cover - diagramasde.comdiagramas.diagramasde.com/otros/disassem.pdf · i 1151sbd0000a u for the...

EP5000/EP4000

DIS/REASSEMBLY,ADJUSTMENT

1156SBD000AA

i

1151SBD0000A

u For the Utmost safety u

D For replacement parts, use the genuine parts with their part numbers specified in the parts manual. Use

of a wrong part could cause an overload or dielectric breakdown resulting in an electric shock or fire.

DReplace a blown fuse or thermal fuse with the corresponding genuine part with its part number specified

in the parts manual. Use of a fuse with a different rating or one with the same rating but of a different

type can result in a fire.

Especially when a thermal fuse blows frequently, the thermal control system is probably faulty.

Be sure to take necessary action.

D Before attempting to disassemble the machine, be sure to unplug its power cord. The machine contains

a high voltage unit and a circuit with a large current capacity that may cause an electric shock or burn

from sparking.

The machine also contains quick moving parts, which could injure a person.

If the machine uses a laser, a person can lose his/her eyesight by a laser beam leak.

DWherever feasible, keep the covers and parts mounted when energizing the machine.

If it is absolutely necessary to energize the machine with its cover removed, do not touch an exposed

part that is being charged and use care not to allow your clothing to be caught by a timing belt, gear,

or other moving part.

DDo not leave the machine unattended while it is being energized.

Warning!

D To actuate an interlock switch with a cover removed or opened, be sure to use the interlock switch actu-

ating jig. Use of folded paper can damage the interlock switch mechanism.

Caution!

ii

D A high voltage is being applied to the part marked with the symbol shown

on the right. Touching it can cause an electric shock. Be sure to unplug the

power cord when servicing this part or other parts near it.

DWhen the machine is energized with any of its covers removed, never use a flammable spray near it,

as a fire can result.

DMake sure that correct screws (diameter and length of the screw, binding/tapping screws) are used in

the correct places when assembling parts. If a wrong screw is used, a short insulating distance could

result. It could also result in collapsed threads, which provides only a poor grounding connection, result-

ing in an electric shock.

D A toothed washer and spring washer, if used originally, must be reinstalled. If they are left out, a contact

failure results, causing an electric shock or fire.

DReplace a lithium cell only with one having the part number specified in the parts manual. An explosion

could result if the cell is installed with wrong polarity or a wrong cell is installed.

Dispose of a used lithium cell according to the applicable local regulations. Never throw it away or aban-

don it on the user’s premises.

Caution!

u Other Precautions u

DWhile the machine is being energized, do not unplug or plug in a connector on a PWB or relay harness.

D Since the Magnet Roller of the Imaging Unit generates a strong magnetic force, do not bring a CRT, watch,

floppy disk, or magnetic card near it.

DUse of an air gun or vacuum generates static electricity which can cause the ATDC Sensor and associated

parts to break down. Be sure therefore to use a blower brush or cloth to clean these parts. If a unit is to

be cleaned, be sure to remove the sensors in advance.

DMOS lCs are susceptible to static electricity. When handling a PWB loaded with MOS ICs, follow precau-

tions given in “INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs.”

D The PC Drum is highly delicate. When handling the PC Drum, follow the precautions given in “HANDLING

OF THE PC DRUM.”

D To reassemble, reverse the order of disassembly unless otherwise specified.

DNote that replacement of a PWB may call for readjustments or resetting of particular items.

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.

ADVARSEL!:Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering. Udskiftning må kun ske med

batteri af samme fabrikat og type. Levér det brugle bafferi tilbage til leverandoren.

iii

1156SBD000BA

CONTENTS

SERVICE INSTRUCTIONS1

1-1. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTS D-1. . . . . .1-2. INSTRUCTIONS FOR HANDLING THE PWBs

WITH MOS ICs D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3. HANDLING OF THE PC DRUM D-3. . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. PARTS WHICH MUST NOT BE TOUCHED D-5. . . . . . . . . . . . . . . . .

DISASSEMBLY/REASSEMBLY2

2-1. DOORS, COVERS, AND EXTERIOR PARTS:IDENTIFICATION AND REMOVAL PROCEDURES D-6. . . . . . . . . .

2-2. REMOVAL OF CIRCUIT BOARDS D-8. . . . . . . . . . . . . . . . . . . . . . . .2-3. PAPER TAKE-UP/TRANSPORT SECTIONS D-10. . . . . . . . . . . . . . .

(1) Removal of the Paper Take-Up Unit D-10. . . . . . . . . . . . . . . . . . . .(2) Removal of the Paper Take-Up Roll/Feed Roll Assy and

Separator Roll Assy D-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(3) Cleaning of the Paper Take-Up Roll, Feed Roll,

and Separator Roll D-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4) Cleaning of the Vertical Transport Rollers D-17. . . . . . . . . . . . . . .(5) Removal of the Drawers D-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(6) Removal of the Upper Synchronizing Roller D-19. . . . . . . . . . . . .(7) Cleaning of the Upper and Lower Synchronizing

Rollers D-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(8) Replacement of the Paper Dust Remover D-20. . . . . . . . . . . . . . .(9) Cleaning of the Paper Dust Remover D-21. . . . . . . . . . . . . . . . . . .(10) Removal of the Suction Unit D-22. . . . . . . . . . . . . . . . . . . . . . . . .(11) Disassembly of the Suction Unit D-23. . . . . . . . . . . . . . . . . . . . . .(12) Disassembly of the Multi Bypass Unit D-24. . . . . . . . . . . . . . . . .

2-4. OPTICAL SECTION D-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(1) Cleaning of the Original Glass D-28. . . . . . . . . . . . . . . . . . . . . . . . .(2) Cleaning of the Scanner Shaft D-28. . . . . . . . . . . . . . . . . . . . . . . .(3) Cleaning of the Scanner Rail D-28. . . . . . . . . . . . . . . . . . . . . . . . . .(4) Removal of the Scanner D-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(5) Cleaning of the Exposure Lamp D-29. . . . . . . . . . . . . . . . . . . . . . .(6) Removal of the Thermal Fuse D-30. . . . . . . . . . . . . . . . . . . . . . . . .(7) Cleaning of the 1st, 2nd, and 3rd Mirrors D-30. . . . . . . . . . . . . . .(8) Cleaning of the Lens and 4th and 5th Mirrors D-31. . . . . . . . . . . .(9) Winding of the Lens Drive Cable D-32. . . . . . . . . . . . . . . . . . . . . .(10) Removal of Scanner Motor M2 D-34. . . . . . . . . . . . . . . . . . . . . . .(11) Removal of the Scanner Drive Cable D-35. . . . . . . . . . . . . . . . . .(12) Winding of the Scanner Drive Cable D-36. . . . . . . . . . . . . . . . . .(13) Cleaning of the 6th Mirror Protective Filter D-37. . . . . . . . . . . . .(14) Cleaning of the Cooling Fan Filter D-37. . . . . . . . . . . . . . . . . . . .

iv

CONTENTS2-5. IMAGING UNIT D-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(1) Removal of the Imaging Unit D-38. . . . . . . . . . . . . . . . . . . . . . . . . .(2) Disassembly of the Imaging Unit D-38. . . . . . . . . . . . . . . . . . . . . .(3) Replacement of the PC Drum D-42. . . . . . . . . . . . . . . . . . . . . . . . .(4) Cleaning of the Developer Scattering Prevention Plate D-42. . .(5) Cleaning of the Ds Positioning Collars D-42. . . . . . . . . . . . . . . . . .(6) Cleaning of the Toner Antispill Trap D-42. . . . . . . . . . . . . . . . . . . .(7) Cleaning of the Cleaning Blade D-42. . . . . . . . . . . . . . . . . . . . . . . .(8) Replacement of the Cleaning Blade D-43. . . . . . . . . . . . . . . . . . . .(9) Replacement of the Starter D-45. . . . . . . . . . . . . . . . . . . . . . . . . . .(10) Cleaning of the AIDC Sensor Board D-46. . . . . . . . . . . . . . . . . .(11) Cleaning of the PC Drum Paper Separator Fingers D-46. . . . .(12) Replacement and Cleaning of the Toner Antispill Seal

and Cleaning of the Toner Antispill Plate D-46. . . . . . . . . . . . . . . .(13) Removal of Main Erase Lamp LA3 D-47. . . . . . . . . . . . . . . . . . . .(14) Cleaning of the Main Erase Lamp Filter D-47. . . . . . . . . . . . . . .(15) Cleaning of Image Erase Lamp LA2 D-47. . . . . . . . . . . . . . . . . .(16) Replacement of Image Erase Lamp LA2 D-47. . . . . . . . . . . . . .(17) Removal of the Ozone Filter

(PC Drum Charge Corona) D-48. . . . . . . . . . . . . . . . . . . . . . . . . .(18) Removal of the Ozone Filter

(Image Transfer/Paper Separator Coronas) D-48. . . . . . . . . . . .(19) Removal of the Toner Collecting Box D-48. . . . . . . . . . . . . . . . . .

2-6. PC DRUM CHARGE CORONA ANDIMAGE TRANSFER/PAPER SEPARATOR CORONAS D-49. . . . . .(1) Removal of the PC Drum Charge Corona D-49. . . . . . . . . . . . . . .(2) Cleaning of the PC Drum Charge Corona Housing D-49. . . . . . .(3) Cleaning of the PC Drum Charge Corona Grid Mesh D-50. . . . .(4) Cleaning of the Comb Electrode D-50. . . . . . . . . . . . . . . . . . . . . . .(5) Removal of the Image Transfer/Paper Separator

Coronas D-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(6) Cleaning and Replacement of the Image Transfer

Corona Wire D-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(7) Cleaning and Replacement of the Paper Separator

Corona Wire D-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(8) Cleaning of the Image Transfer/Paper Separator

Coronas Housing D-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(9) Cleaning of the Lower Pre-Image Transfer

Guide Plate D-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7. FUSING UNIT D-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(1) Removal of the Fusing Unit D-53. . . . . . . . . . . . . . . . . . . . . . . . . . .(2) Disassembly of the Fusing Unit D-53. . . . . . . . . . . . . . . . . . . . . . . .(3) Replacement and Cleaning of the Upper Fusing Paper

Separator Fingers D-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4) Cleaning of the Lower Fusing Paper Separator Fingers D-58. . .(5) Cleaning of the Fusing Unit Entrance Guide Plate D-58. . . . . . . .

v

CONTENTS(6) Cleaning of Fusing Front and Rear Thermistors TH1/2 D-58. . . .(7) Cleaning of Fusing Thermoswitch TS1 D-59. . . . . . . . . . . . . . . . .(8) Replacement and Cleaning of the Cleaning Roller D-59. . . . . . .(9) Replacement and Cleaning of the Upper Fusing

Roller D-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(10) Replacement and Cleaning of the Lower Fusing

Roller D-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8. EXIT UNIT D-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(1) Removal of the Exit/Duplex Switching Unit D-61. . . . . . . . . . . . . .

ADJUSTMENT3

3-1. JIGS AND TOOLS USED D-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. ADJUSTMENT REQUIREMENTS LIST D-63. . . . . . . . . . . . . . . . . . .3-3. ADJUSTMENT OF SWITCHES D-64. . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment of Front Door Interlock Switch S21 D-65. . . . . . . . . . . . .3-4. ADJUSTMENT OF BELT TENSION D-66. . . . . . . . . . . . . . . . . . . . . .

