Ricoh FT8780 Service Manual
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Ricoh FT8780 Service Manual

Ricoh FT8780 Service Manual

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RICOH FT8780
SERVICE MANUAL

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Summary of Contents for Ricoh FT8780

  • Page 1 RICOH FT8780 SERVICE MANUAL...

  • Page 2: Important Safety Notices

    IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. While the machine warms up, it will suddenly start turning to perform the process control data initialization. Keep hands away from any mechanical and electrical components during this period. 2. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier and the second sorter power cord is unplugged.

  • Page 3: Observance Of Electrical Safety Standards

    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. 2. The RAM board on the main control board has a lithium battery which can explode if replaced incorrectly.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 1. OVERALL MACHINE INFORMATION 1. SPECIFICATIONS ........1-1 2.
  • Page 5 1.3.4 Lamp Intensity Sensor Calibration ....... . 2-7 1.3.5 Charge Corona Current Adjustment....... 2-8 1.3.6 Vr Measurement .
  • Page 6 5.7 MIRROR UNIT DRIVE ..........2-31 5.8 MOTOR DRIVE CIRCUIT.
  • Page 7 8.5 PICK-OFF PAWLS..........2-56 8.6 TRANSPORT UNIT .
  • Page 8 11.11.3 3rd Tray..........2-81 11.12 2ND TRAY END FENCE .
  • Page 9 15.6 PAPER END DETECTION........2-105 15.7 PAPER FEED AND SEPARATION .
  • Page 10 3.1 A3/11" x 17" COUNTER INSTALLATION ......3-14 3.2 KEY COUNTER HOLDER INSTALLATION......3-15 4.
  • Page 11 5. LUBRICATION POINTS ........4-41 5.1 MIRROR UNIT GUIDE ROD FELT ........4-41 5.2 LENS HORIZONTAL DRIVE MOTOR GEARS.
  • Page 12 3.6 DEVELOPMENT DUCT FILTER REPLACEMENT..... . 5-34 3.7 DEVELOPMENT ROLLER REPLACEMENT ......5-35 3.8 TONER NEAR END SENSOR BRACKET REMOVAL .
  • Page 13 6.6.4 Paper Size Sensor Replacement....... . 5-60 6.6.5 Tray Heater Replacement........5-60 6.7 TRAY DRIVE MOTOR REPLACEMENT.
  • Page 14 9.4 VERTICAL TRANSPORT UNIT REMOVAL ......5-84 9.5 TRANSPORT UNIT BELTS REPLACEMENT......5-85 9.6 PICK-OFF PAWLS REMOVAL.
  • Page 15 12.4 POSITIONING ROLLER REPLACEMENT ......5-103 12.5 DUPLEX ENTRANCE, PAPER END, PICK-UP ROLLER POSITION SENSOR, AND JOGGER HOME POSITION SENSOR REPLACEMENT.
  • Page 16 14.1 SIDE-TO-SIDE REGISTRATION ADJUSTMENT..... 5-134 14.1.1 3rd Tray and Duplex Tray........5-134 14.1.2 1st Tray.
  • Page 17 2.10.1 Jam Detection Condition........19 2.10.2 Machine Operation in Jam Conditions.
  • Page 18 4.1 JOB SHEET READING ..........4 4.2 MENU READER INDICATOR LIGHTS .

  • Page 19: Overall Machine Information

    SECTION 1 OVERALL MACHINE INFORMATION...

  • Page 20: Specifications

    6 March 1992 SPECIFICATIONS 1. SPECIFICATIONS Main Copier Copier Configuration: Console Copy Process: Dry Electrostatic Transfer System Originals: Sheet/Book Original Size: Maximum: 11" x 17", A3 Copy Paper Size: Maximum: 1st and 2nd tray " x 14", A4 3rd tray 11"...
  • Page 21 SPECIFICATIONS 6 March 1992 Reproduction Ratios: See the following table: LT/DLT version A4/A3 version 200% 200% 155% 141% Enlargement 129% 122% 121% 115% Full Size 100% 100% Reduction Zoom: 50 ~ 200% Copy Exit Tray Capacity: 250 Sheets Toner Replenishment: Cartridge exchange (1500 g) Paper Feed: 1st tray (550 sheets)
  • Page 22 6 March 1992 SPECIFICATIONS Document Feeder Original Size: Stack feed mode Single feed mode Duplex mode Maximum 11" x 17", A3 11" x 17", A3 11" x 17", A3 Minimum " x 11", A4 " x 8 ", A5 " x 11", A4 Original Weight: Stack feed mode Single feed mode Duplex mode...

  • Page 23: Copy Processes Around The Drum

    COPY PROCESSES AROUND THE DRUM 6 March 1992 2. COPY PROCESSES AROUND THE DRUM...
  • Page 24 6 March 1992 COPY PROCESSES AROUND THE DRUM 1. DRUM CHARGE In the dark, the charge corona unit gives a uniform positive charge to the selenium drum. The charge remains on the surface of the drum because the photoconductive selenium has electrical resistance in the dark.

  • Page 25: Mechanical Component Layout

    MECHANICAL COMPONENT LAYOUT 6 March 1992 3. MECHANICAL COMPONENT LAYOUT 3.1 COPIER 22 23 24 25 26 27 28 29 30 31 1. First Mirror 17. Second Tray 2. Second Mirror 18. First Tray 3. Third Mirror 19. Toner Hopper 4.

  • Page 26: Ardf

    6 March 1992 MECHANICAL COMPONENT LAYOUT 3.2 ARDF 1. Original Tray Extension 10. 1st Pick-up Rollers 2. Upper Exit Rollers 11. 2nd Pick-up Rollers 3. Upper Inverter Gate 12. Separation Rollers 4. Lower Inverter Rollers 13. Lower Relay Roller 5. Upper Inverter Rollers 14.

  • Page 27: Electrical Component Descriptions

    ELECTRICAL COMPONENT DESCRIPTIONS 6 March 1992 4. ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout on the reverse side of the Point to Point (Water proof paper) index numbers. 4.1 COPIER Name Function Index. No. Motors 1st Tray Drive Drives the bottom plate in the 1st tray.
  • Page 28 6 March 1992 ELECTRICAL COMPONENT DESCRIPTIONS Name Function Index. No. Interface Interface between the main PCB and other PCBs. Vaccum Motor Controls the vacuum fan motor operation. Power Packs Charge Provides power for the charge corona wire. Development Bias Provides power for the development bias. Provides power for the pre-transfer corona wire.
  • Page 29 ELECTRICAL COMPONENT DESCRIPTIONS 6 March 1992 Name Function Index. No. Paper End - 3rd Tray Detects the presence of paper in the 3rd tray. Paper End - Duplex Detects the presence of paper in the duplex tray. Paper Feed - 1st Tray Turn off the 1st tray paper feed clutch.
  • Page 30 6 March 1992 ELECTRICAL COMPONENT DESCRIPTIONS Name Function Index. No. Solenoids 2nd Tray Lock Locks the 2nd tray. Cleaning Brings the cleaning blade into contact with the drum. Fork Gate 1 Varies the paper path in the duplex unit depending on paper size.
  • Page 31 ELECTRICAL COMPONENT DESCRIPTIONS 6 March 1992 Name Function Index. No. Lamps Exposure Exposes the original with high intensity light. Fusing 1 Provides heat to the hot roller and keeps the roller at the operating temperature. Fusing 2 Provides heat to the hot roller during warm-up. Pre-Transfer Removes excessive positive charge from the drum surface to the transfer and separation process.

  • Page 32: Ardf

    6 March 1992 ELECTRICAL COMPONENT DESCRIPTIONS 4.2 ARDF Symbol Name Function Index. No. Motors Feed-in Drives the pick-up rollers, separation rollers and relay rollers. Belt Drives the transport belt. Inverter Drives the inverter rollers and the exit rollers. Job Separation Drives the job separator.

  • Page 33: Drive Layout

    DRIVE LAYOUT 6 March 1992 5. DRIVE LAYOUT A : Development Unit B : Cleaning Unit C : Relay Transport Unit (to 1st & 2nd Tray) D : Fusing Unit E : Vertical Transport Unit F : Duplex Unit 1. Main Motor 2.

  • Page 34: Paper Path

    6 March 1992 PAPER PATH 6. PAPER PATH 6.1 SINGLE SIDED COPY -- COPY FACE DOWN 6.2 DUPLEX MODE (1ST SIDE) 1-15...

  • Page 35: Duplex Mode (2Nd Side)

    PAPER PATH 6 March 1992 6.3 DUPLEX MODE (2ND SIDE) 6.4 IMAGE OVERLAY MODE (1ST SIDE) 1-16...

  • Page 36: Image Overlay Mode (2Nd Side)

    6 March 1992 PAPER PATH 6.5 IMAGE OVERLAY MODE (2ND SIDE) 1-17...

  • Page 37: Detailed Section Descriptions

    SECTION 2 DETAILED SECTION DESCRIPTIONS...

  • Page 38: Process Control

    6 March 1992 PROCESS CONTROL 1. PROCESS CONTROL 1.1 OVERVIEW The characteristics of each unit which is related to the copy image reproduction are changed by various factors. To get stable images over long periods and in continuous copy runs, these characteristic changes have to be compensated.
  • Page 39 PROCESS CONTROL 6 March 1992 Section Characteristics Causes of Change Compensation Method Drum Charge Repeat Stress Measure the drum potential of a part Potential Temperature that was not exposed (Dark Potential) Humidity with the potential sensor and adjust the charge corona output. Sensitivity Repeat Stress Measure the drum potential of a part...

  • Page 40: Image Control

    6 March 1992 PROCESS CONTROL 1.2 IMAGE CONTROL 1.2.1 Latent Image Control Exposure Charge Black White Erase Potential Sensor Drum The figure shows the changes of the drum potential during the copy process. The drum potential just after charging the drum. Vd (Dark Potential): The drum potential just after exposing the black pattern (Vd pattern)

  • Page 41: Image Density Control

    PROCESS CONTROL 6 March 1992 Drum Potential Dark Original Density Light The above figure shows the relationship between the drum potential and the original density (exposing light intensity). To get constant copy quality, this relationship must be maintained. Since this relationship tends to change to the one represented by the dotted line by various factors, compensations are required as follows: A decrease in dark voltage (Vd) is compensated for by increasing the charge corona output.

  • Page 42: Process Control Data Initialization

    6 March 1992 PROCESS CONTROL 1.3 PROCESS CONTROL DATA INITIALIZATION The following flow chart shows all the steps that will be performed whenever the main switch is turned on while the hot roller temperature is below 100°C. This initializes all the process control settings. Main SW On (Fusing Temp.

  • Page 43: Drum Potential Sensor Calibration

    PROCESS CONTROL 6 March 1992 1.3.1 Drum Potential Sensor Calibration Case Sensor Output Amp. Drum Potential Sensor Drum Current Detection PCB Bias Relay P.P. TRIG 1 (800V) TRIG 2 (100V) Sensor Main PCB The drum potential sensor [A] is located just above the development unit. The sensor has a detector which detects the electric lines of force from the electric potential on the drum.

  • Page 44: Drum Conditioning

    6 March 1992 PROCESS CONTROL 1.3.2 Drum Conditioning When the drum temperature reaches 160°C, the machine starts the drum conditioning process. In this mode, all the coronas and lamps around the drum are activated and drum sensitivity is stabilized, as in continuous copy runs.

  • Page 45: Charge Corona Current Adjustment

    PROCESS CONTROL 6 March 1992 1.3.5 Charge Corona Current Adjustment CN342-3 +12V Potential S. CN342 CN103-B24 T343 CN342-2 Id Set CN342 -12V CN342-1 CN103-A14 CN342 CN341-4 CN104-A28 CN104-B1 CN104-A1 CN341 HIC1 CN341-2 Drum Current Detect PCB MainPCB The charge corona current is measured and adjusted automatically by the drum current detect PCB.

  • Page 46: Vr Measurement

    6 March 1992 PROCESS CONTROL 1.3.6 Vr Measurement Drum Potential Dark Light Original Density The drum residual voltage (Vr) tends to increase during the drums life due to electrical fatigue. The residual voltage cannot be reduced even if the exposure lamp voltage is increased. Therefore, the Vr change has to be compensated by other means.
  • Page 47 PROCESS CONTROL 6 March 1992 1.3.7 Vd Correction Drum Potential Exposure Glass Vd Pattern Original Density Dark Light The drum potential just after the black pattern (Vd Pattern) is exposed (Vd: Dark Potential) tends to lower during drum life due to a decrease in the drum’s capacity to carry a charge.
  • Page 48 6 March 1992 PROCESS CONTROL 1.3.8 VL Correction Pattern Drum Potential Dark Original Density Light Dirty optics and/or exposure lamp deterioration decreases the intensity of the light that reaches the drum. In addition to this, the drum sensitivity also changes during the drum’s life. These factors change the drum potential just after white pattern exposure (V : Light Potential).

  • Page 49: 01 Measuring

    PROCESS CONTROL 6 March 1992 1.3.9 V Measuring Drum Potential Light Dark Original Density Since the ID sensor pattern on the drum is made by the erase lamp and charge corona (except for B4/8 " x 14" copy mode due to the lens horizontal movement.

  • Page 50: Ads Adjustment

    6 March 1992 PROCESS CONTROL 1.3.10 ADS Adjustment Exposure Glass ADS Pattern ADS Pattern The ADS pattern is located underneath the exposure glass bracket. During the process control data initialization, the ADS reference voltage is adjusted. When the first scanner is moved to the return position for the Vd adjustment, the main PCB checks the ADS voltage through the ADS fiber optics cable.

  • Page 51: Compensations During Copy Cycle

    PROCESS CONTROL 6 March 1992 1.4 COMPENSATIONS DURING COPY CYCLE During continuous copying, the drum sensitivity changes due to the electrical fatigue. The drum sensitivity also changes during rest time. The following compensations are used for the drum sensitivity changes in the copy cycle: Pattern Drum...

  • Page 52: 02 Measuring

    6 March 1992 PROCESS CONTROL 1.4.2 V Measuring Start key Charge Corona Exposure Lamp Scanner F Drum Potential Sensor During the process control data initialization, V is measured to determine the development bias for the ID sensor pattern in continuous copy runs. This bias cannot be used for the initial part of the copy run (less that 10 copies) due to the different drum potential after the charge corona is applied.

  • Page 53: Drum

    DRUM 6 March 1992 2. DRUM 2.1 OVERVIEW This model uses an FO-type drum made by applying an urethane resin coating [A] on an F-type drum [B]. This coating provides a long life and minimize the white line problems on the half-tone areas. For the F-type drum, the charge carrying layer [C] is made by the drum conditioning.

  • Page 54: Drum Heater Control

    6 March 1992 DRUM 2.2 DRUM HEATER CONTROL RA353 160°C 65°C CN-3 RA354 CN-2 AC100V CN-1 Drum Heater Drum Thermistor Drum Thermistor CN104-A4 RA354 RA353 Converter CN251-B26 Drum Drum Heater 1 CN255-B9 Heater 1 CN251-B25 CN102-A2 CN251-A30 24V ON Drum Drum Heater 2 Heater 2 CN251-B30...

  • Page 55: Drum Charge

    DRUM CHARGE 6 March 1992 3. DRUM CHARGE 3.1 CHARGE CORONA UNIT This copier uses a dual carbon coated tungsten wire corotron for the drum charge. The corona wire generates a corona of positive ions when the charge power pack [A] applies a high voltage. The output of the charge power pack is determined by the CPU based on the process control data.

  • Page 56: Corona Unit Ventilation

    6 March 1992 DRUM CHARGE 3.2 CORONA UNIT VENTILATION If ozone produced by the corona charge stays in the charge corona area, it may cause uneven corona charging to the drum. To prevent this, ozone is vacuumed out by the vacuum fan through the duct and toner filter in the transport unit, then changed to oxygen by the ozone filter before blown out of the copier.

  • Page 57: Corona Wire Cleaner

    DRUM CHARGE 6 March 1992 3.3 CORONA WIRE CLEANER Paper dust, or toner particles on the charge corona wires may interfere with charging and cause an uneven charge on the drum. The wire cleaner prevents this problem by automatically wiping the charge corona wires clean. Once every 5000 copies, the wire cleaner is activated when the main switch is turned on.

