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BELLINI
(Machine Code: A294)

SERVICE MANUAL

Subject to change Ricoh Technical Service October 22th, 1999

1IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off. 4. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. 5. If the Start key is pressed before the copier completes the warm-up period (the Start key starts blinking red and green alternatively), keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period is completed. 6. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands. HEALTH SAFETY CONDITIONS 1. Never operate the copier without the ozone filters installed. 2. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention. OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. 2. The NVRAM on the SICU has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled in accordance with local regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are non-toxic supplies.) 3. Dispose of replaced parts in accordance with local regulations. 4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.

1WARNING
Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

1WARNING
WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING:

TABLE OF CONTENTS
1. OVERALL MACHINE INFORMATION ........................................ 1-1
1.1 SPECIFICATIONS .................................................................................... 1-1 1.1.1 COPIER ENGINE ............................................................................ 1-1 1.1.2 ADF.................................................................................................. 1-4 1.2 MACHINE CONFIGURATION .................................................................. 1-5 1.3 COMPONENT LAYOUT ........................................................................... 1-6 1.3.1 COPIER ENGINE ............................................................................ 1-6 1.3.2 ADF.................................................................................................. 1-7 1.4 PAPER PATH ........................................................................................... 1-8 1.5 COPY PROCESS ..................................................................................... 1-9 1.6 DRIVE LAYOUT ..................................................................................... 1-11 1.6.1 COPIER ENGINE .......................................................................... 1-11 1.6.2 ADF................................................................................................ 1-12 1.7 ELECTRICAL COMPONENT DESCRIPTIONS...................................... 1-13 1.7.1 COPIER ENGINE .......................................................................... 1-13 1.7.2 ADF................................................................................................ 1-19

2. DETAILED SECTION DESCRIPTIONS....................................... 2-1
2.1 DOCUMENT FEEDER.............................................................................. 2-1 2.1.1 PICK-UP ROLLER RELEASE.......................................................... 2-1 2.1.2 BOTTOM PLATE LIFT..................................................................... 2-2 2.1.3 PICK-UP AND SEPARATION.......................................................... 2-3 2.1.4 ORIGINAL FEED ............................................................................. 2-4 2.1.5 ORIGINAL SIZE DETECTION ......................................................... 2-5 2.1.6 ORIGINAL TRANSPORT................................................................. 2-6 2.1.7 ORIGINAL SKEW CORRECTION ................................................... 2-7 2.1.8 ORIGINAL INVERSION AND FEED-OUT ....................................... 2-8 2.1.9 JAM CONDITIONS ........................................................................ 2-12 2.2 SCANNING............................................................................................. 2-13 2.2.1 OVERVIEW ................................................................................... 2-13 2.2.2 SCANNER DRIVE ......................................................................... 2-14 2.2.3 ORIGINAL SIZE DETECTION IN BOOK MODE............................ 2-15 2.3 IMAGE PROCESSING ........................................................................... 2-17 2.3.1 OVERVIEW ................................................................................... 2-17 2.3.2 SBU ............................................................................................... 2-18 2.3.3 AUTO IMAGE DENSITY (ADS) ..................................................... 2-19 2.3.4 IMAGE PROCESSING STEPS AND RELATED SP MODE .......... 2-20 2.3.5 AUTO SHADING............................................................................ 2-26 2.3.6 BACKGROUND ERASE ................................................................ 2-27 2.3.7 INDEPENDENT DOT ERASE........................................................ 2-28 2.3.8 FILTERING, MAIN SCAN MAGNIFICATION/REDUCTION........... 2-29 2.3.9 GAMMA (C) CORRECTION ........................................................... 2-31 2.3.10 GRADATION PROCESSING....................................................... 2-31 2.3.11 LINE WIDTH CORRECTION ....................................................... 2-32
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2.4 LASER EXPOSURE ............................................................................... 2-33 2.4.1 OVERVIEW ................................................................................... 2-33 2.4.2 OPTICAL PATH ............................................................................. 2-34 2.4.3 AUTO POWER CONTROL (APC) ................................................. 2-35 2.4.4 FOUR BEAM LASER WRITING .................................................... 2-36 2.4.5 LD SAFETY SWITCHES ............................................................... 2-37 2.5 DRUM UNIT............................................................................................ 2-38 2.5.1 PROCESS CONTROL................................................................... 2-38 2.5.2 TONER DENSITY CONTROL ....................................................... 2-43 2.5.3 DRUM UNIT COMPONENTS ........................................................ 2-46 2.5.4 DRIVE............................................................................................ 2-47 2.5.5 DRUM CHARGE............................................................................ 2-48 2.5.6 DRUM CLEANING......................................................................... 2-50 2.5.7 OTHERS ........................................................................................ 2-53 2.6 DEVELOPMENT..................................................................................... 2-56 2.6.1 OVERVIEW ................................................................................... 2-56 2.6.2 DEVELOPMENT MECHANISM ..................................................... 2-57 2.6.3 DRIVE............................................................................................ 2-58 2.6.4 CROSSMIXING ............................................................................. 2-59 2.6.5 DEVELOPMENT BIAS................................................................... 2-60 2.7 TONER SUPPLY AND RECYCLING...................................................... 2-61 2.7.1 TONER BANK................................................................................ 2-61 2.7.2 SUPPLYING TONER TO THE DEVELOPMENT UNIT ................. 2-65 2.7.3 TONER HOPPER .......................................................................... 2-66 2.7.4 TONER RECYCLING AND WASTE TONER COLLECTION ......... 2-68 2.8 PAPER FEED ......................................................................................... 2-71 2.8.1 OVERVIEW ................................................................................... 2-71 2.8.2 DRIVE............................................................................................ 2-72 2.8.3 PAPER LIFT TRAYS 2 & 3 ......................................................... 2-73 2.8.4 PICK-UP AND FEED TRAYS 1 TO 3 ......................................... 2-75 2.8.5 REMAINING PAPER/ PAPER END DETECTION TRAYS 2 & 3 ................................... 2-79 2.8.6 PAPER SIZE DETECTION TRAYS 2 & 3 ................................... 2-80 2.8.7 TRAY LOCK TRAYS 2 & 3 ......................................................... 2-81 2.8.8 TANDEM FEED TRAY 1............................................................. 2-82 2.8.9 VERTICAL TRANSPORT .............................................................. 2-89 2.8.10 PAPER REGISTRATION ............................................................. 2-90 2.9 IMAGE TRANSFER AND PAPER SEPARATION .................................. 2-93 2.9.1 OVERVIEW ................................................................................... 2-93 2.9.2 IMAGE TRANSFER AND PAPER SEPARATION ......................... 2-94 2.9.3 TRANSFER BELT UNIT LIFT ........................................................ 2-96 2.9.4 PAPER TRANSPORTATION AND BELT DRIVE .......................... 2-97 2.9.5 TRANSFER BELT CLEANING ...................................................... 2-98 2.9.6 TONER COLLECTION .................................................................. 2-99 2.9.7 TRANSFER ANTI-CONDENSATION HEATER ........................... 2-100 2.10 FUSING .............................................................................................. 2-101 2.10.1 OVERVIEW ............................................................................... 2-101 2.10.2 FUSING ENTRANCE GUIDE .................................................... 2-102 2.10.3 FUSING UNIT DRIVE ................................................................ 2-103
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2.10.4 FUSING LAMP CONTROL ........................................................ 2-104 2.10.5 OIL SUPPLY AND CLEANING .................................................. 2-105 2.10.6 PAPER COOLING ..................................................................... 2-106 2.10.7 FUSING PRESSURE................................................................. 2-107 2.10.8 HOT ROLLER STRIPPER RELEASE........................................ 2-108 2.11 PAPER EXIT/DUPLEX ....................................................................... 2-109 2.11.1 OVERVIEW ............................................................................... 2-109 2.11.2 PAPER EXIT MECHANISM ....................................................... 2-110 2.11.3 DUPLEX DRIVE MECHANISM.................................................. 2-111 2.11.4 INVERTER................................................................................. 2-112 2.11.5 DUPLEX TRAY FEED MECHANISM......................................... 2-114 2.11.6 BASIC DUPLEX FEED OPERATION ........................................ 2-115 2.12 ENERGY SAVER MODES ................................................................. 2-119 2.12.1 OVERVIEW ............................................................................... 2-119 2.12.2 ENERGY SAVER (PANEL OFF) MODE.................................... 2-120 2.12.3 LOW POWER MODE ................................................................ 2-121 2.12.4 OFF MODE ................................................................................ 2-122 2.12.5 SUMMARY................................................................................. 2-124 2.13 OTHERS............................................................................................. 2-125 2.13.1 OPERATION UNIT .................................................................... 2-125 2.13.2 DOOR SAFETY SWITCH LOCK TOOLS .................................. 2-126 2.13.3 HDD CONTROL......................................................................... 2-127 2.13.4 DATA PATH THROUGH THE INTERFACE BOARD................. 2-129

