(2) Cleaning of Mirrors ..........................................................................D-21

(3) Cleaning of the Lens ........................................................................D-21

(4) Cleaning of the CCD Sensor ...........................................................D-22

(5) Cleaning of the Scanner Rails/Bushings .........................................D-22

(6) Removal of the CCD Unit ................................................................D-23

(7) Removal of the Scanner, Exposure Lamp, and Inverter Board ....... D-23

(8) Removal of the Scanner Drive Cables ............................................D-25

(9) Winding of the Scanner Drive Cables ..............................................D-27

3-6. PH ............................................................................................................D-29

(1) Removal of the PH Unit ...................................................................D-29

(2) Cleaning of the PH Window .............................................................D-29

3-7. Imaging Unit (IU) ......................................................................................D-30

(1) Removal of the IU ............................................................................D-30

(2) Disassembly of the IU ......................................................................D-30

i

(3) Application of Toner .........................................................................D-34

(4) Replacement of the ATDC Sensor ..................................................D-35

3-8. IMAGE TRANSFER SECTION ................................................................D-36

(1) Removal of the Image Transfer Roller Assy .................................... D-36

(2) Cleaning of the Pre-Image Transfer Lower Guide Plate .................. D-36

(3) Cleaning of the Charge Neutralizing Plate ......................................D-36

3-9. FUSING SECTION ..................................................................................D-37

(1) Removal of the Fusing Unit .............................................................D-37

(2) Disassembly of the Fusing Unit .......................................................D-37

3-10.MULTIPLE BYPASS (MB-5): OPTION ....................................................D-42

(1) Removal of the Separator Roll Assy ................................................D-42

(2) Removal of the Paper Take-Up Roll ................................................D-42

(3) Cleaning of the Separator Roll/Paper Take-Up Roll ........................D-45

(4) Cleaning of the Paper Take-Up Roll ................................................D-45

3-11.JOB TRAY (JS-202): OPTION ................................................................D-46

(1) Removal of the Main Board .............................................................D-46

(2) Paper Detecting Board ....................................................................D-48

3-12.SHIFTING UNIT (OT-103): OPTION .......................................................D-49

(1) Removal of the Main Board .............................................................D-49

4. ADJUSTMENT .................................................................................................D-51

4-1. ADJUSTMENT JIGS AND TOOLS USED ...............................................D-51

4-2. TIMING BELT TENSION ADJUSTMENT ................................................D-51

4-3. ACCESSING THE FUNCTION, TECH. REP. CHOICE, AND

ADJUST MODE .......................................................................................D-52

(1) Function Mode .................................................................................D-52

(2) Tech. Rep. Choice Mode .................................................................D-52

(3) Adjust Mode .....................................................................................D-52

4-4. ELECTRICAL/IMAGE ADJUSTMENT .....................................................D-53

(1) Edge Erase Adjustment (Leading, Trailing, and Top/Bottom

Edges) .............................................................................................D-53

(2) Loop Length Adjustment (1st and 2nd Trays, Bypass Tray) ........... D-54

(3) Printer CD Registration Adjustment .................................................D-55

(4) Printer FD Registration Adjustment .................................................D-56

(5) Scanner CD Registration Adjustment ..............................................D-57

(6) Scanner FD Registration Adjustment ..............................................D-58

(7) Scanner CD Zoom Adjustment ........................................................D-59

(8) Scanner FD Zoom Adjustment ........................................................D-60

(9) ATDC Sensor Automatic Adjustment (F8) .......................................D-61

(10) Manual Bypass Registration Adjustment .........................................D-62

(11) Multiple Bypass Registration Adjustment (MB-5): Option ................ D-63

4-5. OTHER ADJUSTMENTS .........................................................................D-64

(1) Adjustment of the Position of the Scanner and

2nd/3rd Mirrors Carriage .................................................................D-64

(2) CCD Unit Position Adjustment .........................................................D-65

(3) Adjustment of the Gap between the Doctor Blade and

Sleeve Roller (Db Adjustment) ........................................................D-66

4-6. MISCELLANEOUS ..................................................................................D-68

ii

(1) Remounting the EEPROM (U29) .....................................................D-68

(2) Installation of the Plug-In Counter Socket (Option) .........................D-69

(3) Installation of the Mechanical Counter (Option) ..............................D-70

iii

1. SAFETY INFORMATION

1-1. LASER SAFETY

• This is a digital machine certified as a class 1 laser product. There is no possibility of
danger from a laser, provided the machine is serviced according to the instruction in this
manual.

