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FrameMaker Ver.5.5E(PC) COVER [FIELD SERVICE] FOR Di181 99.07.06
FrameMaker Ver.5.5E(PC) COVER [FIELD SERVICE] FOR Di181 99.07.06
Di181
SERVICE MANUAL
Di181 SERVICE MANUAL
[FIELD SERVICE]
[FIELD SERVICE]
Copyright 1999 MINOLTA Co., Ltd. Printed in Japan
Use of this manual should be strictly supervised to avoid disclosure of confidential information.
MINOLTA Co., Ltd.
1177-7991-11 99083400
FrameMaker Ver.5.5E(PC) PL Standard Document Ver.03 99.01.27
Safety Precautions for Inspection and Service
When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. V Depending on the model, some of the precautions given in the following do not apply. Different markings are used to denote specific meanings as detailed below.
WARNING CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
The following graphic symbols are used to give instructions that need to be observed. Used to call the service technician's attention to what is graphically represented inside the marking (including a warning). Used to prohibit the service technician's from doing what is graphically represented inside the marking. Used to instruct the service technician's to do what is graphically represented inside the marking.
WARNING
1. Always observe precautions. · Parts requiring special attention in this product will include a label containing the mark shown on the left plus precautionary notes. Be sure to observe the precautions. · Be sure to observe the "Safety Information" given in the Operator's Manual. 2. Before starting the procedures, be sure to unplug the power cord. · This product contains a high-voltage unit and a circuit with a large current capacity that may cause an electric shock or burn. · The product also contains parts that can jerk suddenly and cause injury. · If this product uses a laser, laser beam leakage may cause eye damage or blindness. 3. Use the specified parts. · For replacement parts, always use the genuine parts specified in the manufacturer's parts manual. Installing a wrong or unauthorized part could cause dielectric breakdown, overload, or undermine safety devices resulting in possible electric shock or fire. · Replace a blown electrical fuse or thermal fuse with its corresponding genuine part specified in the manufacturer's parts manual. Installing a fuse of a different make or rating could lead to a possible fire. If a thermal fuse blows frequently, the temperature control system may have a problem and action must be taken to eliminate the cause of the problem.
P-1
FrameMaker Ver.5.5E(PC) PL Standard Document Ver.03 99.01.27
4. Handle the power cord with care and never use a multiple outlet. · Do not break, crush or otherwise damage the power cord. Placing a heavy object on the power cord, or pulling or bending it may damage it, resulting in a possible fire or electric shock. · Do not use a multiple outlet to which any other appliance or machine is connected. · Be sure the power outlet meets or exceeds the specified capacity. 5. Be careful with the high-voltage parts. · A part marked with the symbol shown on the left carries a high voltage. Touching it could result in an electric shock or burn. Be sure to unplug the power cord before servicing this part or the parts near it. 6. Do not work with wet hands. · Do not unplug or plug in the power cord, or perform any kind of service or inspection with wet hands. Doing so could result in an electric shock.
7. Do not touch a high-temperature part. · A part marked with the symbol shown on the left and other parts such as the exposure lamp and fusing roller can be very hot while the machine is energized. Touching them may result in a burn. · Wait until these parts have cooled down before replacing them or any surrounding parts. 8. Maintain a grounded connection at all times. (This item may not apply in the USA.) · Be sure to connect the ground wire to the ground terminal even when performing an inspection or repair. Without proper grounding, electrical leakage could result in an electric shock or fire. · Never connect the ground wire to a gas pipe, water pipe, telephone ground wire, or a lightning conductor. 9. Do not remodel the product. · Modifying this product in a manner not authorized by the manufacturer may result in a fire or electric shock. If this product uses a laser, laser beam leakage may cause eye damage or blindness. 10. Restore all parts and harnesses to their original positions. · To promote safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being crushed. · To promote safety, make sure that all tubing and other insulating materials are returned to their original positions. Make sure that floating components mounted on the circuit boards are at their correct distance and position off the boards.
P-2
FrameMaker Ver.5.5E(PC) PL Standard Document Ver.03 99.01.27
CAUTION
1. Precautions for Service Jobs · A toothed washer and spring washer, if used originally, must be reinstalled. Omitting them may result in contact failure which could cause an electric shock or fire. · When reassembling parts, make sure that the correct screws (size, type) are used in the correct places. Using the wrong screw could lead to stripped threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury. · Take great care to avoid personal injury from possible burrs and sharp edges on the parts, frames and chassis of the product. · When moving the product or removing an option, use care not to injure your back or allow your hands to be caught in mechanisms. 2. Precautions for Servicing with Covers and Parts Removed · Wherever feasible, keep all parts and covers mounted when energizing the product. · If energizing the product with a cover removed is absolutely unavoidable, do not touch any exposed live parts and use care not to allow your clothing to be caught in the moving parts. Never leave a product in this condition unattended. · Never place disassembled parts or a container of liquid on the product. Parts falling into, or the liquid spilling inside, the mechanism could result in an electric shock or fire. · Never use a flammable spray near the product. This could result in a fire. · Make sure the power cord is unplugged before removing or installing circuit boards or plugging in or unplugging connectors. · Always use the interlock switch actuating jig to actuate an interlock switch when a cover is opened or removed. The use of folded paper or some other object may damage the interlock switch mechanism, possibly resulting in an electric shock, injury or blindness. 3. Precautions for the Working Environment · The product must be placed on a flat, level surface that is stable and secure. · Never place this product or its parts on an unsteady or tilting workbench when servicing. · Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period of time. · Avoid dusty locations and places exposed to oil or steam. · Avoid working positions that may block the ventilation ports of the product. 4. Precautions for Handling Batteries · Replace a rundown battery with the same type as specified in the manufacturer's parts manual. · Before installing a new battery, make sure of the correct polarity of the installation or the battery could burst. · Dispose of used batteries according to the local regulations. Never dispose of them at the user's premises or attempt to try to discharge one.
P-3
FrameMaker Ver.5.5E(PC) PL Standard Document Ver.03 99.01.27
5. Precautions for the Laser Beam (Only for Products Employing a Laser) · Removing the cover marked with the following caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure to unplug the power cord before removing this cover. · If removing this cover while the power is ON is unavoidable, be sure to wear protective laser goggles that meet specifications. · Make sure that no one enters the room when the machine is in this condition. · When handling the laser unit, observe the "Precautions for Handling Laser Equipment."
1167P001AA
DANGER
Invisible laser radiation when open.
AVOID DIRECT TO BEAM
EXPOSURE
0947-7127-01 1144D270AA
P-4
FrameMaker Ver.5.5E(PC) PL Standard Document Ver.03 99.01.27
Other Precautions
· To reassemble the product, reverse the order of disassembly unless otherwise specified. · While the product is energized, do not unplug or plug connectors into the circuit boards or harnesses. · The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube. · An air gun and vacuum cleaner generates a strong electrostatic charge that can destroy the ATDC sensor and other sensors. Before cleaning a component with one of these devices, be sure to remove all the sensors. Otherwise, use a blower brush and cloth when cleaning parts. · When handling circuit boards with MOS ICs, observe the "INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs" (applicable only to the products using MOS ICs). · The PC Drum is a very delicate component. Observe the precautions given in "HANDLING OF THE PC DRUM" because mishandling may result in serious image problems. · Note that replacement of a circuit board may call for readjustments or resetting of particular items, or software installation. · After completing a service job, perform a safety check. Make sure that all parts, wiring and screws are returned to their original positions. · Check the area surrounding the service site for any signs of damage, wear or need of repair. · Do not pull out the toner hopper while the toner bottle is turning. This could result in a damaged hopper motor or locking mechanism. · If the product is to be run with the front door open, make sure that the toner hopper is in the locked position.
