Ricoh A66 Service Manual

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A166/A187/A189

SERVICE MANUAL

PN: RCSM2003

RICOH GROUP COMPANIES

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Troubleshooting

Summary of Contents for Ricoh A66

Page 1 A166/A187/A189 SERVICE MANUAL PN: RCSM2003 RICOH GROUP COMPANIES...
Page 2 RICOH GROUP COMPANIES...
Page 4 A166/A187/A189 SERVICE MANUAL PN: RCSM2003...
Page 6 It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
Page 8 WARNING The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program.
Page 10 LEGEND PRODUCT CODE COMPANY GESTETNER RICOH SAVIN A166 2703 Aficio 2003 SDC103 A187 2703D Aficio 2103 SDC103A A189 2703DE Aficio 2203 SDC103E DOCUMENTATION HISTORY REV. NO. DATE COMMENTS 10/96 Original Printing...
Page 12: Table Of Contents
Table of Contents OVERALL MACHINE INFORMATION 1. SPECIFICATIONS ........1-1 1.1 MACHINE CONFIGURATION .
Page 13 5.4 SWITCHES ..........1-29 5.5 LAMPS.
Page 14 1.4 TONER SUPPLY CONTROL ........2-15 1.4.1 Toner Supply Control Method .
Page 15 4.3.5 D/A Conversion ......... . . 2-43 4.3.6 Scan Line Correction .
Page 16 6.2.2 Development Mechanism ........2-77 6.2.3 Toner Mixing ..........2-78 6.2.4 Developer Mixing .
Page 17 8.2.6 Side Fence Double-stopper Mechanism ..... . . 2-118 8.3 BY-PASS FEED..........2-119 8.3.1 By-pass Feed Table Mechanism .
Page 18 11. SYSTEM CONFIGURATION ......2-141 11.1 BLOCK DIAGRAM......... . . 2-141 11.2 COMMAND SEQUENCE .
Page 19 8.2 INSTALLATION PROCEDURE ........3-54 9. OTHERS ..........3-61 9.1 KEY COUNTER.
Page 20 2.1 USER PROGRAM MODE OPERATION ......4-17 2.2 UP MODE TABLE ..........4-18 3.
Page 21 2.4 LUBRICANT BAR REPLACEMENT ......5-12 2.5 CHARGE GRID AND CORONA WIRE REPLACEMENT ....5-13 3.
Page 22 7.2.2 Belt Cleaning Solenoid Replacement ......5-54 7.2.3 Entrance Seal Replacement ....... . . 5-55 7.3 BELT TRANSFER CORONA WIRE .
Page 23 9.11 OIL PAN PADS ..........5-84 9.12 FUSING ENTRANCE GUIDE ADJUSTMENT .
Page 24 3. TROUBLESHOOTING FOR COUNTERS....6-37 AUTO REVERSE DOCUMENT FEEDER A548 1. SPECIFICATIONS ........7-1 2.
Page 25 7.5 VERTICAL REGISTRATION ADJUSTMENT ......7-22 7.5.1 One Sided Thin Original Mode....... . 7-22 7.5.2 Two Sided Original Mode .
Page 26 3. BASIC OPERATION ........9-6 3.1 NORMAL MODE AND SORT/STACK MODE .
Page 27 APPENDIX 1. TIMING CHART Timing Chart 1 Normal speed/Bk/A4 ........11-1 Timing Chart 2 Normal speed/Bk/A3 .
Page 28: Important Safety Notices
IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main switch is turned off.
Page 29 SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate the toner bottle or the used toner. Toner dust may ignite suddenly when exposed to open flame. 2. Dispose of used toner, developer, and organic photoconductor according to local regulations. (These are non-toxic supplies.) 3.
Page 30 TAB INDEX OVERALL MACHINE INFORMATION 10-BIN SORTER STAPLER A555 DETAILED SECTION DESCRIPTIONS FILM PROJECTOR UNIT A718 INSTALLATION PROCEDURE APPENDIX - TIMING CHARTS / SP TABLES SERVICE TABLES REPLACEMENT AND ADJUSTMENT TROUBLESHOOTING AUTO REVERSE DOCUMENT FEEDER A548 PAPER TRAY UNIT A550/A549...
Page 32 OVERALL MACHINE INFORMATION...
Page 34: Specifications
Rev. 11/96 SPECIFICATIONS 1. SPECIFICATIONS 1.1 MACHINE CONFIGURATION Aficio color (Basic Machine) Edit Machine 2003 (A166) 2103 (A187) 2203 (A189) 144 mm x 192 mm Operation Panel 20-digit 2-line LCD Touch Panel Display Paper Tray Unit 250 Sheets Duplex ARDF (DF61) (A548) Copier...
Page 35: General Specifications
SPECIFICATIONS 1.2 GENERAL SPECIFICATIONS Configuration: Desk Top Copy Process: Dry Electrostatic Transfer System Resolutions: 400 dpi Gradations: 256 gradations Originals: Sheet/Book/Object Original Size: Maximum 11" x 17" /A3 Copy Paper Size: Maximum Minimum Paper Tray Feed 11" x 17" /A3 /A5(S) Bypass Feed 11"...
Page 36 SPECIFICATIONS Copying Speed: " x 11" (S) /A4 11" x 17"/A3 Normal Mode Full Color (4 scans) 3 cpm 1.5 cpm Single Color (C, M Y, K) 21 cpm 11 cpm Single Color (R, B) 4 cpm 3 cpm Single Color (G) 3 cpm 2.5 cpm OHP/Thick Paper Mode...
Page 37 SPECIFICATIONS Duplexing: Basic Manual Duplex Manual Duplexing in full color and Single Model (A166): Color mode Basic Auto Duplex Manual & Auto Duplexing in Full Color and Model (A187): Single Color mode Edit Auto Duplex Model Manual & Auto Duplexing in Full Color and (A189): Single Color mode Duplex can be done on 64-104 g/m...
Page 38 SPECIFICATIONS Toner Replenishment: Black: Toner Addition (300 g/cartridge) Color (Y, M, C): Toner Addition (100 g/cartridge) Toner Type E for C, M, Y; Ex for BK Cyan - EDP# 889766 Magenta - EDP# 889765 Yellow - EDP# 889764 Black - EDP# 889763 Developer Type: F all colors Cyan - EDP# 889762 Magenta - EDP# 889761...
Page 39: Detectable Original Size By Platen/Ardf
SPECIFICATIONS 1.3 DETECTABLE ORIGINAL SIZE BY PLATEN/ARDF Size Platen ARDF (width x length) Inch version Metric version Inch version Metric version [mm] A3 (297 x 420)L B4 (257 x 364)L A4 (210 x 297)L A4 (297 x 210)S B5 (182 x 257)L B5 (257 x 182)S A5 (148 x 210)L A5 (210 x 148)S...
Page 40: Copy Paper Size
SPECIFICATIONS 1.4 COPY PAPER SIZE Optional Trays in the main body Bypass Size S.Stapler (width x length) Paper Tray Duplex Tray [mm] Inch Metric Inch Metric version version version version versions A3 (297 x 420)L B4 (257 x 364)L A4 (210 x 297)L A4 (297 x 210)S B5 (182 x 257)L B5 (257 x 182)S...
Page 41: Paper Sizes Available With Aps
SPECIFICATIONS 1.5 PAPER SIZES AVAILABLE WITH APS – For metric machines – – – – – – – – – – A4L 8.5 – x 13 – – – – – – – A4L 8.5 – – – x 13 –...
Page 42: Noise Emission
SPECIFICATIONS NOTE: 1) The tables show which copy paper size is selected for each original size for zoom ratios from 50 to 200 %. 2) When a zoom ratio is specified, APS automatically selects a paper size that can guarantee the quality of the magnified copy image if there is a paper size available for the equivalent standard reproduction ratio.
Page 43: Power Consumption
SPECIFICATIONS 1.7 POWER CONSUMPTION (1) Maximum power consumption 1.5 kVA (2) Average power consumption A189 Copier + A189 Copier DJF + Sorter Standby 0.25 kW 0.5 kW Warm-up 1.25 kW 1.25 kW 1.15 kW 1.15 kW Copying Energy Saver Value for standby Value for standby Mode minus 7 W...
Page 44: Machine Configuration
MACHINE CONFIGURATION 2. MACHINE CONFIGURATION 2.1 COPY PROCESSES AROUND THE DRUM AND BELT 1. Drum Charge In the dark, the charge corona unit gives a negative charge to the organic photoconductive (OPC) drum. The grid plate ensures that corona charge is applied uniformly. The charge remains on the surface of the drum because the OPC layer has a high electrical resistance in the dark.
Page 45 MACHINE CONFIGURATION 4. Development The negatively charged toner is attracted to the latent image on the drum surface. Toner particles are electrostatically attracted to the area of the drum surface where the laser reduced the negative charge on the drum. The development unit is a revolver-type, containing separate development sections for each color toner.
Page 46: Major Unit Overview
MAJOR UNIT OVERVIEW 3. MAJOR UNIT OVERVIEW 5, 6 1-13 A166/A187/A189...
Page 47 MAJOR UNIT OVERVIEW 1. Copier 1. Dimensions (W x D x H): Basic machine - 620 x 700 x 632 mm [24.4"x27.6"x25.2"] (with paper tray unit: 620 x 700 x 1010) [24.4"x27.6"x40.1"] Edit machine - 620 x 750 x 632 mm [24.4"x29.8"x25.2"] (with paper tray unit: 620 x 750 x 1010) [24.4"x29.8"x40.1"] 2.
Page 48 (20-digit 2-line LCD) 2. Edit machine: The SCU is under the scanner unit and connected to the touch panel display (640 x 480 dots). Note for Ricoh Corporation: A166 = model Aficio Color 2003 A187 = model Aficio Color 2103...
Page 49: Parts Layout
PARTS LAYOUT 4. PARTS LAYOUT 4.1 MECHANICAL COMPONENT LAYOUT 1. Paper Tray (A166) 10. Charge Corona Unit 20. OPC Drum Duplex Tray 11. Lens 21. Registration Rollers (A187/189) 22. Relay Roller 12. 2nd fθ Lens 2. Pressure Roller 23. Belt Transfer 13.
Page 50: Pcb (A166/A187 Copiers)
PARTS LAYOUT 4.2 PCB (A166/A187 COPIERS) 1. RAM Board 11. I/O Control Board 2 2. SCU Board 12. By-pass Paper Width Detection Board 3. AC Drive/DC Power Supply Board 13. I/O Control Board 1 4. Operation Panel 14. High Voltage Supply Board 5.
Page 51: Pcb (A189 Copier)
PARTS LAYOUT 4.3 PCB (A189 COPIER) 19. SCU Board 20. Operation Panel 21. Extended IPU Board 22. Duplex Control Board 23. RAM Board A166/A187/A189 1-18...
Page 52: Solenoids And Clutches
PARTS LAYOUT 4.4 SOLENOIDS AND CLUTCHES 1. Transfer Belt Cleaning SOL 6. Registration CL 2. Toner Supply Release SOL 7. Main By-pass Feed Pick-up 3. Junction Gate SOL (A187/A189 only) 8. By-pass Feed CL 4. Sub By-pass Feed Pick-up 9. Paper Feed CL (A166 only) 10.
Page 53: Switches And Heaters
PARTS LAYOUT 4.5 SWITCHES AND HEATERS 1. Lower Tray Heater 12. Optics Anticondensation Heater 2. Pressure Roller Thermofuse 13. Fusing Thermistor 3. Pressure Roller Lamp 14. Charge Corona Unit 4. Fusing Lamp 15. Quenching Lamp 5. Pressure Roller Thermistor 16. Tray Paper Size SW 6.
Page 54: Sensors
PARTS LAYOUT 4.6 SENSORS 1. Used Toner Sensor 15. Registration Sensor 2. Color Toner Cartridge 16. Tray Paper End Sensor Sensor (A166 only) 3. Oil End Sensor 17. By-pass Feed Paper End Sensor 4. Revolver H.P. Sensor 18. Vertical Transport Sensor 5.
Page 55: Motors
PARTS LAYOUT 4.7 MOTORS 1. Toner Supply Motor 7. Main Motor 2. Scanner Motor 8. Duplex Feed Motor (A187/A189 only) 3. Revolver Drive Motor 9. Side Fence Jogger Motor 4. Development Drive Motor (A187/A189 only) 5. Polygon Motor 10. End Fence Jogger Motor (A187/A189 only) 6.
Page 56: Drive Layout
PARTS LAYOUT 4.8 DRIVE LAYOUT 1. Paper Feed Clutch 7. Transfer Belt Drive Gear 2. Vertical Transport Clutch 8. Development Drive Gear 3. Registration Clutch 9. Revolver Drive Gear 4. By-pass Feed Clutch 10. Transport Unit Drive Gear 5. Drum Drive Gear 11.
Page 57: Fans And Air Flow
PARTS LAYOUT 4.9 FANS AND AIR FLOW 1. Development Inlet Fan 9. Exhaust Fan 2. Transport Fan 1 10. Fusing Fan 3. Transport Fan 2 11. Charge Inlet Fan 4. Front Power Supply 12. Optics Exhaust Fan Board Fan 13. Scanner Board Cooling 5.
Page 58: Counters (A166/A187 Copiers)
PARTS LAYOUT 4.10 COUNTERS (A166/A187 COPIERS) 1. Main Counter 2. Back-up Counter (stored in the RAM board on the SCU board) 1-25 A166/A187/A189...
Page 59: Counter (A189 Copier)
PARTS LAYOUT 4.11 COUNTER (A189 COPIER) 1. Main Counter 2. Back-up Counter (stored in the RAM board on the SCU board) A166/A187/A189 1-26...
Page 60: Electrical Component List
ELECTRICAL COMPONENT LIST 5. ELECTRICAL COMPONENT LIST 5.1 PRINTED CIRCUIT BOARDS Symbol Name Function Remarks PCB1 Lamp regulator Supplies dc power for the exposure lamp. Scanner motor drive Supplies dc power for the scanner motor. PCB2 board CCD board Converts the light reflected from the original PCB3 into signals.
Page 61: Solenoids
ELECTRICAL COMPONENT LIST 5.2 SOLENOIDS Symbol Name Function Remarks Sub by-pass feed Lowers the pick-up roller. SOL1 pick-up solenoid Main by-pass feed Lowers the pick-up roller. SOL2 pick-up solenoid Toner supply Releases the toner supply motor. SOL3 release solenoid Transfer belt Controls the contact and release SOL4 cleaning solenoid...
Page 62: Switches
ELECTRICAL COMPONENT LIST 5.4 SWITCHES Symbol Name Function Remarks Main switch Turns the power to the copier on or off. Front door switch Opens the dc line to the high voltage supply board when the front door is open. Front door switch Opens the dc line to the main control board and LD unit when the front door is open.
Page 63: Heaters
ELECTRICAL COMPONENT LIST 5.6 HEATERS Symbol Name Function Remarks Optics Prevents moisture from forming on the anticondensation optics. heater Drum heater Prevents moisture from forming around the drum. Lower tray heater Keeps paper dry on the paper feed tray. 5.7 THERMISTORS Symbol Name Function...
Page 64: Sensors
ELECTRICAL COMPONENT LIST 5.10 SENSORS Symbol Name Function Remarks Platen cover Detects if the platen cover is up or position sensor down. Scanner unit lift Detects if the scanner unit is lifted or sensor not. Scanner HP sensor Detects the scanner home position. Transfer belt HP Detects the transfer belt mark.
Page 65: Motors
ELECTRICAL COMPONENT LIST 5.11 MOTORS Symbol Name Function Remarks Scanner motor Drives the scanner. Polygon motor Drives the polygon mirror. Main motor Drives the paper feed/transport section and fusing units. Drum motor Drives the drum and transfer belt. Toner supply motor Supplies toner.
Page 66: Counter
ELECTRICAL COMPONENT LIST 5.13 COUNTER Symbol Name Function Remarks Main counter Counts up the number of scans for Bk and color copying. 1-33 A166/A187/A189...
Page 68: Detailed Descriptions
DETAILED SECTION DESCRIPTIONS...
Page 70: Process Control
PROCESS CONTROL 1. PROCESS CONTROL 1.1 OVERVIEW Potential Sensor Development Roller Drum [A]: Toner Supply Motor [B]: Charge Corona Unit A166/A187/A189...
Page 71 PROCESS CONTROL Rev. 1/97 This machine uses two control methods: • Latent Image Control (every process control self check) • Toner Supply Control (every copy) Latent Image Control Latent image control controls the development potential to maintain the density of the toner image on the drum. It does this by compensating for variations in drum chargeability and toner chargeability.
Page 72: Process Control Measurement Timing
PROCESS CONTROL 1.2 PROCESS CONTROL MEASUREMENT TIMING The machine uses outputs from the drum potential sensor and the ID sensor. Some outputs are measured every color development cycle during each copy, and others are only measured during the process control self check procedure.
Page 73: Potential Control (Latent Image Control)
PROCESS CONTROL 1.3 POTENTIAL CONTROL (LATENT IMAGE CONTROL) 1.3.1 Concept Latent image control adjusts the development potential to maintain the density of the toner image on the drum. It does this by compensating for variations in drum chargeability and toner chargeability. Development Potential (V The development potential (V ) is the difference between the development...
Page 74: Process Control Self Check
PROCESS CONTROL There are 20 combinations in this table. The machine chooses the combination that is closest to the current V , and will use these values of , and V for copying until the next process control self check. The selected combination is based on actual image conditions, using the density of sensor patterns on the drum, as to better maintain proper copy quality.
Page 75: Process Control Self Check Procedure
PROCESS CONTROL 1.3.3 Process Control Self Check Procedure *NOTE: In the interval process control self check, the Drum Potential Sensor Calibration step is skipped. A166/A187/A189...
Page 76: Drum Potential Sensor Calibration
PROCESS CONTROL 1.3.4 Drum Potential Sensor Calibration The drum potential sensor [A] has a detector which detects the strength of the electrical field from the electrical potential on the drum. Since the output of the sensor is affected by environmental conditions, such as temperature and humidity, the sensor needs to be calibrated.
Page 77: Vsg Calibration
PROCESS CONTROL 1.3.5 Vsg Calibration The ID sensor checks the bare drum’s reflectivity and calibrates the output of the ID sensor to 4 ± 0.1 V. This compensates for both the drum’s and the ID sensor condition, such as dirt on the surface of the drum or ID sensor. 1.3.6 Writing the Gradation Pattern 1st level of LD power...
Page 78: Gradation Pattern Development
PROCESS CONTROL 1.3.8 Gradation Pattern Development The gradation pattern is developed with a fixed development bias. 1.3.9 Gradation Pattern Density Detection The ID sensor detects the developed gradation pattern (12 grades for each color), and the outputs are stored in memory. 1.3.10 Development Potential Calculation The development potential (V ) is the capability to attract toner to the drum...
Page 79: B , Ild
PROCESS CONTROL 1.3.11 V Selection (Pointer Table) The machine now adjusts V , and V to try to bring V to the ideal value. To do this, it uses a pointer table. This is a "look-up" table in memory of V against predetermined values which is compared V , and V The machine takes the value of V...
Page 80: Potential Control In Abnormal Sensor Conditions
PROCESS CONTROL 1.3.14 Potential Control in Abnormal Sensor Conditions You can check the result of the process control self check with SP 3-975. One of the following codes will be displayed. SP3-975 Process control self check result SP No. Code (Displays Error Potential Causes...
Page 81 PROCESS CONTROL SP No. Code (Displays Error Potential Causes Note Values Only) • In a fairly new machine, 3-2 (V 1. ID Sensor 2. Dirty ID Sensor this is caused by the ID 3. Drum Deterioration sensor or electrical noise. •...
Page 82 Rev. 1/97 PROCESS CONTROL The following table shows the error codes and their possible causes. Cause Error ∆ ∆ ∆ ∆ 80 V _ave Error ∆ ∆ ∆ ∆ 81 V _ptn Error Vmin (color) difference ∆...
Page 83: Abnormal Sensor Conditions (Sc)
PROCESS CONTROL 1.3.15 Abnormal Sensor Conditions (SC) If V or V at drum potential sensor calibration is out of specification or if or V do not fall within specification for any color after 40 attempts at adjusting V or I during the Confirmation Procedure, the machine stops or V correction and uses the previous V...
Page 84: Toner Supply Control
PROCESS CONTROL 1.4 TONER SUPPLY CONTROL 1.4.1 Toner Supply Control Method This machine has two toner supply control methods: fuzzy control mode, and fixed supply mode. Normally this machine uses fuzzy control. The fixed supply method is used only when abnormal conditions occur during the process control self check. 1.4.2 Fuzzy Control Mode Copy Vsp Detection for Toner...
Page 85 PROCESS CONTROL (2) Vsp for Toner Supply Control, Vsp(toner) The laser diode writes a sensor pattern for each color using standard laser diode power. After the pattern is developed, the machine then measures the ID sensor output from this pattern and uses the result as Vsp(toner) for that color to control the toner supply.
Page 86: Fixed Supply Mode
PROCESS CONTROL (4) Fuzzy Logic Algorithm The fuzzy logic algorithm has two input factors which are related to the amount of toner on the drum. These are: • The difference between the average of the previous 10 M/As and the target M/A •...
Page 87: Toner End Detection
PROCESS CONTROL Rev. 1/97 1.4.5 Toner End Detection (1) Toner Near-end Detection For detecting the toner near-end condition, this machine has two M/A thresholds (one for Bk toner and one for color toner). For each color, the machine counts the number of times that the current M/A is smaller than the threshold for that color.
Page 88 PROCESS CONTROL 3. If the pattern density is not good after performing the toner supply two times, the machine goes to the toner near-end/end condition again. Toner supply counter 2-19 A166/A187/A189...
Page 89: Developer Agitation
PROCESS CONTROL 1.4.6 Developer Agitation When the developer is replaced, developer agitation must be performed to agitate the developer and the toner. This machine has a program for developer agitation in SP mode (SP 2-225). † When performing the developer agitation for all colors (SP2-225-5) , the machine automatically performs the following steps.
Page 90 PROCESS CONTROL (1) Developer Agitation Result † When an error occurs during the developer agitation (SP2-225) , the machine stops the sequence and generates/stores the error code in SP3-964. The machine also remembers when the error occurred in the sequence. †...
Page 91 PROCESS CONTROL (2) Developer Agitation Error Code Table Code Error Causes and Measures No error – When making the 12-grade pattern, the calculated parameters (γ, Vmin, Vk) are not in the proper range. ↓ Developer Characteristic Wait 10 minutes, then perform the forced process Error control self check (SP3-126).
Page 92 PROCESS CONTROL Code Error Causes and Measures The M/A is smaller than the threshold for a toner end condition after the free run. ↓ Make a full color copy. Then replace the toner cartridges following the guidance on the LCD. Free Run Error with Toner After recovering the toner end condition, perform the †...
Page 93: Drum Unit
DRUM UNIT 2. DRUM UNIT 2.1 OVERVIEW The drum unit consists of the drum [A], the charge corona unit [B], the quenching lamp [C], the drum potential sensor [D], the ID sensor [E], and the cleaning unit [F]. An organic photoconductor drum (diameter: 80 mm) is used in this machine. The cleaning unit is at the upper right side of the drum, and faces downwards.
Page 94: Mechanisms
DRUM UNIT 2.2 MECHANISMS 2.2.1 Drive Mechanism The drum is driven by the drum motor [A] at the speed of 105mm/s. The drum motor is a brushless type motor. This motor contains a drive controller circuit Pcb, which controls the drum rotation. A fly-wheel on the end of the drum shaft stabilizes the rotation speed.
Page 95: Drum Charge
DRUM UNIT 2.2.2 Drum Charge This copier uses a single corona wire system to charge the drum. The single corona wire applies a negative charge to the drum surface (–670V is the standard voltage). The honeycombed stainless steel grid plate [A] makes the corona charge uniform and controls the amount of negative charge on the drum surface by applying the negative grid bias voltage.
Page 96: Drum Cleaning
DRUM UNIT 2.2.3 Drum Cleaning This copier uses a counter blade system with a lubricant bar to clean the drum. 1. Counter Blade The cleaning blade [A] is angled against drum rotation by the pressure spring. The counter blade system has the following advantages: •...
Page 97: Quenching
DRUM UNIT 2.2.4 Quenching In preparation for the next copy cycle, light from the quenching lamp [A] neutralizes any charge remaining on the drum [B]. The quenching lamp turns on at the same time as the drum motor activates. Red LEDs are used for the quenching lamp to reduce ultra-violet light that would cause light fatigue on the OPC drum.
Page 98: Scanner Unit
SCANNER UNIT 3. SCANNER UNIT 3.1 OVERVIEW Original Length Original Length Exhaust Fan Second Scanner Sensor-1 Sensor-2 Scanner H.P. Sensor Lens First Scanner Scanner Board Original Width Cooling Fan Sensor Scanner IPU Optics Cooling Fan Board Optics Anticondensation Filter Heater An image of the original illuminated by the exposure lamp (a halogen lamp, 75V/160 Watt) is reflected onto a color CCD (Charge Coupled Device) via the 1st, 2nd, and 3rd mirrors, filter, and lens.
Page 99: Scanner
SCANNER UNIT 3.2 SCANNER The 1st scanner consists of the exposure lamp [A], main [B] and sub [C] reflectors, and 1st mirror [D]. This model uses a halogen type exposure lamp with eight elements and a frosted surface. This ensures even exposure across the main scan in the main scan direction.
Page 100: Scanner Drive
SCANNER UNIT 3.3 SCANNER DRIVE A five-phase stepper motor [A] drives the scanner. The 1st [B] and 2nd [C] scanners are driven by this scanner drive motor [A] via 2 scanner wires. For easyservicing, the wires at the front side and the rear side are the same. In full size mode, the 1st scanner speed is 105 mm/s during scanning, and 720 mm/s when the scanner returns.
Page 101: Color Ccd
SCANNER UNIT 3.4 COLOR CCD The color CCD converts light reflected from the original into three analog signals, one for each of the three basic colors Red, Green, and Blue. The signals are called the R, G, and B signals. Each of the four scans (for toner colors BkCMY) uses all three signals (RGB).
Page 102: White Plate Scanning
SCANNER UNIT 3.5 WHITE PLATE SCANNING There is a white plate [A] for auto shading, located on the exposure glass [B] underneath the left scale. When this white plate is exposed, the output from all the CCD elements in a line should in theory be equal, but actually they are not, because of the following: * Variations in sensitivity between elements of the CCD * Variations in characteristics of lens and mirror reflectivity...
Page 103: Original Size Detection
SCANNER UNIT 3.7 ORIGINAL SIZE DETECTION APS5 APS4 APS1 APS2 APS3 There are three reflective sensors (APS sensors) in the optics cavity for the original size detection. The original width sensor [A] detects the original width, while the original length sensor -1 [B] and original length sensor -2 [C] detect the original length.
Page 104 SCANNER UNIT Original Size A4/A3 LT/DLT APS1 APS2 APS3 APS4 APS5 Version Version (metric) (inch) 11x17 10x14 F (8"x13") A4-L A4-S 11x8 B5-L B5-S A5-L See Note A5-S NOTE: L: Lengthwise S: Sideways This original size detection method eliminates the necessity for a pre-scan and increases the machine’s productivity.
Page 105: Others
SCANNER UNIT 3.8 OTHERS (1) Anti-condensation Heater An anti-condensation heater [A] is installed on the left side of the optical base plate. It turns on when the main switch is off, to prevent moisture from forming on the optics. (2) Fans 1.
Page 106 SCANNER UNIT (3) Scanner Unit For field servicing, the scanner unit [A] can be opened. When the scanner unit is lifted, the actuator of the scanner unit lift sensor [B] moves out of the sensor. Then, for safety, the CPU disables the scanner motor. The start key stays red under this condition.
Page 107: Image Processing
IMAGE PROCESSING 4. IMAGE PROCESSING 4.1 OVERVIEW The light from the halogen lamp is reflected by the original onto the CCD board. The CCD board has a CCD (Charge Coupled Device) with a three-line (RGB) filter. The reflected light is converted to analog image data signals, and these are transferred to the scanner IPU board.
Page 108: Scanner Section Block Diagram
IMAGE PROCESSING 4.2 SCANNER SECTION BLOCK DIAGRAM CLP (Clamp): Defines the standard black level signals for the black signal. S/H (Sample and Hold): Samples the analog image data signals. MPX (Multiplexer): Combines the even-pixel and odd-pixel analog signals. AGC (Auto Gain Control): Controls the amplification factor for the signals, using the white level data feedback signal.
Page 109: Scanner Section
IMAGE PROCESSING 4.3 SCANNER SECTION 4.3.1 Photoelectric Conversion The color CCD converts the light reflected from the original into RGB analog signals (4.475 MHz for each signal: even-pixel and odd-pixel). Each CCD line has 5,000 pixels and the resolution is 400 dpi (15.7 pixels/mm). 4.3.2 Signal Processing (1) Signal Amplification Odd-pixel and even-pixel RGB analog signals from the CCD are amplified by...
Page 110: Shading Circuit
IMAGE PROCESSING 4.3.4 Shading Circuit (1) Shading Compensation (GA1, GA2) Before scanning each original, the machine generates a reference white waveform (also known as "white shading data") by scanning 5 mm of the white reference plate [A] in the sub-scan direction (this equals 79 lines at 100% magnification).
Page 111 IMAGE PROCESSING The video signal for each pixel obtained during image scanning is corrected by the shading circuit as follows: (Video data for each pixel) – (Black shading data for each line) x 255 (White shading data for each pixel) – (Black shading data for each line) The white shading data are updated before every first scanning (2C and 4C mode) or every scanning (1C mode).
Page 112: D/A Conversion
