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RICOH GROUP COMPANIES
A219/A245/B019
SERVICE MANUAL
000917MIU
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SERVICE MANUAL
A219/A245/B019
RICOH GROUP COMPANIES
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A219/A245/B019
SERVICE MANUAL
000917MIU
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WARNING
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
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LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
A219 2715X FT4015 9115
A245 2718 FT4018 --B019 2913Z FT3813 2013Z
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*
2 7/98 Reprint
3 2/99 A245 Addition
4 3/2000 B019 Addition
3/97 Original Printing
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Table of Contents
OVERALL MACHINE INFORMATION
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. COPY PROCESS AROUND THE DRUM. . . . . . . . . . . . . . . . . . . . . 1-4
3. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 1-6
4. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
5. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
6. ELECTRICA L COMPONENT DESCRIPTIONS. . . . . . . . . . . . . . . . 1-9
DETAILED DESCRIPTIONS
1. DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.1 OPC DRUM CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2. CHARGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 CHARGE CORONA WIRE CLEANER MECHANISM . . . . . . . . . . . . . . . . . . . 2-4
2.3 CHARGE CORONA CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3.2 SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3.3 LENS DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
3.4 4TH/5TH MIRROR DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
3.5 AUTOMATIC IMAGE DENSITY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3.6 EXPOSURE LAMP VOLTAGE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
4. ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
4.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
4.2 LEAD EDGE ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
4.3 SIDE ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
TOC i A219/A245/B019
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4.4 TRAILING EDGE ERASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
5. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
5.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
5.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
5.3 CROSS-MIXING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
5.4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROL. . . . . . . . . . . . . . 2-21
5.4.1 Base Bias Voltage Factor in Manual Image Density Mode. . . . . . . . . . . 2-22
5.4.2 Base Bias Voltage Factor in Automatic Image Density (ADS) Mode . . . 2-23
5.4.3 Drum Residual Voltage (V
5.5 DEVELOPMENT BIAS CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
) Correction Factor. . . . . . . . . . . . . . . . . . . . 2-23
R
6. TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
6.1 TONER BOTTLE REPLENISHMENT MECHANISM . . . . . . . . . . . . . . . . . . . 2-25
6.2 TONER SUPPLY MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
6.3 TONER DENSITY DETECTION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . 2-27
6.4 TD SENSOR CHECK AND TONER SUPPLY TIMING . . . . . . . . . . . . . . . . . 2-28
6.5 TONER SUPPLY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
6.5.1 Modes Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
6.5.2 Detect Supply Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
6.5.3 Fixed Supply Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
6.5.4 Abnormal Condition in Toner Density Detection . . . . . . . . . . . . . . . . . . . 2-32
6.6 TONER END. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
6.6.1 Toner Near End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
6.6.2 Toner End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
6.6.3 Toner End Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
7. IMAGE TRANSFER AND PAPER SEPARATION. . . . . . . . . . . . . 2-35
7.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
7.2 TRANSFER CORONA AND DISCHARGE PLATE CIRCUIT. . . . . . . . . . . . . 2-36
8. DRUM CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
8.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
8.2 TONER RECYCLING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
9. QUENCHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
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10. PAPER FEED AND REGISTRATION . . . . . . . . . . . . . . . . . . . . . 2-40
10.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
10.2 PAPER TRAY FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
10.2.1 Paper Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
10.2.2 Paper Feed Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
10.3 BY-PASS FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
10.3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
10.3.2 Paper Feed Mechanism and Paper End Detection. . . . . . . . . . . . . . . . 2-44
10.4 PAPER REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
10.5 SIDE FENCE DOUBLE STOPPER MECHANISM . . . . . . . . . . . . . . . . . . . . 2-46
10.6 PAPER END DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
10.7 PAPER FEED AND MISFEED DETECTION TIMING . . . . . . . . . . . . . . . . . 2-48
10.8 OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
10.8.1 Paper Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
10.8.2 Shock Absorber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
11. IMAGE FUSIN G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 0
11.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
11.2 FUSING DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
11.3 FUSING LAMP CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
11.4 FUSING LAMP CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
11.4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
11.4.2 On/Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
11.4.3 Phase Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
11.4.4 Overheat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
3. INSTALLATION
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
TOC iii A219/A245/B019
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2. COPIER (A219). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
2.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
2.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3. DOCUMENT FEEDER (A662) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
4. SORTER (A657) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
4.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
4.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
5. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
5.1 OPTICS ANTI-CONDENSATION HEATER INSTALLATION (OPTION) . . . . 3-16
5.2 TRAY HEATER INSTALLATION (OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
SERVICE TABLES
1. SERVICE REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
1.1 GENERAL CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
1.2 IMAGING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
1.3 OPTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
1.4 TRANSFER CORONA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
1.5 FUSING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
1.6 PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
1.7 OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
2. PROGRAM MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
2.1 BASIC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
2.2 SP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
2.3 SP MODE QUICK REFERENCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
2.4 UP MODE AND SP MODE CROSS REFERENCE TABLE . . . . . . . . . . . . . . . 4-9
2.5 SERVICE PROGRAM MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
2.6 CLEAR ALL MEMORY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
3. PRACTICAL SP MODE USE TABLE . . . . . . . . . . . . . . . . . . . . . . 4-26
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4. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.1 TEST POINTS (Main Control Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.2 VARIABLE RESISTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
PREVENTIVE MAINTENANCE
1. PREVENTIVE MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . 5-1
1.1 PM TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
1.2 REGULAR PM PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
2. SPECIAL TOOLS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . 5-7
REPLACEMENT AND ADJUSTMENT
1. EXTERIOR AND INNER COVERS. . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
1.1 EXTERIOR COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
1.1.1 Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
1.1.2 Front Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
1.1.3 Rear Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
1.1.4 Lower Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
1.1.5 Lower Left Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
1.1.6 Upper Left Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
1.1.7 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
1.1.8 Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
1.2 INNER COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
2. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
2.1 EXPOSURE GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
2.2 1ST SCANNER/EXPOSURE LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 6-6
2.3 SCANNER BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
2.4 1ST AND 2ND SCANNER POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . 6-9
2.5 SCANNER DRIVE MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
2.6 LENS DRIVE MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
2.7 4TH/5TH MIRROR DRIVE MOTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . 6-12
TOC v A219/A245/B019
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2.8 2ND MIRROR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
2.9 3RD MIRROR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
2.10 4TH AND 5TH MIRROR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
2.11 ADS SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
3. AROUND THE DRUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
3.1 IMAGING UNIT REMOVAL AND TONER BOTTLE REMOVAL . . . . . . . . . . 6-18
3.2 CHARGE CORONA WIRE AND CHARGE CORONA GRID
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
3.3 CLEANING BLADE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
3.4 DRUM REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
3.5 TONER COLLECTION COIL AND TONER RECYCLING BELT
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
3.6 DEVELOPER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
3.7 REPLACEMENT THE TONER DENSITY SENSOR (TD SENSOR) . . . . . . . 6-24
3.8 AGITATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
3.9 TONER SUPPLY MOTOR ASS’Y REPLACEMENT . . . . . . . . . . . . . . . . . . . 6-26
3.10 ERASE LAMP REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
3.11 QUENCHING LAMP REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
4. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
4.1 PAPER TRAY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
4.2 TRAY FEED ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
4.3 TRAY PAPER FEED ROLLER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 6-31
4.4 BY-PASS FEED ROLLER AND FRICTION PAD REPLACEMENT . . . . . . . . 6-32
4.5 BY-PASS PAPER FEED CLUTCH, HIGH VOLTAGE SUPPLY BOARD,
AND REGISTRATION CLUTCH REPLACEMENT. . . . . . . . . . . . . . . . . . . . . 6-34
4.6 RIGHT VERTICAL GUIDE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . 6-35
4.7 RELAY ROLLER CLUTCH AND PAPER FEED CLUTCH
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
4.8 PAPER SIZE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
4.9 BY-PASS PAPER END SENSOR AND REGISTRATION SENSOR
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
5. FUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
5.1 FUSING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
5.2 HOT ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
A219/A245/B019 vi TOC
Page 17
5.3 PRESSURE ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
5.4 HOT ROLLER STRIPPER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
5.5 FUSING ENTRANCE GUIDE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 6-43
5.6 FUSING PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6. TRANSFER/SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6.1 TRANSFER CORONA WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 6-45
6.2 DISCHARGE PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
7. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
7.1 OZONE FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
7.2 MAIN CONTROL BOARD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
8. COPY QUALITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
8.1 LIGHT INTENSITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
8.1.1 Base Exposure Lamp Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . 6-50
8.1.2 Image Density Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
8.2 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 6-52
8.2.1 Base Bias Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
8.2.2 SP Bias Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
8.3 TONER DENSITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
