Gestetner A193, A224 Service Manual

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SERVICE MANUAL

PN: RCPC0200

A193/A224

RICOH GROUP COMPANIES

SERVICE MANUAL

A193/A224

RICOH GROUP COMPANIES

A193/A224

SERVICE MANUAL

PN: RCSM0200

It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies.

NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY

FASHION AND DISTRIBUTED WITHOUT THE PRIOR

PERMISSION OF RICOH CORPORATION.

All product names, domain names or product illustrations, including desktop images, used in this document are trademarks, registered trademarks or the property of their respective companies.

They are used throughout this book in an informational or editorial fashion only and for the benefit of such companies. No such use, or the use of any trade name, or web site is intended to convey endorsement or other affiliation with Ricoh products.



The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program.

Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property or loss of warranty protection.

Ricoh Corporation

WARNING

LEGEND

PRODUCT CODE COMPANY

GESTETNER RICOH SAVIN

A193 3220 AFICIO 200 9920DP A224 3225 AFICIO 250 9925DP

DOCUMENTATION HISTORY

REV. NO. DATE COMMENTS

11/96 Original Prin tin g 1 1/97 A661 Additi on 2 4/97 A666 Additi on 3 7/97 A224 Additi on

Table of Contents

COPIER

A193 OVERALL MACHINE INFORMATION

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. MACHINE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

3. PAPER PATH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

4. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 1-6

5. ELECTRICAL COMPONENT DESCRIPTIONS. . . . . . . . . . . . . . . . 1-8

6. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

7. COPY PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

7.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

8. BOARD STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

8.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

8.2 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

A193 DETAILED DESCRIPTIONS

1. SCANNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.2 SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

1.3 ORIGINAL SIZE DETECTION IN PLATEN MODE . . . . . . . . . . . . . . . . . . . . . 2-3

2. IMAGE PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.2 SBU (SENSOR BOARD UNIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.3 AUTO IMAGE DENSITY (ADS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.4 IPU (IMAGE PROCESSING UNIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.4.2 Image Processing Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.4.3 Auto Shading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.4.4 Filtering and Main Scan Magnification/Reduction. . . . . . . . . . . . . . . . . . . 2-11

2.4.5 Gamma (γ) Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.4.6 Gradation Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.4.7 Line Width Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5 MSU (MEMORY SUPER-CHARGER UNIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

TOC i A193

2.6 FCI (FINE CHARACTER AND IMAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

3. LASER EXPOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

3.2 OPTICAL PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

3.3 GRADATION CONTROL (LASER POWER MODULATION). . . . . . . . . . . . . . 2-20

3.4 AUTO POWER CONTROL (APC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

3.5 LD SAFETY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

4. PCU (PHOTOCONDUCTOR UNIT). . . . . . . . . . . . . . . . . . . . . . . . 2-23

4.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

4.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

4.3 NEW PCU DETECTION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

4.4 DRUM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

4.4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

4.4.2 Charge Roller Contact Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

4.4.3 Drum Charge Roller Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

4.4.4 Temperature Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

4.5 DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

4.5.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

4.5.2 Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

4.5.3 Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

4.5.4 Development Bias. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

4.5.5 Toner Density Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

4.5.6 Toner Supply in Abnormal sensor Conditions . . . . . . . . . . . . . . . . . . . . . 2-37

4.5.7 Toner Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

4.6 DRUM CLEANING AND TONER RECYCLING. . . . . . . . . . . . . . . . . . . . . . . . 2-42

4.6.1 Drum Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

4.6.2 Toner Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

5. PAPER FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

5.2 PAPER TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

5.2.1 Paper Feed Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

5.2.2 Paper Lift Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

5.2.3 Paper End Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

5.2.4 Side Fence Double Stopper Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

5.2.5 Paper Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

A193 ii TOC

5.3 BY-PASS FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

5.3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

5.3.2 Paper Feed Mechanism and Paper End Detection . . . . . . . . . . . . . . . . . 2-51

5.3.3 By-pass Feed Paper Width Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

5.4 PAPER REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

6. IMAGE TRANSFER AND PAPER SEPARATION. . . . . . . . . . . . . 2-54

6.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

6.2 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM . . . . . . . . . . 2-55

6.3 ROLLER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

6.4 PAPER SEPARATION AND TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . 2-57

7. IMAGE FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

7.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

7.2 FUSING DRIVE AND RELEASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . 2-59

7.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . 2-60

7.4 PRESSURE ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

7.5 CLEANING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

7.6 FUSING TEMPERATURE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

7.7 OVERHEAT PROTECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

8. ENERGY SAVER MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

8.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

8.2 COPIER ONLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

8.3 COPIER/PRINTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

8.4 COPIER/FAX, COPIER/PRINTER/FAX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

8.5 ENERGY SAVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

8.6 ENERGY SAVER TIMING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

9. PAPER EXIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

INSTALLATION PROCEDURE (A193)

1. INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.1 ENVIRONMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.2 MACHINE LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.3 MINIMUM SPACE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.4 POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

2. COPIER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

2.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

TOC iii A193

2.2 COPIER INSTALLATION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

2.3 AUTO DOCUMENT FEEDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

2.4 PAPER TRAY UNIT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

2.5 DUPLEX UNIT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

2.6 1-BIN SORTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

2.7 MEMORY BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

2.8 KEY COUNTER HOLDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

2.9 ANTI-CONDENSATION HEATER INSTALLATION. . . . . . . . . . . . . . . . . . . . . 3-21

2.10 TRAY HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

2.11 TRAY HEATER (OPTIONAL PAPER TRAY UNIT) . . . . . . . . . . . . . . . . . . . . 3-23

A193 SERVICE TABLES

1. SERVICE REMARKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -1

1.1 GENERAL CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.2 PCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.3 TRANSFER ROLLER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.4 SCANNER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.5 LASER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.6 FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.7 PAPER FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

1.8 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

2. SERVICE PROGRAM MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

2.1 SERVICE PROGRAM MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

2.1.1 Service Program Access Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

2.1.2 Accessing Copy Mode from within an SP Mode. . . . . . . . . . . . . . . . . . . . . 4-4

2.1.3 How to select the program number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

2.1.4 To Input a Value or Setting for an SP Mode . . . . . . . . . . . . . . . . . . . . . . . 4-5

2.2 SERVICE PROGRAM MODE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

2.2.1 Main SP Mode Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

2.2.2 Test Pattern Printing (SP 5-902). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

2.2.3 Input Check (SP5-803). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

2.2.4 Output Check (SP5-804) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

2.2.5 Copy Jam History Display (SP7-903). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

2.2.6 Original Jam History Display (SP7-905). . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

2.2.7 System Parameter And Data Lists (SP5-992) . . . . . . . . . . . . . . . . . . . . . 4-39

A193 iv TOC

2.2.8 Memory All Clear (SP5-801). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

2.2.9 Program Download. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

3. USER PROGRAM MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

3.1 HOW TO ENTER AND EXIT UP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

4. SWITCHES/LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

4.1 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

4.2 LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

4.3 TEST PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

5. SPECIAL TOOLS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . 4-44

5.1 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

6. PREVENTIVE MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . 4-45

6.1 PM TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

7. SERVICE PROGRAM MODE TABLE . . . . . . . . . . . . . . . . . . . . . . 4-47

7.1 SERVICE PROGRAM TABLE INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

7.2 COPIER USER TOOLS/PRINTER TOOLS/FAX SERVICE MODES . . . . . . . 4-53

A193 REPLACEMENT AND ADJUSTMENT

1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.1 FRONT COVER/INNER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.2 REAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

1.3 LEFT/RIGHT COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

1.4 EXPOSURE GLASS/OPERATION PANEL/UPPER COVER . . . . . . . . . . . . . . 5-3

2. PHOTOCONDUCTOR UNIT (PCU). . . . . . . . . . . . . . . . . . . . . . . . . 5-4

2.1 PCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

2.2 DRUM CHARGE ROLLER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

2.3 DRUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

2.4 CLEANING BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

3. TRANSFER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

3.1 TRANSFER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

3.2 TRANSFER ROLLER/SEPARATION UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

4. SCANNER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

4.1 LENS COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

4.2 SCANNER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

4.3 ORIGINAL SIZE SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Rev. 08/98

TOC v A193

4.4 LENS BLOCK/SBU ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

4.5 XENON LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

4.6 SCANNER H. P. SENSOR/PLATEN COVER SENSOR . . . . . . . . . . . . . . . . . 5-14

4.7 SCANNER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

4.8 SCANNER WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5. LASER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.1 LASER UNIT/MAIN SCAN SYNCHRONIZATION DETECTOR . . . . . . . . . . . 5-19

5.2 POLYGON MIRROR MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5.3 LD UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5.4 LASER UNIT POSITIONING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

