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Ricoh FT8680, Service Manual

The Ricoh FT8680 is a versatile multifunction printer renowned for its exceptional performance and reliability. To assist you in maximizing its features, our website offers a comprehensive Service Manual available for free download. Unlock its full potential by accessing the manual at manualshive.com today.

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1. SERVICE REMARKS

1.1 HANDLING THE DRUM

  1. Never expose the drum to direct sunlight.

  2. Never expose the drum to direct light of more than 1,000 Lux for more

than 5 minutes (sunlight is about 1,360 Lux).

  3. Never touch the drum surface with bare hands.

  4. Store the drum in a cool dry place.

  5. Always keep the drum in the protective sleeve when inserting or pulling

the drum out from the copier.

  6. Never expose the drum to corrosive gases such as ammonia.

  7. When the drum surface becomes dirty, clean the drum by following the

proper procedure.

a) Dirty with toner or condensation

Clean the drum with a dry soft cloth

b) Finger marks

Clean the drum following this order:
1) A dry soft cloth
2) A wet cotton cloth with water
3) A dry soft cloth

c) Oil or grease

Clean the drum following this order:
1) A dry soft cloth (to remove toner first)
2) A wet cotton cloth with isopropyl alcohol
3) A wet cotton cloth with water (to remove the alcohol)
4) A dry soft cloth

NOTE: Use only isopropyl alcohol. Other types of alcohol may damage

the surface of the drum.

  8. Before inserting or removing the drum, the following should be performed

to avoid damaging the drum.

a) Remove the development unit
b) Remove the cleaning unit
c) Remove the erase lamp, potential sensor, and ID sensor units.
d) Remove the charge corona unit.
e) Lower the T&S corona unit.

31 July 1995

SERVICE REMARKS

4-1

Summary of Contents for FT8680

Page 1: ... main switch is turned off 5 If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on keep hands away from electrified or mechanically driven components 6 The inside and the metal parts of the fusing unit become extremely hot while the copier is operating Be careful to avoid touching those components with your bare hands HEALTH SAFETY ...

Page 2: ...charge or burn this 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 photoconductors according to local regulations 3 Dispose of replaced parts in accordance with local regulatio...

Page 3: ...SECTION 1 OVERALL MACHINE INFORMATION ...

Page 4: ...l scan mode Europe version only A5 Copy Paper Weight Standard Copying 14 42 lb 52 157 g m2 Duplex Copying 17 28 lb 64 105 g m2 Tab Sheets 90 lb index 160 g m2 Warm Up Time Within 8 0 minutes room temp 68 F 20 C First Copy Time 3 8 seconds 81 2 x 11 A4 copier only 6 9 seconds 81 2 x 11 A4 with sorter stapler Copying Speed 80 copies minute 81 2 x 11 82 copies minute A4 Optional Equipment 20 Bin Sort...

Page 5: ...4 A3 version Power Consumption LT DLT version Copier only Full system Warm up less than 2 10 kW less than 2 15 kW Stand by less than 0 50 kW less than 0 55 kW Copying less than 2 50 kW less than 2 60 kW Maximum less than 2 60 kW less than 2 70 kW Full system Copier with document feeder large capacity tray and a sorter stapler A4 A3 version at 230 V Copier only Full system Warm up less than 2 0 kW ...

Page 6: ...5 mm 56 9 Copier with document feeder and one sorter stapler 1 688 mm 66 5 873 mm 34 4 1 445 mm 56 9 Copier with document feeder large capacity tray and one sorter stapler 2 070 mm 81 5 873 mm 34 4 1 445 mm 56 9 Copier with document feeder large capacity tray and two sorter staplers 2 610 mm 102 8 873 mm 34 4 1 445 mm 56 9 Weight LT DLT version A4 A3 version Copier with document feeder 367 kg 809 ...

Page 7: ...less than 74 dB A less than 78 dB A Full system Copier with document feeder large capacity tray and a sorter stapler Document Feeder Original Size Stack feed mode Single feed mode Duplex mode Moving Original Scan Maximum 11 x 17 A3 11 x 17 A3 11 x 17 A3 A2 Minimum 81 2 x 11 A4 51 2 x 81 2 A5 81 2 x 11 A4 B5 Original Weight Stack feed mode Single feed mode Duplex mode Moving Original Scan Maximum 3...

Page 8: ...MEMO 31 July 1995 SPECIFICATIONS 1 5 ...

Page 9: ...2 COPY PROCESSES AROUND THE DRUM 1 2 3 4 5 6 7 8 10 9 A171V513 img COPY PROCESSES AROUND THE DRUM 31 July 1995 1 6 ...

Page 10: ... potential of the toner to improve toner transfer to paper The ac charge decreases positive charge on the drum and makes paper separation easier The pre transfer lamp PTL also makes paper separation easier by illuminating the drum and decreasing the positive charge on the drum 7 IMAGE TRANSFER Paper is fed to the drum surface at the proper time so as to align the copy paper and the developed image...

Page 11: ...eed Roller 13 Vertical Transport Unit Right 14 Third Tray 15 Horizontal Transport Unit 16 Pick off Pawls 17 Transfer and Separation Corona Unit 18 Vertical Transport Unit Left 19 Registration Rollers 20 Pre transfer Corona Unit 21 By pass Feed Table Europe version only 22 Toner Hopper 23 Development Unit 24 Drum Thermistor and Drum Potential Sensor 25 Erase Lamp 26 Fifth Mirror 27 Fourth Mirror 28...

Page 12: ...Inverter Rollers 5 Upper Inverter Rollers 6 Switch Back Gate 7 Switch Back Tray 8 Upper Relay Roller 9 Friction Tab 10 1st Pick up Rollers 11 2nd Pick up Rollers 12 Separation Rollers 13 Lower Relay Roller 14 Pressure Rollers 15 Transport Belt 16 Lower Inverter Gate 17 Lower Exit Rollers 18 CFF Guide 31 July 1995 MECHANICAL COMPONENT LAYOUT 1 9 ...

Page 13: ...82 Optics Cooling 2 Removes the heat from the optics unit 81 Scanner Drive Drive the 1st and 2nd scanners 56 T S Wire Cleaner Drives the transfer and separation wire cleaner 75 Toner Supply Rotates the toner supply roller 78 Vacuum Fan Removes the heat and dust in the machine 53 Clutches LCT Drive Transmits the main copier drive to the LCT feed section 52 Left Vertical Transport Unit Drive Transmi...

Page 14: ...s power to the fusing lamp 111 Relay Unit Provides ac power to ac components 117 Sensor Auto Response Turns on the display from the screen saver condition 93 By pass Table Detects when the by pass table is opened and indicates the display on CRT screen 34 Drum Potential Detects the drum surface voltage 100 Duplex Entrance Detects misfeeds 137 End Fence Home Position Detects when the duplex end fen...

Page 15: ...nly 30 Paper Size 1 LCT Determines what paper size is in the LCT 142 Paper Size 2 1st Tray Determines what paper size is in the 1st tray 41A Paper Size 2 2nd Tray Determines what paper size is in the 2nd tray 41B Paper Size 2 By pass Feed Determines what paper size is in the by pass feed tray European version only 29 Paper Size 2 LCT Determines what paper size is in the LCT 143 Paper Size 3 1st Tr...

Page 16: ...tom plate 13 Upper Limit 3rd Tray Sends signal to stop lifting up the 3rd tray bottom plate 19 Upper Limit LCT Sends signal to stop lifting up the LCT bottom plate 151 Duplex Exit Jam detector 16 Solenoids Cleaning Brings the cleaning blade into contact with the drum 54 Inverter Gate Drives the inverter gate up and down 62 Junction Gate Drives the junction gate up and down 61 LCT Lock Locks the LC...

Page 17: ... too cool 95 Exposure Lamp Warms the exposure lamp when it gets too cool 86 LCT Removes humidity from the paper in the LCT 145 Lamps Exposure Exposes the original with high intensity light 85 Fusing Provides heat to the hot roller and keeps the roller at the operating temperature 89 Pre Transfer Removes excessive positive charge from the drum surface to the transfer and separation process 98 Quenc...

Page 18: ...ver is open 4 S2 Lift Detects if the transport unit is open 14 S3 Inverter Cover Detects if the inverter cover is open 22 S4 Pick up Roller H P Detects if the pick up roller is in the home position 1 S5 Job Separation H P Detects if the job separator is in the home position 7 S6 Job Completion Detects that last original of the first job is fed from the original table 8 S7 Original Detects if the o...

Page 19: ...Detects when the original is set on the moving original scan entrance European version only 24 Others Oth1 CFF Guide Switch Detects whether the CFF guide is in the rear end position or not European version only 26 Oth2 Sheet Feed Clutch Drives the sheet feed rollers European version only 28 ELECTRICAL COMPONENT DESCRIPTIONS 31 July 1995 1 16 ...

Page 20: ...mg G A171V506 img E A171V507 img A C D E F B 2 1 C G A171V508 img F D A Development Unit B Cleaning Unit C Relay Transport Unit to LCT By pass Table D Fusing Unit E Vertical Transport Unit Right F Duplex Unit G Vertical Transport Unit Left A171V512 img 31 July 1995 DRIVE LAYOUT 1 17 ...

Page 21: ...6 PAPER PATH 6 1 SINGLE SIDED COPY COPY FACE DOWN 6 2 DUPLEX MODE 1ST SIDE A171V501 wmf A171V502 wmf PAPER PATH 31 July 1995 1 18 ...

Page 22: ...6 3 DUPLEX MODE 2ND SIDE 6 4 IMAGE OVERLAY MODE 1ST SIDE A171V503 wmf A171V504 wmf 31 July 1995 PAPER PATH 1 19 ...

Page 23: ...6 5 IMAGE OVERLAY MODE 2ND SIDE A171V505 wmf PAPER PATH 31 July 1995 1 20 ...

Page 24: ...SECTION 2 DETAILED SECTION DESCRIPTIONS ...

Page 25: ...continuous copy runs these characteristic changes have to be compensated The following figure and table show how these factors are compensated on this copier Drum Current Detection PCB Development Bias ID Sensor Potential Sensor Exposure Lamp Charge Corona Toner Supply PTC Transfer Corona Separation Corona Main PCB Sensing Item Controlled Item A171D522 wmf 31 July 1995 PROCESS CONTROL 2 1 ...

Page 26: ...that was erased by the erase lamp residual voltage and adjust the development bias light potential and dark potential Charge Corona Charge Potential Dirtiness Temperature Humidity Measure the drum potential of a part that was not exposed dark potential and adjust the charge corona output Exposure Lamp Intensity Repeat Stress Measure the drum potential of a part that was exposed light potential and...

Page 27: ... Vd Dark Potential The drum potential just after exposing the black pattern Vd pattern VL Light Potential The drum potential just after exposing the white pattern VL pattern Vr Residual Voltage The drum potential just after the exposure of the erase lamp QL Charge V0 Exposure Black White Erase Potential Sensor Drum Vd VL Vr A171D507 wmf 31 July 1995 PROCESS CONTROL 2 3 ...

Page 28: ... voltage Vr increase cannot be compensated for by increasing the lamp voltage it is compensated by increasing the development bias voltage and changing the Vd and VL standard value 1 2 2 Image Density Control To maintain constant copy image density the ID sensor detects the toner amount of the ID sensor pattern From this it is understood that drum potential is stabilized with the above compensatio...

Page 29: ...Temp 160 C Drum Conditioning Start Fusing Temp 160 C Exposure lamp ON Vsg Adjustment Lamp Intensity Sensor Calibration Charge Corona Current Adjustment Vr Measurement Lens position shift Exposure lamp OFF Scanner moves to return position Vd Pattern Exposure lamp ON Vd Correction Exposure lamp OFF Scanner returns to home position VL Pattern Exposure lamp ON VL1 Correction Exposure lamp OFF V01 Dete...

Page 30: ... calibrated during process control data initialization The drum current detection board has two relay contacts Usually RA2 grounds the drum However during the initialization the main PCB turns RA1 on and RA2 off and applies the development bias to the drum shaft By measuring the outputs of the drum potential sensor when 100 V and 800V are applied to the drum the sensor output is calibrated automat...

Page 31: ... drum s reflectivity and calibrates the output of the ID sensor to 4 V 1 3 4 Lamp Intensity Sensor Calibration The exposure lamp intensity is monitored by the main PCB through the fiber optics cable A photodiode on the main PCB converts the light intensity to a dc voltage The main PCB sends a PWM signal with a 100 duty cycle to the FL stabilizer and checks the monitored voltage adjusting it to 3 V...

Page 32: ... corona current circuit in the drum current detection PCB which converts the drum current to a voltage and separates it into ac and dc component outputs Then the main PCB reads them through A D converters as digital data The main PCB adjusts the corona current by controlling the PWM signal to the charge corona power pack When the auto drum current adjustment mode is selected by the SP mode the dru...

Page 33: ...r change has to be compensated by other means The main PCB checks the drum potential just after the erase lamp exposure by the drum potential sensor during drum conditioning The drum potential is in fact Vr This measured Vr is used as the standard for the following other compensations 1 Vd Correction 2 VL1 Correction Drum Potential Original Density Dark Light V0 Vd VL Vr A171D510 wmf 31 July 1995 ...

Page 34: ...esidual voltage Vr so that the target Vd voltage is compensated as follows Target Vd Value Vd Vr 770 V 20 M NOTE M is the setting for the Latent Image Adj in the SP mode The adjusted charge power pack output control value PWM value is kept in memory until the next initialization If the target value cannot be achieved within the charge power pack output control range the copier indicates the system...

Page 35: ...oltage change also affects VL so that VL s target voltage is compensated as follows Target Value of VL VL1 Vr 50 10 N 15 M volt NOTE N is the setting for the exposure lamp adjustment in the SP mode M is the setting for the Latent Image Adj in the SP mode The adjusted exposure lamp output control value PWM value is kept in memory until the next initialization If the target value cannot be achieved ...

Page 36: ... properly the development bias for the ID sensor pattern is corrected by measuring the actual drum potential after the charge corona During the process control data initialization the drum potential after the charge corona is applied when the drum sensitivity is stabilized V01 will be measured and used to determine the bias voltage for the ID sensor pattern development in continuous copy run The d...

Page 37: ...usted When the first scanner is moved to the return position for the Vd adjustment the main PCB checks the ADS voltage through the ADS fiber optics cable The measured voltage is calibrated to the standard voltage 3 V as the reference for the auto image density control ADS Pattern A171D508 wmf ADS Pattern Exposure Glass A171D570 img 31 July 1995 PROCESS CONTROL 2 13 ...

Page 38: ...g the copy cycle At the beginning of each original scanning the VL sensor pattern is developed on the drum The main PCB monitors the drum potential VL2 of the latent image of the VL sensor pattern through the drum potential sensor and adjusts the development base bias See development bias section for details Development Base Bias VBB VL2 280 V 10 N 15 M V VL2 Vr Maximum V 210 Minimum V 110 NOTE N ...

Page 39: ...r the charge corona is applied Whenever the Start key is pressed the drum potential after the charge corona is measured at the beginning of the copy run V02 V02 is used to determine the development bias voltage for the ID sensor pattern which is made at the first copy The details will be explained in the Image Density Control section Start key Charge Corona Exposure Lamp Scanner F R Drum Potential...

Page 40: ...O type drums are coated after the charge carrying layer has been made it is not necessary to perform the drum conditioning at the new drum installation When drum temperature drops below the permissible level extreme sensitivity changes occur Additionally the temperature changes can cause condensation To maintain a constant drum temperature a drum heater D 100 V 140 W which is controlled by a therm...

Page 41: ...C and off at 65 C When the main switch is on RA354 is on and bypasses the 65 C thermoswitch from the drum heater control circuit RA353 turns on or off according to the temperature detected by the drum thermistor The drum surface temperature is controlled between 41 C and 50 C To minimize the power consumption RA353 is turned on to bypass the drum heater during the copy cycle 160 C 65 C Drum Heater...

Page 42: ...rates a corona of positive ions when the charge power pack A applies a high voltage The output of the charge power pack is determined by the CPU based on the process control data The charge power pack has a leakage sensor If a leak short circuit is sensed the output is interrupted A171D505 wmf A A171D580 img DRUM CHARGE 31 July 1995 2 18 ...

Page 43: ...corona area it may cause uneven corona charging to the drum To prevent this ozone is vacuumed out by the vacuum fan through the duct and toner filter in the transport unit then changed to oxygen by the ozone filter before blown out of the copier A171D578 img 31 July 1995 DRUM CHARGE 2 19 ...

Page 44: ...ing the charge corona wires clean Once every 5000 copies the wire cleaner is activated when the main switch is turned on The hot roller temperature must be less than 100 C for the wire cleaner to be activated When the dc motor in the front end block turns on it drives the cleaner bracket from the home position to the rear end of the corona unit and then back again A171D577 img DRUM CHARGE 31 July ...

Page 45: ... process control data There is a safety relay RA303 on the dc drive board which is activated by a signal from the main PCB In case of the SC conditions related to the high voltage devices and the abnormal exposure lamp on the main PCB turns the RA303 to cut the power of dc 24 V to the power pack through its contact DC Power Supply Main PCB DC Drive PCB Drum Current Detect PCB Charge Corona P P PWM...

