Ricoh FT5540, FT5550, FT5570 Service manual
RICOH FT5540/5550/5570
RICOH COMPANY, LTD.
SERVICE MANUAL
Table of Contents
OVERALL MACHINE INFORMATION
1. SPECIFICATIONS . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
2. GUIDE TO COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2.1 INTERNAL/EXTERNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2.2 OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2.3 INDICATOR SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2.4 GUIDANCE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
3. COPY PROCESSES AROUND THE DRUM . . . . . . . . . . . . . . . . . . 1-10
4. COPY CYCLE . . . . . . . .
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1-12
5. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
6. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-16
7. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 1-17
8. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 1-18
9. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . 1-23
10. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
11. AC AND DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . 1-29
DETAILED SECTION DESCRIPTIONS
1. DRUM
1.1 SELENIUM DRUM CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.2 HANDLING THE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.3 DRUM HEATER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2. DRUM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 WIRE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 CHARGE CORONA POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 EXPOSURE LAMP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
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2-1
2-7
3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3.3 SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3.4 SCANNER MOTOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
3.5 LENS/MIRROR POSlTIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
3.6 FOURTH AND FlFTH MlRROR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
3.7 ORlGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
3.8 RELATED SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
4. ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
4.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
4.2 LEAD EDGE AND TRAILING EDGE ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
4.3 SlDE ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
4.4 EDGE ERASE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
4.5 ERASE LAMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
5. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 OVERVlEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
