SHARP Z800 Service Manual

Z-800

SERVICE MANUAL

CODE: 00ZZ800//SM/E

MODEL Z-800

Options • Paper tray (SF-UB14)

• Multi paper feed unit (ZT-MF11)

• Copier table (SF-720D2)

• Personal counter (SF-71A/71B)

CONTENTS

[ 1 ] GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

[ 2 ] PRODUCT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

[ 3 ] EXTERNAL VIEW AND INTERNAL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . 3-1

[ 4 ] UNPACKING AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

[ 5 ] GENERAL DESCRIPTIONS OF EACH SECTION . . . . . . . . . . . . . . . . . . . . . . . 5-1

[ 6 ] DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

[ 7 ] ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

[ 8 ] SIMULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

[ 9 ] SELF DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

[10] SERVICE AT MEMORY TROUBLE AND

[10] MAIN CONTROL PWB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

[11] MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

[12] ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Parts marked with "!" is important for maintaining the safety of the set. Be sure to replace these parts with specified
ones for maintaining the safety and performance of the set.

This document has been published to be used

SHARP CORPORATION

for after sales service only.
The contents are subject to change without notice.

CONTENTS

[ 1 ] GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . 1-1

1. Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. Target users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

3. Novel technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

4. Novel functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

5. System outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

[ 2 ] PRODUCT SPECIFICATIONS . . . . . . . . . . . . . . . 2-1

1. Basic specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2. Details of each section . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3. Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

[ 3 ] EXTERNAL VIEW AND INTERNAL

STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1. External view and internal structure . . . . . . . . . . . . . . . 3-1

2. Operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3. Cross section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4. Switches, sensors, detectors . . . . . . . . . . . . . . . . . . . . 3-3

5. Clutches, solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

6. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

7. PWBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

[ 4 ] UNPACKING AND INSTALLATION . . . . . . . . . 4-1

1. Packing drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

(1) Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

(2) Space around the machine . . . . . . . . . . . . . . . . . . . 4-2

(3) Installing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

(4) Power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

(5) Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

3. Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4. Adding toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

5. Optical multi bypass feeder unit Installation Manual . . . 4-6

(1) Open the upper unit of the main copier unit . . . . . . 4-6

(2) Release the lock for the manual bypass unit and

remove the manual bypass unit . . . . . . . . . . . . . . . 4-6

(3) Mount the multi bypass feeder unit onto

the main copier unit . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

[ 5 ] GENERAL DESCRIPTIONS OF

EACH SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1. Paper feed section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

2. Separation, transport section . . . . . . . . . . . . . . . . . . . . 5-2

3. Fuser, paper exit section . . . . . . . . . . . . . . . . . . . . . . . 5-2

4. Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5. Optical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-1. General descriptions . . . . . . . . . . . . . . . . . . . . . . . 5-3

(1) Original table . . . . . . . . . . . . . . . . . . . . . . . . 5-3

(2) Copy lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

(3) Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

(4) Lens (Fixed focus lens) . . . . . . . . . . . . . . . . . 5-3

(5) Lens base . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

(6) No. 4/5 mirror base . . . . . . . . . . . . . . . . . . . . 5-3

(7) Mirror motor . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

(8) Mirror home position sensor (MHPS) . . . . . . 5-4

(9) No. 2/3 mirror base . . . . . . . . . . . . . . . . . . . . 5-4

(10) Copy lamp unit . . . . . . . . . . . . . . . . . . . . . . .5-4

(11) Thermal fuse . . . . . . . . . . . . . . . . . . . . . . . . .5-4

(12) Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

(13) Exposure adjustment plates . . . . . . . . . . . . . .5-4

(14) Lens drive motor . . . . . . . . . . . . . . . . . . . . . .5-4

(15) AE sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-2. Basic operations . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

6. Copy process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

(1) Photoconductor . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

(2) Process diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

(3) Actual process . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

(4) Transit of photoconductor drum surface

potential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

(5) Process correction system . . . . . . . . . . . . . . . . . .5-11

1) Outline of the correction system . . . . . . . . . . .5-11

2) Correction operation . . . . . . . . . . . . . . . . . . . .5-11

[ 6 ] DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . 6-1

1. Paper feed section, paper transport section,

power section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

1-1. Paper feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

1-2. Paper feed roller ass’y removal . . . . . . . . . . . . . .6-1

1-3. Separation roller . . . . . . . . . . . . . . . . . . . . . . . . .6-2

1-4. Takeup roller, paper feed roller . . . . . . . . . . . . . .6-2

1-5. Resist roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

1-6. Transport belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

1-7. Socket holder unit . . . . . . . . . . . . . . . . . . . . . . . . .6-4

1-8. Lower unit PWB . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

1-9. Cassette paper empty detector (CPED1) . . . . . . .6-4

1-10. Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

2. Manual paper feed section . . . . . . . . . . . . . . . . . . . . . . .6-5

2-1. Manual paper feed roller, manual takeup roller . . .6-5

2-2. Reverse rotation roller ass’y . . . . . . . . . . . . . . . . . .6-5

3. Fuser section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

3-1. Fuser unit removal . . . . . . . . . . . . . . . . . . . . . . . . .6-6

3-2. Heater lamp replacement . . . . . . . . . . . . . . . . . . . .6-6

3-3. Upper heat roller ass’y removal . . . . . . . . . . . . . . .6-7

3-4. Upper separation pawl replacement . . . . . . . . . . . .6-7

3-5. Lower cleaning roller and lower heat roller

replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

3-6. Scraper replacement . . . . . . . . . . . . . . . . . . . . . . .6-8

3-7. Thermistor/thermostat removal . . . . . . . . . . . . . . . .6-8

4. Optical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

4-1. Copy lamp replacement . . . . . . . . . . . . . . . . . . . . .6-9

4-2. Copy lamp unit replacement . . . . . . . . . . . . . . . . . .6-9

4-3. Mirror base drive wire replacement . . . . . . . . . . . .6-9

4-4. No.4/5 mirror unit replacement . . . . . . . . . . . . . . .6-10

4-5. Optical unit removal . . . . . . . . . . . . . . . . . . . . . . .6-10

4-6. Other parts in the optical system . . . . . . . . . . . . .6-11

4-7. Light adjustment plate/temperature fuse

removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

5. Drum section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

5-1. Drum unit removal . . . . . . . . . . . . . . . . . . . . . . . .6-12

6. Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-1. Developer unit removal . . . . . . . . . . . . . . . . . . . . .6-12

6-2. Developer cartridge removal . . . . . . . . . . . . . . . .6-13

6-3. Toner motor removal . . . . . . . . . . . . . . . . . . . . . .6-13

6-4. Toner density sensor . . . . . . . . . . . . . . . . . . . . . .6-13

I

7. Operation panel section/medium cabinet . . . . . . . . . . 6-14

8. Major parts in the frame side . . . . . . . . . . . . . . . . . . . . 6-14

8-1. Ozone filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

8-2. Optical unit cooling fan removal . . . . . . . . . . . . . 6-14

8-3. Ventilation fan motor . . . . . . . . . . . . . . . . . . . . . 6-15

8-4. Transport roller clutch . . . . . . . . . . . . . . . . . . . . 6-15

8-5. Paper exit sensor . . . . . . . . . . . . . . . . . . . . . . . . 6-15

[ 7 ] ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

1. Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

(1) MG roller main pole position adjustment . . . . . . . . . 7-1

(2) Adjustment of clearance between DV doctor and MG

roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

2. Optical section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

A. Adjustments list . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

B. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

C. Adjustment contents . . . . . . . . . . . . . . . . . . . . . . . . 7-4

(1) Image distortion adjustment . . . . . . . . . . . . . . 7-4

(2) Copy image center position adjustment . . . . . 7-8

(3) Focus adjustment (Resolution adjustment) . . . 7-8

(4) Uniformity adjustment . . . . . . . . . . . . . . . . . . 7-10

(5) Image loss/void area adjustment . . . . . . . . . . 7-10

3. COPY DENSITY ADJUSTMENT . . . . . . . . . . . . . . . . 7-13

(1) Copy density adjustment timing . . . . . . . . . . . 7-13

(2) Note for copy density adjustment . . . . . . . . . 7-13

(3) Necessary items for the copy density

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

(4) Copy density adjustment mode . . . . . . . . . . . 7-13

(5) Copy density adjustment procedure . . . . . . . 7-13

A. Test chart (UK0G-0162FCZZ) setting . . . 7-13

B. Normal copy mode (Non-toner-save mode)

copy density adjustment . . . . . . . . . . . . . . 7-13

C. Normal copy mode (Toner save mode)

copy density adjustment . . . . . . . . . . . . . 7-14

D. Photo copy mode (Non-toner-save mode)

copy density adjustment . . . . . . . . . . . . . . 7-14

E. Auto copy mode (Non-toner-save mode)

copy density adjustment . . . . . . . . . . . . . 7-14

F. Auto copy mode (Toner save mode) copy

density adjustment . . . . . . . . . . . . . . . . . . 7-15

(6) Copy density adjustment table . . . . . . . . . . . 7-16

4. Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

(1) Transfer charger wire installation . . . . . . . . . . 7-17

(2) DV bias adjustment . . . . . . . . . . . . . . . . . . . . 7-17

(3) Separation charger output adjustment . . . . . 7-17

[ 8 ] SIMULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

1. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

2. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

3. Operating procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

4. Purpose list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

5. Details of simulations . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

6. User simulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

(1) Functions which can be reset or canceled by

user simulation . . . . . . . . . . . . . . . . . . . . . . . 8-10

(2) User simulation procedure . . . . . . . . . . . . . . . 8-10

(3) User simulation code table . . . . . . . . . . . . . . 8-10

[ 9 ] SELF DIAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

1. Summary/purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

3. Clearing the self diag display . . . . . . . . . . . . . . . . . . . . .9-1

4. Self diag contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2

5. Conditions for the JAM display . . . . . . . . . . . . . . . . . . . .9-6

1) Paper feed section . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

2) Transport section . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

[10] SERVICING AT MEMORY TROUBLE AND

MAIN CONTROL PWB REPLACEMENT . . . .10-1

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

2. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

3. Remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

4. Set value recording sheet . . . . . . . . . . . . . . . . . . . . . . .10-3

5. Memory simulation list . . . . . . . . . . . . . . . . . . . . . . . . .10-4

[11] MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

[12] ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . .12-1

1. System block diagram . . . . . . . . . . . . . . . . . . . . . . . . . .12-1

2. System operation at power ON . . . . . . . . . . . . . . . . . . .12-1

3. Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2

(1) Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2

(2) CPU (IC110) M37702 . . . . . . . . . . . . . . . . . . . . . .12-2

1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2

2 Pin arrangement . . . . . . . . . . . . . . . . . . . . . . .12-2

3 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . .12-3

4 CPU: M37702 (IC110) pin signals . . . . . . . . . .12-4

(3) Start/stop control circuit . . . . . . . . . . . . . . . . . . . .12-5

(4) Heater lamp control circuit . . . . . . . . . . . . . . . . . .12-6

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6

(5) Driver circuit (Solen oid, magn etic clu tch) . . . . . . .12-7

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7

(6) AE (Auto Exposure) sensor circuit . . . . . . . . . . . .12-7

(7) Toner supply motor drive circuit . . . . . . . . . . . . . .12-8

(8) Reset IC (IC113) . . . . . . . . . . . . . . . . . . . . . . . . . .12-8

1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8

(9) Copy lamp control section . . . . . . . . . . . . . . . . . .12-9

4. Operating section . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-11

(1) Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-11

(2) Display circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12

1 Block diagram . . . . . . . . . . . . . . . . . . . . . . . .12-12

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12

(3) LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13

5. Power section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13

(1) Signal name and output voltage . . . . . . . . . . . . .12-13

II

[1] GENERAL DESCRIPTION

1. Features

[Small]

• Compact design

• Small area for operation

[Speedy]

• Warm-u p time 30 se c or less, the fi rst co py 5.9 sec ∼ the fastest in

the class.

• The photoconductor and the peripheral parts are integrated into

units. The novel two-component development system eliminates
the need for developer replacement. Parts replacement proce­dures in the fuser section and the paper feed section are simplified
to remarkably reduce maintenance time.

[Soft]

• The energy save mode reduces the total power consumption.

• The noise limiting design results in the quietest machine in the

industry (46 dB).

• Ozone generation is limited.

• Use of materials which can be recycled.

User simulation

The user can select the desired operating conditions easily. Auto
clear time, power save mode time, power save mode warm up time
can be set by the user simulation.

3. Novel technology

Novel two-component development system

During cop y proc ess, de velo pe r is su bsti tute d littl e by litt le to p rev ent
image deterioration. Replacement of developer is not needed. A
developer/toner recycling method is used.

4. Novel functions

Power save function
After a set time, has passed since a copy run has finished, the pwer
save function operates to save energy. There are two kinds of power
save function as shown below. The preferred power save mode can
be selected by the key operator.

1) Pre-heat

• The temperature in the fuser section is lower than that in the ready

state.

• Within 10 sec after completion of pre-heating, the machine returns

to the ready state.

2) Auto power shut off

• Power supply to the fuser section is shut off.

• The time required to return to the ready state and turn on the

ready lamp after completion of auto power shut off is the same as
warm-up time after turning on the power.

2. Target users

Average copy volume of 2,000 ∼ 3,000 sheets/month (max. 10,000
sheets/month)

5. System outli ne

Zooming range

Z-800

250 sheets

(Option)
250-sheets paper tray
(SF-UB14)

* As the other options for all the models, the desk (SF-720D2) and the personal counter (SF-71A/71B) are available.

(1:1)

Single manual feed (Standard)

250-sheet tray

50-sheet mu l ti man ual feed uni t ( ZT - MF11)
(Option)

50

1 – 1

[2] PRODUCT SPECIFICATIONS

1. Basic specifica tio ns

(1) Type: Table top
(2) Copy speed

Paper size Normal Enlargement Reduction

B4 11 sheets/min — —
A4 (Landscape) 14 sheets/min — —
B5 (Landscape) 14 sheets/min — —

10″ × 14″ 11 sheets/min — —

Legal 11 sheets/min — —

Letter (Landscape) 14 sheets/min — —

(3) Warm-up time

Normal Max. 30 sec

Pre-heat Max. 10 sec

Auto power shut off Max. 30 sec

(4) First copy time: 5.9 sec (Fed from No. 1 cassette)
(5) Jam recovery time: 5 sec (Condition: Jam in a section except

for the fuser section, within 6.0 sec from
door open, standard condition.)

(6) Multi copy

Max. quantity of multi copy 99 sheets

(7) Document

Max. document size B4/10″/14″

Document reference position Left side

Detection No

(8) Exposure

Exposure mode Auto/Manual/Photo

Manual steps 9 steps

(13) Power consumption

Max. power consumption 1.4 kW
Average power consumption when operating 0.48 kW
Power consumption in standby 0.095 kW
Power consumption in pre-heating 0.056 kW
Power consumption in auto power shut off 0.026 kW

Note: Max. value when an option is installed.

2. Details of each section

(1) Paper feed section

Copy size

Paper feed system 1 cassette + manual paper feed

Paper feed capacity 250 × 1 + 1 or 50

• AB series

Paper feed

port

Tray B4 ∼ A5

Paper feed
unit
(OP)

Single
manual feed

Multi
manual feed

• Multi

paper feed

• Single

paper feed

AB series B4 ∼ A6

Inch series 10″ × 14″ ∼ 4″ × 6″

Paper feed

size

(Landscape)

B4 ∼ A5

(Landscape)

B4 ∼ A6

(Portrait)

A4 ∼ A5

(Portrait)

B4 ∼ A5

(Portrait)

B4 ∼ A6

(Portrait)

A4 ∼ A5

(Portrait)

Paper weight Special paper

56 ∼ 80g/m2Recycled paper

56 ∼ 80g/m2Recycled paper

52 ∼ 130g/m2Second original,

104 ∼ 130g/m2Postcard, recycled

52 ∼ 130g/m2Postcard, recycled

52 ∼ 130g/m

104 ∼|130g/m

OHP, label

paper

paper

2

Second original,
OHP, label, postcard,

2

recycled paper

(9) Void width

Normal Enlargement Reduction

Void area

Image

loss

(10) Paper exit

Paper exit tray capacity 100 sheets

(11) External demensions

W × D × H (mm) 500 × 480 × 295

Occupying width (mm)

(12) Power source

Power source 120V
Frequency 60Hz

Lead edge

3.0mm or less
Lead edge

3.0mm or less

Weight 26.2 Kg

Lead edge

3.0mm or less
Lead edge

2.5mm or less

Z-800

500 + 261 (Paper exit tray) +

205 (Option MB)

Lead edge

3.0mm or less
Lead edge

5.0mm or less

• Inch series

Paper feed

port

Tray 10″ × 14″ ∼

Single
manual feed

Multi
manual feed
(OP)

• Multi

paper feed

• Single

paper feed

Paper feed size Paper weight Special paper

invoice

10″ × 24″ ∼

4″ × 5″

Letter ∼

4″ × 6″

10″ × 14″ ∼

4″ × 6″

10″ × 14″ ∼

4″ × 6″

Letter ∼

4″ × 6″

15 ∼ 21 lbs Recycled paper

14 ∼ 34.5 lbs Second original,

28 ∼ 34.5 lbs Postcard, recycled

15 ∼ 21 lbs Recycled paper

14 ∼ 34.5 lbs

28 ∼ 34.5 lbs

OHP, label

paper

Second original,
OHP, label,
postcard, recycled
paper

2 – 1

(2) Optical section

Light source Halogen lamp
Exposure system Slit exposure by moving the

light source

Magnification ratio changing
system

Lens Fixed focus lens

(3) Process section

Charging system (–) DC scorotron system
Transfer system (–) DC scorotron system
Separation

system

Copy mode

Main charger
grid voltage

Charge/Transfer
charger applied
voltage

Standard 8-02 –750V±10V

Photo 8-03 –459.9V±10V

Toner save 8-04 –634.4V±10V

By changing the lens
position and scan speed.

Discharge plate/separation pawl

Simulations

No.

–50.0µA ± 4µA

Grid voltage

(4) Developer section

Developing system Novel two-component

developing system
(Developer replacement not
required)

Toner density detection
system

Toner box capacity Developer 48g, toner 180g
Developing bias DC–200V±5V

Magnetic sensor system

• Developer

Material Iron powder carrier
Charging system Negatively charged by friction

• Toner

Charging system Positively charged by friction

(5) Fuser section

Fusing system Heat roller system

Upper heat roller surface
temperature

Standard 170°C
Heater lamp 120V Halogen lamp 1000 W × 1 pc.

(6) Drive section

Main motor

standard

Rating: DC32V, max. 1.32A, 1500 rpm

180°C

3-phase full wave drive, DC brushless

3. Supplies

No. Item Contents Life Model name Packing unit

1 OPC Drum Cartridge • OPC Drum Cartridge x 1 20K ZT-80DR 10
2 Black Toner • Black Toner Cartridge x 1 4K ZT-80TD1 10
3 Black Developer • Black Developer Cartridge x 10 SF-214MD1

(SF-214ND1 x 10)

4 Heat Roller Kit • Upper Heat Roller x 1 80K SF-214HR1 5

• Upper Separation Pawl x 3

• Lower Heat Roller x 1

• Lower Separation Pawl x 3

1

2 – 2

[3] EXTERNAL VIEW AND INTERNAL STRUCTURE

1. External view and intern al str uctu r e

2134

65

97 8

F G H I J

No. Name No. Name No. Name

Exit tray

1

Operation panel

4

Power switch

7

Fusing unit lever

F

Photoconductive drum

I

Document cover

2

Manual by-pass

5

Front cover

8

Toner cartridge

G

Release lever

J

Document glass

3

Manual by-pass guide

6

Paper tray

9

Fusing unit

H

3 – 1

2. Operation panel

1 2 3 4 5 8

EXPOSURE TRAY SELECT

AUTO
MANUAL
PHOTO

No. Name No. Name No Name

Auto/manual/photo key and indicators

1

Misfeed indicator

4

Paper required indicator

7

Zero/read-out key

F

Power save indicator

I

21 345

4

3

2

1

9

8

7

6

6

7

Light and dark keys and exposure

2

indicators
Toner required indicator

5

Copy quantity display

8

Clear key

G

9 10 11 12 13

Drum replacement required indicator

3

Tray select key and indicators

6

10-key pad

9

Print button and ready indicator

H

POWER SAVE

C

5

0

3. Cross section

4

3

2

1

34

78

9

10 1165

12

13

14

15
16

17
18

19
20

21
22

23

2528 27 262930313233

24

No. Name No. Name No Name

No.3 mirror

1

Cleaner unit

4

No.1 mirror

7

No.6 mirror

F

No.4 mirror

I

Manual paper feed roller

L

Tray paper feed takeup roller

O

Tray paper feed roller

R

Resist roller

U

Suction belt

X

Lower heat roller

[

Heater lamp

^

No.2 mirror

2

Discharge lamp

5

Copy lamp

8

Blank lamp

G

No.5 mirror

J

Manual feed take-up roller

M

Tray transport follower roller

P

Tray paper feed reverse roller

S

Transfer charger

V

Upper heat roller

Y

Lower separation pawl

\

Drum separation pawl

3

Main charger unit

6

Lens unit

9

Developer magnet roller

H

Developer tank

K

Manual paper feed follower roller

N

Transport roller (Upper)

Q

Resist roller

T

Photoconductor drum

W

Lower cleaning roller

Z

Upper separation pawl

]

3 – 2

4. Switches, sensors, detectors

2

1

No. Abbreviation Function Type Operation

POD Paper out sensor Transmission photo sensor H when paper is sensed.

1

MHPS Mirror home position sensor Transmission photo sensor H at the home position.

2

PWD Paper size (large/small) sensor Transmission photo sensor L with the large size.

3

PPD Paper transport sensor Transmission photo sensor L when paper is sensed.

4

PED1 Tray paper empty sensor Transmission photo sensor H when paper is present.

