R

DC-1460

SERVICE MANUAL
Published in Apr. 98 19570762 Revision 2

DC-1460 S/M (MCA)

DC-1460

CAUTION: DOUBLE-POLE / NEUTRAL FUSING

Service Manual

DC-1460

Safety precautions

This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.

Safety warnings and precautions

Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below:

DANGER:

High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.

WARNING: Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol. CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect compliance with warning messages using this symbol.

Symbols The triangle ( ) symbol indicates a warning including danger and caution. The specific point of attention is shown inside the symbol. General warning.

Warning of risk of electric shock.

Warning of high temperature. indicates a prohibited action. The specific prohibition is shown inside the symbol. General prohibited action.

Disassembly prohibited.

indicates that action is required. The specific action required is shown inside the symbol. General action required.

Remove the power plug from the wall outlet.

Always ground the copier.

1. Installation Precautions
WARNING Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current. ............................................................... Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or electric shock. Connecting the earth wire to an object not approved for the purpose may cause explosion or electric shock. Never connect the ground cable to any of the following: gas pipes, lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the proper authorities. ........................

CAUTION: Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. ........................................................................... Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ..................................................................................... Do not install the copier near a radiator, heater, other heat source or near flammable material. This may cause fire. ....................................... Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ...............................

 Always handle the machine by the correct locations when moving it. .... Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may cause the copier to move unexpectedly or topple, leading to injury. .......................................................................... Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical attention. .................................................................................... Advice customers that they must always follow the safety warnings and precautions in the copiers instruction handbook. ...................................

2. Precautions for Maintenance

WARNING Always remove the power plug from the wall outlet before starting machine disassembly. ............................................................................ Always follow the procedures for maintenance described in the service manual and other related brochures. ...................................................... Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits. .............................

Always use parts having the correct specifications. ............................... Always use the thermostat or thermal fuse specified in the service manual or other related brochure when replacing them. Using a piece of wire, for example, could lead to fire or other serious accident. ........... When the service manual or other serious brochure specifies a distance or gap for installation of a part, always use the correct scale and measure carefully. ........................................................................... Always check that the copier is correctly connected to an outlet with a ground connection. .................................................................................

 Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it is dirty, clean it to remove the risk of fire or electric shock. ......................................................................................... Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may damage eyesight. .............................................. Handle the charger sections with care. They are charged to high potentials and may cause electric shock if handled improperly. .............

CAUTION Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are safely secured so they will not be caught in rotating sections. ..................................................................................... Use utmost caution when working on a powered machine. Keep away from chains and belts. ............................................................................. Handle the fixing section with care to avoid burns as it can be extremely hot. ......................................................................................... Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause abnormally high temperatures. ......................... Do not remove the ozone filter, if any, from the copier except for routine replacement. ............................................................................... Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself. .............. Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a cable cover or other appropriate item. ........ Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks. ............................................................................

Remove toner completely from electronic components. ......................... Run wire harnesses carefully so that wires will not be trapped or damaged. ................................................................................................

 After maintenance, always check that all the parts, screws, connectors and wires that were removed, have been refitted correctly. Special attention should be paid to any forgotten connector, trapped wire and missing screws. ...................................................................................... Check that all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling. Replace with new ones if necessary. ...................................................... Handle greases and solvents with care by following the instructions below: ..................................................................................................... Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely. Ventilate the room well while using grease or solvents. Allow applied solvents to evaporate completely before refitting the covers or turning the main switch on. Always wash hands afterwards. Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to fire in a furnace, etc. ......................... Should smoke be seen coming from the copier, remove the power plug from the wall outlet immediately. ..................................................

3. Miscellaneous
WARNING Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than the specified refiner; it may generate toxic gas. .........................................................................................................

195-1 195

CONTENTS
I THEORY AND CONSTRUCTION SECTION
1-1 Specifications 1-1-1 Specifications ................................................................................... 1-2 Handling Precautions 1-2-1 Drum ................................................................................................. 1-2-2 Developer and toner ......................................................................... 1-3 Mechanical Construction 1-3-1 Part names and their functions ......................................................... 1-3-2 Machine cross section ...................................................................... 1-3-3 Drive system ..................................................................................... 1-3-4 Mechanical construction ................................................................... 1-1-1 1-2-1 1-2-1 1-3-1 1-3-3 1-3-4 1-3-5

II ELECTRICAL SECTION
2-1 Electrical Parts Layout 2-1-1 Electrical parts layout ....................................................................... 2-2 Detection of Paper Misfeeds 2-2-1 Paper misfeed detection ................................................................... 2-2-2 Paper misfeed detection conditions ................................................. 2-3 Operation of the PCB 2-3-1 Power source PCB ........................................................................... 2-3-2 Main PCB ......................................................................................... 2-3-3 AVR PCB .......................................................................................... 2-3-4 Operation unit PCB .......................................................................... 2-1-1 2-2-1 2-2-2 2-3-1 2-3-2 2-3-3 2-3-4

III SET UP AND ADJUSTMENT SECTION

3-1 Installation 3-1-1 Unpacking and installation ............................................................... 3-1-1 3-1-2 Setting initial copy modes ............................................................... 3-1-10 3-1-3 Installing the dehumidifier heater (optional, 120 V specifications only) ............................................................... 3-1-11 3-1-4 Installing the flicker resistor (optional, 240 V/50 Hz specifications only) ......................................................................... 3-1-13 3-2 Simulation 3-2-1 Simulations ....................................................................................... 3-2-1 3-3 Assembly and Disassembly 3-3-1 Precautions for assembly and disassembly ..................................... 3-3-1 3-3-2 Paper feed section ........................................................................... 3-3-2 3-3-3 Main charging section .................................................................... 3-3-13 3-3-4 Exposure section ............................................................................ 3-3-16 3-3-5 Drum section (metric specification only) ......................................... 3-3-50 3-3-6 Developing section (metric specification only) ............................... 3-3-53 3-3-7 Transfer section .............................................................................. 3-3-55 3-3-8 Cleaning section (metric specification only) ................................... 3-3-59 3-3-9 Fixing section ................................................................................. 3-3-62

195-1 3-4 PCB Initial Setting 3-4-1 Replacing the main PCB .................................................................. 3-4-1 3-4-2 Adjustment-free variable resistors (VR) ........................................... 3-4-3 3-5 Self-diagnostics 3-5-1 Self diagnostic function .................................................................... 3-5-1 3-6 Troubleshooting 3-6-1 Image formation problems ................................................................ 3-6-1 3-6-2 Paper misfeed ................................................................................ 3-6-15 3-6-3 PCB terminal voltages .................................................................... 3-6-17 3-6-4 Electrical problems ......................................................................... 3-6-25 3-6-5 Mechanical problems ..................................................................... 3-6-31 3-7 Appendixes Timing chart No. 1 ...................................................................................... 3-7-1 Timing chart No. 2 ...................................................................................... 3-7-2 Timing chart No. 3 ...................................................................................... 3-7-3 Power source PCB ..................................................................................... 3-7-4 AVR PCB .................................................................................................... 3-7-5 Operation unit PCB ..................................................................................... 3-7-6 Main PCB ................................................................................................... 3-7-7 Connection diagram ................................................................................... 3-7-8 Wiring diagram ........................................................................................... 3-7-9

THEORY AND CONSTRUCTION SECTION

DC-1460 S/M (MCA)

I Theory and Construction Section

195

1-1 Specifications
1-1-1 Specifications .................................................................................... 1-1-1

195

1-1-1 Specifications
Type ......................................... Desktop Copying system ....................... Dry, indirect electrostatic system Originals ................................... Sheets, books and 3-dimensional objects Maximum size: Folio/81/2" 14" Original feed system ................ Fixed Copy paper .............................. Plain paper: 80 g/m2 (metric), 75 g/m 2 (inch) for drawer feed 60 - 120 g/m2 (metric), 75 g/m 2 (inch) for bypass feed Special paper: OHP film, letterhead and colored paper Note: Use the bypass for special paper. Copying sizes ........................... Maximum: Folio/81/ 2" 14" Minimum: A6R/51/ 2" 81/ 2" Magnification ratios .................. 70 - 141%, 1% increments Fixed ratios: Metric 1:1 6 1.0%, 1:1.410, 1:0.700 Inch 1:1 6 1.0%, 1:1.290, 1:0.780 Copy speeds ............................ At 100% magnification: A4R/8 1/ 2" 11": 14 copies/min. A5R/5 1/ 2" 8 1/ 2": 14 copies/min. Folio/81/2" 14": 12 copies/min. First copy time .......................... 5.8 s or less (A4R/8 1/ 2" 11", 100% magnification, manual exposure) Warm-up time .......................... 30 s or less (room temperature 20 C/68 F, 65%RH) Paper feed system ................... Automatic feed from the paper drawer Capacity: 250 sheets of 80 g/m 2 (metric) or 75 g/m2 (inch) Manual feed from the bypass section 1 sheet at a time Multiple copying ....................... 1 - 99 copies Photoconductor ........................ OPC (drum diameter 30 mm) Charging system ...................... Single positive corona charging V (drum potential: 820 V +100 50 V DC) Exposure system ..................... Slit exposure Lens ......................................... Fixed-focal lens, f: 190 mm, F: 7.2 Light source ............................. Halogen lamp, 230 W Developing system ................... Dry, magnetic brush Developer: 2-component, ferrite carrier and N27 T black toner Toner density control: toner sensor Toner replenishing: automatic from a toner cartridge Transfer system ....................... Single positive corona charging, +4.8 kV DC (reference) Separation system ................... Curvature separation

1-1-1

195 Fixing system ........................... Heat roller Heat source: halogen heater (910 W with 120 V supply, 1040 W with 240 V supply) Control temperature: 175 C/347F (at normal ambient temperature) Abnormally high temperature protection devices: 135 C/275 F and 140C/284F thermostats Fixing pressure: 94 N Charge erasing system ............ Exposure by cleaning lamp Cleaning system ...................... Cleaning blade Functions ................................. ( 1 ) Self-diagnostics ( 2 ) Simulation ( 3 ) Auto clear (30 - 270 s, in intervals of 30 s) ( 4 ) Auto start ( 5 ) Auto shutoff (15 - 240 min., in intervals of 15 min.) ( 6 ) Auto preheat/energy saving (5 - 45 min., in intervals of 5 min.) ( 7 ) Exposure adjustment ( 8 ) Auto exposure ( 9 ) Photo mode (10) Manual magnification selection (11) Fixed magnification (12) User exposure control (13) Paper empty detection (14) Toner empty detection (15) Paper jam detection (16) Copy number setting (17) Total counter Power source ........................... 120 V AC, 60 Hz, max. 10.2 A 220 - 240 V AC, 50/60 Hz, 2.4 A (average) Rated power consumption ....... 1361 W (220 - 240 V) 1195 W (120 V) Dimensions .............................. 515 (W) 465 (D) 320 (H) mm 201/ 4" (W) 185/ 16" (D) 12 5/ 8" (H) Weight ...................................... Approx. 22 kg/48.5 lbs Floor requirements ................... 515 (W) 465 (D) mm 201/ 4" (W) 185/ 16" (D) Accessories .............................. Copy tray

1-1-2

195

1-2 Handling Precautions

1-2-1 Drum ................................................................................................. 1-2-1 1-2-2 Developer and toner .......................................................................... 1-2-1

195

1-2-1 Drum
Note the following when handling or storing the drum. When removing the drum unit, never expose the drum surface to strong direct light. Keep the drum at an ambient temperature between 20 C/4 F and 40C/104F and at a relative humidity not higher than 85% RH. Avoid abrupt changes in temperature and humidity. Avoid exposure to any substance which is harmful to or may affect the quality of the drum. Do not touch the drum surface with any object. Should it be touched by hands or stained with oil, clean it. If the machine is left open for more than 5 minutes for maintenance, remove the drum and store it in the drum storage bag (Part No. 78369020).

1-2-2 Developer and toner

Store the developer and toner in a cool, dark place. Avoid direct light, high humidity and temperature.

1-2-1

195

1-3 Mechanical Construction

1-3-1 1-3-2 1-3-3 1-3-4 Part names and their functions ......................................................... 1-3-1 Machine cross section ....................................................................... 1-3-3 Drive system ..................................................................................... 1-3-4 Mechanical construction .................................................................... 1-3-5 ( 1 ) Paper feed section .................................................................... 1-3-5 (1-1) Paper feed from the paper drawer .................................... 1-3-7 (1-2) Paper feed from the bypass slot ....................................... 1-3-8 ( 2 ) Main charging section ............................................................... 1-3-9 ( 3 ) Exposure section ..................................................................... 1-3-12 ( 4 ) Developing section .................................................................. 1-3-18 ( 5 ) Transfer and separation section .............................................. 1-3-26 ( 6 ) Cleaning section ...................................................................... 1-3-29 ( 7 ) Charge erasing section ........................................................... 1-3-30 ( 8 ) Fixing and eject section ........................................................... 1-3-32

E A E

E A E

195

1-3-1 Part names and their functions

1 2 ( ) & * 0 ! @ ( # $

^ % 4 5 6 8 7 9
Figure 1-3-1

1 2 3 4 5 6 7 8

Original holder Contact glass Original size indicator Operation panel Drum unit Developing unit Developing unit release lever Toner cartridge

9 0 ! @ # $ % ^

Front cover Paper drawer Main switch Grips Width guide Length guide Copy tray Auxiliary tray

& * ( )

Bypass section Insertion guides Release unit Release unit button Eject section cover

1-3-1
E A E A A E 195 S/M(1-3-1) E A A E

E A E

E A E

195

Metric

!@

& %

1 2 3 4 5 6 7 8 9 0 ! @ # $ % ^ &

# 9

8 7

Print key Copy start indicator Stop/clear key Quantity/zoom-up key Quantity/zoom-down key Copy quantity/magnification display Zoom input/enter key Zoom copy indicator Copy size key Fixed magnification indicators Add toner indicator Maintenance indicator (metric) Replace unit indicator (inch) Exposure adjustment keys Exposure indicators Exposure mode key Auto exposure indicator Photo original indicator

Inch

! @

& %

# 9

8 7

Figure 1-3-2 Operation panel

1-3-2
E A E A E A 195 S/M(1-3-1) E A A E

195

1-3-2 Machine cross section 6 7

8 4 5 1 2

Figure 1-3-3 Machine cross section 1 2 3 4 Paper feed section (page 1-3-5) Main charging section (page 1-3-9) Exposure section (page 1-3-12) Developing section (page 1-3-18) 5 Transfer and separation section (page 1-3-26) 6 Cleaning section (page 1-3-29) 7 Charge erasing section (page 1-3-30) 8 Fixing and eject section (page 1-3-32)

1-3-3

195

1-3-3 Drive system

2 7

5 4

) % ( *& ^

8 9 0 ! @ # $

As viewed from machine rear

Figure 1-3-4 Drive system 1 Scanner wire 2 Scanner wire pulley 3 Mirror motor gear 4 Scanner drive gear B 5 Scanner wire drum B 6 Scanner motor gear 7 Scanner drive gear 64 8 Scanner wire drum A 9 Eject roller gear 0 Idle gear 20 ! Fixing gear 32 @ Gear 27/38 # Gear 41/56 $ Gear 30/35 % Gear 28 ^ Gear 33 & * ( ) Feed gear 16 Gear 35 Paper feed clutch gear Registration gear 14 Gear 20/43 Drive motor gear Gear 26/54 Drum drive gear Gear 38/43 Developing drive gear Gear 30 Toner cartridge drive gear Toner cartridge drive gear Toner cartridge idle gear Toner cartridge idle gear Toner feed motor gear

1-3-4

195

1-3-4 Mechanical construction

( 1 ) Paper feed section

0 ! % 9 6 @ $ 8 7 # 4

53 2

Figure 1-3-5 Paper feed section 1 2 3 4 5 6 7 8 Drawer bottom plate Drawer spring Front and rear drawer claws Paper feed pulleys A and B Feed roller guide Feed roller Bypass guide Feed pulley 9 0 ! @ # $ % Right registration roller Left registration roller Upper pre-transfer guide Pre-transfer guide Paper feed clutch (PFCL) Registration switch (RSW) Registration clutch (RCL)

1-3-5

195 The paper feed section consists of the primary feed and secondary feed subsections. Primary feed conveys paper from the paper drawer or the bypass slot to the right and left registration rollers, at which point secondary paper feed takes place and the paper travels to the transfer section in sync with the exposure timing.

CN7-7 RCL

CN7-6 CN7-5 RSW

PFCL

MPCB

Figure 1-3-6 Paper feed section block diagram

1-3-6

195 (1-1) Paper feed from the paper drawer The paper drawer consists of the drawer bottom plate, drawer springs and other components and can hold up to 250 sheets of copy paper. Paper is fed out of the drawer by the rotation of paper feed pulleys A and B.
Print key

RSW

HPSW

SM 200 ms PFCL 600 ms RCL 246 P *1 330 ms

AB

Auto exposure mode, A4R/81/2" 14" copy paper, magnification ratio 100% *1 Varies depending on the setting by simulation 58.

Timing chart 1-3-1 Paper feed from the paper drawer A 200 ms after the print key has been pressed, the paper feed clutch (PFCL) turns on for 600 ms, rotating paper feed pulleys A and B to perform primary feed. Then the paper is fed to the right and left registration rollers by the rotation of the feed roller. B The leading edge of the paper turns the registration switch (RSW) on. C 246 pulses after the scanner has started scanning, the registration clutch (RCL) turns on and the right registration roller conveys the paper to start secondary feed. D 330 ms after the trailing edge of the paper has turned the registration switch (RSW) off, the registration clutch (RCL) turns off to complete secondary paper feed.

1-3-7

195 (1-2) Paper feed from the bypass slot The bypass slot can hold one sheet of paper at one time. Copying starts when the paper turns the registration switch (RSW) on and the paper is conveyed to the secondary paper feed section by the feed roller.
Copying start RSW HPSW FWD REV 330 ms RCL 200 ms DM 246 P *1 SM

Manual exposure mode, A4R/81/2" 14" copy paper, magnification ratio 70% *1 Varies depending on the setting by simulation 58.

Timing chart 1-3-2 Paper feed from the bypass slot A 200 ms after the leading edge of the paper has turned the registration switch (RSW) on, the drive motor (DM) turns on and the feed roller feeds the paper to start primary paper feed where the paper is fed to the right and left registration rollers. B 246 pulses after the scanner motor (SM) has started rotating forward, the registration clutch (RCL) turns on and the right registration roller conveys the paper to start secondary paper feed. C 330 ms after the trailing edge of the paper has turned the registration switch (RSW) off, the registration clutch (RCL) turns off to complete secondary paper feed.

1-3-8

195 ( 2 ) Main charging section The main charging section consists of the drum and main charger. The drum is electrically charged uniformly by means of a grid to form a latent image on the surface.

Tungsten wire Main charger

Main charger grid

Figure 1-3-7 Main charging section

1-3-9

195

3 4

Figure 1-3-8 Main charger 1 2 3 4 5 Main charger rear lid Charger spring Charger wire Main charger front lid Charger wire retainer pin

CN8-7 CN8-5 CN8-4

24 V DC DB REM HV REM

CN1-1 CN1-3 CN1-4 MC

CN8-3 CN8-2

PHOTO REM HV ALM

CN1-5 CN1-6

Grid Drum

MPCB

HVTPCB

Figure 1-3-9 Main charging section block diagram

1-3-10

195

Print key

SM 200 ms DM 50 ms HV REM

FWD

REV

384 ms

AB

Manual exposure mode, A4R/81/2" 14" copy paper, paper feed from the paper drawer

Timing chart 1-3-3 Main charging A 200 ms after the print key has been pressed, the drive motor (DM) starts to rotate. B 50 ms after the drive motor (DM) has started to rotate, main charging (HV REM) starts. C 384 ms after the scanner motor (SM) has stopped rotating forward, main charging (HV REM) ends.

1-3-11

195 ( 3 ) Exposure section

&

87@ # 9

3 2!

0 41 5 6 )

^( % *

Figure 1-3-10 Exposure section 1 2 3 4 5 6 7 8 Mirror 1 Mirror 2 Mirror 3 Mirror 4 Mirror 5 Mirror 6 Halogen lamp (HL) Optical section thermostat (TH3) 9 Lens 0 Light source unit 1 ! @ # $ % ^ & * ( ) Light source unit 2 Main reflector Auxiliary reflector Scanner motor (SM) Optical section fan motor (OPFM) AE sensor (AES) Home position switch (HPSW) Lens home position switch (LHPSW) Mirror home position switch (MHPSW) Dust filter

1-3-12

195 This copier employs a slit exposure system with a fixed original table, and a halogen lamp (HL) as the light source. The optical section consists of light source units 1 and 2. Light source unit 1 carries the halogen lamp and the main and auxiliary reflectors. Each unit travels from one side of the machine to the other along scanner rails at machine front and rear. When an enlargement or a reduction ratio is selected, the scanning speeds of the two light source units and the positions of the lens and mirrors 2 and 3 are changed, altering the distance between the original and the drum. A cooling fan is installed to exhaust heat generated by the halogen lamp. If an abnormally high temperature is detected around light source unit 1, the optical section thermostat (TH3) shuts off the supply to the halogen lamp.
Original

AVRPCB HPSW AES HL TH3 CN2-1 CN2-3 SM LM MM LHP SW MHP SW CN4-5 CN7-10 HL CONT CN11-1 CN11-5 CN11-6 CN11-10 CN9-1 CN9-5 CN10-2 CN12-5 CN12-9 MPCB

Figure 1-3-11 Exposure section block diagram

CN12-3

1-3-13

195

Prescan start

Print key 200 ms HPSW 5P 910 P SM 350 ms FWD 100 ms REV 2358 P 55 ms FWD 65 ms REV 5P

HL

D E

Scanner return start

Scan start

Auto exposure mode, A4R/81/2" 14" original

Timing chart 1-3-4 Scanner travel A 200 ms after the print key has been pressed, the halogen lamp (HL) lights at the intensity for prescan. B 350 ms after the halogen lamp (HL) has turned on, the scanner motor (SM) rotates forward for prescan. C After rotating forward for 910 pulses, the scanner motor (SM) pauses for 100 ms. It then reverses to return the scanner to the home position. D 5 pulses after the home position switch (HPSW) has been turned on, the scanner motor (SM) turns off and the scanner stops. E 55 ms after the scanner motor (SM) has turned off, it rotates forward again for scanning. F After rotating forward for 2358 pulses, the scanner motor (SM) pauses. At the same time, the halogen lamp (HL) turns off. 65 ms later, the scanner motor (SM) reverses to return the scanner to the home position. G 5 pulses after the home position switch (HPSW) has been turned on, the scanner motor (SM) turns off and the scanner stops.

1-3-14

195 Exposure control for manual exposure and photo modes The halogen lamp light intensity for manual exposure and photo modes is calculated from the data obtained by running simulation 24. The number of exposure steps depends on the setting in simulation 96-1: 7 or 13 steps when set to NORMAL MODE and 19 or 25 steps when set to SPECIAL AREA. The exposure scale is wider for SPECIAL AREA than for NORMAL MODE.
Light intensity value

6 5 4 3 2 1 1 2 3 4 5 6 7 +1 +2 +3 +4 +5 +6 19 steps 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 +1 +2 +3 +4 +5 +6 25 steps Exposure scale (Exp.) : Exposure width for NORMAL MODE (7 or 13 steps)

Figure 1-3-12 Exposure gradient setting for SPECIAL AREA Exposure control for manual exposure mode The gradient is determined from the halogen lamp intensity values for Exp. 1, Exp. 4 or 7 and Exp. +2 set in simulation 24. The exposure control between Exp. +2 and Exp. +6 is based on the gradient of the light intensity value between Exp. 4 or 7 and Exp. +2. The gradient of the light intensity value between Exp. 6 and Exp. 1 is 2 per step. Exposure control for photo mode The exposure for photo mode is controlled by setting the drum potential below that for manual exposure mode.

1-3-15

195 Exposure control for auto exposure mode In auto exposure mode, the halogen lamp lights at the intensity set by simulation 28-1 to perform prescan. The exposure level to copy that particular original is determined by using the value read in by the AE sensor.
AE detection (prescan) Exposure Scanner movement 148 mm Original Original leading edge 100 mm Detection width Original leading edge

Figure 1-3-13 AE sensor detection width

Halogen lamp voltage

Manual-mode Exp. +2

Manual-mode Exp. 4 or 7

NPTC

NTC AE sensor read-in value

Figure 1-3-14 Exposure control for auto exposure mode The halogen lamp voltage is controlled so that the lamp lights at the intensity for manual-mode Exp. 4 or 7 when the AE sensor read-in value is the NTC level and at the intensity for manual-mode Exp. +2 when the read-in value is the NPTC level when setting auto exposure values in simulation 28-2 and -3. For read-in values below the NPTC level of simulation 28-3, the halogen lamp voltage is kept at a constant level so that the halogen lamp lights at the intensity for manual-mode Exp. +2. For read-in values above the NTC level of simulation 28-2, the halogen lamp voltage is kept at a constant level so that the halogen lamp lights at the intensity for manual-mode Exp. 4 or 7.

1-3-16

195 Light intensity correction for enlargement and reduction modes The halogen lamp light intensity for enlargement and reduction modes is determined by the value for copying at 100% magnification and the correction values set by simulation 29.
Light intensity correction value

Sim. 29-1 (141%) Sim. 29-2 (70%)

70

100

141

Magnification ratio (%)

Figure 1-3-15 Correction of light intensity for enlargement and reduction modes The correction values set by simulation 29 for reduction (70%) and enlargement (141%) copying are linked by a straight line through the value for 100% magnification, and the light intensity is corrected for individual magnification ratios according to the gradients. The gradients vary depending on the setting values in simulation 29. The prescan light intensity for enlargement and reduction copying is increased by 0.1 as the magnification ratio changes by 1%. For copying at 70% the prescan light intensity is the 100% level plus 3; for 141%, the 100% level plus 4.1.

1-3-17

195 ( 4 ) Developing section The developing section consists of the developing unit and toner cartridge.

Toner cartridge

Developing unit

Figure 1-3-16 Developing section The developing unit consists of the developing roller where a magnetic brush is formed, doctor blade and the developing spirals that agitate the developer. Toner in the toner cartridge is mixed with residual toner recovered from the cleaning section, and the mixture is conveyed to the developing unit.