P-5
FrameMaker Ver.5.5E(PC) PL Standard Document Ver.03 99.01.27
Used Batteries Precautions
ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer's instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen ähnlichen Typ. Entsorgung gebrauchter Batterien nach Angaben des Herstellers. France ATTENTION Ily a danger d'explosion s'ily a remplacement incorrec de la batterie. Remplacer uniquement avec une batterie du meme type ou d'un type équivalent recommande par le constructueur. Mettre au rebut les batteries usageés conformément aux instructions du fabricant. Denmark ADVARSEL! Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering Udskiftning må kun ske med batteri af samme fabrikat og type. Levér det brugte batteri tilbage til leverandøren. Norway ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri. Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten. Brukte batterier kasseres i henhold til fabrikantens instruksjoner. Sweden VARNING Explosionsfara vid felaktigt batteribyte. Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren. Kassera använt batteri enligt fabrikantens instruktion. Finland VAROlTUS Paristo voi räjähtää, los se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä Käytetty paristo valmistajan ohjeiden mukaisesti.
P-6
FrameMaker Ver.5.5E(PC) 99. 7. 2
PS (Precaution For Service) Standard Document Ver.01
PRECAUTIONS FOR SERVICE
When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. V Depending on the model, some of the precautions given in the following do not apply.
Precautions Before Service
· When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to overloads. · Never disturb the LAN by breaking or making a network connection, altering termination, installing or removing networking hardware or software, or shutting down networked devices without the knowledge and express permission of the network administrator or the shop supervisor.
How to Use this Book
1. DIS/REASSEMBLY, ADJUSTMENT · To reassemble the product, reverse the order of disassembly unless otherwise specified. 2. TROUBLESHOOTING · If a component on a PWB or any other functional unit including a motor is defective, the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defective unit. · All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions. · The procedures preclude possible malfunctions due to noise and other external causes.
Precautions for Service
· Check the area surrounding the service site for any signs of damage, wear or need of repair. · Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged. · After completing a service job, perform a safety check. Make sure that all parts, wiring and screws are returned to their original positions. · Do not pull out the toner hopper while the toner bottle is turning. This could result in a damaged motor or locking mechanism. · If the product is to be run with the front door open, make sure that the toner hopper is in the locked position. · Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit containing these sensors is to be cleaned, first remove the sensors from the unit.
PS-1
FrameMaker Ver.5.5E(PC) 99. 7. 2
PS (Precaution For Service) Standard Document Ver.01
Precautions for Dis/Reassembly
· Be sure to unplug the copier from the outlet before attempting to service the copier. · The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears. · Before attempting to replace parts and unplug connectors, make sure that the power cord of the copier has been unplugged from the wall outlet. · Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the Interlock Switch with the covers left open or removed. · Do not plug in or unplug print jacks on the PWB or connect or disconnect the PWB connectors while power is being supplied to the copier. · Never use flammable sprays near the copier. · A battery (lithium, nickel-cadmium, etc.) is used in this machine. Do not charge or short circuit it and make sure of the correct polarity at replacement. · A used battery should be disposed of according to the local regulations and never be discarded casually or left unattended at the user's premises. · When reassembling parts, make sure that the correct screws (size, type) and toothed washer are used in the correct places. · If it becomes necessary to replace the thermal fuse or any other fuse mounted on a board, be sure to use one of the rating marked on the blown fuse. Always note the rating marked on the fuse, as the rating and mounting site or number used are subject to change without notice.
Precautions for Circuit Inspection
· Never create a closed circuit across connector pins except those specified in the text and on the printed circuit. · When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the GND wire.
PS-2
FrameMaker Ver.5.5E(PC) 99. 7. 2
PS (Precaution For Service) Standard Document Ver.01
Handling of PWBs
1. During Transportation/Storage: · During transportation or when in storage, new P .W. Boards must not be indiscriminately removed from their protective conductive bags. · Do not store or place P.W. Boards in a location exposed to direct sunlight and high temperature. · When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static electricity. · Do not touch the pins of the ICs with your bare hands. · Protect the PWBs from any external force so that they are not bent or damaged. 2. During Inspection/Replacement: · Avoid checking the IC directly with a multimeter; use connectors on the Board. · Never create a closed circuit across IC pins with a metal tool. · Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unplugged from the outlet. · When removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board. · When touching the PWB, wear a wrist strap and connect its cord to a securely grounded place whenever possible. If you cannot wear a wrist strap, touch a metal part to discharge static electricity before touching the PWB. · Note that replacement of a PWB may call for readjustments or resetting of particular items.
Handling of Other Parts
· The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube.
PS-3
FrameMaker Ver.5.5E(PC) 99. 7. 2
PS (Precaution For Service) Standard Document Ver.01
Handling of the PC Drum
V Only for Products Not Employing an Imaging Cartridge. 1. During Transportation/Storage: · Use the specified carton whenever moving or storing the PC Drum. · The storage temperature is in the range between 20°C and +40°C. · In summer, avoid leaving the PC Drum in a car for a long time. 2. Handling: · Ensure that the correct PC Drum is used. · Whenever the PC Drum has been removed from the copier, store it in its carton or protect it with a Drum Cloth. · The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended period of time. Never, therefore, expose it to direct sunlight. · Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter. · Do not scratch the surface of the PC Drum. · Do not apply chemicals to the surface of the PC Drum. · Do not attempt to wipe clean the surface of the PC Drum. If, however, the surface is contaminated with fingerprints, clean it using the following procedure. 1. Place the PC Drum into one half of its carton.
1076D001
1076D002
2. Gently wipe the residual toner off the surface of the PC Drum with a dry, Dust-Free Cotton Pad. A. Turn the PC Drum so that the area of its surface on which the line of toner left by the Cleaning Blade is present is facing straight up. Wipe the surface in one continuous movement from the rear edge of the PC Drum to the front edge and off the surface of the PC Drum. B. Turn the PC Drum slightly and wipe the newly exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thoroughly cleaned. V At this time, always use a CLEAN face of the dry Dust-Free Cotton Pad until no toner is evident on the face of the Pad after wiping.
PS-4
FrameMaker Ver.5.5E(PC) 99. 7. 2
PS (Precaution For Service) Standard Document Ver.01
3. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front edge and off its surface one to two times. V Never move the Pad back and forth.
1076D003
4. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped. Always OVERLAP the areas when wiping. Two complete turns of the PC Drum would be appropriate for cleaning.