IMAGE PROCESSING 4.3.5 D/A Conversion The CPU monitors the digital feedback signals from the shading circuits and calculates correction factors. Then the D/A circuit converts the signals from the CPU into analog signals and feeds them back to the operational amplifiers and the CLPs (see section 4.3.2.(3)).
Page 113: Ipu Section Block Diagram
IMAGE PROCESSING 4.4 IPU SECTION BLOCK DIAGRAM A166/A187/A189 2-44...
Page 114: Ipu Section
IMAGE PROCESSING 4.5 IPU SECTION 4.5.1 Picture Element Correction and Scanner Gamma Correction (1) Picture Element Correction The Picture Element Correction circuit does two things. 1. Completion of the Scan Line Correction process The discrepancy in the spacing of the RGB signals from the CCD in the subscan direction is corrected by the line correction circuit in the scanner section (refer to 3-6.
Page 115 IMAGE PROCESSING (2) Scanner Gamma Correction (RGB Gamma) Fig. 1 Fig. 2 The RGB video signals detected by the CCD are converted to 8-bit digital signals in the scanner section and sent to the IPU section. These signals are proportional to the light intensity reflected from the original image (Fig. 1). However, the IPU section converts the signal levels as shown in figure 2 by using a gamma correction table in order to improve the accuracy of RGB to CMY (also referred to as "YMC"...
Page 116: Acs (Auto Color Selection)
IMAGE PROCESSING 4.5.2 ACS (Auto Color Selection) Auto color selection mode determines if an original is black/white or color. Then black copy mode or full color mode is automatically selected to match the original. To recognize if the original has a color area or not, the RGB video signals are compared.
Page 117: Auto Letter/Photo Separation
IMAGE PROCESSING 4.5.3 Auto Letter/Photo Separation In auto letter/photo mode, the original image is separated into letter and photo areas (dot screen areas). NOTE: "Letter" refers to an original or area of an original that contains text and/or line drawings. Generally, letter areas have strong contrast between the image and the background.
Page 118 IMAGE PROCESSING (1) Edge separation The edge of letters and line diagram elements are separated by using the following characteristics: Strong contrast, continuity of black or color pixels, continuity of white pixels around the black or color pixels The machine can do this by referring to the green signal only. (2) Dot screen separation Dot screen areas are separated from non-dot screen areas (mainly letters) by using the following characteristics:...
Page 119: Filtering And Color Conversion
IMAGE PROCESSING 4.5.4 Filtering and Color Conversion (1) RGB Smoothing Filter Before After Depending on the results of auto letter/photo separation, the appropriate software filters are applied to the RGB video signals. The RGB smoothing filter is only applied to photo areas; signals from letter areas are not filtered. (2) Background Density Control and ADS (Auto Image Density Selection) a.
Page 120 IMAGE PROCESSING b. ADS (Auto Image Density Selection) In ADS, the user does not set the threshold; the machine calculates it, guided by input from the user (there are 4 settings for each mode: B/W or F/C). In full color mode, after the first scanning (Bk) the machine calculates the threshold for removing background by referring to the RGB data taken from the whole of the original.
Page 121 IMAGE PROCESSING Original Color Toner Color Conversion Table a. Color conversion mode Color conversion mode is a user feature, not to be confused with color conversion (RGB to YMCK) as described on the previous page. In color conversion mode, a selected color (C/M/Y/R/G/B/K/W) on an original that falls within the recognition thresholds for that color is converted into a different color on the copy.
Page 122 IMAGE PROCESSING (4) YMCK Smoothing Before After The YMCK filter smooths the image data in photo areas only to give a softer image. (5) Edge Emphasis Filter (High Contrast Filter) Before After The high contrast filter improves text and graphic elements in letter mode areas by making the edges in the copy stand out more clearly.
Page 123 IMAGE PROCESSING (6) UCR (Under Color Removal) Principle Fig. 7 Getting the right colors using YMC toner addition does not always work perfectly. For example, if for each color (YMC) the same quantity of toner is put on the paper, ideally the image should become black, but in reality it becomes a dark color, such as dark blue.
Page 124 IMAGE PROCESSING Fig. 1 Fig. 2 Fig. 4 Fig. 3 Fig. 5 Fig. 6 In this example, the UCR ratio is 70%. For a Black Image When a black image is copied, the ID values for all colors are equal (figure 1).
Page 125 IMAGE PROCESSING Changes in UCR Ratio with Image Density and Copy Mode MIN: Similar to the Common ID Value - Letter Areas - The UCR ratio in letter areas is always 100%. - Photo Areas, with ACS Priority set to Bk - In photo areas, when the user sets the ACS priority to Bk, UCR begins to replace color toner with Bk toner at low image densities (when MIN is about 13).
Page 126: Main Scan Magnification
IMAGE PROCESSING 4.5.5 Main Scan Magnification Reduction and enlargement in the sub scan direction are done by changing the scanner speed. However, reduction and enlargement in the main scan direction are handled by an LSI on the IPU Board. Scanning and laser writing are done at a fixed pitch (the CCD elements cannot be squeezed or expanded).
Page 127: Gamma Correction (Printer Gamma)
IMAGE PROCESSING 4.5.6 Gamma Correction (Printer Gamma) Fig. 2 Fig. 1 (1) BKCMY Gamma Ideally, the gamma curves for Yellow, Magenta, Cyan, and Black should be identical, as shown in figure 1. However, they are not, because electrical components always vary slightly, resulting in varying gamma curves, as shown in figure 2.
Page 128 IMAGE PROCESSING Fig.3 Fig. 4 Fig. 5 Fig. 6 - ID max. - This mode is used to adjust the total image density level as shown in figure 3. – High ID – The High ID mode should be used to adjust the image density between Level 6 and Level 9 of the color gradation scale on the C-4 test chart (figure –...
Page 129 IMAGE PROCESSING Rev. 1/97 (2) ACC Test Pattern The IPU board firmware has a test pattern that has eight 10-step gradation scales for each color (BKCMY) for Letter mode and Photo mode. –ACC (Auto Color Calibration)– This machine automatically calibrates the printer gamma curve when the user selects ACC.
Page 130: Gradation Treatment (Dither Processing)
Rev. 11/96 IMAGE PROCESSING 4.5.7 Gradation Treatment (Dither Processing) In this machine, 4 x 4 dot dither patterns (4 bits/dot) convert the 8-bit data to 4-bit data before it goes to the printer. This speeds up data processing in the printer.
Page 131: Cpu
IMAGE PROCESSING 4.6 CPU The CPU (16-bit) controls the image data and the timing in the scanner and IPU sections. 4.7 EXTENDED IPU (EDIT MACHINE ONLY) Extended IPU Block Diagram D R A M 2 M B 2 M B C P U DRAM Interface 400 x 200dpi...
Page 132 IMAGE PROCESSING (1) Image processing for the display monitor – Image processing for Editing – 400 dpi image data (from the Green signal only) is converted to 100 dpi and 33 dpi, and these are both kept in the memory. 33 dpi image data is used for the full size display.
Page 133: Others
IMAGE PROCESSING (2) Area data processing Area information edited by an operator is processed in the SCU and is sent to the extended IPU through the CPU as area data. In the area data processing block, area data is processed depending on the selected copy modes (such as magnification, image shift) and is coded as process codes (for Under color, Painting, and Single Color) and is sent to the Image creation for editing circuit.
Page 134: Laser Exposure
LASER EXPOSURE 5. LASER EXPOSURE 5.1 OVERVIEW A: Laser Diode Unit E: Laser Synchronization Detector Board-1 B: F-theta Lenses F: Laser Synchronization Detector Board-2 C: Barrel Toroidal Lens (BTL) G: Polygon Mirror Motor D: Drum Mirror H: Cylindrical Lens I: OPC Drum J: Shield Glass This machine uses a laser diode to produce electrostatic images on an OPC drum [I].
Page 135: Optical Path
LASER EXPOSURE 5.2 OPTICAL PATH 5.2.1 Overview The output path from the laser diode to the drum is shown above. The LD unit [A] outputs the laser beam to the polygon mirror [G] through the cylindrical lens [H]. The polygon mirror reflects a full main scan line with a single surface of the mirror.
Page 136: Cylindrical Lens
LASER EXPOSURE 5.2.2 Cylindrical Lens The laser beam is focused by the cylindrical lens [A], and sent to the polygon mirror. 5.2.3 Polygon Mirror The polygon mirror assembly consists of the polygon motor [B] and the polygon mirror itself [C]. As the mirror rotates, it reflects the laser beam across the drum, via the f-theta lens, BTL, and drum mirror.
Page 137: F-Theta Lenses And The Btl
LASER EXPOSURE 5.2.4 F-theta Lenses and the BTL Wide spaced Narrow spaced Evenly spaced pixels The angles between pixels are equal. However, if the beam were to go directly to the drum as shown in the upper illustration, the spacing between pixels would differ with the angle of the beam.
Page 138: Laser Synchronizing Detector Boards
LASER EXPOSURE 5.2.5 Laser Synchronizing Detector Boards Some of the optical components are made of plastic, and may expand and contract with changes of temperature. If this happens, the number of pulses in the laser main scan across the drum will vary. To counteract the effects of this, the machine adjusts the gap between laser pixels to keep the number of laser pulses in each main scan constant.
Page 139: Gradation Control (Laser Power Modulation)
Rev. 11/96 LASER EXPOSURE 5.3 GRADATION CONTROL (LASER POWER MODULATION) (32 levels) Data: 0 Data: 16 Data: 32 Data: 48 Data: 64 Data: 136 Data: 255 (8 levels) 1 dot Black White Data The LD power for each gradations is defined by process control. To form the latent image, the laser beam illuminates the image area of the drum surface.
Page 140: Auto Power Control (Apc)
LASER EXPOSURE 5.4 AUTO POWER CONTROL (APC) Even if a constant electric current is applied to the laser diode, the intensity of the output light changes with the temperature. The intensity of the output decreases as the temperature increases. In order to keep the output level constant, the output light intensity is monitored through a photodiode (PD) enclosed in the laser diode.
Page 141: Ld Safety Switches
LASER EXPOSURE 5.5 LD SAFETY SWITCHES To ensure that the laser beam does not accidentally switch on during servicing, there are two safety switches located at the front door. These two switches [A] are installed in series on the LD 5 V line coming from the dc power supply board.
Page 142: Development Unit
DEVELOPMENT UNIT 6. DEVELOPMENT UNIT 6.1 OVERVIEW The CMYK development unit is a revolver type, and is composed of the development and toner supply sections for each color (CMYK). When this unit rotates counter-clockwise, the toners are developed in the order Bk, C, M, and Y.
Page 143: Mechanisms
DEVELOPMENT UNIT 6.2 MECHANISMS 6.2.1 Revolver Development Mechanism The Development Unit is a revolver body which is composed of development sections for each color (BkCMY). This unit rotates counter-clockwise in 90-degree steps to develop each color in order (BkCMY). This mechanism allows the size of the main frame to be reduced in site.
Page 144 DEVELOPMENT UNIT (1) Revolver Drive Revolver Motor Speed 93 degrees Forward Time Reverse 3 degrees The center pin [A] at the rear and the two revolver support rollers [B] on the development stay [C] keep the development unit in the proper position. The revolver drive motor [D] rotates the development unit [E].
Page 145 DEVELOPMENT UNIT (2) Revolver H.P. Detection Fig. 1 Fig. 2 The revolver H.P. sensor [A] is at the front side of the development unit (figure 1). The revolver home position is the position at which Bk toner is developed on the drum (figure 2). There is a notch [B] on the revolver frame ring [C].
Page 146: Development Mechanism
DEVELOPMENT UNIT 6.2.2 Development Mechanism The development unit contains four development mechanisms in one body, one for each color. Each development section is reduced in size with respect to previous models, and can hold 400 g (1 package) of developer. The developer from the dual mixing roller [A] is attracted to the surface of the development roller [B] by the magnets inside the development roller.
Page 147: Toner Mixing
DEVELOPMENT UNIT 6.2.3 Toner Mixing Mechanism Toner mixing supplies toner from the cartridges to the sub hoppers. Toner mixing is performed by rotating the development unit (the entire revolver unit). Note how the Bk cartridge opens (3. & 4.) and closes (1. & 2.) as the revolver turns.
Page 148 DEVELOPMENT UNIT Timing The revolver rotates at particular times to prevent errors in toner end detection. This rotation has two purposes; one is to supply toner to the hopper (especially important for Black toner; see section 6.2.4), the other is to agitate the toner in the hopper.
Page 149 DEVELOPMENT UNIT - Toner Agitation - During a multiple copy job in 1C mode (Bk, C, M, and Y single-color copy mode), the development unit does not rotate after the required color development section has been rotated into position. This could result in a false toner end detection because the toner is not carried from the main hopper section [A] to the sub hopper section [B] during copying.
Page 150: Developer Mixing
DEVELOPMENT UNIT 6.2.4 Developer Mixing Mechanism This mechanism supplies toner from the sub hopper to the development roller. The dual mixing roller is composed of the outer paddle [A] and the inner auger [B]. This carries developer to the rear and supplies developer to the development roller [C].
Page 151 DEVELOPMENT UNIT Timing Toner supply for a particular color is performed only when the development section for that color is at the development position. The Bk toner cartridge [A] is installed at the center of the development unit, and is separated from the Bk hopper section [B] and the Bk toner supply section [C].
Page 152 DEVELOPMENT UNIT 180 degrees 270 degrees 3. Then toner is supplied to the development section by the dual mixing roller. For Bk toner the process is as follows: 1. First, the development unit must be rotated to get Bk toner out of the cartridge [A] and into the hopper section [B].
Page 153: Development Roller Drive
DEVELOPMENT UNIT 6.2.5 Development Roller Drive Because the development unit is a revolver unit, there is only one development motor [A], which drives the color development roller that is at the development position. When the development motor turns, the development roller which is at the development position [F], the dual mixing roller [B], and the transfer auger [C] are driven via idle gears 1 [D] and 2 [E].
Page 154: Development Bias
DEVELOPMENT UNIT 6.2.6 Development Bias The high voltage supply board [A] applies the development bias (ac and dc) to the development roller [B] that is currently in position through the bias terminal [C]. The development roller is composed of the roller, development sleeve, and magnet shaft [E].
Page 155: Toner Cartridge Detection
DEVELOPMENT UNIT 6.2.7 Toner Cartridge Detection This machine has two toner cartridge sensors to detect the presence of the toner cartridges. (1) Bk Toner Cartridge Detection When a Bk toner cartridge [A] is installed in the center of the development unit, the hook [B] on the Bk toner cartridge pushes the sensor actuator [C], into the BK toner cartridge sensor [D] and the machine detects that a toner cartridge has been installed.
Page 156: Color Toner Positioning Pin
DEVELOPMENT UNIT (2) Color Toner Cartridge Detection Bk toner hopper Yellow toner cartridge: Replacement position The color toner cartridge sensor [D] is located at the lower right side of the development unit. While the development unit rotates, this sensor (which is a reflective photosensor) detects the presence of each color toner cartridge (CMY).
Page 157: Revolver Positioning
DEVELOPMENT UNIT 6.2.9 Revolver Positioning This section explains how the revolver moves the various color toners into position in the various modes. For a fuller explanation of how the revolver, drum, and belt move in each of the modes, see the "Transfer Belt Unit" section.
Page 158 DEVELOPMENT UNIT (2) In 2C Mode (R, G, and B) After the start key has been pressed, the machine moves the first color development section to the position for development. For Blue or Green, the first color is Cyan, so the revolver must turn 90 degrees, and for Red, the first color is Magenta, so the revolver must turn 180 degrees.
Page 159 DEVELOPMENT UNIT For Green, copying takes longer than for red or blue. This is because the revolver has to rotate 180 degrees to move the second color into position. Toner is likely to cross over to the drum when development roller gears are meshing and unmeshing during revolver rotation.
Page 160 DEVELOPMENT UNIT (3) In 4C Mode (Full Color Mode) After the start key has been pressed, the development unit rotates the four colors into position in order. Each step is 90 degrees, so the revolver turns in the same way as in 2C mode for Red or Blue; no extra belt turn is needed for an 180-degree turn of the revolver (however, only a 90-degree turn is needed between copies of a multi-copy job).
Page 161 Rev. 1/97 DEVELOPMENT UNIT (5) When there is a Toner End Condition Bk toner and yellow toner replacement position When the machine detects a toner end condition, the machine positions the empty color cartridge to the replacement position and stops the job. After the toner cartridge is replaced and the front cover is closed, the machine performs the revolver H.P.
Page 162: Transfer Belt Unit
TRANSFER BELT UNIT 7. TRANSFER BELT UNIT 7.1 OVERVIEW This machine has a transfer belt. Each single color image developed on the drum [A] is transferred separately to the transfer belt [B] by the transfer belt corona unit [D]. After all single color images have been transferred to the transfer belt, the full color image is then transferred to the copy paper by the paper transfer corona unit [E].
Page 163: Layout
TRANSFER BELT UNIT 7.2 LAYOUT 1. Belt Drive Roller 8. Entrance Seal 2. Lubricant Brush 9. Cleaning Blade 3. Transfer Belt 10. PTL 4. Cleaning Support Roller 11. Belt Transfer Charge Unit 5. Paper Transfer Corona Unit 12. Transfer Belt Tension Roller 6.
Page 164: Belt Transfer
TRANSFER BELT UNIT 7.3 BELT TRANSFER 7.3.1 Transfer Belt Drive The drum motor [A], which is a 24V dc brushless motor, drives the transfer belt (through the drive roller [B]), as well as the drum. (The drum and belt always turn at the same time.) The transfer belt always contacts the drum and rotates in one direction.
Page 165 TRANSFER BELT UNIT 1. 1C Mode (Bk, C, M, Y) Black 1. After the start key has been pressed, the drum motor starts, and the drum and transfer belt turn continuously. The revolver does not move because the black development section is already in place. 2.
Page 166 TRANSFER BELT UNIT • Between colors, the revolver must rotate. When one of the development rollers is near the drum, especially while the revolver is locked into place, there is a chance of toner transferring over to the drum [A] (see "Development").
Page 167 TRANSFER BELT UNIT When copying on A4/Letter size sideways paper or shorter, there is enough time for the revolver to move the second color development section into position before the next transfer belt home position is detected. However, when copying on paper that is longer than A4 sideways, there is no time to do this within the same transfer belt rotation (the non-image area on the belt is too short).
Page 168 TRANSFER BELT UNIT 5. Then the revolver must move the next color development section into position. For Green, the next color is Yellow, and the revolver has to turn 180 degrees. Even when copying on paper that is A4/LT sideways or shorter, there is not enough time for the revolver to rotate the complete 180 degrees all in one step before areas of the drum corresponding to an image area on the belt arrive at the revolver position.
Page 169 TRANSFER BELT UNIT 6. Summary The following table shows the number of transfer belt rotations needed per copy for each of the various modes described above (except for OHP/thick paper mode). It does not include the belt rotations that take place during toner replenishment and other procedures.
Page 170: Transfer Belt Release Mechanism
TRANSFER BELT UNIT 7.3.2 Transfer Belt Release Mechanism Nip band width: about 3 mm About 3 mm The transfer belt unit has a release lever at the front side of the drum. This is because the transfer belt unit always contacts the drum during normal operation (the nip band width is about 3 mm), but must be moved away from the drum to remove the transfer belt unit.
Page 171: Belt Transfer Bias
TRANSFER BELT UNIT 7.3.3 Belt Transfer Bias The belt transfer charge unit [A] is a corona unit at the reverse side of the transfer belt. It attracts toner to the transfer belt. The high voltage supply board [B] applies a positive bias voltage to the transfer belt via the belt transfer corona unit.
Page 172: Belt Mark Detection
TRANSFER BELT UNIT 7.3.4 Belt Mark Detection The transfer belt H.P. sensor [A] aligns the position of the image on the belt for each color. The use of this sensor allows the belt transfer unit mechanism to be more simpler than in other machines (e.g. the switchback mechanism for A109 copiers is not needed).
Page 173: Transfer Belt Cleaning
TRANSFER BELT UNIT 7.3.5 Transfer Belt Cleaning After the toner image on the transfer belt is transferred to the paper, the toner remaining on the transfer belt is removed by the cleaning blade [A], which is a counter blade system. The entrance seal [B] prevents the removed toner from falling onto the paper transfer unit or paper.
Page 174: Toner Collection
TRANSFER BELT UNIT 7.3.6 Toner Collection In the transfer belt unit, the toner collection coil [A] at the front side of the transfer belt unit transports the removed toner from the transfer belt cleaning unit to the toner collection bottle [B]. In the drum area, the toner collection coil [C] in the drum cleaning unit transfers the removed toner from the drum cleaning unit to the toner collection bottle.
Page 175: Belt Lubricant Mechanism
TRANSFER BELT UNIT 7.3.7 Belt Lubricant Mechanism Toner filming on the belt will reduce the efficiency of toner separation from the belt. A small amount of lubricant is regularly applied to the surface of the transfer belt [A] to help the cleaning blade easily remove toner from the transfer belt and to help toner to transfer to the paper.
Page 176: Ptl (Pre-Transfer Lamp)
TRANSFER BELT UNIT 7.3.8 PTL (Pre-transfer Lamp) When the belt transfer charge unit switches on, the transfer belt receives a positive charge. Because the drum has a negative charge, the belt will be attracted to the drum. However, when there is toner on the transfer belt. This attraction is greatly reduced.
Page 177: Paper Transfer
TRANSFER BELT UNIT 7.4 PAPER TRANSFER 7.4.1 Paper Transfer Bias High Voltage Power Supply The paper transfer corona unit [A] transfers toner on the transfer belt to the paper [B]. The machine controls the paper transfer bias current by referring to the readings from the thermo-sensor [C] and humidity sensor [D] on the I/O control board 1 [E] .
Page 178 TRANSFER BELT UNIT Normal High Temperature & Low Temperature & Condition High Humidity Low Humidity Mode 1C 2C 4C 1C 2C 1C 2C Leading edge [Normal [Normal Image Front 100 200 200 Condition Condition area Value]-50 Value]+50 Trailing Normal edge Paper Leading edge...
Page 179: Paper Discharge
TRANSFER BELT UNIT 7.4.2 Paper Discharge The paper transfer unit has a discharge brush [F] (see illustration 7.4.1 Paper Transfer Bin) which is grounded to the main frame. This brush discharges the electric charge remaining on the paper to help the paper separate from the transfer belt.
Page 180: Paper Feed And Registration
PAPER FEED AND REGISTRATION 8. PAPER FEED AND REGISTRATION 8.1 OVERVIEW 1. Paper Tray Size Switch (A166 only) 9. By-pass Feed Paper End Sensor 2. Tray Bottom Plate (A166 only) 10. By-pass Feed Roller 3. Vertical Transport Switch 11. Registration Sensor 4.
Page 181: Paper Tray Mechanism (A166 Copier Only)
PAPER FEED AND REGISTRATION 8.2 PAPER TRAY MECHANISM (A166 COPIER ONLY) 8.2.1 Paper Feed Drive Mechanism This paper feed mechanism uses the corner separation system. The shape of the corner separators is as shown above. These corner separators have the following advantages. ...
Page 182 PAPER FEED AND REGISTRATION The main motor [A] drives the paper feed rollers through the relay clutch gears, the timing belt [B], and the paper feed clutch [C]. After the Start key is pressed, the paper feed clutch turns on and the paper feed rollers start rotating to feed the paper.
Page 183: Paper Lift Mechanism
PAPER FEED AND REGISTRATION 8.2.2 Paper Lift Mechanism When the paper tray is closed, projection [A] on the tray pushes the release lever [B], and the other projection [C] pushes the release slider [D]. Then the release slider comes off the bottom plate lift arm [E]. Once the release slider comes off, the spring [F] raises the bottom plate lift arm and the bottom plate is lifted up.
Page 184: Paper End Detection
PAPER FEED AND REGISTRATION 8.2.3 Paper End Detection The paper end feeler [A] is on the same shaft as the paper end actuator [B]. When the tray runs out of paper, the paper end feeler drops into the cutout in the tray bottom plate and the paper end actuator activates the paper end sensor [C].
Page 185: Paper Size Detection
PAPER FEED AND REGISTRATION 8.2.4 Paper Size Detection Actuated = 0 Paper size L: Lengthwise Deactuated = 1 S: Sideways A4/A3 Version LT/DLT Version 01111 A3-L 11" x 17" 00111 B4-L " x 14" 10011 A4-L " x 11" 01001 A4-S 11"...
Page 186: Vertical Transport Mechanism
PAPER FEED AND REGISTRATION 8.2.5 Vertical Transport Mechanism The vertical transport rollers [A] are driven by the main motor. The vertical transport rollers, and the driven vertical transport rollers [B] on the vertical transport door [C], transport the paper from the feed unit to the registration rollers.
Page 187: Side Fence Double-Stopper Mechanism
PAPER FEED AND REGISTRATION 8.2.6 Side Fence Double-stopper Mechanism In this machine, there is a side fence stopper mechanism for both the front and rear side fences. If the tray is closed with excessive force after loading paper, paper may come over the rear side fence because the fence is deformed by the weight of the paper leaning against it.
Page 188: By-Pass Feed
PAPER FEED AND REGISTRATION 8.3 BY-PASS FEED 8.3.1 By-pass Feed Table Mechanism The by-pass feed table switch [A] detects when the by-pass feed table is opened. Then the CPU turns on the by-pass feed indicator on the operation panel. The by-pass feed table can hold up to 40 sheets of (20lb bond) paper. 2-119 A166/A187/A189...
Page 189: Paper Feed
