Ricoh 6010, 6110 Service manual

Aficio Color 6010/6110

(Cattleya, A257/A269)

Service Manual

Issued March 30, 1999, Ricoh CO., LTD.

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged.

2. The wall outlet should be near the copier and easily accessible.

3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main power 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 electrified or mechanically driven components.

5. If the Start key is pressed before the copier completes the warm-up period (the Start key starts blinking red and green alternatively), keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period 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 bare hands.

HEALTH SAFETY CONDITIONS

1. Never operate the copier without the ozone filters installed.

2. Always replace the ozone filters with the specified ones at the specified intervals.

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

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 NVRAM on the system control board has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM 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 dispos e 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

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:

TABLE OF CONTENTS

1. OVERALL MACH INE INFORMATION........................................1-1

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

1.1.1 MAJOR UNITS................................................................................. 1-1

1.1.2 BASIC SPECIFICATIONS............................................................... 1-2

1.1.3 PLATEN/ARDF ORIGINAL SIZE DETECTION................................ 1-6

1.1.4 COPY PAPER SIZES...................................................................... 1-7

1.1.5 NOISE EMISSION........................................................................... 1-8

1.1.6 POWER CONSUMPTION................................................................ 1-8

1.2 MECHANISM OVERVIEW ....................................................................... 1-9

1.2.1 IMAGE GENERATION PROCESS.................................................. 1-9

1.2.2 MAJOR UNITS AND PAPER PATH .............................................. 1-11

1.3 PARTS LAYOUT .................................................................................... 1-13

1.3.1 MAJOR UNIT LAYOUT DIAGRAM................................................ 1-13

1.4 DRIVE LAYOUT ..................................................................................... 1-14

1.5 AIR FLOW .............................................................................................. 1-15

1.5.1 AIR FLOW SYSTEM 1 ................................................................... 1-15

1.5.2 AIR FLOW SYSTEM 2 ................................................................... 1-16

1.6 ELECTRICAL PARTS LAYOUT............................................................. 1-17

1.6.1 ELECTRICAL PARTS LAYOUT 1.................................................. 1-17

1.6.2 ELECTRICAL PARTS LAYOUT 2.................................................. 1-18

1.6.3 ELECTRICAL PARTS LAYOUT 3.................................................. 1-19

1.6.4 ELECTRICAL PARTS LAYOUT 4.................................................. 1-20

1.6.5 ELECTRICAL PARTS LAYOUT 5.................................................. 1-21

1.6.6 ELECTRICAL PARTS LAYOUT 6.................................................. 1-22

1.6.7 ELECTRICAL PARTS LAYOUT 7.................................................. 1-23

1.7 ELECTRICAL PARTS DESCRIPTIONS................................................. 1-24

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

2.1 PROCESS CONTROL.............................................................................. 2-1

2.1.1 OVERVIEW ..................................................................................... 2-1

2.1.2 POTENTIAL CONTROL .................................................................. 2-2

Overview.............................................................................................. 2-2

Potential Control Timing....................................................................... 2-2

2.1.3 PROCESS CONTROL γ CORRECTION ......................................... 2-4

What is process control γ?................................................................... 2-4

How is it done?..................................................................................... 2-4

Process Control γ Correction Timing.................................................... 2-5

Relationship Between Process Control γ Correction, ACC,

and Other γ Corrections.................................................................... 2-5

2.1.4 PROCESS CONTROL SELF CHECK OPERATION FLOW............ 2-6

Step 1: VSG Adjustment...................................................................... 2-7

Step 2: Generating ID Sensor Patch Patterns...................................... 2-7

Step 3: Sensor Pattern Potential Detection.......................................... 2-8

Step 4: Sensor Pattern Density Detection............................................ 2-9

Process................................................................................................ 2-9

Step 5: Toner Amount Calculation ..................................................... 2-11

Step 6: Development Potential Calculation........................................ 2-11

Step 7: Selecting the Optimum VD, VB, VL .......................................2-12

2.1.5 TONER SUPPLY CONTROL......................................................... 2-13

Toner Supply Control Modes ............................................................. 2-13

TD Sensor Output.............................................................................. 2-14

Toner Supply Calculation...................................................................2-14

Detecting VSP for Toner Supply Control............................................ 2-14

Calculating the Amount of Toner on the Drum................................... 2-15

Toner Near End/Toner End Detection................................................ 2-15

2.2 DRUM UNIT............................................................................................ 2-17

2.2.1 MAJOR COMPONENTS................................................................ 2-17

2.2.2 DRUM UNIT DRIVE....................................................................... 2-18

Drum Drive......................................................................................... 2-18

Cleaning Drive.................................................................................... 2-18

2.2.3 CHARGE CORONA UNIT ............................................................. 2-19

2.2.4 CHARGE CORONA UNIT CLEANER............................................ 2-20

2.2.5 CLEANING MECHANISM.............................................................. 2-21

Cleaning............................................................................................. 2-21

Lubricant Application.......................................................................... 2-21

2.2.6 PRE-CLEANING CORONA (PCC) ................................................ 2-21

2.2.7 QUENCHING................................................................................. 2-22

2.2.8 CARRIER CATCHER .................................................................... 2-22

2.3 SCANNER UNIT..................................................................................... 2-23

2.3.1 OVERVIEW ................................................................................... 2-23

2.3.2 SCANNER..................................................................................... 2-24

2.3.3 SCANNER DRIVE ......................................................................... 2-25

2.3.4 COLOR CCD ................................................................................. 2-26

2.3.5 WHITE PLATE SCANNING........................................................... 2-27

2.3.6 SCANNER IPU .............................................................................. 2-27

2.3.7 ORIGINAL SIZE DETECTION....................................................... 2-28

2.3.8 OTHERS........................................................................................ 2-30

Anti-condensation Heater................................................................... 2-30

Fans................................................................................................... 2-30

2.4 IMAGE PROCESSING ........................................................................... 2-31

2.4.1 OVERVIEW ................................................................................... 2-31

2.4.2 SCANNER SECTION BLOCK DIAGRAM...................................... 2-32

2.4.3 SCANNER FUNCTIONS ............................................................... 2-33

Photoelectric Conversion................................................................... 2-33

Signal Processing (Analog ASIC)....................................................... 2-33

A/D Conversion.................................................................................. 2-33

Shading Compensation Circuit........................................................... 2-34

D/A Conversion.................................................................................. 2-35

Scan Line Correction Circuit .............................................................. 2-35

2.4.4 IPU SECTION BLOCK DIAGRAM................................................. 2-36

2.4.5 IPU FUNCTIONS...........................................................................2-37

Scanner γ Conversion and Picture Element Correction...................... 2-37

ACS (Auto Color Selection)................................................................ 2-39

