Download - FT9101 (F5) Field Service Manual - Diagramas dediagramas.diagramasde.com/otros/Ricoh FT9101FM.pdfFIELD SERVICE MANUAL LARGE CAPACITY TRAY RT32 ... CONNECTOR BRACKET KP10 COMPANY, LTD.

RICOH FT9101FIELD SERVICE MANUAL

LARGE CAPACITY TRAY RT32

FINISHER SR500

PRINTER CONNECTOR UNIT PCU10

KEY COUNTER/PRINTER

CONNECTOR BRACKET KP10

COMPANY, LTD.

Read This First

A few simple symbols and notations are used to help you read faster and find the information youneed. Before you use this guide, glance over this list of special notations and be sure youunderstand what they mean.

NOTE

Information under this heading describes helpful hints, restric-tions, and how to avoid difficulties.

CAUTION

Failure to pay attention to CAUTION notices canresult in damage to the equipment.

WARNING

Warnings are for your safety. Failure to payattention to WARNING information can bedangerous to you and others.

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 are supplied with electricalvoltage even if the main switch is turned off.

4. If any adjustment or operation check has to be made with exterior coversoff or open while the main switch is turned on, keep hands away fromelectrified or mechanically driven components.

5. The inside and the metal parts of the fusing unit become extremely hotwhile the copier is operating. Be careful to avoid touching thosecomponents with your bare hands.

HEALTH SAFETY CONDITIONS 1. Never operate the copier without the ozone filter installed.

2. Always replace the ozone filter with the specified one at the specifiedinterval.

3. Toner and developer are non-toxic, but if you get either of them in youreyes by accident, it may cause temporary eye discomfort. Try to removewith eye drops or flush with water as first aid. If unsuccessful, get medicalattention.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1. The copier and its peripherals must be installed and maintained by a

customer service representative who has completed the training courseon those models.

2. The main control board has a lithium battery which can explode if handledincorrectly. Do not replace the battery. Do not recharge, or burn thisbattery. Used batteries must be handled in accordance with localregulations.

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 photoconductorsaccording to local regulations. (These are non-toxic supplies.)

3. Dispose of replaced parts in accordance with local regulations.

4. When keeping used lithium batteries (main control boards) in order todispose of them later, do not put more than 100 batteries (main controlboards) per sealed box. Storing larger numbers or not sealing them apartmay lead to chemical reactions and heat build-up.

SECTION 1

OVERALL MACHINE INFORMATION

1. INSTALLATION

1.1 Installation Requirements

1.1.1 Delivery and installation work flow

Installation environment, floor strengthInstallationcondition check

Operation check as far as themachine stand-by condition

Machine power on

Delivery

Clamp removal

Main body setup

Installation of peripherals

Machine operation check

User guidance

Space around machine, delivery route

Power supply

The user’s acceptance of the limited itemsfor using the machine (See User GuidanceItems section for the limited items.)

Supply developer

Supply cleaning carrier

Set OPC belt

Supply silicon oil

Install power plug and cord

Leveling

Installing original stacker

Installing sub-tray

Installing toner cartridge

Setting copy paper

1 July 1994 Installation Requirements

1-1

1.1.2 Environment

Select the conditions which fully satisfy the following items at installation.

1. Avoid a place exposed to direct sunlight or other strong light (should be below 1500 lux).

2. Avoid locations with high temperatures or high humidity, or low temperatures and lowhumidity. (Standard range of temperature and humidity: 10oC to 30oC, 15% to 90%)

3. Avoid places with hot air or strong heat sources.

4. Avoid locations subject to abrupt temperature changes.

5. Avoid small or dusty rooms.

6. Avoid poorly ventilated locations. (Air turnover should be 3 times or more per hour perperson.)

7. Install the machine flat on the floor. It must be level within 5 mm front to rear and 5 mm leftto right. This is mainly to prevent affecting the tracking operation of the OPC belt.

8. Align the position of the LCT and finisher with the copier. First, adjust the height ofperipherals on the basis of the exterior covers position. Finally, align the paper transportguide plate height between each unit. This is to prevent paper misfeeds where each unitconnects.

9. The unit must be installed on a floor which can support its total weight: copier including ADF482 kg, finisher 77 kg, and LCT 75 kg.

10. Provide enough space, 100 cm in front, 60 cm in rear and 30 cm on both sides for operationand service. No fluorescent lights should be installed above the operation unit. (This is tomake it easier to see the operation display.)

1.1.3 Power connection (For the European version machine only)

1. Plug

The plug must be approved under the TÜV safety standard and for a three-phase power supply.

2. Power supply cord

The cord must be approved under the TÜV safety standard and have five wires inside. Thecross-sectional area of each wire must be 2.5 mm2, and the outside diameter of the cord mustbe 14 to 18 mm. (The capacity must be over 600 volts and 16 A for each phase.) The lengthmust be 5 m or less even if an extension cord is used.

1.1.4 Transportation

Remove the operation unit beforetransporting the copier if the copier cannotget into the elevator or copy room. Thisreduces depth to 775 mm from 830 mm.Remove the cardboard packing in advance.

1. Remove four screws (M4 x 6) from the operationunit.

2. Remove the connector for the operation unit andremove the operation unit.

CAUTION

Never carry the copier side down.

Connector

4 screws (M4 x 6)Operation unit

Installation Requirements 1 July 1994

1-2

1.2 Copier Installation

1.2.1 Accessory list

Name Diagram Quantity UseDeveloper vesselCleaning carrier vesselCleaning carrier magnet

1 of each To collect the developer and cleaning carrier.

Vessel rail

2 To set the developer vessel.

Original stacker

1 To receive originals from the ADF.

OPC belt

1

Leveling shoe

4 For the docking position adjustment.

Original back fence

1 To install on the original stacker.

Development unitgrounding harness

1 To avoid damage of the image density sensor boardwhen a vacuum cleaner is used.

Tray fences fixing plate 3 To fix the paper tray side fences.

Syringe

1 To apply silicon oil in the fusing unit.

Plated screw M 4 x 8 4 To secure the vessel rails.Counter reset key

1 To reset the total counter to 0.

Printer interface board 1 To connect a printer using service tool [6]. Theseparts are needed when the optional printerconnector unit is installed. Keep these parts forfuture use.

Short printer harness

1

Long printer harness

1 To connect a printer using service tool [6].

NOTE

When the optional finisher is not used, the sub-tray (P/N-A0291460) must be ordered and used.

Sub-tray 1 To receive copies fed out. (Not required when thesorter is used.)

1 July 1994 Copier Installation

1-3

1.2.2 Removing the clamps

1. Remove the cushions from the paper feed tray, thecushion from the copy tray, and the strips offilament tape from the exterior.

2. Open the center door and remove the 7 strips offilament tape and a cushion from the transport unit.

3. Remove the right cover (2 screws). Then, removethe clamps from tray 1, tray 2 and tray 3 using aslot head screwdriver.

ADF

Cushions (2)

Cushion Cushions (3)

Center doorCushion

Clamp

Right cover

Copier Installation 1 July 1994

1-4

4. Take off the left cover and remove the red bracket

holding the second mirror.

5. Remove the protective sheets of the exposure

glass and copy tray.

6. Remove the strips of filament tape from the duplexunit.

Protective sheet Copy tray

Filament tape

Holder bracket


1-5

7. To remove the inner cover, remove the left doorfixing screw (2 screws), and disconnect the coolingfan connector.

8. Remove the first mirror bracket (red bracket).

9. To enable accessing the service tool password,turn on DIPSW101-2.

10. Remove the OPC cleaning unit fixing screw to pullout the unit, and cut the unit fastener.

11. To pull out the fusing unit, remove the front fusingcover (2 screws) and one unit fixing screw.

12. Remove the cover from the right side of the unit (4screws).

13. Loosen the pressure fixing screws to remove thewedges on the front and far side. Re-tighten thepressure fixing screws.

14. Install the fusing right side cover.

NOTE

Install the front fusing cover after pouring silicon oil.

15. Peel off the plain sheet behind the fusing oil pan.

Sheet

Left door

Inner cover

Cooling fanconnector

Mirrorbracket

Unit fixing screw

Unit fastener

Unit fixing screw(before removal) Wedges

Pressurefixing screw

Wedge

Pressure fixing screwUnit fixing screw

Front fusing cover


1-6

1.2.3 Setting up the copier

1. Release the development backup rollers by thelever, and remove the development unit fixingbracket. Then, slide out the unit.

2. Remove the filter cover from the developer supplyport (2 screws). While turning the developmentknob in the direction opposite to the arrow, put in 4bags (1 kg/bag) of developer from the supply port.

CAUTION

• Clean off the developer on the unit casing.It may touch the OPC surface.

• Do not put in another compound (cleaningcarrier, etc.) by mistake.

3. Reinstall the filter cover.

4. Turn the development knob in the direction of thearrow and return the developer from thedevelopment roller to the unit inside.

Developmentbackup lever

Fixing bracket

Filter cover

Developer

Developersupply port

Casing

Development knobDevelopment knob

Filter cover

Development knob


1-7

5. Slide in the development unit, and fix it with thefixing bracket.

6. Release the cleaning backup roller by the lever,and remove the cleaning fixing screw to pull outthe cleaning unit.

7. Remove the upper cover from the cleaning unit (4screws). Put in one bag of cleaning carrier (700 g)on the cleaning roller (right side of the unit).

CAUTION

• Be sure that the carrier is not in thescavenging roller side.

• Do not put in another compound bymistake, such as developer, etc.

• Distribute the carrier evenly by turning theknob. This unit has no agitation mechanismas the development unit does.

8. Close the upper cover, set the unit in the mainbody, and secure it with the fixing screw.

Fixing bracket

Cleaning fixing screw

Cleaningbackup lever

Upper cover

Cleaning carrier

Cleaning roller

Fixing screw


1-8

9. Pull out the charge corona unit, and release the

transport unit.

10. Release the development and cleaning back-up

levers, and turn the development knob in thedirection of the arrow. Then, remove the OPC unitstay to pull out the OPC unit.

CAUTION

Be sure to return the developer from thedevelopment roller to the inside of the unitbefore pulling out the OPC unit. Do this byturning the development knob.

11. Insert two paper tubes (OPC belt accessories) inthe two guide holders of the OPC unit. Then,release the pressure release lever to loosen thetension, and pull the OPC belt out of the case.

12. Use the paper tubes as guides to fit the OPC beltto the unit.

CAUTION

• As you fit the OPC belt, be sure to preventfolds and contact between the side plate ofthe OPC unit and the belt end. Do nottouch the OPC surface directly.

• Set the OPC belt so that the OPC homemark is on the rear side of the machine.

• The rear side of the OPC belt must be underthe OPC sensor.

Charge corona unit

Development back-up lever

Cleaningback-up lever

Transport unit

OPC unit stay

OPC belt case

Pressurerelease lever

Paper tubeGuide holder

OPC home mark side

OPC belt


1-9

13. Set the OPC belt in the center of the unit andrestore tension to the belt with the pressurerelease lever.

14. Set the OPC unit in the main body and install theOPC unit stay.

15. Set two backup levers, and position the chargecorona unit, its connector, and transport unit.

16. Install the inner cover (2 screws and a connector)and left door (2 screws).

OPC unit stay

Transport unit

Charge corona unitBackup levers

Inner cover

Left door

Pressure release lever

OPC sensor


1-10

17. Pull out the fusing unit and remove the front fusingcover.

18. Put silicon oil in the oil sump. About 80 g of oil issufficient.

19. Install the front cover and set the unit in the mainbody.

20. Put two cans of silicon oil in the oil tank. (2/3 ofcapacity makes about 200,000 copies.)

CAUTION

Never remove the oil supply unit from the fusingunit to prevent oil marks on copies. It can beremoved only when the oil blade, meteringblade, and oil supply felt are replaced with newones.

21. Tighten the screw (M4 x 8 plated screw:accessory) on the rear of the vessel rails(accessories). Put the screws in the hole at thebottom rear of the machine frame.

22. Fit the vessel rails on the bottom of the machine,and secure each of them with the screw (M4 x 8plated screw) from the front of the machine. Setthe developer vessel (accessory) on the rail. Putthe cleaning carrier vessel and magnet (bothaccessories) in the developer vessel.

Oil tank

Cleaningcarrier vessel

Cleaningcarrier magnet

Developer vessel

Vessel rail


1-11

European version machine only (Steps 23 to 27)

CAUTION

The power supply cord and plug for theEuropean version machine must meet thefollowing requirements:

• The plug must be approved under the TÜVsafety standard and for a three-phasepower supply.

• The cord must be approved under the TÜVsafety standard and have five wires inside.The cross-sectional area of each wire mustbe 2.5 mm 2, and the outside diameter of thecord must be 14 to 18 mm. (The capacitymust be over 600 volts and 16 A for eachphase.) The length must be 5 m or lesseven if an extension cord is used.

23. Remove the rear left cover (2 screw).

24. Remove the power supply cord bracket (2 screws).Then, pass the power supply cord through the cordbushing.

25. Connect the five wires of the power supply cord tothe appropriate terminals as shown.

CAUTION

• Secure each wire to the terminals firmlywith screws.

• The grounding wire is green and yellow.

26. Reinstall the power supply cord bracket. Then,tighten the nut to secure the bushing with the cord.

CAUTION

Be sure that the cord bushing secures the cordfirmly.

27. Install a plug on the other end of the power supplycord.

CAUTION

• Connect five wires to each of the terminals’L1’, ’L2’, ’L3’, ’N’, and "Grounding" in thesame order as on the machine.

• Secure each wire to the plug firmly withscrews.

The machine is set up for a 400 volts 3-phasepower supply (European version) or 240 voltssingle phase power supply (U.S.A. version) atthe production line. To install the machine inareas where the power supply is 380 or 415 volts(220 or 230 volts single phase), follow the stepsbelow:

28. Loose the screw and disconnect the wire from the400 volts (or 240 volts) terminal.

29. Connect the wire to an appropriate terminal andtighten the screw. The terminal to be connecteddepends on the power supply from the wall outlet.

CAUTION

The 200 volts terminal never be used. The copierrequires 380 volts (or 220 volts single phase) atleast.

Cord fixing nut Cord bushingPower supply cord bracket

220 or380V

230 or400V

240 or415V


1-12

30. Remove the rear right cover (2 screws).

31. Be sure that the proper connector of the harnessfrom the timer board is set. The color of eachconnector means the following:

Black: for 380 or 220V power supplyRed: for 400 or 230V power supplyYellow: for 415 or 240V power supply

32. If the connector setting does not meet the powersupply, connect an appropriate connector.

33. Set the leveling shoes (accessories) to level themachine.

STANDARD

Difference, front to rear Within 5 mmDifference, left to right Within 5 mm

CAUTION

Using a level gauge, level the machine flat onthe floor. This is mainly to prevent affecting thetracking operation of the OPC belt.

34. Install the exterior covers.

NOTE

Do not install the exterior covers at this stage if thefinisher or LCT is to be installed.

35. Fit the original stacker (accessory) and sub-tray(must be ordered separately if necessary). To fitthe original stacker, use screws which secured theupper left cove (M4 x 12 plated screw).

36. Put the original back fence (accessory) on theoriginal stacker.

NOTE

The sub-tray is not required if the finisher is used.It is installed in the LCT if the LCT is used and thefinisher is not.

Timer boardtransformer

Red connector

Black connector

Yellow connector

Original stacker

Sub-tray

Leveling shoe

Screws securingupper left cover


1-13

37. When inch size originals are used, make a slot asshown to stop the original stopper at the 81/2 inchposition.

CAUTION

When the slot is made, operating cautions mustbe instructed to operators, so that operatorscan adjust the original stopper positioncorrectly according to the original size set in theADF. The A4 position and 8 1/2 inch position arevery close. If the original stopper position is notproper, original misfeeds will occur.

38. Set the toner cartridge.

CAUTION

Shake the toner cartridge well before you set it.

39. Set paper in each paper tray.

CAUTION

Do not block the fan filter windows of the leftand rear exterior covers.

Original stopper


1-14

Technical Support

See MB 17.

1.3 Machine Operation Check

1.3.1 Stand-by operation check

1.3.2 Copier operation check

CAUTION

Before making copies, carry out forming for the developer, OPC belt, and cleaningcarrier (in this order) using service tool [3-04].

1. Check the stand-by operation referring the above. Connect the power plug, then turn on themain switch.

2. Access the service tool, and do all formings.

3. Check that all the keys on the operation panel and paper tray down keys work properly.

4. Check that safety switches of the center door, upper right door, and copy tray work properly.

5. Place a sheet on the original table of the ADF and check that the ADF mode is selected.Also, insert a sheet in the SADF table and check that the SADF mode is selected.

The cleaning coilcooling fan, twoozone exhaust fans(behind the rear leftcover), andcleaning unitcooling fan (behindthe left cover) startturning.

1. Configuring the first andsecond mirrors.2. The fusing heater ON.3. The OPC belt ON (2 turns).4. The Tracking motor ON .5. All the fans ON except forthe duplex and ADF blowers.

The idling mode starts (30 seconds).The main motor repeats turning on andoff four times during this period.

The Start keyturns green.

200

Approx.30 sec.

Fusing Temp.[° C]

Powerconnection

Main switchON

175 ° C175 to 180 ° C

100

1 July 1994 Machine Operation Check

1-15

1.3.3 Copy quality check

CAUTION

Before checking copy image quality, check the toner density control data in theservice tool [4-02] screen. Perform setting C if the data is not correct. Also, check theAID reference voltage in the [4-03] screen using the PC-1 chart. Perform setting A ifthe value is not correct. (If the AID reference voltage is within the standard, you donot have to perform setting A.)

1. To check the copy image quality and paper transportation in the copier, make some copiesin the platen cover (no ADF and SADF) and AID (Auto Image Density) modes using a testchart.

2. Follow the steps below to complete the image quality adjustment. (Refer to the followingpage for the standards.)

1) Position a test chart on the exposure glass. Make copies to check the side-to-side registration.Adjust it by changing the paper tray position, if necessary. Repeat this step for all paper trays.

2) Select the paper tray which has the largest paper size.

3) Access the service tool and select the [5-02] screen. Check and adjust all items in that screen.

4) Leave the service tool, and select the paper tray which has another paper size.

5) Again, check and adjust the erase margin and duplex side fences width on the [5-02] screen.Repeat this step for each paper size which will be used by the customer.

6) To check and adjust the side-to-side registration of the back side of the copy, make copiesin the duplex mode.

7) Remove the test chart from the exposure glass and insert an original in the SADF. Makecopies to check and adjust the leading edge and side-to-side registration in the SADF mode.

8) Place some originals in the ADF. Make copies to check and adjust the side-to-side registrationin the ADF mode.

CAUTION

a) The side-to-side registration must be checked for all paper trays.

b) The erase margin and duplex side fence width must be checked for all paper sizes.

c) If the erase margin is not sufficient, thin black lines may sometimes appear oncopies (especially on the side edges of copies in the ADF mode). This is because theside-to-side registration varies slightly on each copy if an operator does not set theoriginal side guides securely. You have to make more than 10 copies and check thatall of them are within specifications after the adjustment.

d) Check the side-to-side registration of the back side of the copy in the duplex modebefore installing the peripherals. If the value is outside specifications, you have toremove the copier right cover.

3. Put about 20 originals on the ADF and make one set of copies in the single original duplexmode. Repeat this procedure for all paper trays.

4. Put about 100 originals on the ADF and make one set of copies in the 2-sided original du-plex mode.

5. Insert an original in SADF and check that copying is normal.

6. If peripherals are installed, check that they works properly.

Machine Operation Check 1 July 1994

1-16

Technical Support

RTB 20 Margin adjustment software problems

1.4 Table of Image Quality Standards

Item Standard Measuring Method

Erase margin a) Leading edge 1≤a≤7 mmb) Trailing edge 1≤b≤5 mmc) Left side edge 1≤c≤5 mmd) Right side edge 1≤d≤5 mm

Make one solid black copy and measure blank dimensions at fouredges. After the adjustment, make more than 10 copies and checkthe variation.

2 < c+d ≤ 7 mm

Error in magnification In full size mode: Within ± 0.5%

In magnification mode: Within ±1.0%

Copy a scale and measure copy dimensions.

Registration Platen cover mode

a) Leading edge: 0 ± 2 mm

b) Left and right edges: 0 ± 2 mm

These values also valid on the 2-sidedcopy.

Copy a test chart and compare the image position differencebetween the original and the copy. After the adjustment, make morethan 10 copies and check the variation.

ADF/SADF mode

a) Leading edge:--3 to +5 mm (ADF mode)--4 to +6 mm (SADF mode)

b) Left and right edges: 0 ± 5 mm

The difference of the side-to-sideregistration between the front andback side must be within 5 mm.

Skew Platen cover mode Copy a test chart and compare the image position difference

a) ± 1 mm/200 mm or less. between the original and the copy.

ADF/SADF mode

a) ± 1.5 mm/100 mm or less (onsmaller than A4/Letter paper).

b) ± 1 mm/100 mm or less (onA4/Letter or larger paper).

1 July 1994 Table of Image Quality Standards

1-17

1.5 User Guidance Items

This section contains important information regarding efficient operation of the machine.

1.5.1 Guidance items prior to the installation

Items requiring user approval after explanation. This has to be done before machine installation.

Paper to use

1. We recommend using neutral paper as copy paper to prevent abnormal images. Some acidpapers contain talc, and this white powder will appear on the OPC surface as spots. Thiscauses abnormal copies, which have dirty spots on the background.

2. We recommend using lengthwise grain in all cases to prevent creased copies.

How the original influences copy images

1. In patched originals, shadows around the patched part appear on copies as black lines.

2. In OHP originals, drawn pictures and characters are copied double.

Smoothing original curls

To avoid transport trouble, advise users to correct large curls before setting the original. Refer tothe illustrations and information given below.

1. The original cannot be transported if it curls (face curl).

2. The original cannot be transported if it curls down (back curl) 10 mm or more.

Original to use

There are some types of paper that should not to be used as originals with the ADF. The followingare some examples:

1. Dog-eared, torn, or creased paper

2. Coated paper (carbon paper, thermal paper, etc.)

3. Curled paper

4. Originals that are glued or taped

Face curl (3 mm or less)No curl is acceptable for thickoriginals of 65 g/m2 or heavier.

Back curl (10 mm or less)

User Guidance Items 1 July 1994

1-18

5. Translucent paper (including OHP)

NOTE

The above types of paper may be used as anoriginal in the SADF mode.

6. Damp paper

7. Bound originals

8. Paper that is thicker or thinner than specified for this machine

Originals that have holes as shown cannot be used inthe ADF mode.

A: No holes are allowed on the leadingedge. (To prevent multifeeding.)

B: No holes are allowed in these areas.(The recycle arm may be caught in theholes.)

C: Holes larger than 6 mm in diameter arenot allowed on the trailing edge.

D: Holes larger than 10 mm in diameter arenot allowed in the center. (To prevent sen-

sor’s misdetection.) This type of paper can-not be used in the SADF mode either.

Paper replenishment

When the 2nd or 3rd paper tray runs out of paper and the indication Add paper lights in red, thismeans there are still about 50 sheets of paper left in the tray.

Fusing oil

The pick-off pawls of the fusing unit sometimes make slight oil marks on the leading edge of copies .

Copy image area

1. The blank range is provided as shown to preventoriginal shadows on copies.

2. Damp copy paper will have an 8 mm blank margin(or less) at the trailing edge of the front side, and ifduplex copying, the back side will have a blankmargin of 10 mm (or less) at the trailing edge.

[Leading edge]

10 mm

50 mm

10 mm

100 mm

100 mm

AB

C

D

B

[Leading edge]

Total of left and rightshould be 7 mm orless.

1 July 1994 User Guidance Items

1-19

1.5.2 Additional guidance items

Explain the following if the user is unfamiliar with the subject items.

Stacking duplex copies

When a large number of duplex copies (100 copies or more) are produced, we recommend usingthe finisher so they are stacked in the shift tray because toner from the stacked copies on the cop-ier’s copy tray may be deposited by heat.

How the main switch is used

The ozone exhaust fans and transport vacuum fan continue to operate when the main switch isOFF to discharge air from the machine. This prevents image deterioration on the OPC caused byfumes, which is produced by the corona discharge. Also, heaters turn on when the main switch isOFF and prevent condensation on the mirror and lens and damp paper in trays. Advise users neverto pull out the power plug or shut off power from the source. Tell them to use the main switch topower off.

Toner cartridge replacement

Used toner is collected in the toner cartridge and is never used again because it cannot be used forcopying. Direct users about the following points.

1. Never pull the shutter again after the cartridge is set. If the shutter is pulled, the collectedtoner is used again.

2. Firmly pull the vinyl sheet on the shutter when installing a new cartridge. If not, only abouthalf the amount of toner in the cartridge will fall to the development unit. This may cause aused toner blockage on the way from the cleaning unit.

Loading paper

When loading paper in the paper trays, do not exceed the load limit. It is indicated by a decal. If pa-per is excessively loaded, the top of the paper stack may hit the pick-up roller and damage it whenthe paper tray is set.

Loading original

When loading paper on the original table of the ADF, keep the maximum capacity (40 sheets for A3or 11" x 17" original and 80 sheets for the other sizes original). The load limit is indicated by a de-cal. If originals are excessively set in the ADF, original misfeeding or multifeeding may occur be-cause of the original separation system. The air knife cannot separate the originals when weight ofthe original stack is too heavy.

User Guidance Items 1 July 1994

1-20

1.6 Setting User and Service Tools

Explain all user tool items and some of the service tools to the customer. Then, listen to the cus-tomer’s requests and set the copier accordingly.

Keep the set items using the following format. (If the main control board is replaced, you can set allitems again using the format.)

1.6.1 User tools

* Bold letters in "Set Data" shows the initial setting.

Menuno.

Description Set Data

1 Total sheets copied ----

2 Auto image density level selection [Lighter] [Normal] [Darker]

3 Copy/Original size selection [A3] [11 x 17] [A4] [81/2 x 13]

4 Segment skip ----

5 Date/Time setting ----

6 Disable display Margin adjustment [ON] [OFF]

Duplex [ON] [OFF]

Magnification [ON] [OFF]

7 Disable units ----

8 Select special tray Cover [Tray 1]

Slip sheet [Tray 1] [Tray 2] [Tray 3]

9 User access code ----

10 User Utility Select the finisher mode [Sort] [Stack]

Staple in stack mode [Yes] [No]Auto tray switching [Yes] [No]

3-side full image copy [Yes] [No]Select count up or down mode [Up] [Down]

Display the number of originals [Yes] [No]Exit originals to tray [Yes] [No]Select face up/down in stack mode [Face up] [Face down]Reverse back cover sheet [Yes] [No]

Copy onto slip sheets [Yes] [No]

11 Set staple position 1 staple upper 0 to 20 [ ] 101 staple lower 0 to 20 [ ] 102 staples 0 to 20 [ ] 10

12 Weekly timer ON: 00:00, OFF: 23:59

1 July 1994 Setting User and Service Tools

1-21

Technical Support

Weekly timer See RTB 16 for more details.

Technical Support

RTB 35 User Tool 13 added. This enables the selection of either simplex or duplex cover and/or slip sheets in the Cover or Chaptering mode with the Duplex Copy mode.

1.6.2 Service tools

* Bold letters in "Set Data" shows the initial setting.

Menu no. Description Set Data

1-01 Key operator access code 000 to 099 [ ] 0001-02 Service access code 99900 to 99999 [ ] 999001-03 Service telephone number [ ]

1-04 Disable display Full size indicator: [OFF] [ON]

Tray keys in APS mode: [OFF] [ON]

Density keys in AID mode: [OFF] [ON]

1-05 Weekly timer This function can be set with user tool no. 12.

1-06 Toner supply amount [15%] [30%] [45%] [60%]

1-07 Charge wire cleaning [YES] [NO]

1-08 Option installation [Tray 4] [Finisher] [Key Counter]

2-01 Count up/down [UP] [DOWN]

2-02 Set user program number 0 to 10 [ ] 102-03 Set fixed reproduction ratios See the table below.2-04 Delete fixed reproduction ratios No delete

[Initial Data]

[Set Data]

2-05 Set back side margin 0 to 21 mm in left or right.[ ] mm [Left] [Right] 5 mm Right

2-06 Maximum copy number 1 to 9999 [ ] 99992-07 Staple copy limit 1 to 50 [ ] 502-08 Free/user access code operation [Free use][Access code] [Access code/super user mode]

2-09 3-side full image [YES] [NO]2-10 Auto tray switching [YES] [NO]2-11 Original count display [YES] [NO]2-12 Set special paper tray [NO] [Tray 1] [Tray 2] [Tray 3] [Tray 4]

2-13 Auto reset , auto off Auto reset: [5 sec.] [1 min.] [3 min.] [ ∞ ]

Auto off: [30 min.] [1 hr.] [3 hr.] [ ∞ ]

2-14 Key tone Loudness: [OFF] [Low] [Normal] [High]

Tone pitch: [1] [2] [3] [4] [5]

2-15 Set exit tray copy limit [300] [350] [400] [NO]

2-16 Set initial display Display type selection: [Key operator] [Operator]Auto tray selection: [YES] [NO]

Tray selection priority: [APS] [Tray 1] [Tray 2] [Tray 3] [Tray 4]

Image density level selection:[AID]Density levels [1] [2] [3] [4] [5] [6] [7]

Finishing: [No Staple] [1 upper] [1 lower] [2]

Setting User and Service Tools 1 July 1994

1-22

Technical Support


Menu no. Description Set Data

2-16 Set initial display Margin adjustment mode selection:[No]Front side:

0 to 21 mm in left or right

[ ] mm [Left] [Right] 0 mmBack side:

0 to 21 mm in left or right

[ ] mm [Left] [Right] 5 mm RightDuplex mode selection:[No][Single ⇒ Duplex mode][Duplex ⇒ Duplex mode][Duplex ⇒ Single mode]

Reproduction mode selection:[Full-size]Fixed reproduction [ ] %Zoom reproduction [ ] %Auto paper selection [A3] [B4] [A4] [B5]

Copies number setting: 1 t0 9999 [ ] 14-01 Process control Grid: [ ] step

Flash: [ ] stepBias: [ ] stepPcc: [ ] stepVD: [ ] voltsVL: [ ] voltsVPCC: [ ] volts

4-02 Toner density control Target toner density: [ ] voltsID pattern level: [1] [2] [3] [4]

4-04 OPC cleaning operation [OFF] [5K] [10K] [20K] 10K4-05 Utility Mode no. 1 (0 to 15): [ ] 0

Mode no. 2 (0 to 15): [ ] 10Mode no. 3 (0 to 15): [ ] 0Mode no. 4 (0 to 15): [ ] 0Mode no. 5 (0 to 15): [ ] 0Mode no. 6 (ON or OFF): [ ] OFFMode no. 7 (ON or OFF): [ ] ON-8, 10Mode no. 8 (ON or OFF): [ ] ON-10Mode no. 9 (ON or OFF): [ ] OFFMode no. 10 (ON or OFF): [ ] ON-9 Mode no. 11 (ON or OFF): [ ] OFF Mode no. 12 (ON or OFF): [ ] OFF Mode no. 13 (ON or OFF): [ ] OFF Mode no. 14 (ON or OFF): [ ] OFF

NOTE: When mode no. 5 is set at 8 to 15, modes no. 6 to 14 havedifferent functions. So, describe the set number of mode no. 5 with"ON" when filling in the set data of modes no. 6 to 14. For example, ifmode no. 6 is turned ON while mode no. 5 is set at 8, describe the setdata of mode no. 6 as "ON-8".

5-02 Copy image Lead/trail edge erase: Lead [ ] mm, Trail [ ] mm

Side edge erase: Front [ ] mm, Rear [ ]mm

Lead edge registration: [ ] mm

Reproduction: [ ] %

Duplex side fences width: [ ] mm

5-03 Fusing temperature 0 to 15 [ ] 8 or 95-07 Set staple position This function can be set with user tool no 11.

1 July 1994 Setting User and Service Tools

1-23

Technical Support


Technical Support

RTB 20 Default setting changed Pre-heat did not work even if switched on, if a finisher mode is selected with [2-16]

Technical Support

RTB 28 Change VPCC if the cleaning carrier is older than a certain lot number

1.7 Logging Data Sheet

Size Tray 1 Tray 2 Tray 3 Tray 4 Total Duplex Finisher RDHA3 --------

B4

A4

B5

Sub Total --------

11 x 17 --------

81/2 x 14

81/2 x 11Total

[3-01] Tray Copies[3-02] Duplex/Finishing Copies

[3-03]Original Feeds

Location ON OFFTray 1

Tray 2

Tray 3

Tray 4

Regist

Pick-off

Fusing

Sub TotalDuplex

gate

Exit gate

Exit tray

Horz.Trans 1

Horz.Trans 2

LCT Top

DuplexFeed

Total

[3-05] Copier Misfeeds

Location ON OFFRDH Feed

RDH Trans

RDH Exit

Total

SADF Feed

SADF Exit

Total

Location ON OFF

InverterUnit

Finisher

Total

[3-06] RDH/Finisher Misfeeds

Code Code Code

1 36 80

2 40 81 3 41 82

4 42 83

10 43 84

11 44 85

12 45 86

13 50 87

17 51 88

20 52 8922 55 90

23 60 91

30 61 93

31 62 94

32 63 95

33 64 96

34 70 97

35 71 9899

Fus

ing

Hig

hV

olta

geD

rive

Opt

ics

Imag

ing

Pro

cess

Pap

er F

eed

Du-

plex

Con

trol

Dev

elop

-m

ent

[3-07] Service Calls

OPC

Developer

CL Carrier

Staple 1

[3-04] Supply yield

Date:

Customer:

Serial No. Copy Counter:

SADF

Hours

Power ON

Fusing LampMain Motor

OPC Belt Motor

DevelopmentMotor

Wire Motor

[3-08] Operation Time

3-01 3-05

3-02 3-06

3-03 3-07OPC

Developer

CL Carrier

Staple 1

Mark cleared item(s)

Logging Data Sheet 1 July 1994

1-24

[4-01] Process Control

[4-02] Toner Density Control

Date:

Customer:

Serial No. Copy Counter:

Setting(step)

Shift(step)

Grid Flash Bias PCCTarget(volts)

Actual(volts)

VD VL VR VPCC IDSensor

1 2 3 4ID Pattern Level

Lighter Darker

VSP(volts)

VSG(volts)

T. D.Sensor

Actual

VSG/VSPON

Setting

Actual

DeveloperForming

Target T. D.(volts)

PatternPotential(volts)

1 July 1994 Logging Data Sheet

1-25

Logging Data Sheet (Misfeeds)

ItemDate

Counter

Mark for data clear

Tray 1 ON

OFF

Tray 2 ON

OFFTray 3 ON

OFF

Tray 4 ON

OFF

Regist ON

OFF

Pick-off ON

OFFFusing ON

OFF

Sub total ON

OFF

DuplexGate

ON

OFF

ExitGate

ON

OFFExit Tray ON

OFF

Horz.Trans. 1

ON

OFF

Horz.Trans. 2

ON

OFF

LCT Top ON

OFFDuplexFeed

ON

OFF

Total ON

OFF

RDH Feed ON

OFF

RDH Trans ON

OFFRDH Exit ON

OFF

Total ON

OFF

SADF Feed

SADF Exit

TotalInverter

UnitONOFF

Finisher ON

OFF

Total ON

OFF

Customer

Serial No.


1-26

Logging Data Sheet (Service Calls)

ItemDate

Counter

Mark for data clear 1 2 3 4101112131720222330313233343536404142434445505152556061626364707180818283848586878889909193949596979899

Customer

Serial No.

1 July 1994 Logging Data Sheet

1-27

Logging Data Sheet (Copies/Originals)

Item Date

Counter

Mark for data clear

A3

A4

B5

11" x 17"8" 1/2 x 14"

8" 1/2 x 11"

Sub totalA3

A4

B5

11" x 17"

8" 1/2 x 14"8" 1/2 x 11"

Sub totalA3

A4

B5

11" x 17"

8" 1/2 x 14"

8" 1/2 x 11"Sub total

A4

B5

8" 1/2 x 14"

8" 1/2 x 11"

Sub totalTotal

A3B4

A4

B5

11" x 17"

8" 1/2 x 14"

8" 1/2 x 11"

TotalA3B4

A5

B5

11" x 17"

8" 1/2 x 14"

8" 1/2 x 11"

TotalA3B4

A4

B5

11" x 17"

8" 1/2 x 14"

8" 1/2 x 11"

TotalSADF

Customer

Serial No.

Tra

y 1

Tra

y 2

Tra

y 3

Tra

y 4

Dup

lex

Fin

ishe

rR

DH


1-28

Logging Data Sheet (Others)

Item Date

Counter

Power ON

Fusing Lamp

Main motor

OPC Belt motor

Development motor

Wire Cleaner Motor

OPC

DeveloperCleaning Carrier

Staple 1

[4-01] Process Control

Grid Setting (step)

Shift (step)

Flash Setting (step)

Shift (step)Bias Setting (step)

Shift (step)

PCC Setting (step)

Shift (step)

VD Target (volts)

Actual (volts)

VL Target (volts)

Actual (volts)VR Actual (volts))

VPCC Target (volts)

Actual (volts)

ID sensor Actual (volts)

[4-02] Toner Density Control

VSP Actual (volts)

VSG Actual (volts)

T.D. Sensor (volts)VSG/VSP

Target T. D.

Target (volts)

Actual (volts)

PatternPotential

Target (volts)

Actual (volts)

Remarks

Customer

Serial No.

Ope

ratio

n T

ime

Sup

ply

Yie

ld1 July 1994 Logging Data Sheet

1-29

1.8 LCT Installation

1.8.1 Accessories list

Name Diagram Quantity Use

Horizontal transport unit 1 This is the relay transport part between LCTand the copier and is attached to the copier.

Rear side fence 1 Rear side fence for the tray when 11" x 8 1/2"or 14" x 81/2" size paper (A4 size for theU.S.A. version machine) is used. (Notrequired if such paper is not used.)

Lock lever assembly 1 Guide plate open/close lever to be attachedto the horizontal transport unit.

Knob assembly 1 Manual drive knob to be attached to thehorizontal transport unit.

Sub-tray auxiliary plate 1 Auxiliary stay when the sub-tray is fitted toLCT. (Not required when the finisher is used.)

Docking pin 2 This is used for docking between LCT andthe copier and is attached to the copier.

Fixing stepped screw 2 Stud to install the sub-tray auxiliary plate.(Not required if the finisher is used.)

Leveling shoe 4 For the docking position adjustment.

Wire saddle 2 For clamping the power harnesses of theLCT and finisher to the exterior cover.

Pan head machine screw M4 x 6 6 For fixing the horizontal transport unit, locklever and knob.

Grounding screw M4 x 8 1 For fixing the protective earth wire of thepower supply harness (The copier side).

Plated screw M4 x 6 2 For fixing the sub-tray auxiliary plate.Upper cover stopper 1 To prevent fall of something placed on the

LCT upper cover when the cover is opened.

NOTE:

When the optional finisher is not used, the sub-tray (P/N-A0291460) must be ordered and used with the LCT.

Zinc plated

LCT Installation 1 July 1994

1-30


1. Remove the strips of filament tape holding the

upper cover.

2. Open the upper cover, and remove the filamenttape and cushion.

3. Remove the two screws so that the upper frontcover can slide up.

NOTE

The LCT upper front cover can be slid up to removethe misfed paper at the paper feed section.