PAPER FEED AND REGISTRATION 8.3.2 Paper Feed The by-pass feed table uses an FRR feed system. The feed and separation rollers are always in contact. They are driven by the main motor via the by-pass feed clutch [A]. 8.3.3 Paper End Detection If paper is loaded in the paper tray, the paper end feeler [A] is raised by the paper stack and the paper end sensor [B] is deactuated.
Page 190: By-Pass Feed Paper Width Detection
PAPER FEED AND REGISTRATION 8.3.4 By-pass Feed Paper Width Detection LT version A4 version The by-pass paper width detection board [A] monitors the paper width. The rear side fence is connected to the terminal plate [B]. When the side fences are positioned to match the paper width, the terminal plate slides along the wiring patterns on the detection board.
Page 191: Pick-Up Roller Pressure Mechanism
PAPER FEED AND REGISTRATION 8.3.5 Pick-up Roller Pressure Mechanism This by-pass feed table uses a pick-up roller pressure mechanism, which has two pick-up solenoids. This system uses the main pick-up solenoid [A] and the sub pick-up solenoid [B] to change the pick-up roller pressure, to adapt to various paper types and copy modes.
Page 192: Registration Drive Mechanism
PAPER FEED AND REGISTRATION 8.4 REGISTRATION DRIVE MECHANISM Through the timing belt [A], rotation from the main motor [B] is transmitted to the registration clutch [C]. When the registration clutch activates, the main motor drive is transmitted to the lower registration roller [D], then to the upper registration roller [E].
Page 193: Paper Transport And Image Fusing
PAPER TRANSPORT AND IMAGE FUSING Rev. 1/97 9. PAPER TRANSPORT AND IMAGE FUSING 9.1 PAPER TRANSPORT UNIT 9.1.1 Drive Mechanism The paper transport, fusing, and paper exit mechanisms are driven by the main motor [A]. Drive from the main motor is transmitted to the transport drive gear [B], the fusing roller drive gear [C], then to the paper exit drive gear [D] via idler gears.
Page 194: Fusing Unit Overview
Rev. 11/96 PAPER TRANSPORT AND IMAGE FUSING 9.2 FUSING UNIT OVERVIEW 1. Cleaning Blade 12. Pressure Roller Lamp 2. Cleaning Roller Oil Pan 13. Pressure Roller 3. Junction Gate Solenoid 14. Fusing Thermistor 4. Exit Roller 15. Hot (Fusing) Roller 5.
Page 195: Fusing Unit
PAPER TRANSPORT AND IMAGE FUSING 9.3 FUSING UNIT 9.3.1 Fusing Temperature Control There is a single fusing lamp in both the hot and pressure rollers (the hot roller lamp is 670W, and the pressure roller lamp is 400W). To control fusing temperature, thermistors [A] detect the temperature at each roller.
Page 196: Fusing Pressure Mechanism
PAPER TRANSPORT AND IMAGE FUSING 9.3.2 Fusing Pressure Mechanism The pressure roller [A] is pressed up against the hot roller [B] by a pressure bracket [C]. The hot and pressure rollers are silicone type rollers for improved paper separation. The pressure screw [D] is paint-locked to prevent it from loosening during transportation and storage.
Page 197: Oil Supply Mechanism
PAPER TRANSPORT AND IMAGE FUSING 9.3.3 Oil Supply Mechanism Silicone oil is applied to the hot roller to help prevent toner and paper from sticking to the hot roller, to reduce paper curl, improve hot roller durability, and to help in roller cleaning. A small pump with a one-way valve moves the oil from the oil tank [A] to the oil supply pad [B].
Page 198: Cleaning Mechanism
PAPER TRANSPORT AND IMAGE FUSING 9.3.4 Cleaning Mechanism The hot roller cleaning roller [A], which is always in contact with hot roller, collects toner and paper dust adhering to the surface of the hot roller [B]. The surface of the cleaning roller is coated with teflon. The collected matter is scraped off by a stainless steel blade [C], and goes to the cleaning roller oil pan [D].
Page 199: Fusing Drive Release Mechanism
PAPER TRANSPORT AND IMAGE FUSING 9.3.5 Fusing Drive Release Mechanism The fusing unit drive release mechanism automatically disengages the fusing unit drive gear [A] when the front door is opened. When the front door is opened, the fusing knob [C] is pushed outwards (white arrow inset) by the spring joints [B] in the fusing drive shaft.
Page 200: Junction Gate And Paper Exit
PAPER TRANSPORT AND IMAGE FUSING 9.4 JUNCTION GATE AND PAPER EXIT 9.4.1 Paper Exit After fusing, the exit roller supports the paper exiting. The exit roller improves paper stacking. 2-131 A166/A187/A189...
Page 201: Junction Gate Mechanism (A187/A189 Copiers Only)
PAPER TRANSPORT AND IMAGE FUSING 9.4.2 Junction Gate Mechanism (A187/A189 copiers only) To the duplex unit To the copy tray The junction gate [A] changes the direction of the paper coming out of the fusing unit to the copy tray or to the duplex unit. The junction gate is controlled by switching the junction gate solenoid [B].
Page 202: Paper Exit Door (A187/A189 Copiers Only)
PAPER TRANSPORT AND IMAGE FUSING 9.4.3 Paper Exit Door (A187/A189 copiers only) To remove misfed paper in the duplex unit easily, the paper exit door [A] of the duplex machine can be opened. When this door is opened, the duplex transport rollers [B] are released.
Page 203: Duplex Unit
DUPLEX UNIT 10. DUPLEX UNIT 10.1 OVERVIEW To the From the Fusing Unit Registration Rollers 1. End Fence 8. Vertical Transport Roller 2. End Fence Jogger H.P. Sensor 9. Paper Feed Roller 3. Side Fence Jogger 10. Duplex Turn Sensor 4.
Page 204: Duplex Unit Mechanisms (A187/A189 Copiers Only)
DUPLEX UNIT 10.2 DUPLEX UNIT MECHANISMS (A187/A189 copiers only) 10.2.1 Drive Mechanism All rollers in the duplex tray are driven by the duplex feed motor [A] through a series of gears and a timing belt [B]. Helical gears are used to reduce noise. The duplex feed motor also drives the duplex bottom plate up and down.
Page 205: Duplex Paper Path
DUPLEX UNIT 10.2.2 Duplex Paper Path The duplex feed motor is a stepper motor. The direction that the motor turns depends on whether the duplex unit is stacking or feeding. 1. Duplex Stacking Paper enters the duplex unit through the entrance sensor [A], the duplex turn sensor [B], the paper feed roller [C], and the separation roller [D].
Page 206: Duplex Entrance To Duplex Tray
DUPLEX UNIT 10.2.3 Duplex Entrance To Duplex Tray The duplex feed motor [A] starts turning after the leading edge of the paper activates the fusing exit sensor. This motor drives the duplex feed rollers [B] and the duplex entrance rollers [C]. The copy paper from the junction gate section is directed to the duplex tray through these rollers.
Page 207: Jogger Mechanism
DUPLEX UNIT 10.2.4 Jogger Mechanism There are two motors for driving the fences. The side jogger fences are driven by the side fence jogger motor [A]. The end jogger fence is driven by the end fence jogger motor [B]. Using two separate motors for the side and end fence allows the duplex tray to handle all paper sizes from A3/11"...
Page 208: Paper Feed From The Duplex Tray
DUPLEX UNIT 10.2.5 Paper Feed from the Duplex Tray While the first side is being copied, the duplex feed motor [A] is rotating clockwise and the cam clutch gear [B] is rotating counter-clockwise (see the above drawing). Then all copies are stacked in the duplex tray unit. After the first side copies have been made, the duplex feed motor [A] changes direction, and the cam clutch gear [B] rotates clockwise.
Page 209: Paper Feed System
DUPLEX UNIT 10.2.6 Paper Feed System While paper is being stacked in the duplex tray, the paper flatteners [A] correct curl at the leading edge of the paper. After all the paper has been stacked in the duplex tray, the jogger fences square the paper stack and the duplex feed motor rotates counter-clockwise briefly to prepare to feed the paper from the duplex tray.
Page 210: System Configuration
SYSTEM CONFIGURATION 11. SYSTEM CONFIGURATION 11.1 BLOCK DIAGRAM This machine has three independent modules: Scanner Unit, Printer Unit, and System Control Unit. The SCU board controls the scanner unit and printer unit to manage the whole machine system. The SCU for the edit machine is a different board from that of the basic machine.
Page 211: Command Sequence
SYSTEM CONFIGURATION 11.2 COMMAND SEQUENCE The machine sends commands to control each module using an interface bus. Each unit is connected with a daisy chain connection. Image Data Transmission Printer Scanner S C U Main Board IPU Board 11.2.1 Normal Copy Mode 1.
Page 212: Edit Mode
SYSTEM CONFIGURATION 11.2.2 Edit Mode The process for copying is the same but the image data route for the display editor is different from normal copy mode. 1. The SCU detects the edit command from the operation panel. 2. The SCU sends the scan command and requests the scanner unit for image data to display.
Page 214 INSTALLATION PROCEDURE...
Page 216: Installation Requirements
INSTALLATION REQUIREMENTS 1. INSTALLATION REQUIREMENTS 1.1 DIMENSIONS (1) Copier + Platen Cover Basic machine: 620 mm (W1) x 700 mm (D) x 632 mm (H1) Edit machine: 620 mm (W1) x 750 mm (D) x 632 mm (H1) (2) Copier + Platen Cover + Paper Feed Bank Basic machine: 620 mm (W1) x 700 mm (D) x 1010 mm (H2) Edit machine: 620 mm (W1) x 750 mm (D) x 1010 mm (H2)
Page 217: Environment
INSTALLATION REQUIREMENTS 1.2 ENVIRONMENT To ensure the optimum copy quality, the following environmental requirements need to be observed. When installing this copier at the customer site, make sure that the location meets the following requirements. 1.2.1 Environmental Requirements 1. Avoid an area which is exposed to direct sunlight or is excessively illuminated (the illumination should not exceed 2000 lux).
Page 218 INSTALLATION REQUIREMENTS CAUTION 1. Do not install the machine in a very humid or dusty area. 2. Do not install the machine on a structurally weak or inclined floor. 3. Completely pull out and hold all four handles when moving the machine.
Page 219: Minimum Space Requirements
INSTALLATION REQUIREMENTS 1.2.2 Minimum Space Requirements Provide clearance for the copier, as shown below. If one or more options (such as the ADF or Sorter Stapler) are added to the copier, the specified clearance must be maintained around the entire system. 10 cm or more 37 cm or 10 cm or...
Page 220: Power Requirements
INSTALLATION REQUIREMENTS 1.2.3 Power Requirements WARNING 1. Install the machine as close to the outlet as possible. Firmly plug in the machine after installation. 2. Avoid multi-wiring. 3. The power cord should be placed where it cannot be stepped on or flattened by the machine.
Page 221 COPIER INSTALLATION 2. COPIER INSTALLATION 2.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box with the following list: Description Q’ty 1. Paper Size Decal ............... 1 2. Operating Instructions (not -27 machines) ......1 3. New Equipment Condition Report (-17, -27, -29 machines only) .............
Page 222: Copier Installation
COPIER INSTALLATION 2.2 COPIER INSTALLATION PROCEDURE NOTE: If the copier is to be installed onto a paper tray unit, follow the paper tray unit install procedure prior to installing the copier. Keep all shipping retainers after installing the machine. They must be re-used if the machine is moved to another location in the future.
Page 223 COPIER INSTALLATION Installation Procedure of Language ROM • NOTE: The following procedure given by sub-steps numbered (1) through (6) are required only for A166-26,27, A187-26,27 and A189-26,27 copiers. • These procedure should be done between step 3. and 4. of the copier installation.
Page 224 COPIER INSTALLATION (5) -For A166-26,27, A187-26,27 copiers- Turn the operation panel [a] upside-down and install the desired language ROM [b] into the socket numbered IC40 on the SCU board. -For A189-26, 27 copiers- Turn the operation panel [c] upside-down and install the desired language ROMs [d] into the sockets numbered IC6,7,8 and 9 on the SCU board in accordance with the IC-number label on each IC.
Page 225 COPIER INSTALLATION 4. A187 and A189 copiers only: Close the front cover and Pull out the duplex tray [A] , remove the strips of tape, lift transport lever 21 and remove the sheet of paper [B]. 5. A187 and A189 copiers only: Lift the 22 lever and open the lower duplex guide plate [C], remove the sheet of paper [D].
Page 226 COPIER INSTALLATION 6. Remove the chain [A] and two pins [B] (as shown in illustration above). Then remove the front cover. 7. Remove the transfer belt fan [C] (1 connector and 2 tabs). 8. "Tap" on the toner collection duct joints [D] and [E] once or twice. This prevents toner from scattering when removing the used toner tank.
Page 227 COPIER INSTALLATION 9. Remove the used toner tank [A] (1 connector and 1 plastic strip), while turning up the opening [B] of the duct to prevent the scattering of toner. Then turn down the transport release lever [C]. 10. Lift the "handle" retainer [D], then remove the handle [E] from the back side of the inner cover.
Page 228 COPIER INSTALLATION 12. Remove the screws and connector as shown above (1 long screw, 1 screw, 1 cable clamp, and 1 connector) and slowly pull out the development unit [A] until it is stopped by the chain [B] 13. Remove the revolver stopper [C] (1 screw). NOTE: Keep this shipping retainer after removing it.
Page 229 COPIER INSTALLATION 14. Remove the chain hook [A] from the development unit frame [B]. Then attach the chain hook to the magnet catch [C]. NOTE: The purpose of attaching the chain hook to the magnet catch is to help avoid forgetting to reinstall the chain hook when the development unit is reinstalled.
Page 230 COPIER INSTALLATION Development unit placement position Developer installation position 16. Place the development unit on a clean sheet of paper as shown above (development unit placement position). NOTE: Be sure to use a clean sheet of paper or floor mat when placing the development unit on the floor.
Page 231 COPIER INSTALLATION 20. Remove the following outer covers. (1) Right side front cover [A] (1 screw) (2) Right side cover [B] (open the by-pass feed table [C], then remove 4 screws) 21. Remove the developer collection bottle/supply funnel ass’y [D] from its storage location (1 screw).
Page 232 COPIER INSTALLATION Developer installation position 22. Slide the developer supply funnel [A] from the developer collection bottle [B]. 23. Turn the development unit [C] to the developer installation position as shown. 24. Remove the developer cover [D] (1 screw [E]). 25.
Page 233 COPIER INSTALLATION Developer installation position 26. Attach the development roller rotation handle [A] to the development roller gear [B]. 27. Pour one pack of developer [C] evenly (either black, cyan, magenta, or yellow developer) through the development supply funnel [D]. NOTE: Before pouring the developer, be sure to check that the color of the developer matches the color of the decal [E] beside the opening for the developer.
Page 234 COPIER INSTALLATION Developer installation position 28. Rotate the development roller gear with the development roller rotation handle [A] until the developer is spread evenly on the development roller surface. NOTE: Rotate the development roller rotation handle only in the direction shown in the diagram above.
Page 235 COPIER INSTALLATION Development unit placement position 31. Raise the development unit to the development unit placement position. 32. Check that the entrance side seals [D] of the color’s development roller are in the correct position as shown in the diagram. If they are not positioned correctly, put them in the correct position by rotating the development roller rotation handle [E] in the direction shown in the diagram.
Page 236 COPIER INSTALLATION 36. Remove the cleaning blade release wedge [A] of the transfer belt unit while pushing up the pressure release lever [B]. 37. Remove the transfer belt retainer [C] from the transfer belt stay [D]. NOTE: Keep the cleaning blade release wedge and the transfer belt retainer (along with the retainer’s securing screw) after installing the machine.
Page 237 COPIER INSTALLATION 43. Remove the transfer belt unit [A]. Then remove the paper and strip of tape [B] attached to the transfer belt. NOTE: 1) When removing the transfer belt unit, be sure to hold the chain [C] with your left hand and hold the bottom bracket [D] with your right hand, as shown.
Page 238 COPIER INSTALLATION [F] [C] [D] 45. Remove the charge corona unit [A] (1 screw). 46. Remove the following parts in the following order: Drum stay screw [B] ID sensor shield plate screw [C]. Knob screw [D]. NOTE: When removing the drum stay, be sure to remove the drum stay screw before the knob screw.
Page 239 COPIER INSTALLATION Rev. 1/97 49. Place the drum unit on a clean sheet of paper or floor mat, as shown above. Turn it over in the direction shown. Then remove the two screws [A] and open the drum unit, as shown. NOTE: 1) Use a clean sheet of paper or floor mat when placing the drum unit on the floor.
Page 240 COPIER INSTALLATION 52. Reinstall the following parts using the reverse procedure of their removal: • Drum stay (Install in the following order, to avoid damaging the drum stay: 1 drum securing spring, [LD shield plate: 220/240 V machine only], 1 connector, the drum stay, 1 knob screw, 1 ID sensor shield plate screw, 1 drum stay screw, and 1 final 2 connectors).
Page 241 COPIER INSTALLATION 56. Rotate the revolver, while moving the toner supply motor unit [A] slightly to the right, until the development unit bend plate [B] aligns with the toner catch plate edge [C]. It does not matter which color is in position. NOTE: The above step ensures the development unit is not misaligned during installation.
Page 242 COPIER INSTALLATION 58. Remove the chain hook [A] from the magnet catch [B], and hook it on the frame [C] as shown. 59. Slowly insert the development unit completely into the copier while making sure that the chain is not caught by the development unit. Then secure the development unit to the copier front frame (1 connector, 1 harness clamp, 1 short screw, and 1 long screw).
Page 243 COPIER INSTALLATION 62. Rotate the revolver until the Bk toner hopper [A] is positioned as shown. Remove the shutter [B] from the hopper. Shake the black toner cartridge 10~15 times and install the Bk toner cartridge [C] completely into the development unit.
Page 244 Rev. 1/97 COPIER INSTALLATION NOTE: The Y toner cartridge should be installed after the Bk cartridge. When the Bk toner cartridge is installed, the opening for the Y toner cartridge [H] faces up. 64. Rotate the revolver until the opening for the C toner cartridge faces up and repeat the preceding procedure.
Page 245 COPIER INSTALLATION 68. Pull the fusing unit [A] halfway out. Remove the left fusing cover [B] and open the oil tank cap [C]. 69. Pour in the silicone oil [D]. NOTE: Never fill the silicone oil tank over the MAX line. Otherwise, the silicone oil may overflow.
Page 246 COPIER INSTALLATION 72. Plug in the power cord and turn on the main switch. 73. A166 copier only: Select the paper size for the 1st tray by sliding the paper size slider [A]. Load paper (A4/8 " X11" sideways or A3/8 "...
Page 247 COPIER INSTALLATION Developer Agitation for All Colors Start M a i n S W O n Enter the SP mode, as follows: 1. Press the Clear Modes key. 2. Enter "107" with the no. keys. 3. Hold down the Clear/Stop key for more than 3 seconds.
Page 248 COPIER INSTALLATION NOTE: 1. The covers must be closed before turning on the main switch because the initial process control self check must be performed (this takes about 5 minutes). 2. Displays the process control self check result by a code number. 3.
Page 249 Rev. 11/96 COPIER INSTALLATION Copy image registration test pattern 76. Check whether the copy image registration is within the specification or not as shown in the following procedure. (1) Enter SP5-955 and select pattern number 25. (2) Press the Interrupt key. Select the A3/11" x 17" or A4/8 "...
Page 250 COPIER INSTALLATION 77. Perform the ACC (Auto Color Calibration) procedure in section 5 of the service manual. 78. Input the current date and time with SP5-302-1. EXAMPLE: Date Format: YYYYMMDDhhmmd 1996031200301 1996 = year 03 = month 12 = day of month 00 = hour (00 - 23) 30 = minute (00 - 59) 1 = day of week (Sun.
Page 251: Installation Procedure Flowchart
INSTALLATION PROCEDURE FLOWCHART 3. INSTALLATION PROCEDURE FLOWCHART CAUTION: Refer to the copier installation procedure when performing the steps shown below. Start Installation Requirements C h e c k Accessory Check Shipping Tape Remove the inner cover. Removal Outer Cover/Inner 1. Transfer Belt Fan Cover Removal 2.
Page 252 INSTALLATION PROCEDURE FLOWCHART Remove the following parts: 1. Charge Corona Unit 2. Drum Stay Drum Unit 3. Drum Securing Spring R e m o v a l 4. Drum Protective Sheet 5. Drum Cleaning Blade Release Wedge Drum Unit Reinstallation Transfer Belt Unit Reinstallation Dev.
Page 253 INSTALLATION PROCEDURE FLOWCHART Pouring in the Fusing Unit Silicone Oil Y E S Install the A R D F ? Platen Cover ARDF Installation Installation P o w e r O n Y E S A 1 8 7 o r A 1 8 9 C o p i e r ? Copier Paper Tray Paper Size...
Page 254 INSTALLATION PROCEDURE FLOWCHART Install a Paper Tray Unit? Paper Tray Unit Installation Paper Size Selection for the UP3-3 Paper Tray Unit Developer See the flow Agitation for All chart on page Colors 3-30 3-32 Copy Image Registration SP5-955:25 Check Press the Auto Color "Image Calibration...
Page 255: Paper Tray Unit (A549/A550) Installation
PAPER TRAY UNIT (A549/A550) INSTALLATION 4. PAPER TRAY UNIT (A549/A550) INSTALLATION 4.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box with the following list: 1. Right Support Bracket ..............1 2. Left Support Bracket................1 3. Joint Bracket ..................1 4.
Page 256: Installation Procedure
PAPER TRAY UNIT (A549/A550) INSTALLATION 4.2 INSTALLATION PROCEDURE CAUTION Unplug the copier power cord before starting the following procedure. NOTE: Keep the shipping retainers after installing the machine. They will be reused if the machine is transported to another location. Proper reinstallation of the shipping retainers is required in order to avoid any transport damage.
Page 257 PAPER TRAY UNIT (A549/A550) INSTALLATION For Copiers with an LCT: Do not lift the copier by holding the LCT unit. 3. Set the copier [B] on the paper tray unit [C]. Align the 2 pins [D] on the paper tray unit with the holes in the base plate of the copier. 4.
Page 258: Tray Heater (Option)
PAPER TRAY UNIT (A549/A550) INSTALLATION 4.3 TRAY HEATER (OPTION) - Two-tray type - - Three-tray type - 1. Remove the rear cover [A]. 2. Two-tray type: Remove the second paper tray [B] (4 screws) and the lower front cover [C] (2 screws). Three-tray type: Remove the second and third paper feed trays [D] (4 screws each).
Page 259: Accessory Check
ARDF (A548) INSTALLTION 5. ARDF (A548) INSTALLTION 5.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box with the following list: 1. New Equipment Condition Report ........1 2. Installation Procedure............1 3. Stud Screw ................. 2 4.
Page 260: Installation Procedure
ARDF (A548) INSTALLTION 5.2 INSTALLATION PROCEDURE [E] [D] CAUTION Unplug the copier before starting the following procedure. 1. Remove the strips of tape [A]. 2. Attach the sponge retainer [B] to the top cover of the copier as shown. 3. Tighten the two stud screws [C]. 4.
Page 261: Bin Sorter (A555) Installation
10-BIN SORTER (A555) INSTALLATION 6. 10-BIN SORTER (A555) INSTALLATION 6.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box with the following list: 1. Misfeed Removal Decal............1 2. Staple Position Decal ............1 3. Chain .................. 1 4.
Page 262: Installation Procedure
10-BIN SORTER (A555) INSTALLATION 6.2 INSTALLATION PROCEDURE Incorrect Lifting Method CAUTION Unplug the copier power cord before starting the following procedure. Do not lift the sorter stapler by holding the entrance guide [A]. Otherwise, the resulting damage may cause paper jams to occur. 1.
Page 263 10-BIN SORTER (A555) INSTALLATION 3. Remove the cover caps [A] by carefully prying (or pulling) the caps from the cover . 4. Remove the mounting frame [B] from the sorter stapler by releasing the lever [C]. 5. Remove the exit paper guide [D] from the mounting frame [B]. 6.
Page 264 10-BIN SORTER (A555) INSTALLATION Incorrect Lifting Method 6. Install the sorter stapler [A] on the frame [1 M4 x 8 screw]. NOTE: Do not lift the sorter stapler by holding the entrance guide [B] when installing it. 7. Tighten the M4 x 8 screw [C]. CAUTION If you do not insert and tighten this screw, the sorter stapler may fall from the copier.
Page 265 10-BIN SORTER (A555) INSTALLATION 11. Open the front door [A] of the sorter stapler and swing out the staple unit [B] . 12. Remove the green plastic clip [C] from the staple cartridge and correct the position of the staple sheet [D]. Make it flush with the other sheets in the cartridge.
Page 266: Film Projector Table (A579) Installation
FILM PROJECTOR TABLE (A579) INSTALLATION 7. FILM PROJECTOR TABLE (A579) INSTALLATION 1. Remove the following outer covers: (1) Upper right cover (2) Upper rear cover 2. Remove the two plastic caps [A] from the upper right cover [B] with diagonal cutters (or other suitable cutters). 3.
Page 267 Rev. 11/96 FILM PROJECTOR TABLE (A579) INSTALLATION ⇒ 5. Reinstall the following outer covers: (1) Upper right cover (2) Upper rear cover 6. Mount the two cantilevers [F] and [G] into the openings [I]. 7. Fasten the cantilever [F] ([J]: 1 M4 x 13 screw and 1 spacer [G]). 8.
Page 268: Film Projector Unit (A718) Installation
FILM PROJECTOR UNIT (A718) INSTALLATION 8. FILM PROJECTOR UNIT (A718) INSTALLATION 8.1 ACCESSORY CHECK Make sure that each accessory listed in the following table is in the box. Also check the condition of each item. 1. Mirror Unit ................1 2.
Page 269: Installation Procedure
FILM PROJECTOR UNIT (A718) INSTALLATION 8.2 INSTALLATION PROCEDURE CAUTION Unplug the copier power cord before starting the following procedure. NOTE: The film projector table (A579) must be installed before starting the following procedure. (Refer to the Film Projector Table Installation Procedure preceeding this section.) 1.
Page 270 FILM PROJECTOR UNIT (A718) INSTALLATION 3. Set the four spacers [A] at the four corners (in the indents provided). 4. Place the projector unit [B] on the table by aligning the holes in the projector base plate with the positioning pins [C]. Then secure the projector unit with four M4 x 12 screws.
Page 271 FILM PROJECTOR UNIT (A718) INSTALLATION 5. Remove the lamp cover [A] (1 screw) and open the reflector cover [B]. Then, plug the projection lamp [C] into the socket. Close the reflector cover. NOTE: The projection lamp should be fully inserted. 6.
Page 272 FILM PROJECTOR UNIT (A718) INSTALLATION 8. Place the film position sheet [A] on the exposure glass, aligning it at the rear left corner. 9. Place the mirror unit [B] on the exposure glass by aligning the holes with the positioning pins [C] on the lens cover. 3-57 A166/A187/A189...
Page 273 FILM PROJECTOR UNIT (A718) INSTALLATION 10. Insert the film strip holder [A] into the film projector unit at the base film setting position. NOTE: Push the film strip holder gently to confirm that the film strip holder has been completely inserted. 11.