1-2. INTERNAL LASER RADIATION

Semiconductor laser

Maximum average radiation power(*) 26.4 µW

Wavelength 770-795 nm

*:Laser Aperture of the Print Head Unit

• This product employs a Class 3b laser diode that emits an invisible laser beam. The laser
diode and the scanning polygon mirror are incorporated in the print head unit.

• The print head unit is NOT A FIELD SERVICE ITEM. Therefore, the print head unit
should not be opened under any circumstances.

Laser Aperture of
the Print Head Unit

This figure Shows the view inside the Right Door
with the Imaging Unit removed.

D-1

the U.S.A., Canada
(CDRH Regulation)

• This machine is certified as a Class I Laser product under Radiation Performance Stan­dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory
for Laser products marketed in the United States and is reported to the Center for
Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of
the U.S. Department of Health and Human Services (DHHS). This means that the device
does not produce hazardous laser radiation.

• The label shown to page D-4 indicates compliance with the CDRH regulations and must
be attached to laser products marketed in the United States.

CAUTION

Use of controls, adjustments or performance of procedures other than those specified in
this manual may result in hazardous radiation exposure.

Semiconductor laser

Maximum power of the laser diode 5 mW

Wavelength 770-795 nm

All Areas

CAUTION

Use of controls, adjustments or performance of procedures other than those specified in
this manual may result in hazardous radiation exposure.

Semiconductor laser

Maximum power of the laser diode 5 mW

Wavelength 770-795 nm

Denmark

ADVARSEL

Usynlig Laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion. Undgå
udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene.

Halvlederlaser

Laserdiodens højeste styrke 5 mW

Bølgelængden 770-795 nm

D-2

Finland, Sweden

VARO!

Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä
katso säteeseen.

LOUKAN 1 LASERLAITE
KLASS 1 LASER APPARAT

VAROITUS!

Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa
käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.

Puolijohdelaser

Laserdiodin suurin teho 5 mW

Aallonpituus 770-795 nm

VARNING!

Om apparaten används på annat sätt än i denna bruksanvisning specificerats, kan använ­daren utsättas för osynlig laserstrålning, som överskrider gränsen för laserklass 1.

Halvledarlaser

Den maximala effekten för laserdioden 5 mW

Våglängden 770-795 nm

VARNING!

Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej
strålen.

Norway

ADVERSEL

Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisning, kan
brukeren utsettes for unsynlig laserstråling som overskrider grensen for laser klass 1.

Halvleder laser

Maksimal effekt till laserdiode 5 mW

Bølgelengde 770-795 nm

D-3

1-3. LASER SAFETY LABEL

• A laser safety labels is attached to the outside of the machine as shown below.

Laser safety label

For Europe

CLASS 1 LASER PRODUCT
LASER KLASSE 1

PRODUCT

1155O764AA

For United States

4022D038CA

4002O312CA

1-4. LASER CAUTION LABEL

• A laser caution label is attached to the inside of the machine as shown below.

4022D501AA

4022D027AA

1-5. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

• When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.

• When a disassembly job needs to be performed in the laser beam path, such as when
working around the printerhead and PC Drum, be sure first to turn the copier OFF.

• 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.

D-4

2. SERVICE INSTRUCTIONS

2-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS

Control Board (PWB-C)
125 V 3 A

DC Power Supply (PU1)
100 V system 125 V 15 A (F2)
200 V system 250 V 6.3 A (F2)

Thermoswitch 1 (TS1)
250 V 7.5 A/125 V 15 A

4022D028AA

D-5

2-2. 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 for which no adjusting instructions are given in
“ADJUSTMENT.”
Other Screws not Marked with Red Paint
<PH Unit>

PH Unit

<IR Unit>

Left side face

PH Unit base plate

Right side face

D-6

3. DISASSEMBLY/REASSEMBLY

3-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION

AND REMOVAL PROCEDURES

1

2

11

3

10

9

8

18

17

16

4

5

6

7

12

13

D-7

14

15

No. Part Name Removal Procedure

1 Original Cover Pull the Original Cover straight up.

2 Original Glass

3 Control Panel

4 Right Inside Cover

5 Front Cover

6 Front Door

71st Tray

8 Left Cover

9 Upper Cover

10 Rear Inside Cover

11 ADF Glass Remove two ADF Glass mounting screws.
12 Left Hinge Remove no. 14. → Remove three Left Hinge mounting screws.
13 Right Hinge Remove no. 14. → Remove three Right Hinge mounting screws.
14 Rear Cover Remove six Rear Cover mounting screws.