Automatic Original Type Selection..................................................... 2-40

Image Separation............................................................................... 2-41

Filtering and Color Conversion........................................................... 2-42

Magnification Processing................................................................... 2-46

Image Creation................................................................................... 2-47

Gradation Processing......................................................................... 2-49

Area Manipulation Functions.............................................................. 2-52

CPU ................................................................................................... 2-52

IPU Board Test................................................................................... 2-52

2.5 LASER EXPOSURE............................................................................... 2-53

2.5.1 OVERVIEW ................................................................................... 2-53

2.5.2 LD UNIT......................................................................................... 2-54

LD Safety Switch................................................................................ 2-54

LD Unit Configuration......................................................................... 2-55

Auto Power Control (APC)................................................................. 2-56

2.5.3 LASER OPTICS SYSTEM............................................................. 2-57

Cylindrical Lens.................................................................................. 2-57

Polygon Mirror.................................................................................... 2-57

f θ Lenses and the BTL...................................................................... 2-58

Laser Synchronization Mechanism.................................................... 2-58

Laser Exposure Control ..................................................................... 2-59

Multibeam Laser Exposure ................................................................ 2-60

Laser Diode Control Board Functions................................................ 2-60

2.6 DEVELOPMENT UNIT........................................................................... 2-61

2.6.1 OVERVIEW ................................................................................... 2-61

2.6.2 REVOLVER MECHANISM............................................................. 2-62

Revolver Drive.................................................................................... 2-63

Revolver Home Position Detection..................................................... 2-64

2.6.3 DEVELOPMENT MECHANISM..................................................... 2-65

2.6.4 DEVELOPMENT DRIVE................................................................ 2-66

2.6.5 DEVELOPER AGITATION............................................................. 2-66

2.6.6 TONER AGITATION...................................................................... 2-67

2.6.7 DEVELOPMENT BIAS................................................................... 2-67

2.6.8 TD SENSOR NONCONTACT COUPLER ..................................... 2-68

2.6.9 TONER SUPPLY MECHANISM.................................................... 2-69

2.6.10 TONER CARTRIDGE DETECTION............................................. 2-70

2.6.11 TONER CARTRIDGE SHUTTER LOCK PIN............................... 2-70

2.6.12 INCORRECT TONER INSTALLATION PREVENTION ............... 2- 70

2.6.13 TONER END SENSOR................................................................ 2-71

2.6.14 TONER END RECOVERY........................................................... 2-72

2.6.15 TONER LOOSENING..................................................................2-73

2.6.16 REVOLVER LOCK MECHANISM................................................ 2-74

2.7 TRANSFER BELT UNITS....................................................................... 2-75

2.7.1 OVERVIEW ................................................................................... 2-75

2.7.2 IMAGE TRANSFER BELT SECTION............................................ 2-76

Image Transfer Belt Drive Mechanism............................................... 2-76

Belt Tension Release Mechanism...................................................... 2-77

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Image Transfer Belt Bias.................................................................... 2-78

Belt Mark Sensor Mechanism............................................................ 2-78

Belt Cleaning Mechanism .................................................................. 2-79

Cleaning Vacuum............................................................................... 2-81

Toner Collection Mechanism.............................................................. 2-81

2.7.3 PAPER TRANSFER BELT SECTION............................................ 2-82

Paper Transfer Unit Contact/Release Mechanism............................. 2-82

Paper Transfer Belt Drive................................................................... 2-82

Paper Transfer Belt Cleaning............................................................. 2-83

Paper Transfer Bias........................................................................... 2-84

Paper Transfer Belt Discharge........................................................... 2-85

Paper Separation Mechanism............................................................ 2-85

2.8 PAPER FEED AND REGISTRATION SECTION.................................... 2-86

2.8.1 MAJOR COMPONENTS................................................................ 2-86

Diagram ............................................................................................. 2-86

2.8.2 PAPER TRAY SECTION............................................................... 2-87

Paper Feed/Separation Mechanism................................................... 2-87

Reverse Roller Release Mechanism.................................................. 2-87

Paper Feed Operation........................................................................ 2-87

Paper Lift Mechanism ........................................................................2-88

Paper End Detection..........................................................................2-89

Paper Near End Detection................................................................. 2-89

2.8.3 BY-PASS PAPER FEED SECTION............................................... 2-90

By-pass Feed Table........................................................................... 2-90

By-pass Feed Unit.............................................................................. 2-90

By-pass Paper End Sensor................................................................ 2-90

By-pass Pick-up Roller Pressure........................................................ 2-91

By-pass Pick-up/Reverse Solenoid Timing Chart...............................2-92

2.8.4 PAPER FEED DRIVE.................................................................... 2-93

Tray Feed Unit Drive.......................................................................... 2-93

Registration Roller Drive.................................................................... 2-93

By-pass Feed Unit Drive.................................................................... 2-93

2.9 TRANSPORT, FUSING, AND EXIT........................................................ 2-94

2.9.1 MAJOR COMPONENTS................................................................ 2-94

2.9.2 DRIVE MECHANISM..................................................................... 2-95

2.9.3 FUSING OVERVIEW..................................................................... 2-96

2.9.4 FUSING TEMPERATURE CONTROL........................................... 2-97

2.9.5 FUSING PRESSURE..................................................................... 2-97

2.9.6 OIL SUPPLY.................................................................................. 2-98

2.9.7 CLEANING MECHANISM.............................................................. 2-98

2.9.8 PAPER EXIT AND PAPER INVERSION....................................... 2-99

Paper Exit Mechanism....................................................................... 2-99

Junction Gate Mechanism.................................................................. 2-99

Paper Exit Cover................................................................................2-99

2.10 DUPLEX TRAY................................................................................... 2-100

2.10.1 OVERVIEW ............................................................................... 2-100

2.10.2 DRIVE MECHANISM................................................................. 2-101

2.10.3 PAPER FEED INTO THE DUPLEX TRAY................................. 2-102

Duplex Stacking............................................................................... 2-102

Paper Feed from the Duplex Tray.................................................... 2-102

Duplex Entrance to Duplex Tray...................................................... 2-103

2.10.4 JOGGER MECHANISM............................................................. 2-104

2.10.5 PAPER FEED FROM THE DUPLEX TRAY............................... 2-105

Bottom Plate Lift Mechanism ........................................................... 2-105

2.10.6 PAPER FEED-OUT MECHANISM............................................. 2-106

2.11 SYSTEM CONFIGURATION.............................................................. 2-107

2.11.1 CONFIGURATION..................................................................... 2-107

2.11.2 NORMAL COPY MODE............................................................. 2-108

Main Power Switch Off State ........................................................... 2-108

Power-off (Sleep) State.................................................................... 2-108