4. Remove the right cover and rear cover.

5. Remove the rear side fixing bracket (4 screws).

6. Remove the front fixing bracket (2 screws) fromthe right side.

7. Pull out the tray, and remove the two screws soyou can remove the front fixing bracket.

8. Reinstall the exterior covers.

CushionFilament tape

Filament tape

Upper coverUpperfront cover

Front

Back side of front cover

Fixing bracketFront fixing bracketset screw

Front fixing bracket

1 July 1994 LCT Installation

1-31

9. Pull out the paper feed tray, and remove the backfence fixing cushion.

10. Remove the strips of filament tape from the tablebottom plate.

11. Take the horizontal transport unit out of theaccessory box, and remove the mylar protectingcardboard and strips of filament tape.

Cushion material

Filament tape

Filament tape

Mylar protecting cardboard

Filament tape

Filament tape


1-32

1.8.3 Setting up the LCT

1. Remove the copier right cover, rear right cover andsub-tray auxiliary plate.

NOTE

The sub-tray auxiliary plate is no longer needed.

2. Insert the horizontal transport unit (accessory) inthe lower side of the duplex unit, and fasten theunit with the two M4 x 6 screws (accessory). Atthe same time, connect 4P connector of the unit tothe copier.

3. Open the right cover and fasten the lock leverassembly and knob assembly with each of two M4x 6 screws (all are the accessories).

CAUTION

While holding down the small white roller of theupper left guide plate, tighten the lock leverassembly. Be sure that the lock lever bracketpushes down the upper left guide plate when itis locked.

Sub-tray auxiliary plate

Right cover

Horizontal transport unit

M4 x 6 (2)4P connector

Right cover

Knob assembly

Lock lever assembly


1-33

4. Remove the shielding cover for the LCT harnessand the rear right cover from the copier. Remove one screw to remove the connector cover.

5. Pass the LCT power and signal harnesses throughthe copier frame hole, and fix the harness fixingbracket with the two truss screws removed above.

6. Connect the 15P and 34P connectors respectively.

NOTE

The maximum load current of the LCT is 0.95 A.

7. Take the protective earth wire, feed it throughholes provided as shown, and fix it with thegrounding screw (accessory).

8. Fit the connector cover and copier rear right coverif the finisher will not be installed.

9. Set the two wire saddles (accessories) in the holeof the LCT rear cover, and put the power cord fromthe LCT in it.

NOTE

One of the wire saddles is for the harness from thefinisher.

10. Remove two blind caps from the copier right cover,and reinstall the right cover. Then, install thedocking pins to the copier base.

Connector cover

Shielding cover forLCT (lower side)

M4 x 6 truss screws (2)

Frame hole

34P connector

Connector cover15P connector

Harnessfixingbracket

LCT power andsignal harnesses

Truss screw

Grounding screw

Protective earth wire

Right cover

Docking pin

Main body


1-34

11. Be sure the linking stay of the LCT is locked. Alignthe copier docking pins with the LCT linking holes,and press the LCT until the pins click.

NOTE

If the finisher will be fitted, dock it with the copierafter the finisher’s harnesses are connected to thecopier.

12. Place the leveling shoes (accessories) under thestands. Then, turn the stand nuts to align thedocking position.

CAUTION

Align the position of the LCT with the copier.First, roughly adjust the LCT height on the basisof the exterior covers position. Then, open theLCT upper cover and check the lower paperguide plate position using a flat plate like ascale. Finally, align the paper transport guideplate height between the LCT and copier. Thisis to prevent paper misfeeds where the unitsconnect.

NOTE

If the finisher is to be installed, do the positionadjustment procedure after installing the finisher.

13. If the finisher is not used, remove the two screwsfrom the sub-tray auxiliary plate fitting holes. Then,fit the sub-tray auxiliary plate with the fixingstepped screws (both accessory), and set thesub-tray.

NOTE

The sub-tray must be ordered separately. The partnumber is A0291460.

14. Access service tool [1-08], and set the LCTfunction.

LCT

Linking stay

Fixing steppedscrew

Sub-tray

Sub-tray auxiliary plate

LCT right cover


1-35

1.9 Finisher Installation


Check the quantity and condition of the accessories inthe box according to the following list.

1. Cushion (575 x 15 x 5 mm) 1

2. Docking Pin 2

3. Docking Support Plate 1

4. Wire Clamp 1

5. Panhead Screw with Washer 1

6. Optical Fiber Cable 1

7. Power Harness 1

8. Panhead Screw M4 x 6 4

9. Ground Screw M4 x 8 (with Lock Washer) 2

10. Shift Tray 1

11. Plated Panhead Screw M4 x 8 4

12. Staple Cartridge 1

13. Original Set Position Decal 1

Finisher Installation 1 July 1994

1-36


CAUTION

Unplug the copier power cord before startingthe following procedure.

1. Remove the strips of filament tape on the finisherand remove the styrofoam blocks.

2. Remove the fixing screw and cut the bind for the

stapler using pliers.

Styrofoamblocks

Filamenttape

Filamenttape

Filamenttape

FilamenttapeFilament

tape

Bind

Fixing screw

1 July 1994 Finisher Installation

1-37

1.9.3 Harness connection to the copier

1. Remove the copier right cover (2 screws). If theLCT is not used, remove the two blind caps in theright cover and sub-tray auxiliary plate.

NOTE

The sub-tray auxiliary plate can no longer be used.

2. Remove the blind cover (upper side).

3. Remove the rear right cover (2 screws), thenremove the connector cover.

Rear right cover

Connector cover

Blind cover

Auxiliary plate

Right cover

Blind caps


1-38

4. Install the harness bracket of the power cord(accessory) with the two M4 x 6 pan head screws(accessories).

5. Take the grounding wire, feed it through holeprovided as shown. Secure it with the M4 x 8grounding screw (accessory). The groundingscrew must be firmly secured in place with a force10 to 15 kgfcm torque.

6. Set the optical fiber cable connectors from thecopier and finisher in the sockets of the harnessbracket. Also, connect 3P connector to the powercord.

CAUTION

The connectors (male) and sockets (female)must be set as shown.

7. Reinstall the connector cover and rear right cover.

8. Install the copier right cover. If the LCT is not used,install the two docking pins (accessories).

Connectorcover

Opticalfiber cableconnectors

3P connector

Groundingwire

Harnessbracket

Rightcover

Dockingpins


1-39

1.9.4 Docking preparation

NOTE

This procedure is required only when the LCT isused with the finisher.

1. Remove the right cover (5 screws) then removethe two blind caps.

2. Install the two docking pins (accessory).

3. Remove the 4 screws.

4. Install the docking support plate (accessory).Tighten the 4 screws removed in the above stepwhile holding the plate up.

NOTE

The docking support plate is required to strengthenthe docking parts in the LCT. The left side of thefinisher is supported only by the two docking pins.

5. Reinstall the LCT right cover.

1.9.5 Harness connection and docking

1. Remove the inverter rear cover (4 screws).

2. Pass the power cord and optical fiber cable

(connected to the copier side) through the harnessdocking hole. Then, secure the harness bracketwith the two M4 x 6 screws (accessories). At thesame time, bring the optical fiber cable into theclamp in the harness bracket and secure it with thewire clamp and panhead screw with washer(accessories).

CAUTION

Clamp the optical fiber cable in the harnessbracket so that the portion between the finisherand LCT (or copier) is longer than that of thepower cord.

3. Connect the power cord connector to the dc powersupply PCB and the optical fiber cable connectorto the inverter control PCB. Then, secure thegrounding wire with the M4 x 8 grounding screw(accessory) as shown. The grounding screw mustbe firmly secured in place with a force of 10 to 15kgfcm torque.

CAUTION

The optical fiber cable connector must be set tothe socket on the PCB properly as it has thesetting direction.

4. Bind the power cord with the wire clamp.

5. Reinstall the inverter rear cover.

Screws

Docking supportplate

Docking pins

Inverterrear cover

Groundingscrew

Power cordconnector

Wireclamp

Harnessdocking hole

Wire clamp

Clamp

Harnessbracket

Opticalfiber cableconnector


1-40

6. Stick the cushion (accessory) on the left side of the

finisher as shown.

7. Open the finisher and inverter front doors. Thenremove the linking stay access hole cover (2screws).

8. Be sure that the linking stay of the finisher is in thelock position. Align the docking pins with thelinking holes of the finisher, and press the finisheruntil the docking pins click. Reinstall the linkingstay access hole cover.

9. Install the finisher shift tray with four M4 x 8 platedpanhead screws (accessories).

10. Open the finisher front door and install the staple

cartridge (refer to the instruction decal on the rearside of the front door):

a) Pull out the staple unit.

b) Release the lock lever and turn the stapler counterclockwise until it locks.

c) Remove the green plastic clip from the staple cartridge, and install the cartridge in the stapler.

d) Set the stapler to its original position.

e) Push the staple unit in its original posi tion.

Cushion

0 to 2 mm

5 to 10 mm

Linking stay

Shift tray

Cover

Greenplasticclip

Lock lever

Staple unit


1-41

11. Put the two leveling shoes (accessories) under thestands.

12. From the front and rear, check the clearancebetween the exterior covers of the finisher andcopier (or LCT). It must be 3 to 7 mm. To adjustthe position of the finisher with the copier (or LCT),turn the stand’s nuts as shown.

13. From the top of the finisher, check the position ofthe finisher with the copier (or LCT). The finishermust be aligned with the copier (or LCT) as shownin the upper illustration. Adjust the finisher heightby turning the stand’s nuts again, if necessary.

14. Stick the original set position decal (accessory) onthe RDH as shown.

15. Plug the power cord and turn on the main switch ofthe copier. Wait for the copy stand-by condition.

16. Access service tool [1-08] and set the finisherfunction.

17. Test the operation of the finisher.

NOTE:

• Select the staple mode (2 staple mode) andmake more than 10 sets of copies before start-ing the stapling operation test. This is becausethe staple unit performs stapling motion withoutstaples until the first staple from the cartridgereaches the proper position for stapling. Thisprocedure is required only after installing thefirst staple cartridge.

• If customer prefer the shift tray rise mode,which is to rise the shift tray when the paper onthe tray is removed during a copy run, turn ondip switch 101-1 on the finisher control PCB.

0 ± 1 mm 0 ± 1 mm

100 mm

10 mm

Decal

5 ± 2 mm

Leveling shoe

5 ± 2 mm


1-42

1.10 Printer Installation


Check the quantity and condition of the accessories inthe box according to the following list.

Key counter bracket accessory check

1. Snap Bushing 1

2. Wire Clamp 2

3. Philips Sunken Head Screw - M3 x 8 2

4. Philips Pan Head Screw - M4 x 8 4

5. Philips Plated Screw - M4 x 8 4

6. Grounding Screw with Star Washer 2


8. Key Counter Hole Blind Cover 1

9. Key Counter Fixing Plate 1

10. Printer Connector Hole Blind Cover 1

Printer connector unit accessory check

1. Grounding Screw with Star Washer 2


3. Wire Clamp 1

NOTE:

The printer interface board (P/N A112 5060), printerharness (P/N A531 5420), 2 connector joint studs(2 x P/N 1102 4039), and 4 nylon studs (4 x P/N1105 0193), which are the copier’s accessories, arerequired for the printer connector unit installation.

1.10.2 Installation procedure

1. Remove the exterior cover in the rear of the copytray (3 screws). Then, remove the two coverbrackets (2 screws each).

2. Install the key counter/printer connector bracketwith four M4x8 philips pan head screws and onegrounding screw (accessories).

3. Install the snap bushing (accessory) as shown.

4. Remove the copier rear right cover (2 screws).

5. Take the two connectors which are clampedbehind the key counter/printer connector bracket,then feed them through the hole in the bottom ofthe bracket as shown.

Exteriorcover

Connectorbracket

Groundingscrew

Coverbracket

Coverbracket

Snap bushing

1 July 1994 Printer Installation

1-43

6. If an optional key counter is installed, install the

key counter receptacle with the two M3x8 philipssunken head screws and key counter fixing plate(accessories).

NOTE

The key counter must be one of the following:- Hengstler (For the European version machine only)- Hecon- Veeder Root

7. Remove the shorting connector, then connect theconnectors from the key counter and copier.

8. Install the two wire clamps (accessories) andclamp the harness as shown.

9. If the optional printer connector unit is notinstalled, install the printer connector hole blindcover with the two M3x6 philips plated screws (allare accessories).

10. If the optional printer connector unit is

installed, install it with the grounding screw andM4x8 philips plated screw (accessories).

11. Connect the connector of the harness form thecopier to the PCB on the printer connector unit.

12. Install the 4 nylon studs, then the printer interfaceboard. Connect the connector of the harness fromthe printer connector unit to the interface board.

13. Install the printer harness with the two connectorjoint studs.

NOTE

The printer interface board (P/N A112 5060), printerharness (P/N A531 5420), 2 connector joint studs(2 x P/N 1102 4039), and 4 nylon studs (4 x P/N1105 0193), which are copier accessories, arerequired for the printer connector unit installation.

14. Connect the other end of the printer harness to theconnector on the printer interface board.

15. Fix the grounding wire with the grounding screw(accessory). Then, install the wire clamp(accessory) then clamp the printer harness withthe clamp as shown.

16. 1If an optional key counter is not installed, installthe key counter hole blind cover with the two M3x8philips sunken head screws and key counter fixingplate (accessories).

Groundingscrew

Optional printerconnector unit

GroundingscrewNylonstudsWireclamp

Blind cover

Fixingplate

Connector

Printerharness

Connectorjoint studs

Printer interfaceboard

Keycounterreceptacle Key counter

fixing plate

[E]

Wire clamp

Blind cover

Shortingconnector

Printer Installation 1 July 1994

1-44

17. Install the key counter/printer connector bracketcover [A] with the grounding screw [B] and the 4M4x8 philips plated screws (accessories).

NOTE

If the optional printer connector is installed, a printerwith a standard RS232C interface is required. Usea printer with the following functions:

Mode: Asynchronous

Data format: Start/Stop/Data: 1 bit each

Data bit length: 8 bits

Parity permission: With

Parity setting: Even parity

Baud rate setting: 1,200 bps

Connector: 25 pins, D-connector

Bracketcover

Groundingscrew

1 July 1994 Printer Installation

1-45

SECTION 2

REPLACEMENT AND ADJUSTMENT

2. REPLACEMENT AND ADJUSTMENT

2.1 Paper Feed

2.1.1 Replacing the feed, reverse and pick-up rollers

PM cycle: Replace every 400K

NOTE

One set of the feed, reverse and pick-up rollers canfeed up to approximately 150,000 sheets of paper.If the paper trays are not used evenly, replace therollers that are worn more with the rollers that areworn less. Do this before any rollers wear out.

1. Press the tray down keys for all paper trays.

2. Turn off the main switch.

3. Pull out and remove the 1st tray (2 screws).

CAUTION

Note that the unit fixing screws are the steppedscrew on the right side and the plated screw onthe left side.

4. Pull out the 2nd and 3rd trays.

5. Remove stop rings from rollers in the 1st, 2nd, and

3rd feed station.

6. Slide and remove rollers and replace rollers.

CAUTION

• Do not touch the new roller surfaces withbare hands.

• Install the feed roller in the correct direction.

Stepped screw

Plated screw

Paper feed roller

Pick-up roller

Reverse roller

1 July 1994 Paper Feed

2-1

2.1.2 Replacing parts in the paper feed unit

Replace parts in the paper feed unit when:

• Electric parts are changed (paper feed motor,various sensors and pick-up solenoid).

• The grip roller is replaced.

Removing paper feed unit

1. Remove the inner cover(s) from the vertical

transport unit.

2. Remove the paper tray from the paper feed stationas it is required to remove the feed unit.

3. Disconnect and put the paper feed connector tothe far side.

4. Loosen the slot head fixing shaft and pull it about10 mm in the direction of the arrow.

5. When you need to remove the feed unit at the third

feed station, remove the oil pump unit bracket (2screws).

1st tray

2nd tray

3rd tray

Remove for the 1st tray

Remove for the 2nd or 3rd tray

Paper feed connector

(-) fixing shaft

Fitting screwOil pump unit bracket

Oil tube

Paper Feed 1 July 1994

2-2

6. Remove the screws from the paper feed unit fixing

bracket.

7. Hold the far side of the unit to move it to the rightand push the front to the far side to remove theunit.

Checking the unit

1. Remove the paper tray.

2. Loosen and pull the (slot head) fixing shaft withoutremoving the two screws from the paper feed unitfixing bracket.

3. The far side of the unit can be opened and closedusing the front as a fulcrum.

Replacing the torque limiter

1. Remove the paper feed unit.

2. To pull out the reverse roller, remove the stop ring.

3. Remove the reverse roller pressure arm stopper (one screw).

4. To replace the torque limiter, lower the reverseroller pressure arm.

CAUTION

• Because the torque limit pressure isproperly adjusted, do not loosen the torquelimiter stopper screws.

• Never touch the reverse roller surface withbare hands.

Bracketfixingscrew

Bracket fixing screw

Breakerfixingscrew (Minus head) fixing shaft

Reverse rollerpressure arm

Stopper

Stop ringReverseroller

Torque limiter

Stopper

[NG]


2-3

Replacing the pick-up solenoid

1. Remove the paper feed unit.

2. Mark the position of the solenoid bracket.

3. Remove the two solenoid bracket fixing screws (gold color).

4. Remove the pick-up solenoid from the bracket andreplace it.

CAUTION

• Pull out one side of the plunger spring pinabout 4 mm and put it in the pick-up rollerarm hole.

• The solenoid bracket should be in themarked-off position. The pick-up roller riseamount various with the position.

5. Remove the E-ring from both sides and replacethe grip roller.

6. Assemble in the reverse order.

NOTE

The golden screw (zinc plated) shows the locationadjusted at assembly during manufacture.Therefore, pay attention to how the screw is setoriginally before you start working. When the screwis loosened, adjustment is required.

4 mm

Pick-up solenoid

Gold screwSolenoid bracket

Pick-up roller arm


2-4

2.1.3 Replacing parts in the paper trays

PM cycle: Lubricate the tray motor wormgear every 800K

1. Pull out the tray.

2. Remove the front and rear knobs (2 screws each),and the tray bottom plate (6 screws). You canreplace the anti-condensation heater and papersize sensors.

3. Remove the front tray cover (4 screws). You canreplace the front tray drive wire.

4. Remove the paper tray from the rails (2 screws)when:

• Replacing the rear tray drive wire• Replacing the tray motor and DC drive board• Lubricating the worm gear

Tray drive wire layout diagram

The numbers shows the assembly steps.

Knob

Tray bottomplate

Front tray cover

FRONT REAR

Secure thetension pulley

2 turns counter-clockwise (blue wire)

2.5 turns counter-clockwise 2.5 turns

clockwiseSecure the tensionpulley

2 turnsclockwise (blue wire)


2-5

2.1.4 Replacing the registration sensor

1. Turn off the main switch. Open the front door, and

remove two screws to allow it to open further.

2. Remove the inner cover (2 screws and oneconnector).

CAUTION

Do not pull the harness to the cooling fan in theinner cover.

3. Turn the lever to release the development backuproller of the OPC unit.

4. Remove the development unit fixing plate (onescrew), and slightly pull out the unit to disengagethe joint gear at the rear of the unit.

5. Turn the development knob to collect thedeveloper on the development sleeve.

CAUTION

Be sure to collect the developer, because thedeveloper may attach to the side plate of theOPC unit, fraying or damaging the OPC belt.

6. Slide out the development unit.

7. Remove the registration sensor (2 screws and oneclamp).

8. Remove the main body rear left cover (2 screws).

9. Remove the connector going to the registrationsensor from the back.

10. Reassemble in the reverse order.

CAUTION

Never touch the OPC belt.

2.1.5 Replacing the registration motor


2. Remove the rear left cover, then remove thecleaning coil cooling fan.

3. Disconnect the connector from the registrationmotor.

4. Loosen two screws of the universal joint attachedto the registration motor shaft.

5. Remove two screws fixing the registration motor.

6. Replace the registration motor and reassemble itin the reverse order.

Lever

Development knob

Fixing bracket

Registration sensor

Clamp

Fixing screw

Registration motor

Fixing screw

Connector forregistration motor


2-6

2.1.6 Cleaning the paper dust collecting vessel

PM cycle: Clean every 1,200K

1. Pull out the 3rd tray.

2. Turn off the main switch. Open the front door, andremove two screws to allow it to open further.

3. Remove the inner cover from the lower of thevertical transport unit (3 screws).

4. Remove the OPC unit inner cover (2 screws and aconnector).

CAUTION

Do not pull the connector of the cooling fan inthe machine.




CAUTION

Be sure to collect the developer because it maystick to the side plate of the OPC unit, fraying ordamaging the OPC belt.

8. Slide out the development unit and remove the unitfrom the rails.

9. Remove the vessel fixing screw from the front, andremove the paper dust collecting vessel.

10. Clean inside of the vessel using a dry cloth, andreassemble in the reverse order.

Paper dustcollecting vessel

Fixing screw


2-7

2.1.7 Removing the vertical transport unit

You will have to remove the vertical transport unit when:

• Replacing the drive system• Replacing each roller

WARNING

• Due to the weight, two operators are required.

• Be sure to pull out the power cord during work.

1. Pull out all paper trays.


3. Open the upper right door.

4. Open the front door.

5. Remove all inner covers: fusing, vertical transportupper and vertical transport lower.

6. Remove two screws each to remove all paper

trays.

CAUTION

Tray fixing screws are stepped screws on theright side and plated screws on the left side.Take care during reinstallation.

7. Remove the upper and lower door catch magnets

with their brackets.

Vertical transportupper inner cover

Fusinginnercover

Vertical transportlower inner cover

Plated screwStepped screw

Door catchmagnet, upperbracket

Door catchmagnet, lowerbracket


2-8

8. Remove the horizontal transport unit inner cover.

9. Disconnect the front door switch harnessconnectors.

CAUTION

Terminals on both sides are blue and the twocenter terminals are yellows. Re-install them correctly.

10. Disconnect the connector from the front doorsensor.

11. Mark off the position of the front door switchbracket.

12. Remove the front door switch bracket (2 screws).

13. Remove the fusing unit fixing stepped screw to

remove the unit.

14. Remove the transport unit inner cover.

15. Remove the oil receiver (2 screws).

16. Remove the oil pump unit bracket (2 screws) andthe tube on the oil tank side.

Front door switch

Horizontaltransport innercover

Front doorsensor

Fixingsteppedscrew

Oil receiver

Transport unit innercover

Oil pump unit bracket

Oil tube


2-9

17. Remove the male and female connectors for all

paper feed units.

18. Remove the three cord clamp screws.

19. Remove the grounding screw from the ground wireof the connector to the transport unit.

20. Remove the male and female connectors for thetransport unit from the stay.

21. Release the transport unit to the right.

22. Hang the dismounting and mounting arm of thetransport unit on the pin.

23. Remove the fixing screws from the transport unit toremove the unit.

CAUTION

Carefully pull out the units so that the transferand separation corona unit casing does nottouch the rollers or pressure springs of thevertical transport unit.




CAUTION

Be sure to collect the developer because it maystick to the side plate of the unit, fray or damagethe OPC belt.

27. Slide out the development unit and remove the unitfrom the rails.

28. Remove five M5 screws fixing the vertical transportstay.

Connector for paperfeed unit

Grounding screw

Cord clamp screw

Stay

Connector fortransport unit

Transport unit

Pin

Dismounting andmounting arm

Stay fixing screw

Stay fixing screw


2-10

29. From the back of the machine, remove the

transformer then remove the three M5 screwsholding the vertical transport unit.

30. Disconnect the connectors of the harnesses fromthe registration motor and registration sensor.

31. Disconnect the connector to paper feed motors inall paper trays.

32. From the front, pull the vertical transport unit.

CAUTION

The unit is heavy so you will need a helper to lift it away.

33. Reinstall the unit in the reverse order.

CAUTION

• Fix the front door switch in the marked-offposition.

• Remove the pulley after the tension pulleybracket is marked off.

• Do not loosen the two bracket fixing screws(golden screws) on the front side at thesame time when the registration roller orlike is replaced. If they are removed,clearance with the OPC unit changes andtransport trouble or skew in registrationmay occur.

• Tubes leading to the oil tank should notsink below the oil level.

Timing belt layout diagram

Registration motor

Connectors

M5 screw

Connector forpaper feedmotor

Registration roller

Registration knob

Golden screw

Paperdustcollectingroller

Pinch roller

Paper feedmotor (No. 1)

Grip roller drive

Bracket fixing screw

Tension pulley bracket

Registration

Paper dustcollecting roller

Verticaltransportroller

Joint gear


2-11

Belt tension standard

3 mm deflection at 140 ± 90 g pressure.

2.1.8 Adjusting the side-to-side registration

Standard value: 0 ± 2 mm in the platencover mode.

1. Set paper in the paper tray to be checked.

CAUTION

Be sure to set the paper side guides of the papertray securely.

2. Set the test chart on the exposure glass correctly.

3. Make a copy and measure the difference of theside-to-side registration between the original andcopy.

4. If the value does not match the standard valuethen the following steps should be taken:

1) Pull out the paper tray and remove thetray front cover.

2) Loosen the lock nut and turn the traystopper to change the paper tray positionwhen set.

5. Make more than 10 continuous copies to check thevariation.

6. Be sure that all copies are within the standardvalue. If problems still occur, repeat step 3 to 5.

CAUTION

• An adjusting mechanism for theside-to-side registration is provided foreach tray.

• Because the side-to-side registrationadjustment mechanism is also provided onthe original side (ADF and SADF), makeadjustments for each tray on the basis ofthe platen cover mode.

100 mm

3 mm

140 ± 90 g

Lock nut

Tray stopper


2-12

2.1.9 Adjusting the leading edge registration

Standard value: 0 ±2 mm in the platencover mode.

1. Set paper in the paper tray.

CAUTION

Be sure to set the paper side guides of the papertray securely.

2. Set the test chart on the exposure glass correctly.

3. Make a copy and measure the difference between the leading edge registration of the origi-nal and the copy.

4. If the value does not match the standard, access service tool [5-02] and press the Registra-tion key.

5. Change the value on the screen.

6. Make more than 10 continuous copies to check the variation.

7. Be sure that all copies are within the standard value. If problems still occur, repeat step 3 to6.


2-13

2.2 Optics

2.2.1 Replacing the xenon lamp

PM cycle: Replace every 1,000K or when:

[(set value) + (shifted value)]

of the flash voltage step (Service tool [4-01]) exceeds 28.

CAUTION

If the cooling air flow to the xenon lamp andflash power supply unit becomes low, the flashvoltage step will exceed 28 earlier than normal.Be sure to do the following PM.

PM: Every 200K clean the filters for therear cooling fan, flash blower, exposurecooling fan, flash power cooling faninside the left cover, and the flash powerinside blower on the rear left cover.

WARNING

After you turn off the power, wait at least 1 minutefor discharge before you start working.


2. Remove the left cover (2 screws).

3. Disconnect the two connectors to the exposurecooling unit.

4. Remove the exposure cooling unit (4 screws).

5. Remove the xenon lamp connector (2 screws).

6. Remove the xenon lamp unit (2 screws).

Exposure cooling unit

Connector

Optics 1 July 1994

2-14

WARNING

• To avoid wiring problems of high voltage parts,never disassemble the connector.

• Working near the lamp is dangerous. Neverwork near the lamp without turning off the mainswitch and waiting at least 1 minute fordischarge.

• Take care and check the position of the lampharness. (See illustration below.)

7. Remove the xenon lamp upper cover (2 screws).

8. Remove the thermofuse.

9. Remove the roof reflector (2 screws).

10. Remove lamp cooling guide seal.

11. Remove the lamp clamps from the front and rear(one screw each).

12. Replace the lamp and reassemble in reverse order.

13. When the machine is in the stand-by condition,access service tool [4-03]. Using the PC-1 chartcheck the AID reference voltage. Perform setting Aif the value is not correct.

Lamp harness

[OK] [NG]

Xenon lampconnector

Connectorfitting screw

Unit fitting screw

Flash safety switch

Xenon lamp unit

Xenon lamp upper cover

Roof reflector

Cooling guide seal

Lamp clamp

Xenon lamp

Thermofuse

1 July 1994 Optics

2-15

CAUTION

• To avoid xenon lamp damage, firmly fit thexenon lamp connectors to the sockets.Push each connector end with your fingersas shown. Then tighten two screws.

• When reinstalling the xenon lamp in theunit, position the lamp exactly as shown. Ifthe position is not correct, the life time ofthe lamp might be reduced. Insufficientlight intensity will increase the lamp voltagerapidly due to the process control.

• If the lamp positioning tool (P/N-A0289330)is available, the lamp installation becomesmuch easier. Fix the tool with the twoscrews and install the xenon lamp whilepushing the lamp against the tool (see theillustration to the right). At that time, besure that both the right and left edges of thelamp ("a" in the illustration) are the samelength.

Xenonlampconnector

13.5 mm

Same length atthe right andleft edges.

Lamp positioning tool

a a

Optics 1 July 1994

2-16

2.2.2 Replacing the exposure glass

PM cycle: Clean it and check theresistance at every visit. Wipe with siliconoil to prevent original misfeeds caused bystatic electricity.

WARNING

Working near the xenon lamp is dangerous afterremoving the exposure glass. Never work nearthe lamp without turning off the main switch andwaiting at least 1 minute for discharge.


2. Open the ADF unit.

3. Remove the front upper cover (2 screws).

4. Open the copy tray and remove the SADFtransport plate (one stepped screw on the rear andone plated screw on the front).

5. Loosen two screws of the back upper cover.

6. Remove the exposure glass. Clean it if necessary.

7. Check the resistance of the glass upper surfaceusing the beckman multimeter. Replace theexposure glass if necessary.

Exposure glass surface resistancestandard: 55 KΩ or less.

8. When the machine is in the stand-by condition,access service tool [4-03]. Using the PC-1 chart,check the AID reference voltage. Perform setting Aif the value is not correct.

2.2.3 Replacing the mirror/lens motor

PM cycle: Lubrticate the motor wormgear every 1,200K

1. Remove the exposure glass.

2. Loosen two screws (1) to remove the oppositereflector. Clean the reflector as required.

3. Remove four screws (2) to remove the frontreflector. Also, remove the rear reflector.

CAUTION

Be careful not to scratch the lamp reflectorwhen removing the front and rear reflectors.After removing screws, pull out the reflectorwith the left side first.

4. Remove one screw (3) to remove the front shieldcover.

5. Remove one screw (4) to remove the back shieldcover.

6. Remove 8 fixing screws (5) to remove the 1stmirror shield unit. Remove the unit upwards whileraising the inside plate.

SADF transport plate

Front upper cover

Back shield cover

1st mirrorshield unit

Lamp reflector

Frontshieldcover

Front reflector

Oppositereflector

2-17

CAUTION

The shaft should not come out of the shield unit.

7. To remove the fusing unit, pull out the unit and

remove one stepped screw.

8. Peel off three sheets of shielding mylar for themirror/lens motor fixing screws.

9. Remove the connectors for the mirror/lens motorand mirror/lens home position sensor.

10. Put a screwdriver through the blind to loosen the

mirror/lens motor fixing screws (2 stepped screwsand one M5 screw).

CAUTION

The 1st mirror unit drops if the screw iscompletely removed. Before removing thescrews for the worm gear disengage, insert ascrewdriver in the mirror unit fixing hole to holdthe unit.

11. While holding the mirror/lens motor with one hand,remove the three screws securing the motor.

CAUTION

Lubricate the worm gear of the mirror/lensmotor with Mobil Temp. 78 every 1200 K. Youdo not have to remove the motor at that time.

12. Replace the motor and reinstall it in the reverseorder.

CAUTION

• Check and be sure that the worm gear ofthe mirror/lens motor is correctly engaged.

• When power is turned ON, the mirror/lensmotor starts and stops when the 1st mirrorunit activates the magnification homeposition sensor.

Shielding mylar

Two stepped screws

M5 screw

Connector formirror/lensmotor

Connector formagnificationhome positionsensor

Mirror unitfixing hole

1st mirror unit

Optics 1 July 1994

2-18

2.2.4 Replacing the first mirror

PM cycle: Clean the 1st mirror every200K

NOTE

To clean the 1st mirror, it does not need to beremoved. Just remove the exposure glass to clean.

1. Remove the 2nd mirror according to the

instructions described below.

2. Remove the two set screws from the underside ofthe 1st mirror.

3. Hold the underside of the mirror and slide it downto remove it.

CAUTION

Take care not to drop the mirror.

4. Reinstall the mirror after cleaning.


2.2.5 Replacing and cleaning the 2nd mirror

PM cycle: Clean as necessary at PM



3. Remove two set screws from the 2nd mirror.

CAUTION

Hold the 2nd mirror with one hand so it does notfall.

4. Move the 2nd mirror to the left (outside) to avoidthe DC power source, pulling it out then down.

5. After cleaning, reinstall it in the reverse order.

CAUTION

Set the locating pin first to install the 2nd mirrorunit. (See illustration.)


1st mirror

Set screw

Locating pin

Set screw

2nd mirror

1 July 1994 Optics

2-19

2.2.6 Replacing parts in the shield unit

Removing the shield unit



3. Open the front door and remove two screws toallow it to open further.


5. Remove the four connectors of the DC powersource.

6. Remove four fixing screws and loosen the lowerside screws to remove the DC power source.

7. Remove the two screws fixing the shield unit from

the left.

8. Disconnect the connector for the shield unit fromthe front.

9. Remove the shield unit fixing screws (M6).

10. Pull out the shield unit to the left along the rail.

CAUTION

• Hold the front and back side plates, not theshield screen to pull out the shield unit.

• Press the upper stays of the shield unitagainst the far side of the front and rearrails, and fix the shield unit.

DC powersource

Shield unitfixing screw

Shield unit

Rail

Stay

Shield unitfixing screw

Connector forshield unit

Shield unit

Optics 1 July 1994

2-20

Replacing the shield motor

1. Remove the shield unit.

2. Remove the shield motor cover (one screw).

3. Remove two fixing screws from the shield motorand replace the motor.

Replacing the shield screen

1. Remove the shield unit.

2. Remove the timing belt fixing screws, front andback, from the shield screen unit to enablereplacement.

CAUTION

• Do not lose the spring washer under thefixing plate.

3. Remove one stepped screw and one pan headscrew to remove the back side of the timing belttension. Remove the belt.

4. Loosen one tension fixing screw to remove thefront side belt.

5. Remove E-rings from the shield roller and pull outthe roller.

6. Move the shield screen slider to the center alongthe rail and remove it from the back side. Cleanthe rail and slider with alcohol.

7. Replace the shield screen unit and re-install it inthe reverse order.

Adjusting belt tension

1. Loosen all tension fixing screws.

2. Tighten the screws when the tension spring works.

Shield motor cover

Shield motor left and rightTiming belt fixing screw

Spring washer

Slider

Rail

Timing belt

Shield screen

Shield roller

Stepped screw

[FRONT SIDE]

[REAR SIDE]

1 July 1994 Optics

2-21

Adjusting the shield screen position

1. Adjust belt tension.

2. Move the slider to the center.

3. Turn the shield motor shaft gear by hand to movethe slider. Let it slide until the front or back slider isbrought in contact with the stopper.

4. Bring the other slider in contact with the stopperand turn the motor gear further by two teeth of thebelt gear.

5. Tighten the fixing screw.

6. Turn the motor gear by hand again and check thatthe shield screen moves smoothly without rolling.

NOTE

• If you detect rolling, repeat this procedure.Dirt, toner, etc., should not be on the rail.

• To check tension of the shield screen, fullyclose the leading and trailing edge of screen,and lightly press the center with your finger.Tension is OK if the screen returns easily andis not slackened when it is released.

7. The stays on the shield unit should fit to the mainbody side rails first when the shield unit isreinstalled.

Shield motor shaft

Slider

Slider

Stopper

Timing beltfixing screw

Optics 1 July 1994

2-22

2.2.7 Replacing the flash power supply unit

WARNING

Before you start working, turn off the main switchand wait for at least one minute to allow fordischarge.



3. Disconnect the connector from the flash exhaustunit and remove four screws to remove it.

4. Remove the connectors for the xenon lamp (2 screws).

5. Disconnect the 2P connector to the triggertransformer.

6. Remove three lines connected from the flash

power supply unit to xenon lamp connectortogether with the terminal fixed with two screwseach.

7. Remove the rear left cover.

8. Disconnect two connectors (15P and 3P) from theupper part of the flash power supply unit.

9. Remove the air blow guide (2 screws) from thelower part of the flash power supply unit.

10. Remove the flash power supply unit. Remove the upper two screws and only loosen thelower two.

11. Replace the flash power supply unit andreassemble in the reverse order.

CAUTION

• Be sure to wire the three flash powersource lines correctly, the white wire (fromthe trigger transformer), red line and blackline from the top. If wired incorrectly, thelamp may burn up.

• To avoid xenon lamp damage, firmly fit thelamp connector to the socket. Push eachconnector end with your fingers. Then,tighten two screws.

Trigger transformer

Red

2P connector White line(trigger)

Red wire (tapeindicates polarity)

Black line (tapeindicates polarity)

(+)

(-)

Flash powersource line

Black

Connector

Flash powersupply unit

1 July 1994 Optics

2-23

2.2.8 Checking the flash power supply output

1. Remove the clear cover from the flash powersupply unit.

2. Connect the Beckman multimeter between J1(+)and J2(-). (Range: 20V)

3. Access service tool [5-04], input/output test.

4. Select Lamp/Sol menu and press Charge key.

5. It is normal if the 1/1,000 value of the lamp outputcan be read according to the combination of bits[0][1][2][3][4] as follows:* About 1.07V with [0] to [4] all OFF* About 2.00V with [0] to [4] all ON (full power)

2.2.9 Adjusting the uneven illuminance

CAUTION

This adjustment is usually prohibited.It seems difficult to return the illuminance to theoriginal setting if you change the position of thefront and rear reflectors.

1. Use graph paper of A3 size as the original.

2. Copy at the second level of the image density.

3. Check uneven illuminance and make adjustmentwith front and rear reflectors.

CAUTION

At this time, set the whole density to the darkpart at the trailing edge of the copy image.

4. After the adjustment, access service tool [4-03]

and check the AID reference voltage using thePC-1 chart. Perform setting A if the value is notcorrect.

CAUTION

When you cannot set the V L target data in the[4-01] screen due to too low value of the V Lmeasured data, light quantity to the pattern maybe too high. Therefore, adjust illuminanceagain to lower the light quantity to the pattern.

Hex socket screw

Reflector adjusting nut

Rear reflector

Front reflector

Reflector adjustment shaft

Reflector adjustment bracket

Reflector

Reflectoradjustingmechanism

CAUTION

Never work near the xenon lamp after the flash poweris charged. Be sure to discharge it using theDischarge key ("Dis" key) in the service tool screen.

Set the whole tothis density

Optics 1 July 1994

2-24

2.2.10 Adjusting the magnification

Standard value:±0.5% or less at length and at width inthe full size mode.±1.0% or less at length and at width inany other magnification ratios.

1. Copy a scale as an original.

2. Measure copy dimensions, and calculate the errorin magnification.

3. Access service tool [5-02]. Press the Magnificationkey, and adjust the magnification.

4. Repeat this procedure to set the standard value.

1 July 1994 Optics

2-25

2.3 OPC Unit

2.3.1 Replacing the OPC belt



2. Open the front door, then remove two screws toallow it to open further.

3. Disconnect the connector from the fan and removethe inner cover (2 screws).

4. Disconnect the charge corona connector.

5. Pull out the charge corona unit.

6. Release the cleaning backup roller by turning lever(1).

7. Release the development backup roller by turninglever (2).

8. Release the transport unit to the right side.

9. Turn the development knob and collect thedeveloper on the development sleeves.

CAUTION

• Be sure to collect the developer because itmay stick to the side plate of the OPC unit,damaging the OPC belt.

• To turn the development knob, slightly pullout the unit and disengage the joint gear atthe rear of the unit.