3. INSTALLATION PROCEDURE ................................................... 3-1
3.1 INSTALLATION REQUIREMENTS .......................................................... 3-1 3.1.1 ENVIRONMENT .............................................................................. 3-1 3.1.2 MACHINE LEVEL ............................................................................ 3-1 3.1.3 MINIMUM SPACE REQUIREMENTS.............................................. 3-2 3.1.4 POWER REQUIREMENTS.............................................................. 3-2 3.2 COPIER (A294) ........................................................................................ 3-3 3.2.1 ACCESSORY CHECK ..................................................................... 3-3 3.2.2 INSTALLATION PROCEDURE........................................................ 3-5 3.3 FINISHER INSTALLATION (B302)......................................................... 3-12 3.3.1 ACCESSORY CHECK ................................................................... 3-12 3.3.2 INSTALLATION PROCEDURE...................................................... 3-13 3.4 LCT INSTALLATION (B303)................................................................... 3-16 3.4.1 ACCESSORY CHECK ................................................................... 3-16 3.4.2 INSTALLATION PROCEDURE...................................................... 3-17 3.5 PUNCH UNIT INSTALLATION (A812).................................................... 3-19 3.5.1 ACCESSORY CHECK ................................................................... 3-19 3.5.2 PUNCH UNIT INSTALLATION ...................................................... 3-20 3.6 A3/DLT TRAY (B331) ............................................................................. 3-23 3.6.1 ACCESSORY CHECK ................................................................... 3-23 3.6.2 INSTALLATION PROCEDURE...................................................... 3-24 3.7 KEY COUNTER INSTALLATION ........................................................... 3-27 3.8 INTERFACE BOARD (CD-RW/TANDEM COPY KIT/PRINTER CONTROLLER) ..................... 3-30 3.8.1 INSTALLATION PROCEDURE...................................................... 3-30
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4. SERVICE TABLES ...................................................................... 4-1
4.1 GENERAL CAUTIONS ............................................................................. 4-1 4.1.1 DRUM .............................................................................................. 4-1 4.1.2 DRUM UNIT..................................................................................... 4-1 4.1.3 TRANSFER BELT UNIT .................................................................. 4-2 4.1.4 SCANNER UNIT .............................................................................. 4-2 4.1.5 LASER UNIT.................................................................................... 4-2 4.1.6 CHARGE CORONA......................................................................... 4-3 4.1.7 DEVELOPMENT.............................................................................. 4-3 4.1.8 CLEANING....................................................................................... 4-4 4.1.9 FUSING UNIT .................................................................................. 4-4 4.1.10 PAPER FEED ................................................................................ 4-4 4.1.11 USED TONER ............................................................................... 4-4 4.2 SERVICE PROGRAM MODE................................................................... 4-5 4.2.1 SERVICE PROGRAM MODE OPERATION .................................... 4-5 4.2.2 SERVICE PROGRAM MODE TABLES ......................................... 4-10 4.2.3 TEST PATTERN PRINTING (SP2-902)......................................... 4-59 4.2.4 INPUT CHECK............................................................................... 4-60 4.2.5 OUTPUT CHECK........................................................................... 4-68 4.2.6 SYSTEM PARAMETER AND DATA LISTS (SMC LISTS)............. 4-70 4.2.7 MEMORY ALL CLEAR (SP5-801) ................................................. 4-70 4.2.8 SOFTWARE RESET...................................................................... 4-71 4.2.9 SYSTEM SETTING AND COPY SETTING (UP MODE) RESET ........................................... 4-71 4.3 PM COUNTER........................................................................................ 4-72 4.3.1 PM COUNTER ACCESS PROCEDURE ....................................... 4-72 4.4 PROGRAM DOWNLOAD ....................................................................... 4-78 4.5 NVRAM DATA DOWNLOAD .................................................................. 4-80 4.6 LANGUAGE DATA DOWNLOAD ........................................................... 4-81 4.7 STAMP DATA DOWNLOAD................................................................... 4-81 4.8 USER PROGRAM MODE....................................................................... 4-82 4.8.1 HOW TO ENTER AND EXIT UP MODE ........................................ 4-82 4.8.2 UP MODE TABLE.......................................................................... 4-82 4.8.3 IMAGE QUALITY SETTING BY UP MODE ................................... 4-85 4.8.4 LEDS ............................................................................................. 4-91 4.9 TEST POINTS/DIP SWITCHES/LEDS ................................................... 4-92 4.9.1 DIP SWITCHES ............................................................................. 4-92 4.9.2 TEST POINTS ............................................................................... 4-93 4.9.3 FUSES ........................................................................................... 4-93 4.9.4 VARIABLE RESISTORS................................................................ 4-93 4.10 SPECIAL TOOLS AND LUBRICANTS ................................................. 4-94 4.10.1 SPECIAL TOOLS......................................................................... 4-94 4.10.2 LUBRICANTS .............................................................................. 4-94

5. PREVENTIVE MAINTENANCE SCHEDULE............................... 5-1
5.1 PM PARTS ............................................................................................... 5-1