Copier Modes................................................................................... 2-109

2.11.3 OPERATION PANEL................................................................. 2-110

2.11.4 PRINTER CONTROLLER INTERFACE .................................... 2-111

3. INSTALLATION PROCEDURES................................................. 3-1

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

3.1.1 DIMENSIONS.................................................................................. 3-1

3.1.2 ENVIRONMENT ..............................................................................3-2

Environmental Requirements............................................................... 3-2

Minimum Space Requirements............................................................ 3-3

Power Requirements............................................................................ 3-4

3.2 COPIER.................................................................................................... 3-5

3.2.1 ACCESSORY CHECK..................................................................... 3-5

3.2.2 PREPERATION............................................................................... 3-6

3.2.3 DEVELOPER INSTALLATION....................................................... 3-10

3.2.4 LOADING TONER CARTRIDGES................................................. 3-14

3.2.5 FUSING UNIT................................................................................ 3-16

3.2.6 DEFAULT SETTINGS AND OPERATION CHECKS..................... 3-17

3.2.7 HEIGHT ADJUSTMENT................................................................ 3-19

3.2.8 COUNTER DISPLAY SETTING...................................................... 3-19

3.2.9 RESETTING THE ELECTRONIC TOTAL COUNTER................... 3-19

3.2.10 PREPARATION FOR TRANSPORT............................................ 3-20

3.3 PLATEN COVER (A749-01)................................................................... 3-21

3.3.1 INSTALLATION............................................................................. 3-21

3.4 ARDF (A663).......................................................................................... 3-22

3.4.1 ACCESSORY CHECK................................................................... 3-22

3.4.2 INSTALLATION............................................................................. 3-23

3.5 SORTER STAPLER (A831).................................................................... 3-24

3.5.1 INSTALLATION............................................................................. 3-24

3.6 LCT (A683)............................................................................................. 3-29

3.6.1 INSTALLATION............................................................................. 3-29

3.7 LCT ADAPTER (A840)........................................................................... 3-30

3.7.1 INSTALLATION............................................................................. 3-30

3.8 FILM PROJECTOR TABLE (A702-19)................................................... 3-36

3.8.1 INSTALLATION............................................................................. 3-36

3.9 FILM PROJECTOR UNIT(A846) ............................................................ 3-38

3.9.1 ACCESSORY CHECK................................................................... 3-38

3.9.2 INSTALLATION............................................................................. 3-39

3.10 KEY COUNTER HOLDER.................................................................... 3-46

3.11 USER CODE SETTING........................................................................ 3-47

4. SERVICE TABLES......................................................................4-1

4.1 SERVICE PROGRAM (SP) MODES........................................................ 4-1

4.1.1 HOW TO ENTER AN SP MODE...................................................... 4-1

4.1.2 SP MODE TYPES............................................................................ 4-3

4.1.3 SP MODE CHART........................................................................... 4-3

4.1.4 SP4-301 APS OPERATION CHECK DETAILS ............................... 4-3

4.1.5 TEST PATTERN.............................................................................. 4-5

4.1.6 SP5-803 INPUT CHECK.................................................................. 4-6

4.1.7 SP5-804 OUTPUT CHECK.............................................................. 4-9

4.1.8 SP5-955 PRINTER INTERNAL PATTERN .................................... 4-11

5-955-018: Internal Pattern Types...................................................... 4-11

4.2 USER TOOLS......................................................................................... 4-11

4.2.1 HOW TO ENTER USER TOOLS................................................... 4-11

4.2.2 DETAILED DESCRIPTION OF USER TOOLS.............................. 4-12

4.3 TP/SW/LED/FUSE.................................................................................. 4-12

4.3.1 MAIN CONTROL BOARD TEST PINS.......................................... 4-12

4.3.2 LD MAIN CONTROL BOARD TEST PINS..................................... 4-13

4.3.3 I/O CONTROL BOARD TEST PINS.............................................. 4-13

4.3.4 FUSE SPECIFICATIONS .............................................................. 4-19

4.3.5 LED/SW SPECIFICATIONS OF SCANNER IPU BOARD............. 4-20

LED Specifications............................................................................. 4-20

SW Specifications.............................................................................. 4-20

5. PREVENTIVE MAINTENANCE...................................................5-1

5.1 PM PROCEDURES.................................................................................. 5-1

5.1.1 PM-RELATED COUNTERS............................................................. 5-1

SP7-803 (PM Counter Display)............................................................ 5-1

5.1.2 REGULAR PREVENTIVE MAINTENANCE FLOW DIAGRAM........ 5-4

5.2 REGULAR PM ITEMS.............................................................................. 5-7

5.2.1 REGULAR PM TABLE..................................................................... 5-7

Peripherals......................................................................................... 5-11

6. REPLACEMENT AND ADJUSTMENT ........................................ 6-1

6.1 PM-RELATED COUNTERS...................................................................... 6-1

6.2 SERVICE REMARKS............................................................................... 6-1

6.3 COVERS AND FILTERS.......................................................................... 6-2

6.3.1 UPPER AND LOWER FRONT COVER........................................... 6-2

6.3.2 RIGHT-SIDE FRONT COVER AND RIGHT EDGE COVER............ 6-2

6.3.3 INNER COVERS.............................................................................. 6-3

6.3.4 REAR COVERS............................................................................... 6-3

6.3.5 LEFT COVERS................................................................................ 6-4

6.3.6 EXPOSURE GLASS........................................................................ 6-4

6.3.7 OPERATION PANEL....................................................................... 6-5

6.3.8 USED TONER TANK....................................................................... 6-5

6.3.9 CHARGE CORONA FILTER............................................................ 6-6

6.3.10 DUST AND OZONE FILTERS....................................................... 6-6

6.3.11 SCANNER FILTER........................................................................ 6-7

6.3.12 REVOLVER FILTER...................................................................... 6-7

6.3.13 INNER COVER FILTER................................................................. 6-8

6.3.14 FUSING UNIT FILTER................................................................... 6-8

6.4 UNIT REMOVAL....................................................................................... 6-9

6.4.1 REVOLVER/DRUM DRAWER......................................................... 6-9

6.4.2 DRUM UNIT REMOVAL................................................................ 6-10

6.4.3 REINSTALLING THE REVOLVER/DRUM DRAWER.................... 6-11

6.4.4 IMAGE TRANSFER BELT UNIT REMOVAL................................. 6-12

Reinstalling the Image Transfer Belt Unit........................................... 6-13

6.4.5 PAPER TRANSFER UNIT REMOVAL........................................... 6-14

6.4.6 REMOVING THE FUSING UNIT................................................... 6-15

6.5 DRUM UNIT............................................................................................ 6-16

6.5.1 DRUM REPLACEMENT................................................................ 6-16

Post-replacement Procedure ............................................................. 6-17