(1) Paper Take-Up Unit Timing Belt D-66. . . . . . . . . . . . . . . . . . . . . . .(2) Developing Unit Timing Belt D-66. . . . . . . . . . . . . . . . . . . . . . . . . . .(3) Fusing Unit Timing Belt D-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4) I/U Timing Belt D-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. ACCESSING THE TECH. REP. MODE ANDADJUST MODE D-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. ELECTRICAL/IMAGE ADJUSTMENTS D-68. . . . . . . . . . . . . . . . . . .(1) Initial Adjustment of Original Size Detecting Board D-68. . . . . . .(2) ATDC Adjustment D-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(3) Adjustment of the Aperture Blades D-71. . . . . . . . . . . . . . . . . . . . .(4) Adjustment of Exposure Level in the Auto

Exposure Mode D-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(5) Adjustment of Optimum Exposure Setting in the Manual

Exposure Mode D-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(6) Adjustment of Zoom Ratio in the Crosswise Direction D-75. . . . .(7) Adjustment of Zoom Ratio in the Feeding Direction D-77. . . . . .(8) Adjustment of Reference Position of the Multi

Bypass Table D-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(9) Adjustment of Reference Position of the 1st/2nd

Drawer D-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(10) Adjustment of the Leading Edge Registration D-81. . . . . . . . . .

(1)Leading Edge Registration in Full Size Mode D-81. . . . . . . .(2)Leading Edge Registration in Enlargement Mode D-83. . . .(3)Leading Edge Registration in Reduction Mode D-85. . . . . . .

(11) Adjustment of the Leading Edge Registration for BookSecond Page D-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(12) Adjustment of the Image Leading Edge Erase Width D-89. . . .(13) Adjustment of the Image Trailing Edge Erase Width D-91. . . . .(14) Adjustment of Edge Erase D-93. . . . . . . . . . . . . . . . . . . . . . . . . . .

vi

CONTENTS3-7. OTHER ADJUSTMENTS D-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(1) Focus-Positioning of the Scanner and MirrorsCarriage D-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(2) Adjustment of the Gap Between the Doctor Blade andSleeve Roller (D.B. Adjustment) D-96. . . . . . . . . . . . . . . . . . . . . . .

(3) Adjustment of the PC Drum Paper Separator FingerPosition D-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(4) Adjustment of Manual Feed Paper Take-Up SolenoidSL4 D-98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(5) Adjustment of Exit/Duplex Solenoid SL5 D-99. . . . . . . . . . . . . . . .

MISCELLANEOUS4

4-1. INSTALLATION OF THE PLUG-IN COUNTER (OPTION)MOUNTING BRACKET D-100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. ADJUSTMENT OF THE RIGHT DOOR D-101. . . . . . . . . . . . . . . . . .

D-1

1139SBD0100A

SERVICE INSTRUCTIONS11151SBD0101B

1-1. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTSObserve the following precautions whenever servicing the copier.

D Be sure to unplug the copier from the outlet before attempting to service the copier.D 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 clothingto be caught in revolving parts such as the timing belt and gears.

D Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the Interlock Switchwith the covers left open or removed.

DDo not plug in or unplug print jacks on the Board or connect or disconnect the Board connectors whilepower is being supplied to the copier.

DDo not use flammable spray around the copier in operation.D TheMagnet Roller of the Imaging Unit generates strongmagnetic force. Do not bring it near a cathode-raytube or watch.

D The lithium cell in RAM Board PWB-R can burst. At replacement, make sure of the correct polarity anddo not change it or create a closed circuit.A used lithiumcell should be disposed of according to the local regulations and never be discarded casual-ly or left unattended at the user’s premises.

DDo not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they cancause electrostatic destruction. Use a blower brush and cloth. If a unit containing these sensors is to becleaned, first remove the sensors from the unit.

DWhen handling the PWBs with MOS ICs, observe “Instructions for Handling the PWBs with MOS ICs.”DWhen handling the PC Drum, observe precautions given in “Handling of the PC Drum.”DNote that replacement of a PWB may call for readjustments or resetting of particular items.DUse the right screw in the right place at reassembly. Note that some are longer and some are thicker thanothers.

D A toothed washer is used with the screw that secures the ground wire to ensure positive conduction. Donot forget to insert this washer at reassembly.

D To reassemble the copier, reverse the order of disassembly unless otherwise specified.D If it becomes necessary to replace the thermal fuse or any other fuse mounted on a board, be sure to useone 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 subjectto change without notice.

DDo not pull out the TonerHopper while the Toner Bottle is turning, as a damagedToner ReplenishingMotoror locking mechanism could result.If the copier is to be run with the Front Door swung down, make sure that the Toner Hopper is in the lockedposition.

CAUTION: DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACEONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER.DISCARD USED BATTERIES ACCORDING TO THE MANUFACTURER’S INSTRUCTIONS.

D-2

Fuse Board

PWB-L 250V 3A (4)

Power Supply Board

PWB-C 250V 3A (5)

Power Supply Unit

PU1 125V 8A

Noise Filter Board

PWB-D 250V 15A

Exposure Thermal Fuse

TF1 110°°°°C 10A

Fuse Holder

F3 250V 15A

<List of Fuses Used>

1156D001CA

D-3

1139SBD0102A

1-2. INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICsThe following precautions must be observed when handling P.W. Boards with MOS (Metal OxideSemiconductor) ICs.

During Transportation/Storage:DDuring transportation or when in storage, new P.W. Boards must not be indiscriminately removed fromtheir protective conductive bags.

DDo not store or place P.W. Boards in a location exposed to direct sunlight.DWhen it becomes absolutely necessary to remove a Board from its conductive bag or case, always placeit on its conductive mat in an area as free as possible from static electricity.

DDo not touch the pins of the ICs with your bare hands.

During Replacement:D Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unpluggedfrom the outlet.

DWhen removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs orthe printed pattern. Place it in position by holding only the edges of the Board.

D Before plugging connectors into the Board, make sure that the power cord has been unplugged from thepower outlet.

During Inspection:

D Avoid checking the IC directly with a multimeter; use connectors on the Board.DNever create a closed circuit across IC pins with a metal tool.DWhen it is absolutely necessary to touch the ICs and other electrical components on the Board, be sureto ground your body.

1151SBD0103A

1-3. HANDLING OF THE PC DRUMDuring Transportation/Storage:DUse the specified carton whenever moving or storing the PC Drum.D The storage temperature is in the range between −20°°°°C and +40°°°°C.D In summer, avoid leaving the PC Drum in a car for a long time.

Handling:D Ensure that the correct PC Drum is used.DWhenever the PCDrumhas been removed from the copier, store it in its container or protect it with aDrumCloth.

D The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended periodof time. Never, therefore, expose it to direct sunlight.

DUse care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other for-eign matter.

DDo not scratch the surface of the PC Drum.DDo not apply chemicals to the surface of the PC Drum.DDo not attempt to wipe clean the surface of the PC Drum.

D-4

If, however, the surface is contaminated with fingerprints, clean it using the following procedure.

NOTES

D The Organic Photoconductor Drum is softer than CdS and Selenium Drums and is thereforesusceptible to scratches.

D Even when the PC Drum is only locally dirtied, wipe the entire surface.DDo not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interiorillumination.

D If dirt remains after cleaning, repeat the entire procedure from the beginning one more time.

1. Place the PC Drum into one half of its container.

2. Gently wipe the residual toner off the surface of the PCDrum with a dry, Dust-Free Cotton Pad.a) Rotate the PC Drum so that the area of its surface on

which the line of toner left by theCleaningBlade is pres-ent is facing straight up.Wipe the surface in one contin-uous movement from the rear edge of the PC Drum tothe front edge and off the surface of the PC Drum.

b) Rotate the PC Drum slightly and wipe the newly ex-posed surface areawith aCLEAN faceof theDust-FreeCotton Pad. Repeat this procedure until the entire sur-face of the PC Drum has been thoroughly cleaned.

* At this time, always useaCLEAN faceof the dryDust-FreeCotton Pad until no toner is evident on the face of the Padafter wiping.

3. Soak a small amount of either ethyl alcohol or isopropyl al-cohol into a clean, unused Dust-Free Cotton Pad whichhas been folded over into quarters. Now, wipe the surfaceof the PC Drum in one continuous movement from its rearedge to its front edge and off its surface one to two times.

* Never move the Pad back and forth.

4. Using the SAME face of the Pad, repeat the procedure ex-plained in the latter half of step 3 until the entire surface ofthe PC Drum has been wiped. Always OVERLAP theareas when wiping. Two complete turns of the PC Drumwould be appropriate for cleaning.

D-5

1151SBD0104A

1-4. PARTS WHICH MUST NOT BE TOUCHED

(1) ScrewsPurpose 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 towhich redpaint is applied. In addition, be advisedthat, if two or more screws are designated as those which must not be touched on a single part, onlyone representative screw may be marked with red paint.

(2) Variable Resistors on Board

Do not turn the variable resistors on boards for which no adjusting instructions are given in “ADJUST-MENT.”

(3) Other Screws

Two screws on the LowerPre-Image Transfer Guide Plate

1136D069AA1136D068AA

Two screws on the MirrorMotor Unit

1136D070AA

Two screws on theLens Rail

D-6

1156SBD0200A

DISASSEMBLY/REASSEMBLY21156SBD0201A

2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND

REMOVAL PROCEDURES

12

13

14

15

16

11

5

43

2

1

1156D002AA

1156D003AA

7

8

10

6

9

D-7

No. Part Name Removal Procedure

1 Front Door Swing down No. 1.! Remove two Front Door hinge shafts.Remove one belt mounting screw inside the Front Door.

2 Control Panel Raise No. 12.! Swing down No. 1.! Open No. 8.! Re-move No. 7.! Swing down No. 14.! Remove No. 13.!Remove two control panel mounting screws.! Remove twomagnet attraction plate screws.! Unplug one connectorfrom MSC Board.! Remove one connector.

3 Original Width Scale Raise No. 12.! Remove two scale mounting screws.Note:When the Original Width Scale has been removed use

4 Original GlassNote:When the Original Width Scale has been removed, usecare not to lose two springs.

5 Rear Upper Cover (Small) Raise No. 12.! Open No. 14.! Remove No. 13.! Re-move the screw cover.! Remove one Rear Upper Cover(Small) mounting screw.

6 Rear Upper Cover Raise No. 12.! Open No. 14.! Remove No. 13.! Re-move No. 5.! Open No. 8! Remove No. 7.! Removeone Rear Upper Cover mounting screw.

7 Right Cover Open No. 8.! Open the Multi Bypass Table.! Removefour Right Cover mounting screws.

8 Right Door(Manual Bypass Unit)

Open No. 8.! Remove two cover mounting screws.!Remove the harness from one wiring saddle.! Unplugthree connectors.! Remove two Right Door mountingscrews.

9 Counter Cover Snap off the Counter Cover. (It is secured by catches at twoplaces.)

10 2nd Drawer <Except 120V Areas>See p. D-17

11 1st DrawerSee p. D-17<120V Areas>See p. D-18

12 Original Cover Remove No. 12 by pulling up.

13 Upper Left Cover Swing down No. 14.! Remove six Upper Left Covermounting screws.

14 Left Door (Exit/DuplexSwitching Unit) See p. D-61

15 Middle Left Cover Remove No. 13.! Remove two Middle Left Cover mountingscrews.

16 Rear Cover Remove six Rear Cover mounting screws.

D-8

1156SBD0202A

2-2. REMOVAL OF CIRCUIT BOARDSDWhen removing a circuit board, refer to “PRECAUTIONS FOR HANDLING THE PWBs” contained inSWITCHES ON PWBs and follow the corresponding removal procedures given on the next page.

