Page 1 RICOH R I C O H F T 4 4 6 0 RICOH COMPANY, LTD.
Page 2: Table Of Contents
1.1 MAIN COPIER, FT4460 ........
Page 3 3.1 OVERVIEW .............2-8 3.2 SCANNER DRIVE .
Page 4 5. DEVELOPMENT ........2-29 5.1 OVERVIEW ............2-29 5.2 DEVELOPMENT UNIT CHANGE MECHANISM .
Page 5 6.3.1 Paper Separation ...........2-51 6.3.2 Paper Transport .
Page 6 11.3 JOGGER MECHANISM ..........2-78 11.4 SlNGLE DUPLEX/OVERLAY TIMING .
Page 7 2.9 PAPER FEED ............4-7 2.10 DOCUMENT FEEDER .
Page 8 1.3 2ND AND 3ND MIRROR REMOVAL ......... .5-4 1.4 4TH AND 5TH MlRRORS REPLACEMENT .
Page 9 2.10.2 Measurement (SP Mode #59) ........5-41 2.11 BLACK DEVELOPMENT BIAS ADJUSTMENT (SP Mode #37) .
Page 10 4.14 UPPER REGISTRATION ROLLER REMOVAL .......5-70 4.15 LOWER REGISTRATION REPLACEMENT ......5-71 4.16 REGISTRATION ADJUSTMENT (SP Mode #42) .
Page 11 7.11 NIP WIDTH MEASUREMENT ......... .5-103 7.12 FUSlNG PRESSURE ADJUSTMENT .
Page 12 12.2 FRICTION PAD REPLACEMENT AND ADJUSTMENT ......6-15 12.3 REPLACEMENT OF POSITIONING ROLLER AND ROUND BELT ....6-16 12.4 JOGGER FENCE DRIVE WIRE REPLACEMENT .
Page 13 13.1 FEED-lN UNIT ............7-32 13.1.1 Transport Belt Replacement .
Page 14 7. BIN DRIVE MECHANISM ........8-7 8.
Page 15 4. DATA PRINTING FUNCTION TABLE ......10-4 5. TIME CORRECTION ........10-5 6.
Page 16 9.3 PAPER SlZE SENSOR REPLACEMENT ........11-21 9.4 SIDE REGISTRATION ADJUSTMENT .
Page 17 2.8 CODE #2A AND #2B ..........12-37 2.9 CODE #28 AND #29 .
Page 18 4.15 FUSlNG THERMISTOR ..........12-54 4.16 DC POWER SUPPLY FUSES .
Page 19 SECTION 1 O V E R A L L M A C H I N E I N F O R M A T I O N...
Page 20 1.1 MAIN COPIER, FT4460 ........
Page 21: Specifications
28 February 1989 1. SPECIFICATIONS 1.1 MAIN COPIER, FT4460 Configuration: Desk top Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum A3/11”x17” Copy Paper Size: Maximum A3/11”x17” Minimum A6/5.5”x8.5” (DupIex/Overlay Copying) Maximum A3/11”x17” Minimum A5/5.5”x8.5” Copy Paper Weight: Cassette feed: 52 - 128 g/m²...
Page 22 28 February 1989 First Copy Time: Black Copy: 7.9 seconds (A4/8.5” x11” sideways) 12.3 seconds (APS mode, A4/8.5” x11” sideways) Color Copy: 11.6 seconds (A4/8.5”x11” sideways) 12.8 seconds (APS mode, A4/8.5” x11” sideways) Copy Number Input: Ten keys, 1 to 999 (count up or count down) Manual Image Density 7 steps Selection:...
Page 23 28 February 1989 Weight: 110/115V version: Approximately 86kg(190 lb) 220/240V version: Approximately 88kg(194 lb) Optional Equipment: Document feeder (DF52) 20 bin sorter (CS2090) Large capacity tray (RT15) Color development unit (CU120) Editor board (RE12) Date printer (DP 100) Multi duplex/overlay unit (AD 500) Key counter...
Page 24: Operation Panel
28 February 1989 2. OPERATION PANEL - Section A - - LT/LDG Version - 1. Area Memory Indicator 10. Used Toner Bottle Indicator 2. Check Paper Size/Direction 11. Set Key Counter Indicator 3. Check Paper Size Indicator 12. Ready Indicator 4.
Page 25 28 February 1989 - A4/A3 Version - 18. Second Original Indicator 28. Auto Paper Select Key 19. Auto Image Density Indicator Select Cassette Key 30 . Full Size Indicator 20. Manual Image Density Indicator 31 . Full Size Key 21. Auto Image Density Key 32 .
Page 26 28 February 1989 - Section B (Keys and Indicators for Special/Optional Functions) - - LT/LDG Version - 1. Sorter Key Margin Adjustment Key 2. Stack Indicator Centering Indicator 3. Sort Indicator Centering Key 4. Duplex Indicators Size Magnification Indicators 5. Duplex Key Size Magnification Key 6.
Page 27 28 February 1989 - A4/A3 Version - 21. Edit Image Key 14. Auto Reduce/Enlarge Key 15. Zoom Up Key 22. Edit Image Indicators 16. Zoom Down Key 23. Tone Key 17. Overlay Key 24. Photo Mode Indicator 18. Overlay Indicators 25.
Page 28 28 February 1989 - Section C - - LT/LDG Version - - A4/A3 Version - 1. Number Keys 6. Interrupt Key 7. Clear Modes Key 2. Recall/Enter Key 3. Program Indicator 8. Start Key 4. Program Key 9. Clear/Stop Key 5.
Page 29: Copy Processes Around The Drum
28 February 1989 3. COPY PROCESSES AROUND THE DRUM...
Page 30: Functional Operation
28 February 1989 4. FUNCTIONAL OPERATION 1-10...
Page 31: Paper Path
28 February 1989 5. PAPER PATH stations. The copy The paper feed starts from one of the three paper feed The path followed paper then follows one of two paths inside the copier. depends on which mode the operator has selected. For copy processing, all sheets follow the same path from the paper feed mechanism through the fusing unit.
Page 32: Primary Paper Path
28 February 1989 5.1 PRIMARY PAPER PATH 1. Paper Feed: If paper is fed from the first station, an FRR (Feed and Reverse Roller) mechanism separates one sheet of paper from the paper stack and feeds it to the registration rollers. The second and third stations use a friction pad for separation.
Page 33 28 February 1989 5.2 SINGLE DUPLEX COPY PATH [F]: Duplex/Overlay Transport Gate [G]: Junction Gate [H]: Invertor Gate Duplex Paper Feed: The copy paper is fed down from the fusing unit to the lower section [A], where the paper’s leading edge passes through the inverter rollers. When the inverter sensor detects the paper’s trailing edge, the inverter rollers [B] reverse direction and the paper is fed to the jogger section [C].
Page 34: Multi Duplex Copy Path
28 February 1989 5.3 MULTI DUPLEX COPY PATH Multi Duplex Paper Feed: After the paper makes its first pass through the copier, the junction gate [A] directs the paper to the duplex tray where jogger fences [B] move up against the paper from both sides to correct its lateral position.
Page 35: Single Overlay Copy Path
28 February 1989 5.4 SINGLE OVERLAY COPY PATH Overlay Paper Feed: The copy paper is fed down from the fusing unit to the lower section [A] and sent directly to the jogger section [B]. When the paper enters the jogger sec- tion the jogger fences move up against the paper on both sides.
Page 36: Multi Overlay Copy Path
28 February 1989 5.5 MULTI OVERLAY COPY PATH Multi Overlay Copy Feed: After the paper makes its first pass through the copier, the junction gate [A] directs the paper to the duplex tray, where jogger fences [B] move in from both sides to correct the lateral position of the paper.
Page 37: Drive Layout
28 February 1989 6. DRIVE LAYOUT Gears Sprocket G1: Third Paper Feed Clutch Gear S1: Main Motor Sprocket G2: Second Paper Feed Clutch Timing Belt Gear TB1: Drum Drive Belt G3: First Paper Feed Clutch Gear Belt G4: Toner Supply Clutch Gear B1: Exit Roller Drive Belt G5: Development Unit Change Drive Chains...
Page 38: Mechanical Component Layout
28 February 1989 7. MECHANICAL COMPONENT LAYOUT...
Page 39 28 February 1989 23. Pre-Transfer Lamp 1. Exposure Lamp 24. Registration Roller 2. Cleaning Unit 25. Transfer Corona 3. Ouenching Lamp 26. Separation Corona 4. Lens 27. Pick-off Pawl 5. Charge Corona 28. I.D.Sensor 6. 6th Mirror 29. Cleaning Brush 7.
Page 40: Electrical Component Layout
28 February 1989 8. ELECTRICAL COMPONENT LAYOUT 1. Sorter Interface Board 23. Key Counter (optional) 2. Cooling Fan Motor 24. 1st Cassette Paper End Sensor 3. Scanner Drive Motor 25. Registration Sensor 4. Main Motor Capacitor 26. Jogger Positioning SOL 5.
Page 41 28 February 1989 58. Drum Heater Erase Lamp 59. Lens H.P. Sensor Quenching Lamp 60. Toner Overflow Sensor Auto Density Sensor 61. Lower Relay Sensor Original Length Sensor 62. Vacuum Fan Motor Thermal SW 63. Upper Relay Sensor Exposure Lamp 64.
Page 42: Electrical Component Descriptions
28 February 1989 9. ELECTRICAL COMPONENT DESCRIPTIONS Index P to P Name Function Symbol Location Motors Main Motor Drives all main unit components except optics unit and fans. (100 Vac) Fusing Exhaust Removes heat from around the fusing unit. (100 Vac) Cooling Fan Prevents build up of hot air in the optics cavity.
Page 43 28 February 1989 Index P to P Name Function Symbol Location Development Unit Changes the position of the black develop- SOL2 Change ment unit and color development unit. Red Erase Changes the filter position. SOL3 Duplex/Overlay Directs copies to the Duplex/Overlay units. SOL4 F-11 Transport Gate...
Page 44 28 February 1989 P to P Function Name Symbol Location Informs the CPU when the first cassette D-11 1st Cassette Paper runs out of paper. Informs the CPU when the second cas- 2nd Cassette D-11 Paper End sette runs out of paper. Informs the CPU when the third cassette D-11 3rd Cassette...
Page 45: Printed Circuit Boards
28 February 1989 P to P Index Function Symbol Name Location Lamps Applies high intensity light to the original Exposure for exposure. Provides heat to the Hot Roller. Fusing Discharges the drum outside of the image Erase area. Provides leading/trailing edge erase and editing functions.
Page 46 28 February 1989 Index P to P Function Name Symbol Location Others T h e r m o f u s e Provides back-up overheat protection in TF the fusing unit. Thermal Switch Provides back-up overheat protection around the exposure lamp. Noise Filter Removes electrical noise.
Page 47: Ac And Dc Power Distribution
28 February 1989 10. AC AND DC POWER DISTRIBUTION drum The ac power supply is filtered and distributed to the fusing lamp, heater, anticondensation heater (option), and main transformer. The transformer supplies 100 volts to the cooling fan, fusing fan, exposure lamp, main motor, and sorter (option).
Page 48: Overall Machine Control
28 February 1989 11. OVERALL MACHINE CONTROL The following block diagram shows the flow of control signals within the The system control board is responsible for initiating all actions that take place in a copy cycle. The I/O control board interfaces the system control board to those components it does not directly control.
Page 49 S E C T I O N 2 D E T A I L E D S E C T I O N D E S C R I P T I O N S...
Page 50: Drive Mechanism
CONTENTS 1. DRUM ...........2-1 1.1 OPC DRUM CHARACTERISTICS .
Page 51: Error Detection
3.11.7 Red Erase Mode Correction .........2-20 3.11.8 Pre-scan Correction .
Page 52: Paper Feed
5.18 BIAS CORRECTION ...........2-47 5.18.1 Vr Correction .
Page 53: Image Fusing And Paper Exit
9.9 MANUAL FEED TABLE ..........2-68 9.10 PAPER FEED TlMlNG .
Page 54: Drum
28 February 1989 1. DRUM 1.1 OPC DRUM CHARACTERISTICS An OPC has the characteristics of: • Being able to accept a high negative electrical charge in the dark. (The electrical resistance of a photoconductor is high in the absence of light.) •...
Page 55: Handling The Drum
28 February 1989 1.2 HANDLING THE DRUM The organic photoconductor drum is comparatively more sensitive to light, and ammonia gas than a selenium drum. 1. Never expose the drum to direct sunlight. 2. Never expose the drum to direct light of more than 1000 Lux for more than a minute.
Page 56: Drum Unit
28 February 1989 1.3 DRUM UNIT An organic photoconductor drum [A] is used on this model. A drum unit [B] is used to hold the drum to prevent stress on the drum. The drum unit consists of an OPC drum, ID sensor [C] and separation pawls [D]. The drum is driven by the main motor [H] through the drum drive belt [E] and the drum drive gear [F].
Page 57: Drum Charge
28 February 1989 2. DRUM CHARGE 2.1 OVERVIEW This copier uses a single wire scorotron and a highly sensitive OPC drum. The corona wire [A] generates a corona of negative ions when the charge power pack applies a high voltage (-5.0 to -7.5 KV). The drum coating [B] receives a uniform negative charge as it rotates past the corona unit.
Page 58: Charge Corona Unit
28 February 1989 2.2 CHARGE CORONA UNIT The charge corona unit consists of the charge corona wire [A], the grid mesh [B] and the charge wire cleaner [C]. The applied voltage of the charge corona wire is constant but the surface potential of the drum rises in proportion to the number of copies made.
Page 59: Charge Corona Power Pack
21 April 1989 2.3 CHARGE CORONA POWER PACK The circuit operation for the charge corona begins with the input of 24 volts to the power pack at CN1-1. This power supply is used for the high voltage corona. The charge corona turns on 0.1 seconds after the Start key is pressed. A LOW signal from the I/O control board (at CN1-3) energizes the power pack.
Page 60: Charge Corona Wire Cleaner Mechanism
28 February 1989 2.4 CHARGE CORONA WIRE CLEANER MECHANISM Pads [A] above and below the charge corona wire clean the wire as the charge unit is manually slid in and out. The cleaner pad bracket [B] rotates when the charge unit is fully extended and the bracket is pulled up against the rear block [C].
Page 61: Optics
28 February 1989 3. OPTICS 3.1 OVERVIEW During the copy cycle, an image of the original is reflected onto the drum sur- face via the optics assembly as follows. Light Path: Exposure Lamp [A] –> Original [B] –> 1st mirror [C] –> –>...
Page 62: Scanner Drive
28 February 1989 3.2 SCANNER DRIVE 3.2.1 1st and 2nd Scanner Drive Mechanism This model uses a dc servo motor [A] to drive the scanners. Both ends of each scanner are driven to prevent skewing. The scanners have sliders [B], which ride on guide rails.
Page 63: Scanner Motor Drive
28 February 1989 3.3 SCANNER MOTOR DRIVE The scanner drive motor is a servomotor. The I/O control PCB controls the speed of this servomotor. The I/O control PCB and the system control PCB communicate through a serial interface. At the programmed time, the system control PCB checks the drum speed by monitoring the pulses from the pulse generator.
Page 64: Lens Drive
28 February 1989 3.4 LENS DRIVE : Reduction : Enlargement 3.4.1 Lens Drive The lens drive motor [A] (stepper motor) changes the lens [B] position through the lens drive wire [C] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and the drum surface.
Page 65: Lens Positioning
28 February 1989 3.5 LENS POSITIONING : Reduction : Enlargement The lens home position sensor [A] informs the I/O control PCB when the lens is at full size position (home position). The I/O control PCB determines the lens stop position in reduction and enlargement modes by counting the num- ber of steps the motor makes with reference to the lens home position.
Page 66: 3Rd Scanner Drive
28 February 1989 3.6 3RD SCANNER DRIVE 3.6.1 Drive The 3rd scanner drive motor (stepper motor) changes the 3rd scanner posi- tion through the drive wire [A] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and drum sur- face.
Page 67: Stepper Motor Control
28 February 1989 3.7 STEPPER MOTOR CONTROL Both the lens drive motor and the third scanner drive motor are stepper motors. The stators of these stepper motors have four coils (labeled A, B, above), and the rotors are permanent magnets. Pulse signals energize the four coils as shown in the above illustration.
Page 68: Red Erase Mechanism
28 February 1989 3.8 RED ERASE MECHANISM This model has a red erase function. In red erase mode, the red erase solenoid [A] is energized (ON) to move the red filter [B] into the optical path. (Normally, the green filter [C] is in the optical path.) The red filter allows only red to pass through, thus decreasing the contrast in light intensity between the red and white areas on the original.
Page 69: Automatic Image Density Sensing
