Lexmark and Lexmark with diamond
design are trade ma rks of Lexmark
International, Inc., registered in the
United States and/or ot her countries.
Page 2
4023-001
Edition: March 24, 2006
The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK INTERN ATIONAL, INC. PROVIDES THIS
PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING , BUT NOT LIMITED TO, THE IMPLIED W A RRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not all o w di sc la im er o f e xp res s o r im plie d w ar r ant i es in ce rta in t r ansa ct io ns , t he refore, t hi s
statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.
A form for reader’s comments is provided at the back of this publication. If the form has
been removed, comments may be addressed t o Lexmark International, Inc., Department
D22/032-2, 740 West New Circle Road, Lexington, Kentucky 4055 0, U.S.A. Lexmark may
use or distribute any of the information you supply in any way it believes appropriate
without incurring any obligation to you.
Lexmark, MarkNet, MarkVision, Optra and OptraImage are trademarks of Lexmark
International, Inc., registered in the United Sta tes and/or other co untries .
Other tradema rks are the property of their respective owner s.
This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Right s in Technical Data and Computer Software clause at
DFARS 25 2.227-7013 and in applicable FAR provisions: Le x mark International, Inc.,
Lexington, KY 40550.
Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des
Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es
sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen
der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der
Drucker sind so konzipiert, daß im Normalbetrieb , bei der Wartung
durch den Benutzer oder bei ordnungsgemäßer Wartung durch den
Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde,
Menschen keinesfalls erreicht.
French
Pour les Etats-Unis : cette impri man te est certifiée conforme aux
provisions DHHS 21 CFR alinéa J concernant les produits laser de
Classe I (1). Pour les autres pays : cette imprimante répond aux
normes IEC 60825 relatives aux produits laser de Classe I.
xiv Service Manual
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4023-001
Les produits laser de Classe I sont considérés comme des produits
non dangereux. Cette imprimante est équipée d’un laser de Classe
IIIb (3b) (arséniure de gallium d’une puissance nominale de 5
milliwatts) émettant sur des longueurs d’onde comprises entre 770
et 795 nanomètres. L’imprimante et son système laser sont conçus
pour impossible, dans des conditions normales d’utilisation,
d’entretien par l’utilisateur ou de révision, l’exposition à des
rayonnements laser supérieurs à des rayonnements de Classe I .
Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme
ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di
classe 1 ed è certificata negli altri Paesi come prodotto laser di
classe 1 conforme ai requisiti della norma CEI 60825.
I prodotti laser di classe non sono considerati pericolosi. La
stampante contiene al suo interno un laser di classe IIIb (3b)
all’arseniuro di gallio della potenza di 5mW che opera sulla
lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema
laser e la stampante sono stati progettati in modo tale che le
persone a contatto con la stampante, durante il normale
funzionamento, le operazioni di servizio o quelle di assistenza
tecnica, non ricevano radiazioni laser superiori al livello della classe
1.
Avisos so bre el láser
Se certifica que, en los EE.UU., esta impresora cumple los
requisitos para los productos láser de Clase I (1) establecidos en el
subcapítulo J de la norma CFR 21 del DHHS (Departamento de
Sanidad y Servicios) y, en los demás países, reúne todas las
condiciones expuestas en la norma IEC 60825 para productos láser
de Clase I (1).
Spanish
Italian
Los productos láser de Clase I no se consideran peligrosos. La
impresora contiene en su interior un láser de Clase IIIb (3b) de
arseniuro de galio de funcionamiento nominal a 5 milivatios en una
longitud de onda de 770 a 795 nanóme tros. El sistema láser y la
impresora están diseñados de forma que ninguna persona pueda
verse afectada por ningún tipo de radiación láser superior al nivel de
Notices and Safety Information xv
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4023-001
la Clase I durante su uso normal, el mantenimiento realizado por el
usuario o cualquier otra situación de servicio técnico.
Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformid ade com os
requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a
Classe I (1) de produtos laser. Em outros locais, está certif icada
como um produto laser da Classe I, em conformidade com os
requisitos da norma IEC 60825.
Os produtos laser da Classe I não são considerados perigosos.
Internamente, a impressora contém um prod uto lase r da C lass e IIIb
(3b), designado laser de arseneto de potássio, de 5 milliwatts
,operando numa faixa de comprimento de onda entre 770 e 795
nanómetros. O sistema e a impressora laser foram concebidos de
forma a nunca existir qualquer possiblidade de acesso humano a
radiação laser superior a um nível de Classe I durante a operação
normal, a manutenção feita pelo utilizador ou condições de
assistência prescritas.
Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een
laserprodukt van klasse I. V oor de Verenigde Staten zijn deze eisen
vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 60825.
Dutch
Portugese
Laserproduk ten van klasse I worden niet als ongevaarlijk
aangemerkt. De printer is voorzien van een laser van klasse IIIb
(3b), dat wil zeggen een gallium arsenide- laser van 5 milliwatt met
een golflengte van 770-795 nanometer. Het lasergedeelte en de
printer zijn zo ontworpen dat bij normaal gebr uik, bij onderhoud of
reparatie conform de voorschriften, nooit blootstelli ng mogelijk is
aan laserstraling boven een niveau zoals voorgeschreven is voor
klasse 1.
xvi Service Manual
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Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i
overenstemmelse med kravene i IEC 60825.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren
indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5
milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet
770-795 nanometer. Lasersystemet og printeren er udformet
således, at mennesker aldrig udsættes for en laserstråling over
Klasse I-niveau ved normal drift, brugervedligeholdelse eller
obligatoriske servicebetingelse r.
Danish
Notices and Safety Information xvii
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4023-001
Huomautu s las er laitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS
21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I
laserlaitteiden IEC 60825 -määrityksen mukainen.
Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle.
Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin
galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei
altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen
normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden
huoltotoimien yhteydessä.
LUOKAN 1 LASERLAITE
V AROITUS! Laitteen käyttäminen muulla kuin tässä käyttöohjeessa
mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1
ylittävälle näkymättömälle lasers äteilylle.
KLASS 1 LASER APPARAT
VARNING! Om apparaten används på annat sätt än i denna
bruksanvisning specificerats, kan användaren utsättas för osynlig
laserstrål ning, som överskrider gränsen för laserklass 1.
Finnish
VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina
näkymättömälle lasersäteilylle. Älä katso säteeseen.
VARNING! Osynlig laserstrålning när denna del är öppnad och
spärren är urkopplad. Betrakta ej strålen.
xviii Service Manual
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Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21
CFR, underparagraf J för laserprodukter av Klass I (1). I andra
länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt
kraven i IEC 60825.
Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en
inbyggd laser av Klass IIIb (3b) som består av en laserenhet av
gallium-arsenid på 5 milliwat t so m arbe t ar i våglängdsområdet 770795 nanometer. Lasersystemet och skrivaren är utformade så att det
aldrig finns risk för at t n ågon person utsätts för laserstrålning över
Klass I-nivå vid normal användning, underhåll som utförs av
användaren eller annan föreskriven serviceåtgärd.