6.5.2 CLEANING BLADE REPLACEMENT............................................ 6-18

6.5.3 CLEANING BRUSH REPLACEMENT........................................... 6-19

6.5.4 LUBRICANT BAR REPLACEMENT.............................................. 6-19

6.5.5 BIAS ROLLER BLADE REPLACEMENT....................................... 6-20

6.5.6 CHARGE GRID AND CORONA WIRE REPLACEMENT.............. 6-20

6.5.7 PCC REPLACEMENT ................................................................... 6-21

6.5.8 DRUM POTENTIAL SENSOR REPLACEMENT........................... 6-22

6.5.9 ID SENSOR REPLACEMENT....................................................... 6-23

6.6 SCANNER UNIT..................................................................................... 6-24

6.6.1 EXPOSURE LAMP REPLACEMENT............................................ 6-24

6.6.2 SBU REPLACEMENT.................................................................... 6-25

6.6.3 OPENING THE SCANNER UNIT.................................................. 6-26

6.6.4 SCANNER IPU MAIN/SUB BOARD REPLACEMENT................... 6-28

6.6.5 SCANNER WIRE REPLACEMENT............................................... 6-29

6.6.6 APS AND H.P. SENSOR REPLACEMENT ................................... 6-32

6.7 COPY IMAGE ADJUSTMENT................................................................ 6-33

6.7.1 PRINTER γ ADJUSTMENT............................................................ 6-33

Auto Color Calibration (ACC)............................................................. 6-33

KCMY Color Balance Adjustment...................................................... 6-33

vii

ACC Target Modification.................................................................... 6-36

6.7.2 MAIN SCAN POSITION DOT CORRECTION............................... 6-37

6.8 LASER OPTICS SECTION..................................................................... 6-40

6.8.1 POLYGON MIRROR MOTOR REPLACEMENT............................ 6-40

6.8.2 LASER SYNCHRONIZING DETECTOR REPLACEMENT............ 6-42

6.8.3 LD UNIT REPLACEMENT............................................................. 6-42

LD Pitch Check and Adjustment]........................................................ 6-43

6.8.4 SQUARENESS ADJUSTMENT..................................................... 6-47

6.8.5 LD CONTROL BOARD REPLACEMENT...................................... 6-49

6.9 DEVELOPMENT UNIT........................................................................... 6-50

6.9.1 DEVELOPER REPLACEMENT..................................................... 6-50

Developer Collection.......................................................................... 6-50

6.9.2 DEVELOPER INSTALLATION....................................................... 6-53

6.9.3 DEVELOPMENT UNIT REPLACEMENT....................................... 6-58

6.9.4 TONER CATCH COVER CLEANING............................................ 6-59

6.9.5 REVOLVER MOTOR REPLACEMENT......................................... 6-60

6.9.6 TONER DENSITY SENSOR REPLACEMENT.............................. 6-61

6.9.7 TD SENSOR NONCONTACT COUPLER REPLACEMENT.......... 6-62

Main Unit Element.............................................................................. 6-62

TD Sensor Interface (I/F) Board......................................................... 6-63

6.8 IMAGE TRANSFER SECTION............................................................... 6-65

6.8.1 IMAGE TRANSFER BELT REPLACEMENT ................................. 6-65

6.8.2 IMAGE TRANSFER BELT BLADE REPLACEMENT..................... 6-67

6.8.3 TRANSFER BELT LUBRICANT BAR AND LUBRICANT

BRUSH REPLACEMENT .............................................................. 6-68

6.8.4 PAPER TRANSFER BELT REPLACEMENT ................................. 6-69

6.8.5 PAPER TRANSFER BELT BLADE/CLEANING BRUSH

REPLACEMENT............................................................................ 6-69

6.8.6 BACK BRUSH REPLACEMENT.................................................... 6-70

6.8.7 PAPER TRANSFER BELT DISCHARGE CORONA WIRE

REPLACEMENT............................................................................ 6-70

6.8.8 PAPER DISCHARGE CORONA WIRE REPLACEMENT.............. 6-71

6.9 PAPER FEED AND REGISTRATION SECTION.................................... 6-72

6.9.1 BY-PASS FEED TABLE REMOVAL.............................................. 6-72

6.9.2 BY-PASS FEED PAPER WIDTH SENSOR REPLACEMENT....... 6-73

6.9.3 BY-PASS PICK-UP ROLLER REPLACEMENT............................. 6-74

6.9.4 BY-PASS FEED ROLLER REPLACEMENT.................................. 6-74

6.9.5 BY-PASS SEPARATION ROLLER REPLACEMENT.................... 6-75

6.9.6 BY-PASS PAPER FEED UNIT REMOVAL.................................... 6-75

6.9.7 BY-PASS PAPER FEED UNIT INSTALLATION............................ 6-76

6.9.8 REGISTRATION SENSOR REPLACEMENT................................ 6-78

6.9.9 PAPER TRAY ROLLER REPLACEMENT..................................... 6-78

6.9.10 PAPER FEED UNIT AND PAPER FEED CLUTCH

REPLACEMENT.......................................................................... 6-79

6.9.11 COPY IMAGE AREA ADJUSTMENT .......................................... 6-80

PAPER TRANSPORT, FUSING, AND PAPER EXIT......................... 6-83

6.10.1 TRANSPORT UNIT REMOVAL................................................... 6-83

6.10.2 FUSING UNIT TOP COVER REMOVAL ..................................... 6-83

6.10.3 OIL SUPPLY UNIT REPLACEMENT AND CLEANING............... 6-84

viii

6.10.4 HOT ROLLER BLADE REPLACEMENT ..................................... 6-85

6.10.5 CLEANING THE CLEANING ROLLER SCRAPER...................... 6-86

6.10.6 FUSING THERMOFUSE AND THERMISTOR REPLACEMENT 6-86

6.10.7 FUSING UNIT DISASSEMBLY.................................................... 6-87

6.10.8 FUSING LAMP REPLACEMENT................................................. 6-88

6.10.9 HOT ROLLER REPLACEMENT.................................................. 6-88

6.10.10 HOT ROLLER CLEANING ROLLER CLEANING...................... 6-89

6.10.11 PRESSURE ROLLER LAMP/ROLLER REPLACEMENT.......... 6-89

6.10.12 PRESSURE THERMOFUSE AND THERMISTOR

REPLACEMENT........................................................................ 6-90

6.10.13 PRESSURE CLEANING ROLLER CLEANING......................... 6-90

6.10.14 NIP BAND WIDTH ADJUSTMENT............................................ 6-91

6.10.15 CAUTIONS TO BE TAKEN WHEN USING A FUSING UNIT

THAT HAS BEEN IN STOCK FOR A LONG PERIOD .............. 6-92

6.11 DUPLEX UNIT...................................................................................... 6-93

6.11.1 DUPLEX UNIT REMOVAL........................................................... 6-93

6.11.2 SEPARATION ROLLER REPLACEMENT................................... 6-93

6.11.3 FEED ROLLER REPLACEMENT................................................ 6-94

6.11.4 DUPLEX FEED MOTOR REPLACEMENT.................................. 6-95

6.12 SYSTEM AND ELECTRONICS............................................................ 6-97

6.12.1 SOFTWARE UPDATE USING AN IC CARD............................... 6-97

Care of the IC Card............................................................................ 6-97