  • Page 58: Charge Corona Power Pack

    6 March 1992 DRUM CHARGE 3.4 CHARGE CORONA POWER PACK 24VP CN302-3 CN302-4 CN341-6 CN341-8 24 V CN311-8 CN304-1 CN311-1 GND24VP CN311-10 Door DC Power Supply CN303-2 Drum Current DC Drive PCB Detect PCB CN103-A22 TRIG Charge Main PCB Corona P.P. The main PCB sends a PWM (Pulse Width Modulation) signal to the charge corona power pack.

  • Page 59: Erase

    ERASE 6 March 1992 4. ERASE 4.1 OVERVIEW The electrical charge of the area that does not require any image will be removed by the erase lamp unit [A]. This reduces toner consumption, and the load of the cleaning unit. The erase lamp unit consists of 90 yellow-green LEDs.

  • Page 60: Erase Lamp Circuit

    6 March 1992 ERASE 4.2 ERASE LAMP CIRCUIT S-IN CN113-6 CN651-5 GND IS CN113-2 CN651-E OFF ON S-IN CN113-7 CN651-6 CLOCK GND CK CN113-3 CN651-F LATCH LATCH CN651-C CN311-8 CN113-1 CN651-4 LATCH CN561-1 CN113-4 CN651-2 5V LED CN311-15 CN561-A CN113-5 CN651-8 GND-LED CN561-3...

  • Page 61: Optics

    OPTICS 6 March 1992 5. OPTICS 5.1 OVERVIEW The optics unit reflects an image of the original on the exposure glass onto the selenium drum. This forms a latent electrical image of the original. On this model, to minimize power consumption, a fluorescent lamp is used for the exposure lamp [A].

  • Page 62: Scanner Drive

    6 March 1992 OPTICS 5.2 SCANNER DRIVE A dc servo motor is used as the scanner drive motor [A]. The scanner drive motor drives first [B] and second scanner [C] using four scanner drive wires. The second scanner speed is half of the first scanner speed.

  • Page 63: Scanner Position Sensors

    OPTICS 6 March 1992 5.3 SCANNER POSITION SENSORS There are two scanner position sensors located at the front side of the optics unit. The scanner home position sensor [A] is used to detect the home position at the machine initialization and during the scan cycle. The scanner return position sensor [B] is used to detect the scanner position for the process control data initialization (Vd and ADS data).

  • Page 64: Vertical Lens Drive

    6 March 1992 OPTICS 5.4 VERTICAL LENS DRIVE The lens vertical drive motor [A] changes the lens vertical position in accordance with the selected reproduction ratio. A stepper motor (Approx. 1.8° (0.05 mm)/step) is used to drive the lens through the lens drive belt. The lens vertical home position sensor [B] detects the lens vertical position for full size mode.

  • Page 65: Horizontal Lens Drive

    OPTICS 6 March 1992 5.5 HORIZONTAL LENS DRIVE The original horizontal position on the exposure glass varies in modes (such as platen, ADF, and CFF modes) for easy original handling. On the other hand, the center is the standard position of the paper feed. Therefore, the lens horizontal position has to be changed according to paper size, reproduction ratio, and the original modes.

  • Page 66: Horizontal Lens Positioning

    6 March 1992 OPTICS 5.6 HORIZONTAL LENS POSITIONING 5.6.1 For Original Position 100% Lens Position Horizontal Copy Paper 6.35 12.7 Original Front Edge Platen There are three standard original positions for the platen, ADF, and CFF modes. ADF mode original position is 5 mm to rear of the platen mode original position to maintain the original transport path (5 mm from the front scale).

  • Page 67: For Reproduction Ratio

    OPTICS 6 March 1992 5.6.3 For Reproduction Ratio 100% 200% Copy Paper Horizontal Lens Position Vertical Original Front Edge When the reproduction ratio is changed, the vertical position of the lens is changed. At the same time, the total focal length has to be changed to adjust the image focusing.

  • Page 68: Mirror Unit Drive

    6 March 1992 OPTICS 5.7 MIRROR UNIT DRIVE To compensate the focus change at the reproduction change, the mirror unit (4th and 5th mirrors) position is changed. A stepper motor (Approx. 7.5° (0.1 mm)/step) is used for the mirror unit drive. A mirror unit home position sensor [A] is used to detect the unit position for full size mode.

  • Page 69: Motor Drive Circuit

    OPTICS 6 March 1992 5.8 MOTOR DRIVE CIRCUIT Sensors Encoders Serial Horizontal DC Motor Main Motor Interface Drive Drive PCB Control PCB Vertical Drive Mirror Unit Drive Scanner Drive Encoder The motor control PCB communicates with the main PCB through the serial interface lines.

  • Page 70: Exposure Lamp Unit

    6 March 1992 OPTICS 5.9 EXPOSURE LAMP UNIT This copier uses a fluorescent lamp [A] (100 V 84 W). This has the following advantages: • Low power consumption • There is no bright point and it is easy to get even luminescence •...

  • Page 71: Exposure Lamp Control

    OPTICS 6 March 1992 5.10 EXPOSURE LAMP CONTROL Exposure lamp intensity must be stabilized during the copy cycle to get a constant latent image on the drum. The main PCB [A] monitors and maintains the light intensity through a fiber optics cable [B]. According to the measured value, a lamp power signal (PWM signal) is sent to the fluorescent lamp stabilizer [C].

  • Page 72: Auto Image Density Control

    6 March 1992 OPTICS 5.11 AUTO IMAGE DENSITY CONTROL 50 mm 26 mm 26 mm 50 mm 166 mm The original background density is read through a fiber optics cable on the exposure lamp unit. The sampled strip is at the leading edge of the original and the size depends on the scanner speed (reproduction ratio).

  • Page 73: Uneven Light Intensity Correction

    OPTICS 6 March 1992 5.12 UNEVEN LIGHT INTENSITY CORRECTION The slit plate [A] corrects the uneven light intensity at the ends and center of the fluorescent lamp [B] and evenly distributes light reflected from the original. To compensate for reduced light at the lens edges, the shading plate [C] is located in front of the lens.

  • Page 74: Anti-Condensation Heater

    6 March 1992 OPTICS 5.13 ANTI-CONDENSATION HEATER To prevent condensation in the optics unit, a 40 W anti-condensation heater [A] is installed at the bottom of the lens unit. The anti-condensation heater is controlled by a thermoswitch [B] (On at 17°C, Off at 25°C) under the following conditions: 1.

  • Page 75: Development

    DEVELOPMENT 6 March 1992 6. DEVELOPMENT 6.1 OVERVIEW This copier uses a double roller (diameter 20 mm each) development system. This system differs from single roller development system in that (1) it develops the image in a narrow area and (2) it develops the image twice. Also, fine toner and developer (smaller particle size) are used.

  • Page 76: Drive Mechanism

    6 March 1992 DEVELOPMENT 6.2 DRIVE MECHANISM All the development unit parts, except the toner supply brush, are driven by the development drive motor (dc motor). The toner supply brush is driven by the toner supply motor. The development motor drives the development drive gear through two timing belts.

  • Page 77: Cross Mixing

    DEVELOPMENT 6 March 1992 6.3 CROSS MIXING 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 upper development roller is split into two parts by the doctor blade.

  • Page 78: Development Bias

    6 March 1992 DEVELOPMENT 6.4 DEVELOPMENT BIAS 6.4.1 Bias Power Pack Potential Sensor Drum Current Detection PCB Bias Relay P.P. TRIG 1 (800V) TRIG 2 (100V) Main PCB Sensor PWM Duty Cycle = t2/t1 x 100 (%) Output = 10 x PWM Duty Cycle (V) TRIG1 TRIG2 OUTPUT (V)

  • Page 79: Bias Control In Copy Cycle

    DEVELOPMENT 6 March 1992 6.4.2 Bias Control In Copy Cycle The bias output is determined by four factors. The total bias is described as; (ADS Mode) (Manual ID Mode) 1) Base Bias (V Drum Potential Light Dark Original Density As explained in the process control section, the base bias for development is determined by the drum light potential (V ) measured in each original scan.
  • Page 80 6 March 1992 DEVELOPMENT 3) Manual ID Selection Position Compensation (V ID Selection --60 --120 --180 According to the manual ID selection position, the bias is compensated as follows: = 60 x M -- 240 (When M = 1 to 6) 60 x M -- 360 (When M = 7) NOTE: M = Manual ID selection position.

  • Page 81: Bias For The Id Sensor Pattern

    DEVELOPMENT 6 March 1992 6.4.3 Bias for the ID Sensor Pattern Lens Position A3/11" x 17" Pattern B4/8 " x 14" ID Sensor A4/8 " x 11" Pattern Outside Exposure Glass The lens horizontal position is different in the used paper size on this mode. On the other hand, the ID sensor position is fixed at one position.

  • Page 82: Toner Density Detection And Supply

    6 March 1992 TONER DENSITY DETECTION AND SUPPLY 7. TONER DENSITY DETECTION AND SUPPLY 7.1 TONER SUPPLY MECHANISM The main PCB monitors the ID sensor pattern density on the drum through the ID sensor once every ten copies and turns on the toner supply motor when the pattern density is low (if Vsp/Vsg ≥...

  • Page 83: Toner Density Detection

    TONER DENSITY DETECTION AND SUPPLY 6 March 1992 7.2 TONER DENSITY DETECTION 7.2.1 ID Sensor Pattern Production ID Sensor Pattern Main SW Start Key Start Key Start Key Counter A Counter B Drum sensitivity varies from copy to copy. Especially, drum rest time affects drum sensitivity.

  • Page 84: Toner Density Detection

    6 March 1992 TONER DENSITY DETECTION AND SUPPLY 7.2.2 Toner Density Detection Vsg = 4.0 Low image density 1/13 Vsg = 0.31 1/13 Vsg High image density Bare Sensor drum pattern The ID sensor measures the density of the ID sensor pattern developed on the drum.

  • Page 85: Id Sensor Abnormal Conditions

    TONER DENSITY DETECTION AND SUPPLY 6 March 1992 7.2.3 ID Sensor Abnormal Conditions a. Vsp Abnormal If the measured Vsp is 1.4 V (when Vsg = 4 V) or more and this condition is detected five times in a row, a system error condition will be indicated on the CRT and the 7% fixed toner supply control will be used for the rest of the copy run.

  • Page 86: Toner Cartridge

    6 March 1992 TONER DENSITY DETECTION AND SUPPLY 7.4 TONER CARTRIDGE When the toner cartridge is set, the toner cartridge sensor [A] is de-actuated. The main PCB monitors the toner cartridge sensor signal and detects if the cartridge is replaced at the toner end condition. The main PCB inhibits copying if there is no toner cartridge.

  • Page 87: Toner End Detection

    TONER DENSITY DETECTION AND SUPPLY 6 March 1992 7.5 TONER END DETECTION 7.5.1 Toner Near End Detection Toner near end is detected by measuring physical amount of toner remaining in the toner tank by the following mechanism. The toner near end feeler [A] has a magnet [B] and is installed on the toner mixing vane drive shaft [C].

  • Page 88: Toner End Detection

    6 March 1992 TONER DENSITY DETECTION AND SUPPLY 7.5.2 Toner End Detection When little toner remains in the toner tank, the amount of toner supplied to the development unit decreases, and the image of the ID sensor pattern gets lighter. When the Main PCB detects the low ID sensor pattern density condition (Vsp/Vsg >...

  • Page 89: Image Transfer And Paper Separation

    IMAGE TRANSFER AND PAPER SEPARATION 6 March 1992 8. IMAGE TRANSFER AND PAPER SEPARATION 8.1 PRE-TRANSFER DISCHARGE The pre-transfer corona (PTC) [A] and pre-transfer lamp (PTL) [B] are used to prevent incomplete toner transfer and pick-off pawl marks on the copy. To prevent incomplete toner transfer, the PTC reduces drum potential by applying an ac corona.

  • Page 90: Image Transfer

    6 March 1992 IMAGE TRANSFER AND PAPER SEPARATION 8.2 IMAGE TRANSFER The copy paper is fed from the registration section to the transfer and separation section through the guide mylar [A] which holds the copy paper so that the paper sticks to the drum surface. The transfer corona [B] applies a positive charge from the back side of the copy paper to attract the negatively charged toner image from the drum to the copy paper.

  • Page 91: Paper Separation

    IMAGE TRANSFER AND PAPER SEPARATION 6 March 1992 8.3 PAPER SEPARATION To break the attraction between the paper and the drum, the separation corona applies an ac corona to the back side of the paper. The stiffness of the paper then causes it to separate from the drum. The pick-off pawls [A] which are installed on the cleaning unit assist paper separation.

  • Page 92: Tc/Sc Wire Cleaner

    6 March 1992 IMAGE TRANSFER AND PAPER SEPARATION 8.4 TC/SC WIRE CLEANER The transfer and separation corona unit has the wire cleaners to remove paper dust and/or toner particles which may get on the corona wires. Once every 5000 copies, the wire cleaners are activated when the main switch is on.

  • Page 93: Pick-Off Pawls

    IMAGE TRANSFER AND PAPER SEPARATION 6 March 1992 8.5 PICK-OFF PAWLS The pick-off pawls assist the paper separation process. The pick-off pawls are kept normally in contact with the drum. When the transport unit is lowered, the pick off pawls are released from the drum.

  • Page 94: Transport Unit

    6 March 1992 IMAGE TRANSFER AND PAPER SEPARATION 8.6 TRANSPORT UNIT Four transport belts are used to transport the copied paper to the fusing section. The vacuum fan sucks the air through the holes on the transport unit to hold the paper on the transport belts. The transport unit is pushed up and locked into position by the front and rear guide rollers.

  • Page 95: Cleaning

    CLEANING 6 March 1992 9. CLEANING 9.1 OVERVIEW This copier uses the counter blade system for drum cleaning. The blade is angled against drum rotation. This counter blade system has the following advantages: • Less wearing of the cleaning blade edge. •...

  • Page 96: Drive Mechanism

    6 March 1992 CLEANING 9.2 DRIVE MECHANISM The drive force from the main 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 then transmits the force to the front side through the cleaning brush [C] and flick roller [D].

  • Page 97: Cleaning Blade Pressure Mechanism

    CLEANING 6 March 1992 9.3 CLEANING BLADE PRESSURE MECHANISM When the cleaning solenoid [A] is energized, the solenoid arm lowers the pressure arm [B]. This frees the pressure release lever [C] and the blade spring [D] applies pressure to the cleaning blade. To ensure cleaning blade operation, +38 V is applied to the solenoid for 0.3 seconds as initial activation, then +24 V is applied.

  • Page 98: Cleaning Blade Side-To-Side Movement

    6 March 1992 CLEANING 9.4 CLEANING BLADE SIDE-TO-SIDE MOVEMENT The cleaning blade is held on the cleaning blade holder with a shoulder screw [A] at its center so that the cleaning pressure is evenly applied to the drum surface. The cleaning blade holder touches the cam gear [B] which gives a side-to-side movement to the blade.

  • Page 99: Toner Collection Mechanism

    CLEANING 6 March 1992 9.5 TONER COLLECTION MECHANISM Toner collected by the cleaning unit is transported to the toner cartridge through the toner collection tubes. Three helical coils are used for the toner transport. A magnetic disk torque limiter [A] is used on the toner collection coil drive mechanism to prevent the coil from being damaged by toner clogged in the collection tube.

  • Page 100: Toner Scattering Prevention

    6 March 1992 CLEANING 9.6 TONER SCATTERING PREVENTION The cleaning unit has two air outlets covered by the cleaning filter on its back side. The vacuum fan draws the air from the cleaning unit through the cleaning filters [A] and the toner filter [B] located above the transport section. This prevents the toner in the cleaning unit from being scattered to the drum area.

  • Page 101: Cleaning Solenoid Circuit

    CLEANING 6 March 1992 9.7 CLEANING SOLENOID CIRCUIT DC Drive PCB Main PCB 38VFL OUT RA303 CN304 CN302-5 38VFL IN Cleaning CN103-A3 RA301 CN304-1 CN303-5 CN303-2 -B11 Interface PCB CN258 Scan 2 CN256 Scan 2 Overload Sensor DATA10 -A10 CN104-B24 The main PCB energizes RA301 and 303 for 0.3 seconds to supply +38 V for the cleaning blade solenoid at the initial solenoid activation.