6. FUSING/EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

6.1 HOT ROLLER STRIPPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

6.2 FUSING THERMISTOR/THERMOFUSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

6.3 HOT ROLLER/FUSING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

6.4 PRESSURE ROLLER/CLEANING ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

7. EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

7.1 EXIT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

7.2 UPPER EXIT SENSOR/LOWER EXIT SENSOR . . . . . . . . . . . . . . . . . . . . . . 5-27

8. PAPER FEED/ REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

8.1 BY-PASS FEED TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

8.2 BY-PASS FEED PAPER END SENSOR/REGISTRATION SENSOR. . . . . . . 5-29

8.3 PAPER FEED ROLLER/FRICTION PAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

8.4 BY-PASS FEED PAPER WIDTH SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

8.5 PAPER FEED ROLLERS/PAPER SIZE DETECTOR . . . . . . . . . . . . . . . . . . . 5-31

8.5.1 Paper Feed Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

8.5.2 Paper Size Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

8.6 PAPER END SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

8.7 PAPER FEED CLUTCHES/RELAY CLUTCHES. . . . . . . . . . . . . . . . . . . . . . . 5-33

8.8 RELAY SENSOR/RIGHT VERTICAL GUIDE SWITCH. . . . . . . . . . . . . . . . . . 5-34

9. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

9.1 IOCSS BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

9.2 MSU BOARD/BICU BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

9.3 PSU BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

10. STANDARD WHITE DENSITY ADJUSTMENT. . . . . . . . . . . . . . 5-38

Rev. 08/98

A193 vi TOC

11. COPY ADJUSTMENT PRINTING/SCANNING . . . . . . . . . . . . . . 5-39

11.1 PRINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

11.1.1 Registration - Leading Edge/Side-to-Side . . . . . . . . . . . . . . . . . . . . . . 5-39

11.1.2 Blank Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

11.1.3 Main Scan Magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

11.1.4 Double Copy Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

11.2 SCANNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

11.2.1 Registration: Platen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

11.2.2 Magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

11.3 ADF IMAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

11.3.1 Registration and Blank Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

11.3.2 Sub Scan Magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

12. IMAGE DENSITY ADJUSTMENT BY KEY OPERATOR . . . . . . 5-44

A193 TROUBLESHOOTING

1. SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1.1 SUMMARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

2. SC CODE DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

3. ELECTRICAL COMPONENT DEFECTS. . . . . . . . . . . . . . . . . . . . 6-11

3.1 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

3.2 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

4. BLOWN FUSE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

5. ROM MODIFICATION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

DOCUMENT FEEDER A628

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

2. COMPONENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

2.1 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

2.2 ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

2.3 ELECTRICAL COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

2.4 DRIVE LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

3. DETAILED DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

3.1 ORIGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

3.2 PICK-OFF AND SEPARATION MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Rev. 08/98

TOC vii A193

3.3 ORIGINAL TRANSPORT AND EXIT MECHANISM . . . . . . . . . . . . . . . . . . . . . 7-9

3.4 STAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

3.5 TIMING CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

3.5.1 A4 Lengthwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

3.5.2 A4 Sideways (Stamper Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

3.6 OVERALL ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

4. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 7-14

4.1 ORIGINAL FEED UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

4.2 SEPARATION ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

4.3 PICK-UP ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

4.4 FEED BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

4.5 ORIGINAL SET SENSOR AND WIDTH SENSOR REPLACEMENT . . . . . . . 7-18

4.6 DF COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

4.7 DF FEED COVER OPEN , DF POSITION, AND APS START SENSOR

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

4.8 ORIGINAL LENGTH SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 7-21

4.9 DF FEED CLUTCH AND DF PICK-UP SOLENOID REPLACEMENT. . . . . . . 7-22

4.10 REGISTRATION SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 7-23

4.11 STAMPER SOLENOID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

4.12 SP MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

PAPER TRAY UNIT G697

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

2. COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

2.1 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

2.2 ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

2.3 ELECTRICAL COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

2.4 DRIVE LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

3. DETAILED DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

3.1 PAPER FEED AND TRAY LIFT/LOWER MECHANISM . . . . . . . . . . . . . . . . . . 8-6

3.2 TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

3.3 OVERALL ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

4. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 8-9

4.1 EXTERIOR COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

4.2 PAPER FEED ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Rev. 08/98

A193 viii TOC

4.3 PAPER FEED AND RELAY CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . 8-11

4.4 PAPER FEED MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

4.5 LIFT MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

4.6 PAPER END AND UPPER LIMIT SENSOR REPLACEMENT . . . . . . . . . . . . 8-13

4.7 UPPER RELAY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

4.8 LOWER RELAY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

4.9 PAPER SIZE SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

4.10 TRAY COVER SWITCH REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

DUPLEX G694

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

2. COMPONENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

2.1 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

2.2 ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

2.3 ELECTRICAL COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

3. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

4. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

4.1 A3 PAPER SIZE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

4.2 SHORTER THAN A4 LENGTHWISE (MEMORY COPY) 8 Original (



)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

5. DETAILED DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

5.1 DUPLEX JUNCTION GATE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

5.2 PAPER TRANSPORT AND FEED MECHANISM . . . . . . . . . . . . . . . . . . . . . . 9-13

5.3 TIMING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

5.3.1 A3 (without memory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

5.3.2 A4 sideways (Memory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

5.4 OVERALL ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

6. DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

6.1 DUPLEX CONTROL BOARD : DSW1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

7. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 9-18

7.1 DUPLEX TRANSPORT UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

7.2 DUPLEX TRANSPORT AND FEED MOTOR REPLACEMENT . . . . . . . . . . . 9-19

7.3 DUPLEX TURN AND DUPLEX EXIT SENSORS . . . . . . . . . . . . . . . . . . . . . . 9-19

7.4 DUPLEX JUNCTION GATE SOLENOID AND DUPLEX ENTRANCE

SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

Rev. 08/98

TOC ix A193

1-BIN SORTER A629

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

2. COMPONENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

2.1 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

2.2 ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

2.3 ELECTRICAL COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 10-4

2.4 DRIVE LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

3. DETAILED DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

3.1 BIN JUNCTION GATE AND PAPER TRANSPORT MECHANISM. . . . . . . . . 10-6

3.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

3.3 TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

3.4 OVERALL ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

4. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 10-9

4.1 BIN JUNCTION GATE SOLENOID, TRANSPORT MOTOR AND SORTER

DRIVE BOARD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

4.2 BIN PAPER SENSOR AND INDICATOR REPLACEMENT . . . . . . . . . . . . . 10-10

AUTO REVERSE DOCUMENT FEEDER A661

1. OVERALL MACHINE INFORMATION . . . . . . . . . . . . . . . . . . . . . 11 -1

1.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

1.2 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

1.3 ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

1.4 ELECTRICAL COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 11-4

1.5 DRIVE LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

2. DETAILED DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

2.1 ORIGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

2.2 PICK-OFF AND SEPARATION MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . 11-8

2.3 ORIGINAL TRANSPORT AND EXIT MECHANISM . . . . . . . . . . . . . . . . . . . . 11-9

2.3.1 Single-sided Original. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

2.3.2 Double-sided Original. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

2.4 STAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

2.5 TIMING CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13

2.5.1 LT Sideways (Single-sided Original Mode). . . . . . . . . . . . . . . . . . . . . . . 11-13

2.5.2 LT Sideways-Stamper Mode (Single-sided Original Mode) . . . . . . . . . . 11-14

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A193 x TOC

2.5.3 LT Sideways (Double-sided Original Mode). . . . . . . . . . . . . . . . . . . . . . 11-15

2.5.4 LT Sideways-Stamper Mode (Double-sided Original Mode) . . . . . . . . . 11-16

2.6 JAM DETECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-17

2.7 OVERALL ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18

3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19

4. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22

5. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 11-23

5.1 ORIGINAL FEED UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23

5.2 SEPARATION ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24

5.3 PICK-UP ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25

5.4 FEED BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26

5.5 ORIGINAL SET SENSOR AND WIDTH SENSOR REPLACEMENT . . . . . . 11-27

5.6 DF COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28

5.7 DF FEED COVER OPEN , DF POSITION, AND APS START SENSOR

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29

5.8 ORIGINAL LENGTH SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 11-30

5.9 DF FEED CLUTCH, DF PICK-UP SOLENOID, AND JUNCTION

SOLENOID GATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31

5.10 REGISTRATION SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 11-32

5.11 ORIGINAL EXIT SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . 11-33

5.12 STAMPER SOLENOID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34

FINISHER A666

1. OVERALL MACHINE INFORMATION . . . . . . . . . . . . . . . . . . . . . 12 -1

1.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

1.2 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

1.3 ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

1.4 ELECTRICAL COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 12-4

1.5 DRIVE LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

2. DETAILED DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

2.1 JUNCTION GATE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

2.2 PAPER REVERSING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

2.3 JOGGER UNIT PAPER POSITIONING MECHANISM . . . . . . . . . . . . . . . . . . 12-8

2.4 STAPLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9

2.5 FEED OUT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10

2.6 SHIFT TRAY UP/DOWN MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11

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TOC xi A193

2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . 12-12

2.8 TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

2.8.1 Face-up Mode (A4: 2 sheets). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

2.8.2 Face-down Mode (A4: 2 sheets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

2.8.3 Staple Mode (A4: 2 sheets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15

2.8.4 Jam Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16

2.8.5 Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17

3. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18

4. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21

5. SERVICE TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

5.1 LED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

5.2 DIP SWITCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

5.2.1 Factory Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

5.2.2 Stapling Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

5.2.3 Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

5.2.4 FREE RUN WITHOUT PAPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23

6. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 12-24

6.1 EXTERIOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24

6.2 ALIGNMENT BRUSH ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 12-25

6.3 BELT TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

6.4 STACK HEIGHT SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . 12-27

6.5 EXIT SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

6.6 INVERTER SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29

A224 COPIER

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

2. MACHINE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5

3. ELECTRICAL COMPONENT DESCRIPTIONS. . . . . . . . . . . . . . . 13-6

4. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9

5. COPY PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10

5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10

6. MAIN SCAN MAGNIFICATION/REDUCTION. . . . . . . . . . . . . . . 1 3-1 1

7. LASER EXPOSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12

7.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12

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A193 xii TOC

7.2 OPTICAL PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12

8. PAPER FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13

8.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13

8.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14

9. PAPER SEPARATION AND TRANSPORT. . . . . . . . . . . . . . . . . 13-14

10. IMAGE FUSIN G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15

10.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15

10.2 PRESSURE ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16

10.3 FUSING UNIT FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17

10.4 FUSING TEMPERATURE CONTROL AND OVERHEAT PROTECTION. . 13-18

11. ENERGY SAVER MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-19

12. SERVICE PROGRAM MODE TABLE . . . . . . . . . . . . . . . . . . . . 13-20

12.1 MAIN SP MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20

12.1.1 Input Check (SP5-803) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-49

12.1.2 Output Check (SP5-804). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-53

13. PREVENTIVE MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . 13-55

13.1 PM TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-55

14. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . 13-57

14.1 LASER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-57

14.2 LASER UNIT/MAIN SCAN SYNCHRONIZATION DETECTOR . . . . . . . . . 13-58

14.3 POLYGON MIRROR MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-59

14.4 POLYGON MOTOR DRIVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60

14.5 FUSING THERMISTOR/FUSING EDGE THERMISTOR . . . . . . . . . . . . . . 13-61

14.6 FUSING UNIT FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-62

15. SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 13-63

15.1 SUMMARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63

16. SC CODE DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-64

17. ROM MODIFICA TION HISTROY . . . . . . . . . . . . . . . . . . . . . . . . 13-77

LARGE CAPACITY TRAY A667

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

2. COMPONENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

2.1 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

2.2 ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3

2.3 ELECTRICAL COMPONENT DESCRIPTIONS. . . . . . . . . . . . . . . . . . . . . . . . 14-4

Rev. 08/98

TOC xiii A193

2.4 DRIVE LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5

3. DETAILED SECTION DEACRIPTION. . . . . . . . . . . . . . . . . . . . . . 14-6

3.1 PAPER LIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6

3.2 PAPER FEED MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7

3.3 PAPER NEAR END/END DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8

3.4 PAPER FEED TIMING AND JAM DETECTION . . . . . . . . . . . . . . . . . . . . . . 14-10

4. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11

4.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11

4.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11

4.3 PAPER SIZE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

5. PREVENTIVE MAINTENANCE TABLE . . . . . . . . . . . . . . . . . . . 14-16

6. SERVICE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16

6.1 TEST POINT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16

6.2 FUSE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16

7. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 14-17

7.1 EXTERIOR COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17

7.2 PAPER FEED ROLLER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18

7.3 TRAY LIFT MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19

7.4 PAPER FEED MOTOR AND TRNSPORT MOTOR . . . . . . . . . . . . . . . . . . . 14-20

7.5 PAPER SIZE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-20

7.6 LOWER LIMIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21

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A193 xiv TOC

Table of Contents

FAX

OVERALL MACHINE INFORMATION A639

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. FEATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2.1 FEATURES LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2.2 CAPABILITIES OF PROGRAMMABLE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2.3 POSSIBLE COMBINATIONS OF OPTIONAL IC CARDS . . . . . . . . . . . . . . . . . 1-6

3. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -7

3.1 SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

3.2 POWER DISTRIBUTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

3.3 MEMORY BACK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

4.VIDEO DATA PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

4.1 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

4.2 RECEPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

DETAILED SECTION DESCRIPTIONS A639

1. AUTOMATIC SERVICE CALLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.2 PERIODIC SERVICE CALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

1.3 PM CALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

1.4 EFFECTIVE TERM OF SERVICE CALLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2. PARALLEL MEMORY TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 2-4

