Xerox 5915 User Manual

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XEROX 5915 SERVICE MANUAL

Issued by : Overseas Technical Group,

Xerox of Shanghai Limited.

. July 200

XEROX

THE DOCUMENT COMPANY

Issued: JUNE 2000

XEROX 5915

Service Manual 1st Edition

•••• This service manual covers the follow ing models:

Electrostatic Copier XEROX 5915 manufactured by SHANGHAI XEROX.

•••• Related Materials

No related materials are issued other than this service manual.

•••• Confidentiality

• This service manual is issued intending use by maintenance service

personal authorized by XEROX. Coping, transferring or leasing this manual without prior consent by XEROX is prohibited.

• Whenever a paper is eliminated because of issuance of a replacement

•••• Revision and Modification Information

When design changes or revisions relating to this service manual occur, overseas technical information or overseas service bulletins may be issued as supplementary information until such change will be accommodated in the updated version of this service manual. CAUTION: Important changes including revisions of spare part numbers

and adjustment specifications must immediately be reflected on the respective pages of this service manual upon reception of such information.

page containing changes modifications, burn it or take the necessary action including cutting by a shredder.

• Be careful of handing the manual to avoid missing or damaging it.

Introduction

1. Scope and Comment Sheet

This service manual is prepared to specify service standards for the XERO X 5915.

•••• Service Manual Comment Sheet

When you have comments or corrections, or discover wrong descriptions in the XEROX 5915 service manual, enter these items on the comment sheet and send it to: Overseas Support Group, Technical Services Department, Xerox of Shanghai Ltd.

Via your company’s Technical Department.

2. How to Use the Service Manual

This service manual covers standard maintenance servicing procedures for the XEROX 5915. Observe Section 1 Service Procedure for efficient work during maintenance calls.

2.1 Service Manual Composition

This manual is divided into the following 9 sections:

Section 1 Service Procedure

This section describes general an d servici n g procedures required to carry out maintenance of the XEROX 5915.

Section 2 Troubleshooting

This section specifies troubleshooting procedures, except thos e on the imag e or cop y quality. How to use the diagnostic mode and programs are also contained in this section.

Section 3 Image Troubleshooting (Under

preparation) This section describes troubl esh ooti ng procedures relating to image quality problems.

Section 4 Disassembly, Assembly and

Adjustment

This section instructs the disassembly, assembly, adjustment and replacement procedures for compone nts of the XERO X

5915.

Section 5 Parts List

This section lists the component parts of the

XEROX 5915.

Section 6 General

The following pieces of information relating to the XEROX 5915 are contained in this section:

• Specifications

• Tools and servicing supplies

• Consumables

• Information relating to rnodifications

• Installation and removal procedures

Section 7 Wiring Information

This section contains information relating to electrical wiring of the XERO X 5915 .

• Wiring connectors list

• Wiring connectors positions

• PWBS reference materials

Section 8 Information of Related Products

(Not to be issued as the 5915 is unique)

Section 9 Block Schematic Diagrams (BSD)

This section contains the following Block Schematic Diagrams (BSD) of Chains 1 to 9 and other wiring information on the XEROX 5915.

• Chain 1. STANDBY POWER

• Chain 2. MODE SELECTION, MACHINE

RUN CONTROL START PRINT POWER

• Chain 3. DOCUMENT TRANSPORTATION OPTICS NO.I

• Chain 4. DOCUMENT TRANSPORTATION OPTICS NO.2

• Chain 5. PAPER SUPPLYING AND

TRANSPORTATION NO.1

• Chain 6. PAPER SUPPLYING AND

TRANSPORTATION NO.2

• Chain 7. XEROGRAPHIC, COPY

TRANSPORTATION AND FUSING

2.2 Revision Information

This manual will be revised as specified below and the necessary information sent to all customer engineers. Revisions must be incorporated correctly in or der to keep the manual up-to-date.

Revision Procedure:

• When the entire manual is revised, the Revision 1 on the front cover will be renewed to Revision 2, Revision 3 and so on.

• When the manual is partially revised,

Revision A, B, C and after will be issued. Each revised page will carry Revision A, B, C and up in order to clarify the revision history.

• Change bar:

When a paragraph, table or figure is revised, a change bar will be inserted into respective revisions in order to clearly indicate that a change or addition is made.

Example:

When the same page is changed a second time, the previous change bar will be deleted.

3. Warning, Cautions and Notes

WARNING A Warning is used whenever an operating or maintenance procedure, practice, condition or statement, if not strictly observed, could result in personal injury.

CAUTION A Caution is u sed whenever an o perating or maintenance procedure, practice, condition or statement, if not strictly observed, could result in damage to the equipment.

NOTE

NOTE: A Note is used where it is essential to highlight a procedure, practice, condition or statement.

4. Symbols

The following symbols are used throughout this manual:

• PL: This indicates you should refer to the parts list.

Introduction

XEROX 5915 Service Manual

Section 1 Service Procedure

1.1 Precautions

1.1.1 Safety………………………………………………… 1-2

1.1.2 Other precautions……………………………………1-2

1.2 Work Process When Making Calls ………… 1-2

1.3 Detailed Explanation of Work When Making Calls………………………………..

1.3.1 What to do first………………………………………1-3

1.3.2 Check for repeatability of the problem……………1-3

1.3.3 Check the image quality……………………………1-3

1.3.4 Feed Counter Check ………………………..……. 1-3

1.3.5 Paper Jam Status Check ………………………. 1-4

1.3.6 TRIM …………………………………………………1-4

1-3

1-1 Contents

Section 1 Service Procedure

1-2

Section 1 Service Procedure

1.1 Precautions

Intentional bank page

1. Service Call Procedure

FIRST CALL ACTIONS

Perform the following:

1. Discuss with the customer the requir ed an d agreed configuration for the copier. Check that all required hardware and software is installed and/or enabled to meet this specification.

2. If the copier is configurated with either a

sorter or ADF, check the alignment of the output device.

NORMAL CALL ACTIONS

1. Ask the operator about the reason for the call. Obtain the operators description

of the reason for the call and any other problems that may be occurring. Review any defective copies to determine what actions need to be taken.

2. First Call? If this is the first call, carry out the first call actions.

3. Switch on the copier … Observe the user interface panel <Note to author add

initialising sequence of events>

4. System initialisation… Confirm that the <

Note to author add initialising sequence of events eg drives moving etc>

5. Check the service lo g. Review the copier service log book for any previous actions that may be relevant to the call.

6. Check and record copy counters. Check and record copy counters in the XXX book . Enter the diagnostic Mode and check the number of sheets of copy paper fed from Trays and that of originals fed from Document Feeders.

7. Enter Diagnostic Mode. Perform the following

- Make a note of any faults recorded.

- Make a note of the High Frequency Service Items

8. Verify and classi f y the fa ult . Use the information obtained in the previous steps to determine the cause of the fault. If the previous steps do not determine the faul t, fully exercise the copier utilising all options until the fault is determined.

9. Plan the call. Using the information noted in previous steps, structure the call:

(H.F.S.I) requiring attention.

- Check all H.F.S.I required are available. Any items unavailable shall be ordered at this point.

- When troubleshooting or repairing a fault in a particular subsystem, resolve an y workarou nd and overthreshold faults and replace any noted H.F.S.I applicable to that subsystem.

- Perform any subsystem maintenance actions applica bl e to that system.

FINAL ACTION S

1. Perform any remaining maintenance

actions. Check that all maintenance

actions noted during the call have been completed.

2. Carry out TRIM procedure.

3. Make a copy of the customer do cum e n t. Clean the document glass and make a copy. Ensure that the customer is satisfied with the copy quality.

4. Reset any H.F.S.I counters where items have been replace d.

5. Clean the copier and clean the service area.

- Remove any toner spillage’s.

- Use “Formula A” cleaner to

clean the covers.

Take care when cleaning the control

6. Provide customer with training (if required)

7. Make a note of the copy credits and

record copy counters in the XXX book.

8. Complete the copier log book. Record all service actions performed in the copier log book and record any other rel eva nt information.

WARNING

Do not use solvents.

CAUTION

panel to not use an excessive

amount of the cleaner.

1-3

Section 1 Service Procedure

1-4

Section 1 Service Procedure

HIGH FREQUENCY SERVICE ITEMS

Component Indication Replacement

Photoreceptor drum

Toner Cartridge

Half-Moon Feed Roll MSI Feed Roller MSI Retard Pad Ozone Filter 50K

With the Drum Unit replacement due, the Control Panel display turns on at 50K copies indicating its replacement is required. After “Replace Drum Cartridge” is displayed, J7 is displayed at 5K copies and copying is prohibite d from this point.

When the Toner Cartridge runs short of toner, “Supply Toner” is flashing. When approx. 100 copies have been made since the display began flashing, J1 is displayed and copying is prohibited from this point.

threshold

50K 673S50211 REP 5.1.1

The above copy quantities apply to A4 originals with an area coverage of 6% .

67K 60K 60K

Parts list Replacement

Procedure

6R01020

59K03261 REP 2.5.1

6S50220 REP 2.3.2

19S50212 REP 2.2.2

53E91510 REP 8.5.2

TRIM

• The XEROX 5915 TRIM procedur e shal l be per fo rm ed at all maintenance calls., unless the procedure has been carried out within the last 10 days.

TRIM work items are listed in the TRIM table. The work is categorized into the following:

▼▼▼▼:Check at calls. ∇∇∇∇: Make sure to clean

TRIM Check List

▼▼▼▼:Check at calls.

∇∇∇∇: Make sure to clean

: Make sure to replace at given intervals.

Work Item Category Main Points

Check the overall M/C operation

before work.

Clean Platen Glass(top/bottom

surfaces), Platen Cushion and Mirrors.

Clean Transfer/Detach/Pre-transfer

Corotrons.

4 Clean Paper Transport Assy.

Charge Corotron, Seal Glass, and

I.S.I.L.

6 Check clean parts subject to wear.

7 Check on safety.

Check the overall M/C operation

after work.

▼▼▼▼

• Check on paper feeding, copy quality,

▼▼▼▼

∇∇∇∇

▼▼▼▼

abnormal noise, etc.

• Clean Platen Glass top/bottom surfaces with silicon cloth and lens cleaning liquid.

• Clean Platen Cushion with wet cloth.

• Clean Mirrors 1-4 and Lamp Reflector with

optics cleaning cloth.

• Clean Wire Shield and Guide with a clean brush, and wipe them with dry cloth if necessary.

• Clean Transport Belt and its surrounding area with a brush, and wipe them with a

dry cloth if necessary.

• Wipe Charge Corotron, Seal Glass, and

I.S.I.L. with dry cloth.

• Check lives of the parts and replace/clean if necessary.

• Ozone Filter (50k)

• MSI Feed/Retard Roller/P a d (60k )

• Half-Moon Feed Roller (67k)

• Carry out earth continuity check on mains

cable.

• Check Power Plug for damage(cracks/ exposed core)

• Enable all the operations and check paper feeding, copy quality, abnormal noise, etc.

• Check counters.

• Update the History Card and service

report.

NOTE: a. The Drum doesn’t normally need cleaning.

b. When you can’t help cleaning the Drum because of fingerprints, etc., clean its surface with

the XEROX 5915 toner slightly and then wipe it with dry cloth. (Clean it while rotating it in the Drum rotating direction.)

c. Never u se Drum Cleaner or Refiner.

Section 2 Troubleshooting

2.1 Preface

2.1.1 How to Troubleshoot………………………………. 2-2

2.1.2 Terminology……………………………………….. ..2-2

2.2 Diagnostic(C/E) Mode

2.2.1 How to Enter Diagnostic (C/E) Mode……………. 2-4

2.2.2 Entries of Chain Codes, Function Codes & Set Values………… …………………………………….2-4

2.2.3 How to Exit Diagnostic (C/E) Mode……………….2-4

2.2.4 Diagnostic Functions and Operating Procedures ………………………………………………………………2-4

2.3 Level 1 Troubleshooting

2.3.1 Level 1 FIP…………………………………………2-12

2.3.2 Chart of Jam Status Codes …………………. ...2-13

2.3.3 A List of Status Codes ……………………….. ...2-15

2.4 Level 2 Troubleshooting

2.4.1 General FIPs………………………………… ….2-16

2.4.2 U Code F.I.P.’s ………………………………… .2-19

2.4.3 Misfeed Jams ………………………………….. .2-25

2-1 Contents

Section 2 Troubleshooting

2-2

Section 2 Troubleshooting

2.1 Preface

2.1.1 How to Troubleshoot

Level 1 Troubleshooting

• Level 1 Troubleshooting (Level 1 F.I.P.) is the first step toward the diagnosis of a problem. Level 1 F.I.P. asks you whether or not any Status Code and other problems exist, guiding you to Level 2 Troubleshooting.

Level 2 Troubleshooting

• Level 2 Troubleshooting is a diagnostic procedure of isolating one problem by classified Status Codes, Misfeed Jams and various problematic symptoms. Performing a F.I.P. or an appropriate procedure in the check list enables you to discover causes of a problem in a short period of time.

• Status Code When a Status Code alerts you to a machine failure, perform appropriate troubleshooting items, referring to the list of Status Codes listing problem contents and corrective actions or troublesh ooting items.

How to Troubleshoot and Notes

• First perform Level 1 F.I.P. to isolate one problem.

Then go to an appropriate Level 2 Tro ubleshooting, BSD, or Disassembly/Assem bly/Adjustment proce du re to resolve the problem. W hen you try to find a cause of a problem using a F.I.P. or Check Chart, you should read its procedure carefully and perform it properly. When there are a number of possible causes , yo u may pe rfo rm a F.I.P. of the same title again, because it is impossible to find all causes at once. In this case, pay attention to different judgments made in the process of the same F.I.P.

• When taking voltage measurements or performing

operation tests of electric appli a nce s, you shou l d ch eat their Interlock Switches.

• When replacing PWBs, you should check connectors on

them for proper connections before replacements.

2.1.2 Terminolog y

Troubleshooting uses the following terms. You need to understand these terms in analyzing failures. Common Terminology Status Code The message “Report XX.” appears when the machine discovers a problem. This XX

is called Status Code. Actuate Mechanically press or release the Switch Actuator or the linking Mechanical Linkage. Block Place a document or a sheet of paper against the Photo Sensor to make the Sensor

detect one. Check Visually Check parts such as the Relay or Mechanical Linkage for its proper operation

or check to see if parts are defective. Enter Diagnostic Mode. Enter Diagnostic Mode following the procedure indicated in Diagnostic(C/E) Mode. Check for a short circuit. Power off. Measure the resistances between the wire and the frame with the tester

Ohm range. Check for an open circuit Power off. Measure the resistance on the both ends of the wire with the tester Ohm

range. Set [*.*] to ON Enter Diagnostic Mode following the procedure indicated in Diagnostic(C/E) Mode.

Then enter [Chain Code & Function Code]. Once you have entered Diagnostic Mode,

you must not exit it until you are instructed by the message to “Exit Diagnostic Mode”

or you don’t need to check any more because an area where a failure has occurred is

found. Stop [*.*] Press the Stop button to set the drive signal for the output component being tested to

OFF. Exit Diagnostic Mode Exit Diagnostic Mode follo wing the proce d ure described in Diagnostic Mode/Pro g ram . Check Voltage Levels

+ 5VDC • + 5.2VDC ± 0.25VDC NOTE: The voltage values may exceed their ranges

a little due to varying AC powers or loads. + 24VDC • + 24VDC ± 2.4VDC Breakaway from Failure Analysis Procedure

Mechanical Problem This is used when you should move to mechanical adjustments and parts

replacements. Read all items (describing main causes) and find causes of a problem

in comparison with symptoms the machine shows. PL 4.2 Refer to Parts List PL 4.2, Section 5. BSD 6 Refer to BSD 6, Section 9.

4.1.3 Refer to 4.1.3, Section 4 Disassembly/Assembly/Adjustment. Replace parts in order When it is impossible to further analyze causes of a problem, replace parts in order.

Replacement parts are described in order of highest possible replacement items.

Intentional blank page

2-3

Section 2 Troubleshooting

2-4

Section 2 Troubleshooting

2.2 Diagnostic(C/E) Mode

2.2.1 How to Enter Diagnostic(C/E) Mode

Power on while pressing “0” on the keyboard.

• All the LEDs on Console Panel turn on. When you press the key pad or the Stop Clear button, the three LEDs: “El JAM”, “E3 JAM” and

“TONER EMPTY” starts flashing while the other LEDs turn off.