Page 46: ...t The erase lamp unit consists of 90 yellow green LEDs This reduces drum light fatigue and allows precise control of the light width The erase lamp unit is controlled by the main PCB based on factors such as the reproduction ratio paper size SP mode settings and the image editing settings The maximum erase margin error in the image editing mode is 6 mm A A171D573 img ERASE 31 July 1995 2 22 ...

Page 47: ...d 3rd Feed Mode 2 When the ID sensor pattern is made A4 LT Full Size and 3rd Feed Mode NOTE 1 Depends on the paper feed station 2 Depends on the paper size 3 Will be changed in Margin Adjustment and Image Editing Mode Main PCB Erase Lamp Unit DC Power Supply A171D504 wmf VL Pattern Start Main Motor ON Regist Trail Edge Main Motor OFF Start Main Motor ON Regist Trail Edge Main Motor OFF All ON All ...

Page 48: ...reproduction ratio range 50 200 The lens B is driven by two stepper motors for 1 vertical direction parallel to the paper feed direction and 2 horizontal direction movements To correct focal length change in reduction and enlargement modes the mirror unit C 4th and 5th mirrors position is adjusted by a stepper motor The exposure glass has a special coating on one side to minimize the static electr...

Page 49: ...four scanner drive wires The second scanner speed is half of the first scanner speed The first and second scanners are supported by the front and rear guide rails D To minimize the friction between the scanners and guide rails the play of the scanner movement is minimized by high wire tension A C D B A171D576 img 31 July 1995 OPTICS 2 25 ...

Page 50: ... sensor A is used to detect the home position at the machine initialization and during the scan cycle The scanner return position sensor B is used to detect the scanner position for the process control data initialization Vd and ADS data The return position sensor is not used during normal copying A B A171D586 img OPTICS 31 July 1995 2 26 ...

Page 51: ...ns through the lens drive belt The lens vertical home position sensor B detects the lens vertical position for full size mode The motor control PCB keeps track of the lens position based on the number of pulses sent to the lens vertical drive motor The lens vertical drive encoder C installed on the drive pulley is used to detect if the vertical lens base locks A B C A171D581 img 31 July 1995 OPTIC...

Page 52: ...e reproduction ratio and the original modes A stepper motor approx 7 5 0 35 mm step is used to drive the lens through the lens drive wire The lens horizontal home position sensor A is used to detect the lens horizontal position for A4 LT sideways full size and ADF mode The other positions are determined by counting the number of motor drive pulses The lens horizontal drive encoder B installed on t...

Page 53: ...on hole part transport path 12 7 mm in ADF The above figure shows the lens horizontal positions for each original mode when the identical size paper is used 5 6 2 For Paper Size To keep the high paper feed performance the center is assigned as the paper feed standard position Therefore the lens horizontal position is changed according to the paper size The figure shows the lens horizontal position...

Page 54: ... time the total focal length has to be changed to adjust the image focusing For this focal length change the horizontal position of the lens is also adjusted The figure shows the lens horizontal position for 50 100 and 200 Copy Paper Vertical Horizontal Lens Position Original Front Edge A151D515 wmf OPTICS 31 July 1995 2 30 ...

Page 55: ...sition is changed A stepper motor Approx 7 5 0 1 mm step is used for the mirror unit drive A mirror unit home position sensor A is used to detect the unit position for full size mode The motor control PCB keeps track of the unit position based on the number of motor drive pulses A A171D567 img 31 July 1995 OPTICS 2 31 ...

Page 56: ... sensor signals and controls the motors through the dc motor drive PCB The development motor and the main motor are also be controlled by the dc motor control PCB Main PCB Sensors Encoders Motor Control PCB DC Motor Drive PCB Horizontal Drive Vertical Drive Mirror Unit Drive Encoder Serial Interface Scanner Drive A171D518 wmf OPTICS 31 July 1995 2 32 ...

Page 57: ...iginals High speed scanner operation vibration resistance Omni directional luminescence reduces original shadow Since low fluorescent tube temperature will result in delayed lighting and intensity variation a tube type heater 38 V 60 W B is used to maintain the fluorescent tube temperature at approximately 40 C The lamp unit has a thermister C to monitor the lamp temperature and a thermofuse D 139...

Page 58: ...ntensity through a fiber optics cable B According to the measured value a lamp power signal PWM signal is sent to the fluorescent lamp stabilizer C The PWM signal output is determined based on the standard value 3 V at PWM 100 duty cycle which is set at the process control data initialization see the Process Control Section for details C B A PWM A171D572 img OPTICS 31 July 1995 2 34 ...

Page 59: ... light to a photodiode on the main PCB The photodiode then converts the density to the ADS voltage The CPU compares it with the standard ADS value 3 V which is set at the process control data initialization by checking density of the white pattern underneath the left exposure glass holder and adjust the development bias accordingly Detailed bias control is described in the development bias section...

Page 60: ...nt lamp B and evenly distributes light reflected from the original To compensate for reduced light at the lens edges the shading plate C is located in front of the lens Additionally the shading plate compensates the light intensity when the lens horizontal position is shifted C A171D583 img B A A171D575 img OPTICS 31 July 1995 2 36 ...

Page 61: ...n stand by mode 3 Machine off condition in weekly timer mode The anti condensation heater has a thermofuse 169 C 5 14 OPTICS COOLING FAN The light intensity will be decreased if the fluorescent lamp temperature becomes too high The optics cooling fan A blows in cool air from outside through an air filter B Air from the fan also passes through the 6th mirror slit C to the drum area This prevents th...

Page 62: ...oper guide A upper side by the paddle roller B The magnet of the upper development roller C attracts the developer to the roller surface The doctor blade D trims the developer to the desired thickness and creates back spill to the cross mixing mechanism E The developer is transferred to the lower development roller F and then returned to the agitator roller G area via a paddle roller The developme...

Page 63: ...he development drive gear through two timing belts The rotation is transferred as follows Since reversed toner mixing vane rotation could damage something a one way clutch is installed to the mixing vane drive gear Development Drive Gear A Auger Drive Gear B Idle Gear Idle Gear C Paddle Roller G Timing Belt E Upper Lower Dev Roller D Toner Mixing Vane Drive Gear F D C B A F E G A171D606 img 31 Jul...

Page 64: ...parts by the doctor blade The part trimmed by the doctor blade goes to the backspill plate A As the developer slides down the backspill plate to the agitator B the mixing vanes C move it slightly toward the rear of the unit Part of the developer falls into the auger inlet D and is transported to the front of the unit by the auger E The agitator moves the developer slightly to the front as it turns...

Page 65: ...he output selector as shown in the table When both terminals are low the output can be controlled by the other input terminal which receives the PWM signal from the main PCB 800 and 100 V are used to calibrate the drum potential sensor in the process control data initialization Potential Sensor RA2 Relay Drum Current Detection PCB RA1 Bias P P TRIG 1 800V TRIG 2 100V PWM Sensor Main PCB A171D529 w...

Page 66: ... for development is determined by the drum light potential VL measured in each original scan The base bias is also affected by the exposure lamp adjustment setting in the SP mode VBB VL2 280 V 10 N 15 M V VL2 Vr Maximum V 210 Minimum V 110 NOTE N Number of the lamp adjustment setting in SP mode M Number of the Latent Image Adj in SP mode Drum Potential Dark Light Original Density VBB V0 Vd VL Vr A...

Page 67: ...To compensate for this change VADS A0 A1 is used instead of VADS NOTE VBA VBADJ have a limited range from 0 V to 260 V 3 VBADJ VBADJ 30 M 7 M 7 VBA VBADJ can be adjusted using SP mode ADS Sensor Adjustment to absorb the tolerance of the ADS pattern in the factory In this mode VBA VBADJ can be lowered below 0 V for testing in the factory NOTE Do not adjust the setting of VBADJ in the field Adjust t...

Page 68: ...from 1 darkest to 7 lightest When manual ID is set to 7 lightest the charge corona output is lowered by 10 PWM duty cycle 5 SP Mode ID Selection Compensation VBS In the SP mode the image density level in the ADS mode can be selected from four steps The VBS is determined by the SP setting as follows Selected level VBS V L 60 N 0 Default H 60 VH 120 60 180 120 120 0 60 ID Selection A171D532 wmf DEVE...

Page 69: ... of exposure glass no light B4 81 2 x 14 ID sensor pattern on the exposure glass bracket A3 11 x 17 Exposure lamp off no light The ID sensor bias VBP is determined using the following base voltage in every case VBP 360 V01 V01 which is explained in the process control section is used for the VBP calculation as the drum potential after the charge corona value The VBP can be changed by the SP mode T...

Page 70: ... for a certain period based on the paper size and the supply amount set by SP mode A brush roller with low rotation torque and that can supply large amounts of toner even with low operation speed is used for the toner supply roller Toner mixing vanes C turn slowly while contacting the inner wall surface of the toner tank whenever the development motor is turning This prevents toner blockages and s...

Page 71: ... Start key is pressed or when the ID sensor pattern is made NOTE Both counters are reset when the main switch is turned on or the doors are opened The ID sensor pattern is made in the following conditions 1 At the leading edge of the first copy cycle after the main switch is turned on or when the doors are opened 2 If A 10 At the trailing edge of the copy cycle when A 10n n any numeric number 3 If...

Page 72: ...CB receives two values of the sensor output the value for the sensor pattern Vsp and the value for the bare drum Vsg Toner will be supplied under the following condition Vsp Vsg 1 13 A171D533 wmf Low image density High image density Bare drum Sensor pattern A171D534 wmf TONER DENSITY DETECTION AND SUPPLY 31 July 1995 2 48 ...

Page 73: ...oner supply control will be used for the rest of the copy run If both abnormal values return to normal during the copy run the toner supply control will also be returned to normal 7 3 TONER SUPPLY AMOUNT Vsp V at Vsg 4 0 V Toner Supply Amount Data in SP Mode 15 30 45 60 0 3 Vsp 0 4 7 15 15 30 0 4 Vsp 0 5 15 30 45 45 0 5 Vsp 30 45 60 60 The toner supply ratio is determined based on the supply amoun...

Page 74: ...nhibits copying if there is no toner cartridge The toner cartridge is also used as the used toner collection tank The copy image becomes poor if the collected toner is re used To prevent accidental re used of the collected toner a spring plate lock mechanism B is installed The lock allows the toner cartridge shutter to be pulled and returned only once A A171D607 img B A171D588 img TONER DENSITY DE...

Page 75: ... feeler does not lower due to the resistance of toner When the remaining toner amount in the toner tank becomes below approximately 250 grams the near end feeler lowers and repulses the sensor actuator by the magnet s repulsion force This actuates the toner near end sensor When the main PCB senses the toner near end sensor actuation three times in a row the toner near end condition is displayed on...

Page 76: ... Vsg 1 9 more than three times in a row during the toner near end condition physical check or when main PCB counts 2000 or more copies made since the toner near end condition the toner end condition is displayed on the CRT screen and copying is inhibited until the toner cartridge is replaced Copy Toner End Copy from Near End condition 2 K N E No Yes Yes No No Vsp Vsg 1 9 3 times Yes Near End A171D...

Page 77: ...um potential by applying an ac corona The PTC also applies a dc negative charge at the same time to keep the toner potential negative The PTL further reduces the drum potential Since the PTC gave a negative charge not only to the toner but also to the non image no toner area on the drum PTL reduces the negative charge on the drum which may attract copy paper and cause pick off pawl marks A B A171D...

Page 78: ...e guide mylar A which holds the copy paper so that the paper sticks to the drum surface The transfer corona B applies a positive charge from the back side of the copy paper to attract the negatively charged toner image from the drum to the copy paper A B A171D595 img IMAGE TRANSFER AND PAPER SEPARATION 31 July 1995 2 54 ...

Page 79: ...aper then causes it to separate from the drum The pick off pawls A which are installed on the cleaning unit assist paper separation Two corona wires are used to improve separation by widening the discharge area Also a larger corona current is applied at the leading edge of the paper for the same purpose A A171D602 img 31 July 1995 IMAGE TRANSFER AND PAPER SEPARATION 2 55 ...

Page 80: ...r dust and or toner particles which may get on the corona wires Once every 5000 copies the wire cleaners are activated when the main switch is on The hot roller temperature must be less than 100 C for the wire cleaner to be activated A171D609 img IMAGE TRANSFER AND PAPER SEPARATION 31 July 1995 2 56 ...

Page 81: ...e pick off pawls are released from the drum The pick off pawl shaft is contacted to the cam gear A which is located at the front side and driven by the drum flange gear The cam gear gives side to side movement to the pick off pawl shaft to prevent toner from accumulating on the pick off pawls A171D603 img A A171D589 img 31 July 1995 IMAGE TRANSFER AND PAPER SEPARATION 2 57 ...

Page 82: ...ollers Turning the transport unit release lever to the left releases the lock and lowers the unit to clear paper jams If ozone produced by the corona charges stays in the drum area it may cause uneven corona charging or affect drum sensitivity causing poor image problems The vacuum fan sucks the ozone through the air duct and transports it to the ozone filter Ozone is changed to oxygen by the filt...

Page 83: ... for better efficiency The brush collects toner from the drum surface and scraped by the cleaning blade The flick bar A and the flick roller B mechanically remove toner on the cleaning brush Toner is transported to the toner cartridge by the toner collection coil C To remove the accumulated toner at the edge of the cleaning blade the drum turns in reverse for about 20 mm at the end of every copy j...

Page 84: ...then transmits the force to the front side through the cleaning brush C and flick roller D The force at the front side is used for the blade cam gear E and toner collection coil gear F There is a one way clutch in the transport unit drive gear G to prevent the drive parts in the cleaning unit from receiving the reverse rotation force B A G D C E F A171D599 img CLEANING 31 July 1995 2 60 ...

Page 85: ...owers the pressure arm B This frees the pressure release lever C and the blade spring D applies pressure to the cleaning blade To ensure cleaning blade operation 38 V is applied to the solenoid for 0 3 seconds as initial activation then 24 V is applied B A D C A171D592 img 31 July 1995 CLEANING 2 61 ...

Page 86: ...a shoulder screw A at its center so that the cleaning pressure is evenly applied to the drum surface The cleaning blade holder touches the cam gear B which gives a side to side movement to the blade This movement prevents the cleaning blade from being damaged B A A171D596 img CLEANING 31 July 1995 2 62 ...

Page 87: ...r A is used on the toner collection coil drive mechanism to prevent the coil from being damaged by toner clogged in the collection tube The toner collection coil drive gear B has two actuators for the coil overload sensor The main PCB monitors the sensor output and display an SC code if no signal changes are detected for more than 3 seconds while the development motor is turning B A A171D597 img 3...

Page 88: ...g filter on its back side The vacuum fan draws the air from the cleaning unit through the cleaning filters A and the toner filter B located above the transport section This prevents the toner in the cleaning unit from being scattered to the drum area A B A171D591 img CLEANING 31 July 1995 2 64 ...

Page 89: ...4 V is supplied to the cleaning solenoid The main PCB sends a pulse signal to the coil overload sensor through the interface PCB When the overload sensor is actuated the pulse signal is returned to the main PCB The main PCB is monitoring this signal change for toner collection coil blocking Main PCB DC Drive PCB Interface PCB Overload Sensor Cleaning Sol Scan 2 Scan 2 A171D527 wmf 31 July 1995 CLE...

Page 90: ... reverse rotation The blade touches the drum again while drum is still turning in reverse due to inertia to clean the edge of the blade The cleaning solenoid off timing B is determined based on the accumulated number of copies as follows Accumulated copy number Off Timing 100 copies 15 seconds after the main motor off 100 copies 5 minutes after the main motor off This is to minimize toner scatteri...

Page 91: ...ng on the drum a cold cathode fluorescent lamp A CFL is used as the quenching device When the main PCB sends a trigger signal to the the CFL stabilizer B an ac power ac 480 V 5 mA is supplied to the CFL B A A171D604 img 31 July 1995 QUENCHING 2 67 ...

Page 92: ...is positioned at the center of the trays This copier uses an FRR Feed Reverse Roller paper feed system which uses three rollers pick up roller feed roller and separation roller A slip clutch is used as a torque limiting device for the separation roller One anticondensation switch for all tray heaters is installed on this copier A tray heater is installed on each tray and turns on when the anticond...

Page 93: ...ation The separation roller driven by the separation roller shaft is prevented from turning in the paper feed direction by the built in torque limiter C The separation roller uses a friction mechanism to overcome the torque and stop the roller The separation roller shaft speed is reduced by the low rotational drive ratio of the drive gear D against the feed clutch gear This reduces the main motor ...

Page 94: ...tes in contact with the paper feed roller the separation roller rotates in the direction of the black arrow Paper is fed by the operation described above The paper feed sensor G senses the paper and the pick up solenoid activates The pick up roller is then lifted up to its upper position which is out of the paper path Simultaneously the paper feed clutch temporarily turns off This process of turni...

Page 95: ...he force of the friction between the feed roller and paper F2 is greater than F1 So the separation roller turns counter clockwise If 2 or more sheets are fed between the rollers the forward force on the second sheet F3 becomes less than F1 because the friction between the two sheets is small So the separation roller starts turning clockwise and drives the second sheet back to the tray F2 F1 F2 F1 ...

