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Model S-C1
(Machine Code: B045/B049/B044/B046)
SERVICE MANUAL
B046I100.WMF
17 July, 2001 Subject to change
!IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY 1. Be sure that the power cord is unplugged before disassembling or assembling parts of the copier or peripherals. 2. The wall outlet should be near the copier and easily accessible. 3. Note that electrical voltage is supplied to some components of the copier and the paper tray unit even while the main power switch is off. 4. If you start a job before the copier completes the warm-up or initializing period, keep hands away from the mechanical and electrical components until job execution has started. The copier will start making copies as soon as warm-up or initialization is finished. 5. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands. HEALTH SAFETY CONDITIONS Toner and developer are nontoxic, but getting either of these into your eyes may cause temporary eye discomfort. Try to remove with eye drops or flush with water. If material remains in eye or if discomfort continues, get medical attention. OBSERVANCE OF ELECTRICAL SAFETY STANDARDS The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those relevant models. LITHIUM BATTERIES Incorrect replacement of lithium battery(s) on the FCU may pose risk of explosion. Replace only with the same type or with an equivalent type recommended by the manufacturer. Discard used batteries in accordance with the manufacturer's instructions. SAFE AND ECOLOGICAL DISPOSAL 1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly if exposed to an open flame. 2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are nontoxic supplies.) 3. Dispose of replaced parts in accordance with local regulations.
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LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.
!WARNING
Use of controls not specified in this manual, or performance of adjustments or procedures not specified in this manual, may result in hazardous radiation exposure.
!WARNING FOR LASER UNIT
WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can cause serious damage to eyes. CAUTION MARKING:
Symbols and Abbreviations
This manual uses the symbols and abbreviations shown below.
Symbol ! " # SEF LEF $ Meaning "See," "Refer to" Clip ring Screw Connector Short Edge Feed Long Edge Feed Core Technology manual
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TABLE OF CONTENTS
1 INSTALLATION ........................................................................... 1-1
1.1 INSTALLATION REQUIREMENTS ...........................................................1-1 1.1.1 ENVIRONMENT ...............................................................................1-1 1.1.2 MACHINE LEVEL .............................................................................1-2 1.1.3 MINIMUM OPERATIONAL SPACE REQUIREMENTS ....................1-2 1.1.4 POWER REQUIREMENTS ..............................................................1-3 1.2 COPIER.....................................................................................................1-4 1.2.1 ACCESSORY CHECK......................................................................1-4 1.2.2 INSTALLATION PROCEDURE ........................................................1-4 Initial Programming: Faxless models (B044, B045) .............................1-8 Initial Programming: Fax-equipped models (B046, B049)....................1-8 1.3 PAPER TRAY UNIT ................................................................................1-10 1.3.1 ACCESSORY CHECK....................................................................1-10 1.3.2 INSTALLATION PROCEDURE ......................................................1-10 1.4 PAPER TRAY UNIT HEATER .................................................................1-12 1.4.1 ACCESSORY CHECK....................................................................1-12 1.4.2 INSTALLATION PROCEDURE ......................................................1-12 1.5 DOCUMENT FEEDER ............................................................................1-17 1.5.1 ACCESSORY CHECK....................................................................1-17 1.5.2 INSTALLATION PROCEDURE ......................................................1-17 1.6 DIMM.......................................................................................................1-21 1.6.1 INSTALLATION PROCEDURE ......................................................1-21
2 PREVENTIVE MAINTENANCE SCHEDULES ............................. 2-1
2.1 PM TABLES ..............................................................................................2-1 2.2 HOW TO CLEAR THE PM COUNTER......................................................2-2
3 REPLACEMENT AND ADJUSTMENT......................................... 3-1
3.1 PRECAUTIONS.........................................................................................3-1 3.1.1 GENERAL ........................................................................................3-1 3.1.2 LITHIUM BATTERIES ......................................................................3-1 3.1.3 PCU (PHOTOCONDUCTOR UNIT) .................................................3-1 3.1.4 TRANSFER ROLLER .......................................................................3-1 3.1.5 SCANNER UNIT...............................................................................3-2 3.1.6 LASER UNIT ....................................................................................3-2 3.1.7 FUSING UNIT...................................................................................3-2 3.1.8 PAPER FEED...................................................................................3-2 3.1.9 IMPORTANT ....................................................................................3-3 3.2 SPECIAL TOOLS AND LUBRICANTS ......................................................3-3 3.3 EXTERIOR COVER AND OPERATION PANEL .......................................3-4 3.3.1 PLATEN COVER ..............................................................................3-4 3.3.2 REAR COVER..................................................................................3-4 3.3.3 COPY TRAY.....................................................................................3-5 3.3.4 SCALE PLATE (B044 AND B045 ONLY) .........................................3-5 3.3.5 LEFT COVER ...................................................................................3-6
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3.3.6 RIGHT COVER.................................................................................3-6 3.3.7 FRONT LEFT COVER AND OPERATION PANEL ..........................3-6 3.3.8 FRONT RIGHT COVER ...................................................................3-6 3.3.9 RIGHT DOOR...................................................................................3-7 3.3.10 BYPASS TRAY (B044 AND B046 ONLY) ......................................3-7 3.3.11 PLATEN COVER SENSOR............................................................3-8 3.4 SCANNER SECTION ................................................................................3-9 3.4.1 EXPOSURE GLASS.........................................................................3-9 Non-DF machines.................................................................................3-9 DF-equipped machines.........................................................................3-9 3.4.2 LENS BLOCK .................................................................................3-10 3.4.3 EXPOSURE LAMP, LAMP STABILIZER BOARD ..........................3-10 3.4.4 SCANNER MOTOR........................................................................3-11 3.4.5 SCANNER HP SENSOR ................................................................3-11 3.4.6 SCANNER ALIGNMENT ADJUSTMENT .......................................3-12 3.5 FUSING ...................................................................................................3-13 3.5.1 FUSING UNIT.................................................................................3-13 3.5.2 EXIT SENSOR ...............................................................................3-13 3.5.3 HOT ROLLER STRIPPER PAWLS ................................................3-14 3.5.4 HOT ROLLER & FUSING LAMP ....................................................3-15 3.5.5 THERMOFUSE, THERMOSWITCH, AND THERMISTOR.............3-15 3.5.6 PRESSURE ROLLER.....................................................................3-16 3.6 PCU.........................................................................................................3-17 3.7 TONER SUPPLY CLUTCH .....................................................................3-18 3.8 PAPER FEED SECTION.........................................................................3-19 3.8.1 PAPER FEED ROLLER AND FRICTION PAD...............................3-19 3.8.2 PAPER END SENSOR...................................................................3-19 3.8.3 REGISTRATION SENSOR.............................................................3-20 3.8.4 BYPASS PAPER END SENSOR (B044 AND B046 ONLY) ...........3-20 3.8.5 BYPASS FEED ROLLER (B044 AND B046 ONLY) .......................3-21 3.8.6 BYPASS FEED CLUTCH (B044 AND B046 ONLY) .......................3-22 3.8.7 BYPASS FRICTION PAD (B044 AND B046 ONLY).......................3-22 3.8.8 REGISTRATION CLUTCH .............................................................3-22 3.8.9 PAPER FEED CLUTCH .................................................................3-23 3.9 IMAGE TRANSFER.................................................................................3-24 3.9.1 IMAGE TRANSFER ROLLER ........................................................3-24 3.9.2 ID (IMAGE DENSITY) SENSOR ....................................................3-24 3.9.3 DISCHARGE PLATE ......................................................................3-25 3.10 FUNCTION CONTROL UNIT (FCU) .....................................................3-25 3.11 LASER UNIT .........................................................................................3-27 3.11.1 LOCATION OF "CAUTION" DECAL ............................................3-27 3.11.2 PSU BRACKET ............................................................................3-28 3.11.3 LASER UNIT ................................................................................3-29 3.11.4 LD UNIT........................................................................................3-29 3.11.5 POLYGON MIRROR MOTOR ......................................................3-29
