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Ricoh FT4460, Service Manual, Page: 6 / 413

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Ricoh FT4460 Service Manual Download Page 6

11.3 JOGGER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

11.4 SlNGLE DUPLEX/OVERLAY TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

12. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80

12.1 PAPER MISFEED CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80

12.2 SERVICE CALL CONDlTIONS (Others) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82

13. COPIER TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-83

INSTALLATION

1. INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

1.1 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

1.2 MACHINE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

1.3 MINIMUM SPACE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

1.4 POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

1.5 COPIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

1.5.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

1.5.2 Removal Of Shipping Retainers And Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

1.5.3 For Areas Where The Voltage Is 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

1.5.4 Developer Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

1.5.5 Cassette Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

1.5.6 Key Counter Holder Installation (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

SERVICE TABLES

1. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

1.1 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

1.2 DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

1.3 VARIABLE RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

2. SERVICE REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

2.1 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

2.2 CHARGE CORONA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

2.3 OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

2.4 DEVELOPMENT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

2.5 TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

2.6 TRANSFER and SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

2.7 CLEANING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

2.8 FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Summary of Contents for FT4460

Page 1: ...RICOH R I C O H F T 4 4 6 0 RICOH COMPANY LTD...

Page 2: ...PATH 1 15 5 5 MULTI OVERLAY COPY PATH 1 16 6 DRIVE LAYOUT 1 17 7 MECHANICAL COMPONENT LAYOUT 1 18 8 ELECTRICAL COMPONENT LAYOUT 1 20 9 ELECTRICAL COMPONENT DESCRIPTIONS 1 22 10 AC AND DC POWER DISTRI...

Page 3: ...11 EXPOSURE LAMP VOLTAGE CORRECTION 2 18 3 11 1 Manual Image Density Correction 2 18 3 11 2 Size Magnification Correction 2 18 3 11 3 Drum Sensitivity Correction Vr Correction 2 19 3 11 4 Drum Rotatio...

Page 4: ...lack only 2 40 5 13 ID SENSOR TONER SUPPLY LEVEL 2 41 5 14 ID SENSOR SUPPLY CONTROL IN FIXED SUPPLY MODE 2 42 5 15 TONER SUPPLY AMOUNT FIXED SUPPLY MODE 2 44 5 16 ID SENSOR ERROR DETECTION 2 45 5 17 D...

Page 5: ...paration Rollers 2 61 9 3 FRICTION PAD FEED SYSTEM 2 62 9 4 PAPER LlFT MECHANlSM 1st Feed Station 2 63 9 5 PAPER LIFT MECHANISM 2nd and 3rd Feed Stations 2 64 9 6 PAPER SIZE AND END DETECTION 2 65 9 7...

Page 6: ...LATION 3 4 1 5 1 Accessory Check 3 4 1 5 2 Removal Of Shipping Retainers And Tape 3 4 1 5 3 For Areas Where The Voltage Is 240V 3 14 1 5 4 Developer Conditioning 3 15 1 5 5 Cassette Modification 3 17...

Page 7: ...ICE PROGRAM MODE TABLE 4 15 4 4 SERVICE PROGRAM SP 8 DATA INPUT GUIDE TABLE 4 32 4 5 SERVICE PROGRAM SP 9 DATA OUTPUT GUIDE TABLE 4 34 4 6 USER CODE TABLE 4 36 4 6 1 User Codes 4 36 4 6 2 User Code Co...

Page 8: ...VOLTAGE ADJUSTMENT SP Modes 61 and 62 5 25 1 18 APS LENGTH SENSOR ERROR CORRECTION SP Modes 50 and 46 5 26 1 19 VERTICAL MAGNIFICATION ADJUSTMENT 1 SP Mode 43 5 27 1 20 VERTICAL MAGNIFICATION ADJUSTME...

Page 9: ...ERFLOW SENSOR REPLACEMENT 5 53 3 6 USED TONER COLLECTION 5 54 3 7 QUENCHING LAMP REPLACEMENT CLEANING 5 55 4 PAPER FEED 5 56 4 1 MANUAL FEED TABLE REMOVAL AND MANUAL FEED SENSOR REPLACEMENT 5 56 4 1 1...

Page 10: ...Mode 54 5 86 6 8 SEPARATION PAWL REPLACEMENT 5 87 6 9 CHARGE CORONA CURRENT ADJUSTMENT SP Mode 9 2 5 88 6 10 GRID VOLTAGE ADJUSTMENT SP Mode 9 2 and 3 5 89 6 11 DRUM CURRENT ADJUSTMENT SP Mode 9 5 and...

Page 11: ...L 5 111 9 2 JOGGER HOME POSITION SENSOR REPLACEMENT 5 112 9 3 JOGGER UNIT WIRE REPLACEMENT 5 113 9 4 JOGGER MOTOR REPLACEMENT 5 115 9 5 JOGGER SOLENOID ADJUSTMENT 5 116 10 OTHERS 5 117 10 1 OPERATION...

Page 12: ...ONS 7 1 2 COMPONENT LAYOUT 7 2 3 ELECTRICAL COMPONENT DESCRIPTIONS 7 3 4 OVERALL MACHINE CONTROL 7 5 5 BASIC OPERATION 7 7 6 POWER DISTRIBUTION 7 9 7 INTERFACE CIRCUIT 7 10 8 ORIGINAL FEED 7 11 8 1 OR...

Page 13: ...7 42 13 1 11 Belt Drive Motor Speed Adjustment 7 43 13 2 FEED OUT UNIT 7 44 13 2 1 Feed out Unit Removal 7 44 13 2 2 DF Main PCB Removal 7 45 13 2 3 Inverter Solenoid Adjustment 7 46 13 2 4 DF Leading...

Page 14: ...0 EDITOR 1 2 3 4 5 6 6 1 INITIAL ERROR 9 7 6 2 PARITY ERROR Communication Error 9 7 7 ACCESSORY CHECK 9 8 8 INSTALLATION PROCEDURE 9 9 SPECIFICATIONS 9 1 ELECTRICAL COMPONENT LAYOUT 9 2 ELECTRICAL COM...

Page 15: ...PECIFICATIONS 11 1 2 MECHANICAL COMPONENT LAYOUT 11 2 3 ELECTRICAL COMPONENT LAYOUT 11 3 4 ELECTRICAL COMPONENT DESCRIPTIONS 11 4 5 MECHANICAL OPERATION 11 5 5 1 DRIVE MECHANISM 11 5 5 2 PICK UP ROLLE...

Page 16: ...LINES OR BANDS 4 Thin Distinct 12 14 1 11 HORIZONTAL BLACK LINES 12 15 1 12 JITTER 1 12 17 1 13 JITTER 2 lrregular 12 18 1 14 MARKS AT 251MM INTERVALS 12 19 1 15 SKEWED OPTICAL COPY IMAGE 12 20 1 16 B...

Page 17: ...G PROBLEM A3 LDG Tracing Paper 12 48 3 4 DIRTY BACKGROUND Blue Development Unit 12 48 3 5 PAPER CREASlNG 12 49 4 ELECTRICAL COMPONENT DEFECTS 12 50 4 1 PAPER END SENSOR 12 50 4 2 MANUAL FEED SENSOR 12...

Page 18: ...COPIES 12 58 5 8 MODES CLEARED WHEN FRONT COVER OPENED 12 58 5 9 INADEQUATE FUSING OF UNEVEN COPY SURFACE 12 59 5 10 GAP OR OVERLAPS IN OVERLAY COPYING 12 59 5 11 MULTIPLE PASSES THROUGH FUSING UNIT...

Page 19: ...SECTION 1 OVERALL M A C H I N E INFORMATION...

Page 20: ...5 1 PRIMARY PAPER PATH 1 12 5 2 SlNGLE DUPLEX COPY PATH 1 13 5 3 MULTI DUPLEX COPY PATH 1 14 5 4 SINGLE OVERLAY COPY PATH 1 15 5 5 MULTI OVERLAY COPY PATH 1 16 6 DRIVE LAYOUT 1 17 7 MECHANICAL COMPON...

Page 21: ...system Sheet Book Maximum A3 11 x17 Maximum A3 11 x17 Minimum A6 5 5 x8 5 Maximum A3 11 x17 Minimum A5 5 5 x8 5 Cassette feed 52 128 g m 14 34 lb Manual feed 52 157 g m 14 42 lb Duplex Overlay 64 105...

Page 22: ...12 8 seconds APS mode A4 8 5 x11 sideways Ten keys 1 to 999 count up or count down 7 steps 1 minute standard setting can also be set to 3 minutes or no auto reset Three universal cassettes auto casse...

Page 23: ...ion Approximately 86kg 190 lb 220 240V version Approximately 88kg 194 lb Document feeder DF52 20 bin sorter CS2090 Large capacity tray RT15 Color development unit CU120 Editor board RE12 Date printer...

Page 24: ...ection 11 Set Key Counter Indicator 3 Check Paper Size Indicator 12 Ready Indicator 4 Magnification Indicators 13 Wait Indicator 5 Paper Size Indicator 14 Manual Feed Indicator 6 Check Paper Path Indi...

Page 25: ...21 Auto Image Density Key 22 Manual Image Density Keys 23 Misfeed Location Display 24 Color Toner Indicator 25 Color Copy Key 26 Color Copy Indicator 27 Auto Paper Select Indicator 29 30 31 32 33 34...

Page 26: ...Key 8 2 Stack Indicator 9 3 Sort Indicator 10 4 Duplex Indicators 11 5 Duplex Key 12 6 Front Margin Adjustment Indicator 13 7 Back Margin Adjustment Indicator Margin Adjustment Key Centering Indicator...

Page 27: ...Key 16 Zoom Down Key 17 Overlay Key 18 Overlay Indicators 19 2 Page Overlay Key 20 2 Page Overlay Indicators 21 Edit Image Key 22 Edit Image Indicators 23 Tone Key 24 Photo Mode Indicator 25 Red Eras...

Page 28: ...ruary 1989 Section C LT LDG Version 1 Number Keys 2 Recall Enter Key 3 Program Indicator 4 Program Key 5 Interrupt Indicator A4 A3 Version 6 Interrupt Key 7 Clear Modes Key 8 Start Key 9 Clear Stop Ke...

Page 29: ...28 February 1989 3 COPY PROCESSES AROUND THE DRUM...

Page 30: ...28 February 1989 4 FUNCTIONAL OPERATION 1 10...

Page 31: ...n which mode the operator has selected For copy processing all sheets follow the same path from the paper feed mechanism through the fusing unit After that normal copies are delivered to the copy tray...

Page 32: ...ogrammed time the registration rollers start turning to feed the paper to the drum 3 Image Transfer The toner image on the drum surface is pulled from the drum onto the pass ing paper by the transfer...

Page 33: ...detects the paper s trailing edge the inverter rollers B reverse direction and the paper is fed to the jogger section C When the paper enters the jogger section the jogger fences move up against the...

Page 34: ...sides to correct its lateral position The duplex feed mechanism then feeds the paper to the jogger section inside the copier This time however the jogger fences there do not operate and the paper is...

Page 35: ...to the jogger section B When the paper enters the jogger sec tion the jogger fences move up against the paper on both sides Next the transport rollers move the paper up through the vertical relay rol...

