Ricoh FT9101 Service manual

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RICOH FT9101

FIELD SERVICE MANUAL

LARGE CAPACITY TRAY RT32

FINISHER SR500

PRINTER CONNECTOR UNIT PCU10

KEY COUNTER/PRINTER

CONNECTOR BRACKET KP10

COMPANY, LTD.

Read This First

A few simple symbols and notations are used to help you read faster and find the information you need. Before you use this guide, glance over this list of special notations and be sure you understand what they mean.

NOTE

Information under this heading describes helpful hints, restrictions, and how to avoid difficulties.

CAUTION Failure to pay attention to CAUTION notices can

result in damage to the equipment.

WARNING

Warnings are for your safety. Failure to pay attention to WARNING information can be dangerous to you and others.

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

3. Note that some components of the copier are supplied with electrical voltage even if the main switch is turned off.

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

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

HEALTH SAFETY CONDITIONS

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

2. Always replace the ozone filter with the specified one at the specified interval.

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

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

2. The main control board has a lithium battery which can explode if handled incorrectly. Do not replace the battery. Do not recharge, or burn this battery. Used batteries must be handled in accordance with local regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

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

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

4. When keeping used lithium batteries (main control boards) in order to dispose of them later, do not put more than 100 batteries (main control boards) per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

SECTION 1

OVERALL MACHINE INFORMATION

1 July 1994 Installation Requirements

1. INSTALLATION

1.1 Installation Requirements

1.1.1 Delivery and installation work flow

Installation condition check

Delivery

Clamp removal

Main body setup

Machine power on

Installation environment, floor strength

Space around machine, delivery route

Power supply The user’s acceptance of the limited items

for using the machine (See User Guidance Items section for the limited items.)

Supply developer Supply cleaning carrier

Set OPC belt Supply silicon oil

Install power plug and cord

Leveling

Installing original stacker

Installing sub-tray

Installing toner cartridge

Setting copy paper

Installation of peripherals

Operation check as far as the machine stand-by condition

Machine operation check

User guidance

1-1

Installation Requirements 1 July 1994

1.1.2 Environment

Select the conditions which fully satisfy the following items at installation.

Avoid a place exposed to direct sunlight or other strong light (should be below 1500 lux).

Avoid locations wit h hi gh tem pe r at ure s or hi gh hum id it y, or low te mp era tu r es and low

humidity. (Standard ran ge of te mp era ture and humidity: 10 Avoid places with hot air or strong heat sources.

Avoid locations subject to abrupt temperature changes.

Avoid small or dusty roo ms .

Avoid poorly ventilated locations. (Air turno ve r sho ul d be 3 tim es or more per ho ur pe r

person.) Install the machin e flat on the floor. It must be level within 5 mm front to rear and 5 mm left

to right. This is mainly to prevent affecting the tracking operation of the OPC belt. Align the position of the LCT and finisher with the copier. First, adjust the height of

peripherals on the basis of the exterior covers position. Finally, align the paper transport guide plate height between each unit. This is to prevent paper misfeeds where each unit connects.

The unit must be insta lled on a floor which can support its total weight : copier including ADF

482 kg, finisher 77 kg, and LCT 75 kg. Provide enough space, 100 cm in front, 60 cm in rear and 30 cm on both side s for operation

10.

and service. No fluorescent lights should be installed above the operation unit. (This is to make it easier to see the operation display.)

C to 30oC, 15% to 90%)

1.1.3 Power connection (For the European version machine only)

Plug

The plug must be approved under the TÜV safety standard and for a three-phase power supply. Power supply cord

The cord must b e approved unde r the TÜV safety standard and have five wire s inside. The cross-sectional area of ea ch wire must be 2. 5 mm be 14 to 18 mm. (The capa city must be over 6 00 volt s and 16 A for each ph ase. ) The lengt h must be 5 m or less even if an extension cord is use d.

, and the outside diameter of the cord must

1.1.4 Transportation

Remove the operation unit before transporting the copier if the copier cannot get into the elevat or or co py room . Thi s reduces depth to 775 mm from 830 mm. Remove the cardboard packing in advance.

Remove four screw s (M4 x 6) from the operation

unit. Remove the connector for the operation unit and

remove the operation unit.

CAUTION Never carry the copier side down.

Connector

1-2

Operation unit

4 screws (M4 x 6)

1 July 1994 Copier Installation

1.2 Copier Installation

1.2.1 Accessory list

Name Diagram Quantity Use

Developer vessel Cleaning carrier vessel Cleaning carrier magnet

1 of each To collect the developer and cleaning carrier.

Vessel rail

Original stacker

OPC belt

Leveling shoe

Original back fence

Development unit grounding harness

Tray fences fixing plate 3 To fix the paper tray side fences.

Syringe

2 To set the developer vessel.

1 To receive originals from the ADF.

4 For the docking position adjustment.

1 To install on the original stacker.

1 To avoid damage of the image density sensor board

when a vacuum cleaner is used.