Page 96: ...he input hub The ferrite ring F is fitted into the output hub Ferrite powder G packed between the magnetic ring and the ferrite ring F generates a constant torque due to magnetic force The input hub and the output hub slip when the rotational force exceeds the constant torque This type slip clutch does not require lubrication A171D537 wmf E C G F B D A A171D538 img PAPER FEED 31 July 1995 2 72 ...

Page 97: ...ns When the clutch turns off the swing arm remains in the raised position The separation roller D and feed roller E can rotate in the direction of paper return until the swing lever meets the inside stay F Then the separation roller and feed roller stop rotating This operation returns paper between the reverse and feed rollers to the tray to prevent paper damage when the tray unit is pulled out C ...

Page 98: ...ed by the photo interrupter and feeler B When there is no paper remaining in the tray the feeler rises from the tray bottom hole to deactuate the photo interrupters for the LCT and to actuate the photo interrupter for the 1st 2nd and 3rd Trays 1st 2nd and 3rd Trays A B A171D617 img LCT A B A171D615 img PAPER FEED 31 July 1995 2 74 ...

Page 99: ...ator A to determine the quantity of paper in the tray The amount of paper present is based on the number of pulses generated between the time the tray starts moving up and the time the upper limit sensor turns off A A171D655 img 31 July 1995 PAPER FEED 2 75 ...

Page 100: ...ttom plate so when the wire pulley turns counterclockwise rear view the beads on the wires drive the tray support bracket and the tray moves upward The tray goes up until the upper limit sensor E is actuated by the top sheet pushing up the pick up roller F To lower the tray the pulley turns clockwise until the lower limit sensor G is actuated by the actuator of the bottom plate H 1st 2nd and 3rd T...

Page 101: ...tray paper position sensor G turns off the drive gear stops once At this point the bottom plate or the top sheet of paper is positioned about 70 mm below the feed position This gives enough space for the customer to replenish about 500 sheets of paper If the tray down switch is then pressed again the bottom plate moves down and again stops once the top sheet of the paper just passes the paper posi...

Page 102: ...the lock plate B And the lock lever C engages tray stopper D to prevent the tray from being pulled out while the tray is in the up position When the tray moves to the down position the tray bottom pushes the release lever and the tray stopper is de engaged allowing the tray to be pulled out B A A171D634 img C D A171D647 img PAPER FEED 31 July 1995 2 78 ...

Page 103: ...y moves to the down position the lock solenoid E turns on The lock lever then releases the right side stopper allowing the tray to be pulled out The solenoid will remain on for one minute After one minute the lock solenoid and tray down switch turns off The tray cannot be pulled out The lock solenoid will turn off while the tray is pulled out This lock solenoid on off operation is performed to kee...

Page 104: ...er A is fixed to the tray side The tray stopper bumper B is fixed to the main body or tray body The tray stopper and bumper determine the side to side registration B A 1st 2nd 3rd Trays A171D611 img A B LCT A171D652 img PAPER FEED 31 July 1995 2 80 ...

Page 105: ...nt side fences to another slot The paper size detection sensors are mounted under the paper tray bottom plate When the rear side fence is inserted into one of the paper size position it enters one of the three photointerrupters The signal from this sensor informs the CPU which size paper LT LG U S A versions or A4 European versions is in the tray B A A171D539 img 31 July 1995 PAPER FEED 2 81 ...

Page 106: ...rackets have the actuator plates mounted on their bottom These plates activates 6 sensors photo interrupters mounted under the bottom plate The CPU determines the following paper size by reading the combination of sensors activated European versions A3 B4 A4 A5 LT LG 81 2 x 13 8 x 10 sideways A4 LT lengthwise U S A versions A4 HLT LT LG DLT 10 x 14 81 2 x 13 8 x 101 2 sideways LT lengthwise A B A1...

Page 107: ...by loosening the screw and moving the rear and front side fences to another slot To indicate the paper size on the screen it is required to set the paper size in SP mode The following paper size can be fed from the 3rd tray European version B4 A4 A5 LT LG U S A version LT LG A4 A B A171D565 img 31 July 1995 PAPER FEED 2 83 ...

Page 108: ...ulled out the rear fence A is held in place by the front stay B This makes paper setting easier When the tray is pushed in the rear side plate C guides the rear fence to its home position A B A171D650 img C A171D651 img PAPER FEED 31 July 1995 2 84 ...

Page 109: ... motor Drive from the transport section A of the copier main motor is transmitted via gears and a timing belt to the LCT and by pass feed table paper feed mechanism B C The feed roller drive of the copier tray is provided by the vertical transport sections left right B C A A171D564 img 31 July 1995 PAPER FEED 2 85 ...

Page 110: ...transport unit the horizontal relay guide section E and horizontal transport section F to the registration rollers The copy paper exiting the 3rd paper feed station G pass through the left vertical transport section H to the registration roller The copy paper exiting the LCT I pass through the relay guide section J to the registration rollers The copy paper exiting the by pass feed table K pass th...

Page 111: ...rtical transport unit to detect misfeeds The paper feed for the tray is driven from the vertical transport unit 12 3 RELAY KNOB MECHANISM To make it easier to clear paper jams between the duplex unit and the horizontal transport unit the upper relay rollers can be turned by the relay knob D This delivers the jammed paper to the horizontal transport unit E The relay knob shaft gear F has a one way ...

Page 112: ... side of the driven guide plate When the unit is pushed in the roller F of the main body side presses against the back plate to ensure magnetic attachment and to prevent the driven guide plate from opening by a paper jam in the machine 12 5 UNIT LOCK LEVER When the vertical transport unit is set to the main body it is locked by the lock lever G applying pressure to the stopper bracket H of the mai...

Page 113: ...dust cleaning roller has a teflon coated roller which is charged by the friction with the scraper C contacted and attracts the paper dust and removes it from copy paper The paper dust pan D collects the paper dust from the paper dust cleaning roller and the scraper A B D C A171D632 img 31 July 1995 TRANSPORT UNIT AND REGISTRATION 2 89 ...

Page 114: ... the vertical transport unit drive clutch E The duplex relay roller begins to turn at the same time When the start key is pressed the vertical transport unit drive clutch F turns on The relay roller G together with the paper tray unit drive gear H begin to rotate A one way clutch is built in to the duplex relay drive gear I Due to one way clutch when clearing a paper jam there will be no load from...

Page 115: ...e hot roller temperature through a thermistor A thermofuse 169 C protects the unit against overheating The oil supply roller D applies silicon oil to the hot roller directly Silicon oil is used for several reasons it keeps rollers clean by reducing the amount of toner transferred to them it reduces adhesion between paper and the hot roller and it reduces paper curl As the toner designed for this m...

Page 116: ...The vaporization creates a high speed flow of steam C to the low temperature area When the stream reaches that area the stream cools D The low temperature area is heated by the stream Thus it causes condensation The condensed water is returned to the heating section by capillary action This cycle vaporization stream transfer condensation repeats again and again The heat is transferred along the he...

Page 117: ...wer pressure lever D which are lifted up by the fusing unit release lever E via the pressure cam F The pressure can be adjusted by using the pressure adjustment screw G The fusing pressure is released by turning the fusing unit release lever counterclockwise This is helpful for clearing paper jams A C B E D G F A171D641 img 31 July 1995 FUSING 2 93 ...

Page 118: ...ly roller A is soaked with silicon oil B The roller contacts the hot roller by a spring It turns with the hot roller and applies a light coat of silicon oil to the hot roller A A171D610 img A B A71D612 img FUSING 31 July 1995 2 94 ...

Page 119: ...e It is better for copy paper to be face curled than to be back curled in this copier because the copy paper is stacked facing down in sort mode The de curling roller has inside it a heat pipe similar to the hot roller heat pipe It releases the heat from the paper to the fins C The fusing cooling fan D in the duct E at the machine rear side cools the fins There is a duct F above the de curling rol...

Page 120: ...ction are precisely positioned by the position guide D This minimizes the fusing drive load and prevents drive gear abrasion The pressure roller E is held against the hot roller F and is friction driven by the hot roller The inverter unit is driven by the hot roller gear G through relay gears H and the de curling belt I G C D E H F I B A A171D640 img I A171D638 img FUSING 31 July 1995 2 96 ...

Page 121: ... is 185 C when the drum heater is ready Stand by 1 The lamp turns on at 195 C and turn off at 198 C Copying cycle The lamp turns on when the temperature drops below 195 C A 1600 W lamp B Ready temperature 185 C C Heater on temperature 195 C D Heater off temperature 198 C E Main switch on F Start key on D 198 C C 195 C B 185 C E F A 1 A171D541 img 31 July 1995 FUSING 2 97 ...

Page 122: ...hed even if the fusing temperature is recovered during the copy job Even if the slow down mode is applied the fusing temperature may drop in certain conditions such as A3 continuous copy run A lower limit safety temperature has been newly added to stop the copy run and to avoid any poor fusing problems when the temperature drops below it The lower limit safety temperature is lower than the lower l...

Page 123: ...using and inverter units This helps to clear paper jams The inverter unit does the following jobs 1 Ordinary copying Copies pass through the unit straight to the exit rollers I 2 Duplex copying Copies are sent directly to the duplex tray J 3 Overlay image copying Copies are turned over and then sent to the duplex tray 4 Face down feed out Tab copying Copies are turned over and then sent to the exi...

Page 124: ...tion gate solenoid stays off copies go straight through the inverter rollers to the exit rollers 14 3 DUPLEX COPYING The inverter gate solenoid stays off and the junction gate solenoid turns on Copies go straight to the junction gate C and are directed by the junction gate to the duplex unit D A B A171D637 img C D A171D645 img INVERTER AND PAPER EXIT 31 July 1995 2 100 ...

Page 125: ...es are inverted by the return drive rollers B and return pinch rollers C The junction gate directs copies to the duplex unit D 14 5 FACE DOWN FEED OUT TAB COPYING The inverter gate solenoid turns on and the junction gate solenoid stays off Copies are sent up between the inverter guide plates and inverted by the return drive rollers and return pinch rollers The junction gate directs copies to the e...

Page 126: ...py mode and faced up in the overlay mode The duplex unit uses three separation belts A and the paper feed roller B for duplex paper feed The paper stack is fed from the bottom sheet The jogger fences move inward from the home position to the waiting position and push the all stacked copies against the other fence to square the stack and the end fence C moves to the appropriate position to stop the...

Page 127: ...he spring B Any paper jammed in the middle can be moved to the duplex tray by turning the knob C manually since spring pressure D is applied to the upper duplex entrance feed roller E A photo interrupter the duplex entrance sensor F in the duplex entrance G detects paper jams and jogger motor drive timing The duplex entrance can be opened for paper jam removal B A E C G A171D543 wmf F A171D544 wmf...

Page 128: ...roller solenoid D energizes after the jogger fences reach the appropriate paper position The positioning roller E is lowered and is rotating as a result of main motor drive The paper sheet entering the duplex tray is transported by the positioning roller to the duplex paper feed position The positioning roller solenoid turns off and the positioning roller is lifted up when the paper sheet hits the...

Page 129: ...position for the selected paper size The end fence does not move as a jogger After the leading edge of the copy paper passes the duplex entrance sensor and after the appropriate time for the selected paper the jogger fence drive motor rotates forward then reverses This makes the jogger fence push all the stacked copies against the other fence Also this makes the jogger fence return to the waiting ...

Page 130: ...s the bottom sheet past the separation belts because the force from the feed roller is greater than the resistance of the separation belts The separation belts prevent multiple feeds because the resistance of the separation belt is greater than the friction between the sheets of papers When the duplex feed sensor G detects the leading edge of the paper the paper feed clutch turns off The paper wai...

Page 131: ... roller on the lock arm presses against the lock plate B The duplex tray stopper C is attached to the top of the lock arm The tray stopper bumper D is attached to the main copier The space between the tray stopper and bumper determines the side registration A B C D A171D550 img 31 July 1995 DUPLEX 2 107 ...

Page 132: ...s transmitted to the duplex tray drive gear B The duplex tray drive gear distributes the drive to each roller While the duplex paper feed clutch C is on drive is transmitted to the duplex feed roller D Other rollers are driven while the main motor is rotating A B C D A171D548 wmf DUPLEX 31 July 1995 2 108 ...

Page 133: ...Timing Chart 1 Stack 2 Paper Feed A171D551 wmf A171D552 wmf 31 July 1995 DUPLEX 2 109 ...

Page 134: ... F 2 Two sided Original Feed In two sided original feed mode the inverter gates G are open After the scanner scans the front side of the original the original is inverted around the inverter roller H and transported to the scanning position again by the reversing transport belt After both sides of the original are scanned it is transported to the switch back tray I while the switch back gate J is ...

Page 135: ...nal indicator D and an auto feed indicator F The insert original indicator turns off when the original is set on the original table If the machine is set for SADF operation with more than 2 copies the auto feed indicator lights for thirty seconds If the originals are set on the original table during this time machine operation starts automatically C B A a171D674 img E D A171D664 img 31 July 1995 A...

Page 136: ...dth sensors detect paper width and the timing sensor A detects the original length The original width sensors consist of four reflection type photo sensors SN2 B 3 C 4 D 5 E The above table shows the determined paper size depending on the sensor status While the registration sensor F is on pulse generator pulses are counted to measure original copy length in the direction of travel In this way the...

Page 137: ...uilt in one way gear After the drive motor stops it continues to turn in the feed direction The friction tab is pressed against the separation rollers by springs E To prevent multi feed spring tension can be adjusted by two adjustment screws F at the front and rear side of the tab holder The stopper G controls the gap between the friction tab and the separation rollers to prevent a sheet of paper ...

Page 138: ...sure mylar pushes down the entrance guide mylar by the force of the return spring The pressure mylar lever stops at the stopper F to prevent over pressure being applied A heart shaped cam G is installed on the pick up roller shaft When the cam follower H drops into the depressed portion of the heart shaped cam the pick up roller stops At this time the flat surface of the pick up rollers is level w...

Page 139: ...ey The pick up roller and separation roller are driven by the one way gears The pick up roller has a home position sensor G When the sensor detects that the roller has completed a full turn the motor starts reversing When the motor reverses the one way pulley and gear driving the pick up and separation rollers become idle and the rollers stop The relay rollers continue to turn in the paper feed di...

Page 140: ...aised portion of the friction tab frame C This releases the relay roller pressure to make misfed original removal easier The feeler D moves away from the entrance cover sensor E which detects that cover is open The exit cover F can also be opened for easier misfed original removal F A171D663 img A D C E B A171D686 img ARDF 31 July 1995 2 116 ...

Page 141: ...ion is provided by two springs C The transport belt is driven by a dc motor D A special coated exposure glass E the coated side is marked and should face up is used to prevent the original from sticking due to static electricity The exposure glass is grounded to the main body frame through the conductive front scale F A B A171D683 img D C E F A171D681 img 31 July 1995 ARDF 2 117 ...

Page 142: ...vated In thick paper mode To correct skewing on the exposure glass the original runs 10 mm after the trailing edge passes the right scale The belt motor then reverses and the original travels until it meets the right scale If extremely thin paper is used in the thick paper mode the paper may float near the scale This will result in poor image quality or original copy wrinkling The factory setting ...

Page 143: ...eeler C actuates the lift sensor To keep the transport belt unit parallel to the exposure glass lift springs D and lift up springs E are installed to the transport unit base and the transport drive unit at the point where the two units join The lift springs reduce transport unit weight load to enable everything to remain parallel The lift up springs prevent flutter damage when the transport unit i...

Page 144: ...transport unit can be opened by sliding the release lever C to the right A brake D is installed on each pivot to make the down movement of the transport belt unit gentle when the unit is opened Opening the inverter cover is detected when the feeler E moves away from the inverter sensor F C B D A171D678 img E A F A171D670 img ARDF 31 July 1995 2 120 ...

Page 145: ...nside the inverter loop is approximately 200 mm When an original exceeding A4 LT sideways is used the original leading and trailing edges will overlap When 10 pulses from the inverter motor encoder are counted after the inverter entrance sensor F detects the leading edge of the original the belt motor starts reversing After the inverter registration sensor G detects the original leading edge the b...

Page 146: ... and the upper B and lower C inverter gates open to create an inverter loop path An inverter entrance sensor D and an inverter registration sensor E reflection type photosensors are located in the inverter loop path E C B A D A171D672 img ARDF 31 July 1995 2 122 ...

Page 147: ... the feed in motor also turns on After 175 ms the belt motor and the inverter motor turn on to transport the original to the switch back tray When the inverter entrance sensor E senses the trailing edge of the original the inverter gate solenoid turns off to close the inverter gates When 54 pulses from the inverter motor encoder are counted after the inverter entrance sensor senses the trailing ed...

Page 148: ...n by a dc motor A The drive of the inverter motor A is transmitted to the exit rollers B through the two one way clutches C The exit rollers rotate in the same direction due to the function of these one way clutches C A B A171D656 img ARDF 31 July 1995 2 124 ...

Page 149: ...s the holes lined up on the computer form The CFF sensor C is installed in front of the original guide The CFF sensor consists of one CFF set sensor D and two CFF feed hole sensors E The CFF guide F prevents original feed out failure caused by the perforated lines The CFF extension G ensures stacking of the computer paper When a computer paper is set in the CFF guide the holes are used to calculat...

