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Ricoh A095, Service Manual

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6. FT6645/6655/6665 ROM MODIFICATION

HISTORY

FT6645/6655/6665 - ROM MODIFICATION HISTORY

DESCRIPTION OF MODIFICATION RICOH P/N QTY

SERIAL NUMBER

LOCATION

- Prevents the machine from
entering the Screen Saver
Mode during Auto Counting
Mode.
- Disables operating time
indication for single side original
to duplex copy mode and
increases the accuracy of the
indicated operation time for
duplex original to duplex copy
mode.
- Increase the maximum copy
set for Sort Mode when using
the RDH & Finisher to "999."
- Allows copy paper to exit the
copier in the event of an RDH
misfeed.
- Increases the maximum sorter
bin capacity for 8

1/2

"x11" and

smaller paper from 15 to 30
sheets/bin (ST24/FT6645 only)
- Prevents cover sheets from
being inserted into the middle of
copy job following copier
misfeed.

A0965151B
A0965153B

2

FT6645 - A3355420001
FT6655 - A3365420313
FT6665 - A3375420001

Main
Control
Board

- Prevents black line on front
edge when the original is fed by
the DJF while in reduction
mode.
- Ensures the Erase Lamp turns
"OFF" during a jam indication.
This prevents a horizontal black
line on copiers due to Drum
overexposure by the Erase
Lamp.
- Ensures SC353 and SC357
are counted in SC counter (SP
Mode) only when a malfunction
occurs.

A0965151A
A0965153A

2

FT6645 - A335446077
FT6655 - A3364460002
FT6665 - from 1st      
        production

Main
Control
Board

Rev. 2/17/95

T

rou

ble

-

sh

o

o

ti

n

g

FSM

6-43

A095/A096/A097

Summary of Contents for A095

Page 1: ...SERVICE MANUAL PN RCFM6655 A095 A096 A097 RICOH GROUP COMPANIES ...

Page 2: ...SERVICE MANUAL A095 A096 A097 RICOH GROUP COMPANIES ...

Page 3: ......

Page 4: ...A095 A096 A097 SERVICE MANUAL PN RCFM6655 ...

Page 5: ......

Page 6: ...ation Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury damage to property or loss of warranty protection Ricoh Corporation WARNING ...

Page 7: ......

Page 8: ...ESTETNER RICOH SAVIN A095 2545D FT6645 9450 2555D FT6655 9550 2565D FT6665 9650 DOCUMENTATION HISTORY REV NO DATE COMMENTS 10 93 Original Printing 1 1 94 Revised pages 2 4 94 Revised pages 3 6 94 Revised pages 4 7 94 A097 addition ...

Page 9: ......

Page 10: ...TION REQUIREMENTS 3 1 1 1 ENVIRONMENT 3 1 1 2 MACHINE LEVEL 3 1 1 3 MINIMUM SPACE REQUIREMENTS 3 2 1 4 POWER REQUIREMENTS 3 3 2 COPIER INSTALLATION 3 4 2 1 ACCESSORY CHECK 3 4 2 2 COPIER INSTALLATION PROCEDURE 3 5 2 3 GUIDANCE ROM INSTALLATION 3 12 2 4 PLATEN COVER OPTION INSTALLATION 3 14 2 5 PAPER SIZE CHANGE 3 15 2 5 1 550 Sheet Paper Tray 1st and 3rd feed stations for A095 copier 3 15 2 5 2 15...

Page 11: ...11 FUSING UNIT 4 5 2 SERVICE PROGRAM MODE 4 6 2 1 SERVICE PROGRAM MODE OPERATION 4 6 2 1 1 Service Program Access Procedure 4 6 2 1 2 To Exit SP Mode 4 6 2 1 3 To Return to the Index Menu 4 7 2 1 4 Change the Menu Screen 4 7 2 1 5 Access to Copy in SP Mode 4 7 2 2 SERVICE PROGRAM MODE TABLE 4 8 2 3 SENSOR SWITCH SIGNAL DATA CHECK INPUT MODE 4 36 2 4 ELECTRICAL COMPONENT CHECK OUTPUT MODE 4 42 2 5 ...

Page 12: ...Left Front Cover 5 1 1 1 2 Right Front Door 5 1 1 2 REAR SIDE 5 2 1 2 1 Upper Rear Cover 5 2 1 2 2 Lower Rear Cover 5 2 1 2 3 Left Inner Cover 5 3 1 2 4 Right Inner Cover 5 3 1 2 5 Shutter Inner Cover 5 4 1 3 RIGHT SIDE 5 5 1 3 1 Feed Unit Cover 5 5 1 3 2 Upper Right Cover 5 6 1 3 3 Lower Right Cover 5 6 1 4 LEFT SIDE 5 7 1 4 1 Upper Left Cover 5 7 1 4 2 Lower Left Cover 5 7 1 5 OPERATION PANEL 5 ...

Page 13: ...E BELT REMOVAL 5 35 2 12 LENS VERTICAL DRIVE BELT REMOVAL 5 37 2 13 ORIGINAL SIZE SENSORS 2 LENGTH SENSORS 1 WIDTH SENSOR 5 38 3 DEVELOPMENT AND TONER SUPPLY 5 39 3 1 DEVELOPMENT UNIT REMOVAL 5 39 3 2 DEVELOPER REPLACEMENT 5 41 3 3 DEVELOPMENT ROLLERS REPLACEMENT 5 43 3 4 TONER DENSITY SENSOR REPLACEMENT 5 46 3 5 TONER BOTTLE DRIVE MOTOR REPLACEMENT 5 47 4 DRUM UNIT 5 48 4 1 DRUM UNIT REMOVAL AND ...

Page 14: ...MOVAL A096 A097 copier only 5 70 6 5 TANDEM SIDE FENCE MOTOR REMOVAL A096 A097 copier only 5 72 6 6 PAPER FEED TIMING ADJUSTMENT 5 73 6 6 1 Paper Feed Timing Adjustment FT6645 6655 A095 A096 Only 5 74 6 6 2 Paper Feed Timing Adjustment FT6645 6655 A097 Only 5 74A 6 7 PAPER FEED CLUTCH REMOVAL 5 76 6 8 BY PASS FEED TABLE REMOVAL 5 79 6 9 BY PASS FEED ROLLERS REPLACEMENT 5 80 6 10 BY PASS PAPER SIZE...

Page 15: ...OLLER REPLACEMENT 5 102 7 7 FUSING STRIPPER PAWL REPLACEMENT 5 103 7 8 FUSING PRESSURE ADJUSTMENT 5 104 7 9 PAPER EXIT UNIT REPLACEMENT 5 105 7 10 OIL SUPPLY ROLLER REPLACEMENT 5 107 8 DUPLEX UNIT 5 109 8 1 FEED ROLLER REPLACEMENT 5 109 8 2 SEPARATION BELTS REPLACEMENT 5 111 8 3 DUPLEX UNIT REMOVAL 5 113 8 4 SEPARATION CLUTCH TRANSPORT CLUTCH REMOVAL 5 114 8 5 JOGGER MOTOR REPLACEMENT 5 115 9 COPY...

Page 16: ...RUM 6 12 1 11 PAPER FEED 6 13 1 12 DUPLEX 6 15 1 13 FUSING 6 16 1 14 SYSTEM CONTROL 6 17 1 15 DUAL JOB FEEDER RECIRCULATING DOCUMENT HANDLER 6 19 1 16 FINISHER SORTER STAPLER 6 19 1 17 OTHERS 6 23 2 ELECTRICAL COMPONENT DEFECTS 6 24 2 1 SENSORS 6 24 2 2 SWITCHES 6 29 2 3 FUSES 6 30 2 3 1 DC Power Supply Board 6 30 3 COPY QUALITY 6 31 4 MISFEEDS 6 34 5 MACHINE CONDITIONS 6 35 6 ROM MODIFICATION HIS...

Page 17: ...TS 7 13 6 1 TRANSPORT BELT REPLACEMENT 7 13 6 2 FEED ROLLER REPLACEMENT 7 15 6 3 SEPARATION BELT REPLACEMENT 7 17 6 4 FEED OUT MOTOR FEED OUT UNIT REMOVAL 7 19 6 5 INVERTER SOLENOID REMOVAL AND ADJUSTMENT 7 21 6 6 BELT DRIVE MOTOR REPLACEMENT 7 22 6 7 FEED IN CLUTCH FEED IN UNIT REMOVAL 7 25 6 8 STOPPER SOLENOID REPLACEMENT 7 27 6 9 VERTICAL REGISTRATION ADJUSTMENT 7 28 6 9 1 One Sided Original Mo...

Page 18: ...OL BOARD 8 13 5 1 DIP SWITCHES 8 13 5 2 TEST POINTS 8 14 5 3 FUSES 8 14 6 REPLACEMENTS AND ADJUSTMENTS 8 15 6 1 EXTERIOR COVER REMOVAL 8 15 6 2 STAPLER REMOVAL AND REINSTALLATION 8 17 6 3 JOGGER PLATE REMOVAL AND INSTALLATION 8 18 6 4 BINS 8 19 6 5 MAIN MOTOR REMOVAL 8 23 6 6 GRIP ASSEMBLY REMOVAL AND GRIP SOLENOID AND GRIP POSITIONING SOLENOID ADJUSTMENT 8 24 6 7 MAIN CONTROL BOARD REPLACEMENT 8 ...

Page 19: ...10 6 REPLACEMENTS AND ADJUSTMENTS 9 12 6 1 TRANSPORT BELT REPLACEMENT 9 12 6 2 PAPER FEED ROLLER REMOVAL 9 13 6 3 FRICTION BELT REPLACEMENT 9 14 6 4 PAPER EXIT TRANSPORT BELT REMOVAL 9 15 6 5 RDH MAIN CONTROL BOARD REMOVAL 9 16 6 6 RDH LEADING EDGE REGISTRATION ADJUSTMENT 9 17 6 7 MOTOR SPEED CHECK ADJUSTMENT 9 20 FINISHER SR400 1 OVERALL MACHINE INFORMATION 10 1 1 1 SPECIFICATIONS 10 1 1 2 MECHAN...

Page 20: ...10 15 4 REPLACEMENTS AND ADJUSTMENTS 10 16 4 1 EXTERIOR REMOVAL 10 16 4 2 ALIGNMENT BRUSH ROLLER REPLACEMENT 10 17 4 3 SENSOR REPLACEMENT 10 18 4 4 POSITIONING ROLLER REPLACEMENT 10 19 4 5 BELT TENSION ADJUSTMENT 10 20 11 LARGE CAPACITY TRAY RT31 1 SPECIFICATIONS 11 1 2 MECHANICAL COMPONENT LAYOUT 11 2 3 ELECTRICAL COMPONENT DESCRIPTION 11 3 4 INSTALLATION PROCEDURE 11 4 4 1 ACCESSORY CHECK 11 4 4...

Page 21: ...N 12 5 3 INSTALLATION PROCEDURE 12 7 3 1 ACCESSORY CHECK 12 7 3 2 INSTALLATION PROCEDURE for Machine Code A095 copier 12 8 4 SERVICE TABLE MAIN CONTROL BOARD 12 14 4 1 DIP SWITCHES 12 14 4 2 LED and Variable Resistor 12 14 4 3 TEST POINT 12 14 5 REPLACEMENT AND ADJUSTMENT 12 15 5 1 STAPLER REMOVAL 12 15 5 2 GRIP ASSEMBLY REMOVAL 12 16 5 3 BIN REPLACEMENT 12 17 5 4 BIN LIFT WIRE REPLACEMENT 12 20 5...

Page 22: ...5 6 MAIN CONTROL BOARD REPLACEMENT AND ADJUSTMENT 12 26 5 6 1 Main Control Board Replacement 12 26 5 6 2 Bin Sensor Adjustment 12 27 5 7 BELT TENSION ADJUSTMENT 12 28 BULLETINS FSM xiii A095 A096 A097 ...

Page 23: ......

Page 24: ...leted Keep hands away from the mechanical and the electrical components to avoid any injury 6 If the start key is pressed before the copier completes the warm up period Ready indicator starts blinking 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 7 The inside and the metal parts of the fusing unit bec...

Page 25: ...his battery Used batteries must be handled in accordance with local regulations SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1 Do not incinerate the toner cartridge or the used toner Toner dust may ignite suddenly when exposed to open flame 2 Dispose of used toner developer and organic photoconductor according to local regulations These are non toxic supplies 3 Dispose of replaced parts in accordance ...

Page 26: ...6 TAB POSITION 7 TAB POSITION 8 OVERALL MACHINE INFORMATION RECIRCULATING DOCUMENT HANDLER A378 COMPONENT LAYOUT AND DESCRIPTION FINISHER A379 INSTALLATION LARGE CAPACITY TRAY A380 SERVICE TABLES SORTER STAPLER A374 REPLACEMENT AND ADJUSTMENT TROUBLESHOOTING DUAL JOB FEEDER A376 SORTER STAPLER A377 ...

Page 27: ......

Page 28: ...OVERALL MACHINE INFORMATION ...

Page 29: ......

Page 30: ... x 81 2 Tray B5 81 2 x 11 1 5K LCT A6 51 2 x 81 2 By pass Duplex Copying Maximum A3 11 x 17 Minimum A5 51 2 x 81 2 sideways Copy Paper Weight Paper tray 52 128 g m2 14 34 lb Bypass feed table 52 157 g m2 14 42 lb Duplex copying 64 104 g m2 17 24 lb Reproduction Ratios 4 Enlargement and 6 Reduction A4 A3 Version LT LDG Version Enlargement 200 141 122 115 200 155 129 121 Full Size 100 100 Reduction ...

Page 31: ...30 V machine 120 V machine 230 V machine Warm up 1 20 kVA 1 20 kVA 1 25 kVA 1 25 kVA Stand by 0 25 kVA 0 22 kVA 0 25 kVA 0 24 kVA Copying 1 80 kVA 1 70 kVA 1 80 kVA 1 75 kVA Maximum 1 80 kVA 1 70 kVA 1 80 kVA 1 75 kVA Full System Mainframe with dual job feeder compact sorter stapler and 3 500 sheet large capacity tray Mainframe with dual job feeder floor type sorter stapler and 3 500 sheet large c...

Page 32: ...Copier only Without the optional platen cover Approximately 2 kg FT6645 A095 copier Approximately 333 lbs FT6655 A096 copier Approximately 360 lbs FT6665 A097 copier Approximately 360 lbs Zoom From 50 to 200 in 1 steps Copying Speed A4 LT sideways A3 DLT B4 LG FT6645 copier 45 23 27 FT6655 copier 55 28 35 FT6665 copier 65 33 41 Warm up Time Less than 5 minutes 20 C First Copy Time A4 81 2 x 11 sid...

Page 33: ...tely 1500 sheets Duplex 50 sheets Toner Replenishment 1 100 g cartridge Developer Replenishment Black Only 1Kg Bag 120 000 copies 6 originals Optional Equipment Type 610 Platen cover DF 60 Dual job feeder DH400 Recirculating document handler ST25 20 bin sorter stapler Floor type ST24 20 bin compact sorter stapler SR400 Finisher RT31 3500 sheet Large capacity tray Type B Receiving Tray Toner Collec...

Page 34: ...COMPONENT LAYOUT AND DESCRIPTION ...

Page 35: ......

Page 36: ... 500 sheet large capacity tray FT6655 6665 A096 A097 copier Tandem paper tray including two 500 sheet paper tray One 550 sheet paper tray 1 500 sheet built in large capacity tray Optional 3 500 sheet large capacity tray Rev 10 94 50 3 500 550 550 550 3 500 500 x 2 or 500 550 1 500 50 Component Layout Description FSM 2 1 A095 A096 A097 ...

Page 37: ... A097 with dual job feeder and floor type sorter stapler The mainframe in the illustration below is the FT6655 A096 Rev 10 94 Compact sorter stapler ST24 A374 Dual job feeder DF60 A376 3 500 sheets large capacity tray RT31 A380 Dual job feeder DF60 A376 3 500 sheets large capacity tray RT31 A380 Floor type sorter stapler ST25 A377 A095 A096 A097 2 2 FSM ...

Page 38: ...ument handler and finisher NOTE All references to A096 copier only now refers to A096 and A097 Copiers Rev 10 94 3 500 sheets large capacity tray RT31 A380 Recirculating document handler DH400 A378 Finisher SR400 A379 Component Layout Description FSM 2 3 A095 A096 A097 ...

Page 39: ...2 MECHANICAL COMPONENT LAYOUT 2 3 4 5 11 10 12 7 6 29 26 35 34 25 24 31 30 16 32 33 15 14 13 27 19 18 23 22 21 17 20 28 8 9 1 39 38 37 36 A095 A096 A097 2 4 FSM ...

Page 40: ... Separation Roller By Pass 22 Registration Rollers 23 Transfer Belt 24 Vertical Transport Rollers 25 Tandem Tray A096 copier 550 sheet Tray A095 copier 26 Universal Tray 27 1500 sheet LCT A096 copier 550 sheet Tray A095 copier 28 Toner Collection Bottle 29 Transfer Belt Cleaning Blade 30 Hot Roller 31 Pressure Roller 32 Jogger Fences 33 Duplex Positioning Roller 34 Duplex Pick up Roller 35 Duplex ...

Page 41: ...tor Toner Collection Motor Registration Clutch By Pass Feed Motor BY Pass Feed Clutch Development Drive Motor 1 OPC Drum 2 Scanner Unit 3 Transfer Belt Unit 4 Paper Exit Unit 5 Fusing Unit 6 Duplex Unit 7 Paper Trays 8 Paper Feed Units 9 Toner Hopper 10 Development Unit 11 Cleaning Unit A095 A096 A097 2 6 FSM ...

Page 42: ...toner to the toner hopper 48 M 8 Charge Wire Cleaner Drive Drives the main charge wire cleaner to clean the charge wire 49 M 9 Jogger Drives the jogger fences to square the paper stack in the duplex tray dc stepper 50 M10 Lens Horizontal Drive Shifts the lens horizontal position 51 M11 Lens Vertical Drive Shifts the lens vertical position 52 M12 Optic Cooling Fan Removes heat from the optics unit ...

Page 43: ...rns the toner supply roller to supply toner to the development unit 57 MC2 Registration Drives the registration rollers 58 MC3 By pass Feed Starts paper feed from the by pass feed table 60 MC4 Duplex Transport Drives the duplex transport rollers to transport the paper to the vertical transport rollers 64 MC5 Duplex Feed Starts paper feed from the duplex tray to the duplex transport rollers 65 MC6 ...

Page 44: ...the copier 122 SW10 Tray Down A096 A097 Lowers the LCT bottom plate 126 Solenoids SOL 1 Junction Gate Moves the junction gate to direct copies to the duplex tray or to the paper exit 55 SOL 2 Duplex Positioning Controls the up down movement of the positioning roller 56 SOL 3 By pass Pick up Controls the up down movement of the pick up roller for by pass feed 59 SOL 4 Guide Plate Opens the guide pl...

Page 45: ...ovement of the separation roller in the 3rd feed station 106 Sensors S 1 Scanner HP Informs the CPU when the 1st and 2nd scanners are at the home position 1 S 2 Platen Cover Position 1 Informs the CPU that the platen cover is in the up or down position related to APS ARE function 2 S 3 Platen Cover Position 2 Informs the CPU that the platen cover is in the up or down position to detect if the orig...

Page 46: ...ts the leading edge of the paper to control the jogger motor and the positioning solenoid on timing 12 S15 Exit Detects misfeeds 15 S16 Fusing Exit Detects misfeeds 16 S17 Paper Guide Detects misfeeds 17 S18 Auto Image Density Senses the background density of the original 20 S19 Original Length 1 Detects original length 21 S20 Original Length 2 Detects original length 22 S21 Original Width Detects...

Page 47: ...out of paper 73 S35 Toner Collection Motor Detects the toner collection motor operation 74 S36 2nd Lift Detects the correct feed height of the 2nd cassette 76 S37 3rd Lift Detects the correct feed height of the 3rd cassette 78 S38 3rd Paper Near End A095 Informs the CPU when the 3rd cassette is in near end condition 79 S39 3rd Paper End Informs the CPU when the 3rd cassette runs out of paper 80 S4...

Page 48: ...e paper is set on the LCT bottom tray 125 PCBs PCB 1 AC Drive Provides AC power to the exposure lamp and fusing lamp 108 PCB 2 Main Controls all machine functions 109 PCB 3 Optic Control Controls all optics components 110 PCB 4 High Voltage Control Controls the output of both power packs and development bias 111 PCB 5 Paper Feed Control Controls all components in the paper bank 112 PCB 6 DC Power ...

Page 49: ...1 Optics Thermoswitch Opens the exposure lamp circuit if the optics unit overheats 19 TF1 Fusing Thermofuse Opens the fusing lamp circuit if the fusing unit overheats 33 TH1 Fusing Thermistor Senses the temperature of the hot roller 24 TH2 Optics Thermistor Monitors the temperature of the optics cavity 36 TH3 Drum Thermistor Located on the ID Sensor Ass y Monitors the temperature of the OPC drum 4...

Page 50: ...on the optics 35 RA1 Main Power Relay Controls main power 107 CO1 Total Counter Keeps track of the total number of copies made 114 NF1 Noise Filter Removes electrical noise 115 CB1 Circuit Breaker Provides back up high current protection for the electrical components 116 LA1 Lightening Arrestor Removes current surges from the AC input lines 118 FT6665 A097 copier only unique items Symbol Name Func...

Page 51: ......

Page 52: ...INSTALLATION ...

Page 53: ......

Page 54: ...re changes b where it will be directly exposed to cool air from an air conditioner c where it will be directly exposed to heat from a heater 8 Do not place the machine where it will be exposed to corrosive gasses 9 Do not install the machine at any location over 2 000 m 6 500 feet above sea level 10 Place the copier on a strong and level base 11 Do not place the machine where it may be subjected t...

Page 55: ...374 sorter stapler is installed the distance must be more than 20 cm 8 inches 3 Copier only 128 0 cm 50 4 with LCT 134 7cm 53 Copier A374 S S 110 0 cm 43 4 with LCT 142 2cm 56 Copier A377 S S 125 6 cm 49 4 with LCT 156 8cm 61 7 Copier Finisher 136 1cm 53 6 with LCT 167 3cm 65 9 See NOTE 3 Your machine More than 10 cm 4 inches See NOTE 2 More than 10 cm 4 inches More than 90 cm More than 10 cm 4 in...

Page 56: ...ge fluctuation 10 3 Permissible extension cord At least 300 V 30 A capacity and less than 5 m 16 4 feet long NOTE a be sure to ground the machine Do not ground it to a gas pipe b Make sure the plug is firmly inserted in the outlet c Avoid multi wiring 4 Do not set anything on the power cord INSTALLATION FSM 3 3 A095 A096 A097 ...

Page 57: ...CR 17 27 29 machines only 1 5 Sensor Cover 1 6 Flat Head Screw 4 x 6 1 7 Leveling Foot 4 NOTE This copier requires a 20 Amp service with a USA 20A plug socket The shape of the 20A socket is different from that of the standard 15A The two are not interchangeable If there is no 20A socket at the customer location the electrical supply line must be changed as well as the socket Contact the local elec...

Page 58: ... bring this manual with you CAUTION When installing the copier make sure that the copier is unplugged NOTE Insert the leveling shoes A under the leveling feet B and level the machine before starting the installation The leveling feet B can be screwed up or down 1 Remove the tape strips B A INSTALLATION FSM 3 5 A095 A096 A097 ...

Page 59: ...he paper exit bracket 5 Remove the transfer belt lock plate C 1 screw 6 Remove tape and move toner cartridge holder out to expose the cleaning unit lock pin D 7 Turn about 180 then remove the cleaning unit lock pin D 8 Remove the retaining tape A from the fusing exit guide Rev 1 20 94 A A C D B A095 A096 A097 3 6 FSM ...

Page 60: ... the toner bottle holder D NOTE To open the toner bottle completely while lowering the shutter lever E push the bracket F to the right 11 Close the toner hopper cap G 12 Remove the screw H fixing the drum stay I 13 Remove the drum stay knob J 14 Remove drum stay K C A A B X G H I J F F E D K INSTALLATION FSM 3 7 A095 A096 A097 ...

Page 61: ... Place the development unit on several sheets of paper C to prevent foreign matter from being attracted to the sleeve rollers 3 When pulling out the development unit do not pull the knob D 17 Remove two screws E fixing the toner hopper F 18 Turn the toner hopper 90 degree then move it up to remove it from the development unit B A E F C D A095 A096 A097 3 8 FSM ...

Page 62: ...Install the development unit to the machine 22 Connect two connectors D 23 Install the drum stay E with the drum stay knob F and one screw G NOTE When installing the drum stay be careful not to pinch the harness and keep the harness away from the gear 24 Open the toner hopper cap H A B C H G D F E INSTALLATION FSM 3 9 A095 A096 A097 ...

Page 63: ...ower cord install the guidance ROMs 26 27 machines See page 3 12 27 Plug in the power cord then turn on the main switch The machine automatically enter the process control data initial setting mode NOTE Do not make any copy until completing developer initial setting Do not turn off the main switch during the process control data initial setting mode 28 Add paper to at least one tray A B C A095 A09...

Page 64: ...en replacing the developer Also when the TD sensor is replaced install new developer and perform developer initial setting Note 3 Developer initial setting stops automatically 33 Press the Index key C 34 Press the Quit key D to exit SP mode NOTE If the developer initial setting is not completed you cannot exit the SP mode by pressing the Quit key If this occurs turn the main switch off and on then...

Page 65: ...ration panel PCB with the optional guidance ROMs as follows 1 Remove the pin A then lower the left front door B 2 Remove the left inner cover C 4 screws 3 Remove three screws D 4 Remove the two screws E securing the protective earth ground wires E D B C A Rev 7 94 A095 A096 A097 3 12 FSM ...

Page 66: ... K on the operation panel PCB L 8 Re install the operation panel the left inner cover and the left front door 2 After installing the new guidance ROMs plug in the power cord and turn on the main switch then perform the Touch Panel Display Position Adjustment See page 5 129 for detailed procedure Rev 7 94 I K J L H F G INSTALLATION FSM 3 13 A095 A096 A097 ...

Page 67: ...A which is an accessory of the platen cover B as follows 1 Connect the red connector C to the rear sensor D 2 Connect the white connector E to the front sensor F 3 Secure the sensor assembly with a screw G 2 Install the platen cover hooks H 3 Install the platen cover B A H B G H C F D E A095 A096 A097 3 14 FSM ...

Page 68: ...e the paper size as follows 2 5 1 550 Sheets Paper Tray 1st and 3rd feed stations for A095 copier 1 Draw out the paper feed tray A 2 Change the position of the front and the rear side fences B 2 screws each and end fence C one screw according to the paper size 3 Stick a size decal on the tray C B A B INSTALLATION FSM 3 15 A095 A096 A097 ...

Page 69: ...SP Special Feature key A 6 Press the Next key B 4 times to select the paper tray size setting mode page 5 and press the appropriate paper size key of the 1st or the 3rd feed station 7 Press the Index key C 8 Press the Quit key D to exit SP mode 9 Check copy quality and machine operation 1 0 7 C A D B C A095 A096 A097 3 16 FSM ...

Page 70: ...rs 1 Draw out the third feed tray A 2 Change the position of the front and the rear side fences B 1 screw each and the end fence C one screw according to the paper size 3 Perform steps 3 to 9 from the previous page Rev 7 94 C A B INSTALLATION FSM 3 17 A095 A096 A097 ...

Page 71: ...der set is available as a service part 1 Remove the two plastic caps A and B on the right upper cover of the copier 2 Replace the short circuit connector C with the connector of the accessory harness D 3 Install the stepped screw E A B C D E A095 A096 A097 3 18 FSM ...

Page 72: ...rews 6 Install the key counter cover D 2 screws 7 Connect the connector E of the key counter holder 8 Hook the key counter holder assembly F to the stepped screw G 9 Secure the key counter holder assembly F with a screw H NOTE If your key counter is a Ricoh brand install the mylar I P N A509 1064 as shown Rev 5 94 E G F H INSTALLATION FSM 3 19 A095 A096 A097 ...

Page 73: ...y If a customer requests to have the image density adjusted it can be done through the User Tool mode 1 Enter the User Tool mode as follows 1 Press the clear mode key 2 Press the clear stop key more than 3 seconds 2 Press the Set operation modes key A 3 Press the Next key once B C A B A095 A096 A097 3 20 FSM ...

Page 74: ... Density level 5 steps adjustment 1 Press appropriate ID level key A 2 Press the enter key B 5 Press the Menu key C 6 Press the Exit key D to exit User Tools mode 7 Check copy quality C B A D INSTALLATION FSM 3 21 A095 A096 A097 ...

Page 75: ......

Page 76: ...SERVICE TABLES ...

Page 77: ......

Page 78: ...lves the drum surface 4 Store the drum in a cool dry place away from heat 5 Take care not to scratch the drum as the drum layer is thin and is easily damaged 6 Never expose the drum to corrosive gases such as ammonia gas 7 Always keep the drum in its protective sheet when out of the copier Also always close the protective shutter on the drum unit when keeping the drum unit out of the copier Doing ...

Page 79: ...ocks with a blower brush first to remove toner and paper dust Then clean it with alcohol if any toner still remains on it 4 Do not touch the corona wires with oily bare hands Oil stains may cause white bands on copies 5 Make sure that the corona wires are correctly positioned between the cleaner pads and that there is no foreign material iron filings etc on the casing 6 When installing new corona ...

Page 80: ...usting the vertical lamp position is very difficult because the filament cannot be seen clearly as the lamp is frosted 7 The mirror surface with the reflective coating must face the light path The spring plates must contact the reverse side of the mirror the side without the reflective coating 8 Because the toner shielding filter is coated with an anti static solution which is removed when wiped w...

Page 81: ...drum from being scratched by part of the development unit 8 The doctor gap and the development rollers position must not be adjusted in the field as they are precisely adjusted at the factory using special tools Do not loosen any screws with white paint 9 Before pulling out the development unit disconnect two connectors 10 When inserting out the development unit do not pull the knob 11 When settin...

Page 82: ...re not interchangeable with the feed rollers of the by pass feed tray and 3 5 K LCT because the feeding direction is different 4 When actuating the front door safety switch to check the machine operation while the front doors are open also actuate the lower front door safety switch Otherwise the paper feed motor does not activate causing SC501 1 11 FUSING UNIT 1 Be careful not to damage the edges ...

Page 83: ...for more than 3 seconds until the service program index menu appears on the touch panel display 4 Touch a number A on the display to access the desired function This copier has 9 service program modes mode is not used Only 5 service program modes are visible on the touch panel display at one time Use the down key B or the up key C to see other service program mode menus 2 1 2 To Exit SP Mode 1 Tou...

Page 84: ...page touch C NOTE For the adjustments for which the data is entered by using D the default data is 00 2 1 5 Access to Copy in SP Mode 1 Press F to access Copy in SP mode LCD displays as shown at right 2 Select the appropriate copy mode and make trial copies 3 Return to the SP mode by pressing G Index Next Prev Copy in SP SP mode G A D B C F E Service Tables FSM 4 7 A095 A096 A097 ...

Page 85: ...Perform this program when the following parts are replaced or cleaned Drum potential sensor Exposure lamp OPC drum Main charge wire and casing Mirrors Lamps around the OPC drum Charge P P RAM etc Increases the period to sufficiently heat the pressure roller at power on Default 5 min Perform this only if poor fusing occurs just after the power is turned on Adjusts fusing temperature 1 C step Proced...

Page 86: ... timing Duplex feed clutch ON timing LCT feed clutch ON timing A097 copier Item Function Note Enables or disables automatic charge wire cleaning mechanism Default ON Select OFF only when a cleaning mechanism malfunction occurs Changes the paper feed clutch on timing to adjust the paper buckle at the registration roller 1 mm step Refer to 6 6 Paper Feed Timing Adjustment in section 5 Not used See b...

Page 87: ... Enables or disables the 5 mm width side edge erase Default No Adjusts the lens horizontal stop position for each paper feed section 0 1 mm step Refer to 9 2 Side To Side Registration Adjustment in Section 5 Adjusts the lens horizontal stop position for each paper feed section 0 1 mm step Only for A097 copier with RDH and Finisher the SP data for each feed station should be the same as that for Du...

Page 88: ...1 V This mode is also performed during the process control data initial setting Adjusts the VSG to 4 0 0 2 V This mode is also performed during the process control data initial setting Adjusts the original stop position against the original side scale in one sided original mode 0 5 mm step 1 Refer to 6 9 1 one sided original mode in Section 7 Adjusts the original stop position against the original...

Page 89: ...the problem is related to process control or not Selects the grid bias voltage when auto process control is disabled or RAM is cleared 1 V step Default 870 V Enter the data by using the number keys then touch Enter Selects the development bias voltage when auto process control is disabled or RAM is cleared 1 V step Default 220 V Enter the data by using the number keys then touch Enter Factory Use ...

Page 90: ... number keys then touch Initializes the by pass paper size sensor Procedure 1 Set the by pass table side fence to the A4 81 2 x 11 position then touch the key 2 Set the by pass table side fence to the A6 41 4 x 51 2 position then touch the key Perform this mode when the by pass paper size sensor is replaced NOTE Selecting SP adjust pg 7 4 will enable item 1 above to be used for troubleshooting or ...

Page 91: ... enter copy in SP 2 Feed a sheet of papter to the duplex tray 3 Take out the duplex unit then check the stacked paper and jogger fence position 4 Return to SP mode touch SP mode key 5 Touch or keys to adjust the fogger fence position so that the distance between the fences is 1mm wider then the paper width 6 Repeatstep1to5untiladjustmentcompletes NOTE Enter copy in SP after changing data to correc...

Page 92: ...sts the horizontal staple position 0 5 mm step Changes the duplex positioning roller down timing for both A4 A3 and LT DLT version machines Changes the duplex positioning roller up timing to adjust the paper buckle at the separation roller 5 ms step Adjusts the timing so that the paper leading edge just touches the separation belt without any buckle NOTE PAGE 15 is for factory use only PAGE 16 is ...

Page 93: ...Not effective for peripherals This mode is only effective in the Copy in SP mode Indicates the paper width detected by the by pass paper size sensor Rotates the main and development motors and turns on the toner supply clutch to supply toner in the development unit T D sensor toner supply target data VREF and detected data VT is indicated Toner is supplied under the following conditions 1 Toner su...

Page 94: ...tapler Use to confirm the proper function of the copier electrical components Access this mode as follows 1 Touch the Output mode key 2 Enter the electrical component number by using the number keys on the operation panel Refer to the output check mode on page 4 42 3 Press the enter key Touch to activate and touch to de activate the electrical component This mode cannot be used with the ST24 Opera...

Page 95: ...2 SP TEST MODE PAGE 5 Item Function Note Operates the toner collection drive mechanism After touching the key the toner collection motor turns on for 1 minute Start A095 A096 A097 4 18 FSM ...

Page 96: ...he bare drum surface Standard data 0 200 V Indicates the charge grid bias voltage decided during process control data initial setting Works only when auto process control is enabled SP Adjustment PAGE 7 Standard data 870 1 200 V Indicates the development bias voltage decided during process control data initial setting Works only when auto process control is enabled SP Adjustment PAGE 7 Standard da...

Page 97: ...ocess control data initial setting Previous Previous detected data during ID sensor compensation VTP Last detected data during ID sensor compensation VREF Toner supply level target data Standard data 0 5 4 0 V Indicates the ID sensor output VSGP ID sensor output while detecting the bare drum surface with dev bias and development roller rotation VSP ID sensor output while detecting the ID sensor pa...

Page 98: ...very scan Standard data 2 7 0 1 V Present Output at last detection Initial Output at ID sensor initial setting Indicates the fusing temperature based on the fusing thermistor output Standard data Around 185 C Indicates the drum temperature based on the drum thermistor output Indicates the optics temperature based on the optics thermistor output Service Tables FSM 4 21 A095 A096 A097 ...

Page 99: ...URES PAGE 1 Item Function Setting Default Selects copy count up or down Count up Count down Counts twice when an A3 or 11 x 17 copy is made Count twice Count once Set Reset Reset Set Reset Reset A095 A096 A097 4 22 FSM ...

Page 100: ...ION When is selected at least one user code should be entered 1 Register the user code by using user tool No 8 2 Enter SP mode then enable the user code mode by selecting 3 Turn off the main switch 4 Remove the plastic cap A on the right upper cover 5 Disconnect the key counter short circuit connector B 6 Return the plastic cap A 7 Turn on the main switch and check the operation Set Reset Reset Se...

Page 101: ...y Enable Disable Enables automatic feed out of the last copy on the duplex tray without copying when an odd number of originals is set on the DJF feed tray Enable Disable Cancels the maximum copy quantity limit 50 in staple mode Not used Cancels the maximum copy quantity limit in sort mode 50 and in stack mode 40 Not used Set Reset Set Set Reset Set Rev 4 15 94 A095 A096 A097 4 24 FSM ...

Page 102: ... 2 sided copies from 1 sided originals Enable Disable Limits user access to User Tools No 8 9 10 11 to only those who know the access code Procedure 1 Touch the Key 2 Input the access code with the number keys 3 Touch the enter key See the caution below CAUTION After enabling this mode be sure to instruct the key operator not to forget the access code Set Reset Reset Set Reset 0000 Rev 4 15 94 Set...

Page 103: ...change procedure 1 Default is A4 or 81 2 x 11 sideways Holds the service center telephone number This telephone number is indicated on the LCD with the SC number when a problem occurs Entering procedure 1 Touch the 2 Enter the phone number by pressing the number keys Touch to enter the hyphen 3 Touch Holds the copier s serial number A095 A096 A097 4 26 FSM ...

Page 104: ...m for this model cannot distinguish between A4 and 81 2 x 11 This mode enables recognition of A4 and 81 2 x 11originals as A4 size for the A4 A3 version as 81 2 x 11 for the LT DLT version Enable Disable Indicates the part number with ROM suffixes on each PCB See NOTE below NOTE Only the produced date is indicated for the operation panel guidance ROMs Set Reset Reset Set Reset Reset Service Tables...

Page 105: ...tion Note Indicates the total number of occurrences of each SC code Press to scroll up Press to scroll down See Section 6 for details of each SC code The counters for SCs that have not occurred are not displayed A095 A096 A097 4 28 FSM ...

Page 106: ... Indicates the total number of jams in the copier only Indicates the total number of jams at each location Locations Indicates the total number of jams for each feed station Indicates the total number of jams at each location in the DF Indicates the total number of jams in the DF Service Tables FSM 4 29 A095 A096 A097 ...

Page 107: ... Indicates the total number of originals fed by the DF Indicates the total number of copies Indicates the total number of copies for each paper size Indicates the total number of copies for each magnification Indicates the total number of copies for each edit image mode A095 A096 A097 4 30 FSM ...

Page 108: ...e total number of the copies for each copy mode Indicates the total number related to consumables Indicates the total number of staples for each staple position Indicates the total number of copies broken down by paper feed station Service Tables FSM 4 31 A095 A096 A097 ...

Page 109: ...1 Touch The display changes as shown at right 2 Touch Touch to cancel The display returns to the one shown at left and the beeper sounds four times Clears all paper jam counters Clears all original jam counters Clears all copy counters Clears all counters Clear Yes No A095 A096 A097 4 32 FSM ...

Page 110: ... 2 Clears the PM counter Procedure to clear 1 Touch The display changes as shown at right 2 Touch Touch to cancel The display returns to the one shown at left 1 Indicates the total number of copies since the last PM for each unit unit counter 2 Clears each unit counter Clear Yes No Service Tables FSM 4 33 A095 A096 A097 ...

Page 111: ...total number of copies since the last PM for each unit unit counter 2 Clears each unit counter Procedure to clear 1 Touch The display changes as shown at right 2 Touch Touch to cancel The display returns to the one shown at left Clear Yes No A095 A096 A097 4 34 FSM ...

Page 112: ... PM counter copy counter etc does not require the front door to be opened NOTE After clearing all memory perform at least the following 1 Perform the process data initial setting 2 Install new developer and then perform the Toner Density sensor Developer initial setting 3 Input the Lens Error Correction data SP Adjustment page 5 refer to page 4 11 of the service manual For the other items basicall...

Page 113: ...ter 107 3 Press the clear stop key for more than 3 seconds 2 Touch A on the display to access SP test mode 3 Touch B on the display twice 4 1 Touch C 2 Enter the input sensor switch signal number by using the number keys Refer to the table in the following pages 3 Press the Enter key D 2 Next Input No 00 1 0 7 C A B D C A095 A096 A097 4 36 FSM ...

Page 114: ...Paper Feed Sensor Paper not detected Paper detected 18 2nd Paper Feed Sensor Paper not detected Paper detected 19 3rd Paper Feed Sensor Paper not detected Paper detected 20 Not Used 21 2nd Lift Sensor Not lifted Lifted 22 3rd Lift Sensor Not lifted Lifted 23 Built in LCT Tray Down Sensor Tray at down Tray not down 24 Fusing Set Detection Not set Set 25 Drum Unit Set Detection Not set Set 26 Right ...

Page 115: ... No overflow Overflow 52 By Pass Table Switch Closed Open 53 Front Door Safety Switch Closed Open 54 Toner Collection Bottle Set Switch Not set Set 55 By Pass Feed Motor Lock Detection Not detected Detected 56 Development Motor Lock Detection Not detected Detected 57 Main Motor Lock Detection Not detected Detected 58 Not used 59 Paper Feed motor Lock Detection Not detected Detected 60 Fusing Duple...

Page 116: ... Release Sensor A377 S S Not at release position At release position Jogger Unit Entrance Sensor Finisher Paper detected Paper not detected 108 Bin Rear Plate HP Sensor A377 S S Not at HP At HP Jogger Unit Paper Sensor Finisher Paper not detected Paper detected 109 Jogger HP Sensor A377 S S Not at HP At HP Jogger HP Sensor Finisher Not at HP At HP 110 Grip HP Sensor A377 S S Not at HP At HP Staple...

Page 117: ...iginal not detected Original detected 155 Lift Switch DJF Down Sifted Original Width Sensor RDH Original not detected Original detected 156 Feed out Motor Encoder Pulse DJF Registration Sensor RDH Original not detected Original detected 157 Belt Drive Motor Encoder Pulse DJF Inverter Sensor RDH Original not detected Original detected 158 Feed in Motor Encoder Pulse DJF Feed out Sensor RDH Original...

Page 118: ...itch RDH Down Lifted 165 Not used DJF RDH Position Sensor RDH Lifted Down 166 DF Position SN DJF Open Closed Not used RDH 167 Feed Cover Switch DJF Closed Open Not used RDH 168 Not Used DJF Not used RDH 169 Original Length SN DJF Interrupted Not interrupted Not used RDH Service Tables FSM 4 41 A095 A096 A097 ...

Page 119: ...ectrical component on for a long time to prevent mechanical or electrical damage How to check the motors clutch solenoids 1 Enter SP mode as follows 1 Press the mode clear key 2 Enter 107 3 Press the clear stop key for more than 3 seconds 2 Touch A on the display to access SP Test mode 3 Touch A on the display twice 2 Next 1 0 7 C A A A095 A096 A097 4 42 FSM ...

Page 120: ...he Enter key C 4 Press D to activate and press E to de activate the electrical component NOTE When confirming the activating sound keep the front door open If the front door is closed when is touched a mechanical noise caused by home positioning disturbs actual de activating sound Output No 000 ON OFF OFF B D C E Service Tables FSM 4 43 A095 A096 A097 ...

Page 121: ...19 Development Motor 20 By pass Feed Motor Low Speed 21 By pass Feed Motor High Speed First Copy from 1st feed tray 22 LCT Motor Up 23 LCT Motor Down 24 Paper Feed Motor Low Speed 25 Paper Feed Motor High Speed First Copy from 1st feed tray 26 Anti condensation Heater Relay 27 1st Pick up Solenoid 28 2nd Pick up Solenoid 29 3rd Pick up Solenoid 30 Not used 31 1st Separation Roller Solenoid 32 2nd ...

Page 122: ...Grid Copying 61 Charge Corona Grid ID Sensor Pattern 62 Development Bias Copying 63 Development Bias Non image Area 64 Development Bias ID Sensor Pattern 65 Transfer Current 66 Exhaust Fan Low 67 Exhaust Fan High 68 Not Used 69 Not Used 70 Optic Cooling Fan 2 A097 copier only 71 AC Drive Cooling Fan A097 copier only 72 Duplex Cooling Fan A097 copier only Output No 73 100 are not used 101 Transport...

Page 123: ...olenoid RDH 153 Not used DJF Inverter Solenoid RDH 154 LED READY DJF Push Plate Solenoid RDH 155 LED AUTO DJF Feed in Clutch RDH 156 Not used DJF Feed in Motor Clockwise RDH 157 Feed in motor DJF Feed in Motor Counterclockwise RDH 158 Feed out Motor DJF Feed in Motor Clockwise RDH 159 Not used DJF Feed in Motor Counterclockwise RDH 160 Belt Drive Motor DJF Transport Belt Motor Forward RDH 161 Not ...

Page 124: ...S This mode is for the key operators in charge of this copier The operator can change or set the copier s default settings using the following user tools 2 5 1 User Tools Menu Service Tables FSM 4 47 A095 A096 A097 ...

Page 125: ... on the touch panel display 3 Select the menu number to use by touching the touch panel display This copier has 12 user tools You can see 5 user tools on the touch panel display at the same time Use these keys to see the rest of the user tool menu Use to exit the user tool Use to return to the user tool menu display C A095 A096 A097 4 48 FSM ...

Page 126: ...he SADF mode automatically The SADF Auto reset time can be set from 1 second to 60 seconds or the function can be turned off Default 5 sec 2 Select special tray Tray for Cover Sheet Select the tray for the Cover function Paper for cover sheets will be fed from the selected tray Default No select Tray Display for Cover Sheet You can see which tray is set for cover sheets If you want to see the tray...

Page 127: ... standard time 4 Weekly Timer Use to set the weekly timer If you set the timer the copier turns on and off automatically at the selected time each day Default No weekly timer setting If you want to turn on the machine for an entire day input 000 for the ON time and do not input the OFF time If you want to turn off the machine for an entire day ex Saturday Sunday do not input the ON time and input ...

Page 128: ...ted to be lighter or darker Default center Default Setting You can select Program No 5 see page 42 as a default mode Use it to store job settings you frequently use Default Normal Touch Panel in Waiting Mode You can select the animation display during the warm up period and copying run During the warm up period the remaining warm up time is displayed During copying you can see how long it takes to...

Page 129: ...g the Auto Paper Select is selected You can cancel this setting Default Yes Paper Tray Display in APS mode In the default setting the tray display is shown only when the Auto Paper Select mode is canceled You can cancel this setting and have the tray display shown always Default No Auto Tray Switching If you load paper of the same size and in the same direction in two or more paper trays the machi...

Page 130: ...art of the copy counter On the upper part you can see the number of copies made To cancel the default setting select Yes Default No Auto Paper Select In the default setting the Auto Paper Select is not selected when you set originals in the dual job feeder or recirculating document handler You can cancel this setting Default No Thin Paper mode for machines with dual job feeder only system A or B U...

Page 131: ...um 6 digits Up to 500 user codes can be registered Registered user codes will be sorted in numerical order Change Use to change your present code to a new one The number of copies made under the old code is added to that made under the new user code Delete Use to delete your user code The number of copies made under the code is deleted 9 Check Reset copy count You can check the number of copies ma...

Page 132: ...Size Signal TP106 LAMP Exposure Lamp Voltage Monitor Signal TP107 FUSER Fusing Thermistor Output TP108 5V VCC TP109 GND GND TP110 24V VAA CP101 CPU2 CPU1 CP102 CPU1 CPU2 CP103 RXD SS CP104 TXD SS CP105 RXD CP106 TXD CP107 RXD CP108 TXD CP109 RXD CP110 TXD CP111 RXD CP112 TXD CP113 RXD ADF CP114 TXD ADF CP115 Not Used CP116 Not Used CP117 PRT CTS CP118 PRT SOUT NOTE TP101 110 have test pins Service...

Page 133: ... Lam PWM TP510 SC PWM Scanner PWM TP511 SC DIR Scanner DIR TP512 FREE RUN Scanner Free Run TP513 24V VAA TP514 UNIT ADJ MODE Adjustment Mode TP515 ZERO CROSS Zero Cross TP516 38V VMM TP517 RXD RXD TP518 THRMST Fusing Thermistor Output TP519 LAMP Exposure Lamp Voltage TP520 LE Lead Edge TP521 TXD TXD TP522 SUB IN SUB IN NOTE TP504 512 514 have test pins 3 3 OPERATION PANEL BOARD TP Number Label Mon...

Page 134: ...ation PAPER FEED for each paper feed station Paper Feed Rollers Paper Trays C R R R Water Replace pick up feed and separation rollers as a set Paper Feed Rollers By pass LCT C R R R Water replace pick up feed and separation rollers as a set Paper Feed Guide Plate C C C Alcohol Registration Sensor C C C Blower brush Vertical Transport Rollers C C C Water Paper Dust Cleaner C C C Dry cloth or blower...

Page 135: ...C Side Seals C C C Air Filter R R R Vacuum cleaner Toner Bottle Holder C C L C L C L Dry cloth Refer to NOTE 5 Toner Receiver C C C C Dry cloth Bias Terminal L Refer to NOTE 8 TRANSFER BELT UNIT Transfer Belt C C R C Dry cloth clean both sides Cleaning Blade R R R Belt Drive Guide Bias Rollers C C C Dry cloth Transfer Belt Terminal A096 3864 C C C Replace as necessary Rear Spring Plate A096 3860 C...

Page 136: ...t Rollers C C C Positioning Pins Holes L L L Refer to NOTE 7 OTHERS Ozone Filter R Drive Belts I I I Replace if necessary Exit Sensor C C C Blower brush Bushings L Spindle oil Development Drive Gear C SORTER STAPLER A377 Rollers C C C C Water Bins C C C Water Bushings L L L Use Launa oil or equivalent Gears L L L Use Grease 501 SORTER STAPLER A374 Bins C C C Water Rollers C C C Water Bushings L L ...

Page 137: ...eplace if necessary DUAL JOB FEEDER A376 for copies Transport Belt C R R R Belt cleaner Replace if necessary Pick up Roller C C C C Alcohol Replace if necessary Feed Roller C R R R Alcohol Replace if necessary Separation Belts C R R R Alcohol Replace if necessary FINISHER Rollers C C C Water Bushings L L L Use Launa oil or equivalent Gears L L L Use Grease 501 Rev 8 16 95 A095 A096 A097 4 60 FSM ...

Page 138: ... in the following figures NOTE 1 Scanner Lens Guide Rods 1 Lubricate the horizontal and vertical lens guide rods A with Launa Oil every 120 K copies 2 Lubricate the third scanner guide rod B with Launa oil every 120 K copies A A B Service Tables FSM 4 61 A095 A096 A097 ...

Page 139: ...h Mobil Temp 78 every 240 K copies NOTE 3 Charge Wire Cleaner Drive Gears 1 Open the drive motor cover B 2 screws NOTE When re installing the cover do not tighten the screws too much 2 Lubricate the charge wire cleaner drive gears C with Grease G501 every 240 K copies A B C A095 A096 A097 4 62 FSM ...

Page 140: ...bricate the cleaning section drive gear B with Grease G501 every 240 K copies NOTE 5 Toner Bottle Holder 1 Lubricate the toner bottle drive gears C with Grease G501 every 120 K copies 2 Lubricate the toner bottle holder D with Mobil Temp 78 every 120 K copies A Rev 4 15 94 B C C D Service Tables FSM 4 63 A095 A096 A097 ...

Page 141: ...roller 2 Lubricate the inner and outer surface of the isolating bushing B with BARRIERTA L55 2 grease every 240 K copies NOTE 7 Duplex Unit 1 Lubricate the two positioning pins C and two positioning Holes D with Mobil Temp 78 every 120 K copies A Rev 8 16 94 B B D C D C A095 A096 A097 4 64 FSM ...

Page 142: ...TION Use only conductive grease otherwise bias voltage will not be properly applied to development rollers A A 1 Lubricate the bias terminal sleeve roller shaft A with Grease KS660 SHIN ETSU Service Tables FSM 4 64 A095 A096 A097 ...

Page 143: ...This page intentionally left blank B A095 A096 A097 4 64 FSM ...

Page 144: ...des or replace the transfer belt at regular intervals Belt Drive Guide Bias Rollers Dirty rollers shift the transfer belt to the front or rear Cleaning Blade A dirty or worn out cleaning blade will cause toner to adhere on the rear side of the copy The blade must be replaced at regular intervals Paper Feed Registration Paper Feed Roller Pick up Roller Separation Roller This machine uses paper tray...

Page 145: ...irty background may occur in the erased area that becomes progressively worse in long copy runs Also this affects sensor pattern detection causing incorrect toner density and exposure lamp control Clean this lamp at regular intervals Cleaning Blade A dirty or worn out cleaning blade will cause black lines on copies or scratches on the drum The blade must be replaced at regular intervals Cleaning B...

Page 146: ... Unit Separation Feed Transport Rollers and Separation Belts If paper dust adheres to the separation feed transport rollers and the separation belts paper may not feed correctly or skewing may result Replacement is required at regular intervals Others Ozone Filter When an ozone filter deteriorates ozone produced in the copier will not be absorbed This may cause headaches irritation or other discom...

Page 147: ...sh 3 2 Clean the pick off pawls and the toner shield filter Discharge any static electricity on the filter 3 3 Clean the QL and PTL filter and erase lamp with a dry cloth discharge any static before installation 3 4 Clean the end blocks and casing with water or alcohol 3 5 Replace the grid plate and corona wire 3 6 Clean the registration rollers and paper dust cleaner 3 7 Empty the toner collectio...

Page 148: ...is no interchangeability 5 3 Clean the registration sensor 5 4 Lubricate the transport guide lock pin 6 1 Clean the transfer belt 6 2 Replace the transfer unit cleaning blade 6 3 Clean the belt drive guide rollers and bias roller 6 4 Clean the transfer belt terminal and the rear spring plate 7 1 Replace the separation roller and separation belts 7 2 Clean the feed and transport rollers 7 3 Lubrica...

Page 149: ...2 1 Perform the developer initial setting SP Adjustment PAGE 1 12 2 Perform the process control data initial setting SP Adjustment PAGE 1 Rev 8 16 95 10 Rear side every 80 K Replace the ozone filter every 360 K 9 Exit unit every 80 K Replace the drum grounding plate every 360 K 8 Fusing unit every 120 K Replace stripper pawls hot roller pressure roller and pressure roller bearings Lubricate the is...

Page 150: ...REPLACEMENT AND ADJUSTMENT ...

Page 151: ......

Page 152: ...left front door A 2 Pull out the pin B 3 Unhook the upper pin C 1 1 2 Right Front Door 1 Open the left front door D 2 Open the right front door E 3 Lower the pin F to unhook the upper hinge bracket G 4 Unhook the lower pin H B A C F G H D E Replacement Adjustment FSM 5 1 A095 A096 A097 ...

Page 153: ...connectors A and B so that the fiber optic cable A is located over the electrical cable B Also the fiber optic cable A should not bend while opening and closing the DJF or RDH 3 Remove the upper rear cover C 4 screws 1 2 2 Lower Rear Cover 1 Remove the lower rear cover D 6 screws NOTE When installing the lower rear cover set the hooks in the holes on the right and left side covers A B C D A095 A09...

Page 154: ...he left front door A 2 Remove the left inner cover 4 screws B 1 2 4 Right Inner Cover 1 Open the right door C 2 Remove knob B1 D 1 screw 3 Remove the right inner cover E 2 screws A B E D C Replacement Adjustment FSM 5 3 A095 A096 A097 ...

Page 155: ...e shutter cover A by releasing the hook B 3 Remove the shutter inner cover C 1 screw NOTE 1 Be sure to move the lever D until it contact the part E 2 While installing the shutter cover A the lever D must be pushed as shown D E C A A B D A A095 A096 A097 5 4 FSM ...

Page 156: ...r 1 Open the by pass table A approximately 45 degrees and push the stoppers B of the feed unit cover C by using a small flat head screw driver D then remove the feed unit cover C A D B C B B Replacement Adjustment FSM 5 5 A095 A096 A097 ...

Page 157: ...er Rear Cover Removal 3 Open the manual feed table and remove the upper right cover E 6 screws 1 3 3 Lower Right Cover 1 Remove the lower rear cover Refer to Lower Rear Cover Removal 2 Open the right door NOTE When installing the lower right cover set the hooks in the holes on the right and left side covers 3 Remove the lower right cover F 4 screws C D E B A F A095 A096 A097 5 6 FSM ...

Page 158: ...s NOTE When installing the upper left cover set the hooks in the holes on the right and left side covers 1 4 2 Lower Left Cover 1 Pull out the second and the third feed trays C 2 Remove the lower rear cover D 3 Remove the lower left cover E 4 screws NOTE When installing the lower left cover set the hooks in the holes on the right and left side covers C D E B A Replacement Adjustment FSM 5 7 A095 A...

Page 159: ... Removal 4 Open the right door 5 Open the toner bottle 6 Remove three screws A 7 Remove two screws B securing the protective earth wires 8 Insert the screw driver through the hole C and push the operation panel D up 9 Disconnect the connector E NOTE Be sure not to damage the harness by pulling the connector too strongly B A E C D A095 A096 A097 5 8 FSM ...

Page 160: ...ove the upper cover D 1 6 2 Rear Upper Cover 1 Turn off the main switch 2 Remove the platen cover or document feeder DJF or RDH from the copier 3 Remove the upper cover 4 Remove the 2 screws securing the rear upper cover E 5 Disengage the hooks F by sliding the rear upper cover to the front and remove it C A D A B A E F E Replacement Adjustment FSM 5 9 A095 A096 A097 ...

Page 161: ...d lift slightly Slide the other edge out from under the right glass holder D Remove the exposure glass NOTE When reinstalling the exposure glass make sure that the mark white A096 copier red A095 copier on the edge of the glass is located at the rear right corner This side is smoother and it generates less static electricity when the RDH is used Rev 4 15 94 A B C D A095 A096 A097 5 10 FSM ...

Page 162: ...sure Glass Removal 2 Move the first scanner A to the cutout position at the rear frame B See illustration 3 Remove the reflector cover C 2 screws 4 While holding the lamp with the paper strip release the lamp terminal D as shown then take out the lamp 5 Install a new lamp Use a strip of paper as shown to hold the lamp Confirm that the lamp is properly set by both terminals and that the clip E is s...

Page 163: ...amp points towards the reflector opening left side of the copier as shown 6 Reassemble the copier 7 Turn on the main switch and enter SP mode then perform the process control data initial setting SP Adjustment PAGE 1 1 A A095 A096 A097 5 12 FSM ...

Page 164: ...osure Glass Removal 2 Move the first scanner to the cutout position at the rear frame 3 Remove the reflector cover B 2 screws 4 Remove the exposure lamp leads C from the terminals on both sides of the thermoswitch D 5 Remove the thermoswitch bracket E 1 screw 6 Remove the thermoswitch from the bracket 2 screws and replace it A B C D E Replacement Adjustment FSM 5 13 A095 A096 A097 ...

Page 165: ...2 Remove the exhaust fan B 3 screws 3 Manually turn the scanner drive pulley C counterclockwise to move the scanners about 10mm to the left rear view 4 Remove the scanner HP sensor bracket D 1 screw 5 Disconnect the connector 6 Replace the scanner HP sensor E 1 screw A B D E C A095 A096 A097 5 14 FSM ...

Page 166: ...F RDH connector bracket B 2screws 3 Remove the ADS Sensor C with the cover D 1screw 4 Replace the ADS Sensor C 2 screws 5 Assemble the copier 6 Turn on the main switch and enter SP mode then perform the Auto ADS initial setting SP Adjustment PAGE 5 1 A B C D Replacement Adjustment FSM 5 15 A095 A096 A097 ...

Page 167: ... bracket 2 Hook the tension spring A 3 Install two screws 4 Remove the two connectors E from the Optic Control Board 5 Remove the scanner motor F 4 screws NOTE While replacing the drive pulley the gap G should be 0 5mm so that the upper edge H of the pulley is lower than the upper surface I of the bracket as shown After installing the scanner motor perform the scanner control adjustment Refer to S...

Page 168: ...ove the optics thermistor A 1 screw 1 harness clamp 5 Remove the scanner HP sensor with bracket Refer to Scanner HP Sensor Replacement 6 Remove the scanner drive motor Refer to Scanner Drive Motor Replacement 7 Unhook the harness from the two harness clamps B 8 Remove the upper optics frame C 9 screws A B C Replacement Adjustment FSM 5 17 A095 A096 A097 ...

Page 169: ... NOTE When installing the lens shield plate set the rear part D of the lens shield plate between the guides E as shown Then set the grooves on the guide pins F in the rail G After reinstalling the tension spring confirm that movement of the lens shield plate is smooth C A B D E F G A095 A096 A097 5 18 FSM ...

Page 170: ... the four harness clamps C 15 Disconnect the connector D outside the optic side frame 16 Remove the connector E from the optic side frame 17 Remove the scanner clamps F securing both sides of the first scanner unit to the scanner wires 4 screws A D E B C F Replacement Adjustment FSM 5 19 A095 A096 A097 ...

Page 171: ...or connector C and move the lens unit to the left then remove the rear bracket D 2 screws 21 Unhook the tension spring E and remove the scanner wire F 22 Remove the second scanner G NOTE When re installing the mylar bracket B be sure not to create any gap between the bracket and the lens cover C D A B F G E A095 A096 A097 5 20 FSM ...

Page 172: ...e the front ball bearing C 25 Remove the rear drive pulley D 1 Allen screw and remove the rear ball bearing E 26 Loosen the two Allen screws of the front drive pulley F and slide the pulley about 10 cm to the rear then take out the drive shaft A C B D F E Replacement Adjustment FSM 5 21 A095 A096 A097 ...

Page 173: ... the wire counterclockwise 5 times as shown in the illustration the D cut C on the shaft is at the front side then set the bead D on the wire in the hole E on the pulley In this condition the bead just reaches the hole on the pulley 3 After setting the bead in the hole round the wire two more times in total 7 times 4 Fix the wire with tape F as shown A F D E B C A095 A096 A097 5 22 FSM ...

Page 174: ... 5 times as shown in the illustration the Allen screw holes are at the rear side then set the bead C on the wire in the hole D on the pulley In this condition the bead just reaches to the hole on the pulley 3 After setting the small ball in the hole round the wire twice more in total 7 times 4 Fix the wire with tape E as shown E D A B C Replacement Adjustment FSM 5 23 A095 A096 A097 ...

Page 175: ... drive shaft 7 Set and fully push in the scanner drive pulley E on the front end of the scanner drive shaft then tighten the Allen screw F 8 Install the scanner drive motor Refer to Scanner Drive Motor Replacement 9 Place the second scanner G on the guide rail and fix it there by using two jig pins H NOTE This jig pin is used as the left door hinge pin I However only one pin is used on the copier ...

Page 176: ...r end A of the rear scanner drive wire in the following order Rear track counterclockwise Clockwise Lower track clockwise Fix the end of the wire on the frame with tape B A B Replacement Adjustment FSM 5 25 A095 A096 A097 ...

Page 177: ...f the rear scanner drive wire in the following order Through front track upper side Counterclockwise Upper track counterclockwise Hook the end B of the wire on the cutout on the right optics side frame A B A095 A096 A097 5 26 FSM ...

Page 178: ... end A of the front scanner drive wire in the following order Front track counterclockwise Clockwise Lower track clockwise Fix the end of the wire on the frame with tape B A B Replacement Adjustment FSM 5 27 A095 A096 A097 ...

Page 179: ...side frame 14 Slightly push the front drive pulley B against the front optics side frame and tighten the two Allen screws 15 Remove the jig pins securing the second scanner 16 Remove the tapes C fixing the ends of the scanner drive wires and hook the ends of the scanner drive wires with the tension springs 17 Remove the tapes D fixing the wire to the front and rear drive pulleys A B C D A095 A096 ...

Page 180: ...D to the left end position Fix the rear side of the second scanner by inserting the jig pin E in the holes on the rear side of the second scanner and the rear guide rail 2 Turn the adjusting nut F to adjust the second scanner alignment so that the jig pins G can be smoothly set in the holes on the front side of the second scanner and the front guide rail A B C E D G F Replacement Adjustment FSM 5 ...

Page 181: ...y inserting the jig pin B in the holes on the first scanner and the guide rail 2 Position the first scanner so that the jig pin C can be smoothly set in the holes on the first scanner and the guide rail then tighten the wire clamp brackets D 4 screws 21 Install the scanner HP sensor E 1 screw 22 Secure the scanner flat cable 1 screw 23 Install the upper optics frame F 9 screws A B C D D E F A095 A...

Page 182: ...TP514 and TP504 GND on the optics control Board 4 Turn on the main switch 5 Short circuit TP512 and TP504 GND then the machine automatically starts the scanner free run 6 Turn off the main switch 25 After performing the scanner free run check the second scanner alignment then the first scanner alignment 26 Perform the scanner control adjustment Refer to Scanner Control Adjustment 27 Check the copy...

Page 183: ...ter replacing the optics control Board 1 Perform the free run Test Mode PAGE 1 30 times 2 After the free run is completed turn the rotary dip switch A until LED 501 B turns on NOTE If this adjustment is improper the timing between the scanner and the paper feed will be also improper causing paper jams at the registration roller or causing scanner noise due to wire vibration 2 B A LED 501 A095 A096...

Page 184: ... 2 Remove the upper cover A Refer to Upper Cover Removal 3 Remove the lens unit cover B 2 screws 4 Remove the two screws C fixing the front third scanner bracket 5 Remove the sixth mirror D 6 Remove the third scanner E as shown A B C E E D Replacement Adjustment FSM 5 33 A095 A096 A097 ...

Page 185: ...ver A 3 Remove the shutter inner cover B 1 screw 4 Open the toner bottle C and close the toner hopper cover D 5 Remove the third scanner drive unit E 3 screws F 6 Replace the third scanner drive motor G 1 connector 2 screws 7 Remove the third scanner HP sensor H with the bracket I 1 screw 8 Replace the third scanner HP sensor 1 screw B A C D E H F G I A095 A096 A097 5 34 FSM ...

Page 186: ...cement 2 Remove the light shielding mylar bracket C 1 screw NOTE When re installing the mylar bracket C be sure not to create any gap between the bracket and the lens cover 3 Remove the flat cable bracket D 1 screw 2 connectors 4 Position the roller E underneath the bracket F F E A B D C Replacement Adjustment FSM 5 35 A095 A096 A097 ...

Page 187: ... B 1 screw 7 Push the pulley bracket to the front then unhook the timing belt C 8 Remove the two timing belt holders D 1 screw each NOTE When setting the timing belt align the end E of the timing belt to the edge F of the belt holder A B F C E D D A095 A096 A097 5 36 FSM ...

Page 188: ...he front bracket A Refer to Scanner Drive Wires Replacement 3 Remove the lens unit B Refer to Lens Horizontal Drive Belt Replacement 4 Loosen the two screws C fixing the tension pulley bracket D 5 Push the tension pulley bracket to the left front view then unhook the timing belt A B C D Replacement Adjustment FSM 5 37 A095 A096 A097 ...

Page 189: ...OR 1 Remove the exposure glass Refer to Exposure Glass Removal 2 Remove the lens unit cover A 2 screws 3 Remove the original size sensor covers B 1 screw each 4 Replace each original size sensor C 1 screw 1 connector each A B C C C B A095 A096 A097 5 38 FSM ...

Page 190: ...sing the hook B NOTE Be sure to move the lever C until it contacts part D fully to the front 4 Remove the shutter inner cover E 1 screw 5 Open the toner bottle holder F NOTE To open the toner bottle holder completely while lowering the shutter lever G push the bracket H to the right E A A B C D H G F Replacement Adjustment FSM 5 39 A095 A096 A097 ...

Page 191: ...ment unit F NOTE 1 To prevent drum scratches push the development unit to the right while pulling it out 2 When installing the development unit do not forget to set the two connectors E 3 When installing the drum stay be careful not to pinch the harness Also keep the harness away from gears 4 When pulling out the development unit do not hold the knob G F E G A B C D A095 A096 A097 5 40 FSM ...

Page 192: ...then move it up to remove it from the development unit 5 Turn over the development unit then turn the paddle roller knob D to empty developer onto the sheet The one way clutch in the knob D allows turning the paddle roller counterclockwise only NOTE Dispose of used developer according to local regulations Make sure that no developer remains on the development rollers or in the development unit B C...

Page 193: ...unit in the machine 9 Turn on the main switch then perform developer initial setting SP Adjustment PAGE 1 CAUTION Never make any copy with the new developer before completing the developer initial setting otherwise toner density control will be abnormal NOTE If the developer initial setting is not completed you cannot exit the SP mode by pressing the Quit key If this occur turn the main switch off...

Page 194: ... Remove the developer entrance seal A 2 screws 2 hooks 3 Remove the front and rear side seals B NOTE When re assembling the development unit use new side seals and align the edge of the side seals to the corner C and the edge D as shown B B A C D Replacement Adjustment FSM 5 43 A095 A096 A097 ...

Page 195: ...nd G If the screws at F are loosened the doctor gap will be improper If the screws at G are loosened the photoconductor gap and magnetic field angle will be improper If either of them become abnormal toner density control will be abnormal 6 Remove the front roller holder H 1 screw and 2 E rings and rear roller holder I 1 screw A B C D E H I F G A095 A096 A097 5 44 FSM ...

Page 196: ...the copier CAUTION If the original developer already used is returned to the development unit do not perform the developer initial setting If the new developer is set never make any copy before completing the developer initial setting SP Adjustment PAGE 1 1 Replacement Adjustment FSM 5 45 A095 A096 A097 ...

Page 197: ...stalling the TD Toner Density sensor clean the development unit well so that no carrier particle remains in the gap between the TD sensor and the development unit casing 3 Install the new developer and perform the developer initial setting CAUTION Never make any copy before completing the developer initial setting A A095 A096 A097 5 46 FSM ...

Page 198: ...rews then remove the toner bottle holder by unhooking the hole D from the pin on the hinge 4 Remove the toner receiver E 5 Remove the toner bottle drive motor assembly F 1 connector 2 screws 6 Remove an E ring G and slide the gear H to access a screw 7 Replace the toner bottle drive motor I 3 screws M3 x 4 C A D E F B I G H Replacement Adjustment FSM 5 47 A095 A096 A097 ...

Page 199: ...rvicing 4 Open the upper drum unit 2 screws C 5 Replace the OPC drum Then remove the drum protective sheet from the new drum NOTE When returning the drum unit to the copier do not forget to open the protective shutter B If it is hard to completely set the drum unit in the machine because the gear is disengaged then push in the drum unit while holding down the cleaning blade release knob D 6 Turn o...

Page 200: ...ching lamp then insert the head of the small flat head screw driver B between the quenching lamp and the drum unit casing to release the hook C at the center of the quenching lamp NOTE Do not pull the wire too strongly 3 Disconnect the connector D 4 Replace the quenching lamp 5 Turn on the main switch then perform process control initial setting SP Adjustment PAGE 1 1 D C CN663 A B Rev 8 29 97 Rep...

Page 201: ...s NOTE When installing the grid plate do not tighten the plastic screw C too strongly 3 Remove the front grid terminal D then the front end block cover E 4 Remove the terminal spring F 5 Slide the rear grid terminal G to the rear and remove it then remove the rear end block cover H 6 Remove the charge corona wire I A C B D E F H G I A095 A096 A097 5 50 FSM ...

Page 202: ... the wire in the rear end block as shown Correctly set the wire between the wire cleaner pads Do not loosen the screw C otherwise the charge corona height will change 9 Turn on the main switch then perform process control initial setting SP Adjustment PAGE 1 1 Rev 8 29 97 A B B C Replacement Adjustment FSM 5 51 A095 A096 A097 ...

Page 203: ...to release the rear side of the erase lamp from the drum unit casing 4 Disconnect the connector E NOTE Before removing the drum potential sensor set a few sheets of paper between the sensor and the OPC drum to protect the drum surface 5 Replace the drum potential sensor F CAUTION After replacing the drum potential sensor perform the process control data initial setting SP Adjustment PAGE 1 1 B D E...

Page 204: ... the screw F and separate the upper and the lower drum units 3 Remove the pick off pawl bracket G 2 screws 4 Disconnect the connector H 5 While turning the bracket counterclockwise front view slide the pick off pawl bracket to the rear 4 Install the new cleaning blade NOTE Do not clean the edge of the cleaning blade with cloth otherwise it damages the edge and causes black lines on copy images Do ...

Page 205: ...ng gear A 1 screw 3 Remove the grounding wire B 1 screw 4 Remove the bushing C 5 Pull the cleaning brush shaft to the rear to release the cleaning brush D then remove the cleaning brush NOTE Do not touch the cleaning brush with oily hands After replacement clean the ID sensor surface A C B D A095 A096 A097 5 54 FSM ...

Page 206: ...ove the E ring C then slide out the bushing D 1 screw and collar E 4 Fully slide the shaft F to the rear 5 Replace the pick off pawl G NOTE Do not forget to hook the tension spring H After replacement check that the pick off pawls move smoothly H H A C D G F B Rev 4 15 94 H Replacement Adjustment FSM 5 55 A095 A096 A097 ...

Page 207: ...emove the toner collection bottle A 1 push lock B 2 Remove the upper and lower rear covers Refer to Upper and Lower Rear Covers Removal 3 Remove the tank cover bracket C 2 screws 4 Remove the toner collection motor D 2 connectors 2 screws NOTE When re installing the toner collection motor be sure to set the 2 positioning pins in the holes on the machine rear frame A B D C A095 A096 A097 5 56 FSM ...

Page 208: ...en re installing the timing belt C be sure that the belt is correctly hooked on the four pulleys as shown 7 Remove the belt tightener unit D 2 screws 8 Remove the four screws E fixing the toner collection coil casing F to the machine rear frame E A B C D F E E C Replacement Adjustment FSM 5 57 A095 A096 A097 ...

Page 209: ... B catch the pin with needle nose pliers C accessing from the hole under the main control board as shown When re setting the push lock pin B hold the pin with needle nose pliers Then while holding the pin above the push lock holder D push the pin head down with you finger Insert your finger from the space below the LCT connector bracket as shown A B C B C D A095 A096 A097 5 58 FSM ...

Page 210: ...tor 4 screws 13 Remove the toner collection coil casing C and put it on the sheet of paper 14 Disassemble the toner collection coil casing D 8 screws 15 Remove the drive pulley E 1 E ring 16 Replace the toner collection coil F B C A D E F Replacement Adjustment FSM 5 59 A095 A096 A097 ...

Page 211: ... the toner bottle holder 2 Remove the transfer belt unit prop A 3 screws 3 Replace the ozone filter B NOTE To install the transfer belt unit prop smoothly set in order the lower pins C drive roller shaft D and the upper pins E A B E C D C A095 A096 A097 5 60 FSM ...

Page 212: ...unit NOTE 1 Do not touch the transfer belt with oily hands 2 Take care not to scratch the OPC drum with part of the transfer belt unit Be careful when installing the transfer belt unit Installation 1 While turning the lever C counterclockwise install the transfer belt unit NOTE 1 Insert the gear D in the hole E on the rear frame 2 Place the slot F of the transfer belt unit on the rail G A B C D E ...

Page 213: ... pins A drive roller shaft B and the upper pins C 3 After installation confirm the following points 1 Smooth up down movement of the transfer belt unit 2 Part D of the transfer belt unit is inside the drum stay 3 Part D of the transfer belt unit is set in the dent E on the drum unit casing A B C E D A095 A096 A097 5 62 FSM ...

Page 214: ... Refer to Transfer Belt Unit Removal 2 While raising the knob A disconnect the two connectors B 3 Turn the transfer belt upper unit C 90 degrees counterclockwise then raise and remove it 4 Remove the screws D A C B D D Replacement Adjustment FSM 5 63 A095 A096 A097 ...

Page 215: ...a dry cloth do not use alcohol 2 Before installing the transfer belt clean the following items with alcohol Belt drive roller C Belt roller D Bias roller E Discharge terminal F 3 Position the transfer belt at the center of the belt roller D Both marks G should be visible 4 Set the transfer belts inside the bias terminals H D C A B H H Rev 12 93 G H E A095 A096 A097 5 64 FSM ...

Page 216: ...pack from static electricity remove the power pack as follows 1 Disconnect two connectors C 2 While pushing the power pack toward the solenoid D release the power pack from the hook E 4 Install the new cleaning blade NOTE Do not touch the edge of the cleaning blade If some of the setting powder on the blade edge is removed apply setting powder or toner there B D E C A Replacement Adjustment FSM 5 ...

Page 217: ...e main switch 2 Remove the front covers Refer to Front Cover Removal 3 Remove the four screws C 4 Open the small rear cover D 1 screw 5 Remove the five connectors E 6 Remove the copier main frame A from the paper tray unit B NOTE When re installing the copier main frame on the paper tray unit do not pinch the harness between the copier main frame and the paper feed unit A B C C C C E D A095 A096 A...

Page 218: ...tandem tray C to separate it from the left tandem tray D 3 Remove the stopper E 1 screw 4 Remove the left tandem tray D from the left guide Accuride F 2 screws 5 While holding the right tandem tray C from the bottom remove the right tandem tray from the right guide Accuride G 2 screws NOTE If two screws are removed without holding the right tandem tray it will drop A C B D E G F C D Replacement Ad...

Page 219: ...l Tray 550 sheet tray Built in LCT Removal all trays of the A095 copier 2nd 3rd trays of the A096 copier 1 Draw out the tray 2 Remove the tray from both guide Accurides as shown 4 screws A095 A096 A097 5 68 FSM ...

Page 220: ...ing 5 Remove the snap ring C fixing the separation roller D then separate the separation roller D from the torque limiter E NOTE 1 The paper feed pick up feed separation rollers used in the 1st 3rd feed units in the paper tray unit are different from the feed rollers used in the by pass feed table and 3 5K LCT 2 Do not touch the surface of the rollers with oily hand E A C B D Replacement Adjustmen...

Page 221: ...Removal 3 Remove the rear fence B on the left tandem tray 2 screws 4 Remove the rear base plate C with the rear fence drive motor D 3 screws NOTE When re installing the rear base plate make sure that the grounding plate E is attacked to the rear base plate 5 Remove the end fence F 2 screws 6 Remove the center bottom plate G 2 screws A B C D F G E C A095 A096 A097 5 70 FSM ...

Page 222: ...tors A 8 Loosen the tightener screw B and unhook the tension spring C 9 Remove the timing belt D NOTE When installing the timing belt hook the spring C then tighten the screw B A B C D Replacement Adjustment FSM 5 71 A095 A096 A097 ...

Page 223: ... the lift arm C 2 screws 3 Remove the cover D 1 screw 4 Remove the bracket E 2 screws F 5 Remove the side fence drive motor G 2 screws H and 2 nuts NOTE When installing the side fence drive motor move both side fences to the innermost position then set the motor gear between the two rack gears I B G C A D H E I F A F A095 A096 A097 5 72 FSM ...

Page 224: ...ccess the SP Adjustment PAGE 2 3 Touch the Copy in SP key C then select the 1st feed station 4 Enter a copy quantity of 2 using the number keys 5 Touch the SP Mode key 6 Press the Start key and evaluate the width of the white area D on the copy The adjustment standard is 10 5 mm NOTE In this mode the registration roller does not stop for registration Do not make copies in Copy in SP mode for this ...

Page 225: ...6 to 8 NOTE Concerning the adjustment for the 1st feed station it is necessary to adjust the feed timing for the 1st and 2nd sheets individually 2 Paper feed timing adjustment for the 2nd 3rd feed stations the LCT and duplex unit A095 A096 A097 Copiers Refer to Paper Feed Timing Adjustment for the 1st feed station Eliminate steps 4 and 8 A B C D Rev 7 94 A095 A096 A097 5 74 FSM ...

Page 226: ...select the 1st feed station 4 Touch the SP Mode key 5 Press the Start key and evaluate the width of the white area D on the copy The adjustment standard is 10 5 mm NOTE In this mode the registration roller does not stop for registration Do not make copies in Copy in SP mode for this adjustment In Copy in SP mode the registration clutch stops normally 6 Touch the key E or the key F to adjust the wh...

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Page 228: ...r stops for registration mark the trailing edge C of the paper on the next paper as shown 6 Measure the distance D between the leading edge of the mark E and the trailing edge of the paper F as shown The adjustment standard is 106 115 mm 7 Touch the SP Mode key 8 Touch the key G or the key H to adjust the distance D 9 Touch the Copy in SP B 10 Repeat steps 5 to 9 1 NOTE In this mode the registrati...

Page 229: ...move the push lock A 2 Remove the toner collection bottle B NOTE If the LCT is installed remove it from the copier 3 Remove the lower right cover C Refer to Lower Right Cover Removal 4 Remove the upper then the lower vertical transport guides D and E Rev 4 15 94 A B D E C A095 A096 A097 5 76 FSM ...

Page 230: ...rew D then remove the knob E 7 Remove the magnet F 8 Pull out all paper trays then remove the paper tray unit inner cover G 2 screws 9 Remove the two connectors H 10 Remove the support bracket I 1 screw NOTE The support bracket is used only for the first feed station H I A B G A F Rev 4 15 94 D C E Replacement Adjustment FSM 5 77 A095 A096 A097 ...

Page 231: ...ay feed unit 15 Loosen the two Allen screws D 16 Remove the tray feed clutch E 1 connector NOTE When re installing the tray feed clutch set the stopper F of the clutch on the edge of the bracket G then fully push in the clutch on the feed roller shaft H and secure the Allen screws D Rev 4 15 94 A B C E G D H F D A095 A096 A097 5 78 FSM ...

Page 232: ...Refer to Right Inner Cover Removal 2 Remove the total counter with bracket 1 screw 1 connector 3 Loosen the Allen screw A on the hinge 4 Remove the hinge pin B 1 screw 5 Remove the by pass feed table 1 connector A B B Replacement Adjustment FSM 5 79 A095 A096 A097 ...

Page 233: ...the pick up roller B 1 snap ring and the feed roller C 1 snap ring NOTE The paper feed pick up feed separation rollers used in the by pass feed table and LCT are different from the paper feed rollers used in the 1st 3rd feed units in the paper tray unit They are not interchangeable A C B A095 A096 A097 5 80 FSM ...

Page 234: ...3 Remove the feed unit cover A as shown 4 Replace the separation roller B 1 snap ring A B Replacement Adjustment FSM 5 81 A095 A096 A097 ...

Page 235: ...ass table and remove the feed unit cover Refer to Feed Unit Cover Removal 3 While pushing the hook A with the head of the flat head screw driver as shown remove the table assembly B 2 screws 1 connector C 4 Remove the by pass paper size sensor D 2 screws A B C D A095 A096 A097 5 82 FSM ...

Page 236: ...nsor paper size correction SP Adjustment mode PAGE 9 as follows 1 Enter SP mode refer to Service Program Access Procedure then access SP Adjustment mode PAGE 9 2 Place the side fence C at the A4 or 81 2 x 11 sideways position according to the paper size decal on the table 3 Place the side fence C at the A6 or 41 2 x 51 2 lengthwise position according to the paper size decal on the table 1 1 A B B ...

Page 237: ...PASS FEED CLUTCH REMOVAL 1 Remove the upper rear cover A Refer to Upper Rear Cover Removal 2 Lower the main control board B 2 screws 3 Unhook the main control board bracket hinge C A B C A095 A096 A097 5 84 FSM ...

Page 238: ...Remove the clutch stopper B 1 screw NOTE When re installing the by pass feed clutch C set the pin D of the clutch in the cutout E of the stopper 6 Remove the by pass feed clutch 1 connector A B D C E Replacement Adjustment FSM 5 85 A095 A096 A097 ...

Page 239: ...1 screw NOTE When re installing the registration clutch B set the pin C of the clutch in the cutout of the stopper D 3 Loosen the Allen screw E 4 Remove the registration clutch 1 connector NOTE When re installing the registration clutch fully push in the clutch on the registration roller shaft F and secure the Allen screw A B C D E F A095 A096 A097 5 86 FSM ...

Page 240: ...o Development Unit Removal 2 While pushing down the hook lever A remove the paper dust cleaner B 3 Remove paper dust inside the paper dust cleaner and clean the inside of the cleaner with a dry cloth or a blower brush A B B Replacement Adjustment FSM 5 87 A095 A096 A097 ...

Page 241: ...EMOVAL 1 Remove the right inner cover A Refer to Right Inner Cover Removal 2 Disconnect the connector B 3 Pull out the registration sensor assembly C 4 Clean the photo sensor D with a blower brush A B C D A095 A096 A097 5 88 FSM ...

Page 242: ... solenoid registration clutch and the pick up solenoid NOTE Before disconnecting the connectors make sure to identify them Some of the connectors use identical pin leads but they are not interchangeable Take special care not to misconnect the positioning solenoid and registration clutch connectors 5 Remove the upper right cover B and the paper feed unit cover C 6 Disconnect the three connectors D ...

Page 243: ... A 1 screw 9 Remove the copier feed unit B 4 screws NOTE When installing the copier feed unit to the copier 1 Do not pinch the harness 2 Keep the duplex unit drawn out 3 Fit the two cut outs C to the pins D A C B D A095 A096 A097 5 90 FSM ...

Page 244: ...he 1500 sheet built in LCT refer to the installation procedure section Used as tandem tray for A4 sideways or smaller size paper 1 Draw out the tandem tray A 2 Remove the rear and front side fences B one screw and one pushlock each on the right tandem tray 3 Re position the end fences C on both rear and front side fences 1 screw each according to the paper size A B B B C Replacement Adjustment FSM...

Page 245: ... size from the outside pin A4 11 B5 5 Change the position of the front and rear side fences D 2 screws each and end fence E 2 screws on the left tandem tray according to the paper size 6 Enter SP mode refer to Service Program Access Procedure and access SP Special Features PAGE 5 7 Select the appropriate paper size according to position of the side and end fences 4 B C A A D E A095 A096 A097 5 92 ...

Page 246: ...both the rear and the front side fences 2 screws each NOTE It is not necessary to re install the end fences 4 Install both side fences to the appropriate position according to the paper size one screw and one lock pin for each side fence NOTE Support plates C are used only for A4 B5 and letter lengthwise sizes Keep the end fences and support plates for future use B C C A A Replacement Adjustment F...

Page 247: ...d fence B 2 screws of the left tandem tray according to the paper size 6 Enter SP mode refer to Service Program Access Procedure and access SP Special Features PAGE 5 7 Select the appropriate paper size according to the side and end fences position 4 A A B A095 A096 A097 5 94 FSM ...

Page 248: ...n the customer needs the A5 51 2 x 81 2 lengthwise paper size does a service representative need to change the paper size In this case proceed as follows 1 Install the front and rear side fences A 2 screws NOTE These side fences are the same as the side fences used in the 550 sheet fixed paper tray These side fences are options order them as service parts A Replacement Adjustment FSM 5 95 A095 A09...

Page 249: ...EMOVAL 1 Turn off the main switch 2 Open the left front door 3 Remove the stopper A 1 screw 4 While releasing the lever B pull out the fusing unit as shown NOTE Hold the bottom of the fusing unit as shown A B A095 A096 A097 5 96 FSM ...

Page 250: ... the lever C then lower the cover B to unhook the fusing unit 5 Remove the fusing unit upper cover D 1 screw 6 Replace the thermistor E 1 screw 1 connector NOTE When re assembling the fusing unit secure the harness in the clamps correctly Apply a little silicone oil at the thermistor s point of contact with the hot roller A C B E D Replacement Adjustment FSM 5 97 A095 A096 A097 ...

Page 251: ... fusing unit upper cover Refer to Fusing Thermistor Replacement 2 Remove the terminal bracket A 2 screws 1 hook 3 Disconnect the two connectors B 4 Replace the fusing thermofuse C 1 screw NOTE When re assembling the fusing unit secure the harness in the clamps correctly C B A B Rev 7 94 A095 A096 A097 5 98 FSM ...

Page 252: ...sing Thermistor Replacement 2 Remove the terminal bracket A 2 screws 1 hook 3 Disconnect the three connectors B 4 Replace the fusing thermofuse C 1 screw NOTE When re assembling the fusing unit secure the harness in the clamps correctly A C B B A Rev 7 94 Replacement Adjustment FSM 5 98 A095 A096 A097 ...

Page 253: ...B and B and the rear connector C and C 4 Remove the front fusing lamp holder D and the rear fusing lamp holder E 1 screw each 5 Replace the fusing lamps F NOTE Locate the green connectors C of the fusing lamp to the rear side Set the connectors from the fusing lamps green G and from the thermofuse white H in the correct position on the terminal B Rev 7 94 E C C D B B F G G H H A A095 A096 A097 5 9...

Page 254: ... rear connector C 4 Remove the front fusing lamp holder D and the rear fusing lamp holder E 1 screw each 5 Replace the fusing lamp F NOTE Locate the yellow connector C of the fusing lamp to the rear side Set the connectors from the fusing lamp yellow G and from the thermofuse white H in the correct position on the terminal C B D E F Rev 7 94 G H A Replacement Adjustment FSM 5 99 A095 A096 A097 ...

Page 255: ...the fusing lamp A Refer to Fusing Lamp Replacement 2 Lower the fusing exit assembly B 3 Remove the upper stay C 4 screws 4 Remove the oil supply roller unit D 1 lever Refer to Oil Supply Roller Replacement A B D C A095 A096 A097 5 100 FSM ...

Page 256: ...fusing roller 1 Lubricate the inner and the outer surface of the isolating bushings F with BARRIERTA L55 2 grease 2 Lubricate the fusing drive gears and their shafts with grease G501 3 Peel off 3 cm 1 inch form both ends of the protective sheet and install the hot roller Before applying fusing pressure remove the rest of the protective sheet A B C F G G F D C E E Replacement Adjustment FSM 5 101 A...

Page 257: ...s 3 Lift the pressure roller B and remove it 4 Replace pressure roller and bearings C NOTE When installing a new pressure roller 1 Lubricate the roller shaft and the inner surface of the bearings with BARRIERTA L55 2 grease 2 Lubricate the fusing drive gears and their shafts with G501 grease 5 Re assemble the machine B A C C A095 A096 A097 5 102 FSM ...

Page 258: ...ing the upper exit guide C 4 Unhook the spring D then replace the strippers E NOTE After setting the fusing stripper pawl confirm that the strippers are correctly held by the stripper holders F as shown If not remove the stripper and bend the holders F inward Apply the grease Barrierta L55 2 on the inner surface of the holder F A F F A C B D E Replacement Adjustment FSM 5 103 A095 A096 A097 ...

Page 259: ...ter paper 2 As soon as the paper starts to exit open the left door to stop the paper in the fusing unit 3 Wait about 20 seconds then turn the fusing knob quickly to deliver the paper 4 Measure the nip band width A at the center 5 If the nip band width is not within adjustment standards change the spring hook position B Rear A Front B A095 A096 A097 5 104 FSM ...

Page 260: ...unit A 3 Remove the lever bracket B 2 screws 4 Disconnect the two connectors C 5 Take out the paper exit unit D 4 screws NOTE Place the paper exit unit so that the paper exit roller comes to the bottom to prevent the brush roller from being pressed and damaged Rev 4 15 94 B A D C Replacement Adjustment FSM 5 105 A095 A096 A097 ...

Page 261: ...llowing order 1 Set the drive shaft A on the left rail B 2 Set the plate C on the right rail D 3 Set the positioning pin E in the hole F 2 Install the paper exit unit 2 connectors 4 screws 3 Re assemble the copier A E B F C D A095 A096 A097 5 106 FSM ...

Page 262: ... C 1 screw 5 Loosen screws D then remove the cleaning roller E 6 Install two bushings F on the new cleaning roller 7 Remove the spring G 8 Remove the bushing H 9 Install the new oil supply roller I then reassemble the unit NOTE While pressing down the lever A install the oil supply unit A Rev 7 94 A B C I H G F H G F D E D Replacement Adjustment FSM 5 106 A095 A096 A097 ...

Page 263: ...emove the brackets C 1 screw each 5 Remove the bushings D 1 E ring each 6 Replace the cleaning roller E NOTE Since the spring pressure plate springs on the brackets C is stronger than the A095 A096 copier s cleaning roller there is no interchangeability between A095 A096 and A097 cleaning roller unit 7 Reassemble the unit B A B D C E C D Rev 7 94 A095 A096 A097 5 106 FSM ...

Page 264: ...ower the lever A 3 Remove the oil supply unit B 4 Remove the spring C 5 Remove the bushing D 6 Replace the oil supply roller E 7 Reassemble the unit NOTE While lowering the lever A install the oil supply unit A B E D C Replacement Adjustment FSM 5 107 A095 A096 A097 ...

Page 265: ...rew 3 Remove the cleaning roller unit B 2 screws 4 Remove the bracket C 1 screw 5 Remove the cleaning roller D 6 Remove the seals E and bushings F from both sides of the cleaning roller then install them to the new cleaning roller 7 Reassemble the unit E F D F E C A B A095 A096 A097 5 108 FSM ...

Page 266: ...aw out the duplex unit 2 Remove the duplex front cover A 3 screws 3 Slide the lever B to the rear then open the duplex reverse assembly C 4 Remove the lower separation guide plate D 2 screws 5 Remove the snap ring E A C B E D Replacement Adjustment FSM 5 109 A095 A096 A097 ...

Page 267: ...bracket A 1 screw 7 Remove the gear B 1 E ring 8 Remove the bushing C 1 E ring 9 Slide the feed roller shaft D to the rear then slide the feed roller E to the front and replace it as shown B E C A D A095 A096 A097 5 110 FSM ...

Page 268: ...plex unit 2 Remove the gear A 1 E ring 3 Remove the bracket B 1 screw then remove the gear C 4 Remove the gear D and the bushing E 1 E ring 5 Remove the separation belt unit F 6 Remove the guide mylar G 2 snap rings F E D A C B G Replacement Adjustment FSM 5 111 A095 A096 A097 ...

Page 269: ... C as a set NOTE When setting the tension spring D set it on the hook E normally The hook F applies higher separation pressure Confirm that the separation belt is correctly set between the guides G Confirm that the snap rings H do not touch the separation belts A B G D F E H A095 A096 A097 5 112 FSM ...

Page 270: ... 2 Remove the right inner cover A Refer to the right inner cover removal 3 Draw out the duplex unit B until the stop position 4 Take out the right and left stopper pulleys C 1 snap ring each 5 Take out the duplex unit C A C B Replacement Adjustment FSM 5 113 A095 A096 A097 ...

Page 271: ...moval NOTE When installing both clutches be sure to set the stopper A to the projection B Separation Clutch 1 Remove the harness bracket C 1screw 2 Remove the E ring D 3 Replace the separation clutch E Transport Clutch 1 Remove the E ring F 2 Replace the separation clutch G Rev 12 93 A D B E C A G B F A095 A096 A097 5 114 FSM ...

Page 272: ...lide the lever A to the rear then open the separation belt unit B 4 Remove the lower separation guide plate C 2 screws 5 Remove the pressure arm D 1 snap ring 6 Remove the harness cover E 1 screw 7 Remove the two connectors F 8 Remove the upper stay G 4 screws 1 connector C D A B E F G Replacement Adjustment FSM 5 115 A095 A096 A097 ...

Page 273: ...ove the positioning roller assembly C 12 Remove the front jogger fence D and the rear jogger fence E 1 screw each 13 Remove the duplex tray F 3 screws and a connector NOTE To release the hooks G slide the duplex tray to the upper left as shown Rev 12 93 A D B E C F G G A095 A096 A097 5 116 FSM ...

Page 274: ...left 17 Remove the jogger motor bracket F 1 screw 18 Remove the pressure arm solenoid G 1 screw 19 Replace the jogger motor H 2 screws NOTE When installing the drive pulley I to the jogger motor shaft align the shaft head J with the pulley head H 20 Re assemble the duplex unit A B C A D F E G H I J H Replacement Adjustment FSM 5 117 A095 A096 A097 ...

Page 275: ...as shown 3 Move the rear jogger fence bracket F to the rear end position until the bracket F touches the screw G and keep this condition 4 Under the above condition place the front jogger fence bracket H to the front end position until the bracket H touches the front screw 5 Install the stopper I to fix the front jogger fence bracket with the wire Rev 12 93 A B C D G F I E H A095 A096 A097 5 118 F...

Page 276: ...the jogger fence F 4 After installing the jogger fences manually move the jogger fences F to confirm that they move smoothly 5 After re assembling the duplex unit manually pull the plungers of the positioning roller solenoid and the pressure arm solenoid to confirm that the positioning roller assembly and the pressure arm move up and down correctly 6 After re assembling the duplex unit adjust the ...

Page 277: ... 0 2 mm 0 5 mm 00 Leading edge erase margin 3 3 5 2 5 mm 0 5 mm 00 Vertical magnification 3 100 1 0 1 00 Horizontal magnification 3 100 1 0 1 00 Side to side registration 4 0 2 mm 0 1 00 Focus in full size 5 0 1 00 Focus in enlarge reduce Lens error correction 5 0 1 00 NOTE When performing multiple adjustments perform the items in order from top to bottom Perform each adjustment as explained in th...

Page 278: ...Make a copy of the OS A3 chart 5 Confirm if copy quality is within the adjustment standard 6 If the copy quality is not correct touch the SP Mode key D at the left upper corner of the LCD panel 7 Touch the key E or the key F to change the data then repeat steps 3 to 6 until the copy quality becomes within the adjustment standard 8 Exit the SP mode 1 C F E A B Rev 12 93 D Replacement Adjustment FSM...

Page 279: ...s Fine Adjustment 1 Enter SP mode refer to the service program access procedure and access the side to side registration adjustment mode SP Adjustment PAGE 4 2 Adjust side to side registration for each feed station by changing the SP mode data NOTE Copies can be made in SP mode Touch Copy in SP key to select the paper feed station Adjustment standard Less than 2 mm difference between original and ...

Page 280: ...cedure and access the side to side registration adjustment mode SP Adjustment PAGE4 2 Adjust side to side registration for the duplex tray by changing the SP mode data NOTE Copies can be made in SP mode Touch Copy in SP key to select the paper feed station Adjustment standard Less than 2mm difference between original and copy 3 Change the SP data of each paper feed tray so that it is the same as t...

Page 281: ...This page intentionally left blank B Rev 7 94 A095 A096 A097 5 122 FSM ...

Page 282: ...n across its length 1 Remove the exposure glass See Exposure Glass Removal 2 Position the adjustment wings A so that the side to side copy image density variation is within the adjustment standard 3 Turn on the main switch and enter SP mode then perform the process control data initial setting SP Adjustment PAGE 1 NOTE If uneven density is not solved by this adjustment proceed to the steps 4 and 5...

Page 283: ...sure lamp B should be directly beneath the center of the sight hole C in the reflector cover CAUTION Do not touch the screw D 5 Turn on the main switch and enter SP mode then perform the process control data initial setting SP Adjustment PAGE 1 1 B C A D A C B A095 A096 A097 5 124 FSM ...

Page 284: ...pose To adjust the copy image density How The User Tool image density level mode changes the development bias voltage 1 Enter User Tool mode and access Set operation modes 2 Press the key once 3 Select the appropriate image density level 5 steps adjustment 1 Press the appropriate ID level key A 2 Press the enter key B 4 Press the Menu key C 5 Press the Exit key D to exit User Tool mode 6 Check cop...

Page 285: ...s Purpose To maintain a proper copy image How Turn the 3rd scanner height adjusting cam This changes the 3rd scanner s height 1 Remove the upper right cover A Refer to the upper right cover removal 2 Remove the lens unit cover B 3 Move the third scanner to the far right position A Rev 12 93 B A095 A096 A097 5 126 FSM ...

Page 286: ...off the cover seal A 5 Loosen the Allen screw on the adjusting cam B 6 Adjust the third scanner height by turning the adjusting cam This is a fine adjustment A B Replacement Adjustment FSM 5 127 A095 A096 A097 ...

Page 287: ... 1 screw 2 Peel off the cover seal B 3 Loosen the screws C 4 Rotate the rough adjustment cam D as shown to adjust the third scanner height Black arrow Raise the rear side White arrow Lower the rear side NOTE Normally the cut out of the adjustment cam is at nine o clock 5 Tighten the screw C after the adjustment A D B C C A095 A096 A097 5 128 FSM ...

Page 288: ...age to the Touch Panel 6 Touch a few positions to confirm whether the touch panel is correctly adjusted 7 When a portion of the Touch Panel is touched the corresponding position indicates a mark If this mark is more than 7mm away from the precise point touched press the Clear Stop key and start the adjustment procedure from the beginning 8 If the adjustment is correct press the Enter key to save t...

Page 289: ...meter to CN704 pins 1 and 2 on the AC Drive Board Make a copy the output voltage should be approximately 55 5 VAC This will vary slightly from machine to machine due to variations in the machines and wall voltage If Exposure Lamp AC voltage is out of range Confirm the Exposure Lamp PWM voltage at TP519 on the Optics Control Board refer to the chart below If Exposure Lamp PWM voltage is out of rang...

Page 290: ...ct reset 2 Adjust Grid Voltage to 870 volts see chart below to confirm Grid and Charge PWM 3 Connect meter CN602 on High Voltage Control Board see chart below 4 Make a copy with meter connected to monitor Charge and Grid PWM The 700 to 1200 volt range is provided to illustrate the relationship between Charge and Grid PWM Confirm Development Bias 1 View development bias SP mode Data Out page 2 Deve...

Page 291: ... corresponding to point B above make a second pencil mark 4 Remove the exposure glass then reinstall the left scale 5 Move the first scanner to pencil mark B Look into optics assembly in the upper portion of the third mirror The VL patch or Small VL patch should be visible 6 Move the first scanner to pencil mark A Look into third mirror The VD patch should be visible 7 If either patch is not visib...

Page 292: ...e above During potential sensor calibration the same voltages are applied to the development unit and drum shaft to prevent toner from being transferred to the drum If there is an electrical short or resistance to the frame in the development unit or Rear Development Unit Holder it may effect the VM100 800 voltage Also missing OPC material chips in the surface of the drum may cause VM800 to arc th...

Page 293: ...mp AC Drive Board Optics Control Board Bad Exposure Lamp too bright Insufficient charge on the OPC drum VD If VD data is too high process control sees the VD patch as too dark Possible causes Excessive charge on the OPC drum Dirty optics See If VL data is too high If VD data is too low process control sees the VD patch as too light Possible causes Same as if VL data is too low VR If VR is too high...

Page 294: ...imiter clutch as needed Failure of the Feed Roller Lever Figure 4 Failure of the Feed Roller Lever A0966353 can result in Z folding at the Registration Roller paper feed jamming and copy paper being kicked back into the feed tray during paper feed When replacing the Feed Roller Lever inspect the Feed Roller Shaft AA140498 If it appears polished use Scotchbrite to remove the glazed surface or repla...

Page 295: ...63864 follow the same procedure as item A Figure 1 Item C The Rear Spring Plate A0963860 follow the same procedure as items A B File surface smooth or replace as needed If problems occur with the Transfer Lift Solenoid Figure 2 Install updated parts For details refer to TSB FT6645 55 65 46 A The Transfer Belt Solenoid A0963921 B The Solenoid Bracket A0963922 C The Transfer Belt Casing A0963924 If ...

Page 296: ...rshoot common with other fuser designs 7000 series Please wait warming up during long copy runs Repositioning the Thermistor violates UL standards Any fusing unit modified in this way must be restored to manufacturers standards immediately To avoid toner build up on the Thermistor Figure 2 Install the Thermistor Film A0964209 and apply a thin film of silicone oil At every EM call inspect clean or ...

Page 297: ...xit guide Figure 4 Can become warped causing jams in the Duplex exit area Reform or replace as necessary Jogger Span Adjustment Figure 5 Is the most common cause of Duplex feed out jams Feed a sheet of paper into the duplex unit Pull out Duplex Unit Confirm that the Jogger Fences are 1mm wider than the paper in the Duplex Tray Confirm this for each paper size Duplex Separation Clutch Figure 6 Dupl...

Page 298: ...a lens drive SC code carefully inspect the solder joints and connectors on the harnesses that supply the stepper motors When the lens stepper motors are not rotating 24 volts should be available at all the pins supplying the motor Figure 4 Scanner motor failure can cause SC 125 erratic operation and registration jams If the Scanner Drive Wires come off during operation Refer to TSB s FT6645 55 65 ...

Page 299: ...he Drum in a clockwise direction to insure smooth movement between the Drum and Cleaning Blade Figure 3 Clean and inspect the cleaning brush ground Having a poor ground contact at this point can result in erratic electrical problems stated in the following TSB s FT6645 55 65 7R 31R and 39 update 3 Figure 4 If poor Drum ground is suspected Clean inspect and adjust the Drum ground tab just inside th...

Page 300: ... 895 875 915 265 245 285 345 25 795 775 815 165 145 185 245 126 896 876 916 266 246 286 346 26 796 776 816 166 146 186 246 127 897 877 917 267 247 287 347 27 797 777 817 167 147 187 247 128 898 878 918 268 248 288 348 28 798 778 818 168 148 188 248 129 899 879 919 269 249 289 349 29 799 779 819 169 149 189 249 130 900 880 920 270 250 290 350 30 800 780 820 170 150 190 250 131 901 881 921 271 251 2...

Page 301: ... 826 866 216 196 236 296 177 947 927 967 317 297 337 397 77 847 827 867 217 197 237 297 178 948 928 968 318 298 338 398 78 848 828 868 218 198 238 298 179 949 929 969 319 299 339 399 79 849 829 869 219 199 239 299 180 950 930 970 320 300 340 400 80 850 830 870 220 200 240 300 181 951 931 971 321 301 341 401 81 851 831 871 221 201 241 301 182 952 932 972 322 302 342 402 82 852 832 872 222 202 242 3...

Page 302: ...TROUBLESHOOTING ...

Page 303: ......

Page 304: ...opier cannot be operated at all SC display will not be canceled B The copier can be operated as usual except for the unit related to the service call If the related function is selected this display appears C Only the SC counter is incremented The copier can be operated as usual SC will not be displayed D The SC can be reset by turning main switch off and on if the SC is caused by misdetection Tro...

Page 305: ... and on 4 When an SC condition occurs while in SP mode the display does not indicate the SC number You can recognize the SC condition because in this condition you cannot exit the SP mode by touching the key If this occurs confirm the SC number as follows 1 Perform the same procedure to duplicate the SC condition 2 Enter Copy in SP mode You can see the SC number on the display You can also confirm...

Page 306: ...s control board defective SC104 Exposure lamp malfunction abnormal off Definition level D The scanner start signal is received even if the main relay off condition is detected Possible causes Main relay defective Communication error between the main control board and the optics control board because of a poor harness connection Optics control board defective 1 3 SCANNER SC120 Scanner home position...

Page 307: ...he encoder is lower than the specified speed Possible causes Scanner drive motor defective Optics Control Board defective SC126 High scanner speed Definition level D The scanner speed detected by the optics control board through the encoder is higher than the specified speed Possible causes Scanner drive motor defective Optics control board defective SC127 Scanner drive motor encoder failure Defin...

Page 308: ...lens returns to the home position the lens vertical home position sensor does not detect the off condition for 3 5 seconds or more and more than twice Possible causes Lens vertical home position sensor open Lens vertical drive motor defective Optics control board defective SC142 Lens horizontal home position sensor abnormal stays off Stays OV Definition level D When the lens returns to the home po...

Page 309: ...ble causes 3rd scanner home position sensor shorted 3rd scanner drive motor defective Optics control board defective SC145 3rd scanner home position sensor abnormal stays on Stays 5V Definition level D When the 3rd scanner leaves from the home position the 3rd scanner home position sensor does not detect the off condition OV for 2 0 seconds or more and more than twice Possible causes 3rd scanner h...

Page 310: ...ects a charge corona leakage output 0V for 4 8 msec or detects the output to be more than 7 kV 10 times in one job Possible causes Main charge corona unit defective Main charge power pack defective High voltage control board defective SC303 Charge corona wire cleaner failure Definition level C The current of the charge corona wire cleaner drive motor is over the specified current within 4 seconds ...

Page 311: ...seconds in the toner collection motor on condition Possible causes Toner collection sensor defective Toner collection motor defective Toner clog in the toner collection pipe SC343 Toner collection bottle at improper position Definition level D Toner bottle set switch is off and the front door is closed Possible causes Toner collection bottle set switch defective Toner collection bottle is set inco...

Page 312: ...ive Abnormal toner concentration SC353 Abnormal Vsp Detection Vsp 2 5 V lighter pattern Definition level C Vsp is 2 5 V or higher Possible causes ID sensor defective OPC drum High voltage control board defective Poor contact of the development bias terminal SC354 Abnormal Vsg detection Vsg 2 5 V Definition level C Vsg is 2 5 V or less Possible causes ID sensor defective OPC drum Dirty charge coron...

Page 313: ...D is less than 0 5 V Possible causes Toner density sensor defective Toner concentration is too high SC357 Abnormal Vsp detection Vsp Vsg 25 Definition level C Vsp Vsg is 25 or higher Possible causes ID sensor defective OPC drum Dirty ID sensor SC358 Abnormal Vsp detection Vsp Vsg 2 5 Definition level C Vsp Vsg is less than 2 5 Possible causes ID sensor defective OPC drum Toner scattering A095 A096...

Page 314: ...ensor defective High voltage control board defective Drum shaft terminal not grounded OPC drum Main charge corona unit defective SC364 Abnormal VD detection Definition level C VD is out of specification VR 770 20 V Possible causes Drum potential sensor defective OPC drum Main charge corona unit defective SC365 Abnormal VL detection Definition level C VL is out of specification VR 140 20 V Possible...

Page 315: ...r belt defective Transfer power pack defective Poor contact at transfer bias roller discharge plate terminals High voltage control board defective 1 10 DRUM SC440 Abnormal main motor speed Definition level D OL overload signal stays low in the main motor on condition for 1 0 second or more Possible causes Main motor defective SC442 Drum thermistor open Definition level D The drum thermistor is ope...

Page 316: ...0 seconds or more after the 1st lift motor starts The first time after the paper tray is opened and closed the 1st lift motor starts again If the above condition occurs twice this SC is displayed Possible causes 1st lift sensor shorted 1st lift motor defective Paper feed control board defective SC503 Abnormal 2nd lift motor movement Definition level B The 2nd lift sensor detects the high condition...

Page 317: ...he above condition occurs twice this SC is displayed Possible causes LCT motor defective LCT lift sensor open SC507 Abnormal 3 5 K LCT feed motor movement Definition level B The LCT feed motor OL overload siginal stays low for 1 second or more after this motor starts Possible causes LCT feed motor defective SC508 Abnormal tandem rear fence drive motor movement Definition level B It takes 10 second...

Page 318: ...ositioning sensor stays on blocked for 5 seconds Possible causes Side fence drive motor defective Side fence positioning sensor shorted 1 12 DUPLEX SC520 Abnormal fusing duplex drive motor movement Definition level D The OL overload signal stays low for 1 0 second after the fusing duplex drive motor starts Possible causes Fusing duplex drive motor defective Cleaning roller is too dirty and applies...

Page 319: ...on Possible causes Fusing thermistor open Optics control board defective SC542 Start key stays red Definition level A The fusing temperature does not reach the specified temperature after 5 minutes from turning the main switch on Possible causes Fusing lamp defective AC Drive board defective Thermofuse defective SC543 Fusing overheat detected by the main control board SC544 Fusing overheat detecte...

Page 320: ...d the main relay opens Possible causes AC drive board SC548 Unstable fusing temperature Definition level A If the fusing temperature changes by 21 C second four times in 1 minute this SC is displayed Possible causes AC drive board defective Thermistor defective Countermeasure If this occurs before replacing the optics PCB and main control board check the connection between the main harness and the...

Page 321: ...cate with the high voltage control board Possible causes Main control board defective High voltage control board defective Harness defective SC603 Main control board malfunction CPU Definition level D Communication to the main control board is not completed Possible causes Main control board defective SC620 Communication error main control board and DJF RDH main board Definition level B The main b...

Page 322: ...ition level B Encoder pulse is not detected by the DJF RDH main board in the main motor on condition The first time a jam occurs The second time an SC is displayed Possible causes DJF RDH feed motor defective DJF RDH transport motor defective DJF RDH feed out motor defective RDH inverter motor defective 1 16 FINISHER SORTER STAPLER SC730 Abnormal transport motor A374 A377 sorter staplers A379 fini...

Page 323: ...sher Definition level B The shift tray half turn sensor does not detect the on blocked condition for 2 seconds after the finisher tray shift motor starts The first time a jam is indicated The 2nd time an SC is displayed Possible causes Tray shift motor defective Shift tray half turn sensor defective SC733 Shift tray lift motor A379 finisher Definition level B Stack height sensors 1 or 2 do not det...

Page 324: ...evel B When the gripper moves to the staple position the gripper home position sensor does not detect the off unblocked condition Then a jam is indicated When the gripper moves from the staple position to the bin position the gripper home position sensor does not detect the on blocked condition within 1070 pulses Then a jam is indicated When the gripper moves to the home position the gripper home ...

Page 325: ...staple unit moves forward from the home position and moves back to the home position A jam is indicated If the above conditions occurs twice this SC is displayed Possible causes Staple unit drive motor defective Staple unit home position sensor defective SC741 Abnormal bin rear plate motor movement A377 sorter stapler Definition level B When the rear bin plate is open the bin rear plate open senso...

Page 326: ...Definition level D The total counter stays in the on condition Possible causes Total counter defective SC full used toner bottle Definition level A The toner overflow switch is activated Possible causes Toner collection bottle is full Toner overflow switch defective NOTE Clear the SC full used toner bottle as follows 1 While the main switch is on open the front doors then take out the toner collec...

Page 327: ...C143 is displayed Shorted SC142 is displayed 3rd Scanner HP S 6 511 1 Open SC145 is displayed Shorted SC144 is displayed By Pass Paper End S 7 108 A5 Open Paper end indicator is not displayed even if there is no paper on the by pass feed table Shorted Paper end indicator is displayed even if paper is set on the by pass feed table Guide Plate Position S 8 108 B9 Open Guide plate open indicator is n...

Page 328: ...even if there is no paper Shorted Whenever a copy is made Paper Jam C and D occurs Paper Guide S 17 109 B4 Open Shorted Whenever a duplex copy is made Paper Jam T occurs Auto Image Density S 18 507 1 Open Image density will be abnormal Shorted Original Length 1 S 19 508 8 9 10 Open The CPU cannot properly detect original size APS and AMS do not function correctly Shorted Original Length 2 S 20 509...

Page 329: ...on the paper tray Shorted Paper end indicator is displayed even if paper is set 1st Paper Near End S 30 412 A2 Open Paper near end indicator is not displayed even if the tray is almost empty Shorted Paper near end indicator is displayed even if there is enough paper on the paper tray 1st Paper Feed S 31 402 A1 Open Whenever paper is fed it is folded Shorted Paper jam A indicator is displayed even ...

Page 330: ...pen Whenever paper is fed it is folded Shorted Paper jam A indicator is displayed even if there is no paper 2nd Paper Feed S 41 402 B1 Open Whenever paper is fed it is folded Shorted Paper jam A indicator is displayed even if there is no paper Base Plate Down A096 and A097 copier only S 42 404 A10 Open The bottom plate lift lever locks at the lowest position Shorted The bottom plate is not lowered...

Page 331: ...yed even if the tray is almost empty Shorted Paper near end indicator is displayed even if there is enough paper on the paper tray Tray Down A096 and A097 copier only S 48 403 B2 Open When the bottom plate is lowered it locks at the lowest position Shorted Paper end indicator is displayed even if there is paper on the tray Tray Paper Set A096 and A097 copier only S 49 412 A11 Open The bottom plate...

Page 332: ...ll Used Toner Bottle indicator lights even if the toner bottle is not full Shorted SC Full Used Toner Bottle indicator does not light even if the toner bottle becomes full Toner Collection Bottle Set SW 6 412 B7 Open No caution is displayed on the LCD even if the toner collection bottle is set incorrectly Shorted SC343 is displayed Lower Front Door Safety SW 7 410 1 Open Whenever paper is fed from...

Page 333: ...VDC FU803 125 V 6 3 A Open When the 3rd feed station is selected SC125 is displayed 40VDC FU804 125 V 6 3 A Open When the main switch is turned on SC900 is displayed 24VDC FU805 125 V 6 3 A Open When each feed station is selected the following indication is displayed 1st SC510 or misfeed 2nd Add Paper 3rd SC504 or misfeed When the paper is fed from the By pass or LCT SC342 is displayed 24VDC FU806...

Page 334: ...per going through the copier the machine will return to the normal condition and light copies appear SOLUTION Wipe off the condensed water on the optics and drum then perform the process control data initial setting 2 Uneven image density just after installation SYMPTOM Just after installation up to 50 100 copies the image density solid image at the front and the rear is lighter than the image den...

Page 335: ...t the end of the day turn off the machine for at least 30 minutes fusing temperature should be lower than 100 degrees centigrade 4 Distorted vertical lines SYMPTOM Vertical lines are sometimes distorted if the original is not completely pressed against the exposure glass by the platen cover or DJF RDH Note This is the same situation as previous models FT5590 series FT6750 SOLUTION Instruct the cus...

Page 336: ...he toner hopper agitator shaft scrapes the Toner End Sensor Surface B to keep the surface clean However if the pressure between the sensor and the mylar is too high the sensor may be damaged If this occurs the machine judges that there is toner in the hopper even if the hopper is empty Solution Werecommendperformingstep 2 of thiscountermeasureatmachinesetup installation 1 Replace the Toner End Sen...

Page 337: ...is out of position SOLUTION Set the mylar in the correct position without buckling curling or waving SYMPTOM Originals stick to the exposure glass FT6645 only CAUSE Static electricity built up on the exposure glass SOLUTION Apply a small amount of silicone oil on the exposure glass If this problem occurs frequently because of the kind of originals the customer uses install the FT6655 type exposure...

Page 338: ...tern to maintain precise toner density SYMPTOM The copy counter indicates 8 even if another key for example the Clear Modes key is pressed For instance if the Clear Modes key is touched three times the copy counter indicates 888 CAUSE The grounding wire terminal is touching the operation panel board circuit pattern This may occur after the operation panel is opened to install the guidance ROM s at...

Page 339: ...is closed roughly it bounces slightly to the front disengaging the drawer connectors 2 When the customer pulls out the tandem tray to clear a misfeed paper may drop behind the tray The paper is then caught in the drawer connector at the rear side of the right tandem tray when the tray is pushed back in SOLUTION 1 Instruct the operator to gently push the tandem tray until it stops If any of the abo...

Page 340: ...eet prevents paper from being caught by the upper front stay INSTALLATION PROCEDURE Paper Guide Seal 1 Peel of the seal 2 Adhere the guide seal as shown Paper Guide Sheet 1 Peel off the seals A 2 Adhere the guide sheet B as shown Rev 7 11 94 A Tandem Tray Paper Guide Seal Paper Guide Sheet Upper Front Stay Paper Guide Seal B Trouble shooting FSM 6 37 A095 A096 A097 ...

Page 341: ...ed 4 The erase lamp turns on at the wrong time and position resulting in partially void copy image CAUSE Poor ground connection at one or more of the following points 1 By pass paper size sensor bracket 6 Main corona unit 2 Development unit grounding spring 7 Fusing roller anti static brush 3 Development unit grounding spring plate 8 Drum shaft grounding terminal 4 ID sensor board bracket 9 Cleani...

Page 342: ...te A to the development unit 4 The ID sensor to the ID sensor board bracket via the ground strap this prevents static electricity from arcing between the copy paper and the ID sensor board bracket 5 The pick off pawl tension spring above has been electrically connected to the ID sensor board bracket since the first production machines in December 1993 this prevents arcing between the copy paper an...

Page 343: ...w fixing the ID sensor board bracket 6 Ensure the main charge corona is set properly and is secured to the drum stay with a screw this prevents poor contact at the rear terminal which could result in high voltage leakage 7 The anti static brush A must be in contact with the edge of the fusing roller this prevents static from accumulating on the fusing roller and arcing to nearby metal parts Rev 4 ...

Page 344: ...g may occur this results in electrical malfunction NOTE The drum shaft grounding terminal should be replaced every 360k copies 9 If the grounding wire A is not installed correctly static charge on the cleaning brush may arc to nearby parts this results in electrical malfunction Rev 4 4 94 B A Trouble shooting FSM 6 41 A095 A096 A097 ...

Page 345: ...small object such as a pen or pencil point but DO NOT press too hard to avoid damage to the Touch Panel 2 3 Touch a few positions to confirm whether the touch panel is correctly adjusted NOTE When a portion of the Touch Panel is touched the corresponding position indicates a mark If this mark is more than 7mm away from the precise point touched press the Clear Stop key and start the adjustment pro...

Page 346: ...mum sorter bin capacity for 81 2 x11 and smaller paper from 15 to 30 sheets bin ST24 FT6645 only Prevents cover sheets from being inserted into the middle of copy job following copier misfeed A0965151B A0965153B 2 FT6645 A3355420001 FT6655 A3365420313 FT6665 A3375420001 Main Control Board Prevents black line on front edge when the original is fed by the DJF while in reduction mode Ensures the Eras...

Page 347: ......

Page 348: ...DUAL JOB FEEDER A376 ...

Page 349: ......

Page 350: ...ngthwise A4 lengthwise A4 sideways A5 sideways B4 lengthwise B5 lengthwise B5sideways F 8 x 13 lengthwise 11 x 17 lengthwise 81 2 x 14 lengthwise 81 2 x 11 lengthwise 81 2 x 11 sideways 51 2 x 81 2 lengthwise 51 2 x 81 2 sideways 8 x 13 F lengthwise 81 2 x 13 F4 lengthwise 8 x 101 2 lengthwise 8 x 10 lengthwise 8 x 10 sideways 10 x 14 lengthwise 11 x 15 lengthwise Mixed Original mode Preset mode A...

Page 351: ...ginal Separation Feed and friction belt Original Transport One flat belt Power Source DC24V from the copier 2 0A average Power Consumption 70W Dimensions W x D x H 680 x 508 x 116mm 26 8 x 20 0 x 4 6 Weight 13kg 28 7lb A095 A096 A097 7 2 FSM ...

Page 352: ...on Belt 2 Original Stopper 3 Press Roller 4 Side Fence 5 Original Table 6 Exit Roller 7 Inverter Pawl 8 Inverter Roller 9 Transport Belt 10 Pick up Rollers 11 Pull out Roller 12 Feed Roller 1 7 2 8 3 9 4 10 5 11 6 12 Dual Job Feeder A376 FSM 7 3 A095 A096 A097 ...

Page 353: ... Checks for original misfeeds and sets original stop timing when in auto reverse mode 8 S3 Registration 2 Detects the leading edge of the original to turn off the feed in clutch and to change the feed in belt drive motors speed Also detects the original length 10 S4 Original Width 3 Detects the original width 11 S5 Original Width 1 Detects the original width 12 S6 Original Width 2 Detects the orig...

Page 354: ...nals to the feed roller 9 SOL3 Separation Transmits drive to the separation belts 18 PCBs PCB1 DF Main Board Controls all DJF functions 3 PCB2 Indicator Panel Board Contains operator indicators 21 Switches SW1 Lift Informs the CPU when the DJF is lifted and also serves as the jam reset switch for the DJF 6 SW2 Feed Cover Detects if the feed cover is closed 17 Clutches MC1 Feed in Transmits the fee...

Page 355: ...ies according to the following list Description Q ty 1 Installation procedure 1 2 Stepped screw 2 3 Philips screw with flat washer M5 x 10 2 4 New equipment condition report for 17 27 machines only 1 5 Envelope for 17 machine only 1 A095 A096 A097 7 6 FSM ...

Page 356: ...ving the tape as the tape adheres very strongly to the shaft NOTE If the shaft is out of position the original will not feed CAUTION When installing the Dual Job Feeder DJF make sure that the copier is unplugged 2 If present remove the sensor D from the copier 1 screw NOTE Sensor D is not installed on copiers just out of their box Sensor D is an accessory of the platen cover option Rev 1 20 94 A D...

Page 357: ... screw hole C as shown in the illustration 5 Mount the DJF to the two stepped screws B by aligning the holes in the DJF hinge D and the stepped screws then slide the DJF to the front as shown 6 Secure the DJF to the copier 2 screws M 5 x 10 7 Remove a small cap on the upper rear cover of the copier then connect the connector E and the fiber optic cable connector F CAUTION Locate the fiber optic ca...

Page 358: ...ting the upper dial F NOTE 1 First adjust the DJF height so that the two front stoppers C contact the upper cover then adjust the DJF height so that all four stoppers C and D contact the upper cover B 2 Rotate the right adjusting dial clockwise to lower the left front side of the DJF black arrow in the illustration 3 Rotate the left adjusting dial clockwise to lower the right front side of the DJF...

Page 359: ... not completed even if the gap C is less than 3 mm remove the cover D 4 screws and loosen then tighten 4 screws E Then adjust the height again 9 Plug in the copier and turn on the main switch NOTE The copier automatically recognizes that the DJF has been installed 10 Make copies using the DJF and confirm the copy image Rev 4 15 94 B A C D E A095 A096 A097 7 10 FSM ...

Page 360: ... the original pasted original mode 0 1 0 1 0 1 0 0 0 Exits the original pasted original mode Free run with original 1 0 0 1 0 0 0 0 0 Thick 1 sided original mode 1 0 0 1 0 0 0 1 0 Thin 1 sided original mode 1 0 0 1 1 0 0 0 0 Thick 2 sided original mode 1 0 0 1 1 0 0 1 0 Thin 2 sided original mode 1 0 0 1 0 1 0 0 0 Thick mixed size original mode 1 0 0 1 0 1 0 1 0 Thin mixed size original mode 1 0 0...

Page 361: ...feed out motor speed 5 3 LEDs LED NO FUNCTION 101 Monitors the motor speed too fast 102 Monitors the motor speed normal 103 Monitors the motor speed too slow 5 4 FUSEs FUSE NO FUNCTION 101 Protects the 5 V line 102 Protects the 12 V line 103 Protects the 24 V line from feed in motor failure 104 Protects the 24 V line from belt drive motor failure 105 Protects the 24 V line from feed out motor fail...

Page 362: ...f the copier s main switch 2 Fully raise the DJF then remove the front cover A loosen 4 screws 3 Remove the four screws fixing the transport belt guide assembly B 4 Fold the stay C as shown 5 Remove the transport belt D A B D C Dual Job Feeder A376 FSM 7 13 A095 A096 A097 ...

Page 363: ...the new belt set the belt between the belt guides B 7 While opening the original guide C install the belt guide assembly to the DJF 4 screws 8 Install the front cover D 9 Confirm the DJF height Refer to step 9 of the installation procedure A B D C A095 A096 A097 7 14 FSM ...

Page 364: ...nap ring C 4 Slide the roller D to the rear 5 Hold the feed roller E then slide the shaft to the front then remove the feed roller assembly as shown 6 Remove the four snap rings F then remove the feed rollers 7 Install the new feed rollers then re assemble the machine Rev 1 20 94 A B E F C D Dual Job Feeder A376 FSM 7 15 A095 A096 A097 ...

Page 365: ... feed rollers be careful not to damage the guide mylars D and set the guide mylars correctly as shown 2 When installing the feed roller be sure that the one way bearing silver color is located in the front side the roller must rotate only counter clockwise when the shaft is fixed 3 Do not touch the roller surface with oily hands 4 After this replacement adjust the side to side original registratio...

Page 366: ... main switch 2 Fully raise the DJF then remove the front cover A loosen 4 screws 3 Remove the screw B then remove the feed cover C 4 Remove the bracket D 1 screw 5 Remove the four snap rings E A B C E D Dual Job Feeder A376 FSM 7 17 A095 A096 A097 ...

Page 367: ...aration belt assembly A to the front and remove them 7 Remove the bushings B 8 Remove the pulley C 9 Replace the separation belts D NOTE Do not touch the separation belt with oily hands A B C D A095 A096 A097 7 18 FSM ...

Page 368: ...elt Replacement 2 Remove the right cover A 4 screws 3 Remove the two screws B fixing the transport belt assembly then fold the transport belt stay C as shown 4 Open the original guide D 5 Disconnect the four connectors E 6 Remove the five screws F B B C D A F F E E E Dual Job Feeder A376 FSM 7 19 A095 A096 A097 ...

Page 369: ... the bracket C with the feed out motor from the feed out unit 3 screws NOTE When re installing the bracket be sure to set the arm D on the plunger pin E 10 Remove the pulley F 1 Allen screw G 11 Remove the feed in motor 4 screws H A F G H B C D E A095 A096 A097 7 20 FSM ...

Page 370: ... following 1 The arm B must be set on the plunger pin C 2 Manually pull the inverter solenoid plunger and confirm that when the inverter solenoid does not activate OFF the inverter guide D is inside the outer inverter guide E and when the inverter solenoid activates ON the inverter guide is outside the outer inverter guide as shown A C B D E ON OFF OFF ON Dual Job Feeder A376 FSM 7 21 A095 A096 A0...

Page 371: ...copier 2 Remove the motor cover A 4 screws 3 Remove the DF main control board cover B 4 screws 4 Remove the transport belt Refer to the The Transport Belt Replacement 5 Remove the right cover C 4 screws 6 Remove the belt guide assembly D 6 screws NOTE After re installing the belt guide assembly confirm the DJF height Refer to the procedure 9 of the Installation Procedure A B C D A095 A096 A097 7 2...

Page 372: ...two connectors B 9 Remove the two screws C fixing the belt drive motor bracket 10 While unhooking the pin D from the hole on the feed in motor bracket remove the bracket E with the belt drive motor F 11 Remove the drive pulley 1 Allen screw then replace the belt drive motor 4 screws A B C D E F Dual Job Feeder A376 FSM 7 23 A095 A096 A097 ...

Page 373: ...E 1 Before installing the belt guide assembly A to the DJF set the timing belt B on the drive pulley C 2 Make sure that the timing belt does not touch any harness 3 Do not bend the anti static brush D B C D A A095 A096 A097 7 24 FSM ...

Page 374: ...ng parts 1 Original table A refer to Feed Roller Replacement 2 Feed cover B refer to Separation Belt Replacement 3 Left hinge stay C refer to Belt Drive Motor Replacement 2 Remove the table bracket D 2 screws A B D C Dual Job Feeder A376 FSM 7 25 A095 A096 A097 ...

Page 375: ...feed in unit B 4 screws 5 Replace the feed in clutch C 1 Allen screw NOTE When installing the clutch on the shaft D align the surface of the clutch stopper E and the head of the shaft D as shown A B C E D Rev 4 15 94 D E A095 A096 A097 7 26 FSM ...

Page 376: ... the stopper solenoid pay attention to the following points 1 The spring C must be correctly hooked to the stopper D as shown 2 Manually pull the stopper solenoid plunger to confirm that the press rollers firmly contacts the pick up rollers When the pick up rollers are manually rotated the press rollers also rotate If not adjust the stopper solenoid position A B C D C D Dual Job Feeder A376 FSM 7 ...

Page 377: ...e exposure glass gently raise the DJF so that the original does not move 6 Confirm that the gap between the trailing edge of the paper and the original left scale B is within 2 mm 7 It the gap is larger than 2 mm adjust the registration by using the copier SP mode SP Adjustment PAGE 6 NOTE 1 Before setting the original on the original table again open and close the feed unit cover C 2 After comple...

Page 378: ...r and the left edge C of the original rear scale is 10 2 mm 7 It the gap is not within specification adjust the registration by using the copier SP mode SP Adjustment PAGE 6 NOTE 1 Before setting the original on the original table again open and close the feed unit cover C 2 After completing the adjustment return the DIP switches to their original condition 8 If the registration cannot be adjusted...

Page 379: ... changing the on off combination ofDIP SW 102 3 5mm step as shown in the table NOTE Factory settings are all 0 OFF If DIP SW 102 4 is 0 OFF the distance between the 1st and 2nd copies is wider 102 4 102 3 102 2 102 1 Shift value 0 0 0 0 0 0 0 0 1 3 5 mm 0 0 1 0 7 0 mm 0 0 1 1 10 5 mm 0 1 0 0 14 0 mm 1 0 0 1 3 5 mm 1 0 1 0 7 0 mm 1 0 1 1 10 5 mm 1 1 0 0 14 0 mm A095 A096 A097 7 30 FSM ...

Page 380: ...f the gap between the rear edge of the paper and the original rear scale is 5 2 mm 7 If the gap is not within the specification adjust the registration by using copier s SP mode SP Adjustment PAGE 4 8 It the gap is not within specification by using SP mode loosen the eight screws fixing the original table B and the original guide C and shift the original table and the original guide position accor...

Page 381: ... see the table below 4 Rotate the appropriate VR see the table below so that LED102 green A lights NOTE If the motor rotation speed is too high LED101 red B lights and if too slow LED 103 red C lights 5 Return the DIP switches to their original condition Motor DIP SW VR Feed in 102 1 103 Belt drive 102 2 104 Feed out 102 3 105 A B C VR103 VR104 VR105 DPS101 VR101 DPS102 LED103 SW102 SW101 VR102 LE...

Page 382: ...SORTER STAPLER A377 ...

Page 383: ......

Page 384: ...1 x 17 Minimum paper size A5 51 2 x 81 2 lengthwise Sideways A4 81 2 x 11 Lengthwise A5 51 2 x 81 2 B5 81 2 x 11 Maximum paper weight 157 g m2 42 lb 157 g m2 42 lb 80 g m2 20 lb Minimum paper weight 52 g m2 14 lb 52 g m2 14 lb 64 g m2 17 lb Maximum capacity all sizes 50 sheets bin 2 sided copies 40 sheets bin all sizes 40 sheets bin 2 sided copies 35 sheets bin all sizes 50 sheets Staple Position ...

Page 385: ... cartridge Power Source DC24V from copier Power Consumption Average less than 55W Maximum in sort stack mode less than 55W in staple mode less than 42W Dimensions W x D x H 566 x 583 x 978 mm Weight Approximately 47 kg Rev 4 15 94 A095 A096 A097 8 2 FSM ...

Page 386: ...Transport Rollers 4 Upper Entrance Guide 5 Turn Gate 6 Lower Entrance Guide 7 Sorter Transport Rollers 8 Sorter Exit Rollers 9 Staple Unit 10 Grip Assembly 11 Helical Wheels 12 Jogger Plate 13 Bins 14 Upper Guide Plate 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Sorter Stapler A377 FSM 8 3 A095 A096 A097 ...

Page 387: ...ple Unit Drive Belt 7 Gripper Motor 8 Bin Drive Motor 9 Wheel Drive Belts 10 Grip Drive Belt 11 Jogger Motor 12 Staple Unit Drive Motor 13 Jogger Drive Belts 14 Bin Rear Plate Drive Motor 15 Sorter Exit Drive Belt 16 Sorter Exit Motor 1 2 3 4 5 6 7 8 9 10 12 13 14 15 9 9 5 13 16 5 13 11 A095 A096 A097 8 4 FSM ...

Page 388: ...ger Drives the jogger plate to jog the copies against the front side plate 20 6 Staple Unit Drive Drives the staple unit according to the staple position and angle 23 7 Bin Rear Plate Drive Drives the bin rear plate down and up 24 8 Sorter Exit Delivers the paper into the bins 27 Sensors 1 Bin Jam LED Detects if there is paper jams at the distribution section and detects if there is paper in the b...

Page 389: ...ear Plate Open Detects if the bin rear plate is in the open position 25 14 Bin Rear Plate HP Detects if the bin rear plate is in the home closed position 26 Solenoids 1 Turn Gate Opens and closes the turn gate to direct the copies into either the proof tray or the bins 2 2 Grip Opens and closes the grip arms to grip copies on the bins 12 3 Grip Arm Positioning Moves the grip ass y to the rear and ...

Page 390: ...ting Bracket 1 3 Rear Connecting Bracket 1 4 Staple Cartridge 1 5 Cushion 1 6 Entrance Guide Mylar 1 7 Proof Tray 1 8 Caster Stopper 2 9 Philips Pan Head Screw M4x12 4 10 Philips Screw With Flat Washer M4x6 1 11 New Equipment Condition Report N E C R 1 17 27 machines only 12 Envelope for N E C R 1 17 machine only Sorter Stapler A377 FSM 8 7 A095 A096 A097 ...

Page 391: ...ollowing procedure 1 Remove the strips of tape A and the cushions B 2 Open the front door and remove the inner cover C 3 screws 3 Remove the strip of tape D securing the gripper unit and remove the cushion E Then re install the inner cover C A B B B A A B A C D E A095 A096 A097 8 8 FSM ...

Page 392: ...t connecting bracket B 2 screws M4 x 12 and the rear connecting bracket C 2 screws M4 x 12 on the copier 6 Stick the entrance guide mylar D on the copier exit area as shown NOTE Align the edge E of the cover and the mylar A A C B D E Sorter Stapler A377 FSM 8 9 A095 A096 A097 ...

Page 393: ...al ground and should be connected as shown 8 Connect the 4P connector C and the fiber optic connector D 9 Open the front door of the sorter stapler and remove the screw E fixing the locking lever F then lower the locking lever 10 Stick the cushion G on the proof tray 11 Install the entrance guide plate H 2 screws M4 x 6 which is in the bag on the front door Rev 4 4 94 C D B A E F G H H A095 A096 A...

Page 394: ... raising the locking lever F 13 Secure the locking lever A 1 screw 14 Install the proof tray B 15 If the gap between the top of the sorter stapler and the copier is too great adjust by placing caster stoppers C Rev 4 4 94 C C B A Sorter Stapler A377 FSM 8 11 A095 A096 A097 ...

Page 395: ...re in the initial position 17 Plug in the copier 18 Turn on the main switch of the copier and test the operation of the sorter stapler NOTE The copier automatically recognizes that the sorter stapler has been installed The stapler will not staple for the first 10 or so copies until the first staple moves to the proper position from the cartridge Rev 4 4 94 A B A095 A096 A097 8 12 FSM ...

Page 396: ...tment Value 1 2 3 4 Standard Position 0 0 0 0 5 mm 1 0 0 0 1 1 0 mm 0 1 0 0 1 1 5 mm 1 1 0 0 1 2 0 mm 0 0 1 0 1 2 5 mm 1 0 1 0 1 3 0 mm 0 1 1 0 1 3 5 mm 1 1 1 0 1 direction See the illustration below 0 direction See the illustration below 1 NOTE The adjustment value and the combination of the dip switch positions are exactly the same on DIP SW 101 and DIP SW 102 direction Feed direction direction ...

Page 397: ...5 2 TEST POINTS Number Function TP100 GND TP101 5 V 5 3 FUSES FUSES Connected Point Rated Current and Voltage FUSE100 CN100 3 24 V 250 V T5A FUSE101 CN100 1 5 V 250 V T2A A095 A096 A097 8 14 FSM ...

Page 398: ... door 3 Remove the front inner cover B 3 screws 4 Remove the front wheel cover C 3 screws 5 Remove the four screws fixing the front left cover D and remove the front left cover by shifting the cover up to release the two hooks 6 Remove the front lower cover E 3 screws 7 Remove the front door F 2 hinge pins C B A E F D Sorter Stapler A377 FSM 8 15 A095 A096 A097 ...

Page 399: ... Rear side 1 Remove the rear cover A 4 screws 2 Remove the bottom plate B 2 screws and 1 hook A B A095 A096 A097 8 16 FSM ...

Page 400: ...ctors B and C 2 Hook the cut out D on the stapler on the stepped screw E 3 Install the stapler unit 1 screw NOTE All harnesses should be wired through the cut out F on the stapler cover Do not pinch the harness between the cover and staple unit The two connectors must be put inside the stapler cover 4 Install the front inner cover 3 screws A B C D E F Sorter Stapler A377 FSM 8 17 A095 A096 A097 ...

Page 401: ...A of the upper jogger holder B then pull out the jogger plate C Installation 1 Insert the jogger plate through the upper holder B 2 Push down the jogger plate towards the lower holder D 3 Set the jogger plate in the lower holder D 4 Hook the spring A of the upper jogger holder to the stopper E A B C E D A095 A096 A097 8 18 FSM ...

Page 402: ...refer to Jogger Plate Removal then move the upper jogger holder A to the front side 4 Remove the rear cover then remove the bottom plate to access the drive belt Refer to Exterior Cover Removal section 5 Manually rotate the helical wheel drive belt B and move up the top guide C until the three guide pins D reach the top of the helical wheel as shown A B C D Sorter Stapler A377 FSM 8 19 A095 A096 A...

Page 403: ...lots Then remove the pins E and F from cut outs G and H 7 Move up the next bin to the top position by manually rotating the helical wheel drive belt and remove it as in the top guide removal procedure step 5 and 6 8 Remove the other nineteen bins by repeating step 7 A B C D E F G H A095 A096 A097 8 20 FSM ...

Page 404: ... B to the slot C then lower the rear guide pin to the corner D 2 While still holding the bin rear plate straight insert the front right guide pin E to guide slot F 3 Insert the other guide pins G and H to the slots I and J A E G H C F J E D I B Sorter Stapler A377 FSM 8 21 A095 A096 A097 ...

Page 405: ...stalling the next bin rotate the helical wheels only once Otherwise the distance between the guide pins B become uneven and the bin tilts Good No good 5 Set all bins and the top cover by repeating steps 1 to 4 6 Re install the jogger plate and all covers A B A095 A096 A097 8 22 FSM ...

Page 406: ...over 4 screws 2 Disconnect the connector A 3 Remove the main motor bracket B 4 screws with the main motor 4 Remove all gears and pulleys C D E F 3 E rings 5 Remove the main motor 4 screws A B C D E F Sorter Stapler A377 FSM 8 23 A095 A096 A097 ...

Page 407: ...lenoid C Grip solenoid B and the grip arm positioning solenoid C adjustments It is impossible to perform the fine positioning adjustments for both solenoids because magnets in both solenoids pull the plunger very strongly So mark the original position of each solenoid and remove it Then place the solenoid at the original position by referring to the mark you made D and tighten the screws 4 screws ...

Page 408: ...l board A 6 studs 3 Install the new main control board and set all connectors 4 Position DIP SW101 and 102 as on the original main control board DIP SW 101 and 102 are for staple position adjustment 5 Turn on the copier main switch then confirm the staple position If incorrect adjust the staple position Refer to the Staple Position Adjustment A Sorter Stapler A377 FSM 8 25 A095 A096 A097 ...

Page 409: ...odes key b Enter 107 c Press and hold the clear stop key for three seconds 2 Touch the SP Adjustment key 3 Touch the Prev key A four times to access page 12 4 Adjust the vertical staple position by touching the keys B and the horizontal staple position by touching the keys C NOTE 0 5mm step A B C θ c d a b a c 6 3 mm b 6 3 mm c 6 3 mm d 66 3 mm e 132 2 mm θ 45 5 e A095 A096 A097 8 26 FSM ...

Page 410: ...or Cover and Bins Removal Front Helical wheel 1 Remove the bracket A 4 screws 2 Remove the wheel sensor bracket B 1 screw 3 Unhook the two springs C 4 Loosen the two Allen screws D 5 While holding the pulley E to keep it in position remove the helical wheel F A C C D D E B F Sorter Stapler A377 FSM 8 27 A095 A096 A097 ...

Page 411: ...screws 2 Unhook the spring B at the front side and the spring C at the rear side 3 Loosen the two Allen screws D on the drive pulley 4 While holding the pulley E to keep it in position remove the helical wheel F A E F D C D B E A095 A096 A097 8 28 FSM ...

Page 412: ...el 1 Remove the bracket A 3 screws 2 Loosen the screw B then unhook the tension spring C 3 Loosen the two Allen screws D on the drive pulley 4 Remove the helical wheel E A B C D E D Sorter Stapler A377 FSM 8 29 A095 A096 A097 ...

Page 413: ...ulley E Leave the Allen screws F loosened 3 Set the helical wheel D with the pulley E on the bearing A 4 Set the bracket with the bushing G on top of the helical wheel then install and slightly tighten the three screws H 5 Place a 0 4mm thickness gauge I between the helical wheel and the bushing G on the bracket While holding the bushing down to the helical wheel tighten the three screws H 6 Set t...

Page 414: ...ushing A 3 Set the bracket with the bushing F on top of the helical wheel then install and slightly tighten three screws G 4 Place a 0 4 mm thickness gauge H between the helical wheel E and the bushing F on the bracket While holding the bushing down to the helical wheel tighten the three screws G 5 Hook tension springs I and J then tighten screws K and L A B C J E I K L D F G H E 0 4 mm Sorter Sta...

Page 415: ...w G loosened 4 Set the helical wheel H in the pulley E Leave the Allen screws I loosened 5 Set the bracket with a bushing J on top of the helical wheels then install and slightly tighten the four screws K 6 Place a 0 4 mm thickness gauge L between the helical wheel and the bushing on the bracket While holding the bushing down to the helical wheel H tighten the four screws K 7 Hook tension springs ...

Page 416: ...n guide slots B as shown 3 In this condition tighten all Allen screws C on the helical wheel drive pulleys 2 Allen screws on each drive pulley 4 In this condition place the cut out D on the wheel sensor actuator under the wheel sensor E then tighten the Allen screw on the wheel sensor actuator A B A C C C D E Sorter Stapler A377 FSM 8 33 A095 A096 A097 ...

Page 417: ......

Page 418: ...RECIRCULATING DOCUMENT HANDLER A378 ...

Page 419: ......

Page 420: ...on Feed and Friction Belts system Original Transport One flat belt Original Stop System DC servo motor control system Copying Speed Continuous copy 55 cpm A4S 11 x 81 2 1st feed station Single copy 55 cpm A4S 11 x 8 1 2 1st feed station Number of Cycles per Document Max 30 times Power Source 24V from copier 5 A Power Consumption 70W Dimensions W x D x H 645 x 516 x 132 millimeters 25 4 x 20 4 x 5 ...

Page 421: ... 9 10 1 Friction Belts 2 Feed Roller 3 Original Gate 4 Pick up Rollers 5 Original Stacker 6 Push plate 7 Feed out Rollers 8 Exit Relay Belts 9 Inverter Pawls 10 Inverter Roller 11 Transport Belt 12 Pull out Roller 13 Pulse Generator A095 A096 A097 9 2 FSM ...

Page 422: ...feed out unit 15 M5 Friction Belt Motor Drives the friction belts 21 Solenoids SOL1 Original Gate Solenoid Energizes to open the original gate 22 SOL2 Inverter Solenoid Energizes to invert the original when copying a two sided original 8 SOL3 Push Plate Solenoid Energizes to push the stack of originals to the feed in section 14 Switches SW1 Lift Switch Informs the copier CPU when the RDH is lifted...

Page 423: ...r Sensor Generates the pulses used to measure the original s length 1 S6 Inverter Sensor Sets original stop timing when in auto reverse mode 11 S7 Feed out Sensor Checks for original misfeeds 13 S8 One Turn Sensor Informs the CPU when the pick up roller turns one rotation 6 S9 RDH Position Sensor Informs the CPU when the RDH is being closed so that APS sensor can begin checking the original size 1...

Page 424: ...y 1 Installation Procedure 1 2 RDH Test Chart 1 3 Switch Actuator 1 4 Hinge Stopper 2 5 Shoulder Screw M5 2 6 Shoulder Screw M5 2 7 Shoulder Screw M4 2 8 Philips Pan Head Screw M4 x 6 2 9 NECR for 17 27 machines only 1 10 Envelope NECR for 17 machine only 1 Recirculating Document Handler A378 FSM 9 5 A095 A096 A097 ...

Page 425: ...that the copier is unplugged 1 Remove the tape strips A and the cushion B clamping the belt unit 2 Remove the sensor C from the copier 1 screw NOTE Sensor C is not installed to the copier when it is packed in its box Sensor C is an accessory of the platen cover option A A A B C A095 A096 A097 9 6 FSM ...

Page 426: ...he stepped screws However there are two screw holes available on the right where the stepped screw is to be installed Install the stepped screw into the outer screw hole C as shown in the illustration 5 Mount the RDH to the two stepped screws D by aligning the holes in the RDH hinge E and the stepped screws then slide the RDH to the right as shown B A B C E D Recirculating Document Handler A378 FS...

Page 427: ...ic cable C over the electrical cable B so as not to bend the fiber optic cable C while opening and closing the RDH 8 Install the switch actuator D 1 screw 9 Close the RDH then install the two angle stoppers E 10 Plug in the copier and turn on the main switch NOTE The copier automatically recognizes that the RDH has been installed 11 Make copies using the RDH and confirm the copy image A D E C B A0...

Page 428: ...BLE LED No ON Status LED 1 Motor speed is too high LED 2 Motor speed is normal LED 3 Motor speed is low NOTE While each motor is adjusted if the motor speed is normal LED 2 lights if the motor speed is too high LED 1 lights if the motor speed is too low LED 3 lights Recirculating Document Handler A378 FSM 9 9 A095 A096 A097 ...

Page 429: ...mbinations are set The motors start rotating While SW 3 is held down The motor rotates in the reverse direction Note 2 When these DIP SW combinations are set the motors start rotating While SW 3 is held down the motor rotates slowly Paper Feed DIP SW 2 DIP SW 1 Description 1 2 3 4 1 2 3 4 0 1 0 1 0 0 0 0 Feeds a sheet of paper Scale Registration 0 1 0 0 Feeds a sheet of paper Timing Registration N...

Page 430: ...e Operation Timing Registration Single Side 0 1 Repeat Operation Up to 30 sets 2 1 1 Repeat Operation Limitless Note 1 With these DIP SW combinations press SW 3 to start feeding sheets from a paper stack in and out Each sheet is fed once Note 2 With these DIP SW combinations press SW 3 to feed paper in and out continuously The same stack of sheets is fed in and out repeatedly Free Run Without pape...

Page 431: ...he transport belt unit A 2 screws 3 Slide the belt tension plate B to the left 1 screw then lower the belt tension unit C 4 Replace the transport belt NOTE The RDH belt has to be installed in the notch as shown D The feed out unit E has to be opened when the transport belt unit is reinstalled A B D E C A095 A096 A097 9 12 FSM ...

Page 432: ...t D 4 Remove the feed in unit cover E 4 screws and the paper guide mylar F 2 screws 5 Loosen the feed in unit release button holder pins G then slide the holder to the front and remove the paper feed guide plate H 2 screws 6 Remove the paper feed roller I 3 E rings 1 bearing 2 pins and 2 pull out rollers NOTE Be careful not to lose the pins F I G H a a a E C A D B Recirculating Document Handler A3...

Page 433: ...ON BELT REPLACEMENT 1 Turn off the copier main switch then open the paper feed unit A 2 Remove the paper guide plate B 2 screws 3 Replace the 3 friction belts C 1 E ring and 1 busing B A C A095 A096 A097 9 14 FSM ...

Page 434: ...r exit unit all the way to the left 5 Remove the 2 screws for the transport unit E and open the exit unit Then remove the other 2 screws F 6 Carefully lift the front end of the transport unit G then remove the 4 paper exit transport belts H NOTE Reinstall the inverter solenoid bracket after sliding the paper exit unit all the way to the right D E B C A H F G Recirculating Document Handler A378 FSM...

Page 435: ...for the flexible cable 8 connectors 1 optics cable 1 harness clamp 3 Remove the LED bracket A 1 screw and the flexible cable B 2 screws 4 Remove the main board cover C 2 screws 5 Remove the main control board D NOTE After replacing the main control board perform the leading edge registration and the motor speed adjustments A B C D A095 A096 A097 9 16 FSM ...

Page 436: ... the test chart in platen mode A4 81 2 x 11 sideways 2 Make a copy of the test chart in RDH mode 3 Compare the registration of the copy in platen mode with that in RDH mode and confirm that there is no more than a 1 0 mm difference 4 If the difference is more than 1 0 mm adjust the registration by using the copier s SP mode SP Adjustment PAGE 6 5 Install the RDH rear cover 1 Recirculating Document...

Page 437: ...d mode and confirm that there is no more than a 2 0 mm difference 4 If the difference is more than 2 0 mm remove the left scale A 2 screws then set a sheet of A4 81 2 x 11 sideways paper B on the exposure glass edge as shown NOTE Without the left scale the original jams when it strikes the exposure glass edge This sheet of paper prevents that 5 Set DIP SW 1 and 2 on the main PCB as follows DIP SW ...

Page 438: ...he test chart C does not move from the stop position 9 Confirm that the test chart has stopped at the correct position 10 2 0 mm from the scale edge 0 position D 10 If the test chart did not stop at the correct position adjust the registration by using the copier s SP mode SP Adjustment PAGE 6 3 Turn all DIP SW s off and turn off the main switch then reassemble the machine 4 Check the operation of...

Page 439: ...ar cover 4 screws and set DIP SW 1 and 2 as follows DIP SW DIP SW Combination DPS 2 DPS 1 Description 1 2 3 4 1 2 3 4 1 1 0 1 1 0 0 0 Feed in Motor 1 0 1 0 0 Transport Belt Motor 2 0 0 1 0 Inverter Motor 3 0 0 0 1 Feed out Motor 4 A095 A096 A097 9 20 FSM ...

Page 440: ...pressed ON Turn VR 2 until LED 2 lights 5 Set DIP SW 1 combination 2 The transport belt motor starts Turn VR 1 until LED 2 lights 6 Set DIP SW 1 combination 3 The inverter motor starts turning Turn VR 4 until LED 2 lights 7 Set DIP SW 1 combination 4 The feed out motor starts turning Turn VR 5 until LED 2 lights 8 Check the operation of the RDH 9 Turn all DIP SW s off 10 Reassemble the machine Rev...

Page 441: ......

Page 442: ...FINISHER A379 ...

Page 443: ......

Page 444: ...sheets 81 2 x 11 A4 20 lb 80 g m2 1 000 sheets 81 2 x 14 B4 or larger size 20 lb 80 g m2 Stapler Capacity 81 2 x 11 A4 or smaller size 20 lb 80 g m2 from 2 to 50 sheets 81 2 x 14 B4 or large size 20 lb 80 g m2 from 2 to 30 sheets Staple Replenishment Cartridge exchange 5 000 pieces cartridge Power Source DC 24 V from copier Power Consumption 44 4 W average Weight 35 kg 77 2 lb Rev 4 15 94 Finisher...

Page 445: ...ensions 26 4 x 20 2 x 37 4 671 mm x 514 mm x 950 mm Rev 4 15 94 a 0 24 0 12 6 3 mm b 0 24 0 12 6 3 mm a 0 24 0 12 6 3 mm b 0 24 0 12 6 3 mm a 0 24 0 12 6 3 mm b 5 20 0 08 13 2 2 mm 1 staple 2 staples A095 A096 A097 10 2 FSM ...

Page 446: ...r Feeler 2 Shift Tray 3 Shift Tray Positioning Roller 4 Jogger Unit 5 Positioning Roller 6 Stack Feed out Belt 7 Stapler Unit 8 Alignment Brush Roller 9 Lower Transport Rollers 10 Entrance Rollers 11 Junction Gate 12 Upper Transport Rollers 13 Exit Rollers Finisher A379 FSM 10 3 A095 A096 A097 ...

Page 447: ...side 8 M8 Staple Drives the staple hammer 12 Sensors S1 Entrance Detects copy paper entering into the finisher 25 S2 Jogger Unit Entrance Detects copy paper entering into the jogger unit 18 S3 Jogger Unit Paper Detects copy paper in the jogger unit 6 S4 Stack Feed out Belt HP Detects the home position of the stack feed out belt 15 S5 Jogger HP Detects the jogger home position 16 S6 Exit Detects mi...

Page 448: ... 10 Switches SW1 Front Door Safety Switch Cuts dc power when the front door is opened 26 SW2 Shift Tray Upper Limit Switch Detects the upper limit of the shift tray position 4 Solenoids SOL1 Positioning Roller Lowers the positioning roller in the jogger unit 19 SOL2 Junction Gate Drives the junction gate 21 PCBs PCB1 Main Control Controls overall finisher operation 20 Finisher A379 FSM 10 5 A095 A...

Page 449: ...tor 5 Transport Drive Belt 6 Lower Transport Drive Belt 7 Shift Tray Lift Belt 8 Shift Motor 9 Shift Cam 10 Exit Roller 11 Stack Feed out Motor 12 Jogger Motor 13 Stapler Drive Motor 14 Stapler Drive Belt 15 Jogger Drive Belt 16 Stack Feed out Belt 8 5 6 9 10 1 4 2 3 7 11 13 12 14 15 16 A095 A096 A097 10 6 FSM ...

Page 450: ...ear Connecting Bracket 1 4 Staple Cartridge 1 5 Entrance Guide 1 6 Shift Tray 1 7 NECR for 17 machine only 1 8 Cushion 5 x 10 x 345 1 9 Cushion 5 x 10 x 125 1 10 Cushion 5 x 10 x 637 1 11 Philips Truss Head Screw M4 x 8 4 12 Philips Pan Head Screw M4 x 12 4 13 Philips Screw with Flat Washer M4 x 8 2 14 Envelope NECR for 17 machine only 1 Finisher A379 FSM 10 7 A095 A096 A097 ...

Page 451: ...rting the following procedure 1 Remove the strips of tape A and the cushion B 2 Open the front door and remove the strips of tape C and cushion D 3 Remove the clamp E 1 screw 4 Slide out the staple unit F 5 Remove the strip of tape G A B A C E C F D G A095 A096 A097 10 8 FSM ...

Page 452: ...ont connecting bracket B 2 screws M4 x 12 and the rear connecting bracket C 2 screws M4 x 12 on the copier 8 Stick the entrance guide mylar D on the copier exit area as shown NOTE Align the edge E of the cover and the mylar A C B D D E Finisher A379 FSM 10 9 A095 A096 A097 ...

Page 453: ...iber optic connector D 11 Open the front door of the finisher and remove the screw E fixing the locking lever F then lower the locking lever 12 Stick the cushions G middle H short I long as shown NOTE Stick the cushion G on the metal stay not on the cover Align the upper edge of the cushion H with the edge of the stay J Align the lower edge of the cushion I with the edge of the stay K 13 Install t...

Page 454: ...located between the guides C 15 Secure the locking lever A 1 screw 16 Install the shift tray D with 4 screws M4 x 8 remove tape E 17 Adjust the height of the copier by using the leveling foot F so that the difference in level between the copier and the finisher will be 30 1 mm Rev 4 15 94 E D G A F B C Finisher A379 FSM 10 11 A095 A096 A097 ...

Page 455: ...aple sheets B are in the initial position 19 Plug in the copier 20 Turn on the main switch of the copier and test the operation of the finisher NOTE The copier recognizes automatically that the finisher is installed The stapler will not be stapling for the first 10 or so copies until the first staple comes to the proper position Rev 4 15 94 A B A095 A096 A097 10 12 FSM ...

Page 456: ...n PCB 3 3 LED TABLE LED No ON Status LED1 Motor speed is too high LED3 Motor speed is too low NOTE While each motor is adjusted if the motor speed is normal LED 1 and LED 3 light If the motor speed is too high only LED 1 lights If the motor speed is too low only LED 3 lights There is no LED 2 Finisher A379 FSM 10 13 A095 A096 A097 ...

Page 457: ... 0 1 0 0 0 Shift Tray Mode 1 1 1 0 0 1 0 0 Staple mode 1 1 1 1 0 0 0 1 0 Staple mode 2 1 1 1 0 0 0 0 1 Staple mode 3 Free run test mode starts when SW101 on the main board is pressed and stops when SW102 is pressed If in shift tray mode the finisher works as if 3 sets of 5 LT sized pages are being sorted The shift tray is lowered for each of the 3 sets and then returns to its home position to repe...

Page 458: ...e Mode 1 1 0 10 sheets 1 0 A4 Length wise 0 1 1 0 Staple Mode 2 0 1 30 sheets 0 1 LT Sideways 0 1 0 1 Staple Mode 3 1 1 50 sheets 1 1 LT Length wise Off line test mode starts when SW101 on the main board is pressed and stops when SW102 is pressed The operation of the finisher can be checked without the main copier Finisher A379 FSM 10 15 A095 A096 A097 ...

Page 459: ...et C 1 screw and remove the front door D 4 Remove the lower front cover E 2 screws 5 Remove the front shift cover F 2 screws 6 Remove the rear cover G 4 screws 7 Remove the shift tray H 4 screws 8 Remove the front and rear tray cover I 1 screws at the front 2 screws at the rear 9 Remove the left cover J 4 screws E F G H I J C D A B I A095 A096 A097 10 16 FSM ...

Page 460: ...nsion bracket B 1 screw and 1 spring 4 Remove the E rings C slide out the pulleys D and remove 2 E rings E then remove 2 bushings F 5 Remove the alignment brush roller assembly G 6 Remove the 2 E rings H and remove the brush rollers I NOTE Do not lose the link keys J A C D B E E F F G H I J H I Finisher A379 FSM 10 17 A095 A096 A097 ...

Page 461: ...Remove the stack height sensor actuator A 1 screw 3 Remove the bracket B 1 screw 2 connectors 4 Replace stack height sensor 1 C and stack height sensor 2 D NOTE When reinstalling the bracket B align the edge of the bracket with the stay E C D A B E A095 A096 A097 10 18 FSM ...

Page 462: ...4 4 POSITIONING ROLLER REPLACEMENT 1 Open the front door and slide out the jogger unit 2 Remove the positioning roller A 1 clip A Rev 4 15 94 Finisher A379 FSM 10 19 A095 A096 A097 ...

Page 463: ...nt door and the front shift cover and the front supporting cover 2 screws Adjust the belt B with tightener b Standard 6 mm deflection at 180 100 g pressure 2 Open the front door and slide out the jogger unit Adjust the belt C tension with tightener c Standard 8 mm deflection at 100 30 g pressure Rev 4 15 94 A B A B a b C c C A095 A096 A097 10 20 FSM ...

Page 464: ...3 Open the front door and slide out the jogger unit Adjust the belt D tension with tightener d Standard 8 mm deflection at 150 40 g pressure d D 150 40 g Finisher A379 FSM 10 21 A095 A096 A097 ...

Page 465: ......

Page 466: ...LARGE CAPACITY TRAY A380 ...

Page 467: ......

Page 468: ...er Weight 64 105g m2 16 24lb Power Source DC24V 5V from the copier Power Consumption 40W Dimensions W x D x H 403 x 529 x 608mm 15 9 x 20 8 x 23 9 Weight 19 8kg 43 7lb Tray Capacity 3 500 sheets may vary slightly depending on paper weight Large Capacity Tray A380 FSM 11 1 A095 A096 A097 ...

Page 469: ...2 MECHANICAL COMPONENT LAYOUT 1 Bottom Plate 2 Tray Drive Belt 3 Separation Roller 4 Transport Rollers 5 Feed Roller 6 Pick up Roller 1 2 3 4 6 5 A095 A096 A097 11 2 FSM ...

Page 470: ... off on timing and the pick up solenoid off timing 136 S55 Lift Detects the correct paper feed height 137 Switches SW11 Feed Unit Cover Detects if the feed unit cover is open or not Note There are two switches A and B 128 SW12 LCT Cover Detects if the LCT cover is open or not Note There are three switches A A and B 134 SW13 Tray Down Lowers the LCT bottom plate 135 Motors M22 LCT Lifts and lowers ...

Page 471: ...ist Description Q ty 1 Installation procedure 1 2 New Equipment Condition Report for 17 27 machines only 1 3 LCT feed unit 1 4 Small cover left cover 1 5 Philips pan head screw M4 x 6 1 6 Philips pan head screw M4 x 16 1 7 Tapping screw M4 x 8 1 8 Envelope NECR for 17 machine only 1 A095 A096 A097 11 4 FSM ...

Page 472: ...procedure 1 Remove the four strips of tape A 2 Open the LCT cover B and remove the tape C fixing the paper trailing edge stopper 3 Remove the tray cushion D secured with two strips of tape E 4 Remove the LCT connector F 3 screws A B A A B C D E F Large Capacity Tray A380 FSM 11 5 A095 A096 A097 ...

Page 473: ...ed unit cover C by using a small flat head screw driver D then remove the feed unit cover 6 Remove the harness cover E 7 Install the LCT feed unit F to the copier 3 screws M 4 x 6 CAUTION Do not pinch the harness G located below the by pass table C A D E B C F G A095 A096 A097 11 6 FSM ...

Page 474: ... copier 3 screws M4 x 16 CAUTION When installing the tray unit A to the LCT connector B be careful not to pinch the harness between the feed unit bracket C and the tray unit bracket D as shown below To prevent this fix the harness with a piece of tape as shown on page 11 8 before installing the tray unit Rev 1 20 94 D D B C A F E G C D B A Large Capacity Tray A380 FSM 11 7 A095 A096 A097 ...

Page 475: ...9 Remove the screw fixing the upper cover hinge E then slide and remove the LCT cover F 10 Remove the rear upper cover G 2 screws Rev 1 20 94 Tape A095 A096 A097 11 8 FSM ...

Page 476: ...ace the LCT on the plate B of the LCT connector 12 Move the LCT forward so that the two holes on its assembly are engaged by the two pins C 13 Secure the LCT to the LCT connector 3 screws M 4 x 8 14 Set the cap D in the front screw access hole Rev 1 20 94 A C B D Large Capacity Tray A380 FSM 11 9 A095 A096 A097 ...

Page 477: ...tween the copier and the LCT 3 connectors 13P white 13P red 16P white 2 Between the LCT and the LCT feed unit 2 connectors 10P white 8P white 16 Secure the protective earth wire A on the copier Rev 1 20 94 A A095 A096 A097 11 10 FSM ...

Page 478: ...A 2 screws 18 Install the LCT cover B 1 screw 19 Plug in the copier and check machine operation NOTE The copier automatically recognizes that the LCT has been installed Rev 1 20 94 A B Large Capacity Tray A380 FSM 11 11 A095 A096 A097 ...

Page 479: ...ess the tray down key B to lower the bottom tray 2 Remove the screws C fixing the front and the rear side fences D 3 Tilt the side fences to the right front view and lift to remove 4 Position the side fences according to the paper size 5 Fix the side plates 1 screw each Rev 1 20 94 A A B C D D A095 A096 A097 11 12 FSM ...

Page 480: ...o the paper size 7 Re install the shaft B and the clip A 8 Enter SP mode as follows 1 Press the clear mode key 2 Enter 107 3 Touch the clear stop key for more than 3 seconds 9 Touch the SP Special Features key D Rev 1 20 94 B5 LT A4 B B C A 1 0 7 C D Large Capacity Tray A380 FSM 11 13 A095 A096 A097 ...

Page 481: ...s to select the paper size setting mode page 6 then touch the appropriate paper size of LCT B 11 Touch the Index key C 12 Touch the Quit key D 13 Check the copy quality and machine operation Rev 1 20 94 B A C D A095 A096 A097 11 14 FSM ...

Page 482: ...ove the feed roller C 1 snap ring 4 Remove the separation roller D 1 snap ring NOTE Do not touch the surface of the rollers with oily hands The paper feed rollers used in the LCT are different from rollers used in the 1st 2nd and 3rd feed units in the paper tray unit Rev 1 20 94 A B C D Large Capacity Tray A380 FSM 11 15 A095 A096 A097 ...

Page 483: ...B 3 Remove the harness bracket C 2 screws 4 Remove the bracket D with the LCT feed motor 3 screws 5 Replace the LCT feed clutch E 2 Allen screws NOTE When installing the LCT feed clutch set the stopper pin on the clutch in the cut out F on the bracket Rev 1 20 94 A B C D E F B A095 A096 A097 11 16 FSM ...

Page 484: ... cover A 2 Remove the front cover B 3 Remove the upper cover switches C NOTE When installing the switches set the connectors correctly Yellow Blue Green Small white Large white Rev 1 20 94 A B C Large Capacity Tray A380 FSM 11 17 A095 A096 A097 ...

Page 485: ... mode refer to the service program access procedure and access the side to side adjustment mode SP Adjustment PAGE 4 2 Adjust side to side registration by changing the SP mode data NOTE Copies can be made in SP mode Touch the Copy in SP key to select the paper feed station Adjustment standard less than 2 mm difference between the original and the copy 1 Rev 1 20 94 B A A095 A096 A097 11 18 FSM ...

Page 486: ...SORTER STAPLER A374 ...

Page 487: ......

Page 488: ...ns 20 bins proof tray Bin Capacity Sort mode 30 sheets A4 81 2 x 11 15 sheets A3 11 x 17 Stack mode 15 sheets Proof tray 100 sheets 52 81 g m2 14 22 lb 50 sheets 82 128 g m2 23 34 lb 30 sheets 129 157 g m2 35 42 lb Stapler Capacity From 2 to 20 sheets 80 g m2 20 lb 2 to 10 sheets when using A3 11 x17 or B4 81 2 x14 Stapling Position a b a b 6 2 mm 0 24 0 08 Horizontal a b a 10 2 mm 0 39 0 08 b 16 ...

Page 489: ...ange 3 000 pieces cartridge Power Source DC 24V 5V form the copier Power Consumption 50 W Dimensions W x D x H 412 x 600 x 690 mm 16 2 x 23 6 x 27 1 Weight About 55 1 lb Main Frame 48 5 lb Mounting Frame 3 kg 6 6 A095 A096 A097 12 2 FSM ...

Page 490: ...ay Exit Rollers 3 Vertical Transport Rollers 4 Turn Gate 5 Bin Transport Belt 6 Bin Transport roller 7 Bin Exit Roller 8 Stapler 9 Grip Assembly 10 Bin Support Block 11 Bins 12 Support Bin 13 Jogger Bar 1 2 3 4 5 6 7 8 9 10 11 12 13 Sorter Stapler A374 FSM 12 3 A095 A096 A097 ...

Page 491: ...Belt 15 Bin Transport Drive Gear 14 Bin Transport Belts 17 Vertical Transport Drive Pulley 11 Bin Lift Motor Pulley 8 Bin Lift Drive Belt 7 Bin Lift Gears 6 Bin Lift Gear Pulley 12 Rear Bin Lift Wire 13 Rear Bin Support Block 21 Bin Drive Shaft 20 Front Bin Lift Pully 16 Front Bin Lift Wire 22 Front Bin Support Block 10 Jogger Motor Pulley 13 Lower Jogger Drive Belt 23 Jogger Bar 5 Jogger Drive Sh...

Page 492: ...cting the timing disk 24 or 25 S2 Bin Lift Timing 2 Controls the stop timing of the bin lift motor so that the bin lift timing sensor 1 can detect the timing disk properly 24 or 25 S3 Jogger H P Detects if the jogger bar is in the home position 19 S4 Paper Detects if copies are under the hammer 8 S5 Bin LED Detects if there is paper in the bins light emitting element 3 S6 Bin Photo transistor Dete...

Page 493: ... 14 SW4 Sorter Stapler Set Cuts the dc 24 V line when the sorter stapler unit is open 7 SW5 Staple End Detects the staple end condition 10 SW6 Staple Guide Detects if the staple guide plate is closed 9 SW7 Staple H P Detects if the staple hammer is in the home position 11 A095 A096 A097 12 6 FSM ...

Page 494: ...ics Cable 1 6 Staple Position Decal 1 7 Stepped Screw 1 8 Philips Truss Head Screw M4 x 6 3 9 Philips Truss Head Screw M4 x 14 4 10 Grounding Screw with Toothed Washer M4 x 6 1 11 Envelop N E C R for U S A 1 12 Installation Procedure 1 13 Upper Entrance Guide 1 14 Lower Entrance Guide 1 15 Philips Pan Head Screw M4 x 20 4 16 Tapping Screw M4 x 20 4 Sorter Stapler A374 FSM 12 7 A095 A096 A097 ...

Page 495: ... copier CAUTION Unplug the copier power cord before starting the following procedure 1 Remove the strips of tape A and open the front door B 2 Remove the strips of tape C from the staple unit and close the front door A B C A A A095 A096 A097 12 8 FSM ...

Page 496: ...tes B 4 Release the lock lever C of the sorter stapler and unhook the S S mounting frame D as shown 5 Install the upper guide plate E 2 screws M4 x 6 and the lower guide plate F 2 screws M4 x 6 onto the S S mounting frame C C D B A A E F Sorter Stapler A374 FSM 12 9 A095 A096 A097 ...

Page 497: ...ioning hooks B of the frame are properly inserted in the positioning holes C of the copier 7 Install the sorter stapler D on the S S mounting frame 2 hinge pins at the rear 8 Connect the link lever E with the sorter stapler by using stepped screw F and then close the sorter stapler 9 Install the proof tray G 1 screw M4 x 6 as shown A B C D E F G A095 A096 A097 12 10 FSM ...

Page 498: ...nnector D and the connector E to the mainframe 13 Secure the protective earth wire F on the bracket G 1 protective earth screw with spring washer 14 To prevent the fiber optic cable being pinched by cover round the fiber optic cable through the wire saddles H three times as shown CAUTION Do not bend the fiber optic cable G E D F H B C A Sorter Stapler A374 FSM 12 11 A095 A096 A097 ...

Page 499: ...the harness cover B 2 truss screws M4 x 6 on the sorter stapler 2 truss head screws 17 Stick the staple position decal C on the Dual Job Feeder DJF as shown If there is no DJF stick it on the corresponding position of the platen cover B A C A095 A096 A097 12 12 FSM ...

Page 500: ...staple unit 21 Set the staple unit at the original position close the S S front door and plug in the copier 22 Turn on the copier main switch and test the operation of the sorter stapler NOTE The stapler will not be stapling for the first 10 or so copies until the first staple comes to the proper position from the cartridge The copier automatically recognizes that the sorter stapler has been insta...

Page 501: ...n The sorting operation is repeated from the 1st bin to the 20th bin Operated components Turn gate solenoid Bin lift motor Jogger motor 2 The stapling operation is repeated from the 1st bin to the 20th bin When there is no paper in a bin the stapling operation is skipped for that bin Operated components Bin lift motor Grip motor Stapler motor 3 1 and 2 are repeated together Combinations other than...

Page 502: ... STAPLER REMOVAL 1 Open the front door A of the sorter stapler and swing the staple unit B up 2 Remove the staple unit cover C 1 screw 3 Remove the stapler D 1 screw and 1 connector A B C D Sorter Stapler A374 FSM 12 15 A095 A096 A097 ...

Page 503: ...f tray A 1 screw 2 Swing out the sorter stapler and disconnect the link lever B 1 stepped screw 3 Remove the front cover C remove 2 screws and loosen 2 screws 4 Remove the grip assembly D 2 screws and 1 connector A B C D A095 A096 A097 12 16 FSM ...

Page 504: ...emove the sorter stapler from the copier 2 Remove the proof tray A 1 screw 3 Remove the jogger bar B as shown 4 Remove the upper securing screw of the bin link C 1 screw each A B C Sorter Stapler A374 FSM 12 17 A095 A096 A097 ...

Page 505: ...2 Push the bin forward until the wheels C reach the bend 3 Push the left side of the bin forward and pull that side up 4 As you pull the left side up the right wheel will leave its track 5 When the left wheel reaches the slot D pull the bin out A C D B A095 A096 A097 12 18 FSM ...

Page 506: ... the left side is higher then the right side 3 Pass the left wheel C through the slot D at the same time pass the right wheel E just below the stapler opening 4 Set the left wheel into the left track then push the right wheel into the right track A C D B E Sorter Stapler A374 FSM 12 19 A095 A096 A097 ...

Page 507: ...ove the sorter stapler from the copier 2 Remove the following parts Proof Tray A 1 screw Front Cover B loosen 2 screws and remove 2 screw Rear Cover C 4 screws Support Bin D see Bin Replacement Bins E see Bin Replacement E D A C B A095 A096 A097 12 20 FSM ...

Page 508: ...tor 4 Remove the 3 fixing screws of the stapler unit B 5 Remove the bin support block stopper C as shown 6 Remove the wire pulley D 1 E ring NOTE Be careful not to lose the parallel pin E 7 Remove the bin lift wire F B A E F C D Sorter Stapler A374 FSM 12 21 A095 A096 A097 ...

Page 509: ...ectors and 6 locking supports 9 Remove the bin lift shaft cover B 2 screws 10 Remove the timing sensor bracket C 1 screw 11 Remove the bin drive bracket D 1 grounding screw 1 connector and 2 wire saddles 12 Remove the bushing E B A C D E A095 A096 A097 12 22 FSM ...

Page 510: ... the bin lift block stopper A as shown 13 Remove the wire pulley gear B 2 E rings NOTE Be careful not to lose the parallel pin C 14 Remove the bin lift wire D B A D C Sorter Stapler A374 FSM 12 23 A095 A096 A097 ...

Page 511: ...pulleys 3 Wind the wire once as shown and put the bead F in the slot of the bin support block G 4 Put the bin support block stopper H on the bin support block 5 Place the wire on the pulleys I J K L M N O and put the bead P in the slot of the bin lift shaft Q Front G F H J Q P I D K B A E Rear F G C A E D O Q M H P N L A 550 4 mm 21 67 877 6 mm 34 55 F P A095 A096 A097 12 24 FSM ...

Page 512: ...er cover 3 Remove the upper hinge A 2 screws and the sorter stapler set switch bracket B 1 screw 4 Remove the grounding screw C and disconnect the main harness D 5 connectors and 3 harness clamps 5 Remove the timing belt E from the pulley F 6 Remove the vertical transport unit G 8 screws B A C D F E G Sorter Stapler A374 FSM 12 25 A095 A096 A097 ...

Page 513: ...Remove the proof tray and the rear cover 2 Disconnect the main control board connectors and fiber cable 3 Replace the main control board A and connect the connectors 4 Turn on the copier main switch 5 Adjust the bin sensor see next page 6 Turn off the main switch A A095 A096 A097 12 26 FSM ...

Page 514: ...ment 1 Turn on DIP SW100 5 A 2 If LED100 B is on turn VR100 C counterclockwise until LED100 turns off 3 Turn VR100 clockwise until LED100 just turns on 4 Turn off DIP SW100 5 C B A Sorter Stapler A374 FSM 12 27 A095 A096 A097 ...

Page 515: ...ension adjustment Timing Belt A Roller Drive Motor Proof Tray Rear Cover Timing Belt B Grip Motor Proof Tray Front Cover 2 Adjust the timing belt tension as follows Timing Belt Bending Pressure A 4 mm 0 16 250 50 g B 45 mm 1 77 250 50 g B A a Bending mm inches A095 A096 A097 12 28 FSM ...

Page 516: ...TECHNICAL SERVICE BULLETINS ...

Page 517: ......

Page 518: ... the tray out and gently push the tray back in until it stops and then turn the main power switch OFF and then ON 2 Apply silicone grease G 501 to the points called out in the illustrations below This reduces the friction between the tandem tray and the guide rail which helps the lock lever to position the tandem tray at the correct position If the tandem tray bounces slightly to the front the loc...

Page 519: ... is changed from a resin roller to a metal roller with bearings 3 The spring has been changed so that the tension applied to the tray lock lever is increased from 1 5kgf to 3 0kgf NOTE Because the spring tension has been increased to keep the tandem tray drawing force constant the lock plate C shape is flatter A B C C ...

Page 520: ...pull the tray out and gently push the tray back in until it stops and then turn the main power switch OFF and then ON 2 Apply silicone grease G 501 to the points called out in the illustrations below This reduces the friction between the tandem tray and the guide rail which helps the lock lever to position the tandem tray at the correct position If the tandem tray bounces slightly to the front the...

Page 521: ...eep the tandem tray drawing force constant the lock plate on the Left Rail is flatter REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM AA060570 Tray Lock Spring 20mm Tandem 0 1 1 97 30 AA060592 Lock Spring Tandem Tray 0 1 A0966261 Left Rail 0 1 1 97 20 A0966241 Left Rail Tandem Tray 0 1 A0966266 Tray Lock Arm 0 1 1 97 19 A0966247 Lock Arm Tandem Tray 0 1 A0966246 Left Rail Bracket 0...

Page 522: ...AL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised pages have been highlighted by an arrow Table of Contents vii Updated Information 6 17 Updated Information 6 31 thru 6 36 Additional Information ...

Page 523: ...ENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised pages have been highlighted by an arrow 3 4 Updated Information 3 6 Updated Information 7 7 Updated Information 11 7 Updated Information ...

Page 524: ...lled to the front and the joint part B comes out from the drive shaft SOLUTION The middle roller C position has been changed to the front as shown below FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised pages have been highlighted by an arrow 7 15 Up...

Page 525: ...her system When the following conditions are met the positioning roller A interrupts the paper feed out pawl B resulting in an SC742 condition The previous customer selected the staple mode and did not clear the staple mode after job completion Only one original is being copied More than three copies are made the problem occurs after feeding 4 or more copies NOTE After the software modification wh...

Page 526: ...s this mode 1 Enter SP adjustment mode 00000 2 Touch the Prev key access page 16 extra page 3 Touch the Set key A of the 4th item 4 Input 1 5 Press the enter key on the numeric keypad 00001 CAUSE Software SOLUTION Replace the ROMs on the Main Control Board IC NUMBER OLD PART NUMBER NEW PART NUMBER IC 120 4M Bite A0965121K A0965151 IC 133 1M Bite A0966123K A0965153 ORDERING PROCEDURE To obtain the ...

Page 527: ...e applying power to the unit as serious damage may occur to the new ROM and PCB Power OFF the unit before installing or removing a ROM do not unplug machine Ensure all legs of the ROM are straight and aligned with their corresponding socket hole before placing the ROM completely in its socket Ensure the ROM notch matches the notch etched in the circuit board Pin 1 to Pin 1 When more than one ROM i...

Page 528: ...55 Parts Catalog documentation UPDATE NO 1 PARTS CATALOG CORRECTIONS ADDITIONS Please add the following corrections and additions to your Parts Catalog 1 Correct the illustration on page 20 of the Parts Catalog as shown 2 Correct the illustration on page 80 and add the following part information to page 81 REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM 05730040E Hexagon Headless Set Screw M3 x 40...

Page 529: ...er Holder Set 1 13 50 A0969521 Editing Sheet LT 13 51 A0969520 Editing Sheet A4 13 52 4 Add the index number 33 to the illustration on page 60 as indicated 5 Please correct the part number on page 87 as follows REFERENCE OLD PART NO NEW PART NO DESCRIPTION PAGE ITEM AX400049 AX400053 Anti condensation Heater 240V 18W 87 31 Continued Key Counter Holder Set 33 ...

Page 530: ...bove mentioned fuser jam is removed the selected copy modes are cleared 4 The erase lamp turns on at the wrong time and position resulting in partially void copy image CAUSE Poor ground connection at one or more of the following points 1 By pass paper size sensor bracket 2 Development unit grounding spring 3 Development unit grounding spring plate 4 ID sensor board bracket 5 Pick off pawl shaft SO...

Page 531: ...sensor board bracket via the ground strap this prevents static electricity from arcing between the copy paper and the ID sensor board bracket 5 The pick off pawl tension spring above has been electrically connected to the ID sensor board bracket since the first production machines in December 1993 this prevents arcing between the copy paper and the pick off pawl shaft NOTE A kit containing item 2 ...

Page 532: ...D at the end of the spring to the screw fixing the ID sensor board bracket 6 Ensure the main charge corona is set properly and is secured to the drum stay with a screw this prevents poor contact at the rear terminal which could result in high voltage leakage 7 The anti static brush A must be in contact with the edge of the fusing roller this prevents static from accumulating on the fusing roller a...

Page 533: ...al should be replaced every 360k copies 9 If the grounding wire A is not installed correctly static charge on the cleaning brush may arc to nearby parts this results in electrical malfunction FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised pages ha...

Page 534: ...pick off pawls will wear down with long usage To prevent drum filming and the formation of gray lines on the copy image the pick off pawls must be replaced every 240K copies REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0963510 A0973510 Lower Drum Unit 1 1 1 61 AD025015 AD025018 Pick Off Pawl 2 2 1 61 35 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NE...

Page 535: ...AL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised pages have been highlighted by an arrow 4 58 Updated Information 5 55 Updated Information ...

Page 536: ... front side C to the back side D of the cleaning blade through the gap This air carries a small amount of toner to the back side of the cleaning blade where it gradually accumulates This accumulated toner drops to the drum creating black lines E SOLUTION 1 Clean the back side of the cleaning blade 2 Apply setting powder or toner to the side seals where they touch the cleaning blade 3 Install the c...

Page 537: ...UBJECT FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised pages have been highlighted by an arrow 4 59 Updated Information ...

Page 538: ...is transported after initial installation CAUSE The Scanner Clamp A and or the Transfer Belt Clamp B are not set prior to machine transportation SOLUTION Install the Scanner Clamp A and the Transfer Belt Clamp B as indicated prior to machine transportation These clamps are installed during production and should be retained with each machine B A ...

Page 539: ...ES The revised pages have been highlighted by an arrow 1 2 Updated Information 4 10 Updated Information 4 12 Updated Information 4 24 Updated Information 4 25 Updated Information 4 44 thru 4 46 Updated Information 5 10 Updated Information 5 77 Updated Information 5 78 Updated Information 6 19 Updated Information 7 10 Updated Information 7 26 Updated Information 8 2 Updated Information 9 21 Updated...

Page 540: ... The scanner flat cable and the lens unit cover are installed too close to each other SOLUTION 1 Loosen the two screws C fixing the lens unit cover 2 Pull the lens unit cover A to the front 3 Tighten the two screws C 4 Loosen the screw D fixing the scanner flat cable 5 Turn the scanner flat cable B counterclockwise it can only rotate slightly 6 Tighten the screw D B C A D B A ...

Page 541: ...en increased from two to four REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0961169 A0961173 Fusing Drive Joint 1 1 1 79 15 AB017292 AB017357 Gear 31Z 1 1 1 65 16 UNITS AFFECTED All FT6645 6655 copiers will use the Fusing Drive Joint and Gear as service replacement parts only INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NO...

Page 542: ... 101 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 copiers manufactured after Serial Number A3354450503 and A3364460002 respectively and all FT6665 copiers from first production will have the Bottle Guide Plate Seal and Tapping Screw installed during production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD pa...

Page 543: ...gement projections on the fusing drive joint has been increased from two to four REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0961169 A0961173 Fusing Drive Joint 1 1 1 79 15 AB017292 AB017357 Gear 31Z 1 1 1 65 16 UNITS AFFECTED All FT6645 6655 copiers will use the Fusing Drive Joint and Gear as service replacement parts only ...

Page 544: ...esive labels are fed from the feed trays the angle of the paper path may cause the label to peel off the sheet and become stuck to the feed rollers 4 The customer can load two stacks of copy paper in the Tandem Tray but they can NOT load the built in LCT in the same manner Because there is no paper level detection for the improperly loaded area the LCT lift motor will continue to drive upward even...

Page 545: ... the mylar is too high the sensor may be damaged If this occurs the machine judges that there is toner in the hopper even if the hopper is empty FIELD COUNTERMEASURE 1 Replace the Toner End Sensor A P N AW310003 2 Since replacement of the cleaning mylar is impossible add two 2 0 5mm washers B as shown P N 07080030B thickness 0 5mm inner diameter 3 2mm outer diameter 6mm This will reduce the pressu...

Page 546: ...5 6655 copiers manufactured after Serial Number A3354420001 and A3364420032 respectively will have the new style Toner End Sensor Cleaning Mylar installed during production FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted...

Page 547: ...VICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted by an arrow 3 11 Additional Information 4 14 Additional Information ...

Page 548: ...REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0955110 A0955112 Main Control Board 115V FT6645 1 1 1 89 105 10 A0955115 A0955117 Main Control Board 230V FT6645 1 1 A0965110 A0965112 Main Control Board 115V FT6655 1 1 A0965115 A0965117 Main Control Board 230V FT6655 1 1 A0965121 A0965151 IC AM27C040 150DC 1 1 1 105 1 A0965123 A0965153 IC AM27C010 150DC 1 1 1 105 2 INTERCHANGEABILI...

Page 549: ... Screw with Flat Washer M3 x 6 0 1 61 106 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 copiers manufactured after Serial Number A3354440001 and A3364430119 respectively will have the new style Brush Roller Bracket Agitator Bushing and Gear installed during production UPDATE NO 4 KEY COUNTER HOLDER SET Due to a change in ordering and delivery procedures the Key Counter Holder Set is no longer av...

Page 550: ...ged REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0955110 A0955112 Main Control Board 115V FT6645 1 1 1 89 105 10 A0955115 A0955117 Main Control Board 230V FT6645 1 1 A0965110 A0965112 Main Control Board 115V FT6655 1 1 A0965115 A0965117 Main Control Board 230V FT6655 1 1 A0965121 A0965151 IC AM27C040 150DC 1 1 1 105 1 A0965123 A0965153 IC AM27C010 150DC 1 1 1 105 2 INTERCHANGEA...

Page 551: ...lips Screw with Flat Washer M3 x 6 0 1 61 106 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 copiers manufactured after Serial Number A3354440001 and A3364430119 respectively will have the new style Brush Roller Bracket Agitator Bushing and Gear installed during production UPDATE NO 4 KEY COUNTER HOLDER SET Due to a change in ordering and delivery procedures the Key Counter Holder Set is no longe...

Page 552: ...ounter bracket SOLUTION 1 The fixing plate A has been separated into two parts B so that the distance between the fixing plate and the key counter increases 2 A mylar C P N A5091064 has been added as shown FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The re...

Page 553: ...stance between the Plate Nut and the Key Counter increases 2 A mylar C has been added as shown REFERENCE PART NUMBER DESCRIPTION QTY INT PAGE ITEM A5091260 Holder Cover 0 1 0 12 59 A5091061 Left Plate Nut 0 1 0 12 57 A5091062 Right Plate Nut 0 1 0 12 58 A5091064 Key Counter Holder Mylar 0 1 0 12 56 DENOTES NEW ITEM FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below mu...

Page 554: ...Touch the lower right corner B NOTE When touching the corners use a small object such as a pen or pencil point but DO NOT press too hard to avoid damage to the Touch Panel 2 3 Touch a few positions to confirm whether the touch panel is correctly adjusted NOTE When a portion of the Touch Panel is touched the corresponding position indicates a mark If this mark is more than 7mm away from the precise...

Page 555: ...SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted by an arrow 6 42 Updated Information ...

Page 556: ...ITEM UNITS AFFECTED All FT6645 6655 copiers manufactured after Serial Number A3354420037 and A3364422004 respectively will have the new Cleaning Seals installed during production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machin...

Page 557: ...turn movement of the charge corona wire cleaner the Cleaner Cushion has been added as shown REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM AA161034 Cleaner Cushion 1 59 42 DENOTES NEW ITEM UNITS AFFECTED Not available at time of publication UPDATE NO 4 FLAT WASHER M4 To ensure paper end feeler movement a Flat Washer has been added as shown below REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM 070...

Page 558: ...an 10 C or 50 F the scanner drive wire is more rigid than usual causing the first scanner to overrun the VL pattern SOLUTION To ensure the VL pattern is properly detected an extension called the Small VL Pattern has been added as illustrated below REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A0961739 Small VL Pattern 1 19 27 DENOTES NEW ITEM UNITS AFFECTED Not available at time of publication V...

Page 559: ...first scanner to overrun the VL pattern SOLUTION To ensure the VL pattern is properly detected an extension called the Small VL Pattern has been added as illustrated below REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A0961739 Small VL Pattern 1 19 27 DENOTES NEW ITEM UNITS AFFECTED Not available at time of publication CUSTOMER SERVICE GROUP F S M COPY QUALITY MECHANICAL PARTS PAPER PATH ELECTRI...

Page 560: ...d back in This may result in one or more of the following SC502 Abnormal paper feed drive motor speed SC510 Abnormal tandem side fence home detection stays OFF SC511 Abnormal tandem side fence home detection stays ON SOLUTION To ensure paper is not trapped behind the tandem tray the Paper Guide Seal P N A0966694 and the Paper Guide Sheet P N A0966693 have been added NOTE The Paper Guide Sheet prev...

Page 561: ...QTY PAGE ITEM A0966693 Paper Guide Sheet 1 97 36 A0966694 Paper Guide Seal 1 45 31 DENOTES NEW ITEM UNITS AFFECTED Not available at time of publication FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted by an arrow 6 36 Add...

Page 562: ... Information Please replace Technical Service Bulletin No 6645 6655 023 dated 08 02 94 with this bulletin An error in sequencing was made during distribution of the last bulletin package Control 192 resulting in the existence of two 2 consecutive 6645 6655 023 bulletins Discard the 6645 6655 023 bulletin dated 08 02 94 and retain the 6645 6655 023 bulletin dated 07 11 94 NOTE Since the updated Fie...

Page 563: ...eft and not straight down UNITS AFFECTED All FT6645 6655 copiers manufactured between Serial Numbers A3354450038 A3354470233 and A3364450001 A3364460300 respectively may exhibit the above mentioned symptom All FT6645 6655 copiers manufactured after Serial Numbers A3354470233 and A3364460300 respectively have had the capacitor C103 repositioned toward the ROM so that when pushed the leads will not ...

Page 564: ... Jumper Connector 0 1 12 53 DENOTES NEW ITEM UPDATE NO 2 OPERATION PANEL Please correct your parts catalog as follows INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN ...

Page 565: ... 230V 1 23 17 Correct A0961461 Operation Panel LT 1 17 A0961462 Operation Panel A4 A0967571 Operation Panel Board 220 230V 1 24 17 UPDATE NO 3 STOPPER SPRING To ensure the Side End Fence positioning the tension of the Stopper Spring has been increased from 200gf to 1kgf REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM AA063379 AA066550 Stopper Spring 22mm 2 2 1 43 27 UNITS AFFECTED ...

Page 566: ... 0 1 12 54 A5095100 Key Counter Harness 0 1 12 55 DENOTES NEW ITEM UPDATE NO 2 OPERATION PANEL Please correct your parts catalog as follows INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW mac...

Page 567: ... 230V 1 23 17 Correct A0961461 Operation Panel LT 1 17 A0961462 Operation Panel A4 A0967571 Operation Panel Board 220 230V 1 24 17 UPDATE NO 3 STOPPER SPRING To ensure the Side End Fence positioning the tension of the Stopper Spring has been increased from 200gf to 1kgf REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM AA063379 AA066550 Stopper Spring 22mm 2 2 1 43 27 UNITS AFFECTED ...

Page 568: ...ight tray the operator did not set the paper flush against the right side plate A The rear fences B cannot hold the paper correctly when the tray bottom plate C rises and the paper slides down to the left If this occurs the pick up roller D may not touch the paper and the machine mis detects a paper end condition The left tray then moves toward the right E resulting in the SC508 condition SOLUTION...

Page 569: ...665 SUBJECT FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted by an arrow 4 60 Updated Information ...

Page 570: ...s been changed as shown below REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY PAGE ITEM A0966691 Sensor Bracket FT6655 6665 1 87 6 A0966178 Insulating Sheet 0 2 FT6655 6665 0 3 FT6645 85 16 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 copiers with Serial Number A3354450257 and A3364450002 respectively and all FT6665 copiers from first production will have the new style Sensor Bracket and Insu...

Page 571: ...ROLLER GUIDE MYLAR The Roller Guide Mylars have been added to improve duplex paper feed reliability REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM AA150374 Roller Guide Mylar 0 3 77 44 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 copiers manufactured after Serial Number A3354460237 and A3364460002 respectively and all FT6665 copiers from first production will have the new style Roller Guide My...

Page 572: ...facturing the Wire Fixing Plate has been mounted on the Jogger Support Plate The part number for the Jogger Support Plate remains the same because until now it has not been available as a service part REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0964718 Wire Fixing Plate 2 0 1 77 10 A0964715 A0964715 Jogger Support Plate 2 2 77 11 04340080B Philips Tapping Screw M4 X 8 n n 2 1 ...

Page 573: ...re applied to the Thermistor REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0964211 A0964221 Thermistor 1 1 3 65 3 A0964224 Thermistor Fixing Plate 1 0 3 65 36 A0964209 Thermistor Cover Mylar 0 1 1 65 36 NOTE The Old and New parts are interchangeable as a set UNITS AFFECTED Not available at time of publication Continued Old Thermistor Fixing Plate Thermistor New Thermistor Cover ...

Page 574: ...EFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A0966677 Decal Right Paper Set 0 1 45 32 A0966678 Decal Left Paper Set 0 1 47 29 DENOTES NEW ITEM UNITS AFFECTED FT6645 copiers Not available at time of publication All FT6655 6665 copiers manufactured after Serial Number A3364460244 and A3374460001 respectively will have the Paper Set Decals installed during production Tandem Tray Left Decal Right De...

Page 575: ...C drum Periodically electrical noise which is caused by this arcing affects the 5V lines This noise is transmitted to the main control board resulting in an electrical malfunction This occurs most often just after a new transfer belt is installed in the machine when the electrical resistance of the transfer belt is at its lowest level after 100 200 copies the electrical resistance of the transfer ...

Page 576: ... between the main harness A and the band B 5 Place the remaining core between the band B and the connector C NOTE After installing each Ferrite Core try to slide it along the harness to ensure the core isn t pinching any wires If it can be moved it is installed correctly PERMANENT COUNTERMEASURE A thin copper layer will be added on the Main Control Board to absorb electrical noise UNITS AFFECTED N...

Page 577: ... This noise is transmitted to the main control board resulting in an electrical malfunction This occurs most often just after a new transfer belt is installed in the machine when the electrical resistance of the transfer belt is at its lowest level after 100 200 copies the electrical resistance of the transfer belt stabilizes TEMPORARY COUNTERMEASURE Four 4 Ferrite Cores have been added see Instal...

Page 578: ...ituted for the 115V United States version The 240V version Main Control Board has a double coated copper layer to meet European electrical magnetic compatability standards and has a greater tolerence against electrical noise Therefore the Ferrite Cores added as a temporary countermeasure are not required when the 240V version Main Control Board is used REFERENCE OLD PART NO NEW PART NO DESCRIPTION...

Page 579: ...sing unit roughly the bracket A is gradually tilted and the fusing connector gradually comes out of its socket Finally the poor connection causes a fusing control malfunction The SC code displayed depends on which terminal pins are not connected correctly SOLUTION 1 To prevent the bracket A from tilting install the two Nuts provided in the Fusing Unit Modification Kit see page 2 as shown Continued...

Page 580: ...away to prevent it from being touched by the Stopper UNITS AFFECTED All FT6645 6655 copiers manufactured after Serial Number A3354460068 and A3364460001 respectively will have the new style Fusing Unit part modifications installed during production FUSING UNIT MODIFICATION KIT A0969902 A kit has been made available to correct the symptoms described in this bulletin The Fusing Unit Modification Kit...

Page 581: ... connection causes a fusing control malfunction The SC code displayed depends on which terminal pins are not connected correctly SOLUTION 1 To prevent the bracket A from tilting the Fusing Unit Rail has been modified so that it can be connected to the rear frame of the copier with a screw Also to avoid interference between the Fusing Unit Release Lever and the Toner Bottle the Fusing Lock Lever ha...

Page 582: ...anged the Fusing Unit Front Cover has also been changed Part of the cover has been cut away to prevent it from being touched by the Stopper REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0964251 A0964249 Fusing Unit Rail 1 1 1 99 12 A0964272 A0964273 Fusing Unit Stopper 1 1 1 99 13 04340080B Philips Tapping Screw M4 x 8 n n 1 99 110 A0964261 A0964260 Fusing Lock Lever 1 1 1 99 11...

Page 583: ... described in this bulletin The Fusing Unit Modification Kit A0969902 contains the following items 1 two thumb screw type Nuts 2 one Fusing Unit Stopper 3 one Fusing Unit Front Cover NOTE To prevent the Fusing Unit Bracket from tilting install the two 2 Nuts contained in the Modification Kit as shown above ORDERING PROCEDURE Ricoh Corporation will automatically ship one Fusing Unit Modification Ki...

Page 584: ...O DESCRIPTION QTY INT PAGE ITEM G0134566 Thermistor Spring 1 0 1 63 11 AA063531 Pressure Spring 12mm 0 1 UNITS AFFECTED All FT6665 copiers have had the Pressure Spring installed since first production FT6645 6655 copier Serial Number production cut ins are not available at time of publication UPDATE NO 2 Please correct your Parts Catalog as follows 1 Parts Catalog Correction REFERENCE INCORRECT PA...

Page 585: ...ing Wire 1 89 31 DENOTES NEW ITEM REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM AX520020 Exposure Lamp 115V A097 1 27 6 Symbol No Symbol No C300 172 DENOTES NEW ITEM 3 Please eliminate the following parts from your Parts Catalog REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A0961878 1st Mirror Support Plate 1 0 27 12 A0961879 1st Mirror Cushion 1 0 27 10 Continued 102 31 102 eliminate 10 and 1...

Page 586: ...e at time of publication UPDATE NO 4 PAPER GUIDE SEAL 2 3 When the customer pulls out the tray to clear a misfeed it is possible for paper to drop behind the tray This can occur when the leading edge of the paper stops between the feed roller and the separation roller but has not reached the vertical transport roller To avoid this the Paper Guide Seal has been added as shown The function of the Se...

Page 587: ...CRIPTION QTY INT PAGE ITEM AF021016 AF022084 Lower Fusing Exit Roller 2 2 1 67 17 UNITS AFFECTED All FT6645 copiers manufactured after Serial Number A3354070083 will have the new style Lower Fusing Exit Roller installed during production FT6655 6665 copier Serial Number production cut ins are not available at time of publication UPDATE NO 6 Please correct your Parts Catalog as follows 1 Correct th...

Page 588: ...sher M3 x 1 n 47 107 09653008W Tapping Screw with Flat Washer M3 x 8 n 47 107 5 The Circuit Breaker mentioned on page 91 item 106 is that for the 115V machine The Circuit Breaker used for the 220V machine is a different type Please correct your Parts Catalog as follows REFERENCE INCORRECT PART NO CORRECT PART NO DESCRIPTION QTY PAGE ITEM 11070693 Circuit Breaker 18A 250V 1 91 106 11070693 Circuit ...

Page 589: ...he poor connection results in a defective dc motor 1 5K LCT UNITS AFFECTED FT6655 6665 copier Serial Number production cut ins are not available at time of publication UPDATE NO 8 CLEANER CUSHION To ensure the return movement of the corona wire cleaner the material of the Cleaner Cushion has been changed REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM AA161034 AA161105 Cleaner Cush...

Page 590: ...ates an original misfeed Countermeasure The machine does not enter the Screen Saver Mode while Auto Counting originals UPDATE NO 2 OPERATING TIME INDICATION IS INCORRECT During normal operation the time remaining before the end of the copy job is indicated by animation on the touch panel screen However during duplex mode when using the RDH and Finisher the indicated time was incorrect Countermeasu...

Page 591: ...ying However when using Cover Sheet Mode either 2 in 1 Mode or Duplex Copy Mode the copy job is completed on copy paper fed from the Cover Sheet tray in Cover Sheet Mode cover sheets should be placed only at the top and the bottom of a copy set Countermeasure When using Cover Sheet Modes cover sheets are placed only at the top and the bottom of a copy set After a paper misfeed occurs and is cleare...

Page 592: ... Remove the Side Fences C 1 screw each 5 Remove the Tray Bottom Plate D 4 screws 6 After cleaning the bracket surface E adhere the Lower Sensor Actuator Extension F as illustrated This increases the length of the actuator by 1 5mm NOTE After these modifications the LCT lock release position is 3 5mm lower than before UNITS AFFECTED All FT6645 6655 6665 copiers manufactured after Serial Number A335...

Page 593: ... 1 2 3 4 5 All serial number information will be verified before shipment is made NOTE Old ROMs must be returned within five 5 days to Ricoh Corporation 146 148 Sound Beach Avenue Old Greenwich CT 06870 CAUTION Whenever upgrading the old Main Control Board ROMs to the new version ROMs in the field you MUST also perform the mechanical modification described on page 3 FT6655 6665 only Replacing the ...

Page 594: ...CE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted by an arrow table of contents vii Updated information 6 43 Additional Information ...

Page 595: ...the Entrance Transport Assembly to remain down even if the front door of the machine is open When this condition exists pulling out the Duplex Unit will break the Duplex Paper End Sensor Feeler 2 The Arm Release Spring C has insufficient tension to raise the Duplex Entrance Assembly when the copier front door is opened When this condition exists pulling out the Duplex Unit will break the Duplex Pa...

Page 596: ... Arm Release Spring AA066224 has been changed so that the spring tension is increased UNITS AFFECTED All FT6645 6655 6665 copiers manufactured after Serial Number A335543XXXX A336543XXXX and A337543XXXX respectively will have the new style Arm Release Spring installed during production ...

Page 597: ...e and the LCT is connected while the main switch of the mainframe is turned ON the IC on the Motor Control Board which controls the Paper Feed Motor is destroyed Depending on the extent of the damage to the IC prior to displaying SC507 one or more of the following symptoms may be observed Paper Feed Motor hesitation Skew Varying registration SOLUTION DO NOT connect the LCT Harness to the mainframe...

Page 598: ...ce the pressure applied to the carrier the Entrance Seal has been modified as shown Because of the unique shape of the new style Entrance Seal it absorbs the fluctuating excess pressure of the developer so that there is not enough pressure to scratch the OPC surface NOTE Refer to the Field Service Manual page 5 43 for the Entrance Seal replacement procedure UNITS AFFECTED All FT6645 6655 copiers m...

Page 599: ... after Serial Number A3354470106 and A3364470002 respectively and all FT6665 copiers from first production have had the doctor gap adjusted to the narrower specification during production PERMANENT PRODUCTION COUNTERMEASURE The new style Entrance Seal described in the FIELD COUNTERMEASURE on Page 1 has been applied to the production machines REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PA...

Page 600: ... has been changed slightly REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0964760 A0964763 Rear Jogger Fence 1 1 1 73 17 AA150362 Mylar 0 1 73 43 A0964926 A0964938 Roller Holder Bracket 1 1 1 AS A SET 75 42 A0964927 A0964939 Lower Transport Guide 1 1 75 29 04140082B Binding Self Tapping Screw M4x8 n n 4 75 102 DENOTES NEW ITEM INTERCHANGEABILITY CHART 0 OLD and NEW parts can be u...

Page 601: ...R SEAL To prevent toner contamination on the front edge of the Transfer Belt the Rubber Seal has been added REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A0963940 Front Rubber Seal 1 63 45 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 6665 copiers will utilize the new style Roller Holder Bracket and Mylar as service parts only UPDATE NO 3 GROUNDING WIRE To reduce electrical noise the grounding...

Page 602: ...g Wire installed during production FT6645 6655 Seial Number cut ins not available at time of publication UPDATE NO 4 PARTS CATALOG CORRECTION Please correct your Parts Catalog as follows REFERENCE INCORRECT PART NO CORRECT PART NO DESCRIPTION PAGE ITEM A0964487 Upper Exit Guide 69 8 A0964478 A0975140 Optics Control Board FT6665 89 1 A0975150 A0965441 Drum Unit Harness 95 18 A0965441 Drum Unit Harn...

Page 603: ...s high or when the copy volume is high especially when duplex copying SOLUTION To increase drum cleaning efficiency a new style cleaning brush has been developed for use with machines exhibiting the above mentioned symptom The new style brush A0969523 contains fewer bristles however the diameter of the bristles has been increased NOTE The new style Cleaning Brush should be used only for units exhi...

Page 604: ...se drum cleaning efficiency a new style Cleaning Brush has been developed for use with machines exhibiting the above mentioned symptom The new style Cleaning Brush AD042032 contains fewer bristles however the diameter of the bristles have been increased When installing the new Cleaning Brush the developer should also be replaced because the paper dust in the developer may cause Medaka Replacing th...

Page 605: ...e clutch face plate Wipe off excess oil reassemble clutch 2 Replace the Feed Clutch AX210037 PRODUCTION COUNTERMEASURE The following measures have been taken to prevent the formation of rust on the Feed Clutches during and after the manufacturing process 1 The material used in the washing process has been changed from water to oil 2 To prevent perspiration from contacting the clutch rubber gloves ...

Page 606: ...ed CAUSE Poor solder joints at the switches corresponding to the above mentioned key s on the Key Board A0961517 NOTE When this condition exists the customer may repeatedly push the keys resulting in damage to the Operation Panel PCB FIELD COUNTERMEASURE Re solder the affected switches on the Operation Panel PCB PRODUCTION COUNTERMEASURE The amount of solder used has been strictly controlled since...

Page 607: ...ts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units manufactured prior to the S N cut in On units manu...

Page 608: ...0040B Retaining Ring M4 n n 4 81 107 A0961127 Registration Drive Unit 0 1 81 48 AB030392 Pulley 18Z 0 1 81 39 AA043404 Timing Belt 266P2M4 0 1 81 40 AA066220 Tension Spring 0 1 81 41 A0961136 Tightener 0 1 81 42 AA145799 Drive Shaft 0 1 81 43 AA080198 Bushing 6 x 10 x 4 0 2 81 44 A0961174 Drive Support Bracket 0 1 81 45 AB015012 Gear 12Z 0 1 81 46 08073005 Washer Reverse Gear 0 1 81 113 04340080B ...

Page 609: ...ctors the tension of the Connector Spring has been increased Also to prevent a poor connection caused by an over adjustment for side to side registration of the 1 5K LCT a screw hole on the LCT stopper has been shortened as shown in the illustration below NOTE The same Stopper is used on the Tandem Tray REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM AA063259 AA063286 Connector Spr...

Page 610: ...RIPTION QTY INT PAGE ITEM AB013770 AB013984 Gear 24Z 1 1 1 81 35 A0961125 A0961126 Belt Drive Shaft 1 1 1 81 36 UNITS AFFECTED Not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CA...

Page 611: ...ntermeasure the material of the Left Scale has been changed from ABS to Polycarbonate and the grooves on the back side have been removed REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0961904 A0971736 Left Scale LT 1 1 1 19 1 A0961901 A0971731 Left Scale A4 1 1 1 19 1 UNITS AFFECTED Not available at time of publication UPDATE NO 4 BELT UNIT KNOB If the Belt Unit Knob is rotated e...

Page 612: ...E Inspect and resolder the broken lead to the motor PRODUCTION COUNTERMEASURE To prevent this problem the direction the wire is attached and the soldering method used have been changed UNITS AFFECTED All FT6645 6655 6665 copiers manufactured prior to May 1995 may exhibit this symptom Note This copy intended as master of original for reproduction of additional bulletins CUSTOMER SERVICE GROUP F S M...

Page 613: ...d 1 1 3 S 63 22 A0963918 A0963922 Solenoid Bracket 1 1 3 S 63 23 A0963901 A0963924 Transfer Belt Casing 1 1 3 S 63 32 UNITS AFFECTED Not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD pa...

Page 614: ...PART NO DESCRIPTION QTY INT PAGE ITEM AA066224 AA066275 Arm Release Spring 1 1 1 93 2 UNITS AFFECTED Not available at time of publication UPDATE NO 3 PARTS CATALOG CORRECTION Correct your Parts Catalog as follows REFERENCE PART NUMBER DESCRIPTION ITEM PAGE INCORRECT CORRECT A0961508 Grounding Plate 11 16 17 A0961513 LCD Display Sheet 16 11 17 PART ILLUSTRATION MISSING FROM PAGE 16 Arm Release Spri...

Page 615: ... replacement pages PAGES The revised areas have been highlighted by an arrow 4 58 Additional Information PM Table Addition 4 59 Additional Information PM Table Addition 4 64 Additional Information PM Procedure Addition 4 67 Additional Information PM Procedure Addition 4 69 Additional Information PM Procedure Addition 4 70 Additional Information PM Procedure Addition Note This copy intended as mast...

Page 616: ...PDATE NO 1 DRIVE SHAFT Correct the illustration on page 82 and the part number description on page 83 of the Parts Catalog as shown below REFERENCE INCORRECT PART NO CORRECT PART NO DESCRIPTION QTY INT PAGE ITEM AA145212 Upper Drive Shaft 1 1 1 83 26 AA145211 Lower Drive Shaft Continued Note This copy intended as master of original for reproduction of additional bulletins CUSTOMER SERVICE GROUP F ...

Page 617: ... Operation Panel you must also order the Operation Panel Board A0967560 separately This is because item 23 is different for each market the machine is sold in Also add the part number and description for the Sheet item 25 to your Parts Catalog REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A0961505 Sheet 0 1 17 25 Item 23 is not included in the Operation Panel assembly Add the Sheet item 25 to yo...

Page 618: ...IPTION QTY INT PAGE ITEM A0966283 Cushion Rear Plate 0 1 100 41 A0966174 A0966158 Paper Tray Stopper 2 2 3 87 19 A0966190 A0966191 Middle Guide Plate 1 1 0 101 34 A0966342 A0966362 Paper End Feeler 3 3 1 39 9 A0966360 Paper Flattener 6 3 39 23 A0966363 Paper Flattener 0 3 1 39 62 DENOTES NEW ITEM INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN ...

Page 619: ...ion UPDATE NO 2 GRIP COVER Due to part standardization the front cover grip area has been changed as shown The new type has a self tension structure which has eliminated the grip spring of the old type REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0961323 A0961382 Grip Cover 1 1 1 13 20 A0961324 A0961383 Grip Inner Cover 1 1 1 13 19 AA066110 Grip Spring 1 0 13 34 UNITS AFFECTED ...

Page 620: ...in Board Left Hinge Connector Support Plate DC PCU Connector Bracket and Connector Bracket shown below have been combined as the AC Drive Bracket REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0965506 Left Hinge Main Board 1 0 95 5 A0965520 Connector Support Plate 1 0 95 10 A0965522 Connector Bracket DC PCU 1 0 95 11 A0965523 Connector Bracket 1 0 95 12 A0965514 AC Drive Bracket ...

Page 621: ...the Jogger Sensor Bracket has been added as indicated below REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0964762 Jogger Sensor Bracket 0 1 73 45 A0964886 Duplex Lock Arm 0 1 73 44 A0964883 A0964887 Duplex Lock Lever 1 1 3 73 3 A0964894 A0964895 Duplex Harness Bracket 1 1 3 75 26 04340080B Philips Tapping Screw M4 X 8 n n 2 75 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 6665...

Page 622: ...D and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units manufactured prior to the S N cut in On units manufactured aft er the S N c...

Page 623: ...eable UNITS AFFECTED Not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD...

Page 624: ...66559 Tension Spring 0 1 3 S 47 30 DENOTES NEW ITEM UNITS AFFECTED Not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in...

Page 625: ...6 AA066559 Tension Spring 0 1 3 S 47 30 DENOTES NEW ITEM UNITS AFFECTED Not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be us...

Page 626: ...NTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units manufactu...

Page 627: ... 4 x 6 x 1 2 0 63 10 A1763863 Spacer 4 x 6 x 2 0 1 1 UNITS AFFECTED Not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used i...

Page 628: ...al Sensor Ass y H 3 50 1 1 0 19 11 AA150337 AA150379 Rear Shielding Mylar 1 1 3 31 6 A0961792 A1761792 Rear Shielding Bracket 1 1 3 31 5 A0961821 A1761821 2nd Optics Cover 1 1 3 19 21 A0961835 A1761835 Optics Shielding Belt 1 1 3 31 2 A0961842 A1761842 Rear Optics Cover 1 1 3 19 12 A0961874 A1761874 Harness Guide Plate 1 1 3 19 8 A0961825 A1761825 Main Optics Cover 1 1 1 19 5 AA132163 A1761849 Shi...

Page 629: ... 1 3 23 31 11026245 11026283 Connector 2P 1 1 1 23 117 11026246 11026284 Connector 3P 1 1 1 23 118 11026247 11026285 Connector 4P 1 1 1 23 120 11026260 11026285 Connector 3P 1 1 1 23 119 A0961816 A0971816 Sensor Bracket Lens Position 1 1 3 23 21 A0961994 A0971994 Filter Holder 1 1 0 21 11 AA150336 AA150378 Front Shielding Mylar 1 1 0 31 7 A0961766 A0971766 Lens Slider 1 1 0 31 11 AC051013 AC051016...

Page 630: ...cations have been applied NOTE For information regarding Energy Star Office Equipment refer to Publications Bulletin PUB 066 1 A main switch with an internal relay is now used for the auto off function 2 The main switch bracket and the upper left cover have been changed since the is larger than the old type 3 To control the relay in the new type switch the harnesses shown below have been changed N...

Page 631: ...ontrol Board 115V A095 1 1 3 105 A0965442 A0965113 Main Control Board 115V A096 A097 1 1 3 105 A0965151 A0965155 IC AM27C040 150DC 1 1 3 105 1 A0965153 A0965157 IC AM27C010 120DC 1 1 3 105 2 UNITS AFFECTED All FT6645 6655 6665 copiers manufactured after Serial Number A3356410371 A3366410281 and A3376410001 respectively will have the new style Main Switch etc installed during production UPDATE NO 6...

Page 632: ...PART NO DESCRIPTION QTY PAGE ITEM A0963249 Spring Hook Plate 0 1 57 36 AA060262 Spring 1 2 57 33 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 6665 copiers manufactured after Serial Number A3355500591 A3365500001 and A337550XXXX respectively will have the Spring Hook Plate and additional Spring installed during production CUSTOMER SERVICE GROUP MECHANICAL PAPER PATH ELECTRICAL OTHER Note This co...

Page 633: ... added REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY PAGE ITEM A0963249 Spring Hook Plate 0 1 57 36 AA060262 Spring 1 2 57 33 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 6665 copiers manufactured after Serial Number A3355500591 A3365500001 and A337550XXXX respectively will have the Spring Hook Plate and additional Spring installed during production Continued CUSTOMER SERVICE GROUP MECHANIC...

Page 634: ... spring NOTE The part number for the Toner Bottle Holder has not been changed UNITS AFFECTED All FT6645 6655 6665 copiers manufactured after Serial Number A335602XXXX A336602XXXX and A337602XXXX respectively will have the new style Toner Bottle Holder installed in place of the Spring Hook Plate during production The Spring Hook Plate has been removed Toner Bottle Holder Tab New Type ...

Page 635: ...ublication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on uni...

Page 636: ...s a mandatory standard feature of Energy Star compliant equipment The weekly timer feature for the FT6645 6655 6665 is no longer available 2 For part number information refer to Tech Service Bulletin No 6645 6655 6665 054 Update No 5 AUTO DUPLEX MODE To save paper resources the following have been selected as factory default settings and can be changed with User Program 5 Copiers with a document f...

Page 637: ...ater connectors if necessary CAUTION Unplug the copier power cord before setting the anti condensation heater connectors This is because even though the main switch may be turned OFF AC current is still supplied to the anti condensation circuit INSTRUCTION SHEET An additional explanation sheet has been added to the Operating Instructions Please make copies of pages 3 4 and 5 of this bulletin and a...

Page 638: ...cause of the Auto Off mode To conserve energy this copier model automatically turns off 90 minutes after the last copying job has been completed Power consumption is reduced from 0 25 kW standby to less than 0 01 kW To exit the Auto Off Mode turn on the main switch The main switch for this copier has three positions press it all the way and hold for 1 2 seconds Changing The Auto Off Timer 1 Press ...

Page 639: ...ing Program 5 Copiers with the document feeder and the sorter stapler are set for two sided copies from an even number of originals Copiers with the recirculating document handler and the finisher are set for two sided copies from one sided originals Canceling The Duplex Default Mode To cancel the Duplex Default mode store one sided copy mode in Program 5 as follows 1 Press the Clear Modes key 2 T...

Page 640: ... can select either Two sided copies from an odd number of originals or Two sided copies from two sided originals For the finisher system you can select Two sided copies from two sided originals 3 Press the Program key 4 Touch the Store Program key 5 Touch the 5 key Then the display show Program 5 has been stored Do you want to revise the program 6 Touch the Yes key to overwrite a new program 7 Tou...

Page 641: ...se and the Key Board have been changed Important Due to a change of vendors the old type parts are no longer available as service parts Please replace these parts as a set INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD ...

Page 642: ...p Sheet 1 1 3 17 9 A0961507 A0961523 Left Keytop Sheet 1 1 3 17 10 A0961517 A0961525 Key Board 115V 1 1 3 S 17 18 A0961518 A0961526 Key Board 220 230V 1 1 3 S 17 18 A0961511 Grounding Harness 1 1 0 17 14 A0961521 Grounding Harness 2 1 0 17 15 UNITS AFFECTED All FT6645 6655 6665 copiers manufactured after Serial Number A33509XXXX A336509XXXX and A337509XXXX respectively will have the new style Oper...

Page 643: ...iginals Confirmation can be done by pressing the Check Modes key If Even is not displayed on the Duplex Series Copies tag the correction has been performed successfully NOTE 1 If the default mode is changed to single side copying or two sided to two sided duplexing selecting the one sided to two sided mode will not cause the above mentioned problem 2 The above procedure is to be done one time only...

Page 644: ...vent the gas from leaking onto the left door This information should be incorporated into all existing FT6645 6655 6665 Parts Catalog documentation REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A1761328 Left Door Seal 0 1 13 61 DENOTES NEW ITEM UNITS AFFECTED Not available at time of publication CUSTOMER SERVICE GROUP MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy intended as master of or...

Page 645: ... be incorporated into all existing FT6645 6655 6665 Parts Catalog documentation REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A1761328 Left Door Seal 0 1 13 61 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 6665 copiers manufactured after Serial Number A3356450267 A3366450012 and A3376450072 respectively will have the new style Left Door Seal installed during production CUSTOMER SERVICE GROUP M...

Page 646: ...also can be done by pressing the Check Modes key If Even is not displayed on the Duplex Series Copies tag the correction has been successful NOTE 1 If the default mode is changed to single side copying or two sided to two sided duplexing selecting the one sided to two sided mode will not cause the problem 2 The above procedure is only necessary once per machine The corrected data will be kept on t...

Page 647: ...he part number of the Operation Panel Assembly has been changed REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0961465 A0961455 Operation Panel Assembly LT 1 1 0 17 AW500016 AW500020 Touch Panel 1 1 17 19 UNITS AFFECTED All FT6645 6655 6665 copiers will utilize the new style Operation Panel as a service part only INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OL...

Page 648: ...1 1 29 20 52051694 Adjusting Cam Start Lever n n 1 29 22 54465832 Connector Guide Pin n n 1 29 38 AA143732 Adjusting Screw 0 1 29 39 09524008W Philips Screw M4 x 8 n n 1 29 109 05740060E Hexagon Headless Set Screw M4 x 6 n n 1 29 111 09514008W Philips Screw with Flat Washer M4 x 8 n n 1 29 112 03140060B Philips Pan Head Screw M4 x 6 0 1 29 115 AA066277 Guide Roller Spring 0 1 29 40 DENOTES NEW ITE...

Page 649: ...3 of 3 UPDATE NO 4 FT6665 OIL SUPPLY ROLLER ASSEMBLY The Oil Supply Roller Assembly is available as a service part REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A0964080 Oil Supply Roller Assembly 1 65 59 DENOTES NEW ITEM Oil Supply Roller Assembly ...

Page 650: ...drop all the way down into the cut out Thus the Paper End Sensor does not detect the paper end condition FIELD COUNTERMEASURE File the shaded area of the bottom plate to prevent the feeler from being caught NOTE Make sure that the edges are filed smooth CUSTOMER SERVICE GROUP MECHANICAL ELECTRICAL OTHER Note This copy intended as master of original for reproduction of additional bulletins F S M CO...

Page 651: ...on should be incorporated into all existing FT6645 6655 6665 Parts Catalog documentation REFERENCE OLD PART NUMBER DESCRIPTION QTY PAGE ITEM AA150333 Seal 0 19 X 14 X 74 1 0 21 22 AA150334 Seal 0 19 X 40 X 48 1 0 21 23 97831 6 7 6 6394 MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy intended as master of original for reproduction of additional bulletins F S M COPY QUALITY PARTS ...

Page 652: ...INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units manufact...

Page 653: ...ing Parts Catalog documentation INCORRECT REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM AB013802 Gear 30Z 1 73 28 GB013035 Gear 28Z 2 73 40 AB010089 Gear 35Z 1 73 41 CORRECT REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM AB013802 Gear 30Z 1 73 41 GB013035 Gear 28Z 1 73 28 AB010089 Gear 35Z 1 73 40 CUSTOMER SERVICE GROUP q MECHANICAL q PAPER PATH q ELECTRICAL q OTHER Note This copy intended as m...

Page 654: ...74242 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units ma...

Page 655: ... INT PAGE ITEM AA082063 Bushing 4 X 7 1 1 3 S 65 52 AE031024 AE042012 Lower Cleaning Roller 1 1 3 S 65 51 AE042023 Pressure Roller Cleaning Roller 0720025B Retaining Ring M2 5 n n 2 3 S 65 101 A0974242 Lower Cleaning Roller Assembly 65 60 DENOTES NEW ITEM UNITS AFFECTED Not available at time of publication ...

Page 656: ...TY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units manufactured prior to th...

Page 657: ...UNITS AFFECTED Not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machi...

Page 658: ...replaced with the page s supplied Each bulletin package contains 1 set of replacement pages PAGES The revised areas have been highlighted by an arrow Table of Contents vi Additional Information 5 130 Additional Information 97831 6 7 6 6394 MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy intended as master of original for reproduction of additional bulletins F S M COPY QUALITY PARTS ...

Page 659: ...old parts will no longer be available REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0966303 A1766303 Separation Roller Stay 3 3 3 S 39 44 A0966338 A1766338 Separation Guide 3 3 3 S 39 22 A0966337 A1766337 Paper Feed guide 3 3 3 S 39 14 UNITS AFFECTED Not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW p...

Page 660: ...n by the position sensor To correct this the following parts have been modified 1 The configuration of the position sensor bracket has been changed The height of the position sensor has been raised by 1mm 2 The notch holes A for the Separation Guide and the Paper Feed Guide Position Sensor have been enlarged NOTE When installing the new Position Sensor Bracket you must also replace the Separation ...

Page 661: ...eplaced with the page s supplied Each bulletin package contains 1 set of replacement pages PAGES The revised areas have been highlighted by an arrow 5 48 Updated Information 5 49 Updated Information 5 51 Updated Information 97831 6 7 6 6394 MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy intended as master of original for reproduction of additional bulletins F S M COPY QUALITY PARTS ...

Page 662: ...d new style parts are interchangeable UNITS AFFECTED All FT6645 6655 6665 will utilize the new style Hot Roller as a service part only INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines...

Page 663: ...ller has been changed For your reference the current part numbers for the Oil Supply Rollers are as follows FT6645 6655 REFERENCE CURRENT PART NO DESCRIPTION QTY PAGE ITEM AE040006 Oil Supply Roller A095 A096 1 65 38 FT6665 REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY PAGE ITEM AE040009 AE040013 Oil Supply Roller A097 1 65 38 ...

Page 664: ...ter Weight 1 1 1 71 28 A1764445 Small Inverter Guide Mylar Short 0 1 71 36 A1764447 Small Inverter Guide Mylar Long 0 1 71 37 A1764448 Large Inverter Guide Mylar Short 0 1 71 38 A1764449 Large Inverter Guide Mylar Long 0 1 71 39 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 6665 copiers will utilize the above mentioned parts as service parts only CUSTOMER SERVICE GROUP q MECHANICAL n PAPER PATH ...

Page 665: ...RIPTION QTY INT PAGE ITEM A0964441 A1764442 Inverter Weight 1 1 1 71 28 A1764445 Small Inverter Guide Mylar Short 0 1 71 36 A1764447 Small Inverter Guide Mylar Long 0 1 71 37 A1764448 Large Inverter Guide Mylar Short 0 1 71 38 A1764449 Large Inverter Guide Mylar Long 0 1 71 39 DENOTES NEW ITEM UNITS AFFECTED All FT6645 6655 6665 copiers will utilize the above mentioned parts as service parts only ...

Page 666: ...egistered as service parts The following Parts Updates are being issued for all FT6645 6655 6665 Parts Catalogs REFERENCE NEW PART NO DESCRIPTION QTY PAGE ITEM A0963800 Transfer Belt Assembly 1 63 46 A0963801 Transfer Belt Casing Assembly 1 63 47 DENOTES NEW PART 97831 6 7 6 6394 COPY QUALITY S M ELECTRICAL MECHANICAL PARTS PAPER PATH OTHER 46 47 Note This copy intended as master of original for r...

Page 667: ... used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units manufactured prior to the S N cut in On units manufactured ...

Page 668: ...B MODs FE MODs F MODs MOD MO Bs EBs FEBs s FEBs OD MODs FE MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs Ds FEBs ODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs M MODs MODs FEB MODs FEBs MODs FEBs MO MODs F MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEB...

Page 669: ...021 Fusing Unit 115V A097 1 0 65 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be ins...

Page 670: ... Main Motor DC24V27W A097 1 0 81 23 AB033048 Timing Pulley 31 32Z 1 0 81 22 AX060127 DC Motor 27W A097 0 1 1 81 23 05740050E Hexagon Headless Set Screw M4x5 n n 1 81 104 A0962110 A1762110 Ozone Fan Motor 1 1 0 89 13 04140082B Binding Self Tapping Screw M4x8 n n 3 89 106 04524016B Tapping Bind Screw M4x16 n n 3 3 89 114 New Item number Continued PARTS MAIN MOTOR OZONE FAN MOTOR Due to parts standar...

Page 671: ...an be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units manufactured prior to the S N cut in On units manufact...

Page 672: ...LD machines 3 S Must be installed as a set on units manufactured prior to the S N cut in On units manufactured after the S N cut in or previously modified use the new part numbers individually Note This copy is intended as a master original for reproduction of additional bulletins PARTS ENTRANCE SEAL A high pitched noise may occur if the loop part of the Development Unit Entrance Seal is warped If...

Page 673: ...762061 Screw Shaft 1 3 59 12 A0962054 A1762054 Grounding Plate 1 3 59 17 Denotes that these parts should be replaced as a set Continued Note This copy is intended as a master original for reproduction of additional bulletins CHARGE CORONA UNIT A new style Charge Corona Unit has been released To prevent rusting of the Screw Shaft and the Grounding Plate a material more resistant to rust has been us...

Page 674: ...be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units manufactured prior to the S N cut in On units manufactured after the S N cut in or previously modified use the new part numbers individually FRONT COVER PLATE HARNESS COVER The shape of the Paper Bank...

Page 675: ...ue is applied has been reduced This will decrease the contact pressure of the Loop Seal on the drum This is the second modification of the entrance seal The following Parts Corrections are being issued for all A095 A096 A097 Parts Catalogs REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0963103 A2293092 Entrance Seal 1 0 53 4 Note This copy is intended as a master original for rep...

Page 676: ... Note The Drum Unit Harness color two lines for the Pre transfer Lamp is different between the models P N A0965440 white white A095 A096 A097 P N A1755440 white blue A175 A176 A177 3 Replace the Lower Drum Unit with P N A1763510 4 Change the VP data from 0V default to 40V using the SP Mode adjustment 1 Page 8 Item8 Continued Note This copy is intended as a master original for reproduction of addit...

Page 677: ... Cam Gear 35Z C 1 E ring Spacer M 6 4 Remove the Cleaning Brush Bushing D 1 screw 5 Remove the Cleaning Blade Bracket Ass y E 6 Remove the Lubricant Bar Ass y F 3 screws 7 Remove the Lubricant Bar Seal G 3 screws and replace it 8 Remove the Stopper H and replace the Lubricant Bar I REFERENCE NEW PART NUMBER DESCRIPTION QTY PAGE ITEM A1763515 Lubricant Bar 1 61 59 A1763522 Lubricant Bar Seal 1 61 6...

Page 678: ...FERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM 12041545 12042501 Main Switch 1 1 93 105 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in ...

Page 679: ... 1 0 27 14 UNITS AFFECTED Service parts only INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S...

Page 680: ...e following part updates are being issued for all A095 A096 and A097 Parts Catalogs Please update your Parts Catalogs with the following information REFERENCE PART NUMBER OLD DESCRIPTION NEW DESCRIPTION QTY PAGE ITEM AB013777 Gear 32Z Gear 32Z 1 st and 2 nd Feed 2 39 28 AB013779 Gear 32Z Gear 32Z 3 rd Feed 1 39 28 Note This copy is intended as a master original for reproduction of additional bulle...

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