Ricoh FT 4015 Service Manual
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Ricoh FT 4015 Service Manual

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IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the copier power cord is unplugged.
2. The wall outlet should be near the copier and easily accessible.
3. Note that the optional tray heater and the optional anti-condensation
heaters are supplied with electrical voltage even if the main switch is
turned off.
4. If any adjustment or operation check has to be made with exterior
covers off or open while the main switch is turned on, keep hands away
from electrified or mechanically driven components.
5. The inside and the metal parts of the fusing unit become extremely hot
while the copier is operating. Be careful to avoid touching those
components with your bare hands.
HEALTH SAFETY CONDITIONS
1. Toner and developer are non-toxic, but if you get either of them in your
eyes by accident, it may cause temporary eye discomfort. Try to remove
with eye drops or flush with water as first aid. If unsuccessful, get
medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course
on those models.
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Do not incinerate toner cartridges or used toner. Toner dust may ignite
suddenly when exposed to open flame.
2. Dispose of used toner, developer, and organic photoconductors in
accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.

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

  • Page 2: Overall Machine Information

    SECTION 1 OVERALL MACHINE INFORMATION...

  • Page 3: Specifications

    20 December 1996 SPECIFICATIONS 1. SPECIFICATIONS Configuration: Desk Top Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum: A3/11" x 17" Copy Paper Size: Maximum: A3/11" x 17" Minimum: A5/5 " x 8 " sideways (Paper tray feed) A6/5 "...
  • Page 4 SPECIFICATIONS 20 December 1996 Paper Capacity: Paper tray: 500 sheets or less than 56 mm stack height By-pass feed entrance: Standard paper 80 sheets 10 sheets Others 1 sheet Toner Replenishment: Bottle exchange (215 g/bottle) Copy Tray Capacity: 100 sheets Power Source: 120 V/60 Hz: More than 15 A (for North America) 220 ~ 240 V/50 Hz: More than 8 A (for Europe)
  • Page 5 20 December 1996 SPECIFICATIONS Noise Emissions: Sound pressure level (the measurements are made in accordance with ISO 7779 at the operator position.) Copier only Full system* Copying Less than 57 dB Less than 61 dB *Full system: Copier with document feeder and 10-bin sorter Sound power level (the measurements are made in accordance with ISO 7779) Copier only...

  • Page 6: Copy Process Around The Drum

    COPY PROCESS AROUND THE DRUM 20 December 1996 2. COPY PROCESS AROUND THE DRUM A219V503.wmf...
  • Page 7 20 December 1996 COPY PROCESS AROUND THE DRUM 1. DRUM CHARGE In the dark, the charge corona unit gives a uniform negative charge to the organic photoconductive (OPC) drum. The charge remains on the surface of the drum because the OPC drum has a high electrical resistance in the dark.

  • Page 8: Mechanical Component Layout

    MECHANICAL COMPONENT LAYOUT 20 December 1996 3. MECHANICAL COMPONENT LAYOUT A219V500.wmf 1. 2nd Mirror 14. By-pass Feed Table 15. Relay Rollers 2. 1st Mirror 3. Exposure Lamp 16. Tray Paper Feed Rollers 4. Hot Roller 17. Registration Rollers 5. Lens 18.

  • Page 9: Drive Layout

    20 December 1996 DRIVE LAYOUT 4. DRIVE LAYOUT A219V501.wmf 1. Lens Motor 7. By-pass Paper Feed Clutch 2. Fusing Unit Drive Gear 8. Registration Clutch Gear 3. Main Motor 9. Toner Supply Motor 4. Drum Drive Gear 10. 4th/5th Mirror Motor 5.

  • Page 10: Paper Path

    PAPER PATH 20 December 1996 5. PAPER PATH A219V502.wmf 1. By-pass Feed 2. Paper Tray Feed 3. Copy Tray...

  • Page 11: Electrical Component Descriptions

    20 December 1996 ELECTRICAL COMPONENT DESCRIPTIONS 6. ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout and the point-to-point diagram on the waterproof paper in the pocket for symbols and index numbers. Symbol Name Function Index No. Motors Main Motor Drives all the main unit components except for the optics unit and fans.
  • Page 12 ELECTRICAL COMPONENT DESCRIPTIONS 20 December 1996 Symbol Name Function Index No. Tray Paper End Informs the CPU when the paper tray runs Sensor out of paper. Registration Sensor Detects the leading edge of the copy paper to determine the stop timing of the relay roller clutch, and detects misfeeds.
  • Page 13 20 December 1996 ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Fusing Thermofuse Provide back-up overheat protection in the fusing unit. Fusing Thermistor Monitors the temperature around the exposure lamp for overheat protection. Optics Thermistor Monitors the temperature around the exposure lamp for overheat protection.

  • Page 14: Detailed Descriptions

    SECTION 2 DETAILED DESCRIPTIONS...

  • Page 15: Opc Drum Characteristics

    20 December 1996 DRUM 1. DRUM 1.1 OPC DRUM CHARACTERISTICS The OPC (Organic Photoconductor) drum used in this copier is small in diameter (30 mm), ensuring good paper separation. An OPC drum has the following characteristics. 1. The drum is able to accept a high negative electrical charge in the dark. (The electrical resistance of a photoconductor is high in the absence of light.) 2.

  • Page 16: Drive Mechanism

    DRUM 20 December 1996 1.2 DRIVE MECHANISM A219D520.wmf The drive from the main motor [A] is transmitted to the drum [B] through a series of gears, a timing belt [C], and the drum drive shaft [D]. When the imaging unit is installed in the copier, the drum drive shaft engages inside the drum’s flange [E] as shown.
  • Page 17 20 December 1996 CHARGE 2. CHARGE 2.1 OVERVIEW A219D505.wmf A219D521.wmf This copier uses a single wire scorotron to charge the drum. The corona wire [A] generates a corona of negative ions when the high voltage supply unit applies a negative voltage. The stainless steel grid plate [B] ensures that the drum coating receives a uniform negative charge as it rotates past the corona unit.

  • Page 18: Charge Corona Wire Cleaner Mechanism

    CHARGE 20 December 1996 2.2 CHARGE CORONA WIRE CLEANER MECHANISM A219D536.wmf Pads [A] move along the charge corona wire as the wire cleaner knob [B] is manually slid in and out. The cleaner pad bracket [C] is connected to the wire cleaner knob. When the knob is pulled out, the pads move into contact with the corona wire as shown, since the casing [D] is narrower away from the home position.

  • Page 19: Charge Corona Circuit

    20 December 1996 CHARGE 2.3 CHARGE CORONA CIRCUIT Main Board High Voltage Supply Board 24 V C N 1 0 2 - 7 D C / D C G N D Converter C N 1 0 2 - 6 C Trigger C N 1 0 2 - 5 D C / D C T Trigger...
  • Page 20 OPTICS 20 December 1996 3. OPTICS 3.1 OVERVIEW A219D507.wmf During the copy cycle, an image of the original is reflected onto the drum surface through the optics assembly as follows: Light path: Exposure Lamp [A] → Original → First Mirror [B] → Second Mirror [C] → Third Mirror [D] →...

  • Page 21: Scanner Drive

    20 December 1996 OPTICS 3.2 SCANNER DRIVE A219D522.wmf A stepper motor [A] is used to drive the scanners. The first scanner [B], which consists of the exposure lamp and the first mirror, is connected to the first scanner belt [C]. The second scanner [D], which consists of the second and third mirrors, is connected to the second scanner belt [E].

  • Page 22: Lens Drive

    OPTICS 20 December 1996 3.3 LENS DRIVE A219D509.wmf : Reduction : Enlargement The lens motor [A] (stepper motor) changes the lens [B] position through the timing belt [C] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and the drum surface. The rotation of the lens drive pulley moves the lens back and forth in discrete steps.

  • Page 23: 4Th/5Th Mirror Drive

    20 December 1996 OPTICS 3.4 4TH/5TH MIRROR DRIVE A219D510.wmf The 4th/5th mirror drive motor [A] (stepper motor) changes the 4th/5th mirror assembly position through the pinion gears [B] and the rack gear [C] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and drum surface.

  • Page 24: Automatic Image Density Sensor

    OPTICS 20 December 1996 3.5 AUTOMATIC IMAGE DENSITY SENSOR A219D511.wmf A219D512.wmf The auto ID sensor [A], a photodiode, is mounted on the upper front frame. The sensor cover has a hole in it to allow light to fall directly onto the sensor. Sampling starts 6 millimeters from the leading edge of the original and continues for 11.5 millimeters from the leading edge of original in full size mode.

  • Page 25: Exposure Lamp Voltage Control

    20 December 1996 OPTICS 3.6 EXPOSURE LAMP VOLTAGE CONTROL The main board controls the exposure lamp voltage through the ac drive/dc power supply board. The exposure lamp voltage is based on the base lamp voltage and various correction factors. The method of control is different depending on whether the image density is manually selected or the auto image density mode is selected.
  • Page 26 OPTICS 20 December 1996 2) Image Density Adjustment Factor (SP34) Depending on the SP34 setting, the development bias and the exposure lamp settings are increased or decreased during ADS mode. SP34 Setting Setting Dev. Bias Exposure Lamp Normal Light –40 V Dark +40 V Lightest...
  • Page 27 20 December 1996 OPTICS 4) V Correction 1 Factor The light intensity may decrease because of dust accumulated on the optics parts. Additionally, the drum sensitivity gradually decreases during the drum’s life. This may cause dirty background on copies. To compensate for this, V corrections 1 and 2 are done.
  • Page 28 OPTICS 20 December 1996 6) Reproduction Ratio Correction Factor The exposure lamp voltage is increased depending on the selected magnification ratio in order to compensate for the change in concentration of light on the drum. Magnification Ratio Reproduction Ratio Correction Factor 50% to 61% +2 steps 62% to 119%...
  • Page 29 20 December 1996 ERASE 4. ERASE 4.1 OVERVIEW A219D513.wmf b c d e f g h i j k l m m l k j i h g f e d c b a A219D527.wmf The erase lamp [A], which is installed in the copier main frame, consists of a single row of white LEDs (38 LEDs) extended across the full width of the drum.