5.2 DEVELOPER EXCHANGE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
5.3 DRIVE MECHANlSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
5.4 CROSSMlXlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
5.5 IMAGE DENSlTY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
5.6 BIAS CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
5.7 RELATED SERVICE CALL CONDlTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2-26
6. TONER DENSITY DETECTION AND TONER SUPPLY . . . . . . . . . 2-38
6.1 TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
6.2 BOTTLE DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
6.3 TONER DENSITY DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
6.4 TONER DENSITY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
6.5 TONER SUPPLY AMOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
6.6 TONER END DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
6.7 TONER OVERFLOW SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
7. lMAGE TRANSFER AND PAPER SEPARATION . . . . . . . . . . . . . . 2-46
7.1 PRE-TRANSFER LAMP (PTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
7.2 IMAGE TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
7.3 PAPER SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
7.4 TRANSFER/SEPARATION CORONA POWER PACK . . . . . . . . . . . . . . . . . . . . . . 2-50
7.5 PICK-OFF MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
7.6 PICK-OFF TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
7.7 PRE-TRANSFER LAMP AND QUENCHING LAMP CIRCUIT . . . . . . . . . . . . . . . . . 2-54
8. DRUM CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
8.1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
8.2 PRE-CLEANING CORONA AND BIAS ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
8.3 DRlVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
8.4 CLEANING BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
8.5 CLEANING SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
8.6 PRE-CLEANING CORONA ClRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
9. QUENCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
9.1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
9.2 PRE-QUENCHING CORONA CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
10. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
10.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
10.2 LIFT MECHANISM AND PAPER END DETECTION . . . . . . . . . . . . . . . . . . . . . . 2-64
10.3 ROLLER FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
10.4 SLIP CLUTCH MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
10.5 PAPER FEED DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
10.7 RELAY FEED AND REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
10.8 PAPER SIZE SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
10.9 LIFT MOTOR CONTROL AND PAPER END DETECTION . . . . . . . . . . . . . . . . . . 2-75
11. PAPER TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
11.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
11.2 TRANSPORT UNIT RELEASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
12. lMAGE FUSING AND PAPER EXIT . . . . . . . . . . . . . . . . . . . . . . . 2-79
12.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
12.2 FUSING DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
12.3 ENTRANCE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
12.4 OIL SUPPLY AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
12.5 OIL END SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
12.6 FUSING EXIT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
12.7 FUSING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
12.8 SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
13. PAPER EXIT . . . . . .
13,1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
13.2 EXIT ROLLER DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
14. DUPLEX
14.1 INVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
14.2 DUPLEX TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
14.3 DUPLEX STACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
14.4 DUPLEX TRAY SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
14.5 DUPLEX PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
14.6 RELATED SERVICE CALL CONDlTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
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2-90
2-92
15. OTHER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
15.1 DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
15.2 SAFETY SWITCH CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
15.3 AC COMPONENT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
15.4 CORONA CLEANER MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
15.5 PULSE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
15.6 MAGNETIC CLUTCH AND SOLENOID CONTROL . . . . . . . . . . . . . . . . . . . . . . 2-113
15.7 SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
15.8 COUNTER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117
INSTALLATION
1. INSTALLATION REQUIREMENTS
1.1 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.2 MlNlMUM SPACE REQUlREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
1.3 MACHINE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
1.4 POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
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3-1
2. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.1 COPIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2 CASSETTE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.3 KEY COUNTER HOLDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
SERVICE TABLES
2. SERVICE TABLES
2.1 Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
2.2 Variable Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
2.3 DIP SwitchTables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
2.4 User Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
2.5 Service Program SP-8 Data lnput Guide Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
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4-4
3. SERVICE PROGRAM MODE OPERATION . . . . . . . . . . . . . . . . . . . 4-7
3.1 Service Program Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
3.2 Change Adjustment Values or Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
3.3 Memory Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
3.4 Service Program Mode Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
3.5 Language Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4. SPECIAL TOOLS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . 4-18
5. SERVICE REMARKS
5.1 Handling The Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
5.2 Charge Corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
5.3 Erase Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
5.4 Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
5.5 Development Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
5.6 Transfer and Separation Corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
5.7 Cleaning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
5.8 Pre-transfer and Quenching Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
5.9 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
5.10 Paper Feed and Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
5.11 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
5.12 Handling PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
REPLACEMENT AND ADJUSTMENT
1. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Exposure Glass Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1
1.2 Sixth Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
1.3 Scanner Drive Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
1.4 Fourth and fifth Mirror Drive Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
1.5 Lens Drive Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
1.6 Scanner Harness Replacement (Optics Cables & Exposure Lamp) . . . . . . . . . . 5-10
2. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
2.1 Developer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
2.2 Image Density Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
2.3 Toner Collection Bottle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
2.4 Vsg Voltage Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
2.5 Vsg Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
2.6 Toner Supply System Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
2.7 Toner Density Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
2.8 Fixed Supply Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
2.9 Toner Amount Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
2.10 ID Pattern Bias Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
3. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
3.1 Pick-off Pawl Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
3.2 Cleaning Blade and Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
3.3 Blade Cleaner and Bias Roller Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . 5-23
4. FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
4.1 Fusing Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
4.2 Oil Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
4.3 Thermistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
4.4 Thermofuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
4.5 Hot Roller Stripper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
4.6 Hot Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
4.7 Pressure Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
4.8 Entrance Guide Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
4.9 Fusing Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
4.10 Hot Roller Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
4.11 Idling Period Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.1 Pick-up, Paper Feed and Separation Roller Replacement . . . . . . . . . . . . . . . . . . 5-36
5.2 Transport Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
6. DUPLEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
6.2 Duplex Transport and Fork Gate Units Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
6.3 Jogger Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
6.4 Duplex Pick-up and Feed Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
6.5 Duplex Separation Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
6.6 Positioning and Entrance Actuator Rollers Replacement . . . . . . . . . . . . . . . . . . . 5-45
6.7 Duplex Pick-up Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
6.8 Jogger Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
7. COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
7.1 Vertical Magnification Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
7.2 Horizontal Magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
7.3 Focus Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
7.4 Uneven Exposure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
7.5 Light lntensity Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
7.6 ADS Reference Voltage Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
7.7 ADS Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
7.8 ADS Operation Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
7.9 Erase Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
7.10 Registration Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
7.11 Side-to-Side Registration Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
8. CORONA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
8.1 Charge Corona Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
8.2 Pre-quenching Corona Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
8.3 Transfer and Separation Corona Wires Replacement . . . . . . . . . . . . . . . . . . . . . . 5-62
8.4 Charge Cleaner Drive Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
8.5 TC/SC Cleaner Drive Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
8.6 Drum Current Adjustment Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
8.7 Charge Corona Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
8.8 Transfer Corona Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
8.9 Separation Corona Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
8.10 Pre-Cleaning Corona Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
8.11 Pre-Quenching Corona Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
9. OTHERS
9.1 Power Supply Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-73
ELECTRICAL DATA
1. Main PCB Schematic (1)
Main PCB Schematic (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
2. Optics PCB Schematic
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .
3. Paper Feed PCB Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Timer PCB Schematic
5. Timing Chart
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
. . . . . . . . . . . . . . . . . . . . 6-5
6-1
6-4
6-4
6. 20 Bin Sorter PCB Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
7. ARDF PCB Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
8. Large Capacity Tray PCB Schematic - 1,000 Sheets . . . . . . . . . . . 6-7
9. Large Capacity Tray PCB Schematic - 2,500 Sheets
. . . . . . . . . . 6-8
10. 15 Bin Sorter PCB Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
11. 15 Bin Sorter Timing Chart (A4/Letter Mode) . . . . . . . . . . . . . 6-10
12. Menu Reader PCB Schematic (upper) . . . . . . . . . . . . . . . . . . . . 6-11
13. Menu Reader PCB Schematic (lower) . . . . . . . . . . . . . . . . . . . . 6-12
PAPER BANK
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . 7-2
3. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . 7-3
4. OVERVIEW . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
5. PAPER FEED CLUTCH ON TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
6. PAPER SlZE AND VOLUME SENSORS . . . . . . . . . . . . . . . . . . . . . . 7-6
7. LIFT MOTOR CONTROL AND PAPER END DETECTION . . . . . . . 7-7
7.1 LIFT MOTOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.2 PAPER END DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
. . . . .
7-4
8. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
8.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
8.2 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
DOCUMENT FEEDER
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
2. BASIC OPERATION . .
2.1 INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
2.2 SINGLE-SIDED ORIGINAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
2.3 TWO-SIDED ORIGINAL FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. FEED-IN UNIT MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
4. SEPARATION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
5. MISFEED PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
6. WEAR PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
7. FRICTION ROLLER RELEASE MECHANISM . . . . . . . . . . . . . . . . . 8-9
8. REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
9. INVERTER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
10. FEED-OUT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
11. LIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12. MISFEED CHECK
13. INSTALLATION . .
13.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
13.2 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 8-25
14.1 DF Belt Drive Motor Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
14.2 Inverter Turn Gate Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8-2
8-13
8-14
8-16
20 BIN SORTER
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
2. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
2.1 CLEAR MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
2.2 SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
2.3 STACK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
2.4 EXAMPLE OF SORT MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
3. BIN DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
4. BIN HOME POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
5. BINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
6. ELECTRICAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
7. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
7.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
7.2 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
8. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 9-15
8.1 Bin Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
8.2 Bin Drive Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
8.3 Bin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
8.4 Exit Roller Drive Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
8.5 Lower Exit Roller Unit and Exit Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . 9-20
1 K LCT
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 10-2
3. DRIVE LAYOUT AND DRIVE MECHANISM . . . . . . . . . . . . . . . . . . 10-3
4. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . 10-4
5. FUNCTIONAL AND ELECTRICAL DESCRIPTlON . . . . . . . . . . . . 10-5
5.1 TRAY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
5.2 PAPER SIZE CHANGE AND DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
5.3 PAPER VOLUME DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
5.4 COVER SAFETY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
6. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
6.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
6.2 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
7. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 10-15
7.1 Tray Down Sensor and Positioning Switch Replacement . . . . . . . . . . . . . . . . . . 10-15
7.2 Paper Size Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
7.3 Tray Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
7.4 Paper Volume Cord Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
7.5 Side Registration Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
2.5 K LCT
1. SPECIFICATIONS . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1
2. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . 11-2
3. FUNCTIONAL AND ELECTRICAL OPERATION . . . . . . . . . . . . . . 11-3
3.1 TRAY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
4. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
4.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
