Page 1 (Machine Code: A229) SERVICE MANUAL TS Dept. Imaging System Business Group RICOH Co., LTD.
Page 2: Health Safety Conditions
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 power switch is turned off.
Page 3: Safety And Ecological Notes For Disposal
1. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are non-toxic supplies.) 3.
Page 4: Overall Machine Information
June 30, 1998 SPECIFICATIONS 1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS 1.1.1 COPIER ENGINE Configuration: Console Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum A3/11" x 17" Minimum B6, 5½”x 8 ½” (using ADF) Original Alignment: Rear left corner Copy Paper Size: Maximum A3/11"...
Page 5 SPECIFICATIONS June 30, 1998 Zoom: 32 ~ 400% Copy Speed: Max. 65 cpm (A4 / 8 ½” x 11” sideways) Resolution: Scanning: 400 dpi Printing: 400 dpi 600 dpi (Printer Mode Only) Gradation: 256 levels Warm-up Time: Less than 330 s (from Off-mode) Less than 30 s (from Low Power Mode) First Copy Time: Less than 3.7 s (Face up mode)
Page 6 June 30, 1998 SPECIFICATIONS Power Consumption: A229 copier (120 V Model) Copier only Full system* Warm-up About 1.290 kW About 1.310 kW Stand-by About 0.235 kW About 0.255 kW Copying About 1.560 kW About 1.650 kW Maximum Less than 1.75 kW Less than 1.75 kW Energy Saver About 0.210 kW...
Page 7 SPECIFICATIONS June 30, 1998 Dimensions: 690 x 750 x 1138 mm (27.2” x 29.5” x 44.8”) (W x D x H) (without ADF right exit tray, and options) Weight: 188 kg (without options) • Output tray (A814-01) Optional Equipment: • Finisher (A697) •...
Page 8: Machine Configuration
June 30, 1998 MACHINE CONFIGURATION 1.2 MACHINE CONFIGURATION A229V501.WMF Item Machine Code Mainframe A229 Output Tray A814 - 01 Finisher A697 Large Capacity Tray A698 A812-17 (3 holes) Punch Unit (Option for Finisher) A812-27 (2 holes)
Page 9: Mechanical Component Layout
MECHANICAL COMPONENT LAYOUT June 30, 1998 1.3 MECHANICAL COMPONENT LAYOUT 1.3.1 COPIER ENGINE 14 15 A229V507.WMF...
Page 10 June 30, 1998 MECHANICAL COMPONENT LAYOUT 1. 3rd Mirror 31. Separation Roller 2. 2nd Mirror 32. Tray 1 (Tandem Tray) 3. 1st Mirror 33. Tray 2 (550-sheet Tray) 4. Exposure Lamps 34. Tray 3 (1500-sheet lage capacity tray) 5. LD Unit 35.
Page 11 MECHANICAL COMPONENT LAYOUT June 30, 1998 1.3.2 ADF A229V506.WMF 1. Separation Roller 12. Exit Gate 2. Feed Belt 13. Inverter Roller 3. Pick-up Roller 14. Exit Sensor 4. Bottom Plate 15. Upper Exit Tray 5. Original Tray 16. Transport Belt Upper Tray Exit Roller 17.
Page 12: Paper Path
June 30, 1998 PAPER PATH 1.4 PAPER PATH A229V504.WMF 1. ADF 7. Duplex Unit 2. By-pass Tray 8. Finisher 3. Optional LCT 9. Inverter Unit 4. Tray 3 (1500-sheet LCT) 10. Shift Tray 5. Tray 2 (550-sheet Tray) 11. Upper Tray 6.
Page 13: Copy Process
COPY PROCESS June 30, 1998 1.5 COPY PROCESS A229V508.WMF A229V510.WMF 1. EXPOSURE Two xenon lamps expose the original. Light reflected from the original passes to the CCD, where it is converted into an analog data signal. This data is converted to a digital signal, processed, and stored in the memory.
Page 14 June 30, 1998 COPY PROCESS 4. DRUM POTENTIAL SENSOR The drum potential sensor detects the electric potential on the drum to correct various process control elements. 5. DEVELOPMENT The magnetic developer brush on the development rollers comes in contact with the latent image on the drum surface.
Page 15: Drive Layout
DRIVE LAYOUT June 30, 1998 DRIVE LAYOUT 1.6.1 COPIER ENGINE " & & & A229V505.WMF Cleaning Unit 1. Drum Motor " Scanner Unit 2. Scanner Motor Transfer Belt Unit 3. Fusing/Duplex Motor Fusing Unit 4. Toner Recycling Clutch Duplex Unit 5.
Page 16 June 30, 1998 DRIVE LAYOUT 1.6.2 ADF C229V511.WMF 1. Pick-up Motor 8. Transport Belt 2. Bottom Plate Motor 9. Lower Transport Roller 3. Feed-in Motor 10. Upper Exit Roller 4. Transport Motor 11. Separation Roller 5. Upper Exit Roller 12. Feed Belt 6.
Page 17: Electrical Component Description
ELECTRICAL COMPONENT DESCRIPTION June 30, 1998 1.7 ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the point-to-point diagram for the location of the components using the symbols and index numbers. 1.7.1 COPIER ENGINE Index Symbol Name Function...
Page 18 June 30, 1998 ELECTRICAL COMPONENT DESCRIPTION Index Symbol Name Function Fusing Fan Removes heat from around the fusing unit. Duplex Cooling Fan Removes heat from around the duplex unit. PSU Cooling Fan Removes heat from around the PSU. Magnetic Clutches Toner Supply Turns the toner supply roller to supply toner to the development unit.
Page 19 ELECTRICAL COMPONENT DESCRIPTION June 30, 1998 Index Symbol Name Function Paper Size Determines the size of paper in tray 2. SW10 3rd Tray Down Lowers the tray 3 (LCT) bottom plate SW11 By-pass Tray Detects if the by-pass tray is open or closed.
Page 20 June 30, 1998 ELECTRICAL COMPONENT DESCRIPTION Index Symbol Name Function Toner Density (TD) Detects the amount of toner in the developer. Image Density (ID) Detects the density of the ID sensor pattern on the drum. Toner End Detects toner end. Toner Collection Monitors the toner collection motor.
Page 21 ELECTRICAL COMPONENT DESCRIPTION June 30, 1998 Index Symbol Name Function Base Plate Down Detects when the bottom plate is completely lowered to stop the 1st tray lift motor. Left Tandem Paper Informs the CPU when the left tandem tray runs out of paper. 3rd Tray Paper Detects whether there is paper or not in tray 3.
Page 22 June 30, 1998 ELECTRICAL COMPONENT DESCRIPTION Index Symbol Name Function PCB9 Interface Passes signals and dc supplies from the PSU and IOB to motors and other components. Paper Feed Control Controls the mechanical parts of all PCB10 Board (PFB) paper feed sections. PCB11 Operation Panel 1 Controls the components on the right-...
Page 23 ELECTRICAL COMPONENT DESCRIPTION June 30, 1998 Index Symbol Name Function Circuit Breaker Provides back-up high current protection for the electrical components. HDD 1 Scanned image data is compressed and held here temporarily. LCD 1 Displays the operation menus and messages. LSD 1 Laser Synchronization Detects the laser beam at the start of...
Page 24 June 30, 1998 ELECTRICAL COMPONENT DESCRIPTION 1.7.2 ADF Symbol Name Function Index No. Motors Pick-up Moves the pick-up roller up and down. Feed-in Drives the feed belt, and the separation, pick-up, and transport rollers. Transport Drives the transport belt. Feed-out Drives the exit and inverter rollers.
Page 25 ELECTRICAL COMPONENT DESCRIPTION June 30, 1998 Symbol Name Function Index No. PCBs DF Main Controls the DF and communicates with the PCB1 main copier boards. DF Indicator Indicates whether an original has been PCB2 placed in the feeder; and indicates whether SADF mode has been selected.
Page 26: Detailed Descriptions
June 30, 1998 DOCUMENT FEEDER 2. DETAILED DESCRIPTIONS 2.1 DOCUMENT FEEDER 2.1.1 PICK-UP ROLLER RELEASE MECHANISM A229D651.WMF When the original set sensor is off (no original on the original tray), the pick-up roller stays in the up position. When the original set sensor turns on (or when the trailing edge of a page passes the entrance sensor while pages remain on the original tray), the pick-up motor [A] turns on.
Page 27: Bottom Plate Lift Mechanism
DOCUMENT FEEDER June 30, 1998 2.1.2 BOTTOM PLATE LIFT MECHANISM A229D652.WMF When an original is placed on the original tray, the original set sensor [A] turns on, the pick-up roller [B] drops on to the original, and the bottom plate position sensor [C] turns off.
Page 28: Pick-Up And Separation Mechanism
June 30, 1998 DOCUMENT FEEDER 2.1.3 PICK-UP AND SEPARATION MECHANISM A806D105.WMF A806D106.WMF The original separation system is an FRR system. The pick-up roller [A], feed belt [B], and separation roller [C] are driven by the feed-in motor [D]. To drive this mechanism, the feed-in motor turns in the forward direction. When two sheets of the original are fed by the pick-up roller, the separation roller turns in the opposite direction to the feed belt and the 2nd sheet is pushed back to the original tray.
Page 29: Original Feed Mechanism
DOCUMENT FEEDER June 30, 1998 2.1.4 ORIGINAL FEED MECHANISM A806D107.WMF When the leading edge of the original turns the entrance sensor [A] on, the feed-in motor [B] changes direction, and turns in reverse. However, the transport rollers [C] keep turning in the same direction because of a combination of one-way clutches (see the next page).
Page 30: Original Feed Drive Mechanism
June 30, 1998 DOCUMENT FEEDER 2.1.5 ORIGINAL FEED DRIVE MECHANISM A806D500.WMF [F] [G] Feed Start Feed No Rotation A806D501.WMF The separation roller [A] and transport rollers [B] always turn in the same direction because of a combination of gears and one-way clutches, even if the feed-in motor [C] changes direction.
Page 31: Original Size Detection
DOCUMENT FEEDER June 30, 1998 2.1.6 ORIGINAL SIZE DETECTION A806D108.WMF A4 Lengthwise B4/B5 Sideways DLT/LT Sideways A3/A4 Sideways A806D503.WMF The DF detects original width using three original width sensors-1 [A], -2 [B], -3 [C], and detects original length using entrance sensor [D] and registration sensor [E]. The CPU counts the feed-in motor pulses between when the leading edge of the original turns on the registration sensor and when the trailing edge of the original turns off the entrance sensor.
Page 32: Original Transport Mechanism
June 30, 1998 DOCUMENT FEEDER 2.1.7 ORIGINAL TRANSPORT MECHANISM A806D109.WMF 3.5 mm A806D509.WMF The transport belt [A] is driven by the transport belt motor [B]. The transport belt motor starts when the copier sends an original feed-in signal. Inside the transport belt are five pressure rollers which give the proper pressure between the belt and original.
Page 33: Original Skew Correction Mechanism
DOCUMENT FEEDER June 30, 1998 2.1.8 ORIGINAL SKEW CORRECTION MECHANISM A680D510.WMF The transport belt motor remains energized to carry the original approximately 7 mm past the left scale [A] (see the middle drawing). Then the motor stops and reverses to feed the original back against the left scale (see the bottom drawing). This forces the original to hit the left scale and this aligns the trailing edge to minimize the original skew on the exposure glass.
Page 34: Original Inversion And Feed-Out Mechanism
June 30, 1998 DOCUMENT FEEDER 2.1.9 ORIGINAL INVERSION AND FEED-OUT MECHANISM General Operation A806D110.WMF When the scanner reaches the return position, the copier’s CPU sends the feed-out signal to the DF. When the DF receives the feed-out signal, the transport belt motor and feed-out motor [A] turn on.
Page 35 DOCUMENT FEEDER June 30, 1998 Original Inversion Mechanism A806D113.WMF When the DF receives the original invert signal from the copier, the transport belt motor, feed-out motor, exit gate solenoid [A], and inverter gate solenoid [B] turn on and the original is fed back to the exposure glass through the inverter roller [C], exit gate [D], inverter guide roller [E], inverter gate [F], and inverter roller.
Page 36 June 30, 1998 DOCUMENT FEEDER Original Exit Mechanism (Single-Sided Original Mode) A806D111.WMF The exit gate solenoid [A] remains off and the original is fed out to the right exit tray. The transport belt motor turns off after the exit sensor [B] turns off. To stack the originals neatly on the exit tray, the feed-out motor speed is reduced approximately 30 mm before the trailing edge of the original turns off the exit sensor.
Page 37 DOCUMENT FEEDER June 30, 1998 Original Exit Mechanism (Double-Sided Original Mode) A806D112.WMF The exit gate solenoid [A] turns on and the inverter gate solenoid [B] remains off, and the original is fed out to the upper tray. The transport belt motor turns off when the trailing edge of the original passes through the exit sensor [C].
Page 38: Jam Conditions
June 30, 1998 DOCUMENT FEEDER 2.1.10 JAM CONDITIONS A806D502.WMF 1. The entrance sensor [I] has still not turned on when the feed-in motor has fed the original twice the length [A] (between the original set position and the entrance sensor). 2.
Page 39: Timing Charts
DOCUMENT FEEDER June 30, 1998 2.1.11 TIMING CHARTS A4 Sideways: One-Sided Original (Three Pages) A806D504.WMF 2-14...
Page 40 June 30, 1998 DOCUMENT FEEDER A3: Two-Sided Original (One Page) A806D505.WMF 2-15...
Page 41 SCANNING June 30, 1998 2.2 SCANNING 2.2.1 OVERVIEW A229D532.WMF The original is illuminated by the two exposure lamps (xenon lamps in this model) [A]. The image is reflected onto a CCD (charge coupled device) [B] via the 1st, 2nd, and 3rd mirrors, and through the lens [C]. The 1st scanner consists of the two exposure lamps and the 1st mirror.
Page 42: Scanner Drive
June 30, 1998 SCANNING 2.2.2 SCANNER DRIVE A229D533.WMF The scanner drive motor is a stepper motor. The 1st and 2nd scanners [A, B] are driven by the scanner drive motor [C] through the timing belt [D], scanner drive pulley [E], scanner drive shaft [F], and two scanner wires [G]. The scanner motor drive board controls the scanner drive motor.
Page 43: Original Size Detection In Book Mode
SCANNING June 30, 1998 2.2.3 ORIGINAL SIZE DETECTION IN BOOK MODE A229D534.WMF A229D535.WMF There are three reflective sensors in the optics cavity for original size detection. The original width sensor [A] detects the original width, and the original length sensor-1 [B] and original length sensor-2 [C] detect the original length. These are the APS (Auto Paper Select) sensors.
Page 44 June 30, 1998 SCANNING Length Original Size Width Sensor Sensor SP4301 Display A4/A3 LT/DLT Version Version ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 11" x 17" 00011111 ! ! ! ! ! ! ! ! ! ! ! !
Page 45: Image Processing
IMAGE PROCESSING June 30, 1998 2.3 IMAGE PROCESSING 2.3.1 OVERVIEW S B U Memory Control ICs G A 1 H D D Driver I P U Controller D r u m (GAVD) G A 2 Driver SBICU L D D R A229D578.WMF The CCD generates an analog video signal.
Page 46 June 30, 1998 IMAGE PROCESSING 2.3.2 SBU SBICU Analog A/D 1 8 bit data Processing IC1 Analog A/D 2 8 bit data Processing IC2 A229D579.WMF The CCD converts the light reflected from the original into an analog signal. The CCD line has 5,000 pixels and the resolution is 400 dpi (15.7 lines/mm). The CCD has two output lines, for odd and even pixels, to the analog processing IC.
Page 47: Auto Image Density (Ads)
IMAGE PROCESSING June 30, 1998 2.3.3 AUTO IMAGE DENSITY (ADS) 0 . 5 m m 1 5 m m 7 5 m m Sub scan direction A229D581.WMF This mode prevents the background of an original from appearing on copies. The copier scans the auto image density detection area [A]. This corresponds to a narrow strip at one end of the main scan line, as shown in the diagram.
Page 48 June 30, 1998 IMAGE PROCESSING 2.3.4 IPU (IMAGE PROCESSING UNIT) Overview G A 1 H D D G A 2 LDDR L D 1 G A V D D R A M L D 2 SBICU A229D580.WMF The image data from the SBU goes to the IPU (Image Processing Unit) IC on the SBICU board, which carries out the following processes on the image data.
Page 49: Image Processing Steps And Related Sp Modes
IMAGE PROCESSING June 30, 1998 2.3.5 IMAGE PROCESSING STEPS AND RELATED SP MODES The following tables shows the image processing path and the related SP modes used for each image processing mode. The user can adjust many of the image processing parameters with a UP mode (Copy Features –...
Page 50 June 30, 1998 IMAGE PROCESSING Text Mode In text mode, there is no text/image separation, and the entire image is processed as a text area. The MTF filtering coefficient and strength can be adjusted individually for both main and sub scan. Low density originals are produced better when a stronger MTF filter is selected, but in this case, moiré...
Page 51 IMAGE PROCESSING June 30, 1998 Photo Mode There is no text/image separation, and the entire image is processed as a photo area. With UP Mode (Copy Features – General Features – Original Mode Quality Level), the user can select ‘Screen Printed’, ‘Normal’, ‘Continuous Tone’, and ‘SP Mode Changed’.
Page 52 June 30, 1998 IMAGE PROCESSING Text/Photo Mode When text/photo mode is selected, text/photo separation is done. A text filter or photo filter is applied to each image area. The gradation process also depends on whether the image area is text or photo. With UP Mode (Copy Features –...