Page 150: ...the operation unit PCB D The auto response sensor E which is an infrared rays reflective sensor detects if there is an operator in front of the copier If the auto response sensor has not detected any objects for a certain time the main PCB turns off the CRT display to save the power consumption and to extend the CRT life The time setting can be changed by the user tools The operation unit PCB also...

Page 151: ...the exposure glass at this time the sheet through H P sensor is actuated and the original is transported to be scanned While scanning the original is transported by the inverter roller and the transport belt The inverter motor and belt drive motor speed depends on the selected magnification ratio The original path is as shown in the above illustrations A171D553 img A171D554 img A171D555 img 31 Jul...

Page 152: ...riginal scan mode When the Print Start key is pressed the inverter motor and the sheet feed clutch turn on to drive the sheet feed rollers The original is pushed to the sheet through gate to remove skew After a while the sheet through gate solenoid E is energized The sheet through gate moves down and the sheet pressure rollers are pushed against the sheet feed roller to transport the original The ...

Page 153: ...e the guide C and scale D to the sheet through position The original is transported onto the guide and the scale ready to be fed out When an original is placed on the sheet through table if the reed switch E of the CFF computer form feed guide is not actuated the guide is not in the rear end position a message is displayed advising the user to set the guide at the rear end position E A C A171D557 ...

Page 154: ... is opened the by pass table sensor A is actuated In this condition only the by pass table can be used as a paper tray The by pass tray capacity is 40 sheets 80 g m A A171D559 img MOVING ORIGINAL SCAN AND BY PASS FEED TABLE 31 July 1995 2 130 ...

Page 155: ...thwise Four photo interrupters A are used to detect paper width on the by pass tray The sensor status changes depending on the side guide positions The above table shows the relationship between the sensor status and recognized paper size In the normal copy mode the machine recognizes that the paper on the by pass table is set in sideways In the moving original scan mode the machine recognizes tha...

Page 156: ...on the by pass feed table the paper end sensor A is not actuated After the last sheet is fed the feeler B actuates the sensor and the paper end condition is detected B A A171D561 img MOVING ORIGINAL SCAN AND BY PASS FEED TABLE 31 July 1995 2 132 ...

Page 157: ... pawls B move down Then the main motor starts rotating The solenoid keeps on until the main motor is turned off After the main motor starts rotating the pick up solenoid C is energized and the pick up roller D moves down to feed the paper A B A171D562 img C D A171D563 img 31 July 1995 MOVING ORIGINAL SCAN AND BY PASS FEED TABLE 2 133 ...

Page 158: ...the misfed paper can be removed by turning the manual paper feed knob The drive of the paper feed clutch for the by pass table is also transmitted to the LCT drive gears C through a timing belt D The paper feed roller separation roller and the pick up roller of the by pass feed tray are not interchangeable with those of the other trays of the copier main body because the paper feed direction one w...

Page 159: ...SECTION 3 INSTALLATION ...

Page 160: ...t be subjected to sudden temperature changes b where it will not be directly exposed to cool air from an air conditioner in the summer c where it will not be directly exposed to reflected heat from a space heater in winter 7 Avoid placing the machine in an area filled with corrosive gas 8 Avoid any places higher than 2 000 meters 6 500 feet above seal level 9 Place the machine on a strong and leve...

Page 161: ...4 1000 mm A171I508 img More than 11 8 300 mm More than 11 8 300 mm More than 39 4 1000 mm More than 15 8 400 mm A171I509 img More than 39 4 1000 mm More than 11 8 300 mm More than 11 8 300 mm More than 15 8 400 mm A171I510 img More than 11 8 300 mm More than 15 8 400 mm More than 39 4 1000 mm More than 11 8 300 mm A171I512 img INSTALLATION REQUIREMENT 31 July 1995 3 2 ...

Page 162: ...or European version 2 Permissible voltage fluctuation 10 3 Do not set anything on the power cord N CAUTION a Make sure the plug is firmly inserted in the lutlet b Avoid multi wiring 240V U S A version 220 230 240V European version 120V U S A 220 230 240V European version A171I505 img 31 July 1995 INSTALLATION REQUIREMENT 3 3 ...

Page 163: ...ng Unit Release Lever 1 4 Drum Guide 1 5 Leveling Shoe 4 6 Operating Instructions Holder 1 7 Editing Sheet U S A version only 1 8 Sponge Cushion 1 9 M4 x 6 Screw 4 10 M5 x 8 Screw 4 11 M3 x 10 Screw 2 12 M4 x 8 Screw 10 13 Harness Clamp 2 14 Bushing 1 15 Operation Unit Stopper 1 16 Drum Guide Bracket 1 17 Left Lower Inner Cover 1 ACCESSORY CHECK 31 July 1995 3 4 ...

Page 164: ...ed in order to avoid any transport damage 1 Remove the strips of the filament tape A 2 Open the left and right front doors B C and remove the strips of filament tape D Remove the styrofoam blocks E and the cushion F 3 Remove the left vertical transport fixing bracket G 1 screw pull out the left vertical transport unit and install the left lower inner cover H 2 screws 4 Remove the tray fixing brack...

Page 165: ...ver Install the fusing unit release lever C turn the lever clockwise and fix it 1 M5 x 8 screw 6 Remove the right cover D 2 screws and 2 studs E securing the paper tray Reinstall the right cover B A A171I522 img C A171I523 img D E A171I503 wmf INSTALLATION PROCEDURE COPIER 31 July 1995 3 6 ...

Page 166: ...ll the exposure glass front scale front scale holder and the left top cover NOTE The mark I on the edge of the glass should face up This side is smoother and it generates less static electricity when the DF is used Do not use the screw longer than 6 mm for 4 screws J other wise the screw contacts the first scanner 10 Remove the left inner cover K 4 screws strip of filament tape L Then remove the P...

Page 167: ... sensor F 2 connectors ID sensor G and drum protection sleeve H 14 Reinstall all the units around the drum except for the development unit and PTC unit NOTE Press the drum shaft I to the left and align the cleaning unit to the guides J to prevent the drum damage when reinstalling the cleaning unit D C A171I516 img B A A171I525 img F I H G E J A171I529 img INSTALLATION PROCEDURE COPIER 31 July 1995...

Page 168: ... refer to the instruction decal a Shake a new toner cartridge well while holding it horizontally b Turn the green lever clockwise c Insert the cartridge and return the green lever to the down position d Cut the green tape e Press down tab 1 and pull shutter 2 until you see the green tab 3 f Grasp tab 3 and pull the seal until you see the red line g Push the shutter back in 18 Install the left inne...

Page 169: ... of the operation unit can be selected by the positions of securing screw C The operation unit can be moved left to right by removing one M5 x 8 screw C when the operation unit is mounted at the lower position 21 Secure the grounding wire G of the operation unit 1 screw and reinstall the right rear cover 22 Install the drum guide bracket H 1 screw and set the drum guide I to the lower inner cover ...

Page 170: ...tlets is 220 V or 240 V change the voltage as follows a Disconnect the input line C from the 230 V connector b Disconnect the dummy connector D from the appropriate voltage 220 V or 240 V c Connect the input line to the appropriate voltage 220 V or 240 V d Connect the dummy connector to the 230 V connector D C A171I521 img A171I511 img A171I504 wmf B A A171I507 img 31 July 1995 INSTALLATION PROCED...

Page 171: ...c by the last 2 digits of their part number The lowest one is installed at 0 the middle one at 1 the highest one at c 27 Reinstall all the covers 28 Install the copy tray or follow the sorter stapler unit installation 29 Plug in the power cord and turn on the main switch 30 Check the copy quality and the copier operation B A 1 0 c A171I501 img INSTALLATION PROCEDURE COPIER 31 July 1995 3 12 ...

Page 172: ...cover A 3 screws 2 Install the A3 11 x 17 counter B 1 connector 3 Cut the cap C of the right inner cover by the pliers 4 Reassemble 5 Plug in the copier power cord and turn on the main switch 6 Set the A3 11 x 17 counter mode on by using SP mode 7 Check the counter operation by making an A3 11 x 17 copy B A C A171I524 img 31 July 1995 INSTALLATION PROCEDURE COPIER 3 13 ...

Page 173: ...dummy connector A 3 Remove the right cover B 2 screws and small cap C 4 Connect the key counter holder D to key counter bracket E with key counter plate nut F 2 screws 5 Run the key counter harness G through the bushing H and right cover hole I and fix the key counter harness 1 screw and 1 harness clamp 6 Install the key counter bracket to the right cover 3 screws 7 Set the key counter harness con...

Page 174: ...pean version only 1 3 Screw M4X8 3 4 Grounding Screw M4X8 1 N CAUTION Unplug the copier and 2nd sorter power cord starting the following procedure 1 Remove the strips of filament tape A of LCT 2 Open the top cover B and remove the upper cover C 6 screws 3 Remove the rear cover D 2 screws 4 Remove the fixing plate E 3 screws A D E A C A171I530 img B A171I537 img 31 July 1995 INSTALLATION PROCEDURE ...

Page 175: ...e the left rear cover E of the copier and cut 2 binds F for the LCT interface harness by the pliers 7 Remove the dummy connector G NOTE The dummy connector is required when operating the copier without the LCT Keep it for future use 8 Secure the ground wire H to the copier 1 grounding screw F B A G H A171I531 img C D D A171I538 img E A171I535 img INSTALLATION PROCEDURE LCT 31 July 1995 3 16 ...

Page 176: ...ver F 2 screws and by pass rear lower cover G 1 screw 13 Loosen the nuts H of the feet I 14 Set 4 connectors to the connectors J of the LCT harness 15 Mount the LCT unit on the copier Insert the 2 mounting studs K into the docking holes L 16 Fix the LCT unit to the copier 1 screw E 17 Screw down the feet I to level the LCT so that the LCT is parallel to the copier 18 Carry out the LCT Paper Feed T...

Page 177: ...SECTION 4 SERVICE TABLES ...

Page 178: ...lean the drum with a dry soft cloth b Finger marks Clean the drum following this order 1 A dry soft cloth 2 A wet cotton cloth with water 3 A dry soft cloth c Oil or grease Clean the drum following this order 1 A dry soft cloth to remove toner first 2 A wet cotton cloth with isopropyl alcohol 3 A wet cotton cloth with water to remove the alcohol 4 A dry soft cloth NOTE Use only isopropyl alcohol O...

Page 179: ...ooves of the end blocks see Charge Corona Replacement 7 The corona wire height must be adjusted when the front end block or front end block cover are replaced 1 3 OPTICS 1 When installing the exposure glass make sure that the white marked side of the glass faces up This side is specially treated against anti static electricity 2 When installing the left top cover use only shorter screws for mounti...

Page 180: ...any small metal objects staple clips E rings etc from being attracted to the development roller and getting inside the unit 4 The doctor plate must not be removed in the field It is fixed by precisely adjusting the doctor gap at the factory 5 Do not loosen any screws with white paint They are fixed at the factory using special tools 6 Never load different types of developer and toner into the deve...

Page 181: ...g unit is installed or removed from the copier make sure that the ID sensor is set in the copier Otherwise toner falling from the cleaning unit on the ID sensor rail may accumulate and clog on the ID sensor connector and cause a service call condition 4 Apply setting powder to the new cleaning blade and the flick blade when they are installed 1 8 PRE TRANSFER AND QUENCHING 1 Clean the PTC casing w...

Page 182: ...connected and that they are not touching the inner surface of the hot roller 3 Store the oil supply roller horizontally 1 11 DUPLEX 1 Take care not to injure yourself by dropping the duplex unit when removing and or installing the duplex unit 2 Do not touch the feed roller and separation belts with oily bare hands 1 12 DOCUMENT FEEDER 1 Do not touch the pick up separation inverter and exit rollers...

Page 183: ...mber on the display to access the required function NOTE While any of the following conditions exist you cannot access the SP mode 1 Toner end 2 Paper jam 3 Machine error or service call SC 4 Door open 2 1 2 To Exit SP Mode 1 Return to the index menu by touching on the display 2 Touch 3 Turn off DIP SW 3 on the Reset Switch PCB 2 1 3 Change the Menu Screen 1 To move to the next page touch 2 To mov...

Page 184: ...tion H Fusing Unit I Paper Exit J1 Duplex Entrance J2 Duplex Paper Feed K Duplex Exit S By pass Feed Table U LCT R1 Diagonal Transport Unit R2 Sorter Bins P1 ADF Feed in P2 ADF Transport Unit P3 ADF Feed out NOTE To clear the counters use SP mode Counter Clear 12 A171M501 img A171M502 img A171M503 img A171M542 img 31 July 1995 SERVICE PROGRAM MODE 4 7 ...

Page 185: ...red at the end of the week or month For example if this menu is displayed on Monday the counters of Tuesday through Friday show the data for the previous week NOTE To clear the counters use SP mode Counter Clear 12 A171M504 img A171M505 img A171M506 img SERVICE PROGRAM MODE 1 July 1995 4 8 ...

Page 186: ... number of copies made since a block copy counter clear was done SP mode PAGE 3 Use the block copy counter display when the machine is connected to a Remote Diagnostic System NOTE 1 To clear the counters use SP mode Counter Clear 2 The total number of copies can only be cleared by performing the RAM clear 8 SET 11 10 12 A171M507 img A171M508 img A171M543 img 31 July 1995 SERVICE PROGRAM MODE 4 9 ...

Page 187: ...mode Counter Clear 5 Operating Time This displays the total rotation time of the main motor Minutes are not displayed NOTE This counter can only be cleared by RAM clear Main board DIP SW 1 ON 2 OFF 12 A171M509 img A171M510 img SERVICE PROGRAM MODE 1 July 1995 4 10 ...

Page 188: ...Counters NOTE To clear the counters use SP mode Counter Clear 12 A171M511 img A171M512 img A171M513 img A171M514 img A171M516 img A171M517 img A171M518 img A171M515 img 31 July 1995 SERVICE PROGRAM MODE 4 11 ...

Page 189: ...lied to the drum shaft V800 Potential sensor output when 800V is applied to the drum shaft V01 Drum potential just after charging during the process control sequence V02 Drum potential just after charging during the copy cycle Exposure Sensor Initial Initial value during the process control sequence Current Current value ADS Sensor Vs ADS sensor output value during the process control sequence Vd ...

Page 190: ...urns on Reference Times theoretical values assuming no paper slippage If the displayed time varies by more than 32 ms check the appropriate feed clutch if the clutch disk surface is dirty ms 1st Tray 1 336 2nd Tray 1 617 3rd Tray 620 By pass 444 Duplex Tray 1 741 LCT 730 A171M520 img 31 July 1995 SERVICE PROGRAM MODE 4 13 ...

Page 191: ...ray 111 Upper Limit Sensor 1st tray 112 Lower Limit Sensor 1st tray 113 Paper End Sensor 1st tray 120 Paper Feed Sensor 2nd tray 121 Upper Limit Sensor 2nd Tray 122 Lower Limit Sensor 2nd tray 123 Paper End Sensor 2nd tray 130 Paper Feed Sensor 3rd tray 131 Upper Limit Sensor 3rd tray 132 Lower Limit Sensor 3rd tray 133 Paper End Sensor 3rd tray 150 Paper Feed Sensor LCT 151 Upper Limit Sensor LCT...

Page 192: ...d CL 3rd tray 105 Vertical Drive CL Left 106 Registration CL 200 Pick up SOL 1st tray 204 Paper Feed CL 1st tray 205 Vertical Drive CL Right 208 Pick up SOL 2nd tray 212 Paper Feed CL 2nd tray 300 Pinch Roller SOL 301 Inverter Gate SOL 302 Junction Gate SOL 304 Duplex Paper Feed SOL 308 Pressure Plate SOL 309 Positioning SOL 408 Cleaning SOL 410 Right Scale SOL 411 LCT Lock SOL 500 Pick up SOL LCT...

Page 193: ...ally and measures the original background density Note The test result can be displayed in Sensor Output SP mode Drum Potential Sensor Applies 100 V and 800 V to the drum drive shaft from the development bias power pack and measures V100 and V800 Exposure Lamp Turns on the exposure lamps and measures the lamp intensity sensor value 1 Touch to turn on the lamps 2 Touch to turn off the lamps Note Th...

Page 194: ...he machine in this mode for a long time Scanner Free Run Mode Runs the scanner unit ADF Free Run Mode Feeds originals automatically without main copier operation Before testing place originals in the original table The test is finishes when all originals are fed out CFF Free Run Mode Feeds CFFs computers forms automatically without main copier operation Before testing place CFFs in the original ta...

Page 195: ...e Supplies toner at the 30 setting To avoid over toning stop periodically about every 20 cycles and check the copy quality SC Detection OFF Mode Disables SC detection This is only effective during SP mode Jam Detection OFF Mode Disables jam detection This is only effective during SP mode Auto Drum Current Adjustment Mode Enables adjustment of the T S and PTC power pack outputs during process contr...

Page 196: ...step NOTE This adjustment should only be carried out when the RAM clear has to be done Do not use this mode in the field except for the RAM clear procedure RESET SET A171M524 img A171M525 img A171M526 img C Charge corona T1 Transfer corona first side T2 Transfer corona second side T3 Transfer corona leading edge T4 Transfer corona leading edge translucent paper PTC Pre transfer corona D1 Separatio...