1-3-18

195

Cleaning spiral Toner cartridge spiral

Toner cartridge paddle

Toner cartridge

Developing unit Toner flow Toner recycling spiral

Figure 1-3-17 Toner recycling

1-3-19

195 Formation of the magnetic brush The developing roller consists of a magnet roller with five poles and a sleeve roller. Rotation of the sleeve roller around the magnet roller entrains developer, which in turn forms a magnetic brush at pole N1 on the magnet roller. The height of the magnetic brush is regulated by the doctor blade; the developing result is affected by the positions of the poles on the magnet roller and the position of the doctor blade. The developing bias voltage generated by the high-voltage transformer PCB (HVTPCB) is applied to the developing roller to provide image contrast. Magnetic poles on the magnet roller
S1

4 65 3

84 75 N2

N1 67 80

N3 S2 N1: 850 104 50 10 4 T N2: 500 104 50 10 4 T N3: 450 104 50 10 4 T S1: 880 10 4 50 104 T S2: 900 10 4 50 104 T

A: distance between the doctor blade and developing roller: 0.525 0.025 mm

Figure 1-3-18 Forming the magnetic brush 1 Developing unit housing 2 Developing roller 3 Toner sensor (TNS) 4 Doctor blade 5 Right developing spiral 6 Left developing spiral

1-3-20

195

CN2-1 CN8-5 DB REM CN2-2 CN1-3

HVTPCB

Developing bias

TFM

TNS

CN6-7 CN6-8 MPCB

TNS TNS CONT

Figure 1-3-19 Developing section block diagram Toner density is detected by the toner sensor (TNS). The sensor section of the toner sensor detects the ratio of toner to carrier in the developer near it and converts it into a voltage. As more toner is used, the ratio of toner to carrier decreases, increasing the toner sensor output voltage. When the ratio drops below the specified value, the increase in toner sensor output voltage triggers toner replenishing. When toner is added and the ratio of toner to carrier returns to normal, the toner sensor output voltage drops to the point where toner replenishing stops.

1-3-21

195-1 Toner density control Toner density is controlled by switching the toner feed motor on and off, using as the reference the toner sensor output based on the toner sensor control voltage set when simulation 60 was executed while the developer was first supplied. The toner sensor output is also used to detect an empty toner cartridge.
Toner sensor output voltage (V) AP detection level (3.21) AP reset level (3.00) Toner empty end level (2.75) Toner feed motor on level (2.05) Toner feed motor off level (2.00)

AP blinks on the copy quantity/magnification display.

Max. 2 min. Forced toner feed

Copy operation

D
Forced feed (continuously on) Intermittent feed (0.2 s on/1.0 s off)

Figure 1-3-20 Toner density control

A When the toner sensor output voltage exceeds the toner feed motor on level, the toner feed motor intermittent feed (0.2 s on/1.0 s off) operation is carried out to feed the toner. B When the toner is fed and the toner sensor output voltage falls below the toner feed motor off level, the intermittent feed operation is stopped. C When the toner in the toner cartridge runs low and, even though the toner intermittent feed operation is continued, the toner sensor output voltage rises above the AP detection level, AP blinks on the copy quantity/magnification display and the toner feed motor forced feed (continuously on) operation starts. D If the toner sensor output voltage falls to the AP reset level within the toner feed motor forced feed operation time (2 minutes max.), the copier returns to the ready state and continues the intermittent feed operation. E If the toner sensor output voltage does not fall to the AP reset level within 2 minutes after it has started to fall below the AP detection level, the add toner indicator lights.

1-3-22

195
Toner sensor output voltage (V) AP detection level (3.21) If forced feed does not lower the level, the add toner indicator stays lit. Toner empty end level (2.75) Toner feed motor on level (2.05) Toner feed motor off level (2.00)

Toner cartridge replacement

Max. 3'19" Forced toner feed

The add toner indicator turns off and intermittent feed continues(2 minutes max.) until the toner feed motor off level is reached. Copy operation

F
Figure 1-3-21

F After the toner cartridge is replaced, AP blinks and the forced feed operation (continuously on) is started by turning the safety switch off and on. During forced feed, the toner is fed and when the toner sensor output voltage reaches the toner empty end level, AP on the copy quantity/magnification display goes out and the copier enters the ready state. Further intermittent feed operation is carried out for up to 2 minutes or until the toner sensor output voltage reaches the toner feed motor off level. G If the toner sensor output voltage does not reach the toner empty end level within the forced feed operation time, the add toner indicator stays lit even after the end of the forced feed operation time.

1-3-23

195-1

Controlling the toner sensor output voltage When initializing the toner control level in simulation 60, the toner sensor control voltage (TNS CONT) is set so that the toner sensor output voltage (TNS) is 1.60 V DC. The image density is subject to humidity changes and the developing unit drive time. To maintain the image density constant, the toner sensor output voltage (TNS) is corrected by the toner sensor control voltage (TNS CONT).

Toner sensor control voltage correction 0.1 value (V) 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.397

A 1 2

B
Developing unit drive time 1 0 - 350 min. 2 350 - 700 min. 3 700 - 1050 min. 4 1050 - 1400 min. 5 More than 1400 min.

4 5

11.398

35.849 Absolute humidity (g/m3)

Figure 1-3-22 Correction based on the absolute humidity

A The toner sensor control voltage correction value is kept constant when the absolute humidity is between 1.397 and 11.398 g/m3 . The toner sensor control voltage correction value varies depending on the developing unit drive time (the total drive motor on time since the main switch was last turned on). B The toner sensor control voltage correction value changes so that it is -0.5 V when the absolute humidity is 35.849 g/m3 when the absolute humidity is between 11.398 and 35.849 g/m3. The rate of change is constant and it varies depending on the developing unit drive time (the total drive motor on time since the main switch was last turned on).

1-3-24

195 [Computing the absolute humidity] The humidity sensor (HUMSENS) and external temperature thermistor (ETTH) are located on the humidity sensor PCB (HUMPCB). The humidity sensor (HUMSENS) converts the relative humidity detected by the humidity sensing element into a voltage and sends it to the main PCB (MPCB). The main PCB computes the absolute humidity based on this HUMSENS signal and the temperature (ETTH signal) detected by the external temperature thermistor.
MPCB HUMPCB ETTH 1 2 Humidity sensing element 3 HUMSENS 4 5 HUMSENS GND 5 V DC CN4-3 CN4-2 CN4-1 ETTH GND CN4-5 CN4-4

Figure 1-3-23 Absolute humidity computation block diagram

45 40 35 Absolute humidity (g/m3) 30 25 20 15 10 5 0 10 50 40 60 100

20

15 59

20 68

25 77

30 86

35 (C) 95 (F)

Temperature (C/F)

Figure 1-3-24 Absolute humidity vs. relative humidity

1-3-25

Relative humidity (%RH)

80

195 ( 5 ) Transfer and separation section

Post-transfer guide

Tungsten wire

Transfer charger

Figure 1-3-25 Transfer and separation section The transfer and separation section consists of the transfer charger. In the transfer charger, a high voltage generated by the high-voltage transformer PCB (HVTPCB) is applied across both ends of the tungsten wire for transfer charging and the toner image is transferred from the drum surface onto the paper. After transfer, paper is separated from the drum by curvature separation under its own weight and by the post-transfer guide.

1-3-26

195

6 7

1
Figure 1-3-26 Transfer charger 1 2 3 4 5 Front transfer housing Rear transfer housing Transfer front lid Transfer rear lid Transfer charger shield 6 Pre-transfer guide 7 Charger wire 8 Charger spring 9 Charger wire retainer pin

CN8-7 CN8-4 CN8-2

24 V DC HV REM HV ALM

CN1-1 Drum CN1-4 CN1-6 HV HVTPCB

MPCB

Figure 1-3-27 Transfer and separation section block diagram

1-3-27

195

Print key

SM 200 ms DM 50 ms HV REM

FWD

REV

384 ms

AB

Manual exposure mode, A4R/81/2" 14" copy paper, paper feed from the paper drawer

Timing chart 1-3-5 Transfer and separation A 200 ms after the print key has been pressed, the drive motor (DM) starts to rotate. B 50 ms after the drive motor (DM) has started to rotate, transfer charging (HV REM) starts. C 384 ms after the scanner motor (SM) has stopped rotating forward, transfer charging (HV REM) ends.

1-3-28

195 ( 6 ) Cleaning section The cleaning section consists of the cleaning blade, which removes residual toner from the drum surface after transfer, and the cleaning spiral that carries the residual toner back to the toner cartridge.

4 3

Figure 1-3-28 Cleaning section 1 Drum 2 Cleaning blade 3 Lower cleaning blade 4 Cleaning spiral

1-3-29

195 ( 7 ) Charge erasing section

Cleaning lamp (CL)

Blank lamps (BL)

Figure 1-3-29 Charge erasing section The charge erasing section consists of the blank lamps (BL) and the cleaning lamp (CL). The blank lamps (BL) are 28 LEDs. All the LEDs light to create leading edge and trailing edge blank cut margins. During exposure, the required number of the 28 blank lamps on both sides are lit depending on the paper size and the magnification ratio, removing charge from the sections of the copy where no image is to be formed. The cleaning lamp (CL) removes residual charge from the drum surface.

OPCB CN2-1 SEG ae CN2-5 CN2-13, DIG 5, 6 CN2-14 CN1-16 CN1-12 CN1-4, CN1-3 CN2-1 CN2-5 CN2-6, CN2-7 BL SEG ae BL DIG 5, 6 BL

CN7-4 MPCB

CL REM

CN4-11

CN9-1 CN9-2

24 V DC CL CL

AVRPCB Drum

Figure 1-3-30 Charge erasing section block diagram

1-3-30

195
Scan start

RSW

ESW FWD REV

SM

HV REM 100 ms

DM

200 ms

CL 285 ms BL All on 127 P *1 Side erasure 190 ms *2 All on

Bypass feed, manual exposure mode, A4R/81/2" 14" copy paper, magnification ratio 70% *1 Varies depending on the magnification ratio and the setting by simulation 54. *2 Varies depending on the setting by simulation 59.

Timing chart 1-3-6 Charge erasing A 200 ms after the registration switch (RSW) has been turned on by the paper inserted to the bypass, the drive motor (DM), the cleaning lamp (CL) and all the blank lamps (BL) turn on. B 127 pulses after the scanner has started scanning, the required number of blank lamps (BL) light depending on the paper size and the magnification ratio, removing unnecessary charge in the non-image forming area. C 190 ms after the trailing edge of the paper has turned the registration switch (RSW) off, all the blank lamps (BL) turn on. D 285 ms after the main charging (HV REM) has completed, the blank lamps (BL) turn off. E 100 ms after the paper has been ejected and the eject switch (ESW) has been turned off, the drive motor (DM) and the cleaning lamp (CL) turn off at the same time.

1-3-31

195-1 ( 8 ) Fixing and eject section

^ ! & 0 8 5 9 4 3
Figure 1-3-31 Fixing and eject section
1 Fixing unit cover 2 Fixing unit upper housing 3 Fixing unit lower housing 4 Fixing entrance guide 5 Eject guide 6 Heat roller 7 Press roller 8 Heat roller separation claws 9 Fixing pressure springs 0 ! @ # $ % ^ & Eject pulley Eject roller Fixing heater (H) Fixing unit thermostat 1 (TH1) Fixing unit thermostat 2 (TH2) Fixing unit thermistor (FTH) Eject switch (ESW) Fixing blade

1 # $ % 2

@ 7

1-3-32

195 The fixing and eject section consists of the parts shown in Figure 1-3-31. When the paper reaches the fixing section after the transfer process, it passes through the gap between the press roller and heat roller, which is heated by the fixing heater (H). Pressure is applied by the fixing pressure springs so that toner on the paper is melted and fused onto the paper. When the fixing process is completed, the paper is separated from the heat and press rollers by the heat roller separation claws and is ejected out of the copier by the rotation of the eject pulley and eject roller.
AVRPCB CN13-1 CN13-2 TB1 TB2 H COM Heat roller

FTH 5 V DC H LIVE TH2 TH1

H CN4-4 CN4-7

H REM

CN7-11

CN7-8

FTH

MPCB

Figure 1-3-32 Fixing section block diagram

FTH

1-3-33

195 Heating the heat roller and detecting temperature

3 5

1 2
Figure 1-3-33 Heating the heat roller and detecting temperature 1 Heat roller 2 Fixing heater (H) 3 Fixing unit thermostat 1 (TH1) 4 Fixing unit thermostat 2 (TH2) 5 Fixing unit thermistor (FTH)

The heat roller is heated by the fixing heater (H) inside it; its surface temperature is detected by the fixing unit thermistor (FTH) and is regulated by the fixing heater turning on and off. If the fixing section becomes abnormally hot, either the fixing unit thermistor detects it or fixing unit thermostat 1 or 2 (TH1 or TH2) operates, in each case shutting the power to the fixing heater off.

1-3-34

195 Fixing temperature control

Secondary stabilization fixing temperature 185C/365F Primary stabilization fixing temperature 80C/176F Copying enabled Primary stabilization fixing temperature 175C/347F 10 s

MSW H 200 ms DM CL BL 1s FFM Full speed Copy start indicator Half speed 29 s

A B

DE

Timing chart 1-3-7 Fixing temperature control A When the main switch (MSW) is turned on the fixing heater (H) turns on to heat the heat roller. The fixing fan motor (FFM) rotates at full speed for 1 s and then at half speed. B 200 ms after the fixing temperature has reached 80C/176F, the drive motor (DM), cleaning lamp (CL) and blank lamps (BL) turn on to start primary stabilization. C When the fixing temperature reaches 185 C/365F, secondary stabilization is achieved. The fixing heater (H) is then turned on and off as required to keep the fixing temperature at 185C/365 F. D After secondary stabilization, copying is enabled and the copy start indicator lights if the time from the main switch (MSW) being turned on has reached the following: 29 s if the temperature detected by the fixing unit thermistor is 10C/50F or above and the external temperature is 15C/59F or above when the main switch (MSW) is turned on; 44 s if the temperature detected by the fixing unit thermistor is below 10C/50 F or the external temperature is below 15C/59F when the main switch (MSW) is turned on; 5 s if the temperature detected by the fixing unit thermistor is 80C/176F or above when the main switch is turned on. E After copying has been enabled, the fixing temperature falls to 175 C/347F and the copier enters the standby state. The fixing heater (H) is then turned on and off as required to keep the fixing temperature at 175 C/347F. F 10 s after the copy start indicator has lit, the drive motor (DM) turns off.

1-3-35

195-1 Correcting the fixing temperature control The fixing temperature is changed according to the temperature detected by the external temperature thermistor (ETTH) on the humidity sensor PCB (HUMPCB). When the temperature detected by the thermistor is 32C/89.6 F or above, the fixing temperature is 175 C/347 F during standby and 180 C/356 F during copying. When the temperature detected by the thermistor is below 32C/89.6 F, the fixing temperature is 175 C/347 F during standby and 185 C/365 F during copying. Paper separation Paper is separated in the fixing section by the separation claws as shown in Figure 1-334.

Heat roller separation claws Heat roller

Figure 1-3-34 Paper separation

1-3-36

II ELECTRICAL SECTION

DC-1460 S/M (MCA)

II Electrical Section

195

2-1 Electrical Parts Layout

2-1-1 Electrical parts layout ........................................................................ 2-1-1

195

2-1-1

Electrical parts layout

6 4 1 3

Machine front

Machine inside

Machine rear

Figure 2-1-1 Layout of electrical parts: PCBs 1. Main PCB (MPCB) ....................................... Controls the other PCBs and electrical components. 2. Power source PCB (PSPCB) ....................... Generates 24 V and 5 V DC; supplies AC to the AVR PCB; contains the safety switch and noise filter. 3. AVR PCB (AVRPCB) ................................... Controls the halogen lamp and fixing heater. 4. High-voltage transformer PCB (HVTPCB) ... Performs main charging; generates developing bias and high voltage for transfer charging. 5. Humidity sensor PCB (HUMPCB) ................ Detects absolute humidity. 6. Operation unit PCB (OPCB) ........................ Consists of operation keys and display LEDs.

2-1-1

195 195-1

6 5 7 4 10 8

11 12

14
9 3 13 2

Machine front

Machine inside

Machine rear

Figure 2-1-2 Layout of electrical parts: switches and sensors

1. Main switch (MSW) ...................................... Turns the AC power on and off. 2. Safety switch (SSW) .................................... Breaks the safety circuit when the front cover or release unit is opened, and resets paper jam detection. 3. Registration switch (RSW) ........................... Controls the secondary paper feed start timing. 4. Eject switch (ESW) ...................................... Detects a paper jam in the fixing section. 5. AE sensor (AES) ......................................... Detects the original density. 6. Home position switch (HPSW) .................... Detects the scanner in the home position. 7. Mirror home position switch (MHPSW) ........ Detects mirrors 2 and 3 in the home positions. 8. Lens home position switch (LHPSW) .......... Detects the lens in the home position. 9. Toner sensor (TNS) ..................................... Detects the toner density in the developing section. 10. Fixing unit thermistor (FTH) ......................... Detects the heat roller temperature. 11. Humidity sensor (HUMSENS) ..................... Detects the external humidity. 12. External temperature thermistor (ETTH) ..... Detects the external temperature. 13. Developing unit fuse* (DEVF) ...................... Blows to differentiate between old and new developing units. 14. Toner cartridge detection switch .................. Detects the presence or absence of the (TCDSW) toner cartridge. * Standard equipment only for 120 V, 220 V and 240 V specifications.

2-1-2

195

6 4

3 1 5

10 9

Machine front

Machine inside

Machine rear

Figure 2-1-3 Layout of electrical parts: motors and clutches Drive motor (DM) ......................................... Drives the machine. Scanner motor (SM) .................................... Drives the optical system. Lens motor (LM) .......................................... Drives the lens. Mirror motor (MM) ........................................ Drives mirrors 2 and 3. Toner feed motor (TFM) .............................. Replenishes toner. Optical section fan motor (OPFM) ............... Cools the optical system. Fixing unit fan motor (FFM) ......................... Cools the fixing section. Internal cooling fan motor (ICFM) ................ Cools the machine interior. Paper feed clutch (PFCL) ............................ Performs primary paper feed from the paper drawer. 10. Registration clutch (RCL) ............................ Performs secondary paper feed. 1. 2. 3. 4. 5. 6. 7. 8. 9.

2-1-3

195

5, 6 4 2 3 8

Machine front

Machine inside

Machine rear

Figure 2-1-4 Layout of electrical parts: other electrical parts 1. Halogen lamp (HL) ...................................... Performs exposure. 2. Cleaning lamp (CL) ...................................... Removes residual charge from the drum surface. 3. Blank lamps (BL) ......................................... Remove charge from non-image forming areas of the drum surface. 4. Fixing heater (H) .......................................... Heats the heat roller. 5. Fixing unit thermostat 1 (TH1) ..................... Prevents overheating in the fixing section. 6. Fixing unit thermostat 2 (TH2) ..................... Prevents overheating in the fixing section. 7. Optical section thermostat (TH3) ................. Prevents overheating in the optical system. 8. Total counter (TC) ....................................... Displays the total number of copies produced. 9. Dehumidifying heater (DH)* ......................... Dehumidifies the machine interior. * Option available only for 120 V specifications.

2-1-4

195

2-2 Detection of Paper Misfeeds

2-2-1 Paper misfeed detection ................................................................... 2-2-1 2-2-2 Paper misfeed detection conditions .................................................. 2-2-2

195

2-2-1 Paper misfeed detection

When a paper jam occurs, the copier immediately stops copying and the copy quantity/ magnification display on the operation unit shows PF, J01, J02 or J03 indicating the location of the jam. The letter J and the number alternates on the display. To remove paper jammed in the copier, open the release unit, drawer or eject section cover. The paper misfeed detection can be reset by opening and closing the front cover or release unit to turn the safety switch off and back on.

Alternates.

PF: No paper feed (or, no paper present in the drawer) J01: paper jam in the fixing section J02: paper jam in the eject section J03: paper jam in the registration section Figure 2-2-1 Misfeed location indication

ESW

RCL RSW

PFCL

Figure 2-2-2 Misfeed detection

2-2-1

195

2-2-2 Paper misfeed detection conditions

No paper feed (PF) The registration switch (RSW) does not turn on within 1100 ms after the paper feed clutch (PFCL) has turned on during drawer paper feed.
Off PFCL On 1100 ms Off On

RSW

Timing chart 2-2-1 Paper jam in the registration section (J03) The registration switch (RSW) does not turn off within 4000 ms after the registration clutch (RCL) has turned on.
Off RCL 4000 ms On Off On

RSW

Timing chart 2-2-2 Paper jam in the fixing section (J01) The eject switch (ESW) does not turn on within 1668 ms after the registration clutch (RCL) has turned on.
Off RCL On 1668 ms Off On

ESW

Timing chart 2-2-3

2-2-2

195 Paper jam in the eject section (J02) The eject switch (ESW) does not turn off within 2000 ms after the registration switch (RSW) has turned off.
Off RSW 2000 ms On Off On

ESW

Timing chart 2-2-4

2-2-3

195

2-3 Operation of the PCB

2-3-1 2-3-2 2-3-3 2-3-4 Power source PCB ............................................................................ Main PCB .......................................................................................... AVR PCB .......................................................................................... Operation unit PCB ........................................................................... 2-3-1 2-3-2 2-3-3 2-3-4

195

2-3-1 Power source PCB

MSW SSW

AC input

T1 Noise filter circuit 1 L1 Noise filter circuit 2 L3 Rectifying circuit DB1

+

C9 Q1

Switching circuit IC1

PC1 PC2 24 V DC smoothing /output circuit D101/C102 5 V DC smoothing /output circuit IC201 24 V DC output

Output feedback circuit

5V DC output

PSPCB

Figure 2-3-1 Power source PCB block diagram The power source PCB (PSPCB) consists of the circuit blocks shown in Figure 2-3-1 and converts the AC input into stable 5 V and 24 V DC outputs. Noise filter circuit 1 consists of choke coil L1, a resistor and capacitor. These attenuate external noise and prevent noise generated by the electrical components from escaping out of the copier via the AC line. Noise filter circuit 2 attenuates any external noise that has passed through noise filter circuit 1 and prevents the switching noise generated in the power source PCB from escaping out via the AC line. The AC input is full-wave rectified by diode bridge DB1 and then smoothed by smoothing capacitor C9. The switching circuit turns FET Q1 on and off via switching control IC1, turning current to the primary coil of switching transformer T1 on and off. The 24 V DC smoothing/output circuit converts the potential induced across the secondary coil of T1 into a stable 24 V DC output via diode D101 and smoothing capacitor C102. The 5 V DC smoothing/ output circuit converts the potential induced across the other secondary coil of T1 into a stable 5 V DC output via regulator IC201. Switching control IC1 regulates the 24 V DC supply by controlling the switching operation of FET Q1 depending on the signal fed back by the output feedback circuit via photocoupler PC1. If an overvoltage occurs on the 24 V or 5 V DC output, the output feedback circuit sends that information to switch control IC1 via photocoupler PC2, inhibiting IC1.

2-3-1

195

2-3-2 Main PCB

MPCB Scanner motor drive circuit IC11 HL REM AVR circuit H REM LM DM CPU IC12 Shorted thermistor detection circuit H

AVRPCB HL

SM

MM OP FM Scanningrelated switches and sensors TNS OPCB HVT PCB Reset IC IC1 EPROM IC15 Driver IC IC17

FTH

CL

FFM PFCL RCL RSW ESW

Figure 2-3-2 Main PCB block diagram The main PCB (MPCB) consists of the CPU and control circuits that regulate the electrical components during the copying process. Based on the control programs in EPROM IC15, CPU IC12 controls the overall copier system: the drive motor, scanning-related motors, switches and sensors, toner sensor (TNS), clutches and switches in the paper feed, registration and eject sections; and sends out MC and TC remote signals to the high-voltage transformer PCB (HVTPCB). The halogen lamp (HL) and the fixing heater (H) are also controlled by the main PCB via the AVR PCB (AVRPCB).

2-3-2

195

2-3-3 AVR PCB

AVRPCB PC5 TRC3 Flicker resistor PC2 TRC2 H

PC1

Flicker REM

MPCB

H REM HL CONT

PWM signal/ voltage converter circuit AC input Halogen lamp light intensity control IC (HIC) PC3 TRC1 HL

Figure 2-3-3 AVR PCB block diagram The AVR PCB (AVRPCB) consists of two major sections: the halogen lamp control section with the PWM signal/voltage converter circuit and halogen lamp light intensity control IC (HIC), and the switching section with triacs TRC1, TRC2 and TRC3 that turn the fixing heater (H), flicker resistor* and halogen lamp (HL) on and off. Control signal H REM from the main PCB turns photocoupler PC2 on when low. This applies a trigger voltage to the gate of triac TRC2, causing it to conduct and allow current to flow to the fixing heater (H) to turn it on. The flicker resistor* limits the surge generated by the fixing heater (H) being turned on. The Flicker REM signal from the main PCB turns photocoupler PC5 on when low. This applies a trigger voltage to the gate of triac TRC3, causing it to conduct and allow current to the flicker resistor to operate it. The halogen lamp (HL) light intensity is controlled by control signal HL CONT from the main PCB. HL CONT is a PWM signal turned on and off at a duty ratio set by the halogen lamp light intensity data. This signal is converted into a voltage by the PWM signal/voltage converter circuit and is output to the halogen lamp light intensity control IC (HIC). This adjusts the phase of the trigger which turns photocoupler PC3 on, based on the halogen lamp light intensity data converted into a voltage, using an internal zerocrossing signal as a reference. The phase-shifted trigger applied to the gate of triac TRC1 changes the amount of current flowing to the halogen lamp (HL), regulating the halogen lamp light intensity. * For 230 V specifications and optional for 240 V specifications.

2-3-3

195

2-3-4 Operation unit PCB

OPCB LEDs and 7-seg LEDs MPCB 24 V DC

SEG a SEG b SEG c SEG d SEG e SEG f SEG g DIG 0 DIG 1 DIG 2 DIG 3 DIG 4 DIG 5 DIG 6

Source driver

PG

Sink driver

5 V DC
S

KEY 0 KEY 1 Key switches BL SEG a BL SEG b BL SEG c BL SEG d BL SEG e BL DIG 5 BL DIG 6 Blank lamps

Figure 2-3-4 Operation unit PCB block diagram The operation unit PCB (OPCB) consists of LEDs, 7-segment LEDs and key switches arranged in matrix. To light an LED or 7-segment LED, the main PCB (MPCB) turns on one of the source drivers for lines SEG a to SEG g to allow current to the line on which the LED or 7segment LED to be lit is present. Scan signals which go low in sequence are constantly output to the sink drivers for lines DIG 0 to DIG 5, so current flows through the LED for which the two signals are low simultaneously. The status of key switches is detected by return signals KEY 0 and KEY 1. When none of the keys on the operation panel is pressed, each line of return signals KEY 0 and KEY 1 is pulled high to 5 V DC by the main PCB (MPCB). The main PCB (MPCB) outputs scan signals that go low in sequence to the sink drivers for lines DIG 0 to DIG 4, so when a key is pressed, the key switch conducts and the return signal goes low due to the scan signal. The main PCB (MPCB) identifies the specific key by the location of the point where the line emitting the scan signal and the line with the low return signal meet. The operation unit PCB (OPCB) also controls the blank lamps which are 28 LEDs. To light the blank lamps, the main PCB (MPCB) turns on the source drivers for lines BL SEG a to BL SEG e to allow current to the lines on which the blank lamps to be lit are

2-3-4

195 present. Scan signals which go low in sequence are constantly output to the sink drivers for lines BL DIG 5 and BL DIG 6, so current flows through the LEDs for which the both signals are low simultaneously.