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6. REPLACEMENT AND ADJUSTMENT........................................ 6-1
6.1 EXTERIOR ............................................................................................... 6-1 6.1.1 FRONT ............................................................................................ 6-1 6.1.2 RIGHT.............................................................................................. 6-2 6.1.3 LEFT ................................................................................................ 6-3 6.1.4 REAR............................................................................................... 6-4 6.2 DOCUMENT FEEDER.............................................................................. 6-5 6.2.1 COVER REMOVAL.......................................................................... 6-5 6.2.2 FEED UNIT REMOVAL AND SEPARATION ROLLER REPLACEMENT....................................... 6-7 6.2.3 FEED BELT REPLACEMENT.......................................................... 6-8 6.2.4 PICK-UP ROLLER REPLACEMENT ............................................... 6-9 6.2.5 SENSOR REPLACEMENT ............................................................ 6-10 6.2.6 TRANSPORT BELT REPLACEMENT ........................................... 6-14 6.2.7 MOTOR REPLACEMENT.............................................................. 6-15 6.2.8 FEED-IN CLUTCH REPLACEMENT ............................................. 6-17 6.3 SCANNER UNIT..................................................................................... 6-18 6.3.1 EXPOSURE GLASS ...................................................................... 6-18 6.3.2 LENS BLOCK ................................................................................ 6-19 6.3.3 ORIGINAL SIZE SENSORS .......................................................... 6-20 6.3.4 EXPOSURE LAMP ........................................................................ 6-21 6.3.5 LAMP REGULATOR...................................................................... 6-22 6.3.6 OPTICS DUST FILTER ................................................................. 6-23 6.3.7 SCANNER H.P. SENSOR ............................................................. 6-24 6.3.8 SCANNER MOTOR ....................................................................... 6-25 6.3.9 SCANNER DRIVE WIRES............................................................. 6-26 6.4 LASER UNIT........................................................................................... 6-29 6.4.1 CAUTION DECAL LOCATIONS .................................................... 6-29 6.4.2 LDB AND LD FILTER REPLACEMENT......................................... 6-30 6.4.3 POLYGON MIRROR MOTOR REPLACEMENT............................ 6-31 6.4.4 LASER SYNCHRONIZATION DETECTOR REPLACEMENT ....... 6-32 6.5 DRUM UNIT............................................................................................ 6-33 6.5.1 DRUM UNIT REMOVAL AND DRUM REPLACEMENT ................ 6-33 6.5.2 QUENCHING LAMP REPLACEMENT .......................................... 6-34 6.5.3 GRID PLATE/CHARGE CORONA WIRE/ WIRE CLEANER REPLACEMENT................................................ 6-35 6.5.4 DRUM POTENTIAL SENSOR REPLACEMENT ........................... 6-37 6.5.5 CLEANING BLADE/ID SENSOR REPLACEMENT ....................... 6-38 6.5.6 CLEANING BRUSH REPLACEMENT ........................................... 6-39 6.5.7 PICK-OFF PAWL REPLACEMENT ............................................... 6-40 6.5.8 DRUM FILTER REPLACEMENT ................................................... 6-41 6.6 DEVELOPMENT AND TONER SUPPLY................................................ 6-42 6.6.1 DEVELOPMENT UNIT REMOVAL ................................................ 6-42 6.6.2 DEVELOPER REPLACEMENT ..................................................... 6-43 6.6.3 DEVELOPMENT AND AIR DUST FILTER REPLACEMENT ........ 6-45 6.6.4 DEVELOPMENT ENTRANCE, FRONT, AND REAR SIDE SEALS ....................................................................... 6-46 6.6.5 TONER DENSITY SENSOR REPLACEMENT .............................. 6-47
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6.6.6 TONER HOPPER SENSOR REPLACEMENT .............................. 6-48 6.6.7 DEVELOPMENT MOTOR REPLACEMENT.................................. 6-49 6.6.8 DEVELOPMENT ROLLER SHAFT CLEANING............................. 6-50 6.7 TRANSFER BELT UNIT ......................................................................... 6-51 6.7.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION ................... 6-51 6.7.2 TRANSFER BELT REPLACEMENT.............................................. 6-53 6.7.3 TRANSFER BELT CLEANING BLADE REPLACEMTNT .............. 6-55 6.7.4 TRANSFER BELT BIAS BRUSH REPLACEMENT ....................... 6-56 6.8 PAPER FEED ......................................................................................... 6-57 6.8.1 PAPER TRAY REMOVAL.............................................................. 6-57 6.8.2 PAPER FEED ROLLER REPLACEMENT ..................................... 6-60 6.8.3 PAPER FEED AND VERTICAL TRANSPORT CLUTCH, AND TRAY LIFT, PAPER FEED, AND PAPER END SENSOR REMOVAL............................................... 6-61 6.8.4 REAR FENCE RETURN SENSOR REPLACEMENT .................... 6-64 6.8.5 REAR FENCE HP SENSOR REPLACEMENT .............................. 6-65 6.8.6 RIGHT 1ST TRAY PAPER SENSOR REPLACMENT ................... 6-66 6.8.7 BOTTOM PLATE LIFT WIRE REPLACEMENT............................. 6-67 6.8.8 PAPER DUST REMOVER CLEANING.......................................... 6-69 6.8.9 REGISTRATION SENSOR CLEANING......................................... 6-70 6.8.10 UNIVERSAL TRAY SIZE SWITCH REPLACEMENT .................. 6-71 6.8.11 1ST TRAY LIFT MOTOR REMOVAL........................................... 6-72 6.8.12 LIFT MOTOR REMOVAL (2ND & 3RD TRAYS).......................... 6-73 6.8.13 PAPER FEED MOTOR REMOVAL ............................................. 6-74 6.8.14 RELAY MOTOR, UPPER RELAY CLUTCH, LCT RELAY CLUTCH REMOVAL ............................................... 6-75 6.8.15 REGISTRATION MOTOR REMOVAL ......................................... 6-76 6.8.16 COPIER FEED UNIT/DEVELOPMENT FAN MOTOR REMOVAL ................................................................................... 6-77 6.8.17 LCT RELAY AND RELAY SENSOR REMOVAL.......................... 6-78 6.8.18 TANDEM FEED TRAY PAPER SIZE CHANGE .......................... 6-79 6.8.19 MECHANICAL SIDE REGISTRATION ADJUSTMENT ............... 6-82 6.9 FUSING UNIT......................................................................................... 6-83 6.9.1 OIL SUPPLY & CLEANING WEB UNIT REMOVAL ...................... 6-83 6.9.2 HOT ROLLER UNIT REMOVAL AND PRESSURE ROLLER REPLACEMENT ........................................ 6-84 6.9.3 HOT ROLLER REPLACEMENT .................................................... 6-86 6.9.4 OIL SUPPLY & CLEANING WEB REPLACEMENT ...................... 6-88 6.9.5 WEB CLEANING ROLLER REPLACEMENT ................................ 6-90 6.9.6 HOT ROLLER STRIPPER REPLACEMENT ................................. 6-91 6.9.7 PRESSURE ROLLER STRIPPER REPLACEMENT ..................... 6-92 6.9.8 PRESSURE ROLLER CLEANING ROLLER REPLACEMENT...... 6-93 6.9.9 FUSING AND EXIT UNIT REMOVAL ............................................ 6-94 6.9.10 FUSING PRESSURE ADJUSTMENT.......................................... 6-95 6.10 PAPER EXIT/DUPLEX UNIT ................................................................ 6-96 6.10.1 EXIT SENSOR REPLACEMENT ................................................. 6-96 6.10.2 DUPLEX UNIT REMOVAL........................................................... 6-97 6.10.3 DUPLEX UNIT INNER COVER REMOVAL ................................. 6-98 6.10.4 JOGGER MOTOR REPLACEMENT............................................ 6-99
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DUPLEX UNIT CLUTCH REPLACEMENT ................................ 6-100 DUPLEX ENTRANCE SENSOR REPLACEMENT .................... 6-101 DUPLEX TRANSPORT SENSORS 2 & 3.................................. 6-102 DUPLEX TRANSPORT SENSOR 1/ DUPLEX INVERTER SENSOR ................................................. 6-103 6.11 TONER BANK .................................................................................... 6-104 6.11.1 WASTE TONER BOTTLE REMOVAL ....................................... 6-104 6.11.2 TONER BANK UNIT REMOVAL................................................ 6-105 6.11.3 TONER SUPPLY MOTOR AND TONER SUPPLY MOTOR SENSOR REMOVAL ...................... 6-108 6.11.4 ACCESS TO INSIDE THE TONER BANK ................................. 6-109 6.12 BOARDS AND OTHER ITEMS........................................................... 6-110 6.12.1 SICU BOARD............................................................................. 6-110 6.12.2 HARD DISK DRIVE ................................................................... 6-111 6.12.3 BCU BOARD.............................................................................. 6-112 6.12.4 I/O BOARD ................................................................................ 6-113 6.12.5 PSU ........................................................................................... 6-114 6.12.6 CHARGE/GRID/BIAS POWER PACK ....................................... 6-115 6.12.7 FUSING/DUPLEX MOTOR REPLACEMENT ............................ 6-116 6.12.8 DRUM MOTOR REPLACEMENT .............................................. 6-117 6.13 COPY IMAGE ADJUSTMENT: PRINTING/SCANNING ..................... 6-118 6.13.1 PRINTING.................................................................................. 6-118 6.13.2 PARALLELOGRAM IMAGE ADJUSTMENT.............................. 6-121 6.13.3 SCANNING ................................................................................ 6-123 6.13.4 ADF IMAGE ADJUSTMENT ...................................................... 6-124 6.14 TOUCH SCREEN CALIBRATION ...................................................... 6-125

