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Ricoh FT4227 Manual

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RICOH FT4227/FT4427/FT4727
(A085/A087/A088)
PARTS CATALOG
RICOH COMPANY, LTD.
First Edition August 1992

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Summary of Contents for Ricoh FT4227

  • Page 1 RICOH FT4227/FT4427/FT4727 (A085/A087/A088) PARTS CATALOG RICOH COMPANY, LTD. First Edition August 1992...
  • Page 2 PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of these parts on this machine. INDEX to PARTS CATALOG FT4227/FT4427/FT4727 (A085/A087/A088) PS140/250 (A325/A326) DF56 (A497) CS120 (A327) SORTER ADAPTER TYPE G (A328) CS2080 (A411) CS2090 (A423) ST24 (A374)
  • Page 3 FT4227/FT4427/FT4727 (A085/A087/A088)

  • Page 4: Table Of Contents

    PARTS CATALOG INTRODUCTION This chapter instructs you the numbers and names of these parts on this machine. INDEX to PARTS CATALOG LOCATION OF UNIT ................3 LCT SECTION 3 (A087/A088) ............40 EXTERIOR 1 (A085/A087/A088) ........... 10 VERTICAL TRANSPORT SECTION (A085/A087/A088) ....42 EXTERIOR 2 (A085/A087/A088) ...........
  • Page 5 32. FRAME SECTION 3 (A085/A087/A088) ..........72 50. DECAL AND DOCUMENT (A085/A087/A088) ........111 33. FRAME SECTION 4 (A085/A087/A088) ..........74 51. SPECIAL TOOL (A085/A087/A088) ............. 117 34. DRIVE SECTION 1 (A085/A087/A088) ..........76 Parts Index ....................119 35. DRIVE SECTION 2 (A085/A087/A088) ..........78 36.

  • Page 6: Location Of Unit

    LOCATION OF UNIT...
  • Page 7 LOCATION OF UNIT...
  • Page 8 LOCATION OF UNIT...
  • Page 9 LOCATION OF UNIT...
  • Page 10 LOCATION OF UNIT...
  • Page 11 LOCATION OF UNIT...
  • Page 12 LOCATION OF UNIT...

  • Page 13: Exterior 1 (A085/A087/A088)

    1. EXTERIOR 1 (A085/A087/A088)
  • Page 14 1. EXTERIOR 1 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 1301 Left Cover 0802 5094 Tapping Truss Head Screw - M4x8 A024 1368 Left Cover Cap - Sorter 0434 0080W Tapping Screw - M4x8 AA00 1196 Decal - Switch - 230V 0965 4008W Tapping Screw With Flat Washer-M4x8...

  • Page 15: Exterior 2 (A085/A087/A088)

    2. EXTERIOR 2 (A085/A087/A088)
  • Page 16 2. EXTERIOR 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly 5215 1980 Exposure Glass 0802 5094 Tapping Truss Head Screw - M4x8 AA14 3070 Shoulder Screw - M2x2 0434 0080W Tapping Screw - M4x8 AC04 2051 Original Scale - A4 0434 0082W Tapping Screw - M4x8...

  • Page 17: Operation Panel (A085/A087/A088)

    3. OPERATION PANEL (A085/A087/A088)
  • Page 18 3. OPERATION PANEL (A085/A087/A088) Index Q'ty per Index Q'ty per Description Part No. Part No. Description Assembly Assembly A088 5650 Operation Panel Ass’y - A4 (A088) A087 1496 Keytop Sheet - LT (A087) A088 5550 Operation Panel Ass’y - LT (A088) A087 1497 Key Cover A087 5650...

  • Page 19: Platen Cover (A085/A087/A088)

    4. PLATEN COVER (A085/A087/A088)
  • Page 20 4. PLATEN COVER (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly AC00 1036 Platen Cover Ass’y 0314 0060W Philips Pan Head Screw - M4x6 A069 1670 Platen Cover Ass’y (ASIA) 0314 0080W Philips Pan Head Screw - M4x8 A053 1969 Rear Platen Cover 0314 0100W Philips Pan Head Screw - M4x10...

  • Page 21: Optics Section 1 (A085/A087/A088)

    5. OPTICS SECTION 1 (A085/A087/A088)
  • Page 22 5. OPTICS SECTION 1 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 1835 Spring Plate A 0950 3008W Philips Screw With Lock Washer - M3x8 AC03 0060 2nd Mirror 0951 3012W Philips Screw with Flat Washer - M3x1 A006 1724 Rear Spring Plate 0313 0060W Philips Pan Head Screw - M3x6...

  • Page 23: Optics Section 2 (A085/A087/A088)

    6. OPTICS SECTION 2 (A085/A087/A088)
  • Page 24 6. OPTICS SECTION 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 5261 ADS Sensor Board 0313 0050W Philips Pan Head Screw - M3x5 AA15 0252 Seal - 0.1x37x290 0434 0060W Tapping Screw - M4x6 A069 1803 ADS Sensor Bracket 0951 3006W Philips Screw With Flat Washer - M3x6...

  • Page 25: Optics Section 3 (A085/A087/A088)

    7. OPTICS SECTION 3 (A085/A087/A088)
  • Page 26 7. OPTICS SECTION 3 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 1792 Front Shielding Plate 0951 3005W Philips Screw with Flat Washer - M3x5 A069 1790 Rear Shielding Plate 0951 3008W Philips Screw with Flat Washer - M3x8 A069 1794 Small Lens Cover 0434 0060W Tapping Screw - M4x6...

  • Page 27: Optics Section 4 (A085/A087/A088)

    8. OPTICS SECTION 4 (A085/A087/A088)
  • Page 28 8. OPTICS SECTION 4 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 1913 Timing Pulley Bracket - Front Middle 0720 0040E Retaining Ring - M4 AA06 0478 Tension Spring 0964 4006W Tapping Screw With Flat Washer - M4x6 AB03 0271 Timing Pulley - 24Z 0434 0060W Tapping Screw - M4x6...

  • Page 29: Optics Section 5 (A085/A087/A088)

    9. OPTICS SECTION 5 (A085/A087/A088)
  • Page 30 9. OPTICS SECTION 5 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 1931 Right Rail Holder 0434 0060W Tapping Screw - M4x6 5442 1855 Seal 1105 0200 Clamp AA15 0238 Mylar Seal - 0.2x27x310 0314 0040W Philips Pan Head Screw - M4x4 A069 1882 Exposure Glass Holder...

  • Page 31: By-Pass Feed Table (A085/A087/A088)

    10. BY-PASS FEED TABLE (A085/A087/A088)
  • Page 32 10. BY-PASS FEED TABLE (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly AA06 0339 Lever Spring - By-pass Feed 0964 4008W Tapping Screw with Flat Washer - M4x8 A069 2648 By-pass Feed Bushing 0960 3008W Philips Flange Screw - M3x8 AA14 8253 Rear Shaft - By-pass Feed...

  • Page 33: Paper Feed Tray (A085/A087/A088)

    11. PAPER FEED TRAY (A085/A087/A088)
  • Page 34 11. PAPER FEED TRAY (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 2718 End Fence Cover AA14 3288 Stepped Screw A048 2828 End Fence Stopper A069 2735 Side Fence Stopper AA06 3156 Spring - End Fence Stopper AA06 3081 Spring...

  • Page 35: Paper Feed Section (A085/A087/A088)

    12. PAPER FEED SECTION (A085/A087/A088)
  • Page 36 12. PAPER FEED SECTION (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 2180 Filter PTL AF03 2019 Separation Roller A069 2588 Upper Registration Stay A069 2555 Paper Feed Guide A069 2581 Upper Registration Guide A069 5338 Paper Feed Harness - Non LCT 5206 2686...

  • Page 37: Tray Lift Section (A085/A087/A088)

    13. TRAY LIFT SECTION (A085/A087/A088)
  • Page 38 13. TRAY LIFT SECTION (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 2751 Tray Pressure Arm 0434 0080W Tapping Screw - M4x8 AA14 0339 Bottom Plate Shaft - Tray 0720 0040E Retaining Ring - M4 5447 2805 Slide Pin Holder 0720 0060E Retaining Ring - M6...

  • Page 39: Lct Section 1 (A087/A088)

    14. LCT SECTION 1 (A087/A088)
  • Page 40 14. LCT SECTION 1 (A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A335 1253 LCT Top Cover 0344 0080F Philips Truss Head Screw - M4x8 A335 1311 Top Cover Plate 0344 0100F Philips Pan Head Screw - M4x10 AG07 0007 Magnet Catch 0434 0080W Tapping Screw - M4x8...

  • Page 41: Lct Section 2 (A087/A088)

    15. LCT SECTION 2 (A087/A088)
  • Page 42 15. LCT SECTION 2 (A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly AA04 3124 Timing Belt - 6x501 0623 0160E Spring Pin - 3x16mm AB03 0281 Timing Pulley - 28Z 0720 0060E Retaining Ring - M6 AB01 1133 Gear - 49Z 0313 0060W Philips Pan Head Screw - M3x6...

  • Page 43: Lct Section 3 (A087/A088)

    16. LCT SECTION 3 (A087/A088)
  • Page 44 16. LCT SECTION 3 (A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A335 3110 Front Side Plate 1105 0197 Wire Saddle A335 3210 Rear Side Plate 0314 0100W Philips Pan Head Screw - M4x10 A335 3231 Bracket - Lower Limit Sensor 0434 0080W Tapping Screw - M4x8...

  • Page 45: Vertical Transport Section (A085/A087/A088)

    17. VERTICAL TRANSPORT SECTION (A085/A087/A088)
  • Page 46 17. VERTICAL TRANSPORT SECTION (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 1131 Release Bracket - Fusing Drive A069 2663 Positioning Bracket - Vertical Tr. 5442 4467 Spring - Stripper Pawl Plate A069 2789 Upper Tray Rail A069 1130...

  • Page 47: Paper Registration (A085/A087/A088)

    18. PAPER REGISTRATION (A085/A087/A088)
  • Page 48 18. PAPER REGISTRATION (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly AF02 1044 Upper Registration Roller 0951 4008W Philips Screw with Flat Washer - M4x8 A069 2589 Transfer Entrance Guide 0720 0060E Retaining Ring - M6 AF02 0284 Duplex Stack Roller 0720 0040E Retaining Ring - M4...

  • Page 49: Drum Section 1 (A085/A087/A088)

    19. DRUM SECTION 1 (A085/A087/A088)
  • Page 50 19. DRUM SECTION 1 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 2261 Left Drum Stay 0413 0062W Tapping Screw - M3x6 AA01 0043 Filter 0951 4008W Philips Screw with Flat Washer - M4x8 A069 2258 Top Plate - Drum Unit 0952 3006W Philips Screw - M3x6...

  • Page 51: Drum Section 2 (A085/A087/A088)

    20. DRUM SECTION 2 (A085/A087/A088)
  • Page 52 20. DRUM SECTION 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 2061 Left Rail - Charge Corona 0314 0080W Philips Pan Head Screw - M4x8 A069 2065 Quenching Lamp Filter 0413 0082W Tapping Screw - M3x8 A069 2073 Charge Spring Plate 0951 4008W Philips Screw with Flat Washer - M4x8...

  • Page 53: Development Unit 1 (A085/A087/A088)

    21. DEVELOPMENT UNIT 1 (A085/A087/A088)
  • Page 54 21. DEVELOPMENT UNIT 1 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 3050 Development Unit 0314 0060W Philips Pan Head Screw - M4x6 A006 3330 Development Knob 0314 0080W Philips Pan Head Screw - M4x8 AA15 2161 Rear Upper Seal - Development 0725 0100E Retaining Ring C - M10...

  • Page 55: Development Unit 2 (A085/A087/A088)

    22. DEVELOPMENT UNIT 2 (A085/A087/A088)
  • Page 56 22. DEVELOPMENT UNIT 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 3120 Toner Supply Unit - EU,ASIA 0720 0060E Retaining Ring - M6 A073 3110 Toner Supply Unit - NA 0951 4006W Philips Screw With Flat Washer - M4x6 AA15 1099 Seal - 2x14x37mm 0353 0050W Tapping Screw - M3x5...

  • Page 57: Cleaning Unit (A085/A087/A088)

    23. CLEANING UNIT (A085/A087/A088)
  • Page 58 23. CLEANING UNIT (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 3503 Cleaning Unit 0951 3014W Philips Screw With Flat Washer - M3x14 A069 3585 Used Toner Tank - Upper 0413 0082W Tapping Screw - M3x8 A069 3586 Used Toner Tank - Lower 0413 0142W Tapping Screw - M3x14...

  • Page 59: T & S Corona Unit (A085/A087/A088)

    24. T & S CORONA UNIT (A085/A087/A088)
  • Page 60 24. T & S CORONA UNIT (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly AD00 4062 T/S Corona Unit 0413 0082W Tapping Screw - M3x8 AD02 2202 Front End Block Cover 0952 3006W Philips Screw - M3x6 A069 2188 Paper Guide - T/S Corona 5442 2108...

  • Page 61: Transport Section (A085/A087/A088)

    25. TRANSPORT SECTION (A085/A087/A088)
  • Page 62 25. TRANSPORT SECTION (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 3918 Transport Guide 0434 0060W Tapping Screw - M4x6 A023 2074 High Voltage Decal 0434 0080W Tapping Screw - M4x8 A069 3910 Front Transport Bracket 0720 0040E Retaining Ring - M4 A069 3914...

  • Page 63: Fusing Unit 1 (A085/A087/A088)

    26. FUSING UNIT 1 (A085/A087/A088)
  • Page 64 26. FUSING UNIT 1 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A085 4081 Fusing Unit - 230V AB01 3481 Gear - 18Z A087 4060 Fusing Unit - 115V AB01 3482 Gear - 24/24Z A085 4103 Support Plate 5216 4145...

  • Page 65: Fusing Unit 2 (A085/A087/A088)

    27. FUSING UNIT 2 (A085/A087/A088)
  • Page 66 27. FUSING UNIT 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly AA06 0443 Release Lever Spring 0964 4008W Tapping Screw with Flat Washer - M4x8 A085 4133 Exit Release Lever 0720 0040E Retaining Ring - M4 A085 4181 Shielding Plate - Paper Feed Sensor 0805 0077...

  • Page 67: Paper Exit Section 1 (A085/A087/A088)

    28. PAPER EXIT SECTION 1 (A085/A087/A088)
  • Page 68 28. PAPER EXIT SECTION 1 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 4161 Front Magnet Plate 0964 4008W Tapping Screw with Flat Washer - M4x8 A069 4154 Exit Cover Holder 0960 4030W Philips Flange Screw - M4x30 AG05 0058 Relay Roller Knob (A088) 0720 0060E Retaining Ring - M6...

  • Page 69: Paper Exit Section 2 (A085/A087/A088)

    29. PAPER EXIT SECTION 2 (A085/A087/A088)
  • Page 70 29. PAPER EXIT SECTION 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A030 1370 Decal - C (A088) 0434 0080W Tapping Screw - M4x8 5053 0447 Bushing - 6mm (A088) 0720 0040E Retaining Ring - M4 A069 4163 Exit Guide Bracket 0964 4008W Tapping Screw With Flat Washer - M4x8...

  • Page 71: Frame Section 1 (A085/A087/A088)

    30. FRAME SECTION 1 (A085/A087/A088)
  • Page 72 30. FRAME SECTION 1 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 1092 Right Support Plate 0434 0060W Tapping Screw - M4x6 A069 1288 Rear Cover Bracket 0434 0080W Tapping Screw - M4x8 A069 5827 Duct Bracket 0314 0080W Philips Pan Head Screw - M4x8...

  • Page 73: Frame Section 2 (A085/A087/A088)

    31. FRAME SECTION 2 (A085/A087/A088)
  • Page 74 31. FRAME SECTION 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 2824 Large Positioning Bracket 0314 0060W Philips Pan Head Screw - M4x6 A069 1085 Upper Left Harness Stay 0434 0080W Tapping Screw - M4x8 A069 1081 Grip 1105 0197...

  • Page 75: Frame Section 3 (A085/A087/A088)

    32. FRAME SECTION 3 (A085/A087/A088)
  • Page 76 32. FRAME SECTION 3 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly AA15 1406 Seal - 6x6x48 0951 3006W Philips Screw With Flat Washer - M3x6 A069 1083 Exhaust Fan Bracket 0314 0060W Philips Pan Head Screw - M4x6 AX65 0008 Exhaust Fan Motor - DC 7.7W 0434 0080W Tapping Screw - M4x8...

  • Page 77: Frame Section 4 (A085/A087/A088)

    33. FRAME SECTION 4 (A085/A087/A088)
  • Page 78 33. FRAME SECTION 4 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 5804 Key Counter Bracket 0720 0040E Retaining Ring - M4 A069 3062 Development Lever 1105 0229 Clamp 5216 2676 Spring - Engage Gear Bracket 0434 0080W Tapping Screw - M4x8 A006 3063 Development Stopper...

  • Page 79: Drive Section 1 (A085/A087/A088)

    34. DRIVE SECTION 1 (A085/A087/A088)
  • Page 80 34. DRIVE SECTION 1 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 1191 Drum Shaft 0434 0352W Pan Head Self - Tapping Screw - M4x35 AB01 3339 Gear - 80Z 0725 0170E Retaining Ring C - M17 AB03 0273 Timing Pulley - 20Z 0720 0060E Retaining Ring - M6...

  • Page 81: Drive Section 2 (A085/A087/A088)

    35. DRIVE SECTION 2 (A085/A087/A088)
  • Page 82 35. DRIVE SECTION 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 1197 Jiont Bracket - Fusing Drive AA04 3211 Timing Belt - B90S3M564 AA05 1014 Release Wire A069 1195 Support Bracket - Feed Drive A069 1109 Fusing Drive Bracket A069 1093...

  • Page 83: Electrical Section 1 (A085/A087/A088)

    36. ELECTRICAL SECTION 1 (A085/A087/A088)
  • Page 84 36. ELECTRICAL SECTION 1 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly 5408 5160 Short Connector 0314 0080W Philips Pan Head Screw - M4x8 A085 5623 AC Harness - 230V 0434 0060W Tapping Screw - M4x6 A085 5621 AC Harness - 115V 1105 0199...

  • Page 85: Electrical Section 2 (A085/A087/A088)

    37. ELECTRICAL SECTION 2 (A085/A087/A088)
  • Page 86 37. ELECTRICAL SECTION 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 5819 Bracket - DC Power Supply Board 1105 0183 Spacer A086 5331 Dc Main Harness - 230V (A088) 0964 4008W Tapping Screw with Flat Washer - M4x8 A088 5330 Dc Main Harness - 115V (A088) 0960 4006W Philips Flange Screw - M4x6...

  • Page 87: Electrical Section 3 (A085/A087/A088)

    38. ELECTRICAL SECTION 3 (A085/A087/A088)
  • Page 88 38. ELECTRICAL SECTION 3 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 5821 Lower Hinge - DC Power Supply Board 1105 0197 Wire Saddle A069 5836 Optics Board Bracket 0434 0080W Tapping Screw - M4x8 A069 5161 Scanner Motor Control Board 0434 0060W Tapping Screw - M4x6...

  • Page 89: Electrical Section 4 (A085/A087/A088)

    39. ELECTRICAL SECTION 4 (A085/A087/A088)
  • Page 90 39. ELECTRICAL SECTION 4 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly 5443 2668 Bushing 0720 0030E Retaining Ring - M3 A069 2762 Paper End Feeler 1104 0224 Relay Bracket AW50 0013 Push Switch 0434 0080W Tapping Screw - M4x8 A085 5623 AC Harness - 230V...

  • Page 91: Duplex Unit 1 (A088)

    40. DUPLEX UNIT 1 (A088)
  • Page 92 40. DUPLEX UNIT 1 (A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A334 4504 Duplex Tray Unit - A4 A069 1353 Front Cover - Upper A334 4503 Duplex Tray Unit - LT AA00 1197 Decal - Duplex Tray Removal A334 4625 Duplex Left Cover...

  • Page 93: Duplex Unit 2 (A088)

    41. DUPLEX UNIT 2 (A088)
  • Page 94 41. DUPLEX UNIT 2 (A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A334 5278 Duplex Feed Motor - DC24V A334 4780 Mylar Seal - 0.5x22x24 A334 4700 Feed Motor Bracket A491 4787 Jog Plate A334 4865 Release Lever A334 5332...

  • Page 95: Duplex Unit 3 (A088)

    42. DUPLEX UNIT 3 (A088)
  • Page 96 42. DUPLEX UNIT 3 (A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly AA08 0022 Bushing - 4x7x5mm A334 4823 Bushing - Feed Roller AA06 0310 Turn Gate Spring 5215 2621 Snap Ring - M6 A334 4726 Turn Gate Hook AF02 0184...

  • Page 97: Main Control Board (A085/A087/A088)

    43. MAIN CONTROL BOARD (A085/A087/A088)
  • Page 98 43. MAIN CONTROL BOARD (A085/A087/A088)
  • Page 99 43. MAIN CONTROL BOARD (A085/A087/A088)
  • Page 100 43. MAIN CONTROL BOARD (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A085 5111 Main Control Board 1101 0328 Connector Pin Contact A085 5114 IC - HN27C101G-17 1102 2986 Connector - 14P A085 5118 IC - uPD78CP14G-36 1102 4205 CT Header- 6P...
  • Page 101 Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly Resistor - 1.5K Ω 1/8W ±5% 1407 3258 IC - TC74HC139AF 1630 2152 Resistor - 160 Ω 1/8W ±5% 1407 3285 IC - TC74HC08AF 1630 2161 Resistor - 180 Ω...

  • Page 102: Memory Board (A085/A087/A088)

    44. MEMORY BOARD (A085/A087/A088)
  • Page 103 44. MEMORY BOARD (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A069 5131 RAM Board 1102 2979 Connector - 14P 1400 0382 Transistor - 2SA1037KR 1400 0384 Transistor - 2SC2412KR 1402 0476 Diode - 1SS184 1402 0682 Zener Diode - RD3.6M 1407 2797...

  • Page 104: Ac Harness (A085/A087/A088)

    45. AC HARNESS (A085/A087/A088)
  • Page 105 45. AC HARNESS (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A085 5623 AC Harness - 230V 1100 0853 Closed Terminal A085 5621 AC Harness - 115V 1100 0916 Connector - 2P 1102 1551 Connector - 2P 1100 1171 Fastening Receptacle...

  • Page 106: Dc Harness Type 2 (A085/A087/A088)

    46. DC HARNESS TYPE 2 (A085/A087/A088)
  • Page 107 46. DC HARNESS TYPE 2 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A086 5331 DC Main Harness - 230V (A088) 1100 1346 Pin Contact A088 5330 DC Main Harness - 115V (A088) 1100 1348 Pin Contact A087 5330...