2-3-5

III SET UP AND ADJUSTMENT SECTION

III Set Up and Adjustment Section DC-1460 S/M (MCA)

195-1 195

3-1 Installation
3-1-1 Unpacking and installation ................................................................ 3-1-1 ( 1 ) Installation environment ............................................................ 3-1-1 ( 2 ) Installation procedure ................................................................ 3-1-2 3-1-2 Setting initial copy modes ............................................................... 3-1-10 3-1-3 Installing the dehumidifier heater (optional, 120 V specifications only) .......................................................................... 3-1-11 3-1-4 Installing the flicker resistor (optional, 240 V/50 Hz specifications only) .......................................................................... 3-1-13

195

3-1-1 Unpacking and installation

( 1 ) Installation environment 1. Temperature and humidity: 10 C/50 F to 35C/95F, 15 - 85% RH 2. Power supply: 120 V AC, 12 A, 220 - 240 V AC, 8 A 3. Power source frequency: 50/60 Hz 0.3% 4. Installation location Avoid direct sunlight or bright lighting. Make sure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams. Avoid extremes of temperature and humidity, abrupt ambient temperature changes, and hot or cold air directly hitting the machine. Avoid dust and vibration. Choose a surface capable of supporting the weight of the machine. Place the machine on a level surface (maximum allowable inclination: 1 ). Avoid airborne substances that may adversely affect the machine or degrade the photoconductor, such as mercury, acidic and alkaline vapors, inorganic gases, NOx, SOx gases and chlorine-based organic solvents. Select a room with good ventilation. 5. Allow sufficient access for proper operation and maintenance of the machine. Machine front: 1000 mm/393/8" Machine rear: 100 mm/315/ 16" Machine right: 100 mm/315/ 16" Machine left: 300 mm/1113/16 "

d f c

b e

a: 515 mm/201/ 4" c: 320 mm/125/8" b: 465 mm/185/ 16" d: 775 mm/301/2"

e: 780 mm/3011/16 " f: 660 mm/26"

Figure 3-1-1 Installation dimensions

3-1-1

195 195-1 ( 2 ) Installation procedure

Start

Unpack.

Apply fixing pressure.

Remove the tapes.

Carry out initial developer setting.

Remove the pins.

Install a toner cartridge.

Remove the developing unit spacer.

Install the copy tray.

Remove the developing unit seal (inch specifications only).

Make test copies.

Completion of machine installation. Load developer (metric specifications only).

Copy tray

Lens unit pin

Light source unit 1 pins

Light source unit 2 pin

Figure 3-1-2

3-1-2

195-1 195 Unpack.

!
A

4 $ 0 5 1 7 9
A

! #

Figure 3-1-3 Unpacking

1 2 3 4 5 6 7 Bottom pads Top pads Outer case Plastic sheet Plastic bag Bar code labels Inner frame 8 Copier 9 Copy tray 0 Power cord ! Tag @ Instruction handbook # Plastic bag $ Developing unit spacer

3-1-3

195 195-1 Remove the tapes. 1. Remove the tapes holding the original holder.
Tapes

Tapes

Figure 3-1-4
Remove the pins. 1. Remove the tapes holding the two light source unit 1 pins and one light source unit 2 pin on the machine right, and remove these pins.

Light source unit 2 pin

Light source unit 1 pins

Figure 3-1-5

3-1-4

195-1 195 2. Open the front cover, and remove the tape holding the lens unit pin and then the pin.

Lens unit pin

Figure 3-1-6 Remove the developing unit spacer. 1. Remove the tape and the developing unit spacer from the developing unit.

Developing unit spacer

Developing unit

Figure 3-1-6-1

3-1-5

195 195-1 Remove the developing unit seal (inch specifications only). 1. While holding the developing unit, peel off the developing unit seal.

Developing unit seal

Figure 3-1-7

3-1-6 3-1-5-1

195

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3-1-7

195 Load developer (metric specifications only). 1. Unlock the developing unit release lever and take out the developing unit. Important: Place the developing unit on a level surface.

Developing unit

Figure 3-1-8 2. Remove the developing unit cover from the developing unit by pulling it in the direction of the arrow (four screws).

Developing unit

Developing unit cover

Figure 3-1-9

3-1-8 3-1-6

195 3. Shake the developer bottle well. 4. While turning the gear in the direction of the arrow, pour developer into the developing unit so that it covers the entire developing roller uniformly.

Developing unit gear

Figure 3-1-10 5. Refit the developing unit cover. 6. Reinsert the developing unit into the copier and lock the developing unit release lever. Apply fixing pressure. 1. Press the release unit button to open the unit.

Rerease unit button Release unit

Figure 3-1-11 2. Close the release unit. The fixing pressure is applied. 3. Close the front cover.

3-1-9 3-1-7

195 195-1 Carry out initial developer setting. Inch specifications 1. Plug the power cord into the copier and the wall outlet. 2. Turn the main switch on. The copier starts its drive and automatically carries out initial developer setting. It takes about 2 minutes. 3. Turn the main switch off and back on while pressing the print and stop/clear keys. 4. Press the stop/clear key to enter simulation mode within 2 s after has been displayed on the copy quantity/magnification display. Metric specifications 1. Plug the power cord into the copier and the wall outlet. 2. While pressing the print key and the stop/clear key at the same time, turn the main switch on. 3. Within 2 s after the copy quantity/magnification display shows , press the stop/clear key to enter simulation mode. 4. Enter 60 with the quantity/zoom-up or -down key and press the print key. 5. Press the print key. After about 2 minutes, the toner control voltage is automatically set and the value is indicated as shown below: the integer is indicated by the fixed magnification indicators or auto exposure indicator, and decimals are shown on the copy quantity/magnification display (See page 3-22). Example If the value is 2.35 V
4

1 2 3

2.35 V

Figure 3-1-12 6. Press the stop/clear key.

3-1-10 3-1-8

195-1 195

Setting the destination. 1. Enter 93 with the quantity/zoom-up or -down keys and press the print key. 2. Change the setting with the quantity/zoom-up or down keys.

Setting 0 1 2 3 4 5

Contents Metric, excluding Spain, Belgium, Peru, Australia and New Zealand Inch, excluding the Philippines Spain Belgium Peru, Australia and New Zealand The Philippines

3. Press the print key. The new setting is stored. 4. Press the stop/clear key. 5. Enter 01 with the quantity/zoom-up or -down keys and press the print key. The simulation mode is exited.

3-1-8-1 3-1-11

195

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3-1-12

195 Install a toner cartridge. 1. Open the front cover. 2. Shake the new toner cartridge well and insert it into the copier.

Toner cartridge

Figure 3-1-13 3. Close the front cover. Install the copy tray. 1. Install the copy tray to the eject section of the copier. Make test copies. 1. Place paper in the paper drawer and make test copies.

Completion of machine installation.

3-1-13 3-1-9

195 195-1

3-1-2 Setting initial copy modes

Factory settings are as follows:
Sim. No. 85 89 91 92 93 96 98 99 Contents Selecting between auto preheat on/off Setting the presence of the flicker resistor Setting operation under the toner empty condition Selecting between auto start on/off Setting the destination Setting the memory switch Setting the maintenance method Selecting between E2000-compliant function on/off Factory setting On Not installed 20 copies On Metric 7 steps User No

3-1-14 3-1-10

195

3-1-3 Installing the dehumidifier heater (optional, 120 V specifications only)

Required parts Dehumidifier heater (P/N 36727460) Heater primary wire (P/N 19560010) Binding taptight screw, M3 6 (P/N B3023060) Procedure 1. Remove the right and rear covers. 2. Unplug all the connectors on the power source PCB and remove the PCB from the copier (two screws).

Power source PCB

Figure 3-1-14 3. Fit the dehumidifier heater to the copier with the two M3 6 binding taptight screws.
Dehumidifier heater

Binding taptight screws, M36

Figure 3-1-15

3-1-15 3-1-11

195 4. Remove the copier primary wire from the AVR PCB and connect the heater primary wire in place of it.
AVR PCB

Heater primary wire

Figure 3-1-16 5. Plug the 2-pin connector of the heater primary wire into the dehumidifier heater.

Dehumidifier heater

2-pin connector

Heater primary wire

Figure 3-1-17 6. Refit all the removed parts.

3-1-16 3-1-12

195 195-1

3-1-4 Installing the flicker resistor (optional, 240 V/50 Hz specifications only)
Required parts Resistor wire (P/N 19527230) Resistor, 10 40 W (P/N 36727600) Resistor, 10 40 W 157 (P/N 36727610) Wire saddle, WS-2NS (P/N M2109010) Binding S tight screw, M4 6 (P/N B3024060) Procedure 1. Remove the right and rear covers. 2. Unplug all the connectors on the power source PCB and remove the power source PCB from the copier (two screws).
Power source PCB

Figure 3-1-18 3. Connect the resistor wire to the 10 40 W resistor and 10 40 W 157 resistor.
Resistor, 10 40 W 157

Resistor wire Resistor, 10 40 W

Figure 3-1-19

3-1-17 3-1-13

195 195-1

4. Attach the 10 40 W and 10 40 W 157 resistors to the copier with one M4 6 binding S tight screw each. 5. Attach the wire saddle WS-2NS to the copier and pass the resistor wire through it.
Binding S tight screws M4 6 Resistor, 10 40 W

Wire saddle, WS-2NS

Resistor, 10 40 W 157

Resistor wire

Figure 3-1-20 6. Pass the resistor wire through the cutout in the copier and connect the 4-pin connector to CN3 on the AVR PCB.
4-pin connector CN3

AVR PCB

Resistor wire

Figure 3-1-21 7. Refit the removed parts. 8. Turn the main switch on and change the setting of simulation 89 to 1 (installed).

3-1-18 3-1-14

195

3-2 Simulation
3-2-1 Simulations ........................................................................................ ( 1 ) Running a simulation ................................................................. ( 2 ) Simulation list ............................................................................ ( 3 ) Contents of simulations ............................................................. 3-2-1 3-2-1 3-2-4 3-2-5

195

3-2-1 Simulations
The copier is equipped with a simulation function which can be used to check and adjust the operation of copier components. ( 1 ) Running a simulation

Start

While pressing the print key and stop/clear key at the same time, turn the main switch on. is shown on the copy quantity/magnification display. Press the stop/clear key within 2 s. Simulation mode is entered. 00 is shown on the copy quantity/magnification display. Enter the number of the simulation A simulation is selected. to be executed with the quantity/zoom-up and -down keys*1. The selected simulation number is shown on the copy quantity/magnification display. Press the print key. *1 Press the quantity/zoom-up key to change the 10s digit and the quantity/zoom-down key to change the 1s digit.

The simulation is run.

Press the stop/clear key.

Yes

Run again?

No

Yes

Run another simulation?

No Enter 01 with the quantity/zoomup and -down keys and press the print key.

Simulation mode is exited.

End

3-2-1

195 Indication of the set values When a set value includes decimals, it is indicated as shown below: the integer is shown by the fixed magnification indicators or auto exposure indicator, and decimals are shown on the copy quantity/magnification display. Example If the value is 2.35 V Metric
4

1 2 3

2.35 V

Inch
4

1 2 3

2.35 V

Figure 3-2-1

3-2-2

195 Indication of the selected mode In a simulation with multiple modes, one of the exposure indicators lights to show the selected mode. Use the exposure adjustment keys to change the modes. Metric
Mode

Exposure adjustment keys

Inch
Mode

Exposure adjustment keys

Figure 3-2-2

3-2-3

195 195-1 ( 2 ) Simulation list Sim. No. 01 02 08 Paper feed/ conveying 10 11 54 57 58 59 Optical 20 24 25 26 27 28 29

Section All

Simulation contents Exiting simulation mode Copying without paper Setting shipping defaults Turning the drive motor on Checking switch operation Adjusting the leading edge margin Adjusting the trailing edge blank cut timing Adjusting the leading edge registration timing Adjusting the trailing edge margin Turning the halogen lamp on Setting the exposure amount Adjusting lateral magnification Adjusting longitudinal magnification Making fine adjustment to image focus Adjusting the auto exposure Adjusting exposure amount for enlargement/ reduction mode

Default

Charging
Cleaning Fixing Operation panel Developing

33
42 47 50 60 62 67

Setting the drum potential

Making a blank lamp test copy Setting the fixing temperature Lighting all the LEDs on the operation panel Initializing the toner control level Checking/setting the toner control voltage Checking ambient temperature and humidity Initializing the backup memory Checking/setting the maintenance cycle Checking/clearing the maintenance count 30000 Cleared

Memory initialize Counts

70 71 73

3-2-4

195-1 195 Sim. No. 85

Section Copy modes

Simulation contents Selecting between auto preheat on/off

Default On

89
91 92 93 96 98 99

Setting the presence of the flicker resistor

Setting operation under the toner empty condition Selecting between auto start on/off Setting the destination Setting the memory switch Setting the maintenance method Selecting between E2000-compliant function on/off

Not installed
20 copies On Metric 7 steps User No

3-2-4-1 3-2-5

195

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3-2-6

195 (3) Contents of simulations Sim. No. 01 Exiting simulation mode Description Exits simulation mode and returns to normal mode. Purpose Used when ending simulation mode. Method Press the print key. The copier returns to normal mode. 02 Copying without paper Description Makes copies without feeding paper. Purpose To check general machine operation. Method 1. Put a plain white A4 original in place. 2. Open the drawer. 3. Select copy modes and press the print key to start copying. The copier operates according to the selected modes. Completion Press the stop/clear key. Copying operation stops. 08 Setting shipping defaults Description Moves the scanner to the shipping position. Purpose To be run before moving the machine. Method Press the print key. Important: Since this simulation clears the maintenance count, run simulation 73 and check it beforehand. Completion Press the stop/clear key. Description

3-2-5

195 Sim. No. 10 Turning the drive motor on Description Operates the drive motor. Purpose To check the drive system operation. Method Press the print key. The drive motor, cleaning lamp and developing bias are turned on, and the fixing unit fan motor rotates at full speed. Completion Press the stop/clear key. The fixing unit fan motor slows to half speed and the other components are turned off. 11 Checking switch operation Description Shows the status of the registration and eject switches. Purpose To check if the registration and eject switches are defective. Method Turn each switch on and off manually. The copy quantity/magnification display shows the status of the switch. On Registration switch Eject switch Completion Press the stop/clear key. 01 10 Off 00 00

Description

3-2-6

195 Sim. No. 20

Description Turning the halogen lamp on Description Lights the halogen lamp. Purpose To check the halogen lamp operation. Method 1. Select an exposure level with the exposure adjustment keys. 2. Press the print key. The halogen lamp lights at the selected intensity for 15 s. Completion Press the stop/clear key. The halogen lamp is turned off.

24

Setting the exposure amount Adjustment See page 3-3-37.

25

Adjusting lateral magnification Adjustment See page 3-3-45.

26

Adjusting longitudinal magnification Adjustment See page 3-3-49.

27

Making fine adjustment to image focus Adjustment See page 3-3-32.

28

Adjusting the auto exposure Adjustment See page 3-3-41.

29

Adjusting exposure amount for enlargement/reduction mode Adjustment See page 3-3-42.

3-2-7

195 195-1 Sim. No.

Description

33

Setting the drum potential Description Sets the drum potential. Purpose To be run when adjusting the developing bias. Method Press the print key. The drum potential setting starts. Completion Press the stop/clear key.

42

Making a blank lamp test copy Description Lights the blank lamps. Purpose To check blank lamp operation. Method 1. Load a sheet of the maximum size. 2. Open the original holder. 3. Press the zoom input/enter key. Test copy mode is entered. 4. Press the print key. The blank lamps light in a preset order and the pattern shown below is printed to check operation.

Figure 3-2-3 Completion Press the stop/clear key.

3-2-8

195-1 195 Sim. No. 47

Description Setting the fixing temperature Description Changes the fixing heater control value to adjust the fixing temperature. Purpose To be run when a fixing problem occurs. Setting 1. Select the mode to be set with the exposure adjustment keys. The current setting for that mode is indicated by the combination of lighting of one of the fixed magnification indicators or the auto exposure indicator and the figures on the copy quantity/magnification display. Mode 1 2 3 4 5 Standby Contents Setting range Initial value

1.70 to 4.45 V 3.98 V (175C) 3.41 to 4.45 V 4.15 V (185C) 3.41 to 4.45 V 4.21 V (189C) 0.39 to 4.45 V 1.05 V (80C)

Fixing (secondary) stabilization 3.41 to 4.45 V 4.15 V (185C) During copying During ejection Fixing drive start

2. Change the setting with the quantity/zoom-up and -down keys. Changing the value by one changes the temperature by 0.6C when the fixing temperature is 180 C and 0.3 C when it is 80C. 3. Press the print key. The new setting is stored. Completion Press the stop/clear key. 50 Lighting all the LEDs on the operation panel Description Lights all the LEDs on the operation panel. Purpose To check the operation of the LEDs on the operation panel. Method Press the print key. All the LEDs on the operation panel light. Completion Press the stop/clear key. The LEDs turn off.

3-2-9

195 Sim. No. 54

Description Adjusting the leading edge margin Adjustment See page 3-3-7.

57

Adjusting the trailing edge blank cut timing Adjustment See page 3-3-9.

58

Adjusting the leading edge registration timing Adjustment See page 3-3-5.

59

Adjusting the trailing edge margin Adjustment See page 3-3-11.

60

Initializing the toner control level (metric specifications only) Description Sets the toner control voltage automatically. Purpose To be run during machine setup or after replacing developer or the developing unit. Method Press the print key. The drive motor turns on and aging is carried out for about 2 minutes. The toner control voltage is automatically set and the value is indicated by the combination of lighting of one of the fixed magnification indicators or the auto exposure indicator and the figures on the copy quantity/magnification display. Completion Press the stop/clear key.

3-2-10

195 Sim. No. 62

Description Checking/setting the toner control voltage Description Checks the initial toner control voltage automatically set by simulation 60, or sets the toner control voltage. Purpose To be run after replacing the main PCB. Method Press the print key. The current setting is indicated by the combination of lighting of one of the fixed magnification indicators or the auto exposure indicator and the figures on the copy quantity/magnification display. Setting 1. Change the value with the quantity/zoom-up and -down keys. Setting range: 0.00 to 5.00 V Reference: 3.00 V 2. Press the print key. The drive motor turns on and the new toner control voltage is indicated by the combination of lighting of one of the fixed magnification indicators or the auto exposure indicator and the figures on the copy quantity/magnification display. Completion Press the stop/clear key.

67

Checking ambient temperature and humidity Description Displays ambient temperature and humidity. Purpose To check if the humidity sensor has a problem. Method 1. Press the print key. 2. Select the mode to be checked with the exposure adjustment keys. Mode 1: temperature Mode 2: relative humidity Mode 3: absolute humidity Completion Press the stop/clear key.

3-2-11

195 195-1 Sim. No. 70

Description Initializing the backup memory Description Initializes the contents of the backup memory. Purpose To be run after replacing the main PCB. Method 1. Press the print key.

2. Press the exposure mode key. The following data in memory is initialized.
Sim No. 24 Contents Exposure amount Manual Exp. 4 Manual Exp. 1 Manual Exp. +2 Lateral magnification (lens travel distance) 100% copy Enlargement copy Reduction copy Longitudinal magnification Fine adjustment of image focus Lens home position for enlargement copy Lens home position for reduction copy Mirror home position for enlargement copy Mirror home position for reduction copy Lens home position for 100% copy Mirror home position for 100% copy Auto exposure Prescan exposure amount NTC level NPTC level Enlargement/reduction-mode exposure amount Enlargement copy Reduction copy Fixing temperature Standby Fixing (secondary) stabilization During copying During ejection Fixing drive start Leading edge margin 100% copy Enlargement copy Reduction copy Trailing edge blank cut timing Initial data 62 18 30 0 0 0 13 0 0 0 0 32 32 80 3.50 V 2.00 V 0 1 3.90 V 4.05 V 4.05 V 4.21 V 1.05 V 131 140 127 84

25

26 27

28

29

47

54

57

3-2-12

195-1 195 Sim. No. 70 (cont.) Sim No. 58

Description Contents Leading edge registration timing 100% copy Enlargement copy Reduction copy Trailing edge margin Toner control voltage Maintenance cycle Maintenance count Auto preheat Setting the presence of the flicker resistor Operation under toner empty condition Auto start Destination Memory switch setting Maintenance method E2000-compliant function Initial data 108 121 91 95 3.00 V 30000 Cleared On Not installed 20 copies On Metric 7 steps User No

59 62 71 73 85 89 91 92 93 96 98 99

Completion Press the stop/clear key. After running simulation 70, run the above simulations and reenter the settings recorded on the simulation label.

3-2-13

195 Sim. No. 71

Description Checking/setting the maintenance cycle Description Checks/sets the maintenance cycle. Purpose To be run after replacing the main PCB. Method Press the print key. The current setting is shown on the copy quantity/ magnification display. Mode 1: 100,000s and 10,000s digits Mode 2: 1,000s and 100s digits Mode 3: 10s and 1s digits Setting 1. Select the mode to be set with the exposure adjustment keys. 2. Change the setting with the quantity/zoom-up and -down keys. Setting range: 0 to 999999 Reference: 30000 3. Press the print key. The new setting is stored. Completion Press the stop/clear key.

3-2-14

195 Sim. No. 73

Description Checking/clearing the maintenance count Description Checks/resets the maintenance count. Purpose To be run after replacing the drum and developing units, or before and after replacing the main PCB or running simulation 08 (Setting shipping defaults). Method Press the print key. The current count is shown on the copy quantity/ magnification display. Mode 1: 100,000s and 10,000s digits Mode 2: 1,000s and 100s digits Mode 3: 10s and 1s digits Setting 1. Select the mode to be set with the exposure adjustment keys. 2. Change the value with the quantity/zoom-up and -down keys. Setting range: 0 to 999999 Reference: 0 To clear the count, set every digit to 0. 3. Press the print key. The new setting is stored. Completion Press the stop/clear key.

3-2-15

195 195-1 Sim. No. 85

Description Selecting between auto preheat on/off Description Turns the auto preheat function on/off. Purpose To be set according to user request. Setting 1. Change the setting with the quantity/zoom-up and -down keys. 0: Auto preheat function off 1: Auto preheat function on 2. Press the print key. The new setting is stored. Completion Press the stop/clear key.

89

Setting the presence of the flicker resistor (240 V/50 Hz specifications only) Description Sets the presence of the flicker resistor. Method To be run after the installation of the optional flicker resistor. Setting 1. Change the setting with the quantity/zoom-up or -down keys. 0: Flicker resistor not installed 1: Flicker resistor installed Reference: 0 2. Press the print key. The new setting is stored. Completion Press the stop/clear key.

3-2-16

195-1 195 Sim. No. 91

Description Setting operation under the toner empty condition Description Sets the maximum number of copies that can be made under the toner empty condition. Purpose To be set according to user request. Setting 1. Change the setting with the quantity/zoom-up and -down keys. Setting range: 0 to 199 Reference: 20 2. Press the print key. The new setting is stored. Completion Press the stop/clear key.

3-2-16-1

195

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195-2 195 Sim. No. 92

Description Selecting between auto start on/off Description Turns the auto start function on/off. Purpose To be set according to user request. Setting 1. Change the setting with the quantity/zoom-up and -down keys. 0: Auto start function off 1: Auto start function on 2. Press the print key. The new setting is stored. Completion Press the stop/clear key.

93

Setting the destination Description Sets the destination of the machine. Purpose To be run after replacing the main PCB or machine installation. Setting 1. Change the setting with the quantity/zoom-up and -down keys. Setting 0 Contents

Metric, excluding Spain, Belgium, Peru, Australia and New Zealand

1 2 3 4 5

Inch, excluding the Philippines

Spain Belgium Peru, Australia and New Zealand The Philippines

2. Press the print key. The new setting is stored. Completion Press the stop/clear key.

3-2-17

195 195-2 Sim. No.

Description

96

Setting the memory switch Description Sets the number of exposure steps for manual mode and the copy limit. Purpose To change the number of exposure steps for manual mode or the copy limit. The limit can be set to any number between 1 and 99. Setting 1. Select the mode with the exposure adjustment keys. Mode 1: Setting the number of exposure steps for manual mode Mode 2: Setting the copy limit 2. Change the setting with the quantity/zoom-up and -down keys. Mode 1 0: 7 steps 1: 13 steps Initial value: 0 Mode 2 Setting range: 1 - 99 Initial value: 99 The setting in mode 2 indicates the limit to the number of copies that can be set on the operation panel. The operation of the quantity/zoom-up key (10s digit) and quantity/zoom-down key (1s digit) is restricted as in the following examples. When the setting (the copy limit) is 1

Copy quantity display 1s digit 10s digit 1 none (not available)

3-2-18

195-2 195 Sim. No.

Description

96 (cont.)

When the setting (the copy limit) is 5 Copy quantity display 4 5

1s digit 10s digit

none (not available)

When the setting (the copy limit) is 10 Copy quantity display 4 5 6 7 8

1 1s digit

0 is displayed only when the 10s digit is 1. none 1 1 can be selected only when the 1s digit is 1.

10s digit

When the setting (the copy limit) is 25 Copy quantity display 4 5 6 7 8

1 1s digit

0 cannot be selected when there is no tens digit. When the 10s digit is 2, only numbers between 0 and 5 can be selected. none 1 2

10s digit

2 can be selected only when the 1s digit is between 0 and 5.

When the setting (the copy limit) is 50 Copy quantity display 4 5 6 7 8

1 1s digit

0 cannot be selected when there is no tens digit. none 1 2 3 4 5 5 can be selected only when the 1s digit is 0.

10s digit

3-2-18-1

195 195-2 Sim. No.

Description

96 (cont.)

When the setting (the copy limit) is 99 Copy quantity display 4 5 6 7 8

1 1s digit 10s digit

0 cannot be selected when there is no tens digit. none 1 2 3 4 5 6 7 8 9

3. Press the print key. The new setting is stored. Completion Press the stop/clear key.

3-2-18-2

195-2 195 Sim. No. 98

Description

Setting the maintenance method (available in Peru, Australia and New Zealand only)
Description Sets whether the machine is to be serviced by the user or by service personnel. Purpose To be set according to user request. Setting 1. Change the setting with the quantity/zoom-up and -down keys. 0: User maintenance 1: Service maintenance 2. Press the print key. The new setting is stored. Completion Press the stop/clear key.