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR,
underkapittel J, for klasse I (1) laserprodukter, og er i andre land
godkjent som et Klasse I-laserproduk t i samsvar med kravene i IEC
60825.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren
inneholder internt en klasse IIIb (3b)-laser, som består av en
gallium-ar senlaserenhet som avgir stråling i bølgelengdeområdet
770-795 nanometer. Lasersystemet og skriveren er utformet slik at
personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne
serviceopera sjoner.
Swedish
Norwegian
Notices and Safety Information xix
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4023-001
Avís sobre el Làser
Segons ha estat certificat als Estats Units, aquesta impressora
compleix els requisits de DHHS 21 CFR, apartat J, pels productes
làser de classe I (1), i segons ha estat certificat en altres llocs, és un
producte làser de classe I que compleix els requisits d’IEC 60825.
Els productes làser de classe I no es consideren perillosos. Aquesta
impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li,
nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona
de 770-795 nanòmetres. El sistem a làser i la impressora han sigut
concebuts de manera que mai hi hagi exposició a la radiació làser
per s obre d’un nivell de classe I durant una operació normal, durant
les tasques de manteniment d’usuari ni durant els serveis que
satisfacin les condicions prescrites.
Catalàn
Japanese Laser Notice
xx Service Manual
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4023-001
Chinese Laser Notice
Korean La ser Notice
Notices and Safety Information xxi
Page 22
4023-001
Safety Information
• This product is designed, tested and approved to meet strict
global safety standards with the use of specific Lexmark
components. The safety features of some parts may not alway s
be obvious. Lexmark is not responsible for the use of other
replacement parts.
• The maintenance information for this product has been
prepared for use by a professional service person and is not
intended to be used by others.
• There may be an increased risk of electric shock and personal
injury dur ing disassem bly and ser v icing of this product.
Professional service personnel should understand this and take
necessary precautions.
Consignes de Sécurité
French
• Ce produit a été conçu, testé et approuvé pour respecter les
normes strictes de sécurité globale lors de l'utilisation de
composants Lexmark spécifiqu es. Les caractéristiques de
sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation d'autres
pièces de rechange.
• Les consignes d'entretien et de répa ration de ce produit
s'adressent uniquement à un personnel de m aintenance
qualifié.
• Le démontage et l'entretien de ce produit pouvant présenter
certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.
xxii Service Manual
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4023-001
Norme di sicurezza
Italian
• Il pr odotto è stato progettato, testato e approvato in conformità a
severi standard di sicurezza e per l’utiliz zo con componenti
Lexmark specifici. Le caratteristiche di sicurezza di alcune parti
non sempre sono di immediata comprensione. Lexmark non è
responsabile per l’utilizzo di parti di ricambio di altri produttori.
• Le informazioni riguardanti la manutenzione di questo prodotto
sono indirizzate soltanto al personale di assistenza autorizzato.
• Durante lo smontaggio e la manutenzione di questo prodotto, il
rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.
Sicherheitshinweise
German
• Dieses Produkt und die zugehörigen Komponenten wurden
entworfen und getestet, um beim Einsatz die weltweit gültigen
Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten
Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von
Lexmark sind, wird von Lexmark keinerlei Verantwortung oder
Haftung für dieses Produkt übernommen.
• Die Wartungsinformationen für dieses Produkt sind
ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
• Während des Auseinandernehmens und der Wartung des
Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.
Pautas de Seguridad
Spanish
• Este producto se ha diseñado, verificado y aprobado para
cumplir lo s más estrictos estándares de seguridad global
usando los componentes específicos de Lexmark. Puede que
las características de seguridad de algunas piezas no sean
Notices and Safety Information xxiii
Page 24
4023-001
siempre evidentes. Lexmark no se hace responsable del uso de
otras piezas de recambio.
• La in formaci ón sobre el mantenimiento de este producto está
dirigida exclusivamente al personal cualificado de
mantenimiento.
• Existe mayor riesgo de descarga eléctrica y de daños
personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser conscien te de este
peligro y tomar las precauciones necesarias.
Informações de Segurança
Portugese
• Este produto foi concebido, testado e aprovado para satisfazer
os padrões globais de segurança na utilização de componentes
específicos da Le xmar k. As funções de segurança de alguns
dos componentes podem não ser sempre óbvias. A Lexmark
não é responsável pela utilização de outros componentes de
substituição.
• As informações de segurança relativas a este produto
destinam-se a profissionais destes serv iços e não de vem s er
utilizadas por outras pessoas.
• Risco de choques eléctricos e ferimentos graves durante a
desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessári os.
Informació de Seguretat
Catalàn
• Aquest producte està dissenyat, compr ovat i apro vat per tal
d'acomplir les estrictes nor me s de seguretat globals amb la
utililització de components específics de Lexmark. Les
característiques de seguretat d'algunes peces pot ser que no
sempre siguin òbvies. Lexmark no es responsabilitza de l'us
d'altres peces de recanvi.
• La in formaci ó pel manteniment d’aquest producte està
orientada exclusivament a professionals i no està destinada a
ningú que no ho sigui.
• El risc de xoc elèctric i de danys personals pot augmentar
durant el procés de desmuntatge i de servei d’aquest producte.
xxiv Service Manual
Page 25
4023-001
El personal professional ha d’estar-ne assabentat i prendre les
mesures convenients.
Chinese
Korean
Notices and Safety Information xxv
Page 26
4023-001
xxvi Service Manual
Page 27
4023-001
1. Gen e r a l Informat io n
Maintenance Approach
The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the error code charts,
symptom index, and service checks to determine the symptom and
repair the failure. You may find that the removals in the Repair
Information chapter w ill help you identify parts.
After you complete the repair, perform tests as needed to verify the
repair.
Tools
The removal and adjustment procedures described in this manual
require the following tools and equipment:
• Magnetic tip Phillips screwdrivers, large and small
• Flat-blade screwdrivers
• Analog volt ohmmeter (a digital volt ohmmeter may also be
used)
• Needle nose pliers
• Tweezers, C-ring pliers
When you make voltage readings, always use frame ground unless
another ground is specified.