Upgrading the Main Control Board Software...................................... 6-97

Upgrading the Scanner IPU Software................................................ 6-98

NV-RAM Uploading and Downloading............................................. 6-101

Upload/download procedure............................................................ 6-101

6.12.2 RAM CLEAR.............................................................................. 6-102

RAM Clear Procedure...................................................................... 6-102

6.12.3 MAIN CONTROL BOARD.......................................................... 6-103

Main Control Board Replacement Procedure................................... 6-103

6.12.4 COUNTERS............................................................................... 6-104

About the Total Counter................................................................... 6-104

Mechanical Counter......................................................................... 6-104

NV-RAM Replacement Procedure................................................... 6-105

6.12.5 TOUCH PANEL CALIBRATION................................................. 6-106

7. TROUBLESHOOTING.................................................................7-1

7.1 PROCESS CONTROL ERROR CONDITIONS ........................................ 7-1

7.1.1 PROCESS CONTROL SELF CHECK RESULTS (SP3-975-00)...... 7-1

7.1.2 DEVELOPER SETUP RESULTS (SP3-964-00).............................. 7-2

“Developer Agitation (SP2-225)” OPERATION FLOW........................ 7-3

7.1.3 TD SENSOR INITIALIZATION RESULTS (SP3-005-006)............... 7-3

7.1.4 SELF-CHECK PROCESS CONTROL RELATED SCS ................... 7-4

SC385: Vsg Adjustment Error.............................................................. 7-4

7.2 SC CODE TABLE..................................................................................... 7-4

7.3 DRUM LIGHT FATIGUE............................................................................ 7-5

OPTIONS

ARDF (A663)

1. SPECIFICATIONS.................................................................A663-1

2. COMPONENT LAYOUT........................................................A663-2

2.1 MECHANICAL COMPONENTS..........................................................A663-2

2.2 ELECTRICAL COMPONENTS...........................................................A663-3

3. ELECTRICAL COMPONENT DESCRIPTION.......................A663-4

4. DETAILED DESCRIPTIONS.................................................A663-5

4.1 ORIGINAL PICK-UP MECHANISM....................................................A663-5

4.2 SEPARATION AND PAPER FEED MECHANISM..............................A663-6

4.3 FRICTION BELT DRIVE MECHANISM..............................................A663-7

4.4 ORIGINAL SIZE DETECTION............................................................A663-8

4.5 PAPER TRANSPORT MECHANISM..................................................A663-9

4.6 THICK/THIN ORIGINAL MODES ..................................................... A663-10

4.7 ORIGINAL FEED-OUT MECHANISM...............................................A663-11

4.8 TWO-SIDED ORIGINAL FEED MECHANISM..................................A663-12

5. TIMING CHARTS ................................................................A663-13

5.1 A4 SIDEWAYS: 1 SIDED ORIGINAL ...............................................A663-13

5.2 COMBINE 2 ORIGINAL MODE........................................................A663-14

5.3 A4 SIDEWAYS: DUPLEX.................................................................A663-15

6. SERVICE TABLES..............................................................A663-16

6.1 DIP SWITCHES................................................................................A663-16

6.2 VARIABLE RESISTORS...................................................................A663-17

6.3 LED...................................................................................................A663-17

6.4 FUSE................................................................................................A663-17

7. REPLACEMENT AND ADJUSTMENT................................A663-18

7.1 TRANSPORT BELT REPLACEMENT..............................................A663-18

7.2 FEED ROLLER REPLACEMENT..................................................... A663-19

7.3 FRICTION BELT REPLACEMENT...................................................A663-20

7.4 ORIGINAL SET AND WIDTH SENSOR REPLACEMENT................A663-21

7.5 VERTICAL REGISTRATION ADJUSTMENT...................................A663-22

7.5.1 ONE SIDED THIN ORIGINAL MODE......................................A663-22

7.5.2 TWO SIDED ORIGINAL MODE...............................................A663-23

7.6 SIDE-TO-SIDE REGISTRATION (DF POSITIONING)

ADJUSTMENT..................................................................................A663-24

LCT (A683)

1. OVERALL MACH IN E INF O RMATION..................................A683-1

1.1 SPECIFICATIONS..............................................................................A683-1

1.2 MECHANICAL COMPONENT LAYOUT.............................................A683-2

1.3 ELECTRICAL COMPONENT LAYOUT..............................................A683-3

1.4 ELECTRICAL COMPONENT DESCRIPTION....................................A683-4

1.5 DRIVE LAYOUT .................................................................................A683-5

2. DETAILED DESCRIPTIONS.................................................A683-6

2.1 PAPER FEED MECHANISM..............................................................A683-6

2.2 TRAY LIFT AND PAPER HEIGHT DETECTION MECHANISM.........A683-7

Tray lifting conditions ..................................................................... A683-7

Tray lowering conditions ................................................................A683-7

2.3 TRAY UNIT SLIDE MECHANISM.......................................................A683-8

3. SERVICE TABLES................................................................A683-9

3.1 DIP SWITCHES..................................................................................A683-9

3.2 TEST POINTS....................................................................................A683-9

3.3 SWITCHES.........................................................................................A683-9

3.4 FUSES................................................................................................ A683-9

4. REPLACEMENT AND ADJUSTMENT................................A683-10

4.1 COVER REPLACEMENT.................................................................A683-10

Tray Cover...................................................................................A683-10

Front Cover..................................................................................A683-10

Rear Cover...................................................................................A683-10

Right Lower Cover .......................................................................A683-10

Upper Cover.................................................................................A683-10

4.2 ROLLER REPLACEMENT................................................................A683-11

4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ......A683-11

Pick-up Roller...............................................................................A683-11

Paper Feed Roller........................................................................A683-11

Separation Roller.........................................................................A683-11

4.3 TRAY LIFT AND PAPER END SENSOR REPLACEMENT .............. A683-12

Tray Lift Sensor............................................................................A683-12

Paper End Sensor........................................................................ A683-12