  • Page 102: Cleaning Blade Solenoid Control

    6 March 1992 CLEANING 9.8 CLEANING BLADE SOLENOID CONTROL Start Key Cleaning Sol. 1500 1500 Main Motor The main motor turns in reverse for 40 pulses at the end of every copy job. At this time, the cleaning solenoid is kept on to clean off the toner on the cleaning blade edge.

  • Page 103: Quenching

    QUENCHING 6 March 1992 10. QUENCHING To neutralize any charges remaining on the drum, a cold cathode fluorescent lamp [A] (CFL) is used as the quenching device. When the main PCB sends a trigger signal to the the CFL stabilizer [B], an ac power (ac 480 V/5 mA) is supplied to the CFL.

  • Page 104: Paper Feed

    6 March 1992 PAPER FEED 11. PAPER FEED 11.1 OVERVIEW This machine feeds paper from three trays. (Capacity: 1st tray [A]: 550, 2nd tray [B]: 3000, 3rd tray [C]: 1500). Paper is positioned at the center of the trays. This copier uses an FRR (Feed + Reverse Roller) paper feed system which uses three rollers: pick-up roller, feed roller, and separation roller.

  • Page 105: Paper Feed And Separation

    PAPER FEED 6 March 1992 11.2 PAPER FEED AND SEPARATION While the main motor is rotating, the paper feed clutch gear [A] is being driven from the main motor drive and is always rotating. The separation roller shaft [B] is turning in the direction indicated by the arrow in the illustration. The separation roller driven by the separation roller shaft is prevented from turning in the paper feed direction by the built-in torque limiter [C].
  • Page 106 6 March 1992 PAPER FEED Using the paper feed trigger signal from the main control board the paper feed clutch [A] turns on and paper feed roller shaft [B] begins to turn. A one-way clutch drives the paper feed roller [C]. The pick-up roller [D] rotates via an idler gear.

  • Page 107: Frr Operation

    PAPER FEED 6 March 1992 11.3 FRR OPERATION The direction in which the separation roller turns depends on the frictional forces acting on it. The magnetic torque limiter applies a constant clockwise force [F1]. When there is a single sheet of paper being driven between the rollers, the force of the friction between the feed roller and paper [F2] is greater than F1.

  • Page 108: Paper Return Mechanism

    6 March 1992 PAPER FEED 11.5 PAPER RETURN MECHANISM 3 mm The paper feed clutch [A] turns on and the paper feed roller shaft turns in the direction indicated by the arrow in the illustration. The swing lever [B] is raised by spring tension until it contacts the stopper [C].

  • Page 109: Paper End Detection

    PAPER FEED 6 March 1992 11.6 PAPER END DETECTION 3rd Tray 1st and 2nd Tray The paper end sensor [A] is installed at the rear of the tray bottom plate. The paper end condition is detected by the photo-interrupter and feeler [B]. When there is no paper remaining in the tray, the feeler rises from the tray bottom hole to deactuate the photo-interrupters for the 1st and 2nd tray, and to actuate the photo-interrupter for the 3rd tray.

  • Page 110: Paper Volume Detection

    6 March 1992 PAPER FEED 11.7 PAPER VOLUME DETECTION Each tray uses a pulse generator [A] to determine the quantity of paper in the tray. The amount of paper present is based on the number of pulses generated between the time the tray starts moving up and the time the upper limit sensor turns off.

  • Page 111: Paper Tray Drive Mechanism

    PAPER FEED 6 March 1992 11.8 PAPER TRAY DRIVE MECHANISM 11.8.1 1st & 3rd Tray 1st Tray 3rd Tray Drive from a reversible motor [A] is transmitted trough a worm gear [B] to the drive pulley [C] shaft. The tray wires have metal beads on them. These beads are inserted in the slots at the ends of the tray support bracket [D] of the bottom plate, so, when the wire pulley turns (counterclockwise, rear view), the beads on the wires drive the tray support bracket and the tray moves...

  • Page 112: 2Nd Tray

    6 March 1992 PAPER FEED 11.8.2 2nd Tray Drive from a reversible motor [A] is transmitted trough a timing belt and a worm gear [B] to the drive gear [C] shaft. The tray chains connect the ends of the tray support bracket [D] of the bottom plate, so, when the drive gear turns (clockwise, rear view), the chains drive the tray support bracket and the tray moves upward.

  • Page 113: Tray Lock Mechanism

    PAPER FEED 6 March 1992 11.9 TRAY LOCK MECHANISM 11.9.1 1st & 3rd Tray 1st Tray 3rd Tray When the tray is set, it is positioned by the lock arm [A]. The roller of the lock arm presses against the lock plate [B]. And the lock lever [C] engages the 1st tray top cover stopper [D] (in case of the 3rd tray: tray stopper [E]) to prevent the top cover or 3rd tray from being opened or pulled out while the tray is in the up position.

  • Page 114: 2Nd Tray

    6 March 1992 PAPER FEED 11.9.2 2nd Tray When the tray is set, it is positioned by the lock arm [A]. The roller of the lock arm presses against the lock plate [B]. And the lock lever [C] engages the right side plate stopper [D] to prevent the tray from being pulled out while the tray is in the up position.

  • Page 115: Side-To-Side Registration

    PAPER FEED 6 March 1992 11.10 SIDE-TO-SIDE REGISTRATION 11.10.1 1st Tray The plate [A] under the tray bottom plate can be moved from rear to front by loosening 5 screws. This plate position determines the side-to-side registration. 11.10.2 2nd & 3rd Tray 3rd Tray 2nd Tray The tray stopper [B] is fixed to the tray side.

  • Page 116: Paper Size Detection

    6 March 1992 PAPER FEED 11.11 PAPER SIZE DETECTION 11.11.1 1st Tray The rear side fence [A], front side fence [B], and rear plate [C] can be moved to change the paper size. This is accomplished by loosening the knob screw and moving these fences and plate to another place.

  • Page 117: 2Nd Tray

    PAPER FEED 6 March 1992 11.11.2 2nd Tray The rear side fence [A] and front side fence [B] can be moved to change the paper size. This is accomplished by loosening the knob screw and moving the rear and front side fences to another slot. The paper size detection sensors are mounted under the paper tray bottom plate.

  • Page 118: 3Rd Tray

    6 March 1992 PAPER FEED 11.11.3 3rd Tray The operator can easily adjust the paper side guide posts [A] and end plate [B] for any paper size by pressing the stopper lever and sliding the side guide posts and end plate to the desired position. The guide post brackets have the actuator plates mounted on their bottom.

  • Page 119: 2Nd Tray End Fence

    PAPER FEED 6 March 1992 11.12 2ND TRAY END FENCE When the tray is pulled out, the rear fence [A] is held in place by the front stay [B]. This makes paper setting easier. When the tray is pushed in, the rear side plate [C] guides the rear fence to its home position.

  • Page 120: Feed Unit Drive Mechanism

    6 March 1992 PAPER FEED 11.13 FEED UNIT DRIVE MECHANISM Feed roller drive of the 1st & 2nd tray is provided by the copier main motor. Drive from the transport section [A] of the copier main motor is transmitted via gears and a timing belt to the 1st and 2nd paper feed mechanism [B, C].

  • Page 121: Transport Unit And Registration

    TRANSPORT UNIT AND REGISTRATION 6 March 1992 12. TRANSPORT UNIT AND REGISTRATION 12.1 OVERVIEW The copy paper comes from the 3 paper paths to the registration rollers [A], which correct paper skew and then feed the paper to the drum at the proper time for image transfer.

  • Page 122: Vertical Transport

    6 March 1992 TRANSPORT UNIT AND REGISTRATION 12.2 VERTICAL TRANSPORT The vertical transport unit has relay rollers [A] and their guide plates for the duplex and 3rd tray. The vertical transport unit with the 3rd tray can be slid out by the 2 accurides [B] (upper and lower). The duplex paper feed sensor [C] is installed to the vertical transport unit to detect misfeed.

  • Page 123: Driven Guide Plate Open Mechanism

    TRANSPORT UNIT AND REGISTRATION 6 March 1992 12.4 DRIVEN GUIDE PLATE OPEN MECHANISM The driven guide plate [A] is supported by the support bracket [B]. Torsion springs [C] hold it in the closed position. There are magnets [D] at the front and rear.

  • Page 124: Paper Dust Cleaning Roller

    6 March 1992 TRANSPORT UNIT AND REGISTRATION 12.6 PAPER DUST CLEANING ROLLER Paper passes the paper dust cleaning roller [A] before it reaches to the registration roller [B]. The paper dust cleaning roller has a teflon-coated roller, which is charged by the friction with the scraper [C] contacted, and attracts the paper dust, and removes it from copy paper.

  • Page 125: Drive Mechanism

    TRANSPORT UNIT AND REGISTRATION 6 March 1992 12.7 DRIVE MECHANISM All transport section rollers (with the exception of the registration roller) begin to rotate together with the main motor [A]. The registration clutch [B] engages according to the appropriate registration timing. When the clutch engages, the registration roller will begin to rotate.

  • Page 126: Fusing

    6 March 1992 FUSING 13. FUSING 13.1 OVERVIEW The image fusing on the copy paper is made by the hot roller [A] and pressure roller [B]. The hot roller has three heat pipes [C]. These pipes deliver extra heat from both ends of the hot roller to the center of the roller to distribute heat evenly along the roller.

  • Page 127: Heat Pipe Configuration And Operation Principles

    FUSING 6 March 1992 13.2 HEAT PIPE CONFIGURATION AND OPERATION PRINCIPLES The heat pipes are hollow metal tubes. Water capillary tubes [A] run along the inside of the heat pipe. These capillary tubes are used as heat transfer elements. When one end of the heat pipe is superheated [B], it causes vaporization.

  • Page 128: Pressure Mechanism

    6 March 1992 FUSING 13.3 PRESSURE MECHANISM The fusing pressure is constantly applied between the hot roller [A] and pressure roller [B] by the upper pressure lever [C] and lower pressure lever [D] which are lifted up by the fusing unit release lever [E] via the pressure cam [F].

  • Page 129: Oil Supply

    FUSING 6 March 1992 13.4 OIL SUPPLY The oil supply roller [A] is soaked with silicon oil [B]. The roller contacts the hot roller by a spring. It turns with the hot roller and applies a light coat of silicon oil to the hot roller. 2-92...

  • Page 130: Curling And Cooling Mechanism

    6 March 1992 FUSING 13.5 DE-CURLING AND COOLING MECHANISM The de-curling roller [A] cools the copy paper exiting through the fusing unit. This prevents sheets in the duplex tray from sticking together because the toner is too hot. The copy paper may be back-curled after it passes the fusing unit. The de-curling roller and the de-curling belt [B] make the copy paper face curl to improve paper stacking in the sort mode.

  • Page 131: Fusing Drive Mechanism

    FUSING 6 March 1992 13.6 FUSING DRIVE MECHANISM Main motor drive is provided to the fusing unit through the transport timing belt [A], fusing drive belt [B], and fusing drive gear [C]. The fusing unit and fusing drive section are precisely positioned by the position guide [D]. This minimizes the fusing drive load and prevents drive gear abrasion.

  • Page 132: Fusing Lamps Operation

    6 March 1992 FUSING 13.7 FUSING LAMP OPERATION E (198°C) D (195°C) C (178°C) Warm up: After the main switch is turned on, the 900 W or 950 W lamp turns on first and after one second, the 720 W lamp turns on...(*1). This is because if both lamps turned on simultaneously, it would result in an extremely high current load.
  • Page 133 FUSING 6 March 1992 European version SP mode RESET 169°C 174°C USER (169°C) (174°C) TOOL 184°C 189°C (189°C) (189°C) ( ): Cover sheet or slip sheet mode (Thick paper) U.S.A. version SP mode RESET 159°C 169°C USER (169°C) (169°C) TOOL 179°C 189°C (189°C)

  • Page 134: Inverter And Paper Exit

    6 March 1992 INVERTER AND PAPER EXIT 14. INVERTER AND PAPER EXIT 14.1 OVERVIEW After passing the fusing unit, copies come to the inverter unit which chiefly consists of the inverter roller [A], inverter gate [B], inverter gate solenoid [C], return drive rollers [D], return pinch rollers [E], pinch solenoid [F], junction gate [G], and junction gate solenoid [H].

  • Page 135: Ordinary Copying

    INVERTER AND PAPER EXIT 6 March 1992 14.2 ORDINARY COPYING As the inverter gate [A] stays at the upper position (the inverter gate solenoid stays off) and the junction gate [B] stays at the lower position (the junction gate solenoid stays off), copies go straight through the inverter rollers to the exit rollers.

  • Page 136: Overlay Image Copying

    6 March 1992 INVERTER AND PAPER EXIT 14.4 OVERLAY IMAGE COPYING The inverter gate solenoid stays off and the junction gate solenoid turns on. Copies go straight to the junction gate [A] and are directed by the junction gate to the duplex unit [B]. 14.5 FACE-DOWN FEED-OUT The inverter gate solenoid turns on and the junction gate solenoid stays...

  • Page 137: Duplex

    DUPLEX 6 March 1992 15. DUPLEX 15.1 OVERVIEW Copies are fed to the duplex tray when in duplex copying or overlay copying mode. The copies wait in the tray until the copying of the second original starts. The duplex tray has a maximum capacity of 50 sheets. When a copy number greater than 50 is entered, 50 (copies) is displayed in the copy entered counter and only 50 copies are printed.

  • Page 138: Duplex Entrance

    6 March 1992 DUPLEX 15.2 DUPLEX ENTRANCE Copies transported from the inverter section pass through the relay guide plates [A] to the duplex tray section. To clear paper jams between the inverter section and duplex tray, the relay guide plate can be opened and closed by the spring [B]. The paper jammed in the middle can be moved to the duplex tray by turning the knob [C] manually since the spring pressure [D] is applied to the upper fork gate feed roller [E].

  • Page 139: Fork Gate

    DUPLEX 6 March 1992 15.3 FORK GATE A5/HLT A4, B5/LT, LG A3, B4/DLT Paper passes through the duplex entrance sensor. The two fork gates [A] provide three possible paper routes to the duplex tray. The paper route depends on the paper size. The fork gates open and close to direct the paper flow in response to the solenoids [B, C] on/off combinations depending on paper size as shown.

  • Page 140: Stacking Mechanism

    6 March 1992 DUPLEX 15.4 STACKING MECHANISM The paper stopper solenoid [A] energizes and the paper stopper [B] turns counterclockwise 1229 ms later when the registration clutch turns on and the leading edge of the first sheet passes the registration rollers. That means the leading edge of the first sheet passes a point approximately 50 mm in front of the fusing sensor.

  • Page 141: Jogger

    DUPLEX 6 March 1992 15.5 JOGGER When the start key is pressed to start a duplex or overlay copy cycle, the jogger motor [A] drives the jogger fences [B] inward from the home positions to the waiting positions which are 10 mm away from both edges of the stacked paper.

  • Page 142: Paper End Detection

    6 March 1992 DUPLEX 15.6 PAPER END DETECTION The feeler [A] installed to the pressure plate shaft drops into the groove after the last paper sheet [B] has passed. The photo- interrupter [C] is de-actuated and paper end is detected. 2-105...

  • Page 143: Paper Feed And Separation

    DUPLEX 6 March 1992 15.7 PAPER FEED AND SEPARATION Paper feeding is from the bottom sheet. When the final sheet of paper has been stacked inside the duplex tray, the paper stopper solenoid [A] and the pressure plate solenoid [B] (It turned on simultaneously with the paper stopper solenoid) have turned off.
  • Page 144 6 March 1992 DUPLEX The duplex paper feed sensor [A] is identical to that of the paper feed tray. It has two functions. Its first function is to check pre-registration at the duplex paper feed sensor. When the paper reaches the sensor, the duplex paper feed clutch turns off.