General Information 1-1
Page 28
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Serial Number
The serial number is located in the bottom left corner of the label
illustrated below:
1-2 Service Manual
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4023-001
Abbreviations
ASICApplication-Specific Integrated Circuit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EEPROMElectrically Erasable Programmable Read-
Only Memo ry
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Fi eld Replacea ble Unit
HVPS High Voltage Power Supply
LANLocal Area Network
LASER Light Amplification by Stimulated Emission
of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Vol tage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PICS Problem Isolation Charts
PIXEL Picture Element
PORPower-On Reset
POST Power-On Self Test
PQETPrint Quality Enhancem ent Technology
RIPRaster Image Processor
ROSRead-Only Storage
SRAM Static Random Access Memory
UPR Used Parts Replacement
VAC Volts alternating current
VDC Volts direct current
General Information 1-3
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Standard Feat ures
Printer (Main)
FeatureDescription
Print speed35 ppm (letter/A4) High Speed Printing
Power supplyAC120V, AC220–240V ±10%
Power
consumption
Tempera tur e10 to 35°C
ControllerLexmark Control ler (High Performance)
RIP page
2500 sheet input tray (worldwide)
2000 sheet mailbox
2500 sheet finish er (3 and 4 hole
punching capability, 5k stapling capacity)
TM
Ethernet 10/100, SCSI
scanner and fax
Optra W810
Versions*
A,B,C
A,B,C
B,C
A,B,C
A,B,C
SuppliesPhotoconductor kit
Toner cartridge
Staples
Cables10-foot par allel cable
20-foot par allel cable
50-foot serial cable
10-foot 1284 A-C parallel cable
*Versions are:
A–W810
B–W810n
C–W810dn
1-6 Service Manual
A,B,C
A,B,C
Page 33
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Printer/Options
Parts Identification
General Information 1-7
Page 34
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Printer Configuration
The following diagram shows the major parts of the printer and
paper path. The printer consists of the paper feed section, printhead
unit (exposure section), imaging cartridge (charging section and
development section), image transfer section, fusing section,
cleaning section and paper exit section.
1Paper Exit Roller12 Double Feed Sensor
2Paper Exit Sensor (PS3)13 Tray1 (1st Paper Cassette)
3Lower Fusing Roller14 1st Paper Cassette Near Empty Sensor
4Upper Fusing Roller (Heater Lamp)15 1st Paper Cassette Empty Sensor (PC4)
5Image Transfer Roller16 ATDC Sensor
6Synchronizing Roller17 Sleeve Roller
7Synchronizing Roller Sensor (PC2)18 P C Drum Charger
8Manual Unit19 PC Drum
9Tray2 (2nd Paper Cassette)20 Imaging Cartridge
10 2nd Paper Cassette Near Empty Sensor
(PC25)
11 2nd Paper Cassette Empty Sensor (PC22) 22 Laser Beam
(PC5)
21 Print Head Unit (PH)
1-8 Service Manual
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General Des crip tio n of Each Sectio n
Paper Feed Section
Paper feeds from tray 1 (1st paper cassette), tray 2 or 3 (500-sheet
paper cassette). When the printer receives a print command, the
transport motor M2 turns, paper take-up solenoid turns ON, and the
paper take-up roller in the 1st paper cassette feeds a sheet of paper.
The synchronizing roller sensor (PC2) detects the fed paper and the
paper is then fed to the synchronizing roller fo r printing. When paper
trays (500-sheet cassette (tray 2 or 3), 250-sheet universal cassette
(tray 1)), or 2500-sheet drawer is installed, paper feeds from the
respective paper source.
Printhead Unit (Exposure Section)
The laser diode in the printhead unit emits a laser beam. The
scanning beam creates an electrostatic latent image on the surface
of the PC drum in the imaging cartridg e.
Imaging Cartridge (Charging, Development Section)
The imaging car tr idge consist s of the charging section and
development section. The I/C drive motor (M1) drives the moving
parts of the imaging cartridge.
Image Transfer Section (Release Section)
The toner image on the PC drum transfers to the paper when
passing over the transfer roll. The paper electrostatically releases
from the PC drum.
Fusing Section
Using a heated roller , the fusing section permanently fixes the toner
image onto the paper. A heat sensitive element (thermistor)
attached to the upper fusing roller controls the fusing temperature.
Cleaning Section
The cleaning blade removes excess toner from the paper and
transfers the toner to the waste toner box.
General Information 1-9
Page 36
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Paper Exit Section
After the paper passes the fusing section, the paper exit roller ejects
the paper out the top of the printer. The paper exit sensor (PC3)
senses the ejection of the paper.
Optional manual and duplex unit installed:
The duplex unit switchback motor pulls the trailing edge of the
printed paper inside the duplex unit. The duplex unit transport motor
then feeds the paper to the manual unit where the paper remains
until the second print command.
General Flow for Printing Process
Print command
Polygon Motor ON
CleaningThe transfer roll er becomes negatively
Starting processingThe I/C (imaging cartridge) drive motor (M1)
Paper take-upThe transport motor (M2) starts turning.
Laser emissionA laser beam is emitted at constant power.
Scanning the image dat a
Paper feeding
Dev eloping the image dataT one r is applied to the PC drum to produce a
Transfer the image dataThe toner image on the surface of the PC
Fusing the tonerThe toner is permanently fixed onto the
CleaningExcess toner and electric potential on the
Paper ejectionThe paper ejects.
The motor in the printhead unit starts
turning.
charged to prevent the negat ively-charged
toner from sticking to the PC Drum.
starts turning.
The paper take-up solenoid turns on to feed
paper.
A laser beam scans the sur face of the PC
drum to produce a latent elect rostatic image.
The syc hroniz ing r olle r sen sor (PC2) d etects
the presence of paper. The sychronizing
clutch then turns on which turns on the
sychronizing roller for feeding paper.
visibl e toner image.
drum is transferred onto the paper.
paper.
PC drum are eliminated .
1-10 Service Manual
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Paper Feed Section
Taking Up Paper–Tray 1 (1st Paper Cassette)
Power is transmitted from the transport motor (M2) as follows to take
up paper from the 1st paper cassette:
1. The transport motor (M2) tur n s counterclockwise.
2. The idle gear turns clockwise and the 1st cassette paper takeup solenoid (SL1) turns ON.
3. The paper take-up roller turns counterclockwise and paper is
taken up.
1PC Drum5Synchronizing Roller
2Image Transfer Roller6Paper Take-Up Roller
3Transport Motor (M2)7Paper
4Synchronizing Roller
Sensor (PC2)
General Information 1-11
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Tray 1 Sensors
11st Cassette Paper Near Empty Sensor (PC5) 5 Synchronizing Roller Sensor (PC2)
21st Cassette Set Sensor (PC6)6Double Feed Sensor
31st Cassette Paper Take-up Solenoid (SL1)7Paper Take-up Roller
4Separator Pad81st Paper Cassette Empty Sensor (PC4)
1st Cassette Tray 1 Set Sensor (PC6)
PC6 (1) sensor detects installation of the 1st paper cassette in tray
1.
.
11st Cassette Set Sensor (PC6)
21st Paper Cassette
1-12 Service Manual
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1st Cassette Tray 1 Paper Empty Sensor (PC4)
PC4 (1) detects paper empty status of the 1st paper cassette.
.
11st Paper Cassette Empty Sensor (PC4)
2Paper
1st Cassette Tray 1 Paper Near Empty Sensor (PC5)
PC5 detects when the 1st cassette is near empty.
