Ricoh FT4015 Service Manual ft4018

IMPORTANT SAFETY NOTICES



PREVENTION OF PHYSICAL INJURY

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

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

3. Note that the optional tray heater and the optional anti-condensation heaters are supplied with electrical voltage even if the main switch is turned off.

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

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

HEALTH SAFETY CONDITIONS

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

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

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

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

Grand Kingfisher

(Machine Code:A245)

Service Manual

–

Insert Version

–

The A245 copier is based on the A219 copier. Only the differences from the A219 copier are described in the

following pages. Refer to the A219 copier service manual regarding the other information.

26 September 1997 SPECIFICATIONS

1. SPECIFICATIONS

NOTE:

Only items marked with ✽ are different from the A219 copier.

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

Minimum:

A5/5 A6/5

1/2 1/2

" x 8 " x 8

1/2

" sideways (Paper tray feed)

1/2

" lengthwise (By-pass feed)

Non-standard sizes:

Vertical 45 mm ~ 308 mm, 1.8" ~ 12" Horizontal 148 mm ~ 432 mm, 5.8" ~ 17"

Copy Paper Weight: Paper tray feed: 64 to 90 g/m

By-pass feed: 52 to 157 g/m

Reproduction Ratios:

Enlargement

Full Size 100% 100%

Reduction

Metric Version Inch Version

200% 141% 122%

93% 82% 71% 50%

, 17 to 24 lb

, 14 to 42 lb

Copier

200% 155% 129%

93% 74% 65% 50%

Zoom: From 50% to 200% in 1% steps ✽ Copying Speed: 18 copies/minute (A4/8.5" x 11" sideways)

10 copies/minute (A3/11" x 17")

✽ Warm-up Time:

120 V machines: Less than 35 seconds (at 23°C)

230 V machines: Less than 45 seconds (at 23°C) ✽ First Copy Time: Less than 6.5 seconds (A4/8.5" x 11" sideways) Copy Number Input: Number keys, 1 to 99 Manual Image Density

7 steps Selection:

SPECIFICATIONS 26 September 1997

Automatic Reset: 1 minute standard setting; can also be set to 3

minutes or no auto reset

✽ Paper Capacity: Paper tray: 250 sheets or less than 30 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 America)

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*

1.4 kW

Maximum

Copy cycle 0.82 kW 0.85 kW

Warm-up 0.95 kW 0.95 kW Stand-by 0.16 kW 0.16 kW

Energy saver 0.12 kW 0.12 kW

*Full system : Copier with document feeder and 10 - bi n sorter

Copier

Full system*

*Full system : Co pi er w i th d ocument feeder an d 10- bi n sorter

(120 V machines)

1.1 kW

(230 V machines)

Width Depth Height

579 mm

(22.8")

775 mm

(30.2")

560 mm

(22.1")

560 mm

(22.1")

1.5 kW

(120 V machines)

1.2 kW

(230 V machines)

465 mm (183.8")

563 mm

(21.5")

26 September 1997 SPECIFICATIONS

✽ Noise Emissions: Sound pressure level (the measurements are

made in accordance with ISO 7779 at the

operator position.)

✽ Weight:

Optional Equipment: (Sales items)

Optional Equipment: (Service items)

Copier only Full system*

Copyin g 58 dB or less 62 dB or less

*Full system : Co pi er w i th d ocument feeder an d 10- bi n sorter

Sound power level (the measurements are made

in accordance with ISO 7779)

Copier only Full system*

Stand- by 40 dB or less 40 dB or less

Copy cycl e 64 dB or less 68 dB or le ss

*Full system : Co pi er w i th d ocument feeder an d 10- bi n sorter

Copier only

Full system *

*Full system : Co pi er w i th d ocument feeder an d 10- bi n sorter

45 kg (99.2 lb)

58 kg (128 lb)

Document feeder (A662)

10-bin sorter (A657)

Optics anti-condensation heater

Tray heater

Copier

•

Specifications are subject to change without notice.

MECHANICAL CO M PO N EN T LAYO U T 26 September 1997

2. MECHANICAL COMPONENT LAYOUT

NOTE:

The paper feed area has been changed.