8.4 TONER SUPPLY RATIO SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
8.5 GRID VOLTAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
8.6 TRANSFER CURRENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
8.7 CHARGE CURRENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
8.8 HORIZONTAL MAGNIFICATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 6-58
8.9 VERTICAL MAGNIFICATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 6-58
8.10 FOCUS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
8.11 LEADING EDGE ERASE MARGIN ADJUSTMENT. . . . . . . . . . . . . . . . . . . 6-59
8.12 REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
8.13 4TH/5TH MIRROR HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 6-60
8.14 ADS (Auto Image Density Sensor) ADJUSTMENT . . . . . . . . . . . . . . . . . . . 6-61
8.15 SIDE-TO -SIDE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 6-62
TOC vii A219/A245/B019
Page 18
TROUBLESHOOTING
1. COPY QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
1.1 BLANK COPY (WHITE COPY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
1.2 DIRTY BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
1.3 UNEVEN IMAGE DENSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
1.4 VERTICAL BLACK BANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
1.5 VERTICAL BLACK LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
1.6 VERTICAL WHITE LINES OR BANDS-1 (DULL OR BLURRED) . . . . . . . . . . 7-8
1.7 VERTICAL WHITE LINES OR BANDS-2 (THIN, DISTINCT). . . . . . . . . . . . . . 7-9
1.8 HORIZONTAL BLACK/WHITE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
1.9 JITTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
1.10 BLACK SPOTS ON THE COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
1.11 SKEWED (OPTICAL) COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
1.12 TONER DENSITY ON COPIES TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . . . 7-14
1.13 TONER DENSITY ON COPIES TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
1.14 UNFUSED COPY IMAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
1.15 CREASING PAPER AFTER FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
1.16 PAPER MISFEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
1.17 ABNORMAL CONDITION IN TONER DENSITY DETECTION . . . . . . . . . . 7-21
2. SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
3. ELECTRICAL COMPONENT DEFECTS . . . . . . . . . . . . . . . . . . . . 7-29
3.1 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
3.2 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
4. BLOWN FUSE CON DITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
5. USER CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
A219/A245/B019 viii TOC
Page 19
DOCUMENT FEEDER A662
– DOCUMENT FEEDER (A662) –
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
2. COMPONENT LA YOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
2.1 MECHANICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
2.2 ELECTRICAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
3. ELECTRICA L COMPONENT DESCRIPTIONS. . . . . . . . . . . . . . . . 8-3
4. POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
5. BASIC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
6. INTERFACE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
7. ORIGINAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
7.1 ORIGINAL PICK-UP MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
7.2 ORIGINAL SEPARATION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
7.3 ORIGINAL FEED-IN MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
7.4 ORIGINAL FEED-OUT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
7.5 DF MOTOR CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
7.6 ORIGINAL FEED AND MISFEED DETECTION TIMING. . . . . . . . . . . . . . . . 8-12
8. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.1 DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.2 VARIABLE RESISTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.3 FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
9. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 8-14
9.1 TRANSPORT BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
9.2 FEED-IN UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
9.3 PICK-UP ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
9.4 FEED ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
9.5 FRICTION BELT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
9.6 PICK-UP SOLENOID ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
TOC ix A219/A245/B019
Page 20
SORTER A657
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
2. COMPONENT LA YOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
3. ELECTRICA L COMPONENT DESCRIPTIONS. . . . . . . . . . . . . . . . 9-3
4. BASIC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
5. EXIT ROLLER DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . 9 -5
6. BIN DRIVE MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
7. MISFEED DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
8. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
8.1 FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9. PREPARATION FOR TRANSPORTATION. . . . . . . . . . . . . . . . . . . 9-9
10. ROLLER DRI VE BELT REPLACE MENT. . . . . . . . . . . . . . . . . . . 9-1 0
11. BIN GUIDE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
APPENDIX
ELECTRICAL COMPONENT LAYOUT (A219) (A662) (A657) . . . . . 10-1
COPIER TIMING CHART (A219) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
A245 SERVICE MANUAL
1. SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . 11-4
3. DRIVE LAUOU T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
4. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
5. ELECTRICAL COMPONENT DESCR IPTIONS. . . . . . . . . . . . . . . 11-7
6. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
6.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
6.2 PAPER LIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
A219/A245/B019 x TOC
Page 21
Rev. 03/17/2000
6.3 PAPER FEED AND DRIVE MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . 11-12
6.4 PAPER FEED AND MISFEED DETECTION TIMING . . . . . . . . . . . . . . . . . 11-13
7. IMAGE FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
8. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -15
8.1 COPIER ACCESSORY CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
8.2 COPIER INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
8.3 UPPER AND LOWER TRAY HEATER INSTALLATION (OPTION). . . . . . . 11-20
9. PROGRAM MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
9.1 SP MODE QUICK REFERENCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
9.2 UP MODE AND SP MODE CROSS REFERENCE TABLE . . . . . . . . . . . . . 11-23
9.3 SERVICE PROGRAM MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
10. PREVENTIVE MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . 11-39
10.1 MODIFIES PM TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39
11. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . 11-42
11.1 PAPER FEED ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 11-42
11.2 RELAY ROLLER CLUTCH AND PAPER FEED
CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43
11.3 PAPER SIZE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
11.4 PAPER END SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45
12. REGULAR PM PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46
13. SERVICE CA LL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 11-49
B019 SERVICE MANUAL
1. SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
2. ELECTRICAL COMPONENTS DESCRIPTION. . . . . . . . . . . . . . . 12-2
3. INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
3.1 COPIER ACCESSORY CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
4. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
4.1 SERVICE PROGRAM MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
5. PM TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
TOC xi A219/A245/B019
Page 22
OVERALL MACHINE INFORMATION
SORTER A657
A245 SERVICE MANUAL
DETAILED DESCRIPTIONS
ELECTRICAL COMPONENTS &TIMING CHART
B019 SERVICE MANUAL
INSTALLATION
SERVICE TABLES
PREVENTIVE MAINTENANCE
TAB
POSITION 1
TAB
POSITION 2
TAB
POSITION 3
TAB
POSITION 4
REPLACEMENT & ADJUSTMENT
TROUBLESHOOTING
DOCUMENT FEEDER A662
TAB
POSITION 5
TAB
POSITION 6
TAB
POSITION 7
TAB
POSITION 8
Page 23
Page 24
A219
SERVICE MANUAL
Page 25
Page 26
OVERALL
MACHINE INFORMATION
Page 27
Page 28
SPECIFICATIONS
1. SPECIFICATIONS
Configuration: Desk Top
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:
A5/5
A6/5
Non-standard sizes:
Vertical 45 mm ~ 30 8 m m , 1.8" ~ 12"
Horizontal 148 m m ~ 43 2 mm , 5.8" ~ 17"
Copy Paper Weigh t: Paper tray feed: 64 to 90 g/m2, 17 to 24 lb
By-pass feed: 52 to 157 g/ m2, 14 to 42 lb
1/2
1/2
" x 8
" x 8
" sideways (Paper tray feed )
1/2
" lengthwise (By-pass feed)
1/2
Overall
Information
Reproduction Ratios:
Enlargement
Full Size 100% 100%
Reduction
Metric Version Inch Version
200%
141%
122%
93%
82%
71%
50%
200%
155%
129%
93%
74%
65%
50%
Zoom: From 50% to 200% in 1% step s
Copying Speed: 15 copies/minute (A4/8.5" x 11" sideways)
9 copies/minute (A3/11" x 17")
Warm-up Time:
120 V machines: Less than 30 seconds (at 23°C)
230 V machines: Less than 45 seconds (at 23°C)
First Copy Time: Less than 6.9 seconds (A4/8. 5" x 11" side w ays)
Copy Number Input: Number keys, 1 to 99
Manual Image Density
7 steps
Selection:
Automatic Reset: 1 minute standard settin g; can also be set to 3
minutes or no auto reset
SM 1-1 A219
Page 29
SPECIFICATIONS
Paper Capacity: Paper tray: 500 sheets or less than 56 mm stack
height
By-pass feed entrance:
Standard paper 80 sheets
OHP 10 sheets
Others 1 sheet
Toner Replenishment: Bottle exchange (215 g/bottle)
Copy Tray Capacity: 100 sheets
Power Source: 120 V/60 Hz: More than 15 A (for North Amer i ca)
220 ~ 240 V/50 Hz: More than 8 A (for Europe)
220 V/50 Hz: More than 8 A (for Asia)
220 V/60 Hz:More than 8 A (for Middle East/Asia)
110 V/60 Hz: More than 15 A (for Taiwan)
127 V/60 Hz: More than 15 A (for Middle East)
Power Consumption:
Dimensions:
Copier only Full system*
Maximum 1.4 kW
(120 V machines)
0.9 kW
(230 V machines)
Copy cycle 0.71 kW 0.74 kW
Warm-up 0.95 kW 0.95 kW
Stand-by 0.25 kW 0.25 kW
Energy saver 0.2 kW 0.2 kW
*Full system: Copier with document feeder and 10-bin sorter
Width Depth Height
Copier 579 mm
(22.8")
Full system* 775 mm
(30.2")
*Full system: Copier with document feeder and 10-bin sorter
560 mm
(22.1")
560 mm
(22.1")
1.5 kW
(120 V machines)
1.0 kW
(230 V machines)
420 mm
(16.6")
508 mm
(19.8")
A219 1-2 SM
Page 30
SPECIFICATIONS
Noise Emissions: Sound pressure level (the m ea sur e ments are
made in accordance with ISO 7779 at the
operator positio n.)
Copying Less than 57 dB Less than 61 dB
*Full system: Copier with document feeder and 10-bin sorter
Copier only Full system*
Sound power level (the measurements are made
in accordance with ISO 7779)
Overall
Information
Stand-by Less than 40 dB Less than 40 dB
Copy cycle Less than 63 dB Less than 67 dB
*Full system: Copier with document feeder and 10-bin sorter
Weight:
Optional Equi p m en t:
(Sales items)
Optional Equi p m en t:
(Service items)
*Full system: Copier with document feeder and 10-bin sorter
Document feeder (A662)
10-bin sorter (A657)
Optics anti-condensation heater
Tray heater
• Specifications are subject to change without
Copier only
Full system*
notice.
Toner Yield: 6K / Bottle.
Dev. Yield: 45K / Bag.
Copier only Full system*
42 kg (93.0 lb)
55 kg (121 lb)
SM 1-3 A219
Page 31
COPY PROCESS AROUND THE DRUM
2. COPY PROCESS AROUND THE DRUM
2
8
1
3
7
4
6
A219 1-4 SM
5
A219V503.wmf
Page 32
COPY PROCESS AROUND THE DRUM
1. DRUM CHARGE
In the dark, the charge corona unit gives a uniform negative charge to the
organic photoconductive (OPC) drum. The charge remains on the surface
of the drum because th e OP C drum ha s a high el ect r ic al r esistance in the
dark.
2. EXPOSURE
An image of the origi nal is ref l ect ed to th e dr u m surfa c e via th e op ti cs
assembly. The charge on the drum surface is dissipated in direct
proportion to the int ensity of the reflected light, thus producing an
electrical latent image on the drum surface.
3. ERASE
The erase lamp illuminates the area of the charged drum surface that will
not be used for the copy image. The resistance of the dr um in the
illuminated areas drops and the charge on those areas dissipates.
4. DEVELOPMENT
Positively charged toner is attached to the negatively charged areas of
the drum, thus develo ping the latent image. (The positive tribo el e ctri c
charge is caused by friction between the carrier and toner particles.)
Overall
Information
5. IMAGE TRANSFER
Paper is fed to the drum surface at the proper time so as to align the copy
paper and the develo ped image on the drum surface. Then, a strong
negative charge is appl ied to th e ba ck side of the copy pa pe r , pr o du cing
an electrical force which pulls the toner particles from the drum surface to
the copy paper. At the same ti m e, the copy pa pe r is electrically attracted
to the drum surface.
6. PAPER SEPARATION
A strong positive dc charge is applied to the back side of the copy paper
via a discharge plate, r ed ucin g th e ne ga ti ve charg e on the copy pa pe r
and breaking the ele c tri cal attraction between the paper and the dr um.
Then, the stiffness of the copy paper causes the paper to separate from
the drum surface.
7. CLEANING
The cleaning blade scrapes the toner off the drum. The collected toner is
recycled.
8. QUENCHING
Light from the qu en ching lamp electrically neutralizes the drum surface.