3. TRANSFER BROADCASTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

4. ORIGINAL SCAN PROCESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

4.1 MAIN SCAN DIRECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

4.2 SUB SCAN DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

5. PAGE SPLIT TRANSMISSION (BOOK TRANSMISSION). . . . . . 2-10

6. IMAGE ROTATION BEFORE TRANSMISSION . . . . . . . . . . . . . . 2-11

7. SMOOTHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

8. PAPER SIZE SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

8.1 WIDTH PRIORITY AND LENGTH PRIORITY . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

TOC i A193

8.2 IMAGE ROTATION BEFORE PRINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

8.3 SUB SCAN REDUCTION AND PAGE SEPARATION. . . . . . . . . . . . . . . . . . . 2-14

8.4 PAGE REDUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

8.5 TWO IN ONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

8.6 PAPER SIZE SELECTION PRIORITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

9. TWO-SIDED (DUPLEX) PRINTING. . . . . . . . . . . . . . . . . . . . . . . . 2-25

10. PCBs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

10.1 FCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

10.2 NCU (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

10.3 NCU (Europe/Asia). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

10.4 NCU (France). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

INSTALLATION A639

1. FAX UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.1 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.2 INITIAL PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

2. ISDN G4 UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

2.1 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

2.2 INITIAL PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3. HARD DISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.1 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.2 INITIAL PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4. HANDSET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

4.1 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

5. IC CARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

5.1 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

5.2 ITEMS INITIALIZED WHEN FUNCTION UPGRADE CARD IS INSTALLED OR

REMOVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

SERVICE TABLES AND PROCEDURES A639

1. SERVICE LEVEL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.1 HOW TO ENTER AND EXIT THE FAX SERVICE MODE. . . . . . . . . . . . . . . . . 4-1

1.2 BIT SWITCH PROGRAMMING (FUNCTION 01). . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.3 SYSTEM PARAMETER LISTS (FUNCTION 02). . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.4 ROM VERSION DISPLAY (FUNCTION 02). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

A193 ii TOC

1.5 ERROR CODE DISPLAY (FUNCTION 03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

1.6 SERVICE MONITOR REPORT (FUNCTION 04). . . . . . . . . . . . . . . . . . . . . . . . 4-5

1.7 G3 PROTOCOL DUMP LIST (FUNCTION 05) . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

1.8 G4 PROTOCOL DUMP LIST (FUNCTION 05) . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

1.9 RAM DISPLAY AND REWRITE (FUNCTION 06) . . . . . . . . . . . . . . . . . . . . . . . 4-6

1.10 NCU PARAMETERS (FUNCTION 06). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

1.11 RAM DUMP (FUNCTION 06). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

1.12 RAM CLEAR (FUNCTION 07) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

1.13 HARD DISK (FUNCTION 08). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

1.14 SERVICE STATION FAX NUMBER (FUNCTION 09) . . . . . . . . . . . . . . . . . . . 4-8

1.15 SERIAL NUMBER (FUNCTION 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

1.16 MODEM TEST (FUNCTION 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

1.17 DTMF TEST (FUNCTION 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

1.18 MODEM SIGNAL DETECTION TEST (FUNCTION 11) . . . . . . . . . . . . . . . . 4-10

1.19 RINGER TEST (FUNCTION 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

1.20 STAMP TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

1.21 G4 PARAMETER PROGRAMMING (FUNCTION 12). . . . . . . . . . . . . . . . . . 4-11

1.22 FILE PRINTOUT (FUNCTION 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

1.23 TCR/JOURNAL PRINTOUT (FUNCTION 14) . . . . . . . . . . . . . . . . . . . . . . . . 4-11

1.24 USAGE LOG PRINTOUT (FUNCTION 15) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

1.25 SOFTWARE DOWNLOAD (FUNCTION 16) . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

1.26 SOFTWARE UPLOAD (FUNCTION 16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

1.27 SRAM DATA DOWNLOAD (FUNCTION 16) . . . . . . . . . . . . . . . . . . . . . . . . 4-16

2. BIT SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

2.1 SYSTEM SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

2.2 SCANNER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

2.3 PRINTER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

2.4 COMMUNICATION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

2.5 G3 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

3. NCU PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

4. DEDICATED TRANSMISSION PARAMETERS . . . . . . . . . . . . . . 4-63

4.1 PROGRAMMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

4.2 PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

TOC iii A193

5. SERVICE RAM ADDRESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

6. SPECIAL TOOLS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . 4-77

7. SERVICE PROGRAM / BIT SWITCH TABLE INDEX. . . . . . . . . . 4-79

REMOVAL AND REPLACEMENT A639

1. PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

2. NCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

3. FCU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

TROUBLESHOOTING A639

1. ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

2. FAX SC CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

2.1 SC1201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

2.2 SC1701. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

2.3 FAX SC CODE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

3. ROM MODIFICATION HISTORY. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

FAX UNIT A804

1. OVERALL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

1.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

1.2 OVERALL MACHINE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

2. DETAILED DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

2.1 DOUBLE-SIDED ORIGINAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

2.1.1 Portrait Original - Side Binding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

2.1.2 Portrait Original - Top Binding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

2.1.3 Landscape Original - Side Binding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

2.1.4 Landscape Original - Top Binding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

2.2 PAPER SIZE SELECTION PRIORITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

3.1 INITIAL PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

4. SERVICE TABLES AND PROCEDURE . . . . . . . . . . . . . . . . . . . . 7-21

4.1 BIT SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

4.1.1 System Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Rev. 08/98

A193 iv TOC

4.1.2 Printer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

4.2 RAM ADDRESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

5. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

5.1 SC681 (A224 Copier only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

5.2 OTHER POSSIBLE CASES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

5.2.1 Possible Cases and Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

5.2.2 When A804 Software is Downloaded to the A639 Fax Unit . . . . . . . . . . . 7-24

5.2.3 When A639 Software is Downloaded to the A804 Fax Unit . . . . . . . . . . . 7-24

6.0 ROM MODIFICATION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Rev. 08/98

TOC v A193

Table of Contents

ISDN

INSTALLATION A644

1. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 USER LEVEL PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 SERVICE LEVEL PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2. SWITCH SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.1 INTERNAL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.2 PARAMETER SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

SERVICE TABLES AND PROCEDURES A644

1. SERVICE LEVEL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2. BIT SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.1 G4 INTERNAL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 G4 PARAMETER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

3. DEDICATED TRANSMISSION PARAMETERS

TROUBLESHOOTING A644

1. ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.1. D-CHANNEL LAYER MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.2. D-CHANNEL, LAYER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.3. D-CHANNEL LINK LAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.4. D-CHANNEL NETWORK LAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

1.5. B-CHANNEL LINK LAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

1.6. B-CHANNEL NETWORK LAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

1.7. TRANSPORT LAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

1.8. SESSION LAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

1.9. DOCUMENT LAYER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

1.10. PRESENTATION LAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

2. G4CCU STATUS CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

2.1. LAYER 1 (PHYSICAL LAYER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

2.2. LAYER 2 (LINK LAYER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

2.3. NETWORK LAYER (LAYER 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

2.4. TRANSPORT LAYER (LAYER 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

A193 i TOC

2.5. SESSION LAYER, SESSION CONTROL LAYER (LAYER 5) . . . . . . . . . . . . . 3-8

2.6. SESSION LAYER, DOCUMENT CONTROL LAYER

(LAYER 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3. LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

4. BACK-TO-BACK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

APPENDIX A A644

1. D-Channel Layer 1 Dump List . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

1.1. How to Print the Dump List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

1.2. How to Read the Dump List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

1.2.1. Data Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

1.2.2. Reading the Sample Dump List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

1.2.3. Layer 1 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

1. Activation Procedure from the TE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

2. Activation Procesure from the NT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

3. Termination Procedure from the NT . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

APPENDIX B A644

1. G4 Parameter Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

1.1. Initial Programming Items Comparison List. . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

1.2. Switch Locations Comparison List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

1. Communication Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

2. Default Communication Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

3. Network Used for G3 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

4. Network Used for G3 transmission in G4-to-G3 Fallback . . . . . . . . . . . . B-3

5. Automatic G4-to-G3 Fallback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

6. Specified Two Step Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

7. Cable Equalizer for ISDN Transmission . . . . . . . . . . . . . . . . . . . . . . . . . B-4

8. Cable Equalizer for ISDN Reception . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

APPENDIX C A644

1. Conditions for Receiving a Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

TOC ii A193

Table of Contents

PRINTER

1. OVERALL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1.1 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1.2 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 CONTROLLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2. DETAILED SECTION DESCRIPTIONS. . . . . . . . . . . . . . . . . . . . . . 1-3

2.1 BLOCK DIAGRAM (OVERALL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.2 INTERFACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2.2.1 Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2.2.2 Machine Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

2.3 BLOCK DIAGRAM (INTERNAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

2.3.1 Printer Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

2.3.2 Printer Enhancement Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

2.4 Hard Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

2.5 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

2.5.1 Sorting Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

2.5.2 Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

3.1 PRINTER CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

3.2 PRINTER ENHANCEMENT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

3.3 HARD DISK DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

3.4 SIMM MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

3.5 CONNECTING THE INTERFACE CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

3.5.1 Parallel Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

3.5.2 Serial (RS-232C) Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

3.5.3 LocalTalk Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

3.6 CHECKING THE CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

3.6.1 Connection Between Printer Controller (and related options; Printer

Enhancement Unit, Hard Disk Drive, SIMM) and Copier . . . . . . . . . . . . . 1-20

3.6.2 Connection Between Printer Controller (Printer Enhancement Unit) and Host

PC or Macintosh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

A193 i TOC

4. SERVICE TABLES AND PROCEDURES . . . . . . . . . . . . . . . . . . . 1-24

4.1 SERVICE REMARKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

4.1.1 Hard Disk Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

4.1.2 About Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

5. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

5.1 ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

5.2 HARDWARE ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

5.3 CONNECTION ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

5.4 IMAGE PROBLEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

6.0 Printer Controller ROM Modification History

Printer Controller (A643) ROM Modification History . . . . . . . . . . . . . . . . . . . . . . . 1-29

APPENDIX A

TOC ii A193

+ 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 cop ier and the paper tray unit are supplied with electrical voltage even if the main switch is turned off.

4. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrifie d or m ech an i cal ly dri ve n com p on en ts.

5. If the Start key is presse d be fo re th e cop ier comp let es th e warm-up period (the Start key starts blinking red and green alternatively), keep hands away from the mechanical and the electrical co mponents as the copier starts making copi es as soo n as the w ar m- u p pe r iod is completed.

6. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your ba r e ha nd s.

HEALTH SAFETY CONDITIONS

1. Always repl a ce th e ozo ne fi lte r s wit h th e spe c ifi e d on es at the speci f i ed intervals.

2. Toner and de vel o pe r ar e no n-toxic, but if you get either of them in your eyes by accident, it may cause tempo rar y eye discom f or t . Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attent i on .

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models.

2. The RAM board on the system control board has a lithium battery which can explode if replaced incorrectly. Replace the battery only with an identical one. The manufacturer recommends replacing the entire RAM board. Do not rechar g e or bu r n th i s bat te r y. Us ed bat te ri es must be handled in accordance with local regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame.

2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are non-toxic supplies.)

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

4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

LASER SAFETY

The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.



WARNING

Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.



WARNING FOR LASER UNIT

WARNING: Turn off the main switch before attempting any of the

procedures in the Laser Unit section. Laser beams can seriously damage your eyes.

CAUTION MARKING:

DANGER

INVISIBLE LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO BEAM.

>PS<

DANGER

INVISIBLE LASER RADIATION WHEN DISCONNECT OPTICAL FIBER CABLE. AVOID DIRECT EXPOSURE TO BEAM.