Page 53 IMAGE PROCESSING June 30, 1998 Pale Mode The image processing for pale mode is basically the same as in text mode. However, the contrast of the original is low. So, to preserve details, a stronger MTF filter is used. Also, the independent dot erase level is set at a lower level, so that only the faintest of dots are deleted;...
Page 54 June 30, 1998 IMAGE PROCESSING Generation Copy Mode The image processing for generation mode is basically the same as in text mode, except that in order to prevent lines in the main scan direction from being reproduced too thickly, line width correction is applied for the final gradation treatment.
Page 55: Auto Shading
IMAGE PROCESSING June 30, 1998 2.3.6 AUTO SHADING A229D645.WMF Two things happen during auto shading. Black level correction The black level is zeroed for each scan line of data by reading the dummy elements at the end of the CCD signal for each scan line, which should be black. White level correction The data is corrected for variations in white level across the main scan.
Page 56 June 30, 1998 IMAGE PROCESSING 2.3.7 TEXT/PHOTO AREA SEPARATION Text/Photo Separation Auto E d g e Final Filtering Shading Determination Evaluation Dot Screen Determination A229D625.WMF This is used only in text/photo mode. Text/photo separation is done at two points during image processing. The first one is immediately after auto shading, and is a complex process involving comparison with surrounding pixels and the use of matrixes.
Page 57 IMAGE PROCESSING June 30, 1998 Dot Screen Determination The machine determines whether the pixel is in a dot screen area or not. The process can be adjusted with SP4912-017. The page is divided into 4 x 4 blocks of pixels. Each block [A] is placed at the center of a 5 x 3 array of these blocks, and becomes either text or photo, depending on the other blocks in the 5 x 3 area .
Page 58: Background Erase
June 30, 1998 IMAGE PROCESSING 2.3.8 BACKGROUND ERASE Scanner Output Scanner Input (Threshold) A229D591.WMF By default, this process is used only in text mode, text/photo mode, and generation copy mode. Usually, dirty background is erased using Auto Image Density (ADS). However, sometimes, dirty background areas will still appear.
Page 59: Independent Dot Erase
IMAGE PROCESSING June 30, 1998 2.3.9 INDEPENDENT DOT ERASE By default, this process is used in all image processing modes except for photo mode. This function allows independent black dots appearing on copies to be completely erased, or to be reduced in image density. As shown in the drawing below, the software compares each pixel with the pixels in the surrounding 5 x 5 area (except for the immediately adjacent pixels).
Page 60 June 30, 1998 IMAGE PROCESSING The threshold level for deciding whether a dot is independent can be changed using SP mode. The default value of this threshold level is different for each image processing mode. As shown below, in Text/Photo mode, independent dots are reduced, but in Text, Pale, or Generation mode, they are erased.
Page 61: Filtering, Main Scan Magnification/Reduction
IMAGE PROCESSING June 30, 1998 2.3.10 FILTERING, MAIN SCAN MAGNIFICATION/REDUCTION Overview After auto shading, the image data is processed by both filtering and main scan magnification. However, to reduce the occurrence of moiré in the image, the processing order depends on the reproduction ratio, as follows. 1.
Page 62 June 30, 1998 IMAGE PROCESSING Main scan magnification/reduction A229D646.WMF Reduction and enlargement in the sub scan direction are done by changing the scanner speed. However, reduction and enlargement in the main scan direction are handled by the IPU chip on the SBICU board. Scanning and laser writing are done at a fixed pitch (the CCD elements cannot be squeezed or expanded).
Page 63: Gradation Processing
IMAGE PROCESSING June 30, 1998 2.3.11 GAMMA (γ γ γ γ ) CORRECTION Gamma correction ensures accurate generation of the various shades in the gray scale from black to white, accounting for the characteristics of the scanner and printer. Scanner gamma correction corrects the data output to the IPU to account for the characteristics of the scanner (e.g., CCD response, scanner optics).
Page 64 June 30, 1998 IMAGE PROCESSING Error Diffusion and Dithering The error diffusion process reduces the difference in contrast between light and dark areas of a halftone image. Each pixel is corrected using the difference between it and the surrounding pixels. The corrected pixels are then corrected using an error diffusion matrix.
Page 65: Line Width Correction
IMAGE PROCESSING June 30, 1998 2.3.13 LINE WIDTH CORRECTION This function is effective only in generation copy mode. Usually, lines will bulge in the main scan direction as a result of the negative/positive development system that is used in this model. So, pixels on edges between black and white areas are compared with adjacent pixels, and if the pixel is on a line, the line thickness will be reduced.
Page 66 June 30, 1998 IMAGE PROCESSING 2.3.14 COMPRESSION AND STORAGE Circuit FIFO GA 1 H D D GA 2 D R A M D R A M D R A M D R A M D R A M D R A M A229D626.WMF The compression and storage circuit consists of the GA1 IC, GA2 IC, DRAM, and the hard disk drive.
Page 67 IMAGE PROCESSING June 30, 1998 Compression A229D627.WMF After image processing, the image data from the IPU first goes to the FIFO block. This block consists of 14 FIFO memories (7 for data input, 7 for data output). FIFOs are used because four scan lines are compressed at the same time to improve the image compression speed.
Page 68: Laser Exposure
June 30, 1998 LASER EXPOSURE 2.4 LASER EXPOSURE 2.4.1 OVERVIEW This machine uses two laser diodes to produce electrostatic images on an OPC drum. The laser diode unit converts image data from the SBICU board into laser pulses, and the optical components direct these pulses to the drum. Exposure of the drum by the laser beam creates the latent image.
Page 69: Optical Path
LASER EXPOSURE June 30, 1998 2.4.2 OPTICAL PATH A229D522.WMF The output path from the laser diode to the drum is shown above. The LD unit [A] outputs two laser beams to the polygonal mirror [B] (six mirrors) through the cylindrical lens [C] and the 1st mirror [D]. Each surface of the polygon mirror reflects two full main scan lines.
Page 70: Auto Power Control
June 30, 1998 LASER EXPOSURE 2.4.3 AUTO POWER CONTROL Front Cover Safety Switch +5VLD Error Error LEVEL1 VIDEO IC 2 REF1 VIDEO GAVD (IC 7) SBICU +5VLD LDOFF VIDEO LEVEL2 IC 3 REF2 Error LDDR A229D523.WMF IC2 and IC3 on the LDDR drive the laser diodes. Even if a constant electric current is applied to the laser diode, the intensity of the output light changes with the temperature.
Page 71: Dual Beam Writing
LASER EXPOSURE June 30, 1998 2.4.4 DUAL BEAM WRITING A229D524.WMF This LD unit has two laser diodes; LD1 [A] and LD2 [B] for writing the image. This means that each face of the polygon mirror writes two main scan lines, and twelve main scans are produced when the polygon mirror rotates once.
Page 72: Laser Beam Pitch Change Mechanism
June 30, 1998 LASER EXPOSURE 2.4.5 LASER BEAM PITCH CHANGE MECHANISM 2 mm A229D525.WMF P1: 400 dpi P2: 600 dpi A229D516.WMF A printer option is available for this machine and the resolution of the printer is 600 dpi. The machine changes the resolution between 400 and 600 dpi by rotating the LD unit.
Page 73: Ld Safety Switches
LASER EXPOSURE June 30, 1998 2.4.6 LD SAFETY SWITCHES Front Cover SBICU LDDR Safety Sw CN307-2 CN402-3 CN403-1 CN402-4 LD5V CN403-3 A229D500.WMF To ensure technician and user safety and to prevent the laser beam from inadvertently switching on during servicing, there are two safety switches located at the front cover.
Page 74: Process Control
June 30, 1998 DRUM UNIT 2.5 DRUM UNIT 2.5.1 PROCESS CONTROL Overview The drum potential will gradually change because of the following factors. • Dirty optics or exposure glass • Dirty charge corona casing and grid plate • Changes in drum sensitivity To maintain good copy quality, the machine does the following just after the main switch has been turned on (if the fusing temperature is less than 100 °C and SP3- 901 is on).
Page 75 DRUM UNIT June 30, 1998 Drum potential sensor calibration R A 1 0 1 -200/-700 R A 1 0 2 A229D641.WMF The drum potential sensor [A] detects the electric potential of the drum surface [B]. Since the output of the sensor is affected by environmental conditions, such as temperature and humidity, the sensor needs recalibration at times.
Page 76 June 30, 1998 DRUM UNIT Adjustment Charge/Grid P . P S B I C U A229D642.WMF The potential on unexposed areas of the drum (V ) gradually changes during drum life. To keep V constant, the grid voltage (V ) is adjusted during process control initial setting.
Page 77 DRUM UNIT June 30, 1998 LD power adjustment L D D R S B I C U A229D643.WMF This adjustment uses the drum potential sensor to keep the ID sensor pattern at the same density, so that V will be updated correctly (see the next page). The V pattern is developed using the current LD power (the density is the same as the ID sensor pattern).
Page 78 June 30, 1998 DRUM UNIT Update The TD sensor reference voltage (V ) is updated to stabilize the concentration of toner in the development unit as follows; + ∆V New V = Current V ∆V is determined using the following Vsp/Vsg and V table REF–...
Page 79: Drum Unit Components
DRUM UNIT June 30, 1998 2.5.2 DRUM UNIT COMPONENTS A229D554.WMF The drum unit consists of the components shown in the above illustration. An organic photoconductor drum (diameter: 100 mm) is used for this model. 1. OPC Drum 6. Cleaning Brush 2.
Page 80: Drive Mechanism
June 30, 1998 DRUM UNIT 2.5.3 DRIVE MECHANISM A229D555.WMF The drive from the drum motor [A] is transmitted to the drum, the cleaning unit and the toner recycling unit [D] through some timing belts, gears, the drum drive shaft [B], and the cleaning unit coupling [C]. The drum motor has a drive controller, which outputs a motor lock signal when the rotation speed is out of the specified range.
Page 81: Drum Charge
DRUM UNIT June 30, 1998 2.5.4 DRUM CHARGE Overview A229D557.WMF This copier uses a double corona wire scorotron system to charge the drum. Two corona wires are needed to give a sufficient negative charge to the drum surface. The stainless steel grid plate makes the corona charge uniform and controls the amount of negative charge on the drum surface by applying a negative grid bias voltage.
Page 82 June 30, 1998 DRUM UNIT Charge Corona Wire Cleaning Mechanism A229D558.WMF Air flowing around the charge corona wire may deposit toner particles on the corona wires. These particles may interfere with charging and cause low density bands on copies. The wire cleaner pads [A] automatically clean the wires to prevent such a problem. The wire cleaner is driven by a dc motor [B].
Page 83: Drum Cleaning And Toner Recycling
DRUM UNIT June 30, 1998 2.5.5 DRUM CLEANING AND TONER RECYCLING Overview 4 mm A229D561.WMF A229D560.WMF This copier uses a counter blade system to clean the drum. In a counter blade system, the drum cleaning blade [A] is angled against drum rotation. The counter blade system has the following advantages: •...
Page 84 June 30, 1998 DRUM UNIT Drive Mechanism A229D562.WMF Drive from the drum motor is transmitted to the cleaning unit drive gear via the timing belt [A] and the cleaning unit coupling [B]. The cleaning unit drive gear [C] then transmits the drive to the front through the cleaning brush [D]. The gear at the front drives the toner collection coil gear [E].
Page 85 DRUM UNIT June 30, 1998 Cleaning Blade Pressure Mechanism and Side-to-Side Movement A229D563.WMF The spring [A] always pushes the cleaning blade against the drum. The cleaning blade pressure can be manually released by pushing up the release lever [B]. To prevent cleaning blade deformation during transportation, the release lever must be locked in the pressure release (upper) position.
Page 86 June 30, 1998 DRUM UNIT Toner Recycling and Waste Toner Collection Mechanism Toner Recycling A229D630.WMF A229D628.WMF This machine has a toner recycling system, using a screw-pump unit. This mechanism reduces the amount of waste toner by 90%. Only toner which is transferred from the drum cleaning blade is recycled. Toner collected from the transfer belt cleaning blade is not recycled, but is transported to the toner collection bottle for waste toner through the toner collection tube [A].
Page 87 DRUM UNIT June 30, 1998 To the Toner Collection Bottle (Waste Toner) To the Toner Supply A229D629.WMF Unit (Recycled Toner) The toner recycling unit mechanism is controlled by the image pixel count. The recycling clutch [A] is engaged for 2 seconds after making the equivalent of about 100 copies of a 6% test chart.
Page 88 June 30, 1998 DRUM UNIT Waste Toner Collection A229D633.WMF A229D634.WMF Toner collected by the transfer belt unit is transported to the toner collection bottle [A] through the toner collection tube. Three helical coils transport the toner. One coil [B] feeds the toner in from the transfer belt unit. The next coil [C], driven by the drum motor via drive belts, feeds the toner through the toner collection tube, and the final coil [D], driven by the toner collection motor [E], feeds the toner to the toner collection bottle.
Page 89 DRUM UNIT June 30, 1998 2.5.6 OTHERS Air Flow Around the Drum A229D565.WMF The exhaust fan [A] located above the fusing unit provides air flow to the charge corona unit to prevent uneven build-up of negative ions that can cause uneven drum surface charge.
Page 90 June 30, 1998 DRUM UNIT Pick-off Mechanism A229D559.WMF The pick-off pawls are always in contact with the drum surface as a result of weak spring pressure. They move from side to side during the copy cycle to prevent drum wear at any particular location. This movement is made via a shaft [A] and an a cam [B].
Page 91 DRUM UNIT June 30, 1998 Quenching A229D556.WMF In preparation for the next copy cycle, light from the quenching lamp [A] neutralizes any charge remaining on the drum. The quenching lamp consists of a line of 16 red LEDs extending across the full width of the drum.
Page 92: Development And Toner Supply
June 30, 1998 DEVELOPMENT AND TONER SUPPLY 2.6 DEVELOPMENT AND TONER SUPPLY 2.6.1 OVERVIEW A229D566.WMF A229D567.WMF • Paddle Roller [A] • Development Filter [G] • Upper Development Roller [B] • Toner Supply Motor [H] • Lower Development Roller [C] • Toner End Sensor [I] •...
Page 93: Development Mechanism
DEVELOPMENT AND TONER SUPPLY June 30, 1998 2.6.2 DEVELOPMENT MECHANISM A229D568.WMF The paddle roller [A] picks up developer and transports it to the upper development roller [B]. Internal permanent magnets in the development rollers attract the developer to the development roller sleeve. The upper development roller carries the developer past the doctor blade [C].
Page 94 June 30, 1998 DEVELOPMENT AND TONER SUPPLY 2.6.3 DRIVE MECHANISM A229D569.WMF The gears of the development unit are driven by the development drive gear [A] when the development motor [B] (a dc servomotor) turns. The gears of the toner hopper are driven by the toner supply roller drive gear [C] when the toner supply clutch [D] activates.
Page 95 DEVELOPMENT AND TONER SUPPLY June 30, 1998 2.6.4 CROSSMIXING A229D570.WMF A229D571.WMF This copier uses a standard cross-mixing mechanism to keep the toner and developer evenly mixed. It also helps agitate the developer to prevent developer clumps from forming and helps create the triboelectric charge. The developer on the turning development rollers [A] is split into two parts by the doctor blade [B].
Page 96: Development Bias
June 30, 1998 DEVELOPMENT AND TONER SUPPLY 2.6.5 DEVELOPMENT BIAS A229D572.WMF To attract negatively charged toner to the black areas of the latent image on the drum, the development power pack [A] applies the negative development bias to the lower sleeve roller through the receptacle [B] and the lower sleeve roller shaft [C].
Page 97: Toner Supply
DEVELOPMENT AND TONER SUPPLY June 30, 1998 2.6.6 TONER SUPPLY Toner Bottle Mechanism A229D575.WMF A229D576.WMF The bottle drive mechanism transports toner from the bottle to the toner supply unit [A]. A worm gear [B] on the toner supply motor [C] drives this mechanism. The toner bottle [D] has a spiral groove that helps move toner to the supply unit.
Page 98 June 30, 1998 DEVELOPMENT AND TONER SUPPLY Toner Supply Mechanism A229D573.WMF When the toner supply clutch [A] turns on, the agitator [B] mixes the recycled toner transported by the air tube [G] with new toner. Then it moves the toner from front to rear and sends it to the toner supply roller.
Page 99 DEVELOPMENT AND TONER SUPPLY June 30, 1998 Toner End Detection A229D574.WMF The toner end sensor [A] detects whether sufficient toner remains in the toner hopper or not. The toner end sensor checks for a toner end condition once when the toner supply clutch turns on. When there is only a small amount of toner inside the toner hopper and pressure on the toner end sensor becomes low, the toner end sensor outputs a pulse signal (once per copy).
Page 100: Toner Density Control
June 30, 1998 DEVELOPMENT AND TONER SUPPLY 2.6.7 TONER DENSITY CONTROL Overview There are two modes for controlling toner supply: sensor control mode and image pixel count control mode. The mode can be changed with SP2-208. The factory setting is sensor control mode. Image pixel count mode should only be used if the TD or ID sensor is defective.
Page 101 DEVELOPMENT AND TONER SUPPLY June 30, 1998 and V detection The ID sensor detects the following voltages. • V : The ID sensor output when checking the drum surface • V : The ID sensor output when checking the ID sensor pattern In this way, the reflectivity of both the drum and the pattern on the drum are checked.
Page 102: Toner End Detection
June 30, 1998 DEVELOPMENT AND TONER SUPPLY 2.6.8 TONER END DETECTION Toner near end and toner end are detected every copy using the toner end sensor and toner supply motor as follows. Toner Near End When the toner end sensor is on for two consecutive pages, the toner supply motor turns on for 1.1s.