3-2-18-3

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195

3-3 Assembly and Disassembly

3-3-1 Precautions for assembly and disassembly ...................................... 3-3-1 ( 1 ) Precautions ............................................................................... 3-3-1 3-3-2 Paper feed section ............................................................................ 3-3-2 ( 1 ) Detaching and refitting paper feed pulleys A and B .................. 3-3-2 ( 2 ) Replacing the feedshift films ..................................................... 3-3-4 ( 3 ) Adjustments after installing roller and clutches ......................... 3-3-5 (3-1) Adjusting leading edge registration timing ........................ 3-3-5 (3-2) Adjusting the leading edge margin ................................... 3-3-7 (3-3) Adjusting the trailing edge blank cut timing ...................... 3-3-9 (3-4) Adjusting the trailing edge margin .................................. 3-3-11 3-3-3 Main charging section ..................................................................... 3-3-13 ( 1 ) Replacing the charger wire ...................................................... 3-3-13 3-3-4 Exposure section ............................................................................. 3-3-16 ( 1 ) Detaching and refitting the halogen lamp ................................ 3-3-16 ( 2 ) Detaching and refitting the optical section thermostat ............. 3-3-17 ( 3 ) Adjusting the positions of the light adjusters ........................... 3-3-18 ( 4 ) Detaching and refitting the scanner wires ............................... 3-3-19 (4-1) Detaching the scanner wires .......................................... 3-3-19 (4-2) Installing the scanner wires ............................................ 3-3-21 ( 5 ) Adjusting longitudinal image squareness (inclination of light source 2) .................................................... 3-3-30 ( 6 ) Adjusting lateral image squareness (height of light source 2) .......................................................... 3-3-31 ( 7 ) Making fine adjustment to image focus .................................... 3-3-32 (7-1) Adjusting the mirror home position for 100% copying .................................................................. 3-3-33 (7-2) Adjusting the mirror home position for enlargement mode ........................................................... 3-3-35 (7-3) Adjusting the mirror home position for reduction mode ................................................................ 3-3-36 ( 8 ) Setting the exposure amount .................................................. 3-3-37 ( 9 ) Adjusting the auto exposure .................................................... 3-3-41 (10) Adjusting exposure amount for enlargement /reduction mode. ...................................................................... 3-3-42 (10-1) Adjusting exposure amount for enlargement mode (141%) ......................................................................... 3-3-43 (10-2) Adjusting exposure amount for reduction mode (70%) ........................................................................... 3-3-44 (11) Adjusting lateral magnification (correcting the lens travel distance) ........................................ 3-3-45 (11-1) Correcting the lens travel distance for 100% copying .............................................................. 3-3-46 (11-2) Correcting the lens travel distance for enlargement copying.................................................... 3-3-47 (11-3) Correcting the lens travel distance for reduction copying ......................................................... 3-3-48 (12) Adjusting longitudinal magnification (scanning speed) ............ 3-3-49

195-1 3-3-5

3-3-6

3-3-7 3-3-8

3-3-9

Drum section (metric specification only) ......................................... 3-3-50 ( 1 ) Detaching and refitting the drum ............................................. 3-3-50 ( 2 ) Cleaning the drum ................................................................... 3-3-52 Developing section (metric specification only) ................................ 3-3-53 ( 1 ) Replacing developer ................................................................ 3-3-53 ( 2 ) Adjusting the formation position of the magnetic brush (reference) .................................................................. 3-3-54-1 ( 3 ) Adjusting developing bias voltage (reference) ..................... 3-3-54-2 Transfer section .............................................................................. 3-3-55 ( 1 ) Replacing the charger wires .................................................... 3-3-55 Cleaning section (metric specification only) .................................... 3-3-59 ( 1 ) Replacing the cleaning blade .................................................. 3-3-59 ( 2 ) Detaching and refitting the lower cleaning blade ..................... 3-3-61 Fixing section .................................................................................. 3-3-62 ( 1 ) Detaching and refitting the fixing heater .................................. 3-3-62 ( 2 ) Detaching and refitting the fixing unit thermistor ..................... 3-3-65 ( 3 ) Detaching and refitting fixing thermostats 1 and 2 .................. 3-3-66 ( 4 ) Detaching and refitting the press roller .................................... 3-3-67 ( 5 ) Detaching and refitting the heat roller ..................................... 3-3-69 ( 6 ) Detaching and refitting the heat roller separation claws .......... 3-3-71 ( 7 ) Detaching and refitting the fixing blade ................................... 3-3-72

195

3-3-1 Precautions for assembly and disassembly

( 1 ) Precautions Be sure to turn the main switch off and disconnect the power plug before starting disassembly. When handling PCBs, do not touch connectors with bare hands or damage the board. Do not touch any PCB containing ICs with bare hands or any object prone to static charge. Use only the specified parts to replace the fixing unit or optical section thermostats. Never substitute simple wire or similar for thermostats since the copier may be seriously damaged. When installing a thermostat, ensure the correct clearance, if specified, using a thickness gauge. Use the following testers when measuring voltages: Hioki 3200 Sanwa MD-180C Sanwa YX-360TR Beckman TECH300 Beckman DM45 Beckman 330 (capable of measuring RMS values) Beckman 3030 (capable of measuring RMS values) Beckman DM 850 (capable of measuring RMS values) Fluke 8060A (capable of measuring RMS values) Arlec DMM1050 Arlec YF1030C Prepare the following as test originals: 1. NTC (new test chart) 2. NPTC (newspaper test chart) 3. Blue graph paper

3-3-1

195

3-3-2 Paper feed section

( 1 ) Detaching and refitting paper feed pulleys A and B Clean or replace paper feed pulleys A or B as follows. Procedure 1. Detach the drawer. 2. Detach the rear cover. 3. Release the lever of the paper feed clutch with a straight screwdriver in the direction of the arrow.

Lever

Paper feed clutch

Figure 3-3-1 4. Turn the paper feed shaft to an angle of 180 degrees where paper feed pulleys A and B can be seen.

Paper feed pulley B Paper feed pulley A Paper feed pulley B

Figure 3-3-2

3-3-2

195 5. Remove the paper feed pulley unit: push it toward the machine rear and pull it out of the bushing toward the machine front.

Bushing

Paper feed pulley unit

Figure 3-3-3 6. Remove each screw and then paper feed pulleys A and B from the paper feed pulley unit.

Paper feed pulley B

Paper feed pulley A Paper feed pulley B

Figure 3-3-4 7. Clean or replace paper feed pulleys A and B. When installing a new pulley, be sure that the white film surfaces are facing the machine front. 8. Refit all the removed parts.

3-3-3

195 ( 2 ) Replacing the feedshift films Replace the feedshift films as follows. Procedure 1. Open the front cover and take the toner cartridge out of the copier. 2. Unlock the developing unit release lever and remove the developing unit and drum unit. 3. Remove the left, right, front left and front right covers. 4. Remove the E-ring holding the release unit shaft and detach the unit in the direction of the arrow in the figure.

Release unit

E-ring

Figure 3-3-5 5. Replace the feedshift films by aligning their edges with the line a shown in the figure.

Feedshift films

Figure 3-3-6 6. Refit all the removed parts.

3-3-4

195

3-3-5

195

B
Yes

A
Setting range: 89 to 249 Reference: 108 for 100% copy 121 for enlargement copy 91 for reduction copy Change per step: 0.12 mm Increasing the value makes the timing of the second paper feed earlier, and reducing it makes the timing later.

Adjust another mode?

No Press the stop/clear key.

Exit simulation mode.

End

Original

Copy example 1

Copy example 2

Figure 3-3-7

3-3-6

195 (3-2) Adjusting the leading edge margin Adjust the leading edge margin as follows if it is not within the specified range.
No. 58 (page 3-3-5) No. 54

Important: Before starting this adjustment, ensure the above simulations have been completed. Procedure

Start

Enter simulation mode.

Enter 54 with the numeric keys.

Press the print key.

Select the mode to be adjusted with the copy exposure adjustment keys. The current setting is displayed. Press the zoom input/enter key. Test copy mode is set. Place an A4/81/2" 11" sheet on the contact glass with the original holder open (see Figure 3-3-8).

Mode 1: 100% copy Mode 2: enlargement (141%) copy Mode 3: reduction (70%) copy Press the print key. The new setting is stored.

Press the print key and make a test copy.

Is leading edge margin A within the specified range*1? Yes

No

Change the setting with the zoomup/down key. *1 Specified setting 3 mm for 100% copy 4.5 mm for enlargement copy 3 mm for reduction copy

3-3-7

195

B
Yes

A
Setting range: 25 to 167 References: 131 for 100% copy 140 for enlargement copy 127 for reduction copy Change per step: 0.12 mm Increasing the value makes the margin wider, and reducing it makes the margin narrower.

Adjust another mode?

No Press the stop/clear key.

Exit simulation mode.

End

Contact glass

A4/81/2" 11" sheet

Figure 3-3-8

A: Use a scale to measure accurately.

Figure 3-3-9

3-3-8

195 (3-3) Adjusting the trailing edge blank cut timing Adjust the trailing edge blank cut timing as follows if the trailing edge margin is not 5 3 mm (inch specs) or 15 3 mm (metric specs).
No. 58 (page 3-3-5) No. 54 (page 3-3-7) No. 57

Important: Before starting this adjustment, ensure the above simulations have been completed. Procedure
Start

Enter simulation mode.

Enter 57 with the numeric keys.

Press the print key. The current setting is displayed. Press the zoom input/enter key. Test copy mode is set. Place the maximum size of sheet on the contact glass with the original holder open (see Figure 3-310). Press the print key. The new setting is stored.

Press the print key to make a test copy.

Is the trailing edge margin within the setting range?*1 Yes

No

Change the setting with the zoomup/down key. *1 Setting range: 5 mm 3 mm (inch specs) 15 mm 3 mm (metric specs)

3-3-9

195

A
Press the stop/clear key. Setting range: 0 to 84 Reference: 84 Change per step: 0.12 mm Increasing the value makes the margin wider, and decreasing it makes the margin narrower.

Exit simulation mode.

End

Copy paper (maximum size)

Contact glass

Figure 3-3-10

A: Use a scale to measure accurately

Figure 3-3-11

3-3-10

195 (3-4) Adjusting the trailing edge margin Adjust the trailing edge margin as follows if it is not 0 mm.
No. 58 (page 3-3-5) No. 54 (page 3-3-7) No. 57 (page 3-3-9) No. 59

Important: Before starting this adjustment, ensure the above simulations have been completed. Procedure
Start

Enter simulation mode.

Enter 59 with the numeric keys.

Press the print key. The current setting is displayed. Press the zoom input/enter key. Test copy mode is set. Place an A4/81/2" 11" sheet on the contact glass with the original holder open (see Figure 3-3-12). Press the print key. The new setting is stored.

Press the print key to make a test copy.

Is the trailing edge margin A 0 mm? Yes

No

Change the setting with the zoomup/down keys

3-3-11

195

A
Press the stop/clear key. Setting range: 10 to 110 Reference: 95 Change per step: 0.2 mm Increasing the value makes the margin wider, and decreasing it makes the margin narrower.

Exit simulation mode.

End

A4/81/2" 11" sheet

Contact glass

Figure 3-3-12

A: Use a scale to measure accurately.

Figure 3-3-13

3-3-12

195

3-3-3 Main charging section

( 1 ) Replacing the charger wire Take the following procedure when the charger wire is broken or to be replaced. Precautions Use the specified tungsten wire for the charger wire. The part of the wire wrapped around the charger spring must not protrude from the charger housing. The cut end of the charger wire must not protrude more than 2 mm from under the charger wire retainer pin. Use a clean, undamaged tungsten charger wire. Keep the charger wire taut by ensuring that the charger spring is under tension. Clean the main charger shield first with a damp cloth and then with a dry cloth when replacing the charger wire. Caution: Do not use organic solvents such as alcohol or thinner to clean the main charger. Procedure 1. Open the front cover and take the toner cartridge out of the copier. 2. Unlock the developing unit release lever and remove the developing unit and drum unit. 3. Remove the screw and main charger retainer.

Main charger retainer

Screw

Figure 3-3-14

3-3-13

195 4. Remove the main charger. 5. Remove the main charger front and rear lids with a straight screwdriver. 6. Remove the charger wire retainer pin and charger spring, then the charger wire.

Charger spring Main charger rear lid

Charger wire

Main charger front lid

Charger wire retainer pin

Figure 3-3-15

7. Wind the new tungsten wire at least five turns around one end of the charger spring. The length of the cut wire must be less than 2 mm. 8. Hook the other end of the charger spring onto the main charger terminal of the main charger rear housing.

Main charger terminal 2 mm or less

Charger spring

Charger wire

Figure 3-3-16

3-3-14

195 9. Run the wire through the notch in the main charger front and rear housing and pull it tight so that the distance from the end of the charger spring to the notch in the main charger rear housing is between 7 and 9 mm.
Charger spring Notch

7 to 9 mm

Figure 3-3-17 10. Insert the retainer pin into the main charger front housing to fix the charger wire 11. Cut off the excess wire under the retainer pin so less than 2 mm protrudes.

2 mm or less

Charger wire

Charger wire retainer pin

Figure 3-3-18 12. Refit the front and rear lids to the main charger. Ensure that the larger lid is refit to the front housing and smaller lid to the rear housing. 13. Refit all the removed parts.

3-3-15

195

3-3-4 Exposure section

( 1 ) Detaching and refitting the halogen lamp Clean or replace the halogen lamp as follows. Procedure 1. Remove the rear and right covers, then the contact glass. 2. Move light source unit 1 to the cutout in the copier rear. 3. Press the lamp terminal at the copier rear in the direction of the arrow and remove it from the halogen lamp. 4. Remove the halogen lamp from the cutout in the copier rear. When removing the lamp, touch only the ceramic parts.

Lamp terminal

Halogen lamp

Figure 3-3-19 5. Clean or replace the halogen lamp. When replacing the halogen lamp, ensure that the projection of the lamp is facing up so that it does not come in contact with the other parts such as the reflectors. 6. Refit all the removed parts.

3-3-16

195 ( 2 ) Detaching and refitting the optical section thermostat Check or replace the optical section thermostat as follows. Caution: Use the specified thermostat for replacement. Do not substitute a simple wire or similar; otherwise, the copier will be seriously damaged. Procedure 1. Remove the right cover, then the contact glass. 2. Remove the fast-on terminals of the optical section thermostat. 3. Check for continuity across the terminals using a tester. 4. If none, remove the two screws and then the optical thermostat, and fit a new thermostat.

Optical section thermostat

Fast-on terminals

Figure 3-3-20 5. Refit all the removed parts.

3-3-17

195 ( 3 ) Adjusting the positions of the light adjusters Perform the following adjustment after refitting or replacing the light adjusters, or if the copy image is abnormally light or dark on one side. Before starting this adjustment, be sure that the main and transfer charges, mirrors and dust filter are not stained with toner. Procedure
Start

Make a test copy at 100% with the maximum size of copy paper.

Adjust the positions of the light adjusters.

Is the copy image correct?

No

Yes End

If the copy image is not correct on the machine front, adjust the light adjuster on the machine rear. If the copy image is not correct on the machine rear, adjust the light adjuster on the machine front. Moving an adjuster to the machine right (e) makes the copy image darker, and moving it to the machine left (a) makes the copy image lighter.
Light adjusters

Figure 3-3-21

3-3-18

195 ( 4 ) Detaching and refitting the scanner wires Perform the following steps when a scanner wire is broken or to be replaced. Important: After replacing a scanner wire, proceed to ( 5 ) Adjusting longitudinal image squareness (see page 3-3-30) and ( 7 ) Making fine adjustment to image focus (see page 3-3-32). (4-1) Detaching the scanner wires Procedure 1. Remove the rear, right and left covers, then the contact glass. 2. Remove the front left and front right covers, then the operation unit. 3. Remove the screw holding the scanner feed wire and remove the feed wire connector.

Connector

Clamp

Scanner feed wire

Figure 3-3-22 4. Remove the scanner feed wire from the feed wire guide.

Feed wire guide Scanner feed wire

Figure 3-3-23

3-3-19

195 5. Remove each two screws and then the wire retainers on the front and rear of light source unit 1. 6. Remove light source unit 1 from the copier.

Light source unit 1

Wire retainers

Figure 3-3-24 7. Unhook the springs on the ends of each scanner wire and remove the scanner wires from each pulley.

3-3-20

195 (4-2) Installing the scanner wires Required installation jig Scanner wire drum clips (P/N 75700330) Procedure 1. Take the fixing unit out of the copier (see page 3-3-62). 2. Remove the eight screws and then the upper left reinforcement plate from the copier.

Upper leftreinforcement plate

Figure 3-3-25

3-3-21

195 3. Remove the two screws and then the scanner motor from the scanner motor mount.

Scanner motor

Scanner motor mount

Figure 3-3-26 4. Remove the E-ring, bushing and the four screws, and then detach the scanner motor mount from the copier.

E-ring

Bushing

Scanner motor mount

Figure 3-3-27

3-3-22

195 5. Remove the screw and then scanner drive gear 64 from the copier.
Scanner drive gear 64

Figure 3-3-28 6. Remove the E-ring and bushing on the copier front, and then detach scanner wire drum A from the copier.

Scanner wire drum A

Bushing

E-ring

Figure 3-3-29

3-3-23

195 7. Fit a new scanner wire to scanner wire drum A (on the machine front) as follows. Numbers in circles correspond with those in Figure 3-3-30. 1 Holding the scanner wire by the ball furthest from an end, with that longer end on the right side of the machine and the other end on the left, insert the ball into the hole in scanner wire drum A. 2 Run the shorter end of the scanner wire six times around the drum toward the machine outside. 3 Run the longer end of the wire three times around the drum toward the machine inside. 4 Hold the scanner wire in place with the scanner wire drum clip.

Machine left

2
Shorter end

4 1
3 turns

Scanner wire drum clip

Machine front

Machine rear

6 turns Scanner wire drum A Longer end

Machine right

Figure 3-3-30

3-3-24

195 8. Install the new scanner wire to the scanner wire drum A (on the machine rear) as follows. Numbers in circles correspond with those in Figure 3-3-31. 1 Holding the scanner wire with the ball furthest from an end, with that longer end from the ball on the right side of the machine and the other end on the left, insert the ball into the hole in scanner wire drum A. 2 Run the shorter end of the scanner wire six times around the drum toward the machine outside. 3 Run the longer end of the wire three times around the drum toward the machine inside. 4 Hold the scanner wire in place with the scanner wire drum clip.
Machine left

2
Shorter end Scanner wire drum clip

4
3 turns

1
Machine rear

Machine front

6 turns Scanner wire drum A

Longer end

Machine right

Figure 3-3-31

3-3-25

195 9. Refit the scanner wire drum A to the copier. 10. Refit scanner drive gear 64, the bushing, scanner motor mount and upper left reinforcement plate. 11. Remove the two screws holding the optical fan motor.

Screws

Optical section fan motor

Figure 3-3-32 12. Move light source unit 2 to the copier center and hold it with the two screws removed from the optical section fan motor.

Screw

Light source unit 2

Screw

Figure 3-3-33

3-3-26

195 13. Route the scanner wire on the machine front around each pulley as follows. Numbers in circles correspond with those in Figure 3-3-34. 1 Loop the shorter end of the scanner wire around the inner groove in the pulley on the left side of the machine from bottom to top. 2 Loop the wire around the outer groove in the pulley of light source unit 2 from top to bottom. 3 Loop the wire around the inner groove in the pulley in the center of the machine from top to bottom. 4 Hook the spring on the end of the wire temporarily onto its holder on the right side of the machine. 5 Loop the longer end of the wire around the inner groove in the pulley of the upper right side of the machine from bottom to top. 6 Loop the wire around the inner groove in the pulley of light source unit 2 from top to bottom and then thread wire c between wires a and b from top to bottom. 7 Loop the wire around the inner groove in the pulley of the lower right of the machine from top to bottom. 8 Run the wire twice toward the inside of scanner wire drum B and insert the ball into the hole in the drum. 9 Run the wire another two turns around the drum. 0 Unhook the spring from its holder in step 4 and hook the two springs together.

1 Inner

2 Outer

Inner

3 Inner 4 5 Inner 8
2 turns

7 Inner

9 2 turns
Figure 3-3-34

3-3-27

195 14. Route the scanner wire on the machine rear around each pulley as follows. Numbers in circles correspond with those in Figure 3-3-35. 1 Loop the shorter end of the scanner wire around the inner groove in the pulley on the left side of the machine from bottom to top. 2 Loop the wire around the outer groove in the pulley of light source unit 2 from top to bottom. 3 Loop the wire around the inner groove in the pulley in the center of the machine from top to bottom. 4 Hook the spring on the end of the wire temporarily onto its holder on the right side of the machine. 5 Loop the longer end of the wire around the inner groove in the pulley of the upper right side of the machine from bottom to top. 6 Loop the wire around the inner groove in the pulley of light source unit 2 from top to bottom, and then thread wire c between wires a and b from top to bottom. 7 Loop the wire around the inner groove in the pulley of the lower right of the machine from top to bottom. 8 Run the wire twice toward the inside of scanner wire drum B and insert the ball into the hole in the drum. 9 Run the wire another two turns around the drum. 0 Unhook the spring from its holder in step 4 and hook the two springs together.

1 Inner

Inner

2 Outer

3 Inner b 4 0
2 turns

5 Inner

9 2 turns

7 Inner

Figure 3-3-35

3-3-28

195 15. Remove the front and rear scanner wire drum clips from scanner wire drum A. 16. Remove the screw holding light source unit 2 and refit the optical section fan motor. 17. Turn scanner wire drum A and move light source unit 2 all the way toward the machine right. 18. Turn scanner wire drum B until the screw on the front side of the drum can be seen through the cutout in the upper right reinforcement plate.

Upper right reinforcement plate

Screw

Scanner wire drum B

Figure 3-3-36 19. Mount light source unit 1 onto the front and rear scanner rails. When mounting, ensure that the scanner wire on the top is above light source unit 1. 20. Run the scanner feed wire along the feed wire guide and refit it to the connector on the machine rear. Refit the clamp to hold the scanner feed wire. Be sure that the scanner feed wire is not twisted. 21. Move light source unit 1 all the way toward the machine right and refit the wire retainers. 22. Refit all the removed parts. 23. Perform ( 5 ) Adjusting longitudinal image squareness (see 3-3-30) and ( 7 ) Making fine adjustment to image focus (see 3-3-32).

3-3-29

195 ( 5 ) Adjusting longitudinal image squareness (inclination of light source 2) Make the following adjustment after replacing the scanner wires, or if the copy image is longitudinally skewed (longitudinal squareness is not obtained). Procedure
Start

Make a test copy with an A4/81/2" 11" sheet.

Tighten the adjustment screw on the scanner wire drum.

Adjust the inclination by loosening the adjustment screw on scanner wire drum B and then turning the drum. Is the copy image correct? No

Yes End

Original

Copy example 1 Copy example 2

Figure 3-3-37 To correct an image as in copy example 1, turn scanner wire drum B in the direction of the black arrow ( a). To correct an image as in copy example 2, turn scanner wire drum B in the direction of the white arrow ( e).

Scanner wire drum B Adjustment screw

Figure 3-3-38

3-3-30

195 ( 6 ) Adjusting lateral image squareness (height of light source 2) Make the following adjustment if the copy image is laterally skewed (lateral squareness is not obtained). Procedure
Start

Make a test copy with an A4/81/2" 11" sheet.

Tighten the two screws of the mirror frame adjustment plate.

Adjust the height of light source unit 2 by turning its adjustment screw.

Loosen the two screws holding the mirror frame adjustment plate. Is the copy image in focus? No

Yes End

Original

Copy example 1 Copy example 2

Figure 3-3-39 To correct an image as in copy example 1, turn the adjustment screw clockwise. To correct an image as in copy example 2, turn the adjustment screw counterclockwise. Important: Paint-lock the adjustment screw of light source 1 after adjustment.

Adjustment screw

Light source 2

Screws

Mirror frame adjustment plate

Figure 3-3-40

3-3-31

195 ( 7 ) Making fine adjustment to image focus Perform the following adjustment after replacing the optical wires, or if the entire copy image is out of focus. Mode setting procedure

Start

Check that exposure is correctly set in ( 8 ) Setting the exposure amount.

Run simulation (7-1) Adjusting the mirror home position for 100% copying.

Run simulation (7-2) Adjusting the mirror home position for enlargement mode.

Run simulation (7-3) Adjusting the mirror home position for reduction mode.

End

3-3-32

195 (7-1) Adjusting the mirror home position for 100% copying Procedure
Start

Enter simulation mode.

Enter 25 with the numeric keys.

Press the print key.

Select the mode to be adjusted and change the setting to 0.

Press the stop/clear key.

Enter 27 with the numeric keys.

Press the print key.

Select the mode to be adjusted and change the setting to 0 for modes 1 to 4 and 32 for modes 5 and 6 with the zoom up/down keys.

Select mode 6 with the copy expo The current setting is displayed. sure adjustment keys.

Place the NTC on the contact glass and A4/81/2" 11" copy paper.

3-3-33

195

A
Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy.

Is the copy image in focus? Yes Press the stop/clear key.

No

Change the setting with the zoom up/down keys. Setting range: 0 to 63 Reference: 32

Exit simulation mode.

End

3-3-34

195 (7-2) Adjusting the mirror home position for enlargement mode Procedure
Start

Enter simulation mode.

Enter 27 with the numeric keys.

Press the print key.

Select mode 3 with the copy expo The current setting is displayed. sure adjustment keys.

Place the NTC on the contact glass and A4/81/2" 11" copy paper. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy at 141%.

Is the copy image in focus?

No

Change the setting with the zoom up/down keys. Setting range: 8 to 8 Reference: 0

Yes Press the stop/clear key.

Exit simulation mode.

End

3-3-35

195 (7-3) Adjusting the mirror home position for reduction mode Procedure
Start

Enter simulation mode.

Enter 27 with the numeric keys.

Press the print key.

Select mode 4 with the copy expo The current setting is displayed. sure adjustment keys.

Place the NTC on the contact glass and A4/81/2" 11" copy paper. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy at 70%.

Is the copy image in focus?

No

Change the setting with the zoom up/down keys. Setting range: 8 to 8 Reference: 0

Yes Press the stop/clear key.

Exit simulation mode.

End

3-3-36

195 ( 8 ) Setting the exposure amount Perform the following adjustment when the drum is replaced. Precautions Check that the developer density is correct. Check that the halogen lamp has not deteriorated. Clean the optical system. Never touch controls VR1, VR2 or VR3 on the AVR PCB. Mode setting procedure

Start

Select mode 1 (manual Exp. 4).

Select mode 2 (manual Exp. 1).

Select mode 3 (manual Exp. +2).

End

3-3-37

195 Procedure

Start

Enter simulation mode.

Enter 24 with the numeric keys.

Press the print key.

Place the NTC on the contact glass and select mode 1 with the copy exposure adjustment keys.

The current setting is displayed.

Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy at Exp. 4. Setting range: 20 to 100 Reference: 62 Is the image abnormally light? No Yes Decrease the setting with the zoom-down key.

Is the image abnormally dark? No

Yes

Increase the setting with the zoom-up key. Increasing the value makes the image lighter, and decreasing it makes the image darker.

3-3-38

195

A
Place the blue graph paper on the contact glass and select mode 2 The difference from the setting in with the copy exposure adjustmode 1 (Exp. 4) is displayed. ment keys. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy at Exp. 1. Setting range: 40 to 0 Reference: 18 Is the image abnormally light? No Yes Decrease the setting with the zoom-down key.

Is the image abnormally dark? No

Yes

Increase the setting with the zoom-up key. Increasing the value makes the image lighter, and decreasing it makes the image darker.

3-3-39

195

B
Place the NPTC on the contact glass and select mode 3 with the copy exposure adjustment keys. The difference from the setting in mode 1 (Exp. 4) is displayed. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy at Exp. +2. Setting rage: 0 to 50 Reference: 30 Is the image abnormally light? No Yes Decrease the setting with the zoom-down key.