23 May 1989 3.9 AUTOMATIC IMAGE DENSITY SENSING The input for the automatic image density circuit is via a fiber optic cable [A] mounted on the first scanner. Light from the exposure lamp [B] passes through a small hole in the reflector, reflects from the original, and is collected by the fiber optic cable.
Page 70: Automatic Original Size Detection
28 February 1989 3.10 AUTOMATIC ORIGINAL SIZE DETECTION The original length sensor [A] and width sensor [B] on the first scanner detect the original size during pre-scanning. Length and width sensor data are combined as shown in the size detection table to determine the original size.
Page 71: Exposure Lamp Voltage Correction
28 February 1989 3.11 EXPOSURE LAMP VOLTAGE CORRECTION 3.11.1 Manual Image Density Correction The I/O control PCB controls the exposure lamp voltage based on the manual image density level (selected using the operation panel image density key) and ADS base level. Lamp voltage at level 4 in manual image density mode can be set to 50 to 75 V using SP mode #48 (Standard 64 V).
Page 72: Drum Sensitivity Correction (Vr Correction)
28 February 1989 3.11.3 Drum Sensitivity Correction (Vr correction) As the OPC drum is used, residual voltage rises gradually in repeat copying due to characteristics of the drum. The lamp voltage is adjusted to keep copy quality consistent. 3.11.4 Drum Rotation Correction To compensate for fogging of the OPC drum surface by the cleaning brush, main motor “on”...
Page 73: Photo Mode Correction
28 February 1989 3.11.5 Photo Mode Correction S P Mode #40 Correcting Voltage setting Data Normal N(0) Lighter L(1) ±0V Darker D(2) When photo mode is selected, the image density level can only be changed manually and the lamp voltage is shifted by -2V from the standard voltage in normal mode (V0).
Page 74: Exposure Lamp Control Clrcult
28 February 1989 3.12 EXPOSURE LAMP CONTROL CIRCUIT AC power Zero cross Trigger pulse Lamp power Feedback signal The I/O control board sends lamp trigger pulses to the ac drive board from CN304-A19. PC401 activates TRC401, which provides ac power to the ex- posure lamp at the trailing edge of each trigger pulse.
Page 75: Service Call Conditions
28 February 1989 3.13 SERVICE CALL CONDITIONS Self Diagnostic Code 11: Code 11 is displayed if a lamp circuit malfunction is detected during standby (lamp ON), or if the lamp filament or thermal switch opens. Self Diagnostic Code 12: Exposure Lamp Malfunction Code 12 is displayed if the lamp circuit malfunctions (stays ON), or if the lamp filament or thermal switch opens for longer than 20 seconds during a copy cycle.
Page 76 28 February 1989 Self Diagnostic Code 25: Code 25 is displayed if the scanner motor encoder pulse phase is not detected. Self Diagnostic Code 2E Scanner Motor Malfunction Code 2E is displayed if the scanner motor encoder pulse is not detected for more than 100m seconds.
Page 77: Erase
28 February 1989 4. ERASE 4.1 OVERVIEW Lead edge erase margin 2.5 ± 1.5 mm SE : Side erase margin 1.5 ± 1.5 mm on each side; total of both sides 4 mm or less Original width Charged width of drum Lead edge erase Side erase The erase lamp [A] consists of a line of 120 LEDs extending across the 300...
Page 78: Lead Edge Erase
28 February 1989 ERASE LAMP TIMING 4.1.1 Lead Edge Erase The entire line of LEDs turns on when the main motor turns on. They stay on until the erase margin slightly overlaps the lead edge of the original image area on the drum (Lead Edge Erase Margin). This prevents the toner density sensor pattern from being developed every copy cycle and the shadow of the original edge from being developed on the paper.
Page 79: Special Mode Erase
28 February 1989 EDGE ERASE MARGIN A 3 , A 4 4.5mm 14.5mm 19.5mm 9.5mm ( 2 0 . 5 m m ) ( 5 . 5 m m ) ( D L T , L T ) ( 1 0 . 5 m m ) ( 1 5 .
Page 80: Erase Lamp Circuit
28 February 1989 4.2 ERASE LAMP CIRCUIT This copier uses 120 LEDs in the erase lamp unit. Shift register drivers control the LEDs. Initially, the RESET signal (LOW active) turns off all the shift registers. Then the system control PCB sends erase lamp data to the shift registers.
Page 81: Erase Timing
28 February 1989 4.3 ERASE TIMING Operation Timing T0: Start key ON. All erase lamps turn on, bias is applied. T1: T1 = T0 + 0.1 sec. Change corona outputs ID sensor grid voltage for 0.49 seconds. T0 + 0.63 sec. Some erase lamps switcn off to create the ID sensor pattern.
Page 82: Development
28 February 1989 5. DEVELOPMENT 5.1 OVERVIEW The development section is composed of a black development unit [A] and a color development unit [B]. Normally, the black development roller is in con- tact with the drum [C]. When color copy mode is selected, the color develop- ment unit moves against the drum and the black development unit is pulled back.
Page 83: Development Unit Change Mechanism
28 February 1989 5.2 DEVELOPMENT UNIT CHANGE MECHANISM The development guide rails [A] are slid back and forth by the color develop- ment change shaft [B] The change shafts are turned by the development change cam [C] through the change lever [D]. The cam is driven by the main motor through gears and a drive chain.
Page 84: Development Unit Support Mechanism
28 February 1989 5.3 DEVELOPMENT UNIT SUPPORT MECHANISM This model has a plate [A] that supports the development units. The plate is locked at a 45 degree angle for the color development unit, and at a 90 de- gree angle for the black development unit. The stopper [C] inside the inner cover can be released with a screwdriver to lower the support plate to the 90 degree angle.
Page 85: Drive Mechanism (Black)
28 February 1989 5.4 DRIVE MECHANISM (Black) The development unit drive is controlled by the development drive clutch [A] and the toner supply clutch [B]. The development drive clutch controls the rotation of the development roller [C] and the paddle rollers [D] through the drive gears.
Page 86: Drive Mechanism (Color)
28 February 1989 5.5 DRIVE MECHANISM (Color) The color development unit drive is controlled by the same magnetic clutches [A] and [B] as the black development unit. When color copy mode is selected, the black development unit gears are dis- engaged from the development drive gear [C] and the toner supply gear [D], and the color development unit gears engage with the gears [C] and [D].
Page 87 28 February 1989 This copier uses a stsndard agitating mechanism to keep the toner and developer evenly mixed. It also helps agitate the developer to prevent clumps from forming and helps create the triboelectric charge. The developer on the rotating development roller is split into two parts by the doctor blade [A].
Page 88: Toner Supply And Agitator Drive Mechanism
23 May 1989 5.7 TONER SUPPLY AND AGITATOR DRIVE MECHANISM The toner supply clutch [A] controls the rotation of the agitator [B] and toner supply roller [C]. The toner agitator prevents toner from clumping and rotates at the same speed as the toner supply roller. The black toner agitator is in the toner cartridge and the color development agitator is in the toner hopper.
Page 89: Toner Density Detection
23 May 1989 5.8 TONER DENSITY DETECTION In this model, the ID sensor normally does not perform a check at the first copy after power up. Instead, the previous value is stored in memory and the sensor pattern is checked every 10 copies even if the machine has been turned off and on several times.
Page 90: Toner Density Control
28 February 1989 5.9 TONER DENSITY CONTROL [COLOR] [BLACK] The image density sensor checks the density of the sensor pattern image 5 copy cycles in color copy mode). The once every 10 copy cycles (every CPU receives two voltage values directly from the sensor: the value for the bare drum (Vsg) and the value for the sensor pattern (Vsp).
Page 91: Toner End Detection (Black)
28 February 1989 5.10 TONER END DETECTION (Black) 5.10.1 Black When the black development unit is in use, the ID sensor detects toner end. The system control PCB detects toner end when Vsp is continuously detected at a level higher than 0.91V for more than five times. The Add Toner indicator then blinks.
Page 92: Color
28 February 1989 5.11 TONER END DETECTION (Color) 5.11.1 Color unit is performed by the Toner end detection in the color development piezoelectric sensor [A] in the development unit. Up to 50 additional copies can be made when the toner end condition is detected in both black and color copying modes.
Page 93: Id Sensor Supply Control (Black Only)
28 February 1989 5.12 ID SENSOR SUPPLY CONTROL (Black only) ID Sensor Rate (%) Vsp (V) Toner Supply Level Name of Vsp/Vsg Toner Density Toner Supply 0-12.5 0-0.50 is High stops a)Black Toner Supply Toner Mode 12.6-15.0 0.51-0.60 Level 1 Supply Rate (1) Toner Supply 0.61-0.70...
Page 94: Id Sensor Toner Supply Level
28 February 1989 5.13 ID SENSOR TONER SUPPLY LEVEL The amount of toner supplied depends on the toner supply level data, toner supply ratio data, and the paper size. The toner supply clutch on time (in pul- ses) is calculated as follows: MC ON Time = l x T x P Where: I = ID Sensor Supply level Data...
Page 95: Id Sensor Supply Control In Fixed Supply Mode
28 February 1989 5.14 ID SENSOR SUPPLY CONTROL IN FIXED SUPPLY MODE M o d e # 7 0 s e t A m o u n t T o n e r S u p p l y R a t e 2 1 % 2 8 % S t a n d a r d...
Page 96 28 February 1989 F I X E D S U P P L Y M O D E m o d e N o . 3 2 S e t v a l u e T o n e r s u p p l y r a t e 3 .
Page 97: Toner Supply Amount (Fixed Supply Mode)
28 February 1989 5.15 TONER SUPPLY AMOUNT (FIXED SUPPLY MODE) Black/Color Toner Supply Level Paper Size Data Black Toner (# SP No. 32) UNIVERSAL Supply Level P-MODE DATA CONSTANT ADD DATA 0 DATA 1 3.5% DATA 2 10.5% DATA 3 Color Toner (# SP No.
Page 98: Id Sensor Error Detection
28 February 1989 5.16 ID SENSOR ERROR DETECTION 1. Vsg If Vsg is lower than 3.2V (color) or 2.5V (black), the toner supply stops. In color mode, if Vsg is low in 10 consecutive checks, the wrench mark and the color unit indicator are displayed on the operation panel. In black mode, if Vsg is low in 5 consecutive checks, the wrench mark in displayed.
Page 99: Development Blas Control
21 April 1989 5.17 DEVELOPMENT BIAS CONTROL This model has two bias voltage control modes: Manual control and ADS Control. There are also two bias voltage correction modes: Vr correction and SP mode. 5.17.1 Manual bias control (MANUAL I.D. LEVEL) The negative bias (-120 to -280V) corresponding to the selected image den- sity level is applied to the development roller.
Page 100: Bias Correction
28 February 1989 5.18 BIAS CORRECTION 5.18.1 Vr Correction C O R R E C T I O N With repeat copies, the residual potential on the OPC drum gradually affects the copy image density. With Vr correction, the residual potential is corrected using the ID sensor.
Page 101: Id Sensor Bias Compensation
21 April 1989 5.19 ID SENSOR BIAS COMPENSATION In order to ensure consistent operation of the ID sensor system, the bias for the development of the sensor pattern must be able to change (or be changed) to accommodate the following factors/conditions. (Numbers refer to the charts above) 5.19.1 Standard Bias I.D.
Page 102: Developer Counter Correction
28 February 1989 5.19.3 Developer Counter Correction Developer B l a c k D e v e l o p e r C o u n t e r C o u n t e r Initial Vsg (%) 0 - 4 9 9 C o p i e s Mode Then 500 C o r r e c t i o n 12-15...
Page 103: Image Transfer
28 February 1989 6. IMAGE TRANSFER 6.1 PRE-TRANSFER LAMP (PTL) After the latent image is developed but before the image is transferred to the copy paper [D], the drum surface is illuminated by the pre-transfer lamp [A]. This illumination reduces the negative potential on the drum surface [B]. This prevents the toner particles from being re-attracted to the negatively charged drum during the paper separation process.
Page 104: Paper Separation And Transport
28 February 1989 6.3 PAPER SEPARATION AND TRANSPORT After image transfer the copy must be separated from the drum. To break the attraction between the paper and the drum, the separation corona wire [D] applies an ac corona to the reverse side of the paper. The stiffness and weight of the paper causes it to separate from the drum [E].
Page 105: Ptl And T/S Charge Circuit
23 May 1989 6.4 PTL AND T/S CHARGE CIRCUIT The PTL is composed of 50 LEDs supplied by VPP. The PTL LEDs are wired in series. When the Start key is pressed, the I/O control PCB sends LOW sig- nals to turn on the vacuum fan motor and the PTL. The I/O control PCB sends a LOW signal to turn on (T1) the transfer corona 0.7 seconds after the original leading edge signal (L.E.) and continues for a period corresponding to the paper length + 6.7mm.
Page 106: Id Sensor
7. ID SENSOR 7.1 ID SENSOR IMAGE CORRECTION (Vr Pattern) The ID sensor image correction system, detects residual voltage on the OPC drum, and corrects the image by changing the grid bias, development bias, and lamp voltage. The residual voltage is detected by comparing the Vsg and the Vrp. The Vrp pattern is created by applying a 0 voltage bias.
Page 107 28 February 1989 The grid bias and the development bias change by -40 volts in each specific ratio. The exposure voltage changes 1 volt in each specific ratio. 2-54...
Page 108: Id Sensor Pattern (Vsp)
28 February 1989 7.2 ID SENSOR PATTERN (Vsp) The ID sensor pattern controls toner density. This pattern is transferred to the drum before creation of the latent image. The ID sensor illuminates the pattern and checks the reflectivity. The system control PCB detects variations in the light intensity (Vsp voltage) and controls the toner supply.
Page 109: Drum Cleaning
28 February 1989 8. DRUM CLEANING 8.1 OVERVIEW The cleaning brush [A] and cleaning blade [B] remove any toner remaining on the drum [C] after the image is transferred to the paper. The cleaning brush and drum move in opposite directions at their point of contact.
Page 110: Drive Mechanism
28 February 1989 8.2 DRIVE MECHANISM The cleaning brush [A] and the toner collection roller [B] are driven by the main motor through a chain and gears. The cleaning brush and the cleaning blade [C] are always touching the drum surface. The toner collection roller rotates at the same time as the cleaning brush to collect used toner.
Page 111: Release Mechanism
28 February 1989 8.3 RELEASE MECHANISM The cleaning guide rail [A] releases when the cleaning unit is removed. This prevents the drum [B] from being scratched by the cleaning unit [C]. The cleaning blade releases when the release knob [F] is pressed. This will clean the cleaning blade [D] using the blade scraper [E] which is installed under the cleaning blade.
Page 112: Toner Overflow Detection
28 February 1989 8.4 TONER OVERFLOW DETECTION The toner overflow sensor [A] sends the overflow signal to the I/O control PCB when the toner collection tank [C] is full. This sensor is a photo interrup- ter. A rubber sheet [B] under the toner overflow sensor is lifted up by the gradual collection of toner.
Page 113: Paper Feed And Registration
