SERVICE MANUAL THEORY OF OPERATION AD Ver. 1.0

Transcription

1 SERVICE MANUAL THEORY OF OPERATION Ver. 1.0

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3 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required. Revision mark: To indicate clearly a section revised, show 1 to the left of the revised section. A number within 1 represents the number of times the revision has been made. To indicate clearly a section revised, show 1 in the lower outside section of the corresponding page. A number within 1 represents the number of times the revision has been made. NOTE Revision marks shown in a page are restricted only to the latest ones with the old ones deleted. When a page revised in Ver. 2.0 has been changed in Ver. 3.0: The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted. When a page revised in Ver. 2.0 has not been changed in Ver. 3.0: The revision marks for Ver. 2.0 are left as they are. 2005/ Issue of the first edition Date Service manual Ver. Revision mark Descriptions of revision

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5 Theory of Operation Ver. 1.0 Apr CONTENTS Outline 1. Product specification... 1 Composition/Operation 2. Duplex Unit () Construction Operation Electric Parts Layout Switchback Operation sided Copying with a Single Sheet of Paper Resident in the Unit Operation sided Copying with Two Sheets of Paper Resident in the Unit Operation... 7 Outline Composition/Operation i

6 Theory of Operation Ver. 1.0 Apr Composition/Operation Outline Blank page ii

7 Theory of Operation Ver. 1.0 Apr Outline 1. Product specification 1. Product specification Name Duplex Unit Type Sheet duplex paper take-up section Installation Installed to the right side door Paper Size A3, A4 R, A4, A5 R, A5, B4, B5 R, B5, FLS, Ledger, Legal, Letter, Invoice R, Invoice Paper Type Plain paper (60 to 90 g/m 2 ), recycled paper (60 to 90 g/m 2 ) Document Alignment Center Power Requirements DC24 V (supplied from the copier) DC5 V Max. Power Consumption 9 W or less Dimensions Width = 412 mm Depth = 215 mm Height = 88 mm Mass 2.5 kg (Duplex Unit + Manual Bypass Assy Operating Environment Conforms to that of the copier Outline 1

8 1. Product specification Theory of Operation Ver. 1.0 Apr Outline Blank page 2

9 Theory of Operation Ver. 1.0 Apr Composition/Operation 2. Duplex Unit () 2.1 Construction 2. Duplex Unit () M503AA 3 Composition/Operation [1] Duplex Unit Transport Roller 1 [3] Duplex Unit Transport Roller 2 [2] Duplex Unit Transport Roll 1 [4] Duplex Unit Transport Roll 2 3

10 2. Duplex Unit () Theory of Operation Ver. 1.0 Apr Operation The Duplex Unit Transport Motor provides the drive for the Duplex Unit. Composition/Operation 2.3 Electric Parts Layout M501AA M001AA [1] Duplex Unit Transport Motor (M2/AD) [3] Control Board (PWB-A/AD) [2] Duplex Unit Transport Sensor (PC2/AD) 4

11 Theory of Operation Ver. 1.0 Apr Duplex Unit () 2.4 Switchback Operation The paper printed on one side is switched back by the exit rollers on copier to transport it into the duplex unit. The switchback operation of transport rollers is carried out by the Duplex Unit Switchback Motor. 4532M502CA Composition/Operation 5

12 2. Duplex Unit () Theory of Operation Ver. 1.0 Apr sided Copying with a Single Sheet of Paper Resident in the Unit Operation 1. The first sheet of paper is taken up and the image of page 2 of the original is printed. 4034M510AA Composition/Operation 4034M511AA 2. Immediately before the first sheet of paper leaves the Paper Exit Roller, the direction of rotation of the Paper Exit Roller is reversed and the first sheet of paper is transported toward and into the Duplex Unit. 3. The paper moving through the Duplex Unit is directly subjected to the second print cycle without being stopped. 4034M512AA 4. The image of page 1 of the original is printed on the other side of the first sheet of paper. 4034M513AA 5. While the first sheet of paper is being fed out of the copier, the image of page 4 of the original is printed on one side of the second sheet of paper. 4034M514AA Steps 2 through 5 are repeated. 6