  • Page 30: Lead Edge Erase

    ERASE 20 December 1996 4.2 LEAD EDGE ERASE The entire line of LEDs turn on when the main motor turns on. They stay on until the erase margin slightly overlaps the lead edge of the original image area on the drum (Lead Edge Erase Margin). This prevents the shadow of the original edge from being developed on the copy.

  • Page 31: Trailing Edge Erase

    20 December 1996 ERASE 4.4 TRAILING EDGE ERASE This minimizes toner consumption. The entire line of LEDs turns on when the drum has turned 9 mm at the end of scanning (about 100 ms). The LEDs stay on to erase the leading edge of the latent image in the next copy cycle.
  • Page 32 DEVELOPMENT 20 December 1996 5. DEVELOPMENT 5.1 OVERVIEW A219D514.wmf When the main motor turns on, the development roller [A] and two agitators [B] and [C] start turning. There are permanent magnets in the development roller which attract the developer particles (which are about 50 µm in diameter) to the roller. The turning sleeve of the development roller carries the developer past the doctor blade [D] which trims the developer to the desired thickness.
  • Page 33 20 December 1996 DEVELOPMENT 5.2 DRIVE MECHANISM A219D515.wmf When the main motor [A] turns on, the drive is transmitted to the development drive shaft [B] through gears and a timing belt. The rotation of the development roller gear is transmitted to the agitator gears [C] through other gears.

  • Page 34: Cross-Mixing

    DEVELOPMENT 20 December 1996 5.3 CROSS-MIXING A219D516.wmf A cross-mixing mechanism is used 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. Two agitators (helical coils) [A] and [B] are used for cross-mixing. The 1st agitator [A] moves the developer from left to right.

  • Page 35: Development Bias For Image Density Control

    20 December 1996 DEVELOPMENT 5.4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROL The image density is controlled by changing two items: the amount of bias voltage applied to the development roller sleeve, and the amount of voltage applied to the exposure lamp. Applying a bias voltage to the development sleeve reduces the potential between the development roller and the drum, thereby reducing the amount of toner transferred.
  • Page 36 DEVELOPMENT 20 December 1996 5.4.1 Base Bias Voltage Factor in Manual Image Density Mode Darker Lighter Manual ID Level Exposure – 6 – 4 – 2 + 12 Lamp Voltage steps steps steps steps steps steps Factor Development Bias Voltage –200 –200 –200...
  • Page 37 20 December 1996 DEVELOPMENT 5.4.2 Base Bias Voltage Factor in Automatic Image Density (ADS) Mode The bias voltage for ADS mode depends on the background image density of the original which is measured by the ADS sensor. (See "Automatic Image Density Sensor"...

  • Page 38: Development Bias Circuit

    DEVELOPMENT 20 December 1996 5.5 DEVELOPMENT BIAS CIRCUIT Main Board High Voltage Supply Board 24 V C N 1 0 2 - 7 D C / D C G N D Converter C N 1 0 2 - 6 C Trigger C N 1 0 2 - 5 D C / D C T Trigger...

  • Page 39: Toner Supply

    20 December 1996 TONER SUPPLY 6. TONER SUPPLY 6.1 TONER BOTTLE REPLENISHMENT MECHANISM [C] [B] A219D517.wmf A219D518.wmf When a toner bottle is placed on the bottle holder unit [A] and pushed back in completely, the following happens automatically. • The pin [B] on the imaging unit toner shutter [C] is pushed out (shutter opened) by the projection [D].

  • Page 40: Toner Supply Mechanism

    TONER SUPPLY 20 December 1996 6.2 TONER SUPPLY MECHANISM A219D519.wmf The toner supply motor [A] drives the toner bottle [B] and the mylar blades [C]. First, the toner falls down into the toner holder. The two toner supply mylar blades transfer the toner to the opening [D], then the toner falls down into the development unit.

  • Page 41: Toner Density Detection Mechanism

    20 December 1996 TONER SUPPLY 6.3 TONER DENSITY DETECTION MECHANISM A219D516-2.wmf A toner density sensor (TD sensor) [A] is used for toner density control. The TD sensor is located under the 1st agitator [B]. The developer being conveyed by the 1st agitator passes over the top of the sensor. As the toner in the developer is consumed during development, the toner to carrier ratio changes, resulting in a change in the magnetic permeability of the developer.

  • Page 42: Td Sensor Check And Toner Supply Timing

    TONER SUPPLY 20 December 1996 6.4 TD SENSOR CHECK AND TONER SUPPLY TIMING (seconds) Original Scan D r u m C h a r g e TD Sensor Toner Supply Motor A219D540.wmf The TD sensor voltage is monitored for two seconds when the 1st copy drum charge starts.

  • Page 43: Toner Supply Control

    20 December 1996 TONER SUPPLY 6.5 TONER SUPPLY CONTROL 6.5.1 Modes Available NOTE: The following pages explain how the various settings control the toner supply mechanism. They should not be adjusted in the field, unless instructed to do so as a countermeasure for a specific problem that may occur in the future.
  • Page 44 TONER SUPPLY 20 December 1996 1) Target Toner Sensor Voltage - Method 1 - Normally (if 0 or 2 is selected with SP30) the voltage is determined by the following factors: Target Toner Sensor Voltage (V ) = Initial Developer Setting Voltage (V Toner Density Adjustment Factor a) Initial Developer Setting Voltage (V This voltage is adjusted to 1.9 ±...
  • Page 45 20 December 1996 TONER SUPPLY 2) Toner Supply Amount - Method 1 - Normally (if 0 or 1 is selected with SP30), the toner supply amount is determined by the difference between the actual TD sensor voltage (V ) and the target toner sensor voltage (V ).
  • Page 46 TONER SUPPLY 20 December 1996 6.5.3 Fixed Supply Mode If 4 is selected with SP30, the TD sensor is not used for toner supply control. A fixed amount of toner is supplied every copy cycle. The toner supply amount is determined by the SP32 setting. 6.5.4 Abnormal Condition in Toner Density Detection If the output of the TD sensor goes below 0.2 volts (indicating far too much toner), the CPU determines that the toner density supply is abnormal.

  • Page 47: Toner End

    20 December 1996 TONER SUPPLY 6.6 TONER END Toner Supply Level TD Sensor Voltage Level [V Toner Supply Motor On Time < V ≤ V + S/16 ≤ V + S/16 < V + S/8 2 x t ≤ V + S/8 <...
  • Page 48 TONER SUPPLY 20 December 1996 6.6.3 Toner End Recovery If the main switch is turned off and on, or the front door is opened and closed during a toner end condition, the machine checks the toner bottle for replacement. The main motor turns on and the toner supply motor is intermittently energized.

  • Page 49: Image Transfer And Paper Separation

    20 December 1996 IMAGE TRANSFER AND PAPER SEPARATION 7. IMAGE TRANSFER AND PAPER SEPARATION 7.1 OVERALL A219D528.wmf A high negative voltage (approximately –5 kV) is applied to the transfer corona wire [A], and the corona wire generates negative ions. These negative ions are applied to the back side of the copy paper.

  • Page 50: Transfer Corona And Discharge Plate Circuit

    IMAGE TRANSFER AND PAPER SEPARATION 20 December 1996 7.2 TRANSFER CORONA AND DISCHARGE PLATE CIRCUIT Main Board High Voltage Supply Board 24 V C N 1 0 2 - 7 D C / D C G N D Converter C N 1 0 2 - 6 C Trigger C N 1 0 2 - 5 D C / D C...

  • Page 51: Drum Cleaning

    20 December 1996 DRUM CLEANING 8. DRUM CLEANING 8.1 OVERVIEW A219D528-2.wmf A counter blade system is used for drum cleaning. The cleaning blade [A] scrapes off any toner remaining on the drum after the image is transferred to the paper. The removed toner is transported into the developer to be recycled.

  • Page 52: Toner Recycling Mechanism

    DRUM CLEANING 20 December 1996 8.2 TONER RECYCLING MECHANISM A219D530.wmf The toner removed from the drum falls onto the toner collection coil [A]. The drum gear rotation is directly transmitted to the toner collection coil drive gear. As the coil rotates, the toner moves from rear to front until it reaches the toner recycling belt [B].
  • Page 53 20 December 1996 QUENCHING 9. QUENCHING A219D513-2.wmf In preparation for the next copy cycle, light from the quenching lamp (QL) [A], which is installed in the upper unit, neutralizes any charge remaining on the drum. LEDs are used for quenching and the lamp is turned on whenever the main motor rotates.

  • Page 54: Paper Feed And Registration

    PAPER FEED AND REGISTRATION 20 December 1996 10. PAPER FEED AND REGISTRATION 10.1 OVERVIEW A219D500.wmf This copier has one paper feed station and a by-pass feed table. The paper feed station uses a paper tray [A] which can hold 500 sheets. The by-pass feed table [B] can hold 80 sheets.

  • Page 55: Paper Tray Feed

    20 December 1996 PAPER FEED AND REGISTRATION 10.2 PAPER TRAY FEED 10.2.1 Paper Lift Mechanism A219D534.wmf A219D535.wmf The capacity of this tray is higher than usual for a corner separator type. Because of this, there are two springs to lift the bottom plate. As the tray is pushed into the machine, shutter [A] under the tray pushes against projection [B].
  • Page 56 PAPER FEED AND REGISTRATION 20 December 1996 10.2.2 Paper Feed Mechanism A219D508.wmf A219D523.wmf Through several gears and a timing belt, main motor rotation is transmitted to the tray paper feed clutch gear [A] and the relay roller clutch gear [B]. -Feed rollers- The tray paper feed clutch gear is on the same shaft as the semicircular feed rollers [C].