11st Paper Cassette Near Empty Sensor (PC5)
2Paper
3Paper Lifting Plate
General Information 1-13
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1st Cassette Tray 1 Double Feed Sensor
The double feed sensor (located on the double feed detecting
sensor board (PWB-H)) detects the possibility of double feed. This
sensor uses a photo reflector.
The double feed sensor detects whether the leading edge of paper
to be taken up next runs 10 mm or more from the paper nip point. If
paper runs 10 mm or more, double feeding may occur if the paper is
taken up in the normal printing interval. To avoid this, the printer
prolongs the printing intervals as long as the double feed sensor
detects a double feed status. This results in the reduction of the
number of sheets fed per minute.
Light reflects: Output=LLight does not reflect: Output=H
This sensor detects that the paper is fed inside the printer.
1 Synchronizing Roller Sensor (PC2)
2 Paper
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1st Cassette Tray 1 Paper Size Detection
Five DIP switches indicate the paper size for the 1st paper cassette.
Four of the switches indicate length and one width. The DIP
switches are located on the 1st cassette paper size board (PWBS1).
The ON(1)/OFF(2) settings of the length dip switches set the analog
input voltage. The input voltage and the normal input data from the
width dip switch port determine paper size.
The precise paper size cannot be identified by detection and must
be selected from the operation panel.
When no cassette is set, all switches are set to off.
General Information 1-15
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Tray 2 (2nd Paper Cassette)
12nd Cassette Paper Empty Sensor (PC22)4 2nd Cassette Right Door Detecting Sensor
22nd Cassette Paper Near Empty Sensor (PC25) 5 Paper Take-Up Roller
32nd Cassette Paper Take-up Solenoid (SL21)
(PC23)
Taking up Paper–Tray 2 (2nd Paper Cassette)
Power transmits from the transport motor (M2) as follows to take up
paper from the 2nd paper cassette:
1. The transpor t motor (M2) turns counterclockwise.
2. The idle gear turns clockwise.
3. The 1st cassette paper take-up gear turns counterclockwise.
4. The 1st cassette idle gear turns clockwise and the transport
clutch (CL1) turns ON.
5. Power is transmitted to the 2nd paper cassette.
a. The 2nd cassette paper take-up solenoid (SL21) turns ON.
b. Paper take-up roller turns counterclockwise.
c. Paper is taken up.
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1PC Drum6Paper
2Image Transfer Roller7Paper Take-up Roller
3Transport Motor (M2)8Transport Clutch (CL1)
4Synchronizing Roller Sensor
(PC2)
5Transport Gear
9Synchronizing Roller
General Information 1-17
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Tray 2 Sensors
2nd Cassette Detection
This sensor detects installation of the 2nd paper cassette in tray 2.
The paper size indicated by the 2nd cassette paper size board
(PWB-S2, -S3) is also checked. The length dip switch setting
determines paper size.
2nd Cassette Paper Empty Sensor (PC22)
PC22 detects the paper empty status of the 2nd paper cassette.
Paper empty status occurs when paper runs out in the 2nd paper
cassette.
12nd Cassette Paper Near Empty Sensor (PC22)
2Paper
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2nd Cassette Paper Near Empty Sensor (PC25)
PC25 detects paper near empty status of the 2nd cassette.
1 2nd Cassette Paper Near Empty Sensor (PC25)3 Paper Lifting Plate
2 Paper
2nd Cassette Right Door Detecting Sensor (PC23)
PC23 detects if the 2nd cassette right door is open or closed. The
right door is normally closed except when removing jammed paper.
12nd Cassette Right Door Detecting Sensor (PC23)
2Right Door
General Information 1-19
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Edge Guide and Trailing Edge Stop
Universal Cassette/500-Sheet Tray 2 & 3
The edge guide and trailing edge stop of the universal cassette slide
to accommodate different paper sizes.The edge guide and trailing
edge stop of the fixed paper size cassette are attached in fixed
positions.
Fixed Paper Size Cassette
Paper Lifting Plate
Two paper lifting springs in each cassette constantly raise the paper
lifting plate.
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Cassette-in-Position Detection
The rib on the cassette frame presses the cassette set switch on the
back panel of the printer, indicating the cassette is inserted. The
position of the rib on the cassette frame is different between the
fixed paper size and universal cassette. This lets the printer detect
which cassette is inserted.
General Information 1-21
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Paper Near Empty Detection
Height of the paper lifting plate determines paper-near-empty
condition. Since the amount of paper available during the take-up
sequence varies, detection occurs when the paper take-up roll is in
the retracted position.
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Paper Empty Detection
When the cassette runs out of paper, the actuator of the paper
empty sensor drops into the cutout of the paper lifting plate. This
exposes the sensor, signaling that the cassette is out of paper.
General Information 1-23
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Paper Separating Mechanism
Each cassette has fingers that separate the top sheet of paper from
the rest of the paper stack during paper take-up. When the paper
take-up roll starts to turn, the turning force transmits to the top sheet
of paper. The transmitted force overcomes the block of the fingers,
causing the top sheet of paper to ride over the fingers and feed out
of the cassette into the printer. The paper transport force obtained
through friction with the top sheet of paper is weak and does not
allow the second sheet of paper to ride over the block of the fingers.
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Paper Take-Up Roll
Two paper take-up rolls are mounted in both the fixed paper size
cassette and universal cassette. As the take-up solenoid energizes,
the spring tension increases, meshing the drive and clutch gear
which transmits drive to the paper take-up rolls.
General Information 1-25
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Paper Feed
The paper taken up by the paper take-up section feeds to the
transfer section after registration compensation.
Registration Compensation
Registration compensation eliminates paper skew by controlling the
paper take-up roller and synchronizing roller rotation timing.
The taken-up paper passes the synchronizing roller sensor (PC2)
and reaches the synchronizing roller. The printer delays the
synchronizing roller to align the leading edge of the paper with the
stopping synchronizing roller. The leading edge of the paper slacks
a little as shown in the figure. The synchronizing clutch (CL1)
activates and the paper take-up roller turns for a moment to securely
feed the paper to the inside of the printer.
1Slack of Paper4Synchronizing Roller Sens or (P C2)
2Synchronizing Roller5Paper
3Transport Motor (M2)6Paper Take-up Roller
Paper Feeding
1. The transpor t motor (M2) turns counterclockwise.
2. The idle gear turns clockwise. The synchronizing clutch (CL1)
turns. The I/C drive motor (M1) drives the PC drum.
As the PC Drum turns, the transfer roller also turns.
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The synchronizing roller feeds paper to the PC drum and transfer
roller. The PC drum and transfer roller pinch the paper and feed it to
the fusing section.
1PC Drum4 Synchronizing Clutch (CL1)
2Image Transfer Roller5 Paper
3Transport Roller6 Synchronizing Roller
General Information 1-27
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Printhead Unit (Exposure section)
The printhead unit incorporates a laser diode that emits a laser
beam corresponding to the print image data.