1076D004
NOTES · Even when the PC Drum is only locally dirtied, wipe the entire surface. · Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interior illumination. · If dirt remains after cleaning, repeat the entire procedure from the beginning one more time.
Handling of the Imaging Cartridge
V Only for Products Employing an Imaging Cartridge. 1. During Transportation/Storage: · The storage temperature is in the range between 20°C and +40°C. · In summer, avoid leaving the Imaging Cartridge in a car for a long time. 2. Handling: · Store the Imaging Cartridge in a place that is not exposed to direct sunlight. 3. Precautionary Information on the PC Drum Inside the Imaging Cartridge: · Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter. · Do not scratch the surface of the PC Drum. · Do not attempt to wipe clean the surface of the PC Drum.
PS-5
FrameMaker Ver.5.5(PC) Di181 99.08.03
INDEX (FIELD SERVICE) DIS/REASSEMBLY, ADJUSTMENT SWITCHES ON PWBs, TECH. REP SETTINGS . TROUBLESHOOTING
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
DIS/REASSEMBLY, ADJUSTMENT
18605
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
CONTENTS
1. SERVICE INSTRUCTION ............................................................................... D-1 1-1. PARTS WHICH MUST NOT BE TOUCHED ........................................... D-1 (1) Screws ............................................................................................. D-1 (2) Variable Resistors on Boards .......................................................... D-1 (3) Other Screws ................................................................................... D-1 1-2. READING THE TEXT .............................................................................. D-1 1-3. IDENTIFICATION OF FUSES ................................................................. D-2 1-4. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ............... D-2 2. DISASSEMBLY/REASSEMBLY ...................................................................... D-3 2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES ..................................................................... D-3 2-2. REMOVAL OF PWBs .............................................................................. D-5 2-3. MAINTENANCE SCHEDULE .................................................................. D-7 2-4. BELT INSTALLATIONS ........................................................................... D-8 2-5. REMOVAL OF UNITS ............................................................................. D-9 (1) Removal of the Manual Bypass Unit ............................................... D-10 (2) Removal of the Paper Take-Up Unit ................................................ D-11 (3) Removal of the Imaging Unit ........................................................... D-12 (4) Removal of the PH Unit ................................................................... D-13 (5) Removal of the Transport Unit ......................................................... D-14 (6) Removal of the Fusing Unit ............................................................. D-15 (7) Removal of the Power Supply Unit .................................................. D-16 2-6. PAPER TAKE-UP SECTION ................................................................... D-17 (1) Disassembly of the Manual Bypass Unit Replacement of the Manual Bypass Separator Roll Assy ............... D-17 (2) Disassembly of the Paper Take-Up Roll .......................................... D-19 2-7. IR SECTION ............................................................................................ D-20 (1) Cleaning of the 1st to 3rd Mirrors, Slide Rails, Lens and Cooling Fan Filter ............................................................................ D-20 (2) Disassembly of the IR Section ......................................................... D-20 (3) Removal of the Exposure Lamp and Inverter .................................. D-23 (4) Removal of the Drive Cable ............................................................. D-24 (5) Winding of the Drive Cable .............................................................. D-24 2-8. IMAGING UNIT SECTION ....................................................................... D-25 (1) Cleaning of the PC Drum Paper Separator Fingers and Ds Positioning Collars Replacement of the PC Drum and Toner Scattering Prevention Plate ................................................................................................ D-25 (2) Replacement of the Cleaning Blade ................................................ D-26 (3) Cleaning of the Pre-Image Transfer Upper Guide Plate, Magnet Roller Lower Filter and Paper Dust Remover Replacement of the Toner Antispill Mylar ........................................ D-26 (4) Cleaning of the Main Erase Lamp ................................................... D-27 (5) Cleaning and Replacement of the PC Drum Charge Corona Assy ................................................................................................. D-28
i
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Cleaning and Replacement of the Image Transfer/ Paper Separator Corona Assy Cleaning of the Pre-Image Transfer Lower Guide Plate .................. D-29 (7) Replacement of the Ozone Filter ..................................................... D-30 2-9. TRANSPORT SECTION .......................................................................... D-30 (1) Cleaning of the Suction Deck, Belt and Ple-Fusing Guide Plate ..... D-30 2-10.FUSING SECTION .................................................................................. D-31 (1) Cleaning and Replacement of the Thermistor Cleaning of the Fusing Thermoswitch ............................................. D-31 (2) Cleaning and Replacement of the Upper Fusing Roller Cleaning and Replacement of the Upper Separator Fingers ........... D-31 (3) Cleaning and Replacement of the Lower Fusing Roller Cleaning of the Lower Separator Fingers ........................................ D-32 3. ADJUSTMENT ................................................................................................. D-33 3-1. JIGS AND TOOLS USED ........................................................................ D-33 3-2. ADJUSTMENT REQUIREMENTS LIST .................................................. D-34 3-3. ADJUSTMENT OF SWITCHES ............................................................... D-34 (1) Adjustment of Front Door Interlock Switch S2 ................................. D-34 3-4. ELECTRICAL/IMAGE ADJUSTMENT ..................................................... D-35 (1) Adjustment of the ATDC Sensor ..................................................... D-35 (2) Registration FD ................................................................................ D-36 (3) Adjustment of the Manual Bypass Table Reference Position .......... D-37 (4) Adjustment of the 1st/2nd Drawer Reference Position .................... D-38 (5) IR/Registration CD ........................................................................... D-39 (6) IR/Registration FD ........................................................................... D-40 (7) IR / Zoom CD ................................................................................... D-41 (8) IR / Zoom FD ................................................................................... D-42 (9) IR/Shading Position ......................................................................... D-43 (10) Adjustment of the Paper Lifting Plate Springs (2nd Drawer) ........... D-45 3-5. OTHER ADJUSTMENTS ......................................................................... D-46 (1) Adjustment of the Scanner/Mirrors Carriage Position ..................... D-46 (2) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller ................................................................................... D-47 (3) Adjustment of the Original Size Detecting Board ............................ D-47 4. MISCELLANEOUS .......................................................................................... D-48 4-1. INSTALLATION OF ORIGINAL SIZE DETECTING SENSORS CD2/FD3 .................................................................................................. D-48 4-2. INSTALLATION OF THE PLUG-IN COUNTER MOUNTING BRACKET (OPTION) ................................................................................................. D-49
(6)
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FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
1
1-1.
SERVICE INSTRUCTION
PARTS WHICH MUST NOT BE TOUCHED
(1) Screws
Purpose of Application of Red Paint Red paint is applied to the screws which cannot be readjusted, set, or reinstalled in the field. The basic rule is not to remove or loosen the screws to which red paint is applied. In addition, be advised that, if two or more screws are designated as those which must not be touched on a single part, only one representative screw may be marked with red paint.
(2) Variable Resistors on Boards
Do not turn the variable resistors on boards for which no adjusting instructions are given in "ADJUSTMENT." (3) Other Screws Original Glass Positioning Bracket (2 screws) Lower Pre-Image Transfer Guide Plate (2 screws)
1177D069AA
1139D078AA
1-2.
READING THE TEXT
The disassembly order is indicated by the corresponding number in the illustration. For parts that require special attention and service jobs, they are given inside a separate frame.
