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DIGITAL PLAIN PAPER COPIER
DP1600/2000/2500
File No. 31100011 R0111216600-TTEC
Copyright 2000
TOSHIBA TEC CORPORATION
GENERAL PRECAUTIONS REGARDING THE INSTALLATION AND SERVICE FOR DP1600/2000/2500 SERIES
The installation and service should be done by a qualified service technician.
1. Transportation
· When transporting/installing the copier, employ two persons and be sure to use the positions as indicated below. The copier is fairly heavy and weighs approximately 50 kg (110 lb), therefore pay full attention when handling it.
4 portions
2. Installation
· · · · · · Be sure to use a dedicated outlet with AC 115 or 120V/15A (220V, 230V, 240V/10A) or more for its power source. The copier must be grounded for safety. Never ground it to a gas pipe or a water pipe. Select a suitable place for installation. Avoid excessive heat, high humidity, dust, vibration and direct sunlight. Also provide proper ventilation as the copier emits a slight amount of ozone. To insure adequate working space for the copying operation, keep a minimum clearance of 80 cm (32") on the left, 80 cm (32") on the right and 10 cm (4") in the rear. After having installed the copier, be sure to push the carrying handles into the copier.
3. Service of Machines
· · · · · · Basically, be sure to turn the main switch off and unplug the power cord during service. Be sure not to touch high-temperature sections such as the exposure lamp, the fuser unit, the damp heater and their periphery. Be sure not to touch high-voltage sections such as the chargers and the high-voltage transformer. Be sure not to touch rotating/operating sections such as gears, belts, pulleys, fans, etc. When servicing the machines with the main switch turned on, be sure not to touch live sections and rotating/operating sections. Avoid exposure to laser radiation. Use suitable measuring instruments and tools.
December 2000 © TOSHIBA TEC
1600/2000/2500 GENERAL PRECAUTIONS
·
Avoid exposure to laser radiation during servicing. Avoid direct exposure to beam. Do not insert tools, parts, etc. that are reflective into the path of the laser beam. Remove all watches, rings, bracelets, etc. that are reflective.
4. Main Service Parts for Safety
· The breaker, door switch, fuse, thermostat, thermofuse, thermistor, etc. are particularly important for safety. Be sure to handle/install them properly.
5. Cautionary Labels
· During servicing, be sure to check the rating plate and the cautionary labels such as "Unplug the power cord during service", "Hot area", "Laser warning label" etc. to see if there is any dirt on their surface and whether they are properly stuck to the copier.
6. Disposition of Consumable Parts/Packing Materials
· Regarding the recovery and disposal of the copier, supplies, consumable parts and packingm a terials, it is recommended to follow the relevant local regulations or rules.
7. When parts are disassembled, reassembly is basically the reverse of disassembly unless otherwise noted in this manual or other related documents. Be careful not to reassemble small parts such as screws, washers, pins, E-rings, toothed washers in the wrong places. 8. Basically, the machine should not be operated with any parts removed or disassembled. 9. Precautions Against Static Electricity
· The PC board must be stored in an anti-electrostatic bag and handled carefully using a wristband, because the ICs on it may become damaged due to static electricity. Caution: Before using the wrist band, pull out the power cord plug of the copier and make sure that there is no uninsulated charged objects in the vicinity. Caution: Dispose of used batteries and RAM-ICs including lithium batteries according to the manufacturer's instructions. Attention: Se débarrasser de batteries et RAM-ICs usés y compris les batteries en lithium selon les instructions du fabricant. Vorsicht: Entsorgung des gebrauchten Batterien und RAM-ICs (inklusive der Lithium-Batterie) nach Angaben des Herstellers.
1600/2000/2500 GENERAL PRECAUTIONS
December 2000 © TOSHIBA TEC
1.
SPECIFICATIONS · ACCESSORIES · OPTIONS · SUPPLIES ............................. 1-1
1.1 Specifications ............................................................................................ 1-1 1.2 Accessories .............................................................................................. 1-5 1.3 Options ..................................................................................................... 1-6 1.4 Replacement Units/Supplies ..................................................................... 1-6 1.5 System List ............................................................................................... 1-7
1. SPECIFICATIONS · ACCESSORIES · OPTIONS · SUPPLIES
1.1 Specifications
· Copy process ................ Indirect electrophotographic process (dry) · Type ............................... Desktop type (console type when the paper feed pedestal and Large capacity feeder are installed) · Original table ................. Fixed table (the left rear corner used for standard original placement) · Acceptable originals ...... Type: sheet, book, and 3-dimensional object. However, the automatic document feeder (option) only accepts sheets of paper (Multi-sheet: 50 - 105 g/m2, or 13 - 29 lb/Single-sheet: 105 - 127 g/m2, or 29 - 34 lb.), excluding carbon paper, pasted sheets and stapled sheets. Max size: A3/LD · Copy speed DP1600 series
Paper supply Paper size
(Copies/min.) PFP Upper Lower cassette cassette (with CM) 16 12 13 11 11 9 LCF Bypass feeding (SFB) No paper size Paper size designated designated 9 9 9 9 9 9 16 12 13 11 11 9
Upper PFU cassette 16 12 13 11 11 9 16 12 13 11 11 9
A4, LT A4-R LT-R B4 LG A3, LD
-
DP2000 series
Paper supply Paper size
(Copies/min.) PFP Upper Lower cassette cassette (with CM) 20 16 16 14 14 12 20 16 16 14 14 12 LCF Bypass feeding (SFB) No paper size Paper size designated designated 12 12 12 12 12 12 20 16 16 14 14 12
Upper PFU cassette 20 16 16 14 14 12 20 16 16 14 14 12
A4, LT A4-R LT-R B4 LG A3, LD
20 -
December 2000 © TOSHIBA TEC
1-1
1600/2000/2500 SPECIFICATIONS
DP2500 series
Paper supply Paper size
(Copies/min.) PFP Upper Lower cassette cassette (with CM) 24.6 19 20 16 16 14 24.6 19 20 16 16 14 LCF Bypass feeding (SFB) No paper size Paper size designated designated 14 14 14 14 14 14 24.6 19 20 16 16 14
Upper PFU cassette 24.6 19 20 16 16 14 24.6 19 20 16 16 14
A4, LT A4-R LT-R B4 LG A3, LD
24.6 -
* "-" shows "Cannot be used". * The copy speeds in the above table are available when originals are manually placed for singleside, multiple copying. · System copy speed Copy mode Single-sided originals Single-sided copies (Non sort) Single-sided originals Two-sided copies (Sort) Two-sided originals Single-sided copies (Sort) Two-sided originals Two-sided copies (Sort) 1 set 3 sets 5 sets 1 set 3 sets 5 sets 1 set 3 sets 5 sets 1 set 3 sets 5 sets (Copies/min.) DP1600/1600S DP2000/2000S DP2500/2500S series series series 12/12 15/15 15/15 14/14 17/17 19/19 15/15 18/18 21/21 4/5 5/6 5/6 6/8 7/10 8/11 6/9 8/12 8/13 6/6 7/7 7/7 10/10 12/12 14/14 12/12 14/14 17/17 4/5 5/6 5/6 6/8 7/11 8/11 6/10 8/12 9/13