98654321

15 16

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 Mi r r or

23 22 1920

11. 5th Mi r r or

12. Toner Bottle Holder

13. By-pass Feed Roller

14. By-pass Feed Table

15. Upper Relay Rollers

16. Upper Tray Pap er F eed Rollers

17. Lower Relay Rollers

18. Lower Tray Paper Feed Rollers

19. Registration Rollers

17 18

A245V500.wmf

20. Development Roller

21. Transfer/Separation Unit

22. Drum

23. Cleaning Bl ade

24. Pressure Roller

25. Lower Paper Tray

26. Upper Paper Tray

27. Copy Tray

28. Exit Rollers

29. 3rd Mi r ror

26 September 1997 DRIVE LAYOUT

3. DRIVE LAYOUT

NOTE:

12 11

The paper feed area has been changed.

Copier

1. Lens Motor

2. Fusing Unit Drive Gear

3. Main Motor

4. Drum Drive Gear

5. Lower Tray Paper Feed Clutch Gear

6. Upper Tray Paper Feed Clutch Gear

7. Lower Relay Roller Clutch Gear

54 3

A245V501.wmf

8. Upper Relay Roller Clutch Gear

9. By-pass Paper Feed Clut ch

10. Registration Clutch Gear

11. Toner Supply Motor

12. 4th/5th Mirror Motor

13. Scanner Drive Motor

PAPER PATH 26 September 1997

4. PAPER PATH

NOTE:

The paper feed area has been changed.

1. By-pass Feed

2. Lower Paper Tray Feed

3. Upper Paper Tray Feed

4. Copy Tray

A245V502.wmf

26 September 1997 ELECTRICAL COMPONENT DESCRIPTIONS

5. 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 M ot or Dri ves the scanners (1s t and 2nd). 9 M3

Main Motor Drives all th e m ai n unit component s except for

the optics un i t an d fa ns.

Lens Motor Moves the lens position in accor dance with

the selecte d m agnification.

4th/5th Mirror Motor Moves the 4th/5th mirror position in

accordanc e w ith the selected magnification.

Toner Supply M ot or Rotates the to ner bot tle to supply toner to the

development uni t .

Optics Cooling Fan Motor

Exhaust Fan Mot or Removes heat from a ro und the fusing unit and

Prevents buil d- up of hot air in the opti cs cavity.

blows the ozone built up around the charge corona unit towards the ozone filter.

Copier

Clutches

CL1

CL2

CL3 CL4 Registration Clutch Drives the registration rollers. 11 CL5

CL6

Switches

SW1 Main Swit ch Supplies power to the copier. 43 SW2 Interlock Switch Cuts all power when the front cover is opened. 42

SW3

SW4

SW5

Upper Tray Paper Feed Clutch

By-pass Paper F eed Clutch

Lower Tray Paper Feed Clutch

Upper Relay Roller Clutch

Lower Relay Roller Clutch

Upper Tray Paper Size Switch

Right Vertical Guide Switch

Lower Tray Paper Size Switch

Transfers ma in motor drive to the upper paper feed roller.

Starts paper fee d fr om t he by-pass feed tabl e.

Transfers ma in motor drive to the l ow er paper feed roller.

Drives the upp er relay rollers for upper paper tray feed.

Drives the lower relay rollers for lower paper tray feed.

Determin es w hat size of paper is in t he upper paper tray.

Cuts the +24 V dc power line of the relay roller clutch.

Determines what size of paper is in the lower paper tray.

Sensors

4th/5th Mirro r Hom e Position Sensor

Informs the CPU when the 4th/5th mirror assembly is at the home position (full size position).

ELECTRICAL COMPONENT DESCRIPTIONS 26 September 199 7

Symbol Name Function Index No.

S2 ADS Sensor Detects the background density of th e or i gi nal. 26 S3

Upper Tray Paper End Sensor

Informs the CPU w hen the upper paper tr ay runs out of pape r.

Registratio n Sensor Detects the leading edge of th e copy paper to

determine t he st op timing of the rela y roller

clutch, and det e ct s m i sf eeds.

By-pass Feed Paper End Sensor

Informs the CPU w hen there is no paper in the by-pass tray .

33 S6 Exit Sensor Detects misfeeds. 25 S7

S10

Scanner Home Position Sensor

Lens Home Posit ion Sensor

Toner Density (TD) Sensor

Lower Tray Paper End Sensor

Informs the CPU w hen the 1st scanner i s at the home position.

Informs the CPU w hen the lens is at the hom e position.

Detec ts the ra tio of ton er to car rier in th e developer.

Informs the CPU when the lower paper tray runs out of pape r.

Printed Circuit Boards

PCB1 Main Control Boar d Controls all copier functions. 1

PCB2

High Voltage Supply Board - C/G/B/T/S

Provides high voltage to the charge corona, grid, development bias, transfer corona, and

discharge plate.