>PS<

A193/A224 TAB INDEX

A193 OVERALL MACHINE INFORMATION

DOCUMENT FEEDER A628

OVERALL MACHINE INFORMATION A639

PRINTER CONTROLLER A643

A224 OVERALL MACHINE INFORMATION

TAB

POSITION 1

TAB

POSITION 2

TAB

POSITION 3

A193 DETAILED DESCRIPTIONS

PAPER TRAY UNIT G697

DETAILED DESCRIPTIONS A639

A193 INSTALLA TION

DUPLEX UNIT G694

INST ALLATION A639

TAB

POSITION 4

A193 SERVICE TABLES

1 BIN SORTER TRAY A629

SERVICE TABLES A639

TAB

POSITION 5

Rev. 7/97

TAB

POSITION 6

TAB

POSITION 7

TAB

POSITION 8

A193 REPLACEMENT & ADJUSTMENT

REPLACEMENT & ADJUSTMENT A639

AUTO REVERSE DOCUMENT FEEDER

A661

A224 OVERALL MACHINE INFORM

A193 TROUBLESHOOTING

FINISHER A666

TROUBLESHOOTING A639

LARGE CAPACITY TRAY A667

ISDN A644

F AX UNIT A804

APPENDIX A, B, C,

COPIER (A193)

SECTION 1

OVERALL MACHINE

INFORMATION

SPECIFICATIONS

Configuration: Desktop Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum A3/11" x 17" Copy Paper Size: Maximum

A3/11" x 17"

Minimum

A5/8

1/2

" x 5

1/2

" sideways (Paper tray)

A6/5

1/2

" x 8

1/2

" lengthwise (By-pass)

Copy Paper Weight: Paper tray:

60 ~ 90 g/m2, 16 ~ 24 lb

By-pass:

60 ~ 157 g/m2, 16 ~ 42 lb

Reproduction Ratios: 5 Enlargement and 7 Reduction

A4/A3 Version LT/DLT Version

Enlargement

400% 200% 141% 122% 115%

400% 200% 155% 129% 121%

Full size 100% 100%

Reduction

93% 87% 82% 71% 65% 50% 25%

93% 85% 77% 74% 65% 50% 25%

Zoom: 25% to 400% in 1% steps Power Source: 120V/60 Hz:

More than 12 A (for North America)

220V ~ 240V/50 Hz:

More than 7 A (for Europe)

220V ~ 240V/60 Hz:

More than 7 A (for Asia)

Power Consumption:

Overall

Machine

Information

SPECIFICATIONS

SM 1-1 (A193)

Mainframe Only Full System

120V 220V ~ 240V 120V 220V ~ 240V

Maximum Less than 1.1 kW Less than 850 W Less than 1.2 kW Less than 1 kW

Copying Approx. 470 W Approx. 500 W Approx. 500 W Approx. 530 W Warm-up Approx. 1.0 kW Approx. 750 W Approx. 1.0 kW Approx. 750 W Stand-by Approx. 130 W Approx. 130 W Approx. 140 W Approx. 140 W

Auto Shut Off Approx. 2.0 W Approx. 2.2 W Approx. 2.2 W Approx. 2.4 W

NOTE:

Full System: Mainframe + ADF + Paper Tray Unit + Duplex Tray + 1-bin Sorter

Noise Emission:

Mainframe Only Full System

1. Sound Power Level

Copying 61.5 dB(A) 64.5 dB(A)

Stand-by 30.0 dB(A) 30.0 dB(A)

2. Sound Pressure Level at the Operator Position

Copying 47.5 dB(A) 52.0 dB(A)

Stand-by 17.5 dB(A) 17.5 dB(A)

NOTE:

The above measurements were made in accordance with ISO 7779. Full System: Mainframe + ADF + Paper Tray Unit + Duplex Tray + 1-bin Sorter

Dimensions (W x D x H): 550 x 580 x 652 mm (21.7" x 22.9" x 25.7")

Measurement Conditions

1) With by-pass feed table closed

2) Without the optional paper tray unit

3) Without the ADF Weight: Less than 57 kg (126 lb) Copying Speed in Multicopy mode (copies/minute):

Non-Memory Mode

A4 sideways/

11" x 8

1/2

A3/11" x 17" B4/8

1/2

" x 14"

(1 to 1 copy) 15 9 10 Memory Copy Mode 20 11 12

Warm-up Time

Less than 30 seconds (20°C, 68°F): 115V machine Less then 35 seconds (20°C, 68°F): 230V machine

First Copy Time: Less than 9.8 s (from 1st paper tray to face

down copy tray) Less than 8.8 s (from 1st paper tray to face up copy tray)

Rev. 2/28/97

⇒

SPECIFICATIONS

(A193) 1-2 SM

Copy Number Input: Ten-key pad, 1 to 99 (count up or count down) Manual Image Density: 7 steps Automatic Reset: 60 s is the standard setting; it can be changed

with a UP mode.

Auto Shut Off 15 min. is the standard setting; it can be

changed with a UP mode.

Copy Paper Capacity: Paper Tray: 250 sheets

Optional Paper Tray Unit: 500 sheets x 2 Bypass: 100 sheets (A4, B5, A5, B6, 8.5 x 11",

5.5 x 8.5")

10 sheets (A3, B4, 11 x 17", 8 x 13")

1 sheet (non-standard sizes) Toner Replenishment: Cartridge exchange (216 g/cartridge) Toner Yield: 8 k copies (A4 sideways, 6% full black, 1 to 1

copying, ADS mode) Optional Equipment:

•

Platen cover

•

Auto document feeder

•

Paper tray unit with two paper trays

•

1-bin sorter (tray)

•

Duplex unit

•

Key counter

•

Tray heater

•

Optical anti-condensation heater

•

Auto Reversing Document Feeder

Copy Tray Capacity Face down mode: 500 sheets

Face up mode: 100 sheets Memory Capacity:

Standard (4 MB) Optional 4 MB Optional 8 MB

Multi duplex copy X O O Sort, Rotate Sort A4, LT O O O

B4, LG X O O A3, DLT X O O

Number of pages A4 6% 35 99 99

ITU-T#4 15 45 75

X: Not Available O: Available

Overall

Machine

Information

SPECIFICATIONS

SM 1-3 (A193)

MACHINE CONFIGURATION

Version Item Machine Code No.

Copier Copier A193 E

ADF (Option) A628 D Paper Tray Unit (Option) G697 F Duplex Unit (Option) G694 C 1-bin Sorter (Option) A629 B Platen Cover (Option) A645 Memory 4MB (Option) A642-01 Memory 8MB (Option) A642-02

Fax Fax Controller (Option) A639-01 (115V),

-02(230V),

-03(France), -04 (TWN) Telephone (Option) H160 A ISDN (Option) A644-01(115V),

-02(230V) HDD (Option) A641 Memory Card (Option) H130-54 Function Card (Option) H130-52 Page Memory (Option) A640

Printer Printer Controller (Option) A643-00 (115V),

-01(230V) PS Option (Option) A643-02 HDD (Option) A643-03

A193V501.wmf

MACHINE CONFIGURATION

(A193) 1-4 SM

PAPER PATH

Optional 1-bin Sorter

Face Down Tray

Face Up Tray

Optional Duplex Tray

Paper Tray

Optional Paper Tray Unit

A193V005.wmf

Overall

Machine

Information

PAPER PATH

SM 1-5 (A193)

MECHANICAL COMPONENT LAYOUT

31 30

A193V502.wmf

MECHANICAL COMPONENT LAYOUT

(A193) 1-6 SM

1. 2nd Mirror (Scanner)

2. 1st Mirror (Scanner)

3. DF Exposure Glass

4. Xenon Lamp

5. Exposure Glass

6. Original Width Sensors

7. 1st Mirror (Laser)

8. Barrel Toroidal Lens (BTL)

9. Original Length Sensors

10. Lens

11. SBU Board

12. Scanner Motor

13. F-theta Mirror

14. 2nd Mirror (Laser Unit)

15. PCU

16. Toner Bottle

17. By-pass Feed Roller

18. By-pass Table

19. Relay Rollers

20. Paper Feed Rollers

21. Bottom Plate

22. Transfer Roller

23. Separation Brush

24. Transport Vacuum Fan

25. Pressure Roller

26. Hot Roller

27. Fusing Exit Roller

28. Left Vertical Door/Face Up Tray

29. Junction Gate

30. Hot Roller Strippers

31. Left Vertical Roller

32. Lower Exit Sensor

33. Polygonal Mirror Motor

34. 3rd Mirror (Scanner)

35. Face Down Tray

Overall

Machine

Information

MECHANICAL COMPONENT LAYOUT

SM 1-7 (A193)

ELECTRICAL COMPONENT DESCRIPTIONS

Refer to the electrical component layout and the point-to-point diagram on the waterproof paper in the pocket for the locations of these components.

Symbol

Index

No.

Description Note

Printed Circuit Boards

PCB1 54

High Voltage Supply Board

Supplies high voltage to the drum charge roller, development roller, transfer roller, and discharge brush.

PCB2 50 Lamp Stabilizer Provides dc power for the exposure lamp. PCB3 58

PSU (Power Supply Unit)

Provides dc power to the system and ac power to the fusing lamp.

PCB4 61 LD Unit (Laser Diode) Controls the laser diode. PCB5 62

Operation Panel Controls the touch panel display and LED

matrix, and monitors the key matrix.

PCB6 51

SBU (Sensor Board Unit)

Contains the CCD, and outputs a video signal to the BICU board.

PCB7 55

IOCSS (Input/Output & Customer Support System)

Controls the mechanical parts of the printer.

PCB8 52

BICU (Base Engine & Image Control Unit)

Controls all copier functions both directly or through other control boards.

PCB9 53

MSU (Memory Supercharge Unit)

Compresses the image data, stores the data, and applies the image editing.

Motors

M1 45 Main Drives the main body components. M2 36

Scanner Drive Drives the 1st and 2nd scanners (dc stepper

motor).

M3 47

Transport Vacuum Fan

Aids paper transportation from the transfer roller to the fusing unit.

M4 49 Polygonal Mirror Rotates the polygonal mirror. M5 37

Toner Supply Rotates the toner bottle to supply toner to

the toner supply unit.

M6 35 Exhaust Fan Removes heat from around the fusing unit.

Sensors

S1 33

Upper Exit Detects paper feed misfeeds from the upper

optional cassette tray.

S2 31

Lower Exit Detects paper feed misfeeds from the lower

optional cassette tray. S3 28 Left Vertical Door Cuts the +5 and +24 Vdc power lines. S4 27 Left Door Detects when the left door is open.

S5 17

Relay Detects the leading edge of paper from the

paper tray and duplex unit to determine the

stop timing of the paper feed clutch and

duplex feed motor. Also detects misfeeds.

ELECTRICAL COMPONENT DESCRIPTIONS

(A193) 1-8 SM

Symbol

Index

No.

Description Note

S6 10

PCU Detects when a new PCU (Photo Contuctor

Unit) is installed. S7 29 Fusing Exit Detects misfeeds in the fuser unit.

S8 9

Charge Roller H.P Informs the CPU when the drum charge

roller is in home position. S9 14

Upper Tray Paper End

Informs the CPU when the upper paper tray

is out of paper.

S10 15

Lower Tray Paper End

Informs the CPU when the lower paper tray

runs out of paper.

S11 16

By-pass Feed Paper End

Informs the CPU when there is no paper in

the by-pass tray.

S12 12

Registration Detects the leading edge of the copy paper

to determine the stop timing of the paper

feed clutch, and detects misfeeds.

S13 11

By-pass Feed Paper Width

Detects the width of the paper in the by-pass

feed table.

S14 59 Humidity Monitors the humidity around the PCU. S15 4

Original Width Detects the width of the original. This is one

of the APS (Auto Paper Select) sensors.