* Copy speeds include the first copy time. They are available when the copy modes in the above table are selected and 10 LT-size originals are set in the automatic document feeder. · Copy paper Cassette Size Weight Special paper Duplexing Bypass copy A3 - A5-R, FOLIO LD - ST-R, COM Continuous copy: 64 - 80 g/m2, 17 - 21 lbs Single copy: 80 - 163 g/m2, 21 - 43 lbs Recommended OHP film/Thick paper Remarks
A3 - A5-R, FOLIO LD - ST-R, COM 64 - 80 g/m2 17 - 21 lbs -- --
1600/2000/2500 SPECIFICATIONS
1-2 02/04
December 2000 © TOSHIBA TEC
· First copy time ...................... DP1600 series: DP2000 series: DP2500 series:
Less than 7.9 seconds (A4/LT, the Upper cassette, 100%, original placed manually) Less than 7.0 seconds (A4/LT, the Upper cassette, 100%, original placed manually) Less than 7.0 seconds (A4/LT, the Upper cassette, 100%, original placed manually)
· Warming-up time .................. DP1600 series: DP2000 series: DP2500 series:
Less than 60 seconds Less than 75 seconds Less than 75 seconds
· Multiple copying .................... Up to 999 copies; entry by numeric keys · Reproduction ratio ................ Actual ratio: Zooming: 100% 50 - 200% in increments of 1% 25 - 400% in increments of 1% (for DP2000/2500 series; with original cover) · Resolution/Gradation ............ Read: Copy: Printer: Fax: · Paper feeding ....................... Automatic feeding: DP1600 series: 600 dpi x 600 dpi 600 dpi x 600 dpi 1200 dpi x 600 dpi 16 dot/mm x 15.4 dot/mm (406 dpi x 392 dpi) Copier's cassette 1 piece standard Expandable up to 3 pieces by installing optional cassettes. DP2000/2500 series: Expandable up to 4 pieces by installing optional cassettes. PFU-optional (Stack height 60.5 mm, Equivalent to 550 sheets; 64 to 80 g/m2 (17 to 21 lb.)) PFP-optional (Stack height 60.5 mm, Equivalent to 550 sheets; 64 to 80 g/m2 (17 to 21 lb.)) LCF-optional (Stack height 165 mm, Equivalent to 1250 x 2 sheets; 64 to 80 g/m2 (17 to 21 lb.)) Bypass feeding (Stack height 16 mm, Equivalent to 100 sheets; 64 to 80 g/m2 (17 to 21 lb.)) · Capacity of originals of automatic document feeder .. A4, A4-R, B5, B5-R, A5-R, LT, LT-R, ST-R: 50 sheets (with ADF) B4, Folio, LG, Comp, A3, LD: B4, Folio, LG, Comp, A3, LD: · Toner supplying .................... Automatic toner sensor detection · Density control ...................... Automatic density mode and manual density mode selectable in 7 steps 50 sheets (with ADF) 100 sheets (with RADF) A4, A4-R, B5, B5-R, A5-R, LT, LT-R, ST-R: 100 sheets (with RADF)
December 2000 © TOSHIBA TEC
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1600/2000/2500 SPECIFICATIONS
· Weight ................................ Standard:
50 Kg (110 lb.) (with Process unit/Toner cartridge) 124 Kg (273 lb.) (DP2000/2500 series)
Full system: 92 Kg (203 lb.) (DP1600 series)/
· Power requirements ............ 115VAC, 50Hz/60Hz 120VAC, 50Hz/60Hz 127VAC, 50Hz/60Hz 220-240VAC, 50Hz/60Hz · Power consumption ............ 1.4 KW or less · Dimensions: ....................... (W) x (D) x (H) mm DP1600 series Standard Standard + Original cover Standard + ADF Standard + RADF Standard + ADU + RADF Standard + Original cover + PFU Standard + Original cover + PFU + PFP Standard + Original cover + JSP Standard + Original cover + SFB Standard + Original cover + OCT Standard + Original cover + Stapler Standard + Original cover + Finisher 530 x 554 x 600 mm 530 x 554 x 643 mm 530 x 554 x 731 mm 545 x 599 x 772 mm 607 x 599 x 772 mm 530 x 554 x 757 mm 530 x 554 x 1039 mm 604 x 554 x 643 mm 801 x 554 x 643 mm 604 x 554 x 643 mm 787 x 554 x 676 mm ----DP2000/2500 series 530 x 554 x 600 mm 530 x 554 x 643 mm 530 x 554 x 731 mm 545 x 599 x 772 mm 607 x 599 x 772 mm 530 x 554 x 757 mm 530 x 554 x 1039 mm 604 x 554 x 643 mm 801 x 554 x 643 mm 604 x 554 x 643 mm 787 x 554 x 676 mm 957 x 554 x 643 mm
DP1600 series
03-3
03-4
1600/2000/2500 SPECIFICATIONS
1-4
December 2000 © TOSHIBA TEC
DP2000/2500 series
T-808
T-101-2
1.2 Accessories
Setup instructions Operator's manual Setup report Warranty sheet CS card Process unit Toner cartridge Operator's manual pocket Detouchable power cord * Machine version NAD: North America MJD: Europe AUD: Australia ASD: Asia SAD: Saudi Arabia TWD: Taiwan CND: China 1pc. 1pc. 1pc. (for NAD and MJD) 1pc. (for NAD) 1pc. (for MJD) 1pc. 1pc. 1pc. 1pc.
December 2000 © TOSHIBA TEC
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1600/2000/2500 SPECIFICATIONS
1.3 Options
Original cover Paper feed pedestal-1 (PFP) Automatic duplexing unit-1(ADU) Automatic document feeder (ADF) Reverse automatic document feeder-1 (RADF) Paper feed unit (PFU) Cassette module (CM) Large capacity feeder (LCF) Paper feed controller (PFC) Paper feed controller (PFC) Paper feed controller (PFC) Job separator (JSP) Offset tray Stack feed bypass (SFB) Printer kit (Printer control) Printer kit (Printer control) Memory kit Fax board kit Internet fax kit NIC kit (Network interface card) Staple with surface Finisher KA-1600PC, KA-1600PC-N KD-1009, KD-1009-N MD-0101, MD-0101-N MR-2012, MR-2012-N MR-3011 MY-1015, MY-1015-N MY-1017, MY-1017-N (for DP2000/2000S/2500/2500S series) KD-1010, KD-1010-N (for 2000/2000S/2500/2500S series) GH-1010, GH-1010-N (for DP1600 series) GH-1020, GH-1020-N (for DP1600/2000/2500 series) GH-1030, GH-1030-N (for DP1600S/2000S/2500S series) MJ-5001, MJ-5001-N MJ-5002, MJ-5002-N MY-1016, MY-1016-N GA-1030 (for DP1600 series) GA-1031 GC-1050, GC-1050-N GD-1060-EU, GD-1060-NA, GD-1060-AU, GD-1060-TW GD-1070 GF-1110 KK-1600 MJ-1011 (for DP2000/2000S/2500/2500S series)
1.4 Replacement Units/Supplies
(1) Replacement units FUSER-1600-120, FUSER-1600-240 (for DP1600/1600S series) FUSER-2500-120, FUSER-2500-240 (for DP2000/2000S/2500/2500S series) Transfer charger unit MAIN-CH-1600 (2) Process unit Process unit PU-1600N, PU-1600CA, PU-1600EN, PU-1600DN, PU-1600DNN, PU-1600CN (for DP1600/2000/2500 series) PU-1600S, PU-1600ES, PU-1600DS, PU-1600DSN, PU-1600CS (for DP1600S/2000S/2500S series) Fuser unit
(3) Supplies Toner cartridge T-1600, T-1600E, T-1600D, T-1600C (for DP1600/1600S series) T-2500, T-2500E, T-2500D, T-2500C (for DP2000/2000S/2500/2500S series)
1600/2000/2500 SPECIFICATIONS
1-6 02/03
December 2000 © TOSHIBA TEC
1.5 System List
Reverse automatic document feeder (RADF) MR-3011 Automatic document feeder (ADF) MR-2012, MR-2012-N Original cover KA-1600PC, KA-1600PC-N
Stapler with surface KK-1600 Finisher kit (Hanging type) MJ-1011 (for DP2000/2000S/2500/2500S series) Job separator (JSP) (Inner type) MJ-5001, MJ-5001-N
DP1600/2000/2500 series DP1600S/2000S/2500S Stack feed bypass series (SFB) MY-1016-N MY-1016, 1st cassette (Std.)
Paper feed controller (PFC) GH-1010, GH-1010-N (for DP1600 series) GH-1020, GH-1020-N (for DP1600/2000/2500 series) GH-1030, GH-1030-N (for DP1600S/2000S/2500S series)
Automatic duplexing unit (ADU) MD-0101, MD-0101-N
Offset tray (Inner type) MJ-5002, MJ-5002-N
Memory kit GC-1050, GC-1050-N
Printer kit (Printer control) GA-1030 (for DP1600 series) GA-1031
2nd cassette
Paper feed unit (PFU) MY-1015, MY-1015-N
Network interface card kit (NIC) GF-1110 Relay board NIC
3rd cassette
LCF (for DP2000/2000S/ 2500/2500S series) Paper size: A4/LT Large capacity feeder KD-1010, KD-1010-N
Fax board kit GD-1060-EU, GD-1060-NA GD-1060-AU, GD-1060-TW NCU Operation FAX board panel board
Paper feed pedestal (PFP) KD-1009, KD-1009-N
4th cassette
Cassette module (CM) MY-1017, MY-1017-N
(for DP2000/2000S/2500/2500S series)
Internet fax kit GD-1070
01-05-01
Fig. 1-5-1
December 2000 © TOSHIBA TEC
1-7 02/03
1600/2000/2500 SPECIFICATIONS
2.