4.4 RELAY SENSOR REPLACEMENT..................................................A683-13

4.5 SIDE FENCE POSITION CHANGE..................................................A683-14

SORTER STAPLER (A831)

1. OVERALL MAHC INE INFORMATION..................................A831-1

1.1 SPECIFICATIONS..............................................................................A831-1

1.2 COMPONENT LAYOUT.....................................................................A831-3

1.2.1 MECHANICAL COMPONENT LAYOUT .................................... A831-3

1.2.2 DRIVE LAYOUT.........................................................................A831-4

2. DETAILED DESCRIPTION.................................................... A831-5

2.1 BASIC OPERATION...........................................................................A831-5

2.1.1 NORMAL (PROOF MODE) AND SORT/STACK MODE............A831-5

Normal (Proof) Mod e (From the Turn Gate Section

to the Proof Tray) ...............................................................A831-5

Sort Mode (From the Turn Gate Section to the Bins).....................A831-6

Stack Mode (From the Turn Gate Section to the Bins)...................A831-7

Reverse Mode (From the Turn Gate Section to the Bins)..............A831-8

2.1.2 STAPLE MODE.........................................................................A831-9

2.2 TURN GATE SECTION....................................................................A831-11

2.3 BIN DRIVE MECHANISM.................................................................A831-12

2.4 BIN HOME POSITION......................................................................A831-13

2.5 JOGGER SECTION..........................................................................A831-14

2.6 BIN REAR PLATE DRIVE SECTION................................................ A831-15

2.7 GRIP ASSEMBLY.............................................................................A831-16

2.7.1 GRIP MOTOR..........................................................................A831-17

2.7.2 GRIP SHIFT MOTOR ..............................................................A831-18

2.8 STAPLE UNIT...................................................................................A831-19

2.8.1 STAPLE UNIT DRIVE MECHANISM.......................................A831-19

2.8.2 STAPLER ................................................................................A831-20

Staple Prohibit Conditions............................................................ A831-21

2.8.3 STAPLE UNIT PULLED-OUT MECHANISM...........................A831-22

3. REPLACEMENTS AND ADJUSTMENTS...........................A831-23

3.1 EXTERIOR COVER REMOVAL....................................................... A831-23

3.2 STAPLER REMOVAL AND REINSTALLATION...............................A831-24

3.3 JOGGER PLATE REMOVAL AND INSTALLATIOIN........................A831-25

Removal.......................................................................................A831-25

Installation....................................................................................A831-25

3.4 BINS REMOVAL...............................................................................A831-26

Removal.......................................................................................A831-26

Installation....................................................................................A831-28

3.5 MAIN MOTOR REMOVAL................................................................A831-30

3.6 GRIP ASSEMBLY REMOVAL..........................................................A831-31

3.7 UPPER GRIP ASSEMBLY REMOVAL ............................................. A831-32

3.8 GRIP SHIFT MOTOR REMOVAL.....................................................A831-33

3.9 HELICAL WHEELS REMOVAL........................................................A831-34

Removal.......................................................................................A831-34

Front Helical Wheel......................................................................A831-34

Rear Helical Wheel ...................................................................... A831-35

Installation....................................................................................A831-36

Rear Helical Wheel ...................................................................... A831-36

Front Helical Wheel......................................................................A831-37

Alignment of the 2 Helical Wheels................................................A831-38

3.10 GRIP MOTOR AND SENSORS REMOVAL...................................A831-39

3.10.1 GRIP MOTOR/GRIP MOTOR HP SENSOR/GRIP

SHIFT MOTOR HP SENSOR REMOVAL............................. A831-39

3.11 MAIN CONTROL BOARD REPLACEMENT...................................A831-40

xii

4. SP MODE AND STAPLE POSITION ADJUSTMENT..........A831-41

4.1 SERVICE TABLES (MAIN CONTROL BOARD)...............................A831-41

4.1.1 DIP SWITCHES.......................................................................A831-41

DIP 1 (Mode) SP Mode................................................................A831-41

DIP 2 (Staple) Staple Position Adjustment (A) DIP 3 (Chuck)

Staple Position Adjustment (B).................................................A831-41

FPU (A846)

1. SPECIFICAT IONS..................................................................

A846-

2. ELECTRICAL COMPONENT LAYOUT

AND DESCRIPTIONS...........................................................

3. SECTIONAL DESCRIPTIONS................................................

3.1 OVERVIEW ........................................................................................ A846-3

3.2 SHADING ...........................................................................................A846-4

3.3 MIRROR UNIT....................................................................................A846-5

A846A846-

APPENDIX

APPENDIX-1

SC CODE TABLE

APPENDIX-2

SP MODE

APPENDIX-3

POP-UP DISPALYS

APPENDIX-4

TIMING CHARTS

2 3

xiii

30 March 1999 SPECIFICATIONS

1. OVERALL MACHINE INFORMATION

1.1 SPECIFICATIONS

1.1.1 MAJOR UNITS

•

A257 copier: Basic model

•

A269 copier: Editing model

Overall

Information

1. Original tray (A430)

2. FPU (A846)

3. FPU table (A702-19)

4. LCT (A683) + LCT adapter (A840-01)

5. 20 bin sorter stapler (A831)

6. ARDF (A663)

A269V001.PCX

Other options

•

Platen cover (A749-01)

•

Controller interface (A839)

1-1

SPECIFICATIONS 30 March 1999

1.1.2 BASIC SPECIFICATIONS

Type: Console type Copy process: Dry electrostatic transfer system Number of scans: 1 (image memory for A3/DLT full color copy is

installed) Pre-scan: Only when Auto Original Type mode is used Resolution: Copy mode (read/write): 400 dpi/600 dpi

Print mode (write): 600 dpi Gradations: 256 gradations (8 bits) Original types: Sheet, book, object Maximum original size: A3/11" x 17" Original reference position: Left rear corner Maximum print size: 323 mm x 473 mm Copy paper size: First tray

Maximum: A4 (S/L)/8 Minimum: A5 (S)/ 8

Other trays

Maximum: A3/11" x 17" Minimum: A5 (S)/ 8

By-pass

Maximum: 13" x 19" (330 x 483 mm) Minimum: Postcard (100 x 148 mm)

Auto/duplex

Maximum: A3/11" x 17" Minimum: A5 (S)/ 8

" x 11" (S/L)

1/2

" x 5

1/2

" x 5

1/2

" x 5

1/2

" (S)

Paper thickness: Tray feed (including duplex):

64 to 105 g/m2, 17 to 28 lb

By-pass feed:

64 to 256 g/m2, 17 to 68 lb Thick paper 1 (105 ~ 157 g/m2, 28 ~ 42 lb) Thick paper 2 (157 ~ 256 g/m2, 42 ~ 68 lb)