13 Theory of Operation Ver. 1.0 Apr Duplex Unit () sided Copying with Two Sheets of Paper Resident in the Unit Operation 1. The first sheet of paper is taken up and the image of page 2 of the original is printed. 4034M510AA 4034M511AA 2. Immediately before the first sheet of paper leaves the Paper Exit Roller, the direction of rotation of the Paper Exit Roller is reversed and the first sheet of paper is transported toward and into the Duplex Unit. 3. At the same time, the second sheet of paper is taken up and fed in. 4. The image of page 4 of the original is printed on one side of the second sheet of paper. 5. At the same time, the first sheet of paper is transported through the Duplex Unit. Composition/Operation 4034M512AA 4034M513AA 6. The image of page 1 of the original is printed on the other side of the first sheet of paper that has been fed into the copier again. 7. At the same time, the second sheet of paper is subjected to a switchback sequence at the exit section. 8. It is then fed through the Duplex Unit without. 9. While the first sheet of paper is being fed out of the copier, the image of page 4 of the original is printed on one side of the second sheet of paper. 4034M514AA 7

14 2. Duplex Unit () Theory of Operation Ver. 1.0 Apr While the second sheet of paper is being fed out of the copier, the third sheet of paper is taken up and the image of page 6 of the original is printed. Steps 2 through 10 are repeated. 4034M514AA Composition/Operation 8

15 SERVICE MANUAL FIELD SERVICE Ver. 1.0

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17 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required. Revision mark: To indicate clearly a section revised, show 1 to the left of the revised section. A number within 1 represents the number of times the revision has been made. To indicate clearly a section revised, show 1 in the lower outside section of the corresponding page. A number within 1 represents the number of times the revision has been made. NOTE Revision marks shown in a page are restricted only to the latest ones with the old ones deleted. When a page revised in Ver. 2.0 has been changed in Ver. 3.0: The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted. When a page revised in Ver. 2.0 has not been changed in Ver. 3.0: The revision marks for Ver. 2.0 are left as they are. 2005/ Issue of the first edition Date Service manual Ver. Revision mark Descriptions of revision

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19 Field Service Ver. 1.0 Apr CONTENTS General 1. Product specification... 1 Maintenance 2. Other Disassembly/Adjustment prohibited items Disassembly/Assembly procedure Exterior Parts Control Board (PWB-A/AD) Cleaning procedure Duplex Unit Transport Rollers/Rolls Switch Back Unit Transport Roller/Roll Duplex Unit Ventilation Section Bypass Transport Roller/Rolls... 7 Adjustment/Setting 3. How to use the adjustment section Service Mode Service Mode function setting procedure Procedure Exiting Changing the Setting Value in Service Mode Functions Setting in the Service Mode SERVICE S CHOICE Troubleshooting 5. Introduction Electrical Components Check Procedure Sensor Switch Solenoid Clutch Motor Jam Display Misfeed Display Display Resetting Procedure Troubleshooting Adjustment / Setting Maintenance General i

20 Field Service Ver. 1.0 Apr Sensor layout Solution Initial Check Items Duplex Reversal Housing Block Troubleshooting Adjustment / Setting Maintenance General ii

21 Field Service Ver. 1.0 Apr General 1. Product specification 1. Product specification Name Duplex Unit Type Sheet duplex paper take-up section Installation Installed to the right side door Paper Size A3, A4 R, A4, A5 R, A5, B4, B5 R, B5, FLS, Ledger, Legal, Letter, Invoice R, Invoice Paper Type Plain paper (60 to 90 g/m 2 ), recycled paper (60 to 90 g/m 2 ) Document Alignment Center Power Requirements DC24 V (supplied from the copier) DC5 V Max. Power Consumption 9 W or less Dimensions Width = 412 mm Depth = 215 mm Height = 88 mm Mass 2.5 kg (Duplex Unit + Manual Bypass Assy Operating Environment Conforms to that of the copier General 1

22 1. Product specification Field Service Ver. 1.0 Apr General Blank page 2

23 Field Service Ver. 1.0 Apr Maintenance 2. Other 2.1 Disassembly/Adjustment prohibited items A. Paint-locked Screws 2. Other NOTE Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B. Red Painted Screws NOTES When the screws are removed, the red paint is coated on the points where readjustment is required. Once the red painted screw is removed or loosened, you should make adjustment. Accordingly check the adjustment items in operation manual and make necessary adjustment. Note that when two or more screws are used on the part in questions, only one representative screw may be marked with red paint. C. Variable Resistors on Board NOTE Do not turn the variable resistors on boards for which no adjusting instructions are given in Adjustment/Setting. Maintenance D. Removal of PWBs NOTES When removing a circuit board or other electrical component, refer to Handling of PWBs and follow the corresponding removal procedures. The removal procedures given in the following omit the removal of connectors and screws securing the circuit board support or circuit board. Where it is absolutely necessary to touch the ICs and other electrical components on the board, be sure to ground your body. 3