DReplacement of a circuit board may call for readjustment or resetting of particular items.D The removal procedures given on the next page omit the removal of connectors and screws securing thecircuit board support or circuit board.

DWhere it is absolutely necessary to touch the ICs and other electrical components on the board, be sureto ground your body.

1156D004AA

PWB-H PWB-J UN2 PWB-A

PWB-R

PWB-F

HV1

PU1

PWB-L

PWB-C

UN3

PWB-G

PWB-D

PWB-I

PWB-B

UN1

D-9

Symbol Part Name Removal Procedure

PWB-A Master Board Remove No. 16.

PWB-B MSC Board Swing down No. 1.! Remove the Circuit Board cover.

PWB-C Power Supply Board Remove No. 16.! Remove the Toner Pipe.<EP4000 Except U.S.A., Canada and Europe>Remove No. 16.! Remove the Toner Collecting Box.Remove the Toner Pipe.

PWB-D Noise Filter Board Remove No. 16.

PWB-E1 1st Drawer Paper EmptyBoard Slide out the drawer.! Remove the Holder.! Remove the

PWB-E2 2nd Drawer PaperEmpty Board

Slide out the drawer.! Remove the Holder.! Remove thePaper Mounting Plate.

PWB F SCP Board Remove No 16PWB-F SCP Board Remove No. 16.

PWB-G AIDC Sensor Board Swing down No. 1.! Remove the IU.! Remove the PCDrum Charge Corona.! Remove the PC Drum Paper Sepa-rator.

PWB-H AE Sensor Board Remove No. 3.! Remove No. 4.

PWB-I Tech. Rep. SettingsSwitches Board

Swing down No. 1.! Remove the Circuit Board Cover.

PWB-J Exposure LampRegulator

Remove No. 16.! Remove PWB-A Mounting Bracket Assy.! Remove the ADF Connector Unit.! Remove the Expo-sure Lamp Regulator Cover.

PWB-L Fuse Board Remove No. 16.<EP4000 Except U.S.A., Canada and Europe>Remove No. 16.! Remove the Toner Collecting Box.Remove the Toner Pipe.

PWB-M1 1st Drawer Flexibleprinted Circuit

Slide out the drawerPWB-M2 2nd Drawer Flexible

printed Circuit

Slide out the drawer.

PWB-R RAM Board Remove No. 16.

UN1 Control Panel Swing down No. 1! Remove No. 2.

UN2 Original Size DetectingBoard

Remove No. 16.

UN3 ATDC Sensor Swing down No. 1.! Remove the IU.

UN5 1st Drawer PaperDescent Key Slide out the drawer.! Remove the Cassette Cover.! Re-

UN6 2nd Drawer PaperDescent Key

Slide out the drawer.! Remove the Cassette Cover.! Re-move the Switch Cover.

PU1 Power Supply Unit Remove No. 16.! Remove the Power Supply Unit Cover.

HV1 Hight Voltage Unit Remive No. 16.! Remove the HV1 Cover.

z Readjustment/Resetting Involved in Replacement of PWB-G, PWB-R, UN2 and UN3DWhen PWB-G is replaced:Adjust the exposure level in the Auto Exposure mode. (See p. D-72.)

DWhen PWB-R (RAM Board) is replaced:Carry out Memory Clear and then make the Tech. Rep. Choice, User’s Choice, and Adjust settingsagain.

DWhen UN2 is replaced:Make the initial adjustment of the Original Size Detecting Board. (See p. D-68.)

DWhen UN3 is replaced:Discard the developer which had been used until UN3 was replaced, recharge the Developing Unitwith fresh starter, and adjust the ATDC. (See p. D-69.)

D-10

1156SBD0203

2-3. PAPER TAKE-UP/TRANSPORT SECTIONS

(1) Removal of the Paper Take-Up Unit<Except 120V Areas>

1. Remove the Right Door, Right Cover, and Rear Cover.2. Remove the 1st and 2nd Drawers. (For the removal of the 1st and 2nd Drawers, see p. D-17.)3. Remove two locking wiring saddles.4. Unplug one connector from Power Supply Board PWB-C.5. Disconnect the hookup connector.

1156D005AA

<120V Areas>

1. Remove the Right Door, Right Cover, and Rear Cover.2. Remove the 1st and 2nd Drawers. (For the removal of the 1st and 2nd Drawers, see p. D-18.)3. Remove one locking wiring saddle.4. Disconnect the hookup connector.

1156D006CA

D-11

1156D007AA

1134D006AA

1134D007AA

<Except 120V Areas>

1134D008AA

<120V Areas>

1156D008CA

6. Remove three screws to free the Paper Take-Up Connec-tor Assy.

7. Remove two screws each to free 1st Drawer Paper Take-UpMotor M11 and 2nd Drawer paper Take-UpMotorM12.

* For ease of understanding, the illustration shows wherethe connectors and Paper Take-Up Motors are removed.

8. Remove two screws and the Paper Guide Plate.

9. Remove two edge covers with locks.10. Unplug three hookup connectors.

9. Remove two edge covers with locks.10. Unplug one hookup connector.

D-12

1134D009AA

12. Remove five screws and the Paper Take-Up Unit.

1156D009AA

11. Pull the harness out to the front from the rear frame.

D-13

(2) Removal of the Paper Take-Up Roll/Feed Roll Assy and Separator Roll

Assy1. Remove the Right Door.2. Remove two screws and the Paper Guide Plate from each drawer.

1134D011AA

3. Unhook the front and rear springs from the copier frame. Remove the Paper Separator Roll/PaperGuide Plate Assy by turning it about 90_ in the direction of the arrow.

1156D010AA

D-14

1156D011AA

5. Disassemble the Paper Separator Roll Assy.

1156D012AA

4. Remove one screw and the Paper Separator Roll AssyMounting Bracket from each drawer. (The illustrationshows how the Paper Separator Roll Assy is removedfrom the 2nd Drawer.)

D-15

1156D013AA

1156D014AA

1156D015AA

1156D016AA

6. Remove two C-clips from each Paper Take-Up Roll/FeedRoll Assy. (The illustration is for the Paper Take-Up Roll/Feed Roll Assy for the 2nd Drawer.)

7. Remove the bushing from the front end of each PaperTake-Up Roll/Feed Roll Assy.

8. Remove the rear bushing from the holder.

9. Move the coupling holder of each Paper Take-Up Roll/FeedRoll Assy in the direction of the arrow to work it off thepin of the copier. This allows thePaper Take-UpRoll /FeedRoll Assy to come out of the copier.

NOTE

When reinstalling the Paper Take-UpRoll/Feed Roll Assy,place it above the Pressure Release Lever.

D-16

10. Disassemble the Paper Take-Up Roll/Feed Roll Assy.

1156D017AA

*Keep the lock pin for later use.

(3) Cleaning of the Paper Take-Up Roll, Feed Roll, and Separator Roll1. Remove each Paper Take-Up Roll/Feed Roll Assy.2. Remove each Paper Separator Roll Assy.3. Using a soft cloth dampened with alcohol, wipe each roll clean of dirt.

1156D019AA1156D018AA

Cleaning the Paper Take-up Roll/Feed Roll Cleaning the Paper Separator Roll

D-17

(4) Cleaning of the Vertical Transport Rollers

1134D016AA

(5) Removal of the Drawers*Though the following steps and illustrations are for the 1st Drawer, the same procedure applies also to

the 2nd Drawer.

<Except 120V Areas>

1156D020AA

1134D133AA

1134D143AA

1. Remove the Right Door, Right Cover, and Rear Cover.2. Using a soft cloth dampened with alcohol, wipe each roller

clean of dirt.

1. Slide out the drawer and remove one screw and the rightstopper.

2. Remove one screw and the left stopper.

3. Remove the drawer from the copier.

D-18

<120V Areas>

1156D023AA

1134D139CA

1134D140CA

1134D141CA

1. Turn ON Power Switch S1.2. Press the Paper Descent Key and then slide out the draw-

er.

3. As with the metric areas, remove the right and left stop-pers.

4. Remove one screw and the hookup connector cover.

5. Remove one screw and the hookup connector mountingbracket.

6. Unplug the hookup connector. Remove the drawer.

D-19

(6) Removal of the Upper Synchronizing Roller

1156D024AA

1156D025AA

1156D026AA

1156D027AA

Rear

1134D025AA

Front

1. Swing down the Front Door.2. Swing the Transport Section Release Lever down.3. Remove the Rear Cover.4. Unplug the bias terminal from High Voltage Unit HV1.5. Unplug CN1 of HV1.

6. Remove two screws to free HV1.

7. Snap off one E-ring to free Synchronizing Roller ClutchCL2.

8. Snap off the E-ring and remove the bushing from the rearend of the Upper Synchronizing Roller.

9. Swing down the Front Door and slide out the IU.10. Snap off the E-ring and remove the bushing from the front

end of the Upper Synchronizing Roller.

D-20

1156D028AA

(7) Cleaning of the Upper and Lower Synchronizing Rollers

1136D092AA

1134D027AA

(8) Replacement of the Paper Dust Remover

1136D093AA

Rear

1136D094AA

11. Remove the Upper Synchronizing Roller.

1. Swing down the Front Door and slide out the IU.2. Using a brush or a soft cloth dampenedwith alcohol, clean

the Upper Synchronizing Roller.

3. Swing down the Transport Section Release Lever.4. Using a brush or a soft cloth dampenedwith alcohol, clean

the Lower Synchronizing Roller.

1. Swing down the Front Door and slide out the IU.2. Loosen the screw that secures the Paper Dust Remover

Assy at the rear of the copier.3. Remove the screw that secures the Paper Dust Remover

Assy at the front of the copier.4. Remove and replace the Paper Dust Remover Assy.

5. When only the Paper Dust Remover is to be replaced, affixthe new one along the reference line as shown on the left.

D-21

(9) Cleaning of the Paper Dust Remover

1136D095AA

1. Remove the Paper Dust Remover Assy.2. Using a brush, whisk dust off the Paper Dust Remover.

D-22

(10) Removal of the Suction Unit1. Remove the 1st and 2nd Drawers.2. Swing down the Front Door and slide out the IU.3. Remove the Paper Dust Remover Assy.4. Remove the Fusing Unit.

1156D029AA

1156D030AA

1156D031AA

5. Remove the motor cover.

6. Unplug two connectors from the lower end of the SuctionUnit.

7. Swing the Transport Section Release Lever back to itsoriginal position.

8. Pressing down the Image Transfer/Paper Separator Coro-nas Unit, pull it out of the copier.

D-23

1156D032AA

1136D101AA

1134D028AA

(11) Disassembly of the Suction Unit

1136D102AA

1136D103AA

9. Swing down the Transport Section Release Lever.10. Holding up the Suction Unit, remove the compression coil.

11. Remove the Suction Unit by sliding it to the right.

NOTEWhen removing and reinstalling the SuctionUnit, use carenot to bend the ground plate located on the right in the rear.

NOTEWhen reinstalling the Suction Unit, make sure that twopositioning pins on the copier fit into the positioning holes

in the Suction Unit.

1. Remove the Suction Unit.2. Remove two screws and the duct.3. Remove four screws and the Suction Drive Unit.

NOTE

When reinstalling the Suction Drive Unit, try to press itdown against the Suction Base Plate.

4. Remove three driven rolls.

D-24

1136D104AA

1136D105AA

(12) Disassembly of the Multi Bypass Unit

1156D033AA

1156D034AA

1156D035AA

5. Remove three Suction Belts.

6. Remove the Suction Roller as shown on the left.

1. Open the Right Door.2. Remove two screws and the cover.3. Remove the harness from one locking wiring saddle.4. Unplug three connectors.