10. Remove the OPC unit stay by turning the knob.

11. Slide out the OPC unit.

12. Turn lever (3) to loosen the tension of OPC belt.

13. Insert two OPC mounting/dismounting tubes in thebosses and pull out the OPC belt this way.

Lever (1)

Transport unit

Developmentknob

Lever (2)

Chargecorona unit

Charge coronaconnector

OPC unit

OPC unit stay

Knob

Lever (3)

OPC mounting/dismounting tube

OPC Unit 1 July 1994

2-26

14. Set a new OPC belt.

CAUTION

• Set the OPC belt so the mark is on the farside.

• Put far side of the OPC in the OPC sensorand set it in the center.

• Never touch the OPC surface, and positionthe OPC belt carefully to prevent bending it.

• Do not expose the OPC belt to daylight formore than a few minutes. When notinstalled, keep the OPC belt in its case andstore it in a cool, dark place. If copying isdone while the exterior covers are off and inslight daylight, even after it is set in thecopier, the copy image becomes extremelylight.

• Never use alcohol or other chemicals toclean the OPC.

15. Slowly turn lever (3) back to its original positionand put tension the OPC belt.

16. Press and set the OPC unit.

17. Fit the OPC unit stay.

18. Turn levers (1) and (2) to set the development andcleaning backup rollers.

19. Shift the transport unit to the left.

20. Fit the charge corona unit and the connector.

21. Install the inner cover and doors in the reverseorder.

22. Turn on the main switch and wait for the machinestand-by.

23. Access service tool [3-04] (or [4-04]) and performthe OPC forming. Reset the supply yield counterfor the OPC to 0 at the same time.

24. Select service tool [5-06] and check the trackingoperation. If necessary, adjust the tracking amount(see Adjusting the tracking amount section).

25. Select service tool [4-02] and check the VSG. Ifthe value is not between 2.5 and 4.5 volts or it islocked, perform setting C.

Mark

Lever (3)

OPC sensor

Lever (1)

Transport unit

Lever (2)

Chargecorona unit

1 July 1994 OPC Unit

2-27

2.3.2 Replacing parts in the OPC unit

PM cycle: Every 400K clean: The OPCback cleaning pad, all rollers, OPCsensor, and quenching lamp filter.Every 800K: Lubricate the trackingsliders, and check the timing belt tension.

1. Remove the OPC belt by following the procedure

on the preceding page. Keep the OPC belt in itscase.

2. Clean each part as follows:

Cleaning pad Wipe with a cloth damp with alcohol. Reverseif it becomes dirty.

Drive anddriven rollers

Wipe with a dry cloth. Never use either,toluene or another organic cleaning solvent.

OPC sensor Blower brush

Replacing the quenching lamp

PM cycle: Clean the lamp filter every400K

1. Remove the OPC belt.

2. Pull down the two lamp connectors.

3. Remove two screws to remove the lamp fixingbracket.

4. Remove three screws to remove the lamp filter.

5. Remove and replace the quenching lamp.

Removing the OPC unit

1. Remove the OPC belt.

2. From the back of the OPC unit, while holding downthe lock pawl with your fingers, pull out the OPCunit.

3. Erect the unit on the floor with the far side down.

WARNING

• Do not hold the frame and stays inside the unitwhen you pull out it. Their edges are very sharp.

• If the slide guides keep slid out, it is dangerousduring working. Set the release lever on the farside of the rail parallel, and put slide guide onthe main body side.

CAUTION

To reinstall the OPC unit, bring the rollerbearing unit inside the slide guide to the frontend of the rail. If the roller baring unit is kept onthe far side, the roller bearings may drop whenthe unit is inserted.

OPC belt

Packing case

Lamp fixing bracket

Quenching lamp

Lamp connector

Lamp filter

Lock pawl

Release lever


2-28

Replacing the development backup roller

1. Remove the OPC unit.

2. Turn the lever to apply tension to the developmentbackup rollers.

3. While holding down the backup rollers with yourhand, set free the release hook.

4. Remove the roller unit.

5. Replace the rollers.

CAUTION

If the backup rollers are changed or thearrangement of the three rollers are changed,this may affect the PG (Photoconductor Gap).Check copy image, and adjust the developmentmotor speed if necessary (see Developmentunit section for the adjustment).

Developmentbackup roller

Lever

Release hook

Backup roller unit


2-29

Replacing the sector sensor and tracking motor

1. Remove two screws to remove the tracking motorfixing bracket.

2. Remove two screws to replace the motor andremove one screw to replace the sector sensor.

Replacing the quenching lamp stabilizer

1. Remove three screws to remove the QL stabilizer.

Lubricating the tracking slider

PM cycle: Lubricate every 800K

1. Lubricate the moving parts (front and rear of theOPC unit) using G-40M.

Replacing the OPC motor and timing belt

PM cycle: Check tension of the timingbelt every 800K

1. Remove two screws to remove the motor.

2. When the motor is removed, the drive belt can bealso replaced.


Adjust by moving the OPC motor.


Fixing bracket

Sector sensorTrackingmotor

QL stabilizer

Tracking slider

OPC motor

OPC sensor

Drive roller

Drive belt

Set screw

2 mm

200 ± 50 g


2-30

2.3.3 Cleaning the ground brush

PM cycle: Clean every 400K.

1. Pull out the OPC unit.

2. Wipe the ground brush at the front with a dry cloth.

3. Slightly pull out the development unit and turn thedevelopment knob to collect the developer on thesleeves.

4. Pull out the development unit to clean the groundbrush at the rear.

2.3.4 Replacing the slide guide

1. Remove the OPC unit.

2. Remove the stepped screw holding the slide guide.

3. Replace the slide guide.

CAUTION

Replace the slide guides as a set of the mainbody and OPC unit sides. If the fit is poor, theroller bearings inside the rail may get out ofalignment when the unit is set.

Front ground brush

Stepped screw


2-31

2.3.5 Adjusting the tracking amount

1. Access service tool [5-06].

2. Turn OPC motor ON.

3. Tracking from the front side to back side will startdisplaying the transfer time on the screen.Tracking from the back to front then occurs.

4. If the transfer time is within the standard time, 60sec. (120 sec. both ways), OK is displayed.

If it is longer than the standard time, or ifthere is a significant difference in the timingfrom one side to the other (more than 20sec.), you will have to follow the adjustmentprocedure below.

5. If the interval from the front side to the back side istoo long, tighten the nut.

6. If the interval from the back side to the front side istoo long, loosen the nut.

7. Check the tracking time again. Leave the servicetool if it becomes OK.

2.3.6 Checking the tracking motor operation


2. Turn Tracking motor ON.

3. Read the measured and displayed tracking time.

4. The time is usually about 0.5 sec. If the time is 1sec. or more, check the following items.

• Tracking motor damaged?• Gears failing to mesh?• Carrier sticking to worm gear?• Slider lacks lubrication?• Sector sensor defective?

OPC beltTrackingadjusting nut


2-32

2.4 Charge Corona Unit, Eraser, and Potential Sensor

2.4.1 Replacing the charge corona wires and wire cleaners

PM cycle: Clean every 200K and replaceevery 400K.


remove two screws to allow it to open further.


3. Disconnect the connector from the charge coronaunit, and pull out the unit.

4. Remove the motor cover from the charge coronaunit.

5. Remove four screws to remove the cleaner unit.

6. Remove the two flat head screws to remove thewire cleaners.

7. Clean the grid wires, end blocks, and casing.

8. Clean or replace the charge corona wires, coronawire cleaner, and grid wire cleaner.

CAUTION

• Every 200K use a cloth damped with waterto clean the casing. Use a dry cloth to cleanthe corona wires.

• The corona wire joint should be in the endblock and the wire should be in the Lgroove corner.

• To prevent breaking the corona wire, turnthe screw shaft by hand and fit the cleanerbracket with the front end block. Then,install the wire cleaners and cleaner unit.

• Pay attention to the fitting direction of thewire cleaner.

9. Reassemble in the reverse order of disassembly.

10. Check the copy image. Loose the height fixingscrews and turn the cam to adjust the position ofthe front side of the unit if there is difference indensity between the front and rear of the copyimage.

Cleaner unit

Motor cover

Flat head screw

Cleaner bracket

End block

L groove

Grid wire cleaner

Coronawire cleaner

Screw shaftCleaner bracket

Corona wire cleaner

Cleaning motor

Corona wire cleaner

Height adjusting cam Height fixing screw

1 July 1994 Charge Corona Unit, Eraser, and Potential Sensor

2-33

2.4.2 Cleaning the eraser and potential sensor

PM cycle: Clean every 200K

1. Turn off the main switch. Open the front door, andremove two screws to allow it to open further.

2. Remove the inner cover (2 screws and oneconnector)

3. Disconnect a connector from the eraser blower.

4. Remove one screw to remove the eraser blower.

5. Pull out the eraser and wipe it off with a dampcloth.

6. Pull the sensor connector out of the potentialcontrol board.

7. Pull out the potential sensor and clean it.

CAUTION

Blow air to remove toner and dust from theelectrode. To prevent clogging or jamming, donot use a rag.

8. Assemble in the reverse order of disassembly.

NOTE

The copy image density may change slightly afterthe potential sensor is replaced because the readpotential value may differ slightly from the oldsensor. Check data in the [4-02] screen afterreplacing it.

2.4.3 Checking the potential sensor

1. In the copy stand-by condition, measure the voltage between TP6 and TP1 (Ground) on theinterface board. If it is between 1.99 and 2.01 volts, the sensor B is normal. (If the sensor isdefective, it will be 7 to 9 volts or 0 volt.)

2. To turn on the sensor A, short connector CP2-2 and CP2-3 (Ground) on the potential controlboard. Otherwise, select "Lamp/Sol" in service tool [5-04] and press "VD Sensor" key. Fol-low the same procedure as the above to check the sensor A.

Potential sensor

Clear by blowing air

Charge Corona Unit, Eraser, and Potential Sensor 1 July 1994

2-34

2.5 Transfer/Separation Corona Unit and Transport Unit

2.5.1 Replacing the transfer and separation corona wires

PM cycle: Clean every 200K and replacethe corona wires every 400K.Replace the receptacle and its twosprings on the corona unit every 1,200K.

1. Turn off the main switch and open the front door.

2. Remove the screws to remove the knob (C) of thetransport unit.

3. Pull out the T/S corona unit.

4. Pull out the covers at the front and rear, andremove the separation guides. Clean every 600K.

5. Replace or clean the corona wires with a clothdamp with water. Also, clean the end blocks andcasing.

6. Put anti-vibration rings in new wires and assemblein the reverse order.

7. Replace the receptacle and its two springs on thecorona unit as required.

CAUTION

• Every 200K use a cloth damped with waterto clean the casing. Use a dry cloth to cleanthe corona wires.

• The corona wire has no directionalrequirements but the anti-vibration ringshould be in the space of the end block.

• The wire should be put in the L groovecorner of the end block.

Separation guide

Front endblock cover

Anti-vibration ring

Spring

Receptacle

1 July 1994 Transfer/Separation Corona Unit and Transport Unit

2-35

2.5.2 Replacing parts in the transport unit

Removing the transport unit

1. Pull out first paper tray.

2. Turn off the main switch, and open the front andupper right doors.

3. Remove each inner cover from the fusing, uppervertical transport, and transport units.

4. Pull out the connector of the transport unit.

5. Shift the transport unit to the right.

6. Loosen the fixing screw of the mounting anddismounting arm, and hook the arm on the pin.

7. Remove one screw fixing the transport unit.

8. Draw the fusing unit and pull out the transport unit.

CAUTION

Carefully pull out the unit so that the casing ofthe T/S corona unit is not brought in contactwith rollers and pressure springs of the verticaltransport unit.

Removing the vacuum unit

PM cycle: Clean the fusing entranceguide plate every 200K

1. Remove three screws (two on the front and one onthe far side) fixing the vacuum unit.

2. Slide the vacuum unit to the front to disengage thedrive joint.

3. Disconnect the connector from the separationsensor.

4. Remove the unit and clean the fusing entranceguide plate on the main body side. If the unit is notremoved every 200K, remove the fusing unit andclean it from the top.

Unit fixing screw

Connector

PinMounting anddismounting arm

Fixing screw

Drive joint

Transport belt

Fixing screw

Connector forseparationsensor

Transfer/Separation Corona Unit and Transport Unit 1 July 1994

2-36

Replacing the transport belt and roller


1. Pull the joint side of the transport roller and slidethe roller.

2. Move the transport roller to the underside of theguide plate.

3. Replace the transport belts and assemble them inthe reverse order.

NOTE

Drive the transport roller by hand and check that thetransport belts are not put aside and rotatesmoothly.

Replacing the separation sensor

1. Remove the transport belts.

2. Remove four screws to divide the transport guideplate into upper and lower parts.

3. Replace the separation sensor and assemble inthe reverse order.

Replacing the transfer and separation power pack

1. Remove the transport unit and place it up sidedown. Remove three screws to remove the powerpack inner cover.

2. Pull out the power pack connector.

3. Disconnect the ground wire.

4. Remove the cord clamp and disconnect the cordterminals.

5. Remove three screws to remove the power packand assemble in the reverse order.

Separation sensor

Power pack inner cover

Ground wire

Power pack

Transport belt

Joint

Transport roller

1 July 1994 Transfer/Separation Corona Unit and Transport Unit

2-37

2.5.3 Replacing the transfer entrance guide mylar


1. Measure the length between the leading edge of

the mylar and the corona unit casing as shown.

2. Replace the mylar and its bracket with new ones (2 pan head screws).

3. Loosen the 2 flat head screws (mylar positionfixing screws) and turn the adjusting knobs so thatthe length between the mylar and corona unitcasing becomes the same as the old one’s.

NOTE

The clearance between the mylar and OPC belt is1.45 ± 0.1 mm when fitted to the main body. Notethat transport trouble, irregular transfer, etc. mayoccur when the value changes.

4. If the whole T/S corona unit is replaced, adjust the

mylar position as follows:

(1) Loosen the 2 flat head screws (mylarposition fixing screws) and install the T/Scorona unit in the machine.

(2) Using the tracking motor ON key on theservice tool [5-06], move down the frontside of the tracking rollers. The OPCsurface comes close to the leading edge ofthe transfer entrance guide mylar.

(3) Turn the front side of the adjusting knobso that the leading edge of the mylar is justin contact with the OPC surface.

(4) Remove the T/S corona unit.

(5) Turn the rear side of the adjusting knobto level the front and rear of the leadingedge of the mylar. To do so, refer to theedge of the corona unit casing as shown.

(6) Turn the front and rear adjusting knobs28 notches (2 turns) and 3 notches counterclockwise. Then, turn them 2 notchesclockwise and tighten the mylar positionfixing screws. (One notch turn of the knobmoves the mylar 0.05 mm.)

NOTE

If the mylar position is not proper, an insufficientimage transfer may occur on the leading edge ofcopies (blank or faint image).

Measuring

Adjusting knob

OPC beltFront adjustingknob

Rear adjusting knob

Transfer/Separation Corona Unit and Transport Unit 1 July 1994

2-38

2.6 Cleaning UnitCAUTION

When you pull out the cleaning unit and turn thecleaning knob, toner will fall from the toner exitpipe of the unit. When you do this, place a sheetunder the toner exit pipe to prevent the OPC unitfrom becoming dirty by toner.

2.6.1 Replacing the cleaning carrier



remove 2 screws to allow it to open further.


3. Remove the cleaning unit fixing screw.

4. Turn the lever to release the cleaning backup rollerof the OPC unit.

5. Grasp the knob of the cleaning unit and pull it out.

6. Put the cleaning carrier collecting vessel on the

bottom of the unit. Set its lever to the carriercollecting position to erect the rubber blade.

7. Loosen the main pole adjusting plate fixing screw

(gold screw) and move the main pole adjustingplate to the carrier collecting side.

CAUTION

Remember the position of the main poleadjusting plate. This position is sometimesdifferent from one machine to another.

8. Turn the cleaning knob toward the arrow andcollect the cleaning carrier.

9. Remove the cleaning filter cover (4 screws), andclean the inside from the above using the carriercollecting magnet.

10. Return the main pole adjusting plate to its originalposition. Tighten the gold screw.

Cleaning unitfixing screw

Cleaning knob

lever

Cleaning carriercollecting vessel

Originalposition

Main poleposition decal

Gold screw

Cleaning roller gear

Main poleadjusting plate

Carrier collecting direction

1 July 1994 Cleaning Unit

2-39

11. Put one bag of cleaning carrier in the right side

spread evenly.

CAUTION

Never put in cleaning carrier on the left side(scavenging roller side).

12. Turn the cleaning knob to circulate the cleaningcarrier evenly on the cleaning roller.

NOTE

The cleaning unit has no agitation mechanism like as thedevelopment unit.


14. Turn on the main switch and wait for the copystand-by.

15. Access service tool [3-04] and perform thecleaning carrier forming. At the same time, resetthe supply yield counter for the cleaning carrier to0.

2.6.2 Replacing the air filters

PM cycle: Rotate between left and rightevery 200K. Replace every 400K.

1. Slide out the cleaning unit.

2. Remove the filter cases (2 screws).

3. Rotate the filter right to left, or replace them.

CAUTION

The filters have a setting direction. Be sure thatthe side with a red line on the edge is facing theinside of the unit.

2.6.3 Replacing the scavenging blade

PM cycle: Inspect every 200K. Replaceevery 600K.

1. Slide out the cleaning unit, and remove cleaningfilter cover.

2. Remove the blade bracket (3 screws).

3. To replace the blade, remove the blade supportplate (4 screws).

NOTE

• Align the holes of the scavenging blade withthe projections of the blade support plate.

• If the blade is dirty, clean it with alcohol.

Cleaning filter coverCleaningcarrier

Cleaning knob

Filter case

Air filter

Bladesupport plate

Projection

Hole

Scavenging blade

Blade bracket

Cleaning Unit 1 July 1994

2-40

2.6.4 Replacing the scavenging roller

PM cycle: Inspect every 200K. Replaceevery 600K.

1. Remove the unit fixing screw and slide out the

cleaning unit.

2. Remove the filter cover, and remove the cleaningcarrier.

3. Remove the cleaning knob with the E-ring.

4. Remove the E-ring and drive gear from thescavenging roller shaft.

5. Remove the other E-ring from the shaft, then takeoff the two screws to remove the bearing case.Pull out the scavenging roller to replace it ifrequired.

NOTE

If the scavenging roller is dirty, clean it.

6. Wipe off the internal air guide mylar with a drycloth.


NOTE

• Do not remove the doctor blade. If it isremoved, adjust the doctor gap to 2 ± 0.15 mmafter the cleaning carrier is cleaned frombetween the doctor blade and the cleaningroller, after the unit is divided into two parts.(See Replacing the cleaning roller section)

• Clean the area near the scavenging rollerbearing thoroughly to remove any remainingcleaning carrier.

Cleaning knob

Drive gearBearing case

Scavenging roller

Doctor blade

Cleaning roller


2-41

2.6.5 Replacing the PCC wire

PM cycle: Clean every 200K. Replaceevery 400K.

1. Remove the PCC corona unit fixing screw on the

cleaning unit and pull out the unit.

2. Remove the end block covers (front and rear).

3. Clean the PCC wire and casing, or replace thePCC wire if required.


CAUTION

• Every 200K use a cloth damped with waterto clean the casing. Use a dry cloth to cleanthe corona wire.

• Check and be sure that the wire on the farside is in the V-groove of the end block.

• Height adjustment is possible on this sidebut is normally not done. Adjust to heightof 10 ±1 mm if the end block is replaced.

2.6.6 Removing the cleaning unit

1. Remove the cleaning unit fixing screw, and slideout the unit.

2. To pull the cleaning unit out of slide guide, pull thecleaning unit while holding down the lock pawl.

CAUTION

• Because the slide guides have sharp edges,keep them in the main body.

• Lay paper in place where the cleaning unitis put. Be sure there is no metal debrispresent that can cause damage. Metalscrews, paper clips, etc. attracted by thecleaning roller can scratch the roller andblade.

• Because the cleaning unit has no horizontalagitating roller, do not tilt the unit when thecleaning carrier is in the unit.

• When the cleaning carrier is in the cleaningunit, do not turn the unit up side down.

Rear end block cover

PCC wire

Front end block cover

Slide guide

Lock pawl


2-42

2.6.7 Replacing the cleaning roller

1. Remove the cleaning carrier, then remove the unit.

2. Remove three screws to move the rear magnet

holder bracket together with the V-seal at the backof the unit.

3. Remove the C-ring, drive gear and V-seal. If tootight, this can be done after dividing the unit casing.

4. Remove the front magnet holder bracket (4

screws) from the front of the unit, together with themain pole adjusting plate.

CAUTION

• Do not loosen the main pole adjusting platefixing screw (gold screw). If it needs to beloosened, remember the original position ofthe adjusting plate.

5. Remove the C-ring and the relay gear. It can bedone after dividing the unit casing if too tight.

Rear magnetholder bracket

V-seal

Drive gear

V-seal

Front magnetholder bracket

Main poleadjusting plate

Relay gear


2-43

6. Tilt the unit 90o so that the cleaning roller moves to

the top.

7. Disconnect the PCC power pack connector.

8. Remove the drawing rail (2 screw).

9. Divide the cleaning unit into two parts (4 screws).

10. Remove the front and rear bearings and bearingcases (one C-ring each front and rear).

11. Remove the cleaning roller, and replace it.


CAUTION

• Use a dry cloth to wipe and clean the inside.• Confirm that the bias terminal board is in

close contact with the bearing case.• Because the cleaning roller shaft moves, fit

the rear magnet holder bracket after thefront magnet holder bracket is fitted.

• Take care that the two V-seals have thedifferent setting direction as shown.

• Use three M4 x 14 screws to fit the rearmagnet holder bracket. Gradually, tightenthe three screws so that the inside V-sealjust fits the cleaning roller shaft.

2.6.8 Replacing the slide guide

1. Remove the cleaning unit from the slide guides.

2. Remove the stepped screw from the front side andreplace the slide guide on the main body side.

3. Replace the guides as a pair on the main bodyside, and on the cleaning unit side in the sameway as the slide guide of the OPC unit. This isbecause the roller bearing inside the rail maycome out of place when the unit is set.

Drawing rail

Connecting screw

PCC powerpack connector

Cleaning roller

Shaft

M4 x 14 (3)

V-seal


2-44

2.6.9 Replacing the PCC power pack

1. Pull out the cleaning unit.

2. Take off the two power pack fitting screws.

3. Remove ground wire fixing screw, and disconnectthe connector and harness.

2.6.10 Checking the cleaning and scavenging bias

1. Pull out the cleaning unit.

2. Remove the varistor.

NOTE

Although the cleaning power pack is a constantcurrent type, the varistor makes the bias voltage tothe cleaning roller constant. Removing the varistorallows for adjusting the amperage.

3. Remove the rear left cover and set an ammeter tothe cleaning power pack as shown.

NOTE

To measure the cleaning roller side, disconnect thewire from the "CL" terminal (indicated on the powerpack). Then, set an ammeter between the wireconnector and terminal. To measure thescavenging roller side, use the "S" terminal.

WARNING

When the main switch is ON, never touchanything inside the rear left cover to avoidpossible injuries.

4. Turn on the main switch. After the copier entersthe stand-by condition, access the service tools.

5. Select [5-04] "I/O Test". Press the "Motor" key,then press the "Main" and "OPC" keys. Press the"Lamp/Sol" key, then press the "QL" key.

NOTE

This procedure is necessary to avoid OPCdeterioration.

PCC power pack

Power pack fitting screw

Varistor

A

A

CL S

Cleaning powerpack

Ammeter

VR


2-45

6. Press the "P. Pack 2" key, then press the"Cleaning Bias" key to measure the amperage. Itmust be --20 ± 0.5 µA.

7. Set an ammeter to the "S" terminal side, thenpress the "Scav. Bias" key. The amperage must be--10 ± 0.5 µA.

8. If the values do not meet the standards, adjust theamperage by turning the VR above each terminal.

Standards

Cleaning Bias --20 ± 0.5 µAScavenging Bias --10 ± 0.5 µA

NOTE

When both the "Cleaning Bias" and "Scav. Bias"keys are ON, both amperages become --10 µA.Therefore, if the cleaning bias is measured while ina copy run, be sure to disconnect the scavengingbias terminal from the power pack.

SW1 in the middle figure to the right represents the"Scav. Bias" key and SW2 represents the "CleaningBias" key.

SW1 SW2

A1 A2

A1

A2

R1

R2

10µA

10µA

20µA

Carrier (R1)

Cleaning roller

Carrier

Scavenging roller

OPC

Cleaningpower pack

Ammeter

20µA -- 10µA = 10µA

R2

When both SW1 andSW2 are turned on.


2-46

2.7 OPC Cleaning Unit

2.7.1 Replacing the OPC cleaning brush

PM cycle: Replace the brush roller andlubricate the gear every 600K.Clean the brush fibers scattered insideand around the unit using a vacuumcleaner every 600K.


2. Open the front door. Remove two screws to allowit to open further.

3. Pull out the 2P connector for the oscillating motor.

4. Remove the OPC cleaning unit fixing screw.

5. Pull out the OPC cleaning unit.

6. Remove the oscillating motor assembly (3 screws).

7. Remove the brush roller set screw.

8. Pull the brush roller drive joint toward the front andpull out the brush roller.

9. Replace the brush roller and assemble it in thereverse order.

CAUTION

Give the oscillating gear and its groove(including the pin) a thin coat of grease (G-40M)every 600K.

NOTE

If the scattered brush fibers are not cleaned every600K copies, the transfer or separation coronaleakage tends to occur.

2.7.2 Replacing the oscillating motor

1. Remove the oscillating motor assembly.

2. Remove the gear cover (one screw).

3. Remove the oscillating gear (one Allen screw).

4. Remove the motor support plate (2 screws).

5. Remove the oscillating motor (2 screws) andreplace the motor.


Unit fixing screw 2P connector foroscillating motor

Brush roller

Brush roller set screw

Drive joint

Oscillating motorassembly

Fixing screws (3)

Motor gear

Oscillating motorassembly Motor support

plate

Oscillatingmotor

Gear cover

1 July 1994 OPC Cleaning Unit

2-47

2.7.3 Replacing the OPC cleaning brush motor

1. Turn off the main switch, and remove the rear left

cover (2 screws).

2. Remove the power cord clamp bracket (2 screws).

3. Remove the terminal block (2 screws).

4. To access the four screws securing the drive unit,remove the arrester board with its bracket (2 screws).

5. Remove the OPC cleaning brush drive unit (fourM5 screws).

6. Remove the OPC cleaning brush motor (4 screws)and replace the motor.


2.7.4 Replacing the OPC cleaning brush pressure solenoid

1. Remove the OPC cleaning brush drive unit.

2. Remove the solenoid plunger (one E-ring).

3. Mark off the position of the OPC cleaning brushpressure solenoid. Remove the solenoid (2screws) and replace it.


2.7.5 Replacing the OPC cleaning brush drive solenoid

1. Remove the OPC cleaning brush drive unit.

2. Mark the position of the OPC cleaning brush drivesolenoid, and remove the solenoid (2 screws).

3. Remove the plunger spring and replace thesolenoid.


NOTE

Lightly press down the OPC cleaning brush drivesolenoid, and fix it when the plunger stroke comesto between 6.5 and 7.0 mm.

OPC cleaningbrush drive unit

Terminalblock

Power cordclamp bracket

OPC cleaningbrush motor

OPC cleaning brushpressure solenoid

Plunger spring

OPC cleaning brushdrive solenoid

OPC Cleaning Unit 1 July 1994

2-48

2.8 Development Unit

2.8.1 Replacing the developer and air filter

PM cycle: Replace the developer every400K and air filter every 200K.

CAUTION

When you use a vacuum cleaner to clean thedevelopment unit, heavy electrostatic willoccur. To avoid damage of electrical parts, besure to do the following:

• Pull out the toner density control board.• Disconnect the harness from the ID sensor

board and ground the board using thedevelopment unit grounding harness (mainbody’s accessory).


2. Open the front door, and remove two screws toallow it to open further.


4. Turn the lever and release the developmentbackup roller of the OPC unit.

5. Remove the development unit fixing bracket (onescrew). Then, slightly pull out the unit to disengagethe joint gear at the rear of the unit.

6. Turn the development knob to collect developerfrom the development sleeves.

CAUTION

If you do not collect the developer, it mightscatter or damage the OPC.


8. Put the developer collecting vessel under the unit,and lay a vinyl sheet (developer’s accessory) onthe collecting vessel.

9. Remove the developer collecting shutter fixingscrew and pull out the shutter.

10. To dump all the developer, turn the developmentknob in the direction of the arrow.

11. Clean the developer collecting shutter using a drycloth.

12. Clean the side seals of the development unit.

NOTE

Clean the side seals every 200K to remove tonerand paper dust. Replace the side seals if they arewarped, or if there is a contact failure.

Fixing bracket

Vinyl sheet

Developer collectingvessel

Developer collectingshutter

Development knobSide seal

1 July 1994 Development Unit

2-49

13. Remove the air filter case (2 screws). Replace the

air filter every 200K copies.

CAUTION

The filter has a setting direction. Be sure thatthe side with a red line on the edge is facing theinside of the unit.

NOTE

The air filters used in the development unit andcleaning unit are common.

14. Put four bags of developer (4 kg) through the filtercase openings. Use both openings (one opening isfor two bags of the developer) to distribute itevenly.

CAUTION

Clean the developer around the air filter case asthe place is very close to the OPC surface. If thisis not, the OPC may be damaged.

15. Turn the development knob to check thedistribution of the developer.



18. Access service tool [3-04] to do the developerforming. At the same time, reset the supply yieldcounter for the developer to 0.

19. Select service tool [4-02] and press the Start key.After 5 flashes, press the Stop key and check the"Vsg/Vsp" data in the screen. The value must bebetween 6 and 10. If it is not, carry out setting C.

NOTE

PM cycle of other partsSide seals To be cleaned every 200K. (To be replaced

if deformation or close contact failureexists.)

Entrance seal

ID sensor Clean every 200KDrive gear Clean every 400KTiming belt Clean every 400K. Replace every 1,600K.Sleeve gear Clean every 400K. Replace 3 sleeve gears

and 1 idle gear every 1,600K.

CAUTION

Do not lubricate the sleeve gears and the othergears in the development unit to avoid toneradhering to the gears. Lubricate the twoprojections of the unit drive joint roller with asmall amount of G-40M when the unit does notslide in the main body smoothly.

Filter case

Development Unit 1 July 1994

2-50

2.8.2 Cleaning the toner vessel


1. Pull out and remove the development unit.

2. Remove the toner vessel on the rear of the unit (2screws).

3. Clean the toner vessel using a dry cloth, andreassemble in the reverse order.

Toner vessel


2-51

2.8.3 Replacing the development sleeves


2. Remove the inner cover from the rear part of theunit (2 screws).

3. Peel off front and rear side seals.

4. Remove the front and rear sleeve retainers (2screws each).

5. Take off the slot head stepped screw to removeno. 2 sleeve (middle one) main pole fixing plate.Unless this screw is removed, sleeve 1 and 3cannot be pulled out.

6. Take off the slot head stepped screw to removethe main pole fixing plate of the sleeve to bereplaced.

7. Remove the C-rings, sleeve drive gear, bearing,coupling, and V-seal in this order and replace thesleeve.


CAUTION

• Development sleeves 1, 2, and 3 differ fromone another. If they are arrangedincorrectly, this can cause a developercirculation failure or an image error due toimproper main pole position and PG(Photoconductor Gap). The developmentsleeves are designated as follows:

No. 1 sleeve (lower one): 1095ANo. 2 sleeve (middle one): 1096ANo. 3 sleeve (upper one): 1097A

• The sleeve drive gears have the settingdirection.

• Be sure that bias terminal plate is in contactwith the bearing case.

• The V-seal has the setting direction.• Take care not to catch the V-seal when the

sleeve retainer is installed.• Meet the cutout of the bearing coupling

flange with the projection when set.

Sleeve retainer Side seal

Inner cover

Minussteppedscrew

Main pole fixing plateV-seal

Coupling

Bearing

C-ring

Sleeve drive gear

Drive gear


2-52

Adjusting the development motor speed

When no. 3 sleeve (lower one) is changed, the PG(Photoconductor Gap) may change, so you will have toadjust the development motor speed as follows:

Make copies, and If the background is dirty,step up the speed of the developmentmotor by the DGS (the red dial on theupper side, not blue one) of thedevelopment DC power supply. To preventtoner from clogging, do not step up thespeed excessively.

If a half tone is difficult to see, or if thetrailing edge is blank, decrease the speed.

Adjusting the clearances of the sleeves

1. Adjust the clearance between no. 3 sleeve (upperone) and the development casing to between 1.4and 1.6 mm using a clearance gauge. (Usuallyadjustment is prohibited.)

2. Adjust the clearance (doctor gap) between sleeve

1 (lower one) and the doctor blade to between0.70 and 0.80 mm using a clearance gauge.(Usually adjustment is prohibited.)

CAUTION

• When making the adjustments above,developer must not be attached to thesleeve surface. If these clearances becomewider, the toner scatters. If they becomenarrower, the developer runs on thedevelopment casing and scratches thesurface of the OPC belt.

• Check the copy image after adjusting thedoctor gap. Adjust the development motorspeed if necessary. (See Adjusting thedevelopment motor speed section in thepreceding page.)

DGS (red)

VR (blue)

Sleeve 3

Development exit casing


2-53

2.8.4 Replacing parts in the toner hopper

Removing the toner hopper


2. Tilt the development unit and bring the developernear the sleeve 1 (lower one) side.

3. Pull out the toner density control board.

CAUTION

No developer should be allowed to fall on thetoner density control board. Otherwise theboard might be damaged.

4. Remove the toner hopper inner cover (one screw).

5. Remove the one slot head stepped screw on thetoner hopper side from the front toner hopper fixingplate.

6. Remove one toner hopper fixing stepped screw.

7. Remove two slot head stepped screws on the

toner hopper side from the rear toner fixing plate.

8. Remove one toner hopper fixing stepped screwfrom the rear of the unit.

9. Remove the toner hopper.


CAUTION

Pay attention to sealing the toner hopper withthe development unit when the toner hopper isreinstalled.

NOTE

When tightening the front and rear fixing steppedscrews for the toner hopper, slightly lift the tonerhopper up to make it easier.

Replacing the toner supply mylar


2. Remove the toner supply mylar with its bracket (3screws), and replace it.

CAUTION

Confirm that the edge of the mylar and spongeare in contact with the toner supply roller whenreinstalling them.

Front tonerhopper fixingplate Toner hopper

inner cover

Toner hopper fixingstepped screw

Rear tonerhopper fixingplate

Toner hopper fixingstepped screw

Toner supply mylar

Toner supply roller

Sponge blade


2-54

Replacing the toner supply roller


2. Remove the motor bracket (2 screws).

3. Remove E-rings, bearings, couplings, and V-sealsfrom front and rear sides of the toner supply roller.

4. Remove the toner supply mylar (2 screws).

5. Replace the toner supply roller.

CAUTION

Set the V-seals in the proper direction toprevent toner from scattering and jamming thebearing.

2.8.5 Replacing the toner density sensor

1. Pull out the toner density control board.


3. Remove the mixing vanes (one stainless steelscrew).

CAUTION

Be careful not to drop the stainless steel screwin the unit.

4. Remove toner density sensor (two screws). Takeout the harness and pull out the connector toreplace the sensor.


CAUTION

• The developer should not drop on the tonerdensity control board to avoid damaging it.

• The toner density sensor connectionshould be secured with no play whenreinstalling the sensor.


7. Access service tool [4-02] and carry out setting C.

Toner supply roller

Motor bracket

V-seal

Coupling

Toner densitycontrol board

Toner density sensor Mixing vanes


2-55

2.8.6 Replacing the development motor

1. Remove the development unit.

2. Remove rear left cove (2 screws).

3. Remove the development motor with its bracket(four M5 gold screws).

CAUTION

Use a large size screwdriver to loosen the M5screw.

4. Disconnect the connector of the developmentmotor and replace the motor.


CAUTION

• If the motor is removed from the bracket,be sure during reassembling to secure themotor when the development joint comes tothe center of the development motorbracket hole.

• Set the development unit and fix the setscrew of the development motor bracketwhen the development joint is engaged withthe development unit side.

• If the development motor or developmentDC power supply is replaced with a newone, the sleeve linear speed may change.This may appear on the copy image, socheck the copy image after thereplacement. Adjust the development motorspeed if necessary. (See Adjusting thedevelopment motor speed in the Replacingthe development sleeve section.)

2.8.7 Replacing the ID (Image Density) sensor


2. Disconnect the connector from the ID sensorboard located on the top of the development unit.

3. Remove the sensor board, and replace it.

4. Reassemble the removed parts.


6. Access service tool [4-02] and carry out setting C.

Development joint

Development motor

Developmentmotor bracket

Development joint

Development motor bracket


2-56

2.8.8 Checking the ID and toner density sensors

ID sensor

1. Turn off the main switch, and open the front door. Remove two screws to allow it to openfurther.

2. Remove the inner cover at the lower right of the operation panel (2 screws).

3. Set the Beckman multimeter between TP4 and TP1 (ground) on the interface board tomeasure the voltage.

4. Activate the front door safety switch, and turn on the main switch. Wait for the machinestand-by.

5. While pressing the SW1 on the board, turn VR1 on the board. If the multimeter shows 0 to 4volts change by turning VR1, the ID sensor is normal.

Toner density sensor

1. Set the Beckman multimeter between TP5 and TP1 (ground) on the interface board tomeasure the voltage.

2. Activate the front door safety switch, and turn on the main switch. Wait for the machinestand-by.

3. Make copies. If the multimeter shows about 8 volts during the copying run, the toner densitysensor and the toner density control board are normal.

2.8.9 Checking the development DC power supply

1. Turn off the main switch, and remove the rear left

and right covers (2 screws each).

2. Set DGS (red dial) of the development DC powersupply at 7.

3. Disconnect the small 3-pin connector of theencoder (pulse generator sensor) on the top of thedevelopment motor.

4. Turn on the main switch, and access the servicetool.

5. Select [5-04] and turn on the OPC motor anddevelopment motor.

6. Measure input voltage to the development motorusing the Beckman multimeter. Use the large 2-pinconnector of the dc power supply harness (blackand red wires) from the motor.

7. Adjust VR (blue dial) of the DC power supply sothat input voltage come to 34.3 ± 0.5 volts.

8. Check that input voltage is below 4 volts (± 1 volt)when the encoder 3P connector is connected.

CAUTION

If the position of DGS is changed from theoriginal position, check the copy image. If theimage is not normal, adjust the developmentmotor speed. (See Adjusting the developmentmotor speed in Replacing the developmentsleeve section.)

DGS (red dial)

VR (blue dial)

Development DC power supply


2-57

2.9 Fusing UnitCAUTION

After the oil supply unit is removed andreinstalled, oil marks might appear on copies.This is due to the toner built up on the edges ofthe blades. If this occurs, replace the fusingblade, metering blade, and oil supply pad withnew ones as a set.

2.9.1 Replacing the fusing blade, metering blade, and oil supply pad

PM cycle: Replace the two blades and oilsupply pad every 200K.Clean the oil path in both the unit andmain body every 200K.Add silicon oil every 200K.Replace the oil tube going to the oil tankand oil tank if necessary.

1. Turn off the main switch, and open the front door.

2. Pull out the fusing unit.

3. Remove the lower two plated screws from the heatinsulating cover.

4. Remove the upper two plated screws, and removethe heat insulating cover with the oil supply unit.

5. Take out the oil supply unit from the heat insulating

cover.

CAUTION

To avoid spilling the silicon oil, do not tilt theunit.

6. Remove the oil supply pad unit (one stepped

screw each front and rear).