5

4
3

5

5. Clutches, sol eno id s

1 2 6

3

5

4

No. Abbreviation Name Function and operation

PSPS Paper separation solenoid For paper separation solenoid drive

1

RRC Resist roller clutch For resist roller rotation

2

TRC Transport roller clutch For transport roller rotation

3

MPFS Manual paper feed solenoid For takeup roller pressing

4

CPFC1 Tray paper feed clutch For paper feed roller rotation

5

MPFC Multi paper feed clutch For multi paper feed roller rotation

6

3 – 3

6. Motors

No. Abbreviation Name Function Type

VFM Paper exit fan motor

1

CFM Cooling fan motor For cooling the optical system DC brushless

2

MM Main motor For the main body drive and the option drive DC brushless

3

LM Lens motor For the optical lens drive DC stepping

4

TM Toner motor For toner supply DC synchronous

5

1

For ventilation of the fuser unit.
For cooling the machine and removing ozone.

2 3

4

5

DC brushless

7. PWBs

No. Name Description

AC circuit PWB AC power input

1

Discharge lamp PWB Discharge lamp drive

2

Main PWB Main body control

3

AE PWB Document density auto exposure detection

4

Blank lamp PWB Blank lamp control

5

Lower unit PWB Lower unit parts control

6

High voltage PWB Supply of the process high voltage and the developer bias voltage.

7

Operation PWB Operation input, display control

8

8 312 4

5

6

7

3 – 4

[4] UNP ACKING AND INSTALLATI ON

1. Packing drawi ng

2. Installat ion

Installation conditions

The following installing conditions must be satisfied to assure the
normal operations of the machine.

Toner Cartridge

Exit Tray

Operation Manual

Developer Cartridge
Drum Cartridge

Copier

(1) Environment

1 Keep the machine away from direct sunlight and avoid instal-

lation near a window or in a bright place.

(Draw the curtain and close the blind shutter completely.)
The plastic parts and the original cover may be deformed by direct
sunlight. Avoid installation near a window even with frosted glass.

2 Avoid installation in high temperature or high humitity en-

vironments. Also, avoid installation where temperature or
humidity may change quickly. (e.g., near an air conditioner).

Otherwise copy papers may be dampened and condensation may
be generated in the machine. This may result in paper jams or
poor copy quality.

(Ideal conditions): The best suitable conditions for machine

operation:
20°C ∼ 25°C: 65 ±5%RH

(Temperature/humidity range): 15°C ∼ 30°C, 20% ∼ 85%

65% for 35°C

Accessories

Drum cartridge 1
Developer cartridge 1
Toner cartridge 1
Exit tray 1
Operation manual 1

* Save the carton and packing materials. The carton and packing

can be re-used for transporting the machine, should it be neces­sary.

% RH

85

65

Humidity

20

15 30 35

˚C

4 – 1

3 Avoid installation where there is a lot of dust or vibrations.

If dust enters the machine, it may degrade copy quality and cause
malfunctions.

(2) Space around the machine

Allow a space of about 15 cm (6 inches) between the rear side of the
machine and the wall for ventilation of the cooling fan. Also allow
sufficient space around the machine for operations.

15cm

4 Avoid installation on an unstable surface.

To assure the proper operations, install on a level surface.

5 Install in a well ventilated place.

6 Avoid installation where there is inflammable gases or am-

monium gases.

Installation near a diazonium copier may degrade copy quality and
cause malfunctions.

(3) Installing table

Use a level (UKOGM0054CSZZ) to install the machine horizontal­ly.

(Note) If the machine is not installed horizontally, toner density con-

trol may not function properly. This may result in poor copy
quality.

(4) Power source

1 The power source should be the rated voltage ±10% with the

capacity corresponding to the max. power consumption.

2 Do not use an extension cord, or operate any other equipment

from the same wall outlet.

(5) Grounding

To avoid electrical hazard, use the properly grounded wall outlet only.

(Carrying the machine)

When carrying the machine, remove the copy tray and hold the dent
portions on the bottom.

7 Install near a power outlet.

4 – 2

3. Installation procedure

1 Remove the copier from the bag and remove all pieces of

tape from the copier.

• Also remove the packing materials as shown.

3 Press the buttons on both sides to unlatch the front cover

and open it.

4 Press the release lever to open the upper half of the copier.

CAUTION: Be sure to open the upper unit slowly and gently, and

do not let go of it until it is fully open.

2 Remove the screw on the left side as shown, and remove the

two screws above the manual by-pass.

5 Grasp the handle of the toner cartridge holder, and swing the

holder out and to the right of the copier until it stops.

6 Remove the drum cartridge from its storage box.

• Remove the black wrapping paper from the drum cartridge.

• Save the box of the drum cartridge. The box should be used to

pack the drum cartridge if the copier must be transported for
servicing.

7 Slide the new drum cartridge in by holding the handle until

the cartridge locks in place.

• Be sure not to touch the surface of the drum.

4 – 3

8 Push down on the upper half of the copier to close it.

H Close the front cover.

9 Insert the developer cartridge by positioning the lower left of

the cartridge along the rail and sliding it until it latches into
place.

CAUTION: When handling developer and toner cartridges for the

first time, do not remove sealing tape until the
cartridges are fully installed into the copier.

F Pull out the sealing tape and remove it from the developer

cartridge.

I Fan the copy paper and load it into the paper tray.

J Fit the exit tray onto the copier by inserting it at an upward

angle into the grooves on the left side of the copier.

G Shake the toner cartridge back and forth several times to

loosen the toner and then install it in the copier as shown.
Pull out the toner sealing tape. See steps 5 to 8 of ADDING
TONER on page 4-5.

• Save the box of the toner cartridge. The box should be used to

pack the toner cartridge if the copier must be transported for
servicing. The box should also be used for disposal of a used
toner cartridge.

➀

➁

K Plug the power cord into a grounded 120 volt outlet.

NOTE: Be sure the power cord is securely plugged in.

L Turn the power on.

• After about three minutes, the READY indicator will light up.

Copying is now possible.

• If

CH

blinks on the copy quantity display, the developer
cartridge is not installed properly. Check the developer
cartridge installation.

• If

CH

blinks on the copy quantity display and the drum re­placement required ( ) indicator blinks, the drum cartridge
is not installed properly. Check the drum cartridge installation.

4 – 4

4. Addi ng to ne r

1 Press the buttons on both sides to unlatch the front cover and

open it.

2 Press down on the toner release lever while pulling the handle to

unlatch the toner cartridge. Grasp the handle and carefully swing
the cartridge out and to the right of the copier until it stops.

5 Take the replacement toner cartridge from its storage box and

shake the cartridge nine or ten times.

• Save the box for disposal of a toner cartridge.

CAUTION: Do not remove sealing tape until the toner cartridge is

fully installed into the copier.

Keep this side up.

6 Install the new toner cartridge by positioning the protrusions in the

slots and then rotating the cartridge counterclockwise 90°.

1

2

3 Gently rotate the cartridge clockwise 90° and then pull to remove

it.
CAUTION: Keep the old toner cartridge with the two holes up so

as not to spill used toner.

2

1

4 Attach the sealing cap onto the old toner cartridge.

• Use the storage box for disposal of the used toner cartridge.

1

2

7 While holding the toner cartridge, pull out the toner sealing tape

completely.

8 Swing the toner cartridge back in place and close the front cover.

Old toner cartridge

4 – 5

5. Optional multi bypass feeder unit
Installation Manual

For use with compatible SHARP copiers.
See SHARP copier Installation Manual to determine suitability.

(1) Open the upper unit of the main copier unit.

1 Press the release buttons on the left and right sides of the main

copier unit’s front cover, then open the front cover.

2 Push the upper half release lever (green) to the right and down,

then gently open the upper unit.

(2) Release the lock for the manual bypass unit and

remove the manual bypass unit.

1 Release the manual bypass unit by pressing upward on the rock

claws (green; 2 locations) which lock it in place in the main copier
unit’s upper unit.
The manual bypass unit will come out toward you slighly.

2 Pull out upon the manual bypass unit to remove it from the main

copier unit.

Manual bypass unit

(3) Mount the multi bypass feeder unit onto the

main copier unit.

1 Slide the positioning pins which project from the multi bypass

feeder unit in to the grooves in the main copier unit, then push the
multi bypass feeder unit into place to in stall it.
At this time, to be sure that the multi bypass feeder unit is securely
installed, push down once more on the fourcorners of the unit. (If it
has not been securely installed, "CH" may appear in the COPIES
MADE display when the power is turned on.)

Multi bypass feeder unit

Rock claw (latch)

Rock claw (latch)

Rock claw (latch)

Rock claw

(latch)

Positioning pins

Positioning pins

Multi bypass
feeder unit

2 Close the upper unit of the main copier unit.

4 – 6

[5] GENERAL DESCRIPTIONS OF

EACH SECTION

The general descriptions of the following sections are given:

1 Paper feed section
2 Separation, transport section
3 Fuser, paper exit section
4 Developer section
5 Optical system
6 Image forming section

Internal structure

When the CPCF turns off, rotation is stopped, and the takeup roller is
pushed up by the roller release arm spring to the position.

(Manual paper feed operation) Multi
When the solenoid B (MPFS) turns on, the takeup roller falls and the
gate rises.
Almost simultaneously the solenoid A (MPFC) turns on and the
takeup roller and the paper feed roller turns to perform the paper feed
operation.

1. Paper feed secti on

The paper feed system is in two ways: the cassette feed and the
manual feed. The cassette is of the universal type and has the
capacity of 250 sheets. It is attached and detached at the front
cabinet, that is, the front loading system.
The manual paper feed is single. (The multi paper feed unit (ZT­MF11) is an option.)

(Cassette paper feed operation)
The cassette paper feed clutch (CPFC) turns on, the paper feed roller
shaft, the paper feed roller, and the takeup roller rotate. At the same
time, the roller release arm is lowered by the limiter spring. As a
result, the takeup roller falls by its own weight to reach the paper
surface, performing the paper feed operation.

ON

When the PPD turns on, the MPFS turns off and the RRC turns on.
Almost simultaneously the MPFC turns off to return the roller and the
gate to the initial state.

OFF

5 – 1

2. Separation, transport section

4. Developer section

After passing the resist roller section, the paper is transported to the
transfer section. After transfer, the paper is separated from the drum
by the separation electrode and the drum separation pawl, then
transported to the fuser section by the transport belt.

3. Fuser, paper exit section

The toner image transferred on the paper is fused by the heat and
pressure of the upper and the lower heat rollers. After fusing, dis­charge static electricity on the paper with the discharge brush. Then
the paper is discharged to the copy tray.

In the developer section, toner is attached to the electrostatic latent
image on the drum to change the latent image into a visible image.
Toner and carrier are charged by friction caused by the stirring roller
in the developer unit. Toner is charged in positive, and carrier is
charged in negative charge.
Since the latent image on the drum (area not exposed to light) is
negatively charged, it draws toner which is positively charged.
To prevent against excessive copying, a bias voltage of -200V is
applied to the MG roller.
This model employs the novel two-component developing system
(Developer replacement not required).
When, in the case of the conventional development method,
developer (mixture of carrier and toner) is deteriorated, developer
itself must be replaced or the whole developer unit must be replaced
as in the personal machines.
In the new development system, however, developer is supplied in a
certain cycle during development process (developer is mixed with
toner and supplied with toner when toner is supplied), and removed
(automatically by the overflow system when the rate of deteriorated
developer in the developer unit reaches a certain level), preventing
against deterioration in image quality and eliminating the need for
developer replacement in maintenance.
Therefore, "toner cartridge" supplied as a supply item is developer
(mixture of toner and carrier).
Deteriorated developer will overflow from the discharge port of the
developer unit automatically and collected by the waste toner collec­tion container together with residual toner on the photoconductor
drum.

• Temperature control

Heat roller surface
temperature detection

The heat roller is heated by the
heater lamp.
(When the heat roller surface
temperature is 180 C˚ or lower,
the heater lamp is actuated)

Contact open (*)

Abnormal high
tem p erature

CPU

(Heater troub l e)
Self diag di spl ay

Thermistor

Heat r olle r

Heater lamp

Thermostat

• Abnormally high temperature (H3)

• Abnormally low temperature (H4)

• Thermistor disconnection (H2)

When the thermostat contact is open, it is required to press the

*

reset button in the upper side of the thermostat. (The contact is not
reset automatically.)

Flow of the new toner

Deteri orat e d deve lope r
(Automatical l y di scha rged to t he w aste t o ner
collection container)

Residual toner on the photoconductor drum
(Cleaned in section and sent to the waste toner collection container)

Toner box
(mix tu re o f tone r and carri e r)

Waste toner collection
container

5 – 2

5. Optical system

5-1. General descriptions

• The optical system is composed of the fixed focus lens and six

mirrors.
Since the fixed focus lens is employed, No.4/No. 5 mirror base is
moved as well as the lens to change the distance between the
document and the drum (OID, Original Image Distance) for reduc­tion and enlargement.
To move the lens, he stepping motor is driven by the signal from
the main control PWB (This model has no zooming function, and
its lens and No.4/No.5 mirror base are fixed.)

4

5

15

10

9

• Exposure is adjusted by changing the voltage of the copy lamp.

The copy lamp unit is provided with the AE sensor for detection of
the original density to adjust the light quantity of the copy lamp
according to the original density.

• For exposure, the slit exposure system is employed where the light

source is moved. (The original table is fixed.)

16

12

6

127

13113

8

14

1 Copy lamp 2 Reflector 3 No. 1 mirror
4 No. 2 mirror 5 No. 3 mirror 6 Lens
7 No. 4 mirror 8 No. 5 mirror 9 No. 6 mirror
F No. 2/No. 3 mirror base unit G Copy lamp unit H No. 4/No. 5 mirror base unit
I Mirror motor J Lens drive motor K Mirror home position sensor
L Auto exposure sensor

(1) Original table

The original table is fixed, and originals are set to the left frame side
as the reference.

(2) Copy lamp

100V s ystem (285W)

(3) Mirror

Six mirrors are used.
No. 1 mirror is provided in the copy lamp, No. 2/3 mirrors at the
No.2/3 mirror base, No. 4/5 mirrors at the No. 4/5 mirror base. The
No.2/3 mirror base is scanned during copying.

(4) Lens (Fixed focus lens)

• Construction (One group 3 lenses)

• Brightness (F8)

• Focus (175mm)

(5) Lens base

The lens is mounted to this lens base.

(6) No. 4/5 mirror base

The No. 4/5 mirror is installed to this base.

5 – 3

(7) Mirror motor

The mirror motor is a stepping motor, and used to move the copy
lamp unit and the No. 2/3 mirror base in order to obtain the rpm
corresponding to each magnification ratio.

(8) Mirror home position sensor (MHPS)

Used to sense the home position of the copy lamp unit. This sensor is
a photo transmission type sensor.

(9) No. 2/3 mirror base

The No. 2/3 mirrors are attached to this base. The mirror base is
scanned by the mirror motor.

(Copy lamp control in each copy density)

80

70

CLV
(Copy lamp
application
voltage)

60
50
40

(V)

[MAX. 85V(170V)]

[MIN. 40V(80V)]

(10) Copy lamp unit

This is composed of No. 1 mirror, the thermal fuse, the copy lamp,
the exposure adjustment plate, and the reflector, and is scanned by
the mirror motor.

(11) Thermal fuse

The thermal fuse is closely attached to the reflector in order to
prevent against abnormal temperature rise in the optical system. In
case of abnormal temperature rise, the power for the copy lamp is
turned off.

100V system (117°C)

(12) Reflector

Light from the copy lamp is reflected onto the original.

(13) Exposure adjustment plates

Three exposure adjustment plates are attached to the copy lamp unit
to adjust the exposure balance in the front and the rear frame direc­tion.

(14) Mirror base drive wire

This wire is used to transmit the drive power of the mirror motor to the
copy lamp unit and the No. 2/3 mirror base to scan the mirror base.

(15) AE sensor

The original density is detected with the intensity of the copy lamp
light reflected from the original. The measurement area is the mirror
base scan area of about 100mm at the center.
The element is a photo diode.

EX1

(Optical system dirt correction)

The Z-800 perform dirt correction by changing the copy lamp intensity
according to the dirt degree in the optical system (the copy lamp unit,
No. 1 mirror, No.2 mirror, No.3 mirror) to prevent against remarkable
degrading of copy quality.
The reference value is the AE sensor output value which is obtained
when the reference plate is exposed with the copy lamp voltage of

67.7V (135.4V) at power ON.
This value is checked with sim 44-02.

Reference plate (Glass holder)

CPU

Reference value

> Measured value

Correction data output

234

Table glass

Copy lamp light quantity "UP"

Automatic exposure
sensor

EX5

5-2. Basic operati on s

(Relationship among the original, the lens and the image in normal
copy ratio)
The distance between the surface of original on the table glass and
the lens is made equal to the distance between the lens and the
exposure surface of the photoconductor to make the original and the
image equal to each other.

5 – 4

6. Copy process

(1) Photoconductor

• This model uses OPC (organic photoconductor) as photoconduc-

tive material.

OPC layer CTL (Electric charge moving layer)

CGL (Electric charge generating layer)
Aluminum layer

(2) Process diagram

Original

Copy lampMirror lens

High voltage unit

Exposure

Transfer

Exposure

Development

Drum upper

ima ge/paper

synchronization

Resist roller

Discharge lamp

Cleaning bl ade

Waste toner collection

Paper exit

Main corona unit

Separ a tion

Fusing

Charging

Discharging

Cleaning

Separation

Blank lamp

Toner

Developer

High voltage unit

Paper feed roller
Transportroller

Manual paper feed
Pape r ca sse tte

Discharge lamp

Cleaning bl ade

Seper ati on pa w l

Heat r olle r

Heater lamp

Separation cor ona unit

High voltage unit

Main corona unit

Seperation corona unit

Transfer charger

High voltage unit

Blank lamp

Devel oper u nit
MG roller

Resist roller

Transfer corona unit

Image forming process

Paper transport path

5 – 5

(3) Actual process

Step 1 (charging)

The OPC drum is negativelycharged by corona discharge of the
transfer charger . Positive charges are generated in the aluminum
layer.

Aluminum layer

OPC drum

CGL

CTL

Seperation pawl

Transfer corona unit

High voltage unit

Step 2 (Discharging)

When the OPC drum is exposed to the discharge lamp light, positive
and negative charges are generated in the OPC drum CGL. The
negative charges move to the positive charges generated in the
aluminum layer in step 1, and the positive charges move to the
negative charges on the OPC drum surface charged in step 1. The
positive charges and the negative charges are neutralized each other
in the aluminum layer and on the OPC drum surface. As a result, the
OPC dru m surface potential become s 20V ∼ 30V.

Discharge lamp

Cleaning blade

Main corona unit

Seperation corona unit

Blank lamp

Devel oper u nit
MG roller

Resist roller

Transfer corona unit

Discharge lamp

Light

OPC drum

CTL

CGL

Aluminum layer

By performing step 1 (Charging) and step 2 (Discharging), the
photoconductor itself is initialized to stabilize the drum surface poten­tial.

Discharge lamp

Cleaning blade

Seper ati on pa w l

Main corona unit

Seperation corona unit

Blank lamp

Devel oper u nit
MG roller

Resist roller

Transfer corona unit

5 – 6

Step 3 (Main Charging)

By negative discharging of the main charger, uniform negative char­ges are applied to the OPC drum surface.
The OPC drum surface potential is controlled by the screen grid
voltage to maintain the grid voltage at a constant level.

• When the drum surface potential is lower than the grid voltage,

electric charges generated by discharging of the charger go
through the screen grid to charge the drum surface potential until it
becomes equal to the grid voltage.

• When the drum surface potential virtually reaches the grid potential

level, electric charges generated by discharging of the charger
flows through the electrode of the screen grid to the high voltage
unit grid voltage output circuit, thus always maintaining the drum
surface potential at a level virtually equal to the grid voltage.

• The main corona unit employs the scorotron system to charge the

photoconductor surface to a certain level uniformly.
In addition, the conventional corona wire is replaced with the
corona charging mechanism by saw-teeth plate (stainless steel
plate of 0.1 mm thick). In corona discharge, oxygen molecules in
the air are ionized to generate ozone (O3). The mechanism restrict
the generation of ozone.

Main corona unit

Main corona unit

Blank lamp

High voltage unit

Screen grid

CTL

CGL

OPC drum

Aluminum
layer

Step 4 (Exposure)

Light from the copy lamp is radiated on the document, and the optical
image of the document is reflected by the mirrors and projected
through the lens to the OPC drum.
The lighter portion of the document reflects more light (high intensity)
to the OPC drum, and the darker portion of the document reflect less
light (low intensity) to the OPC drum. Positive or negative charges are
generated in the CGL of the OPC drum where lights are radiated.
Negative charges generated in the CGL move towards the positive
charges in the aluminum layer generated in step 3. While the positive
charges in the CGL move towards the negative charges on the CPU
drum surface generated in step 3. Therefore, positive charges and
negative charges are neutralized in the aluminum layer and the OPC
drum surface at the light radiating position, decreasing the OPC drum
surface potential. The CGL electric charge generating amount in­creases in proportion to the document density, that is, reflected light
intensity (the OPC drum surface intensity). Therefore, electric char­ges are generated less in the CGL layer corresponding to the lighter
density of document (higher intensity of the OPC drum surface), and
a greater quantity of the negative charges on the OPC drum surface
is neutralized, decreasing the OPC drum surface potential more.

Discharge lamp

Cleaning blade

Seperation pawl

Seperation corona unit

On the contrary, electric charges are generated more in the CGL
layer corresponding to the darker density of document (lower intensity
of the OPC drum surface), and less quantity of the negative charges
on the CPU drum surface is neutralized, decreasing the OPC drum
surface less. Therefore, the OPC drum surface potential correspond­ing to the lighter portion of the document is lower, and that cor­responding to the darker portion of the document is higher. Latent
static-electricity images are formed in the above manner.