The scanning laser beam scans the PC drum from left to right,
producing an electrostatic latent image on the surface of the PC
drum.
Imaging Cartridge (Charging/Development
Section)
The printer main body I/C drive motor (M1) transmits power to the
gears of the imaging cartridge. The I/C drive motor (M1) turns
clockwise (as viewed from the front of the printer).
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Part NameFunction
1Waste toner boxCollects excess toner.
2Transf er screwTransfers exc ess toner to the
3Rotary bladeTransfers the waste toner
4Separating clawEnsures paper release fro m the
5Cleaning bladeRemoves excess toner from the
6Sheet eraseNegatively charges the PC Drum
7PC drumCharged roller that applies image
8Sleeve rollerTransfers toner to the su rface of
9ScrewMixe s toner and carrier inside the
10ATDC SensorAdjusts the toner density.
waste toner box.
collected by the cleaning blade to
the waste toner box.
PC Drum.
PC Drum (waste toner) aft er
transfer to the paper.
to eliminate the remaining elect ric
polarity after tr ansfer to the paper.
to paper.
the PC Drum via a rotating resin
sleeve and then dev elops it.
toner hopper.
11Toner fil ler openingToner is supplied from the sub-
hopper.
12ChargerCharges the PC Drum.
General Information 1-29
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Development Section
Development
The development section feeds toner to the electrostatic latent
image on the surface of the PC drum to produce a visible toner
image.
A screw circulates the toner in the toner hopper. The toner mixes
with the carrier to produce the developer. The ATDC sensor detects
the ratio of toner to carrier, and voltage controls the toner density.
The developer is then supplied to the sleeve roller.
The sleeve roller negatively charges the toner. The toner adheres to
the electrostatic latent image due to the reduced negative voltage in
the image area. The toner does not adhere to the area where the
laser beam has not been applied. This occurs because the charge
brush maintains the negatively charged voltage in the non-image
area.
Three empty-toner conditions are detected: sub-hopper empty, toner
bottle near empty, and toner bottle empty.
Sub-Hopper Empty
The toner detection plate lead switch checks the toner level by
detecting the position of the toner detection plate.
The toner bottle supplies toner to the rotating mixing plate. The
rotating mixing plate spreads the toner evenly in the sub-hopper .
The toner pushes upward on the toner detection plate. The position
of the toner detection plate indicates the amount of toner in the subhopper.
A toner empty status occurs when the toner detection plate lowers
enough for the lead switch to detect the plate. However, the lead
switch is not activated when the toner supply motor stops or the
bottle motor rotates. When the sub-hopper empty status occurs, the
bottle motor activates to supply toner to the sub-hopper from the
toner bottle.
The toner bottle empty status is detected when the toner bottle
rotates and feeds toner to the sub-hopper. The bottle rotation
counter checks the number of bottle rotations. If the number of
rotations exceeds 10, the near empty status occurs. The bottle
supplies toner after the near empty status occurs.
Toner bottle empty
The toner bottle empty status in the imaging cartridge occ urs when
the ATDC sensor detects a toner density (ratio of toner to carrier)
below 10%. When this occurs, the appropriate toner density cannot
be maintained. The bottle motor and toner supply motor stop. The
toner empty status is recorded and will not reset until the toner
cartridge is replaced.
A TDC Sensor
The developer, circulated by a screw, passes over the ATDC sensor.
The sensor measures the ratio of toner to carrier (T/C ratio) in the
developer . This ratio is converted to a charge and input to PWB-A.
When the sensor detects a low T/C ratio, T/C recovery mode begins.
General Information 1-33
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Image Transfer Section (Release Section)
The transfer roller transfers the toner image on the surface of the PC
Drum onto the paper.
Normally the paper separates from the PC drum without any outside
interference. When the paper fails to separate from the PC drum, the
separating claw releases the paper by force.
1PC Drum
2Image Transfer Roller
3Paper
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Optical Erase
During the optical erase, light from the eraser lamp irradiates the PC
drum, eliminating the negative charge applied by the cleaning blade
during PC drum cleaning. This prevents blac k lines from being
created on the front and rear ends and both sides of the image.
1 Cleaning Blade
2 Optical Erase
General Information 1-35
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Fusing Section
Fusing
Toner-transferred paper feeds from the transfer section to the fusing
section when power from the transport motor (M2) transmits to the
upper fusing roller.
The fusing roller heater lamp (H1, built in the roller) heats the upper
fusing roller. The fusing roller thermistor (TH1) attached to the upper
fusing roller controls the heater temperature. To ensure overheating
does not occur, the fusing roller thermostat (TS1) and fusing roller
heater lamp fuse (TF1) are connected in series to the heater lamp
(H1). The heater lamp (H1) heats when an AC voltage is applied.
The resistance of the thermistor (TH1) attached to the upper fusing
roller varies with temperatures. When temperature rises, the
resistance of the thermistor (TH1) decreases, and vice versa.
Thermostat (TS1) and Heater Lamp Fuse (TF1)
If an abnormal current flows into the heater lamp because of
thermistor trouble and the upper fusing roller temperature reaches
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approximately 220°C, the contact of the thermostat automatically
opens to shut off AC voltage. (As the temperature decreases, the
contact of the thermostat closes again. However, once the
thermostat activates, you must replace it with a new one.) The
thermostat cannot respond quickly enough to protect against a
sudden overload current. In this case, the heater lamp fuse blows to
protect the heater lamp.
Fusing Temperature Control
The fusing section start s to warm up when the main switch turns
ON. Preliminary rotation occurs for 20 seconds when the
temperature of the upper fusing roller reaches 170°C (338°F). When
the rotation stops, the temperature of the upper fusing roller is
approximately 200°C (392°F) and warm-up is complete. (Warm-up
takes approximately 1 minute.)
Fusing PPM Control
The sides of the fusing roller become excessively hot when small
sheets of paper (paper width of 250 mm (9-3/4") or less) print
continuously. When this occurs, "fusing PPM control" activates to
maintain specific paperfeed intervals and prevent the roller from
becoming too hot.
General Information 1-37
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Paper Exit Section
Paper Path Through Exit
Paper fed from the fusing section passes through the paper exit
roller and ejects printed-side down out the top of the printer. The
transport motor (M2) provides transmit power for feeding paper.
The paper exit sensor (PC3) detects paper eject. As paper passes
through the sensor, it presses the sensor arm until the sensor arm
end engages with the photointerrupter.
1 Paper Exit Sensor (PC3)
2 Paper
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1 Paper6Synchronizing Roller
2 Paper Exit Roller7Transport Motor (M2)
3 Paper Exit Sensor (PC3)8PC Drum
4 Lower Fusing Roller9Upper Fusing Roller
5 Synchronizing Roller Sensor (PC2)
Detection of a New Imaging Cartridge
The printer checks for a new imaging cartridg e when:
• The printer is turned on after installing a new imaging cartrid ge.