Page 103 DEVELOPMENT AND TONER SUPPLY June 30, 1998 2.6.10 ABNORMAL TD SENSOR CONDITIONS The TD sensor is checked every copy. If the reading from the TD sensor becomes abnormal during a copy job, the machine holds the GAIN factor constant to allow toner supply to vary with only the pixel count for the rest of the copy job.
Page 104: Image Transfer And Paper Separation
June 30, 1998 IMAGE TRANSFER AND PAPER SEPARATION 2.7 IMAGE TRANSFER AND PAPER SEPARATION 2.7.1 OVERVIEW A229D501.WMF This model uses a transfer belt unit consists of the following parts: [A] Transfer belt A belt (length: 321 mm) with high electrical resistance which holds a high positive electrical potential to attract toner from the drum to the paper.
Page 105: Image Transfer And Paper Separation Mechanism
IMAGE TRANSFER AND PAPER SEPARATION June 30, 1998 2.7.2 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM The registration rollers [A] feed the paper [B] to the gap between the drum [C] and the transfer belt [D]. A229D507.WMF As soon as the leading edge of the paper reaches the gap between the transfer belt and the drum, the transfer belt lift lever [E] raises the transfer belt into contact with...
Page 106 June 30, 1998 IMAGE TRANSFER AND PAPER SEPARATION After the image transfer is completed, the charge on the transfer belt holds the paper to the transfer belt. After separating the paper from the transfer belt, the transfer belt is discharged by the transfer belt drive roller [A].
Page 107: Transfer Belt Unit Lift Mechanism
IMAGE TRANSFER AND PAPER SEPARATION June 30, 1998 2.7.3 TRANSFER BELT UNIT LIFT MECHANISM A229D506.WMF The transfer belt lift solenoid [A] inside the transfer belt unit turns on to raise the transfer belt into contact with the drum. The front lever [B] and the rear lever [C] are connected to the solenoid by links [D], and they push up the stays [E] when the solenoid turns on.
Page 108: Paper Transportation And Belt Drive Mechanism
June 30, 1998 IMAGE TRANSFER AND PAPER SEPARATION 2.7.4 PAPER TRANSPORTATION AND BELT DRIVE MECHANISM A229D502.WMF The transfer belt is driven by the drum motor [A] through belts and gears. Since the transfer belt electrically attracts the paper [B], a transport fan is not required.
Page 109: Transfer Belt Cleaning Mechanism
IMAGE TRANSFER AND PAPER SEPARATION June 30, 1998 2.7.5 TRANSFER BELT CLEANING MECHANISM A229D504.WMF Some toner may adhere to the transfer belt when paper jams occur, or when the by-pass feed table side fences are set in the wrong position. The adhered toner must be removed to prevent the rear side of the copy paper from getting dirty.
Page 110: Toner Collection Mechanism
June 30, 1998 IMAGE TRANSFER AND PAPER SEPARATION 2.7.6 TONER COLLECTION MECHANISM A229D505.WMF Transfer belt drive is transmitted to the toner collection coil [A] through idle gears [B]. The toner collection coil [C] transports the collected toner to the toner recycling unit [D] and from there it goes to the waste toner collection bottle.
Page 111: Paper Feed
PAPER FEED June 30, 1998 2.8 PAPER FEED 2.8.1 OVERVIEW A229D615.WMF This model has three built-in paper feed trays: tandem feed tray [A] (500 + 500 sheets), universal tray [B] (550 sheets) and built-in LCT [C] (1500 sheets). Paper can also be fed using the by-pass feed table [D] which has an independent feed mechanism.
Page 112 June 30, 1998 PAPER FEED 2.8.2 DRIVE MECHANISM A22916.WMF Paper Feed Motor Paper Feed Clutches 1 to 3 Vertical Relay Clutches 1 to 3 Relay Clutch By-pass Feed Motor By-pass Feed Clutch The paper feed motor [A] drives feed, pick-up, and separation rollers in trays 1, 2, and 3 via timing belts, clutches [B], and gears.
Page 113 PAPER FEED June 30, 1998 2.8.3 TRAY POSITIONING MECHANISM – TRAYS 1 AND 2 A229D618.WMF When the tray is placed in the paper feed unit, the lock lever [A] drops behind the lock plate [B] on the support bracket to lock the tray in the proper position. 2-88...
Page 114 June 30, 1998 PAPER FEED 2.8.4 PAPER LIFT MECHANISM - TRAYS 1 AND 2 A229D604.WMF When the machine detects that the paper tray has been placed in the machine, the lift motor [A] turns on. The coupling gear [B] on the tray lift motor engages the pin [C] on the lift arm shaft [D], then it turns the tray lift arm [E] to lift the tray bottom plate [F].
Page 115 PAPER FEED June 30, 1998 A229D605.WMF A229D606.WMF When the lift motor turns on, the pick-up solenoid [A] activates to lower the pick-up roller [B]. When the top sheet of paper reaches the proper paper feed level, the paper pushes up the pick-up roller and the actuator [C] on the pick-up roller supporter [D] activates the lift sensor [E] to stop the lift motor.
Page 116 June 30, 1998 PAPER FEED 2.8.5 PICK-UP AND FEED MECHANISM – TRAYS 1 TO 3 Overview A229D598.WMF Drive from the paper feed motor is transmitted to the gear [A] in the paper feed unit via the timing belt [B]. Then the gear [A] transmits the drive to the pick-up [C], paper feed [D] and separation [E] rollers via gears and the paper feed clutch [F].
Page 117 PAPER FEED June 30, 1998 Pick-up and Feed A229D600.WMF If a paper feed station is not selected, its separation roller solenoid [A] de-activates and the separation roller [B] can turn freely in the opposite direction to paper feed. When the paper feed station is selected and the start key is pressed, the feed clutch [C], separation roller solenoid [A], and the pick-up solenoid [D] all turn on.
Page 118 June 30, 1998 PAPER FEED Separation Roller Release Mechanism A229D602.WMF The separation roller [A] is normally away from the feed roller [B]. When the paper feed station is selected, the separation roller solenoid [C] contacts the separation roller with the feed roller as explained on the previous two pages. This contact/release mechanism has the following three advantages: 1.
Page 119 PAPER FEED June 30, 1998 Paper Skew Prevention Mechanism A229D603.WMF The paper press arms [A] on each side press down both sides of the paper, especially if the paper is curled. This helps to prevent paper skew or jams. 2-94...
Page 120: Vertical Transport Mechanism
June 30, 1998 PAPER FEED 2.8.6 VERTICAL TRANSPORT MECHANISM A229D617.WMF The vertical transport rollers [A] in each feed unit are all driven by the paper feed motor. The vertical transport rollers and the idle vertical transport rollers [B], on the inner and outer vertical guide plates, transport the paper up from each feed unit towards the relay and registration rollers.
Page 121: Paper Registration
PAPER FEED June 30, 1998 2.8.7 PAPER REGISTRATION Overview A229D595.WMF The registration sensor [A] is positioned just before the registration rollers [B]. When the paper leading edge activates the registration sensor, the registration motor is off and the registration rollers are not turning. However, the relay clutch [C] stays on for a bit longer.
Page 122 June 30, 1998 PAPER FEED Registration Drive Mechanism A229D596.WMF The registration motor [A] drives the lower registration roller [B] through a timing belt [C] and some gears. Drive is transmitted to the upper registration roller [D] via two gears [E] at the front. There is a paper dust remover [F] at the center of the upper registration roller [D].
Page 123 PAPER FEED June 30, 1998 Guide Plate Release Mechanism A229D597.WMF When a paper misfeed occurs between the vertical transport rollers and the registration rollers, the lower paper guide plate [A] automatically opens. When the registration sensor is not activated at a certain jam check timing, the guide plate solenoid [B] turns on.
Page 124 June 30, 1998 PAPER FEED 2.8.8 PAPER NEAR-END/END DETECTION – TRAYS 1 TO 3 A229D607.WMF A229D608.WMF Near-end Detection A feeler [A] on the lift arm shaft rotates counterclockwise as the paper is used up. When about 50 sheets are left on the tray, the feeler activates the paper near end sensor [B].
Page 125 PAPER FEED June 30, 1998 2.8.9 PAPER SIZE DETECTION – TRAY 2 A229D614.WMF L: Lengthwise Paper size S: Sideways Actuated – 0 A4/A3 LT/DLT De-actuated – 1 Version Version 00111 A3-L 11 x 17-L 00011 x 13 x 14-L 10011 A4-L x 11-L 01001...
Page 126 June 30, 1998 PAPER FEED 2.8.10 BUILT IN LCT Paper Tray Lift Mechanism A229D621.WMF Drive from the reversible LCT motor [A] is transmitted through a worm gear [B] to the drive pulley shaft [C]. The tray wires [D] are secured in the slots [E] at the ends of the tray support rods [F] and [G].
Page 127 PAPER FEED June 30, 1998 Tray Lock Mechanism A229D622.WMF When the tray bottom plate starts moving up, the tray lock lever [A] drops into the opening in the base plate to engage the stopper [B], locking the tray in position. This prevents the tray from being pulled out while the bottom plate is up.
Page 128: By-Pass Feed Table
June 30, 1998 PAPER FEED 2.8.11 BY-PASS FEED TABLE Feed Mechanism/Paper End Detection A229D623.WMF A229D624.WMF The by-pass feed table uses an FRR feed system. The by-pass feed motor [A] drives the rollers. The pick-up solenoid [B] drops the pick-up roller onto the top sheet of paper, and the by-pass feed clutch [C] transfers drive from the motor to the feed roller.
Page 129 PAPER FEED June 30, 1998 Table Open/Close Detection A229D593.WMF The by-pass tray switch [A] detects when the by-pass feed table [B] is opened. Then the CPU turns on the by-pass feed indicator on the operation panel. The start key LED remains red until paper is placed on the tray (see the previous page). In this model, opening the by-pass feed table does not shift the copier into interrupt mode.
Page 130 June 30, 1998 PAPER FEED Paper Size Detection A229D594.WMF The by-pass paper size sensor [A] (variable resistor) monitors the paper width. The rear side fence is connected to the by-pass paper size sensor actuator. When the paper side fences [B] and [C] are positioned to match the paper width, the electrical resistance of the sensor changes in accordance with the side fence position, This informs the CPU of the paper width.
Page 131: Tandem Feed Tray
PAPER FEED June 30, 1998 2.8.12 TANDEM FEED TRAY Overview A229D609.WMF 500 sheets of paper can be placed in each of the left [A] and right trays [B]. Paper is fed from the right tray. When the paper in the right tray runs out, the stack in the left tray is automatically moved across to the right tray.
Page 132 June 30, 1998 PAPER FEED Side Fence Drive Mechanism A229D610.WMF A229D611.WMF The side fences [A] of the right tray are normally closed. They open only when the stack of paper in the left tray is being moved across to the right tray. The side fences are driven by the side fence drive motor [B] (a stepper motor).
Page 133 PAPER FEED June 30, 1998 Rear Fence Drive Mechanism A229D612.WMF When the paper end sensor [A] in the left tray detects paper but the paper end sensor in the right tray detects a paper end condition, the rear fence drive motor [B] (a dc motor) in the left tray turns counterclockwise to drive the rear fence [C] to push the paper stack into the right tray.
Page 134 June 30, 1998 PAPER FEED Tray Lock Mechanism A229D613.WMF Normally, the tray lock lever [A] is in the cutout [B] in the left tray [C], locking it in place. During copying, if paper in the left tray runs out, the tandem lock solenoid [D] turns on to release the tray lock lever so that the left tray can be separated from the right tray.
Page 135: Image Fusing
IMAGE FUSING June 30, 1998 2.9 IMAGE FUSING 2.9.1 OVERVIEW A229D518.WMF After the developed latent image is transferred from the drum to the paper, the copy paper enters the fusing unit. Then the image is fused to the copy paper by a heat and pressure process through the use of a hot roller [A] and pressure roller [B].
Page 136: Fusing Entrance Guide
June 30, 1998 IMAGE FUSING 2.9.2 FUSING ENTRANCE GUIDE A229D519.WMF The entrance guide [A] for this machine is adjustable for thick or thin paper. For thin paper, the entrance guide should be in the upper position (this is the standard position). This slightly lengthens the paper path which prevents the paper from creasing in the fusing unit.
Page 137: Fusing Drive Mechanism
IMAGE FUSING June 30, 1998 2.9.3 FUSING DRIVE MECHANISM A229D520.WMF The fusing drive gear [A] transmits drive from the fusing/duplex drive motor [B] to the gear [C], which drives the hot roller gear [D]. Rotation passes from the gear [C] through the idle gear [E] to the exit roller drive gear [F].
Page 138: Fusing Lamp Control
June 30, 1998 IMAGE FUSING 2.9.4 FUSING LAMP CONTROL 200 °C 180 °C 185 °C ➀ : Main switch on ➁ : Process control data initial setting start ➂ : Idling start ➃ : Ready ➀ ➁ ➂ ➃ A229D521.WMF When the main switch is turned on, the CPU turns on the two fusing lamps.
Page 139: Paper Exit/Duplex
PAPER EXIT/DUPLEX June 30, 1998 2.10 PAPER EXIT/DUPLEX 2.10.1 OVERVIEW A229D529.WMF The printed page from the fusing unit goes either straight through to the output tray or finisher, or downward through to the inverter or duplex unit, depending on the position of the junction gate [A].
Page 140: Paper Exit Mechanism
June 30, 1998 PAPER EXIT/DUPLEX 2.10.2 PAPER EXIT MECHANISM A229D537.WMF Paper Exit A229D538.WMF Inverter/Duplex Section A229D539.WMF Drive from the fusing/duplex motor [A] is transmitted to the paper exit roller [B] and transport rollers [C]. The curl correction roller [D] removes the paper curl caused by the fusing unit, to prepare it for the next process (duplexing or finishing).
Page 141: Duplex Drive Mechanism
PAPER EXIT/DUPLEX June 30, 1998 2.10.3 DUPLEX DRIVE MECHANISM A229D528.WMF The duplex drive gear [A] transmits drive from the fusing/duplex drive motor [B] to the duplex unit. The duplex transport clutch [C] transmits this drive to the duplex transport section, and the duplex feed clutch [D] transmits it to the duplex paper feed-out section.
Page 142 June 30, 1998 PAPER EXIT/DUPLEX 2.10.4 INVERTER Feed-in and Jogging A229D540.WMF A229D541.WMF When the paper is fed to the jogger section by the inverter feed roller [A], it pushes down the gate [B]. After the paper passes through the gate [B], the jogger fences [C] move to square the paper.
Page 143 PAPER EXIT/DUPLEX June 30, 1998 Feed-out A229D542.WMF A229D543.WMF After jogging, the reverse roller solenoid [A] energizes to push down the reverse trigger roller [B]. The reverse roller [C] turns counterclockwise continuously, so the paper starts to reverse when the reverse trigger roller is down and catches the paper between the rollers.
Page 144: Duplex Tray Feed Mechanism
June 30, 1998 PAPER EXIT/DUPLEX 2.10.5 DUPLEX TRAY FEED MECHANISM A229D544.WMF In duplex mode, after the paper leaves the inverter, the duplex inverter solenoid [A] switches the junction gate [B] to direct the paper to the duplex tray. The paper is fed through the duplex tray by duplex transport rollers 1 [C] and 2 [D], and the duplex feed roller [E].
Page 145: Basic Duplex Feed Operation
PAPER EXIT/DUPLEX June 30, 1998 2.10.6 BASIC DUPLEX FEED OPERATION To increase the productivity of duplex copying, a non-stacking style duplex mechanism is adopted. This type of mechanism allows more than one page to be processed at once, in a process called ‘interleaving’. Examples of this are given below.
Page 146 June 30, 1998 PAPER EXIT/DUPLEX 2. The first 3 sheets go into the duplex unit. 3. The 4th sheet is fed in. A229D546.WMF 4. The back of the 1st sheet is printed (2nd page). 5. The 4th sheet is printed (7th page). A229D547.WMF 6.
Page 147 PAPER EXIT/DUPLEX June 30, 1998 14. The 3rd sheet (5th and 6th pages) is fed out 15. The back of the 4th sheet (8th page) is printed. 16. The 7th sheet is fed and printed (13th page). A229D583.WMF 17. The back of the 5th sheet (10th page) is printed. 18.
Page 148 June 30, 1998 PAPER EXIT/DUPLEX Longer than A4 / Letter lengthwise The duplex unit can process two sheets of copy paper Example: 8 pages. The number [A] in the illustration shows the order of pages. The number [B] in the illustration shows the order of sheets of copy paper (if shaded, this indicates the second side).
Page 149 PAPER EXIT/DUPLEX June 30, 1998 3. The back of the 1st sheet (2nd page) is printed. 4. The 3rd sheet (5th page) is fed and printed. A229D587.WMF 5. The 1st sheet (1st and 2nd pages) is fed out. 6. The back of the 2nd sheet (4th page) is printed.
Page 150 June 30, 1998 PAPER EXIT/DUPLEX 10. The 3rd sheet (5th and 6th pages printed) is fed out. 11. The back of the 4th sheet (8th page) is printed. 12. The 4th sheet (7th and 8th pages) is fed out. A229D590.WMF 2-125...
Page 151 ENERGY SAVER MODES June 30, 1998 2.11 ENERGY SAVER MODES 2.11.1 OVERVIEW Stand-by Mode Auto Off Enabled? Energy Low Power Saver Key Timer Runs Pressed Energy Saver key Pressed or Copy/ Energy Saver Print Operation Mode Fusing lamp to low temp Energy Saver LED On System 5 V On Operation...