2.2.2 Entries of Chain Codes, Function

Codes and Set Values

If you enter a wrong Chain Code or Fun ction Code, press the Stop Clear button and re-enter a correct one.

• If you enter an unspecified Chain Code, Function Code or Set Value, “Er” appears.

2.2.3 How to Exit Diagnostic(C/E) Mode

Set the Power to OFF/ON.

2.2.4 Diagnostic Functions & Operating Procedures

Input Check

Function:

This displays the input voltage level from the Sensor or the Switch with “H” or “L”

Procedure:

1. Enter Diagnostic (C/E) Mode.

2. Enter the Chain Code for a part to be checked and press the Start but to n.

3. Enter the Function Code for a part to be checked and press the Start but to n.

4. Operate the part to be checked.

• When the voltage level is high, “H” is

displayed. When it is low, “L” is displayed.

5. When you press the Stop Clear button once

during the check, the Function Code Entry awaiting status is initiated, while you press it twice, the Chain Code Entry awaiting status is initiated.

A/D Input Check

Function:

This displays the input voltage level from the Sensor with a digital value.

Procedure:

1. Enter Diagnostic (C/E) Mode.

2. Enter the Chain Code for a part to be checked and press the Start but to n.

3. Enter the Function Code for a part to be checked and press the Start but to n.

• The voltage levels are displayed with the

digital values of 0~FF. The varying voltage level will change the display.

4. When you press the Stop Clear button once

during the check, the Function Code Entry awaiting status is initiated, while you press it twice, the Chain Code Entry awaiting status is initiated.

Console Button Check (2-1)

Function:

This checks any other button than the Stop Clear one on the Console Panel.

Procedure:

1. Enter Diagnostic (C/E) Mode.

2. Enter Chain Code “2” and press the Start button.

3. Enter Function Code “1” and press the Start button.

4. Set any other button than the Stop Clear one to ON/OFF, then + 2 is added to the displayed value.

5. When you press the Stop Clear button once

during the check, the Function Code Entry awaiting status is initiated, while you press it twice, the Chain Code Entry awaiting status is initiated.

2.2 Diagnostic(C/E) Mode

2.2.4 Diagnostic Functions & Operating procedures

Input Check

CHAIN

FUNCTION

CODE

1 1 Front Interlock Switch H/L 1

2 RH Upper Interlock Switch H/L 5 2 1 Console Button +1 2 3 10 Option Set H/L 2

11 Option Start H/L 2 12 Option Stop H/L 2

6 1 Lens Sensor H/L 3

2 Optical Regi Sensor H/L 3

8 Exposure Monitor Sign al A/D 3

17 Fuser Thermistor A/D 7 18

7 1 Tray 1 Size Sensor H/L 5

6 Tray 1 No Paper Sensor H/L 5

10 MSI No Paper Sensor H/L 5

8 8 Regi Gate Sensor H/L 5

9 Fuser Exit Switch H/L 7

10 MSI Size Sensor H/L 5

9 9 Toner Empty Sensor H/L 7

PART/SIGNAL

Fuser Thermistor Open Circuit

DIS-

PLAY

A/D 7

REF.

BSD

2-5 2.2 Diagnostic(C/E) Mode

Section 2 Troubleshooting

2-6

Output Check

Function:

This operates parts such as the Solenoid, the Clutch and the Motor. You can set parts within the same Chain to the ON positions simultaneously.

Procedure:

1. Enter Diagnostic(C/E) Mode.

2. Enter the Chain Code for a part to be operated. Press the Start button.

3. Enter the Function Code and press the Start button.

• The designated part starts operating.

4. When you operate parts simultaneously,

enter the Function Codes for the parts you will operate successively. Press the Start button.

5. When you stop operating a part

simultaneously, press the Stop Clear

button.

• When parts are operating, stop them simultaneously.

• The following parts stop automatically after

respective specified periods of time:

• All Solenoids/Clutches ..... 1 sec.

• Lamp Carriage Motor ....... 1 sec.

• Exposure Lamp ................ 30 sec.

REF.: When you press the Start button

again after the above parts stop automatically, they start operating again.

Section 2 Troubleshooting

2.2 Diagnostic(C/E) Mode

Output Check

CHAIN FUNCTION PART/SIGNAL

4 1 Main Motor(& Erase Lamp) 2,7 6 3 Lamp Carriage Motor(Scan) 1sec 3

4 Lamp Carri age Motor(Return) 1sec 3 7 Exposure Lamp(& Erase Lamp) 30sec 2,3,7

8 1 Main Motor (& Erase Lamp) 2,7

2 Tray 1 Feed Solenoid 5 6 Regi Gate Solenoid 5 7 MSI Feed Clutch 5

9 1 Main Motor (& Erase Lamp) 2,7

2 DEVE Bias 7 3ISIL 7

10 1 Optical Cooling Fan Motor 3

4 Fuser fan Motor 7

TIME

REF.

BSD

2-7 2.2 Diagnostic(C/E) Mode

Section 2 Troubleshooting

2-8

Section 2 Troubleshooting

2.2 Diagnostic(C/E) Mode

Parameter (NVM Value) Adjustment

Function:

This performs the Parameter (NVM Value) Adjustment.

Procedure:

1. Enter Diagnostic(C/E) Mode.

2. Enter Chain Code “20” and press the Start button.

3. Enter the Function Code for the parameter to be adjusted. Press the Start button.

• The current value is displayed flashing on

the Quantity Display.

4. Enter a new set value with the key pad and press the Start button.

• The flashing display comes to remain on.

Then the old set value has been changed to the new one.

5. When you press the Stop Clear button

once,

the Function Code Entry awaiting status is initiated, while you press it twice, the Chain Code Entry awaiting status is initiated.

NVM Initialization (20-96)

Function:

This initializes all NVM contents.

Procedure:

1. Enter Diagnostic(C/E) Mode.

2. Enter Chain Code “20” and Function Code “96.” Press the Start button.

• The Quantity is displayed as follows:

“55” →→ “Ed”

• Initialize the following NVM items:

1) Set initial values in all Functions in Chain 20.

2) Reset alI Counters in Chains 30/40.

3) Set set-values in all Functions in Chain

50.

4) Set initial values in all programs in

Specification Setup.

3. To exit this mode, press the Stop Clear button twice.

Chain Code 20 Table

CHAIN

CODE

FUNCTION

CODE

20 1 Registration Adjustment 16(-4.13mm) 32 64(+4.13mm) 0.2564mm

2 Light Quantity Adj. 100% 0 30 80 0.8%

Enlargement/Reduction 0 50 99 0.8% 3 Paper Loop Amount Adjustment 0(-8.27mm) 32 64(+8.27mm) 0.2584mm 4 ISIL Lead Edge Erase Amount Adjustment 0(-8.27mm) 32 64(+8.27mm) 0.2584mm 5 ISIL Trail Edge Erase Amount Adjustment 0(-8.27mm) 32 64(+8.27mm) 0.2584mm 6 Fine Tuning of 100% Horizontal Magnification 0(-2.272%) 32 64(+2.272%) 0.071% 7 Fine Tuning of 100% Vertical Magnification 0(-3.16%) 32 64(+3.16%) 0.099%

10 MSI Paper Loop Amount Adjustment 0(-8.27mm) 32 64(+8.27mm) 0.2584mm 11 Registration Adjustment (MSI) 16(-4.13mm) 32 64(+4.13mm) 0.2564mm 14 Selection of Exposure Photoreceptor Sensitivity Correction 0(OFF) 1(ON) 1(ON) 16 Bias Curve Selection 1 0 4 8 17 Bias Curve Selection 2 0(slot) 1(Flat) 1(Flat) 20 Exposure Lamp Adj. 0 50 99 23 Drum Photoreceptor Sensitivity Correction Constant 0(0) 11(1.1) 40(4.0) 0.1 30 Fuser Temperature Adjustment (Stand-by) 31 Fuser Temp. Adjustment (Copy cycle) 41 Density Correction Light 6 0(0V) 52(-413V) 64(-500V) -7.8125V 42 Density Correction Dark 6 0(0V) 16(-125V) 64(-500V) -7.8125V 45 Density Correction Photo Light 6 0(0V) 50(-388V) 64(-500V) -7.8125V 46 Density Correction Photo Dark 6 0(0V) 24(-184V) 64(-500V) -7.8125V 96 NVM Initialization This initializes all NVM values.

50 9 Black band Function Time 1 0(-5.168mm) 20(+9.56mm) 64(+5.168mm) 0.2584mm

10 Black band Function Time 2 0(-6.732mm) 64(+10.3mm) 64(+6.732mm) 0.2584mm

SETUP ITEM MIN. VALUE INITIAL VALUE MAX.VALUE 1 STEP CHANGE ADJ

0(-23°C) 0(-23°C)

32 32

39(+5°C) 0.72°C 39(+5°C) 0.72°C

2.7.6

5.1.4-

5.1.6

4.3.4

5.1.4-

2-9 2.2 Diagnostic(C/E) Mode

Section 2 Troubleshooting

2-10

Section 2 Troubleshooting

2.2 Diagnostic(C/E) Mode

Feed Counter Check/Clearance.

Function:

This displays or clears Feed Cou nt ers for all

trays .

Procedure:

1. Enter Diagnostic(C/E) Mode.

2. Enter Chain Code “30” and press the Start button.

3. Enter the Function Code for the Feed Counter to be checked. Press the Start button.

• The counter value is displayed by the unit

of k on the Quantity Display.

• When not clearing the counter value, go to

Step 5.

4. Enter “0” with the keyboard and press the Start button.

• The counter value is cleared.

• If you enter any other value than “0, ” “Er”

appears.

5. Pressing the Stop Clear button once will initiate the Function Code Entry awaiting status, while pressing it twice will initiate the Chain Code Entry awaiting status. REF.: Counter Value is countable within the

range of 0~99k feeds, but uncount abl e when it exceeds 99k.

CHAIN

CODE

30 1 Tray 1 Feed Counter

FUNCTION

CODE

4 MSI Feed Counter

COMPONENT

COUNTER

JAM Counter Check.

Function:

This counts Original/Paper Jams and display their counts for every component where they occur.

Procedure:

1. Enter Diagnostic(C/E) Mode.

2. Enter Chain Code “40” and press the Start button.

3. Enter the Function Code for the counter to be checked. Press the Start button.

• The counter value is displayed on the

Quantity Display.

5. To exit this mode, press the Stop Clear button twice. NOTE: Counter Value is countable within

the range of 0~99 feeds, but uncountable when it exceeds 99K .

CHAIN

CODE

40 1 E1 JAM Counter

FUNCTION

Jam Counter Reset.

Function:

This clears Original/Pap er Jam Count ers.

Procedure:

1. Enter Diagnostic(C/E) Mode.

2. Enter Chain Code “40” and press the Start button.

3. Enter the Function Code for the counter to be checked. Press the Start button.

4. To exit this mode, press the Stop Clear button twice.

CODE

2 E3 JAM Counter

5 C1 JAM Counter 10 C9 JAM Counter 21 E1 JAM Counter Reset 22 E3 JAM Counter Reset 25 C1 JAM Counter Reset 30 C9 JAM Counter Reset

COMPONENT COUNTER

Individual Mode Setup

Function:

This sets up the execution/ inhibition of certain functions for individual users.

Procedure:

1. Enter Diagnostic(C/E) Mode.

2. Enter Chain Code “50” and press the Start button.

3. Enter the Function Code for the mode (function) to be set up. Press the Start button.

• The present value appears on the

Quantity Display.

• When not changing the set value, go to

Step 5.

4. Enter a new set value with the key pad and press the Start button.

• The old set value is rewritten into the new

one.

5. Pressing the Stop Clear button once will initiate the Function Code Entry awaiting status, while pressing it twice will initiate the Chain Code Entry awaiting status.

U4-6 Failure Clearance

Function:

When U4-6(Fuser Over Heat Fail) occurs, clear U4-6 by executing [50-20] in Diagnostic (C/E) Mode.

Procedure:

1. Open the Front Interlock and enter Diagnostic(C/E) Mod e. NOTE: During the occurrence of U4-6, you

cannot enter Diagnostic (C/E ) Mo de

2. Enter Chain Code “50” and press the Start

3. Enter Function Code “20” and press the

4. Close the Front Interlock.

5. Set the power to OFF/ON.

without opening the Front Interlock.

button.

Start button.

• The Quantity Display displays “Ed”

indicating the clearance is complete.

U8-7 Failure Clearance

Function:

When U8-7(Exposure Lamp mistakenly turns on) occurs, clear U8-7 by executing [50-21] in. Diagnostic(C/E) Mod e.

Procedure:

1. Open the Front Interlock and enter Diagnostic(C/E) Mod e.

2. Enter Chain Code “50” and press the Start

button.

3. Enter Function Code “21” and press the Start button.

• The Quantity Display displays “Ed”

indicating the clearance is complete.

4. Close the Front Interlock.

5. Set the power to OFF/ON.

CHAIN

CODE

50 1

FUNCTION

CODE

2 Nation Configuration Setup

7 Fuser Warm Up Function

8 Copy density selection

9 10

SETUP ITEM

Toner Touch Up Function

Black Band Creation Function

U1-1 M/C CLOCK FAIL

Ref. BSD: 2 Preparation: Ensure that the following connector is securely

Open the Front Cover and cheat the Front Interlock. Enter Diag. (C/E) Mode. Enter Code[4 -1] and rot ate the Main Motor. Does the Main Motor keep stoppi ng?

Y N

disconnect the power cord.

power cord

connected.

• P/J404 of Main PWB

Procedure

Does the Main Motor stop after rotatin g for 1-2 seconds?

Open the ClamShell and rest art the Main Mo tor . Do abnormal noises occur or does the Main Motor rotate irregularly?

WARNING: Pow er off the machi ne an d

Check the mechanics (Gear, Bearing, etc.) of the following and replace parts if necessary. Fuser Assy(PL8.4)

Regi. Roller Gear(PL2.7) Slide out the Drum Unit and restart the Main Motor. Do abnormal noises occur or does the Main Motor rotate irregularly?

Check the Drum Unit for its drive mechanics. If

any load or abnormal noise exists, replace the

Drum Unit. WARNING: Power off the machine an d disco nn ect the

Check the mechanics(Gear, Bearing, etc.) of the following and replace parts if necessary. Deve Assy(PL6.2) Main Drives(PL1.1/1.2/1.3)

A B

Is the voltage from J404-5 of Main PWB to COM +5VDC?

order. Is the voltage from J404-1of Main PWB to COM +24VDC?

Is the voltage from J404-3 of Main PWB to COM +5VDC?

Is the voltage from J404-6 of Main PWB to COM +5VDC?

Replace the Main Motor .

Replace the Main Motor(PL1.1/1.2)/Main PWB(PL9.1) in

Replace the Main PWB.

Check +24VDC circuit in the DC Wiring Diagram.

Check +5VDC circuit in the DC Wiring Diagram.

Replace the Main PWB.

2-19 2.4 Level 2 Troubleshooting

Section 2 Troubleshooting

2-20

Section 2 Troubleshooting

2.4 level 2 Troubleshooting

U2-1 LAMP CARRIAGE FAIL-STAND-BY U2-2 LAMP CARRIAGE FAIL-POSITION U2-3 LAMP CARRIAGE FAIL-SCAN U2-4 LAMP CARRIAGE FAIL-RETURN

REF. BSD: 3 Preparation: Ensure that the following connectors are securely

• Gently move the Lamp Carriage fro and back by hand, Check it for the mechanical jam.

• Ensure that the following Connectors are securely connected.

Procedure

Power on, enter Diag. Mode and enter (6-3). Press the start button. Does the Lamp Carriage scan?

Are voltages from P/J 405-7,P/J 405-8 to COM +24VDC?

Replace the Main PWB. Enter [6-4] and press the start button.

Does the Lamp Carriage return?

Y N Replace the Main PW B.

Using the Permeable Sensor F.I.P., General F.I.P. and the wiring diagram, perform the diagnosis of Optical Regi Sensor. If no problem exists, replace the Main PWB.

connected.

• P/J404 of Main PWB.

• P/J405 of Lamp Carriage Motor.

• Check the Scan Cable for disengagement, binding,

load, etc.

Check +24VDC INTLK circuit.