  • Page 57: By-Pass Feed

    20 December 1996 PAPER FEED AND REGISTRATION 10.3 BY-PASS FEED 10.3.1 Overview A219D501.wmf The by-pass feed table [A] can hold 80 sheets of paper. This machine does not have a by-pass feed cover sensor. The by-pass feed indicator is always displayed on the operation panel. The Add Paper indicator will light when the user selects by-pass feed while the by-pass feed table is closed or if there is no paper on the by-pass feed table.
  • Page 58 PAPER FEED AND REGISTRATION 20 December 1996 10.3.2 Paper Feed Mechanism and Paper End Detection A219D524.wmf A219D502.wmf This machine uses a feed roller [A] and friction pad [B] mechanism, with drive from the main motor [C] transmitted when the by-pass feed clutch [D] turns on.

  • Page 59: Paper Registration

    20 December 1996 PAPER FEED AND REGISTRATION 10.4 PAPER REGISTRATION A219D529.wmf A219D523-2.wmf Main motor rotation is transmitted to the registration roller clutch gear [A] through several gears and a timing belt. When the registration clutch [B] is energized, the rotation of the clutch gear is transmitted to the lower registration roller [C].

  • Page 60: Side Fence Double Stopper Mechanism

    PAPER FEED AND REGISTRATION 20 December 1996 10.5 SIDE FENCE DOUBLE STOPPER MECHANISM A219D503.wmf There is a side fence stopper mechanism for both the front and rear side fences. If the tray is closed with excessive force after loading paper, paper may come over the rear side fence, because the fence is deformed by the weight of the paper leaning against it.

  • Page 61: Paper End Detection

    20 December 1996 PAPER FEED AND REGISTRATION 10.6 PAPER END DETECTION A219D504.wmf The paper end feeler [A] is on the same shaft as the paper end actuator [B]. When the paper tray runs out of paper, the paper end feeler drops into the cutout [C] in the tray bottom plate.

  • Page 62: Paper Feed And Misfeed Detection Timing

    PAPER FEED AND REGISTRATION 20 December 1996 10.7 PAPER FEED AND MISFEED DETECTION TIMING (second) A4 sideways Start Key Main Motor 0 . 1 0 0 . 3 5 Tray Paper Feed Clutch 0 . 1 3 Relay Roller Clutch 2 .
  • Page 63 20 December 1996 PAPER FEED AND REGISTRATION 10.8 OTHERS (from right to left) Size A3, F( 8 "x13" ) A4 Lengthwise A4 Sideways A5 Sideways, 11"x17" B4, 8 "x14" B5 Sideways, "x11" B5 Lengthwise, 11"x8 " * (Asterisk) : ON (Not pushed) : OFF (Pushed) A219D525.wmf 10.8.1 Paper Size Detection...

  • Page 64: Image Fusing

    IMAGE FUSING 20 December 1996 11. IMAGE FUSING 11.1 OVERVIEW A219D531.wmf A219D539.wmf After the image is transferred, the copy paper enters the fusing unit. The image is fused to the copy paper by heat and pressure using a hot roller [A] and a pressure roller [B].

  • Page 65: Fusing Drive Mechanism

    20 December 1996 IMAGE FUSING 11.2 FUSING DRIVE MECHANISM A219D539-2.wmf A219D532.wmf Drive from the main motor [A] is transmitted to the hot roller [B] through idle gears and a timing belt. The hot roller always rotates while the main motor rotates.

  • Page 66: Fusing Lamp Control

    IMAGE FUSING 20 December 1996 11.3 FUSING LAMP CONTROL The CPU monitors the temperature of the hot roller surface using a thermistor. The fusing lamp is turned on and off to keep the hot roller surface at the target temperature. The target temperature depends on the machine condition as follows: A219D533.wmf Fusing Lamp ON/OFF...
  • Page 67 20 December 1996 IMAGE FUSING When the main switch is turned on, the CPU turns on the fusing lamp. When the fusing thermistor detects the ready temperature, the machine enters the ready condition. After the ready temperature is detected, the CPU keeps the fusing temperature at 190°C for one minute, then the target temperature is changed to 120°C (120 V machines) or 130°C (230 V machines).

  • Page 68: Fusing Lamp Control Circuit

    IMAGE FUSING 20 December 1996 11.4 FUSING LAMP CONTROL CIRCUIT 11.4.1 Overview C N 1 1 3 - 2 Fusing C N 1 1 3 - 1 Thermistor C N 2 0 7 - 7 C N 1 0 1 - 3 T 2 0 8 24 V F u s i n g L a m p...
  • Page 69 20 December 1996 IMAGE FUSING 11.4.2 On/Off Control When the main switch is turned on, the main board starts to output a trigger pulse, which has the same timing as the zero cross signal, to the ac drive/dc power supply board. This trigger pulse allows maximum ac power to be applied to the fusing lamp.
  • Page 70 IMAGE FUSING 20 December 1996 11.4.4 Overheat Protection There is an overheat protection circuit in the main board. If the hot roller temperature reaches 245°C during the main motor off condition, or 255°C during the main motor on condition, the resistance of the thermistor (between CN113-1 and CN113-2) becomes too low.

  • Page 71: Installation

    SECTION 3 INSTALLATION...

  • Page 72: Installation Requirements

    20 December 1996 INSTALLATION REQUIREMENTS 1. INSTALLATION REQUIREMENTS 1.1 ENVIRONMENT 1. Temperature Range: 10°C to 30°C (50°F to 87°F) 2. Humidity Range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 lux (Do not exposure to direct sunlight.) 4. Ventilation: Room air should turn over at least 3 times per hour 5.

  • Page 73: Minimum Space Requirements

    INSTALLATION REQUIREMENTS 20 December 1996 1.3 MINIMUM SPACE REQUIREMENTS Place the copier near the power source, providing clearance as shown: More than 10 cm, 4.0" More than More than 20 cm, 7.9" 21 cm, 8.1" More than 70 cm, 27.6" A219I506.wmf 1.4 POWER REQUIREMENTS CAUTION...

  • Page 74: Accessory Check

    20 December 1996 COPIER (A219) 2. COPIER (A219) 2.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: 1. Model Name Decal (-10, -22 machines) 2. Symbol Explanation Decal - Multi-language 3. Installation Procedure - Multi-language (-10, -15, -22, -26 machines) 4.

  • Page 75: Installation Procedure

    COPIER (A219) 20 December 1996 2.2 INSTALLATION PROCEDURE A219I500.wmf A219I501.wmf CAUTION Do not plug in the power cord before starting the following procedure. 1. Remove all strips of tape shown above. 2. Pull out the paper tray [A], and remove the cardboard [B]. 3.
  • Page 76 20 December 1996 COPIER (A219) A219I502.wmf A219I503.wmf 4. Turn the "B1" lever [A] counterclockwise to lower the transfer corona unit. 5. Remove the knob screw [B] and gently pull out the imaging unit [C]. Then place it on a clean sheet of paper. 6.
  • Page 77 COPIER (A219) 20 December 1996 A219I504.wmf 9. Install the toner bottle holder [A] in the copier as shown. 10. Shake the toner bottle [B] well. NOTE: Do not remove the bottle cap [C] of the toner bottle at this time. 11.
  • Page 78 20 December 1996 COPIER (A219) A219I505.wmf 13. Pull the paper tray [A] out and turn the paper size dial [B] to select the appropriate size. Adjust the side guides [C] and the end guide [D] to match the paper size. NOTE: 1) Make sure the stack of paper is aligned, and that there is no space between the side guides and the paper stack.

  • Page 79: Document Feeder (A662)

    DOCUMENT FEEDER (A662) 20 December 1996 3. DOCUMENT FEEDER (A662) 3.1 ACCESSORY CHECK Check the accessories against the following list: Description Q’ty 1. Voltage Reference Decal..........1 2. Thumb Screw M4 x 12............2 3. Stud Screw (M3) ............... 2 4.
  • Page 80 20 December 1996 DOCUMENT FEEDER (A662) 3.2 INSTALLATION PROCEDURE [F] 230 ~ 240 V [D] 220 ~ 230 V A662I500.wmf A662I501.img CAUTION When installing the DF, make sure the copier is unplugged. 1. Remove the platen cover [A] from the copier. 2.
  • Page 81 DOCUMENT FEEDER (A662) 20 December 1996 A662I502.img A662I503.wmf A662I504.wmf 5. Insert the DF [A] into the holes [B] in the copier upper cover. 6. Secure the DF to the copier (2 thumb screws [C]). 7. Remove the rear cover [D] (2 screws) and cut away the portion [E] with cutting pliers as shown.
  • Page 82 20 December 1996 DOCUMENT FEEDER (A662) A662I514.img A662I505.wmf A662I515.img 10. Reinstall the rear cover. 11. Plug the optics fiber cable [A] into the DF and the copier. 12. Plug the power supply cord [B] of the DF into the outlet in the copier rear cover.
  • Page 83 SORTER (A657) 20 December 1996 4. SORTER (A657) 4.1 ACCESSORY CHECK Check the accessories against the following list: Description Q’ty 1. Holder Bracket ..............1 2. Magnet Catch ..............1 3. Tapping Screw M4 x 6 ............6 4. Grounding Screw M4 x 8 ..........1 5.
  • Page 84 20 December 1996 SORTER (A657) 4.2 INSTALLATION PROCEDURE A657I500.wmf A657I501.wmf NOTE: 1) Keep the shipping retainers after installing the machine. They will be reused if the machine will be transported to an another location in the future. 2) Proper installation of the shipping retainers is required in order to avoid any transport damage.
  • Page 85 SORTER (A657) 20 December 1996 A657I502.wmf A657I503.wmf 3. Remove the 2 portions [A] on the left hand side of the copier with cutting pliers as shown. 4. Remove the rear cover [B] (2 screws). 5. Mount the sorter holder bracket [C] on the copier frame (3 tapping screws).
  • Page 86 20 December 1996 SORTER (A657) A657I504.wmf 7. Install the sorter [A] on the sorter holder bracket [B] (1 snap ring) as shown. 8. Insert the sorter harness [C] and the grounding wire [D] through the opening in the lower left cover. Plug the connector in to CN130 [E] on the main control board, and secure the grounding wire to the copier frame [F] (1 M4 x 8 screw).
  • Page 87 OTHERS 20 December 1996 5. OTHERS 5.1 OPTICS ANTI-CONDENSATION HEATER INSTALLATION (OPTION) A219I507.wmf NOTE: The optics anti-condensation heater keeps water from condensing on the copier’s mirrors. Such condensation occurs at cold temperatures with high humidity, and causes the first few copies of the day to be dark, or even black. The heater is available as a service part.
  • Page 88 20 December 1996 OTHERS 4. Pass the connector [B] through the opening [C], and mount the anit-condensation heater [D] as shown (1 screw). 5. Connect the red two-pin connector [E] at the rear of the copier to the heater’s connector [B] (red). 6.