PCB3

AC Drive/DC Power Supply Board

Drives the exp o sure lamp, fusing l amp, and main motor. Rectifies 30 Vac and 8 Vac input

and outputs 5 Vdc and 24 Vdc.

PCB4

Operation Pane l Board

Informs the CPU of the selected mode s and displays the si t uation on the panel.

Lamps

Erase Lamp Discharges the dr um outside of the image

area. (Provides leading/trailing edge and side erases.)

Quenching Lamp Neutralizes any char ge r em a ining on the drum

surface after cl eaning.

Exposure Lamp Applies high intensity light to the original for

exposure.

L4 Fusing Lamp Provides hea t to the hot r oller. 27

Others

CO1

Total Counter Keeps track o f the t ot al num ber of copies

made.

Upper Tray Heat er (Option)

Optics Anti-condensat i on Heater (Opti on)

Turns on when t he main switch is of f to keep paper in the up per paper tray dry.

Turns on when t he main switch is of f to prevent moisture from accumulating in the optics.

26 September 1997 ELECTRICAL COMPONENT DESCRIPTIONS

Symbol Name Function Index No.

TF1

TF2

TH1

TH2

Lower Tray Heat er (Option)

Exposure Lamp Thermofuse

Fusing Therm of u se Provide back-up overheat protection in the

Fusing Therm i st or M onitors the tem per ature around the ex posure

Optics Therm i st or Monitors th e te mperature around t he exposure

Transformer Steps down the wall vol t age to 30 Vac and 8

Turns on when t he main switch is of f to keep paper in the lower paper tray dry .

Provide back-up overheat protection around the exposure lamp.

fusing unit.

lamp for over heat protection.

Vac.

Copier

PAPER FEED 26 September 1997

6. PAPER FEED

6.1 OVERVIEW

[E]

[D]

[A]

[B]

[F]

[C]

[G]

A245D500.wmf

There are two paper trays and a by-pass feed table [A]. The upper [B] and lower [C] paper trays each hold 250 sheets. The by-pass

feed table can hold 1, 10, or 80 sheets of paper, depending on the paper type. The semicircular feed rollers [D] drive the top sheet of paper from the tray to

the registration rollers [E] through the relay rollers [F]. The tray has two corner separators (see [F] in the diagram in the "Paper Lift

Mechanism" section), which allow only one sheet to feed at a time. The corner separators, along with the tray’s springs, also serve to set the height of the paper stack.

When the tray is closed after the paper is loaded, the paper size actuator located at the front right of the tray pushes the paper size sensor. This informs the cpu what paper size is loaded in the tray and that the tray is in place.

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 heaters [G] are available as service parts to keep copy paper dry. It can be installed for both paper trays.

26 September 1997 PAPER FEED

6.2 PAPER LIFT MECHANISM

[F]

[D]

[E]

[A]

[C]

[B]

[F]

A245D501.wmf

When the paper tray [A] is closed after paper is loaded, the release slider [B], which is mounted on the bottom part of the tray, is pushed by the projection [C] on the main frame and the release slider comes off the bottom plate hook [D].

Copier

Once the release slider comes off, the bottom plate is raised by the pressure springs [E] and the top sheet pushes up the corner separators [F]. This keeps the stack of paper at the correct height.

PAPER FEED 26 September 1997

6.3 PAPER FEED AND DRIVE MECHANISM

[E]

[D]

[C]

A245D502.wmf

[A]

[F]

[B]

[G]

A245D503.wmf

Through several gears and a timing belt, main motor rotation is transmitted to the tray paper feed clutch gear [A] and the relay roller clutch gear [B].

-Feed rollers-

The tray paper feed clutch gear is on the same shaft as the semicircular 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 main motor drive is transmitted, and the feed rollers make one complete rotation to feed the top sheet of paper, which is enough for the leading edge 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 the relay rollers to the registration rollers.

26 September 1997 PAPER FEED

6.4 PAPER FEED AND MISFEED DETECTION TIMING

Start Key

Main Motor

Upper Tray Paper Feed Clutch

Upper Relay Roller Clutch

Registration Clutch

Registration Sensor

Exit Sensor

A4 sideways

0.30 0.55

0.30

0.10

2.13

2.05

(1)

4.48

(2)

(seconds)

6.50

(3)

6.78

(4)

A245D508.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.

Copier

Just after the main switch is turned on, the CPU checks these sensors for any jammed paper.

During the copy cycle, the CPU performs four kinds of misfeed detection. The following explains jam detection timing for copying on A4 sideways paper from the upper paper tray unit.