  • Page 145: Pick-Up Roller Stop Mechanism

    DUPLEX 6 March 1992 15.8 PICK-UP ROLLER STOP MECHANISM The pick-up roller [A] makes one turn for each paper sheet. The pick-up roller is flat on one side and, during machine stand-by, the flat side faces up. Paper feed begins. The feeler [B] installed to the pick-up roller shaft turns. After the pick-up roller position sensor [C] shifts from being actuated to being de-actuated, the duplex paper feed clutch is de-engaged (after approximately 3/4 of a turn).

  • Page 146: Duplex Unit Lock Mechanism

    6 March 1992 DUPLEX 15.9 DUPLEX UNIT LOCK MECHANISM Like the paper tray, the duplex tray is positioned by the lock arm [A]. The roller of the lock arm presses against the lock plate [B]. The duplex tray stopper [C] is fixed to the top of the lock arm. The tray stopper bumper [D] is fixed to the main copier.

  • Page 147: Duplex Drive Mechanism

    DUPLEX 6 March 1992 15.10 DUPLEX DRIVE MECHANISM The duplex tray is driven by the main motor drive. The drive from the main motor is transmitted through the timing belt [A], transport drive pulley [B] to the duplex tray drive gear [C]. The duplex tray drive gear distributes the drive to each roller.

  • Page 148: Ardf

    6 March 1992 ARDF 16. ARDF 16.1 OVERVIEW 1. One-sided Original Feed When the start key is pressed after an original is set face down on the original table [A], the bottom sheet of the original stack is fed onto the exposure glass [B] by the rollers [C] and the transport belt [D].

  • Page 149: Original Detection

    ARDF 6 March 1992 16.2 ORIGINAL DETECTION When an original is set on the original table [A] , the original sensor feeler [B] is pushed up by the original and the original sensor [C] is activated. The paper feed tray has an insert original indicator [D] and an auto feed indicator [F].

  • Page 150: Original Size Detection

    6 March 1992 ARDF 16.3 ORIGINAL SIZE DETECTION U.S.A. Sensor Size HLT sideways,10 " x 8", LT lengthwise LT sideways F4 sideways LG sideways, 15" x 11", 14" x 10" DLT sideways Europe Sensor Size A4 lengthwise, B5 sideways, 10" x 8", A5 LT sideways A4 sideways F, F4...

  • Page 151: Original Separation

    ARDF 6 March 1992 16.4 ORIGINAL SEPARATION Paper is fed by friction between the separation rollers [A] and the friction tab [B]. Friction tab permit only the bottom sheet of the set of originals to be fed by the separation rollers and the pick-up rollers [C] to the relay rollers [D]. The separation rollers have a built-in one-way gear.

  • Page 152: Pick-Up Roller

    6 March 1992 ARDF 16.5 PICK-UP ROLLER The entrance guide mylar [A] holds the originals against the pick-up roller [B] to facilitate paper feed. The pressure release cam [C] lobe pushes the lever [D] upward to release the pressure mylar [E]. This makes it easier to set the originals. During paper feed, the cam rotates and the pressure mylar pushes down the entrance guide mylar by the force of the return spring.

  • Page 153: Original Feed Drive Mechanism

    ARDF 6 March 1992 16.6 ORIGINAL FEED DRIVE MECHANISM The two-directional feed-in motor [A] drives the pick-up rollers [B], the separation rollers [C], and the relay rollers [D]. Three one-way clutches (two gears [E] and a pulley [F]) control the rollers’ rotation. Upon receiving the paper-feed signal from the copier, the paper feed motor turns in the direction shown by the black arrow in the illustration.

  • Page 154: Relay Roller Pressure Release Mechanism

    6 March 1992 ARDF 16.7 RELAY ROLLER PRESSURE RELEASE MECHANISM When the entrance cover [A] is opened, the bushing [B] of the pull-out roller is pressed down by the raised portion of the friction tab frame [C]. This releases the relay roller pressure to make misfed original removal easier. The feeler [D] moves away from the entrance cover sensor [E] which detects that cover is open.

  • Page 155: Job Separation

    ARDF 6 March 1992 16.8 JOB SEPARATION There is a mechanism to separate two different stacks of originals when the preset mode is used. When the job separation motor [A] rotates, the job separator [B] is set on the original top sheet. The separation motor stops when the job separation home position sensor [C] is actuated.

  • Page 156: Original Transport Mechanism

    6 March 1992 ARDF 16.9 ORIGINAL TRANSPORT MECHANISM Three pressure rollers [A] are built into the transport unit to maintain friction between the transport belt [B] and the original. Transport belt tension is provided by two springs [C]. The transport belt is driven by a dc motor [D]. A special coated exposure glass [E] (the coated side is marked and should face up) is used to prevent the original from sticking due to static electricity.
  • Page 157 ARDF 6 March 1992 Thin Paper Mode Thick Paper Mode Customers can choose the paper transport mode by "User Tool" depending on the thickness of the original used. -- In thin paper mode -- The belt motor stops exactly when the trailing edge of the original passes the right scale [A] edge.

  • Page 158: Transport Unit Lift Mechanism

    6 March 1992 ARDF 16.10 TRANSPORT UNIT LIFT MECHANISM To make opening the transport unit easier, there are six balance springs [A]. Three springs are on the right and three on the left. There is a lift sensor [B] to detect if the transport unit opens. When the transport unit is opened, the feeler [C] actuates the lift sensor.

  • Page 159: Transport Belt Unit / Inverter Cover

    ARDF 6 March 1992 16.11 TRANSPORT BELT UNIT / INVERTER COVER The inverter cover [A] and the transport belt unit [B] can be opened to allow easy removal of original jams. The transport unit can be opened by sliding the release lever [C] to the right. A brake [D] is installed on each pivot to make the down movement of the transport belt unit gentle when the unit is opened.

  • Page 160: Original Inverter Mechanism

    6 March 1992 ARDF 16.12 ORIGINAL INVERTER MECHANISM When the inverter signal is received from the copier, the belt motor (drives transport belt [A]) and the inverter motor (drives inverter rollers [B] and exit rollers [C]) start rotating. Simultaneously, the inverter gate solenoid turns on to open the upper inverter gate [D] and lower inverter gate [E].
  • Page 161 ARDF 6 March 1992 For original inversion, the inverter gate solenoid [A] turns on and the upper [B] and lower [C] inverter gates open to create an inverter loop path. An inverter entrance sensor [D] and an inverter registration sensor [E] (reflection-type photosensors) are located in the inverter loop path.

  • Page 162: Switch Back Mechanism

    6 March 1992 ARDF 16.13 SWITCH BACK MECHANISM To return the inverted originals to their original page order, the originals are inverted again and traveled to the switch back tray [A] before being fed-out from the document feeder. When the inversion signal is received from the copier, the inverter solenoid turns on to open the upper and lower inverter gates [B].

  • Page 163: Inverter Drive Mechanism

    ARDF 6 March 1992 16.14 INVERTER DRIVE MECHANISM The inverter unit is driven by a dc motor [A]. The drive of the inverter motor [A] is transmitted to the exit rollers [B] through the two one-way clutches [C]. The exit rollers rotate in the same direction due to the function of these one-way clutches.

  • Page 164: Cff Mechanism

    6 March 1992 ARDF 16.15 CFF MECHANISM There are four guides to maintain computer paper transport and stacking capabilities. The CFF stopper [A] of the paper feed unit prevents the original from entering the ADF paper feed entrance. The rear CFF guide [B] prevents side to side movement of the original to ensure that the CFF sensor [C] counts the holes lined up on the computer form.

  • Page 165: Operation Unit

    OPERATION UNIT 6 March 1992 17. OPERATION UNIT CGROM IC131 ROM2 IC137 ROM1 IC138 Serial Interface Main PCB A CRT (9 inches) [A] and a touch panel are used to achieve easy machine operation. The touch panel consists of a transparent film [B] and a glass sheet [C] on which transparent matrix conductors (32 x 25 lines) are printed.

  • Page 166: Installation

    SECTION 3 INSTALLATION...

  • Page 167: Installation Requirement

    6 March 1992 INSTALLATION REQUIREMENT 1. INSTALLATION REQUIREMENT 1.1 ENVIRONMENT 1. Temperature Range: 10°C to 30°C (50°F to 86°F) 2. Humidity Range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 lux (do not exposure to direct sunlight) 4. Ventilation: Minimum space 20 m .

  • Page 168: Minimum Space Requirements

    INSTALLATION REQUIREMENT 6 March 1992 1.3 MINIMUM SPACE REQUIREMENTS With 2 sorters More than 15.8" (400 mm) More than More than 11.8" (300 mm) 11.8" (300 mm) More than 39.4" (1000 mm) With 1 sorters More than 15.8" (400 mm) More than More than 11.8"...

  • Page 169: Power Requirements

    6 March 1992 INSTALLATION REQUIREMENT 1.4 POWER REQUIREMENTS 1. Input voltage level: 120 V/60 Hz: More than 20 A (for U.S.A. version) 220 V/230 V/240 V/50 Hz: More than 10 A (for European version) 2. Permissible voltage fluctuation: ±10% 3. Do not set anything on the power cord. NOTE: a) Make sure the plug is firmly inserted in the outlet.

  • Page 170: Accessory Check

    ACCESSORY CHECK 6 March 1992 2. ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: 1. Operation Unit ..............1 2. Operation Unit Stand ............1 3. Fusing Unit Release Lever ..........1 4. Key Counter Cover ............1 5.

  • Page 171: Installation Procedure

    6 March 1992 INSTALLATION PROCEDURE 3. INSTALLATION PROCEDURE CAUTION: While the leveling shoes are not installed, do not completely pull out many units simultaneously. Otherwise, the machine could topple. NOTE: Keep the shipping retainers after installing the machine. They will be reused if in the future the machine is transported to another location.
  • Page 172 INSTALLATION PROCEDURE 6 March 1992 3. Remove the fusing cover [A] (3 screws), fixing bracket [B] (1 screw), and reinstall the fusing cover. Install the fusing unit release lever [C], turn the lever clockwise, and fix it (1 M5 x 8 screw). 4.
  • Page 173 6 March 1992 INSTALLATION PROCEDURE 6. Remove the front scale holder [A] (2 screws), front scale [B] (2 screws), exposure glass [C], left top cover [D] (7 screws), and right rear cover [E] (front view, 2 screws). 7. Remove the lens fixing bracket [F] (2 screws), 3rd scanner fixing bracket [G] (1 screw), and scanner fixing screw [H].
  • Page 174 INSTALLATION PROCEDURE 6 March 1992 10. Remove the charge corona unit [A] (1 connector and 1 clamp) and erase unit [B]. 11. Lower the transport unit by the lever [C] as shown and remove the drum stay [D] and cleaning unit [E]. 12.
  • Page 175 6 March 1992 INSTALLATION PROCEDURE 14. Remove the development filter [A] from the development unit. 15. Pour the developer (1 bag: 1.7 kg) evenly between the left and right side of the development unit and reinstall the development filter. Then, reinstall the development unit (1 connector and 1 screw), and PTC unit on the copier.
  • Page 176 INSTALLATION PROCEDURE 6 March 1992 18. Connect the operation unit [A] to the operation unit stand [B] (4 screws and 1 connector). 19. Install the operation unit (1 M5 x 8 screw [C] and 1 connector [D]) and the operation unit stopper [E] (2 M5 x 8 screws). The oval hole [F] of the operation unit stopper should be at the lower position.
  • Page 177 6 March 1992 INSTALLATION PROCEDURE 22. Insert the leveling shoes [A] under the feet, and level the machine by securing down the feet. 23. Insert the sponge cushion [B]. 24. Remove the strips of filament tape [C] of LCT. 25. Remove the LCT lower rear cover [D] (2 screws), fixing plate [E] (3 screws) and reinstall the LCT lower rear cover.
  • Page 178 INSTALLATION PROCEDURE 6 March 1992 26. Remove the copier left lower cover [A] (3 screws) and left upper cover [B] (2 screws). 27. Cut 2 binds [C] for the LCT interface harness by the pliers. 28. Secure the ground wire [D] to the copier (1 screw). 29.
  • Page 179 6 March 1992 INSTALLATION PROCEDURE 30. Pass 6 connectors of the interface harness [A] through the rear upper hole [B] of the left lower cover and reinstall the left lower cover. (Do not fix the screw [C]). Set 6 connectors to the connectors of the LCT harness [D]. 31.

  • Page 180: A3/11" X 17" Counter Installation

    INSTALLATION PROCEDURE 6 March 1992 3.1 A3/11" x 17" COUNTER INSTALLATION CAUTION: Unplug the copier power cord before starting the following procedure. 1. Open the right front door and remove the right inner cover [A] (3 screws). 2. Install the A3/11" x 17" counter [B] (1 connector). 3.

  • Page 181: Key Counter Holder Installation

    6 March 1992 INSTALLATION PROCEDURE 3.2 KEY COUNTER HOLDER INSTALLATION CAUTION: Unplug the copier power cord before starting the following procedure. 1. Open the right front door and remove the right inner cover (3 screws). 2. Remove the dummy connector [A]. 3.

  • Page 182: Service Tables

    SECTION 4 SERVICE TABLES...

  • Page 183: Service Remarks

    6 March 1992 SERVICE REMARKS 1. SERVICE REMARKS 1.1 HANDLING THE DRUM 1. Never expose the drum to direct sun light. 2. Never expose the drum to direct light of more than 1,000 Lux for more than 5 minutes (sun light is about 1,360 Lux). 3.

  • Page 184: Charge Corona Unit

    SERVICE REMARKS 6 March 1992 1.2 CHARGE CORONA UNIT 1. Clean the charge corona casing with water first to remove NOx. Then clean it with alcohol if any toner still remains on the casing. 2. The corona wires can be cleaned only with a dry soft cloth. Using water or alcohol may damage the coating of the wire surface.

  • Page 185: Erase Lamp And Potential Sensor

    6 March 1992 SERVICE REMARKS 1.4 ERASE LAMP AND POTENTIAL SENSOR 1. Use water to clean the erase lamp unit and then use a dry soft cloth. 2. After cleaning the erase lamp unit, rub it lightly with your finger to discharge any static electricity on the surface.

  • Page 186: Transfer And Separation

    SERVICE REMARKS 6 March 1992 1.6 TRANSFER AND SEPARATION 1. Clean the T & S corona casing with water then with alcohol if necessary. 2. The corona wires can be cleaned only with a dry soft cloth. Using water or alcohol may damage the wire coating. 3.

  • Page 187: Fusing Unit

    6 March 1992 SERVICE REMARKS 1.10 FUSING UNIT 1. Do not touch the fusing lamps with bare hands. 2. Two lamps of different wattage are used for fusing. Make sure that the lamps are connected and positioned correctly and that they are not touching the inner surface of the hot roller.

  • Page 188: Service Program Mode

    SERVICE PROGRAM MODE 6 March 1992 2. SERVICE PROGRAM MODE 2.1 SERVICE PROGRAM MODE OPERATION The service program (SP) mode is used to check electrical data and change modes or adjustment values. 2.1.1 To Access SP Mode 1. Turn on DIP SW #3 on the reset Switch PCB. 2.