Page 36: ...erter gate C guides the paper to the inverter rollers D The inverter rollers turn until the trailing edge of the paper is detected by the inverter sensor E The rollers then reverse direction and the p...

Page 37: ...Clutch Gear G4 Toner Supply Clutch Gear G5 Development Unit Change Drive Gear G6 Duplex Overlay Transport Clutch Gear G7 Registration Clutch Gear G8 Relay Clutch Gear Sprocket S1 Main Motor Sprocket T...

Page 38: ...28 February 1989 7 MECHANICAL COMPONENT LAYOUT...

Page 39: ...Unit 18 Pick up Roller 19 Feed Roller 20 Separation Roller 21 Feed Roller 22 Friction Pad 23 Pre Transfer Lamp 24 Registration Roller 25 Transfer Corona 26 Separation Corona 27 Pick off Pawl 28 I D Se...

Page 40: ...Paper End Sensor 18 3rd Paper Feed MC 19 I O Control Board 20 3rd Cassette Paper End Sensor 21 Relay Roller MC 22 Registration MC 23 Key Counter optional 24 1st Cassette Paper End Sensor 25 Registrati...

Page 41: ...ensor Anti Condensation Heater 64 3rd Paper Size Switches Optional 50 Fusing Exhaust Fan Motor 51 Fusing Lamp 52 Fusing Exit Sensor 53 Inverter Relay Sensor 54 Inverter Sensor 55 Main Motor 56 Main Tr...

Page 42: ...he transport belt 100 Vac Drives the scanner dc servo Positions the 3rd scanner dc stepper Positions the lens Drives the jogger plates to keep paper evenly stacked on the jogger tray dc stepper Lifts...

Page 43: ...s while copies are being jogged Supplies power to the copier Cuts ac power line Indicates which color development unit is installed Determines what size paper is in the first cassette Determines what...

Page 44: ...plates are at the home position Detects misfeeds Detects misfeeds Detects the correct feed height of the 1st cassette Detects the density of the image on the drum Used for determining paper size in t...

Page 45: ...fore transfer Interfaces the copier functions to the Sys tem Control Board Controls the speed of the scanner the position of the lens and the position of the mirrors and AC Drive Board Controls all co...

Page 46: ...r Capacitor 56 Main Transformer Function Symbol P to P Location Provides back up overheat protection in TF H 5 the fusing unit Provides back up overheat protection TS H 5 around the exposure lamp Remo...

Page 47: ...eceives 100 Vac from the main transformer This voltage is rectified and regulated to 24 and 5 volts respectively It is distributed to the ac drive board I O control board system control board ADF and...

Page 48: ...diagram shows the flow of control signals within the The system control board is responsible for initiating all actions that take place in a copy cycle The I O control board interfaces the system cont...

Page 49: ...SECTION 2 DETAILED SECTION D E S C R I P T I O N S...

Page 50: ...1 3 4 1 Lens Drive 2 11 3 4 2 Shading Mechanism 2 11 3 5 LENS POSlTIONING 2 12 3 6 3RD SCANNER DRIVE 2 13 3 6 1 Drive 2 13 3 6 2 Positioning 2 13 3 7 STEPPER MOTOR CONTROL 2 14 3 8 RED ERASE MECHANISM...

Page 51: ...2 31 5 4 DRIVE MECHANISM Black 2 32 5 5 DRIVE MECHANISM Color 2 33 5 6 AGITATOR MECHANISM 2 34 5 7 TONER SUPPLY AND AGITATOR DRIVE MECHANISM 2 35 5 8 TONER DENSITY DETECTION 2 36 5 9 TONER DENSITY CON...

Page 52: ...CIRCUIT 2 52 7 ID SENSOR 2 53 7 1 ID SENSOR IMAGE CORRECTION Vr Pattern 2 53 7 2 ID SENSOR PATTERN Vsp 2 55 8 DRUM CLEANING 2 56 8 1 OVERVIEW 2 56 8 2 DRIVE MECHANISM 2 57 8 3 RELEASE MECHANISM 2 58...

Page 53: ...LEASE MECHANISM 2 72 10 3 FUSING CONTROL 2 73 10 3 1 Phase Control 2 74 10 4 SERVlCE CALL CONDlTIONS 2 75 11 DUPLEX OVERLAY MECHANISM 2 76 11 1 OVERVIEW 2 76 11 2 DRIVE MECHANISM 2 77 11 3 JOGGER MECH...

Page 54: ...al charge when exposed to light Exposure to light greatly increases the conductivity of a photoconductor Dissipating an amount of charge in direct proportion to the intensity of the light That is wher...

Page 55: ...or becomes dirty wipe with a dry cloth or clean with wet cotton Wipe with a dry cloth after cleaning with wet cotton 4 Never use alcohol to clean the drum alcohol dissolves the drum surface 5 Store t...

Page 56: ...vent stress on the drum The drum unit consists of an OPC drum ID sensor C and separation pawls D The drum is driven by the main motor H through the drum drive belt E and the drum drive gear F The sepa...

Page 57: ...applies a high voltage 5 0 to 7 5 KV The drum coating B receives a uniform negative charge as it rotates past the corona unit A stainless steel grid plate C makes the corona charge uniform The charge...

Page 58: ...opies made A volt age corresponding to the drum surface potential is applied to the grid B to achieve consistent copy quality The amount of compensation is determined by the ID sensor Vrp Vsg The flow...

Page 59: ...nds after the Start key is pressed A LOW signal from the I O control board at CN1 3 energizes the power pack The OFF timing is the same as the scanner return timing The grid voltage is also applied by...

Page 60: ...ally slid in and out The cleaner pad bracket B rotates when the charge unit is fully extended and the bracket is pulled up against the rear block C This moves the pads against the corona wire see illu...

Page 61: ...g every copy cycle The 1st scanner lamp and 1st mirror 2nd scanner 2nd and 3rd mirrors 3rd scanner 4th and 5th mirrors and the lens function together to achieve a wide range of reproduction ratios The...

Page 62: ...amp and the first mirror is connected to the scanner drive wire by the wire clamps E The second scanner F which consists of the second and third mirrors is connected to the scanner drive wire by movab...

Page 63: ...cks the drum speed by monitoring the pulses from the pulse generator Based on this input the I O control PCB determines the proper speed for the scanner drive motor The encoder on the servomotor is a...

Page 64: ...h in discrete steps The home position of the lens is detected by the home position sensor D The I O control PCB keeps track of the lens position based on the num ber of pulses sent to the lens drive m...

Page 65: ...ition is registered each time the lens starts from or passes through the lens home position sensor As the lens moves from right to left as viewed from the front the sensor registers the home position...

Page 66: ...e wire A in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and drum sur face 3 6 2 Positioning The positioning mechanism is similar to that of...

Page 67: ...the third scanner drive motor are stepper motors The stators of these stepper motors have four coils labeled A B and above and the rotors are permanent magnets Pulse signals energize the four coils a...

Page 68: ...ode the red erase solenoid A is energized ON to move the red filter B into the optical path Normally the green filter C is in the optical path The red filter allows only red to pass through thus decre...

Page 69: ...S circuit is determined by the following equa tion in each copy mode 88 mm Black copy mode L Reproduction Ratio 44 mm Color copy mode L Reproduction Ratio The highest voltage detected by the ADS is he...

Page 70: ...ength sensor A and width sensor B on the first scanner detect the original size during pre scanning Length and width sensor data are combined as shown in the size detection table to determine the orig...

Page 71: ...el 4 in manual image density mode can be set to 50 to 75 V using SP mode 48 Standard 64 V The following inputs will also change the lamp voltage to ensure consistent copy quality Lamp voltage is varie...

Page 72: ...rises gradually in repeat copying due to characteristics of the drum The lamp voltage is adjusted to keep copy quality consistent 3 11 4 Drum Rotation Correction To compensate for fogging of the OPC d...

Page 73: ...he standard voltage in normal mode V0 The amount of shift can be changed with SP mode 40 Auto density cannot be used 3 11 6 ADS Correction SP mode 34 Users can vary the voltage in ADS mode using SP mo...

Page 74: ...ng edge of each trigger pulse The voltage applied to the exposure lamp is also provided to the feedback cir cuit The feedback circuit steps down T401 rectifies DB405 and smoothes zener diodes and capa...

Page 75: ...displayed if the 1st scanner home position sensor is not actuated within 6 seconds scanner does not return home Self Diagnostic Code 22 Scanner Malfunction Code 22 is displayed if the 1st scanner home...

Page 76: ...Position At certain times power ON clear auto reset the third scanner either moves to its home position or moves out and back Code 2A is displayed if the third scanner home position sensor stays OFF l...

Page 77: ...Lead edge erase ES Side erase The erase lamp A consists of a line of 120 LEDs extending across the 300 mm width of the drum C The function of the erase lamp is to prevent the toner from being attract...

Page 78: ...hen the residual voltage is being detected Vr correction 4 1 2 Side Erase Based on the paper size and the reproduction ratio the LEDs turn on in pairs one on either side to discharge the drum potentia...

Page 79: ...g and erase are controlled The erase margins can be changed by SP Mode 39 Center Erase and SP Mode 38 Erase Edge in 5 mm steps Center Erase Margin Standard 20 mm Edge Erase Margin Standard 10 mm 4 1 4...

Page 80: ...ata If the data line is HIGH at the time of the CLOCK pulse rising edge the shift register is set to turn the LED on if it is LOW the shift register is set to keep the LED off The data in the shift re...

Page 81: ...ack this happens at T0 0 9 seconds T3 T0 0 81 sec The erase lamps which were switched off turn on again and there is full erase until T0 0 94 seconds In order to create the Vr pattern bias is reduced...

Page 82: ...agnets in the development roller at tract the developer to the development roller sleeve The turning sleeve of the development roller then carries the developer past the doctor blade The doctor blade...

Page 83: ...and forth by the color develop ment change shaft B The change shafts are turned by the development change cam C through the change lever D The cam is driven by the main motor through gears and a driv...

Page 84: ...supports the development units The plate is locked at a 45 degree angle for the color development unit and at a 90 de gree angle for the black development unit The stopper C inside the inner cover can...

Page 85: ...opment drive clutch controls the rotation of the development roller C and the paddle rollers D through the drive gears The toner supply clutch controls the rotation of the toner supply roller E and th...

Page 86: ...development unit When color copy mode is selected the black development unit gears are dis engaged from the development drive gear C and the toner supply gear D and the color development unit gears en...

Page 87: ...to two parts by the doctor blade A The part that stays on the development roller B forms the magnetic brush and develops the latent image on the drum The rest of the developer slides down the backspil...

Page 88: ...ly roller The black toner agitator is in the toner cartridge and the color development agitator is in the toner hopper The black toner supply roller has 16 grooves E Toner is caught in these grooves a...

Page 89: ...copy cycle From then on it will check every 10 copies During the check cycles the sensor pattern is exposed prior to exposure of the original The development bias is fixed for the development of the...

Page 90: ...lue for the bare drum Vsg and the value for the sensor pattern Vsp These two values are then compared to determine whether more toner should be added This model has two modes the ID sensor supply mode...