Separator Roll Assy. Clean
1177D023AA
D-1
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
1-3.
IDENTIFICATION OF FUSES
Noise Filter Board PWB-D 250V 15A
125/250V 1.25A
250V 15A Master Board PWB-A 125V 3A
250V 15A
DC Power Supply 3 PU3 250V/125V 5A
DC Power Supply 1 PU1 Inch Area Metric Area 125V 4A 250V 3.15A 125V 315mA 250V 160mA
DC Power Supply 2 PU2 125V 10A 125V 15A
1177D003AB
1-4.
PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT
· The laser used in this copier is a semiconductor laser having the following specifications. Max. power: 5mW Output wavelength: 770~795nm · When laser protective goggles are to be used, select ones with a lens conforming to the above specifications. · When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC Drum, be sure first to turn the copier OFF. · If the job requires that the copier be left ON, take off your watch and ring and wear laser protective goggles. · A highly reflective tool can be dangerous if it is brought into the laser beam path. Use utmost care when handling tools on the user's premises. · The printerhead is notmaintainable in the field. It is to be replaced as an assembly including the control board. Never, therefore, attempt to remove the laser diode or adjust trimmers on the control board.
D-2
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
2
2-1.
DISASSEMBLY/REASSEMBLY
DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES
6 5 4 3 2 9 10 1 11 7 8
12 15 14 13
1151D001AA
18 19 17 16 21 20
23
22
1177D028AA
D-3
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
No.
Name
Removal Procedure Swing down No. 1. Remove screw that secures the Belt. Remove screws that secure the Front Door (only on one side). Slide the Door to the side from which the screws have been removed. Swing down No. 1. Remove No. 9, 10 and 11. Release and swing up the Upper Half of the copier. Remove No. 19. Remove screws that secure the control panel. Remove screws that secure the Scales.
1
Front Door
2 3 4 5 6 7 8 9
Control Panel Original Scale Original Glass
Rear Upper Cover Remove the Original Cover. Remove the screw cover and (Small) mounting screw of No. 5. Left Hinge Cover Rear Upper Cover Right Hinge Cover Upper Right Cover Remove No. 11. Remove No. 9. Remove screws that secure No. 10. Remove screws that secure No. 11. Open No. 12 and remove it by lifting it up. Remove No. 13 by snapping if off. Slide out the Drawer and remove the screw that secures the stopper at the rear left corner. Remove the Original Cover. Remove the screw cover and mounting screw of No. 6. Remove the Original Cover. Remove No. 6, 8 and 9. Remove screw that secures No. 7.
10 Right Cover 11 Middle Right Cover
12 Right Door 13 Counter Cover 14 1st Drawer 15 2nd Drawer
16 Lower Rear Cover Remove screws that secure No. 16. 17 Upper Rear Cover Remove screws that secure No. 17. 18 Original Cover 19 Left Cover Swing down No. 1. Release and swing up the Upper Half of the copier. Remove screws that secure No. 19. Swing down No. 1. Release and swing up the Upper Half of the copier. Remove No. 21. Remove screws that secure No. 20. Swing down No. 1. Release and swing up the Upper Half of the copier. Remove No. 25. Remove screws that secure No. 21. Remove screws that secure No. 22. Swing down No. 1. Release and swing up the Upper Half of the copier. Remove screws that secure No. 23.
20 Front Exit Cover
21 Rear Exit Cover 22 Lower Left Cover Middle Rear Left 23 Cover
D-4
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
2-2.
REMOVAL OF PWBs
· When removing a PWB, first go over "PRECAUTIONS FOR HANDLING THE PWBs" contained and use the removal procedures given on the next page. · Replacement of a PWB may call for readjustments or resetting of particular items. · The removal procedures given on the next page omit the steps to unplug connectors and remove the PWB from the PWB support. PWB-Y PWB-A PWB-D HV
PU3
PU1 PU2 PWB-F
1177D051AA
D-5
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Symbol PWB-A
Part Name Master Board
Removal Procedure Remove No. 17. Remove metal bracket from the Master Board. Swing down No. 1. Release and swing up the Upper Half of the copier. Remove the Electrical Cover. Swing down No. 1. Remove No. 9, 10, 11. Remove Manual Bypass Unit. Remove No. 17. Remove metal bracket from the Master Board. Remove the Original Glass. Remove the CCD Assy Cover. Swing down No .1. Remove No. 9, 10, 11 and 19. Remove No. 17. Remove metal bracket from the Master Board. Swing down No. 1. Release and swing up the Upper Half of the copier. Remove the Electrical Cover. Swing down No. 1. Release and swing up the Upper Half of the copier. Remove the Electrical Cover. Swing down No. 1. Release and swing up the Upper Half of the copier. Remove the Electrical Cover. Remove No. 17 Remove Master Board. Remove the Original Glass. Remove the Original Size Detecting Board Cover. Swing down No. 1. Release and swing up the Upper Half of the copier. Slide out the Imaging Unit. Remove the Synchronizing Roller Unit.
PWB-D
Noise Filter Board
PWB-F
SCP Board
PWB-IA
CCD Sensor Board
PWB-P PWB-Y
Control Panel RAM Board
PU1
DC Power Supply 1
PU2
DC Power Supply 2
PU3 HV UN2
DC Power Supply 3 High Voltage Unit Original Size Detecting Board
UN3
ATDC Sensor
NOTE To remove the Original Glass, first remove the Original Scales and then slide the glass to the scale side and remove it.
Details of Readjustments/Resetting Involved In Replacement of RAM Board, Original Size Detecting Board and ATDC Sensor. · When RAM Board is replaced: Carry out Memory Clear and then make the Tech. Rep. Choice, User's Choice, Security mode, and Adjust settings again. · When Original Size Detecting Board is replaced: Adjust the Original Size Detecting Board. · When ATDC Sensor is replaced: Discard the developer which had been used until ATDC Sensor was replaced, reload the Developing Unit with fresh starter, and adjust ATDC.
D-6
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
2-3.
