ft9101 (f5) field service manual - diagramas dediagramas.diagramasde.com/otros/ricoh...
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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
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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.)
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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
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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
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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
Copier Installation 1 July 1994
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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
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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
Copier Installation 1 July 1994
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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
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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
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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 July 1994 Copier Installation
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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
Copier Installation 1 July 1994
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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 July 1994 Copier Installation
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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
Copier Installation 1 July 1994
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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
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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
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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
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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
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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
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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
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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
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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
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
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.
Logging Data Sheet 1 July 1994
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
Logging Data Sheet 1 July 1994
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
1.8.2 Removing the clamps
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
LCT Installation 1 July 1994
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 July 1994 LCT Installation
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
LCT Installation 1 July 1994
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 July 1994 LCT Installation
1-35
1.9 Finisher Installation
1.9.1 Accessories list
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
1.9.2 Removing the clamps
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
Finisher Installation 1 July 1994
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 July 1994 Finisher Installation
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
Finisher Installation 1 July 1994
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 July 1994 Finisher Installation
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
Finisher Installation 1 July 1994
1-42
1.10 Printer Installation
1.10.1 Accessories list
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
7. Philips Plated Screw - M3 x 6 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
2. Philips Plated Screw - M4 x 8 1
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]
1 July 1994 Paper Feed
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
Paper Feed 1 July 1994
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)
1 July 1994 Paper Feed
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
1. Turn off the main switch.
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
Paper Feed 1 July 1994
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.
5. Turn the lever to release the development backuproller of the OPC unit.
6. Remove the development unit fixing plate (onescrew), and slightly pull out the unit to disengagethe joint gear at the rear of the unit.
7. Turn the development knob to collect thedeveloper on the development sleeve.
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
1 July 1994 Paper Feed
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.
2. Turn off the main switch.
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
Paper Feed 1 July 1994
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
1 July 1994 Paper Feed
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.
24. Turn the lever to release the development backuproller of the OPC unit.
25. Remove the development unit fixing plate (onescrew), and slightly pull out the unit to disengagethe joint gear at the rear of the unit.
26. Turn the development knob to collect thedeveloper on the development sleeve.
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
Paper Feed 1 July 1994
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
1 July 1994 Paper Feed
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
Paper Feed 1 July 1994
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.
1 July 1994 Paper Feed
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.
1. Turn off the main switch.
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.
1. Turn off the main switch.
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.
5. 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.
2.2.5 Replacing and cleaning the 2nd mirror
PM cycle: Clean as necessary at PM
1. Turn off the main switch.
2. Remove the left cover (2 screws).
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.)
6. 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.
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
1. Turn off the main switch.
2. Remove the left cover (2 screws).
3. Open the front door and remove two screws toallow it to open further.
4. Remove the inner cover (2 screws and oneconnector).
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.
1. Turn off the main switch.
2. Remove the left cover (2 screws).
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
PM cycle: Replace every 200K
1. Turn off the main switch.
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
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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
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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
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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.
Belt tension standard
Adjust by moving the OPC motor.
2 mm deflection at 200 ± 50 g pressure.
Fixing bracket
Sector sensorTrackingmotor
QL stabilizer
Tracking slider
OPC motor
OPC sensor
Drive roller
Drive belt
Set screw
2 mm
200 ± 50 g
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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
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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
1. Access service tool [5-06].
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
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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.
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).
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
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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
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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
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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
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Replacing the transport belt and roller
PM cycle: Clean every 600K
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
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2.5.3 Replacing the transfer entrance guide mylar
PM cycle: Replace every 800K
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
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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
PM cycle: Replace every 400K
1. Turn off the main switch. Open the front door, and
remove 2 screws to allow it to open further.
2. Remove the inner cover (2 screws and oneconnector).
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
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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.
13. Assemble in the reverse order.
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
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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.
7. Assemble in the reverse order.
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
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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.
4. Assemble in the reverse order.
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
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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
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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.
12. Reassemble in the reverse order.
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
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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
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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.
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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.
1. Turn off the main switch.
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.
6. Reassemble in the reverse order.
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
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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.
7. Reassemble in the reverse order.
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.
4. Reassemble in the reverse order.
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.
4. Reassemble in the reverse order.
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
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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).