Is the image abnormally dark? No Press the stop/clear key.

Yes

Increase the setting with the zoom-up key. Increasing the value makes the image lighter, and decreasing it makes the image darker.

Exit simulation mode.

End

3-3-40

195-1 195 ( 9 ) Adjusting the auto exposure Procedure

Start

Check that exposure is correctly set in ( 8 ) Setting the exposure amount.

Select mode 2 with the exposure adjustment keys.

Enter simulation mode.

Place the NTC on the contact glass.

Enter 28 with the numeric keys.

Press the copy size key to start prescanning.

Press the print key. Select mode 3 with the exposure adjustment keys. Select mode 1 with the exposure adjustment keys. Place the NPTC on the contact glass. Place five sheets of A4/81/2" 11" plain white paper on the contact glass.

Press the copy size key to start prescanning.

Press the copy size key. Prescan is performed repeatedly until the output level stabilizes at around the reference. Prescan then stops automatically.*1

Press the stop/clear key.

Exit simulation mode.

End

*1 When the AE sensor or exposure lamp is broken, prescanning is repeated until the stop/clear key is pressed.

3-3-41

195 (10) Adjusting exposure amount for enlargement/reduction mode Make the following adjustment when replacing the main PCB or drum. Mode setting procedure

Start

Check that exposure is correctly set in ( 8 ) Setting exposure amount.

Perform (10-1) Adjusting exposure amount for enlargement mode.

Perform (10-2) Adjusting exposure amount for reduction mode.

End

3-3-42

195 (10-1) Adjusting exposure amount for enlargement mode (141%) Procedure
Start

Enter simulation mode.

Enter 29 with the numeric keys.

Press the print key.

Select mode 1 with the exposure adjustment keys.

The difference from the setting in simulation 24-1 is displayed.

Place the NTC on the contact glass and A4/81/2" 11" copy paper. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy at 141%.

Is the copy image abnormally light? No

Yes

Decrease the setting with the zoom-down key.

Is the copy image abnormally dark? No Press the stop/clear key.

Yes

Increase the setting with the zoom-up key. Setting range: 20 to 20 Reference: 0 Increasing the value makes the image lighter, and decreasing it makes the image darker.

Exit simulation mode.

End

3-3-43

195 (10-2) Adjusting exposure amount for reduction mode (70%) Procedure
Start

Enter simulation mode.

Enter 29 with the numeric keys.

Press the print key.

Select mode 2 with the exposure adjustment keys.

The difference from the setting in simulation 24-1 is displayed.

Place the NTC on the contact glass and A4/81/2" 11" copy paper. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy at 70%.

Is the copy image abnormally light? No

Yes

Decrease the setting with the zoom-down key.

Is the copy image abnormally dark? No Press the stop/clear key.

Yes

Increase the setting with the zoom-up key. Setting range: 20 to 20 Reference: 0 Increasing the value makes the image lighter, and decreasing it makes the image darker.

Exit simulation mode.

End

3-3-44

195 (11) Adjusting lateral magnification (correcting the lens travel distance) Make the following adjustment if the lateral magnification is not correct. Mode setting procedure
Start

Check that exposure is set correctly in ( 8 ) Setting exposure amount.

Perform (11-1) Correcting the lens travel distance for 100% copying.

Perform (11-2) Correcting the lens travel distance for enlargement copying.

Perform (11-3) Correcting the lens travel distance for reduction copying.

End

3-3-45

195 (11-1) Correcting the lens travel distance for 100% copying Procedure
Start

Enter simulation mode.

Enter 25 with the numeric keys.

Press the print key.

Select mode 1 with the exposure adjustment keys.

The current setting is displayed.

Place the NTC on the contact glass and A4/81/2" 11" copy paper. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy.

Is the copy image too wide? No

Yes

Decrease the setting with zoomdown key.

Is the copy image too narrow? No Press the stop/clear key.

Yes

Increase the setting with zoom-up key. Setting range: 20 to 20 Reference: 0 Change per step: 0.1% Increasing the value makes the wider, and decreasing it makes the image narrower.

Exit simulation mode.

End

3-3-46

195 (11-2) Correcting the lens travel distance for enlargement copying Procedure
Start

Enter simulation mode.

Enter 25 with the numeric keys.

Press the print key.

Select mode 2 with the exposure adjustment keys.

The current setting is displayed.

Place the NTC on the contact glass and A4/81/2" 11" copy paper. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy at 141%.

Is the copy image too wide? No

Yes

Decrease the setting with zoomdown key.

Is the copy image too narrow? No Press the stop/clear key.

Yes

Increase the setting with zoom-up key. Setting range: 20 to 20 Reference: 0 Change per step: 0.1% Increasing the value makes the image wider, and decreasing it makes the image narrower.

Exit simulation mode.

End

3-3-47

195 (11-3) Correcting the lens travel distance for reduction copying Procedure
Start

Enter simulation mode.

Enter 25 with the numeric keys.

Press the print key.

Select mode 3 with the exposure adjustment keys.

The current setting is displayed.

Place the NTC on the contact glass and A4/81/2" 11" copy paper. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy at 70%.

Is the copy image too wide? No

Yes

Decrease the setting with zoomdown key.

Is the copy image too narrow? No Press the stop/clear key.

Yes

Increase the setting with zoom-up key. Setting range: 20 to 20 Reference: 0 Change per step: 0.1% Increasing the value makes the image wider, and decreasing it makes the image narrower.

Exit simulation mode.

End

3-3-48

195 (12) Adjusting longitudinal magnification (scanning speed) Perform the following adjustment if the longitudinal magnification is not correct. Procedure
Start

Enter simulation mode.

Enter 26 with the numeric keys.

Press the print key.

The current setting is displayed.

Place the NTC on the contact glass and A4/81/2" 11" copy paper. Press the print key. The new setting is stored. Press the zoom input/enter key. Test copy mode is set.

Press the print key to make a test copy.

Is the copy image too long? No

Yes

Decrease the setting with zoomdown key.

Is the copy image too short? No Press the stop/clear key.

Yes

Increase the setting with zoom-up key. Setting range: 1 to 20 Reference: 13 Change per step: 0.2% Increasing the value makes the image longer, and decreasing it makes the image shorter.

Exit simulation mode.

End

3-3-49

195

3-3-5 Drum section (metric specification only)

( 1 ) Detaching and refitting the drum Perform the following steps when cleaning or replacing the drum. Precautions Avoid direct sunlight and strong light when detaching and refitting the drum. Hold the drum at the ends and never touch the drum surface. After removing the drum, keep it in the drum case or storage bag to protect the surface from light. Procedure 1. Open the front cover and take the toner cartridge out of the copier. 2. Unlock the developing unit release lever and detach the developing unit and drum unit. 3. Remove the screw and then the drum pin from the drum unit. 4. Detach the drum from the drum unit. 5. Remove the bushing from the drum and pull out the drum shaft.

Drum unit Drum shaft

Bushing

Drum

Drum pin

Figure 3-3-41

3-3-50

195 6. Replace the drum. 7. Refit all the removed parts. When refitting the drum pin, ensure that it is inserted correctly into the drum shaft so that the D-cut part of the pin corresponds with that of drum shaft.

3-3-51

195 ( 2 ) Cleaning the drum Clean the drum as follows when an image problem occurs, or if the drum is dirty. Precautions Avoid direct sunlight and strong light when cleaning the drum. Dust in the air and from the cleaning pad may damage the drum during operation. Avoid working in dusty place. Clean the drum entirely even if it is only dirty locally. Do not clean the drum with alcohol, thinner or other organic solvent. Required supplies Polishing cloth: specified synthetic cotton Toner Procedure 1. Detach the drum (see page 3-3-50). 2. Apply a polishing cloth to the drum and gently wipe the drum taking care not to damage the surface. 3. Apply toner to another cloth and wipe the drum surface with it in the same manner. 4. Refit the drum. 5. Refit all the removed parts and let the copier stand for 30 minutes. 6. Make a test copy and check the image.

Polishing cloth Drum

Figure 3-3-42

3-3-52

195

3-3-6 Developing section (metric specification only)

( 1 ) Replacing developer Perform the following steps when replacing developer. Important: When replacing developer, place the developing unit on a level surface. Procedure 1. Open the front cover and take the toner cartridge out of the copier. 2. Unlock the developing unit release lever and detach the developing unit. 3. Remove the four screws and then the developing cover from the developing unit by pulling the cover in the direction of the arrow in the figure.

Developing unit

Developing unit cover

Figure 3-3-43

3-3-53

195 4. Remove the old developer from the developing unit. 5. Shake the new developer bottle well to agitate the developer. 6. Pour the new developer evenly into the developing unit while turning the gear in the direction of the arrow in the figure.

Gear Developing unit

Figure 3-3-44 7. Refit all the removed parts. 8. Turn the main switch on while pressing the print key and stop/clear key. 9. 2 s or less after is shown on the copy quantity/magnification display, press the stop/clear key to enter simulation mode. 10. Enter 60 with the copy quantity/zoom-up or -down keys and press the print key. 11. Press the print key. The toner control voltage is set automatically. 12. Press the stop/clear key. 13. Enter 01 with the copy quantity/zoom-up or -down keys and press the print key to exit the simulation mode.

3-3-54

195-1 195

( 2 ) Adjusting the formation position of the magnetic brush (reference) Check or adjust when the image density is too light or a background is visible. Note: Check if the amount of the developer is correct before the adjustment. Procedure 1. Open the front cover and remove the toner cartridge. 2. Unlock the developing unit release lever and remove the developing unit. 3. Remove the developing unit terminal cover from the developing unit (two screws).

Developing unit

Developing unit terminal cover

Figure 3-3-44-1 4. Loosen the screw holding the developing roller retainer. Adjust the developing roller shaft using a scale so that the distance between the top of the magnetic brush and the bottom of the developing unit housing is 12.5 mm (reference value).
Developing roller retainer Screw
A

A:12.5 mm Developing roller shaft

Figure 3-3-44-2 5. Refit the removed parts. 6. Make a test copy and check the copy image.

3-3-54-1 3-3-55

195 195-1

( 3 ) Adjusting developing bias voltage (reference) Make the following adjustment if VR DB on the high voltage PCB has been accidentally turned. Be sure to turn VR DB only when absolutely necessary. Adjustment tools Tester Procedure
Start Tester

Ground

VR DB

With the developing unit removed from the machine, connect the tester positive terminal to the purple DB terminal of the high voltage PCB and the negative one to ground (an uncoated area on the frame).

DB terminal

Figure 3-3-44-3 Adjusting developing bias

Enter the simulation mode.

Run simulation 33.

Is the developing bias correct (reference value: 270 V)? Yes Press stop/clear.

No

Turn VR DB on the high voltage PCB clockwise (e ) to increase the voltage; turn it counterclockwise (a ) to decrease it*. * If the developing bias is set above the reference level, the copy image is too light; if it is below the reference level, a dark background shows.

Exit the simulation mode.

Turn the main switch off and disconnect the tester terminals.

End

3-3-54-2 3-3-56

195

3-3-7 Transfer section

( 1 ) Replacing the charger wires Perform the following steps when the transfer charger wire is broken or is to be replaced. Precautions Use the specified tungsten wire for the charger wire. The part of the wire wrapped around the charger spring must not protrude from the charger housing. The cut end of the charger wire must not protrude more than 2 mm from under the charger wire retainer pin. Use a clean, undamaged tungsten charger wire. Keep the charger wire taut by ensuring the charger spring is under tension. Clean the transfer charger shield first with a damp cloth and then with a dry cloth when replacing the charger wire. Caution: Do not clean the transfer charger shield with alcohol, thinner or other organic solvent. Procedure 1. Open the release unit. 2. Loosen the pins on the front and rear of the release unit.

Pin

Release unit

Pin

Figure 3-3-45

3-3-57 3-3-55

195 3. Remove the connector of the transfer unit and detach the unit.
Connector

Transfer unit

Figure 3-3-46 4. Remove the three screws and then the pre-transfer guide from the transfer unit. 5. Remove the screw holding each of the front and rear transfer stoppers and then detach the stoppers from the transfer unit. 6. Remove the transfer charger front and rear transfer lids with a straight screwdriver. 7. Remove the charger wire retainer pin and charger spring, then the charger wire.

Transfer charger rear lid Charger spring

Pre-transfer guide

Charger wire Transfer charger rear stopper Transfer charger front lid

Charger wire retainer pin

Transfer unit

Transfer charger front stopper

Figure 3-3-47

3-3-58 3-3-56

195 8. Wind the new tungsten wire at least five turns around one end of the charger spring. The length of the cut wire must be less than 2 mm. 9. Hook the other end of the charger spring to the transfer charger terminal of the transfer charger rear housing.

Transfer charger terminal

Charger spring Charger wire

2 mm or less

Figure 3-3-48 10. Run the wire through the notch in the charger wire retainer pin and pull it tight so that the distance from the end of the charger spring to the notch in the main charger rear housing is between 6 and 8 mm.

Charger wire

6 to 8 mm

Notch

Figure 3-3-49

3-3-59 3-3-57

195 11. Press the retainer pin into the projection of the main charger front housing, so holding the charger wire with it. 12. Cut off the excess wire under the retainer pin so less than 2 mm protrudes.

Charger wire

Charger wire retainer pin

2 mm or less

Figure 3-3-50 13. Refit the front and rear lids to the transfer charger. Ensure that the larger lid is refitted to the front housing and smaller lid to the rear housing. 14. Refit all the removed parts.

3-3-60 3-3-58

195

3-3-8 Cleaning section (metric specification only)

( 1 ) Replacing the cleaning blade Replace the cleaning blade as follows. Procedure 1. Open the front cover and take the toner cartridge out of the copier. 2. Unlock the developing unit release lever and detach the developing unit and drum unit. 3. Detach the drum from the drum unit (see page 3-3-50). 4. Remove the two screws and then the upper cleaning cover from the drum unit.

Upper cleaning cover

Drum unit

Figure 3-3-51

3-3-61 3-3-59

195 5. Remove the two screws and then the cleaning upper cover from the drum unit.

Cleaning blade

Drum unit

Figure 3-3-52 6. Replace the cleaning blade. When fitting the cleaning blade, ensure that the projections of the drum unit are seated in the positioning holes in the cleaning blade. 7. Refit all the removed parts.

3-3-62 3-3-60

195 ( 2 ) Detaching and refitting the lower cleaning blade Replace the lower cleaning blade as follows. Procedure 1. Open the front cover and take the toner cartridge out of the copier. 2. Unlock the developing unit release lever and detach the developing unit and drum unit. 3. Detach the drum from the drum unit (see page 3-3-50). 4. Remove the two screws and then the lower cleaning blade from the drum unit.

Drum unit

Lower cleaning blade

Figure 3-3-53 5. Replace the cleaning blade. When fitting the lower cleaning blade, ensure that the projections of the drum unit are seated in the positioning holes in the cleaning blade. 6. Refit all the removed parts.

3-3-63 3-3-61

195

3-3-9 Fixing section

( 1 ) Detaching and refitting the fixing heater Check or replace the fixing heater as follows. Procedure 1. Detach the left cover. 2. Remove the four connectors of the fixing unit from the copier. 3. Remove the four screws and then the fixing unit from the copier.

Connectors

Fixing unit

Figure 3-3-54

3-3-64 3-3-62

195-1 195 4. Remove the four screws and then the copy tray attachment from the fixing unit.

Fixing unit

Figure 3-3-55 5. Remove the two screws and then the fixing unit cover from the fixing unit.

Fixing unit cover

Fixing unit

Figure 3-3-56

3-3-65 3-3-63

195 195-1 6. Remove the fixing unit connector from fixing thermostat 1 (on the copier front). 7. Remove the screw holding each of the front and rear heater mounts, and then detach them from the fixing unit.

Rear heater mount

Fixing thermostat 1

Connector Front heater mount

Fixing unit

Figure 3-3-57
8. Pull the fixing heater out via the front of the fixing unit. 9. Check or replace the fixing heater. 10. Refit all the removed parts.

3-3-66 3-3-64

195-1 195 ( 2 ) Detaching and refitting the fixing unit thermistor Check, clean or replace the fixing unit thermistor as follows. Procedure 1. Take the fixing unit out of the copier (see page 3-3-62). 2. Remove the copy tray attachment and fixing unit cover from the fixing unit (see page 3-3-63). 3. Remove the screw and then the fixing unit thermistor from the fixing unit.

Fixing unit thermistor

Fixing unit

Figure 3-3-58
4. Check, clean or replace the fixing unit thermistor. 5. Refit all the removed parts.

3-3-67 3-3-65

195 195-1 ( 3 ) Detaching and refitting fixing thermostats 1 and 2 Check or replace thermostats 1 and 2 as follows. Caution: Use the specified thermostat for replacement. Do not substitute a simple wire or similar; otherwise, the copier will be seriously damaged. Procedure 1. Take the fixing unit out of the copier (see page 3-3-62). 2. Remove the copy tray attachment and fixing unit cover from the fixing unit (see page 3-3-63). 3. Remove the connectors of the fixing heater, fixing heater wire and thermostat relay wire from fixing thermostats 1 and 2. 4. Remove the two screws holding each of the fixing thermostats and then remove the thermostats from the fixing unit.

Thermostat relay wire Fixing thermostat 2 Fixing heater wire Fixing thermostat 1

Fixing heater Fixing unit

Figure 3-3-59
5. Check or replace fixing thermostat 1 and 2. When fitting, check the temperature indications on the thermostats and fixing stay, and install the thermostats in the correct positions. 6. Refit all the removed parts.

3-3-68 3-3-66

195-1 195 ( 4 ) Detaching and refitting the press roller Clean or replace the press roller as follows. Procedure 1. Take the fixing unit out of the copier (see page 3-3-62). 2. Remove the copy tray attachment from the fixing unit (see page 3-3-63). 3. Remove the fixing unit lower housing and heat roller grounding plate from the fixing unit (two screws).

Fixing unit lower housing Fixing unit

Heat roller grounding plate

Figure 3-3-60

3-3-69 3-3-67

195 4. Remove the screw and then the fixing entrance guide from the fixing unit lower housing. 5. Remove the press roller from the fixing unit lower housing.

Press roller

Fixing entrance guide

Fixing unit lower housing

Figure 3-3-61 6. Clean or replace the press roller. 7. Refit all the removed parts. Press the fixing entrance guide all the way down while refitting it.

3-3-70 3-3-68

195 ( 5 ) Detaching and refitting the heat roller Clean or replace the heat roller as follows. Procedure 1. Take the fixing unit out of the copier (see page 3-3-62). 2. Remove the copy tray attachment, fixing unit cover and fixing unit lower housing from the fixing unit (see page 3-3-63, 67). 3. Remove the three heat roller separation claws from the fixing unit (see page 3-371). 4. Remove the E-ring and then idle gear 20 from the fixing unit.

Fixing unit

E-ring

Idle gear 20

Figure 3-3-62

3-3-71 3-3-69

195 5. Remove the heat roller stopper on the rear of the fixing unit rear, then fixing gear 32 and the heat roller bushing. 6. Remove the heat roller stopper on the front of the fixing unit front and then detach the heat roller bushings. 7. Remove the heat roller from the fixing unit.

Heat roller stopper Heat roller bushing

Fixing gear 32

Heat roller

Heat roller bushing Heat roller stopper

Figure 3-3-63 8. Clean or replace the heat roller. 9. Refit all the removed parts.

3-3-72 3-3-70

195 ( 6 ) Detaching and refitting the heat roller separation claws Check, clean or replace the heat roller separation claws as follows. Procedure 1. Take the fixing unit out of the copier (see page 3-3-62). 2 Remove the copy tray attachment and fixing unit cover from the fixing unit (see page 3-3-63). 3. Orient the heat roller separation claws in the direction of the arrows in the figure, and then detach them.

Fixing unit

Heat roller separation claws

Figure 3-3-64 4. Check, clean and replace the heat roller separation claws. 5. Refit all the removed parts.

3-3-73 3-3-71

195 195-1

( 7 ) Detaching and refitting the fixing blade Perform the following procedure when checking, cleaning or replacing the fixing blade. Procedure 1. Take the fixing unit out of the copier (see page 3-3-62). 2. Remove the copy tray attachment and fixing unit cover from the fixing unit (see page 3-3-63). 3. Remove the screw and then the fixing unit thermistor from the fixing unit. 4. Remove the fixing unit thermistor and fixing blade from the fixing unit (one screw).

Fixing thermistor

Fixing blade

Fixing unit

Figure 3-3-65 4. Check, clean or replace the fixing blade. When refitting the fixing blade, make sure that the blade is in contact with the heat roller. 5. Refit all the removed parts.

3-3-72 3-3-74

195

3-4 PCB Initial Setting

3-4-1 Replacing the main PCB ................................................................... 3-4-1 3-4-2 Adjustment-free variable resistors (VR) ............................................ 3-4-3

195

3-4-1 Replacing the main PCB

After replacing the main PCB, remove the EEPROM from the old main PCB and fit it to the new main PCB. If the new EEPROM is used, perform the following steps. Procedure Before removing the old EEPROM: 1. Record the user settings of the following items which must be reentered after replacement. Exposure mode Manual exposure adjustment Auto exposure adjustment Auto shutoff on/off Auto shutoff time Auto preheat time Preheat recovery time Auto clear on/off Auto clear time 2. Enter simulation mode. 3. Run simulation 73 and record the maintenance count. 4. Exit simulation mode. 5. Turn the main switch off and unplug the power cord. 6. Replace the EEPROM with the new one.

3-4-1

195 195-1 After installing the new EEPROM: 7. Insert the power plug and turn the main switch on. 8. Enter simulation mode. 9. Run simulation 70. 10. Run simulation 93 to select the destination. 11. Run the following simulations to check or reenter the data recorded on the simulation label. Sim. No. 24 25 26 27 28 29 47 54 57 58 59 62 71 73 85 89 91 92 96 98 99 Contents Setting the exposure amount Adjusting lateral magnification Adjusting longitudinal magnification Making fine adjustment to image focus Adjusting the auto exposure Adjusting exposure amount for enlargement/reduction mode Setting the fixing temperature Adjusting the leading edge margin Adjusting the trailing edge blank cut timing Adjusting the leading edge registration timing Adjusting the trailing edge margin Checking/setting the toner control voltage Checking/setting the maintenance cycle Checking/clearing the maintenance count Selecting between auto preheat on/off Setting the presence of the flicker resistor Setting operation under the toner empty condition Selecting between auto start on/off Setting the memory switch Setting the maintenance method (available in Peru only) Selecting between E2000-compliant function on/off

12. Exit simulation mode. 13. Reenter the contents of the user settings recorded in step 1.

3-4-2

195

3-4-2 Adjustment-free variable resistors (VR)

The variable resistors listed below are set at the factory prior to shipping and cannot be adjusted in the field. AVR PCB: VR1, VR2, VR3 High-voltage transformer PCB: VRDB, VRDC

3-4-3

195

3-5 Self-diagnostics
3-5-1 Self diagnostic function ..................................................................... 3-5-1 ( 1 ) Self diagnostic display ............................................................... 3-5-1

195

3-5-1 Self-diagnostic function

(1) Self-diagnostic display This unit is equipped with a self-diagnostic function. When it detects a problem with itself, it disables copying and displays C and a two digit number between 01 and 76 alternately on the copy quantity/magnification display in the operation unit, indicating the nature of the problem. After removing the problem, the self-diagnostic function can be reset by opening and closing the front cover or release unit to turn the safety switch off and back on.

Display alternates

21

Figure3-5-1 Service call code display

3-5-1

195 Self diagnostic codes Code C01 Contents Causes Backup memory Backup memory data problem. data problem Abnormal data is written on the Defective main EEPROM (IC8). PCB or EEPROM (IC8). EEPROM write problem The copier does not enter RDY state more than 1 s after starting to write data to EEPROM (IC8). Drive motor problem The drive motor alarm signal (DM ALM) is detected more than 2 s after the drive motor has been turned on. Defective Main PCB. Defective EEPROM (IC8). Remarks Check procedures/corrective measures Turn the main switch off and on, then run simulation 70 and re-enter the backup memory contents. If C01 persists after re-entering the backup memory contents, replace the main PCB or EEPROM (IC8). Replace the main PCB and check for correct operation. Replace the EEPROM (IC8) and check for correct operation.

C02

C21

Defective rotation Replace the drive motor. control circuit in the drive motor. Poor contact in the connector terminals. Check for continuity across the connector terminals. If none, replace them.

Check if rollers and gears rotate Defective drive transmission sys- smoothly. If not, grease the bushings and gears. Check for broken gears tem. and replace if any. Defective main PCB. Replace the main PCB and check for correct operation. Check for the continuity across the scanner motor coil. If none, replace the scanner motor. Check if CN10-2 on the main PCB goes high when the home position switch is on and goes low when the switch is off. If not, replace the home position switch. Check for continuity across the home position switch connector terminals. If none, replace them.

C30

Scanner motor problem The home position switch does not turn off within 5 s after the scanner motor has started forward rotation. The home position switch does not turn on within 7 s after the scanner motor has started reverse rotation.

Broken scanner motor coil. Defective home position switch.

Poor contact in the home position switch connector terminals.

3-5-2

195 Remarks Causes C30 Scanner motor problem The home position switch does not turn off within 5 s after the scanner motor has started forward rotation. The home position switch does not turn on within 7 s after the scanner motor has started reverse rotation. Lens motor problem The lens home position switch does not turn on or off within 5 s after initial operation has started. Loose scanner drive belt. Loose scanner wire. Check procedures/corrective measures Reinstall the scanner drive belt and adjust the tension. Reinstall the wire.

Code

Contents

Loose screws Retighten the screws and adjust the holding the scan- image focus. ner wire retainers. Defective main PCB. Replace the main PCB and check for correct operation.

C41

Defective lens motor. Defective lens home position switch.

Check for continuity across the coil. If none, replace the lens motor. Check if CN12-9 on the main PCB goes high when the lens home position switch is on and goes low when the switch is off. If not, replace the lens home position switch. Check for continuity across the connector terminals. If none, replace them.

Poor contact in the lens home position switch connector terminals. Defective main PCB.

Replace the main PCB and check for correct operation. Check for continuity across the coil. If none, replace the mirror motor. Check if CN12-3 on the main PCB goes high when the mirror home position switch is on and goes low when the switch is off. If not, replace the mirror home position switch. Check for continuity across the connector terminals. If none, replace them.

C42

Mirror motor problem The mirror home position switch does not turn on or off within 4 s after initial operation has started.

Defective mirror motor. Defective mirror home position switch.

Poor contact in the mirror home position switch connector terminals. Defective main PCB.

Replace the main PCB and check for correct operation.