5. Remove two screws and the Right Door.

NOTE

TheRight Doormust be adjusted for correct positionwhenit is reinstalled. (See p. D-101.)

6. Remove four screws and the Separator Guide Plate Assy.

D-25

1136D107AA

Close-Coiled End

1136D108AA

1136D109AA

1136D110AA

1156D036AA

7. Remove the compression coil.NOTE

When reinstalling the compression coil, place it so that itsclose-coiled end faces the Separator Unit.

8. Remove one C-clip and the Separator Assy.

9. Remove one C-clip and the Separator Roll Assy.

10. Remove the harness from the edge cover and cord clamp.

11. Remove four screws and the Solenoid Mounting Bracket.NOTE

When the solenoid has been replaced or the solenoidmounting screws removed, be sure to adjust the position

of the solenoid. (For the adjustment procedure, see p.D-98.)

D-26

1156D037AA

1136D114AA

1136D115AA

0 to−1mm A

1156D038AA

1139D112AA

12. Remove two set screws and the electromagnetic springclutch.

NOTES

DWhen reinstalling the electromagnetic spring clutch, ori-ent the Paper Take-Up Roll shaft and the clutch as

shown on the left.D The end of the clutch must be flush with or slightly re-cessed (up to 1mm) from theend faceof thePaperTake-Up Roll shaft. (The roll shaft should never protrude.)

D There must be a gap of 1 mm or more at A when the Pa-per Take-Up Roll shaft is pushed in the direction of thearrow.

13. Snap off two C-clips and remove the Paper Take-Up RollAssy.

14. Snap off three C-clips and remove the Feed Roll.

D-27

1139D113AA

DCleaning of the Manual Bypass Paper Take-Up Roll

1136D117AA

DCleaning of the Manual Bypass Feed Roll

1136D118AA

DCleaning of the Manual Bypass Separator Roll

1156D039AA

15. Snap off the C-clip and remove the Paper Take-Up Roll.

Using a soft cloth dampened with alcohol, clean the Paper-Take-Up Roll.

Using a soft cloth dampened with alcohol, clean the FeedRoll.

Using a soft cloth dampened with alcohol, clean the Separa-tor Roll.

D-28

1156SBD0204A

2-4. OPTICAL SECTION

(1) Cleaning of the Original Glass

1136D120AA

(2) Cleaning of the Scanner Shaft

1136D121AA

1156D040AA

(3) Cleaning of the Scanner Rail

1156D041AA

Wipe clean the Original Glass with a soft cloth.

NOTE

Thesurface of theOriginalGlass is coated with conductivematerial. Do not use a wax-based detergent.

An alcohol-dampened cloth may be used if the glass is se-riously contaminated.

1. Remove the Original Width Scale.2. Remove the Original Glass.

3. Wipe clean the Scanner Shaft (in the rear of the copier)with a soft cloth.

NOTEApply a lubricating oil after cleaning the Scanner Shaft.

Wipe clean the Scanner Rail (at the front of the copier) witha soft cloth.

NOTEApply a lubricating oil after cleaning the Scanner Rail.

D-29

(4) Removal of the Scanner

1156D042AA

1156D043AA

1156D044AA

(5) Cleaning of the Exposure Lamp

1156D045AA

1076D131

1. Move the Scanner to the right side of the copier.Remove three screws to free the Scanner.

NOTE

Hold the Scanner at a point near the Scanner Shaft whenmoving it.

To remove the Scanner, turn it counterclockwise.

2. Unplug the Thermal Fuse terminal connector and removethe Thermal Fuse wire from three clamps.

3. Unplug the Exposure Lamp terminal connector.

4. Turn over the Scanner and remove one screw, one wash-er, and the ground wire.

5. Remove the tie band and harness.6. Remove the Scanner from the copier.

1. Remove one screw and the Exposure Lamp terminal.2. Slide out the Exposure Lamp.

NOTE

When the Exposure Lamp has been cleaned or replaced,be sure to make the “adjustment of exposure level in the

Auto Exposure mode.” (See p. D-72.)

3. Using a soft cloth dampened with alcohol, clean the lampby gently wiping its surface in one direction.

NOTE

When reinstalling the lamp, point the protruding navel ofthe lamp toward the opening in the Lamp Reflector so that

the protruding navelwill not hit against the LampReflector.

D-30

(6) Removal of the Thermal Fuse

1156D046AA

(7) Cleaning of the 1st, 2nd, and 3rd Mirrors

1156D047AA

1136D130AA

1136D131AA

1. Unplug the Thermal Fuse connector.2. Remove the Thermal Fuse cord from three clamps.3. Remove one screw and Thermal Fuse cover.4. Remove two screws and the Thermal Fuse.

1. Wipe clean the 1st Mirror with a soft cloth.

2. Wipe clean the 2nd Mirror with a soft cloth.

3. Wipe clean the 3rd Mirror with a soft cloth.

D-31

(8) Cleaning of the Lens and 4th and 5th Mirrors

1136D133AA

1136D132AA

1136D134AA

1. Remove the Original Glass.2. Remove two screws and the Optical Cover.3. Remove two screws and the Lens Cover.

4. Gently dust off the surface of the Lens using a soft cloth.

5. Wipe clean the 4th and 5th Mirrors with a soft cloth.

D-32

(9) Winding of the Lens Drive Cable

1136D135AA

Cable Drive Gear

A

B

1136D136AA

1136D137AA

1136D138AA

1. Hold the Cable Drive Gear with the bead at the bottom.

2. Wind the longer length of the cable three and 1/2 turnsclockwise around the Cable Drive Gear, working from theback to the front side. Then tape it.

3. Wind the shorter length of the cable three and 1/2 turnscounterclockwise around the Cable Drive Gear, workingfrom the front to back side. Then tape it.

D-33

1136D139AA

1136D140AA

A

1136D141AA

2mm or Less

1136D142AAB

4. Pass the longer length of the cable through the hole in thelight blocking plate.

5. Slide the Cable Drive Gear onto its shaft and insert awrench into the hole (4-mm dia.) to position the gear.

6. Wind the shorter length of the cable around pulley A.

7. Secure the shorter length of the cable to the Cable FixingBracket.

NOTE

Ensure a distanceof 2mmor less for the dimension shownon the left.

8. Wind the longer length of the cable around pulley B.9. Hook the spring onto the longer length of the cable andpull

the spring to hook it onto the shorter length of the cable.10. Remove the wrench and peel off the two pieces of tape

used in steps 2 and 3.

D-34

(10) Removal of Scanner Motor M2

1156D048AA

1156D049AA

1. Remove the Right Cover, Rear Cover, and Rear UpperCover.

2. Remove four screws to free PWB-F.

3. Unplug one connector. Then, remove the edge cover witha lock and the harness.

4. Remove four screws and Scanner Motor M2.

D-35

(11) Removal of the Scanner Drive Cable1. Remove the Original Cover.2. Remove the Right Cover, Rear Cover, Rear Upper Cover, and Upper Left Cover.3. Remove the Original Glass.4. Remove the Scanner.5. Remove Scanner Motor M2.

1156D048AA

1156D050AA

1134D037AA

1134D038AA

6. Remove two screws to free the SCP Board (PWB-F)mounting bracket.*The illustration showswhere the SCP Board has been re-moved for ease of understanding.

7. Remove two screwsandOriginalGlassCoolingFanMotorM5.

8. Using a flat blade screwdriver, loosen the right spring an-chor to unhook the bead from the anchor, thereby remov-ing the cable.

9. Move the Scanner to the center and remove the ScannerFixing Bracket.

D-36

(12) Winding of the Scanner Drive Cablez Important

When the Scanner Drive Cable has been wound:

1) Perform the “Focus-positioning of the Scanner and Mirrors Carriage.”

2) Slide the Scanner by hand to check for cable tension before turning the copier ON.

3) No part of the cable should ride on others whenwinding the cable around theCable DrivePulley. Further,

no part in the cable should be bent or no part of the cable jacket frayed.

* Wind the cable five turns around the Cable Drive Pulley.

1156D054AA

Wind Cable5 Turns.

D-37

1156D051AA

(13) Cleaning of the 6th Mirror Protective Filter

1156D174AA

1156D175AA

(14) Cleaning of the Cooling Fan Filter

1156D052AA

10. Remove the Scanner Drive Cable from the pulleys.11. Remove one screw to free the Original Cover Detecting

Sensor Assy.12. Remove four screws and the Scanner Drive Pulleymount-

ing bracket.13. Snap off one E-ring and remove the Scanner Drive Pulley.

1. Swing down the Front Door and slide out IU.2. Remove the Plate Spring.3. Remove the 6th Mirror Protective Filter.

4. Using a soft cloth, wipe clean the 6th Mirror Protective Fil-ter.

1. Remove six screws and the Rear Cover.2. Clean the Cooling Fan Filter using a brush or a vacuum

cleaner.

D-38

1156SBD0205A

2-5. Imaging Unit

(1) Removal of the Imaging Unit

1136D150AA

1156D055AA

(2) Disassembly of the Imaging Unit

1136D152AA

1156D056AA

1156D057AA

1. Swing down the Front Door.2. Swing the Transport Section Release Lever down.

3. Loosen two screws that secure the IU.4. Slide out the IU.

1. Remove the PC Drum Charge Corona by moving it to therear.

2. Loosen one screw and remove the stopper.3. Remove the PC Drum.

4. Pull the Main Hopper to the front and unplug two HopperUnit connectors.

D-39

1136D155AA

1156D058AA

1156D059AA

1156D060AA

Rear

Front

1136D157AA

5. Remove three screws and the Main Hopper.

6. Unplug one connector and remove three screws and theSub Hopper.

7. Remove two screws and the Developer Scattering Pre-vention Plate.

NOTE

Do not remove the Doctor Blade Assy, as a changed Dbcould result.

NOTE

Install the Developer Scattering Prevention Plate so thatits seal is placed behind the side seals of the Developer

Mixing Chamber.

8. Dump the developer out of the Developing Unit.

D-40

1136D172AA

1136D173AA

1156D061AA

1134D047AA

Coupling Holder

Collar

9. Remove two screws and the Cleaning Blade.

NOTE

When reinstalling the Cleaning Blade, press the bladetightly up against the mounting bracket.

10. Unplug one connector.11. Remove three screws and the PC Drum Paper Separator

Finger Holder Assy.

NOTE

When reinstalling the PC Drum Paper Separator FingerHolder Assy, fit the collar of the assy onto the coupling

holder in the rear.

D-41

12. Remove the PC Drum Paper Separator Fingers and AIDC Sensor Board PWB-G as shown below.

1156D062AA

Torsion Spring

PWB-G

Assy

* PC Drum Paper Separator FingersAt removal and reinstallation, use care not to damage the tip of the fingers.Also, use care not to get hurt by the tip of the fingers.

* Hook the torsion spring properly.After installation, check that thePaper Separator Fingers oper-ate smoothly.Top View Bottom View

1156D063AA

PC Drum Paper Separator Finger Installed

D-42

(3) Replacement of the PC Drum

1136U014AA

(4) Cleaning of the Developer Scattering Prevention Plate

1136D050AA

(5) Cleaning of the Ds Positioning Collars

1136D177AA

(6) Cleaning of the Toner Antispill Trap

1136D178AA

(7) Cleaning of the Cleaning Blade

1156D167AA

1. Slide out the IU.2. Loosen one screw and remove the stopper.3. Remove and replace the PC Drum.

NOTEWhen the PC Drum has been replaced, reset the count of“PC Drum” of “Port/Option” counters of the Tech. Rep.

mode and then make the “adjustment of exposure level inthe Auto Exposure mode.” (For the “adjustment of expo-sure level in the Auto Exposure mode,” see p. D-72.)