1. Turn off the main switch.
2. Open the front door, and remove two screws toallow it to open further.
3. Remove the inner cover (2 screws and oneconnector).
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.
7. Slide out the development unit.
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
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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.
16. Reassemble in the reverse order.
17. Turn on the main switch and wait for the machinestand-by.
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
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2.8.2 Cleaning the toner vessel
PM cycle: Clean every 1,000K
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
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2.8.3 Replacing the development sleeves
1. Pull out and remove the development unit.
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.
8. Reassemble in the reverse order.
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
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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
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2.8.4 Replacing parts in the toner hopper
Removing the toner hopper
1. Pull out and remove the development unit.
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.
10. Reassemble in the reverse order.
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
1. Remove the toner hopper.
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
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Replacing the toner supply roller
1. Remove the toner hopper.
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.
2. Remove the toner hopper.
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.
5. Reassemble in the reverse order.
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.
6. Turn on the main switch and wait for the machinestand-by.
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
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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.
5. Reassemble in the reverse order.
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
1. Slide out the development unit.
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.
5. Turn on the main switch and wait for the machinestand-by.
6. Access service tool [4-02] and carry out setting C.
Development joint
Development motor
Developmentmotor bracket
Development joint
Development motor bracket
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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
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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
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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.
14. Reassemble in the reverse order.
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
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• 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
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2.9.2 Replacing the oil pump tube
PM cycle: Replace every 800K
1. Press the tray lowering keys for the 2nd and 3rdpaper tray. Then, pull out the paper trays.
2. Turn off the main switch, and open the front door.
3. Remove the lower vertical transport inner cover (3 screws).
4. Remove the oil pump tube and replace it.
5. Reassemble in the reverse order.
2.9.3 Removing the fusing unit
1. Turn off the main switch, and open the front door.
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.
5. Reassemble in the reverse order.
Oil pump tube
Fusing unitfixing screw
Front grip
Heater holder
Heater connector
Inner cover
Heater
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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.
9. Reassemble in the reverse order.
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
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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.
8. Reassemble in the reverse order.
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
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2.9.7 Replacing the fusing pick-off pawls
PM cycle: Clean every 200K
1. Turn off the main switch, and open the front door.
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.
9. Reassemble in the reverse order.
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
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2.9.8 Replacing the thermofuse and thermistor
PM cycle: Clean the thermistor every400K.
1. Turn off the main switch, and open the front door.
2. Slide out the fusing unit.
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
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2.9.9 Adjusting the fusing temperature
CAUTION
When the main control board is replaced, thefollowing procedure should be carried out:
1. Turn off the main switch, and open the front door.
2. Slide out the fusing unit.
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).
12. Access service tool [5-03].
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
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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
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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]
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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.
10. Reassemble in the reverse order.
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
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2.10.2 Replacing the copy tray sensor
1. Turn off the main switch, and open the copy tray.
2. Remove the sensor bracket at the rear left cornerof the paper exit unit (2 screws).
3. Remove and replace the sensor.
4. Reassemble in the reverse order.
2.10.3 Replacing the duplex exit sensor
PM cycle: Clean every 400K
1. Turn off the main switch.
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.
5. Reassemble in the reverse order.
WARNING
Be careful of the sharp edges around the bracketand bracket fixing stay.
2.10.4 Replacing the fusing exit sensor
1. Turn off the main switch.
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.
6. Reassemble in the reverse order.
[Rear left corner ofthe duplex/exit unit]
Sensor bracket
Copy traysensor
Duplex exit sensor
Knob
Duplex exitsensor bracket
Fusing exit sensor
Fusing exit sensor
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2.10.5 Replacing the upper and lower duplex paper end sensors
PM cycle: Clean every 400K
1. Turn off the main switch, and open the copy tray.
2. Raise the exit transport guide.
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
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2.10.6 Removing the tray upper cover
1. Turn off the main switch, and open the copy tray.
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.
4. Reassemble in the reverse order.
2.10.8 Replacing the duplex entrance junction sensor
1. Turn off the main switch, and remove the tray
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
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2.10.9 Replacing the eject tray sensor
1. Turn off the main switch, and remove the tray
upper cover.