Page 197: ...perature Use this mode with a thermometer 16 Approx 1 C Lower temperature Latent Image Vd Vb Vl Adj Reduce Vd Vb and VL1 to prevent the charge corona from arching abnormally causing black spots on copies in high altitude areas 0 9 20 V Vd 15 V VB VL1 Lower voltages ADS Sensor Adjustment NOTE For factory use VBA VBADJ can be reduced below 0 V using the ADS sensor adjustment for testing in SP mode C...

Page 198: ...nification Adjustment 200 Adjusts the lens and the mirror unit vertical stop position at 200 Focus Adjustment Full Size Adjusts the stop position of the mirror unit 32 Focus Adjustment 50 Adjusts the stop position of the mirror unit Focus Adjustment 200 Adjusts the stop position of the mirror unit Vertical Magnification Adjustment Adjusts the main motor speed Affects all reproduction ratios 3 0 3 ...

Page 199: ... side Side to Side Registration Adjustment ADF Adjusts the lens horizontal stop position Effective in ADF Side to Side Registration Adjustment 50 Adjusts the lens horizontal stop position Effective for 50 Side to Side Registration Adjustment 200 Adjusts the lens horizontal stop position Effective for 200 Adjustment Standards Leading Edge Registration 0 2 mm 0 0 08 Platen Full Size Leading Edge Era...

Page 200: ...he leading edge erase in the moving original scan mode Approx 1 mm Widen erase width Side to Side Regist Adj Sheet Through Adjusts the lens horizontal stop position Effective in moving original scan mode 0 7 mm Rear side Adjustment standards Leading Edge Registration 0 3 mm 0 0 12 Leading Edge Erase 4 3 mm 0 16 0 12 50 150 6 3 mm 0 24 0 12 50 200 Side to Side Registration 0 4 mm 0 16 0 12 Full Siz...

Page 201: ...Registration Adj Adjusts the original 1st side stop position in thin paper mode 0 05 mm Moves original away from the right scale ADF 2nd Side Registration Adj Adjusts the original 2nd side stop position in thin paper mode CFF Registration Adjustment Adjust the CFF stop position Adjustment Standards ADF 1st Side Registration 0 2 mm 4 mm 0 0 08 0 16 Thin mode 0 1 mm 2 mm 0 0 04 0 08 Thick mode ADF 2...

Page 202: ...amount of paper buckle at the registration rollers for each paper feed When the registration clutch paper feed or duplex feed clutch or the paper feed or duplex feed roller is replaced check the amount of paper buckle 99 Approx 1 mm Increase amount A171M532 img 31 July 1995 SERVICE PROGRAM MODE 4 25 ...

Page 203: ...hange Step Jogger Span Adjustment Duplex Jogger Fence Adjustment Adjusts the jogger position of the jogger fence for each paper size 16 0 6 mm Widens the span A171M533 img A171M534 img A171M544 img A171M545 img SERVICE PROGRAM MODE 1 July 1995 4 26 ...

Page 204: ...cted Access Code Registers key operator access code for Accounting Mode User Tool 9 and 10 To register the access code press the Access Code key input a 4 digit of access code and press Access Code key to store it The user must input this access code before entering User Tools 9 and 10 PM Alarm Enable Set PM interval to display PM call when the PM counter reaches PM alarm level 150K NOTE When the ...

Page 205: ...ressing the number key tops Touch to input a dialing pause 3 Touch Serial No 1 Touch 2 Enter the machine serial number by pressing the number key tops 3 Touch SC Telephone No SC Telephone No Serial No Serial No SERVICE PROGRAM MODE 1 July 1995 4 28 ...

Page 206: ...ial Features 2 PAGE 2 Item Function Tray 3 3rd tray does not have a paper size sensor To indicate the paper size on the screen select a paper size A171M536 img A171M550 img 31 July 1995 SERVICE PROGRAM MODE 4 29 ...

Page 207: ...de Rotates the main motor and development motor for approximately 5 minutes after warm up No Yes Toner Density Selection Selects a voltage shift for ID sensor bias 60 V 0 V 60 V 120 V Toner Supply Amount Selects how much toner is supplied in detect mode ID Selection in ADS Mode Selects the voltage shift for the development bias in ADS Mode 60 V 0 V 60 V 120 V RESET SET RESET SET SET HIGH 30 NORMAL...

Page 208: ...Features 3 PAGE 3 Item Function Default Remarks Tray Priority Select feed station at power on or after reset selects 3rd tray without LCT or LCT No Select No Select A171M540 img 31 July 1995 SERVICE PROGRAM MODE 4 31 ...

Page 209: ... changed to Manual Image Density Center Preset level Select Tray Display in APS Displays copy trays in APS mode No Yes Copy Disable Mode Turns the print key red and disables copying No Yes Test Copy Counter ON Counts the copy quantity in SP test mode Counter OFF Counter ON SET SET SET SET RESET RESET RESET RESET RESET RESET RESET RESET 0 93 Reduce Enlarge A171M538 img SERVICE PROGRAM MODE 1 July 1...

Page 210: ...des 1 to 6 Communication Configuration Mode Asynchronous Data Print II Prints out logging data of SP modes 7 9 and UP modes 1 9 Data format Start bits 1 Stop bits 1 Data bits 7 Parity check Even parity Transmission speed 1200 bps Connector type 25 pin female connector A3 11 x 17 Double Count Counts twice when A3 or 11 x 17 copy is made Count once Count twice Enable Auto Reset Function at Key Count...

Page 211: ...Connector for printer Copier Printer RS232C Pin No Signal Pin No Signal 1 FG 1 FG 2 TXD 3 RXD 3 RXD 4 CTS 5 RTS 7 SG 7 SG SERVICE PROGRAM MODE 1 July 1995 4 34 ...

Page 212: ...nit PCB Main 1 IC154 Main 2 IC127 Operation unit 1 IC138 ROM0 Operation unit 2 IC131 ROMCG NOTE The suffix of IC137 ROM1 should be the same as that of IC138 ROM0 The suffix of IC155 should be the same as that of IC154 Therefore the part number indication of these ROMs are omitted A171M541 img 31 July 1995 SERVICE PROGRAM MODE 4 35 ...

Page 213: ...ter Clear 1 Touch beside the counter you wish to clear 2 Touch to clear the counter Clear Yes Clear YES NO A171M546 img A171M547 img Clear YES NO A171M548 img A171M549 img SERVICE PROGRAM MODE 1 July 1995 4 36 ...

Page 214: ... 2 4 9 8 5 CFF Registration Adjustment 9 8 4 24 1 3 Charge Cleaner 8 1 4 16 3 1 Cleaning Blade OFF Mode 8 3 4 18 1 1 Copier Jam Counter Clear 12 1 4 36 1 1 Copier Operating Time 5 1 4 10 1 6 Copy Counter Clear 12 1 4 36 6 2 Copy Counter Up Down Mode 10 6 4 33 5 4 Copy Disable Mode Set 10 5 4 32 6 1 Copy Number to Release Blade Pressure 10 6 4 33 7 3 Counter 6 7 4 11 1 1 Daily Copier Jam Counter 2 ...

Page 215: ...17 1 6 Fusing Temperature 7 1 4 12 4 4 Fusing Temperature Adjustment 9 4 4 20 5 3 Horizontal Magnification Adjustment 200 9 5 4 21 5 2 Horizontal Magnification Adjustment 50 9 5 4 21 5 1 Horizontal Magnification Adjustment Full Size 9 5 4 21 4 6 ID Selection In ADS Mode 10 4 4 30 2 4 ID Sensor 6 2 4 11 1 1 ID Sensor 7 1 4 12 1 4 ID Sensor Test 8 1 4 16 3 2 Image Transfer 6 3 4 11 3 5 Jam Detection...

Page 216: ...j Sheet Through 9 7 4 23 6 2 Remote Diagnostics 6 6 4 11 7 1 ROM Part Number 10 7 4 35 1 3 SC Counter Clear 12 1 4 36 3 4 SC Detection OFF Mode 8 3 4 18 1 3 SC Telephone No 10 1 4 27 1 2 Scanner 6 1 4 11 2 4 Scanner Free Run Mode 8 2 4 17 6 3 Scanner Motor Gain Adjustment 9 6 4 22 4 1 Se Drum 6 4 4 11 2 1 Select Paper Size For Tray 10 2 4 29 5 3 Select Tray Display in APS Mode 10 5 4 32 1 1 Sensor...

Page 217: ... 3 2 4 9 1 1 Total Number of Copies 3 1 4 9 1 1 Total Number of Copies 3 1 4 9 8 1 Total Number of SC 6 8 4 11 3 1 Total original jams 1 3 4 7 4 1 Transfer Separation Corona ON Timing Adjustment 9 4 4 20 3 1 Tray Priority 10 3 4 31 1 10 User Codes User Counters Clear 12 1 4 36 5 7 Vertical Magnification Adjustment 9 5 4 21 3 2 Week Peripheral Jam Counter 2 3 4 8 1 2 Weekly Copier Jam Counter 2 1 4...

Page 218: ...ain switch is turned on 3 2 RESET SWITCH PCB Function 1 SC reset after solving the problem 2 Not used 3 Enable SP mode access Invalid for user codes and weekly timer codes 4 Reset all SP and UT except SP 9 to default settings 5 Not used 6 Connect to a Remote Diagnostic System NOTE 1 and 3 are effective while the main switch is ON 4 and 6 are only detected just after the main switch is turned on Se...

Page 219: ... Drive Gear L Mobil Temp 78 if lubrication is necessary Lens Guide Rod C C C C Dry cloth PAPER FEED for each paper feed station Pick up Rollers R R R R Copy numbers are for each paper feed station Replace the rollers as a set Paper Feed Rollers R R R R Separation Roller R R R R Paper Feed Sensors C C C C Blower brush Paper Feed Guides C C C C Dry cloth Relay Rollers C C C C Water Tray Drive Worm G...

Page 220: ...ace if damaged Cleaning Filter I C I C I C I C Blower brush Replace if damaged Cleaning Unit Inside C C C C Blower brush Remove toner DEVELOPMENT UNIT Developer R R Upper Seal C C C C Blower brush Side Seals I I I R Toner Cartridge Seals I I I I Replace if necessary Sleeve Drive Gears C C C R Blower brush Do not use any grease Timing Belt Pulley C C C C Blower brush Toner Near End Sensor Feeler I ...

Page 221: ...Blower brush Positioning Roller I I I I Positioning Roller Belt I I I I Paper End Sensor C C C C Blower Brush Timing Belt A A A A Transport Rollers C C C C Clean with water DOCUMENT FEEDER for originals Pick up Rollers C C C C Alcohol Separation Rollers C C R C Alcohol Friction Tabs I I R I Transport Belt C C R C Alcohol or belt cleaner Inverter Rollers C C C C Alcohol Exit Rollers C C C C Alcohol...

Page 222: ...fan filter Replace it if necessary 7 Inspect the exposure flat cable for damage 8 Inspect the exposure lamp for dark spots Every 900K 1 Replace the exposure lamp Every 3M 1 Replace the fiber optics cable and the flat cable Every 1M originals 1 Replace the exposure glass 3 Paper Feed every 150K for each feed station 1 Clean the paper feed sensor of each feed station using a dry cloth or a blower br...

Page 223: ...Feeder every 150K originals 1 Clean the pick up separation and exit rollers using water 2 Clean the inverter rollers using alcohol 3 Clean the transport belt using belt cleaner or alcohol 4 Inspect the friction tabs Every 450K originals 1 Replace the separation roller the friction tabs and the transport belt Every 1 2M originals 1 Lubricate the roller bushings 6 Around The Drum every 150K 1 Clean ...

Page 224: ... 2 Inspect the toner cartridge seals the sleeve side seals and toner near end sensor feeler movement 3 Replace the development filter and the duct filter Every 300K 1 Replace the developer Every 600K 1 Replace the sleeve side seals and the sleeve drive gears 9 Fusing Unit every 150K 1 Inspect the bushings and bearings of the hot and pressure rollers 2 Inspect and clean the stripper pawls using a s...

Page 225: ...300K 1 Replace the hot roller together with the bushings and the bearings Every 600K 1 Replace the pressure roller together with the bushings and the bearings PREVENTIVE MAINTENANCE SCHEDULE 1 July 1995 4 48 ...

Page 226: ...etting dry lubricate the following parts using a suitable lubricant 5 1 MIRROR UNIT GUIDE ROD FELT Lubricant Launa 40 oil or equivalent 5 2 LENS HORIZONTAL DRIVE MOTOR GEARS Lubricant Mobil Temp 78 A171M558 img A171M560 img 31 July 1995 LUBRICATION POINTS 4 49 ...

Page 227: ...5 3 TRAY DRIVE WORM GEARS Lubricant Mobil Temp 78 5 4 PAPER FEED DRIVE GEARS Lubricant Mobil Temp 78 A171M559 img A171M554 img A171M552 img A171M551 wmf A171M555 img LUBRICATION POINTS 1 July 1995 4 50 ...

Page 228: ...5 FUSING DRIVE GEARS Lubricant Mobil Temp 78 5 6 DF BUSHINGS Interval Every 1 2M originals Lubricant Launa 40 oil or equivalent A171M557 img A171M553 img A171M556 img 31 July 1995 LUBRICATION POINTS 4 51 ...

Page 229: ...SECTION 5 REPLACEMENT AND ADJUSTMENT ...

Page 230: ...he doors up and remove them by swinging out the bottom part of each door NOTE To re install the doors set the top hole located on the door to the pin match the position of the lower pin to the mark located at the bottom of the door and slide the door in A A171R565 img 31 July 1995 EXTERIOR AND INNER COVERS 5 1 ...

Page 231: ...wer cover B 3 screws Rear Covers 1 Remove the left rear C and right rear D covers 2 screws each Right Cover 1 Remove the right cover E 2 screws Left Top Cover 1 Lift the document feeder 2 Remove the left top cover F 7 screws NOTE Use only short screws less than 6mm for G E D F A B C A171R510 imd EXTERIOR AND INNER COVERS 31 July 1995 5 2 ...

Page 232: ...over B 3 screws 1 4 UPPER COVER REMOVAL 1 Remove the right inner cover 2 Disconnect the auto response sensor connector C 3 Remove the front upper cover D 4 screws 4 Remove the rear upper cover E 3 screws 5 Remove the rear top cover F 2 screws A B A171R566 img D E F C A171R567 img 31 July 1995 EXTERIOR AND INNER COVERS 5 3 ...

Page 233: ...holder A 2 screws and 2 plates 3 Remove the front scale B 2 screws 3 Loosen the three screws C securing the rear scale 4 Remove the exposure glass D NOTE When reinstalling the exposure glass make sure the mark on the glass edge E is facing up C D E B A A171R572 img OPTICS 31 July 1995 5 4 ...

Page 234: ...URE LAMP REPLACEMENT 1 Remove the front upper cover A and rear top cover B 2 Remove exposure glass C and rear scale D 3 screws 3 Move the first scanner to the center A C B D A171R578 img 31 July 1995 OPTICS 5 5 ...

Page 235: ... the lamp intensity sensor fiber optics cable A 1 screw and remove the cable end B 5 Remove the front lamp holder C 2 screws and pull out the lamp while holding the lamp heater D B A C D A171R551 img OPTICS 31 July 1995 5 6 ...

Page 236: ...er D NOTE Make sure that the pin is properly positioned on the terminal of the rear lamp holder E 8 Set the right terminal pin F of the lamp into the center of the front lamp holder G 9 Fix the front terminal while pressing it to the rear 2 screws NOTE Take care that the lead wires are not pinched by the terminal 10 Set the lamp pins by pressing and turning the lamp as shown in the figure B A F G ...

Page 237: ... transparent part of the lamp is at the center of the heater opening see figure 12 Reinstall the end of the fiber optics cable A and fix the cover B 1 screw 13 Reassemble the machine 14 Perform the process control initial setting in the SP test mode see Service Program section B A A171R575 img A171R574 img OPTICS 31 July 1995 5 8 ...

Page 238: ...r cover 2 Remove the DF transport unit 3 Remove the exposure glass 4 Remove the rear upper and rear top covers 5 Move the first scanner to the left and remove the fiber optics cable ends A 1 screw and cover each 6 Remove four harness clamps on the first scanner 1 screw each A A171R550 img 31 July 1995 OPTICS 5 9 ...

Page 239: ... 3 connectors 10 Remove the fiber optics cable running through the harness clamps NOTE 1 The fiber optics cable with the white mark on the end is for the light intensity sensor CN115 on the main PCB 2 The fiber optics cable has to be reinstalled with the white mark side E facing the flat cable see figure A A171R553 img C D B E A171R581 img A171R 584 img OPTICS 31 July 1995 5 10 ...

Page 240: ... and right rear covers Left upper cover Front top cover Rear upper and rear top covers 3 Remove the DF feed and transport units and the exposure glass 4 Loosen the screws of the wire tension brackets A and slacken the wire tension 5 Remove the DF brackets B 6 screws each A B A171R554 img 31 July 1995 OPTICS 5 11 ...

Page 241: ...of the first scanner 2 screws each NOTE Do not loosen any screws which are marked with white paint 8 Remove the flat cable holder bracket fixed on the main frame D 1 screw 9 Remove front scanner guides E 1 screw each 10 Remove the first scanner unit F 11 Remove the scanner wires A B E F D C C A171R530 img OPTICS 31 July 1995 5 12 ...