MAINTENANCE SCHEDULE
· To keep the copier in good operating condition, it is recommended that the maintenance jobs described in this schedule be carried out. Maintenance Schedule Reference (K) Part No. Qty Page Cleaning Replacement Paper Take-Up Section Paper Take-Up Roll 80 320 1151-3001-01 5 D-19 Synchronizing Roller 80 1 -- Manual Bypass Take-Up Roll 80 1 D-18 Manual Bypass Feed Roll 80 1 D-18 Manual Bypass Separator Roll 80 1 D-18 IR Section 1st Mirror 80 1 D-20 2nd Mirror 80 1 D-20 3rd Mirror 80 1 D-20 Lens 80 1 D-20 Cooling Fan Filter 80 1 D-20 Scanner, Scanner Rail 80(*1) 1 D-20 Imaging Unit Section Starter 160 -- -- -- PC Drum 80 -- 1 -- Toner Scattering Prevention 80 320 1174-5222-01 1 D-25 Plate Cleaning Blade 80 1139-5711-17 1 D-26 PC Drum Paper Separator Fin80 2 D-25 gers Ds Positioning Collar (Front) 80 320 1139-5204-01 1 D-25 Ds Positioning Collar (Rear) 80 320 1136-5004-01 1 D-25 Paper Dust Remover 80 160 1139-3253-01 1 D-27 Toner Antispill Mylar 80 1 D-26 Magnet Roller Lower Filter 80 1 D-26 Pre-Image Transfer Upper 80 1 D-26 Guide Plate PC Drum Charge/Image Transfer Coronas/Transport Unit PC Drum Charge Corona 80 1 D-28 Housing PC Drum Charge Corona 320 1139-4253-02 1 D-28 Comb Electrode PC Drum Charge Corona Grid 80 1 D-28 Mesh Image Transfer/Paper Separa80 1 D-29 tor Corona Housing Image Transfer/Paper Separa80 1075-0765-01 2 D-29 tor Corona Wire Pre-Image Transfer Lower 80 1 D-29 Guide Plate PM Parts
D-7
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
PM Parts Ozone Filter Main Erase Suction Belt, Deck Pre-Fusing Guide Plate Thermistor Fusing Thermoswitch Upper Fusing Roller Lower Fusing Roller Upper Separator Finger Lower Separator Finger
Maintenance Schedule (K) Cleaning Replacement 80 80 80 Fusing Section 80 80 320 80 80 320 80 320 80 320 80
Part No. 1151-4509-01
Qty 1 1 4 1 1 1 1 1 4 5
Reference Page D-30 D-28 D-30 D-30 D-31 D-31 D-31 D-32 D-31 D-32
9372-2610-11 1177-5521-02 1174-5522-01 1054-4753-01
NOTE K=1,000 copies This information is subject to change without notice. Clean at 80K, based on Total Counter. Replace at 320K, based on the PM Counter *1: Wipe these parts with a dry cloth, then lubricate them.
2-4.
BELT INSTALLATIONS
· Rear View Drive/Suction Unit PC Drive
1151D052AB
Paper Take-Up Unit
1177D085AA
Scanner
1151D050AA
1177D086AA
D-8
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
2-5.
REMOVAL OF UNITS
PH Unit
Manual Bypass Unit
Imaging Unit
Paper Take-Up Unit
1177D001AA
Fusing Unit
Transport Unit
Power Supply Unit
1177D002AA
D-9
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(1) Removal of the Manual Bypass Unit Remove the Manual Bypass Unit after the Right Door, Right Cover and Middle Right Cover have been removed.
Connector
Manual Bypass Unit
Screws
Guide Lever Unit Fig. 1
1177D004AA
Fig. 1 Removal of the Guide Lever Unit
Screws
1177D010AA
D-10
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(2) Removal of the Paper Take-Up Unit Remove the Rear Cover, Lower Rear Cover, and Manual Bypass Unit and slide out the drawer in question before attempting to remove the Paper Take-Up Unit.
Paper Take-Up Unit
Screws
Cord Clamp
Fig. 1
1177D005AA
Fig. 1 Removal of the Connector
Master Board PWB-A
Connector
1177D006AA
NOTE When mounting the Paper Take-Up Unit, secure the harness of the hookup connector with the cord clamp.
D-11
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(3) Removal of the Imaging Unit
Fixing Screw Fig. 1
Fig. 1 Removal of the Fixing Screws
1177D014AA
Clockwise: Tighten Counterclockwise: Loosen
Clockwise: Loosen Counterclockwise: Tighten
1177D008AA
NOTE When the Imaging Unit is installed, the positioning pins should fit in the indentations in the flange of the PC Drum. (The fixing screws should also be tightened firmly.) If the positioning pins are not properly aligned with the indentations in the PC Drum flange, turn the end of the PC Drum until they fit into position.
Slit
Positioning Pin
1177D009AA
D-12
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(4) Removal of the PH Unit
Fig. 2 Fixing Screw Fig. 1
Connector Fig. 3
Screw
1177D013AC
Fig. 1 Removal of the IR Fixing Screws Paper take-up end: Both sides (at 2 places) Paper exit end: Center (at 1 place)
NOTE Use a long screwdriver to remove the screws.
1177D011AA
Fig. 2 Removal of the Flat Cable Clamp
Terminal
Screw
1177D070AA
D-13
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Fig. 3 Removal of the Connector Connector position: Under the duct for the Ventilation Fan Motor.
1177D012AA
Ventilation Fan Motor M9
NOTE NEVER touch the terminal of the flat cable.
(5) Removal of the Transport Unit After the Fusing Unit has been removed, remove the Transport Unit.
Fig. 1
Fig. 1 Parts to be Taken Apart in the Rear
Transport Unit
1177D035AA
Lower Drive Motor M2
1177D036AA
NOTE Use care not to lose the springs (front and rear) installed under the guide plate.
D-14
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(6) Removal of the Fusing Unit
Fusing Unit
1177D015AA
Removal of the Fusing Unit Locking Plate
Parts to be Taken Apart in the Rear
1177D016AA
1177D017AA
D-15
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(7) Removal of the Power Supply Unit
Connector for Paper Dehumidifing Heater Side of the Power Supply Unit
1177D018AD
Connector for Cabinet
1177D019AA
Remove of the Connectors: Inside of "( )" is descrived number of connectors. Power Transformer T1 (2) Power Supply Unit 1 PU1 (2) Power Supply Unit 3 PU3 (3) Noise Filter Board PWB-D (1)
Sleep Mode Relay RY2 (6) Power Supply Unit Cooling Fan Motor M7 (1) Hookup Connectors (2) Power Supply Unit 2 PU2 (2) Main Relay RY1 (6)
1177D020AA
D-16
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Where Relays are Connected BL(R) BL(LB) W(Y) Main Relay RY1 W(R) R(BK) W(BK) W(W) Sleep Mode Relay 1177D021AB RY2 W(LB)
2-6.
PAPER TAKE-UP SECTION
(1) Disassembly of the Manual Bypass Unit Replacement of the Manual Bypass Separator Roll Assy
Manual Bypass Separator Roll Assy
1177D022AA
D-17
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Manual Bypass Separator Roll: Clean.
1177D023AA
Cleaning of the Manual Bypass Take-Up Roll and Manual Bypass Feed Roll
Manual Bypass Take-Up Roll/ Manual Bypass Feed Roll Assy Fig. 1
1177D024AA
Fig. 1
Manual Bypass Take-Up Roll / Manual Bypass Feed Roll: Clean.
1177D025AA
D-18
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(2) Disassembly of the Paper Take-Up Roll
Paper Take-Up Roll: Clean.
1177D026AA
D-19
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
2-7.
IR SECTION
NOTE To remove the Original Glass, first remove the Original Scales and then slide the glass to the scale side and remove it. (Do not remove the Original Glass positioning bracket.)
(1) Cleaning of the 1st to 3rd Mirrors, Slide Rails, Lens and Cooling Fan Filter Slide Rails: Clean.
Cooling Fan Filter: Clean.
2nd Mirror: Clean. Lens: Clean. 3rd Mirror: Clean. 1st Mirror: Clean.