2. Remove the eject tray sensor (2 screws).
3. Replace the sensor, and reassemble in thereverse order.
2.10.10 Replacing the eject junction sensor
1. Turn off the main switch, and remove the tray
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).
7. Replace the sensor, and reassemble in thereverse order.
Eject tray sensor
Copy tray
Upper cover stay Copy traybracket
Grip bracket
Eject junction sensor
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2.10.11 Replacing the upper and lower duplex feed sensors
PM cycle: Clean every 400K
1. Turn off the main switch, and open the copy tray.
2. Raise the exit transport guide.
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
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2.10.12 Replacing the duplex entrance junction solenoid
1. Turn off the main switch, and open the copy tray.
2. Raise the exit transport guide.
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
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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
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2.10.15 Replacing the 2nd fusing cooling blower
1. Turn off the main switch, and open the front door.
2. Slide out the fusing unit, and remove it (onestepped screw).
3. Open the copy tray.
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.
7. Reassemble in the reverse order.
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
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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
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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).
8. Reassemble in the reverse order.
Belt tension standards
• Back fence belt
3 mm deflection at 20 ± 10 g pressure.
• 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
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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).
8. Open the copy tray.
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
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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
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Belt tension standard
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)
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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].
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2.11 ADF
2.11.1 Replacing the transport belt
PM cycle: Replace every 600K
1. Turn off the main switch.
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
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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.
5. Reassemble in the reverse order.
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
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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
1. Remove the original table and vacuum belt unit.
2. Remove the vacuum belts.
3. Remove the sensors (one screw and connectoreach), and replace them.
Replacing the 1st transport sensor
1. Remove the original table and vacuum belt unit.
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
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2.11.4 Replacing parts under the original end fence unit
Follow this procedure to replace these items:
• 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.
3. Reassemble in the reverse order.
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.
3. Remove the ADF front cover (3 plated screws onthe top and 4 on the bottom).
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.
9. Replace the sensor, and reassemble in thereverse order.
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
Follow this procedure to replace these items:
• 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)
5. Remove the ADF front cover (3 plated screws onthe top and 4 on the bottom).
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
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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.
3. Reassemble in the reverse order.
Recycle arm Recycle armsolenoid
Auti-staticbrush
Solenoid fixing screws
6.5 mm
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2.11.6 Replacing the feed, transport and reverse motors
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 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
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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
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2.11.7 Replacing the original feed magnetic clutch
Turn off the main switch, and remove the ADF rearcover (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.
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.
• Do not pull the fiber optics cable when youdisconnect it from the ADF control board.Grasp its connector using pliers and pull itout.
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
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2.11.8 Replacing the ADF blower motor
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 upper casing (4 screws).
3. Disassemble the blower unit and replace the motor.
4. Reassemble in the reverse order.
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
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 control board.
3. Remove the solenoid (2 screws) and replace it.
4. Reassemble in the reverse order.
Solenoid position standard
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
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 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.
• 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.
5. Reassemble in the reverse order.
CAUTION
• The lift switch must be turned on and off bythe actuator when the ADF is opened andclosed.
Solenoid position standard
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
2-96
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
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 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.
• 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 harness bracket (2 screws).
4. Remove the solenoid (2 screws) and replace it.
5. Reassemble in the reverse order.
Solenoid position standard
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
2-97
2.11.12 Replacing the reverse junction solenoid
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 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.
• Do not pull the fiber optics cable when youdisconnect it from the ADF control board.Grasp its connector using pliers and pull itout.
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.
Solenoid position standard
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
2-98
2.11.13 Removing the intermediate transport unit
1. Turn off the main switch, and remove the ADF rearcover (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 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.
• 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 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.
7. Reassemble in the reverse order.
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
1 July 1994 ADF
2-99
2.11.14 Removing the ADF unit
WARNING
Due to the weight of the unit, two operators arerequired for this procedure.
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 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
2-100
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
2-101
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
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.
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
1. Turn on DIP switches 101-1, 2 and 4 on the ADF
control board.
2. Turn on DIP switch 100-2. The motor will startrotating.
3. After the transport motor is turned on, adjustVR100 to light LED112.
Adjusting the speed of the reverse motor
1. Turn on DIP switches 101-1, 2 and 4 on the ADF
control board.