Page 242: ...sitioning pins A special tool 13 Position the drive pulley B as shown in the figure and secure it with the scanner fixing screw C NOTE The scanner fixing screw is removed during installation A A C A171R560 img B C A171R583 img 31 July 1995 OPTICS 5 13 ...

Page 243: ... and wrap the wire three and a half times on the pulley from bottom to top counterclockwise 15 Run the blue wire through the pulleys as shown Use the following tracks of the pulley B Lower C Lower D Upper 16 Hook the wire end to the tension spring E A E C D B A171R556 img OPTICS 31 July 1995 5 14 ...

Page 244: ...ey as shown and wrap the wire four times on the pulley from bottom to top counterclockwise 18 Run the gray wire through the pulleys as shown Use the following tracks of the pulley B Upper C Upper 19 Hook the wire end to the tension spring D D A B C A171R559 img 31 July 1995 OPTICS 5 15 ...

Page 245: ...wn and wrap the wire four times on the pulley from top to bottom clockwise 21 Run the black wire through the pulleys as shown Use the following tracks of the pulley B Lower C Upper 22 Fix the wire end with the bushing D the ring nut E and the nut F A D E F B C A171R555 img OPTICS 31 July 1995 5 16 ...

Page 246: ...ley as shown and wrap the wire three and a half times on the pulley from top to bottom clockwise 24 Run the red wire through the pulleys as shown Use the following tracks of the pulley B Upper C Upper 25 Hook the wire end to the bracket D A C B D A171R558 img 31 July 1995 OPTICS 5 17 ...

Page 247: ...nsion brackets C Second Scanner Position Adjustment 27 Slide the second scanner D back and forth several times manually 28 Adjust the ring nut position E so that both scanner positioning pins A can be easily set to the positioning holes 29 Fix the ring nut E with the nut F A B D F E A C A171R552 img OPTICS 31 July 1995 5 18 ...

Page 248: ...h 33 Remove the scanner positioning pins A and slide the scanner back and forth several times manually Then confirm the scanner position by resetting the positioning pins NOTE If they cannot be set smoothly repeat steps 27 to 33 34 Reassemble the machine 35 Perform the scanner free run by the SP test mode and check the scanner movement 36 Make copies and confirm the copy quality adjust the magnifi...

Page 249: ... the scanner drive pulley with tape A to fix the scanner wires 6 Loosen the Allen screws B on the drive pulley 7 Remove the scanner drive motor C together with the bracket D 4 screws 8 Remove the scanner drive motor from the bracket 4 screws NOTE a The rating label of the motor should face the rear of the machine b The gap between the pulley and motor has to be between 1 5 and 2 mm A D C B 1 5 2 0...

Page 250: ...oard A 4 studs 4 Unhook the tension spring B and loosen two screws C fixing the belt pulley bracket 5 Remove the encoder sensor D 1 screw and 1 connector 6 Remove the encoder disc E 1 screw and remove the timing belt 7 Remove the motor bracket F 1 screw and 1 connector 8 Remove the lens vertical drive motor G A E F G D C B A171R562 img 31 July 1995 OPTICS 5 21 ...

Page 251: ...AL 1 Remove the left upper cover and the exposure glass 2 Remove the lens shielding cover A 3 screws 3 Remove the shading plate B 3 screws 4 Unhook the tension spring C and remove the drive wire A C B A171R564 img OPTICS 31 July 1995 5 22 ...

Page 252: ...acket B 2 screws 6 Remove the motor bracket B 3 screws and 2 connectors 7 Remove the encoder sensor bracket C 1 screw the encoder disc D 1 screw and the drive pulley E 8 Remove the drive motor F 2 screws D E C B F A A171R563 img 31 July 1995 OPTICS 5 23 ...

Page 253: ... and wrap the wire on the drive pulley B two and a half times from bottom to top clockwise Fix the spring to the lens base as shown NOTE Confirm that no wire is overlapping on the drive pulley 11 Reassemble the machine NOTE Fix the shading plate C at the nearest position to the lens A B A171R580 img C A171R579 img OPTICS 31 July 1995 5 24 ...

Page 254: ... spring B and loosen the mounting screws of the belt tightener bracket C 2 screws 4 Remove the encoder sensor D 1 screw and the encoder disc E 1 screw then remove the timing belt F 5 Remove the motor bracket G 2 screws 6 Remove the idle gear H 1 E ring and the drive motor I 2 screws A A171R582 img D I F C B G H E A171R561 img 31 July 1995 OPTICS 5 25 ...

Page 255: ... bracket A 1 screw 4 Remove the screw B fixing the mirror bracket and remove the 6th mirror unit C NOTE a Do not loosen any screw which has white paint D b When reinstalling the mirror unit make sure the unit is set to the guides E correctly C A B A171R515 img E D B A171R521 img OPTICS 31 July 1995 5 26 ...

Page 256: ...ILTER REPLACEMENT 1 Remove the fan filter holder A 1 screw 2 Replace the filter B in the filter holder NOTE Make sure that the filter is set underneath the projections C A A171R577 img B C A171R576 img 31 July 1995 OPTICS 5 27 ...

Page 257: ...e left inner cover 4 Remove the PTC unit A 5 Disconnect the connector B of the PTL 6 Remove the development unit 1 screw NOTE a When reinstalling the development unit confirm the drive gear mesh by turning the paddle roller knob C b When reinstalling the PTC unit make sure that the front unit bracket is set to the projections D on the drum stay correctly B C A D A171R568 img DEVELOPMENT 31 July 19...

Page 258: ...3 2 DEVELOPMENT FILTER REPLACEMENT 1 Remove the development unit 2 Remove the filter A by pressing the levers down as shown A A171R548 img 31 July 1995 DEVELOPMENT 5 29 ...

Page 259: ...ait more than 5 seconds and return the collection lever 6 Remove the developer catch pan to collect the developer 7 Reinstall the developer catch pan and turn the collection lever clockwise 8 Turn on the main switch 9 Enter the SP test mode and select the drum conditioning mode 10 After about one minute reset the drum conditioning mode and turn off the main switch 11 Return the collection lever to...

Page 260: ... Otherwise return the collection lever 14 Remove the development unit and the development filter 15 Pour one bag 1 7 kg of the developer into the development unit While pouring the developer turn the paddle roller knob A clockwise to evenly distribute the developer 16 Reassemble the machine NOTE Reinstall the safety switch actuator to the duplex unit stay for future use A A171R544 img 31 July 1995...

Page 261: ... the doctor plate 3 Peal off the old side seals C and clean the parts with alcohol 4 Install the new seals as shown NOTE Make sure that the corner of each seal are positioned as shown 5 Reassemble the machine NOTE When reinstalling the entrance seal bracket A press and fix it as shown B A171R520 img C A171R518 img A171R519 img DEVELOPMENT 31 July 1995 5 32 ...

Page 262: ...nt unit 2 Remove two drive gears A for the development sleeves 1 E ring and 1 pin each NOTE Take care not to lose the pins 3 Install the new gears and reassemble the machine NOTE Do not use any lubricant on these gears A A171R569 img 31 July 1995 DEVELOPMENT 5 33 ...

Page 263: ...3 6 DEVELOPMENT DUCT FILTER REPLACEMENT 1 Remove the development unit 2 Remove the duct cover A 3 Replace the filter B in the duct 4 Reassemble the machine B A A171R546 img DEVELOPMENT 31 July 1995 5 34 ...

Page 264: ...erminal A 2 screws with star washer and 1 lead wire 4 Remove the magnet angle levers B 1 screw and 1 E ring each NOTE Do not loosen three screws C with white paint fixing the development unit guide 5 Remove the entrance seal bracket D 2 screws A B C C A171R570 img D A171R547 img 31 July 1995 DEVELOPMENT 5 35 ...

Page 265: ...aint for the sleeve positioning plate 10 Pull the development sleeves H out the rear side NOTE 1 To prevent developer leakage the following parts must be replaced whenever the development rollers are removed a Rear Sleeve Seal A and C b Rear Drum Seal B c Sleeve Bearing Case Assembly E 2 Note that the upper development roller has a shorter front shaft than the lower development roller H C A B D F ...

Page 266: ...unit 2 Remove the wire clamp A fixing the development unit harness 1 screw 3 Slide out the toner near end sensor bracket B 1 screw NOTE When reinstalling the sensor bracket make sure that no lead wire touches the gear C C B A A171R549 img 31 July 1995 DEVELOPMENT 5 37 ...

Page 267: ...NG UNIT REMOVAL 1 Remove the left inner cover 2 Remove the development unit 3 Release the transport unit with the lever A and remove the drum stay B 4 Remove the cleaning unit C C B A A171R599 img CLEANING 31 July 1995 5 38 ...

Page 268: ...ENT 1 Remove the cleaning unit 2 Remove the four screws A fixing the cleaning blade 3 Replace the cleaning blade B 4 Confirm proper movement of the cleaning blade 5 Assemble the machine A B A171R595 img 31 July 1995 CLEANING 5 39 ...

Page 269: ...ng unit and remove the cleaning blade 2 Remove the front brush holder A 1 screw and remove the cleaning brush B NOTE When replacing the brush make sure that the notch C of the brush fits the drive boss D D C B A A171R594 img CLEANING 31 July 1995 5 40 ...

Page 270: ...move the two screws A securing the flick blade to the cleaning unit 3 Remove the flick blade B NOTE When reinstalling the flick blade make sure that the blade bracket holes are set to the projections C correctly as shown C B A A171R587 img 31 July 1995 CLEANING 5 41 ...

Page 271: ...emove the flick blade and unhook the blade pressure spring A NOTE Do not loosen the blade pressure stopper screw B 3 Remove the rear cover of the cleaning unit C 4 screws 4 Remove the flick roller drive gear D 1 E ring D A B C A171R600 img CLEANING 31 July 1995 5 42 ...

Page 272: ...n pipe A with the spring 6 Remove the bushing bracket B 1 screw and 1 bushing 7 Remove the coupling gear C 1 E ring 8 Remove the brush gear D and the flick roller gear E 1 E ring each C D E A B A171R597 img 31 July 1995 CLEANING 5 43 ...

Page 273: ...lide the flick roller D out of the rear of the cleaning unit NOTE When reassembling the cleaning unit after maintenance fix the bushing bracket so that the mounting screw is located in the middle of the long screw hole E D C B A A171R601 img E A171R680 img CLEANING 31 July 1995 5 44 ...

Page 274: ...the left inner cover and remove the development unit 2 Lower the transport unit with the lever A and remove the drum stay B 3 Remove the cleaning unit C and the ID sensor board D 4 Remove the charge corona unit E erase lamp unit F and drum potential sensor unit G B A A171R589 img D C A171R598 img F E G A171R592 img 31 July 1995 AROUND THE DRUM 5 45 ...

Page 275: ...the drum shaft and pull out the old drum 7 Insert the new drum with the drum protective sleeve then remove the drum protective sleeve Keep the protective sleeve for future maintenance 8 Reassemble the machine A B A171R593 img AROUND THE DRUM 31 July 1995 5 46 ...

Page 276: ... unhook the tension springs C 4 Remove the old corona wires D and cleaner pads E 5 Clean the corona casing and end blocks NOTE Use water first and then use alcohol to remove toner remaining on the unit 6 Install the new cleaner pads and corona wires NOTE Make sure that the corona wires are set in the grooves F of the end blocks and between the cleaner pads correctly B F D C A F E A171R590 img 31 J...

Page 277: ...over B 4 Unhook the tension spring C and remove the old corona wire D 5 Clean the corona casing and the end blocks 6 Install the new corona wire with the damper ring E NOTE a The position of the damper ring must be as shown in the figure b Make sure that the wire is set in the grooves of the end blocks E A D B C E A171R586 img AROUND THE DRUM 31 July 1995 5 48 ...

Page 278: ...er the transport unit with the lever A 3 Pull out the fusing unit 4 Remove the transport unit lever A 1 screw and the middle inner cover B 2 screws 5 Remove the transport unit cover C 2 screws and pull out the T S corona unit D 1 connector B A C D A171R603 img 31 July 1995 AROUND THE DRUM 5 49 ...

Page 279: ...and end block NOTE Use water first and then use alcohol to remove toner remaining on the unit 11 Install the new wires with the damper rings G and new cleaner pads 12 Reassemble NOTE Note that two kinds of tension spring are used The hooks of the spring differ as shown H is for the transfer corona and I is for the separation corona B A C D H I G E A171R585 img F A171R596 img AROUND THE DRUM 31 Jul...

Page 280: ... heater holder A 3 screws and 1 bracket 4 Disconnect the connector B and slide out the drum heater C NOTE The drum heater has notches which have to be matched to the rear flange Position the heater as shown in the figure and fix the heater when reassembling B C A A171R602 img A171R607 img 31 July 1995 AROUND THE DRUM 5 51 ...

Page 281: ...t Mode 8 page 3 4 Set the Process Control Initial Setting and press Start key 5 Exit from the SP mode and reset DIP SW 3 on the reset switch PCB 5 6 2 T S Corona and PTC Current Adjustment NOTE 1 The following procedure will also adjust the charge corona current at the same time Make sure that the charge corona unit is also cleaned and the wire is new 2 Even if only one of these power packs is rep...

Page 282: ...7 Exit from the SP mode and reset DIP SW 3 on the reset switch PCB 8 Check the copy quality and the paper separation function 31 July 1995 AROUND THE DRUM 5 53 ...

Page 283: ...1 2 Upper Cover 1 Remove the LCT from the copier 2 Open the top cover B and remove the upper cover C 6 screws 6 1 3 Left Cover 1 Remove the upper cover 2 Remove the left cover D 2 screws 6 1 4 Rear Cover 1 Remove the upper cover 2 Remove the rear cover E 2 screws D A E A171R532 img B A171R523 wmf C A171R522 wmf LCT 31 July 1995 5 54 ...

Page 284: ...and the harness A 2 screws and 1 connector from the LCT unit 2 While releasing the tray lock lever B pull out the LCT 3 Remove the 4 screws of the LCT C and lift the tray from the accuride rails A B A171R511 img C A171R512 img 31 July 1995 LCT 5 55 ...

Page 285: ... touch the surface of the rollers with oily hands Make sure that the paper feed roller is installed in the proper direction as shown The paper feed rollers used in the LCT and the by pass feed are different from the feed rollers in the 1st 3rd feed stations Distinguish them by the color of the side plate hub of the rollers White one 1st 3rd feed Black one LCT and by pass feed A C B A171R540 wmf LC...

Page 286: ...6 4 PICK UP SOLENOID GAP ADJUSTMENT Adjustment standard 5 0 3mm 1 Remove the upper cover 2 Adjust the pick up solenoid gap A 2 screws A A171R513 img 31 July 1995 LCT 5 57 ...

Page 287: ...1 connector C 4 Remove the paper end sensor D and or paper size sensors E and or tray heater F 1 screw and 1 connector each NOTE 1 Take care not to damage the paper end sensor connector C when the paper tray bottom plate B is removed 2 Remember to connect the paper end sensor harness to the connector C when installing the paper tray bottom plate A B C A A171R604 img E D F A171R591 img LCT 31 July ...

Page 288: ...hafts D are horizontal NOTE Hold the tray bottom plate during the following step to prevent the bottom plate from falling down 4 Remove the tray motor with the bracket by sliding it to the left see illustration so that the connecting shafts are disconnected 5 Remove the tray motor E 2 harness clamps and 4 screws from the bracket D C B A A171R588 img E A171R605 img 31 July 1995 LCT 5 59 ...

Page 289: ...djust the timing belt tension A 1 screw as shown 6 8 TRAY DRIVE CHAIN PRESSURE ADJUSTMENT 1 Remove the front and rear covers 2 Loosen the screws B for the chain tension brackets 3 When the tension is determined by the spring tighten the screws for the chain tension B A171R514 img A A171R606 img LCT 31 July 1995 5 60 ...

Page 290: ...crews and rear cover 2 screws 3 Pull out the LCT while releasing the tray lock lever 4 Remove the paper feed unit 2 connectors A and 4 screws NOTE When re installing the paper feed unit insert the paper feed unit projections B into the LCT cutouts C A A B C B A171R533 img 31 July 1995 LCT 5 61 ...

Page 291: ... 2 Remove the tray fixing plate B 1 screws 3 Disengage the tray unit by pressing the tray stoppers C inward while pulling out and up on the tray N CAUTION Take care not to injure yourself with the hooks D B A C D D C A171R536 img 1ST 2ND AND 3RD TRAYS 31 July 1995 5 62 ...

Page 292: ...eed and separation rollers A B and C 1 snap ring each NOTE Do not touch the surface of the rollers with oily hands The paper feed rollers used in the 1st 3rd feed stations are different from the feed rollers in the LCT and the by pass feed table Distinguish them by the color of the side plate hub of rollers White one 1st 3rd feed Black one LCT and by pass feed A B C A171R541 wmf 31 July 1995 1ST 2...

Page 293: ...JUSTMENT Adjustment standard 5 0 3 mm 1 Pull out the vertical transport unit 2 Remove the paper feed unit top cover A 2 screws 3 Adjust the pick up solenoid gap B 2 screws A B A171R614 img 1ST 2ND AND 3RD TRAYS 31 July 1995 5 64 ...