Page 91: ...nce ever 5 copies Toner supply mode goes to 15 fixed supply If at the second check Vsp is still above 0 91V the toner supply mode moves up to 30 If at the third check still Vsp is still above 0 91V to...

Page 92: ...sor A in the development unit unit is performed by the Up to 50 additional copies can be made when the toner end condition is detected in both black and color copying modes At the 51st copy after tone...

Page 93: ...pply Rate Is Four Times Of 1 22 6 62 4 For 5 Check Cycles Then Toner End Condition Is Detected Goes to Fixed 62 5 or mode Supply Mode 2 50 or mode ID sensor Level is made on the ratio of Vsg and Vsp S...

Page 94: ...ime l x T x P Where I ID Sensor Supply level Data T Toner Supply Ratio Data P Paper Size Data For example Vsp 0 65V which means that the ID sensor toner supply level is 2 and the data 52 The toner sup...

Page 95: ...onditioning SP mode 10 procedure is completed This level is determined by calculating the average of Vsp and Vsg Since the fixed supply system is selected when in color toner mode it is necessary to i...

Page 96: ...S Up p l y l e v e l Black Toner is supplied every copy cycle according to the supply mode selected by SP Mode 32 The toner supply clutch is de energized when Vsp is lower than 1 8 Vsg in black copy m...

Page 97: ...l P MODE DATA CONSTANT ADD 2 DATA 0 7 1 DATA 1 3 5 3 DATA 2 10 5 4 DATA 3 14 Color Toner SP No 70 Supply Level P MODE DATA CONSTANT ADD 2 DATA 0 14 1 DATA 1 7 3 DATA 2 21 4 DATA 3 28 Supply Mode Data...

Page 98: ...oner supply changes to 60 fixed supply mode In color mode if Vsp is high in 10 consecutive checks the wrench mark and the color unit indicator are displayed In black mode if Vsp is high in 5 consecuti...

Page 99: ...EVEL The negative bias 120 to 280V corresponding to the selected image den sity level is applied to the development roller 5 17 2 Auto Image Density bias control S P 3 4 A D S A d j u s t m e n t D a...

Page 100: ...orrection the residual potential is corrected using the ID sensor 5 18 2 SP Mode Correction S P m o d e N o 3 7 S e t V a l u e 0 1 2 3 4 B i a s V o l t a g e 0 4 0 V 2 0 V 2 0 V 4 0 V C o d e N D D...

Page 101: ...75 1 L 2 0 0 2 8 0 2 H 2 6 0 3 4 0 3 HH 2 8 0 3 6 0 Initial Developer Conditioning Red 280V Blue Green 320V 1 1 and 1 2 ID sensor bias can be manually changed to accommodate cus tomer copy quality pre...

Page 102: ...counter correction Vsp Vsg compensates for the change in the triboelectric charge as the new developer mixture black only is broken in 5 19 4 Total ID Sensor Bias N o r m a l I n i t i a l D e v e l...

Page 103: ...re attracted to the negatively charged drum during the paper separation process It also makes image transfer and paper separation easier 6 2 IMAGE TRANSFER A high negative voltage 5 6 kilovolts is ap...

Page 104: ...s unnecessary because the separation corona is wide and diffuse The negative charge on the paper from the transfer corona is not completely dis charged until the paper is far enough from the drum that...

Page 105: ...signal to turn on T1 the transfer corona 0 7 seconds after the original leading edge signal L E and continues for a period corresponding to the paper length 6 7mm The separation corona is turned on T...

Page 106: ...e is detected by comparing the Vsg and the Vrp The Vrp pattern is created by applying a 0 voltage bias Toner particles are at tracted to the drum surface by the residual voltage The Vrp pattern is che...

Page 107: ...28 February 1989 The grid bias and the development bias change by 40 volts in each specific ratio The exposure voltage changes 1 volt in each specific ratio 2 54...

Page 108: ...pattern is transferred to the drum before creation of the latent image The ID sensor illuminates the pattern and checks the reflectivity The system control PCB detects variations in the light intensit...

Page 109: ...sh removes paper dust and nearly half of the toner from the drum surface to reduce the cleaning load placed on the blade The cleaning blade removes the remaining toner The falling toner catches in the...

Page 110: ...in motor through a chain and gears The cleaning brush and the cleaning blade C are always touching the drum surface The toner collection roller rotates at the same time as the cleaning brush to collec...

Page 111: ...en the cleaning unit is removed This prevents the drum B from being scratched by the cleaning unit C The cleaning blade releases when the release knob F is pressed This will clean the cleaning blade D...

Page 112: ...rol PCB when the toner collection tank C is full This sensor is a photo interrup ter A rubber sheet B under the toner overflow sensor is lifted up by the gradual collection of toner Once full the actu...

Page 113: ...le E which utilizes the first feed station feed mechanism The first feed station uses a FRR feed system A grip roller H is installed in the first feed station to prevent skewing when using small sized...

Page 114: ...n one direction The separation roller C however is driven through a slip clutch which allows it to turn in either direction depending on the friction between the rollers A spring keeps the separation...

Page 115: ...of the first sheet leaves the feed roller The leading edge of the next sheet is then held ready for feeding be tween the friction pad and feed roller Sometimes sheets of paper tend to stick together p...

Page 116: ...assette has been in serted and turns on the lift motor H The lift motor raises the bottom plate I until the top sheet pushes up the pick up roller J When the paper pushes up the pick up roller the lif...

Page 117: ...force the release levers down The release levers rotate the cassette arm shaft B moving the cassette arm down and out of the way When the cas sette is fully seated the release guides allow the release...

Page 118: ...y the actuator plate to determine which size cassette has been inserted When a cassette or the LCT runs out of paper the paper end feeler C drops through a slot in the cassette or LCT bottom plate The...

Page 119: ...he drive gear These rollers are always rotating when the main motor is rotating The pick up roller is normally in contact with the paper stack The pick up solenoid E raises the pick up roller When the...

Page 120: ...ockets turn the second paper feed B third paper feed C and relay F magnetic clutches through the idle gears The registration roller D is driven by the main chain and its ON OFF timing is controlled by...

Page 121: ...ned the manual feed sensor B sends a signal to the I O control PCB The I O control PCB then shifts to manual feed mode The lift motor assembly C is mechanically released by a release lever E when the...

Page 122: ...buckles the paper in order to correct skewing The third paper feed clutch will be turned off as soon as the leading edge of the copy paper is detected by the upper relay sensor The relay clutch will d...

Page 123: ...agnostic Code 41 First Cassette Lift Sensor The I O control board will monitor the upper lift sensor while the lift motor is ON If the output of the lift sensor stays low for 25 seconds after the lift...

Page 124: ...ot roller axis is turned on and off to maintain the operating temperature The temperature control circuit monitors the hot roller surface temperature through a thermistor D The thermofuse 169 C J prev...

Page 125: ...it drive gear to rotate freely so that jammed paper can be easily removed When the front cover is opened the safety lever is released and the release shaft D rotates as shown above This moves the rele...

Page 126: ...SP Mode 29 fusing power can be phase controlled Normally phase control is used only if the customer has a problem with electrical noise or interference When the main switch is turned on the I O contro...

Page 127: ...nt of power is regulated by the width of the trigger pulse The wider the trigger pulse C1 the more ac power the lamp receives D1 therefore the temperature increases As the temperature rises the LOW tr...

Page 128: ...uit is open for longer than 10 seconds Self Diagnostic Code 54 Fusing Warm up Failure Code 54 will be displayed if the hot roller does not reach the ready tempera ture within five minutes after the po...

Page 129: ...er is sent to the jogger section B and is fed to the registration roller C again When duplex copy mode is selected 2 paper is sent to the inverter section and then fed to the jogger section The invert...

Page 130: ...solenoid B also switches the direction of roller rotation The inverter roller drive gear is engaged with the in gear D in feed in operation and the out gear E in feed out operation The inverter sensor...

Page 131: ...As the paper is being jogged the guide plates C will be lifted by the jogger solenoid D preventing the rollers from interfering with the jogging process NOTE The I O The jogging process performed whe...

Page 132: ...tion 10mm from the paper s edge T3 The inverter solenoid is de energized 0 07 seconds after the inverter sensor detects the trailing edge of the paper T4 The duplex overlay transport clutch turns off...

Page 133: ...lay Sensor D Inverter Sensor This model uses six sensors to detect misfeed conditions inside the copier Each sensor performs both ON and OFF detection as shown above Four LEDs on the operation panel i...

Page 134: ...turned on Paper does not reach the fusing exit sensor 1 Checked about 3 5 seconds after the registration MC is turns on Paper does not reach the inverter sensor 1 Check about 2 3 seconds after the fus...

Page 135: ...ition sensor remains high as the I O con trol board is driving the fences inward code 82 will be displayed Self Diagnostic Code 91 No Total Counter The total counter is monitored by the system control...

Page 136: ...Section 2 Timing Chart following page...

Page 137: ......

Page 138: ...S E C T I O N 3...

Page 139: ...EMENTS 3 2 1 4 POWER REQUIREMENTS 3 3 1 5 COPIER INSTALLATION 3 4 1 5 1 Accessory Check 3 4 1 5 2 Removal Of Shipping Retainers And Tape 3 4 1 5 3 For Areas Where The Voltage Is 240V 3 14 1 5 4 Develo...

Page 140: ...lation place is air conditioned or heated place the machine as follows a Where it will not be subjected to sudden temperature changes b Where it will not be directly exposed to cool air from an air co...

Page 141: ...ble and screw the Ieveling feet up or down in order to level the machine Use a leveling gauge if necessary 1 3 MINIMUM SPACE REQUIREMENTS 1 Front 70 cm 27 6 2 Back 10 cm 3 9 3 Right 80 cm 31 5 4 Left...

Page 142: ...an 8A 240V 50Hz More than 8A Permissible voltage fluctuation 10 Permissible extension cord At least 300V 30A capacity and less than 5 meters 16 4 ft long Do not set anything on the power cord NOTE a B...

Page 143: ...t 1 3 Envelope for NECR 115V only 1 4 Cassette Large 1 5 Cassette Small 2 6 Copy Tray 1 7 Operating Instructions 1 115V English only 220V Five Languages 8 Original Holder 1 9 Multilingual Decals 220V...

Page 144: ...he copier front cover B Remove the strips of tape C and the fixing plate D 2 screws as shown Remove the yellow seal E from the toner tank Remove the clamp F from the cleaning unit NOTE Save the fixing...

Page 145: ...e scanner lock plates and lens lock pin for future use b If the copier is to be transported install the scanner lock plates and lens lock pin after turning off the power switch in the full size mode 1...

Page 146: ...b Do not touch the surface of the entrance seal D or the development roller E 15 Remove the development guide F 6 screws 16 Pour one pack of 4460 type color developer G into the color develop ment un...

Page 147: ...hanging to an optional color development unit 18 Set the DIP SW A as shown above so that the color indicated on the operation panel matches the color in the color development unit 19 Stick the color d...

Page 148: ...er to lower the development unit supporter B to a horizontal position 21 Move the development unit lock lever C to the right to the lock posi tion 22 Move the release lever D to the right and pull out...