6.10.5 6.10.6 6.10.7 6.10.8

7. TROUBLESHOOTING................................................................. 7-1
7.1 SERVICE CALL CONDITIONS................................................................. 7-1 7.1.1 SUMMARY....................................................................................... 7-1 7.1.2 SC CODE DESCRIPTIONS............................................................. 7-2 7.2 ELECTRICAL COMPONENT DEFECTS................................................ 7-36 7.2.1 SENSORS ..................................................................................... 7-36 7.2.2 SWITCHES .................................................................................... 7-40 7.3 BLOWN FUSE CONDITIONS................................................................. 7-41

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OPTION
3,000-SHEET FINISHER (B302) 1. OVERALL MACHINE INFORMATION ..................................B302-1
1.1 1.2 1.3 1.4 SPECIFICATIONS .............................................................................. B302-1 MECHANICAL COMPONENT LAYOUT............................................. B302-3 ELECTRICAL COMPONENT DESCRIPTION .................................... B302-4 DRIVE LAYOUT ................................................................................. B302-6

2. DETAILED DESCRIPTIONS .................................................B302-7
2.1 TRAY AND STAPLER JUNCTION GATE........................................... B302-7 2.2 PAPER PRE-STACKING.................................................................... B302-8 2.3 JOGGER UNIT PAPER POSITIONING.............................................. B302-9 2.4 STAPLER UNIT MOVEMENT .......................................................... B302-10 2.5 STAPLER ......................................................................................... B302-12 2.6 FEED-OUT ....................................................................................... B302-14 2.7 SHIFT TRAY UP/DOWN MOVEMENT ............................................. B302-15 2.8 SHIFT TRAY SIDE-TO-SIDE MOVEMENT ...................................... B302-16 2.9 PUNCH UNIT DRIVE........................................................................ B302-17 2.10 PUNCH WASTE COLLECTION ..................................................... B302-18 2.11 JAM CONDITIONS ......................................................................... B302-19

3. SERVICE TABLES ..............................................................B302-20
3.1 DIP SWITCHES................................................................................ B302-20 3.2 TEST POINTS .................................................................................. B302-20 3.3 FUSES.............................................................................................. B302-20

4. REPLACEMENT AND ADJUSTMENT................................B302-21
4.1 4.2 4.3 4.4 COVER REPLACEMENT ................................................................. B302-21 POSITIONING ROLLER REPLACEMENT ....................................... B302-24 ALIGNMENT BRUSH ROLLER REPLACEMENT ............................ B302-25 SENSOR REPLACEMENT............................................................... B302-26 4.4.1 STACK HEIGHT 1, 2 AND EXIT GUIDE OPEN SENSOR ...... B302-26 4.4.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR ................. B302-27 4.4.3 SHIFT TRAY EXIT SENSOR ................................................... B302-28 4.4.4 ENTRANCE AND STAPLER TRAY ENTRANCE SENSORS............................... B302-29 4.4.5 PRE-STACK STOPPER SENSOR .......................................... B302-30 4.4.6 STAPLE WASTE HOPPER SENSOR ..................................... B302-31 4.4.7 STAPLER ROTATION HP AND STAPLER RETURN SENSORS .............................................. B302-32 4.5 STAPLER REMOVAL ....................................................................... B302-33 4.6 PUNCH POSITION ADJUSTMENT .................................................. B302-34

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LCT (B303) 1. OVERALL MACHINE INFORMATION ..................................B303-1
1.1 1.2 1.3 1.4 SPECIFICATIONS .............................................................................. B303-1 MECHANICAL COMPONENT LAYOUT............................................. B303-2 ELECTRICAL COMPONENT DESCRIPTIONS.................................. B303-3 DRIVE LAYOUT ................................................................................. B303-5

2. DETAILED DESCRIPTIONS .................................................B303-6
2.1 PAPER FEED ..................................................................................... B303-6 2.2 PICK-UP AND FEED .......................................................................... B303-7 2.2.1 OVERVIEW ............................................................................... B303-7 2.2.2 PICK-UP AND FEED ................................................................. B303-8 2.2.3 SEPARATION ROLLER RELEASE ........................................... B303-9 2.3 PAPER LIFT ..................................................................................... B303-10 2.3.1 TRAY DETECTION.................................................................. B303-10 2.3.2 LIFT MECHANISM................................................................... B303-10 2.3.3 LIFT SENSOR ......................................................................... B303-11 2.4 PAPER SIZE DETECTION ............................................................... B303-12 1.5 PAPER END DETECTION ............................................................... B303-13

3. REPLACEMENT AND ADJUSTMENT................................B303-14
EXTERIOR COVER REMOVAL ....................................................... B303-14 INNER COVER REMOVAL .............................................................. B303-15 PAPER FEED ROLLER REPLACEMENT ........................................ B303-16 LCT MOTOR REPLACEMENT......................................................... B303-17 RELAY SENSOR REPLACEMENT .................................................. B303-18 PAPER HEIGHT SENSOR AND PAPER SIZE SWITCH REPLACEMENT.......................................... B303-19 3.7 MAIN DRIVE BELT REPLACEMENT ............................................... B303-20 3.8 SIDE REGISTRATION ADJUSTMENT............................................. B303-21 3.1 3.2 3.3 3.4 3.5 3.6

A3/DLT TRAY KIT (B331) 1. OVERALL MACHINE INFORMATION ..................................B331-1
1.1 SPECIFICATIONS .............................................................................. B331-1

2. DETAILED DESCRIPTIONS .................................................B331-2
2.1 SECTIONAL DESCRIPTION .............................................................. B331-2