  • Page 108: Dc Harness Type 4 (A085/A087/A088)

    47. DC HARNESS TYPE 4 (A085/A087/A088)
  • Page 109 47. DC HARNESS TYPE 4 (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A074 5331 DC Harness - Paper Feed (A088) 1100 1204 Socket - Mate-N-Lock A073 5331 DC Harness - Paper Feed (A087) 1100 1205 Terminal A069 5331...

  • Page 110: Fusing Unit Harness (A085/A087/A088)

    48. FUSING UNIT HARNESS (A085/A087/A088)
  • Page 111 48. FUSING UNIT HARNESS (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A085 5339 Fusing Unit Harness 1100 0965 Pin - Mate-n-lock 1102 5186 Connector - 14P 1102 4124 Connecter - 1P 1100 1249 Receptacle Terminal 1100 1342 Terminal...

  • Page 112: Lct Harness (A087/A088)

    49. LCT HARNESS (A087/A088)
  • Page 113 49. LCT HARNESS (A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A335 5330 LCT Harness (A087/A088) 1100 1155 Contact 1100 1172 Fastening Receptacle 1100 1204 Socket - Mate-N-Lock 1100 1205 Terminal 1100 1249 Receptacle Terminal 1100 1322 Contact...

  • Page 114: Decal And Document (A085/A087/A088)

    50. DECAL AND DOCUMENT (A085/A087/A088)
  • Page 115 50. DECAL AND DOCUMENT (A085/A087/A088)
  • Page 116 50. DECAL AND DOCUMENT (A085/A087/A088)
  • Page 117 50. DECAL AND DOCUMENT (A085/A087/A088)
  • Page 118 50. DECAL AND DOCUMENT (A085/A087/A088)
  • Page 119 50. DECAL AND DOCUMENT (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly A074 1326 Decal - Misfeed Removal C (A088) AA00 2148 Decal - Paper Size - A4 A074 1327 Decal - Misfeed Removal A-B (A088) AA00 1005 Decal - A A073 1327...

  • Page 120: Special Tool (A085/A087/A088)

    51. SPECIAL TOOL (A085/A087/A088)
  • Page 121 51. SPECIAL TOOL (A085/A087/A088) Index Q'ty per Index Q'ty per Part No. Description Part No. Description Assembly Assembly 5203 9501 Grease 501 5420 9507 Digital Multimeter - Beckman 5447 9078 Heat Resisting Grease MT-78 A028 9300 Grease NOK Barrierta - JFE 5 5/2 5442 9103 Launa Oil 5420 9516...