S16 5

Original Length-1 Detects the length of the original. This is one

of the APS (Auto Paper Select) sensors.

S17 6

Original Length-2 Detects the length of the original. This is one

of the APS (Auto Paper Select) sensors.

S18 3

Platen Cover Informs the CPU when the platen cover is up

(related to APS/ARE functions). ARE: Auto

Reduce and Enlarge

S19 1

Scanner H.P. Informs the CPU when the 1st and 2nd

scanners are at the home position.

S20 23

Toner Density (TD) Detects the amount of toner inside the

development unit. (PCU)

Switches

SW1 21 AC Supplies power to the copier. SW2 32 Main Supplies power to operate the machine. SW3 13 Right Vertical Guide Cuts the +5 and +24 Vdc power lines.

SW4 20

Upper Paper Size Identifies the size of paper is in the upper

paper tray.

SW5 19

Lower Paper Size Identifies the size of paper is in the lower

paper tray.

SW6 26

Front Door Safety Cuts the +5VLD and +24V dc power lines

and detects whether the front cover is open

or not.

Magnetic Clutches

MC1 46

Charge Roller Contact Controls the touch and release movement of

the drum charge roller.

MC2 42 Upper Relay Drives the upper relay rollers. MC3 43 Lower Relay Drives the lower relay rollers.

Overall

Machine

Information

ELECTRICAL COMPONENT DESCRIPTIONS

SM 1-9 (A193)

Symbol

Index

No.

Description Note

MC4 40

By-pass Feed Starts paper feed from the by-pass feed

table.

MC5 41 Upper Paper Feed Starts paper feed from the upper paper tray. MC6 44 Lower Paper Feed Starts paper feed from the lower paper tray. MC7 39 Registration Drives the registration rollers.

MC8 38

Development Drives the development roller.

Solenoids

SOL1 48

Junction Gate Moves the junction gate to direct copies to

the face up or face down copy tray.

Lamps

L1 60

Quenching Neutralizes any charge remaining on the

drum surface after cleaning.

L2 2 Scanner Applies light to the original for exposure. L3 8 Fusing Provides heat to the hot roller.

Heaters

H1 18

Tray (option) Turns on when the main switch is off to keep

paper in the paper tray dry. Tray heaters are

also available for the optional paper feed unit. H2 34

Anti-condensation (option)

Turns on when the main switch is off to

prevent moisture from accumulating.

Thermistors

TH1 24

Charge Roller Monitors the temperature of the drum charge

roller.

TH2 22 Fusing Monitors the temperature of the hot roller.

Thermofuses

TF1 7

Fusing Provides back-up overheat protection in the

fusing unit.

Counters

CO1 25

Total Keeps track of the total number of copies

made.

CO2 ---

Key (option)

Used for control of authorized use. The

copier will not operate until it is installed.

Others

LSD1 30

Laser Synchronization Detector

Detects the laser beam at the start of the

main scan.

NF 56

Noise Filter (230V machine only)

Removes electrical noise from the AC input

line.

ELECTRICAL COMPONENT DESCRIPTIONS

(A193) 1-10 SM

Symbol

Index

No.

Description Note

CB 57

Circuit Breaker (230V machine only)

Guards against voltage surges in the AC

input line.

Overall

Machine

Information

ELECTRICAL COMPONENT DESCRIPTIONS

SM 1-11 (A193)

DRIVE LAYOUT

A193V503.wmf

1. Scanner Drive Motor

2. Development Clutch

3. Charge Roller Contact

4. Main Motor

5. Registration Clutch

6. Lower Paper Feed Clutch

7. Lower Relay Clutch

8. Upper Relay Clutch

9. Upper Paper Feed Clutch

10. By-pass Feed Clutch

DRIVE LAYOUT

(A193) 1-12 SM

COPY PROCESS

7.1 OVERVIEW

A193V505.wmf

Pow er Pack

Pow er P ack

-1750 V

-900 V

-140 V

-600 V

+15 µA

-2 kV

-90 V

Laser Pulse

Rev. 2/28/97

⇒

A193V506.wmf

Overall

Machine

Information

COPY PROCESS

SM 1-13 (A193)

1. EXPOSURE

A xenon lamp exposes the original. Light reflected from the original passes to the CCD, where it is converted into an analog data signal. The analog data is converted to a digital signal, processed, and stored in the memory. At the time of printing, the digital data is retrieved and sent to the laser diode. For multi-copy runs, the original is scanned once only and stored to the memory.

2. DRUM CHARGE

In the dark, the charge roller gives a negative charge to the organic photo-conductive (OPC) drum. The charge remains on the surface of the drum because the OPC material has a high electrical resistance in the dark.

3. LASER EXPOSURE

The processed data scanned from the original is retrieved from the memory and transferred to the drum by a laser beam, which forms an electrical latent image on the drum surface. The amount of charge remaining as a latent image on the drum depends on the laser beam intensity, which is controlled by the BICU board.

4. DEVELOPMENT

The magnetic developer brush on the development rollers comes in contact with the latent image on the drum surface. Toner particles are electrostatically attracted to the areas of the drum surface where the laser reduced the negative charge on the drum.

5. IMAGE TRANSFER

Paper is fed to the area between the drum surface and the transfer roller at the proper time for aligning the copy paper and the developed image on the drum surface. Then, the transfer roller applies a high positive charge to the reverse side of paper. This positive charge produces an electrical force which pulls the toner particles from the drum surface on to the paper. At the same time, the paper is electrically attracted to the transfer roller.

6. PAPER SEPARATION

Paper separates from the drum as a result of the electrical attraction between the paper and the transfer roller. The discharge brush helps separate the paper from the drum.

7. CLEANING

The cleaning blade removes any toner remaining on the drum surface after the image is transferred to the paper.

8. QUENCHING

The light from the quenching lamp electrically neutralizes the charge on the drum surface.

COPY PROCESS

(A193) 1-14 SM

BOARD STRUCTURE

8.1 OVERVIEW

Motor

Scanner

Sensors

Sensors,

Solenoids

High Voltage Supply

Laser Printer

Sensors, Solenoids,

Motors, Clutches

Peripheral

Sensors,

Motors, Solenoids,

Clutches

Laser Synchronization Signal = Optical Cable

MSU

Additional

Memory

Standard Option

Flat Cable

Harness

SBU

LD Unit

Polygon

Mirror Motor

BICUIOCSS

Operation

Panel

Fax Controller Mother Board

Printer

Controller

Flat Cable

Harness

Scanner

Motor

A193V504.wmf

Overall

Machine

Information

BOARD STRUCTURE

SM 1-15 (A193)

8.2 DESCRIPTION

1. BICU (Base Engine and Image Control Unit)

This is the main board. It controls the following functions:

•

Engine sequence

•

Scanner, laser printer engine

•

Timing control for peripherals

•

Image processing, video control

•

Operation control

•

Corresponding application boards

•

Machine control, system control

2. IOCSS (I/O and Customer Support System Unit)

The IOCSS board handles the following functions:

•

Drive control for the sensors, motors, solenoids of the printer and scanner

•

PWM control for the high voltage control board

•

Serial interfaces with peripherals

•

Circuit for fusing control

3. SBU (Sensor Board Unit)

The SBU deals with the analog signals from the CCD and converts the analog signals into digital signals.

4. MSU (Memory Super-charger Unit)

The MSU stores and compresses the image data. It also performs the image editing on the data if requested by the user. An extra 4 MB or 8 MB of memory can be added (see below).

5. Additional Memory (Option)

This is an additional image memory board for the MSU.

6. LD Unit

This is the laser diode drive circuit board. It controls the laser diode drive circuit to write the latent image onto the surface of the drum.

7. Mother Board

The printer control board which works in conjunction with the BICU interface board. It receives the signals from the printer control board and sends signals to the printer control board.

BOARD STRUCTURE

(A193) 1-16 SM

SECTION 2

DETAILED SECTION

DESCRIPTIONS

1. SCANNING

1.1 OVERVIEW

The original is illuminated by the exposure lamp (a xenon lamp in this model) [A]. The image is reflected onto a CCD (charge coupled device) [B] via the 1st, 2nd, 3rd mirrors, and lens [C].

The 1st scanner [D] consists of the exposure lamp, a reflector [E], and the 1st mirror [F].

The exposure lamp is energized by a dc supply to avoid uneven light intensity as the 1st scanner moves in the sub scan direction. The entire exposure lamp surface is frosted to ensure even exposure in the main scan direction.

The light reflected by the reflector is of almost equal intensity, to reduce shadows on pasted originals.

An optics anti-condensation heater [G] is available as an option. It can be installed on the left side of the inner cover. The heater will turn on whenever the power cord is plugged in.

[A]

[B]

[C]

[D]

[F]

[G]

[E]

A193D001.wmf

Detailed

Descriptions

SCANNING

SM 2-1 (A193)

1.2 SCANNER DRIVE

A stepper motor is used to drive the scanner. The 1st and 2nd scanners [A,B] are driven by this scanner drive motor [C] through the timing belt [D], scanner drive pulley [E], scanner drive shaft [F], and two scanner wires [G].

– Book mode –

The scanner drive board controls and operates the scanner drive motor. In full size mode, the 1st scanner speed is 90 mm/second during scanning. The 2nd scanner speed is half that of the 1st scanner. (45mm/second)

In reduction or enlargement mode, the scanning speed depends on the magnification ratio (M: 0.25 to 4.00). The return speed is always the same, whether in full size or magnification mode. The image length change in the sub scan direction is done by changing the scanner drive motor speed, and in the main scan direction it is done by image processing on the BICU board.

Magnification in the sub-scan direction can be adjusted by changing the scanner drive motor speed using SP4-101. Magnification in the main scan direction can be adjusted using SP4-008. Refer to section 4.2.2.

– ADF mode –

The scanners are kept at their home position (the scanner H.P sensor [H] detects the 1st scanner) to scan the original. The ADF motor feeds the original through the ADF. In reduction/enlargement mode, the image length change in the sub-scan direction is perfomed by changing the ADF motor speed. Magnification in the main scan direction is performed in the BICU board, same as the book mode.

Magnification in the sub-scan direction can be adjusted by changing the ADF motor speed using SP6-007. In the main scan direction, it can be adjusted with SP4-008, like for book mode. Refer to setion 4.2.2.

Rev. 1/97

[E]

[G]

[F]

[C]

[D]

[E]

[A]

[B]

[G]

[H]

A193D546.wmf

SCANNING

(A193) 2-2 SM

1.3 ORIGINAL SIZE DETECTION IN PLATEN MODE

In the optics to identify the size of the original placed on the exposure glass, there are four (4) reflective sensors in the 115V machines, and six (6) reflective sensors in the 230V machines. The Original Width Sensors [A] detect the original width, and the Original Length Sensors [B] detect the original length. These are the APS (Auto Paper Select) sensors. Each APS sensor is a reflective photosensor.

While the main switch is on, these sensors are active and the original size data is always sent to the CPU. However, the CPU will only check the data from the sensors only when the platen cover is in the process of being closed.

The original size data is sent to the main CPU when the platen cover sensor [C] is activated. This is when the platen is positioned about 15 cm above the exposure glass. At this time, only the sensor(s) located underneath the original receive the reflected light and switch on. The other sensor(s) are off. The main CPU will identify the original size from the on/off signals from the APS sensors.

If the copy is made with the platen fully open, the main CPU will identify the original size from the sensor outputs when the Start key is pressed.