28 February 1989 9. PAPER FEED AND REGISTRATION 9.1 OVERVIEW This model has three paper feed stations [A][B][C]. Each cassette has a capacity of 250 sheets. As an option, a 1000 sheet large capacity tray [D] can be installed in the third paper feed station [C]. Paper can also be fed using the manual feed table [E] which utilizes the first feed station feed mechanism.
Page 114: Frr Feed System
28 February 1989 9.2 FRR FEED SYSTEM 9.2.1 Pick-up Roller The pick-up roller [A] is in contact with the paper stack before it starts feeding paper. A few moments after the Start key has been pressed, the rotation of the pick-up roller feeds the top sheet to the feed [B] and separation [C] rollers.
Page 115: Friction Pad Feed System
28 February 1989 9.3 FRICTION PAD FEED SYSTEM When the feed roller [A] starts turning, it forces a single sheet of paper across the friction pad [B]. The roller stops turning when the paper reaches the registration rollers [C]. At that time the friction pad is pressing the paper up against the feed roller. So, when the registration rollers start turning, the friction of the moving paper as it is pulled from under the feed roller causes the feed roller to start turning again.
Page 116: Paper Llft Mechanlsm (1St Feed Station)
28 February 1989 9.4 PAPER LIFT MECHANISM (1st Feed Station) When the cassette [A] is inserted into the copier, the cassette actuator pin [B] is pushed down by the cassette. The lift motor unit then mechanically pivots clockwise at point [C] so that the lift gear [D] engages with the sector gear [E].
Page 117: Paper Llft Mechanlsm (2Nd And 3Rd Feed Stations)
28 February 1989 9.5 PAPER LIFT MECHANISM (2nd and 3rd Feed Stations) When a cassette is inserted into the copier, the curved release guides on the sides of the cassette press against the rollers on the release levers [A] and force the release levers down.
Page 118: Paper Size And End Detection
28 February 1989 9.6 PAPER SIZE AND END DETECTION Five microswitches in the cassette entrance detect each cassette is paper The paper size switches [A] are actuated by a plate on the front of the size. cassette. Each paper size has its own unique combination of notches in the actuator plate [B].
Page 119 28 February 1989 9.7 PAPER FEED DRIVE MECHANISM (FRR) The feed roller is driven by the main chain [A] through the drive gear. The feed timing is controlled by the paper feed clutch [B]. The drive gear turns the pick-up roller [C] through an idle gear. The separation roller [G] and the grip roller [D] are driven by the main chain through the drive gear.
Page 120: Paper Feed Registration Drive Mechanism
28 February 1989 9.8 PAPER FEED REGISTRATION DRIVE MECHANISM The main chain [A] turns the paper feed drive sprockets. These sprockets turn the second paper feed [B], third paper feed [C] and relay [F] magnetic clutches through the idle gears. The registration roller [D] is driven by the main chain and its ON/OFF timing is controlled by the magnetic clutch [E].
Page 121: Manual Feed Table
28 February 1989 9.9 MANUAL FEED TABLE The manual feed mode allows multi-feeding without a cassette. (Maximum paper quantity is twenty sheets of normal weight paper.) This is accomplished by the manual feed table [A] and the rollers at the first feed station. When the manual feed table is opened, the manual feed sensor [B] sends a signal to the I/O control PCB.
Page 122: Paper Feed Timing
28 February 1989 9.10 PAPER FEED TIMING Each paper feed clutch start timing is almost the same (T1). Paper feed begins 0.1 seconds after the Start key is pressed. When the leading edge of the paper triggers the registration sensor (T2), the first and second paper feed clutches are turned OFF 0.07 seconds later.
Page 123: Servlce Call Condition
28 February 1989 9.11 SERVICE CALL CONDITION Self Diagnostic Code 41: First Cassette Lift Sensor The I/O control board will monitor the upper lift sensor while the lift motor is ON. If the output of the lift sensor stays low for 25 seconds after the lift motor starts turning, code 41 will be displayed.
Page 124: Image Fusing And Paper Exit
28 February 1989 10. IMAGE FUSING AND PAPER EXIT 10.1 OVERVIEW Two fusing rollers, which apply heat and pressure, fuse the image to the copy paper. The hot roller [A] is made of teflon, and the pressure roller [B] is made of silicon rubber with a teflon sleeve.
Page 125: Fusing Drive Release Mechanism
28 February 1989 10.2 FUSING DRIVE RELEASE MECHANISM The fusing unit drive release mechanism automatically disengages the fusing unit drive gear [A] when the front cover [B] is opened. This allows the fusing unit drive gear to rotate freely so that jammed paper can be easily removed. When the front cover is opened, the safety lever is released and the release shaft [D] rotates as shown above.
Page 126: Fusing Control
28 February 1989 10.3 FUSING CONTROL The I/O control PCB monitors the fusing temperature through a thermistor (TH1). It also uses the zero-cross signal generated by the ac drive PCB to ac- curately control the applied power. Normally, the voltage applied to the lamp is a full ac waveform. However, through SP Mode #29, fusing power can be phase controlled.
Page 127: Phase Control
28 February 1989 10.3.1 Phase Control In the phase control mode, the fusing lamp receives ac power constantly. The amount of power is regulated by the width of the trigger pulse. The wider the trigger pulse (C1), the more ac power the lamp receives (D1); therefore, the temperature increases.
Page 128: Service Call Conditions
28 February 1989 10.4 SERVICE CALL CONDITIONS Self Diagnostic Code 53: Fusing Thermistor Abnormal The I/O control PCB monitors the condition of the thermistor. Code 53 is dis- played if the thermistor or its circuit is open for longer than 10 seconds. Self Diagnostic Code 54: Fusing Warm-up Failure Code 54 will be displayed if the hot roller does not reach the ready tempera-...
Page 129: Duplex/Overlay Mechanism
28 February 1989 11. DUPLEX/OVERLAY MECHANISM 11.1 OVERVIEW This model has a duplex and overlay mechanism. Paper exiting from the fusing unit is sent to the duplex/overlay section through the duplex/overlay transport gate [A]. When overlay copy mode is selected (1), paper is sent to the jogger section [B] and is fed to the registration roller [C] again.
Page 130: Drive Mechanism
28 February 1989 11.2 DRIVE MECHANISM The relay rollers are driven by the main chain [A]. The transport gate, junction gate and inverter gate are opened and closed by solenoids [B][C]. The inverter gate solenoid [B] also switches the direction of roller rotation. The inverter roller drive gear is engaged with the “in”...
Page 131: Jogger Mechanism
28 February 1989 The jogger mechanism aligns the paper in the duplex/overlay copy mode. The jogger motor [A] drives the jogger fences [B] to within 10 mm of the sides of the paper when the paper enters the jogger section. When paper is in the jogger section, it is stopped and the jogger fences are then driven against both sides of the paper.
Page 132: Slngle Duplex/Overlay Timing
28 February 1989 11.4 SINGLE DUPLEX/OVERLAY TIMING Single Overlay Copy/Single Duplex Copy Mode T1: The jogger fences move to the home position when the start key is pressed. T2: The duplex/overlay transport clutch, the duplex/overlay transport solenoid, and the inverter gate solenoid (single overlay copy mode) are turned on when the fusing exit sensor detects the leading edge of the paper.
Page 133: Others
28 February 1989 12. OTHERS 12.1 PAPER MISFEED CHECK A: Registration Sensor Upper Relay Sensor Lower Relay Censor B: Fusing Sensor C: Inverter Relay Sensor D: Inverter Sensor This model uses six sensors to detect misfeed conditions inside the copier. Each sensor performs both ON and OFF detection as shown above.
Page 134 28 February 1989 No paper feed: 1) 1st and 2nd feed station Checked by the registration sensor about 1.5 seconds after the 1st and 2nd feed MC is turned on. 2) 3rd feed station Checked by the upper relay sensor about 1.6 seconds after the 3rd feed MC is turned on.
Page 135: Service Call Condltions (Others)
28 February 1989 12.2 SERVICE CALL CONDITIONS (Others) Self Diagnostic Code 61: Functional Drive If the I/O control PCB does not receive pulses from the pulse generator for longer than two seconds, Code 61 will be displayed. Self Diagnostic Code 81: jogger Fails to Return to Home Position If the output of the jogger home position sensor remains low as the I/O con- trol board is driving the fences outward, code 81 will be displayed.
Page 136 Section 2 Timing Chart (following page)
Page 138 S E C T I O N...
Page 139 CONTENTS INSTALLATION REQUIREMENTS 1.1 ENVIRONMENT ............3-1 1.2 MACHINE LEVEL .
Page 140: Installation Requirements
28 February 1989 1. INSTALLATION REQUIREMENTS 1.1 ENVIRONMENT Temperature Range: 10°C to 30°C (50°F to 86°F) Humidity Range: 15% to 90% RH Ambient Illumination: Less than 1,500 Iux (do not exposure to direct sun- light) Ventilation: Room of more than 30 m .
Page 141: Machine Level
28 February 1989 1.2 MACHINE LEVEL Front to back: Within 5 mm (0.2”) of level Right to left: Within 5 mm (0.2”) of level Place the machine on a table and screw the Ieveling feet up or down in order to level the machine. Use a leveling gauge if necessary. 1.3 MINIMUM SPACE REQUIREMENTS 1.
Page 142: Power Requirements
28 February 1989 1.4 POWER REQUIREMENTS Input voltage level: 110V/60Hz: More than 15A 115V/60Hz: More than 15A 220V/50Hz: More than 8A 220V/60Hz: More than 8A 240V/50Hz: More than 8A Permissible voltage fluctuation: ± 10% Permissible extension cord: At least 300V, 30A capacity and less than 5 meters (16.4 ft) long.
Page 143: Copier Installation
28 February 1989 1.5 COPIER INSTALLATION 1.5.1 Accessory Check Check the quantity and condition of the accessories in the box according to the following list: 1. Installation Procedure ......... . . 1 (115V - English only / 220V - Five Languages) 2.
Page 144 21 April 1989 Open the copier front cover [B]. Remove the strips of tape [C] and the fixing plate [D] (2 screws) as shown. Remove the yellow seal [E] from the toner tank. Remove the clamp [F] from the cleaning unit. NOTE: Save the fixing plate [D] for future use.
Page 145 28 February 1989 6. Remove the original scale [A] (2 screws). 7. Remove the 3 scanner lock plates [B]. 8. Remove the lens lock pin [C]. 9. Replace the original scale. NOTE: a) Save the scanner lock plates and lens lock pin for future use. b) If the copier is to be transported, install the scanner lock plates and lens lock pin after turning off the power switch in the full size mode.
Page 146 28 February 1989 13. Push up the lock lever [A]; then, grasp the handle [B] of the color development unit and pull the color development unit out half way. Release the lock lever [A] and pull the color development unit out until it stops.
Page 147 28 February 1989 NOTE: As the color development unit in the copier is originally set up for red toner, the following procedure is required when changing to an optional color development unit. 18. Set the DIP SW [A] as shown above so that the color indicated on the operation panel matches the color in the color development unit.
Page 148 28 February 1989 20. Insert the screwdriver [A] into the hole in the right cover to lower the development unit supporter [B] to a horizontal position. 21. Move the development unit lock lever [C] to the right (to the lock posi- tion).
Page 149 28 February 1989 23. Separate the toner tank [A] from the development unit [B] (3 screws). 24. Pour one pack of 4460 type black developer [C] into the development unit while turning the knob [D] counterclockwise to distribute the developer. 25.
Page 150 28 February 1989 29. Install the black development unit [A]. CAUTION: When installing the development unit, be sure the development unit rail is placed directly on the development unit rail. NOTE: a) Shake the cartridge well to break up any clumps in the toner. b) Remove the strip of tape covering the toner cartridge 30.
Page 151 28 February 1989 31. Insert the toner cartridge [A] completely and turn it counterclockwise. NOTE: Confirm that the toner cartridge gear is properly engaged by attempting to rotate the toner cartridge knob counterclockwise. When the toner cartridge gear is properly engaged, the toner cartridge knob will not rotate freely.
Page 152 28 February 1989 34. Install the color development unit. Side it about 8 cm down the guide rails until you hear a click. CAUTION: When installing the color development unit, be sure the develop- ment unit rail is placed directly on the unit guide rail. 35.
Page 153: For Areas Where The Voltage Is 240V
28 February 1989 1.5.3 For Areas Where The Voltage Is 240V 36. Remove the copier rear cover (2 screws), disconnect the red wire [A] from the 220V terminal [B], and connect this wire to the 240 volt terminal [C] as shown. Then reinstall the copier rear cover. 3-14...
Page 154: Developer Conditioning
28 February 1989 1.5.4 Developer Conditioning Do the following after installing the developer and toner: B: Black developer conditioning A: Color developer conditioning 37. Plug in the machine and turn on the main switch. 38. After the warm up period is completed, press the keys in the following order: A: Color developer conditioning 1) Press the Clear Modes key.
Page 155 28 February 1989 39. Install the receiving tray [A]. 40. Install the original holder [B] on the platen cover. Remove the vinyl sheets from the operation panel covers. 41. Load paper into the cassette and check machine operation and copy quality.
Page 156: Cassette Modification
28 February 1989 1.5.5 Cassette Modification Take off the cassette cover [A]. Remove the side fences [B] (1 screw each) and the bottom plate [C]. Reposition the rear fence [D] in the desired paper size position (1 screw). NOTE: Paper size positions are shown on the inside of the cassette. Reinstall the bottom plate.
Page 157: Key Counter Holder Installation (Option)
28 February 1989 1.5.6 Key Counter Holder Installation (Option) Open the front cover. Remove the right cover [A] (6 screws). Remove the key counter cover [B] (2 screws). Remove the right inner cover [C] and the stopper chain [D] (3 screws). To do so, lower the Development unit supporter (insert screwdriver in hole in right inner cover) and release the transfer unit lever [A1].
Page 158 S E R V I C E T A B L E S...
Page 159: Service Tables
CONTENTS 1. SERVICE TABLES .........4-1 1.1 TEST POINTS .
Page 160: Preventive Maintenance Schedule
4.6.2 User Code Counter Check (SP Mode #91) ......4-37 4.6.3 User Code Counter Reset ..........4-37 4.7 MISFEED TABLE .
Page 161: Service Tables
28 February 1989 1. SERVICE TABLES 1.1 TEST POINTS 1. I/O Control Board NUMBER FUNCTION TP301 TP302 Bias TP303 Fusing Thermistor = 0.9V TP304 ADS (3.0 ± 0.1V) Voltage adjustment using VR101 TP305 Exposure Lamp Voltage (+) TP306 Original Width Sensor Output Voltage TP307 Original Length Sensor Output Voltage TP308...
Page 162: Dip Switches