2. Turn on DIP switch 100-3. The motor will startrotating.
3. After the reverse motor is turned on, adjust VR101to light LED 112.
1 July 1994 ADF
2-103
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.
1. Turn on DIP switches 101-1, 2 and 4 on the ADF
control board.
2. Turn on DIP switch 100-4. The motor will startrotating.
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
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.
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
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.
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
2-106
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
2-107
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
2-109
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
2-110
2.12 Operation unit
2.12.1 Removing the operation unit
1. Turn off the main switch.
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.
5. Reassemble in the reverse order.
CAUTION
Remember the original locations for each ROMwhen you remove the ROM’s.
Operation unit
ROM board
Dismount pawl
1 July 1994 Operation unit
2-111
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.
8. Reassemble in the reverse order.
2.13.2 Replacing the vacuum fan
1. Turn off the main switch and remove the rear left
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.
5. Reassemble in the reverse order.
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
1. Turn off the main switch and remove the rear left
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.
5. Reassemble in the reverse order.
2.13.5 Replacing the front and upper right door switches
1. Turn off the main switch.
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.
5. Reassemble in the reverse order.
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
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. 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.
6. Reassemble in the reverse order.
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.
8. Reassemble in the reverse order.
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
2-115
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.
8. Reassemble in the reverse order.
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
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2.14.4 Replacing the paper end sensor
PM cycle: Clean every 1,000K
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.
6. Reassemble in the reverse order.
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
1. Pull out the tray, and turn off the main switch.
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)
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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.
5. Reassemble in the reverse order.
2.14.7 Replacing the back fence motor
1. Pull out the tray, and turn off the main switch.
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).
5. Reassemble in the reverse order.
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.
4. Reassemble in the reverse order.
Lower transport guide
Transport sensorTransport roller
Stud
Sensor cover
Back fence
Drive beltMotorconnector Back fence
motor
Motorpulley
LCT control board
Lower frontcover
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2.14.9 Replacing the paper feed magnetic clutch
1. Pull out the tray, and turn off the main switch.
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.
8. Reassemble in the reverse order.
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
1. Pull out the tray, and turn off the main switch.
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.
9. Reassemble in the reverse order.
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]
1 July 1994 Finisher
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2.15.3 Removing the staple unit
1. Turn the main switch off and unplug the copier.
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
1. Turn the main switch off and unplug the copier.
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
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2.15.5 Removing the jogger drive belt
1. Turn the main switch off and unplug the copier.
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
1. Turn the main switch off and unplug the copier.
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]
1 July 1994 Finisher
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2.15.8 Removing the sensors
Stack height sensors
1. Turn the main switch off and unplug the copier.
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
1. Turn the main switch off and unplug the copier.
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
1. Turn the main switch off and unplug the copier.
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]
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Shift tray half turn sensor
1. Turn the main switch off and unplug the copier.
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
1. Turn the main switch off and unplug the copier.
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
1. Turn the main switch off and unplug the copier.
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
1 July 1994 Finisher
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2.15.10 Replacing the inverter guide brush roller
PM cycle: Replace every 2,000K
1. Turn the main switch off and unplug the copier.
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
1. Turn the main switch off and unplug the copier.
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]
Finisher 1 July 1994
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2.15.12 Adjusting the inverter junction gate solenoid position
1. Turn the main switch off and unplug the copier.
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
1. Turn the main switch off and unplug the copier.
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]
1 July 1994 Finisher
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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]
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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.
Standard: 2 mm deflection at 40 ± 20 g pressure.
[A, B]
[a, b]
[D]
[E]
[F]
[B]
[A]
[C]
[H]
[C]
[c]
[G]
1 July 1994 Finisher
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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]
Finisher 1 July 1994
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6. Remove the inverter rear cover and adjust the belt[J] tension with the tightener [j].
Standard: 6 mm deflection at 100 ± 30 g pressure.
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]
1 July 1994 Finisher
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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
Finisher 1 July 1994
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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.
3.4.1 Test point table
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
3.8.1 Test point table
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
C C C C C C C Wipe with dry cloth
Front and rearsliders
L L L G-40M
4-1
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
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
C C C C C C C C C C C C C C C Water
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
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
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
C C C C C C C C C C C C C C C Water
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
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
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
C C C C C C C Wipe with dry cloth
Vertical transportdrive timing belt
A
All transport rollers C C C Water
4-4
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
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
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
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
All transport rollers C C C Water
4-6
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
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
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
5-2
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
5-3
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
5-4
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.
