Page 1 Cardinal Bird (Machine Code:A220) Service Manual – Insert Version – The A220 machine is based on the A175/A176/A177/A191/A192 Copier. Only the differences from the base copier are described in the following pages. Therefore, this documentation should be treated as an insert version of the base copier’s service manual. It should...
Page 2 INSERTION PROCEDURE OF SERVICE MANUAL 1. Replace the book spine tag with the new one. 2. Insert the A220 service manual after the A175/A176/A177/A191/A192 manual.
Page 3: Overall Machine Information
SECTION 1 OVERALL MACHINE INFORMATION...
Page 4: Specification
30 June 1997 SPECIFICATION 1. SPECIFICATION Configuration: Console Copy Process: Dry electrostatic transfer system Toner Supply Control: Fuzzy Control Photoconductor: OPC drum Originals: Sheet/Book Original Size: Maximum A3/11" x 17" Original Alignment: Left rear corner Copy Paper Size: Maximum A3/11" x 17" Minimum A5/5 "...
Page 5 Power Source: 115 V, 60 Hz, more than 20 A (for N.A) 220 ~ 240 V, 50 Hz/60 Hz, more than 10 A (for Europe and Asia) Power Consumption: A220 copier (average) Copier only Full system* Warm up 0.90 kVA 0.92 kVA...
Page 6 Zoom: From 50% to 200% in 1% steps Copying Speed: A4/LT (sideways) A3/DLT B4/LG 51 (A4) A220 copier 50 (LT) Warm-up Time: Less than 5 minutes (20°C) First Copy Time: 3.1 seconds (A4/81/2: x 11" sideways from the 1st feed station)
Page 7 Finisher (A608) • 3500-sheet Large capacity tray (A609) • Receiving Tray (A446-05) • Key Counter Bracket D (A509-03) • 20 bin sorter stapler (Floor type) with punch (A606-57, -67: Ricoh, -52, -62: NRG , -55: Savin) • Editing sheet (spare part)
Page 8 30 June 1997 MACHINE CONFIGURATION 2. MACHINE CONFIGURATION 2.1 COPIER OVERVIEW There are two types of mainframe. A220 - (10, 17, 20, 29:) copiers Three 550-sheet paper trays Optional 3,500-sheet large capacity tray (3,500) A220V500.img A220 - (22: china) copier...
Page 9: System Overview
MACHINE CONFIGURATION 30 June 1997 2.2 SYSTEM OVERVIEW DJF version (Mainframe type with dual job feeder and floor type sorter stapler. The mainframe in the illustration below is the two-tray version.) Dual job feeder (A610) 3,500-sheets Floor type sorter large capacity stapler (A60617, tray (A609) 22, 15) or Floor...
Page 10: Electrical Component Description
There are no 1,500-sheet LCT, 4th tray, tandem tray, 60 CPM, or 70 CPM versions. Refer to the A175/A176/A177/A191/A192 service manual. You can find those components, which are not used for the A220 copier because the notes for the various versions are indicated in the component name column.
Page 11: Detailed Section Descriptions
SECTION 2 DETAILED SECTION DESCRIPTIONS...
Page 12 30 June 1997 DEVELOPMENT UNIT 4. DEVELOPMENT UNIT Illustration Correction for the Paddle Roller (service manual page 2-46 and 2-48 of the A175/A176/A177/A191/A192 copiers) The illustration for the paddle roller on page 2-46 and 2-48 is incorrect. Please correct your service manuals, as shown below. This correction have been already issued for the A175/A176/A177/A191/A192 copiers.
Page 13: Paper Feed
A220D500.wmf This model has two or three drawer tray paper feed stations. The following table shows the configuration of each feed stations of the copiers. A220 - 10, 17, 20, 29 A220 - 22 Feed station three tray copiers two tray copiers...
Page 14: Paper Lift Mechanism
30 June 1997 PAPER FEED 6.8 PAPER LIFT MECHANISM A220D501.wmf When the tray is set in the machine, the machine detects this condition by using several detection methods as shown in the table: Feed station Tray set switch Paper size switch Tray set switch (not used for storage tray version) When the machine detects that the paper tray is set in the machine, the lift motor [A] rotates and the coupling gear [B] on the tray lift motor engages the...
Page 15 ENERGY STAR COMPLIANT MACHINES (North American version only) 30 June 1997 9. ENERGY STAR COMPLIANT MACHINES (North American version only) The lower power timer and the auto off periods have been revised. Lower power timer: The copier enters Low Power mode automatically at the selected time after your job is finished.
Page 16: Installation
SECTION 3 INSTALLATION...
Page 17: Accessory Check
30 June 1997 COPIER INSTALLATION 2. COPIER INSTALLATION 2.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: Description Q’ty 1. Sensor Cover ..............1 2. Flat Head Screw 4 x 6 ............1 3.
Page 18: Copier Installation Procedure
COPIER INSTALLATION 30 June 1997 2.2 COPIER INSTALLATION PROCEDURE NOTE: Since the installation procedure is not packed with the copier as an accessory, always bring this manual with you. A220I500.wmf Note: There are two types of bottom plate. One has two leveling feet [B] installed.
Page 19: Service Tables
SECTION 4 SERVICE TABLES...
Page 20: Service Remarks
30 June 1997 SERVICE REMARKS 1. SERVICE REMARKS 1.11 FUSING UNIT The following remark is not written in the A175/A176/A177/A191/A192 service manual. However, this remark has been added as a A175/A176/A177/A191/A192 copiers service remark by RTB. 5. Silicon oil may slightly soak into the surface of the hot roller during machine storage.
Page 21: Service Program Mode Table
A192 service manual. A175M500.img The A220-22 copier does not have the 3rd and 4th trays. The other A220 copiers do not have 4th tray. In the SP mode there are 3rd and 4th tray settings [A,B] because the software is the same as for the A175/A176/ A177/A191/A192 copiers.
Page 22 30 June 1997 SERVICE PROGRAM MODE SP ADJUSTMENT PAGE 7 A220M501.img Item Function Note Changes the toner supply level in auto Select "N" in the field. and detect toner supply mode. Default: Toner Supply level Toner Supply Coeffcient x 0.3 x 0.5 x 1.0 Max.
Page 23 (0.5 V/step). Default: 65.0 V Adjusts the transfer current for the 1st Standard Data: side (1 µA/step). 40 µA (A175, A220), 45 µA (others) Default: 40 µA (A175, A220) Enter the setting using the number keys, 50 µA (others) then touch...
Page 24 30 June 1997 SERVICE PROGRAM MODE SP SPECIAL FEATURES PAGE 1 A220M503.img Item Function Setting Default Selects copy count up or down. Count Up Count Down NOTE: The Default has been corrected for all the versions (A175/A176/A177/ A191/A192/A220).
Page 25 Enables automatic feed-out of the last Enable copy on the duplex tray without copying when an odd number of originals is set on the DJF feed tray. Disable NOTE: The Default has been corrected for all the versions (A175/ A176/A177/A191/A192/A220).
Page 26 The hot roller thermistor PM action has been revised. Please see the following table. *: These items have been revised for all the versions (A175/A176/A191/A192/ A220). NOTE 6: Fusing Section 1. Do not apply silicone oil on the hot roller thermistor.
Page 27: Replacements And Adjustments
SECTION 5 REPLACEMENTS AND ADJUSTMENTS...
Page 28: Cleaning Blade Replacement
A220R516.wmf A220R517.wmf *NOTE: The callouts ([E] and [F]) have been added to the illustration for all the versions (A175/A176/A177/A191/A192/A220). 1. Remove the OPC drum. (Refer to Drum Unit Removal and OPC Drum Replacement.) 2. Remove the cleaning blade [A] (2 screws).
Page 29: Pick-Off Pawl Replacement
30 June 1997 4.7 PICK-OFF PAWL REPLACEMENT A220R518.wmf *NOTE: Step1 has been added for all the versions (A175/A176/A177/A191/ A192/A220). 1. Remove the pick-off pawl bracket. (Refer to Cleaning Blade Replacement.) 2. Remove the bushing [A] (1 screw and retaining ring).
Page 30 6.18 NOTE for the PAPER FEED UNIT -OLD- Blue circle A220R519.wmf -OLD- 12.5 mm -NEW- 7.5 mm A220R520.wmf There are two types of the paper feed unit. One type has a blue circle on its rear side plate (A220 only).
Page 31: Fusing Thermistor Replacement
FUSING UNIT 30 June 1997 7.2 FUSING THERMISTOR REPLACEMENT A220R521.wmf A220R522.wmf 1. Remove the fusing unit. (Refer to Fusing Unit Removal.) 2. Remove the knob [A] (1 screw). 3. Remove the two screws fixing the fusing front cover [B]. 4. Pull the lever [C] then lower the cover [B] to unhook the fusing unit. 5.
Page 32: Fusing Pressure Adjustment
Front A220R523.wmf A220R524.wmf NIP BAND WIDTH ADJUSTMENT STANDARD: 8.1 ± 0.8 mm (A175, A220), 10.0 ± 0.5 (others) 1. Make a black copy (sky shot, A3/Double Letter paper). 2. As soon as the paper starts to exit, open the left door to stop the paper in the fusing unit.
Page 33 8.5 JOGGER MOTOR REPLACEMENT A220R503.wmf A220R504.wmf – A220 only – 1. Take out the duplex unit. (Refer to the duplex unit removal.) 2. Remove the duplex front cover (3 screws). 3. Slide the lever [A] to the rear then open the separation belt unit [B].
Page 34 30 June 1997 DUPLEX UNIT A220R505.wmf A220R506.wmf 9. Remove the positioning roller drive gear [A] (1 E-ring). 10. Remove the bushing [B] (1 E-ring). 11. Remove the positioning roller assembly [C]. 12. Remove the front jogger fence [D] and the rear jogger fence [E] (1 screw each).
Page 35 DUPLEX UNIT 30 June 1997 -OLD- -NEW- A220R507.wmf A220R500.wmf A220R508.wmf A220R509.wmf 14. Remove the drive wire stoppers [A]. NOTE: There are two types of the drive wire stoppers [A]. 15. Unhook the tension spring [B] and remove the drive wire [C]. 16.
Page 36 30 June 1997 DUPLEX UNIT -NEW- -OLD- A220R510.wmf A220R501.wmf -NEW- A220R511.wmf -OLD- A220R512.wmf A220R502.wmf - Jogger Drive Wire Installation - 1) Set the bead [A] which is closer to the red colored hook [B] in the hole [C] and install the stopper [D] (1 screw). 2) Round the drive wire twice around the drive motor pulley [E] as shown.
Page 37 DUPLEX UNIT 30 June 1997 A220R513.wmf A220R514.wmf A220R515.wmf NOTE: 1) Adjust the position of the stopper [A] so that the jogger fences [B] and side plate [C] are parrallel. 2) When installing the jogger fences, confirm if the two positioning pins [D] are correctly set in the two holes on the side fences after the screw is set.
Page 38 Point To Point Diagram (A175/A191/A192 4 Tray Version and A220 Version) Optic Thermistor Exposure CN1-3 120V 60HZ Fusing Fusing Lamps CN1-1 Thermistor Circuit (L2) Lens Lens Optics Auto Platen CN1-4 Lens Lens Platern Breaker Noise Horizontal Vertical Cooling Image Original...
Page 39: Prevention Of Physical Injury
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 40: Safety And Ecological Notes For Disposal
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate the toner cartridge or the used toner. Toner dust may ignite suddenly when exposed to open flame. 2. Dispose of used toner, developer, and organic photoconductor according to local regulations. (These are non-toxic supplies.) 3.
Page 41 SECTION 1 OVERALL MACHINE INFORMATION...
Page 42: Specification
15 July 1996 SPECIFICATION 1. SPECIFICATION Configuration: Console Copy Process: Dry electrostatic transfer system Toner Supply Control: Fuzzy Control Photoconductor: OPC drum Originals: Sheet/Book Original Size: Maximum A3/11" x 17" Original Alignment: Left rear corner Copy Paper Size: Maximum A3/11" x 17" Minimum A5/5 "...
Page 43 SPECIFICATION 15 July 1996 Power Source: 115 V, 60 Hz, more than 20 A (for N.A) 220 ~ 240 V, 50 Hz/60 Hz, more than 10 A (for Europe and Asia) Power Consumption: A175 copier Copier only Full system* Warm-up 1.20 kVA 1.22 kVA Stand-by...
Page 44 15 July 1996 SPECIFICATION Noise Emission: Sound Pressure Level: The measurements are made according to ISO7779 A175 copier Sound pressure level (The measurements are made according to ISO 7779 at the operator position.) Copier only Stand-by less than 34 dB (A) Copying less than 57 dB (A) (average) Sound power level...
Page 45 SPECIFICATION 15 July 1996 Dimensions: Width Depth Height Copier only 690 mm 690 mm 980 mm 27.2" 27.2" 38.6" Copier with dual job feeder, sorter stapler, and 1,659 mm 690 mm 1,116 mm 3,500-sheet large capacity tray 65.4" 27.2 mm" 43.9"...
Page 46 Platen cover (A528-04) • Dual job feeder (A610) • Recirculating document handler (A607) • 20 bin sorter stapler (Floor type) (A606-17: Ricoh, -22: NRG, -15: Savin, -26: Infotec) • Finisher (A608) • 3500-sheet Large capacity tray (A609) • Receiving Tray (A446-05) •...
Page 47: Machine Configuration
MACHINE CONFIGURATION 15 July 1996 2. MACHINE CONFIGURATION 2.1 COPIER OVERVIEW There are three types of mainframe. A175 copier Four 550-sheet paper trays Optional 3,500-sheet large capacity tray (3,500) A176V500.img A176/A177 (U.S.A., Asia) copiers Tandem paper tray (including two 500-sheet paper tray) One 550-sheet paper tray 1,500-sheet built-in large capacity tray...
Page 48 15 July 1996 MACHINE CONFIGURATION A191/A192 (Europe) copiers Tandem paper tray Three 550-sheet paper trays Optional 3,500-sheet large capacity tray 500 x 2 or 550 (3,500) A176V500.img...
Page 49 MACHINE CONFIGURATION 15 July 1996 2.2 SYSTEM OVERVIEW DJF version (Mainframe type (A175/A176/A177 (U.S.A.), A175/A191/A192 (EU)) with dual job feeder and floor type sorter stapler. The mainframe in the illustration below is the A176.) Dual job feeder (A610) 3,500-sheets Floor type large capacity sorter stapler tray (A609)
Page 50 15 July 1996 MACHINE CONFIGURATION MEMO...
Page 51: Copy Process Around The Drum
COPY PROCESS AROUND THE DRUM 15 July 1996 3. COPY PROCESS AROUND THE DRUM A176V504.wmf 1. OPC DRUM The organic photo conductive (OPC) drum (100 mm diameter) has high resistance in the dark and low resistance under light. 2. DRUM CHARGE In the dark, the charge corona unit gives a uniform negative charge to the OPC drum.
Page 52 15 July 1996 COPY PROCESS AROUND THE DRUM 5. DRUM POTENTIAL SENSOR The drum potential sensor detects the electric potential on the drum to compensate image processing elements. 6. DEVELOPMENT Positively charged toner is attracted to the negatively charged areas of the drum, thus developing the latent image.
Page 53: Mechanical Component Layout
MECHANICAL COMPONENT LAYOUT 15 July 1996 4. MECHANICAL COMPONENT LAYOUT A176V505.wmf 1-12...
Page 54 15 July 1996 MECHANICAL COMPONENT LAYOUT 1. 3rd Mirror 22. Registration Rollers 2. 2nd Mirror 23. Transfer Belt 3. 1st Mirror 24. Vertical Transport Rollers 4. Exposure Lamp 25. Tandem Tray 550-sheet Tray 5. Lens 26. Universal Tray 6. Cleaning Brush 27.
Page 55: Drive Layout
DRIVE LAYOUT 15 July 1996 5. DRIVE LAYOUT A176V506.wmf Main Motor 1. OPC Drum 2. Scanner Unit Scanner Drive Motor 3. Transfer Belt Unit Fusing/Duplex Drive Motor 4. Paper Exit Unit Paper Feed Motor 5. Fusing Unit Toner Collection Motor 6.
Page 56: Paper Path
15 July 1996 PAPER PATH 6. PAPER PATH 6.1 STANDARD COPYING A176V507.wmf Paper feed begins from the exterior LCT, by-pass feed table or paper feed stations in the paper tray unit. The copy paper then follows one of two paths inside the copier.
Page 57 PAPER PATH 15 July 1996 6.2 MULTIPLE 2-SIDED COPYING a. Front Side A176V508.wmf b. Rear Side A176V509.wmf In this mode the junction gate [A] directs sheets exiting the fusing unit to the duplex tray entrance. After that, all sheets follow the path through the duplex entrance rollers [B].
Page 58: Electrical Component Description
15 July 1996 ELECTRICAL COMPONENT DESCRIPTION 7. ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the attached Point to Point for symbols and index numbers. Symbol Name Function Index No. Motors Scanner Drive Drives the 1st and 2nd scanners (dc servo).
Page 59 ELECTRICAL COMPONENT DESCRIPTION 15 July 1996 Symbol Name Function Index No. AC Drive Cooling Fan Remove heat from around the AC (60/70 CPM version only) drive unit. Optic Cooling Fan-2 Remove heat from the optic unit. (60/70 CPM version only) Duplex Cooling Fan Cools the paper on the duplex tray to *143A, B...
Page 60 15 July 1996 ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. Toner Collection Bottle Detects if the toner collection bottle is set or not. Lower Front Door Safety Detects if the front door is open or not. 3rd Tray Set Detects if the 3rd tray is set or not.
Page 61 ELECTRICAL COMPONENT DESCRIPTION 15 July 1996 Symbol Name Function Index No. 3rd Separation Roller Controls the up-down movement of SOL13 the separation roller in the 3rd feed station. 4th Pick-up Controls the up-down movement of SOL14 (4 Tray version only) the pick-up roller in the 4th feed station.
Page 62 15 July 1996 ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. Fusing Exit Detects misfeeds. Paper Guide Detects misfeeds. Auto Image Density Senses the background density of the original. Original Length-1 Detects original length. Original Length-2 Detects original length. Original Width Detects original width.
Page 63 ELECTRICAL COMPONENT DESCRIPTION 15 July 1996 Symbol Name Function Index No. 3rd Paper Feed Controls the 3rd paper feed clutch off/on timing and the 3rd pick-up solenoid off timing. 2nd Paper Feed Controls the 2nd paper feed clutch off/on timing and the 2nd pick-up solenoid off timing.
Page 64 15 July 1996 ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. PCB6 DC Power Supply Unit Provides DC power. PCB7 Guidance Controls the guidance display. Operation Panel Controls the LED matrix, and monitors PCB8 the key matrix. Lamps Exposure Applies high intensity light to the original for exposure.
Page 65 ELECTRICAL COMPONENT DESCRIPTION 15 July 1996 Symbol Name Function Index No. Total Counter Keeps track of the total number of copies made. Noise Filter Removes electrical noise. Circuit Breaker Provides back-up high current protection for the electrical components. Lightening Arrestor Removes current surges from the AC input lines.
Page 66 SECTION 2 DETAILED SECTION DESCRIPTIONS...