1 To apply silicon oil in the fusing unit.

Plated screw M 4 x 8 4 To secure the vessel rails. Counter reset key

Printer interface board 1 To connect a printer using service tool [6]. These

Short printer harness

Long printer harness

1 To reset the total counter to 0.

parts are needed when the optional printer connector unit is installed. Keep these parts for future use.

1 To connect a printer using service tool [6].

NOTE

When the optional fin is he r is no t us ed , the sub-tray (P/N-A029146 0) mu st be ord ere d and used.

Sub-tray 1 To receive copies fed out. (Not required when the

sorter is used.)

1-3

Copier Installation 1 July 1994

1.2.2 Removing the clamps

ADF

Remove the cushions from the paper feed tray, the

cushion from the co py tray, and the strips of filament tape from the exterior.

Cushions (2)

Cushion Cushions (3)

Open the center door and remove the 7 strips of

filament tape and a cushion from the transport unit.

Remove the right cover (2 screws). Then, remove

the clamps from tray 1, tray 2 and tray 3 using a slot head screwdriver.

Center door

Cushion

Clamp

Right cover

1-4

1 July 1994 Copier Installation

Take off the left cover and remove the red bracket

holding the second mirror.

Remove the protective sheets of the expo sure

glass and copy tray.

Protective sheet

Holder bracket

Copy tray

Remove the strips of filament tape from the duplex

unit.

Filament tape

1-5

Copier Installation 1 July 1994

To remove the inner cover, remove the left door

fixing screw (2 screws), and di sc on ne ct the cooling

Left door

fan connector.

Cooling fan connector

Inner cover

Remove the first mirror bracket (red bracket).

To enable accessing the service tool password,

turn on DIPSW101-2. Remove the OPC cleaning unit fixing screw to pull

10.

Mirror bracket

out the unit, and cut the unit fastener.

To pull out the fusing unit, remove the front fusing

11.

cover (2 screws) and one unit fixing screw. Remove the cover from the right side of the unit (4

12.

screws). Loosen the pressure fixing screws to remove the

13.

wedges on the front and far side. Re-tighten the pressure fixing screws.

Install the fusing right side cover.

14.

NOTE

Install the front fusing cover after pouring silicon oil.

Peel off the plain sheet behind the fusing oil pan.

15.

Unit fixing screw

Unit fixing screw (before removal)

Front fusing cover

Wedge

Unit fixing screw

Unit fastener

Wedges

Pressure fixing screw

1-6

Sheet

1 July 1994 Copier Installation

1.2.3 Setting up the copier

Release the development backup rollers by the

lever, and remove the development unit fixing bracket. Then, slide out the unit.

Development backup lever

Fixing bracket

Remove the filter cover from the developer supply

port (2 screws). While turning the development knob in the direction opposite to the arrow, put in 4 bags (1 kg/bag) of developer from the supply port.

CAUTION

• Clean off the developer on the unit casing.

It may touch the OPC surfa ce.

• Do not put in another compound (cleaning

carrier, etc.) by mistake.

Filter cover

Developer

Developer supply port

Casing

Reinstall the fi lter cover.

Turn the development knob in the direction of the

arrow and return the developer from the development roller to the unit inside.

Development knobDevelopment knob

Filter cover

Development knob

1-7

Copier Installation 1 July 1994

Slide in the development unit, and fix it with the

fixing bracket.

Fixing bracket

Release the cleaning backup roller by the lever,

Cleaning fixing screw

and remove the cleaning fixing screw to pull out the cleaning unit.

Remove the upper cover from the cleaning unit (4

screws). Put in one bag of cleaning carrier (700 g) on the cleaning roll er (rig ht sid e of t he uni t).

CAUTION

• Be sure that the carrier is not in the

scavenging roller side.

• Do not put in another compound by

mistake, such as developer, etc.

• Distribute the carrier evenly by turning the

knob. This unit has no agitation mechanism as the development unit does.

Upper cover

Cleaning carrier

Cleaning roller

Cleaning backup lever

Close the upper cover, set the unit in the main

body, and secure it with the fixing screw.

Fixing screw

1-8

1 July 1994 Copier Installation

Pull out the charge corona unit, and release the

transport unit.

Release the development and cleaning back-up

10.

levers, and turn the development knob in the direction of the arrow. Then, remove the OPC unit stay to pull out the OPC unit.

CAUTION

Charge corona unit

Development back-up lever

Cleaning back-up lever

Transport unit

Be sure to return the developer from the development roller to the inside of the unit before pulling out the OPC unit. Do this by turning the development knob.

Insert two paper tubes (OPC belt accessories) in

11.

the two guide holders of the OPC unit. Then, release the pressure rele as e le ve r t o lo os en the tension, and pull the OPC belt out of the case.

Use the paper tubes as guides to fit the OPC belt

12.

to the unit.

CAUTION

• As you fit the OPC belt, be sure to prevent

folds and contact between the side plate of the OPC unit and the belt end. Do not touch the OPC surface directly.

•

Set the OPC belt so that the OPC home mark is on the rear side of the machine.