Page 149: ...emount the toner tank on the development unit 26 Release the cleaning tank lever E and the transport unit lever A1 F CAUTION To avoid damaging the pick off pawls remove the drum protec tion sheet by p...

Page 150: ...unit be sure the development unit rail is placed directly on the development unit rail NOTE a Shake the cartridge well to break up any clumps in the toner b Remove the strip of tape covering the toner...

Page 151: ...y attempting to rotate the toner cartridge knob counterclockwise When the toner cartridge gear is properly engaged the toner cartridge knob will not rotate freely 32 Insert the screwdriver B into the...

Page 152: ...hear a click CAUTION When installing the color development unit be sure the develop ment unit rail is placed directly on the unit guide rail 35 Add the color toner Follow the instructions How to Add T...

Page 153: ...r Areas Where The Voltage Is 240V 36 Remove the copier rear cover 2 screws disconnect the red wire A from the 220V terminal B and connect this wire to the 240 volt terminal C as shown Then reinstall t...

Page 154: ...he Clear Modes key 2 Press the Clear Stop key 3 Press the Recall Enter key 4 Enter 10 5 Press the Recall Enter key 6 Close the platen cover and press the Start key NOTE Buzzer sounds after color devel...

Page 155: ...ray A 40 Install the original holder B on the platen cover Remove the vinyl sheets from the operation panel covers 41 Load paper into the cassette and check machine operation and copy quality 42 Fill...

Page 156: ...ce D in the desired paper size position 1 screw NOTE Paper size positions are shown on the inside of the cassette 4 5 6 7 Reinstall the bottom plate Reinstall the side fences in the desired size posit...

Page 157: ...e A2 lever and pull off the cover Remove the shorting plug E from the 4P key counter connector Connect the 4P connector of the key counter holder F to the key counter harness through the key counter a...

Page 158: ...SERVICE T A B L E S...

Page 159: ...8 2 12 LARGE CAPACITY TRAY 4 8 2 13 OTHERS 4 9 3 SPECIAL TOOLS AND LUBRICANTS 4 10 4 SERVICE PROGRAM MODE 4 11 4 1 DIP SWITCHES TABLES 4 11 4 1 1 DIP SW 1 Operation Panel 4 11 4 2 SERVICE PROGRAM MOD...

Page 160: ...eset 4 37 4 7 MISFEED TABLE 4 38 4 7 1 Location of Jams Number of Jams SP Mode 131 4 38 4 7 2 Sensor Location 4 40 5 PREVENTIVE MAINTENANCE SCHEDULE 4 41 5 1 LUBRICATION POINTS 4 45 5 2 REPLACEMENT PO...

Page 161: ...1 Exposure Lamp Voltage Original Width Sensor Output Voltage Original Length Sensor Output Voltage Scan Factory Use Only 2 DF Main Board NUMBER FUNCTION TP101 Factory Use Only TP102 5V TP103 GND TP104...

Page 162: ...18 cpm Factory setting 1 sided free run SW101 must be ON 2 sided free run SW101 must be ON Solenoid test SW101 solenoids ON SW102 solenoids OFF Motor test lift switch must be ON All indicators ON lift...

Page 163: ...id voltage VR4 Adjusts ID sensor grid voltage 4 Power Pack SC NUMBER FUNCTION VR DC Adjusts separation current dc VR AC Adjusts separation current ac 5 Power Supply Board NUMBER FUNCTION VR201 Adjusts...

Page 164: ...ng or pulling out the drum the following should be per formed to avoid drum damage a Release the cleaning unit release lever b Remove the black and color development units c Remove the charge corona u...

Page 165: ...re When replacing the sensor mark the position of the sensor bracket before removing it and adjust the fine position of the sensor by checking the copy image magnification and focus 3 Do not bend or d...

Page 166: ...bias terminal Clean the drive gears and end magnets after removing used developer Be careful not to add black developer or toner into the color development unit do not add color developer or toner int...

Page 167: ...pulling out the cleaning unit place a sheet of paper under it to catch any toner that spills out When inserting the cleaning unit into the copier be sure the cleaning unit rail is properly engaged wi...

Page 168: ...2 10 DOCUMENT FEEDER 1 Do not bend the DF interface harness at a sharp angle This damages the fiber optics cables 2 When installing or reinstalling the document feeder make sure that the document feed...

Page 169: ...e screw If the screw is overtightened the sensor may be damaged If red portions of the original are not showing up on the copy and the cus tomer requests this increase the image density Press the manu...

Page 170: ...on Drum Shoe Shaft Doctor Gap Gauge Color Development Unit Doctor Gap Gauge Black Development Unit Scanner Wire Clamper Scanner Positioning Pin 4pcs Grease G 40M Gap Gauge 0 1mm Sensor Checker Grease...

Page 171: ...l SW 1 2 3 4 Description Free run Forced start Ready temperature bypass Clear counter see CLEAR MEMORY PROCEDURE Service Program mode access When ON the SP mode is disabled The copy quality and transp...

Page 172: ...id SP number is entered and the Enter key is pressed 0 is displayed in the copy counter 4 To leave SP mode turn the main switch OFF set DIP SW1 4 to the off position and turn the main switch on 4 2 2...

Page 173: ...ation panel and turn the main switch ON Select Service program SP 97 and press the 1 key on the key pad then press the Enter key At this point Service Programs SP 120 through 131 will be cleared and d...

Page 174: ...ard Turn the main switch on Select SP 99 and press the 1 key on the key pad then press the Enter key to perform the memory clear function NOTE The buzzer sounds five times when the memory clear functi...

Page 175: ...om sensors Electrical com ponent turns on Used to condition the color developer Turns on all the in dicators on the operation panel Selects auto reset of 1 or 3 minutes Selects count up or count down...

Page 176: ...elects shut off time 0 5 sec 0 Off Time for SADF mode 1 60 sec 23 ADF Free Size Enables originals of 0 No 0 If No CPM of A4 various sizes to be 1 Yes LT sideways in fed from the same ADF mode 1 to 1 s...

Page 177: ...ustment value Adjusts black bias output if the Image density in level 4 can not be adjusted using Light Intensity Adjustment mode SP 48 Data 0 ON OFF control 1 Phase control 0 ID sensor 1 Fixed Supply...

Page 178: ...sts the lead 0 15 8 0 8 mm per step Erase Margin edge margin max 6 4 mm to Adjustment 5 6 mm 42 Registration Adjusts registration 0 15 8 0 8 mm per step Adjustment max 6 4 mm to 5 6 mm 43 Vertical Mag...

Page 179: ...oltage Displays the fusing temperature Adjusts Vsg Displays Vsg and Vsp Data 0 15 0 14 50 75 Vac 175 190 degrees Factory Setting 8 8 64 185 4 0 2V Comments 1 mm per step Max 8 mm to 7 mm 0 48 mm per s...

Page 180: ...bias volt age Press Start key to turn on Press C S key to stop Displays APS length voltage Adjusts APS length voltage using VR302 on the I O control PCB so that it is 2 8 0 2V Displays width volt age...

Page 181: ...ding to the type drum Nor mally this should be 0 Detects Vr value to be forced and cor rects the lamp grid and bias voltages according to the Vr correction ratio Selects the color toner supply ratio E...

Page 182: ...e digits 74 Color Toner ID sensor check is 0 5 copies 0 Supply Detec performed every 5 1 10 copies tion copies or 10 copies 75 ID Sensor Selects the bias volt Blue Green 0 0 Normal Bias Color age appl...

Page 183: ...7 was set in SP detected by SP Mode 10 is dis Mode 10 played ID sensor level Vsp Vsg x 100 81 ID Sensor Displays ID sensor Reference Value The value which Level Green level for green toner 60 was set...

Page 184: ...own keys to select user code The last two digits of user code are dis played in the copy counter Resets counters of all user codes Data 1 7 0 No PM 1 40K 2 60K 3 80K 4 100K 0 OFF 1 ON 0 No 1 Yes Facto...

Page 185: ...ies board must be on S C Jam counter User Program PM counter Main Motor on Time User Code Counter 99 Clear All Clears all counters 0 No 0 DIP SW1 3 and 4 Memory and returns all 1 Yes on the operation...

Page 186: ...first three digits in the Magnification in dicator Press the key to display the second three digits Press the key to display the first three digits in the Magnification in dicator Press the key to di...

Page 187: ...g 0 0 0 0 0 0 Comments Press the key to display the first three digits in the Magnification in dicator Press the key to display the second three digits Press the key to display the first three digits...

Page 188: ...tory Setting 0 0 0 0 0 0 0 Comments Press the key to display the first three digits in the Magnification in dicator Press the key to display the second three digits Press the key to display the first...

Page 189: ...eed station 3 4th feed station Not used 4 5th feed station Not used Data Factory Setting 0 0 0 0 0 0 0 0 Comments Press key to dis play the total num ber of Drive service calls in the Magnification in...

Page 190: ...to the fusing unit 8 Paper jams in the fusing unit 9 Paper is not fed to the Sorter unit 10 Paper jams in the Sorter unit 11 Paper does not reach the paper exit sensor in the Multi Duplex Overlay unit...

Page 191: ...e Single Duplex Overlay mode 16 Registration jam 0 in overlay duplex copies 17 Paper stays on 0 the inverter relay sensor in the Multi Duplex Overlay mode 18 Inverter relay 0 sensor is not activated w...

Page 192: ...Copier 5 Lower Relay Sensor Copier 6 5th Relay Sensor Paper Bank 8 lnverter Sensor Copier 9 Inverter Relay Sensor Copier 10 Paper Exit Sensor Multi Duplex Overlay 11 Paper End Sensor Multi Duplex Ove...

Page 193: ...itch is not activated 16 Wheel Sensor Sorter OFF H P Sensor Sorter Cover Safety Switch Sorter OFF 17 18 20 Close OFF Color Toner End Sensor Copier ON ON Sensor is activated High Low Counter OFF High C...

Page 194: ...Main Corona Charge ID Sensor Grid Copier 4 Main Corona Charge VR Grid Copier 5 Transfer Charge Copier 6 Transfer Charge Transfer Up Charge Copier 7 Separation Charge Copier 8 Black Development Unit Se...

Page 195: ...osition Copier 34 Move the jogger side fences to the home position Multi Duplex Overlay 35 Positioning Roller Solenoid Multi Duplex Overlay 36 Cam Clutch Solenoid Multi Duplex Overlay 37 Eraser Lamps...

Page 196: ...707 8 1808 9 1909 10 2010 12 2212 13 2313 14 2414 15 2515 16 2616 17 2717 18 2818 19 2919 20 3020 How to use User Code 1 Enter a user code 4 digits using the numeral keys 2 Press the Enter key 3 Press...

Page 197: ...to 20 of the user codes are displayed in the copy counter Press the key to display the second three digits in the Magnification in dicator In case the key is not pressed the first three digits are dis...

Page 198: ...ration jams This includes 1st 2nd feed station jams Registration Sensor not ON 3rd feed station Upper Relay Sensor not ON 4th feed station Not used 5th feed station Not used Paper is not fed from the...

Page 199: ...not OFF Paper does not reach the inverter relay sensor in the Single Duplex Overlay mode Inverter Sensor not ON Registration jam in duplex overlay copies Registration Sensor not ON Paper stays on the...

Page 200: ...Sensor Copier B Upper Relay Sensor Copier C Lower Relay Sensor Copier F Paper Exit Sensor Multi D O G Paper Sensor Sorter H Fusing Exit Sensor Copier D Inverter Relay Sensor Copier I Registration Sens...

Page 201: ...3 0 0 1V Carry out ADS Memory Reference Voltage Press the start key in SP Mode No 56 and let the scanner run more than 5 times Adjust the Vsg Select SP Mode No 54 and turn VR102 to adjust Vsg to 4 0...

Page 202: ...cohol or water replace if necessary C C C C Dry cloth C C C C Dry cloth C C C C Silicone cloth C C Blower brush 5 Separation roller L spring clutch 1st feed station 6 Separation roller 1st C feed stat...

Page 203: ...aning brush R R Replace if necessary 4 Pick off pawls C C C C C Replace if necessary 5 Used toner bottle C C C C C Empty used toner E DEVELOPMENT UNIT 1 Developer R R R R Replace if necessary Refer to...

Page 204: ...ecessary 4 Friction belt R R R R Water replace if necessary 5 Registration Original C C C C Blower brush width sensor 6 Spring clutch L Mobil temp 78 7 Belt drive motor gears L Mobil temp 78 I LARGE C...

Page 205: ...lutch spring B and drive gear C Then lubricate them with Mobil Temp 78 every 120K NOTE 2 1 Black Development Unit Use Silicon Grease G 40M a Clean the gears A located on the rear side of black develop...

Page 206: ...ers A Clean the positioning roller shafts B and shaft holders Then lubri cate them with Mobil Temp 78 every 120K 5 2 REPLACEMENT POINTS Replace the following parts at PM if figures NOTE 5 1 Fusing Uni...

Page 207: ...loper at PM refering to the following supply yield table if necessary TYPE OF DEVELOPER TARGETED SUPPLY YIELD Black developer Red developer Blue developer Green developer 5 3 ADJUSTMENT POINTS NOTE 8...

Page 208: ...ure lamp af fects the copy image Check the lamp at regular intervals and replace if dis colored A dirty optical fiber receptor can result in insufficient image density Clean at regular intervals This...

Page 209: ...e image to be reat tracted to the drum during transfer resulting in reduced image density Clean the PTL at regular intervals ID Sensor If paper dust or toner accumulates on the ID sensor the image den...

Page 210: ...ing of the copy image Clean or replace at regular intervals Transport Roller A transport roller that is dirty or slips may cause a dirty copy image or a paper jam Clean the rollers at regular interval...

Page 211: ...Item Explanation CS2090 Bin Drive Wheel Bin Dust adhering to the bin drive wheel or Guide bin guide may interfere with bin move ment and result in uneven bin postition ing Clean and lubricate at regul...

Page 212: ...REPLACEMENT AND...

Page 213: ...0 1 14 EXPOSURE LAMP VOLTAGE ADJUSTMENT SP Mode 48 5 22 1 15 ADS ADJUSTMENT SP Mode 58 5 23 1 16 ADS CORRECTION SP Mode 56 5 24 1 17 APS VOLTAGE ADJUSTMENT SP Modes 61 and 62 5 25 1 18 APS LENGTH SENS...

Page 214: ...OUNT SP Mode 70 5 48 3 CLEANING 5 49 3 1 CLEANING UNIT REMOVAL 5 49 3 2 CLEANING BLADE REPLACEMENT 5 50 3 3 CLEANING BRUSH REPLACEMENT 5 51 3 4 BLADE SCRAPER REPLACEMENT 5 52 3 5 TONER OVERFLOW SENSOR...

Page 215: ...A GRID REPLACEMENT 5 79 6 3 CHARGE CORONA HElGHT ADJUSTMENT 5 80 6 4 TRANSFER SEPARATION CORONA WIRE REPLACEMENT 5 81 6 5 DRUM REPLACEMENT 5 82 6 6 ID SENSOR REPLACEMENT 5 85 6 7 ID SENSOR Vsg ADJUSTM...

Page 216: ...LATE HEIGHT ADJUSTMENT 5 105 7 14 FUSING EXIT SENSOR REPLACEMENT 5 106 8 TRANSPORT 5 107 8 1 TRANSPORT GUIDE UNIT REMOVAL 5 107 8 2 RELAY SENSOR REPLACEMENT 5 108 8 3 INVERTER SENSOR REPLACEMENT 5 109...

Page 217: ...sure glass B and lift up slightly Slide the other edge out from under the right glass holder C Remove the ex posure glass NOTE When reinstalling the exposure glass make sure that the left edge of the...

Page 218: ...the left scale 4 Remove the reflector cover A 2 screws 5 Remove the sub reflector cover B 2 screws 6 Remove the front spring plate C using a small screwdriver to release the plate then slide the plat...

Page 219: ...plate NOTE Make sure when installing the mirror that the reflecting surface is on the upper side and the beveled edge A of the mirror is on the lower side 10 Insert the rounded part B of the front pla...

Page 220: ...ss See the Exposure Glass Removal section 3 Slide the 1st scanner 2 3 of the way to the right 4 Remove the front spring plate A by pressing the top of the spring and moving the plate towards the front...

Page 221: ...irror B into the front side plate cutout 9 Insert the rear side of the mirror into the rear spring plate 10 Locate the bottom of the front spring plate C and rotate the top of the spring into position...

Page 222: ...their brackets is the same as with the second and third mirrors NOTE Make sure that the mirrors are installed in their original positions as the fourth and fifth mirrors are different in size The fou...

Page 223: ...around the exposure lamp B as shown 6 Press the release lever C on the rear terminal as shown and remove the lamp 7 Install a new lamp using a strip of paper Set the front terminal first Make sure th...

Page 224: ...posure Glass Removal section 3 Remove the reflector cover 2 screws 4 Remove the exposure lamp lead A from the exposure lamp terminals D 5 Remove the auto size sensor B 1 screw 6 Remove the ADS sensor...

Page 225: ...front cover Remove the upper inner cover Remove the rear cover Move the AC drive board A out of the way Disconnect the fiber optic cable connectors B from the system control PCB C and the I O control...

Page 226: ...the first scanner 150 mm to the right 3 Remove the reflection plate cover 2 screws 4 Remove the exposure lamp leads from the terminals A on both sides of the thermoswitch 5 Remove the thermoswitch br...

Page 227: ...late J Left cover Right cover 2 Loosen the front and rear first scanner wire clamp screws 3 Remove the front and rear wire tightener springs B 4 Loosen the front and rear wire fixing plate screws C 5...

Page 228: ...e extra wrap on the silver wire 4 Position the blue wire 3 in the hole on the Allen screw side and wind it halfway around the pulley 5 Position the silver wire 4 6 Wind the blue wire 3 one and a half...

Page 229: ...t shown and position to the side 12 Loosen the fixing screw of the wire tension bracket F and loosen the wire tension adjusting screw M 13 Position the silver scanner wires 2 and 4 at points B and D a...

Page 230: ...ld be pulled towards the wire timing plate G and fixed to the spring H 15 Tighten the first scanner wire clamps and remove the four jig pins and the fixing jig 16 Perform Free Run turn DIP switch 1 1...

Page 231: ...screw D until the rear jig pin drops and is locked in position Clamp the two fixing screws of the wire tension bracket C Make sure the jig pin moves smoothly If not repeat step 3 Clamp the fixing scr...

Page 232: ...front side of the scanner motor and partially remove the harness duct 4 Remove the two Allen screws of the scanner motor pulley and place it on the stud D 5 Remove the 4P connector E and the 2P connec...

Page 233: ...Remove the screws securing the lens drive motor and the bracket C 2 screws 6 Separate the motor from the bracket 2 screws and replace the motor 7 Reassemble all parts NOTE a Wind the lens drive wire A...

Page 234: ...r to the left viewed from the front 3 Remove the third scanner drive wire A 4 Remove the 6P connector B of the third scanner drive motor 5 Remove the motor and the bracket C 2 screws 6 Separate the 3r...

Page 235: ...ctor of the red erase solenoid 5 Remove the 6P connector of the erase lamp unit 6 Remove the red erase unit 2 screws 7 Push the plunger C of the red erase solenoid by half a stroke to make the lever D...

Page 236: ...the sight hole C of the reflector cover to form a right angle for viewing alignment as shown 6 View the lamp filament D through the sight hole in parallel with the scale The filament should be direct...

Page 237: ...own NOTE If you do not have a mirror remove and use the 2nd mirror 9 View the lamp filament C through the sight hole reflected on the mirror The filament should be level with the sight hole 10 To corr...

Page 238: ...A3 chart and make a full size copy at manual image density level 4 4 Adjust the voltage with the numeric keys ADJUSTMENT STANDARD Level 2 of the gray scale on the OS A3 chart should be just visible o...

Page 239: ...with the numeric keys SP mode 58 Press the Start key Use VR101 of the system control board to adjust the peak value dis played on the magnification display B to 3 0 0 1V NOTE This adjustment should b...

Page 240: ...ment is made as follows 1 2 3 4 5 Place a few sheets of A3 LDG size paper on the exposure glass Remove the DIP switch cover A and turn DIP switch 1 4 ON Set to ADS reference voltage memory mode with t...

Page 241: ...ode 61 4 Remove the rear cover 5 Press the Start key and use VR302 I O control PCB to adjust the peak value on the magnification display B to 2 8 0 1V 6 Press the Clear Stop key 7 Enter the APS width...

Page 242: ...mode SP Mode 46 using the numeric keys The original length is displayed in mm 5 The setting value is displayed in the magnification indicator blinking 6 Change the value with the numeric keys and cor...

Page 243: ...over A and turn DIP switch 1 4 ON 3 Enter the vertical magnification adjusting mode with the numeric keys SP Mode 43 4 The setting value is displayed in the magnification indicator blinking 5 Change t...

Page 244: ...e of overlay dupIex with the numeric keys SP Mode 45 4 The setting value is displayed in the magnification indicator blinking 5 Change the value with the numeric keys and adjust the magnification rati...

Page 245: ...perform the following 2 Remove the DIP switch cover A and turn DIP switch 1 4 ON 3 Enter the horizontal magnification adjusting mode with the numeric keys 4 The setting value is displayed in the magni...

Page 246: ...t of the 3rd scanner only when a parallelogram skewed image appears 1 Remove the exposure glass 2 Remove the lens cover Two screws 3 Open the front cover and remove the upper inner cover 3 screws 4 Re...

Page 247: ...nto the paper 5 Turn the unit right side up and pour in one bottle of 4460 type developer 1kg 6 Reinstall the toner tank and set the development unit in the machine 7 Remove the DIP switch cover D and...

Page 248: ...2 screws 4 Remove the black development roller drive gear D C ring 5 Remove the upper screws holding the bearing retainer E and loosen the lower screw 6 Remove the black development upper unit F 3 sc...

Page 249: ...octor gap with the jig B Part No A006 9513 ADJUSTMENT STANDARD 0 75 0 07mm a Before adjusting the doctor gap remove the developer from the development roller b When reassembling the development unit c...

Page 250: ...and turn the development unit over NOTE Be careful not to spill the used developer 4 Turn the paddle roller knob C counterclockwise The developer will fall out onto the paper 5 Turn the unit right sid...

Page 251: ...developer is replaced Check that Vsg is 4 0 2V before making the initial setting 1 Remove the DIP switch cover A and turn DIP switch 1 4 ON 2 Press the keys in the order shown above 3 Press the Start...

Page 252: ...F Remove the color development roller drive gear G Remove the bearing holder H 2 screws Remove the mag angle adjustment plate I 1 screw NOTE Take note of the mag angle mounting position 7 Remove the c...

Page 253: ...s A and adjust the doctor gap with the jig B Part No A006 9101 ADJUSTMENT STANDARD 0 72 0 07mm NOTE a Before adjusting the doctor gap remove any developer from the development roller b When reassembli...

Page 254: ...e screws securing the DC harness guide D 6 Remove the bracket E 4 screws by loosening the screw at the bottom of bracket F and rotating it 180 counterclockwise as shown 7 Remove the 2P connector H yel...

Page 255: ...t F 4 screws 8 Open the manual feed table or it will interfere with the removal of the switching solenoid bracket G 9 Remove the development unit change solenoid 2P connector H and remove the developm...

Page 256: ...4 Turn DIP switch 1 1 free run ON 5 Set meter scale to 1500 Vdc 6 Attach one lead of the meter to the retainer B and the other to the bot tom of the chassis C as shown in the figure 7 Press the Start...

Page 257: ...error may occur in bias value in the measurement by Beckman or by monitor display 1 Measurement by SP mode bias voltage display a Remove DIP switch cover A and turn DIP switches 1 1 and 1 4 ON b Enter...

Page 258: ...as value of the 4th setting is 200V and the setting value SP 37 is 1 the voltage becomes 160V 1 Remove the DIP switch cover A and turn DIP switch 1 4 ON 2 Enter the black bias adjustment mode with the...

Page 259: ...of the 4th setting is 200V and the setting value SP 79 is 1 the voltage becomes 160V 1 Remove the DIP switch cover A and turn DIP switch 1 4 ON 2 Enter the color development bias adjustment mode with...

Page 260: ...Enter the highlight color density adjustment mode with the numeric keys SP Mode 86 3 Numerals displayed in the magnification ratio indicator blink 4 Input a number from 1 to 7 with the numeric keys to...

Page 261: ...1 Remove the DIP switch cover A and turn DIP switch 1 4 ON 2 Enter the black toner supply mode with the numeric keys SP Mode 30 3 Numerals displayed in the magnification ratio indicator B blink 4 For...

Page 262: ...Supply Ratio 15 1 Remove the DIP switch cover A and turn DIP switch 1 4 ON 2 Enter the black toner supply mode with the numeric keys 3 Numerals displayed in the magnification ratio indicator B blink...

Page 263: ...pply Ratio 7 1 Remove the DIP switch cover A and turn DIP switch 1 4 ON 2 Enter the black toner fixed supply mode with the numeric keys 3 Numerals displayed in the magnification ratio indicator B blin...

Page 264: ...rn DIP switch 1 4 ON 2 Enter the color toner supply amount mode with the numeric keys 3 Numerals displayed in the magnification ratio indicator B blink 4 Input a number from 0 to 3 with the numeric ke...

Page 265: ...3 CLEANING 3 1 CLEANING UNIT REMOVAL 1 Open the front cover 2 Lower the transport unit A 3 Place some paper B underneath the cleaning unit C 4 Turn the cleaning unit release lever 90 and remove the cl...

Page 266: ...ng Unit Removal 2 Remove the cleaning blade B 1 screw 3 Install the new cleaning blade between blade brackets C and secure with the collar screw NOTE a Do not touch the edge of a new cleaning blade as...

Page 267: ...the 4 cleaning brush bracket screws and remove the cleaning brush C together with the cleaning side brackets B 3 Remove the E rings D on both sides and the rear side gear E and replace the cleaning b...

Page 268: ...February 1989 3 4 BLADE SCRAPER REPLACEMENT 1 Remove the cleaning blade and brush See Cleaning Brush Replacement section 2 Hold down the cleaning blade knob A and remove the blade scraper B 2 screws 5...

Page 269: ...MENT 1 2 3 4 Remove the cleaning unit Lower the transport unit A Remove the toner overflow sensor bracket B from the duct bracket 1 screw Disconnect the connector C and remove the toner overflow senso...

Page 270: ...sible 2 Remove the toner collection cap B and check the toner quantity by in serting a screwdriver 3 When the toner collection bottle is more than one half full remove the cleaning unit and cover it t...

Page 271: ...bruary 1989 3 7 QUENCHING LAMP REPLACEMENT CLEANING 1 Open the front cover 2 Pull out the QL A 3 Wipe the surface of the QL with a cloth 4 Reset replace the QL NOTE Do not use alcohol to clean the QL...

Page 272: ...REPLACEMENT 4 1 1 Table 1 Lower the manual feed table A 2 Remove the right cover 6 screws 3 Remove the manual feed table in the direction of the arrow 4 1 2 Sensor 1 Remove the right cover 6 screws 2...

Page 273: ...e size switch A from the paper feed station 1 screw 2 Pull the connector harness as far as possible into the machine before dis connecting the switch or the new switch unit will be very difficult to i...

Page 274: ...er feed guide plate A 1 screw Separation guide plate B 2 screws 3 Remove the snap ring C from the pick up roller shaft and remove the pick up roller D NOTE Do not bend the paper end actuator 4 Remove...

Page 275: ...he new rollers as shown NOTE Do the following for cleaning lubrication a Use a damp cloth to clean the rollers b Clean the clutch spring before lubricating it c Put Mobil Temp 78 in the three grease h...

Page 276: ...ee the 1st Feed Rollers Replacement section 2 Remove the holding spring plate A 1 collar screw NOTE Do not bend the spring plate B or the mylar strip C 3 Remove the grip roller bracket D 1 screw 4 Rem...

Page 277: ...nd replace the roller 4 To remove the friction pad assembly G press down on the bottom plate raising arm H and replace the friction pad I 1 screw NOTE a Clean the bracket with solvent before attaching...

Page 278: ...in the paper feed roller to slip Be sure to wipe any grease off these parts with a cloth 3 To remove the friction pad assembly D press down the bottom plate raising arm E and remove the friction pad 1...

Page 279: ...ance between the paper feed roller and the pad narrows as the longer grooved side of the eccentric cam nears the up position Keep the longer grooved side to the left when the cam is in horizontal posi...

Page 280: ...etting In the fol lowing cases change the position 1 The friction coefficient is large and multiple feeding occurs Increasing the friction pad pressure fails to correct the problem Adjust the spring p...

Page 281: ...ew paper feed clutch as the gear is provided as part of the assembly 1 Remove the rear cover 2 screws 2 Lower the I O control board A 1 screw 3 Release the upper limit sensor lever C 4 Remove the E ri...

Page 282: ...Disconnect the paper end sensor connector B and remove the paper end sensor bracket C 1 screw 5 Replace the paper end sensor D 4 10 2 2nd and 3rd Feed Stations 1 Remove the rear cover 2 screws 2 Lowe...

Page 283: ...w 3 Disconnect the 2P connector white D of the pick up solenoid C 4 Disconnect the 3P connector brown E of the 1st cassette lift sensor 5 Remove the spring F 6 Remove the pick up solenoid bracket G 4...

Page 284: ...units and place them on a sheet of paper Color development unit Black development unit Charge corona unit 1 screw Drum unit 1 screw 2 Remove the registration sensor bracket A 2 screws 3 Disconnect th...

Page 285: ...tion clutch B 4 Remove the connecting plate C and the registration clutch bracket D 3 screws 5 Separate the registration clutch from the bracket 1 screw 6 Remove the idle gear shaft assembly E and rep...

Page 286: ...Remove the rear cover and lower the I O control PCB 1 screw 3 Remove the drive gear A 2 Allen screws then remove the E ring B 4 Remove the E ring D and the bearing E from the front of the upper regis...

Page 287: ...4 Remove the bushing D 1 screw 5 Remove the lower registration roller assembly NOTE When removing the lower registration assembly make sure not to drop the bushing from the shaft rear side 6 Remove th...

Page 288: ...registration adjusting mode with the numeric keys as shown above 3 The magnification indicator C shows the current registration setting blinking 4 Input a number from 0 to 15 with the numeric keys to...

Page 289: ...oller 1 screw 3 Remove the second feed station lower entrance guide plate 1 screw 4 Remove the auxiliary roller assembly A 1 screw 5 Remove the upper relay sensor bracket B 1 screw and disconnect the...

Page 290: ...d Replacement section NOTE Make a note of the positions of the slots on the eccentric cam B Otherwise friction pad pressure will require re adjusting 2 Remove the lower relay sensor bracket C and sens...

Page 291: ...and disconnect the 2P connector A on the rear side plate Lower the registration release lever B to lower the transfer unit C Pull out the transfer separation corona unit D Unhook the spring E connect...

Page 292: ...ew C bushing D 8 Remove the following parts from the rear side of the transport roller 3 E rings E transport drive gear F parallel pin G busing H 9 Slide the transport belt assembly I to the rear side...

Page 293: ...8 February 1989 5 2 DRUM HEATER REPLACEMENT 1 Remove the transport unit See the Transport Belt Replacement section 2 Remove the drum heater A one connector B and 1 screw C and take out the heater 5 77...

Page 294: ...A 1 screw and the rear end block cover B 3 Unhook the spring from the corona wire C and replace the wire NOTE a Do not touch the wire Oils and chemicals on your hands will deteriorate the wire b Do no...

Page 295: ...NT 1 Remove the charge corona unit 2 Push in the front pawls A of the grid anchor as shown in order to remove the grid NOTE a Oils and chemicals on your hands will deteriorate the grid b Do not bend t...

Page 296: ...harge corona height to achieve even gradation A using an OS A3 test chart as following order 1 Place the charge corona unit on a flat surface with the grid side B down 2 Measure the height of the rear...

Page 297: ...lock cover B T S unit paper guide C NOTE When replacing the T S unit paper guide verify that all three tabs are properly latched in place D 3 Unhook the springs E from the wires 4 Replace the transfer...

Page 298: ...long the rail NOTE Take care when removing the drum unit not to strike the erase unit D 3 Place the drum unit on a sheet of paper Loosen the two screws E secur ing the bearing holder and rotate the ho...

Page 299: ...the screws NOTE a When setting the drum in the unit be careful not to strike it against the rail b Do not bend the bearing holder Make sure the bearing holder is in contact with the bearing B as they...

Page 300: ...ove sequence SP Mode 66 in order to initialize the drum counter and measure the amount of residual voltage on the drum surface NOTE After the keys are pressed and the beeper sounds five times 11 Turn...

Page 301: ...1 Remove the drum unit then remove the drum A from the unit See the Drum Replacement section 2 Remove the ID sensor holder B 2 screws 3 Peel the plastic strip off the back of the holders and remove t...

Page 302: ...agnification ratio display NOTE a An incorrect adjustment of the ID sensor output may cause a toner density control error b Adjustment is required in the following cases System control board replaceme...

Page 303: ...e removing the drum unit This prevents the drum from being exposed to light 1 Remove the drum unit then separate the drum A from the unit See the Drum Replacement section 2 Remove the separation pawl...