  • Page 189: Sp Mode Function

    6 March 1992 SERVICE PROGRAM MODE 2.2 SP MODE FUNCTION Jam Counter Location Code Third Tray Not used Not used Not used Horizontal Transport Unit Registration Paper Separation Fusing Unit Paper Exit Duplex Entrance Duplex Paper Feed First Tray Second Tray Diagonal Transport Unit Sorter Bins ADF Feed-in...
  • Page 190 SERVICE PROGRAM MODE 6 March 1992 Daily / Weekly Jam Counter Week 1 means first week of a month Counters are not cleared at the end of the week or month. For example, if this menu is displayed on Monday, the counters of Tuesday through Friday is the data of previous week.
  • Page 191 6 March 1992 SERVICE PROGRAM MODE Copy Counter Test mode copy counter displays the number of copies in SP Test Mode This counter only counts up when Test Copy Counter ON is (SP mode PAGE 4). Block copy counter displays the number of copies after block copy counter clear (SP mode PAGE 1).
  • Page 192 SERVICE PROGRAM MODE 6 March 1992 Daily / Weekly Copy Counter NOTE: To clear counters, use SP mode (Counter Clear). Operating Time Display the total rotating time of the main motor. Minutes are not displayed. NOTE: This counter is only cleared by RAM clear. (Main board DIP SW #1: ON, #2: OFF) 4-10...
  • Page 193 6 March 1992 SERVICE PROGRAM MODE SC Counters NOTE: To clear counters, use SP mode (Counter Clear). 4-11...
  • Page 194 SERVICE PROGRAM MODE 6 March 1992 Sensor Output ID Sensor ID sensor output for bare drum surface ID sensor output for pattern Drum Potential Sensor Vd set up value during the process control sequence VL set up value during the process control sequence VL2 VL value during copy cycle Residual voltage during the...
  • Page 195 6 March 1992 SERVICE PROGRAM MODE SP Test Mode -- 1 (PAGE 1 - 1) Sensors Turns on and off the 12-volt line of the dc drive board (CN302-2), which applies power to sensors, and checks sensor operation. The sensors which are normally activated during the stand-by condition cannot be checked because sensor output does not change.
  • Page 196 SERVICE PROGRAM MODE 6 March 1992 SP Test Mode -- 2 (PAGE 1 - 2) Solenoids/Clutches Turns on and off the 24-volt lines to solenoids and clutches from the main board, and confirms component activity by checking electrical current value. Touch on the display.
  • Page 197 6 March 1992 SERVICE PROGRAM MODE SP Test Mode -- 3 (PAGE 1 - 3) Item Function Test Method Charge Cleaner Turns on charge and T/S corona Touch START wire cleaners. (one round) ID Sensor Adjusts Vsg value automatically 1. Touch on the display.
  • Page 198 SERVICE PROGRAM MODE 6 March 1992 SP Test Mode -- 4 (PAGE 2) Test Procedure Touch on the display and press "START" key top to start. Touch or press "CLEAR/STOP" key top to stop. RESET Item Function Remarks Drum Conditioning Turns on the main motor, the Mode development drive motor, corona...
  • Page 199 6 March 1992 SERVICE PROGRAM MODE SP Test Mode -- 5 (PAGE 3) Test Procedure Touch on the display and press "START" key top to start. Touch or press "CLEAR/STOP" key top to stop. RESET Item Function Remarks Cleaning Blade Turns off the cleaning blade.
  • Page 200 SERVICE PROGRAM MODE 6 March 1992 SP Test Mode -- 6 (PAGE 4) 1. Function Turn on the individual power pack. Two or more power packs cannot be turned on at the same time in this mode. 2. Test Procedure Touch to turn on and touch to turn off.
  • Page 201 6 March 1992 SERVICE PROGRAM MODE SP Adjustment -- 1 (PAGE 1 and 2) Adjusts an output voltage from each power pack. Output value changes 0.5% per step. Note: This adjustment is only for the test purpose. Do not use this mode in the field.
  • Page 202 SERVICE PROGRAM MODE 6 March 1992 SP Adjustment -- 2 (PAGE 3) Change/ Item Function Range Step Horizontal Magnification Adjusts the lens and the mirror unit Adjustment (Full Size) horizontal stop position at the full size. Horizontal Magnification Adjusts the lens and mirror unit ±...
  • Page 203 6 March 1992 SERVICE PROGRAM MODE SP Adjustment -- 3 (PAGE 4) Item Function Test Procedure ADF Motor Adjusts the paper feed motor, transport Adjustment motor, and inverter motor speed of the Touch START document feeder automatically. Change/ Item Function Range Step ADF 1st Side...
  • Page 204 SERVICE PROGRAM MODE 6 March 1992 SP Special Feature -- 1 (PAGE 1 and 2) <PAGE 1> Item Function Setting Default Fusing Lower Select lower limit 159°C (Cover Mode - 169°C) -- LT RESET RESET Temperature temperature to 169°C (Cover Mode - 169°C) -- A4 Limit: High enter idling.
  • Page 205 6 March 1992 SERVICE PROGRAM MODE SP Special Feature -- 2 (PAGE 3) Item Function Setting Default RESET RESET Process Control Disable the process control. Enable OFF Mode Disable RESET RESET Fusing Idling Rotates the main motor and Mode development motor for approximately 20 minutes after warm up.
  • Page 206 SERVICE PROGRAM MODE 6 March 1992 SP Special Feature -- 3 (PAGE 4) Item Function Setting Default 0.93 Magnification Selects the magnification when Ratio Priority is selected. Reduce/Enlarge RESET Manual ID Selects ID level when Auto Image RESET Center Level Selection Density is changed to Manual Image Preset level Density.
  • Page 207 6 March 1992 SERVICE PROGRAM MODE SP Special Feature -- 4 (PAGE 5) Item Function Setting Default Copy Number Selects the blade release 15 seconds (100 RESET RESET to Release timing after copying jobs. copies or more) Blade Pressure 5 minutes (less than 100 copies) 15 seconds (250 copies or more)
  • Page 208 SERVICE PROGRAM MODE 6 March 1992 Alarm Level Setting Item Function Setting Default Sensor Alarm Set the output level of electrical Level volume (sensor) against full value (100%) to start RDS alarm call. Output of each sensor in normal condition is designed to 50%. LEVEL 1 LEVEL 2 Jam Alarm Level Select jam ratio for one week to...
  • Page 209 6 March 1992 SERVICE PROGRAM MODE Counter Clear Clear Clear 1. Touch beside the counter you wish to clear. 2. Touch to clear the counter. 4-27...

  • Page 210: Sp Mode Index

    SERVICE PROGRAM MODE 6 March 1992 2.3 SP MODE INDEX SP Menu Manual Item Page Page A3/11x17 counter on mode 4-22 A3/11x17 double count 4-23 ADF 1st side registration adjustment 4-21 ADF 2nd side registration adjustment 4-21 ADF free run mode 4-16 ADF motor adjustment 4-21...
  • Page 211 6 March 1992 SERVICE PROGRAM MODE SP Menu Manual Item Page Page Daily copier jam counter Daily copy counter 4-10 Daily original jam counter Daily peripheral jam counter Data print 4-25 Drum conditioning mode 4-16 Drum potential sensor output 4-12 Drum potential sensor test 4-15 Drum temperature...
  • Page 212 SERVICE PROGRAM MODE 6 March 1992 SP Menu Manual Item Page Page ID sensor test 4-15 Jam alarm level 4-26 Jam counter - Location Jam counter - Original location Jam counter - Original total Jam counter - Paper Size Jam counter - Total Jam detection off mode 4-17 Leading edge erase adjustment...
  • Page 213 6 March 1992 SERVICE PROGRAM MODE SP Menu Manual Item Page Page SC counter - Duplex 4-11 SC counter - Exposure 4-11 SC counter - Fan motor 4-11 SC counter - Fusing 4-11 SC counter - ID sensor 4-11 SC counter - Image transfer 4-11 SC counter - Magnification 4-11...
  • Page 214 SERVICE PROGRAM MODE 6 March 1992 SP Menu Manual Item Page Page Toner density selection 4-23 Toner forced supply mode 4-17 Toner supply amount 4-23 Total copies by paper size Total number of copies Total original jams Total paper jams Tray priority 4-22 User codes/counters clear...

  • Page 215: Dip Sw Table

    3.1 MAIN PCB Function Normal mode RAM clear SC off mode (except fusing SCs) Not used Destination RICOH Not used Not used NOTE: Machine only detect DIP SW positions when the main switch is turned on. 3.2 RESET SWITCH PCB Function...

  • Page 216: Preventive Maintenance Schedule

    PREVENTIVE MAINTENANCE SCHEDULE 6 March 1992 4. PREVENTIVE MAINTENANCE SCHEDULE 4.1 PM TABLE NOTE: The amounts mentioned in the PM interval are copy numbers. C: Clean R: Replace L: Lubricate I: Inspect A: Adjustment 150K 300K 450K 600K NOTE OPTICS Mirrors, Lens, Soft cloth Reflector...
  • Page 217 6 March 1992 PREVENTIVE MAINTENANCE SCHEDULE 150K 300K 450K 600K NOTE Drum Water/Dry cloth Corona Wires Wire Cleaner Pads Toner Filter Ozone Filter Replace at 1.2M Corona Casing Water/Alcohol Potential Sensor and Dry cloth/Blower brush Drum Thermistor Charge Corona Unit Brush Seal Erase Lamp Water...
  • Page 218 PREVENTIVE MAINTENANCE SCHEDULE 6 March 1992 150K 300K 450K 600K NOTE Pressure Roller Bearing Oil Supply Roller Oil Supply Roller Suitable solvent Bushing Stripper Pawls Suitable solvent I, C I, C I, C I, C Replace if damaged Fusing Drive Gears Mobil Temp 78 Guide Plates Suitable solvent...

  • Page 219: Regular Pm Schedule

    6 March 1992 PREVENTIVE MAINTENANCE SCHEDULE 4.2 REGULAR PM SCHEDULE 1. Make A Copy and Remove the Developer (every 150K) 1. Make a copy of OS-UA3 test chart at manual image density level 4. 2. Remove the developer. 3. Unplug the copier and 2nd sorter stapler. 2.
  • Page 220 PREVENTIVE MAINTENANCE SCHEDULE 6 March 1992 Every 600K 1. Clean the registration roller using water. 2. Adjust the 2nd tray drive chain tension. Every 1.2M 1. Replace the paper dust cleaning roller and the dust pan. 4. Duplex Unit (every 150K duplex copies) 1.
  • Page 221 6 March 1992 PREVENTIVE MAINTENANCE SCHEDULE 5. Clean the drum potential sensor and the drum thermistor using a dry cloth or blower brush. 6. Clean the erase lamp, the QL filter, and the ID sensor using water. 7. Clean the pick-off pawls with alcohol. Every 1.2M 1.
  • Page 222 PREVENTIVE MAINTENANCE SCHEDULE 6 March 1992 Every 300K 1. Replace the hot roller together with the bushings and the bearings. Every 600K 1. Replace the pressure roller together with the bushings and the bearings. 4-40...

  • Page 223: Lubrication Points

    6 March 1992 LUBRICATION POINTS 5. LUBRICATION POINTS At an EM call or when the parts are getting dry, lubricate the following parts using a suitable lubricant. 5.1 MIRROR UNIT GUIDE ROD FELT Lubricant: Launa-40 oil or equivalent 5.2 LENS HORIZONTAL DRIVE MOTOR GEARS Lubricant: Mobil Temp 78 4-41...

  • Page 224: Tray Drive Worm Gears

    LUBRICATION POINTS 6 March 1992 5.3 TRAY DRIVE WORM GEARS Lubricant: Mobil Temp 78 5.4 PAPER FEED DRIVE GEARS Lubricant: Mobil Temp 78 4-42...

  • Page 225: Fusing Drive Gears

    6 March 1992 LUBRICATION POINTS 5.5 FUSING DRIVE GEARS Lubricant: Mobil Temp 78 5.6 DF BUSHINGS Interval: Every 1.2M originals Lubricant: Launa-40 oil or equivalent 4-43...

  • Page 226: Replacement And Adjustment

    SECTION 5 REPLACEMENT ADJUSTMENT...

  • Page 227: Exterior And Inner Covers

    6 March 1992 EXTERIOR AND INNER COVERS 1. EXTERIOR AND INNER COVERS 1.1 LEFT AND RIGHT DOOR REMOVAL 1. Remove the door stoppers [A] (1 screw each). 2. Lift the doors up and remove them by swinging out the bottom part of each door.

  • Page 228: Exterior Cover Removal

    EXTERIOR AND INNER COVERS 6 March 1992 1.2 EXTERIOR COVER REMOVAL -- Left Covers -- 1. Remove the left upper cover [A] (2 screws). 2. Remove the LCT (see LCT unit removal). 3. Remove the left lower cover [B] (3 screws). -- Rear Covers -- 1.

  • Page 229: Left And Right Inner Cover

    6 March 1992 EXTERIOR AND INNER COVERS 1.3 LEFT AND RIGHT INNER COVER 1. Open the front doors. 2. Remove the left inner cover [A] (4 screws). 3. Remove the right inner cover [B] (3 screws). 1.4 UPPER COVER REMOVAL 1.

  • Page 230: Optics

    OPTICS 6 March 1992 2. OPTICS 2.1 EXPOSURE GLASS REMOVAL 1. Lift the document feeder. 2. Remove the front scale holder [A] (2 screws and 2 plates). 3. Remove the front scale [B] (2 screws). 3. Loosen the three screws [C] securing the rear scale. 4.

  • Page 231: Exposure Lamp Replacement

    6 March 1992 OPTICS 2.2 EXPOSURE LAMP REPLACEMENT 1. Remove the front upper cover [A] and rear top cover [B]. 2. Remove exposure glass [C] and rear scale [D] (3 screws). 3. Move the first scanner to the center.
  • Page 232 OPTICS 6 March 1992 4. Remove the cover of the lamp intensity sensor fiber optics cable [A] (1 screw) and remove the cable end [B]. 5. Remove the front lamp holder [C] (2 screws) and pull out the lamp while holding the lamp heater [D].
  • Page 233 6 March 1992 OPTICS 6. Insert the new exposure lamp into the lamp heater so that the two terminal pins [A] are in a horizontal position and the lamp manufacturer mark [B] faces the rear. 7. Set the right terminal pin [C] of the lamp into the center of the rear lamp holder [D].
  • Page 234 OPTICS 6 March 1992 11. Adjust the lamp heater position so that the lamp intensity sensor fiber optics cable can be properly installed. Confirm that the transparent part of the lamp is at the center of the heater opening (see figure). 12.

  • Page 235: Scanner Flat Cable And Fiber Optics Cable Replacement

    6 March 1992 OPTICS 2.3 SCANNER FLAT CABLE AND FIBER OPTICS CABLE REPLACEMENT 1. Remove the left and right rear covers, and left upper cover. 2. Remove the DF transport unit. 3. Remove the exposure glass. 4. Remove the rear upper and rear top covers. 5.
  • Page 236 OPTICS 6 March 1992 7. Remove the flat cable holder fixed on the first scanner [A] (2 screws). 8. Slide out the flat cable holder bracket [B] (1 screw) and remove the holder [C] (2 screws). 9. Remove the flat cable [D] (3 connectors). 10.

  • Page 237: Scanner Drive Wire Replacement

    6 March 1992 OPTICS 2.4 SCANNER DRIVE WIRE REPLACEMENT 1. Unplug the machine. 2. Remove the following covers: Left and right covers Left and right rear covers Left upper cover Front top cover Rear upper and rear top covers 3. Remove the DF feed and transport units and the exposure glass. 4.
  • Page 238 OPTICS 6 March 1992 6. Remove the upper optics housing [A] (4 screws at front and 4 screws on top). 7. Loosen the front and rear wire clamps [B] of the first scanner (2 screws each). NOTE: Do not loosen any screws which are marked with white paint. 8.
  • Page 239 6 March 1992 OPTICS 12. Secure the second scanner position using two positioning pins [A] (special tool). 13. Position the drive pulley [B] as shown in the figure and secure it with the scanner fixing screw [C]. NOTE: The scanner fixing screw is removed during installation. 5-13...
  • Page 240 OPTICS 6 March 1992 -- Blue Wire -- 14. Set the bead of the blue wire [A] into the slot of the scanner drive pulley as shown and wrap the wire three and a half times on the pulley from bottom to top, counterclockwise.
  • Page 241 6 March 1992 OPTICS -- Gray Wire -- 17. Set the bead of the gray wire [A] into the slot of the scanner drive pulley as shown and wrap the wire four times on the pulley from bottom to top, counterclockwise.
  • Page 242 OPTICS 6 March 1992 -- Black Wire -- 20. Set the bead of the black wire [A] into the slot of the scanner drive pulley as shown and wrap the wire four times on the pulley from top to bottom clockwise.
  • Page 243 6 March 1992 OPTICS -- Red Wire -- 23. Set the bead of the red wire [A] into the slot of the scanner drive pulley as shown and wrap the wire three and a half times on the pulley from top to bottom clockwise.
  • Page 244 OPTICS 6 March 1992 26. Remove the scanner positioning pins [A] and the scanner fixing screw [B], and apply tension to the wires by fixing the wire tension brackets [C]. -- Second Scanner Position Adjustment -- 27. Slide the second scanner [D] back and forth several times manually. 28.
  • Page 245 6 March 1992 OPTICS 30. Reinstall the first scanner and fix the front guides (1 screw each). -- First Scanner Position Adjustment -- 31. Set four positioning pins [A] to the first and second scanners as shown. 32. Fix the scanner wires to the first scanner using the front and rear wire clamps as shown (2 screws each).