SM 1-5 A219
Page 33
MECHANICAL COMPONENT LAYOUT
3. MECHANICAL COMPONENT LAYOUT
26
25
24
23
7
10
98654321
11
12
13
14
15
16
22
1. 2nd Mirror
2. 1st Mirror
3. Exposure Lamp
4. Hot Roller
5. Lens
6. Quenching Lamp
7. Charge Corona Unit
8. 6th Mirror
9. Erase Lamp
10. 4th Mirror
11. 5th Mirror
12. Toner Bottle Holder
13. By-pass Feed Roller
21 20
19
18
17
A219V500.wmf
14. By-pass Feed Table
15. Relay Rollers
16. Tray Paper Feed Rollers
17. Registration Rollers
18. Development Roller
19. Transfer/Sep ara ti o n U nit
20. Drum
21. Cleaning Blade
22. Pressure Roller
23. Paper Tray
24. Copy Tray
25. Exit Rollers
26. 3rd Mirror
A219 1-6 SM
Page 34
4. DRIVE LAYOUT
DRIVE LAYOUT
10
11
9
8
2
1
Overall
Information
7
6
543
1. Lens Motor
2. Fusing Unit Drive Gear
3. Main Motor
4. Drum Drive Gear
5. Tray Paper Feed Clutch Gear
6. Relay Roller Clutch Gear
A219V501.wmf
7. By-pass Paper Feed Clutch
8. Registration Clutch Gear
9. Toner Supply Motor
10. 4th/5th Mi r ror M ot or
11. Scanner Drive Motor
SM 1-7 A219
Page 35
PAPER PATH
5. PAPER PATH
3
1
1. By-pass Feed
2. Paper Tray Feed
3. Copy Tray
2
A219V502.wmf
A219 1-8 SM
Page 36
ELECTRICAL COMPONENT DESCRIPTIONS
6. ELECTRICAL COMPONENT DESCRIPTIONS
Refer to the electrical component layout and the point-to-point diagram on the
waterproof paper in the pocket for symbols and index numbers.
Symbol Name Function Index No.
Motors
M1
M2 Scanner Drive Motor Drives the scanners (1st and 2nd). 9
M3
M4
M5
M6
M7
Main Motor Drives all the main unit components except
for the optics unit, fans and toner supply.
Lens Motor Moves the lens position in accordance with
the selected magnification.
4th/5th Mirror Motor Moves the 4th/5th mirror position in
accordance with the selected magnification.
Toner Supply Motor Rotates the toner bottle to supply toner to the
development unit.
Optics Cooling Fan
Motor
Exhaust Fan Motor Removes heat from around the fusing unit
Prevents build-up of hot air in the optics
cavity.
and blows the ozone built up around the
charge corona unit towards the ozone filter.
8
18
16
10
17
7
Overall
Information
Clutches
CL1
CL2
CL3 Relay Roller Clutch Drives the relay rollers for paper tray feed. 13
CL4 Registration Clutch Drives the registration rollers. 11
Switches
SW1 Main Switch Supplies power to the copier. 38
SW2
SW3
SW4
Sensors
S1
S2
Tray Paper Feed
Clutch
By-pass Paper Feed
Clutch
Interlock Switch Cuts all power when the front cover is
Tray Paper Size
Switch
Right Vertical Guide
Switch
4th/5th Mirror Home
Position Sensor
ADS Sensor Detects the background density of the
Transfers main motor drive to the paper feed
roller.
Starts paper feed from the by-pass feed
table.
opened.
Determines what size of paper is in the
paper tray.
Cuts the +24 V dc power line of the relay
roller clutch.
Informs the CPU when the 4th/5th mirror
assembly is at the home position (full size
position).
original.
14
12
37
31
27
33
24
SM 1-9 A219
Page 37
ELECTRICAL COMPONENT DESCRIPTIONS
Symbol Name Function Index No.
S3
S4
S5
S6 Exit Sensor Detects misfeeds. 23
S7
S8
S9
Printed Circuit Boards
PCB1 Main Control Board Controls all copier functions. 1
PCB2
PCB3
PCB4
Tray Paper End
Sensor
Registration Sensor Detects the leading edge of the copy paper
By-pass Feed Paper
End Sensor
Scanner Home
Position Sensor
Lens Home Position
Sensor
Toner Density (TD)
Sensor
High Voltage Supply
Board - C/G/B/T/S
AC Drive/DC Power
Supply Board
Operation Panel
Board
Informs the CPU when the paper tray runs
out of paper.
to determine the stop timing of the relay
roller clutch, and detects misfeeds.
Informs the CPU when there is no paper in
the by-pass tray.
Informs the CPU when the 1st scanner is at
the home position.
Informs the CPU when the lens is at the
home position.
Detects the ratio of toner to carrier in the
developer.
Provides high voltage to the charge corona,
grid, development bias, transfer corona, and
discharge plate.
Drives the exposure lamp, fusing lamp, and
main motor. Rectifies 30 Vac and 8 Vac input
and outputs 5 Vdc and 24 Vdc.
Informs the CPU of the selected modes and
displays the situation on the panel.
28
30
29
40
22
26
2
3
6
Lamps
Erase Lamp Discharges the drum outside of the image
L1
L2
L3
L4 Fusing Lamp Provides heat to the hot roller. 25
Others
CO1
H1
H2
TF1
Quenching Lamp Neutralizes any charge remaining on the
Exposure Lamp Applies high intensity light to the original for
Total Counter Keeps track of the total number of copies
Tray Heater (Option) Turns on when the main switch is off to keep
Optics
Anti-condensation
Heater (Option)
Exposure Lamp
Thermofuse
area. (Provides leading/trailing edge and
side erases.)
drum surface after cleaning.
exposure.
made.
paper in the paper tray dry.
Turns on when the main switch is off to
prevent moisture from accumulating in the
optics.
Provide back-up overheat protection around
the exposure lamp.
4
5
20
34
32
39
21
A219 1-10 SM
Page 38
ELECTRICAL COMPONENT DESCRIPTIONS
Symbol Name Function Index No.
TF2
TH1
TH2
TR
Fusing Thermofuse Provide back-up overheat protection in the
fusing unit.
Fusing Thermistor Monitors the temperature around the
exposure lamp for overheat protection.
Optics Thermistor Monitors the temperature around the
exposure lamp for overheat protection.
Transformer Steps down the wall voltage to 30 Vac and 8
Vac.
36
35
19
15
Overall
Information
SM 1-11 A219
Page 39
Page 40
DETAILED DESCRIPTIONS
Page 41
Page 42
DRUM
1. DRUM
1.1 OPC DRUM CHARACTERISTICS
The OPC (Organic Photoconductor) drum used in this copier is small in
diameter (30 mm), ensuring good paper separation. An OPC drum has the
following characteristics.
1. The drum is able to accept a high negative electrical charge in the dark.
(The electrical resistance of a photoconductor is high in the absence of
light.)
2. It dissipates the electrical charge when exposed to light.
(Exposure to light greatly increases the conductivity of a photoconductor.)
3. The amount of charge dissipated is in direct proportion to the intensity of
the light. That is, w he re str o ng er l igh t i s di rect ed t o the photoconductor
surface, a smaller voltage remains on the drum.
4. An OPC drum is less sensitive to changes in temperature (when
compared to selenium F type drums).
Detailed
Descriptions
5. During the drum’s life, drum res i dual voltage gradually increases and the
photoconductive surfa c e be comes worn. Therefor e, some com p en sat i on
for these characteristics is required.
SM 2-1 A219
Page 43
DRUM
1.2 DRIVE MECHANISM
[C]
[E]
[D]
[B]
[A]
A219D520.wmf
The drive from the main motor [A] is transmitted to the drum [B] through a
series of gears, a timing belt [C], and the drum drive sha ft [D].
When the imaging unit is i nst al led in the copier, the drum drive shaft en ga ge s
inside the drum’s fl an ge [E] as show n .
A219 2-2 SM
Page 44
2. CHARGE
2.1 OVERVIEW
CHARGE
[A]
[B]
A219D505.wmf
[C]
Detailed
Descriptions
[D]
A219D521.wmf
This copier uses a single wire scorotron to charge the drum. The corona wire
[A] generates a coro na of ne ga tive ions when the high voltage supply unit
applies a negative voltage. The stai nless stee l grid pla te [B] ensures th at the
drum coating receive s a unif or m ne ga tive char g e as it r ot at es pa st th e cor o na
unit.
The exhaust fan [C] caus es a flo w of ai r ab ove and through the cha r ge
corona section. This preve nt s an uneve n bu i ld- u p of neg at ive i on s tha t can
cause uneven image de nsity.
An ozone filter [D], which absorbs ozone (O3) generated by the charge
corona, is located be side the exhaust fan. The oz one filter decreases in
efficiency over time as it ab sor b s ozon e. The ozo ne fil te r shou ld be repl a ced
every PM cycle (45 k copies).
SM 2-3 A219
Page 45
CHARGE
2.2 CHARGE CORONA WIRE CLEANER MECHANISM
[C]
[D]
[A]
[B]
A219D536.wmf
Pads [A] move along the cha r ge coron a w ir e as th e w ir e clea ner knob [B] is
manually slid in and out.
The cleaner pad bracket [C ] i s conn ect ed to th e wi re cl ea ne r knob . Whe n th e
knob is pulled out, the pads move into contact with the corona wire as shown,
since the casing [D] is narrower away from the home position.
The pads move away from the wire when the wire cleaner knob is fully
inserted and the pad br a cket is pu she d ba ck to th e ho m e po siti o n.
After copier installation, the key operator should be instructed to use this
mechanism when copies ha ve white streaks or uneven image density.
Instruct the operato r to fi rm l y pu sh th e pa d br a cket in to the home position.
Poor copy quality will result if the cleaning pads remain in contact with the
charge corona wire.
A219 2-4 SM
Page 46
2.3 CHARGE CORONA CIRCUIT
gg
gg
gg
Main Board High Voltage Supply Board
24 V
C Tri
GND
er
CN102-7
CN102-6
CN102-5
DC/DC
Converter
CHARGE
T Tri
B-PWM
S Tri
4.7 k
er
er
5 V
CN102-4
CN102-3
CN102-2
CN102-1
DC/DC
Converter
DC/DC
Converter
Zener
Diode
DC/DC
Converter
Protection
Circuit
GC
Drum
B
S
T
A219D506.wmf
Detailed
Descriptions
The main board suppli es + 24 V to th e hig h vol t ag e sup pl y bo ar d at C N10 2- 7 .
After the ! key is pressed , th e C PU dr o ps CN 102- 5 fr om + 5V to LO W .
This activates the charge cor ona ci rc uit wh ic h ap pli e s a high negative voltage
of approximately –5 k volts to the charge corona wire. The corona wire then
generates a negative cor ona cha r ge .
The grid plate limits the charge voltage to ensure that the charge does not
fluctuate and that an even charge is applied to the entire drum surface. The
grid plate is connect ed to gr o un d th r ou gh a zene r diod e i n th e high voltage
supply unit. The grid pl at e dr a ins an y char g e in exce ss of –9 10 V, whi ch is
discharged to ground through the zener diode.
SM 2-5 A219
Page 47
OPTICS
3. OPTICS
3.1 OVERVIEW
[C][C] [A][B] [K] [E] [I] [G]
[D]
[F]
[H]
[J]
A219D507.wmf
During the copy cycle, an image of the original is reflect ed onto th e dru m
surface through the op ti cs asse mbl y as fo ll ows:
Light path:
Exposure Lamp [A] → Original → First Mirror [B] → Second Mirror [C] →
Third Mirror [D] → Lens [E] → Blue Filter [F] → Fourth Mirror [G] → Fifth
Mirror [H] → Sixth Mirror [I] → Drum [J]
This copier has eight standard reproduction ratios and a zoom function. The
operator can also chan ge the repr o du cti o n r at io i n on e- p erc e nt step s fr om
50% to 200%. Stepper motors are used to change the positions of the lens
and 4th/5th mir r ors to enla r ge /r e du ce th e i m ag e acr o ss the pag e. Changes in
reproduction ratio down the page are achieved by changing the sc anner
speed.