• With the printer turned on, the right door is closed after
replacing the imaging cartridg e.
The imaging car tr idge has an activating fuse. When the printer is
turned ON, the fuse is blown and the PC drum counter clears,
enabling detection of the image cartridge life. When power is turned
OFF, the counter value is stored in the imaging cartridge EEPROM.
When power is turned ON, the counter value is recalled from the
imaging cartridge EEPROM to continue counting.
General Information 1-39
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Right Door Interlock Switch (S2)
The right door is normally closed. It is open when the imaging
cartridge is replaced or jammed pape r is removed.
With the door closed, the projection of the right door presses the
spring attached to the switch lever, turning the switch ON. When it is
opened, the lever of the switch is released, turning the switch OFF.
1 Right Door3 Right Door Interlocks
2 Projection4 Spring
1-40 Service Manual
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Duplex Unit Option
Parts Identification
General Information 1-41
Page 68
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Cross-Sectional View
1 Duplex Unit Transport Roller 13 Duplex Unit Transport Roller 2
2 Duplex Unit Transport Roll 14 Duplex Unit Transport Roll 2
Switchback Mechanism
Switchback Operation
To accomplish the switchback operation, the switchback motor
reverses the rotational direction of the paper exit roller. The onesided print then feeds into the duplex unit. The drive of the
switchback motor is transmitted through a gear train.
1-42 Service Manual
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Paper Exit Roller Drive Coupling Mechanism
When the duplex unit is mounted, the tip of the duplex unit lever
raises the idle lever. This disconnects the printer drive (fusing roller)
from the paper exit roller and connects the switchback motor drive.
Switchback Motor Control
The switchback motor is a two-phase stepping motor.
Transport and Dupl ex Paper Take-Up Mechanism
Transport and Duplex Paper Take-Up Operation
The transport and duplex paper take-up operations are performed by
two pairs of duplex unit transport rollers/rolls and the manual feed
paper take-up roll of the printer. The drive for these operations
comes from the duplex unit transport motor and manual feed paper
take-up clutch.
General Information 1-43
Page 70
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Duplex Unit Transport Motor Control
The duplex unit transport motor is a two-phase stepping motor.
1-44 Service Manual
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Paper Deck 2500-Sheet (LCC) Option
Cross-Sectional View
1 Lift 25 Vertical Transport Roller
2 Paper Take-Up Roll 26 Vertical Transport Roll
3 Lift 17 Feed Roll
4 Paper Take-Up Roll 18 Separator Roll
Vertical Transport Drive Mechanism
Vertical Transport Drive Operation
The Vertical T r ansport Roller is driven by LCC (paper deck) transport
motor (HMOT). The driving force of HMOT is transmitted via a gear
train and registration clutch (RCL) to the vertical transport roller
which feeds the paper from lift 1 or 2 to the printer. Because of the
long paper path from lift 2, skew tends to occur in the paper fed from
General Information 1-45
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lift 2. To correct skew, RCL forms a loop in the paper between the
separator roll and vertical transport roller.
Control of LCC Transport Motor HMOT
The printer main engine board energizes and de-energizes HMOT
by sending signals to HMOT through the LCC (paperdeck) main
board (PWB-A). HMOT is a DC motor .
1-46 Service Manual
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Paper Take-Up Mechanism
The paper take-up mechanism takes up a sheet of paper from the
paper stack on each lift and feeds it to the vertical transport roller.
A paper take-up sequence occurs when drive from LCC Transport
Motor HMOT transmits through take-up clutch 1/2 P1CL/P2CL to
paper take-up roll 1/2. When lift 1 runs out of paper, paper feeds
from lift 2.
A roll with a torque limiter prevents double feed of the last two sheets
of paper. The roll is mounted beneath paper take-up roll 1 of lift 1.
Paper take-up roll 1 is active when paper is fed from lift 1.
Both paper take-up roll 1 and 2 activate to perform the paper take-up
sequence when paper feeds from lift 2. During this sequence, paper
empty sensor 1 PPS1 detects proper feed of paper through take-up
roll 1.
The sheet of paper taken from lift 1/2 temporarily stops at the paper
standby position sensor to minimize variations in the position of the
leading edge of the paper. Separator clutch BCL transmits drive to
the separator roll which moves the sheet of paper to the vertical
transport section.
General Information 1-47
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Paper Take-Up From Lift 1
After Lift 1 completes lifting motion, paper take-up roll 1 takes-up
and feeds a sheet of paper until the paper blocks paper standby
position sensor S1. This serves as the standby position of the paper.
When the printer sends a paper take-up signal, the separator/feed
rolls and paper take-up roll 1 transport s the paper up to registration
sensor RSEN. After RSEN has been blocked, the paper moves a
1-48 Service Manual
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4023-001
little further to reach the vertical transpor t roller, and forms a
registration loop, before stopping.
The vertical transport roller transports the paper to the printer. When
the trailing edge of the paper being transported by the vertical
transport roller unblocks paper standby position sensor S1, the
subsequent sheet of paper is transpor ted to the standby position
and the LCC waits for the next paper take-up signal.
Registration clutch RCL de-energizes a given period of time after the
trailing edge of the paper being taken up unblocks registration
sensor RSEN. The next paper take-up signal transmits after the
timer (which starts when the vertical transport roller rotates for the
preceding sheet of paper) runs out.
General Information 1-49
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Paper Take-Up From Lift 2
After all sheets of paper have been taken up and fed from lift 1, lift 1
moves to the top level position to serve as part of the paper path for
feeding paper from lift 2.
After the trailing edge of the last sheet of paper from Lift 1 unblocks
paper empty sensor 1 PPS1, both paper take-up roll 1 and 2 turn.
Paper take-up roll 1 and 2 transports the sheet of paper until the
paper blocks LCC take-up sensor PPS0.
Paper take-up roll 1 transports the paper located at PPS0 until the
paper blocks paper standby position sensor S1. This is the standby
position of the paper.
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After the printer sends a paper take-up signal, the separator/feed
rolls and paper take-up roll 1 transports the paper until the paper
blocks registration sensor RSEN. The paper travels a little further to
reach the vertical transport roller and form a registration loop before
stopping. The vertical transport roller transports the paper to the
printer.
After the trailing edge of the paper transported by the vertical
transport roller unblocks paper empty sensor 1 PPS1, paper take-up
roll 1 and 2 transport the subsequent sheet of paper until the
subsequent sheet of paper blocks PPS1.
General Information 1-51
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4023-001
If PPS0 is unblocked and a sheet of paper is blocking PPS1, the
sheet of paper blocking PPS1 transports to the standby position
uninterrupted. LCC then waits for the next paper take-up signal.
Registration clutch RCL de-energizes a given period of time after the
trailing edge of the paper being taken-up unblocks registration
sensor RSEN. The next paper take-up signal transmits after the
timer (which starts when the vertical transpor t roller rotates for the
preceding sheet of paper) runs out.