3. REPLACEMENT AND ADJUSTMENT..................................B331-3
3.1 BOTTOM PLATE LIFT WIRE REPLACEMENT ...................... B331-3

ix

22 October 1999

SPECIFICATIONS

1.1 SPECIFICATIONS
1.1.1 COPIER ENGINE
Configuration: Copy Process: Originals: Original Size: Original Alignment: Paper Size/Weight: Size: Mainframe, Tray 1 (Tandem Tray): A4 sideways and LT sideways Mainframe, Trays 2 and 3 (Universal Trays): Europe/Asia: A5 sideways - A3 lengthwise, 8-kai sideways, 16-kai N. America: 51/2" x 81/2" sideways - 11" x 17" lengthwise LCT, Trays 4 ~ 6: A4 sideways, B5 sideways, LT sideways, A5, HLT Duplex Tray: A5/HLT (lengthwise or sideways) to A3/DLT, except that tab paper cannot be used Mainframe, Trays 1 to 3: 52 to 163 g/m2 16 to 40 lbs Bond 50 to 60 lbs Cover 90 lbs Index (no Tab) LCT, Trays 4 and 5: 52 to 216 g/m2 16 to 40 lbs Bond 50 to 80 lbs Cover 90 to 110 lbs Index LCT, Tray 6: Same as Mainframe, Trays 1 to 3 Duplex Tray: 64 to 163 g/m2 20 to 40 lbs Bond 50 to 60 lbs Cover 90 lbs Index (no Tab) Console Dry electrostatic transfer system Sheet/Book Maximum: A3/11" x 17" Minimum: A5, 51/2"x 81/2" (using ADF) Rear left corner

Weight:

1-1

Overall Information

1. OVERALL MACHINE INFORMATION

SPECIFICATIONS

22 October 1999

Reproduction Ratios:

7 reduction and 5 enlargement
Metric Version 400% 200% 141% 122% 115% 100% 93% 82% 75% 71% 65% 50% 25% Inch Version 400% 200% 155% 129% 121% 100% 93% 85% 78% 73% 65% 50% 25%

Enlargement

Full Size

Reduction

Zoom: Copy Speed: Resolution: Gradation: Warm-up Time: First Copy Time: (1st Tray, A4 sideways)

25 ~ 400% Max. 85 cpm (A4/81/2" x 11" sideways) Scanning: 600 dpi Printing: 600 dpi 256 levels Less than 360 s (from Off mode) Less than 5.4 s (Finisher upper tray: face down) Less than 4.1 s (Finisher upper tray: face up) Less than 4.5 s (Copier: face down) Less than 3.2 s (Copier: face up) Ten-key pad, 1 to 9999 1st Tray: 1,000 sheets (2,000 when used as a tandem tray) 2nd/3rd Tray: 500 sheets each 4th/5th Tray (LCT): 1,000 sheets each 6th Tray (LCT): 2,500 sheets RAM: 48 MB x 2 HDD: 4.3 GB x 2 Cartridge exchange (1,450 g/cartridge) 55 k copies (A4 sideways, 6% full black, 1 to 25 copying) North America: 240 V, 60 Hz, 20 A Europe/Asia: 220 ~ 240 V, 50Hz/60 Hz, 16 A

Copy Number Input: Copy Paper Capacity:

Memory Capacity: Toner Replenishment: Toner Yield: Power Source:

1-2

22 October 1999

SPECIFICATIONS

N. America Version

(Unit: Wh) NA (240 V/60 Hz) Copier Only System Single Side Duplex Single Side Duplex Copy Copy Copy Copy 1,864 1,888 444 462 470 502 2,122 2,135 2,152 2,182 190 203 753 766 169 183 733 746 293.2 11 (Unit: Wh) EU (230 V/50 Hz) Copier Only System Single Side Duplex Single Side Duplex Copy Copy Copy Copy 1,800 1,810 453 472 467 510 2,014 2,036 2,032 2,074 190 203 718 733 169 182 698 712 299.0 11

Warm-up Copying Stand-by Energy Star (15 min) Low Power Mode OFF Mode

ON OFF ON OFF ON OFF ON

Europe Version

Warm-up Copying Stand-by Energy Star (15 min) Low Power Mode OFF Mode

ON OFF ON OFF ON OFF ON

NOTE: ON: Fusing Lamp On, OFF: Fusing Lamp Off

1-3

Overall Information

Power Consumption:

SPECIFICATIONS

22 October 1999

Noise Emission: Sound Power Level:
The measurements were made in accordance with ISO 7779. Stand-by Copying (ADF 1 to 1) Copying Copier only Less than 59 dB(A) Less than 72 dB(A) Less than 71 dB(A) Full system Less than 58 dB(A) Less than 78 dB(A) Less than 77 dB(A)

Sound Pressure Level:
The measurements were made in accordance with ISO 7779. Stand-by Copying (ADF 1 to 1) Copying (From Memory) Copier only Less than 44 dB(A) Less than 67 dB(A) Less than 59 dB(A) Full system Less than 45 dB(A) Less than 68 dB(A) N/A

Dimensions: (W x D x H) Weight: Optional Equipment:

870 x 735 x 1,476 mm (34.3" x 28.9" x 58.1") (without options) 252 kg (without options) Refer to Machine Configuration

1.1.2 ADF
Original Size: Normal Original Mode: A3 to B6, DLT to HLT Thin Original Mode: A3 to B6 sideways, DLT to HLT Duplex Original Mode: A3 to A5, DLT to HLT Normal Original Mode: 52 ~ 156 g/m2, 14 ~ 42 lb Thin Original Mode: 40 ~ 156 g/m2, 11 ~ 42 lb Duplex Original Mode: 52 ~ 128 g/m2, 14 ~ 34 lb 100 sheets (80 g/m2, 20 lb) 72 cpm (A4/LT sideways, 1 to 1) Rear left corner FRR One flat belt From the top original DC 24 V and DC 38 V from the copier 145 W 680 x 560 x 150 mm
1-4

Original Weight:

Table Capacity: Original Feeding Speed: Original Standard Position: Separation: Original Transport: Original Feed Order: Power Source: Power Consumption: Dimensions (W x D x H):

22 October 1999

MACHINE CONFIGURATION

6

5

4

1 3

2

7

A294V502.WMF

Item Mainframe Finisher LCT Interface Kit Type 850: * A3/DLT Tray Kit Type 850

Machine Code A294 B302 B303 B327 B331

No. 1 2 3 4 7 Replaces the tandem LCT 5 Inside the Finisher 6

CD-RW B334 (CDROM reader/writer): * Punch Unit A812-30, 31, 32, 57, 67 Connector B328 (for the Tandem Copy feature): *

*: When the CD-RW and/or the copy connector cable are/is installed, the interface kit is required.

1-5

Overall Information

1.2 MACHINE CONFIGURATION

COMPONENT LAYOUT

22 October 1999

1.3 COMPONENT LAYOUT
1.3.1 COPIER ENGINE
1 33 34 32 31 30 29 28 27 26 25 24 11 12 13 14 15 16 17 18 10 2 3 4 5 6 7 8 9

23
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

22

21

20

19
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

A294V101.WMF

Laser Diode Board fG Lenses Sensor Board Unit Exposure Lamp Cleaning Brush Lamp Regulator Cleaning Blade Charge Corona Unit System Image Control Unit Color LCD Drum Development Unit Registration Roller LCT Relay Roller Transfer Belt Unit Relay Roller Pick-up Roller 1-6

Vertical Transport Rollers Separation Roller Feed Roller 1st Tray (Tandem, 1,000 sheets each) 2nd Tray (500 sheets) 3rd Tray (500 sheets) Used Toner Bottle Toner Bank Unit Duplex Tray Inverter Unit Paper Exit Roller Inverter Feed Roller Pressure Roller Paper Cooling Pipe Hot Roller Motor Control Unit Oil Supply & Cleaning Web Drum Unit

22 October 1999

COMPONENT LAYOUT

2 1

3

4

5

6

7

8 9

21 20 19 18 17 16 15 14 13 12

10

11

B301V001.WMF

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Separation Roller Feed Belt Pick-up Roller Bottom Plate Original Tray Upper Tray Exit Roller Inverter Gate Inverter Guide Roller Inverter Sensor Right Tray Exit Roller Right Exit Tray

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Exit Gate Inverter Roller Exit Sensor Upper Exit Tray Transport Belt Registration Sensor Lower Transport Roller Width Sensor Upper Transport Roller Entrance Sensor

1-7

Overall Information

1.3.2 ADF

PAPER PATH

22 October 1999

1.4 PAPER PATH

1 10 9

8 7 6 5 2 4 3
A294V504.WMF

1. 2. 3. 4. 5.