Page 274 FILM PROJECTOR UNIT (A718) INSTALLATION 17. Adjust the angle [A] of the mirror unit as follows: 1) Turn on the copier main switch and wait for the ready condition. 2) Open the lens cover and position the mirror unit on the exposure glass. 3) Set the correction filter [B] (for positive film) in the filter slot.
Page 275 FILM PROJECTOR UNIT (A718) INSTALLATION 8-2) When the trailing part of the image is dark (as shown in [A]). a) Move the front and rear arm guides [B] to the right so that the mirror angle is reduced (2 screws each). NOTE: Position the arm guides in the same location at the front and rear, using the ruled marks.
Page 276: Others
OTHERS 9. OTHERS 9.1 KEY COUNTER 9.1.1 Key Counter Installation 1. Remove the right front cover [A] (1 screw). 2. Cut the key counter cover [B] out of the right front cover with diagonal cutters (or other suitable cutters). 3. Couple the connector [C] with the key counter connector [D]. 4.
Page 277: Setting Up The Sp Modes For The Key Counter
OTHERS 9.1.2 Setting up the SP Modes for the Key Counter SP5-113: Key Card/Coin Lock (Key Card /Key Counter/Coin Lock Selection) This mode can be used to select the key counter mode. 0: None (Default), 1: Key card, 2: Key counter, 3: Coin Lock NOTE: After installing the key counter, this SP mode must be changed to 2.
Page 278: Mounting The Packing Retainers For Moving The Copier
OTHERS 9.2 MOUNTING THE PACKING RETAINERS FOR MOVING THE COPIER Before re-transporting the copier after installation, reinstall the following packing retainers which were removed at installation (see section 3. COPIER INSTALLATION PROCEDURE). NOTE: If moving the machine for only a short distance after installation, it is only necessary to mount only the revolver stopper (step 5).
Page 279 OTHERS 3. Install the transfer belt release wedges [A] (1 screw for each). 4. Install the transfer belt retainer [B] (1 screw). 5. Install the revolver stopper [C] (1 screw). A166/A187/A189 3-64...
Page 280: Service Tables
SERVICE TABLES...
Page 282: Service Program Modes
Rev. 11/96 SERVICE PROGRAM MODES 1. SERVICE PROGRAM MODES 1.1 SP TABLE See Appendix 2. 1.2 SERVICE PROGRAM MODE OPERATION The service program (SP) mode is used to check electrical data, change modes, and adjust values. Service Program Access Procedure →...
Page 283: Sp Mode Additional Notes
SERVICE PROGRAM MODES 1.3 SP MODE ADDITIONAL NOTES 1.3.1 SP 3-973 Process Control Interval Self Check 1. Up to 5000 copies after replacing the developer, do not change the setting from the default (150). 2. If you input a number larger than 150, it might lead to a low toner concentration in the development unit after copying an original with a high image density ratio.
Page 284: Sp5-501 Pm Counter
Rev. 1/97 SERVICE PROGRAM MODES Code Paper Size Code Paper size 45~127 Not Used 60 mm x 45 mm Detection Error 60 mm x 60 mm A0 Lengthwise 60 mm x 70 mm A1 Lengthwise 60 mm x 80 mm A2 Lengthwise 60 mm x 90 mm A3 Lengthwise...
Page 285: Sp5-802-4 System Free Run
SERVICE PROGRAM MODES Rev. 1/97 1.3.5 SP5-802-4 System Free Run Running Condition 1. Wait for the fusing unit to warm up. 2. The free run can be only performed: • With paper in the selected tray and will simulate copying and scanning with A4 sideways, DLT or letter sideways paper Process 1.
Page 286 SERVICE PROGRAM MODES SP No. Status Display Sensor/Switch/Signal Main Motor Detect Detect Syncronization Signal (Motor IN:Main Mtr Lck Detect Detection Rotation) Rotation) Drum Motor Detect Detect Syncronization Signal IN:Drum Mtr Lck Detect (Motor Detection Rotation) Rotation Development Drive Detect Motor Syncronization Detect (Motor IN:Dev Dr Mtr Lck Detect...
Page 287 SERVICE PROGRAM MODES * SP5-803-2 (Paper Tray Size Check) Displays a code indicating paper size as follows: Code Metric machine Inch machine Displayed 11" x 17" 8.5" x 14" 8.5" x 11" 11" x 8.5" 8.5" x 5.5" F4 (8.5" x 13") 8"...
Page 288: Sp5-804 Output Check
SERVICE PROGRAM MODES 1.3.7 SP5-804 Output Check To activate the electrical component, press the start key. To stop the electrical component, press the clear modes key. NOTE: After pressing the start key, the machine displays "Result =01 (#)". After that, press the key, and the display goes back to the menu display.
Page 289 SERVICE PROGRAM MODES SP No. Display Electrical Component/Mode 29 OUT:Optics Cooling Fan 1 Optics Cooling Fan 1 30 OUT:Optics Cooling Fan 2 Optics Cooling Fan 2 32 OUT:Exposure Lamp Exposure Lamp 33 OUT:Scanner Motor Crnt Scanner Motor Current 34 OUT:Fusing Exhaust Fan 1 Fusing Exhaust Fan 1 35 OUT:Fusing Exhaust Fan 2 Fusing Exhaust Fan 2...
Page 290: Sp5-955 Printer Test Pattern
SERVICE PROGRAM MODES 1.3.8 SP5-955 Printer Test Pattern No Pattern (normal operating mode) 1 dot vertical line 2 dot vertical line 1 dot horizontal line 2 dot horizontal line 1 dot/line grid pattern 2 dot/line grid pattern 2 x 2 dot pattern 4 x 4 dot pattern Full dot pattern Print margin pattern...
Page 291: Sp6-107 Sorter Free Run
SERVICE PROGRAM MODES 1.3.11 SP6-107 Sorter Free Run Stop System free run 1 (2 sets for 2 bins and A4 sideways) Continuous free run (for 2 bins and B5 lengthwise) System free run 2 (2 sets for 10 bins and A4 sideways) Sort free run Stapler free run (without staple) 1.3.12 SP6-901 Optional Paper Bank Input Check.
Page 292 SERVICE PROGRAM MODES – SP6-901-1 to 3– (Check Paper Size) Metric version Inch version A4 sideways A4 sideways A4 lengthwise A4 lengthwise B5 sideways – B5 lengthwise – A5 sideways A5 sideways 11" x 17" 11" x 17" – " x 14" "...
Page 293: Sp6-902 Output Check For The Optional Paper Bank Unit
SERVICE PROGRAM MODES – SP6-901-8 to 10 – Input Check Paper Tray Unit Displayed Tray Upper Limit SP6-901 - Tray Set Sensor Number Sensor 8 = Tray Bank 1 OFF (blocked) OFF (Not set) 9 = Tray Bank 2 OFF (blocked) ON (Set) 10 = Tray Bank 3 ON (un-blocked)
Page 294: Sp6-903 Sorter Input Check
SERVICE PROGRAM MODES 1.3.14 SP6-903 Sorter Input Check SP No. Status Display Sensor/Switch /Signal 1st 2nd 3rd 6 903 1 IN:No(10)/Entrance(3) Not used – – 6 903 2 IN:No(10)/1st Bin(3) Not used – – IN:Entry(10)/2nd Bin(3) Sorter Entrance Sensor Paper 6 903 3 No Paper present...
Page 295: Sp7-507-1 Paper Jam (Last 10)
SERVICE PROGRAM MODES 1.3.16 SP7-507-1 Paper Jam (Last 10) SP7-507-1 displays information about the last paper jam. Pressing the "+" zoom key displays up to the last ten previous paper jams. [A]: Jam Location Code Location Cause Indication No Jam Recovery –...
Page 296 SERVICE PROGRAM MODES [B]: Jam Paper Size Paper Size Paper Size No Paper Cannot recognize the paper size. A0 Sideways A0 Lengthwise A1 Sideways A1 Lengthwise A2 Sideways A2 Lengthwise A3 Sideways A3 Lengthwise A4 Sideways A4 Lengthwise A5 Sideways A5 Lengthwise A6 Sideways A6 Lengthwise...
Page 297: Sp7-507-2 Original Jam (Last 10)
SERVICE PROGRAM MODES 1.3.17 SP7-507-2 Original Jam (Last 10) SP7-507-2 displays information about the last original jam. Pressing the "+" zoom key displays up to the last ten previous paper jams. [A]: Code Location Cause Registration Sensor The original passed this sensor. Feed-out Sensor The original passed this sensor.
Page 298: User Program Modes
USER PROGRAM MODES 2. USER PROGRAM MODES 2.1 USER PROGRAM MODE OPERATION The user program (UP) mode is used to change modes and adjust values. User Program Access Procedure → 1. Press the clear modes key. 2. Hold down the clear/stop key for more than 3 seconds until the user program (UP) mode menu appears on the display (LCD).
Page 299: Up Mode Table
USER PROGRAM MODES 2.2 UP MODE TABLE UP-1 Default Image Settings No.: Choices (range) and Function Description specification method name 1: Default Changes the default photo type. Printed photo type Glossy (Photo Copied mode) 2: Default The “1: Default photo type (Photo mode)” is photo type specified when the Photo mode is selected with (Auto...
Page 300 USER PROGRAM MODES No.: Choices (range) and Function Description specification method name 6: Auto Color When in Auto Color Select mode, you can specify Select the level at which the copier identifies whether an Sensitivity original is “Color” or “Black.” (Auto color selection) The copier easily identifies black originals when...
Page 301 USER PROGRAM MODES No.: Choices (range) and Function Description specification method name 4: Auto With the default setting, the first page of copies Empty will be delivered with one side blank when making Duplex two-sided copies from an odd number of Tray one-sided originals using the optional document feeder.
Page 302 USER PROGRAM MODES 2: Paper This function selects the default paper tray. This Select from trays 1 to 4. Tray function also changes the paper tray which is Tray 1 Priority selected preferentially when the Auto Paper Select Tray 2 mode is specified.
Page 303 USER PROGRAM MODES No.: Function Description Choices (range) and specification method name 3: Paper Specifies the size of Select from trays 1 to 4. Size paper set in the optional For the optional paper tray unit Selection paper tray unit. When using the optional paper tray Select the paper...
Page 304 USER PROGRAM MODES No.: Function Description Choices (range) and specification method name 5:Remarked Sets the guidance paper display to display the paper type in each paper tray. When you specify a Select from trays 1 to 4. value for this function, See "Feed station priority selection."...
Page 305 USER PROGRAM MODES UP-4 Basic User Settings No.: Function Choices (range) and Description name specification method 1: Auto Paper Specifies whether Auto Paper Select mode is Selection selected as a default 2: Color Mode Changes the default color mode. Auto Selection Full Color 3: Default...
Page 306 USER PROGRAM MODES UP-5 Operation Mode Settings No.: Choices (range) and Description Function specification method name 1: Auto Changes the time after which the copier resets itself. Reset You can also turn off this function. Enter a value in the range of 10 to 900 seconds.
Page 307 USER PROGRAM MODES UP-6 User Code Settings No.: Choices (range) and Description Function specification method name 1: User Specifies whether to manage the copier with user Code codes. Mode To enter the accounting mode, follow the (Set procedure shown below. account- Enter “1”...
Page 308 USER PROGRAM MODES No.: Choices (range) and Function Description specification method name 3: Input Registers user code numbers (6 digits or less). Enter a code number User in the range of 0 to Code 999999. You can (User register up to 20 code set) codes.
Page 309 USER PROGRAM MODES No.: Choices (range) and Function Description specification method name • 7: Print You can print the contents (number of copies Press the Start key to print the counter data. Counter made) of all user code counters. This data is printed on A4 "...
Page 310 USER PROGRAM MODES UP-7 ADF/Sorter Settings No.: Choices (range) and Description Function specification method name 1: Sorter: You can set the copier to disable the Sort/Stack Full and Staple functions when you make copies in the Color Full Color Copy or Auto Color Select mode. Sorting 2: ADF: Adjusts the optional document feeder so that thin...
Page 311: Tp/Fuse/Led/Sw
TP/FUSE/LED/SW 3. TP/FUSE/LED/SW 3.1 TEST POINT Main Control Board Stand-by Signal Description Note TP201 Ground Received serial signal TP202 SS_RXD 0 to 5.0 V from the sorter stapler Temparature sensor TP203 2.0 to 4.0 V output TP204 Humidity sensor output 1.0 to4.0 V Feed back data from the When the paper transfer...
Page 312 TP/FUSE/LED/SW Stand-by Signal Description Note TP214 *INT_BLT Belt H.P. sensor output 0 to 5.0 V TP215 FB_DAC Not used Feed back data from the When the paper transfer high voltage supply charge unit (casing) is 2.381 ± applied with –2.5 kV, this board: DDC TP216 FB_DDC...
Page 313 TP/FUSE/LED/SW Stand-by Signal Description Note TP241 MCLK Laser writing clock: Pixel 0 to 5.0 V SCSI controller: DMA TP242 DREQS 0 to 5.0 V Request TP243 Ground TP244 *DBRD SCSI controller: 0 to 5.0 V Active Low TP245 REQ_SC SCSI: *REQ 0 to 5.0 V Active Low TP246 Ground...
Page 314 TP/FUSE/LED/SW I/O Board 1 Stand-by Signal Description Note Temperature sensor If maintaining 0 V or TP251 1.0 to 4.0 output 5 V: NG TP252 Humidity sensor output 1.0 to 4.0 TP253 ANGND Ground Serial Data (for output) If maintaining 0 V or TP254 S_IN 0 to 5.0...
Page 315: Fuse Conditions
TP/FUSE/LED/SW 3.2 FUSE CONDITIONS AC Drive/DC Power Supply Board Rating FUSE Function Condition 220/240 V 115 V FU101 250 V, 6.3 A 125 V, 15 A AC IN LINE If defective, no response. If defective, anti-condensation *FU102 250 V, 1.6 A 250 V, 3.15 A AC STANBY heater does not work.
Page 316: Switches
TP/FUSE/LED/SW 3.4 SWITCHES Scanner IPU Simbol Function Note Scanner free run in ON: Perform SW1-1 normal speed Scanner Motor ON: Motor off, SW1-2 OFF: Motor on Exposure Lamp ON: Lamp off, SW1-3 OFF: Lamp on OpticsCooling Fan ON: Motor off, SW1-4 1 and 2 OFF: Motor on...
Page 317: Regular Pm Table
REGULAR PM TABLE 4. REGULAR PM TABLE Regular PM items: To be performed every 40,000 scans in accordance with the following table. NOTE: To wipe off toner, use a dry cloth. If toner is mixed with alcohol, it solidifies. Symbol Key: C: Clean R: Replace L: Lubricate I: Inspect and adjust * Refer to the "SP Modes Used After Replacement and Cleaning"...
Page 318 REGULAR PM TABLE Interval Regular PM (Scans) Remarks Item 80K 120K 160K 200K Torque limiter DRIVE Main motor Use G40M. drive unit Drum motor Use G40M. drive unit AROUND THE DRUM Drum * Clean with dry cloth. Charge corona Wipe with a dry cloth at wire * every visit.
Page 319 REGULAR PM TABLE Interval Regular PM (Scans) Remarks Item 80K 120K 160K 200K Development Wipe with a dry cloth. roller side seal Visually check. If cracks, warps or breakages are found, replace. Development If cracks, warps or roller seals, breakages are found, development replace.
Page 320 REGULAR PM TABLE Interval Regular PM (Scans) Remarks Item 80K 120K 160K 200K Discharge Clean taking care not to brush bristle up the brush. Exit guide Wipe with a dry cloth. (Paper transfer) Cleaning blade When replacing, apply setting powder (54429101). Cleaning Clean with a dry cloth.
Page 321 REGULAR PM TABLE Interval Regular PM (Scans) Remarks Item 80K 120K 160K 200K Oil supply pad Oil sump Clean with a cloth and wipe with alcohol. Thermistor Clean with a suitable solvent and apply silicone oil over the contact surface. Silicone oil After removing paper dust precipitated in the oil tank...
Page 322 REGULAR PM TABLE OPTIONAL EQUIPMENT Cycle Regular PM Remarks Item ARDF (A548) 80k 160k 240k (Number of originals) Transport belt Wipe with a damp cloth. Separation belt Water Separation roller Wipe with Alcohol. Registration/size/paper Clean with a blower brush. exit sensors PAPER FEED BANK (A549/A550) 120k 240k 360k (Number of copies) Paper feed roller...
Page 323 REGULAR PM TABLE NOTE 1. When replacing the belt, clean each roller, the stays, and the belt H.P. sensor with alcohol. Also, clean the grounding brushes and the belt mark brush with a blower brush. Belt H.P. Sensor Belt Drive Roller Grounding Brush Belt Mark Brush Transfer Belt Tension Roller...
Page 324: Sp Modes Used After Replacement And Cleaning
SP MODES USED AFTER REPLACEMENT AND CLEANING 5. SP MODES USED AFTER REPLACEMENT AND CLEANING The following table shows the necessary SP modes, procedures and priority when the listed items are replaced or cleaned: ∆ : Replacement : Cleaning Priority SP mode Description Devel-...
Page 325 SP MODES USED AFTER REPLACEMENT AND CLEANING 3) Check the amount of toner remaining before developer agitation. If there is insufficient toner, replace the toner cartridge to prevent an agitation error. When you replace the Bk developer only, for the developer agitation procedure, use SP2-225-1 instead of SP2-225-5.
Page 326: Regular Pm Procedure
REGULAR PM PROCEDURE 6. REGULAR PM PROCEDURE 4-45 A166/A187/A189...
Page 327 REGULAR PM PROCEDURE A166/A187/A189 4-46...
Page 328 REGULAR PM PROCEDURE 4-47 A166/A187/A189...
Page 329 REGULAR PM PROCEDURE A166/A187/A189 4-48...
Page 330 REGULAR PM PROCEDURE 4-49 A166/A187/A189...
Page 332: Replacement And Adjustment
REPLACEMENT AND ADJUSTMENT...
Page 334: Exterior
EXTERIOR 1. EXTERIOR 1.1 PLATEN COVER 1. Remove the screws [A]. 2. Slide the platen cover [B] to the right to unlock it. While lifting the hook [C] up, lift the cover up to remove it, as shown. 1.2 FRONT COVER 1.
Page 335: Rear Cover
EXTERIOR 1.3 REAR COVER 1. Remove the rear cover [A] (4 screws). 1.4 EXPOSURE GLASS 1. Remove the left scale [B] (2 screws). 2. Remove the rear scale [C] (3 screws). 3. Remove the upper front cover [D] (2 screws). 4.
Page 336: Upper Covers
EXTERIOR 1.5 UPPER COVERS 1. Remove the right upper bracket [A] (1 screw). 2. Remove the left upper bracket [B] (1 screw). 3. Remove the front upper cover [C] (2 screws). 4. Remove the upper right cover [D] (2 screws). 5.
Page 337: Operation Panel
EXTERIOR 1.6 OPERATION PANEL First, remove the Upper Covers (see procedure 1.5, steps 1-3). 1.6.1 A166/A187 Copiers 1. Loosen the screws [A]. 2. Remove the Operation Panel [B] (2 screws, 3 connectors, and 1 screw with grounding wire). 1.6.2 A189 Copier 1.
Page 338: Right Covers
EXTERIOR 1.7 RIGHT COVERS 1. Remove the right rear cover [A] (2 screws). 2. Open the bypass tray [B]. 3. Remove the right front cover [C] (1 screw and 2 hooks). 4. Remove the right cover [D] (4 screws). 1.8 LEFT COVERS 1.
Page 339: Inner Covers
EXTERIOR 1.9 INNER COVERS 1. While lifting up the hook, remove the inner cover [A] (2 screws, 1 hook). 2. Remove the counter cover [B] (2 screws). 3. Remove the inlet fan cover [C] (1 screw). 1.10 USED TONER TANK 1.
Page 340: Lifting The Scanner Unit
EXTERIOR 1.11 LIFTING THE SCANNER UNIT CAUTION Before beginning this installation procedure, be sure to remove the ARDF. If the scanner unit is opened with the ARDF installed, the machine may fall over. First, remove the Exposure Glass Upper Covers, Operation Panel, Right Covers, and Left Covers (see procedures 1.4, 1.5, 1.6, 1.7, 1.8).
Page 341: Drum Unit
DRUM UNIT 2. DRUM UNIT A166R528.wmf NOTE: Place a mat on the floor to keep the floor clean before performing this procedure. 2.1 DRUM REPLACEMENT 1. Remove the drum unit [A] (see chapter 3. COPIER INSTALLATION PROCEDURE). 2. In the work area, rotate the drum unit into the position as shown. Then remove the 2 screws.
Page 342 DRUM UNIT A166R530.wmf 5. Apply setting powder to the entire drum surface [D]. NOTE: Be sure to apply the setting powder over the entire drum. This prevents the cleaning blade from catching on the drum surface. 6. Rotate the drum forward two or three times to settle the setting powder between the drum surface and cleaning blade.
Page 343: Cleaning Blade Replacement
DRUM UNIT 2.2 CLEANING BLADE REPLACEMENT 1. Remove the drum unit and place it in the work area (see procedure 2.1). 2. Remove the cleaning unit [A] (2 screws). 3. Remove the cleaning blade [B] (2 screws). 4. Install the new cleaning blade on the cleaning unit. 5.
Page 344: Cleaning Brush Replacement
DRUM UNIT 2.3 CLEANING BRUSH REPLACEMENT 1. Remove the drum unit and place it in the work area (see procedure 2.1). 2. Remove the cleaning unit (see procedure 2.2). 3. Remove and replace the cleaning brush [A] (1 screw). NOTE: When installing the new cleaning brush, be sure to place its notch over the pin on the cleaning unit, as shown.
Page 345: Lubricant Bar Replacement
DRUM UNIT 2.4 LUBRICANT BAR REPLACEMENT 1. Remove the drum and cleaning units (see procedures 2.1 and 2.2). 2. Remove the cleaning blade from the cleaning unit [A] (see procedure 2.2). 3. Turn the pressure release lever up [B] and remove the cleaning unit top cover [C] (2 screws).
Page 346: Charge Grid And Corona Wire Replacement
DRUM UNIT 2.5 CHARGE GRID AND CORONA WIRE REPLACEMENT 1. Remove the front and inner covers, (see procedures 1.2 and 1.9). 2. Remove the charge corona unit [A] (1 screw). Hold the toner supply motor bracket [B] away while removing the charge corona unit. 3.
Page 347: Scanner Unit
SCANNER UNIT 3. SCANNER UNIT 3.1 SCANNER UNIT REMOVAL CAUTION Before beginning this installation procedure, be sure to remove the ARDF. If the scanner unit is opened with the ARDF installed, the machine may fall over. First, remove the Exposure Glass Upper Covers, Operation Panel, Right Covers, and Left Covers (see procedures 1.4, 1.5, 1.6, 1.7, 1.8).
Page 348: Halogen Lamp Replacement
SCANNER UNIT 3.2 HALOGEN LAMP REPLACEMENT 1. Remove the exposure glass (see procedure 1.4). 2. Position the 1st scanner into the slot on the frame. 3. Push the halogen lamp terminal [A] in the direction shown. This allows the removal of the halogen lamp [B]. 4.
Page 349: Scanner Inner Cover Removal
SCANNER UNIT 3.3 SCANNER INNER COVER REMOVAL 1. Remove the exposure glass (see procedure 1.4). 2. Remove the front cover and the upper right cover [A] (see procedures 1.2 and 1.5) 3. Remove the scanner inner cover [B] (11 screws). 3.4 SBU REPLACEMENT 1.
Page 350: Scanner Ipu Board Replacement
SCANNER UNIT 3.5 SCANNER IPU BOARD REPLACEMENT 1. Remove the exposure glass (see procedure 1.4). 2. Remove the scanner inner cover (see procedure 3.2). 3. Remove the SBU (see procedure 3.3). 4. Remove the scanner board cooling fan [A] (1 screw). 5.
Page 351: Scanner Home Position Sensor Replacement
SCANNER UNIT 3.6 SCANNER HOME POSITION SENSOR REPLACEMENT 1. Remove the left upper bracket [A] on the left of the operation panel (1 screw). 2. Disconnect the HP sensor connector [B]. 3. Remove the HP sensor bracket [C] (1 screw). 4.
Page 352: Scanner Wire Replacement
SCANNER UNIT 3.7 SCANNER WIRE REPLACEMENT 1. Remove the exposure glass and exterior covers (see procedures 1.1 through 1.9). 2. Remove the upper right stay [A] (4 screws) and the upper left stay [B] (2 screws) from the scanner unit. 3.
Page 353 SCANNER UNIT 5. Remove the scanner unit lift sensor bracket [A] (1 screw, 1 connector). 6. Remove the lamp regulator PCB [B] (2 screws, 3 connectors). 7. Remove the drive pulley [C]. 8. Remove the pulley shaft bearing [D] and bearing retainer [E]. 9.
Page 354 SCANNER UNIT Inside Outside 1st turn 7th turn 11. In the 1st scanner, loosen the screw [A] of both wire clamps. (Only the front scanner wire is shown above.) 12. Route the new scanner wire: The scanner wire has a ball attached to one end and a ring attached to the other.
Page 355 SCANNER UNIT 13. Pull the wire taut with the wire tension spring [A] and attach the wire tension bracket [B] (1 screw). 14. Reinstall the frames and upper stays by the reverse procedure of their removal. 15. Secure the 1st scanner at the front and rear with the scanner locking pins [C] as shown.
Page 356: Idu (Image Discriminate Unit) Replacement
SCANNER UNIT 3.8 IDU (IMAGE DISCRIMINATE UNIT) REPLACEMENT 1. Remove the exposure glass (see procedure 1.4). 2. Remove the scanner inner cover (see procedure 3.2). 3. Remove the platen cover frame (see item [D] in step 3 of Scanner Wire Replacement).
Page 357: Copy Image Adjustment
COPY IMAGE ADJUSTMENT 4. COPY IMAGE ADJUSTMENT 4.1 PRINTER γ ADJUSTMENT 4.1.1 Auto Color Calibration (ACC) ACC test pattern NOTE: When performing the ACC procedure, one of the following sizes of copy paper must be placed in the copier paper tray or paper tray unit: A4-sideways, 11"...
Page 358: Bkcmy Color Balance Adjustment
COPY IMAGE ADJUSTMENT Rev. 1/97 7. "Auto Color Calibrator/Completed" is displayed on the LCD if the ACC was completed successfully. NOTE 1. If the ACC was not completed successfully for any reason, retry the ACC as follows: (1) Select "2: Reset to previous calibration" at step 2. (2) This deletes the unwanted ACC data and restores the previous data.
Page 359 COPY IMAGE ADJUSTMENT Rev. 1/97 K(Bk) Glossy photo Low ID 4-919-1 4-920-1 4-921-1 4-922-1 mode (GP) Middle ID 4-919-2 4-920-2 4-921-2 4-922-2 High ID 4-919-3 4-920-3 4-921-3 4-922-3 ID Max 4-919-4 4-920-4 4-921-4 4-922-4 Adjustment Procedure NOTE: Do not change the order of these steps. 1.
Page 360 COPY IMAGE ADJUSTMENT 5. Copy the C-4 chart in photo mode (with Bk and white mode for Bk adjustment and full color mode for C, M and Y adjustment). 6. Open the appropriate SP 4-XX-X screen (see the following table). Y Value Photo mode Low ID...
Page 361: Main Scan Position Dot Correction
COPY IMAGE ADJUSTMENT 4.2 MAIN SCAN POSITION DOT CORRECTION NOTE: Before adjusting the scanner, perform the printer registration adjustment (see procedure 8.11). 1. Enter the SP mode and open SP4-10 and SP4-11. 2. Check that each value corresponds to the factory-set value. 3.
Page 362 COPY IMAGE ADJUSTMENT 6. Change the values in accordance with the following tables. Condition Sub condition Location of new value The yellow line The edges of the yellow and cyan The new value is in the middle row, is to the left of lines deviate evenly from the black to the left of the current value’s the black line,...
Page 363 COPY IMAGE ADJUSTMENT Example: 1. The C-4 chart’s vertical lines do not overlap properly. On the right side of the chart, the yellow line is to the left of the black line and the cyan line is to the right of the black line. The yellow line’s edge is the most distant edge from the black line.
Page 364: Laser Unit
LASER UNIT 5. LASER UNIT DANGER Turn off the main switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes. - CAUTION DECALS - Two caution decals are located in the laser section as follows. 5-31 A166/A187/A189...
Page 365: Polygon Motor Replacement
LASER UNIT DANGER Be sure to turn the main switch off and disconnect the power plug before any disassembly or adjustment of the laser unit. This copier uses a class 3B laser beam with a wavelength of 780 nm and an output of 10 mW.
Page 366 LASER UNIT 8. Carefully pull the harness [A] so as to provide slack while opening the printer control box [B] as shown (1 screw). Set the printer control box support bar [C]. CAUTION Take care not to knock the support bars (C and D) while the scanner unit and printer control box are open.
Page 367: Laser Synchronizing Detector Board Replacement
LASER UNIT 5.2 LASER SYNCHRONIZING DETECTOR BOARD REPLACEMENT 1. Open the front cover and remove the inner cover (see procedure 1.9). 2. Remove the toner shield glass [A]. 3. Open the printer control box (see procedure 5.1). 4. Remove the optical housing unit [B] (3 screws and 3 connectors). 5.
Page 368: Ld Unit Replacement
LASER UNIT 5.3 LD UNIT REPLACEMENT 1. Remove the inner cover (see procedure 1.9) 2. Remove the used toner tank (see procedure 1.10) 3. Remove the development unit (see procedure 6.1). 4. Remove the transfer belt unit (see procedure 7.1.1). 5.
Page 369: Development Unit
DEVELOPMENT UNIT 6. DEVELOPMENT UNIT 6.1 DEVELOPER 6.1.1 Developer Collection 1. Remove the following outer covers. (1) Right front cover [A] (1 screw) (2) Right cover [B] (open the by-pass feed table [C], then remove 4 screws) 2. Remove the developer collection bottle/supply funnel ass’y [D] (1 screw). Then remove the development roller rotation handle [E] (1 screw).