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3.12 OTHER REPLACEMENTS....................................................................3-30 3.12.1 QUENCHING LAMP .....................................................................3-30 3.12.2 HIGH-VOLTAGE POWER SUPPLY BOARD ...............................3-30 3.12.3 PSU ..............................................................................................3-30 3.12.4 MAIN MOTOR ..............................................................................3-31 3.12.5 EXHAUST FAN ............................................................................3-31 3.13 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING .....................3-32 3.13.1 PRINTING ....................................................................................3-32 Registration - Leading Edge/Side-to-Side...........................................3-32 Blank Margin.......................................................................................3-33 Main-Scan Magnification.....................................................................3-33 3.13.2 SCANNING...................................................................................3-34 Registration: Platen Mode...................................................................3-34 Magnification.......................................................................................3-34 Standard White Density Adjustment ...................................................3-35 3.13.3 DF IMAGE ADJUSTMENT ...........................................................3-36 Registration and Blank Margin............................................................3-36 Sub-scan Magnification.......................................................................3-36
4 TROUBLESHOOTING ................................................................. 4-1
4.1 SERVICE CALL CONDITIONS .................................................................4-1 4.1.1 SUMMARY .......................................................................................4-1 4.1.2 SC CODE DESCRIPTIONS .............................................................4-2 4.2 ELECTRICAL COMPONENT DEFECTS ..................................................4-7 4.2.1 SENSOR/SWITCH OPEN ERRORS ................................................4-7 4.3 BLOWN FUSE CONDITIONS ...................................................................4-7 4.4 DUMPING THE FUSER TEMPERATURE LOG........................................4-8
5 SERVICE TABLES....................................................................... 5-1
5.1 USING SERVICE PROGRAM MODE .......................................................5-1 Accessing SP Mode..............................................................................5-1 Accessing Copy Mode from within SP Mode ........................................5-1 How to Select a Program Number ........................................................5-2 To Input a Value or Setting ...................................................................5-2 5.1.1 SP MODE TABLES ..........................................................................5-3 SP1-XXX (Feed) ...................................................................................5-3 SP2-XXX (Drum)...................................................................................5-4 SP4-XXX (Scanner) ..............................................................................5-9 SP5-XXX (Mode) ................................................................................5-14 SP6-XXX (Peripherals) .......................................................................5-18 SP7-XXX (Data Log)...........................................................................5-19 5.1.2 TEST PATTERN PRINTING (SP5-902) .........................................5-23 5.1.3 INPUT CHECK (SP5-803) ..............................................................5-24 Input Check Table...............................................................................5-24 5.1.4 OUTPUT CHECK (SP5-804) ..........................................................5-25 Input Check Table...............................................................................5-25 5.1.5 SMC PRINTING (SP5-992) ............................................................5-26 5.1.6 MEMORY ALL CLEAR (SP5-801) ..................................................5-27 5.1.7 FREE RUNS...................................................................................5-28
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5.1.8 PROGRAM UPLOAD/DOWNLOAD ...............................................5-29 Program Download (SP5-827)............................................................5-29 Program Upload (SP5-826) ................................................................5-31 5.1.9 SRAM DATA UPLOAD/DOWNLOAD .............................................5-32 SRAM Data Upload (SP5-824) ...........................................................5-32 SRAM Data Download (SP5-825).......................................................5-33 5.1.10 SERIAL NUMBER INPUT (SP5-811) ...........................................5-33 5.1.11 ID SENSOR ERROR ANALYSIS (SP2-221) ................................5-34 5.1.12 MEMORY READ/WRITE ..............................................................5-35 5.2 USER TOOLS .........................................................................................5-36 5.2.1 HOW TO ENTER AND EXIT USER TOOLS ..................................5-36 5.2.2 USER TOOLS TABLE ....................................................................5-36 System Settings Table ........................................................................5-36 Copy Features Table ..........................................................................5-36
6 DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW ...............................................................................................6-1 6.1.1 COMPONENT LAYOUT ...................................................................6-1 6.2 PAPER PATH............................................................................................6-5 6.3 DRIVE LAYOUT ........................................................................................6-6 6.4 BLOCK DIAGRAM: PCBS AND COMPONENTS......................................6-7 6.5 MAIN PCBS...............................................................................................6-8 6.5.1 FCU (FUNCTION/FACSIMILE CONTROL UNIT).............................6-8 SPC2 ....................................................................................................6-9 VPL (Video Processing LSI) .................................................................6-9 CIOP (Communications and I/O Processing)........................................6-9 FROM (Flash ROM) 2MB ..................................................................6-9 DRAM 8MB.......................................................................................6-9 SRAM 128K .......................................................................................6-9 3V/5V Converter ...................................................................................6-9 Energy-Save Switching.........................................................................6-9 Reset/Backup Circuit ..........................................................................6-10 SAF Backup........................................................................................6-10 Analog Processing Circuit...................................................................6-10 Modem................................................................................................6-10 Speaker Driver ....................................................................................6-10 Heater Control ....................................................................................6-10 Video Processing Circuit.....................................................................6-10 Power Pack Control ............................................................................6-10 Scanner Driver ....................................................................................6-10 Plotter Driver.......................................................................................6-10 6.5.2 SBU (SENSOR BOARD UNIT).......................................................6-11 Buffer ..................................................................................................6-11 CCD ....................................................................................................6-11 Amplifier..............................................................................................6-11 6.5.3 NCU (NETWORK CONTROL UNIT) ..............................................6-12 North America version ........................................................................6-12 Europe/Asia version............................................................................6-12
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6.6 COPY PROCESS OVERVIEW ...............................................................6-13 6.7 SCANNING..............................................................................................6-15 6.7.1 OVERVIEW ....................................................................................6-15 6.7.2 SCANNER DRIVE ..........................................................................6-16 6.8 IMAGE PROCESSING ............................................................................6-17 6.8.1 OVERVIEW ....................................................................................6-17 6.8.2 IMAGE PROCESSING PATH.........................................................6-18 6.8.3 ORIGINAL MODES ........................................................................6-19 Original Modes: Copying....................................................................6-20 6.8.4 IMAGE PROCESSING STEPS FOR EACH MODE .......................6-21 6.8.5 MODE ADJUSTMENTS .................................................................6-22 To customize... ...................................................................................6-22 Default plotter customization settings for each mode... ......................6-23 6.9 LASER EXPOSURE................................................................................6-24 6.9.1 OVERVIEW ....................................................................................6-24 6.9.2 LD SAFETY SWITCHES ................................................................6-25 6.10 PHOTOCONDUCTOR UNIT (PCU) ......................................................6-26 6.10.1 OVERVIEW ..................................................................................6-26 6.10.2 DRUM DRIVE ...............................................................................6-27 6.11 DRUM CHARGE ...................................................................................6-28 6.11.1 OVERVIEW ..................................................................................6-28 6.11.2 CHARGE ROLLER VOLTAGE CORRECTION ............................6-29 Correction for Ambient Environment ...................................................6-29 6.11.3 CHARGE ROLLER CLEANING....................................................6-30 6.11.4 DETECTION OF A NEW PCU......................................................6-31 At time of copier installation ................................................................6-31 When a replacement PCU is installed.................................................6-31 6.12 DEVELOPMENT ...................................................................................6-32 6.12.1 OVERVIEW ..................................................................................6-32 6.12.2 DEVELOPMENT BIAS .................................................................6-33 6.12.3 TONER SUPPLY ..........................................................................6-34 Toner-Bottle Models (B044 and B046)................................................6-34 Toner Hopper Magazine (B045 and B049) .........................................6-35 6.12.4 TONER DENSITY CONTROL ......................................................6-36 Overview.............................................................................................6-36 Reference Voltage ..............................................................................6-36 Toner Density Sensor Initial Setting....................................................6-36 Toner Concentration Measurement ....................................................6-37 Vsp/Vsg Detection ..............................................................................6-37 Calculation of Vref ..............................................................................6-37 Toner Supply Determination ...............................................................6-37 Toner Clutch ON Time ........................................................................6-37 6.12.5 TONER SUPPLY IF SENSOR READING IS ABNORMAL ...........6-38 ID Sensor............................................................................................6-38 TD Sensor...........................................................................................6-38
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6.12.6 DETECTION OF TONER NEAR END AND TONER END ...........6-38 Toner Near End detected when either of the following occurs............6-38 Toner End detected when any of the following occurs........................6-38 6.13 DRUM CLEANING AND TONER RECYCLING.....................................6-39 6.14 PAPER FEED........................................................................................6-40 6.14.1 OVERVIEW ..................................................................................6-40 6.14.2 PAPER FEED DRIVE MECHANISM ............................................6-41 From Paper Tray.................................................................................6-41 From 100-Sheet Bypass Tray (B044, B046) .......................................6-41 From 1-Sheet Bypass Tray (B045, B049) ...........................................6-41 6.14.3 PAPER FEED AND SEPARATION ..............................................6-42 6.14.4 PAPER LIFT MECHANISM ..........................................................6-42 PAPER END DETECTION .................................................................6-43 Main Tray............................................................................................6-43 100-Sheet Bypass Tray (B044, B046) ................................................6-43 6.14.5 PAPER REGISTRATION..............................................................6-43 6.15 IMAGE TRANSFER AND PAPER SEPARATION .................................6-44 6.15.1 OVERVIEW ..................................................................................6-44 6.15.2 IMAGE TRANSFER CURRENT TIMING......................................6-45 6.15.3 TRANSFER ROLLER CLEANING................................................6-46 6.16 IMAGE FUSING AND PAPER EXIT......................................................6-47 6.16.1 OVERVIEW ..................................................................................6-47 6.16.2 FUSING DRIVE AND RELEASE MECHANISM ...........................6-47 6.16.3 PRESSURE ROLLER...................................................................6-48 6.16.4 PRESSURE RELEASE ................................................................6-48 Separation ..........................................................................................6-48 6.16.6 FUSING TEMPERATURE CONTROL..........................................6-49 Overview.............................................................................................6-49 Fusing Temperature Control for Thick Paper......................................6-49 6.16.7 OVERHEAT PROTECTION .........................................................6-49 6.17 ENERGY SAVER MODES ....................................................................6-50 6.17.1 MODE TRANSITIONS..................................................................6-50 6.17.2 SYSTEM SETTINGS ....................................................................6-51 6.17.3 LOW POWER MODE LEVELS.....................................................6-51 6.17.4 AUTO-OFF LEVEL .......................................................................6-51 6.17.5 TRANSITION OPERATION..........................................................6-51
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PAPER TRAY UNIT (B421) 1 OVERALL MACHINE INFORMATION ................................... B421-1
1.1 1.2 1.3 1.4 1.5 MECHANICAL COMPONENT LAYOUT ............................................ B421-1 ELECTRICAL COMPONENT LAYOUT.............................................. B421-1 DRIVE LAYOUT ................................................................................. B421-2 OVERALL ELECTRICAL CIRCUIT .................................................... B421-2 DETAILED DESCRIPTIONS .............................................................. B421-3 1.5.1 PAPER FEED AND SEPARATION ........................................... B421-3 1.6 PAPER LIFT MECHANISM ................................................................ B421-3 1.7 PAPER END DETECTION ................................................................. B421-4 1.8 SIDE AND END FENCES .................................................................. B421-5
2 REPLACEMENT AND ADJUSTMENT................................... B421-6
2.1 FEED ROLLER AND FRICTION PAD................................................ B421-6 2.2 REMOVING THE PAPER TRAY UNIT FROM THE COPIER............. B421-6 If Optional Tray Heater Is Not Installed .......................................... B421-6 If Optional Tray Heater Is Installed ................................................ B421-6 2.3 SENSORS .......................................................................................... B421-7 2.4 DRIVE SECTION................................................................................ B421-8 2.4.1 DRIVE BLOCK .......................................................................... B421-8 2.4.2 PAPER FEED MOTOR.............................................................. B421-8 2.4.3 PAPER FEED CLUTCH ............................................................ B421-9 2.4.4 TRAY MAIN BOARD ( 2.4.1) ..................................................... B421-9
DOCUMENT FEEDER (B444) 1 OVERALL INFORMATION .................................................... B444-1
1.1 MECHANICAL COMPONENT LAYOUT ............................................ B444-1 1.2 ELECTRICAL COMPONENT LAYOUT.............................................. B444-2 1.3 DRIVE LAYOUT ................................................................................. B444-3
2 DETAILED SECTION DESCRIPTIONS ................................. B444-4
2.1 2.2 2.3 2.4 2.5 3.1 3.2 3.3 3.4 3.5 PICK-UP AND SEPARATION ............................................................ B444-4 CLUTCH OPERATION....................................................................... B444-4 TRANSPORT AND EXIT .................................................................... B444-4 UNIT OPEN SWITCH AND GUIDE OPEN SENSOR......................... B444-5 OVERALL ELECTRICAL CIRCUIT .................................................... B444-5 DF UPPER COVERS ......................................................................... B444-6 ORIGINAL TABLE .............................................................................. B444-6 FEED UNIT......................................................................................... B444-6 DF PICKUP ROLLER ......................................................................... B444-7 DF FEED ROLLER............................................................................. B444-7
3 REPLACEMENT AND ADJUSTMENT................................... B444-6
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3.6 DF SEPARATION ROLLER ............................................................... B444-8 3.7 DF MOTOR ........................................................................................ B444-9 3.8 DF FEED CLUTCH........................................................................... B444-10 3.9 SENSORS ........................................................................................ B444-10 3.10 DF EXPOSURE GLASS ................................................................. B444-11 3.11 DF CONNECTION BOARD ............................................................ B444-11
SPECIFICATIONS
1 GENERAL SPECIFICATIONS.............................................................. SPEC-1 2 MACHINE CONFIGURATION .............................................................. SPEC-5 3 OPTIONAL EQUIPMENT ..................................................................... SPEC-6 ADF .................................................................................................. SPEC-6 PAPER TRAY UNIT ........................................................................... SPEC-6
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24 July, 2001
INSTALLATION REQUIREMENTS
!CAUTION
Before installing options, please do the following: 1. If there is a fax unit on the machine, print out all messages stored in the memory, all user-programmed items, and a system parameter list. 2. If there is a printer option on the machine, print out all data in the printer buffer. 3. Turn off the main switch and disconnect the power cord, the telephone line, and the network cable.