[C]

A193D003.wmf

[B]

[A]

A193D526.wmf

Detailed

Descriptions

SCANNING

SM 2-3 (A193)

Original Size Length Sensors

Width

Sensors

A4/A3 version LT/DLT version

L1 L2 L3 L4 S1 S2 A3 11" x 17" OOOOOO B4 10" x 14" OOOOOX F4 8

1/2

" x 14" (8" x 13") O O O X X X

A4–L 8

1/2

" x 11" OOXXXX

B5–L — OXXXXX

A4–S 11" x 8

1/2

" XXXXOO

B5–S — X X X X O X

O: ON X: OFF

NOTE:

The length sensors L3 and L4 are used only for 230V machines.

For other combinations, the message "CANNOT DETECT ORIG. SIZE" will be displayed on the operation panel display.

The above table shows the outputs of the sensors for each original size. This original size detection method eliminates the necessity for a pre-scan cycle and increases the machine’s productivity.

However, if the by-pass feeder is used, note that the machine assumes that the copy paper is lengthwise. For example, if A4 sideways paper is placed on the by-pass tray, the machine assumes it is A3 paper and scans the full A3 area, disregarding the original size sensors. However, in this machine, for each page, the data signal to the laser diode is stopped to match the copy paper length detected by the registration sensor.

Original size detection using the ADF is described in the manual for the ADF.

⇒

Rev. 2/28/97

SCANNING

(A193) 2-4 SM

2. IMAGE PROCESSING

2.1 OVERVIEW

The CCD (Charged Couple Device) generates an analog video signal. The SBU (Sensor Board Unit) converts the analog signal to an 8-bit digital signal, then it sends the digital signal into the BICU (Base-engine and Image Control Unit) board.

The BICU board can be divided into three image processing blocks; the IPU (Image Processing Unit), FCI (Fine Character Image), and LD controller GAVD (Gate Array Video Drive)

•

IPU: Auto shading, filtering, magnification, γ correction, and gradation processing

•

FCI: Smoothing (binary picture processing mode only)

•

LD controller: LD print timing control and laser power PWM (Pulse Width Modulation) control

On completion, the BICU board sends the video data to the LD drive board at the proper exposure time.

SBU

LD Driver

Controller

(GAVD)

FCI

IPU

MSU

Fax Controller

CCD

Drum

BICU

LDDR

Printer

Controller

Fax

Controller

LDDR: Laser Diiode Driver BICU: Base Engine & Image Controller Unit. SBU: Sensor Board Unit IPU: Image Processing Unit

A193D501.wmf

Detailed

Descriptions

IMAGE PROCESSING

SM 2-5 (A193)

2.2 SBU (SENSOR BOARD UNIT)

The CCD converts the light reflected from the original into an analog signal. The CCD line contains 5,000 pixels and the resolution is 400 dpi (15.7 lines/mm).

The CCD has two output lines, for odd and even pixels, which are sent to the analog processing IC. The analog processing IC performs the following operations on the signals from the CCD:

1) Z/C (Zero Clamp): Adjusts the black level reference for even numbered pixels to match black level of the numbered odd pixels.

2) Signal Composition: Analog signals for odd and even pixels from the CCD are merged by a switching device.

3) Signal Amplification The analog signal is amplified by operational amplifiers in the AGC circuit. The maximum gains of the operational amplifiers are controlled by the CPU on the BICU board.

After the above processing, the analog signals are converted into 8-bit signals by the A/D converter. This will give a value for each pixel on a scale of 256 grades. Then, the digitized image data will be sent to the BICU board.

CCD

AGC

Reference

Controller

Z/C

Vin

ref

IPU

Analog Processing IC

SBU

BICU

Z/C: Zero Clamp AGC: Automatic Gain Control Circuit

ODD

EVEN

Amp.

A/D

SBU: Sensor Board Unit BICU: Base Engine & Image Processing Control A/D: Analog/Digital Converter

A193D502.wmf

IMAGE PROCESSING

(A193) 2-6 SM

2.3 AUTO IMAGE DENSITY (ADS)

The auto image density (ADS) mode prevents the background of an original from appearing on copies.

The copier scans the auto image density detection area [A] as shown in the diagram. This corresponds to a few mm at one end of the main scan line. As the scanner scans down the page, the IPU on the BICU detects the peak white level for each scan line. The IPU determines the reference value for the A/D conversion for a particular scan line using the peak white level for that scan line. Then, the IPU sends the reference value data to the reference controller on the SBU.

When an original with a gray background is scanned, the density of the gray area is the peak white level density. Therefore, the original background will not appear on copies. Because peak level data is taken for each scan line, ADS corrects for any changes in background density while scanning down the page.

As with previous digital copiers, the user can manually select the image density when selecting auto image density mode, and the machine will use both settings when processing the original.

[A]

Sub scan direction

A193D004.wmf

Detailed

Descriptions

IMAGE PROCESSING

SM 2-7 (A193)

2.4 IPU (IMAGE PROCESSING UNIT)

2.4.1 Overview

The image data from the SBU (Sensor Board Unit) is sent to the IPU (Image Processing Unit) IC on the BICU board, which can perform any of the following processes on the image data:

1. Auto shading

2. Filtering (MTF and smoothing)

3. Magnification

4. γ correction

5. Grayscale processing

6. Binary picture processing

7. Error diffusion

8. Dithering

9. Video path control

10. Test pattern generation

The image data then goes to either the LD controller (GAVD) or the FCI depending on the selected copy modes.

SBU

MSU

Unit

IPU

GAVD FCI

Fax controller

CPU

BICU

CPU BUS

8 bit

Data

1 bit

Data

Printer

controller

Fax Controller

A193D527.wmf

IMAGE PROCESSING

(A193) 2-8 SM

2.4.2 Image Processing Path

SBU

ADS and Auto

Shading

Smoothing

MTF

Correction

Main Scan

Magnification/

Reduction

Correction

(Scanner)

Grayscale

Processing

Dithering Error Diffusion

Binary Picture

Processing

Fax Controller

Printer

Controller

Video Path Controller

Edge Smoothing

Line Width Correction

Laser Diode Power

Modulation

Correction (Printer)

LDDR

Image Compression/

Decompression, Image

Rotation/Adjust Image

Text mode Text/Photo mode

Photo mode

IPU

BICU

FCI

MSU

Line Width Correction

A193D506.wmf

Detailed

Descriptions

IMAGE PROCESSING

SM 2-9 (A193)

2.4.3 Auto Shading

There are two different auto shading methods, black level correction and white level correction. Auto shading corrects errors in the signal level for each pixel.

1) Black Level Correction

The CPU reads the black level from the dummy pixels located at one end of the CCD signal (64 pixels at the end are blacked off) and takes the average value of the black dummy data. Then, the CPU deletes the black level value from each image pixel.

2) White Level Correction

Before scanning the original, the machine reads a reference waveform from the white plate. The average of the white video level for each individual pixel pixel is stored as the white shading data in the FIFO memory in the IPU chip.

The video signal information for each pixel obtained during image scanning is corrected by the IPU chip.

In book mode, auto shading is done at the beginning of each scan. In ADF mode, auto shading is done at a specific time interval. This interval can be set with SP4-913 (the default setting is 30 seconds). The machine waits until the end of the page before performing the auto shading.

A193D517.wmf

IMAGE PROCESSING

(A193) 2-10 SM

2.4.4 Filtering and Main Scan Magnification/Reduction

1. Overview

After auto shading, the image data is processed by both filtering and main scan magnification. However, to reduce the occurrence of moire in the image, the processing order is different depending on the reproduction ratio, as follows.

1) Reduction and Full size Main Scan Reduction → Filtering

2) Enlargement Filtering → Main Scan Magnification

2. Filtering

There are two software filters for enhancing the desired image qualities of the selected original mode: the MTF filter and the smoothing filter.

The MTF filter emphasizes sharpness and is used in Text and Text/Photo modes. The smoothing filter is used in Photo mode.

The relationships between the coefficient of the filter and the filter strengths are as follows. Note that these relationships are for copier mode only. Fax mode has its own unique table. (Refer to the fax section of the service manual) The filter strengths for each mode can be adjusted using the service program mode, SP4-407.

NOTE:

Never select "1." Abnormal images may result.

A193D503.wmf

Detailed

Descriptions

IMAGE PROCESSING

SM 2-11 (A193)

3. Main Scan Magnification/Reduction

Reduction and enlargement in the sub scan direction are done by changing the scanner speed. However, reduction and enlargement in the main scan direction are handled by the IPU chip. The processing for main scan magnification/reduction is the same as in the previous digital machines.

When making a copy using the ADF, the magnification circuit creates a mirror image. This is because the scanning starting position in the main scan direction is at the other end of the scan line in ADF mode (as compared with platen mode). In platen mode, the original is placed face down on the exposure glass, and the corner at [A] is at the start of the main scan. The scanner moves down the page. In ADF mode, the ADF feeds the leading edge of the original to the DF exposure glass, and the opposite top corner of the original is at the main scan start position.

To convert the mirror image, the CPU stores the main scan line data in the LIFO (Last In First Out) memory of the magnification block, from the last pixel. When loading the main scan line data from the LIFO memory, the CPU loads the first pixel of the main scan line.

[A]

A193D504.wmf

IMAGE PROCESSING

(A193) 2-12 SM

2.4.5

Gamma (γ) Correction

Gamma correction ensures accurate generation of the various shades in the gray scale from black to white, accounting for the characteristics of the scanner and printer. Scanner gamma correction corrects the data output to the IPU to account for the characteristics of the scanner (e.g., CCD response, scanner optics). Printer gamma correction corrects the data output from the IPU to the laser diode to account for the characteristics of the printer (e.g., the characteristics of the drum, laser diode, and lenses). The data for the scanner gamma correction is fixed and stored in the memory. The printer gamma correction can be adjusted using the service program mode, SP 2-916.

2.4.6 Gradation Processing

These are four types of gradation processing:

•

Grayscale processing: This has 64 output levels for each pixel, and is used only in one-to-one copy mode.

•

Binary picture processing: This has only two output levels (black and white), and is used in memory copying (e.g., multiple copy, rotate sort, and editing image) and facsimile transmission.

•

Error diffusion: In Text/Photo mode, this is used with either grayscale processing or binary processing.

•

Dithering: In Photo mode, this is used with either grayscale processing or binary processing.

These four processes are used as follows.

1) Grayscale processing mode Text mode: Grayscale processing

Text/Photo mode: Grayscale processing + error diffusion Photo mode: Grayscale processing + dithering

2) Binary picture processing mode Text mode: Binary picture processing

Text/Photo mode: Binary picture processing + error diffusion Photo mode: Binary picture processing + dithering

Copying using the memory (e.g., multiple copying) and fax mode always use binary picture processing. (Users requiring grayscale mode output for multiple copies will have to make a succession of one-to-one copies.) For one-to-one copying, the processing mode used depends on the setting of the service program mode, SP 4-403. The factory setting is for grayscale processing.

Detailed

Descriptions

IMAGE PROCESSING

SM 2-13 (A193)

1. Grayscale Processing

As stated on the previous page, the gray scale process generates up to 64 image density levels for each pixel. To realize this, this machine uses a form of pulse width modulation. Pulse width modulation consists of the following processes:

•

Laser diode pulse positioning (Horizontal)

•

Laser diode power/pulse width modulation (Vertical)

Laser diode power and pulse width modulation is done by the laser diode drive board (LDDR), and will be explained in the Laser Exposure section. Briefly, the width of the laser pulse for a pixel depends on the output level (from 0 to 63) of the pixel.