3-5-3

195 Remarks Causes C50 Main/transfer high-voltage problem The high-voltage alarm signal (HV ALM) is detected more than 2 s after the main highvoltage output has been turned on. Broken main charger wire. The main charger leaks. Broken transfer charger wire. The transfer charger leaks. Defective highvoltage transformer PCB. Defective main PCB. C61 Broken fixing heater filament The fixing stabilization temperature is not reached within 60 s after fixing control has started. The fixing temperature drops below 80 C/ 176F (fixing unit thermistor output voltage: 1.06 V DC) after having reached the stabilization level. Broken fixing heater filament. Fixing heater installed incorrectly. Fixing unit thermostats 1 and 2 triggered. Fixing unit thermistor installed incorrectly. Defective main PCB. Check procedures/corrective measures Check the charger wire visually. If it is broken, replace it. Check the main charger housing. If it is dirty, clean it. Check the transfer charger wire visually. If it is broken, replace it. Check the transfer charger housing. If it is dirty, clean it. Detach the main or transfer charger assembly; if C50 persists, replace the high-voltage transformer PCB. Replace the main PCB and check for correct operation. Check for continuity. If none, replace the fixing heater. Check the fixing heater and reinstall if necessary. Check for continuity. If none, replace fixing unit thermostats 1 and 2. Check the fixing unit thermistor and reinstall if necessary. Replace the main PCB and check for correct operation.

Code

Contents

3-5-4

195 Remarks Causes C63 Broken fixing unit thermistor wire The fixing unit thermistor output voltage does not exceed 0.039 V DC within 7 s after fixing control has started with the fixing temperature remaining below 100 C/212 F (fixing unit thermistor output voltage: 1.71 V DC). Shorted fixing unit thermistor/ abnormally high temperature The fixing temperature exceeds 250 C/ 482 F (fixing unit thermistor output voltage: 4.73 V DC). Broken external temperature thermistor wire The external temperature thermistor output is below 0.3 V DC. Check procedures/corrective measures Broken fixing unit Measure the resistance. If it is , thermistor. replace the fixing unit thermistor. Poor contact in the fixing unit thermistor connector terminals. Defective main PCB. Check for continuity across the connector terminals. If none, replace them. Replace the main PCB and check for correct operation.

Code

Contents

C64

Shorted fixing unit thermistor. Defective main PCB.

Measure the resistance. If it is 0 , replace the fixing unit thermistor. Replace the main PCB and check for correct operation.

C74

Poor contact in Check that the connectors are inthe humidity sen- serted properly. sor PCB connectors. Broken external Measure the resistance across the extemperature ther- ternal temperature thermistor. If it is mistor wire. , replace the humidity sensor PCB. Defective main PCB. Replace the main PCB and check for correct operation.

3-5-5

195 Remarks Causes C75 Shorted external temperature thermistor The external temperature thermistor output is above 4.3 V DC. Developing unit fuse problem The developing unit fuse does not blow within 2 s of power being applied to it, just before the developing unit initialization ends. Check procedures/corrective measures

Code

Contents

Shorted external Measure the resistance across the extemperature ther- ternal temperature thermistor. If it is mistor. 0 , replace the humidity sensor PCB. Defective main PCB. Replace the main PCB and check for correct operation.

C76*

Poor contact in the connector. Defective developing unit fuse.

Check the contacts. Replace the developing unit fuse and check for correct operation.

* Only for 120 V, 220 V and 240 V specifications.

3-5-6

195

3-6 Troubleshooting
3-6-1 Image formation problems ................................................................ 3-6-1 ( 1 ) No image (entirely white). .......................................................... 3-6-3 ( 2 ) No image (entirely black). .......................................................... 3-6-4 ( 3 ) Image is too light. ...................................................................... 3-6-5 ( 4 ) Background is visible. ................................................................ 3-6-5 ( 5 ) A white line appears longitudinally. ........................................... 3-6-6 ( 6 ) A black line appears longitudinally. ........................................... 3-6-6 ( 7 ) A black line appears laterally. .................................................... 3-6-7 ( 8 ) One side of the copy image is darker than the other. ................ 3-6-8 ( 9 ) Black dots appear on the image. ............................................... 3-6-8 (10) Image is blurred. ........................................................................ 3-6-9 (11) The leading edge of the image is consistently misaligned with the original. ........................................................................ 3-6-9 (12) The leading edge of the image is sporadically misaligned with the original. ...................................................................... 3-6-10 (13) Paper creases. ........................................................................ 3-6-10 (14) Offset occurs. .......................................................................... 3-6-11 (15) Black lines appear on both sides of the image in reducation copies. ............................................................... 3-6-12 (16) Image is partly missing. ........................................................... 3-6-12 (17) Fixing is poor. .......................................................................... 3-6-13 (18) Image is out of focus. .............................................................. 3-6-13 (19) Image is not square longitudinally. .......................................... 3-6-13 (20) Image is not square laterally. .................................................. 3-6-14 (21) Image is partially missing laterally. .......................................... 3-6-14 3-6-2 Paper misfeeds ............................................................................... 3-6-15 ( 1 ) A paper jam in the registration section is detected as soon as the main switch is turned on (J03 appears). ......... 3-6-15 ( 2 ) A paper jam in the eject section is detected as soon as the main switch is turned on (J02 appears). ............................ 3-6-15 ( 3 ) A paper jam in the paper drawer is detected during copying (PF appears). ............................................................. 3-6-15 ( 4 ) A paper jam in the registration section is detected during copying (J03 appears). ............................................................ 3-6-16 ( 5 ) A paper jam in the fixing section is detected during copying (J01 appears). ............................................................ 3-6-16 ( 6 ) A paper jam in the eject section is detected during copying (J02 appears). ............................................................ 3-6-16 3-6-3 PCB terminal voltages ..................................................................... 3-6-17 ( 1 ) Power source PCB .................................................................. 3-6-17 ( 2 ) Main PCB ................................................................................ 3-6-19 ( 3 ) AVR PCB ................................................................................. 3-6-22 ( 4 ) Operation unit PCB ................................................................. 3-6-24

195 3-6-4 Electrical problems .......................................................................... ( 1 ) The machine does not operate when the main switch is turned on. ............................................................................. ( 2 ) The drive motor does not operate (C21). ................................ ( 3 ) The scanner motor does not operate (C30). ........................... ( 4 ) The lens motor does not operate (C41). ................................. ( 5 ) The mirror motor does not operate (C42). ............................... ( 6 ) The toner feed motor does not operate. .................................. ( 7 ) The optical section fan motor does not operate. ..................... ( 8 ) The fixing unit fan motor does not operate. ............................. ( 9 ) The internal cooling fan motor does not operate. .................... (10) The paper feed clutch does not operate. ................................. (11) The registration clutch does not operate. ................................ (12) The halogen lamp does not light. ............................................ (13) The halogen lamp does not turn off. ........................................ (14) The cleaning lamp does not light. ............................................ (15) The fixing heater does not turn on (C61, C63). ....................... (16) The fixing heater does not turn off (fixing unit thermostat triggered, C64). .................................... (17) Main charging does not take place (C50). ............................... (18) Transfer charging does not take place (C50). ......................... (19) No developing bias is output. .................................................. (20) A paper jam is indicated as soon as the main switch is turned on. ............................................................................. (21) Others. ..................................................................................... Mechanical problems ...................................................................... ( 1 ) No primary paper feed. ............................................................ ( 2 ) No secondary paper feed. ....................................................... ( 3 ) Skewed paper feed. ................................................................ ( 4 ) The scanner does not travel. ................................................... ( 5 ) Multiple sheets of paper are fed at one time. .......................... ( 6 ) Paper jams. ............................................................................. ( 7 ) Toner drops on the paper conveying path. .............................. ( 8 ) Abnormal noise is heard. ......................................................... 3-6-25 3-6-25 3-6-25 3-6-25 3-6-26 3-6-26 3-6-26 3-6-26 3-6-27 3-6-27 3-6-27 3-6-27 3-6-28 3-6-28 3-6-28 3-6-28 3-6-28 3-6-29 3-6-29 3-6-29 3-6-30 3-6-30 3-6-31 3-6-31 3-6-31 3-6-31 3-6-31 3-6-31 3-6-31 3-6-31 3-6-32

3-6-5

195

3-6-1 Image formation problems

Contents

(1) No image (entirely white).

(2) No image (entirely black).

(3) Image is too light.

(4) Background is visible.

See page 3-6-3. (5) A white line appears longitudinally.

See page 3-6-4. (6) A black line appears longitudinally.

See page 3-6-5. (7) A black line appears laterally.

See page 3-6-5. (8) One side of the copy image is darker than the other.

See page 3-6-6. (9) Black dots appear on the image.

See page 3-6-6. (10) Image is blurred.

See page 3-6-7. (11) The leading edge of the image is consistently misaligned with the original.

See page 3-6-8. (12) The leading edge of the image is sporadically misaligned with the original.

See page 3-6-8.

See page 3-6-9.

See page 3-6-9.

See page 3-6-10.

3-6-1

195 (13) Paper creases. (14) Offset occurs. (15) Black lines appear on both sides of the image in reduction copies. (16) Image is partly missing.

See page 3-6-10. (17) Fixing is poor.

See page 3-6-11. (18) Image is out of focus.

See page 3-6-12. (19) Image is not square longitudinally.

See page 3-6-12. (20) Image is not square laterally.

See page 3-6-13. (21) Image is partially missing laterally.

See page 3-6-13.

See page 3-6-13.

See page 3-6-14.

See page 3-6-14.

3-6-2

195 (1) No image (entirely white). Causes 1. No original present. 2. No main charging. 3. No transfer charging. 4. All blank lamps on. 5. Developing section not driven.

Causes 1. No original present. 2. No main charging. A. Broken main charger wire.

Check procedures/corrective measures Place an original in the correct position.

Replace the wire.

B. Leaking main charger housing. Clean the main charger housing. C. The connector terminals of the Check for continuity across the terminals. If none, high-voltage transformer PCB replace them. make poor contact. D. Defective main PCB. E. Defective high-voltage transformer PCB. 3. No transfer charging. A. Broken transfer charger wire. Replace the wire. Run simulation 33 and check if CN8-4 on the main PCB goes low. If not, replace the main PCB. If main charging does not take place during simulation 33 after the main PCB has been found to be normal, replace the high-voltage transformer PCB.

B. Leaking transfer charger hous- Clean the transfer charger housing. ing. C. The connector terminals of the Check for continuity across the terminals. If none, high-voltage transformer PCB replace them. make poor contact. D. Defective main PCB. E. Defective high-voltage transformer PCB. Run simulation 33 and check if CN8-4 on the main PCB goes low. If not, replace the main PCB. If transfer charging does not take place during simulation 33 after the main PCB has been found to be normal, replace the high-voltage transformer PCB. Run simulation 42 and if the check pattern copy is not obtained, replace the main PCB. Check the gears driving the developing section and replace any broken gears.

4. All blank lamps on. 5. Developing section not driven.

3-6-3

195 (2) No image (entirely black). Causes 1. Broken halogen lamp filament. 2. Halogen lamp fails to light.

Causes

Check procedures/corrective measures

1. Broken halogen lamp filament. Take the halogen lamp out of the unit and check for continuity across the terminals. If none, replace it (see page 3-3-16). 2. Halogen lamp fails to light. A. The optical section thermostat is triggered. Check for continuity. If none, replace the thermostat after determining the cause (see page 3-317).

B. The connector terminals of the Check for continuity across the terminals. If none, AVR PCB make poor contact. replace them. C. Defective main PCB. Run simulation 20 and check if CN7-10 on the main PCB remains low. If it does, replace the main PCB. If the halogen lamp does not light during simulation 20 after the main PCB has been found to be normal, replace the AVR PCB.

D. Defective AVR PCB.

3-6-4

195 (3) Image is too light. Causes 1. Insufficient toner. 2. Deteriorated developer. 3. Misadjusted developing section. 4. Dirty or deteriorated drum.

Causes 1. Insufficient toner. 2. Deteriorated developer.

Check procedures/corrective measures If the add toner indicator is on, replace the cartridge. Check the number of copies made with the current developer. If it has reached the specified limit, replace the developer. Adjust the developing section. Clean the drum. If the maintenance level has been reached, replace it (see page 3-3-50).

3. Misadjusted developing section. 4. Dirty or deteriorated drum.

(4) Background is visible.

Causes 1. Dirty optical section. 2. Deteriorated developer.

Causes 1. Dirty optical section. 2. Deteriorated developer.

Check procedures/corrective measures Clean the main and auxiliary reflectors, mirrors and other parts in the optical section. Check the number of copies made with the current developer. If it has reached the specified limit, replace the developer.

3-6-5

195 (5) A white line appears longitudinally. Causes 1. Dirty or flawed main charger wire. 2. Foreign matter in the developing section. 3. Flawed drum.

Causes 1. Dirty or flawed main charger wire. 2. Foreign matter in the developing section. 3. Flawed drum.

Check procedures/corrective measures Clean the main charger wire. If the wire is flawed, replace it. Check if the magnetic brush is formed uniformly. If not, replace the developer. Replace the drum (see page 3-3-50).

(6) A black line appears longitudinally.

Causes 1. Dirty optical section. 2. Dirty or flawed drum. 3. Deformed or worn cleaning blade. 4. Dirty or flawed main charger grid.

Causes 1. Dirty optical section. 2. Dirty or flawed drum. 3. Deformed or worn cleaning blade. 4. Dirty or flawed main charger grid.

Check procedures/corrective measures Clean the mirrors, dust filter and other parts in the optical section. Clean the drum or, if it is flawed, replace it (see page 3-3-50). Check visually if the edge of the cleaning blade is deformed or worn. If it is, replace (see page 3-359). Replace the main charger grid.

3-6-6

195 (7) A black line appears laterally. Causes 1. Flawed drum. 2. Poor developing bias wire contact. 3. Dirty developing section. 4. No developing bias output.

Causes 1. Flawed drum.

Check procedures/corrective measures Check the drum visually. If it is flawed, replace it (see page 3-3-50).

2. Poor developing bias wire con- Check for poor developing bias wire contact. tact. 3. Dirty developing section. 4. No developing bias output. A. Shorted developing bias wire or it makes poor contact. B. Defective main PCB. C. Defective high-voltage transformer PCB. Check the developing bias wire. If there is any problem, replace it. Run simulation 10 and check if CN8-5 on the main PCB goes low. If not, replace the main PCB. If no developing bias voltage is output during simulation 10 after the main PCB has been found to be normal, replace the high-voltage transformer PCB. Clean any part contaminated with toner or carrier in the developing section.

3-6-7

195 (8) One side of the copy image is darker than the other. Causes 1. Unevenly distributed halogen lamp light. 2. Dirty optical section. 3. Dirty main charger wire or grid.

Causes 1. Unevenly distributed halogen lamp light. 2. Dirty optical section.

Check procedures/corrective measures Adjust the positions of the light adjusters (see page 3-3-18). Clean the mirrors, dust filter and any other dirty parts in the optical section.

3. Dirty main charger wire or grid. Check if the main charger wire or grid is dirty. If it is, replace it.

(9) Black dots appear on the image.

Causes 1. Dirty or flawed drum. 2. Dirty contact glass. 3. Deformed cleaning blade.

Causes 1. Dirty or flawed drum. 2. Dirty contact glass. 3. Deformed cleaning blade.

Check procedures/corrective measures Clean the drum or, if it is flawed, replace it (see page 3-3-50). Clean the contact glass. Replace the cleaning blade if it is deformed (see page 3-3-59).

3-6-8

195 (10) Image is blurred. Causes 1. Scanner moving erratically. 2. Foreign matter on the scanner rail. 3. Deformed press roller. 4. Drive system problem.

Causes 1. Scanner moving erratically. 2. Foreign matter on the scanner rail. 3. Deformed press roller. 4. Drive system problem.

Check procedures/corrective measures Adjust the tension of the scanner wire (see page 3-3-19). Check visually and remove, if any. Check visually and replace (see page 3-3-67). Check the gears and belts. Grease the gears or readjust the belt tension if necessary.

(11) The leading edge of the image is consistently misaligned with the original.

Causes 1. Misadjusted leading edge registration.

Causes 1. Misadjusted leading edge registration.

Check procedures/corrective measures Readjust the leading edge registration timing (see page 3-3-5).

3-6-9

195 (12) The leading edge of the image is sporadically misaligned with the original. Causes 1. Registration clutch is installed or operating incorrectly.

Causes 1. Registration clutch is installed or operating incorrectly.

Check procedures/corrective measures Check the installation position and operation of the registration clutch.

(13) Paper creases.

Causes 1. Paper curled. 2. Paper damp. 3. Defective fixing pressure springs.

Causes 1. Paper curled. 2. Paper damp. 3. Defective fixing pressure springs.

Check procedures/corrective measures Check the paper storage conditions. Check the paper storage conditions. Replace the fixing pressure springs.

3-6-10

195 (14) Offset occurs. Causes 1. Cleaning blade installed in the wrong position. 2. Defective cleaning blade. 3. Cleaning lamp fails to light. 4. Abnormally high heat roller control temperature.

Causes 1. Cleaning blade installed in the wrong position. 2. Defective cleaning blade. 3. Cleaning lamp fails to light.

Check procedures/corrective measures Check the installation position of the cleaning blade and correct it, if necessary (see page 3-359). Replace the cleaning blade.

A. The connector terminals of the Check for continuity across the terminals. If none, cleaning lamp make poor con- replace them. tact. B. Defective cleaning lamp. Check for one-way continuity across all the LEDs comprising the cleaning lamp. If none, replace the cleaning lamp. Force CN7-4 on the main PCB to go low and check if the cleaning lamp lights. If it does, replace the main PCB. Check if the fixing unit thermistor is installed correctly.

C. Defective main PCB.

4. Abnormally high heat roller control temperature.

3-6-11

195 (15) Black lines appear on both sides of the image in reduction copies. Causes 1. Dirty blank lamps. 2. Defective blank lamps. 3. Defective main PCB.

Causes 1. Dirty blank lamps. 2. Defective blank lamps.

Check procedures/corrective measures Clean the blank lamps. Check for one-way continuity across all the LEDs comprising the blank lamps. If none, replace the blank lamp unit. Check for signal level changes on the main PCB. Replace the main PCB if necessary.

3. Defective main PCB.

(16) Image is partly missing.

Causes 1. Paper damp. 2. Paper creased. 3. Drum condensation. 4. Flawed drum.

Causes 1. Paper damp. 2. Paper creased. 3. Drum condensation. 4. Flawed drum.

Check procedures/corrective measures Check the paper storage conditions. Change the paper. Clean the drum (see page 3-3-52). Replace the drum (see page 3-3-50).

3-6-12

195 (17) Fixing is poor. Causes 1. Wrong paper. 2. Defective fixing pressure springs. 3. Flawed press roller.

Causes 1. Wrong paper. 2. Defective fixing pressure springs. 3. Flawed press roller.

Check procedures/corrective measures Check if the paper meets specifications. Replace the fixing pressure springs. Replace the press roller (page 3-3-67).

(18) Image is out of focus

Causes 1. Incorrect focus adjustment.

Causes 1. Incorrect focus adjustment.

Check procedures/corrective measures Adjust the focus of the image (see page 3-3-32).

(19) Image is not square longitudinally.

Causes 1. The horizontal alignment of light source unit 2 is adjusted incorrectly.

Causes 1. The horizontal alignment of light source unit 2 is adjusted incorrectly.

Check procedures/corrective measures Adjust the longitudinal squareness of the image (see page 3-3-30).

3-6-13

195 (20) Image is not square laterally. Causes 1. The vertical alignment of light source unit 2 is adjusted incorrectly.

Causes

Check procedures/corrective measures

1. The vertical alignment of light Adjust the lateral squareness of the image (see source unit 2 is adjusted incor- page 3-3-31). rectly.

(21) Image is partially missing laterally.

Causes 1. Registration clutch incorrectly installed or malfunctioning. 2. Paper feed clutch incorrectly installed or malfunctioning.

Causes 1. Registration clutch incorrectly installed or malfunctioning. 2. Paper feed clutch incorrectly installed or malfunctioning.

Check procedures/corrective measures Check and correct the clutch installation condition and its operation. Check and correct the clutch installation condition and its operation.

3-6-14

195

3-6-2 Paper misfeeds

Problem (1) A paper jam in the registration section is detected as soon as the main switch is turned on (J03 appears). (2) A paper jam in the eject section is detected as soon as the main switch is turned on (J02 appears). (3) A paper jam in the paper drawer is detected during copying (PF appears). Causes/check procedures Corrective measure A piece of paper torn from Check visually and remove it, if any. copy paper is caught around the registration switch. Defective registration switch. With 5 V DC present at CN5-1 on the AVR PCB, check if CN5-2 on the AVR PCB remains low when the registration switch is turned on and off. If it does, replace the registration switch. A piece of paper torn from Check visually and remove it, if any. copy paper is caught around the eject switch. Defective eject switch. With 5 V DC present at CN11-1 on the AVR PCB, check if CN11-3 on the AVR PCB remains low when the eject switch is turned on and off. If it does, replace the eject switch. Change the paper. Remedy if deformed.

Paper in the drawer is extremely curled. Check if the front or rear claws inside the paper drawer are deformed. Check if the springs inside the paper drawer are deformed. Check if paper feed pulleys A and B are deformed.

Remedy if deformed.

Replace if deformed.

Defective registration switch. With 5 V DC present at CN5-1 on the AVR PCB, check if CN5-2 on the AVR PCB goes low when the registration switch is turned on. If not, replace the registration switch. Check if the paper feed clutch malfunctions. Electrical problem with the paper feed clutch. Remedy if necessary. See page 3-6-27.

3-6-15

195 Problem (4) A paper jam in the registration section is detected during copying (J03 appears). Causes/check procedures Corrective measure

Check if the contact Remedy if necessary. between the feed rollers and feed pulleys is correct. Check if the contact Remedy if necessary. between the right and left registration rollers is correct. The registration clutch malfunctions. Electrical problem with the registration clutch. Check and remedy. See page 3-6-27.

(5) A paper jam in the fixing section is detected during copying (J01 appears).

Check if the contact Remedy if necessary. between the right and left registration rollers is correct. Defective eject switch. With 5 V DC present at CN11-1 on the AVR PCB, check if CN11-3 on the AVR PCB goes low when the eject switch is turned on. If not, replace the eject switch. Check and remedy. See page 3-6-27. Clean or replace the press roller (see page 3-3-67). Clean or replace the heat roller separation claws (see page 3-3-71). Remedy if necessary.

The registration clutch malfunctions. Electrical problem with the registration clutch. (6) A paper jam in the eject section is detected during copying (J02 appears). Check if the press roller is extremely dirty or deformed. Check if the heat roller separation claws are extremely dirty or deformed. Check if the contact between the eject rollers and pulleys is correct.

3-6-16

195

3-6-3 PCB terminal voltages

Precautions When handling PCBs, do not touch connectors with bare hands or damage the board. Do not touch any PCB containing ICs with bare hands or any object prone to static charge. Store PCBs wrapped in aluminum foil, conductive sponge rubber or similar material. ( 1 ) Power source PCB 120 V specifications
TB3 F1 TB1 AC 250 V 15A

[L]

TB4 JP1 JP2

[L]
TB2

FH1 FH3

FH7 FH8

FH2 R1 FH4

1952802
TB6

[N]
F2 TB9 AC 250 V 15A

3F78-1 RICOH KEIKI CO.,LTD.

CAUTION:
LCN3

[WHT]
C1 L1 C2 C3 VZ1 LCN2

[N]
TB8 LCN1

[L]
TB7 F3 FG1 AC 125 V 15A FG

[L]
TB10 LCN4

[BLK]

FOR CONTINUED PROTECTION AGAINST FIRE HAZARD. REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE.

[N]
D102 D203 ZD201

[WHT]
PC2

TRANSFORMER CORE NOT GROUNDED. TEST BEFORE TOUCHING.

PC1 R18 R16 JP3 R14 JP4 FB1

JP10

FG2

ZD102 R109 R102 Q101 R110 JP7

R15 JP5 D3 C14 R17 C15 IC1 ZD1 D1 C12 C13 R4 R3 C7 C16

FB201

JP8

R9

C102

R2

C6 FB2

R19 R7

FB103

C10 R8 FB4 R13 C5

R108 C202 FG4 C201 D202 JP9 IC201

FB101

D201 R101 C101 D101

JP8

T1

FB102

Q1

C9

DB1

FB5 D4

C4 C8

220 - 240 V specifications

TB3 F1 TB1 AC 250 V T8AL

[L]

TB4 JP1 JP2

[L]
TB2

FH1 FH3

FH7 FH8

FH2 R1 FH4

1952803
TB6

[N]
F2 TB9 AC 250 V T8AL

3F78-2 RICOH KEIKI CO.,LTD.

CAUTION:
LCN3

[WHT]
C1 L1 C2 C3 VZ1 LCN2

[N]
TB8 LCN1

[L]
TB7 F3 AC 250 V T2AL FG1 FG

[L]
TB10 LCN4

[BLK]

FOR CONTINUED PROTECTION AGAINST FIRE HAZARD. REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE.

[N]
D102 D203 ZD201

[WHT]
PC2

TRANSFORMER CORE NOT GROUNDED. TEST BEFORE TOUCHING.

PC1 R18 R16 JP3 R14 JP4 FB1

JP10

FG2

ZD102 R109 R102 Q101 R110 JP7

R15 JP5 D3 C14 R17 C15 IC1 ZD1 D1 C12 C13 R4 R3 C7 C16

FB201

JP8

R9

C102

R2

C6 FB2

R19 R7

FB103

C10 R8 FB4 R13 C5

R108 C202 FG4 C201 D202 JP9 IC201

FB101

D201 R101 C101 D101

JP8

T1

FB102

Q1

C9

DB1

FB5 D4

C4 C8

3-6-17

3F782310A

D2

L3

ZD101 R104 R103 R107 R106 C104 R105

1

C11 R5 R6

L2 FB3

CN1

R1 1

C103

R10

JP11

R11

FH6

FH5

CAUTION:

[BLK]

TB5

3F781310A

D2

L3

ZD101 R104 R103 R107 R106 C104 R105

11

C11 R5 R6

L2 FB3

CN1

R1

C103

R10

JP11

R11

FH6

FH5

CAUTION:

[BLK]

TB5

195 Terminals (CN) TB1 TB3 TB4 TB5 TB7 TB9 1-1 1-2 1-7 1-8 TB2 TB2 TB2 TB6 TB8 TB10 1-3 1-4 1-5 1-6 Voltage 120 V AC 220 - 240 V AC 120 V AC 220 - 240 V AC 120 V AC 220 - 240 V AC 120 V AC 220 - 240 V AC 120 V AC 220 - 240 V AC 120 V AC 220 - 240 V AC 24 V DC 24 V DC 5 V DC 5 V DC Remarks AC supply, input AC supply for MSW, output AC supply, input AC supply for SSW, output AC supply, input AC supply for AVRPCB and DH*, output 24 V DC supply for MPCB, output 24 V DC supply for AVRPCB, output 5 V DC supply for MPCB, output 5 V DC supply AVRPCB, output

* Option available only for 120 V specifications.