1.1 INSTALLATION REQUIREMENTS
1.1.1 ENVIRONMENT
Temperature and Humidity Chart
Humidity 80%
54% Operation range
15%
10°C (50°F)
27°C 32°C (80.6°F) (89.6°F)
Temperature
B046I512.WMF
1. Temperature Range: 10°C to 32°C (50°F to 89.6°F) 2. Humidity Range: 4. Ventilation: 5. Ambient Dust 15% to 80% RH Room air should turn over at least 3 times/hr/person Less than 0.1 mg/m3 3. Ambient Illumination: Less than 1,500 lux (Do not expose to direct sunlight.)
6. Do not install the machine where it will be exposed to direct sunlight or to direct airflow (from a fan, air conditioner, air cleaner, etc.). 7. Do not install the machine where it will be exposed to corrosive gas. 8. Place the machine on a firm and level base. 9. Do not install the machine where it may be subjected to strong vibration.
1-1
Installation
1. INSTALLATION
INSTALLATION REQUIREMENTS
24 July, 2001
1.1.2 MACHINE LEVEL
Front to back: Right to left: Within 5 mm (0.2") of level Within 5 mm (0.2") of level
1.1.3 MINIMUM OPERATIONAL SPACE REQUIREMENTS
Place the machine near the power source, providing clearance as shown. [C]
[D] [B] 450 mm (17.7")
[A]
A: Front B: Left C: Rear D: Right
B046I130.WMF
> > > >
750 mm (29.6") 100 mm (3.9") 105 mm (4.1") 230 mm (9.0")
468 mm (18.4")
NOTE: 1) The 750-mm front space indicated above is sufficient to allow the paper tray to be pulled out. Additional space is required to allow an operator to stand at the front of the machine. 2) Actual minimum space requirement for left, rear, and right sides is 10mm (0.4") each, but note that this will not allow room for opening of the bypass tray, right door, platen cover, or ADF unit.
1-2
24 July, 2001
INSTALLATION REQUIREMENTS
1.1.4 POWER REQUIREMENTS
!CAUTION
1. Make sure that the wall outlet is near the machine and easily accessible. After completing installation, make sure the plug fits firmly into the outlet. 2. Avoid multi-wiring. 3. Be sure to ground the machine. Input voltage: North America: Europe: 120 V, 60 Hz, 7 A 220 240 V, 50/60 Hz, 4 A
Image quality guaranteed at rated voltage ± 10%. Operation guaranteed at rated voltage ± 15%.
1-3
Installation
COPIER
24 July, 2001
1.2 COPIER
1.2.1 ACCESSORY CHECK
Check that you have the accessories indicated below. Note that accessories vary according to model and location.
No. 1 2 3 4 5 6 7 8 Description Copier Operating Instructions (-17, -26, -29) EU safety sheet (-22, -24, -26, -27) NECR (-17, -27, -29) Paper-size decals Energy Star seal (-26) Branding plaques (-22) Brand decals (-22) Handset bracket (B046-17) Q'ty 1 1 1 1 set 1 1 set 1 set 1
1.2.2 INSTALLATION PROCEDURE
!CAUTION
Make sure that the copier remains unplugged during installation.
[A]
B046I101.WMF
[B]
B046I124.WMF
1. Remove the strips of tape. 2. Remove the bag [A] holding the included accessories. 3. Remove the spacing wedge [B].
1-4
24 July, 2001
COPIER
4. Remove the 3 scanner lock pins. (A tag is hanging from each pin.) To remove: Grasp the base of the pin [A], turn 90 degrees, and pull down and out. [B] [A] 5. Remove the tags from the pins. Then break each pin off of its base [A], discard the pin part [B], and set each base [A] back into its original hole, turning it 90° to lock it into place. (Be sure to do this for all three pins.)
B046I106.WMF
6. If installing a DF-equipped model (B046 or B049): Raise the DF upper guide [C] and remove the protective paper [D] at the feed unit. Then lower the guide.
[E]
[C] [D]
7. Open the platen cover [E] and remove the protective paper [F] covering the exposure glass. Then close the platen cover.
B046I107.WMF
[F]
1-5
Installation
COPIER
24 July, 2001
8. Open the front door [A]. 9. If installing a toner-bottle model (B044 or B046): · Lift lever [B], press in on latch [C] and pull the bottle holder [D] out. (It is not necessary to pull it completely out of the machine, however.) · Take a new bottle of toner, shake it several times, remove its outer cap [E], and load as shown. Then push the bottle holder back into the machine, and press the latch [B] down to lock it.
[C]
[D]
[A]
B046I112.WMF
[E]
If installi ng a toner-hopper magazine model (B045 or B049): · Shake the magazine several times, then peel off the paper [F] from a new THM [G], and load the THM into the machine.
B046I301.WMF
[F]
[G]
B046I114.WMF
1-6
24 July, 2001
COPIER
[A]
B046I104.WMF
11. Pull open the paper tray, and remove the tape [C] securing the end fence in the compartment. 12. Push the bottom plate [D] down, load paper, and adjust the side fences. If loading paper shorter than A4, remove the end fence [E] from its compartment, set it into the tray, and adjust it to the correct length. 13. Push the tray back in. 14. Adhere the appropriate branding decal (not shown) to the center of the front door [F], and adhere the tray number decal and appropriate paper-size decal to the front of the paper tray (at [G]) as shown. 15. Hong Kong only: If installing model B046 or B049 in Hong Kong, you must change the position of the TB1 jumper on the NCU. Turn to the fax service manual and carry out steps 4 to 8 of the installation procedure (fax service manual, section 1.2.2).
[E] [D]
[C]
B046I119.WMF
[F]
[G]
B046I515.WMF
16. Plug in the machine and turn on the main switch. 17. Enter SP mode, and run SP7-825 to initialize the electrical total counter to 0. NOTE: 1) After selecting SP7-825, enter "1" and then hold down the Original Type key and press the OK key to initialize the counter. If initialization is successful, the screen displays "Action completed." 2) SP7-825 is effective only once, at time of machine installation.
1-7
Installation
10. Remove the foam cushion [A] and pull the tabbed strips [B] all the way out of the PCU. Then close the front door.
[B]
COPIER
24 July, 2001
18. Models B046 and B049 only: Access SP5-992 and select "2" to print out a full SMC report. Confirm that the report shows a "YES" for SP7-801-3. 19. Models B046 and B049 only: Press the On Hook key on the fax operation panel, and confirm that you hear a dial tone coming from the monitor speaker. 20. Program the required items, as indicated below.
Initial Programming: Faxless models (B044, B045)
Items to Program (Service Level SP Mode)*1 Date and time Language replacement (Firmware download) SP No. 5-302 5-827
*1: See Section 5 for SP-mode usage instructions.
Items to Program (User Level) *2 Display contrast Energy saver level (low power mode) Reception mode Other items, as necessary User Tools User Tools System Settings *2
*2: Refer to the Operating Instructions for details.