4.2 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
MENU READER
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
2. OVERALL MACHINE CONTROL
3. DATA FORMAT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
4.1 Job Sheet Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
4.2 Menu Reader Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
4.3 Processing Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
5.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
5.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
6. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 12-11
6.1 Lower Transport Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
. . . . . . . . . . . . . . . . . . . . . . . . . .12-2
12-3
TROUBLESHOOTING
1. SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1
2. DEFECTIVE SENSOR TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
15 BIN SORTER
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 14-2
3. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
4. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . 14-4
5. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . 14-5
6. BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
7. FUNCTIONAL AND ELECTRICAL DESCRIPTION . . . . . . . . . . . 14-10
7.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
7.2 Bin Gate Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
7.3 Relay Guide Plate Reset Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-12
7.4 Interface with the Copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
7.5 Jam Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
7.6 Inlet Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16
7.7 Misfeed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
8. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
8.1 Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
8.2 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-20
9. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25
10. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 14-27
10.1 Sorter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27
10.2 Inlet sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
10.3 Jam Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-29
10.4 Sponge Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-30
10.5 DC Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-32
SECTION 1
OVERALL MACHINE
INFORMATION
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
2. GUIDE TO COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2.1 INTERNAL/EXTERNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2.2 OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2.3 INDICATOR SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2.4 GUIDANCE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
3. COPY PROCESSES AROUND THE DRUM . . . . . . . . . . . . . . . . . . 1-10
4. COPY CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. PAPER PATH
6. DRIVE LAYOUT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-12
1-13
1-16
7. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 1-17
8. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 1-18
9. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . 1-23
10. OVERALL MACHINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
11. AC AND DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . 1-29
1. SPECIFICATIONS
31 August 1989
- Item -
Configuration:
Copying Process:
Original:
Original Size:
Reproduction Ratios:
Reproduction Ratio Change:
Warm-Up Time:
Copy Paper
Copying Speed:
- Specifications Desk top
Dry electrostatic transfer system
Book/Sheet
Maximum A3, 11” x 17”
5 reduction ratios, 3 enlargement ratios, zoom : – from
60% to 155% in 1% steps
- A4 Version 5R: 93%, 82%, 75%, 71%, and 65%
3E: 115%, 122%, and 141%
- Letter Version 5R: 93%, 85%, 77%, 74%, and 65%
3E: 121%, 129%, and 155%
Maximum 6.5 seconds
Within 5 minutes (Room Temp. 20°C, 68°F)
Size:
– Maximum A3, 11” x 17”
– Minimum A6, 5½” x 8½”
2
Weight: – 52 g/m
A3 A4 (S)
(11” x 17”)
F33 22
18
to 157 g/m2 (14 lb to 42 lb)
A4 (L) A5 (S)
(11” x 8½”) (8½” x 11”) 5½” x 8½”)
43 33
35
27
48
38
First Copy Time:
Copy Number Input:
F33: 3.8 seconds (A4 or 8½” x 11”) (1st cassette)
F34: 4.2 seconds (A4 or 8½” x 11”) (1st cassette)
Number keys, 1 to 999 (count up or count down)
1-1
31 August 1989
Special Functions:
Manual Image Density
Selection:
Automatic Reset:
Paper Feed:
Paper Feed System:
Exposure System:
Lens:
Light Source:
Photoconductor:
Charge System:
Erase:
Development System:
Development:
Toner Replenishment:
Toner Consumption:
• Auto duplexing (3 modes)
• Margin adjustment (0 to 16 mm [5/8”] on both sides)
• Auto image density selection (ADS)
• Automatic paper selection (APS) (with ADF or RDH)
• Automatic reduction/enlargement (AMS) (with ADF)
• 2 single copies mode (Copies facing pages of a bound
original with one press of the Start key.)
7 steps
1 minute standard setting; can also be set to 3 minutes or
no auto reset.
All functions canceled except cassette selection. Quantity
entered returns to “1”, and reproduction ratio returns to full
size.
• Dual universal cassette feed, 500 sheets each
• Manual feed table
• Large capacity tray (LCT) (optional: 1,000 or 2,500
sheets)
• Two additional cassettes with cassette bank (optional:
500 sheets)
Feed and reverse roller
Slit exposure, moving optics
Through lens, F5, f = 215 mm
Halogen lamp (85 V, 160 W; control range 50 to 80 volts
RMS)
Selenium drum (F-type)
Dual wire dc corona
LED lamp unit (80 segments)
Magnetic brush roller
Automatic voltage change (The control board monitors the
selected image density level, drum temperature, and rest
time.)