Power off and disconnect P/J 605. Are J605-1 to -3,J605-1 to-4, J605-2 to -5,J605-2 to -6 resistance values approx. 6.3Ω each?

Replace the Lamp Carriage Motor.

U3-1 LENS POSITION FAIL

Ref. BSD: 3

Preparation: Ensure that the following connectors are securely

Procedure

Power on. Does the Lens Assy move?(Does it perform its initial operation?)

Check +24VDC circuit Power off and disconnect P/J604.A re J604-1 to - 3,J604-1 to

-5,J604-2 to -4,J604-2 to -6 resistance values approx. 100Ω each?

Check P405-3,4,5,6 of Main PWB and P604-3,4,5,6 of Lens Motor for an open circuit or a short circuit to ground. If the harness is good, replace the lens Motor. Replace the main PWB. Using the Permeable Sensor F.I.P., General F.I.P. and the wiring diagram, perform the diagnosis of Lens Sensor. If no problem exists, replace the Main PW B.

connected.

• P/J405 of Main PWB

• Relay Connector P/J604 of Lens Motor

•

Remedy the mechanical jam Check the Lens Cable for disengagement, binding,

• load, etc.

Are voltages from P/J 405-1,P/J 405-2 to COM +24VDC?

Y N

U4-1 FUSER THERMISTOR OPEN FAIL

Ref. BSD: 7

Preparation: Ensure that the following connectors are securely

Procedure WARNING: Power off the machine an d disco nn ect the power cord.

WARNING: Fuser surfaces are hot, allow the fuser to cool down before attempting service procedure. Fuser lubricant can cause discomfort to eyes. Do not allow fuser lubricant to touch eyes

Disconnect P/J118. Measure the resistance from J118-1 to J118-2.

• Fuser is hot: approx. 13k

• Fuser is cool: approx. 236kΩ

Does the resistance value satisf y the above sp ec. ? YN(∞)

P/J118-2 to P/J410-4. If no problem exists, replace the Fuser

Replace the Main PWB.

connected.

• P/J410 of Main PWB

• P/J118 of Fuser Thermistor

Ω

Check the wire from P/J118-1 to P/J410-3, and the wire from Thermistor.

U4-2 FUSER WARM UP FAIL

Ref. BSD: 7

Preparation: Ensure that the following connectors are securely

NOTE: This is sometimes displayed when C/E visits the customer

Procedure WARNING: Power off the machine an d disco nn ect the power cord.

connected.

• P/J410 of Main PWB

• P/J430/T111/T110 of AC Drive PWB

• P/J 12/13 of Main Heater Rod

• Relay Connector P/J14

and switches the m/c on after the power has been off after the occurrences of U4-3, U4-4 & U4-6. Therefore, the diagnosis of Thermostat is first performed.

WARNING: Fuser surfaces are hot, allow the fuser to cool down before attempting service procedure. Fuser lubricant can cause discomfort to eyes. Do not allow fuser lubricant to touch eyes

Remove the Fuser Cover. Is there continuity between the Fuser Thermostat leads? Y N(∞)

Press the Manual Reset button of the Fuser Thermostat. Is there continuity between the Fuser Thermostat leads?

Y N

Disconnect J12/J13 of Heater Rod? Is there continuity between J12 and J13?

Y N

Remove the Fuser Cover. Cheat the Front Interlock Swit ch. Power on. Does the Main Heater Rod turn on?

Y N Y N

Replace the Fuser Thermostat. Proceed with the

diagnosis using U4-3/U4-4/U4-6 Over Heat FIPs. Proceed with the diagnosis using U4-3/U4-4/U4-6 Over Heat FIPs.

Replace the Heater Rod.

Is the voltage form T110 to T111 of AC Drive PWB 220VAC?

ABC

Is the voltage from P410-11 of Main PWB to COM + 24VDC?

Is the voltage from P410-12 of Main PWB to COM

+ 24VDC?

Check 220VAC circuit.

Is the voltage between Relay Connectors P/J14-1 and -2

220VAC?

Y N

Check the wire from P/J14-1 to P/J12. Check the wire from P/J14-2 to P/J13.

Power off. Check for the scraped Heat Roll surface, the raised-off Fuser Thermistor, the deteriorated Heater Rod. If no problem exists, replace the Fuser Thermistor.

Replace the AC Drive PWB.

Check the wire from P/J14-1 to T111 of AC DRIVER. Check the wire from P/J14-2 to T110 of AC DRIVER.

A B C

2-21 2.4 Level 2 Troubleshooting

Section 2 Troubleshooting

2-22

U4-3 FUSER OVER HEAT FAIL 1 U4-4 FUSER OVER HEAT FAIL 2 U4-6 FUSER OVER HEAT SAFETY FAIL

Ref. BSD: 7 NOTE: At the occurrence of U4-6, open the Front Cover, enter

Diagnostic(C/E) Mod e and clea r U4-6 by exe cuting [50-20].

Procedure

Power on. Check the starting signal of Fuser. Does the level between P/J410-12 to COM remain low(L)?

YN WARNING: Power off the machine and disconnect the power cord.

WARNING: Fuser surfaces are hot, allow the fuser to cool down before attempting service procedure. Fuser lubricant can cause discomfort to eyes. Do not allow fuser lubricant to touch eyes

Disconnect P/J14. Check the circuit continuity from T111 to T110. (AC DRIVER)

Y N

Replace the AC Drive PWB. Replace the Main PWB.

Check the following harnesses for short circuits.

• from P/J12 to COM.

• from P/J13 to COM.

Section 2 Troubleshooting

2.4 level 2 Troubleshooting

U6-4 NVM FAIL

Ref. BSD: 2

Preparation: • Install th e gro und wire.

Procedure

Power OFF/ON. Has the display of Status Code disappeared?

Enter Diag.(C/E) Mode.

• Ensure that the power voltage hasn’t dropped 10% or more (with Power ON or Power OFF).

• Ensure that there is neither operating power sources nor devices generating high frequencies around the installation site.

• Ensure that no high voltage wires such as the Corotron have burnt out or have leakage.

Enter [20-96] and press the Start button. Power OFF/ON. Has the display of Status Code disappeared?

Replace the Main PWB.

Make copies. Confirm that the machine operates properly and

monitor the machine operation for several days. If the problem reoccurs, replace the Main PWB.

2-23 2.3 Level 1 Troubleshooting

Section 2 Troubleshooting

2-24

Section 2 Troubleshooting

2.4 level 2 Troubleshooting

U8-1 EXPOSURE CONTROL FAIL

Ref. BSD: 3

Problem Area: Initial Light Quantity Control(Optics)

Cause/Corrective Action

• Defective Main PWB

• Defective AC Drive PWB

• Open harnesses or improper P/J connections of the circuits

controlling the above PWB’s.

U8-2 NO ZERO CROSS FAIL

Ref. BSD: 7

Preparation: Ensure that P/J410 of Main PWB is securely

WARNING: Hazardous voltage. Use extreme care.

Procedure

Power on. Detect the zero cross signal. Is the level from P/J410-9 to COM +0.5VDC?

connected to P/J430 of AC Drive PWB.

Y N

Is the voltage from P/J437-1 to P/J437-2 220VAC?

Y N

Check 220VAC input circuit.

Is the Front INTLK switch close? Is the voltage from J431 to COM +24VDC?

Y N

Check the trouble chain E5.

Check the start signal of the INTLK Power Relay. Is the level from P/J410-11 to com 0v? Y N

Replace the Main PWB.

Check the wire from P/J430-4 of AC DRIVER to P/J410-11 of Main PWB for an open circuit, short circuit or improper connection. If no problem exists, replace the Main PWB

Replace the Main PWB.

U8-4 EXPOSURE VOLTAGE OVER FAIL

Ref. BSD: 3

Problem Area: Light Quantity/Voltage Control(Optics) Procedure

check the wire from P/J430-1 of AC DRIVER to P/J410-10 of Main PWB. Power on. Detect the Exposure Sensor Signal level. Is the level from P/J410-10 to COM over 2.9VDC?

Y N

Replace Main PWB.

Replace AC DRIVER.

U8-5 EXPOSURE LIGHT QTY/VOLTAGE UNDER FAIL

Ref. BSD: 3

Problem Area: Light Quantity/Voltage Control(Optics) Preparation: Ensure that P/J410-10 of Main PWB is securely

connected to P/J430-1 of AC Drive PWB.

Procedure

Enter Diag. Mode. Enter [6-7],[6-8]. Check the A/D value, A5-A7. Is the voltage from P/J430-1 to COM ≤ 0.5V? Y N

Replace the Main PWB.

Replace the AC DRIVER.

2.4.3 MISFEED JAM

C1-3 TRAY 1 MISFEED JAM

Preparation:

• Ensure that no paper jam occurred.

• Ensure that the Feed Roller has not worn out and the friction is

proper.

Procedure

Clear paper jam, start copying. Does the Feed Roller rotate?

Y N

Enter Diag. (C/E) Mode. Enter [8-2], and check the operation of Feed Solenoid.

Y N

Check the start signal of Feed Solenoid. Does the voltage from P/J406-10 to com go high correctly?

Y N

Replace the Main PWB Remedy the mechanical jam, then check the operation of Solenoid. If it cannot turn on, replace it. Check the tension of the pick up gear spring. If the tension is

weak, replace the spring. Clean the Feed Roller and the Pinch Roller, Check them for the deterioration.

Y N

Did the lead edge of paper reach the Regi-Gate.

Y N

Replace the Feed Roller, Clean the paper path. Check the Regi-Gate sensor. Enter [8-8], check the level from

P/J407-8 to com, does it go high(H) and go low(L)? If no change is the voltage from P/J600-1 to P/J600-3 +5VDC?

Y N

Check the +5VDC circuit. Replace the Regi-Gate Sensor.

• Replace the Feed Roller.

• Clean the paper path.

C9-3 MSI MISFEED JAM

Procedure:

Start the copying in by in by pass Mode. Does the MSI feed Roller operate? Y N Does the MSI Solenoid operate? Y N Enter Diag. Mode, Enter [8-7], does MIS Solenoid turn on? Y N

Replace the Main PWB. Check the wire from P406-2 to P/J210-2. Remedy mechanical trouble. Check the operation of Solenoid again. If it does not turn on , replace it.

Replace the pick up Gear Spring.

• Clean MSI Feed Roller and paper path.

• If necessary, replace MSI Feed Roll er, or adjust / replace the Retard

Pad.

2-25 2.4 Level 2 Troubleshooting

Section 2 Troubleshooting

Section 4 Disassembly/Assembly / Adjustment

Section 4 Disassembly/ Assembly/ Adjustment

1. Main Drive

1.1.1 Main Motor Replacement ………..…………… 4-3

2. Paper Handling

2.1.1 Side Registration Adjustment ……………..…… 4-3

2.2.1 MSI Feeder Assy Removal/Installation ……….. 4-4

2.2.2 MSI Retard Pad Replacement ...............…....... 4-4

2.3.2 MSI Feed Roller Replacement …………………. 4-5

2.3.3 MSI Size Sensor Replacement ………..………. 4-5

2.3.4 MSI No Paper Sensor Replacement ................. 4-5

2.5.1 Feed Roller Replacement ………………………. 4-6

2.5.3 No Paper Sensor Replacement ................……. 4-6

2.5.4 Right Cover Intlk switch Replacement .....…….. 4-8

2.5.5 Tray1 Intlk Switch Replacement…………………4-9

2.5.6 Tray1 Intlk Switch Adjustment...…………………4-9

2.7.1 Registration Assy Removal/Installation ……… 4-10

2.7.2 Registration Gate Solenoid Replacement …... 4-10

Regi-Gate Sensor Replacement .…………. 4-10

2.7.3

2.7.4 Registration Roller Replacement ……………. 4-10

2.7.6 Lead Edge Registration Adjustment …………. 4-11

3. Paper Transport

3.1.1 Vacuum Transport Belt Replacement ……..... 4-12

4. Optics

4.1.1 Plate Glass Replacement ... .....................….... 4-1 3

4.1.2 Optical Cooling Fan Replacement …...………. 4-13

4.2.1 Optical Regi-Sensor Replacement .................. 4-14

4.2.2 Lamp Carriage Motor Replacement ……….. 4-14

4.2.3 Carriage Cable Replacement ………………... 4-15

4.3.1 Full-Rate & Half-Rate Carriages Parallel Adjustment …………...…………………………. 4-16

4.3.2 Exposure Lamp Replacement ...........….......... 4-18

4.3.3 Optical Skew Adjustment .....................…….... 4 - 1 8

4.3.4 Size-for-Size Fine Tuning ………………...…… 4-19

4.5.3 Lens Cable Replacement ........... ............……. 4-20

4.5.4 Lens Motor Replacement ………………..…… 4-22

5.1.4 Basic Copy Quality Adjustment ………………. 4-24

5.1.5 IS IL Assembly Replacement ………………….. 4-26

5.1.6 ISIL Copy Edge Erase Amount Adjustment ... 4-26

6. Development

6.2.1 Deve. Unit Removal/Installation …………..….. 4-27

6.2.2 Mag. Roll Blade Replacement ……………..… 4-27

6.2.3 Toner Empty Sensor Replacement …..……… 4-27

8. Fuser

8.1.1 Fuser Th e rmostat Replacement ..............….... 4-28

8.1.2 Fuser Thermistor Replacement ………………. 4-28

8.2.1 Heater Rod Replacement ……………...……… 4-29

8.2.2 Heat Roller Replacement ……………………… 4-30

8.2.3 Pressure Roller Replacement …………..……. 4-31

8.2.4 Contact Arc Adjustment ………………………. 4-32

8.3.1 Heat Roller Fingers Replacement …………… 4-33

8.3.2 Pressure Roller Fingers Replacement ………. 4-33

8.5.1 Fuser Fan Motor Assy Replacement ………… 4-34

8.5.2 Ozone Filter (Fuser Fan) Replacement .......... 4-34

9. Electrical

9.1.2 Main PWB Replacement …………………….... 4-35

9.1.3 LVPS Replacement ……………………………. 4-38

9.1.4 AC Drive PWB Replacement ……..………… 4-38

10. Covers L Frame

10.1.1 Front Gas Spring Replacement ……………... 4-39

10.1.2 Rear Gas Spring Replacement ……………… 4-39

10.2.1 Console Assembly Replacement ……………. 4-40

10.2.2 Top Cover Removal/Installation ………………4-40

How to Use the Disassembly/Assembly/Adjustment Manual

1. Specific removal/installation procedures are not described for parts for which those procedures are at first sight understood.

2. Installation procedures refer only to items requiring your attention.

2. Install parts with their protrusions, if any, fitted into half-

punched dents.

3. Circled numbers such as ➀/➁/➂in each Figure

indicate the order of a procedure and parts applicable.

5. Xerographic

5.1.1 Drum Unit Replacement ……………….……… 4-23

5.1.2 Drum Finger Replacement ……………………. 4-23

5.1.3 Charge Corotron Wire Replacement ………… 4-24

4-1 Contents

Section 4 Disassembly/Assembl y/Adjustment

4-2

Section 4 Disassembly/Assembly/Adjustment

Intentional blank page

1.1.1 Main Motor Replacement

Removal

1. WARNING: Power off the machine and disconnect the power cord.

2. Open the Front Cover and the machine.

3. Remove the Drum Unit ……………....... (5.1.1)

4. Remove the Rear Upper Cover.

5. (Fig. 1): Remove the Main Motor.

➀. Disconnect P/J404. ➁. Remove screws (3). ➂. Remove Main Motor

(Fig. 1)

Installation

1. Perform the installation in the reverse order of the removal.

2.1.1 Side Registration Adjustment

Purpose To adjust the position of the Cassette

Tray to align the document image transferred onto the Drum with paper(in the Drum axis direction).

Reference The Tray positions in front/rear

directions are each adjus ta ble b y 2mm (4mm in total) .

Adjustment

1. Slide out the Cassette Tray from the machine.

2. (Fig. 1): Perform the Side Registration Adjustment as follows.

NOTE: • The Right/Left Stoppers should be

moved by the same distance.

➀. Remove Screws. ➁. Install Screws to slots of both

Stoppers respectively.

➂. Change the positions of Stoppers.

A direction (Front): X will widen. B direction (Rear): X will narrow.

➃. Tighten Screws.

3. (Fig. 1): After adjustment make a copy-if it is NOT OK, repeat Steps 1~3.