Initial Programming: Fax-equipped models (B046, B049)
Items to Program (Service Level Service Functions)*3 Country code (System switch 0F) Protocol requirements (G3 switch 0B) - EU only PM call (System switch 01 bit 0) Country code (NCU parameter 00) Service station's fax number Function No. 01 01 01 07 09
*3: See Section 5.1.1 of the fax service manual for information about using service functions.
1-8
24 July, 2001
COPIER
Items to Program (Service Level SP Mode)*4 Machine's serial number Language replacement (Firmware download) PSTN access code (RAM address 4000DB) PSTN access method (RAM address 4000CD) Periodic service call (RAM addresses 40054F to 400553)
SP No. 5-811 5-827 7-955
*4: See Section 5 for SP-mode usage instructions.
Items to Program (User Administrator Level)*5 Monitor volume Display contrast Date and Time Reception mode Fax Header/Own Name/Own No. (TTI/RTI/CSI) Reports on/off Country Code (except NA) Fusing power control during energy saver mode Language selection Other initial programming items User Tools
Fax Features Setup
Key Op. Tools System Settings Language *5
*5: Refer to the Operating Instructions for details.
1-9
Installation
PAPER TRAY UNIT
24 July, 2001
1.3 PAPER TRAY UNIT
1.3.1 ACCESSORY CHECK
Confirm that you have the accessories indicated below.
No. 1 2 3 Description Paper-size decals Installation Procedure (for service person) Installation Procedure (for user) Q'ty 1 sheet 1 1
1.3.2 INSTALLATION PROCEDURE
!CAUTION
Unplug the main machine's power cord before starting the following procedure.
1. Remove the tape at [A], and the tape and cardboard at [B]. 2. Pull the paper tray part way out of the unit, remove the tape and cardboard at [C], and push the tray back in. [B]
[C] [A]
B046I516.WMF
1-10
24 July, 2001
PAPER TRAY UNIT
B046I527.WMF
4. Remove the paper tray from the paper tray unit. 5. Load paper into the paper tray. Adjust the side and end fences as necessary. If loading 81/2"x 14" paper, remove the end fence and set it into the special compartment. 6. Set the paper tray back into the paper tray unit. 7. Stick on the appropriate tray-number decal and paper-size decal, at the locations indicated in the illustration.
B046I517.WMF
1-11
Installation
3. Set the machine onto the paper tray unit.
PAPER TRAY UNIT HEATER
24 July, 2001
1.4 PAPER TRAY UNIT HEATER
1.4.1 ACCESSORY CHECK
Confirm that you have the accessories indicated below.
No. 1 2 3 4 5 6 7 8 9 10 Description Grounding wire Relay harness Clamps Ferrite core Heater fastening screws PTU fastening screws Grounding screw Decal for copier Decal for paper unit Tie wrap Q'ty 1 1 2 1 2 3 1 1 1 1
1
2 3
10 4
9 8
5 6 7
B046I518.WMF
1.4.2 INSTALLATION PROCEDURE
!CAUTION
Unplug the main machine's power cord before starting the following procedure. 1. If the paper tray unit is already installed, uninstall it by lifting the copier off of it. (Refer to illustrations for Procedure 1.3.2, above.) 2. Remove both paper trays--the one from the copier, and the one from the paper tray unit.
1-12
24 July, 2001
PAPER TRAY UNIT HEATER
[C] 4. Fasten the heater [B] and the supplied ground wire [C] to the paper tray unit with 3 screws as shown. Note that [A] is the grounding screw you removed at Step 3 (returned to its original hole), and [D] and [E] are the two supplied heater fastening screws. NOTE: Be sure to position the ground wire [C] and heater harness [F] so that they will be out of the way of the copier when you set it onto the paper tray unit. 5. Set the copier onto the paper tray unit. [D]
[A]
[F] [B]
[E]
B046I519.WMF
6. Screw the paper tray unit into place using three supplied PTU fastening screws.
B046I500.WMF
1-13
Installation
3. Remove the ground screw [A] at the rear of the paper tray unit.
PAPER TRAY UNIT HEATER
24 July, 2001
7. Open the front door [A] and remove the copy tray [B] (!×1). Then close the front door.
[B]
[A]
B046I501.WMF
8. Remove the rear cover [C] (! x 5). [C]
B046I502.WMF
9. Remove the FCU cover plate [D] (7 screws on faxless machines, 8 screws on fax-equipped machines). NOTE: On fax-equipped machines, detach the NCU connector [E] first. Faxless machines: Fax-equipped machines:
[E] [D]
B046I503.WMF B046I504.WMF
1-14
24 July, 2001
PAPER TRAY UNIT HEATER
11. Pass relay harness [B] through the circular opening at [C] (at the rear of the PSU board bracket), and then through the hole at [A]. Then connect the relay harness to the heater's harness [D].
[A] [B] [C]
[D] [L] [F] 12. Pull the relay harness back into the copier. Then set the ferrite core [E] over the relay harness, and push it back so that it is over the heater's harness. 13. Wrap the heater's harness once around the core (see [F]). Adjust so that the core is located toward the rear of the copier (at position [E], behind the rear clamp). Secure the core into position using the supplied tie wrap [G]. 14. Clip off the excess length of the tie wrap [H].
B046I520.WMF
[G] [H]
[E] [K] [I]
[J]
B046I521.WMF
15. Connect the relay harness connector [I] to the large connector at the front center of the PSU board. Screw the ground wire [J] to the PSU board bracket, using the included grounding screw. 16. Attach the supplied clamps [K] to corresponding holes on the PSU board bracket, and set the heater harness though the clamps. Position the harness so that the front clamp is between the two bindings [L] on the harness. Then fasten the clamps.
1-15
Installation
10. Pass the heater's harness through the hole [A] at the rear of the copier.
PAPER TRAY UNIT HEATER
24 July, 2001
17. Pull the excess length of the heater's harness out the hole at the rear [A]. NOTE: Be sure that the harness passes to the side of the grounding plate [B] at the bottom of the hole. (The front of the grounding plate must remain clear.)
[B] [A]
B046I522.WMF
18. Arrange the excess harness length so that it sits beneath the FCU cover plate. 19. Attach the caution decals to the locations shown in the illustration.
B046I523.WMF
20. Reinsert the paper trays, and reattach the copy tray and the rear cover.
1-16
24 July, 2001
DOCUMENT FEEDER
1.5.1 ACCESSORY CHECK
Confirm that you have the components and accessories indicated below.
No. 1 2 3 4 5 6 7 8 Description DF connection board DF body Hex wrench Hex screws DF original table Wire harness Phillips-head screws Bracket Installation Procedure Q'ty 1 1 1 4 1 1 5 1 1
8
1
2 3
7 4
5
6
B046I524.WMF
1.5.2 INSTALLATION PROCEDURE
!CAUTION
Unplug the main machine's power cord before starting the following procedure.
1-17
Installation
1.5 DOCUMENT FEEDER
DOCUMENT FEEDER
24 July, 2001
1. Unpack the ADF and remove the packing tape from the bottom of the ADF body. [C] 2. Remove the platen cover [A]. To remove: Lift the cover, unlatch the two latches [B] (press down on the tabs [C] and push the latch back), and detach the cover from the hook [D]. [A]
[B]
[D]
B046I505.WMF
3. Remove the left piece [E] of the copier's platen cover by pushing the piece to the left and then pulling it up and off.