1177D027AA
(2) Disassembly of the IR Section
CCD Assy Cover
Scanner CCD Assy
Fig. 1
1177D037AA
D-20
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Fig. 1 Removal of the CCD Assy
1177D071AB
Parts to be Taken Apart in the Rear
1177D075AA
D-21
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Removal of the Scanner
1177D031AA
Key Points for Reinstallation of the Scanner Face against which the Scanner is pressed
Dowels Scanner Drive Cable
Scanner Fixing Base
1177D032AA
NOTE When reinstalling the Scanner, let the dowels on the Scanner Fixing Base fit into the Scanner positioning holes and slightly turn the Scanner clockwise so that the rear left end of the Scanner is pressed tightly into position in the fixing base. Use care not to allow the Scanner Drive Cable to be caught in the mechanism.
D-22
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(3) Removal of the Exposure Lamp and Inverter
Exposure Lamp LA1
Socket
Inverter Assy
Disassembly of the Inverter Assy
1177D033AA
1177D034AA
NOTE When removing the Exposure Lamp, be sure to hold onto its socket. When removing the PWB from the Inverter Assy, use care not to touch its pattern surface.
D-23
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(4) Removal of the Drive Cable
(5) Winding of the Drive Cable
1177D042AC
11
Pulley Fig. 1 Tension Adjusting Metal Bracket Fig. 2
1177D094AA
1177D043AC
NOTE Start winding the Scanner Drive Cable with the spring end. (When winding the cable, ensure that the cable has no slack.) To hook the bead, pinch the cable with lineman's pliers and try to hook it while turning the pulley counterclockwise.
D-24
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Winding the Cable Around the Pulley and Adjusting Tension in the Timing Belt Fig. 1 Fig. 2 Fixing Screws Wind the cable 5 turns counterclockwise.
1177D040AB
1177D039AA
NOTE Temporarily loosen the fixing screw and find a position at which the Tension Adjusting Metal Bracket is stopped by the tension of the spring. Then, holding the Tension Adjusting Metal Bracket in that position, tighten the fixing screw again.
2-8.
IMAGING UNIT SECTION
(1) Cleaning of the PC Drum Paper Separator Fingers and Ds Positioning Collars Replacement of the PC Drum and Toner Scattering Prevention Plate
Ds Positioning Collars: Clean.
Ds Positioning Collars: Clean.
PC Drum Paper Separator Fingers: Clean. Toner Scattering Prevention Plate: Replace.
1177D044AA
D-25
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(2) Replacement of the Cleaning Blade
Cleaning Blade: Replace.
1177D045AA
NOTE When reinstalling the Cleaning Blade, do not forget to rehook the spring.
Applying Toner to Cleaning Blade 1. Apply toner to the entire surface of the Cleaning Blade. (Do not forget to coat the surfaces on both ends.) 2. Install the PC Drum. 3. Apply a thin coat of toner to the PC Drum. 4. Turn the PC Drum 1/2 turns backward, then turn it one complete turn forward. (3) Cleaning of the Pre-Image Transfer Upper Guide Plate, Magnet Roller Lower Filter and Paper Dust Remover Replacement of the Toner Antispill Mylar
Toner Antispill Mylar: Replace.
Pre-Image Transfer Upper Guide Plate: Clean.
Magnet Roller Lower Filter: Clean.
1177D046AA
D-26
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Paper Dust Remover Clean.
1177D047AA
(4) Cleaning of the Main Erase Lamp 1. Removal of the Master Board.
1177D041AB
2. Removal of the High Voltage Unit. Main Erase Lamp Connector
1177D057AA
D-27
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
Main Erase Lamp: Clean.
1177D058AA
(5) Cleaning and Replacement of the PC Drum Charge Corona Assy
PC Drum Charge Corona Grid Mesh: Clean.
PC Drum Charge Corona Comb Electrode: Replace.
PC Drum Charge Corona Housing: Clean.
1177D084AA
D-28
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(6) Cleaning and Replacement of the Image Transfer/Paper Separator Corona Assy Cleaning of the Pre-Image Transfer Lower Guide Plate
Image Transfer/ Paper Separator Image Transfer/ Paper Separator Coronas Fixing Bracket
1177D029AA
Pre-Image Transfer Lower Guide Plate: Clean. Image Transfer/Paper Separator Coronas Wires: Replace.
1177D030AA
Image Transfer/Paper Separator Coronas Housing: Clean.
D-29
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(7) Replacement of the Ozone Filter
Ozone Filter: Replace.
1177D056AA
2-9.
TRANSPORT SECTION
(1) Cleaning of the Suction Deck, Belt and Ple-Fusing Guide Plate
Ple-Fusing Guide Plate: Clean. Suction Deck and Belt: Clean.
1177D048AB
D-30
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
2-10. FUSING SECTION
(1) Cleaning and Replacement of the Thermistor Cleaning of the Fusing Thermoswitch Fusing Thermoswitch: Clean. Thermistor: Clean/Replace.
1177D049AA
(2) Cleaning and Replacement of the Upper Fusing Roller Cleaning and Replacement of the Upper Separator Fingers Upper Separator Fingers: Clean/Replace.
Upper Fusing Roller: Clean/Replace.
1177D054AA
D-31
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(3) Cleaning and Replacement of the Lower Fusing Roller Cleaning of the Lower Separator Fingers
Rear Front
Lower Fusing Roller: Clean/Replace.
1177D055AA
Lower Separator Fingers: Clean.
NOTE When installing the springs under the Lower Fusing Roller, use care not to confuse them (front side: white paint; rear side: red paint).
D-32
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
3
3-1.
ADJUSTMENT
JIGS AND TOOLS USED
1. Front Door Interlock Switch Actuating Jig 2. Scanner Positioning Jig
1174D009AA
1177D059AA
3. Scanner/Mirrors Carriage Positioning Jig
4. Sleeve/Magnet Roller Position Jig
1177D050AA
1139D075AA
5. D.B. Adjusting Jigs
1074D129
D-33
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
3-2.
ADJUSTMENT REQUIREMENTS LIST
Adjustment Item Requirements 3.5 ± 0.2mm -- -- × 2.00 : 200 ± 2mm × 1.00 : 200 ± 2mm × 0.50 : 100 ± 1mm × 2.00 : 200 ± 2mm × 1.00 : 300 ± 3mm × 0.50 : 150 ± 1.5mm 10.8 ± 0.5mm 10.8 ± 0.5mm -- -- 0.35 +0.07 mm -0 -- Adjusting Point Control Panel Control Panel Control Panel Control Panel Control Panel Ref. Page. D-43 D-36 D-39 D-40 D-41
Shading Position Print / Regist (FD) IR / Regist (CD) IR / Regist (FD) IR / Zoom (CD)
IR / Zoom (FD) Manual Bypass Table Reference Position 1st and 2nd Drawer Reference Position Adjustment of the Paper Lifting Plate Position Adjustment of the Scanner/Mirrors Carriage Position Adjustment of the Doctor Blade Adjustment of the Original Size Detecting Board
Control Panel Manual Bypass Table Drawer Cover Spring Position Scanner/Mirrors Carriage Position Doctor Blade Control Panel
D-42
D-37 D-38 D-45 D-46 D-47 D-48
3-3.