  • Page 246: Scanner Drive Motor Removal

    OPTICS 6 March 1992 2.5 SCANNER DRIVE MOTOR REMOVAL 1.5 ~ 2.0 mm 1. Unplug the machine. 2. Remove the ADF transport unit. 3. Remove the right cover, rear right cover, and rear upper cover. 4. Loosen the screws of the scanner wire tension bracket and slacken the wire tension.

  • Page 247: Lens Vertical Drive Motor Removal

    6 March 1992 OPTICS 2.6 LENS VERTICAL DRIVE MOTOR REMOVAL 1. Unplug the machine. 2. Remove the rear right cover, the left upper cover, and the exposure glass. 3. Remove the FL stabilizer board [A] (4 studs). 4. Unhook the tension spring [B] and loosen two screws [C] fixing the belt pulley bracket.

  • Page 248: Lens Horizontal Drive Motor Removal

    OPTICS 6 March 1992 2.7 LENS HORIZONTAL DRIVE MOTOR REMOVAL 1. Remove the left upper cover and the exposure glass. 2. Remove the lens shielding cover [A] (3 screws). 3. Remove the shading plate [B] (3 screws). 4. Unhook the tension spring [C] and remove the drive wire. 5-22...
  • Page 249 6 March 1992 OPTICS 5. Remove the harness clamps [A] fixed on the motor bracket [B] (2 screws). 6. Remove the motor bracket [B] (3 screws and 2 connectors). 7. Remove the encoder sensor bracket [C] (1 screw), the encoder disc [D] (1 screw), and the drive pulley [E].
  • Page 250 OPTICS 6 March 1992 -- Lens Horizontal Drive Wire Installation -- 9. Reassemble the drive motor unit. 10. Set the bead of the drive wire to the hook [A] on the lens base and wrap the wire on the drive pulley [B] two and a half times from bottom to top clockwise.

  • Page 251: Mirror Unit Drive Motor Removal

    6 March 1992 OPTICS 2.8 MIRROR UNIT DRIVE MOTOR REMOVAL 1. Remove the left rear cover and left top cover. 2. Remove the optics shielding cover [A] (4 screws). 3. Remove the tension spring [B] and loosen the mounting screws of the belt tightener bracket [C] (2 screws).

  • Page 252: 6Th Mirror Unit Removal

    OPTICS 6 March 1992 2.9 6TH MIRROR UNIT REMOVAL 1. Open the front doors. 2. Remove the left inner cover. 3. Remove the connector bracket [A] (1 screw). 4. Remove the screw [B] fixing the mirror bracket and remove the 6th mirror unit [C].

  • Page 253: Optics Cooling Fan Filter Replacement

    6 March 1992 OPTICS 2.10 OPTICS COOLING FAN FILTER REPLACEMENT 1. Remove the fan filter holder [A] (1 screw). 2. Replace the filter [B] in the filter holder. NOTE: Make sure that the filter is set underneath the projections [C]. 5-27...

  • Page 254: Development

    DEVELOPMENT 6 March 1992 3. DEVELOPMENT 3.1 DEVELOPMENT UNIT REMOVAL 1. Turn off the main switch. NOTE: The development unit will start turning when it is installed in toner end or near end condition. 2. Open the front doors. 3. Remove the left inner cover. 4.

  • Page 255: Development Filter Replacement

    6 March 1992 DEVELOPMENT 3.2 DEVELOPMENT FILTER REPLACEMENT 1. Remove the development unit. 2. Remove the filter [A] by pressing the levers down as shown. 5-29...

  • Page 256: Developer Replacement

    DEVELOPMENT 6 March 1992 3.3 DEVELOPER REPLACEMENT 1. Turn off the main switch. 2. Open the front doors and remove the left inner cover. 3. Actuate the left door safety switch using the safety switch actuator [A] fixed on the left stay of the duplex unit and close the right door. 4.
  • Page 257 6 March 1992 DEVELOPMENT 9. Remove the development unit and the development filter. 10. Pour one bag (1.7 kg) of the developer into the development unit. While pouring the developer, turn the paddle roller knob [A] clockwise to evenly distribute the developer. 11.

  • Page 258: Side Seal Replacement

    DEVELOPMENT 6 March 1992 3.4 SIDE SEAL REPLACEMENT 1. Remove the development unit. 2. Remove the entrance seal bracket [A] (2 screws). NOTE: Do not loosen any screw with white paint [B] fixing the doctor plate. 3. Peal off the old side seals [C] and clean the parts with alcohol. 4.

  • Page 259: Development Sleeve Gear Replacement

    6 March 1992 DEVELOPMENT 3.5 DEVELOPMENT SLEEVE GEAR REPLACEMENT 1. Remove the development unit. 2. Remove two drive gears [A] for the development sleeves (1 E-ring and 1 pin each). NOTE: Take care not to lose the pins. 3. Install the new gears and reassemble the machine. NOTE: Do not use any lubricant on these gears.

  • Page 260: Development Duct Filter Replacement

    DEVELOPMENT 6 March 1992 3.6 DEVELOPMENT DUCT FILTER REPLACEMENT 1. Remove the development unit. 2. Remove the duct cover [A]. 3. Replace the filter [B] in the duct. 4. Reassemble the machine. 5-34...

  • Page 261: Development Roller Replacement

    6 March 1992 DEVELOPMENT 3.7 DEVELOPMENT ROLLER REPLACEMENT 1. Remove the developer. 2. Remove the development unit. 3. Remove the bias terminal [A] (2 screws with star washer and 1 lead wire). 4. Remove the magnet angle levers [B] (1 screw and 1 E-ring each). NOTE: Do not loosen three screws [C] with white paint fixing the development unit guide.
  • Page 262 DEVELOPMENT 6 March 1992 [C] [A] 6. Peal off the side seals [A], [B], and [C] on the rear sleeve. 7. Remove the sleeve drive gears [D] (1 E-ring and 1 pin each). 8. Remove the idle gear [E] (1 O-ring). 9.

  • Page 263: Toner Near End Sensor Bracket Removal

    6 March 1992 DEVELOPMENT 3.8 TONER NEAR END SENSOR BRACKET REMOVAL 1. Remove the development unit. 2. Remove the wire clamp [A] fixing the development unit harness (1 screw). 3. Slide out the toner near end sensor bracket [B] (1 screw). NOTE: When reinstalling the sensor bracket, make sure that no lead wire touches the gear [C].

  • Page 264: Cleaning

    CLEANING 6 March 1992 4. CLEANING 4.1 CLEANING UNIT REMOVAL 1. Remove the left inner cover. 2. Remove the development unit. 3. Release the transport unit with the lever [A] and remove the drum stay [B]. 4. Remove the cleaning unit [C]. 5-38...

  • Page 265: Cleaning Blade Replacement

    6 March 1992 CLEANING 4.2 CLEANING BLADE REPLACEMENT 1. Remove the cleaning unit. 2. Remove the four screws [A] fixing the cleaning blade. 3. Replace the cleaning blade [B]. 4. Confirm proper movement of the cleaning blade. 5. Assemble the machine. 5-39...

  • Page 266: Cleaning Brush Replacement

    CLEANING 6 March 1992 4.3 CLEANING BRUSH REPLACEMENT 1. Remove the cleaning unit, and remove the cleaning blade. 2. Remove the front brush holder [A] (1 screw) and remove the cleaning brush [B]. NOTE: When replacing the brush, make sure that the notch [C] of the brush fits the drive boss [D].

  • Page 267: Cleaning Flick Blade Removal

    6 March 1992 CLEANING 4.4 CLEANING FLICK BLADE REMOVAL 1. Remove the cleaning unit. 2. Remove the two screws [A] securing the flick blade to the cleaning unit. 3. Remove the flick blade [B]. NOTE: When reinstalling the flick blade, make sure that the blade bracket holes are set to the projections [C] correctly as shown.

  • Page 268: Cleaning Flick Roller Removal

    CLEANING 6 March 1992 4.5 CLEANING FLICK ROLLER REMOVAL 1. Remove the cleaning unit. 2. Remove the flick blade and unhook the blade pressure spring [A]. NOTE: Do not loosen the blade pressure stopper screw [B]. 3. Remove the rear cover of the cleaning unit [C] (4 screws). 4.
  • Page 269 6 March 1992 CLEANING 5. Slide off the toner collection pipe [A] with the spring. 6. Remove the bushing bracket [B] (1 screw and 1 bushing). 7. Remove the coupling gear [C] (1 E-ring). 8. Remove the brush gear [D] and the flick roller gear [E] (1 E-ring each). 5-43...
  • Page 270 CLEANING 6 March 1992 9. Take out the bushing [A], the ground terminal [B], and the flick roller holder [C]. 10. Slide the flick roller [D] out of the rear of the cleaning unit. 5-44...

  • Page 271: Around The Drum

    6 March 1992 AROUND THE DRUM 5. AROUND THE DRUM 5.1 DRUM REPLACEMENT CAUTION: If the drum is removed for maintenance purposes, the drum protective sleeve must be inserted. 1. Remove the left inner cover and remove the development unit. 2.
  • Page 272 AROUND THE DRUM 6 March 1992 5. Remove the drum flange [A]. 6. Install the drum guide [B] on the drum shaft, and pull out the old drum. 7. Insert the new drum with the drum protective sleeve, then remove the drum protective sleeve.

  • Page 273: Charge Corona Wire And Charge Corona Cleaner Pad

    6 March 1992 AROUND THE DRUM 5.2 CHARGE CORONA WIRE AND CHARGE CORONA CLEANER PAD REPLACEMENT 1. Remove the left inner cover and take out the charge corona unit (1 connector). 2. Remove the rear end block cover [A]. 3. Remove the front end block cover [B] (1 screw) and unhook the tension springs [C].

  • Page 274: Ptc Wire Replacement

    AROUND THE DRUM 6 March 1992 5.3 PTC WIRE REPLACEMENT 1. Open the front doors and remove the left inner cover. 2. Pull out the PTC unit. 3. Remove the front end block cover [A] and rear end block cover [B]. 4.

  • Page 275: Transfer And Separation Corona Wire And Cleaner

    6 March 1992 AROUND THE DRUM 5.4 TRANSFER AND SEPARATION CORONA WIRE AND CLEANER REPLACEMENT 1. Open the front doors. 2. Lower the transport unit with the lever [A]. 3. Pull out the fusing unit. 4. Remove the transport unit lever [A] (1 screw) and the middle inner cover [B] (2 screws).
  • Page 276 AROUND THE DRUM 6 March 1992 6. Remove the paper guides [A]. 7. Remove the front end block cover [B] and the rear end block cover [C]. 8. Unhook the tension springs [D] and remove the corona wires [E]. 9. Remove the cleaner pads [F]. 10.

  • Page 277: Drum Heater Replacement

    6 March 1992 AROUND THE DRUM 5.5 DRUM HEATER REPLACEMENT 1. Unplug the copier power cord. 2. Remove the drum and take out the drum guide. 3. Remove the drum heater holder [A] (3 screws and 1 bracket). 4. Disconnect the connector [B] and slide out the drum heater [C]. NOTE: The drum heater has notches which have to be matched to the rear flange.

  • Page 278: Corona Current Auto Adjustment

    AROUND THE DRUM 6 March 1992 5.6 CORONA CURRENT AUTO ADJUSTMENT NOTE: 1. Since each corona current has been adjusted precisely at the factory using special tools, the following procedure can be performed only when a power pack is replaced. 2.
  • Page 279 6 March 1992 AROUND THE DRUM 7. Exit from the SP mode and reset DIP SW #3 on the reset switch PCB. 8. Check the copy quality and the paper separation function. 5-53...

  • Page 280: First Tray

    FIRST TRAY 6 March 1992 6. FIRST TRAY 6.1 LCT REMOVAL 1. Remove the fixing screw [A] for the LCT (1 screw). 2. De-engage the mounting studs [B] from the docking holes. 3. Disconnect the 6 connectors [C] of the interface harness. 5-54...

  • Page 281: Exterior Cover Removal

    6 March 1992 FIRST TRAY 6.2 EXTERIOR COVER REMOVAL 6.2.1 Front Cover 1. Slide the 1st tray unit [A] to the left, open the right top cover [B], and remove the shoulder screw [C]. 2. Open the left LCT top cover [D] and remove the 2 knob screws for the front side fence [E], and place the fence as shown.

  • Page 282: Tray Unit Removal

    FIRST TRAY 6 March 1992 6.3 TRAY UNIT REMOVAL 1. Remove the front and rear covers. 2. Remove the 1st tray unit [A] (8 screws [B]) as shown. 5-56...

  • Page 283: Replacement

    6 March 1992 FIRST TRAY 6.4 PAPER FEED ROLLER, SEPARATION ROLLER, AND PICK-UP ROLLER REPLACEMENT 1. Open the left top cover. 2. Slide off the pick-up and feed rollers [A, B] (1 snap ring each). 3. Remove the 3 screws [C] for the separation roller guide [D] and place it so that the separation roller [E] can be accessed.

  • Page 284: Pick-Up Solenoid Gap Adjustment

    FIRST TRAY 6 March 1992 6.5 PICK-UP SOLENOID GAP ADJUSTMENT 5±0.3 Adjustment standard: 5 ± 0.3 mm 1. Remove the left top cover [A] (4 screws). 2. Adjust the pick-up solenoid gap [B] (2 screws). 5-58...

  • Page 285: Paper End Sensor, Lower Limit Sensor, Paper Size Sensor, And Tray Heater Replacement

    6 March 1992 FIRST TRAY 6.6 PAPER END SENSOR, LOWER LIMIT SENSOR, PAPER SIZE SENSOR, AND TRAY HEATER REPLACEMENT 6.6.1 Preparation 1. Open the left top cover. 2. Remove the rear side guide [A] (2 knob screws). 3. Remove the paper tray bottom plate [B] (5 screws, 1 connector [C], and 1 clamp [D]).

  • Page 286: Lower Limit Sensor Replacement

    FIRST TRAY 6 March 1992 6.6.3 Lower Limit Sensor Replacement 1. Remove the harness cover [F] (4 screws) and lower limit sensor bracket [G] (1 screw). 6.6.4 Paper Size Sensor Replacement 1. Remove the harness cover [F] (4 screws), the paper size sensor bracket [H] (2 screws), and paper size sensors [I] (1 screw and 1 connector each) for the rear side guide post.

  • Page 287: Tray Drive Motor Replacement

    6 March 1992 FIRST TRAY 6.7 TRAY DRIVE MOTOR REPLACEMENT 1. Remove the rear cover. 2. Remove the 4 screws [A] fixing the 1st tray and slide the rear accuride rail [B] to the left while lifting the 1st tray. 3.

  • Page 288: Tray Drive Wire Replacement

    FIRST TRAY 6 March 1992 6.8 TRAY DRIVE WIRE REPLACEMENT 1. Remove the paper tray. 2. Remove the following parts: Front side a) Front stay [A] (4 screws) b) Safety switch actuator [B] (1 retaining ring) c) Tray cover safety switches [C, D] (2 screws each) d) Wire cover [E] (2 screws) Rear side e) Paper volume sensor bracket [F] (1 screw)
  • Page 289 6 March 1992 FIRST TRAY 3. Rear wire replacement a) Remove the wire tension spring [A]. b) Loosen the screws [B]. c) Insert the red bead [C] of the new wire into the slot of the drive pulley [D] and wrap the wire around the drive pulley 3/4 of a turn counterclockwise.
  • Page 290 FIRST TRAY 6 March 1992 5. Front wire replacement a) Remove the wire tension springs [A]. b) Loosen the screws [B]. c) Insert the red bead [C] of the new wire into the slot of the drive pulley [D] and wrap the wire around the drive pulley 3/4 of a turn clockwise. d) String the wire over all pulleys, except the tension pulley [E].