Non-reproduction area:

Leading edge: 4±2 mm Left and right: 2±2 mm (4 mm or less in total) Trailing edge: 2±2 mm

1-2

30 March 1999 SPECIFICATIONS

Copying speed (cpm):

Normal paper/

normal mode

OHP/thick

paper

ARDF 1 to 1

Duplex feed

Full

color

A4/8

" x 11" or less 10 40 13.5 10 13.5 10

1/2

A3/11" x 17" 5207575

" x 11" or less 4.5 7 5 4.5 5 4.5

1/2

A3/11" x 17" 2 3.5 2.5 2 2.5 2

" x 11" or less8318888

1/2

A3/11" x 17" 5155554

" x 11" or less 10 35 13.5 10 13.5 10

1/2

A3/11" x 17"T 5207575

C/M/

Y/K

B, G R

Warm-up time: 8 minutes and 30 seconds or less First copy time (A4/8

" x 11") Normal Paper:

1/2

Full color: 16.5 seconds or less

K, C, M, Y: 8 seconds or less

B, G: 14 seconds or less

R: 16.5 seconds or less Thick paper/OHP:

Full color: 29 seconds or less

Paper feed capacity: Tray:

500-sheet paper tray: 3 trays By-pass feed:

50 sheets Duplex tray:

50-sheet s (30 sheets for A3/11" x 17"

20 sheets (Full color)

K+M

K+Y

K+C

Overall

Information

Paper feed system: Tray:

FRR system (Stack height: 53 mm max.) By-pass feed:

FRR system (Stack height: 6 mm max.) Duplex tray:

Friction roller separation system

Reproduction Ratios:

" x 11"LT/11" x 17"DLT version A4/A3 version

1/2

Enlargement Full size Reduction Programmable Zoom

121, 129, 155, 200, 400% 115, 122, 141, 200, 400%

100% 100%

25, 50, 65, 73, 78, 85, 93% 25, 50, 65, 71, 75, 82, 93%

2 user ratios 2 user ratios

25% to 400% in 1% steps 25% to 400% in 1% steps

1-3

SPECIFICATIONS 30 March 1999

Number of continuous copies: 1 to 999 sheets Scanning system: 3-line 1-chip CCD sensor (400 dpi/5,000 pixels) Light source: 1-halogen-lamp indirect lighting (frosted surface) Print system: Twin laser beam, 600 dpi Development system: 2-component magnetic brush Drum cleaning system: Counter blade Image Transfer system: Belt transfer system Fusing system: Heat and pressure roller system with oil application Dimensions:

A269V155.WMF

A269V156.WMF

1. Copier

730 mm (W1) x 780 mm (D) x 980 mm (H1)

2. Copier + Platen Cover + Paper Exit Tray + By-pass Tray

1,643 mm (W2) x 780 mm (D) x 1,045 mm (H2)

1-4

30 March 1999 SPECIFICATIONS

A269V158.WMF

3. Copier + ARDF + LCT + Sorter Stapler + By-pass Tray

1,930 mm (W3) x 780 mm (D) x 1,110 mm (H3)

Overall

Information

Weight: 240 kg Power source: 120 V, 60 Hz, 16 A (North America)

220 ~ 240 V, 50 Hz, 8 A (Europe, Mid-East) 220 ~ 240 V, 50/60 Hz, 8 A (Asia)

1-5

SPECIFICATIONS 30 March 1999

1.1.3 PLATEN/ARDF ORIGINAL SIZE DETECTION

Size (width x length)

[mm]

A3 (297 x 420) L No Yes No Yes B4 (257 x 364) L No Yes No Yes A4 (210 x 297) L No Yes Yes Yes A4 (297 x 210) S No Yes Yes Yes B5 (182 x 257) L No Yes No Yes B5 (257 x 182) S No Yes No Yes A5 (148 x 210) L No Yes No Yes A5 (210 x 148) S No Yes No Yes B6 (128 x 182) L No No No Yes B6 (182 x 128) S No No No Yes 11" x 17" (DLT) Yes No Yes Yes 11" x 15" No No Yes No 10" x 14" Yes No Yes Yes

8.5" x 14" (LG) Yes No Yes No

8.5" x 13" (F4) Yes Yes Yes Yes

8.25" x 13" No No No No 8" x 13"(F) Yes No Yes No

8.5" x 11" (LT) Yes No Yes Yes 11" x 8.5" (LT) Yes No Yes Yes 8" x 10.5" No No No No 8" x 10" Yes No Yes No

5.5" x 8.5" (HLT) Yes No Yes No

8.5" x 5.5" (HLT) Yes No Yes No A6 (105 x 148) L No No No No

Inch Metric Inch Metric

Platen ARDF

NOTE:

In the above table "Inch" refers to versions of the machine that use nonmetric traditional paper sizes and "Metric" refers to versions that use ISO standard paper sizes.

1-6

30 March 1999 SPECIFICATIONS

1.1.4 COPY PAPER SIZES

Size (width x length)

[mm]

A3 (297 x 420) L No Yes Yes Yes B4 (257 x 364) L No Yes Yes Yes A4 (210 x 297) L Yes Yes Yes Yes A4 (297 x 210) S Yes Yes Yes Yes B5 (182 x 257) L Yes Yes Yes Yes B5 (257 x 182) S Yes Yes Yes Yes A5 (148 x 210) L No No No Yes A5 (210 x 148) S Yes Yes Yes Yes B6 (128 x 182) L No No No Yes B6 (182 x 128) S No No No Yes 13" x 19" No No No Yes 12" x 18" No No No Yes 11" x 17" (DLT) No Yes Yes Yes 11" x 15" No Yes No No 10" x 14" No Yes Yes No

8.5" x 14" (LG) No Yes Yes No

8.5" x 13" (F4) No Yes Yes No

8.25" x 13" No Yes Yes No 8" x 13"(F) No Yes Yes No

8.5" x 11" (LT) Yes Yes Yes Yes 11" x 8.5" (LT) Yes Yes Yes Yes 8" x 10.5" No Yes Yes No 8" x 10" No Yes Yes No

5.5" x 8.5" (HLT) No No No Yes

8.5" x 5.5" (HLT) Yes Yes Yes Yes A6 (105 x 148) L No No No Yes

1st Tray 2nd/3rd Tray Duplex Tray By-pass Tray

Overall

Information

NOTE:

The by-pass sizes shown above are those that the machine can automatically detect. When by-pass feeding other sizes, the user should select "Custom Size" and input the length and width. (Length limitations = 148 ~ 483 mm, Width limitations = 100 ~ 330 mm).