Page 67: Process Control
15 July 1996 PROCESS CONTROL 1. PROCESS CONTROL 1.1 OVERVIEW Original Scale Image Density Control ADS Pattern (Fuzzy Control) Pattern Latent Image Control Pattern Pattern Pattern Original Exposure Glass Lamp Voltage Latent image Control Exposure Control Charge Control Grid Voltage Erase Lamp Drum Potential Sensor Toner Supply On time...
Page 68 PROCESS CONTROL 15 July 1996 1.1.1 Latent Image Control Exposure Charge Black White Erase Potential Sensor Drum A176D501.wmf The figure shows the changes of the drum potential during the copy process. The drum potential just after charging the drum. (Dark Potential): The drum potential just after exposing the black pattern (V pattern)
Page 69 15 July 1996 PROCESS CONTROL 1.1.2 Image Density Control Image density is controlled by the following sensors: Toner density sensor (TD sensor) Image density sensor (ID sensor) Data from the TD sensor is used to keep the toner concentration in the developer at a constant level.
Page 70 PROCESS CONTROL 15 July 1996 1.2 PROCESS CONTROL DATA INITIAL SETTING The following flow chart shows all the steps that will be performed whenever the machine is turned on while the hot roller temperature is below 100°C. This initializes all the process control settings. Main SW On (Fusing Temp.
Page 71 15 July 1996 PROCESS CONTROL 1.3 LATENT IMAGE CONTROL 1.3.1 Drum Potential Sensor Calibration Case Sensor Output Amp. Drum A176D503.wmf Main PCB A176D502.wmf The drum potential sensor [A] is located just above the development unit. The sensor has a detector which detects the strength of the electric field from the electric potential on the drum.
Page 72 PROCESS CONTROL 15 July 1996 1.3.2 Drum Conditioning When the fusing temperature reaches 180°C, the machine starts the drum conditioning process. In this mode, the main motor, main charge corona, erase lamp and development bias are activated for about 30 seconds and drum sensitivity and residual voltage (V ) are stabilized, as in continuous copy runs.
Page 73 15 July 1996 PROCESS CONTROL 1.3.5 V Correction Exposure Pattern Glass [–V] A176D505.wmf Compensated Drum Potential –770 After many copies New Drum Dark Original Density Light A176D506.wmf The drum potential just after the black pattern (V Pattern) is exposed (V Dark Potential) tends to lower during drum life due to a decrease in the drum’s capacity to carry a charge.
Page 74 PROCESS CONTROL 15 July 1996 1.3.6 V Correction Exposure Glass [–V] Pattern Only V A176D505-2.wmf Compensated and V Drum Compensated Potential New Drum –770 –140 Dark Original Density Light A176D507.wmf Dirty optics and/or exposure lamp deterioration decreases the intensity of the light that reaches the drum.
Page 75 15 July 1996 PROCESS CONTROL 1.3.7 V Correction [–V] Development Bias (V Drum Potential and V Compensated New Drum –770 –140 Dark Original Density Light A176D508.wmf Potentials (V ) are monitored by the potential sensor. (This is done only when the fusing temperature is less than 100°C after the machine is turned on.) During the check cycle, the V and V...
Page 76 PROCESS CONTROL 15 July 1996 1.3.8 Initial Setting Sequence The following graph shows the sequence of events during process control data initial setting. for the purpose of ADS sensor correction Exposure Lamp New V New V Potential New V Sensor Output 1.
Page 77 15 July 1996 PROCESS CONTROL 3. V and V corrections Using the calculated V and V data, V and V patterns are GRID LAMP developed again and the new V , and V data are detected. If both V and V data are within specifications, the new V GRID LAMP...
Page 78: Image Density Control
PROCESS CONTROL 15 July 1996 1.4 IMAGE DENSITY CONTROL 1.4.1 Toner Density Sensor A: V (Gain data) is high. B: V is within the specification. low. C: V (Gain data) is Main PCB (12 V) Sensor Gain IN x Gain = 12 x Sensor Output...
Page 79 15 July 1996 PROCESS CONTROL By selecting the proper gain data, the sensor output is set within the targeted = 2.5 ± 0.1 V). Now, the sensor characteristic is control level (V illustrated by curve B and the TD sensor initial setting is completed. The selected gain data is stored in memory, and V from the auto gain control circuit stays constant during the toner sensor detection cycle.
Page 80 PROCESS CONTROL 15 July 1996 <Toner Supply Clutch on Time> To stabilize toner concentration, toner supply amount (toner supply clutch on time) is controlled by referring to V and V The toner supply amount is calculated at every copy. The toner supply amount is determined by using the following factors.
Page 81 15 July 1996 PROCESS CONTROL 1.4.2 Image Density Sensor Detection Drum bias A176D514.wmf A176D513.wmf and V are checked by the ID sensor [A]. The ID sensor is located underneath the drum cleaning section. There is no ID sensor pattern in the optics, however, a pattern image is made on the OPC drum by the charge corona unit [B] and the erase lamp [C].
Page 82 PROCESS CONTROL 15 July 1996 –700 V Potential Sensor Detection ID Sensor –300 Bias Level +300 (V) 4.0 V ID Sensor A176D517.wmf Output A176D516.wmf While developing the ID sensor pattern, ID sensor bias is applied. ID sensor bias is determined during process control data initial setting as follows: Apply charge while grid voltage is –700 V to create the ID sensor pattern.
Page 83 15 July 1996 PROCESS CONTROL 1.4.3 Sensor Abnormal Conditions a. ID sensor (V ) abnormal Whenever V falls under 2.5 V or V rises over 2.5 V, the CPU fixes the data and toner concentration is controlled only by using TD sensor output.
Page 84 DRUM UNIT 15 July 1996 2. DRUM UNIT 2.1 OVERVIEW 7. 8 A176D518.wmf The drum unit consists of the components as shown in the above illustration. An organic photoconductor drum (diameter: 100 mm) is used for this model. 1. OPC Drum 9.
Page 85: Opc Drum Characteristics
15 July 1996 DRUM UNIT 2.2 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 86: Drum Charge
DRUM UNIT 15 July 1996 2.3 DRUM CHARGE 2.3.1 Overview A176D519.wmf 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 (330 mm/s.). The stainless steel grid plate makes the corona charge uniform and controls the amount of negative charge on the drum surface by applying the negative grid bias voltage.
Page 87 15 July 1996 DRUM UNIT 2.3.2 Air Flow Around the Drum A176D520.wmf The exhaust fan [A] located above the fusing unit provides an air flow to the charge corona unit to prevent uneven built-up of negative ions that can cause an uneven charge of the drum surface as shown.
Page 88 DRUM UNIT 15 July 1996 2.3.3 Charge Wire Cleaning Mechanism A176D521.wmf The flow of air around the charge corona wire may deposit toner particles on the corona wires. These particles may interfere with charging and cause low density bands on copies. The wire cleaner pads [A] automatically clean the wires to prevent such a problem.
Page 89 15 July 1996 DRUM UNIT 2.4 ERASE 2.4.1 Overview A176D522.wmf 3.5 ± 2.5 mm : Lead edge erase margin : Side erase margin total of both sides 3 mm or less Lo: Original width Lc: Charged width of drum : Lead edge erase Es: Side erase The erase lamp unit consists of a line of 123 LEDs extending across the full width of the drum, the width of each being about 2.5 mm.
Page 90 DRUM UNIT 15 July 1996 2.4.2 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 91 15 July 1996 DRUM UNIT 2.5 CLEANING 2.5.1 Overview A176D523.wmf 4 mm A176D524.wmf This copier uses the counter blade system for drum cleaning. The blade [A] is angled against drum rotation. This counter blade system has the following advantages: • Less wearing of the cleaning blade edge.
Page 92 DRUM UNIT 15 July 1996 2.5.2 Drive Mechanism A176D525.wmf The drive force from the main motor is transmitted to the cleaning unit drive gear via the timing belt [A] and the cleaning unit coupling [B]. The cleaning unit drive gear [C] then transmits the force to the front side through the cleaning brush [D].
Page 93 15 July 1996 DRUM UNIT 2.5.3 Cleaning Blade Pressure Mechanism and Side-to-Side Movement A176D526.wmf The spring [A] always pushes the cleaning blade against the OPC drum. The cleaning blade pressure can be manually released by pushing up the release lever [B]. To prevent cleaning blade deformation during the transportation, the release lever is locked in the pressure release (upper) position.
Page 94 DRUM UNIT 15 July 1996 2.5.4 Toner Collection Mechanism A176D527.wmf Toner collected by the cleaning unit is transported to the toner collection bottle [A] through the toner collection tubes. Three helical coils are used for toner transport. One coil [B] is driven by the main motor via drive belts and the other coil [C] is driven by an independent toner collection drive motor [D].
Page 95 15 July 1996 DRUM UNIT A176D528.wmf A176D529.wmf 2.5.5 Pick-off mechanism The pick-off pawls are always in contact with the drum surface with weak spring pressure. They move side to side during the copy cycle. This movement is made via a shaft [A] and an eccentric cam [B]. 2.5.6 Toner Collection Bottle Set Detection The toner collection bottle set switch [C] prohibits machine operation by indicating SC343 while the toner collection bottle is not set.
Page 96 DRUM UNIT 15 July 1996 2.6 QUENCHING A176D530.wmf In preparation for the next copy cycle, light from the quenching lamp (QL) [A] neutralizes any charge remaining on the drum. The quenching lamp consists of a line of 16 LEDs extending across the full width of the drum.
Page 97 15 July 1996 OPTICS 3. OPTICS 3.1 OVERVIEW A176D532.wmf The optics unit reflects an image of the original on the exposure glass onto the OPC drum. This forms a latent electrical image of the original. On this model a halogen lamp (85 V 200 W: A175 copier, 225 W: others) is used for the exposure lamp [A].
Page 98: Scanner Drive
OPTICS 15 July 1996 3.2 SCANNER DRIVE A176D533.wmf A dc servo motor is used as the scanner drive motor [A]. Scanner drive speed is 330 mm/s (A175 coper) or 430 mm/s (others). during scanning, and 1,950 mm/s (50/51, 60 CPM versions) or 2,670 mm/s (70 CPM version) when the scanner goes back.
Page 99 15 July 1996 OPTICS 3.3 VERTICAL LENS DRIVE Enlarge Reduce HP (100%) A176D534.wmf (Enlarge → HP) (Reduce → HP) (Enlarge → Enlarge) (Reduce → Reduce) (Enlarge → Reduce) (Reduce → Enlarge) steps A176D535.wmf The lens vertical drive motor [A] changes the lens vertical position in accordance with the selected reproduction ratio.
Page 100 OPTICS 15 July 1996 3.4 HORIZONTAL LENS DRIVE A176D536.wmf steps Enlarge Reduce A176D537.wmf The original horizontal position on the exposure glass varies depending on the mode (such as platen, DJF and RDH modes) for easy original handling. However, the center is the standard position for paper feed. Therefore, the lens horizontal position has to be changed according to paper size, reproduction ratio, original feed modes and the edit modes (centering, margin adjust, etc.).
Page 101 15 July 1996 OPTICS 3.5 HORIZONTAL LENS POSITIONING 3.5.1 For Original Position Platen Copy Paper (Center) Horizontal Lens Position A176D539.wmf A176D538.wmf There are three standard original positions for the platen, DJF and RDH modes. In platen mode, the original is aligned with both the rear [A] and the left [B] original scales (rear left corner [C] is the standard position).
Page 102 OPTICS 15 July 1996 3.5.3 For Reproduction Ratio Original Rear Edge Original 100% Copy Paper 200% 200% 100% 3rd Scanner Position A176D541.wmf When the reproduction ratio is changed, the vertical position of the lens is changed. At the same time, the total focal length has to be changed to adjust the image focusing.
Page 103 15 July 1996 OPTICS 3.6 3RD SCANNER DRIVE A176D542.wmf (Initialize) (Reduce/Enlarge → HP) (Reduce/Enlarge → Reduce/Enlarge) (Reduce/Enlarge → Reduce/Enlarge) (Reduce/Enlarge → Enlarge/Reduce) 40 steps 40 steps A176D543.wmf To compensate the focus for reproduction and lens position changes, the 3rd scanner (4th and 5th mirrors) position is changed. A stepping motor [A] (approx.
Page 104 OPTICS 15 July 1996 3.7 OPTICS CONTROL CIRCUIT Sensors Encoder Data Scanner Drive Main Optics Control Board Control Horizontal Lens Board Drive Vertical Lens Optics Drive Control 3rd Scanner Main Drive Optic Cooling Exposure Lamp Optic Thermistor AC Drive Board A176D544.wmf The optic control board communicates with the main board through a data bus.
Page 105: Automatic Image Density Control System (Ads)
15 July 1996 OPTICS 3.8 AUTOMATIC IMAGE DENSITY CONTROL SYSTEM (ADS) A176D545.wmf In ADS mode the original background density is sensed by the ADS sensor [A] and the main CPU determines an appropriate development bias voltage for the original to prevent dirty backgrounds from appearing on copies. The ADS sensor board is mounted on the rear side of the optics side plate.
Page 106 OPTICS 15 July 1996 90 mm (mm) M = 1.0 (m = 50 ~ 100) 20 mm (m = 101 ~ 200) 8.25 x 100 (mm) m: reproduction ratio (50 ~ 200) Original Sensor Voltage Output Peak hold A176D546.wmf For the first scanning of an original in ADS mode, the CPU starts sampling of the ADS sensor output while exposing the ADS pattern at the scanner home position.
Page 107 15 July 1996 OPTICS 3.9 MANUAL IMAGE DENSITY CONTROL When the image density is set manually, the voltage applied to the exposure lamp changes as shown in the table below. Lighter Darker –90 Dev. Bias –60 Voltage (negative) +4.5 LAMP +3.0 LAMP +0.5...
Page 108 OPTICS 15 July 1996 3.10 UNEVEN LIGHT INTENSITY CORRECTION A176D548.wmf exposure intensity original illumination distribution Shading plate A176D549.wmf The entire exposure lamp surface is frosted to ensure even exposure. To compensate for reduced light at the edge of the lens, a shading plate is placed in front of the lens.
Page 109: Original Size Detection In Platen Mode
15 July 1996 OPTICS 3.11 ORIGINAL SIZE DETECTION IN PLATEN MODE A176D551.wmf A176D550.wmf There are three reflective sensors (APS sensors) in the optics cavity for the original size detection. Original width Sensor [A] is used for sensing the original width and Original Length Sensor-1 [B] and Original Length Sensor-2 [C] sense the original length.
Page 110 OPTICS 15 July 1996 A176D552.wmf Original Size Length Sensor 1 Length Sensor 2 Width Sensor A4/A3 version LT/DLT version 11 x 7 10 x 14 — x 14 — — 8 x 13 A4-L x 11 B5-L — A5-L B6-L —...
Page 111 15 July 1996 OPTICS 3.12 HALF TONE MODE A176D553.wmf This machine has a half tone mode. In this mode, which can be select in the operation panel, the charge corona grid voltage is decreased by 200 V but the charge corona grid voltage might blank out low density areas of the original.
Page 112 DEVELOPMENT 15 July 1996 4. DEVELOPMENT 4.1 OVERVIEW A176D554.wmf This copier uses a double roller (diameter 20 mm each) development (DRD) system. This system differs from single roller development systems in that (1) it develops the image in a narrower area, (2) it develops the image twice, and (3) the relative speed of each development roller against the drum is reduced.
Page 113: Drive Mechanism
15 July 1996 DEVELOPMENT 4.2 DRIVE MECHANISM A176D555.wmf The gears of the development unit are driven by the development drive gear [A] when the development motor [B] (dc servomotor) turns. The gears of the toner hopper are driven by the toner supply roller drive gear [C] when the toner supply clutch [D] activates.
Page 114 DEVELOPMENT 15 July 1996 4.3 CROSSMIXING A176D556.wmf A176D557.wmf This copier uses a standard cross-mixing mechanism to keep the toner and developer evenly mixed. It also helps agitate the developer to prevent developer clumps from forming and helps create the triboelectric charge. The developer on the turning development rollers [A] is split into two parts by the doctor blade [B].
Page 115: Development Bias
15 July 1996 DEVELOPMENT 4.4 DEVELOPMENT BIAS 4.4.1 Overview A176D558.wmf The high voltage control Board [A] applies the negative development bias to the lower sleeve roller through the receptacle [B] and the lower sleeve roller shaft [C]. Then the bias is applied to the upper sleeve roller through the rear sleeve roller holder made of conductive resin.
Page 116 DEVELOPMENT 15 July 1996 4.4.2 Bias Control In Copy Cycle The bias output is determined by five factors. The total bias is described as; ADS Mode: Manual ID Mode: Total bias Base bias ADS Compensation User Tool mode ID Selection Compensation : Magnification Compensation : Manual ID Selection Compensation 1) Base Bias (V...
Page 117 15 July 1996 DEVELOPMENT 3) Manual ID Selection Position Compensation (V According to the manual ID selection position, the bias is compensated as follows: Lighter Darker +4.5 LAMP +3.0 LAMP +0.5 LAMP Exposure → LAMP Lamp Voltage –1.5 LAMP –3.5 LAMP –5.5 LAMP...
Page 118 DEVELOPMENT 15 July 1996 5) Magnification Compensation (V is determined by the selected reproduction ratio as follows: –100 Dev. Bias Voltage –60 (negative) –40 –30 –20 123% 142% 161% 116% 115% 122% 141% 160% A176D563.wmf 4.4.3 Bias Control Out of Copy Cycle To hold the toner on the sleeve rollers while the development sleeve rollers are rotating without image development, a constant –300 V bias is applied.
Page 119 15 July 1996 DEVELOPMENT 4.4.4 ID Sensor Pattern Bias –700 V Potential Sensor Detection ID Sensor Bias Level –300 +300 (V) 4.0 V ID Sensor A172D565.wmf Output A176D564.wmf While developing the ID sensor pattern, ID sensor bias is applied. ID sensor bias is determined during process control initial setting as follows: A charge is applied while grid voltage is –700 V to create the ID sensor pattern.
Page 120: Toner Supply
DEVELOPMENT 15 July 1996 4.5 TONER SUPPLY 4.5.1 Toner Supply Mechanism A176D566.wmf When the toner supply clutch [A] turns on, the agitator [B] moves the toner from front to rear and sends the toner to the toner supply roller. The toner supply clutch [A] located inside the development motor [C] applies the rotation from the development motor to the toner supply roller gear [D], which drives the agitator gear [E].
Page 121 15 July 1996 DEVELOPMENT 4.5.2 Toner End Detection A176D567.wmf The toner end sensor [A] detects if sufficient toner remains in the toner hopper or not. The toner end sensor monitors toner end condition once when the toner supply clutch turns on. When there is little toner inside the toner hopper and toner pressure on the toner end sensor becomes low, the toner end sensor outputs a pulse signal for each (one detection per one copy).
Page 122 DEVELOPMENT 15 July 1996 4.5.3 Toner Supply Control By using an SP mode ( SP Adjustment - PAGE 7), the following 3 kinds of toner supply controls can be selected. • Auto Process Control Mode • Detect Mode • Fixed Mode 1) Auto Process Control Mode Originals have various image proportions and image densities.
Page 123 15 July 1996 DEVELOPMENT Fuzzy Control 2 The image on the OPC drum changes due to variations in toner chargeability (influenced by the environment) even if toner concentration is constant. The ID sensor directly checks the image on the OPC drum and shifts the V data under fuzzy control to keep the image on the OPC drum constant.