Page 304: ...ower pack 5 Connect the multimeter leads as shown and measure the main corona current 6 Turn DIP switch 1 4 ON 7 Turn on the main switch and select SP Mode 9 2 as shown 8 Adjust the charge corona curr...

Page 305: ...imeter range at DC 1500V and connect the probe to terminal G 3 Turn ON DIP switch 1 4 Adjustment of standard grid voltage a Turn on the main switch b Set SP Mode 9 2 as shown c Adjust VR3 of the CC TC...

Page 306: ...color Drum unit 2 Remove the paper guide from the transfer corona unit 3 Clean the transfer separation corona wires 4 Turn on the front door safety switch 5 Turn ON DIP switch 1 4 6 Remove the drum f...

Page 307: ...sur face facing the transfer corona wire B 2 Set the range of the multimeter to DC200 A 3 Make sure that the release lever of the transport unit is in the up position 4 Turn on the main switch 5 Ente...

Page 308: ...hen lock the drum shoe in place 2 Set the multimeter range to AC200 A 3 Turn on the main switch 4 Enter SP Mode 9 7 as shown 5 Adjust the VR AC of the separation power pack to obtain the standard valu...

Page 309: ...he fusing front cover A while pushing the release lever B and pull out the fusing unit until it stops 3 Remove the fusing unit lock screws C 2 screws 4 Remove the fusing unit completely NOTE Before co...

Page 310: ...ove the fusing knob A by simply lifting the leaf spring with a screwdriver 3 Remove the front cover B of the fusing unit 1 screw 4 Pull out on the front lamp terminal D to remove the fusing lamp Repla...

Page 311: ...ear pressure springs B 4 Remove the rear lamp terminal C 1 screw 5 Remove the front and rear C rings D drive gear E front and rear col lars F and front and rear fusing bearings G Then remove the hot r...

Page 312: ...s fully installed Remove the sheet before setting the pressure springs 1 Remove the hot roller See the Hot Roller Replacement section 2 Remove the fusing entrance guide A 2 screws 3 Lift both ends of...

Page 313: ...ACEMENT 1 Lower the paper exit assembly A 2 Remove the pawl spring B 3 Loosen the step screw C and release the pawl spring D 4 Loosen the screws holding the fusing pawl bracket E in place 5 Remove the...

Page 314: ...using Lamp Replacement section Remove the fusing unit upper cover C 4 screws Lower the paper exit assembly D Pull out the temperature fuse connector E Disconnect the fuse harness lead from the rear te...

Page 315: ...e Fusing Lamp Replacement section 2 Remove the fusing unit upper cover C See the Temperature Fuse Replacement section 2 Remove the upper paper entrance guide D 1 step screw 1 flat seat screw 3 Pull ou...

Page 316: ...de 52 1 Remove the DIP switch cover A and turn ON DIP switch 1 4 2 Enter the fusing temperature check mode using the numeric keys SP Mode 52 3 The current temperature setting is indicated on the magni...

Page 317: ...A and turn ON DIP switch 1 4 2 Enter the fusing temperature adjustment mode using the numeric keys SP Mode 49 3 The current temperature setting blinks in the magnification display Enter the new tempe...

Page 318: ...ntrol 0 1 Remove the DIP switch cover A and turn ON DIP switch 1 4 2 Enter the control mode using the numeric keys SP Mode 29 3 0 blinks in the magnification indicator 4 Enter 1 to select phase contro...

Page 319: ...t roller knob clockwise one half turn NOTE Before turning the fusing unit roller knob make sure that the front cover safety switch is turned off This releases the fusing unit drive gear 4 Wait another...

Page 320: ...ment combinations Hook settings Nip Width A a 3 0 0 3 mm A b B a 3 3 0 3 mm B b 3 6 0 3 mm Standard setting Three different nip widths can be selected Adjust the width if poor fusing oc curs or if the...

Page 321: ...creasing in the fusing unit can also be corrected by adjusting the height of the fusing entrance guide plate D 1 Remove the guide plate mounting screws from the A position and place them in the lower...

Page 322: ...the fusing knob and the fusing front cover See the Fusing Lamp Replacement section 2 Lower the fusing exit assembly A 3 Remove the fusing exit sensor bracket B 1 screw 4 Remove the exit sensor connec...

Page 323: ...8 TRANSPORT 8 1 TRANSPORT GUIDE UNIT REMOVAL 1 Remove the fusing unit See the Fusing Unit Removal section 2 Release the transport guide unit A and remove the collar screw B 3 Pull out the transport g...

Page 324: ...move the collar screw A 2 Remove the inverter relay sensor connector B from the rear side plate and remove the reverse unit C 3 Remove the collar screw D 4 Remove the turn guide plate E from the rever...

Page 325: ...s installed press the release lever E1 and slide the unit out until it stops 1 Remove the left lower cover A 2 screws 2 Remove the inverter sensor bracket B 1 screw 3 Pull out the inverter sensor conn...

Page 326: ...ower supply board C to the right 1 screw Remove the main transformer 1 screw 1 connector Remove the tension spring D and take the duplex overlay drive chain E off its sprocket Disconnect the clutch co...

Page 327: ...screws If the multi duplex unit is installed remove the E1 knob C in order to remove the inner cover 1 collar screw 3 Mark the original position of the jogger unit D on the bottom plate E 4 Remove two...

Page 328: ...oval section 2 Remove the screw A and disconnect the connector B Then replace the jogger home position sensor C NOTE a Access the screw A by inserting a screwdriver through the hole in the jogger unit...

Page 329: ...Unhook the jogger wire tension spring C from the jogger wire 5 Remove the jogger wire D Installation 6 Temporarily place the colored wire eyelet E over the anchorage point F and route the wire around...

Page 330: ...plate B and tighten the stop plate screw 11 Position the rear logger fence to 11 0 3 mm home position from the rear side plate C 12 Position the front jogger fence D 10 mm from the front side plate E...

Page 331: ...section Disconnect the jogger motor connector B from the connector bracket Remove the jogger motor assembly C 2 screws Separate the drive pulley D from the motor and replace the motor Reassemble the u...

Page 332: ...solenoid bracket A to satisfy the following condi tions When solenoid is OFF Press the solenoid plunger B and release it Adjust the stroke C to 3 0 3 mm When solenoid is ON Make sure the clearance bet...

Page 333: ...remove the inner cover A 3 screws 2 Remove the operation panel B 4 screws 6 connectors 3 Replace the operation panel NOTE a Remove the RAM IC from the old operation panel and install it in the new pa...

Page 334: ...SECTION 12...

Page 335: ...14 1 11 HORIZONTAL BLACK LINES 12 15 1 12 JITTER 1 12 17 1 13 JITTER 2 Irregular 12 18 1 14 MARKS AT 251MM INTERVALS 12 19 1 15 SKEWED OPTICAL COPY IMAGE 12 20 1 16 BLACK SPOTS ON THE COPY IMAGE 12 21...

Page 336: ...G PROBLEM A3 LDG Tracing Paper 12 48 3 4 DIRTY BACKGROUND Blue Development Unit 12 48 3 5 PAPER CREASING 12 49 4 ELECTRICAL COMPONENT DEFECTS 12 50 4 1 PAPER END SENSOR 12 50 4 2 MANUAL FEED SENSOR 12...

Page 337: ...OTO MODE lD LEVEL SETTlNG 12 57 5 5 INCOMPLETE IMAGE TRANSFER AT TRAILING EDGE 12 57 5 6 LOW IMAGE DENSITY WITH RED ORIGINALS 12 58 5 7 LOW ID LEVEL WITH MULTIPLE SOLID COLOR COPIES 12 58 5 8 MODES CL...

Page 338: ...opy image grid gives no output Development roller does not turn due to binding caused by a broken drive gear Correct bias voltage is not applied If the bias terminal is not connected properly the deve...

Page 339: ...ge between pins 1 and 2 of CN1 15p on the power pack with main power ON If the voltage is 24V replace the CC TC bias power pack If the voltage is 0V check FU3 of the power supply unit If FU3 is defect...

Page 340: ...must be replaced 2 If the surface integrity of the drum has been destroyed by ammonia replace the drum and instruct the user to move the copier away from the sourse of ammonia fumes NOTES 1 After repl...

Page 341: ...details refer to the troubleshooting section If the toner density is too high toner scatters inside the copier getting on the toner shield glass PTL ID sensor charge corona wire and transfer corona wi...

Page 342: ...exposure lamp and replace if deteriorated If the exposure lamp has no defects adjust the exposure lamp voltage SP Mode No 48 and ADS SP Mode No 58 NOTE Set the exposure lamp voltage so that level 2 of...

Page 343: ...orrection rate is less than 37 Vr correction is no longer effective and the drum must be replaced 2 Correct the deformation of the drum holder 7 Set the standard value 3V 0 1V for Vde with SP Mode No...

Page 344: ...n the grid Uneven image density with a solid black copy is usually caused by a dirty transfer corona wire Uneven image density with a halftone image is usually caused by a dirty charge corona wire Act...

Page 345: ...even area does not move when the reproduction ratio is changed the problem is not with the optics unit 2 Deterioration of the exposure lamp or an incorrectly aligned filament Actions 1 2 Clean the opt...

Page 346: ...oner density is too high Actions NOTE See if the black bands shift when the reproduction ratio is changed 1 2 3 4 5 If so the problem is in the optics unit Check and replace the inlet seal if defectiv...

Page 347: ...scratching the drum surface Adjust the doctor gap Confirm that the line was caused by a scratched hot roller This can be determined by stopping the copy on the transport unit and seeing if the same li...

Page 348: ...d grid The inlet seal on the development unit is damp or is contaminated with oil Actions 1 2 3 Clean the charge corona wire and or transfer corona wire Check the charge and transfer casings for burrs...

Page 349: ...Tone Images Phenomenon Blurred white lines appear on half tone images Possible Cause The light intensity of the exposure lamp is too strong Action Adjust the position of the exposure lamp See the sec...

Page 350: ...face prior to fusing cause fuzzy white lines on the copy image Possible Causes 1 Deformation of PTL filter 2 Deformation of ID sensor board 3 Deformation of transfer guide 4 Incorrectly positioned cle...

Page 351: ...use Scratched drum Actions Replace the drum Find out what caused the scratches on the drum and cor rect the problem 1 2 3 4 5 6 Paper jam Pick off pawls pushing too hard against the drum Deformed ID s...

Page 352: ...ay be attached to the blade causing toner to attach to the drum suface when the drum stops Things to look for The black lines appear at the same location on copies from different single copy runs rega...

Page 353: ...lean dry cloth or replace the drum b Clean or replace the cleaning blade 2 a Clean the cleaning blade and brush b If cleaning the blade or brush does not solve the problem or if the problem reoccurs r...

Page 354: ...ed by the diameter of the optics unit drive pulley 30 mm Possible Causes 1 Irregular rotation speed of scanner drive motor 2 The optics drive pulley is defective or it has burrs or scratches on its su...

Page 355: ...speed 2 Overload of the scanner caused by worn out sliders an uneven slider unit guide rail surface or incorrect adjustment of the drive wire tension Actions 1 Check the system control board DC power...