3. Access service tool [4-01].
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.
1. Select the [4-01] screen.
2. Press the Process Control OFF key, then press the ON key to reset all shift steps to 0.
3. Select 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.)
2. Select the [4-01] screen.
3. Press the Process Control OFF key, then press the ON key to reset all shift steps to 0.
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
5-8
Flash and grid steps setting
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.
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.)
4. Access service tool [4-01].
5. Press the Process Control OFF key, then press the ON key to reset all shift steps to 0.
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
5-9
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.
1. Turn ON the main switch and wait for the copy stand-by condition.
2. Access service tool [4-02].
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
5-10
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
Item Description Setting Method
(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
Item Description Setting Method
(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.
1 July 1994 TABLE OF USER TOOLS
6-3
Item Description Setting Method
(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.
TABLE OF USER TOOLS 1 July 1994
6-4
Item Description Setting Method
(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.
1 July 1994 TABLE OF USER TOOLS
6-5
Item Description Setting Method
(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
TABLE OF USER TOOLS 1 July 1994
6-6
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
Item Description Setting Method
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
Item Description Setting Method
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.
Initial setting: 99900
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
7.3 User Functions
Item Description Setting Method
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
Item Description Setting Method
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
Item Description Setting Method
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.
1 July 1994 User Functions
7-5
Item Description Setting Method
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".
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Item Description Setting Method
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).
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Item Description Setting Method
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.
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Item Description Setting Method
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.
Initial setting: 300
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
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7.4 Data Logging
Item Description Setting Method
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
* Up to 8 digits are displayed.
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.
* Clearing dataPress Clear key. ⇓Select "YES (clear the data)/NO".
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Item Description Setting Method
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.
* Clearing dataPress Clear key. ⇓Select "YES (clear the data)/NO".
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)
* Up to 4 digits are displayed.
Press [3-05] of the data logging menu. ⇓Move the page by Next/Prev.
* Clearing dataPress Clear key. ⇓Select "YES (clear the data)/NO".
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)
* Up to 4 digits are displayed.
Press [3-06] of the data logging menu. ⇓Move the page by Next/Prev.
* Clearing dataPress Clear key. ⇓Select "YES (clear the data)/NO".
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Item Description Setting Method
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.)
* Clearing dataPress Clear key. ⇓Select "YES (clear the data)/NO".
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.
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7.5 Process Control
Item Description Setting Method
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.
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7.6 System Test
Item Description Setting Method
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.
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Item Description Setting Method
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.
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Item Description Setting Method
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.
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Item Description Setting Method
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
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Item Description Setting Method
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
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Item Description Setting Method
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].
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7.7 Print Out
Item Description Setting Method
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".
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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
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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.
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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
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.
Utility Modes 1 July 1994
7-24
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
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
Utility Modes 1 July 1994
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.
Service call indication appears for thisstatus code.
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.
Service call indication appears for thisstatus code.
SC4 Fusing thermistor open Fusing thermistor open or fusing unitconnector contact failure (fusing unitnot set properly).
Service call indication appears for thisstatus code.
8-2
Classification StatusCode
Item Symptom Possible Cause Remarks
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.
Service call indication appears for thisstatus code.
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
Classification StatusCode
Item Symptom Possible Cause Remarks
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.
Service call indication appears for thisstatus code.
8-4
Classification StatusCode
Item Symptom Possible Cause Remarks
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
Classification StatusCode
Item Symptom Possible Cause Remarks
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
Classification StatusCode
Item Symptom Possible Cause Remarks
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
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.)
1 July 1994 Machine Installation
9-1
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.
Paper Feed Section 1 July 1994
9-2
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
9-3
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.
• Because the slide guides have sharp edges, keep them in the main body while servicing.
• 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.
• Because the slide guides have sharp edges, keep them in the main body while servicing.
Potential Sensor 1 July 1994
9-4
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.
• Because the slide guides have sharp edges, keep them in the main body while servicing.
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.
1 July 1994 Fusing Unit
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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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