Page 124 DEVELOPMENT 15 July 1996 4.5.4 Bottle Drive Mechanism A176D568.wmf For easy access, the toner bottle is just inside the front cover. The bottle is positioned horizontally. The bottle drive mechanism transports toner from the bottle to the toner hopper [A]. A worm gear [B] on the bottle drive motor drives this mechanism. The toner bottle has a spiral groove [C] that helps move the toner to the toner hopper.
Page 125: Image Transfer
15 July 1996 IMAGE TRANSFER 5. IMAGE TRANSFER 5.1 PRE-TRANSFER LAMP A176D569.wmf The pre-transfer lamp [A] located in the drum unit is used to prevent incomplete toner transfer. 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.
Page 126 IMAGE TRANSFER 15 July 1996 5.2 IMAGE TRANSFER AND PAPER SEPARATION OVERVIEW A176D570.wmf This model uses a unique transfer belt unit instead of the transfer and separation corona unit. The transfer belt unit consists of the following parts: [A] Transfer belt A belt (length: 321 mm) with high electrical resistance which holds a high negative electrical potential and attracts the toner on the OPC drum onto the paper.
Page 127: Image Transfer And Paper Separation Mechanism
15 July 1996 IMAGE TRANSFER 5.3 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM The registration rollers [A] starts feeding the paper [B] to the gap between the OPC drum [C] and the transfer belt [D] in proper timing. A176D571.wmf Immediately when the leading edge of the paper reaches the gap between the transfer belt and the OPC drum, the transfer...
Page 128 IMAGE TRANSFER 15 July 1996 After the image transfer is completed, the charge on the transfer belt holds the paper to the transfer belt. After separating the paper from the transfer belt, the transfer belt is discharged by the discharge plate [A]. A176D574.wmf The transfer power pack [B] inside the transfer belt unit...
Page 129: Transfer Belt Unit Lift Mechanism
15 July 1996 IMAGE TRANSFER 5.4 TRANSFER BELT UNIT LIFT MECHANISM A176D576.wmf The transfer belt lift solenoid [A] located inside the transfer belt unit turns on to raise the transfer belt to contact the OPC drum at the appropriate timing. The front lever [B] and the rear lever [C] are connected to the solenoid by links [D] and push up the stays [E] when the solenoid turns on.
Page 130: Paper Transportation And Belt Drive Mechanism
IMAGE TRANSFER 15 July 1996 5.5 PAPER TRANSPORTATION AND BELT DRIVE MECHANISM A176D577.wmf A176D578.wmf The transfer belt is driven by the main drive motor [A] through belt and gears. Since the transfer belt electrically attracts the paper [B], the transport fan is not required.
Page 131: Transfer Belt Cleaning Mechanism
15 July 1996 IMAGE TRANSFER 5.6 TRANSFER BELT CLEANING MECHANISM A176D579.wmf A176D580.wmf A176D581.wmf Some toner may adhere to transfer belt when paper jams occur, or when the by-pass feed table side fences are set in the wrong position causing the erase lamp to miss some toner.
Page 132: Toner Collection Mechanism
IMAGE TRANSFER 15 July 1996 5.7 TONER COLLECTION MECHANISM A176D582.wmf Through idle gears [A], transfer belt drive is transmitted to the toner collection coil [B]. The toner collection coil transports the collected toner to the toner collection bottle. See section 2.2.5 for details. 2-66...
Page 133: Paper Feed
15 July 1996 PAPER FEED 6. PAPER FEED 6.1 OVERVIEW A176D583.wmf This model has three or four drawer tray paper feed stations. The following table shows the configuration of each feed stations of the copiers. Feed station A175 copier A176/177 copiers A191/A192 copiers 550 sheets tray 500 + 500 sheets...
Page 134: Frr Feed System
PAPER FEED 15 July 1996 6.2 FRR FEED SYSTEM A184D584.img This copier uses an FRR paper feed system using three rollers. 6.2.1 Pick-up Roller The pick-up roller [A] is not in contact with the paper stack before it starts feeding paper. Shortly after the Start key is pressed, the pick-up roller drops down and feeds the top sheet between the feed [B] and the separation rollers [C].
Page 135 15 July 1996 PAPER FEED A76D585.img 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 than F1.
Page 136: Slip Clutch Mechanism
PAPER FEED 15 July 1996 6.3 SLIP CLUTCH MECHANISM A176D586.wmf A176D587.img The slip clutch [A] consists of the input hub [B] and the output hub [C] which is the case of the clutch as well. The magnetic ring [D] and the steel spacers [E] are fitted onto the input hub.
Page 137 15 July 1996 PAPER FEED 6.4 FRR FEED DRIVE MECHANISM A176D588.wmf A176D589.wmf The rotation of the paper feed motor [A] is transmitted to the gear [B] via the timing belt [C], and then transmitted to the separation roller via the feed clutch gear [D], gear [E], gear [F] and gear [G].
Page 138 PAPER FEED 15 July 1996 A176D589-2.wmf A176D590.wmf When the paper feed station is selected and the start key is pressed, the feed clutch [A], separation roller solenoid [B], and the pick-up solenoid [C] turn on at once. When the feed clutch [A] activates to rotate the feed roller [D], the feed roller and the pick-up roller [E] turn together because they are linked by the idle gear [F].
Page 139: Separation Roller Release Mechanism
15 July 1996 PAPER FEED 6.5 SEPARATION ROLLER RELEASE MECHANISM A176D591.wmf In this model, the separation roller [A] is normally away from the feed roller [B]. When the paper feed station is selected, the separation roller solenoid [C] contacts the separation roller to the feed roller as explained in the previous two pages.
Page 140 PAPER FEED 15 July 1996 6.6 PAPER RETURN MECHANISM A176D592.wmf 3 mm A176D593.wmf When the paper feed clutch [A] activates and the feed roller drive shaft [B] rotates, the lever [C] rotates together with the shaft. However, the lever is immediately stopped by the stopper [D].
Page 141 15 July 1996 PAPER FEED 6.7 PAPER SKEW PREVENTION MECHANISM A176D594.img A176D595.wmf In this model, paper corner holders [A] are not used to facilitate paper loading. Instead of the corner holders, both paper press arms [B] press down both paper side edges, especially in the case of paper with a face curl. This helps to keep paper from being guided by the tray side fences to prevent paper skew or jam.
Page 142 PAPER FEED 15 July 1996 6.8 PAPER LIFT MECHANISM A176D596.wmf When the tray is set in the machine, the machine detects this condition by using several detection methods as shown in the table: Feed station A175 copier A176/A177 copiers A191/A192 copiers Tray set switch Tray set signal through Tray set signal through...
Page 143 15 July 1996 PAPER FEED A176D597.wmf A176D598.wmf When the lift motor turns on, the pick-up solenoid [A] activates to lower the pick-up roller [B]. When the top sheet of paper reaches the proper paper feed level, the paper pushes up the pick-up roller and the actuator [C] on the pick-up roller supporter [D] activates the lift sensor [E] to stop the lift motor.
Page 144 PAPER FEED 15 July 1996 6.9 PAPER NEAR END/PAPER END DETECTION A176D599.wmf A176D600.wmf A feeler [A] on the lift arm shaft rotates counterclockwise in accordance with the change of the top paper level. When almost 50 sheets are left on the tray, the feeler activate the paper near end sensor [B] and informs the copier CPU of the paper near end condition.
Page 145: Tandem Feed Tray
15 July 1996 PAPER FEED 6.10 TANDEM FEED TRAY (A176/A177/A191/A192 Copiers Only) 6.10.1 OVERVIEW A176D601.wmf A176D602.img 500 sheets of paper can be set in each of the left [A] and right trays [B]. Paper is fed from the right tray. When the paper in the right tray runs out, the paper in the left tray is automatically transported to the right tray.
Page 146 PAPER FEED 15 July 1996 6.10.2 Fences Drive Mechanism A176D603.wmf A176D604.wmf The side fences [A] of the right tray are normally closed. They open only when paper in the left tray is transported to the right tray. The side fences are driven by the side fence drive motor [B] (stepping motor). When the paper loaded in the left tray is transported to the right tray, the side fence drive motor turns counterclockwise to open the side fences until the side fence positioning sensor [C] is activated.
Page 147 15 July 1996 PAPER FEED 6.10.3 Rear Fence Drive Mechanism A176D605.wmf When the paper end sensor [A] in the left tray detects paper and the paper end sensor in the right tray detects the paper end condition, the rear fence drive motor [B] (dc motor) in the left tray rotates counterclockwise to drive the rear fence [C] to push the paper into the right tray.
Page 148 PAPER FEED 15 July 1996 6.10.4 Tray Lock Mechanism A176D606.wmf Normally the left tray lock lever [A] in the right tray [B] fits in the hole [C] in the left tray [D]. During copying, if there is no paper in the left tray, the tray lock solenoid [E] turns on to release the tray lock lever so that the left tray can be separated from the right tray.
Page 149: Paper Size Detection
15 July 1996 PAPER FEED 6.11 PAPER SIZE DETECTION A176D607.img L: Lengthwise Paper size Actuate..0 S: Sideways De-actuate..1 A4/A3 LT/DLT A176D608.wmf Version version 01111 A3-L 11 x 17-L 00111 B4-L x 14-L 10011 A4-L x 11-L 01001 A4-S x 11-S 00100 x 13 00010...
Page 150: Vertical Transport Mechanism
PAPER FEED 15 July 1996 6.12 VERTICAL TRANSPORT MECHANISM A176D610.wmf The vertical transport rollers [A] in each feed unit is driven by the paper feed motor. The vertical transport rollers and the driven vertical transport rollers [B], on the upper and the lower vertical guide plates, transport the paper from each feed unit to the registration roller.
Page 151 15 July 1996 PAPER FEED 6.13 TRAY POSITIONING MECHANISM A176D611.wmf A176D612.wmf - Tray Lock Mechanism - When the feed tray is set in the paper feed unit, the lock lever [A] drops behind the lock plate [B] on the Accuride support bracket to lock the tray in the proper position.
Page 152 PAPER FEED 15 July 1996 A176D613.wmf - Side-to-side Positioning Mechanism (except for tandem and built-in LCT trays) - Side plates [A] are fixed on the positioning plate [B]. By moving the positioning plate (fixed by four screws), the paper position can be changed to adjust the side-to-side registration.
Page 153 15 July 1996 PAPER FEED 6.14 BUILT IN LCT 6.14.1 Paper Tray Lift Mechanism A176D614.img Drive from the reversible LCT motor [A] is transmitted through a worm gear [B] to the drive pulley shaft [C]. The tray wires [D] are fixed in the slots [E] at the ends of the tray support rods [F] and [G].
Page 154 PAPER FEED 15 July 1996 6.14.2 Tray Lock Mechanism A176D615.img When the tray starts moving up, the tray lock lever [A] drops in the hole on the base plate to engage the stopper [B], locking the tray in position. This prevents the tray from being pulled out while in the up position.
Page 155: By-Pass Feed Table
15 July 1996 PAPER FEED 6.15 BY-PASS FEED TABLE 6.15.1 Feed Mechanism/Paper End Detection A176D617.wmf A176D616.wmf The by-pass feed table uses the FRR feed system. The by-pass feed motor [A], pick-up solenoid [B], and by-pass feed clutch [C] control paper feeding from the by-pass feed table.
Page 156 PAPER FEED 15 July 1996 6.15.2 Table Open/Close Detection A176D618.wmf When the by-pass feed table is opened, the by-pass table switch [A] is activated by part of the feed table [B]. Then the CPU turns on the by-pass feed indicator on the operation panel. On this model, opening the by-pass feed table does not shift the copier into interrupt mode.
Page 157 15 July 1996 PAPER FEED 6.15.3 Paper Size Detection A176D619.wmf The paper width detection is necessary to decide the lens horizontal position because the standard position of the optics (rear left corner) and the paper (center) is different. The by-pass paper size sensor [A] (variable resistor) monitors the paper width.
Page 158: Paper Registration
PAPER FEED 15 July 1996 6.16 PAPER REGISTRATION A176D620.wmf The registration rollers [A] have two functions. One is aligning the lead edge of the paper with the leading edge of the latent image on the OPC drum. When the CPU receives the signal from the registration sensor, the registration clutch turns on.
Page 159: Registration Drive Mechanism
15 July 1996 PAPER FEED 6.17 REGISTRATION DRIVE MECHANISM A176D621.wmf A176D622.wmf Through the timing belt [A], main motor [B] rotation is transmitted to the registration clutch [C]. When the registration clutch activates, the main motor drive is transmitted to the lower registration roller [D], then to the upper registration roller [E] via two gears [F] at the front side.
Page 160 PAPER FEED 15 July 1996 6.18 GUIDE PLATE RELEASE MECHANISM A176D623.wmf When a paper misfeed occurs between the vertical transport rollers and the registration rollers, the lower paper guide plate [A] automatically opens. When the registration sensor is not activated at a certain jam check timing, the guide plate solenoid [B] turns on.
Page 161: Image Fusing
15 July 1996 IMAGE FUSING 7. IMAGE FUSING 7.1 OVERVIEW A176D624.wmf After the image is transferred, 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].
Page 162: Fusing Entrance Guide
IMAGE FUSING 15 July 1996 7.2 FUSING ENTRANCE GUIDE A176D625.wmf 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. This slightly lengthens the paper path which prevents the paper from creasing in the fusing unit.
Page 163 15 July 1996 IMAGE FUSING 7.3 FUSING DRIVE MECHANISM A176D626.wmf The fusing drive gear [A] transmits the drive from the fusing/duplex drive motor to the gear [B] which drives the hot roller gear [C]. Rotation passes from the gear [B] through the idle gear [D] to the exit roller drive gear [E]. The pressure roller is driven by the friction between the two fusing rollers.
Page 164: Fusing Lamp Control
IMAGE FUSING 15 July 1996 7.4 FUSING LAMP CONTROL °C 200 °C 180 °C 185°C : Main SW on : Process control data initial setting start : Idling start : Get ready A176D627.wmf 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.
Page 165 15 July 1996 IMAGE FUSING 7.5 INVERTER AND PAPER EXIT A176D628.wmf A176D629.wmf After passing the fusing unit, copies enter the inverter unit where paper is distributed to the paper exit rollers [A] or the duplex unit. The junction gate solenoid changes the position of the junction gate [B]. In duplex mode, the junction gate solenoid turns on to raise the junction gate so that the junction gate guides the paper into the duplex unit.
Page 166 IMAGE FUSING 15 July 1996 7.6 INVERTER AND EXIT DRIVE MECHANISM A176D630.wmf The gear [A] transmits the drive from the fusing/duplex drive motor [B] to the next gear [C]. This gear [C] transmits the drive to the paper exit and the inverter section through the timing belt [D].
Page 167 15 July 1996 DUPLEX 8. DUPLEX 8.1 OVERVIEW A176D631.wmf In this mode the junction gate [A] directs sheets exiting the fusing unit to the duplex tray entrance. After that, all sheets follow the path through the entrance rollers [B]. After all front side copying is completed, the sheets follow (the sheets on the duplex tray are fed in order from the bottom to the top) the path through the duplex feed mechanism and vertical transport rollers [C] to the registration rollers.
Page 168 DUPLEX 15 July 1996 8.2 DRIVE MECHANISM A176D632.wmf The duplex drive gear [A] transmits drive from the fusing/duplex drive motor [B] to the duplex unit. This drive is transmitted to the duplex paper feed section under the control of the duplex feed clutch [C] and transmitted to the duplex transport section under the control of the duplex transport clutch [D].
Page 169: Duplex Entrance To Duplex Tray
15 July 1996 DUPLEX 8.3 DUPLEX ENTRANCE TO DUPLEX TRAY A176D633.wmf After paper passes through the junction gate, it pushes the feeler [A] up. The feeler and the paper guide [B] form one part, so that when it is pushed up, the paper guide is moved out of the paper path.
Page 170: Duplex Stacking
DUPLEX 15 July 1996 8.4 DUPLEX STACKING 10 mm A176D634.wmf 10 mm A176D635.wmf The jogger motor (stepping motor) [A] drives the side fence drive wire [B] to move the side fences [C] inward or outward. When the main switch is turned on, the jogger motor rotates to place the jogger fences at the home position by monitoring the signal of the jogger home position sensor [D].
Page 171 15 July 1996 DUPLEX 8.5 DUPLEX PICK-UP ROLLER MECHANISM A176D636.wmf A176D637.wmf The positioning roller [A] is basically in the upper position. 150 ms after the duplex transport sensor [B] detects the trailing edge of the paper (ON → OFF), the positioning solenoid [C] turns on to lower the positioning roller until it contacts the paper.
Page 172 DUPLEX 15 July 1996 8.6 DUPLEX PAPER FEED A176D638.wmf A176D639.wmf The paper on the duplex tray is fed in order from the bottom to the top sheet. After all copies are stacked on the duplex tray, the duplex pressure solenoid [A] turns on to lower the pressure arm [B] so that the pressure arm presses the paper against the pick up roller [C].
Page 173 15 July 1996 DUPLEX A176D640.wmf A176D641.wmf A176D642.wmf When the duplex entrance sensor [A] detects the trailing edge of the last paper, the pressure solenoid [B] turns off to raise the pressure arm [C]. 200 ms after the duplex entrance sensor [A] detects the leading edge of the paper, the duplex feed clutch [D] turns off and the paper is transported by the duplex transport rollers [E].
Page 174 ENERGY STAR COMPLIANT MACHINES (North American version only) 15 July 1996 9. ENERGY STAR COMPLIANT MACHINES (North American version only) In conjunction with the modification for the Energy Star compliance, field technicians are requested to understand the changes in operation modes so as to configure the machine for the customer specific environment/ requirements.
Page 175 15 July 1996 ENERGY STAR COMPLIANT MACHINES (North American version only) A176D649.img 2-109...
Page 176 ENERGY SAVING INFORMATION 15 July 1996 10. ENERGY SAVING INFORMATION As an Energy Star Partner, we have determined that this copier model meets Energy Star Guidelines for energy efficiency. This product was designed to reduce the environmental impact associated with copying equipment by means of energy saving feature such as AUTO OFF and DUPLEX DEFAULT MODES.
Page 177 15 July 1996 ENERGY SAVING INFORMATION 4. Adjust the Auto off timer following the instructions on the display. • Time can be adjusted from 1 to 120 minutes in 1 minute steps. • You cannot cancel the Auto off mode. The [OFF] key cannot be selected.
Page 178 ENERGY SAVING INFORMATION 15 July 1996 3. Press the Program key. 4. Touch the [Store Program] key. 5. Touch the [5] key. Then, the display shows "Program 5 has been stored. Do you want to revise the program?". 6. Touch the [Yes] key to overwrite a new program.
Page 179 15 July 1996 ENERGY SAVING INFORMATION 3. Press the Program key. 4. Touch the [Store Program] key. 5. Touch the [5] key. Then, the display show "Program 5 has been stored. Do you want to revise the program?". 6. Touch the [Yes] key to overwrite a new program.
Page 180: Installation
SECTION 3 INSTALLATION...