  • Page 89: Tray Heater Installation (Option)

    OTHERS 20 December 1996 5.2 TRAY HEATER INSTALLATION (OPTION) A219I508.wmf NOTE: The optional tray heater keeps copy paper dry. In humid environments, copy paper may crease as it comes out of the fusing unit. The heater is available as a service part. (See the parts catalog.) CAUTION Unplug the copier power cord before starting the following procedure.

  • Page 90: Service Tables

    SECTION 4 SERVICE TABLES...

  • Page 91: Service Remarks

    20 December 1996 SERVICE REMARKS 1. SERVICE REMARKS 1.1 GENERAL CAUTIONS 1. To prevent physical injury, keep hands away from the mechanical drive components when the main switch is on (especially during the warm-up cycle). If the key is pressed before the copier finishes the warm-up cycle, the Start indicator starts blinking and the copier starts making copies as soon as the warm-up cycle is completed.
  • Page 92 SERVICE REMARKS 20 December 1996 10. Be careful not to damage the edge of the cleaning blade. 11. After installing a new cleaning blade, be sure to apply setting powder evenly on the surface and edge of the blade. 12. When installing a NEW drum, do the following: 1) Apply setting powder to the entire surface of the drum.

  • Page 93: Transfer Corona

    20 December 1996 SERVICE REMARKS 8. Whenever cleaning or replacing the optics, all the following actions must be done in order. 1) Optics cleaning 2) Open SP33 (Image Bias Adjustment - Manual ID Mode) and return the setting to the normal value if it has been changed. 3) SP48 (Light Intensity Adjustment) - see the SP mode table for details 4) SP56 (ADS Reference Voltage Adjustment) - see the SP mode table for details...
  • Page 94 SERVICE REMARKS 20 December 1996 1.6 PAPER FEED 1. Do not touch the feed rollers with bare hands. 2. The side fences and the end fence of the paper tray should be positioned correctly so that they securely hold the paper. Make sure the stack of paper is aligned, and that there is no space between the side guides and the paper stack.
  • Page 95 20 December 1996 SERVICE REMARKS 5. Securely tighten the screws used for grounding the following PCBs when reinstalling them. • Main Control Board • AC Drive/DC Power Supply Board • High Voltage Supply Board C/G/B/T/S 6. If the optional tray and anti-condensation heaters have been installed, keep the copier power cord plugged in, even when the copier main switch is turned off.

  • Page 96: Program Modes

    PROGRAM MODES 20 December 1996 2. PROGRAM MODES 2.1 BASIC OPERATION 1. Component This copier is equipped with two program modes. One is the Service Program (SP) Mode for factory and field technician usage, and the other is the User Program (UP) mode for the user.
  • Page 97 20 December 1996 PROGRAM MODES 2.2 SP MODE 1. Service Program Mode Access Procedure How to enter the SP mode 1. Press the following keys in sequence. → → → → NOTE: 1) The above procedure must be finished within 20 seconds. 2) Hold the final key for more than 3 seconds.

  • Page 98: Sp Mode Quick Reference Table

    PROGRAM MODES 20 December 1996 2.3 SP MODE QUICK REFERENCE TABLE SP Mode SP Mode Function Function Forced Start (Free Run) Lead Edge Erase Margin Adjustment Free Run with Exposure Lamp Registration Adjustment Misfeed Detection Off Vertical Magnification Adjustment Free Run Horizontal Magnification Adjustment Input Check...

  • Page 99: Up Mode And Sp Mode Cross Reference Table

    20 December 1996 PROGRAM MODES SP Mode SP Mode Function Function Imaging Unit Counter Display Correction Reset Sorter Operation Correction Reset Special Paper Size Setting Toner End Force Cancel Sorter Bin Capacity Service Call (E5) Reset Auto Shut Off (Energy Star) Total Counter Clear On/Off Auto Energy Saver Mode On/Off...

  • Page 100: Service Program Mode Table

    PROGRAM MODES 20 December 1996 2.5 SERVICE PROGRAM MODE TABLE 1. In the Function column, comments (extra information) are in italics. 2. In the Settings column, the default value is printed in bold letters. 3. If there is a mark in the Mode No. column, copies can be made within this SP Mode.
  • Page 101 20 December 1996 PROGRAM MODES Mode No. Function Settings Input Check Enter the desired number given in the following table. The magnification indicator is used to display the input data from the sensors while making a normal copy. Press the key to perform this mode.
  • Page 102 PROGRAM MODES 20 December 1996 Mode No. Function Settings Output Check Use to turn on individual electrical components. Enter the desired number given in the following table. Press the key to turn on the electrical component. Press the key to turn off the electrical component.
  • Page 103 20 December 1996 PROGRAM MODES Mode No. Function Settings Auto Shut Off Selects the auto shut off time. 0: 30 min. Time Setting 1: 15 min. The copier main switch is shut off automatically after (Energy Star) 2: 60 min. the selected auto shut off time, if SP77 is at "0".
  • Page 104 PROGRAM MODES 20 December 1996 Mode No. Function Settings Toner Supply Selects the toner supply system. Default = 0 Mode Selection Normally, this value should not be changed. Toner Supply System Note Setting Detect supply mode using Default the initial TD sensor setting.
  • Page 105 20 December 1996 PROGRAM MODES Mode No. Function Settings Image Bias Adjusts the development bias voltage used in 0: Normal Adjustment manual ID mode. This adjustment affects all manual 1: Darker (Manual ID ID settings. Use this SP mode to adjust the density 2: Darkest Mode) of pale gray areas.
  • Page 106 PROGRAM MODES 20 December 1996 Mode No. Function Settings TD Sensor Adjust the sensitivity of the TD sensor. 0 ~ 20 Sensitivity Default = 15 Normally, this value should not be changed. Setting SP Setting Sensitivity (V/wt%) Note 0.05 0.10 ↓...
  • Page 107 20 December 1996 PROGRAM MODES Mode No. Function Settings Horizontal Adjusts magnification perpendicular to the direction 0 ~ 50 Magnification of paper travel, by changing the home position of Default = 20 Adjustment the lens and mirrors. 0.2% per step (–4.0% to +6.0%). Check the focusing after doing this SP mode, and adjust with SP47 if necessary.
  • Page 108 PROGRAM MODES 20 December 1996 Mode No. Function Settings Fusing Adjusts the control temperature of the hot roller 120 V Machines Temperature during copying in 1°C steps. 180°C ~ 195°C Adjustment Default = 190°C 230 V Machines 180°C ~ 200°C Default = 190°C Fusing Ready Adjusts the ready temperature of the hot roller...
  • Page 109 20 December 1996 PROGRAM MODES Mode No. Function Settings Optics Displays the optics temperature detected by the Temperature optics thermistor. Display Press the key to monitor the temperature during the normal copy cycle. Drum Potential Factory use only. Measurement (With Paper) Drum Potential Factory use only.
  • Page 110 PROGRAM MODES 20 December 1996 Mode No. Function Settings Correction Selects or deselects V correction. 0: V Selection Correction Keep this setting at 0. 1: No V Correction Imaging Unit Shows the total number of copies made so far by Counter the imaging unit installed in the machine.
  • Page 111 20 December 1996 PROGRAM MODES Mode No. Function Settings Factory Factory use only. Potential Adjustment Total Copy Displays the total (electrical) copy counter. Counter The first three digits are displayed in the Display magnification indicator. Press the key to view the last three digits. The mechanical total counter and the electrical total counter may not always display the same value, because of initial differences in the...
  • Page 112 PROGRAM MODES 20 December 1996 Mode No. Function Settings Clear All Clears all counters and returns all modes to the 0: No Memory default settings. See the Clear All Memory 1: Yes Procedure in this section for more details. Normally, this SP mode should not be performed.
  • Page 113 20 December 1996 PROGRAM MODES Mode No. Function Settings Total Misfeeds Displays the total number of misfeeds excluding original misfeeds in the DF. Since the copy counter for displaying the current SP mode number has only 2 digits, the manual image density indicator is used to display the first digit.

  • Page 114: Clear All Memory Procedure

    PROGRAM MODES 20 December 1996 2.6 CLEAR ALL MEMORY PROCEDURE CAUTION: The Clear All Memory procedure (SP99) resets all the correction data for copy process control and all the software counters, and returns all modes and adjustments to the default settings. Normally, this SP mode should not be performed.
  • Page 115 20 December 1996 PROGRAM MODES 4. Refer to the "SP MODE FACTORY SETTING DATA" sheet located behind the operation guide sheet installed on the front cover, and enter the data that were stored in the following SP modes at the factory. •...