ADJUSTMENT OF SWITCHES
(1) Adjustment of Front Door Interlock Switch S2 1. Loosen screws that secure the Front Door Interlock Switch Actuating Plate to the Front Door.
1174M023AA
D-34
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
2. Move the Switch Actuating Plate back and forth to meet the requirements below. Requirements · When the Front Door is closed, the Magnetic Catches on both sides are in secure contact. · When the Front Door is closed, the Interlock Switch indicator on the Control Panel goes out.
1174M024AA
3-4.
ELECTRICAL/IMAGE ADJUSTMENT
Method of inputting mode · Tech. Rep. Mode Meter Count key Stop key 0 0 Stop key 0 1 · Adjust Mode Tech. Rep. Mode Stop key Start key Keypad Start key (E.g.: A4 mode if "4" of Keypad is entered) · Function Mode Tech. Rep. Mode 1 Start key Keypad Start key (E.g.: F8 mode if "8" of Keypad is entered) (1) Adjustment of the ATDC Sensor Adjustment Procedure 1. Call F8 of the function mode (ATDC level adjustment) to the screen. F8 ATDC SENSOR XXX 2. Press the Start key to let the copier make the ATDC Sensor adjustment automatically. (It takes about 4 to 5 min. for the copier to complete the adjustment procedure.) Enter the adjustment value on the label "I/U Assy". 3. After the adjustment has been made, press the Panel Reset key twice (or turn OFF the Power Switch) to return the copier back to the normal mode.
NOTE Make the ATDC Sensor adjustment whenever fresh starter has been loaded. If data has been cleared by Memory Clear, use Adjust Mode A8 [ATDC Sensor (Manual)] to re-input the data.
D-35
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(2) Registration FD Adjustment Procedure
A
1177D095AA
· Setting value range: 74 to 126 · Movement equivalent to 1 step of setting value: 0.23 mm 1. Produce a test pattern by running the F12-0 operation. 2. Check that width A on the test pattern falls within the specified range. 3. If it falls outside the range, use Adjust Mode A1 [Registration (FD)] and change the adjustment value so that width A falls within the specified range. REGISTRATION(FD) 10 KEY INPUT : Enter the adjustment value from the Keypad and press the Start key to validate the value entered. (If a wrong value is entered, press the Clear key to clear it.) If width A is longer than the specifications, decrease the adjustment value. If width A is shorter than the specifications, increase the adjustment value.
D-36
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(3) Adjustment of the Manual Bypass Table Reference Position Adjustment Procedure · Dimension A on the copy should measure 10.8 ± 0.5 mm.
1177D102AA
1. Produce a test pattern by running the F12-1 operation. 2. Check that width A on the test pattern falls within the specified range. Width A : Gap between the edge of the paper and the first thick line from the edge. 3. If the line does not meet the requirement, loosen the screws that secure the Manual Bypass Table and move the Table as necessary in the direction of the arrows.
NOTE If dimension A on the copy is smaller than 10.3 mm, move the Table to the front. If it is more than 11.3 mm, move the Table to the rear.
1177D085AB
D-37
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(4) Adjustment of the 1st/2nd Drawer Reference Position Adjustment Procedure · Dimension A on the copy should measure 10.8 ± 0.5 mm.
1177D102AA
1. Produce a test pattern by running the F12-1 operation. 2. Check that width A on the test pattern falls within the specified range. Width A : Gap between the edge of the paper and the first thick line from the edge. 3. If the line does not meet the requirement, slide out the 1st Drawer, loosen the adjusting screws, and move the Paper Tray as necessary to the front or rear. Using the same steps (1 through 4), adjust the reference position of the 2nd Drawer.
NOTE If dimension A on the copy is smaller than 10.3 mm, move the Paper Tray to the rear. If it is more than 11.3 mm, move the Paper Tray to the front.
1177D086AB
D-38
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(5) IR/Registration CD · Produce a test pattern by running the F12-1 operation.
1177D090AA
· Setting value range: 36 to 164 · Movement equivalent to 1 step of setting value: 0.0846 mm Adjustment Procedure 1. Place the test pattern produced on the Original Glass and make a copy in the full size mode. 2. Align the copy with the original and check for any deviation in dimension A. 3. If it falls outside the range, use Adjust Mode A2 [IR/Registration (CD)] and change the adjustment value so that the deviation falls within the specified range. IR/REGISTRATION(CD) 10 KEY INPUT : Enter the adjustment value from the Keypad and press the Start key to validate the value entered. (If a wrong value is entered, press the Clear key to clear it.) If the dimension A on the copy is on the right side of that on the original, decrease the adjustment value. If the dimension A on the copy is on the left side of that on the original, increase the adjustment value.
D-39
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(6) IR/Registration FD · Produce a test pattern by running the F12-1 operation.
1177D091AA
· Setting value range: 84 to 116 · Movement equivalent to 1 step of setting value: 0.1227mm Adjustment Procedure 1. Place the test pattern produced on the Original Glass and make a copy in the full size mode. 2. Align the copy with the original and check for any deviation in dimension A. 3. If it falls outside the range, use Adjust Mode A3 [IR/Registration (FD)] and change the adjustment value so that the deviation falls within the specified range. IR/REGISTRATION(FD) 10 KEY INPUT : Enter the adjustment value from the Keypad and press the Start key to validate the value entered. (If a wrong value is entered, press the Clear key to clear it.) If the dimension A on the copy is on the upper side of that on the original, decrease the adjustment value. If the dimension A on the copy is on the lower side of that on the original, increase the adjustment value.
D-40
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(7) IR / Zoom CD · Setting value range: 90 to 110 · Movement equivalent to 1 step of setting value: ×0.001mm
1177D092AA
Adjustment Procedure 1. Place a scale on the Original Glass and make a copy at each of the following zoom ratios ×2.00, ×1.00, and ×0.50. 2. Check that the copy meets the specifications. 3. If it does not, use Adjust Mode A4 [IR/Zoom (CD) Copy] and change the adjustment value so that the copy meets the specifications.
1134D124AA
IR/ZOOM (CD) 10 KEY INPUT :
Enter the adjustment value from the Keypad and press the Start key to validate the value entered. (If a wrong value is entered, press the Clear key to clear it.) If the image on the copy is longer than the specifications, decrease the adjustment value. If the image on the copy is shorter than the specifications, increase the adjustment value.
D-41
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(8) IR / Zoom FD · Setting value range: 90 to 110 · Movement equivalent to 1 step of setting value: ×0.001mm
1177D093AA
Adjustment Procedure 1. Place a scale on the Original Glass and make a copy each at each of the following zoom ratios X2.00, X1.00, and X0.50. 2. Check that the copy meets the specifications. 3. If it does not, use Adjust Mode A6 [IR/Zoom (FD) Copy] and change the adjustment value so that the copy meets the specifications.
1138D154AA
IR/ZOOM (FD) 10 KEY INPUT :
Enter the adjustment value from the Keypad and press the Start key to validate the value entered. (If a wrong value is entered, press the Clear key to clear it.) If the image on the copy is longer than the specifications, decrease the adjustment value. If the image on the copy is shorter than the specifications, increase the adjustment value.