The CPU monitors the temperature around the optics through a thermistor
which is located on the scanner frame. When the temperature reaches 40°C,
the optics cooling fan [K] starts rotating to draw cool air into the optics cavity.
The fan operates until the temp erature drops below 38°C.
Additionally, a the rm of use on th e 1st scann er pr o vi des back-u p ove r he at
protection. It opens when the temperature reaches 128°C and cuts ac power
to the exposure lamp.
A blue filter is located jus t after the lens to improve the reproduction of red
areas of the original on copi e s.
A219 2-6 SM
Page 48
3.2 SCANNER DRIVE
[H]
[F]
[D]
OPTICS
Detailed
Descriptions
[C]
[A]
[E]
[B]
A219D522.wmf
[G]
A stepper motor [A] is used to drive the scanners.
The first scanner [B], which consists of the exposure lamp and the first mirror,
is connected to the first scanner belt [C]. The second scanner [D], which
consists of the second and third mirrors, is connected to the second scanner
belt [E]. Both the scanners move along the guide rod [F].
There are no scanner drive wires, and only one side of the scanner is
supported (by a rod and guide rail). Therefore, the scanners should be
moved by moving the timing be lt, and never by moving the scanner s di re ctl y.
The pulley [G] drives both the fir st an d seco nd scann er be l ts. The 2n d
scanner moves at half the speed of the first scanner. This maintains the focal
distance between the original and the lens during scanning.
The scanner home position is detected by a home position sensor [H]. The
scanner return position is determined by counting the scanner motor drive
pulses.
SM 2-7 A219
Page 49
OPTICS
3.3 LENS DRIVE
[A]
[C]
A219D509.wmf
[B]
: Reduction
: Enlargement
The lens motor [A] (stepper motor) changes the lens [B] position through the
timing belt [C] in accordanc e with the selected reproduction ratio to provide
the proper optical di st an ce between the lens and the drum surface.
[D]
The rotation of the lens driv e pulley moves the lens back and fort h in discrete
steps. The home position of the lens is detected by a home position sen sor
[D]. The main board keep s tr ack of the lens po si tio n ba sed on th e nu m be r of
pulses sent to the lens motor.
A219 2-8 SM
Page 50
3.4 4TH/5TH MIRROR DRIVE
OPTICS
[D]
[A]
[C]
[B]
A219D510.wmf
The 4th/5th mirror drive motor [A] (stepper motor) changes the 4th/5th mirror
assembly position thr ou gh the pi nio n ge ar s [B ] an d th e r ack ge ar [C ] in
accordance with the sele cte d r epr od uction ratio to provide the proper optical
distance between the le ns an d dr u m sur fa c e.
Detailed
Descriptions
The home position of the 4th/5th mirror assembly is detected by a home
position sensor [D]. The ma in bo ar d keep s track of the lens position ba sed on
the number of pulses sent to the 4th/5th mirror motor.
SM 2-9 A219
Page 51
OPTICS
3.5 AUTOMATIC IMAGE DENSITY SENSOR
A219D511.wmf
[A]
The auto image density (ADS) sensor [A], a photodiode, is mounted on the
A219D512.wmf
upper front fram e. The sen sor cove r has a hol e in i t to all ow l igh t to fal l
directly onto the sensor.
Sampling starts 6 millimeters from the leading edge of the original and
continues for 11.5 millimeters from the leading edge of original in full size
mode. These lengths "a" and "b" will vary dependin g on the selected
reproduction ratio. The lengths "a" and "b" for each reproduction ratio are
calculated as follows:
For every original in ADS mo de , th e ph ot ose nso r circu i t con ver t s the lig ht
intensity into a voltage. The detected voltage is amplified and sent to the
main board. If less light is reflect ed from the original (the image is darker), the
sensor outputs a lower voltage. The CPU compares the maximum ADS
output voltage with the st andard ADS reference voltage and compensates
the copy image density by changing the development bias voltage in
accordance with the di fference. The standard ADS reference voltage (2.5 ±
0.1 V) is generated by SP 56. De ta i ls about changes to the develo pm e nt bi as
voltage are expla i ne d i n "De v elopment Bias for Image Density Con trol".
A219 2-10 SM
Page 52
OPTICS
3.6 EXPOSURE LAMP VOLTAGE CONTROL
The main board control s th e exp osu r e lam p volta ge thr o ug h th e ac dr iv e /d c
power supply board . The expo sur e lam p voltage is based on the base lamp
voltage and various correction factor s. The method of contro l is diffe ren t
depending on wheth er th e i m ag e de nsity is manually select ed or t he auto
image density mode is selected.
The exposure lamp voltage is determined by the following factors:
Lamp Voltage = Base Lamp Voltage Setting (SP48)
+
*Image Density Adjustment Factor (SP34)
+
*Manual Image Den s ity Se tting Factor
+
VL Correction 1 Factor (SP62)
+
VL Correction 2 Factor
+
Reproduction Ratio Correction Factor
Detailed
Descriptions
*NOTE:
SP34 (Image Density Adjustment Factor) is applied for ADS mode
only.
The "Manual Image Density Factor" is applied for manual ID mode
only.
1) Base Lamp Voltage Setting
The lamp voltage is determined by the SP48 setting.
Base Lamp Voltage = SP48 setting x 0.5 (120 V machi n es)
SP48 setting x 1.0 (230 V machines)
The default setting is: 140 = 70 V (120 V machines)
140 = 140 V (230 V machines)
The current lamp voltage (after all correction factors are included) can be
viewed with SP 51.
SM 2-11 A219
Page 53
OPTICS
2) Image Density Adjustment Factor (SP34)
Depending on the SP34 setting, the development bias and the exposure
lamp settings are increas ed or decreased during ADS mode.
SP34 Setting Setting Dev. Bias Exposure Lamp
0 Normal 0 0
1 Light –40 V 0
2 Dark +40 V 0
3 Lightest –40 V +4 steps
4 Darkest +40 V –4 steps
1 step = 0.5 V (120 V machines) or 1. 0 V ( 23 0 V mach i ne s)
3) Manual Image Density Setting Factor
Depending on the ma nu al im ag e de nsi t y setting on the operation panel, the
exposure lamp voltage is changed as shown in the ta ble below:
LighterDarker
Manual ID
Level
Exposure
Lamp Voltage
Factor
Development
Bias Voltage
(Volts)
1234567
V
– 6
0
steps
–200 –200 –200 –200 –200 –240 –240
V0 – 4
steps
V0 – 2
steps
V
0
V0 + 2
steps
V
: Base lamp voltage setting (SP48)
0
1 step = 0.5 V (120 V machines) or 1. 0 V ( 23 0 V mach i ne s)
V0 + 6
steps
V0 + 12
steps
A219 2-12 SM
Page 54
OPTICS
4) VL Correction 1 Factor
The light intensity may de crease because of dust accumulated on the optical
parts. Addition ally, the drum sensitivity gradually decreases during the drum’s
life. This may cause dirty background on copies. To compensate for this, V
L
corrections 1 and 2 are don e.
The exposure lamp voltage is increased by two steps at the set copy count
interval (a step is +2.0 V for 230 V machines, and +1 V for 120 V machines).
The table below shows the relationship between the SP setting and the copy
interval.
SP62 Setti ng VL Correction Interval
0 2 steps/8,000 copies
1 2 steps/6,000 copies
2 2 steps/4,000 copies
3 2 steps/2,000 copies
4 2 steps/1,000 copies
5 No correction
(Default setting: 2)
Detailed
Descriptions
VL correction 1 compensates for the decrease of drum sensit ivity and th e
decrease in reflectivity of the 4th, 5th, and 6th mirrors due to dust.
5) VL Correction 2 Factor
VL correction 2 compensates for dust on the lens and mirrors 1 to 3, but is
independent of the drum condition.
The ADS sensor receives th e l i gh t r ef lected through the 1st, 2nd and 3rd
mirrors from the white plate located under the middle of the left scale. The
photosensor circuit con v ert s this l i ght i nt en si ty int o a vol t ag e. The C PU sto r es
this voltage in memory as the white plate reference voltage. This is done
every time SP56 (ADS ref er e nce volta ge adju stm e nt) is done, before
sampling starts for the ADS sensor adjustment.
Every 500 copies, the machine reads the intensity of light reflected from the
white plate and compares it with the white plate reference voltage.
If the measured voltage difference is more than 0.1 volt, +2 steps will be
added to the exposure la m p set ti n g as th e VL correction 2 factor.
The sum of VL correction factors 1 and 2 cannot exceed +40 steps.
VL correction factors 1 and 2 are automatically reset every time the light
intensity is adjusted with SP48. (SP56 must be done immediately after SP48;
see Service Remarks for details.)
SM 2-13 A219
Page 55
OPTICS
6) Reproduction Ratio Correction Factor
The exposure lamp volta ge is increased depending on the selected
magnification ratio in ord er to compensate for the change in concentration of
light on the drum.
Magnification Ratio Reproduction Ratio Correction Factor
50% to 61% +2 steps
62% to 119% 0
120% to 139% +2 steps
140% to 159% +4 steps
160% to 179% +8 steps
180% to 200% +12 steps
1 step = 0.5 V (120 V machines) or 1. 0 V ( 23 0 V mach i ne s)
A219 2-14 SM
Page 56
4. ERASE
j
4.1 OVERVIEW
ERASE
A219D513.wmf
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k lm mlkjihgfedcban
[A]
Detailed
Descriptions
A219D527.wmf
The erase lamp [A], which is installed in the copier main frame, consists of a
single row of white LEDs (38 LEDs) extended across the full width of the
drum. The erase lamp has the following functions: lea ding edge erase, side
erase and trail edge erase. (Trail edge erase begins after the trailing edge of
the copy paper; therefore, the trailing edge of the copy will not be erased.)
In side erase mode, the appropriate LEDs turn on in accordance with the
modes selected by the user.
SM 2-15 A219
Page 57
ERASE
4.2 LEAD EDGE ERASE
The entire line of LEDs turn on when the main motor turns on. They stay on
until the erase margin slightly overlaps the lead edge of the original image
area on the drum (Lead Edge Erase Margin). This prevents the shadow of
the original edge from being developed on the copy. At this point, side erase
starts. The width of the lead i ng er ase mar gin can be adju sted using SP41.
4.3 SIDE ERASE
Based on the combination of copy paper size and the reproduction ratio data,
the LEDs turn on in blocks (labeled "a" to "n" on the previous page). This
reduces drum cleaning load.
Also, to prevent horizontal black lines from appearing on the edge of copies
as a result of light leaki n g un de r the edg e of t he DF be lt, the side erase
combination is changed between platen mode and DF mode; in DF mode,
more of the image is erased at the sides. (The setting of SP24 must be 0.)