  • Page 122: Parts Index

    PARTS INDEX...
  • Page 123 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A085 1114 Toner Supply Clutch Bracket 79- 15 A085 4116 Side Plate - Entrance Guide 61- 24 A085 1262 Front Upper Cover (A085) 11- 16 A085 4119 Spring Plate 61- 20 A085 1463...
  • Page 124 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A085 5621 AC Harness - 115V 59- 26 A087 1520 Decal - Instruction - A4 (A085/A087) 115- 36 A085 5621 AC Harness - 115V 81- 2 A087 1525 Panel - Sorter - NA 15- 39...
  • Page 125 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A088 5330 DC Main Harness - 115V (A088) 103- * AA00 0008 Decal - A2 11- 14 A088 5550 Operation Panel Ass’y - LT (A088) 11- 7 AA00 0008 Decal - A2 115- 4...
  • Page 126 Paper and Paper and Part No. Description Part No. Description Index No. Index No. AA00 1230 Decal - Fusing Unit Removal - 115V 115- 16 AA06 0146 Spring 73- 9 AA00 1231 Decal - Fusing Unit Removal - 230V 63- 17 AA06 0257 Spring - Bottom Plate Clutch 93- 14...
  • Page 127 Paper and Paper and Part No. Description Part No. Description Index No. Index No. AA06 3242 Registration Pressure Spring - Rear 45- 10 AA14 3070 Shoulder Screw - M2x2 13- 2 AA06 3246 Pressure Spring 33- 27 AA14 3120 Stepped Screw - M3x3 89- 9 AA06 6094 End Fence Spring...
  • Page 128 Paper and Paper and Part No. Description Part No. Description Index No. Index No. AA15 0257 Mylar Seal - 0.2x39x178 21- 9 AA16 2053 Platen Cover Pad (ASIA) 17- 12 AA15 0258 Seal - 0.2x13x250 23- 21 AB00 0014 Gear - 20Z And 72Z 23- 17 AA15 0259 Seal - 0.1x30x75...
  • Page 129 Paper and Paper and Part No. Description Part No. Description Index No. Index No. AB01 3487 Gear - 20Z 45- 17 AB03 0273 Timing Pulley - 20Z 79- 20 AB01 3492 Gear - 16Z 29- 16 AB03 0273 Timing Pulley - 20Z 79- 26 AB01 3492 Gear - 16Z...
  • Page 130 Paper and Paper and Part No. Description Part No. Description Index No. Index No. AD02 2261 Front End Block Cover - Main Charge 49- 24 AF03 1009 Paper Feed Roller 93- 42 AD02 5012 Pick-off Pawl 47- 31 AF03 1019 Feed Roller 33- 7 AD03 3002...
  • Page 131 Paper and Paper and Part No. Description Part No. Description Index No. Index No. AW40 0012 Original Length Sensor - LT 21- 7 A006 1352 Key Counter Cover 13- 17 AW50 0013 Push Switch 87- 4 A006 1352 Key Counter Cover 75- 12 AW50 0014 Push Switch - F87B-AJDL...
  • Page 132 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A009 2645 Lift Lever Guide 35- 11 A069 1092 Right Support Plate 69- 1 A009 2647 Lift Sensor Bracket 35- 18 A069 1093 Frame Support Plate 79- 38 A023 2074 Hight Voltage Decal...
  • Page 133 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A069 1346 Left Optics Cover 13- 4 A069 1795 Lens Shutter 23- 5 A069 1353 Front Cover - Upper 31- 14 A069 1801 Large Lens Cover 21- 8 A069 1353 Front Cover - Upper...
  • Page 134 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A069 1958 Positioning Sensor Shutter (ASIA) 17- 22 A069 2589 Transfer Entrance Guide 45- 2 A069 2012 Receptacle Cover 59- 31 A069 2610 Upper Relay Guide 45- 20 A069 2014 T/S Corona Receptacle...
  • Page 135 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A069 2718 End Fence Cover 31- 1 A069 2823 Rail Guide Roller 71- 13 A069 2719 Spring Plate - End Fence 31- 4 A069 2824 Large Positioning Bracket 43- 38 A069 2720 Paper Size Actuator - A4...
  • Page 136 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A069 3586 Used Toner Tank - Lower 55- 2 A069 4164 Exit Sensor Stay 67- 15 A069 3589 Release Lever - Cleaning Blade 55- 4 A069 4168 Front Magnet Holder (A088) 65- 10 A069 3612...
  • Page 137 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A069 5811 Power Cord Bracket - 110V 85- 7 A070 4928 Tray Lock Lever - Duplex 87- 13 A069 5814 Main Control Board Bracket 83- 11 A070 5337 Harness - Exit Cover Switch (A088) 67- 14...
  • Page 138 Paper and Paper and Paper and Paper and Part No. Part No. Description Description Part No. Part No. Description Description Index No. Index No. Index No. Index No. A074 4912 Decal - Duplex Misfeed Removal 115- 3 A334 4710 Bracket - Paper End Sensor 93- 35 A074 5331 DC Harness - Paper Feed (A088)
  • Page 139 Paper and Paper and Part No. Description Part No. Description Index No. Index No. A335 1231 LCT Rear Cover (A087/A088) 13- 22 A335 4322 Left Stay 39- 13 A335 1241 Rear Lower Cover - Right 37- 19 A335 4341 Tray Bottom Plate 39- 14 A335 1253 LCT Top Cover...
  • Page 140 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 5053 0223 Bushing - 8mm 79- 13 5215 2840 Pin - 4 x 115 mm 17- 10 5053 0447 Bushing - 6mm 33- 16 5215 2842 Right Spring - Platen Cover 17- 17 5053 0447...
  • Page 141 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 5442 1111 Spring - Main Drive Tightener 79- 8 5447 9104 Shoe Adaptor 117- 10 5442 1372 Decal - Power Source - 220V 13- 11 5448 2803 Platen Cover Pad 17- 12 5442 1372...
  • Page 142 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 0313 0030B Philips Pan Head Screw - M3x3 89-110 0314 0060W Philips Pan Head Screw - M4x6 89-106 0313 0030B Philips Pan Head Screw - M3x3 93-105 0314 0060W Philips Pan Head Screw - M4x6...
  • Page 143 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 0413 0082W Tapping Screw - M3x8 31-100 0434 0080W Tapping Screw - M4x8 39-105 0413 0082W Tapping Screw - M3x8 49-101 0434 0080W Tapping Screw - M4x8 41-103 0413 0082W Tapping Screw - M3x8...
  • Page 144 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 0707 4050W Bushing - 4x5 41-108 0720 0040E Retaining Ring - M4 91-101 0707 4060B Bushing - 4x5 77-103 0720 0040E Retaining Ring - M4 93-101 0720 0020E Retaining Ring - M2 47-103...
  • Page 145 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 0805 3104 Ball Bearing - 8x22x7mm 61- 5 0951 5014W Philips Screw W/H Flat Washer - M5x14 17-106 0805 3377 Ball Bearing - 25x42x9mm 61-103 0952 3006W Philips Screw - M3x6 47-102 0805 3384...
  • Page 146 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 0965 4012W Philips Pan Head Screw - M4x12 17-107 1100 1249 Receptacle Terminal 105-103 0965 4080W Tapping Screw With Flat Washer - M4x8 31-110 1100 1249 Receptacle Terminal 107-104 0971 3006A...
  • Page 147 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 1102 1426 Connector - 3P 103-130 1102 1919 Connector - 11P 83-106 1102 1426 Connector - 3P 105-106 1102 1919 Connector - 11P 103-143 1102 1507 Connector - 2P 101-120 1102 1940...
  • Page 148 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 1102 5376 Connector - 30P 97-112 1105 0200 Clamp 79-106 1102 5620 Plug Housing - NSW - 01 - 3PH 103-119 1105 0201 Harness Clamp 35-106 1103 0441 Connector - 4P 97-113...
  • Page 149 Paper and Paper and Part No. Description Part No. Description Index No. Index No. 1402 1035 Diode - S5688G 103-107 1604 1353 Capaciter - 47uF 10V 97-157 1402 1037 Diode - U1ZB12 97-125 1604 1728 Capacitor - 100uF 10V 97-158 1402 1055 Zener Diode - 1/2W 33V 109-116...
  • Page 150 Paper and Paper and Part No. Description Part No. Description Index No. Index No. Resistor - 5.23k Ω ±1% 1632 5231 97-188 Resistor - 6.19K Ω 1/8W ±1% 1632 6191 97-189...
  • Page 151 INTRODUCTION The A085/A087/A088 copier is based on the A069/A073/A074 copier, the base copier. This documentation gathers the modifications to the base copier’s service manual that service personnel will need to service this copier. This package contains the following: A table of contents for the modified manual °...
  • Page 152 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main switch is turned off.
  • Page 153 OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. 2. The RAM board on the main control board has a lithium battery which can explode if replaced incorrectly.
  • Page 154 SECTION 1 OVERALL MACHINE INFORMATION...
  • Page 155 10 July 1992 MAJOR DIFFERENT POINTS FROM THE BASE COPIER : A069/A073/A074 MAJOR DIFFERENT POINTS FROM THE BASE COPIER : A069/A073/A074 The major different points of this copier A085/A087/A088 from the base copier A069/A073/A074 are listed in the following table: Section/Item This model (A085/A087/A088) Base model...
  • Page 156 MAJOR DIFFERENT POINTS FROM THE BASE COPIER : A069/A073/A074 10 July 1992 Section/Item This model (A085/A087/A088) Base model (A069/A073/A074) Development 13 Development unit Not applicable Standard shift mechanism Around the drum 14 Automatic drum Not applicable Standard current adjustment Paper Feed 15 Tray lock Solenoid Not applicable Standard...
  • Page 157 10 July 1992 MAJOR DIFFERENT POINTS FROM THE BASE COPIER : A069/A073/A074 Section/Item This model (A085/A087/A088) Base model (A069/A073/A074) 28 Sorter stapler (A366; Not applicable Option fixed bin type) 29 Sorter stapler (A374; Option Not applicable moving bin type) 30 Auto reverse Option with combine 2 Option document feeder...
  • Page 158 SPECIFICATIONS 10 July 1992 SPECIFICATIONS Configuration: Desktop Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum A3/11" x 17" Copy Paper Size: Maximum A3/11" x 17" Minimum B5/11" x 8 " - Paper tray A6/5 " x 8 "(lengthwise) -By-pass feed table (LCT B5/A4/11"...
  • Page 159 10 July 1992 SPECIFICATIONS Power Source: 115V, 60H , more than 12A (for N.A) 110V, 60H , (for Taiwan) 220/230/240V, 50H /60H , more than 8A (for EU and AA) Power Consumption: Maximum: 1.5 KW Warm-up: 0.77 KW Stand-by: 0.14 KW Copy Cycle (average): 1.2 KW Noise Emission: Stand-by: less than 40 dB...
  • Page 160 SPECIFICATIONS 10 July 1992 First Copy Time: 5.4 seconds (A4/8 " x 11" sideways) Type 1, 3: (Upper tray feed) 5.8 seconds Type 2: (Large capacity tray feed) Copy Number Input: Ten keys, 1 to 999 (count up or count down) manual Image Density 7 steps Selection:...
  • Page 161 10 July 1992 MACHINE CONFIGURATION MACHINE CONFIGURATION COPIER TYPE 1 (A085) TYPE 2 (A088) TYPE 3 (A087) UPPER TRAY DUPLEX LOWER TRAY – 1,000 1,000 OPTIONAL EQUIPMENT 10BIN SORTER (A327) MENU READER (A952) ARDF (A497) 20BIN SORTER (A423) SORTER ADAPTER 20BIN SORTER (A328) (A411)
  • Page 162 MACHINE CONFIGURATION 10 July 1992 REQUIRED COPIER OPTIONAL EQUIPMENT SORTER INTERFACE TYPE 1 TYPE 2 TYPE3 ADAPTER (A085) (A088) (A087) (A328) (A344) 1 TRAY PAPER (A325) TRAY UNIT 3 TRAY (A326) 10 BIN (A327) 20 BIN MINI (A423) SORTER 20 BIN MIDI (A411) 20 BIN STAPLER...
  • Page 163 SECTION 2 DETAILED SECTION DESCRIPTION...
  • Page 164 10 July 1992 OPTICS OPTICS FIRST SCANNER [Fig. 1] [Fig. 2] The first scanner of this copier has been re-designed from the one for the base model (A069/A073/A074) to reduce shadows of pasted originals. Although the exposure lamp’s rating voltage is the same, the shape of the reflectors have been changed, as shown above.
  • Page 165 SECTION 3 INSTALLATION...
  • Page 166 10 July 1992 COPIER INSTALLATION COPIER INSTALLATION ACCESSORY CHECK 1. Receiving Tray ............... 1 2. Outer Decal - Symbol Explanation ......... 1 3. Sorter Key Top and Cover ............. 1 4. Counter Set Key (–17 machine only) ........1 5. Installation Procedure ............1 6.
  • Page 167 COPIER INSTALLATION 10 July 1992 INSTALLATION PROCEDURE NOTE: Keep the shipping retainers after installing the machine. They will be reused if in the future the machine is transported to an another location. Proper reinstallation of the shipping retainers is required in order to avoid any transport damage.
  • Page 168 10 July 1992 COPIER INSTALLATION 4. Remove the left scale [A] (2 shoulder screws). 5. Remove the scanner lock pin [B] simply by pulling it up from the front and the rear side of the left scale bracket. 6. Reinstall the left scale. 7.
  • Page 169 COPIER INSTALLATION 10 July 1992 10. Push the development unit lock lever [A] to the right (to the lock position). 11. Move the development release lever [B] to the right and pull out the black development unit [C] half way. Holding the toner supply unit [D] with your right hand and the bottom of the development unit with your left hand, pull the unit all the way out .
  • Page 170 10 July 1992 COPIER INSTALLATION 15. Lower the transfer & separation corona unit by pulling down the release lever [A]. 16. Turn the cleaning unit release lever [B] counterclockwise to the upright position. (The cleaning unit is released from the drum.) 17.
  • Page 171 COPIER INSTALLATION 10 July 1992 21. Install the black development unit [A] in the copier, and remove the cover sheet [B] from the toner supply unit. • NOTE: When installing the development unit, be sure that the development unit rail is placed directly on the development unit guide rail.
  • Page 172 10 July 1992 COPIER INSTALLATION 25. Close the front door and set the copy tray [A]. NOTE: The following steps from 26 to 29 are required only to install the optional platen cover [B]. 26. Remove the rear cover (remove 2 screws and loosen 2 screws). 27.
  • Page 173 COPIER INSTALLATION 10 July 1992 32. Load A3 (11" x 17") paper either in the 1st or the 2nd paper tray and plug in the machine. 33. While pressing both the "1" and "3" on the operation panel number keys, turn on the main switch in order to access the SP mode.
  • Page 174 10 July 1992 COPIER INSTALLATION 36. Enter "54" using the number keys and press the enter key, then the start key. (The copier performs ID/V sensor adjustments.) 37. Enter "48" using the number keys and then press the enter key twice. 38.
  • Page 175 COPIER INSTALLATION 10 July 1992 40. Confirm that level 2 of the gray scale is just visible on the copy. If the image density is not correct, go through the following steps. (1) Press the enter key twice. (2) Change the exposure lamp voltage data displayed in the magnification ratio indicator.
  • Page 176 10 July 1992 COPIER INSTALLATION 41. Press the enter key and enter "56" using the number keys. 42. Press the enter key, then the start key. (The copier performs the ADS sensor adjustment.) 43. Turn the main switch off and on. 44.
  • Page 177 COPIER INSTALLATION 10 July 1992 VOLTAGE CHANGE (220V to 230/240V) NOTE: If the voltage of electrical power supply from wall outlets is 230V or 240V, the following procedure must be done before plugging in the machine. CAUTION: Make sure that the power cord of the machine is unplugged before starting the following procedure.
  • Page 178 SECTION 4 SERVICE TABLES...
  • Page 179 10 July 1992 SERVICE PROGRAM MODE SERVICE PROGRAM MODE MEMORY ALL CLEAR PROCEDURE (SP99) CAUTION: Memory all clear mode (SP99) clears all the correction data for process control and software counters, and returns all the modes to the default settings. Normally, this mode should not be performed.
  • Page 180 SERVICE PROGRAM MODE 10 July 1992 7. Replace the OPC drum with a new one. NOTE: Since the drum counter for the process control has been cleared, the old drum cannot be used. If the old drum is used after all memory is cleared, a dirty background and/or toner scattering will appear on copies sooner or later because proper correction will not be applied to the drum.
  • Page 181 10 July 1992 SERVICE PROGRAM MODE SERVICE PROGRAM MODE TABLE NOTE: 1. A "p" after the mode name means that copies can be made. For these modes, the copier goes automatically into copy mode when an SP mode number is selected by pressing the "# "...
  • Page 182 SERVICE PROGRAM MODE 10 July 1992 Mode No. Function Data Turns on all the indicators on the operation • 11 All Indicators ON panel. (To turn off the indicators, press the "# " key.) Selects single or double count for the total counter and key counter in A3/11"...
  • Page 183 10 July 1992 SERVICE PROGRAM MODE Mode No. Function Data Sets the staple limit of copies in each bin, in staple mode. (Only when the sorter stapler is installed.) 0: Yes Staple Limit Yes: 20 sheets, No: 25 sheets for A4, B5, and 1: No "...
  • Page 184 SERVICE PROGRAM MODE 10 July 1992 Mode No. Function Data Selects the margin on the right side of the 0: 5 mm reverse page in duplex 1 mode. Image Shift 1: 0 mm • 36 (For type 2 copier only. When duplex 1 (Duplex 1) 2: 10 mm [1-sided original mode] is selected, this...
  • Page 185 10 July 1992 SERVICE PROGRAM MODE Mode No. Function Data Selects the development bias voltage of manual ID level 7. 0: N Highlight Bias (0: –240 V = Normal 1: D • 46 1: –200 V = Darker (Manual ID Level 7) 2: L 2: –280 V = Lighter 3: LL...
  • Page 186 SERVICE PROGRAM MODE 10 July 1992 Mode No. Function Data Adjusts the ADS gain data automatically when the start key is pressed. (Close the platen cover to prevent external light from reaching the ADS sensor when Auto ADS Gain performing this adjustment. Adjustment The gain data is displayed in the three digit indicator.
  • Page 187 10 July 1992 SERVICE PROGRAM MODE Mode No. Function Data Detects V correction level regardless of the drum counter. Sense Drum Press the start key to set operation. Correction Level (The detection will be done in the first 5 copy ) (Forced V cycles after exiting the SP mode.
  • Page 188 SERVICE PROGRAM MODE 10 July 1992 Mode No. Function Data Displays contents of the PM counter. (When entering this mode by pressing the "# " key, the first three digits are displayed in the three digit indicator. PM Counter Hold down the " • " key to display the second three digits.
  • Page 189 10 July 1992 SERVICE PROGRAM MODE Mode No. Function Data Clears the following counters: - Operation Time (motor count only) (SP100) - Copy/Original Counters (SP101) - SC Counters (SP120) - Jam Counters (SP130) 0: No Counter Clear - PM Counter (SP88) 1: Yes - User Code Counters (SP91) - User Program...
  • Page 190 SERVICE PROGRAM MODE 10 July 1992 Mode No. Function Data Displays the total number of sets of stapled 101-8 Staple Counter copies. Paper Tray Unit Displays the total number of sheets fed from 101-9 Counter the paper tray unit. By-pass/LCT Displays the total number of sheets fed from 101-10 Counter...
  • Page 191 10 July 1992 SERVICE PROGRAM MODE Mode No. Function Data Displays the total number of "Optics" service 120-2 SC Optics Counter calls. SC Exposure Displays the total number of "Exposure" 120-3 Counter service calls. Displays the total number of "Functional Drive" 120-4 SC Drive Counter service calls.
  • Page 192 SERVICE PROGRAM MODE 10 July 1992 Mode No. Function Data Displays the total number of paper jams in the 130-12 Jam Exit Counter copier exit area. Displays the total number of paper jams in the 130-13 Jam Sorter Counter sorter. Displays the total number of original jams in 130-14 Jam ADF Counter the ADF.
  • Page 193 10 July 1992 SERVICE PROGRAM MODE Mode No. Function Data Displays the grid bias voltage for the image Grid Voltage area in the three digit indicator. 715 V (Image) (Grid bias voltage can be changed by using "+ " & "–" ["up" & "down"] keys in 5V steps.) Displays the grid bias voltage for the ID sensor Grid Voltage pattern in the three digit indicator.
  • Page 194 SERVICE PROGRAM MODE 10 July 1992 Mode No. Function Data Displays the ADS sensor output in the three digit counter. (When entering this mode by pressing the "# " key, the adjusted gain data for the ADS sensor is displayed. ADS Gain/Output Hold down the start key to display the ADS Check...
  • Page 195 10 July 1992 SERVICE PROGRAM MODE SP-8 SENSOR/SWITCH/SIGNAL DATA CHECK - How to check sensor/switch/signal - 1. While pressing both 1 and 3 on the operation panel number keys, turn on the main switch in order to access the SP mode. NOTE: Release the number keys after confirming that the ADS indicator and the copy counter number "0"...
  • Page 196 SERVICE PROGRAM MODE 10 July 1992 Data Input No. Sensor/Switch/Signal Tray upper limit sensor - 1 Down (Paper tray unit) (S4) Tray upper limit sensor - 2 Down (Paper tray unit) (S5) Tray upper limit sensor - 3 Down (Paper tray unit) (S6) Upper tray paper end sensor (S5) Paper detected Paper not detected Lower tray paper end sensor (S6) Paper detected...
  • Page 197 10 July 1992 SERVICE PROGRAM MODE Data Input No. Sensor/Switch/Signal Upper tray paper size switches (SW1 - SW4) Lower tray paper size switches (SW5 - SW8) Tray paper size switches - 1 Refer to table 1 Refer to table 1 (Paper tray unit) (SW1 - SW4) Tray paper size switches - 2 (Paper tray unit) (SW5 - SW8)
  • Page 198 SERVICE PROGRAM MODE 10 July 1992 SP-9 ELECTRICAL COMPONENT CHECK - How to turn electrical component on/off - 1. While pressing both 1 and 3 on the operation panel number keys, turn on the main switch in order to access the SP mode. NOTE: Release the number keys after confirming that the ADS indicator and the copy counter number "0"...
  • Page 199 10 July 1992 SERVICE PROGRAM MODE Output No. Electrical component Development drive clutch (MC1) Toner supply clutch (MC2) Pre-transfer lamp (L2) Erase lamp unit - All blocks (L5) Erase lamp unit - Designated blocks for ID sensor pattern (L5) Erase lamp unit - Designated blocks for V pattern (L5) Sorter drive motor Sorter bin drive motor : Up (CAUTION)
  • Page 200 PREVENTIVE MAINTENANCE SCHEDULE 10 July 1992 PREVENTIVE MAINTENANCE SCHEDULE PM TABLE (NOTE) Note3: Fusing Section (1)Hot and Pressure Rollers Replace the hot [A] and pressure [B] rollers every 160K if necessary. Then, lubricate the roller shaft [C] and bearings [D] with BARRIERTA L55/2 grease.
  • Page 201 SECTION 5 REPLACEMENT AND ADJUSTMENT...
  • Page 202 10 July 1992 OPTICS OPTICS EXPOSURE LAMP REPLACEMENT NOTE: Do not touch the reflector or the new exposure lamp with your bare hands. Use a strip of paper as shown. (Oil marks from your fingers on the lamp or reflectors will be affected by heat from the lamp and will cause discoloration.) 1.
  • Page 203 OPTICS 10 July 1992 6. Remove the exposure lamp [A] from the front terminal by moving the lamp towards the rear. 7. Install a new lamp. Use a strip of paper to hold the lamp as shown. Reassemble the rear terminal bracket [B]. NOTE: Make sure that the blister [C] on the lamp points towards the reflector opening (left side of the copier) as shown.
  • Page 204 10 July 1992 OPTICS OPTICS THERMOSWITCH REPLACEMENT NOTE: The thermoswitch can be reset manually by pushing the red button [C] when the exposure lamp area cools. 1. Turn off the main switch. 2. Remove the exposure glass. 3. Remove the exposure lamp leads [A] from the terminals on both sides of the thermoswitch [B].
  • Page 205 OPTICS 10 July 1992 SCANNER DRIVE BELT REPLACEMENT 1.3.1 Belt Removal 1. Remove the following parts: Platen cover or ADF [A] Left scale [B] (2 shoulder screws) Exposure glass [C] Top cover [D] (6 screws) Rear cover [E] (loosen 2 screws and remove 2 screws) Right upper cover [F] (4 screws) Front upper cover [G] (3 screws) Operation panel [H] (4 screws and 2 connectors)
  • Page 206 10 July 1992 TONER SUPPLY TONER SUPPLY TONER SUPPLY CLUTCH REMOVAL 1. Turn off the main switch and remove the rear cover. 2. Swing out the main control board assembly. 3. Remove the tension spring [A]. 4. Remove the support bracket [B] (3 screws) and gear [C]. 5.
  • Page 207 FUSING 10 July 1992 FUSING FUSING UNIT REMOVAL 1. Open the front door. 2. Remove the fusing unit lock plate [A] (1 screw). 3. Hold the fusing unit cover [B] while pushing the release lever [C], and pull out the fusing unit [D] until it stops. 4.
  • Page 208 10 July 1992 FUSING FUSING LAMP REPLACEMENT 1. Remove the fusing unit (see Fusing Unit Removal). 2. Remove the fusing unit cover [A] (1 shoulder screw, 1 screw). 3. Remove the harness cover [B] (1 screw) and disconnect the fusing lamp harness [C] (1 connector each).
  • Page 209 FUSING 10 July 1992 HOT ROLLER REPLACEMENT [G] [H] 1. Remove the fusing lamp (see Fusing Lamp Replacement). 2. Press both release levers [A] and lower the fusing exit assembly [B]. 3. Remove the front and rear pressure springs [C]. 4.
  • Page 210 10 July 1992 FUSING PRESSURE ROLLER REPLACEMENT 1. Unhook the fusing pressure springs [A]. 2. Place the fusing unit up side down. 3. Remove the bottom plate [B] (5 screws). 4. Remove the bearing stopper [C] (1 screw) and swing the pressure arms [D] as shown.
  • Page 211 FUSING 10 July 1992 FUSING STRIPPER PAWL REPLACEMENT 1. Remove the fusing unit (see Fusing Unit Removal). 2. Lower the fusing exit assembly [A]. 3. Remove the pawl pressure springs [B] and pawl release springs [C]. 4. Remove the fusing pawl bracket [D] (2 screws). 5.
  • Page 212 10 July 1992 FUSING THERMOFUSE HARNESS REPLACEMENT 1. Remove the fusing unit (see Fusing Unit Removal). 2. Remove the fusing unit cover [A] (1 shoulder screw, 1 screw). 3. Lower the fusing exit assembly [B], and remove the harness cover [C] (1 screw).
  • Page 213 FUSING 10 July 1992 FUSING THERMISTOR REPLACEMENT [D] [E] 1. Remove the fusing unit (see Fusing Unit Removal). 2. Remove the fusing unit cover [A] (1 shoulder screw, 1 screw). 3. Lower the fusing exit assembly [B], and remove the harness cover [C] (1 screw).