28 February 1989 1.2 DIP SWITCHES 1. System Control Board (Operation Board) FUNCTION DIP SWITCH NORMAL Free run Forced start (Ready Temp. By-pass) Clear counter Service Program mode access 2. DF Main Board DIP SW 101 101-1 101-2 101-3 101-4 FUNCTION Normal mode 12 cpm (Not used) Normal mode 18 cpm (Factory setting)
Page 163 28 February 1989 2. System Control Board (Operation Board) NUMBER FUNCTION VR101 Adjusts APS voltage (3 ± 0.1V) VR102 Adjust Vsg (4 ± 0.2V) 3. Power Pack (CC/TC/Bias/Grid) NUMBER FUNCTION Adjusts Main Charge Current Adjusts Transfer Current Adjusts standard grid voltage Adjusts ID sensor grid voltage 4.
Page 164: Service Remarks
28 February 1989 2. SERVICE REMARKS 2.1 DRUM 1. Never touch the drum surface with bare hands. 2. Store the drum in a cool dry place. 3. Always wear gloves when cleaning the drum. 4. Never expose the drum to light for a long time. 5.
Page 165: Optics
28 February 1989 5. Clean the charge grid with a blower brush (not with a cloth). 6. The corona height should only be adjusted in the following cases: The front end block is replaced. The drum charge current is uneven. 2.3 OPTICS 1.
Page 166: Development Unit
28 February 1989 9. After adjusting the light intensity (SP No.48), check and adjust the follow- ing items: ADS Voltage Adjustment (SP No.58) ..3.0 ± 0.1V ADS Reference Voltage Memory (SP No.56) NOTE: When adjusting the ADS voltage, perform SP No.56 to store the auto ID reference voltage as a standard.
Page 167: Transfer And Separation
28 February 1989 3. Image density sensor adjustment is required in the following cases: The ID sensor is replaced. The system control board is replaced. The drum has been replaced and Vsg is out of specification. Problems with toner supply have occurred and the ID sensor check shows Vsg to be out of specification.
Page 168: Document Feeder
28 February 1989 3. When replacing the friction pad, adjust the gap between the feed roller and the friction pad. 4. Do not touch the feed roller or the friction pad with oily hands. 5. If the copy paper stacked in the cassette binds against the side or back fences and the frequency of paper misfeeds increases when using a non- standard paper, adjust the position of the side fences and/or the back fence of the cassette.
Page 169: Others
28 February 1989 2.13 OTHERS If the toner density of a solid area decreases, shift the ID sensor bias level to ‘2’ or ‘3’ using SP#33. When installing a new system control board, remove the RAM from the old main board. Reinstall the old RAM on the system control board if the old RAM is not faulty.
Page 170: Special Tools And Lubricants
28 February 1989 3. SPECIAL TOOLS AND LUBRICANTS Description Part Number Q’ ty A006 9105 Drum Shoe Shaft A006 9101 Doctor Gap Gauge: Color Development Unit Doctor Gap Gauge: Black Development Unit A006 9513 A006 9103 Scanner Wire Clamper 1 set A006 9104 Scanner Positioning Pin (4pcs) A008 9502...
Page 171: Service Program Mode
28 February 1989 4. SERVICE PROGRAM MODE 4.1 DIP SWITCHES TABLES 4.1.1 DIP SW 1 (Operation Panel) Description SW # Free run 2 ** Forced start (Ready temperature bypass) Clear counter (see CLEAR MEMORY PROCEDURE) Service Program mode access When ON, the SP mode is disabled. The copy quality and transport ability cannot be guaranteed until the fusing temperature reaches the standard level.
Page 172: Service Program Mode Operation
28 February 1989 4.2 SERVICE PROGRAM MODE OPERATION The service program mode is used to check electrical data and change modes or adjustment values. 4.2.1 Service Program Access Procedure Turn the main switch off. Remove the key cover and the DIP switch cover on the Operation Panel and turn on DIP SW 1-4, then turn the main switch on.
Page 173: Memory Clear Procedure
28 February 1989 Press the Enter key. Service program mode is cleared by pressing the Clear Modes key. If an invalid SP number is entered and the Enter key is pressed, “0” is dis- played in the copy counter. 4.2.3 Memory Clear Procedure <SP-97 “Clears service call counters and jam counters”>...
Page 174: Others
28 February 1989 5) Secret Mode counters (1 - 20) are cleared <SP-99 “Clear all memory”> This Service Program clears all service programs previously described as well as all adjustments and modes. All modes default to factory settings. Turn the main switch OFF. Turn on DIP SW1-3 and 4 on the operation board.
Page 175: Service Program Mode Table
28 February 1989 4.3 SERVICE PROGRAM MODE TABLE *: Accessible through the key board (Sales/Customer Access Mode) Mode No. Data Factory Comments Setting 1 SP Mode Data Make copy of SP Check the setting mode data sheet. data of SP mode. Free run with ex- Check function of 5 Exposure...
Page 176: Sort Mode
28 February 1989 Mode No. Function Data Factory Comments Setting *18 Beeper Turns beeper ON or 0: ON OFF. 1: OFF *19 Auto ID Selects the priority 0: ADS Priority of image density 1: Manual control when the main switch is turned on.
Page 177 28 February 1989 Mode No. Function Data Factory Comments Setting 29 Fusing Selects fusing 0: ON/OFF After the selected Temperature temperature control control mode is set and mode. 1: Phase the main switch Control control turns off/on, the fusing temperature control is changed.
Page 178 28 February 1989 Mode No. Function Data Factory Comments Setting *38 Edge erase Sets the width of 0: 10 mm margin erased. 1: 5 mm 2: 15 mm 3: 20 mm *39 Center Erase Sets the width of the 0: 20 mm Margin center erase margin.
Page 179 28 February 1989 Mode No. Function Data Factory Comments Setting 46 Size Detec- Corrects size detec- 0 - 15 1 mm per step. tion Error Cor- tion. (Max. -8 mm to rection +7 mm) Adjusts 4th/5th mir- 0 - 14 47 Focus Adjust- 0.48 mm per step.
Page 180 28 February 1989 Mode No. Function Data Factory Comments Setting 56 ADS Automatically Place more than 5 Reference memorizes the auto sheets of A3 (LDG) Voltage ID reference voltage white paper on the Memory as a standard. exposure glass. NOTE: Do SP Mode #56 after adjust- ing #58.
Page 181 28 February 1989 Mode No. Data Factory Comments Setting 64 Black Toner Displays the black Press “#” key to Density Level toner density level display the level (0 Check in initial condition to 4). (SP65). 0: 12 - 15 (Vsp/Vsg%) 1: 0 - 7 (Vsp/Vsg%) 2: 8 - 11 (Vsp/Vsg%) 3: 16 - 21...
Page 182: Stack Mode
28 February 1989 Mode No. Function Data Factory Comments Setting 72 Multi Enables Multi 0: No Must be set to 1 to Duplex/Over- Duplex/Overlay 1: Multi multi-duplex/over- Iay Operation Operation. Duplex/ lay unit is installed. Overlay 73 Total Color Shows the total Press # key to dis- Copy Count number of color...
Page 183 28 February 1989 Mode No. Function Data Factory Comments Setting 77 ADF Odd Sets the copier to 0: ON When on, the final Number eject the final copy 1: OFF sheet is fed out; if an odd number of Originals when off, it stays in (Duplex/Over- originals are set.
Page 184 28 February 1989 Mode No. Function Data Factory Comments Setting Displays the total 85 Color Copy Press # key to dis- number of blue Count (Blue) play the first three copies. digits in the Mag- nification indicator. Press “.” key to dis- play the second three digits.
Page 185 28 February 1989 Mode No. Function Data Factory Comments Setting Limits the maximum 1 - 999 The magnification *93 Maximum Copy Quantity copy quantity that indicator blinks can be entered. and the limit quan- tity is displayed. If you enter 10, the max.
Page 186 28 February 1989 Mode No. Function Data Factory Comments Setting Press the “#” key 101 Total Copies Displays the total number of copies. to display the first three digits in the Magnification in- dicator. Press the “.” key to display the second three digits.
Page 187 28 February 1989 Data Factory Comments Mode No. Function Setting Press the “#” key 107 Overlay Displays the total to display the first Copies number of overlay three digits in the copies mode. Magnification in- dicator. Press the “.” key to display the second three digits.
Page 188 28 February 1989 Mode No. Function Data Factory Comments Setting 114 Originals Displays the total Press the “#” key Copied number of originals to display the first copied. three digits in the Magnification in- dicator. Press the “.” key to display the second three digits.
Page 189 28 February 1989 Mode No. Function Data Factory Comments Setting 123 Service Calls Displays the total Press # key to dis- for Drive number of “Drive” play the total num- service calls. ber of “Drive” service calls in the Magnification in- dicator (3 digits).
Page 190 28 February 1989 Data Factory Mode No. Function Comments Setting 5. Paper is not fed from the Multi Duplex/Overlay unit and the inverter relay sensor in the copier is not activated when making multi duplex copies. 6. The inverter sensor is not activated in the Multi Overlay mode.
Page 191 28 February 1989 Mode No. Function Data Factory Comments Setting 15. Paper does not reach the invert- er relay sensor in the Single Duplex/Overlay mode. 16. Registration jam in overlay/duplex copies. 17. Paper stays on the inverter relay sensor in the Multi Duplex/Overlay mode...
Page 192: Service Program Sp-8 Data Input Guide Table
28 February 1989 4.4 SERVICE PROGRAM SP-8 DATA INPUT GUIDE TABLE - How to use this table - After “8” is entered, press the Enter (#) key. Enter the desired input number using the numeral keys according to the above table. Press the Enter (#) key.
Page 193 28 February 1989 Input Remarks Sensor / Switch/ Signal Jogger H.P. Sensor (Copier) OFF ON OFF: When the jogger fen ces are positioned at Jogger H.P. Sensor OFF ON home positioned by (Multi Duplex/Overlay) hand Paper Sensor (Sorter) OFF ON ON: Paper is present OFF: Paper is not present Wheel Sensor (Sorter)
Page 194: Service Program Sp-9 Data Output Guide Table
23 May 1989 4.5 SERVICE PROGRAM SP-9 DATA OUTPUT GUIDE TABLE - How to use this table - After “9” is entered, press the Enter (#) key. Enter the desired output number using the numeral keys according to the table. Press the Start key to turn on the electrical component.
Page 195 28 February 1989 Output Electrical Component Duplex/Overlay Feed MC (Multi Duplex/Overlay) 1st Pick-up Solenoid (Copier) 1st Lift Motor (Copier) Duplex/Overlay Transport Solenoid (Copier) Junction Gate Solenoid (Multi Duplex/Overlay) Inverter Solenoid (Copier) Positioning Roller Solenoid (Copier) Duplex/Overlay Transport MC (Copier) Move the jogger side fences to the home position (Copier) Move the jogger side fences to the home position (Multi Duplex/Overlay) Positioning Roller Solenoid (Multi Duplex/Overlay)
Page 196: User Code Table
28 February 1989 4.6 USER CODE TABLE 4.6.1 User Codes There are 20 user codes as follows: User Code 1101 1202 2212 1303 2313 1404 2414 1505 2515 1606 2616 1707 2717 1808 2818 1909 2919 2010 3020 - How to use “User Code” - 1.
Page 197: User Code Counter Check (Sp Mode #91)
23 May 1989 4.6.2 User Code Counter Check (SP Mode #91) The contents of each user counter (20 codes) can be checked using the fol- lowing procedure: Select SP Mode #91 using the numeric keys. Press the Enter (#) key. Select the desired user code using the “+”...
Page 198: Misfeed Table
21 April 1989 4.7 MISFEED TABLE 4.7.1 Location of Jams/Number of Jams (SP Mode #131) The number of jams in each area mentioned in the following table can be checked using the following procedure: Enter “1 31” using the numeric keys. Press the Enter (#) key.
Page 199 28 February 1989 FC Code Jam Area / Detection Sensor Paper stays on the paper exit sensor in the Multi Duple/Overlay unit. (Paper Exit Sensor not OFF) Paper does not reach the inverter sensor in the Single Duplex mode. (Inverter Sensor not ON) Paper stays on the inverter sensor in the Single Duplex mode.
Page 200: Sensor Location
28 February 1989 4.7.2 Sensor Location F: Paper Exit Sensor (Multi D/O) A: Registration Sensor (Copier) B: Upper Relay Sensor (Copier) G: Paper Sensor (Sorter) H: Fusing Exit Sensor (Copier) C: Lower Relay Sensor (Copier) D: Inverter Relay Sensor (Copier) I: Registration Sensor (ADF) E: Inverter Sensor (Copier) J: Exit Sensor (ADF) 4-40...
Page 201: Preventive Maintenance Schedule
28 February 1989 5. PREVENTIVE MAINTENANCE SCHEDULE After performing the preventive maintenance, do the following: Make a copy of the O-S-A3 test chart at manual image density level 4 to set the lamp voltage (SP Mode No.48) and achieve the proper exposure lamp intensity (see Exposure Lamp Voltage Adjustment).
Page 202 28 February 1989 Symbol keys: L = Lubricate R = Replace C = Clean I = Inspection EM 60K 120K 180K 240K NOTES A. OPTICS 1. Mirrors, lens, Silicone cloth or reflectors, toner shield water (cotton pad), blower glass brush NOTE: Clean 6th mirror with blower brush.
Page 203 21 April 1989 EM 60K 120K 180K 240K NOTES C. AROUND DRUM 1. Corona wires Dry cloth 2. Wire cleaner 3. Charge grid Blower brush 4. End blocks and casing Dry cloth Dry cloth 5. Transfer guide plate 6. Pre-Transfer lamp Dry cloth, discharge any static before installation 7.
Page 204 28 February 1989 EM 60K 120K 180K 240K NOTES G. OTHERS 1. Main drive chain Mobil temp 78, adjust if necessary. Refer to NOTE 8 2. Ozone filter Alcohol or water 3. Transport belt 4. Bushings Spindle oil Mobil temp 78. Refer to 5.
Page 205: Lubrication Points
28 February 1989 5.1 LUBRICATION POINTS The location of the parts which should be lubricated at PM, are shown in the following figures: NOTE 1: 1. Development Unit Change Section * Use Mobil Temp 78 a) Clean the planetary gears [A] and the development unit change clutch spring [B] and drive gear [C].
Page 206: Replacement Points
28 February 1989 NOTE 3: 1. 1st Feed Roller Drive Section * Grease G501 a) Clean the shaft [A] and the inside of the idle gears [B]. Then lubri- cate them with Grease G501 every 120K. NOTE 4: Jogger Section * Mobil Temp 78 Remove the shaft holders [A].
Page 207: Adjustment Points
28 February 1989 NOTE 6: Development Roller Drive Section Replace the development roller drive gear [A] every 240K, if necessary. Then, lubricate it with Silicon Grease G-40M. A: Development Roller Drive Gear [P/N AB013142] NOTE 7: Replace the black and color developer at PM, refering to the following supply yield table, if necessary.
Page 208: Explanation Of Regular Pm
28 February 1989 5.4 EXPLANATION OF REGULAR PM Item Explanation Optics Unit Mirrors, Lens, Stains on any part of the optics unit Reflector, Exposure result in a dirty background, black Glass, Platen Cover lines, or areas of decreased sharp- ness on the copy image. Periodic cleaning is required.
Page 209 28 February 1989 Item Explanation Around Drum Charge Wires Dirty charge wires may cause uneven image density. They should be cleaned or replaced at regular inter- vals. End Blocks Toner tends to accumulate on the corona end blocks, and this can result in poor copy quality or even a high voltage leak.
Page 210 28 February 1989 Item Explanation Thermistor If toner accumulates on the thermistor, Fusing Unit fusing temperature control may not be accurate. Inspect the thermistor at regular intervals. Stripper Pawls Toner or dust adhering to the stripper pawls can cause a paper jam. Clean or replace the pawls at regular inter- vals.