Using a brush, whisk dust off the Developer Scattering Pre-vention Plate.

Using a brush or a soft clothdampenedwith alcohol, clean theDs Positioning Collars.

Using a brush or a vacuum cleaner, clean the Toner AntispillTrap.

Using a brush, whisk paper dust and toner off the CleaningBlade.

D-43

(8) Replacement of the Cleaning Blade

1136D172AA

1138D321AA

1136U013AA

1136D303AA

1. Remove and replace the Cleaning Blade.

2. Remove the Toner Bottle from the IU. Insert a brushthrough the toner port and into the toner.

3. Apply toner to the entire surface of the new CleaningBlade.

NOTE

Be sure to apply toner to both end faces of theCleaning Blade.

4. Using the brush, apply lubricant shippedwith theCleaningBlade to the two side seals shown.

D-44

1136U014AA

1156D064AA

1156D065AA

1134U022AA

1156D066AA

5. Install the PC Drum.

NOTE

Do not touch the surface of the PC Drum with barehands. Hold onto both ends of the PC Drum when

installing the drum.

6. Fit the PC Drum stopper and tighten the screw.

7. Apply a thin coat of toner to the surface of the PC Drum.

8. Holding onto both ends of the PC Drum, turn the PC Drumone complete turn in the forward direction.

9. Holding onto both ends of the PC Drum, turn the PC Drum1/2 turns in the backward direction.

10. Holding onto both ends of the PC Drum, turn the PC Drum1/2 turns in the forward direction.

D-45

(9) Replacement of the Starter

1136D157AA

2. Turning the Bucket Roller, pour fresh starter evenly into the chamber.

NOTE

Shake the packet of starter well before opening it.

NOTE

When the starter has been replaced, reset the count of “Starter” of the “Port/Option” counters of theTech. Rep. mode and then make the ATDC adjustment. (For the ATDC adjustment, see p. D-69.)

1134D051AA

1. Dump the developer out of the Developing Unit.

D-46

(10) Cleaning of the AIDC Sensor Board

1156D067AA

(11) Cleaning of the PC Drum Paper Separator Fingers

1136D181AA

(12) Replacement and Cleaning of the Toner Antispill Seal and Cleaning ofthe Toner Antispill Plate

1136D182AA

1134D052AA

1136D184AA

1. Remove the PC Drum Paper Separator Fingers Assy.2. Using a brush or a soft cloth dampenedwith alcohol, clean

the AIDC Sensor Board.

1. Remove the PC Drum Paper Separator Fingers Assy.2. Using a brush or a soft cloth dampenedwith alcohol, clean

the PC Drum Paper Separator Fingers.

1. Remove the IU.2. Remove two screws, the Toner Antispill Plate, and Toner

Antispill Seal.3. Replace the Toner Antispill Seal.

4. Using a brush, clean the Toner Antispill Seal.5. Using a brush, clean the Toner Antispill Plate.

NOTE

When reinstalling the Toner Antispill Plate and Toner Anti-spill Seal, press them in the direction of the arrows.

D-47

(13) Removal of Main Erase Lamp LA3

1156D068AA

(14) Cleaning of the Main Erase Lamp Filter

1136D186AA

1136D187AA

(15) Cleaning of Image Erase Lamp LA2

1136D188AA

(16) Replacement of Image Erase Lamp LA2

1134D055AA

1. Swing down the Front Door.2. Unplug one connector.3. Remove one screw and Main Erase Lamp LA3.

1. Swing down the Front Door.2. Remove the Main Erase Lamp Filter.

3. Using a soft cloth dampened with alcohol, wipe clean theMain Erase Lamp Filter.

1. Swing down the Front Door.2. Remove the IU.3. Using a soft cloth dampened with alcohol, wipe clean

Image Erase Lamp LA2.

1. Swing down the Front Door.2. Remove the IU.3. Remove one adjusting screw to free Image Erase Lamp

LA2.

D-48

1134D056AA

(17) Removal of the Ozone Filter (PC Drum Charge Corona)

1134D057AA

(18) Removal of the Ozone Filter (Image Transfer/Paper Separator Coronas)

1136D189AA

(19) Removal of the Toner Collecting Box (Except the U.S.A., Canada, andEurope)

1136D087AA

4. Unplugone connector in the rear and remove ImageEraseLamp LA2.

NOTE

When Image Erase Lamp LA2 has been removed, makethe “adjustment of edge erase.” (For the adjustment of

edge erase, see p. D-93.)

1. Swing down the Front Door.2. Swing out the Main Hopper.3. Slide out the Ozone Filter.

1. Remove the Rear Cover.2. Remove one screw and the Filter Cover.3. Pull out the Ozone Filter.

1. Remove the Rear Cover.2. Remove the Toner Collecting Box.

*For removal of the large capacity Toner Collecting Box,please refer to the instructions on the large capacityBox.

D-49

1156SBD0206A

2•6. PC DRUM CHARGE CORONA AND IMAGE TRANSFER/PAPERSEPARATOR CORONAS

(1) Removal of the PC Drum Charge Corona

1156D069AA

(2) Cleaning of the PC Drum Charge Corona Housing

1156D070AA

1156D071AA

1139D176AA

1139D177AA

Move the PC Drum Charge Corona to the rear and pull it off.

1. Remove the IU.2. Remove one screw and PC Drum charge Corona Unit.3. Press the Mesh Holder on the front of the Corona Unit in

the direction of arrow A to remove the Grid Mesh.

4. Remove the Cleaning Pad Cover.5. Remove the End Caps from the front and rear ends of the

Unit.

6. Remove the Comb Electrode.

NOTE

Use care not to deform the Electrode. When removing it,first snap off its spring end.

7. Using a soft cloth dampened with alcohol, wipe the Hous-ing clean of dirt.

D-50

(3) Cleaning of the PC Drum Charge Corona Grid Mesh

1139D178AA

(4) Cleaning of the Comb Electrode

1156D072AA

(5) Removal of the Image Transfer/Paper Separator Coronas

1134D062AA

(6) Cleaning and Replacement of the Image Transfer Corona Wire

1136D198AA

1136D199AA

Blow all foreign matter off the Grid with a blower brush.

NOTE

If the blower brush is not effective in cleaning the Grid, usea soft cloth dampened with alcohol to clean serious con-

tamination.

Clean Comb Electrode using the Corona Unit Cleaning Lever.

1. Swing down the Front Door.2. Pull out the Image Transfer/Paper Separator Coronas.

1. Swing down the Front Door.2. Clean the Image Transfer Corona Wire using the Corona

Wire Cleaning Lever.

NOTE

If the Image Transfer Corona Wire is seriously contami-nated, dampen a soft cloth with alcohol, hold it with a pair

of tweezers, and wipe thewire gently in one direction-fromthe hook end to the spring end.

D-51

1136D200AA

1136D201AA

(7) Cleaning and Replacement of the Paper Separator Corona Wire

1136D202AA

1136D203AA

(8) Cleaning of the Image Transfer/Paper Separator Coronas Housing

1136D205AA

3. Remove the Holder Covers at the front and rear.

4. Remove the corona wire, first at the spring end.5. Replace the corona wire with a new one.

1. Remove four Paper Guides.

2. Dampena soft clothwith alcohol, hold it with a pair of twee-zers, and wipe the Paper Separator CoronaWire gently inone direction − from the hook end to spring end.

3. Replace the Paper Separator Corona Wire by using thesame procedure as that for the Image Transfer CoronaWire.

1. Remove four Paper Guides.2. Remove the Holder Covers at the front and rear.3. Remove the Image Transfer and Paper Separator Corona

Wires − first at the spring end.4. Using a soft cloth dampened with alcohol, wipe the hous-

ing clean of dirt.

D-52

(9) Cleaning of the Lower Pre-Image Transfer Guide Plate

1136D206AA

Using a soft cloth dampened with alcohol, wipe clean the LowerPre-Image Transfer Guide Plate.

D-53

1156SBD0207A

2•7. FUSING UNIT

(1) Removal of the Fusing Unit

1156D073AA

(2) Disassembly of the Fusing Unit

1156D074AA

1156D075AA

1156D076AA

1156D077AA

Cover Harness Cover

Fusing Unit

1. Open the Left Door.2. Swing down the Front Door.3. Remove one screw and the Fusing Unit.

1. Remove two screws and the Front Cover.

2. Unplug the connector of the Heater Lamp on the front.3. Remove three harness holders.4. Remove the Heater Lamp cord from the two edge covers.5. Remove two screws and the front lamp holder.

6. Remove two screws and the cover.

NOTE

At reinstallation, position the cover between theFusing Unit and harness cover.

D-54

1156D078AA

1156D079AA

1156D080AA

1156D081AA

1136D213AA

7. Remove one screw and the Heater Lamp cord in the rear.8. Remove the Heater Lamp cord from the locking edge cov-

er.

9. Remove three screws and the rear lamp holder.10. Remove the Heater Lamp cord from the wiring saddle.11. Remove the Heater Lamp.

12. Remove four screws and the Upper Cover.

13. Remove two screws and the Upper Fusing Paper Separa-tor Finger mounting bracket.

NOTE

When reinstalling the Upper Fusing Paper SeparatorFinger mounting bracket, be sure that both ends

of the bracket are in tight contact with the frame.

D-55

1156D082AA

1156D083AA

1156D084AA

1136D217AA

1156D085AA

14. Remove the harness from the Harness Guide.15. Unplug the connectors of the two Thermistors.

16. Remove one screw, shoulder screw, and the HarnessGuide.

17. Remove one screw and the Thermoswitch cord.

18. Remove two screws and the Temperature Detector Assy.

NOTE

When reinstalling the Temperature Detector Assy, besure that both ends of the assy are in tight contact with

the frame.

19. Remove the Gear.20. Remove two shoulder screws and the Fusing Unit En-

trance Guide Plate.

D-56

21. Remove the two torsion springs.22. Remove two shoulder screws and the Lower Exit Guide Assy.

LowerFusing Roller

Upper Fusing Roller

Torsion Spring

ShoulderScrew

Shoulder Screw

Torsion Spring

Lower Exit Guide Assy1156D086AA

Front

Rear

Lower Exit Guide Assy Position

➀ Installing the Lower Exit Guide Assy

➁ Lower Fusing Paper Separator FingerContact

Lower FusingRoller

No ClearanceAllowed.

1134D067AA

D-57

23. Loosen the screw that secures the spring bracket at the front and then unhook the spring at the top.Repeat the same step for the spring in the rear.

NOTEWhen reinstalling the springs, alternately tighten the bracket mounting screws until the bracketscompletely contact the ends of the Lower Exit Guide Assy.

1156D087AA

1156D088AA

1156D089AA

1156D090AA

24. Remove the Lower Fusing Roller.

25. Remove two extension springs.26. Remove twoE-rings, thegear, bushing, andCleaningRoll-

er.

27. Remove two E-rings, then two gears.28. Remove two screws, the Upper Fusing Roller drive gear,

and Upper Fusing Roller.

D-58

(3) Replacement and Cleaning of the Upper Fusing Paper Separator Fingers

1156D091AA

1136D227AA

(4) Cleaning of the Lower Fusing Paper Separator Fingers

1136D228AA

(5) Cleaning of the Fusing Unit Entrance Guide Plate

1156D092AA

(6) Cleaning of Fusing Front and Rear Thermistors TH1/2

1156D093AA

1. Remove theUpper Fusing Paper Separator Fingermount-ing bracket.

2. Remove five springs.3. Slide out the shaft to remove theUpper Fusing Paper Sep-

arator Fingers.4. Replace the fingers with new ones.