Page 152: Energy Saver Mode
June 30, 1998 ENERGY SAVER MODES 2.11.2 ENERGY SAVER MODE Entering energy saver mode The machine enters energy saver mode when one of the following is done. • The low power timer runs out after the end of a job. NOTE: If the low power timer is 0, the machine will wait for the low power shift timer to run out, and then it will go straight to low power mode (see Low Power Mode).
Page 153: Low Power Mode
ENERGY SAVER MODES June 30, 1998 2.11.3 LOW POWER MODE Entering low power mode The low power shift timer runs out after the end of a job. What happens in low power mode The fusing lamp drops to a certain temperature, that depends on the setting of SP5-920 (the default is 177 °C).
Page 154: Off Mode
June 30, 1998 ENERGY SAVER MODES 2.11.4 OFF MODE Off mode has two separate modes. • Auto Off Mode (Sleep mode) • Weekly Timer Off Mode Off Mode (Sleep Mode) Entering off mode The machine enters off mode when one of the following is done. •...
Page 155 ENERGY SAVER MODES June 30, 1998 Weekly Timer Off Mode Weekly timer The user can program ‘on periods’ and ‘off periods’ for each day of the week. Entering weekly timer off mode The machine enters this mode when: • The auto off timer runs out after the end of a job, and the weekly timer has already reached the start of an off period •...
Page 156 June 30, 1998 ENERGY SAVER MODES 2.11.5 SUMMARY For reference, the following flow chart summarizes the various energy saver modes, and their entry and exit conditions. Any Status Main Power Power Off Main Power Main Power Main Power Switch Off Switch On Operation Switch On...
Page 157: Installation Procedure
June 30, 1998 INSTALLATION REQUIREMENTS 3. INSTALLATION PROCEDURE 3.1 INSTALLATION REQUIREMENTS 3.1.1 ENVIRONMENT 10°C to 32°C (50°F to 89.6°F) 1. Temperature Range: 15% to 80% RH 2. Humidity Range: Less than 1,500 lux (do not expose to direct sunlight 3. Ambient Illumination: or strong light.) Room air should turn over at least 3 times per hour 4.
Page 158: Minimum Space Requirements
INSTALLATION REQUIREMENTS June 30, 1998 3.1.3 MINIMUM SPACE REQUIREMENTS Place the copier near the power source, providing clearance as shown below. The same amount of clearance is necessary when optional equipment is installed. 0 cm, 0" More than More than 10 cm, 4.0"...
Page 159: Accessory Check
June 30, 1998 COPIER (A229) 3.2 COPIER (A229) 3.2.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description Q’ty 1. Model Name Decal (-10, -22 machines) ......1 2. Operation Instructions – English (-10, -22, -26, -29 machines) ..........1 3.
Page 160 COPIER (A229) June 30, 1998 3.2.2 INSTALLATION PROCEDURE CAUTION Rating voltage for Peripherals Make sure to plug the cables into the correct sockets. FINISHER “Rating voltage of Output Connector for Accessory; Max. DC 24 V” “Rating voltage of Output Connector for Accessory; Max.
Page 161 June 30, 1998 COPIER (A229) NOTE: Since the installation procedure is not packed with the copier as an accessory, always bring this manual with you. A229I513.WMF A229I517.WMF A229I518.WMF CAUTION Keep the power cord unplugged when starting the following procedure. NOTE: 1) Keep the shipping retainers after installing the machine. They will be reused if the machine is moved to another location in the future.
Page 162 COPIER (A229) June 30, 1998 A229I520.WMF A229I102.WMF 4. Open the front cover and remove the strips of tape [A]. 5. Remove the blade release pin [B] together with the transfer belt lock plate [C] (1 screw). 6. Pull out the fusing unit. Lower the lever [D], remove the oil supply unit [E], and remove the front and rear clamps [F].
Page 163 June 30, 1998 COPIER (A229) A229I515.PCX A229I160.WMF A229I105.WMF 7. Remove the shutter inner cover [A] (1 screw). 8. Remove the screw [B] securing the toner bottle holder. 9. Swing out the toner bottle holder [C]. 10. Remove the screw [D] that holds the drum stay [E]. 11.
Page 164 COPIER (A229) June 30, 1998 A229I501.WMF A229I529.WMF 12. Disconnect two connectors [A]. 13. Pull out the development unit [B] as shown. NOTE: 1) To prevent scratches on the drum, push the development unit to the right while pulling it out. 2) When pulling out the development unit, do not pull the knob [C].
Page 165 June 30, 1998 COPIER (A229) A229I503.WMF A229I504.WMF A229I505.WMF 16. Pour in one pack of developer [A] while turning the knob [B]. Distribute the developer evenly along the development unit. 17. Attach the toner hopper [C] to the development unit (2 screws). 18.
Page 166 COPIER (A229) June 30, 1998 A229I160.WMF A229I153.WMF 21. Set the toner bottle holder in position (1 screw [A]) and attach the shutter inner cover [B] (1 screw). NOTE: When attaching the shutter cover, make sure that the pin [C] in the shutter engages the stopper [D].
Page 167 June 30, 1998 COPIER (A229) A229I521.WMF 24. Install the original exit tray [A] (3 screws). 25. Connect the ARDF connector [B] to the socket at the rear of the copier. 26. Attach the face up decal [C] to the feed tray as shown. 27.
Page 168 COPIER (A229) June 30, 1998 A229I522.TIF A229I523.TIF 29. Select “Copy SP” [A] on the LCD, and perform the initial setting as follows: 1) Enter “2963” using the numeric keys. 2) Press the “Enter” key. 3) Press the “Start” key [B] on the LCD. NOTE: This SP mode performs the TD initial setting, then the forced toner supply.
Page 169: Paper Size Change
June 30, 1998 PAPER SIZE CHANGE 3.3 PAPER SIZE CHANGE If the customer requests, change the paper size as follows. 3.3.1 550-SHEET PAPER TRAY (TRAY 2) NOTE: At the factory, this tray is set up for A3 or DLT depending on the machine destination code.
Page 170 PAPER SIZE CHANGE June 30, 1998 3.3.2 1,500-SHEET PAPER TRAY (TRAY 3) NOTE: 1) At the factory, this tray is set up for A4 or LT sideways depending on the machine destination code. 2) A protection bracket [A] on the guide rail of the end fence [B] prevents users from putting stacks of paper in the empty space (this would lead to machine damage).
Page 171 June 30, 1998 PAPER SIZE CHANGE A229I525.TIF A229I524.TIF A229I527.TIF 4. Press the “User Tools/Counter” key. 5. Press the “System Settings” key [A]. 6. Press the “Paper Size Setting” key [B], then press the “Tray 3: Paper Size Setting” key [C]. Then press the appropriate paper size key. 7.
Page 172 PAPER SIZE CHANGE June 30, 1998 3.3.3 TANDEM FEED TRAY PAPER SIZE CHANGE (TRAY 1) NOTE: At the factory, this tray is set up for A4 or LT sideways. Only B5, A4, or LT sideways paper can be used for tandem feed. If the user requests other paper sizes than these, this tray will be used as a fixed tray.
Page 173 June 30, 1998 PAPER SIZE CHANGE A229I510.WMF A229I511.WMF 4. Re-install both side fences [A] in the appropriate position for the required paper size, as shown. NOTE: The position of the side fence holders [B] and the pins [C] on the rack gear is different for each paper size (from the outside pin: A4, 11", B5).
Page 174 PAPER SIZE CHANGE June 30, 1998 A229I508.WMF A229I512.WMF - To used as a fixed tray for paper longer than A4/Letter sideways - 1. Draw out the tandem feed tray. 2. Remove the rear and the front side fences [A] (1 screw and 1 push-lock pin each) on the right tandem tray.
Page 175 June 30, 1998 PAPER SIZE CHANGE A229I511.WMF 5. Change the position of the front and rear side fences [A] (2 screws each) and end fence [B] (2 screws) of the left tandem tray to match the required paper size. 6. Enter System Settings in User Tools, and select the paper size that you just set the fences up for.
Page 176 PAPER SIZE CHANGE June 30, 1998 3.3.5 CHANGING THE UNIVERSAL TRAY PAPER-SIZE At the factory, the universal paper tray is set to A4/8 " x 11" sideways. Normally, the customer changes the paper size by following the operating instructions. Only when the customer needs A5/5 "...
Page 177 June 30, 1998 LCT (A698) 3.4 LCT (A698) 3.4.1 ACCESSORY CHECK Check the accessories in the box against the following list. Description Q'ty 1. LCT Feed Unit ..............1 2. Small Cap - Left Cover ............1 3. Tapping Screw - M4 x 8............3 4.
Page 178 LCT (A698) June 30, 1998 3.4.2 INSTALLATION PROCEDURE A698I501.WMF A698I500.WMF A698I502.WMF A698I503.WMF CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape [A]. 2. Open the LCT cover [B] and remove the tape [C] that holds the paper trailing edge stopper.
Page 179 June 30, 1998 LCT (A698) A698I504.WMF A698I505.WMF A698I506.WMF 5. Remove the feed unit cover [A] (2 screws) and free the LCT connectors [B]. 6. Remove the shipping retainers [C]. 7. Install the LCT feed unit [D] in the copier (3 screws - M4 x 8). 3-23...
Page 180 LCT (A698) June 30, 1998 A698I507.WMF A698I508.WMF 8. Attach the LCT connector [A] to the copier. 1) Remove the three caps [B]. 2) Fit the two pins [C] on the LCT connector into the two holes [D] in the copier. 3) Attach the LCT connector to the copier (3 screws - M4 x 16).
Page 181 June 30, 1998 LCT (A698) A698I509.WMF A698I510.WMF 11. Hold the upper stay [A] of the LCT and place the LCT on the bottom plates [B] of the LCT connector. CAUTION Place the LCT on the bottom plates [B] of the LCT connector properly (the sides of the LCT and the copier must be parallel).
Page 182 LCT (A698) June 30, 1998 A698I511.WMF A698I512.WMF 15. Connect the connectors. • Between the copier and the LCT (2 connectors). • Between the LCT and the LCT feed unit (2 connectors). 16. Secure the protective earth wire [A] to the copier (1 screw – M4 x 6). 17.
Page 183 June 30, 1998 3,000-SHEET FINISHER (A697) 3.5 3,000-SHEET FINISHER (A697) 3.5.1 ACCESSORY CHECK Check the accessories in the box against the following list. Description Q’ty Description Q’ty 1. Front Joint Bracket......1 9. Tapping Screw – M4 x 14....4 2. Rear Joint Bracket ......1 10.
Page 184 3,000-SHEET FINISHER (A697) June 30, 1998 3.5.2 INSTALLATION PROCEDURE A697I506.WMF A697I507.WMF CAUTION Unplug the main machine’s power cord before starting the following procedure. 1. Unpack the finisher and remove the tapes. 3-28...
Page 185 June 30, 1998 3,000-SHEET FINISHER (A697) A697I502.WMF 2. Remove the four plastic caps [A] from the copier’s left cover. 3. Remove the connector cover [B]. 4. Install the front joint bracket [C] and rear joint bracket [D] (2 screws – M4 x 14 each).
Page 186 3,000-SHEET FINISHER (A697) June 30, 1998 A229I534.WMF A697I511.WMF A229I528.WMF 7. Attach the cushion [A] to the plate as shown. 8. Install the entrance guide plate [B] (2 screws). 9. Open the front door of the finisher, and remove the screw [C] which secures the locking lever [D].
Page 187: Punch Unit Installation (A812)
June 30, 1998 PUNCH UNIT INSTALLATION (A812) 3.6 PUNCH UNIT INSTALLATION (A812) 3.6.1 ACCESSORY CHECK Check the accessories in the box against the following list. Description Q’ty 1. Spacer –2 mm ..............1 2. Spacer – 1 mm ..............2 3. Stepped Screw – Short............1 4.
Page 188: Punch Unit Installation
PUNCH UNIT INSTALLATION (A812) June 30, 1998 3.6.2 PUNCH UNIT INSTALLATION A812I500.WMF A812I501.WMF CAUTION Unplug the copier power cord and remove the 3,000-sheet finisher from the copier before starting the following procedure. 1. Unpack the punch unit and remove the shipping retainers [A] (4 screws) and [B] (1 screw).
Page 189 June 30, 1998 PUNCH UNIT INSTALLATION (A812) A812I502.WMF A812I503.WMF 4. Install the spacer [A] (thickness = 2 mm). NOTE: There are three spacers in the accessory box. Do not lose the other two spacers (1 mm), because they are used for adjusting the punch hole position.
Page 190 PUNCH UNIT INSTALLATION (A812) June 30, 1998 A812I504.WMF A812I505.WMF A812I506.WMF 8. Install the sensor bracket [A] (1 short stepped screw, 1 spring). 9. Connect the cables [B]. NOTE: 1) The cable binders [C] must not be between the cable clamps [D]. 2) The cable binder [E] must be positioned to the left of the cable clamp.
Page 191 June 30, 1998 OUTPUT TRAY (A814) 3.7 OUTPUT TRAY (A814) 3.7.1 ACESSORY CHECK Check the accessories in the box against the following list. Description Q’ty 1. Output Tray................1 2. Tray Paper Limit Sensor Feeler ...........1 3. Feeler Securing Bracket ............1 4.
Page 192 OUTPUT TRAY (A814) June 30, 1998 3.7.2 OUTPUT TRAY INSTALLATION PROCEDURE A814I502.WMF A814I501.WMF A814I500.WMF 1. Remove the left cover [A] (2 screws). 2. Attach the sensor feeler [B] to the feeler securing bracket [C], and install it in the copier as shown (1 screw). 3.
Page 193: Key Counter Installation
June 30, 1998 KEY COUNTER INSTALLATION 3.8 KEY COUNTER INSTALLATION A229I532.WMF A229I531.WMF A229I530.WMF 1. Hold the key counter plates [A] on the inside of the key counter bracket [B] and insert the key counter holder [C]. 2. Secure the key counter holder to the bracket (2 screws). 3.
Page 194: Service Tables
June 30, 1998 GENERAL CAUTIONS 4. SERVICE TABLES 4.1 GENERAL CAUTIONS Do not turn off either of the power switches while any of the electrical components are active. Doing so might cause damage to units such as the transfer belt, drum, and development unit when they are pulled out of or put back into the copier.
Page 195: Laser Unit
GENERAL CAUTIONS June 30, 1998 4.1.3 TRANSFER BELT UNIT 1. Never touch the transfer belt surface with bare hands. 2. Take care not to scratch the transfer belt, as the surface is easily damaged. 3. Before installing the new transfer belt, clean all the rollers and the inner part of the transfer belt with a dry cloth to prevent the belt from slipping.
Page 196: Charge Corona
June 30, 1998 GENERAL CAUTIONS 4.1.6 CHARGE CORONA 1. Clean the corona wires with a dry cloth. Do not use sandpaper or solvent. 2. Clean the charge corona casing with water first to remove NOx based compounds. Then clean it with alcohol if any toner still remains on the casing. 3.
Page 197: Used Toner
GENERAL CAUTIONS June 30, 1998 4.1.8 CLEANING 1. When servicing the cleaning section, be careful not to damage the edge of the cleaning blade. 2. Do not touch the cleaning blade with bare hands. 3. Before disassembling the cleaning section, place a sheet of paper under it to catch any toner falling from it.
Page 198: Service Program Mode Operation
June 30, 1998 SERVICE PROGRAM MODE 4.2 SERVICE PROGRAM MODE 4.2.1 SERVICE PROGRAM MODE OPERATION The service program (SP) mode is used to check electrical data, change modes, and adjust values. Service Program Access Procedure Entering SP mode 1) Press the following keys in sequence. !"→"#"→"$"→"%"→"&...
Page 199 SERVICE PROGRAM MODE June 30, 1998 3) Touch the application which you need. Then, the application’s SP mode display will appear, as shown. A229M501.TIF Exiting SP mode 1) Touch the “Exit” keys to return to the standby mode display.
Page 200 June 30, 1998 SERVICE PROGRAM MODE Accessing Copy Mode from within an SP Mode 1) Touch the “Copy Mode” key. A229M502.TIF 2) Select the appropriate copy mode and make trial copies. 3) To return to the SP mode, touch the “SP mode” key. A229M503.TIF...
Page 201 SERVICE PROGRAM MODE June 30, 1998 Selecting the Program Number Program numbers are composed of two or three levels. There are two ways to select the program number. Ten-key Pad Input the required program number. Touch Panel 1. Touch the 1st level program. A229M501.TIF 2.
Page 202 June 30, 1998 SERVICE PROGRAM MODE Inputting a Value or Setting for an SP Mode 1. Select the required program mode as explained on the previous page. 2. Enter the required setting using the ten-key pad, then touch the “Start” key or OK key or ' key.
Page 203: Service Program Mode Tables
SERVICE PROGRAM MODE June 30, 1998 4.2.2 SERVICE PROGRAM MODE TABLES NOTE: 1) In the Function column, comments are in italics. 2) In the Settings column, the default value is in bold letters. 3) An asterisk ( * ) in the right hand side of the mode number column means that this mode is stored in the NVRAM.
Page 204 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 1-002 Side-to-Side Registration By-pass Tray Adjusts the printing side-to-side +9 ~ -9 registration from the by-pass feed table mm/step using the trimming area pattern (SP2-902- + 0.0 mm 3, No.10).
Page 205 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 1-105 Fusing Temperature Adjustment By-pass Adjusts the fusing temperature for paper 170 ~ 200 fed from a by-pass tray. 1°C/step 185° ° ° ° C Adjusts the fusing temperature for OHP +10 ~ -10°C sheets fed from the by-pass feed unit.
Page 206 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 2-001 Charge Corona Bias Adjustment Total Corona Adjusts the current applied to the charge -900 ~ -1500 10 µA/step Current corona wire. –1200 µ...