Page 211 28 February 1989 Item Explanation Bin Drive Wheel, Bin Dust adhering to the bin drive wheel or CS2090 bin guide may interfere with bin move- Guide ment and result in uneven bin postition- ing. Clean and lubricate at regular intervals. 4-51...
Page 212 R E P L A C E M E N T A N D...
Page 213: Development And Toner Supply
CONTENTS 1. OPTICS ..........5-1 1.1 EXPOSURE GLASS REMOVAL .
Page 214 2.7 DOCTOR GAP ADJUSTMENT (Color) ........5-37 2.8 TONER SUPPLY CLUTCH CLEANING .
Page 215 4.10.1 1st Feed Station ...........5-66 4.10.2 2nd and 3rd Feed Stations .
Page 216 7.7 FUSING THERMISTOR REPLACEMENT ........5-99 7.8 FUSING TEMPERATURE CHECK (SP Mode #52) .
Page 217: Optics
28 February 1989 1. OPTICS 1.1 EXPOSURE GLASS REMOVAL 1. Take off the left scale [A] (2 short screws). 2. Grasp the left edge of the exposure glass [B] and lift up slightly. Slide the other edge out from under the right glass holder [C]. Remove the ex- posure glass.
Page 218: 1St Mirror Removal
28 February 1989 1.2 1ST MIRROR REMOVAL 1. Turn off the main switch. 2. Remove the exposure glass. (See the Exposure Glass Removal section.) 3. Move the first scanner to the cutout position (150 mm from the left scale). 4. Remove the reflector cover [A] (2 screws). 5.
Page 219 28 February 1989 - To install - 9. Insert the 1st mirror into the front side plate cutout. Then place the rear spring plate and insert the rear side of the mirror into the rear spring plate. NOTE: Make sure when installing the mirror that the reflecting surface is on the upper side and the beveled edge [A] of the mirror is on the lower side.
Page 220: 2Nd And 3Nd Mirror Removal
28 February 1989 1.3 2ND AND 3ND MIRROR REMOVAL NOTE: The 2nd mirror is usually removed to make 3rd mirror cleaning easier. 1. Turn off the main switch. 2. Remove the exposure glass. (See the Exposure Glass Removal section.) 3. Slide the 1st scanner 2/3 of the way to the right. 4.
Page 221 28 February 1989 - To Reinstall - 7. Place the rear spring plate [A] in place and hold it. 8. Insert the 2nd mirror [B] into the front side plate cutout. 9. Insert the rear side of the mirror into the rear spring plate. 10.
Page 222: 4Th And 5Th Mirrors Replacement
28 February 1989 1.4 4TH AND 5TH MIRRORS REPLACEMENT 1. Remove the exposure glass. (See the Exposure Glass Removal section.) 2. Remove the lens cover (2 screws). 3. Remove the 2 fixing screws [A] from the third scanner [B]. 4. Slide the third scanner to the right. 5.
Page 223: Exposure Lamp Replacement
28 February 1989 1.5 EXPOSURE LAMP REPLACEMENT Do not touch the reflector or the new exposure lamp with your bare hands. Use a strip of paper as shown. (Oil marks from fingers on the lamp or reflec- tors will be affected by heat from the lamp and will cause discoloration.) 1.
Page 224: Auto Size/Ads Fiber Optic Cable Replacement
28 February 1989 1.6 AUTO SIZE/ADS FIBER OPTIC CABLE REPLACEMENT 1. Turn off the main switch. 2. Remove the exposure glass. (See the Exposure Glass Removal section.) 3. Remove the reflector cover (2 screws). 4. Remove the exposure lamp lead [A] from the exposure lamp terminals [D]. 5.
Page 225 28 February 1989 Open the front cover. Remove the upper inner cover. Remove the rear cover. 12 . Move the AC drive board [A] out of the way. 13 . Disconnect the fiber optic cable connectors [B] from the system control PCB [C] and the I/O control PCB [D].
Page 226: Thermoswitch Replacement
28 February 1989 1.7 THERMOSWITCH REPLACEMENT 1. Remove the exposure glass (2 screws). 2. Slide the first scanner 150 mm to the right. 3. Remove the reflection plate cover (2 screws). 4. Remove the exposure lamp leads from the terminals [A] on both sides of the thermoswitch.
Page 227: Scanner Drive Wire Replacement
23 May 1989 1.8 SCANNER DRIVE WIRE REPLACEMENT 1.8.1 Wire Removal 1. Remove the following covers and parts. Control panel Sorter (if installed) Rear cover Upper inside cover Optics cooling fan cover [K] (2 screws) Contact glass ID sensor pattern plate [J] Upper cover Right cover Left cover...
Page 228 28 February 1989 1. Position the blue wire [1] as shown in the figure (opposite the Allen screws) and wind it halfway around the pulley. (The upper half of the round ball at the end of the wire should be in the hole.) 2.
Page 229 28 February 1989 9. Manually set the first and second scanners in their home position. 10. Set the four jig pins [A] to fix the first and second scanners. 11. Remove the sorter interface PCB bracket (not shown) and position to the side.
Page 230 28 February 1989 14. Attach the blue wires [1] and [3]. NOTE: The blue wire [1] should be pulled towards the wire timing plate [G] and fixed to the spring [H]. 15. Tighten the first scanner wire clamps and remove the four jig pins and the fixing jig.
Page 231 21 April 1989 17. Adjust the second scanner wire tension. Set the jig pin [A] at the front of the second scanner. Loosenly set the jig pin [B] at the rear of the second scanner. Loosen the two fixing screws of the wire tension bracket [C] and turn the 2nd scanner positioning screw [D].
Page 232: Scanner Motor Replacement
28 February 1989 1.9 SCANNER MOTOR REPLACEMENT 1. Remove the rear cover and the upper cover. 2. Secure the wire with the fixing jig [A] so that it does not come off the pul- ley. (Use tape of no jigs are available.) 3.
Page 233: Lens Drive Motor Replacement
28 February 1989 1.10 LENS DRIVE MOTOR REPLACEMENT 1. Remove the exposure glass and the lens cover. 2. Move the scanner to the return side. 3. Remove the tension spring and the lens drive wire [A]. 4. Remove the 6P connector of the lens drive motor [B]. 5.
Page 234: 3Rd Scanner Drive Motor Replacement
28 February 1989 1.11 3RD SCANNER DRIVE MOTOR REPLACEMENT 1. Remove the exposure glass, upper cover and lens cover. 2. Move the third scanner to the left (viewed from the front). 3. Remove the third scanner drive wire [A]. 4. Remove the 6P connector [B] of the third scanner drive motor. 5.
Page 235: Red Erase Filter Replacement
21 April 1989 1.12 RED ERASE FILTER REPLACEMENT 1. Open the front cover and remove the upper inner cover [A] (3 screws). 2. Remove the following units: Color development Black development Charge Corona Drum unit (Release cleaning unit and transfer unit) 3.
Page 236: Exposure Lamp Position Adjustment
28 February 1989 1.13 EXPOSURE LAMP POSITION ADJUSTMENT 1. Turn off the main switch. 2. Remove the exposure glass. (See Exposure Glass Removal section.) 3. Move the first scanner to the cutout position. 4. Remove the front and rear terminal covers [A] (1 screw each). - Horizontal Adjustment - 5.
Page 237 28 February 1989 - Vertical Adjustment - 8. Position a mirror [A] beside the rear sight hole [B] at a 45 degree angle as shown. NOTE: If you do not have a mirror, remove and use the 2nd mirror. 9. View the lamp filament [C] through the sight hole reflected on the mirror. The filament should be level with the sight hole.
Page 238: Exposure Lamp Voltage Adjustment (Sp Mode #48)
28 February 1989 1.14 EXPOSURE LAMP VOLTAGE ADJUSTMENT (SP Mode #48) 1. Remove the DIP switch cover [A] from the control panel and turn DIP switches 1 - 4 ON. 2. Enter the lamp voltage setting mode with the numeric keys. (SP mode #48).
Page 239: Ads Adjustment (Sp Mode #58)
28 February 1989 1.15 ADS ADJUSTMENT (SP Mode #58) Standard Value: 3.0 ± 0.1V Place a couple of sheets of A3 (LDG) size paper on the exposure glass. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. Enter ADS adjusting mode with the numeric keys.
Page 240: Ads Correction (Sp Mode #56)
28 February 1989 1.16 ADS CORRECTION (SP Mode #56) SP Mode #56 is used to store the ADS value in memory for ADS correction. This mode is used when the ADS value (3.0V) becomes slightly different. Ad- justment is made as follows: Place a few sheets of A3 (LDG) size paper on the exposure glass.
Page 241: Aps Voltage Adjustment (Sp Modes #61 And #62)
28 February 1989 1.17 APS VOLTAGE ADJUSTMENT (SP Modes #61 & #62) Standard Value: 2.8 ± 0.1V 1. Place a few sheets of A3 (LDG) size paper on the exposure glass. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3.
Page 242: Aps Length Sensor Error Correction (Sp Modes #50 And #46)
28 February 1989 1.18 APS LENGTH SENSOR ERROR CORRECTION (SP Modes #50 and #46) 1. Place a sheet of A3 (LDG) size paper on the exposure glass. 2. Remove the DIP SW cover [A] and turn DIP switch 1 - 4 ON. 3.
Page 243: Vertical Magnification Adjustment 1 (Sp Mode #43)
28 February 1989 1.19 VERTICAL MAGNIFICATION ADJUSTMENT 1 (SP Mode #43) NOTE: Vertical magnification adjustment is made after wire clamp position adjustment. 1. Check the measurement of the 100 mm vertical scale on a copy of the OS- A3 test chart. If the measurement is incorrect, perform the following. 2.
Page 244: Overlay And Duplex) (Sp Mode #45)
28 February 1989 1.20 VERTICAL MAGNIFICATION ADJUSTMENT 2 (Overlay and Duplex) SP Mode #45 1. Measure the 100mm vertical scale on the first side of a duplex (overlay) copy. If the measurement is incorrect, perform the following. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3.
Page 245: Horizontal Magnification Adjustment (Sp Mode #44)
28 February 1989 1.21 HORIZONTAL MAGNIFICATION ADJUSTMENT (SP Mode #44) Horizontal magnification adjustment is made after wire clamp position adjust- ment. 1. Measure the 100mm horizontal scale on a copy of the OS-A3 test chart. If the measured value is incorrect, perform the following. 2.
Page 246: Rd Scanner Height Adjustment
28 February 1989 1.22 3RD SCANNER HEIGHT ADJUSTMENT CAUTION: Never perform this adjustment until you have positively verified that the source of the skewing is optical and not in the paper path . Adjust the height of the 3rd scanner only when a parallelogram (skewed) image appears.
Page 247: Development And Toner Supply
28 February 1989 2. DEVELOPMENT AND TONER SUPPLY 2.1 BLACK DEVELOPER REPLACEMENT (SP Mode #65) 1. Take out the development unit. 2. Set the development unit on a large sheet of paper [A]. 3. Remove the toner tank [B] (3 screws). 4.
Page 248: Black Development Roller Replacement
28 February 1989 2.2 BLACK DEVELOPMENT ROLLER REPLACEMENT 1. Remove the toner tank [A] (3 screws) and empty the black developer. During this procedure, keep the black developer away from foreign mat- ters. 2. Remove the inlet seal plate [B] (1 screw). 3.
Page 249: Doctor Gap Adjustment (Black)
28 February 1989 2.3 DOCTOR GAP ADJUSTMENT (Black) 1. Remove the toner tank (3 screws) and dump the black developer. 2. Remove the inlet seal plate [A]. (1 screw) 3. Remove any developer on the black development roller. 4. Loosen the four fixing screws [C], and adjust the doctor gap with the jig [B] (Part No.
Page 250: Color Developer Replacement
28 February 1989 2.4 COLOR DEVELOPER REPLACEMENT 1. Take out the development unit. 2. Set the development unit on a large sheet of paper [A] 3. Remove the toner tank [B] and the development guide (3 screws and 1 connector [E]), and turn the development unit over. NOTE: Be careful not to spill the used developer.
Page 251: Color Developer Conditioning (Sp Mode #10)
28 February 1989 2.5 COLOR DEVELOPER CONDITIONING (SP Mode #10) NOTE: This procedure should be performed at installation and when color developer is replaced. Check that Vsg is 4 ± 0.2V before making the initial setting. 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2.
Page 252: Color Development Roller Replacement
28 February 1989 2.6 COLOR DEVELOPMENT ROLLER REPLACEMENT Remove the toner tank [A] (3 screws). Remove the toner end connector [B], color setting switch connector [C], and color bias lead wire [D]. Peel off the side seals [E] and remove the color development rail [F]. Remove the color development roller drive gear [G].
Page 253: Doctor Gap Adjustment (Color)
28 February 1989 2.7 DOCTOR GAP ADJUSTMENT (Color) 1. Perform steps 1 through 4 of the Color Development Roller Replacement section. 2. Remove any developer from the color development roller. 3. Loosen the fixing screws [A], and adjust the doctor gap with the jig [B] (Part No A006 9101).
Page 254: Toner Supply Clutch Cleaning
28 February 1989 2.8 TONER SUPPLY CLUTCH CLEANING 1. Remove the rear cover (4 screws). 2. Lower the I/O control PCB [A]. 3. Remove the AC drive board [B] (1 screw and 3 connectors). 4. Remove the bracket [C] (2 screws). 5.
Page 255: Developer Shift Clutch Lubrication
21 April 1989 2.9 DEVELOPER SHIFT CLUTCH LUBRICATION 2. Lower the main PCB [A]. 3. Remove the AC drive board [B]. 4. Remove the bracket [C]. 5. Remove the manual feed sensor connector and paper feed relay board. 6. Remove the screws securing the DC harness guide [D]. 7.
Page 256: Development Bias Measurement
28 February 1989 2.10 DEVELOPMENT BIAS MEASUREMENT 1. Place the SP mode data sheet on the exposure glass and turn DIP switch 1 - 4 ON. 2. Press the keys in the following order and make an A3 (DLT) size copy to confirm the bias set for the SP mode data sheet.
Page 257: Measurement (Sp Mode #59)
21 April 1989 2.10.2 Measurement (SP Mode #59) Manual ID setting level ADS setting — ADS adjustment mode (SP#34) is set to “0” or “2”. - - - A D S a d j u s t m e n t m o d e ( S P # 3 4 ) i s s e t t o “ 1 ” . NOTE: A maximum of 10% error may occur in bias value in the measurement by Beckman or by monitor display.
Page 258: Black Development Bias Adjustment (Sp Mode #37)
28 February 1989 2.11 BLACK DEVELOPMENT BIAS ADJUSTMENT (SP Mode #37) SP Mode #37 Set value Bias voltage +40V +20V -20V -40V Code Density Standard Darkest Darker Lighter Lightest Example: When the bias value of the 4th setting is -200V and the setting value (SP #37) is “1”, the voltage becomes -160V.
Page 259: Color Development Bias Adjustment (Sp Mode #79)
28 February 1989 2.12 COLOR DEVELOPMENT BIAS ADJUSTMENT (SP Mode #79) SP Mode #79 Set value +40V +20V -20V -40V Bias voltage Code Density Standard Darkest Dark Lighter Lightest Example: When the bias value of the 4th setting is -200V and the setting value (SP #79) is “1”, the voltage becomes -160V.
Page 260: Highlight Color Density Amount (Sp Mode #86)
28 February 1989 2.13 HIGHLIGHT COLOR DENSITY AMOUNT (SP Mode #86) Normal Set Value = 4 (-200V) 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter the highlight color density adjustment mode with the numeric keys (SP Mode #86).
Page 261: Black Toner Supply Adjustment (Sp Mode #30)
28 February 1989 2.14 BLACK TONER SUPPLY ADJUSTMENT (SP Mode #30) SP mode #30 Set value ID sensor mode Fixed supply mode Mode Normal Set Value = “0” (ID sensor mode) 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2.
Page 262: Black Toner Supply Amount (Id Sensor Mode) (Sp Mode #31)
28 February 1989 2.15 BLACK TONER SUPPLY AMOUNT (ID Sensor Mode) SP MODE #31 SP Mode #31 Set value Supply ratio Normal Supply Ratio: 15% 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2.
Page 263: Black Toner Supply Amount (Fixed Supply Mode) (Sp Mode #32)
28 February 1989 2.16 BLACK TONER SUPPLY AMOUNT (Fixed Supply Mode) SP Mode #32 SP Mode #32 Set value Supply ratio 3.5% 10.5% 14% Normal Supply Ratio: 7% 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2.
Page 264: Color Toner Supply Amount (Sp Mode #70)