  • Page 116: Practical Sp Mode Use Table

    PRACTICAL SP MODE USE TABLE 20 December 1996 3. PRACTICAL SP MODE USE TABLE The following table shows the SP modes that must be done, and the order in which they must be done when the listed items are replaced or cleaned. (Priority Number) Replaced or Cleaned Item Optics...

  • Page 117: Test Points (Main Control Board)

    20 December 1996 SERVICE TABLES 4. SERVICE TABLES 4.1 TEST POINTS (Main Control Board) Number Label Monitored Signal TP101 (HET) Fusing thermistor output TP102 (ADS) Auto image density sensor output TP103 (ETH) Optics thermistor output TP104 (T. CON) Toner density sensor target control voltage output TP105 (TV) Toner density sensor output...

  • Page 118: Preventive Maintenance

    SECTION 5 PREVENTIVE MAINTENANCE...

  • Page 119: Preventive Maintenance Schedule

    20 December 1996 PREVENTIVE MAINTENANCE SCHEDULE 1. PREVENTIVE MAINTENANCE SCHEDULE 1.1 PM TABLE NOTE: 1) The amounts mentioned as the PM interval indicate the number of copies. 2) Refer to "REGULAR PM PROCEDURE" in this section. Symbol key: L: Lubricate R: Replace C: Clean I: Inspect A: Adjust 45 k 90 k 135 k 180 k Notes...
  • Page 120 PREVENTIVE MAINTENANCE SCHEDULE 20 December 1996 45 k 90 k 135 k 180 k Notes Cleaning Entrance Seal Dry cloth. Replace if necessary Development Unit Developer Development Unit Entrance Seal Toner Supply Drive Gear Development Drive Gear Grease - CPL501 Imaging Unit Lower Cover Dry cloth Paper Feed (for each paper feed station)
  • Page 121 20 December 1996 PREVENTIVE MAINTENANCE SCHEDULE 24 k 48 k Notes DOCUMENT FEEDER (A662) (for originals) Transport Belt Belt cleaner Friction Belt Belt cleaner Pick-up Roller Soft cloth dampened with water Feed Roller Soft cloth dampened with water Notes SORTER (A657) Bin Guide/Wheel Silicone Grease - G501: If movement is not smooth.

  • Page 122: Regular Pm Procedure

    PREVENTIVE MAINTENANCE SCHEDULE 20 December 1996 1.2 REGULAR PM PROCEDURE Every 90 k Others Every 45 k 1. Make a copy Make a copy of an OS-A3 test chart at manual image density level 4. 2. Optics (every 45 k) 1.
  • Page 123 20 December 1996 PREVENTIVE MAINTENANCE SCHEDULE 4. Remove all toner, developer and the drum from the imaging unit. Clean the whole imaging unit, especially the lower cover with a dry cloth. 5. Inspect the development entrance seal, toner supply drive gear, and development drive gears in the imaging unit (lubricate the latter with 2 or 3 spots of CPL501).
  • Page 124 PREVENTIVE MAINTENANCE SCHEDULE 20 December 1996 7. Fusing Unit 1. Clean the stripper pawls with a suitable (every 45 k) solvent. (Replace every 135 k.) 2. Clean the fusing entrance and exit guide plates with a suitable solvent. 3. Clean the fusing thermistor with a suitable solvent.

  • Page 125: Special Tools And Lubricants

    20 December 1996 SPECIAL TOOLS AND LUBRICANTS 2. SPECIAL TOOLS AND LUBRICANTS Part Number Description Q’ty A184 9501 Scanner Positioning Pin (2 pcs/set) 5420 9516 Test Chart - OS-A3 (10 pcs/set) 5442 9103 Launa Oil 5203 9501 Silicone Grease - G-501 5420 9507 Digital Multimeter 5442 9101...

  • Page 126: Replacement And Adjustment

    SECTION 6 REPLACEMENT ADJUSTMENT...

  • Page 127: Exterior And Inner Covers

    20 December 1996 EXTERIOR AND INNER COVERS 1. EXTERIOR AND INNER COVERS 1.1 EXTERIOR COVER REMOVAL A219R500.wmf 1.1.1 Front Cover 1. Open the front cover [A]. 2. Remove the front cover [A] (2 locking pins [B]). 1.1.2 Front Right Cover 1.
  • Page 128 EXTERIOR AND INNER COVERS 20 December 1996 A219R500-2.wmf 1.1.4 Lower Right Cover 1. Remove the lower right cover [A] (2 screws). 1.1.5 Lower Left Cover 1. Remove the lower left cover [B] (2 screws). 1.1.6 Upper Left Cover 1. Remove the lower left cover [B] (2 screws). 2.
  • Page 129 20 December 1996 EXTERIOR AND INNER COVERS 1.1.8 Upper Cover A219R500-3.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the platen cover or DF. 3. Remove the left side scale [A] (2 screws). 4. Remove the exposure glass [B]. (See Exposure Glass Removal.) 5.

  • Page 130: Inner Cover Removal

    EXTERIOR AND INNER COVERS 20 December 1996 1.2 INNER COVER REMOVAL A219R501.wmf 1. Open and remove the front cover [A]. (See Front Cover Removal.) 2. Pull up the toner supply unit lever [B]. 3. Remove the registration knob [C] and the fusing unit knob [D] (1 screw each).

  • Page 131: Exposure Glass Removal

    20 December 1996 OPTICS 2. OPTICS 2.1 EXPOSURE GLASS REMOVAL A219R502.wmf 1. Remove the left scale [A] (2 shoulder screws). 2. To remove the exposure glass, grasp the left edge of the exposure glass and lift it up, then slide the other edge out from under the right glass holder.

  • Page 132: 1St Scanner/Exposure Lamp Removal

    OPTICS 20 December 1996 2.2 1ST SCANNER/EXPOSURE LAMP REMOVAL A219R508.wmf A219R528.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the platen cover or DF. 3. Remove the exposure glass. (See Exposure Glass Removal.) 4. Remove the upper cover. (See Upper Cover Removal.) 5.
  • Page 133 20 December 1996 OPTICS -Reinstallation- A219R509.wmf A219R527-2.wmf 1. Reinstall the 1st scanner. (2 screws [A]; do not fully tighten the screws.) 2. Remove the lens cover [B]. NOTE: When replacing the lens cover, be sure to: • Position the ribbon cable [C] so that it is not caught by the cover, as shown.

  • Page 134: Scanner Belt Removal

    OPTICS 20 December 1996 2.3 SCANNER BELT REMOVAL A219R510.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the platen cover or DF. 3. Remove the exposure glass. (See Exposure Glass Removal.) 4. Remove the upper cover. (See Upper Cover Removal.) 5.

  • Page 135: 1St And 2Nd Scanner Position Adjustment

    20 December 1996 OPTICS 2.4 1ST AND 2ND SCANNER POSITION ADJUSTMENT A219R511.wmf NOTE: Adjust when replacing the scanner belt or the 2nd scanner. 1. Turn off the main switch and unplug the power supply cord. 2. Remove the upper cover. (See Upper Cover Removal.) 3.

  • Page 136: Scanner Drive Motor Removal

    OPTICS 20 December 1996 2.5 SCANNER DRIVE MOTOR REMOVAL A219R503.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the upper cover. (See Upper Cover Removal.) 3. Remove the motor [A] (2 screws and 1 connector). 6-10...

  • Page 137: Lens Drive Motor Removal

    20 December 1996 OPTICS 2.6 LENS DRIVE MOTOR REMOVAL A219R508-2.wmf A219R504.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the upper cover. (See Upper Cover Removal.) 3. Remove the lower left cover. (See Lower Left Cover Removal.) 4.

  • Page 138: 4Th/5Th Mirror Drive Motor Removal

    OPTICS 20 December 1996 2.7 4TH/5TH MIRROR DRIVE MOTOR REMOVAL A219R505.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the inner cover. (See Inner Cover Removal.) 3. Remove the toner supply unit. 4. Remove the imaging unit. (See Imaging Unit Removal.) 5.

  • Page 139: 2Nd Mirror Replacement

    20 December 1996 OPTICS 2.8 2ND MIRROR REPLACEMENT A219R526.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the upper cover. (See Upper Cover Removal.) 3. Move the 1st scanner to home position. CAUTION: To move the 1st scanner, pull the scanner belt. Do not apply force to the scanner directly.

  • Page 140: 3Rd Mirror Replacement

    OPTICS 20 December 1996 2.9 3RD MIRROR REPLACEMENT A219R506.wmf A219R507.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the upper cover. (See Upper Cover Removal.) 3. Move the 1st scanner two thirds of the way from the left scale, as shown. CAUTION: To move the 1st scanner, pull the scanner belt.

  • Page 141: 4Th And 5Th Mirror Replacement

    20 December 1996 OPTICS 2.10 4TH AND 5TH MIRROR REPLACEMENT A219R527.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the upper cover. (See Upper Cover Removal.) 3. Remove the lens cover [A]. NOTE: When replacing the lens cover, be sure to: •...
  • Page 142 OPTICS 20 December 1996 A219R531.wmf A219R532.wmf 4. Remove the 4th/5th mirror unit. 1) Remove the bracket [A]. 2) Remove the 4th/5th mirror unit [B], as shown. 5. Replace the 4th and 5th mirrors [C, D] in the same way as the 2nd mirror. NOTE: Make sure that the reflecting surface [E] faces the lens.

  • Page 143: Ads Sensor Replacement

    20 December 1996 OPTICS 2.11 ADS SENSOR REPLACEMENT A219R566.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the exposure glass. (See Exposure Lamp Removal.) 3. Remove the ADS sensor [A] and cover [B] as an ass’y (1 screw and 1 connector).

  • Page 144: Around The Drum

    AROUND THE DRUM 20 December 1996 3. AROUND THE DRUM 3.1 IMAGING UNIT REMOVAL AND TONER BOTTLE REMOVAL A219R516.wmf A219R517.wmf 1. Open the front cover. 2. Raise the toner bottle holder lever [A] as shown. 3. Then push down the securing lever [B], and remove the toner bottle holder [C]. 4.