Page 207 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 2-109 Laser Beam Pitch Adjustment 400 dpi Adjusts the laser beam pitch value for 400 0 ~ 262 dpi resolution. pulses/step After replacing the LD unit or replacing or clearing the NVRAM, use this SP mode and SP2-109-3 to adjust the laser beam...
Page 208 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 2-201 Development Bias Adjustment Image Area Adjusts the development bias for copying. -200 ~ -700 10 V/step -550 V This can be adjusted as a temporary measure if faint copies appear due to an aging drum.
Page 209 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 2-220 Manual Setting Adjusts the TD sensor reference voltage 1.60 ~ 3.50 0.01V/step 2.5 V Change this value after replacing the development unit with another one that already contains toner.
Page 210 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 2-506 Cleaning Interval – Multiple Copy Operation Selects whether multiple copy jobs are 1 : No stopped at regular intervals for the 2 : Yes following purposes.
Page 211 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 2-909 Main Scan Magnification Copier Adjusts the magnification in the main scan - 2.0 ~+ 2.0 direction for copy mode. 0.1 %/step + 0.0 % Use the “...
Page 212 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 2-962 Auto Process Control Automatically adjusts the following process Start control factors. 1. ID sensor 2. Drum potential sensor 3. Charge grid voltage (by changing V 4.
Page 213 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 2-965 Toner Pump Adjustment Aggregate of Factory use only Toner Waste 3-001 ID Sensor PWM Setting ID Sensor This SP mode is added to recover the 0 ~ 255 PWM Setting machine when an SC condition occurs...
Page 214 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-008 Scanner Main Scan Magnification * Adjusts the magnification in the sub scan - 0.9 ~ + 0.9 direction for scanning. 0.1 %/step If this value is changed, the scanner motor + 0.0 %...
Page 215 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-301 APS Sensor Output Display Displays the APS sensor output signals 00000000 when an original is placed on the exposure glass. 0: Not Bit 0: Width sensor 1 detected...
Page 216 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-901 SBU Adjustment Digital Gain * Checks the AGC gain value of the white 0 ~ 1 Adjustment – level for the EVEN channel after adjusting 1/step E ch the white level at power-up.
Page 217 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-901 SBU Adjustment Time Out Flag Checks the time out flag data during the TIME automatic scanner adjustment. OUT/SGDO This SP mode is for designer use only. = 0000 Error Flag Checks the error flag data during the...
Page 218 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-903 Filter Setting MTF Filter in * Selects the MTF filter coefficient for photo 0 ~ 4 Photo Mode mode, if MTF is enabled for this mode with 1/step SP 4-904-3.
Page 219 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-903 Filter Setting Filter Strength * Selects the MTF strength in the main scan 0: x 0.25 (257% ~ 400%) 1: x 0.5 direction for 257% ~ 400% enlargement for text mode.
Page 220 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-903 Filter Setting MTF Filter * Selects the MTF filter coefficient in the sub 0 ~ 11 Level scan direction for 155% ~ 256% 1/step enlargement for text mode.
Page 221 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-904 IPU Setting -1 Laser Pulse * Selects whether or not laser pulse 0: Off 1: On Positioning in positioning control is used in text and Text and text/photo modes Text/Photo...
Page 222 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-904 IPU Setting -1 Binary Thresh * Not used in this machine 0 ~ 255 Level 1/step Binary Dither * Not used in this machine 0: 70 (8x8) Pattern 1: 95 (6x6)
Page 223 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-908 Text/Photo Separation Method 0: Letter and * Select the text/photo separation processing type during the auto text/photo separation photo filters stage.
Page 224 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-909 IPU Setting - 2 Image Data Selects one of the following video data outputs, which will be Path - Printing used for printing.
Page 225 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-912 Text/Photo Separation Setting MTF Filter * Selects the strength of the MTF filter (sub 0 ~ 7 (Sub Scan) – scan) for edge detection in text/photo 1/step Edge...
Page 226 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 4-912 Text/Photo Separation Setting L. Max. * This SP mode is for designer use only. 0 ~ 255 Thresh Level 1/step (Main Scan) –...
Page 227 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 5-112 Non-standard Paper Selection * Selects whether a non-standard paper size can be input for tray 2 (universal tray) or not. If “1”...
Page 228 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 5-504 Jam Alarm Level(RSS function) Jam Auto Call * Japanese version only. 0: Off (RSS function) Do not change the values. 1: On 5-505 Error Alarm Level...
Page 229 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 5-802 Printer Free Run * Performs a free run. The scanner scans once and the printer prints for the number of copies requested.
Page 230 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 5-821 CSS PI Device Code * Japanese version only. 0 ~ 4 Do not change the value. 1/step 5-822 Server Data Clear * Clears all archive file data stored in the Start HDD.
Page 231 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 5-990 SMC Print Copy Program Prints the Copy Mode list (UP Mode No.10) Start No. 10 See the "System Parameter and Data Lists" section for how to print the lists.
Page 232 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 6-105 Stapling Position Adjustment * Adjusts the stapling position in the main - 1~ +3.5 scan direction 0.5 mm/step +0.0 mm Use the “...
Page 233 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-001 Main Motor (Drum Motor) Operation Time * Displays the total drum rotation time. Min. 7-002 Original Counter Total * Displays the total number of fed originals. Copy * Displays the total number of fed originals in copy mode.
Page 234 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-202 Original Counter By Size * Displays the total number of scanned * originals by original size. Other Sizes 7-204 Copy Counter – Paper Tray 1st Paper Tray * Displays the total number of sheets fed from 2nd Paper...
Page 235 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-304 Total Copies By Copy Mode Combine * Displays the total number of prints by copy Erase Copy * mode. Duplex Copy Double 2-sided Original...
Page 236 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-321 Copy Server : Each Size of Original Other Size 7-323 Copy Server : Each Size of Cpies A4 Sideways * Displays the total number of prints made A5 Sideways * from the copy server by paper size.
Page 237 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-328 Copy Server : Copy Number of Each Job Duplex Copy * Displays the total number of duplex prints of one-sided originals from the copy server. Duplex * Display the total number of prints of two- Original...
Page 238 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-333 Tandem : Copy Number of Each Slave Mode Original Mode * Japanese version only : Generation Original Mode : Pale Punch Repeat Sort...
Page 239 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-504 Copy Jam Counter by Jam Location At Power On * Displays the total number of copy jams by location. These are jams when the paper does not activate the sensor.
Page 240 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-504 Copy Jam Counter by Jam Location Entrance * Displays the total number of copy jams by Sensor - PP location. Proof Tray * These are jams when the paper does not Exit Sensor -...
Page 241 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-505 Original Jam Counter by Jam Location At Power On * Displays the total number of original jams by location. ADF Feed-in * (Entrance and Registration Sensor) Sensor ADF Feed-out...
Page 242 June 30, 1998 SERVICE PROGRAM MODE Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-801 ROM Version Display Main Displays the ROM versions. MAIN: LCDC: SIB: HDC: CSS (P1) BAN: Options Displays the ROM versions. ADF: FIN: Print Post (Mailbox):...
Page 243 SERVICE PROGRAM MODE June 30, 1998 Mode No. Function Settings (Class 1 , 2 & & & & 3) 7-902 SC Details Latest Displays details about latest SCs. Not all Latest 1st SCs have these details. Latest 2nd 7-904 Copy Counter Reset – Copy Mode Resets all counters of SP7-304.
Page 244 June 30, 1998 SERVICE PROGRAM MODE 4.2.3 TEST PATTERN PRINTING (SP2-902) NOTE: Do not operate the machine until the test pattern is printed out completely. Otherwise, an SC may occur. 1. Access the SP mode which contains the test pattern you need. 2.
Page 245: Input Check
SERVICE PROGRAM MODE June 30, 1998 4.2.4 INPUT CHECK Main Machine Input Check (SP5-803) 1. Access SP mode. 2. Select the class 3 SP number which will access the switch or sensor you wish to check. 3. Check the status of the sensor or switch. NOTE: If you wish to change to another class 3 level, press the “Next”...
Page 246 June 30, 1998 SERVICE PROGRAM MODE Reading Class 3 no. Bit no. Description Left Tandem Paper End Not paper end Paper end Sensor (Paper Feed Right Tandem Tray Set Not set Detection 2 (Connector) 1st Paper Feed Sensor Paper detected No paper (Paper Feed 2nd Paper Feed Sensor...
Page 247 SERVICE PROGRAM MODE June 30, 1998 Reading Class 3 no. Bit no. Description Dip Switch – 8 (I/O Board Dip Switch 101) Dip Switch – 7 Dip Switch – 6 Dip Switch – 5 Dip Switch – 4 Dip Switch – 3 Dip Switch –...
Page 248 June 30, 1998 SERVICE PROGRAM MODE Reading Class 3 no. Bit no. Description LCT Paper Height 2 Not detected Detected Sensor (LCT2) LCT Paper Height 3 Not detected Detected Sensor LCT Near End Sensor Not detected Near end LCT Paper Feed Sensor Paper detected Paper end LCT Paper Position...
Page 249 SERVICE PROGRAM MODE June 30, 1998 ADF Input Check (SP6-007) Class 3 no. Bit no. Description Reading Original Set Sensor No Original Original detected Original Width Sensor 1 No Original Original detected Original Width Sensor 2 No Original Original detected Original Width Sensor 3 No Original Original...
Page 250: Output Check
June 30, 1998 SERVICE PROGRAM MODE 4.2.5 OUTPUT CHECK NOTE: Motors keep turning in this mode regardless of upper or lower limit sensor signals. To prevent mechanical or electrical damage, do not keep an electrical component on for a long time. Main Machine Output Check (SP5-804) 1.
Page 251: System Parameter And Data Lists (Smc Lists)
SERVICE PROGRAM MODE June 30, 1998 Description Description Stapler Junction Gate Solenoid Laser Diode (Finisher) Positioning Roller Solenoid Not used (Finisher) Not used Tray Lift Motor (Finisher) Mechanical Counter Jogger Motor (Finisher) Upper Transport Motor (Finisher) Stapler Motor (Finisher) Lower Transport Motor (Finisher) Stack Feed-out Belt Motor (Finisher) Shift Tray Exit Motor (Finisher)
Page 252: Memory All Clear (Sp5-801)
June 30, 1998 SERVICE PROGRAM MODE 4.2.7 MEMORY ALL CLEAR (SP5-801) NOTE: Memory All Clear mode resets all the settings stored in the NVRAM to their default settings except the following: • Electrical total counter value (SP7-003-1) • Machine serial number (SP5-811) •...
Page 253: Software Reset
SERVICE PROGRAM MODE June 30, 1998 4.2.8 SOFTWARE RESET The software can be reset when the machine hangs up. Use the following procedure. Either Turn the main power switch off and on. Hold down the “#” key and “.” key at the same time for over 10 seconds. 4.2.9 SYSTEM SETTING AND COPY SETTING (UP MODE) RESET System Setting Reset The system settings in the UP mode can be reset to their defaults using the...
Page 254: Program Download
June 30, 1998 PROGRAM DOWNLOAD 4.3 PROGRAM DOWNLOAD In this machine, the SBICU software is upgraded using a flash memory card. There are two program download procedures. One downloads from the flash memory card to the SBICU. The other downloads from the SBICU to a flash memory card.
Page 255 PROGRAM DOWNLOAD June 30, 1998 5. Touch “Install”. The machine erases the current software, then writes the new software to the SBICU. This takes about 200 seconds. Display during erasing A229M508.TIF Display during writing A229M509.TIF Display when the download is complete A229M510.TIF If downloading failed, an error message appears on the display.
Page 256 June 30, 1998 PROGRAM DOWNLOAD Download from SBICU to Flash Memory Card A229R120.WMF 1. Turn off the main power switch. 2. Remove the flash memory card cover [A]. 3. Plug the flash memory card [B] into the card slot. NOTE: Make sure that the surface printed “A” faces upwards. 4.
Page 257: User Program Mode
USER PROGRAM MODE June 30, 1998 4.4 USER PROGRAM MODE The user program (UP) mode is accessed by users, and by sales and service staff. UP mode is used to input the copier’s default settings. 4.4.3 HOW TO ENTER AND EXIT UP MODE Press the User Tools button, then select the UP mode program.
Page 258 June 30, 1998 USER PROGRAM MODE Copy Features Table Item Detail General Auto Paper Select Priority Features 1/3 Auto Paper Select Tray Display Auto Image Density Priority Original Mode Priority Original Mode Display Original Mode Quality Level Text Text/Photo Photo Pale Generation Original Image Density Level...
Page 259 USER PROGRAM MODE June 30, 1998 Item Detail Cover Mode Page Format Copy Back Cover Front Margin : Left/Right Back Margin : Left Right Front Margin : Top/Bottom Back Margin : Top/Bottom 1→2 Duplex Auto Margin Adjust Ease Border Combine Original Shadow Erase Page Format Erase Center Repeat Separation Line...
Page 260: Image Quality Setting By Up Mode
June 30, 1998 USER PROGRAM MODE 4.4.5 IMAGE QUALITY SETTING BY UP MODE The ‘Original Mode Quality Level in Copy Features’ UP mode is related to the ‘MTF Filter Settings’ SP mode. Soft N o r m a l S h a r p SP Mode Changed Text P h o t o M o d e...
Page 261 USER PROGRAM MODE June 30, 1998 Magnification Ratio: 65 − 154% MTF Filter Strength Strong Weak Normal UP mode Sharp Soft Coefficient Level – Main Scan SP4-903-012 Coefficient Level – Sub Scan SP4-903-042 Strength Level – Main Scan SP4-903-021 Strength Level – Sub Scan SP4-903-051 Magnification Ratio: 155 −...
Page 262 June 30, 1998 USER PROGRAM MODE Text/Photo Mode Text areas and photo areas in text/photo mode use different filters. However, the filter for text areas is used for the entire image (including photo areas) if the magnification ratio is 110% or more. (This threshold magnification ratio of 110% can be changed with SP4-912-018.) Text areas Magnification Ratio: 32 −...
Page 263 USER PROGRAM MODE June 30, 1998 Magnification Ratio: 32 – 109 % (Photo areas, and all areas when the user selects Photo Mode) Smoothing Smoothing Smoothing Filter Type none Strong Medium Weak Strong Medium Weak Filter Strength •Normal UP Mode •Text mode •Photo mode (all areas)
Page 264 June 30, 1998 USER PROGRAM MODE Pale Mode Magnification Ratio: 32 − 64% MTF Filter Strength Strong Weak UP mode Sharp Normal Soft Coefficient Level SP4-903-018 Magnification Ratio: 65 − 109% MTF Filter Strength Strong Weak UP mode Sharp Normal Soft Coefficient Level SP4-903-018...
Page 265 USER PROGRAM MODE June 30, 1998 Generation Mode Magnification Ratio: 32 − 64% MTF Filter Strength Strong Weak UP mode Sharp Normal Soft Coefficient Level SP4-903-019 Magnification Ratio: 65 − 109% MTF Filter Strength Strong Weak UP mode Sharp Normal Soft Coefficient Level SP4-903-019...
Page 266: Test Points/Dip Switches/Leds
June 30, 1998 TEST POINTS/DIP SWITCHES/LEDS 4.5 TEST POINTS/DIP SWITCHES/LEDS 4.5.3 DIP SWITCHES ADF Main Board DPS101 Description Normal operating mode Free run: one-sided original, thin mode, with originals Free run: one-sided original, with originals Free run: one-sided original, no originals Free run: two-sided original, with original Free run: two-sided original, no original Motor test...
Page 267: Variable Resistors
TEST POINTS/DIP SWITCHES/LEDS June 30, 1998 4.5.5 FUSES Number Description FU101 Protects the ac input line. FU102 Protects +24V FU103 Protects +24V FU104 Protects +24V FU105 Protects +24V FU106 Protects +24V FU107 Protects +24V FU108 Protects +24V FU109 Protects +12V FU110 Protects +5V FU111...
Page 268: Special Tools And Lubricants
June 30, 1998 SPECIAL TOOLS AND LUBRICANTS 4.5.7 LEDS BICU Number Monitored Signal LED102 Blinking : Normal Stays on or off : CPU defective LED103 Turns on when the main power switch on. LED104 Blinking : Normal Stays on or off : HDD abnormal LED105 Off : Normal LED106...
Page 269: Preventive Maintenance Schedule
June 30, 1998 PM TABLE 5. PREVENTIVE MAINTENANCE SCHEDULE 5.1 PM TABLE NOTE: The amounts mentioned as the PM interval indicate the number of prints, unless stated otherwise. Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect 150K 300K 450K NOTE SCANNER/OPTICS...
Page 270 PM TABLE June 30, 1998 150K 300K 450K NOTE Toner Bottle Holder Dry cloth or vacuum cleaner Toner Hopper Entrance Dry cloth PAPER FEED (Main frame and by-pass tray) Registration Rollers Water or alcohol Relay Roller Water or alcohol Paper Dust Remover Dry cloth Paper Feed Roller (by- Replace the pick-up, feed, and...
Page 271 June 30, 1998 PM TABLE 150K 300K 450K NOTE Oil Supply Roller Replace these parts as a set. Oil Supply Cleaning Roller Cleaning Roller Brush Dry cloth (EU only) Cleaning Roller Support Replace if out of shape Plate Fusing Entrance and Exit Clean with water or alcohol Guide Plates Transport/Exit Rollers...
Page 272 PM TABLE June 30, 1998 150K 300K 450K NOTE 3,000-SHEET FINISHER Rollers Clean with water or alcohol. Brush Roller Replace if necessary. Discharge Brush Clean with a dry cloth. Sensors Blower brush Jogger Fences Replace if necessary. Punch Waste Hopper Empty the hopper.