  • Page 291: Second Tray

    6 March 1992 SECOND TRAY 7. SECOND TRAY 7.1 EXTERIOR COVERS REMOVAL 7.1.1 Front Cover 1. Pull out the 2nd tray and remove the front cover [A] (4 screws and 1 connector). 7.1.2 Left Cover 1. Remove the left cover [B] (2 screws). 7.1.3 Rear Cover 1.

  • Page 292: Tray Unit Removal

    SECOND TRAY 6 March 1992 7.2 TRAY UNIT REMOVAL 1. Remove the rear cover and the harness [A] (2 screws and 1 connector) from the 2nd tray unit. 2. While releasing the tray lock lever [B], pull out the 2nd tray. 3.

  • Page 293: Replacement

    6 March 1992 SECOND TRAY 7.3 PAPER FEED ROLLER, SEPARATION ROLLER, AND PICK-UP ROLLER REPLACEMENT 1. Remove the paper from the 2nd tray and slide the 1st tray to the left. Remove the 2nd tray right top cover [A] (2 screws). 2.
  • Page 294 SECOND TRAY 6 March 1992 3. Slide off the pick-up, feed, and separation rollers [C, D, and E] (1 snap ring each). NOTE: Do not touch the surface of the rollers with oily hands. Make sure that the paper feed roller is installed in proper direction as shown. When replacing the separation roller, hold the torque limiter [F] with your fingers so that the limiter does not slide together with the roller.

  • Page 295: Pick-Up Solenoid Gap Adjustment

    6 March 1992 SECOND TRAY 7.4 PICK-UP SOLENOID GAP ADJUSTMENT Adjustment standard: 5 ± 0.3mm 1. Slide the 1st tray to the left and remove the 2nd tray top cover [A] (2 screws). 2. Adjust the pick-up solenoid gap [B] (2 screws). 5-69...

  • Page 296: Paper End Sensor, Lower Limit Sensor, Paper Size Sensor, And Tray Heater Replacement

    SECOND TRAY 6 March 1992 7.5 PAPER END SENSOR, LOWER LIMIT SENSOR, PAPER SIZE SENSOR, AND TRAY HEATER REPLACEMENT 1. Pull out the 2nd paper tray. 2. Remove the side guides grips [A] (1 knob screw each). 3. Remove the paper tray bottom plate [B] (4 screws and 1 connector [C]) 4.

  • Page 297: Tray Motor Replacement

    6 March 1992 SECOND TRAY 7.6 TRAY MOTOR REPLACEMENT 1. Pull out the 2nd tray and remove the left cover (2 screws). 2. Disconnect the 6P connector [A] of the tray motor and remove the 3 screws [B]. 3. Turn the tray motor [C] so that the connecting shafts [D] are horizontal. NOTE: Hold the tray bottom plate during the following step to prevent the bottom plate from falling down.

  • Page 298: Tray Motor Timing Tension Adjustment

    SECOND TRAY 6 March 1992 7.7 TRAY MOTOR TIMING TENSION ADJUSTMENT Adjustment standards: 1 ± 0.2 Kg 1. Remove the tray motor with the bracket. 2. Adjust the timing belt tension [A] (1 screw) as shown. 7.8 TRAY DRIVE CHAIN PRESSURE ADJUSTMENT 1.

  • Page 299: Third Tray

    6 March 1992 THIRD TRAY 8. THIRD TRAY 8.1 TRAY UNIT REMOVAL 1. Pull out the third tray [A]. 2. Disengage the tray unit by pressing the tray stoppers [B] inward, while pulling out and up on the tray. CAUTION: Take care not to injure yourself with the hooks [C]. 5-73...

  • Page 300: Replacement

    THIRD TRAY 6 March 1992 8.2 PAPER FEED ROLLER, SEPARATION ROLLER, AND PICK-UP ROLLER REPLACEMENT 1. Remove the third tray. 2. Pull out the vertical transport unit. 3. Slide off the pick-up, feed, and separation rollers [A, B, and C] (1 snap ring each).

  • Page 301: Pick-Up Solenoid Gap Adjustment

    6 March 1992 THIRD TRAY 8.3 PICK-UP SOLENOID GAP ADJUSTMENT Adjustment standard: 5 ± 0.3 mm 1. Pull out the vertical transport unit. 2. Remove the paper feed unit top cover [A] (2 screws). 3. Adjust the pick-up solenoid gap [B] (2 screws). 5-75...

  • Page 302: Paper End Sensor, Lower Limit Sensor, Paper Size Sensor, And Tray Heater Replacement

    THIRD TRAY 6 March 1992 8.4 PAPER END SENSOR, LOWER LIMIT SENSOR, PAPER SIZE SENSOR, AND TRAY HEATER REPLACEMENT 8.4.1 Preparation 1. Pull out the paper tray. 2. Remove the side guides grips [A] (2 screws each). 3. Remove the paper tray bottom plate [B] (7 screws, 1 connector [C], and 1 clamp [D]).

  • Page 303: Paper Size Sensor Replacement

    6 March 1992 THIRD TRAY 8.4.3 Paper Size Sensor Replacement 1. Rear Guide Post 1. Remove the paper size sensors [G] (1 screw and 1 connector each) from the rear side guide post. 2. End Plate 1. Remove the end plate bracket [H] (2 screws). 2.

  • Page 304: Tray Drive Wire Replacement

    THIRD TRAY 6 March 1992 8.5 TRAY DRIVE WIRE REPLACEMENT 1. Remove the paper tray. 2. Remove the following parts: a) Tray front cover (3 screws and 1 connector) b) Tray upper rear cover [A] (2 screws) c) Tray motor [B] (6 screws and 2 connectors) d) Wire tension springs [C] (front and rear) e) Wire support brackets [D] (2 screws each: front and rear) 3.
  • Page 305 6 March 1992 THIRD TRAY 4. Rear wire replacement a) Insert the blue bead [A] of the new wire into the slot of the drive pulley [B] and wrap the wire around the drive pulley twice clockwise. b) String the wire over all pulleys, except the tension pulley [C]. c) Wrap the other end of the wire around the drive pulley 3.5 times clockwise and insert the bead into the slot of the drive pulley as shown.
  • Page 306 THIRD TRAY 6 March 1992 5. Front wire replacement a) Insert the blue bead [A] of the new wire into the slot of the drive pulley [B] and wrap the wire around the drive pulley twice counterclockwise. b) String the wire over all pulleys, except the tension pulley [C]. c) Wrap the other end of the wire around the drive pulley 3.5 times counterclockwise and insert the bead into the slot of the drive pulley as shown.

  • Page 307: Registration And Transport

    6 March 1992 REGISTRATION AND TRANSPORT 9. REGISTRATION AND TRANSPORT 9.1 PAPER DUST PAN REPLACEMENT 1. Remove the development unit. 2. Remove the registration knob [A] and transport inner cover [B] (4 screws). 3. Remove the receiving plate [C] (1 screw). 4.

  • Page 308: Relay Transport Unit Removal

    REGISTRATION AND TRANSPORT 6 March 1992 9.2 RELAY TRANSPORT UNIT REMOVAL 1. Remove the LCT. 2. Remove the transport inner cover [A] (5 screws and 1 knob). 3. Remove the relay transport unit [B] (4 screws) as shown. 5-82...

  • Page 309: Horizontal Transport Unit Removal

    6 March 1992 REGISTRATION AND TRANSPORT 9.3 HORIZONTAL TRANSPORT UNIT REMOVAL CAUTION: Do not loosen the painted positioning screws [A]. 1. Remove the relay transport unit. 2. Remove the development unit and receiving plate. 3. Remove the drum. 4. Disconnect the 2 connectors [B] and remove the 1 screw [C]. 5.

  • Page 310: Vertical Transport Unit Removal

    REGISTRATION AND TRANSPORT 6 March 1992 9.4 VERTICAL TRANSPORT UNIT REMOVAL 1. Remove the 3rd tray unit. 2. Pull out the vertical transport unit [A]. 3. While supporting the vertical transport unit, remove the 3 screws [B]. Otherwise, it may cause the vertical transport unit fall down. 4.

  • Page 311: Transport Unit Belts Replacement

    6 March 1992 REGISTRATION AND TRANSPORT 9.5 TRANSPORT UNIT BELTS REPLACEMENT 1. Remove the transport unit release lever [A] (1 screw) and middle inner cover [B] (2 screws). 2. Remove the transport unit cover [C] (2 screws) and transfer and separation corona unit [D] (1 connector).

  • Page 312: Pick-Off Pawls Removal

    REGISTRATION AND TRANSPORT 6 March 1992 9.6 PICK-OFF PAWLS REMOVAL WARNING: Be careful not to cut yourself on the sharp edges of the pick-off pawls. 1. Remove the drum. 2. Remove the pick-off pawl unit [A]as shown. 9.7 TONER FILTER REPLACEMENT 1.

  • Page 313: Ozone Filter Replacement

    6 March 1992 REGISTRATION AND TRANSPORT 9.8 OZONE FILTER REPLACEMENT 1. Remove the left rear cover. 2. Remove the duct cover [A] (2 screws). 3. Replace the ozone filter [B]. 5-87...

  • Page 314: Image Fusing

    IMAGE FUSING 6 March 1992 10. IMAGE FUSING 10.1 FUSING UNIT REMOVAL 1. Open the right front door, turn the fusing unit release lever [A] counterclockwise, and pull out the fusing & inverter unit [B]. 2. Turn the fusing unit release lever clockwise and remove it (1 screw). Remove the fusing cover [C] (3 screws).

  • Page 315: Hot Roller And Pressure Roller Replacement

    6 March 1992 IMAGE FUSING 10.2 HOT ROLLER AND PRESSURE ROLLER REPLACEMENT 1. Remove the fusing unit. 2. Remove the top fusing cover stoppers [A] (front and rear: 1 screw each) and unhook the front and rear springs. 3. Turn the top fusing cover [B] 1/4 of a turn counterclockwise and lift it up. 4.
  • Page 316 IMAGE FUSING 6 March 1992 8. Remove the fusing exit guide plate [A] and lower fusing entrance guide plate [B] (2 screws each). 9. Remove the pressure roller [C]. 10. Remove the bushing [D] and bearing [E] (1 C-ring) from the shaft. 5-90...

  • Page 317: Oil Supply Roller Replacement

    6 March 1992 IMAGE FUSING 10.3 OIL SUPPLY ROLLER REPLACEMENT 1. Pull out the fusing unit. 2. Remove the upper fusing entrance guide [A] (2 screws). 3. Remove the the pressure springs [B] and the bushings [C] from the cutouts, and then the oil supply roller [D]. 5-91...

  • Page 318: Replacement

    IMAGE FUSING 6 March 1992 10.4 HOT ROLLER STRIPPER AND PRESSURE ROLLER STRIPPER PAWL REPLACEMENT 10.4.1 Preparation 1. Pull out the fusing unit and remove the fusing unit release lever [A] (1 screw) and fusing cover [B] (3 screws). 2. Remove the top fusing cover stoppers [C] (front and rear: 1 screw each) and unhook the front and rear spring.

  • Page 319: Thermistor And Thermofuse Replacement

    6 March 1992 IMAGE FUSING 10.5 THERMISTOR AND THERMOFUSE REPLACEMENT 1. Remove the top fusing cover [A]. 2. Remove the upper fusing entrance guide [B] (2 screws). 3. Remove the thermistor [C] (1 screw and 1 connector). 4. Remove the thermofuse [D] (4 screws, 3 harness clamps, and 1 connector).

  • Page 320: Fusing Temperature Adjustment

    IMAGE FUSING 6 March 1992 10.6 FUSING TEMPERATURE ADJUSTMENT 1. Pull out the fusing unit. 2. Remove the upper fusing entrance guide. 3. Push the fusing unit into the main body. 4. Remove the right inner cover (3 screws). 5. Disconnect the door safety switch harness connectors (2 connectors from lower and wires [A, B]).

  • Page 321: Fusing Pressure Adjustment

    6 March 1992 IMAGE FUSING 10.7 FUSING PRESSURE ADJUSTMENT Adjustment standards: Nip width 10 ± 0.5 mm (the difference between front and rear measurement should be less than 0.5 mm). 1. Select the fusing nip width measure mode in the SP mode. 2.

  • Page 322: Inverter & Paper Exit

    INVERTER & PAPER EXIT 6 March 1992 11. INVERTER & PAPER EXIT 11.1 INVERTER UNIT REMOVAL CAUTION: While doing the following step, take care not to drop the inverter unit. 1. Remove the fusing unit. 2. Open the inverter unit [A] and disconnect the connectors [B] as shown: 3.

  • Page 323: Fusing Sensor And Exit Sensor Replacement

    6 March 1992 INVERTER & PAPER EXIT 11.2 FUSING SENSOR AND EXIT SENSOR REPLACEMENT 11.2.1 Exit Sensor Replacement 1. Pull out the fusing unit. 2. Remove the exit sensor bracket [A] (1 screw). 3. Remove the exit sensor [B] (1 screw and 1 connector). 11.2.2 Fusing Sensor Replacement 1.

  • Page 324: Pinch Roller Solenoid And Inverter Solenoid

    INVERTER & PAPER EXIT 6 March 1992 11.3 PINCH ROLLER SOLENOID AND INVERTER SOLENOID REPLACEMENT 11.3.1 Pinch Roller Solenoid Replacement 1. Remove the inverter unit. 2. Remove the fixing screw [A] for the pinch roller solenoid bracket. 3. Unhook the return spring [B] for the inverter solenoid, spring [C], and solenoid spring [D].

  • Page 325: Junction Gate Solenoid Replacement

    6 March 1992 INVERTER & PAPER EXIT 11.4 JUNCTION GATE SOLENOID REPLACEMENT 1. Remove the inverter unit. 2. Remove the fixing screw [A] for the junction gate solenoid bracket. 3. Unhook the solenoid spring [B]. 4. Remove the solenoid from the bracket (3 screws, 1 clamp, and 1 connector).

  • Page 326: Duplex

    DUPLEX 6 March 1992 12. DUPLEX 12.1 DUPLEX UNIT REMOVAL 1. Pull out the duplex unit [A]. 2. Disengage the duplex unit by pressing the duplex unit stoppers [B] inward, while pulling out and up on the duplex unit. CAUTION: Take care not to injure yourself with the hooks [C]. 5-100...

  • Page 327: Separation Roller And Feed Roller Replacement

    6 March 1992 DUPLEX 12.2 SEPARATION ROLLER AND FEED ROLLER REPLACEMENT 12.2.1 Separation Roller Replacement 1. Pull out the duplex unit. 2. Remove the separation roller [A] (1 snap ring). 12.2.2 Feed Roller Replacement 1. Pull out the duplex unit. 2.

  • Page 328: Pick-Up Roller Replacement

    DUPLEX 6 March 1992 12.3 PICK-UP ROLLER REPLACEMENT 1. Remove the duplex unit. 2. Remove the duplex unit cover (4 screws). 3. Remove the pick-up position sensor feeler [A] (1 retaining ring), pick-up position sensor [B] (1 screw), and gear [C] (1 retaining ring). 4.

  • Page 329: Positioning Roller Replacement

    6 March 1992 DUPLEX 12.4 POSITIONING ROLLER REPLACEMENT 1. Pull out the duplex unit. 2. Remove the positioning roller [A] (1 snap ring) together with the drive belt [B]. 5-103...
  • Page 330 DUPLEX 6 March 1992 12.5 DUPLEX ENTRANCE, PAPER END, PICK-UP ROLLER POSITION SENSOR, AND JOGGER HOME POSITION SENSOR REPLACEMENT 12.5.1 Duplex Entrance Sensor Replacement 1. Pull out the duplex unit. 2. Remove the duplex entrance sensor bracket [A] (1 screw) and duplex entrance sensor [B] (1 screw and 1 connector).
  • Page 331 6 March 1992 DUPLEX 12.6 JOGGER HOME POSITION SENSOR REPLACEMENT AND ADJUSTMENT 5 mm Adjustment standard: 5 ± 0.5 mm 1. Pull out the duplex unit and remove the duplex cover. 2. Adjust the jogger home position by moving the sensor bracket [A] front to rear (loosen 1 screw).
  • Page 332 DUPLEX 6 March 1992 12.7 JOGGER MOTOR REPLACEMENT 1. Pull out the duplex unit and remove the duplex cover (4 screws). 2. Remove the pulley [A] (1 allen screw). 3. Remove the jogger motor [B] (4 screws and 1 connector). 5-106...