5. Using a soft cloth dampened with alcohol or silicone oil,wipe clean the Upper Fusing Paper Separator Fingers.

1. Remove the Lower Exit Guide Assy.2. Using a soft cloth dampened with alcohol or silicone oil,

wipe clean the Lower Fusing Paper Separator Fingers.

Using a soft cloth dampenedwith alcohol,wipe clean theFus-ing Unit Entrance Guide Plate.

1. Remove the Temperature Detector Assy.2. Using a soft cloth dampened with alcohol, wipe clean the

two thermistors.

D-59

(7) Cleaning of Fusing Thermoswitch TS1

1156D094AA

(8) Replacement and Cleaning of the Cleaning Roller

1156D089AA

1136D232AA

(9) Replacement and Cleaning of the Upper Fusing Roller

1156D090AA

1136D233AA

1. Remove the Temperature Detector Assy.2. Using a soft cloth dampened with alcohol, wipe clean the

thermoswitch.

1. Remove two screws and the Upper Cover.2. Remove the Cleaning Roller.3. Replace the Cleaning Roller with a new one.

4. Using a brush, whisk dust off the Cleaning Roller.

1. Remove the Upper Fusing Roller.2. Replace the Upper Fusing Roller with a new one.

3. Using a soft cloth dampened with alcohol or silicone oil,wipe clean the Upper Fusing Roller.

D-60

(10) Replacement and Cleaning of the Lower Fusing Roller

1156D088AA

1136D234AA

1. Remove the Lower Fusing Roller.2. Replace the Lower Fusing Roller with a new one.

3. Using a soft cloth dampened with alcohol or silicone oil,wipe clean the Lower Fusing Roller.

D-61

1156SBD0208A

2-8. EXIT UNIT

(1) Removal of the Exit/Duplex Switching Unit1. Remove the Rear Cover.2. Open the Left Door.3. Remove the Upper Left Cover.

1134D144AA

1156D095AA

1156D096AA

1156D097AA

4. Remove four screws to free the Sorter Connector Assy.

5. Unplug two connectors.6. Remove one screw and the ground wire.

7. Snap off the E-ring from the shaft onto which the Exit/Du-plex Switching Unit is mounted.

8. Work the harness indicated by the arrow off the wiringsaddle.

9. Remove one screw that holds the belt.10. Remove two screws and the mounting bracket.11. Remove the Exit/Duplex Switching Unit.

D-62

1156SBD0300A

ADJUSTMENT31156SBD0301A

3-1. JIGS AND TOOLS USEDz Important

DWhen adjusting the positions of the Scanner and Mirrors Carriage, use jigs number➂ and➃.

DWhen adjusting the gap between the Doctor Blade and Sleeve Roller, use jigs number➄ and➅.

DWhen adjusting the position of the PC Drum Paper Separator Fingers, use jigs number➄ and➆.

➀Front Door Interlock SwitchActuating Jig

➁Predrive Inhibit SwitchActuating Jig

➂Scanner Positioning Jig➃Scanner/Mirrors

Carriage Positioning Jig

➄Sleeve/Magnet RollerPositioning Jig

➅D.B. Adjusting Jigs

➆PC Drum PaperSeparator FingerPositioning Jig

1136D006AA

1136D003AA

1136D002AA

1136D005AA1136D001AA

1136D004AA

D-63

1156SBD0302A

3-2. ADJUSTMENT REQUIREMENTS LIST

Adjustment Item Requirements Adjusting Point Ref.Page

Optimum exposure in theManual Exposure mode

Kodak Gray Scale: no imageof the 1st step, faint image ofthe 2nd step

Control panel D-73

Crosswise zoom ratio, fullsize (⋅ 1.000) 200 ±±±± 1.0 mm Control panel D-75

Feeding direction zoomratio, full size (⋅ 1.000) 300 ±±±± 1.5 mm Control panel D-77

Multi Bypass Tablereference Position (⋅ 1.000) 20 ±±±± 2.0 mm Multi Bypass Table D-79

1st Drawer referencePosition (⋅ 1.000) 20 ±±±± 2.0 mm Drawer Positioning Plate D-80

2nd Drawer referencePosition (⋅ 1.000) 20 ±±±± 2.0 mm Drawer Positioning Plate D-80

Leading edge registration,full size (⋅ 1.000) 20 ±±±± 1.5 mm Control panel D-81

Leading edge registration,enlargement (⋅ 2.000) 40 ±±±± 3.0 mm Control panel D-83

Leading edge registration,reduction (⋅ 0.500) 10 ±±±± 1.5 mm Control panel D-85

Leading edge registration,book second page (⋅ 1.000) 20 ±±±± 3.0 mm Control panel D-87

Image leading edge erasewidth (⋅ 1.000) 1µ6.5 mm Control panel D-89

Image trailing edge erasewidth (⋅ 1.000) 0.5µ5.5 mm Control panel D-91

Edge erase (⋅ 1.000) 0.5µ4.0 mm Edge Erase Adjusting Screw D-93

D-64

1151SBD0303A

3-3. ADJUSTMENT OF SWITCHES

MicroswitchesThe following microswitches are used in various parts of this copier.

Wiring for the NO Type Wiring for the NC Type

NC (Normally-Closed) : Current flows between NC and COM when the actuator is open.

NO (Normally-Open) : Current flows between NO and COM when the actuator is closed.

COM (Common) : Common contact for NC and NO.

Yellow (NO)

Red (COM)

Blue (NC)

Red (COM)1136D007AA 1136D009AA

Requirement

0.1 mm to0.5 mm

Actuator

Out-of-Adjustment (When the actuator is closed)

D If the gap between the switch and actuator is too big, current does not at times flow to NC or NO.D If there is no gap between the switch and actuator, the actuator is bent or the switch can be broken.

The gap between the switch and actuator should be 0.1 to 0.5mm when the actuator is closed.

D-65

Adjustment of Front Door Interlock Switch S21

1136D009AA

1136D010AA

1156D098AA

1. Swing down the Front Door.2. Remove six screws and the Upper Left Cover.

3. Remove three screws and the cover.4. Loosen two screws that secure Front Door Interlock

Switch.

5. Close the Front Door.6. Slowly move the switch to the front until the actuator is

closed by the actuator stop on the Front Door. Then, tight-en the two mounting screws.

D The switch is wired for the NO type.

D-66

1156SBD0304A

3-4. ADJUSTMENT OF BELT TENSIONz Important

DMake sure that all gears are in positive mesh with each other and the belts snugly fit in the

pulley grooves.

D Each belt should flex a little when finger-pressed down on the location indicated by the arrow.

Belt Tension Deflection (Reference only)

(1) Paper Take-Up Unit Timing Belt 300 ±±±± 100 g Approx. 3 mm

(2) Developing Unit Timing Belt 350 ±±±± 100 g Approx. 4 mm

(3) Fusing Unit Timing Belt 350 ±±±± 100 g Approx. 3 mm

(4) IU Timing Belt 350 ±±±± 100 g Approx. 5 mm

Loosen two screws that secure the Tension Lever. Move the Tension Lever in the direction of the arrow twoto three times. When the belt tension is correct, tighten the two screws.

1156D172AA

350 ±±±± 100 g

300 ±±±± 100 g

350 ±±±± 100 g

350 ±±±± 100 g

Move lever 2 to 3times, thentighten screws.



D-67

1156SBD0305A

3-5. ACCESSING THE TECH. REP. MODE AND ADJUST MODEz Accessing the Tech. Rep. Mode

To access the Tech. Rep. mode, press the following keys in order.

Stop Key Stop Key“0” “1”! ! !

1156D134CA

Press the keys in order of [1], [2], [3], and [4].

1134D069AA

z Accessing the Adjust Mode

To access the Adjust mode, press the following keys in order with the Tech. Rep. mode menu on the

screen.

Stop Key Start Key!

1156D138CAPress the keys in order of [1] and [2].

1134D071AA

D-68

1156SBD0306A

3-6. ELECTRICAL/IMAGE ADJUSTMENTS

(1) Initial Adjustment of Original Size Detecting Boardz Important

D The following adjustment must be made when memory has been cleared, RAM Board PWB-R

or Original Size Detecting Board UN2 replaced, or an Original Size Detecting Sensor replaced

or added.

1136D017AA

2. Call the Tech. Rep. mode menu to the screen.

3. Touch Function to show the Function menu on the screen.

4. Touch F7 Orig. Sensor .

5. Press the Start Key to let the copier make the initial adjustment of the Original Size Detecting Board.

1156D142CA 1156D135CA

NOTE

While the copier is in the adjustment cycle, the Start Key is lit up orange. The key turns green assoon as the adjustment cycle is completed.

6. After the adjustment has been made, press the Panel Reset Key to return the copier to the Basicscreen.

1. Lower the Original Cover with no original placed on theOriginal Glass.

D-69

(2) ATDC Adjustmentz Important

Make this adjustment only after the starter has been replaced.

1134D051AA



5. Touch F8 ATDC Adjust .

6. Press the Start Key to let the copier make the ATDC adjustment. (It will run for about 3 minutes.)

1156D142CA 1156D139CA

NOTES

DWhile the copier is in the adjustment cycle, the Start Key is lit up orange. The key turns greenas soon as the adjustment cycle is completed.

D Pressing the Start Key will automatically start the ATDC adjustment cycle. Be sure to runthis cycle only after the starter has been replaced.

1. Load the IU with fresh starter.2. Reinstall the IU in the copier.

D-70

7. Touch Menu on the screen to show the Tech. Rep. mode menu again.

8. Touch Level History and enter the value for the “ATDC Ref. Level” on the Adjust Label affixed

inside the Front Door.9. Then, press the Panel Reset Key to return the copier to the Basic screen.

1156D143CA 1156D168CA

Enter This Value on the Adjust Label.

z Should the F8 operation be runwhen the starter has not been replaced, check that the “ATDCRef. Level”

value on the “Level History” screen matches that written on the Adjust Label. If they do not agree with

each other, change the “ATDC Ref. Level” value on the screen so that it matches the value on the Adjust

Label.

1156D143CA

Touch the shift key A or " to changethe value and touch Enter to validate thenew setting.

1156D169CA

D-71

(3) Adjustment of the Aperture Bladesz Requirement

D There should be no dark or light bands running in the feeding direction on copies produced. (Adjust to

obtain the mean image density for all areas.)

z Important

D If dark and light bands running in the feeding direction occur on copies, make this adjustment after

checking the following.

1) The Drum Charge Corona Wire, Grid Mesh, and Image Transfer Corona Wire are free of dirt.

2) The surfaces of the Mirrors and Lens are free of dirt.

3) The surfaces of the Exposure Lamp and Main Erase Lamp are free of scratches and dirt.

4) The Cleaning Blade is free of waviness.

1. Make a copy under the following control panel settings.Original : A3 or A4 crosswise,

11” ⋅ 17” or 11” ⋅ 8-1/2” crosswisePaper : A3 or A4 crosswise,

11” ⋅ 17” or 11” ⋅ 8-1/2” crosswiseMagnification : 100 %ratioExposure : Manual (setting convenient for check)

2. Remove the Original Glass.3. Turn the copy on the Copy Tray around as shown to re-

verse the leading and trailing edges and align it with theAperture Blades.

4. Adjust to obtain themean image density for all areas of thecopy.

NOTE

To make the image darker, move the Aperture Bladetoward the Auxiliary Reflector.