-Platen Mode-
Blocks On Paper Size
None 99% to 200%
a to b 95% to 98%
a to c
a to d 88% to 91%
a to e
a to f 80% to 83%
a to g 75% to 79%
a to h
a to i
a to j 63% to 67%
a to k B5 59% to 62%
a to l 54% to 58%
a to m 50% to 53%
All (a to n)
11" x 17",
11" x 8
B4, B5
sideways
" x 11",
8
1/2
8
" x 5
1/2
A4
Lengthwise
Lead Edge and Trail Edge
Erase
Reproduction
"
1/2
"
1/2
Ratio (%)
92% to 94%
84% to 87%
72% to 74%
68% to 71%
-DF Mode-
Blocks On Paper Size
None 99% to 200%
a to b 97% to 98%
a to c
a to d 90% to 92%
a to e
a to f 81% to 85%
a to g 77% to 80%
a to h
a to i
a to j 65% to 69%
a to k B5 61% to 64%
a to l 56% to 60%
a to m 50% to 55%
All (a to n)
11" x 17",
11" x 8
B4, B5
sideways
" x 11",
8
1/2
8
" x 5
1/2
A4
Lengthwise
Lead Edge and Trail Edge
Erase
Reproduction
"
1/2
"
1/2
Ratio (%)
93% to 96%
86% to 89%
73% to 76%
70% to 72%
A219 2-16 SM
Page 58
ERASE
4.4 TRAILING EDGE ERASE
This minimizes toner consumption.
The entire line of LEDs turns on when the drum has turned 9 mm at the end
of scanning (about 100 ms). The LEDs stay on to erase the leading edge of
the latent image in the next copy cycle. Af te r the fina l copy, the erase lamps
turn off at the same time as the main motor.
Detailed
Descriptions
SM 2-17 A219
Page 59
DEVELOPMENT
5. DEVELOPMENT
5.1 OVERVIEW
[C]
[A]
[E]
[D]
[B]
A219D514.wmf
When the main motor turns on, the development roller [A] and two agitators
[B] and [C] start turning.
There are permanent magnets in the development roller which attract the
developer particles (which are about 50 µm in diameter) to the roller. The
turning sleeve of the development roller carries the developer past the doctor
blade [D] which trims the developer to the desired thickness.
The development roller slee ve continues to turn, carrying the developer to the
drum [E]. When the de vel o pe r brush contacts the drum surface, the
negatively charged areas of the drum surface attract and hold the positively
charged toner. In this way, the latent image is developed.
The development roller is given a suitable negative bias to prevent toner from
being attracted to th e no n- im a ge ar ea s on th e dru m wh ic h may ha ve a
residual negative char ge . The bias al so cont rol s im ag e de nsi t y.
A219 2-18 SM
Page 60
5.2 DRIVE MECHANISM
DEVELOPMENT
[B]
[C]
[A]
A219D515.wmf
When the main motor [A] turns on, the drive is transmitted to the
development dri ve sha f t [B] through gears an d a ti m ing belt. The rotation of
the development ro l ler ge ar is transmitted to the agitator gears [C] thr ou gh
other gears.
Detailed
Descriptions
SM 2-19 A219
Page 61
DEVELOPMENT
5.3 CROSS-MIXING
[C]
[B]
[D]
[A]
A219D516.wmf
A cross-mixing mechanis m is use d to keep the toner an d de veloper evenly
mixed. It also helps agitate the developer to prevent developer clumps from
forming and helps create the triboelectric charge.
Two agitators (helical coils) [A] and [B] are used for cross-mixing. The 1st
agitator [A] moves the developer from left to right. The toner supplied from
the cutout in the toner cartridge holder is mixed with the developer by the 1st
agitator. The 2nd agitator [B] rotates to move the developer back from right to
left. In this way, the de vel o pe r is eve nly distributed in the development unit.
The magnets in the development roller [C] attract the developer, and the
development roller sleeve rotates to carry the developer to the drum. The
doctor blade [D] trims the developer on the development roller to the desired
thickness.
A219 2-20 SM
Page 62
DEVELOPMENT
5.4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROL
The image density is controlled by changing two items: the amount of bias
voltage applied to the development roller sleeve, and the amount of voltage
applied to the exposure lamp.
Applying a bias voltage to the development sleeve reduces the potential
between the development roller and the drum, th ereby reducing the amount
of toner transferred. As the bias voltage becomes greater, the copy becomes
lighter.
The method of control depends on whether the image density is manually
selected or auto image density is used.
The development bias voltage applied to the development roller sleeve has
the following factors:
Development bias voltag e = Base Bias Voltage
(Manual or auto image density mode)
+
*Image Bias Adjust men t Fact or ( SP 33)
+
*Image Density Adjustment Factor (SP34)
+
Drum Residual Voltage (VR) Correction Factor
Detailed
Descriptions
*NOTE:
Image Bias Adjustment Factor (SP33) is applied for manual ID mode
only.
Image Density Adjustment Factor (SP34) is applied for ADS mode
only.
SM 2-21 A219
Page 63
DEVELOPMENT
5.4.1 Base Bias Voltage Factor in Ma nual Ima ge D ensit y Mode
Manual ID
Level
Exposure
Lamp Voltage
Factor
Development
Bias Voltage
(Volts)
1234567
V
– 6
0
steps
–200 –200 –200 –200 –200 –240 –240
V0 – 4
steps
V0 – 2
steps
V
0
V0 + 2
steps
V
: Depends on the setting of SP48
0
V0 + 6
steps
LighterDarker
V0 + 12
steps
When manual ID level 6 or 7 is select ed, –40 V is added to the base bias
voltage.
Using SP33 (Image Bias Adjustment), the base bias voltage can be
increased or decreased for all manual ID levels as follows:
SP Setting Setting Dev. Bias Note
0 Normal 0 Default
1 Darkest +40 V
2 Darker +20 V
3 Lighter –20 V
4 Lightest –40 V
A219 2-22 SM
Page 64
DEVELOPMENT
5.4.2 Base Bias Voltage Factor in Auto m at i c Im age De nsi ty ( A DS) Mode
The bias voltage for AD S mod e de pe nds on the background i m ag e de nsity of
the original which is measured by the ADS sensor. (See "Automatic Image
Density Sensor" for more information about the ADS sensor.)
The CPU checks the voltage output from the automatic ID circuit. This circuit
has a peak hold function. The pe ak ho ld vol t ag e is the maxi mum ADS senso r
output voltage, which corr espon ds to the maxi mum ref l ect i vity of the ori gin al .
The CPU then determ ine s t he prop er ba se bi a s le vel by com p ar ing this
voltage (read fro m the ori gi n al) w it h the stan da r d ADS reference volt age.
The table below shows the relationship between the original background
density (ADS voltag e r at i o) an d the base bias voltage.
Detailed
Descriptions
ADS Voltage Ratio [α] (%)
80 to 100 (light) –200 V
75 to 79 –240 V
70 to 74 –280 V
60 to 69 –320 V
29 to 59 –360 V
0 to 28 (dark) –380 V
ADS Voltage Ratio [α]
V
: Standard ADS Reference Voltage (2.5 ± 0.1 V)
ADS0
Maximum ADS Output Voltage
=
Bias Voltage
V
ADS0
Using SP34, the base bias voltage and the exposure lamp setting can be
increased or decreased for th e ADS mo de as fol lo w s:
SP Setting Setting Dev. Bias Exposure Lamp
0 Normal 0 0
1 Lighter –40 V 0
2 Darker +40 V 0
3 Lightest –40 V +4 steps
4 Darkest +40 V –4 steps
(Default Setting: 0)
5.4.3 Drum Residual Voltage (VR) Correction Factor
During the drum’s life, drum residual voltage (VR) will gradually increase. To
compensate for this, the bias voltage is increased by –20 V every 5 k copies.
The VR correction is done up to 20 k copies. The VR correction will not
change after 20 k copies.
SM 2-23 A219
Page 65
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DEVELOPMENT
5.5 DEVELOPMENT BIAS CIRCUIT
Main Board High Voltage Supply Board
24 V
C Tri
GND
er
CN102-7
CN102-6
CN102-5
DC/DC
Converter
T Tri
B-PWM
S Tri
4.7 k
er
er
5 V
CN102-4
CN102-3
CN102-2
CN102-1
DC/DC
Converter
DC/DC
Converter
Zener
Diode
DC/DC
Converter
Protection
Circuit
GC
Drum
B
S
T
A219D506-2.wmf
The main board supplies +24 volts to the high voltage supply board from
CN102-7. When the ! key is pressed, the CPU starts sending the bias
trigger pulses fr om C N10 2- 3 . Thi s en er g izes th e development bias circuit
within the high volt ag e supply board, which applies a high negative vol ta ge to
the development roller. The development bias is applied whenever the drum
is rotating.
A219 2-24 SM
Page 66
TONER SUPPLY
6. TONER SUPPLY
6.1 TONER BOTTLE REPLENISHMENT MECHANISM
[F]
[E]
[I]
[A]
[J]
[H]
Detailed
Descriptions
[G]
[D][C] [B]
A219D517.wmf
[K]
A219D518.wmf
When a toner bottle is placed on the bottle holder unit [A] and pushed back in
completely, the following happens automatically.
• The pin [B] on the imaging unit toner shutter [C] is pushed out (shutter
opened) by the proj ect i on [D].
• The pin [E] on the toner shutt er [F] is pu l led up ( shu tter opened) as a
result of the shape of the dev eloper cartridge.
When the toner bottle holder lever [G] is pushed down to the operation
position, the following happens automatically to allow toner to be supplied to
the development unit.
•
The shaft [H] is pushed out fr o m the machi n e by th e cur ve d r ail be hin d
the toner bottle holder lever, and this pulls out the cap [I] into the chuck
[J], where it is held.
The toner end detection system determines whe n to dr ive the to ne r bot tle
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 [K] that helps move toner to the development
unit.
When the bottle holder unit is pulled out to add new toner, the following
happens automatica l ly t o pre vent toner from scattering.
• The chuck releas es the toner bottle cap into its proper position.
• Both shutters close as a result of pressure from their springs.
SM 2-25 A219
Page 67
TONER SUPPLY
6.2 TONER SUPPLY MECHANISM
[A]
[F]
[B]
[E]
[C]
[D]
A219D519.wmf
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 two toner supply
mylar blades transfer the toner to the opening [D], then the toner falls down
into the developme nt unit.
There is a notch [E] on the to ner bottle, and a roller [F] locate d under the
toner bottle. They both shake the toner bottle to prevent toner clumps from
forming. They also help to transport the toner inside the toner bottle when the
amount of toner inside is low.
A219 2-26 SM
Page 68
6.3 TONER DENSITY DETECTION MECHANISM
[A]
TONER SUPPLY
Detailed
Descriptions
[B]
A219D516-2.wmf
A toner density sensor (TD senso r) [A] is use d fo r ton er de nsi t y cont r ol.
The TD sensor is located under the 1st agitator [B]. The developer being
conveyed by the 1st agitat or pa sses ove r t he top of th e sen s or. As the toner
in the developer is cons umed during development, the toner to carr i er r at i o
changes, resulting in a change in the magnetic permeability of the develo per.