7. Remove the pad from the bracket (4 screws).

Oil supply unit

Fusing heat insulating cover

Lock pawl Oil supply unit

Fusing heatinsulatingcover

Oil supply pad unit

Fusing Unit 1 July 1994

2-58

8. Put the lock pawls of the oil supply unit on the stay

of the fusing unit and hang up the unit as shown.

CAUTION

Place a large sheet to avoid spilling the siliconoil on the floor.

9. Remove the cleaning blade (5 screws).

10. Remove the front and rear pressure springs of the

metering blade unit.

11. Remove the minus head stepped screw from therear of the blade unit (front side in this position)and pull the blade unit out.

12. Remove the metering blade from the bracket (5screws).

13. Replace the blades and pad with new ones.


CAUTION

At the reassembling, be careful of the following:

• Check that the front and rear pressuresprings of the metering blade unit arehooked after installing the oil supply uniton the heat insulating cover. They tend tobe unhooked easily.

• At the installation of the fusing andmetering blades, align the holes of thebronze plate with the pins of the bladesupport bracket. They have settingdirections. Be careful of the settingdirections of the blade support plates asthey also have setting directions.

Stay

Cleaning blade

Front pressurespring

Metering blade unit

Rear pressurespring

Metering blade

Stepped screw

Pin

1 July 1994 Fusing Unit

2-59

• Fit the oil supply pad and soak it withsilicon oil so its surface is coatedsufficiently. If coating is not sufficient, thefusing roller will be damaged.

• Clean the oil pan using a dry cloth every200K copies. At the same time, check theoil hoses, drains in the oil pan, oil exit fromthe unit, and oil receiver of the main bodyside to make sure that the oil passesthrough smoothly.

• If inside of the oil tube going to the oil tank(P/N- A0284904) becomes very dirty, thetube might clog and oil might overflow fromthe oil receiver. If the oil does not passthrough smoothly, replace the tube with anew one. At the same time, clean or replacethe oil tank with a new one to prevent dirtyoil from generating circulating. If papergenerating a lot of paper dust is used,replace the tube and oil tank every 1,000Kcopies.

Oil supply pad

Oil pan

Oil drain

Oil exit

Oil receiver


2-60

2.9.2 Replacing the oil pump tube


1. Press the tray lowering keys for the 2nd and 3rdpaper tray. Then, pull out the paper trays.


3. Remove the lower vertical transport inner cover (3 screws).

4. Remove the oil pump tube and replace it.


2.9.3 Removing the fusing unit


2. Pull out the fusing unit.

3. Remove the front fusing inner cover (2 screws).

4. Remove the fusing unit fixing screw (one steppedscrew).

5. Spread paper on the work table, and remove theunit from the guide rails and put it on the table.

CAUTION

• To prevent damage of parts, grasp the frontgrip and rear upper edge of the unit framewhen you lift the unit.

• Be careful as there is a projection for the oilreturning guide at the bottom of the unit.Set the oil returning guide aside from thework table.

2.9.4 Replacing the fusing heater

1. Remove the fusing unit from the guide rails.

2. Disconnect the front and rear fusing heaterconnectors.

3. Remove the front side of the heater holder (2screws).

4. Pull the fusing heater out, and replace it.

CAUTION

Do not touch the heater glass surface andhandle it carefully to prevent damage.


Oil pump tube

Fusing unitfixing screw

Front grip

Heater holder

Heater connector

Inner cover

Heater


2-61

2.9.5 Replacing the fusing roller

PM cycle: Clean the fusing roller every200K. Replace the fusing roller and heatinsulating bushings every 400K.Replace the bearings and two spacersevery 800K.Every 400K lubricate the drive gear withMobil Temp. 78 and heat insulatingbushings with Barrierta L55/2 (P/NA0289300).

1. Remove the fusing unit from the guide rails.

2. Remove the fusing heater.

3. Open the fusing right cover, and remove the frontand rear pressure lever fixing screws from the rightside of the unit.

4. Pull down the front and rear pressure levers to

release the roller pressure.

5. Remove the upper fusing unit (2 screws each,front and rear).

6. Remove the fusing roller.

7. Remove the C-rings from the fusing roller shaftand pull out the shaft.

8. Replace the fusing roller, heat insulating bushings,bearings, and two spacers beside the fusing rolleras required.


CAUTION

• Do not lose the parallel key in the drive gear.• Face the milled part of the spacers to the

inside of the roller. • When you remove the fusing roller, clean

the thermistor with alcohol and oil drain inthe front side of the oil pan.

NOTE

• Clean the fusing and pressure rollers surface

with a soft dry cloth.

• Clean the drive gear of the fusing roller every400K and lubricate with Mobil Temp. 78.

• Lubricate the inside surface and both edges ofthe heat insulating bushings with BarriertaL55/2 (P/N A0289300) when they are replaced.

• When the fusing roller is removed, clean the oilpan and its oil drains using a dry cloth.

Upper fusing unit

Pressure coverPressure leverfixing screw

Fusing right cover

Fusing roller

Spacer

Heatinsulatingbushing

Parallel key

Spacer

Heatinsulatingbushing

Oil pan

Oil drain

Oil exit

Oil receiver


2-62

2.9.6 Replacing the pressure roller

PM cycle: Clean the roller every 200K.Replace the roller and bearings every800K.

1. Remove the fusing roller.

2. Remove the right inner cover (4 plated screws).

3. Open the fusing right cover.

4. Remove the front and rear pressure lever fixing

screws from the right side of the unit. Then, pulldown the pressure levers to release the rollerpressure.

5. Pull out the pressure roller. Hold both ends of thepressure holder when pulling it out.

6. Remove the C-rings from the pressure roller shaft

and remove the shaft.

7. Replace the pressure roller and bearings as a set.


NOTE

Clean the pressure and fusing rollers surface witha soft dry cloth.

Fusing right cover

Right inner cover

Pressure roller

Pressure lever fixing screw

Pressure lever

Shaft Pressure roller

Bearing

C-ring


2-63

2.9.7 Replacing the fusing pick-off pawls



2. Slide out the fusing unit.

3. Remove the upper two plated screws from the leftside of the unit. Turn the heat insulating cover withthe oil supply unit to left.

4. Slightly turn the pick-off pawl unit to the left.

CAUTION

The unit is fixed by magnets. Be careful not todamage the fusing roller by the pawls whenremoving the pawl unit.

5. Pull out the pick-off pawl unit when the slit of thefulcrum hole, of the pick-off pawl unit, is alignedwith the milled surface of the fulcrum pin.

6. Remove the pick-off pawl pressure springs.

CAUTION

When removing or installing the pressuresprings, do not damage the springs. They arevery weak.

7. Move the pawls to the small diameter part of thepick-off pawl shaft, and remove the pawls.

8. Replace all the pick-off pawls as a set.


NOTE

• Replace the pick-off pawls only when they aredamaged or oil marks appear on copies.

• Clean the pick-off pawls with toluene.

Pick-off guide plate

Fulcrumhole

Fulcrum pin

Pick-off guide plate

Pick-off pawl shaft

Small diameter part

Pick-off pawl Pick-off pawlspring


2-64

2.9.8 Replacing the thermofuse and thermistor

PM cycle: Clean the thermistor every400K.



3. Remove the upper two plated screws from the leftside of the unit. Remove the heat insulating coverwith the oil supply unit.

4. Remove the thermofuse and thermistor and theirassociated brackets (2 screws each).

5. To replace them, remove the thermofuse or

thermistor from the bracket.

6. Reassemble in reverse order.

CAUTION

• The harness should not be in contact withthe fusing roller or catch in the bracketwhen assembled.

• The thermistor should be in contact withthe fusing roller when assembled.

• The thermofuse should have a clearance ofabout 0.9 mm against the fusing roller.

Temperature fuseThermistor

Thermofuse

Fuse fitting screw

Thermistor

Thermistor fitting screw


2-65

2.9.9 Adjusting the fusing temperature

CAUTION

When the main control board is replaced, thefollowing procedure should be carried out:



3. Remove the fusing front inner cover (2 platedscrews). Then, remove the fusing right inner cover(4 plated screws).

4. Remove the fusing right cover (one E-ring).

5. Set the fusing unit, and close the front door.

6. Turn on the main switch, and wait for the machinestand-by.

7. Open the copy tray.

8. Activate the copy tray safety switches on the frontand rear.

9. Open the curl remover fan guide.

10. Set the probe of the surface thermometer.

11. Measure the surface temperature of the fusingroller and calculate the difference from thestandard value (175 ± 2oC).


13. Consider 2oC per step and add the difference fromthe standard value by changing the key position inthe screen.

CAUTION

Do not adjust the fusing temperature whenreferring the value displayed on the service tool[5-03] screen. It does not show the actual fusingtemperature. The displayed value shows whatfusing temperature the CPU takes at the moment. The displayed value will return to thestandard value a few minutes later.

14. Repeat steps 11 through 13 to obtain the standardvalue.

15. Reassemble all removed parts.

Curl remover fan guide

Surfacethermometer probe


2-66

2.9.10 Adjusting the nip width

1. Make A3 solid black copies.

2. Open the front door just before the paper reachesthe fusing unit and stop it between the rollers.

3. Leave it as it is for about 20 seconds.

4. Open the copy tray, and open the curl remover fanguide.

5. Turn the fusing unit knob to eject the paper.

6. Measure the shining part as shown.

StandardsCenter 8.5 ± 0.5 mmDifferencebetween right andleft

0.4 mm or less

7. Turn the pressure adjusting screw if the nip width

is not within the standard value.

NOTE

The pressure lever width is about 38 mm instandard as shown.

Pressure roller

Pressureadjustingscrew

Fusing roller

About 38 mm


2-67

2.9.11 Left side blades fitting standards

1. Face the higher side of the blades to the inside.

2. The front and rear side blade brackets should beparallel and of equal height.

3. Fit the left side blades against the fusing roller asshown in the lower illustration.

2.9.12 Right side blades fitting standards

1. Face the higher side of the blades to the outside.

2. Fit the right side blades against the fusing roller asshown in the lower illustration.

Left side blade

Fusing roller

Pressure roller

Left side blade

Bracket

[FRONT] [REAR]

Right side blade

[FRONT] [REAR]


2-68

2.10 Duplex/Exit Unit

2.10.1 Replacing the duplex feed and reverse rollers

PM cycle: Clean the transport belts every400K.Replace the duplex feed and reverserollers every 600K.

1. Before turning off the main switch, move the

duplex tray side fences to their maximumpositions. Access the service tool [5-05], and pressA3 key.

CAUTION

Do not move the side fences manually. Thetiming belt behind the fences might slip out ofthe pulleys.

2. Turn off the main switch, and open the copy tray.

3. Raise the exit transport guide.

4. Remove one screw each from the front and rear toopen the duplex entrance junction guide above theduplex feed unit.

5. Remove the stop ring, and replace the reverseroller.

CAUTION

Avoid touching the surface of new duplex feedand reverse rollers.

6. Remove the duplex transport belt unit (one flathead screw on the rear and one pan head screwon the front).

7. Remove the stop ring from the front side of the

drive roller shaft and remove the bearing.

8. Pull the drive roller shaft out and bring it onto thetransport guide.

9. Remove the front side of the drive roller andreplace the duplex feed roller.


NOTE

• Turn the drive roller by hand before the duplextransport belt unit is fitted to the copier, andbring the transport belt to the center of eachdrive roller.

• When you only want to clean the belt, you donot have to remove the unit.

Torque limiter

Reverse roller

Stop ring

Unit fixing screws

Drive roller shaft Duplex transport belt

Transport guide

Duplex feed roller

Drive roller

Stop ring

1 July 1994 Duplex/Exit Unit

2-69

2.10.2 Replacing the copy tray sensor


2. Remove the sensor bracket at the rear left cornerof the paper exit unit (2 screws).

3. Remove and replace the sensor.


2.10.3 Replacing the duplex exit sensor



2. Open the upper right door.

3. Pull out the two knobs, and remove the sensorwith its bracket. Disconnect the connector.

4. Clean or replace the sensor.


WARNING

Be careful of the sharp edges around the bracketand bracket fixing stay.

2.10.4 Replacing the fusing exit sensor


2. Open the front door and remove the fusing unit.

3. Remove the SADF transport plate (one steppedscrew on the rear and one plated screw on thefront).

4. Remove the two screws of the fusing exit sensorbracket from the upper side. You can catch it in thespace where the fusing unit was.

5. Clean or replace the sensor.


[Rear left corner ofthe duplex/exit unit]

Sensor bracket

Copy traysensor

Duplex exit sensor

Knob

Duplex exitsensor bracket

Fusing exit sensor

Fusing exit sensor

Duplex/Exit Unit 1 July 1994

2-70

2.10.5 Replacing the upper and lower duplex paper end sensors




3. Remove the duplex transport belt unit (one flathead screw on the rear side and one pan headscrew on the front).

4. Remove the lower duplex paper end sensor board.

5. Remove the duplex tray guide plate, then removethe upper duplex paper end sensor board.

6. Replace the sensor boards, and reassemble in thereverse order.

Guide platefixing screw

Lower duplex paperend sensor board

Duplex tray guide plate

Upper duplex paper end sensor board


2-71

2.10.6 Removing the tray upper cover


2. Remove the auxiliary cover from under the trayupper cover (3 plated screws).

3. Remove two plated screws on the left edge and aplated screw at the rear right corner from under thetray upper cover.

4. Disconnect the connector at the front left corner ofthe copy tray.

CAUTION

Do not forget to re-connect the connector whenreassembling. The connector cannot be setafter installing the tray upper cover.

5. Close the copy tray and remove the tray uppercover.

2.10.7 Replacing the SADF size sensor

1. Turn off the main switch, and remove the tray

upper cover.

2. Remove the slide bracket under the tray uppercover (2 screws).

3. Remove the SADF size sensor with its bracket (2screws). Replace the sensor.


2.10.8 Replacing the duplex entrance junction sensor


upper cover.

2. Remove the duplex entrance junction sensor (2screws).

3. Replace the sensor, and reassemble in thereverse order.

Tray upper cover fixing screw

Auxiliary coverfixing screw

Tray uppercover

Auxiliarycover

Auxiliarycover fixingscrew

Slide bracket

SADF size sensor

Sensor bracketfixing screw

[Behind the tray upper cover]

ADF unit

Duplexentrancejunctionsensor


2-72

2.10.9 Replacing the eject tray sensor


upper cover.

2. Remove the eject tray sensor (2 screws).


2.10.10 Replacing the eject junction sensor


upper cover.

2. Remove the upper cover stay (2 flat head screws).

3. Remove 4 screws from the copy tray bracket.Then, turn the bracket to right.

4. Remove the grip bracket (3 flat head screws).

CAUTION

When installing the grip bracket, check the gripoperation. The copy tray must be opened by thegrip operation.

5. Remove the copy tray.

6. Remove the eject junction sensor (2 screws).


Eject tray sensor

Copy tray

Upper cover stay Copy traybracket

Grip bracket

Eject junction sensor


2-73

2.10.11 Replacing the upper and lower duplex feed sensors




3. Remove a screw on both the front and rear, thenturn the entrance junction guide to the left.

4. Remove the upper duplex feed sensor board (2

screws).

5. Remove the duplex transport belt unit (one flat

head screw on the rear side and one pan headscrew on the front).

6. Remove the feed sensor board bracket (2 screws).

7. Remove the lower duplex feed sensor board fromthe bracket (2 screws).

8. Replace the boards, and reassemble in thereverse order.

Entrancejunctionguide

Upper duplexfeed sensorboard

Lower duplex feedsensor board Feed sensor

board bracket


2-74

2.10.12 Replacing the duplex entrance junction solenoid



3. Remove a screw on both the front and rear, thenturn the entrance junction guide to left.

4. Remove the entrance junction inner cover at thefront left corner of the duplex/exit unit (2 platedscrews).

5. Remove the entrance junction bracket with thesolenoid (2 screws).

6. Remove an E-ring from the junction arm.

7. Remove a screw from the solenoid guide.

8. Remove the solenoid from the bracket (2 screws).

9. Replace the solenoid, and reassemble in thereverse order.

2.10.13 Replacing the air knife and duplex vacuum solenoids

1. Turn off the main switch, and remove the rear right

cover (2 screws).

2. Disconnect two connectors from the duplex blowerunit.

3. Remove the duplex blower unit (4 screws).

4. Remove the air knife solenoid (2 screws).

CAUTION

Do not remove the solenoid stroke adjustingscrew (gold screw). If removed, you will have tomake the following stroke adjustments.

5. Remove the duplex vacuum solenoid.

6. Replace the solenoids, and reassemble in thereverse order. Carry out the stroke adjustments asdescribed in the following.

Entrance junctioninner cover

Entrancejunctionguide

Entrancejunctionsolenoid

Entrancejunctionbracket

Solenoid guide

Entrance junction solenoid

Junction arm

Air knife solenoid

Unit fixing screw

Duplex blower unit

Duplex vacuumsolenoid


2-75

Adjusting the stroke of the air knife solenoid

1. Loosen the air knife solenoid fixing screws.

2. Adjust the solenoid position so that the shutteropens when the air knife solenoid is turned on andcloses tightly when the solenoid is turned off.Check this by pressing the plunger manually.

3. Tighten the fixing screws.

Adjusting the stroke of the duplex vacuum solenoid

1. Loosen the duplex vacuum solenoid fixing screws.

2. Adjust the solenoid position so that the shuttercloses tightly when the solenoid is turned on andopens when the solenoid is turned off. Check thisby pressing the plunger manually.

3. Tighten the fixing screws.

2.10.14 Replacing the torque limiter

1. Remove the reverse roller. (See Replacing the

duplex feed and reverse rollers section.)

2. Lift the torque limiter up and pull it out to the rearside.

CAUTION

• Because the torque limit pressure isproperly adjusted, do not loosen the torquelimiter stopper Allen screws.

• Do not lose the torque limiter shaft bearing.

3. Replace the torque limiter, and reassemble in thereverse order.

Solenoid fixing screw(Gold screw)

Air knife solenoid

Duplexvacuumsolenoid

Entrance junction guide

Torque limiter


2-76

2.10.15 Replacing the 2nd fusing cooling blower


2. Slide out the fusing unit, and remove it (onestepped screw).


4. Remove the entrance junction inner cover at thefront left corner of the duplex/exit unit (2 platedscrew).

5. Loosen the one plated screw fixing the 2nd fusingcooling blower from the top. The blower will slidedown, and you can catch it in the space where thefusing unit was.

6. Disconnect the connector, and replace the blower.


CAUTION

• Do not catch the connector and harnessbetween the frame and blower wheninstalling the blower.

• There are four hooks at the corner of theblower. Meet the hooks with the edges ofthe duplex/exit unit frame, and slide theblower up. The hooks should come beyondthe frame.

2.10.16 Replacing the curl remover fans

1. Remove the 2nd fusing cooling blower. (Refer the

above steps.)

2. Raise the curl remover fan guide.

3. Remove two fixing screws from the front and rearends of the curl remover fan unit.

4. Catch the unit in the space where the fusing unitwas.

5. Bring the connector of the fan unit out from thespace where the fusing cooling blower was.

6. Disconnect the connector and remove the fan unit.

7. Remove the small and large curl remover fans (2screws and one connector each).

8. Replace the fans, and reassemble in the reverseorder.

CAUTION

• Do not catch the connector and harnessbetween the frame and blower wheninstalling the fusing cooling blower.

• Put the pin at the bottom middle of the fanunit in the hole. Then, tighten screws toinstall the fan unit.

Blowerfixing screw

2nd fusingcooling blower

Hook

Hook

Curl remover fan unit

Curl removerfan guide


2-77

2.10.17 Removing the duplex tray unit

1. Turn off the main switch. If peripherals are

installed, remove them from the copier.

2. Remove the copier’s right cover (2 screws).

3. If the machine is equipped with the LCT, removethe horizontal transport unit as follows:

1) Remove the lock lever and knob assemblies.

2) Disconnect the connector at the right side of thehorizontal transport unit from the main body.

3) Remove two screws and pull out the unit fromthe right side.

CAUTION

• Be careful not to damage the paper guideplates when pulling out or installing the unit.

• When reinstalling the lock lever assembly,be sure that the assembly completely locksthe upper guide plates and that the locklever bracket pushes down the upper leftpaper guide plate of the unit. Otherwise,paper misfeeds may occur there.

4. Remove the horizontal transport connector bracket

(one screw).

5. Open the copy tray. Raise the exit transport guide,then remove the duplex transport belt unit (onestepped screw on the rear side and one pan headscrew on the front).

6. Disconnect two connectors going to the joggermotor from the space where the duplex transportbelt unit was removed.

7. Remove eight screws, then slide out the duplextray unit to the right side of the copier.

Knob assembly

Lock lever assembly

Horizontaltransportconnectorbracket

Duplex tray unit

Unit fixing screw

Horizontaltransport unit


2-78

2.10.18 Replacing parts in the duplex tray unit

This procedure explains how to remove or replace thefollowing parts:

• The jogger and back fence motors and theirtiming belts.

• The jogger and back fence home positionsensors.

1. Remove the duplex tray unit from the copier.

2. Reverse the unit and remove the motor cover (4screws).

3. Remove or replace the jogger motor and backfence motor (2 screws each).

4. Remove the belt fixing screws (one each for thejogger and back fence timing belts).

5. Mark off the position and remove the belt tensionbrackets (2 gold screws each).

6. Replace the timing belts.

CAUTION

• The belt tension brackets should be in themarked positions.

• Before installing the back fence motortiming belt, the back fence should besmooth enough to drop by its weight whenthe duplex tray unit is stood up with themotors at the top.

• The side fences should not come up abovethe tray bottom plate.

7. Replace the jogger and back fence home positionsensors (2 screws each).


Belt tension standards

• Back fence belt


• Side fence (jogger) belt

6.5 mm deflection at 20 ± 10 g pressure.

Motor cover

Jogger HPsensor

Belt tensionbracket (jogger)

Belt tensionbracket (backfence)

Belt fixing screw

Side fence

Jogger motor

Back fencemotor

3 mm

20 ± 10 g

20 ± 10 g

6.5 mm


2-79

2.10.19 Removing the duplex/exit unit

WARNING

Due to the weight of the duplex/exit unit, thisprocedure needs two operators.

1. Turn off the main switch. If peripherals areinstalled, remove them from the copier.

2. Remove the copier’s right cover (2 screws).

3. If the machine is equipped with the LCT, removethe horizontal transport unit as follows:

1) Remove the lock lever and knob assemblies.

2) Disconnect the connector at the right side of thehorizontal transport unit from the main body.

3) Remove two screws and pull out the unit fromthe right side.

CAUTION

• Be careful not to damage the paper guideplates when pulling out or installing the unit.

• When reinstalling the lock lever assembly,be sure that the assembly completely locksthe upper guide plates and that the locklever bracket pushes down the upper leftpaper guide plate of the unit. Otherwise,paper misfeeds may occur there.

4. Remove the rear right cover (2 screws).

5. Remove the duplex blower unit (3 connectors and4 screws).

6. Disconnect the two connectors behind the duplex

blower unit.

7. Raise the ADF and remove the SADF transportplate (one stepped screw on the rear and oneplated screw on the front).


9. Remove the eight duplex/exit unit fixing screws

from the right side of the copier.

10. Slide the duplex/exit unit to the right side. Twooperators are required for this step due to theweight of the unit.

11. Lay down the unit.

Knob assembly

Lock lever assembly

Connectors

Duplexblower unit

Blowerconnectors


2-80

2.10.20 Replacing parts in the duplex/exit unit

Replacing the drive gears

Replace gears referring the illustration below.

Replacing the paper feed motor

1. Put a screwdriver through the holes and loosentwo screws.

2. Disconnect the connector and replace the motor.

Replacing the eject junction solenoid

NOTE

You do not have to remove the duplex/exit unit fromthe main body to remove the eject junction solenoid.You just slide the unit to the right until the solenoidappears, then you can replace it.

1. Put a screwdriver through the holes on the rightside frame of the unit and remove two screws.

2. Remove the junction spring and replace thesolenoid.

3. Adjust the position of the solenoid to meet thesetwo conditions:

• When the solenoid is energized, the ejectjunction pawls end should be under the flat guideplate.

• When the solenoid is de-energized, the pawls hitthe edges of the turn guide plate.

Largerelay gear

Duplex transportdrive gear

Horizontal transportdrive gear

Main bodyconnecting gear

Small relay gear

Paper feedmotor

Turn guideplate

Junctionspring

Ejectjunctionsolenoid

Flat guideplate

Eject junctionpawl

Solenoidfixingscrews


2-81


2.8 mm deflection at 227 ± 35 g pressure.

2.10.21 Adjusting the side-to-side registration in the back side copy

Adjustment standard:

Within 0 ± 2 mm in the platen covermode.Within 0 ± 5 mm (the difference betweenthe front and back side must be within 5mm) in the ADF/SADF modes.

NOTE

Before this adjustment, you should finish theadjustments of the side-to-side registrations in thefront side copy for all paper trays. (Refer toAdjusting the side-to-side registration of Paper feedunit section.)

1. Place a test chart on the exposure glass properly.

2. Make copies in the duplex mode (without the ADFor SADF mode).

3. Measure the side-to-side registration on the backside of the copy. It should be within 0 ± 2 mm.

4. If not, follow the steps below:

1) Turn off the main switch, and remove the rightcover.

2) Loosen the four screws securing the duplex sidefences position.

3) Loosen the cam fixing screws, turn the eccentriccams and move the front and rear side fencesseparately.

4) Turn on the main switch, and make more than10 continuous copies.

5) Be sure that all copies are in the standard. Ifnot, repeat step 1 to 4.

6) Adjust the side fences width using service tool[5-02].

227 ± 35 g

2.8 mm

Side fence fixing screws (gold screws)


2-82

2.10.22 Adjusting the duplex blower speed

NOTE

• When you replace the duplex blower driveboard, you do not need to adjust the blowerspeed. They are adjusted at the factory(including spare parts).

• The blower speed is changed according toamount of the copies stacked in the duplex tray.

Measure the low, medium, and high speed of the blower using a digital tachometer. They canseparately be adjusted by the three dials (VR1, VR2, and VR3) on the duplex blower drive board asfollows:

VR1 Low speed adjustment Standard: 4,500 rpmVR2 Medium speed adjustment Standard: 6,000 rpmVR3 High speed adjustment Standard: 7,000 rpm

CAUTION

This adjustment is usually prohibited.

2.10.23 Adjusting the duplex side fence width

The side fence width is just the same as the copy width in the duplex tray, or 0.5 mm wider. Thewidth can be adjusted by pressing "Side Fence" key in service tool [5-02].


2-83

2.11 ADF

2.11.1 Replacing the transport belt



2. Raise the ADF.

3. Push the release button to the right to lower theintermediate transport unit.

CAUTION

When pushing the release button, support theintermediate transport unit with the left hand.

4. Remove the connecting holder (2 flat head screws).

5. Take off a plated screw and slide the tension armsupport plate to the right.

6. Bend the transport belt tension arm down.

7. Raise the upper guide plate of the intermediate

transport unit, and pull out the transport belt.

Release button

Tension arm supportplate fixing screw

Connecting holder

Tension arm

Upper guideplate

Transport belt

ADF 1 July 1994

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8. Replace the transport belt, and reassemble in the

reverse order.

CAUTION

• Be sure that the front and rear belt endsinstall themselves in the transport beltguides (one on the far side and two on thefront side).

• If the tension arm does not move smoothly,apply Mobil Temp. 78 to the back side.

NOTE

Other PM

PM cycle: Clean the vacuum belts and allrubber rollers every 200K.Replace the belts when they slip on thedrive roller even after cleaning.

• You do not need to remove the vacuum beltunit to clean the vacuum belts.

• Clean the back side of all vacuum belts using acloth damp with alcohol.

• Clean all rubber rollers using a cloth damp withalcohol. Do not forget to clean the reversingentrance rollers.

• To clean rollers, you can use the feed,transport, reverse motor free run modes.(Refer to Adjusting the motor speed section.)You need to activate the upper left cover safetyswitches and/or lift switch manually to rotatethe motors.

PM cycle: Every 200K and at every visit,clean the exposure glass using glasscleaner or alcohol. Then, wipe with siliconoil.

• Wiping the exposure glass with silicon oil helpstransport originals more smoothly and preventoriginal misfeeds caused by static electricity.

• Wipe the mylar strips on the original transportpath for the same reason.

2.11.2 Replacing the 1st reverse sensor

1. Turn off the main switch and open the ADF left cover.

2. Remove the 2nd reverse sensor bracket (2 screws).

3. Loosen two bolts (gold color) and remove the bracket with the 1st reverse (reverseentrance) sensor.

4. Remove the sensor from the bracket (one screw) and replace it.


CAUTION

When installing the bracket with the 1st reversesensor, push it down until the lower end of thebracket is in contact with the turn guide plate.Then, tighten the gold bolts.

Transport belt guide

Tension arm

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2.11.3 Replacing parts under the original table

Follow this procedure to replace these items:

• Vacuum belts• Original size sensor• Original set sensor• Recycle arm sensor• 1st transport sensor

Removing the original table and vacuum belt unit

CAUTION

You must adjust the side-to-side registration forthe ADF mode after removing and reinstallingthe original table. (For the adjustment, refer toAdjusting the side-to-side registration in theADF/SADF modes section.) Mark off the originaltable position to make the adjustment easierbefore removing it.

1. Turn off the main switch, and raise the ADF.

2. Remove the ADF front cover (3 plated screws onthe top and 4 on the bottom).

3. Disconnect the connector for the original sizesensor (red 3-pin connector). Remove its femaleside on the frame and bring it beyond the frame.(This is because the original size sensor fixed inthe original table cannot be disconnected fromunder the original table.)

4. Remove the original table (4 flat head screws).

CAUTION

• Mark off the original table position.• The original size sensor is fitted to the back

of the original table. Do not cut harness bypulling the original table if you have notfollowed the above steps.

5. Remove four screws from the vacuum belt unit.

6. Loosen two Allen screws of the belt drive joint andslide the joint to the far side.

7. Remove the vacuum belt unit and disconnect theconnector for the recycle arm and original setsensors.

8. After replacing some parts, reassemble in thereverse order.

CAUTION

• Do not forget to set the female connectorfor the original size sensor on the framebefore installing the original table.

• Do not forget to connect the connector forthe recycle arm and original set sensorsbefore installing the vacuum belt unit.

• Do not forget to tighten the Allen screws ofthe belt drive joint before installing theoriginal table.

• Be careful not to snag any harnesses.

Original size sensor(behind of table)

Female connector

Red 3-pin connector for original size sensor

Original table

ADF 1 July 1994

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9. Check the side-to-side registration in the ADFmode after the machine is in the stand-bycondition.

Replacing the original size sensor

1. Remove the original table.

2. Remove the sensor (2 screws) from under theoriginal table, and replace it.

Replacing the vacuum belts

1. Remove the original table and vacuum belt unit.

2. Slide the five vacuum belts off the unit, andreplace them all at the same time.

Replacing the original set and recycle arm sensors


2. Remove the vacuum belts.

3. Remove the sensors (one screw and connectoreach), and replace them.

Replacing the 1st transport sensor


2. Remove the sensor behind the vacuum belt unit(one screw and connector), and replace it.

Vacuum belts

Vacuum belt unit

Beltdrivejoint

1st transport sensor

Original set sensor

Recycle arm sensor

1 July 1994 ADF

2-87

2.11.4 Replacing parts under the original end fence unit


• 2nd transport sensor• Registration sensor

Removing the original end fence unit

1. Turn off the main switch, and open the original

table cover.

2. Remove two screw from the rear unit side fenceand a screw from the front.

3. Remove the original end fence unit (2 flat headscrews on the left side and 4 pan head screws onthe right side).

Replacing the 2nd transport sensor

1. Remove the original end fence unit.

2. Remove the 2nd transport sensor (one screw andconnector), and replace it.


Replacing the registration sensor

1. Remove the original table cover (2 flat headscrews each on the right and left hinges).

2. Remove the original end fence unit.


4. Remove two screws fixing the right turn guide fromthe front side of the ADF.

5. Remove two screws on the rear side of the rightturn guide from the top.

6. Push down the three pressure arms and removethe driven roller unit for the right turn rollers.

7. Pull out the right turn guide upwards.

8. Raise the ADF and remove the registration sensor(2 flat head screws) from under the ADF unit.


Rear unit side fence

Front unit side fence

2nd transport sensor

Driven roller unit

Right turn guide

Registration sensor

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2.11.5 Replacing parts in the air knife casing


• Recycle arm and its solenoid• Recycle arm height sensor• ADF exit sensor

CAUTION

Do not lubricate the recycle arm to avoidmoving failure.

Removing the air knife casing

1. Turn off the main switch and remove the ADF rear

cover (7 plated screws).

CAUTION

The ADF rear cover is made of metal. So, thecover may touch electric elements on theboards shorting them out when you remove thecover. Be sure to turn off the main switch whenyou remove the ADF rear cover.

2. Remove the blower unit.

3. Remove the two air knife casing fixing screws fromthe rear side of the ADF.

4. Remove the front and rear magnet catches for theADF left cover (one minus head stepped screwseach, front and rear)


6. Remove the two air knife casing fixing screws fromthe front side of the ADF.

7. Disconnect the connector to the air knife casing.

8. Pull out the air knife casing to the left.

9. Remove five screws to divide the casing into two

parts.

CAUTION

Remove only the five screws shown in theillustration. The other screws are for securingthe parts inside the casing.

10. After replacing some parts, reassemble in thereverse order.

CAUTION

Be sure that there is no air leakage from thecasing.

Air knife casing

Connector

Magnet catch

Five screws to be removed

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Adjusting the air knife casing position

CAUTION

This adjustment should be done if the air knifecasing is removed and reinstalled.

1. Turn on the main switch.

2. Place 10 sheets of paper on the original table.

3. Put the recycle arm on the top of the paper stack.

4. Loosen the recycle arm height sensor fixing screw(gold screw) and slide the screw.

5. Thighten the sensor fixing screw just when theLED114 on the ADF control board goes OFF.

6. Place another 10 sheets of paper (20 sheets total).Place the recycle arm on the top.

7. Be sure that LED114 turns ON.

8. If this adjustment is impossible, change the air

knife casing position as follows:

(1) Loosen two casing fixing screws on thefront.

(2) Loosen the gold screw and move up ordown the front side of the casing.

(3) Tighten the screws.

(4) Repeat steps 2 to 7 above.

Sensor fixing screw

Casing fixingscrews

Gold screw

ADF 1 July 1994

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Anti-static brush resistance standard

Check that the resistance between theanti-static brush and ADF frame is 50 Ωor less.

Replacing the recycle arm and solenoid

1. Remove and disassemble the air knife casing.

2. Remove the solenoid (2 screws).

3. Unhook the two plunger springs.

CAUTION

The springs are of different lengths. Be carefulwhen you install them.

4. Remove the plunger together with the recycle armand actuator.

5. Replace the recycle arm assembly and/or recyclearm solenoid, and reassemble in the reverse order.

Solenoid position standard

Check the operation of the recycle arm by pressing thesolenoid plunger manually. Adjust the solenoid position ifnecessary.

When the solenoid is energized, theleading edge of the recycle arm goes into6.5 mm from the exit edge of the air knifecasing.

CAUTION

After changing the solenoid position, you mustcarry out "Adjusting the air knife casingposition" on the previous page.

Replacing the recycle arm height and ADF exit sensors

1. Remove and disassemble the air knife casing.

2. Remove the sensors (one screw each), andreplace them.


Recycle arm Recycle armsolenoid

Auti-staticbrush

Solenoid fixing screws

6.5 mm

1 July 1994 ADF

2-91

2.11.6 Replacing the feed, transport and reverse motors

1. Turn off the main switch, and remove the ADF rear


CAUTION


2. Remove the blower control board for the reversemotor and ADF control board for the feed andtransport motors.

CAUTION

• Before installing the ADF control board, besure to connect the three connectors onboth the front and back side of the board.

• Be sure not to damage electric elements onthe boards.

• Be sure not to cut the harnesses by pullingthe boards or rubbing the harnesses withthe edges of any brackets or plates.

• Do not pull the fiber optics cable when youdisconnect it from the ADF control board.Grasp its connector using pliers and pull itout.

3. Disconnect the motor connectors and remove thefixing screws.

4. Replace the motor and reinstall in the reverseorder.

CAUTION

Fix the motor in a proper position to preventexcessive tension on the timing belt. If thetension is too strong, the motor shaft may bebroken. When the motor is reinstalled, be sureto follow "Adjusting the motor belt tension"below.

Blower control board

Reverse motor

ADF 1 July 1994

2-92

Adjusting the motor belt tension

1. Loosen the two screws securing the reverse motor.

2. While firmly pushing the motor to the left, retightenthe screws in the order described in the illustration.Fully tighten the first screw before the second one.(The belt tension will be proper even if the motor isstrongly pushed to the left.)

Caution

If the screws are tightened in a different orderfrom the specified one, too much tension will beapplied. (When the second screw is tightened,the motor pulley slightly moves, applying moretension to the timing belt. This will cause themotor shaft to break.)

3. Loosen three screws each securing the transport

motor and original feed motor.

4. In the same way, retighten the screws asdescribed in the illustration.

5. Check if the tension of each timing belt is proper.

Note:

Proper tension can be obtained by following steps2 and 4 only. At step 5, make sure the timing beltsdo not slip on the pulleys when drive is applied.

Reverse Motor

Blower Control Board

Motor Pulley Timimg Belt

Original FeedMotor

Motor Pulley

TansportMotor

Motor Pulley

1 July 1994 ADF

2-93

2.11.7 Replacing the original feed magnetic clutch

Turn off the main switch, and remove the ADF rearcover (7 plated screws).

CAUTION


1. Remove the ADF control board.

CAUTION

• Before installing the board, be sure toconnect the three connectors on both thefront and back of the board.

• Be sure not to damage electric elements onthe board.

• Be sure not to cut the harnesses by pullingthe board or rubbing the harnesses with theedges of any brackets or plates.


2. Remove the magnetic clutch bracket (2 screwsand one E-ring).

3. Slide and pull out the magnetic clutch.

CAUTION

Take care not to lose the inside collar andparallel key.

4. Replace the magnetic clutch, and reassemble inthe reverse order.

CAUTION

• After installing the bracket, remove theoriginal table and loosen the two Allenscrews of the belt drive joint. Move the beltdrive shaft to the magnetic clutch side andcheck that the shaft moves smoothly. If itdoes not, the shaft is not connectedstraight. Loosen the screws securing themagnetic clutch bracket and adjust itsposition.

• The screw on the bracket works as theturning stopper of the magnetic clutch. Besure that the screw catches the magneticclutch when installing the bracket.

Belt drive joint Magnetic clutch bracket

Parallel key

Original feedmagnetic clutch

Collar

Turning stopperBelt drive shaft

ADF 1 July 1994

2-94

2.11.8 Replacing the ADF blower motor



CAUTION


2. Remove the blower unit upper casing (4 screws).

3. Disassemble the blower unit and replace the motor.


CAUTION

• If you disassemble all the blower unit, becareful when you install the upper andlower turbine fans because they aredifferent.

• The nut securing the upper turbine fan hasreverse threads.

• Do not snag the harness when the unit isinstalled.

2.11.9 Replacing the SADF exit gate solenoid



CAUTION


2. Remove the blower control board.

3. Remove the solenoid (2 screws) and replace it.



Check the operation of the exit gate plate by pressingthe solenoid plunger manually. Adjust the solenoidposition if necessary.

When the solenoid is energized, the gateplate touches the reverse guide.

When the solenoid is de-energized, thegate plate end drops below the undersurface of the exposure glass.