To make the image lighter, move the Aperture Bladeaway from the Auxiliary Reflector.

D-72

(4) Adjustment of Exposure Level in the Auto Exposure Modez Important

D Before starting the procedure, check that the Auto Exposure mode is selected on the Touch Panel.

D For the adjustment, stack about five blank sheets of A3 or 11” ⋅ 17” paper on the Original Glass

and lower the Original Cover.

D After this adjustment, be sure to check the optimumexposure setting in theManual Exposuremode.

1. Make sure that the Auto Exposure mode is selected on the Touch Panel. Then, stack about five blanksheets of A3, or 11” ⋅ 17”, paper on the Original Glass and lower the Original Cover.

1134D079AA

1156D140CA



4. Touch F5 Optimum & AE .

5. Press the Start Key to let the copier adjust the exposure level in the Auto Exposure mode. (It will runfor about 30 seconds.)

1156D142CA 1156D144CA

While the copier is in the adjustment cycle, the Start Key is lit up orange. The key turns green as soon

as the adjustment cycle is completed.

6. After the adjustment, touch Menu to return the copier to the Tech. Rep. menu.

7. Check the optimum exposure setting in the Manual Exposure mode. (See p. D-73.)

D-73

(5) Adjustment of Optimum Exposure Setting in the Manual Exposure Modez Requirement

D Exposure Lamp voltage setting range in the Manual Exposure mode ... 44 to 56

DWhen the manual exposure setting is at the central indication, no image of step no. 1 of a Kodak Gray

Scale should be produced on the copy, but a faint image of step no. 2 should be produced.

1136D300AA

z Important

D This adjustment should be made only after completing the “Adjustment of Exposure Level in the

Auto Exposure Mode” and “Adjustment of the Aperture Blades”.

D If the setting has been changed in this adjustment, be sure to make the “adjustment of exposure

level in the Auto Exposure mode”.

1156D137CB


4. Touch Tech. Rep. Choice to show the “Tech. Rep. Choice 1” menu on the screen.

1156D141CA 1156D145CA

1. Place the Kodak Gray Scale lengthwise, facedown, and at the center on the Original Glass.Place a sheet of pure white A3 or 11” ⋅ 17” pa-per over it and then lower the Original Cover.

2. Set the copier into the Manual Exposure modeand set the exposure setting to the central orfifth indication (EXP5). Make about 3 copiesusing A3 or 11” ⋅ 17” paper (so that the PCDrum sensitivity stabilizes). Then, check thatthe third copy meets the requirement givenabove.*If the image density is outside the specifica-tions, make the following adjustment.

D-74

5. Touch Next twice to show the “Tech. Rep. Choice 3” menu on the screen.

6. Observing the image density of the sample copy, touch the shift key A or " to change the setting

for “Image Exposure”.

7. Touch Enter to validate the setting.

8. Run the F5 operation again.

D If the image density is low, decrease the setting value.

D If the image density is high, increase the setting value.

D If the image density does not fall within the specifications through one setting, try another

setting.

Setting Instructions

1156D150CA

Touch This Key Twice.Touch This Keyif ID is High.

Touch This Keyif ID is Low.

1156D146CA

NOTE

Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basic screen.If this is not done, the old setting remains valid.

D-75

(6) Adjustment of Zoom Ratio in the Crosswise Direction

(“Adjust A1 = Lens Full Size Position”)z Requirement

D This adjustment is made for the zoom ratio in the crosswise direction.

D A scale is placed on the Original Glass to run parallel with the Scanner and the length of the scale on

the copy is compared with that of the actual scale. The adjustment must be made so that the difference

between the two dimensions falls within the following specifications.

The difference should be within 0.5% of the actual length.

For 200 mm, the allowance is 200 mm ⋅ 0.005 = 1.0 mm.

Zoom Ratio Specifications Adjusting Mode Setting Range

Full size (⋅ 1.000) 200 1.0mm Adjust A1 = Lens Full SizePosition 43 to 58

z Important

This adjustment must be made before the “Reference Position Adjustments”.

1134D136AA

1134D124AA

1. Place a scale in parallel with the Original Width Scale andmake a copy.*Make three copies in full size (⋅ 1.000) mode and using200-mm-or-wider paper.*If the scale is of plastic and transparent, place a blanksheet of paper over it.

2. Allow the copy to stand for 5 minutes, then measure thelength to determine the zoom ratio in the crosswise direc-tion. (Make the check with the third copy.)Using the scale, measure the length of the scale on thecopy to find any difference.*If the zoom ratio deviates from the specifications, go to thenext step.

D-76

3. Call the “Adjust 1/2” menu to the screen.

4. Touch the select key ! or " to highlight “A1 Lens Full Size Position”.

1156D138CA 1156D154CA

5. Touch the shift key A or " to change the set value.


D If the scale on the copy is longer than the actual scale, decrease the setting value.

D If the scale on the copy is shorter than the actual scale, increase the setting value.

*If the measurement does not fall within the specifications through one setting, try anothersetting.


Touch This Key if Measurement is Shorter.Touch This Key if Measurement is Longer.

Setting Value

1156D147CA

NOTE


D-77

(7) Adjustment of Zoom Ratio in the Feeding Direction

(“Adjust A3 = Feed Direction Mag. Ratio”)z Requirement

D This adjustment is made for the zoom ratio in the feeding direction.

D A scale is placed on the Original Glass perpendicularly to the Scanner and the length of the scale on

the copy is compared with that of the actual scale. The adjustment must be made so that the difference

between the two dimensions falls within the following specifications.

The difference should be within 0.5% of the actual length.

For 300 mm, the allowance is 300 mm ⋅ 0.005 = 1.5 mm.


Full size (⋅ 1.000) 300 1.5mm Adjust A3 = Feed DirectionMag. Ratio 46 to 54

z Important

This adjustment must be made before the “Adjustment of the Leading Edge Registration”.

1134D137AA

1138D154AA

1. Place a scale in parallel with theOriginal Length Scale andmake a copy.*Make three copies in the full size (⋅ 1.000) mode usingA3 or 11” ⋅ 17” paper.*If the scale is of plastic and transparent, place a blanksheet of paper over it.

2. Allow the copy to stand for 3 minutes, then measure thelength to determine the zoom ratio in the feeding direction.(Make the check with the third copy.)Using the scale, measure the length of the scale on thecopy to find any difference.*If the zoom ratio deviates from the specifications, go to thenext step.

D-78


4. Touch the select key ! or " to highlight “A3 Feed Direction Mag. Ratio”.

1156D138CA 1156D151CA

5. Touch the shift key A or " to change the set value.


D If the scale on the copy is longer than the actual scale, decrease the setting value.

D If the scale on the copy is shorter than the actual scale, increase the setting value.



Touch This Key if Measurement is Shorter.

Touch This Key if Measurement is Longer.

1156D155CA

NOTE


D-79

(8) Adjustment of Reference Position of the Multi Bypass Tablez Requirement

Dimension A1134D196AB

z Important

This adjustment should be made after the “adjustment of zoom ratio in the crosswise direction”.

1136D030AA

1136D031AA

1156D099AA

➁➀

➂

DDimension A on the copy of the GTC-test chart shouldmea-

sure 20 mm 2.0 mm in the full size (⋅ 1.000) mode.

1. Place the GTC-test chart face down on the Original Glassand align its rear left corner with the reference marker onthe Original Width Scale. Then, lower the Original Cover.

2. Make three copies in the full size (⋅ 1.000)mode using A3or 11” ⋅ 17” paper fed from the Multi Bypass Table.

3. Check if dimension A (from the edge up to the referenceline) on the copy is up to the specifications. (Make thecheck with the third copy.)

4. If dimension A deviates from the specifications, loosenthree screws that secure theMulti Bypass Table andmovethe table in the direction of the arrow as necessary.

D If dimension A on the copy is shorter than 18 mm, move

the table to the front of the copier.

D If dimension A on the copy is longer than 22 mm, move

the table to the rear of the copier.

Adjusting Instructions

NOTE

When tightening the screws, hold the Multi Bypass Tablefrom the underside with your hand and tighten screws in the

order shown.When a Duplexing Document Feeder is mounted, itinvolves changing the Original Glass. This in turn resultsin the position of the Original Length Scale beingslightly shifted to the rear. This can nonetheless becorrected with the Original Positioning Plate.

D-80

(9) Adjustment of Reference Position of the 1st/2nd Drawerz Requirement

1134D196ABDimension A

z Important

This adjustment should be made after the “adjustment of zoom ratio in the crosswise direction”.

1136D030AA

1134D146AA

D If dimension A on the copy is longer than 22 mm, move the Positioning Plate to the front of

the copier.

D If dimension A on the copy is shorter than 18 mm, move the Positioning Plate to the rear of

the copier.


1139U037AA


sure 20 mm 2.0 mm in the full size (⋅ 1.000) mode.


2. Feeding three sheets of A3 or 11” ⋅ 17” paper from the 1stDrawer, make two full-size copies.

3. Check if dimension A (from the edge up to the referenceline) on the third copy is up to the specifications.

4. If dimension A deviates from the specifications, slide outthe 1st Drawer. Then, loosen the three screws shown onthe left and move the Drawer Positioning Plate to the frontor rear as necessary. (Use the same procedure for the 2ndDrawer.)

5. After the adjustment, loosen the four screws shown on theleft and adjust the position (tilt) of the Drawer Cover.

D-81

(10) Adjustment of the Leading Edge Registrationz Requirement

1138D170AA

Dimension A


Full size (⋅ 1.000) 20 1.5mm Adjust A4 = Lens PositionFull Size

Enlargement(⋅ 2.000) 40 3.0mm Adjust A11 = Lens Position

Enlargement 40 to 60

Reduction(⋅ 0.500) 10 1.5mm Adjust A5 = Lens Position

Reduction

z Important

This adjustment should be made after the “adjustment of zoom ratio in the feeding direction”.

(1) Leading Edge Registration in Full Size Mode

1136D033AA


sure as follows at the respective zoom ratios.


2. Make three single copies on A3 or 11” ⋅ 17” paper in fullsize mode and check the third copy for leading edge regis-tration.(If the registration is up to the specifications, go to the ad-justment in the enlargement mode. If it deviates from thespecifications, perform the following steps tomake the ad-justment of leading edge registration in the full sizemode.)

D-82


4. Touch the select key ! or " to highlight “A4 Scan Regist Full Size”.

1156D148CA1156D138CA

5. Touch the shift key A or " to change the setting value.


D If dimension A on the copy is longer than 21.5 mm, increase the setting value.

D If dimension A on the copy is shorter than 18.5 mm, decrease the setting value.





1156D152CA

NOTE

Be sure to touch Enter before pressing the Panel Reset Key to return the copier to the Basicscreen. If this is not done, the old setting remains valid.

D-83

(2) Leading Edge Registration in Enlargement Modez Important

This adjustment should be made after the “adjustment of leading edge registration in the full size

mode”.

1136D034AA

2. With the “Adjust 1/2” menu on the screen, touch Next to show the “Adjust 2/2” menu.

3. Touch the select key ! or " to highlight “A11 Scan Regist Enlargement”.

1156D156CA1156D166CA

1. After the leading edge registration in the full sizemode hasbeen adjusted, make three single copies on A3 or 11”⋅ 17” paper at ⋅ 2.000 and check the 3rd copy for leadingedge registration.(If the registration is up to the specifications, go to the ad-justment in the reductionmode. If it deviates from thespec-ifications, perform the following steps to make the adjust-ment of leading edge registration in the enlargementmode.)