Page 181: Installation Requirements
15 July 1996 INSTALLATION REQUIREMENTS 1. INSTALLATION REQUIREMENTS 1.1 ENVIRONMENT 1. Temperature Range: 10°C to 30°C (50°F to 86°F) 2. Humidity Range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 lux (Do not expose to direct sunlight.) 4. Ventilation: Room air should turn over at least 3 times/hour.) 5.
Page 182: Minimum Space Requirements
INSTALLATION REQUIREMENTS 15 July 1996 1.3 MINIMUM SPACE REQUIREMENTS Place the copier near the power source, providing clearance as shown: More than 10 cm More than 20 cm More than 10 cm (See NOTE: *2) (See NOTE: *1) Your machine More than 70 cm A176I500.wmf NOTE: *1.
Page 183: Power Requirements
15 July 1996 INSTALLATION REQUIREMENTS 1.4 POWER REQUIREMENTS 1. Input voltage level: 120 V/60 Hz: More than 20 A 220 ~ 240 V, 50/60 Hz: More than 10 A 2. Permissible voltage fluctuation: 10% 3. Permissible extension cord: At least 300 V/30 A capacity and less than 5 m (16.4 feet) long. NOTE: a) be sure to ground the machine.
Page 184: Copier Installation
COPIER INSTALLATION 15 July 1996 2. COPIER INSTALLATION 2.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box according to the following list: Description Q’ty 1. Sensor Cover ..............1 2. Flat Head Screw 4 x 6 ............1 3.
Page 185 15 July 1996 COPIER INSTALLATION 2.2 COPIER INSTALLATION PROCEDURE NOTE: Since the installation procedure is not packed with the copier as an accessory, always bring this manual with you. A176I501.wmf A176I502.wmf CAUTION When installing the copier, make sure that the copier is unplugged. NOTE: Insert the leveling shoes [A] under the leveling feet [B] for the front side, and level the machine before starting the installation.
Page 186 COPIER INSTALLATION 15 July 1996 A176I504.wmf A176I503.wmf 2. Open the front doors. 3. Remove the tape strips. 4. Remove the scanner clamp [A] (1 screw) and install the cap [B] stuck on the paper exit bracket with a tape. 5. Remove the transfer belt lock plate [C] (1 screw). 6.
Page 187 15 July 1996 COPIER INSTALLATION A176I505.wmf A176I506.img A176I507.wmf 8. Remove the shutter cover [A] by releasing the hook [B]. 9. Remove the shutter inner cover [C] (1 screw). 10. Open the toner bottle holder [D]. NOTE: To open the toner bottle completely, while lowering the shutter lever [E], push the bracket [F] to the right.
Page 188 COPIER INSTALLATION 15 July 1996 A176I508.wmf A176I509.wmf 14. Disconnect two connectors [A]. 15. Pull out the development unit [B]. NOTE: 1. To prevent drum scratches, push the development unit to the right while pulling it out. 2. Place the development unit on the sheet [C] attached with the new developer to prevent foreign matter from being attracted to the sleeve rollers.
Page 189 15 July 1996 COPIER INSTALLATION A176I510.wmf A176I511.wmf A176I512.wmf 18. Evenly pour in one pack of developer [A] while turning the knob [B]. 19. Install the toner hopper [C] to the development unit (2 screws). 20. Install the development unit to the machine. 21.
Page 190 COPIER INSTALLATION 15 July 1996 A176I513.wmf A176I514.wmf 24. Install the shutter inner cover [A] (1 screw). 25. While pushing the lever [B], set the shutter cover [C]. 26. Set a toner bottle by following the instructions on the decal. NOTE: Before plugging in the power cord, install the guidance ROMs. (-26, -27 machines) (See page 3-13) 27.
Page 191 15 July 1996 COPIER INSTALLATION 28. Enter SP mode as follows: 1) Press the clear modes key. 2) Enter "107". 3) Press the clear/stop key for more than 3 seconds. 29. Press the "SP Adjustment" key [A]. A176I515.img 30. Press the "Start" key [B] of the developer initial setting.
Page 192 COPIER INSTALLATION 15 July 1996 33. (Only in France) This step is for the 50 CPM version machine only. a) Enter SP mode and press "SP Adjustment" key. b) Open page 17 and enter "1" into No. 7 entry. c) Exit SP mode. A176I531.img 34.
Page 193 15 July 1996 COPIER INSTALLATION 2.3 GUIDANCE ROM, INSTALLATION (OPTION: EUROPE VERSION ONLY) A176I517.wmf 1. If necessary, replace the three guidance ROMs on the operation panel PCB with the optional guidance ROMs as follows: 1) Remove three screws [A]. 2) Remove the two screws [B] securing the protective earth wires. 3-13...
Page 194 COPIER INSTALLATION 15 July 1996 A176I518.wmf A176I519.img 3) Insert the screw driver from the hole [F] and push the operation panel [G] up. 4) Disconnect the connector [H]. 5) Replace the guidance ROMs (IC111 [I], IC112 [J], IC113 [K]) on the operation panel PCB [L].
Page 195 15 July 1996 COPIER INSTALLATION 2.4 PLATEN COVER (OPTION) INSTALLATION A176I521.wmf A176I520.wmf Install the optional platen cover as follows: 1. Install the sensor ass’y [A] which is an accessory of the platen cover [B] as follows: 1) Connect the red connector [C] to the rear sensor [D]. 2) Connect the white connector [E] to the front sensor [F].
Page 196: Paper Size Change
COPIER INSTALLATION 15 July 1996 2.5 PAPER SIZE CHANGE A176I522.wmf At the factory, all paper cassettes are set as A4 sideways. According to the customer’s request, change the paper size as follows. 2.5.1 550 Sheets Paper Tray 1. Draw out the paper feed tray [A]. 2.
Page 197 15 July 1996 COPIER INSTALLATION 4. Enter SP mode as follows: 1) Press the mode clear key. 2) Enter "107". 3) Press the clear/stop key more than 3 seconds. 5. Press the "SP Special Feature" key [A]. A176I515.img 6. Press the "Next" key [B] 6 or 7 times to select the paper tray size setting mode (page 7 or 8) and press the appropriate paper size...
Page 198 COPIER INSTALLATION 15 July 1996 2.5.2 1,500 Sheets Paper Tray A176I524.img 1. Draw out the third feed tray [A]. 2. Change the position of the front and the rear side fences [B] (1 screw each) and the end fence [C] (one screw) according to the paper size. 3.
Page 199 15 July 1996 COPIER INSTALLATION 2.6 KEY COUNTER HOLDER INSTALLATION (OPTION) A176I525.wmf CAUTION Unplug the copier power cord before starting the following procedure. NOTE: The Key Counter Bracket Set includes the following parts. The key counter holder and key counter should be procured locally. 1.
Page 200 COPIER INSTALLATION 15 July 1996 A176I526.wmf A176I527.wmf 4. Hold the key counter plate nuts [A] on the inside of the key counter bracket [B] and insert the key counter holder [C]. 5. Fix the key counter holder [C] to the bracket [B] (2 screws). 6.
Page 201: Image Density Adjustment
15 July 1996 COPIER INSTALLATION 2.7 IMAGE DENSITY ADJUSTMENT The copy image density is already adjusted to the standard level at the factory. If a customer requests to have the image density adjusted, it can be done through the User Tool mode. 1.
Page 202 COPIER INSTALLATION 15 July 1996 4. Select appropriate Image Density level (5 steps) adjustment: 1) Press appropriate ID level key [A]. 2) Press the enter key [B]. 5. Press the "Menu" key [C]. A176I530.img 6. Press the "Exit" key [D] to exit User Tools mode.
Page 203: Accessory Check
15 July 1996 DUAL JOB FEEDER (A610) 3. DUAL JOB FEEDER (A610) 3.1 ACCESSORY CHECK Check the accessories against the following list: Description Q’ty 1. Stepped Screw ..............2 2. Sponge Retainer............... 1 3. Philips Pan Head Screw with Washer - M5 x 10 ....2 4.
Page 204: Installation Procedure
DUAL JOB FEEDER (A610) 15 July 1996 3.2 INSTALLATION PROCEDURE A610I501.wmf A610I500.wmf A610I502.wmf A610I510.wmf CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the tape strips and the cushions [A] as shown. 2. Remove the sensor [B], if installed (1 screw). NOTE: Sensor [B] is not installed with the copier.
Page 205 15 July 1996 DUAL JOB FEEDER (A610) A610I511.wmf A610I512.wmf A610I513.wmf 3. Install the cover [A] with the screw (if necessary). The cover and screw are supplied as an accessory with the copier. 4. Install two stepped screws [B]. NOTE: There is one screw hole on the left side for the stepped screw. However, there are two screw holes on the right where the stepped screw is to be installed.
Page 206 DUAL JOB FEEDER (A610) 15 July 1996 A610I514.wmf A610I507.wmf F a c e u p Mit der Schriftseite n a c h o b e n F a c e i m p r i m é e d e u u u s Faccia in su Boca arriba A610I515.wmf...
Page 207 15 July 1996 SORTER STAPLER (A606) 4. SORTER STAPLER (A606) 4.1 ACCESSORY CHECK Check the contents of the box according to the following list. Description Q’ty 1. Front connection Bracket............1 2. Rear Connecting Bracket ............1 3. Cushion ..................1 4.
Page 208 SORTER STAPLER (A606) 15 July 1996 4.2 INSTALLATION PROCEDURE A606I500.wmf A606I501.wmf A606I502.wmf CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape [A] and the cushions [B]. 2. Open the front door and remove the inner cover [C] (3 screws). 3.
Page 209 15 July 1996 SORTER STAPLER (A606) A606I503.wmf A606I504.wmf A606I505.wmf 4. Remove five plastic caps [A] on the copier’s left cover. 5. Install the front connecting bracket [B] (2 screws - M4 x 12) and the rear connecting bracket [C] (2 screws - M4 x 12) on the copier. 6.
Page 210 SORTER STAPLER (A606) 15 July 1996 A606I506.wmf A606I507.wmf A606I508.wmf 7. Secure the protective earth wire [A]* (1 screw) and the wire [B] (1 screw). NOTE*: For all models other than those intended for North America, the green wire is intended as a functional earth and should be connected as shown.
Page 211 15 July 1996 SORTER STAPLER (A606) A606I509.wmf A606I510.wmf 14. If the gap between the top of the sorter stapler and the copier is too great, adjust by placing caster stoppers [A]. 15. Stick the punch position decal [B] on the DF entrance cover (punch version only).
Page 212 RECIRCULATING DOCUMENT HANDLER (A607) 15 July 1996 5. RECIRCULATING DOCUMENT HANDLER (A607) 5.1 ACCESSORY CHECK Check the accessories in the box according to the following list: Description Q’ty 1. Switch Actuator..............1 2. Hinge Stopper..............2 3. Shoulder Screw (+) - M5 ..........2 4.
Page 213 15 July 1996 RECIRCULATING DOCUMENT HANDLER (A607) 5.2 INSTALLATION PROCEDURE A607I500.img A607I501.wmf CAUTION When installing the Recirculating Document Handler (RDH), make sure that the copier is unplugged. 1. Remove the tape strips [A] and the cushion [B] clamping the belt unit. 2.
Page 214 RECIRCULATING DOCUMENT HANDLER (A607) 15 July 1996 A607I502.img A607I503.img 3. Install the cover [A] with a screw (if necessary). The cover and screw are supplied as an accessory with the copier. 4. Replace the front two screws with M4 shoulder screws [B] and install the 6 mm collar M5 shoulder screws [C] to hook the RDH.
Page 215 15 July 1996 RECIRCULATING DOCUMENT HANDLER (A607) A607I505.wmf A607I504.img A607I506.img 6. Secure the RDH to the copier with two 2 mm collar M5 shoulder screws [A]. 7. Remove a small cap on the upper rear cover of the copier then connect the connector [B] and the fiber optic cable connector [C].
Page 216 FINISHER (A608) 15 July 1996 6. FINISHER (A608) 6.1 ACCESSORY CHECK Check the accessories in the box according to the following list. Description Q’ty 1. Front Connecting Bracket..........1 2. Rear Connecting Bracket ..........1 3. Relay Guide ..............1 4.
Page 217 15 July 1996 FINISHER (A608) 6.2 INSTALLATION PROCEDURE A608I500.wmf A608I501.wmf CAUTION Unplug the power cord before beginning the following procedure. 1. Remove the strips of tape [A] and the cushions [B]. 2. Open the front door and remove the strips of tape [C] and cushions [D]. 3.
Page 218 FINISHER (A608) 15 July 1996 A608I502.wmf A608I503.wmf [D] [E] A608I504.wmf 5. Remove five plastic caps [A] on the copier’s left cover. 6. Install the front connecting bracket [B] (2 screws - M4 x 12) and the rear connecting bracket [C] (2 screws - M4 x 12) on the copier. 7.
Page 219 15 July 1996 FINISHER (A608) A608I505.wmf A608I506.img A608I507.wmf A608I510.wmf 8. Open the front door of the finisher and remove the screw [A] fixing the locking lever [B], then lower the locking lever. 9. Stick the cushions [C] (middle), [D] (short), [E] (long) as shown. NOTE: Stick the cushion [C] on the metal stay (not on the cover).
Page 220 FINISHER (A608) 15 July 1996 A608I508.img A608I509.img A608I511.wmf 15. Install the shift tray [A] with 4 screws - M4 x 8 (remove tape [B]). 16. Adjust the height of the copier by using the leveling foot [C] so that the difference in level between the copier [D] and the finisher will be 30 ±...
Page 221 15 July 1996 LCT (A609) 7. LCT (A609) 7.1 ACCESSORY CHECK Check the accessories in the box according to the following list: Description Q’ty 1. LCT feed unit ................1 2. Small cover - left cover .............. 1 3. Philips pan head screw - M4 x 6 ..........3 4.
Page 222 LCT (A609) 15 July 1996 7.2 INSTALLATION PROCEDURE A609I500.wmf A609I501.wmf A609I502.wmf A609I503.wmf CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the four strips of tape [A]. 2. Open the LCT cover [B] and remove the tape [C] fixing the paper trailing edge stopper.
Page 223 15 July 1996 LCT (A609) A609I504.wmf A609I505.wmf A609I506.wmf 5. Open the by-pass table [A] approximately 45 degrees and push the stoppers [B] of the feed unit cover [C] by using a small flat head screw driver [D], then remove the feed unit cover. 6.
Page 224 LCT (A609) 15 July 1996 A609I507.wmf A609I508.wmf 9. Install the LCT connector [A] to the copier. 1) Remove the three caps [B]. 2) Set the two pins [C] of the LCT connector into the two holes [D] on the LCT feed unit. 3) Install the LCT connector to the copier (3 screws - M4 x 16).
Page 225 15 July 1996 LCT (A609) A609I509.wmf A609I510.wmf 12. Hold the upper stay [A] of the LCT and place the LCT on the plates [B] of the LCT connector. CAUTION Properly place the LCT on the plate [B] of the LCT connector. 13.
Page 226 LCT (A609) 15 July 1996 A609I511.wmf 16. Connect the connectors. 1) Between the copier and the LCT (3 connectors). • 13P white • 13P red • 16P white 2) Between the LCT and the LCT feed unit (2 connectors). • 10P white •...
Page 227 15 July 1996 LCT (A609) A609I512.wmf 18. Install the rear upper cover [A] (2 screws). 19. Install the LCT cover [B] (1 screw). 20. Plug in the copier and check machine operation. NOTE: The copier automatically recognizes that the LCT has been installed.
Page 228 LCT (A609) 15 July 1996 7.2.1 PAPER SIZE CHANGE A609I513.wmf A609I514.wmf Change the paper size, if the customer requests it. NOTE: A4/Letter sideways is the factory setting. 1. While covering two sensors [A] with your hand, press the tray down key [B] to lower the bottom tray.
Page 229 15 July 1996 LCT (A609) A609I515.wmf 6. Remove the clip [A] and pull out the shaft [B]. Position the paper trailing edge stopper [C] according to the paper size. 7. Re-install the shaft [B] and the clip [A]. 8. Enter SP mode as follows: 1) Press the clear mode key.
Page 230 LCT (A609) 15 July 1996 10. Touch the "Next" key [A] seven times to select the paper size setting mode (page 8), then touch the appropriate paper size of "LCT" [B]. 11. Touch the "Index" key [C]. A609I517.img 12. Touch the "Quit" key [D]. A609I518.img 13.
Page 231 SECTION 4 SERVICE TABLES...
Page 232: Service Remarks
15 July 1996 SERVICE REMARKS 1. SERVICE REMARKS 1.1 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 fingers or becomes dirty, wipe with a dry cloth or clean with wet cotton.
Page 233: Charge Corona
SERVICE REMARKS 15 July 1996 1.3 CHARGE CORONA 1. Clean the corona wires with a dry cloth. Do not use sandpaper or solvent. 2. Clean the charge corona casing with water first to remove NO X based . Then clean it with alcohol if any toner still remains on the compounds casing.
Page 234: Erase Lamp
15 July 1996 SERVICE REMARKS 5. To clean the mirrors and lens, use only a clean soft cloth dampened with alcohol or water. 6. Do not turn the vertical lamp position adjusting cam. Adjusting the vertical lamp position is very difficult because the filament cannot be seen clearly as the lamp is frosted.
Page 235: Development Unit
SERVICE REMARKS 15 July 1996 1.6 DEVELOPMENT UNIT 1. Be careful not to nick or scratch the development roller sleeves. 2. Place the development unit on a sheet of paper after removing it from the copier. This prevents any small metal objects (staples, clips, E-rings, etc.) from being attracted to the development roller and getting inside the unit.
Page 236: Pre-Transfer Lamp
15 July 1996 SERVICE REMARKS 3. Before disassembling the cleaning section, place a sheet of paper under it to catch any toner falling from it. 4. Empty the used toner collection bottle at every PM. 5. Apply setting powder to the new cleaning blade. 1.9 PRE-TRANSFER LAMP 1.
Page 237: Service Program Mode Operation
SERVICE PROGRAM MODE 15 July 1996 2. SERVICE PROGRAM MODE 2.1 SERVICE PROGRAM MODE OPERATION The service program (SP) mode is used to check electrical data, change modes, and adjust values. 2.1.1 Service Program Access Procedure 1. Press the clear modes key. 2.
Page 238 15 July 1996 SERVICE PROGRAM MODE 2.1.3 To Return to the Index Menu 1. Return to the index menu by touching on the display. A176M501.img 2.1.4 Change the Menu Screen 1. To move to the next page, touch [B]. 2. To move to the previous page, touch [C].
Page 239 SERVICE PROGRAM MODE 15 July 1996 2.2 SERVICE PROGRAM MODE TABLE SP ADJUSTMENT PAGE 1 A176M503.img Item Function Note Both the TD sensor toner supply target With new developer, do not make any voltage (V ) and the TD sensor gain copy before performing the developer value are set automatically by using new initial setting.
Page 240 15 July 1996 SERVICE PROGRAM MODE SP ADJUSTMENT PAGE 2 A176M501.img Item Function Note Enables or disables the automatic charge Select OFF only when a cleaning corona wire cleaning mechanism. mechanism malfunction occurs. Default: ON Changes the paper feed clutch on timing Refer to "6.6 Paper Feed Timing to adjust the paper buckle at the Adjustment"...