Paper Take-Up Retry Control
To minimize the occurrence of paper misfeed due to a slippery paper
take-up roll, separator clutch BCL energizes again if a sheet of
paper fails to reach registration sensor RSEN within a given period
of time after BCL first energizes.
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Paper Separating Mechanism
The paper separating mechanism employs a system with a torque
limiter that is fitted to the separator roll shaft. It stops the separator
roll when friction changes between the feed and separator rolls.
Paper Pressure Releasing Mechanism
When LCC is pulled out, the pressure release rail pushes the
separator roll assembly downward, releasing the pressure between
the feed and separator roll. The pressure release rail is located
above the rail on the paper take-up end.
General Information 1-53
Page 80
4023-001
Paper Take-Up Roll Retracting Mechanism
When LCC is slid out, the projection on the back of the LCC front
cover disengages from the pressure release lever . This pushes the
paper take-up roll upward, releasing pressure between the paper
and paper take-up roll.
Edge Guides and Trailing Edge Stop
The trailing edge stop screws into position (not used for letter
crosswise). Edge guides slide into any position you want.
Whenever the positions of the edge guides and trailing edge stop
change, be sure to perform the paper size setting procedure. (See
“Paper Size Setting” that follows.)
1-54 Service Manual
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Paper Size Setting
The paper sizes that can be set are A4 crosswise and Letter
crosswise.
After the positions of the edge guides and trailing edge stop change,
place the DIP switch keys on LCC main engine board PWB-A in the
corresponding positions according to the current paper size
Note: Positions 3 and 4 are not used.
SW1Letter CrosswiseA4 Crosswise
1OFFON
2OFFOFF
3OFFOFF
4OFFOFF
General Information 1-55
Page 82
4023-001
LCC-in-Position Detection
The LCC is detected at its closed position when the light blocking
plate located on the rear end of the right rail blocks LCC Set Sensor
FRONT.
Lifting Mechanism
When the LCC is slid into the printer, the couplings engage. The
LCC lift-up motor EMOT rotates forward and backward, turning the
one-way gear and gear train to raise Lift 1 and Lift 2 respectively.
Lift 1 and 2 drive mechanisms each contain a one-way gear. When
EMOT turns forward, drive transmits to Lift 1 and when the motor
turns backward, drive transmits to Lift 2.
1-56 Service Manual
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o
o
Lifting Operations
LCC set sensor FRONT is blocked.
LCC lift-up motor EMOT turns forward raising lift
1.
The paper stac k caus es the li gh t blo c ki ng pla te
the pape r take-up roll 1 assembly to block lift-up
sensor 1 LS1.
EMOT de-energizes and then energizes to start
turning backward, raising Lift 2.
The paper stac k caus es the li gh t blo c ki ng pla te
the pape r take-up roll 2 assembly to block lift-up
sensor 2 LS2.
EMOT de-ener gizes.
Paper is consumed as print cycles run.
The paper take-up roll gradually lowers, unblocking the lift-u p Sensor.
EMOT energizes and the lift raises. This lifts the
paper stack to block the lift- up sensor.
General Information 1-57
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Both lift 1 and 2 perform the following sequence of operations to
maintain pressure between the paper and paper take-up roll.
1. Lift 1 and 2 ascends.
• LCC is slid into position.
• The lift-up sensor is unblocked while a paper take-up
sequence occurs with paper present on the lift.
2. Lift 1 and 2 stops.
• Lift-up sensor is blocked.
• The paper stack top level position is being corrected.
3. LCC lift-up motor EMOT energizes.
4. Lift 1 and 2 descends.
• LCC is slid out of the printer.
• Lift 1 and 2 are lowered.
Note: To absorb shocks that would otherwise be applied during
the descent motion, springs are loaded in the rear side of the
LCC.
1-58 Service Manual
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Paper Near Empty Detection
A paper-near-empty condition is detected by sensing the height of
lift 1 or lift 2. When paper is used during a print cycle, lift 1 or 2
gradually moves up. This eventually unblocks the paper near empty
sensor, indicating that the LCC (paper deck) is near empty.
Paper Empty Detection
Paper empty sensor 1 PPS1 and paper empty sensor 2 PPS2
(reflector-type photosensors), installed in the paper take-up unit,
detect the paper-empty condition. When a paper-empty condition is
detected, the corresponding message displays on the panel.
² When Paper is Loaded
The light from the LED of paper empty sensor 1
PPS1 or paper empty sensor 2 PPS2 reflects ind
cating that there is paper in LCC.
General Information 1-59
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² When Paper is Not Loaded
The light from the LED of paper empty sensor 1
PPS1 or paper empty sensor 2 PPS2 does not
reflect, indicating th ere is no paper loaded in the
LCC.
Paper Dehumidifying Heaters
Paper dehumidifying heaters (mounted on both sides of the LCC)
prevent paper passage performance from being degraded by damp
paper during highly humid conditions. As long as the power cord is
plugged in, these heaters are kept ON at all times.
1-60 Service Manual
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Mailbox/Transport Option
Parts Identification
Horizontal Transport Unit Cross-Sectional View
1 Paper Entrance Switching Mechanism
2 Upper Attachment
3 Transport Roller
4 Horizontal Unit Paper Sensor
General Information 1-61
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Paper Path
The path of the paper ejected from the printer varies with the paper
output selection. Various sensors and switches check whether the
paper travels properly in the designated path. The follo wing
illustration shows the relationship between the paper path and
sensors/switches.
In single-side printing, as the entrance of the horizontal transport
unit moves up, the paper trav els into the horizontal transport unit and
then into the storage unit, where the storage unit sorts the paper into
the designated bin. If the paper has not passed the PC1 or PWB-C
within a certain time after the printer paper exit sensor turns ON, the
paper has jammed inside the horizontal transport unit or at the
entrance/exit of the storage unit. This results in a jam error.
Paper ejects from the horizontal transport unit. The storage unit
entrance roller then forwards the paper. The subsequent paper path
varies with the paper output selection. The paper passes to the
paper exit sensor (PWB-C), exit roller and arrives in the designated
bin. If the paper has not reached/passed the paper exit sensor
(PWB-C) within a certain time after the horizontal unit paper sensor
(PC1) turns ON, the paper has jammed at the entrance/exit of the
storage unit, causing a jam error.
1-62 Service Manual
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Paper Transport Mechanism
Entrance Path Switching Mechanism
Non-Sort mode:
Paper entrance switching solenoid (SL1) energizes to swing the path
switching guide upward and stop it when non-sort tray transport
position detecting sensor is blocked.
Mode other than Non-Sort:
Paper entrance switching solenoid (SL1) energizes to swing the path
switching guide upward and stop it when finisher transport position
detecting sensor is blocked.