  • Page 333: Jogger Unit Removal

    6 March 1992 DUPLEX 12.8 JOGGER UNIT REMOVAL 1. Remove the duplex unit and the duplex cover (4 screws). 2. Remove the bottom plate [A] (3 screws) and pulley [B] (1 allen screw). 3. Remove the jogger unit [C] by unhooking the pins [D]. 5-107...
  • Page 334 DUPLEX 6 March 1992 12.9 JOGGER DRIVE BELT TENSION ADJUSTMENT 1. Remove the duplex unit and the duplex cover (4 screws). 2. Turn over the duplex unit as shown. 3. Remove the bottom plate [A] (3 screws). 4. Remove the support stay [B] (2 screws). 5.

  • Page 335: Transport Belt Replacement

    6 March 1992 ARDF 13. ARDF 13.1 TRANSPORT BELT REPLACEMENT 1. Slide the belt unit release lever [A] to the right to release the belt unit [B]. 2. Loosen the screw [C] and slide the lever [D] supporting the left transport belt unit [E].

  • Page 336: Separation Roller Replacement

    ARDF 6 March 1992 13.2 SEPARATION ROLLER REPLACEMENT 1. Open the entrance cover [A]. 2. Remove the front cover [B] of the original feed unit (2 screws). 3. Remove the separation roller shaft stopper [C] (1 screw). 4. Slide out the separation roller shaft [D]. 5.

  • Page 337: Original Feed Unit Removal

    6 March 1992 ARDF 13.3 ORIGINAL FEED UNIT REMOVAL 1. Remove the front cover [A] (2 screws) and the rear cover [B] (3 screws) of the original feed unit. 2. Remove the right rear cover of the copier (2 screws). 3.
  • Page 338 ARDF 6 March 1992 4. Remove the screw [F] fixing the right ground line. 5. Disconnect the 6 connectors [G]. 6. Remove the 3 screws [H] and slide the original feed unit to the right to remove it. 5-112...
  • Page 339 6 March 1992 ARDF 13.4 FEED-IN MOTOR REPLACEMENT 1. Remove the original feed unit. 2. Remove the rear under cover [A] (4 screws). 3. Remove the DF main board [B] (3 screws and 8 connectors) and disconnect the 2 connectors [C] of the feed-in motor [D]. 4.

  • Page 340: Pick-Up Roller Replacement

    ARDF 6 March 1992 13.5 PICK-UP ROLLER REPLACEMENT 1. Remove the rear side plate as per steps 1 to 8 of FEED-IN MOTOR REPLACEMENT procedure. 2. Remove the heart-shape cam stopper spring [A]. 3. Remove the front under cover [B] (1 screw). 4.
  • Page 341 6 March 1992 ARDF 6. Remove the E-rings [G] on the pick-up roller shafts [H]. 7. Slide the shafts [H] toward the rear of the machine. Remove the pins [I], heart-shape cam [J], one-turn disk [K], and gears [L]. 8. Remove the bushings [M] on the front and rear side of the 2nd pick-up roller shaft and replace the 2nd pick-up rollers [N].
  • Page 342 ARDF 6 March 1992 13.6 TRANSPORT BELT UNIT REMOVAL 1. Remove the screw [A] fixing the inverter cover shaft bracket [B] and remove the inverter cover [C]. 2. Remove the transport unit cover [D] (7 screws). 3. Mark the position of the tension bracket [E] and loosen the screw [F]. 4.
  • Page 343 6 March 1992 ARDF 13.7 RELAY ROLLER REMOVAL 1. Remove the right rear cover (2 screws). 2. Remove the 2 screws [A] fixing the bracket to the operation unit shaft [B]. 3. Remove the screw [C] fixing the ground line. Disconnect the connector [D].
  • Page 344 ARDF 6 March 1992 7. Remove the relay roller drive pulley [M] (1 E-ring [N]) and the bushing [O]. 8. Remove the E-ring [P], relay roller drive gear [Q], the pin [R] and E-ring [S]. 9. Remove the E-ring [T] in the front of the relay roller shaft. 10.

  • Page 345: Friction Tab Replacement

    6 March 1992 ARDF 13.8 FRICTION TAB REPLACEMENT 1. Open the entrance cover [A]. 2. Remove the screw [B] supporting the friction tab holder [C]. 3. Remove the 3 screws [D] and replace the friction tab [E]. NOTE: Install the friction tab [E] so that its edge contacts the upstand of the separation tab supporter [F].
  • Page 346 ARDF 6 March 1992 13.9 BELT MOTOR / INVERTER MOTOR REPLACEMENT 1. Remove the inverter cover and the transport unit cover. 2. Mark the position of the transport belt drive timing belt tension bracket [A] of the transport belt drive and loosen the screw [B]. 3.

  • Page 347: Transport Unit Removal

    6 March 1992 ARDF 13.10 TRANSPORT UNIT REMOVAL 1. Remove the rear cover [A] of the paper feed unit (3 screws). 2. Remove the screw [B] fixing the ground line and disconnect the 6 connectors [C]. 3. Remove the upper rear cover [D] of the copier (3 screws). 4.
  • Page 348 ARDF 6 March 1992 13.11 JOB SEPARATION UNIT REMOVAL 1. Remove the upper front cover [A] (2 screws) and the lower front cover [B] (1 screw). 2. Remove the job separation H. P. sensor [C] (1 screw). 3. Remove the DF main board [D] (3 screws). 4.

  • Page 349: Inverter Roller Replacement

    6 March 1992 ARDF 13.12 INVERTER ROLLER REPLACEMENT 1. Remove the inverter cover and the transport unit cover. 2. Remove the inverter entrance guide springs [A]. 3. Loosen the screw [B] which limits the inverter entrance guide [C] movement. 4. Mark the position of the inverter drive belt tension bracket [D] and loosen the screw [E].
  • Page 350 ARDF 6 March 1992 13.13 EXIT ROLLER REMOVAL [R] [Q] [I] [H] 1. Remove the inverter cover and the transport unit cover. 2. Disconnect the 4 connectors [A]. 3. Loosen the 2 screws [B], remove the 2 screws [C], and remove the transport drive unit [D].

  • Page 351: Sensor Replacement

    6 March 1992 ARDF 13.14 SENSOR REPLACEMENT Original Sensor/Entrance Cover Sensor 1. Remove the ADF main board [A] (3 screws). 2. Remove the sensor bracket [B] (1 screw). 3. Replace the original sensor [C] and the entrance cover sensor [D] (1 screw each).
  • Page 352 ARDF 6 March 1992 Inverter Registration Sensor 1. Release the transport belt unit [A]. 2. Remove the sensor cover [B] (1 screw). 3. Replace the inverter registration sensor [C] (1 screw). Inverter Entrance Sensor 1. Remove the transport unit cover. 2.
  • Page 353 6 March 1992 ARDF Exit Sensor 1. Remove the transport unit cover. 2. Remove the harness guide cover [A] (1 screw). 3. Remove the sensor bracket [B] (1 screw). 4. Replace the exit sensor [C] (1 screw). 5-127...
  • Page 354 ARDF 6 March 1992 13.15 STOPPER POSITION ADJUSTMENT Stopper Position Adjustment 1. Remove the feed unit left cover [A] (3 screws) and the entrance upper cover [B] (2 screws). 2. Loosen the screw [C] and slide the stopper [D] to the front of the machine. 3.

  • Page 355: Skew Correction

    6 March 1992 ARDF 13.16 SKEW CORRECTION 1. Open the front door and remove the right inner cover [A]. 2. Turn DIP SW-3 on the error reset board [B]. 3. Input "99900" using the number keys on the operation unit to access SP mode.

  • Page 356: Motor Speed Adjustment

    ARDF 6 March 1992 13.17 MOTOR SPEED ADJUSTMENT 1. Access page 4 of "SP adjustment" as per steps 1 to 5 of the SKEW CORRECTION procedure. 2. Press ADF motor "START" on the display. The motor speed is automatically adjusted to the standard speed in the following order: Feed-in motor - Belt motor - Inverter motor - Belt motor - Inverter motor.
  • Page 357 6 March 1992 ARDF 6. Adjust the back side copy registration so that the distance between the right scale and the original is 0.5 to 2 mm by pressing "+" or "--" on the display. Pressing "+" shifts the original stop position to the left. Pressing "--"...

  • Page 358: Belt Tension Adjustment

    ARDF 6 March 1992 13.20 BELT TENSION ADJUSTMENT 1. Remove the rear cover of the paper feed unit and adjust the belt [A] tension with the tightener [a]. Standard: 3 mm deflection at 500 ± 100 g pressure. 2. Remove the rear cover of the paper feed unit and adjust the belt [B] tesion with the motor position bracket (2 screws [b]).
  • Page 359 6 March 1992 ARDF 4. Remove the upper cover the transport unit and adjust the tension of the belts [D] with the motor position brackets [d] (3 screws). Standard: 3 mm deflection at 450 ± 300 g pressure. 5. Remove the upper cover of the transport unit and adjust the belt [E] tension with the tightener [e].

  • Page 360: Side-To-Side Registration Adjustment

    OTHERS 6 March 1992 14. OTHERS 14.1 SIDE-TO-SIDE REGISTRATION ADJUSTMENT Adjustment standard: 0 ± 2 mm 14.1.1 3rd Tray and Duplex Tray 1. Adjust the side-to-side registration for the 3rd tray and duplex tray by the SP mode. CAUTION: Do not adjust the 3rd tray stopper [A] and duplex tray stopper [B].
  • Page 361 6 March 1992 OTHERS 14.1.2 1st Tray a) Copy the test chart for the 1st tray in the platen mode. b) Remove the left top cover [A] (2 screws). c) Adjust the side-to-side registration by loosening the 5 screws [B]. 14.1.3 2nd Tray a) Copy the test chart for the 2nd tray in the platen mode.

  • Page 362: Ram Clear Procedure

    OTHERS 6 March 1992 14.2 RAM CLEAR PROCEDURE CAUTION: This procedure clears all the machine control settings and returns them to the default values. Perform the procedure only when replacing the RAM board or when the copier malfunctions due to damaged RAM data. 1.

  • Page 363: Troubleshooting

    SECTION 6 TROUBLESHOOTING...

  • Page 364: System Error And Service Call Conditions

    6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS 1. SYSTEM ERROR AND SERVICE CALL CONDITIONS An SC code is displayed on the CRT screen with the "System Error" message when its condition is detected by the main PCB. The operator can reset the system error condition by pressing the error reset switch [A].
  • Page 365 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC100 - Lamp Intensity Sensor Calibration Error Definition: During process data initialization, the CPU cannot calibrate the sensor output to 3 V even with a 100% duty cycle PWM signal to the exposure lamp stabilizer.
  • Page 366 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC104 - Exposure Lamp Malfunction - Abnormal Off Definition: The main PCB cannot detect a lamp intensity sensor signal (1.0 V) during the lamp on condition for more than 0.5 seconds. Points to check: •...
  • Page 367 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC106 - Low FL Temperature Definition: During stand-by, the main PCB detects a high resistance (> 5.6k: 10°C) of the FL thermistor for more than 15 minutes. NOTE: 1. No detection in copy mode. 2.
  • Page 368 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC124 - Scanner Home Position Sensor Abnormal Definition: The main PCB cannot detect the scanner home position sensor output change at the scanner position initialization and scanner start. Points to check •...
  • Page 369 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC129 - Scanner Motor Overload Definition: The motor control PCB detects a large current (2 A) of the scanner drive motor power for more than 0.2 seconds. Points to check: • Mechanical interference with the scanner •...
  • Page 370 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC144 - Mirror Unit Drive Failure Definition: The motor control PCB cannot detect the mirror unit home position sensor signal or mirror unit drive encoder signal. Points to check: • Mechanical interference with the mirror unit drive •...
  • Page 371 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC191 - ADS Adjustment Error Definition: ADS voltage cannot be adjusted to its standard value (3.0 V ± 0.5 V) during the process data initialization. NOTE: After resetting the system error condition, the ADS adjustment will be tried again.
  • Page 372 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC302 - Charge Corona Leakage Definition: The charge power pack detects charge corona leakage and sends the leak signal to the main PCB for more than 3 seconds. NOTE: The dc power, 24 V (VP) and 38 V (VFL), will be cut at the same time.
  • Page 373 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC307 - Vd Correction Error Definition: During process control data initialization, the target Vd value cannot be achieved within the charge power pack output range. NOTE: After resetting the system error condition, Vd correction will be tried again.
  • Page 374 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC353 - Vsg Abnormal Definition: The main PCB detects a low Vsg value (V) five times in a row. NOTE: Toner supply shifts to the 7% fixed supply mode. If the Vsg returns to normal level, standard detect supply resumes.
  • Page 375 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC391 - Toner Collection Coil Overload Definition: The main PCB detects no signal change from the toner collection coil overload sensor for more than 3 seconds. NOTE: When the system error condition is reset, the copier shows the toner end condition message on the screen, Points to check: •...
  • Page 376 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC401 - Transfer Corona Leakage Definition: The transfer corona power pack detects the transfer corona leakage and sends the leak signal to the main PCB for more than 3 seconds. NOTE: DC power, 24 V (VP) and 38 V (VFL), will be cut at the same time.
  • Page 377 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC404 - Transfer Corona Cleaner Failure Definition: The main PCB detects a large current for the transfer corona wire cleaner motor (mechanism lock) for more than 3 seconds when the cleaner is activated.
  • Page 378 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC440 - Main Motor Overload Definition: The motor control PCB cannot maintain the motor speed within the specification for more than 1 second, or the motor control PCB detects a large current (8 A) at the main motor for more than 2 seconds. Points to check: •...
  • Page 379 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC444 - No Drum Temperature Increase Definition: When the detected drum temperature is below 35°C, the main PCB cannot detect within 3 minutes a temperature increase of more than 1°C. NOTE: 1. The main relays will be opened in this condition. 2.
  • Page 380 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC505 - 1st Tray Drive Abnormal Definition: The main PCB cannot detect any pulses from the first tray paper volume sensor within 3 seconds after the tray up or down operation has been started. Points to check: •...
  • Page 381 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC510 - 2nd Tray Lower Limit Sensor Failure Definition: The main PCB cannot detect the lower limit sensor signal within 4.5 seconds after the tray down operation has been started. Points to check: •...
  • Page 382 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC522 - Duplex Jogger Home Position Sensor Failure Definition: The main PCB cannot detect the jogger home position sensor signal within 5 seconds after the duplex mode is selected. Points to check: •...
  • Page 383 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC543 - Fusing overheat Definition: The main PCB detects an extremely low resistance (< 500Ω/220°C) of the fusing thermistor for more than 3 seconds. NOTE: The service call message will be displayed at the first detection. The main relays will be opened in this condition.
  • Page 384 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC701 - DF Transport Belt Motor Overload Definition: The DF main PCB cannot detect any pulses from the belt drive motor encoder when the motor starts turning. Or, the motor continues turning after the DF main PCB signals the motor to turn off.
  • Page 385 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC721 - Sorter Main Motor Overload Definition: The sorter main PCB cannot detect any pulses from the main motor encoder within 0.1 second when the main motor is activated. Points to check: •...
  • Page 386 6 March 1992 SYSTEM ERROR AND SERVICE CALL CONDITIONS SC723 - Sorter Staple Unit and/or Grip Home Position Sensor Failure Definition: The sorter main PCB cannot detect the home position signals from the following sensors when they are actuated: Staple unit home position sensor Grip home position sensor Points to check: •...
  • Page 387 SYSTEM ERROR AND SERVICE CALL CONDITIONS 6 March 1992 SC745 - 2ND Sorter Hammer Home Position Sensor Failure Same as SC725 SC746 - Sorter Connection Failure Definition: The copier main PCB cannot communicate with the sorter main PCB, or the sorter main PCB cannot communicate with the second sorter main PCB.

  • Page 388: Blown Fuse Table

    6 March 1992 BLOWN FUSE TABLE 2. BLOWN FUSE TABLE Fuses provide current overload protection on some of the power supply lines. The following table shows the machine’s response to an open fuse. Copier DC Power Supply Board Rated Fuse No. Voltage Protect Symptom...

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