This in turn is converted to a corresponding voltage. The CPU monitors the
voltage to control the toner supply mechanism.
When new developer is installed, and SP66 (TD Sensor Initial Setting) is
done, the machine starts idling for developer initialization. During developer
initialization, the CPU adjusts the TD sensor control voltage so that the TD
sensor outputs 1.9 ± 0.1 V for the ton er to carrier ratio of new developer
(4.0% by weight). This voltage is used as the standard TD sensor voltage.
SM 2-27 A219
Page 69
g
y
(
)
TONER SUPPLY
6.4 TD SENSOR CHECK AND TONER SUPPLY TIMING
Original Scan
seconds
Drum Char
TD Sensor
Toner Suppl
e
Motor
2 s
2 s
A219D540.wmf
When a copy job begins t he TD sen sor vol t ag e i s mo nitored for two seconds
when the 1st copy drum charge starts. The CPU checks the voltage every 40
ms and stores the second highest voltage of every 240 ms period. The
voltages stored during the two seconds are averaged, and then the average
is used as the TD sensor output value for that detection period. The TD
sensor output value is used to determine the toner supply clutch on time.
Then an appropriate amount of toner is added by the toner supply motor (as
described in Toner Supp ly Am ou nt ) . The TD sen sor is moni t ore d for
two-second intervals until the last original scan is finished. Unlike a toner
supply clutch mechanism, with a toner supply motor, the copie r can ad d to ner
during image development.
A219 2-28 SM
Page 70
6.5 TONER SUPPLY CONTROL
6.5.1 Modes Available
TONER SUPPLY
NOTE:
The following pages explain how the various settings control the
toner supply mechanism. They should not be adjusted in the field,
unless instructed to do so as a countermeasure for a specific
problem that may occur in the future.
SP30
Setting
0
1
2
3
4
Toner Supply
Mode
Detect Supply
Mode
Fixed Supply Mode None Fixed
Target Toner
Sensor Voltage
Depends on th e
initial TD sensor
setting (1.9 ± 0.1 V).
Depends on SP53
(input manually).
Depends on th e
initial TD sensor
setting (1.9 ± 0.1 V).
Depends on SP53
(input manually).
Toner Supply
Depends on the
TD sensor output.
SP31
Depends on the
TD sensor output.
SP31
Fixed
SP31
Fixed
SP31
SP31
Toner Near/End
Amount
Default setting: 0
Detection
Yes
Yes
No
No
No
Depending on the SP30 setting, Detect Supply mode or Fixed Supply mode
is selected. If 0, 1, 2, or 3 is selected with SP30, Detect Supply mode is used.
If 4 is selected, Fixed Supply mode is used.
Detailed
Descriptions
Note that when 2, 3, or 4 is selected, the machine will not perform the toner
near-end/or toner end detection. Normally, SP30 should always be kept at
the default setting. The following pages describe the toner supply mode
settings in detail.
6.5.2 Detect Supply Mode
In Detect Supply mode, the CPU monitors the TD sensor voltage, which
depends on the toner to carrier ratio in new developer. As the toner in the
developer is consumed, the TD sensor output volta ge incr ea ses.
The TD sensor voltage is compared with the standard voltage (known as the
Target Toner Sensor Voltage), and toner is supplied when the TD sensor
output is higher than this target voltage.
The machine has two ways of calculating the target toner sensor voltage
(either the initial TD sensor setting is used, or a value can be input using
SP53); the metho d use d de pe nd s on SP 30 . The ton er sup ply am o un t can
also be changed using SP31 or 32.
SM 2-29 A219
Page 71
TONER SUPPLY
1) Target Toner Sensor Voltage
- Method 1 -
Normally (if 0 or 2 is selected with SP30) the voltage is determined by the
following factors:
Target Toner Sensor Voltage (VTS) = Initial Developer Setting Voltage (VT0)
+
Toner Density Adjustment Factor
a) Initial Developer Setting Voltage (VT0)
This voltage is adjusted to 1.9 ± 0.1 V during developer initialization
(refer to Toner Density Detection).
b) Toner Density Adjustment Factor
The target toner de nsit y can be chan ge d by cust om e r s or ser vic e
engineers using SP mode 38 or user tool No. 6.
SP 38 Setti ng
00 Normal 0
1 1 Darker –S x 1/2
2 2 Lighter +S x 1/2
3 Darkest –S
4 Lightest +S
User Tool 6
Setting
S: TD Sensor Sensitivity (SP36) Default: Normal
Toner Density
Toner Density
Adjustment Factor (β)
The sensor sensitivity is stored in SP36.
TD Sensor Sensitivity (S) [V/wt%] =
Change of TD sensor outp ut [V] /C h an ge of to ne r den si ty [wt%] =
SP36 setting x 0.05 [V] (Default: SP36 = 15)
- Method 2 -
If 1 or 3 is selected with SP30, the setting of SP53 is used as the target toner
sensor voltage. In th i s case, the tar g et toner sensor volt ag e i s det er mi n ed by
the following formula:
Target Toner Se nsor Voltage = SP53 setting x 0.02 [V] (Default: 97 = 1.94 V)
The TD sensor initial setting is not changed by this SP mode. However, it is
ignored if method 2 is selected.
A219 2-30 SM
Page 72
TONER SUPPLY
2) Toner Supply Amount
- Method 1 -
Normally (if 0 or 1 is selected with SP30), the toner supply amount is
determined by the difference between the actual TD sensor voltage (VT) and
the target toner sensor voltage (VTS). The following table shows the
relationship between the sensor output and the toner supply motor on time
for each copy.
Toner Supply Level TD Sensor Voltage Level [VT] Toner Supply Motor On Time
1
2
3
4
5
6 (Near End Level)
7 (Toner End Level)
< VT ≤ VTS + S/16
V
TS
V
+ S/16 < VT ≤ VTS + S/8
TS
+ S/8 < VT ≤ VTS + S/4
V
TS
V
+ S/4 < VT ≤ VTS + S/2
TS
+ S/2 < VT ≤ VTS + 4S/5
V
TS
V
≥ VTS + 4S/5
T
≥ VTS + S
V
T
The toner supply time unit "t" can be changed using SP31.
t = SP31 setting x 0.1 [second] (Default: 4 = 0.4 second)
S: TD Sensor Sensitivity (SP36)
* This value can be changed using SP35.
t
2 x t
4 x t
8 x t
16 x t
*10 seconds
*10 seconds
- Method 2 -
If 2 or 3 is selected with SP30, a fixed amount of toner is supplied when the
TD sensor voltage become s higher than the target toner sensor voltage. The
amount of toner can be selected using SP32.
SP32 Setti ng
00.3 3.5
10.6 7
21.2 15
32.4 30
43.6 45
54.8 60
6
7 0 (No toner supply) 0
Toner Supply Motor On Time
(seconds)
Stays on until the TD sensor
voltage becomes lower than the
target voltage.
Corresponding image area ratio
(%)
Detailed
Descriptions
SM 2-31 A219
Page 73
TONER SUPPLY
6.5.3 Fixed Supply Mode
If 4 is selected with SP30, th e TD sensor is not used for toner supply control.
A fixed amount of toner is supplied every copy cycle. The toner supply
amount is determined by the SP32 setting.
6.5.4 Abnormal Condition in Toner Density Detection
If the output of the TD sensor go es be l ow 0. 2 vol t s (in di ca ti n g fa r too mu ch
toner), the CPU determines that the toner density supply is abnormal. The
CPU changes from the de tect supply mode to the fix ed supply mode. At the
same time, either the Auto ID indicator or the selected manual ID level starts
blinking, and the machine can be used. No SC code is generated. Under this
condition, the machine will not perform the toner end detection.
If the value recovers above 0.2 volts, or the main switc h is turned off and on,
this condition is canceled and the toner density detection will recover to the
toner supply mode that was in us e immediately before the abnormal condition
occurred.
A219 2-32 SM
Page 74
TONER SUPPLY
6.6 TONER END
Toner Supply Level TD Sensor Voltage Level [VT] Toner Supply Motor On Time
1
2
3
4
5
6 (Near End Level)
7 (Toner End Level)
6.6.1 Toner Near End
V
< VT ≤ VTS + S/16
TS
+ S/16 < VT ≤ VTS + S/8
V
TS
V
+ S/8 < VT ≤ VTS + S/4
TS
+ S/4 < VT ≤ VTS + S/2
V
TS
V
+ S/2 < VT ≤ VTS + 4S/5
TS
≥ VTS + 4S/5
V
T
V
≥ VTS + S
T
The toner supply time unit "t" can be changed using SP31.
t = SP31 setting x 0.1 [second] (Default: 4 = 0.4 second)
S: TD Sensor Sensitivity (SP36)
* This value can be changed using SP35.
t
2 x t
4 x t
8 x t
16 x t
*10 seconds
*10 seconds
Detailed
Descriptions
If the CPU detects toner supply level 6 (VT ≥ VTS + 4S/5) five times
consecutively, the toner end indicator blinks and the mac hine goes to the
toner near end condition.
In this condition, the toner supply motor is energized for 10 seconds for every
copy (this time can be changed using SP35). Also, the toner supply motor
stays on continuously between pages of a multi-copy job.
If a toner sensor voltage lower than VTS + 4S/5 is detected twice
consecutively while the toner supply motor is on, the machine recovers from
the toner near end condition. Also, if this condition is detected during the
normal copy cycle, the toner near end is canceled.
6.6.2 Toner End
If toner supply level 6 is detected, the machine supplies toner between
copies and for 10 seconds after the copy job is finished (as explained above).
While the toner supply motor is on, if the CPU detects toner supply level 7
(VT ≥ VTS +S) three times consecutively, a toner end condition is detected
and copier opera tion is disabled.
If the toner sensor vo ltage stays at level 6 after the toner near end condition
is detected, 50 more copies can be made. After 50 copies, the toner end
indicator lights and copying is disabled.
SM 2-33 A219
Page 75
TONER SUPPLY
6.6.3 Toner End Recovery
If the main switch is turned off and on, or the front door is opened and closed
during a toner end condition, the machine checks th e to ne r bottle for
replacement. The main motor turns on and the toner supply motor is
intermittently energized. If the TD sensor voltage does not recover from level
7 within 40 seconds, the machine stops, keeping the toner end condition. If
the TD sensor voltage become s lower than VTS +3S/5 in this period, the
machine recovers from the toner end condition. Then the toner supply motor
stops, but the main motor continuously rotates for 40 seconds to distribute
toner evenly inside the development unit.
A219 2-34 SM
Page 76
IMAGE TRANSFER AND PAPER SEPARATION
7. IMAGE TRANSFER AND PAPER
SEPARATION
7.1 OVERALL
[C]
Detailed
Descriptions
[B]
[A]
A219D528.wmf
A high negative voltag e (approximately –5 kV) is applied to the transfer
corona wire [A], and the corona wire generates negative ions. These
negative ions are appl ied to th e ba ck side of the copy pa pe r . This ne ga tive
charge forces the paper against the drum and attracts the positively charged
toner onto the paper.