3-6-18

195 ( 2 ) Main PCB

CN6 8 1 C5 D5 D6 R5 DT5 CN7 TR2 14 7 D4 DT4 1 D3 E 1 D2 DT3 1 8 IC11 1 IC10 R108 R107 4

CN5 1

1952801 REV:2
1 15 IC17 11 1

CN4 5 10 1 CN3

C4

+
C3 1

+
1 IC16 5 1 IC14 IC13 9 R12 R11 R10 R9 R8 R7 R6 81 50 IC15 IC12 80 51 B C 100 1 X1 9 IC7 1 9 CN9 1 2 CN13 1 C1 3 CN10 R1 18 DT6 1 IC4 1 10 CN11 1 IC3 1 9 CN12 9 1 IC2 1 1 IC6 D1 ZD1 1 8 C2 1 TR3 ECB 30 IC8 1 5 31 5 9 1 IC9 8 IC5

2 1 CN2

1-1 1-2 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15

CN8 5

Terminals (CN) 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-3

R4

16

+
1 IC1

5 DT1

1 CN1 2

Voltage 24 V DC 24 V DC 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 0/5 V DC (pulse)

Remarks 24 V DC supply for MSW, output MSW on/off, output OPCB LED lighting signal, output (SEG a) OPCB LED lighting signal, output (SEG b) OPCB LED lighting signal, output (SEG c) OPCB LED lighting signal, output (SEG d) OPCB LED lighting signal, output (SEG e) OPCB LED lighting signal, output (SEG f) OPCB LED lighting signal, output (SEG g) OPCB scan sink, output (DIG 0) OPCB scan sink, output (DIG 1) OPCB scan sink, output (DIG 2) OPCB scan sink, output (DIG 3) OPCB scan sink, output (DIG 4) OPCB scan sink, output (DIG 5) OPCB scan sink, output (DIG 6) OPCB return, input (KEY 0)

3-6-19

195 Terminals (CN) 2-16 3-1 3-2 4-1 4-3 4-5 5-1 5-4 6-1 6-3 6-4 6-5 6-7 6-8 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9 7-10 7-11 7-12 7-13 7-14 8-1 8-2 8-3 8-4 8-5 8-7 9-1 9-2 9-3 9-4 5-3 5-2 5-2 4-2 4-4 4-4 5-2 5-3 6-2 6-6 6-6 6-6 6-6 6-6 5-3 5-2 5-3 5-2 5-3 5-2 5-2 5-3 5-3 5-2 5-2 5-2 5-2 5-2 8-6 8-6 8-6 8-6 8-6 8-6 5-2 5-2 5-2 5-2 24 V DC 5 V DC 0/24 V DC 24 V DC 0/24 V DC 24 V DC Voltage 0/5 V DC (pulse) 24 V DC 0/24 V DC 5 V DC Remarks OPCB return, input (KEY 1) 24 V DC supply for TC, output TC on/off, output 5 V DC supply for HUMPCB, output HUMPCB humidity detection voltage, input HUMPCB temperature detection voltage, input 24 V DC supply, input 5 V DC supply, input TCDSW on/off, input 24 V DC supply for DEVF, output*1 Developing unit new/old differentiation signal, input 24 V DC supply for TNS, output TNS detection voltage, input TNS control voltage, output Zero-cross signal for AVR PCB, output Flicker resistor on/off, output*2 5 V DC supply for AVRPCB, output CL on/off, output RSW on/off, input PFCL on/off, output RCL on/off, output FTH detection voltage, input ESW on/off, input HL light intensity control PWM, output H on/off, output DM ALM, input DM on/off, output FFM and ICFM full speed/half speed/off, output TFM on/off, output HVTPCB main/transfer charging ALM, input HVTPCB PHOTO, output HVTPCB main/transfer charging on/off, output HVTPCB developing bias on/off, output 24 V DC supply for HVTPCB, output SM coil energization pulse, output (SM B) SM coil energization pulse, output (SM B) SM coil energization pulse, output (SM A) SM coil energization pulse, output (SM A)

0/5 V DC 24/0 V DC 5 V DC 0/24 V DC 0/5 V DC 0/24 V DC 0/24 V DC 0/5 V DC 0/24 V DC (pulse) 0/24 V DC 0/24 V DC 0/24 V DC 0/12/24 V DC 0/24 V DC 0/12 V DC 0/12 V DC 0/12 V DC 0/24 V DC 24 V DC 0/24 V DC (pulse) 0/24 V DC (pulse) 0/24 V DC (pulse) 0/24 V DC (pulse)

*1 Standard equipment only for 120 V, 220 V and 240 V specifications. *2 For 230 V specifications and optional for 240 V specifications.

3-6-20

195 Terminals (CN) 9-5 10-1 10-2 11-1 11-2 11-3 11-4 11-5 11-6 11-7 11-8 11-9 11-10 12-1 12-3 12-4 12-5 12-7 12-9 13-1 13-2 5-2 10-3 10-3 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 12-2 12-2 12-6 12-6 12-8 12-8 5-2 5-2 Voltage 24 V DC 5 V DC 5/0 V DC 0/24 V DC (pulse) 0/24 V DC (pulse) 0/24 V DC (pulse) 24 V DC 0/24 V DC (pulse) 0/24 V DC (pulse) 0/24 V DC (pulse) 0/24 V DC (pulse) 24 V DC 0/24 V DC (pulse) 5 V DC 5/0 V DC 24 V DC 5 V DC 5/0 V DC 24 V DC 0/24 V DC Remarks 24 V DC supply for SM, output 5 V DC supply for HPSW, output HPSW on/off, input LM coil energization pulse, output (LM 2) LM coil energization pulse, output (LM 1) LM coil energization pulse, output (LM 3) 24 V DC supply for LM, output LM coil energization pulse, output (LM 4) MM coil energization pulse, output (MM 2) MM coil energization pulse, output (MM 1) MM coil energization pulse, output (MM 3) 24 V DC supply for MM, output MM coil energization pulse, output (MM 4) 5 V DC supply for MHPSW, output MHPSW on/off, input 24 V DC supply for AES, output AES detection voltage, input 5 V DC supply for LHPSW, output LHPSW on/off, input 24 V DC supply for OPFM, output OPFM on/off, output

3-6-21

195 ( 3 ) AVR PCB 120 V specifications

R14 R13 R12 D2 D3 NP PC3 CR1 L

1952806 100V
CN10 R24 R25 1 1 J12 1 1 J18 J16 J15 J14 J11 J10 1 1 1 1 CN10 R24 R25 1 1 PC5 J20 CN9 CN5 CN8 J16 J15 J14 J12 1 1 J18 R23 J11 J10 1 1 1 1 1 CN11 J17 1 CN5 RF CN13 J13 1 CN8 CN9 RF C8 CN11 CN13 J13 CN2

R15 C3 + VR2 C5 R17B R11

VR3

C4

R10

R21

R9

R5 R7

R8

C7

B Q2 C6

TRC1 J19

R4

D1

ZD1 R3

VR1

R22

R6

J3 J4

J17

J7

TB1 TB2

J8

R16B R17A

C2 C1 B Q1 J1 R2 R1 PC1 R18 PC4 J2

CR2

J5 J6 PC2 R19 J21

C9

TRC2

CN14

CN1 HEAT SINK NOT GROUND, TEST BEFORE TOUCHING. DB 1

WARNING

1 CN4 1 CN7 CN6

J9

J22 CN12

220 - 240 V specifications

R14 R13 R12 D2 D3 NP PC3 CR1 L

1952807 170V
CN2 C8

C3 VR2 R15 C5 R17B R11

VR3

C4

R10

R21

R9

R5 R7

R8

C7

B Q2 C6

TRC1 J19 TRC3 CR3 1 CN3 TB2 TB1 CR2

R4

D1

R16A

R16C

ZD1 R3

VR1

R22

R6

J3 J4

R16B R17A

C2 C1 B Q1 J1 R2 R1 PC1

J5 J6 PC2 R19 J21

C9

J8 TRC2

J7 C10

PC4 J2

CN14

CN1 HEAT SINK NOT GROUND, TEST BEFORE TOUCHING. DB 1

WARNING

1 CN4 1 CN7 CN6

R18

J9

J22 CN12

3-6-22

195 Terminals (CN) TB1 1-1 2-1 3-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 5-1 5-2 6-1 6-2 7-1 7-2 8-2 8-3 8-4 9-1 9-2 10-1 10-2 11-1 11-3 12-1 12-4 13-1 13-2 14-1 14-2 TB2 1-2 2-3 3-4 12-2 12-2 12-2 12-2 12-2 12-3 12-3 12-2 12-2 12-3 12-2 12-3 12-2 12-3 5-3 5-3 12-2 12-2 12-2 12-2 8-1 8-1 8-1 12-2 12-2 12-2 12-2 11-2 11-2 12-2 12-3 12-3 12-3 12-2 12-2 220 - 240 V AC 0/12/24V V DC 0/24 V DC 0/24 V DC 0/24 V DC 0/24 V DC (pulse) 0/5 V DC 0/24 V DC 0/24 V DC 0/5 V DC 0/24 V DC 5 V DC 24/0 V DC 0/5 V DC 5 V DC 0/5 V DC 24 V DC 0/24 V DC 24 V DC 0/24 V DC 24 V DC 0/24 V DC 0/24 V DC 24 V DC 0/24 V DC 24 V DC 0/12/24 V DC 5 V DC 0/5 V DC 24 V DC 5 V DC 5 V DC 24 V DC 0/12/24 V DC Voltage 120 V AC 220 - 240 V AC 120 V AC 220 - 240 V AC Remarks AC supply for H, output AC supply, input HL control voltage, output 220 - 240 V AC supply for flicker resistor, output* FFM full speed/half speed/off, output DM on/off, input DM ALARM, output H on/off, input HL light intensity control PWM, input ESW on/off, output FTH detection voltage, output RCL on/off, input PFCL on/off, input RSW on/off, output CL on/off, input 5 V DC supply, input Flicker resistor on/off, input* Zero-cross signal, input 5 V DC supply for RSW, output RSW on/off, input 24 V DC supply for PFCL, output PFCL on/off, output 24 V DC supply for RCL, output RCL on/off, output 24 V DC supply for DM, output DM on/off, output DM ALM, input 24 V DC supply for CL, output CL on/off, output 24 V DC supply for FFM, output FFM full speed/half speed/off, output 5 V DC supply for ESW, output ESW on/off, input 24 V DC supply, input 5 V DC supply, input FTH detection voltage, input 5 V DC supply for FTH, output 24 V DC supply for ICFM, output ICFM full speed/half speed/off, output

* For 230 V specifications and optional for 240 V specifications.

3-6-23

195 ( 4 ) Operation unit PCB

L11 L5L19 L6L20 L18 L17 L16 L8 L9L10 CN2 SW7 1 7

L13 L14 L15 L4 SW9 L3 SW4 SW3 SW5 SW6 SW2 L2 7SEGMENT LED SW1 L1

L12

SW8

Terminals (CN) 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 2-1 2-2 2-3 2-4 2-5 2-6 2-7 MPCB 5-3

Voltage 0/5 V DC (pulse) 0/5 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 24/0 V DC (pulse) 5/0 V DC (pulse) 5/0 V DC (pulse) 5/0 V DC (pulse) 5/0 V DC (pulse) 5/0 V DC (pulse) 0/5 V DC (pulse) 0/5 V DC (pulse)

Remarks MPCB return, output (KEY 1) MPCB return, output (KEY 0) Scan sink, input (DIG 6) Scan sink, input (DIG 5) Scan sink, input (DIG 4) Scan sink, input (DIG 3) Scan sink, input (DIG 2) Scan sink, input (DIG 1) Scan sink, input (DIG 0) LED lighting signal, input (SEG g) LED lighting signal, input (SEG f) LED lighting signal, input (SEG e) LED lighting signal, input (SEG d) LED lighting signal, input (SEG c) LED lighting signal, input (SEG b) LED lighting signal, input (SEG a) BL LED lighting source, output (BL SEG a) BL LED lighting source, output (BL SEG b) BL LED lighting source, output (BL SEG c) BL LED lighting source, output (BL SEG d) BL LED lighting source, output (BL SEG e) BL scan sink, output (BL DIG 5) BL scan sink, output (BL DIG 6)

MPCB 5-3

3-6-24

CN1

16

195

3-6-4 Electrical problems

Problem (1) The machine does not operate when the main switch is turned on. Causes No electricity at the power outlet. The power cord is not plugged in properly. The front cover or release unit is not closed completely. Broken power cord. Defective main switch. Blown fuse in the power source PCB. Defective safety switch. Defective power source PCB. Check procedures/corrective measures Measure the input voltage. Check the contact between the power plug and the outlet. Check the front cover and release unit.

Check for continuity. If none, replace the cord. Check for continuity across the contacts. If none, replace the main switch. Check for continuity. If none, remove the cause of blowing and replace the fuse. Check for continuity across the contacts of the safety switch. If none, replace the switch. With AC present, check for 24 V DC at CN1-1 and CN1-2 on the power source PCB and 5 V DC at CN1-7 and CN1-8. If none, replace the power source PCB.

(2) The drive motor does not operate (C21).

Poor contact in the Check for continuity across the connector drive motor connector terminals. If none, replace them. terminals. Defective main PCB. Run simulation 10 and check if CN7-13 on the main PCB goes low. If not, replace the main PCB. Check visually and replace the drive motor if necessary.

Broken drive motor gear. (3) The scanner motor does not operate (C30).

Broken scanner motor Check for continuity across the coil. If none, coil. replace the scanner motor. Poor contact in the scanner motor connector terminals. Defective main PCB. Check for continuity across the connector terminals. If none, replace them. Run simulation 21 and check if the motor drive coil energization pulse signals are output at CN9-1, -2, -3 and -4 on the main PCB. If not, replace the main PCB.

3-6-25

195 Problem (4) The lens motor does not operate (C41). Causes Broken lens motor coil. Poor contact in the lens motor connector terminals. Defective main PCB. Check procedures/corrective measures Check for continuity across the coil. If none, replace the lens motor. Check for continuity across the connector terminals. If none, replace them. Run simulation 23 and check if the motor drive coil energization pulse signals are output at CN11-1, -2, -3 and -5 on the main PCB. If not, replace the main PCB. Check for continuity across the coil. If none, replace the mirror motor. Check for continuity across the connector terminals. If none, replace them. Run simulation 23 and check if the motor drive coil energization pulse signals are output at CN11-6, -7, -8 and -10 on the main PCB. If not, replace the main PCB. Check for continuity across the coil. If none, replace the toner feed motor coil. Check for continuity across the connector terminals. If none, replace them. Run simulation 10 and check if CN8-1 on the main PCB goes low. If not, replace the main PCB.

(5) The mirror motor does not operate (C42).

Broken mirror motor coil. Poor contact in the mirror motor connector terminals. Defective main PCB.

(6) The toner feed motor does not operate.

Broken toner feed motor coil. Poor contact in the toner feed motor connector terminals. Defective main PCB.

(7) The optical section fan motor does not operate.

Broken optical section Check for continuity across the coil. If none, fan motor coil. replace the optical section fan motor. Poor contact in the optical section fan motor connector terminals. Defective main PCB. Check for continuity across the connector terminals. If none, replace them.

Run simulation 20 and check if CN13-2 on the main PCB goes low. If not, replace the main PCB.

3-6-26

195 Problem (8) The fixing unit fan motor does not operate. Causes Broken fixing unit fan motor coil. Poor contact in the fixing unit fan motor connector terminals. Defective main PCB. Check procedures/corrective measures Check for continuity across the coil. If none, replace the fixing unit fan motor. Check for continuity across the connector terminals. If none, replace them. Run simulation 10 and check if CN7-14 on the main PCB goes low. If not, replace the main PCB.

(9) The internal cooling fan motor does not operate.

Broken internal Check for continuity across the coil. If none, cooling fan motor coil. replace the internal cooling fan motor. Poor contact in the internal cooling fan motor connector terminals. Defective main PCB. Check for continuity across the connector terminals. If none, replace them.

Run simulation 10 and check if CN14-2 on the main PCB goes low. If not, replace the main PCB. Check for continuity across the coil. If none, replace the paper feed clutch. Check for continuity across the connector terminals. If none, replace them. Run simulation 02 and check if CN7-6 on the main PCB goes low. If not, replace the main PCB. Check for continuity across the coil. If none, replace the registration clutch. Check for continuity across the connector terminals. If none, replace them. Run simulation 02 and check if CN7-7 on the main PCB goes low. If not, replace the main PCB.

(10) The paper feed clutch does not operate.

Broken paper feed clutch coil. Poor contact in the paper feed clutch connector terminals. Defective main PCB.

(11) The registration clutch does not operate.

Broken registration clutch coil. Poor contact in the registration clutch connector terminals. Defective main PCB.

3-6-27

195 Problem Causes Check procedures/corrective measures Check for continuity. If none, replace the halogen lamp (see page 3-3-16). See page 3-6-4.

(12) Broken halogen lamp The halogen filament. lamp does not Optical section light. thermostat triggered. Poor contact in the AVR PCB connector terminals. Defective main PCB. Defective AVR PCB. Defective main PCB. (13) The halogen lamp does not turn off. Defective AVR PCB.

If the HL CONT (PWM) signal is always output from CN7-10 on the main PCB, replace the main PCB. If the halogen lamp does not turn off when HL CONT (PWM) is not output to CN4-5 on the AVR PCB, replace the AVR PCB. Check for one-way continuity across all the LEDs comprising the cleaning lamp. If none, replace the cleaning lamp. Check for continuity across the connector terminals. If none, replace them. Run simulation 10 and check if CN7-4 on the main PCB goes low. If not, replace the main PCB. Check for continuity. If none, replace the fixing heater (see page 3-3-62). Check for continuity across the thermostat. If none, remove the cause of blowing and replace the fixing unit thermostat. Measure the resistance. If it is , replace the fixing unit thermistor. Check visually and clean the thermistor sensor part. If the fixing heater stays on with CN4-4 on the AVR PCB high, replace the AVR PCB. If CN7-11 on the main PCB is always low, replace the main PCB.

Defective cleaning (14) The cleaning lamp. lamp does not light. Poor contact in the cleaning lamp connector terminals. Defective main PCB.

(15) The fixing heater does not turn on (C61, C63).

Broken fixing heater wire. Fixing unit thermostat 1 or 2 triggered. Broken fixing unit thermistor.

(16) The fixing heater does not turn off (fixing unit thermostat triggered, C64).

Dirty sensor part of the fixing unit thermistor. Defective AVR PCB. Defective main PCB.

3-6-28

195 Problem Causes Check procedures/corrective measures Check visually and replace the main charger wire if it is broken (see page 3-3-13). See page 3-6-3.

(17) Broken main charger Main charging wire. does not take Leaking main charger place (C50). housing. Poor contact in the high-voltage transformer PCB connector terminals. Defective main PCB. Defective high-voltage transformer PCB. (18) Transfer charging does not take place (C50). Broken transfer charger wire. Leaking transfer charger housing. Poor contact in the high-voltage transformer PCB connector terminals. Defective main PCB. Defective high-voltage transformer PCB. Poor contact in the (19) developing bias wire. No developing Poor contact in the bias is output. high-voltage transformer PCB connector terminals.

Check visually and replace the transfer charger wire if it is broken (see page 3-3-55). See page 3-6-3.

Check the developing bias wire for poor contact. Check for continuity across the connector terminals. If none, replace them.

Defective high-voltage Run simulation 10. If no developing bias is transformer PCB. output while CN1-3 on the high-voltage transformer PCB goes low, replace the highvoltage transformer PCB. Defective main PCB. Run simulation 10 and check if CN8-5 on the main PCB goes low. If not, replace the main PCB.

3-6-29

195 Problem (20) A paper jam is indicated as soon as the main switch is turned on. Causes A piece of paper torn from copy paper is caught around the registration or eject switch. Defective registration switch. Check procedures/corrective measures Check visually and remove, if any.

With 5 V DC present at CN5-1 on the AVR PCB, if CN5-2 on the AVR PCB remains low when the registration switch is turned on and off, replace the registration switch.

Defective eject switch. With 5 V DC present at CN11-1 on the AVR PCB, if CN11-3 on the AVR PCB remains low when the eject switch is turned on and off, replace the eject switch. (21) Others. Wiring is broken, shorted or makes poor contact. Noise. Check for continuity. If none, repair.

Locate the source of noise and remove.

3-6-30

195

3-6-5 Mechanical problems

Problem (1) No primary paper feed. Causes/check procedures Check if the surfaces of paper feed pulleys A & B, feed roller and pulley are dirty with paper powder. Electrical problem with the paper feed clutch. (2) No secondary paper feed. Corrective measure Clean with isopropyl alcohol.

See page 3-6-27.

Check if the surfaces of the feed roller Clean with isopropyl alcohol. and pulley, right and left registration rollers are dirty with paper powder. Electrical problem with the registration See page 3-6-27. clutch.

(3) Skewed paper feed.

Check if the front or rear claws inside the paper drawer are deformed. Check if the springs inside the paper drawer are deformed.

Remedy if deformed. Remedy or replace if deformed. Reinstall the scanner wires (see page 3-3-19). See page 3-6-25. Remedy if deformed. Change the paper.

(4) Check if the scanner wires are loose. The scanner does not travel. Electrical problem with the scanner motor. Check if the front or rear claws inside (5) Multiple sheets the paper drawer are deformed. of paper are fed Check if the paper is curled. at one time. (6) Paper jams.

Check if the paper is extremely curled. Change the paper. Check if the front or rear claws inside the paper drawer are deformed. Check if the springs in the paper drawer are deformed. Check if the press roller is extremely dirty or deformed. Remedy if deformed. Remedy if deformed. Clean or replace the press roller (see page 3-3-67).

Check if the heat roller separation Clean or replace the heat claws are extremely dirty or deformed. roller separation claws (see page 3-3-71). Check if the developing unit is (7) Toner drops on extremely dirty. the paper conveying path. Clean the developing unit.

3-6-31

195 Problem Causes/check procedures Corrective measure Grease the bushings and gears. Remedy.

(8) Check if the rollers and gears operate Abnormal noise smoothly. is heard. Check if the paper feed clutch and registration clutch are installed correctly.

3-6-32

195

3-7 Appendixes
Timing chart No. 1 ......................................................................................... Timing chart No. 2 ......................................................................................... Timing chart No. 3 ......................................................................................... Power source PCB ........................................................................................ AVR PCB ...................................................................................................... Operation unit PCB ....................................................................................... Main PCB ...................................................................................................... Connection diagram ...................................................................................... Wiring diagram .............................................................................................. 3-7-1 3-7-2 3-7-3 3-7-4 3-7-5 3-7-6 3-7-7 3-7-8 3-7-9

E A E

E A E

195

Timing chart No. 1 The main switch is turned on when the fixing temperature (as measured by the fixing unit thermistor) is higher than 12C/ 53.6F and the machine internal temperature (as meassured by the drum thermistor) is higher than 15C/59 F
A B C D E F G H I J

MSW: On

2
Fixing temperature

185C/365F 175C/347F 160C/320F 80C/176F

4
H CN7-11

DB

CN8-5

200 ms 1s

5
DM CN7-13 200 ms 29 s*

Copy start indicator

FFM

CN7-14

1s Fast

BL

CN2-1 - CN2-7

All off

2s

All on 10 s

285 ms

All off

HV

CN8-4

50 ms

* If, when the main switch is turned on FTH temperature 10C/50F and ambient temperature 15C/59F: 29 s FTH temperature < 10C/50F or ambient temperature < 15C/59F: 44 s FTH temperature 80C/176F: 5 s

3-7-1
E A E A A E DC-1460 S/M (MCA,MCE) E A A E

E A E

E A E

195

Timing chart No. 2 A single copy (70% magnification ratio, bypass feed, A4R/81 /2 " 14" paper)
HPSW: On

C
RSW: On

E
RSW: Off

G
ESW: Off

1
Print key

Input

RSW

CN7-5

ESW

CN7-9

HPSW

CN10-2

3
SM FWD CN9-1 - CN9-4 500 ms min 2845 P SM REV CN9-1 - CN9-4 65 ms 5P 198 ms max.

4
DM CN7-13

100 ms

100 ms

PFCL

CN7-6 330 ms

RCL

CN7-7

246 P (SIM58)

5
200 ms

DB Output

CN8-5

100 ms

HL

CN7-10

6
50 ms 127 P (SIM54) All on Side erasure 190 ms All on (SIM59) Fast 384 ms

HV

CN8-4

BL

CN2-1 - CN2-7

285 ms

All off

7
FFM CN7-14 Slow

7
3000 ms Slow

OPFM

CN13-2

8
H (Fixing temp.) High-level control

A TC

CN3-2 B

300 ms H

3-7-2
E A E A E A DC-1460 S/M (MCA,MCE) E A A E

E A E

E A E

195

Timing chart No. 3 A single copy (100% magnification ratio, drawer feed, A4R/81 /2" 14" paper, AE)
Print key: On HPSW: On HPSW: On

E
RSW: Off

G
ESW: Off

Print key

Input

RSW

CN7-5

ESW

CN7-9

HPSW

CN10-2

3
SM FWD CN9-1 - CN9-4 350 ms 910 P 100 ms 55 ms min. 5P 198 ms max. 2358 P 65 ms 5P

SM REV

CN9-1 - CN9-4

4
DM CN7-13 100 ms 100 ms

PFCL

CN7-6

600 ms 246 P (SIM58) 330 ms

RCL

CN7-7

DB Output

CN8-5

100 ms

200 ms

HL

CN7-10

6
50 ms 127 P (SIM54) All on 450 ms 384 ms

HV

CN8-4

BL

CN2-1 - CN2-7

7
FFM CN7-14 Slow

Side erasure 190 ms All on (SIM59) Fast

285 ms

All off

7
3000 ms Slow

OPFM

CN13-2

8
H (Fixing temp.) High-level control

A TC

B CN3-2

300 ms H

3-7-3
E A E A A E DC-1460 S/M (MCA,MCE) E A A E

E A E

E A E

195

Power source PCB

A B C D E F G H I J

1
R101 R2 F3 L2* ~ R8 + ~ R3 + C9
FB4

1
C101 T1 FB101 R5 C10 R9
D2 R6

L TB1

1 IN

R102

R103

R104

R105

R106

F1 L1
R1 C1

1 OUT

TB3

TB7

1 IN

D101 FB103
D102

1 OUT 2 OUT 3 OUT 4 OUT

CN1 CN1 +24 V

C2

C4

C8

C104

L3 VZ1 C3

FB102
C103 R110

2
CN1 CN1 DG

DB1

C102

PC1

N TB2

1 IN

F2

1 OUT 1 IN

TB6

TB8

1 IN R4 C5 C6 D1 R10 ZD1 C16 C7

R13

D201 FB201 1 + C201

D202 IC201 3

Q101
D203

R111

ZD102

7 OUT 8 OUT 5 OUT 6 OUT

CN1 CN1 +5 V

FB5

ZD201

S D4 R19 R7

R107

TB5

R109

1 OUT

ZD101

FB2

FB3

+ 4 C202

PC2

TB4

Q1 D G

CN1 CN1 SG

4
TB9

1 OUT

FG R17 +

D3

R11

FB1

TB10

1 OUT
C12 C13

C11

PC2 R18

IC1

6
R14 R16

6
C15

R15

PC1

C14

* For 220 - 240 V specifications only.

