STINGER-C1 (Machine Code: A250)
SERVICE MANUAL
1IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling disassembling or assembling parts parts of the copier and peripherals, peripherals, make sure that the copier power cord is unplugged. 2. The wall wall outlet should be near the copier copier and easily accessible. 3. Note that some some components of the copier and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off. 4. If any adjustment or operation check has to be made with exterior exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. 5. If the “Start” key is is pressed before the copier completes the warm-up period (the “Start” key starts blinking red and green alternatively), keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period is completed. 6. The inside and the metal parts of the fusing unit become extremely hot while while the copier is operating. Be careful to avoid touching those components with
1IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling disassembling or assembling parts parts of the copier and peripherals, peripherals, make sure that the copier power cord is unplugged. 2. The wall wall outlet should be near the copier copier and easily accessible. 3. Note that some some components of the copier and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off. 4. If any adjustment or operation check has to be made with exterior exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. 5. If the “Start” key is is pressed before the copier completes the warm-up period (the “Start” key starts blinking red and green alternatively), keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period is completed. 6. The inside and the metal parts of the fusing unit become extremely hot while while the copier is operating. Be careful to avoid touching those components with
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate AIO AIO cartridge. Toner dust may ignite ignite suddenly when exposed to and open flame. 2. Dispose of used AIO cartridge in accordance with with local regulations. (This is non-toxic supplies.) 3. Dispose of replaced replaced parts in accordance with local regulations. 4. When keeping used lithium lithium batteries in order to dispose of them later, later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.
LASER SAFETY The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all
TABLE OF CONTENTS 1. OVERALL MACHINE INFORMATION INFORMATION ........................................ 1-1 1.1 1.2 1.3 1.4 1.5
SPECIFICATI SPECIFICATIONS ONS................ .................................. ................................... ................................... ................................. ............... 1-1 MACHINE MACHINE CONFIGURATIO CONFIGURATION N ............................. ............................................ ............................... ...................... ...... 1-5 PAPER PAPER PATH .................................. .................................................... ................................... .................................. ...................... ..... 1-6 MECHANICAL MECHANICAL COMPONENT COMPONENT LAYOUT........................... LAYOUT........................................... ........................ ........ 1-7 ELECTRICA ELECTRICAL L COMPONEN COMPONENT T DESCRIPTI DESCRIPTIONS............... ONS............................... ......................... ......... 1-8 1.5.1 COPIER ENGINE ................................. .................................................. .................................. .......................... ......... 1-8 1.6 DRIVE LAYOUT LAYOUT ................................. .................................................. .................................. ................................. .................. .. 1-11 1.7 COPY PROCESS PROCESS ................................ ................................................. .................................. .................................. ................. 1-12 1.7.1 OVERVIEW OVERVIEW ................................... ..................................................... .................................... .............................. ............ 1-12 1.8 BOARD STRUCTURE STRUCTURE............... ............................... ................................ ................................ ............................. ............. 1-14 1.8.1 OVERVIEW OVERVIEW ................................... ..................................................... .................................... .............................. ............ 1-14 1.8.2 DESCRIPTION DESCRIPTION .................................. .................................................... ................................... .......................... ......... 1-15
2. DETAILED DETAILED SECTION DESCRIPTIONS....................................... DESCRIPTIONS....................................... 2-1 2.1 SCANNING SCANNING................ ................................. .................................. ................................. ................................. ............................. ............ 2-1
2.6.1 OVERVIEW ................................................................................... 2-47 2.6.2 BUILT-IN TRAY ............................................................................. 2-48 2.6.3 BY-PASS TRAY............................................................................. 2-51 2.6.4 PAPER REGISTRATION............................................................... 2-53 2.6.5 MISFEED DETECTION ................................................................. 2-54 2.7 IMAGE FUSING...................................................................................... 2-57 2.7.1 OVERVIEW ................................................................................... 2-57 2.7.2 FUSING UNIT DRIVE .................................................................... 2-58 2.7.3 PRESSURE ROLLER/PAPER EXIT.............................................. 2-59 2.7.4 FUSING UNIT DRIVE RELEASE................................................... 2-59 2.7.5 FUSING TEMPERATURE CONTROL........................................... 2-60 2.7.6 OVERHEAT PROTECTION........................................................... 2-63 2.7.7 ENERGY SAVER MODE............................................................... 2-63
3. INSTALLATION........................................................................... 3-1 3.1 INSTALLATION REQUIREMENTS .......................................................... 3-1 3.1.1 ENVIRONMENT .............................................................................. 3-1 3.1.2 MACHINE LEVEL ............................................................................ 3-2 3.1.3 MINIMUM SPACE REQUIREMENTS.............................................. 3-3 3.1.4 POWER REQUIREMENTS.............................................................. 3-4 3.2 COPIER INSTALLATION 3-5
4. SERVICE TABLES...................................................................... 4-1 4.1 GENERAL CAUTION................................................................................ 4-1 4.1.1 AIO CARTRIDGE (ALL-IN-ONE CARTRIDGE) ............................... 4-1 4.1.2 TRANSFER ROLLER UNIT............................................................. 4-1 4.1.3 SCANNER UNIT.............................................................................. 4-1 4.1.4 LASER UNIT.................................................................................... 4-2 4.1.5 FUSING UNIT.................................................................................. 4-2 4.1.6 PAPER FEED .................................................................................. 4-2 4.1.7 OTHERS.......................................................................................... 4-2 4.2 SERVICE PROGRAM MODE................................................................... 4-3 4.2.1 SERVICE PROGRAM MODE OPERATION.................................... 4-3 4.1.2 SERVICE PROGRAM MODE TABLES ........................................... 4-4 4.1.3 TEST PATTERN PRINTING (SP5-902)......................................... 4-38 4.1.4 INPUT CHECK (SP5-803) ............................................................. 4-39 4.1.5 OUTPUT CHECK (SP5-804) ......................................................... 4-44 4.1.6 COPY JAM HISTORY DISPLAY (SP7-903) .................................. 4-46 4.1.7 ORIGINAL JAM HISTORY DISPLAY (SP7-905) ........................... 4-47 4.1.8 SYSTEM PARAMETER AND DATA LISTS (SP5-992).................. 4-48 4.1.9 MEMORY ALL CLEAR (SP5-801) ................................................. 4-49 4.1.10 PROGRAM UPLOAD/DOWNLOAD........... 4-50
6.2 SCANNER ................................................................................................ 6-5 6.2.1 EXPOSURE GLASS REMOVAL...................................................... 6-5 6.2.2 LENS BLOCK REMOVAL................................................................ 6-7 6.2.3 EXPOSURE LAMP REPLACEMENT .............................................. 6-8 6.2.4 1ST SCANNER ALIGNMENT ADJUSTMENT................................. 6-9 6.2.5 2ND SCANNER POSITION ADJUSTMENT .................................. 6-10 6.3 LASER UNIT........................................................................................... 6-11 6.3.1 CAUTION DECAL LOCATIONS .................................................... 6-11 6.3.2 LASER UNIT/TONER SHIELD GLASS REMOVAL ....................... 6-12 6.3.3 LD UNIT/LASER SYNCHRONIZATION DETECTOR REMOVAL ..................................................................................... 6-13 6.3.4 EXIT TRAY PAPER SENSOR REMOVAL..................................... 6-13 6.3.5 POLYGONAL MIRROR MOTOR REMOVAL................................. 6-14 6.3.6 LASER UNIT ALIGNMENT ADJUSTMENT................................... 6-15 6.4 IMAGE TRANSFER................................................................................ 6-16 6.4.1 TRANSFER ROLLER REMOVAL.................................................. 6-16 6.5 FUSING .................................................................................................. 6-17 6.5.1 FUSING UNIT REMOVAL ............................................................. 6-17 6.5.2 HOT ROLLER, FUSING LAMP AND THERMOFUSE REPLACEMENT ............................................................................ 6-18 6.5.3 PRESSURE ROLLER REPLACEMENT 6-20
7. TROUBLESHOOTING................................................................. 7-1 7.1 SERVICE CALL CONDITIONS................................................................. 7-1 7.1.1 SUMMARY....................................................................................... 7-1 7.1.2 SC CODE DESCRIPTIONS............................................................. 7-2 7.2 BLOWN FUSE TABLE............................................................................ 7-10 7.3 ELECTRICAL COMPONENT DEFECTS................................................ 7-10 7.3.1 SWITCHES .................................................................................... 7-10 7.3.2 SENSORS ..................................................................................... 7-11
OPTIONS DOCUMENT FEEDER (A859) 1. OVERALL INFORMATION....................................................A859-1 1.1 1.2 1.3 1.4 1.5
SPECIFICATIONS.............................................................................. A859-1 MECHANICAL COMPONENT LAYOUT............................................. A859-2 ELECTRICAL COMPONENT LAYOUT .............................................. A859-3 ELECTRICAL COMPONENT DESCRIPTION.................................... A859-4 DRIVE LAYOUT ................................................................................. A859-5
PAPER TRAY UNIT (A860) 1. OVERALL MACHINE INFORMATION ..................................A860-1 1.1 1.2 1.3 1.4 1.5
SPECIFICATIONS.............................................................................. A860-1 MECHANICAL COMPONENT LAYOUT............................................. A860-2 ELECTRICAL COMPONENT LAYOUT .............................................. A860-3 ELECTRICAL COMPONENT DESCRIPTION.................................... A860-4 DRIVE LAYOUT ................................................................................. A860-5
2. DETAILED DESCRIPTIONS .................................................A860-6 2.1 2.2 2.3 2.4 1.5 1.6
PAPER FEED AND SEPARATION MECHANISM.............................. A860-6 PAPER LIFT MECHANISM ................................................................ A860-7 PAPER END DETECTION ................................................................. A860-9 PAPER HEIGHT DETECTION ......................................................... A860-10 PAPER SIZE DETECTION ............................................................... A860-12 SIDE AND END FENCES................................................................. A860-13
3. REPLACEMENT AND ADJUSTMENT................................A860-14 3.1 FEED ROLLER REPLACEMENT ..................................................... A860-14 3.2 TRAY MAIN BOARD REPLACEMENT............................................. A860-15
3. REPLACEMENT AND ADJUSTMENT................................A861-14 3.1 3.2 3.3 3.4 3.5 3.6 3.7
FEED ROLLER REPLACEMENT ..................................................... A861-14 TRAY MAIN BOARD REPLACEMENT............................................. A861-15 TRAY MOTOR REPLACEMENT ...................................................... A861-15 TRAY MOTOR REPLACEMENT ...................................................... A861-16 LIFT MOTOR REPLACEMENT ........................................................ A861-17 PAPER END SENSOR REPLACEMENT ......................................... A861-18 PAPER SIZE SWITCH REPLACEMENT.......................................... A861-18
1-BIN SORTER (A869) 1. OVERALL INFORMATION....................................................A869-1 1.1 1.2 1.3 1.4
SPECIFICATIONS.............................................................................. A869-1 MECHANICAL COMPONENT LAYOUT............................................. A869-2 ELECTRICAL COMPONENT LAYOUT .............................................. A869-3 ELECTRICAL COMPONENT DESCRIPTION.................................... A869-4
2. DETAILED SECTION DESCRIPTIONS.................................A869-5 2.1 BASIC OPERATION
A869-5
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SPECIFICATIONS
1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS Configuration:
Desktop
Copy Process:
Dry electrostatic transfer system
Originals:
Sheet/Book
Original Size:
Maximum A3/11" x 17"
Copy Paper Size:
Maximum A3/11" x 17" Minimum A5/81/2" x 51/2" sideways (Paper tray) B6 lengthwise/51/2" x 81/2" (By-pass) Custom sizes in the by-pass tray: Width: 90 ~ 305 mm (3.5" ~ 12.0") Length: 148 ~ 1,260 mm (5.8" ~ 49.6")
Copy Paper Weight:
Paper Tray: 60 ~ 90 g/m2, 16 ~ 24 lb
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SPECIFICATIONS
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Power Consumption:
Maximum Copying Warm-up Stand-by Energy Saver Level 1 Energy Saver Level 2 Auto Shut off
Mainframe Only 120 V 220 ~ 240 V Less than Less than 1.1 kW 1.1 kW Approx. Approx. 450 W 450 W Approx. Approx. 860 W 760 W Approx. Approx. 110 W 110 W Approx. 60 W Approx. 60 W Approx. 30 W Approx. 30 W 0W 0W
Full System 120 V 220 ~ 240 V Less than Less than 1.2 kW 1.3 kW Approx. Approx. 460 W 460 W Approx. Approx. 870 W 770 W Approx. Approx. 130 W 130 W Approx. 60 W Approx. 60 W Approx. 30 W Approx. 30 W 0W 0W
NOTE: 1) Full system: Mainframe + ADF + 1-bin Sorter + Paper Tray Unit 2) Without the optional heaters, fax unit, and printer controller
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SPECIFICATIONS
Copying Speed in Multicopy mode (copies/minute):
Non-memory copy mode Memory copy mode
A4 sideways/ 11" x 81/2" 15 18
A3/11" x 17"
B4/81/2" x 14"
10 10
11 12
NOTE: Measurement Conditions 1) Not APS mode 2) A4/LT copying 3) Full size Warm-up Time:
Less than 30 seconds (20°C, 68°F): 115 V machine Less than 40 seconds (20°C, 68°F): 230 V machine
First Copy Time:
Less than 6.5 seconds NOTE: Measurement Conditions 1) When polygonal mirror motor is spinning. 2) Not APS mode 3) A4/LT copying 4) Full size
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SPECIFICATIONS
Optional Equipment:
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· · · · · · · · ·
Copy Capacity:
Platen cover Auto document feeder Paper tray unit (1 tray) Paper tray unit (2 trays) 1-bin sorter Tray heater Optics anti-condensation heater Drum heater Copier feature expander (48 MB memory)
Copy Tray: 250 sheets (without 1-bin sorter), 125 sheets (with 1-bin sorter) 1-bin Sorter: 125 sheets
Memory Capacity:
Sort, Rotate Sort
A4, 81/2" x 11" B4, 81/2" x 14" A3, 11" x 17"
Standard (16 MB)
Optional (+48 MB)
r
r
r
r
r
r
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MACHINE CONFIGURATION
1.2 MACHINE CONFIGURATION
A
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C
B D
PAPER PATH
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1.3 PAPER PATH 1
5
2
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MECHANICAL COMPONENT LAYOUT
1.4 MECHANICAL COMPONENT LAYOUT
1
2
3
4
5
6
7
8
9
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10
21 11 20
12 13 14
15
ELECTRICAL COMPONENT DESCRIPTIONS
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1.5 ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout on the reverse side of the point-to-point diagram for the location of the components, using the symbols and index numbers.
1.5.1 COPIER ENGINE Symbol Motors M1 M2 M3 M4
Name Scanner Polygonal Mirror Main Exhaust Fan
Magnetic Clutches MC1 Paper Feed MC2 By-pass Feed MC3 Vertical Transport MC4 Registration
Function
Index No.
Drives the 1st and 2nd scanners. Turns the polygonal mirror. Drives the main unit components. Removes heat from around the fusing unit.
4 28 12 46
Starts paper feed from the tray. Starts paper feed from the by-pass table. Drives the vertical transport rollers. Drives the registration rollers.
14 15 18 13
17 May, 1999 Symbol S8 S9 S10 S11 S12 S13
Name By-pass Tray Paper By-pass Paper Size Vertical Transport Registration Fusing Exit Exit Tray Paper Platen Cover
S14 S15
AIO Set
ELECTRICAL COMPONENT DESCRIPTIONS Function Index No. Informs the CPU that there is paper in the 16 by-pass feed table. Detects the paper size in the by-pass tray. 20 Detects misfeeds. 22 Detects misfeeds and controls registration 17 clutch off-on timing. Detects misfeeds. 35 Detects if there is paper on the exit tray or 27 not. Informs the CPU that the platen cover is in the up or down position (related to the 5 APS/ARE functions). Informs the CPU that an AIO is installed. 33
PCBs PCB1 PCB2 PCB3
BICU PSU IOB
Controls all base engine functions both directly and through other control boards. Provides dc power to the system and ac power to the fusing lamp and heaters. Controls the fusing lamp and the
44 39 45
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ELECTRICAL COMPONENT DESCRIPTIONS Symbol Others TF1 TH1 PP1 LSD 1 CO1 CO2 LED1 LED2 SP1
Name
17 May, 1999 Function
Opens the fusing lamp circuit if the fusing unit overheats. Fusing Thermistor Detects the temperature of the hot roller. Provides high voltage for the charge, C/B/T Power Pack development and transfer rollers. Laser Synchronization Detects the laser beam at the start of the Detector main scan. Total Counter Keeps track of the total number of prints made. Key Counter (Option) Used for control of authorized use. If this feature is enabled for coping, coping will be impossible until it is installed. Exit Tray Indicates if there is paper on the exit tray. 1-bin Sorter Indicates if there is paper on the 1-bin sorter. 1-bin sorter is option. Speaker Turns on during fax communication. Fusing Thermofuse
Index No. 9 11 38 29 48 — 32 34 41
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DRIVE LAYOUT
1.6 DRIVE LAYOUT
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5
1 2
4
3
COPY PROCESS
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1.7 COPY PROCESS 1.7.1 OVERVIEW
6 1
O PC 2
–600 V
5
–100 V
4