15 Rear Right Cover

Multiple Bypass

16

Cover (when the
option is mounted)

17 Right Door

18 Right Cover

Remove no. 18. → Remove two holding brackets or no. 11 and
the Original Glass.

Remove two control panel mounting screws. → Remove two
ground wire mounting screws. → Remove one flat cable and
unplug one connector.

Remove no. 5. → Remove one Right Inside Cover mounting
screw.

Remove no. 3. → Open the Front Door and remove six Front
Cover mounting screws.

Open the Front Door and remove one band mounting screw. →
Snap off one C-clip.

Slide out the 1st Tray. → Remove the fixing brackets on the right
and left.

Remove no. 3. → Remove no. 5. → Remove no. 14. → Remove
five Left Cover mounting screws.

Remove no. 3. → Remove no. 5. → Remove no. 14. → Remove
no. 8. → Remove two screws and two Upper Cover mounting
screws.

Remove no. 3. → Remove no. 5. → Remove no. 14. → Remove
no. 8. → Remove no. 9. → Remove no. 4. → Remove two Rear
Inside Cover mounting screws.

Remove no. 14. → Remove one Rear Right Cover mounting
screw.

Remove two Multiple Bypass Cover mounting screws.

Remove no. 14. → Remove no. 15. → Remove three Right Door
mounting screws.

Remove no. 3. → Remove no. 5. → Remove no. 14. → Remove
four Right Cover mounting screws.

D-8

3-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL

COMPONENTS

• When removing a circuit board 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 circuit board support or circuit board.

• Where it is absolutely necessary to touch the ICs and other electrical components on the
board, be sure to ground your body.

PWB-A
Job Tray (JS-202): Option
Shifting Unit (OT-103): Option

PWB-R1

PWB-J

PWB-C

PU3

PU2

PWB-A

PWB-I

HV1

4022D029AA

PWB-R2

PU1

PWB-B
Job Tray (JS-202): Option

D-9

Symbol Part Name Removal Procedure
PWB-A Master Board
PWB-C Control Board

PWB-I

PWB-J CCD Board

PWB-R1 Fusing Board Remove the Fusing Unit. → PWB-R1

PWB-R2

PU1 DC Power Supply
PU2 Inverter Board

PU3 Control Panel

HV1 High Voltage Unit

Job Tray (JS-202): Option

Symbol Part Name Removal Procedure
PWB-A Main Board
PWB-B Paper Detecting Board☞ D-48

Shifting Unit (OT-103): Option

Symbol Part Name Removal Procedure
PWB-A Main Board

Paper Size Detecting
Board

Pre-Image Transfer
Board

☞

D-10

☞

D-11

Remove the Rear Cover. → Remove the PWB Assy. →
Remove two screws and the PWB-I Assy. → PWB-I

☞

D-23

✽

Remove the CCD Unit as a unit.

Open the Right Door. → PWB-R2

☞

D-13

☞

D-23

Remove two control panel mounting screws. → Remove
two ground wire mounting screws. → Remove one flat
cable and unplug one connector. → PU3

☞

D-11

☞

D-46

☞

D-49

(1) Removal of the Master Board

1. Remove the Rear Cover.

2. Remove 12 screws and the PWB Cover Assy.

D-10

3. Unplug all connectors (but PJ20) from the Master
Board.

4. Remove four screws and the Master Board.

(2) Removal of the Control Board

1. Remove the Rear Cover.

2. Remove the PWB Cover Assy.

3. Unplug all connectors from the Control Board.

4. Remove six screws and the Control Board.

(3) Removal of the High Voltage Unit

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, Upper Cover, Right
Inside Cover, and Rear Inside Cover.

2. Remove the PWB Cover Assy.

3. Unplug all connectors from the Master Board (except for PJ20) and from the Control
Board.

4. Remove the harness from seven wiring saddles and two edge covers.

D-11