24 2. Other Field Service Ver. 1.0 Apr Disassembly/Assembly procedure Exterior Parts 3 1 Maintenance D006AB No. Part Name Removal Procedure 1 Right Cover Remove the Lower Right Cover. Remove two screws. Remove the Right Cover. 2 Lower Right Cover Remove one screw. Remove the Lower Right Cover. 3 Front Door Remove the Right Cover. Remove one screw, snap off one C- clip, and remove one washer. Slide the Front Door to the left and take it off. 4

25 Field Service Ver. 1.0 Apr Other Control Board (PWB-A/AD) PWB-A/AD 4532D007AA 1. Remove one screw and the Lower Right Cover. Maintenance 4532D011AA 2. Remove two screws and the Right Cover. 4532D017AB 3. Remove two screws, unplug all connectors, and remove the Control Board. 4532D018AA 5

26 2. Other Field Service Ver. 1.0 Apr Cleaning procedure Duplex Unit Transport Rollers/Rolls 1. Open the Front Door of the Duplex Unit. 2. Using a soft cloth dampened with alcohol, wipe the Duplex Unit Transport Rollers/Rolls clean of dirt. 4532D001AA Switch Back Unit Transport Roller/Roll 1. Remove two screws and the Duplex Unit. Maintenance 4532D002AA 2. Using a soft cloth dampened with alcohol, wipe the Switch Back Unit Transport Roller/Roll clean of dirt. 4532D003AA Duplex Unit Ventilation Section 1. Using a soft cloth dampened with alcohol, wipe the outside of the Duplex Unit Ventilation Section clean of dirt. 4532D004AA 6

27 Field Service Ver. 1.0 Apr Other 2. Open the Front Door of the Duplex Unit. 3. Using a soft cloth dampened with alcohol, wipe the inside of the Duplex Unit Ventilation Section clean of dirt. 4532D005AB Bypass Transport Roller/Rolls 1. Remove the Rear Right Cover Open the Right Door. 3. Remove two screws, unplug one connector, and remove the Bypass Assy. Maintenance 4532D013AB 4. Using a soft cloth dampened with alcohol, wipe the Bypass Transport Roller clean of dirt. 4532D010AA 5. Using a soft cloth dampened with alcohol, wipe the Bypass Transport Rolls clean of dirt. 4532D015AA 7

28 2. Other Field Service Ver. 1.0 Apr Maintenance Blank page 8

29 Field Service Ver. 1.0 Apr Adjustment/Setting 3. How to use the adjustment section 3. How to use the adjustment section Adjustment/Setting contains detailed information on the adjustment items and procedures for this machine. Throughout this Adjustment/Setting, the default settings are indicated by. A. Advance Checks Before attempting to solve the customer problem, the following advance checks must be made. Check to see if: 1. The power supply voltage meets the specifications. 2. The power supply is properly grounded. 3. The machine shares the power supply with any other machine that draws large current intermittently (e.g., elevator and air conditioner that generate electric noise). 4. The installation site is environmentally appropriate: high temperature, high humidity, direct sunlight, ventilation, etc.; levelness of the installation site. 5. The original has a problem that may cause a defective image. 6. The density is properly selected. 7. The Original Glass, slit glass, or related part is dirty. 8. Correct paper is being used for printing. 9. The units, parts, and supplies used for printing (developer, PC Drum, etc.) are properly replenished and replaced when they reach the end of their useful service life. 10. Toner is not running out. B. Precautions for Service Jobs 1. To unplug the power cord of the machine before starting the service job procedures. 2. If it is unavoidably necessary to service the machine with its power turned ON, use utmost care not to be caught in the Scanner Cables or gears of the Exposure Unit. 3. Special care should be used when handling the Fusing Unit which can be extremely hot. 4. The Developing Unit has a strong magnetic field. Keep watches and measuring instruments away from it. 5. Take care not to damage the PC Drum with a tool or similar device. 6. Do not touch IC pins with bare hands. Adjustment / Setting 9

30 4. Service Mode Field Service Ver. 1.0 Apr Service Mode 4.1 Service Mode function setting procedure NOTE Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the Service mode Procedure 1. Press the Utility key. 2. Press the following keys in this order. 3. Stop 0 0 Stop The Service mode menu screen will appear Exiting Press the Panel Reset key as many times as it is required to display the initial screen Changing the Setting Value in Service Mode Functions 1. Select the desired item using [ / ] key. 2. Select the setting value using [ / ] key, [ < / > ] key, or the 10-Key Pad. 3. Validate the selection by pressing the [Yes] key. 4. To go back to previous screen, press the [No] key. Adjustment / Setting 10