Transfer corona unit

Developer unit
MG roller

Resist roller

5 – 7

CTL

CGL

Low intensity in
the area corre­sponding to the
darker density
portion of the
document

Medium intensity
in the area corre­sponding to the
medium density
portion of the
document

HIgh intensity in
the area corre­sponding to the
lighter density of
the document

Aluminum
layer

OPC drum

Surface potential

(High)

CTL

CGL

Surface
potential
(Medium)

Surface
potential
(Low)

Aluminum
layer

OPC drum

Step 5 (Development)

Toner is attached to the latent static-electricity images on the drum
surface to change them to visible images. The two-component mag­netic brush development system charges toner positively by friction
with carriers, and toner is attached to negative charges on the drum
surface. The potential in the darker document projecting area (low
intensity) is high (much negative charges) and attracts more toner.
The potential in the lighter document projecting portion (high inten­sity) is low (less negative charges), and attracts less toner.

Discharge lamp

Cleaning blade

Seperation pawl

Main corona unit

Seperation corona unit

Blank lamp

Developer unit
MG roller

Resist roller

Transfer corona unit

OPC drum

CGL

Aluminum layer

Higher surface
potential
(Much negative

(charges)

Medium surface
potential
(Less negative

(charges)

Lower surface
potential
(No negative

(charges)

CTL

MG roller

-200V

High voltage unit
bias voltage

At that time, a bias of –200V is applied to the MG roller (magnet
roller), which is provided for preventing toner from being attracted by
the residual voltage (about –80V to –100V) in the lighter portion after
exposure.

Discharge lamp

Cleaning blade

Seperation pawl

5 – 8

Main corona unit

Seperation corona unit

Blank lamp

Developer unit

MG roller

Resist roller

Transfer corona unit

Step 6 (Transfer)

g

The transfer paper is charged higher than the OPC drum surface
potential by strong negative discharge of the transfer charger, making
the binding force between the transfer paper and toner stronger than
that between the drum and toner, attracting toner to the transfer
paper.

Aluminum
layer

OPC drum

CGL

CTL

Toner

Transfer paper

Seperation pawl

Transfer corona unit

h voltage unit

Hi

Step 7 (Separation)

After transfer, the copy paper and the drum are negatively charged.
Since, however, the negative potential of the copy paper is higher
than that of the drum, a attraction force is applied between the drum
and the copy paper. To avoid this, AC corona is applied to the copy
paper by the separation charger to decrease the copy paper potential
to the same level as the drum surface potential. The attraction be­tween the copy paper and the drum is weakened by this, allowing
separation of the copy paper by its own extending force. If the copy
paper is not separated by the separation charger, it is separated by
the separation pawl mechanically.

Discharge lamp

Cleaning blade

Main corona unit

Seperation corona unit

Blank lamp

Developer unit
MG roller

Resist roller

Transfer corona unit

Aluminum
layer

CGL

CTL

High voltage unit

Seperation corona unit

OPC drum

Toner

Transfer paper

Discharge lamp

Cleaning blade

Seperation pawl

5 – 9

Main corona unit

Seperation corona unit

Blank lamp

Developer unit
MG roller

Resist roller

Transfer corona unit

Step 8 (Cleaning)

Residual toner on the drum is removed by the cleaning blade. The
removed toner is sent to the waste toner container by the waste toner
transport screw.

Blade Aluminum layer

CTL

CGL

Residual toner

OPC drum

Step 9 (Discharging)

When the OPC drum is exposed to the discharge lamp light, positive
and negative charges are generated in the OPC drum CGL. The
negative charges generated in the CGL move towards the residual
positive charges in the aluminum layer, while the positive charges in
the CGL move towards the residual negative charges on the OPC

Discharge lamp

Discharge lamp

Cleaning blade

drum surface. Therefore, the positive and the negative charges are
neutralized in the aluminum layer and on the OPC drum surface,
removing the residual charges on the OPC drum surface. As a result,
the OPC drum surface potential becomes 20V ∼ 30V.

Main corona unit

Seperation pawl

Seperation corona unit

Main corona unit

Blank lamp

Developer unit
MG roller

Resist roller

Transfer corona unit

Blank lamp

Residual charge

OPC drum

CTL

CGL

Aluminum layer

Residual cha rge

(4) Transit of photoconductor drum surface potential

-800V

-600V

-400V

-200V

Separate
(OFF)

Clean

DLTransfer

Charge

Exposure

Discharge lamp

Cleaning blade

Seperation pawl

BL

Develop

Dark area

Light area

Seperation corona unit

Transfer

Developing
bias voltage

Transfer corona unit

Separate Clean

Developer unit
MG roller

Resist roller

DL

T (Time)

5 – 10

Residual potential

(5) Process correction system

1) Outline of the correction system

This model is provided with the correction system for the optical unit
and the photoconductor drum unit. The combination of the two cor­rection systems provides stable clear copy.
These functions are to maintain the copy quality for a long time and to
correct the characteristics of the parts, and are controlled by the
software and invisible from the outside.

2) Correction operation

1. Photoconductor drum unit correction (Photoconductor
drum sensitivity correction)

Cleaner

Fig. 2

VCL

Correction level
(CL voltage)

Fig. 3

Change the tickness of the carrier transport layer (CTL).

Develop

OPC drum

By the developper.
By the cleaner blade.

Fig. 1

(NEW)

CTL

CGL

(USED)

Wear down

CTL

CGL

Manual mode exposure 1

Photo m od e exp o s u r e 1

Manual mode exposure 5

Photo m od e exp o s u r e 5

Correction level is initialized by Simulation 46 or
by replacing the photoconductor drum.

0 100 150 200 250

50

Drum r o tating time

min

The photoconductor drum is subject to mechanical stress by the
cleaning blade, resulting in wear in the OPC layer. In addition to that,
the photoconductor drum receives optical stress from the copy lamp.
These stresses reduce the photo sensitivity of the photoconductor
drum, producing unnecessary dirt copy. This trouble is removed by
adjusting the copy lamp voltage. For this model, however, to reduce
the number of service calls, the copy lamp voltage is automatically
dropped according to the reduction in the photo sensitivity of the
photoconductor drum to correct it.

The drum rotating time from installation of a new photoconductor
drum is counted by the timer and the copy lamp voltage is corrected
in every mode. (Refer to Fig. 3.)
The correction is performed within the range of the max. supply volt­age of the copy lamp. (The rotating time of the photoconductor drum
can be checked with Simulation 44-4.)

* The correction level is initialized by Simulation 46 or by replacing

the photoconductor drum.

5 – 11

2. Optical unit correction (Dirt correction)

Diagram of correction system in the optical section

Referance refrection p late

Copy
lamp

AC power supply unit
(Copy lamp control circuit)

Mirror

AE SENSOR

The purpose of this correction is to maintain the copy density even
though the optical unit is contaminated and to reduce troublesome
cleaning of the optical unit.
When the lamp, the mirror, and the reflector are dirtied with dusts and
toner, the light quantity radiated to the photoconductor drum is
reduced, increasing the copy density and producing unnecessary
background copy.
The above trouble is removed by changing the copy lamp voltage to
adjust the copy density. It, however, requires serviceman’s operation.
In this model, the AE sensor senses dirt on the copy lamp, the mirror,
and the reflector, and the copy lamp light quantity is changed accord­ing to the dirt level to reduce the change in the copy density due to
the optical unit dirt.
When the optical parts are dirtied, the reflection rate is reduced to
reduce the quantity of light which is passed to the optical dirt sensor.
In this manner the dirt level is sensed.

[Initial setting]

After execution of Simulation 46, the scanner unit stops at the posi­tion of the standard reflection plate on the back of the document
stopper to light the copy lamp at a certain level, and the AE sensor
output level at that time is recorded as the reference value. (The
reference value can be checked with Simulation 44-2.)

[Correction timing]

The correction is performed after the copy cycle after turning on the
power, or after the specified time of rotation of the photoconductor
drum.

[Correction operation]

The same operation as the initializing is performed to change the
copy lamp voltage until the AE sensor output level reaches the same
level as the reference value, performing the correction.
The copy lamp voltage is revised to a new value at every correction,
and the new value will be used in the next correction.
(The correction voltage value can be checked with Simulation 44-3.)

AMP

Driver

Referance refrection plate

MAIN CONTROL PWB

Counter
watcher

A/D
converte r

CPU

Arithmetic unit

Copy lamp control
clock generator

START

Scanner unit
initial operation

The sc an ner unit s tops
at the standard reflec­tion plate position.

YES

Correction

mode ?

NO

Copy lamp ON

Optical dirt sensor
standard level
(DSENS) memory

End

Total
counter

Copy lamp ON

Table glass

AE sensor
(Next to the lens)

EE-PROM

Copy lamp
referance control
level

Sensor output

(Standard level ?)

New copy lamp
voltage calculation

Fig.5

Copy lamp voltage
lighting voltage
decreasing ON

67.7V <

copy
voltage ?

67.7V

NO

NO

YES YES

5 – 12

[6] DISASSEMBLY AND ASSEMBLY

The descriptions of this chapter are divided into the following sec­tions:

1. Paper feed section, paper transport section, power section

2. Manual paper feed section

3. Fuser section

4. Optical system

5. Drum section

6. Developer section

7. Operation panel/medium cabinet

8. Major parts in the frame side

1.Paper feed section, paper transport
section, power section

1-1. Paper feed unit

1 Open the front cover and open the body. Release the right and

the left lock levers and pull out the manual paper feed unit.

2 Disconnect the CN-B connector of the lower PWB, remove the

paper feed unit fixing screws (4 pcs.), and lift the paper feed unit
to remove.

1-2. Paper feed roller ass’y removal

1 Disconnect the connector of the magnetic clutch in the rear frame

side.

2 Remove the hook section of the paper feed roller bearing in the

front frame side by using a screwdriver $ .

3 Remove the roller release arm spring from the paper feed frame.

2

3

4

1

6 – 1

4 Remove the bearing in the rear frame and remove the paper feed

roller ass’y.
Note for assembly (1): Hang the roller release arm spring on the

spring hook of the roller release arm. At­tach the paper feed roller ass’y to the
paper feed unit, and hang the spring on
the paper feed frame.

A

A

Note for assembly (2): Attach the paper feed roller ass’y so that

the paper feed roller clutch faces the
lower frame.
When attaching the paper feed unit, insert
it in the base unit hole of the copier.

1-3. Separation roller

1 Remove the paper feed unit and remove the separation roller.

1-4. Takeup roller, paper feed roller

1 Remove the paper feed roller ass’y, and remove the takeup roller.

2 Remove the roller holder, the stop ring, and the bearing, then

remove the paper feed roller.

6 – 2

Note for assembly (1): Attach the paper feed roller so that the

one-way clutch in the rear frame side. (Be
careful to the installing direction.)
Attach the roller holder as shown below:

One-way clutch side

1-5. Resist roller

1 Insert a screwdriver into the front frame hole to release the lock

pawl, and remove the TC case.

3 Remove the clutch, and the gear as shown below:

Note for assembly (1): When assembling, attach the positioning

pin of the resist roller clutch in the direc­tion of paper exit.

2 Disengage the hook section of the bearing in the front frame side,

lift it upward and remove towards the upper frame side. Remove
the spring in the rear frame side. Disconnect the CN-E connector
in the lower frame PWB unit. Slide the resist roller ass’y to the rear
frame side and remove it upwards.

Note for assembly (2): When assembling the resist roller ass’y to

the copier, attach it over the PS roller
lower mylar and rotate the mylar and
return the mylar to the original position.
(To prevent deformation of the mylar)

1

2

6 – 3

1-6. Transport belt

1 Remove the fuser unit.
2 Remove the TC case.
3 Remove the transport belt drive shaft in the TC case from the

holder, and remove the drive shaft in the paper exit side, and
remove the belt.

1-7. Socket holder unit

1 Remove the CN-C connector of the lower unit PWB, the ground-

ing wire, and the red high voltage lead wire (for separation
electrode) which in the socket holder.

2 Remove the two fixing screws in the paper feed side, remove the

pawl from the positioning hole in the paper exit side, and slide it in
the direction of paper feed to remove.

1-8. Lower unit PWB

1 Open the body up, and remove the rear lower cabinet.
2 Remove the connector, the PWB fixing screw (1 pc.), and the

CN-F fixing screws (2 pcs.). Slide the lower unit PWB to the front
frame side and remove it upwards.

1-9. Cassette paper empty detector (CPED1)

1 Remove the rear lower cabinet.
2 Remove the fixing screw and the CN-D connector, and remove

CPED1.

1-10. Power unit

1 Remove the upper and the lower cabinets in the rear side.
2 Remove 12 connectors, two fixing screws, and the grounding

wire. Lift the power unit to remove it upwards.

6 – 4

Note for assembly (1): When attaching the harness, be careful to

the connector color and the lead wire
color. (Carefully refer to the indication on
the PWB for connection of the harness.)

Example: YE (WH) → Yellow connector and white lead wire

YE = Yellow, WH = White, BK = Black,
GR = Green, BL = Blue

2. Manual paper feed section

2-1. Manual paper feed roller, manual takeup roller

1 Remove the manual paper feed unit from the copier.
2 Remove the roller auxiliary spring, the manual solenoid connector,

the E-rings in the front and the rear frames, and the bearing.
Remove the manual roller ass’y together with the solenoid holder.

4 Remove the manual arm and the E-ring, and remove the manual

paper feed roller.
Note: Gear 20T has a positioning pin. When removing the

manual arm, be careful not to miss the positioning pin.

Gear 20T (Positioning pin included)

Arrow mark

3 Remove the manual feed takeup roller from the manual arm.

Note for assembly (1): The manual paper feed roller is provided

with the one-way clutch. When attaching
it, attach so that the arrow mark on the
roller is in the E-ring side. (Be careful to
the installing direction.)

2-2. Reverse rotation roller ass’y

1 Remove the manual feed roller ass’y.
2 Remove the reverse roller ass’y from the roller holder.

6 – 5

3. Fuser section

3-1. Fuser unit removal

1 Open the front panel
2 Remove the table glass.
3 Turn the open/close lever to the right and open the upper unit

slowly.

4 Remove the connectors (2 pin × 2), slightly lift the right side of the

unit and pull it out.

5 Move the copy lamp unit to the left of the body (the paper exit

side).

6 Disconnect the connector (2-pin) of the dehumidifier heater which

extends from the dark box cover. Insert a long screwdriver (+) into
that port and remove the screw which is fixing the fuser cover.

7 Remove the fuser cover in the direction of arrow A.

8 Remove an E-ring and two connectors.

3-2. Heater lamp replacement

1 Remove the fuser cover fixing screw (1 pc.), and slide it to the

front side, and remove it.

2 While pushing the projection of the Faston terminal connected to

the thermostat, remove the lead wire from the connected section.

3 Remove the lamp holder fixing screw on the top of the rear frame,

and remove the holder.
4 Pull out the heater lamp from the front frame.
For assembly, reverse the disassembly procedures.

A

6 – 6

3-3. Upper heat roller ass’y removal

1 Remove the bearing fixing screws (2 pcs.) in the front and the rear

frames.

2 Put the paper guide to the paper exit side and separate the

separation pawl from the roller and fix it.

3 Rotate the fixing screw section of the bearing about 45 degrees

below and pull it upwards.

For assembly, reverse the disassembly procedures.

3-5. Lower cleaning roller and lower heat roller

replacement

1 Remove the fuser unit.
2 Remove the CL roller springs (2 pcs.) which is fixing the lower

cleaning roller from the hook section.

3 Remove the lower cleaning roller.
4 Lift the paper exit guide, and remove the lower heat roller without

making contact between the roller and the scraper.
For assembly. reverse the disassembly procedures.

3-4. Upper separation pawl replacement

1 Remove the fuser unit and remove the cover.
2 Place the fuser unit so that the paper guide is in the lower side.

(The separation pawl is in the upper side.)

3 Remove the tension spring, hold the tip of the separation pawl and

remove it from the supporting section, and tilt it to remove.

For assembly, reverse the disassembly procedures.

6 – 7

3-6. Scraper replacement

1 Remove the upper fuser unit.
2 Remove the paper exit paper guide fixing screw (step screw) in

the front frame side, and remove the paper exit paper guide.

Paper exit paper guide

3 Remove the scraper hook section from the paper exit paper guide,

and remove the scraper.

3-7. Thermistor/thermostat removal

Press this projection to desassemble

* Note for assembly

• Be sure to bring the thermistor center into contact with the heat

roller.

• Clean and remove foreign materials from the thermistor surface

with alcohol.

Scraper

Note: When attaching the scraper, be careful not to deform it. Also

be careful to check that the scraper hook section is completely
inserted into the paper exit paper guide.

6 – 8

4. Optical system

4-1. Copy lamp replacement

1 Open the body up. Release the lock lever of the manual paper

feed unit and remove the manual paper feed unit.

2 Remove the fixing screws (2 pcs.) in the right upper cabinet, and

remove the right upper cabinet.

3 Remove the fixing screws (4 pcs.) of the glass holder, and remove

the glass holder.

4 Remove the table glass.

4-2. Copy lamp unit replacement

1 Remove the manual paper feed unit, the right upper cabinet, the

glass holder, the table glass, and the operation panel.

2 Move the copy lamp unit to the frame notch (refer to the figure).
3 Remove the terminal section of the copy lamp lead wire. (One

screw and insertion terminal)
4 Loosen the fixing screw of the front and the rear frame wire, fixing

plate and remove the wire from the copy lamp unit.
5 Slide the whole unit forward, and remove the rear frame side

upwards.
For assembly, reverse the disassembly procedures.

Wire fixing screw

5 While pushing the copy lamp electrode in the rear frame, remove

the copy lamp.

For assembly, reverse the disassembly procedure.
Note: Be careful to the direction of the copy lamp installation. The

projection must be in the rear side. Attach as shown in the
figure.

Copy lamp

Fron t side R ear s ide

Main reflector

Projection

Copy lamp

Projection

Projection

Note: When the copy lamp unit is removed, the position adjustment

must be required when attaching again. Refer to the adjust­ment item for the work.

4-3. Mirror base drive wire replacement

<Removal>

1 Remove the manual paper feed unit, the right upper cabinet, the

glass holder, the table glass and the operation panel.
2 Remove the fixing screws (2 pcs.) of the left upper cabinet, and

slide to the rear frame side to remove the cabinet.
3 Loosen the fixing screw of the copy lamp unit wire fixing plate, and

remove the wire from the unit.
4 Remove the tension spring (7 in the figure) of the mirror base

drive wire in the paper exit side from the hook section.
5 Slightly shift the mirror base to the paper feed side, and remove

the terminal 1 of the mirror base drive wire.
6 Remove the wire fixing screw of the drive pulley.

<Installation>

1 Set the mirror base to the positioning plate position.
2 Set the terminal side of the mirror base drive wire on the hook

section 1, turn the mirror base pulley 2 outside to wind the wire

around the drive pulley from the above.
3 Wind the wire 8 turns from the outside to the inside of the drive

pulley, and put the 7th turn into the groove, and fix it with a screw

temporarily.
4 Pass the wire under the mirror base and wind around the paper

exit pulley (the larger one).
5 Pass the wire to the inside of the mirror base pulley, and pass

through the paper exit pulley (the smaller one), then fix the tension

spring to the hook section 7.
6 Check that the mirror base is in contact with the positioning plate,

and tighten the wire fixing screw of the drive pulley.

6 – 9

2

5

7

7

5

6

4

2

5

2

4

2

6

3

5

1

1

3

Note: After replacement of the mirror base drive wire, perform the

vertical skew copy adjustment, the focus adjustment, and the
horizontal skew copy adjustment.

4-4. No. 4/5 mirror unit replacement

1 Remove the manual paper feed unit, the right upper cabinet, and

the table glass.

2 Remove the dark box cover fixing screw (1 pc.) and remove the

cover.

3 Remove the mirror holder spring.
4 Remove the shaft mounting plate, pull out the shaft towards the

paper feed side, and remove No. 4/5 mirror unit.

4 Remove connector B between the mirror motor and the main

PWB (CN-C).
5 Remove two snap bands C which are binding cables of the

operation panel.
6 Remove the optical unit .

C

A

B

A

4-5. Optical unit removal

1 Remove the drum unit and the developer unit.
2 Remove the right cabinet, the left cabinet, the operation panel, the

medium cabinet, and the rear cabinet.

3 Remove three connectors A from the sensors in the rear as

shown in the figure.

6 – 10

4-6. Other parts in the optical system

1 Remove the rear upper cabinet.
2 Remove the CN-C connector of the main PWB and the fixing

screws (2 pcs.), and pull out the mirror motor towards the rear
frame.

3 Remove the connector and the fixing screw (1 pc.), and remove

the mirror home position sensor (MHPS) towards the rear frame.

5 Remove the connector, the manual paper feed unit, the right

upper cabinet, the table glass, and the dark box cover. Remove

the fixing screw from the above and remove the AE sensor

towards the front frame side.

4 Remove the fixing screw (1 pc.) of the upper frame and the screw

and the connector in the rear frame, then remove the main PWB.

For assembly, reverse the disassembly procedures.

6 – 11

4-7. Light adjustment plate/temperature fuse

removal

1 Remove the document glass.
2 Remove the parts as shown in the figure.

5. Drum section

5-1. Drum cartridge removal

1 Open the front cover.
2 While pressing down the release lever A, open the toner

cartridge slowly. (Arrow B)
3 Grasp the handle on the drum cartridge, depress and hold the

release lever C on the cartridge, and pull the cartridge out of the

copier. (Arrow D)

A

C

B

D

6. Developer section

6-1. Developer unit removal

1 Open the front cover.
2 While pressing down the release lever, open the toner cartridge

slowly and remove it.

3 Loosen the step screw A.
4 Pull out the developer unit.

6 – 12

A

6-2. Developer cartridge removal

1 Place the magnet roller of the developer unit on the box to protect

it.

2 Remove two screws C and remove the motor.

2 As shown in the figure below, open the section which is pressing

the cartridge pawl with a screwdriver, and pull out the developer
cartridge.

6-3. Toner motor removal

1 Remove four short screws A and one long screw B, and the

connector, and separate the toner cartridge section.

6-4. Toner density sensor

6 – 13

7. Operation pan el sect io n/med iu m
cabinet

1 Open the front cabinet.
2 Remove three screws A and two harnesses from the operation

panel.

3 Remove the operation panel unit.

A

A

B

A

B

8-2. Optical unit cooling fan removal

1 Remove the rear cabinet.
2 Remove as shown below.

4 When removing the medium cabinet, first remove the process unit

and the developer unit then remove four screws B and remove
the medium cabinet.

8. Major parts in th e frame side

8-1. Ozone filter

1 Remove the document glass.
2 Remove the black sheet and remove the ozone filter.

6 – 14

8-3. Ventilation fan motor

1 Remove the optical unit. (For details, refer to "4. Optical unit

removal.")

2 As shown in the figure below, remove the ventilation fan motor.

8-4. Transport roller clutch

1 Remove the rear cabinet.
2 Remove the transport clutch as shown in the figure below.

8-5. Paper exit sensor

1 Open the front panel.
2 Move the open/close lever to the right and open the upper unit

slowly.

3 Remove the sensor as shown in the figure below.

6 – 15

[7] ADJUSTMENTS

The descriptions of this chapter are divided into the following sec­tions:

1. Developer section

(1) MG roller main pole position adjustment
(2) Adjustment of clearance between DV doctor and MG roller

2. Optical section

(1) Lens unit angle adjustment
(2) Mirror unit angle/position adjustment
(3) Image distortion adjustment
(4) Copy image center position adjustment
(5) Focus adjustment
(6) Copy magnification ratio adjustment
(7) Uniformity adjustment
(8) Image loss/void area adjustment

3. Copy density adjustment

(1) Copy Density adjustment timing
(2) Note for copy density adjustment
(3) Necessary thing for copy density adjustment
(4) Copy density adjustment mode
(5) Copy density adjustment procedure
(6) Copy density adjustment table

4. Others

(1) Transfer charger wire installation
(2) DV bias adjustment
(3) Separation charger output adjustment

2 Tie a string to a needle as shown in the figure below.
3 Hold the string and move the needle to the MG roller.
4 Mark the point where the needle makes contact with the MG

roller.

Marking

5 Measure the distance between the marking and the developer unit

bottom A and check that the distance is within 15.1mm. If the
measured distance is outside the range, loosen the MG adjust­ment plate fixing screw, and move the adjustment plate in the
arrow direction to perform procedures 3 to 5 again.

1. Developer section

(1) MG roller main pole position adjustment

If the MG roller main pole position is improper, the following troubles
may occur:

• Insufficient copy density

• Toner splash

1 Remove the DV unit from the body and remove the DV cover.

DV cover

A

15.1mm

6 Tighten the MG adjustment plate fixing screw.

7 – 1

(2) Adjustment of clearance between DV doctor

and MG roller

If the clearance between the DV doctor and the MG roller is improper,
the following troubles may occur:

• Insufficient copy density

• Copy dirt

• Toner splash

1 Remove the DV cover.
2 Loosen the DV doctor fixing screw.
3 Insert a 0.6mm thickness gauge into the clearance between the

MG roller and the DV doctor in the range of 30mm width under the
DV doctor fixing screw.

A

4 Press the DV doctor in the arrow direction and tighten the DV

doctor fixing screw.

5 Check that the clearance of the DV doctor is 0.6 ±0.03mm in the

range of 30mm width under the DV doctor fixing screw.

0.6±0.03mm

MG

30mm

30mm

2. Optical section

A. Adjustments list

Classification No. Adjustment content

Copy picture quality

For details, refer to the Ref. page.

*

(1)

Image distortion adjustment

(2)

Copy image center position adjustment

(3)

Focus adjustment (Resolution
adjustment)

(4)

Uniformity adjustment

(5)

Image loss, void area adjustment

A

a
b

a
b

Note: When adjusting, be careful not to scratch the DV doctor.

Adjustment

value/Standard

value

Horizontal image distortion adjustment
Vertical image distortion adjustment

Copy image loss adjustment
Void area adjustment

— — 7-4
— — 7-6

— — 7-9

— — 7-9

* — 7-10

+3

0

mm — 7-11

−0

Necessary

special tool

Ref.

page

7-8

B. Notes

When performing the adjustment, observe the following notes:

1) Observe the sequence of procedures shown in the flowchart

below.

2) Adjustment can be started midway in the flowchart only if all the

previous items have been properly adjusted.

3) If the content of an adjustment item in the flowchart is changed,

all the following items must be adjusted accordingly.
Any adjustment item is based on the previous adjustment items
and relates to the following adjustment items.

4) "Sim" in the flowchart stands for "Simulation."

7 – 2

START

Fix the blank lamp to the center.

Fix the lens center position adjustment
rail at the center temporarily.

Fix No.4/5 mirror position to the
center.

End

1'

2'

Make a test chart. (Draw a rectangle
on A4 or 8 1/2" x 11" paper.)

With the document cover open,
make a copy on A4 or 8 1/2" x 11"
paper.

NO

Check horizontal image distortion.

The

distances at the

right and the left of the horizontal

copy image line and the black background

made by the blank lamp are equal

to each other.

YES

With the document cover closed,
make a 10% copy on A4 or
8 1/2" x 11" paper.

Check that the right corner and the left
corner angles of the copy image are
right angles.

Is the

right corner angle

of the copy image equal

to the left corner

angle ?

YES

With the document cover closed,
make a copy on A4 or 8 1/2" x 11"
paper.

Change the relative positions of
the rear or the front frame side

NO

scanner drive pulley and the
shaft, and adjust horizontal
image distortion.

Change the height balance of
right and left scanner slide rails,

NO

and adjust so that the corner
angles of the copy image
rectangle are equal to each
other.

Use the test chart (UKOG-0089CSZZ)
or the resolution chart to make a copy
on A4 or 8 1/2" x 11" paper so that the
resolution patterns are copied at the
center and the four corners.

Check the resolution at the center
and the four corners.

Is the center

resolution more than

5.0 lines/mm and are the corner
resolutions more than

4.5 lines/mm ?

YES

Set the scale along the document
reference plate (vertical to the paper
transport direction) and make a 100%
copy on A4 or 8 1/2" x 11" paper.

Compare the scale and its copy
image size.

Are they the same size ?

YES

3

Change No.4/5 mirror positions

NO

to adjust focus.

Set the Sim48-1 se t value s m a l ler.

NO

Is the copy

image greater than the

actual scale ?

3'

Set the Sim48-1 set value greater.

YES

NO

Check the copy image vertical
distortion.

Are the

four angles of the copy

image rectangle right

angles ?

Make a test chart. (Draw a rectangle at
the center of A4 or 8 1/2" x 11" paper in
the longitudinal direction.)

Set the test chart to the document
positioning reference plate, and make
a copy on A4 or 8 1/2" x 11" paper by
cassette paper feed.

Check that the copy image is at the
center of the copy paper.

Is the
copy image at the
center of the copy

paper ?

//9/

YES

YES

2

Change No. 4/5 mirror height

NO

balance and adjust vertical
image distortion.

Change the lens position so

NO

that the copy image comes at
the center of the copy paper.

Use a half-tone document and make a
copy on A4 or 8 1/2" x 11" paper in
the half tone mode.

Check the uniformity.

Is the uniformity OK ?

YES

Put the scale to the document
reference plate and set in the paper
transport direction.

Set the Sim45 set value to "0."

Make a copy with Sim50-1.

Measure the distance between the
copy image lead edge and the copy
paper lead edge.

0 ± 0.5 mm ?

Change the installing position of

NO

the exposure adjustment plate
to adjust the uniformity.

Change the Sim50-1 set value

NO

B so that the difference is
within the specified range.

7 – 3

End

C. Adjustment contents

(1) Image distortion adjustment

There are following two types of image distortion.

Horizontal image distortion

*

Vertical image distortion

*

Image distortion is generated mainly by insufficient parallelism of the
mirror and misalignment of the lens optical axis.
In this model, image distortion is adjusted by adjusting parallelism of
each mirror.

a. Horizontal image distortion adjustment

I. Summary

This adjustment is to adjust horizontal image distortion by setting
the horizontal optical axis of the copier and the horizontal optical
axis of each mirror in parallel with each other. The relative posi­tions of the front frame and the scanner unit drive pulley of the
frame are changed to perform the above adjustment.
Install the No. 1 and No. 2 scanner units to the specified posi­tions, adjust the mechanical horizontal parallelism, and perform
the final adjustment while making copies.

II. Purpose

The purpose of this adjustment is to reduce horizontal image
distortion by setting the horizontal optical axis of the copier and
the No. 1 and No. 2 scanner unit horizontal optical axis in paral­lel with each other.

III. Note

Before starting this adjustment, the following items must have
been completed. If not, this adjustment cannot reduce image
distortion.

The lens unit right angle adjustment must have been com-

*

pleted.
The No. 4/5 mirror unit right angle adjustment must have

*

been completed.

IV. Cases when the adjustment is required

1) When the No. 1 and No. 2 scanner units are disassembled or
their part is replaced.

2) When the scanner unit drive section is disassembled or its
part is replaced.

3) When the copy image is distorted as shown below:

VI. Adjustment procedure

1) Remove the right upper side cabinet and the document refer­ence plate.

Document
reference plate

Document table glass

Right upper side cabinet

2) Remove the document glass.

3) Loosen the fixing screw of the No. 1 scanner unit wire.

Wire fixing screw

Document Copy A Copy B

V. Necessary tools

Screwdriver (+)

*

Hex wrench

*

Scale

*

Test chart for distortion adjustment (Make a chart shown

*

below by yourself.)
Draw a rectangle on a paper (A4 or 8 1/2" x 11") as shown
below.
Be sure to make four right angles.

L

L

L=50mm

7 – 4

4) Manually turn the scanner unit drive gear to bring No. 2
scanner unit into contact with No. 2 scanner unit positioning
plate. When No.2 scanner unit makes contact with No.2
scanner unit positioning plate in the rear frame side simul­taneously, the mechanical parallelism of No.2 scanner unit is
proper.
If one side of No.2 scanner unit makes contact with No.2
scanner unit positioning plate and the other side does not,
the parallelism is improper.
If the parallelism is improper, perform the procedure of step

5).

(Note)
Allow a clearance of about 0.5mm between the scanner
unit drive pulley and the positioning E-ring.

0.5mm

7) Manually turn the scanner unit drive gear to bring No.2
scanner unit into contact with the positioning plate, and
perform the procedure of step 4).
Repeat procedures of steps 4) to 7) until the parallelism of
No.2 scanner unit is properly set.

8) With No. 2 scanner unit being in contact with No. 2 scanner
unit positioning plate, bring No.1 scanner unit into contact
with No.1 scanner unit positioning plate, and fix it to the
scanner unit drive wire.

5) Loosen the scanner unit drive pulley setscrew in the side
where No.2 scanner unit does not make contact with No.2
scanner unit positioning plate.

Set screw

Scanner unit drive pulley

6) Without moving the scanner unit drive pulley shaft, manual-

ly turn the scanner nit drive pulley in the same side of the
loosened setscrew. When it makes contact with No.2 scan­ner unit positioning plate, tighten and fix the setscrew.

Do not move
the shaft.

No.1 scanner unit

Positioning
plate

Wire fixing screw

No.2 scanner unit

Positioning plate

Scanner unit drive pulley

7 – 5

Procedures 1) to 8) are for adjustment of mechanical
horizontal parallelism. No.1 scanner unit and No.2 scanner
unit are fixed to the specified positions and the mechanical
horizontal parallelism of No.2 scanner unit is adjusted.
(When No.1 and No.2 scanner units are shifted to the right
end, the scanner units are in contact with the four position­ing plates.)

12) Without moving the scanner unit drive pulley shaft, manual­ly turn the scanner unit drive pulley whose setscrew was
loosened, and adjust the parallelism of No.1 and No.2
scanner units.

No.2
scanner
unit.

No.1
scanner
unit

Then the optical horizontal parallelism must be adjusted in
the following procedures.

9) Set the A3 or 11" x 17" paper along the guide which is
located this side on the document table and make a copy.

10) Check the horizontal image distortion.
If LL = LR, there is no horizontal distortion.

Distance between the copy
horizontal line and the outer
edge of the black background

Black background

LL

LL and LR =

LR

11) If LL is not equal to LR, perform the following procedure.
Loosen the setscrew of the scanner unit drive pulley in the
front or the rear frame.

Set screw

Scanner unit drive pulley

Do not move the shaft.

13) Tighten the set screw of the scanner unit drive pulley.

14) Check the image distortion in the same manner as step

10).
Repeat procedures 11) to 14) until horizontal image distor­tion is eliminated.

VII. Troubles caused by improper adjustment

b. Vertical image distortion adjustment

I. Summary

This adjustment is to adjust parallelism of the vertical optical axis
of the copier and that of each mirror to eliminate vertical image
distortion.
For adjusting vertical image distortion, the overall adjustment
and the right-left balance adjustment must be performed inde­pendently.
The overall adjustment is performed by changing the height of
No.4/5 mirror unit in the front frame side. The right-left balance
adjustment is performed by changing the right-left balance of
No.2 scanner unit rail.
The right-left balance adjustment must be performed in advance
to the overall adjustment.

II. Purpose

The purpose of this adjustment is to set parallelism of the verti­cal optical axis of the copier and that of No.4/5 mirror unit and
No.2 mirror unit to eliminate vertical image distortion.

III. Note

Before performing this adjustment, the following adjustments
must have been completed.
If not, this adjustment cannot be performed properly.

The lens unit right angle adjustment

*

No.4/5 mirror unit right angle adjustment

*

Horizontal image distortion adjustment

*

IV. Cases when the adjustment is required

1) When No.4/5 mirror unit is disassembled or its part is
replaced.

2) When the scanner unit drive section is disassembled or its
part is replaced.

3) When the copy image is distorted as follows:

Scanner unit drive pulley

Document Copy C Copy D

7 – 6

V. Necessary tools

Screwdriver (+)

*

Screwdriver (–)

*

Scale

*

Test chart for distortion adjustment (Make by yourself.)

*

Draw a rectangle on A4 or 8 1/2" x 11" paper as shown
below:
Be sure to make four right angles.

L

LL

L = 10mm

L

VI. Adjustment procedure

1) Set the test chart for image distortion adjustment on the
document glass, and make a normal copy on a paper of A4
or 8 1/2" x 11".

2) Check image distortion in the right and the left sides.
If the both vertical lines are in parallel with each other, the
right-left distortion balance is proper. (However, there may be
some distortion.)
If all the four angles are right angles, there in no distortion
and the following procedures are not required.

Large
distortion

Small
distortion

Change the right side
height of the rail.

Change the left side
height of the rail.

Scanner unit fixing screw

Scanner unit rail

Repeat procedures 2) and 3) until the right-left balance of
image distortion is proper.

4) Change the height of the roller in No.4/5 mirror unit front
frame side to adjust the vertical image distortion.
If the copy image is tilting as shown in sample (X) below,
lower No.4/5 mirror unit. If it is tilting as shown in sample (Y)
below, lift No.4/5 mirror unit.

3) If the right-left distortion balance is improper, loosen the
fixing screw of No.2 scanner unit rail to change and adjust
the right-left balance of No.2 scanner unit rail.
(Note)
This procedure is to have the balance between the right
image distortion and the left image distortion, which does not
mean to eliminate the image distortion. Change the height of
No.2 scanner unit rail in the greater distortion side.
If the distortion in the lead edge side (when viewed in the
paper transport direction) is greater, change the height of the
left rail of No.2 scanner unit.
If the distortion in the rear edge side (when viewed in the
paper transport direction) is greater, change the height of the
right rail of No.2 scanner unit.

(X) (Y)

5) Make a copy to check the vertical image distortion.
If the four angles are right angles, the adjustment is com­pleted.

Repeat procedures 4) and 5) until the vertical image distor­tion is eliminated.
(Note)
If a vertical image distortion is not eliminated with procedure

4), change the overall height of No.2 scanner unit rail. Then
repeat procedures 1) to 5).

VII. Troubles caused by improper adjustment

7 – 7

(2) Copy image center position adjustment

I. Summary

The optical axis is changed by changing the lens unit position to
optically align the document table and the vertical position of the
copy image on the copy paper.
When the lens unit position is changed, the lens position in the
front and the rear frame direction is changed to change the
optical axis.
As a result, the document table is optically aligned with the copy
image on the copy paper.

II. Purpose

The purpose of this adjustment is to set the copy image center
at the vertical center of the copy paper.

III. Note

Before performing this adjustment, the following adjustment
must have been completed. If not, this adjustment cannot be
performed properly.

No.4/5 mirror unit right angle adjustment

*

Image distortion adjustment

*

IV. Cases when the adjustment is required

1) When the lens unit is disassembled or its part is replaced.

2) When the copy image is shifted from the vertical center of the
paper.

V. Necessary tool

Screwdriver (+)

*

Scale

*

Test chart for center position adjustment (Make a chart

*

shown below by yourself.)
Draw a line in the paper transport direction at the center of A4
or 8 1/2" x 11" paper.

4) If the image of the line is not at the center of the paper,
perform the following procedure.

5) Remove the right side cabinet and the document reference
plate.

Document
reference plate

Document table glass

Right upper side cabinet

6) Remove the document glass.

7) Remove the optical unit cover.

8) Loosen the lens rail fixing screw, and slide the lens unit back
and forth.

9) Make a copy and check that the image line is at the center of
the paper. If not, repeat the procedures 1) to 9) until the
image line comes at the center of the paper.

VII. Troubles caused by improper adjustment

Center
Copy paper

(A4 or 8 1/2" x 11")

VI. Adjustment procedure

1) Set the test chart for center position adjustment at the docu­ment reference position.

2) Make a copy on A4 or 8 1/2" x 11" paper.

3) Check that the image of the line is at the center of the paper.
(Standard: 0±1.5mm)

1.5mm or less

(Copy A)

Shift

1.5mm or less

(Copy B)

Shift

Copy image
Folding of copy paper

Folding of copy paper
Copy image

(3) Focus adjustment (Resolution adjustment)

I. Summary

The distance between the document and the photoconductor
drum is changed by changing No.4/5 mirror unit drive lever posi­tion to adjust the focus.

II. Purpose

The purpose of this adjustment is to correct the lens variations
and the optical section dimensional variations to have good copy
images with a proper focus.

III. Note

Before performing this adjustment, the following adjustment
must have been completed. If not, this adjustment cannot be
performed properly.

Image distortion adjustment

*

IV. Cases when the adjustment is required

1) When the lens or the mirror unit is disassembled or any one
of their parts is replaced.

2) When the scanner unit drive section is disassembled or its
part is replaced.

3) When a cop image of improper focus is obtained.

V. Necessary tools

Screwdriver (+)

*

Test chart (One with the resolution adjustment chart)

*

7 – 8

VI. Adjustment procedures

1) Set the test chart on the document table.

2) Make a normal copy on A4 or 8 1/2" x 11" paper.

3) Check that resolutions at the copy paper center and the four
angles are as shown in the table below:

(Standard) (Unit: lines/mm)

Copy center Corner
Normal (100%) 5.0 4.5
Enlargement 5.0 4.5
Reduction 4.5 3.6

(Copy)

Check
the corners.

4.5

5.0

5.6

6.3

7.1

4.0

8.0

9.0

9.1

9.2

9.2

9.2

9.2 9.2

7) Loosen No.4/5 mirror unit drive lever fixing screw, and adjust
the No.4/5 mirror unit position.

2.8

3.2

3.6

If any resolution is out of the above specifications, perform
the following procedures.

4) Remove the right cabinet and the document reference plate.

Document
reference plate

Document table glass

Right upper side cabinet

5) Remove the document glass.

6) Remove the optical unit cover.

Optical unit cover

8) Make a copy and check that the resolutions are in the
specified range.
If any resolution is out of the specified range, repeat proce­dures 1) to 8).

9) Put the No.4/5 mirror drive lever to the base plate side and
tighten the fixing screw.

VII. Troubles caused by improper adjustment

7 – 9

(4) Uniformity adjustment

I. Summary

The uniformity adjustment is performed by changing the ex­posure plate position attached to No.1 scanner unit.
The above procedure changes the balance of light quantity
radiated onto the document.

II. Purpose

The purpose of this adjustment is to have uniform copy density.

III. Note

When this adjustment is performed, the exposure will be
changed. Therefore, the copy density adjustment must be per­formed after this adjustment. Also, this adjustment must be per­formed always before the copy density adjustment.

IV. Cases when the adjustment is required

1) When the reflector is replaced.

2) When the copy lamp is replaced.

3) When the exposure adjustment plate is disassembled or
replaced.

4) In maintenance

V. Necessary tools

Screwdriver (+)

*

A4 or 8 1/2" x 11" paper

*

Half-tone paper of A4 or 8 1/2" x 11" or larger

*

VI. Adjustment procedure

1) Set a half-tone paper of A4 or 8 1/2" x 11" on the document
table.

2) Set the exposure level to the min. level in the photo mode,
and make a copy on A4 or 8 1/2" x 11" paper.

3) Check the uniformity. If there is any unevenness, perform the
following procedures.

4) Move the exposure adjustment plate of the lighter copy sec­tion towards Y or move the exposure adjustment plate of the
darker copy section towards X.

(Example)
If a copy shown below is made, move the front frame side of
the sub exposure adjustment plate in the direction of X to
adjust the exposure balance.

Less exposure
(Dark copy)

Paper exit
direction

Half-tone copy

[Fig. 1]

Y

X

5) Make a copy in the same manner as procedure 2), and
check the uniformity.
Repeat procedures 1) to 5) until proper uniformity is ob­tained.

VII. Troubles caused by improper adjustment

Y

X

Y

X

(5) Image loss/void area adjustment

The image loss/void area adjustment is performed by the combination
of the copied image position adjustment on the copy paper and the
void area adjustment.
Since the image loss and the void area are closely related each other,
they must be adjusted simultaneously.
(Definitions of image loss and void area)
Void area: Empty (white) area on a copy paper (without toner on it)
Image loss: The qua nt it y (le ng th) of an imag e los t on a cop y pa pe r .

(Document)

(Copy)

Paper lead
edge

Li

Li: Lead edge image loss

Lv

Lv: Lead edge void area
(In some cases, Lv

a. Copy image loss adjustment

I. Summary

In order to adjust the copy image position on a copy paper, the
lead edge position of an image on the photoconductor for the
lead edge position of a document on the document table is
changed with simulations 50-1, and the relative position of the
paper to the image position on the photoconductor is changed.
In the models which have no zoom copy functions, however, the
lead edge position of an image on the photoconductor for the
lead edge position of a document on the document table is not
changed.
The relative position of the paper is changed at OFF timing of
the scanner home position sensor after starting scanning to ad­just the copy image position on the paper.
After adjusting the copy image position with the above proce­dure, the blank lamp OFF timing for the lead edge position of an
image on the photoconductor is changed with simulations 45-1
to adjust the void area.

II. Purpose

The purpose od this adjustment is to improve separation in the

Y

X

photoconductor section and in the fuser section and reduce dirt
on the fuser section pawl by obtaining the max. effective copy
area and the proper void area.

III. Note

If the proper void area is not obtained, the separation ability in
the photoconductor section may be degraded and dirt on the
fuser section pawl may be increased.
Before performing this adjustment, the following adjustment
must have been completed. If not, this adjustment cannot be
performed properly.

Adjustment of paper pressure against the resist roller (Sim

*

51-2 set value must be properly set.)

IV. Cases when the adjustment is required

1) When the optical section is disassembled or its part is
replaced (including the scanner home position sensor).

>

Lv)

=

7 – 10

2) When the main PWB is replaced.

3) When the RAM in the main PWB is replaced.

4) When "U2" trouble occurs.

5) When the resist roller unit is disassembled or replaced.

V. Necessary tools

Screwdriver

*

Scale

*

Test chart

*

VI. Adjustment procedure

(Copy image position adjustment)

1) Execute simulations 45. (C → 0→ 0 → C→ 45 → CB)
Simulations 45 is to adjust the size of the void area in the
lead edge of the copy paper.
The set adjustment value is displayed on the COPIES
SELECTED display.

2) Set the set value of simulations 45 to "0."
Enter "0" with the numeric key and press PRINT button.

3) Execute simulations 50-1. (C → 0 → 0 → C → 50 → CB → 1
→ CB)
This simulations is to adjust the copy image position for the
paper. The currently set adjustment values is displayed on
the COPIES SELECTED display.

Adjustment value B: Corresponds to the time interval from

the scanner unit starting and the scan­ner home position sensor OFF to the
resist roller ON.
According to this value, the paper feed
timing for the image on the photocon­ductor drum is changed and the copy
image position on the copy paper is
also changed.
When the set value is changed by "1,"
the position of the copy image on the
copy paper is changed by about 0.123
mm.
When the set value is made greater,
the copy image position for the copy
paper moves backward. When the set
value is made greater, the copy image
position for the copy paper moves for­ward.

Use the paper tray select key to select the display of adjust­ment value B and to select the set mode.

Display lamp Display content/set mode

Copier tray cassette paper feed
lamp BLINKS

Adjustment value B

4) Press the scale onto the document alignment plate and set it
horizontally as shown below:

Scale

5) Execute simulations 50-1 to make several copies.

6) Make a copy, and check that the copy image lead edge is in
the range of 0 ±1.5 mm from the paper lead edge position
reference.
If it is out of the above range, change adjustment value B
and repeat procedure 6) until it is within the above range.

VII. Troubles caused by improper adjustment

b. Void area adjustment

I. Summary

The copy image position on the copy paper is adjusted with
simulations 50-1, then the main corona grid ON timing for the
image lead edge on the photoconductor is changed with simula­tions 45 to adjust the void area.
In concrete, in the case of the document table mode, the adjust­ment is performed by changing the time interval from the scan­ner motor ON to the main corona grid ON.

II. Purpose

The purpose od this adjustment is to improve separation in the
photoconductor section and in the fuser section and reduce dirt
on the fuser section pawl by obtaining the max. effective copy
area and the proper void area.

III. Note

If the proper void area is not obtained, the separation ability in
the photoconductor section may be degraded and dirt on the
fuser section pawl may be increased.
Before performing this adjustment, the following adjustment
must have been completed. If not, this adjustment cannot be
performed properly.

Adjustment of paper pressure against the resist roller (Sim

*

51-2 set value must be properly set.)

IV. Cases when the adjustment is required

1) When the optical section is disassembled or its part is
replaced (including the scanner home position sensor).

2) When the main PWB is replaced.

3) When the RAM in the main PWB is replaced.

4) When "U2" trouble occurs.

5) When the resist roller unit is disassembled or replaced.

V. Necessary tools

Screwdriver

*

Scale

*

Test chart

*

Black background document

*

7 – 11

VI. Adjustment procedure

(Copy image position adjustment)

1) Execute simulations 45. (C → 0 → 0 → C → 45 F128Ä CB)
Simulations 45 is to adjust the size of the void area in the
lead edge of the copy paper.
The set adjustment value is displayed on the COPIES
SELECTED display.

2) Set the set value of simulations 45 to "0."
Enter "0" with the numeric key and press PRINT button.

3) Execute simulations 50-1. (C → 0 → 0 → C → 50 → CB → 1
→ CB)
This simulations is to adjust the copy image position for the
paper. The currently set adjustment values is displayed on
the COPIES SELECTED display.

Adjustment value B: Corresponds to the time interval from

the scanner unit starting and the scan­ner home position sensor OFF to the
resist roller ON.
According to this value, the paper feed
timing for the image on the photocon­ductor drum is changed and the copy
image position on the copy paper is
also changed.
When the set value is changed by "1,"
the position of the copy image on the
copy paper is changed by about 0.123
mm.
When the set value is made greater,
the copy image position for the copy
paper moves backward. When the set
value is made greater, the copy image
position for the copy paper moves for­ward.

Use the paper tray select key to select the display of adjust­ment value B, and to select the set mode.

Display lamp Display content/set mode

Copier tray cassette paper feed
lamp BLINKS.

Adjustment value B

6) Calculate the average lead edge void area.

7) Check that the void area is within the specified range.

Void area

mm
1/2mm

10

20 30

Copy scale image

Black background edge

Paper lead edge

Standard:

+3

0

mm

−0

If the void area is outside the specified range, change the set
value of simulations 45 and repeat procedures 6) to 7).
When the set value is changed by "1," the void area is
changed by about 0.123 mm.
When the set value is made greater, the void area becomes
greater, and vise versa.

4) Set adjustment value B to "0."
Enter "0" with the numeric key and press PRINT button.

5) Press the scale onto the document alignment plate and set it
horizontally as shown below:

Scale

7 – 12

3. COPY DENSITY ADJUSTMENT

120mm

White paper

Test char t

Front side

(1) Copy density adjustment timing

The copy density adjustment must be performed in the following
cases:

✱ When in maintenance.
✱ When the high voltage unit output current or voltage is adjusted.
✱ When the developing bias voltage is adjusted.
✱ When the copy lamp is replaced.
✱ When the optical section is cleaned.
✱ When an optical part is replaced.
✱ When the optical section is disassembled.
✱ When the photoconductor drum is replaced.
✱ When the developer is replaced.
✱ When the AE sensor is replaced.
✱ When the main control PWB is replaced.
✱ When the EEPROM on the main control PWB is replaced.
✱ When the memory trouble (U2) occurs.
✱ When a part of the copy lamp control circuit is replaced.
✱ When the AC power source PWB is replaced.

(2) Note for copy density adjustment

1) Necessary procedures before adjustment

✱ Clean the optical section.
✱ Clean the AE sensor.
✱ Clean or replace the charger wire.
✱ Check that the high voltage section voltage and the developing

bias voltage are in the specified range.

2) Note

✱ The auto mode copy density adjustment must be performed after

the normal mode copy density adjustment. Never reverse the se­quence.

(4) Copy density adjustment mode

The copy density adjustment must be performed in the following five
mode:

Copy density adjustment mode Exposure level

Normal mode

Non-toner-save mode 1 5
Toner save mode 1 5

Photo mode Non-toner-save mode 1 5
Auto mode

Non-toner-save mode 1 5
Toner save mode 1 5

(5) Copy density adjustment procedure

The copy density is adjusted by using Simulations 46 to change the
exposure level and the copy lamp voltage in each copy mode.
The copy density adjustment must be performed in the five modes.
To select each mode, use the copy mode select key.

A. Test chart (UK0G-0162FCZZ) setting

1) Set the test chart and B4 (14″ × 8 1/2″) white paper on the original
table as shown below.
The sensing area of the AE sensor is about 120 mm wide from the
rear frame side edge on the original table glass. Place the white
paper on that area, but keep the test chart away from that area.

(3) Necessary items for the copy density

adjustment

✱ Test chart

(Use one of the following three: UKOG-0162FCZZ, UKOG­0089CSZZ, KODAK GRAY SCALE)

✱ B4 (14″ × 8 1/2″) white paper

1 10

Test chart comparison

UKOG-0162FCZZ
DENSITY No.

UKOG-0089CSZZ
DENSITY No.

KODAK GRAY
SCALE

12345678910W

0.1 0.2 0.3 0.5 1.9 0

123419A

9

SHARP CORPORATION

MADE IN JAPAN

W2345678

B. Normal copy mode (Non-toner-save mode) copy

density adjustment

1) Enter the simulations 46 mode.

2) Set the adjustment mode to the normal copy mode (Non-toner­save mode).
(Press the copy mode select key to light the normal copy mode
lamp.)

Copy mode lamp

B5 A4

B4 B5

Copy sheet display

%

Lighting

Copy d ensity di splay lamp

12345

Copy mode
select key

Copy densi ty
adjust me nt key

122% A4 B4
115%

100%

81% B4 A4
70%

7 – 13

3) Set the density level to "1" with the copy density adjustment key.
(The currently set copy lamp voltage level will be displayed on the
COPIES SELECTED display.)

Copy mode lamp

Lighting

Copy d ensity di splay lamp

12345

Copy mode
select key

Copy density
adjustment key

122% A4 B4
115% B5 A4
100%

81% B4 A4
70%

B4 B5

Copy sheet dis p l ay

%

4) Press the print button to make a copy.
Check the gray scale copy to insure that "6" is slightly copied and
"5" is not copied.
When the copy density is too dark, increase the copy lamp voltage
level.
When the copy density is too light, decrease the copy lamp volt­age level.
Enter a new set value of the copy lamp voltage level with the
numeric keys and press the print button, then the entered value
will be set and the copy density will be adjusted according to the
set value.

1 10

23

4

567

8

9

W

Slightly copied

Not copied

5) Set the copy density level to "5" with the copy density adjustment
key.
(The currently set copy lamp voltage level will be displayed on the
COPIES SELECTED display.)

Copy mode lamp

Copy s heet displa y

B5 A4

%

Lighting

Copy de nsit y dis pl ay lam p

12345

Copy mode
select key

Copy dens i ty
adjus tment key

Lighting

122% A4 B4
115%
100%

81% B4 A4
70% B4 B5

6) Press the print key to make a copy.
Check the gray scale copy to insure that "2" is clearly copied and
"1" is not copied.
When the copy density is too dark, increase the copy lamp voltage
level.
When the copy density is too light, decrease the copy lamp volt­age level.
Enter a new set value of the copy lamp voltage level with the
numeric keys and press the print button, then the entered value
will be set and the copy density will be adjusted according to the
set value.

1 10

2

34

56

78

9

W

C. Normal copy mode (Toner save mode) copy density

adjustment

1) Set the adjustment mode to the normal copy mode (Toner save
mode). (Press the copy mode select key to light the normal copy
mode lamp and the photo copy mode lamp.)

Copy mode lamp

B5 A4

B4 B5

Copy sheet display

%

Lighting

Copy d ensity di splay lamp

12345

Copy mode
select key

Copy densi ty
adjust me nt key

122% A4 B4
115%
100%

81% B4 A4
70%

Adjust in the same manner as the above copy density adjustment
procedures i the normal mode (Non-toner-save mode).

D. Photo copy mode (Non-toner-save mode) copy density

adjustment

There is no toner save mode in the photo copy mode.

1) Set the adjustment mode to the photo copy mode.
(Press the copy mode select key to light the photo copy mode
lamp.)

Copy mode lamp

B5 A4

B4 B5

Copy s heet displa y

%

Lighting

Copy d ensity di splay lamp

12345

Copy mode
select key

Copy densi ty
adjust me nt key

122% A4 B4
115%
100%

81% B4 A4
70%

Check the gray scale copy to insure that "7" is slightly copied and
"6" is not copied.
When the copy density is too dark, increase the copy lamp voltage
level.
When the copy density is too light, decrease the copy lamp volt­age level.
Enter a new set value of the copy lamp voltage level with the
numeric keys and press the print button, then the entered value
will be set and the copy density will be adjusted according to the
set value.

1 10

234567

8

9

W

Slightly copied

Not copied

E. Auto copy mode (Non-toner-save mode) copy density

adjustment

1) Set the adjustment mode to the auto copy mode (Non-toner-save
mode). (Press the copy mode select key to light the auto copy
mode lamp.)

Not copied

Copied

7 – 14

Copy mode lamp

120mm

White paper

Test char t

Front side

Lighting

Copy de nsit y dis pl ay lam p

12345

122% A4 B4
115%

B5 A4

100%

81% B4 A4
70%

B4 B5

Copy s heet displa y

%

F. Auto copy mode (Toner save mode) copy density

adjustment

1) Set the adjustment mode to the auto copy mode (Toner save
mode).
(Press the copy mode select key to light the auto copy mode lamp
and the photo copy mode lamp.)

Copy mode
select key

Copy densi ty
adjust me nt key

2) Set the density level to "1" with the copy density adjustment key.
(The currently set copy lamp voltage level will be displayed on the
COPIES SELECTED display.)

Copy mode lamp

B5 A4

B4 B5

Copy s heet displa y

%

Lighting

Copy de nsit y dis pl ay lam p

12345

Copy mode
select key

Copy dens i ty
adjus tment key

122% A4 B4
115%

100%

81% B4 A4
70%

3) Set the copy lamp voltage level set value to "0."
Enter the new set value with the numeric key and press the print
button, then the entered value will be set. (Be sure to set to "0.")

4) Set the copy density level to "5" with the copy density adjustment
key.
(The currently set copy lamp voltage level will be displayed on the
COPIES SELECTED display.)

Copy mode lamp

Copy de nsit y dis pl ay lam p

Copy s heet displa y

Copy mode lamp

Lighting

Copy d ensity di splay lamp

12345

Copy mode
select key

Copy density
adjustment key

122% A4 B4
115% B5 A4
100%

81% B4 A4

B4 B5

70%

Copy s heet displa y

%

122% A4 B4
115%

B5 A4

100%

81% B4 A4
70%

B4 B5

%

Lighting

Copy mo de
select key

12345

Copy densi ty
adjust me nt key

Lighting

5) Press the print button to make a copy.
Check the gray scale copy to insure that "3" is slightly copied and
"1" is not copied.
When the copy density is too dark, increase the copy lamp voltage
level.
When the copy density is too light, decrease the copy lamp volt­age level.
Enter a new set value of the copy lamp voltage level with the
numeric keys and press the print button, then the entered value
will be set and the copy density will be adjusted according to the
set value.

1 10

5

678

9

Slightly copied

Not copied

Adjust the copy density in the same manner as the Photo copy mode
(Non-toner-save mode) copy density adjustment.

W234

7 – 15

A : Auto copy mode N.TS : Non-toner-save mode

(6) Copy density adjustment table

P : Photo copy mode TS : Toner save mode
N : Normal copy mode

Copy mode Mode display Density level Test chart copy density

1 10 W2

34

56

1

N.TS N

Not copied

1 10

2

34

56

5

Normal

Not copied

1 10

2

Copied

34

56

1

TS N & P

Not copied

1 10

2

34

56

5

2

Copied

34

56

Not copied

1 10

78

Slightly copied

78

78

Slightly copied

78

78

9

9

9

9

9

W

W

W

W

Photo N.TS P

N.TS A

Auto

TS A & P

1

Slightly copied

Not copied

1 10

2

34

56

78

9

W

5

Not copied

Copied

1

1 10

2

34

56

78

9

W

5

Slightly copied

Not copied

1 10

2

34

56

78

9

W

1

Slightly copied

Not copied

5

7 – 16

4. Others

(1) Transfer charger wire installation

Install the transfer charger wire as shown below. (Clean the charger
wire at every 40K copies and replace it at every 80K copies.)
Transfer charger unit (TC unit)

10 0.5

(3) Separation charger output adjustment

1) Install the DV unit and the process unit to the copier.

2) Set the digital multi mater range to DCV 100V or more.

3) Connect the high voltage probe to the lower unit PWB separation
output terminal ((+) side) and the chassis (GND).

4) Execute simulation 8-9. (The separation voltage is outputted form
30 sec.)

5) Adjust the separation voltage adjustment control (VR1) so that the
output voltage is 3.5V ±0.35V.

(Note for replacement of the charger wire)

a Do not twist or deform the charger wire.

Charger wire

Improper

Charger wire

Improper

b After replacement, be sure to clean the charger wire with alcohol.

(Be sure to use alcohol only.)

c After wiping with alcohol, wipe with a dry cloth.
d Use charger wire of 70µ (DWIR-0466CSZZ).

Cut the wire at the

Tension spring

2~3mm

root of the screw

Wind two turns and
tight en t he sc rew

(2) DV bias adjustment

1) Set the digital multi meter range to DCV 300V or more.

2) Put the test rod between the bias output faston tab terminal ((+)
side) of the lower unit PWB and the chassis (GND).

3) Execute simulation 8-1. (The DV bias voltage is outputted for 30
sec.)

4) Adjust the DV bias adjustment control (VR2) so that the output
voltage is –200V–3V.

7 – 17

[8] SIMULATIONS

1. Outline

This model is equipped with the simulations feature which allows the
following operations with the keys on the operation panel:

1) Adjustments

2) Setting of sp ec if ic at ions and functions

3) Resetting trouble codes

4) Checking operations

2. Purpose

The purpose of the simulations feature is to improve serviceability in
repairs and adjustments.
Since the mechanical adjustments can be performed electrically, the
above purpose is achieved with low costs.

3. Opera tin g pr oc edu r e

Simulations operating procedure

Start

Press the cle a r ke y

Press the zero key

Press the zero key

Press the cle a r ke y

All l a mps and indicat ors
on the operation panel go off.
Ready for entry of the main
test command num b er

Enter the main test command
number with numeric keys

The s et adjus t ment va lue or
the counter value is displayed
on the copy quantity display

To change t he set adjustment
value or the counter value,
enter a new value with numeric
keys

The entered valu e is displayed
on the copy quantity display

Press the print key

The new set value is stored

Is there a su b co de ?

Press the prin t key

Is the test

NO

command for operati on
check?

Operat i o ns acc or ding to the
sim u l at ions are perfor med

Do you
perform anot he r
simulations?

Press the cle a r ke y

NO

YES

NO

YES

YES

Press the print ke y

"00" blinks on the copy
quantity display . Ready for
entry of the s ub c ode.

Enter the sub code with
numeric keys

Press the print key

YES

Is the main
code same?

The main sim ulations
number i s disp l ayed on the
copy quantity display

NO

Is the sub
code display?

Enter a new m ain code

The main code is display on
the copy quantity display

NO

YES

Press the clear key

All the lamps and indicators
on the operation panel go off.
Ready for entry of the main
simulations number

Press the cle a r ke y

End

8 – 1

4. Purpose list

Purpose Section Main Sub Function Ref. page

Adjustments Paper feed section 51 2 Resist amount adjustment

Optical section 45 1 Lead edge void amount setting

46 1 Copy density (exposure level) adjustment 8-4
47 AE sensor characteristics value data auto input
50 1 Lead edge image position adjustment

Developer 8 1 Developing bias voltage check

25 2 Auto developer adjustment

Process 8 2 MC/TC output check (Normal mode)

3 MC/TC output check (Photo mode)
4 MC/TC output check (Toner save mode)
7 SC output check
9 MC/TC/SC output check

Setting Specifications 26 6 Destination setting

Paper feed section 26 12 Manual copy mode setting
Fuser section 26 13 Main motor operation mode setting at warming up

43 1 Fuser temperature setting

2 Fuser temperature setting (in power save)

Process 44 1 Correction mode setting

Counter Copy count 22 1 Maintenance counter display

2 Maintenance preset counter display
5 Total counter display

12 Drum counter display

Operation check Paper feed section 30 1 Main body sensor operation check

Optical section 1 1 Mirror base scan operation check

2 Optical system sensor operation check

5 3 Copy lamp lighting operation
Operation panel 5 1 LED lighting check
Fuser section 5 2 Heater lamp lighting check
Process 5 4 Discharge lamp lighting check

5 Blank lamp lighting check

6 2 Separation pawl auto operation check

44 2 Optical system dirt correction reference value display

3 Optical system dirt correction voltage correction value display
4 Photoconductor drum rotation time display

Developer section 10 Toner motor auto operation check

25 1 Toner density sensor operation check/toner density monitor

Trouble cancel 14 Cancel of troubles other than U2

16 U2 trouble cancel

8-3

8-5

8-6

8-7

8-8

8-9

8 – 2

5. Details of simulations

PPD
TRC

Purpose/kind Section Main

Adjustment Paper feed

section

Optical unit 45 1 Used to adjust the copy paper lead edge void and the rear edge void amount.

Contents

Sub

code

code

51 2 Used to adjust contact pressure between paper and the main body resist

roller. (Amount of paper buckle at the resist roller)
Change the set value when the shift between the paper and the image varies.

(Operation/procedure)
When the simulation key operation is performed, the currently set value is
displayed on the COPIES SELECTED display.
Enter the set value with the numeral key and press the print button, and the
entered set value will be stored in the main PWB RAM.
The standard set value is 25.
Tray paper feed mode: Tray (upper) paper feed lamp ON
Manual paper feed mode: Manual paper feed lamp ON
The set value corresponds to the time interval between when the paper detec­tor (PPD) in front of the main body resist roller detects paper and when the
transport roller (TRC) turns off.
The greater this time interval is, the greater the contact pressure between the
paper and the resist roller is.

(Operation/procedure)
When the simulation key operation is performed, warming-up operation is
performed. After completion of warming up, the currently set void amount is
displayed on the COPIES MADE display.
Use the tray select key to select between the lead edge void amount adjust­ment and the rear edge void amount adjustment mode. The upper tray lamp
will change as shown in the table below.

Mode Tray lamp

Lead edge void amount adjustment mode Upper tray lamp –

Read edge void amount adjustment mode
(Cassette)

Read edge void amount adjustment mode
(Manual feed)

Enter the set value with the numeral keys and press the PRINT button, and
the set value will be stored.
The standard set value is 50. The void area increases 0.123mm for an in­crease of the set value by 1.

Description

* The time interval can be set. The

greater the time interval is, the
greater the contact pressure be­tween the paper and the resist
roller is. If the contact pressure is
too great, a paper jam may occur.
If the contact pressure is too
small, variations of image position
for the copy paper becomes
greater. This must be adjusted ac­cording to the paper quality.

Light

Upper tray lamp –

Blink

Manual tray lamp –

Blink

Ref. page

7-10

8 – 3

Contents

12345

B'

B

A

A'

MAX 85V

MIN 40V (80V)

Great

Exposure

Small

Light

Copy
density

Dark

Copy lamp
application
voltage

Density display level in the operation panel

Purpose/kind Section Main

code

Sub

code

Description

Adjustment Optical unit 46 1 Used to adjust the copy density (exposure level) and the copy density gradient

(exposure gradient) in each copy mode.
The exposure level is changed by changing the copy lamp applying voltage.
The adjustment points are exposure levels "1" and "5" in each copy mode.
The copy density (exposure level) and the copy density gradient (exposure
gradient) can be adjusted arbitrarily.

(Operation/procedure)
When the simulation key operation is performed, the currently set exposure
level will be displayed on the COPIES SELECTED display.
Select exposure level "1" or "5" with the copy density adjustment key, and
enter the set value with the numeral keys and press the print button. Then the
set value is stored.
To select each copy mode, use the copy mode key.

Copy mode

Copy density level

(exposure level)

Manual copy mode Non-toner-save mode 1 5

Toner save mode 1 5

Auto copy mode Non-toner-save mode 1 5

Toner save mode 1 5

Photo copy mode Non-toner-save mode 1 5

Copy density level (exposure level (copy lamp applying voltage) to operation
panel density display level)

Ref. page

5-4

7-12

In the manual copy mode and the photo copy mode
Set point A (exposure level (copy lamp applying voltage) at copy density level
"1") and point B (exposure level (copy lamp applying voltage) at copy density
level "5"), and the exposure gradient (copy density gradient) and the exposure
level (copy density level) will be set.
A – B charact eristic: A great exposure gradient (copy density gradient).
A′ – B′ characteristic: A small exposure gradient (copy den s ity gradient).
Point A and point B can be set arbitrarily.

8 – 4

Contents

[V] 80(160) 50(100)

[V]

AE sensor
output level
(AE sensor
light receotion
amount)

Copy lamp application voltage to AE sensor
output characteristics
(When simulation 47 is performed)

Copy lamp application voltage (Exposure amount)

Copy lamp
application
voltage

AE sensor output to copy lamp application
voltage characteristics (AE copy mode)

AE sensor output level (Document density)

Dark Light

A

RRC ON

Mirror unit
scan start

Reaching the
document lead
edge posit ion

B

Purpose/kind Section Main

code

Sub

code

Description

Adjustment Optical unit 47 Used to store the characteristics of the AE sensor and the optical section for

the change in the copy lamp applying voltage. The exposure level in the auto
copy mode is automatically determined by the stored data and the document
density.
This simulation is used to correct the output characteristics of the AE sensor
output characteristics, which differ in different machines.

(Operation/procedure)
When the simulation key operation is performed, the scanner unit performs
initializing and feeds about 10cm and stops.
When the print button is pressed again, the copy lamp applying voltage chan­ges from 80V to 50V by the increment of 5V. The AE sensor output charac­teristics at that time are stored in the main PWB RAM.
At that time, the AE sensor gain is automatically adjusted.
This operation must be performed before the copy density adjustment in the
auto copy mode.

50 1 Used to adjust the copy image position on the copy paper. 7-9

(Operation/procedure)
The adjustment is performed by changing the set value A.
When the simulation key operation is performed, warming-up is performed
and the ready lamp is lighted. Then the currently set value is displayed on the
COPIES SELECTED display.

Display lamp Set value

Tray cassette paper feed lamp ON A

It is required to make a copy and adjust. However, the rough input value can
be obtained from the following formula:
Input value A = Currently set value – Shift between copy paper lead edge and
copy image (mm) ÷ 0.12

Ref. page

Developer unit 8 1 Used to check the developing bias voltage.

(Operation/procedure)
The developing bias voltage is outputted for 30 sec.

25 2 Used for initial setting of toner density when replacing developer. 4-3

8 – 5

Contents

3min

8sec

DV.Bias

M.M

500msec

Purpose/kind Section Main

code

Sub

code

Adjustment Developer unit 25 2 (Operation/procedure)

After 3 minutes from start of stirring of the DV unit after the main motor
rotation, toner density is sampled 16 times during 8 sec, and the average
value is stored as the toner density reference value in the RAM.
With this reference value as the threshold value, the toner density is control­led.

(Note) Do not perform this simulation except for when replacing the developer
with a new one.
If this simulation is performed in the other case, overtoning or undertoning
may occur, resulting in a poor copy quality.

Process 8 2 Used to check the voltage of the main charger and the transfer charger.

(Operation/procedure)
The main charger and the transfer charger unit are turned on for 30 sec in the
manual copy mode.

3 Used to check the voltage of the main charger and the transfer charger.

(Operation/procedure)
The main charger and the transfer charger unit are turned on for 30 sec in the
photo copy mode.

4 Used to check the voltage of the main charger and the transfer charger.

(Operation/procedure)
The main charger and the transfer charger unit are turned on for 30 sec in the
toner save mode.

7 Used to check the separation charger voltage.

(Operation/procedure)
The separation charger unit is turned on for 30 sec.

9 Used to check the voltage of the main charger, the transfer charger, and the

separation charger.
(Operation/procedure)

The main charger unit, the transfer charger unit, and the separation charger
unit are turned ON for 30 sec.

Setting Specifications 26 6 Used to set the destination.

(Operation/procedure)
When the simulation key operation is performed, the code number of the
currently set destination is displayed.
Enter the code number corresponding to the desired destination and press the
print button, and the specifications for the destination will be set.

Code number Destination

6 USA

Description

Ref. page

Paper feed unit 26 12 Used to set the manual paper feed mode.

There are two operation modes: auto and manual. Either of the two can be
set.

(Operation/procedure)
When the simulation key operation is performed, the code number of the
currently set operation mode is displayed.
Enter the code number corresponding to the desired operation mode and
press the print button, and the operation mode will be set.

Code number Operation mode Operation

1 Manual

0 Auto

8 – 6

When the print button is pressed,
copying is started.

When copy paper is set, coping is
automatically started.

Contents

Purpose/kind Section Main

code

Setting Fuser unit 26 13 Used to set the operation mode of the main motor in warming up.

Process 44 1 Used to set the correction modes. 5-11

Counter Copy count 22 1 Used to check the maintenance count value.

Sub

code

There are two operation modes: auto and manual. Either of the two can be
set.

(Operation/procedure)
When the simulation key operation is performed, the code number of the
currently set operation mode is displayed.
Enter the code number corresponding to the desired operation mode and
press the print button, and the operation mode will be set.

Code number Operation mode Operation

0 Normal mode

1 Long mode

43 1 Used to set the fusing temperature.

(Operation/procedure)
When the simulation key operation is performed, the lower two digits of the
currently set temperature is displayed on the COPIES SELECTED display.
(Example: 75 ——— 175 °C)
Pressing the paper select key under that state allows selection of fusing
temperature by the increment of 5 °C. To set the temperature, press the print
button. (Standard set value: 85 ——— 185°C)

2 Used to set the fusing temperature in the power save mode.

(Operation/procedure)
When the simulation key operation is performed, the lower two digits of the
currently set temperature is displayed on the COPIES SELECTED display.
Pressing the paper select key under that state allows selection of fusing
temperature by the increment of 5 °C. To set the temperature, press the print
button.
*00 → 05 → 10 → 85 → 90 → 95 *: Standard set value

(Operation/procedure)
When the simulation key operation is performed, the code number of the
currently set mode is displayed on the COPIES SELECTED display. Enter the
code number corresponding to the desired correction mode and press the
print button, and the mode will be set.

Code Correction mode

1 Charging potential selection enable
2 Optical system dirt correction enable
4 Photoconductor drum membrane wear correction enable

Set the total of codes of above modes.
Factory setting is "6."

(The count value of the installed DV unit is displayed.)
(Operation/procedure)

The maintenance count value is displayed dividedly by two digits three times
on the COPIES SELECTED display.
There is a pause between any two displays. After the longest pause, the top
two digits are displayed.

2 Used to check the set maintenance cycle (maintenance preset counter).

(Operation/procedure)
The currently set maintenance cycle value is displayed dividedly by 2 digits
three times on the COPIES SELECTED display.
There is a pause between any two displays. After the longest pause, the top
two digits are displayed.

5 Used to check the total count value.

(Operation/procedure)
The total count value is displayed dividedly by 2 digits three times on the
COPIES SELECTED display.
There is a pause between any two displays. After the longest pause, the top
two digits are displayed.

12 Used to check the drum counter value inside the installed OPC drum unit.

Description

The main motor rotates until the
process cleaning is completed.

The main motor keeps rotating
until completion of warming up.

Ref. page

8 – 7

Purpose/kind Section Main

1sec

4sec

EXP1~5 voltage

CLV

Full power

code

Operation

Paper feed unit 30 1 Used to check the operations of the sensors and detectors in the paper feed

check

Optical unit 1 1 Used to check the operation of the scanner unit and its control circuit.

Contents

Sub

code

Description

section, and their related circuits.
The operations of the sensors and the detector in the paper feed section can
be monitored by the lamps on the operation panel.

(Operation/procedure)
ON/OFF of the sensors and detectors in the paper feed section can be
monitored with the lamps on the operation panel.

Sensor name Display lamp
Paper size detector (PWD) Toner empty lamp
Resist detector (PPD) Jam lamp
Paper exit detector (POD) OPC drum lamp
Tray open/close detector (PED1) Paper feed cassette lamp
Manual paper feed detector (PID) Manual paper feed lamp

(Operation/procedure)
When the print button is pressed, scanning is performed at the speed cor­responding.
The copy magnification ratio can be set arbitrarily.

2 Used to check the operations of the sensors and detectors in the optical unit

and their related circuits.
(Operation/procedure)

ON/OFF of the sensors and detectors in the optical unit can be monitored with
the lamps on the operation panel.

Sensor name Display lamp

Mirror home position sensor (MHPS) OPC drum lamp

Ref. page

3-3

3-2

5 3 Used to check the operation of the copy lamp and its control circuit.

(Operation/procedure)
The copy lamp lights up for first one sec at full power, and lights for 4 sec at
the currently set exposer level (copy density).

Operation unit 5 1 Used to check the operations of the lamps on the operations panel and their

control circuits.
(Operation/procedure)

All display lamps on the operation panel turns on for 5 sec.

Fuser unit 5 2 Used to check the operation of the heater lamp and its control circuit.

(Operation/procedure)
The heater lamp turns on for 500ms, and off for 500ms five times repeatedly.

Process 5 4 Used to check the operation of the discharge lamp and its control circuit.

(Operation/procedure)
The discharge lamp lights up for 30 sec.

5 Used to check the operation of the blank lamp and its control circuit.

(Operation/procedure)
The blank lamps lights up sequentially from the rear frame side to the front
frame side, and all the lamps light up for 10 sec.

Operation
check

6 2 Used to check the operation of the OPC separation pawl solenoid and its

control circuit.
(Operation/procedure)

The OPC separation pawl solenoid repeats 0.5 sec ON and 0.5 sec OFF
twenty times.

8 – 8

Purpose/kind Section Main

code

Operation
check

Trouble code
resets

Process 44 2 Used to display the reference value of the optical system dirt correction.

Developer unit 10 Used to check the operation of the toner motor and its control circuit.

25 1 Used to check the operation of the sections other than the optical unit and to

14 Used to cancel troubles other than self diag U2 trouble code.

16 Used to cancel the self diag U2 trouble code.

Contents

Sub

code

This value affects the process correction system. For details, refer to the
descriptions on the process correction system.

3 Used to display the reference value of the optical system dirt correction. 5-11

(Operation/procedure)
When the simulation key operation is performed, the current correction
amount is displayed in hexadecimal number on the COPIES SELECTED dis­play.
The decimal number converted from the hexadecimal number shows the ac­tually corrected copy lamp voltage.
Example --- 1d] : 2.9V correction

4 Used to display rotating time of the photoconductor drum.

This value affects the process correction system. For details, refer to the
descriptions on the process correction system.

(Operation/procedure)
When the simulation key operation is performed, the current rotating time of
the photoconductor drum is displayed in the unit of minute on the COPIES
SELECTED display.

(Operation/procedure)
The toner motor turns on for 30 sec.

check the operation of the toner density sensor.
(Operation/procedure)

The main motor rotates and the units connected to the main motor operate
accordingly. The output level of the toner density sensor is displayed on the
COPIES SELECTED display.

(Operation/procedure)
After cancellation of the trouble code, the simulation is also automatically
cancelled.

(Operation/procedure)
After cancellation of the trouble code, the simulation is also automatically
cancelled.

Description

Ref. page

5-4

5-11

5-11

8 – 9

6. User simulation

User simulation allows the user to change or cancel the factory set­tings easily according to his or her desirable operating environment
on the following functions.

(1) Functions which can be reset or canceled by

User simulation.

Auto clear function: Time for returnign to the standard state can

Pre-heating function
(Power saving):

Stream feeding mode: When set to this mode, the document feed

(2) User simulation procedure

Simulation procedure State

1. Pres s the paper feed s ection select
key for more than 5 sec.

2. Enter a code number with 10 key. Simulation code selection.

3. Press the COPY button. Simulation code determined.

4. Enter the selection code with 10 key. Simulation code menu selection.

5. Press the COPY button. Simulation code menu determined.

6. Pres s the paper feed s ection select
key.

* Press the clear key.

( : Blink)

be changed or canceled. (Standard state:
copy quantity "0," 100% AE mode)

Time to enter the pre-heat mode and the auto
power shut-off mode can be changed or can­celed. (Refer to [1]-4 New functions, page 1-

1.)

lamp blinks for about 5 sec after copying with
the SPF. If a document is set again, copying
is started automatically.

User simulation input allowed.

Escape from user simulation.

• When this key is pressed during user

simulation selection, the mode returns to
state 1 (user simulation input allowed.)
(Use this key to correct mistyping of input.)

• After completion of program setting, when

this key is pressed, the mode the following
program input can be made.

Paper jam/

photoconductor/

toner supply

warning LED

Blink OFF

Blink ON

Blink ON

Blink ON

Blink OFF

OFF

Blink OFF

Copy quantity

display

1

11

21

21

Returns to
copy quantity
display.

Print LED

—

(3) User simulation code table

Program Sim code

Auto clear time
setting

Pre-heat mode
setting and time
setting

1

2

Selection code:

setting content

0: OFF
1: 30 sec.
2: 60 sec.
3: 90 sec.
4: 120 sec.

0: OFF
1: 30 sec.
2: 60 sec.
3: 90 sec.
4: 120 sec.

Factory

setting

F

F

8 – 10

Program Sim code

Auto shut-off mode
setting and time
setting

Stream feeding
mode setting and
time setting
(* Machines with
SPF installed only.)

3

4

Selection code:

setting content

0: OFF
1: 2 min.
2: 3 min.
3: 5 min.
4: 10 min.
5: 15 min.

0: ON
1: OFF F

Factory

setting

F

[9] SELF DIAG

1. Summary/purpose

This model has the self diag function for the following purposes:

1) When a trouble occurs in the machine, the machine detects the
trouble and displays the trouble content on the copy quantity dis­play to alert the customer and the serviceman.

2) When any abnormality is detected, the power supply line is cut off
immediately for safety and to protect the machine from damage.

2. Operation

The self diag content is displayed in the following procedure.

A trouble occurs

The abnormalality is detected
by sensors and detectors

The main trouble code is
displayed on the copy
quantity display

YES

Is there

sub code?

NO

Check the trouble position
(Use the suitable simulation)

Repair

Turn off/on the power or
cancel the self diag with
simulation 14 or 16

Press the print key

The sub trouble code
is displayed on the copy
quantity display

3. Clearing the self diag display

After repairing the trouble section, clear the self diag display accord­ing to the table below:
Clearing the self diag display

Self diag display Display clearing procedure

L1, L3, L4, L8, F2 Turn off/on the power.

H3, H4 Execute simulation 14.

U2 Execute simulation 16.

CH, PC

When the trouble is cancelled,, the display is
cleared.

9 – 1

4. Self diag contents

Error code

Main Sub

L1 0 Content Scanner feed trouble 8-8

L3 0 Content Scanner return trouble 8-8

L4 1 Content Main motor lock trouble

Item Description Ref. page

Detail 1) 86 pulses (45 mm) of the scanner motor drive pulse have been outputted after the

scanner unit started scanning, but the scanner home position sensor (MHPS) does not
turn off.

2) The scanner unit is not at its home position (MHPS does not turn on) when the scanner
unit starts scanning.

3) The scanner home position sensor (MHPS) does not turn on when the scanner
performs the initial operation.

Cause 1) Scanner motor trouble

2) Scanner motor control circuit trouble

3) Scanner motor rotati on sensor and its control cir cuit trouble

4) Sc anner home po sition se nsor (MH PS)and its inpu t circuit trouble (main cont rol circ uit
trouble)

5) Scanner unit drive mechani s m trouble

6) An overload to the drive section

Remedy Use simulations 1-1 and 1-2 to check the following:

A. Check the mirror motor control circuit and its peripheral sections.

1) The scanner unit operates normall y .

2) The scann er home pos iti on se nsor (( MHPS) oper ates n ormal ly an d i ts ou tpu t sig na l is
inputted to the main control PWB.

3) The scanner m otor dri v e signal is outpu tt ed.

4) The scanner motor rotation sensor signal is inputted to the control circuit.

B. Check the scanner unit drive mechanism.

1) Drive wire

2) Pulley

3) Gear

After repair, turn off/on the power switch.

Detail 1) The scanner motor drive pulses required for the scanner unit to return are shifted more

than 50 pulses for the drive pulses required for feeding. (The corresponding distance is
10mm or more.)

2) The scanner motor drive pulses required for the scanner unit to return are within 50
pulses for the drive pulses req uired to feed.

3) The scanner unit does not return. Or through it returns, the scanner unit does not
return to its home position (the MHPS does not turn on).
(Though the scanner motor drive pulses required to return are 50 pulses greater than
the drive pulses required for the scanner unit to feed, the scanner unit is not in the
home position (the MHPS does not turn on).

4) After the scanner unit returns, the MHPS does not turn on.

Cause 1) Scanner motor trouble

2) Scanner motor control circuit trouble

3) Scanner motor rotati on sensor and its peripheral sections troub le

4) Scanner home position sensor (MHPS) and its input circuit trouble

5) Scanner unit drive mechani s m trouble

6) Overload at the scanner motor drive section

Remedy Use simulation 1-1 and 1-2 to check the following:

A. Check the mirror motor control circuit and its peripheral.

1) The scanner unit operates normall y .

2) The scanner home position sensor (MHPS) operates normally and its output signal is
inputted to the main control circuit.

3) The scanner m otor dri v e signal is inputted.

4) The scanner motor rotation sensor signal is inputted to the control circuit.

B. Check the scanner unit drive mechanism.

1) Drive wire

2) Pulley

3) Gear

After repair, turn off/on the power switch.

9 – 2

Error code

Main Sub

L4 1 Detail The rotary encoder signal cannot be detected for more than 1s during delivery of the main

L8 1 Content Power frequency abnormality

3 Content During execution of simulation 47, the AE sensor output does not change according to

H2 0 Content Fuser section thermistor trouble

H3 0 Content Abnormally high temperature in the fuse section 8-11

H4 0 Content An abnormally high temperature in the fuse section 8-11

Item Description Ref. page

motor On signal output.

Cause 1) Main moor trouble

2) Main control circuit trouble

3) Main motor rotation sensor and its input circuit (main control circuit) trouble

4) Main motor drive mechanism trouble

5) An overload on the main motor drive section

Remedy Check the following items:

A. Check the main motor control circuit and its peripheral sections.

1) Main moto r drive signal is inputted .

2) The main motor rotation sensor signal is inputted to the control circuit.

B. Check the main motor drive mechanism.

1) Drive wire

2) Pulley

3) Gear

After repair, turn off/on the power switch.

Detail The power frequency is shifted from the specified level by 15% or more for 10 cycles or

more, or the FW signal cannot be detected for more than 5 sec.

Cause 1) FW is not outputted o r the output waveform is abnormal.

2) Power circuit trouble (AC power unit/DC power unit)

3) FW input circuit trouble (m ain control circuit)

4) AC power tr ou ble (wa veform/voltag e)

Remedy Check the waveforms of the following units with an oscilloscope.

1) FW signal waveform in the DC power unit

2) FW signal waveform in the main control circuit

3) AC power line

After repair, turn OFF/ON the power switch.

change in the copy lamp voltage.
Detail AE sensor trouble
Cause 1) AE sensor or its in put circuit (main control PWB) trouble

2) Cop y lamp control circuit trouble (copy lamp con tr ol sign al abnormality)

3) A white paper is not set on the document table or the document table or the document
cover is dirty.

Remedy Check the following items:

1) AE sensor or its input circ uit

2) Cop y lamp control circuit (copy lamp cont rol signal)

After repair, turn off/on the power switch.

Detail The voltage across the thermistor input circuit remains 4.6V or more.
Cause 1) Thermistor and its inp ut circuit (main control PWB) trouble (disconnection)
Remedy Check the thermistor and its input circuit (main control circuit) for disconnection.

AFter repair, used simulations 14 to cancel the self diag.

Detail The voltage across the thermistor input circuit remains 1.39V or less. (A high temperature

above 241 C is detected.)

CAuse 1) Thermistor and its input circuit (main control PWB) trouble (disconnection)

2) Heater lamp control signal an d its control circuit tro uble

(The heater lamp remains ON.)

Remedy Check the following items:

1) Ther mistor and its input circuit (main control PWB) disconnect ion

2) Heater lamp control signal an d its control circuit

After repair, use simulations 14 to cancel the self diag.

Detail 1) T he voltage across the thermistor input circuit remain 3.39V or more. (A temperature

below 148°C is detected.)

2) The tempe rat ure doe s n ot re ach the sp ecifi ed t em perat ure wi thi n 60 sec af ter start ing
warming up.

Cause 1) Thermistor and its inp ut circuit (main control circuit) trouble (disconnection)

2) Heater lamp trouble

8-5

9 – 3

Error code

Main Sub

H4 0 Cause 3) Heater lamp control signal and its control circuit trouble (The heater lamp remains ON.)

U2 1 Content In the main PWB EEPROM data sum check, the data do not correspond to the CPU data.

4 Content memory line communication trouble

F2 3 CRU type error
U2 4 Remedy Check the following items:

EE EU Content Toner density initial setting trouble (undertoner) 8-5

EL Content Toner density initial setting trouble (overtoner) 8-5

Item Description Ref. page

Remedy Check the following items:

1) Che c k the ther m istor and its input circuit (main control PWB) for disconnection or shot.

2) Heater lamp control signal an d its control circuit

3) Heater lamp

After repair, use simulations 14 to cancel the self diag.

Cause 1) Main PWB EEPROM trouble

2) Main control circuit trouble

3) Communication line trouble between the main PWB EEPROM and the CPU

4) CPU trouble

5) Data bus line trouble

Remedy Check the following items:

1) main PWB EEPROM

2) Memory control circuit

3) Communication line between main PWB EEPROM and CPU

4) CPU

5) Data bus line

After repair, use simulations 16 to cancel the self diag.
When the power is turned on, data in the main PWB EEPROM are transferred to the CPU

to perform sum check. The operation can be checked at that time.

Detail 1) I n access to the main PWB EEPROM, the re spond command ACK is not inputted to

the CPU.

2) When writing da ta in to th e main PWB EEPROM, the writ e e nabl e s igna l is n ot input ted
to the CPU for 11ms or more.

Cause 1) Main EEPROM RAM trouble

2) Memory control circuit trouble

3) Communication line trouble between main PWB and C PU

4) CPU trouble

5) Data bus line trouble

1) Main PWB EEPROM

2) Memory control circuit

3) Communication line between main PWB EEPROM and CPU

4) CPU

5) Data bus line

After repair, use simulation 16 to cancel the self diag
When the power is turned on, data communication is performed with the main PWB

EEPROM and the CPU. The operation can be checked at that time.

Detail When setting the toner density initial level with simulation 25-2, the toner density sensor

output is below the specified voltage (1.53V).

Cause 1) Toner sensor trouble

2) Toner sens or input circuit trouble (main con trol PWB )

Remedy Use simulations 25-2 to check the following items:

1) Toner sensor

2) Toner sens or input circuit

After repair, use simulations 14 to cancel the self diag.

Detail When setting the toner density initial level with simulation 25-2, the toner density sensor

output is above the specified voltage (3.49V).

Cause 1) Toner sensor trouble

2) Toner sens or input circuit trouble (main con trol circuit)

3) Toner motor and its control circuit trouble

Remedy Use simulations 25-2 to check the following items:

1) Toner sensor

2) Toner sensor input circuit

3) Toner motor and its control circuit

After repair, use simulations 14 to cancel the self diag.

9 – 4

Error code

Main Sub

CH Light Content Manual paper feed unit installation trouble (MFD0, MFD1)

Blink Content Developer detection trouble 8-5

PC Content Personal counter installation trouble

Paper
empty

Toner empty Light Content Toner supply trouble 8-9

Toner empty Blin Content Toner density fall 8-9

Item Description Ref. page

Detail 1) The manual paper feed unit signal (CSDSW) and its control circuit remains MFD0 level

and MFD1 level.

Cause 1) The manual paper feed unit signal (MFD1) line is not connected or disconnection in the

line. (The manual paper feed unit is not installed.)

Remedy Check the following item:

1) Manual paper feed unit signal (MFD1) line

Detail 1) The toner density sensor input (main PWB) voltage is below 0.5V.
Cause 1) Toner density s ensor and its input circuit (main PWB) trouble

2) Developer seal is not removed.

Remedy Use simulation 25-2 to check the following items:

1) Toner dens ity sensor and its control circuit (main PWB)

2) Developer seal

Content Drum cartridge installation trouble
Detail The drum cartridge is not installed.
Cause
Remedy Install the drum cartridge

Detail The personal counter is not installed in the personal counter mode.

The input circuit of the personal counter installation detect signal does not turn HIGH level.

Cause 1) Personal counter trouble

2) Personal counter in stallati on detec ting signal input ci rcuit (main PWB ) trouble

3) Personal counter wiring

Remedy Check the following items:

1) Personal counter

2) Personal counter installation detecting signal input circuit (main PWB)

3) Personal counter wiring

Content Paper tray open/no copy paper 8-8
Detail 1) The selected paper tray is removed.

2) There is no paper in the selected paper tray.

Cause 1) The selected paper tray is removed.

2) There is no paper in the selected paper tray.

3) The select ed paper tray detector (PED 1) and its input c ircuit ( m ain PWB) trouble

4) The select ed paper tray pape r empty detector (PED1) an d its inpu t circuit (main PWB)

Remedy Check the following items:

1) The select ed paper tray pape r empty detector (PED1) an d its inpu t circuit (main PWB)

Detail 1) No toner in the toner box

2) Toner supp ly troub le

Cause 1) No toner in the toner box

2) Toner motor and its control circuit (main PWB) trouble

3) Toner supply secti on clogging

4) Toner sensor and its i nput circuit (mai n PWB) trouble

Remedy Use simulation 25-2 to check the following items:

1) Toner box

2) Toner motor and its control circuit (main PWB)

3) Toner supply secti on

4) Toner sens or and its control circuit (main PWB)

Detail 1) No toner in the toner box

2) Toner dens ity fall s below the specified level.

Cause 1) No toner in the toner box

2) Toner motor and its control circuit (main PWB) trouble

3) Toner supply secti on clogging

4) Toner sensor and its i nput circuit (mai n PWB) trouble

Remedy Check the following items:

1) Toner box

2) Toner motor nd its control circuit (main PWB)

3) Toner supply secti on

4) Toner sensor and its i nput circuit (mai n PWB)

9 – 5

Error code

Main Sub

Item Description Ref. page

JAM Content Copy paper misfeed trouble 8-3

Detail 1) Misfeed of copy paper occurs in the copy paper f eed section, the transfe r section, the

transport section, or the fuse section.

Cause 1) The copy paper dete ctor in each section remains ON or OFF.

2) The copy paper detector in each section and its input circuit (main PWB) trouble

3) The co py pa per feed and tr an sport clutches in each section an d its control cir cu it ( m ain
PWB) trouble

4) Paper feed roller and transport roller trouble

5) Copy paper fed and tra nsport drive mechanism trouble (motor, ge ar, etc.)

6) Insufficient or excessive contact pressure betwee n copy paper and the resist r oller
because of improper setting with simulation 51-2.

Remedy Check the following items:

1) Copy paper detector in each section

2) Cop y paper detector and its input circuit (main PWB) in each section

3) Cop y paper feed and tran sport clut ches and t heir control circuit (main PWB) tr ouble

4) Paper feed roller, transport roller

5) Copy paper feed and tr ansport drive mec hanisms trouble (motor, gear, etc.)

6) Set value of simulation 51-2

OPC drum

replacement

Light Content OPC drum replacement timing alarm 8-9

Detail OPC drum replacement after copying 2,000 sheets.

Blink Content OPC drum replacement

Detail OPC drum replacement timing is reached.
Cause The OPC drum unit counter exceeds the specified copy quantity (40K).

(Note) The OPC drum counters are in the main PWB RAM and in the OPC drum. The two
counters normally coincide each other. If there is any discrepancy between them, the data
in the EEPROM in the OPC drum takes priority.

Remedy Replace the OPC drum unit.

5. Conditions for the JAM display

1) Paper feed section

(1) The JAM lamp lights up if 3 PPD does not turn on within about

1.5 sec after G CPFC1 ON.

(2) The Jam lamp lights up if 3 PPD does not turn on within about

1.0 sec after 9 MPFC ON.

2

1

2) Transport section

(1) The JAM lamp lights up if 3 PPD does not turn off within about

3.2 sec after 8 RRC ON.

(2) The JAM lamp lights up if 1 POD does not turn off within about

2.8 sec after 3 PPD ON.

(3) The JAM lamp lights up if 1 POD does not turn on within about

2.4 sec after 8 RRC ON.

7 8

3
4

5

9

10

11

12

9 – 6

[10] SERVICING A T MEMORY

TROUBLE AND MAIN
CONTROL PWB REPLACEMENT

1. General

The EEPROM in the control PWB and the EEPROM in the OPC drum
unit are storing various set values, adjustment values, and counter
values.
These data are very important and used for operating the machine
properly and for service control.
In the following cases, therefore, various set values, adjustment
values and counter values must be set again.

When a memory trouble (U2) occurs.

@

When the EEPROM in the main control PWB is replaced.

@

When the EEPROM in the OPC drum unit is replaced.

@

When the main control PWB is replaced.

@

When "U2" trouble occurs, the data cannot be relied upon, and they
must be set properly.

2. Purpose

Memory trouble

Procedures for memory trouble, main control PWB replacement,
and main control PWB EEPROM replacement

"U2" troub l e

occurs

NO

Repair the

defective section

Do you replace

the main control

PWB?

YES

Replace the main

control PWB

Cancel "U2" trouble

with simulation 16

1

The purpose is to reset the memory data to operate the machine
properly.
Use the attached service memory data recording sheet to memorize
the newest data when servicing in order to cope with the above
situations. This improves efficiency in servicing and realizes quick
recovery.

3. Remedies

Perform the procedures according to the following flowcharts.
"Sim" in the flowchart means "Simulation."

Replace the main

control PWB

Is the

EEPROM in
the main control
PWB defective?

Replace the main

control PWB

1

YES

Replace the

EEPROM in the

main control PWB

NO

Mount the EEPROM of

the old main control to

the new main control

End

Replace the EEPROM

10 – 1

1

2'

Is the toner

density reference value

recorded?

NO

YES

Use Sim 43-1 to set the
fusing temperature

Use Sim 26-13 to set the
operation mode in warm-up

Is the copy

densi ty adjus tment

value re c or ded?

NO

YES

Use Sim 46-1 to set the copy
density adjustment value

Is the adjustment

value of contact pressur

between the main body resist

roller and the copy paper

recorded?

NO

YES

Use Sim 51-2 to set the adjustment
value of contact pressure between
the main body resist roller and the
copy paper

Use Sim 25-2 to set the
toner de ns ity r eferenc e value

Make a copy and
adjust the copy
density

Make a c o py and adjust the
contac t pressure between
the main body res i st rol le r
and the copy paper

Are the image

lead edge position

adjustment value and

the resist roller ON

timing adjustment value

recorded?

NO

YES

Use S im 50- 1 t o s e t the image lead edge

position adjus tment value and the resist

roller ON timing adj ustment value

Is the void

amount adjustmant

value rec o rd ed?

NO

YES

Use S im 45 to set t he void amount
adjustm ent value

End

Make a copy and adjust the
im age lead efge position and the
resist roller ON timing

Make a c o py and adjust the
void amount

2

10 – 2

4. Set value recording sheet

Purpose/kind Section

Adjustment Paper feed section 51 2 Adjustment value of contact pressure of the paper on the main

Optical unit 45 Adjustment value of copy paper lead edge void amount

SPF unit 51 7 The adjustment value of the contact pressure between the SPF

Setting Specifications 26 6 Destination specifications

Fuser unit 26 13 Setting of the main motor operation mode in warming up

Memorize set values in the column of "Set value" for efficient servicing when the memory trouble occurs and the EEPROm is replaced.
Make a copy of this sheet and use with the service sheet.

Main code Sub code Set value Description

46 1 Adjustment value of copy density (exposure level) in each copy

47 The AE sensor and the optical section characteristics memory

50 1 The adjustment value of copy image position on the copy

43 1 The set value of fusing temperature

Contents

body resist roller

mode and of copy density gradient (exposure gradient)
Manual copy mode density level 1 (Not toner save mode)
Manual copy mode density level 5 (Not toner save mode)
Manual copy mode density level 1 (Toner save mode)
Manual copy mode density level 5 (Toner save mode)
Auto copy mode density level 1 (Not toner save mode)
Auto copy mode density level 5 (Not toner save mode)
Auto copy mode density level 1 (Toner save mode)
Auto copy mode density level 5 (Toner save mode)
Photo copy mode density level 1 (Not toner save mode)
Photo copy mode density level 5 (Not toner save mode)

data for the change in the copy lamp application voltage

paper
SEt value A

resist roller and the document

10 – 3

5. Memory simulation list

Contents

Purpose/kind Section

Adjustment Paper feed

section
Optical unit 45 50 Adjustment value of copy paper lead edge void amount

Developer unit 25 2 Toner density initial set value

Setting Specifications 26 6 Specifications setting by destination

Main
code

51 2 50 Adjustment value of contact pressure of the paper on the main

46 1 Adjustment value of copy density (exposure level) in each copy

47 The AE sensor and the optical section characteristics memory data

50 1 The adjustment value of copy image position on the copy paper

Sub

code

Default

value

body resist roller

mode and of copy density gradient (exposure gradient)
Manual copy mode density level 1 (Not toner save mode)
Manual copy mode density level 5 (Not toner save mode)
Manual copy mode density level 1 (Toner save mode)
Manual copy mode density level 5 (Toner save mode)
Auto copy mode density level 1 (Not toner save mode)
Auto copy mode density level 5 (Not toner save mode)
Auto copy mode density level 1 (Toner save mode)
Auto copy mode density level 5 (Toner save mode)
Photo copy mode density level 1 (Not toner save mode)
Photo copy mode density level 5 (Not toner save mode)

for the change in the copy lamp application voltage

50 Set value A

Description

Ref. page

Code No. Destination

6 U.S.A.

Fuser unit 26 13 0 Setting of the main motor operation mode in warming up.

Code

43 1 185°C Fusing temperature set value

Counter Developer unit 22 6 Used to confirm the developer counter value of the installed

developer unit.

7 Used to confirm the developer replacement cycle of the installed

developer unit.

OPC drum
unit

Total counter 22 5 Used to confirm the total counter value.

Trouble
cancel

22 10 Used to confirm the drum counter value in the installed OPC drum

unit.

11 Used to confirm the drum replacement cycle in the installed OPC

drum unit.

14 Used to cancel troubles other than self diag "U2".

After cancellation of the trouble, the simulation is also cancelled
automatically.

16 Used to cancel self diag "U2" trouble.

After cancellation of the trouble, the simulation is also cancelled
automatically.

No.

0

1

Operation

mode

Normal

mode

Long

mode

Operation

When the fusing temperature reaches
the specified level, the main motor stops.

The main motor keeps rotating until the
completion of the warming up.

10 – 4

[11] MAINTENANCE

▲ Replacement/installation F Cleaning by the user

Content

Developer Developer (New two-component

developing system)
Toner supply Replacement at every 4K by the user
DV seal Servicing by the service call

Drum Drum

main charger (Case, saw teeth)

Screen grid
Drum separation pawl
Cleaning blade
Toner reception seal Replace whole unit at every 40K by the user

Transfer Transfer charger wire

Separation plate (Half-etching)
Transfer charger case Replace whole unit at every 40K by the user

Fusing Fuser lower CL roller

Fuser upper heat roller
Fuser bearing
Fuser gears
Fuser lower heat roller
Thermistor
Fuser upper separation pawl
Fuser lower separation pawl

Optical Mirror, lens, reflector

Sensors
Drive wire, pulley
Mirror base rail
Glass, OC matt FFFFFF

Transport Manual paper feed section roller

Cassette paper feed section roller

Paper transport roller in each section

Suction belt (Only for the specified
destination)

Paper transport section paper guide

Other Gear section (Driving)

Blank lamp. descharge lamp
Ozone filter
Picture quality

CRU specifications

40K 80K 120K 160K 200K 240K

Replace at the same time as toner supply by small quantity.

(No periodic replacement)

▲▲▲▲▲▲

▲▲▲▲▲▲

Servicing by the service call

Servicing by the service call

Servicing by the service call

Servicing by the service call

11 – 1

[12] ELECTRICAL SECTION

1. System block dia gr am

+30V

2

1 3 6

7

2 3 1 3 2 2 33 2 2

LM

Personal

counter

LHPS

2

AE PWB

MIR.M

MHPS

BL PWB DL PWB

Main circuit PWB

MFD1 MFD0 DV UNIT

CPU/memo ry /driver

Operation PWB

1

AC power

3 6

Interlock

switch

HL CL

AC circuit PWB

Power

trans

DC power supply circuit

6

Main switch

Dry heater

CRU PWB

4

+32V
+24V

2

+5V1

3

+5V2

4

FW

5

GND

6

BIAS

SHV

MHV

THV

GRID

6

SPFM

SDH PWB

Main motor

4

Lower unit PWB

31 6

High voltage
circuit PWB

1 6

PWB

3RE PWB 6

SPFD

SPM

SPFC
SRRC
SPPD

SDSW

SPOD

TRC

1

MM

VFM

CFM

RRC

TM

PSPS

POD
MPFS
MPFC

LUM

CPFC1

PWD

PPD
LUPD

CPED1

CPED2
CSDSW
CSPPD

CPED2

3

7

2
2
3
6
3
2

2

2

2

2

2
3
2
2

2

2
3
3
3
3
2
3
3
3

2. System oper ati on at power ON

Power ON

Initial satting

Memory transfer

Trouble

NO

JAM

NO

Door open

NO

Warm up

Warm up complete

Racing

Racing com plete

RPL ON

PSW ON

RPL ON

Copy cycle

Copy end

• Heater lamp ON

• Mirror initializa tion

• Toner density control

12 – 1

3. Main circuit

(1) Block diagram

Lower unit

control

Toner m otor

CPU
RAM

+32V +24V

Q101

IC109

DC power section

Operation panel

IC105

RAM

IC103

+5V1 +5V2

IC101

Multi bypas s detec tion paper
trans port se nsor
Mirror home pos ition s e nsor
Paper ex it sensor

FW GND

Q102 Q103 Q109

CPU

IC110

IC113

+5V2 FW

IC112

Ventilation fan
Cooling fan

Thermistor
Toner sensor
Developer color detection
Main P WB destinati on detec tion

IC112

IC111

Heat er lamp
Copy lamp
Power relay

Q110 Q111

Q108

IC112

Thermistor

Q107

FW

Blank lam p
Discharge lamp

Q106

Q105

Driver

(Invertor)

IC102
IC104
IC105
IC108

Driver
IC107

IC111

Counter

Transport clutch
Separation solenoid
Mul ti by pass paper
feed clutch solenoid

Main motor

control

New developer
detection

External interface

Mirror motor

AE sensor

(2) CPU (IC110) M37702

1 Outline

The M37702M2-XXXFP is a 16-bit, single-chip microprocessor which
employs the high performance silicon gate CMOS process, and it is
packed in 80-pin plastic mold flat package. The single chip
microprocessor is equipped with a big address space of 16MB, the
command cue buffer to execute commands at high speeds, and the
data buffer. The CPU is of 16 bit parallel process, and allows selec­tion of 8 bit parallel process mode if necessary.