Page 370 DEVELOPMENT UNIT 4. Attach the handle [A] to the development unit [B] (follow the steps numbered through above). CAUTION When the handle is pulled (step ), ensure that it attaches to the development unit with a click. If the handle is not correctly installed, the development unit may fall when you attempt to remove it.
Page 371 DEVELOPMENT UNIT 6. Remove the chain hook [A] from the frame [B]. Then attach the chain hook to the magnet catch [C]. NOTE: The aim of attaching the chain hook to the magnet catch is to avoid forgetting to reinstall the chain hook when the development unit is reinstalled.
Page 372 DEVELOPMENT UNIT Development unit placement position Developer installation position 8. Place the development unit on a clean sheet of paper as shown above (development unit placement position) NOTE: Be sure to use a clean sheet of paper or floor mat when placing the development unit on the floor.
Page 373 DEVELOPMENT UNIT 11. Remove the developer cover [A]. 12. Attach the developer collection bottle/supply funnel ass’y [B] to the development unit using the screw [C] (M4 x 6). NOTE: 1. Before tightening the screw [C], ensure the two tabs [D] are completely inserted into the slots and the screw holes are aligned correctly.
Page 374 DEVELOPMENT UNIT Development unit placement position 13. Place the development unit in the development unit placement position, as shown. 14. Release the development revolver stay [A] and turn the revolver [B] 90 degrees, as shown. 15. Attach the development roller rotation handle [C] to the development roller gear [D] 5-41 A166/A187/A189...
Page 375 DEVELOPMENT UNIT Development unit placement position Developer installation position 16. Do the following a few times to get the developer out of the unit. Rotate the development roller gear with the development roller rotation handle. Then rotate the revolver into the developer installation position, as shown.
Page 376 DEVELOPMENT UNIT 17. Place the development unit in the development unit installation position and check the amount of used developer [A] in the developer collection bottle/supply funnel ass’y [B]. 18. If the used developer has reached the fill line [C] the developer must be emptied.
Page 377 DEVELOPMENT UNIT 21. Remove the developer supply funnel [A] and mount the developer cover (1 screw). NOTE: 1. Before reinstalling the developer cover, clean any developer spills on the sponge seal around the opening with a vacuum cleaner. If any developer remains on the sponge seal, a gap may be eroded in the sponge by the spilt developer.
Page 378 DEVELOPMENT UNIT 4. Hold the developer cover in position when tightening the screw. This is to prevent the screw holes from misaligning. 5. Never overtighten the screw [B]. If the screw is overtightened, the development unit’s screw hole (made of aluminum) may be damaged and the entire development unit may need to be replaced.
Page 379 DEVELOPMENT UNIT 24. Hold the development unit as shown above. Align the guide [A] with the guide rail [B]. Then insert the development unit halfway. NOTE: Never hold the hopper part [C] of the development unit when installing the unit. Otherwise the hopper part will be broken or the doctor gap of the development rollers will become uneven.
Page 380 DEVELOPMENT UNIT 26. Remove the chain hook [A] from the magnet catch [B], and hook it on the frame [C], as shown. 27. Slowly insert the development unit completely into the copier while making sure that the chain is not caught by the development unit. Then secure the development unit to the copier front frame (1 connector, 1 harness clamp, 1 short screw, and 1 long screw).
Page 381: Process Control Self-Check
DEVELOPMENT UNIT Rev. 11/96 6.2 PROCESS CONTROL SELF-CHECK After replacing developer, the development unit (containing new black, cyan, magenta and yellow developers) or the photoconductor drum, do the SP modes listed in the SP Modes After Replacing and Cleaning table in section 4, Service Tables.
Page 382: Revolver Motor Replacement
DEVELOPMENT UNIT 6.3 REVOLVER MOTOR REPLACEMENT 1. Remove the rear cover. 2. Disconnect the connector No. 307 [A] from I/O control board 2 [B]. 3. Remove I/O control board 2 [B] (4 screws). 4. Remove developer drive motor bracket with developer motor. (Refer to Development Motor Replacement Procedure).
Page 383: Development Motor Replacement
DEVELOPMENT UNIT 6.4 DEVELOPMENT MOTOR REPLACEMENT Apply grease. 1. Remove the rear cover. 2. Remove the flywheel [A] (1 screw). 3. Disconnect the connector CN1 from the development motor control board. 4. Remove the development motor [B] (4 screws). NOTE: After replacing the development motor, apply silicone grease G-40M (A0089502) to the development motor shaft gear.
Page 384: Transfer Belt Unit
TRANSFER BELT UNIT 7. TRANSFER BELT UNIT 7.1 TRANSFER BELT SECTION 7.1.1 Transfer Belt 1. Remove the transfer belt unit (see section 3. INSTALLATION PROCEDURE). 2. Remove the cleaning unit bracket [A] (1 screw). 3. Remove the cleaning unit. Lift as shown by arrows above. NOTE: Keep the cleaning unit level to prevent toner spillage.
Page 385 TRANSFER BELT UNIT 6. Replace the transfer belt and reset the transfer belt bracket. NOTE: 1) When installing a new transfer belt, make sure that white mark [A] on the edge of the belt is at the upper side. 2) When installing a new transfer belt, make sure that both belt lips are placed over each roller edge.
Page 386: Cleaning Unit
TRANSFER BELT UNIT 7.2 CLEANING UNIT NOTE: Be careful not to dirty the customer’s site. Place a floor mat or other protective sheet on the floor before removing the cleaning unit. 7.2.1 Cleaning Blade Replacement 1. Remove LED Array (2screws, 1 connector) 2.
Page 387: Belt Cleaning Solenoid Replacement
TRANSFER BELT UNIT 7.2.2 Belt Cleaning Solenoid Replacement 1. Remove the cleaning unit bottom cover [A] (6 latches). 2. Remove the spring [B] (1 spring). 3. Remove the belt cleaning solenoid [C] (2 screws and 1 connector). NOTE: When turning the cleaning unit upside-down, be careful of the toner that will spill out.
Page 388: Entrance Seal Replacement
TRANSFER BELT UNIT 7.2.3 Entrance Seal Replacement 1. Remove the rear gear from the cleaning unit [A] (1 snap-ring). 2. Remove the rear plastic side plate [B] (2 screws). 3. Remove the cleaning entrance seal unit [C] and spring [E]. 4.
Page 389: Belt Transfer Corona Wire
TRANSFER BELT UNIT 7.3 BELT TRANSFER CORONA WIRE 1. Remove the corona unit from the transfer belt unit (see section 3. COPIER INSTALLATION PROCEDURE). 2. Remove the front and rear end block caps [A]. 3. Remove the corona wire [B] (1 spring). NOTE: 1.
Page 390: Lubricant Unit
TRANSFER BELT UNIT 7.4 LUBRICANT UNIT 7.4.1 Lubricant Brush and Bar Replacement 1. Remove the bracket [A] (1 spring and 1 screw). 2. Remove the lubricant unit [B]. 3. Remove the lubricant brush [C] (2 snap-rings). 4. Remove the lubricant bar [D] (2 screws). 5-57 A166/A187/A189...
Page 391: Lubricant Solenoid Replacement
TRANSFER BELT UNIT 7.4.2 Lubricant Solenoid Replacement 1. Remove the right front cover and the right cover (see procedure 1.7). 2. Remove the lubricant solenoid bracket [A] (2 screws and 1 connector). 3. Remove the lubricant solenoid [B] (2 screws). A166/A187/A189 5-58...
Page 392: Paper Transfer Corona Wire
TRANSFER BELT UNIT 7.5 PAPER TRANSFER CORONA WIRE 1. Remove the paper transfer corona unit (see section 3. COPIER INSTALLATION PROCEDURE). 2. Remove the end blocks [A]. 3. Remove the corona wire [B]. NOTE: 1) During replacement, ensure the corona wire is threaded correctly in the rear slot.
Page 393 PAPER FEED AND REGISTRATION 8. PAPER FEED AND REGISTRATION 8.1 BY-PASS FEED TABLE REMOVAL 1. Open the by-pass feed table [A]. 2. Disconnect the connector [B]. 3. Remove the snap ring [C]. 4. Raise the by-pass feed table almost vertically and push it toward the ...
Page 394: Paper Feed And Registration
PAPER FEED AND REGISTRATION 8.2 BY-PASS FEED ROLLER, PICK-UP ROLLER, AND SEPARATION ROLLER REPLACEMENT 1. Remove the by-pass feed table (see procedure 8.1). 2. Open the vertical transport door [A]. 3. Remove the snap-rings from the feed roller [B], separation roller [C] and pick-up roller [D].
Page 395: By-Pass Feed Unit Replacement
PAPER FEED AND REGISTRATION 8.3 BY-PASS FEED UNIT REPLACEMENT 1. Remove the right cover, the right rear cover, and the right front cover (see procedure 1.7). 2. Remove the by-pass feed table (see procedure 8.1). 3. Remove the developer collection bottle/supply funnel ass’y [A] from its storage position (1 screw).
Page 396: By-Pass Feed Pick-Up Solenoids And End Sensor Replacement
PAPER FEED AND REGISTRATION 8.4 BY-PASS FEED PICK-UP SOLENOIDS AND END SENSOR REPLACEMENT 1. Remove the by-pass feed unit. (see procedure 8.3.) 2. Remove the upper part of the by-pass feed unit [A] (3 screws [B] and 2 connectors [C]). 3.
Page 397: By-Pass Feed Paper Size Sensor Replacement
PAPER FEED AND REGISTRATION 8.5 BY-PASS FEED PAPER SIZE SENSOR REPLACEMENT Latch 1. Remove the by-pass feed table (see procedure 8.1). 2. Remove the by-pass feed table base [A] (2 screws). 3. Move the by-pass feed table cover [B] to the right (this releases the latch) Remove it from the by-pass feed table base.
Page 398: Registration Sensor Replacement
PAPER FEED AND REGISTRATION 8.6 REGISTRATION SENSOR REPLACEMENT 1. Remove the right front cover and the right cover (see procedure 1.7). 2. Remove the developer collection bottle (see procedure 6.1.1). 3. Remove the registration sensor bracket [A] (1 screw). 4. Replace the registration sensor [B] (1 connector). 5-65 A166/A187/A189...
Page 399: Paper Feed Tray Removal
PAPER FEED AND REGISTRATION 8.7 PAPER FEED TRAY REMOVAL 1. Open the paper feed tray [A] 2. Lift and remove the paper feed tray (2 screws). A166/A187/A189 5-66...
Page 400: Paper Feed Roller (Semicircular Roller) Replacement
PAPER FEED AND REGISTRATION 8.8 PAPER FEED ROLLER (SEMICIRCULAR ROLLER) REPLACEMENT 1. Remove the front cover, the inner cover, and the used toner tank (see procedures 1.2, 1.9 and 1.10). 2. Remove the paper feed tray (see procedure 8.7). 3. Remove the paper feed roller shaft holder [A] (1 screw). 4.
Page 401: Paper Feed Clutch Replacement
PAPER FEED AND REGISTRATION 8.9 PAPER FEED CLUTCH REPLACEMENT 1. Remove the rear cover (see procedure 1.3). 2. Swing out the I/O control board [A] (4 screws). 3. Remove the rear transfer fan [B] (1 screw, 1 connector). 4. Remove the connector and the rotation stopper [C] and replace the paper feed clutch [D].
Page 402: Vertical Transport Switch And Sensor
PAPER FEED AND REGISTRATION 8.10 VERTICAL TRANSPORT SWITCH AND SENSOR REPLACEMENT 1. Open the vertical transport door [A]. 2. Remove the vertical transport cover [B] (2 screws). 3. Replace the vertical transport sensor [C] (1 connector [D]). 4. Remove the vertical transport switch bracket [E] (1 screw). 5.
Page 403: Copy Image Area Adjustment
Rev. 11/96 PAPER FEED AND REGISTRATION 8.11 COPY IMAGE AREA ADJUSTMENT The leading edge margin can be adjusted for both normal paper and OHP/thick paper. This can be done in the SP mode for both paper types. The right and left edge margins can also be adjusted for both paper types. This can be done with the side to side registration adjustment SP mode for each paper feed station.
Page 404 Rev. 11/96 PAPER FEED AND REGISTRATION SP mode Plus Minus Paper Feed Direction 10.0 mm ± 2.0 mm 10.0 mm ± 2.0 mm Standard margins Required registration pattern adjustment range 5 ± 2 mm a must be 10 ± 2 mm Leading edge margin 2 ±...
Page 405: Paper Transport And Fusing
PAPER TRANSPORT AND FUSING 9. PAPER TRANSPORT AND FUSING 9.1 TRANSPORT UNIT REMOVAL 1. Remove the transfer belt unit (see procedure 7.1). 2. Remove the fusing unit (see procedure 9.3). 3. Remove the inlet fan cover [A] (1 screw). 4. Remove the development inlet fan [B] if necessary (1 connector and 1 screw).
Page 406: Transport Belt Removal
PAPER TRANSPORT AND FUSING 9.2 TRANSPORT BELT REMOVAL 1. Remove the transport unit (see procedure 9.1). 2. Remove the transport assembly [A] (2 screws). 3. Remove the transport belt roller [B]. 4. Replace the transport belt [C]. 5-73 A166/A187/A189...
Page 407: Fusing Unit Removal
PAPER TRANSPORT AND FUSING 9.3 FUSING UNIT REMOVAL CAUTION 1. Be careful when handling the fusing unit. It is hot. 2. Take care not to spill silicone oil on the floor. If silicone oil spills on the floor, immediately clean it off with a silicone oil remover. Silicone oil is very slippery and can cause someone to fall.
Page 408: Oil Supply Pad Replacement
PAPER TRANSPORT AND FUSING 9.4 OIL SUPPLY PAD REPLACEMENT 1. Remove the fusing unit (see procedure 9.3) 2. Remove the fusing unit top cover [A] (1 screw). 3. Remove and replace the oil supply pad [B] (4 screws). 5-75 A166/A187/A189...
Page 409: Hot Roller, Pressure Roller, And Fusing Lamp Replacement
PAPER TRANSPORT AND FUSING 9.5 HOT ROLLER, PRESSURE ROLLER, AND FUSING LAMP REPLACEMENT 1. Remove the fusing unit (see procedure 9.3.). 2. Remove the fusing unit top cover (see procedure 9.4). 3. Remove the fusing knob hub [A] (1 screw). 4.
Page 410 PAPER TRANSPORT AND FUSING 11. Disconnect the fusing thermofuse connector [A]. 12. Disconnect the fusing thermistor connector [B]. 13. Disconnect the connector [C] at the rear of the fusing lamp. 14. Disconnect the connector [D] at the rear of the pressure roller lamp. 15.
Page 411 PAPER TRANSPORT AND FUSING 17. Disconnect the fusing lamp connector [A] from the rear lamp holder [B] and remove the fusing lamp [C] from the rear. 18. Replace the hot roller [D] and the hot roller shaft bearings [E] (2 C-rings, 1 gear, 2 spacers, and 2 bushings).
Page 412 PAPER TRANSPORT AND FUSING 19. Open the paper it door [A]. 20. Remove the fusing entrance guide plate [B] (2 screws). NOTE: Be sure to use the upper screw holes when reinstalling the fusing entrance guide plate. The lower screw holes are used to adjust the paper feed path (see procedure 9.12).
Page 413 PAPER TRANSPORT AND FUSING 22. Remove the lower plate [A] (2 screws). 23. Remove the pressure roller thermofuse [B] (1 screw). 24. Remove the two pressure blade springs [C]. 25. Remove the pressure roller cleaning blade assembly [D]. 26. Remove the pressure roller cleaning blade [E] (1 shoulder screw). A166/A187/A189 5-80...
Page 414: Hot Roller Thermistor Replacement
PAPER TRANSPORT AND FUSING 9.6 HOT ROLLER THERMISTOR REPLACEMENT 1. Remove the fusing unit upper assembly (see procedure 9.5). 2. Remove and replace the thermistor [A] as shown. 9.7 HOT ROLLER THERMOFUSE REPLACEMENT 1. Remove the oil supply pad (see procedure 9.4). 2.
Page 415: Pressure Roller Thermistor Replacement
Rev. 11/96 PAPER TRANSPORT AND FUSING 9.8 PRESSURE ROLLER THERMISTOR REPLACEMENT 1. Remove the fusing unit (see procedure 9.3). 2. Remove the paper exit door [A] (1 snap-ring). 3. Replace the pressure roller thermistor [B] (1 connector and 1 screw). 9.9 PRESSURE ROLLER THERMOFUSE REPLACEMENT 1.
Page 416: Cleaning Roller Oil Pan And Scraper
Rev. 11/96 PAPER TRANSPORT AND FUSING 9.10 CLEANING ROLLER OIL PAN AND SCRAPER 1. Remove the fusing unit (see procedure 9.3). 2. Remove the paper exit door (see procedure 9.8). 3. Remove the cleaning roller oil pan [A] (2 screws). 4.
Page 417: Oil Pan Pads
PAPER TRANSPORT AND FUSING 9.11 OIL PAN PADS 1. Remove the hot roller, the pressure roller, and the pressure roller cleaning blade assembly. (see procedure 9.5.) 2. Replace the following oil pan pads. • Right oil pan pad [A] • Left oil pan pad [B] •...
Page 418: Fusing Entrance Guide Adjustment
PAPER TRANSPORT AND FUSING 9.12 FUSING ENTRANCE GUIDE ADJUSTMENT • The height of the fusing entrance can be adjusted to correct for wrinkling on special paper types or jams when using postcards. 1. Remove the screws from the standard positions (as set at the factory). 2.
Page 419: Nip Band Width Adjustment
PAPER TRANSPORT AND FUSING 9.13 NIP BAND WIDTH ADJUSTMENT 9.13.1 Procedure NOTE: 1) Check and adjust the nip band width only after the copier has warmed up. 2) Place an OHP sheet (Folex 100 or equivalent) on the by-pass feed table before starting this procedure. 3) Use only A4/LT sideways (if you use an OHP of other sizes, a paper jam will occur).
Page 420: Troubleshooting
PAPER TRANSPORT AND FUSING 9.13.2 Troubleshooting 1. When the paper is wrinkled Adjust the pressure roller screw to set the nip band width close to the upper limit of the standard value (since the standard value is 6.5 ±0.5 mm, adjust the pressure roller screw to obtain a nip width of about 7 mm).
Page 421: Duplex Unit
DUPLEX UNIT 10. DUPLEX UNIT 10.1 DUPLEX UNIT REMOVAL 1. Open the duplex unit [A]. 2. Remove the duplex unit (4 screws). 10.2 SEPARATION ROLLER REPLACEMENT 1. Remove the duplex unit (see procedure 10.1). 2. Remove the separation roller assembly [A] (2 screws). 3.
Page 422: Feed Roller Replacement
DUPLEX UNIT 10.3 FEED ROLLER REPLACEMENT 1. Open the duplex unit. 2. Remove the guide rail [A] (1 screw and 1 snap-ring). 3. Remove the upper guide plate [B] and lower guide plate [C] (1 snap-ring). 4. Remove the inner cover [D] (2 screws). 5.
Page 423: Duplex Feed Motor Replacement
DUPLEX UNIT 10.4 DUPLEX FEED MOTOR REPLACEMENT 1. Perform steps 1 through 4 in procedure 10.3. 2. Remove the bracket [A] (1 screw). 3. Remove the feed roller shaft assembly [B] (2 snap-rings). 4. Remove the pulley [C] and the timing belt [D]. 5.
Page 424 DUPLEX UNIT 6. Disconnect the connector [A] of the dupl feed motor [B]. 7. Close the side fences [C] and remove the dupl feed assembly [D] (5 screws). 8. Remove the duplex feed motor assembly (3 screws). 9. Replace the duplex feed motor (2 screws). NOTE: 1.
Page 425: Filters
FILTERS 11. FILTERS 11.1 OPTICS FAN FILTER REPLACEMENT 1. Remove the filter cover [A] on the left side of the copier (2 screws). 2. Remove and replace the dust filter [B]. 11.2 EXHAUST OZONE FILTER REPLACEMENT 1. Remove the rear cover (see procedure 1.3). 2.
Page 426: Fusing Filter Replacement
FILTERS 11.3 FUSING FILTER REPLACEMENT 1. Remove the rear cover (see procedure 1.3). 2. Replace the dust filter [A]. 11.4 CHARGE INLET FILTER REPLACEMENT 1. Remove the rear cover (see procedure 1.3). 2. Replace the dust filter [B]. 5-93 A166/A187/A189...
Page 427: Rear Ozone Filter Replacement
FILTERS 11.5 REAR OZONE FILTER REPLACEMENT 1. Remove the rear cover (see procedure 1.3). 2. Replace the ozone filter [A]. 11.6 FRONT OZONE FILTER REPLACEMENT 1. Remove the front cover (see procedure 1.3). 2. Remove the inner cover (see procedure 1.9). 3.
Page 428: Power Supply Ozone Filter Replacement
Rev. 11/96 FILTERS 11.7 PAPER EXIT OZONE FILTER REPLACEMENT 1. Remove the left front cover (see procedure 1.8). 2. Replace the ozone filter [A]. 11.8 POWER SUPPLY OZONE FILTER REPLACEMENT 1. Remove the development unit (see procedure 6.1.1, steps 1 through 8). 2.
Page 429: Others
OTHERS Rev. 1/97 12. OTHERS 12.1 SCU 12.1.1 SCU Replacement 1. A166/A187 Copiers Only 1. Remove the operation panel [A] (see procedure 1.6 ). 2. Remove the RAM board [B] from the SCU board [C]. 3. Remove the SCU board (6 screws). NOTE: When removing the SCU from the operation panel, take care not to bend the connector pins of the SCU.
Page 430 Rev. 1/97 OTHERS 2. A189 Copier Only Operation panel 1. Open the scanner unit [A] (see procedure 1.11). 2. Remove the RAM board [C] from the SCU [B] (1 screw). 3. Remove the SCU (9 screws). 4. Install the existing RAM board on the new SCU and reinstall it. NOTE: When replacing the SCU, you must retain and reinstall the isting RAM board on the new SCU.
Page 431: Ram Clear
Rev. 08/2000 OTHERS 12.2 RAM CLEAR 12.2.1 RAM (Memory Board) Clear Procedure ⇒ 1. Before clearing the RAM, execute SP7-902 and SP7-903 to output the current SP mode values. NOTE: Clearing the RAM resets all SP and UP values, except the serial number and main counter value, to the defaults.
Page 432 OTHERS 1. Relationship between Main and Backup Counters A166/A187 Copiers A189 Copier SCU board SCU board Main counter Main counter Counter key Backup counter Backup counter Counter key (stored on the (stored on the RAM board) RAM board) The following describe the main and backup counters: 1.
Page 433 OTHERS 6. When SC900 is displayed it indicates a problem with the main counter. If this occurs, do the following: • Check the connection of the main counter connector. • If you determine that the main counter is faulty, replace it. 7.
Page 434: Touch Panel Calibration
OTHERS 12.4 TOUCH PANEL CALIBRATION A189 Copier Only Cancel After replacing the operation panel, the touch panel must be calibrated as follows: 1. Enter SP5-901 "Touch Panel Calibration" and select "0" (reset). This step cancels the isting touch panel calibration and allows the panel to be re-calibrated.
Page 436: Troubleshooting
TROUBLESHOOTING...
Page 438: Service Call Conditions
SERVICE CALL CONDITIONS 1. SERVICE CALL CONDITIONS This copier provides the following five types of service call (SC) conditions that help minimize the possibility of system down time. TYPE 1: Safety Action Immediately stops the copier and displays an SC. Turning the power off and on cannot recover the copier.
Page 439 SERVICE CALL CONDITIONS SC101: Lamp failure (broken or persistently on) Type: 3 - Description - When the lamp regulator detects that the exposure lamp is not turned on or is not turned off, the scanner IPU informs the SCU of this. - Detection Timing - Failure to go on (break) is detected when the lamp is turned on.
Page 440 SERVICE CALL CONDITIONS SC121: Scanner HP sensor abnormal - Stays on Type: 3 - Description - The scanner IPU board notifies the SCU when the home sensor does not go on even though the scanner carriage has been retracted from the home position during the scanner carriage homing process of the power-on sequence.
Page 441 SERVICE CALL CONDITIONS SC171: VPU abnormal 2 Type: 3 - Description - The scanner IPU board notifies the SCU when feedback data for the white level is not in the proper range at power-on. - Detection Timing - When the power switch is turned on - Possible Causes - •...
Page 442 SERVICE CALL CONDITIONS SC192: Bar code number mismatch Type: 2 - Description - The SCU compares the bar code data read by the CCD and analyzed by the scanner IPU board with the machine identification number stored in the machine. If they do not match, the SCU determines that there is a bar code number mismatch.
Page 443 SERVICE CALL CONDITIONS SC197: Extended IPU connection abnormal (A189 machine only) Type: 4 - Description - The SCU detects when the extended IPU is not connected. - Detection Timing - When the power switch is turned on - Possible Causes - •...
Page 444 SERVICE CALL CONDITIONS SC322: Laser synchronizing signal error Type: 5 - Description - The main control board notifies the SCU when image transfer is aborted and the image transfer buffer (FIFO) on the printer main board is full or in an error condition. - Detection Timing - During the image transfer process - Possible Causes -...
Page 445 SERVICE CALL CONDITIONS SC341: Development motor abnormal Type: 2 - Description - The main control board notifies the SCU when the development motor does not start up within a predetermined period of time or does not output the LOCK signal for more than a predetermined period of time during the rotation.
Page 446 SERVICE CALL CONDITIONS SC362: Revolver HP sensor abnormal - Stays on Type: 2 - Description - The main control board notifies the SCU when the revolver home sensor does not go off even though the revolver was moved from the home position to an appropriate color.
Page 447 SERVICE CALL CONDITIONS SC382: VD adjustment error (charging failure - the target is not reached within 40 trials) Type: 5 - Description - The main control board notifies the SCU when VD does not come within ±5 V of the target after 40 trials in the VD check mode during the potential control process.
Page 448 SERVICE CALL CONDITIONS SC384: LD writing error (the response from the 12th grade of the pattern is out of range) Type: 5 - Description - The main control board notifies the SCU when the potential is out of tolerance (0 ≤ V12 ≤ 300) at the creation of the potential control pattern (12th grade).
Page 449 SERVICE CALL CONDITIONS SC386: Vmin abnormal Type: 5 - Description - The main control board notifies the SCU when Vmin for black is out of range (between 0.01 V and 0.20 V) and Vmin for color is out of range (between 1.5 V and 2.2 V) at the creation of the 12-grade patterns during process control.
Page 450 SERVICE CALL CONDITIONS SC400: Belt transfer charge abnormal Type: 2 - Description - The main control board notifies the SCU that the belt transfer charge output from the high voltage power pack does not reach the target due to such causes as a leak or power pack failure. - Detection Timing - When the belt transfer charge is active - Possible Causes -...
Page 451 SERVICE CALL CONDITIONS SC450: Paper transfer charge abnormal Type: 2 - Description - The main control board notifies the SCU that the paper transfer charge output value from the high voltage power pack does not reach the target due to such causes as a leak or power pack failure. - Detection Timing - When the paper transfer charge is active - Possible Causes -...
Page 452 SERVICE CALL CONDITIONS SC495: Thermo sensor abnormal Type: 5 - Description - The voltage read by the thermosensor on I/O control board 1 is out of the specified range (between 0.2 V and 3.5 V) for a successive 30 times. - Detection Timing - When the power switch is turned on When the front cover is closed...
Page 453 SERVICE CALL CONDITIONS SC502: Tray upper limit sensor disabled (2nd bank) Type: 4 - Description - The paper tray unit diagnostics notify the main control board when the 2nd bank upper limit sensor does not operate. - Detection Timing - When the power switch is turned on When the paper tray unit operates - Possible Causes -...
Page 454 SERVICE CALL CONDITIONS SC523: Side fence jogger H.P. abnormal - Stays on Type: 4 - Description - The main control board notifies the SCU when the jogger H.P. sensor does not go off even though the jogger was moved from the home position during the duplex tray side fence homing process.
Page 455 SERVICE CALL CONDITIONS SC541: Fusing (hot roller) thermistor open Type: 1 - Description - When the fusing (hot roller) thermistor outputs an analog value corresponding to 0°C, the main control board determines that the fusing thermistor is broken and notifies the SCU of this. - Detection Timing - Always - Possible Causes -...
Page 456 SERVICE CALL CONDITIONS SC544: Fusing (hot roller) low temperature Type: 1 - Description - The main control board notifies the SCU when the fusing (hot roller) thermistor outputs an analog value corresponding to 90°C after it had previously reached the ready temperature. - Detection Timing - Always - Possible Causes -...
Page 457 SERVICE CALL CONDITIONS SC551: Pressure roller thermistor open Type: 1 - Description - When the pressure roller thermistor outputs an analog value corresponding to 0°C, the main control board determines that the pressure roller thermistor is broken and notifies the SCU of it. - Detection Timing - Always - Possible Causes -...