Page 294: ...ides grips A 2 screws each 3 Remove the paper tray bottom plate B 7 screws 1 connector C and 1 clamp D 7 4 2 Paper End Sensor and Lower Limit Sensor Replacement 1 Remove the paper end sensor E and or lower limit sensor F 1 screw and 1 connector each H I A171R635 img A D B E G F C K A171R633 img J L A171R634 img 31 July 1995 1ST 2ND AND 3RD TRAYS 5 65 ...

Page 295: ... the end plate 7 4 4 Tray Heater Replacement 1 Remove the end plate bracket H 2 screws 2 Remove the tray heater cover J 2 screws and tray front cover K 3 screws and 1 connector 3 Remove the tray heater L 1 screw and 1 connector NOTE When reassembling the machines make sure that the tray metal beads are inserted in the slots at the ends of the tray support brackets A D B E G F C K A171R633 img H I ...

Page 296: ...r 3 screws and 1 connector b Tray upper rear cover A 2 screws c Tray motor B 6 screws and 2 connectors d Wire tension springs C front and rear e Wire support brackets D 2 screws each front and rear 3 Loosen the screws E front and rear B A D D C E E C A171R638 img 31 July 1995 1ST 2ND AND 3RD TRAYS 5 67 ...

Page 297: ...ing the wire over all pulleys except the tension pulley C c Wrap the other end of the wire around the drive pulley 3 5 times clockwise and insert the bead into the slot of the drive pulley as shown d Insert the support beads D into the slots of the lift rods E e String the wire over the tension pulley B A D E C A171R611 img 1ST 2ND AND 3RD TRAYS 31 July 1995 5 68 ...

Page 298: ...ys except the tension pulley C c Wrap the other end of the wire around the drive pulley 3 5 times counterclockwise and insert the bead into the slot of the drive pulley as shown d Insert the support beads D into the slots of the lift rods E e String the wire over the tension pulley 6 Reassemble the machine and confirm the tray operation B A D C E A171R612 img 31 July 1995 1ST 2ND AND 3RD TRAYS 5 6...

Page 299: ...nces A and rear fence B 2 Change the positions of these fences to the appropriate ones for required paper size 3 Access SP mode and change the paper size setting to required one 10 SP Special Features page 2 B A A A171R534 img 1ST 2ND AND 3RD TRAYS 31 July 1995 5 70 ...

Page 300: ...d paper feed station 3rd tray 2 Pull out the vertical transport unit and remove the inner cover A 3 screws in case of the 3rd paper feed station 2 screws 3 Remove the appropriate paper feed unit B 4 screws and 1 connector A B A171R535 img 31 July 1995 1ST 2ND AND 3RD TRAYS 5 71 ...

Page 301: ...CEMENT 1 Remove the development unit 2 Remove the registration knob A and transport inner cover B 4 screws 3 Remove the receiving plate C 1 screw 4 Remove the paper dust pan D A B C A171R620 img D A171R613 img REGISTRATION AND TRANSPORT 31 July 1995 5 72 ...

Page 302: ...E VERSION 1 Remove the LCT if it is installed 2 Remove all the by pass feed covers 3 Remove the transport inner cover A 5 screws and 1 knob 4 Remove the relay transport unit B 4 screws as shown A B A171R621 img 31 July 1995 REGISTRATION AND TRANSPORT 5 73 ...

Page 303: ...aper feed roller separation roller and pick up roller replacement of the by pass feed tray 3 Remove the by pass rear lower and upper covers A B 1 screw each 4 Remove the transport inner cover C 5 screws and 1 knob 5 Remove the relay transport unit D 4 screws and 1 connector E as shown E C D A171R537 img A B A171R542 wmf REGISTRATION AND TRANSPORT 31 July 1995 5 74 ...

Page 304: ...t unit and receiving plate 3 Remove the drum 4 Disconnect the 2 connectors B and remove the 1 screw C 5 Remove the horizontal transport unit NOTE Reinstall the horizontal transport unit while turning the knob screw D to engage the registration clutch gear with the gear of the main body B A D B C A171R722 img 31 July 1995 REGISTRATION AND TRANSPORT 5 75 ...

Page 305: ... 4 Push the upper accuride C into the main body while supporting the vertical transport unit 5 Lift up the vertical transport unit and remove it NOTE When reinstalling the vertical transport unit align the front side positioning pin D to the front hole of the vertical transport unit then align the rear pin E with the rear hole Next pull out the upper accuride and align the screw holes A C D E B A1...

Page 306: ...per C 2 screws 4 While supporting the vertical transport unit disengage the rail D from the main body by pulling out the left vertical transport unit 5 Lift up the left vertical transport unit and remove it NOTE When reinstalling the left vertical transport unit align the positioning pins E to the hole F of the vertical transport unit then engage the rail with the main body C A D E A171R524 img B ...

Page 307: ...oning bracket E 2 screws the grounding wire F 1 screw and harness G 3 clamps 4 Remove the transport unit H and transport tank I 4 screws 5 Replace the transport unit belts NOTE When reinstalling the transport unit guide the transport unit right of the guide J of the horizontal transport unit and insert the positioning pin K in the hole A B A171R628 img K C F E G D H J A171R610 img I A171R627 img R...

Page 308: ... pawls 1 Remove the drum 2 Remove the pick off pawl unit A as shown Pull out it and turn it counterclockwise 8 9 TONER FILTER REPLACEMENT 1 Remove the left inner cover 2 Remove the filter shutter B 3 Replace the toner filter C A A171R528 img C B A171R615 img 31 July 1995 REGISTRATION AND TRANSPORT 5 79 ...

Page 309: ...8 10 OZONE FILTER REPLACEMENT 1 Remove the left rear cover 2 Remove the duct cover A 2 screws 3 Replace the ozone filter B A B A171R616 img REGISTRATION AND TRANSPORT 31 July 1995 5 80 ...

Page 310: ...ter unit B 2 Turn the fusing unit release lever clockwise and remove it 1 screw Remove the fusing cover C 3 screws 3 Disconnect the following connectors Fusing lamp D front and rear 1 connector each Thermofuse E Thermistor F 4 Open the inverter unit G and remove the fusing unit H 2 screws D G B C A D F E H A171R525 img 31 July 1995 IMAGE FUSING 5 81 ...

Page 311: ... D front and rear 2 screws each and fusing lamp E 6 Release the fusing pressure and remove the following parts a Fusing drive gear F 1 C ring and 1 parallel key b Bushings G and bearings H 1 C ring each NOTE For the next step take care not to damage the thermistor 7 Remove the hot roller I as shown NOTE When reassembling the fusing lamp make sure that the blue wire J of the lamp is at the front si...

Page 312: ...each 9 Remove the pressure roller C 10 Remove the bushing D and bearing E 1 C ring from the shaft 11 After reassembling the machine check the nip width and adjust fusing pressure if necessary See fusing pressure adjustment E D A171R617 img B A C A171R632 img 31 July 1995 IMAGE FUSING 5 83 ...

Page 313: ...ut the fusing unit 2 Remove the upper fusing entrance guide A 2 screws 3 Remove the the pressure springs B and the bushings C from the cutouts and then the oil supply roller D A A171R637 img B C D C B A171R629 img IMAGE FUSING 31 July 1995 5 84 ...

Page 314: ...urn the top fusing cover D 1 4 of a turn counterclockwise and lift it up 9 4 2 Hot Roller Stripper Replacement 1 Remove the fusing exit guide plate E 4 screws 2 Unhook the springs F and slide out the hot roller stripper pawls G 9 4 3 Pressure Roller Stripper Pawl Replacement 1 Open the inverter unit H and remove the fusing exit guide plate I 2 crews 2 Remove the pressure roller strippers pawls J 2...

Page 315: ...ove the top fusing cover A 2 Remove the upper fusing entrance guide B 2 screws 3 Remove the thermistor C 1 screw and 1 connector 4 Remove the thermofuse D 4 screws 3 harness clamps and 1 connector A C D B A171R608 img IMAGE FUSING 31 July 1995 5 86 ...

Page 316: ...wer the transport unit 7 Actuate the right and left door safety switches with the tools 8 Turn on the main switch and wait until ready condition 9 Using a digital thermometer and probe measure the temperature at the middle of the hot roller when the lamp is turned on 10 If the measured temperature is out of the adjustment range change the setting of the fusing temperature in SP mode 9 NOTE Use to ...

Page 317: ...ing unit for 15 seconds and then will exit 3 Measure the nip band width the shiny band at both ends 4 If the nip band width is not within specifications at both ends release the fusing pressure and adjust it using the adjustment screw A clockwise increase pressure counterclockwise decrease pressure NOTE Loosen the lock nuts B before turning the pressure adjustment screw Re tighten the nuts after a...

Page 318: ...s Set it in the middle position or top position if paper creasing occurs 1 Pull out the fusing unit 2 Remove the two screws A from lowest holes B 3 Insert the two screws C into the middle or top holes D 4 Slide up the entrance guide D to the middle or top position 5 Tighten the two screws A B C B D C A A171R527 img 31 July 1995 IMAGE FUSING 5 89 ...

Page 319: ...isconnect the connectors B as shown 3 Remove 4 screws C of the inverter unit NOTE Do not remove the shoulder screw D which supports and positions the inverter unit Otherwise the inverter unit will fall 4 Close the inverter unit 5 Remove the inverter unit from the large cutout of the bracket in which the shoulder screw is fixed A C B D C A171R631 img INVERTER PAPER EXIT 31 July 1995 5 90 ...

Page 320: ... exit sensor bracket A 1 screw 3 Remove the exit sensor B 1 screw and 1 connector 10 2 2 Fusing Sensor Replacement 1 Pull out the fusing unit 2 Remove the fusing sensor bracket C 1 screw from the lower side 3 Remove the fusing sensor D 1 screw and 1 connector B A C D A171R632 img 31 July 1995 INVERTER PAPER EXIT 5 91 ...

Page 321: ...ing C and solenoid spring D 4 Remove the solenoid from the 2 brackets 5 screws 1 clamp and 1 connector 10 3 2 Inverter Solenoid Replacement 1 Remove the pinch roller solenoid 2 Remove the fixing screw E for inverter solenoid bracket 3 Unhook the return spring F for the pinch roller solenoid and the solenoid spring G 4 Remove the solenoid from the bracket 3 screws 1 clamp and 1 connector E G F A C ...

Page 322: ...ove the inverter unit 2 Remove the fixing screw A for the junction gate solenoid bracket 3 Unhook the solenoid spring B 4 Remove the solenoid from the bracket 3 screws 1 clamp and 1 connector A B A171R624 img 31 July 1995 INVERTER PAPER EXIT 5 93 ...

Page 323: ... main body 4 Lift up the duplex unit and remove it NOTE When re installing the duplex unit hook the right cutouts D of the duplex unit on the projections E of the right slide rail Then slide out the left side rail N CAUTION Take care not to injure yourself by dropping the duplex unit when removing and or installing the duplex unit B B C E A D A171R500 wmf DUPLEX 31 July 1995 5 94 ...

Page 324: ...11 2 DUPLEX COVER REMOVAL 1 Remove the duplex knob A 1 screw 2 Remove the duplex cover B 3 screws A B A171R501 wmf 31 July 1995 DUPLEX 5 95 ...

Page 325: ...EMENT 1 Pull out the duplex unit and remove the duplex cover 2 Remove the two gears A 1 snap ring B 3 Remove the separation belt unit C 1 gear D 1 retaining ring E and 1 bushing F A B C D E F A171R502 wmf DUPLEX 31 July 1995 5 96 ...

Page 326: ...ler D 7 Replace the three separation belts E as a set NOTE Make sure that the snap rings F do not touch the separation belt When setting the tension spring G set it on the hook H The white side of the separation belts should be face out B H A G C E D A171R503 wmf F A171R509 wmf 31 July 1995 DUPLEX 5 97 ...

Page 327: ...moving the duplex feed guide plate C in step 2 2 Remove the duplex feed guide plate C 2 screws and 1 connector 3 Slide the feed roller shaft D to the rear then slide the feed roller E to the front 1 snap ring and 1 bushing and replace it as shown NOTE When re assembling set the duplex feed clutch stopper F to the bracket G G F A B E D C A171R504 wmf DUPLEX 31 July 1995 5 98 ...

Page 328: ...cket A 4 screws 3 Remove the front and rear jogger fences C 1 screw each 4 Remove the end fence D 2 screws 5 Remove the five screws E for fixing the duplex tray F 6 Take the duplex tray as shown so that the cutouts G of the tray should not be touch the screws on the both duplex side plates H G E H F E G C D A171R505 wmf A A171R506 wmf B A171R681 wmf 31 July 1995 DUPLEX 5 99 ...

Page 329: ...as follows Otherwise the jogger fence guides drop from the jogger fence drive wire 1 Move the beads B to the tabs C as shown 2 Set the jogger fence guides A on the beads 3 Place the jogger fence guides on the tabs 4 Re install the duplex tray A B C A171R507 wmf DUPLEX 31 July 1995 5 100 ...

Page 330: ...e at the correct position by sliding the fences 4 Select a duplex mode and feed a copy paper to the duplex unit 5 Access the SP mode and select the duplex jogger span adjustment SP Adjustment page 10 6 Check the jogger fence position in the duplex unit and measure the gap between the fence and paper edge 7 If the gap is small and fences are pressing the paper make the jogger fence position wider b...

Page 331: ...EPLACEMENT 1 Follow steps 1 to 6 of the duplex tray removal 2 Run the jogger fence drive wire A or end fence drive wire B as shown Wrap each wire on each motor pulley 1 and half times B A A171R682 img DUPLEX 31 July 1995 5 102 ...

Page 332: ...ase lever A to the right to release the belt unit B 2 Loosen the screw C and slide the lever D supporting the left transport belt unit E 3 Fold the transport belt unit to release tension and replace the transport belt F A F C E D B A171R659 img 31 July 1995 ARDF 5 103 ...

Page 333: ...nit 2 screws 3 Remove the separation roller shaft stopper C 1 screw 4 Slide out the separation roller shaft D 5 Replace the separation rollers E NOTE When installing the separation rollers set them so that the mark F of the rollers face to the front of the machine D B C A E F A171R660 img ARDF 31 July 1995 5 104 ...

Page 334: ...r A 2 screws and the rear cover B 3 screws of the original feed unit 2 Remove the right rear cover of the copier 2 screws 3 Remove the screw C fixing the ground line and disconnect the 2 connectors D A B A171R642 img C D A171R647 img 31 July 1995 ARDF 5 105 ...

Page 335: ...the screw F fixing the right ground line 5 Disconnect the 6 connectors G 6 Remove the 3 screws H and slide the original feed unit to the right to remove it G F A171R641 img H A171R661 img ARDF 31 July 1995 5 106 ...

Page 336: ...4 Mark the tension bracket E position loosen the screw F and remove the screw G Remove the timing belt H 5 Remove the relay roller pulley I 1 E ring 6 Remove the pick up roller home position sensor J 1 screw and 1 connector 7 Remove the rear side plate K 6 screws 8 Remove the tension bracket E 2 screws 9 Replace the feed in motor L 4 screws D B A E F H I J G C A171R662 img L E K A171R663 img 31 Ju...

Page 337: ...NT procedure 2 Remove the heart shape cam stopper spring A 3 Remove the front under cover B 1 screw 4 Remove the separation roller shaft stopper C 1 screw and the separation roller shaft D 5 Remove the bracket E 2 screws and the feed unit under cover F 1 screw D F B A E C A171R664 img ARDF 31 July 1995 5 108 ...

Page 338: ...ar side of the 2nd pick up roller shaft and replace the 2nd pick up rollers N 9 Remove the E ring O and replace the 1st pick up rollers P NOTE Reassemble the machine so that the 1st and 2nd pick up rollers flat surfaces are parallel Make sure that the one turn disk K and the pressure release cam Q installation directions are as shown in the illustration J K L I M H G Q N P O A171R649 img 31 July 1...

Page 339: ...ver C 2 Remove the transport unit cover D 7 screws 3 Mark the position of the tension bracket E and loosen the screw F 4 Remove the timing belt G 5 Remove the 4 screws H fixing the transport belt unit hinge 6 Release the transport belt unit I and remove it G E I H F A171R645 img D C A B A171R665 img ARDF 31 July 1995 5 110 ...

Page 340: ...ound line Disconnect the connector D 4 Remove the operation unit E 5 Remove the operation unit shaft cover F 3 screws feed unit front cover G 2 screws rear cover H 3 screws and left cover I 3 screws 6 Mark the position of the tension bracket J and loosen the 3 screws K Then remove the timing belt L B E A D C A171R643 img G I F L J K H A171R652 img 31 July 1995 ARDF 5 111 ...

Page 341: ...shing O 8 Remove the E ring P relay roller drive gear Q the pin R and E ring S 9 Remove the E ring T in the front of the relay roller shaft 10 Slide the relay roller U to the rear of the machine and remove it T U S R Q P O M N A171R666 img ARDF 31 July 1995 5 112 ...

Page 342: ...ion tab E NOTE Install the friction tab E so that its edge contacts the upstand of the separation tab supporter F 4 Make sure of the original sensor feeler G position when installing the friction tab holder 5 After replacement pass approximately 20 A3 papers over the surface of the friction tab C G A171R668 img C A B A D F E A171R667 img 31 July 1995 ARDF 5 113 ...