OUTLINE OF THE MACHINE ................... 2-1
2.1 Sectional View .......................................................................................... 2-1 2.2 Location of Electrical Parts ....................................................................... 2-5 2.3 Symbols and Functions of Various Devices .............................................. 2-13 2.4 Copy Paper Path ....................................................................................... 2-18 2.4.1 2.4.2 2.4.3 2.4.4 Normal ......................................................................................... 2-18 When the PFU, PFP, ADU, SFB and OCT are mounted .............. 2-18 When the PFU, PFP, CM, ADU, SFB and JSP are mounted ........ 2-19 When the PFU, LCF, ADU, SFB and Finisher are mounted ......... 2-19
2.5 System Block Diagrams ............................................................................ 2-20 2.6 Removal and Reinstallation of Covers and PC Boards ............................. 2-21 2.6.1 2.6.2 Removal and reinstallation of covers............................................ 2-21 Removal of PC boards ................................................................. 2-29
2. OUTLINE OF THE MACHINE
2.1 Sectional View
[A] Front view
1 7 4 3 5 2
12
10
11
8
6
9 13 15 16 21 22 24 23 18 19 20 17 14
43
44
45
46 47
42
25 26 27 28 29
41
30 33
40
39
38
32
49
31
48
37 36 35
34
December 2000 © TOSHIBA TEC
2-1
1600/2000/2500 OUTLINE OF THE MACHINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
ADF glass Original glass Carriage 1 Carriage 2 Exposure lamp Reflecting mirror 1 Reflecting mirror 2 Reflecting mirror 3 CCD unit Scanner control PWA Shading sheet Wire F Exit cover Scraper Exit pinch roller Exit roller Fuser unit Separation claw Pressure roller Cleaning roller Heat roller Heater lamp Heater thermofuse Heater thermistor 1/2 Process unit Transfer charger Transfer guide roller Pinch roller Registration roller Feed roller Pickup roller Timing pulley Separate roller 2nd pinch roller 2nd feed roller Cassette slider Cassette catch Toner supply gear
39 40 41 42 43 44 45 46 47 48 49
Toner supply motor Paper cassette (STD) LSU stay Laser scanner unit Duct lower Ozone filter cover/Ozone filter Duct upper Duct front Toner cartridge Timing belt 194 Timing belt 124
1600/2000/2500 OUTLINE OF THE MACHINE
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December 2000 © TOSHIBA TEC
[B] Rear view
1 2 3 4 5
6
10 9 11 12 8 13 7 14 15 16 24 29 26 27 51 32 33 52 34 31 30 36 35 41 42 43 44 48 49 50 45 39 40 23 28 25 37 38 21 22 17 18 19 20
47 46
December 2000 © TOSHIBA TEC
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1600/2000/2500 OUTLINE OF THE MACHINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
Scanner drive gear Timing belt 157 Scanner motor pulley Timing belt 142 Scanner motor Wire R PS fan motor Exit drive gear 1 Exit drive gear 2 Exit drive gear 3 Exit drive gear 4 Exit drive gear 6 Exit drive gear 5 Exit drive gear 7 HR drive gear 1 HR drive gear 2 HR drive gear 3 Transmission gear 1 Transmission gear 2 Main drive gear 1 Main drive gear 2 Main drive gear 3 Main drive gear 4 Main drive gear 5 Main drive gear 6 Timing belt 176 Developer drive pulley Main motor Drum drive gear Transmission gear 3 Registration drive gear Registration roller clutch Cassette feed gear 1 Cassette feed gear 2 Timing belt 309 Pickup clutch Cassette feed gear 3 Cassette feed gear 4 Cassette feed gear 5
40 41 42 43 44 45 46 47 48 49 50 51 52
Cassette feed gear 6 Cassette feed gear 7 Cassette feed gear 8 2nd feed clutch Clutch pulley Tray-up motor Tray-up gear 1 Tray-up gear 2 Tray-up gear 3 Tray-up gear 4 Tray-up gear 5 Pinch roller gear (DP2000/2500 series) Registration wheel
1600/2000/2500 OUTLINE OF THE MACHINE
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December 2000 © TOSHIBA TEC
2.2 Location of Electrical Parts
(A-1) Boards
RLY
MAN
MEM-1 (Option)
MEM-2 (Option)
02-02-01
FUS (ASD/AUD/CND/TWD/SAD models) HVPS PIF
December 2000 © TOSHIBA TEC
2-5
1600/2000/2500 OUTLINE OF THE MACHINE
(A-2) Boards
CCD SLG INV LCD
PNL
VL
LDR
LVPS
02-02-02
PDV
1600/2000/2500 OUTLINE OF THE MACHINE
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December 2000 © TOSHIBA TEC
(B-1) Sensors, switches and clutches
*APS-3 *APS-2 *APS-1 (ASD/AUD/CND/TWD/SAD/MJD models) *APS-5 *APS-4 *APS-6 (NAD model)
SEN1
SEN2 SEN3
SEN4 SEN5 CL1
02-02-03
CL2
* : DP2000/2500 series
December 2000 © TOSHIBA TEC
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1600/2000/2500 OUTLINE OF THE MACHINE
(B-2) Switches
SW1
SW2
02-02-04
1600/2000/2500 OUTLINE OF THE MACHINE
2-8
December 2000 © TOSHIBA TEC
(B-3) Sensors, switches and clutches
SEN6
02-02-05
SEN7
SW3
CL3
December 2000 © TOSHIBA TEC
2-9
1600/2000/2500 OUTLINE OF THE MACHINE
(C-1) Motors
M1 M2
M3
M4
02-02-06
M5 M6 M7
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December 2000 © TOSHIBA TEC
(D-1) Thermofuse, thermistors and heaters
THM1
HL2 (ASD/AUD/CND/MJD models)
HL3 (ASD/AUD/CND/MJD models)
THM2
02-02-07
THM3 HL1 (NAD/TWD/SAD models)
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1600/2000/2500 OUTLINE OF THE MACHINE
(D-2) Sensors, switches, thermofuse, thermistors, lamps and heaters
*THM4
EXP
*DH1
DLE
SW5
SW6
02-02-08
SEN8
SW4 THM5
* : ASD/AUD/CND/TWD/SAD models
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December 2000 © TOSHIBA TEC
2.3 Symbols and Functions of Various Devices
(1) Boards Symbol MAN RLY PIF INV CCD SLG Main PWA PWA-F-RLY Relay PWA PWA-F-PIF PC I/F PWA INV-EXPO Inverter PWA PWA-F-CCD CCD PWA PWA-F-SLG Scanner control PWA LCD PNL VL LDR PDV MEM-1 MEM-2 LCD UNIT LCD PWA PWA-F-PNL-TO Operation panel PWA PWA-F-VR-TO LCD volume PWA PWA-LDR Laser drive PWA PWA-PDV Polygonal motor drive PWA PWA-F-MEM Optional memory PWA (GC-1050) 64 Mbyte expansion memory PWA. (Option) (A-1) PWA which drives the polygon motor. (A-2) Variable resistor PWA for adjusting the LCD display darkness. PWA which drives the laser. (A-2) (A-2) Key switch PWA (A-2) PWA which relays signals between PWA and I/O. PWA which locally connects the copier to a PC. PWA which controls exposure when scanning a document. PWA which controls the processing of CCD images. PWA which controls the scanning optical system and ADF (MR-2012)/RADF (MR-3011) (Option). LCD PWA (A-2) (A-2) (A-2) (A-2) (A-1) (A-1) Name PWA-F-MAN Function PWA which controls the entire system. Remarks (A-1)
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(2) Sensors Symbol APS-1 APS-2 APS-3 APS-4 APS-5 APS-1 APS-2 APS-3 APS-4 APS-5 APS (Automatic Paper Size detection) sensor APS-2 APS-3 APS-4 APS-5 APS-6 APS-2 APS-3 APS-4 APS-5 APS-6 APS (Automatic Paper Size detection) sensor SEN1 SEN2 SEN3 SEN4 SEN5 SEN6 SEN7 SEN8 HOME-SEN Home position sensor ORCOV-SEN Original cover sensor EXT-SEN Exit sensor FED-SEN Feed sensor OCF-SEN 2nd feed sensor PE-SEN Paper empty sensor T-UP-SEN Tray-up sensor TNRE-SEN Toner empty sensor Detects the toner density. (In Process unit) (D-2) Detects the open/close state of the original cover. Detects the transport of paper at the exit section. Detects the transport of paper at the developer. Detects the transport of paper from the option cassette. Detects the presence or absence of paper placed in the copier cassette. Detects the lift-up of the tray. (B-3) (B-3) (B-1) (B-1) (B-1) (B-1) Detects the first scanning position. (B-1) Detects the size of document. (DP2000/2500 series, NAD model) (B-1) Name Function Detects the size of document. (DP2000/2500 series, ASD/AUD/CND/TWD/SAD/MJD models) Remarks (B-1)