Page 273: Replacement And Adjustment
June 30, 1998 EXTERIOR 6. REPLACEMENT AND ADJUSTMENT CAUTION Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. 6.1 EXTERIOR 6.1.1 FRONT Front Door A229R638.WMF 1. Open the front door [A]. 2.
Page 274 EXTERIOR June 30, 1998 6.1.2 RIGHT A229R639.WMF Paper Feed Cover 1. Remove the paper feed cover [A] (2 screws). Upper Right Cover 1. Remove the paper feed cover [A] (2 screws). 2. Remove the upper right cover [B] (2 screws). Lower Right Cover 1.
Page 275 June 30, 1998 EXTERIOR 6.1.3 LEFT A229R640.WMF Upper Left Cover 1. Remove the upper left cover [A] (2 screws). Lower Left Cover 1. Remover the lower left cover [B] (2 screws). NOTE: When re-installing the covers, put the hooks in the holes in the frame.
Page 276 EXTERIOR June 30, 1998 6.1.4 REAR A229R641.WMF Upper Rear Cover 1. Turn off the main switch. 2. Disconnect the ADF connector [A]. 3. Remove the upper rear cover [B] (2 screws). Lower Rear Cover 1. Turn off the main switch. 2.
Page 277: Cover Removal
June 30, 1998 DOCUMENT FEEDER 6.2 DOCUMENT FEEDER 6.2.1 COVER REMOVAL A806R101.WMF Front Cover Removal 1. Remove the front cover [A] (2 screws). Rear Cover Removal 2. Remove the rear cover [B] (2 screws). Left Cover Removal 1. Remove the front cover. 2.
Page 278 DOCUMENT FEEDER June 30, 1998 A806R102.WMF Original Tray Removal 1. Remove the front and rear covers. 2. Remove the original tray [A] (4 screws). Upper Cover Removal 1. Remove the front and rear covers 2. Remove the original tray. 3. Remove the upper cover [B] (2 screws). Bottom Plate Removal 1.
Page 279: Feed Unit Removal And Separation Roller Replacement
June 30, 1998 DOCUMENT FEEDER 6.2.2 FEED UNIT REMOVAL AND SEPARATION ROLLER REPLACEMENT A806R103.WMF 1. Open the left cover. 2. Remove the clip [A]. 3. Remove the feed unit [B]. (Pull the feed unit to the front, release the shaft at the rear, and release the front bushing.) 4.
Page 280: Feed Belt Replacement
DOCUMENT FEEDER June 30, 1998 6.2.3 FEED BELT REPLACEMENT A806R104.WMF A806R113.WMF 1. Remove the feed unit. 2. Remove the pick-up roller unit [A]. 3. Remove the feed belt holder [B]. NOTE: The springs [C] come off the feed belt cover easily. 4.
Page 281: Pick-Up Roller Replacement
June 30, 1998 DOCUMENT FEEDER 6.2.4 PICK-UP ROLLER REPLACEMENT A806R114.WMF 1. Open the left cover. 2. Remove the two snap rings [A]. 3. Remove the two bushings [B]. 4. Replace the pick-up roller [C]. NOTE: When reinstalling the pick-up roller, make sure that the one-way clutch [D] is not at the gear side.
Page 282: Sensor Replacement
DOCUMENT FEEDER June 30, 1998 6.2.5 SENSOR REPLACEMENT Entrance and Registration Sensors A806R105.WMF A806R106.WMF Entrance Sensor 1. Remove the left cover. 2. Remove the guide plate [A] (5 screws). 3. Replace the entrance sensor [B] (1 connector). Registration Sensor 1. Release the transport belt unit [C]. 2.
Page 283 June 30, 1998 DOCUMENT FEEDER Width Sensor A806R107.WMF 1. Remove the feed unit. 2. Remove the front cover. 3. Remove the stopper screw [A]. 4. Remove the guide plate [B] (2 screws). 5. Release the front end of the upper transport roller [C] (1 bushing, 1 E-ring). 6.
Page 284 DOCUMENT FEEDER June 30, 1998 Exit Sensor and Inverter Sensor A806R109.WMF A806R108.WMF Exit Sensor 1. Remove the front and rear covers. 2. Remove the exit guide unit [A] (4 screws). 3. Replace the exit sensor [B] (1 connector). NOTE: When reinstalling the exit guide unit, make sure that the guide plate [C] on the exit unit is over the exit gate [D].
Page 285: Transport Belt Replacement
June 30, 1998 DOCUMENT FEEDER 6.2.6 TRANSPORT BELT REPLACEMENT A806R110.WMF A806R111.WMF A806R112.WMF 1. Remove the front cover. 2. Remove the lower two screws [A] securing the transport belt assembly [B]. 3. Remove the upper four screws [C] securing the transport belt assembly. 4.
Page 286: Scanner Unit
SCANNER UNIT June 30, 1998 6.3 SCANNER UNIT 6.3.1 EXPOSURE GLASS A229R657.WMF 1. Open the ADF. 2. Remove the rear scale [A] (3 screws). 3. Remove the left scale [B] (2 screws). 4. Remove the exposure glass [C]. NOTE: When reinstalling the exposure glass, make sure that the mark [D] is positioned at the rear left corner, as shown.
Page 287: Operation Panel
June 30, 1998 SCANNER UNIT 6.3.2 OPERATION PANEL A229R675.WMF 1. Remove the operation panel [A] (2 screws, 1 connector). 6-15...
Page 288: Lens Block
SCANNER UNIT June 30, 1998 6.3.3 LENS BLOCK A229R659.WMF 1. Remove the exposure glass. (See Exposure Glass.) 2. Remove the lens cover [A] (12 screws). 3. Replace the lens block assembly [B] (2 screws, 3 connectors). 4. Do the scanner and printer copy adjustments. (See Replacement and Adjustment –...
Page 289: Original Size Sensors
June 30, 1998 SCANNER UNIT 6.3.4 ORIGINAL SIZE SENSORS A229R658.WMF 1. Remove the exposure glass. (See Exposure Glass.) 2. Remove the original width sensor [A] (1 screw, 1 connector). 3. Remove the lens cover [B] (12 screws). 4. Remove the original length sensors [C] (1 screw and 1 connector each). 6-17...
Page 290: Exposure Lamp
SCANNER UNIT June 30, 1998 6.3.5 EXPOSURE LAMP A229R670.WMF 1. Remove the ADF. 2. Remove the scanner rear cover. (See Scanner Wire.) 3. Remove the exposure glass. (See Exposure Glass.) 4. Slide the 1st scanner [A] to the cutout [B] in the rear scanner frame. 5.
Page 291: Scanner H.p Sensor
June 30, 1998 SCANNER UNIT 6.3.6 SCANNER H.P SENSOR A229R671.WMF 1. Remove the operation panel. (See Operation Panel.) 2. Open the front door and swing out the toner bottle. 3. Remove the operation panel bottom cover [A] (4 screws – see Scanner Wire). 4.
Page 292 SCANNER UNIT June 30, 1998 6.3.7 SCANNER MOTOR/SCANNER MOTOR DRIVE BOARD A229R672.WMF A229R673.WMF Scanner Motor 1. Remove the scanner rear cover. (See Covers - Rear.) 2. Remove the exhaust fan [A] (1 screw, 1 connector, 2 snap fit screws). NOTE: Do not lose the mylar [B]. 3.
Page 293: Scanner Wires
June 30, 1998 SCANNER UNIT 6.3.8 SCANNER WIRES A229R674.WMF 1. Remove the ADF. 2. Remove the following parts: • Exposure glass [A] (See Exposure Glass.) • Operation panel under cover [B] (See Scanner H.P Sensor.) • Scanner rear cover [C] (2 screws) •...
Page 294 SCANNER UNIT June 30, 1998 A229R681.WMF A229R682.WMF 3. Remove the left upper stay [A] (2 screws). 4. Remove the right upper stay [B] (3 screws). 5. Remove the shutter inner cover (see Development Unit) and swing out the toner bottle holder [C]. 6.
Page 295 June 30, 1998 SCANNER UNIT A229R683.WMF 7. Remove the ARDF support brackets [A] (4 screws each). 8. Remove the scanner upper frame [B] (4 screws). 9. Remove the fan duct [C] (1 screw). 6-23...
Page 296 SCANNER UNIT June 30, 1998 A229R684.WMF A229R685.WMF Rear Scanner Drive Wire 11. Remove the scanner motor and the scanner motor drive board. (See Scanner Motor and Scanner Motor Drive Board.) 12. Remove the drive pulley [A] (1 Allen screw), bearing [B], and the bearing holder bracket [C] (1 screw).
Page 297 June 30, 1998 SCANNER UNIT A229R686.WMF Front Scanner Drive Wire 18. Remove the inner cover [A] (3 screws). 19. Remove the HDD grounding screw [B]. 20. Loosen the rear scanner securing screws [C]. 21. Remove the front scanner securing screws [D]. 22.
Page 298 SCANNER UNIT June 30, 1998 ➂, ➅ ➃ ➆ ➁ ➀ ➄ A229R687.WMF 23. Remove the front scanner wire bracket [A], tension spring [B], and the wire tension bracket [C] (1 screw). Then remove the front scanner wire. Reinstallation 24. While making sure of the direction, place the bead on the middle of the wire in the pulley hole.
Page 299 June 30, 1998 SCANNER UNIT A229R689.WMF 30. Install the 1st scanner and adjust the position with the positioning tools (P/N A0069104) [A]. 31. Secure the 1st scanner with the scanner wire bracket (1 screw). 32. Fully tighten the tension bracket. 33.
Page 300: Optics Dust Filter
SCANNER UNIT June 30, 1998 6.3.9 OPTICS DUST FILTER A229R656.WMF 1. Remove the right exit tray [A] (3 screws). 2. Remove the upper right cover [B] (4 screws). 3. Replace the optics dust filter [C]. 6-28...
Page 301: Caution Decal Locations
June 30, 1998 LASER UNIT 6.4 LASER UNIT WARNING Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes. 6.4.1 CAUTION DECAL LOCATIONS There are three caution decals in the laser section as shown below. CAUTN-V.WMF A229I514.WMF LASER-3.WMF...
Page 302: Ld Unit Replacement
LASER UNIT June 30, 1998 6.4.2 LD UNIT REPLACEMENT A229R500.WMF WARNING Turn off the main power switch and unplug the machine before attempting this procedure. Laser beams can seriously damage your eyes. 1. Remove the exposure glass. (See Exposure Glass Removal.) 2.
Page 303: Laser Beam Pitch Adjustment
June 30, 1998 LASER UNIT 6.4.3 LASER BEAM PITCH ADJUSTMENT There are two laser beam pitch adjustment procedures: one for 400 dpi, and one for 600 dpi. These adjustments use the following SP modes. • SP2-109-1: Laser Beam Pitch Adjustment – 400 dpi •...
Page 304 LASER UNIT June 30, 1998 9. Adjust the laser beam pitch position until the thin lines are of uniform thickness (no striping effect should appear on the printout), doing steps 2, 3, and 4. (In step 2, input a value which is estimated to be correct, then do steps 3 and 4, then if necessary go back to step 2 and try another value.) 10.
Page 305: Polygon Mirror Motor Replacement
June 30, 1998 LASER UNIT 6.4.4 POLYGON MIRROR MOTOR REPLACEMENT A229R501.WMF 1. Turn off the main power switch and unplug the machine. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Remove the lens cover. (See Lens Block Assembly Replacement.) 4.
Page 306: Laser Synchronization Detector Replacement
LASER UNIT June 30, 1998 6.4.5 LASER SYNCHRONIZATION DETECTOR REPLACEMENT A229R502.WMF 1. Turn off the main power switch and unplug the machine. 2. Remove the drum unit. (See Drum Unit Removal.) 3. Remove the laser synchronization detector securing plate [A] using a small screwdriver (1 screw).
Page 307: Drum Unit Removal And Drum Replacement
June 30, 1998 DRUM UNIT 6.5 DRUM UNIT 6.5.1 DRUM UNIT REMOVAL AND DRUM REPLACEMENT A229R550.WMF A229R551.WMF 1. Take out the development unit. (Refer to Development Unit Removal.) 2. Lower the transfer belt unit. 3. Take out the drum unit by holding the knob [A]. NOTE: 1) Cover the drum unit with a sheet of paper to protect it from light when the drum unit is left outside the machine for servicing.
Page 308: Quenching Lamp Replacement
DRUM UNIT June 30, 1998 6.5.2 QUENCHING LAMP REPLACEMENT A229R552.WMF 1. Remove the drum. (Refer to Drum Unit Removal and Drum Replacement.) NOTE: Wrap a protective sheet or a few sheets of paper around the drum to protect it from light. 2.
Page 309: Grid Plate/Charge Corona Wire/Wire Cleaner Replacement
June 30, 1998 DRUM UNIT 6.5.3 GRID PLATE/CHARGE CORONA WIRE/WIRE CLEANER REPLACEMENT A229R555.WMF A229R556.WMF 1. Take out the charge corona unit [A] (1 screw, 1 connector). 2. Remove the grid plate [B] (1 plastic screw, 4 hooks). NOTE: When installing the grid plate, do not tighten the plastic screw [C] too strongly.
Page 310 DRUM UNIT June 30, 1998 A229R553.WMF 7. Remove the wire cleaner [A] (1 snap ring). 8. Install the wire cleaner and the charge corona wire. NOTE: Locate the joint part [B] of the wire in the rear end block as shown. After installing new wires, reset SP 2-001-1 and 2-001-4 (corona voltages) to the defaults.
Page 311 June 30, 1998 DRUM UNIT 6.5.4 DRUM ENTRANCE SEAL AND DRUM POTENTIAL SENSOR REPLACEMENT A229R557.WMF 1. Take out the drum unit. (Refer to Drum Unit Removal.) 2. Remove the drum entrance seal [A]. 3. Disconnect the connector [B]. NOTE: Before removing the drum potential sensor, put a few sheets of paper between the sensor and the drum to protect the drum surface.
Page 312: Cleaning Blade Replacement
DRUM UNIT June 30, 1998 6.5.5 CLEANING BLADE REPLACEMENT A229R558.WMF A229R559.WMF 1. Remove the drum. (Refer to Drum Unit Removal and Drum Replacement.) 2. Remove the cleaning blade [A] (2 screws). 3. Clean the entrance seal [B], side seals [C] and cleaning brush [D]. NOTE: When a vacuum cleaner is used, to protect the electrical parts from static electricity, disconnect the connector on the charge power pack and remove the ID sensor as follows:...
Page 313: Cleaning Brush Replacement
June 30, 1998 DRUM UNIT 6.5.6 CLEANING BRUSH REPLACEMENT A229R560.WMF 1. Remove the cleaning blade. (Refer to Cleaning Blade Replacement.) 2. Remove the coupling gear [A] (1 screw). 3. Remove the bushing [B] (1 screw). 4. Pull the cleaning brush shaft to the rear to release the cleaning brush [C], then remove the cleaning brush.
Page 314: Pick-Off Pawl Replacement
DRUM UNIT June 30, 1998 6.5.7 PICK-OFF PAWL REPLACEMENT A229R561.WMF 1. Take out the pick-off pawl unit. (Refer to Cleaning Blade Replacement.) 2. Remove the bushing [A] (1 screw and 1 retaining ring). 3. While pulling the shaft [B] to the rear, turn the pick-off pawl about 45 degrees clockwise (as viewed from the front) in order to move up the pick-off pawl.
Page 315: Ozone Filter Replacement
June 30, 1998 DRUM UNIT 6.5.8 OZONE FILTER REPLACEMENT A229R562.WMF 1. Open the front doors and open the toner bottle holder. 2. Remove the transfer belt unit prop [A] (3 screws). 3. Remove the ozone filter unit [B]. 4. Replace the ozone filter [C]. NOTE: To attach the transfer belt unit prop easily, set the following in order: lower pins [D], drive roller shaft [E], upper pins [F].
Page 316: Drum Motor Replacement
DRUM UNIT June 30, 1998 6.5.9 DRUM MOTOR REPLACEMENT A229R563.WMF A229R564.WMF 1. Turn off the main switch. 2. Remove the rear cover and the fly wheel. (Refer to Development Motor Replacement.) 3. Loosen the tension brackets [A] (2 screws). 4. Remove the timing belts [B] from the drum motor’s pulleys. 5.
Page 317 June 30, 1998 DRUM UNIT 6.5.10 TONEER OUTPUT AND RECYCLING PUMP UNIT REPLACEMENT A229R565.WMF A229R567.WMF NOTE: Before starting the procedure, remove the drum unit and the transfer belt unit to prevent toner from dropping into the machine. 1. Turn off the main switch. 2.
Page 318 DRUM UNIT June 30, 1998 6.5.11 AIR PUMP AND TONER COLLECTION MOTOR REPLACEMENT A229R568.WMF A229R569.WMF 1. Open the front doors then remove the toner collection bottle [A] (1 push-lock [B]). 2. Remove the upper and lower rear covers. (Refer to Upper and Lower Rear Cover Removal.) 3.
Page 319: Development Unit Removal
June 30, 1998 DEVELOPMENT AND TONER SUPPLY 6.6 DEVELOPMENT AND TONER SUPPLY 6.6.1 DEVELOPMENT UNIT REMOVAL A229R536.WMF 1. Turn off the main switch. 2. Open the front doors. 3. Remove the shutter inner cover [A]. 4. Release the shutter lever [B] (fully to the front). NOTE: When attaching the shutter inner cover [A], hang the shutter lever [B] on the hook [C].
Page 320 DEVELOPMENT AND TONER SUPPLY June 30, 1998 A229R537.WMF 5. Open the toner bottle holder [A]. 6. Remove the screw [B] that holds the drum stay. 7. Remove the drum stay knob [C] then take out the drum stay [D]. 8. Disconnect the two connectors [E]. 9.
Page 321: Development And Air Dust Filter Replacement
June 30, 1998 DEVELOPMENT AND TONER SUPPLY 6.6.2 DEVELOPMENT AND AIR DUST FILTER REPLACEMENT A229R540.WMF 1. Take out the development unit. (Refer to Development Unit Removal.) 2. Remove the development guide rail [A] (two screws). 3. Replace the development filter [B]. 4.
Page 322: Developer Replacement
DEVELOPMENT AND TONER SUPPLY June 30, 1998 6.6.3 DEVELOPER REPLACEMENT A229R574.WMF A229R542.WMF 1. Take out the development unit. (Refer to Development Unit Removal.) 2. Place the development unit on a sheet of paper [A]. 3. Remove the two screws [B] that hold the toner hopper [C]. 4.
Page 323 June 30, 1998 DEVELOPMENT AND TONER SUPPLY A229R541.WMF A229R544.WMF 6. Clean the side seals [A] and entrance seal [B]. NOTE: Cover the sleeve rollers with a sheet of paper [C] to prevent the used developer from being attracted to the sleeve rollers. 7.
Page 324 DEVELOPMENT AND TONER SUPPLY June 30, 1998 6.6.4 DEVELOPMENT ENTRANCE, FRONT, AND REAR SIDE SEALS A229R545.WMF A229R546.WMF A229R571.WMF 1. Remove the developer. (Refer to Developer Replacement.) 2. Replace the developer entrance seal [A] (2 screws, 2 hooks). 3. Replace the front and rear side seals [B]. NOTE: When re-assembling the development unit, use new side seals and align the edges of the side seals with the corner [C] and the edge [D] as shown.
Page 325: Toner Density Sensor Replacement
June 30, 1998 DEVELOPMENT AND TONER SUPPLY 6.6.5 TONER DENSITY SENSOR REPLACEMENT A229R547.WMF 1. Remove the developer. (Refer to Developer Replacement.) 2. Replace the TD sensor [A] (2 screws). NOTE: Before installing the TD sensor, clean the development unit well so that no carrier particles remain in the gap between the TD sensor and the development unit casing.
Page 326: Development Motor Replacement
DEVELOPMENT AND TONER SUPPLY June 30, 1998 6.6.6 TONER END SENSOR REPLACEMENT A229R548.WMF 1. Take out the toner hopper. (Refer to Developer Replacement.) 2. Replace the toner end sensor [A]. 6.6.7 DEVELOPMENT MOTOR REPLACEMENT A229R570.WMF A229R549.WMF 1. Turn off the main switch. 2.
Page 327: Transfer Belt Unit Removal/Installation
June 30, 1998 TRANSFER BELT UNIT 6.7 TRANSFER BELT UNIT 6.7.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION A229R527.WMF A229R528.WMF - Removal - 1. Turn off the main switch. 2. Remove the transfer belt unit prop [A] (3 screws). 3. Disconnect the connector [B]. 4.
Page 328 TRANSFER BELT UNIT June 30, 1998 A229R519.WMF A229R520.WMF 2. Attach the transfer belt unit prop (3 screws). NOTE: To attach the transfer belt unit prop easily, set the following in order: lower pins [A], drive roller shaft [B], upper pins [C]. 3.
Page 329: Transfer Belt Replacement
June 30, 1998 TRANSFER BELT UNIT 6.7.2 TRANSFER BELT REPLACEMENT A229R521.WMF A229R522.WMF 1. Take out the transfer belt unit. (Refer to Transfer Belt Unit Removal.) 2. While raising the knob [A], disconnect the two connectors [B]. 3. Turn the transfer belt upper unit [C] 90 degrees counterclockwise, then raise and remove it.
Page 330 TRANSFER BELT UNIT June 30, 1998 A229R525.WMF A229R523.PCX A229R524.WMF 5. Turn the belt drive roller holder [A] clockwise (front view) and remove the bias terminal [B] (1 screw). 6. Replace the transfer belt [C]. NOTE: 1) Before installing the transfer belt, clean both sides of the transfer belt with a dry cloth (do not use alcohol).
Page 331 June 30, 1998 TRANSFER BELT UNIT 6.7.3 BIAS ROLLER CLEANING BLADE REPLACEMENT A229R526.WMF 1. Remove the transfer belt unit. (Refer to Transfer Belt Replacement.) 2. Remove the cleaning roller cleaning blade [A]. 3. Clean the cleaning bias roller [B]. NOTE: When using a vacuum cleaner, to protect the transfer power pack from static electricity, remove the power pack connectors [C].
Page 332: Paper Tray Unit Removal
PAPER FEED June 30, 1998 6.8 PAPER FEED 6.8.1 PAPER TRAY UNIT REMOVAL A229R592.WMF A229R593.WMF To facilitate transportation, the upper part of the copier (copier main frame) [A] and the lower part of the copier (paper tray unit) [B] can be separated as follows: 1.
Page 333: Paper Tray Removal
June 30, 1998 PAPER FEED 6.8.2 PAPER TRAY REMOVAL Tandem Tray Removal A229R595.WMF A229R594.WMF 1. Open the left door and draw out the tandem tray. 2. While pushing the release lever [A] to the right with a screwdriver [B], slightly push the right tandem tray [C] to separate it from the left tandem tray [D].
Page 334 PAPER FEED June 30, 1998 Universal Tray/Built-in LCT Removal A229R596.WMF A229R597.WMF 1. Draw out the tray. 2. Remove the tray from both guide rails as shown (4 screws). 6-62...
Page 335: Paper Feed Roller Replacement
June 30, 1998 PAPER FEED 6.8.3 PAPER FEED ROLLER REPLACEMENT A229R598.WMF 1. Turn off the main switch. 2. Remove the paper tray which the feed rollers need replacing for. (Refer to Paper Tray Removal.) 3. Remove the pick-up roller [A] (1 snap ring). 4.
Page 336 PAPER FEED June 30, 1998 6.8.4 TANDEM REAR FENCE DRIVE BELT REMOVAL A229R599.WMF A229R600.WMF 1. Draw out the tandem tray. 2. Separate the right tandem tray from the left tandem tray [A]. (Refer to Tandem Tray Removal.) 3. Remove the rear fence [B] on the left tandem tray (2 screws). 4.
Page 337 June 30, 1998 PAPER FEED A229R601.WMF 7. Disconnect the three connectors [A]. 8. Loosen the screw [B] and unhook the spring [C]. 9. Remove the timing belt [D]. NOTE: When installing the timing belt, hook the spring [C] first, then tighten the screw [B].
Page 338: Tandem Side Fence Motor Removal
PAPER FEED June 30, 1998 6.8.5 TANDEM SIDE FENCE MOTOR REMOVAL A229R602.WMF 1. Remove the bottom plate [A] of the right tandem tray (2 nylon rivets [B]). 2. Raise the lift arm [C] (2 screws). 3. Remove the cover [D] (1 screw). 4.
Page 339 June 30, 1998 PAPER FEED 6.8.6 3RD TRAY PAPER SENSOR REMOVAL A229R678.WMF 1. Remove the built-in LCT. (Refer to Paper Tray Removal.) 2. Remove the front side fence [A] (1 screw). 3. Remove the rear side fence [B] (1 screw). 4.
Page 340 PAPER FEED June 30, 1998 6.8.7 3RD TRAY LIFT WIRE REMOVAL A229R677.WMF A229R676.WMF 1. Remove the built-in LCT. (Refer to Paper Tray Removal.) 2. Remove the front cover [A] (4 screws, 1 connector, 3 hooks). 3. Remove the 3rd tray lift motor unit [B] (4 screws, 1 connector). 6-68...
Page 341 June 30, 1998 PAPER FEED A229R679.WMF 4. Remove the spring [A]. 5. Remove the wire [B]. 6. Wind the end of the new wire with no marking around the tray lift drive pulley À [C] in the correct direction, as shown. ( Á...
Page 342 PAPER FEED June 30, 1998 6.8.8 PAPER FEED CLUTCH/RELAY CLUTCH REMOVAL A229R603.WMF A229R604.WMF 1. Turn off the main switch, then open the right front door and remove the push- lock [A]. 2. Remove the toner collection bottle [B]. NOTE: If the LCT is installed, remove it from the copier. 3.
Page 343 June 30, 1998 PAPER FEED A229R605.WMF A229R606.WMF 5. While holding the shaft [A] with an Allen key, remove the screw [B], then remove the knob [C]. 6. Pull out all paper trays, then remove the paper tray unit inner cover [D] (2 screws).
Page 344 PAPER FEED June 30, 1998 A229R608.WMF A229R609.WMF 9. Fully draw out the paper tray. 10. Remove the two screws [A] that hold the tray feed unit [B]. 11. Disconnect the connectors [C]. 12. Remove the tray feed unit. 13. Remove the bracket [D] (1 screw). 14.
Page 345: By-Pass Feed Table Removal
June 30, 1998 PAPER FEED 6.8.9 BY-PASS FEED TABLE REMOVAL A229R610.WMF 1. Remove the right inner cover. (Refer to Right Inner Cover Removal.) 2. Remove the total counter with bracket [A] (1 screw, 1 connector). 3. Loosen the Allen screw [B] on the hinge. 4.
Page 346: By-Pass Feed Roller Replacement
PAPER FEED June 30, 1998 6.8.10 BY-PASS FEED ROLLER REPLACEMENT A229R611.WMF A229R613.WMF 1. Open the by-pass feed table, then remove the cover [A] (3 screws). 2. Replace the pick-up roller [B] (1 snap ring) and the feed roller [C] (1 snap ring). NOTE: The paper feed (pick-up, feed, separation) rollers used in the by-pass feed table and LCT are different from the paper feed rollers used in the 1st ~ 3rd feed units in the paper tray unit.
Page 347 June 30, 1998 PAPER FEED 6.8.11 BY-PASS PAPER SIZE BOARD REPLACEMENT A229R614.WMF A229R615.WMF 1. Turn off the main switch. 2. Open the by-pass table and remove the feed unit cover. (Refer to Right Cover Removal.) 3. While pushing the hook [A] with a flat-head screwdriver as shown, remove the table assembly [B] (2 screws, 1 connector [C]).
Page 348 PAPER FEED June 30, 1998 A229R616.WMF 5. Re-install the by-pass paper size sensor, then reassemble the by-pass feed table. NOTE: When installing the table assembly, route the wires [A] correctly as shown. The paper guides [B] must be in the lower position as shown. 6.
Page 349 June 30, 1998 PAPER FEED 6.8.12 BY-PASS FEED MOTOR/CLUTCH REMOVAL A229R617.WMF A229R618.WMF 1. Remove the upper rear cover. (Refer to Upper Rear Cover Removal.) 2. Remove the by-pass feed motor [A] (2 screws, 1 connector). 3. Remove the guide plate solenoid [C] (1 screw, 1 connector). See Copier Feed Unit Removal 4.
Page 350: Registration Motor Removal
PAPER FEED June 30, 1998 6.8.13 REGISTRATION MOTOR REMOVAL A229R619.WMF A229R620.WMF 1. Remove the upper rear cover. (Refer to Cover Removal.) 2. Remove the bracket [A] (1 screw). 3. Remove the fly wheel [B] (3 screws). 4. Remove the bracket [C] with the motor (3 screws, 1 connector). 5.
Page 351 June 30, 1998 PAPER FEED 6.8.14 PAPER DUST REMOVER REMOVAL A229R621.WMF 1. Remove the development unit. (Refer to Development Unit Removal.) 2. While pushing down the hook lever [A], remove the paper dust remover [B]. 3. Remove paper dust inside the paper dust remover and clean inside it with a dry cloth or a blower-brush.
Page 352: Registration Sensor Removal
PAPER FEED June 30, 1998 6.8.15 REGISTRATION SENSOR REMOVAL A229R622.WMF 1. Remove the relay roller knob [A] (1 screw). 2. Remove the registration roller knob [B] (1 screw). 3. Remove the right inner cover [C] (1 screw). 4. Disconnect the connector [D]. 5.
Page 353: Copier Feed Unit Removal
June 30, 1998 PAPER FEED 6.8.16 COPIER FEED UNIT REMOVAL A229R623.WMF 1. Remove the development unit. (Refer to Development Unit Removal.) 2. Remove the right inner cover and the registration roller knob. (Refer to Registration Sensor Removal.) 3. Remove the by-pass feed motor. (Refer to By-pass Feed Motor/Clutch Removal.) 4.
Page 354 PAPER FEED June 30, 1998 A229R624.WMF 6. Disconnect the three connectors [A]. 7. Draw out the duplex unit about 10 cm. 8. Remove the copier feed unit [B] (4 screws). NOTE: When installing the copier feed unit in the copier: 1) Do not pinch the harness.
Page 355: Fusing Unit Removal
June 30, 1998 FUSING UNIT 6.9 FUSING UNIT 6.9.1 FUSING UNIT REMOVAL A229R517.WMF 1. Turn off the main switch. 2. Open the front door. 3. Remove the stopper [A] (1 screw). 4. While releasing the lever [B], pull out the fusing unit as shown. NOTE: Hold the bottom of the fusing unit as shown.
Page 356 FUSING UNIT June 30, 1998 6.9.2 FUSING THERMISTOR AND FUSING THERMOFUSE REPLACEMENT A229R531.WMF A229R575.WMF Fusing Thermistor Replacement 1. Remove the fusing unit. (Refer to Fusing Unit Removal.) 2. Remove the knob [A] (1 screw). 3. Remove the two screws that hold the fusing front cover [B]. 4.
Page 357: Fusing Lamp Replacement
June 30, 1998 FUSING UNIT 6.9.3 FUSING LAMP REPLACEMENT A229R504.WMF A229R505.WMF 1. Remove the fusing unit. (Refer to Fusing Unit Removal.) 2. Remove the terminal bracket [A] (2 screws). 3. Disconnect the front connectors [B] and the rear connectors [C]. 4.
Page 358 FUSING UNIT June 30, 1998 [NG] A229R651.WMF A229R650.WMF NOTE: 2) When re-installing the thermistor, thermofuse, and lamps, secure all harnesses in the clamps [A] correctly and do not locate them in the area indicated as ‘NG’ [B]. 3) When re-installing the lamps, check that the grounding brush [C] contacts the hot roller [D].
Page 359: Hot Roller Replacement
June 30, 1998 FUSING UNIT 6.9.4 HOT ROLLER REPLACEMENT A229R507.WMF 1. Remove the fusing lamps. (Refer to Fusing Lamp Replacement.) 2. Lower the fusing exit assembly [A]. 3. Remove the upper stay [B] (4 screws). 4. Lower the lever [C] and remove the oil supply unit [D]. 6-87...
Page 360 FUSING UNIT June 30, 1998 A229R508.WMF A229R652.WMF 5. Lower the pressure spring holders [A] at both sides using a screwdriver [B] as a lever. 6. Remove the front and rear C-rings [C], gear [D], anti-static spacers [E], isolating bushings [F], and bearings [G]. NOTE: When installing a new hot roller: 1) Lubricate the inner and outer surfaces of the isolating bushings [F] with BARRIERTA L55/2 grease.
Page 361 June 30, 1998 FUSING UNIT 6.9.5 PRESSURE ROLLER AND BEARING REPLACEMENT A229R509.WMF 1. Remove the hot roller. (Refer to Hot Roller Replacement.) 2. Remove the lower fusing entrance guide [A] (2 screws). 3. Lift the pressure roller [B] and remove it. 4.
Page 362 FUSING UNIT June 30, 1998 6.9.6 HOT ROLLER STRIPPER PAWL REPLACEMENT A229R510.WMF A229R653.WMF A229R511.WMF 1. Turn off the main switch and pull out the fusing unit. 2. Lower the fusing exit assembly [A]. 3. Remove the fusing exit guide [B] (2 screws). 4.
Page 363: Fusing Pressure Adjustment
June 30, 1998 FUSING UNIT 6.9.7 FUSING PRESSURE ADJUSTMENT A229R512.WMF A229R513.WMF 1. Make a black copy (sky shot, A3/Double Letter paper). 2. As soon as the paper starts to exit, open the left door to stop the paper in the fusing unit.
Page 364 FUSING UNIT June 30, 1998 6.9.8 OIL SUPPLY/CLEANING ROLLER REPLACEMENT A229R514.WMF A229R654.WMF 1. Pull out the fusing unit. 2. Lower the lever [A]. 3. Remove the oil supply unit [B]. 4. Remove the upper entrance guide [C] (1 screw). 5. Remove the mylar bracket [D] (2 screws).
Page 365: Pressure Roller Cleaning Roller Replacement
June 30, 1998 FUSING UNIT 6.9.9 PRESSURE ROLLER CLEANING ROLLER REPLACEMENT A229R516.WMF A229R693.WMF 1. Pull out the fusing unit. 2. Remove the bottom plate [A] (1 screw). 3. Remove the cleaning roller unit [B] (2 screws). 4. (EU only) Remove the cleaning roller brush [C]. 5.
Page 366: Paper Exit/Duplex Unit
PAPER EXIT/DUPLEX UNIT June 30, 1998 6.10 PAPER EXIT/DUPLEX UNIT 6.10.1 EXIT SENSOR/FUSING EXIT SENSOR A229R579.WMF A229R580.WMF 1. Open the front door. 2. Pull out the duplex unit. 3. Remove the left cover (see Exterior). 4. Remove the left inner cover [A] (2 screws). 5.
Page 367: Jogger Motor
June 30, 1998 PAPER EXIT/DUPLEX UNIT 6.10.2 JOGGER MOTOR A229R581.WMF A229R582.WMF 1. Open the front door. 2. Pull out the duplex unit. 3. Remove the duplex front cover [A] (3 screws). 4. Remove the jogger motor bracket [B] (2 screws). 5.
Page 368 PAPER EXIT/DUPLEX UNIT June 30, 1998 6.10.4 DUPLEX TRANSPORT/DUPLEX FEED CLUTCHES A229R585.WMF A229R584.WMF 1. Open the front door. 2. Pull out the duplex unit. 3. Remove the two pulleys [A] (1 snap ring each). 4. Remove the duplex unit [B]. 5.
Page 369 June 30, 1998 PAPER EXIT/DUPLEX UNIT 6.10.6 DUPLEX TRANSPORT SENSORS 2 & 3 A229R587.WMF A229R588.WMF 1. Open the front door. 2. Pull out and remove the duplex unit (see Duplex Transport/Duplex Feed Clutch Removal). 3. Remove the duplex front cover (see Jogger Motor Removal). 4.
Page 370: Jogger Hp Sensor
PAPER EXIT/DUPLEX UNIT June 30, 1998 6.10.7 JOGGER HP SENSOR A229R680.WMF 1. Open the front door. 2. Pull out the duplex unit. 3. Remove the duplex unit. (See Duplex Transport/Feed Clutch Removal.) 4. Remove the duplex connector bracket [A] (2 screws). 5.
Page 371 June 30, 1998 BOARDS AND OTHER ITEMS 6.11 BOARDS AND OTHER ITEMS 6.11.1 SBICU BOARD A229R646.WMF A229R647.WMF 1. Remove the lens block assembly. (Refer to Lens Block Removal.) 2. Remove the original exit tray [A] (3 screws). 3. Remove the upper right cover [B] (4 screws). 4.
Page 372: Hard Disk Drive
BOARDS AND OTHER ITEMS June 30, 1998 6.11.2 HARD DISK DRIVE A229R648.WMF 1. Remove the upper right cover. (Refer to Upper Right Cover Removal.) 2. Remove the hard disk ground plate [A] (3 screws). 3. Replace the hard disk [B] (2 screws, 2 connectors). NOTE: Do not drop the hard disk or shock it violently.
Page 373 June 30, 1998 BOARDS AND OTHER ITEMS 6.11.3 I/O BOARD A229R642.WMF A229R649.WMF 1. Turn off the main switch. 2. Remove the upper rear cover (Refer to Upper Rear Cover Removal.) 3. Disconnect all connectors from I/O Board [A]. 4. Remove the I/O board [A] (6 screws). NOTE: If the screws [B] of the I/O board bracket are removed, the I/O board can be swung out.
Page 374 BOARDS AND OTHER ITEMS June 30, 1998 6.11.4 PSU A229R643.WMF 1. Turn off the main switch. 2. Remove the upper and lower rear cover. (Refer to Upper and Lower Rear Cover Removal.) 3. Remove the harness clamp [A] (2 screws). 4.
Page 375: Copy Image Adjustments: Printing/Scanning
1 July 1998 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING 6.12 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING NOTE: 1) You need to perform these adjustment(s) after replacing any of the following parts: • Scanner Wires • Lens Block • Scanner Motor • Polygon Mirror Motor •...
Page 376 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING 1 July 1998 Mechanical Adjustment - Side-to-side Positioning Adjustment (Tandem Tray and Built-in LCT) - When the tray is put in the paper feed unit, the side-to-side positioning plate [C] presses the feed tray against the rubber stopper on the frame of the paper tray unit.
Page 377 1 July 1998 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING Blank Margin NOTE: If the leading edge/side-to-side registration can not be adjusted within the specifications, adjust the leading/left side edge blank margin. 1. Check the trailing edge and right side edge blank margins using the Trimming Area Pattern, and adjust them using the following SP modes if necessary.
Page 378: Parallelogram Image Adjustment
COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING 1 July 1998 6.12.2 PARALLELOGRAM IMAGE ADJUSTMENT Do the following procedure if a parallelogram type image is printed while using a trimming area pattern to adjust the printing registration or the printing margin. NOTE: 1) The following procedure should be done after adjusting the side-to-side registration for each paper tray.
Page 379 1 July 1998 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING A229R535.WMF 1 m m Feed Direction A229R591.WMF 6. Adjust the laser unit position using a flat screwdriver [A] as shown. If the right side of the trimming area pattern is down by about 1 mm as shown [B], the laser unit should be rotated about one graduation in the direction of the black arrow as shown [C].
Page 380 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING 1 July 1998 6.12.3 SCANNING NOTE: 1) Before doing the following scanner adjustments, check the printing registration/side-to-side adjustment and the blank margin adjustment. 2) Use an OS-A3 test chart to perform the following adjustments. Registration: Platen Mode 1.
Page 381: Adf Image Adjustment
1 July 1998 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING 6.12.4 ADF IMAGE ADJUSTMENT Registration A229R637.WMF A: Leading Edge Registration B: Side-to-side Registration A229R692.WMF NOTE: Make a temporary test chart as shown above left using A3/DLT paper. 1. Place the temporary test chart on the ADF and make a copy from one of the feed stations.
Page 382: Touch Screen Calibration
TOUCH SCREEN CALIBRATION June 30, 1998 6.13 TOUCH SCREEN CALIBRATION After doing a memory all clear or when the touch panel detection mechanism is not working properly, calibrate the touch screen as follows. 1. Press the following keys in sequence to enter touch screen calibration mode. K 1 9 9 3 C x5 k Self Diagnostic Menu [a] ROM Checksum Test...
Page 383: Troubleshooting
June 30, 1998 SERVICE CALL CONDITIONS 7. TROUBLESHOOTING 7.1 SERVICE CALL CONDITIONS 7.1.1 SUMMARY There are 4 levels of service call conditions. Level Definition Reset Procedure To prevent the machine from being damaged, Enter SP mode, then turn the the SC can only be reset by a service main power switch off and representative (see the note below).
Page 384: Sc Code Descriptions
SERVICE CALL CONDITIONS June 30, 1998 7.1.2 SC CODE DESCRIPTIONS SC101: Exposure lamp error - Definition - [B] The standard white level was not detected properly when scanning the white plate. - Possible cause - • Exposure lamp defective • Lamp regulator defective •...
Page 385 June 30, 1998 SERVICE CALL CONDITIONS SC302-01: Charge corona output error 1 -Definition- [B] The feedback voltage from the charge corona unit is too high. - Possible causes - • Charge P.P. defective • Poor charge corona unit connection SC302-02: Charge corona output error 2 -Definition- [B] The control PWM for the charge corona unit is too high.
Page 386 SERVICE CALL CONDITIONS June 30, 1998 SC303-02: Charge corona wire cleaner error 2 -Definition- [B] The charge corona wire cleaner motor connector is not connected. - Possible causes - • The charge corona wire cleaner motor connector is not connected. SC320: Polygon motor error -Definition- [B] The polygon motor does not reach its operating speed within 20 seconds after...
Page 387 June 30, 1998 SERVICE CALL CONDITIONS SC323: LD drive current over -Definition- [B’] The LD drive board applies more than 110 mA to the LD. - Possible causes - • LD unit defective (not enough power, due to aging) • Poor connection between the LD unit and the SBICU board •...
Page 388 SERVICE CALL CONDITIONS June 30, 1998 SC329: Laser beam pitch adjustment error -Definition- [B] The LD unit home position sensor does not detect an on condition while changing the LD unit position for correcting the LD position or changing the dpi. - Possible causes - •...
Page 389 June 30, 1998 SERVICE CALL CONDITIONS SC350-3: ID sensor error 3 -Definition- [D] For 2 s during the ID sensor pattern check, the ID sensor pattern edge voltage is not 2.5V. - Possible causes - • ID sensor defective • ID sensor connector defective •...
Page 390 SERVICE CALL CONDITIONS June 30, 1998 SC360: Hard disk drive error 1 -Definition- [B] The machine does not detect the connection signal from the HDD. - Possible causes - • Poor connection between the HDD and SBICU • The dc power connector to the HDD is disconnected •...
Page 391 June 30, 1998 SERVICE CALL CONDITIONS SC370-01: Potential sensor error 1 Definition- [D] When calibrating the drum potential sensor at the process control initial setting, the drum potential sensor output voltage is out of specification. - Possible causes - • Potential sensor defective •...
Page 392 SERVICE CALL CONDITIONS June 30, 1998 SC370-04: Potential sensor error 4 Definition- [D] When adjusting the drum potential (V ) at the process control initial setting, the drum potential sensor detects that V is more than V (grid voltage). - Possible causes - •...
Page 393 June 30, 1998 SERVICE CALL CONDITIONS SC370-07: Potential sensor error 7 Definition- [D] When adjusting the drum potential (V ) for half tone at the process control initial setting, the drum potential sensor detects that V does not become –300 + 20 V even though the LD power has been changed twenty times.
Page 394 SERVICE CALL CONDITIONS June 30, 1998 SC390-3: TD sensor error 3 -Definition- [B] The TD sensor output voltage is not adjusted to 2.5 + 0.1V within 20 s during TD sensor initial setting. - Possible causes - • TD sensor defective •...
Page 395 June 30, 1998 SERVICE CALL CONDITIONS SC440: Drum motor lock -Definition- [B] The drum motor lock signal is longer than 2 seconds while the drum motor is on. - Possible causes - • Too much load on the drive mechanism •...
Page 396 SERVICE CALL CONDITIONS June 30, 1998 SC496: Toner collection bottle error -Definition- [B] The toner collection bottle set switch remains off. - Possible causes - • No toner collection bottle • Toner collection bottle switch defective SC497: Toner recycling motor error -Definition- [B] The toner recycling motor connector set signal remains off.
Page 397 June 30, 1998 SERVICE CALL CONDITIONS SC503: 3rd tray lift malfunction -Definition- [C] One of following conditions is detected in the 3rd tray. 1) The 3rd lift sensor is not activated after the tray lift motor has been on for 10 seconds.
Page 398 SERVICE CALL CONDITIONS June 30, 1998 SC508: Tandem rear fence motor error -Definition- [C] One of following conditions is detected in the tandem tray. 1) When the tray is placed in the machine, the rear fence return sensor and the rear fence HP sensor are already on. 2) It takes 10 seconds or more for the rear fence return sensor to detect the on condition after the rear fence motor starts.
Page 399 June 30, 1998 SERVICE CALL CONDITIONS SC510: LCT tray malfunction (optional LCT) -Definition- [C] 1) The LCT lift sensor does not activate for more than 18 seconds after the LCT motor starts to lift the bottom plate. 2) The LCT down sensor does not activate for more than 18 seconds after the LCT motor starts to lower the bottom plate.
Page 400 SERVICE CALL CONDITIONS June 30, 1998 SC521-2: Duplex jogger motor error 2 -Definition- [C] When the jogger fence moves from the home position, the jogger fence HP sensor does not turn off even if the jogger motor has moved the jogger fence 153.5 mm.
Page 401 June 30, 1998 SERVICE CALL CONDITIONS SC542: Fusing temperature warming-up error -Definition- [A] The fusing temperature does not reach the fusing standby temperature within 5 minutes after the main power switch is turned on. - Possible causes - • Fusing thermistor defective or out of position •...
Page 402 SERVICE CALL CONDITIONS June 30, 1998 SC547: Zero cross signal malfunction -Definition- [A] Zero cross signals are not detected within a certain period after the main power switch has been turned on. - Possible causes - • Power supply board defective •...
Page 403 June 30, 1998 SERVICE CALL CONDITIONS SC620-1: Communication error between SBICU and ADF 1 -Definition- [B] The TXD and RXD signals between SBICU and ADF main board do not stabilize. - Possible causes - • Poor connection between the SBICU board and ADF main board •...
Page 404 SERVICE CALL CONDITIONS June 30, 1998 SC623: Communication error between SBICU and paper feed board -Definition- [B] The SBICU cannot communicate with the paper feed board properly. - Possible causes - • Poor connection between the SBICU board and the paper feed board •...
Page 405 June 30, 1998 SERVICE CALL CONDITIONS SC701: ADF original table lift-up malfunction -Definition- [B’] The bottom plate position sensor does not activate when the original table motor lifts the original table. - Possible causes - • Bottom plate H.P sensor defective •...
Page 406 SERVICE CALL CONDITIONS June 30, 1998 SC726: Finisher shift/lift motor error - Definition - [B] 1) Tray shift does not finish within a certain time after the shift motor turned on. 2) The stack height sensor does not activate within a certain time after the shift tray lift motor turned on.
Page 407 June 30, 1998 SERVICE CALL CONDITIONS SC900: Electrical total counter error -Definition- [A] The total counter contains something that is not a number. - Possible causes - • NVRAM defective SC951: F-gate signal error 2 -Definition- [B’] When the IPU has already received the F-gate signal (laser writing start trigger signal), the IPU receives another F-gate signal.
Page 408 SERVICE CALL CONDITIONS June 30, 1998 SC959: Printer setting ID error -Definition- [B’] The ID that is required for image processing using the printer is not sent from the IPU. - Possible causes - • Software defective SC960: Printer return ID error -Definition- [B’] The ID that is sent from the printer controller after finishing the printout is incorrect.
Page 409 June 30, 1998 SERVICE CALL CONDITIONS SC964: Printer ready error -Definition- [B’] The print ready signal is not generated for more than 17 seconds after the IPU received the print start signal. - Possible causes - • Software defective SC980: HDD access error -Definition- [B] Incorrect parameter sent to the HDD controller.
Page 410 SERVICE CALL CONDITIONS June 30, 1998 SC990: Software performance error -Definition- [B’] The software performs an unexpected function. - Possible causes - • Software defective NOTE: When this SC occurs, the file name, address, and data will be stored in the NVRAM. These data can be checked by entering SP mode then pressing “0”.
Page 411: Electrical Component Defects
June 30, 1998 ELECTRICAL COMPONENT DEFECTS 7.2 ELECTRICAL COMPONENT DEFECTS 7.2.1 SENSORS Component Condition Symptom (Symbol) Scanner Home CN312-7 Stays On SC121 is displayed. Position (S1) (SBICU) Stays Off SC120 is displayed. Original Width CN312- Stays On The CPU cannot detect the original size (S2) 4.5.6 properly.
Page 412 ELECTRICAL COMPONENT DEFECTS June 30, 1998 Component Condition Symptom (Symbol) 1st Paper Feed CN269- Stays On “Paper Jam” is displayed even if there is no (S12) paper. (PFB) Stays Off “Paper Jam” is displayed whenever a copy is made. 2nd Paper CN269- Stays On “Paper Jam”...
Page 413 June 30, 1998 ELECTRICAL COMPONENT DEFECTS Component Condition Symptom (Symbol) 3rd Near End CN263-2 Stays On “Paper Near End” is not displayed even if (S24) the tray is almost empty. (PFB) Stays Off “Paper Near End” is displayed even if there is enough paper in the paper tray.
Page 414 ELECTRICAL COMPONENT DEFECTS June 30, 1998 Component Condition Symptom (Symbol) CN208- Stays On “Paper Jam” is displayed whenever a copy Duplex is made. Transport 3 (IOB) Stays Off “Paper Jam” is displayed even if there is no (S36) paper. Duplex Jogger CN208- Stays On SC521-02 is displayed.
Page 415 June 30, 1998 ELECTRICAL COMPONENT DEFECTS 7.2.2 SWITCHES Component Condition Symptom (Symbol) Main Power CN100- Open The machine does not turn on. (SW1) 1,2,3,4 (PSU) Shorted The machine does not turn off. Front Door CN103- Open SC322 is displayed. Safety (SW3,5) (LDDR) Shorted Front Door...
Page 416: Blown Fuse Conditions
BLOWN FUSE CONDITIONS June 30, 1998 7.3 BLOWN FUSE CONDITIONS Rating Symptom when turning on the main Fuse power switch 115V 210 ~ 230V Power Supply Board FU101 12A/125V 6.3A/250V No response FU102 6.3A/125V 6.3A/125V SC521-02 is displayed. FU103 6.3A/125V 6.3A/125V SC391 and “Paper Jam”...
Page 417 COPIER (A229) ELECTRICAL COMPONENT LAYOUT (1/2) 66 67 68 110 111 112...
Page 418 COPIER (A229) ELECTRICAL COMPONENT LAYOUT (2/2) Index Index Index Index Symbol Description P to P Symbol Description P to P Symbol Description P to P Symbol Description P to P Printed Circuit Board Sensors Magnetic Clutches Lamps PCB 1 SBICU Scanner HP MC 1 Toner Supply...
Page 419 A229 Point to Point Diagram Signal Table CN304 (L11) CN306 (N9) CN308 (J10) (PCB4) -12V XDO1 AC Line -12V ADE7 XALLRST XARLGT DC Line Circuit Braker +12V ADO7 XDO0 Not Used XARLSYC (CB1) Puls +12V ADE6 VDSDO Not Used XARFGT Signal Direction ADO6 TDX-PRN...
Page 420 AUTO DOCUMENT FEEDER (A806) ELECTRICAL COMOPONENT LAYOUT A806D102.WMF Index Index Symbol Description P to P Symbol Description P to P Sensors Motors APS Start Pick-up DF Position Feed-in Original Set Transport Bottom Plate HP Feed-out Bottom Plate Position Bottom plate Pick-up Roller HP Solenoids Entrance...
Page 421 POINT TO POINT DIAGRAM (ARDF: A806) CN100-1 CN200-1 CN340-3 CN610-3 [24] +24V GND [0] Registration [24] +24V [!5] Sensor [24] +24V +5V [5] [0] GND CN200-4 CN350-6 CN590-3 [0] GND GND [0] Copier Original Set [0] GND [!5] Sensor CN110-2 [0] GND +5V [5] CN200-7...

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