31 Field Service Ver. 1.0 Apr Service Mode 4.2 Setting in the Service Mode SERVICE S CHOICE A. LOOP ADJUST (DUPLEX) Purpose/Use To adjust the length of the loop formed in the paper before the Synchronizing Roller. Setting/ Procedure Adjustment Procedure When a skew feed, fold, or misfeed of paper occurs When variations in the amount of void on the leading edge occurs Setting range: -3.9 to 3.9 mm (1 step: 0.6 mm) 1. Call Service s Choice of Service Mode to the screen. 2. Select Loop Adjust (Duplex) and press the [Yes] key. 3. Using [ / ] key, select the desired setting value. 4. Press the [Yes] key to validate the setting value selected in step 3. Adjustment Instructions Try a different setting value until there are no variations in the amount of void on the leading edge, and paper skew, fold, or misfeed. Adjustment / Setting 11

32 4. Service Mode Field Service Ver. 1.0 Apr Adjustment / Setting Blank page 12

33 Field Service Ver. 1.0 Apr Troubleshooting 5. Introduction 5. Introduction Information required for troubleshooting and steps that must be performed are described in this chapter. 5.1 Electrical Components Check Procedure If a paper misfeed or malfunction occurs, perform the following operations to check the condition of the electrical components Sensor Step Check Result Action 1 Does the input signal of the control board change when the sensor light is interrupted? (H L, L H) NO YES Replace the sensor. Replace the control board. 4025T520AA 4025T521AA Troubleshooting 13

34 5. Introduction Field Service Ver. 1.0 Apr Switch Step Check Result Action 1 Does the input signal (NO) of the control board change from L to H when the switch is activated? NO YES Replace the switch. Replace the control board. NO Not Use COM 4025T523AB Solenoid Step Check Result Action 1 Does the output signal of the control board change from H to L when the solenoid is activated? NO YES Replace the control board. Replace the solenoid T522AA Clutch Troubleshooting Step Check Result Action 1 Does the output signal of the control board change from H to L when the clutch is activated? NO YES Replace the control board. Replace the clutch. 4025T528AA 14

35 Field Service Ver. 1.0 Apr Introduction Motor Step Check Result Action 1 2 Does the LOCK signal switch to H when the machine goes into standby? Does the REM signal of the master board change from H to L when the motor is turned on? NO YES NO Replace the control board. Replace the motor. Replace the motor. Replace the control board. GND REM LOCK T526AA Step Check Result Action 1 Does the input signal of the master board change from H to L when the motor is turned on? (The input signal differs depending on the rotation direction.) YES NO Replace the motor. Replace the control board. 4025T525AA Step Check Result Action 1 Are the relay connector of the motor and the print jack of the control board correctly connected? YES NO Replace the motor or the control board. Connect the connector or the print jack. Troubleshooting 4025T527AA 15

36 6. Jam Display Field Service Ver. 1.0 Apr Jam Display 6.1 Misfeed Display When a paper misfeed occurs, the Error indicator lights up steadily and the Display gives a corresponding message. 4532T501CA Display Message Misfeed/Paper Location Ref. Page OPEN DUPLEX COVER Duplex Reversal Housing Block Display Resetting Procedure Open the corresponding cover, clear the sheet of paper misfed, and close the cover. Troubleshooting 16

37 Field Service Ver. 1.0 Apr Jam Display 6.2 Sensor layout Troubleshooting 4532T502CA [1] Duplex Unit Transport Sensor (PC2/AD) 17

38 6. Jam Display Field Service Ver. 1.0 Apr Solution Initial Check Items When a paper misfeed occurs, first perform the following initial checks. Check Item Does paper meet product specifications? Replace paper. Action Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures. Is a foreign object present along the paper path, or is the Clean or change the paper path. paper path deformed or worn? Are the Paper Separator Fingers dirty, deformed, or worn? Are rolls/rollers dirty, deformed, or worn? Are the Edge Guide and Trailing Edge Stop at the correct position to accommodate the paper? Are the actuators operational and checked for correct operation? Clean or replace the defective Paper Separator Finger. Clean or replace the defective roll/roller. Set as necessary. Correct or replace the defective actuator Duplex Reversal Housing Block A. Detection Timing Type Duplex Reversal Housing Block Description If the Duplex Unit Transfer Sensor does not turn on even when a specified time elapses after the Exit Sensor turns off. B. Action Relevant Electrical Components Duplex Unit Transport Motor (M2/AD) Control Board (PWB-A/AD) Duplex Unit Transport Sensor (PC2/AD) Troubleshooting Step Operations Ref. Page WIRING DIAGRAM Control signal Location (Electrical Components) 1 Initial checks 2 M2/AD operation check 15 F~G-7 () 3 PC2/AD sensor check 13 PWB-A/AD PJ4A/AD-5 (ON) C~D-3~4 () 4 Replace PWB-A/AD 18