  • Page 214 10 July 1992 COPY QUALITY ADJUSTMENT COPY QUALITY ADJUSTMENT UNEVEN EXPOSURE ADJUSTMENT When: If the exposure is uneven. Purpose: To maintain even exposure. Adjustment standard: The side-to-side variation of the gray scales on the test chart should be less than one level. How: Change the position of the exposure adjusting plates to make the light intensity from the...
  • Page 215 OTHERS 10 July 1992 OTHERS EXHAUST BLOWER FILTER (OZONE FILTER) REPLACEMENT 1. Turn off the main switch. 2. Remove the rear cover. 3. Swing out the dc power supply board. 4. Unhook the high voltage cables from the vacuum fan bracket [A] and disconnect the vacuum fan harness [B] (1 connector).
  • Page 216 10 July 1992 OTHERS OPERATION PANEL REMOVAL 1. Remove the rear cover, right upper cover and front upper cover. 2. Remove the operation panel [A] (4 screws and 2 connectors). 5-15...
  • Page 217 OTHERS 10 July 1992 HIGH VOLTAGE SUPPLY BOARD - CTBG REPLACEMENT 1. Turn off the main switch and unplug the power cord. 2. Remove the rear cover. 3. Swing out the main control board assembly (1 screw). 4. Disconnect the bias cable [A] (1 connector, 2 harness clamps). 5.
  • Page 218 10 July 1992 OTHERS HIGH VOLTAGE SUPPLY BOARD – D REPLACEMENT 1. Turn off the main switch and unplug the power cord. 2. Remove the rear cover. 3. Disconnect the high-voltage cable [A] and the harness [B] (2 connectors). 4. Replace the high voltage supply board – D [C] (3 locking supports). 5.
  • Page 219 OTHERS 10 July 1992 TRANSFER AND SEPARATION CORONA CURRENT ADJUSTMENT NOTE: The corona current varies with environmental conditions such as humidity and atmospheric pressure. The corona current is adjusted at the factory and is suitable under a wide range of environmental conditions.
  • Page 220 10 July 1992 OTHERS 4. Remove the bearing screw [A] and the bearing [B] from the drum, then install them on the drum shaft [C]. 5. Install the drum shoe [D] and the shoe adapter at [E] the middle of the drum shaft.
  • Page 221 OTHERS 10 July 1992 7. Install the drum unit in the copier while connecting the rear end of the drum shaft [A] with the drum drive shaft [B] as shown. 8. Secure the drum unit with a screw and run the drum shoe harness [C] through the development unit cavity.
  • Page 222 10 July 1992 OTHERS [Transfer Corona Current Adjustment] Adjustment standard: –19.5± 0.5 µA 1. Position the drum shoe at the center of the drum shaft so that the axis of the current sensing plate [A] is aligned with the transfer corona wire as shown.
  • Page 223 OTHERS 10 July 1992 8. If the transfer corona current is out of the adjustment standard, do the following steps. 9. Enter "162" (T-CH PWM) by using the number keys, then press the enter key. 10. Change the PWM value displayed in the three digit indicator by using the number keys as follows: To increase the corona current (absolute value): increase the PWM value.
  • Page 224 10 July 1992 OTHERS [Separation Corona Current Adjustment] ac 46.0± 1.2 µA Adjustment standard: dc + 6.3± 0.8 µA 1. Position the drum shoe at the center (between the pick-off pawls) of the drum shaft so that the upper edge [A] of the current sensing plate is aligned with the pick-off pawl bracket [B] as shown.
  • Page 225 OTHERS 10 July 1992 10. Change the PWM value displayed in the three digit indicator by using the number keys as follows: To increase the corona current (absolute value): increase the PWM value. To decrease the corona current (absolute value): decrease the PWM value.
  • Page 226 10 July 1992 OTHERS 21. Press the enter key. 22. Repeat steps 14 to 21 until the proper separation dc corona current is obtained. 23. Check the separation ac corona current again by repeating steps 2 to 7 to make sure that it is still within the adjustment standard. 24.
  • Page 227 FT5233/5433/5733 SERVICE MANUAL...
  • Page 228 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main switch is turned off.
  • Page 229 OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. 2. The RAM board on the main control board has a lithium battery which can explode if replaced incorrectly.
  • Page 230 SECTION 1 OVERALL MACHINE INFORMATION...
  • Page 231 12 February 1992 SPECIFICATIONS SPECIFICATIONS Configuration: Desktop Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum A3/11" x 17" Copy Paper Size: Maximum A3/11" x 17" Minimum B5/11" x 8 " - Paper tray A6/5 " x 8 "...
  • Page 232 SPECIFICATIONS 12 February 1992 Power Source: 115V, 60H , more than 12A (for N.A) 110V, 60H , (for Taiwan) 220/230/240V, 50H /60H , more than 7A (for EU and AA) Power Consumption: Maximum: 1.5 KW Warm-up: 0.77 KW Stand-by: 0.14 KW Copy Cycle (average): 1.2 KW Noise Emission: Stand-by: less than 40 dB...
  • Page 233 12 February 1992 SPECIFICATIONS First Copy Time: Black copy: 4.5 seconds (A4/8 " x 11" sideways) Type 1, 3: (Upper tray feed) 4.9 seconds Type 2: (Large capacity tray feed) Color copy: 6.6 seconds Type 1, 3: (Upper tray feed) 7.0 seconds Type 2: (Large capacity tray feed) Copy Number Input:...
  • Page 234 SPECIFICATIONS 12 February 1992 • Color development unit • Key counter • Menu reader (except for Europe) • A3 counter (service part)
  • Page 235 12 February 1992 MACHINE CONFIGURATION MACHINE CONFIGURATION COPIER TYPE 1 (A069) TYPE 2 (A074) TYPE 3 (A073) UPPER TRAY DUPLEX LOWER TRAY – 1,000 1,000 OPTIONAL EQUIPMENT 10BIN SORTER (A327) MENU READER (A952) EDITOR (A916) 20BIN SORTER ARDF (A497) (A423) 20BIN SORTER (A411) SORTER ADAPTER...
  • Page 236 MACHINE CONFIGURATION 12 February 1992 REQUIRED OPTIONAL COPIER EQUIPMENT SORTER EDITING INTERFACE 1 TRAY TYPE 1 TYPE 2 TYPE3 ADAPTER INTERFACE PAPER (A325) (A069) (A074) (A073) ADAPTER (A344) TRAY UNIT (A328) (A345) 3 TRAY (A326) 10 BIN (A327) 20 BIN MINI (A423) SORTER 20 BIN MIDI...
  • Page 237 12 February 1992 COPY PROCESS AROUND THE DRUM COPY PROCESS AROUND THE DRUM 2. EXPOSURE 4. DEVELOPMENT 1. DRUM (COLOR) 3. ERASE CHARGE 9. QUENCHING 8. CLEANING 4. DEVELOPMENT (BLACK) ID/V SENSORS PICK-OFF PAWLS 5. PRE-TRANSFER LAMP 7. PAPER 6. IMAGE TRANSFER SEPARATION...
  • Page 238 COPY PROCESS AROUND THE DRUM 12 February 1992 1. DRUM CHARGE In the dark, the charge corona unit gives a uniform negative charge to the organic photo conductive (OPC) drum. The charge remains on the surface of the drum because the OPC layer has a high electrical resistance in the dark. The amount of negative charge on the drum is proportional to the negative grid bias voltage applied to the grid plate on the charge corona unit.
  • Page 239 12 February 1992 COPY PROCESS AROUND THE DRUM 6. IMAGE TRANSFER Paper is fed to the drum surface at the proper timing so as to align the copy paper and the developed image on the drum surface. Then, a strong negative charge is applied to the reverse side of the copy paper, producing an electrical force which pulls the toner particles from the drum surface onto the copy paper.
  • Page 240 MECHANICAL COMPONENT LAYOUT 12 February 1992 MECHANICAL COMPONENT LAYOUT 1. 3rd Mirror 22. Large Capacity Tray 2. 2nd Mirror 23. Relay Rollers 3. 1st Mirror 24. Registration Rollers 4. Exposure Lamp 25. Paper Tray Feed Roller 5. Lens 26. Friction Pad 6.
  • Page 241 12 February 1992 DRIVE LAYOUT DRIVE LAYOUT 1-11...
  • Page 242 DRIVE LAYOUT 12 February 1992 1: Main Motor Pulley 3: Fusing Drive Belt 2: Drum Drive Belt 26: Development Drive Belt 4: Drive Distribution 25: Drum Drive Pulley 24: Development Drive Gear/Pulley CL Pulley Drum Development Unit 23: Drive Distribution Belt Cleaning drive Gear 9: Fusing Unit Drive Gear...
  • Page 243 12 February 1992 PAPER PATH PAPER PATH NORMAL COPYING Paper feed begins from the LCT or paper tray unit paper feed stations. The copy paper then follows one of two paths inside the copier. The path followed depends on which mode the operator has selected. For copy processing, all sheets follow the same path from the paper feed mechanism [A] through the registration [B], T &...
  • Page 244 PAPER PATH 12 February 1992 MULTIPLE 2-SIDED COPYING Paper that is A4, B5, and 8 " X 11" sideways can be used for multiple 2-sided copying. In this mode the junction gate [A] directs sheets exiting the fusing unit to the duplex tray entrance [B]. After that, all sheets follow the path through the entrance rollers [C], and the turn gate [D].
  • Page 245 12 February 1992 PAPER PATH SINGLE 2-SIDED COPYING Any sheet up to A3\11" x 17" but except for A4, B5, or 8 " X 11" sideways can be used for single 2-sided copying. In this mode, the sheet follows the same path as in multiple 2-sided copying to the duplex tray.
  • Page 246 PAPER PATH 12 February 1992 SINGLE IMAGE OVERLAY COPYING In this mode, the sheet follows the same path as in multiple 2-sided copying to the turn gate [A]. The turn gate directs the sheet to the relay rollers [B]. The sheet stays there once. After that, the sheet follows the same path as in multiple 2-sided copying from the relay rollers to the copy tray.
  • Page 247 12 February 1992 ELECTRICAL COMPONENT DESCRIPTION ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the Point to Point (Water proof paper) for symbols and index numbers. Symbol Name Function Index No. Motors Main Drives the main unit components. Exhaust blower Blows the ozone built up around the charge section through the ozone filter.
  • Page 248 ELECTRICAL COMPONENT DESCRIPTION 12 February 1992 Symbol Name Function Index No. Circuit Board PCB1 dc power supply Drives the exposure and fusing lamps and rectifies 100 Vac or 220/230/240 Vac input and outputs dc voltages. PCB2 Main control Controls all copier functions both directly and through the other control boards.
  • Page 249 12 February 1992 ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. PCB14 Interface - type Interfaces the sorter stapler and menu G (option for reader with the main control board. sorter stapler and menu reader) PCB15 Nose filter Removes electrical noise (230 V machine only) Switches...
  • Page 250 ELECTRICAL COMPONENT DESCRIPTION 12 February 1992 Symbol Name Function Index No. SW12 Front door safety Cuts the ac power line through RA1 and detects if the front door is open or not. SW13 Main Supplies power to the copier. SW14 LCT cover - 1 Detects if the LCT cover is open or not.
  • Page 251 12 February 1992 ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. Upper paper Starts paper feed from the upper paper tray. feed (non-duplex machine only) Lower paper feed Starts paper feed from the lower paper tray. Solenoids SOL1 Development Changes the position of the black unit change development unit and color development unit.
  • Page 252 ELECTRICAL COMPONENT DESCRIPTION 12 February 1992 Symbol Name Function Index No. Lower tray paper Informs the CPU when the lower paper tray runs out of paper. Upper tray upper Detects the upper position of the paper limit (non-duplex stack in the upper tray to stop the upper lift machine only) motor.
  • Page 253 12 February 1992 ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. Original width Detects the original width. Duplex entrance Detects misfeed. (duplex machine only) Duplex turn gate Detects the trail edge of paper to determine (duplex machine the reverse timing of the duplex motor and only) detects misfeed.
  • Page 254 ELECTRICAL COMPONENT DESCRIPTION 12 February 1992 Symbol Name Function Index No. Optics Monitors the temperature of the optics cavity. Duplex motor Monitors the temperature of the duplex (duplex machine motor. only) Thermofuse Fusing Provides back-up overheat protection in the fusing unit. Thermoswitch Optics Provides overheat protection in the optics...
  • Page 255 SECTION 2 DETAILED SECTION DESCRIPTIONS...
  • Page 256 12 February 1992 PROCESS CONTROL 1. PROCESS CONTROL 1.1 OVERVIEW ID Sensor Pattern V Sensor Pattern Exposure Lamp Toner Voltage Supply (Color) Grid Bias Voltage Development Drum Thermistor Bias (Black) Voltage ID Sensor V Sensor As seen in section 1 the copy process around the drum and the copy image (image and background density) are controlled by many factors.
  • Page 257 PROCESS CONTROL 12 February 1992 1.2 ID SENSOR CONTROL Sensor Original Lead Edge Pattern Original Development Leading Edge Erase Bias ID Sensor Pattern RAM Clear Toner Density Detection Toner Density Detection Toner Density Detection Low Toner Density Toner Supply Timing Detection Toner Add Toner Supply Clutch ON...
  • Page 258 12 February 1992 PROCESS CONTROL After the ID sensor pattern is developed, the ID sensor checks the pattern’s reflectivity and the CPU notes it. If the reflected light is too strong, indicating toner density is too low, toner is added to the development unit. The toner is not added all at once.
  • Page 259 PROCESS CONTROL 12 February 1992 1.2.2 ID Sensor Output VSG = 4.0 ± 0.2 Low image density High image density 1/10 VSG 1/10 VSG = 0.4 Sensor Bare pattern drum When in the toner density check cycle, the CPU receives two voltage values directly from the ID sensor: Vsg and Vsp.
  • Page 260 12 February 1992 PROCESS CONTROL 100% (4.0 V) 100% (4.0 V) Low Density Low Density 25% (1.0 V) 10% (0.4 V) [Color Toner] High Density [Black Toner] High Density (1) Detect supply mode In the detect supply mode toner will be supplied under the following conditions: Black toner ......Vsp/ Vsg x 100 ≥...
  • Page 261 PROCESS CONTROL 12 February 1992 100% (4.0 V) 4.0 V 2.5 V 50% (2.0 V) [Vsp abnormal] [Vsg abrormal] (3) ID Sensor Abnormal Conditions The following ID sensor abnormal conditions apply to both the detect and fixed supply modes. a. Vsg abnormal When Vsg falls under 2.5V, the CPU stops the toner supply and continues the ID sensor pattern detection (every 10 copies for black and every 5 copies for color).
  • Page 262 12 February 1992 PROCESS CONTROL 1.3 V PATTERN CONTROL 1.3.1 Overview Drum Drum residual potential voltage Copy volume Light intensity During the OPC drum’s life, drum residual voltage gradually increases due to electrical fatigue. This may cause dirty backgrounds on copies. The V sensor is used to avoid this problem.
  • Page 263 PROCESS CONTROL 12 February 1992 1.3.2 V Pattern Detection Image 0V Bias Non-image Fixed Bias V Sensor Pattern The V pattern is made on the drum before the original latent image, as in the case of the ID sensor pattern. During V pattern detection, the drum surface is charged with a fixed grid bias voltage: –...
  • Page 264 12 February 1992 PROCESS CONTROL 1.3.3 V Correction Grid bias correction Development bias level Vrp/Vrg x 100(%) voltage correction voltage ± 0 V ± 0 V 100~84 83~58 – 40 V – 40 V 57~41 – 80 V – 80 V 40~28 –...
  • Page 265 PROCESS CONTROL 12 February 1992 1.4 V PATTERN CONTROL 1.4.1 Overview D Sensor Pattern Pattern Main Board V Sensor Drum Potential Exposure lamp voltage Dirty optics or deterioration of the exposure lamp decreases the intensity of the light that reaches the drum via the optics cavity. As more copies are made during the drum’s life, the photo conductive layer gets worn and drum sensitivity drops.
  • Page 266 12 February 1992 PROCESS CONTROL 1.4.2 V Pattern Detection Main SW on data correction done ? Programmed copy interval ? Pattern Drum Temp. > 25°C 150 mm pattern detection 20 mm Is copy Job completed ? 20 mm pattern detection Vdat = Vlp/Vlg pattern detection is done after V pattern detection, but unlike V...
  • Page 267 PROCESS CONTROL 12 February 1992 When the drum initial setting (SP mode #66) is performed and more than 7 black copies are made, the initial V detection is performed at the end of the copy job and the CPU stores the V reference value (initial Vlp/Vlg = Vref) in memory.
  • Page 268 12 February 1992 PROCESS CONTROL 1.5 DRUM TEMPERATURE CONTROL 1.5.1 Overview Drum Drum potential potential Exposure lamp voltage Light intensity Under low temperature conditions drum sensitivity drops and drum residual voltage increases. This is a characteristic of the drum and may cause dirty backgrounds on copies.
  • Page 269 PROCESS CONTROL 12 February 1992 Low Temp. Data correction correction Exposure lamp Development bias Grid bias voltage voltage voltage Over 25°C No correction No correction No correction 25°C or lower Lamp voltage + 1V level + 1 level + 1 1.5.2 Low Temp.
  • Page 270 12 February 1992 PROCESS CONTROL 1.6 DRUM ROTATION CONTROL Drum potential Drum rotation time Grid bias Grid bias Correction for Sensor voltage voltage Correction for Image Pattern –600 –850 –825 –580 –560 –805 –800 –550 –540 –785 –520 –765 –500 –500 –750 –745...
  • Page 271 PROCESS CONTROL 12 February 1992 The drop of drum sensitivity due to the drum wear is compensated by V correction. V correction is performed more often than V correction, therefore, V correction is not applied to the exposure lamp voltage, only to the grid bias voltage.
  • Page 272 12 February 1992 DRUM 2. DRUM 2.1 OPC DRUM CHARACTERISTICS An OPC has the characteristics of: 1. 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.) 2.
  • Page 273 DRUM 12 February 1992 2.2 DRUM UNIT An organic photoconductor drum is used on this model. To prevent stress on the drum, a drum unit is used to hold the drum without a drum shaft. The drum unit consists of an OPC drum [A], ID sensor board with a drum thermistor [B], V sensor board [C], pick-off pawls [D], erase lamp unit [E], and toner shield glass.
  • Page 274 12 February 1992 DRUM CHARGE 3. DRUM CHARGE 3.1 OVERVIEW This copier uses a double corona wire scorotron system for drum charge. Two corona wires are required to give sufficient negative charge on the drum surface because of a rather high drum speed (180 mm/sec.). The stainless steel grid plate [A] makes the corona charge uniform and controls the amount of negative charge on the drum surface by applying the negative grid bias voltage.
  • Page 275 DRUM CHARGE 12 February 1992 3.2 CHARGE CORONA WIRE CLEANER MECHANISM The flow of air around the charge corona wire may deposit paper dust or toner particles on the corona wires. These particles may interfere with charging and cause low density bands on copies. The wire cleaner pads [A] above and below the charge corona wires clean the wires as the charge corona unit is manually slid in and out.
  • Page 276 12 February 1992 DRUM CHARGE 3.3 GRID BIAS VOLTAGE CORRECTION The grid bias voltage differs depending on the modes and correction factors (see the process control section). 3.3.1 Base Grid Bias Voltage There are two base grid bias voltages, one for image and the other for sensor patterns (ID sensor pattern and V pattern).
  • Page 277 DRUM CHARGE 12 February 1992 3.3.3 V Correction Grid Bias Correction Voltage –160 V –120 V –80 V –40V Level Level Vrp/Vrg x 100 (%) Grid Bias Correction Voltage ±0V 100~84 83~58 –40V 57~41 –80V 40~28 –120V 27~0 –160V According to the results of the V pattern detection, the grid bias voltage is corrected as shown in the above table.
  • Page 278 12 February 1992 DRUM CHARGE 3.3.5 V Correction Grid Bias Correction Voltage –80 V – 60 V –40 V –20 V Drum Rotation Time (H) SP100: Drum Rotation Time Grid Bias Correction Voltage ±0V 2~36 –20V 37~62 –40V 63~87 –60V According to the drum rotation time after performing SP mode #66 when a new drum is installed, V correction is applied to the grid bias voltage as...
  • Page 279 DRUM CHARGE 12 February 1992 3.3.7 Total Grid Bias Voltage The total grid bias voltage for each mode is determined by the CPU as follows: (1) ADS Mode Vgi(–745 V) + V Correction + V Data Correction + V Correction + ADS Density(SP34) (2) Manual ID Mode Vgi(–745 V) + Manual ID Correction + V...
  • Page 280 12 February 1992 OPTICS 4. OPTICS 4.1 OVERVIEW During the copy cycle, an image of the original is reflected onto the drum surface via the optics assembly as follows. Light Path: Exposure Lamp [A] → → → Original [B] 1st Mirror [C] →...
  • Page 281 OPTICS 12 February 1992 4.2 SCANNER DRIVE This model uses a stepper motor [A] to drive the scanners via a timing belt [B], scanner drive pulley [C], and 2 long & short scanner drive belts [D, E]. Both ends of each scanner are driven to prevent skewing. The scanners have sliders [F], which ride on guide rails.
  • Page 282 12 February 1992 OPTICS 4.3 LENS DRIVE : Reduction : Enlargement 4.3.1 Lens Drive The lens 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. The rotation of the lens drive pulley [D] moves the lens back and forth in discrete steps.
  • Page 283 OPTICS 12 February 1992 4.3.3 Lens Positioning (Initialize) (Enlarge → Full Size) (Reduce → Full Size) (Full Size → Enlarge) (Full Size → Reduce) (Reduce → Enlarge) (Enlarge → Reduce) (Enlarge → Enlarge) (Reduce → Reduce) pulses 1 pulse = 0.06 mm Lens H.P.
  • Page 284 12 February 1992 OPTICS 4.4 3RD SCANNER DRIVE (Initialize) (Enlarge/Reduce → Full Size) (Full Size → Enlarge/Reduce) (Enlarge/Reduce → Enlarge/Reduce) pulses 1 pulse = 0.06 mm 3rd Scanner H.P. Sensor Signal 4.4.1 Drive The 3rd scanner drive motor (stepper motor) changes the 3rd scanner position through the pinion gears [A] and the rack gear [B] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and drum surface.
  • Page 285 OPTICS 12 February 1992 4.5 ORIGINAL SIZE DETECTION There are six (for LT version) or seven (for A4 version) reflective sensors in the optics cavity for the original size detection. Two of them [A] are used for sensing the original width and the other four/five [B] are for the original length. While the main switch is on, these sensors are active and the original size data is always sent to the main CPU.
  • Page 286 12 February 1992 OPTICS If there is any difference between the first and second check, the CPU judges if the original exists above the respective sensor or not according to the following table. Second First data Judgment data High High Paper exists High No paper...
  • Page 287 OPTICS 12 February 1992 4.6 AUTOMATIC IMAGE DENSITY CONTROL SYSTEM (ADS) In ADS mode the original background density is sensed by the ADS sensor [A] and the CPU determines an appropriate development bias voltage for the original to prevent the background from appearing on copies. The ADS sensor board is mounted on the front side of the optics base plate.
  • Page 288 12 February 1992 OPTICS 35 mm A= 8 mm, B= 18 mm C= 5 mm D= 64 mm (Full size) Original Lead Edge Peak hold ADS Reference Voltage Sensor Output ADS Original Voltage Peak hold (mm) - 18 Scan Positon For the first scanning of an original in ADS mode, the CPU starts sampling of the ADS sensor output from when the scanner moves from -18mm to -8mm from the original lead edge.
  • Page 289 OPTICS 12 February 1992 4.7 EXPOSURE LAMP CONTROL The base exposure lamp voltage (Vexp) is determined by SP mode #48 according to the actual copy image when the drum initial setting (SP66) is performed. Based on this Vexp, the exposure lamp voltage differs depending on the modes and correction factors.
  • Page 290 12 February 1992 OPTICS 4.7.2 Reproduction Ratio Correction Lamp Correction Lamp Voltage Reproduction Correction Ratio (%) Voltage ±0V 50~120 121~140 141~160 161~180 181~200 Reproduction Ratio In the reduction and enlargement modes the light path is longer than the full size mode. The light intensity for a unit square in enlargement mode is less than that in the full size mode and that in the reduction mode is more.
  • Page 291 OPTICS 12 February 1992 4.7.4 Low Temperature Correction Drum Lamp Correction Temperature Voltage ±0V Over 25°C 25°C or lower If the temperature around the drum is 25°C or less when the main switch is turned on, low temperature correction is applied to the exposure lamp voltage as shown in the above table.
  • Page 292 12 February 1992 OPTICS 4.8 OPTICAL COMPONENT CONTROL TIMING 4.8.1 Normal Copying (A4 sideways, full size) Lead Edge Original Correction 1 (555) Timing (ms) Start Key Correction 2 Platen Position Sensor Original Size Detection Palten Cover 1167 Switch Exposure Lamp Scanner Return Motor...
  • Page 293 OPTICS 12 February 1992 T5: The exposure lamp turns on 172ms after the drum idling period is • completed. This period differs depending on the selected paper feeding • station. By-pass Upper Lower Duplex feed paper paper Tray table tray tray After the drum idling period is...
  • Page 294 12 February 1992 OPTICS 4.8.2 V Pattern Detection Complete Exiting Paper 1,000 2,000 3,000 4,000 5,000 (ms) Fusing Exit Sensor Main Motor 5470 /PTL/QL Development 5470 Drive CL 5192 Charge Corona Unit Exposure Lamp 1527 1655 2316 2489 Erase Lamp Unit All Blocks ON 1794 2116 2626 Development...
  • Page 295 ERASE 12 February 1992 5. ERASE 5.1 OVERVIEW 2.5 ± 1.5 mm LE: Lead edge erase margin 1.5 ± 1.5 mm on each side; SE: Side erase margin total of both sides 4 mm or less : Original width : Charged width of drum : Lead edge erase : Side erase The erase lamp unit consists of a line of LEDs extending across the full width...
  • Page 296 12 February 1992 ERASE 5.2 LEAD EDGE AND TRAIL 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 on the drum (lead edge erase margin).
  • Page 297 ERASE 12 February 1992 5.3 SIDE ERASE a b c d e f g h i j k l m n Based on the combination of copy paper size and the reproduction ratio data, the LEDs turn on in blocks. This prevents the shadow of the original side edge and unexposed front and rear sides of the drum surface in reduction mode from being developed.
  • Page 298 12 February 1992 ERASE 5.4 PATTERN ERASE A B C X Y Z Pattern Sensor Pattern The erase lamp unit has another task besides the lead edge erase, trail edge erase, and side erase which is making the ID sensor pattern, V pattern, and pattern.
  • Page 299 ERASE 12 February 1992 5.5 EDIT ERASE LAMP UNIT 120 blocks The edit erase lamp unit has 120 blocks the width of each being about 2 mm. When the editor is installed, this erase lamp unit must be used for the editing function.
  • Page 300 12 February 1992 ERASE 5.6 ERASE LAMP CONTROL TIMING (Upper paper tray, black development unit) Correction 1 Correction 3 Correction 2 Start key Scanner Return Start Start Key Main Motor Side Erase Erase Lamp Unit All Blocks ON All Blocks ON Charge Corona Grid Bias Unit...
  • Page 301 DEVELOPMENT 12 February 1992 DEVELOPMENT 6.1 OVERVIEW The development section is composed of a black development unit [A] and a color development unit [B] (option). Normally, the black development roller [C] is in contact with the drum. When color copy mode is selected, the color development unit moves against the drum and the black development unit is pulled back.
  • Page 302 12 February 1992 DEVELOPMENT 6.2 DEVELOPMENT UNIT CHANGE MECHANISM The development guide rails [A] are slid back and forth by the color development 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 timing belts.
  • Page 303 DEVELOPMENT 12 February 1992 6.3 DRIVE MECHANISM [Black] [Color] The main motor [A] rotation is transmitted to the development unit drive gears through a timing belt [B] and the development drive clutch [C]. When the drive clutch is energized, the rotation of the clutch gear [D] is transmitted to the development roller gear [E] and the paddle roller gears [F].
  • Page 304 12 February 1992 DEVELOPMENT [Black] 6.4 CROSS MIXING [Color] This copier uses a standard cross-mixing mechanism to keep the toner and developer evenly mixed. It also helps agitate the developer to prevent developer clumps from forming and helps create the triboelectric charge. The developer on the rotating development roller [A] is split into two parts by the doctor blade [B].
  • Page 305 DEVELOPMENT 12 February 1992 6.5 DEVELOPMENT BIAS CONTROL The base development bias voltage for image is –160 V. However, it differs depending on the modes and correction factors (see the process control section). 6.5.1 Manual ID Correction Manual ID Correction SP46: Highlight Bias Development Bias ID Level...
  • Page 306 12 February 1992 DEVELOPMENT 6.5.2 ADS Data Correction When in the ADS mode, original background density is detected by the ADS Data Correction ADS sensor board. According to the Development Bias original background ratio, the CPU Voltage Original decides the appropriate development Background SP34: ADS Density bias voltage, as shown in the table at...
  • Page 307 DEVELOPMENT 12 February 1992 6.5.3 V Correction Correction Development Bias Level Vrp/Vrg x 100 (%) Correction Voltage ±0V 100~84 83~58 –40V 57~41 –80V 40~28 –120V 27~0 –160V –160 V Grid Bias Correction Voltage –120 V –80 V –40V Level According to the results of the V pattern detection, the development bias voltage is corrected as shown in the above table.
  • Page 308 12 February 1992 DEVELOPMENT 6.5.5 Bias Voltage Selection by SP Mode SP37: Black Bias SP79: Color Bias Develpment Bias Data Density Correction Voltage ±0V Normal Darkest +40V Darker +20V Lighter –20V Lightest –40V The development bias for original image can be selected from among four levels by SP mode #37 for black and SP mode #79 for color as shown in the above table.
  • Page 309 DEVELOPMENT 12 February 1992 6.5.6 Bias for Sensor Patterns (1) Development bias voltage for ID sensor pattern SP33: Black Pattern Bias Development Bias Voltage for Black Toner Data ID sensor Pattern Density 0~500 501~ Normal –220V –200V Lighter –180V –160V Darker –240V –220V...
  • Page 310 12 February 1992 DEVELOPMENT 6.5.7 Total Development Bias Voltage The total development bias voltage for each mode is determined by the CPU as follows: (1) ADS Mode –160V + ADS Data Correction + V Correction + V Data Correction + SP Mode Data Setting (SP34:ADS Density / SP37:Black Bias / SP79:Color Bias) (2) Manual ID Mode...
  • Page 311 DEVELOPMENT 12 February 1992 6.6 COLOR DEVELOPMENT UNIT DETECTION Color Development unit detection table Color SW 1 SW 2 Blue Green No Dev. Unit When a color development unit [A] is installed in the copier, the color switch [B] is activated by a color detect plate [C] at the development unit. The color switch has two microswitches inside.
  • Page 312 12 February 1992 DEVELOPMENT 6.7 DEVELOPMENT COMPONENT CONTROL TIMING (A4 sideways, upper paper tray, black development unit) Correction 1 Correction 3 (1722) Main Motor Correction 2 Scanner Return Start Key Development Drive Clutch Development Unit Change Solenoid Image Dev, Bias Color Development Non Image Bias...
  • Page 313 DEVELOPMENT 12 February 1992 T3: The timing is corrected to 0 again (correction 2) when the image process preparation period starts. This timing differs depending on the selected paper feeding station. Paper Feeding Station Black Dev. Unit Upper Paper Tray 172ms Lower Paper Tray 728ms...
  • Page 314 12 February 1992 TONER SUPPLY TONER SUPPLY 7.1 OVERVIEW [Color] The black toner supply roller [A] has 16 grooves. Toner is caught in these grooves and trimmed by the toner supply shaft plate located on one side of the toner supply roller. This toner then enters the development unit. The black toner agitator [B] is in the toner cartridge and prevents toner from clumping.
  • Page 315 TONER SUPPLY 12 February 1992 7.2 TONER SUPPLY DRIVE MECHANISM The main motor [A] rotation is transmitted to the toner supply gears [B] through timing belts [C,D] and the toner supply clutch [E]. When the toner supply clutch is energized, the rotation of the clutch gears is transmitted to the toner supply gears.
  • Page 316 12 February 1992 TONER SUPPLY 7.3 TONER SUPPLY CONTROL 7.3.1 Detect Supply Mode (SP #30 = 0) The amount of toner supplied depends on the ID sensor data, the detect toner supply ratio data, the paper size data, and color data. The toner supply clutch on time in each copy cycle is calculated as explained below.
  • Page 317 TONER SUPPLY 12 February 1992 Toner Supply Ratio: This ratio can be selected by following SP modes. When select the color toner supply ratio, the color development unit must be installed the machine. SP31: Black Toner Supply Ratio (Detect Mode) Data Supply Ratio 15% 7.5% 30% 60%...
  • Page 318 12 February 1992 TONER SUPPLY 7.3.2 Fixed Supply Mode (SP mode #30 = 1) The amount of toner supplied depends on the ID sensor data, the fixed toner supply ratio data the paper size data and the color data (black only). The toner supply clutch on time in each copy cycle is calculated as explained below: The fixed supply mode is used for black toner only.
  • Page 319 TONER SUPPLY 12 February 1992 Toner Supply Ratio: The amount of toner supplied depends on the toner supply ratio. SP32: Black Toner Supply Ratio (Fixed Mode) Data Supply Ratio 3.5% 10.5% 14.0% Toner Supply Ratio Parameter ID Sensor Data (Fixed Mode): The ID sensor level parameter is fixed to 1/2. ID Sensor Level Vsp/Vsg x 100 (%) ID Sensor Level Parameter No Toner Supply...
  • Page 320 12 February 1992 TONER SUPPLY 7.4 TONER END DETECTION 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 49 50 Toner Toner Toner...
  • Page 321 TONER SUPPLY 12 February 1992 After the second check if the ID sensor data is still at the toner end level on every check, the toner supply ratio increases by 1 step until it reaches the maximum toner supply ratio (60%: black, 28%: color). If the CPU detects the toner end level twice at maximum toner supply ratio, the Add Toner indicator starts blinking.
  • Page 322 12 February 1992 IMAGE TRANSFER AND PAPER SEPARATION IMAGE TRANSFER AND PAPER SEPARATION 8.1 PRE-TRANSFER LAMP (PTL) After the latent image is developed but before the image is transferred to the copy paper, the drum surface is illuminated by the pre-transfer lamp [A]. This illumination reduces the negative potential on the drum surface [B].
  • Page 323 IMAGE TRANSFER AND PAPER SEPARATION 12 February 1992 8.3 PAPER SEPARATION 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 [A] 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.
  • Page 324 12 February 1992 IMAGE TRANSFER AND PAPER SEPARATION The pick-off pawls [A] are always in contact with the drum. They have a side to side movement mechanism to prevent the parts of the drum surface touched by the pick-off pawls from wearing faster than other parts. The cleaning brush drive gear [B] drives the pick-off pawl drive shaft [C] which has a worm gear [D] on the other end.
  • Page 325 IMAGE TRANSFER AND PAPER SEPARATION 12 February 1992 8.4 AUTOMATIC DRUM CURRENT ADJUSTMENT TP111 Main Board OPC Drum (I Drum) TP106 (Drum-AC) [Drum Current] 11 DR1 CN111-A25 TP107 (Drum-DC) DCPOL TP112 IC 148 (DCPOL) IC 138 [I/O Expander] IC 132 CN103-2 IC 137 Transfer Corona Trigger...
  • Page 326 12 February 1992 IMAGE TRANSFER AND PAPER SEPARATION 8.4.2 Automatic Drum Current Adjustment When SP mode #57 (auto drum current adjustment) is performed, the high voltage supply for transfer corona turns on first. The I/O CPU detects the drum current and compares it with the target current. If it is different, the I/O CPU changes PWM value which is sent to IC137 (PWM timer) by an 8 bit signal through data bus line.
  • Page 327 IMAGE TRANSFER AND PAPER SEPARATION 12 February 1992 8.5 T&S CORONA CONTROL TIMING (A4 sideways, upper paper tray, black development unit) Correction 2 Correction 3 Fusing Exit Scanner Start key Sensor OFF Return 83 ms PTL/QL/Main Motor Transfer Corona 694 ms Separation Corona 767 ms T1: When the start key is pressed, the PTL, QL, and main motor turn on...
  • Page 328 12 February 1992 DRUM CLEANING DRUM CLEANING 9.1 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 the drum move in opposite directions at their point of contact.
  • Page 329 DRUM CLEANING 12 February 1992 9.2 DRIVE MECHANISM The cleaning brush [A] and the toner collection roller [B] are driven by the main motor [C] through a timing belt and gears. The cleaning brush and the cleaning blade [D] are always touching the drum surface. The toner collection roller rotates at the same time as the cleaning brush to collect used toner.
  • Page 330 12 February 1992 DRUM CLEANING 9.3 RELEASE MECHANISM 9.3.1 Cleaning unit Release The cleaning unit releases with the cleaning unit guide rail [A] when the cleaning unit release lever [B] is turned counterclockwise. This prevents the drum from being scratched by the cleaning unit, when the cleaning unit is pulled out.
  • Page 331 DRUM CLEANING 12 February 1992 9.3.2 Cleaning Blade Release The cleaning blade [A] releases when the cleaning blade release lever [B] is held up. This cleans the edge of the cleaning blade using the blade scraper [C], which is mounted underneath the cleaning blade. 2-76...
  • Page 332 12 February 1992 DRUM CLEANING 9.4 USED TONER DETECTION This copier does not use a sensor to detect used toner overflow. Instead, this is determined by software counters. When the CPU has counted 10 black toner end occurrences meaning that 10 cartridges have been used, the CPU calculates the number of copies per toner cartridge n.
  • Page 333 QUENCHING 12 February 1992 10. QUENCHING In preparation for the next copy cycle, light from the quenching lamp (QL) [A] neutralizes any charge remaining on the drum [B]. A cold cathode lamp is used for quenching and it is turned on whenever the main motor rotates.
  • Page 334 12 February 1992 PAPER FEED AND REGISTRATION 11. PAPER FEED AND REGISTRATION 11.1 OVERVIEW This model has three paper feed stations. The large capacity tray feed station [A] (1000 sheets) is located on the right side of the copier (LCT machine only) and the upper paper tray [B] (non- duplex machine only) and lower paper tray [C] feed stations are located inside the copier.
  • Page 335 PAPER FEED AND REGISTRATION 12 February 1992 11.2 FRICTION PAD SYSTEM This copier uses a feed roller and friction pad feed system for paper feed from the paper trays. When the paper tray is set in the copier, the pressure release lever [A] is pushed and turns clockwise.
  • Page 336 12 February 1992 PAPER FEED AND REGISTRATION The tray bottom plate [A] is also lifted up when the paper tray [B] is set, and the lead edge of the paper stack is pressed against the paper feed roller [C]. When the feed roller starts turning, it forces the top sheet of the paper stack across the friction pad [D].
  • Page 337 PAPER FEED AND REGISTRATION 12 February 1992 11.3 FRR FEED SYSTEM This copier uses an FRR paper feed system which utilizes three rollers. 11.3.1 Pick-up Roller The pick-up roller [A] is not in contact with the paper stack before it starts feeding paper.
  • Page 338 12 February 1992 PAPER FEED AND REGISTRATION The direction in which the separation roller [A] turns depends on the frictional forces acting on it. The slip clutch applies a constant clockwise force (F1). When there is a single sheet of paper being driven between the rollers, the force of friction between the feed roller [B] and the paper (F2) is greater then F1.
  • Page 339 PAPER FEED AND REGISTRATION 12 February 1992 11.4 PAPER TRAY 11.4.1 Paper Lift Mechanism – when setting the paper tray – When the paper tray is set in the copier, the tray set feeler [A] activates the tray set sensor [B] and the tray lift motor [C] starts turning the worm gear[D].
  • Page 340 12 February 1992 PAPER FEED AND REGISTRATION – when pulling out the paper tray – While the paper tray is being set in position, the operator side of the tray set feeler [A] is pushed down by the tray release lever [B]. When the tray is completely set in position, the operator side of the tray set feeler rotates up and is positioned behind the tray release lever.
  • Page 341 PAPER FEED AND REGISTRATION 12 February 1992 11.4.2 Paper End Detection The paper end sensor [A] (photointerruptor) is located on the rear side frame next to the tray lift assembly for each paper tray. When the paper tray is not set in position, the paper end actuator [B] is pushed away from the paper end sensor by the tray lift lever [C].
  • Page 342 12 February 1992 PAPER FEED AND REGISTRATION 11.4.3 Tray Lock Mechanism A tray lock solenoid [A] is installed on the rear side frame for each paper tray. When the start key is pressed, the tray lock solenoid for the selected paper tray is energized and the tray lock lever [B] catches the rear part of the left tray rail.
  • Page 343 PAPER FEED AND REGISTRATION 12 February 1992 11.4.4 Paper Size Detection Four paper size switches (SW-A [A], SW-B [B], SW-C [C], SW-D [D]) on the rear side frame are used for detecting the paper size loaded in the paper tray. The paper size switches are actuated by actuator plate [E] on the rear of the paper tray.
  • Page 344 12 February 1992 PAPER FEED AND REGISTRATION 11.5 LARGE CAPACITY TRAY 11.5.1 Paper Lift Mechanism There is an LCT upper limit sensor [A] above the paper feed upper guide plate to control the LCT lift motor[B]. The actuator [C] for the sensor is located on the pick-up roller bracket [D].
  • Page 345 PAPER FEED AND REGISTRATION 12 February 1992 When the top sheet of the paper stack raises the pick-up roller, the LCT upper limit sensor is activated and the LCT lift motor stops. Shortly after, the pick-up solenoid turns off and the pick-up roller goes back to the up position. During the copy cycle the pick-up roller is lowered to prepare for feeding the next sheet of paper.
  • Page 346 12 February 1992 PAPER FEED AND REGISTRATION 11.5.2 Paper End Detection There are two paper end sensors for the FRR feed station above the paper feed upper guide plate. One [A] is for the LCT and the other [B] is for the by-pass feed table.
  • Page 347 PAPER FEED AND REGISTRATION 12 February 1992 11.5.3 Paper Size Setting The LCT can hold three paper sizes (A4 sideways, B5 sideways, and 11" X 8 ") by changing the side fence [A] position. However, there is no paper size switches for the LCT.
  • Page 348 12 February 1992 PAPER FEED AND REGISTRATION 11.6 BY-PASS FEED TABLE The by-pass feed table [A] uses the FRR feed system for feeding non- standard sized paper, thick paper, and application paper such as OHP sheet, translucent paper, etc. When the by-pass feed table is opened, the by-pass feed table sensor [B] is activated by the by-pass feed side plate [C].
  • Page 349 PAPER FEED AND REGISTRATION 12 February 1992 11.6.2 Pick-up Roller Position for LCT Machine For the LCT machine the pick-up roller [A] is positioned for feeding paper from the LCT when the by-pass feed table is closed. When the by-pass feed table is opened, the pick-up roller lift lever [B] fixed on the by-pass feed table shaft rotates counterclockwise.
  • Page 350 12 February 1992 PAPER FEED AND REGISTRATION 11.7 PAPER FEED AND REGISTRATION DRIVE MECHANISM 11.7.1 Friction Pad Feed and Registration Drive Mechanism Through several timing pulleys and timing belts, main motor rotation is transmitted to the registration, feed relay, upper paper feed (non-duplex machine only), and lower paper feed clutches.
  • Page 351 PAPER FEED AND REGISTRATION 12 February 1992 The registration rollers have two functions. One is aligning the lead edge of the paper with the leading edge of the latent image on the drum with the lead edge of paper. When the CPU receives the lead edge signal from the I/O CPU, the registration clutch turns on 364 ms after that.
  • Page 352 12 February 1992 PAPER FEED AND REGISTRATION 11.7.2 FRR Feed Drive Mechanism The rotation of the main motor is first transmitted to the registration clutch, and then is transmitted to the by-pass feed clutch [A] via several idle gears. The feed roller shaft [B] and the pick-up roller [C] turn together because they are engaged by the idle gear [D].
  • Page 353 PAPER FEED AND REGISTRATION 12 February 1992 11.8 PAPER FEED AND MISFEED TIMING <A4 Sideways, Full Size> Start Key ON (Main Motor ON) Lead Edge Signal Correction 1 Upper Tray Lock Sol Upper Paper 200 ms Feed Cl. Feed Relay 61 ms Upper Clutch...
  • Page 354 12 February 1992 PAPER FEED AND REGISTRATION T1: The time from when the start key is pressed until the paper feed clutch turns on differs depending on the paper feeding station and the selected development unit. This is to have enough time for cleaning the drum surface before feeding the paper.
  • Page 355 IMAGE FUSING 12 February 1992 12. IMAGE FUSING 12.1 OVERVIEW After the image is transfered, the copy paper enters the fusing unit. Then the image is fused to the copy paper by a heat and pressure process through the use of a hot roller [A] and pressure roller [B]. The fusing lamp [C] located inside the hot roller is turned on and off to maintain the operating temperature of 185°C.
  • Page 356 12 February 1992 IMAGE FUSING 12.2 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 misfed paper can be easily removed. When the front cover is opened, the actuator plate [C] pulls release wire [D] and the fusing unit drive gear is disengaged.
  • Page 357 IMAGE FUSING 12 February 1992 12.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM Upper Lower The entrance guide [A] for this machine is adjustable for thick or thin paper. With thin paper, set the entrance guide in the upper position (standard position). This slightly lengthens the paper path which prevents the paper from creasing in the fusing unit.
  • Page 358 12 February 1992 IMAGE FUSING 12.4 FUSING LAMP CONTROL Temp 185°C 180°C 175°C 60°C Time Fusing Lamp 100S 5S 5S When the main switch is turned on the CPU starts sending a trigger pulse to the fusing control circuit to turn on the fusing lamp. When the CPU detects a fusing temperature of 175°C through the thermistor, the copier starts fusing idling.
  • Page 359 DUPLEX 12 February 1992 13. DUPLEX 13.1 OVERVIEW The duplex tray unit is used for multiple 2-sided, single 2-sided, and single image overlay copying. When the registration clutch turns on, the junction gate [A] rotates up to direct the copy to the duplex tray. Shortly after the fusing exit sensor detects the lead edge of the paper, the entrance roller [B] and duplex feed roller [C] start to rotate.
  • Page 360 12 February 1992 DUPLEX 13.1.2 Single 2-sided Copy The sheet, except for the multiple 2-sided copy of A4, B5 or 81/2" x 11" sideways, can be used for single 2-sided copying. In single 2-sided copying mode, the same operation as in multiple 2-sided copying mode is made until the copy is directed to the duplex stack section [A].
  • Page 361 DUPLEX 12 February 1992 13.2 DRIVE MECHANISM The copier exit roller gear [A] drives the transport rollers [B] through the timing belt [C]. All the rollers in the duplex tray are driven by the duplex feed motor [D]. The drive of the duplex feed motor is transmitted to the duplex feed rollers [E] and the duplex entrance rollers [F] through a series of gears.
  • Page 362 12 February 1992 DUPLEX 13.3 TURN GUIDE SECTION When the registration clutch turns on for feeding the first copy in the duplex mode, the junction gate solenoid [A] is energized. Then, the junction gate [B] rotates up to direct the copy paper to the duplex turn guide section. The junction gate solenoid stays on until first side copying is finished.
  • Page 363 DUPLEX 12 February 1992 13.4 DUPLEX ENTRANCE TO DUPLEX TRAY 139 ms after the leading edge of the copy paper actuates the fusing exit sensor, the duplex feed motor [A] starts turning. This rotation is transmitted to the duplex feed rollers [B] and the duplex entrance rollers [C]. 63 ms after that, the duplex turn gate solenoid [D] is energized to rotate the duplex turn gate [E].
  • Page 364 12 February 1992 DUPLEX 13.5 DUPLEX STACKING The jogger motor (stepper motor) [A] drives the end fence rack gear [B] inward or outward. The other end of the end fence rack gear is engaged with the side fence rack gears [C] through an idle gear. Therefore, the drive of the jogger motor moves the jogger end fence [D] and the jogger side fences [E] inward or outward.
  • Page 365 DUPLEX 12 February 1992 The jogger fences move inward to square the paper stack at the same timing as before. After the last copy of the first side copying run enters the duplex tray, the jogger fences remain against the paper stack. In single 2-sided copying mode, the jogger motor rotates at the same time as in the multiple 2-sided copying mode.
  • Page 366 12 February 1992 DUPLEX 13.6 PAPER FEED FROM DUPLEX TRAY 13.6.1 Tray Lift Mechanism The rotation of the duplex feed motor [A] is transmitted to the cam clutch gear [B] through a series of idle gears. When the duplex feed motor rotates clockwise, the cam clutch gear also rotates clockwise.
  • Page 367 DUPLEX 12 February 1992 13.6.2 Paper Feed System While stacking the copy paper in the duplex tray, the paper flatteners [A] correct curl on the leading edge of the copies. After the last copy of the first side copying run enters the duplex tray, the jogger fences square the paper stack and then the duplex feed motor starts reverse rotation (counterclockwise).
  • Page 368 12 February 1992 DUPLEX After the final copy leaves the duplex bottom plate, the paper end feeler [G] drops through a slot in the duplex bottom plate. The duplex paper end actuator [H], which is on the same shaft as the duplex paper end feeler, pivots into the duplex paper end sensor [I], sending a High signal to the main board to stop the next paper feeding cycle.
  • Page 369 DUPLEX 12 February 1992 13.7 DUPLEX TRAY LOCK MECHANISM A tray lock solenoid is installed for the duplex tray on the rear side frame like for paper trays. The location of the tray lock solenoid is on the left side rail but that of the duplex tray lock solenoid is on the right side rail.
  • Page 370 12 February 1992 DUPLEX 13.8 DUPLEX FEED DRIVE RELEASE MECHANISM If a paper jam occurs when feeding paper from the duplex tray, the duplex feed motor [A] rotates counterclockwise to lower the duplex bottom plate. At this time the duplex tray is locked as the duplex tray lock solenoid is energized.
  • Page 371 DUPLEX 12 February 1992 13.9 DUPLEX COMPONENT CONTROL TIMING Lead Edge Signal Correction 4 Single Duplex (1780) (555) (ms) (1534) Registration Clutch Junction Gate Solenoid (1167) Fusing Exit Sensor 2170 Duplex Stock Duplex Feed Motor Direction Duplex Turn Gate Sol. (*2) (380) (1550)
  • Page 372 12 February 1992 DUPLEX Single Duplex Mode T1: 364ms after the lead edge signal is sent from the I/O CPU to the main CPU, the registration clutch and the junction gate solenoid turn on together. T2: When the fusing exit sensor detects the lead edge of the paper, the timing is corrected to 0 (Correction 4).
  • Page 373 SECTION 3 INSTALLATION...
  • Page 374 12 February 1992 INSTALLATION REQUIREMENT INSTALLATION REQUIREMENT 1.1 ENVIRONMENT 1. Temperature Range: 10 C to 30 C (50 F to 86 2. Humidity Range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight) 4.
  • Page 375 INSTALLATION REQUIREMENT 12 February 1992 1.2 MACHINE LEVEL 1. Front to back level: within 5 mm (0.2") 2. Right to left level: within 5 mm (0.2") Use a carpenter’s level to level the machine 1.3 MINIMUM SPACE REQUIREMENTS Copier only Full system a: more than 10 cm/3.9"...
  • Page 376 12 February 1992 INSTALLATION REQUIREMENT 1.4 POWER REQUIREMENTS 1. Input voltage level: 110V/60Hz : More than 12A (for Taiwan) 115V/60Hz : More than 12A (for N.A.) 220V/230V/240V/50Hz : More than 7A (for EU.) 220V/60Hz : More than 7A ± 2. Permissible voltage fluctuation: 3.
  • Page 377 COPIER INSTALLATION 12 February 1992 COPIER INSTALLATION 2.1 COPIER INSTALLATION 2.1.1 Accessory Check 1. Receiving Tray................ 1 2. Outer Decal - Symbol Explanation ......... 1 3. Sorter Key Top and Cover............1 4. Counter Set Key (–17 machine only) ........1 5.
  • Page 378 12 February 1992 COPIER INSTALLATION 2.1.2 Installation Procedure NOTE: Keep the shipping retainers after installing the machine. They will be reused if in the future the machine is transported to another location. Proper reinstallation of the shipping retainers is required in order to avoid any transport damage.
  • Page 379 COPIER INSTALLATION 12 February 1992 5. Remove the left scale [A] (2 shoulder screws). 6. Remove the scanner lock pin [B] simply by pulling it up from the front and the rear side of the left scale bracket. 7. Reinstall the left scale. 8.
  • Page 380 12 February 1992 COPIER INSTALLATION 11. Push the development unit lock lever [A] to the right (to the lock position). 12. Move the development release lever [B] to the right and pull out the black development unit [C] half way. Holding the toner supply unit [D] with your right hand and the bottom of the development unit with your left hand, pull the unit all the way out .
  • Page 381 COPIER INSTALLATION 12 February 1992 16. Lower the transfer & separation corona unit by pulling down the release lever [A]. 17. Turn the cleaning unit release lever [B] counterclockwise to the upright position. (The cleaning unit is released from the drum.) 18.
  • Page 382 12 February 1992 COPIER INSTALLATION 22. Install the black development unit [A] in the copier, and remove the cover sheet [B] from the toner supply unit. • NOTE: When installing the development unit, be sure that the development unit rail is placed directly on the development unit guide rail.
  • Page 383 COPIER INSTALLATION 12 February 1992 26. Close the front door and set the copy tray [A]. NOTE: The following steps from 27 to 30 are required only to install the optional platen cover [B]. 27. Remove the rear cover (remove 2 screws and loosen 2 screws). 28.
  • Page 384 12 February 1992 COPIER INSTALLATION 33. Load A3 (11" x 17") paper either in the 1st or the 2nd paper tray and plug in the machine. 34. While pressing both the "1" and "3" on the operation panel number keys, turn on the main switch in order to access the SP mode.
  • Page 385 COPIER INSTALLATION 12 February 1992 37. Enter "54" using the number keys and press the enter key, then the start key. (The copier performs ID/V sensor adjustments and the beeper sounds 2 times after 4 seconds.) 38. Enter "48" using the number keys and then press the enter key twice. 39.
  • Page 386 12 February 1992 COPIER INSTALLATION 41. Confirm that level 2 of the gray scale is just visible on the copy. If the image density is not correct, go through the following steps. (1) Press the enter key twice. (2) Change the exposure lamp voltage data displayed in the magnification ratio indicator.
  • Page 387 COPIER INSTALLATION 12 February 1992 42. Press the enter key and enter "56" using the number keys. 43. Press the enter key, then the start key. (The copier performs the ADS sensor adjustment and the beeper sounds 2 times after 4 seconds.) 44.
  • Page 388 12 February 1992 COPIER INSTALLATION 2.2 VOLTAGE CHANGE (220V to 230/240V) NOTE: If the voltage of electrical power supply from wall outlets is 230V or 240V, the following procedure must be done before plugging in the machine. CAUTION: Make sure that the power cord of the machine is unplugged before starting the following procedure.
  • Page 389 COPIER INSTALLATION 12 February 1992 2.3 COLOR DEVELOPMENT UNIT INSTALLATION (OPTION) NOTE: This is a universal color development unit for red, blue, and green developer and toner. 1. Install the appropriate color detection plate [A] on the rear bracket of the color development unit.
  • Page 390 12 February 1992 COPIER INSTALLATION 6. Shake the color toner cartridge [A]. 7. Open the color toner supply unit cover [B] and set the color toner cartridge on the color toner supply unit as shown. 8. Holding the center part of the cartridge, push down and pull out the slide plate [C] until it stops.
  • Page 391 COPIER INSTALLATION 12 February 1992 13. Open the copier front door. 14. While lifting the color development unit lock lever [A], pull out he cover plate [B]. 15. Holding the strap of the color development unit with your left hand, hold the toner supply unit with your right hand, and insert the development unit along the guide rails [C].
  • Page 392 12 February 1992 COPIER INSTALLATION 2.4 KEY COUNTER HOLDER INSTALLATION (OPTION) CAUTION: Make sure that the main switch is turned off. [Machines without LCT] 1. Remove the rear cover [A] (remove 2 screws and loosen 2 screws). 2. Open the by-pass feed table and remove the right upper cover [B] (4 screws).
  • Page 393 COPIER INSTALLATION 12 February 1992 6. Pass the 4P connector [A] of the key counter holder [B] through the key counter holder access hole and couple it with the key counter connector [C] of the copier. 7. Hold the fixing plate [D] on the inside of the key counter holder bracket [E] and insert the key counter holder.
  • Page 394 12 February 1992 COPIER INSTALLATION 2.5 TRAY HEATER INSTALLATION (OPTION) NOTE: The optional tray heaters keep copy paper dry. In humid environments, copy paper may crease as it comes out of the fusing unit. The heaters are available as service parts. Required parts: P/N A0699500: Tray Heater Kit –115V 2 sets...
  • Page 395 COPIER INSTALLATION 12 February 1992 4. Remove the rear cover (remove 2 screws and loosen 2 screws). 5. Swing out the dc power supply board assembly [A] (1 screw). 6. Remove the main transformer assembly [B] (2 screws and 2 connectors). 7.
  • Page 396 12 February 1992 COPIER INSTALLATION [Lower tray heater] 10. Pass the heater harness [A] through the lower heater access hole [B] and install the tray heater assembly as shown (1 screw at the front). 11. Connect the heater connector [C] with the copier as shown (2P red). [Upper and Lower tray heaters] 12.
  • Page 397 COPIER INSTALLATION 12 February 1992 2.6 OPTICS ANTI-CONDENSATION HEATER INSTALLATION (OPTION) NOTE: The optional optics anti-condensation heater keeps water from condensing on the copier’s mirrors. Such condensation occurs under cold and high humidity conditions, and causes the first few copies of the day to be black or dark. The heater is available as a service part.
  • Page 398 12 February 1992 COPIER INSTALLATION 4. Move the 1st and 2nd scanners [A] to the left so that you can access under the left scale bracket [B]. 5. Install the optics anti-condensation heater [C] on the optics bottom plate as shown with 2 screws. 6.
  • Page 399 COPIER INSTALLATION 12 February 1992 2.7 SORTER ADAPTER INSTALLATION (OPTION) 2.7.1 Accessory Check 1. Cover Bracket............1 2. Gear Assembly ............1 3. Cover Plate ............1 4. Hinge Bracket ............1 5. Front Door.............. 1 6. Hinge Pin ............... 2 7.
  • Page 400 12 February 1992 COPIER INSTALLATION 2.7.2 Installation Procedure NOTE: The sorter adapter is required to transport copy papers from the copier exit rollers to the sorter entrance guide plates. It is required when the mini-sorter (A423), midi-sorter (A411), or sorter stapler (A366) is installed.
  • Page 401 COPIER INSTALLATION 12 February 1992 6. Remove the 2 corners [A] of the left bottom cover [B] as shown with the cutting pliers. 7. Install the sorter adapter [C] (4 screws) on the paper exit section of the copier. • NOTE: The front upper right part of the sorter adapter bracket [D] should be placed in-between the copier front side plate and...
  • Page 402 12 February 1992 COPIER INSTALLATION 11. Reinstall the copier left cover and secure the left and front sides of the front upper cover. 12. Install the cover plate [A] (2 screws) on the sorter adapter. 13. Install the hinge bracket [B] (2 screws) on the front side plate of the sorter adapter.
  • Page 403 SECTION 4 SERVICE TABLES...
  • Page 404 12 February 1992 SERVICE REMARKS SERVICE REMARKS 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 touch the drum surface with bare hands. When the drum surface is touched with a finger or becomes dirty, wipe with a dry cloth or clean with wet cotton.
  • Page 405 SERVICE REMARKS 12 February 1992 DRUM UNIT 1. Make sure that the drum unit is set in position and secured with the screw when the main switch is turned on. If the drum unit is loose, poor contact of the drum connectors may cause electrical noise, resulting in unexpected malfunction (RAM data change is the worst case).
  • Page 406 12 February 1992 SERVICE REMARKS OPTICS 1. When installing the exposure glass, make sure that the red mark on the edge of the glass faces up. This side has received a special treatment to be smoother and generate less static electricity. This is especially important when the ARDF is installed.
  • Page 407 SERVICE REMARKS 12 February 1992 ERASE LAMP 1. A narrower lead edge erase margin increases the possibility of fusing jams. The margin should be at least 1.0 mm. 2. After cleaning the erase lamp unit, rub it lightly with your finger to discharge any static electricity on the unit surface.
  • Page 408 12 February 1992 SERVICE REMARKS TRANSFER AND SEPARATION 1. Clean the T&S corona unit casing with water then with alcohol if necessary. 2. Clean the separation corona wire only with dry cloth as it is carbon coated. 3. Clean the end blocks with a blower brush and alcohol. CLEANING UNIT 1.
  • Page 409 SERVICE REMARKS 12 February 1992 1.10 PAPER FEED 1. Do not touch the pick-up, feed, separation rollers and the friction pads with oily bare hands. 2. The side fences and the rear fence of the paper trays should be positioned correctly to align with the actual paper size. Otherwise, paper misfeeds may occur.
  • Page 410 12 February 1992 SERVICE PROGRAM MODE SERVICE PROGRAM MODE SERVICE PROGRAM MODE OPERATION The service program (SP) mode is used to check electrical data, change mode, and adjust settings. 2.1.1 Service Program Access Procedure There are three ways to access the SP mode. 1: By key operation (for users and sales representatives).
  • Page 411 SERVICE PROGRAM MODE 12 February 1992 NOTE: 1. An SP mode number will blink in the copy counter. The Copy Counter will stop blinking and stay on when the Enter key is pressed. 2. When the SP mode number is blinking, it can be changed by pressing the Clear/Stop key and entering a new number.
  • Page 412 12 February 1992 SERVICE PROGRAM MODE Access Procedure 3: Main switch and mode keys Accessible SP mode numbers: All SP mode numbers including the SP99 (memory all clear) 1. Turn the main switch off. 2. While pressing both the Modes Clear and Clear/Stop keys on the operation panel, turn on the main switch.
  • Page 413 SERVICE PROGRAM MODE 12 February 1992 4. Enter the factory-set values in the following SP modes: 40: Jogger span (Duplex machine only) 41: Lead edge erase 42: Registration 43: Vertical magnification 44: Horizontal magnification 45: Duplex magnification (Duplex machine only) 47: Focus adjustment 50: Lens error correction 62: Grid reference voltage...
  • Page 414 12 February 1992 SERVICE PROGRAM MODE 11. Enable optional equipment operation by SP71 (sorter), SP72 (paper tray unit), and SP84 (edit erase lamp unit) as necessary. 12. Perform the following SP modes: SP66: Drum initialize SP54: Auto Vsg/Vlg adjustment SP48: Exposure lamp voltage adjustment SP56: Auto ADS gain adjustment 13.
  • Page 415 SERVICE PROGRAM MODE 12 February 1992 SERVICE PROGRAM MODE TABLE NOTE: 1. A " " after the mode name means that copies can be made. For these modes, the copier goes automatically into copy mode when an SP mode number is selected by pressing the "#"...
  • Page 416 12 February 1992 SERVICE PROGRAM MODE Mode No. Function Data Agitates new color developer for about 1 minute. Press the start key to begin operation. Color Developer (This must be done when new color developer Initialize is put in. Beeper sounds 5 times when initialization is completed.) Turns on all the indicators on the operation •11...
  • Page 417 SERVICE PROGRAM MODE 12 February 1992 Mode No. Function Data Specifies whether the copier defaults to APS 0: APS APS Priority •21 or manual mode when the main switch is 1: Manual (Copier) turned on. 2: No 0: 5 sec. SADF Auto Reset Selects auto reset time for SADF mode.
  • Page 418 12 February 1992 SERVICE PROGRAM MODE Mode No. Function Data Sets the bias voltage applied to the development roller for the ID sensor pattern. 0: N Black (ID sensor) (0: –200 V= Normal 1: L 1: –160 V= Lighter Pattern Bias 2: H 2: –220 V= Darker 3: HH...
  • Page 419 SERVICE PROGRAM MODE 12 February 1992 Mode No. Function Data Adjusts magnification perpendicular to the Horizontal direction of paper travel. Magnification 16 = default (0.2 % per tep. [max. –3.2% to +3.0%].) 0: +0.4% 1: No correction 2: +0.2% 3: +0.6% Adjusts vertical magnification of the first image Duplex 4: +0.8%...
  • Page 420 12 February 1992 SERVICE PROGRAM MODE Mode No. Function Data Drum Temperature Displays the temperature around the drum. [°C] Check Adjusts Vsg of ID sensor and Vlg of V sensor automatically at once. (Adjusted PWM values of ID sensor and V Auto Vsg/Vlg sensor are displayed in the three digit Adjustment...
  • Page 421 SERVICE PROGRAM MODE 12 February 1992 Mode No. Function Data Sets the grid voltage correction data to correct the output from the high voltage supply board. (A label on the high voltage supply board gives Grid Reference the correct value. Voltage When the high voltage supply board [CTBG] is replaced, set the data using SP62 before...
  • Page 422 12 February 1992 SERVICE PROGRAM MODE Mode No. Function Data Enables sorter operation 0: No (0: No sorter 1: MC 1: Micro sorter 2: MIN 2: Mini sorter Sorter 3: MID 3: Midi sorter 4: SS 4: Sorter stapler 5: ADP 5: Sorter adapter).
  • Page 423 SERVICE PROGRAM MODE 12 February 1992 Mode No. Function Data Enables edit erase lamp unit operation. 0: No Editing Eraser (The copier CPU automatically enables edit 1: Yes erase lamp unit when the editor is installed.) Use to input the telephone number of the service depot.
  • Page 424 12 February 1992 SERVICE PROGRAM MODE Mode No. Function Data Displays the contents of each user code counter. use the "+" and "–" ("up" and "down") keys to select user code. (The last two digits of the user code are displayed in the copy User code Counter counter.) •91...
  • Page 425 SERVICE PROGRAM MODE 12 February 1992 Mode No. Function Data Displays the total (accumulated) time that the main motor has operated. ( Time in hours. -Motor Count- Press the "#" key to display the first three digits in the three digit indicator. Hold down the "...
  • Page 426 12 February 1992 SERVICE PROGRAM MODE Mode No. Function Data 101-15 B5 Counter Displays the total number of B5 copies. Original Total 101-16 Displays the total number of originals copied. Counter Original Counter Displays the total number of originals copied 101-17 (ADF) using the ADF.
  • Page 427 SERVICE PROGRAM MODE 12 February 1992 Mode No. Function Data SC Exposure Displays the total number of "Exposure" 120-3 Counter service calls. Displays the total number of "Functional Drive" 120-4 SC Drive Counter service calls. Displays the total number of "Fusing" service 120-5 SC Fuser Counter calls.
  • Page 428 12 February 1992 SERVICE PROGRAM MODE Mode No. Function Data Displays the total number of paper jams in the 130-12 Jam Exit Counter copier exit area. Displays the total number of paper jams in the 130-13 Jam Sorter Counter sorter. Displays the total number of original jams in 130-14 Jam ADF Counter the ADF.
  • Page 429 SERVICE PROGRAM MODE 12 February 1992 Mode No. Function Data Displays the grid bias voltage and the charge corona current for the image area in the three digit indicator. (When entering this mode by pressing the "#" Grid Volt./M-CH key, grid bias voltage [V] is displayed. Drum Current 745 V Hold down the start key to display the charge...
  • Page 430 12 February 1992 SERVICE PROGRAM MODE Mode No. Function Data Displays the ID sensor output in the three digit indicator. (When entering this mode by pressing the "#" key, the adjusted PWM value for the ID sensor ID-sensor PWM/Output is displayed. Check Hold down the start key to display the ID sensor output voltage.
  • Page 431 SERVICE PROGRAM MODE 12 February 1992 SP-8 SENSOR/SWITCH/SIGNAL DATA CHECK - How to check sensor/switch/signal - 1. While pressing both 1 and 3 on the operation panel number keys, turn on the main switch in order to access the SP mode. NOTE: Release the number keys after confirming that the call service indicator and the copy counter number "0"...
  • Page 432 12 February 1992 SERVICE PROGRAM MODE Data Input No. Sensor/Switch/Signal Tray upper limit sensor - 1 Down (Paper tray unit) (S4) Tray upper limit sensor - 2 Down (Paper tray unit) (S5) Tray upper limit sensor - 3 Down (Paper tray unit) (S6) Upper tray paper end sensor (S5) Paper detected Paper not detected Lower tray paper end sensor (S6) Paper detected...
  • Page 433 SERVICE PROGRAM MODE 12 February 1992 Data Input No. Sensor/Switch/Signal Upper tray paper size switches (SW1 - SW4) Lower tray paper size switches (SW5 - SW8) Tray paper size switches - 1 Refer to table 1 Refer to table 1 (Paper tray unit) (SW1 - SW4) Tray paper size switches - 2 (Paper tray unit) (SW5 - SW8)
  • Page 434 12 February 1992 SERVICE PROGRAM MODE SP-9 ELECTRICAL COMPONENT CHECK - How to turn electrical component on/off - 1. While pressing both 1 and 3 on the operation panel number keys, turn on the main switch in order to access the SP mode. NOTE: Release the number keys after confirming that the call service indicator and the copy counter number "0"...
  • Page 435 SERVICE PROGRAM MODE 12 February 1992 Output No. Electrical component Erase lamp unit - Designated blocks for ID sensor pattern (L5) Erase lamp unit - Designated blocks for V pattern (L5) Sorter drive motor Sorter bin drive motor : Up (CAUTION) Sorter bin drive motor : Down (CAUTION) Registration clutch (MC5) By-pass feed clutch (MC3)
  • Page 436 12 February 1992 SERVICE PROGRAM MODE NOTE 1: When the start key is pressed, the main motor starts turning and the development unit change solenoid is energized. While the "•" key is held down, the development drive and toner supply clutches turn on to supply black toner.
  • Page 437 SP MODE PRACTICAL USE TABLE 12 February 1992 SP MODE PRACTICAL USE TABLE REPLACEMENT AND CLEANING The following table shows the necessary SP modes and the priority order when the listed items are replaced or cleaned: (Priority Number) NOTE: Replaced or Exposure Cleaned Black...
  • Page 438 12 February 1992 SP MODE PRACTICAL USE TABLE MAJOR ADJUSTMENT The following table shows SP modes for major adjustments in the field: TONER DENSITY (Detect Mode) [Black] Mode No. Description Data Black Toner Supply SP31 0:15% 1:7% 2:30% 3:60% Ratio Black (ID Sensor) SP33 0:N 1:L 2:H 3:HH...
  • Page 439 SP MODE PRACTICAL USE TABLE 12 February 1992 CHECKING The following table shows SP modes for checking major items in the field: Mode No. Description Free Run Set Free Run Reset SP8-1 to -72 Sensor/Switch/Signal Data Check SP9-1 to -60 Electrical Component Check SP51 Lamp Voltage Check...
  • Page 440 12 February 1992 TEST POINTS TEST POINTS MAIN CONTROL BOARD Number Label Function TP101 (LAMP) Exposure lamp feedback voltage Drum thermistor reference voltage TP102 (DRAMTH) (25°C: 2V, 35°C: 1.6V, Open: 5V, Short: 0V) Scanner free run with exposure lamp off by TP103 (SCN-TNT) shorting TP103 and TP104.
  • Page 441 PREVENTIVE MAINTENANCE SCHEDULE 12 February 1992 PREVENTIVE MAINTENANCE SCHEDULE PM TABLE NOTE: The amounts mentioned in the PM interval indicate the number of scans. Symbol key: C: Clean R: Replace L: Lubricate A: Add I: Inspect 80K 160K 240K NOTE OPTICS Mirrors, Lens, Reflectors Cotton pad with water, or blower...
  • Page 442 12 February 1992 PREVENTIVE MAINTENANCE SCHEDULE 80K 160K 240K NOTE End Blocks and Casing Water or alcohol Transfer Guide Plate Dry cloth Dry cloth and blower brush, Pre-Transfer Lamp Filter discharge any static before installation Dry cloth, discharge any static Quenching Lamp Filter before installation Toner Shield Glass and Filter...
  • Page 443 PREVENTIVE MAINTENANCE SCHEDULE 12 February 1992 80K 160K 240K NOTE Mobil temp. 78, Iubricate if Clutch Spring necessary Refer to NOTE 4 OTHERS Ozone Filters (Paper) Ozone Filter (Ceramic) Replace at 400K Drive Belt Replace if necessary Bushings Spindle oil Refer to NOTE 5 Exit Sensor Blower brush Development Unit Shift...
  • Page 444 12 February 1992 PREVENTIVE MAINTENANCE SCHEDULE Sorter Stapler (A366) 320K NOTE Transport, Distribution, and Damp cloth Exit Rollers Bins Damp cloth Bin/Jam, Paper Sensors Blower brush Launa oil or equivalent; if Bushings bushings generate noise. Grease-501; if gears generate Gears noise.
  • Page 445 PREVENTIVE MAINTENANCE SCHEDULE 12 February 1992 Note2: Development Section (1)Development Unit Change Clutch Clean the shift clutch assembly [A]. Then, lubricate the clutch spring [B] with Mobil Temp. 78 every 240K. (2)Development Drive Gear Replace the development drive gear [E] every 240K. Then, lubricate it with Silicone Grease G-40M.
  • Page 446 12 February 1992 PREVENTIVE MAINTENANCE SCHEDULE Note3: Fusing Section (1)Hot and Pressure Rollors Replace the hot [A] and pressure [B] rollers every 160K if necessary. Then, lubricate the roller shaft [C], bushings [D] and bearings [E] with BARRIERTA L55/2 grease. (2)Fusing Drive Gears Replace the fusing drive gears [F] every 160K.
  • Page 447 PREVENTIVE MAINTENANCE SCHEDULE 12 February 1992 Note4: Duplex Section (1)Clutch Spring Clean the clutch assembly [A]. Then, lubricate the clutch spring with Mobil Temp. 78 every 80K. Note5: Bushings Lubricate the following bushings with machine oil every 160K. (1)Paper Feed (LCT/By-pass Feed) (2)Relay Rollers and Tray Paper Feed 4-44...
  • Page 448 12 February 1992 PREVENTIVE MAINTENANCE SCHEDULE (3)Registration Roller [Rear] [Front] (4)Development Shift Section (5)Exit Roller 4-45...
  • Page 449 PREVENTIVE MAINTENANCE SCHEDULE 12 February 1992 (6)Duplex Tray 4-46...
  • Page 450 12 February 1992 PREVENTIVE MAINTENANCE SCHEDULE EXPLANATION OF REGULAR PM Item Explanation Stains on any part of the optics unit result in black lines or areas of decreased sharpness on the copy Mirrors, Lens, image. Periodic cleaning is required. The exposure Reflector, Exposure glass and the platen cover must also be cleaned.
  • Page 451 PREVENTIVE MAINTENANCE SCHEDULE 12 February 1992 Item Explanation The drum exceeding its lifetime may cause black lines Drum in half tone area, dirty background, and overtoning. Replace the drum at regular intervals. Dirty charge wires may cause uneven image density. Charge Wires They should be cleaned or replaced at regular Charge Grid...
  • Page 452 12 February 1992 PREVENTIVE MAINTENANCE SCHEDULE Item Explanation If toner accumulates on the thermistor, fusing Thermistor temperature control may not be accurate. Inspect the thermistor at regular intervals. Toner or dust adhering to the stripper pawls can Fusing Unit Stripper Pawls cause a paper jam.
  • Page 453 PREVENTIVE MAINTENANCE SCHEDULE 12 February 1992 REGULAR PM PROCEDURE Every 80k Every 160k or 240k (400k Make a copy of 0-S-A3 test chart at manual 1. Make a Copy image density level 4. 1. Clean the mirrors, lens and reflectors by using 2.
  • Page 454 12 February 1992 PREVENTIVE MAINTENANCE SCHEDULE 1. Empty the used toner tank. 4. Cleaning Unit 2. Clean the inside of the cleaning unit and seals. (every 80 K) 3. Replace the cleaning blade and brush. 1. Clean the development unit guide plate in the 5.
  • Page 455 PREVENTIVE MAINTENANCE SCHEDULE 12 February 1992 1. Clean the exit rollers. 8. Exit Unit 2. Inspect the antistatic brush. (every 80 K) Replace the ozone filter (ceramic) for the fusing exhaust fan (every 400 K) 1. Replace the ozone filter (paper) for the exhaust 9.
  • Page 456 SECTION 5 REPLACEMENT AND ADJUSTMENT...
  • Page 457 12 February 1992 EXTERIOR AND INNER COVERS EXTERIOR AND INNER COVERS EXTERIOR COVER REMOVAL 1.1.1 Front Door 1. Open the front door [A]. 2. Pull out the 2 pins [B]. 1.1.2 Front Upper Cover 1. Open the front door and remove. 2.
  • Page 458 EXTERIOR AND INNER COVERS 12 February 1992 1.1.3 Rear Cover 1. Remove the rear cover [A] (remove 2 screws and loosen 2 screws). 1.1.4 Left Cover 1. Open the front door and pull out the upper and lower paper trays (or the duplex tray) [B].
  • Page 459 12 February 1992 EXTERIOR AND INNER COVERS 1.1.6 Right Upper Cover Type 2 and Type 3 1. Remove the rear cover. 2. Remove 4 screws of the right upper cover [A]. 3. Open the LCT top cover [B]. 4. Open the by-pass feed table [C] and remove the right upper cover. Type 1 1.
  • Page 460 EXTERIOR AND INNER COVERS 12 February 1992 1.1.7 Right Lower Cover (for Type 1) 1. Remove the rear cover. 2. Remove the lower side 2 screws [A] of the right upper cover. 3. Remove the right lower cover [B] (2 screws). 1.1.8 Right Lower Covers (for Type 2 and Type 3) 1.
  • Page 461 12 February 1992 EXTERIOR AND INNER COVERS 1.1.9 Top Cover NOTE: Remove the document feeder or platen cover if either is installed. 1. Remove the left scale [A] (2 shoulder screws). 2. Remove the exposure glass [B]. 3. Remove the right and left optics covers [C, D] ( 1 screw each). 4.
  • Page 462 EXTERIOR AND INNER COVERS 12 February 1992 INNER COVER REMOVAL 1. Open the front door and remove. 2. Insert an Allen key [A] in the hole of the registration roller shaft through a hole in the bracket. 3. While holding the Allen key, remove the fixing screw [B]. 4.
  • Page 463 12 February 1992 OPTICS OPTICS EXPOSURE GLASS REMOVAL 1. Remove the left scale [A] (2 shoulder 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 exposure glass.
  • Page 464 OPTICS 12 February 1992 EXPOSURE LAMP REPLACEMENT NOTE: Do not touch the reflector or the new exposure lamp with your bare hands. Use a strip of paper as shown aver page. (Oil marks from fingers on the lamp or reflectors will be affected by heat from the lamp and will cause discoloration.) 1.
  • Page 465 12 February 1992 OPTICS 6. Remove the exposure lamp [A] from the front terminal by moving the lamp toward the rear. 7. Install a new lamp. Use a strip of paper as shown to hold the lamp. Reassemble the rear terminal bracket while confirming that the lamp is properly set by both terminals and the clip [B] is set properly.
  • Page 466 OPTICS 12 February 1992 OPTICS THERMOSWITCH REPLACEMENT NOTE: The thermoswitch can be reset manually to push the red button [E] when the exposure lamp area cools. 1. Turn off the main switch. 2. Remove the exposure glass. 3. Slide the 1st scanner about 150 mm (6") to the right. 4.
  • Page 467 12 February 1992 OPTICS OPTICS FAN FILTER CLEANING AND REPLACEMENT 1. Turn off the main switch. 2. Remove the right optics cover [A] (1 screw). 3. Clean or replace the optics fan filter [B]. 5-11...
  • Page 468 OPTICS 12 February 1992 SCANNER DRIVE BELT REPLACEMENT 2.5.1 Belt Removal 1. Remove the following parts: Platen cover or ADF [A] Left scale [B] (2 shoulder screws) Exposure glass [C] Top cover [D] (6 screws) Rear cover [E] (loosen 2 screws and remove 2 screws) Front upper cover [F] (3 screws) Operation panel [G] (4 screws and 2 connectors) Left scale bracket [H] (2 screws, 1 connector and 1 harness clamp)
  • Page 469 12 February 1992 OPTICS <Rear side of the scanner drive belts> 2. Remove the PTL/QL stabilizer [A] (1 screw, 6 connectors, 2 wire saddles). 3. Swing out the main control board assembly [B] (1 screw). 4. Loosen the screws [C] for the tension brackets of the long and short scanner drive belts (2 screws each).
  • Page 470 OPTICS 12 February 1992 <Front side of the scanner drive belts> 8. Loosen the screws for the tension bracket [A]. 9. Remove 2 tension springs [B]. 10. Remove the 2nd scanner [C] (loosen 2 screws). 5-14...
  • Page 471 12 February 1992 OPTICS 11. Unhook the long timing belt [A] from the belt clamp of the 1st scanner and put the 1st scanner [B] on the machine as shown. 12. Remove the front and rear guide rails [C, D] (2 screws each). 13.
  • Page 472 OPTICS 12 February 1992 2.5.2 Belt Installation 1. Install the short and long scanner drive belts [A, B] or both sides. NOTE: Put the short scanner drive belt on to the left pulley [C] first. 2. Reinstall the 4 tension springs and tighten the 4 tension brackets (2 screws each).
  • Page 473 12 February 1992 OPTICS 3RD SCANNER DRIVE MOTOR REPLACEMENT 1. Turn off the main switch. 2. Remove the following parts: • The exposure glass • The top cover • The rear cover • The lens cover 3. Remove the 2 fixing screws of the rear scanner guide rail [A]. 4.
  • Page 474 OPTICS 12 February 1992 LENS DRIVE WIRE REPLACEMENT 2.7.1 Wire Removal 1. Turn off the main switch. 2. Remove the following parts: • The exposure glass • The top cover • The rear cover • The lens cover • The left scale bracket 3.
  • Page 475 12 February 1992 OPTICS 2.7.2 Wire Installation 1. Remove the pulley [A] (1 E-ring). 2. Wind the lens drive wire [B] three and a half turns around the pulley and then wrap the pulley with tape as shown. 3. Reinstall the pulley. 4.
  • Page 476 OPTICS 12 February 1992 LENS DRIVE MOTOR REPLACEMENT 1. Remove the lens drive wire (see Lens Drive Wire Replacement). 2. Remove the lens drive motor assembly (2 screws and 1 connector). 3. Separate the motor [A] from the bracket [B] (2 screws) and replace. 5-20...
  • Page 477 12 February 1992 OPTICS ORIGINAL SIZE SENSORS REPLACEMENT Original size Data 11" x 17" A4 Lensthwise A4 sideways/8 " x 11" lengthwise B5 length wise B5 sideways/8 " x 11" sideways A5 lengthwise 1. Turn off the main switch. A5 sideways No original 2.
  • Page 478 DEVELOPMENT AND TONER SUPPLY 12 February 1992 DEVELOPMENT AND TONER SUPPLY DEVELOPMENT UNIT REMOVAL 3.1.1 Black Development Unit 1. Open the front door. 2. Push the development unit lock lever [A] to the right (to the lock position). 3. Move the development release lever [B] to the right and pull out the black development unit [C] half way.
  • Page 479 12 February 1992 DEVELOPMENT AND TONER SUPPLY 3.1.2 Color Development Unit 1. Open the front door. 2. While lifting the color development unit lock lever [A], pull out the color development unit [B] until it stops. 3. Holding the strap [C] of the color development unit with the left hand, pull out the color development unit while lifting the color development unit lock lever.
  • Page 480 DEVELOPMENT AND TONER SUPPLY 12 February 1992 DEVELOPER REPLACEMENT 3.2.1 Black Developer (SP#65) 1. Take out the development unit. 2. Set the development unit on a large sheet of paper [A]. 3. Remove the toner supply unit [B] (3 screws). 4.
  • Page 481 12 February 1992 DEVELOPMENT AND TONER SUPPLY 3.2.2 Color Developer (SP #10) 1. Take out the color development unit. 2. Put the color development unit on a large sheet of paper [A]. 3. Remove the toner supply unit [B] (3 screws). 4.
  • Page 482 DEVELOPMENT AND TONER SUPPLY 12 February 1992 DEVELOPMENT UNIT SHIFT CLUTCH LUBRICATION 1. Turn off the main switch. 2. Remove the rear and right upper cover. 3. Swing out the main control board assenbly [A] (1 screw). 4. Remove the development unit change solenoid bracket [B] (3 screws). 5.
  • Page 483 12 February 1992 DEVELOPMENT AND TONER SUPPLY TONER SUPPLY CLUTCH REMOVAL 1.Turn off the main switch. 2. Remove the development unit shift clutch assembly. 3. Remove the 3 gears [A] (1 E-ring). 4. Remove the support bracket [B] (3 screws) and gear [C]. 5.
  • Page 484 DEVELOPMENT AND TONER SUPPLY 12 February 1992 COLOR DEVELOPMENT SWITCH REPLACEMENT 1. Turn off the main switch. 2. Remove the color development unit. 3. Remove the rear cover. 4. Swing out the main control board assenbly (1 screw). 5. Unhook the color development switch [A] and replace (1 connector). 5-28...
  • Page 485 12 February 1992 CLEANING CLEANING CLEANING UNIT REMOVAL 1. Open the front door and lower the transfer & separation corona unit [A] by pulling down the release lever [B]. 2. Place a sheet of paper under the cleaning unit. 3. Turn the cleaning unit release lever [C] counterclockwise. 4.
  • Page 486 CLEANING 12 February 1992 CLEANING BLADE REPLACEMENT 1. Remove the cleaning unit [A] (see Cleaning Unit Removal.) 2. Remove the cleaning blade [B] (1 shoulder screw). 3. While holding up the cleaning blade release lever, install the new cleaning blade between the blade bracket [C] and the blade scraper. NOTE: a) Do not touch the edge of a new cleaning blade, as it is damaged easily.
  • Page 487 12 February 1992 CLEANING CLEANING BRUSH REPLACEMENT 1. Remove the cleaning blade [A]. (See Cleaning Blade Replacement.) 2. Remove the screw of the rear cleaning side bracket [C] and pull out the cleaning brush [B] together with the cleaning side bracket (1 E-ring) and gear [D].
  • Page 488 CLEANING 12 February 1992 BLADE SCRAPER REPLACEMENT 1. Remove the cleaning blade and brush. (See Cleaning Blade and Brush Replacement.) 2. While holding up the cleaning blade release lever [A], remove the blade scraper [B] (2 screws). 5-32...
  • Page 489 12 February 1992 CLEANING USED TONER COLLECTION (SP83) 1. Turn off the main switch. 2. Remove the cleaning unit and set it on a large sheet of paper. 3. Remove the used toner tank cover [A] (2 screws). 4. Pour the used toner slowly onto the paper so that it does not scatter. 5.
  • Page 490 CLEANING 12 February 1992 ENTRANCE SEAL REPLACEMENT 1±1 4±1 4±1 3±1 1. Remove the cleaning unit and the following parts: Cleaning Blade Cleaning Brush 2. Remove the used toner. (See Used Toner Collection.) 3. Clean the cleaning unit with a vacuum cleaner. 4.
  • Page 491 12 February 1992 PAPER FEED PAPER FEED PAPER TRAY REMOVAL 1. Open the copier front door. 2. Pull out the paper tray [A] and remove the tray stopper brackets [B], [C] on both sides as shown (1 screw each) and then remove the paper tray from the copier.
  • Page 492 PAPER FEED 12 February 1992 PAPER FEED ROLLER REPLACEMENT 5.2.1 Friction Pad Feed System (Paper Tray) NOTE: Replace the paper feed roller and the friction pad assembly as a set to maintain paper feeding ability. (1) Feed Roller Replacement 1. Remove the paper tray (see Paper Tray Removal). 2.
  • Page 493 12 February 1992 PAPER FEED (2) Friction Pad Replacement 1. Pull out the paper tray. 2. Remove the friction pad holder mounting bracket [A] from the paper tray (2 screws with washers). 3. Unhook the spring [B] from the pressure release lever. 4.
  • Page 494 PAPER FEED 12 February 1992 5.2.2 FRR-Feed System (Manual Feed/Large Capacity Tray) (1) Pick-up, Paper Feed, and Separation Rollers Replacement 1. Open the by-pass feed table. 2. Loosen the screw [A] and remove the by-pass feed guide plate [B] while lifting the by-pass feed table a little.
  • Page 495 12 February 1992 PAPER FEED (2) Separation Clutch Lubrication 1. Remove the separation roller [A] (see Separation Roller Replacement). 2. Slide the slip clutch [B] with the clutch cover [C] off the shaft. 3. Separate the slip clutch into the three components. 4.
  • Page 496 PAPER FEED 12 February 1992 BY-PASS FEED TABLE REMOVAL 1. Open the by-pass feed table. 2. Loosen the screw [A] and remove the by-pass feed guide plate [B] while lifting the by-pass feed table a little. 3. Remove the right upper cover and the rear cover. 4.
  • Page 497 12 February 1992 PAPER FEED PAPER FEED CLUTCHES REPLACEMENT < Common Procedure> 1. Turn off the main switch and unplug the power cord. 2. Remove the rear cover. 3. Swing out the main control board assembly (1 screw). (1) By-pass Feed Clutch 1.
  • Page 498 PAPER FEED 12 February 1992 (4) Lower Paper Feed Clutch 1. Take the high voltage cables off the hooks on the exhaust blower housing. 2. Remove the exhaust blower assembly [A] (2 screws and 1 connector). 3. Move the high voltage supply board assembly [B] from the copier base plate (1 screw, 2 wire saddles for bias cable).
  • Page 499 12 February 1992 PAPER FEED REGISTRATION CLUTCH REPLACEMENT 1. Turn off the main switch and unplug the power cord. 2. Remove the rear cover. 3. Take the high voltage cables off the hooks on the exhaust blower housing. 4. Remove the exhaust blower assembly [A] (2 screws and 1 connector). 5.
  • Page 500 PAPER FEED 12 February 1992 TRAY LIFT MOTOR/TRAY REPLACEMENT <Lower paper tray for example> 1. Turn off the main switch and unplug the power cord. 2. Remove the lower tray from the copier. (see paper tray removal) 3. Remove the rear cover and swing out the main control board and the dc power supply board assemblies (1 screw each).
  • Page 501 12 February 1992 PAPER FEED LCT DRIVE BELT REPLACEMENT 1. Remove the right upper cover. 2. Remove the LCT front and rear covers (1 screw each). 3. Remove the right front lower and right rear lower covers (2 screws each). 4.
  • Page 502 PAPER FEED 12 February 1992 LCT LIFT MOTOR REPLACEMENT 1. Remove the LCT from the copier (refer to LCT Drive Belt Replacement). 2. Remove the motor cover plate [A] (2 screws). 3. Remove the LCT lift motor assembly [B] (4 screws, 4 rubber rings, 1 connector).
  • Page 503 12 February 1992 AROUND THE DRUM AROUND THE DRUM DRUM UNIT REMOVAL 1. Open the front door and lower the transfer & separation corona unit [A] by pulling down the release lever [B]. 2. Push the development unit lock lever [C] to the right (to the lock position). 3.
  • Page 504 AROUND THE DRUM 12 February 1992 4. If the color development unit (option) is installed, continue the following: (1) While lifting the color development unit lock lever [A], pull the color development unit [B] until it locks. (2) Hold the belt [C] of the unit and pull out the unit while lifting the lock lever again.
  • Page 505 12 February 1992 AROUND THE DRUM 5. Turn the cleaning unit release lever [A] counterclockwise. While holding up the cleaning blade release lever [B], remove the cleaning unit. Place the unit on a clean sheet of paper. 6. Remove the charge corona unit [C] together with the wire cleaner (1 screw).
  • Page 506 AROUND THE DRUM 12 February 1992 7. Remove the fixing screw [A] securing the drum stay and pull out the drum unit [B] gently along the rail. 8. Place the drum unit on a clean sheet of paper. 5-50...
  • Page 507 12 February 1992 AROUND THE DRUM DRUM REPLACEMENT 1. Pull out the drum unit from the copier and place it with the left side down on a clean sheet of paper (see Drum Unit Removal). 2. Loosen the two screws [A] securing the bearing holder [B] and rotate the holder as shown.
  • Page 508 AROUND THE DRUM 12 February 1992 8. Install the new drum in the drum unit, then position and secure the bearing holder. NOTE: a) When setting the drum in the unit, be careful not to strike it against the unit frame or the pick-off pawls [F]. b) Do not bend the bearing holder.
  • Page 509 12 February 1992 AROUND THE DRUM PICK-OFF PAWL REPLACEMENT CAUTION: Be careful not to injure your hands with the pick-off pawls as the top of them is very sharp. 1. Remove the drum from the drum unit (see Drum Replacement) and keep the drum wrapped in the protective sheet or a clean sheet of paper.
  • Page 510 AROUND THE DRUM 12 February 1992 ID SENSOR CLEANING AND REPLACEMENT 1. Remove the drum from the drum unit (see Drum Replacement) and keep the drum wrapped in the protective sheet or a clean sheet of paper. [Cleaning] 2. Clean the ID sensor [A] with a blower brush from the drum side. [Replacement] 2.
  • Page 511 12 February 1992 AROUND THE DRUM V SENSOR CLEANING AND REPLACEMENT 1. Remove the drum from the drum unit (see Drum Replacement) and keep the drum wrapped in the protective sheet or a clean sheet of paper. [Cleaning] 2. Clean the V sensor [A] with a blower brush from the drum side. [Replacement] 2.
  • Page 512 AROUND THE DRUM 12 February 1992 7. Run the V sensor harness [A] and the drum grounding wire [B] on the drum unit frame as shown and install the front drum cover. NOTE: Make sure that the harnesses are correctly positioned and that no wire is nicked or pinched by the drum front cover.
  • Page 513 12 February 1992 AROUND THE DRUM TONER SHIELD GLASS AND GREEN FILTER CLEANING 1. Remove the drum unit from the copier (see Drum Unit Removal) and place it on a clean sheet of paper with the drum unit top plate up [A]. 2.
  • Page 514 AROUND THE DRUM 12 February 1992 ERASE LAMP UNIT REPLACEMENT 1. Remove the drum and the toner shield glass from the drum unit (see Drum Replacement and Toner Shield Glass Cleaning). 2. While unhooking the positioning pawls [A], remove the erase lamp unit [B] (1 connector) as shown.
  • Page 515 12 February 1992 AROUND THE DRUM PTL FILTER CLEANING AND REPLACEMENT 1. Lower the T&S corona unit and remove the following units from the copier: Black (and color) development unit/Cleaning unit/Charge corona unit / Drum unit 2. While holding the tab [A] of the PTL top mylar [B], bend the mylar and unhook the front side of the mylar from the hook [C], then from the rear side.
  • Page 516 AROUND THE DRUM 12 February 1992 PRE-TRANSFER LAMP REPLACEMENT 1. Remove the PTL filter assembly from the copier (see PTL Filter Cleaning And Replacement). 2. Remove the registration clutch from the copier (see Registration Clutch Replacement). 3. Slide out the pre-transfer lamp [A] from the copier (1 screw, 1 connector, and 2 wire saddles).
  • Page 517 12 February 1992 AROUND THE DRUM 6.10 QUENCHING LAMP FILTER CLEANING 1. Open the front cover and pull out the quenching lamp filter [A]. 2. Clean the filter with a dry cloth and discharge static electricity on the filter by touching it with your finger. 3.
  • Page 518 AROUND THE DRUM 12 February 1992 6.11 QUENCHING LAMP REPLACEMENT 1. Remove the copier rear cover. 2. Remove the tension spring [A] of the drum drive belt [B]. 3. Slip off the drum drive belt from the tension pulley [C] and lower the tension pulley.
  • Page 519 12 February 1992 AROUND THE DRUM 6.12 CHARGE CORONA WIRE REPLACEMENT 1. Remove the screw securing the charge corona wire cleaner [A] and pull out the charge corona unit with the wire cleaner. 2. Remove the wire cleaner from the charge corona unit. 3.
  • Page 520 AROUND THE DRUM 12 February 1992 6. Install new corona wires with the damper rings on the corona unit. NOTE: a) Set the big eyelet [G] of the corona wire in the rear hook [H], then set the front end with the tension spring. The spring should be positioned at the bottom part of the hooking pole [I].
  • Page 521 12 February 1992 AROUND THE DRUM 6.13 CHARGE CORONA WIRE HEIGHT ADJUSTMENT NOTE: a) The charge corona wire height adjustment should be done only when the front end block is replaced. b) Before replacing the front end block of the charge corona unit, adjust the uneven exposure with the exposure adjusting plates and make a copy sample with the test chart for the reference.
  • Page 522 AROUND THE DRUM 12 February 1992 6.14 CHARGE GRID PLATE REPLACEMENT 1. Remove the wire cleaner from the charge corona unit. 2. Unhook the grid anchor plate [A] from the hook on the front end block, and lift up the grid anchor plate as shown. NOTE: When unhooking the anchor grid plate, be careful not to break off the hook [B].
  • Page 523 12 February 1992 AROUND THE DRUM 6.15 TRANSFER/SEPARATION CORONA WIRE REPLACEMENT 1. Lower the T & S corona unit and remove it from the copier. 2. Remove the paper guide [A] from the T & S corona unit by lifting the rear part and sliding it to the rear.
  • Page 524 AROUND THE DRUM 12 February 1992 6. Clean the T & S corona casing and the end blocks. NOTE: a) Clean the casing with water first to remove NOx. Then clean it with alcohol if any toner still remains on the casing. b) Clean the end blocks with a blower brush to remove toner and paper dust.
  • Page 525 12 February 1992 FUSING FUSING FUSING UNIT REMOVAL 1. Open the front cover and lower the T & S corona unit. 2. Remove the cleaning unit (see Cleaning Unit Removal). 3. Hold the fusing unit cover [A] while pushing the release lever [B], and pull out the fusing unit [C] until it stops.
  • Page 526 FUSING 12 February 1992 FUSING LAMP REPLACEMENT 1. Remove the fusing unit (see Fusing Unit Removal). 2. Remove the fusing unit cover [A] (2 shoulder screws, 1 screw). 3. Remove the fusing lamp harness [B] from the front and rear fusing lamp terminals [C] (1 screw each).
  • Page 527 12 February 1992 FUSING HOT ROLLER REPLACEMENT 1. Remove the fusing lamp (see Fusing Lamp Replacement). 2. Press both "B2" release levers [A] and lower the fusing exit assembly [B]. 3. Remove the front and rear pressure springs [C]. 4. Remove the fusing thermistor [D] (1 screw). 5.
  • Page 528 FUSING 12 February 1992 PRESSURE ROLLER REPLACEMENT 1. Remove the hot roller (see Hot Roller Replacement). 2. Remove the upper fusing entrance guide [A] (2 screws). 3. Remove the lower fusing entrance guide [B] (1 screw) as shown. 4. Remove the front lamp holder (1 screw). 5.
  • Page 529 12 February 1992 FUSING FUSING STRIPPER PAWL REPLACEMENT 1. Remove the fusing unit (see Fusing Unit Removal). 2. Lower the fusing exit assembly [A]. 3. Remove the pawl pressure springs [B] and pawl release springs [C]. 4. Remove the 3 fusing pawl brackets [D] (5 screws). 5.
  • Page 530 FUSING 12 February 1992 THERMOFUSE REPLACEMENT 1. Remove the fusing unit (see Fusing Unit Removal). 2. Remove the fusing unit cover [A] (2 shoulder screws, 1 screw). 3. Lower the fusing exit assembly [B]. 4. Remove the thermofuse harness lead [C] (1 screw) from the front fusing lamp terminal and disconnect the thermofuse harness from the fusing harness [D].
  • Page 531 12 February 1992 FUSING FUSING THERMISTOR REPLACEMENT 1. Remove the fusing unit (see Fusing Unit Removal). 2. Remove the fusing unit cover [A] (2 shoulder screws, 1 screw). 3. Lower the fusing exit assembly [B]. 4. Disconnect the thermistor harness [C] from the fusing harness. 5.
  • Page 532 FUSING 12 February 1992 FUSING TEMPERATURE CHECK (SP52) 1. Turn the main switch off. 2. While pressing both "1" and "3" on the operation panel number keys, turn on the main switch to access the SP mode. 3. Enter "52" (fusing temperature check mode) using the number keys and then press the enter key.
  • Page 533 12 February 1992 FUSING FUSING TEMPERATURE ADJUSTMENT (SP49) Standard Setting: 185°C The fusing temperature can be adjusted between 175°C and 190°C in 1°C steps according to the following procedure: 1. Turn the main switch off. 2. While pressing both "1" and "3" on the operation panel number keys, turn on the main switch to access the SP mode.
  • Page 534 DUPLEX 12 February 1992 DUPLEX DUPLEX UNIT REMOVAL 1. Open the front door. 2. Pull out the duplex tray [A] and remove the tray stopper brackets [B, C] from both side rails as shown (1 screw each), then remove the duplex tray from the copier.
  • Page 535 12 February 1992 DUPLEX 5. Unhook the lift spring [A] from the duplex lift lever [B] and the cam clutch [C]. 6. Remove 3 clamps [D] with a pair of pliers. 7. Disconnect CN602, and CN603 [E] from the duplex control board. 8.
  • Page 536 DUPLEX 12 February 1992 -Installation- 1. When placing the duplex unit back into the tray, hold up the bottom plate [A] so that the flipmylar brackets [B] fit under it as shown. 2. Hook the lift spring [C] to the cam clutch [D] and the duplex lift lever [E] as shown.
  • Page 537 12 February 1992 DUPLEX DUPLEX FEED ROLLER REPLACEMENT 1. Open the front door. 2. Pull out the duplex tray. 3. Remove the side inner cover [A] and front inner cover [B] (5 screws). 4. Raise the upper and lower paper guide plates [C] all the way up and remove the snap ring [D] for the guide plate support arm.
  • Page 538 DUPLEX 12 February 1992 DUPLEX FRICTION ROLLER REPLACEMENT 1. Remove the duplex unit [A] from the tray (see Duplex Unit Removal). 2. Remove the friction roller assembly [B] (2 screws) from the duplex unit. 3. Remove the friction rollers [C] (1 E-ring each) from the shaft [D]. 4.
  • Page 539 12 February 1992 DUPLEX JOGGER HOME POSITION SENSOR AND JOGGER MOTOR REPLACEMENT 1. Pull out the duplex tray and remove the side and front inner covers. 2. Remove the clamp [A] and sensor bracket [B] (1 screw). 3. Remove the jogger home position sensor [C] from the bracket and replace it (1 screw and 1 connector).
  • Page 540 DUPLEX 12 February 1992 DUPLEX MOTOR REPLACEMENT 1. Remove the duplex unit from the tray (see duplex unit removal). 2. Remove the duplex motor assembly [A] (2 screws). 3. Separate the duplex motor [B] from the bracket [C] and replace it (2 screws).
  • Page 541 12 February 1992 COPY QUALITY ADJUSTMENT COPY QUALITY ADJUSTMENT LIGHT INTENSITY ADJUSTMENT (SP48) When: After performing SP66 (Drum initialize) and before exiting the SP mode when replacing the drum. Purpose: To properly adjust light intensity for the initial V pattern detection (storing Vref = initial Vlp/Vlg) Adjustment standard: Level 2 of the gray scale on the OS-A3 test chart should be just visible on the copy when the 4th...
  • Page 542 COPY QUALITY ADJUSTMENT 12 February 1992 6. Make a full size copy at the manual image density level 4 (center) after the copier has warmed up (when the beeper sounds 3 times). NOTE: Make sure that the data in SP37 (black bias) is set to "0" (standard value).
  • Page 543 12 February 1992 COPY QUALITY ADJUSTMENT UNEVEN EXPOSURE ADJUSTMENT When: If the exposure is uneven. Purpose: To maintain even exposure. Adjustment standard: The side-to-side variation of the gray scales on the test chart should be less than one level. How: Change the position of the exposure adjusting plates to make the light intensity from the exposure lamp even across its length.
  • Page 544 COPY QUALITY ADJUSTMENT 12 February 1992 IMAGE AREA BIAS VOLTAGE ADJUSTMENT 9.3.1 Black Bias Adjustment (SP37) When: If the image density at the manual density level 4 cannot be adjusted by exposure lamp voltage (SP48) after performing SP66 (drum initialize) when replacing the drumis replaced.
  • Page 545 12 February 1992 COPY QUALITY ADJUSTMENT 9.3.2 Color Bias Adjustment (SP79) When: If color image density is improper compared with black image density. Purpose: To improve color image density. How: SP79 changes the development bias voltage for color images. SP79: Color Bias Development Bias Data Density...
  • Page 546 COPY QUALITY ADJUSTMENT 12 February 1992 9.3.3 Highlight Bias (Manual ID Level 7) Adjustment (SP46) When: If a customer requests a lighter or darker copy image density at manual image density level 7. Purpose: To meet customer’s request about the image density at manual ID level 7.
  • Page 547 12 February 1992 COPY QUALITY ADJUSTMENT TONER DENSITY ADJUSTMENT 9.4.1 Black Toner Density Adjustment (SP33) When: If a customer wants to change the overall image density of black copies. Purpose: To change toner concentration inside the black development unit. How: SP33 changes the development bias for the black ID sensor pattern.
  • Page 548 COPY QUALITY ADJUSTMENT 12 February 1992 9.4.2 Color Toner Density Adjustment (SP75) When: If a customer wants to change the overall image density of color copies. Purpose: To change toner concentration inside the color development unit. How: SP75 changes the development bias for the color ID sensor pattern.
  • Page 549 12 February 1992 COPY QUALITY ADJUSTMENT DETECT / FIXED TONER SUPPLY MODE SELECTION (SP30) When: If the type of original is almost the same with high image density and proportion, and adjusting the toner supply ratio (SP31) and toner density check interval (SP35) do not give constant image density without toner scattering problem.
  • Page 550 COPY QUALITY ADJUSTMENT 12 February 1992 TONER SUPPLY RATIO SELECTION (SP31/SP32/SP81) When: If the standard setting for toner supply amount is not appropriate for the type of original in use. Purpose: To adjust the toner supply amount. How: Detect mode:SP31 for black toner, SP81 for color toner Fixed mode: SP32 for black toner All three service programs change the toner...
  • Page 551 12 February 1992 COPY QUALITY ADJUSTMENT TONER DENSITY CHECK INTERVAL SELECTION (SP35/SP74) When: If a customer complains of low image density of copies during a toner near end condition. Purpose: To check toner density more often. How: SP35 for black toner and SP74 for color toner change the interval of ID sensor pattern detection.
  • Page 552 COPY QUALITY ADJUSTMENT 12 February 1992 ADS SENSOR AUTOMATIC ADJUSTMENT (SP56) When: 1. If ADS output voltage is not within the adjustment standard after cleaning the optics. 2. At replacement of the following parts: ADS board, Exposure lamp, RAM board on the main control board, and dc power supply board 3.
  • Page 553 12 February 1992 COPY QUALITY ADJUSTMENT 9.11 VERTICAL MAGNIFICATION ADJUSTMENT (SP43) When: If vertical magnification is not within the adjustment standard. Purpose: To maintain proper vertical magnification. Less than ±1.0% difference between original and Adjustment standard: copy. How: SP43 changes the scanner speed compensation. 1.
  • Page 554 COPY QUALITY ADJUSTMENT 12 February 1992 9.12 HORIZONTAL MAGNIFICATION ADJUSTMENT (SP44) When: If horizontal magnification is not within the adjustment standard. Purpose: To maintain proper horizontal magnification. Less than ±0.5% difference in full size mode Adjustment standard: between original and copy. How: SP44 changes the lens home position.
  • Page 555 12 February 1992 COPY QUALITY ADJUSTMENT 9.13 FOCUS ADJUSTMENT IN FULL SIZE (SP47) When: If the copy image in full size mode is out of focus. After adjusting horizontal magnification. Purpose: To maintain correct focus in full size mode. How: SP47 changes the 3rd scanner home position.
  • Page 556 COPY QUALITY ADJUSTMENT 12 February 1992 9.15 VERTICAL MAGNIFICATION ADJUSTMENT IN DUPLEX/ OVERLAY MODE (SP45) When: If vertical magnification is different between the first and second images in duplex/overlay mode. Purpose: To equal vertical magnification between the first and second images in duplex/overlay mode. How: SP45 increases vertical magnification for the first image to equal that for the second image.
  • Page 557 12 February 1992 COPY QUALITY ADJUSTMENT 9.17 LEAD EDGE ERASE MARGIN ADJUSTMENT (SP41) When: If lead edge erase margin is not within the adjustment standard. Purpose: To maintain a proper lead edge erase margin. 2.5 ±1.5 mm (0.1 ±0.06") Adjustment Standard: How: SP41 changes the erase lamp off timing.
  • Page 558 COPY QUALITY ADJUSTMENT 12 February 1992 9.18 SIDE-TO-SIDE REGISTRATION ADJUSTMENT 9.18.1 Lens Position Adjustment When: If side-to-side registration is not within the adjustment standard, and image shift direction (to the front or to the rear) is the same from every paper feeding stations.
  • Page 559 12 February 1992 COPY QUALITY ADJUSTMENT 4. Remove the small lens cover [A] (2 screws). 5. Mark the original position of the lens assembly on the lens bracket. 6. Loosen the 2 screws, shift the lens assembly [B] according to the following rule, and tighten the screws.
  • Page 560 COPY QUALITY ADJUSTMENT 12 February 1992 9.18.2 Tray Side Fence Adjustment When: If side-to-side registration on copies fed from a paper tray is not within the adjustment standard. Purpose: To maintain proper side to side registration from a paper tray. 0 ±2 mm (0 ±0.08") Adjustment standard: How:...
  • Page 561 12 February 1992 COPY QUALITY ADJUSTMENT 9.18.3 Duplex Tray Side Fence Adjustment When: If side-to-side registration of the second image in multiple 2-sided copying mode is not within the adjustment standard. Purpose: To maintain proper side to side registration of the second image in 2-sided copying mode.
  • Page 562 COPY QUALITY ADJUSTMENT 12 February 1992 9.18.4 LCT Side to Side Registration Adjustment When: If side-to-side registration on copies fed from the large capacity tray is not within the adjustment standard Purpose: To maintain proper side to side registration from the large capacity tray.
  • Page 563 12 February 1992 COPY QUALITY ADJUSTMENT 9.19 3RD SCANNER HEIGHT ADJUSTMENT When: If skewed images appear after adjusting the 1st and 2nd scanner positions. Purpose: To maintain proper copy image. How: Turn the 3rd scanner height adjustment screw. This changes the 3rd scanner’s height. CAUTION: Never perform this adjustment unless you have positively verified that the source of the skewing of image is optical and not in the paper path.
  • Page 564 COPY QUALITY ADJUSTMENT 12 February 1992 9.20 OVERLAP/WHITE MARGIN SELECTION IN OVERLAY MODE (SP24) When: If a customer wants a white frame on the border line when using "Black-in area" and "Color-in area" mode. (This is applied only when the editor is installed.) Purpose: To satisfy the customer’s requirement.
  • Page 565 12 February 1992 OTHERS 10. OTHERS 10.1 OZONE FILTER REPLACEMENT 10.1.1 Fusing Exhaust Fan Filter 1. Turn off the main switch. 2. Open the front door and remove the fusing unit. 3. While holding up the ozone filter [A] slightly slide it out as shown. 4.
  • Page 566 OTHERS 12 February 1992 10.1.2 Vacuum Fan Filters 1. Turn off the main switch. 2. Remove the rear cover. 3. Remove the ozone filter [A] NOTE: The PM interval of this paper ozone filter is 80K copies. 4. Swing out the dc power supply board. 5.
  • Page 567 12 February 1992 OTHERS 10.1.3 Optics Cooling Fan Filter 1. Remove the optics left cover [A] (1 screw). 2. Replace the ozone filter [B]. NOTE: The PM interval of this paper ozone filter is 80 k copies. 5-111...
  • Page 568 OTHERS 12 February 1992 10.2 MAIN CONTROL BOARD REPLACEMENT 1. Turn off the main switch and unplug the power cord. 2. Remove the rear cover. 3. Disconnect the harnesses (11 connectors) from the main control board [A]. 4. Replace the main control board (6 locking supports). 5.
  • Page 569 12 February 1992 OTHERS 10.3 RAM BOARD REPLACEMENT 1. Turn off the main switch and unplug the power cord. 2. Remove the rear cover. 3. Replace the RAM board [A]. 4. Reassemble the copier and plug it in. 5. Perform the memory all clear (SP99) and follow the necessary procedure (see Memory All Clear Procedure in Service Program Mode of Service Table section).
  • Page 570 OTHERS 12 February 1992 10.4 OPERATION PANEL REMOVAL 1. Turn off the main switch. 2. Remove the front door and the upper front cover. 3. Remove the operation panel [A] (4 screws, 2 connectors). 5-114...
  • Page 571 12 February 1992 OTHERS 10.5 HIGH VOLTAGE SUPPLY BOARD - CTBG REPLACEMENT 1. Turn off the main switch and unplug the power cord. 2. Remove the rear cover. 3. Swing out the main control board assembly (1 screw). 4. Disconnect the bias cable [A] (1 connector, 1 harness lamp). 5.
  • Page 572 OTHERS 12 February 1992 10.6 HIGH VOLTAGE SUPPLY BOARD – D REPLACEMENT 1. Turn off the main switch and unplug the power cord. 2. Remove the rear cover. 3. Disconnect the high-voltage cable [A] and a harness [B] (2 connectors). 4.
  • Page 573 12 February 1992 OTHERS 10.7 T/S CORONA CURRENT AUTO ADJUSTMENT (SP57) NOTE: 1. Setting data of SP62 must be done, before performing the T/S corona current auto adjustment. 2. Adjust the corona current only when a high voltage supply board is replaced. 3.
  • Page 574 OTHERS 12 February 1992 10.8 DC POWER SUPPLY BOARD REPLACEMENT NOTE: 1. Check the fuses (F1, F2, F3, and F4) on the board before determining that the dc power supply board is defective. 2. When checking if the dc power supply board is defctive or not by installing the board on another machine, wait for 10 minutes before turning on the main switch.
  • Page 575 SECTION 6 TROUBLESHOOTING...
  • Page 576 12 February 1992 INTRODUCTION 1. INTRODUCTION This troubleshooting guide is compiled to help field engineers solve some of the more common field problems. However, it does not cover all the potential problems. We request your help in improving our troubleshooting documenta- tion.
  • Page 577 COPY QUALITY 12 February 1992 2. COPY QUALITY BLANK COPY (WHITE COPY) - Phenomenon - White or almost white copy. - Possible Causes - 1. Charge is not applied. High voltage supply board - CTBG (charge or grid) failure • Poor contact of high voltage lead wires •...
  • Page 578 12 February 1992 COPY QUALITY - Action - Are the charge and T/S corona units correctly installed? Install the charge and T/S corona units correctly. Do the charge corona unit terminal and the springs of the T/S corona unit properly contact the receptacle terminals? Replace the defective parts.
  • Page 579 COPY QUALITY 12 February 1992 Does the drum rotate properly? Check drum drive mechanisms such as the drum drive belt and the drum pulleys. Check the following points: CN103-4 (Charge/grid trigger line) • (1) If the signal stays HIGH after the Start key is pressed, replace the main control board.
  • Page 580 12 February 1992 COPY QUALITY DIRTY BACKGROUND - Phenomenon - 1. Dirty background at image density level 4 (manual setting). 2. ADS copies have a dirty background. - Possible Causes - 1. V correction failure Very dirty optics (V correction cannot compensate). •...
  • Page 581 COPY QUALITY 12 February 1992 - Action - Make a copy in reduction mode at manual image density level 4. Is the non-image area dirty? Perform the forced VL detection (SP70). No good Clean the optics and perform the forced V detection (SP70) till the target lamp voltage (SP51) does not change.
  • Page 582 12 February 1992 COPY QUALITY Check the continuity between the development roller shaft and the development bias terminal Good No good Repair the harness or terminals. Is the signal at CN108-3 LOW after the start key is pressed? Replace the main control board. Replace the high voltage supply boar - CTBG.
  • Page 583 COPY QUALITY 12 February 1992 UNEVEN IMAGE DENSITY - Phenomenon - Uneven image density appears on copies. - Possible Cause - 1. Dirty optics 2. Improper position of exposure adjustment plates 3. Dirty corona wires or grid plate 4. Uneven height of charge corona wire 5.
  • Page 584 12 February 1992 COPY QUALITY VERTICAL BLACK BANDS - Phenomenon - Vertical black bands appear on the copy. - Possible Causes - 1. Dirty optics 2. Dust between the cleaning blade and drum 3. Edge of the cleaning blade deformed 4.
  • Page 585 COPY QUALITY 12 February 1992 VERTICAL BLACK LINES - Phenomenon - Thin black lines appear on the copy. - Possible Causes - 1. Scratched cleaning blade 2. Dirty or scratched mirrors 3. Scratched or dirty drum 4. Scratched hot roller - Action - Do the black lines shift when a reduction copy is made? Clean or replace the exposure glass or mirrors.
  • Page 586 12 February 1992 COPY QUALITY 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 wires 2. Dirty or deformed grid plate 3.
  • Page 587 COPY QUALITY 12 February 1992 VERTICAL WHITE LINES OR BANDS—2 (THIN, DISTINCT) - Phenomenon - Vertical white lines appear on the copy. - Possible Causes - 1. Paper dust on the edge of the cleaning blade 2. Scratched drum 3. Scratched hot roller - Action - Press the cleaning blade release lever several times.
  • Page 588 12 February 1992 COPY QUALITY HORIZONTAL BLACK/WHITE LINES - Phenomenon - Black or white lines perpendicular to the paper feed direction appear on the copy image. - Possible Causes - 1. Drum is scratched. If black lines appear at 251 mm (9.89") intervals, the cause is a scratched drum or toner build up.
  • Page 589 COPY QUALITY 12 February 1992 BLACK SPOTS ON THE COPY IMAGE - Phenomenon - The grid voltage is not applied correctly. Poor contact between the charge corona casing • and grid plate High voltage supply board - CTBG defective • Main control board defective •...
  • Page 590 12 February 1992 COPY QUALITY 2.10 SKEWED (OPTICAL) COPY IMAGE - Phenomenon - IMAGE The copy image is skewed (parallelogram shape). The sides of the copy image are straight, but the leading and trailing edges are skewed. (This differs from skewing originating in the paper path type of skewing.) - Possible Causes - 1.
  • Page 591 COPY QUALITY 12 February 1992 2.11 TONER DENSITY TOO HIGH - Phenomenon - 1. Dirty background appears on the copy. 2. The image density of black solid areas is too high. 3. Toner has built up on the endblock cover of the T/S corona unit and also on the PTL top mylar.
  • Page 592 12 February 1992 COPY QUALITY Make copies with a test chart and monitor the Vsp value and the toner supply clutch function. Is the toner supply clutch controlled properly? Is the voltage at CN110-B9 alway LOW? Replace the toner supply clutch. Replace the main control board.
  • Page 593 COPY QUALITY 12 February 1992 2.12 TONER DENSITY TOO LOW - Phenomenon - 1. Light copy 2. Carrier is on the copy. 3. Light spots appear in black solid areas. - Possible Causes - 1. Toner supply clutch does not rotate. 2.
  • Page 594 12 February 1992 COPY QUALITY Does the toner supply clutch rotate? Is the voltage at CN110-B9 always HIGH? Replace the toner supply clutch. Replace the main control board. Is the toner cartrige nearly emply? Replenish new toner cartridge Is the grid reference voltage (SP62) correctly set? Set the correct data in SP62, refering to the label on the high voltage supply board - CTBG.
  • Page 595 COPY QUALITY 12 February 1992 2.13 TONER SCATTERING - Phenomenon - Toner scatters from the development unit. - Possible Causes - 1. Toner density is too high. 2. Inlet seal on the development unit is out of position. 3. Developer has deteriorated. - Action - Is toner density too high? See section "TONER DENSITY TOO HIGH".
  • Page 596 12 February 1992 COPY QUALITY 2.14 UNFUSED COPY IMAGE - Phenomenon - Solid image rubs off easily. - Possible Causes - 1. Fusing pressure is too weak. 2. Fusing temperature is too low. 3. Thermistor is malfunctioning. - Action - Adjust the position of the pressure springs to increase the fusing pressure.
  • Page 597 COPY QUALITY 12 February 1992 2.15 A HORIZONTAL THIN LINE APPEARING CLOSE TO THE LEADING EDGE - Phenomenon - When an original has black solid areas at the trailing edge, toner transferred from the trailing edge onto the hot roller will appear on the next copy paper. - Action - Set SP157 (trail edge erase) to leave a blank margin on the trailing edge of copies.
  • Page 598 12 February 1992 SERVICE CALL CONDITIONS 3. SERVICE CALL CONDITIONS CODE #11 - EXPOSURE LAMP ERROR 1 (STAND-BY) - Definition - The exposure lamp turns on or opens during stand-by condition. - Possible Cause - • Exposure lamp open • Optics thermoswitch open •...
  • Page 599 SERVICE CALL CONDITIONS 12 February 1992 CODE #20 - SCANNER MOTOR ERROR - Definition - The difference of pulse numbers for the scanner drive motor between the number of pulses in forward and reverse exceeds a certain number. (When initializing and copying.) - Possible Cause - •...
  • Page 600 12 February 1992 SERVICE CALL CONDITIONS CODE #23 - LEAD EDGE SIGNAL ERROR - Definitions - The main CPU does not receive a scan lead edge signal from the I/O CPU on the main control board from when the scanner starts going forward till it starts returning.
  • Page 601 SERVICE CALL CONDITIONS 12 February 1992 CODE #29 - LENS HOME POSITION ERROR 2 -Definition - The lens H.P. sensor remains deactivated (photo-transistor stays on) 2.4 seconds after the reduction mode is selected or the main switch is turned on. - Possible Cause - •...
  • Page 602 12 February 1992 SERVICE CALL CONDITIONS 3.12 CODE #41 TO #45 - PAPER TRAY LIFT MOTOR ERROR - Definition - The tray lift motor stays on over 15 seconds for lifting or lowering. #41: Copier upper tray lift motor (non-duplex machine only)— #42: Copier lower tray lift motor #43: Tray lift motor 1 (paper tray unit) #44: Tray lift motor 2 (paper tray unit)
  • Page 603 SERVICE CALL CONDITIONS 12 February 1992 3.15 CODE #54 - FUSING WARM-UP ERROR - Definition - The fusing temperature does not reach 175°C 4 minutes after the main switch is turned on. - Possible Cause - • Fusing lamp open •...
  • Page 604 12 February 1992 SERVICE CALL CONDITIONS 3.17 CODE #61 - MAIN DRIVE MOTOR ERROR - Definition - The main motor does not start rotating within 2 seconds after the CPU sends the main motor on signal. The CPU detects this condition by the lock signal "L" from the main motor control board.
  • Page 605 SERVICE CALL CONDITIONS 12 February 1992 3.20 CODE #64 - FUSING EXHAUST FAN MOTOR ERROR - Definition - The fusing exhaust fan motor does not start rotating within 2 seconds after the CPU sends the fusing exhaust fan motor on signal. The CPU detects this condition through the lock signal "L"...
  • Page 606 12 February 1992 SERVICE CALL CONDITIONS 3.22 CODE #73 - SEPARATION CORONA CURRENT ADJUSTMENT ERROR - Definition - When performing SP57 (auto drum current adjustment): 1. Separation drum current is lower than the adjustment standard at the maximum output from the high voltage power supply board - D. 2.
  • Page 607 SERVICE CALL CONDITIONS 12 February 1992 3.24 CODE #75 - V SENSOR ADJUSTMENT ERROR - Definition - When performing SP54 (auto Vsg/Vlg adjustment): 1. V sensor output (Vlg) is lower than the adjustment target (4.0 V) at the maximum output of the V sensor’s LED. 2.
  • Page 608 12 February 1992 SERVICE CALL CONDITIONS 3.26 CODE #81 - JOGGER HOME POSITION ERROR 1 - Definition - The jogger H.P. sensor remains deactivated (photo-transistor stays on) 0.8 seconds after the jogger fence started the returning. - Possible Cause - •...
  • Page 609 SERVICE CALL CONDITIONS 12 February 1992 3.29 CODE #92 - TOTAL COUNTER SHORT - Definition - The CPU always receives a total counter reed switch on signal. - Possible Cause - • Total counter defective 3.30 CODE #93 - INTERFACE SIGNAL ERROR - Definition - Main CPU does not receive a response signal from the I/O CPU.
  • Page 610 12 February 1992 SERVICE CALL CONDITIONS 3.33 CODE #dE - VL INITIAL DETECTION ERROR - Definition - The CPU cannot detect the proper Vref setting at the initial V pattern detection after performing SP66 (drum initialization). - Possible Cause - •...
  • Page 611 SERVICE CALL CONDITIONS 12 February 1992 3.34 BLINKING "CALL SERVICE" INDICATOR (WITHOUT ANY SC CODE #) - Definition - The possible problems are listed below. Check the actual causes through the data of SP7. 1: The PM counter (SP88) has reached the set PM interval (SP87). 2: The copier is operating under ID sensor abnormal condition.
  • Page 612 12 February 1992 ELECTRICAL COMPONENT DEFECTS 4. ELECTRICAL COMPONENT DEFECTS SENSORS Component Symptom Condition (Symbol) Main SW turns on Ready condition "By-pass feed" By-pass feed mode is indicator lights even if By-pass Open selected and "paper ≥0.9 Vcc the by-pass feed table feed table 104-B9 end"...
  • Page 613 ELECTRICAL COMPONENT DEFECTS 12 February 1992 Component Symptom Condition (Symbol) Main SW turns on Ready condition When the last paper was fed out from the lower tray, "Paper end" indicator lights for an Lower tray Open ≥0.9 Vcc instant. upper limit 104-B17 The lower tray lift motor does not rotate.
  • Page 614 12 February 1992 ELECTRICAL COMPONENT DEFECTS Component Symptom Condition (Symbol) Main SW turns on Ready condition "Paper jam C" Junction indicator starts gate Open — blinking when copies ≥2.5 Vcc (duplex 111-B9 are made in duplex machine mode. ≤0.5 V only) (S15) "Paper jam C"...
  • Page 615 ELECTRICAL COMPONENT DEFECTS 12 February 1992 Component Symptom Condition (Symbol) Main SW turns on Ready condition Duplex "Paper jam E" Open — entrance indicator starts ≥2.4 V — (duplex 111-A5 blinking when copies machine are made in duplex Shorted — ≤0.8 V only) (S22) mode.
  • Page 616 12 February 1992 ELECTRICAL COMPONENT DEFECTS SWITCHES Component CN No. Condition Symptom Upper paper size 104-B1 Open (SW1) The CPU cannot detect proper 104-B2 (SW2) paper size, and misfeeds may 104-B3 (SW3) occur when copies are made. 104-B4 Shorted (SW4) Lower paper size 104-B 9 Open...
  • Page 617 ELECTRICAL COMPONENT DEFECTS 12 February 1992 Component CN No. Condition Symptom The tray does not go down even if the tray down switch is pressed. Open After 30 seconds, "SC#46" is 105-A5 displayed. Shorted The tray goes down continuously. LCT cover -2 •...

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