A high positive voltage (approximately +2.2 kV) is applied to the discharge
plate [B]. The negative charge on the copy paper is discharged after image
transfer by this discharge plate to ensure paper separation from the drum.
The spurs [C] prevent unf used toner on the paper from being smeared by the
bottom surface of the imaging unit.
SM 2-35 A219
Page 77
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IMAGE TRANSFER AND PAPER SEPARATION
7.2 TRANSFER CORONA AND DISCHARGE PLATE CIRCUIT
Main Board High Voltage Supply Board
24 V
C Tri
GND
er
CN102-7
CN102-6
CN102-5
DC/DC
Converter
T Tri
B-PWM
S Tri
4.7 k
er
er
5 V
CN102-4
CN102-3
CN102-2
CN102-1
DC/DC
Converter
DC/DC
Converter
Zener
Diode
DC/DC
Converter
Protection
Circuit
GC
Drum
B
S
T
A219D506-3.wmf
When the CPU drops CN102-4 from +24 V to 0 V, the transfer corona (-5kv)
is applied to the back of the copy paper and the drum. When the CPU drops
CN102-2 from 5V to LO W , a hig h po si tive vol ta ge (+2 .2 kV) is ap pli e d to the
discharge plate.
A219 2-36 SM
Page 78
8. DRUM CLEANING
8.1 OVERVIEW
[A]
DRUM CLEANING
Detailed
Descriptions
A219D528-2.wmf
A counter blade system is used for drum cleaning. The cleaning blade [A]
scrapes off any toner remaining on the drum after the image is transf er r e d to
the paper.
The removed toner is transported into the develope r to be recycled.
SM 2-37 A219
Page 79
DRUM CLEANING
8.2 TONER RECYCLING MECHANISM
[A]
[B]
A219D530.wmf
The toner removed from the drum falls onto the toner collection coil [A]. The
drum gear rotation is directly trans mitted to the toner collection coil drive gea r .
As the coil rotates, the toner moves from rear to front until it reaches the
toner recycling belt [B ]. The paddles of the belt, which is driven by the toner
collection coil shaft , tr a nsp or t s the ton er i nt o th e de vel o pe r , an d th e to ne r is
recycled.
A219 2-38 SM
Page 80
9. QUENCHING
QUENCHING
[A]
Detailed
Descriptions
A219D513-2.wmf
In preparation for the next copy cycle, light from the quenching lamp (QL) [A],
which is installed in the upper unit, neutralizes any charge remaining on the
drum.
LEDs are used for quenching and the lamp is turned on whenever the main
motor rotates.
SM 2-39 A219
Page 81
PAPER FEED AND REGISTRATION
10. PAPER FEED AND REGISTRATION
10.1 OVERVIEW
[C]
[B]
[D]
[E]
This copier has one paper feed station and a by-pass feed table.
The paper feed station uses a pa pe r tr ay [A ] whi ch can ho l d 50 0 she et s. The
by-pass feed table [B] can hold 80 sheets.
The paper tray uses two semic i rcular feed rollers [C] and corne r separators.
The semicircular feed rollers make one rotation to drive the top sheet of the
paper stack to the relay rollers [D]. The paper tray has two corner separators,
which allow only one sheet to feed. They also hold the paper stack. When the
paper tray is drawn out of the machine, the spring pressure is released, and
the tray bottom plate drops. In addition, there is no need to press the bottom
plate down when putting the tray back in.
The by-pass feed table uses a feed roller and friction pad system to feed the
top sheet of paper to the registration rollers.
In humid environments, copy paper may crease as it comes out of the fusing
unit. The optional tray heater [E] is available as a service part to keep copy
paper dry.
[A]
A219D500.wmf
A219 2-40 SM
Page 82
10.2 PAPER TRAY FEED
10.2.1 Paper Lift Mechanism
[A]
[C]
[B]
[H]
PAPER FEED AND REGISTRATION
[J]
[E]
[D]
A219D534.wmf
[I]
[G]
[F]
[K]
A219D535.wmf
The capacity of this tray is higher than usual for a corner separator type.
Because of this, the r e are t wo spr i n gs to lif t th e bo ttom plate.
As the tray is pushed into the machine, shutter [A] under the tray pushes
against projection [B]. As the shutter slides past the projection, the shutter
rotates, which forces the main lift spring [C] to pull the bottom plate lever [D].
The secondary lift spring [E] also pulls the bottom plate lever (this is
described below).
The tension applied to the main lift spring is always the same. However, the
secondary spring is only used when wider paper is installed, to lift the extra
weight of the paper stack. The tension applied to the secondary lift spring
depends on the paper wid th . Be l ow a certain threshold width, tension is no t
applied. Above this width, the wider the paper, the more tension is applied.
To apply spring tension fo r wid er pa pe r , pr o jection [F] stops against the end
of rail [G]. When this happens, lever [H] swings out in the direction shown
above, which stretches the spring as the tray is pu shed in. The side fence
position affects the orientation of [F]; wider paper causes [F] to contact [G]
earlier, leading to greater spring tension when the tray has been pushed all
the way in.
For narrow paper, th e seco nd ar y l ift spring is not needed . The side fence
orients projection [F] so that it slides past the rail as the tray is pushed into
the machine, and the spring stays slack.
Detailed
Descriptions
The bottom plate stop per [I] rests on the bottom plate [J]. It stops the botto m
plate at the maximum heigh t. When the tray is getting empty, the corner
separators [K] s tart to rise, and continue to rise as the amount of paper in the
tray decreases, so that the paper is always at the correct height.
SM 2-41 A219
Page 83
PAPER FEED AND REGISTRATION
10.2.2 Paper Feed Mechanism
[E]
[D]
[A]
[C]
[B]
A219D508.wmf
[H]
[F]
[G]
A219D523.wmf
Through several gears and a timing belt, main motor rotation is transmitted to
the tray paper feed cl utch gear [A] and the relay roller clutch gear [B].
-Feed rollers-
The tray paper feed clut ch ge ar is on th e sam e shaf t as th e sem ici r cu lar
feed rollers [C]. After the ! key is pressed, the tray paper feed clutch [D] is
energized for 250 milliseconds to release the stopper [E]. Then the drive of
the main motor is transmitted, and the feed rollers make one complete
rotation to feed the top sheet of paper which is enough for the leadi n g ed ge
of the paper to be caught by the relay rollers [F]. The feed rollers stop when
the stopper drops back into the notch at the end of one complete turn.
-Relay rollers-
The relay roller clutch gear is on the same shaft as the relay rollers. The
rotation timing of the relay rollers is controlled by the relay roller clutch [G].
The CPU energizes the relay roller clutch after the ! key is pressed (at the
same time as the tray paper feed clutch). Paper is fed from th e relay rollers to
the registration rollers [H].
A219 2-42 SM
Page 84
10.3 BY-PASS FEED
10.3.1 Overview
PAPER FEED AND REGISTRATION
Detailed
Descriptions
[A]
A219D501.wmf
The by-pass feed table [A] can hold 80 sheets of paper.
This machine does not have a by-pass feed cover s ensor. The by-pass feed
indicator is always displayed on the operation panel. The Add Paper indicator
will light when the user selects by-pass feed while the by-pass feed table is
closed or if there is no paper on the by-pass feed table.
After the ! key is pressed, the cpu energize s the by-pass fee d clut ch and
the by-pass feed roller starts to feed paper to the registration roller.
This machine does not have any sensor or switch to determine the paper
size for by-pass feed. The machine will perform a full scan for all copies.
SM 2-43 A219
Page 85
PAPER FEED AND REGISTRATION
10.3.2 Paper Feed Mechanism and Paper End Detection
[A]
[C]
[D]
[B]
[F]
A219D524.wmf
[E]
A219D502.wmf
This machine uses a feed roller [A] and friction pad [B] mechanism, with drive
from the main motor [C] transmitted when the by-pass feed clutch [D] turns
on. The friction pad pr e v en ts all bu t th e to p sheet from feeding. Therefore,
during paper feed, the top sheet of paper is separated from the stack and fed
to the registration rollers.
Before placing paper on the by-pass feed table, the user must lower the
by-pass feed table by usin g th e leve r [E] . Thi s i s to en sur e tha t th e pa pe r is
placed between the friction pad and the feed roller. Then, before starting to
copy, it must be put back up to move the paper stack int o conta ct with the
feed roller.
When there is no paper on the by-pass feed table, the paper end feeler [F]
drops into the cutout in th e by- p ass fe ed tab l e an d th e by- p ass fe ed paper
end sensor is activated.
A219 2-44 SM
Page 86
10.4 PAPER REGISTRATION
PAPER FEED AND REGISTRATION
[A]
[B]
[E][F]
[C]
[D]
A219D529.wmf
A219D523-2.wmf
Main motor rotation is transmit ted to the registration roller clut ch gear [A]
through several gears and a timing belt. When the registration clutch [B] is
energized, the rot ation of the clutch gear is transmitted to th e l owe r
registration roller [C].
Detailed
Descriptions
The registration sensor [D], which is positioned just before the registration
rollers, controls the relay roller clutch stop timing. The relay roller clutch stays
on for 130 milliseconds after the leading edge of the paper actuates the
registration sensor. The CPU then turns off the relay roller clutch. This delay
allows time for the paper to press against the registration rollers an d buckle
slightly to correct skew.
The CPU energizes the reg istration clutch at the proper time to align the
paper with the image on the drum.
The registration sensor is also used for paper misfeed detection.
The paper dust mylar [E] on the upper registration roller [F] removes paper
dust before the pape r reach es th e tr a nsf er / s ep ar a tion unit.
SM 2-45 A219
Page 87
PAPER FEED AND REGISTRATION
10.5 SIDE FENCE DOUBLE STOPPER MECHANISM
[B]
[A]
[A]
[B]
A219D503.wmf
There is a side fence stopper mechanism for both the front and rear side
fences.
If the tray is closed with excessive force after loading pa per, paper may come
over the rear side fence, because the fence is deformed by the weight of the
paper leaning against it. As a result, skewing or paper jams may occur. To
prevent this, a side fence stopper mechanism has been added to the rear
side fence.
The release levers [A] each have a stopper which contains teeth like those
on a gear. The guide rails [B] also have teeth. When the release lever is
pushed, the gear teeth release each other and the side fences can be moved.
A219 2-46 SM
Page 88
10.6 PAPER END DETECTION
PAPER FEED AND REGISTRATION
[B]
[D]
[A]
Detailed
Descriptions
[E]
[C]
A219D504.wmf
The paper end feeler [A] is on the same shaft as the paper end actuator [B].
When the paper tr ay run s out of pa pe r , th e paper end feeler drops into the
cutout [C] in the tray bottom plate. The paper end actuator activates the
paper end sensor [D].
The paper end actuator is in contact with the lever [E]. When the tray is
drawn out, th e lever turns as shown by the arrow in the diagram. Then the
lever pushes up the actuator. As a result, the feeler rotates upwards. This
mechanism is necessary to prevent the feeler from getting damaged by the
paper tray body.