(1): Checks whether the registration sensor is actuated within 2.05

seconds after the main motor starts rotating.

(2): Checks whether the exit sensor is actuated within 4.48 seconds after

the main motor starts rotating.

(3): Checks whether the copy paper has passed through the registration

sensor 6.50 seconds after the main motor starts rotating.

(4): Checks whether the copy paper has passed through the exit sensor

6.78 seconds after the main motor starts rotating.

NOTE:

(1) and A (2) are detected from the leading edge of the copy

paper. copy paper. The detection timing for

(3) and A (4) are detected from the trailing edge of the

(3) and A (4) will vary with

the copy paper size in use.

IMAGE FUSING 26 September 1997

7. IMAGE FUSING

1. Both the hot roller and pressure roller for the A245 are different from the

A219. To distinguish between the two types of roller, check the end of the roller shaft as described below.

HOT ROLLER

- A219 -

- A245 -

A245D504.wmf

PRESSURE ROLLER

- A219 -

A245D505.wmf

- A245 -

A245D506.wmf

A245D507.wmf

2. Due to the increase in copier CPM, the thickness of the metal core of the

hot roller has been increased for the A245 copier. This causes the ready temperature to be higher, and the temperatures are as follows:

A245 copier A219 copier

172°C: 120 V machines 165°C: 120 V machines 177°C: 230 V machines 172°C: 230 V machines

Also, to achieve the same warm-up time as for the A219 copier in the 230 V machines, the fusing lamp wattage has been increased from 650 W to 760 W. For the 120 V machine, the warm-up time specification is slightly longer than for the A219, so the lamp is not changed.

3. FUSING IDLING (SP116)

Fusing idling can be selected with SP116. This mode should be used when the copier has fusing problems with copies which are made soon after warm up. This problem is most likely to occur in low temperature locations where the wall outlet condition is also not stable. Please note that when this mode is selected, copier warm-up will take a couple of seconds extra, and the first copy time will not be within specification. When the start key is pressed, fusing idling is performed for 2 seconds. If the temperature of the fusing unit is below the operating temperature by up to 10°C, copying starts. If the detected temperature is more than 10°C lower than the operating temperature, fusing idling will continue until the

detected temperature reaches 180°C. This will take 6 ~ 7 seconds longer to warm up than if fusing idling is not used.

26 September 19 97 INSTALLATION

8. INSTALLATION

8.1 COPIER ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the followings list :

1. Model Name Decal (-10, -22 machines)

2. Symbol Explanation Decal - Multi-language

3. Installation Procedure - Multi-language (-10, -15, -22, -26 machines)

4. Operation Instructions English (-10, -15, -17, -19, -22, -26, -29, -39 machines)

5. NECR - English (-17 machines)

6. NECR - Multi-language (-27, -29, -39 machines)

7. Copy Tray

Copier

8. User Survey Card (-17 machines)

9. Paper Set Direction Deal - Multi-language (-22, -26, -27 machines)

INSTALLATION 26 September 1997

8.2 COPIER INSTALLATION PROCEDURE

[B]

[A]

A245I500.wmf

[D]

[C]

[F]

[H]

A245I501.wmf

CAUTION



[E]

A245I506.wmf

Do not plug in the power cord before starting the following procedure.

1. Remove all strips of tape shown above.

[G]

2. Pull out the paper trays [A], and remove the cardboards [B].

3. Open the platen cover and remove the lock pin [C].

NOTE:

Save the lock pin for future shipping.

4. Remove the left side scale [D] (2 screws) and remove the lock pins [E].

NOTE:

Save the lock pins for future shipping.

5. Open the front cover and raise the toner bottle holder lever [F].

Then pull down the securing lever [G], and remove the toner bottle holder [H].

26 September 19 97 INSTALLATION

[B]

Copier

[F]

[C]

[E]

[D]

[A]

A245I502.wmf

[G]

A245I503.wmf

6. Turn the "B1" lever [A] counterclockwise to lower the transfer corona unit.

7. Remove the knob screw [B] and gently pull out the imaging unit [C].

Then place it on a clean sheet of paper.

8. Remove the cover [D] from the imaging unit (1 screw and 1 snap [E]).

9. Pour in the developer [F] evenly into the imaging unit. Then rotate the

outer gear [G] for one or two turns to distribute the developer as shown.

NOTE:

When installing new developer or manually rotating the development roller, always make sure to turn the gear in the direction shown above. Also do not rotate the gear more than 3 turns to prevent damage to the unit.

10. Remount the cover on the imaging unit, and install the unit in the copier

(1 knob screw).

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