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December 2000 © TOSHIBA TEC
(3) Switches Symbol SW1 SW2 SW3 SW4 SW5 TC-SW Toner cartridge switch FRCOV-SW Front cover switch CST-SW Paper cassette switch MAIN-SW Main switch SIIL-SW Interlock switch (Side cover) SW6 FRIL-SW Interlock switch (Front cover) Detects the open/close state of the side cover when removing a jam at the transfer section, etc. and cuts off the +24V power supply. Detects the open/close state of the front cover when changing the toner cartridge, etc. and cuts off the +24V power supply. (D-2) (D-2) Detects the open/close state of the front cover. Detects the open/close state of the copier cassette. Power ON/OFF switch (D-2) (B-3) (B-2) Name Function Detects the presence of a toner cartridge. Remarks (B-2)
(4) Motors Symbol M1 M2 M3 SCN-MOT Scanner motor PU-FAN Process unit FAN motor POW-FAN Power supply unit FAN motor M4 M5 M6 M7 VCM-FAN Vacuum FAN motor MD-MOT Main motor TS-MOT Toner supply motor T-UP-MOT Tray-up motor Drives the auger in the toner cartridge and supplies toner to the process unit. Lifts up the tray of the copier cassette. (C-1) (C-1) Main drive motor to drive the entire system. (C-1) Sucks the developed paper from the drum. (C-1) Allows ozone to escape from the inside of the copier. Cools the inside of the copier. (C-1) (C-1) Name Function Performs scanning for the optical system. Remarks (C-1)
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1600/2000/2500 OUTLINE OF THE MACHINE
(5) Clutches Symbol CL1 CL2 CL3 Name RGST-CLT Registration roller clutch OCF-CLT 2nd feed roller clutch PU-CLT Pickup roller clutch Transmits power to the 2nd feed roller of the option cassette. Transmits power to the pickup roller and feed roller of the copier cassette. (B-3) (B-1) Function Transmits power to the registration roller. Remarks (B-1)
(6) Thermofuse and thermistors Symbol THM1 THM2 THM3 THM4 FUS-THM Heater thermofuse HEA1-THM Heater thermistor 1 HEA2-THM Heater thermistor 2 SCN-THM Scanner thermofuse THM5 DRM-THM Drum thermistor Name lamp. Detects the surface temperature of the heat roller. Detects the surface temperature of the heat roller end. Keeps the scanner damp heater at a fixed temperature. (ASD/AUD/CND/TWD/SAD models) Detects the surface temperature of the drum. (D-2) (D-2) (D-1) (D-1) Function Prevents abnormal overheat of the heater Remarks (D-1)
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December 2000 © TOSHIBA TEC
(7) Heaters and lamps Symbol EXP HL1 HL2 HL3 DH1 Name EXPO-LAMP Exposure lamp U900-HL Heater lamp U900 E400-HL Heater lamp E400 E500-HL Heater lamp E500 SCN-DH-100 Scanner dump heater SCN-DH-115 Scanner dump heater SCN-DH-230 Scanner dump heater DLE PWA-F-DLE Discharge LED PWA Dehumidifies the inside of the scanner. (TWD model) Dehumidifies the inside of the scanner. (SAD model) Dehumidifies the inside of the scanner. (ASD/AUD/CND models) Removes residual charge on the drum surface. (In Process unit) (D-2) (D-2) Fixes toner to the paper. (NAD/TWD/SAD models) Fixes toner to the paper. (ASD/AUD/CND/MJD models) (D-1) (D-1) (D-1) Function A light source lamp for document scanning. Remarks (D-2)
(8) Transformers Symbol HVPS PS-HVPS High voltage power supply unit Name Function PWA which generates high voltage power. Remarks (A-1)
(9) Others Symbol
LVPS
Name PS-LVPS-US PS-LVPS-EU
Function PWA which generates DC power. PWA which generates DC power. PWA which relays AC power to each damp heater. (ASD/AUD/CND/TWD/SAD models)
Remarks (A-2) (A-2) (A-1)
Switching power supply unit (NAD/TWD/SAD models) Switching power supply unit (ASD/AUD/CND/MJD models) FUS PWA-F-FUS Fuser relay PWA
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2.4 Copy Paper Path
2.4.1 Normal
02-04-02
2.4.2 When the PFU, PFP, ADU, SFB and OCT are mounted
Duplex print
02-04-03
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December 2000 © TOSHIBA TEC
2.4.3 When the PFU, PFP, CM, ADU, SFB and JSP are mounted
Duplex print
02-04-04
2.4.4 When the PFU, LCF, ADU, SFB and Finisher are mounted
Duplex print
02-04-05
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PWA-F-CCD
8
PWA-F-SLG
PWA-F-MAN
CCD
Amp
A/D Converter
Scanner control GA
LSU
EET 8 16 16 Sensors 16 16 16 16 Flash ROM 16Mbit x2 CODEC 16 Motors 16 CPU SDRAM 64Mbit x4
8
Exposure lamp SRAM 256Kbit Flash ROM 1Mbit/4Mbit
Inverter
Scanner motor 16 SDRAM 64Mbit x8 SRAM 256Kbit x2 8 I/O port GA-1 16 PTC GA Flash ROM 4Mbit 16
Motor control IC
Scanner MPU
PWA-F-MEM 1 (GC-1050/GC-1050-N)
PIX data bus
Sensors
SFB (MY-1016/MY-1016-N) Process unit ADU (MD-0101/MD-0101-N) PFU (MY-1015/MY-1015-N) PWA-F-RLY PS-HVPS PFP (KD-1009/KD-1009-N) PS-LVPS-US/EU
2.5 System Block Diagrams
1600/2000/2500 OUTLINE OF THE MACHINE
4 RTC 16 16 8 I/O port GA-2 SRAM 256Kbit x2
RADF (MR-3011)
SDRAM 64Mbit x8
PWA-F-MEM 2 (GC-1050/GC-1050-N)
8 16 Sub-MPU System control GA
System data bus
ADF (MR-2012/MR-2012-N)
CM (MY-1017/MY-1017-N) DP2000/2000S/ 2500/2500S series
2 - 20 02/05
16 16 16 A/D Converter 8 D/A Converter SDRAM 64Mbit
PC
PWA-F-PIF
PWA-F-PCL-AU1 (GA-1030) DP1600 series
(GA-1031)
PFC (GH-1010/GH-1010-N) DP1600 series (GH-1020/GH-1020-N) DP1600/2000/2500 series (GH-1030/GH-1030-N) DP1600S/2000S/2500S series
LCF (KD-1010/KD-1010-N) DP2000/2000S/ 2500/2500S series JSP (MJ-5001/MJ-5001-N) Coin vendor DP2000/2000S/2500/2500S series OCT (MJ-5002/MJ-5002-N)
PWA-F-MAN-AU1 (GD-1070)
Network
PWA-F-NIC-AU1 (GF-1110)
PWA-F-RLY-AU1 (GF-1110) PWA-F-FAX
16 CODEC 16 8
Finisher (MJ-1011) DP2000/2000S/2500/2500S series IPC
Bridge cover
SRAM 256kbit x2
Finisher
8
PWA-F-PNL-TO
Battery (NiMH) Memory backup circuit
PWA-F-OTK-TO
PC board
PSTN
V.34 MODEM
Option
PWA-F-NCU-US/EU
External telephone FAX kit (GD-1060-NA/TW/AU/EU)
02-04-01
December 2000 © TOSHIBA TEC
2.6 Removal and Reinstallation of Covers and PC Boards
2.6.1 Removal and reinstallation of covers [A] Rear cover 1. If a STP (KK-1600) is attached to the copier, disconnect the power cable. 2. Detach the manual pocket. 3. Remove all screws (17 or 9) and detach rear cover.
Screw Screw Rear cover
Fig. 2-6-1
001
Position of 9 screws
Fig. 2-6-1-1 [B] Top cover 1. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, detach it. 2. If a STP (KK-1600) is attached to the copier, disconnect the power cable. 3. Detach the manual pocket. 4. Remove 3 screws, release hook, and detach top cover.
Top cover
002
Screw
Hook
Fig. 2-6-2 [C] Scanner cover 1. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, open it. 2. Remove the cushion rubber at 3 places.
Cushion rubber
003-1
Fig. 2-6-3
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3. Remove 3 screws and detach scanner cover.
