Ricoh FT5540.50 Service Manual

RICOH FT5540/5550/5570

SERVICE MANUAL

RICOH COMPANY, LTD.

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

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

2-7

3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 3.2 EXPOSURE LAMP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

13,1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 13.2 EXIT ROLLER DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

14. DUPLEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-92

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.1 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1.2 MlNlMUM SPACE REQUlREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 1.3 MACHINE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1.4 POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

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

REPLACEMENT AND ADJUSTMENT

1. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

1.1 Exposure Glass Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

9.1 Power Supply Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

ELECTRICAL DATA

1. Main PCB Schematic (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Main PCB Schematic (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

2. Optics PCB Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .		. 6-4
3. Paper Feed PCB Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		6-4
4.	Timer PCB Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-4
5.	Timing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-5
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 12. MISFEED CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 13. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 3. DATA FORMAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 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

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

31 August 1989

1. SPECIFICATIONS

- 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”
Weight:	– 52 g/m2 to 157 g/m2 (14 lb to 42 lb)

		A3	A4 (S)	A4 (L)	A5 (S)
		(11” x 17”)	(11” x 8½”)	(8½” x 11”)	5½” x 8½”)
	F33	22	43	33	48
		18	35	27	38
First Copy Time:	F33: 3.8 seconds (A4 or 8½” x 11”) (1st cassette)
	F34: 4.2 seconds (A4 or 8½” x 11”) (1st cassette)
Copy Number Input:	Number keys, 1 to 999 (count up or count down)

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31 August 1989
Special Functions:	• 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.)
Manual Image Density	7 steps
Selection:
Automatic Reset:	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.
Paper Feed:	• 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)
Paper Feed System:	Feed and reverse roller
Exposure System:	Slit exposure, moving optics
Lens:	Through lens, F5, f = 215 mm
Light Source:	Halogen lamp (85 V, 160 W; control range 50 to 80 volts
	RMS)
Photoconductor:	Selenium drum (F-type)
Charge System:	Dual wire dc corona
Erase:	LED lamp unit (80 segments)
Development System:	Magnetic brush roller
Development:	Automatic voltage change (The control board monitors the
	selected image density level, drum temperature, and rest
	time.)
Toner Replenishment:	Cartridge exchange (330 g/bottle)
Toner Consumption:	10,000 copies/bottle (7%/A4)

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							31 August 1989
Cleaning System:	Blade and brush, pre-cleaning corona
Quenching System:	Photo-quenching (cold cathode tube) and dc corona
Image Transfer:	Single wire dc corona, pre-transfer lamp
Paper Separation:	Dual wire ac corona and pick-off pawls
Image Fusing:	Heat and pressure rollers
Fusing Lamp:	Halogen lamp (750 W)
Oil Consumption:	80,000 copies per oil tank (360 cc)
Electronic Control System:	8-bit microprocessor
Copy Tray Capacity:	250 sheets (all sizes)
Self-diagnostics:	24 codes, displayed in Guidance Display
Service Programs:	100 programs controlled from the operation panel
Power Source:	110V/60Hz –> 15A
	115V/60Hz –> 15A
	220V/50Hz –> 8A
	240V/50Hz –> 8A
Power Consumption:	See the following table. Numbers are in kilowatts per hour.
		Warm-up		Copying		Stand-by		Max.
	Copier	1.0		1.8		0.18		1.5
Dimensions:	See the following table. The numbers are in millimeters
	with inches in parenthesis:
			Width		Depth		Height
	Copier only with		750 mm		763 mm		500 mm
	platen cover		(29.5”)		(30.0”)		(19.7”)
	Full System*		1,575 mm		763 mm		1,065 mm
			(62.0”)		(30.0”)		(41 .9”)
	*With DF, Sorter, LCT (RT21), Paper Bank, Menu Reader
Weight:	(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)

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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

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.

31 August 1989

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.

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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

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.

31 August 1989

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.

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31 August 1989

2.3 INDICATOR SCREEN

A4/A3 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.

Letter/legal version

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.

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31 August 1989

2 . 4 G U I D A N C E D I S P L A Y

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

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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.

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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.

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31 August 1989

4. COPY CYCLE

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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.

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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.

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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.

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