Page 241 SERVICE PROGRAM MODE 15 July 1996 SP ADJUSTMENT PAGE 3 PAGE 4 A176M504.img A176M505.img Item Function Note Adjustment standard: 0 ± 2 mm Changes the ON timing of the registration clutch (0.5 mm/step). Adjustment standard: 3.5 ± 2.5 mm Changes the OFF timing of the erase lamp to adjust the leading edge erase margin (0.5 mm/step).
Page 242 15 July 1996 SERVICE PROGRAM MODE SP ADJUSTMENT PAGE 5 PAGE 6 A176M506.img A176M507.img Item Function Note Adjusts the lens position to correct Input only the value marked on the lens. magnification in enlarge/reduce modes. Adjusts the 3rd scanner home position to correct the focus.
Page 243 SERVICE PROGRAM MODE 15 July 1996 SP ADJUSTMENT PAGE 7 PAGE 8 A176M509.img A176M508.img Item Function Note Selects toner supply mode. Select "Auto Mode" in the field. (See the process control section for details about each supply mode.) Default: Auto Mode Factory use only Select "N"...
Page 244 15 July 1996 SERVICE PROGRAM MODE SP ADJUSTMENT PAGE 9 PAGE 10 A176M510.img A176M511.img Item Function Note Inputs the exposure lamp voltage when Enter the setting using the number keys, then touch auto process control is disabled or RAM is cleared (0.5 V/step). Default: 65.0 V Selects whether or not the transfer Default:...
Page 245 SERVICE PROGRAM MODE 15 July 1996 SP ADJUSTMENT PAGE 11 A4/A3 VERSION PAGE 12 T/DLT VERSION A176M512.img A176M513.img Item Function Note Press to decrease the distance Adjusts the duplex jogger fence position between the side fences . for each paper size Press to increase the distance (0.3 mm/step).
Page 246 15 July 1996 SERVICE PROGRAM MODE SP ADJUSTMENT PAGE 13 NOTE: PAGE 16 is for factory use only. A176M514.img A4/A3 VERSION T/DLT VERSION PAGE 14 PAGE 15 A176M515.img A176M516.img Item Function Note Adjusts the staple position. This mode affects only the Sorter Stapler (horizontal and vertical) and the Adjusts the vertical...
Page 247 SERVICE PROGRAM MODE 15 July 1996 SP ADJUSTMENT PAGE 17 A176M519.img Item Function Note Selects whether the Taiwanese paper European and Asian versions only sizes (8 k, 16 k) are detected in the 2nd Not detected: 0 (Default) tray or not. 8 k, 16 k paper sizes are detected: 1 Selects the machine version.
Page 248 15 July 1996 SERVICE PROGRAM MODE SP TEST MODE PAGE 1 PAGE 2 A176M517.img A176M518.img Item Function Note Operates the copier without feeding Place sheets of white paper (A3 or 11" x paper. 17") on the exposure glass. Operates the copier without feeding Do not operate the machine in this mode paper or turning on the exposure lamp.
Page 249 SERVICE PROGRAM MODE 15 July 1996 SP TEST MODE PAGE 3 PAGE 4 A176M520.img A176M521.img Item Function Note Use to check if the original size sensors Status 0 ------ de-activated (no paper) are correctly activated and de-activated. Status 1 ------ activated (paper) Use to check if the sensors or switches Status 0 ------ de-activated (no paper) are correctly activated and de-activated.
Page 250 15 July 1996 SERVICE PROGRAM MODE SP TEST MODE PAGE 5 A176M522.img Item Function Note After touching the key, the toner Operates the toner collection drive mechanism. collection motor turns on for 1 minute. 4-19...
Page 251 SERVICE PROGRAM MODE 15 July 1996 DATA OUT MODE PAGE 1 PAGE 2 A176M523.img A176M524.img Item Function Note Indicates the drum potential sensor Standard: 0.1 ~ 0.7 V output when –100 V is applied to the drum. Indicates the drum potential sensor Standard: 2.7 V ~ 4.2 V output when –800 V is applied to the drum.
Page 252 15 July 1996 SERVICE PROGRAM MODE DATA OUT MODE PAGE 2 PAGE 3 A176M524.img A176M525.img Item Function Note Indicates the exposure lamp voltage Works only when auto process control is (ID Level 4) decided during process enabled ( SP Adjustment - PAGE control data initial setting.
Page 253 SERVICE PROGRAM MODE 15 July 1996 DATA OUT MODE PAGE 4 A176M526.img Item Function Note Indicates the TD sensor output: Standard: 0.5 ~ 4.0 V : Current detected voltage Initial: TD sensor output at last process control data initial setting. Previous: Previous detected voltage during ID sensor compensation.
Page 254 15 July 1996 SERVICE PROGRAM MODE DATA OUT MODE PAGE 5 A176M527.img Item Function Note Standard: 2.7 ± 0.1 V Indicates the ADS sensor output at every scan. Present: Output at last detection. Initial: Output at ID sensor initial setting. Indicates the fusing temperature based Standard: Around 185°C on the fusing thermistor output.
Page 255 SERVICE PROGRAM MODE 15 July 1996 SP SPECIAL FEATURES PAGE 1 A176M528.img Item Function Setting Default Selects copy count up or down. Count up Count down Counts once or twice when an A3 or 11" Count twice x 17" copy is made. Count once 4-24...
Page 256 15 July 1996 SERVICE PROGRAM MODE SP SPECIAL FEATURES PAGE 2 A176M529.img A176M568.wmf Item Function Setting Default Enables user code mode. Enable * See the note below. Disable Enables the PM alarm. Enable Disable Selects the PM alarm interval after the counter was cleared (using 120 k Counter Clear - PAGE 1)
Page 257 SERVICE PROGRAM MODE 15 July 1996 SP SPECIAL FEATURES PAGE 3 A176M530.img Item Function Setting Default Enables automatic sort mode selection Enable when 2 or more is entered in the copy counter and an original is set on the DJF feed tray.
Page 258 15 July 1996 SERVICE PROGRAM MODE SP SPECIAL FEATURES PAGE 4 A176M531.img Item Function Setting Default Enables automatic access to the Enable border/center erase mode in platen cover mode. Disable Enables automatic selection of a right Enable margin (5 mm, 0.2") for the duplex back side when making two-sided copies from one-sided originals.
Page 259 SERVICE PROGRAM MODE 15 July 1996 SP SPECIAL FEATURES PAGE 5 A176M532.img Item Function Setting Default Enables the separation of two different sort or stack jobs into two different blocks of the bins. 1st block: from 1st to 10th bins, 2nd block: from 12th to 20th bins.
Page 260 15 July 1996 SERVICE PROGRAM MODE SP SPECIAL FEATURES PAGE 6 A176M533.img Item Function Setting Default Selects the fusing lower temperature limit. During a copy run, when the fusing temperature drops to a certain temperature, the copy speed will reduce to keep good fusing conditions.
Page 261 SERVICE PROGRAM MODE 15 July 1996 SP SPECIAL FEATURES PAGE 7 PAGE 8 A176M534.img A176M535.img PAGE 9 A176M536.img Item Function Note Selects the paper size for each paper 1. The default is A4 or 8 x 11 sideways. feed station. 2.
Page 262 15 July 1996 SERVICE PROGRAM MODE SP SPECIAL FEATURES PAGE 10 PAGE 11 A176M537.img A176M538.img Item Function Setting Default Selects the staple mode for the 1st job Enable when the staple mode is selected for the 2nd job in the pre-set mode. Disable The original size detection system for this model cannot distinguish between A4...
Page 263 SERVICE PROGRAM MODE 15 July 1996 JAM/SC COUNTERS PAGE 1 A176M539.img A176M540.img Item Function Note Indicates the total number of occurrences Press to scroll up. of each SC code. Press to scroll down. See Section 6 for details of each SC code.
Page 264 15 July 1996 SERVICE PROGRAM MODE JAM/SC COUNTERS PAGE 2 PAGE 3 A176M541.img A176M542.img PAGE 4 A176M543.img Item Function Note Indicates the total number of jams in the copier and all peripherals. Indicates the total number of jams in the copier only.
Page 265 SERVICE PROGRAM MODE 15 July 1996 COPY COUNTERS PAGE 1 PAGE 2 A176M544.img A176M545.img Item Function Note Indicates the total main motor rotation time. Indicates the total number of originals fed by the DF. Indicates the total number of copies. Indicates the total number of copies for each paper size.
Page 266 15 July 1996 SERVICE PROGRAM MODE COPY COUNTERS PAGE 3 PAGE 4 A176M546.img A176M547.img PAGE 5 PAGE 6 A176M548.img A176M549.img Item Function Note Indicates the total number of copies for each copy mode. Indicates the total number related to consumables. Indicates the total number of staples for each staple position.
Page 267: Counter Clear
SERVICE PROGRAM MODE 15 July 1996 COUNTER CLEAR PAGE 1 A176M550.img A176M551.img PAGE 2 A176M552.img A176M553.img Item Function Note Clears all SC counters. Procedure to clear: 1. Touch Clears all paper jam counters. The display changes as shown above Clears all original jam counters. right.
Page 268: Pm Counter Clear
15 July 1996 SERVICE PROGRAM MODE PM COUNTER CLEAR PAGE 1 A176M554.img A176M555.img PAGE 2 A176M556.img A176M557.img PAGE 3 A176M558.img A176M559.img Item Function Note 1. Indicates the total number of copies Procedure to clear: since the last PM (PM counter). 1.
Page 269 SERVICE PROGRAM MODE 15 July 1996 PM COUNTER CLEAR PAGE 4 A176M560.img A176M561.img PAGE 5 A176M562.img A176M563.img Item Function Note 1. Indicates the total number of copies Procedure to clear: since the last PM for each unit. 1. Touch (unit counter) The display changes as shown above 2.
Page 270: Memory Clear
15 July 1996 SERVICE PROGRAM MODE MEMORY CLEAR PAGE 1 A176M564.img A176M565.img Item Function Note Returns all settings to the default settings. Procedure to clear: 1. Touch and open the door. The display changes as shown above right. 2. Touch (Touch to cancel.) The display returns to the one shown...
Page 271 SERVICE PROGRAM MODE 15 July 1996 2.3 SENSOR/SWITCH/SIGNAL DATA CHECK (INPUT MODE) – How to check the sensor/switch/signal – 1. Enter SP mode as follows: 1) Press the mode clear key. 2) Enter "107" 3) Hold down the clear/stop key for more than 3 seconds. 2.
Page 272 15 July 1996 SERVICE PROGRAM MODE Input Status Sensor/Switch/|Signal Registration Sensor Paper not detected Paper detected Fusing Exit Sensor Paper not detected Paper detected Exit Sensor Paper not detected Paper detected Vertical Transport Sensor Paper not detected Paper detected 1st Tray Set Switch (A175 only) Not set By-pass Paper End Sensor Paper detected...
Page 273 SERVICE PROGRAM MODE 15 July 1996 Input Status Sensor/Switch/|Signal 3.5 k LCT Feed Sensor Paper not detected Paper detected 3.5 k LCT Tray Down Sensor Tray not down Tray down 3.5 k LCT Door Switches Closed Open 3.5 k LCT Paper Position Sensor Paper not detected Paper detected Duplex Jogger HP Sensor...
Page 274 15 July 1996 SERVICE PROGRAM MODE Input Status Sensor/Switch/|Signal Bin Sensor (Phototransistor) (S/S) Paper detected Paper not detected Stack Height Sensor 2 (Finisher) At HP Not at HP Bin HP Sensor (S/S) Not at HP At HP Stack Height Sensor 1 (Finisher) Not at HP At HP Wheel Sensor (S/S)
Page 275 SERVICE PROGRAM MODE 15 July 1996 Input Status Sensor/Switch/|Signal 135 Platen Cover Position Sensor 1 Not interrupted Interrupted 136 Platen Cover Position Sensor 2 Not interrupted Interrupted 137 Optics Thermistor Low Temp. High Temp. Input Nos. 138 ~ 150 are not used. Not Used (DJF) —...
Page 276 15 July 1996 SERVICE PROGRAM MODE Input Status Sensor/Switch/|Signal Feed-out SN (DJF) Original not Original detected detected Lift Switch (RDH) Down Lifted Not used (DJF) — — RDH Position Sensor (RDH) Lifted Down DF Position SN (DJF) Open Closed Not used (RDH) —...
Page 277 SERVICE PROGRAM MODE 15 July 1996 2.4 ELECTRICAL COMPONENT CHECK (OUTPUT MODE) NOTE: The motors keep turning in this mode regardless of the upper or lower limit sensor signals. To prevent mechanical or electrical damage, do not keep an electrical component on for a long time. –...
Page 278 15 July 1996 SERVICE PROGRAM MODE 4. 1) Touch [B]. 2) Enter the electrical component number by using the number keys on the operation panel. (Refer to the table on the following pages.) 3) Press the Enter key [C]. 4) Press [D] to activate and press [E] to...
Page 279 SERVICE PROGRAM MODE 15 July 1996 Output Check Mode Table Output No. Electrical Component Not used Junction Solenoid LCT Feed Clutch By-pass Feed Clutch Duplex Transport Clutch Toner Supply Clutch By-pass Pick-up Solenoid Guide Plate Solenoid LCT Pick-up Solenoid Toner Bottle Motor Duplex Transport Clutch Pressure Arm Solenoid Duplex Positioning Solenoid...
Page 280 15 July 1996 SERVICE PROGRAM MODE Output No. Electrical Component 3rd Lift Motor (Down) 4th Lift Motor (Up) 4th Lift Motor (Down) Rear Fence Drive Motor (Counterclockwise) Rear Fence Drive Motor (Clockwise) 1st Paper Feed Clutch 2nd Paper Feed Clutch 3rd Paper Feed Clutch 4th Paper Feed Clutch Registration Clutch...
Page 281 SERVICE PROGRAM MODE 15 July 1996 Output No. Electrical Component Turn Gate Solenoid (S/S) Junction Gate Solenoid (Finisher) Bin Drive Motor (S/S) Positioning Roller Solenoid (Finisher) Jogger Motor (S/S) Jogger Motor (Finisher) Bin Rear Plate Drive Motor (S/S) Shift Motor (Finisher) Grip Motor (S/S) Stack Feed-out Motor (Finisher) Grip Positioning Solenoid (S/S)
Page 282: User Tools
15 July 1996 SERVICE PROGRAM MODE 2.5 USER TOOLS This mode is for the key operators in charge of this copier. The operator can change or set the copier’s default settings using the following user tools. 2.5.1 How To Access The User Tools 1.
Page 283 SERVICE PROGRAM MODE 15 July 1996 2.6 TOUCH PANEL DISPLAY POSITION ADJUSTMENT Due to inaccurate display position adjustment, it is possible that the touch panel sometimes does not respond if the key is touched. In this case, precisely adjust the touch panel display position as follows: 1.
Page 284 15 July 1996 SERVICE PROGRAM MODE A176M576.img A176M577.img A176M578.img 4-53...
Page 285: Preventive Maintenance Schedule
PREVENTIVE MAINTENANCE SCHEDULE 15 July 1996 3. PREVENTIVE MAINTENANCE SCHEDULE 3.1 PM TABLE NOTE: The numbers mentioned for PM intervals indicate the number of copies. Symbol key: C: Clean R: Replace L: Lubricate I: Inspect 120 K 240 K 360 K NOTE OPTICS Mirrors, Lens, Reflectors...
Page 286 15 July 1996 PREVENTIVE MAINTENANCE SCHEDULE 120 K 240 K 360 K NOTE Pre Transfer Lamp Filter Dry cloth and blower brush. Discharge any static before installation. Quenching Lamp Dry cloth and blower brush. ID Sensor Blower brush. Erase Lamp Unit Dry cloth.
Page 287 PREVENTIVE MAINTENANCE SCHEDULE 15 July 1996 120 K 240 K 360 K NOTE DUPLEX (for duplex copies) Feed Roller Separation Belts Pick-up/Transport Rollers Positioning Pins/Holes Refer to NOTE 7. OTHERS Ozone Filter Drive Belts Replace if necessary. Exit Sensor Blower brush. Development Drive Gear Dust Protection Filter 70 CPM machine only.
Page 288 15 July 1996 PREVENTIVE MAINTENANCE SCHEDULE The location of the parts which should be lubricated at PM, are shown in the following figures: NOTE 1: Scanner/Lens Guide Rods 1. Lubricate the horizontal and vertical lens guide rods [A] with Launa Oil every 120 k copies.
Page 289 PREVENTIVE MAINTENANCE SCHEDULE 15 July 1996 NOTE 2: Vertical Transport Guide Lock Pin 1. Lubricate the vertical transport guide lock pin [A] with Mobil Temp. 78 every 240 k copies. A176M581.wmf NOTE 3: Charge Wire Cleaner Drive Gears 1. Open the drive motor cover [B] (2 screws). NOTE: When re-installing the cover, do not tighten the screws too much.
Page 290 15 July 1996 PREVENTIVE MAINTENANCE SCHEDULE NOTE 4: Cleaning Drive Section 1. Lubricate the cleaning blade shift cam [A] with Grease G501 every 240 k copies. A176M583.wmf 2. Lubricate the cleaning section drive gear [B] with Grease G501 every 240 k copies.
Page 291 PREVENTIVE MAINTENANCE SCHEDULE 15 July 1996 NOTE 6: Fusing Section 1. Clean the surface of the fusing thermistor [A] where touching the hot roller at every PM. A176M586.wmf 2. Lubricate the inner and outer surface of the isolating bushing [B] with BARRIERTA L55/2 grease every 240 k copies.
Page 292 15 July 1996 PREVENTIVE MAINTENANCE SCHEDULE NOTE 8: Development Unit 1. Lubricate the bias terminal (sleeve roller shaft) [A] with Grease: KS660: SHIN-ETSU A176M590.img NOTE: Use only conductive grease, otherwise bias voltage will not be properly applied to the development rollers. 4-61...
Page 293: Explanation Of Regular Pm
PREVENTIVE MAINTENANCE SCHEDULE 15 July 1996 3.2 EXPLANATION OF REGULAR PM Item Explanation Optics Unit Mirrors, Lens, Stains on any part of the optics unit result in Reflector, Exposure black lines or areas of decreased sharpness on Glass, Platen Cover, the copy.
Page 294 15 July 1996 PREVENTIVE MAINTENANCE SCHEDULE Item Explanation Around the Charge Corona Wires/ Dirty charge corona wires may cause uneven Drum Wire Cleaner/ image density. They should be replaced at Charge Corona Grid regular intervals. End Blocks Toner tends to accumulate on the corona end blocks.
Page 295 PREVENTIVE MAINTENANCE SCHEDULE 15 July 1996 Item Explanation Development Developer The tribo-chargeability of overused developer Unit decreases. This results in toner scattering. Developer must be replaced at regular intervals. Bias Terminal Less lubricant increases the friction between the bias terminal and the bias receptacle. This may degrade the terminal.
Page 296 15 July 1996 PREVENTIVE MAINTENANCE SCHEDULE Item Explanation Transport Belt A dirty transport belt can leave stains on copies. Clean or replace the belt at regular intervals. Feed Roller Separation When dirty, these rollers and these belts can Belts leave stains on the copier. Also, original misfeeds or multi-feeds may occur.
Page 297: Regular Pm Procedure
PREVENTIVE MAINTENANCE SCHEDULE 15 July 1996 3.3 REGULAR PM PROCEDURE Every 120 k Every 240 k or 360 k Make a copy of an O-S-A3 test chart at manual 1. Make a copy image density level 4. 2-1. Clean the mirrors, lens and reflectors by 2.
Page 298 15 July 1996 PREVENTIVE MAINTENANCE SCHEDULE 4. Development unit 4-1. Remove the developer. (every 120 k) 4-2. Clean the development unit and gears. 4-3. Pour a pack of new developer. 4-4. Replace the air filter. Lubricate the bias 4-5. Clean the toner bottle holder and toner terminal receiver.
Page 299 PREVENTIVE MAINTENANCE SCHEDULE 15 July 1996 8-1. Clean the entrance and exit guide plates. 8. Fusing unit (every 120 k) 8-2. Clean the thermistor. 8-3. Clean the stripper pawls. 8-4. Replace the oil supply roller. Replace the stripper 8-5. Replace the oil supply cleaning roller. pawls, hot roller, 8-6.
Page 300 SECTION 5 REPLACEMENTS AND ADJUSTMENTS...
Page 301: Front Side
15 July 1996 EXTERIOR AND INNER COVER REMOVAL 1. EXTERIOR AND INNER COVER REMOVAL 1.1 FRONT SIDE A176R500.img A176R501.img 1.1.1 Left Front Cover 1. Open the left front door [A] then unhook the chain (1 screw). 2. Pull out the pin [B]. 3.
Page 302: Rear Side
EXTERIOR AND INNER COVER REMOVAL 15 July 1996 1.2 REAR SIDE A176R502.wmf A176R503.img 1.2.1 Upper Rear Cover 1. Turn off the main switch. 2. If the DJF or RDH is installed, disconnect the fiber optics connectors [A] and [B]. NOTE: After the upper rear cover is re-installed, set the fiber optics connectors [A] and [B] so that the fiber optic cable [A] is located over the electrical cable [B].
Page 303 15 July 1996 EXTERIOR AND INNER COVER REMOVAL A176R504.img A176R505.wmf 1.2.3 Left Inner Cover 1. Remove the left front door [A]. 2. Remove the left inner cover (4 screws) [B]. 1.2.4 Right Inner Cover 1. Open the right door [C]. 2.
Page 304 EXTERIOR AND INNER COVER REMOVAL 15 July 1996 1.2.5 Shutter Inner Cover A176R506.wmf A176R507.wmf 1. Open the right door. 2. Remove the shutter cover [A] by releasing the hook [B]. 3. Remove the shutter inner cover [C] (1 screw). NOTE: 1) Be sure to move the lever [D] until it contact the part [E]. 2) While installing the shutter cover [A], the lever [D] must be pushed as shown.
Page 305: Right Side
15 July 1996 EXTERIOR AND INNER COVER REMOVAL 1.3 RIGHT SIDE 1.3.1 Feed Unit Cover A176R508.wmf 1. Open the by-pass table [A] approximately 45 degrees and push the stoppers [B] of the feed unit cover [C] by using a small flat head screw driver [D], then remove the feed unit cover.
Page 306 EXTERIOR AND INNER COVER REMOVAL 15 July 1996 A176R509.wmf A176R510.wmf 1.3.2 Upper Right Cover 1. Remove the right inner cover [A], shutter cover [B] and the shutter inner cover [C]. (Refer to Shutter Inner Cover Removal.) 2. Remove the upper rear cover [D]. (Refer to Upper Rear Cover Removal.) 3.
Page 307: Left Side
15 July 1996 EXTERIOR AND INNER COVER REMOVAL 1.4 LEFT SIDE A176R511.wmf A176R512.img 1.4.1 Upper Left Cover 1. Remove the left inner cover. (Refer to Left Inner Cover Removal.) 2. Remove the upper rear cover [A]. (Refer to Upper Rear Cover Removal.) 3.
Page 308: Operation Panel
EXTERIOR AND INNER COVER REMOVAL 15 July 1996 1.5 OPERATION PANEL A176R513.wmf A176R514.wmf 1. Turn off the main switch. 2. Remove the left door. (Refer to Left Door Removal.) 3. Remove the left inner cover. (Refer to Left Inner Cover Removal.) 4.
Page 309: Upper Side
15 July 1996 EXTERIOR AND INNER COVER REMOVAL 1.6 UPPER SIDE A176R515.wmf 1.6.1 Upper Cover A176R516.wmf 1. Turn off the main switch. 2. Remove six screws [A]. 3. Remove two screws [B] securing the grounding wires. 4. Disconnect two connectors [C]. 5.
Page 310: Exposure Glass Removal
OPTICS 15 July 1996 2. OPTICS 2.1 EXPOSURE GLASS REMOVAL A176R517.wmf 1. Turn off the main switch. 2. Remove the left scale [A] (2 shoulder screws). 3. Remove the rear scale [B] (3 screws). 4. Grasp the left edge of the exposure glass [C] and lift slightly. Slide the other edge out from under the right glass holder [D].
Page 311: Exposure Lamp Replacement
15 July 1996 OPTICS 2.2 EXPOSURE LAMP REPLACEMENT A176R518.wmf 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 fingers on the lamp or reflectors will be affected by heat from the lamp.) 1.
Page 312 OPTICS 15 July 1996 A176R519.img NOTE: Make sure that the blister [A] on the lamp points towards the reflector opening (left side of the copier) as shown. 6. Reassemble the copier. 7. Turn on the main switch and enter SP mode, then perform the process control data initial setting ( SP Adjustment - PAGE 1).
Page 313: Optics Thermoswitch Replacement
15 July 1996 OPTICS 2.3 OPTICS THERMOSWITCH REPLACEMENT A176R520.img NOTE: The thermoswitch can be reset manually by pushing the red button [A] when the exposure lamp area cools. 1. Remove the exposure glass. (Refer to Exposure Glass Removal.) 2. Move the first scanner to the cutout position at the rear frame. 3.
Page 314 OPTICS 15 July 1996 2.4 SCANNER HP SENSOR REPLACEMENT A176R521.wmf A176R522.wmf 1. Remove the upper rear cover [A]. (Refer to Upper Rear Cover Removal.) 2. Remove the exhaust fan [B] (3 screws). 3. Manually turn the scanner drive pulley [C] counterclockwise to move the scanners about 10 mm to the left (rear view).
Page 315 15 July 1996 OPTICS 2.5 ADS SENSOR REMOVAL A176R521-2.wmf A176R524.wmf 1. Remove the exhaust fan [A]. (Refer to Scanner HP Sensor Replacement.) 2. Remove the DJF/RDH connector bracket [B] (2 screws). 3. Remove the ADS Sensor [C] with the cover [D] (1 screw). 4.
Page 316 OPTICS 15 July 1996 2.6 SCANNER DRIVE MOTOR A176R525.wmf 0.5 mm A176R526.wmf 1. Remove the exhaust fan. (Refer to Scanner HP Sensor Replacement.) 2. Remove the tension spring [A]. 3. Remove the tension tightener [B]. NOTE: Re-install the tightener as follows; 1) Hook part [C] of the bracket on the screw [D] installed on the scanner drive motor bracket.
Page 317 15 July 1996 OPTICS 2.7 SCANNER DRIVE WIRES REPLACEMENT - Removal - A176R527.wmf A176R528.wmf 1. Turn off the main switch. 2. Remove the exposure glass. 3. Remove the upper cover and the rear upper cover. 4. Remove the optics thermistor [A] (1 screw, 1 harness clamp). 5.
Page 318 OPTICS 15 July 1996 A176R529.wmf A176R530.wmf 9. Remove the lens unit cover [A] (2 screws). 10. Unhook the tension spring [B]. 11. Remove the lens shield plate [C]. NOTE: When installing the lens shield plate, set the rear part [D] of the lens shield plate between the guides [E] as shown.
Page 319 15 July 1996 OPTICS A176R531.wmf A176R532.wmf 12. Remove the front bracket [A] (2 screws). 13. Remove the screw [B] securing the scanner flat cable. 14. Unhook the four harness clamps [C]. 15. Disconnect the connector [D] outside the optic side frame. 16.
Page 320 OPTICS 15 July 1996 A176R533.wmf A176R534.wmf 18. Remove the harness cover [A] (2 screws). 19. Remove the light shield mylar bracket [B] (1 screw). 20. Disconnect the paper length size sensor connector [C] and move the lens unit to the left, then remove the rear bracket [D] (2 screws). 21.
Page 321 15 July 1996 OPTICS A176R535.wmf A176R536.wmf 23. Remove the left inner cover [A] (4 screws). 24. Remove the E-ring [B] of the scanner drive shaft and remove the front ball bearing [C]. 25. Remove the rear drive pulley [D] (1 Allen screw) and remove the rear ball bearing [E].
Page 322 OPTICS 15 July 1996 - INSTALLATION - A176R537.wmf 1. Round the rear scanner drive wire on the rear pulley as follows: 1) Align the cut out [A] on the edge of the rear drive pulley and the blue mark [B] on the wire as shown. 2) Round the wire counterclockwise 5 times as shown (in the illustration, the D-cut [C] on the shaft is at the front side) then set the bead [D] on the wire in the hole [E] on the pulley.
Page 323 15 July 1996 OPTICS A176R538.wmf 2. Round the front scanner drive wire on the front pulley as shown: 1) Align the cut out [A] on the edge of the front drive pulley and the red mark [B] on the wire. 2) Round the wire clockwise 5 times as shown (in the illustration, the Allen screw holes are at the rear side) then set the bead [C] on the wire in the hole [D] on the pulley.
Page 324 OPTICS 15 July 1996 A176R539.wmf A176R541.img A176R540.wmf 3. Set the front drive pulley [A] on the drive shaft. (Leave the Allen screws loosened.) 4. Place the scanner drive shaft [B] in the holes on the optics front and rear side frames. 5.
Page 325 15 July 1996 OPTICS A176R542.wmf 10. Route the shorter end [A] of the rear scanner drive wire in the following order. Rear track counterclockwise Clockwise Lower track clockwise. Fix the end of the wire on the frame with tape [B]. 5-25...
Page 326 OPTICS 15 July 1996 A176R543.wmf 11. Route the longer end [A] of the rear scanner drive wire in the following order. Through front track, upper side. Counterclockwise. Upper track counterclockwise. Hook the end [B] of the wire on the cutout on the right optics side frame.
Page 327 15 July 1996 OPTICS A176R544.wmf 12. Route the shorter end [A] of the front scanner drive wire in the following order. Front track counterclockwise Clockwise Lower track clockwise. Fix the end of the wire on the frame with tape [B]. 5-27...
Page 328 OPTICS 15 July 1996 A176R545.wmf 13. Route the longer end [A] of the front scanner drive wire in the following order. Through rear track, upper side. Counterclockwise. Upper track clockwise. Hook the end of the wire [A] on the cut out on the right optics side frame.
Page 329 15 July 1996 OPTICS A176R546.wmf A176R547.wmf 18. Install the rear bracket [A] (2 screws, 1 connector), shielding mylar bracket [B] (1 screw) and harness cover [C] (2 screws). 19. Adjust the second scanner alignment as follows: - Second Scanner Alignment - 1) Move the second scanner [D] to the left end position.
Page 330 OPTICS 15 July 1996 A176R548.wmf A176R549.wmf 20. Place the first scanner unit on the guide rail then adjust the first scanner alignment as follows: - First Scanner Alignment - 1) Move the first scanner [A] to the left end position. Fix the rear end of the first scanner by inserting the jig pin [B] in the holes on the first scanner and the guide rail.
Page 331 15 July 1996 OPTICS Except for 70 CPM version TP504 TP504 TP512 A176R550.wmf TP514 70 CPM version A176R551.wmf TP504 DPS501 TP512 A176R720.wmf 24. Turn on the main switch and perform the scanner free run for about 5 minutes to break in the wires and to confirm correct scanner movement as follows: - Scanner Free Run - 1.
Page 332 OPTICS 15 July 1996 2.8 SCANNER CONTROL ADJUSTMENT (except for 70 CPM version) LED 501 A176R552.wmf Perform this adjustment under any one of the following conditions: After the scanner motor replacement After the scanner wire replacement After the scanner timing belt replacement After replacing the optics control Board 1.
Page 333 15 July 1996 OPTICS 2.9 THIRD SCANNER REMOVAL A176R553.wmf A176R554.wmf A176R555.wmf 1. Remove the exposure glass. (Refer to Exposure Glass Removal.) 2. Remove the upper cover [A]. (Refer to Upper Cover Removal.) 3. Remove the lens unit cover [B] (2 screws). 4.
Page 334 OPTICS 15 July 1996 2.10 THIRD SCANNER DRIVE MOTOR/HP SENSOR REPLACEMENT A176R556.wmf A176R557.wmf A176R558.wmf 1. Remove the third scanner unit. (Refer to the Third Scanner Removal.) 2. Open the right front cover then remove the shutter cover [A]. 3. Remove the shutter inner cover [B] (1 screw). 4.
Page 335 15 July 1996 OPTICS 2.11 LENS HORIZONTAL DRIVE BELT REMOVAL A176R559.wmf A176R560.wmf 1. Remove the lens unit cover [A] and light shielding plate [B]. (Refer to Scanner Drive Wires Replacement.) 2. Remove the light shielding mylar bracket [C] (1 screw). NOTE: When re-installing the mylar bracket [C], be sure not to create any gap between the bracket and the lens cover.
Page 336 OPTICS 15 July 1996 A176R561.wmf A176R562.wmf 5. Remove the lens unit [A] (2 screws). 6. Loosen the tension pulley bracket [B] (1 screw). 7. Push the pulley bracket to the front then unhook the timing belt [C]. 8. Remove the two timing belt holders [D] (1 screw each). NOTE: When setting the timing belt, align the end [E] of the timing belt to the edge [F] of the belt holder.
Page 337 15 July 1996 OPTICS 2.12 LENS VERTICAL DRIVE BELT REMOVAL A176R563.wmf A176R564.wmf 1. Remove the third scanner drive unit. (Refer to Third Scanner Drive Motor Replacement.) 2. Remove the front bracket [A]. (Refer to Scanner Drive Wires Replacement.) 3. Remove the lens unit [B]. (Refer to Lens Horizontal Drive Belt Replacement.) 4.
Page 338 OPTICS 15 July 1996 2.13 ORIGINAL SIZE SENSORS (2 LENGTH SENSORS, 1 WIDTH SENSOR) A176R565.wmf 1. Remove the exposure glass. (Refer to Exposure Glass Removal.) 2. Remove the lens unit cover [A] (2 screws). 3. Remove the original size sensor covers [B] (1 screw each). 4.
Page 339: Development And Toner Supply
15 July 1996 DEVELOPMENT AND TONER SUPPLY 3. DEVELOPMENT AND TONER SUPPLY 3.1 DEVELOPMENT UNIT REMOVAL A176R568.wmf A176R569.img 1. Turn off the main switch. 2. Open the front doors. 3. Remove the shutter cover [A] by releasing the hook [B]. NOTE: Be sure to move the lever [C] until it contacts part [D] (fully to the front).
Page 340 DEVELOPMENT AND TONER SUPPLY 15 July 1996 A176R570.wmf A176R571.wmf 6. Close the toner hopper cap [A]. 7. Remove the screw [B] fixing the drum stay [C]. 8. Remove the drum stay knob [D] then take out the drum stay. 9. Disconnect the two connectors [E]. 10.
Page 341: Developer Replacement
15 July 1996 DEVELOPMENT AND TONER SUPPLY 3.2 DEVELOPER REPLACEMENT A176R572.wmf A176R573.wmf 1. Take out the development unit. (Refer to Development Unit Removal.) 2. Place the development unit on the sheet [A] included with new developer. 3. Remove the two screws [B] fixing the toner hopper [C]. 4.
Page 342 DEVELOPMENT AND TONER SUPPLY 15 July 1996 A176R574.wmf A176R575.wmf 6. Clean the side seals [A] and entrance seal [B]. NOTE: Cover the sleeve rollers with a sheet of paper [C] to prevent the used developer being attracted to the sleeve rollers. 7.
Page 343 15 July 1996 DEVELOPMENT AND TONER SUPPLY 3.3 DEVELOPMENT ROLLERS REPLACEMENT A176R576.wmf A176R577.wmf 1. Remove the developer. (Refer to Developer Replacement.) 2. Remove the developer entrance seal [A] (2 screws, 2 hooks). 3. Remove the front and rear side seals [B]. NOTE: When re-assembling the development unit, use new side seals and align the edge of the side seals to the corner [C] and the edge [D] as shown.
Page 344 DEVELOPMENT AND TONER SUPPLY 15 July 1996 A176R578.wmf A176R579.img 4. Remove the coupling gear [A] (1 screw). NOTE: Be careful not to lose the pin [B]. 5. Remove the gear [C] (1 E-ring), gear [D] (1 E-ring) and gear [E]. CAUTION Do not touch the screws at [F] and [G].
Page 345 15 July 1996 DEVELOPMENT AND TONER SUPPLY 7. Replace the sleeve rollers. 8. Re-assemble the development unit and set the developer, then re-assemble the copier. NOTE: 1) If the original developer (already used) is returned to the development unit, do not perform the developer initial setting. 2) If the new developer is set, never make any copy before completing the developer initial setting ( SP Adjustment -...
Page 346: Toner Density Sensor Replacement
DEVELOPMENT AND TONER SUPPLY 15 July 1996 3.4 TONER DENSITY SENSOR REPLACEMENT A176R580.wmf 1. Remove the developer. (Refer to Developer Replacement.) 2. Replace the TD sensor [A] (2 screws). NOTE: Before installing the TD (Toner Density) sensor, clean the development unit well so that no carrier particle remains in the gap between the TD sensor and the development unit casing.
Page 347 15 July 1996 DEVELOPMENT AND TONER SUPPLY 3.5 TONER BOTTLE DRIVE MOTOR REPLACEMENT A176R581.wmf A176R582.img 1. Open the toner bottle holder [A] with the bracket [B]. (Refer to Development Unit Removal.) 2. Remove the toner bottle [C]. 3. Remove four screws then remove the toner bottle holder by unhooking the hole [D] from the pin on the hinge.
Page 348 DRUM UNIT 15 July 1996 4. DRUM UNIT 4.1 DRUM UNIT REMOVAL AND OPC DRUM REPLACEMENT A176R583.wmf A176R584.img 1. Take out the development unit. (Refer to Development Unit Removal.) 2. Lower the transfer belt unit. 3. Take out the drum unit by holding the knob [A]. NOTE: Close the protective shutter [B] to protect the OPC drum from light when the drum unit is left outside the machine for servicing.
Page 349: Quenching Lamp Replacement
15 July 1996 DRUM UNIT 4.2 QUENCHING LAMP REPLACEMENT A176R585.img CN663 A176R586.wmf 1. Remove the OPC drum. (Refer to Drum Unit Removal and OPC Drum Replacement.) NOTE: Wrap a protective sheet or a few sheets of paper around the drum to protect it from light. 2.
Page 350 DRUM UNIT 15 July 1996 4.3 GRID PLATE/CHARGE WIRE/WIRE CLEANER REPLACEMENT A176R587.wmf A176R588.wmf 1. Take out the main charge corona [A] (1 screw, 1 connector). 2. Remove the grid plate [B] (1 plastic screw, 4 hooks). NOTE: When installing the grid plate, do not tighten the plastic screw [C] too strongly.
Page 351 15 July 1996 DRUM UNIT A176R589.wmf A176R590.wmf A176R591.wmf 7. Remove the wire cleaner [A] (1 snap ring). 8. Install the wire cleaner and the charge corona wire. NOTE: Locate the joint part [B] of the wire in the rear end block as shown.
Page 352 DRUM UNIT 15 July 1996 4.4 ERASE LAMP AND DRUM POTENTIAL SENSOR REPLACEMENT A176R592.wmf A176R593.wmf 1. Open the drum shutter [A]. 2. While pushing the hook [B] to the front by using a small flat head screw driver [C], move up the front side of the erase lamp [D] as shown. 3.
Page 353: Cleaning Blade Replacement
15 July 1996 DRUM UNIT 4.5 CLEANING BLADE REPLACEMENT A176R594.wmf A176R595.wmf 1. Remove the OPC drum. (Refer to Drum Unit Removal and OPC Drum Replacement.) 2. Remove the cleaning blade [A] (2 screws). 3. Clean the entrance seal [B], side seals [C] and cleaning brush [D]. NOTE: When a vacuum cleaner is used, to protect the electrical parts from static electricity, disconnect the connector on the charge power pack and remove the ID sensor as follows:...
Page 354: Cleaning Brush Replacement
DRUM UNIT 15 July 1996 4.6 CLEANING BRUSH REPLACEMENT A176R596.wmf 1. Remove the cleaning blade. (Refer to Cleaning Blade Replacement.) 2. Remove the coupling gear [A] (1 screw). 3. Remove the grounding wire [B] (1 screw). 4. Remove the bushing [C]. 5.
Page 355 15 July 1996 DRUM UNIT 4.7 PICK-OFF PAWL REPLACEMENT A176R597.wmf 1. Remove the bushing [A] (1 screw and retaining ring). 2. While pulling the shaft [B] to the rear, turn the pick-off pawl about 45 degree clockwise (front view) and move up the pick-off pawl. 3.
Page 356 DRUM UNIT 15 July 1996 4.8 TONER COLLECTION MOTOR REPLACEMENT A176R598.wmf A176R599.img NOTE: Before starting the procedure remove the drum unit and the transfer belt unit to prevent toner from dropping in the machine. 1. Open the front doors then remove the toner collection bottle [A] (1 push-lock [B]).
Page 357: Ozone Filter Replacement
15 July 1996 DRUM UNIT 4.9 OZONE FILTER REPLACEMENT A176R600.wmf 1. Open the front doors and open the toner bottle holder. 2. Remove the transfer belt unit prop [A] (3 screws). 3. Replace the ozone filter [B]. NOTE: To install the transfer belt unit prop smoothly, set in order the lower pins [C], drive roller shaft [D], and the upper pins [E].
Page 358: Transfer Belt Unit
TRANSFER BELT UNIT 15 July 1996 5. TRANSFER BELT UNIT 5.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION A176R601.wmf A176R602.wmf - Removal - 1. Turn off the main switch. 2. Remove the transfer belt unit prop [A] (3 screws). 3. Disconnect the connector [B]. 4.
Page 359 15 July 1996 TRANSFER BELT UNIT A176R603.wmf A176R604.wmf 2. Install the transfer belt unit prop (3 screws). NOTE: To install the transfer belt unit prop smoothly, set in order the lower pins [A], drive roller shaft [B], and the upper pins [C]. 3.
Page 360: Transfer Belt Replacement
TRANSFER BELT UNIT 15 July 1996 5.2 TRANSFER BELT REPLACEMENT A176R605.wmf A176R606.wmf 1. Take out the transfer belt unit. (Refer to Transfer Belt Unit Removal.) 2. While raising the knob [A], disconnect the two connectors [B]. 3. Turn the transfer belt upper unit [C] 90 degrees counterclockwise, then raise and remove it.
Page 361 15 July 1996 TRANSFER BELT UNIT A176R607.wmf A176R608.wmf A176R609.img 5. Turn the belt drive roller holder [A] clockwise (front view) and remove the bias terminal [B] (1 screw). 6. Replace the transfer belt [C]. NOTE: 1) Before installing the transfer belt, clean both sides of the transfer belt with a dry cloth (do not use alcohol).
Page 362 TRANSFER BELT UNIT 15 July 1996 5.3 CLEANING BLADE REPLACEMENT A176R610.wmf A176R612.wmf A176R611.wmf 1. Remove the transfer belt unit. (Refer to Transfer Belt Replacement.) 2. Remove the cleaning blade [A] and the small blade [B] (2 screws). 3. Clean the seals [C]. NOTE: When using a vacuum cleaner, to protect the transfer power pack from static electricity, remove the power pack as follows: 1) Disconnect two connectors [D].
Page 363: Paper Feed
15 July 1996 PAPER FEED 6. PAPER FEED 6.1 PAPER TRAY UNIT REMOVAL A176R613.wmf A176R614.wmf To facilitate transportation, the upper part of the copier (copier main frame) [A] and the lower part of the copier (paper tray unit) [B] can be separated as follows: 1.
Page 364: Paper Tray Removal
PAPER FEED 15 July 1996 6.2 PAPER TRAY REMOVAL - Tandem Tray Removal (1st tray of the A176/A177/A191/A192 copier) - A176R615.wmf A176R616.wmf 1. Open the left door and draw out the tandem tray. 2. While pushing the release lever [A] to the right with the head of the screw driver [B], slightly push the right tandem tray [C] to separate it from the left tandem tray [D].
Page 365 15 July 1996 PAPER FEED - Universal Tray/550 sheet tray/Built-in LCT Removal - A176R617.img A176R618.img 1. Draw out the tray. 2. Remove the tray from both guide Accurides as shown (4 screws). 5-65...
Page 366 PAPER FEED 15 July 1996 6.3 PAPER FEED ROLLERS REPLACEMENT A176R619.wmf 1. Turn off the main switch. 2. Remove the paper tray where the feed rollers belong to. (Refer to Paper Tray Removal.) 3. Remove the pick-up roller [A] (1 snap ring). 4.
Page 367 15 July 1996 PAPER FEED 6.4 TANDEM REAR FENCE DRIVE BELT REMOVAL A176R620.wmf A176R621.wmf 1. Draw out the tandem tray. 2. Separate the right tandem tray from the left tandem tray [A]. (Refer to Tandem Tray Removal.) 3. Remove the rear fence [B] on the left tandem tray (2 screws). 4.
Page 368 PAPER FEED 15 July 1996 A176R622.wmf 7. Disconnect the three connectors [A]. 8. Loosen the tightener screw [B] and unhook the tension spring [C]. 9. Remove the timing belt [D]. NOTE: When installing the timing belt, hook the spring [C] then, tighten the screw [B].
Page 369: Tandem Side Fence Motor Removal
15 July 1996 PAPER FEED 6.5 TANDEM SIDE FENCE MOTOR REMOVAL A176R523.wmf 1. Remove the bottom plate [A] of the right tandem tray (2 nylon rivets [B]). 2. Raise the lift arm [C] (2 screws). 3. Remove the cover [D] (1 screw). 4.
Page 370 PAPER FEED 15 July 1996 6.6 PAPER FEED TIMING ADJUSTMENT 10 mm A176R625.img 10 ± 5 mm A176R624.wmf 1) Paper feed timing adjustment for the 1st feed station 1. Place a white paper on the exposure glass so that there is a gap of 10 mm between the white paper [A] and the left scale [B].
Page 371 15 July 1996 PAPER FEED A176R625-2.img 7. For the first copy, touch the – key [A] or the + key [B] to adjust the white area width. 8. For the second copy, touch the – key [C] or the + key [D] to adjust the white area width.
Page 372 PAPER FEED 15 July 1996 A176R626.wmf A176R625-3.img 3) Paper feed timing adjustment for the by-pass feed station 1. Set two sheets of paper on the by-pass feed table [A]. 2. Enter SP mode (refer to Service Program Access Procedure) and access SP Adjustment - PAGE 2.
Page 373: Paper Feed Clutch Removal
15 July 1996 PAPER FEED 6.7 PAPER FEED CLUTCH REMOVAL A176R627.wmf A176R628.wmf 1. Turn off the main switch then open the right front door and remove the push-lock [A]. 2. Remove the toner collection bottle [B]. NOTE: If the LCT is installed, remove it from the copier. 3.
Page 374 PAPER FEED 15 July 1996 A176R629.wmf A176R630.wmf A176R631.img 5. Remove the knobs [A] (1 screw each) then remove the right inner cover [B] (2 screws). 6. While holding the shaft [C] with an Allen key, remove the fixing screw [D], then remove the knob [E].
Page 375 15 July 1996 PAPER FEED A176R632.wmf A176R633.img 11. Fully draw out the paper tray. 12. Remove the two screws [A] fixing the tray feed unit [B]. 13. Disconnect the connectors [C]. 14. Remove the tray feed unit. 15. Loosen the two Allen screws [D]. 16.
Page 376: By-Pass Feed Table Removal
PAPER FEED 15 July 1996 6.8 BY-PASS FEED TABLE REMOVAL A176R634.wmf 1. Remove the right inner cover. (Refer to Right Inner Cover Removal.) 2. Remove the total counter with bracket (1 screw, 1 connector). 3. Loosen the Allen screw [A] on the hinge. 4.
Page 377 15 July 1996 PAPER FEED 6.9 BY-PASS FEED ROLLERS REPLACEMENT A176R635.wmf A176R636.wmf 1. Open the by-pass feed table then remove the cover [A] (3 screws). 2. Replace the pick-up roller [B] (1 snap ring) and the feed roller [C] (1 snap ring).
Page 378 PAPER FEED 15 July 1996 A176R637.wmf A176R638.wmf 3. Remove the feed unit cover [A] as shown. 4. Replace the separation roller [B] (1 snap ring). 5-78...
Page 379 15 July 1996 PAPER FEED 6.10 BY-PASS PAPER SIZE SENSOR REPLACEMENT A176R639.wmf A176R640.wmf 1. Turn off the main switch. 2. Open the by-pass table and remove the feed unit cover. (Refer to Feed Unit Cover Removal.) 3. While pushing the hook [A] with the head of the flat head screw driver as shown, remove the table assembly [B] (2 screws, 1 connector [C]).
Page 380 PAPER FEED 15 July 1996 A176R641.wmf 5. Re-install the by-pass paper size sensor then reassemble the by-pass feed table. NOTE: When installing the table assembly, route the wires [A] correctly as shown. The paper guides [B] must be in the lower position as shown. 6.
Page 381 15 July 1996 PAPER FEED 6.11 BY-PASS FEED CLUTCH REMOVAL A176R642.wmf A176R643.wmf 1. Remove the upper rear cover [A]. (Refer to Upper Rear Cover Removal.) 2. Lower the main control board [B] (2 screws). 3. Unhook the main control board bracket hinge [C]. 5-81...
Page 382 PAPER FEED 15 July 1996 A176R644.wmf A176R645.wmf 4. Remove the by-pass feed motor [A] (2 screws). 5. Remove the clutch stopper [B] (1 screw). NOTE: When re-installing the by-pass feed clutch [C], set the pin [D] of the clutch in the cutout [E] of the stopper. 6.
Page 383: Registration Clutch Removal
15 July 1996 PAPER FEED 6.12 REGISTRATION CLUTCH REMOVAL A176R646.wmf 1. Lower then unhook the main control board bracket hinge. (Refer to By-Pass Feed Clutch Removal.) 2. Remove the clutch stopper [A] (1 screw). NOTE: When re-installing the registration clutch [B], set the pin [C] of the clutch in the cutout of the stopper [D].
Page 384 PAPER FEED 15 July 1996 6.13 PAPER DUST CLEANER REMOVAL A176R647.wmf 1. Remove the development unit. (Refer to Development Unit Removal.) 2. While pushing down the hook lever [A], remove the paper dust cleaner [B]. 3. Remove paper dust inside the paper dust cleaner and clean the inside of the cleaner with a dry cloth or a blower-brush.
Page 385: Registration Sensor Removal
15 July 1996 PAPER FEED 6.14 REGISTRATION SENSOR REMOVAL A176R648.wmf 1. Remove the right inner cover [A]. (Refer to Right Inner Cover Removal.) 2. Disconnect the connector [B]. 3. Pull out the registration sensor assembly [C]. 4. Clean the photo sensor [D] with a blower-brush. 5-85...
Page 386: Copier Feed Unit Removal
PAPER FEED 15 July 1996 6.15 COPIER FEED UNIT REMOVAL A176R649.wmf A176R650.wmf 1. Remove the development unit. (Refer to Development Unit Removal.) 2. Remove the right inner cover. (Refer to Right Inner Cover Removal.) 3. Remove the by-pass feed motor. (Refer to By-pass Feed Clutch Removal.) 4.
Page 387 15 July 1996 PAPER FEED A176R651.wmf 8. Remove the registration roller knob [A] (1 screw). 9. Remove the copier feed unit [B] (4 screws). NOTE: When installing the copier feed unit to the copier: 1) Do not pinch the harness. 2) Keep the duplex unit drawn out.
Page 388 PAPER FEED 15 July 1996 6.16 TANDEM FEED TRAY PAPER SIZE CHANGE NOTE: 1) At the factory, all paper trays (1st, 2nd and 3rd) are set as A4 sideways. At the customer’s request, change the paper size as follows. 2) For the 550 sheet fixed paper tray and the 1500 sheet built-in LCT, refer to the installation procedure section.
Page 389 15 July 1996 PAPER FEED A176R654.wmf A176R655.wmf 4. Re-install both side fences [A] to the appropriate position according to the paper size, as shown. NOTE: The position of the side fence holders [B] and the pins [C] on the lack gear differs according the paper size (from the outside pin: A4, 11", B5).
Page 390 PAPER FEED 15 July 1996 A176R652-2.wmf A176R656.wmf - Used as fixed tray for paper longer than A4/Letter sideways - 1. Draw out the tandem tray. 2. Remove the rear and the front side fences [A] (1 screw and 1 push-lock pin each) on the right tandem tray.
Page 391 15 July 1996 PAPER FEED A176R655-2.wmf 5. Change the position of the front and rear side fences [A] (2 screws each) and end fence [B] (2 screws) of the left tandem tray according to the paper size. 6. Enter SP mode (refer to Service Program Access Procedure) and access SP Special Features - PAGE 7.
Page 392 PAPER FEED 15 July 1996 6.17 UNIVERSAL TRAY PAPER SIZE CHANGE At the factory, the universal paper tray is set as A4/8 " x 11" sideways. Normally, paper size is changed by the customer by following the operating instructions. Only when the customer needs the A5/5 "...
Page 393: Fusing Unit Removal
8 July 1996 FUSING UNIT 7. FUSING UNIT 7.1 FUSING UNIT REMOVAL A176R658.wmf 1. Turn off the main switch. 2. Open the left front door. 3. Remove the stopper [A] (1 screw). 4. While releasing the lever [B], pull out the fusing unit as shown. NOTE: Hold the bottom of the fusing unit as shown.
Page 394 FUSING UNIT 8 July 1996 7.2 FUSING THERMISTOR REPLACEMENT A176R659.wmf A176R660.wmf 1. Remove the fusing unit. (Refer to Fusing Unit Removal.) 2. Remove the knob [A] (1 screw). 3. Remove the two screws fixing the fusing front cover [B]. 4. Pull the lever [C] then lower the cover [B] to unhook the fusing unit. 5.
Page 395: Fusing Thermofuse Replacement
8 July 1996 FUSING UNIT 7.3 FUSING THERMOFUSE REPLACEMENT A176R661.wmf 1. Remove the fusing unit upper cover. (Refer to Fusing Thermistor Replacement.) 2. Remove the terminal bracket [A] (2 screws, 1 hook). 3. Disconnect the three connectors [B]. 4. Replace the fusing thermofuse [C] (1 screw). NOTE: When re-assembling the fusing unit, secure the harness in the clamps correctly.
Page 396: Fusing Lamp Replacement
FUSING UNIT 8 July 1996 7.4 FUSING LAMP REPLACEMENT A176R662.wmf A176R663.wmf 1. Remove the fusing unit. (Refer to Fusing Unit Removal.) 2. Remove the terminal bracket [A] (2 screws). 3. Disconnect the front connectors [B] and the rear connectors [C]. 4.
Page 397: Hot Roller Replacement
8 July 1996 FUSING UNIT 7.5 HOT ROLLER REPLACEMENT A176R662-2.wmf A176R665.wmf 1. Remove the fusing lamps [A]. (Refer to Fusing Lamp Replacement.) 2. Lower the fusing exit assembly [B]. 3. Remove the upper stay [C] (4 screws). 4. Remove the oil supply unit [D] (Refer to Oil Supply Roller Replacement). 5-97...
Page 398 FUSING UNIT 8 July 1996 A176R666.wmf 5. Lower both side pressure spring holders [A] by using the screw driver [B] as a lever. 6. Remove the front and rear C-rings [C], gear [D], antistatic spacers [E] isolating bushings [F] and bearings [G]. NOTE: When installing a new fusing roller: 1) Lubricate the inner and the outer surface of the isolating bushings [F] with BARRIERTA L55/2 grease.
Page 399 8 July 1996 FUSING UNIT 7.6 PRESSURE AND BEARING ROLLER REPLACEMENT A176R667.wmf 1. Remove the hot roller. (Refer to Hot Roller Replacement.) 2. Remove the lower fusing entrance guide [A] (2 screws). 3. Lift the pressure roller [B] and remove it. 4.
Page 400: Fusing Stripper Pawl Replacement
FUSING UNIT 8 July 1996 7.7 FUSING STRIPPER PAWL REPLACEMENT A176R668.wmf A176R669.img A176R670.wmf 1. Turn off the main switch and pull out the fusing unit. 2. Lower the fusing exit assembly [A]. 3. Remove the two screws (the front screw [B] is a stepped screw) fixing the upper exit guide [C].
Page 401 8 July 1996 FUSING UNIT 7.8 FUSING PRESSURE ADJUSTMENT Rear Front A176R671.wmf A176R672.wmf NIP BAND WIDTH ADJUSTMENT STANDARD: 8.1 ± 0.8 mm (A175), 10.0 ± 0.5 (others) 1. Make a black copy (sky shot, A3/Double Letter paper). 2. As soon as the paper starts to exit, open the left door to stop the paper in the fusing unit.
Page 402 FUSING UNIT 8 July 1996 7.9 PAPER EXIT UNIT REPLACEMENT - Removal - A176R673.wmf A176R674.wmf 1. Remove the upper left cover. (Refer to Upper Left Cover Removal.) 2. Draw out the duplex unit [A]. 3. Remove the lever bracket [B] (2 screws). 4.
Page 403 8 July 1996 FUSING UNIT - Installation - A176R675.wmf 1. Set the paper exit unit in the following order: 1) Set the drive shaft [A] on the left rail [B]. 2) Set the plate [C] on the right rail [D]. 3) Set the positioning pin [E] in the hole [F].
Page 404 FUSING UNIT 8 July 1996 7.10 OIL SUPPLY/CLEANING ROLLER REPLACEMENT A176R676.img A176R716.wmf 1. Pull out the fusing unit. A176R717.wmf 2. Lower the lever [A]. 3. Remove the oil supply unit [B]. 4. Remove the upper entrance guide [C] (1 screw). 5.
Page 405: Pressure Roller Cleaning Roller Replacement
8 July 1996 FUSING UNIT 7.11 PRESSURE ROLLER CLEANING ROLLER REPLACEMENT A176R677.wmf A176R718.wmf 1. Pull out the fusing unit. 2. Remove the bottom plate [A] (1 screw). 3. Remove the cleaning roller unit [B] (2 screws). 4. Remove the brackets [C] (1 screw each). 5.
Page 406: Duplex Unit
DUPLEX UNIT 8 July 1996 8. DUPLEX UNIT 8.1 FEED ROLLER REPLACEMENT A176R678.wmf A176R679.wmf 1. Open the front doors and draw out the duplex unit. 2. Remove the duplex front cover [A] (3 screws). 3. Slide the lever [B] to the rear then open the duplex reverse assembly [C]. 4.
Page 407 8 July 1996 DUPLEX UNIT A176R680.img 6. Remove the harness bracket [A] (1 screw). 7. Remove the gear [B] (1 E-ring). 8. Remove the bushing [C] (1 E-ring). 9. Slide the feed roller shaft [D] to the rear then slide the feed roller [E] to the front and replace it as shown.
Page 408 DUPLEX UNIT 8 July 1996 8.2 SEPARATION BELTS REPLACEMENT A176R681.wmf A176R682.wmf 1. Open the front doors and draw out the duplex unit. 2. Remove the gear [A] (1 E-ring). 3. Remove the bracket [B] (1 screw) then remove the gear [C]. 4.
Page 409 8 July 1996 DUPLEX UNIT A176R683.wmf A176R684.wmf A176R685.wmf 7. Remove the bushing [A] (1 snap ring). 8. Remove the drive roller [B]. 9. Replace the three separation belts [C] as a set. NOTE: When setting the tension spring [D], set it on the hook [E] normally.
Page 410: Duplex Unit Removal
DUPLEX UNIT 8 July 1996 8.3 DUPLEX UNIT REMOVAL A176R686.wmfV A176R687.wmf 1. Open the front doors and remove the left door. 2. Remove the right inner cover [A]. (Refer to the right inner cover removal.) 3. Draw out the duplex unit [B] until the stop position. 4.
Page 411 8 July 1996 DUPLEX UNIT 8.4 SEPARATION CLUTCH/TRANSPORT CLUTCH REMOVAL A176R688.wmf A176R689.wmf Before replacing both clutches, take out the duplex unit. (Refer to Duplex Unit Removal.) NOTE: When installing both clutches, be sure to set the stopper [A] to the projection [B].
Page 412 DUPLEX UNIT 8 July 1996 8.5 JOGGER MOTOR REPLACEMENT A176R690.wmf A176R691.wmf 1. Take out the duplex unit. (Refer to the duplex unit removal.) 2. Remove the duplex front cover (3 screws). 3. Slide the lever [A] to the rear then open the separation belt unit [B]. 4.
Page 413 8 July 1996 DUPLEX UNIT A176R692.wmf A176R693.wmf 9. Remove the positioning roller drive gear [A] (1 E-ring). 10. Remove the bushing [B] (1 E-ring). 11. Remove the positioning roller assembly [C]. 12. Remove the front jogger fence [D] and the rear jogger fence [E] (1 screw each).
Page 414 DUPLEX UNIT 8 July 1996 A176R694.wmf A176R696.wmf A176R695.wmf 14. Remove the drive wire stoppers [A]. 15. Unhook the tension spring [B] and remove the drive wire [C]. 16. Remove the E-ring [D] and slide the shaft [E] to the left. 17.
Page 415 8 July 1996 DUPLEX UNIT A176R697.wmf A176R698.wmf A176R699.wmf - Jogger Drive Wire Installation - 1) Set the bead [A] which is closer to the red colored hook [B] in the hole [C] and install the stopper [D] (1 screw). 2) Round the drive wire twice around the drive motor pulley [E] as shown. 3) Move the rear jogger fence bracket [F] to the rear end position (until the bracket [F] touches the screw [G]) and keep this condition.
Page 416 DUPLEX UNIT 8 July 1996 A176R515.wmf A176R719.wmf A176R700.wmf NOTE: 1) Adjust the position of the stopper [A] so that the jogger fences [B] and side plate [C] are parrallel. 2) When installing the jogger fences, confirm if the two positioning pins [D] are correctly set in the two holes on the side fences after the screw is set.
Page 417: Copy Quality Adjustment
8 July 1996 DUPLEX UNIT 8.6 COPY QUALITY ADJUSTMENT 8.6.1 SP Adjustment Mode The copy quality adjustments in the table below can be performed by using the appropriate SP Adjustment mode. SP Adjustment Change Item Standard Default - PAGE Amount/1 step 0 ±...
Page 418 DUPLEX UNIT 8 July 1996 A176R701.img A176R702.img 1. Enter SP mode (refer to Service Program Access Procedure) and access SP Adjustment mode. 2. Access the appropriate page by touching the "Prev." [A] or "Next" [B] key. 3. Touch the "Copy in SP" key [C] then select the proper copy mode. 4.
Page 419 8 July 1996 DUPLEX UNIT 8.6.2 Side-to-side Registration Adjustment (except for copier with RDH and Finisher) A176R703.wmf A176R705.wmf A176R704.wmf – Rough Adjustment – 1. Loosen the screws [A] for the tandem tray or built-in LCT, [B] for 550 sheets fixed tray or universal tray, or [C] for by-pass feed tray. 2.
Page 420 DUPLEX UNIT 8 July 1996 8.6.3 Side-to-side Registration Adjustment (copier with RDH and Finisher) If the side-to-side image registration for paper fed from the duplex tray should be adjusted, follow the entire procedure below. If the side-to side registration for duplex tray feed does not need to be adjusted but side-to-side registration for the paper feed tray should be adjusted, follow only steps 4 and 5 of the procedure below.
Page 421 8 July 1996 DUPLEX UNIT 8.6.4 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 lamp or exposure adjustment wings to make light intensity from the exposure lamp even across its...
Page 422 DUPLEX UNIT 8 July 1996 A176R707.img A176R708.wmf 4. Turn the screw [A] to correct the position of the filament. The left edge of the exposure lamp [B] should be directly beneath the center of the sight hole [C] in the reflector cover. CAUTION Do not touch the screw [D].
Page 423 8 July 1996 DUPLEX UNIT 8.6.5 Image Density Adjustment When: The copy image density is already adjusted to the standard level at the factory, and process control maintains copy image density until the next PM. If the customer asks you to adjust the image density, it can be done by using the User Tool mode.
Page 424 DUPLEX UNIT 8 July 1996 8.6.6 Scanner Height Adjustment When: If optically skewed images appear after adjusting the 1st and 2nd scanner positions. Purpose: To maintain a proper copy image. How: Turn the 3rd scanner height adjusting cam. This changes the 3rd scanner’s height. A176R566.wmf Leading edge A176R567.wmf...
Page 425: Troubleshooting
SECTION 6 TROUBLESHOOTING...
Page 426: Service Call Conditions
15 July 1996 SERVICE CALL CONDITIONS 1. SERVICE CALL CONDITIONS 1.1 SUMMARY There are 4 levels of service call conditions. Level Definition Display The SC can only be reset by SC display will not be canceled. service representative (see note in the next page) to prevent the machine from being damaged.
Page 427 SERVICE CALL CONDITIONS 15 July 1996 NOTE: 1) If the problem is related to electrical circuit boards, first disconnect then reconnect the connectors before replacing the PCBs. 2) If the problem is related to motor lock, first check the mechanical load before replacing motors or sensors.
Page 428 15 July 1996 SERVICE CALL CONDITIONS 1.2 EXPOSURE SC101 - Exposure lamp malfunction - abnormal On/Off Definition: [level: A] During the lamp off condition, the optics control board detects a lamp voltage. Possible causes • Exposure lamp open • Triac shorted •...
Page 429 SERVICE CALL CONDITIONS 15 July 1996 1.3 SCANNER SC120 - Scanner home position sensor abnormal - stays off Definition: [level: D] The scanner home position sensor does not detect the on condition even if the scanner returns home. Possible causes: •...
Page 430 15 July 1996 SERVICE CALL CONDITIONS 1.4 LENS MAGNIFICATION SC140 - Lens vertical home position sensor abnormal - stays off Definition: [level: D] When the lens returns to the home position, the lens vertical home position sensor does not detect the on condition for 2 seconds or more, and more than twice.
Page 431 SERVICE CALL CONDITIONS 15 July 1996 SC144 - 3rd scanner home position sensor abnormal - stays off Definition: [level: D] When the 3rd scanner returns to the home position, the 3rd scanner home position sensor does not detect the on condition for 1.2 seconds or more, and more than twice.
Page 432 15 July 1996 SERVICE CALL CONDITIONS 1.5 OPTICS THERMISTOR SC190 - Optics thermistor open Definition: [level: D] The optics thermistor is open. Possible causes: • Optics thermistor open NOTE: When the optics thermistor is shorted, no SC code is indicated. The exhaust fan rotates quickly and continuously.
Page 433 SERVICE CALL CONDITIONS 15 July 1996 SC303 - Charge corona wire cleaner failure Definition: [level: C] The current of the charge corona wire cleaner drive motor is over the specified current within 4 seconds after the cleaner motor starts. The charge corona wire cleaner does not move back to the end block within 30 seconds.
Page 434 15 July 1996 SERVICE CALL CONDITIONS 1.8 PROCESS SENSOR SC351 - Abnormal Vsg Detection (Vsg > 4.2V) Definition: [level: C] The detected Vsg value is over 4.2 V. Possible causes: • ID sensor defective • Main control board defective SC352 - Incomplete TD sensor initial setting Definition: [level: C] The output voltage of the TD sensor is higher than 2.6 V or lower than 2.4 V during the developer initial setting mode.
Page 435 SERVICE CALL CONDITIONS 15 July 1996 SC354 - Abnormal Vsg detection (Vsg ≤ 2.5 V) Definition: [level: C] Vsg is 2.5 V or less. Possible causes: • ID sensor defective • OPC drum • Dirty charge corona casing • Quenching lamp defective •...
Page 436 15 July 1996 SERVICE CALL CONDITIONS SC361 - Incomplete drum potential sensor calibration Definition: [level: C] When the process control initial setting is performed and a development bias of –100 V or –800 V is applied to the drum shaft, the drum potential voltage is out of these ranges: 0.1 ≤...
Page 437: Transfer Current
SERVICE CALL CONDITIONS 15 July 1996 1.9 TRANSFER CURRENT SC402 - Transfer current leakage Definition: [level: D] When the transfer power pack output voltage exceeds 4.5 kV for 200 ms or more, the output current is multiplied by 0.8. If this condition occurs 11 time in a row, an SC is displayed.
Page 438: Paper Feed
15 July 1996 SERVICE CALL CONDITIONS 1.11 PAPER FEED SC500 - Abnormal manual feed drive motor speed Definition: [level : D] Lock signal stays low in the manual feed motor on condition for 1.0 second or more. Possible causes: • Manual feed motor defective SC501 - Abnormal paper feed drive motor speed Definition: [level: D]...
Page 439 SERVICE CALL CONDITIONS 15 July 1996 SC504 - Abnormal 3rd lift motor (1.5 k LCT motor for A096 copier) movement Definition: [level: B] The 3rd lift sensor detects the high condition for 10 seconds or more after the 3rd lift motor starts. The first time, after the paper tray is opened and closed, the 3rd lift motor starts again.
Page 440 15 July 1996 SERVICE CALL CONDITIONS SC510 - Abnormal tandem side fence home position detection - stays off Definition: [level: B] When the side fence goes back to the home position or the side fence drive motor works to open the fence, the side fence positioning sensor does not detect the on condition for 5 seconds or more.
Page 441 SERVICE CALL CONDITIONS 15 July 1996 SC523 - Abnormal jogger home position sensor detection - stays on Definition: [level: B] The jogger home position sensor does not detect the off condition for 1 second after its sensor detects the on condition in the initializing mode. Possible causes: •...
Page 442 15 July 1996 SERVICE CALL CONDITIONS SC545 - Low fusing temperature (detected by the main control board) SC546 - Low fusing temperature (detected by the optics control board) Definition: [level: A] The fusing temperature stays lower than 100°C for 5 seconds after the machine becomes ready.
Page 443: System Control
SERVICE CALL CONDITIONS 15 July 1996 1.14 SYSTEM CONTROL SC600 - Communication error (main control board and operation panel) Definition: [level: D] The main control board does not communicate with the operation panel. Possible causes: • Main control board defective •...
Page 444 15 July 1996 SERVICE CALL CONDITIONS SC621 - Communication error (main control board and sorter staplers/ finisher main board) Definition: [level: D] The main control board does not communicate with the sorter stapler/ finisher main board. Possible causes: • Main control board defective •...
Page 445 SERVICE CALL CONDITIONS 15 July 1996 1.16 FINISHER/SORTER STAPLER SC730 - Abnormal *transport motor sorter stapler/finisher) movement Definition: [level: D] When the encoder pulse is not detected by the SS (or finisher) main board for 200 ms after the *transport motor starts, a jam is displayed. If this occurs twice, an SC is displayed.
Page 446 15 July 1996 SERVICE CALL CONDITIONS SC735 - Abnormal jogger motor movement (sorter staplers/finisher) Definition: [level: B] When the jogger moves back to the home position, the jogger home position sensor does not detect the on condition within 650 pulses. Then, a jam is indicated.
Page 447 SERVICE CALL CONDITIONS 15 July 1996 SC740 - Abnormal staple unit drive motor movement (sorter stapler/ finisher) Definition: [level: B] The staple unit home position sensor does not detect the on condition when the staple unit is in the home position. A jam is indicated. The staple unit home position sensor does not detect the on condition (within 1640 pulses) when the staple unit moves to the home position.
Page 448 15 July 1996 SERVICE CALL CONDITIONS SC743 - Punch motor abnormal (sorter stapler with punch) Definition: [level: B] When turning on the main switch, the punch home position sensor is not activated within 1100 pulses. Then an R2 jam is indicated. In punch mode, the punch home position sensor is not activated within 950 pulses after rotating the punch motor.
Page 449 SERVICE CALL CONDITIONS 15 July 1996 1.17 OTHERS SC900 - Total counter failure (staying in the off condition) Definition: [level: D] The total counter stays in the off condition. Possible causes: • Total counter defective SC901 - Total counter failure (staying in the on condition) Definition: [level: D] The total counter stays in the on condition.
Page 450: Electrical Component Defects
15 July 1996 ELECTRICAL COMPONENT DEFECTS 2. ELECTRICAL COMPONENT DEFECTS 2.1 SENSORS NOTE: All photo-interrupters go low (GND) when the actuator interrupts the gap between the LED and the photo transistor. Component Symptom Condition (Symbol) (when the main switch turns on) Scanner HP Open SC125 is displayed...
Page 451 ELECTRICAL COMPONENT DEFECTS 15 July 1996 Component Symptom Condition (Symbol) (when the main switch turns on) Duplex Paper End "Copies left in the duplex tray.." indicator is (S-13) Open displayed even if there is paper in the duplex 112-A9 tray. Only one rear side copy is made regardless Shorted of the quantity of copies.
Page 452 15 July 1996 ELECTRICAL COMPONENT DEFECTS Component Symptom Condition (Symbol) (when the main switch turns on) Auto-Response The machine does not exit "Screen Saver" (S-26) Open mode even if an operator approaches the 113-B3 machine. Shorted "Screen Saver" mode does not work. Drum Potential Open Machine quits auto process control and...
Page 453 ELECTRICAL COMPONENT DEFECTS 15 July 1996 Component Symptom Condition (Symbol) (when the main switch turns on) 3rd Paper Near End "Paper near end" indicator is not displayed Open (4 Tray version even if the tray is almost empty. 412-A8 only) "Paper near end"...
Page 454 15 July 1996 ELECTRICAL COMPONENT DEFECTS 2.2 SWITCHES Component CN No. Condition Symptom By-Pass Table "Open the by-pass tray" indicator is (SW-1) Open displayed even if the by-pass tray is opened. 108-B11 Print key stays red. Shorted By-pass feed motor continuously turns. Front Door Safety "Close the door"...
Page 455 ELECTRICAL COMPONENT DEFECTS 15 July 1996 2.3 FUSES 2.3.1 DC Power Supply Board Component Condition Symptom FU801 (125 V, 10 A) Power is not provided when the main switch is on Open (No indicator displayed on the operation panel). FU802 (125 V, 5 A) Power is not provided when the main switch is on Open (No indicator displayed on the operation panel).
Page 456 COPIER ELECTRICAL COMPONENT LAYOUT A176S500.wmf...
Page 457 A176S501.wmf...
Page 458 A176S502.wmf...
Page 459 143B 143A A176S503.wmf...
Page 460 A176S504.wmf...
Page 461 A176S505.wmf...
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Page 467 Copier Symbol Description Index No. P-to-P Motors Scanner Drive Exhaust Fan Main Development Drive By-pass Feed 3rd Scanner Drive Toner Bottle Drive Charge Wire Cleaner Drive Jogger Lens Horizontal Drive Lens Vertical Drive Optic Cooling Fan Fusing/Duplex Drive Paper Feed 1st Lift 2nd Lift Toner Collection...
Page 468 Symbol Description Index No. P-to-P 2nd Feed 3rd Feed 4th Feed (4 Tray version only) Switches By-pass Table Front Door Safety 1st Tray Set (Non-Tandem version only) 2nd Paper Size Toner Overflow Toner Collection Bottle Set Lower Front Door Safety 3rd Tray Set (4 Tray version only) Main SW10...
Page 469 Symbol Description Index No. P-to-P Lens Vertical HP Lens Horizontal HP 3rd Scanner HP By-Pass Paper End Guide Plate Position Jogger HP Vertical Transport Duplex Exit Duplex Entrance Sensor Duplex Paper End Duplex Transport Exit Fusing Exit Paper Guide Auto Image Density Original Length-1 Original Length-2 Original Width...
Page 470 Symbol Description Index No. P-to-P Side Fence Positioning (Tandem version only) Rear Fence Return (Tandem version only) Rear Fence HP (Tandem version only) Left Tandem Paper End (Tandem version only) LCT Near End (1,500 Tray version only) Tray Down (1,500 Tray version only) Tray Paper Set (1,500 Tray version only) Side Fence Close (Tandem version only) 4th Lift (4 Tray version only)
Page 471 Symbol Description Index No. P-to-P Fusing Thermistor Optics Thermistor Drum Thermistor (Located on the ID Sensor Ass’y) Transfer Anti-Condensation Optics Anti-Condensation Main Power Relay Total Counter Noise Filter Circuit Breaker Lightening Arrestor...
Page 472 3.5 k LCT Symbol Name Index No. P-to-P Sensors Paper End Paper Near End Paper Position Tray Down Feed Lift Switches LSW1 Feed Unit Cover LSW2 LCT Cover LSW3 Tray Down Motors Feed Others LSOL1 Pick-up LMC1 Feed...
Page 473 Point To Point Diagram (A175 5911) Optic Thermistor Exposure CN1-3 Fusing 120V 60HZ CN1-1 Fusing Lamps Thermistor Circuit (L2) Lens Lens Optics Auto Platen CN1-4 Lens Lens Platern Breaker Noise Horizontal Vertical Cooling Image Original Original Original Scanner Scanner Cover CN1-2 Horizontal Scanner...

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