D-84







Touch This Key if Measurement is Longer.Touch This Key if Measurement is Shorter.

1156D149CA

NOTE


D-85

(3) Leading Edge Registration in Reduction Mode

1136D035AA

z Important

This adjustment should be made after the “adjustment of leading edge registration in the full size mode”.


3. Touch the select key ! or " to highlight “A5 Scan Regist Reduction”.

1156D138CA 1156D153CA

1. After the leading edge registration in the enlargementmode has been adjusted, make three single copies on A3or 11” ⋅ 17” paper at ⋅ 0.500 and check the 3rd copy forleading edge registration.(If the registration deviates from the specifications, per-form the following steps to make the adjustment of leadingedge registration in the reduction mode.)

D-86








1156D157CA

NOTE


D-87

(11) Adjustment of the Leading Edge Registration for Book Second Pagez Requirement

1136D036AA

z Important

This adjustment should be made after the “adjustment of the leading edge registration”.

1136D037AA

2. On the Basic screen, touch Origi." Copy ; then, select Separation .

1156D140CA 1156D158CA

3. Select Book"1 and make three single copies on A4 crosswise paper at full size (⋅ 1.000)

mode. Check the third copy for the leading edge registration. (If the dimensions deviate from the speci-fications, perform the following steps to make the adjustment.)

1156D161CA

DDimension A on the copy of a test chart (A3 or 11” ⋅ 17”) as

shownon the left shouldmeasure 20 3.0mmandB equals

C.

D Setting range: 45 to 55

1. Place the test chart face down on the Original Glass andalign its rear left corner with the reference marker on theOriginal Width Scale. Then, lower the Original Cover.

D-88

4. With the “Adjust 1/2” menu on the screen, touch Next to show the “Adjust 2/2” menu. Then, high-

light “A6 Book B-Scan Regist”.

1156D163CA1156D166CA



D If dimension A on the copy is longer than 23 mm, increase the setting value.

D If dimension A on the copy is shorter than 17 mm, decrease the setting value.

*If the measurement does not fall within the specifications through one setting, try another

setting.




1156D163CA

NOTE


D-89

(12) Adjustment of the Image Leading Edge Erase Widthz Requirement

1134D135AA

Dimension A

z Important

This adjustment should be made after the “adjustment of the leading edge registration” and

“adjustment of the leading edge registration for book second page”.

1136D040AA


4. Touch the select key ! or " to highlight “A12 Leading Edge Erase Adjust”.

1156D159CA1156D166CA

D The erase width, dimension A, on the copy of the GTC−test

chart should measure 1.0 to 6.5 mm.

D Setting range: 45 to 55


2. Make three single copies on A3 or 11” ⋅ 17” paper in fullsize mode and check the third copy for leading edge erasewidth.(If the erase width deviates from the specifications, per-form the following steps to make the adjustment of imageleading edge erase width.)

D-90



D If dimension A on the copy is longer than 6.5 mm, decrease the setting value.

D If dimension A on the copy is shorter than 1.0 mm, increase the setting value.




1156D162CA

NOTE


D-91

(13) Adjustment of the Image Trailing Edge Erase Widthz Requirement

1134D134AA

Dimension A

z Important

D This adjustment should be made after the “adjustment of the image leading edge erase width”.

D Before this adjustment can be made, “Trailing Edge Erase” on the “Tech. Rep. Choice 2” screen

must be set to “Yes”.

1136D042AA


4. Touch the select key ! or " to highlight “A13 Trailing Edge Erase Adjust”.

1156D166CA 1156D164CA

D The erase width, dimension A, on the copy of the GTC-test

chart should measure 0.5 to 5.5 mm.

D Setting range: 42 to 58.


2. Make three single copies on A3 or 11” ⋅ 17” paper in fullsize mode and check the third copy for trailing edge erasewidth.(If the erase width deviates from the specifications, per-form the following steps to make the adjustment of imagetrailing edge erase width.)

D-92



D If dimension A on the copy is longer than 5.5 mm, decrease the setting value.

D If dimension A on the copy is shorter than 0.5 mm, increase the setting value.




1156D160CA

NOTE


D-93

(14) Adjustment of Edge Erasez Requirement

1136D043AA

z Important

This adjustment must be made after the “adjustments of reference positions”.

1136D044AA

1134D114AA

DDimensionA, which is the erasewidth from the front edge on

the copy of the GTC-test chart, should be in the range be-

tween 0.5 mm and 4.0 mm.


2. Make a single copy on A3 or 11” ⋅ 17” paper in full sizemode.*If A3 or 11” ⋅ 17” paper is not available, use A4 or 8−1/2”⋅ 11” crosswise paper.

3. If the front edge erase width deviates from the specifica-tions, adjust as necessary by turning the Edge Erase Ad-justing Screw.

D If dimension A on the copy (of the original width of 3.0 mm)

is narrower than 0.5 mm, tighten the Adjusting Screw.

D If dimension A on the copy (of the original width of 3.0 mm)

is wider than 3.0 mm, loosen the Adjusting Screw.


D-94

1156SBD0307A

3-7. OTHER ADJUSTMENTS

(1) Focus-Positioning of the Scanner and Mirrors Carriagez Requirement

DWith the Scanner positioned correctly with reference to the Scanner Drive Cable, there should be nogap between one end of the Scanner/Mirrors Carriage Positioning Jig and the Scanner, and betweentheother endof the jig and theMirrorsCarriage. Thedistance between theScanner andMirrorsCarriageshould be 83.5 mm.

1134D138AA

1136D046AA

Scanner Positioning Jig

Scanner/MirrorsCarriage PositioningJig 1136D047AA

1136D048AA

83.5mm

1. Remove the Original Cover, Upper Rear Cover, andOrigi-nal Glass.

2. Slide the Scanner to a position at which the hole is alignedwith the Scanner Positioning Screw.

3. Insert a screwdriver into the hole and loosen the ScannerPositioning Screw. (This allows the Scanner Drive Cableto move independently of the Scanner.)

4. Align the rectangular hole in the upper copier frame withthe U-groove in the Scanner. Insert the Scanner Position-ing Jig.

5. Install the Scanner/Mirrors Carriage Positioning Jig be-tween the Scanner and the Mirrors Carriage.

6. Move the Mirrors Carriage in the direction of the arrow.7. Check that both ends of the Scanner/Mirrors Carriage

Positioning Jig have no gap.

D-95

1139D051AA

8. Tighten the Scanner Positioning Screw which was loos-ened in step 3.

D-96

(2) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller

(D.B. Adjustment)z Requirement

D The gap between the Doctor Blade and Sleeve Roller should be 0.53 0.05 mm.

1136D049AA

1136D050AA

1136D051AA

1136D052AA

1. Remove the IU, PC Drum Charge Corona, and PC Drum.2. Remove two screws and the Developer Scattering Pre-

vention Plate.

3. Using a brush, whisk developer off the surface of theSleeve Roller.

4. Install theSleeve/MagnetRoller Positioning Jig into the IU.

5. Loosen three screws that secure the Doctor Blade. Insertthe D.B. Adjusting Jigs between the Doctor Blade andSleeve Roller.

6. Press down theDoctor Blade until it positively contacts theD.B. Adjusting Jigs. Then, tighten the three screws to se-cure the Doctor Blade.

D-97

(3) Adjustment of the PC Drum Paper Separator Finger Positionz Requirement

D The gap between the PC Drum and Paper Separator Fingers should be 1.0 0.5 mm when SeparatorSolenoid SL1 is in the deenergized position.

z Important

DUse care not to deform the Separator Fingers during the adjustment procedure.

1136D053AA

1136D054AA

1136D055AA

1136D056AA

1. Attach the PC Drum Paper Separator Finger PositioningJig to the IU.

2. Using anAllenwrench, adjust the position of oneof the twoPaper Separator Fingers. (Either one will do.)

DWith the solenoid in the deenergized position, the tipof the finger should be at a point between A and B,preferably more on the B end.

DWith the solenoid energized, the tip of the fingershould touch C.A 41.5 mm. . . . . . .B 40.5 mm. . . . . . .C 40.0 mm. . . . . . .


3. After this adjustment, check that the other finger alsomeets the above requirement.

NOTE

If the fingers cannot be positioned correctly throughsteps 2 and 3, loosen the two solenoid mounting

screws and adjust the position of the solenoid. Then,repeat steps 2 and 3.

D-98

(4) Adjustment of Manual Feed Paper Take-Up Solenoid SL4

1134D119AA

1134D120AA

4. Slowly move the SL4 in the direction opposite that in step 3. When the two Stoppers just swing intothe upright position, tighten the two SL4 mounting screws.

1134D121AA

1. Remove the SL4 mounting bracket. (For the removalsteps, see p. D-25.)

2. Manually bring SL4 into the energized position (plungerpushed in).* A click is heard when the solenoid is energized.Then, hold the plunger in position.

3. Loosen two screws that secure the SL4 and slide SL4 allthe way in the direction of the arrow.

D-99

(5) Adjustment of Exit/Duplex Solenoid SL5z Requirement

DWith the lever in contact with the stopper (SL5 in the deenergized position), the gapbetween theplungerrubber washer and the solenoid should be 4.0 to 4.5 mm.

z Important

D After the adjustment, move the plunger manually to check that it moves smoothly and the SwitchingPlate swings up and down properly.

1134D122AA

3. Bring the lever into contact with the stopper. Keeping that position, move SL5 so that the gap betweenthe plunger rubber washer and solenoid measures 4.0 to 4.5 mm. When the specified dimension isreached, tighten the two SL5 mounting screws.

1156D173AA

1. Open the Left Door.2. Loosen two screws that secure SL5.

D-100

1156SBD0400A

MISCELLANEOUS41156SBD0401A

4-1. Installation of the Plug-In Counter (Option) Mounting Bracket

1156D033AA

1156D034AA

1136D060AA

1136D061AA

1136D062AA

1. Open the Right Door.2. Remove two screws and the cover.3. Remove the harness from the locking wiring saddle.4. Unplug three connectors.

5. Remove two screws and the Right Door.

6. Remove the Counter Cover.7. Remove four screws and the Right Cover.

8. Remove the IU.9. Remove two screws and the cover.

10. Connect the Plug-In Counter connector.11. Secure the Plug-In CounterMounting Bracket with the two

screws.NOTE

When the Plug-In Counter is mounted, be sure to turn“ON” the “Plug-In Counter” of “System Input”

available from the Tech. Rep. mode.

D-101

1156SBD0402A

4-2. ADJUSTMENT OF THE RIGHT DOORIf theRightDoor has been removed and reinstalled, the position of the actuator of RightUpperDoor Interlock

Switch S22 may deviate from the correct position. Hence, the necessity of the following adjustment.

1156D100AA

1134D116AA

1134D117AA

1134D118AA

1. Mount the Right Door with two screws. (At this time, onlytemporarily tighten these screws.)

2. Lightly close the Right Door so that the S22 actuator willnot contact the frame.

3. Due to its ownweight, the front endof theRight Door tendsto hang lower. Lifting the front end slightly, tighten the twomounting screws.

4. Open and close the Right Door two to three times to checkthat the S22 actuator properly actuates and deactuatesS22.

Copyright1997 MINOLTA Co., Ltd.

Printed in Japan

Use of this manual shouldbe strictly supervised toavoid disclosure ofconfidential information.

MINOLTA CO., LTD. 1156-7992-11 97046000Printed in Japan

1156SBD000EA

cover - diagramasde.comdiagramas.diagramasde.com/otros/disassem.pdf · i 1151sbd0000a u for the...

Documents