ADF Optional LCT Tray 3 (1,500-sheet LCT) Tray 2 (550-sheet Tray) Tray 1 (Tandem Tray)

6. 7. 8. 9. 10.

Duplex Unit Finisher Inverter Unit Shift Tray Upper Tray

1-8

22 October 1999

COPY PROCESS

1
A229V508.WMF

2 10

3 4

9 5 8 7

6
A229V510.WMF

1. EXPOSURE A xenon lamp exposes the original. Light reflected from the original passes to the CCD, where it is converted into an analog data signal. This data is converted to a digital signal, processed, and stored in the memory. At the time of printing, the data is retrieved and sent to the laser diode. For multi-copy runs, the original is scanned once only and stored to the hard disk. 2. DRUM CHARGE An OPC (organic photoconductor) drum is used in this machine. In the dark, the charge corona unit gives a negative charge to the drum. The grid plate ensures that corona charge is applied uniformly. The charge remains on the surface of the drum because the OPC layer has a high electrical resistance in the dark.

1-9

Overall Information

1.5 COPY PROCESS

COPY PROCESS

22 October 1999

3. LASER EXPOSURE The processed data from the scanned original is retrieved from the hard disk and transferred to the drum by four laser beams, which form an electrostatic latent image on the drum surface. The amount of charge remaining as a latent image on the drum depends on the laser beam intensity, which is controlled by the laser diode board (LDB). 4. DRUM POTENTIAL SENSOR The drum potential sensor detects the electric potential on the drum to correct various process control elements. 5. DEVELOPMENT The magnetic developer brush on the development rollers comes in contact with the latent image on the drum surface. Toner particles are electrostatically attracted to the areas of the drum surface where the laser reduced the negative charge on the drum. 6. IMAGE TRANSFER Paper is fed to the area between the drum surface and the transfer belt at the proper time to align the copy paper and the developed image on the drum. Then, the transfer bias roller and brush apply a high positive charge to the reverse side of the paper through the transfer belt. This positive charge pulls the toner particles from the drum to the paper. At the same time, the paper is electrically attracted to the transfer belt. 7. PAPER SEPARATION Paper separates from the drum as a result of the electrical attraction between the paper and the transfer belt. The pick-off pawls also help separate the paper from the drum. 8. ID SENSOR The laser forms a sensor pattern on the drum surface. The ID sensor measures the reflectivity of the pattern. The output signal is one of the factors used for toner supply control. 9. CLEANING The cleaning brush removes toner remaining on the drum after image transfer and the cleaning blade scrapes off all remaining toner. 10. QUENCHING The light from the quenching lamp electrically neutralizes the charge on the drum surface.

1-10

22 October 1999

DRIVE LAYOUT

1.6.1 COPIER ENGINE

1 7

2

6

3

5

4
A294V501.WMF

1. 2. 3. 4. 5. 6. 7.

Drum Motor Scanner Motor Fusing/Duplex Motor Paper Feed Motor Registration Motor Relay Motor Development Motor

1-11

Overall Information

1.6 DRIVE LAYOUT

DRIVE LAYOUT

22 October 1999

1.6.2 ADF

14 13 12 11 10

1 2 3 4 5

9 6

8

7

B301V101.WMF

1. 2. 3. 4. 5. 6. 7.

Pick-up Motor Bottom Plate Motor Feed-in Motor Transport Motor Upper Exit Roller Feed-out Motor Right Exit Roller

8. 9. 10. 11. 12. 13. 14.

Transport Belt Lower Transport Roller Upper Transport Roller Separation Roller Feed Belt Pick-up Roller Feed-in Clutch

1-12

22 October 1999

ELECTRICAL COMPONENT DESCRIPTIONS

Refer to the electrical component layout on the reverse side of the point-to-point diagram for the location of the components using the symbols and index numbers.

1.7.1 COPIER ENGINE
Symbol Motors M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22 M23 M24 Name Scanner Polygonal Mirror Drum Development Toner Supply Toner Bank Upper Toner Bottle Upper Bottle Cap Lower Toner Bottle Lower Bottle Cap Charge Corona Wire Cleaner Fusing/Duplex Paper Feed Relay 1st Tray Lift 2nd Tray Lift 3rd Tray Lift Registration Oil Supply/Cleaning Web Rear Fence Drive Jogger Optics Cooling Fan Polygonal Mirror Motor Cooling Fan LDB Cooling Fan Function Drives the 1st and 2nd scanners. Turns the polygonal mirror. Drives the drum, cleaning unit, and transfer belt unit. Drives the development unit. Supplies the toner to the toner hopper. Drives the toner transport coil, which feeds fresh toner from the toner bank to the toner supply cylinder. Rotates the upper toner bottle to supply toner to the toner entrance tank. Opens and closes the inner cap of the upper toner bottle. Rotates the lower toner bottle to supply toner to the toner entrance tank. Opens and closes the inner cap of the lower toner bottle. Drives the charge corona wire cleaner. Drives the fusing unit, duplex unit, inverter unit, and paper exit rollers. Drives the paper feed, separation, pick-up, lower relay, and vertical transport rollers. Drives the upper relay roller and the LCT relay roller. Raises and lowers the bottom plate in the 1st paper tray. Raises and lowers the bottom plate in the 2nd paper tray. Raises and lowers the bottom plate in the 3rd paper tray. Drives the registration rollers. Drives the oil supply/cleaning web. Moves the paper stack in the left tandem tray to the right tandem tray. Drives the jogger fences to square the paper stack in the duplex unit. Removes heat from the scanner optics unit. Removes heat from around the polygonal mirror motor. Removes heat from around the LDB.

1-13

Overall Information

1.7 ELECTRICAL COMPONENT DESCRIPTIONS

ELECTRICAL COMPONENT DESCRIPTIONS Symbol M25 M26 M27 M28 M29 M30 M31 M32 M33 M34 Sensors S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19 S20 Scanner HP Original Width Original Length 1 Original Length 2 Drum Potential Toner Density (TD) Image Density (ID) Toner Hopper Toner Supply Motor Upper Toner Bottle Lower Toner Bottle Upper Bottle Inner Cap Lower Bottle Inner Cap Toner Collection Bottle Toner Overflow Toner Near End 1st Paper Feed 2nd Paper Feed 3rd Paper Feed 1st Tray Lift Name SICU Cooling Fan Drum Cooling Fan Development Unit Cooling Fan 1 Development Unit Cooling Fan 2 Paper Cooling Pipe Fan Duplex Cooling Fan Exhaust Fan Steam Removal Fan PSU Cooling Fan 1 PSU Cooling Fan 2

22 October 1999

Function Removes heat from around the SICU. Removes heat from the drum. Removes heat from the development unit. Removes heat from the development unit. Removes heat from the paper cooling pipe. Removes heat from around the duplex unit. Removes heat from around the fusing unit. Removes water vapour from around the fusing unit. Removes heat from the PSU. Removes heat from the PSU.