Page 458 SERVICE CALL CONDITIONS SC554: Pressure roller low temperature Type: 1 - Description - The main control board notifies the SCU when the pressure roller thermistor outputs an analog value corresponding to 70°C after it had already reached the ready temperature. - Detection Timing - At all times - Possible Causes -...
Page 459 SERVICE CALL CONDITIONS SC558: Zero cross signal abnormal Type: 1 - Description - The main control board notifies the SCU when the number of zero cross signals generated within a certain period of time does not reach a predetermined number. - Detection Timing - At all times - Possible Causes -...
Page 460 SERVICE CALL CONDITIONS SC603: Communication error between SCU and printer main control board Type: 3 - Description - The SCU detects a communication error in the printer module during communication with the main control board based on the SCSI connection protocol. - Detection Timing - Always - Possible Causes -...
Page 461 SERVICE CALL CONDITIONS SC606: Printer SCSI communication error Type: 2 - Description - The main control board detects an error or hardware-related noise during communication between the SCU or SCN and the main control board. - Detection Timing - Always - Possible Causes - •...
Page 462 SERVICE CALL CONDITIONS SC620: Communication error between scanner and ADF Type: 4 - Description - When the scanner IPU board detects a communication error in the ADF during communication with the ADF based on the ASAP optical-fiber connection protocol, it notifies the SCU of this. - Detection Timing - When the power switch is turned on When the ADF prepares for operation...
Page 463 SERVICE CALL CONDITIONS SC625: Communication error between scanner and projector Type: 4 - Description - When the scanner IPU board detects a communication error in the projector during communication with the projector based on the projector optical-fiber connection protocol, it notifies the SCU of this. - Detection Timing - When the power switch is turned on When the projector prepares for operation...
Page 464 SERVICE CALL CONDITIONS SC720: Sorter transport motor abnormal Type: 2 - Description - The sorter diagnostics notify the main control board of an anomaly with the sorter transport motor. Then the main control board notifies the SCU of it. - Detection Timing - When the power switch is turned on When the sorter is active - Possible Causes -...
Page 465 SERVICE CALL CONDITIONS SC724: Sorter grip motor abnormal Type: 2 - Description - The sorter diagnostics notify the main control board of an anomaly with the sorter grip motor. Then the main control board notifies the SCU of it. - Detection Timing - When the power switch is turned on When the sorter is active - Possible Causes -...
Page 466 SERVICE CALL CONDITIONS SC732: Lift motor abnormal Type: 2 - Description - The sorter diagnostics notify the main control board of an anomaly with the sorter lift motor. Then the main control board notifies the SCU of it. - Detection Timing - When the power switch is turned on When the sorter is active - Possible Causes -...
Page 467 SERVICE CALL CONDITIONS SC791: Projector lamp does not go off Type: 4 - Description - The projector diagnostics notify the scanner IPU board when the projector lamp does not go off although the OFF command is issued. Then the scanner IPU board notifies the SCU of it. - Detection Timing - When the projector is stopped - Possible Causes -...
Page 468 SERVICE CALL CONDITIONS SC901: Inconsistent main counter and backup counter Type: 2 - Description - This SC is displayed when the difference between the main and backup counter values is more than ±5. - Detection Timing - When the power switch is turned on When the Counter key is pressed - Possible Causes - •...
Page 469 SERVICE CALL CONDITIONS SC920: SCU/RAM board abnormal Type: 2 - Description - The SCU executes the read/write test for the RAM board on the SCU and the read/write operation is not successfully done. This SC is not displayed just after the read/write test because the CPU enters the hold state.
Page 470 SERVICE CALL CONDITIONS SC990: I/O control board 1 abnormal Type: 2 - Description - This SC is displayed when a serial/parallel I/O error is detected in the I/O control board 1 for a successive five times. - Detection Timing - Always - Possible Causes - •...
Page 471: How To Determine If The Potential Sensor Or Id Sensor Is Defective
HOW TO DETERMINE IF THE POTENTIAL SENSOR OR ID SENSOR IS DEFECTIVE 2. HOW TO DETERMINE IF THE POTENTIAL SENSOR OR ID SENSOR IS DEFECTIVE Purpose When an image problem occurs, it is difficult to recognize whether there is a problem with these sensors with only the SP data print out.
Page 472 HOW TO DETERMINE IF THE POTENTIAL SENSOR OR ID SENSOR IS DEFECTIVE Procedure CAUTION Before checking the resistance or potential of the sensors, make sure to unplug the power cord. 1-1. Measure the resistance between the drum surface and drum shaft. Normal resistance*: 0.3Ω...
Page 473 HOW TO DETERMINE IF THE POTENTIAL SENSOR OR ID SENSOR IS DEFECTIVE 2-1. Potential sensor/ID sensor check Using a digital oscilloscope, check the waveforms at the following terminals. If the waveforms are flat, the sensor is broken. • Potential sensor (V-SEN) TP213 on the main control board and GND (Ground) •...
Page 474: Troubleshooting For Counters
TROUBLESHOOTING FOR COUNTERS 3. TROUBLESHOOTING FOR COUNTERS Inconsistent main and backup S C 9 0 1 counters Enter SP mode M a i n S W O F F Main Counter P/N : A1669099 Check the backup counter values Replace the main counter Counter value : SP7-3-1 Bk counter value A...
Page 476: Auto Reverse Document Feeder A548
AUTO REVERSE DOCUMENT FEEDER A548...
Page 478: Specifications
SPECIFICATIONS 1. SPECIFICATIONS Original Size and Weight: Thick original mode (default mode) Use this setting for normal paper types Maximum A3, 11" x 17" Minimum B6 (sideways), 5 " x 8 " Weight 52 ~ 128 g/m (14 ~ 34 lb) Thin original mode Maximum A3, 11"...
Page 479: Component Layout
COMPONENT LAYOUT 2. COMPONENT LAYOUT 2.1 MECHANICAL COMPONENTS 1. Original Stopper 7. Transport Belt 2. Press Lever 8. Pick-up Rollers 3. Original Table 9. Pull-out Roller 4. Exit Rollers 10. Feed Roller 5. Inverter Pawls 11. Friction Belt 6. Inverter Rollers A166/A187/A189...
Page 480: Electrical Components
COMPONENT LAYOUT 2.2 ELECTRICAL COMPONENTS 1. Original Set Sensor 10. Feed-out Motor 2. Feed-in Cover Open Sensor 11. Feed-out Sensor 3. Stopper Solenoid 12. APS Start Sensor 4. Indicator Panel Lamps 13. DF Position Sensor 5. Feed-in Motor 14. Original Width Sensor - 1 6.
Page 481: Electrical Component Description
ELECTRICAL COMPONENT DESCRIPTION 3. ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. Motors Drives the feed-in system (pick-up, feed Feed-in and pull-out rollers, separation belt) Belt Drive Drives the transport belt Drives the feed-out and the inverter Feed-out system Sensors Detects whether originals have been Original Set placed on the original table...
Page 482: Detailed Descriptions
DETAILED DESCRIPTIONS 4. DETAILED DESCRIPTIONS 4.1 ORIGINAL PICK-UP MECHANISM When an original is placed on the table, the leading edge is stopped by the stopper [A], and the feeler activates the original set sensor [B]. The Insert Original indicator light goes out and the DF informs the copier’s CPU that the originals have been set.
Page 483: Separation And Paper Feed Mechanism
DETAILED DESCRIPTIONS 4.2 SEPARATION AND PAPER FEED MECHANISM Originals are separated using the friction belt [A] and the feed roller [B]. When the copier sends a signal to the DF to feed in the original, the feed-in motor [C] starts rotating (clockwise) to drive the pick-up [D], feed and pull-out [E] rollers.
Page 484: Friction Belt Drive Mechanism
DETAILED DESCRIPTIONS 4.3 FRICTION BELT DRIVE MECHANISM The feed-in motor [A] drives the friction belt [B] through timing belts and gears. The one-way bearing allows the belt to rotate in the direction shown only when the feed-in motor is rotating counterclockwise. (The feed-in motor rotates counterclockwise when the original is passing over the registration sensor, and only the pull-out rollers are rotating to feed the paper to the exposure glass.)
Page 485: Original Size Detection
DETAILED DESCRIPTIONS 4.4 ORIGINAL SIZE DETECTION The DF detects original width using three original width sensors-1 [A], -2 [B] and -3 [C]. It also detects the original length using the registration sensor. The DF CPU counts the feed-in motor’s drive pulses during the on timing of the registration sensor.
Page 486: Paper Transport Mechanism
DETAILED DESCRIPTIONS 4.5 PAPER TRANSPORT MECHANISM Left Scale Rear Scale 3.5 mm Original The transport belt [A] is driven by an independent motor called the belt drive motor [B] (a dc stepper motor). The belt drive motor starts rotating soon after the copier sends an original feed-in signal.
Page 487: Thick/Thin Original Modes
DETAILED DESCRIPTIONS 4.6 THICK/THIN ORIGINAL MODES Fig. 1 7 mm Fig. 2 Fig. 3 This document feeder has two different ways of stopping originals at the correct position on the exposure glass. The technician can select one of these using a copier SP mode. The user can also select the mode. 1.
Page 488: Original Feed-Out Mechanism
DETAILED DESCRIPTIONS 4.7 ORIGINAL FEED-OUT MECHANISM When the scanner reaches the return position, the copier’s CPU sends the feed-out signal to the DF CPU. When the DF receives the feed-out signal, the belt drive and feed-out motors [A] turn on. The feed-out sensor [B] installed in the feed-out section counts the number of pulses to calculate how long the feed-out motor must stay on to feed the original out of the machine completely.
Page 489: Two-Sided Original Feed Mechanism
DETAILED DESCRIPTIONS 4.8 TWO-SIDED ORIGINAL FEED MECHANISM Unlike one-sided original feed, the back side of the original must be copied first to keep the originals and copies in the correct order. During original feed-in, the sequence is the same as for one-sided feed. However, the belt drive motor continues rotating until the original reaches the inverter section.
Page 490: Timing Charts
TIMING CHARTS 5. TIMING CHARTS 5.1 A4 SIDEWAYS: 1 SIDED ORIGINAL 7-13 A166/A187/A189...
Page 491: Combine 2 Original Mode
TIMING CHARTS 5.2 COMBINE 2 ORIGINAL MODE A166/A187/A189 7-14...
Page 492: A4 Sideways: Duplex
TIMING CHARTS 5.3 A4 SIDEWAYS: DUPLEX 7-15 A166/A187/A189...
Page 493: Service Tables
SERVICE TABLES Rev. 11/96 6. SERVICE TABLES 6.1 DIP SWITCHES DPS 101 Function Normal setting One-sided thin original mode free run with paper (35 cpm) One-sided thick original mode (normal mode) free run with paper (35 cpm) One-sided thick original mode (normal mode) free run without paper (35 cpm) Two-sided mode free run with paper (35 cpm) Two-sided mode free run without paper (35 cpm)
Page 494: Variable Resistors
SERVICE TABLES 6.2 VARIABLE RESISTORS VR No. Function Adjusts the lead-edge registration in one-sided thin original mode. Adjusts the lead-edge registration in two-sided original mode. 6.3 LED LED No. Function Monitors the communication with the copier. 6.4 FUSE FUSE No. Function Protects the 24 V line.
Page 495: Replacement And Adjustment
REPLACEMENT AND ADJUSTMENT 7. REPLACEMENT AND ADJUSTMENT 7.1 TRANSPORT BELT REPLACEMENT 1. Turn off the main switch and lift up the DF. 2. Remove the grip [A] (3 screws). 3. Remove the 6 screws securing the transport belt assembly [B]. NOTE: Remove the two lower screws [C] first.
Page 496: Feed Roller Replacement
REPLACEMENT AND ADJUSTMENT 7.2 FEED ROLLER REPLACEMENT 1. Turn off the main switch and open the feed-in cover [A]. 2. Remove the feed roller assembly [B] by pulling it towards the front. 3. Replace the feed roller. NOTE: When installing the feed roller assembly, make sure the pins [C, D] on both sides are fixed properly.
Page 497: Friction Belt Replacement
REPLACEMENT AND ADJUSTMENT 7.3 FRICTION BELT REPLACEMENT 1. Turn off the main switch and open the feed-in cover [A]. 2. Gently pull up the friction belt assembly [B] and remove it from the shaft. 3. Replace the friction belt [C]. A166/A187/A189 7-20...
Page 498: Original Set And Original Width Sensor Replacement
REPLACEMENT AND ADJUSTMENT 7.4 ORIGINAL SET AND ORIGINAL WIDTH SENSOR REPLACEMENT 1. Turn off the main switch. 2. Remove the upper cover [A] (7 screws). 3. Remove the pick-up solenoid spring [B]. 4. Remove the stopper/pressure lever shaft [C] (2 E-rings). 5.
Page 499: Vertical Registration Adjustment
REPLACEMENT AND ADJUSTMENT 7.5 VERTICAL REGISTRATION ADJUSTMENT 7.5.1 One Sided Thin Original Mode Note: • After replacing the DF main board, always do the Rough Adjustment using VR101 first. Then do the Fine Adjustment procedure. • At other times, just do the Fine Adjustment procedure. •...
Page 500: Two Sided Original Mode
REPLACEMENT AND ADJUSTMENT 7.5.2 Two Sided Original Mode Note: • After replacing the DF main board, always do the Rough Adjustment using VR102 first. Then do the Fine Adjustment procedure. • At other times, just do the Fine Adjustment procedure. •...
Page 501: Side-To-Side Registration (Df Positioning) Adjustment
REPLACEMENT AND ADJUSTMENT 7.6 SIDE-TO-SIDE REGISTRATION (DF POSITIONING) ADJUSTMENT Note: • First, adjust the DF side-to-side registration using the copier SP mode for this (see Replacement and Adjustment - Side-to-Side Registration Adjusment in the copier manual). • Do the following adjustment only when the registration cannot be brought within the specification (0 ±...
Page 502: Paper Tray Unit
PAPER TRAY UNIT A549/550...
Page 504: Specifications
Rev. 1/97 SPECIFICATIONS 1. SPECIFICATIONS Configuration: Two-tray table or three-tray table Copy Paper Size: Maximum A3/11" X 17" Minimum B5/8 " X 5 " Copy Paper Weight: 52 - 105 g/m , 14 - 28 lb Copy Paper Capacity: Approximately 500 sheets Paper Feed Speed: 20 ~ 40 copies/minute (A4 / 8 "X11"...
Page 505: Component Layout
COMPONENT LAYOUT 2. COMPONENT LAYOUT 2.1 MECHANICAL COMPONENT LAYOUT 1. Paper Tray 1 6. Lower Right Door 2. Pick-up Roller 7. Paper Lift Motors 3. Paper Feed Roller 8. Paper Tray 3 (A549 model only) 4. Relay Rollers 9. Paper Tray 2 5.
Page 506: Drive Layout
COMPONENT LAYOUT 2.2 DRIVE LAYOUT A549V503.img 1. Vertical Transport Roller Gears 6. Main Motor 2. Paper Feed Clutch 1 7. Relay Clutch 3. Paper Feed Clutch 2 8. Timing Pulley 4. Separation Roller Gears 5. Paper Feed Clutch 3 A166/A187/A189...
Page 507 COMPONENT LAYOUT 2.3 ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the Point to Point Diagram (on the large sized sheet). Index Symbol Description Note Motors Main Drives all the components of the paper tray Tray lift 1 Raises the bottom plate in the paper tray Tray lift 2...
Page 508: Overview
OVERVIEW 3. OVERVIEW There are two versions of this paper tray unit: the two-tray and three-tray versions. Each paper tray [A] is a drawer type that can hold up to 500 sheets of paper. The paper feed mechanism uses an FRR feed system. The function of the system is exactly the same as for the main machine except that there is no paper size detection.
Page 509: Drive Mechanism
DRIVE MECHANISM 4. DRIVE MECHANISM All the tray rollers are driven by the main motor [A] via timing belts, clutches and a train of gears. Drive is transmitted to the timing pulley [B] through the timing belt [C], relay clutch [D] and the gears. Paper Feed Unit 1: The drive from the timing pulley is transmitted to the unit through the timing belt [E].
Page 510: Paper Feed And Misfeed Detection Timing
PAPER FEED AND MISFEED DETECTION TIMING 5. PAPER FEED AND MISFEED DETECTION TIMING A4 Sideways, Lower Paper Feed Station, Line speed 200 mm/s J1 and J2: Checks whether the sensor is activated within 500 ms after the designated time for these sensors. A166/A187/A189...
Page 511: Service Tables
SERVICE TABLES Rev. 1/97 6. SERVICE TABLES 6.1 DIP SWITCHES DIP SW 101 (Free Run Mode) Function Off On Off On Off Off Off Off Standard Factory Setting, A550 Off On Off On On Off Off Off Standard Factory Setting, A549 Speed in the free run mode: 200 mm/s Speed in the free run mode: 150 mm/s On Off...
Page 512: Test Points
SERVICE TABLES Free Run Mode 1 The paper feed operation performs up to 20 times for each paper feed station. (10 s) (10 s) (10 s) 1st feed station 2nd feed station 3rd feed station Repeat Two paper feed tray type Repeat Three paper feed tray type Free Run Mode 2...
Page 513: Replacement And Adjustment
REPLACEMENT AND ADJUSTMENT 7. REPLACEMENT AND ADJUSTMENT 7.1 EXTERIOR COVER REMOVAL Rear Cover [A]: (2 screws) Front Lower Cover [B]: [Two-tray type only] 1. Slide out the cassettes. 2. Remove the front lower cover (2 screws). Right Front Cover [C]: 1.
Page 514: Paper Feed Clutch Replacement
REPLACEMENT AND ADJUSTMENT 7.2 PAPER FEED CLUTCH REPLACEMENT 1. Remove the rear cover (see Exterior Cover Removal). 2. Remove the timing belt [A]. 3. Remove the drive unit [B] (2 screws, 2 connectors). 4. Remove the separation roller gear [C]. 5.
Page 515: Paper Feed Unit Replacement
REPLACEMENT AND ADJUSTMENT 7.3 PAPER FEED UNIT REPLACEMENT 1. Remove the paper feed clutch (see Paper Feed Clutch Replacement). 2. Remove the paper feed roller gear [A]. 3. Pull out all the trays. 4. Two-tray type only: Remove the front lower cover (see Exterior Cover Removal).
Page 516: Feed Roller, Pick-Up Roller, And Reverse Roller Replacement
REPLACEMENT AND ADJUSTMENT 7.4 FEED ROLLER, PICK-UP ROLLER, AND REVERSE ROLLER REPLACEMENT 1. Remove the paper feed tray [A] (4 screws). 2. Remove the feed roller [B], pick-up roller [C], and reverse roller [D] (1 clip each). NOTE: After reinstalling the paper tray, perform the side-to-side registration adjustment (see Removal and Adjustment in the manual for the copier).
Page 517: Relay Sensor Replacement
REPLACEMENT AND ADJUSTMENT 7.5 RELAY SENSOR REPLACEMENT 1. Remove the rear cover (see Exterior Cover Removal). 2. Remove the right rear cover (see Exterior Cover Removal). 3. Remove the drive unit [A] (2 screws, 2 connectors). 4. Remove the vertical transport unit [B] (2 screws). 5.
Page 518 10-BIN SORTER STAPLER A555...
Page 520: Specifications
SPECIFICATIONS 1. SPECIFICATIONS Paper Size for Bins: Sort/Stack Modes: Maximum: A3, 11 x 17" Minimum: B5, 8 x 11" Paper Weight for Bins: Sorting: 52 ~ 157 g/m (14 ~ 42 lb) Stacking: 52 ~ 157 g/m (14 ~ 42 lb) Stapling: 52 ~ 80 g/m (14 ~ 21 lb)
Page 521 SPECIFICATIONS Staple Replenishment: Cartridge exchange (2,000 staples/cartridge) Power Source: DC 24 V, 5 V (from the copier) Power Consumption: Average: less than 33 W Average for Sorting: less than 25 W Average for Stapling: less than 33 W Weight: 12.4 kg (27.4 lb) Dimensions (W x D x H): 381 x 548 x 443 mm (15.0"...
Page 522: Component Layout
COMPONENT LAYOUT 2. COMPONENT LAYOUT 2.1 MECHANICAL COMPONENT LAYOUT 1. Helical Wheels 5. Staple Unit 2. Jogger Plate 6. Bins 3. Grip Assembly 7. Proof Tray 4. Transport Rollers A166/A187/A189...
Page 523: Drive Layout
COMPONENT LAYOUT 2.2 DRIVE LAYOUT 1. Jogger Drive Belt 5. Jogger Motor 2. Transport Roller 6. Wheel Drive Belts 3. Helical Wheels 7. Bin Drive Motor 4. Transport Motor 8. Jogger Plate A166/A187/A189...
Page 524 COMPONENT LAYOUT 2.3 ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the Point to Point Diagram (on large sized sheet). Symbol Index No. Description Note Motors Transport Drives the transport roller Jogger Drives the jogger plate to square the copies Bin Drive Drives the bins...
Page 525: Basic Operation
BASIC OPERATION 3. BASIC OPERATION 3.1 NORMAL MODE AND SORT/STACK MODE Copies exiting the copier pass through the entrance guide plate [A]. The transport roller will send copies either to the proof tray or to each bin, depending on the selected mode. During copying, all rollers in the sorter stapler transport the paper at a speed which depends on the copier.
Page 526: Normal Mode And Sort/Stack Mode
BASIC OPERATION The first copy of the second original is delivered to the final bin that was used for the first original, then the final bin descends one step. The bins descend each time a copy of the second original is delivered. The direction of motion of the bins alternates for each page of the original until the copy run is finished.
Page 527: Staple Mode
BASIC OPERATION 3.2 STAPLE MODE Stapling is only available in sort mode. When the jogger plate has squared the final set of copies, the grip arms [A] move inside the front side frame and catch the paper. The grip assembly brings the copies into the stapler [B], and the stapler staples the copies.
Page 528 BASIC OPERATION There are two staple modes. Automatic Stapling In ADF mode, when staple mode is selected before pressing the Start key, copies will be delivered to each bin and stapled automatically. Manual Stapling In platen cover mode, after the copies have been sorted into the bins, the staple mode LED starts to blink.
Page 529: Bin Drive Mechanism
BASIC OPERATION 3.3 BIN DRIVE MECHANISM The bin drive mechanism moves the bins up and down to receive copies. There are four pins on each bin. Two pins fit into the slots [A] in both the front and rear side frames; the pins slide up and down in these slots. The other two pins fit into the slot in the helical wheels;...
Page 530: Bin Home Position
BASIC OPERATION 3.4 BIN HOME POSITION The bin home position sensor [A] ensures that the proof tray is lower than the transport roller when the bins are in the home position. When the main switch is turned on, the sorter stapler initializes itself to ensure component operation.
Page 531: Jogger Mechanism
BASIC OPERATION 3.5 JOGGER MECHANISM The jogger motor [A] drives the jogger plate [B] via timing belts [C]. The jogger is at home position when the actuator on the jogger plate enters the jogger home position sensor [D]. At standby, the jogger plate is at the home position. When the Start key is pressed, the copier sends the paper size information to the sorter stapler.
Page 532: Grip Assembly
BASIC OPERATION 3.6 GRIP ASSEMBLY The grip assembly consists of the grip motor [A], the timing belt [B], the drive gear [C], the grip home position sensor [D], and the cam gear [E]. The grip motor drives the cam gear through the timing belt and drive gear. Cam gear rotation drives the mechanism that catches the copies and moves the grip arm unit [F].
Page 533: Stapler Unit
BASIC OPERATION 3.7 STAPLER UNIT The stapler motor [A] drives the staple hammer [B] via the gears [C] and the eccentric cam [D]. The roller [E] feeds the sheets to be stapled under the hammer. When the aligned copies are brought to the staple position by the grip unit, the stapler motor starts rotating and the copies are stapled.
Page 534: Stapler Switch
BASIC OPERATION 3.8 STAPLER SWITCH The stapler switch [A] below the grip assembly removes the 24 volt line to the stapler. In proof mode, all bins lower and push lever [B]. This opens the stapler switch so that the signal to the stapler is cut. In sort and staple modes, all bins are advanced and the switch is closed so that the signal can be supplied to the stapler.
Page 535: Paper Feed And Misfeed Detection Timing
BASIC OPERATION 3.9 PAPER FEED AND MISFEED DETECTION TIMING A4 sideways, 5 copies, 150 mm/s – Proof Mode – *1: The value of the low speed depends on the copier. – Sorter Mode – A4 sideways, two copies a of two-page original, 150 mm/s *1: The start timing of the bin drive and the jogger motors depend on the paper size as shown in the following table.
Page 536 BASIC OPERATION – Staple Mode – A4 sideways, two copies of a two-page original, after sorting, 150 mm/s 9-17 A166/A187/A189...
Page 537: Jam Detection
BASIC OPERATION 3.10 JAM DETECTION – Paper Jam – J1: The sorter entrance sensor does not turn on within 2 s after the fusing exit sensor has turned on. J2: The fusing exit sensor does not turn off within 11.4 s after the sorter entrance sensor has turned on.
Page 538: Service Tables
SERVICE TABLES 4. SERVICE TABLES 4.1 DIP SWITCHES DIP SW100 Switch No. Function Normal Setting Sorter Free Run Staple Free Run System Free Run Bin Jam Sensor Adjustment (refer to the A555 Replacement and Adjustment section 5.6) Using a Free Run Mode 1.
Page 539: Test Points
SERVICE TABLES 4.2 TEST POINTS Number Function TP100 +24 V TP101 +5 V TP102 4.3 LED Number Function LED100 Bin jam sensor status 4.4 VARIABLE RESISTOR Number Function Bin jam sensor (LED) adjustment VR100 (see Bin Jam Sensor Adjustment) A166/A187/A189 9-20...
Page 540: Replacement And Adjustment
REPLACEMENT AND ADJUSTMENT 5. REPLACEMENT AND ADJUSTMENT 5.1 EXTERIOR COVER REMOVAL 1. Rear Cover [A] (2 screws) 2. Front Cover [B] (3 screws) 3. Lower Cover [C] (1 screw) 4. Top Cover [D] (2 screws) 5.2 STAPLE UNIT REMOVAL 1. Remove the front cover (see Exterior Cover Removal). 2.
Page 541: Grip Arm Replacement
REPLACEMENT AND ADJUSTMENT 5.3 GRIP ARM REPLACEMENT 1. Remove the front cover (see Exterior Cover Removal). 2. Remove the grip assembly [A] (4 screws, 2 connectors, 1 grounding wire). 3. Remove the holder bracket [B] (1 screw). 4. Remove the spring [C] and remove the slider [D]. 5.
Page 542: Bin Replacement
REPLACEMENT AND ADJUSTMENT 5.4 BIN REPLACEMENT 1. Remove the front, rear, and top covers (see Exterior Cover Removal in this section). 2. Remove the spring [A] and the grip cover [B] (2 screws). 3. Remove the upper stay bracket [C] (6 screws, 1 grounding wire, 1 connector).
Page 543: Transport Motor Replacement
REPLACEMENT AND ADJUSTMENT 5.5 TRANSPORT MOTOR REPLACEMENT 1. Remove the sorter stapler [A] (1 screw, 1 chain). 2. Remove the lower plate [B] (3 screws). 3. Remove the entrance guide [C] (4 screws). 4. Remove the transport motor unit [D]. 5.
Page 544: Bin Jam Sensor Adjustment
REPLACEMENT AND ADJUSTMENT 5.6 BIN JAM SENSOR ADJUSTMENT After replacing the sorter main board, perform the bin jam sensor adjustment as follows. 1. Turn on the main switch. 2. Remove any copies from the bins. 3. Set switch 5 of DIP SW 100 on the sorter main board to the ON position. 4.
Page 546 SECTION 10 FILM PROJECTOR UNIT SPU 3 (A718)
Page 548: Specifications
SPECIFICATIONS 1. SPECIFICATIONS • Acceptable Film Types: Type: Positive film/Negative film • Size: 35 mm - Approx. 140 x 210 mm Others: 45 x 60 mm, 60 x 60 mm, 60 x 70 mm, 60 x 80 mm, 60 x 90 mm, 4" x 5" Max: 142 x 210 mm or 5.6"...
Page 549: Electrical Component Layout And Descriptions
ELECTRICAL COMPONENT LAYOUT AND DESCRIPTIONS 2. ELECTRICAL COMPONENT LAYOUT AND DESCRIPTIONS Index Symbol Name Function Projector Lamp Regulator Supplies dc voltage to the projector lamp PCB1 and lamp cooling fan. Projector Control Board Controls the projector unit, PCB2 communicating with the copier main board.
Page 550: Sectional Descriptions
SECTIONAL DESCRIPTIONS 3. SECTIONAL DESCRIPTIONS 3.1 OVERVIEW This film projector unit allows making copies from the following kinds of films: 35 mm positive slides (both mount films and glass mount films) 35 mm negative or positive strip films Positive or negative films of wide size (45 x 60 / 60 x 60 / 60 x 70 / 60 x 80 / 60 x 90 mm / 4"...
Page 551: Shading