  • Page 145: Charge Corona Wire And Charge Corona Grid Replacement

    20 December 1996 AROUND THE DRUM 3.2 CHARGE CORONA WIRE AND CHARGE CORONA GRID REPLACEMENT A219R560.wmf A219R518.wmf 1. Open the front cover. 2. Remove the imaging unit. (See Imaging Unit Removal.) 3. Remove the charge corona unit [A] (1 screw) from the imaging unit. 4.

  • Page 146: Cleaning Blade Replacement

    AROUND THE DRUM 20 December 1996 3.3 CLEANING BLADE REPLACEMENT A219R519.wmf 1. Open the front cover. 2. Remove the imaging unit. (See Imaging Unit Removal.) 3. Remove the charge corona unit [A] (1 screw) and development case [B] (1 screw and 1 snap [C]) from the imaging unit. 4.

  • Page 147: Drum Replacement

    20 December 1996 AROUND THE DRUM 3.4 DRUM REPLACEMENT A219R520.wmf A219R521.wmf 1. Open the front cover. 2. Remove the imaging unit. (See Imaging Unit Removal.) 3. Remove the charge corona unit, cover, and cleaning blade from the imaging unit. 4. Remove the front side plate [A] (2 screws). 5.

  • Page 148: Toner Collection Coil And Toner Recycling Belt Replacement

    AROUND THE DRUM 20 December 1996 3.5 TONER COLLECTION COIL AND TONER RECYCLING BELT REPLACEMENT A219R558.wmf A219R522.wmf 1. Open the front cover. 2. Remove the imaging unit. (See Imaging Unit Removal.) 3. Cut the seal [A] as shown. 4. Remove the toner recycling cover [B] (2 screws). 5.

  • Page 149: Developer Replacement

    20 December 1996 AROUND THE DRUM 3.6 DEVELOPER REPLACEMENT A219R523.wmf A219R524.wmf NOTE: When performing the following procedures, make sure that the developer is not spilt in the imaging unit drive gear section. 1. Open the front cover. 2. Remove the imaging unit. (See Imaging Unit Removal.) 3.

  • Page 150: Replacement The Toner Density Sensor (Td Sensor)

    AROUND THE DRUM 20 December 1996 3.7 REPLACEMENT THE TONER DENSITY SENSOR (TD SENSOR) A219R568.wmf 1. Open the front cover. 2. Remove the imaging unit. (See imaging unit Removal.) 3. Empty all the developer on to the paper. (See developer replacement.) 4.

  • Page 151: Agitator Replacement

    20 December 1996 AROUND THE DRUM 3.8 AGITATOR REPLACEMENT A219R525.wmf 1. Open the front cover. 2. Remove the imaging unit. (See Imaging Unit Removal.) 3. Set the imaging unit on a large sheet of paper. 4. Remove the charge corona unit from the imaging unit. (See the charge corona unit removal procedures.) 5.

  • Page 152: Toner Supply Motor Ass'y Replacement

    AROUND THE DRUM 20 December 1996 3.9 TONER SUPPLY MOTOR ASS’Y REPLACEMENT A219R559.wmf NOTE: 1) Do not manually rotate the new toner supply motor. Doing so may cause damage to the motor. 2) Make sure not to touch the 6th mirror when performing this procedure.

  • Page 153: Erase Lamp Replacement

    20 December 1996 AROUND THE DRUM 3.10 ERASE LAMP REPLACEMENT A219R557.wmf A219R541.wmf 1. Open the front cover. 2. Remove the imaging unit. (See Imaging Unit Removal.) 3. Open the rear cover. (See Rear Cover Removal.) 4. Remove the high voltage supply board (4 screws and 6 connectors). 5.

  • Page 154: Quenching Lamp Replacement

    AROUND THE DRUM 20 December 1996 3.11 QUENCHING LAMP REPLACEMENT A219R540.wmf 1. Open the front cover. 2. Remove the imaging unit. (See Imaging Unit Removal.) 3. Open the rear cover. (See Rear Cover Removal.) 4. Remove the erase lamp. (See Erase Lamp Replacement.) 5.

  • Page 155: Paper Feed

    20 December 1996 PAPER FEED 4. PAPER FEED 4.1 PAPER TRAY REMOVAL A219R551.wmf 1. Pull the paper tray out. 2. Remove the paper tray [A] (4 screws). 6-29...

  • Page 156: Tray Feed Roller Replacement

    PAPER FEED 20 December 1996 4.2 TRAY FEED ROLLER REPLACEMENT A219R512.wmf A219R513.wmf 1. Turn off the main switch. 2. Remove the paper tray. (See Paper Tray Removal.) 3. Remove the front cover. (See Front Cover Removal.) 4. Remove the inner cover. (See Inner Cover Removal.) 5.

  • Page 157: Tray Paper Feed Roller Adjustment

    20 December 1996 PAPER FEED 4.3 TRAY PAPER FEED ROLLER ADJUSTMENT A219R567.wmf NOTE: Perform this adjustment if the customer uses only either A size (A3, A4, or A5) or B size (B4 or B5) paper in the paper tray. 1. Remove the tray paper feed roller. (See Tray Feed Roller Replacement.) 2.

  • Page 158: By-Pass Feed Roller And Friction Pad Replacement

    PAPER FEED 20 December 1996 4.4 BY-PASS FEED ROLLER AND FRICTION PAD REPLACEMENT A219R514.wmf A219R515.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the by-pass feed table. 1) Open the by-pass feed table. 2) Slide out the left shaft [A] and the right shaft of the by-pass feed table, as shown.
  • Page 159 20 December 1996 PAPER FEED A219R542.wmf 7. Remove the by-pass feed roller [A], as shown. 8. Remove the spring [B]. 9. Push the friction pad [C] down and then pull it out. NOTE: Don’t touch the feed roller with bare hands. - To reinstall - 1.

  • Page 160: By-Pass Paper Feed Clutch, High Voltage Supply Board, And Registration Clutch Replacement

    PAPER FEED 20 December 1996 4.5 BY-PASS PAPER FEED CLUTCH, HIGH VOLTAGE SUPPLY BOARD, AND REGISTRATION CLUTCH REPLACEMENT A219R545.wmf A219R546.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the rear cover. (See Rear Cover Removal.) 3.

  • Page 161: Right Vertical Guide Switch Replacement

    20 December 1996 PAPER FEED 4.6 RIGHT VERTICAL GUIDE SWITCH REPLACEMENT A219R547.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the rear cover. (See Rear Cover Removal.) 3. Remove the switch bracket [A] (2 screws and 1 connector). 4.

  • Page 162: Relay Roller Clutch And Paper Feed Clutch Replacement

    PAPER FEED 20 December 1996 4.7 RELAY ROLLER CLUTCH AND PAPER FEED CLUTCH REPLACEMENT [E] [C] A219R548.wmf A219R549.wmf 1. Turn off the main switch and unplug the power supply plug. 2. Remove the rear cover. (See Rear Cover Removal.) 3. Remove the switch bracket [A] (2 screws and 1 connector). 4.

  • Page 163: Paper Size Switch Replacement

    20 December 1996 PAPER FEED 4.8 PAPER SIZE SWITCH REPLACEMENT A219R550.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the front right cover. (See Front Right Cover Removal.) 3. Remove the size switch bracket [A] (1 screw). 4.

  • Page 164: By-Pass Paper End Sensor And Registration Sensor Replacement

    PAPER FEED 20 December 1996 4.9 BY-PASS PAPER END SENSOR AND REGISTRATION SENSOR REPLACEMENT A219R515-2.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the by-pass feed table. (See step 2 of By-pass Feed Roller and Friction Pad Replacement.) 3.

  • Page 165: Fusing Unit Removal

    20 December 1996 FUSING 5. FUSING 5.1 FUSING UNIT REMOVAL A219R533.wmf 1. Make sure that main switch is turned off and the power supply cord is unplugged. 2. Open the front cover. 3. Remove the inner cover. (See Inner Cover Removal.) 4.

  • Page 166: Hot Roller Replacement

    FUSING 20 December 1996 5.2 HOT ROLLER REPLACEMENT A219R534.wmf A219R535.wmf 1. Take out the fusing unit and remove the upper cover [A] from the fusing unit. 2. Remove the hot roller stripper bracket [B] (2 screws). NOTE: When reinstalling the stripper bracket, be careful not to scratch the hot roller surface.

  • Page 167: Pressure Roller Replacement

    20 December 1996 FUSING 5.3 PRESSURE ROLLER REPLACEMENT A219R539.wmf 1. Remove the hot roller. (See Hot Roller Replacement.) 2. Remove the pressure roller [A]. 6-41...

  • Page 168: Hot Roller Stripper Replacement

    FUSING 20 December 1996 5.4 HOT ROLLER STRIPPER REPLACEMENT A219R537.wmf 1. Open the exit unit [A]. 2. Remove the bracket [B] (2 screws). 3. Replace the hot roller strippers [C] (1 spring each). 6-42...

  • Page 169: Fusing Entrance Guide Adjustment

    20 December 1996 FUSING 5.5 FUSING ENTRANCE GUIDE ADJUSTMENT A219R536.wmf If there is paper creasing after fusing, move the guide plate [A] to the upper position as shown. 6-43...

  • Page 170: Fusing Pressure Adjustment

    FUSING 20 December 1996 5.6 FUSING PRESSURE ADJUSTMENT A219R538.wmf - Fusing pressure adjustment combinations - Combination Pressure Level Stronger Factory Setting Weaker The fusing pressure can be set at three different levels. Adjust the pressure spring position to [A] if poor fusing occurs or to [C] if copy paper becomes creased.