NOTE If the adjustment value is changed in "IR/Zoom (FD) Copy," be sure to perform "IR/Shading Position."
D-42
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(9) IR/Shading Position · · · · Setting value range: 60 to 140 Movement equivalent to 10 steps of setting value: 1.227mm Increase the setting value to move to the right (scanning position). Decrease the setting value to move to the left (scanning position).
Confirmation matter before adjusts · The original glass must contact the CD scale folder side.
CD scale folder
CD scale folder
1177D098AA
Adjustment method 1. Position an original (solid black, colored paper) as shown below and, with a sheet of A3 paper placed on top of it, make a copy. Then, check the image of the copy.
Shading Sheet
1177D080AB
NOTE When positioning the paper, make sure that the corner of the paper is in contact with the Shading Sheet.
2. Change (increase) the adjustment value in Adjust Mode A9 (IR/Shading Position) to move the shading position until the void on the copy image disappears.
D-43
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
NG
NG
OK
Fig. 1
Fig. 2
1177D076AA
Step 1.
Step 2.
Decrease the adjustment value in Adjust Mode A9 until void occurs on the copy image. (Fig. 1) Increase the adjustment value in Adjust Mode A9 until the void on the copy image disappears (the edge of the Shading Sheet) to find the exact value at which the void disappears.
NOTE Increase the A9 adjustment value only gradually.
Input a value that is the value found in step 2 plus 25 (which is equivalent to about 3 mm). (Fig. 2) Example: If the void disappears at 85 (adjustment value) 85 + 25 = 110 (Input 110 as the adjustment value.) Step 4. Make a copy and check that the Scanner does not hit against the right side bracket. Step 5. This completes the shading position correction procedure. Step 3.
D-44
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(10) Adjustment of the Paper Lifting Plate Springs (2nd Drawer)
NOTE · When the paper size loaded in the 2nd Drawer has been changed, be sure to replace the Springs by referring to the Table given below. · When the Springs have been replaced, change the position of the 2nd Drawer Paper Take-Up Roll by referring to the Table given below.
Roll Position
1139U038AA
Setting Position/Type of Spring Paper Size A3 (L) B4 (L) A4 (L) A4 (C) B5 (L) B5 (C) A5 (L) 11" × 17" 11" × 14" 10" × 14" 9-1/4" × 14" 8-1/2" × 14" 8-2/3" × 13" F.L.S 8-1/2" × 13" 8-1/4" × 13" 8" × 13" 8-1/4" × 11-3/4" LETTER (L) GOVERNENT LETTER (L) LETTER (C) GOVERNENT LETTER (C) 10" × 8" 5-1/2" × 8-1/2" Gold Gold Silver Silver Gold Silver Gold Gold Silver Gold Silver Silver Gold Silver Gold Silver Gold Silver Silver Gold Silver Silver Silver Silver Silver SP1, 1~9 SP2, 10~14 SP2 12~14 SP1, 6~9 SP2, 10~11 SP1 2~5 SP1, 1 Silver
Roll Position 6 4 3 4 2 4 1 5 5 4
3
2 3 2
5 4 1
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FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
3-5.
OTHER ADJUSTMENTS
(1) Adjustment of the Scanner/Mirrors Carriage Position Adjustment Procedure · With the Scanner correctly positioned, there should be no clearance between the Scanner/Mirrors Carriage and the Positioning Jig. · Before installing the jigs, temporarily secure the set screws of the cable holding plate of the Scanner. (The cable holding plate should be installed so that its marked side faces up.)
Scanner Positioning Jig
Scanner/Mirrors Carriage Positioning Jig
1177D060AB
Jig Installation Positions Scanner Positioning Jig installed in the Scanner Mirrors Carriage Positioning Jig installed in the 2nd/3rd Mirrors Carriage
1177D62AA
1177D061AC
NOTE Fit the Scanner Positioning Jig in the hole on the paper exit end.
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FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
(2) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller Adjustment Procedure · The gap between the Doctor Blade and the Sleeve Roller should be 0.35 mm mm. +0.07 0
NOTE Cover the PC Drum with the Drum Cloth to prevent it from being scratched.
1. Remove the Developer Scattering Prevention Plate. 2. Wipe the developer off the surface of the Sleeve Roller. 3. Install the Sleeve/Magnet Roller Positioning Jig onto the Imaging Unit.
1177D066AA
4. Loosen the three screws securing the Doctor Blade in position. Insert the D.B. Adjusting Jigs into the space between the Doctor Blade and Sleeve Roller. 5. Press down the Doctor Blade until it positively contacts the D.B. Adjusting Jigs, then tighten the three screws to secure it in position.
1139D057AA
(3) Adjustment of the Original Size Detecting Board Adjustment Procedure 1. Call "F7 (Original Sensor)" of the Function Mode to the screen. 2. Press the Start key to make the adjustment automatically. 3. When the adjustment sequence is completed, press the Panel Reset key twice to return the copier back to the normal mode.
NOTE Make this adjustment when Memory Clear has been performed, and when the RAM Board, Original Size Detecting Board, or Original Size Detecting Sensor has been replaced. During the adjustment sequence, the Start key is lit up orange. As soon as the sequence is completed, it turns to green.
D-47
FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
4
4-1.
MISCELLANEOUS
INSTALLATION OF ORIGINAL SIZE DETECTING SENSORS CD2/FD3
Original Size Detecting Sensor CD2 PC116
Original Size Detecting Sensor FD2 PC113
Original Size Detecting Sensor CD1 PC114 Original Size Detecting Board UN2 Original Size Detecting Sensor FD3 PC115
1177D064AA
If Original Size Detecting Sensors CD2 and FD3 are mounted, change the jumper connection of J1 and J2, respectively.
1177D065AA
NOTE · Connect Original Size Detecting Sensor CD2 to blue CN4UN2 and Original Size Detecting Sensor FD3 to white CN3UN2. · Be sure to run the F7 operation after FD3 and CD2 have been installed or the copier is unable to detect the paper size.
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FrameMaker Ver.5.5E(PC) Di181 DIS/REASSEMBLY, ADJUSTMENT 99.07.15
4-2.
INSTALLATION OF THE PLUG-IN COUNTER MOUNTING BRACKET (OPTION)
Before starting the procedure, remove the Upper Right Cover and Right Cover.
1177D099AA
1177D100AA
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FrameMaker Ver.5.5(PC) Di181 SWITCHES ON PWBs/TECH. REP. SETTINGS 99.07.06
SWITCHES ON PWBs, TECH. REP. SETTINGS
17196
FrameMaker Ver.5.5(PC) Di181 SWITCHES ON PWBs/TECH. REP. SETTINGS 99.07.06
CONTENTS
1. CONTROL PANEL KEYS AND INDICATORS ................................................ S-1 2. FUNCTIONS OF SWITCHES AND OTHER PARTS ON PWBs ..................... S-3 2-1. PWB Location .......................................................................................... S-3 2-2. Master Board PWB-A .............................................................................. S-3 3. USER'S CHOICE MODE ................................