SECTIONAL DESCRIPTIONS 3.2 SHADING This "Shading" should be performed whenever the type of film is changed or the mirror unit is moved. When the projector unit is selected, shading should be done after selecting the type of film. The shading should be done with a base film and the N-correction filter for the negative films and with the P-correction filter (without base film) for the positive films.
Page 552: Mirror Unit
SECTIONAL DESCRIPTIONS 3.3 MIRROR UNIT Subscan Main scan direction direction The film image projected through the projection lens [A] is reflected to the Fresnel lens [B] by the mirror [C]. The Fresnel lens consists of two components, a circle pitch Fresnel lens [D] and a parallel pitch Fresnel lens [E].
Page 554 SECTION 11 APPENDIX...
Page 556 APPENDIX 1 TIMING CHARTS...
Page 557: Timing Chart 1 Normal Speed/Bk/A4
TIMING CHART 1 [Normal speed/Bk/A4] 1. Start Key 2. Drum Motor 4 7 3 3 3. Main Motor 4 7 8 7 5 3 0 5 4. Belt H.P. Detection 2 7 8 0 5. Scanner Lamp 6. Scanner Motor 7.
Page 558: Timing Chart 2 Normal Speed/Bk/A3
TIMING CHART 2 [Normal speed/Bk/A3] 1. Start Key 2 . D r u m M o t o r 4 7 3 3 3 . M a i n M o t o r 4 7 8 7 5 3 0 5 4.
Page 559 TIMING CHART 3 [Normal speed/Red/A4] 1. Start Key 2. Drum Motor 4733 3. Main Motor 5305 4787 4. Belt H.P. Detection 5. Scanner Lamp 6. Scanner Motor 7. FGATE 2000 8. QL 9. Charge corona 10. Development Bias DC 1000 1495 11.
Page 560 TIMING CHART 4 [Normal speed/Red/A3] 1. Start Key 2. Drum Motor 4733 5305 3. Main Motor 4787 4. Belt H.P. Detection 5. Scanner Lamp 6. Scanner Motor 7. FGATE 4000 8. QL 9. Charge corona 1000 1495 10. Development Bias DC 1467 11.
Page 561: Timing Chart 5 Normal Speed/Green/A4
TIMING CHART 5 [Normal speed/Green/A4] 1. Start Key 2 . D r u m M o t o r 4 7 3 3 3 . M a i n M o t o r 4 7 8 7 5 3 0 5 4.
Page 562 TIMING CHART 6 [Normal speed/Green/A3] 1. Start Key 2 . D r u m M o t o r 4 7 3 3 3 . M a i n M o t o r 4 7 8 7 5 3 0 5 4.
Page 563 TIMING CHART 7 [Normal speed/Full Color/A4] 1. Start Key 2. Drum Motor 4733 3. Main Motor 4787 5305 4. Belt H.P. Detection 5. Scanner Lamp 6. Scanner Motor 7. FGATE 2000 8. QL 9. Charge corona 1000 10. Development Bias DC 1495 11.
Page 564: Timing Chart 8 Normal Speed/Full Color/A3
TIMING CHART 8 [Normal speed/Full Color/A3] 1. Start Key 2. Drum Motor 4733 3. Main Motor 4787 5305 4. Belt H.P. Detection 5. Scanner Lamp 6. Scanner Motor 7. FGATE 4000 8. QL 9. Charge corona 1000 10. Development Bias DC 1495 11.
Page 565 TIMING CHART 9 [Half-speed/Bk/A4] 1. Start Key Half-speed 2. Drum Motor 4733 3724 14495 Half-speed 3. Main Motor 5305 4. Belt H.P. Detection 5. Scanner Lamp 6. Scanner Motor 7. FGATE 2000 8. QL 9. Charge corona 1000 10. Development Bias DC 1495 1190 11.
Page 566 TIMING CHART 10 [Half-speed/Bk/A3] 1. Start Key H a l f - s p e e d 2 . D r u m M o t o r 8 5 6 2 4 7 3 3 1 8 4 9 5 3 .
Page 567: Timing Chart 11 Half-Speed/Red/A4
TIMING CHART 11 [Half-speed/Red/A4] 1. Start Key Half-speed 3724 4733 2. Drum Motor 14495 Half-speed 4787 5305 3. Main Motor 4. Belt H.P. Detection 5. Scanner Lamp 6. Scanner Motor 7. FGATE 2000 8. QL 9. Charge corona 1000 10. Development Bias DC 1495 11.
Page 568 TIMING CHART 12 [Half-speed/Red/A3] 1. Start Key Half-speed 2. Drum Motor 8562 4733 18495 3. Main Motor 4787 Half-speed 5305 4. Belt H.P. Detection 5. Scanner Lamp 6. Scanner Motor 7. FGATE 4000 8. QL 9. Charge corona 1000 10. Development Bias DC 1495 11.
Page 569 TIMING CHART 13 [Half-speed/Green/A4] 1. Start Key Half-speed 2. Drum Motor 14495 3724 4733 3. Main Motor 4787 (Half-speed) 5305 4. Belt H.P. Detection 5. Scanner Lamp 6. Scanner Motor 7. FGATE 2000 8. QL 9. Charge corona 1000 10. Development Bias DC 1495 11.
Page 570 TIMING CHART 14 [Half-speed/Green/A3] 1. Start Key H a l f - s p e e d 2. Drum Motor 4 7 3 3 8 5 6 2 1 8 4 9 5 3. Main Motor 4 7 8 7 H a l f - s p e e d 5 3 0 5 4.
Page 571 TIMING CHART 15 [Half-speed/Full Color/A4] 1. Start Key Half Speed 2 . D r u m M o t o r 3724 4733 14495 3 . M a i n M o t o r 4787 Half Speed 5305 4. Belt H.P. Detection 5 .
Page 572 TIMING CHART 16 [Half-speed/Full Color/A3] 1. Start Key H a l f S p e e d 2 . D r u m M o t o r 8 5 6 2 1 8 4 9 5 4 7 3 3 3 .
Page 573 TIMING CHART 17 [Cartridge check sequence] 1. Start Key 2. Drum Motor 3. Main Motor 4787 4. Belt H. P. Detection 5. QL 6. Charge Corona 7. Development Bias DC 8. Development Bias AC 9. Development Motor 10. Toner Supply Motor C k 1 C k 2 C k 3 11.
Page 574: Timing Chart 18 Sequence For The Revolver H
TIMING CHART 18 [Sequence for the Revolver H.P. Process] 1. Start Key 2. Drum Motor 4 7 3 3 3. Main Motor 4 7 8 7 4. Belt H.P. Detection 5. QL 5 3 0 5 5 6 1 6. Charge Corona 3 2 6 7 1 0 0 0 7.
Page 575 TIMING CHART 19 [Sequence for Lubrication] (Forced Belt Cleaning) 1. Start Key 2. Drum Motor 4 7 3 3 3. Main Motor 4 7 8 7 4. Belt H.P. Detection 5. QL 5 3 0 5 6 0 0 6. Charge Corona 4 1 2 4 1 0 4 1 7.
Page 576 APPENDIX 2 SP TABLE Groups of SP Modes SP mode has 8 groups as follows: (1) Paper Feed/Transport/Fusing (2) Around the Drum/Belt Units (3) Process Control (4) Scanner (5) Operation and System (6) Peripherals (7) Logged Data (8) Others Do not change the data in the field: Report Column: : Printed with SP7-902 (if changed from the default) and 7-903 : Printed with SP7-809...
Page 577 PAPER FEED/TRANSPORT/FUSING Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe PAPER FEED/TRANSPORT/FUSING 1 Lead Edge Regist.:Nrml Shifts the vertical image position -5.0 to +5.0 (mm) See "Replacement and by changing the ON timing of the Adjustment: Copy Image registration clutch for each paper Adjustments"...
Page 578 PAPER FEED/TRANSPORT/FUSING Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the target temperature of the hot roller during idling. After the Do not input a value higher Set Hot Rllr.Tmp.Idling 130 to 170 (°C) setting is changed, the main than 167°C.
Page 579 PAPER FEED/TRANSPORT/FUSING AROUND THE DRUM/BELT UNITS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Displays the temperature on the Normal range in stand-by Pressure Roller Temp surface of the central area of the 0 to 200 (°C) mode: 150 to 157°C pressure roller.
Page 580 AROUND THE DRUM/BELT UNITS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Adjusts the blank margin at the Trail Mrgn (OHP/Thk) trailing edge in OHP/thick paper 0 to 10.0 (mm) mode. Adjusts the blank margin at the Trail Mrgn (Thk/Back) trailing edge for the reverse side 0 to 10.0 (mm)
Page 581 AROUND THE DRUM/BELT UNITS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Adjusts the paper transfer current to compensate for various high Do not change the factory 301 21 Paper Trans Current voltage supply boards (using the 100 to 400 (µA) setting.
Page 582 AROUND THE DRUM/BELT UNITS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the paper transfer current for 301 38 P.T.C.Sp:1/2Spd:1C 1C mode with special paper, 30 to 800 (µA) when the belt is at half speed. Sets the paper transfer current for Do not change the factory 301 39 P.T.C.Special:1/2Spd:2C...
Page 583 AROUND THE DRUM/BELT UNITS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the paper transfer current for 301 47 P.T.C.(Nrml/Lead Edge) 2C and 4C mode at the leading 30 to 800 (µA) edge of normal paper. Sets the paper transfer current for 301 48 P.T.C.(Thin/Lead Edge) 2C and 4C mode at the leading...
Page 584 AROUND THE DRUM/BELT UNITS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the paper transfer current for 2C and 4C mode at the leading 301 57 P.T.C.(Nrml-Bk/Trail) 30 to 800 (µA) edge of the back side of thick paper.
Page 585 AROUND THE DRUM/BELT UNITS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the paper transfer current for 301 69 P.T.C.(1C/Nrml-Bk/Trail) 1C mode at the trailing edge of 30 to 800 (µA) the back side of normal paper. Do not change the factory settings.
Page 586 AROUND THE DRUM/BELT UNITS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the duration for the forced Do not change the factory Forced Blt Cleaning Time 0 to 999 (s) belt cleaning (2-311). setting. Do this after replacing the Forced Belt Cleaning Cleans the belt.
Page 587 AROUND THE DRUM/BELT UNITS PROCESS CONTROL Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the negative voltage applied to the paper transfer corona unit. Do not change the factory Paper Trans Reverse Crnt 1700 1000 to 2500 V This is applied at all times, except setting.
Page 588 PROCESS CONTROL Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Dev Ptnl ID Sn Ptrn:K Sets the development potential for 0 to 300 (V) the ID sensor pattern for each Do not change the factory Dev Ptnl ID Sn Ptrn:C 0 to 300 (V) color (VB - VL at the ID sensor...
Page 589 PROCESS CONTROL Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Toner Supply Coef:K 0 to 100 (%) Sets the toner supply coefficient in Do not change the factory Toner Supply Coef:C 0 to 100 (%) fixed supply mode for each color.
Page 590 PROCESS CONTROL Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the coefficient used to calculate the toner supply ratio for Tnr End Rec Coef:K toner end recovery for Bk. The 0 to 1000 greater this coefficient is, the Do not change the factory smaller the toner supply is.
Page 591 PROCESS CONTROL Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Displays the Copy Count This is one of the correction Correction for the development Dev Ptnl Comp Cpy Cnt:K -32767 to 32767 factors mentioned above. It potential for the ID sesnor pattern is done in the Confirmation for each color.
Page 592 PROCESS CONTROL Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Actual VD: K Displays the actual VD after the 0 to 65535 (V) process control for each color. Actual VD: C 0 to 65535 (V) If this value is not within +/- 5V of Actual VD: M 0 to 65535 (V)
Page 593 PROCESS CONTROL Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Do this after replacing the drum, unless the developer Performs the forced process Forced P-Ctrl Self Chk 1: Start was replaced at the same control self check. time, in which case it can be omitted.
Page 594 PROCESS CONTROL SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sends the data concerning Do not change the factory P-Ctrl Data Tx process control through the serial 0 to 5 setting. port (the optics fiber) to the P/C. See the developer agitation Displays the result of the most 01: Success...
Page 595 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the blank margin for the rear Do not change the factory Scanning Blnk Mrgn:Rear side (as viewed form the 0.0 to 3.0 (mm) settings. operation side of the machine). Sets the blank margin for the front Do not change the factory Scanning Blnk Mrgn:Front...
Page 596 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe R_GAIN 0 G_GAIN 0 Sets or displays the gain value of Keep all these at the factory B_GAIN 0 the amplifiers on the scanner IPU 0 to 255 settings.
Page 597 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Performs IPU board test 1. The test 1 program diagnoses problems with register Write/Read IPU Board Test 1 of the LSIs on the IPU board ON: Start, OFF: C/S (except the picture element Use this to test the scanner correction LSI and SCSI FIFO).
Page 598 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Adjusts the offset data of the K:Letter/Offset:L printer gamma (lower range) for 0 to 31 Bk in Letter mode. If the user does not like the Adjusts the offset data of the color output after doing the K:Letter/Offset:M...
Page 599 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Adjusts the offset data of the M:Letter/Offset:L printer gamma (lower range) for M 0 to 31 in Letter mode. If the user does not like the Adjusts the offset data of the color output after doing the M:Letter/Offset:M...
Page 600 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Adjusts the offset data of the printer gamma (lower range) for K(SC):Letter/Offset:L 0 to 31 Bk (single color mode) in Letter mode. If the user does not like the Adjusts the offset data of the color output after doing the printer gamma (medium range) for...
Page 601 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Adjusts the offset data of the C:Photo/Offset:L printer gamma (lower range) for C 0 to 31 in Photo mode. If the user does not like the Adjusts the offset data of the color output after doing the C:Photo/Offset:M...
Page 602 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Adjusts the offset data of the Y:Photo/Offset:L printer gamma (lower range) for Y 0 to 31 in Photo mode. If the user does not like the Adjusts the offset data of the color output after doing the Y:Photo/Offset:M...
Page 603 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Adjusts the offset data of the C:G-Photo/Offset:L printer gamma (lower range) for C 0 to 31 in Glossy Photo mode. If the user does not like the Adjusts the offset data of the color output after doing the C:G-Photo/Offset:M...
Page 604 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Adjusts the offset data of the Y:G-Photo/Offset:L printer gamma (lower range) for Y 0 to 31 in Glossy Photo mode. If the user does not like the Adjusts the offset data of the color output after doing the Y:G-Photo/Offset:M...
Page 605 SCANNER Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Color Background: R1 Color Background: G1 Programs the density level of Color Background: B1 Used only for the edit each color for the color 1 to 10 Color Background: C1 machine background.
Page 606 SCANNER OPERATION AND SYSTEM Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe OPERATION AND SYSTEM If Yes is selected, paper sizes that cannot be Selects whether the copier detected by the APS sensors determines that the original is A5 0: No, 1:Yes are regarded as A5 APS Smallest Size...
Page 607 OPERATION AND SYSTEM Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe 1: English (NA) 1. When the setting is NA, 2: English (EU) the original size detection is set to LT/DLT version. 3: German (EU) 4: French (EU) 2.
Page 608 OPERATION AND SYSTEM Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Specifies whether the current Clear Md On/Off Key Cntr mode is cleared or not when the 0: Cleared, 1: Kept key counter is removed. Selects the update timing for the 0: Paper Feed-in Cntr Updt Tmg Key Cnter...
Page 609 OPERATION AND SYSTEM Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Set Date: Day Sets the day of the date. 1 to 31 (Date) Set Time: Hour Sets the hour of the time. 0 to 23 (Hour) Set Time: Minute Sets the minute of the time.
Page 610 Rev. 11/96 OPERATION AND SYSTEM Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Sets the toner amount ratio of C Ratio in Blue 0 to 100 (%) cyan in blue. Sets the toner amount ratio of M Ratio in Blue 0 to 100 (%) magenta in blue.
Page 611 Rev. 11/96 OPERATION AND SYSTEM Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Resets a type 1 service call condition that was caused by the See section 6, Fusing SC Reset fusing unit. After doing 1: Reset "Troubleshooting"...
Page 612 OPERATION AND SYSTEM Rev. 11/96 Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe When the polygon motor Adjusts the time from after making current is off and start key is image on the drum until the pressed, the copy process polygon motor current turns off.
Page 613 PERIPHERALS Rev. 11/96 Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe PERIPHERALS Starts the FPU free run with the FPU Free Run following conditions: FPU lamp ON: Start, OFF: C/S FPU: Film Projector Unit on, Scanner lamp off Starts the shading for the film Do this to test the shading Shading : FPU...
Page 614 PERIPHERALS Rev. 11/96 LOGGED DATA Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Selects whether there is a stapling limit for the sorter stapler. On: Copies of up to 20 pages can Staple Sheet Limit 0: OFF, 1: ON be stapled for all paper sizes.
Page 615 LOGGED DATA Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe CE Counter: B/W These counters can be used by 0 to 9999999 (copies) the technician for any purpose. They increment at the same time CE Counter: FC 0 to 9999999 (copies) as the main counter.
Page 616 LOGGED DATA Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Counter: Normal 0 to 9999999 Counter: OHP/Thick 0 to 9999999 Displays the total number of Counter: Thin 0 to 9999999 copies in each mode. For non-standard sized Counter: Odd Paper 0 to 9999999 paper on the by-pass tray.
Page 617 LOGGED DATA Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe 302 17 Copy Data: AP1/1 0 to 9999999 302 18 Copy Data: AP1/2 0 to 9999999 302 19 Copy Data: AP1/3 0 to 9999999 302 20 Copy Data: AP1/4 Not used 0 to 9999999 Not used...
Page 618 LOGGED DATA Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe SC Counter: Scan 0 to 10000 Displays the service call counters SC Cntr:Charge/LD/Dev. 0 to 10000 for each service call code. By SC Cntr:T&S/Clean/QL/Drm 0 to 10000 pressing the "+"...
Page 619 LOGGED DATA Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Displays data for the latest 10 Paper Jam (Last10) 80 digits See section 4. (1.3.15) paper jams. Displays data for the latest 10 Original Jam (Last10) 80 digits See sectoin 4.
Page 620 LOGGED DATA OTHERS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Dev.Counter Clear:K 1: Clear Resets the development counter Dev.Counter Clear:C 1: Clear for each color. Dev.Counter Clear:M 1: Clear Dev.Counter Clear:Y 1: Clear Clears the paper size copy Op Cntr Clear:Ppr Sz counters (displayed with 1: Clear...
Page 621 OTHERS Default, 1st 2nd 3rd Display Function Settings/Range Comments Report ( ): For Europe Beeper See UP5-3 in section 4 (2.2) 0, 1 Set User R/E-1 See UP5-4 in section 4 (2.2) 0, 25 to 400 (%) Set User R/E-2 See UP5-4 in section 4 (2.2) 0, 25 to 400 (%) Rcycl Ppr Setting:Tray...
Page 622 OTHERS Default, Display Function Settings/Range Comments Report ( ): For Europe SADF Auto Reset See UP7-3 in section 4 (2.2) 5 to 60 (s) These SP modes can not be ADF Free Size See UP7-4 in section 4 (2.2) 0, 1 accessed from the SP Auto Sort Selection See UP7-6 in section 4 (2.2)
Page 624 TECHNICAL SERVICE BULLETINS...
Page 626 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO 2103/2203 - 001 12/03/96 APPLICABLE MODEL: AFICIO 2103/2203 SUBJECT: SERVICE MANUAL - INSERT GENERAL: The Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin package contains 1 set of replacement pages. PAGES: ⇒...
Page 627 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U####%*-'-3#'3036#FNNGfFENGfFFNG#g#NNF NGfEGfMK %440-'%&0)#13()0U# %*-'-3#'3036#FNNG SUBJECT: OIL MARKS ON LEADING EDGE OF FIRST COPY GENERAL: The Cleaning Blade Bracket has been modified to change the contact angle of the pressure roller cleaning blade from 12 degrees to 20 degrees. This is to prevent oil marks on the leading edge of the first copy after a long (more than 2 days) period of inactivity.
Page 628 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U####%*-'-3#'3036#FNNGfFENGfFFNG#g#NNG NGfEGfMK %440-'%&0)#13()0U# %*-'-3#'3036#FNNGfFENGfFFNG SUBJECT: PARTS CATALOG CORRECTIONS GENERAL: The following Parts Catalog Corrections are being issued for all Aficio Color 2003 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation. 1. Correct your parts Catalog as follows: REFERENCE OLD PART NO.
Page 629 Tech Service Bulletin No. Aficio Color 2003/2103/2203 - 003 Page 2 of 3 2. Add the following parts to your Parts Catalog: REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM 0 → 1 A1661805 Spring Plate 0 → 1 A1661804 Spring Plate - Left Main Corona Rear Seal REFERENCE NEW PART NUMBER...
Page 630 Tech Service Bulletin No. Aficio Color 2003/2103/2203 - 003 Page 3 of 3 Paper Transfer Plate REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM 0 → 1 A1666260 Plate - Paper Transfer * DENOTES NEW ITEM Left Stay REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM...
Page 631 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U####%*-'-3#'3036#FNNGfFENGfFFNG#g#NNH NGfEGfMK %440-'%&0)#13()0U# %*-'-3#'3036#FNNG SUBJECT: DUPLEX COPIES CREASING GENERAL: To prevent creasing of duplex copies, the Hot Roller and Pressure Roller have been changed. This information should be incorporated into all existing Aficio Color 2003 Parts Catalog documentation. REFERENCE OLD PART NO.
Page 632 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 EFfNIfMK &900)8-2#291&)6U####%*-'-3#'3036#FNNGfFENGfFFNG#g#NNH# #6)-779) %440-'%&0)#13()0U# %*-'-3#'3036#FNNG SUBJECT: DUPLEX COPIES CREASING GENERAL: To prevent creasing of duplex copies, the Hot Roller and Pressure Roller have been changed. This information should be incorporated into all existing Aficio Color 2003 Parts Catalog documentation. REFERENCE OLD PART NO.
Page 633 ORDERING PROCEDURE: The following ROM Kits can be obtained until June 30th, 1997, through normal NSPC channels or by downloading a Hex file for local programming via the Ricoh Technical Services BBS (refer to Service News and Information No.147): Aficio Color 2003 & Aficio Color 2103 ROM Kit (FL009014) Aficio Color 2203 ROM Kit (FL009015) - contains four (4) ROMs.
Page 634 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 006 06/13/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all Aficio Color 2003/2103/2203 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation. •...
Page 635 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 007 06/13/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: FIRMWARE UPDATE GENERAL: The following Parts Updates are being issued for all AFICIO COLOR 2003/2103/2203 Parts Catalogs. To enable the scanner and printer function with the installation of the optional controller, the EPROM’s has been changed.
Page 636 UPDATED COLOR FILE TARGETS r3.1 GENERAL: Ricoh Corporation and EFI have developed an update to the XJ80e print server Target for the Aficio 2003/2103/2203 color copiers. The updated color file targets, (refered to as r3.1), improve the print output color quality of the copier when calibrating with either the EFI Print Calibrator (utilizing the Xrite DTP-32 Densitometer) or Calibrating from the copier glass.
Page 637 Tech Service Bulletin No. AFICIO Color 2003/2103/2203 - 008 Page 2 of 2 SUBJECT: UPDATED COLOR FILE TARGETS (r3.1) Fax this entire page in "DETAIL" mode ATTN: Technical Services - Image Processing Department Fax Number: 201-882-3960 Each serial number given will represent a request for one (1) r3.1 CD ROM Update (A7245404) XJ Serial Number (s) All serial number information will be verified before shipment is made.
Page 638 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U####%*-'-3#'3036#FNNGfFENGfFFNG#g#NNM KfFMfMK %440-'%&0)#13()0U# %*-'-3#'3036#FFNG SUBJECT: GUIDANCE DISPLAY ROM’S GENERAL: To enable French, Spanish, and Portuguese, on the Guidance Display use Service Program 5-9-1 to select the desired language. The Guidance Display ROM’s have been changed. The following Parts Updates are being issued for all Aficio Color 2203 Parts Catalogs.
Page 639 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U####%*-'-3#'3036#FNNGfFENGfFFNG#g#NEN NKfFMfMK %440-'%&0)#13()0U# %*-'-3#'3036#FNNGfFENGfFFNG SUBJECT: DUPLEX MODE NOT WORKING SYMPTOM: When a new Main PCB (PCB 6) is replaced Duplex Mode is not working. CAUSE: Dip Switches not set properly on the Main PCB (PCB 6). SOLUTION: Set Dip Switch 201 - 2 to the "ON" position. DPS201 No.
Page 640 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U####%*-'-3#FNNGfFENGfFFNG#g#NEE NKfFMfMK %440-'%&0)#13()0U# %*-'-3#FENGfFFNG SUBJECT: PARTS CATALOG UPDATES • • • • UPDATE NO. 1 - Remove the following parts from your Parts Catalog. REFERENCE PART NO. DESCRIPTION PAGE ITEM 54432668 Bushing 4x6x7mm A1664587 Brush Holder A1664583 Antistatic Brush A1664584 Antistatic Brush Bracket •...
Page 641 Tech Service Bulletin No. Aficio Color 2003/2103/2203 - 011 Page 2 of 2 • • • • UPDATE NO. 3 - Correct the quantity of the following part. Upper Exit Roller REFERENCE PART NO. DESCRIPTION PAGE ITEM AF040031 Upper Exit Roller...
Page 642 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U####%*-'-3#'3036#FNNGfFENGfFFNG#g#NEF NKfFMfMK %440-'%&0)#13()0U# %*-'-3#'3036#FNNGfFENGfFFNG SUBJECT: E1 OR E2 AT POWER UP SYMPTOM: When turning the main power switch "ON", the machine displays one of the following self-diagnostic codes: • E1: Timer Initialization Error • E2: Memory Check Error CAUSE: These self-diagnostic codes are displayed when the CPU detects an abnormal condition during the hardware check routine which is the first routine the SCU performs when the main switch is turned "ON".
Page 643 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U####%*-'-3#'3036#FNNGfFENGfFFNG#g#NEG NLfFMfMK %440-'%&0)#13()0U# %*-'-3#'3036#FFNG SUBJECT: OPERATION MANUAL HOLDER GENERAL: The Operation Manual Holder is now available as a service part. This information should be incorporated into all existing Aficio Color 2203 Parts Catalog documentation. REFERENCE NEW PART NUMBER. DESCRIPTION PAGE ITEM...
Page 644 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 014 09/05/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: NEW DEVELOPER TYPE "G" (COLOR ONLY) GENERAL: In order to improve serviceability of the machine, the developer initialization time has been shortened. A new Printer Main Control Board ROM and the new color developer type "G"...
Page 645 Tech Service Bulletin No. AFICIO COLOR 2003/2103/2203 - 014 Page 2 of 3 Recovery Procedure for Developer Agitation Error Code 75 The condition for Error Code 75 is has not changed. The color which had the error condition can be checked with the SP Mode.
Page 646 Tech Service Bulletin No. AFICIO COLOR 2003/2103/2203 - 014 Page 3 of 3 Installation of Supplemental Toner Bottle in Developer Type "G" Carton Box Note: This procedure is necessary only when installing type "G" developer into a 2003/2103/2203. Each carton of new color developer contains two small bottles containing 30g of corresponding color toner. This supplemental toner should be added to the toner cartridge in the machine before performing developer agitation.
Page 647 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 15 10/17/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: SERVICE MANUAL - INSERT GENERAL: The Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin package contains 1 set of replacement pages.
Page 648 SERVICE CALL CONDITIONS Rev. 10/97 SC990: I/O control board 1 abnormal Type: 2 - Description - This SC is displayed when a serial/parallel I/O error is detected in the I/O control board 1 for a successive five times. - Detection Timing - Always - Possible Causes - •...
Page 649 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 016 12/05/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: PARTS CATALOG CORRECTION GENERAL: The illustration in the Parts Catalog, Toner Hopper section is incorrect, please correct the illustration as shown below.
Page 650 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 017 12/05/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: FUSING UNITS SERVICE INFORMATION GENERAL: To ensure that all 2003/2103/2203 Fusing units have the most current modifications and have the correct parts installed, see the following information.