For each pixel, the location of the active (laser on) part of the pixel can be either at the left side of the pixel, at the center, or at the right side (see fig 2). The machine determines which method to use depending on the settings of the service program mode, SP 2-903. There are different settings for pixels at the left edge, at the right edge, and in the middle of a series of black/grey pixels across the main scan, and for single black pixels with white pixels at the left and right. The edges of characters and lines become clearer and sharper with this processing.

2. Binary Picture Processing

Each video signal level is converted from 8-bit to 1-bit (black and white image data) in accordance with a threshold value.

The threshold value can be adjusted using service program mode, SP 4-418. The printout density of the black pixel depends on the pixel type (left, center,

or right of a series, or isolated, in the same way as for grayscale processing). These values can be adjusted using service program mode, SP2-904.

Fig. 2

Center

A193D507.wmf

Fig. 1

A193D518.wmf

IMAGE PROCESSING

(A193) 2-14 SM

3. Error Diffusion

Error Difusion is used only in Text/Photo mode. The error diffusion process reduces the difference in contrast between light

and dark areas of a halftone image. Each pixel is corrected using the difference between it and the surrounding pixels. The corrected pixels are then compared with a error diffusion matrix. Separate error diffusion matrixes are used for copy mode and fax mode.

1) Grayscale processing mode

The output image signal level has 9 levels (from white to black). There is only one matrix available.

2) Binary picture processing mode

The output image signal level has just 2 levels (white and black). The threshold level can be changed using the service program mode, 418-2.

4. Dithering

Dithering is only used in Photo mode. Each pixel is compared with a pixel in a dither matrix. Several matrixes are

available, to increase or decrease the detail on the copy.

1) Grayscale processing mode The matrix type can be selected using the service program mode, 421-1

or the user tool program mode.

2) Binary picture processing The matrix type can be selected using the service program mode, 421-2

or the user tool program mode.

2.4.7 Line Width Correction

This function is effective only in Letter mode. Usually, lines will bulge in the main scan direction as a result of the

negative/positive development system that is used in this machine. So, the pixels on the edges between black and white areas are compared with their adjacent pixels, and if the pixel is on a line, the line thickness will be reduced.

The line width correction in grayscale processing mode is done in the IPU, and in binary processing mode, it is done in the FCI chip.

Detailed

Descriptions

IMAGE PROCESSING

SM 2-15 (A193)

2.5 MSU (MEMORY SUPER-CHARGER UNIT)

The MSU consists of the memory controller and the DRAM. The functions of each device are as follows.

Memory Controller: Compressing the 1-bit image data

Image rotation Image data transfer to the DRAM

DRAM (standard 4MB): Stores the compressed data (2 MB)

Working area (2 MB)

The data which was treated with binary picture processing is sent to the MSU. The data is first compressed using the MMR (modified modified read) process and the compressed data is stored in the DRAM. When printing, the data from the DRAM goes back to the memory controller, where the data is decompressed and image editing is performed (e.g., image rotation, repeat image, combine image).

The memory capacity changes when optional memory is installed onto the MSU board. The copier functions for each memory combination are as follows.

Standard (4 MB) Optional 4 MB Optional 8 MB

Multi duplex copy X O O Sort, Rotate Sort A4, LT O O O

B4, LG X O O A3, DLT X O O

Number of pages A4 6% 35 99 99

ITU-T#4 (12% black)

15 45 75

X: Not Available O: Available

IPU

CPU

Memory

Controller

DRAM

MSU

BICU

BUS

A193D528.wmf

IMAGE PROCESSING

(A193) 2-16 SM

2.6 FCI (FINE CHARACTER AND IMAGE)

The FCI performs image smoothing and line width correction. These functions only affect binary picture processed images in Letter mode. The fax board and the printer controller each have independent smoothing circuits.

Usually, binary picture processing generates jagged edges on characters as shown in the above left illustration. The FCI reduces jagged edges of characters using the image smoothing process.

Whether or not the object pixel undergoes smoothing depends on the surrounding image data. The smoothing process for the object pixel is performed by changing the laser pulse positioning and the laser power.

FCI smoothing can be switched on or off using the service program mode, SP 2-902.

A193D511.wmf

Detailed

Descriptions

IMAGE PROCESSING

SM 2-17 (A193)

3. LASER EXPOSURE

3.1 OVERVIEW

This machine uses a laser diode to produce electrostatic images on an OPC drum. The laser diode unit converts image data from the BICU board into laser pulses, and the optical components direct these pulses to the drum surface.

To produce a high quality copy image, these are 64 gradations for the laser pulses, controlled through power modulation and pulse width modulation.

Exposure of the drum surface by the pulsing laser beam creates the latent image. The laser beam create the main scan while the drum rotation controls the sub scan.

The strength of the beam is 0.6 mW on the drum surface at a wavelength of 780 nm.

There are four polygon motor speeds:

Resolution (dpi) Modes Motor Speed (rpm) Data Frequency (MHz)

400 dpi Copy and Printer 14173.23 9.276 600 dpi Printer 21259.84 20.872

391.16 dpi Fax (Image rotation) 13860.00 9.216

406.4 dpi Fax (mm printing) 14400.00 9.216

⇒

Rev. 2/28/97

LASER EXPOSURE

(A193) 2-18 SM

3.2 OPTICAL PATH

The output path from the laser diode to the drum is shown above. The LD unit [A] outputs pulsing the laser beam to the rotating polygon mirror

[B] through the cylindrical lens [C]. Each surface of the polygon mirror reflects a full main scan line. The laser

beam goes to the F-theta mirror [D], 1st mirror [E], and BTL (Barrel Toroidal Lens) [F]. The 2nd mirror [G] reflects the laser beam onto the surface of the drum through the toner shield glass.

The laser synchronizing detector [H] is used to determines the main scan starting position.

[B]

[F]

[G]

[D]

[A]

[H]

[B]

[E]

[C]

[H]

[D]

[F]

[E]

[G]

A193D523.wmf

Detailed

Descriptions

LASER EXPOSURE

SM 2-19 (A193)

3.3 GRADATION CONTROL (LASER POWER MODULATION)

To create the latent image, the laser beam illuminates the image area of the drum surface. The longer the laser is on and the stronger its intensity is, the darker the developed pixel becomes. Modulating (changing) the width of the pulse changes the on time of the laser longer or shorter (PWM). There are eight pulse width levels in this machine.

While the laser is on to make one dot, the intensity of the laser is controlled by power modulation (PM). The laser’s intensity is controlled by the amount of current sent to the laser diode. Modulating the power makes the laser brighter or dimmer. There 8 power levels, or laser intensity levels. The power is modulated only on the final part of the laser pulse (example: see data 11 in the diagram).

The machine uses the 8 pulse width levels and 8 power levels to create the 64 possible grayscale values for each pixel.

7 5

PWM (8 levels)

Data: 0

1 dot

Data: 3

Data: 7

Data: 11

Data: 63Data: 15 Data: 34

071

22 5 7

PM (8 levels)

Black

White

A193D519.wmf

A193d520.wmf

LASER EXPOSURE

(A193) 2-20 SM

3.4 AUTO POWER CONTROL (APC)

Even if a constant electric current is applied to the laser diode, the intensity of the output light changes with the temperature. The intensity of the output decreases as the temperature increases.

In order to maintain a constant output level, the output light intensity is monitored through a photodiode (PD) enclosed in the laser diode. The photodiode passes an electrical current that is proportional to the light intensity. The output is not affected by temperature, so it faithfully reflects the changes in the LD output, without adding anything itself.

Just after the machine is turned on, IC2 on the laser drive board excites the laser diode at full power and the output of the photodiode is stored as a reference in IC2. IC2 monitors the current passing through the photodiode (PD). Then it increases or decreases the current to the laser diode as necessary, comparing it with the reference level (LVL2). Auto power control is performed during printing while the laser diode is active.

The laser diode level is adjusted on the production line. Do not touch the variable resistors on the LD unit in the field.

IC 1 IC 2IC 3

LD5V

LVL1

ERR

LDOFF

LD1

DATA

LDOFF

LDERR

DATA

LEVEL

LD Drive Board

LVL2

A193D521.wmf

Detailed

Descriptions

LASER EXPOSURE

SM 2-21 (A193)

3.5 LD SAFETY SWITCHES

To ensure that the laser beam does not inadvertently expose the drum during servicing, there are two safety switches located at the front cover. The two switches are installed in series on the LD5 V line from the dc power supply board.

When the front cover is opened, the power supply to the laser diode is interrupted.

A193D008.wmf

LASER EXPOSURE

(A193) 2-22 SM

4. PCU (PHOTOCONDUCTOR UNIT)

4.1 OVERVIEW

The PCU consists of the components shown in the above illustration. An organic photoconduntor (OPC) drum (diameter: 30 mm) is used in this machine.

1. OPC Drum (CW) 8. Toner Collection Coil (CCW)

2. Doctor Blade 9. Cleaning Blade

3. Developer Cartridge 10. Charge Roller Thermistor

4. TD Sensor 11. Charge Roller (CCW)

5. Mixing Auger 1 (CCW) 12. Charge Roller Cleaning Pad

6. Mixing Auger 2 (CCW) 13. Humidity Sensor

7. Development Roller (CCW) The output of the humidity sensor is used for toner density control processing.

A193D010.wmf

Detailed

Descriptions

PCU (PHOTOCONDUCTOR UNIT)

SM 2-23 (A193)

4.2 DRIVE MECHANISM

The drive from the main motor [A] is transmitted to the drum through a series of gears, a timing belt [B], and the drum drive shaft [C]. The main motor has a drive controller, which outputs a motor lock signal when the rotation speed is out of the specified range.

The fly-wheels (2) [D] on the end of the drum drive shaft stabilizes the rotation speed (this prevents banding and jitter of the image from appearing on copies).

[A]

[C]

[B]

[D]

A193D542.wmf

PCU (PHOTOCONDUCTOR UNIT)

(A193) 2-24 SM

4.3 NEW PCU DETECTION MECHANISM

The PCU sensor (a push switch) [A] detects when a new PCU is installed. Each PCU has an actuator. When a new PCU is installed in the machine, the actuator [B] pushes the PCU sensor. The actuator is a sector gear, and this gear engages with the drum gear. When the drum rotates, the actuator is released from the drum gear. The actuator drops away from the PCU sensor and remains in this "down" position for the duration of the PCU’s life.

The machine recognizes when a new PCU has been installed in the machine because the actuator of the new PCU contacts the PCU sensor. After the front cover is closed, the machine then performs the TD sensor initial setting procedure automatically (for about two minutes). During this time, the drum rotates and the actuator drops away from the sensor.

[B]

A193D535.wmf

[A]

[B]

A193D536.mwf

Detailed

Descriptions

PCU (PHOTOCONDUCTOR UNIT)

SM 2-25 (A193)

4.4 DRUM CHARGE

4.4.1 Overview

This copier uses a drum charge roller system instead of a corona wire scorotron system to charge the drum. For the copy image area or during roller cleaning, the drum charge roller [A] contacts the surface of the drum [B] to give it a negative charge.

The drum charge roller system has the following advantages over the corona wire scorotron charge system.

•

The amount of ozone generated during drum charging is less than about 1/10 of that for a corona wire scorotron system.

•

The applied voltage is 1/2 ~ 1/3 that of a corona wire scorotron system.

•

The efficiency of drum charge is high.