Scanner cover
Screw
003-2
Fig. 2-6-4 [D] Top cover L 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate. 2. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, detach it. 3. If a STP (KK-1600) is attached to the copier, disconnect the power cable. 4. Detach the manual pocket. 5. Detach top cover. (See Fig. 2-6-2) 6. Remove 2 screws, release 2 tabs, and detach top cover L by lifting in the direction of the arrow. [E] Top cover R 1. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, detach it. 2. If a STP (KK-1600) is attached to the copier, detach it. 3. Detach the manual pocket. 4. Detach top cover. (See Fig. 2-6-2) 5. Remove 3 screws, release 2 tabs, and detach top cover R by lifting in the direction of the arrow. Fig. 2-6-6
Screw
005
Tab
Top cover L Tab
Screw
004
Fig. 2-6-5
Top cover R Tab
Tab
Screw
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December 2000 © TOSHIBA TEC
[F] Control panel front cover 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate. 2. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, open it. 3. Detach scanner cover. (See Fig. 2-6-3 and 2-6-4)
006-1
4. Remove one screw, release one tab, and detach control panel front cover. [G] Control panel bottom cover 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate. 2. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, open it. 3. Detach scanner cover. (See Fig. 2-6-3 and 2-6-4) 4. Detach control panel front cover. (See Fig. 2-6-7) 5. Remove 2 screws, release one tab, and detach control panel bottom cover. [H] Control panel 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate. 2. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, open it. 3. Detach scanner cover. (See Fig. 2-6-3 and 2-6-4) 4. Detach control panel front cover. (See Fig. 2-6-7) 5. Detach control panel bottom cover. (See Fig. 2-6-8) 6. Remove one screw and detach the ground wire. 7. Detach control panel harness. 8. Remove 2 screws at the lower part of control panel, release 2 hooks, and remove control panel. Note: When attaching the control panel, secure it with the clamp to prevent the core from dropping.
December 2000 © TOSHIBA TEC 2 - 23 01/05
Screw
Control panel front cover
Fig. 2-6-7
Screw
Control panel bottom cover
006-2
Screw
Fig. 2-6-8
Control panel Screw Ground wire Screw Screw
Core
007
Clamp
Control panel harness
Fig. 2-6-9
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[I] Ozone filter/ozone cover 1. If a JSP (MJ-5001) or OCT (MJ-5002) is attached to the copier, detach the tray. 2. Lift ozone cover off while holding both sides. 3. Detach ozone filter.
Ozone filter
Ozone cover
Ozone cover
008
Fig. 2-6-10 [J] Paper tray cover 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate and junction block. 2. If a JSP (MJ-5001) or OCT (MJ-5002) is attached to the copier, detach it. 3. Detach the toner cartridge. 4. Detach ozone cover. (See Fig. 2-6-10) 5. Remove 3 screws, release 2 tabs, and detach power switch cover. 6. Detach paper tray cover. [K] Paper cassette 1. Draw out paper cassette and lift it off in the direction of the arrow.
Screw Power switch cover
009
Paper tray cover
Fig. 2-6-11
Paper cassette
Fig. 2-6-12 [L] Left cover 1. If a Finisher (MJ-1011) is attached to the copier, detach it. 2. Remove 3 screws holding the paper tray cover. (See Fig. 2-6-11) 3. Take out the paper cassette. 4. Remove 4 screws and detach left cover.
Screw Paper cassette Left cover
010
011
Fig. 2-6-13
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December 2000 © TOSHIBA TEC
[M] Left cover R 1. If a Finisher (MJ-1011) is attached to the copier, detach it. 2. Remove 3 screws holding the paper tray cover. (See Fig. 2-6-11) 3. Detach left cover. (See Fig. 2-6-13) 4. Remove one screw holding the top cover L. 5. Remove 3 screws, release one hook, and detach left cover R. [N-1] Right cover R 1. If an ADU (MD-0101) and/or SFB (MY-1016) are attached to the copier, detach it. 2. Pull release lever and open side cover. 3. Remove 3 screws and detach right cover R.
Screw
Screw Left cover R
Top cover L
Hook
012
Fig. 2-6-14
Right cover R
Screw
Screw Side cover
013
Fig. 2-6-15 [N-2] Upper right cover R/Lower right cover R In case that an ADU and SFB are not attached or a SFB is attached. 1. Open side cover. 2. Remove 2 screws and detach upper right cover R. 3. If a SFB (MY-1016) is attached to the copier, detach it. 4. Remove 2 screws and detach lower right cover R.
Side cover Lower right cover R Upper right cover R
Screw
Screw
In case that an ADU is attached or an ADU and SFB are attached. 1. Open an ADU (MD-0101) and release the wire. 2. Open side cover. 3. Remove 2 screws and detach upper right cover R. 4. Detach an ADU (MD-0101) from the copier. 5. If a SFB (MY-1016) is attached to the copier, detach it. 6. Remove 2 screws and detach lower right cover R.
Fig.2-6-15-1
013-3
December 2000 © TOSHIBA TEC
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[O] Side cover assembly 1-1. If an ADU (MD-0101) and/or SFB (MY-1016) are attached to the copier, detach it. 1-2. Open ADU (MD-0101) if it is attached. 2-1. Detach right cover R. (See Fig.2-6-15) 2-2. Detach upper right cover R. (See Fig.2-6-151) 3. Detach one connector and release the clamp.
Connector Side cover
014
Clamp
Fig. 2-6-16 4. Remove 2 screws securing stopper and guide pin, then detach paper guide B, spring and side cover assembly.
Guide pin Screw Paper guide B Guide pin Spring
Stopper Side cover assembly Stopper Screw
015
Fig. 2-6-17 [P] Right cover 1. If an ADU (MD-0101) and/or SFB (MY-1016) are attached to the copier, detach it. 2. Detach right cover R. (See Fig. 2-6-15) 3. Remove 2 screws, release 2 hooks, and detach right cover.
Hook Right cover Screw
016
Fig. 2-6-18
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December 2000 © TOSHIBA TEC
[Q] Front frame cover F/R 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate and junction block. 2. If a JSP (MJ-5001) or OCT (MJ-5002) is attached to the copier, detach it. 3. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, open it. 4. If an ADU (MD-0101) is attached to the copier, open it. 5. Detach scanner cover. (See Fig. 2-6-3 and 2-6-4) 6. Detach control panel front cover. (See Fig. 2-6-7) 7. Detach control panel bottom cover. (See Fig. 2-6-8) 8. Open side cover. 9. Open exit cover. 10. Remove one screw, release 4 hooks, and detach front frame cover F and front frame cover R.
Hook Screw Front frame cover R Side cover Exit cover
Fig. 2-6-19
017
Hook
Front frame cover F
018
Fig. 2-6-20 [R] Exit cover 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate and junction block. 2. If a JSP (MJ-5001) or OCT (MJ-5002) is attached to the copier, detach it. 3. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, open it. 4. If an ADU (MD-0101) is attached to the copier,
019
Stop ring
Exit cover
open it. 5. Detach scanner cover. (See Fig. 2-6-3 and 2-6-4) 6. Detach control panel front cover. (See Fig. 2-6-7) 7. Detach control panel bottom cover. (See Fig. 2-6-8) 8. Detach front frame covers F and R. (See Fig. 2-6-19 and 2-6-20) 9. Remove stop ring and detach exit cover.
Fig. 2-6-21
December 2000 © TOSHIBA TEC
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[S] Inner cover 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate and junction block. 2. If a JSP (MJ-5001) or OCT (MJ-5002) is attached to the copier, detach it. 3. Remove one screw holding the top cover L. 4. Remove 2 screws holding the left cover R. 5. Detach ozone cover. (See Fig. 2-6-10) 6. Detach paper tray cover. (See Fig. 2-6-11) 7. Open side cover. (See Fig. 2-6-19) 8. Open exit cover. (See Fig. 2-6-19) 9. Remove one screw, release 4 hooks, and detach inner cover. [T] Front cover 1. Open front cover, release one hook, and detach front cover.
Top cover L Left cover R Screw Inner cover
Screw
Inner cover
Screw
020
Fig. 2-6-22
Hook
Front cover
021
Fig. 2-6-23 [U] Main cover 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate and junction block. 2. If a JSP (MJ-5001) or OCT (MJ-5002) is attached to the copier, detach it. 3. If an Original Cover (KA-1600PC), ADF (MR-2012), or the RADF (MR-3011) is attached to the copier, open it. 4. Detach the toner cartridge. 5. Detach scanner cover. (See Fig. 2-6-3 and 2-6-4) 6. Detach control panel front cover. (See Fig. 2-6-7) 7. Detach control panel bottom cover. (See Fig. 2-6-8) 8. Detach ozone cover. (See Fig. 2-6-10) 9. Detach paper tray cover. (See Fig. 2-6-11) 10. Detach front frame cover F and front frame cover R. (See Fig. 2-6-19 and 2-6-20) 11. Detach front cover. (See Fig. 2-6-23) 12. Remove 4 screws, release 2 hooks, and detach main cover.
Main cover Screw
022
Screw
Screw
Fig. 2-6-24
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December 2000 © TOSHIBA TEC
2.6.2 Removal of PC boards [A] MAIN PWA Before removing the MAIN PWA, print the FUNCTION LIST for setup after MAIN PWA replacement. If it is unable to print it, use the FUNCTION LIST on the inside of the rear cover. 1. If a STP (KK-1600) is attached to the copier, disconnect the power cable. 2. Detach the manual pocket. 3. Detach rear cover. (See Fig. 2-6-1) 4. If a FAX kit (GD-1600-NA/TW/EU/AU) is attached to the copier, detach the FAX PWA and NCU PWA. 5. If a PCL kit (GA-1030/GA-1031) or Memory (GC-1050) is attached to the copier, detach it. 6. If a NIC kit (GF-1110) or I-FAX (GD-1070) is attached to the copier, unplug the connectors for CN14 and CN17. 7. If finisher (MJ-1011) is attached to the copier, detach the finisher PWA. 8. Detach the connectors from MAIN PWA (CN4/CN8/CN9/CN18). 9. Remove 4 screws and remove MAIN PWA (CN15) from RELAY PWA (CN21). (for DP1600) 10. Remove 4 screws and then release the clamp, to remove MAIN PWA (CN15) from RELAY PWA (CN21). (for DP2000/2500) [CAUTION] There is a danger of a component explosion, if the 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. Important: After the replacement of the MAIN PWA, set the copier according to the following procedures. Fig. 2-6-25-1
023-1
CN9
Battery
DP1600
CN8 MAIN PWA
CN4 CN18 Screw
023
Fig. 2-6-25
CN8
CN9
Battery
DP2000/2500
Screw CN4 CN18
Screw
Clamp
Screw
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Settings after the replacement of the MAIN PWA 1. Downloading of the MAIN PWA firmware For details, see chapter 5 of the Service Handbook. 2. Execution of 08-388 mode. (Reading of the total counter value) 0 8 3 8 8 SET or START Power OFF
Power ON
3. RAM Clear with the [1], [3], and [*] keys. 1 3 * Power ON Warming up Power OFF
4. Execution of 08-665 mode (05: adjustment clear/08: programming clear) 0 8 6 6 5 SET or START Power OFF
Power ON
5. RAM Clear with the [1], [3], and [#] keys. 1 3 # Power ON Warming up Power OFF
6. Download the scanner PWA firmware, if necessary, after confirming the version of it. 7. Settings for the country code or region code Without Fax kit Setting the country or region code for the CND and TWD. CND: 8 6 , TWD: 8 8 6 With Fax kit See the 1.2.6 of the Service Handbook (GD-1060). 8. Settings for the date and time For details, see chapter 5 of the Operator's Manual. SETTING PROGRAM 0 3 0 1 DD-MM-YYYY DAY 15-11-2000 WED HH:MM 10:10PM
LT: 0 2 A4: 4 Power ON
1 4
SET or START
INITIAL SETUP
DATE & TIME
9. Writing in memory (entering the drum counter value (DRUM COUNTER), long size counter value (A3/ LD) and short size counter value (A4/LT)). For the setting value, refer to the DRUM UNIT LIST printed before replacing the MAIN PWA. When the DRUM UNIT LIST is not printed, perform the following setting. Drum counter value: Find a remainder by dividing the total counter value (08-351) by the process unit life value (27k or 33k). Enter the value obtained by multiplying the remainder by 10. Long size counter value: Enter "0." Short size counter value: Enter the remainder obtained by dividing the total counter value (08-351) by the process unit life value (27k or 33k). For the setting procedures, refer to section 1.2.5 of the Service Handbook.
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10. Entering the adjustment value for the printing position. Enter the setting value for the following 21 items. For the setting values, refer to the FUNCTION LIST printed before replacing the MAIN PWA, or the FUNCTION LIST on the inside of the rear cover of the copier. When the FUNCTION LIST is not printed in 08-404/401/251/252, perform the following setting. 08-404: Enter the remainder obtained by dividing the total counter value (08-351) by the process unit life value (27k or 33k). 08-401: Find a remainder by dividing the total counter value (08-351) by the process life unit value (27k or 33k). Enter the value obtained by multiplying the remainder by 4.7 (for DP1600/2000 series) or 4.5 (for DP2500 series). 08-251: When it was set before the MAIN PWA was replaced, perform the setting again. 08-252: Enter the remainder obtained by dividing the total counter value (08-351) by the PM life value (81k or 99k). When 08-251 is "0," however, it is not necessary to enter the 08-252 value. For the setting procedures, refer to sections 1.2.1 and 1.2.2 of the Service Handbook. 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 05-205 (Developer bias DC adjustment) 05-210 (Grid voltage initial value adjustment) 05-220 Transfer H 05-221 Transfer C 05-233 Separation H 05-234 Separation C 05-235 Separation L 05-400 (Printer primary scanning reproduction ratio) 05-410 (Laser start position) 05-421 (Printer secondary scanning reproduction ratio) 05-440 (Leading edge) 05-430 (Top margin) 05-431 (Left margin) 05-432 (Right margin) 05-433 (Bottom margin) 08-404 (Developer material counter) 08-401 (Drum life counter) 08-251 (PM counter setting value) 08-252 (PM counter present value) 08-446 Transfer ON position 08-447 Transfer OFF position
11. Sensor test in the [1] [3] test mode. 1: 2: Confirm whether the attached options are reflected on the bit information correctly. Refer to 1.2.4 of the Service Handbook.
12. SRAM test/DRAM test/Clock IC test/CODEC test mode. For details, see chapter 8 of the Operator's Manual.
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[B] RELAY PWA 1. If a STP (KK-1600) is attached to the copier, disconnect the power cable. 2. Detach the manual pocket. 3. Detach rear cover. (See Fig. 2-6-1) 4. If a FAX kit (GD-1600-NA/TW/EU/AU) is attached to the copier, detach the FAX PWA and NCU PWA. 5. If a PCL kit (GA-1030/GA-1031) or Memory (GC-1050) is attached to the copier, detach it. 6. If a NIC kit (GF-1110) or I-FAX (GD-1070) is attached to the copier, unplug the connectors for CN14 and CN17. 7. If finisher (MJ-1011) is attached to the copier, detach the finisher PWA. 8. Remove MAIN PWA. (See Fig. 2-6-25 and 2-6-25-1) 9. Detach all the connectors from RELAY PWA. 10. Remove 4 screws and remove RELAY PWA. [C] PC I/F PWA 1. If a STP (KK-1600) is attached to the copier, disconnect the power cable. 2. Detach the manual pocket. 3. Detach rear cover. (See Fig. 2-6-1) 4. Remove one screw, detach PC I/F PWA cover, and detach the connector. 5. Remove 2 screws and remove PC I/F PWA.
Screw PC I/F PWA RELAY PWA
RELAY PWA
Screw
024
Fig. 2-6-26
PC I/F PWA
CN2 Screw
025
PC I/F PWA cover
Fig. 2-6-27
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December 2000 © TOSHIBA TEC
[D] High voltage power supply 1. If a STP (KK-1600) is attached to the copier, disconnect the power cable. 2. Detach the manual pocket. 3. Detach rear cover. (See Fig. 2-6-1) 4. If a PCL kit (GA-1030/GA-1031) is attached to the copier, detach it. 5. If a NIC kit (GF-1110) or I-FAX (GD-1070) is attached to the copier, unplug the connectors for CN14 and CN17. 6. Remove 2 screws, release 2 clamps, and detach HVPS cover. 7. Detach all the connectors, remove 4 screws, then remove high voltage power supply.
Screw High voltage power supply Clamp Clamp
Screw
HVPS cover
026-1
Fig. 2-6-28
High voltage power supply
Screw
026-2
Fig. 2-6-29
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[E] LVPS 1. If a Finisher (MJ-1011) is attached to the copier, detach the finisher plate and junction block. 2. If a JSP (MJ-5001) or OCT (MJ-5002) is attached to the copier, detach it. 3. Detach the toner cartridge. 4. Detach ozone cover. (See Fig. 2-6-10) 5. Detach paper tray cover. (See Fig. 2-6-11) 6. Loosen 5 screws. 7. Remove one screw and detach LVPS cover. 8. Detach all the connectors and release one clamps. 9. Remove 3 screws and remove LVPS.
LVPS LVPS cover
027-1
Screw Screw
Fig. 2-6-30
Screw
Clamp LVPS Screw
027-2
Fig. 2-6-31
Main power switch White Blue
Note: With the CND model, pay attention to the color of the connectors when connecting the power cables. When attaching the main power switch, make sure that the reset switch connector is in the lower side. (CND model)
CND model
Yellow LVPS
Red Reset switch Connector
Screw Clamp LVPS Screw
Fig. 2-6-31-1
027-2-3
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[F] FUS PWA (TWD/SAD/ASD/AUD/CND models) 1. If a STP (KK-1600) is attached to the copier, disconnect the power cable. 2. Detach the manual pocket. 3. Detach rear cover. (See Fig. 2-6-1) 4. Remove one screw and detach FUS PWA cover. (SAD/ASD/AUD/CND models)
SAD/ASD/AUD/CND models
FUS PWA cover
Screw
028-1
Fig. 2-6-32 5. Remove 5 screws to detach PFC PWA cover and FUS PWA cover (TWD model). TWD model
FUS PWA cover
PFC PWA cover
028-4
Fig. 2-6-32-1
6. Detach all the connectors from FUS PWA. 7. Release 4 locking supports and remove FUS PWA.
CN110 CN111
Locking support
FUS PWA
028-2
Fig. 2-6-33
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3.
COPYING PROCESS ............................... 3-1
3.1 Copying Process ....................................................................................... 3-1 3.2 Details of Copying Process ....................................................................... 3-2 3.3 List of Copying Process Conditions .......................................................... 3-9 3.4 Disassembly and Replacement ................................................................ 3-10
01/11
3. COPYING PROCESS
3.1 Copying Process
Image processing
3
Scanning CCD
600DPI (7450 pixels)
2
Orignal exposur Xenon lamp
14 W : 1900 V rms for DP1600 series 1250 V rms for DP2000/2500 series
9
Fixing Paper exit Heat roller 100V: 900W x 1 200V: 400W x 1 500W x 1
10 11
Discharger LED array Wavelength 660 nm x 15
Cleaning
Separation H : -4.3 KV C : -4.1 KV L : -3.9 KV Transfer H : 5.5 KV C : 5.2 KV
8
1
Charger Charger
-674 V DC -637 V DC for DP2000/2500 for DP1600 series series
4
Printing
Semiconductor laser Pw = 3.5 nJ/mm 2
7 6
Guide bias +375 V DC
Toner Carrier Development
5
Magnetic roller
Bias -430 V DC Bias -460 V DC +150 V DC +150 V DC for DP2000/2500 series for DP1600 series
Sheet feed bypass (100 sheets : Option)
Paper cassette (550 sheets) Paper feed unit (550 sheets : Option) Large capacity feeder (1250 x 2 sheets : Option) for DP2000/2500 series Paper feed pedestal (550 sheets : Option)
Cassette module (550 sheets : Option) for DP2000/2500 series
03001
Fig. 3-1-1
Charging: Negatively charges the surface of the photosensitive drum. Original exposure: Images are converted to optical signals. Scanning: Image optical signals are converted to electrical signals. Printing: Image electrical signals are converted to optical signals (for laser emission) and exposed on the photosensitive drum. Development: toner adheres to the surface of the photosensitive drum and forms a visible image.
Transfer bias: Increases transfer efficiency. Transfer: Transfers the visible image from the drum onto the transfer (copy) sheet. Separation: Separates the transfer sheet, along with the toner, from the drum Fixing: Fixes the toner on the transfer sheet by applying heat and pressure. Cleaning: Mechanically removes any remaining toner on the drum. Discharger LED array: Discharges any remaining charge from the drum.
December 2000 © TOSHIBA TEC
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3.2 Details of Copying Process
(1) Photosensitive Drum The photosensitive drum has two layers, an outer and an inner layer. The outer layer is a photoconductive layer that uses an organic photoconductive carrier (OPC), and the inner layer is an aluminum, conductive cylindrical drum. The resistance held by the drum material changes (increases, decreases) according to the strength of the light incident to the photoconductive carrier. (Example) · When incident light is strong, the resistance decreases (photosensitive drum becomes a carrier). · When incident light is weak, the resistance increases (photosensitive drum becomes an insulator). [Formation of Electrostatic Latent Image] The minus potential on the drum surface corresponding to black areas of the original are removed by the charging, scanning, printing and discharging processes (described later), and the minus potential remains on areas corresponding to white areas of the original. The image on the drum resulting from this minus potential is called a "latent image" as it cannot be seen directly by the human eye. (2) Charging "Charging" is the process of uniformly applying a charge to the surface of the photosensitive drum. The minus corona discharge of the charger wire is controlled by the grid to charge the drum surface to a uniform minus potential. The drum surface potential is determined by the potential of the grid, and the grid is determined by the grid control circuit inside the transformer.
Transformer Grid control circuit
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Photoconductive layer Base
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Fig. 3-2-1 Structure of the photosensitive drum
Time (t)
0
Surface potential (V)
Black area of original
500
White area of original
1000
Discharge process Charging process
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Fig. 3-2-2 Electric potential of the photosensitive drum
Main charger
Rotation of drum
Fig. 3-2-3
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(3) Scanning: "Scanning" is the process of directing light at the original, and converting light reflected from the original to electrical signals. Light reflected from the original is picked up by a CCD (charged coupled device), the image information held by that light is converted to electrical signals (image signals), and the image signals are sent to the image processor.
Image processor Scanner control PC board CCD board
03005
Fig. 3-2-4
(Example) Light intensity at the CCD photodetector Light
Value of signals to be output 255 Contrast (differences in light and dark) is divided into 256 steps.
Dark
0
Fig. 3-2-5 (4) Printing "Printing" is the process of converting the image signals sent from the image processor to optical signals, and exposing these optical signals on photosensitive drum. Image signals from the image processor are converted to optical signals, and these optical signals are exposed by a semiconductor laser to form a static latent image on the photosensitive drum.
Photosensitive drum
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Image processor
Printing controll block
Polygonal mirror
Semiconductor laser
Fig. 3-2-6
December 2000 © TOSHIBA TEC
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(5) Development · "Developing" is the process of converting the electrostatic latent image to an image visible to the human eye.
Drum
Sleeve roller
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Fig. 3-2-7 The developing agent is fed to the surface of the photosensitive drum by the magnetic rollers, and impressed on the rollers. Toner in the developer agent attaches to areas on the photosensitive drum having a potential lower than the developer bias (reverse developing method).
Magnet Carrier (Always attracted on to the magnet)
When the potential of the photosensitive drum is higher than the developer bias:
White background
Intermediate tones
Black solid
Sleeve
White background
600V 460V or 430V 300V
Image is not developed by bias potential. Image is developed by toner.
Bias voltage
Toner Bias voltage -460V or -430V
When the potential of the photosensitive drum is lower than the developer bias:
200V
100V
0
03009 03009-a
Fig. 3-2-8
Fig. 3-2-9
· Switching of developing bias polarity Fogging is reduced by switching the bias of negative (approx. +150V).
Magnetite (40 ~ 65%) Ferrite
voltage charged areas to positive
polarity
· About Developing Agent Toner and carrier are mixed. The toner is charged to minus polarity, and the carrier is charged to plus polarity by friction caused by stirring. Toner: Comprises plastic and Magnetite. Fig. 3-2-10 Carrier: Ferrite
Resin (35 ~ 60 %) [Toner] [Carrier] 5 ~ 20 µm Approx. 60 µm
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·
Magnetic roller
- Magnetic brush development The South and North poles are arranged, as shown in the figure on the right inside the magnetic roller. The developer material contacts the drum forming a brush. This is caused by the lines of magnetic force between the South and North poles.
Sleeve
03012
Drum Lines of magnetic force
N
S
Magnet
Fig. 3-2-11
(6) Transfer · This process transfers the (visible) image developed on the drum surface by the toner onto the paper. · Method: Corona discharge (reverse polarity of toner) is caused by the transfer charger to happen to paper
03013
S
Drum
Paper
Transfer charger
passing between the drum and the transfer charger. Fig. 3-2-12
Progress of paper Transfer charger
The toner moves from the drum surface onto the paper.
Rotation of drum
Toner
03014
Fig. 3-2-13 * For smooth transfer, this machine features a transfer bias stage. The transfer bias process prevents the charge of the transfer charger from flowing to the paper feed pinch roller and paper transfer guide plate through the paper by applying the bias voltage (375V DC) to the paper feed pinch roller and paper transfer guide plate. This is done to improve transfer efficiency. Normally, the corona discharge is applied by a voltage of 5.2 kV DC. However, to improve transferability at the leading edge of the paper, a higher output (5.5 kV DC) is applied to the leading edge of the paper.
December 2000 © TOSHIBA TEC
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(7) Separation · At the transfer process, the sheet of paper becomes temporarily attached to the drum due to static electricity. The separation process separates the paper from the drum. · Method: A negative DC bias is applied to
Rotation of drum Separation chager
the separation charger.
Progress of paper
03015
The negative charge on the paper is decreased.
Fig. 3-2-14 The electrostatic attraction between the paper and the drum weakens.