28 February 1989 2.17 COLOR TONER SUPPLY AMOUNT (SP Mode #70) SP Mode #70 Set Value Supply Ratio Normal Supply Ratio: 14% 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter the color toner supply amount mode with the numeric keys. 3.
Page 265: Cleaning
28 February 1989 3. CLEANING 3.1 CLEANING UNIT REMOVAL 1. Open the front cover. 2. Lower the transport unit [A]. 3. Place some paper [B] underneath the cleaning unit [C]. 4. Turn the cleaning unit release lever 90°, and remove the cleaning unit. 5-49...
Page 266: Cleaning Blade Replacement
28 February 1989 3.2 CLEANING BLADE REPLACEMENT 1. Remove the cleaning unit [A]. (See Cleaning Unit Removal.) 2. Remove the cleaning blade [B] (1 screw). 3. Install the new cleaning blade between blade brackets [C] and secure with the collar screw. NOTE: a) Do not touch the edge of a new cleaning blade, as it is damaged easily.
Page 267: Cleaning Brush Replacement
28 February 1989 3.3 CLEANING BRUSH REPLACEMENT 1. Remove the cleaning blade [A]. (See Cleaning Blade Replacement sec- tion). 2. Remove the 4 cleaning brush bracket screws, and remove the cleaning brush [C] together with the cleaning side brackets [B]. 3.
Page 268: Blade Scraper Replacement
28 February 1989 3.4 BLADE SCRAPER REPLACEMENT 1. Remove the cleaning blade and brush. (See Cleaning Brush Replacement section.) 2. Hold down the cleaning blade knob [A] and remove the blade scraper [B] (2 screws). 5-52...
Page 269: Toner Overflow Sensor Replacement
3.5 TONER OVERFLOW SENSOR REPLACEMENT Remove the cleaning unit. Lower the transport unit [A]. Remove the toner overflow sensor bracket [B] from the duct bracket (1 screw). Disconnect the connector [C] and remove the toner overflow sensor from the bracket [B] (1 screw). 5-53...
Page 270: Used Toner Collection
28 February 1989 3.6 USED TONER COLLECTION 1. Slide out the cleaning unit [A] until the toner collection cap [B] is acces- sible. 2. Remove the toner collection cap [B], and check the toner quantity by in- serting a screwdriver. 3.
Page 271: Quenching Lamp Replacement/Cleaning
28 February 1989 3.7 QUENCHING LAMP REPLACEMENT/CLEANING 1. Open the front cover. 2. Pull out the QL [A]. 3. Wipe the surface of the QL with a cloth. 4. Reset (replace) the QL. NOTE: Do not use alcohol to clean the QL. 5-55...
Page 272: Paper Feed
28 February 1989 4. PAPER FEED 4.1 MANUAL FEED TABLE REMOVAL AND MANUAL FEED SENSOR REPLACEMENT 4.1.1 Table 1. Lower the manual feed table [A]. 2. Remove the right cover (6 screws). 3. Remove the manual feed table in the direction of the arrow. 4.1.2 Sensor 1.
Page 273: Paper Size Switch Replacement
28 February 1989 4.2 PAPER SIZE SWITCH REPLACEMENT 1. Remove the size switch [A] from the paper feed station (1 screw). 2. Pull the connector harness as far as possible into the machine before dis- connecting the switch or the new switch unit will be very difficult to install. 3.
Page 274: 1St Feed Rollers Replacement
28 February 1989 4.3 1ST FEED ROLLERS REPLACEMENT 1. Remove the right cover and the manual feed table. (See the Manual Feed Table Removal section.) 2. Remove the following parts: Paper feed guide plate [A] (1 screw) Separation guide plate [B] (2 screws) 3.
Page 275 28 February 1989 6. Reinstall the new rollers as shown. NOTE: Do the following for cleaning/lubrication: a) Use a damp cloth to clean the rollers. b) Clean the clutch spring before lubricating it. c) Put Mobil Temp.78 in the three grease holes [G] in the drive hub [H].
Page 276: Grip Roller Replacement
28 February 1989 4.4 GRIP ROLLER REPLACEMENT 1. Remove the first paper feed station pick-up roller, paper feed roller, and reverse roller. (See the 1st Feed Rollers Replacement section.) 2. Remove the holding spring plate [A] (1 collar screw). NOTE: Do not bend the spring plate [B] or the mylar strip [C]. 3.
Page 277: 2Nd Feed Roller And Friction Pad Replacement
28 February 1989 4.5 2ND FEED ROLLER AND FRICTION PAD REPLACEMENT 1. Remove the first separation guide plate [A] (2 screws). 2. Remove the paper feed roller bracket [B] (1 screw). CAUTION: Be careful not to drop the spacer [C], spring [D], or bushing [E]. 3.
Page 278 28 February 1989 4.6 3RD ROLLER AND FRICTION PAD REPLACEMENT 1. Remove the auxiliary roller assembly [A] (1 screw). 2. Remove the third feed roller [B] and the hub [C] from the shaft and replace the roller. NOTE: Do not apply grease to the bearings in the paper feed roller bracket or to the auxiliary roller assembly.
Page 279: Friction Pad Pressure Adjustment
28 February 1989 4.7 FRICTION PAD PRESSURE ADJUSTMENT 1. Turn the eccentric cam [A] to adjust the clearance between the friction pad [B] and the paper feed roller [C] (0.8 ± 0.1 mm). NOTE: a) Put the 0.9 mm clearance gauge [D] between the roller and the pad.
Page 280: Pressure Arm Adjustment
28 February 1989 4.8 PRESSURE ARM ADJUSTMENT [A]...250g [B]...380g : Normal Setting Position [C]...450g The pressure spring is normally at the [B] position (factory setting). In the fol- lowing cases, change the position: 1. The friction coefficient is large and multiple feeding occurs. Increasing the friction pad pressure fails to correct the problem.
Page 281: Feed And Relay Clutch Replacement
28 February 1989 4.9 FEED AND RELAY CLUTCH REPLACEMENT NOTE: No gap adjustment is required when installing a new paper feed clutch as the gear is provided as part of the assembly. 1. Remove the rear cover (2 screws). 2. Lower the I/O control board [A] (1 screw). 3.
Page 282: Paper End Sensor Replacement
28 February 1989 4.10 PAPER END SENSOR REPLACEMENT 1. Remove the right cover (6 screws). 2. Remove the manual feed table. 3. Remove the paper feed guide plate [A]. 4. Disconnect the paper end sensor connector [B] and remove the paper end sensor bracket [C] (1 screw).
Page 283: Lift Motor Replacement
28 February 1989 4.11 LIFT MOTOR REPLACEMENT 1. Remove the rear and right covers (10 screws). 2. Disconnect the 3P connector (white) [A] of the manual feed sensor, and remove the paper feed control board [B] (1 screw). 3. Disconnect the 2P connector (white) [D] of the pick-up solenoid [C]. 4.
Page 284: Registration Sensor Replacement
28 February 1989 4.12 REGISTRATION SENSOR REPLACEMENT 1. Remove the following units and place them on a sheet of paper: • Color development unit • Black development unit • Charge corona unit (1 screw) • Drum unit (1 screw). 2. Remove the registration sensor bracket [A] (2 screws). 3.
Page 285: Registration Clutch Replacement
28 February 1989 4.13 REGISTRATION CLUTCH REPLACEMENT 1. Remove the rear cover (2 screws). 2. Lower the I/O control PCB (1 screw). 3. Disconnect the 2P connector (yellow) [A] of the registration clutch [B]. 4. Remove the connecting plate [C], and the registration clutch bracket [D] (3 screws).
Page 286: Upper Registration Roller Removal
28 February 1989 4.14 UPPER REGISTRATION ROLLER REMOVAL 1. Open the front cover. 2. Remove the rear cover and lower the I/O control PCB (1 screw). 3. Remove the drive gear [A] (2 Allen screws), then remove the E ring [B]. 4.
Page 287 28 February 1989 4.15 LOWER RESISTRASION REPLACEMENT 1. Remove the transport unit. (See the Transport Belt Replacement section.) 2. Remove the spring [A] from the lower registration roller assembly [B]. 3. Remove the release lever [C] of the lower registration roller (1 screw). 4.
Page 288: Registration Adjustment (Sp Mode #42)
21 April 1989 4.16 REGISTRATION ADJUSTMENT (SP Mode #42) Standard Setting: 8 (0 ± 2.0 mm) 1. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 2. Enter registration adjusting mode with the numeric keys as shown above. 3.
Page 289: Upper Relay Sensor Replacement
28 February 1989 4.17 UPPER RELAY SENSOR REPLACEMENT 1. Remove the 1st separation guide plate (2 screws). 2. Remove the second paper feed roller (1 screw). 3. Remove the second feed station lower entrance guide plate (1 screw). 4. Remove the auxiliary roller assembly [A] (1 screw). 5.
Page 290: Lower Relay Sensor Replacement
28 February 1989 4.18 LOWER RELAY SENSOR REPLACEMENT 1. Remove the third paper feed roller and friction pad assembly [A]. (See the 3rd Paper Feed Roller and Friction Pad Replacement section.) NOTE: Make a note of the positions of the slots on the eccentric cam [B]. Otherwise, friction pad pressure will require re-adjusting.
Page 291: Transport
28 February 1989 5. TRANSPORT 5.1 TRANSPORT BELT REPLACEMENT Open the front cover and disconnect the 2P connector [A] on the rear side plate. Lower the registration release lever [B] to lower the transfer unit [C]. Pull out the transfer/separation corona unit [D]. Unhook the spring [E] connecting the transport unit to the rear pIate.
Page 292 23 May 1989 6. Remove the transport unit [A]. 7. Remove the following parts from the front side of the transport unit: E ring [B] step screw [C] bushing [D]. 8. Remove the following parts from the rear side of the transport roller: 3 E rings [E] transport drive gear [F] parallel pin [G]...
Page 293: Drum Heater Replacement
28 February 1989 5.2 DRUM HEATER REPLACEMENT 1. Remove the transport unit. (See the Transport Belt Replacement section.) 2. Remove the drum heater [A] (one connector [B] and 1 screw [C]) and take out the heater. 5-77...
Page 294: Drum
28 February 1989 6. DRUM 6.1 CHARGE CORONA WIRE REPLACEMENT 1. Remove the charge corona. 2. Remove the front end block cover [A] (1 screw) and the rear end block cover [B]. 3. Unhook the spring from the corona wire [C] and replace the wire. NOTE: a) Do not touch the wire.
Page 295: Charge Corona Grid Replacement
28 February 1989 6.2 CHARGE CORONA GRID REPLACEMENT 1. Remove the charge corona unit. 2. Push in the front pawls [A] of the grid anchor (as shown) in order to remove the grid. NOTE: a) Oils and chemicals on your hands will deteriorate the grid. b) Do not bend the grid.
Page 296 28 February 1989 6.3 CHARGE CORONA HEIGHT ADJUSTMENT NOTE: Adjust the charge corona height after cleaning the optics section. Adjust the charge corona height to achieve even gradation [A] using an OS- A3 test chart as following order. 1) Place the charge corona unit on a flat surface with the grid side [B] down. 2) Measure the height of the rear side of the corona wire [C].
Page 297: Transfer/Separation Corona Wire Replacement
28 February 1989 6.4 TRANSFER/SEPARATION CORONA WIRE REPLACEMENT 1. Remove the transfer/separation (T/S) corona unit. 2. Remove the following parts: T/S unit front end block cover [A] T/S unit rear end block cover [B] T/S unit paper guide [C]. NOTE: When replacing the T/S unit paper guide, verify that all three tabs are properly latched in place [D].
Page 298: Drum Replacement
28 February 1989 6.5 DRUM REPLACEMENT 1. Remove the following units: color development unit black development unit cleaning unit charge corona unit [A]. 2. Remove the fixing screw [B] of the drum stay and pull out the drum unit [C] gently along the rail. NOTE: Take care when removing the drum unit not to strike the erase unit.
Page 299 28 February 1989 5. Remove the drum knob [A] and the bearing [B] and install them with the screw [C] on the new OPC drum. Do not remove the protective sheet from the new drum. 6. Set the OPC drum in the unit and put the bearing holder [D] back in place.
Page 300 28 February 1989 9. Remove the DIP switch cover [A] and turn switch 1 - 4 ON. 10. Press the numeric keys in the above sequence (SP Mode #66) in order to initialize the drum counter and measure the amount of residual voltage on the drum surface.
Page 301: Id Sensor Replacement
28 February 1989 6.6 ID SENSOR REPLACEMENT NOTE: Cover the drum with the protective sheet to prevent the drum from being exposed to light. 1. Remove the drum unit, then remove the drum [A] from the unit. (See the Drum Replacement section.) 2.
Page 302: Id Sensor Vsg Adjustment (Sp Mode #54)
28 February 1989 6.7 ID SENSOR Vsg ADJUSTMENT (SP Mode #54) 1. Clean the ID sensor (LED and photo transistor) with a blower brush. 2. Remove the DIP switch cover [A] and turn DIP switch 1 - 4 ON. 3. Enter ID sensor Vsg adjustment mode with the numeric keys (SP Mode #54).
Page 303: Separation Pawl Replacement
28 February 1989 6.8 SEPARATION PAWL REPLACEMENT NOTE: Cover the drum with the protective sheet before removing the drum unit. This prevents the drum from being exposed to light. 1. Remove the drum unit, then separate the drum [A] from the unit. (See the Drum Replacement section.) 2.
Page 304: Charge Corona Current Adjustment (Sp Mode #9-2)
23 May 1989 6.9 CHARGE CORONA CURRENT ADJUSTMENT (SP Mode #9-2) Standard Value: -400 ± 2µA 1. Turn off the main switch. 2. Remove the rear cover (4 screws). 3. Lower the I/O control board [A]. 4. Disconnect the charge corona terminal [M] from the CC/TC/Bias power pack.
Page 305: Grid Voltage Adjustment (Sp Mode #9-2 And 3)
21 April 1989 6.10 GRID VOLTAGE ADJUSTMENT (SP Mode #9-2 and 3) Standard value (V) Adjusting VR SP Mode Standard grid voltage -920 ± 18V #9-2 ID sensor grid voltage #9-3 -560 ± 10V 1. Remove the rear cover and lower the I/O control board. 2.
Page 306: Drum Current Adjustment (Sp Mode #9-5 And 7)
21 April 1989 6.11 DRUM CURRENT ADJUSTMENT (SP Mode #9-5&7) VR-2 DC - 18.0 ± 1.5 Transfer VR AC Separation AC 44 ± 2.0 SC Power Pack VR DC } DC +1.5 ± 1.5 NOTE: The above values are measured with the Beckman 330 or 3030. 1.
Page 307: Transfer Current Measurement (Sp Mode #9-5)
21 April 1989 6.11.1 Transfer Current Measurement (SP Mode #9-5) Standard Value: DC -18.0 ± 1.5µA 1. Put the drum shoe [A] on the center of the drum shaft with the curved sur- face facing the transfer corona wire [B]. 2.
Page 308: Separation Corona Current Measurement (Sp Mode #9-7)
21 April 1989 6.11.2 Separation Corona Current Measurement (SP Mode #9-7) Standard Value: AC 44 ± 2.0µA DC +1.5 ± 1.5µA NOTE: Turn off the main switch before changing the multimeter setting. 1. Shift the drum shoe [A] slightly to the left so that the distance between the stay of the pick-off pawl and the edge of the drum shoe is 10 mm (as shown).
Page 309: Fusing
28 February 1989 7. FUSING 7.1 FUSING UNIT REMOVAL 1. Open the front cover. 2. Hold the fusing front cover [A] while pushing the release lever [B], and pull out the fusing unit until it stops. 3. Remove the fusing unit lock screws [C] (2 screws). 4.
Page 310 28 February 1989 7.2 FUSING LAMP REPLACEMENT 1. Remove the fusing unit. (See the Fusing Unit Removal section.) 2. Remove the fusing knob [A] by simply lifting the leaf spring with a screwdriver. 3. Remove the front cover [B] of the fusing unit (1 screw). 4.
Page 311: Hot Roller Replacement
28 February 1989 7.3 HOT ROLLER REPLACEMENT 1. Remove the fusing lamp. (See the Fusing Lamp Replacement section.) 2. Press both “B2” release levers and lower the paper exit assembly [A]. 3. Remove the front and rear pressure springs [B]. 4.
Page 312: Pressure Roller Replacement
28 February 1989 7.4 PRESSURE ROLLER REPLACEMENT NOTE: Keep the protective sheet on the pressure roller until the hot roller is fully installed. Remove the sheet before setting the pressure springs. 1. Remove the hot roller. (See the Hot Roller Replacement section.) 2.
Page 313: Fusing Stripper Pawl Replacement
28 February 1989 7.5 FUSING STRIPPER PAWL REPLACEMENT 1. Lower the paper exit assembly [A]. 2. Remove the pawl spring [B]. 3. Loosen the step screw [C] and release the pawl spring [D]. 4. Loosen the screws holding the fusing pawl bracket [E] in place. 5.
Page 314: Thermal Fuse Replacement
28 February 1989 7.6 THERMAL FUSE REPLACEMENT Remove the fusing knob [A] and the fusing front cover [B]. (See the Fusing Lamp Replacement section.) Remove the fusing unit upper cover [C] (4 screws). Lower the paper exit assembly [D]. Pull out the temperature fuse connector [E]. Disconnect the fuse harness lead from the rear terminal [F] of the fusing lamp (1 screw).
Page 315: Fusing Thermistor Replacement
28 February 1989 7.7 FUSING THERMISTOR REPLACEMENT 1. Remove the fusing knob [A] and the fusing front cover [B]. (See the Fusing Lamp Replacement section.) 2. Remove the fusing unit upper cover [C]. (See the Temperature Fuse Replacement section.) 2. Remove the upper paper entrance guide [D] (1 step screw, 1 flat seat screw).
Page 316: Fusing Temperature Check (Sp Mode #52)
28 February 1989 7.8 FUSING TEMPERATURE CHECK (SP Mode #52) 1. Remove the DIP switch cover [A] and turn ON DIP switch 1 - 4. 2. Enter the fusing temperature check mode using the numeric keys (SP Mode #52). 3. The current temperature setting is indicated on the magnification indicator. 4.
Page 317: Fusing Temperature Adjustment (Sp Mode #49)
28 February 1989 7.9 FUSING TEMPERATURE ADJUSTMENT (SP Mode #49) Normal Setting: 185°C The fusing temperature can be adjusted within the range of 175°C to 190°C (in 1°C steps) according to the following procedure: 1. Remove the DIP switch cover [A], and turn ON DIP switch 1 - 4. 2.
Page 318: Fusing Temperature Control Selection
28 February 1989 7.10 FUSING TEMPERATURE CONTROL SELECTION (Full Wave Control or Phase Control) SP Mode #29 Normal Setting: Full Wave Control “0” 1. Remove the DIP switch cover [A], and turn ON DIP switch 1 - 4. 2. Enter the control mode using the numeric keys (SP Mode #29). 3.
Page 319: Nip Width Measurement
28 February 1989 7.11 NIP WIDTH MEASUREMENT Specified Value 3.3 ± 0.3 mm Center Front Should be equal to within 0.4mm } Back • Deviation between the front and back should not exceed 0.4 mm. 1. Perform free run for about 30 times to eliminate pressure roller distortion. 2.
Page 320 28 February 1989 7.12 FUSING PRESSURE ADJUSTMENT < Fusing pressure adjustment combinations > Nip Width Hook settings A - a 3.0 ± 0.3 mm A - b 3.3 ± 0.3 mm ** B - a } B - b 3.6 ± 0.3 mm ** Standard setting Three different nip widths can be selected.
Page 321: Fusing Guide Plate Height Adjustment
28 February 1989 7.13 FUSING GUIDE PLATE HEIGHT ADJUSTMENT Mounting positions A + 1mm A - 0.5mm Factory Paper creasing in the fusing unit can also be corrected by adjusting the height of the fusing entrance guide plate [D]. 1. Remove the guide plate mounting screws from the A position and place them in the lower mounting plate holes.
Page 322: Fusing Exit Sensor Replacement
28 February 1989 7.14 FUSING EXIT SENSOR REPLACEMENT 1. Remove the fusing knob and the fusing front cover. (See the Fusing Lamp Replacement section.) 2. Lower the fusing exit assembly [A]. 3. Remove the fusing exit sensor bracket [B] (1 screw). 4.
Page 323: Transport
28 February 1989 8. TRANSPORT 8.1 TRANSPORT GUIDE UNIT REMOVAL 1. Remove the fusing unit. (See the Fusing Unit Removal section.) 2. Release the transport guide unit [A] and remove the collar screw [B]. 3. Pull out the transport guide unit. 5-107...
Page 324: Relay Sensor Replacement
28 February 1989 8.2 RELAY SENSOR REPLACEMENT 1. Open the front cover and remove the collar screw [A]. 2. Remove the inverter relay sensor connector [B] from the rear side plate and remove the reverse unit [C]. 3. Remove the collar screw [D]. 4.
Page 325: Inverter Sensor Replacement
28 February 1989 8.3 INVERTER SENSOR REPLACEMENT NOTE: If the duplex unit is installed, press the release lever “E1” and slide the unit out until it stops. 1. Remove the left lower cover [A] (2 screws). 2. Remove the inverter sensor bracket [B] (1 screw). 3.
Page 326: Duplex/Overlay Transport Magnetic Clutch Replacement
28 February 1989 8.4 DUPLEX/OVERLAY TRANSPORT MAGNETIC CLUTCH REPLACEMENT Remove Pull out the vacuum fan motor connector [A] and remove the vacuum fan motor [B] (3 screws). Pivot the DC power supply board [C] to the right (1 screw). Remove the main transformer (1 screw, 1 connector). Remove the tension spring [D] and take the duplex/overlay drive chain [E] off its sprocket.
Page 327: Jogger
28 February 1989 9. JOGGER 9.1 JOGGER UNIT REMOVAL NOTE: Before removing the jogger unit, place a mark along the front edge of the bottom plate. This is so that the unit can be reinstalled in the same position, to maintain side-to-side registration. 1.
Page 328: Jogger Home Position Sensor Replacement
28 February 1989 9.2 JOGGER HOME POSITION SENSOR REPLACEMENT 1. Remove the jogger unit. (See the Jogger Unit Removal section.) 2. Remove the screw [A] and disconnect the connector [B]. Then replace the jogger home position sensor [C]. NOTE: a) Access the screw [A] by inserting a screwdriver through the hole in the jogger unit bracket.
Page 329: Jogger Unit Wire Replacement
28 February 1989 9.3 JOGGER UNIT WIRE REPLACEMENT - Removal - 1. Remove the jogger unit. (See the Jogger Unit Removal section.) 2. Loosen the screws [A] securing the front and rear jogger fences (2 screws). 3. Remove the jogger unit lower cover [B] (1 screw). 4.
Page 330 10. Attach the rear jogger fence [A] to the jogger wire by placing the bead in the hole under the rear stop plate [B], and tighten the stop plate screw. 11. Position the rear logger fence to 11 ± 0.3 mm (home position) from the rear side plate [C].
Page 331: Jogger Motor Replacement
28 February 1989 9.4 JOGGER MOTOR REPLACEMENT Remove the jogger unit wire tension spring [A]. (See the Jogger Unit Wire Replacement section.) Disconnect the jogger motor connector [B] from the connector bracket. Remove the jogger motor assembly [C] (2 screws). Separate the drive pulley [D] from the motor, and replace the motor.
Page 332: Jogger Solenoid Adjustment
28 February 1989 9.5 JOGGER SOLENOID ADJUSTMENT Adjust the position of the solenoid bracket [A] to satisfy the following condi- tions: When solenoid is OFF Press the solenoid plunger [B] and release it. Adjust the stroke [C] to 3 ± 0.3 mm. When solenoid is ON Make sure the clearance between the relay roller [D] and the transport roller [E] is at least 0.5 mm.
Page 333: Others
28 February 1989 10. OTHERS 10.1 OPERATION PANEL REMOVAL 1. Open the front cover and remove the inner cover [A] (3 screws). 2. Remove the operation panel [B] (4 screws, 6 connectors). 3. Replace the operation panel. NOTE: a) Remove the RAM IC from the old operation panel and install it in the new panel.
Page 334 S E C T I O N 1 2...
Page 335 CONTENTS TROUBLESHOOTING 1. COPY QUALITY ......... .12-1 1.1 BLANK COPY (WHITE COPY) .
Page 336 2.8 CODE#2A AND #2B ..........12-37 2.9 CODE #28 AND #29 .
Page 337 4.15 FUSING THERMISTO R ..........12-54 4.16 DC POWER SUPPLY FUSES .
Page 338: Copy Quality
28 February 1989 1. COPY QUALITY 1.1 BLANK COPY (WHITE COPY) - Phenomenon - White or almost white copy - Possible Causes - Charge is not applied. This is the result of a CC/TC bias power pack (charge) failure, poor contact of the lead wire, a broken charge corona wire, or a leak in the insulator or endblock.
Page 339 28 February 1989 Actions - 1. 2. 3. No charge or transfer No grid output (1) Make sure that the charge corona unit and transfer corona unit have been installed correctly. (2) Check for a broken charge wire or a leak in the insulator or endblocks.
Page 340 28 February 1989 6. (1) Leave the drum in darkness so that it regains sensitivity. However, if the drum cannot regain sensitivity due to excess exposure to fluorescent light or direct sunlight, it must be replaced. (2) If the surface integrity of the drum has been destroyed by ammonia, replace the drum, and instruct the user to move the copier away from the sourse of ammonia fumes.
Page 341: Dirty Background
28 February 1989 1.2 DIRTY BACKGROUND - Phenomena - The background is dirty at image density level 4 (manual setting). When newspapers are copied, the background is dirty even at level 7. ADS copies have a dirty background. - Possible Causes - Dirty optics The optics fan brings in dust from outside the copier;...
Page 342 28 February 1989 7. In ADS Mode, VDE (reflected light from white original) is too high. 8. The ADS optical fiber is cut or bent. - Actions - Dirty optics. (1) Wipe the toner shield glass with a soft dry cloth. (2) Clean the exposure glass and mirrors 1 to 5.
Page 343 28 February 1989 6. Defective or deteriorated drum. (1) With a deteriorated drum, check the Vr correction level. NOTE: If the Vr correction rate is less than 37%, Vr correction is no longer effective and the drum must be replaced. (2) Correct the deformation of the drum holder.
Page 344 28 February 1989 1.3 UNEVEN IMAGE DENSITY - 1 - Phenomena - 1. Uneven image density appears on solid black copies. 2. Areas where the image density is uneven do not move when the reproduction ratio is changed. - Possible Cause - Uneven charge on the drum (1) Dirty charge corona wires or grid (2) Uneven height of charge corona wires...
Page 345: Uneven Image Density
28 February 1989 1.4 UNEVEN IMAGE DENSITY - 2 - Phenomena - Uneven image density appears in the copy background, but not in the solid black area. Areas where the image density is uneven move when the reproduction ratio is changed. - Possible Causes - 1.
Page 346 28 February 1989 1.5 VERTICAL BLACK BANDS - 1 Phenomenon - Vertical black bands on the copy (paper feed direction). - Possible Causes - The inlet seal (mylar strip) on the development unit is defective; toner scatters and coats the toner shield glass. Optics unit components are dirty.
Page 347: Vertical Blacklines - 2
28 February 1989 1.6 VERTICAL BLACK LINES - 2 - Phenomenon - Thin black lines on the copy - Possible Causes - Scratched drum Scratched hot roller Dirty or scratched exposure glass. Glue from labels sticks to the drum suface, causing toner build-up. Scratched cleaning blade - Actions - Check the drum.
Page 348: Vertical White Lines Or Bands - 1 (Dull Or Blurred)
28 February 1989 1.7 VERTICAL WHITE LINES OR BANDS - 1 (Dull or Blurred) - Phenomenon - Dull or blurred white lines appear on the copy. - Possible Causes - 1. Dirty or deteriorated charge corona wire or burrs on the charge or W h i t e L i n e transfer casings.
Page 349 28 February 1989 1.8 VERTICAL WHITE LINES - 2 (Half Tone Images) - Phenomenon - Blurred white lines appear on half tone images. - Possible Cause - The light intensity of the exposure lamp is too strong. - Action - Adjust the position of the exposure lamp.
Page 350: Vertical White Lines - 3 (Smeared Image)
28 February 1989 1.9 VERTICAL WHITE LINES - 3 (Smeared Image) - Phenomenon - Objects rubbing against the image on the drum or paper surface (prior to fusing) cause fuzzy white lines on the copy image. - Possible Causes - 1.
Page 351: Vertical White Lines Or Bands - 4 (Thin, Distinct)
28 February 1989 1.10 VERTICAL WHITE LINES OR BANDS - 4 (Thin, Distinct) - Phenomenon - Thin, distinct white lines - Possible Cause - Scratched drum - Actions - Replace the drum. Find out what caused the scratches on the drum and cor- rect the problem.
Page 352: Horizontal Black Lines
28 February 1989 1.11 HORIZONTAL BLACK LINES - Phenomenon - Black lines perpendicular to the paper feed direction appear on the copy image. - Possible Causes - Drum is scratched. Hot roller is scratched. Blade presses so hard that toner sticks to the drum surface. For cause 1, 2 and 3, measure the distance between the horizontal black lines.
Page 353 28 February 1989 5. The development roller is shorted to ground. - Actions - 1. 2. 3. Replace the drum or hot roller if scratched. 4. (1) a. Clean (dry cloth) or replace the drum. b. Clean or replace the cleaning blade. (2) a.
Page 354: Jitter - 1
28 February 1989 1.12 JITTER - 1 Phenomenon - Jitter appears at 94mm intervals on the copy. (The length of the interval is determined by the diameter of the optics unit drive pulley--30 mm.) - Possible Causes - 1. Irregular rotation speed of scanner drive motor. 2.
Page 355: Jitter - 2 (Irregular)
28 February 1989 1.13 JITTER - 2 (Irregular) - Phenomenon - Jitter appears at irregular intervals, especially with enlargement copies. - Possible Causes - 1. There is a DC power surge in the +24V scanner drive line, and this changes the scanner drive motor speed. 2.
Page 356: Marks At 251Mm Intervals
28 February 1989 1.14 MARKS AT 251 MM INTERVALS - Phenomenon - Imperfections in the copy image appear at 251 mm intervals. - Possible Causes - Scratches or areas of reduced sensitivity on the drum (Drum diameter: 80 mm). If a positive image remains at 251 mm intervals, a dirty quenching lamp filter or a defective quenching lamp may be the problem.
Page 357: Skewed (Optical) Copy Image
28 February 1989 1.15 SKEWED (OPTICAL) COPY IMAGE - Phenomena - The copy image is skewed (parallelogram shape). The sides of the copy image are straight, but the leading and trailing edges are skewed. (The image differs from the paper path type of skewing.) - Possible Causes - The 3rd scanner is not parallel with the 1st and 2nd scanners;...
Page 358: Black Spots On The Copy Image
28 February 1989 1.16 BLACK SPOTS ON THE COPY IMAGE - Phenomenon - Black spots 2 to 3mm in diameter appear all over the copy image. - Possible Cause - The grid voltage is not applied correctly. If the grid terminal does not properly contact its terminal, the grid will be insu- lated from all charges (floating).
Page 359: Toner Density Too High
28 February 1989 1.17 TONER DENSITY TOO HIGH - Phenomena - Toner density is too high. (1) A dirty background appears on the copy. Also, a 1 mm thick vertical black line may appear. (2) The image density of the black solid area is too high. (3) Toner is built-up on the end block cover of the transfer/separating corona unit and also on the upper cover of the development unit.
Page 360 28 February 1989 2. Check Vsg in SP Mode No.54 Adjust Vsg to 4 ± 0.2V by turning VR102 on the operation panel. NOTE: Though the Vsp level can be displayed by pressing the 0 key in SP Mode No.55, adjustments can only be made in SP Mode No.54. 3.
Page 361: Toner Density Too Low
28 February 1989 1.18 TONER DENSITY TOO LOW - Phenomena - Toner density is too low. (1) Density of the solid black areas is too low. (2) Solid areas feel rough to the touch. (3) Carrier is on the copy. (4) Light spots appear on solid black copies.
Page 362 28 February 1989 3. Make copies to check whether the toner supply clutch is on or off. (1) If toner is not supplied even though the image density is low: Check Vsp with SP Mode No.55 If Vsp is too low, check and adjust the ID sensor bias, charge corona current, and ID sensor grid voltage.
Page 363 28 February 1989 1.19 UNFUSED CORY IMAGE - Phenomenon - Solid image rubs off easily. - Possible Causes - 1. Nip width is too narrow. 2. Fusing temperature is too low. 3. Thermistor malfunction - Actions - 1. Adjust the position of the pressure spring in the fusing unit. Nip width Standard Value: Center = 3.3 mm Front...
Page 364 28 February 1989 3. Confirm the temperature. (1) Enter SP Mode No.52 (2) Temperature is displayed in the size magnification indicator. (3) Check to see if temperature is 185 ± 5°C. (4) If the surface temperature is still low although 185 ± 5°C is displayed in the size magnification indicator, the problem is a thermistor malfunction.
Page 365: Optics Unit Control Failure - 1 (Initialization)
28 February 1989 1.20 OPTICS UNIT CONTROL FAILURE - 1 (Initialization) - Phenomenon - When the main switch is turned on, the scanner moves all the way to the right (return position), strikes the copier frame, and stops. - Possible Cause - A drop in the power supply voltage below the minimum specified level prevents the CPU from being reset.
Page 366: Optics Unit Control Failure - 2 (Copy Cycle)
28 February 1989 1.21 OPTICS UNIT CONTROL FAILURE - 2 (Copy Cycle) - Phenomenon - The scanner moves all the way to the right (return position) and strikes the copier frame. - Possible Causes - 1. Scanner motor malfunction 2. I/O control board malfunction 3.
Page 367: Side Registration Malfunction Ln Duplex/Overlay Copy Mode
1 s t c o p y i m a g e Duplex/overlay copy images do not register as specified. This usually occurs in duplex copy mode in the main body (FT4460) or in mulltiple overlay copy mode with the multi-duplex/overIay unit (option).
Page 368 28 February 1989 Duplex/overlay When the second copy image is shifted to the left of the position of the first copy image. Duplex mode * Position of spring Overlay mode in main body in main body Duplex/overlay Rear spring Front spring transport roller Duplex/overlay Rear spring...
Page 369: Service Call Conditions
28 February 1989 2. SERVICE CALL CONDITIONS 2.1 CODE #11 - Phenomenon - SC #11: The exposure lamp circuit is open (stand by). - Possible Causes - 1. Exposure lamp circuit open 2. Optical thermoswitch open 3. I/O control board malfunction 4.
Page 370: Code #12
28 February 1989 2 . 2 C O D E # 1 2 - Phenomena - SC #12: The exposure lamp circuit stays open longer than 20 seconds during a copy cycle. SC #12: The exposure lamp stays on longer than 20 seconds during a copy cycle.
Page 371: Code #21
28 February 1989 2.3 CODE #21 - Phenomenon - SC #21: 1st scannner not at home position - Possible Causes - 1. Scanner home position sensor malfunction 2. I/O control board malfunction 3. System control board malfunction - Action - Check CN301-B17 on the I/O control board with the scanner at the home position.
Page 372: Code #23
28 February 1989 2 . 5 C O D E # 2 3 - Phenomenon - SC #23: The sytstem control board does not receive the lead edged signal (LE) until the scanner reaches the maximum return position. - Possible Causes - 1.
Page 373: Codes #25 And #2E
28 February 1989 - Actions - Replace the I/O control board. Replace the system control board. Check the scanner drive load. Check fuse FU2 on the dc power supply board. Check the scanner wire. 2.7 CODES #25 AND #2E - Phenomena - SC #25: The I/O control board cannot detect the scanner drive direction from encoder pulses.
Page 374: Code#2A And #2B
21 April 1989 2.8 CODE #2A AND #2B - Phenomena - SC #2A: 3rd scanner home position sensor output stays LOW. SC #2B: 3rd Scanner home position sensor output stays HIGH. - Possible Causes - 1. 3rd scanner home position sensor failure 2.
Page 375: Code #28 And #29
28 February 1989 2.9 CODE #28 AND #29 - Phenomena - SC #28: Lens home position sensor output stays HIGH SC #29: Lens home position sensor output stays LOW - Possible Causes - 1. Lens home position sensor malfunction 2. Lens drive motor malfunction 3.
Page 376: Code #41
28 February 1989 2.10 CODE #41 - Phenomenon - SC #41: Upper lift sensor output stays HIGH for more than 25 seconds after the lift motor turns on. - Possible Causes - 1. Cassette not inserted correctly. 2. Lift sensor malfunction 3.
Page 377: Code #53
28 February 1989 2.11 CODE #53 - Phenomenon - SC #53: Thermistor open longer than 10 seconds - Possible Causes - 1. Fusing thermistor failure 2. Fusing unit not installed correctly 3. Fusing unit connector loose or defective - Actions - 1.
Page 378: Code #55
28 February 1989 2.13 CODE #55 - Phenomenon - SC #55: Thermistor has shorted, or the fusing temperature is higher than 220 -240°C. - Possible Causes - 1. Fusing thermistor malfunction 2. I/O control board malfunction 3. AC drive board malfunction - Action - 1.
Page 379: Code #81 And #82
28 February 1989 - Actions - 1. If the main motor turns: Check the voltage at CN101-A13 on the system control board while manually interrupting and uninterrupting the pulse generator sensor (interrupted: 5V, not interrupted: 0V). If the output does not change, replace the pulse generator sensor. If the output changes, replace the main motor or the ac drive board.
Page 380: Code #91
23 May 1989 2. If the jogger drive motor does not turn and nothing is binding the jogger assembly, do the following: Check the jogger drive motor by measuring the drive pulses at CN304-A29, A30, B29, and B30, and re-intialize the copier. If the outputs are constant at +24V, replace the I/O control board.
Page 381: Code #93
28 February 1989 2.18 CODE #93 - Phenomenon - SC #93: System control board and I/O control board are disconnected. - Possible Causes - 1. Poor connection of the harness connectors between the system control board and I/O control board. 2.
Page 382: Call Service Condition #95
28 February 1989 - Actions - 1. Check the connections between the system control board and the editor main board. System control board: CN101 Check the connector on the editor side: CN1. 2. Replace the editor main board. 3. Replace the system control board. 2.20 CALL SERVICE CONDITION #95 - Phenomenon - SC #95: Destination codes are not unique.
Page 383: Others
28 February 1989 3. OTHERS 3.1 ID SENSOR MALFUNCTION (Color Copy Mode) - Phenomena - 1. The ID sensor malfunctions in color copy mode. 2. The color copy indicator and the call service indicator blink on the operation panel. 3. Only the color copy indicator blinks. - Possible Cause - The color developer is deteriorated.
Page 384 28 February 1989 3.2 LOW IMAGE DENSITY (Black) - Phenomena - 1. Solid areas have uneven image density. - Possible Causes - 1. Certain characteristics of the toner cause low image density with the first 100 to 500 copies after black toner is initialized. (The low ID level will be around 1.0;...
Page 385: Sorter Paper Stacking Problem (A3/Ldg Tracing Paper)
28 February 1989 3.3 SORTER PAPER STACKING PROBLEM (A3/LDG Tracing Paper) - Phenomenon - A3 (LDG) tracing paper copies do not always feed correctly into the sorter bins. - Possible Cause - A3 (LDG) tracing paper is not very stiff. When stacked to feed in the short grain direction, sheets sometimes bend or curl so that they do not feed smoothly into the sorter inlet.
Page 386: Paper Creasing
28 February 1989 3.5 PAPER CREASING - Phenomenon - Paper creasing on trailing edge of thin paper C r e a s i n g - Possible Cause - The lower registration roller is greater in diameter in the center, and it tends to wear out the upper registration roller (made of rubber) at the point of contact.
Page 387: Electrical Component Defects
23 May 1989 4. ELECTRICAL COMPONENT DEFECTS 4.1 PAPER END SENSOR - Conditions - 1. Stays OFF (lnterrupted) 2. Stays ON (Not interrupted) - Phenomena - 1. Paper End is displayed even though paper is still in the cassette. 2. Paper End is not detected; the Start key green light is on when the cassette is inserted and no paper in the cassette.
Page 388: Registration Sensor
28 February 1989 4.4 REGISTRATION SENSOR - Conditions - 1. Stays ON (Activated) 2. Stays OFF (Not activated) - Phenomena - 1. The Check Paper Path indicator turns on and point A blinks on the Misfeed Location display when the main switch is turned on. 2.
Page 389: Inverter Relay Sensor
28 February 1989 4.7 INVERTER RELAY SENSOR - Conditions - 1. Stays ON (Not Interrupted) 2. Stays OFF (Interrupted) - Phenomena - The Check Paper Path indicator turns on and point “C” on the Misfeed Location display blinks when the Start key is pressed in duplex/overlay mode.
Page 390: 1St Scanner Home Position Sensor
28 February 1989 4.10 1ST SCANNER HOME POSITION SENSOR - Conditions - 1. Stays ON (Not interrupted) 2. Stays OFF (Interrupted) - Phenomena - 1. Service Call code 21 is displayed after the main switch is turned on. 2. Service Call code 22 is displayed when the Start key is pressed and the 1st scanner moves 14 cm from the home position.
Page 391: Fusing Thermistor
28 February 1989 4.13 FRONT COVER SAFETY SWITCH - Conditions - 1. Stays ON (Actuated) 2. Stays OFF (Not actuated) - Phenomena - 1. The indicators on the operation panel stay on even when the front cover is opened. 2. When the front cover is closed, indicators on the operation panel stay off and the copier cannot be used.
Page 392: Dc Power Supply Fuses
28 February 1989 4.16 DC POWER SUPPLY FUSES - Conditions - 1. Fuse 1 open - no power supply output 2. Fuse 2 open - no +24 Vaa output 3. Fuse 3 open - no +24 Vpp output - Phenomena - 1,2.
Page 393: Cautions For Users
28 February 1989 5. CAUTIONS FOR USERS Explain the following items to users in order to reduce the number of service calls. 5.1 PICK-OFF PAWL TRACES (Overlay mode) - Phenomenon - Traces from the pick-of pawls appear on overlay copies in high humidity or low humidity.
Page 394: Ohp Misfeeds
28 February 1989 5.3 OHP MISFEEDS - Phenomenon - Multi-sheet feeding and other types of misfeeds may occur depending upon how the sheets are cut or under certain environmental conditions. - Explanation - Instruct users to make copies one sheet at a time from the manual feed table.
Page 395: Low Image Density With Red Originals
28 February 1989 5.6 LOW IMAGE DENSITY WITH RED ORIGINALS - Phenomenon - The image density is low in copies of red originals. - Explanation - This copier uses an OPC drum, which has higher spectrosensitivity in red areas than a selinium (F type) drum. Instruct the user to make copies at manual image density level 2.
Page 396: Inadequate Fusing Of Uneven Copy Surface
28 February 1989 5.9 INADEQUATE FUSING OF UNEVEN COPY SURFACE - Phenomenon - The fusing unit, an oilless mechanism, uses a smooth teflon fusing roller. This roller sometimes misses indented areas on the paper surface. - Explanation - Instruct the customer to use paper that has an even surface. 5.10 GAP OR OVERLAPS IN OVERLAY COPYING - Phenomenon - Absolute precision is difficult to achieve...
Page 397: Paper Exit Roller Marks On Direct Image Masters (C & P)
28 February 1989 5.12 PAPER EXIT ROLLER MARKS ON DIRECT IMAGE MASTERS (C & P) - Phenomenon - Paper exit roller marks appear on copies of direct image masters used in offset printing. - Explanation - Explain to the user that copies cannot be made of direct image masters. 12-60...
Page 398 Water Proof Pocket Electrical Component Layout Page 401 - 406 Connector Layout Page 407 - 412 Point to Point Page 413 - 415...
Page 400 COPIER Index Index P to P P to P Index P to P N a m e Function Symbol N a m e Function Symbol Symbol Location Location Location 3rd Scanner Home Informs the CPU when the 4th/5th mirror Lamps Magnetic Clutches Position assembly Is in the full size position...
Page 401 OPTION Index P to P Name Function Symbol Location Motors Belt Drive Motor DC servomotor that drives the transport bell and feed-in system (pick up roller. feed roller, pull out roller and relay roller) DC servomotor that drives t h e feed out Feed out Motor unit of the DF Solenolds...
Page 402 P to P Location Motor LCT Motor Lilts and lowers the LCT bottom plate to A-10 paper bring feed position and allow loading of paper Switches LCT Safety Switch A-10 P o s i t i o n i n g Switch SW12 Sensors Detects when tray is completely down to...
Page 403 SORTER SORTER Index Name P to P Function S y m b o l Location Motors Wheel Drive Motor Drives the wheel that changes the bin posi t i o n Roller Drive Motor Drives all rollers in the sorter paper path Sensors Paper Sensor Misfeed detection for the sorter...
Page 404 MULTI DUPLEX/OVERLAY MULTI DUPLEX/OVERLAY P t o P I n d e x S y m b o l Function Name Location M o t o r D - 7, C-7 Drives the jogger fences that keep paper Jogger stacked evenly in the duplex tray Magnetic Clutch D - 8, C - 8 M C 9...
Page 405 CONNECTOR LAYOUT 1. COPIER 1. COPIER Index No . Component P to P Type CN26 1st Scanner F1.P. Sensor 3P/W Interface Board F-6/7 8P/W DC Power Suppl y Board G-112 7P/W CN39 Pulse Generator Sensor D-1/2 3P/T CN802 Lens Drive Motor/Len s H P. 9P/W D-4/5 Sensor...
Page 406 CONNECTOR LAYOUT Fusing Exhaust Fan H-4/5 3P/W DC Power Supply Board 3P/W 1. COPIER Main Motor 3P/W CN403 AC Drive Board H - 6 3P/W CN402 AC Drive Board 7P/W H-415 CN504 Paper Feed Board 9P/R D-10/11 CN503 Paper Feed Board 3P/R D-12 CN505...
Page 407 2. ADF 2 . A D F Index No CN. No. Component P to P Type CN201 Indicator Panel Harness 6P/W CN114 Pick-up Solenoid Harness 2P/R CN115 Feed-in Solenoid Harness 2P/Y CN26 Original Set Sensor Harness 3P/W CN25 Pulse Generator Sensor Harness 3P/R CN24 Original Width Sensor Harness...
Page 408 3. LCT 3. LCT Index No. CN. No. Component P to P Type CN111 Paper End Sensor 3P/B CN112 Upper Limit Sensor 3P/W CN 101 Tray Interface Harness 7P/W C N 5 1 0 Tray Interface Harness 4P/W CN113 Tray Interface Harness 3P/R CN103 LCT Main Board...
Page 409 4. SORTER 4. SORTER Index No. CN. No. Component P to P Type CN101 Sorter Board 2P/W CN103 Sorter Board 12P/R G-6/7 CN 104 Sorter Board 1 5 P / W Covor Safety Switch 1 P/W Cover Safety Switch 1 P/W CN116 Paper Sensor 3 P / W...
Page 410 5. MULTI DUPLEX/OVERLAY 5 . M U L T I D U P L E X / O V E R L A Y Index No. CN. No. Component P t o P Type Paper Exit Sensor 3P/R Paper End Sensor 3P/W Positioning Roller SOL 2P/ W...

Ricoh FT4460 Service Manual

Ricoh

Table of Contents

Troubleshooting

Section 1

Specifications

Operation Panel

Copy Processes Around the Drum

Functional Operation

Paper Path

Drive Layout

Mechanical Component Layout

Electrical Component Layout

Electrical Component Descriptions

Ac and DC Power Distribution

Overall Machine Control

Drive Mechanism

Image Fusing and Paper Exit

Drum

Drum Charge

Optics

4 Erase

5 Development

6 Image Transfer

7 ID Sensor

8 Drum Cleaning

9 Paper Feed and Registration

10 Image Fusing and Paper Exit

11 Duplex/Overlay Mechanism

12 Others

Table of Contents

Service Tables

Preventive Maintenance Schedule

1 Service Tables

2 Service Remarks

3 Special Tools and Lubricants

4 Service Program Mode

Development and Toner Supply

1 Optics

2 Development and Toner Supply

3 Cleaning

4 Paper Feed

5 Transport

6 Drum

7 Fusing

8 Transport

9 Jogger

10 Others

Quick Links

Chapters

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Summary of Contents for Ricoh FT4460