1-7

SPECIFICATIONS 30 March 1999

1.1.5 NOISE EMISSION

Copier Only

Stand-by mode 54 dB (A)

Copy-mode average 70 dB (A)

1.1.6 POWER CONSUMPTION

1. Maximum power consumption

1.75 kVA

2. Average power consumption

Sleep mode 0.015 kW

Stand-by mode 0.6 kW

Warm-up time 1.7 kW

Copying 1.5 kW

1-8

30 March 1999 MECHANISM OVERVIEW

1.2 MECHANISM OVERVIEW

1.2.1 IMAGE GENERATION PROCESS

11 10

1 2

Overall

Information

A269V101.WMF

1. Drum charge

The charge corona applies a negative charge to the OPC drum and the grid ensures that this charge is even.

2. Quenching

After cleaning, the OPC is fully exposed to light from an array of red LEDs, quenching the residual charge on the OPC drum in preparation for the next copy cycle.

3. Drum cleaning

The cleaning brush increases drum cleaning efficiency by applying lubricant to the OPC drum. The cleaning blade scrapes the residual toner off the OPC drum.

4. PCC (Pre-cleaning corona)

The PCC discharges the photoconductor drum and applies AC and negative DC discharges to reduce the charge holding the residual toner to the drum, thereby improving the efficiency of cleaning.

1-9

MECHANISM OVERVIEW 30 March 1999

5. Image transfer to image transfer belt

Positive charge applied to the back of the image transfer belt transfers the toner image on the OPC drum to the image transfer belt.

6. Image transfer to paper

The negatively charged toner image is transferred to the paper by giving a positive charge to the back of the paper.

7. Image transfer belt cleaning and lubricant application

The brush applies lubricant, which makes it easier for the counter blade to scrape excess toner off the transfer belt. The lubricant improves toner transfer ability and reduces the amount of the partial blanking image.

8. Paper transfer belt cleaning

The paper transfer belt blade and brush always contact the paper transfer belt to clean the belt surface.

9. Paper transfer belt discharging

The belt discharge corona unit removes the charge on the paper transfer belt.

10. Paper Separation

A combination of curvature separation and corona discharge separate the paper from the paper transfer belt. The pick-off plate provides mechanical assistance to the separation process.

11. ID sensor

The ID sensor senses the density of the test patch patterns developed on the OPC drum.

12. Development

The latent image on the drum attracts the negatively charged toner. Toner is preferentially attracted to those places on the drum surface where the laser reduced the negative charge. (The development units for each color are included in the revolver unit.)

13. Drum potential sensor

The electrical potential on the OPC drum is sensed by the drum potential sensor for process control.

14. Laser exposure

The laser beam emitted from the laser assembly is reflected by the polygon mirror and projected onto the drum through the fθ lens, drum mirror, and toner shield glass. The laser output varies in intensity to correspond to the image data, and this forms a latent image.

1-10

30 March 1999 MECHANISM OVERVIEW

1.2.2 MAJOR UNITS AND PAPER PATH

3 4

Overall

Information

7 6

1. Scanner

•

400 dpi, 10-bit scanning in both main and sub scan directions

•

3-line CCD with reduction optics

•

Halogen exposure lamp

•

5-phase micro-stepper motor drive

A269V102.WMF

2. Operation panel

•

10.4-inch (640 x 480) color LCD (8 bit) touch-panel

3. Laser exposure unit

•

2 laser diode multi-beam system

•

Optics: 6-sided polygon mirror + 2 fθ lenses + barrel toroidal lens (BTL)

•

Polygon motor (23,622 rpm)

•

600 dpi (8 bit) print density

•

Modulation: power modulation + pulse width modulation

1-11

MECHANISM OVERVIEW 30 July, 1999 (Revised)

4. Drum unit

•

Drum unit contains OPC drum, charge corona unit, and cleaning unit.

•

Charge corona unit: Single scorotron charge

•

Quenching lamp: LED

•

Drive: Synchronized with the image transfer belt (timing belt + flywheel)

•

Potential sensor and ID sensor included

•

Cleaning unit: Blade, brush, lubricant, and pre-cleaning corona

5. Image transfer and belt drive

•

Image transfer belt: Full time contact with the drum

•

Image transfer: Bias/roller indirect application

•

Paper transfer: Belt transfer

•

Registration: Synchronization by the belt mark detection sensor

•

Image transfer belt: Driven by the image transfer belt motor

•

Paper transfer belt: Driven by the paper transfer motor

•

Separation: Curvature separation + corona discharge

•

Belt cleaning: Counter blade system

•

Lubrication: Brush roller with lubricant bar

6. Paper feed/transport system

•

Paper feed: 3 front loading 500-sheet trays + by-pass transport

•

Transport: Transport belt + vacuum fan

•

Duplexing: Duplex unit installed

7. Development and toner supply

•

Development: Two-component magnetic brush development

•

Development color switching: Revolver system

•

Image density control: TD sensor + ID sensor + process control

•

Toner supply: Cartridge type

•

Toner supply unit: Front of development units (on the revolver)

8. Fusing and paper exit section

•

Fusing: Silicone rubber roller fusing

•

Oil application method: roller

•

Cleaning: Roller cleaning for hot and pressure rollers (-15, -17, -19)

Roller cleaning for hot and cleaning blade for pressure roller (-22, -26, -27, -29)

•

OHP/thick paper speed selection

1-12

30 March 1999 PARTS LAYOUT

1.3 PARTS LAYOUT

1.3.1 MAJOR UNIT LAYOUT DIAGRAM

4321

6 7

10 11

Overall

Information

27 26

1. 1st scanner

2. Sensor board unit (SBU)

3. Drum mirror

4. Toner shield glass

5. 2nd scanner

6. Barrel toroidal lens (BTL)

7. Charge corona unit

8. 2nd fθ lens

9. 1st fθ lens

10. Polygon mirror

11. Drum cleaning unit

12. Pre-cleaning corona (PCC)

13. Image transfer unit

14. Image transfer belt cleaning unit

15. By-pass feed table

12 13 14

16 17

18 19

21 202223

A269V103.WMF

16. Registration rollers

17. 1st paper tray

18. Duplex unit

19. 2nd/3rd paper trays

20. Paper transfer belt unit

21. Paper transfer belt cleaning unit

22. Belt discharge corona unit

23. Transport belt

24. Used toner tank

25. Pressure roller

26. Hot roller

27. Separation corona unit

28. Revolver (development units)

29. OPC drum

1-13

DRIVE LAYOUT 30 July, 1999 (Revised)

1.4 DRIVE LAYOUT

1. Fusing transport drive

2. Revolver drive

3. Drum drive

4. Scanner drive

A269V110a.WMF

5. Drum peripheral drive

6. Image transfer belt drive

7. Registration drive

8. Paper feed drive

1-14

+ 631 hidden pages