(Fig. 1)

4-3 1. Main Drive/2. Paper Handling

Section 4 Disassembly/Assembly/Adjustment

4-4

Section 4 Disassembly/Assembly/Adjustment

2. Paper Handling

2.2.1 MSI Feeder Assy Removal/Installation

Removal

1. WARNING: Power off the machine and

disconnect the power cord.

2. Open the Rear Upper Cover.

3. Open the Right Upper Cover.

4. (Figs. 1 & 2): Remove the MSI Tray.

➀. Open MSI Tray. ➁. Remove Screw and then open MSI Tray

slide it toward rear and remove it.

(Fig. 1)

5. Open the Right Transport Cover.

6. (Fig. 2): Remove the MSI Feeder Assembly.

➀. Disconnect P/J616 and P/J210 . ➁. Remove Screw. ➂. Remove MSI Feeder Assembly.

(Fig. 2)

Installation

1. Perform the installation in the reverse order of removal.

2.2.2 MSI Retard Pad Replacement

NOTE: • You should replace the Retard Pad, the

Feed Roller(2.3.2).

• You should clear the Feed Counter in Diag. Mode [30-4].

Removal

1. WARNING: Power off the machine and disconnect the power cord.

2. Remove the MSI Feeder Assembly ….. (2.2.1)

3. (Fig.1): Remove the Tie Plate Assembly.

➀. Remove Screws (2). ➁. Remove Tie Plate Assembly.

(Fig. 1)

4. (Fig. 2): Remove the Retard Pad.

➀. Turn over Tie Plate Assy. ➁. Release locking of the Retard Pad.

==➀

=➁

(Fig. 2)

➂. Remove Retard Pad.

(Fig. 3)

Installation

1. Perform the installation in the reverse order of removal.

2.3.2 MSI Feed Roller Replacement

NOTE: • You should clear the Feed Counter in

Diag. Mode [30-4] at the time of replacement.

Removal

1. WARNING: Power off the machine and disconnect the power cord.

2. Remove the MSI Feeder Assy……….. (2.2.1)

3. (Fig. 1): Remove the MSI Feed Roller.

➀. Remove E Clip. ➁. Remove bearing. ➂. Slide MSI Roll Assy. ➃. Push up hook and then slide Core Roll. ➄. Remove MSI Feed Roller.

2.3.3 MSI Size Sensor Replacement

Removal

1. WARNING: Power off the machi ne an d disconnect the power cord.

2. Remove the MSI Feeder Assembly ….. (2.2.1)

3. (Fig.1): Remove the MSI Size Sensor.

➀. Disconnect P/J110. ➁. Remove Size Sensor. ➂. Remove Size Sensor Actuator .

2.3.4 MSI No Paper Sensor Replacement

Removal

1. WARNING: Power off the machi ne an d disconnect the power cord.

2. Remove the MSI Feeder Assembly ….. (2.2.1)

3. (Fig.1): Remove the MSI No Paper Sensor.

➀. Remove Cover. ➁. Disconnect P/J111. ➂. Remove MSI No Paper Sensor.

(Fig. 1)

Installation

1. Perform the installation in the reverse order of removal.

(Fig. 1)

Installation

1. Perform the installation in the reverse order of removal.

2. Perform an Input Check of the MSI Size

Sensor in Diag. Mode[8-10].

=➀

=➁

(Fig. 1)

Installation

1. Perform the installation in the reverse order of removal.

2. Perform an Input Check of the MSI No Paper

Sensor in Diag. Mode[7-10].

4-5 2. Paper Handling

Section 4 Disassembly/Assembly/Adjustment

4-6

Section 4 Disassembly/Assembly/Adjustment

2. Paper Handling

2.5.1 Feed Roller Replacement

2.5.3 No Paper Sensor Replacement

NOTE: • When replacing the Feed Roller, clear

the Feed Counter of the appr opri at e Tray, using the Diag. Mode applicable:

Content Diag Mode

Tray 1 Feed Counter 30-1

Replacement Procedure Common

to the Above

Removal

1. WARNING: Power off the machine and disconnect the power cord.

2. Slide out the appropriate Tray.

3. Remove the Transport Cover.

➀. Remove Screw. ➁. Push Transport Cover to rear side. ➂. Remove Transport Cover by sliding away

Pin on its front side.

4. (Fig. 2): Remove the Chute. ➀. Remove Chute from Pins by pulling its rear

side.

➁. Slide Chute to rear and remove it.

(Fig. 2)

5. (Fig. 3): Remove the Feeder Assy. ➀. Disconnect P/J610 (Tray 1) and the Ground wire.

➁. Remove Screws (2). (Wire Guard

disengages together.)

➂. Lift No Paper Sensor Actuator manually. ➃. Remove Feeder Assy.

(Fig.4)

Replacement Procedure

for Feed Roller only

6. (Fig. 5): Remove the Feed Roller. NOTE: • Do not contaminate the Roller surface

with grease, etc. Clean the contaminated Roller surface with the Drum Cleaner.

Feed Roller

(Fig. 5)

(Fig. 1)

Replacement Procedure

For Pick Up Gear only

6. (Fig. 5): Remove the Pick Up Gear.

➀. Remove the Spring. ➁. Keep pushing the hook of the pick up gear

using the small screw gear. ➂. Remove the pick up gear.

Replacement Procedure

for No Paper Sensor only

6. (Fig. 6): Remove the No Paper Sensor.

➀. Remove No Paper Sensor tab. ➁. Lift Actuator. ➂. Remove No Paper Sensor. ➃. Remove Connector.

Common Procedure

Installation

1. Perform the installation in the reverse order of removal.

NOTE: • (Fig.7): Install the Feeder Assy to the

machine with the Feed Roller halfmoon shaped facing upwards.

Face up

• (Fig. 8): Install the Feeder Assy to the machine with the Assy cutouts hooked on the machine pins.

Cut outs

➂

➀

(Fig. 5)

➁

(Fig. 8)

(Fig.6)

(Fig. 7)

• When installing the Feeder Assembly to the machine, take great care not to damage the No Paper Sensor Actuator.

• Reconfirm that the Feed Roller half-moon shape faces upwards before installing the appropriate Tray.

NOTE: • After the replacement of the No

Paper Sensor, check the Sensors using the following Diag Codes.

Sensor Diag. C od e

Tray 1 No Paper Sensor 7-6

4-7 2. Paper Handling

Section 4 Disassembly/Assembly/Adjustment

4-8

2.5.4 Transport Cover INTLK Switch Replacement

Section 4 Disassembly/Assembly/Adjustment

4. Paper Handling

Removel

1. WARNING: Power off the machine and disconnect the power cord.

2. Open the Transport Cover.

3. Remove the Transport Cover.

➀. Remove Screw. ➁. Push Transport Cover to rear side. ➂. Remove Transport Cover by sliding away

Pin on its front side.

(Fig. 1)

4. (Fig.2)Remove Transport Cover INTLK Switch. ➀. Push up the hook that fixes INTLK Switch.

➁. Slide out INTLK switch then disconne ct.

Installation:

1. Perform the installation in the reverse order of removal.

(Fig.2)

2.5.5 TRAY 1 Switch Replacement

2.5.6 TRAY 1 Switch Adjustment

Removal

1. WARNING: Power off the machine and disconnect the power cord.

2Remove the Rear Lower Cover. 3Remover the LVPS 4(Fig1) Remove the Switch Bracket.

➀Remove screw.

Installation

1. Perform the installation in the reverse order of the removal.

(Fig.1)

Purpose: To prevent the Tray from hitting the Tray Switch, as deformation of the Switch Actuator will lead to poor contact.

1. WARNING: Power off the machi ne an d disconnect the power cord.

2. Remove the Rear Lower Cover.

3. Remover the LVPS……………..………..9.1.3

4. (Fig.1)Loosen two fi xin g scre ws of Tray 1 Switch Bracket.

(Fig.1)

5. Tighten two fixing screws of Tray 1 Switch Bracket.

4-9 2Paper Handling

Section 1 Service Procedure

4-10

Section 4 Disassembly/Assembly/Adjustment

2. Paper Handling

2.7.1 Registration Assy Removal/Installation

Removal

1. Power off the machine and disconnect the

Power Plug.

2. Remove the Drum Unit and place a black

bag over it ……………………………….. (5.1.1)

3. Remove the Deve. Unit. ………………. (6.2.1)

4. Remove the TC/DTC Assy.

5. Remove the following Covers:

• Right Upper Cover

• Rear Upper Cover

• Rear Lower Cover

6. Remove the MSI Feeder Assy. ……… (2.2.1)

7. (Fig. 1): Remove the Upper Chute Assy.

➀. Loosen Screw and remove Chute Bias

resistance.

➁. Remove Spring. ➂. Open Registration Assy pin-installed

bracket.

➃. Remove Upper Chute Assy.

8. (Fig. 2): Remove the Registration Assy. ➀. Disconnect P/J116 (for Regi-Sensor) &

P/J214 (for Regi-Gate Solenoid).

➁. Remove Screws(2). ➂. Remove Registration Assy.

(Fig. 2)

Installation

1. Reinstall the Registration Assy by reversing Step 8, Removal.

2. Restore the machine to its original state in the reverse order of the removal.

2.7.2 Registration Gate Solenoid Replacement

2.7.3 Regi-Gate Sensor Replacement

• Replace both by removing the Registration

Assy....................………………………... (2.7.1)

• The Solenoid/Sensor can now be replaced.

2.7.4 Registration Roller Replacement

Removal

1. Power off the machine and disconnect the Power Plug.

2. Remove the Registration Assembly ….. (2.7.1)

3. Remove the Registration Roller. ➀. (Fig.1): Remove E Clip and then Bearing.

(Fig. 1)

➁. (Fig.2): Remove Screw and then Gear.

(Fig. 2)

(Fig. 1)

➂. (Fig. 3): Remove One-Way Clutch and

Gear. (Spring disengag es tog eth er. )

➃. Remove E Clip and then Bearing.

(Fig. 3)

➄. (Fig. 4): Turn over Registration Assy. ➅. Push in Registration Gate Solenoid plunger

with your finger.

➆. Remove Registration Roller (with plunger

pushed in).

(Fig. 4)

Installation

1. Perform the installation in the reverse order of the removal.

2.7.6 Lead Edge Registration Adjustment

Purpose To properly align the copy image on

the Drum with the lead edge of paper.

Check

1. In 100% Mode, align Test Chart(4 99T 2 47 or

248) with Regi-Guide and make a copy.

2. (Fig. 1): Check that there is 10±1.6mm from

the copy’s lead edge to the reference line.

(Fig. 1)

Adjustment

• Fast Paper Feed(The distance is more than

10±1.6mm from the copy’s lead edge to the reference line.)

1. Key in Diag. [20-1].

2. Increase data.

NOTE: • Changing the data by 1 will change the

distance by 0.2584mm.

• Slow Paper Feed(The distance is less than 10+

1.6mm from the copy’s lead edge to the reference line.)

1. Key in Diag. [20-1].

2. Decrease data.

NOTE: • Changing the data by 1 will change the

distance by 0.2584mm.

3. Make a copy and check it.

4. Perform the ISIL Copy Edge Erase Amount

Adjustment ...................……………....... (5.1.6)

4-11 2. Paper Handling

Section 4 Disassembly/Assembly/Adjustment

4-12

Section 4 Disassembly/Assembly/Adjustment

2. Paper Transport

3.1.1 Vacuum Transport Belt Replacement

Removal

1. Power off the machine and disconnect the

Power Plug.

2. Open the Front Cover and then the machine.

3. Remove the Drum Unit and place a black

bag over it ……………………………... (5.1.1)

4. Remove the Rear Upper Cover.

5. Remove the TC/DTC Assembly.

6. (Fig. 1): Remove the Main Switch Cover.

➀. Remove Screw. ➁. Remove Main Switch Cover.

(Fig. 1)

7. (Fig. 2): Remove AC DRIVE PWB.

➀. Remove Screw. ➁. Remove AC Drive PWB Cover. ➂. Disconnect the plug and remove AC Drive

PWB,

ºóÃæ

(Fig. 2)

8. (Fig. 3): Remove the Vacuum Transport Assembly.

➀. Remove Screw. ➁. Remove Vacuum Transport Assy.

NOTE: • Pushing the rear pin with a screw

driver as shown in Fig. 3 makes it easier to remove.

(Fig. 3)

9. (Fig. 4): Remove the Transport Belt.

➀. Remove E Clip and then Bearing. ➁. Slide Shaft. ➂. Remove Transport Belt.

Installation

1. Perform the installation in the reverse order of removal.

NOTE: • (Fig. 5): Pay attention to the Belt

direction.

(Fig. 5)

(Fig. 4)

4.1.1 Platen Glass Replacement

Removal

1. Power off the machine and disconnect the Power Plug.

2. Open the Platen Cover.

3. (Fig. 1): Remove the Platen Glass.

➀. Remove Screws (2). ➁. Remove Platen Glass Support. ➂. Remove Platen Glass.

4.1.2 Optical Cooling Fan Replacement

Removal

1. Power off the machine and disconnect the Power Plug.

2. Remove the Left Upper/Rear Upper Covers.

3. (Fig. 1): Remove the Optical Cooling Fan.

➀. Disconnect P/J408. ➁. Remove Screws(2). ➂. Remove Optical Cooling Fan.

(Fig. 1)

Installation

1. Perform the installation in the reverse order of removal.

Installation

1. Perform the installation in the reverse order of removal.

Reference • This Fan cools the Optics by taking air into the machine.

• Do not turn the Fan over when installing it.

(Fig. 1)

4-13 4. Optics

Section 4 Disassembly/Assembly/Adjustment

4-14

Section 4 Disassembly/Assembly/Adjustment

4. Optics

4.2.1 Optical Regi-Sensor Replacement

Removal

1. Power off the machine and disconnect the Power Plug.

2. Remove the Platen Glass. ........…….... (4.1.1)

3. Open the Front Cover and remove the Console Assy. ………………………... (10.2.1)

4. (Fig. 1): Loosen the Top Cover. ➀. Remove Front Screws(2) to enable Top

Cover Fron t to be raised.

(Fig. 1)

5. (Fig. 2): Remove Optical Regi-Sensor.

➀. Raise Top Cover a little. ➁. Remove Screw. ➂. Remove Regi-Sensor. ➃. Disconnect P/J100.

(Fig. 2)

Installation

1. Perform the installation in the reverse order of removal.

NOTE: • While pushing the Regi-Sensor toward

the lower right to eliminate end play, tighten the Screw.

4.2.2 Lamp Carriage Motor Replacement

Removal

1. Power off the machine and disconnect the

Power Plug.

2. Remove Rear Upper Covers.

3. (Fig. 1): Remove Lamp Carriage Motor.

➀. Disconnect P/J605. ➁. Remove Screws(2). ➂. Remove the Motor.

(Fig. 1)

Installation

1. Perform the installation in the reverse order of removal.

2. Make a copy of Test Chart(499T247 or 248) and check that it exhibits no skip, that no abnormal noises are heard, etc.

4.2.3 Carriage Cable Replacement

NOTE: • The Cable winding procedur e is

described only for the Front Cable because the Front and Rear Cables are symmetrically wound.

• Prepare Scotch tape.

• Replace Cables one by one.

Refer to the location of the installed wiring for the correct Cable routing.

Reference The Rear Cable is painted in black.

Removal

1. Power off the machine and disconnect the Power Plug.

2. Remove the Platen Cover .

3. Remove the Platen Glass. ……………. (4.1.1)

4. Remove the Top Cover. ……………. . (10.2.2)

5. Remove the Regi-Guide.

6. (Fig. 1): Gently move the Full-Rate Carriage

manually up to the frame hole at the right of the Regi-Sensor.

(Fig. 1)

7. (Fig. 2) : Loosen the Cable Mounting Screw for the Full-Rate Carriag e.

NOTE: • When replacing the Rear Cable, remove

the Optical Cooling Fan. …….... (4.1 2)

(Fig. 2)

8. (Fig. 3): To make the rest of this procedure

easier, gently move the Full-Rate Carriage

up to the frame cutout.

NOTE: • Move the Carriage by holding at the rear keeping it perpendicular to the frame because its front is not fixed to the Cable.

9. (Fig. 4): Remove the Cable from the spring and then the whole Cable from the machine.

(Fig. 4)

Installation

1. (Figs. 5 & 6): Wind the Cable on the Capstan Pulley.

➀. (Fig. 5): Determine the Cable direction. ➁. Wind Cable on Capstan Pulley shaft nine

turns.

NOTE: • The Full-Rate Carriage should be

positioned at the frame cutout in Fig.3.

➂. (Fig. 6): With the Cable-centering ball in the Capstan Pulley hole, wind the Cable five turns on the front side and three turns on the rear side centering on the ball. The total number of winds is nine, including one wind at the central ball. (Overlap of the cable windings is allowed here.)

(Fig. 6)

(Fig. 3)

(Fig. 5)

4-15 4. Optics

Section 4 Disassembly/Assembly/Adjustment

4-16

Section 4 Disassembly/Assembly/Adjustment

4. Optics

2. (Fig. 7): Route the ball-attached side of Cable to the Pulley via the far left Pulley as shown in Fig. 7, then fasten the ball into the left-hand Frame hole.

(Fig. 7)

3. (Fig. 8): Route the ring-attached side of cable to the Pulley via the Full-Rate Carriage and, then hook the ring on the right-hand-Frame spring.

4. (Fig. 9): Finger tighten the Cable Mounting Screw for the Full-Rate Carriage.

(Fig. 9)

5. (Fig. 10): Arrange the cable windings on the Capstan Pulley by holding the Full-Rate Carriage with your hand and gently moving it right and left.

4.3.1 Full-Rate & Half-Rate Carriages Parallel Adjustment

Purpose To set the Carriages parallel so that

the Front/Rear Light Paths ar e the same in length.

NOTE: • This adjustment should be performed

when the following problem occurs or after the work is complete:

1. Optical Skew(Skewed image)

2. Carriage Cable Removal/Installation (4.2.3)

Check

1. Power off the machine and disconnect the Power Plug.

2. Remove the Platen Cover.

3. Remove the Platen Glass. ………….… (4.1.1)

4. Remove the Left Upper Cover.

5. Remove the Top Cover. …………….. (10.2.2)

6. Remove the Regi-Guide.

7. Remove the Blocks for Parallel Adjustment from the Left-Hand Frame by moving the FullRate & Half-Rate Carriages manually to the Right.

➀. (Fig. 1): Push Block A convex from the

frame hole and turn Block A through 180 degrees. (Both front and rear).

(Fig. 1)

➁. (Fig. 2): Remove Block B’s and install them

to Full-Rate Carriage front/rear.

(Fig. 8)

(Fig. 10)

6. Perform the Full-Rate & Half-Rate Carriage

Parallel Adjustment. ...............……...... (4.3.1)

7. Reinstall all the parts and make a copy. Check that the copy exhibits no optical skew, etc.

(Fig. 2)

8. (Fig. 3): Move gently the Full/Half-Rate Carriages toward their hom e posi ti ons by rotating the Capstan Pulley shaft manually to check the following:

• The Half-Rate Carriage convex contacts

Block A’s at its front and rear.

• Block B’s installed to the Full-Rate Carriage

contact the Left-Hand Frame at its front and rear.

Adjustment Half-Rate Carriage Adjustmen t

1. (Fig. 4): Make the Half-Rate Carriage convex contact (Front/Rear) Block A’s.

➀. Loosen screws(2) for Front Capstan Pulley. ➁. Adjust by rotating Capstan Pulley or Shaft.

NOTE: • Do not remove Screw for Rear

➂. Tighten Screws(2).

Reference The standard tightening Torque is

Capstan Pulley.

0.5N

•m(5kgf•cm).

2. (Fig. 5): Remove the end play in the Drive Shaft axis direction and tighten the screws for the Capstan Pulley.

➀. Insert 0.5mm Thickness Gauge between

Capstan Pulley and Bearing.

➁. Push Capstan Pulley to front and Shaft to

rear and tighten screws(2).

Full-Rate Carriage Adjustment

1. (Fig. 6): Make (Front/Rear) Block B’s installed to the Carriage contact the Left-Hand Frame.

➀. Loosen the Carriage Wire Mounting Screw.

NOTE: • For the adjustment of Rear Block B,

remove the Optical Cooling Fan.

.........………………………….. (4.1.2)

➁. Adjust by moving the Carriage. ➂. Tighten Screw.

(Fig. 4)

(Fig. 3)

(Fig. 5)

(Fig. 6)

4-17 4. Optics

Section 4 Disassembly/Assembly/Adjustment

4-18

Section 4 Disassembly/Assembly/Adjustment

4. Optics

4.3.2 Exposure Lamp Replacement

NOTE: • Do not touch the Exposure Lamp glass

tube with your hand. If you touch it, wipe it with the Drum Cleaner.

• Take care not to hit the Exposure Lamp glass tube. It is fragile.

Removal

1. Power off the machine and disconnect the Power Plug.

2. Open the Platen Cover.

3. Remove the Platen Glass. .......……..... (4.1.1)

4. (Fig. 1): Move the Full-Rate Carriage gently to the frame cutout and remove the Lamp.

➀. Remove Screw. ➁. Remove Front/Rear Side Reflectors. ➂. Remove Cover. ➃. Push open Front Contact Plate with your

fingers.

➄. Remove Lamp .

Installation

1. Perform the installation in the reverse order of removal. NOTE: • (Fig. 2): Install the Lamp with its

protrusion facing the Reflector opening approx. 45° from the Platen Glass surface .

(Fig. 2)

2. Key in Diag. Mode [6-7] and check that the Lamp is on.

3. Perform the Basic Copy Quality Adjustment. …………………………………………….. (5.1. 4)

4.3.3 Optical Skew Adjustment

Purpose To correct the optical image skew in

the Drum axis and paper feed

directions. NOTE: • Ensure that the following are functioning correctly:

1. Paper is fed properly.

a. There is no difference in skew level between

Trays.

b. There is no difference in skew level between

continuously-made copies.

2. The Regi-Guide(or Gate) and the Platen Glass

are positioned properly.

3. The Full-Rate/Half-Rate Carriages Parallel

Adjustment is properly performed. …...

(4.3.1)

4. There is no difference in skew level between

A4 & A3 ( or between B5 & B4). * If there is some difference, check to see if the bottom half of A3(or B4) paper skews due to the uneven transporting force of the Fuser

owing to a defective P Roll. Replace the P Roll if necessary.

* The Regi-Roll is deteriorated or worn out.

5. Do not ad just paper skew by this means.

6. After this adjustment, make sure to record in

the Machine History Card that it has been performed.

Adjustment Flow chart

(Fig. 1)

Check

1. Align Test Chart(499T24 7) wit h th e RegiGuide and make a size- for-size copy of it on A3 paper.

2. (Fig. 1): Measure A, B, C & D each. Check that the values each obtained by subtracting B from A and D from C are in the specifications below: A – B → within ± 1.6mm C – D → within ± 2.0mm

(Fig. 1)

Adjustment A - B is out of spec.

1. Power off the machine and disconnect the Power Plug.

2. Remove the Platen Glass. .........……... (4.1.1)

3. Remove the Optical Cooling Fan. ...….. (4.1.2 )

4. (Fig. 2): Move the Full-Rate Carriage holding it at its rear. NOTE: • Do not move the Carriage right and left

more than 2mm; otherwise, there could occur problems such as poor resolution and the Carriage slamming on the frame.

➀. Remove Carriage Wire Mounting

Screw.

➁. Adjust by moving Full-Rate Carriage

with Carriage Cable still.

• A>B Move the Carriage to the right.

• A<B Move the Carriage to the left.

➂.Tighten Screw.

C - D is out of spec.

1. Power off the machine and disconnect the Power Plug.

2. Remove the Platen Glass. ………….…. (4.1.1)

3. Remove the Right Upper Cover.

4. (Fig. 3): Move the Half-Rate Carriage holding it at its front. NOTE: • Do not move the Carriage right and left

Reference The standard tightening torque is

more than 2mm; otherwise, there could occur problems such as poor resolution and the Carriage slamming on the frame.

➀. Loosen Front Capstan Pulley

screws(2).

➁. (Fig. 3): To adjust, move the Half-

Rate Carriage by rotating the Capstan Pulley.

NOTE: • Do not remove the screw for

➂. Tighten Screw.

the Rear Capstan Pulley.

• Do not rotate the Carriage Drive Shaft.

• In the case of C > D, rotate the

Capstan in the −

• In the case of C < D, rotate the

Capstan in the −

0.5N

• m(5kgf • cm).

a direction. b direction.

4.3.4 Size-for-Size Fine Tuning

Purpose To set the vertical magnification

(Scan direction) and horizontal magnification(Drum axis direction).

Reference When the machine is shipped out

from the plant , its copy ma gn if icat io n is set to 100% ± 0.8%.

Check

1. Make a size-for-size A3 copy of Test Chart (499T247).

2. (Fig. 1): Check that designated locations are

the same in length by comparing Test Chart with the copy as follows:

• Vertical Magnification Check on ➁ to ➃, ➁ to ➄ and ➃ to ➄.

• Horizontal Magnification Check on ➀ to ➁, ➁ to ➂ and ➀to ➂.

(Fig. 1)

(Fig. 3)

(Fig. 2)

4-19 4. Optics

Section 4 Disassembly/Assembly/Adjustment

4-20

Section 4 Disassembly/Assembly/Adjustment

4. Optics

Adjustment

• Vertical Magnification Change the vertical magnification (Scan direction) referring to Table 1.

• Horizontal Magnification Change the horizontal magnification (Drum axis direction) referring to Table 1.

(-2%)

(-3%)

Initial

Value

(±0%)

Chain Code Content Min.

100% Horizontal Mag.

Fine Tuning 100% Vertical

Mag. Fine Tuning

Max.

(+2%)

(+3%)

4.5.3 Lens Cable Replacement

Removal

1. Select 100% Magnification. After the Lens stops, power off the machine and disconnect the Power Plug.

2. Open the Platen Cover and remove the

Platen Glass. …………………………… (4.1.1)

3. (Fig. 1): Remove the Optical Shield.

➀. Loosen Screws(2) ➁. Raise the rear side of Mirror Carriage and

remove Optical Shield.

(Fig. 1)

4. (Fig. 2): Remove the Lens Carriage Shield.

➀. Remove Screw. ➁. Remove Lens Carriage Shield.

NOTE: • Take care not to break the film

5. Check the following:

• (Fig. 3): The Lens Carriage timing hole should align with the Rail timing hole.

(Fig. 3)

6. (Fig. 4): Remove the Lens Cable.

• First unhook the spring-attached side of Cable.

attached to the Shield.

(Fig. 2)

(Fig. 4)

Installation

1. (Fig. 5): Check that the Lens Carriage timing hole aligns with the Rail timing hole. Tape the Lens Carriage to the frame.

(Fig. 5)

2. Hook the shorter side of Cable from its ball on the Lens Carriage. NOTE: • (Fig. 5): Hook the Cable with the flat

side of the hook toward the Carriage .

3. (Fig. 6): Route the Cable to shaft of Pulley  then to the Pulley  Gear Pulley. Wind the Cable five turns in total,

inserting the ball into the Gear

Pulley hole.

, and finally wind it on the

(Fig. 6)

4. (Fig. 7): Route the longer side of Cable form its ball to the Pulley, then hook it on the Lens Carriage with the spring.

(Fig. 7)

5. Remove the tape fixing the Lens Carriage and route the Cable to the Pulley 

6. Power on the machine. Check that the Lens Carriage timing hole aligns with the Rail timing hole(Step 5, Removal) when the Lens is set to 100%. If the holes don’t align with eac h other, check the installation procedure again. Check, in particular, that the Cable ball is in the Gear Pulley hole.

7. Select 61%/163% Magnifications respectively. Check the following:

• The Lens Carriage moves smoothly.

• The Cable windings on the Gear Pulley are

not overlapped.

8. Restore the machine to its original state. Make copies using Enlargement/100%/Reduction Modes respectively. Check that the copies are good. Perform the Size-for-Size Fine Tuning (4.3.4) if necessary.

4-21 4. Optics

Section 4 Disassembly/Assembly/Adjustment

4-22

Section 4 Disassembly/Assembly/Adjustment

4. Optics

4.5.4 Lens Motor Replacement

Removal

1. Select 100%. After the Lens stops, power off the machine and disconnect the Power Plug.

2. Remove the Right/Rear Upper Covers.

3. Open the Front Cover, and then the machine.

4. Remove the Drum Unit and place a black bag over it. ………………………….. (5.1.1)

5. Remove the Deve. Unit. ...........….….. (6.2.1)

6. Close the machine.

7. Remove the Platen Glass. …………… (4.1.1)

8. (Fig. 1): Remove the Optical Shield.

➀. Loosen Screws(2). ➁. Raise the rear side of Mirror Carriage and

remove Optical Shield.

(Fig. 1)

9. (Fig. 2): Disconnect Connector P/J604 from the Lens Motor.

(Fig. 2)

10. Remove the Motor wire from each Cable

clamp.

11. (Fig. 3): To fix the Mirror Carriage positi on

at 100%, insert the Phillips Screwdriver through the Worm Wheel timing hole to the frame timing hole. (The scre wdri v er goe s through the frame hole.)

12. (Fig. 4): Remove the Gear.

➀. Remove E Clip. ➁. Remove Gear.

(Fig. 4)

13. (Fig. 5): Remove the Lens Mot or.

➀. Remove Screws (2). ➁. Remove Lens Motor.

Installation

1. Perform the installation in the reverse order of removal. Pay attention to the following: NOTE: • (Fig. 6): When installing the Lens

Motor, check that the Lens Carriage is set to 100%.

(Fig. 6)

2. Make copies using 100%, 70% and 141% Magnifications respectively. Check that the copies are good.

(Fig. 3)

(Fig. 5)

5.1.1 Drum Unit Replacement

NOTE: • Be careful of the following in handling

the Drum Unit: a. Place the removed Unit on a flat

surface.

b. Keep the Drum away from direct

strong light. Put a protective cover over it.

c. Do not rotate the Drum anti --

clockwise.

e. Do not touch the Drum surface with

your bare hand(s).

Removal

1. Power off the machine and disconnect the Power Plug.

2. Open the Front Cover and then the machine.

3. (Fig. 3): Remove the Drum Unit.

➀. Push Lock Lever. ➁. Pull out Drum Unit.

(Fig. 1)

Installation

1. Install the Drum Unit securely. Its improper installation will cause J3 to be displayed. Put the plug ID into the socket.

2. Perform the Basic Copy Quality Adjustment. …………………………………………….. (5.1. 4)

Reference •••• Drum Unit

a. When replacing the Drum,

replace the whole Drum Unit. (It is impossible to replace the Drum alone.) The Drum Unit contains the Drum Cleaning Blade, Film Seal and Charge Corotron.

b. Max. Copy Output Quantity

When the Drum Unit is shipped out of the plant, the max. copy output quantity is set on ID as below:

Max. Copy Output

M/C

Type

Qty on ID

(Initial Value)

5915 50,000

c. “Drum Cartridge(Unit)

Replacement” Display

Remaining

Copy

Output Qty

5,000 ON -- Possible

500 Flash -- Possible

Drum

Cartridge

Replacement

Display

Flash

(continuously)

Status

Code

J7-1

When the cartridge reaches the end of its service life, the Replace copy cartridge lamp flashes and the Copy Quantity

display shows “J7”.

d. Remaining Copy Output Qty

The remaining copy output quantity is stored in EPROM incorporated into the Drum Unit. You can check on the remaining copy output quanti ty in [81] of “Performance Spec.”

Copy

Not

possible

5.1.2 Drum Finger Replacement

Removal

1. Power off the machine and disconnect the Power Plug.

2. Open the Front Cover and then the machine.

3. Remove the Drum Unit......………......... (5.1.1)

4. (Figs. 1 & 2): Remove the Finger Assembly. ➀. (Fig. 1): Remove Stopper preventing the

disengagement of Finger Assy.

(Fig. 1)

➁. (Fig. 2): Remove Finger Assy from Bracket

by sliding it to the front of Drum Unit.

(Fig. 2)

5. (Fig. 3): Remove the Drum Finger. WARNING: • Take care not to hurt yourself in

removing the Finger. Its tip is sharp.

➀. Remove Spring. ➁. Remove Drum Finger.

(Fig. 3)

Installation

1. Perform the installation in the reverse order of removal.

CAUTION: • Check that the Drum Finger tip is

not damaged.

• Take care not to damage the Drum surface in installing the Finger Assy.

• Install the Stopper in the proper direction referring to Fig. 1.

4-23 5. Xerographic

Section 4 Disassembly/Assembly/Adjustment

4-24

Section 4 Disassembly/Assembly/Adjustment

5. Xerographic

5.1.3 Charge Corotron Wire Replacement

Removal

1. Power off the machine and disconnect the Power Plug.

2. Open the Front Cover and then the machine.

3. Remove the Drum Unit. ……................

(5.1.1)

4. (Fig. 1): Remove the Charge Corotron Assembly.

➀. Remove Screw.

➁. Remove Charge Corotron Assy.

(Fig. 1)

5. (Fig. 2): Remove the Charge Corotron Wire.

➀. Remove Front/Rear Arc Shields. ➁. Remove Spring. ➂. Remove Corotron Wire.

(Fig. 2)

Installation

1. Perform the installation in the reverse order of removal.

NOTE: • The copy edge erase amount changes

according to the Front Arc Shield installing position. Install the Arc Shield so that the copy edge erase amount after replacement is the same as before.

5.1.4 Basic Copy Quality Adjustment

Purpose To determine the correction values

of Exposure Light Quantity and Deve. Bias to obtain copy densities appropriate to various t ypes of original.

NOTE: • Copy Quality Adjustment should

be performed when copy qual it y problems occur or the following are replaced:

➀. Drum Unit Replacement ....... (5.1.1)

➁. Exposure Lamp Replacement

……………………………….. (4.3.2)

➂. Main PWB Replacement ...... (9.1.2)

NOTE: • Perform TRIM before making the Copy

Quality Adjustment.

Adjustment Fl ow

5.1.4-A Exposure Light Quantity Setup

Purpose To adjust light quantities applicable

Check

1. Enter Diag. Mode [20-2]. The Control Panel displays the following:

2. Check that the magnification is 100%.

3. Set Test Chart(499T247 or 499T248) and

select A3 or B4.

4. Press the Start button and make three straight copies. (Press the Stop button when the third copy has been made.)

NOTE: • Because pressing the Start button in

5. Evaluate the third copy. Spec: At the target in the center of the copy.

to each magnification and store the values in NVM.

Set/Count 30

Diag. [20-2] will allow ten straight copies to be made, press the Stop button at the completion of the third copy.

• This Diag Mode detects paper jams and counts.

• (Fig. 1): 0.1 gray vertical/horizontal lines disappear.

• 0.2 gray vertical/horizontal lines are reproduced.

(Fig. 1)

6. Go to one of the following steps per the result of the evaluation. Within Spec. → Perform Steps 3 through 5 in

70%/141% magnification modes.

Out of Spec. → Proceed with the adjustment

procedure.

Adjustment Reference

NOTE: • Make sure to first perform the

Adjustment Fl ow

The Exposure Light Quantity can

be set up by changing the NVM value. a. Normally adjust by the [20-2]

value.

b. Adjust by [20-20] in the cases

below:

• Light Quantity is unadjustable by the NVM value.

• The Main PWB has been

replaced.

adjustment in 100% mode.

Adjustment by NVM Value (Normal Adjustment)

1. Enter Diag. Mode [20-2].

2. Select 100% Magnification .

3. The exposure setting is adjusted by pressing the following buttons on the keyboard: . a. Button 6 to decrease the Exposure. b. Button 9 to increase the Exposure.

4. While making the copies, adjust the exposure so that the .20 gray lines are reproduced clearly and the .10. gray lines disappear.

5. When the correct setting has been achieved,

press the Start button and make three straight

copies.

6. Repeat Steps 3,4 & 5 until the results satisfy

the spec. in Step 5, Check.

7. When the reproduced copies meet the spec,

press the Start button while the machine is running in Diag. Mode[20-2]. This enables the light quantity to be stored in NVM.

8. Perform Steps 3 through 7 in 70%/141%

modes.

Adjustment by [20- 20]

1. Enter Diag. Mode [20-20]. The Control Panel displays the following: Set/ Count 50

2. Select 100% Magnification

3. Using the ke ybo ar d, ent er num b er: Increasing the number increases the exposure Decreasing the number decreases the exposure.

4. Check the copy meets the spec in step 5 of “check” .

5. Perform steps 3 to 7 of Adjustment by NVM [20-2] Value Process Normal Value.

4-25 5. Xerographic

Section 4 Disassembly/Assembly/Adjustment

4-26

Section 4 Disassembly/Assembly/Adjustment

5. Xerographic

5.1.5 ISIL Assembly Replacement

Removal

1. WARNING: Power off the machine and disconnect the power cord.

2. Open the Front Cover and then the machine.

3. Remove the Drum Unit and place a black bag over it. ……………………………. (5.1.1)

4. Remove the Deve. Unit. .........……….... (6.2.1)

5. (Fig. 1): Remove the ISIL Assembly.

➀. Remove P/J200. ➁. Remove Screw.

NOTE: • Do not lose Spring.

➂. Remove ISIL.

(Fig. 1)

Installation

1. Perform the installation in the reverse order of removal.

2. Perform the Rear Side Edge Erase Amount Check of the ISIL Copy Edge Erase Amount Adjustment. …………………………….. (5.1.6)

5.1.6 ISIL Copy Edge Erase Amount Adjustment

NOTE: • Ensure that the following adjustment is

properly performed before making this adjustment: Lead Edge Registration Adjustment ……………………………………. (2.7.6)

Check

1. Make three size-for- size copies of Test

Chart(499T247) onto A3. Check the third copy.

2. (Fig. 1): Check the erase amount.

• 4mm along lead/trail edges

• 4mm or less at rear

NOTE: • Front Side Edge Amount is set up by

moving the Front Shield Cover of the Charge Corotron.

(Fig. 1)

Adjustment

Lead Edge

1. Enter Diag. Mode and key in [20-4].

2. The current set value appears.

3. Key in a new set value and press the Start button. Increase the value. → The erase amount

Decrease the value. → The erase amount

• The adjustable range in the Diag. Mode is 0~64.

• A step of “1” will change the erase amount by 0.2584mm.

• The initial value is 32.

Trail Edge

1. Enter Diag. Mode and key in [20-5].

2. The current set value appears.

3. Key in a new set value and press the Start button. Increase the value. → The erase amount

Decrease the value. → The erase amount

• The adjustable range in the Diag. Mode is 0~64.

• A step of “1” will change the erase amount by 0.2584mm.

• The initial value is 32.

Rear Side

1. Open the Front Cover.

2. (Fig. 2): Perform the ISIL Positioning Adjustment.

. The erase amount decreases.



. The erase amount increases.



decreases.

increases.

decreases.

increases.

(Fig. 2)

6.2.1 Deve. Unit Removal/Installation

Removal

1. WARNING: Power off the machine and disconnect the power cord.

2. Open the Front Cover and then the machine.

3. (Fig. 1): Remove the Deve. Unit. NOTE: • Ensure before the work that the Deve.

Unit separates fully from the Drum . When you open the machine, the Deve. Unit will separate from the Drum.

➀. Remove Screw. ➁. Remove Deve. Unit.

(Fig. 1)

Installation

1. Perform the installation in the reverse order of removal.

6.2.2 Mag. Roll Blade Replacement

6.2.3 Toner Empty Sensor Replacement

Common Procedure

Removal

1. WARNING: Power off the machi ne an d disconnect the power cord.

2. Open the Front Cover and then the machine.

3. (Fig. 1): Remove the Deve. Unit. …...... (6.2.1)

Replacement Procedure Exclusively

For Mag. Roll Blade

4. (Fig. 1): Remove the Deve. Housing Upper Cover and then the Mag. Roll Blade. NOTE: • Do not rotate the Mag. Roll after

removing the Mag. Roll Blade, otherwise; a large quantity of toner will be spilled.

➀. Remove Screws (5). ➁. Remove Upper Cover. ➂. Remove Screws(2). ➃. Remove Mag. Roll Blade.

Installation

1. Perform the installation in the reverse order of removal. Pay attention to the following:

NOTE: • Ensure that the Blade and the Mag.

Roll have no foreign objects on thei r surfaces.

• Install the Blade flat.

• (Fig.2): After the assembly, ensure that

there are no white streaks, etc. in the Mag. Roll rotating direction, by turning the Mag. Roll Gear in the direction of arrow. If any white streaks, etc. exist, find their cause such as mixed foreign objects and remove them.

(Fig. 2)

Replacement Pr oce d ur e for To ner Empty

Sensor only

4. (Fig. 3): Remove the Toner Empty Sensor.

NOTE: • Take care not to cause any pressure or

shock to the detection surface of the Empty Sensor.

➀. Remove Deve. Housing Front Cover. ➁. Remove Screws (2). ➂. Remove Toner Empty Sensor, then

disconnect P/J122.

NOTE: • When loosening or removing the

Installation

1. Perform the installation in the reverse order of

Screw wi t h ✴, put the MSA Plate ➀ against the protrusion ↑ and tighten the screw ➂ as shown in Fig. 4.

(Fig. 4)

removal.

(Fig. 1)

(Fig. 3)

4-27 6. Development

Section 4 Disassembly/Assembly/Adjustment

4-28

Section 4 Disassembly/Assembly/Adjustment

8. Fuser

8.1.1 Fuser Thermostat Replacement

8.1.2 Fuser Thermistor Replacement

Common Procedure

Removal

1. WARNING: Power off the machine and disconnect the power cord.

WARNING

Fuser surfaces are hot, allow the fuser to cool down before attempting service procedure. Fuser lubricant can cause discomfort to eyes. Do not allow fuser lubricant to touch eyes.

2. Open the Front Cover and then the machine:

3. Remove the Drum Unit and place a black cover over it. …………………………….. (5.1.1)

4. Remove the Left Upper Cover.

5. (Fig. 1): Remove the Main Switch Cover.

➀. Remove Screw. ➁. Remove Main Switch Cover.

6. (Fig. 2): Remove the Fuser Cover.

➀. Loosen Screw. ➁. Remove Fuser Cover.

(Fig. 2)

Replacement Pr oce d ur e for Th er m os ta t only

7. (Fig. 3): Remove the Thermostat.

➀. Remove Wire going to Thermostat. ➁. Loosen Screws (2) and remove Sensor

Bracket.

➂. Remove Thermostat.

(Fig. 3)

Replacement Pr oce d ur e for Th er m ist or only

7. (Fig. 4): Remove the Thermistor.

➀. Disconnect P/J118. ➁. Remove Screw and then Thermistor.

(Fig. 4)

Common Procedure

Installation

1. Perform the installation in the reverse order of removal.

(Fig. 1)

8.2.1 Heater Rod Replacement

NOTE: a. Take great care in handling the Heater

Rod glass tube. It is fragile.

b. Do not touch the Heater Rod glass

tube with your bare hand(s). If you touch it, wipe it with Drum Cleaner.

Removal

1. WARNING: Power off the machine and disconnect the power cord.

WARNING Fuser surfaces can be hot. Fuser lubricant can cause discomfort to eyes. Do not allow fuser lubricant to touch eyes.

2. Open the Front Cover and then the machine.

3. Remove the Drum Unit and place a black

bag over it. …………………………….. (5.1.1)

4. Remove the Left/Rear Upper Covers.

5. (Fig. 1): Remove the Main Switch Cover.

➀. Remove Screw. ➁. Remove Main Switch Cover.

6. Disconnect P/J’s 12, & 13 from the Heater Rod.

7. (Fig. 2): Remove the Front/Rear Heater Rod Covers each.

➀. Loosen Screw.

➁. Remove Front/Rear Heater Rod Covers.

(Fig. 2)

8. (Fig. 3): Remove the Heater Rod.

➀. Loosen Screw. ➁. Remove Front Support Bracket. ➂. Remove Heater Rod.

NOTE: • Hold the in su la to r an d ta ke out the Heater Rod.

(Fig. 3)

Installation

1. Perform the installation in the reverse order of removal.

NOTE: • Determine which way(front or re ar ) the Heater faces by the color of the connector.

(Fig. 1)

4-29 8. Fuser

Section 4 Disassembly/Assembly/Adjustment

4-30

Section 4 Disassembly/Assembly/Adjustment

8. Fuser

8.2.2 Heat Roller Replacement

Removal

1. WARNING: Power off the machine and disconnect the power cord.

WARNING

Fuser surfaces are hot, allow the fuser to cool down before attempting service procedure. Fuser lubricant can cause discomfort to eyes. Do not allow fuser lubricant to touch eyes.

2. Open the Front Cover and then the machine.

3. Remove the Drum Unit and place a black bag over it. ……………………………. (5.1.1)

4. Remove the Left/Rear Upper Covers.

5. (Fig. 1): Remove the Main Switch Cover.

➀. Remove Screw. ➁. Remove Main Switch Cover.

(Fig. 1)

6. (Fig. 2): Disconnect P/J117 (for Fuser Exit Switch) at rear. Remove the Fus er Cove r an d the Finger Assy.

➀. Disconnect P/J117. ➁. Loosen Screw and Remove Fuser Cover. ➂. Loosen Screw and Remove Finger Assy.

(Fig. 2)

7. (Fig. 3): Remove the Sensor Bracket.

➀. Loosen Screws (2). ➁. Remove Sensor Bracket.

(Fig. 3)

8. Remove the Heater Rod. …….............. (8.2.1)

9.(Fig. 4): Remove the Heat Roller.

➀. Remove Front/Rear Heat Roller Rings ➁. Remove Web Washer. ➂. Remove Heat Roller Collar. ➃. Remove Bearing. ➄. Remove Heat Roller. (Rear Gear will also

be disengaged.)

(Fig. 4)

Installation

1. Perform the installation in the reverse order of removal.

8.2.3 Pressure Roller Replacement

Removal

1. WARNIN: Power off the machine and disconnect the power cord.

WARNING

Fuser surfaces are hot, allow the fuser to cool down before attempting service procedure. Fuser lubricant can cause discomfort to eyes. Do not allow fuser lubricant to touch eyes.

2. Open the Front Cover and then the machine.

3. Remove the Heat Roller………………….(8.2.2)

4. (Fig.1):Remove the Pressure Roller Finger Assy.

➀. Remove Screw (2). ➁. Remove the Pressure Roller Finger Assy.

➀

(Fig. 1)

5. (Fig.2):Remove the Pressure Roller.

➀. Remove the Pressure Roller Finger Assy.

➁

➀

(Fig.2)

4-31 8. Fuser

Section 4 Disassembly/Assembly/Adjustment

4-32

Section 4 Disassembly/Assembly/Adjustment

8. Fuser

8.2.4 Contact Arc Adjustment

Purpose To obtain the appropriate fusing NOTE: A narrow contact arc would cause

Check

1. (Fig 1): Make two or three copies of A4(LEF)

paper with their halves solid bl ack . Regard the copies as the measurement paper.

level.

improper fusing. Wide contact arc or a great difference in contact arc between front and rear would cause wrinkled or curled copies.

(Fig. 1)

2. Make fifteen copies of Test Chart onto A3 paper to even the temperatur es of the Hea t Roller and the Pressure Roller.

3. Put the black copy obtained from procedure No.1 on the MSI face down

4. Hold the measurement paper so that it copy

reaches the Heat Roll & the Pressure Roll.

5. Take out the measurement paper after closing

the machine for approx. 8~10 seconds

6. (Fig. 2): Open the measurement paper gently.

Take measurements at the positions 75 mm from the both sides of the paper respectively (at two positions on the fold made when the paper is folded into quarters with its lead edge aligning to its trail edge.)

•••• Proper width of NIP

5.5±0.15mm

75mm 75mm

NIP

297mm

measurement paper A4LEF

(Fig. 2)

Adjustment

1. (Fig. 3): Adjust by rotating the Adjustment Screws(at front/rear).

➀. Loosen Lock Nut. ➁. Slide the bracket. ➂. Tighten Lock Nut.

NOTE: Width of NIP increases: Slide the bracket to inside. Width of NIP decreases: Slide the bracket to inside.

decrease increas e

2. Adjust by repeating Check Steps 1 through 6.

Increase decrease

(Fig. 3)

8.3.1 Heat Roller Fingers Replacement

8.3.2 Pressure Roller Fingers Replacement

Common Procedure

Removal

1. WARNING: Power off the machine and

disconnect the power cord.

WARNING

Fuser surfaces are hot, allow the fuser to cool down before attempting service procedure. Fuser lubricant can cause discomfort to eyes. Do not allow fuser lubricant to touch eyes.

2. Open the Front Cover and then the machine.

3. (Fig. 1): Remove the Main Switch Cover.

➀. Remove Screw. ➁. Remove Main Switch Cover.

Installation

1. Perform the installation in the reverse order of removal.

NOTE: • (Fig. 4): When installing the Shaft to

the Finger Assy, pay attention to the following:

➀. the position of the Exit Sensor

actuator.

➁. The longer hook of the spring

should be installed to the Finger Assy.

Replacement Procedure for Pressur e Roller

Fingers only

5. (Fig. 5): Remove the Heat Roller Fingers.

➀. Remove Screws (2). ➁. Remove Pressure Roller Finger Assy.

(Fig. 5)

(Fig. 6)

(Fig. 1)

4. (Fig. 2): Disconnect P/J117(for Fuser Exit Switch) at rear and remove the Fuser Cover and the Finger Assy.

➀. Disconnect P/J117. ➁. Loosen Screw and remove Fuser Cover. ➂. Loosen Screw and remove Finger Assy.

(Fig. 2)

Replacement Procedure for Heat Roller

Fingers onl y

5. (Fig. 3): Remove the Heat Roller Fingers.

➀. Remove Screws(4). ➁. Remove KL Clips(2). ➂. Remove Heat Roller Fingers along with

their shafts.

(Fig. 3)

(Fig. 4)

6. (Fig. 6): Remove the Pressure Roller Fingers.

➀. Unhook the spring end. ➁. Pull out the Shaft ➂. Remove the Finger.

4-33 8. Fuser

Section 4 Disassembly/Assembly/Adjustment

4-34

Section 4 Disassembly/Assembly/Adjustment

8. Fuser

Installation

1. Perform the installation in the reverse order of removal.

NOTE: • (Fig. 7): Install the Finger with the both ends of the Spring under the Shaft.

(Fig. 7)

8.5.1 Fuser Fan Motor Assembly Replacement

Removal

1. WARNING: Power off the machine and

disconnect the power cord.

2. Remove the Platen Glass. ……............ (4.1.1)

3. Open the Front Cover and then the machine.

4. Remove the Left/Rear Upper Covers.

5. Remove the Drum Unit and place a black

bag over it. ……..,………………………. (5.1.1)

6. Move the Full-Rate Carriage slowly to the

right.

7. (Fig. 1): Loosen the Fuser Fan Motor Assy

Mounting Screw. NOTE: • (Fig. 2): The Vibration Preventing

Damper Tapes are attached to the Fan Motor Assy securing ar eas . If the screws are not loose enough, you may not be able to remove the Fan Motor Assy.

➀. Loosen Screws enough. ➁. Remove Screw.

➀

➁

8. (Fig. 2): Remove the Fuser Fan Motor Assy.

➀. Disconnect P/J409 from Main PWB. ➁. Remove Fuser Fan Motor Assy.

(Fig. 2)

Installation

1. Perform the installation in the reverse order of removal.

CAUTION: • Put the shock absorber of the Fan

Motor. Assy against the Ozone Filter securely.

8.5.2 Ozone Filter(Fuser Fan) Replacement

Removal

1. WARNING: Power off the machi ne an d

disconnect the power cord.

2. Open the Front Cover and then the machine.

3. (Fig. 1): Remove the Ozone Filter.

➀. Put the Filter at front by pushing the rear

end of the Ozone Filter.

NOTE: • When you can’t push out the Filter by

Step ➀, remove the Fuse r Fa n Moto r

Assy. ……………………......... (8.5.1)

➁. Using the screwdriver in an upright position,

prise out the Ozone Filter.

NOTE: • When removing the Ozone Filter

alone without replacing it wi th a ne w one, do not use Step ➁. Remove the Filter by removing the Fuser Fan Motor Ass y inste ad.

(Fig. 1)

Installation

1. Insert the new Filter into the area from which

the old one has been removed.

9.1.2 Main PWB Replacement

Removal

1. If the ma chine is ready, make a copy of Table Diag. Modes from the succeeding pages.

2. Enter Diag. Mode and record the data of Chain Codes into Table Diag. Mode. NOTE: • If there is any unreadable data,

3. WARNING: Power off the machi ne an d

disconnect the power cord.

4. Open the Front Cover and then machine.

5. Remove the Rear Upper Cover.

6. Disconnect all connectors from the Main PWB.

7. (Fig. 1): Remove the Main PWB.

perform its appropriate adjustment after the replacement of the Mai n PWB.

Installation

1. Install the Main PWB.

2. (Fig. 2): Perform the Dip Switch(SW2) Setup.

3. Enter Diag. Mode and key in [20-96]. Perform the initialization. NOTE: • The initialization is required because

Reference

4. Key-in to NVM the data recorded in the table

in Removal Step 2.

5. Perform the Basic Copy Quality Adjustment. ……………………………………………. (5.1.4)

the new Main PWB’s NVM values are unstable.

Items to be Initialized:

➀. Set the initial value in each item

of Reference Chain 20.

➁. Set the initial value in each item

of Chain 50.

➂. Reset counters of Chain 30. ➃. Reset the jam histories of Chain

40.

NVM stands for Nonvolatile Memory.

(Fig. 1)

4-35 8. Electrical

Section 4 Disassembly/Assembly/Adjustment

4-36

CHAIN CODE 20 TABLE ∗ The list below deletes Function which do not need recording.

Section 4 Disassembly/Assembly/Adjustment

9. Electrical

CHAIN

CODE

FUNCTION

CODE

20 1 Registration Adjustment 16(-4.13mm) 32 64(+4.13mm) 0.2584mm

2 Light Quantity Adj. 100% 0 30 80 0.8%

10 MSI Paper Loop Amount Adjustment 0(-8.27mm) 32 64(+8.27mm) 0.2584mm 11 MSI Registration Adjustment 16(-4.13mm) 32 48(+4.13mm) 0.2584mm 14 Selection of Exposure Photoreceptor Sensitivity Correction 0(OFF) 1(ON) 1(ON) 16 Bias Curve Selection 1 0 4 8 17 Bias Curve Selection 2 0(slot) 1(Flat) 1(Flat) 20 Light Quantity Adj. 0 50 99 23 Drum Photoreceptor Sensitivity Correction Constant 0(0) 11(1.1) 40(4.0) 0.1 30 Fuser Temperature Adjustment (Stand-by) 31 Fuser Temp. Adjustment (Copy cycle) 41 Density Correction Light 6 0(0V) 52(-413V) 64(-500V) -7.8125V 42 Density Correction Dark 6 0(0V) 16(-125V) 64(-500V) -7.8125V 45 Density Correction Photo Light 6 0(0V) 50(-388V) 64(-500V) -7.8125V 46 Density Correction Photo Dark 6 0(0V) 24(-184V) 64(-500V) -7.8125V 96 NVM Initialization This initializes all NVM values.

50 9 Black band Function Time 1 0(-5.168mm) 20(+9.56mm) 64(+5.168mm) 0.2584mm

10 Black band Function Time 2 0(-6.732mm) 64(+10.3mm) 64(+6.732mm) 0.2584mm

SETUP ITEM MIN. VALUE INITIAL VALUE MAX.VALUE 1 STEP CHANGE ADJ

0(-23°C) 0(-23°C)

32 32

39(+5°C) 0.72°C 39(+5°C) 0.72°C

2.7.6

5.1.4-A

5.1.6

4.3.4

5.1.4-A

CHAIN 30 CODE TABLE

CHAIN

CODE

30 1 Tray 1 Feed Counter

FUNCTION

CODE

4 MSI Feed Counter

CURRENT

VALUE

COMPONENT COUNTER

CHAIN 40 CODE TABLE

CHAIN

CODE

40 1 E1 JAM Counter

FUNCTION

CODE

2 E3 JAM Counter

5 C1 JAM Counter 10 C9 JAM Counter 21 E1 JAM Counter Reset 22 E3 JAM Counter Reset 25 C1 JAM Counter Reset 30 C9 JAM Counter Reset

CURRENT

VALUE

COMPONENT COUNTER

CHAIN 50 CODE TABLE

CHAIN

FUNCTION

CODE

50 1

Toner Touch Up Function

2 Nation Configuration Setup

Black Band Creation

Function

5.1 Preface

5.1.1

Section 5 Parts List contains information on XEROX 5915 main Processor and Spare P arts. Use this section for applying for replacement spare parts and entering area codes.

5.1.2 Plate Structure

Each plate is constructed as follows:

➀ ➂

PL-4 OPTICAL

➁ 4.3 Full Rate & Half Rate Carriage

15{

WITH 16~18

(See PL4.3)

➀ PLATE NAME MODULE NAME ➁ SUB PLATE No. ………. Parts List reference No. as described in

each Section.

➂ SUB PLATE NAME …… Art title of the Plate dividing the module. ➃ ITEM ……………………. Shows the number in the A rt for the same

plate.

➄PART No. ……………… Nos. to be used for ordering parts and

entering the Service Report.

➅ DESCRIPTION ……….. Describes the Part Name, V code and

Note.

➃ ➄ ➅

ITEM PART NO DESCRIPTION

1 12E 93380 REAR CARRIAGE CABLE

2 41S 50210 HALF RATE CARRIAGE ASSY

3 41S 50211 FULL RATE CARRIAGE ASSY

4 413W

5 113E 16680 HOLDER CABLE 6 9P 20224 SPRING EXT 7 20E 21721 PULEY CAPSTAN 8 20E 22063 PULLEY CAPSTAN OUT

9 12E 93390 CABLE SCAN OUT 10 130E 80970 SENSOR REGI OPT 11 20K 94411 PULLEY IDLER METAL 12 - - FULL RATE ADJUST BLOCK (REF

13 - - HALF RATE ADJUST BLOCK (REF

14 6K 82301 SHAFT ASSY DRIVE 15 68S 50270 MOT SCAN ASSY (WITH 16-18) 16 127S 50222 MOT SCAN 17 68S 50269 BRKT MOT SCAN 18 7E 94981 GEAR

77559

(CABLE SCAN IN)

(SEE PL4.3)

(SEE PL4.3) BEARING

ONLY)

5.1.3 Symbols and Marks

Symbols Marks

With 2~10

DETAIL “A” Shows detailed illustration of “A”.

SEE PLxx

(P/O Item)

Shows assembly parts containing “Item 2~10”.

For a part item related, indicates to refer to an appropriates PL No. Shows that removal and installation procedure are included in the Service Manual. Shows that the adjustment procedure is included in the Service Manual.

Shows that the removal, installation, and adjustment procedure are included in the Service Manual. Shows that the leader lines ○A is connected to another leader lines ○ Shows correction part for Item 1. Replace Item 1 as required.

as described.

PL-1 DRIVE

1.1 Main Drive(1)

ITEM PART NO. DESCRIPTION

1 127K 87031 MOTOR ASSY MAIN (WITH 2,3) 2 7E 35210 DRUM GEAR 3 7E 35200 MAIN MOTOR GEAR 4 7E 27680 GEAR HELICAL T36/T41 5 - - SHAFT (REF ONLY) 6 - - BRACKET (REF ONLY) 7 7E 41270 GEAR T18/34 8 7E 41280 GEAR T22

9 9E 76500 SPRING EXTENSION 10 12E 97580 LINK ASSY 11 121E 84454 MSI SOLE NOID ASSY 12 - - SADDLE (REF ONLY) 13 - - BRACKET 14 7E 27970 GEAR SPUR T35/28 15 7E 32890 GEAR T40 16 7E 28000 GEAR-T21

5-3 PL-1 DRIVE

Section 5 Parts List

5-4

PL-1 Drive

1.2 Main Drive (2)

Section 5 Parts List

ITEM PART NO. DESCRIPTION

1 7E 32461 GEAR T36 2- -WASHER(REF ONLY) 3 7E 30530 GEAR-SPUR.T41/35 4 68K 85541 BRACKET ASSY (REF ONLY) 5 7E 32961 GEAR T36 6 7E 28881 GEAR-T25/16 7 7E 32981 GEAR T27 8 7E 22910 GEAR-T37/23

9- -WASHER(REF ONLY) 10 7E 33020 GEAR SPUR T25 11 - - GEAR BRACKET(REF ONLY) 12 7E 32450 GEAR T28 13 22E 83690 ROLLER 14 7E 32970 GEAR T18/32 15 7E 32951 GEAR HELICAL T19R 16 7E 33010 GEAR HELICAL T25 17 - - SUPPORT BRACKET(REF ONLY) 18 13E 92520 BEARING-DRUM 19 - - EARTH PLATE(REF ONLY) 20 - 21 - - EARTH PLATE(REF ONLY) 22 - - SCREW(RE F ONLY) 23 7E 32990 GEAR T23 24 7E 33000 GEAR T30/T44 25 - - GEAR BRACKET 26 - - DRIVE FRAME(REF ONLY)

SCREW M3×8 (REF ONLY)

PL-1 DRIVE

PL-2 PAPER HANDLING

2.1 Paper Cassette Assembly

ITEM PART NO. DESCRIPTION

1 50S 20240 CASSETTE ASSY 2 38P 50216 GUIDE ASSY-SIDE 3 9P 50223 SPRING 4 19P 50218 SNUBBER-R 5 19E 93480 PAD-SIDE

{

WITH 2~19

12 13

6 49P 50212 PLATE BOTTOM 7 9P 50222 SPRING-N/F 8 9P 50221 SPRING-N/F

9 3P 63172 STOPPER 10 19P 50217 SNUBBER-F 11 - - SPRING(REF ONLY) 12 12E 93400 LINK 13 - - TAPPING SCREW(REF ONLY) 14 50P 50237 CASSETTE 15 - - INSTRUCTION LABEL 16 38P 50217 GUIDE-END 17 3E 30040 STOPPER CASSETTE 18 68K 85602 BRKT ASSY 19 9P 50213 SPRING

ITEM 7ITEM 8

28. 5 ±0.7mm29 ±0.7mm

5-5 PL-2 Paper Handling

Section 5 Parts List

5-6

PL-2 PAPER HANDLING

2.2 Multi Sheet Inserter Assembly

Section 5 Parts List

PL-1 Paper Handling

ITEM PART NO. DESCRIPTION

1 22S 50256 MSI FEEDER ASSY (WITH 2-5)

(SEE PL2.3) 2 54E 09243 CHUTE-MSI AP 220V 3 19S 50212 PAD ASSY RETARD 4 9E 78271 SPRING 5 19E 42170 FILM CHUTE 6 9E 78782 SPRING N/F MSI 7 50S 50238 TRAY ASSY MSI 8 7E 32871 GEAR-T29/28 9 7E 27521 GEAR-SKEW T22

10 - - SUPPORT(REF ONLY)

PL-2 PAPER HANDLING

2.3 MSI Upper Assembly

ITEM PART NO. DESCRIPTION

1 7K 85620 GEAR PICK UP 2 13E 84520 BEARING 3 120E 13150 MSI ACTUATOR 4 107E 06650 MSI SIZE SENSOR 5 13E 84490 BEARING 6 22E 84350 ROLL CORE 7 120E 09921 ACTUATOR N.P 8 107E 06650 SENSOR

9 - - FRONT BRACKET ASSY(REF ONLY) 10 - - REAR BRACKET ASSY (REF ONLY) 11 8E 93751 CAM PICK-UP 12 6S 50220 SHAFT ASSY PICK UP 13 802E 05051 COVER ROLL

5-7 PL-2 Paper Handling

Section 5 Parts List

5-8

PL-2 PAPER HANDLING

2.4 RH Transport Cover & Paper Chute

Section 5 Parts List

PL-1 Paper Handling

ITEM PART NO. DESCRIPTION

1 121E 83330 MAGNET CATCH 2 63P 50206 TAPE STOPPER 3- -SCREW(REF ONLY) 4 54E 82040 CHUTE-FEED 5 110P 50202 SWITCH-SPOT MINIATURE 6 - - PLATE COVER(REF ONLY) 7 121E 83312 MAGNET CATCH 8 48P 50237 COVER R/H

9 - - PLATE COVER(REF ONLY) 10 9P 50214 SPRING FRONT 11 9P 50215 SPRING BACK 12 22E 81851 ROLLER-PINCH 13 22E 81861 ROLLER-PINCH

PL-2 PAPER HANDLING

2.5 Feeder Assembly

ITEM PART NO. DESCRIPTION

1 22S 50260 FEEDER ASSY H/M (WITH 2-21) 2 22K 46310 ROLLER ASSY-TRANS 3 13E 84490 BEARING 4 59K 03261 ROLL ASSY FEED 5 - - WASHER(REF ONLY) 6 7E 41593 GEAR PICK UP-FEED 7 9E 76810 SPRING PICK-UP 8 7E 41571 GEAR-T28

9 3E 35531 STOPPER 10 13E 84490 BEARING 11 6P 50236 SHA F T FEED ROLL 12 9E 65960 SPRING 13 12E 97890 LINK-SOL 14 121K 16860 SOLENOID ASSY 15 107E 06650 PHOTO INTERRUPT 16 120E 99400 ACTUATOR-SNR 17 - - COV E R(RE F ONLY) 18 - - FRAME ASSY(REF ONLY) 19 7K 83521 DRIVE ASSY 20 7E 34950 GEAR IDLER T17 21 22P 50262 PINCH

5-9 PL-2 Paper Handling

Section 5 Parts List

5-10

PL-2 PAPER HANDLING

2.6 Upper Chute Assembly

WITH 2-12

Section 5 Parts List

PL-2 Paper Handling

ITEM PART NO. DESCRIPTION

1 54K 08210 UPPER CHUTE ASSEMBLY (WITH 2~12) 2 - - TORSION SPRING 3 - - TORSION SPRING 4 13E 80030 BEARING 5 13E 93670 BEARING 6 - - HOOK (REF ONLY) 7 22K 49970 ROLL ASSY-REGI PINCH 8 22K 47662 ROLL ASSY PRE-REGI PINCH

9 32E 99342 CHUTE-GUIDE 10 - - PINCH SUPPORT (REF ONLY) 11 - - CHUTE UP (REF ONLY) 12 - - FILM CHUTE (REF ONLY) 13 9E 65760 SPRING

PL-2 PAPER HANDLING

2.7 Registration Chute Assembly

WITH 215

ITEM PART NO. DESCRIPTION

1 54K 16331 REGISTRATION LOW CHUTE ASSY

(WITH 2-15) 2 7E 32360 GEAR-T27 3 7E 32940 GEAR-T18 4 13E 80030 BEARING 5 7E 32930 GEAR-18 6 13E 84520 BEARING 7 12K 93160 LINK-STUD 8 9E 65810 SPRING 9 54E 08345 CHUTE-LOW REGI

10 22K 47222 ROLL ASSY-PRE,REGI 11 50K 28751 GATE ASSY-REGI 12 130K 56130 SE NSOR RE GI 13 22K 47211 ROLL ASSY-REGI 14 121K 22340 SOLENOID ASSY 15 9E 65800 SPRING GATE 16 13E 84490 BEARING

5-11

PL-2 Paper Handling

Section 5 Parts List

5-12

PL-3 PAPER TRANSPORT

3.1 Vacuum Transport Assembly

{

WITH 5~13

{

WITH 15~21

7 A

Section 5 Parts List

PL-2 Paper Transport

ITEM PART NO. DESCRIPTION

1 20K 94292 WHEEL ASSY(WITH 5-13) 2 6E 47160 SHAFT WHEEL 3 13E 84130 BEARING 4 49E 40130 BRKT STOPPER 5 - - WHEEL SHAFT (P/O ITEM 1) 6 - - WHEEL WEIGHT (P/O ITEM 1) 7 - - SPACER (P/O ITEM 1) 8 - - TUBE (P/O ITEM 1) 9 20E 21860 WHEEL METAL

10 - - TUBE (P/O ITEM 1)

11 - - WHEEL SUPPORT (P/O ITEM 1) 12 - - SPACER (P/O ITEM 1) 13 103K 80361 REGISTOR ASSY 14 1S 50286 FRAME ASSY-TRANSPORT

(WITH15-21) 15 22E 19430 ROLL I DLE R 16 - - SHAFT (P/O ITEM 14) 17 13E 84490 B EARING 18 - - VACUUM TRANSPORT ASSEMBLY

(P/O ITEM 14) 19 23E 12250 V ACUUM TRANSPORT BELT 20 - - SHAFT(P/O ITEM 14) 21 7E 32421 GEAR-24T

PL-4 OPTICAL

AQA

4.1 Optical Assembly

ITEM PART NO. DESCRIPTION

1 90S 50209 GLASS ASSY PLATEN

2 15P 50249 PLATE GLASS 3- -SCREW(REF ONLY) 4 57K 90521 SEA L GLASS 5 127S 50224 FAN ASSY OPT 6 55K 20881 SHIELD ASSY OPTIC 7 53E 91530 FI LTER-RIGHT 8 14P 61844 P LATEN SPACER 9 48E 17460 COV E R GLASS SEAL

5-13

PL-2 Optical

Section 5 Parts List

5-14

PL-4 OPTICAL

4.2 Optical Drive

{

WITH 16~18

(See PL4.3)

Section 5 Parts List

PL-4 Optical

ITEM PART NO. DESCRIPTION

1 12E 93380 REAR CARRIAGE CABLE

2 41S 50210 HALF RATE CARRIAGE ASSY

3 41S 50211 FULL RATE CARRIAGE ASSY 4 413W 77559 BEARING

5 113E 16680 HOLDER CABLE 6 9P 20224 SPRING EXT 7 20E 21721 PULEY CAPSTAN 8 20E 22063 PULLEY CAPSTAN OUT

9 12E 93390 CABLE SCAN OUT 10 130E 80970 SENSOR REGI OPT 11 20K 94411 P ULLE Y I DLER METAL 12 - - FULL RATE ADJUST BLOCK (REF

13 - - HALF RATE ADJUST BLOCK (REF 14 6K 82301 SHAFT ASSY DRIVE

15 68S 50270 MOT SCAN ASSY (WITH 16-18) 16 127S 50222 MOT SCAN 17 68S 50269 BRK T MOT SCAN 18 7E 94981 GEAR

(CABLE SCAN IN) (SEE PL4.3) (SEE PL4.3)

ONLY) ONLY)

PL-4 OPTICAL

4.3 Full Rate & Half Rate Carriage

WITH 2~7

WITH 9~13

ITEM PART NO. DESCRIPTION

1 41S 50211 FULL RATE CARRIAGE ASSY (WITH 2-7) 2 48E 20972 COVER CONTACT IN 3 108K 90710 FUSE ASSY EXP 4 9E 65820 SPRING FUSE 5 162K 12611 CABLE ASSY 6 122P 50201 LAMP HALOGEN 7 62E 93400 MIRROR #1 8 41S 50210 HALF RATE CARRIAGE ASSY (WITH 2-

9 - - HALF RATE CARRIAGE (P/O ITEM 8) 10 20K 94441 CA RRIAGE CABLE PULLEY 11 113E 16410 CORD PULLEY 12 - - MIRROR SPRING (P/O ITEM 8) 13 62E 93420 NO. 2,3 MIRROR

5-15 PL-2 Optical

Section 5 Parts List

5-16

AQA

Section 5 Parts List

PL-4 Optical

PL-4 OPTICAL

4.4 Mirror Carriage

ITEM PART NO. DESCRIPTION

1 - - NO.4 MIRROR ASSY (REF ONLY) 2 35E 30190 SEAL 3 9E 65650 SPRING NO. 4 HSG 4 - - SHAFT (REF ONLY) 5 9E 65360 SPRING EXTENSION 6 - - ANGLE PLATE (REF ONLY)

7 9E 65610 SPRING 8 6E 57190 SHAFT CAM

9 20E 24480 WORM WHEEL 10 9E 65600 SPRING NO. 4 SHAFT 11 15K 87900 WORM GEAR

PL-4 OPTICAL

4.5 Lens Carriage

ITEM PART NO. DESCRIPTION

1 - - SENSOR BRACKET(REF ONLY) 2 127K 84530 LENS MOTOR ASSY 3 - - SENSOR BRACKET(REF ONLY) 4 107E 06650 LENS SENSOR 5 - - LENS CARRIAGE SHIELD(REF ONLY) 6 9E 65630 SPRING EXTENSION 7 41K 93880 LENS CARRIAGE ASSY 8 9E 65460 SPRING EXTENSION

9 12E 93370 LENS CABLE 10 7E 32820 CABLE GEAR PULLEY 11 7E 32830 GEAR-24/50T 12 7E 32840 GEAR-24/32T 13 7E 32850 GEAR-48T 14 20E 21710 P ULLE Y IDLER

5-17 PL-4 Optical

Section 5 Parts List

5-18

PL-5 XEROGRAPHIC

5.1 XERO Module Assembly

WITH 2~8

(See PL 8.5)

{

Section 5 Parts List

PL-5 Xerographic

ITEM PART NO. DESCRIPTION

1 125K 92513 COROTRON ASSY-CC(WITH 2-8) 2 55E 27511 SHIELD-CC 3 118K 91572 REAR INSULATOR BLOCK 4 55K 18323 REAR ARC SHIELD 5 9E 65900 WIRE SPRING 6 117K 19220 COROTRON WIRE

{

WITH 1,14~20

7 118E 12000 FRONT INSULATOR BLOCK 8 55E 27391 FRONT ARC SHIELD

9 15K 34621 PLATE CRU ASSY 10 122S 50203 ISIL LAMP ASSY 11 9P 50220 SPRING COMPRESSION 12 9E 65710 SPRING 13 - - XERO MODULE 14 - - TAPPING SCREW (REF ONLY) 15 91E 71050 LA BEL VOLTA GE(REF ONLY) 16 - - TONER SEAL (REF ONLY) 17 - - SPRING (REF ONLY) 18 19K 92822 FI NGE R-ASSY 19 - - SPRING (REF ONLY) 20 19E 93200 DRUM FI NGE R 21 - - COOLING DUCT & ERASELAMP

(SEE PL8.5)

22 - - ID ASSY

PL-5 XEROGRAPHIC

5.2 TC/DTC Corotron

ITEM PART NO. DESCRIPTION

1 125S 50201 TRANSFER & DETACH COROTRON

ASSY (WITH 2-10 13-14) 2 55E 27650 REAR ARC SHIELD 3 55E 29550 FRONT ARC SHIELD 4- -VOLTAGE LABEL 5 32E 05740 DTC GUIDE 6 9E 65900 WIRE SPRING 7 117K 19220 COROTRON WIRE 8 118K 91591 REAR INSULATOR BLOCK 9 118E 98610 FRONT INSULATOR BLOCK

10 - - TC/TDC SHIELD(P/O ITEM 1) 11 9E 65722 REAR TC/DTC SPRING 12 9E 65732 FRONT TC/DTC SPRING 13 55S 50204 E A RTH SPRING 14 - - SCREW(REF ONLY)

5-19 PL-5 Xerogaphic

Section 5 Parts List

5-20

PL-6 DEVELOPMENT

6.1 Deve Mechanism

Section 5 Parts List

PL-6 Development

ITEM PART NO. DESCRIPTION

1 1K 49781 DEVE RAIL ASSY (WITH 2-5) 2 1K 51861 RAIL ASSY 3 - - PLATE FRONT (REF ONLY) 4 - - PLATE REAR (REF ONLY) 5 9E 65630 SPRING 6 68K 11652 BRACKET SUPPORT ASSY 7 - - ROLL(P/O ITEM 6) 8 - - STUD ROLL (P/O ITEM 6) 9 48S 50267 DEVE ASSY (SEE PL 6.2)

10 - - TONER CARTRIDGE

PL-6 DEVELOPMENT

6.2 Deve Assembly

ITEM PART NO.

1 48S 50267 DEVE ASSY (WITH 221)

WITH 221

{

2~21

°üÀ¨

2 - - SCREW (P/O ITEM 1) 3 48K 49550 UPPER DEVE COVER(P/O ITEM 1) 4 - - LABEL (P/O ITEM 1) 5 9E 65870 SPRING COMPRASSION 6 3E 36350 CARTRIDGE STOPPER (P/O ITEM 1) 7 - - PLATE (P/O ITEM 1) 8 33K 91570 MAG ROLLER BLADE (P/O ITEM 1) 9 - - COVER PLATE

10 49E 37860 COUP LING PLATE 11 7K 82601 GEAR-27T (WITH 1012) 12 9E 65850 SPRING 13 7E 32480 IDLER GEAR-40T 14 7E 41250 GEAR-22/31T 15 7E 41240 GEAR-27T 16 7E 34880 IDLER GEAR-32/21T

(P/O ITEM 1)

17 - - ROLLER ASSY MAG (P/O ITEM 1) 18 7E 88070 GEAR-24/20T 19 130E 80990 TONER EMPTY SENSOR 20 48E 62480 COV E R 21 121K 86670 MAG ROLLER

DESCRIPTION

5-21 PL-6 Development

Section 5 Parts List

5-22

PL-8 FUSER

8.1 Inlet Chute & Temperature Control

Section 5 Parts List

PL-8 Fuser

ITEM PART NO. DESCRIPTION

1 48K 75880 FUSER COVER (WITH 2)

WITH 46,10

4~6, 10

°üÀ¨

{

WITH 2

°üÀ¨

{

2 - - CAUTION LABEL 3 130K 85732 FUSER SENSOR ASSY (WITH 46,10) 4 - - SENSOR BRACKET(REF ONLY) 5 - - HARNESS ( REF ONLY) 6 130P 08241 FUSER THERMOSTAT 7 54E 11970 INLET CHUTE 8 21E 93630 REAR HEATER ROD COVER

9 21K 91341 FRONT HEATER ROD COVER 10 - - HARNESS (REF ONLY) 11 130K 85790 FUSER THERMISTOR

10 7

PL-8 FUSER

8.2 Heat Roller

ITEM PART NO. DESCRIPTION

1 22P 50261 HEAT ROLLER 2 59S 50200 PRESSURE ROLLER

3 13P 61059 BEARING 4 49E 40170 FRONT HEATER ROD SUPPORT 5 28E 93121 HEAT ROLLER RING 6 5J 90590 COLLAR 7 13E 82160 BEARING 8 7E 34910 GEAR-48T

9 49E 40190 REAR HEATER ROD SUPPORT 10 7E 34921 IDLER GEAR-22T 11 7K 82230 IDLER GEAR-22T 12 7K 82220 IDLER GEAR-23T 13 7E 32431 IDLER GEAR-24T 14 7E 32441 IDLER GEAR-31T 15 - - ROLLER (RE F ONLY) 16 12E 90560 LINK 17 9E 65930 SPRING 18 126K 97451 HEATER ROD (220V) 19 - - REAR LEVER (REF ONLY) 20 - - WAVE WASHER 21 10E 91872 SLIDE 22 9E 76490 SPRING LEVER 23 49E 63961 FRONT SLIDE BRACKET 24 49E 63971 REAR SLIDE BRACKET 25 - - FRONT LEVER (REF ONLY)

5-23 PL-8 Fuser

Section 5 Parts List

5-24

PL-8 FUSER

8.3 Paper Exit

Section 5 Parts List

PL-8 Fuser

ITEM PART NO DESCRIPTION

1 120K 91080 EXIT SWITCH ACTUATOR ASSY 2 9E 65940 SPRING 3 19E 22120 HEAT ROLLER FINGER

19E 92740 HEAT ROLLER FINGER (ALT) 4 - - SHAFT (REF ONLY) 5 110K 91880 EXIT SWITCH ASSY 6 22K 39321 E XIT PINCH ROLLER ASSY 7 59K 09000 FUSER EXIT ROLLER ASSY 8 54K 09470 CHUTE AS SEMBLY (WI TH 9~12) 9 19E 22130 PERSSURE ROLLER FINGER

(P/O ITEM 8) 10 9E 65950 TORSION SPRING (P/O ITEM 8) 11 26E 56030 STUD (P/O ITEM 8) 12 - - CHUTE (P/O ITEM 8) 13 7E 34931 GEAR-25T 14 13E 84490 BEARING

Xerox 5915 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

XEROX 5915 SERVICE MANUAL

Introduction

Section 1 Service Procedure

Section 2 Troubleshooting

Output Check

Chain Code 20 Table

Individual Mode Setup

U1-1 M/C CLOCK FAIL

U3-1 LENS POSITION FAIL

U6-4 NVM FAIL

5.1 Preface

1.1 Main Drive(1)

1.2 Main Drive (2)

2.4 RH Transport Cover & Paper Chute

4.2 Optical Drive

4.3 Full Rate & Half Rate Carriage

4.5 Lens Carriage

5.2 TC/DTC Corotron

6.1 Deve Mechanism

8.1 Inlet Chute & Temperature Control

8.2 Heat Roller

8.3 Paper Exit