  • Page 171: Transfer Corona Wire Replacement

    20 December 1996 TRANSFER/SEPARATION 6. TRANSFER/SEPARATION 6.1 TRANSFER CORONA WIRE REPLACEMENT A219R554.wmf A219R555.wmf 1. Turn off the main switch. 2. Open the front cover. 3. Remove the transfer corona unit [A]. 4. Remove the 2 sheets of mylar [B]. 5. Replace the transfer corona wire [C]. 6-45...

  • Page 172: Discharge Plate Replacement

    TRANSFER/SEPARATION 20 December 1996 6.2 DISCHARGE PLATE REPLACEMENT A219R556.wmf 1. Turn off the main switch. 2. Open the front cover. 3. Remove the transfer corona unit. 4. Remove the discharge plate by squeezing the knobs [A] on both sides. 6-46...

  • Page 173: Ozone Filter Replacement

    20 December 1996 OTHERS 7. OTHERS 7.1 OZONE FILTER REPLACEMENT A219R552.wmf 1. Turn off the main switch. 2. Remove the rear cover. (See Rear Cover Removal.) 3. Remove the ozone filter cover [A]. 4. Replace the ozone filter [B]. 6-47...

  • Page 174: Main Control Board Replacement

    OTHERS 20 December 1996 7.2 MAIN CONTROL BOARD REPLACEMENT A219R553.wmf 1. Turn off the main switch and unplug the power supply cord. 2. Remove the rear cover. (See Rear Cover Removal.) 3. Remove the main control board [A] (4 screws and all connectors). 4.

  • Page 175: Copy Quality Adjustment

    20 December 1996 COPY QUALITY ADJUSTMENT 8. COPY QUALITY ADJUSTMENT - General Information - Image density is affected by the following factors: (1) Light Intensity (2) Development Bias Voltage (3) Toner Density (4) Grid Voltage/Drum Current The items listed above must be kept in balance to maintain correct image density.

  • Page 176: Light Intensity Adjustment

    COPY QUALITY ADJUSTMENT 20 December 1996 8.1 LIGHT INTENSITY ADJUSTMENT 8.1.1 Base Exposure Lamp Voltage Adjustment When: Every Call Purpose: To maintain the correct light intensity. Adjustment Level 2 (E0.2) of the gray scale on the OS-A3 chart should be slightly Standard: visible on the copy when the 4th manual image density level is selected.
  • Page 177 20 December 1996 COPY QUALITY ADJUSTMENT 8.1.2 Image Density Adjustment When: The customer requires the image density to be either darker or lighter. Purpose: To get proper image density. Method: SP34 How it works: Changes the ac drive/dc power board output voltage. NOTE: SP34 settings can be changed by customers.

  • Page 178: Development Bias Voltage Adjustment

    COPY QUALITY ADJUSTMENT 20 December 1996 8.2 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT 8.2.1 Base Bias Voltage Adjustment A219R561.wmf ADJUSTMENT STANDARD Adjusting VR SP Mode DC –200 ± 4 V SP9-5 NOTE: Normally, each High Voltage Supply Board spare part is adjusted in the factory before shipment.
  • Page 179 20 December 1996 COPY QUALITY ADJUSTMENT 8.2.2 SP Bias Settings When: 1. The image is blurred in ADS mode, even though the image density in black solid areas is acceptable. 2. Dirty background in ADS mode. The problem is not caused by excess toner and cannot be solved by adjusting the light intensity.

  • Page 180: Toner Density Adjustment

    COPY QUALITY ADJUSTMENT 20 December 1996 8.3 TONER DENSITY ADJUSTMENT When: The customer wants to change the overall image density of the copies. Purpose: To change the toner concentration inside the development unit. How to Adjust: SP38 How it works: Changes the development bias voltage and either raises/lowers the toner supply threshold.

  • Page 181: Grid Voltage Adjustment

    20 December 1996 COPY QUALITY ADJUSTMENT 8.5 GRID VOLTAGE ADJUSTMENT A219R562.wmf ADJUSTMENT STANDARD Adjusting VR SP Mode DC –910 ± 15 V SP9-2 NOTE: Normally, each High Voltage Supply Board spare part is adjusted in the factory before shipment. This adjustment is not required when the board is replaced.

  • Page 182: Transfer Current Adjustment

    COPY QUALITY ADJUSTMENT 20 December 1996 8.6 TRANSFER CURRENT ADJUSTMENT A219R563.wmf ADJUSTMENT STANDARD Adjusting VR SP Mode DC –350 ± 4 µA SP9-3 NOTE: Normally, each High Voltage Supply Board spare part is adjusted in the factory before shipment. This adjustment is not required when the board is replaced.

  • Page 183: Charge Current Adjustment

    20 December 1996 COPY QUALITY ADJUSTMENT 8.7 CHARGE CURRENT ADJUSTMENT A219R564.wmf ADJUSTMENT STANDARD Adjusting VR SP Mode DC –400 ± 2 µA SP9-2 NOTE: Normally, each High Voltage Supply Board spare part is adjusted in the factory before shipment. This adjustment is not required when the board is replaced.

  • Page 184: Horizontal Magnification Adjustment

    COPY QUALITY ADJUSTMENT 20 December 1996 8.8 HORIZONTAL MAGNIFICATION ADJUSTMENT When: The horizontal magnification is not within the adjustment standard. Purpose: To maintain proper horizontal magnification. Less than ± 0.8% difference between original and copy. Adjustment Standard: How to Adjust: SP44 (0.2%/step, 51 steps) How it works: Changes the lens home position.

  • Page 185: Focus Adjustment

    20 December 1996 COPY QUALITY ADJUSTMENT 8.10 FOCUS ADJUSTMENT When: The copy image is out of focus. After adjusting the horizontal magnification. Purpose: To maintain proper focus. Adjustment Copy image in focus. Standard: How to Adjust: SP47 (0.1 mm/step,101 steps) How it works: Adjusts the 4th/5th mirror assembly home position, changing the distance between the original and the drum surface.

  • Page 186: 4Th/5Th Mirror Height Adjustment

    COPY QUALITY ADJUSTMENT 20 December 1996 8.13 4TH/5TH MIRROR HEIGHT ADJUSTMENT When: Parallelogram (skewed) image appears. Purpose: To maintain the proper copy image. How to Adjust: Turn the 4th/5th mirror height adjustment screw. How it works: Changes the 4th/5th mirror height. CAUTION: Never perform this adjustment until you have positively verified that the source of the skewing is optical and not in the paper path.

  • Page 187: Ads (Auto Image Density Sensor) Adjustment

    20 December 1996 COPY QUALITY ADJUSTMENT 8.14 ADS (Auto Image Density Sensor) ADJUSTMENT When: 1. After light intensity adjustment. 2. ADS voltage is not within the adjustment standard. 3. After replacing the main board. Purpose: To maintain correct ADS mode operation. ADS Reference Voltage = 2.5 ±...

  • Page 188: Side-To -Side Registration Adjustment

    COPY QUALITY ADJUSTMENT 20 December 1996 8.15 SIDE-TO -SIDE REGISTRATION ADJUSTMENT When: Side-to-side registration is out of the adjustment standard. Purpose: To main the proper side-to-side registration 0 ± 2 mm (0 ± 0.08") Adjustment Standard: How to Adjust: 1. Change the lens position. 2.
  • Page 189 20 December 1996 COPY QUALITY ADJUSTMENT -Lens Position Adjustment- A219R565.wmf 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Remove the lens cover (2 screws). 4. Loosen 2 screws [A] and shift the lens by trial-and-error to adjust the side-to side registration.

  • Page 190: Troubleshooting

    SECTION 7 TROUBLESHOOTING...

  • Page 191: Copy Quality

    20 December 1996 COPY QUALITY 1. COPY QUALITY 1.1 BLANK COPY (WHITE COPY) - Problem - White or almost white copy. - Possible Causes - 1. Charge is not applied. A219T500.wmf • High voltage supply board (charge or grid) failure •...
  • Page 192 COPY QUALITY 20 December 1996 - Action - Is the charge corona wire cleaner knob fully inserted? Is the cleaner mechanism working properly? Fully insert the knob or fix the cleaner pad bracket. Are the charge and transfer corona units correctly installed? Install the charge and transfer corona units correctly.

  • Page 193: Dirty Background

    20 December 1996 COPY QUALITY 1.2 DIRTY BACKGROUND - Problem - 1. Dirty background at image density level 4 (manual setting). 2. When newspapers are copied, the background is dirty even at level 7. 3. ADS copies have a dirty background. - Possible Causes - 1.
  • Page 194 COPY QUALITY 20 December 1996 Is the exposure lamp light intensity too weak due to deterioration? Replace the 1st scanner unit. Is the signal at CN102-3 LOW after the key is pressed? (No bias voltage is applied to the development roller.) Replace the main board.

  • Page 195: Uneven Image Density

    20 December 1996 COPY QUALITY 1.3 UNEVEN IMAGE DENSITY - Problem - Uneven image density appears on the copies. - Possible Cause - 1. Dirty optics 2. Uneven cutout position of the reflectors 3. Dirty corona wires or grid 4. Uneven height of the charge corona wire - Action - Does the uneven image area shift when a reduction copy is made? Is the optics section dirty?

  • Page 196: Vertical Black Bands

    COPY QUALITY 20 December 1996 1.4 VERTICAL BLACK BANDS - Problem - Vertical black bands appear on the copy. - Possible Causes - 1. Dirty optics 2. Dust between the cleaning blade and drum A219T501.wmf 3. Deformed edge of the cleaning blade 4.

  • Page 197: Vertical Black Lines

    20 December 1996 COPY QUALITY 1.5 VERTICAL BLACK LINES - Problem - Thin black lines appear on the copy. - Possible Causes - 1. Scratched cleaning blade 2. Dirty or scratched exposure glass or dirty A219T502.wmf or scratched mirrors 3. Scratched or dirty drum 4.