Unit fixing screw

Lower turbine fan

Upperturbinefan

SADF exit gate solenoidReverse motor

Reverse guide

SADF exit gate plate

Transport beltExposureglass

1 July 1994 ADF

2-95

2.11.10 Replacing the SADF registration gate and entrance gate solenoids



CAUTION



CAUTION




• Do not pull the fiber optics cable when youdisconnect it from the ADF control board.Grasp its connector using pliers and pull itout. Remove the ADF control board.

3. Remove the solenoid fixing bracket (2 screws).

4. Remove the solenoids from the bracket (2 screwseach) and replace them.


CAUTION

• The lift switch must be turned on and off bythe actuator when the ADF is opened andclosed.


Check the operation of the registration gate andentrance gate plates by pressing the plungers of eachsolenoid manually. Adjust the solenoids’ position ifnecessary.

• SADF entrance gate solenoid

When the solenoid is de-energized, thegate plate projects 4.0 mm or more fromthe ADF bottom frame. When it isenergized, the gate plate goes into thebottom frame.

• SADF registration gate solenoid

When the solenoid is de-energized, thegate plate goes into the bottom frame.When it is energized, the gate plateprojects 5.0 to 5.5 mm from the ADFbottom frame.

Solenoidfixingbracket

Entrance gatesolenoid

Registration gatesolenoid

Transport motor

Original feed motor

Registration gate solenoid

Lift switchEntrance gate solenoid

ActuatorFeeler

Bottomframe

Registrationgate plate

ADF 1 July 1994

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2.11.11 Replacing the shutter solenoid

PM cycle: Adjust the solenoid positionevery 2,000K.

1. Turn off the main switch, and remove the ADF rearcover (7 plated screws).

CAUTION



CAUTION





3. Remove the harness bracket (2 screws).

4. Remove the solenoid (2 screws) and replace it.



Check the shutter operation by pressing the solenoidplunger manually. Adjust the solenoid position ifnecessary.

When the solenoid is energized, theshutter tightly shuts the air exit.

When the solenoid is de-energized, theshutter opens.

NOTE

Because the moving part of the solenoid link is wornoff, adjust the solenoid position every 2,000Kcopies. If the shutter is not closed tightly, originalmisfeeds may occur.

Harness bracket

Shutter solenoid

Shutter

Shutter solenoid

1 July 1994 ADF

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2.11.12 Replacing the reverse junction solenoid



CAUTION



CAUTION





3. Remove the solenoid plunger assembly (oneE-ring and spring).

4. Remove the two solenoid fixing screws from thetop.

5. Raise ADF and pull the solenoid out of the bottomof the ADF.

6. Replace the solenoid and reassemble in thereverse order.


Check the operation of the reverse junction pawls bypressing the solenoid plunger manually. Adjust thesolenoid position if necessary.

When the solenoid is energized, thereverse junction guide (black plate) edgeand reverse junction pawls end are 4mmapart. You can check this from thebottom of the ADF by opening theintermediate transport unit.

Reverse junction solenoid

Solenoid plungerassembly

Reverse junctionpawl

Reverse junction guide

4 mm

ADF 1 July 1994

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2.11.13 Removing the intermediate transport unit

1. Turn off the main switch, and remove the ADF rearcover (7 plated screws).

CAUTION



CAUTION





3. Remove the blower unit.

4. Remove two screws each from the right and leftsupport shafts at the rear of the intermediatetransport unit.

5. Raise the ADF and push the release button to theright to lower the intermediate transport unit.

CAUTION

When pushing the release button, support theintermediate transport unit with the left hand.

6. Pull out the intermediate transport unit.


CAUTION

Pay attention to the setting position of the drivepulleys at the rear of the intermediate transportunit. The drive pulleys must be situated underthe 2-sided timing belt. (See illustration.)

Support shaft screws (4)

Unit drive pulleys

2-sided timingbelt

Intermediatetransport unit

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2.11.14 Removing the ADF unit

WARNING

Due to the weight of the unit, two operators arerequired for this procedure.



CAUTION


2. Remove the left and right stopper cushions (2stepped screws each) and the left and rightstopper brackets (2 screws each).

3. Raise the ADF, remove the rear exposure glass

cover (2 screws) and the left exposure glass cover(5 screws).

4. Open the front door, and remove two screws toallow it to open further.

5. Remove the upper left inner cover (2 screws).

6. Disconnect the DF fiber cable (CN110) from themain body main control board and remove it fromthe lower left corner of the operation unit.

7. Remove the two DF harness clamps, ground wire

fixing screws, and the bushing that protects theharness, then disconnect the ADF harnessconnector from the DC main harness.

8. Remove the four screws each from the right andleft unit hinges to remove the DF unit.

9. Reinstall the unit in the reverse order.

CAUTION

• Check the original transport performanceon the SADF and ADF. If an original misfeedoccurs on the exposure glass, remove theADF front cover and check that the twoprojections at the front edge of theintermediate transport unit (just behind themagnets) are in contact with the exposureglass when the ADF closes. If this is not,adjust the height of the magnets. Thepriority of attraction is determined by theright magnet.

• In the SADF mode, check the original stopposition on the exposure glass. If theoriginal is skewed, loosen the hinge fixingscrews and twist the ADF unit right or left.Then, tighten the screws.

ADF rear cover

Stoppercushion

Stopper bracket

Rear exposure glass cover

Left exposureglass cover

Fiber cable

Inner cover

Harness clamps

Fibercable

ADF harness

Bushing

Ground wirefixing screw

8 hinge fixing screws

ADF 1 July 1994

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2.11.15 Adjusting the side-to-side registration in the ADF/SADF modes

Standard: 0 ± 5 mm(The difference between the front andback side image must be within 5 mm.)

NOTE

Before following this procedure, adjust theside-to-side registrations for all paper trays and forthe front and back side copies. (Refer to Adjustingthe side-to-side registration of the Paper feed unitsection and Adjusting the side-to-side registrationin the back side copy of Duplex/exit unit section.)

SADF

1. Set an original in the SADF set table and make a

copy.

2. Measure the difference in the side-to-sideregistration between the copy and original.

3. If the value is different from the standard, changethe SADF original guides position as follows: 1) Press the left end of the rear SADF originalguide to release the cover pawl and slide out thecover to the right. 2) Loosen two screws in the rear of the originalguide. 3) Adjust the rear original guide position. Then,tighten the screws.

4. Finally make more than 10 continuous copies tocheck the variation. Be sure that all copies arewithin the standard. If not, repeat the above step.

ADF

1. Set an original on the ADF original table and makea copy in the single side original mode.

2. Measure the difference of the side-to-sideregistration between the copy and original.

3. If the value is out of the standard, loosen the fourflat head screws to change the original tableposition. Then, tighten the screws.

4. Finally make more than 10 continuous copies tocheck the variation. Be sure that all copies are inthe standard. If not, repeat the above step.

5. Make a copy in the 2-sided original to 1-sidedcopies mode and check the side-to-sideregistration of the second copy. If it does notsatisfy the standard, the original might haveskewed. Check it (refer to Disabling the originalreturn motion in the ADF mode section), andadjust the ADF unit position if necessary (refer toRemoving the ADF unit section).

Rear SADF originalguide fixing screws (2)

Cover

Front SADF originalguide

1 July 1994 ADF

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2.11.16 Adjusting the leading edge registration in the ADF/SADF modes

Standard:Between --3 and +5 mm (ADF mode)Between --4 and +6 mm (SADF mode)

CAUTION

This procedure is required when the ADFcontrol board is replaced.

NOTE

Before following this procedure, adjust the leadingedge registrations in the platen (not ADF andSADF) mode. (Refer to Adjusting the leading edgeregistration of the Paper feed unit section.)

1. Set an original in the SADF set table and make acopy.

2. Measure the difference in the leading edgeregistration between the copy and original.

3. If the value is different from the standard, turnVR104 on the ADF control board. Turn off themain switch, and remove the ADF rear cover (7plated screws) to access VR104.

NOTE

• Turn VR104 clockwise to move the leadingedge of the copy image backward.

• Turn VR104 counterclockwise to move theleading edge of the copy image forward.

CAUTION


4. Finally make more than 10 continuous copies tocheck the variation. Be sure that all copies arewithin the standard. If not, repeat the above step.

NOTE

• You do not need to check the leading edgeregistration in the ADF mode if it is satisfied inthe SADF mode.

• In the ADF mode, originals are passed 7 mmthrough the correct original stop position on theexposure glass. Then, they return 12 mm to hittheir trailing edges against the original scaleand stop. When VR104 is turned, 7 mmpassed and 12 mm return, the amount in theADF mode also changes.

ADF control board

VR104

ADF 1 July 1994

2-102

2.11.17 Adjusting the motor speed (Free run mode)

CAUTION

• This procedure is required when the ADFcontrol board is replaced.

• The ADF rear cover is made of metal. So,the cover may touch electric elements onthe boards shorting them out when youremove the cover. Be sure to turn off themain switch when you remove the ADF rearcover.

• The power line for the motors is commonwith the one for the recycle arm solenoid.While adjusting the speed of the motors, ifthe speed decreases, the solenoid willvibrate. This will cause the solenoid to heat.Therefore, finish the speed adjustmentquickly. Otherwise, disconnect theconnector going to the solenoid.

NOTE

To stop the motor, turn off all DIP switches or raisethe ADF to turn off the lift switch. The original settingfor all DIP switches is OFF.

Adjusting the speed of the original feed motor

1. Turn on DIP switches 101-1, 2 and 4 on the ADF

control board.

2. Turn on DIP switch 100-1. The motor will startrotating.

3. After the original feed motor is turned on, adjustVR102 to light LED 112.

Adjusting the speed of the transport motor


control board.


3. After the transport motor is turned on, adjustVR100 to light LED112.

Adjusting the speed of the reverse motor


control board.


3. After the reverse motor is turned on, adjust VR101to light LED 112.

1 July 1994 ADF

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Technical Support

RTB 21 Improved adjustments when there are original double-feed misdetections.

2.11.18 Adjusting the speed of the ADF blower motor

CAUTION

• This adjustment is usually prohibited. Whenyou replace the ADF blower control board,you do not need to adjust the blower speed.They are adjusted at the factory (includingspare parts).

• The ADF rear cover is made of metal. So,the cover may touch electric elements onthe boards shorting them out when youremove the cover. Be sure to turn off themain switch when you remove the ADF rearcover.

NOTE

To stop the motor, turn off all DIP switches or raisethe ADF to turn off the lift switch. The original settingfor all DIP switches is OFF.


control board.


3. After the blower motor is turned on, use a digitaltachometer to measure revolutions of the fan. Puta mark on the flat part of the fan to let thetachometer read it.

4. Adjust VR1 on the blower control board so that the

speed is 4,500 rpm when 10 or less originals areset on the original table (the recycle arm heightsensor OFF).

5. Set more than 20 sheets of the original to turn onthe recycle arm height sensor. Next, adjust VR3 onthe blower control board so that the speed comesto 7,000 rpm.

Blowercontrol board

ADF 1 July 1994

2-104

2.11.19 Original transport test mode

CAUTION


NOTE

The original setting for all DIP switches is OFF.

Single-side original mode

1. Turn on DIP switches 101-1 and 4 on the ADF

control board.

2. Put some originals on the original table.

3. Operation starts when SW101 is pressed.

4. Operation stops when SW 100 is pressed.

5. Raise the ADF and press SW101 again for restart.

2-sided original to single-side copies mode

1. Turn on DIP switches 101-2 and 4 on the ADF

control board.

2. Follow the same steps as the above.

2-sided original to 2-sided copy mode

1. Turn on DIP switches 101-1, 101-4 and 100-3.

2. Follow the same steps as the above.

1 July 1994 ADF

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2.11.20 Disabling the original return motion in the ADF mode

CAUTION


1. Turn on DIP switch 101-1 on the ADF controlboard. This setting disables the return motion oforiginals to the scale on the exposure glass in ADFmode.

NOTE

• The original setting for all DIP switches is OFF.

• This mode will prevent damage of originalwhen a thin original is used in the ADF mode.

• Using this mode, the original skew on theexposure glass can be checked. Check theoriginal stop condition as follows: 1) Disable the return motion and set anoriginal on the original table. 2) Select more than 10 repeat copies andpress Start key. 3) Press Clear/Stop key soon after the originalis fed. 4) Slowly raise the ADF and check the originalstop position on the exposure glass. 5) If the original skewed, try to adjust the ADFunit position. (Refer to Removing the ADF unitsection.)

ADF 1 July 1994

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2.11.21 Standard resistance values of the ADF/SADF original size sensors

SADF (KΩ) ADF KΩ Size

10.12 8.75 MAX9.20 8.24 A36.20 5.46 B42.48 2.14 A40.17 0.23 B5

0 0.05 MIN

2.11.22 LED’s on the ADF control board

LED No. Sensor Name

100 1st reverse sensor101 Original set sensor102 2nd transport sensor103 Entrance sensor104 ADF exit sensor105 1st transport sensor106 SADF exit sensor107 Registration sensor 108 2nd reverse sensor109 Recycle arm sensor110 SADF set sensor111 Stays ON112 Stays ON113 Stays ON114 Recycle arm height sensor

1 July 1994 ADF

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2.11.23 How to use the jam checker

CAUTION

• Protect the soldered part of the indicationboard using insulating tape.

• To make the jam checker, the indicationboard and harness are required. (See theparts catalog for the part numbers.)

By using the jam checker, you know which sensor has detected the jam after an original jam.Use the jam checker as follows:

1. After an original jam occurs, remove the ADF rear cover and connect the jam checkerharness connector to CN102 on the ADF control board.

2. Turn on DIP switches 101-1 and 3. Be sure that the jam checker indicates "00". If not, pressSW100 to reset it.

3. Turn on DIP switch 101-2 (101-1, 2, and 3 ON). The jam checker will indicate a number. Usethe table below to find out which sensor has detected the original jam.

Displayed No. Description Logging Location01 Entrance sensor ON check jam "RDH Feed" in service tool [3-06]02 Entrance sensor OFF check jam03 1st transport sensor ON check jam04 1st transport sensor OFF check jam05 2nd transport sensor ON check jam "RDH Trans" in service tool [3-06]06 2nd transport sensor OFF check jam07 Registration sensor ON check jam (in ADF mode)08 Registration sensor OFF check jam (in ADF mode)09 1st reverse sensor ON check jam "RDH Exit" in service tool [3-06]10 1st reverse sensor OFF check jam11 2nd reverse sensor ON check jam12 2nd reverse sensor OFF check jam13 Exit sensor ON check jam14 Exit sensor OFF check jam15 Registration sensor ON or OFF check jam (in SADF mode) "SADF Feed" in service tool [3-06]16 SADF exit sensor ON or OFF check jam (in SADF mode) "SADF Exit" in service tool [3-06]17 Jam due to abnormal original feed motor SC33 in service tool [3-07] when 4

times or more occur during one jobcycle

18 Jam due to abnormal transport motor SC34 in service tool [3-07] when 4times or more occur during one jobcycle

19 Jam due to abnormal reverse motor SC35 in service tool [3-07] when 4times or more occur during one jobcycle

20 Original end detection failure by recycle arm sensor --21 Original end detection failure by recycle arm sensor

(in job recovery mode)--

ADF 1 July 1994

2-108

Switchback roller2nd reverse sensor

1st reversesensor

SADF exitsensor

Reverseentranceroller

SADF exitroller

Reverse exitroller

SADF exitgate plate

Reverse junction gate pawls

Originalfeed roller

Antistaticbrush

Relayrollers

1st transportsensor

Exposure glass

Transport belt

Original size sensorRelay rollers

2ndtransportsensor

Antistaticbrush

SADF registrationgate plate

Registration sensor

SADF entrancegate plate

SADF setsensor

Right turn roller

Original lengthsensor

Original stopper

Original guides

Original transport belt

Recycle arm sensor

Original set sensor

Exit sensor

Exit roller

Recycle arm heightsensor

Entrance sensor

ADF left coversafety switch

1 July 1994 ADF

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2.11.24D

rive layout diagram

Vacuum belt

Feed-out roller

2-sided timing belt (long)

Originalfeedmagnetic clutch

S3M525[60]

Original feed motor

S3M123[80]Transport motor

S3M141[60]

S3M351[60]

Right turn roller(built-in anone-way clutch)

Transport belt drive roller S3M189[60]Transport belt

Intermediate transportdrive pulleys

Original feed roller

Reverse junction pawl

Reversemotor

SADF exit gate plate

Reverse exit roller

Reverse entrance roller

2-sided timing belt (short)

Flanged bearing

S3M123[80]

Switchback roller pulley(built-in an one-way clutch)

S3M150 [80]

Relay pulley(built-in an one-way clutch)S3M351[40]

Original Feed MotorTo right turn roller

S3M351[60]

S3M123[80]

S3M525[60]

Original feed motorTo original feed roller

To intermediatetransport drivepulleys

Long 2-sidedtiming belt

2-sided timing belt

B40S3M354

AD

F1 July 1994

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2.12 Operation unit

2.12.1 Removing the operation unit


2. Remove the four operation unit fixing screws.

3. Disconnect the two connectors and remove theunit.

NOTE

If the connectors are difficult to disconnect, openthe front door and remove the two screws to allowit to open further. Then, remove the inner coverunder the operation unit and disconnect theconnectors from the underside.

2.12.2 Removing the operation ROM board

1. Remove the operation unit.

2. Pull the dismount pawl.

3. Pull out the board.

4. Replace the ROM’s if required.


CAUTION

Remember the original locations for each ROMwhen you remove the ROM’s.

Operation unit

ROM board

Dismount pawl

1 July 1994 Operation unit

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2.13 Others

2.13.1 Replacing the main motor

1. Turn off the main switch and remove the rear left

cover (2 screws).

2. Remove the power transformer (2 screws).

3. Disconnect the two main motor connectors.

4. Mark off the tension pulley bracket position.

5. Remove two screws to loosen the tension pulleybracket.

6. Remove the main motor bracket (8 screws) anddrive pulley (2 Allen screws and one parallel key).

CAUTION

Do not lose the parallel key.

7. Remove the main motor from the bracket andreplace it.


2.13.2 Replacing the vacuum fan


cover (2 screws).

2. Disconnect the vacuum fan connector.

3. Remove the vacuum fan unit (3 screws).

4. Disassemble the vacuum fan unit and replace thefan.


2.13.3 Adjusting the main motor and main drive belt tension and alignment

Belt tension standards

• Main motor belt

8 mm deflection at 1.2 ± 0.25 kg pressure.

Main motor

Main motor bracket

Tension pulleybracket

Powertransformer

Connector

Drive pulley

Vacuum fan

Fan casing

Main motorpulley

8 mm

1.2 ± 0.25 kg

Others 1 July 1994

2-112

• Main drive belt

7 mm deflection at 1.2 ± 0.25 kg pressure.

Belt alignment standards

• Main motor belt

41.5 ± 1.2 mm from the copier rear frameat the two locations shown.

• Main drive belt

Between 83.7 and 81.1 mm from thecopier rear frame at the two locationsshown.

1.2 ± 0.25 kg

7 mm

41.5 ± 1.2 mm

Copier rear frame

Copier rear frame

83.7 ∼ 81.1 mm

1 July 1994 Others

2-113

2.13.4 Replacing the fusing cooling exhaust fan


cover (2 screws).

2. Remove the outside duct of the fusing coolingexhaust fan (2 screws).

3. Disconnect the connector of the fan.

4. Remove the fan (2 screws) and replace it.


2.13.5 Replacing the front and upper right door switches


2. Open the front or upper right door and remove theapplicable inner cover.

3. Mark off the switch bracket position.

4. Remove the switch or sensor from the bracket andreplace it.


CAUTION

Fix the door switches in the marked off position.If you can not do this, tighten the switch bracketfixing screws when the center of the oval holesof the bracket meet the screw holes. Check thatthe switch turns on prior to the sensoractivation. When the door is closed, the sensoractuator should be pushed more than 6.5 mmby the switch as shown.

Fusing coolingexhaust fan

6.5 mm or more

Others 1 July 1994

2-114

2.14 LCT

2.14.1 Replacing the paper feed, reverse, and pick-up rollers


NOTE

One set of the feed, reverse and pick-up rollers canfeed up to approximately 150,000 sheets of paper.If the paper trays are not used evenly, replace therollers that are worn more with the rollers that areworn less. Do this before any rollers wear out.

1. Pull out the LCT tray, and turn off the main switch.

2. Open the top cover and upper front cover.

3. Loosen the minus head shaft holding the paperfeed unit and pull out the shaft about 10 mm.

4. Hold the far side of the paper feed unit and turn itto the right.

5. Remove the stop rings from each roller andreplace the rollers.


CAUTION

• Do not touch the surface of the new rollerswith bear hands.

• Be sure that the feed roller has the settingdirection.

2.14.2 Removing the paper feed unit

1. Pull out the LCT tray, and turn off the main switch.

2. open the upper and upper front covers.

3. Remove the left inner cover (a flat head screw onthe top and 2 pan head screws on the bottom).

4. Remove an E-ring from the fixing bracket thatholds the paper feed unit.

5. Disconnect the paper feed unit connector.

6. Loosen the minus head shaft and pull it out about10 mm.

7. Hold the far side of the paper feed unit and turn itto the right. Then, hold the front side of the unitwith the other hand and lift it up to slide the unit offthe bracket pins. Take out the unit through theupper space.


Upper front cover

Paper feed unitfixing shaft

Paper feed unit

Tray

Left inner coverE-ring

Paper feed connector

Paper feed unit

Cover fixing screws

1 July 1994 LCT

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2.14.3 Replacing the tray motor

PM cycle: Grease the worm gear withMobil Temp. 78 every 1,000K.

1. Press the tray down key.

WARNING

Do not forget to lower the tray before you turn offthe main switch. It is dangerous to remove thetray motor while the tray stays in the upper side.

2. Turn off the main switch, and remove the LCT rearcover (5 screws).

3. Disconnect the two tray motor connectors andpaper volume sensor connector.

4. Remove the bracket with the tray motor (5 screws).

5. Loosen the two screws holding the tension pulleyto release the belt tension.

6. Remove the motor pulley from the motor (2 Allenscrews).

7. Remove the motor from the bracket (4 screws) andreplace the motor.


CAUTION

Fix the motor pulley so that the motor shaft endaligns with the pulley end face.

Tray drive motor belt tension standard

2 to 4 mm deflection at 500 g pressure.

Motor fixing screws (4)

Bracket fixingscrews (5)

Tray drive motor

Worm gear

2 to 4 mm

Tension pulley

Motorpulley

Motorconnector

Paper volumesensor connector

LCT 1 July 1994

2-116

2.14.4 Replacing the paper end sensor


1. Pull out the tray, and turn off the main switch.

2. Remove the tray bottom plate (4 screws).

3. Turn the shaft holding the paper end sensorbracket by 180o counterclockwise.

4. Remove the sensor bracket (2 screws).

5. Remove the sensor from the bracket (a screw) andreplace it.


CAUTION

When the tray bottom plate is installed on thefixing shaft:

• The front edge of the sensor bracket shouldbe put on the pin of the tray stopper.

• Before installing the tray bottom plate, besure that the milled surface of the center ofthe right bottom plate fixing shaft faces theinside of the tray.

2.14.5 Replacing the paper size sensors


2. Remove the tray bottom plate (4 screws).

3. Unhook the pawls of the sensors and remove them.

4. Replace the sensors, and reassemble in thereverse order.

CAUTION

When the tray bottom plate is installed on thefixing shaft:

• The front edge of the paper end sensorbracket should be put on the pin of the traystopper.

• Before installing the tray bottom plate, besure that the milled surface of the center ofthe right bottom plate fixing shaft faces theinside of the tray.

Tray bottom plate

Paper end sensor

Sensor bracket

Paper size sensor (5)

1 July 1994 LCT

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2.14.6 Replacing the transport sensor

PM cycle: Clean the sensor every 600Kand transport rollers every 1,000K.

1. Turn off the main switch, and remove the LCT rear

cover (5 screws).

2. Remove the two screws fixing the rear of the lowertransport guide.

3. Open the upper cover and remove two screws andone stud from the front of the lower transportguide. Then, remove the lower transport guide.

4. Remove the sensor (one screw) and replace it.


2.14.7 Replacing the back fence motor


2. Open the top cover and upper front cover, andremove the sensor cover (2 screws).

3. Remove the motor pulley (one Allen screw).

4. Remove the back fence motor (2 screws and oneconnector).


2.14.8 Replacing the LCT control board

1. Turn off the main switch, and remove the lower

front cover (2 screws).

2. Remove the two screws fixing the board bracketand slide out the bracket.

3. Remove the LCT control board from the bracketand replace it.


Lower transport guide

Transport sensorTransport roller

Stud

Sensor cover

Back fence

Drive beltMotorconnector Back fence

motor

Motorpulley

LCT control board

Lower frontcover

LCT 1 July 1994

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2.14.9 Replacing the paper feed magnetic clutch


2. Remove the LCT rear cover (5 screws).

3. Remove the E-ring and bearing from the clutchshaft.

4. Remove the clutch fixing bracket (3 screws).

5. Unhook the tension spring from the tension pulley.

6. Push the clutch shaft toward the front of the LCT totake the inside bearing off the side plate. Now, youcan take the timing belt off the clutch pulley.

7. Slide out the magnetic clutch (one Allen screw andconnector) and replace it.


CAUTION

The screw on the clutch bracket works as aturning stopper for the clutch. Be sure that thescrew catches the clutch after installing thebracket.

2.14.10 Replacing the transport motor


2. Remove the LCT rear cover (5 screws).

3. Unhook the two tension springs from the tensionpulleys.

4. Remove the motor pulley (one Allen screw).

5. Remove the three screws fixing the motor and thecollars.

6. Open the upper cover and remove the lowertransport guide (one stud and 2 screws on thefront and 2 screws on the rear).

7. Remove the transport motor with its bracket fromthe top (a connector).

8. Remove the motor from the bracket (2 screws) andreplace it.


CAUTION

• A D-type stepped collar is used to fix theright lower part as viewed from the back ofthe machine when the transport motor isinstalled. Do not confuse this collar with thetwo other collars.

• Install the transport motor with the motorlead wire on the top.

• Align the motor pulley end face with theend of the motor shaft when installing thepulley.

Tension pulley

Paper feedmagnetic clutch

Clutch fixingbracket

Clutchconnector

Inside bearing

Turningstopper

Tension spring

Transport motorTensionspring

Tension pulley

Motor connector

Tension spring

Motor fixingscrew (3)

Motor pulley

Tension pulley

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2.14.11 Adjusting the side-to-side registration

CAUTION

Follow this procedure when the LCT is removedand installed. The side-to-side registration willbe changed in that case.

Standard value: 0.2 mm in the platencover mode.

1. Make a copy and measure the difference in theside-to-side registration between the copy andoriginal.

2. Pull out the tray.

3. To change the tray position, turn the slot headscrew of the tray stopper and fix it with the lock nut.

4. Make more than 10 continuous copies using thepaper in the LCT, and be sure that all copies arewithin the standard. If not, repeat the above steps.

Lock nut

LCT 1 July 1994

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2.15 Finisher

2.15.1 Removing the exterior covers

1. Turn the main switch off. Then, unplug the copier.

2. Open the front doors [H] [I] and remove the uppercover [A] (2 screws).

3. Remove the upper door bracket [J] (2 screws) andremove the finisher front door [H].

4. Remove the grounding wire (1 screw) and removethe inverter front door [I].

5. Remove the front shift cover [G] (2 screws).

6. Remove the finisher rear cover [B] (3 screws).

7. Remove the inverter rear cover [K] (4 screws).

8. Remove the right upper cover [D] (2 screws).

9. Remove the shift tray [C] (4 screws).

10. Remove the front and rear tray cover [E] (1 screweach).

11. Remove the right cover [F] (2 screws).

2.15.2 Removing the shift tray unit

1. Turn the main switch off and unplug the copier.

2. Remove the front door, upper cover, front shiftcover, rear cover, right upper cover, and the rightcover.

3. Remove the shift tray lift motor assembly [A] (4screws).

4. Remove the harness holder plate [B] (3 screws).

5. Remove the screw [C] spring [D], bushing [E] andpulley [F].

6. Disconnect the 7 connectors [G].

7. Remove the 6 screws [H].

8. Lift the shift tray unit [I] off from the hooks [J] andremove.

[E]

[A]

[B]

[C]

[D]

[F][G][H][I]

[K]

[J]

[A]

[B]

[G] [J] [F] [E] [D] [C]

[H]

[G][I] [H]

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2.15.3 Removing the staple unit


2. Open the front door.

3. Slide out the staple unit [A].

4. Remove the four screws [B] fixing the unit to theslide rails [C].

5. Lift the staple unit off from the slide rails.

2.15.4 Replacing the Alignment Brush Rollers

PM cycle: Replace every 2,000K


2. Remove the rear cover.

3. Mark the position of the tension bracket [A] andloosen the screw [B].

4. Remove the 2 E-rings [C], slide out the pulley [D]and bushing [E], and remove the alignment brushroller assembly [F].

5. Remove the screws [G], E-rings [H], pins [I], andremove the brush rollers [J].

NOTE:

• When reassembling, put the bracket [A] backto the marked position.

• Do not lose the pins [I].

[C]

[B][A]

[B]

[A]

[A][E]

[C]

[D]

[F]

[C]

[H]

[J]

[G][I]

Finisher 1 July 1994

2-122

2.15.5 Removing the jogger drive belt


2. Open the front door and slide out the staple unit [A].

3. Remove the front and rear jogger fences [B] (2screws each).

4. Remove the 2 screws [C] fixing the jogger fencesliders [D] to the belt clampers [E].

5. Mark the position of the tension bracket [F] andremove (1 screw).

6. Remove the jogger drive belt [G] with the beltclampers [E].

NOTE:

When reassembling, put the bracket [F] back to themarked position.

2.15.6 Removing the exit rollers


2. Remove the upper cover, front door, front shiftcover, rear cover, and right upper cover.

3. Remove the screw [A], spring [B], bushing [C], andpulley [D].

4. Remove the 4 screws [E] fixing the lower exitguide plate [F].

5. Remove the 2 E-rings [G] and remove the exitroller assembly [H].

6. Remove the E-rings [I], pins [J] and replace theexit rollers [K].

NOTE:

Do not lose the pins [J].

2.15.7 Removing the shift tray positioning roller

1. Raise the stack height sensor actuator [A] andhold it until the shift tray automatically lowers.

2. Turn off the main switch before the shift trayreturns to its home position. Then, unplug thecopier.

NOTE:

If the machine is in a condition that does not allowthe shift tray to be lowered electrically, then removethe shift tray [B].

3. Remove the 2 E-rings [C] and replace the shift traypositioning roller [D].

[G]

[E]

[D]

[A][B]

[C] [F]

[E]

[F]

[G]

[H]

[D]

[I]

[C]

[J]

[G]

[K]

[B] [A]

[E]

[C]

[A]

[D]

[B]


2-123

2.15.8 Removing the sensors

Stack height sensors


2. Remove the upper cover.

3. Remove the stack height sensor actuator [A] (1screw).

4. Remove the bracket [B] (1 screw).

5. Replace the stack height sensor 1 [C] and thestack height sensor 2 [D].

NOTE:

When reinstalling the bracket [B], align the edge of the bracketwith the stay [E].

Exit unit home position sensor/exit unit half turnsensor


2. Remove the upper cover.

3. Remove the exit unit lift motor [F] (2 screws).

4. Replace the exit unit half turn sensor [G].

5. Remove the bracket [H] (1 screw) and replace theexit unit home position sensor [I].

Jogger unit entrance sensor


2. Remove the jogger entrance guide [A] (1 screw).

3. Remove the sensor bracket [B] (2 screws).

4. Replace the jogger unit entrance sensor [C] (1screw).

[E]

[F]

[C]

[B]

[D]

[A]

[G]

[H]

[I]

[B]

[C]

[A]


2-124

Shift tray half turn sensor


2. Remove the rear cover.

3. Remove the shift motor bracket [A] (3 screws).

4. Remove the sensor bracket [B] (1 screw) andreplace the shift tray half turn sensor [C].

Jogger unit paper sensor


2. Open the front cover and slide out the staple unit[D].

3. Remove the 2 screws [E] fixing the bracket [F].

4. Slightly pull out the bracket in the direction shownand remove the jogger unit paper sensor [G] (1screw).

2.15.9 Adjusting the finisher junction gate solenoid paotion


2. Remove the finisher rear cover (3 screws).

3. Open the finisher front door and check the gapbetween the paper guide plate and junction gatepawl end. Be sure that the gap is as shown in theabove illustration when the solenoid is pressedand pulled manually.

4. If the gap is not correct, adjust the position of thesolenoid [A].

[A]

[B][C]

[F]

[E]

[G]

[D]

[A]

7 mm ormore

4 mm or more


2-125

2.15.10 Replacing the inverter guide brush roller

PM cycle: Replace every 2,000K


2. Disconnect the finisher from the copier.

3. Open the inverter front door then remove the ballbearing [A] (one E-ring).

4. Slightly push the brush roller [B] to the rear torelease the ball bearing on the rear from the rearframe.

NOTE:

Do not push the brush roller too much. The rear ofthe brush roller is engaged with a timing belt.

5. Bring the front end of the brush roller to the left andpull out the brush roller from the shaft (one E-ringand bushing). Replace the brush roller if necessary.

NOTE:

When reinstalling the brush roller, its rear end mustbe engaged with a pin as shown.

2.15.11 Remoiving the inverter stopper plate drive belts


2. Disconnect the finisher from the copier.

3. Remove the front and rear belt clamps [B] (onescrew each).

4. Loosen the Allen screws of the four belt pulleys [A]then slide them inside.

5. Remove the upper and lower stopper drive shaftsand remove the drive belts.

NOTE:

• When reinstalling the front and rear beltclamps, make sure that the stopper plate [C] ispositioned properly. When the stopper plate ismanually moved to the bottom end, both thefront and rear belt clamps must just touch thebottom ends as shown in the lower illustration.

• Be sure that thrust play of the upper and lowerstopper drive shafts is between 0.05 and 0.5mm after reinstalling the belt pulleys.

[A]

[B]

[A]

[B]

[C]


2-126

2.15.12 Adjusting the inverter junction gate solenoid position


2. Remove the inverter rear cover (4 screws).

3. Open the inverter front door then check the gapbetween the junction gate pawl end and paperguide plate. Be sure that the gap is as shown inthe above illustration when the solenoid plunger ispressed and released manually.

4. If the gap is not correct, remove the invertercontrol PCB and adjust the solenoid position.

2.15.13 Removing the stapler and clearing a staple jam


2. Open the finisher front door and slide out thestaple unit.

3. Move the stapler [B] toward the rear manually asshown until the stapler is released from the shaft[A].

CAUTION:

Do not slide the stapler by holding other partsthan those shown. The stapler support platesmight easily be deformed.

4. While holding the stapler release lever (light bluelever), gradually turn the stapler [D] until it stops.

5. Disconnect the connector [C] and pull out thestapler.

Lessthan 1mm

Lessthan 2.5mm

[A]

[B]

[C]

[D]


2-127

6. If there are any jammed staples, push the levers[A] to remove the jammed staples.

7. If the jammed staples cannot be removed, spreadapart the side plates [B] and slide up the frontpressure guide plate [C]. Then, remove thejammed staples.

8. Remove the staple cartridge, then check for anystaples jammed in the stapling mechanism fromthe rear.

[A]

[B]

[C]


2-128

2.15.14 Adjusting the belt tensions

NOTE:

All procedures should be performed with the copier power cordunplugged from the wall outlet.

1. Remove the rear cover and adjust the belt [A]tension with tightener [a].Remove the upper cover, the front door, and thefront shift cover. Adjust the belt [B] with thetightener [b].

Standard: 6 mm deflection at 50 ± 20 g pressure.

2. Remove the upper cover and the rear cover.Loosen the two screws [c] and adjust the belt [C]tension by changing the motor position.


[A, B]

[a, b]

[D]

[E]

[F]

[B]

[A]

[C]

[H]

[C]

[c]

[G]


2-129

3. Remove the rear cover and adjust the belt [D] [E][F] tension with the tightener [d] [e] [f].

<Standard>[D]: 6 mm deflection at 60 ± 20 g pressure[E]: 6 mm deflection at 170 ± 30 g pressure[F]: 6 mm deflection at 100 ± 30 g pressure

4. Open the front door and slide out the jogger unit.Adjust the belt [G] tension with the tightener [g].

Standard:10 mm deflection at 65 ± 20 g pressure

5. Remove the rear cover. Loosen the 2 screws [h]and [i]. Retighten the screw [h] and then retighten[i]. The belt [H] tension is automatically adjusted bythe spring tension.

[g]

[G]

[D]

[d]

[f]

[F][e]

[E]

[i] [h]

[H]


2-130

6. Remove the inverter rear cover and adjust the belt[J] tension with the tightener [j].


NOTE:

Do not move tighteners other than tightener [j].

7. Remove the inverter rear cover. Loosen the 2screws fixing the motor [k], then retighten thescrews. The belt [K] tension is automaticallyadjusted by the spring tension.

[J]

[K]

[J]

[j]

[k]

[K]


2-131

2.15.15 Lubrication points

At an EM call or when the parts lack lubrication, lubricatethe following parts using a suitable lubricant.

Shift tray positioning roller arm

Lubricant: Launa-40 oil or equivalent

Jogger/staple unit shafts

Lubricant: launa-40 oil or equvalent

Shift tray drive gears

Lubricant: Grease G-501


2-132

SECTION 3

ELECTRICAL COMPONENTINFORMATION

3. ELECTRICAL COMPONENT INFORMATION

3.1 DC Power Destinations

[U.S.A. version]

[European version]

1 July 1994 DC Power Destinations

3-1

In the DC power supply unit, each DC power supply isgenerated from wall outlet and is supplied to each load.

Output Voltage (V) Main Uses

(A) +5 Power supply for each PCB IC and operation unit PCB.(B) +5 Power supply for each sensor and eraser LEDs.(C) +12 Power supply for each sensor and operational amplifier.(D) +12 For operational amplifier.(E) +24 Power supply for each dc motor (except OPC cleaning, toner

supply, and agitator motors), solenoid, relay and each powerpack control line.

(F) +24 Power supply for paper feed, registration, OPC cleaning, tonersupply, and agitator motors.

(K) +40 Main motor.(H) +24 Power source for each power pack.

Note: GND is common (A) to (K). GND of output (H) is GND (P).

NOTE

Protection from output shorting

• When output (A) shorts, all outputs stop,except output (H).

When one output from (B) to (K) shorts, output from (B)to (K) stop, and only (A) continues.

DC Power Destinations 1 July 1994

3-2

3.2 Fuse Table

Location Specification Connection Part number Notes

DC power supply unit 6.3A/250V CN1-3 11070673 (EU)11070753 (NA)

AC power source IN

DC power supply unit 4A/250V CN2-2 ---- (EU)11070751 (NA)

DC 5V OUT (Each photo-sensor and eraserdrive)

DC power supply unit 6.3A/250V CN3-3 11070673 (EU)11070753 (NA)

AC power source IN

Flash power supply unit 6.3A/250V (EU)6A/250V (NA)

CN1-3 11070281 (EU) ---- (NA)

AC power source IN

ADF DC power supply unit 6.3A/250V CN1-3 11070673 (EU) ---- (NA)

AC 100V IN

Paper feed DC power supply unit 4A/250V CN1-3 ---- AC 100V INDevelopment DC power supply unit 4A/250V CN1-3 ---- AC 100V INDC motor drive board (FU401) 3.15A/250V (EU)

3.15A/125V (NA)CN406-2 11070355 (EU)

11070354 (NA)Agitator motor drive

DC motor drive board (FU403) 3.15A/250V (EU)3.15A/125V (NA)

CN406-1 11070355 (EU)11070354 (NA)

Toner supply motor drive

DC motor drive board (FU404) 3.15A/250V (EU)3.15A/125V (NA)

CN406-3 11070355 (EU)11070354 (NA)

OPC cleaning motor drive

DC motor drive board (FU402) 1A/250V (EU)1A/125V (NA)

CN406-4 11070452 (EU)11070386 (NA)

OPC cleaning pressuresolenoid drive

Main/OPC motor drive board 8A/125V CN3-3 11070393 Main motor driveMain/OPC motor drive board 1.6A/250V (EU)

2A/125V (NA)CN4-2 ---- (EU)

11070388 (NA)OPC motor drive

Duplex blower drive board 3.15A/250V (EU)4A/125V (NA)

CN1-6 11070355 (EU)11070390 (NA)

Duplex blower drive

Varistor board 3.15A/250V (EU)3A/250V (NA)

---- 11070672 (EU)11070596 (NA)

AC power source IN

ADF control board 5A/250V (EU)5A/125V (NA)

CN104-3 11070752 (EU)11070391 (NA)

DC 24V IN

Blower control board 3.15A/250V (EU)4A/125V (NA)

CN1-6 11070355 (EU)11070390 (NA)

ADF blower drive

LCT control board (FU400) 6.3A/250V CN402-1 11070753 AC 37V INLCT control board (FU401) 2A/250V CN409-1 11070748 Magnetic clutch driveFinisher control PCB 5A/250V CN101-1 11070752 DC 24V INTransport drive motor control PCB 3.15A/250V ---- 11070355 Finisher transport motor driveInverter control PCB 5A/250V CN175-3

(Not used)11070752 Not used

Finisher DC power supply PCB 5A/250V CN1-1 11070752 AC 100V IN

Note:

EU -- European version machine, NA -- U.S.A. version machine

1 July 1994 Fuse Table

3-3

3.3 Main Control Board

NOTE

Never adjust VR101. The setting is paint locked at 4 ± 0.05Vbetween TP115 and TP116.

3.3.1 DIP switch table

Dipswitch No. Function at ON Function at OFF Default Setting

DPS101-1 Allows the use of the service tool accesscode which is entered with service tool[1-02].

Disables the service tool access code whichis entered with service tool [1-02].

OFF

DPS101-2 1) Allows the use of the initial service toolaccess code: 99900.2) Allows the operation of the copier withoutentering any user codes, even in the normaland security accounting modes.

1) Disables the initial service tool accesscode: 99900.2) Allows the selection of the normal andsecurity accounting modes with service tool[2-08].

OFF

DPS101-3 Not used. Not used. OFFDPS102-1 Overseas version (destination identification). Japanese version. ONDPS102-2 Not used. Not used. OFFDPS102-3 Not used. Not used. OFFDPS103-1 Production use only. (Must be ON.) Production use only. (Must be ON.) ONDPS103-2 Production use only. (Must be OFF) Production use only. (Must be OFF) OFFDPS103-3 Not used. Not used. OFF

Main Control Board 1 July 1994

3-4

3.3.2 Test point table

No. Description

101 RXD Finisher receiving data102 TXD Finisher transmission data103 RXD Paper feed control receiving data104 RXD ADF receiving data105 TXD Paper feed control transmission data106 TXD ADF transmission data107 GND108 +5V Power line109 --12V "110 +24V "111 +12V "112 RMAIN Main motor standard clock pulse113 ROPC OPC motor standard clock pulse114 ENC OPC motor encoder input115 4V AD converter standard voltage116 AGND AD converter standard GND117 GND118 TXD Operation unit transmission data119 RXD Operation unit receiving data

3.3.3 Table of connector destinations

No. CPU Destination

101 M Printer connector102 M Sensors, switches and detection signals input103 M Solenoids, motors, relays, and other loads output104 S Main and OPC motors standard clock and encoder pulses input105 S Analog data input106 S Sensors, power pack leak detecting signals, and other input107 S Power packs, flash, and other loads outputs108 M Optical fiber: Finisher109 M Optical fiber: Paper feed control board110 M Optical fiber: ADF112 -- DC power input113 Not used

⇑ M is controlled by the main CPU and S by the sequence CPU.

1 July 1994 Main Control Board

3-5

3.4 Paper Feed Control Board

NOTE

LED and DGS are for system checks.


No. Description

301 Clock pulse for shield screen motor reverse rotation302 Clock pulse for shield screen motor forward rotation303 Clock pulse for jogger motor304 Clock pulse for mirror/lens motor305 Clock pulse for back fence motor306 Clock pulse for duplex paper feed motor307 Clock pulse for LCT motor308 Not used309 Clock pulse for 1st paper feed motor310 Clock pulse for 2nd tray motor311 Clock pulse for 2nd paper feed motor312 Clock pulse for 3rd tray motor313 Clock pulse for 3rd paper feed motor314 --315 Clock pulse for registration motor316 +12V317 +5V318 GND319 TXD320 RXD

Paper Feed Control Board 1 July 1994

3-6

3.5 Duplex Blower Drive Board

3.5.1 VR table

VR No. Description

VR1 Adjusts the blower low speed (4,500 rpm).VR2 Adjusts the blower medium speed (6,000 rpm).VR3 Adjusts the blower high speed (7,000 rpm).

CAUTION

Adjusting these VR’s is usually prohibited.

3.6 ADF Control Board

3.6.1 LED table

LED No. Sensor Name

100 1st reverse sensor101 Original set sensor102 2nd transport sensor103 Entrance sensor104 ADF exit sensor105 1st transport sensor106 SADF exit sensor107 Registration sensor108 2nd reverse sensor109 Recycle arm sensor110 SADF set sensor111 Stays ON112 Stays ON113 Stays ON114 Recycle arm height sensor

3.6.2 VR table

VR No. Description

100 Adjusts the transport motor speed.101 Adjusts the reverse motor speed.102 Adjusts the original feed motor speed.103 Not used.104 Adjusts the original leading edge registration.

3.6.3 Push switch table

No. Description

SW100 Stops the original transport test.SW101 Starts the original transport test.

1 July 1994 Duplex Blower Drive Board

3-7

3.6.4 DIP switches

NOTE

The original setting for all DIP switches is OFF.

Turning on the original feed motor

Turning on the transport motor

Turning on the reverse motor

Turning on the ADF blower motor

Single-side original mode test

2-sided original to single-side copies mode test

ADF Control Board 1 July 1994

3-8

2-sided original to 2-sided copy mode test

Disabling the original return motion in the ADF mode

3.7 ADF Blower Control Board

3.7.1 VR table

VR No. Description

VR1 Adjusts the blower low speed (4,500 rpm).VR2 Not used.VR3 Adjusts the blower high speed (7,000 rpm).

CAUTION

Adjusting these VR’s is usually prohibited.

1 July 1994 ADF Blower Control Board

3-9

3.8 Finisher Electrical Components


Number Function Location

TP1 24 V Finisher Control PCB

TP2 GND Finisher Control PCB

TP3 5 V Finisher Control PCB

TP100 GND Inverter Control PCB

TP101 5 V Inverter Control PCB

TP102 24 V Inverter Control PCB

TP103 Not used Inverter Control PCB

3.8.2 LED table

LED No. ON Status

Finisher Control PCBLED 1 Stack feed-out belt H.P. sensor is not actuated.LED 2 Jogger unit connector is not completely set.LED 3 Stapler H.P. sensor is actuated.LED 4 Jogger H.P. sensor is actuated.LED 5 Jogger unit paper sensor is activated.LED 6 Jogger unit entrance sensor detects paper.LED 7 Shift tray lower limit sensor is actuated.LED 8 Stack height sensor 2 is actuated.LED 9 Exit unit H.P. sensor is actuated.LED 10 Exit unit half turn sensor is not actuated.LED 11 Stack height sensor 1 is actuated.LED 12 Shift tray half turn sensor is actuated.LED 13 Exit sensor detects paper.LED 14 Finisher entrance sensor is activated.LED 15 Hammer H.P. sensor detects the hammer.LED 16 Staple end sensor is activated.LED 17 OFF: Motor speed is too low. NoteLED 18 OFF: Motor speed is too high. Note

NOTE: In the motor test mode, the finisher transport motor, stack feed motor, and exit drive motorspeeds are adjusted automatically in order. While each motor is adjusted, if the motor speed isnormal, LED17 and LED18 light. If the motor speed is too high, only LED17 lights. If the motor speedis too low, only LED18 lights.Transport Drive Motor Control PCB

LED 1 Finisher transport motor speed is normal.Inverter Control PCB

LED 100 Not used.LED 101 Not used.

NOTE: VR100 and VR101 are not used either.

Finisher Electrical Components 1 July 1994

3-10

3.8.3 Finisher control PCB DIP switch table

Factory setting

DIP101 DIP102

0 0 0 0 0 0 0 0

0: OFF

Motor test mode

DIP101 DIP102 Motor

1 2 3 4 1 2 3 4

1 0 0 0 1 1 0 1 Finisher Transport Motor

0 1 0 0 1 1 0 1 Exit Drive Motor

0 0 1 0 1 1 0 1 Stack Feed-out Motor

0 0 0 1 1 1 0 1 Shift Tray Lift Motor

0: OFF 1: ON

After setting the DIP SW102, turn on one of the DIPSW101 switches to start the appropriate motor, turn it offto stop the motor.

Free run test mode

DIP102 Function

1 2 3 4

1 1 0 0 Motor Free Run

1 1 1 0 Staple Free Run

1 1 1 1 Shift Free Run

0: OFF 1: ON

Free run test mode starts when SW100 on the mainboard is pressed, and stops when SW101 is pressed.

Operation

1. Motor Free RunThe motors of the finisher are energized in thefollowing order:Finisher transport motor → Exit motor → Stackfeed out motor → Shift motor → Shift tray lift motor→ Exit unit lift motor

The PCB checks the speed of the transport drive,exit and stack feed motors, and mechanical lock ofthe other motors.

2. Staple Free RunThe finisher works as if 5 sets of 5 11" x 81/2" sizepaper are being stapled and delivered. Themachine is then initialized and repeats the sameoperation.

3. Shift Free RunThe finisher works as if 10 sets of 5 LT papers arebeing sorted. The shift tray is lowered for each ofthe 10 sets and then returns to its home position torepeat the same operation.

1 July 1994 Finisher Electrical Components

3-11

Shift tray rise mode

DIP101 DIP102

1 2 3 4 1 2 3 4

1 0 0 0 0 0 0 0

In this mode, the shift tray moves to its uppermostposition if the copy paper stacked on the tray is removedwhile copying.

NTOE:

When the stapling copy mode is used with the shifttray rise mode, the shift tray moves up and downslightly for each stapled copy set delivered to thetray.

3.8.4 Inverter control PCB DIP switch table

Factory setting

DIP100 DIP101

1 2 3 4 1 2 3 4

0 0 0 0 0 0 0 0

0: OFF

Free run test mode

DIP100 DIP101

1 2 3 4 1 2 3 4

0 0 0 0 0 1 0 0

0: OFF 1: ON

Free run test mode starts when the finisher and inverterfront doors are closed, and stops when one of them isopened.

Finisher Electrical Components 1 July 1994

3-12

4. TABLE OF PM ITEMS

C: Cleaning R: Replacement L: Lubrication, greasing A: Check and adjust Cycle

ItemEvery visit As

necessary200K 400K 600K 800K 1M 1.2M 1.4M 1.6M 1.8M 2M 2.2M 2.4M 2.6M 2.8M 3M Remarks

OpticsExposure glass C R C C C C C C C C C C C C C C C Clean with glass

cleaner, then wipewith silicon oil.Check the resistance.

1st mirror C C C C C C C C C C C C C C C Silicon cloth

2nd mirror C Silicon cloth

Reflectors C C C C C C C C C C C C C C C Silicon cloth

Xenon lamp R R RLens motor drivegear

L L Mobil Temp. 78

Lens motor timingbelt

A A

Rear cooling, flashblower, exposurecooling, and flashpower cooling fanfilters inside theleft cover and flashpower insideblower filter on therear left cover

C C C C C C C C C C C C C C C Remove dust

Lens C C C C C C C C C C C C C C C Blower brush

OPCOPC belt R R R R R R R R R R R R R R ROPC cleaner pad C C C C C C C C Alcohol

OPC drive roller C C C C C C C Wipe with dry cloth(ether and toluene notallowed)

OPC sensor C C C C C C C Blower brush

Quenching lampcover

C C C C C C C Wipe with dry cloth

OPC motor timingbelt

R A A A

Front and rearground brushes


Front and rearsliders

L L L G-40M

4-1

Technical Support

RTB 19 Extra notes about cleaning the exposure glass and other components

Technical Support

RTB 36 One-off PM action required on cleaning cooling pump to prevent cushions from melting


ItemEvery visit As


OPC Cleaning UnitBrush roller R,L R,L R,L R,L R,L G-40M on the

oscillating gearCasing C C C C C Wipe with dry cloth

Around OPCGrid wires C C C C C C C C C C C C C C C Water

Corona wires C R C R C R C R C R C R C R C Wipe with dry cloth

Corona unit casingand end blocks

C C C C C C C C C C C C C C C Water

Charge and gridwire cleaners

C R C R C R C R C R C R C R C Wipe with dry cloth

Potential sensor C C C C C C C C C C C C C C C Blower brush

Eraser C C C C C C C C C C C C C C C Water

Eraser blower andinner cover coolingfan filters

C C C C C C C Remove dust

Transfer and SeparationCorona wires C R C R C R C R C R C R C R C Wipe with dry cloth

Corona unit casingand end blocks


Corona unitreceptacle and itssprings

R R

Separation guideson corona unit

C C C C C Wipe with dry cloth

Fusing entranceguide (Main body side)

C C C C C C C C C C C C C C C Wipe with dry cloth

Separation sensor C C C C C C C C C C C C C C C C Blower brush

Transfer entrancemylar

R R R

Transport belts C C C C C Water

Transport beltdrive roller

C C C C C Water

4-2


ItemEvery visit As


DevelopmentDeveloper R R R R R R REntrance seal C C C C C C C C C C C C C C C C Blower brush

ID sensor C C C C C C C C C C C C C C C C Blower brush

Side seals C R C C C C C C C C C C C C C C C Blower brush

Sleeve gears andidler gear

C C C R C C C Wipe with dry cloth

Timing belt pulleys C C C C C C C Wipe with dry cloth

Air filter R R R R R R R R R R R R R R RID sensor blowerfilter

C C Remove dust

Toner vessel C C C Wipe with dry cloth

CleaningScavenging roller R R R R RScavenging blade R R R R RCleaning seals C R C C C C C C C C C C C C C C C Blower brush

Inside cleaning unit C C C C C C C Wipe with dry cloth

PCC wire C R C R C R C R C R C R C R C Water

PPC casing andend blocks


Cleaning carrier R R R R R R RAir filters *C R *C C *C C *C l *C C *C C *C R *C

Replace from side to sideCleaning drive gear L L L G-40M

Paper FeedPick-up rollers R R R R R R RPaper feed rollers R R R R R R RReverse rollers R R R R R R R1st tray paper endsensor

C C C Blower brush

Paper dustcollecting vessel

C C

Tray drive gears L L L Mobil Temp. 78

4-3


ItemEvery visit As


DuplexDuplex vacuumbelts

C C C C C C C Water

Duplex feed roller R R R RReverse roller R R R RAnti-static brushes C C C C C C C C C C C C C C Alcohol

Duplex exit sensor C C C C C C C Blower brush

Lower duplex endsensor

C C C C C C C Blower brush

Lower duplexpaper feed sensor

C C C C C C C Blower brush

All transport rollers C C C Water

Vertical TransportVertical transportguide plate


Vertical transportdrive timing belt

A


4-4


ItemEvery visit As


FusingFusing roller C C R C R C R C R C R C R C R C Wipe with dry cloth

Heat insulatingbushings

R R R R R R R Barrierta

Fusing rollerbearings

R R R

Fusing rollerspacers

R R R

Pressure roller C C C C R C C C R C C C R C C CPressure rollerbearings

R R R

Fusing pick-offpawls

C R C C C C C C C C C C C C C C C Wipe with toluene

Metering blade R R R R R R R R R R R R R R RCleaning blade R R R R R R R R R R R R R R RSide blades C C C C C C C Alcohol

Oil supply pad R R R R R R R R R R R R R R RFusing thermistor C C C C C C C Wipe with alcohol

Oil pump tube R R RFusing drive jointgear

L L L L L L L Mobil Temp. 78

Fusing entranceguide plates

C C C C C C C C C C C C C C C Wipe with toluene

Each transportroller

C C C C C C C Alcohol

Drive gears L L L L L L L Mobil Temp. 78

Silicon oil A A A A A A A A A A A A A A AOil pan C C C C C C C Wipe with dry cloth

Oil path C C C C C C C C C C C C C C C C Wipe with dry cloth

Oil tube and oiltank

R

4-5

Technical Support

RTB 8 Maintenance notes for the oil tank and oil tube


ItemEvery visit As


Main BodyOzone filter R R RMain timing belt A AFilters for frontcooling andcleaning unitcooling fans, etc.

C C C C C

Process controlsetting A

A A A

ADFTransport belt C C C R C C R C C R C C R C C R Belt cleaner

Original set sensor C C C C C C C C C C C C C C C Blower brush

ADF exit sensor C C C C C C C C C C C C C C C Blower brush

Recycle armsensor

C C C C C C C C C C C C C C C Blower brush

Vacuum belts R C C C C C C C C C C C C C C C Alcohol

All transport rollers C C C C C C C C C C C C C C C Alcohol

Black mats forsensor

C C C C C C C C C C C C C C C Blower brush

Shutter solenoid ALCTPick-up roller R R R R R R RPaper feed roller R R R R R R RReverse roller R R R R R R RTray drive gear L L L Mobil Temp. 78

Paper end sensor C C C Blower brush

Transport sensor C C C C C Blower brush


4-6


ItemEvery visit As


FinisherAll transport rollers C Alcohol

Antistatic brushes C Dry cloth

Brush rollers R 2 large and 2 smallrollers

All bushings L Launa oil; if it makesnoise

All photo sensors C Blower brush

Inverter guidebrush roller

R

Inverter stoppers R Cushions and theirmylar sheets.

Stapler R Estimated life time is200,000 staples.

4-7

SECTION 5

PROCESS AND TONER DENSITYCONTROL SETTINGS

5. PROCESS AND TONER DENSITY CONTROL SETTINGS

5.1 Service Tools Display

5.1.1 Process control ON screen [4-01]

5.1.2 Process control OFF screen

"6" is automatically set. (This exposes theblack-and-white pattern on the OPC at 6th level ofthe image density.)

By pressing this key, the processcontrol is disabled. All the shiftsteps are cleared if it is turnedON again.

Shows the actual values of theOPC potential for each item. (VDis measured by the A sensor, andthe other items are measured bythe B sensor.) All target and actualvoltages are negative except forVPCC which is positive.

NOTE:VD, VL, and VPCC are controlledto meet their target values. Whenthere is some residual potential onthe OPC (VR) and there is somebias compensation (Bias shift), thevalue added to VR’s actual valueon VD or VL target value, isindicated as VD or VL actual value.

Shows the target valuesfor VD,VL, and VPCC.They can be changedby the value changekeys (). All targetand actual voltages arenegative except forVPCC which is positive.

NOTE:VPCC target valueshould always be set at130 volts. VD and VLtarget values aredifferent from onemachine to another.

Shows the number of stepsshifted to have VD, VL, andVPCC reach their targetvalues, and to compensate forVR. When a shift step isnegative, the window turns red.

NOTE:The maximum shift steps forone time compensation are 1for PCC and 3 for the otheritems.

Shows the outputlevels for each item.They can be changedon the processcontrol OFF screen.

NOTE:They are adjusted at[20] [9] [0] [2] at theproduction line. Thegrid output (--650volts) is adjusted bythe volume of thepower pack. Theflash output isadjusted on thisscreen. (Therefore,the flash setting is notalways "9".)

On this screen, the process control is disabled.The output levels for each item can be changed bythe value change keys ( ).

NOTE:When this screen is selected, the AID keydisappears from the operation display. This isbecause AID mode needs the potential sensor, tobe operative.

1 July 1994 Service Tools Display

5-1

Technical Support


5.1.3 Toner density control ON screen [4-02]

5.1.4 Toner density control OFF screen

Shows VSG measuredresults (usually 3.5 to 4.5).

By pressing this key, the ID sensorcontrol is disabled. The toner densitycontrol is done by the toner densitysensor only. The toner densitysensor target value can be changedon the OFF screen.

Shows the target IDsensor pattern makingpotential selected by theID pattern level selectorkey. (630, 560, 510, or480V is displayed.)

The actual IDsensor patternmaking potential isdisplayed. Theabove setting value±20 volts is usuallydisplayed.

Shows the toner densitylevel measured by thetoner density sensor whenthe developer forming keyis pressed. The value isnot changed unless thekey is pressed again.

Shows the targetvalue for the tonerdensity sensorcontrol. The value ischanged by 0.12volts when theVSG/VSP is too low(lower than 7) or toohigh (higher than 9).

NOTE:The value iscontrolled in a rangeof ± 0.74 volts fromthe "Setting TargetT.D." value.

Developer Forming key. Whenpressed, the toner densitysensor detects the toner densityof the developer and the result isindicated in the " Actual T.D.Sensor", "Setting Target T.D.",and "Actual Target T.D."

CAUTIONUnlike the Developer Formingkey in service tool 3-04, thedeveloper forming "ON" key inthis screen changes the data forthe "Target T.D." Use this keyonly when setting C is carriedout. For usual developerforming, use the key in servicetool 3-04.

Shows the toner densitylevel measured by thetoner density sensor. Thetoner density in thedevelopment unit iscontrolled to meet thisvalue with the actual targetvalue.

Shows VSPmeasuredvalue.

Shows thecalculatedratio of themeasuredVSG and VSP(VSG/VSP).

The setting target value can be changed bythe value change keys ( ) . The actualtarget value is also changed accordingly.

Service Tools Display 1 July 1994

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5.1.5 AID reference voltage screen [4-03]

When the Start key is pressed, the light reflected from the originalon the exposure glass exposes the OPC surface. The OPCpotential is measured and indicated in this window. This isrepeated 10 times and is stopped automatically.

NOTE:In normal copying, the AID reference voltage is used to determinethe development bias level in the auto image density mode tomeet the original background density.

Shows the number of steps forcompensated development biasdetermined by the above AIDreference voltage.

1 July 1994 Service Tools Display

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5.2 Setting ANOTE

Setting A is sometimes needed when the following replacementsand adjustments are made:

Replacing the exposure glass (black-and-white pattern on the back of the original scale), xenon lamp, potentialsensor, or adjusting the reflectors (or mirrors) for uneven illumination

CAUTION

1. The target VL and VD are adjusted at the factory. Even after doing any of theprocedures above, you do not usually have to perform setting A. Read the OPCpotentials for the black and white areas of the PC-1 chart with service tool [4-03]. Onlywhen they are very different from the preceding values as a result of the aboveprocedures, perform setting A. Do not change the target VL and VD values too much.

2. Every 1,000K copies use the PC-1 chart in the same way as the above.

3. Install all exterior covers when doing setting A. External light might affect the OPCpotential.

4. Do not continue free run (more than 100 copies) from the [4-01] screen. Tonerdensity in the cleaning unit will be reduced and the cleaning carrier’s power to attracttoner will lower. This may cause toner scattering from the cleaning unit. This problemoccurs also when:

1) Making more than 100 free run copies from the [4-01] or [4-02] screen.2) Turning on the main motor for more than 5 minutes using the I/O test mode in theservice tools.3) Making more than 100 white copies.

If dirty copy images appear due to toner scattering from the cleaning unit, perform thecleaning carrier forming with service tool [3-04].

The process control of this machine runs based on the VL and VD data set in the service tool [4-01]screen (Target VD and VL). However, the data varies from one machine to another. This is due tostains and/or variations in reflectivity of reflectors, exposure glass, mirrors, etc. (distortions of thelight path). For example, if the position of the light reflectors are changed, the ratio of light densityfrom the black pattern and from the white pattern varies. (If the OPC belt or flash power supply unitis replaced, the OPC potential made by the light reflected from the original or the light density thatexposes the OPC surface might change. However, as the light density ratio from the black patternand from the white pattern does not change, the target VL and VD do not have to be changed.) Tocompensate for variations between machines, setting A should be performed.

To do setting A, use the PC-1 chart. It has a uniform and steady density of black and white areas.On the service tool [4-03] screen, the potential of the OPC made by exposing an original on theexposure glass can be known. (This data is usually used to determine the development bias levelfor the auto image density mode.) When the PC-1 chart is placed on the exposure glass, theuniform and steady black and white areas of the chart should make the same potential on the OPCand the data on the [4-03] screen should be the same from one machine to another. Adjust the gridand flash setting on the [4-01] screen, so the white area of the PC-1 chart makes a potential of--125 volts on the OPC and the black one makes a potential of --710 volts. Under this setting of thegrid and flash output, the values of the actual VL and VD (measured values) on the [4-01] screenshow those of the target VL and VD.

Setting A 1 July 1994

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Technical Support


1. Grid step setting

Set the grid output on the [4-01] screen. The potential on the area of the OPC that was exposed tothe black area of the PC-1 chart should be --710±10 volts, after setting. This potential is displayedon the [4-03] screen.

1. Turn ON the main switch and wait for the copy stand-by condition.

2. Select a paper tray that has A3 or 11"x17" paper. If there is no tray with such paper, adjustthe side fences and back fence of one paper tray at the A3 size position.


4. Press the Process Control OFF key, then press the ON key to reset all shift steps to 0.

5. Select the [4-03] screen.

6. Set the PC-1 chart on the exposure glass so that the black area comes to the original scaleside.

7. Press the Start key. The machine automatically stops after 10 flashes.

8. Read the AID reference voltage during flashing. If the mean value is between --700 and --720 volts, proceed to the next step (flash step setting). If the [4-01] screen shows any VR,check the standard value so that:

Standard value: between --(700 + VR) and --(720 + VR) volts

NOTE

The target and actual voltage (except the target and actualVPCC’s) on the [4-01] and [4-03] screens are negative.

9. If the mean value is improper, select the [4-01] screen and change the grid setting step withthe value change keys () on the process control OFF screen. Changing one step willchange approximately 25 volts in the AID reference voltage.

10. Press the Process Control ON key on the screen and be sure that all shift steps are 0. Then,select the [4-03] screen again and repeat steps 6 to 9.

2. Flash step setting

Set the flash output on the [4-01] screen. The potential on the area of the OPC that was exposed tothe white area of the PC-1 chart should be -125 ± 10 volts, after setting. This potential is displayedon the [4-03] screen.




4. Set the PC-1 chart on the exposure glass, so that the white area comes to the original scaleside.

5. Press the Start key. The machine automatically stops after 10 flashes.

6. Read the AID reference voltage during flashing. If the mean value is between --115 and --135 volts, proceed to the next step (target VL and VD setting). If the [4-01] screen showsany VR, check the standard value so that:

Standard value: between --(115 + VR) and --(135 + VR) volts

NOTE

The target and actual voltages (except the target and actualVPCC’s) on the [4-01] and [4-03] screens are negative.

1 July 1994 Setting A

5-5

7. If the mean value is improper, select the [4-01] screen and change the flash setting step withthe value change keys () on the process control OFF screen. Changing one step willchange approximately 25 volts in the AID reference voltage.

8. Press the Process Control ON key on the screen and be sure that all shift steps are 0. Then,select the [4-03] screen again and repeat steps 4 to 7.

NOTE

• When the correct flash setting step is obtained, set the value of the actual VL (measured value) asthe target VL. During the flashing on the [4-03] screen, the actual VL shows the value that shouldbe the target for the VL if the flash output is proper. This makes it easier to obtain the target VL andVD values. (You cannot know the target VD by doing the flashing 10 times on the [4-03] screen. Thisis because the VD is measured and corrected after flashing 20 times.)

• As VD and VL are related, the measured AID reference voltage for the black (or white) area of thePC-1 chart may change when the flash (or grid) step setting is changed. Therefore, make thefollowing checks and reset the value if the proper flash and grid setting steps have deviated.

1) Repeat steps 3 to 9 of the grid step setting.

2) Repeat steps 1 to 7 of the flash step setting.

3) Set the value of the actual VL (measured value) as the target VL when the correct flash settingstep is obtained.

3. Target VL and VD setting

The correct flash and grid setting steps have been set in the preceding procedures. In thisprocedure, read with the [4-01] screen what voltages of the OPC potentials are produced for theblack and white patterns on the back of the original scale, and set them as the target VL and VD.

After setting the targets, the machine will modify the flash and grid outputs so that the actual VL andVD match the target VL and VD.

1. Place a sheet of A3 (or larger) white paper on the exposure glass, near the original scale.(This is to prevent change of reflectivity from the white-and-black pattern by a change oforiginal density near the pattern.)



4. Press the Start key, and press the Clear/Stop key immediately after the 18th flash. The ma-chine stops after 20 flashes. (This is because the flash output compensation is applied justafter flashing 10 times and the grid output compensation is applied just after 20 times.)

5. Read the actual VL (measured value).

6. Set the actual VL value as the target VL using the value change keys () (10 volts perstep). If the actual VL is outside of the target VL adjustable range, set the closest value, andrepeat steps 3 to 8 once again after doing step 8.

7. Read the actual VD (measured value).

8. Set the actual VD value as the target VD using the value change keys () (10 volts perstep). If the actual VD is outside of the target VD adjustable range, set the closest value andrepeat steps 3 to 8 once again.

Setting A 1 July 1994

5-6

9. As the target VL and VD have been obtained, make sure that the flash and grid setting stepsare stabilized. If necessary, make fine adjustment so that no compensation is applied to theflash and grid setting steps (no change of the flash and grid shift steps) as follows:

1) Select the [4-01] screen. (Be sure that all shift steps are 0.)

2) Press the Start key, and press the Clear/Stop key immediately after the 38th flash. Themachine stops after 40 flashes.

3) Read the flash and grid shift steps. If they are not 0 ± 2, add the value to the flash or gridsetting steps. Then, repeat the above step.

NOTE

• When you replace the OPC belt with a new one and the residual potential on the OPC is cleared,reset the bias shift step to 0 as follows. This will let you know how many steps have been shifted upor down at the next check of the data since the OPC belt replacement. 1) Select the [4-01] screen and read the bias shift step (compensated value). When the value is 0,the check is completed. 2) Add (or reduce) the shifted-up (or down) value to (or from) the bias setting step using the valuechange keys () on the process control OFF screen.

• In the [4-01] screen, VR is measured and the bias shift step is changed when the Clear/Stop key ispressed during free run.

• The PC-1 chart is used for setting A. For the measurement of the black area of the chart, align thecenter of face A (see figure) with the center of the original scale. For the white area, use face B.

1 July 1994 Setting A

5-7

5.3 Setting BNOTE

Setting B is sometimes needed when the following parts arereplaced:

The OPC belt, charge corona wires, charge/grid power pack, or flash power supply unit

CAUTION

1. Usually, you do not have to do setting B even after replacing the above items. Theflash, grid, and bias output levels are automatically adjusted by the process control.However, if the flash, grid, or bias shift step are significantly changed since the partsreplacement, you cannot know how many steps have been shifted up or down at thenext check of the data. Therefore, perform setting B only when the shift steps aresignificantly changed after replacing the above items.

2. Before setting B, clean the charge corona unit and light path (the mirrors, lens,reflectors, and exposure glass).

3. Install all exterior covers when doing setting B. External light may affect the OPCpotential.

4. Do not continue free run (more than 100 copies) from the [4-01] screen. Tonerdensity in the cleaning unit will be reduced and the cleaning carrier’s power to attracttoner will lower. This may cause toner scattering from the cleaning unit. This problemoccurs also when:

1) Making more than 100 free run copies from the [4-01] or [4-02] screen.2) Turning on the main motor for more than 5 minutes using the I/O test mode in theservice tools.3) Making more than 100 white copies.

If dirty copy images appear due to toner scattering from the cleaning unit, try to dothe cleaning carrier forming.

5. After setting A, setting B does not have to be done.

6. When the OPC belt is replaced, V SG might lock. So, access service tool [4-02] andmake a free run to check V SG operation. If it is locked, perform setting C (release theVSG lock).

The flash, grid, and bias output levels are changed by the VL, VD, and VR compensations (theprocess control) when OPC belt fatigue, or change of the operating environment (temperature andhumidity) occurs, or the light path (the mirrors, lens, etc.) or charge corona unit becomes dirty. Aftercleaning the charge corona unit and light path, if any shift steps (compensated values) remain, theyrepresent the level of the wear of the OPC belt, charge corona wires, xenon lamp, etc.

Checking the shift steps in the [4-01] screen is useful to know the level of wear of such parts and tofind out machine condition. However, when the parts described above are replaced, the output levelfor the flash, grid, or bias might change. When the process control compensates the output levelsautomatically, the shift steps are shifted up or down. The purpose of setting B is to reset the shiftsteps to 0 and to enable the check of the shift steps in the [4-01] screen.

For example, consider the grid output when the OPC belt is replaced. After the OPC belt isreplaced, process control changes the grid output to obtain the target VD value as the OPCpotential for the black pattern. As a result, the grid output is normally reduced. As the grid shift stepincreases negatively, performing settting B reduces the grid setting step and reset the grid shift stepto 0. You can know how many steps have been shifted up or down at the next check of the dataafter replacing the OPC belt.

Setting B 1 July 1994

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Technical Support


Flash and grid steps setting


2. Select a paper tray that has A3 or 11"x17" paper. If there is no tray with such paper, adjustthe side fences and back fence of one paper tray at the A3 size position.

3. Place a sheet of A3 (or larger) white paper on the exposure glass, near the original scale.(This is to prevent change of reflectivity from the white-and-black pattern.)



6. Press the Start key, and press the Clear/Stop key immediately after the 18th flash. The ma-chine stops after 20 flashes. (This is because the flash output compensation is applied justafter flashing 10 times and the grid output compensation is applied just after 20 times.)

7. Read the flash and grid shift steps (compensated values). When the values are 0 ± 2, thecheck is completed.

8. Add (or reduce) the shifted-up (or down) value to (or from) the flash and grid setting steps us-ing the value change keys () on the process control OFF screen.

NOTE

The maximum flash and grid shift steps for one time compensationis 3. Therefore, if the shift-up (or down) value is 3, you have tofollow the step below.

9. Make sure that no compensation is applied to the flash and grid setting steps (no change ofthe flash and grid shift steps) as follows:

1) Select the [4-01] screen. (Be sure that all shift steps are 0.)

2) Press the Start key, and press the Clear/Stop key immediately after the 38th flash. Themachine stops after 40 flashes.

3) Read the flash and grid shift steps. If they are not 0 ± 2, add (or reduce) the shifted-up (ordown) value to (or from) the flash or grid setting steps. Then, repeat the above step.

Bias step setting

1. Read the bias shift step (compensated value) on the [4-01] screen. When the value is 0 ± 2,the check is completed.

2. Add (or reduce) the shifted-up (or down) value to (or from) the bias setting step using thevalue change keys () on the process control OFF screen.

1 July 1994 Setting B

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5.4 Setting C

NOTE

Setting C is sometimes needed when making the followingreplacements:

Replacing the development unit, ID sensor board, toner density sensor, toner density control board. VSG lock releasemight be required when the OPC belt is replaced.

CAUTION

1. When the parts described above are replaced, the target toner density data mightchange. Perform setting C to store the new data.

2. When the OPC belt is replaced, V SG may lock. So, access service tool [4-02] andmake a free run to check V SG operation. If it is locked, perform setting C (release theVSG lock).

3. When the Developer Forming key in the [4-02] screen is pressed, the "Setting TargetT. D." value is changed according to the toner density measured by the toner densitysensor. As the "Actual Target T. D." value (the actual target for the toner densitycontrol) is controlled only in a range of ± 0.74 volts from the "Setting Target T. D."value, the toner density control cannot be operated properly if the "Setting Target T.D." value is not correct. Do not press the Developer forming key without performingsetting C. (The developer forming key in the [3-04] screen does not change the "SettingTarget T. D." value.)

4. The toner density of new developer is approximately 3%. This makes the V SG/VSPon the [4-02] screen 8 ± 2 without performing setting C. Use the developer formingkey in the [3-04] screen when the developer is replaced with new one.



3. Press the Developer Forming key. (This is to store the new target toner density data.)

4. Press the Start key, and press the Clear/Stop key after about 5 to 10 flashes.

NOTE

In the [4-02] screen, the VSG and VSP are checked and changedwhen the Clear/Stop key is pressed during free run.

5. Read the VSG/VSP on the screen.

6. If the value is 10 or more, leave the service tool and make 5 to 10 black solid copies to re-duce the toner density.

If the value is 6 or less, leave the service tool and make 5 to 10 blank copies to increase thetoner density.

If the value is between 6 and 10, the setting is completed.

CAUTION

Use the manual density key when you makeblack solid copy. In the AID mode, excessivedevelopment bias is applied, so do not use thismode.

Setting C 1 July 1994

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Technical Support


NOTE

• Toner can be supplied using the [4-02] screen by following the steps below.

1) Press the Toner Density Control OFF key.

2) Raise the target T. D. setting and actual values using the value change keys ().

3) Press the Toner Density Control ON key.

4) Press the Start key, and press the Clear/Stop key after about 5 to 10 flashes. (If the target T. D.value is higher than the actual T. D. sensor value, toner is supplied during the free run.) 5) Press the Developer Forming key to store the new target toner density data.

• Before making black solid copies to reduce the toner density, lower the target T. D. setting value toprevent toner from being supplied. Be sure to press the Developer Forming key after reducing tonerdensity.

7. Repeat the above step until VSG/VSP becomes 8 ± 2.

8. Press the Developer Forming key. Then, leave the service tools.

NOTE

The VSG is locked if it exceeds approximately 4.5 volts. If it islocked (during setting C, after replacing the OPC belt, etc.),release the lock as follows:

1) Access service tool [4-02], and press the Toner Density ControlOFF key, then press the ON key.

2) Turn off the main switch, wait, and turn it back on. These stepsreleases the VSG lock.

3) Press the Start key, and press the Clear/Stop key after 5 to 10flashes.

4) Read the VSG on the screen.

5) If the value is not between 3.0 and 4.5, repeat steps 1) to 4). Ifit is so, perform setting C.

1 July 1994 Setting C

5-11

SECTION 6

TABLE OF USER TOOLS

6. TABLE OF USER TOOLS

The user tools can be accessed by entering "000" with the key pad. The access number can bechanged by service tool [1-01].

CAUTION

The data for the user tools will be cleared if the main control board is replaced. Write down the set data and use itin that case. The data in user tool [1] "Total sheets copied" and [9] "User access code" must be cleared in order toreset RAM on the main control board and start up the use of these modes.

Item Description Setting Method

(1) Total sheets copied The number of paper sheets fed by sizeand total are displayed.

Display items:Totals of A3, B4, A4, B5 11 x 17, 8 1/2 x 14, 8 1/2 x 11

* Paper feed tray is not specified.* Within 8 digits

Press [1] of the menu of the user tools tosee the data.

When Clear key is pressed⇓Select "Yes/No".Press [Yes] to clear data.Press [No] to cancel.

(2) Auto image density level selection Change AID (Auto Image Density) levelin 3 steps as desired by user.

Initial setting: normal

Press [2] of the menu of the user tools.⇓Select "Lighter/Normal/Darker".

(3) Copy/original size selection

Paper and original sizes are identified.

Initial setting: A3, A4 (For Europe) 11 x 17, A4 (For U.S.A.)

Press [3] of the menu of the user tools.⇓Select "A3/11 x 17" or "A4/8 1/2 x 13".

* Paper/original size display is made asshown in the table according to theselection for all trays. Note that A3originals and paper and B4 originalscannot be used when [11 x 17] key ispressed, and that 11 x 17 originals andpaper and 81/2 x 14 originals cannot beused when [A3] key is pressed. A4originals and paper cannot be used when[81/2 x 13] key is pressed, and 8 1/2 x 13originals and paper cannot be used when[A4] key is pressed.

Key A3, 81/2 x 13 11 x 17, 81/2 x 13Paper/original

sizePaper Original Paper Original

11 x 17 A3 11 x 17A3 A3 11 x 17B4 B4 B4 81/2 x 14

81/2 x 14 81/2 x 14 B4 81/2 x 1481/2 x 11 81/2 x 1181/2 x 13 81/2 x 13

A4 81/2 x 13B5 B5

Key A3, A4 11 x 17, A4Paper/original

sizePaper Original Paper Original

11 x 17 A3 11 x 17A3 A3 11 x 17B4 B4 B4 81/2 x 14

81/2 x 14 81/2 x 14 B4 81/2 x 1481/2 x 11 81/2 x 1181/2 x 13 A4

A4 A4B5 B5

1 July 1994 TABLE OF USER TOOLS

6-1


(4) OPC segment skip When part of the OPC belt cannot beused due to scratch, etc. copying ismade skipping the defective part.

Initial setting: All sizes and segmentscan be used.

* Copies used for segment tests are notcounted in the total counter.

How to reset the segment skip:(1) Lower paper for all trays.

(2) Select user tools [4].

(3) Press [#].

(4) Press [CLEAR] and select [Yes].

(5) Press [EXIT].

(1) Press [4] of the menu of user tools.⇓(2) Press Enter [#] key.(The maximum paper size in the papertray will be selected.)

(3) Press the Start key.(Blank copies will be made. Check theimage to be skipped.) * Number of copies *

DLT, A3 3 copiesB4 4 copiesLT, LG, A4, B5 5 copies

(4) Select the segment to be skippedamong 1st/ 2nd/ 3rd/ 4th/ 5th.(Skipping all segments is not possible.) (5) Press Enter [#] key to select anotherpaper tray. * Paper size selecting order *

11x17 (DLT), A3 1st segment testB4 2nd segment test81/2x14 (LG) 3rd segment testA4 4th segment test81/2x11 (LT) 5th segment testB5 6th segment test

Change the paper to be used and repeat(3) to (5) above to make the segmentskips for all paper sizes. (6) Press Exit to finish this mode or theClear key to cancel this mode.When the Clear key is pressed⇓Select "Yes/No".Press "Yes" to clear skip data.Press "No" to cancel clear.

(5) Set date/time Set and display of data/time for theweekly timer.

(1) Press [5] of the menu of user tools.

(2) Select year/month/date/day ofweek/hour/minute.(Two or more cannot be selected at thesame time.)

(3) Input the numerical value from thekey pad. Select day of week from thescreen.

(4) Press the Enter [#] key.Repeat (2) to (4) and set all items.

* Use Clear/Stop key to change the setnumber.* When the Enter key is not input,previous data are effective.* If an improper value is set, the valuewill automatically be corrected as shownbelow.

Size No skip skip #1 Skip #2DLT, A3 61CPM 41CPM 21CPM

B4 81 61 41LT, LG,A4, B5 101 81 61

Item Setting CorrectionMonth Not 1 to 12 1Day Not 1 to 31 1Hour Not 0 to 23 0

Minute Not 0 to 59 0

TABLE OF USER TOOLS 1 July 1994

6-2

Technical Support



(6) Disable display Delete unused functions on request fromuser.Functions that can be deleted:

Margin adjustmentDuplexMagnification

Initial setting: All OFF (all functions effective)

Press [MarginAdj.]/[Duplex]/[Reduce/Enlarge].

(7) Disable unit Temporarily isolate a defective unit fromthe machine to prevent disability of thewhole system when an SC code lights orpaper misfeeds occur.

Initial setting: All units can be used.

Press [7] of the menu of the user tools.⇓Select "Tray 1/Tray 2/Tray 3/Tray 4/Finisher/RDH/Duplex".

Try to isolate the units as follows:Duplex: SC70, SC71, or frequent

misfeedsRDH: SC33, 34, 35, 84, 85 or

frequent misfeedsTray 1: SC60 or frequent misfeedsTray 2: SC61 or frequent misfeedsTray 3: SC62 or frequent misfeedsTray 4: SC63, SC64, or frequent

misfeedsFinisher: SC93, 94, 95, 96, 97, or

frequent misfeeds(8) Select special tray The Tray 1 can be set as the special tray

for cover sheets.One of the Tray 1, 2, and 3 can be set asthe special tray for slip sheets.

*The paper tray set as the cover sheet orslip sheet tray is not intended for:1) Auto tray switching mode2)APS (Auto Paper Selection) mode3) Tray selection by the user program*When set as the cover sheet or slipsheet tray, "SP." will be shown on thepaper tray key on the operation displayfor identification.

Initial setting: No cover sheet and slipsheet trays set.

Press [8] of the menu of the user tools. ⇓Press key(s) of the tray(s) to be set asthe cover sheet tray and/or slip sheet tray.


6-3


(9) User access code When the accounting mode ("AccessCode" key) or security accounting mode("Access Code/Super User Mode" key) isselected with service tool 2-08, thefollowing are available with this function:

1) Up to 500 user codes can beregistered.

2) The registered user codes can bechanged or deleted.

3) The number of copies made usingeach user code can be displayed. Thedata can also be printed if the optionalprinter and printer connector unit areinstalled.NOTE: The DIP switch setting (theprinter side) is different from that for theF200. The data bit length for the F200 is7-bit, and that for the F5 is 8-bit.

4) When the security accounting mode isselected, selected only key operators canuse the above features. Other operatorscan only check the number of copiesmade using their own user codes.

5) In the security accounting mode,selected key operators can disable theuse of normal user codes by selectingthe "Key Operator Only" key.

Press [9] of the menu of the user tools.⇓Select "Set Code/Display Data/PrintData".⇓Press "Enter Code/Change Code/DeleteCode" for "Set Code" and "OneCode/Range of Codes /All Codes" for"Display Data/Print Data".

* When the security accounting mode isselected, only selected key operators canpress "Key Operator Only" after selecting"Enter Code".

How to enter the copy mode in theaccounting modeEnter one of the user access codes bypressing the Number keys.

How to leave the copy mode in theaccounting modePress the Clear/Stop key while pressingthe Clear Modes key. When service toolutility (4-05) 13-5-10 is ON, the copierautomatically leaves the copy mode andrequires user access codes to use thecopier after the time set with service tool[2-13].

NOTE: When the main control board isreplaced with a new one, all data in usertool [9] must be cleared in order to resetRAM of the main control board and startup the use of the user access code mode.


6-4


(10) User utility Select the finisher mode:The sort or stack mode can be selected.(Initial setting: Sort)

Staple in stack mode:Stapling with the stack mode is available.(Initial setting: No, not effective) Thisfunction is the same as service tool utility(4-05) 13-5-9.

Auto tray switching:This function is the same as service tool2-10. (Initial setting: Yes)

3-side full image copy:A new key, beside the Check modes key, to select the 3-side full image copymode can be used. This function is thesame as service tool utility (4-05) 7-5-0.(Initial setting: No)The 3-side full image mode is selected at power on when "Yes" is selected withservice tool 2-09 "3-side Full Image"

Select count up or down mode:Adding each copy or subtracting eachcopy for the copy number counter can beselected. This function is the same asservice tool 2-01. (Initial setting: Up)

Display the number of originals:The number of originals copied in thestack original feed mode is displayed inthe message area after copying. Thisfunction is the same as service tool 2-11"Original Count Display." (Initial setting:No)

Exit originals to tray:A new key, beside the Check modes key,to select the original tray exit mode canbe used. When the original tray exitmode is selected, the stack mode isautomatically selected because thismode cannot be used with the sort mode.This function is the same as service toolutility (4-05) 4-1. (Initial setting: No)

Select face up/down in stack mode:Copies made in the stack mode can bedelivered face up (image side up) to theshift tray. (Initial setting: Face Down)

Reverse back cover sheet:When the back cover is selected in thecover mode, users can select to have theimage of the back cover face inside ofthe copy set or outside. (Initial setting:Yes, It faces outside.) Copy onto slip sheets:When copies are made in the chapteringmode, users can be select to have theimage of the designated original copiedon the slip sheet or not. (Initial setting:Yes)

NOTE:For functions which can be set with boththe user utility and service tools, if thedata is changed with one, the data in theother will be changed automatically.

Press [10] of the menu of the user tools. ⇓Press "Yes/No", "Sort/Stack", "Up/Down",or "Face Up/Face Down" for thefunction(s) to be used.


6-5


(11) Set staple position The staple position on the copy papercan be changed for each stapling modeas shown below.

Press [11] of the menu of the user tools. ⇓Press " / " for each stapling mode.

(12) Weekly timer The power ON and OFF of the machineis automatically done based on the setdata.

Operation during the weekly timer ON:* The machine can be used temporarilyby inputting the key operator accesscode or turning off and on the mainswitch.* The machine will automatically bepowered off again based on the auto offtime set by the service tool [2-13] (initialsetting: 30 minutes) after doing theabove. When the machine ON time of theweekly timer is reached before the autooff time, priority is given to the machineON mode and the auto off mode iscanceled.* The weekly timer does not power offthe machine during SC code mode,door(s) open, or paper jam condition.

Initial setting:All weekON time 00:00OFF time 23:59*This means that the weekly timer is notselected.

Set correct date and time. (User tool [5])⇓Press [12] of the menu of the user tools.⇓1) Select area of day of week and inputON time from the key pad.⇓2) Press the Enter [#] key.⇓3) Select another area of day of weekand input OFF time from the key pad.⇓4) Press the Enter [#] key⇓5) Repeat 2) to 4) above for each day ofweek.

* 24-hour system is used.* Press Clear/Stop key to change theentered item.* When the Enter [#] key is not pressed,previous data are effective.* If you want to turn off the machine foran entire day (e.g. Saturday, Sunday)while the weekly timer mode is selected,input the same time (e.g. 00:00) for bothON and OFF of the day you want themachine off.

0 mm

20 mm

1 Staple Lowemode

0 mm

20 mm

20 mm

20 mm

0 mm

0 mm

1 Staple Uppermode

2 Staple mode


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Technical Support


Technical Support

RTB 35 User Tool 13 added. This enables the selection of either simplex or duplex cover and/or slip sheets in the Cover or Chaptering mode with the Duplex Copy mode.

SECTION 7

TABLE OF SERVICE TOOLS

7. TABLE OF SERVICE TOOLS

The service tools can be accessed by entering "99900" using key pad. The access number can bechanged by service tool [1-02].

CAUTION

The data for the service tools will be cleared if the main

control board is replaced. Write down the set data and use it

in that case. The data in service tools 3-01 to 3-07 must be

cleared in order to reset RAM on the main control board and

start up the use of these modes.

7.1 Main Menu

The service tools have six items as shown in the main menu above.

7.2 System Set-up


1-01 Key operator access code Change the user tool access number.

* This number is used to access the usertools or to cancel the weekly timer ONmode temporarily (the machine can beused based on the auto off time set inthe service tool [2-13] during the weeklytimer turning off the machine.) * Set the lower two figures ofthree-figure code number beginning with0. The first 0 cannot be changed.

Initial setting: 000

Press [1-01] of system set-up menu. ⇓Input one or two-figure value from thekey pad. (The third figure and onwardare ineffective.) ⇓Press the Enter [#] key. * If only one figure is input, the codenumber is 00x.* Use the Clear/Stop key to change theentered number. * When the Enter [#] key is not pressed,previous data is effective.

1 July 1994 Main Menu

7-1


1-02 Service access code Change the service tool access number.

* This number is used to access theservice tools.* To use the changed number, DIPswitch 101-1 on the main control boardmust be on. To use the original number"99900", DIP switch 101-2 must be on.* Set the lower two figure of 5-figure codenumber beginning with 999. The thirdfigure and onwards cannot be changed.


Press [1-02] of system set-up menu. ⇓Input one or two figure value from thekey pad. (The third figure and onward areineffective.) ⇓Press the Enter [#] key.

* If only one figure is input, the codenumber is 9990x.* Use Clear/Stop key to change theentered number.* When the Enter key [#] is not pressed,previous data are effective.

1-03 Service telephone number Enter the telephone number that will beshowed on the guidance display with anSC code to make contact with a servicerepresentative.

* The maximum number of digits is 19,including hyphens.

Initial setting: All digits 0

Press [1-03] of system set-up menu. ⇓Press Clear key. ⇓Input the value in the cursor position fromthe key pad. (Put [-] key between officenumbers.) ⇓Press the Enter [#] key

* Use Clear/Stop key to change thenumber.* When the Enter [#] key is not pressed,previous data are effective.

1-04 Disable display (1) When the non-key operator screen isselected, display or erase of "100 %"meaning the full size mode is selected.

(2) When APS mode is selected, displayor erase of the paper table keys isselected.

(3) When ADS mode is selected, displayor erase of the manual density changekeys is selected.

Initial setting: "Don’t Display" areselected for all items.

Press [1-04] of the system set-up menu. ⇓Select "Don’t Display/Display" for eachitem.

1-05 Weekly timer This function is set with user tool [12].1-06 Toner supply amount Toner supply amount is changed in four

steps (15 %, 30 %, 45 %, 60 %).

Initial setting: 30 %

Press [1-06] of the system set-up menu. ⇓Select one of each %.

1-07 Charge wire cleaning Automatic charge and grid wires cleaningmode ON or OFF is selected.

* Cleaner ON timing: When power isturned on by the main switch or weeklytimer after 20,000 copies.

Initial setting: Automatic cleaning isselected.

Press [1-07] of the system set-up menu. ⇓Select "Yes (Auto-cleaner ON)/No(Auto-cleaner OFF)".

1-08 Option installation Set system composition condition whenthe machine is installed.System to be set: Tray 4 (LCT) Finisher Key Counter

Initial setting:All system setting OFF

Press [1-08] of the system set-up menu. ⇓Press [Tray 4]/[Finisher]/[Key Counter]

System Set-up 1 July 1994

7-2

Technical Support

1-05 RTB 16, 17: More details

7.3 User Functions


2-01 Count up/down Up count: Adding each copyDown count: Subtracting each copySelect one of the above for copy count.*This function is the same as the function inuser utility [10].

Initial setting: Up selected

Press [2-01] of the user functions menu. ⇓Select Up/Down.

2-02 Set user program number(s) The number of user programs can beselected in a range from 1 to 10.

Programmable modes:* Set copy number* Paper size (including auto paper selection))* Image density level (including AID)* Sort/stack/normal* Margin adjustment* Duplex* Magnification (Including auto magnificationselection)

Initial setting: 10

Press [2-02] of the user functions menu. ⇓Input the numerical value (1 to 10) from thekey pad. (Input of 11 or more is automaticallycorrected to 10.) ⇓Press the Enter [#] key.

* When the Enter [#] key is not pressed,previous data are effective.

1 July 1994 User Functions

7-3


2-03 Set fixed reproduction ratios Each size display and % display are setas desired in a range of 7 types of fixedreproduction ratios (3 types ofenlargement and 4 types of reduction).

* % display can be set without regard tonormal reproduction ratios correspondingto size display. (No size display)

Selection priority* Priority order in selection when themagnification mode is selected in thenon-key operator screen.

* Layout must be made to meet thepriority order desired by user.When setting is made by original sizeand copy size

Initial setting:

There are two methods to set desiredreproduction ratios as follows:* Input the reproduction ratio by enteringoriginal and copy sizes. (Both sizes andreproduction ratio are displayed. Theselected ratio can be finely adjusted last.)

* Input the reproduction ratio from thekey pad. (Size is not displayed and %only is displayed.)

1) Press [2-03] of the user functionsmenu. ⇓2) Press the key to be changed. The keycan be selected from 3 types ofenlargement and 4 types of reduction.(See the illustration above for the keys.) ⇓3) Press the Enter [#] key. ⇓ (Screen will change.)4) Select "Paper size entry/Percent entry". ⇓5) Press the Enter [#] key. ⇓

Enlargement3rd Priority

Position

Enlargement2nd Priority

Position

Enlargement1st Priority

PositionReduction1st Priority

Position

Reduction2nd Priority

Position

Reduction3rd Priority

Position

Reduction4th Priority

Position

(141%)A4 → A3B5 → B4

(122%)A4 → B4A5 → B5

(115%)B4 → A3B5 → A4

(93%) (87%)A3 → B4A4 → B5

(82%)B4 → A4

(71%)A3 → A4B4 → B5

User Functions 1 July 1994

7-4


2-03

(Screen will change.) ⇓ 6) Set a desired reproduction ratio asfollows:

When the "Paper size entry" has beenselected, the screen shown below will bedisplayed. Select the original and copysizes. (The proper reproduction ratio willbe displayed automatically.)

[Paper size entry display]

When the "Percent entry" has beenselected, the screen shown below will bedisplayed. Input a desired reproductionratio using the numeric keys. (Paper sizewill not be displayed in this method.)

[Percent entry display]

⇓ 7) Press the Enter [#] key. ⇓ 8) Set ratio is displayed in the set area asshown below. Press the Enter [#] key tostore the data, or fine adjustmentpossible by "+" and " --" keys, then pressthe Enter [#] key

[Paper size entry display]

[Percent entry display]

⇓ 9) Repeat 2) to 8) above and set otherdisplay areas one by one.


7-5


2-04 Delete fixed reproduction ratios 7 types of fixed reproduction ratio (3enlargements and 4 reductions) areseparately deleted as desired.

Initial setting: All 7 types are effective

Press [2-04] of the user functions menu. ⇓Press the key to be deleted.

2-05 Set back side margin Set the automatic back side margin in theduplex modes in a range from 0 to 21mm.

* When the margin is not set by the user,back copy right (left) margin in thesingle-side original duplex mode isautomatically set in a range from 0 to 21mm. The set value is also applied to backcopy left (right) margin in the 2-sidedoriginal duplex mode and in ADF mode.

Initial setting: 5 mm at right

Press [2-05] of the user functions menu. ⇓Press [→] to set right margin and [ ←] toset left margin. (Press [C] to set margindimension at 0.) ⇓Press the Enter [#] key.

* When the Enter [#] key is not pressed,previous data are effective.

2-06 Maximum copy number Set copy number can be limited asdesired in a range of 4 digits (9999).

Initial setting:Set copy number limit:no limit (9999 copies)

Press [2-06] of the user functions menu. ⇓Press [Maximum Copies]. ⇓Input the value with numeric keys. ⇓Press the Enter [#] key.

* Zero in the first digit is ineffective.* Input of 5 or more digits is ineffective.* Use the Clear/Stop key to change theset number.* When the Enter [#] key is not pressed,previous data are effective.

2-07 Staple copy limit The maximum staple capacity in thestaple mode can be changed within arange of 40 to 50 sheets.

* The set limit is effective without regardto copy size and single/duplex copy.

Initial setting: 50

Press [2-07] of the user functions menu. ⇓Press [Maximum Copies]. ⇓Input the value with numeric keys. ⇓Press the Enter [#] key.

* Use the Clear/Stop key to change thenumber of copies.* When the Enter [#] key is not pressed,previous data are effective.

2-08 Free/User access code operation The accounting mode and securityaccounting mode can be set.

Initial setting: Free use

Press [2-08] of the user functions menu. ⇓Select "Free Use", "Access Code"(accounting mode), or "AccessCode/Super User Mode" (securityaccounting mode).

How to set the accounting modes* Normal Accounting ModePress the "Access Code" key in servicetool [2-08]. Then enter appropriate useraccess codes with user tool [9].

*Security Accounting Mode1) Be sure that the "Free Use" key isselected with service tool [2-08]. Thenenter an appropriate user access codewith user tool number [9]. The useraccess codes entered in this conditionwill be the codes for the key operator.

2) Press the "Access Code/Super UserMode" key with service tool [2-08]. Thenreturn to the normal screen.

3) Enter appropriate user access codeswith user tool [9]. This will be the codesfor normal operator.

How to enter the copy mode in theaccounting mode for servicingThe accounting mode is canceled whenDIP switch 101-2 on the main controlboard is ON. Note that DIP switch 101-2is commonly used to enable accessingthe service tool password "99900".


7-6

Technical Support



2-09 3-side full image The 3-side full image mode can be set.

* In this mode, each of two eraser LED’son both edges will turn off from thenormal side erase width.* The 3-side full image mode key will bemade effective by setting the 3-side fullimage mode in user tool [10] or servicetool utility (4-05) 7-5-0. In that case, the3-side full mode is automatically selectedat power ON when the 3-side full imagemode is selected in this screen.* The 3-side full image mode is noteffective when the ADF stays open andcopied.

Initial setting: The 3-side full imagemode is not selected.

Press [2-09] of the user functions menu. ⇓Select "Yes (3-side full image mode)/No(normal erase mode)".

2-10 Auto tray switching The auto tray switching mode can be set.

* In this mode, when paper runs outduring copying, the paper tray that hasthe same size paper as used in theprevious paper tray is automaticallyselected without stopping the copy job.* Paper tray priority order in selection: No LCT: Tray 2 → Tray 3 LCT available: LCT → Tray 2 → Tray 3* The Tray 1 and the paper tray set asthe special tray by service tool [2-12] isnot intended for the auto tray switchingmode.* This function is the same as thefunction in user tool [10].

Initial setting: The auto tray switchingmode is selected.

Press [2-10] of the user functions menu. ⇓Select "Yes (auto tray switching)/No".

2-11 Original count display The number of originals copied in ADFmode can be displayed in the messagearea after copying.

* In the 2-sided original mode (2-sidedoriginal to 2-sided copy or 2-side tosingle side), the original count doubles.* The original count display is cleared bythe auto reset mode or by pressing anykey.* When one copy is made from anoriginal, the original count is notdisplayed.* This function is the same as thefunction in user tool [10].

Initial setting:No original count display

Press [2-11] of the user functions menu. ⇓Select "Yes (original count display)/No".

2-12 Set special paper tray Each paper tray can be set as a specialtray.

* The paper tray set as the special tray isnot intended for:1) Auto tray switching mode2) APS (Auto Paper Selection) mode3) Tray selection by the user programSet the special tray when there is thepaper tray that does not allow thefunctions above. For example, whencolor paper is used in a paper tray, thetray should not be intended for thelimitless paper feed mode.* When set as the special tray, a smallred circle will be shown on the paper traykey on the operation display foridentification.

Initial setting: No special tray set

Press [2-12] of the user functions menu. ⇓Press key(s) of the tray(s) to be set asthe special tray(s).


7-7


2-13 Auto reset, auto OFF Select time for the auto reset and auto offmodes.

1) Auto reset modeAutomatically returns the operation paneldisplay to the standard mode selected byservice tool [2-16] after a fixed time.

Modes to be set:. Set copy number. Counted copy (or original) number. Paper tray (including APS). Magnification (including AMS). Duplex. Margin adjustment. Image density level (including AID). Finishing. Interrupt mode (returns to the modeprior to interrupt)

* Auto reset mode does not work underthe following conditions:. Start key red (Non copy stand-by). Paper in duplex tray. Paper in sorter bin. During job recovery. During operation of user tools or servicetools

2) Auto off modeAutomatically powers off the machine infixed time after the machine istemporarily powered ON during themachine OFF time by the weekly timer.

* Auto off mode does not work under thefollowing condition: . During the machine ON time by weeklytimer . Start key red (non copy stand-by) . During job recovery mode . During user tools mode or service toolsmode

* When the machine ON time of theweekly timer is reached before the autooff time, priority is given to the machineON mode and the auto off mode iscanceled.

Initial setting:Auto reset mode: One minuteAuto off mode: 30 minutes

Press [2-13] of the user functions menu. ⇓Select "5 sec./1 min./3 min./ ∞ (no autoreset mode)" for the auto reset mode,and/or "30 min./1 hr./3 hr./ ∞ (no auto offmode)" for the auto off mode.

2-14 Key tone Buzzer sound loudness and pitch at thekey ON can be selected.

* Type of buzzer sound: . When any key (except Start key) ispressed. (Sounds once) . When the machine goes into stand-bycondition. Start key turns green. (Soundsthree times) . When an input signal exists in the I/Otest mode. (Continuously sounds)* Buzzer sound for the copy stand-by andwarning is effective even with the soundOFF set. Initial setting:Loudness: NormalPitch: 3

Press [2-14] of the users functions menu. ⇓Select "Off/Low/Normal/High" for thesound loudness, and/or "1/2/3/4/5" forthe sound pitch.


7-8


2-15 Set exit tray copy limit Select number of copies fed out into thecopy tray on the main body.

* When copies are continuously madeusing the copy tray, the copyingautomatically stops after the selectednumber of copies are made.


Press [2-15] of the user functions menu. ⇓Select "300/350/400/No (no limit)".

2-16 Set initial display The initial modes of the operation displaycan be selected.

* The operation display returns its initialscreen in the cases below: . When the machine is powered on . When the clear mode key is pressed . When the auto reset mode works

Modes that can be set* Display type (Key operator screen/Freeoperator screen)* Auto paper tray shift (When the firstpriority paper tray has no paper, thepaper tray that has paper is automaticallyselected a few seconds after themachine goes into copy stand-bycondition. This is not done when the APSmode is selected as initial display.)* Set copy number* Paper tray (Including APS. The specialtray is not included.)NOTE: When the APS is selected as aninitial mode, the paper tray that wasselected before accessing the servicetool becomes the second priority tray.The second priority tray will be selectedwhen the APS mode is canceled byraising the ADF or by pressing the APSkey again. * Image density level (Including AID) * Sorter * Margin adjustment * Duplex * Magnification (except AMS) Initial setting: * Free operator screen * Auto paper tray shift ON * Set copy number 1 * APS * ADS * Finishing OFF * Margin adjustment OFF * Duplex OFF * Magnification OFF (Full size)

Press [2-16] of the user functions menu. ⇓Select "Key operator (screen)/Operator(free operator screen)" and/or "Yes (autopaper tray shift)/No". ⇓Press the Enter [#] key. ⇓ (Screen will change)Select each mode. ⇓Press the Enter [#] key


7-9

Technical Support


7.4 Data Logging


3-01 Tray copies Total sheets copied are displayed bypaper tray and size.

Display itemsPaper tray . Tray 1 . Tray 2 . Tray 3 . Tray 4 (LCT) . TotalSize . A3, B4, A4, B5, and their sub total . 11x17 (Double letter) . 8-1/2 x 14 (Legal) . 8-1/2 x 11 (Letter) . Total

* Up to 8 digits are displayed.

Press [3-01] of the data logging menu. ⇓Move the page by Next/Prev. * Clearing dataPress Clear key. ⇓Select "YES (clear the data)/NO".

3-02 Duplex/finishing copies Total sheets copied using the duplexmode and finisher are displayed by size.

Display itemsUnit . Duplex tray . FinisherSize . A3, B4, A4, B5, and their sub total . 11x17 (Double letter) . 8-1/2 x 14 (Legal) . 8-1/2 x 11 (Letter) . Total


Press [3-02] of the data logging menu. ⇓Move the page by "Next/Prev".

* Clearing dataPress Clear key. ⇓Select "YES (clear the data)/NO".

3-03 Original feeds Total number of original feeds in RDH(by size) and SADF are displayed.

Display itemsUnit . RDH . SADFSize (for ADF only) . A3, B4, A4, B5, and their sub total . 11x17 (Double letter) . 8-1/2 x 14 (Legal) . 8-1/2 x 11 (Letter) . Total

* Display digits are up to 8 digits.* In the single side original to 2-sidedcopy, 2-sided to 2-sided, and 2-sided tosingle side modes, the original is fedtwice.

Press [3-03] of the data logging menu.


Data Logging 1 July 1994

7-10


3-04 Supply yield/forming (1) Total copies made by the OPC belt,developer, and cleaning carrier and thenumber of used staple are displayed.

* Up to 8 digits are displayed.* In the duplex mode (single side originalto 2-sided copy and 2-sided to 2-sided),the count doubles.

(2) There are ON key’s for the OPC belt,developer, and cleaning carrier formingmodes.

CAUTION:In the cleaning carrier forming mode, ablack image in A3 size is made on theOPC 30 times. Next, a blank image ismade 30 times. Then, this cycle isrepeated once more (a total of 120images are made). To prevent the tonerdensity of the developer from lowering,follow the order below:

1) Developer forming

2) OPC forming

3) Cleaning carrier forming

Press [3-04] of the data logging menu. ⇓Press "OPC/Developer/CL carrierforming ON key" one by one.


3-05 Copier misfeeds Copier misfeeds are accumulated anddisplayed by location and type (sensorON or OFF check misfeed).

Display itemsLocation . Tray 1 feed . Tray 2 feed . Tray 3 feed . Tray 4 (LCT) feed . Registration . Pick-off (separation) . Fusing (fusing exit) . Sub total (total of the items above) . Duplex gate (duplex entrance junction) . Exit gate (eject junction) . Exit tray . Horizontal transport 1 (entrance) . Horizontal transport 2 (exit) . LCT top (LCT transport) . Duplex feed . Total

Misfeed type . ON (sensor ON check misfeed) . OFF (sensor OFF check misfeed)


Press [3-05] of the data logging menu. ⇓Move the page by Next/Prev.


3-06 RDH/finisher misfeeds Misfeeds are accumulated and displayedby location of RDH, SADF, inverter unit,finisher, and by type.

Display itemsLocation . RDH feed (entrance and 1st transport) . RDH transport (2nd transport andregistration) . RDH exit (1st and 2nd reverse, andexit) . SADF feed (registration) . SADF exit . Inverter unit (inverter entrance) . Finisher

Misfeed type . ON (sensor ON check misfeed) . OFF (sensor OFF check misfeed)


Press [3-06] of the data logging menu. ⇓Move the page by Next/Prev.


1 July 1994 Data Logging

7-11


3-07 Service calls (self-diagnostics) The service calls occurred are displayedwith the service call code

Press [3-07] of the data logging menu. ⇓Move the page by Next/Prev. (If theservice calls are made for 30 or lessitems, they can be covered in one pageand there is no page movement.)


3-08 Operation time System operating time are accumulatedand displayed.

Display items . Power ON . Fusing lamp ON . Main motor ON . OPC motor ON . Development motor ON . Wire motor (wire cleaner motor) ON * The display unit is one hour andfractions are not displayed.* Up to 8 digits are displayed.

Press [3-08] of the data logging menu.

Data Logging 1 July 1994

7-12

7.5 Process Control


4-01 Process control The data for the process control can beseen and adjusted. For details, see 4.1Display with Service Tools.

4-02 Toner density control The data for the toner density control canbe seen and adjusted. For details, see 4.1 Display with Service Tools.

CAUTION:Unlike the developer forming key inservice tool 3-04, the developer forming"ON" key in this screen changes the datafor the "Target T.D.". Use this key onlywhen setting C is carried out. For usualdeveloper forming, use the key in servicetool 3-04.* Changing the ID sensor pattern level (1to 4) will change the toner density of thedeveloper.

4-03 AID reference voltage By pressing the Start key, the potentialsensor measures the image density ofthe original placed on the exposure glass10 times. (The data is used for the AIDlevel selection.) The voltage is shown 10times with the development bias stepsthat is raised by the determined AID level.

Press [4-03] of the process control menu. ⇓Place the PC-1 chart on the exposureglass and press the Start key.

4-04 OPC cleaning operation (1) The OPC cleaning operation intervalcan be selected.

* if the copy volume is extremely high orlow and dirty background copies appear,set the interval to 5K.

Initial setting: 10K

(2) The manual ON key is used to doOPC cleaning.

* It takes about 5 minutes to clean oneround of the OPC belt.

(3) The OPC belt forming ON key is thesame function as that of the screen[3-04].

* In this mode, OPC belt turns 10rotations with the OPC cleaning ON.

CAUTION:Do not stop the OPC cleaning operationmidway. The OPC belt will have aninsufficiently cleaned part, and this mayappear on the copy image.

Press [4-04] of the process control menu. ⇓Select "OFF/5K/10K/20K".

4-05 Utility Extra functions can be selected. Refer toUtility modes section for details.

1 July 1994 Process Control

7-13

Technical Support

RTB 20 Default setting changed Pre-heat did not work even if switched on, if a finisher mode is selected with [2-16]

Technical Support


Technical Support

RTB 35 Do not change 4-40 normally. However, this RTB gives some conditions when it is OK to change it.

7.6 System Test


5-01 Running test mode Paper transport test modes. Thefollowing three types can be selected.

(1) Jam OFF: The jam detection, exceptthe inverter unit, sorter, and separation(main body) jam detection, is disabled.

(2) SC OFF: The SC detection isdisabled.

(3) Blank copy: The exposing is not done.

* The total counter counts copies even inthese mode.

Press [5-01] of the system test menu. ⇓Select "Jam OFF/SC OFF/Blank Copy". ⇓ (Screen will change)Select the desired copy modes and pressthe Start key.

5-02 Copy image The following adjustments can be done:

(1) Lead/trail erase: The leading andtrailing edge erase margins can beadjusted separately in 1 mm steps.

(2) Side erase: Both side (front and rear)erase margins can be adjustedseparately in 2.5 mm steps.

(3) Registration: The leading edgeregistration can be adjusted in 0.5 mmsteps.

(4) Magnification: The magnification errorin the full size (100 %) mode can beadjusted in 0.1 % steps.

(5) Side fence: The duplex side fenceswidth can be adjusted in 0.6 mm steps tomatch with the used copy paper.

* The paper tray that was selected beforeaccessing the service tool will be used foreach adjustment.

CAUTION:Repeat the side erase and side fenceadjustments for each of paper size thatwill be used by the customer.

Press [5-02] of the system test menu. ⇓Select the desired item key. ⇓Change data using the arrow keys. ⇓Press the Start key to make a copy. ⇓Check the copy image.

5-03 Fusing temperature The fusing roller temperature can beadjusted.

* When one of keys [0] to [15] is pressed,the key may turn red. This means thefusing lamp is ON.* The standard temperature is between173 and 177 oC.* The temperature increases ordecreases in 2 oC steps. Initial setting: 8 or 9 CAUTION:Do not refer to the displayed temperatureon the screen to adjust the fusingtemperature. This does not show actualfusing temperature.

Press [5-03] of the system test menu. ⇓Adjust using keys [0] to [15] as follows. Measured value < displayed value Select a key of bigger value than present.

Measured value > displayed value Select a key of smaller value than present.

System Test 1 July 1994

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Technical Support



5-04 I/O test The following tests can be done.

(1) Output (operation) test for eachmotor, solenoid, etc.* Two or more items can be selected atthe same time for the test.

(2) Input test for each sensor.* If a sensor or detection signal isactivated, the buzzer sounds.

(3) Combination of input and output tests

Press [5-04] of the system test menu. ⇓Press one of the menu keys: [Motor]/[P.Pack 1]/[P. Pack 2]/[FanMotor]/[Lamp/Sol.]/[Jam Sensor]/[Others]. ⇓Select output and input item(s) for eachpage.

When you want to select other item(s),move to another page by pressing themenu key.

1. Motor

* Output test items

Main Main motorOPC OPC motorLCT Top LCT transport motorWire Wire cleaner motor (automatic stop after one cycle)Dev. Development motor (after OPC is turned ON)Toner Toner supply motorAgitat. Agitator motor

CAUTION: To turn on the development motor, turn on the OPC motor first. This is toprevent OPC damage. * Input test items Overload Main motor overload detection Set OPC unit set detection OPC Mark OPC sensor (home mark sensor only) F Edge OPC sensor (front edge sensor only) R Edge OPC sensor (rear edge sensor only) Tracking Sector sensor Overload Wire cleaner motor overload detection

2. Power pack 1

* Output test items

Select output levels for each item using keys [0] to [4].Charge Charge corona wiresTransfer Transfer corona wire. Standard output level: [0] key ONSeparate Separation corona wire. Standard output level: [0] key ONPCC PCC wire. Standard output level: [3] key ON

CAUTION:Turn on the OPC motor for these items to prevent OPC damage.

* Input test items

Press one of the output item keys and its [Leak] key. When leakage occurs, the buzzer sounds.

1 July 1994 System Test

7-15


5-04 I/O test

3. Power pack 2

* Output test items

Dev. Bias Development rollers bias.Select output level using keys [0] to [9],then press [Dev. bias] key. Keys [0] to [4]are for the 1st (lower) and 2nd (middle)rollers, and keys [5] to [9] are for the 3rd(upper) roller.

Cleaning Bias Cleaning roller biasScav. Bias Scavenging roller bias

4. Fan motor

* Output test items

Air Knife Duplex blower. Select output level using [Air Knife 1],[Air Knife 2], and [Air Knife 3] keys, then press [Air Knife] key.[Air Knife 1] and [Air Knife 2] ON: High speed (7,000 rpm)[Air Knife 1] and [Air Knife 3] ON: Medium speed (6,000 rpm)[Air Knife 2] and [Air Knife 3] ON: Low speed (4,500 rpm)

Air Knife Sol. Duplex air knife solenoidOzone Ex., Exposure, Exhaust, Duplex, Cooling, Vacuum

These keys are not valid because all fans stay on after the mainswitch turns on.


7-16


5-04

5. Lamp/Sol

* Output test items

Charge Flash charge. Select output level using keys [0] to [4], then press [Charge] key.

Flash Flash ON. Charge using [Charge] key before use of this key.DIS Flash discharging. Effective only when [Charge] key is OFF.Fusing Fusing lamp ONQL Quenching lamp ONErase All eraser LEDs ONVD Sensor "A" sensor of potential sensor ON (channel selection for A and

B sensors)Duplex Sol Duplex entrance junction solenoid ONExit Sol Eject junction solenoid ON

* Input test items

Charge Flash charge completion detectionFlash Detect Flash ON detectionOver Charge Flash over charge (charge error) detectionFlash safety Flash safety switch OFF (flash cover is removed)

6. Jam Sensor

* Input test items

First 1st paper feed sensorSecond 2nd paper feed sensorEnd Paper end sensor (Tray 1), or paper set sensor (Tray 2, 3, and 4)Horz. Trans. 1 Horizontal transport entrance sensorHorz. Trans. 2 Horizontal transport exit sensorDuplex Exit Duplex exit sensorRegistration Registration sensorPick-off Separation sensorFusing Exit Fusing exit sensorDuplex Entry Duplex entrance junction sensorExit Gate Eject junction sensorExit Tray Eject tray sensorLCT Top LCT transport sensor


7-17


5-04

7. Others

* Input test items

Upper (Door/Cover) Copy tray sensorRight (Door/Cover) Upper right door sensorLeft (Door/Cover) Front door sensorLCT Top (Door/Cover) LCT upper cover safety switchSet (Cartridge) Cartridge set switchShutter (Cartridge) Cartridge shutter switchToner End Toner near-end sensorCL Coil Cleaning coil sensor


7-18


5-05 Feed unit test The operation test of each part for thepaper feed can be done.

Press [5-05] of the system test menu. ⇓Select [Motor]/[Pick-up Sol.]/[VacuumSol.]/[A3]/[11 x 17]/[A4]/[8 1/2 x 11]/[B4]/[8 1/2 x 14]/[B5].

Motor (Tray 1, Tray 2, Tray 3, LCT, Duplex, and Registration)Paper feed motor of Tray 1, Tray 2, Tray 3, or LCT, duplex paper feed motor, or registration motor

Pick-up Sol. (Tray 1, Tray 2, Tray 3, and LCT)Pick-up solenoid of Tray 1, Tray 2, Tray 3, or LCT

Vacuum Sol. (Duplex)Duplex vacuum solenoid

A3, 11 x 17, A4, 8 1/2 x 11, B4, 8 1/2 x 14, B5Duplex jogger and back fences, and right and left shield screens moveaccording to the paper size selected by the key.

5-06 Tracking test (1) The operation test of the OPC belttracking can be done.* The OPC belt traveling (tracking) timefrom the front and rear edge sensors ON(or OFF) to sensors OFF (or ON) isdisplayed. (The tracking motion iscontinued until the [OFF] key is pressed.)* OK is displayed if the traveling time is60 seconds or less, and NG is displayedif it is more than 60 seconds or thedifference in the timing from one side tothe other is more than 20 seconds.

(2) The tracking motor rotation time inseconds (half turn of the sector disk untilthe sector sensor activation) can bedisplayed.

Press [5-06] of the system test menu. ⇓Press the OPC motor [ON] key to do thetracking test. Press [Stop] to stop it.

Press the Tracking motor [ON] key todisplay the tracking motor rotation time.

5-07 Set staple position This function is set with user tool [11].


7-19

Technical Support

RTB 17 Tool 5-07 details.

7.7 Print Out


6 Print out The following data can be printed If theoptional printer and printer connector unitare installed.

NOTE:(1) A printer with a standard RS232Cinterface is required. Use the printer withfunctions as follows:Mode: AsynchronousData format: Start/Stop/Data bit: 1

bit eachData bit length: 8 bitsParity permission: WithParity setting: Even parityBaud rate setting: 1,200 bpsConnector: 25 pins, D-connector(2) If a Seiko printer DPU-411 is used,the dip switch settings are as follows(note that the setting of DIP02 SW1 isdifferent from that for the F200. The databit length for the F200 is 7 bits, and thatfor the F5 is 8 bits):SW1 to 8 of DIP01:OFF/OFF/OFF/ON/ON/OFF/ON/ONSW1 to 6 of DIP02: ON/OFF/OFF/OFF/ON/ON

Process Control: Data for service tool 4-01 to 4-03.Copies: Data for service tool 3-01 to 3-04.Misfeeds: Data for service tool 3-05 and 3-06.Service Calls: Data for service tool 3-07.Operation Time: Data for service tool 3-08.System Setup: Data for user tool no. 2, 3, 4, 6, 7, 8, 10,service tool 1-01 to 1-08, 2-01 to 2-16,4-04, 4-05, 5-02, 5-03, 5-07.All Items: All data for the above items.

Press [6] of the main menu. ⇓Select "Process Control/Copies/Misfeeds/Service Calls/ Operation Time/System Setup/All Items". ⇓Press "Start Print".

Print Out 1 July 1994

7-20

7.7.1 Setting the printer

NOTE

The printer interface board with the 4 nylon studsand holder, and the short and long printerharnesses are copier accessories.

1. Fully open the front door to access the maincontrol board.

2. Disconnect CN101 on the main control board.Then, connect the two harnesses and printerinterface board as shown in the illustration.

CAUTION

• Never disconnect CN101 before turning offthe main switch.

• Bind the grounding wire with vinyl tape toavoid possible damage to PCB’s. Thegrounding wire is necessary when theharness is used with the optional printerconnector.

• The bottom of the PCB holder is apermanent magnet. Stick it on the copierleft cover before turning on the main switchto avoid possible damage to PCB’s.

3. Connect the printer.

4. Turn on the main switch and access service tool[6] "Print Out". Then, press the appropriate key.

NOTE

The printer interface board, short printer harness,and 4 nylon studs are used when the optionalprinter connector unit is installed. Keep them foreach machine for future use.

Short printerharness

Vinyl tape

Printerinterface board

Printer

Long printerharness

1 July 1994 Print Out

7-21

7.8 Utility ModesUsing service tool [4-05], extra functions can be set. The following table shows condition of keys onthe screen for each function.

CAUTION

• Since the utility mode functions are notstandard to the machine, the customer’sapproval is required when they are set.

• Do not set any modes not mentioned in thetable below. The machine might not workproperly.

Mode No.Set No.

1 2 3 4 5

0 5-01 4-1 5-12 5-23 5-345678 3-89

10 1-10 2-101112 1-12131415

Mode No.Set No. of Mode No. 5

6 7 8 9 10 11 12 13 14

0 to 7 6-5-0 7-5-0 13-5-08 6-5-8 7-5-8 10-5-8 11-5-8 12-5-8 14-5-89 6-5-9 8-5-9 9-5-9 10-5-9 12-5-9 13-5-910 6-5-10 7-5-10 8-5-10 9-5-10 11-5-10 13-5-101112131415

NOTE

• The numbers in the table show the condition of each mode number. For example, "6-5-10" meansthat mode number 6 (which can be turned ON or OFF) is ON when mode number 5 (which can beset between 0 and 15) is set at 10. Refer to the following pages for details of each function.

• Modes 1 to 5 each have sixteen settings (numbered 0 to 15) that can be changed by pressing the\ keys. The desired function according to the set number can be set. Modes 6 to 14 do not haveset numbers, but they can be turned ON or OFF by pressing the number key. When the setting ofmode 5 is between 8 and 15, the functions for modes 6 to 14 are different. Refer to the lower tablefor modes 6 to 14.

Utility Modes 1 July 1994

7-22

Technical Support

RTB 35 Utilities 6-5-12 and 14-5-11 added.

1-10: Disables paper near-end indication

1-12: Clears all stored user programs

To clear the programs, the "0" key must be pressed after setting this mode.

2-10: Duplex speed-up mode

When the stack mode is selected with user tool 10 and one is entered for the copy set number inthe 2-sided copies from 2-sided original or single sided original mode (duplex mode), originals arecopied as follows:

The originals in ADF are fed twice. At the first feed, the even numbered originals are copied. Thecopies are stacked in the duplex tray. The originals are continuously fed again and the oddnumbers are copied on the back side of the copies from the duplex tray. This makes copying fasterthan in normal mode. If this mode is not selected, originals are copied as in the usual stack modeeven in the above copy mode.

3-8: Paper size erase mode

The machine selects the erase margins using the paper size to be copied, even in the ADF/SADFmodes. User program number 10 must be pressed when using this mode.

NOTE

Normally, the original size is used for erasing in the ADF/SADF modes. For example, when acomputer feed form is copied on A4 size paper using the SADF and reduction modes, the machinetakes the original size B4 size. This is because only the original width is detected in the SADF modeand the width of a computer feed form is close to that of B4 paper. As a result, the trailing part of theoriginal is erased and does not appear on the copy. In such a case, set this mode and select thenumber 10 key of the user program mode before a copy is made. Since the erase margins arematched with the paper size (A4 size in this case), the whole image of the computer feed form iscopied.

4-1: Original tray exit mode

In the ADF mode originals do not return to the original table, but fed out to the original table used inthe SADF mode. The originals are fed out without the reversing motion. This mode is not used withthe duplex and/or sort mode. When the original tray exit mode is selected, the duplex mode iscanceled and the stack mode is selected automatically. A new key, beside the Check mode key, toselect this function can be used. The position of the original stopper on the original table must becorrectly adjusted to the original width to use this mode.

NOTE

• When paper with holes is used as originals, the holes tend to be caught by the reverse junction pawlsand this makes an original jam. To prevent such case, this mode can be used.

• This mode can be set as an initial selection at power on. First, select this mode. Then, access servicetool [2-16] and press the Enter [#] key twice.

• This function is the same as the function in user tool [10].

5-0: SADF 50 cpm (Initial setting)5-1: SADF 34 cpm5-2: SADF 25 cpm5-3: SADF 20 cpm

Changes the copying speed in the SADF mode. The operator can select the most suitable timing ofthe SADF original feed to make the job faster.

1 July 1994 Utility Modes

7-23

Technical Support


6-5-0: Automatic sort selection

The machine automatically selects the shift tray ON mode when 2 or more for the copy set numberis entered in the ADF mode.

NOTE

At this mode, set originals in the ADF first and enter a copy set number so as not to select the shifttray ON mode.

6-5-8: Fusing jam indication

When a paper jam occurs, jam location indicators C and D (fusing jam) are always lit. This is todirect the operator to remove paper in the fusing unit. On some types of paper, it may be difficult tofeed out paper stopped in the fusing unit by the job recovery mode.

6-5-9: A3 double copy count

The mechanical copy counter (also the user code counter in user tool [9] if it is used) counts up 2when an A3 or 11"x17" size copy is made.

6-5-10: Automatic staple mode selection

Users can select to have the auto staple mode (1 upper staple) or shift tray ON mode selectedwhen the Finishing key in the free operator screen is selected.

7-5-0: 3-side full image mode

Copies with no erase margin can be made. (The leading edge erase margin is as in the normalcopy mode.) A new key, beside the Check modes key, to select the 3-side full image or normalcopy can be used.

NOTE:

• The 3-side full image mode is automatically selected at power ON when service tool 2-09 is set.

• This function is the same as the function in user tool [10].

7-5-8: Automatic APS selection

When originals are set in the ADF, the automatic paper selection mode is selected if a paper trayhas been selected.

7-5-10: Reverse back cover sheet

This mode is the same as that in the user tool [10] "User Utility."

8-5-9: Duplex tray maximum limit

The maximum number of copies stacked in the duplex tray can be changed. ON: 50 for A3, B4,11"x17", and 81/2x14" and 100 for A4, B5, 81/2"x11", and 8"1/2x13". OFF: 40/80.

8-5-10: Copy onto slip sheet

This mode is the same as that in the user tool [10] "User Utility."

9-5-10: Manual staple mode

Enables the use of the manual staple mode when originals are set in the single original feed modeor on the exposure glass. For understanding how to use the manual staple mode, refer to theoperating instructions.


7-24

Technical Support

RTB 35 Utiltiy 6-5-12 added. By setting utility 6-5-12 to ON, the copier disregards situations when the number of copies that the copier has made does not match the number of copies that the finisher has received.

10-5-8: Disable flash life notice

Disables the message indicating the flash lamp’s end of life (the notice of SC#17).

10-5-9: Valid 8 1/2"x13" Key

The 81/2"x13" and A4 keys are displayed in user tool [3] to select original and copy paper sizes.

11-5-8: Fusing rush current prevention

Rush current from the wall outlet is absorbed to prevent the circuit breaker for the wall outlet frombeing blown. This must be always ON.

11-5-10: Automatic paper feed out in manual staple mode

While copies are made in the manual staple mode, when this mode is selected and the number ofcopies stacked in the staple tray of the finisher exceeds the stack capacity set with service tool[2-07], the copies are automatically fed out from the jogger tray.

12-5-9: Disable cover/chaptering modes

The special features (cover/chaptering modes) are disabled.

13-5-0: Margin adjustment present memory

The present value of the margin adjustment mode is put in memory. As the value in memory iscleared by pressing the Clear Modes key or by the auto mode clear function, the auto mode clearfunction must be canceled using service tool [2-13].

13-5-9: Stapling with stack mode

Stapling with the stack mode is available.

13-5-10: Automatic accounting mode selection by auto reset

When security or normal accounting mode is selected with service tool [2-08], the copierautomatically leaves the copy mode and requires a user access code after the period set withservice tool [2-13].

14-5-8: Valid pre-heat key

By holding on the Clear Modes key for a while, all displays on the operation unit turn off.

1 July 1994 Utility Modes

7-25

Technical Support


Technical Support

RTB 20 Pre-heat did not work even if switched on, if a finisher mode is selected with [2-16]

Technical Support

RTB 35 Utility 14-5-11 added. By setting utility 14-5-11 to ON, the copier displays a prompt to enable the operator to carry out the OPC filming removal any time when 10,000 copies or more have been made when a copy run finishes.

Initial Setting Table

Mode No. Set No. Mode Name Initial Setting for Each Mode No.

1 10 Disables Paper Near-end Indication 012 Clears All Stored User Programs

2 10 Duplex Speed-up Mode 103 8 Paper Size Erase Mode 04 1 Original Tray Exit Mode 05 0 SADF 50 cpm 0

1 SADF 34 cpm2 SADF 25 cpm3 SADF 20 cpm

Mode No.(6 to 14)

Setting ofMode No. 5

Mode Name Initial Setting for Each Mode No.

6

0 to 7

Automatic Sort Selection OFF7 No Erase Copy Mode OFF8 Not used Must be OFF9 Not used Must be OFF10 Not used Must be OFF11 Not used Not valid12 not used Must be OFF13 Margin Adjustment Present Memory OFF14 Not used Must be OFF6

8

Fusing Jam Indication OFF7 Automatic APS Selection ON8 Not used Must be OFF9 Not used Must be OFF10 Disable Flash Life Notice OFF11 Fusing Rush Current Prevention ON12 Not used Not valid13 Not used Must be OFF14 Valid Pre-heat Key OFF6

9

A3 Double Copy Count OFF:Double Count Mode7 Not used Not valid8 Duplex Tray Maximum Limit OFF: 40 (A3)/80(A4)9 Not used Not valid10 Valid 81/2"x13" key ON11 Not used Must be OFF12 Disable Cover/Chaptering Modes OFF13 Stapling with Stack mode OFF14 Not used Not valid6

10

Automatic Staple Mode Selection OFF7 Reverse Back Cover Sheet ON8 Copy onto Slip Sheet ON9 Manual Staple Mode OFF10 Not used Must be OFF11 Automatic Paper Feed Out in Manual

Staple ModeOFF

12 Not used Must be OFF13 Automatic Accounting Mode Selection by

Auto ResetOFF

14 Not used Must be OFF


7-26

SECTION 8

TABLES FOR SELF-DIAGNOSTICS

8. TABLES FOR SELF-DIAGNOSTICS

There are two types of self-diagnostics for this machine: one is "Service call" and the other is "Error reset". When an Error reset occurs, the operation display advises theoperator to turn the main switch off and on in order to clear the error reset condition. If the problem does not happen again, the error reset condition is cleared. When aproblem that may cause serious damage to the machine is detected, a Service call occurs instead of Error reset. The operation display shows which status code is Indicated(SC1, SC2, SC3, SC4, SC17, or SC23).

When a Service call is displayed, the situation can be cleared by the following steps. This is to prevent the service call condition from being cleared by the customer, causingdamage to the machine.

How the service call condition is cleared

1. Enter the service tools access number with the number keys while a Service call is displayed.

2. Press the Clear/Stop key on the operation panel.

3. Enter "099" with the number keys.

4. Turn the main switch off and on.

8-1

Classification StatusCode

Item Symptom Possible Cause Remarks

Fusing SC1 Fusing high temperature The fusing roller stays at 230 °C ormore for 3 sec.

Thermistor short circuit, relay shortcircuit, defective interface board (0volt between TP3 and ground), ordefective main control board(unchanged low output fromCN103-2B).

Service call indication appears for thisstatus code.

SC2 Fusing low temperature The fusing roller is at 130 °C or less for20 seconds after the machine entersthe copy stand-by condition.

Fusing lamp broken, poor connectionof fusing lamp connector, thermistorcontrol failed, defective relay, or oneof the door safety switches (for thefront door, copy tray, and upper rightdoor) broken.


SC3 Fusing temperature not stabilized The fusing temperature does notreach 175°C within 10 minutes afterthe main switch is turned on.

Fusing lamp broken, thermistor shortcircuit, one of the door switches (forthe front door, copy tray, and upperright door) broken, defective relay, orblown fusing thermofuse.


SC4 Fusing thermistor open Fusing thermistor open or fusing unitconnector contact failure (fusing unitnot set properly).


8-2



High voltage SC10 Charge leak Both the charge corona and gridoutputs are stopped when the chargeoutput leak is detected. In this case,blank image copies may be madebefore the leak is detected. When the grid output leak is detected,only the grid output is stopped. In thiscase, black solid copies may be made.

Dirt on corona wire, endblock,terminal, or casing contaminated bytoner, paper powder, cleaning brushfiber, antistatic brush fiber, etc.

When this condition is detected for thefirst time, the paper misfeed indicator(location A) is indicated (stays ON)instead of the error reset display. (Incase of a real paper jam, the indicatorblinks, but it does not stay ON.) This isnot recorded as a paper misfeed inthe logging data, but is recorded as anSC in the service tool [3-07] screen.After that, an Error reset is indicated ifthe problem occurs more two times(three times total) in 100 continuouscopies.

SC11 Transfer leak The transfer corona output is stopped.In this case, blank or faint imagecopies may be made before the leakis detected.

SC12 Separation leak The separation corona output stopped.SC13 PCC leak The PCC output stopped. In this case,

a dirty background image due tocleaning failure may be appears oncopies before the leak is detected.

SC17 Life end of xenon lamp The flash output exceeds 28 steps(maximum output level for the full sizecopy mode). This can be seen on theservice tool [4-01] screen.

Worn xenon lamp. Otherwise,incorrect position of the xenon lamp ordirty mirrors, lens, reflectors, orblack-and-white pattern on the back ofthe original scale, Poor cooling for thexenon lamp and flash power supplyunit may also cause this symptom.


From when the flash output reaches28 steps, the message advising toreplace the xenon lamp appears onthe guidance display. The messageshows that 40,000 copies left can bemade. After that, the number that canbe made copies is changed and isdisplayed every 10,000 copies. Afterthe message is displayed the firsttime, if 50,000 copies are made, SC#17 is displayed. To clear the message, the flash outputmust be lowered under 20 steps.Then, carry out 50 or more flashesfree run in service tool [4-01].

8-3



Development SC20 Toner collection error Due to an overload of the used tonercollecting coil drive, the sensing diskconnected with the coil drive does notturn the cleaning coil sensor on andoff at a certain interval. the cleaningsensor’s ON/OFF count is 17 or lessfor 5 seconds, and this continues for15 seconds.

Overloard of the used toner collectingcoil drive due to toner block.Otherwise, the vinyl sheet on thetoner cartridge shutter maybe was notpulled off properly at the cartridgereplacement, and some amount ofnew toner remains in the cartridge. Inthis case, used toner cannot becharged in the cartridge sufficientlyand this causes coil drive overload.

SC22 Toner density sensor error The difference in the toner densitysensor output levels between beforeand after the toner quick supply mode(continues for 2 minutes) is 0.12 voltsor less.

Defective toner density sensor ortoner density control board.

SC23 Paper on the development unit Paper comes between the OPC beltand development unit.

After a paper jam occurs and the frontdoor is opened, the ID sensormeasures the OPC surface (V SGmeasurement). The ID sensormeasures the OPC surface againafter closing the front door (the jam iscleared). SC #23 will be displayed ifpaper comes on the ID sensor andthere is 0.5 volts or more difference inthe ID sensor measurement betweenbefore and after closing the front door.

At that time, the measured ID sensoroutput (VSG) must be 4.0 volts ormore. This is to prevent mis-detectiondue to operation error for the normalID sensor control.

When an operator opens the frontdoor and releases the transport unit(TS/ corona unit) to remove thejammed paper, the paper theremistakenly falls and goes into thedevelopment units side.


8-4



Drive SC30 OPC motor error No encoder signal from the OPCmotor.

Defective motor or main/OPC motordrive board (0 volt between CN6-3and CN6-1), or one of the door safetyswitches (for the front door, copy tray,and upper right door) maybe broken.

SC31 Main or OPC motor overload An over current of 1.2A or more flowsinto the OPC motor continuously for 2seconds or longer, or an over currentof 5A or more flows into the mainmotor continuously for 2 seconds orlonger.

Overload of the motor or load side,defective motor, or defectivemain/OPC motor drive board (0 voltbetween CN4-1 and CN4-2).

For the main motor overload, LED 3on the main/OPC motor drive boardturns on. LED 4 turns on for the OPCmotor overload.

SC32 Development motor overload When current of 5A or more flows intothe development motor continuouslyfor 2 seconds or longer.

Overload of the motor or load side,defective motor, or defectivedevelopment DC power supply unit.

SC33 ADF original feed motor error No encoder pulse from the motor for100 milliseconds.

Overload of the motor or load side,defective motor, defective ADF controlboard, defective ADF DC powersupply unit, or ADF upper cover safetyswitch broken.

When this condition is detected, theoriginal misfeed indicator stays ON onthe operation display. (In case of areal jam, the indicator blinks.) This isnot recorded as a misfeed in thelodding data, but is recorded as an SCin the service tool [3-07] screen. Afterthat, an Error reset is indicated if theproblem occurs more three times (fourtimes total).

SC34 ADF transport motor errorSC35 ADF reverse motor error

SC36 Tracking motor error No signal from the sector sensor isoutput within 10 seconds from whentracking motor ON signal is produced.

Overload of the motor or load side,defective motor, or defective sectorsensor.

Optics SC40 Flash over charge Flash power outputs 2100 ± 50 voltsor more. (Signal output after charge)

Defective flash power supply unit.

SC41 No flash lighting No flash detection signal is outputduring copying at an certain flashtiming. A blank copy is made in thiscase.

The xenon lamp or lamp trigger wirebroken or poor contact of theconnectors. Otherwise, defective flashpower supply unit or triggertransformer. Poor cooling for thexenon lamp and flash power supplyunit may also cause this problem.

SC42 Flash safety switch open or blownflash thermofuse

The flash safety switch broken, blownflash (xenon lamp) thermofuse, orpoor cooling for the xenon lamp andflash power supply unit.

SC43 Mirror/lens drive error The magnification sensor is notactivated within 5 seconds from whenthe mirror lens motor starts turning.

Overload of the motor or load side ordefective motor, magnification sensor,paper feed control board, ormirror/lens drive board.

SC44 Left shield screen error From when the Start key is pressed,the shield home position sensor is notactivated within 3 seconds.

Defective home position sensor,shield motor, paper feed controlboard, or mirror/lens drive board orscreen drive error.

SC45 Right shield screen error

8-5

Technical Support

SC35 RTB 24: Causes and solutions



Imaging process SC50 OPC home mark detection error The OPC home mark sensor stays onlonger than normal. The OPC homemark, which should be 6 mm in theforward direction, is detected as 20mm or more.

Defective OPC home mark sensor orthere is flaw related to the OPC homemark.

SC51 No OPC home mark The OPC home mark sensor stays off.The OPC home mark does not comewithin one belt cycle.

Dirty OPC home mark sensor surface,dirty home mark surface, or trackingoperation error.

SC52 Wire cleaner drive error The lock signal (detection signal forthe cleaner hitting the endblock) is notproduced within 30 seconds fromwhen the motor starts turning.

Defective motor or drive board ordisconnected connector.

Even when this condition is detected,Error reset # 52 is not displayed.However, the status code is recordedin the logging data of the service tools.

SC55 OPC motor drive error at OPCcleaning mode

During the OPC cleaning operation,no encoder pulse is produced fromthe OPC motor. The OPC cleaning isstopped and the copier enters thecopy standby condition. At the nextpower ON, the OPC cleaning is triedagain and the same procedure isrepeated.

Overload of the OPC motor due to anabnormal operation of the OPCcleaning brush roller, defective OPCmotor, or defective main/OPC motordrive board.

Even when this condition is detected,Error reset # 55 is not displayed.However, the status code is recordedin the logging data of the service tools.

Paper feed SC60 First tray drive error When the tray motor rotatescontinuously for 20 seconds or more,there is no output from the papervolume sensor.

Overload of the tray motor or loadside, defective tray motor, upper limitsensor, paper set sensor,k or traymotor DC drive board, or the tray liftwire broken.

SC61 Second tray drive error Same as above. Same as above.SC62 Third tray drive error Same as above. Same as above.SC63 Large capacity tray (LCT) drive error Same as above. Overload of the tray motor or load

side, defective tray motor, upper limitsensor, paper end sensor, overrunswitch, or LCT control board, or thetray lift chain broken.

SC64 LCT back fenced drive error When the back fence doesn’t return tothe home position within 5 seconds.

Drive belt slid off or defective homeposition sensor (unchanged lowoutput form CN302-9B on the paperfeed control board).

Duplex SC70 Jogger (side) fences drive error The home position sensor is notactivated within a certain period.

Overload of the fence drive motor orload side, defective motor, homeposition sensor, paper feed controlboard, jogger motor drive board, ortiming belt slid off.

SC71 Back fence drive error

8-6

Technical Support

SC60 RTB 33: Possible cause

Technical Support


Technical Support


Technical Support


Technical Support

RTB 35 Information about SC55



Control SC80 Paper feed signal transmission error A communication error from the mainboard.

Optics fiber cable disconnected ordefective main control board or paperfeed control board.

SC81 Paper feed signal receiving error

SC82 Operation unit transmission error Same as above. Optics fiber cable disconnected ordefective main control board oroperation unit.

If SC82 is displayed, there is apossibility of CPU malfunction and ofthe machine going out of control. Thebeeper sound instructs the customerto turn off the main switch or to callthe service representative.

SC83 Operation unit receiving error

SC84 ADF signal transmission error Same as above. Optics fiber cable disconnected ordefective main control board or ADFcontrol board.

SC85 ADF signal receiving error

SC88 Sequencer error Sequencer fails to respond. Defective main control board.SC89 Total counter error No count signal is produced. Defective counter or DC driver board

or disconnected connector.SC90 Process control data error Defective main control board or

battery short on the main controlboard.

SC91 Non-volatile memory error Voltage of the backup battery dropsbelow 2.5 volts or less.

Worn battery. Normally, the batteryvoltage is approximately 3 volts.

SC93 Wait/busy signal error A wait or busy signal from the finisherstays generated for more than 25seconds.

Defective finisher or inverter controlboard.

SC94 Signal transmission error from thefinisher

After the copier CPU sends a statusrequest signal to the finisher, there isno response signal from the finisherfor more than 10 seconds.

Optics fiber cable disconnected, ordefective copier main, finisher, orinverter control board.

SC95 Motor drive error 1 A status that the finisher cannot makecopies in both shift tray and staplemodes due to a defective motor isdetected.

Defective inverter or finisher transportmotor, shift tray lift motor, exit drivemotor, stopper drive motor, or theirrelated sensor.

SC96 Motor drive error 2 A status that the finisher cannot makecopies in shift tray mode due to adefective shift motor is detected.

Defective shift motor or shift tray halfturn sensor.

SC97 Motor drive error 3 A status that the finisher cannot makecopies in staple mode due to adefective motor is detected.

Defective jogger, stapler drive, staple,stack feed-out, or inverter stopperdrive motor, or their related sensor.

SC98 Non-volatile memory drive error Defective non-volatile memory on themain board.

Defective main control board.

SC99 Control system error A communication error between thecopier and ADF, LCT, or finisher.

Defective main control board, invertercontrol board, LCT control board, orADF control board.

8-7

Technical Support

SC99 RTB 20: False occurrence of SC99 RTB 27: Causes RTB 33: More causes RTB 35: Other possible causes

Technical Support

SC94 RTB 26: Possible cause and solution RTB 35: Another possible cause

Technical Support

SC80 RTB 27: Causes

Technical Support

SC81 RTB 27: Causes

Technical Support

SC84 RTB 33: Causes

SECTION 9

SERVICE REMARKS

9. SERVICE REMARKS

The following pages contains remarks for common situations. Be sure to follow all warnings,cautions, and notes described in this manual, including those not described in this section.

9.1 Machine Installation

1. Select the environment conditions as described in "1.1.2 Environment."

2. To avoid unnecessary service calls, explain the items described in "1.5 User GuidanceItems" to the customer before installing the machine.

3. Use the following cautions for the copier installation:

• When the optional finisher is not used, the sub-tray must be ordered and used.

• Distribute the cleaning carrier evenly by turning the knob. The cleaning unit has no agitation mechanism as thedevelopment unit does.

• Be sure to return the developer from the development roller to the inside of the unit before pulling out the OPC unit.Do this by turning the development knob.

• Never remove the oil supply unit from the fusing unit to prevent oil marks on copies. It can be removed only whenthe oil blade, metering blade, and oil supply felt are replaced with new ones.

• The machine is set up for a 400 volts 3-phase power supply (European version) or 240 volts single phase powersupply (U.S.A. version) at the production line. To install the machine in areas where the power supply is 380 or415 volts (220 or 230 volts single phase), be sure to follow steps 28 to 32 described in "1.2 Copier Installation."

• Using a level gauge, level the machine flat on the floor. This is mainly to prevent affecting the tracking operationof the OPC belt.

• When inch size originals are used, make a slot to stop the original stopper at the 81/2 inch position. When the slotis made, operating cautions must be instructed to operators, so that operators can adjust the original stopperposition correctly according to the original size set in the ADF. If the original stopper position is not proper becausethe A4 position and 81/2 inch position are very close, original misfeeds will occur.

• Before making copies, carry out forming for the developer, OPC belt, and cleaning carrier (in this order) usingservice tool [3-04].

• Before checking copy image quality, check the toner density control data in the service tool [4-02] screen. Performsetting C if the data is not correct. Also, check the AID reference voltage in the [4-03] screen using the PC-1 chart.Perform setting A if the value is not correct. (If the AID reference voltage is within the standard, you do not haveto perform setting A.)

• The side-to-side registration must be checked for all paper trays.

• The erase margin and duplex side fence width must be checked for all paper sizes.

• If the erase margin is not sufficient, thin black lines may sometimes appear on copies (especially on the side edgesof copies in the ADF mode). This is because the side-to-side registration varies slightly on each copy if an operatordoes not set the original side guides securely. You have to make more than 10 copies and check that all of themare within specifications after the adjustment.

• Check the side-to-side registration of the back side of the copy in the duplex mode before installing the peripherals.If the value is outside specifications, you have to remove the copier right cover.

• Explain all user tool items and some of the service tools to the customer. Then, listen to the customer’s requestsand set the copier accordingly. Keep the set items using the format described in "1.6 Setting User and ServiceTools." (If the main control board is replaced, you can set all items again using the format.)

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1. Use the foolowing cautions for the peripheralinstallations:

• When you install the horizontal transport unit (LCT accessory) in the copier, while holding down the small whiteroller of the upper left guide plate, tighten the lock lever assembly. Be sure that the lock lever bracket pushes downthe upper left guide plate when it is locked.

• Align the position of the LCT and finisher with the copier. This is to prevent paper misfeeds where the units connect.For details, refer to their installation procedure explanations.

• The optical fiber cable connectors must be set to the sockets properly as they have the setting direction.

• The printer interface board, printer harness, 2 connector joint studs, and 4 nylon studs, which are the copier’saccessories, are required for the printer connector unit installation.

9.2 Paper Feed Section• Do not touch the feed, reverse, and pick-up roller surfaces with bare hands.

• Install the feed roller in the correct direction as it has a one-way clutch built-in.

• Because the torque limit pressure is properly adjusted, do not loosen the torque limiter stopper screws.

• Because the side-to-side registration adjustment mechanism is also provided on the original side (ADF and SADF), makeadjustments for each tray on the basis of the platen cover mode.

• When you adjust the leading edge or side-to-side registration, be sure to set the paper side guides of the paper traysecurely.

9.3 Optics Section• Every 200K and at every visit, clean the exposure glass using glass cleaner or alcohol. Then wipe with silicon oil. Wiping

the exposure glass with silicon oil helps transport originals more smoothly and prevent original misfeeds caused by staticelectricity. Wipe the mylar strips on the original transport path for the same reason.

• If the cooling air flow to the xenon lamp and flash power supply unit becomes low, the flash voltage step will exceed 28earlier than normal. Be sure to clean the air filters every PM.

• Working near the lamp is dangerous. Never work near the lamp without turning off the main switch and waiting at least 1minute for discharge.

• To avoid wiring problems of high voltage parts, never disassemble the connector going to the xenon lamp.

• Take care and check the position of the harness going to the xenon lamp.

• To avoid xenon lamp damage, firmly fit the xenon lamp connectors to the sockets. Push each connector end with yourfingers, then tighten two screws.

• Be sure to wire the three flash power source lines correctly, the white wire (from the trigger transformer), red line and blackline from the top. If wired incorrectly, the lamp may burn up.

• When reinstalling the xenon lamp in the unit, position the lamp exactly. If the position is not correct, the life time of thelamp might be reduced. Insufficient light intensity will increase the lamp voltage repidly due to process control.

• Normally adjusting the uneven illuminance is prohibited. It seems difficult to return the illuminace to the original setting ifyou change the position of the front and rear reflectors.

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9.4 Safety Notices for Flash Power SupplyHigh voltages of 1,070 to 2,000 V are applied to the xenon lamp (flash lamp) to produce lightimmediately. Therefore, working near the xenon lamp is dangerous after removing the exposureglass. Never work near the lamp without turning off the main switch and waiting at least 1 minute fordischarge.

Conditions for discharge of the flash powerFor safety purpose, the power charged to light the xenon lamp is discharged under the followingconditions:

(1) When a "Service Call" or "Error Reset" condition is detected and the machine is stopped during copying or operating with the free run mode in the service tools.

(2) When an original or copy paper jam occurs and the machine is stopped during copying or operating with the free run mode in the service tools.

(3) When any doors are opened and the machine is stopped during copying or operating with the free run mode in the service tools.

NOTE

When the above three conditions happen, the machine is stopped after an extra flash. The flashpower is discharged immediately.

(4) When the main switch is turned off.

(5) When the "Dis" (the flash discharge) key in service tool [5-04] "I/O test mode" is pressed.

NOTE

When the above two conditions happen, the flash power is discharged by the discharge circuitbuilt-in the flash power supply unit. In this case, it takes approximately 1 minute to completedischarging.

CAUTION

Even in the copy stand-by condition, if the flash power is manually charged using the"Charge" key in service tool [5-04] "I/O test mode" or the charge key (blue push switch )installed in the flash power supply unit, be sure to discharge it by turning off the main switchor using the I/O test mode before accessing the xenon lamp.

9.5 OPC Unit• Set the OPC belt so the home mark is on the far side.

• Put far side of the OPC in the OPC sensor and set it in the center.

• Never touch the OPC surface, and position the OPC belt carefully to prevent bending it.

• Do not expose the OPC belt to daylight for more than a few minutes. When not installed, keep the OPC belt in its caseand store it in a cool, dark place. If copying is done while the exterior covers are off and in slight daylight, even after it isset in the copier, the copy image becomes extremely light.

• Never use alcohol or other chemicals to clean the OPC.

• Because the slide guides have sharp edges, keep them in the main body while servicing.

1 July 1994 Safety Notices for Flash Power Supply

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9.6 Potential Sensor• Blow air to remove toner and dust from the electrode of the potential sensor. To prevent clogging or jamming, do not use

a rag.

9.7 Charge, Pre-cleaning, and Transfer/Separation Corona Units• Clean the unit casings with water first to remove NOx. Then clean them with alcohol if any toner still remains on the casings.

• The corona wires can be cleaned only with a dry soft cloth. Using water or alcohol might damage the coating of the wiresurface.

9.8 Cleaning Unit• When you pull out the cleaning unit and turn the cleaning knob, toner will fall from the toner exit pipe of the unit. When

you do this, place a sheet under the toner exit pipe to prevent the OPC unit from becoming dirty by toner.

• Never put in cleaning carrier on the left side (scavenging roller side).

• The air filters have a setting direction. Be sure that the side with a red line on the edge is facing the inside of the unit.


• Lay paper in place where the cleaning unit is put. Be sure there is no metal debris present that can cause damage. Metalscrews, paper clips, etc. attracted by the cleaning roller can scratch the roller and blade.

• Because the cleaning unit has no horizontal agitating roller, do not tilt the unit when the cleaning carrier is in the unit.

• When the cleaning carrier is in the cleaning unit, do not turn the unit up side down.

9.9 Development Unit• When you use a vacuum cleaner to clean the development unit, heavy electrostatic will occur. To avoid damage of electrical

parts, be sure to do the following:

(1) Pull out the toner density control board.

(2) Disconnect the harness from the ID sensor board and ground the board using the development unit grounding harness (copier accessory).

• Collect the developer by turning the development knob before pulling out the unit. It might scatter, or damage the OPC.

• The air filter has a setting direction. Be sure that the side with a red line on the edge is facing the inside of the unit.

• Clean the developer around the air filter case as the place is very close to the OPC surface. If this is not done, the OPCmay be damaged.

• Do not lubricate the sleeve gears and the other gears in the development unit to avoid toner adhering to the gears. Lubricatethe two projections of the unit drive joint roller with a small amount of G-40M when the unit does not slide in the main bodysmoothly.

• No developer should be allowed to fall on the toner density control board. Otherwise the board might be damaged.


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9.10 Fusing Unit• After the oil supply unit is removed and reinstalled, oil marks might appear on copies. This is due to the toner built up on

the edges of the blades. If this occurs, replace the fusing blade, metering blade, and oil supply pad with new ones as aset.

• To avoid spilling the silicon oil, do not tilt the unit.

• Fit the oil supply pad and soak it with silicon oil so its surface is coated sufficiently. If coating is not sufficient, the fusingroller will be damaged.

• Clean the oil pan using a dry cloth every 200K copies. At the same time, check the oil hoses, drains in the oil pan, oil exitfrom the unit, and oil receiver of the main body side to make sure that the oil passes through smoothly.

• If inside of the oil tube going to the oil tank becomes very dirty, the tube might clog and oil might overflow from the oilreceiver. If the oil does not pass through smoothly, replace the tube with a new one. At the same time, clean or replacethe oil tank with a new one to prevent dirty oil from circulating. If paper generating a lot of paper dust is used, replace thetube and oil tank every 1,000K copies.

• To prevent damage of parts, grasp the front grip and rear upper edge of the unit frame when you lift the unit.

• Be careful as there is a projection for the oil returning guide at the bottom of the unit. Set the oil returning guide aside fromthe work table.

• Do not touch the heater glass surface and handle it carefully to prevent damage.

• Do not adjust the fusing temperature when referring the value displayed on the service tool [5-03] screen. It does notshown the actual fusing temperature. The displayed value shows what fusing temperature the CPU takes at the moment.The displayed value will return to the standard value a few minutes later.


9.11 Duplex/Exit Unit• Do not move the side fences manually. The timing belt behind the fences might slip out of the pulleys.

• Avoid touching the surface of new duplex feed and reverse rollers.

• Because the torque limit pressure is properly adjusted, do not loosen the torque limiter stopper Allen screws.

• When reinstalling the lock lever assembly of the horizontal transport unit, be sure that the assembly completely locks theupper guide plates and that the lock lever bracket pushes down the upper left paper guide plate of the unit. Otherwise,paper misfeeds might occur there.

• Before this adjustment, you should finish the adjustments of the side-to-side registrations in the front side copy for all papertrays.

9.12 ADF• The ADF rear cover is made of metal. So, the cover may touch electric elements on the boards shoring them out when

you remove the cover. Be sure to turn off the main switch when you remove the ADF rear cover.

• Before adjusting the side-to-side registration in the ADF/SADF modes, adjust the side-to-side registrations for all papertrays and for the front and back side copies.

• Before adjusting the leading edge registration in the ADF/SADF modes, adjust the leading edge registrations in the platen(not ADF and SADF) mode.


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9.13 User and Service Tools• The data for the user and service tools will be cleared if the main control board is replaced. Write down the set data and

use it in that case. The data in user tool [1] "Total sheets copied", [9] "User access code", service tools [3-01] to [3-07]must be cleared in order to reset RAM on the main control board and start up the use of these modes.

• The "Actual Target T.D." value shown in service tool [4-02] is changed in a range of ± 0.74 volts from the "Setting TargetT.D." value according to the ID sensor output. Therefore, if the "Setting Target T.D." is abnormal, a proper level of thetarget to control the toner density might not be obtained. Do not press the "Developer Forming "key in service tool [4-02]without carrying out setting C. (The "Developer Forming" key in service tool [3-04] does not change the "Setting TargetT.D.")

• Since the utility mode functions are not standard to the machine, the customer’s approval is required when they are set.

• Do not set any modes not mentioned in the utility mode table. The machine might not work properly.

9.14 LCT• Do not touch the surface of the new rollers with bear hands.

• Be sure that the feed roller has the setting direction.

• Check the side-to-side registration of the copies from the LCT when the LCT is removed and installed. The side-to-sideregistration will be changed in that case.

9.15 Others• Golden screws (zinc plated) in all locations show a location adjusted during assembly. Therefore, pay attention to how

the screw is set originally before you start working. When the screw is loosened, adjustment is required.

User and Service Tools 1 July 1994

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