3-7-4
E A E A E A DC-1460 S/M (MCA,MCE) E A A E

E A E

E A E

AVR PCB

195

1
5V G (5 V) G (24 V) 24 V ZERO CROSS Flicker REM 5V CL REM RSW PFCL RCL FTH ESW HL CONT H REM DM ALM DM REM FFM REM DM ALM DM REM G (24 V) CN12-4 CN12-3 CN12-2 CN12-1 CN4-14 CN4-13 CN4-12 CN4-11 CN4-10 CN4-9 CN4-8 R24 R25 CN10-2 CN10-1 CN9-2 CN9-1 CN5-3 CN5-2 CN5-1 CN6-1 CN6-2 CN7-1 CN7-2 CN11-2 CN11-3 CN11-1 CN13-2 CN13-1 CN13-3 CN14-2 CN14-1 FFM 24 V CL 24 V G (5 V) RSW 5V 24 V PFCL 24 V RCL G (5 V) ESW 5V 5V FTH ICFM 24 V 5.9 PC1 R19 R18 PC5 R23 R1 C2 + R4 ZD R5 R2 VR1 3 8 D1 R7 2+ 1 4 R6 VR3 R8 R9 R10 C4 R11 R12 R13 D2 R14 D3 C5 1 Q2 12 5.9 HIC 11 0 V 8 R21 C7 4 PC3 TRC1 L CR1 C8 CN2-3 HL COM 2 12 14 (R16A) (R16B)

PART NAME TRC3 PC5 CN3 CR3 C10 R16A, C R23

120 V NOT MOUNT NOT MOUNT NOT MOUNT NOT MOUNT NOT MOUNT NOT MOUNT NOT MOUNT

220 - 240 V MOUNT MOUNT MOUNT MOUNT MOUNT MOUNT MOUNT

DM

CN4-7 CN4-6 CN4-5 CN4-4 CN4-3 CN4-2 CN4-1 CN8-4 CN8-3 CN8-1 24 V CN8-2

PC2 R3 Q1 C1

6+ 5 IC 7 R15

PC1 PC4

C3 R22

PC4

13 SS 7 ZERO

7
PC2

E A E A A E DC-1460 S/M (MCA,MCE)

+
3 +12 (R16C) 12 R17B R17A DB RF TB1 CN2-1 CN1-1 CN1-2 H LIVE HL LIVE AC LIVE AC COM

VR2

C6

C9

C10 TRC2 CR2

Flicker resistor (for 230 V specifications and optional for 240 V specifications) PC5 CN3-4 TRC3 CR3 CN3-1 TB2 H COM

3-7-5
E A A E

E A E

E A E

195

Operation unit PCB

A B C D E F G H I J

L11 L5 L19 L6 L20 L18 L17 L16 1 L8 L9 L10 CN2 SW7 7

L13 L14 L15 L4 SW9 L3 SW4 SW3 SW5 SW6 SW2 L2 7SEGMENT LED SW1 L1

b1 f2

L12

SW8

7 SEGMENT LED

CN1

16

a3 f3 g2 b2 g3 b3 e3 c1 e2 c2 c3 d2 d3

a2

CN1-16 SEG a

CN1-15 SEG b

CN1-13 SEG d

CN1-12 SEG e

CN1-10 SEG g

CN1-14 SEG c

KEY 0

CN1-11 SEG f

KEY 1

DIG 0

DIG 1

DIG 2

DIG 3

DIG 4

DIG 5

DIG 6

CN1-9

CN1-8

CN1-7

CN1-6

CN1-5

CN1-4

CN1-3

CN1-2

CN1-1

CN2-7 CN2-6 CN2-5 CN2-4 CN2-3 CN2-2 CN2-1

BL DIG 6 BL DIG 5 BL SEG e BL SEG d BL SEG c BL SEG b BL SEG a

6
L19 L1 L8 L2 L9 L16 b2 b3 L3 L10 L17 c2 c3 L4 L11 L18 d2 d3 e2 e3 L5 L12 L6 L13 b1 f2 f3 L14 c1 g2 g3 L20 SW9 D9 SW7 SW8 D7 D8 SW5 SW6 D5 D6 SW3 SW4 D3 D4 SW1 SW2 D1 D2

7
L15 a2 a3

3-7-6
E A E A E A DC-1460 S/M (MCA,MCE) E A A E

Main PCB
A B C
24 V MSW CN1-1 IC13 CN1-2 CN7-2 CN3-1 CN3-2 B 15 C E DT1 S G R109 B
R107 R108

195 195 D E
S
R21 R22 3 R106 S Flicker resistor REM* 24 V TC C E DT5 IC7 14 S G R15 R51 S G TC IN
WD

R26

R27

CN12-3 CN12-9

MHPSW LHPSW

B DEVF IN TC IN

IC7 3 2 CN7-14 FFM REM C8 IC10 5 6

S
R19

S
R105

WD

24 V

CN9-5 C1

+
P G 24 V CN11-9

R110

C E S G

S
CN7-10 HL CONT C6 S G

DT6 10 TFM REM CN8-1 IC7 E C H ALARM B 11

SM A SM A SM B SM B

CN9-4 CN9-3 CN9-2 CN9-1

8 ADJ2 7 _RES2 6 VCC 5 ADJ1

R16

1 WD 2 S G TC 3 _RES1 4 R17 GND

R18 1 C7

S
IC6 7 6 IC6 2

_OC

_RESET

IC1

S G

3 6 11

IC4 IC4

2 CN11-10 7 CN11-8

2 H REM R32
R52

MM 4 MM 3 MM 1 MM 2

CN7-11 IC10 D3

S
R31 VSA VSB A A B B

IC11 7 12 8 1 18 11 2 TdA 13 TdB OUT A IN A B B 6 5 7 16 DM REM CN7-13

IC4 10 CN11-7 IC4 15

4 IC10

C25

TR2 P G R58

100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81

R30

C10

RSA REFA REFB RSB CNDA CNDB

CL REM

CN7-4

R57 C

E B IC13 6 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 IC13 _WR _RD 11 9 IC10 10 8 CN7-7 CN8-3 RCL PHOTO REM 7 CN7-6 PFCL

D2

14

CN11-6

C15

9 3 1410 4 15 C14 P G
R1

R53

24 V LM 2 LM 1

R54

P G

P G

CN11-4 CN11-1 CN11-2 CN11-3 CN11-5 2 7 10 15 IC3 IC3 IC3 IC3 3 6 11 14 R14 R86 R37 R34 R33 4 7 R85 R36 5 IC5 2 IC5 1 1 3

LM 3 LM 4

C23

S R13
HPSW ZERO CROSS KEY0 DEV-UNIT KEY1 CN10-2 CN7-1 CN2-15 CN6-1 CN2-16

2 X1 S G

H ALARM S G _RESET INTP 1

+
S S R38

+
6

P16 P17 AVSS ANO0 P131 AVREF RD TD ASCK VSS P20 P21 P22 P23 P24 P25 P26 P27 A0 A1

RSW

R35 R82 S G R81 CN7-5 R68 R67

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

RTP0 RTP1 RTP2 RTP3 RTP4 RTP5 RTP6 RTP7 IC X2 X1 VDD XT2 P07 _RESET INTP0/P00 INTP1/P01 INTP2/P02 INTP3/P03 INTP4/P04 INTP5/P05 P06 AVDD AVREF0 AN10 AN11 AN12 AN13 AN14 AN15

P96 P95 P94 P93 P92 P91 P90 P37 P36 P35 P34 P33 P32 P31 T00 P103 P102 P101 P100 ASTB

P G
R4

DT4

IC12

P66 _WR _RD P63 P62 P61 P60 A15 A14 VSS A13 A12 A11 A10 A9 A8 AD7 AD6 AD5 AD4 AD3 AD2 AD1 AD0 A7 A6 A5 A4 A3 A2

A15 A14 A13 A12 A11 A10 A9 A8 D7 D6 D5 D4 D3 D2 D1 D0 A7 A6 A5 A4 A3 A2 A1 A0 S G

11

IC10

10

CN8-4

HV REM

13

IC10

12

CN8-5

DB REM

4
R45

R44

11

IC5 3

R40

S
INTP1 _OC IC6 A15 3 5 1

10
ZD1 R46

IC16 1 IC16 _OC CLK D0 D1 D2 D3 D4 D5 D6 D7 3 4 7 8 13 14 17 18 D1 D2 D3 D4 D5 D6 D7 D8 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 IC17 IC7 6 7 CN13-2 OPFM REM 2 5 6 9 12 15 16 19 IC16 IC16 4 IC16 5 IC16 6 IC16 7 15 14 13 12 R9 R8 R7 R6 CN2-4 CN2-5 CN2-6 CN2-7 CN13-1 SEG d SEG e SEG f SEG g 24 V 2 3 18 17 16 R12 R11 R10 CN2-1 CN2-2 CN2-3 SEG a SEG b SEG c

S R20 S R23 2
_WR 3

S G

A15 A15 _RD

R92

S S
IC15 20 22 10 9 8 7 6 5 4 3 25 24 21 23 2 26 27 _CE _OE A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 Vcc Vpp Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7 28 1 11 12 13 15 16 17 18 19 C28

IC2

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

FSW

CN7-9 R43

R94

FTH

CN7-8
R42 C13

S G 8 R39 9 R83 IC5 14 R41 S C22 S G H ALARM

S G

S
IC9 1 16 IC9 15 IC9 3 IC9 4 IC9 5 IC9 6 11 IC9 7 D5 10 12 CN2-12 CN2-13 CN2-14 CN6-2 DIG 4 DIG 5 DIG 6 13 CN2-11 DIG 3 14 CN2-10 DIG 2 CN2-8 CN2-9 DIG 0 DIG 1

S G S G R47 TNS CN6-7 R84

S
D6

S
8 7 6 5
C16

IC8 VCC CS NC SK TEST DI GND DO

2 1 2 3 4

+
D1

6
AES CN12-5 R24 S G

C3 S G R25

S
S G

C21

S G C20 S G

R72 R73 R74 R75 R76 R77 R78 R79 R97 R96 R93 R95 R80 R98 R99

A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14

S G D0 D1 D2 D3 D4 D5 D6 D7

NON MOUNT R71 R70 R69 R87 R88 R89 R90 R91

R100 S G

NON MOUNT

CN7-3 DEV SW CN6-5 CN6-4 15 R59 DEVF IN R60 S G C17 S G S G R5 CN6-3 DEVF SHORT C11 S G C26 24 V CN5-1 C4 C9 C30 G (24 V) CN5-2 P G CN6-6 CN8-6 CN12-6 G (24 V) G (24 V) G (24 V) CN8-7 24 V 24 V 24 V G (5 V) CN5-3 S G C5 5V CN5-4

5V 5V 5V 5V

S
5V CN4-1 R63 CN4-3 C27 G (5 V) CN4-2 R64 2 R103 CN4-5
C33

IC14 3 + 1 R66

S
D4

CN10-1 CN12-1

IC13 14 C18 S G

HUMSENS

C29

CN12-4

CN12-7 C31 CN10-3 CN12-2 CN12-8

S S G
ETTH G (5 V)

R65 R102

C24

C12

G (5 V) G (5 V) G (5 V)

CN4-4

S G

S
DM ALM HV ALM CN7-12

R55

R56 R48

S
9, 16 1, 8

CN8-2 R49 CN6-8

R104 C34

TNS CONT

IC14 7

5 9 6 R61 S G 8 11 S G 10

9 COM

+
S G 12 IC5 S G IC2, 6, 10, 17

8
* For 230 V specifications and optional for 240 V specifications.

P G 8

P G S G 4 4, 5, 12, 13 IC3, 4, 7, 13 IC14

S G

R62

S G IC16 IC16 IC9

3-7-7

Connection diagram
A B C D E
Flicker resistor
(for 230 V specifications and optional for 240 V specifications)

195-1 195

TH3 1 1 2 2 HL

DH SSW
2
optional for 120 V specifications

1
TH1 120 V 910 W 240 V 1040 W

MSW

FUSE

2- 3 HL COM

2- 1 HL LIVE

H LIVE H COM
TB1 TB2

TH2 1 1 1 1 14- 1 24 V 14- 2 ICFM 10- 1 24 V 10- 2 FFM 9- 1 24 V 9- 2 CL 6- 1 24 V 6- 2 PFCL 7- 1 24 V 7- 2 RCL 5- 3 G (5 V) 5- 2 RSW 5- 1 5 V 11- 3 ESW 11- 2 G (5 V) 11- 1 5 V 13- 2 5 V 13- 1 FTH 13- 3 N. C
1 1 2 2 3 3 1 1 2 2 1 2 3

H ICFM FFM
2 1 1 2

3- 1

TB5

TB3

TB4

TB6

1 2
TB7 TB8

2
LIVE 120 V 220 - 240 V

CORE
(for 220 - 240 V specifications only)

120 V 220 - 240 V

FUSE 250 V/15 A FUSE 250 V/8 A

1 2

3- 4

TB1
120 V FUSE 250 V/15 A

TB 9

1- 1

CL

NF
TB10 1- 2

TB2 NEUTRAL

PFCL

FUSE 220 - 240 V 250 V/8 A

RCL

1-2 1-4 1-6 1-8

24 V G (24 V) G (5 V) 5V

12-1 12-2 12-3 12-4

RSW

ESW

1 2 3 4

1-1 1-3 1-5 1-7

PSPCB

AVRPCB

4- 1 4- 2 4- 3 4- 4 4- 5 4- 6 4- 7 4- 8 4- 9 4-10 4-11 4-12 4-13 4-14

FTH MHPSW AES LHPSW HPSW

GND (24 V) 24 V DM REM DM ALM

8888-

3 2 1

1 2 3

3 2 1

3 2 1

BL

LM
54321

MM
54321

SM
FFM REM DM REM DM ALM H REM HL CONT ESW FTH RCL PFCL RSW CL REM 5V Flicker REM ZERO CROSS

1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1

BL SEG a BL SEG b BL SEG c BL SEG d BL SEG e BL DIG 5 BL DIG 6

1 2 3 4 5 5 4 3 2 1

1-4 1-3 1-2 1-1

DM

5V G (5 V) MHPSW 24 V AES G (24 V) 5V G (5 V) LHPSW

24 V G (24 V) G (5 V) 5V

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

121212121212121212-

10- 1 5 V 10- 2 HPSW G (5 V) 10- 3

LM 2 LM 1 LM 3 24 V LM 4 MM 2 MM 1 MM 3 24 V MM 4

1 2 3 4

7-14 7-13 7-12 7-11 7-10 7- 9 7- 8 7- 7 7- 6 7- 5 7- 4 7- 3 7- 2 7- 1

SM B SM B SM A SM A 24 V

2222222-

5555-

99999-

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7

1 2 3 4 5

OPCB

13- 1 13- 2

3- 1 3- 2

6- 1

6- 2

6- 1 6- 2

1- 1

KEY 1

1- 2

666666-

8888888-

DEVF SHORT 24 V G (24 V) TNS TNS CONT

DEV.UNIT

DEV.UNIT DEV SW

DEV SW

24 V G (24 V) DB REM HV REM PHOTO REM HV ALM TFM REM

1 1 3 3

1 2 3

1 2 3 4 5 6 7 8 9 10 11 12

MSW

24 V

24 V OPFM REM

5V G (5 V) HUMSENS G (5 V) ETTH

44444-

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

SEG a SEG b SEG c SEG d SEG e SEG f SEG g DIG 0 DIG 1 DIG 2 DIG 3 DIG 4 DIG 5 DIG 6 KEY 0

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

MPCB
6
3 4 5 6 7 8 7 6 5 4 3 2 1 1 2 3 4 5

24 V TC

1 2 3 1 2 3 1 2 3
TCDSW

1 2 3 1 2 3 1 2 3
TCDSW

5 4 3 2 1 HUMPCB OPFM

1 2 3 4 1 2 3 4

TC

1111111-

1 2 3 4 5 6 7

HVTPCB
2 4 3 1

24 V 2- 1 2- 2 TFM
DB HV FB

TFM

TNS

for 120 V, 220 V and 240 V specifications

DEVF

MC

Dev.bias
TC

3-7-8

Wiring diagram
A B C D E F G H I J

195

GY C12-9 GY C12-8 GY C12-7 GY C12-6 GY C12-5 GY C12-4 GY C12-3 GY C12-2 GY C12-1

1
C10-1 3 OE C10-2 2 GN 1 BE C10-3 DM

GY C11-6 GY C11-7 GY C11-8 GY C11-9 GY C11-10

220 - 240 V

C25 DM ALM DM REM 24 V G (24 V) FFM C16 BK C43-2 RD C43-1 BE C40-2 BE C40-1 BE C39-2 BE C39-1 RCL PFCL

RD BK

RD

FB

P16

OE C25-3 1 GN C25-2 2 BE C25-1 3

GY C26-5 GY C26-4 GY C26-3 GY C26-2 GY C26-1 GY C30-5 GY C30-4 GY C30-3 GY C30-2 GY C30-1

5V HPSW G (5 V)

GY C41-4 GY C41-3 GY C41-2 GY C41-1

2
HPSW

RD P17 RD YW C20-12

RD 1 2 GN

HVTPCB

GY C28-9 GY C28-8 GY C28-7 GY C28-6 GY C28-5 GY C28-4 GY C28-3 GY C28-2 GY C28-1

C23 (CN1) TFM REM HV ALM PHOTO REM HV REM DB REM G (24 V) 24 V

2 1 3 24 V 4

SM

HUMPCB C30 C17 5V G (5 V) HUMSENS G (5 V) ETTH 5 4 3 2 1 GY C4-1 GY C4-2 GY C4-3 GY C4-4 GY C4-5

7 6 5 4 3 2 1

1 2 3 4

GY C8-1 GY C8-2 GY C8-3 GY C8-4 GY C8-5 GY C8-6 GY C8-7

C54 1 2 3

MM

HV DB

P15 X1

C9 (CN9)

24 V OPFM REM

C1 (CN1)

C24 (CN2) 1 24 V 2 TFM

INLET 120 V CORE (for 220 - 240 V specifications only)

YW C9-1 BE C9-2 RD C9-3 BN C9-4 WE C9-5

GY C11-5 GY C11-4 GY C11-3 GY C11-2 GY C11-1

OPFM

C28 1 2 3 4 5 6 7 8 9 C29 9 8 7 6 5 4 3 2 1 GY C34-1 GY C34-2 GY C34-3 BE C33-3 GN C33-2 RD C33-1 GY C32-1 GY C32-2 GY C32-3

1 2 3 4 5 6 C26 6 5 4 3 2 1 C27 GY C31-1 GY C31-2 GY C31-3 GY C31-4 GY C31-5

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9

5 4 3 2 1

TFM

LM 2 LM 1 LM 3 24 V LM 4 MM 2 MM 1 MM 3 24 V MM 4

5V HPSW G (5 V)

C11 (CN11)

C13 (CN13) GY C23-7 GY C23-6 GY C23-5 GY C23-4 GY C23-3 GY C23-2 GY C23-1 1 2 3 4 5 6 7 TFM REM HV ALM PHOTO REM HV REM DB REM G (24 V) 24 V C8 (CN8)

C12 (CN12) SEG a SEG b SEG c SEG d SEG e SEG f SEG g DIG 0 DIG 1 DIG 2 DIG 3 DIG 4 DIG 5 DIG 6 KEY 0 KEY 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 GY C14-16 GY C14-15 GY C14-14 GY C14-13 GY C14-12 GY C14-11 GY C14-10 GY C14-9 GY C14-8 GY C14-7 GY C14-6 GY C14-5 GY C14-4 GY C14-3 GY C14-2 GY C14-1

C10 (CN10)

MHPSW

MPCB

GN C19-2 OE C19-1

1 FTH 2 5V 3

DEV. UNIT DEV SW DEVF SHORT 24 V G (24 V) TNS TNS CONT

5V G (5 V) HUMSENS G (5 V) ETTH

BK C36-1 WE C36-2

C3 (CN3)

RD BK 1 24 V 2 FFM OE C47-1 BE C47-2 GN C47-3 GY C51-2 GY C51-1 GY C16-4 GY C16-3 GY C16-2 GY C16-1 1 5V 2 G (5 V) 3 ESW 1 24 V 2 CL 1 2 3 4 G (24 V) 24 V DM REM DM ALM

C37 (CN3)

C36 (CN2) C35 (CN1) P14 P13

AVRPCB

C42 (CN9)

C40 (CN7) C38 (CN5) C39 (CN6)

C22 (CN4) ZERO CROSS Flicker REM 5V CL REM RSW PFCL RCL FTH ESW HL CONT H REM DM ALM DM REM FFM

14 13 12 11 10 9 8 7 6 5 4 3 2 1

1 2 3 4 5 6 7 8

1 2 3 4

RD C18-1 BE C18-3 BE C18-5 OE C18-7

C45 (CN12) C41 (CN8) OE 1 5 V YW 2 RSW BE 3 G (5 V) RE C18-2 1 24 V BE C18-4 2 G (24 V) BE C18-6 3 G (5 V) OE C18-8 4 5V C53 (CN14) 1 RD 24 V 2 BK ICFM GY C55-2 1 GY C6-1 GY C55-3 2 GY C20-1 3 RD C29-4 GN C29-5 BE C29-6

BE BE

BE BE

1 24 V 2 PFCL

1 24 V 2 RCL

C33 1 24 V 2 AES 3 G (24 V)

AES

GY C54-1 GY C20-2,3 PE C20-6 PE C20-7 RD C20-8 BE C20-9 PK C20-10 GN C20-11

GY C17-5 GY C17-4 GY C17-3 GY C17-2 GY C17-1

1 2 3 4 5

GY C7-1 GY C7-2 GY C7-3 GY C7-4 GY C7-5 GY C7-6 GY C7-7 GY C7-8 GY C7-9 GY C7-10 GY C7-11 GY C7-12 GY C7-13 GY C7-14

24 V G (24 V) G (5 V) 5V

GY C22-14 GY C22-13 GY C22-12 GY C22-11 GY C22-10 GY C22-9 GY C22-8 GY C22-7 GY C22-6 GY C22-5 GY C22-4 GY C22-3 GY C22-2 GY C22-1

C46 1 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14

ZERO CROSS Flicker REM 5V CL REM RSW PFCL RCL FTH ESW HL CONT H REM DM ALM DM REM FFM

C7 (CN7)

C5 (CN5) C6 (CN6)

C4 (CN4)

C2 (CN2)

C46 (CN13) C43 (CN10) BK C44 (CN11) LIVE 1 2 3 BK COM 4 WE C50-1 TB2 H COM WE C49-1 H LIVE TB1 BK P12 1 AC LIVE IN 2 WE P11 3 AC COM IN WE C46-2 3 HL COM 2 BK C46-1 1 HL LIVE

C32 1 MHPSW 2 G (5 V) 3 5V

GY C29-3 GY C29-2 GY C29-1

5V G (5 V) MHPSW 24 V AES G (24 V) 5V G (5 V) LHPSW

YW BE RD BN WE

1 2 3 4 5

SM B SM B SM A SM A 24 V

24 V MSW

1 RD P1-5 2 GN P1-6

TC 24 V TC 1 BK 2 BK

5
RD C53-1 BK C53-2 C56 ICFM BK C37-1 RD C5-1 RD C45-1 BE C5-2 BE C45-2 BE C5-3 BE C45-3 OE C5-4 OE C45-4 WE C56-2 WE C35-3 BK C56-1 BK C35-1

GN C46-1 OE C46-2

OE C44-1 BE C44-2 GN C44-3

PE C6-3 PE C6-4 RD C6-5 BE C6-6 PK C6-7 GN C6-8 YW X1

GY C6-1

GY C6-2

GY C6-1 GY C6-2

GY C42-1 GY C42-2

DEVF RD SHORT BE 24 V PK G (24 V) GN TNS YW TNS CONT DB

BK C37-4

DEV SW DEV SW

BE C56-1 BE C56-2

DEV SW

WE

OE BE GN

1 2 3 C47

GY GY DEV. UNIT DEV SW

DEV. UNIT

C49 1

C55 1 2 3

40 W 10

BK BK

P11 TB10

1 2 3 4 5 6 7 8

RD P15

TB9 P12

C50 1 321 C19

1 2 3 4 5 6 7 8 9 1011 12

BK C46-1

C20

BK C46-2

GY C54-1 GY C54-2

WE P13

WE P14

21

BK P12 BK P11

P4 LIVE COM P5 TB1 TB2

RD P16

TH3

BK WE

RD P15

BK

P17 BK BK MC

FUSE 40 W 10 BK BK

GY

GY

HL

FB

DH Optional for 120 V specifications

6
TH2 FTH 1 5V 2 G (5 V) 3 ESW

24 V 24 V G (24 V) G (24 V) G (5 V) G (5 V) 5V 5V

C51 2 1 C52 1 2

40 W 10

COM

1 2 3 4 C21 RD BE PK GN *1 GY C27-2 GY C27-3 GY C27-4 GY C27-5 GY C27-6 *2 DEVF*

3

TCDSW

C18 (CN1)

LIVE

RSW

WE

TC

CLEANING UNIT BL CL

P2 LIVE LIVE TB3 TB4 P3 BK P1-1 BK P1-2 P1 1 2 RD C1-1 4 GN C1-2 5 6 BK P2 BK P3 LIVE LIVE 24 V MSW

MSW

TNS

TH1

C48

ESW

Dev. bias DEVELOPING UNIT LHPSW C34 1 LHPSW 2 G (5 V) 3 5V GY C29-9 GY C29-8 GY C29-7

LM 2 LM 1 LM 3 24 V LM 4

7
FIXING UNIT

Flicker resistor for 230 V specifications and optional for 240 V specifications SSW P10 1A 1 1B 2 2A 3 2B 4

WE

5 4 3 2 1

PSPCB

TB8 COM P9

WE WE WE WE WE WE WE

GY C2-16 GY C2-15 GY C2-14 GY C2-13 GY C2-12 GY C2-11 GY C2-10 GY C2-9 GY C2-8 GY C2-7 GY C2-6 GY C2-5 GY C2-4 GY C2-3 GY C2-2 GY C2-1

LM

WE P10-4

BL SEG a BL SEG b BL SEG c BL SEG d BL SEG e BL DIG 5 BL DIG 6

OPCB

KEY 1 KEY 0 DIG 6 DIG 5 DIG 4 DIG 3 DIG 2 DIG 1 DIG 0 SEG g SEG f SEG e SEG d SEG c SEG b SEG a

WE P10-3

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

BK P10-2

BK P10-1

1 2 3 4 5 6 7

TB6 COM P7

P8 TB7 LIVE

P6 TB5 LIVE

BK P6 BK P8 WE P7 WE P9

Wire color Symbol BLACK BK BROWN BN YELLOW YW GREEN GN BLUE BE WHITE WE PINK PK RED RD ORANGE OE LIGHT BLUE LB PURPLE PE GRAY GY GREEN/YELLOW GN/YW RED/WHITE RD/WE

C15 (CN2)

C14 (CN1) *1 For 220 V/60 Hz and 230 V specifications. *2 For 120 V, 220 V/50 Hz, 220 V/60 Hz and 240 V specifications. *3 For 120 V, 220 V and 240 V specifications.

3-7-9

MITA COPYSTAR AMERICA, INC.

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