SM 2-47 A219
Page 89
y
y
y
g
g
(
)
PAPER FEED AND REGISTRATION
10.7 PAPER FEED AND MISFEED DETECTION TIMING
Start Ke
Main Motor
Paper Feed Clutch
Tra
Roller Clutch
Rela
istration Clutch
Re
istration Sensor
Re
Exit Sensor
0
A4 sideways
0.10 0.35
0.13
A
2.09
2.01
(1)
4.97
A
(2)
second
7.45
(3)
A
7.80
(4)
A
A219D526.wmf
The registration sensor and the exit sensor are used for misfeed detection. If
the CPU detects a misfeed, the Check Paper Path and the Location
indicators turn on.
Just after the main switch is turned on, the CPU checks these sensors for
any jammed pape r.
During the copy cycle, the CPU performs four kinds of misfeed de te ctio n. The
following explains jam detection timing for copying A4 sideways paper.
(1): Checks whether the registration sensor is actuated within 2.01 seconds
A
after the ! key is pressed.
(2): Checks whether the exit sensor is actuated within 4.97 seconds after
A
the ! key is pressed.
(3): Checks whether the copy paper has passed through the registration
A
sensor 7.45 seconds after the ! key is pressed.
(4): Checks whether the copy paper has passed through the exit sensor
A
7.80 seconds after the ! key is pressed.
NOTE:
(1) and A (2) are detected from the lead edge of the copy paper.
A
(3) and A (4) are detected from the trail edge of the copy paper.
A
The detection timin g fo r A (3) and A (4) will vary with the
copy paper size in use.
A219 2-48 SM
Page 90
PAPER FEED AND REGISTRATION
10.8 OTHERS
[C]
SW
(from right to left)
Size
[B]
A219D525.wmf
A3, F( 8
A4 Lengthwise
A4 Sideways
A5 Sideways,
11"x17"
B4, 8
B5 Sideways,
8
[A]
1/2
B5 Lengthwise,
11"x8
* (Asterisk)
●: ON (Not pushed) ❍: OFF (Pushed)
1/2
"x11"
1/2
"x13" )
1/2
"x14"
"
10.8.1 Paper Size Detection
There are four microswitches [A] on the front right plate of the main frame.
The sensors are actuated by a pa pe r size actu at or [B ] be hi n d th e pa pe r size
indicator plate on the front right of the tray. Each paper size has its own
actuator, with a unique combination of notches. To determine which size tray
has been installed, the cpu reads which switches have been pressed. The
cpu disables paper feed i f th e pa pe r size cann ot be de te cte d. If the pap er
size actuator is broken, or if there is no tray, the Add Paper indicator will light.
1234
●●●❍
●❍●❍
●●❍❍
●❍❍❍
❍●❍❍
❍❍❍❍
❍❍●❍
❍❍●●
Detailed
Descriptions
When the paper size actuator is at the "*" mark, the paper tray can be set up
to accommodate one of a wider range of paper sizes. The setting for this
mode is performed with SP74. Paper length will be taken from this setting,
and not from the registration sensor readings.
Because of the limited space on the operation panel, not all the paper sizes
possible with the paper size actuator can be displayed on the operation
panel. In some cases, the " * " mark will be displayed, but the machine will
operate in accordance with the selected paper size.
The paper size switch also acts as a tray open sensor.
10.8.2 Shock Absor b er
At the position shown, a damper [C] is installed to reduce the shock to the
paper tray when it is pushed back int o the cop i er. This is to prevent the stack
of paper inside the paper tray from coming over the corner separators, which
will cause double feeding or image skew on copies.
SM 2-49 A219
Page 91
IMAGE FUSING
11. IMAGE FUSING
11.1 OVERVIEW
[A]
[E]
[B]
[D]
[F]
[C]
A219D531.wmf
[G]
A219D539.wmf
After the image is transfe rred, the copy paper enters the fusing unit. The
image is fused to the copy paper by heat and pressure using a hot roller [A]
and a pressure roller [B].
The CPU monitors the hot roller temper ature through a thermistor [C] which
is in contact with the hot roller surface. A thermofuse [D] prevents the fusing
unit from overheating.
The hot roller strippers [E] separate the copy paper from the hot roller and
direct it to the exit rollers. The exit sensor [F] monitors the progress of the
copy paper through the fusing unit and acts as a misfeed detector. The exit
rollers [G] drive the copy paper to the copy tray.
A219 2-50 SM
Page 92
11.2 FUSING DRIVE MECHANISM
[B]
A219D539-2.wmf
[C]
IMAGE FUSING
[A]
Detailed
Descriptions
[D]
[E]
[F]
[G]
A219D532.wmf
Drive from the main motor [A] is transmitted to the hot roller [B] through idle
gears and a timing bel t. The ho t rol le r alw ays rotates while the main motor
rotates.
The fusing unit drive release mechanism automatically disengages the fusing
drive gear [C] when the front cover [D] is opened. This allows the fusing unit
drive gear to rotate freely so that misfed paper can be easily removed.
When the front cover is opened, the actuator plate [E] pulls the release wire
[F]. The wire pulls the fusing unit gear bracket [G] and the fusing unit drive is
disengaged.
SM 2-51 A219
Page 93
IMAGE FUSING
11.3 FUSING LAMP CONTROL
The CPU monitors the temperature of the hot roller surface using a
thermistor. The fusing lamp is turned on and off to keep the hot roller surface
at the target temperature. The target temperature depends on the machine
condition as follows:
Machine Condition
Ready
After the main switch is turned
on, and after one minute has
passed since the fusing
temperature reached the
Ready condition.
After the above time period, the
copier enters the energy saver
mode.
During copying
Fusing Lamp ON/OFF
Threshold
165°C: 120 V machines
172°C: 230 V machines
190°C
120°C: 120 V machines
130°C: 230 V machines
190°C
A219D533.wmf
Remarks
—
After the fusing unit reaches
the ready temperature, the
fusing lamp is kept on until it
reaches 190°C.
$
When the
the red indicator blinks and
copying starts after the fusing
temperature reaches the Ready
condition.
key is pressed,
—
A219 2-52 SM
Page 94
IMAGE FUSING
When the main switch is turned on, the CPU turns on the fusing lamp. When
the fusing thermist or detects the ready temperature, the machine enters the
ready condition. After the ready temperature is detected, the CPU keeps the
fusing temperature at 190°C for one minute, then the target temperature is
changed to 120°C (120 V machines) or 130°C (230 V machines).
When the $ key is pressed, if the fusing lamp temp er a tu re i s hi gh er th an
the ready temperature, the machine starts copying immediately. If the
temperature is lower, the fusing lamp is turned on and the start indicator turns
red and blinks. Copying starts after the fusing temperature reaches the ready
temperature, and the fusing temperature is kept at 190°C during copying.
After copying is finished, the fusing temperature is kept at 190°C for one
minute.
To prevent any copy quality problem caused by exposure lamp intensity
fluctuation, the fusing lamp does not turn on while the exposure lamp is on,
even if the fusing temp er a tu r e dro ps be l ow 190°C.
Detailed
Descriptions
SM 2-53 A219
Page 95
g
g
IMAGE FUSING
11.4 FUSING LAMP CONTROL CIRCUIT
11.4.1 Overview
CN113-1
Trigger Pulse
24 V
0 V
Main Board
CN113-2
5 V
CN101-3
24 V
CN101-4
CN207-7
CN207-6
T202
AC Power Source
T201
PC2
FU1
T208
✽
C20
✽
L4
RY1
T207
T205
T206
T204
T203
AC Drive/DC Power
Supply Board
Fusin
Thermistor
Lamp
Fusin
Main Switch
Interlock
Switch
✽
230 V machines only
A219D537.wmf
The main board monitors the fusing temperature through a thermistor. It uses
the zero cross signal generated by the ac drive/dc power supply board to
control the applied power accurately.
Normally, the voltage applied to the lamp is the full du ty cycle of the ac
waveform. However, through SP29, fusing power can be set to phase control
mode. (Phase control is used only if the customer has a problem with
electrical noise or interference.)
A219 2-54 SM
Page 96
IMAGE FUSING
11.4.2 On/Off Control
When the main switch is turned on, the main board starts to output a trigger
pulse, which has the same timing as the zero cross signal, to the ac drive/dc
power supply board. This trigger pulse allows maximum ac power to be
applied to the fusin g l am p . W he n th e op er a ti n g te m pe rature is reached, the
CPU stops outputting the trigger pulse (the trigger stays HIGH) and the fusing
lamp turns off.
11.4.3 Phase Control Mode
Detailed
Descriptions
A219D538.wmf
The main board sends the fusin g l amp tr i gger pu ls e (LOW active) to the ac
drive/dc power supply board, which provides ac power to the fusing lamp at
the falling edge of each trigger pulse. The trigger pulse goes HIGH when the
main board receives the zero cross signal.
The amount of time that power is applie d to the fusing lamp depends on the
temperature of the hot roller.
The trigger pulse (LOW part) is wider [C1] and power is supplied for longer
[D1] when the hot roller temperature is lower. It is narrower [C2] and power is
supplied for a shorter time [D2] when the hot roller is near the operating
temperature.
SM 2-55 A219
Page 97
IMAGE FUSING
11.4.4 Overheat Protection
There is an overheat protection circuit in the main board. If the hot roller
temperature reaches 245°C during the main motor of f con di t i on , or 25 5°C
during the main motor on condition, the resistance of the thermistor (between
CN113-1 and CN113-2) becomes too low. If the main board detects this
condition, "E-53" lights on the operation panel and power to the fusing lamp
is cut.
Even if the thermistor ove r he at pr ot ect i on fail s, the thermofuse opens w he n it
reaches 169°C, removing power from the fusing lamp.
A219 2-56 SM
Page 98
INSTALLATION
Page 99
Page 100
INSTALLATION REQUIREMENTS
1. INSTALLATION REQUIREMENTS
1.1 ENVIRONMENT
1. Temperature Range: 10°C to 30°C (50°F to 87°F)
2. Humidity Range: 15% to 90% RH
3. Ambient Illumination : Less than 1,500 lux (Do not exposure to dir ect
sunlight.)
4. Ventilation: Room air should turn over at least 3 times per
hour
5. Ambient Dust: Less than 0.15 mg/m3 (4 x 10-3 oz/yd3)
6. If the place of installation is air-conditioned or heat ed , do not pl ace the
machine:
1) Where it will not be subjected to sudden temperature changes.
2) Where it will not be directly exposed to cool air from an air-conditioner.
3) Where it will not be directly exposed to heat from a heater.
7. Do not place the machine where it will be exposed to corrosive gasses.
8. Do not install the machine at any location over 2, 000 m (6,500 feet)
above sea level.
9. Place the cop ier on a strong and level base.
10. Do not place the mach ine where it may be subjected to strong vibrations.
1.2 MACHINE LEVEL
1. Front to back: Within 5 mm (0.2") of level
Installation
2. Right to left: Within 5 mm (0.2") of level
SM 3-1 A219
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