Page 343: ... B 3 Mark the position of the inverter drive belt tension bracket C and loosen the screw D 4 Disconnect the 2 connectors E of the belt motor F and the 2 connectors G of the inverter motor H 5 Remove the motor bracket I 4 screws 6 Mark the position of each motor positioning plate J and loosen the each 3 screws K 7 Replace the belt inverter motor 3 screws L each B A L K E I L G C D K F J H A171R669 ...

Page 344: ...it 3 screws 2 Remove the screw B fixing the ground line and disconnect the 6 connectors C 3 Remove the upper rear cover D of the copier 3 screws 4 Remove the 8 screws E fixing the transport unit hinge and remove the transport unit A C B D E A171R670 img 31 July 1995 ARDF 5 115 ...

Page 345: ...screws and the lower front cover B 1 screw 2 Remove the job separation H P sensor C 1 screw 3 Remove the DF main board D 3 screws 4 Remove the 2 screws E disconnect the 2 connectors F and remove the job separation unit G E C A B G D F A171R671 img ARDF 31 July 1995 5 116 ...

Page 346: ...e belt tension bracket D and loosen the screw E 5 Remove the 2 E rings F inverter drive pulley G pin H and bushing I 6 Mark the position of the exit roller drive belt tension bracket J and loosen the screw K supporting it 7 Remove the 2 E rings L exit roller drive pulley M pin N and bushing O 8 Open the upper and lower inverter gates P manually and replace the inverter roller Q L M N O A D B A I F...

Page 347: ... the gear support plate G 3 screws 6 Remove the 2 E rings H exit roller drive pulley I pin J and bushing K 7 Remove the E ring L and bushing M 8 Remove the front and rear lower screws N fixing the exit stay O 9 Rotate the exit stay clockwise and replace the exit rollers P NOTE When reassembling the machine install the one way gears so that the white gear Q is in the lower left and the black gear R...

Page 348: ...ws 2 Remove the sensor bracket B 1 screw 3 Replace the original sensor C and the entrance cover sensor D 1 screw each Timing Sensor 1 Remove the original feed unit 2 Remove the sensor bracket E 1 screw 3 Replace the timing sensor F 1 screw C D B A A171R674 img E F A171R651 img 31 July 1995 ARDF 5 119 ...

Page 349: ...sensor cover B 1 screw 3 Replace the inverter registration sensor C 1 screw Inverter Entrance Sensor 1 Remove the transport unit cover 2 Remove the sensor cover D 1 screw 3 Replace the inverter entrance sensor E 1 screw D E A171R677 img C A B A171R675 img ARDF 31 July 1995 5 120 ...

Page 350: ...it Sensor 1 Remove the transport unit cover 2 Remove the harness guide cover A 1 screw 3 Remove the sensor bracket B 1 screw 4 Replace the exit sensor C 1 screw A C B A171R650 img 31 July 1995 ARDF 5 121 ...

Page 351: ...he entrance upper cover B 2 screws 2 Loosen the screw C and slide the stopper D to the front of the machine 3 Then gradually slide the stopper D to the rear of the machine until it slightly touches the separation tab bracket E 4 Retighten the screw C B A A171R679 img D E C E D A171R648 img ARDF 31 July 1995 5 122 ...

Page 352: ...DF NOTE Both original and copy paper in tray must be the same size 7 Press the Start key When the original stops open the transport unit gently and check the original position 8 If the front side of the original is advanced remove the front cover of the original feed unit 2 screws and loosen the screw C If the rear side of the original is advanced tighten the screw C NOTE 1 Factory setting of the ...

Page 353: ...eck the original position 4 Adjust the front side copy registration so that the distance between the right scale and the original is o to 2 mm by pressing or on the display Pressing shifts the original stop position to the left Pressing shifts the original stop position to the right 0 05 step 5 Repeat steps 2 to 5 until the original stops at the correct position NOTE In SP mode Thin Paper mode is ...

Page 354: ...t scale even though Thin Paper mode is selected This is because it is very rare that a 2 sided thin paper is used 12 19 CFF REGISTRATION ADJUSTMENT 1 Access page 8 of SP adjustment as per step 1 to 5 of the SKEW CORRECTION procedure 2 Set a computer form so that the CFF sensor detects the trailing edge of the computer form and close the transport unit gently 3 Press the Start key When the computer...

Page 355: ...r of the paper feed unit and adjust the belt B tension with the motor position bracket 2 screws b Standard 2 mm deflection at 200 80 g pressure 3 Remove the upper cover of the transport unit and adjust the belt C tension with the tightener c Standard 3 mm deflection at 400 100 g pressure C D E A171R646 img b B A171R653 img C c A171R654 img A a A171R655 img A B A171R644 img ARDF 31 July 1995 5 126 ...

Page 356: ...ure 5 Remove the upper cover of the transport unit and adjust the belt E tension with the tightener e Standard 2 mm deflection at 300 120 g pressure 6 Remove the upper cover of the transport unit and adjust the belt F tension with the tightener f Standard 3 mm deflection at 340 120 g pressure d D D A171R657 img e E A171R658 img F f A171R656 img 31 July 1995 ARDF 5 127 ...

Page 357: ...he side to side registration for the 1st 2nd 3rd trays and duplex tray by the SP mode NOTE Do not adjust the 1st 2nd or 3rd trays stopper A and duplex tray stopper B The side to side registration for the 3rd tray and duplex unit have been already adjusted at the factory A A171R640 img B A171R529 img OTHERS 31 July 1995 5 128 ...

Page 358: ...13 1 2 LCT a Copy the test chart for the LCT in the platen mode b Adjust the side to side registration by moving the tray stopper A A A171R539 img 31 July 1995 OTHERS 5 129 ...

Page 359: ... SW 1 on the copier main PCB 3 Turn on the copier RAM data have been reset 4 Turn off DIP SW 1 5 Enter factory setting values in the SP mode NOTE Remove the left upper cover There is SP data sheets inside the left upper cover which gives the factory settings 6 Perform the T S corona and PTC current adjustments 7 Set all the User Tool settings according to customer requirements 8 Check the copy qua...

Page 360: ... SP Adjustment Paper Feed Timing Adjustment 2 Make a line A 20 mm B from the leading edge on the original C as shown and make 3 copies of the original from the paper feed stations 1st 2nd 3rd duplex by pass or LCT that need to be checked 3 Measure the distance D of line E from the leading edge of the 3 copies Average them 4 If the average of D B is not within the adjustment standard change the set...

Page 361: ... F 2 screws NOTE This cover has been removed when the LCT is installed 6 Remove the by pass feed lower cover G and upper by pass feed cover H 2 screws each 7 Slide off the pick up feed and separation rollers I J and K NOTE Do not touch the surface of the rollers with oily hands The paper feed rollers used in the 1st 3rd feed stations are different from the feed rollers in the LCT and the by pass f...

Page 362: ...SECTION 6 TROUBLESHOOTING ...

Page 363: ...tion cannot be reset by turning the main switch off and on or by pressing the error reset switch The following actions must be done to reset the service call condition while the main switch is on 1 Open the right door 2 Remove the right inner cover B 3 Turn the DIP SW 1 C on the reset switch PCB on and off NOTE The above action can reset one SC condition so that if more than one SC condition exist...

Page 364: ...s cable for the exposure lamp intensity sensor Flat cable Exposure lamp FL Stabilizer Power input for the FL stabilizer 38 V CN641 1 and 2 5 V CN641 3 and 4 Exposure lamp heater Exposure lamp heater thermistor DC drive PCB Main PCB Photodiode SC101 Exposure Lamp Malfunction Abnormal On Definition During the lamp off condition the main PCB detects a lamp intensity sensor signal 1 0 V for more than ...

Page 365: ... power input 38 V CN641 1 and 2 5 V CN641 3 and 4 DC drive PCB Main PCB Photodiode SC105 FL Thermistor Open Definition The main PCB detects an extremely high resistance 14k 10 C of the FL thermistor for more than 3 seconds during stand by mode NOTE 1 No detection in copy mode because of the FL heater off 2 24 V VP and 38 V VFL will be cut by the relays on the dc drive PCB in this SC condition Poin...

Page 366: ...CN102 B20 SC108 VL Correction Error Definition Target VL value cannot be achieved within the exposure lamp output control range during the process control data initialization NOTE After resetting the system error condition VL correction will be tried again Even if the second execution fails no service call condition is displayed and the copier uses previous reference data until its next initializa...

Page 367: ...d detected by the motor control PCB through the encoder differs from a specified speed by more than 25 Points to check Mechanical interference with the scanner drive Scanner drive motor and encoder DC motor drive PCB Motor control PCB SC128 Scanner Drive Motor Encoder Failure Definition The motor control PCB detects no encoder pulse from the scanner drive motor at scanner initialization and scanne...

Page 368: ...h the motor control PCB through the serial interface lines Points to check Interface lines CN111 on the main PCB External noise Motor control PCB SC142 Lens Vertical Drive Failure Definition The motor control PCB cannot detect the lens vertical home position sensor signal or vertical drive encoder signal Points to check Mechanical interference with the lens vertical drive Lens vertical drive motor...

Page 369: ...ive encoder Motor control PCB DC motor drive PCB Fuse F6 SC146 Lens Horizontal Drive Failure Definition The motor control PCB cannot detect the lens horizontal home position sensor signal or horizontal drive encoder signal Points to check Mechanical interference with the lens horizontal drive Lens horizontal drive motor Lens horizontal home position sensor Lens horizontal drive encoder sensor Moto...

Page 370: ...cs cable ADS pattern Exposure lamp Main PCB Photodiode SC301 Charge Corona Current Adjustment Error Definition During process control data initialization the main PCB cannot adjust the charge corona current to its target value NOTE After resetting the system error condition the adjustment will be tried again Even if the second execution fails no service call condition is displayed and the copier u...

Page 371: ...ed NOTE The cleaner moves back to its home position when the error condition is reset Points to check Mechanical interference with the charge corona wire cleaner Wire cleaner motor Main PCB motor drive circuit SC306 Drum Potential Sensor Calibration Error Definition During process control data initialization the drum potential sensor output is out of the adjustment range NOTE After the system erro...

Page 372: ... initialization Points to check Drum Vd pattern Charge corona Charge corona power pack Drum potential sensor FU3 on the power supply unit dc 24 V VP SC352 Vsp Abnormal Definition The main PCB detects a high Vsp value 1 4 V five times in a row NOTE Toner supply shifts to 7 fixed toner supply mode If the Vsp returns to normal level standard detect supply resumes No service call condition is displaye...

Page 373: ...oltage 4 0 0 2 V NOTE After resetting the system error condition the toner supply shifts to 7 fixed supply mode until the next adjustment Points to check ID sensor Drum Main PCB ID sensor control circuit SC390 Development Motor Overload Definition The motor control PCB cannot maintain the motor speed within the specification for more than 1 5 seconds The motor control PCB detects a large current v...

Page 374: ... overload sensor Interface PCB SC400 Transfer Corona Current Adjustment Error Definition When process control data initialization is selected in the SP mode the main PCB cannot adjust the transfer corona current to its target value NOTE After resetting the system error condition the adjustment will be tried again Even if the second execution fails no service call condition is displayed and the cop...

Page 375: ...he PTC current to its target value NOTE After resetting the system error condition the adjustment will be tried again Even if the second execution fails no service call condition is displayed and the copier uses previous reference data until its next initialization Points to check PTC unit PTC power pack Drum Drum current detection PCB SC403 PTC Leakage Definition The PTC power pack detects the PT...

Page 376: ...st the separation corona current to its target value NOTE After resetting the system error condition the adjustment will be tried again Even if the second execution fails no service call condition is displayed and the copier uses previous reference data until its next initialization Points to check Separation Corona unit Separation Corona power pack Drum Drum current detection PCB SC411 Separation...

Page 377: ...e F2 SC442 Drum Thermistor Open Definition The Main PCB detects an extremely low temperature 10 C by the drum thermistor for more than 3 seconds NOTE The main relays will be opened in this condition Points to check Drum thermistor Main PCB CN104 A4 SC443 High Drum Temperature Definition The main PCB detects an extremely high temperature 60 C by the drum thermistor for more than 3 seconds NOTE 1 Th...

Page 378: ...r Drum heater relays Drum heater thermoswitches Drum Thermistor Main PCB CN104 A4 SC490 Vacuum Fan Motor Overload Definition The main PCB detects a lock signal from the vacuum fan for more than 3 seconds Points to check Vacuum fan Interface PCB SC491 Optics Cooling Fan Motor Overload Definition The main PCB detects a lock signal from the optics cooling fan for more than 3 seconds Points to check O...

Page 379: ...main PCB cannot detect the lower limit sensor signal within 4 5 seconds after the tray down operation has been started Points to check Lower limit sensor Tray drive motor Tray drive wires Interface PCB SC508 2nd Tray Drive Abnormal Definition The main PCB cannot detect any pulses from the 2nd tray paper volume sensor within 3 seconds after the tray up or down operation has been started Points to c...

Page 380: ...er volume sensor within 3 seconds after the tray up or down operation has been started Points to check Mechanical interference with the tray drive Paper volume sensor Tray drive motor Interface PCB FU2 on the power supply unit dc 24 V Main PCB SC513 3rd Tray Lower Limit Sensor Failure Definition The main PCB cannot detect the lower limit sensor signal within 10 seconds after the tray down operatio...

Page 381: ...nce home position sensor signal within 5 seconds after the duplex mode is selected Points to check End fence home position sensor Mechanical interference with the end fence drive End fence drive motor Interface PCB SC541 Fusing Thermistor Open Definition The main PCB detects an extremely low temperature 10 C by the fusing thermistor for more than 3 seconds NOTE The Service Call message will be dis...

Page 382: ...g overheat Definition The main PCB detects an extremely low resistance 500Ω 220 C of the fusing thermistor for more than 3 seconds NOTE The service call message will be displayed at the first detection The main relays will be opened in this condition Points to check Fusing lamp control SSR Fusing thermistor Fusing lamp Interface PCB SC547 Fusing Thermofuse Open Definition Main PCB detects the fusi...

Page 383: ... cannot detect any pulses from the belt drive motor encoder when the motor starts turning Or the motor continues turning after the DF main PCB signals the motor to turn off Points to check Mechanical interference with the transport belt drive Transport belt drive motor and encoder Fuse F1 and F3 on the DF main PCB DF main PCB SC702 DF Inverter Motor Overload Definition The DF main PCB cannot detec...

Page 384: ...any pulses from the main motor encoder within 0 1 second when the main motor is activated Points to check Mechanical interference with the main motor Main motor Sorter main PCB SC722 Sorter Jogger Home Position Sensor Failure Definition The sorter main PCB cannot detect the home position signals from the following sensors when they are actuated Jogger home position sensor Jogger unit home position...

Page 385: ...itioning motor Grip motor Sorter main PCB SC725 Sorter Hammer Home Position Sensor Failure Definition The sorter main PCB cannot detect the home position signal from the hammer home position sensor when it is actuated Points to check Hammer home position sensor Mechanical interference with the hammer Staple motor Sorter main PCB FU100 on the sorter main PCB Staple motor power SC741 2ND Sorter Main...

Page 386: ...to check Connectors between the 1st and 2nd sorters 2nd sorter interface PCB 2nd sorter power line Sorter main PCBs FUSE1 on the sorter power supply PCB SC790 LCT Drive Abnomal Definition The main PCB cannot defect any pulses from LCT paper volume sensor within 3 seconds after the tray up or down operation has been started Points to check Mechanical interference with the tray drive Paper volume se...

Page 387: ...to check Lower limit sensor Tray drive motor Tray drive wires Interface PCB SC900 Copy Counter Failure Definition The main PCB cannot detect any count confirmation signal from the total counter or the A3 11 x 17 counter enabled by SP mode when the counter is de energized Points to check Total counter A3 11 x 17 counter 31 July 1995 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 25 ...

Page 388: ...urrent Voltage Protect Symptom F1 0 3A 12V Size Detection Sensor SC701 F2 3 15A 38V Feed in Motor SC700 F3 3 15A 38V Belt Motor SC701 F4 3 15A 38V Inverter Motor SC702 Motor DC Drive PCB Fuse No Rated Current Voltage Protect Symptom F1 10A 38V Scanner Drive Motor SC129 F2 10A 38V Main Motor SC440 F3 8A 38V Development Motor SC390 F4 3 15A 38V Lens Vertical Drive Motor SC142 F5 3 15A 38V Lens Horiz...

Page 389: ...N102 B8 CN656 1 2 CN103 B5 CN104 A2 B9 CN653 6 F 4 CN102 A28 CN104 B15 B16 B17 A16 A17 CN680 4 5 6 7 13 14 15 16 CN102 B7 A8 A25 CN342 1 2 3 4 5 6 7 8 CN328 2 3 4 5 CN103 B24 A24 CN104 A1 B1 CN641 1 2 3 4 CN642 3 2 6 5 CN641 5 CN645 7 1 2 3 4 8 CN651 C 1 A 3 CN565 1 3 4 5 6 2 7 CN760 5 6 CN761 2 4 1 3 CN304 6 CN302 7 CN302 1 2 5 6 CN302 3 CN302 4 CN653 D CN680 1 T345 CN342 6 CN346 1 T345 CN341 4 C...

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