General Information 1-63
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Paper Entrance Switching Mechanism
The paper entrance switching solenoid (SL1) energizes according to
the selected mode (duplex or single-side), which moves the
entrance of the horizontal transport unit up or down. The entrance of
the horizontal transport unit moves down in duplex printing, and
moves up in single-side printing. A tab interlocked with the paper
entrance switching solenoid (SL1) turns ON/OFF the non-sort tray
positioning sensor (PC2) and the sort bin positioning sensor (PC3),
detecting the position of the entrance.
If the entrance moves up and down when the horizontal transport
unit is not attached to the printer properly, the entrance may be
damaged. To prevent this, a stopper is provided. If the horizontal
transport unit is not attached to the printer properly, this stopper
prevent the gears from engaging. As a result, drive force of the
paper entrance transport motor (M1) in the printer does not transfer
to the entrance.
Paper Transport Mechanism (Horizontal Transport Unit)
This mechanism transpor ts the paper from the horizontal transpor t
unit to the storage unit. Drive force transfers from the storage unit
transport motor (M1). Make sure that the gear at the exit of this
mechanism engages with the gear at the entrance of the storage
unit.
1-64 Service Manual
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Paper Entrance Transport Mechanism
The transport motor (M1) dr ives the horizontal transpor t rollers and
entrance roller, transporting the print into the mailbox/finisher.
The paper ejects from the horizontal transpor t unit. The entrance
roller guides the paper into the storage unit. The subsequent paper
path varies with the paper output selection. In stacker mode, the 1st
bin switching deflector moves down to close the downward paper
path, forcing the paper toward the 1st bin. The paper then passes to
the paper exit sensor, exit roller, and arrives in the 1st bin tray.
In mailbox mode, if a bin other than 1st bin is designated, the 1st bin
switching deflector moves up, causing the paper to move down
toward the 2nd and subsequent bins. For instance, if the 2nd bin is
designated, the 2nd bin switching deflector moves down to close the
downward paper path, forcing the paper toward the 2nd bin. The
paper then passes to the paper exit sensor , e xi t roller, and arrives in
the 2nd bin tray. The same applies to other bins. Bin switching
deflectors move down when their corresponding solenoid turns ON.
General Information 1-65
Page 92
4023-001
Paper Empty Detection
A paper empty detecting sensor board, provided for each bin,
checks for presence of paper. When paper is not present in a bin,
the corresponding sensor turns ON. Sensor boards act in pairs (one
as the emitter and the other as the receiver) to perform the paper
sensing function. For instance, in the case of the 2nd Bin, the light
emits from the topside (emitter) of the PWB-D2 (3rd bin) to the
underside (receiver) of the PWB-D1 (2nd bin). If paper is not present
in the 2nd Bin, the sensor turns ON, indicating a paper empty. If
paper(s) is present, the paper blocks the light, keeping the sensor
turned OFF.
Paper Full Detection
Each bin contains a lever-type switch. When the height of the
stacked papers exceeds a certain level, the paper pushes the lever
up, turning the switch ON. The switch is attached to the underside of
each paper empty detecting sensor board.
1-66 Service Manual
Page 93
4023-001
Paper Output Modes
The mailbox has two paper output modes—stacker and mailbox.
Stacker Mode
The horizontal transport unit moves up and all papers output through
the horizontal transport unit into the 1st bin.
Mailbox Mode
The entrance of the horizontal transport unit moves up and all
papers output through the horizontal transpor t unit into the
designated bin. Any bins from the 1st to 10th bins can be assigned
as dedicated bins.
General Information 1-67
Page 94
4023-001
Finisher Option
Parts Identification
1 1st Tray6 Rear Cover
2 Upper Right Cover7 Finisher Tray Cover
3 Misfeed Clearing Cover8 Upper Rear Cover
4 Front Cover9 Staple Door
5Elevator Tray
1-68 Service Manual
Page 95
4023-001
Paper Transport Path Switching Mechanism
1st Tray/Finisher Tray Path Switching Mechanism
When the upper entrance switching solenoid energizes through
PWM control, the print exits into the 1st tray. When the upper
entrance switching solenoid de-energizes, the print exits toward the
finisher tray.
General Information 1-69
Page 96
4023-001
Paper Transport Mechanism
Paper Entrance Transport Mechanism
The transport motor (M1) drives the horizontal transport rollers and
entrance roller which transports the print into the finisher.
1st Tray Tran spo rt Mechanism
Upper exit motor drives the 1st tray exit roller and transport roller to
feed the print into the 1st tray. The speed at which the print
transports decelerates as it feeds into the 1st tray.
1-70 Service Manual
Page 97
4023-001
Upper Exit Motor Control
Changing the driving action varies the upper exit motor (M2) speed.
Punch Mec hanism
The print traveling through the finisher briefly stops, allowing the
punch rods to punch the paper.
The transport motor and the electromagnetic spring clutch fitted to
the punch roller energize and de-energize, moving the punch rods
up and down to punch holes in the print.
Punch Operatio n
The print transports from the printer into the horizontal transport
unit. M1 energizes to turn the horizontal transpor t rollers and
entrance roller. At the same time, upper exit motor energizes to turn
the transport roller. The trailing edge of the print moves past the
paper sensor of the horizontal transport unit. After a given period of
time, the upper exit motor deenergizes to stop the transport roller.
The transport motor remains energized, forming a loop in the print
before the transport roller. The electromagnetic spring clutch
energizes causing the Punch Roller and eccentric cams to turn. The
eccentric cams cause the punch rods to move up and down,
punching holes in the print. The upper exit motor energizes again to
feed the print into a tray or bin.
General Information 1-71
Page 98
4023-001
Fini sher Tray
The finisher tray is used when aligning, shifting, and stapling a print
set/stack in the shift or staple mode. The finisher tray and paper
holding tray retract to let the processed print set/stack drop onto the
elevator tray.
CD Aligning Mechanism
The CD aligning plate moves and the paddle rotates to press each
print against the shift reference plate.
CD Aligning P l a te
The CD aligning motor rotates in the forward or backward direction,
turning the spiral shaft to move the CD aligning plate.
1-72 Service Manual
Page 99
4023-001
To ensure positive print aligning motion, the CD aligning plate moves
from its home position to standby position before the print feeds into
the finisher. The CD aligning plate moves between the standby and
aligning positions until the last print is aligned. The CD aligning
home position sensor detects the CD aligning plate home position.
This position serves as the reference point for movement of the CD
aligning plate. The standby position varies according to the paper
size (CD length).
The standby position is 8.5 mm away from the print end face.
General Information 1-73
Page 100
4023-001
CD Aligning Motor Control
The CD aligning motor sequences the movement of the CD aligning
plate.
Paddle
The paddle moves the print, which has been fed by the CD aligning
plate, toward the stapling corner. The gear is normally locked by the
torque limiter and, when paddle motor turns forward, the paddle
lowers. As the tension of the spring exceeds the force of the torque
limiter, the rotation of the motor transmits to the paddle through the
gear train.
1-74 Service Manual
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