Informs the CPU when the 1st and 2nd scanners are at home position. Detects original width. This is one of the APS (Auto Paper Select) sensors. Detects original length. This is one of the APS (Auto Paper Select) sensors. Detects original length. This is one of the APS (Auto Paper Select) sensors. Detects the drum surface potential. Detects the amount of toner in the developer. Detects the density of the ID sensor pattern on the drum. Detects toner in the toner hopper. Monitors the toner supply motor. Detects when the upper toner bottle is set. Detects when the lower toner bottle is set. Detects when the inner cap of the upper toner bottle is opened. Detects when the inner cap of the lower toner bottle is opened. Detects when the waste toner collection bottle is set. Detects when the waste toner collection bottle is full. Detects toner near end in the toner bank unit. Controls the 1st paper feed clutch on/off timing and the 1st pick-up solenoid off timing. Controls the 2nd paper feed clutch on/off timing and the 2nd pick-up solenoid off timing. Controls the 3rd paper feed clutch on/off timing and the 3rd pick-up solenoid off timing. Detects when the paper in tray 1 is at the correct height for paper feed.

1-14

22 October 1999 Symbol S21 S22 S23 S24 S25 S26 S27 S28 S29 S30 S31 S32 S33 S34 S35 S36 S37 S38 S39 S40 S41 S42 S43 S44 S45 S46 S47 S48 Name 2nd Tray Lift 3rd Tray Lift 1st Paper End 2nd Paper End 3rd Paper End Rear Fence HP Rear Fence Return Front Side Fence Open Front Side Fence Closed Rear Side Fence Open Rear Side Fence Closed Base Plate Down 1st Tray Paper Height 1 1st Tray Paper Height 2 1st Tray Paper Height 3 1st Tray Paper Height 4 Left 1st Tray Paper Right 1st Tray Paper Duplex Inverter Duplex Entrance Duplex Transport 1 Duplex Transport 2 Duplex Transport 3 Duplex Jogger HP LCT Relay Relay Registration Guide Plate Position

ELECTRICAL COMPONENT DESCRIPTIONS Function Detects when the paper in tray 2 is at the correct height for paper feed. Detects when the paper in tray 3 is at the correct height for paper feed. Informs the CPU when tray 1 runs out of paper. Informs the CPU when tray 2 runs out of paper. Informs the CPU when tray 3 runs out of paper. Informs the CPU when the tandem tray rear fence is in the home position. Informs the CPU when the tandem tray rear fence is in the return position. Detects whether the tandem tray front side fence is opened. Detects whether the tandem tray front side fence is closed. Detects whether the tandem tray rear side fence is opened. Detects whether the tandem tray rear side fence is closed. Detects when the bottom plate is completely lowered, to stop the 1st tray lift motor. Detects the paper height in the 1st tray. Detects the paper height in the 1st tray. Detects the paper height in the 1st tray. Detects the paper height in the 1st tray. Detects whether there is paper in the left side of the 1st tray. Detects whether there is paper in the right side of the 1st tray, allowing the tray to lift if paper is present. Detects misfeeds. Detects the leading and trailing edges of the paper to determine the reverse roller solenoid on or off timing. Detects the position of paper in the duplex unit. Detects the position of paper in the duplex unit. Detects the position of paper in the duplex unit. Detects if the duplex jogger fences are at the home position or not. Detects misfeeds. Detects misfeeds. Detects misfeeds and controls registration clutch on/off timing. Detects whether the registration guide plate is open or closed.

1-15

Overall Information

ELECTRICAL COMPONENT DESCRIPTIONS Symbol S49 S50 S51 Switches SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 SW9 SW10 SW11 Main Power Right Front Door Safety 1 Right Front Door Safety 2 Right Front Door Safety 3 Right Front Door Safety 4 Left Front Door Safety 1 Left Front Door Safety 2 Left Front Door Safety 3 Left Front Door Safety 4 2nd Tray Paper Size 3rd Tray Paper Size Name Oil Supply/Cleaning Web End Fusing Exit Exit

22 October 1999

Function Detects when the oil supply/cleaning web has been used up. Detects misfeeds. Detects misfeeds.

Provides power to the machine. If this is off, there is no power supplied to the machine. Cuts the +24 V dc power line for the fusing/duplex motor. Detects if the front door is open or not, and cuts the +24 V dc power line for the IOB. Cuts the +5 V LD dc power line. Cuts the +5 V LD dc power line. Cuts the +24 V dc power line for the fusing/duplex motor. Detects if the front door is open or not, and cuts the +24 V dc power line for the IOB. Cuts the +5 V LD dc power line. Cuts the +5 V LD dc power line. Determines the size of paper in tray 2. Also detects when the tray has been placed in the machine. Determines the size of paper in tray 3. Also detects when the tray has been placed in the machine.

Solenoids Transfer Belt Lift SOL1 SOL2 SOL3 SOL4 SOL5 SOL6 SOL7 SOL8 SOL9 1st Pick-up 2nd Pick-up 3rd Pick-up 1st Separation Roller 2nd Separation Roller 3rd Separation Roller Front Side Fence Rear Side Fence

Controls the up-down movement of the transfer belt unit. Controls the up-down movement of the pick-up roller in tray 1. Controls the up-down movement of the pick-up roller in tray 2. Controls the up-down movement of the pick-up roller in tray 3. Controls the up-down movement of the separation roller in tray 1. Controls the up-down movement of the separation roller in tray 2. Controls the up-down movement of the separation roller in tray 3. Opens and closes the front side fence in the tandem tray. Opens and closes the rear side fence in the tandem tray.

1-16

22 October 1999 Symbol SOL10 SOL11 SOL12 SOL13 SOL14 SOL15 SOL16 Name Tandem Tray Connect Left 1st Tray Lock Duplex Inverter Gate Reverse Roller Inverter Guide Plate Guide Plate Inverter Gate

ELECTRICAL COMPONENT DESCRIPTIONS Function Connects/disconnects the two halves of the tandem tray. Locks the left tandem tray while paper is being transported from left tray to right tray. Moves the junction gate to direct copies to the duplex tray or to the paper exit. Controls the up-down movement of the reverse roller in the duplex unit. Controls the up-down movement of the inverter feed guide plate in the duplex unit. Opens the guide plate when a paper misfeed occurs around this area. Moves the junction gate to direct copies to the duplex/inverter unit or to the paper exit unit.

Magnetic Clutches Toner Supply Coil MC1 MC2 MC3 MC4 MC5 MC6 MC7 MC8 MC9 MC10 MC11 MC12 MC13 MC14 PCBs PCB1 PCB2 BCU (Base Engine Control Unit) SICU (Scanner Image Control Unit) Toner Supply Roller 1st Paper Feed 2nd Paper Feed 3rd Paper Feed Inverter Exit Roller Duplex Transport Duplex Feed 1st Vertical Transport 2nd Vertical Transport 3rd Vertical Transport Upper Relay LCT Relay Lower Relay

Transfers drive from the toner bank motor to the toner transport coil, to transport toner towards the hopper. Turns the toner supply roller to supply toner from the toner hopper to the development unit. Starts paper feed from tray 1. Starts paper feed from tray 2. Starts paper feed from tray 3. Releases the drive from the inverter exit roller in the duplex unit. Drives the duplex transport rollers to transport the paper to the duplex feed rollers. Starts paper feed out of the duplex tray back into the machine via to the relay rollers. Drives the 1st vertical transport rollers. Drives the 2nd vertical transport rollers. Drives the 3rd vertical transport rollers. Drives the upper relay rollers (between tray1 and the registration rollers) Drives the relay rollers for paper feed into the machine from the LCT. Drives the lower relay rollers (between paper trays 1 and 2).