  • Page 198: Vertical White Lines Or Bands-1 (Dull Or Blurred)

    COPY QUALITY 20 December 1996 1.6 VERTICAL WHITE LINES OR BANDS-1 (DULL OR BLURRED) - Problem - Dull or blurred white lines appear on the copy. - Possible Causes - 1. Dirty or deteriorated charge corona wire A219T503.wmf 2. Dirty or deformed grid plate 3.

  • Page 199: Vertical White Lines Or Bands-2 (Thin, Distinct)

    20 December 1996 COPY QUALITY 1.7 VERTICAL WHITE LINES OR BANDS-2 (THIN, DISTINCT) - Problem - Vertical white lines appear on the copy. - Possible Causes - 1. Paper dust on the edge of the cleaning blade 2. Scratched drum A219T504.wmf 3.

  • Page 200: Horizontal Black/White Lines

    COPY QUALITY 20 December 1996 1.8 HORIZONTAL BLACK/WHITE LINES - Problem - Black or white lines perpendicular to the paper feed direction appear on the copy image. - Possible Causes - 1. Drum or hot roller is scratched. If black lines appear at 94.6 mm intervals, the cause A219T505.wmf is a scratched drum, scratched hot roller, or toner build up.
  • Page 201 20 December 1996 COPY QUALITY 1.9 JITTER - Problem - Jitter appears on the copy. - Possible Causes - 1. Drum not turning smoothly 2. Scanner not moving smoothly - Action - Does the jitter interval change when a reduction copy is made? Check drum drive mechanisms such as the drum drive gears and drum pulleys.

  • Page 202: Black Spots On The Copy Image

    COPY QUALITY 20 December 1996 1.10 BLACK SPOTS ON THE COPY IMAGE - Problem - The grid voltage is not applied correctly. • Poor contact between the charge corona casing and grid plate • Main control board defective • High voltage supply board C/G/B/T/S defective A219T506.wmf - Action - Is there good electrical contact between the charge corona casing and the...

  • Page 203: Skewed (Optical) Copy Image

    20 December 1996 COPY QUALITY 1.11 SKEWED (OPTICAL) COPY IMAGE - Problem - The copy image is skewed (parallelogram shape). The sides of the copy image are straight, but the leading and trailing edges are skewed. (This differs from skewing originating in the paper path.) A219T507.wmf - Possible Causes -...

  • Page 204: Toner Density On Copies Too High

    COPY QUALITY 20 December 1996 1.12 TONER DENSITY ON COPIES TOO HIGH - Problem - 1. Dirty background appears on the copy. 2. The image density of black solid areas is too high. - Possible Causes - 1. The toner supply motor keeps on turning continuously. 2.
  • Page 205 20 December 1996 COPY QUALITY 24 volts 0 volt Replace the main board. Replace the toner supply motor. Is SP30 (Toner Supply Mode Selection) set to the default value? Change the value to the default setting "0". Is the grid voltage correct? Readjust the grid voltage.

  • Page 206: Toner Density On Copies Too Low

    COPY QUALITY 20 December 1996 1.13 TONER DENSITY ON COPIES TOO LOW - Problem - 1. Light copy 2. Carrier on the copy. 3. Light spots appear in black solid areas. - Possible Causes - 1. The toner supply motor does not rotate. 2.
  • Page 207 20 December 1996 COPY QUALITY Is SP30 (Toner Supply Mode Selection) set to the default value? Change the value to the default setting "0". Go to A Is the grid voltage correct? Readjust the grid voltage. Check the related SP mode settings (SP30, 31, 32, 33, 34, 35, 36, 38, 48, 53, 54 and 62).

  • Page 208: Unfused Copy Image

    COPY QUALITY 20 December 1996 1.14 UNFUSED COPY IMAGE - Problem - Solid images rub off easily. - Possible Causes - 1. The fusing pressure is weak. 2. The fusing temperature is too low. 3. The thermistor is malfunctioning. - Action - Adjust the position of the pressure springs to increase the fusing pressure.

  • Page 209: Creasing Paper After Fusing

    20 December 1996 COPY QUALITY 1.15 CREASING PAPER AFTER FUSING - Problem - The copy paper is creased. - Possible Causes - 1. The fusing temperature is too high. 2. The thermistor is malfunctioning. 3. The copier is installed in humid environment. - Action - Decrease the fusing temperature using SP49.

  • Page 210: Paper Misfeed

    COPY QUALITY 20 December 1996 1.16 PAPER MISFEED - Problem - 1. The Check Paper Path indicator turns on when the main switch is turned on, even if there is no paper in the copier. 2. The Check Paper Path always turns on at the same location when copies are made.

  • Page 211: Abnormal Condition In Toner Density Detection

    20 December 1996 COPY QUALITY 1.17 ABNORMAL CONDITION IN TONER DENSITY DETECTION - Problem - The Auto ID indicator or the selected manual ID level blinks. (No SC Code is indicated.) - Definition - The detected TD sensor output goes below 0.2 volts. - Possible Causes - •...
  • Page 212 COPY QUALITY 20 December 1996 Change or clean the defective parts. Replace the main control board. 7-22...

  • Page 213: Service Call Conditions

    20 December 1996 SERVICE CALL CONDITIONS 2. SERVICE CALL CONDITIONS NOTE: 1) E-codes are displayed in the copy counter. The "E" and the "code number" are displayed alternatively. 2) To clear the service call condition, turn the main switch off and on. 3) When E5 service call conditions occur, for safety reasons they cannot be cleared by turning the main switch off/on.
  • Page 214 SERVICE CALL CONDITIONS 20 December 1996 CODE #13 — ZERO CROSS SIGNAL ERROR - Definition - The CPU does not receive the zero cross signal within 2.0 seconds, or the interval between zero cross signals is more than 2.0 seconds. - Possible Causes - •...
  • Page 215 20 December 1996 SERVICE CALL CONDITIONS CODE #2A — 4TH/5TH MIRROR HOME POSITION ERROR 1 - Definition - The 4th/5th mirror home position sensor’s output remains LOW for 10 seconds after driving the 4th/5th mirror motor. - Possible Causes - •...
  • Page 216 SERVICE CALL CONDITIONS 20 December 1996 CODE #29 — LENS HOME POSITION ERROR 2 - Definition - The lens home position sensor’s output remains HIGH (actuated) for 10 seconds after the unit leaves the home position. - Possible Causes - •...
  • Page 217 20 December 1996 SERVICE CALL CONDITIONS CODE #52 — FUSING ERROR 1 - Definition - The temperature detected by the thermistor does not reach 100°C within 24 (NA) or 35 (EU) seconds after the main switch is turned on. To clear this error, refer to note 3 at the beginning of this chapter. - Possible Causes - •...
  • Page 218 SERVICE CALL CONDITIONS 20 December 1996 CODE #55 — FUSING ERROR 4 - Definition - • The temperature value output by the thermistor has not changed at all 16 (NA) or 20 (EU) seconds after the main switch is turned on. •...

  • Page 219: Electrical Component Defects

    20 December 1996 ELECTRICAL COMPONENT DEFECTS 3. ELECTRICAL COMPONENT DEFECTS 3.1 SENSORS Component Condition Symptom 4th/5th Mirror Home Position Stays HIGH Service code E2B is displayed. Sensor (S1) (CN114-2) Stays LOW Service code E2A is displayed. (CN114-2) ADS Sensor (S2) Stays HIGH The image density will be abnormal.
  • Page 220 ELECTRICAL COMPONENT DEFECTS 20 December 1996 3.2 SWITCHES Component Condition Symptom Main Switch (SW1) OPEN The copier does not turn on. SHORT The copier does not turn off. Interlock Switch (SW2) OPEN The copier does not turn on. The copier does not turn off when the SHORT upper unit is opened.

  • Page 221: Blown Fuse Conditions

    20 December 1996 BLOWN FUSE CONDITIONS USER CODES 4. BLOWN FUSE CONDITIONS Rating Symptom when turning FUSE on the Main Switch 120 V 230 V AC Drive/DC Power Supply Board 15 A/125 V T6.3 A/250 V No response 8 A/125 V T6.3 A/250 V E2B is displayed 3.15 A/125 V...
  • Page 222 SECTION 8 OPTIONS...
  • Page 223 SECTION 9 APPENDIX TIMING CHART...
  • Page 224 COPIER TIMING CHART (A219) (Second) 2nd Original Leading Edge 3rd Original Leading Edge 1st Original Leading Edge 2.30 6.30 10.30 Start Key 4.64 8.64 DF Original Feed-in 4.64 8.64 12.64 DF Original Feed-out Original Set Main Motor Quenching Lamp 2.43 6.43 10.43 ADS Detection...
  • Page 225 COPIER (A219) ELECTRICAL COMPONENT LAYOUT A219S500.wmf...
  • Page 226 A219S501.wmf...
  • Page 227 A219S502.wmf...
  • Page 228 Description Index No. P-to-P Location Main Control Board (PCB1) High Voltage Supply Board - C/G/B/T/S (PCB2) AC Drive/DC Power Supply Board (PCB3) Erase Lamp (L1) Quenching Lamp (L2) Operation Panel Board (PCB4) Exhaust Fan Motor (M7) Main Motor (M1) Scanner Drive Motor (M2) Toner Supply Motor (M5) Registration Clutch (CL4) By-pass Paper Feed Clutch (CL2)
  • Page 229 POINT-TO-POINT DIAGRAM A219 COPIER November 20,1996 PCB1 SORTER MAIN BOARD AC POWER CORD CN1-6 ROLLER DRIVE CN1-7 [ 24]FEED M MOTOR CN1-8 24]BIN M CN1-9 CN118-1 24]BIN M 5]SCAN0 CN118-2 5]SCAN1 MAIN CONTROL BOARD BIN DRIVE CN118-3 5]SCAN2 MOTOR CN118-4 5]SCAN3 (PCB1) CN118-5...

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