[E]
B046I525.WMF
4. Place the DF original table [F] flat onto the platen cover, so that the 3 latches go all the way into the openings and so that the contact area [G] around each [1] latch is flush against the cover. Then push so that latch [1] locks into place, then latch [2], and then latch [3] (at the rear left). NOTE: The latches may break if you try to push the table in at an angle.
[3]
[F] [2]
[G]
B046I526.WMF
1-18
24 July, 2001
DOCUMENT FEEDER
[A]
B046I514.WMF
6. Remove the left scale plate [B] (! x 2). [B]
B046I506.WMF
7. Set the DF body [C] onto the copier in its correct position. Press the latch [D] to raise the top half of the body, and fasten to the copier with the 4 hex screws (using the included hex wrench). [D]
B046I528.WMF
[C]
1-19
Installation
5. Remove the rear cover [A] (! x 5).
DOCUMENT FEEDER
24 July, 2001
8. Install the DF connection board [A] and DF board bracket [B]. (! x 5)
[D]
[C]
[B]
[A]
B046I513.WMF
9. Connect the four wire sets from the DF body to CN103, CN105, CN106, and CN107 on the DF connection board. (Not shown in illustration.) 10. Connect one end of the supplied wire harness [C] to CN101 and CN102 on the DF connection board, and connect the other end to connectors CN9 and CN10 on the FCU. Secure the wire harness into the clamp [D] located to the side of the DF board. 11. Reattach the rear cover and the platen cover. 12. Plug in the power cord, and turn on the main switch. 13. Make a full-size copy from the first tray using the ADF, and check the side-toside and leading edge registrations. If the registration is incorrect, adjust as necessary ( 3.13.3).
1-20
24 July, 2001
DIMM
1.6.1 INSTALLATION PROCEDURE
!CAUTION
Unplug the main machine's power cord before starting the following procedure.
1. Remove the rear cover [A] (! x 5).
[A]
B046I508.WMF
2. Remove the FCU cover plate [B] (7 screws on faxless machines, 8 screws on fax-equipped machines). NOTE: On fax-equipped machines, detach the NCU connector [C] first. Faxless machines: Fax-equipped machines:
[C]
[B]
B046I509.WMF B046I510.WMF
1-21
Installation
1.6 DIMM
DIMM
24 July, 2001
3. Insert the DIMM [A] at an angle into slot CN2 on the FCU. 4. Press the free end of the DIMM toward the FCU, so that the DIMM snaps into place parallel to the FCU. 5. Reinstall the FCU cover plate and the rear cover.
[A]
B046I105.WMF
1-22
24 July, 2001
PM TABLES
2. PREVENTIVE MAINTENANCE SCHEDULES
2.1 PM TABLES
NOTE: 1) After carrying out PM, clear the PM counter (SP7-804). 2) PM intervals (45k, 90k) indicate the number of prints. Key: AN: As necessary C: Clean
Every 90k
R: Replace
AN C C C C C C C
I: Inspect
NOTE
Every 45k OPTICS Reflector 1st mirror 2nd mirror 3rd mirror Platen cover Exposure glass Toner shield glass DRUM AREA PCU Transfer roller Discharge plate PAPER FEED Paper feed roller Friction pad Bottom-plate pad Registration roller FUSING UNIT Hot roller Pressure roller Hot roller bearings Pressure-roller bushings Inlet guide Outlet guide Hot roller stripper pawls Thermistor R C C C C C C C
Optics cloth Optics cloth Optics cloth Optics cloth Dry cloth Dry cloth Dry cloth
On B044 and B046: Also clean toner-bottle holder. R R
R R C C
C C C C
Water or alcohol. Dry cloth Water or alcohol. Water or alcohol.
R R R I C C R C
2-1
Preventive Maintenance
HOW TO CLEAR THE PM COUNTER
24 July, 2001
Every 90k DF Separation roller Pick-up roller White plate DF exposure glass Rollers R0, R1, R2 R R
AN C C C C C Water or alcohol Water or alcohol Water or alcohol Water Water or alcohol
NOTE
Every 120k PAPER TRAY UNIT Paper feed roller Bottom-plate pad Friction pad R
AN
NOTE
C R
Dry cloth
2.2 HOW TO CLEAR THE PM COUNTER
After finishing PM, clear the PM counter as follows. 1. Access SP mode 7-804. 2. Hold down the Original Type key and press the OK key (or ! key) to reset the counter. If the reset is successful, the display shows "Action completed." If the reset fails, the display shows "Error!!!"
2-2
24 July, 2001
PRECAUTIONS
3. REPLACEMENT AND ADJUSTMENT
3.1 PRECAUTIONS
3.1.1 GENERAL
!CAUTION
Turn off the main power switch and unplug the machine before starting any of the replacement procedures described in this section. But note that you should not turn off the main switch while mechanical parts are active, as this may cause parts to stop out of home position. Attempting to remove or install the PCU or other such units while parts are out of home position may result in damage. Wait for operation to stop before turning off the machine.
3.1.2 LITHIUM BATTERIES
!CAUTION: Lithium Batteries
Incorrect replacement of lithium battery(s) on the FCU poses risk of explosion. Replace only with the same type or with an equivalent type recommended by the manufacturer. Discard used batteries in accordance with the manufacturer's instructions.
3.1.3 PCU (PHOTOCONDUCTOR UNIT)
The PCU consists of the OPC drum, charge roller, development unit, and cleaning components. Observe the following precautions when handling the PCU. 1. Never touch the drum surface with bare hands. If the drum surface is dirty or if you have accidentally touched it, wipe it with a dry cloth, or clean it with wet cotton and then wipe it dry with a cloth. 2. Never use alcohol to clean the drum. Alcohol will dissolve the drum surface. 3. Store the PCU in a cool dry place. 4. Do not expose the drum to corrosive gases (ammonia, etc.). 5. Do not shake a used PCU, as this may cause toner and developer to spill out. 6. Dispose of used PCU components in accordance with local regulations.
3.1.4 TRANSFER ROLLER
1. Never touch the surface of the transfer roller with bare hands. 2. Be careful not to scratch the transfer roller, as the surface is easily damaged.
3-1
Replacement Adjustment
PRECAUTIONS
24 July, 2001
3.1.5 SCANNER UNIT
1. Use alcohol or glass cleaner to clean the exposure and scanning glass. This will reduce the static charge on the glass. 2. Use a blower brush or a water-moistened cotton pad to clean the mirrors and lenses. 3. Take care not to bend or crease the exposure lamp's ribbon cable. 4. Do not disassemble the lens unit. Doing so will throw the lens and copy image out of focus. 5. Do not turn any of the CCD positioning screws. Doing so will throw the CCD out of position.
3.1.6 LASER UNIT
1. Do not loosen or adjust the screws securing the LD drive board on the LD unit. Doing so will throw the LD unit out of adjustment. 2. Do not adjust the variable resistors on the LD unit, as these are permanently adjusted at the factory. If replacement of the LD drive board is necessary, replace the entire LD unit. 3. Keep the polygon mirror and toroidal lens free of dust. Laser performance is very sensitive to dust on these components. 4. Do not touch the shield glass, the lenses, or the surface of the polygon mirror with bare hands.