Page 356: ...ratches or areas of reduced sensitivity on the drum Drum diameter 80 mm If a positive image remains at 251 mm intervals a dirty quenching lamp filter or a defective quenching lamp may be the problem A...

Page 357: ...port of the copier They should have been locked into place before transport The 3rd scanner may have been bent at installation if the technician pressed the magnification key without first removing th...

Page 358: ...properly contact its terminal the grid will be insu lated from all charges floating This hinders the flow of ions from the charge corona wire to the drum surface Ions must pass through the grid This r...

Page 359: ...xed toner supply mode black development In fixed toner supply mode toner is supplied regardless of the actual usage Consequently excessive toner may be supplied depending on customer s originals Toner...

Page 360: ...as voltage charge current and ID sensor grid If Vsp is too low check the level of CN303 A13 on the I O control board L Replace toner supply clutch H Replace I O control board Considerations System Con...

Page 361: ...decrease 3 ID sensor bias voltage of is too low 4 5 Exposure lamp voltage is too low Toner supply clutch is defective Too many solid dense copies are being made The amount of toner supplied is inadequ...

Page 362: ...current and ID sensor grid voltage If Vsp is too high check the level of CN303 A13 on the I O control board L Replace toner supply clutch H Replace I O control board 2 If Vsp does not decrease even th...

Page 363: ...alfunction Actions 1 Adjust the position of the pressure spring in the fusing unit Nip width Standard Value Center 3 3 mm Front Rear Deviation between the front and the rear is within 0 3 mm Check Pos...

Page 364: ...3 Check to see if temperature is 185 5 C 4 If the surface temperature is still low although 185 5 C is displayed in the size magnification indicator the problem is a thermistor malfunction NOTE Resis...

Page 365: ...he CPU from being reset The voltage in the Vcc line is low Actions 1 Use a digital multimeter to measure the power supply voltage exactly when the main switch is turned on Do not take this measurement...

Page 366: ...in a program error that causes the scanner control failure Actions 1 2 3 Check the encoder output of the scanner drive motor on the I O control board CN301 B14 and CN301 B15 while slowly turning the s...

Page 367: ...i duplex overIay unit option Possible Cause The jogger in the copier does not work in duplex overlay mode with paper larger than A4 8 x 11 so the small skews caused at each transport stage are not cor...

Page 368: ...de Overlay mode in main body in main body Duplex overlay Rear spring x x transport roller Front spring o o Duplex overlay Rear spring o x guide roller Front spring x o o Replace the spring x No replac...

Page 369: ...rd malfunction Actions 1 2 3 Replace the exposure lamp Test the resistance across the optical thermoswitch If there is no conductivity replace the thermoswitch Check the voltage at CN304 A19 in standb...

Page 370: ...1 Check the conductivity in the exposure lamp filament If there is no conductivity replace the exposure lamp 2 Check the conductivity in the optical thermoswitch If there is no conductivity replace t...

Page 371: ...0V Replace 1st scanner home position sensor 5V Replace I O control board or system control board 2 4 CODE 22 Phenomenon SC 22 1st scanner stays at home position Possible Causes 1 Scanner home position...

Page 372: ...ol board Voltage changes to 0V Replace system control board See the note below NOTE Normally the lead edge signal drops from 5V to 0V just before the registration clutch turns on then rises to 5V when...

Page 373: ...lure I O control board malfunction Optical scanner overload binding The dc power supply is not supplying 24V The scanner wire is slipping Actions 1 2 3 4 5 Check the encoder output of the scanner driv...

Page 374: ...change replace the 3rd scanner home position sensor If the voltage does change replace the 3rd scanner drive motor or the I O control board 2 If the 3rd scanner drive motor does not turn and nothing i...

Page 375: ...f the output does not change replace the lens home position sensor If the output does change replace the lens drive motor or the I O control board If the lens drive motor does not turn and nothing is...

Page 376: ...ly interrupting and uninterrupting the sensor interrupted 5V not interrupted 0V If the lift sensor voltage level remains the same replace the lift sensor If the Iift sensor voltage level changes repla...

Page 377: ...e fusing unit connector 2 12 CODE 54 Phenomenon SC 54 Ready signal is not received within 5 minutes after main switch is turned on Possible Causes 1 2 3 4 5 Thermofuse blown Fusing lamp open I O contr...

Page 378: ...r If there are any gaps replace it See note 2 With the fusing lamp on check the voltage at CN304 B19 fusing lamp on the I O control board Constant at 0V Constant at 24V 2 14 CODE 61 Phenomenon Replace...

Page 379: ...ntrol board 0V Replace the main motor 5 Connect the pulse generator sensor connector 2 15 CODE 81 AND 82 Phenomena SC 81 Jogger home position sensor output stays LOW SC 82 Jogger home position sensor...

Page 380: ...drive motor If the outputs are constant at 0V check CN304 B28 if it is 0V replace the I O control board If it is 24V replace the jogger drive motor 3 Check the jogger fences for binding 4 Set the jogg...

Page 381: ...heck the connections between the system control board and the I O control board System control board CN101 I O control board CN301 2 Replace the I O control board 3 Replace the system control board 2...

Page 382: ...stem control board CN101 Check the connector on the editor side CN1 2 Replace the editor main board 3 Replace the system control board 2 20 CALL SERVICE CONDITION 95 Phenomenon SC 95 Destination codes...

Page 383: ...opy indicator blinks Possible Cause The color developer is deteriorated Action Replace and initialize SP Mode No 10 the color developer When the values of Vsg and Vsp are detected correctly the indica...

Page 384: ...anges Action When over 4000 copies have been made select H 2 or HH 3 for the black toner ID sensor bias SP Mode No 33 to increase the toner density in the developer mixture NOTES 1 If this bias level...

Page 385: ...the first few copies 2 After replacing the toner cartridge dirty background copy may appear on the first few copies with originals that have a small amount of black image Possible Causes 1 2 Blue ton...

Page 386: ...iling edge of thin paper C r e a s i n g Possible Cause The lower registration roller is greater in diameter in the center and it tends to wear out the upper registration roller made of rubber at the...

Page 387: ...Conditions 1 Stays OFF Interrupted 2 Stays ON Not interrupted Phenomena 1 The Manual Feed indicator is not displayed when the manual feed table is opened 2 The Manual Feed indicator is displayed when...

Page 388: ...ath indicator turns on and point B blinks on the Misfeed Location display when the main switch is turned on When the Start key is pressed the leading edge stops 10 cm after exiting the fusing unit The...

Page 389: ...cm beyond the inverter relay sensor when the Start key is pressed in duplex overlay mode The Check Paper Path indicator turns on and point C blinks on the Misfeed Location display 4 8 COLOR TONER END...

Page 390: ...1 Stays OFF Interrupted 2 Stays ON Not interrupted Phenomena 1 2 Service Call code 28 is displayed approximately 6 seconds after the main switch is turned on Service Call code 29 is displayed approxim...

Page 391: ...the operation panel stay off and the copier cannot be used NOTE The copier becomes inoperable when the front cover is opened 4 14 THERMOFUSE Condition Open Phenomenon 1 Service Call code 54 is displa...

Page 392: ...in switch is turned on 3 Copies are blank NOTE Check the power pack if Fuse 3 blows after it is replaced 4 17 SHORT CIRCUIT IN DC 5V LINE Phenomenon Indicators on the operation panel stay off when the...

Page 393: ...cess the sheet curls The sheet then contacts the pick off pawls during overlay copying Explanation Instruct customer to insert the paper lengthwise long grain direction A3R Letter R This will reduce t...

Page 394: ...gray scale than the image density in normal mode Manual Level 4 Explanation Select setting 1 or 2 in SP Mode No 40 5 5 INCOMPLETE IMAGE TRANSFER AT TRAILING EDGE Phenomenon The copy image may be faint...

Page 395: ...t unit Instruct the user to limit the number of such copies in multi copy runs Or if many copies are needed instruct the user to do so one copy at a time this is because the fixed supply mode is used...

Page 396: ...placing an overlay original on the exposure glass and or inputting the desig nated area In overlay mode a small gap or overlaps of up to 5 mm 0 2 may ap pear between the designated area and the surrou...

Page 397: ...T ROLLER MARKS ON DIRECT IMAGE MASTERS C P Phenomenon Paper exit roller marks appear on copies of direct image masters used in offset printing Explanation Explain to the user that copies cannot be mad...

Page 398: ...Water Proof Pocket Electrical Component Layout Page 401 406 Connector Layout Page 407 412 Point to Point Page 413 415...

Page 399: ......

Page 400: ...rollers of the Duplex Overlay section Starts paper feed from the 1st feed station Changes the position of the black develop ment unit and color development unit Changes the filler position Directs cop...

Page 401: ...1 bell and feed in system pick up roller feed roller pull out roller and relay roller DC servomotor that drives the feed out unit of the DF M12 Energizes to press the pick u p lever against the stack...

Page 402: ...lowers the LCT bottom plate to bring paper to feed position and allow loading of paper Detects when tray is completely down to stop tray motor Determines what size paper is loaded into the LCT Detect...

Page 403: ...Sensor Misfeed detection for the sorter S31 H 8 4 Bin Home Position Detects when all bins are in the down posi S32 H 9 Sensor tion home 5 Wheel Sensor Detects each 1 2 turn of the wheel 1 bin S33 H 8...

Page 404: ...gger fences that keep paper stacked evenly in the duplex tray M10 D 7 C 7 Starts paper feed from the duplex tray MC9 D 8 C 8 Opens and closes the j u c t i o n gate to change the paper path Raises and...

Page 405: ...7 48 49 50 51 52 53 54 55 56 57 50 CN301 CN12 CN14 CN21 CN19 CN3 CN1 CN2 CNI CN807 CN806 CN111 I O Control Board 3rd Paper Feed MC Jogger H P Sensor Jogger Motor Positioning Roller SOL Key Counter CC...

Page 406: ...aper Feed Board Paper Feed Board Paper Feed Board Paper Feed Board Main Transformer Drum Heater Fusing Lamp Front Cover Switch Front Cover Switch Front Cover Switch Front Cover Switch Exposure Lamp Ma...

Page 407: ...R Original Width Sensor Harness 4P W DF Main Board 34P B Registration Sensor Harness 3P Y Original Select Switch 2P W DF DC Harness 4P W DF TXD RXD Harness 2P B Feed out Sensor Harness 3P W Feed out...

Page 408: ...Tray Interface Harness Tray Interface Harness LCT Main Board LCT Main Board LCT Main Board LCT Main Board LCT Main Board LCT Main Board Tray Drive Motor Intermediate Transformer Transformer Down Sens...

Page 409: ...Board Sorter Board Covor Safety Switch Cover Safety Switch Paper Sensor Wheel Drive Motor Roller Drive Motor H P Sensor Wheel Sensor Relay Drive Motor Sorter Board Sorter Interface Harness Sorter DC H...

Page 410: ...mponent Paper Exit Sensor Paper End Sensor Positioning Roller SOL Cam Clutch SOL Jogger H P Sensor Jogger Motor Duplex Feed MC Junction Gate SOL Multi Duplex Overlay Harness Multi Duplex Overlay Harne...

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