2 Pin arrangement

80 P71/AN1

79 P72/AN2

1P70/AN0
2P67/TB2IN
3P66/TB1IN
4P65/TB0IN
5P64/INT2
6P63/INT1
7P62/INT0
8P61/TA4IN

9P60/TA4OUT
10P57/TA3IN
11P56/TA3OUT
12P55/TA2IN
13P54/TA2OUT
14P53/TA1OUT
15P52/TA1IN
16P51/TA0OUT
17P50/TA0IN
18P47
19P46
20P45
21P44

P42/Φ1

22P43
23
24P41/RDY

25P40/HOLD

26BYTE

78 P73/AN3

77 P74/AN4

76 P75/AN5

75 P76/AN6

74 P77/AN7/ADTRG

73 VSS

72 AVSS

71 VREF

70 AVCC

69 VCC

68 P80/CTS0/RTS0

67 P81/CLK0

66 P82/RXD0

65 P83/TXD0

64 P84/CTS1/RTS1
63 P85/CLK1
62 P86/RXD1
61 P87/TXD1

38P26/A22/D6

39P25/A21/D5

40P24/A20/D4

60 P00/A0
59 P01/A1
58 P02/A2
57 P03/A3
56 P04/A4
55 P05/A5
54 P06/A6
53 P07/A7
52 P10/A8/D8
51 P11/A9/D9
50 P12/A10/D10
49 P13/A11/D11
48 P14/A12/D12
47 P15/A13/D13
46 P16/A14/D14
45 P17/A15/D15
44 P20/A16/D0
43 P21/A17/D1
42 P22/A18/D2
41 P23/A19/D3

M37702M2-XXXFP

27CNVSS

28RESET

29XIN

30XOUT

31E

32VSS

33P33/HLDA

34P32/ALE

35P31/BHE

36P30/R/W

37P27/A23/D7

12 – 2

3 Block diagram

26

BYTE

Data buffer D BH (8)

Data buffer D BL (8)

Data bus (Even)

Data bus (Odd)

(5V)

(0V)

(0V)

(0V)

(5V)

VREF

AVCC

AVSS

CNVSS

VSS

VCC

71

Command cue buffer Q0 (8)

Command cue buffer Q1 (8)

Command regist er (8)

70

Command cue buffer Q2 (8)

Address bus

Incrementor (24)

72

Program address register PA (24)

Data address register DA (24)

Incrementor/decrementor (24)

Program counter PC (16)

73 27
32

Program bank register PG (8)

A-D convertor

Data bank register DT (8)

69

Input buffer register IB (16)

UART1 (9)

UART0 (9)

P4 (8 ) P3 (8) P2 (8) P1 (8) P0 (8)

Processor status register PS (11)

Direct page register DPR (16)

28

RESET

Stack pointer S (16)

Monitor ti me r

Timer TB2 (16)

Timer TB1 (16)

Timer TB0 (16)

Index register Y (16)

Index register X (16)

Accumulator B (16)

Timer TA4 (16)

Timer TA3 (16)

Timer TA2 (16)

Timer TA1 (16)

Timer TA0 (16)

Accumulator A (16)

E

31

RAM

30

XOUT

512K byte

Arithmetic logic unit (16)

Clock generating circuit

29

XIN

Clock input Clock output Enable output Reset input Reference voltage input Bus width select input

ROM

16K byte

P8 (8) P7 (8) P6 (8) P5 (8)

I/O port P8 I/O port P7 I/O port P6 I/O port P5 I/O port P4 I/O port P3 I/O port P2 I/O port P1 I/O port P0

61 62 63 64 65 66 67 68 74 75 76 77 78 79 80 1 2 3456789 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 5233 34 35 36 53 54 55 56 57 58 59 60

12 – 3

4 CPU: M37702 (IC110) pin signals

Pin No. Port Signal name IN/OUT H/L Description

1 P70 AES IN Analog input signal (AE sensor)
2 P67 IN1 IN Lower unit serial parallel IC input 2 port
3 P66 IN0 IN Lower unit serial parallel IC input 2 port
4 P65 MMRE IN Main motor timer input
5 P64 FWS IN Power zero cross pulse detection signal
6 P63 MHPS IN H Mirror home position detecting signal ("HIGH at Home position)
7 P62 AEG2 OUT AE gain select signal
8 P61 AEG1 IN/OUT AE gain select signal

9 P60 SMPWM IN/OUT H Transport motor timer output clock
10 P57 AEG0 OUT AE gain select signal
11 P56 CLPWM OUT H Copy lamp control signal
12 P55 HL OUT H Heater lamp control signal
13 P54 MMPWM OUT H Main motor timer output clock
14 P53 PR OUT H Power relay control signal
15 P52 BLPWM OUT Blank lamp control signal
16 P51 PSPS OUT H Paper separation solenoid control signal
17 P50 DL OUT H Discharge lamp control signal
18 P47 SCLK OUT Data output clock signal to EEPROM
19 P46 SDAT IN/OUT — Serial data I/O to EEPROM
20 P45 — — — (NC)
21 P44 IMP IN — (NC)
22 P43 — — — (NC)
23 P42 VFM OUT H Ventilation fan motor control signal
24 P41 CFM OUT H Optical system cooling fan motor control signal
25 P40 POD OUT H Paper exit detecting sinal
26 BYTE BYTE IN External data bus select signal ("L" = 16 bit, "H" = 8 bit)
27 CNVss CNVSS IN H Processor mode selection
28 RESET RESET IN L Reset signal (Reset at "L")
29 XIN XIN IN Clock IN
30 XOUT XOUT OUT Clock OUT
31 E E OUT Enable output
32 Vss Vss OUT Power (GND)
33 P33 PNC OUT Personal counter clock
34 P32 TRC OUT H Transport roller clutch
35 P31 DVCUT OUT H Developer fuse cut
36 P30 DVF IN L Developer fuse (Not use)
37 P27 TMb OUT H Toner supply motor drive signal
38 P26 TMa OUT H Toner supply motor drive signal
39 P25 — — — (NC)
40 P24 — — — (NC)
41 P23 — — — (NC)
42 P22 — — — (NC)
43 P21 MPFC OUT H Multi paper feed clutch control signal
44 P20 MPFS OUT H Multi paper feed solenoid control signal
45 P17 MFD1 IN Single/multi input 1 L
46 P16 MFD0 IN Single/multi input 2 H L L H
47 P15 MRPS OUT H
48 P14 MRMT0 OUT H Mirror motor drive signal A
49 P13 MRMT1 OUT H Mirror motor drive signal B
50 P12 MRMT2 OUT H Mirror motor drive signal –A
51 P11 MRMT3 OUT H Mirror motor drive signal –B
52 P10 SRPL OUT H SDF lamp
53 P07 SRRC OUT H Resist roller clutch drive signal
54 P06 SPFC OUT H Paper feed roller clutch drive signal
55 P05 SME OUT Transport motor ON/OFF control signal

Not set

H

Single paper
present

L

Multi

H

Single paper
exhaust

12 – 4

Pin No. Port Signal name IN/OUT H/L Description

56 P04 SMG OUT H Transport motor gain signal
57 P03 SPPD IN H Paper entry detecting signal
58 P02 KEY3 IN L Operation PWB key input signal
59 P01 KEY1 IN L Operation PWB key input signal
60 P00 KEY0 IN L Operation PWB key input signal
61 P87 OP-DATA OUT Serial data output to operation PWB
62 P86 NC — — (NC)
63 P85 OP-CLK OUT Data output clock signal to operation PWB
64 P84 OP-LATCH OUT Data latch signal to operation PWB
65 P83 UN-DATA OUT Serial data output to lower unit PWB
66 P82 NC — — (NC)
67 P81 UN-CLK OUT Data output clock signal to lower unit PWB
68 P80 UN-LATCH OUT Data latch signal to lower unit PWB
69 Vcc Vcc Power (5V)
70 AVcc AVcc Analog/Digital convertor reference power voltage
71 VREF VREF Analog/Digital convertor reference voltage input
72 AVSS AVSS Analog/Digital convertor ground pin
73 Vss Vss Power (GND)
74 P77 — — (NC)
75 P76 MBT IN Analog input signal (Main PWB destination setting)
76 P75 CLV IN Analog input signal (Copy lamp control)
77 P74 RTH IN Analog input signal (Fusing thermistor)
78 P73 CRUT IN Analog input signal (CPU destination setting)
79 P72 DVC IN Analog input signal (Developer color detection)
80 P71 TCSA IN Analog input signal (Toner density sensor)

(3) Start/stop control circuit

1 General
The circuit senses ON/OFF state of the power source to control
start/stop of the circuits.
The DC power section supplies power voltages (VH=+32V, VB=+24V,
VC=+10V, VD1=5V, VD2=5V).
After the power voltage reaches the specified level, the circuit opera­tion is started. Before the power voltage falls below the specified
level, the circuit operation is stopped, preventing against malfunc­tions.

RESET

28

CPU
(IC110)

5V2

C134

22000PF

C106

0.1uF

1
2
4

IC113

VCC
NC
CAP

M51953BL

/RESET

GND

5V2

R145

2.4kJ

C135
22000PF

RESET1

RESET2

5

3

12 – 5

(4) Heater lamp control circuit

1 General

The heater lamp control circuit detects the heat roller surface
temperature with the thermistor, converts it into voltage level, and
outputs it to the CPU analog input pin.
The CPU converts the analog voltage into digital signal level, com­pares it with the value set by simulations, turns on/off the heater lamp
according to the level, and maintain the heat roller surface tempera­ture at a constant level.

VAREF

R145
1K

R147
10K

D105
MA700

R146
56KJ

R149

7.5KJ

R150

4.7KJ

9

+

­IC112C

NJM2901M

14

8

FTH

1
2
3
4
5
6
7
8

IC102

I1
I2
I3
I4
I5
I6
I7
GND

ULN2003A

COM

24V

Q110

47K

10K

24V

9
16

O7

15

O6

14

O5

13

O4

12

O3

11

O2

10

O1

47K

10K

DTA114YK

R105

2.2KJ 1/2W

24V

Q111
DTA114YK

PR

C507

HL

RTH

HL

I/O

PR

AN4

CPU

AC

When the heat roller surface temperature is low, the thermistor resis­tance increases. When the surface temperature is high, the resis­tance decreases. The thermistor terminal voltage, therefore, in­creases when the heat roller surface temperature is low, and
decreases when the temperature is high. The thermistor terminal
voltage is inputted to the CPU analog port, and the CPU controls
on/off of the heater lamp with the input voltage level.

[High temperature protecting circuit in hung up of the
CPU]

The voltage at IC133 3 pin (reference voltage) is divided by R149 and
R150, and the thermistor terminal voltage is applied to IC112 9 pin.
When 9 pin voltage is lower than 8 pin voltage (the heat roller surface
temperature: about 230 degree C), IC112 14 pin becomes LOW. As a
result, HL signal is pulled to the GND level and the heater lamp
lighting signal is not generated. (IC112 output 14 pin is normally
HIGH (Open state).)

AC PWB
(RY201)

R504

CR501

Heat rol le r

GND

-PR

GATE

T1

T2

TD501

R503

Thermostat
170˚C

Heater
lump

[When the heat roller surface temperature is lower than
the set temperature]

a. Since the thermistor pin voltage is higher than the set level, output

signal HL from the CPU becomes HIGH.

b. HL signal is passed through IC102, TR, and Q110 to the solid

state relay.
When, therefore, HL signal is LOW, the internal triac turns on.

c. When the internal traic turns on, a pulse is applied to the gate of

the external triac to allow a current to flow from the power source
through the heater lamp to the triac, thus lighting the heater lamp.

[When the heat roller surface temperature is higher than
the set temperature]

a. Since the thermistor pin voltage is lower than the set level, output

signal HL from the CPU becomes low.

b. HL becomes low, SSR is turned off, the external triac is turned off,

and the heater lamp is turned off.

SSR501

[Q110]

Q110 protects the heater lamp from lighting due to trouble in the
harness of the heater lamp drive signal.

12 – 6

(5) Driver circuit (Solenoid, magnetic clutch)

1 General

The control signals of each load outputted from the CPU and I/O
cannot drive the load directly. The output, therefore, is delivered to
the load through the driver IC.

2 Operation

The driver circuit forms a Darlington circuit with two transistors to
obtain a large drive current (load current) from a small input current
(I/O output current). When the driver input voltage is HIGH (+5V), the
transistor is turned on to flow a current in the arrow direction, operat­ing the load. When the driver is turned on, the driver output pin
voltage is 0V.

+24V

I/O
Output

LOAD

(6) AE (Auto Exposure) sensor circuit

The AE circuit is composed of the AE sensor PWB which is com­posed of the photo diode, and the I-V convertor circuit, and the
amplifier circuit on the control PWB.

+10V

3

D115

AEG
AES

DAN202K

21

D115

3

DAN202K

21

AESI

R6 R1

6
5

R5 R4

A

R3

7

AE sensor PWB

2
3

R2

1

B

Operation amplifier A performs I-V conversion of the original density
level (minute current) from the sensor. Operation amplifier B amplifies
the output of operation amplifier A to a suitable level for inputting to
the CPU.
The amplifying level is automatically set by selecting the AE gain
signal (AEG0 ~ AEG2) outputted from the CPU when simulations SIM
47 is executed.
AE operation is performed by the software in the control PWB. When
a reflected ray enters the sensor, a voltage corresponding to the light
quantity is inputted to the CPU. The CPU compares the input voltage
and the copy lamp application voltage and controls the copy lamp
voltage so that the exposure level corresponds to the original density.

R229

15KF

TP124 TP125

00

4

IC130A

2
3

+10V

1

B

UPC358

8

R119
10KJ

ANO

CPU

CLPWM

ZD104
HZ6A1

AE

JUMPER

AES

R225
13KF

AEG0

R226

4.3KF

AEG1

R227

5.2KF

AEG2

R228

9.1KF

I/O

12 – 7

(7) Toner supply motor drive circuit

IC104 is the motor control IC which drives the toner supply motor with
the pulse signals (TMa, TMb) outputted from the I/O chip.

IC104

2

R208
47KJ

+5V

R209
47KJ

9

IN1

1

IN2

5

GND

TA7291S

TMa

TMb

I/O

Internal circuit

+5V +24V

2

8

+24V

C102

+

6
8

10UF35V

7

TMa

TMb

3

M

6

+24V

2 Operation

After td (= 30msec) from when the voltage exceeds 4.25V after power
rising, the output becomes HIGH.
"td" is set by the external capacitor.

Power

5µA

-

+

reference

Output

-

R1

R2

1.25V

TMa

7

M

3

TMb

TMa
TMb

REG

Protection
circuit
(Heat insulated)

91

5

GND

Truth value table

Input Output

TMa TMb TMa TMb

LL∞∞ Stop
H L H L CW/CCW
L H L H CCW/CW
H H L L Brake

Mode

∞: High impedance

(8) Reset IC (IC113)

1 Outline

The M51953 BL is the most suitable semiconductor IC for detecting
the power voltage to reset the CPU and every type of logic circuit. It is
equipped with the delay circuit to provide delay time just by adding an
external capacitor.

4.25V

0.65V

Power voltageOutput state

GND Delay capacity

H

L

Output not constant
ta = 30m sec

t

ta ta

t

M51953 BL

External view 5P5

5

Output

Delay capacity

4

GND

3
2

NC
Power

1

12 – 8

(9) Copy lamp control section

The change in the copy lamp exposure level is adjusted by changing
the ON period duty of the output pulse (CLPUM) from the CPU and
controlling the copy lamp voltage. Fig. 1 and Fig. 2 show the circuit
diagram and the waveform.

5V2

CLPWM

CLPWM

FW

Q107

DTC114YK

5V2

V4

V1

R165
15KF

R166
30KF

R202

4.7KJ

V2

10

9

24V

C133

0.047µF

+

-

R171

3.9KF

ZD103
HZ59A3

R160
47KJ

R161
10KJ

IC1128
NJM2901M

8

10
11

D103
1SS133

­+

IC1120
NJM2901M

R173
1KJ

13

C131

0.01µF

R167
15KF

C107

0.47µF
50V

D102
1SS133

V5

A

R174
1KJ

1

BR102
10KJ x 4

5

R166
30KF

R166
30KF

R175
10KJ

7

+

8

IC1128
NJM2901M

-

V3'

Q108
2SC2411K

1

R169
200KF

1

4

5V2

BR102
10KJ x 4

C138
1000P

Q109
DTA114YK

V3

R170
82KF

R105

2.2KJ
1/2W

FWS

CLV

CL

12 – 9

The relationship between the CLV and the pulse ON period is as
shown in the figure below:

V1

0V

V2

0V

V3

0V

+5V

V4

0V

V5

0V

0VVCL

The copy lamp is switched by the triac. At the rising of CLPWM signal
(V4), the trigger signal CL is sent to the triac to light the lamp. The
lamp will goes off later at the zero cross point of V1 waveform.
The CPU reads the control voltage level (CLV) corresponding to the
change in the copy lamp voltage, and compares it with the reference
level to change the ON period of the output pulse.
The CLV forms the same waveform as the copy lamp voltage
waveform where the Ac input’s full rectified waveform (FW) is dis­abled for ON periods of the pulse. It is converted into a DC level by
the low pass filter composed of C107 and R168, and is inputted to the
CPU.

CPU output (CLPWM)

8 or 10 msec

Pulse ON (Changeing)

(V)

CLV

50Hz60Hz

Pluse ON period

(msec)

• When the pulse ON period is shorter, the CLV becomes higher,

and vice versa.

• The pulse ON period rises at he AC zero cross timing and is driven

by the duty.

• The copy lamp lighting signal generates positive pulses with C133

at falling of the CPU output, and inputs the pulses through the
two-stage transistor to the photo triac.

• Section A in the figure shows the circuit which prevents against

application of an overvoltage to the copy lamp.
When the pulse on period is abnormally short, the DC level applied
to the IC112 10 pin becomes higher than the reference voltage of
11 pin, driving the 13 pin output to the GND level.
Therefore the lighting signal is not transmitted to R174 and later
section and the lamp is not lighted.
By setting the reference voltage to a level not exceeding the rated
voltage, an abnormal lighting is avoided.

1 When the AC input voltage becomes low (with the copy lamp

control voltage at constant):
The FW peak at point becomes lower to decrease the CLU
voltage at .

Then the CPU shortens the output pulse ON period until the CLV
reaches the reference level, increasing the power applied to the
coy lamp.

V3

2 When the Ac input voltage becomes higher (with the copy lamp

control voltage at constant):
The reversed operations of 1 are performed to lengthen the
output pulse ON period, decreasing the current flowing through
the copy lamp.

3 When the copy lamp control voltage is decreased:

The CLV reference level in the CPU is lowered. The output pulse
ON period is lengthen until the CLV reaches the level, decreasing
the power supplied to the copy lamp.

4 When the copy lamp control voltage is increased:

The reversed operations of 3 are performed, to shorten the out­put pulse ON period, increasing the power applied to the coy
lamp.

V1

12 – 10

4. Operating sect io n

(1) Outline

The operating circuit is composed of the key matrix circuit and the
display matrix circuit.
Key detection: Keys are detected with signal matrix of W0 (Q25) ∼
W7 (Q32) and KEY0 ∼ KEY2.
With W0 signal at LO W (GND) and W1 ∼ W 7 at HIGH (open), the
level of KEY0 ∼ KEY2 is checked and "H" or "L" state of 4K, 2K and
3K in the key matrix is judged to judge ON/OFF.
For W1 ∼ W7, switching is made e very 2 msec for judgement.

+5V2 +5V1

KEY0

KEY1

W0

W1

W2

W3

W4

W5

CPU

KEY2

3K2K4K

LC7935

W0 (Q25)

16m sec

2m sec

HIGH

GND

W6

W7

KEY0
KEY0

4K-ON

4K-OFF

12 – 11

(2) Display circuit

Control is performed with the data signal and the control signal from
the control circuit.

1 Block diagram

VD (+10V)

LED

VD (+5V)

DATA

CLK

LATCH

DATA

CLK

Main
control
circuit

LATCH

ENABLE

32 bit Shift Register

32 bit Latch

Sout

S IN

VD

OUT

CLK LATCH

2 Operation

Data signal

Latch signal

S OUT

STROBE

Clock

BEO

1

VD (+5V)

VD (+5V) VD (+10V)

DC power
circuit

8

5V

5V

ENABLE

GND

Driver ON/OFF Control

Driver

01

032

VD

GND

Strobe signal

Output LED

1

2

3

4

51
52

DAta signal (8 bit) sent from the main control PWB is shifted at the
rising timing of the clock and retained at the rising timing of the latch
signal.
The retained data is outputted when STROBE signal becomes HIGH
(5V).

12 – 12

5V

LED light
up at LOW
level (0V)

(3) LED display

The lED is lighted up by the sig na l m a tr ix of MDL0 (Q1) ∼ MDL1 (Q2)
and F0 (Q 3) ∼ F20 (Q23).
By turnin g on /off por ts F0 ∼ F20 with t he tim ing of M DL0 an d MDL1,
the LED at the matrix cross point is lighted up.

+5V1

RDL1

DTB113ZS

PEL

MDL0 MDL1

Q1

Q2

F1

Q4

LC7935

MDL0

MDL1

FO

2m sec

RDL1-ON

PEL-ON

Cycle 4 msec 1/2 duty

GND

GND

GND

5. Power section

Each AC voltage generated by the power trans in the AC PWB unit is
full-wave rectified and smoothed to stabilize each voltage (UH, UB,
VD) in the main PWB side, and is supplied to loads.

(1) Signal name and output voltage

GND: 0V
VH: +30 ∼ 44V (Separated into 24V and 32V supply in the main

PWB.)
VD: +24V ∼ 35V (For m s 5V supply in th e m ain PWB.)
FW: Full-wave rectification

• AC PWB unit

L2

N1

F503

10~14VFW

CNA-3

CNA-1

POWER TRANS

CNB-5

CNB-6

CNB-1

CNB-2

CNB-3

CNB-4

F504

F505

+

RBV-608
BD501

~~

_

+

S1NB60
BD502

~~

_

+

S1ZB60
BD503

~~

_

C509
6800uF 50V

C510
2200uF 25V

R508
24KJ

CNE-1
CNE-2

CNE-3
CNE-4
CNE-7

CNE-8
CNE-5

CNE-6

VH
VH

GND(VH)
GND(VH)
VD

GND(VD)
FW

GND(FW)

12 – 13

• In the main PWB unit

VH

32V

L-7

32V

L-8

P-GND

L-5

P-GND

L-6

R101
510J 1/2W

C142

22000PF

C143
22000PF

Zenor diode

VD

5V1

L-3

C101

0.47uF 25V

S-GND

L-4

D101

DSS131

Q101
2SD1769

ZD101
RD13EB1

ZD102
RD13EB1

Three-termonal regulator

IC101
MC7805CT

12 3

C103

470uF 63V

NPN transistor

C102
47uF 35V

C104
47uF 10V

C144

22000PF

C145
22000PF

C146

22000PF

32V

CHK JP

24V

CHK JP

5V1

CHK JP

+5V (VD)

D126

RB411D

C147

22000PF

About 32V (VH)

+24V (VB)

C105

4.7mF

5V2

CHK JP

FB105

POWER GN D

32V

32V

32V

24V

24V

5V1

5V1

5V2

5V2

12 – 14