Due to these advantages, no ozone filter is required in this copier. The high voltage supply board [C] povides a negative dc voltage to the drum

charge roller through the charge roller terminal [D], rear pressure spring [E], and the rear roller bushing [F]. The charge roller will provide the drum surface with a negative charge of –900 V.

[A]

[B]

[C]

[E]

[D]

[F]

A193Dd543.wmf

PCU (PHOTOCONDUCTOR UNIT)

(A193) 2-26 SM

4.4.2 Charge Roller Contact Mechanism

To prevent toner from adhering to the drum charge roller and to prevent the drum charge roller from sticking to the drum, the drum charge roller contacts the drum only under the following conditions:

•

When the image processing area comes under the drum charge roller

•

During charge roller cleaning

This function is performed by the charge roller contact clutch [A] (a one-third turn clutch) charge roller H.P. (home position) sensor [B], and cam [C] located at the end of the clutch shaft. When the clutch is driven one third of a complete rotation, the pressure lever [D] riding on the cam presses down the drum charge roller unit [E] downward to contact the roller with the drum.

When the drum charge roller contacts the drum, the drum charge roller is rotated by the drum.

The following table shows the relationship between the clutch rotation and each processing mode.

Mode Copying Cleaning (see next

page)

Home Position

Clutch 1/3 turn 1/3 turn 1/3 turn

Charge Roller

Position

Charge Roller

Contact H.P. Sensor

OFF OFF ON

[C]

[D] [E]

A193D014.wmf

[A]

[C]

[D]

[E]

[B]

A193D543.wmf

Detailed

Descriptions

PCU (PHOTOCONDUCTOR UNIT)

SM 2-27 (A193)

4.4.3 Drum Charge Roller Cleaning

If the drum charge roller gets dirty, drum charge efficiency decreases. This affects the copy quality, for example causing vertical black lines.

Drum charge roller cleaning is performed for 2 seconds after every copy job. After the copy job, the charge roller contact clutch is driven another third of a

rotation (see the diagram at the bottom of the previous page). The pressure lever presses down further, so that the cleaning pad [A] contacts the charge roller.

After charge roller cleaning, the clutch is driven the final third of the rotation (until the charge roller H.P sensor [B] is activated) to release the charge roller from the drum. The pressure lever moves away from the charge roller unit. Then the charge roller unit is released from the drum by the spring [C].

[A]

A193D015.wmf

[C]

[B]

A193D544.wmf

PCU (PHOTOCONDUCTOR UNIT)

(A193) 2-28 SM

4.4.4 Temperature Compensation

The voltage transferred from roller to drum varies with the temperature around the drum charge roller. The lower the temperature is, the higher the applied voltage required.

To compensate for this, the drum charge thermistor [A] detects the temperature around the drum charge roller. Before the copy job starts, the CPU monitors the temperature and instructs the high voltage supply board to supply the correct the charge voltage in accordance with the temperature.

[A]

A193D012-3.wmf

Detailed

Descriptions

PCU (PHOTOCONDUCTOR UNIT)

SM 2-29 (A193)

4.5 DEVELOPMENT

4.5.1 Overview

This copier uses a single roller development system. The developer cartridge [A], which includes the developer, is located just

above the development unit section of the PCU. At installation, the developer falls into the development unit. The mixing augers [B] transport the developer and toner to the development roller [C]. Internal permanent magnets in the development roller attract the developer to the development roller sleeve. The development roller carries the developer past the doctor blade [D]. The doctor blade trims the developer to the desired thickness and creates backspill into the mixing mechanism. The development roller continues to rotate, carrying the developer to the drum [E] where the latent image is developed.

The toner density sensor [F], located on the side of the development unit, measures the toner concentration in the developer. The humidity sensor [G] located above the development cartridge measures the humidity level around the drum.

[D]

[E]

[F]

[A]

[B]

[C]

[G]

A193D010-3.wmf

PCU (PHOTOCONDUCTOR UNIT)

(A193) 2-30 SM

4.5.2 Drive Mechanism

When the development clutch [D] turns on, the main motor drive is transmitted to the development drive shaft [A] and the development drive gear [B] through a timing belt [C], and a train of gears.

The development drive gears (except for the gears in the development unit) are helical gears. These gears are quieter than normal gears. When the PCU is pushed in, the development drive shaft engages the development roller gear.

[C]

[B]

[A]

[D]

A193D017.wmf

Detailed

Descriptions

PCU (PHOTOCONDUCTOR UNIT)

SM 2-31 (A193)

4.5.3 Mixing

The PCU uses 2 mixing augers, [A] and [B], to keep the developer evenly mixed. Mixing auger 1 [A] transports excess developer, scraped off the development roller [C] by the doctor blade, towards the front of the machine. Mixing auger 2 [B] returns the excess developer, along with new toner, to the rear of the mixing assembly. Here the developer is reapplied to the development roller.

[C]

[A]

[B]

A193D016.wmf

PCU (PHOTOCONDUCTOR UNIT)

(A193) 2-32 SM

4.5.4 Development Bias

This machine uses a negative-positive development system (write to black), in which the black areas of the latent image are at a low negative charge (-140 ± 50 V) and white areas are at a high negative charge (-900 V).

To transfer negatively charged toner to the black areas of the latent image on the drum, the high voltage supply board [A] applies a bias of -600 volts to the development rollers throughout the image development process. The bias is applied to the development roller shaft [B] through that shaft’s gear [C].

The development bias is kept at 0V until the latent image on the drum comes to the development roller. This is to prevent toner from transferring to the area of drum near the development roller, which has not yet been charged. The development bias is then increased to -600 V at the same time as the development clutch turns on.

The development bias voltage (-600 V) can be adjusted using the service program mode, SP2-201.

[A]

[C]

[B]

A193D534.wmf

Detailed

Descriptions

PCU (PHOTOCONDUCTOR UNIT)

SM 2-33 (A193)

4.5.5 Toner Density Control

- Toner Density Control Flow Chart -

Each step is explained in more detail on the following pages.

Copy

TREF

determination

VTE determination

VT – V

TREF

= ∆V

Have 30 copies

been made?

VT > V

∆

VT > 0

Has the

copy job been

finished?

Toner supply motor

on time calculation

VT detection

See the Toner End

Detection Flow Chart

Yes

A193D545.mwf

PCU (PHOTOCONDUCTOR UNIT)

(A193) 2-34 SM

- Toner Density Sensor -

Developer consists of carrier particles (ferrite) and toner particles (resin and pigment). Inside the development unit, developer passes through a magnetic field created by coils inside the toner density sensor, When the toner concentration changes, the voltage output of the sensor changes accordingly.

The output from the sensor (VT) is checked before every copy. The machine tries to keep VT constant by varying the toner supply, as shown in the flow chart on the previous page.

(Add Toner)

Toner density

A193D522.wmf

Detailed

Descriptions

PCU (PHOTOCONDUCTOR UNIT)

SM 2-35 (A193)

- Toner Density Sensor Initial Setting -

The TD sensor initial setting procedure is performed in the factory. During TD initial setting, the machine calibrates the TD sensor control voltage (V

CONT

) so that the TD sensor output voltage is 2.0 ± 0.1V using new developer with a standard toner concentration (6% by weight, 21.6 g of toner in 360 g of developer). This factory-adjusted value will be used for toner density control processing.

- Toner Density Measurement -

Toner density in the developer is detected once every copy cycle (point "1" on the flow chart). The sensor output voltage (VT) during the detection cycle is compared with the toner supply reference voltage (V

TREF

- Toner Supply Reference Voltage (V

TREF

) Determination -

The toner reference voltage (V

TREF

) is the TD sensor initial setting voltage, corrected for humidity as detected by the humidity sensor (point "2" on the flow chart). To change the image density, the humidity correction coefficient for V

TREF

can be changed using SP 2-911 (there are five settings). The

larger the value entered in this SP mode, the lighter the copies will be.

- Toner Supply Determination -

TREF

is the threshold voltage for determining whether or not to supply toner.

If VT becomes greater than V

TREF

(points "3" and "4" on the flow chart), the

machine supplies additional toner.

PCU (PHOTOCONDUCTOR UNIT)

(A193) 2-36 SM

- Toner Supply Motor On Time Calculation -

The toner motor on time is determined by the following factors (point "5" on the flow chart).

•

∆

(this is VT - V

TREF

)

•

Copy volume counter

•

Paper size

The copy volume counter (C

VOL

) is determined as follows: 0: 1-9 consecutive copies have been made with ∆VT > 0 1: 10-19 consecutive copies have been made with ∆VT > 0

If ∆VT becomes negative at any time (i.e., there is enough toner), the counter (C

VOL

) will be reset to 0.

The toner motor on times are shown below.

Paper Length

< 250 mm

Paper Length

250 - 400 mm

Paper Length

> 400 mm

0 < ∆V

<= 0.22,

VOL

= 0

0.5 0.7 0.9

0 < ∆V

<= 0.22,

VOL

= 1

1.0 1.3 1.8

∆

> 0.22,

VOL

= 0 or 1

1.0 1.3 1.8

NOTE:

The toner supply amount is 0.1 g for 0.5 seconds

4.5.6 Toner Supply in Abnormal Sensor Conditions

There are two service codes for a TD sensor error. These SC conditions can be cleared by turning the main switch off and on again. After doing this, the machine automatically performs the TD sensor initial setting.

1. TD sensor error 1

When the TD sensor output voltage (VT) is less than 0.5 Volts for, 20 seconds after the TD sensor initial setting has been performed, SC390 will be generated. Refer to section 7.1.2 for the definition and possible cause.

2. TD sensor error 2

When the TD sensor initial setting is completed, if the TD sensor output voltage (VT) exceeds the specified range (2 ± 0.2 V), SC393 is generated. Refer to section 7.1.2. for the definition and possible cause.

Detailed

Descriptions

PCU (PHOTOCONDUCTOR UNIT)

SM 2-37 (A193)

4.5.7 Toner Supply

- Toner Bottle Replenishment Mechanism -

When a toner bottle is placed on the bottle holder unit [A] and pushed forward and the toner bottle holder lever [B] is lowered to its original position, the following actions will occur automatically to allow toner to be supplied to the development unit.

•

The pin [C] on the toner shutter [D] is pulled out (opened) as a result of the shape of the developer cartridge.

•

The cap [E] remaining on the toner bottle is pulled out of the bottle and moved away from the movement of the roller [G] by the chuck [F], which rides along the curved rail behind the toner bottle holder lever.

The toner end detection system determines when to drive the toner bottle replenishment mechanism (see Toner End Detection). The toner supply mechanism transports toner from the bottle to the development unit. The toner bottle has a spiral groove [H] that helps move toner to the development unit.

When the bottle holder unit is pulled out to add new toner, the following actions will occur automatically to prevent toner from spilling.

•

The chuck releases the toner bottle cap and insert the cap into the bottle.

•

The toner shutter shuts the opening as a result of pressure from a spring.

A193D516.wmf

[A]

[E]

[F]

[G]

[D]

[C]

[E]

[F]

[G]

[B]

[H]

A193D019.wmf

PCU (PHOTOCONDUCTOR UNIT)

(A193) 2-38 SM

- Toner Supply Mechanism -

The toner supply motor [A] drives the toner bottle [B] and the mylar blades [C]. First, the toner falls down into the toner holder. The toner supply mylar blades are used to transfer the toner to the slit [D], then the toner falls down into the development unit through the opening.

[D]

[C]

[A]

[B]

A193D020.wmf

Detailed

Descriptions

PCU (PHOTOCONDUCTOR UNIT)

SM 2-39 (A193)

Gestetner A193, A224 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual