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Ricoh FW870 User Manual

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IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the copier power cord is unplugged.
2. The wall outlet should be near the copier and easily accessible.
3. Note that some components of the copier and the paper tray unit are
supplied with electrical voltage even if the main switch is turned off.
4. 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.
5. 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.
6.The copier is not attached to the table. Pushing the copier too heard may
cause it to drop onto the floor. While moving the copier, push the table.
7. When the main switch is tuned on, the machine will suddenly start turning
to perform the developer initialization. Keep hans away from any
mechanical and electrical components during this period.
HEALTH SAFETY CONDITIONS
1. Never operate the copier without the ozone filters installed.
2. Always replace the ozone filters with the specified ones at the specified
intervals.
3. Toner and developer are non-toxic, but if you get either of them in your
eyes by accident, it may cause temporary eye discomfort. Try to remove
with eye drops or flush with water as first aid. If unsuccessful, get medical
attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course
on those models.
CAUTION
2. The RAM board on the main control board has a lithium battery
which can explode if replaced incorrectly. Replace the RAM board
only with an identical one. The manufacturer recommends
replacing the entire RAM board. Do not recharge or burn this
battery. Used RAM board must be handled in accordance with
local regulations.

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  • Page 1 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main switch is turned off.

  • Page 2: Safety And Ecological Notes For Disposal

    SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate the toner cartridge or the used toner. Toner dust may ignite suddenly when exposed to open flame. 2. Dispose of used toner, developer, and organic photoconductor according to local regulations. (These are non-toxic supplies.) 3.

  • Page 3: Overall Machine Information

    SECTION 1 OVERALL MACHINE INFORMATION...

  • Page 4: Specifications

    25 July 1996 SPECIFICATIONS 1. SPECIFICATIONS Configuration: Console Copy Process: Electrostatic transfer system Original Feed: Sheet feed Original Size: Maximum: 914 x 3,600 (36" x 142")mm Minimum: 182 x 257 (B5), 8 " x 11" lengthwise Copy Size: Same as "Original Size" Copying Speed: 7.5 cpm (A1/D sideways) First Copy:...
  • Page 5 SPECIFICATIONS 25 July 1996 Paper Feeding: Manual feed and 2 roll feeds (3rd roll feeder optional) Image Fusing: Heat and pressure type, teflon (upper) and silicone rubber (lower) rollers Fusing Lamp: Halogen lamp (115 V: 1,100 W, 230 V: 1,100 W) Self-diagnostic Codes: 18 codes, displayed in copy counter Power Source:...

  • Page 6: Paper Path

    25 July 1996 PAPER PATH 2. PAPER PATH  ‘ “  ’ ” A174V502.wmf A: Original Path D: Original Path from Rear Feeder Switching back E: Upper Copy Exit B: Paper from the manual feed F: Lower Copy Exit C: Paper from the roller feed...

  • Page 7: Drum Processes

    DRUM PROCESSES 25 July 1996 3. DRUM PROCESSES A174V503.img 1. Charge In the dark the charge corona unit applies a negative charge to the drum. The grid plate ensures the charge is applied uniformly. The charge remains on the surface of the drum because the photoconductive drum has a high electrical resistance in the dark.
  • Page 8 25 July 1996 DRUM PROCESSES 3. Development The magnetic developer brush on the development roller comes in contact with the latent image on the drum surface. Toner particles are electrostatically attracted to the negatively charged latent image areas. 4. Pre-Transfer Lamp The pre-transfer lamp (PTL) illuminates the drum prior to image transfer.

  • Page 9: Mechanical Component Layout

    MECHANICAL COMPONENT LAYOUT 25 July 1996 4. MECHANICAL COMPONENT LAYOUT A174V500.wmf...
  • Page 10 25 July 1996 MECHANICAL COMPONENT LAYOUT 1. Original Registration Roller 14. Paper Registration Rollers 2. Original Feed Roller 15. Manual Feed Table 3. Copy Tray 16. Development Unit 4. Exit Rollers 17. Toner Cartridge 5. Fusing Exit Rollers 18. Charge Corona Unit 6.

  • Page 11: Drive Layout

    DRIVE LAYOUT 25 July 1996 5. DRIVE LAYOUT A174V501.wmf 1. Original Feed Motor 7. Drum Drive Relay Gear 2. Drum 8. Transport Unit Drive Belt 3. Development Unit 9. Fusing Drive Motor 4. Development Relay Gear 10. Fusing Unit 5. Development Motor 11.

  • Page 12: Electrical Component Descriptions

    25 July 1996 ELECTRICAL COMPONENT DESCRIPTIONS 6. ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout on the reverse side of the Point to Point (Water proof paper) index numbers. Name Function Index No. Motor Main Motor Drives the drum and the registration roller. (dc motor) Development Motor Drives the development unit components.
  • Page 13 ELECTRICAL COMPONENT DESCRIPTIONS 25 July 1996 Name Function Index No. Exit Cover Safety Cuts ac power when the exit cover is open. Switch Anti-humidify Supplies power to the anti-humidify heater. Heater Switch Roll Feed Unit Cuts dc power when the roll feed unit is open. Safety Switch Anti-humidify Cuts power to the anti-humidify heater when the roll...
  • Page 14 25 July 1996 ELECTRICAL COMPONENT DESCRIPTIONS Name Function Index No. Printed Circuit Boards Controls all copier functions both directly and through Main Board other PCBs. AC Drive Board Provides ac power to the lamps, heaters, and PSU. Converts the ac voltage to dc voltage. Informs the CPU of the selected modes, and displays Operation Panel the situation on the panel.

  • Page 15: Detailed Section Descriptions

    SECTION 2 DETAILED SECTION DESCRIPTIONS...
  • Page 16 25 July 1996 DRUM 1. DRUM 1.1 DRUM CHARACTERISTICS The organic photoconductor (OPC) drum has the following characteristics: • It is able to accept a high negative electrical charge in the dark. (The electrical resistance of the OPC drum is high in the absence of light.) •...

  • Page 17: Drum Drive

    DRUM 25 July 1996 1.2 DRUM DRIVE A174D517.wmf The OPC drum [A] is 80 millimeters in diameter and 970 millimeters long. It turns constantly when the main motor [B] is on. When the main motor turns on, the drive is transmitted to the drum in the following way: ⇒...
  • Page 18 25 July 1996 CHARGE 2. CHARGE 2.1 OVERVIEW A174D501.wmf A174D502.wmf This model uses a single wire corona unit [A] to charge the OPC (organic photoconductor) drum [B]. The corona unit generates a corona of negative ions when a high negative voltage is applied to it by the charge/grid power pack.

  • Page 19: Charge Corona Circuit

    CHARGE 25 July 1996 2.2 CHARGE CORONA CIRCUIT A174D503.wmf The main board supplies +24 volts (V ) to the charge/bias/grid power pack as the power supply source. Approximately 12 seconds after the copy process starts, the CPU drops CN102-B7 from 5 volts to 0 volts. This actuates the dc/dc converter within the power pack which applies a high negative voltage of approximately –5.0 kV to the charge corona wire.
  • Page 20 25 July 1996 CHARGE 2.3 CHARGE WIRE CLEANING MECHANISM A174D501-2.wmf The wire cleaner pads [A] automatically clean the wires every 297 m (500 copies/A1). The wire cleaner is driven by a dc motor [B]. Normally the wire cleaner is located at the front end position (home position). After 297 m (500 copies/A1) or more copies are made and fusing temperature is less than 100°C after the main switch is turned on, the wire cleaner motor turns on to bring the wire cleaner to the rear end and then back to the home position.

  • Page 21: Corona Unit Ventilation

    CHARGE 25 July 1996 2.4 CORONA UNIT VENTILATION A174D504.wmf If ozone produced by the corona charge stays in the charge corona area, it may cause uneven corona charging to the drum. To prevent this, ozone is vacuumed out through the exhaust fan [A], and changed to oxygen by the ozone filter before being blown out of the copier.
  • Page 22 25 July 1996 EXPOSURE 3. EXPOSURE 3.1 OVERVIEW [G] [F] A174D505.wmf Light from the exposure lamp [A] reflects off the original and through the fiber optics [B] to the OPC drum [C]. During exposure, the original moves across the exposure glass at the same speed as the drum’s peripheral velocity. The platen roller [D] presses the original [E] flat against the exposure glass [F] just above the fiber optic array.
  • Page 23 EXPOSURE 25 July 1996 3.2 PAPER AND ORIGINAL FEED 3.2.1 Normal Original Feed P: Original Exit Sensor Q: Original Switch Back Sensor A174D506.wmf When an original is placed on the original table, it activates the original set sensor [A]. The main motor and development motor start rotating and the exposure lamp turns on.
  • Page 24 25 July 1996 EXPOSURE When the original lead edge sensor [D]detects the leading edge of the original, the roll feed motor and the roll feed clutch turn on, and paper feed starts. The original is fed to the original registration sensor [E] and stops at 33 mm [F] ahead of the original registration sensor to wait for the copy paper.
  • Page 25 EXPOSURE 25 July 1996 3.2.2 CHANGING MODE TO LONG NARROW ORIGINALS A174D536.wmf A174D535.wmf A174D537.wmf If the original width is less than 515 mm (18’’) and it is longer than the standard paper size (A0/E size), the original may be skewed by the middle four of the 8 original feed rollers.
  • Page 26 25 July 1996 EXPOSURE 3.3 ROLL FEED A174D507.wmf This machine has two standard roll feed units (1st [A] and 2nd [B]), one manual feed unit, and one optional roll feed unit (3rd [C]). The cutter unit [D] uses a sliding rotary cutting blade. When turning on the main switch or when roll paper is replenished, the roll feed motor rotates and the leading edge of the roll paper is fed until the roll lead edge sensor [E] is activated.
  • Page 27 EXPOSURE 25 July 1996 3.3.1 Roll End Detection A174D508.wmf The roll paper end sensor [A] is located above each roll. When the roll paper runs out and the roll paper end sensor detects the black core of the roll, roll end is indicated on the operation panel.
  • Page 28 25 July 1996 EXPOSURE 3.3.3 Drive Mechanism A174D510.wmf The original feed roller [A] is driven through the original feed drive pulley [B] and belt [C] by the original feed motor [D]. The platen roller [E] is rotated by the original feed motor [D] through the gears [F] and belt [G].
  • Page 29 EXPOSURE 25 July 1996 3.4 FL REGULATOR CONTROL A174D511.wmf The FL regulator [A] receives 24 volts dc at CN401-1 from the main board [B]. The control signal, which is a pulse width modulated (PWM) signal, is received at CN401-3. The PWM signal has a period (T) of 1 millisecond and a duty ratio of 15% to 100%.
  • Page 30 25 July 1996 EXPOSURE 3.5 MANUAL ID CONTROL VS ADS Light Sensor Light Sensor Manual ID Level Manual ID Level Output [V] Output [V] 1.275 1.882 1.275 1.922 1.275 2.020 1.294 2.118 1.294 2.216 1.314 2.314 1.333 2.412 1.373 2.529 1.412 2.627 1.510...
  • Page 31 EXPOSURE 25 July 1996 3.5.2 ADS Control VS [V] VS [V] 0~0.45 3.118 0.64~0.65 2.020 0.46~0.47 2.922 0.66~0.67 1.922 0.48~0.49 2.824 0.68~0.69 1.882 0.50~0.51 2.725 0.70~0.71 1.843 0.52~ 0.53 2.627 0.72~0.73 1.745 0.54~0.55 2.529 0.74~0.75 1.627 0.56~0.57 2.412 0.76~0.80 1.510 0.58~0.59 2.314 0.81~0.84...
  • Page 32 25 July 1996 EXPOSURE 3.6 AUTO DENSITY SENSOR (ADS) A174D520.wmf The ADS measures the reflectivity of the original’s background. Based on the originals background image density, the CPU automatically adjusts the development bias and exposure light intensity to achieve a good copy image. The ADS is located at the original registration rollers.
  • Page 33 DEVELOPMENT 25 July 1996 4. DEVELOPMENT 4.1 OVERVIEW [C] [B] A174D512.wmf When the development motor turns on, the paddle roller [A] and development roller [B] start turning. The paddle roller picks up developer in its paddles and transports it to the development roller. Internal magnets in the development roller attract the developer to the development roller sleeve.

  • Page 34: Drive Mechanism

    25 July 1996 DEVELOPMENT 4.2 DRIVE MECHANISM A174D513.wmf When the development motor [A] is on, the paddle roller [B], development roller [C], and mixing auger [D] in the development unit are driven through the development drive belt [E] and gears [F]. The toner agitator shaft [G] is rotated through the gears [H] by the toner supply clutch [I] engaged in the toner supply condition.

  • Page 35: Cross-Mixing

    DEVELOPMENT 25 July 1996 4.3 CROSS-MIXING "Cross-mixing" keeps the developer’s toner and carrier evenly mixed and evenly distributes the developer within the development unit. Cross-mixing also agitates the developer to generate the necessary triboelectric charge on the toner and carrier particles. The arrows in the above illustration show the developer movement directions within the machine.

  • Page 36: Toner Density Control

    25 July 1996 DEVELOPMENT 4.4 TONER DENSITY CONTROL The toner supply amount ratio is determined by the following conditions. 51 ~ 100 101 ~ 150 151 ~ 200 201 ~ 250 Level 0 ~ 50 sheets 251 sheets ~ sheets sheets sheets sheets...
  • Page 37 DEVELOPMENT 25 July 1996 During the initial conditioning, the main motor rotates the development unit to stabilize the triboelectric charge generated on the toner and carrier and the toner density sensor is automatically adjusted to 4.0±0.1V using new developer. The initial conditioning (SP40) must be performed whenever the developer is replaced.
  • Page 38 25 July 1996 DEVELOPMENT 4.4.3 Toner Density Sensor A174D515.img A174D516.wmf The toner density sensor circuit controls the amount of toner in the developer mixture. The toner density sensor is powered by 12 volts from CN105-B18 of the main board. (The potential of CN105-B18 is 24 V when the connector is disconnected.) The sensor’s sensitivity is set by the feedback signal applied from CN105-B16.

  • Page 39: Development Bias

    DEVELOPMENT 25 July 1996 4.5 DEVELOPMENT BIAS 4.5.1 Basic Concept When the drum is exposed, most of the negative charge is eliminated from the areas where light strikes the drum. This leaves a negative charge pattern corresponding to the dark areas of the original. After exposure, however, a small residual charge of about –100 volts (for white paper) remains in the exposed areas.
  • Page 40 25 July 1996 DEVELOPMENT 4.5.3 Auto Image Density Bias The ADS can be switched to the "Darker"setting with service program mode #18 or "Lighter" setting. In addition to the development bias, the image density is also controlled by varying the exposure light intensity. (See the exposure section.) Vod/Vsd Bias [V] Vod/Vsd...

  • Page 41: Toner Supply

    DEVELOPMENT 25 July 1996 4.6 TONER SUPPLY A174D519.img A174D518.wmf To allow a compact design, the toner supply mechanism is built into the toner cartridge. An agitator [A] in the toner cartridge turns when the toner supply clutch is engaged. As the agitator rotates, mylar strips [B] on the ends of the agitator force toner through small holes (0.5 mm in diameter) in a plastic strip [C] along one side of the toner cartridge.

  • Page 42: Image Transfer And Paper Separation

    25 July 1996 IMAGE TRANSFER AND PAPER SEPARATION 5. IMAGE TRANSFER AND PAPER SEPARATION [A] [C] [D] A174D522.wmf 5.1 PRE-TRANSFER LAMP (PTL) After the latent image is developed but before the image is transferred to the copy paper, the drum surface is illuminated by the pre-transfer lamp [A]. This illumination reduces the negative potential on the drum surface.

  • Page 43: Pick-Off Mechanism

    IMAGE TRANSFER AND PAPER SEPARATION 25 July 1996 5.4 PICK-OFF MECHANISM A174D521.wmf The pick-off pawl solenoid [A] is energized after the registration clutch turns on to feed the copy paper to the drum. The pick-off shaft [B] then rotates clockwise and the pick-off pawls [C] touch the drum surface. Just after the leading edge of the copy paper passes the pick-off pawls, the pick-off solenoid turns off again.
  • Page 44 25 July 1996 IMAGE TRANSFER AND PAPER SEPARATION 5.5 T/S CORONA CIRCUIT A174D523.wmf The T/S power pack is powered by +24 volts (Va) from the Main Board. The dc/dc converters and dc/ac inverter change the +24 volts supply into the high voltages used by the transfer and separation coronas.
  • Page 45 CLEANING 25 July 1996 6. CLEANING 6.1 OVERVIEW A174D522-2.wmf This copier uses the counter blade system for drum cleaning. The blade [A] is angled against the drum rotation. This counter blade system has the advantage of high cleaning efficiency. The cleaning blade removes any toner remaining on the drum after the image is transferred to the copy paper.
  • Page 46 25 July 1996 CLEANING 6.2 COLLECTION OF USED TONER A174D524.wmf The toner collection coil [A], which is rotated by the main motor [B] through the gears [C], moves used toner from the cleaning unit to the toner collection bottle [D]. The toner collection bottle capacity is enough to hold used toner from making 6 km (10K/A1, capacity: 4000 ml) copies.
  • Page 47 QUENCHING 25 July 1996 7. QUENCHING A174D525.img A174D526.wmf After the drum [A] is cleaned by the cleaning blade, light from the quenching lamp [B] neutralizes any charge remaining on the drum. The quenching lamp turns on and off at the same time as the main motor. The main board turns on the quenching lamp LEDs by dropping CN104-B24 to 0 volt.

  • Page 48: Fusing And Paper Exit

    25 July 1996 FUSING AND PAPER EXIT 8. FUSING AND PAPER EXIT 8.1 OVERVIEW A174D527.wmf [D] [F] After separation from the drum, copy paper rides on the transport belt [A]. Air flow directly from the vacuum fan [B] against the belts so that there is enough friction between the paper and belt for the smooth transportation.
  • Page 49 FUSING AND PAPER EXIT 25 July 1996 8.2 DRIVE MECHANISM 8.2.1 Fusing Unit Drive A174D528.wmf The hot roller [A] is turned by the hot roller drive gear [B] as shown. The pressure roller [C] is friction driven by the hot roller. The fusing rollers turn constantly when the fusing drive motor [D] is on, driven via the gear [E], through the fusing drive chain [F], sprocket [G], and gear [H], to the hot roller drive gear.

  • Page 50: Fusing Temperature Control

    25 July 1996 FUSING AND PAPER EXIT 8.3 FUSING TEMPERATURE CONTROL A174D529.wmf 8.3.1 Fusing Circuit Operation The fusing lamp is powered by the ac drive board and controlled by the main board. The ac drive board receives direct wall voltage ac power (not stepped down) at T201 and T202.
  • Page 51 FUSING AND PAPER EXIT 25 July 1996 RA201 guards against a failure of the +24 volt power supply. When +24 volts is applied at CN201-2 and CN102-A15 drops to LOW, RA201 is energized and its ac contacts stay open. If the +24 volts power from CN102-A20 stops, the ac contacts of RA201 close, stopping the drive circuit and turning off the fusing lamp.

  • Page 52: Temperature Control

    25 July 1996 FUSING AND PAPER EXIT 8.4 TEMPERATURE CONTROL 8.4.1 Normal A174D534.wmf 2-37...
  • Page 53 FUSING AND PAPER EXIT 25 July 1996 8.4.2 High Pressure Roller Copy Disable Condition Temperature Paper Mode Width 150155160165170175 180 Pressure Roller Roller (mm) Temperatu Temperature 185~ 105°C or lower 180~185 110°C or lower wider 115~130°C 175~180 120°C or lower pass Copy unconditionally ~175...
  • Page 54 25 July 1996 FUSING AND PAPER EXIT The main board monitors the temperature of the hot roller through TH1 and the temperature of the pressure roller through TH2. The CPU determines whether or not to turn on the fusing lamp based on the combination of the input from these two thermistors.
  • Page 55 FUSING AND PAPER EXIT 25 July 1996 A174D533.wmf – Key operation to change the temperature setting– First, hold the fusing temperature key [A] down for longer than 3 seconds, a) The roll feed station (1st, 2nd, or 3rd) indicator [B], which is selected, blinks.
  • Page 56 25 July 1996 FUSING AND PAPER EXIT – High temperature mode – The fusing rollers rotate in copy stand-by condition to keep the pressure roller temperature as shown in the diagram. During copy job, the machine keep the relationship between the hot and pressure roller as shown in the diagram. During copy job, the hot roller and pressure roller temperatures may come into the copy disable conditions.

  • Page 57: Energy Saver Function

    FUSING AND PAPER EXIT 25 July 1996 8.5 ENERGY SAVER FUNCTION When the copier is not in use, the energy saver function reduces the power consumption by decreasing the fusing temperature. When the Clear Modes/Stand-by key is hold down for over 2 seconds, the copier goes into the energy saver mode.
  • Page 58 25 July 1996 FUSING AND PAPER EXIT 8.6 FUSING ENTRANCE GUIDE HEIGHT A174D531.wmf Paper creasing may occur depending on the type of paper used. The fusing entrance guide [A] height is changed by adjusting a lever (there are three settings). 2-43...
  • Page 59 FUSING AND PAPER EXIT 25 July 1996 8.7 TRANSPORT UNIT VENTILATION A174D532.wmf To hold the copy paper firmly against the transport belts, two vacuum fans [A] underneath the transport belt unit suck air. As the vacuumed air includes ozone, the air is changed to oxygen by the ozone filter [B] before blown out of the copier.
  • Page 60 25 July 1996 ENERGY STAR COMPLIANT MACHINES (North American version only) 9. ENERGY STAR COMPLIANT MACHINES (North American version only) In conjunction with the modification for the Energy Star compliance, field technicians are requensted to understand the changes in operation modes so as to configure the machine for the customer specific environment/requirements.

  • Page 61: Installation

    SECTION 3 INSTALLATION...
  • Page 62 25 July 1996 ENVIRONMENT 1. ENVIRONMENT 1. Temperature Range: C to 30 C (59 F to 86 2. Humidity Range: 20% to 80% RH 3. Ambient Illumination: Less than 1,500 Lux (do not expose to direct sunlight). 4. Ventilation: Minimum space 20 m Room air should turn over at least 30 /hr/person.

  • Page 63: Minimum Space Requirements

    ENVIRONMENT 25 July 1996 1.1 MINIMUM SPACE REQUIREMENTS A174I528.wmf 1. Front: 1,000 mm (39 in) 2. Back: 600 mm (24 in) 3. Right: 600 mm (24 in) 4. Left: 600 mm (24 in) 1.2 MACHINE LEVEL 1. Front to back: Within 5 mm (0.2") of level 2.

  • Page 64: Power Source

    25 July 1996 ENVIRONMENT 1.3 POWER SOURCE 1. Input Voltage Level: 115 V/60 Hz More than 12 A (for U.S.A. version) 220 V/230 V/240 V/50 Hz More than 7 A (for European version) ± 2. Permissible Voltage Fluctuation: 3. Do not set anything on the power cord. NOTE: a) Make sure the plug is firmly inserted in the outlet.
  • Page 65 COPIER INSTALLATION PROCEDURE (A174) 25 July 1996 2. COPIER INSTALLATION PROCEDURE (A174) 2.1 ACCESSORY CHECK Check the accessories and their quantities against the following list: Description Q’ty 1. Paper Spool................2 2. Copy Tray ................1 3. Guide Wire................2 4.Copy Guide................
  • Page 66 25 July 1996 COPIER INSTALLATION PROCEDURE (A174) A174I500.wmf A174I501.wmf A174I502.wmf A174I503.wmf 1. Unpack the machine carton box and place the copier onto a flat floor using such a fork lift. 2. Remove the strips of filament tape [A] and cardboard [B]. 3.
  • Page 67 COPIER INSTALLATION PROCEDURE (A174) 25 July 1996 A174I504.wmf A174I505.wmf A174I506.wmf 5. Remove the left and right lower covers [A, B] (3 screws each) and the left and right upper front covers [C, D] (2 screws each). 6. Remove the shipping retainers [E] (4 screws each) from the right and left sides.
  • Page 68 25 July 1996 COPIER INSTALLATION PROCEDURE (A174) A174I507.wmf A174I508.wmf A174I509.wmf 8. Remove the strips of filament tape [A] from the 1st and 2nd roll feed unit. 9. Open the paper path section [B] and remove the two strips of shipping tape [C] and protection sheet [D].
  • Page 69 COPIER INSTALLATION PROCEDURE (A174) 25 July 1996 A174I510.wmf A174I512.wmf A174I511.wmf 11. Open the paper path section, and place a level [A] in the middle of the guide plate as shown in the illustration. Adjust the level of the machine by turning the bolts [B] on the four Machine feet.
  • Page 70 25 July 1996 COPIER INSTALLATION PROCEDURE (A174) A174I513.wmf A174I515.wmf A174I514.wmf 15. Install the right inner cover [A] (2 - M4 x 6 screws) and the total counter cover [B] (1 - M4 x 8 tapping screw). 16. Hook the original guides [C] into the cutouts [D] in the stay and install the pin screws [E].
  • Page 71 COPIER INSTALLATION PROCEDURE (A174) 25 July 1996 A174I516.wmf A174I517.wmf A174I518.wmf 17. Connect the original trays (original tray 1 [A] and 2 [B]). 18. Open the toner cartridge cover [C] and hook the tabs [D] on the original tray into the metal fittings [E]. NOTE: 1) Slightly bend the original tray as shown by the arrows in the illustration.
  • Page 72 25 July 1996 COPIER INSTALLATION PROCEDURE (A174) A174I519.wmf A174I520.wmf 22. Open the original feed unit [A], manual feed table [B], and toner supply cover [C]. Remove the sheet [D] covering the developer entrance. Pour 1 kg of developer [E] into the development unit evenly across its width as shown.
  • Page 73 COPIER INSTALLATION PROCEDURE (A174) 25 July 1996 A174I521.wmf NOTE: If the fusing temperature is lower than 60 C when the main switch is turned on, the development motor will rotate. In this case, it is not necessary to access the SP mode to load the total 2 Kg of developer (steps 25 to 28).
  • Page 74 25 July 1996 COPIER INSTALLATION PROCEDURE (A174) A174I521.wmf 28. Press the following keys on the operation panel: Clear Modes/Stand-by key [A] + key [B] – key [C] Clear/Stop key [D] 29. Press the "Clear/Stop" key again for longer than 3 seconds. The roll paper end and wrench mark indicators will blink (SP mode).
  • Page 75 COPIER INSTALLATION PROCEDURE (A174) 25 July 1996 A174I522.wmf A174I523.wmf 31. Shake a new toner cartridge [A] gently 5 to 10 times to remove the lumps. 32. Install the toner cartridge [A] as shown. Remove the sealing tape [B] from the cartridge and turn the knob [C] until it stops.

  • Page 76: Roll Feeder Installation Procedure

    25 July 1996 ROLL FEEDER INSTALLATION PROCEDURE (A613) 3. ROLL FEEDER INSTALLATION PROCEDURE (A613) 3.1 ACCESSORY CHECK CAUTION Unplug the copier power cord before starting the following procedure. Check the accessories and their quantities against the following list: Description Q’ty 1.
  • Page 77 ROLL FEEDER INSTALLATION PROCEDURE (A613) 25 July 1996 A613I500.wmf A613I501.wmf A613I502.wmf 1. Pull out the 1st & 2nd roll feed unit [A]. Remove the left inner cover [B] and 3rd drive inner cover [C] (2 screws each). 2. Remove the 3rd cover securing plates [D] (1 screw each: right and left). 3.
  • Page 78 25 July 1996 ROLL FEEDER INSTALLATION PROCEDURE (A613) A613I503.wmf A613I504.wmf A613I505.wmf 6. Connect the 3rd feeder harness to the roll end sensor connector [A] and install the roll end sensor stay [B] (1 - M4 x 6 screw, right ). 7.
  • Page 79 ROLL FEEDER INSTALLATION PROCEDURE (A613) 25 July 1996 A613I506.wmf A613I507.wmf A613I515.wmf 11. Install the interlock switch assembly [A] (2 - M4 x 6 screws and 2 connectors [B]). 12. Install the oil damper brackets [C] (2 - M4 x 6 screws) and remove the 2 shoulder screws [D].
  • Page 80 25 July 1996 ROLL FEEDER INSTALLATION PROCEDURE (A613) A613I508.wmf A613I509.wmf 16. Replace the 3rd cover cap [A] of the 3rd cover with the 3rd roll grip [B]. NOTE: The 3rd cover open lever should come out of the 3rd roll grip [B] for the next step.
  • Page 81 ROLL FEEDER INSTALLATION PROCEDURE (A613) 25 July 1996 A613I510.wmf A613I511.wmf 19. Reinstall the left inner cover [A] (2 screws). 20. Remove the upper part [B] from the 3rd drive inner cover using cutting pliers. Install the upper part on the left side plate (2 screws). The lower part is not necessary.
  • Page 82 25 July 1996 ROLL FEEDER INSTALLATION PROCEDURE (A613) A613I512.wmf A613I513.wmf 23. Set the paper spool [A] on the 3rd roll feeder. 24. Plug in the power supply cord and turn on the main switch. 25. Press the following keys on the operation panel: Clear Modes/Standby key [B] + key [C] - key [D]...
  • Page 83 ROLL FEEDER INSTALLATION PROCEDURE (A613) 25 July 1996 A613I514.wmf 30. If the door open indicator lights when the 3rd roll feed door is closed, adjust the position of the interlock switch bracket [A]. 31. Check the roll feeder operation. 3-22...

  • Page 84: Key Counter Holder Installation

    25 July 1996 KEY COUNTER HOLDER INSTALLATION 4. KEY COUNTER HOLDER INSTALLATION A174I524.wmf A174I525.wmf CAUTION Unplug the copier power cord before starting the following procedure. NOTE: The Key Counter Bracket Set includes the following parts. The key counter holder and key counter should be procured locally. 1.
  • Page 85 KEY COUNTER HOLDER INSTALLATION 25 July 1996 A174I526.wmf 3. Install the key counter bracket [A] (4 screws). 4. Pass the key counter holder harness [B] through the opening [C]in the key counter bracket and install the key counter holder (2 screws). Connect the key counter holder harness to the key counter harness [D].

  • Page 86: Service Tables

    SECTION 4 SERVICE TABLES...

  • Page 87: Preventive Maintenance Schedule

    25 July 1996 PREVENTIVE MAINTENANCE SCHEDULE 1. PREVENTIVE MAINTENANCE SCHEDULE 1.1 PM TABLE A: Adjustment C: Clean R: Replacement I: Inspect PM Interval 6 km 12 k m 18 k m 24 k m Notes ( ) A1 sideways/D (10k) (20k) (30k) (40k)
  • Page 88 PREVENTIVE MAINTENANCE SCHEDULE 25 July 1996 PM Interval 6 km 12 k m 18 k m 24 k m Notes ( ) A1 sideways/D (10k) (20k) (30k) (40k) Dry cloth Transfer Corona Wire Dry cloth Separation Corona Dry cloth Wire T &...
  • Page 89 25 July 1996 PREVENTIVE MAINTENANCE SCHEDULE PM Interval 6 km 12 k m 18 k m 24 k m Notes ( ) A1 sideways/D (10k) (20k) (30k) (40k) Fusing Entrance Clean using Guide Plate suitable solvent if necessary Fusing Exit Guide Clean using Plate suitable...

  • Page 90: Regular Pm Procedure

    PREVENTIVE MAINTENANCE SCHEDULE 25 July 1996 1.2 REGULAR PM PROCEDURE 1. Make a copy Make a copy of OS-A1 chart. 2. Original feed 1. Clean the original feed rollers using alcohol. (every 10k) 2. Clean the original table using water or alcohol.
  • Page 91 25 July 1996 PREVENTIVE MAINTENANCE SCHEDULE 5. Cleaning 1. Clean the used toner bottle. (ever 10k) 2. Inspect the cleaning seal. Replace if it is damaged. 3. Inspect inside the cleaning unit. Clean it if necessary. Cleaning Replace the cleaning blade. (every 20k) 6.
  • Page 92 PREVENTIVE MAINTENANCE SCHEDULE 25 July 1996 7. Paper Feed 1. Clean the entrance guide plate using water. (every 10k) 2. Clean the registration roller using water. 3. Inspect the registration roller break and clean it if necessary. 4. Clean the vacuum belt using water. 5.
  • Page 93 25 July 1996 PREVENTIVE MAINTENANCE SCHEDULE 9. Fusing 1. Clean the small separation rollers using (every 10k) suitable solvent. 2. Clean the exit turn guide using alcohol. Fuising 1. Clean the thermistors using suitable solvent. (every 20k) 2. Clean the hot roller strippers using suitable solvent.
  • Page 94 PREVENTIVE MAINTENANCE SCHEDULE 25 July 1996 11. Copy Quality 1. Check copy quality. (every 10k) 2. Perform the light sensor adjustment.

  • Page 95: Test Points

    25 July 1996 SERVICE TABLES 2. SERVICE TABLES 2.1 TEST POINTS Charge/Bias/Grid Power Pack Number Function Development Bias Voltage Grid Voltage 2.2 VARIABLE RESISTORS Charge/Bias/Grid Power Pack Number Function Charge Corona Voltage Caution: VR1 should not be changed in the field. Charge corona can be adjusted using SP mode.

  • Page 96: Service Tools

    SERVICE TOOLS 25 July 1996 3. SERVICE TOOLS 3.1 SERVICE PROGRAM MODE The service program (SP) mode is used to check electrical data, change mode or adjustment values. 3.1.1 Service Program Mode Access Procedure How to access the SP mode for service representatives (All service program modes can be accessed with this procedure.) Press the following keys in sequence.
  • Page 97 25 July 1996 SERVICE TOOLS How to change settings 1. Access the SP mode and select the program number. 2. Press the "#" key to select the paper length indicator (the four digit indicator). 3. The present setting is displayed in the paper length indicator. 4.
  • Page 98 SERVICE TOOLS 25 July 1996 3.1.2 Service Program Mode Table 1: A "*" before the mode number means that the mode can be accessed by custormers or sales representative. 2: In the data colum, the default value is printed in bold letters. The default settings for several items depend on the machine destination (refer to page 4-26.).
  • Page 99 25 July 1996 SERVICE TOOLS Mode No. Function Data Manual Feed Selects the time to when the registration 0: 2 seconds Start Time Setting roller starts rotating after the entrance 1: 3 seconds sensor detects the paper leading edge in 2: 4 seconds the manual feed mode.
  • Page 100 SERVICE TOOLS 25 July 1996 Mode No. Function Data Paper Length If a customer holds the + or - key to change (In mm mode) Up/Down Step the paper length, the speed begins to 0: 1 mm Setting change after a few (SP16) 0.25 second 1: 10 mm intervals.
  • Page 101 25 July 1996 SERVICE TOOLS Mode No. Function Data Original Determines the timing when the Set 0: Original can be Acceptation Time Original indicator lights after previous inserted before Setting original is scanned. the previous original is completely fed out. 1: Original can be inserted after the previous original...
  • Page 102 SERVICE TOOLS 25 July 1996 Mode No. Function Data New Developer Carries out the new developer initialization If the initialization is Initialization for 5 minutes. The machine counts down canceled before the remaining time on the display. After the returning to the initialization, the machine automatically normal operating adjusts the toner sensor output to 3.9 ±...
  • Page 103 25 July 1996 SERVICE TOOLS Mode No. Function Data Repeat Copy Determines the maximum copy length for (In mm mode) Length Limit repeat copy. 0: 1200 mm Setting 1: 1500 mm (In inch mode) 0: 49 inch 1: 60 inch (common) 2: The maximum paper length...
  • Page 104 SERVICE TOOLS 25 July 1996 Mode No. Function Data 0: Auto change Auto Fusing Determines whether the fusing temperature Temperature is automatically changed when a different (Start key is Change paper mode is selected, or not. disabled until the fusing temperature reaches target value.)
  • Page 105 25 July 1996 SERVICE TOOLS Mode No. Function Data Auto Copy Exit Selects whether the copy exit is 0: No Change automatically selected depending on the 1: Auto Copy Exit copy length, or not. Change Longer than Pre-set Cut Lower Exit 710 mm Shorter than Variable Cut...
  • Page 106 SERVICE TOOLS 25 July 1996 Mode No. Function Data ROM Version Indicates the ROM version. Example: Display vEr_1994_06_06_01 Year Date Month Suffix 0: No, 1: A, 2: B, 3: C ..9: J Internal Use Only OPC Counter Displays the total length of copied paper do = XX,XXX after the OPC drum is installed.
  • Page 107 25 July 1996 SERVICE TOOLS Mode No. Function Data Toner Supply Indicates the present toner sensor level. dL = ab – – c Level Indication a: Toner density setting n, H, L b: TS level 0 ~ 5 c: Copy length step 1: ~30m 2: ~60m 3: ~90m...
  • Page 108 SERVICE TOOLS 25 July 1996 Mode No. Function Data Number of Displays the number of misfeeds by PJ = Number of total Misfeeds by location on the cut length indicator. Misfeed jam before the Location location code is displayed in the trailing registration sensor edge margin counter.
  • Page 109 25 July 1996 SERVICE TOOLS Mode No. Function Data Original Misfeed Displays the locations of the last five d1 = XX (Last jam) ↓ Record Display original misfeeds one after the other. d2 = XX (1 before the last jam) ↓...
  • Page 110 SERVICE TOOLS 25 July 1996 Mode No. Function Data Service Call Displays the last five service calls one after = XX (The last Records the other. error code) ↓ = XX (1 before the last error code) ↓ = XX (2 before the last error code) ↓...
  • Page 111 25 July 1996 SERVICE TOOLS Mode No. Function Data RAM Clear Clears selected data items form the RAM. 0: Not Used To clear the memory, input the number of 1: Copy Number the item you want to delete, then press the Counter "#"...
  • Page 112 SERVICE TOOLS 25 July 1996 Mode No. Function Data 21: Change the setting to the U.S.A. version 22: Change the setting to the Europe version 23: Change the setting to the Asia version 24: Charge the settings to the Hoechst version 25:Change the settings to the Regma version...
  • Page 113 25 July 1996 SERVICE TOOLS Mode No. Function Data 36: Clear all the memories and change the –1 setting to the K+E version 37 to 40: Factory use Total Counter Selects the unit in which the total counter 0: 1 m Unit Setting counts up by.
  • Page 114 SERVICE TOOLS 25 July 1996 Mode No. Function Data 80: Standard Light Sensor Change the light sensor setting. 0 ← 80 → 99 Adjustment Turn on and off the exposure lamp using –12 the Leading Edge Cut key. Darker Lighter ON: Indicator on OFF: Indicator off Drum Charge...
  • Page 115 25 July 1996 SERVICE TOOLS Mode No. Function Data Separation DC Determines the DC separation corona 70: Standard 0 ← 70 → 249 Voltage Setting-2 voltage at the paper leading edge. In this mode, the separation corona can be High –21 turned on and off using the Leading Edge Cut key.
  • Page 116 SERVICE TOOLS 25 July 1996 Mode No. Function Data –10 ← 0 → 10 Fusing Motor Determines the fusing motor speed Speed Correction correction value for Film setting. 1 step increment will –32 (Film) decrease the motor speed by 0.05%. 0 ←...
  • Page 117 25 July 1996 SERVICE TOOLS Mode No. Function Data –50.0 ← 0 → 50 Synchro-cut Adjusts the synchro cut length when 1189 Length Manual mm original is used. Increasing the number 1 setp = 0.1 mm Adjustment will shorten the paper cut length. (This value is over –39 (1189 mm)
  • Page 118 SERVICE TOOLS 25 July 1996 Mode No. Function Data –9.9 ← 0 → 9.9 Preset Cut Adjusts the cutting length of 297 mm in the Length plain paper mode. 1 step = 0.1 mm –48 Adjustment (3rd roll feed, 297 mm, plain paper) –50.0 ←...
  • Page 119 25 July 1996 SERVICE TOOLS Mode No. Function Data ADS Auto Adjusts the ADS output voltage 0: No Adjustment automatically to 3.0V with the manual 1: Adjustment Start –56 density level 7 when the ADS sensor reads the white plate. 0 ←...
  • Page 120 SERVICE TOOLS 25 July 1996 Mode No. Function Data 0 → 250 Q/M Correction Displays the number of copies made after –64 Counter the new developer initialization is done. This value can be re input using +,- keys. Toner Supply Selects the toner supply mode.
  • Page 121 25 July 1996 SERVICE TOOLS Mode No. Function Data Pressure Roller Determines the pressure roller temperature -4: -20°C Temperature correction value during the hot roller -3: -15°C Correction Value rotation. The setting of this SP mode is -2: -10°C Setting 2 (Normal added to the standard correction value.
  • Page 122 SERVICE TOOLS 25 July 1996 Mode No. Function Data 0: Normal Misfeed Ignores jam detections selected. Detection Cancel 1: Paper Feed Mode Jam (C) 2: Paper Feed Jam 3: Paper Feed Jam (C) and (B) –82 4: Original Jam (A) 5: Original Jam (A) and (C) 6: Original Jam...
  • Page 123 25 July 1996 SERVICE TOOLS Mode No. Function Data Minimum Paper Specifies the minimum paper length. (In mm mode) Length Setting 0: 245 mm 1: 210 –90 (In inch mode) 0: 9.6 inch 1: 8.5 inch –91 Factory Use Only Synchro-cut Rear Normally, an original cannot be inserted 0: Normal...
  • Page 124 SERVICE TOOLS 25 July 1996 Paper Size Pattern Data (SP No. 28) SP28 Preset Size Pattern Setting In mm Mode 3600, 1189, 841, 594, 420, 297 3600, 3000, 2500, 2000, 1500, 1189, 841, 594, 420, 297 3600, 1456, 1030, 728, 515, 364, 257 3600, 3000, 2500, 2000, 1456, 1030, 728, 515, 364, 257 3600, 1456, 1189, 1030, 841, 728, 594, 515, 420, 364, 297, 257 3600, 3000, 2500, 2000, 1456, 1189, 1030, 841, 728, 594, 515, 420, 364,...

  • Page 125: Input/Output Check Mode Access Procedure

    25 July 1996 SERVICE TOOLS 3.2 INPUT/OUTPUT CHECK MODE The input check mode allows you to check the current status of electrical components (such as sensors, switches, etc.) from the operation panel. The output check mode allows you to turn the individual electrical components (such as motors, solenoids, etc.) ON/OFF from the operation panel.

  • Page 126: Input Check Mode Table

    SERVICE TOOLS 25 July 1996 3.2.2 INPUT CHECK MODE TABLE The on/off status of the selected electrical component is displayed on the paper length indicator ("ON" or "OFF" is displayed.). If a program number not used is selected, "NOT" is displayed. Program Electrical Component Note...

  • Page 127: Output Check Mode

    25 July 1996 SERVICE TOOLS Program Electrical Component Note Key Counter Set Signal "ON" is displayed when the key counter is not set. Not Used Not Used Original Exit Sensor 2 Original Exit Sensor 3 Emergency Stop Key "ON" is displayed when the Emergency Stop key is pressed.
  • Page 128 SERVICE TOOLS 25 July 1996 Program Electrical Component Note Development Bias for Non-image Area Main Charge Corona + Grid Voltage Main Motor + Development Motor + PTL + QL + Development Bias for Non-image Area Not Used Fusing Motor Vacuum Motors Exhaust Fan Not Used Original Feed Motor (forwarding and...

  • Page 129: Power On Initial Setting Mode

    25 July 1996 SERVICE TOOLS Program Electrical Component Note Motor Operation Number/Time Determines which is displayed when the Display cutter motor (No. 45) or the wire cleaner motor (No. 59) is activated. ON: Total time of the motor operation OFF: Total number of times the motor operates.

  • Page 130: Jam Code List

    JAM CODE LIST 25 July 1996 4. JAM CODE LIST When a document (original) jam or paper jam occurs, the cause of the jam is displayed by using the following jam code. 4.1 ACCESS PROCEDURE 1. When a document jam or paper jam occurs, press and hold the Clear/Stop key.
  • Page 131 25 July 1996 JAM CODE LIST Original leading edge sensor OFF check at original trailing edge (when the dJ40 original is forwarded) Original leading edge sensor ON check at original trailing edge (when the original dJ41 is forwarded) Original Exit sensor OFF check at original trailing edge (when the original is dJ42 forwarded) Original Repeat sensor OFF check at original trailing edge (when the original is...

  • Page 132: Special Tools And Lubricants

    SPECIAL TOOLS AND LUBRICANTS 25 July 1996 5. SPECIAL TOOLS AND LUBRICANTS DESCRIPTION PART NO. REMARKS Digital Multimeter 54209507 BECKMAN RMS3030 Deluxe Test Lead BECKMAN DL241 54209508 Accessory Kit Grease – Mobil Temp.78 54479078 400 g/can Grease-G501 52039501 Current Measuring Drum A0239520 Test Chart OS-A1 A0239504...

  • Page 133: Service Remarks

    25 July 1996 SERVICE REMARKS 6. SERVICE REMARKS 6.1 DRUM UNIT 6.1.1 Drum The organic photoconductor drum is comparatively more sensitive to light and ammonia gas than a selenium 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 a minute.

  • Page 134: Charge Corona

    SERVICE REMARKS 25 July 1996 15. When the drum unit is removed from the copier, do not close the paper path section if possible. Otherwise, the gas springs at both sides open the paper path section forcibly if the paper path section is released. If you close the paper path section, take care not to injure yourself by opening the paper path section.
  • Page 135 25 July 1996 SERVICE REMARKS 6.3 OPTICS 1. Clean the exposure glass with water or alcohol. 2. Clean the fiber optics array with lens paper or silicone cloth. 3. Make sure that the exposure glass is under the rear original guide plate when reassembling.

  • Page 136: Transfer And Separation

    SERVICE REMARKS 25 July 1996 6.5 TRANSFER AND SEPARATION 1. Clean the corona wires with a blower brush. If the wires are cleaned with a dry cloth, make sure that the wire does not become stretched. 2. When adjusting the corona current, always use the drum current measuring drum.

  • Page 137: Fusing Unit

    25 July 1996 SERVICE REMARKS 6.7 FUSING UNIT 1. Be careful not to damage the edges of the hot roller strippers and tension springs. 2. Do not touch the fusing lamp with bare hands. 3. Make sure that the fusing lamp does not touch the hot roller. 4.
  • Page 138 SERVICE REMARKS 25 July 1996 6.10 OTHERS 1. When replacing the main board, if the RAM on the old main board is still usable, remove and place it on the new main board. Then, install the new main board in the copier. 2.

  • Page 139: Replacement And Adjustment

    SECTION 5 REPLACEMENT AND ADJUSTMENT...

  • Page 140: Original Feed Unit Removal

    25 July 1996 OPTICS 1. OPTICS 1.1 ORIGINAL FEED UNIT REMOVAL (preparation of the optics parts replacement). A174R500.wmf 1. Remove the left upper front [A] and right upper front [B] covers (2 screws each) and left upper rear [C] and right upper rear [D] covers (1 screw each).
  • Page 141 OPTICS 25 July 1996 A174R501.wmf 3. Remove 2 screws [A], 1 ground wire screw [B] and 2 connectors [C] of the rear feed table assembly. NOTE: Be careful not to dislodge the gate pawls [D]. If the pawls are dislodged, make sure that the pawl positions are aligned into the hole on the copier.
  • Page 142 25 July 1996 OPTICS A174R502.wmf A174R505.wmf CAUTION For the next step, do not remove the retaining rings [B] while the original feed unit [C] being closed. Otherwise, the compressed gas spring may injure you. 5. Remove the stopper screws [A] both ends. 6.

  • Page 143: Exposure Lamp Removal

    OPTICS 25 July 1996 1.2 EXPOSURE LAMP REMOVAL A174R503.wmf 1. Stand the original feed unit. 2. Remove the spring plate [A] (1 screw, either right or left) and exposure glass [B]. 3. Remove the left exposure lamp bracket [C] (1 screw) and exposure lamp [D].

  • Page 144: Fiber Optics Array Removal

    25 July 1996 OPTICS 1.3 FIBER OPTICS ARRAY REMOVAL A174R504.wmf 1. Remove the exposure glass. (Follow the steps from 1 to 2 of the exposure lamp removal.) 2. Remove the rear original guide plate [A] (5 screws). 3. Remove the right and left spring plates [B] (1 screw each). 4.
  • Page 145 OPTICS 25 July 1996 1.4 PLATEN ROLLER GAP ADJUSTMENT A174R549.wmf Adjustment standard: 0.2~0.8 mm 1. Measure the gap [A] between the platen roller [B] and the exposure glass [C]. If the gap is not within specification, adjust the gap by loosening the screw [D] and changing the position of the adjusting plate [E].
  • Page 146 25 July 1996 OPTICS 1.6 PRESET CUT LENGTH ADJUSTMENT The cut length adjustment should be done when the roll feeder is installed to correct cutting errors. The cut error correction data is determined in the factory without the copier installed. The cut length varies depending on the copier on which it is installed and/or paper type used.

  • Page 147: Development Unit Removal

    DEVELOPMENT 25 July 1996 2. DEVELOPMENT 2.1 DEVELOPMENT UNIT REMOVAL A174R506.wmf 1. Remove the left and right upper front cover. 2. Open the paper path section and original feed unit. 3. Remove the toner supply cover [A]. 4. Remove the manual entrance feed cover [B] (2 pins). 5.
  • Page 148 25 July 1996 DEVELOPMENT A174R507.wmf A174R528.wmf 6. Remove the 4 shoulder screws [A] and 2 screws [B] fixing the development unit. 7. Disconnect the 14p connector [C] and remove it out of the cutout [D]. 8. Remove the development unit [E]. CAUTION Do not loosen the painted screws [F] which determine the development doctor blade height and do not push the doctor blade...

  • Page 149: Developer Removal

    DEVELOPMENT 25 July 1996 2.2 DEVELOPER REMOVAL A174R508.wmf A174R509.wmf NOTE: Be careful not to bend the bias terminal. 1. Remove the development unit and place it on a large sheet of paper [A] as shown. 2. Remove the toner supply unit casing [B] (2 pins) and development filter [C] and bracket [C] and clean them.

  • Page 150: Toner Density Sensor Replacement

    25 July 1996 DEVELOPMENT 2.3 TONER DENSITY SENSOR REPLACEMENT A174R510.wmf 1. Remove the development unit. 2. Disconnect the harness connector [A] and take the harness from the 2 clamps [B]. 3. Remove the 2 screws [C] of the toner density sensor holder. 4.

  • Page 151: Ptl Replacement

    DEVELOPMENT 25 July 1996 2.4 PTL REPLACEMENT A174R511.wmf 1. Remove the paper feed driven unit (follow the steps from 1 to 5 of the development unit removal). 2. Remove the PTL assembly [A] (4 screws, 3 connectors, and 4 clamps [B]).

  • Page 152: Development Bias Voltage Adjustment

    25 July 1996 DEVELOPMENT 2.5 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT A174R512.wmf NOTE: This adjustment is required when the charge/bias/grid power pack is replaced. Preparation: 1. Turn off the main switch, and remove the rear cover. 2. Connect the ground terminal of the multimeter to the machine ground, and connect the voltage terminal to TP1 on the charge/bias/grid power pack.
  • Page 153 DEVELOPMENT 25 July 1996 2.5.2 Bias Voltage for Non-image Area ADJUSTMENT STANDARD: dc –200 ± 10V 1. Access SP mode and select No. –26. 2. Press the "Roll Edge Cut" key to turn on the bias voltage. 3. Check the multimeter. If the voltage is not that of the standard voltage, press the "#"...

  • Page 154: Drum Unit Removal

    25 July 1996 DRUM UNIT 3. DRUM UNIT 3.1 DRUM UNIT REMOVAL A174R513.wmf A174R514.wmf A174R515.wmf 1. Remove the development unit. 2. Remove the 2 screws [A] at both ends. 3. Remove grounding plate spring [B] (1 screw) and disconnect the harness connector [C].

  • Page 155: Drum Replacement

    DRUM UNIT 25 July 1996 3.2 DRUM REPLACEMENT A174R516.wmf 1. Remove the drum unit. 2. Remove the pulley [A] (1 C-ring). 3. Remove the 2 bearing holders [B] (2 screws each). NOTE: Be careful not to scratch the drum with the pick-off pawls when removing or reinstalling the drum.

  • Page 156: Cleaning Blade Replacement

    25 July 1996 DRUM UNIT 3.3 CLEANING BLADE REPLACEMENT A74R518.wmf A174R517.wmf A74R519.wmf 1. Remove the drum unit. 2 Remove the quenching lamp unit [A]. 3. Remove the pressure spring [B] and bushing [C]. 4. Slide the cleaning blade [D] to the left side and remove it from the right side.

  • Page 157: Charge Corona Unit Removal

    DRUM UNIT 25 July 1996 3.4 CHARGE CORONA UNIT REMOVAL A174R520.wmf 1. Remove the drum unit. 2. Remove the ground springs [A]. 3. Remove the charge corona unit [B] (2 connectors). NOTE: When reinstalling the charge corona unit, make sure that the 2 connectors (C for the charge corona, G for the grid bias) are set properly.

  • Page 158: Charge Corona Wire Replacement

    25 July 1996 DRUM UNIT 3.5 CHARGE CORONA WIRE REPLACEMENT A174R521.wmf 1. Remove the charge corona unit. 2. Remove the 4 grid wires [A] (4 springs). NOTE: Keep the grid wires with taping one ends of them and hanging them to prevent the wires from bent or being damaged. 3.

  • Page 159: Pick-Off Pawl Unit Removal

    DRUM UNIT 25 July 1996 3.6 PICK-OFF PAWL UNIT REMOVAL A174R522.wmf 1. Remove the drum unit and place it as shown. 2. Remove the pressure spring [A] and pick-off pawl unit [B] (2 screws and 1 connector). NOTE: When installing and/or removing the pick-off pawl unit, do not press too strongly.

  • Page 160: Grid Voltage Adjustment

    25 July 1996 DRUM UNIT 3.7 GRID VOLTAGE ADJUSTMENT A174R523.wmf ADJUSTMENT STANDARD: dc –940 ± 10V. NOTE: This adjustment is required when the charge/bias/grid power pack is replaced. 1. Turn off the main switch and remove the rear cover. 2. Connect the ground terminal of the multimeter to the machine ground, and connect the voltage terminal to TP2 on the charge/bias/grid power pack.

  • Page 161: Drum Current Adjustment

    DRUM UNIT 25 July 1996 3.8 DRUM CURRENT ADJUSTMENT NOTE: 1) The drum currents vary with environmental conditions such as humidity and atmospheric pressure. Generally it is not necessary to adjust the drum currents because they have already been adjusted for a wide range of environments at the factory. 2) Drum current adjustment is necessary whenever the power packs are replaced: adjustment may also be necessary to correct problems with paper separation, incomplete toner transfer, or...
  • Page 162 25 July 1996 DRUM UNIT 4. Install the drum unit [A] on the machine. A174R525.wmf CAUTION Be careful not to turn on the main motor. If the main motor accidentally turns on, some parts around the drum may be damaged. 5-23...
  • Page 163 DRUM UNIT 25 July 1996 3.8.1 Charge Current Adjustment A174R526.wmf ADJUSTMENT STANDARD: dc–1250 ± 20 µA WARNING Make sure that the machine is unplugged before connecting the multimeter on the charge/bias/grid power pack. Pay extreme attention when connecting the multimeter. The potential of the charge corona terminal becomes –5kV.

  • Page 164: Adjustment Standard

    25 July 1996 DRUM UNIT 3.8.2 Transfer Current Adjustment ADJUSTMENT STANDARD:  dc –120 ± 5 µA (  dc –260 ± 5 µA ( A174R527.wmf Plain Paper Plain Paper Translucent Film Manual Feed Roll Feed Paper    ...
  • Page 165 DRUM UNIT 25 July 1996 3.8.3 Separation Current Adjustment ADJUSTMENT STANDARD:  ac 250 ± 10 µA dc -10 ± 1 µA  ac 350 ± 10 µA dc –10 ± 1 µA A174R527-2.wmf Plain Paper Plain Paper Translucent Film Roll Feed Manual Feed Paper...
  • Page 166 25 July 1996 DRUM UNIT 12. Set the multimeter range at dc 200 µA. 13. Select SP mode No. –19. 14. Press the "Roll Edge Cut" key to turn on the separation corona. 15. Check the multimeter. Press the "#" key and then change the current using "+"...

  • Page 167: Fusing Unit Removal

    FUSING 25 July 1996 4. FUSING 4.1 FUSING UNIT REMOVAL A174R529.wmf NOTE: Close the paper path section to remove and reinstall the fusing unit. 1. Remove the copier rear cover. 2. Open the exit cover [A] and remove the shoulder screws [B] at both ends. Remove the screws [C] for the grounding wires.
  • Page 168 25 July 1996 FUSING A174R530.wmf A174R531.wmf 5. Disconnect the connectors [A]. 6. Remove the screw [B] fixing the safety switch bracket. 7. Remove the 2 screws [C] and disconnect lamp harness [D] from the clamps [E]. 8. Pull out the fusing unit [F]. NOTE: Set the fusing unit on the guides [G] and align the cuts [H] to the side plates [I] at both ends when reinstalling the fusing unit.

  • Page 169: Hot Roller Replacement

    FUSING 25 July 1996 4.2 HOT ROLLER REPLACEMENT A174R532.wmf A174R533.wmf NOTE: Be careful not to damage the hot roller thermistor when removing and reinstalling the hot roller. 1. Remove the fusing unit. 2. Remove the pressure springs [A]. 3. Remove the gear [B] (1 C-ring [C]) and the upper plate [D] (4 screws). 4.

  • Page 170: Pressure Roller Replacement

    25 July 1996 FUSING 4.3 PRESSURE ROLLER REPLACEMENT A174R534.wmf A174R535.wmf CAUTION 1. Do not touch the hot roller or pressure roller while they are hot. 2. Be careful not to damage the hot roller thermistor [A]and pressure roller thermistor [B] when removing and reinstalling the pressure roller.

  • Page 171: Pressure Roller Stripper Unit Replacement

    FUSING 25 July 1996 A174R536.wmf A174R537.wmf 4.4 PRESSURE ROLLER STRIPPER UNIT REPLACEMENT 1. Follow step 1 to 5 of the fusing unit removal. 2. Remove the pressure roller stripper unit [A] (4 screws). 4.5 PRESSURE ROLLER THERMISTOR REPLACEMENT 1. Remove the pressure roller stripper unit. 2.

  • Page 172: Hot Roller Thermistor Replacement

    25 July 1996 FUSING [E] [D] A174R538.wmf 4.7 HOT ROLLER THERMISTOR REPLACEMENT 1. Remove the fusing unit. 2. Remove the 4 screws [A] of the fusing stay. 3. Disconnect the thermofuse connector [B] from the fusing lamp harness [C]. 4. Remove the hot roller thermistor [D] (1 screw and 1 spring, 7 clamps [E]). 4.8 FUSING THERMOFUSE REPLACEMENT 1.
  • Page 173 FUSING 25 July 1996 4.9 FUSING TEMPERATURE ADJUSTMENT A174R539.wmf CAUTION When the main switch is turned on, the machine will suddenly start to drive the fusing section. Keep your hands away from any mechanical and electrical components during this period. This procedure is required only when the hot roller thermistor is replaced.
  • Page 174 25 July 1996 FUSING 10. If the actual temperature is different from the value, adjust the temperature using SP#–6. 11. Repeat steps 7 to 10 and confirm the temperature. 12. Reassemble the machine. 4.10 FUSING NIP BAND CONFIRMATION [A]27 ± 0.5 A174R550.wmf Adjustment Standard 27 ±...
  • Page 175 FUSING 25 July 1996 4.11 FUSING MOTOR SPEED ADJUSTMENT A174R547.wmf A174R548.wmf NOTE: Prepare test charts (A and B) by drawing the lines as shown. 1. Remove the four small separation rollers in front of the fusing unit. 2. Access SP#-29 (fusing motor adjustment) and set it to "0". 3.

  • Page 176: T & S Corona Unit Removal

    25 July 1996 T & S CORONA UNIT 5. T & S CORONA UNIT 5.1 T & S CORONA UNIT REMOVAL A174R540.wmf 1. Open the paper path section [A] and take out the T & S corona unit [B] (2 connectors [C]).

  • Page 177: Transfer And Separation Corona Wire Replacement

    T & S CORONA UNIT 25 July 1996 5.2 TRANSFER AND SEPARATION CORONA WIRE REPLACEMENT A174R541.wmf NOTE: 1) Handle the new wire by the ends only. Oil from your hands may cause uneven charging of the drum. 2) Do not stretch or bend the corona wires. 3) Do not rub the corona wires with rough material (sand paper, etc.) as this will damage the corona wire.
  • Page 178 25 July 1996 T & S CORONA UNIT 5.2.2 Separation Corona Wire Replacement 1. Remove the separation corona wire [C]. 2. Hook the new separation corona wire on the terminal [D] of the right endblock. NOTE: Make sure that the wire junction [E] is positioned inside the right endblock.

  • Page 179: Cutter Unit Replacement

    CUTTER UNIT REPLACEMENT 25 July 1996 6. CUTTER UNIT REPLACEMENT A174R545.wmrf A174R546.wmf 1. Remove the 1st & 2nd cover [A] (2 screws) and the roll reed left inner cover. 2. Remove the left bracket [B] (2 screws) and left lock lever [C] (1 screw and 1 spring).

  • Page 180: Roll Feed Unit Removal

    25 July 1996 ROLL FEEDER UNIT AND IMAGE PRODUCTION UNIT REMOVAL 7. ROLL FEEDER UNIT AND IMAGE PRODUCTION UNIT REMOVAL 7.1 ROLL FEED UNIT REMOVAL A174R551.wmf A174R552.wmf To facilitate transportation by hand the upper part of the copier (image production unit) and the lower part of the copier (roll feed unit) can be removed.
  • Page 181 ROLL FEEDER UNIT AND IMAGE PRODUCTION UNIT REMOVAL 25 July 1996 7.2 IMAGE PRODUCTION UNIT REMOVAL A174R553.wmf CAUTION Do not remove the image production unit before removing the roll feed unit. Otherwise, the machine could topple over when pulling out the roll feed unit.
  • Page 182 25 July 1996 ROLL FEEDER UNIT AND IMAGE PRODUCTION UNIT REMOVAL 7.3 RE-INSTALLING IMAGE PRODUCING UNIT A174R554.wmf 1. While aligning the cutouts [A] in the stand with the cutouts [B] in the image production unit, place the image production unit [C] on the stand [D].

  • Page 183: Ozone Filter Replacement

    OTHERS 25 July 1996 8. OTHERS 8.1 OZONE FILTER REPLACEMENT A174R542.wmf A174R543.wmf NOTE: Take care not to damage the mylars [A] on the rear feed table. 1. Open the fusing exit cover [B] and exit unit [C]. 2. Remove the copy tray [D]. 3.

  • Page 184: Copy Quality Adjustment

    25 July 1996 COPY QUALITY ADJUSTMENT 9. COPY QUALITY ADJUSTMENT – General Information – Image density is affected by the following factors: (1) Light Intensity (2) Bias Voltage (3) Toner Density (4) Grid Voltage (5) Charge Corona Current The items listed above must be kept in balance to maintain correct image density.

  • Page 185: Light Sensor Adjustment

    COPY QUALITY ADJUSTMENT 25 July 1996 9.1 LIGHT SENSOR ADJUSTMENT 1. Every Call 2. When replacing the following part When: • Exposure lamp • Light sensor • Drum • RAM on the main board Purpose: To maintain the correct light intensity. Level 2 (10%) of the 9 step gray scale on the OS-A1 chart Adjustment should be slightly visible when the 7 manual image density...

  • Page 186: Image Bias Adjustment

    25 July 1996 COPY QUALITY ADJUSTMENT 9.2 IMAGE BIAS ADJUSTMENT 1. The image is blurred even though the image density in black solid areas is acceptable. When: 2. Dirty background, where the problem is not caused by excess toner and cannot be solved by adjusting the light sensor voltage.

  • Page 187: Toner Density Adjustment

    COPY QUALITY ADJUSTMENT 25 July 1996 9.3 TONER DENSITY ADJUSTMENT Customer wants to change the overall image density of the When: copies. Purpose: To change toner concentration inside development unit. Perform: SP#-9 How: Change the toner density setting by SP#-9 NOTE: The toner density can also be adjusted using SP#-61 (toner density sensor voltage setting).

  • Page 188: Troubleshooting

    SECTION 6 TROUBLESHOOTING...

  • Page 189: Copy Quality Troubleshooting

    25 July 1994 COPY QUALITY TROUBLESHOOTING 1. COPY QUALITY TROUBLESHOOTING 1.1 LOW IMAGE DENSITY Is the used paper moist or extremely dry? Replace the paper. Is the toner sensor voltage within the no toner supply level (level 0) ? (Refer to Page 2-20.) Is there sufficient toner in the cartridge? Replace the toner cartridge.

  • Page 190: Uneven Copy Image

    COPY QUALITY TROUBLESHOOTING 25 July 1994 1.2 UNEVEN COPY IMAGE Make a solid black copy using SP#–81. Is the image density even? Is the developer level in the development unit? Check and correct the machine level. Clean the charge corona wire, grid wire, and transfer corona wire. Check if they are correctly set on the slots of the end blocks.

  • Page 191: Dirty Background

    25 July 1994 COPY QUALITY TROUBLESHOOTING 1.3 DIRTY BACKGROUND Clean the optics and check the copy image. No good Change the light sensor setting to a lighter position using SP#–12. No good Is the bias voltage correct? Adjust the bias voltage. Is the toner sensor voltage much lower than the threshold between level 0 and 1? (Check using SP#–63 referring to Page 2-20.) Check the main board and toner supply clutch.

  • Page 192: Black Line Or Band

    COPY QUALITY TROUBLESHOOTING 25 July 1994 1.4 BLACK LINE OR BAND Vertical line or band? Does the black line appear at 251 mm intervals? Clean or replace the drum. If a black band appears 250 mm from the leading edge, turn the main switch off and on . If the problem is not fixed, check the T&...

  • Page 193: Entirely Blank Copy

    25 July 1994 COPY QUALITY TROUBLESHOOTING 1.5 ENTIRELY BLANK COPY Is the used paper moist? Replace the paper. Are the terminals of the charge corona unit and the T& S corona unit connected properly? Set the terminals properly. Is the charge corona wire or the T & S corona wire broken? Replace the broken part.

  • Page 194: Paper Creasing

    COPY QUALITY TROUBLESHOOTING 25 July 1994 1.6 PAPER CREASING Is the used paper moist? Change the paper. Is the paper feed direction the same as the paper fiber direction? Change the paper transport direction, if possible. (NOTE 1.) Decrease the fusing temperature at the key operation (refer to 2-39). (NOTE 2.) NOTE: 1) If there is rib shape creasing, the paper feed direction should be the same as the paper fiber direction.

  • Page 195: Service Call Condition

    25 July 1994 SERVICE CALL CONDITION 2. SERVICE CALL CONDITION When a service call condition occurs, the Call Service indicator service call codes are displayed. When the service call conditions E2, E3, E4, E5, E6, E7, E8 , and E15 conditions occur, for safety reason they cannot be cleared by turning the main switch off and on.

  • Page 196: Sc Code E-3: Hot Roller Thermistor Open

    SERVICE CALL CONDITION 25 July 1994 2.3 SC CODE E-3: HOT ROLLER THERMISTOR OPEN -Definition- The temperature detected by the hot roller thermistor does not reach 50°C within 3 minutes after the main switch is turned on. <Point to check> Hot roller thermistor AC drive board (CN203-2, T203) Fusing thermofuse...

  • Page 197: Sc Code E-6: Pressure Roller Thermistor Short

    25 July 1994 SERVICE CALL CONDITION 2.6 SC CODE E-6: PRESSURE ROLLER THERMISTOR SHORT -Definition- The resistance of the pressure roller thermistor is less than 0.55 KΩ. <Point to check> Pressure roller thermistor Main board (CN106-A6, -A7)) 2.7 SC CODE E-7: FUSING OVERHEAT -Definition- The temperature detected by the hot roller thermistor becomes higher than 220°C...

  • Page 198: Sc Code E-8: Fusing Warm-Up Error

    SERVICE CALL CONDITION 25 July 1994 2.8 SC CODE E-8: FUSING WARM-UP ERROR -Definition- The temperature detected by the hot roller thermistor does not reach the target ready temperature within 12 minutes after main switch is turned on. <Point to check> Hot roller thermistor Fusing lamp Fusing thermofuse...
  • Page 199 25 July 1994 SERVICE CALL CONDITION 2.10 SC CODE E-10: MAIN MOTOR ABNORMAL -Definition- The main board does not receive a signal from the main motor for 2 seconds while the main motor is on. <Point to check> Main motor Mechanical interference of the main motor drive Main board (CN102-A8, -A9) 2.11 SC CODE E-11: DEVELOPMENT MOTOR ABNORMAL...

  • Page 200: Sc Code E-14: Zero Cross Signal Detection Abnormal

    SERVICE CALL CONDITION 25 July 1994 2.12 SC CODE E-12: CHARGE CORONA CLEANER MOTOR ABNORMAL -Definition- 1. The over current of the charge corona wire drive motor is not detected continually for 1.5 seconds within 3 minutes after main switch is turned on. 2.
  • Page 201 25 July 1994 SERVICE CALL CONDITION 2.15 SC CODE E-15: MAIN SWITCH ABNORMAL (U.S.A version only) -Definition- The main switch does not turn off within 0.45 second after sending reset signal. <Point to check> Main Switch Main board 2.16 SC CODE E-16: TONER DENSITY SENSOR ADJUSTMENT ERROR -Definition- The toner density sensor voltage cannot be adjusted to its standard value...
  • Page 202 SERVICE CALL CONDITION 25 July 1994 2.17 SC CODE E-17: ADS AUTO ADJUSTMENT FAILURE -Definition- The ADS sensor voltage cannot be adjusted to its standard value (3.9 ± 0.2 V) during the ADS auto adjustment (SP#–56). <Point to check> ADS pattern ADS sensor 2.18 SC CODE E-18: ORIGINAL REGISTRATION AUTO ADJUSTMENT FAILURE...

  • Page 203: Blown Fuse Table

    25 July 1994 BLOWN FUSE TABLE 3. BLOWN FUSE TABLE 3.1 POWER SUPPLY UNIT Europe version Fuse No. Specification Symptom FU301 250V 5A No power. FU302 250V 6.3A No indication and Beeper sounds if 2 or FU303 250V 6.3A more fuses are blown. FU304 250V 6.3A USA version...

  • Page 204: Electrical Component Layout

    ELECTRICAL COMPONENT LAYOUT 15 17 14...

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