Controls all base engine functions both directly and through other control boards. Controls image processing, the laser diode, and the polygonal mirror motor.

1-17

Overall Information

ELECTRICAL COMPONENT DESCRIPTIONS Symbol PCB3 PCB4 PCB5 PCB6 PCB7 PCB8 PCB9 PCB10 PCB11 PCB12 Lamps L1 L2 L3 L4 L5 Exposure Lamp Fusing Lamp 1 Fusing Lamp 2 Fusing Lamp 3 Quenching Name PSU (Power Supply Unit) IOB (Input/Output Board) SBU (Sensor Board Unit) MCU (Motor Control Unit) Lamp Regulator Polygonal Mirror Motor Control LDB AC Drive Operation Panel Operation Key

22 October 1999

Function Provides dc power to the system and ac power to the fusing lamp and heaters. Controls the paper feed components. Contains the CCD, and outputs a video signal to the SBICU board. Drives the scanner motor. Provides dc power to the exposure lamp. Drives and controls the polygonal mirror motor. Controls the laser diode. Drives the ac components. Controls the components of the operation panel. Controls the operation switch.

Applies high intensity light to the original for exposure. Provides heat to the hot roller. Provides heat to the hot roller. Provides heat to the hot roller. Neutralizes any charge remaining on the drum surface after cleaning.

Power Packs Charge/bias/grid PP1 PP2 Others CB1 H1 H2 H3 H4 HDD1 HDD2 NF1 Circuit Breaker Optics Anti-Condensation (option) Drum (option) Tray Heater 1 (option) Tray Heater 2 (option) HDD HDD Noise Filter Transfer

Provides high voltage for the charge corona wires, grid plate, and the development roller. Provides high voltage for the transfer belt.

Provides back-up high current protection for the electrical components. Turns on when the main switch is off to prevent moisture from forming on the optics. Turns on when the main switch is off to prevent moisture from forming around the drum. Turns on when the main switch is off to keep paper dry in the paper tray. Turns on when the main switch is off to keep paper dry in the paper tray. Scanned image data is compressed and held here temporarily. Scanned image data is compressed and held here temporarily. Removes noise from the power line.

1-18

22 October 1999 Symbol SD1 TC1 TF1 TH1 Name Laser Synchronization Detector Total Counter Fusing Thermofuse Fusing Thermistor

ELECTRICAL COMPONENT DESCRIPTIONS Function Detects the laser beam at the start of the main scan.

Counts the number of copies. Opens the fusing lamp circuit if the fusing unit overheats. Detects the temperature of the hot roller.

1.7.2 ADF
Symbol Motors M1 M2 M3 M4 M5 Sensors APS Start S1 S2 S3 S4 S5 S6 DF Position Original Set Bottom Plate HP Bottom Plate Position Pick-up Roller HP Entrance S7 Informs the CPU when the DF is opened and closed (for platen mode) so that the original size sensors in the copier can check the original size. Detects whether the DF is lifted or not. Detects whether an original is on the table. Detects whether the bottom plate is in the down position or not. Detects when the original is at the correct position for feeding. Detects whether the pick-up roller is up or not. Detects when to restart the pick-up motor to lift up the pick-up roller, detects when to change the feed motor direction, detects the trailing edge of the original to finish checking the original length, and checks for misfeeds. Detects the leading edge of the original to check the original length, detects when to stop the original on the exposure glass, and checks for misfeeds. Detects the original width. Detects the original width. 12 13 19 20 4 2 Name Pick-up Feed-in Transport Belt Feed-out Bottom Plate Function Moves the pick-up roller up and down. Drives the feed belt, and the separation, pick-up, and transport rollers. Drives the transport belt. Drives the exit and inverter rollers. Moves the bottom plate up and down. Index No. 3 8 9 14 7

26

Registration S8 S9 S10 Original Width 1 Original Width 2

21 22 23

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Overall Information

ELECTRICAL COMPONENT DESCRIPTIONS Symbol S11 S12 S13 S14 S15 S16 Feed Cover Exit Cover Name Original Width 3 Original Length Exit Inverter

22 October 1999 Index No. 24 25 18 17 5 15

Function Detects the original width. Detects the original length. Detects when to stop the transport belt motor and checks for misfeeds. Detects when to turn the inverter gate and exit gate solenoids off and checks for misfeeds. Detects whether the feed cover is open or not. Detects whether the exit cover is open or not.

Solenoids SOL1 Exit Gate SOL2 Inverter Gate Magnetic Clutches Feed-in MC1 PCBs PCB1 PCB2 DF Main DF Indicator

Opens and closes the exit gate. Opens and closes the inverter gate.

16 11

Drives the feed belt, separation roller, and pick-up roller.

1

Controls the DF and communicates with the main copier boards. Indicates whether an original has been placed in the feeder, and indicates whether SADF mode has been selected.

10 6

1-20

22 October 1999

DOCUMENT FEEDER

2. DETAILED SECTION DESCRIPTIONS
2.1 DOCUMENT FEEDER
2.1.1 PICK-UP ROLLER RELEASE
Detailed Descriptions

[F] [E] [B] [C] [A] [D]

B301D103.WMF

When the original set sensor is off (no original on the original tray), the pick-up roller stays in the up position. When the original set sensor turns on (or when the trailing edge of a page passes the entrance sensor while pages remain on the original tray), the pick-up motor [A] turns on. The cam [B] rotates away from the pick-up roller release lever [C]. The lever then rises and the pick-up roller [D] drops onto the original. When the original reaches the entrance sensor, the pick-up motor turns on again. The cam pushes the lever down, and the pick-up roller rises until the pick-up roller HP sensor [E] detects the actuator [F].

2-1

DOCUMENT FEEDER

22 October 1999

2.1.2 BOTTOM PLATE LIFT
[F] [B] [E]

[A] [B]

[C]

[D]

[F]

B301D105.WMF

When an original is placed on the original tray, the original set sensor [A] turns on, the pick-up roller [B] drops on to the original, and the bottom plate position sensor [C] turns off. Then the bottom plate motor [D] turns on and lifts the bottom plate [E] by raising the lift lever [F] until the bottom plate position sensor turns on. The level of the pick-up roller drops as the stack of originals becomes smaller, and eventually, the bottom plate position sensor [C] turns off. Then, the bottom plate motor turns on and lifts the bottom plate until the bottom plate position sensor turns on. This keeps the original at the correct height for feeding.

2-2

22 October 1999

DOCUMENT FEEDER

2.1.3 PICK-UP AND SEPARATION
[D] [A] [E] [C] [A] [B]
B301D102.WMF

[B]

[C]

B301D506.WMF

The original separation system is a Feed and Reverse Roller (FRR) system. The pick-up roller [A], feed belt [B], and separation roller [C] are driven by the feed-in motor [D]. To drive this mechanism, the feed-in motor [D] and feed-in clutch [E] turn on. When two