3.1.7 FUSING UNIT
1. After installing the fusing thermistor, make sure that it is in contact with the hot roller and that the roller can rotate freely. 2. Be careful to avoid damage to the hot roller stripper pawls and their tension springs. 3. Do not touch the fusing lamp and rollers with bare hands. 4. Make sure that the fusing lamp is positioned correctly and that it does not touch the inner surface of the hot roller.
3.1.8 PAPER FEED
1. Do not touch the surface of paper feed rollers. 2. To avoid misfeeds, the side and end fences in each paper tray must be positioned correctly so as to align with loaded paper size.
3-2
Replacement Adjustment
24 July, 2001
SPECIAL TOOLS AND LUBRICANTS
3.1.9 IMPORTANT
1. The machine will automatically start toner agitation when you install a new PCU. Be sure to wait for initialization to finish before reopening the front cover or turning off the main switch. 2. If the optional anti-condensation heater (for the optional paper tray unit) is installed, keep the copier's power cord plugged in even while the main switch is off, so that the heater remains energized.
Part Number A1849501 A2929500 A0299387 N8036701 N8031000 A2579300 52039501 G0219350
Description Optics Adjustment Tools (2 pcs/set) Test Chart S5S (10 pcs/set) Digital Multimeter Fluke 87 Flash Memory Card (4MB) Case for Flash Memory Card Grease Barrierta S552R Silicone Grease G-501 Loopback connector
Q'ty 1 set 1 set 1 1 1 1 1 1
Common with... Skylark Mojito Russian-C, Stinger-C Russian-C, Stinger-C Russian-C, Stinger-C Russian-C, Stinger-C Russian-C, Stinger-C Russian-C, Stinger-C
3-3
Replacement Adjustment
3.2 SPECIAL TOOLS AND LUBRICANTS
EXTERIOR COVER AND OPERATION PANEL
24 July, 2001
3.3 EXTERIOR COVER AND OPERATION PANEL
3.3.1 PLATEN COVER
1. Lift the platen cover [A]. 2. Unlatch the two latches [B]. NOTE: To unlatch, press down on the tabs [C] and then push the latch back. 3. Detach the cover from the hook [D] [C] [A] [B]
Replacement Adjustment
[D]
B046R904.WMF
3.3.2 REAR COVER
1. Platen cover ( 3.3.1) 2. Rear cover [A] (! x 5)
[A]
B046R903.WMF
3-4
24 July, 2001
EXTERIOR COVER AND OPERATION PANEL
3.3.3 COPY TRAY
1. Open the front door [A]. 2. Copy tray [B] (! x 1)
[B]
[A]
B046R912.WMF
3.3.4 SCALE PLATE (B044 AND B045 ONLY)
1. Scale plate [A] (! × 2)
[A]
B046R551.WMF
3-5
Replacement Adjustment
EXTERIOR COVER AND OPERATION PANEL
24 July, 2001
3.3.5 LEFT COVER
1. Rear cover ( 3.3.2) 2. Slide the left cover [A] toward the rear to remove it. [A] [B]
[E]
[D] [F] [G]
B046R901.WMF
3.3.6 RIGHT COVER
1. Rear cover ( 3.3.2) 2. Remove the metal fitting [B], and the platen-cover arm [C]. 3. Slide the right cover [D] toward the rear to remove it.
3.3.7 FRONT LEFT COVER AND OPERATION PANEL
1. Front left cover [E] (On B044/5: ! × 2) (On B046/9: ! × 2, " × 2) NOTE: The illustration shows B046/9. 2. Operation panel [F] (! × 4, " × 1)
3.3.8 FRONT RIGHT COVER
1. Operation panel ( 3.3.7) 2. Open the right door. 3. Front right cover [G]
3-6
Replacement Adjustment
[C]
24 July, 2001
EXTERIOR COVER AND OPERATION PANEL
3.3.9 RIGHT DOOR
1. Open the right door [A]. 2. Undo the strap [B]. 3. Right door (" × 1) [B]
[A]
B046R909.WMF
3.3.10 BYPASS TRAY (B044 AND B046 ONLY)
1. Press the stopper rails [A] inward and remove the bypass tray [B].
[B]
[A]
B046R908.WMF
3-7
Replacement Adjustment
EXTERIOR COVER AND OPERATION PANEL
24 July, 2001
3.3.11 PLATEN COVER SENSOR
1. Rear cover ( 3.3.2) 2. Platen cover sensor [A] (" × 1) [A]
B046R931.WMF
3-8
Replacement Adjustment
24 July, 2001
SCANNER SECTION
3.4 SCANNER SECTION
3.4.1 EXPOSURE GLASS
[A] [B]
Replacement Adjustment
B046R005.WMF
Non-DF machines
1. Rear cover ( 3.3.2) 2. Scale plate ( 3.3.4) 3. Exposure glass [A]
DF-equipped machines
1. Rear cover ( 3.3.2) 2. Right cover ( 3.3.6) 3. Exposure glass [A] NOTE: When reinstalling: Be sure that the marking on the glass is at the rear left corner, and be sure the left edge of the glass is aligned flush against the support ridge [B] on the frame.
3-9
SCANNER SECTION
24 July, 2001
3.4.2 LENS BLOCK
1. Exposure glass ( 3.4.1) 2. Unclamp four clamps [A], and take the wire out of the clamps. 3. Lens block [B] (! × 4, 1 flat cable) NOTE: 1) Do not loosen the paintlocked screws holding the lens unit in place. 2) After installing a new lens block, carry out copy adjustments. ( 3.13)
B046R003.WMF
[B] [A]
3.4.3 EXPOSURE LAMP, LAMP STABILIZER BOARD
1. Exposure glass ( 3.4.1) 2. Operation panel ( 3.3.7) 3. Slide the 1st scanner to a position where the lamp and scanner are clear of the metal lids. 4. Disconnect the lamp connector [A]. 5. Remove either or both of the following: · Exposure lamp [B] (1 screw at [C]) · Lamp stabilizer board [D] (2 screws at [E], 1 flat cable) [C] [A] [D] [E] [B]
B046R001.WMF
3-10
Replacement Adjustment
24 July, 2001
SCANNER SECTION
3.4.4 SCANNER MOTOR
1. Right cover ( 3.3.6) 2. Scanner motor [A] (! × 4, 1 spring, " × 1) NOTE: When reinstalling: Fasten the screws loosely, then set the spring in place, then tighten up the screws.
Replacement Adjustment
[A]
B046R923.WMF
3.4.5 SCANNER HP SENSOR
1. Left cover ( 3.3.6) 2. If non-DF machine: Scale plate ( 3.3.4) If DF-equipped machine: Press on the DF latch and open the DF. 3. Scanner HP sensor [A] (" × 1)
[A]
B046R020.WMF
3-11
SCANNER SECTION
24 July, 2001
3.4.6 SCANNER ALIGNMENT ADJUSTMENT
1. Remove the rear cover ( 3.3.2), operation panel ( 3.3.7), and exposure glass ( 3.4.1). 2. Loosen the 2 screws holding the 1st and 2nd scanner belts in place.
B046D002.WMF
3. Slide the 1st and 2nd scanners so that all four of the following are roughly aligned on both the front and back sides: · The hole on the copier's lid · The hole on the 1st scanner · The corner right hole on the 2nd scanner · The hole at the base of the scanner [A] 4. Insert the two optics adjustment tools [A], and adjust the scanners as necessary so that the tools go through all four holes. 5. Tighten the two screws that you loosened at step 2 above, so that the belts are firmly clamped into place. 6. Remove the adjustment tools.
B046D003.WMF
3-12
Replacement Adjustment
24 July, 2001
FUSING
3.5 FUSING
3.5.1 FUSING UNIT
!CAUTION
The fusing unit can become very hot. Be sure that it has cooled down sufficiently before handling it. 1. Turn off the main switch, and unplug the machine. 2. Copy tray ( 3.3.3) 3. Fusing unit [A] (! × 3, " × 3) NOTE: When reinstalling the unit: Replace the spacer [B] in the correct position, and remember to set the grounding wire [C] into place. [C] [B]
Replacement Adjustment
[A]
B046R501.WMF
3.5.2 EXIT SENSOR
1. Fusing unit ( 3.5.1) 2. Exit sensor [A] (" × 1)
[A]
B046R508.WMF
3-13
FUSING
24 July, 2001
3.5.3 HOT ROLLER STRIPPER PAWLS
[A]
B046R502.WMF
[E]
[D]
B046R507.WMF
[C]
1. Fusing unit ( 3.5.1) 2. Separate the fusing unit into two sections: the hot roller section [A], and the pressure roller section [B]. (! × 2) NOTE: After removing the screws, lower the pressure roller section about halfway and then slide it toward the front side to detach it. 3. Hot roller stripper pawls [C] (1 spring for each pawl) NOTE: 1) To remove the right pawl, first remove the plastic spacer at [D] (! × 1). 2) When reinstalling the center pawl, be sure to set roller [E] back into place.
3-14
Replacement Adjustment
[B]
24 July, 2001
FUSING
3.5.4 HOT ROLLER & FUSING LAMP
[A] 1. Hot roller stripper pawls ( 3.5.3) 2. Hot roller assembly [A] (! × 2) NOTE: 1) Each of the screws has a washer. 2) After removing the screws, lift the hot roller assembly out from the rear side. 3. Fusing lamp [B]
Replacement Adjustment
B046R505.WMF
[B] 4. Hot roller [C] (2 C-rings, 1 spacer, 1 gear, 2 bushings)
[B]
[C]
B046R509.WMF
3.5.5 THERMOFUSE, THERMOSWITCH, AND THERMISTOR
1. Remove the hot roller assembly from the hot roller section. ( 3.5.3) 2. Thermofuse [A] (! × 2). 3. Thermoswitch [B] (! × 2) NOTE: You must remove the thermofuse first. 4. Thermistor [C] (! × 1) [C] [A] [B]
B046R506.WMF
3-15
FUSING
24 July, 2001
3.5.6 PRESSURE ROLLER
1. Fusing unit ( 3.5.1) 2. Separate the fusing unit into two sections: the hot roller section and the pressure roller section ( 3.5.3, Step 2). Carry out the remaining steps on the pressure roller section. 3. Fusing entrance guide [A]
Replacement Adjustment
[A]
B046R504.WMF
[C] 4. 2 springs ([B], [C]) 5. 2 pressure arms ([D], [E]) NOTE: Manipulate each arm so that it comes out through the slit in the casing. 6. 2 bushings ([F], [G]) 7. Pressure roller [H] [F] [H] [B] [D] [E]
[G]
B046R503.WMF
3-16
24 July, 2001
PCU
3.6 PCU
[A] [B]
B046I109.WMF
1. Open the right door. NOTE: Do not forget to open the right door. The PCU may become stuck if you try to remove it while the front door is closed. 2. Open the front door. 3. Remove the toner bottle holder or THM. NOTE: If working on a toner-bottle model, clean away all spilled toner from the toner bottle area and from the inside of the front door. 4. Detach the connector [A] and pull out the PCU [B]. NOTE: 1) After installing the new PCU, be sure to remove the Styrofoam piece and to pull off the two tags. ( 1.1.2, Step 10) 2) The machine will automatically detect the new PCU and begin toner initialization. ( 6.10.4)
3-17
Replacement Adjustment
TONER SUPPLY CLUTCH
24 July, 2001
3.7 TONER SUPPLY CLUTCH
[C]
[B]
B046R932.WMF
1. Remove the toner bottle or THM. 2. Copy tray ( 3.3.3) 3. Rear cover ( 3.3.2) 4. Disconnect the connector on C19 on the FCU. 5. Reach into to the machine and push the clutch coupler [A] toward the rear, and at the same time reach around the back and remove the clip ring [B]. 6. Remove the cone and spring, then lift the toner supply clutch mechanism [C] out of its housing and remove it. NOTE: When removing, note how the wire goes through a clamp, and also note where it passes through the rear of the machine.
3-18
Replacement Adjustment
[A]
24 July, 2001
PAPER FEED SECTION
3.8 PAPER FEED SECTION
3.8.1 PAPER FEED ROLLER AND FRICTION PAD
1. Take out the paper tray. 2. Clip ring [A] 3. Pull the shaft back, and lift it out. 4. Remove either or both of the following: · Paper feed roller [B] · Friction pad [C] [A]
B046R702.WMF
[B]
3.8.2 PAPER END SENSOR
1. Take out the paper tray. 2. Open the right door. 3. PCU ( 3.5) 4. Paper end sensor [A] (" × 1) NOTE: When installing the new sensor, reach your left hand in through the front and your right hand in through the right side, and view from the right side.
B046R929.WMF
[A]
3-19
Replacement Adjustment
[C]
PAPER FEED SECTION
24 July, 2001
3.8.3 REGISTRATION SENSOR
[C]
[A]
B046R926.WMF
[B]
B046R927.WMF
1. Take out the paper tray. 2. Open the right door. 3. Black guide piece [A] 4. Registration sensor feeler [B] 5. Registration sensor [C] (" × 1)
3.8.4 BYPASS PAPER END SENSOR (B044 AND B046 ONLY)
1. Right door ( 3.3.9) 2. Detach the sensor compartment [A]. 3. Bypass paper end sensor [B] (" × 1)
[A]
B046R924.WMF
[B]
3-20
Replacement Adjustment
24 July, 2001
PAPER FEED SECTION
3.8.5 BYPASS FEED ROLLER (B044 AND B046 ONLY)
[B]
[B] [A] 1. Right door ( 3.3.9)
[A]
B046R938.WMF B046R930.WMF
[D]
[E]
[C]
2. Unscrew the feed roller frame [A] (! × 2) and rotate it about the feed roller shaft [B] so that it is upside down. 3. Detach the feed roller shaft [B] from the feed roller frame (unsnap the two snap pawls [C] and remove the spacer [D]). 4. Bypass feed roller [E]
3-21
Replacement Adjustment
PAPER FEED SECTION
24 July, 2001
3.8.6 BYPASS FEED CLUTCH (B044 AND B046 ONLY)
1. Rear cover ( 3.3.2) 2. Right door ( 3.3.9) 3. Detach the bypass feed clutch connector [A] from CN3 on the high-voltage power supply board. 4. Unscrew the bypass feed roller housing [B] (! × 2), and pull it out of the machine. NOTE: It is not necessary to remove or disconnect the bypass paper end sensor. 5. Bypass feed clutch [C] (# × 1)
B046R925.WMF
[A]
[B]
[C]
3.8.7 BYPASS FRICTION PAD (B