The paper is separated from the drum by its own weight. * Output is controlled as follows to obtain satisfactory separability and transferability. Position of Paper in Relation to Transfer Point Leading edge Trailing edge Separation Output -4.3 KV DC -3.9 KV DC
Reference · Combined use of separation charger and separation claw. To prevent the copy paper from failing to be separated during the operation, due to incomplete transfer charging, incomplete separation charging, or absorption of moisture, and thus jamming up the cleaner, a separation claw mechanically separates any copy paper which fails to be separated.
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Separation claw
Paper movement
Rotation of drum
Separation chager
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December 2000 © TOSHIBA TEC
(8) Fixing The toner on the paper is melted by applying heat and fixed on the paper. Method: Melting point of the toner (main component: resin) is 100°C - 110°C.
Heat roller Pressure
(Heat)
A heat roller with a surface temperature melts the toner.
Paper
03017
Fig. 3-2-15 plus (Pressure) + A pressure roller pressured by a spring solidifies the toner.
Separation claw Heat roller
(Fixing)
Heat and pressure are applied to the paper going through the two rollers. The toner on the paper becomes fixed.
Heater lamp
(Pressure)
Direction of paper movement
Pressure roller
03018
Fig. 3-2-16
(9) Cleaning This process collects any toner remaining on the drum. Method: The edge of a urethane rubber blade (main blade) is placed
Rotation of drum
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Main blade
Recovery blade
against the drum surface.
This blade scrapes off the remaining toner from the drum.
Fig. 3-2-17
Another blade collects the scraped toner (recovery blade).
The drum surface is cleaned.
December 2000 © TOSHIBA TEC
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(10) Discharge Erases any electric charge remaining on the drum after transfer. If discharge is not performed:
Drum Discharge LED array
The electric charge remains on the drum surface.
The potential of the drum surface becomes uneven at charging for the next copy.
03020
Fig. 3-2-18
The copy image is doubled (the previous image remains). Method: Discharge LED array illuminates the entire drum surface.
The drum becomes a conductor.
Since the drum is grounded, the electric charge escapes.
The drum is ready for the next copy.
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3.3 List of Copying Process Conditions
Process 1. Drum (1) Sensitivity (2) Surface potential 2. Main charger 3. Exposure (1) Light control (2) Light source 4. Development (1) Developer roller (2) Auto-toner (3) Toner replenishment (4) Toner-empty detection (5) Toner (6) Developing material (7) Developer bias With magnetic roller inside Toner end sensor Toner cartridge system Toner end sensor T-1600 D-1600 -430 V DC, output adjustable (at printing) +150 V DC fix (others) 5. Transfer bias 6. Transfer 7. Separation 8. Discharge (1) Discharging position (2) Discharge lamp 9. Cleaning (1) System (2) Recovered toner Blade system Non-reusable Discharge by exposure after cleaning Discharge by red LED Adjustment not needed Adjustable output (constant current) using the digital keys Adjustable output (constant current) using the digital keys -460 V DC, output adjustable (at printing) +150 V DC fix (others) T-2500 Automatic exposure and manual 7-step LCD setting Laser scan (adjustment not needed) OPC ř30 Highly sensitized, high copy volume drum -637 V DC -674 V DC Scolotron system (constant current) Variable grid output (constant voltage) DP1600 DP2000/2500
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3.4 Disassembly and Replacement
When disassembling the process unit, pay special attention not to damage the drum and magnetic roller. Also, be careful not to be injured by the edges of the parts. [A] Separation claw 1. Remove the toner cartridge and the process unit. 2. Lift the shutter and detach the separation claw. Note: Be careful not to be injured by the edges of the separation claw and star wheel.
Shutter
Spring
Separation claw
Fig. 3-4-1 [B] Main charger wire/ Main charger grid 1. Remove the toner cartridge and the process unit. 2. Remove 4 screws and detach the drum assembly.
Drum assembly
3-4-01
Screw Screw
Fig. 3-4-2 3. Remove 2 screws and detach the DLE PWA assembly.
3-4-02
Screw
DLE PWA assembly
Screw
Fig. 3-4-3
3-4-03
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4. Detach the main charger assembly. Note: Be sure not to touch the grid part of the main charger grid.
2 1
Fig. 3-4-4 5. Release 4 hooks and detach the main charger grid.
Main charger grid Main charger assembly
3-4-04
Hook Hook
Fig. 3-4-5 6. Pull out the main charger wire bracket and remove the main charger wire located in front side from the spring. 7. Remove the main charger wire located in rear side from the hook.
Spring Main charger wire bracket Main charger wire
3-4-05
Hook
Fig. 3-4-6 Notes: 1. Be sure to attach the main charger wire through the space between the main charger cleaning pads. (See Fig. 3-4-7.) 2. Do not touch the main charger wire with your fingers. 3. Clean the inside of the main charger assembly if toner is stuck.
Main charger wire cleaning pad Main charger wire Main charger wire cleaning pad
3-4-06
Fig. 3-4-7
3-4-07
December 2000 © TOSHIBA TEC
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[C] Drum 1. Remove the toner cartridge and the process unit. 2. Detach the separation claw. (See Fig. 3-4-1.) 3. Detach the drum assembly. (See Fig. 3-4-2.) 4. Remove 2 screws and detach the drum bracket. 5. Detach the drum. Note: When the drum is replaced with a new one, apply patting powder (lubricant) on the entire surface of the new drum (including both edges to where the OPC is not coated).
3-8-08
Drum
Screw Drum bracket
Fig. 3-4-8
[D] Drum cleaning blade 1. Remove the toner cartridge and the process unit. 2. Detach the separation claw. (See Fig. 3-4-1.) 3. Detach the drum assembly. (See Fig. 3-4-2.) 4. Detach the DLE PWA assembly. (See Fig. 3-43.) 5. Detach the main charger assembly. (See Fig. 3-4-4.) 6. Detach the drum. (See Fig. 3-4-8.) 7. Pull out 2 pins and detach the drum cleaning blade. Note: Be sure not to touch the contact part of the drum cleaning blade and drum. Fig. 3-4-9
3-8-09
Pin
Drum cleaning blade
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December 2000 © TOSHIBA TEC
[E] Recovery sheet 1. Remove the toner cartridge and the process unit. 2. Detach the separation claw. (See Fig. 3-4-1.) 3. Detach the drum assembly. (See Fig. 3-4-2.) 4. Detach the drum. (See Fig. 3-4-8.) 5. Peel off the recovery sheet.
3-4-10
Recovery sheet
Fig. 3-4-10 Notes: 1. Before attaching the recovery sheet, wipe the surface to be attached. 2. Attach the recovery sheet in the position described in right. Attach the recovery sheet securely with no portion lifted and no wrinkles appeared.
Recovery sheet
Reference position
Fig. 3-4-11 [F] Cover sheet A/ Cover sheet B 1. Remove the toner cartridge and the process unit. 2. Detach the drum assembly. (See Fig. 3-4-2.) 3. Peel off the cover sheet B from the developer assembly.
Cover sheet B
3-4-11
Developer assembly
Fig. 3-4-12 Notes: 1. Before attaching the cover sheet B, wipe the surface to be attached. 2. Attach the cover sheet B by putting it against the reference position described in right. Attach the cover sheet B securely with no portion lifted and no wrinkles appeared.
Cover sheet B Reference position Reference position
3-4-12
Fig. 3-4-13
3-4-13
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4. Peel off the cover sheet A from the developer assembly.
Cover sheet A
Developer assembly
Fig. 3-4-14 Notes: 1. Before attaching the cover sheet A, wipe the surface to be attached. 2. Attach the recovery sheet A in the position described in right. Attach the cover sheet A securely with no portion lifted and no wrinkles appeared.
Reference position Reference position
3-4-14
Cover sheet A
3-4-15
Fig. 3-4-15
Screw
[G] Developer material 1. Remove the toner cartridge and the process unit. 2. Detach the drum assembly. (See Fig. 3-4-2.) 3. Remove 2 screws and detach the developer cover.
Screw
Developer cover
Developer assembly
Fig. 3-4-16 4. Turn the developer assembly up side down and detach the old developer material.
Developer assembly
3-4-16
Fig. 3-4-17
3-4-17
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5. Clean the developer materials remaining on the surface of the magnetic roller inside of the developer assembly by a vacuum cleaner. Notes: 1. Be careful not to damage the surface of the magnetic roller. 2. Be careful so that the vacuum cleaner does not touch the toner empty sensor. 3. Be careful not to damage the mylar for stirring. 6. Fill with new developer material. 7. Shake the developer assembly from right to left several times to flatten the developer material. 8. Rotate the gear several times until the developer is supplied to the magnetic roller.
Magnetic