Cartridge exchange (330 g/bottle)
10,000 copies/bottle (7%/A4)
1-2
31 August 1989
Cleaning System:
Quenching System:
Image Transfer:
Paper Separation:
Image Fusing:
Fusing Lamp:
Oil Consumption:
Electronic Control System:
Copy Tray Capacity:
Self-diagnostics:
Service Programs:
Power Source:
Power Consumption:
Dimensions:
Blade and brush, pre-cleaning corona
Photo-quenching (cold cathode tube) and dc corona
Single wire dc corona, pre-transfer lamp
Dual wire ac corona and pick-off pawls
Heat and pressure rollers
Halogen lamp (750 W)
80,000 copies per oil tank (360 cc)
8-bit microprocessor
250 sheets (all sizes)
24 codes, displayed in Guidance Display
100 programs controlled from the operation panel
110V/60Hz –> 15A
115V/60Hz –> 15A
220V/50Hz –> 8A
240V/50Hz –> 8A
See the following table.
Warm-up
Copier
See the following table.
Numbers are in kilowatts per hour.
Copying Stand-by
1.0
1.8
The numbers are in millimeters
0.18
with inches in parenthesis:
Height
500 mm
(19.7”)
Copier only with
platen cover
Width
750 mm
Depth
763 mm
(29.5”) (30.0”)
Max.
1.5
Weight:
Full System* 1,575 mm
(62.0”) (30.0”)
763 mm
1,065 mm
(41 .9”)
*With DF, Sorter, LCT (RT21), Paper Bank, Menu Reader
(Duplex Model):
115V - 104 kg (228.5 lb)
220V - 107 kg (235.4 lb)
(Non-duplex Model): 115V - 96 kg (211.2 Ib)
220V - 99 kg (217.8 lb)
1-3
31 August 1989
2. GUIDE TO COMPONENTS
2.1 lNTERNAL/EXTERNAL
1. Exposure Glass
Position the original to be copied here.
2. Manual Feed Table
Open to manually feed the copy paper.
3. Key Counter Holder
Insert the key counter into this holder
[optional] before copying.
4. Toner Bottle Lever
Turn counterclockwise to remove the toner
bottle from its holder.
5. Cassettes
Hold the copy paper.
6. Total Counter
Shows the total number of copies made.
7. A3/11” x 17” Counter
Shows the total number of A3/11” x 17”
copies made (optional).
8. Registration Roller Knob
Turn to remove misfed paper.
1-4
31 August 1989
9. Duplex Tray
Stores the copies before reverse side
copying.
10. Toner Bottle Holder
Swing down to replace the toner bottle.
11. Transport Unit Release Lever
Push down to lower the transport unit when
removing misfed paper.
12. Fusing Unit Release Lever
Press down to slide out the fusing unit.
13. Fork Gate Unit Lever
Press down to lower the fork gate unit.
14. Fusing Unit Knob
Turn clockwise to remove misfed paper.
15. Silicon Oil Bottle
Add silicone oil to this bottle when the Add
Oil indicator lights.
16. Front Cover
Open this cover when the Misfeed, Add
Toner, or Add Oil indicator lights.
17. Exit Guide Plate Tab
Raise this guide plate to gain access to the
exit area.
18. Copy Tray
Completed copies are delivered here.
19. Inverter Unit
Inverts and feeds copies to the duplex tray.
20. Main Switch
Turns on the machine.
21. Operation Panel
The copier’s keys and indicators are
located here.
22. Platen Cover
Lower the platen cover over originals before
copying.
1-5
31 August 1989
2.2 OPERATION PANEL A4/A3 Version
1. Sorter Key
Press to use the sorter. Select sort or stack
mode.
2. Stack Indicator
Lights when stack mode is selected.
3. Sort Indicator
Lights when sort mode is selected.
4.2 Single Copies Key
Press to make copies from bound originals
or two sided originals.
5.2 Single Copies Indicator
Lights when 2 single copies mode is
selected.
6. Margin Adjustment Indicator
Lights when Margin Adjustment mode is
selected.
7. Margin Adjustment Key
Press to create a margin on copies.
8. Zoom Keys
Press to alter the reproduction ratio in 1%
steps.
9. Guidance Indicator
Lights when guidance mode is selected.
10. Guidance Key
Press to select guidance mode.
11. Enter Key
Press after entering data.
12. Interrupt Indicator
Lights when interrupt mode is selected.
13. Interrupt Key
Press to make interrupt copies during a
copy run.
14. Program Indicator
Lights when the user program mode is
selected.
15. Program Key
Press to enter or recall user programs.
16. Timer Indicator
Lights when the machine has been turned
off by the weekly timer or automatic shut-off
timer.
17. Timer Key
Press to operate the copier after it has been
turned off by the weekly timer or automatic
shut-off timer.
1-6
Letter/Legal Version
31 August 1989
18. Clear Modes Key
Press to clear the copier of previously
entered settings and modes.
19. Start Key
Press to start copying.
20. Clear/Stop Key
Press to cancel the copy number entered or
to stop copying.
21. Number Keys
Use the number keys to enter the number
of copies. Also, use to select user
programs and input original size and copy
size when in size magnification mode.
22. Auto Image Density Key
Press to select/clear automatic image
density mode.
23. Image Density Keys
Press to cancel automatic control and
manually select the image density level.
24. Select Cassette Key
Press to select a cassette.
25. Full Size Key
Press to change reproduction ratio to 100%.
26. Enlarge Key
Press to make enlarged copies.
27. Reduce Key
Press to make reduced copies.
28. Auto Reduce/Enlarge key
Press to select automatic reduce/enlarge
mode.
29. Auto Reduce/Enlarge Indicator
Lights when auto reduce/enlarge mode is
selected.
30. Auto Paper Select Key
Press to select automatic paper select
mode.
31. Auto Paper Select Indicator
Lights when automatic paper select mode is
selected.
32. Duplex Key
Press to select a duplex mode.
33. Duplex Indicators
Show selected duplex mode.
1-7
31 August 1989
2.3 INDICATOR SCREEN A4/A3 Version
Letter/legal version
1. Full Size Mode Indicator
Lights when full size mode is selected.
2. Auto Paper Select Indicator
Lights when auto paper select mode is
selected.
3. Auto Reduce/Enlarge Indicator
Lights when auto reduce/enlarge mode is
selected.
4. Paper Size Indicator
Shows the selected cassette and paper size.
5. Empty Used Toner Indicator
Lights when the used toner bottle is full;
simultaneously, the Call Service indicator
blinks.
6. Add Toner Indicator
Blinks when the copier needs toner.
7. Add Oil Indicator
Lights when the silicone oil level is low.
8. Check Paper Path Indicator
Lights if there are misfeeds.
9. Load Paper Indicator
Lights when the selected cassette runs out
of paper.
10. Copy Cycle Indicator
Lights during a copy cycle.
11. Ready Indicator
Lights when the copier is ready to copy.
12. Wait Indicator
Lights during warm-up.
13. Call Service Indicator
Lights when the copier has a functional
problem.
14. Copy Counter Indicator
(Upper) Displays the number of copies
entered.
(Lower) While copying, it shows the number
of copies made. (If in count-down mode, it
shows the number of copies to be made.)
15. Auto Image Density Indicator
Lights when the copier is automatically
controlling image density.
16. Manual Feed Indicator
Lights when the copier is automatically
controlling image density.
17. Manual Image Density Indicator
Shows the selected image density.
18. Misfeed Location Display
Shows where to check inside the copier if
there is a misfeed.
19. Magnification Ratio Indicator
Shows the selected reproduction ratio.
20. Zoom Indicator
Lights when zoom mode is selected.
1-8
31 August 1989
2.4 GUIDANCE DISPLAY
The Guidance Display shows information about keys and modes, and it guides you through
the procedures for operating the copier.
- Information about keys and modes -
When you need information about keys or modes, press the Guidance key and the key you
want information about.
After starting copier operation, you can get information about the current mode by pressing
the Guidance key.
Guidance is not available for the following Keys:
• Number keys
• Decimal key
• Start key
• Manual Image Density key
• Select Cassette key
1-9
31 August 1989
3. COPY PROCESSES AROUND THE DRUM
DRUM CHARGE
In the dark, the charge corona unit gives a uniform positive charge to the selenium drum. The
charge remains on the surface of the drum because the photoconductive selenium has
electrical resistance in the dark.
EXPOSURE
An image of the original is reflected to the selenium drum surface via the optics assembly. The
charge on the drum surface is dissipated in direct proportion to the intensity of the reflected
light, thus producing an electrical latent image on the drum surface.
1-10
31 August 1989
ERASE
The erase lamp illuminates the areas of the charged drum surface that will not be used for the
copy image. The resistance of the drum in the illuminated areas drops and the charge on
those areas dissipates.
DEVELOPMENT
Negatively charged toner is attracted to the positively charged areas of the drum, thus
developing the latent image. (The negative triboelectric charge is caused by friction between
the carrier and toner particles.)
PRE-TRANSFER LAMP (PTL)
The PTL illuminates the drum to remove all positive charge from the exposed areas of the
drum. This prevents the toner particles from being reattracted to the drum surface during
paper separation and makes paper separation easier.
IMAGE TRANSFER
Paper is fed to the drum surface at the proper time so as to align the copy paper and the
developed image on the drum surface. Then, a strong positive charge is applied to the back
side of the copy paper, providing an electrical force which pulls the toner particles from the
drum surface to the copy paper. At the same time, the copy paper is electrically attracted to
the drum surface.
PAPER SEPARATION
A strong ac corona discharge is applied to the back side of the copy paper, reducing the
positive charge on the copy paper and breaking the electrical attraction between the paper
and the drum. Then, the stiffness of the copy paper causes it to separate from the drum
surface. The pick-off pawls help to separate paper which has low stiffness.
PRE-CLEANING
The pre-cleaning corona (PCC) applies an ac corona with a negative bias to the drum. This
removes the positive charge from the drum and makes the negative charge on the toner
remaining on the drum even.
CLEANING
The cleaning brush removes most of the toner on the drum and loosens the remainder. Then,
the bias roller, which has a positive potential, attracts the toner particles from the cleaning
brush to keep it clean. Finally, the cleaning blade scrapes off the loosened toner.
QUENCHING
The pre-quenching corona applies a positive corona charge to the selenium drum to eliminate
any negative charge remaining from the pre-cleaning corona. Then, light from the quenching
lamp electrically neutralizes the drum.
1-11
31 August 1989
4. COPY CYCLE
1-12
31 August 1989
5. PAPER PATH
Paper feed starts from one of the four paper feed stations. The copy paper then follows one
of two paths inside the copier. The path followed depends on which mode the operator has
selected. For copy processing, all sheets follow the same path from the paper feed
mechanism through the fusing unit. After that, normal copies are delivered to the copy tray;
however, duplex copies are diverted for further processing. The following discussion follows
the route of a single sheet of paper through a duplex cycle.
1. PRIMARY PAPER PATH
Paper Feed:
An FRR (Feed and Reverse Roller) mechanism separates one sheet of paper from the paper
stack and feeds it to the registration rollers. If the paper is fed from the second, third, or fourth
station, relay rollers move the paper to the registration roller. The registration rollers are not
turning at this time. The paper buckles slightly when the leading edge reaches the registration
rollers. Buckling seats the sheet securely between the registration rollers and corrects skew.
Registration:
At the programmed time, the registration rollers start turning to feed the paper to the drum.
Image Transfer:
The toner image on the drum surface is pulled from the drum onto the passing paper by the
transfer corona.
1-13
31 August 1989
Paper Separation:
The electrostatic attraction between the paper and the drum is broken by the separating
corona. The suction of the vacuum fan and the weight of the paper pulls the paper onto the
transport belt. The transport belt moves the paper with the developed copy image to the
fusing unit.
Fusing:
The paper passes between two rollers which bond the toner image to the paper by applying
heat and pressure. At this point the copy is complete, and the paper path splits two ways.
Ordinary copies go directly through the exit rollers to the copy tray. Duplex copies are
diverted to the inverter unit.
1-14
31 August 1989
2. DUPLEX COPY PATH
Inverter Unit:
The junction gate directs the paper to the inverter unit, which inverts the copy and sends it to
the duplex transport unit.
Duplex Transport:
The duplex transport rollers move the copy to the right. The appropriate fork gate is opened
according to the paper size. Then, the copy is sent to the jogger unit through the duplex
delivery tray.
Jogger Unit:
The copies are neatly stacked in the jogger unit to prepare them for duplex paper feed.
Duplex Paper Feed
The copy is kept in the duplex tray until the operator sets the next original and presses the
Start key. Then the duplex feed mechanism feeds the copy up through the first relay rollers to
the registration rollers. After reaching the registration rollers, the sheet follows the same path
as when the front side was copied. However, this time the reverse side faces up to receive the
image.
1-15
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