Page 651 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 018 12/05/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: TRANSFER BELT FAILURE SYMPTOM: Horizontal banding image on the copy in half tone areas. CAUSE: The Transfer Belt is getting curled by the tension applied from the Transfer Belt Rollers, by the two springs which applied the the tension to the Pressure Roller (A1666059).(See page 2 of 2 for illustration) SOLUTION: 1.
Page 652 Tech Service Bulletin No. Aficio Color 2003/2103/2203 - 018 Page 2 of 2 REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM A1666363 AA150689 Toner Collection Plate AA063369 Spring UNITS AFFECTED: All Aficio Color 2003/2103/2203 copiers manufactured after Serial Number A3967080001, A3977070001, & A3997070001 respectively will have the new style Toner Collection Plate installed during production.
Page 653 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 019 12/22/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: FIREFLY SPOT SYMPTOM: The Firefly spots are caused by carrier or toner adhesion on the OPC drum, creating a gap between the drum and the transfer belt, and as a result, the perimeter of the toner or the carrier is not transferred.
Page 654 Tech Service Bulletin No. Aficio Color 2003/2103/2203 - 019 Page 2 of 2 SOLUTIONS: Drop in Toner Density Under normal conditions for toner density, the carrier is covered with toner, but if the toner density drops by approximately 2%, the amount of exposed carrier increases and this results in carrier adhesion. If the toner density is returned to normal levels, this problem can be prevented.
Page 655 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 020 12/22/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: Original Sensor GENERAL: The Original Sensor has been changed to a new type that has an adjustable Potentiometer.This is to enable adjustment of its sensitivity and allow you to compensate for miss-detection of original size.
Page 656 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: AFICIO COLOR 2003/2103/2203 - 021 12/22/97 APPLICABLE MODEL: AFICIO COLOR 2003/2103/2203 SUBJECT: DEVELOPMENT REVOLVER MOTOR NOISE GENERAL: The following Parts Corrections are being issued for all AFICIO COLOR 2003/2103/2203 Parts Catalogs. To reduce the noise level of the development unit rotation, a rubber cushion has been added to the motor. The gear material has been changed from metal to plastic.
Page 657 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U %*-'-3#'3036#FNNGfFENGfFFNG#g#NFE#6)-779)#+ + + + ##########NGfEKfML %440-'%&0)#13()0U %*-'-3#'3036#FNNGfFENGfFFNG SUBJECT: DEVELOPMENT MOTOR NOISE GENERAL: To reduce the noise level of the development unit rotation, a rubber cushion has been added to the motor. The gear material has been changed from metal to plastic. The motor and the gear should be changed at the same time.
Page 658 SUBJECT: LED ARRAY GENERAL: The LED Array for the optional printer interface kit has been installed in the copier at the factory. It is no longer necessary to replace the LED Array when installing the printer option. REFERENCE OLD PART NO.
Page 659 U FNNGfFENGfFFNG g NFG NFfFNfML U FNNGfFENG SUBJECT: OPERATION PANEL DECAL GENERAL: Due to field, request the blank decal for the Operation Panel has been made available as service parts. The following Parts Corrections are being issued for all Aficio Color 2003/2103 Parts Catalogs.
Page 660 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U %*-'-3#'3036#FNNGfFENGfFFNG#g#NFH NFfNMfML %440-'%&0)#13()0U %*-'-3#'3036#FNNGfFENGfFFNG SUBJECT: FUSING OIL OVERFLOW SYMPTOM: Fusing oil overflows from the fusing unit oil pan and drops on the paper tray or the duplex tray. CAUSE: The amount of silicone oil collected by the Pressure Roller Cleaning Blade in the actual field situation exceeds the amount found projected from production testing.
Page 661 Tech Service Bulletin No. Aficio Color 2003/2103/2203 – 024 Page 2 of 2 NOTES: 1. The Pressure Roller Cleaning Blade may scrape off the oil, if only its springs are removed and the blade is remaining in the Fusing Unit. 2.
Page 662 Modification BuIIetin PAGE: l/l Model: SDC103 / SDC103A / SDC103E SDC103 Serial Number: S D C 103A - 4A2707000 1 Modified Article: LED Array Reason for Modification: New Part Old Part Description Q ’ t y I n t . P a g e I n d e x Number Number A1666161...
Page 663 odification ulletin PAGE: 1/1 No: SDC103/A/E - 002 Model: SDC103/A/E Date: 12/5/97 SDC103 - 4A17070001 Serial Number: SDC103/A - 4A27070001 Modified Article: REVOLVER MOTOR, ETC. SDC103/E - 4A37070001 Reason for Parts catalog correction Vendor change To meet standards Modification: To facilitate assembly To improve reliability Part standardization Other...
Page 664 PAGE: 1/3 odification ulletin PAGE: 2/3 No: SDC103 - 003 Model: SDC103 Interface Kit Type D Date: April 3, 1998 (Fiery XJ80e) Modified Article: PARTS CATALOG Serial Number: Reason for Parts catalog correction Vendor change To meet standards Modification: To facilitate assembly To improve reliability Part standardization Other...
Page 665 odification ulletin PAGE: 2/3 IK/D for AZ - 1...
Page 666 Page: 3/3 odification ulletin PAGE: 2/3 One screw was added into the Controller Interface Type D from March mass production. Please correct the following part your parts catalog. Old P/N New P/N Description P/C Location Reason Index No. Page 03130050B 03130080B Philips Pan Head To mount the EXU bracket to 101→103...
Page 667 Field Engineering Bulletin Digital Color BULLETIN NO. O-00001 DATE 03/06/97 Subject: FIERY XJ80e PRINTER CONTROLLER - COPIER SCU ROM UPGRADE Modification Schedule: Model - Product/Serial Numbers Affected I ~ Copy Quality Electrical SDC103 Mechanical Scheduled Visit Modification Next Call Safety Information Next PM Technical Information As Necessaw...
Page 668 Field Engineering Bulletin Digital Color Series TECHNICAL OPERATIONS BULLETIN NO: SDCI 03/A/E - 002 DATE: Model - Product/Serial Numbers Affected Scheduled Visit Symptom El or E2 displayed when main power switch is turned ON El : Abnormal timer initialization E2: Abnormal memory check (For the DRAM not the NVRAM) Cause The SCU performs a memory check at power on.
Page 669 Field Engineering Bulletin Digital Color Series TECHNICAL OPERATIONS SDC103 BULLETIN NO: Subject: LED ARRAY El Copy Quality Modification Schedule Model - Product/Serial Numbers Affected Electrical Mechanical •i Next PM Install Time The LED array for the printer option has been installed in the copier beginning with July 1997, therefore, It is no longer necessary to replace the LED array when installing the printer option.
Page 670 Field Engineering Bulletin Digital Color Series TECHNICAL OPERATIONS BULLETIN NO: SDC103/A/E - 004 DATE: 1/30/98 Subject: E1 & E2 SELF DIAGNOSTIC CODE OF SCU Model - Product/Serial Numbers Copy Quality Modification Schedule Affected Electrical Mandatory SDC103 Mechanical Scheduled Visit Modification SDC103/A Next Call Safety Information...
Page 671 December 1996 production (See Table). As always if frequent fusing problems occur, replacing the Hot and Pressure Rollers as a set is recommended. MODEL NAME SERIAL NUMBER Gestetner 2703 4A16120001 Ricoh Aficio Color 2003 A3966120001 Savin SDC103 4A16120001 Continued… #'328630#23T#FLH...
Page 672 All copiers manufactured after the Serial Numbers listed below will have the new style Hot Roller & Pressure Roller installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703 4A18030001 Gestetner 2703d 4A2804XXXX Gestetner 2703de 4A3804XXXX Ricoh Aficio Color 2003 A396804XXXX Ricoh Aficio Color 2103 A397804XXXX Ricoh Aficio Color 2203 A399804XXXX Savin SDC103 4A18030001 Savin SDC103A 4A2804XXXX...
Page 673 December 1996 production (See Table). As always if frequent fusing problems occur, replacing the Hot and Pressure Rollers as a set is recommended. MODEL NAME SERIAL NUMBER Gestetner 2703 4A16120001 Ricoh Aficio Color 2003 A3966120001 Savin SDC103 4A16120001 Continued… #'328630#23T#FLL...
Page 674 All copiers manufactured after the Serial Numbers listed below will have the new style Hot Roller & Pressure Roller installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703 4A18030001 Gestetner 2703d 4A2804XXXX Gestetner 2703de 4A3804XXXX Ricoh Aficio Color 2003 A396804XXXX Ricoh Aficio Color 2103 A397804XXXX Ricoh Aficio Color 2203 A399804XXXX Savin SDC103 4A18030001 Savin SDC103A 4A2804XXXX...
Page 675 December 1996 production (See Table). As always if frequent fusing problems occur, replacing the Hot and Pressure Rollers as a set is recommended. MODEL NAME SERIAL NUMBER Gestetner 2703 4A16120001 Ricoh Aficio Color 2003 A3966120001 Savin SDC103 4A16120001 Continued… #'328630#23T#FLM...
Page 676 All copiers manufactured after the Serial Numbers listed below will have the new style Hot Roller & Pressure Roller installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703 4A18030001 Gestetner 2703d 4A2804XXXX Gestetner 2703de 4A3804XXXX Ricoh Aficio Color 2003 A396804XXXX Ricoh Aficio Color 2103 A397804XXXX Ricoh Aficio Color 2203 A399804XXXX Savin SDC103 4A18030001 Savin SDC103A 4A2804XXXX...
Page 677 (∝ on an analog meter and a Beckman digital meter should read OL, the indicator for “Overload”). REFERENCE PART NUMBER DESCRIPTION PAGE ITEM AA180054 Oil Supply Tube A1664014 Oil Supply Unit CONTROL NO. 295 RICOH GROUP COMPANIES...
Page 678 Ensure that the Drum Charge Corona (P/N AD004081) is seated correctly. Replace defective Drum Charge Corona Receptacle (P/N A1662271). Replace defective High Voltage Power Supply (P/N AZ320082). Replace defective Front Door Safety Switch (P/N 12042437). CONTROL NO. 296 RICOH GROUP COMPANIES...
Page 679 Replace defective Drum Charge Corona Receptacle (P/N A1662271). Replace defective High Voltage Power Supply (P/N AZ320082). Replace defective Front Door Safety Switch (P/N 12042437). Clean and apply conductive grease to the Bias Terminal (P/N A1663363) Replace if necessary. RICOH GROUP COMPANIES CONTROL NO. 319...
Page 680 Replace defective Drum Charge Corona Receptacle (P/N A1662271). Replace defective High Voltage Power Supply (P/N AZ320082). Replace defective Front Door Safety Switch (P/N H5219610). Clean and apply conductive grease to the Bias Terminal (P/N A1663363) Replace if necessary. RICOH GROUP COMPANIES CONTROL NO. 345...
Page 681 Knob (AG50080) and the Drive Release Slider (A1664297) to ensure that the Fuser Unit Gears engage when the Front Cover is closed. NOTE: Spacer AA132097: thickness 1.2 mm, outer diameter 16 mm, inner diameter 8.5 mm. CONTROL NO. 296 RICOH GROUP COMPANIES...
Page 682 (AG50080) and the Drive Release Slider (A1664297) to ensure that the Fuser Unit Gears engage when the Front Cover is closed. NOTE: Spacer AA132097: thickness 1.2 mm, outer diameter 16 mm, inner diameter 8.5 mm. Continued… RICOH GROUP COMPANIES CONTROL NO. 326...
Page 683 All A166/A187/A189 copiers manufactured after the Serial Numbers listed below will have the new style Spacer installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703 A168075001 Gestetner 2703D A18807xxxx Gestetner 2703DE A208075001 Ricoh Aficio Color 2003 A3968070001 Ricoh Aficio Color 2103 A397807xxxx Ricoh Aficio Color 2203 A3998070001 Savin SDC103 4A18070001 Savin SDC103A 4A28070001...
Page 684 A166, A187 and A189 Parts Catalogs. Roller - Development Unit Plate REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM AA161110 Roller - Development Unit Plate 26 * * Denotes new item number. CONTROL NO. 296 RICOH GROUP COMPANIES...
Page 685 The following individual parts are now available for the A166 Operation Panel. Please update your Parts Catalog with the following parts illustration and part numbers. The following parts updates are being issued for all A166 Parts Catalogs. 1. EXTERIOR Operation Panel (A166) 8< 7< 6< Page 11A Continued… CONTROL NO. 300 RICOH GROUP COMPANIES...
Page 686 Tech Service Bulletin No. A166/A187/A189 – 006 Page 2 of 2 REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM A1661508 Key Top Cover - SP A1661510 Lower Case - Operation Panel A1661530 Key Top - Counter A1661531 Key Top - Start A1661538 Key Top - Color Mode A1661540...
Page 687 OPERATION PANEL – The following individual parts are now UPDATE 1: available for the A187 Operation Panel. Please update your Parts Catalog with the following parts illustration and part numbers. 1. EXTERIOR Operation Panel (A187) 8< 7< 6< Page 11A Continued… CONTROL NO. 300 RICOH GROUP COMPANIES...
Page 688 Tech Service Bulletin No. A166/A187/A189 – 007 Page 2 of 4 REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM A1661508 Key Top Cover - SP A1661510 Lower Case - Operation Panel A1661530 Key Top - Counter A1661531 Key Top - Start A1661538 Key Top - Color Mode A1661540...
Page 689 Tech Service Bulletin No. A166/A187/A189 – 007 Page 3 of 4 • OPERATION PANEL – The following individual parts are now UPDATE 2: available for the A189 Operation Panel. Please update your Parts Catalog with the following parts illustration and part numbers. 1.
Page 690 Tech Service Bulletin No. A166/A187/A189 – 007 Page 4 of 4 REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM A1661556 Key Top - Cursor A1661557 Key Top - Point Set A1661558 Key Top - Counter A1661559 Key Top - Enter A1661560 Shield Plate A1661561 LCD Cushion - Upper/Lower...
Page 691 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: A166/A187/A189 – 007 REISSUE 03/27/2000 APPLICABLE MODEL: GESTETNER – 2703D/2703DE RICOH – AFICIO COLOR 2103/2203 SAVIN – SDC103A/SDC103E SUBJECT: PARTS CATALOG UPDATES GENERAL: The following parts updates are being issued for all A187 and A189 Parts Catalogs.
Page 692 ! ! ! ! Tech Service Bulletin No. A166/A187/A189 – 007 Reissue Page 2 of 4 REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM A1661508 Key Top Cover - SP A1661510 Lower Case - Operation Panel A1661530 Key Top - Counter A1661531 Key Top - Start A1661538...
Page 693 ! ! ! ! Tech Service Bulletin No. A166/A187/A189 – 007 Reissue Page 3 of 4 • OPERATION PANEL – The following individual parts are now UPDATE 2: available for the A189 Operation Panel. Please update your Parts Catalog with the following parts illustration and part numbers. 1.
Page 694 ! ! ! ! Tech Service Bulletin No. A166/A187/A189 – 007 Reissue Page 4 of 4 REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM A1661556 Key Top - Cursor A1661557 Key Top - Point Set A1661558 Key Top - Counter A1661559 Key Top - Enter A1661560 Shield Plate...
Page 695 The originals have paper curl. • User Program 1 (default image settings) Function 4 (Auto Image Density) is set too dark. SOLUTION: • Adjust SP 5-106-1 color to 1 Adjust SP 5-106-2 black to 1 RICOH GROUP COMPANIES CONTROL NO. 302...
Page 696 • User Program 1 (default image settings) Function 4 (Auto Image Density) is set too dark. SOLUTION: • Set User Program 1 (default image settings), Function 4 (Auto Image Density) to the lightest setting. RICOH GROUP COMPANIES CONTROL NO. 313...
Page 697 It is not available as a service part. If this part needs to be replaced, order the Drum Shaft Holder. REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM A166 A187/A189 A1662261 Drum Shaft Holder 1→1 A1662296 Drum Joint Shaft 1→0 Continued… RICOH GROUP COMPANIES CONTROL NO. 304...
Page 698 All copiers manufactured after the Serial Numbers listed below will not have the parts listed above installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703 A168065001 Gestetner 2703D A18805xxxx Gestetner 2703DE A208075001 Ricoh Aficio Color 2003 A3968050001 Ricoh Aficio Color 2103 A397805xxxx Ricoh Aficio Color 2203 A3998070001 Savin SDC103 4A18040050 Savin SDC103A 4A28060001...
Page 699 Dip Switch 3. Replace the SCU Board. (Follow the procedure in the Service Manual Section 12.1.1.) REFERENCE PART NUMBER DESCRIPTION PAGE ITEM A166 A187 A1875268 SCU Board (A166/A187) A1895260 SCU Board – Edit (115v) (A189) CONTROL NO. 304 RICOH GROUP COMPANIES...
Page 700 All copiers manufactured after the Serial Numbers listed below will have the new style Separation Roller Spacer installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703D A18805xxxx Gestetner 2703DE A207125001 Ricoh Aficio 2103 A3976110001 Ricoh Aficio 2203 A3996110001 Savin SDC103A 4A26110001 Savin SDC103E 4A36110001 RICOH GROUP COMPANIES CONTROL # 307...
Page 701 NOTE: 1. New P/N has adhesive tape on the backside. 2. P/N A1666754 (Model Nameplate -SVN) is not necessary for the A187/A189-15 models because the model name/number is silk-screened on the front cover of the A187/A189-15 models. CONTROL No. 307 RICOH GROUP COMPANIES...
Page 702 NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or previously modified, use the new part numbers individually. RICOH GROUP COMPANIES CONTROL # 307...
Page 703 UNITS AFFECTED: All copiers manufactured after the Serial Numbers listed below will have the new style Operating Instruction Holder installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703DE A207070001 Ricoh Aficio2203 A3997030001 Savin SDC103E 4A37030001 CONTROL # 307 RICOH GROUP COMPANIES...
Page 704 MODEL NAME SERIAL NUMBER Gestetner 2703 A167075001 Gestetner 2703D A18805XXXX Gestetner 2703DE A208075001 Ricoh Aficio 2003 A3966090001 Ricoh Aficio 2103 A3976080001 Ricoh Aficio 2203 A3996110001 Savin SDC103 4A16090001 Savin SDC103A 4A26110001 Savin SDC103E 4A36110001 CONTROL # 307 RICOH GROUP COMPANIES...
Page 705 Mirror installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703 A167075001 Gestetner 2703D A18805xxxx Gestetner 2703DE A208075001 Ricoh 2003 A3966120001 Ricoh 2103 A3976120001 Ricoh 2203 A3996120001 Savin SDC103 4A16120001 Savin SDC103A 4A26120001 Savin SDC103E 4A36120001 RICOH GROUP COMPANIES CONTROL # 307...
Page 706 Drum Shaft and the edge of the Drum (exposed metal). A normal reading is 5Ω or less. If this reading is more than 5Ω then clean and or reform the Drum Ground Tabs, located inside the rear of the Drum. Con tin ued… RICOH GROUP COMPANIES CONTROL NO. 313...
Page 707 Tech Service Bulletin No. A166/A187/A189 – 017 Page 2 of 2 Check 3: Isolating The Drum Bearing and/ or High Voltage Supply Board: If you are reading more than .5VDC at the Drum Shaft, then take a voltage reading at the connector that is soldered directly to the High Voltage Supply Board.
Page 708 The new style Oil Valve has an additional groove to distinguish it from the old style part. Please update your Parts Catalog with the updated information. Item 27 Additional groove REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM A1664167 Oil Valve 0→2 Continued… RICOH GROUP COMPANIES CONTROL NO. 314...
Page 709 All copiers manufactured after the Serial Numbers listed below will have the new style Oil Valve installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703 A168085001 Gestetner 2703D A18810xxxx Gestetner 2703DE A20810xxxx Ricoh Aficio Color 2003 A3968090001 Ricoh Aficio Color 2103 A397810xxxx Ricoh Aficio Color 2203 A3998080001 Savin SDC103 4A18090001 Savin SDC103A 4A28080001...
Page 710 Tech Service Bulletin No. A166/A187/A189 – 018 Page 3 of 4 • SPRING PLATE MIDDLE REAR – The Spring Plate Middle Rear has UPDATE 4: been added to the A166 Parts Catalog. The Philips Screw with Washer M4x6 (Item 107) quantity has been incremented by 2. Please update your A166 Parts Catalog with the updated information.
Page 711 Tech Service Bulletin No. A166/A187/A189 – 018 Page 4 of 4 • DENSITY SENSOR BRACKET – The Density Sensor Bracket UPDATE 5: mounted onto the Optical Lower Frame has been changed in the A166 Parts Catalog. Please see the figure below. Update your A166 Parts Catalog with the following information.
Page 712 The new style Oil Valve has an additional groove to distinguish it from the old style part. Please update your Parts Catalog with the updated information. Item 27 Additional groove REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM A1664167 Oil Valve 0→2 Continued… RICOH GROUP COMPANIES CONTROL NO. 315...
Page 713 All copiers manufactured after the Serial Numbers listed below will have the new style Oil Valve installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703 A168085001 Gestetner 2703D A18810xxxx Gestetner 2703DE A20810xxxx Ricoh Aficio Color 2003 A3968090001 Ricoh Aficio Color 2103 A397810xxxx Ricoh Aficio Color 2203 A3998080001 Savin SDC103 4A18090001 Savin SDC103A 4A28080001...
Page 714 Tech Service Bulletin No. A166/A187/A189 – 018 Reissue H Page 3 of 4 • SPRING PLATE MIDDLE REAR – The Spring Plate Middle Rear has UPDATE 4: been added to the A166 Parts Catalog. The Philips Screw with Washer M4x6 (Item 107) quantity has been incremented by 2. Please update your A166 Parts Catalog with the updated information.
Page 715 Tech Service Bulletin No. A166/A187/A189 – 018 Reissue H Page 4 of 4 • DENSITY SENSOR BRACKET – The Density Sensor Bracket UPDATE 5: mounted onto the Optical Lower Frame has been changed in the A166 Parts Catalog. Please see the figure below. Update your A166 Parts Catalog with the following information.
Page 716 Fusing Rollers, Ricoh/Savin/Gestetner will accept return of these older type Hot and Pressure Rollers for credit. Return the old type Fuser Rollers that exist in your inventory to Ricoh/Savin/Gestetner for credit by completing the attached form. All rollers must be new and in the original OEM packaging.
Page 717 Unit Code Number Model Year Month Savin SDC103 0001 Gestetner 2703 Ricoh 2003 A396 0001 1996 December This example indicates that these machines were manufactured in December of 1996. The Pressure Roller AE020066 should be used in these machines. NOTES: 1.
Page 718 Tech Service Bulletin No. A166/A187/A189 – 019 Page 3 of 4 3. Fusing Unit Servicing Tips ITEM DESCRIPTION RECOMMENDED ACTION/COMMENT REFER TO Clean the gears with alcohol and apply Disengaging High Temperature grease. TSB-004 Gear Noise Install spacer (AA132097) behind fusing knob.
Page 719 For All Latin America Locations: Ship to: Ship to: Ship to: Ricoh Corp-TSC Ricoh Canada Inc. Ricoh Latin America, Inc. 155 Passaic Ave. 1550 Enterprise Road 7650 N.W. 19 St. Suite 290 Fairfield, NJ 07004 Mississauga, Ontario Miami, FL 33126...
Page 720 Silicone oil dripping from the Oil Supply Sub Roller migrates to the bottom surface of the Oil Sump. SOLUTION: Install the Oil Guide ( P/N A1664385) on the Oil Sump. Indicates new part Continued… CONTROL NO. 324 RICOH GROUP COMPANIES...
Page 721 All copiers manufactured after the Serial Numbers listed below will have the new style Oil Guide installed during production. MODEL NAME SERIAL NUMBER Gestetner 2703 A168075001 Gestetner 2703D A18807xxxx Gestetner 2703DE A208075001 Ricoh Aficio Color 2003 A3968070001 Ricoh Aficio Color 2103 A397807xxxx Ricoh Aficio Color 2203 A3998070001 Savin SDC103 4A18070001 Savin SDC103A 4A28070001 Savin...
Page 722 Tech Service Bulletin No. A166/A187/A189 – 020 Page 3 of 3 ORDERING PROCEDURE: To obtain the Oil Guide P/N A1664385 at no charge, please complete and fax the attached form to Technical Services . SUBJECT: Fax this entire page in “DETAIL” mode ATTN: Technical Services – Copier Fax Number: (973) 882-3960 Each serial number given will represent a request for one (1) Oil Guide.
Page 723 NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or previously modified, use the new part numbers individually. CONTROL NO. 324 RICOH GROUP COMPANIES...
Page 724 1. Replace the old Interlock Switch with the new Interlock Switch Kit (H5219610). The new Interlock Switch has been made airtight with a sealant at the terminal and a Sealing Sheet. See Figure A below. New Interlock Switch with Sealant and Sealing Sheet (H5219610) Bracket Figure A Continued… RICOH GROUP COMPANIES CONTROL NO. 345...
Page 725 Tech Service Bulletin No. A166/A187/A189 – 022 Page 2 of 2 2. Attach the double-sided Adhesive Tapes to the Interlock Switch Covers (2 pieces each). See Figure B below. Cover Interlock Switch Adhesive Tape - SWFL Adhesive Tape - SWFL Figure B Cover Interlock Switch 3.
Page 726 APPLICABLE MODEL: : : : GESTETNER – 2703/2703D/2703DE GESTETNER – 2703/2703D/2703DE GESTETNER – 2703/2703D/2703DE GESTETNER – 2703/2703D/2703DE RICOH – AFICIO COLOR 2003/2103/2203 RICOH – AFICIO COLOR 2003/2103/2203 RICOH – AFICIO COLOR 2003/2103/2203 RICOH – AFICIO COLOR 2003/2103/2203 SAVIN – SDC103/SDC103A/SDC103E SAVIN –...
Page 727 Tech Service Bulletin No. A166/A187/A189 – 022 REISSUE ! ! ! ! Page 2 of 2 2. Attach the double-sided Adhesive Tapes to the Interlock Switch Covers (2 pieces each). See Figure B below. Cover Interlock Switch Adhesive Tape - SWFL Adhesive Tape - SWFL Figure B Cover Interlock Switch...
Page 728 3. Identification of New Toner Company Toner Name Ricoh Ricoh Color Toner Type HX Black Ricoh Color Toner Type H Yellow Ricoh Color Toner Type H Magenta Ricoh Color Toner Type H Cyan Savin...
Page 729 NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or previously modified, use the new part numbers individually. RICOH GROUP COMPANIES CONTROL NO. 348...
Page 730 The following part is being issued for all A166/A187/A189 Parts Catalogs. Harness Support Plate REFERENCE NEW PART NUMBER DESCRIPTION PAGE ITEM A1664085 Harness Support Plate DENOTES NEW ITEM NUMBER     2000 RICOH Corporation. All rights reserved. CONTROL NO. 050CLR...
Page 731 The Service Manual page listed below must be replaced with the page supplied. Each bulletin package contains 1 set of replacement pages. PAGES: ⇒ The revised areas have been highlighted by an arrow • 5-98 Updated Information (RAM Clear)     CONTROL NO. 031CLR 2000 RICOH Corporation. All rights reserved.
Page 732 Rev. 08/2000 OTHERS 12.2 RAM CLEAR 12.2.1 RAM (Memory Board) Clear Procedure ⇒ 1. Before clearing the RAM, execute SP7-902 and SP7-903 to output the current SP mode values. NOTE: Clearing the RAM resets all SP and UP values, except the serial number and main counter value, to the defaults.
Page 733 Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or previously modified, use the new part numbers individually.     2000 RICOH Corporation. All rights reserved. CONTROL NO 054CLR...

This manual is also suitable for:

A87 A189

Ricoh A66 Service Manual

Overall Machine Information

Specifications

Machine Configuration

Major Unit Overview

Parts Layout

Electrical Component List

Detailed Descriptions

Process Control

Drum Unit

Scanner Unit

Image Processing

Laser Exposure

Development Unit

Transfer Belt Unit

Paper Feed and Registration

Paper Transport and Image Fusing

Duplex Unit

System Configuration

Installation Requirements

Copier Installation

Installation Procedure Flowchart

Paper Tray Unit (A549/A550) Installation

5 Ardf (A548) Installation

Bin Sorter (A555) Installation

Film Projector Table (A579) Installation

Film Projector Unit (A718) Installation

Service Tables

Replacement and Adjustment

Scanner Unit

Copy Image Adjustment

Laser Unit

Development Unit

Transfer Belt Unit

Paper Feed and Registration

Paper Transport and Fusing

Quick Links

Troubleshooting

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Summary of Contents for Ricoh A66