• The rear side of the OPC belt must be und er

the OPC sensor.

Guide holder

Pressure release lever

Paper tube

OPC home mark side

OPC unit stay

OPC belt case

OPC belt

1-9

Copier Installation 1 July 1994

Set the OPC belt in the center of the unit and

13.

restore tension to the belt with the pressure release lever.

Pressure release lever

OPC sensor

Set the OPC unit in the main body and install the

14.

OPC unit stay.

Set two backup levers, and position the charge

15.

corona unit, its connector, and transpo rt unit.

Install the inner cover (2 screws and a connector)

16.

and left door (2 screws).

Charge corona unit

OPC unit stay

Transport unit

Backup levers

Left door

1-10

Inner cover

1 July 1994 Copier Installation

Pull out the fusing unit and remove the front fusing

17.

cover. Put silicon oil in the oil sump. About 80 g of oil is

18.

sufficient. Install the front cover and set the unit in the main

19.

body.

Put two cans of silicon oil in the oil tank. (2/3 of

20.

capacity make s ab out 200,000 copies .)

CAUTION Never remove the oil supply unit from the fusing

unit to prevent oi l marks on copies. It can be removed only when the oil blade, metering blade, and oil supply felt are replaced with new ones.

Oil tank

Tighten the screw (M4 x 8 plated screw:

21.

accessory) on the rear of the vessel rails (accessories). Put the screws in the hole at the bottom rear of the machine frame.

Fit the vessel rails on the bottom of the machine,

22.

and secure each of them with the screw (M4 x 8 plated screw) from the front of the machine. Set the developer vessel (accessory) on the rail. Put the cleaning carrier vessel and magnet (both accessories) in the developer vessel.

Cleaning carrier vessel

Cleaning carrier magnet

Vessel rail

Developer vessel

1-11

Copier Installation 1 July 1994

European version machine only (Steps 23 to 27)

CAUTION The power supply cord and plug for the

European version machine must meet the following requirements:

•

The plug must be approved under the TÜV safety standard and for a three-phase power supply.

• The cord must be approved under the TÜV

safety standard and have five wires inside. The cross-sectional area of each wire must be 2.5 mm cord must be 14 to 18 mm. (The capacity must be over 600 volts and 16 A for each phase.) The length must be 5 m or less even if an extension cord is used.

, and the outside diameter of the

Remove the rear left cover (2 screw).

23.

Remove the power supply cord bracket (2 screws).

24.

Then, pass the power supp ly cord t hro ug h th e co rd bushing.

Connect the five wires of the power supply cord to

25.

the appropriate terminals as shown.

CAUTION

• Secure each wire to the terminals firmly

with screws.

• The grounding wire is green and yellow.

Reinstall the power supply cord bracket. Then,

26.

tighten the nut to secure the bushing with the cord.

CAUTION Be sure that the cord bu shin g se cures the cord

firmly.

Install a plug on the other end of the power supply

27.

cord.

CAUTION

• Connect five wires to each of the terminals

’L1’, ’L2’, ’L3’, ’N’, and "Grounding" in the same order as on the machine.

•

Secure each wire to the plug firmly with screws.

The machine is set up for a 400 volts 3-phase power supply (Eu ropean version) or 240 vo lts single phase powe r supply (U.S.A. ver sion) at the production li ne. To install the machine in areas where the power supply is 380 or 415 volts (220 or 230 volts single phase), follow the steps below:

Loose the screw and disconnect the wire from the

28.

400 volts (or 240 volts) terminal. Connect the wire to an appropriate terminal and

29.

tighten the screw. The terminal to be connected depends on the power supply from the wall outlet.

CAUTION The 200 volts terminal ne ver be used. The copier

requires 380 volts (or 220 v olts sin gle pha se) at least.

Cord fixing nut

220 or 380V

230 or 400V

240 or 415V

Cord bushing

Power supply cord bracket

1-12

1 July 1994 Copier Installation

Remove the rear right cover (2 screws).

30.

Be sure that the proper connector of the harness

31.

from the timer board is set. The color of each connector means the following:

Black: for 380 or 220V power su pp ly Red: for 400 or 230V power supp ly

Red connector

Black connector

Timer board transformer

Yellow: for 415 or 240V power su pp ly If the connector setting does not meet the power

32.

supply, connect an appropriate connector.

Yellow connector

Set the leveling shoes (accessories) to level the

33.

machine.

STANDARD

Difference, front to rear Within 5 mm Difference, left to right Within 5 mm

Screws securing upper left cover

CAUTION Using a level gauge, level the machine flat on

Original stacker

the floor. This is mainly to pre vent affectin g the tracking operation of the OPC belt.

Install the exterior covers.

34.

NOTE

Do not install the exterior covers at this stage if the finisher or LCT is to be installed.

Fit the original stacker (accessory) and sub-tray

35.

(must be ordered separately if necessary). To fit the original stacker, use screws which secu red the upper left cove (M4 x 12 plated screw).

Put the original back fence (accessory) on the

36.

original stacker.

NOTE

The sub-tray i s no t req uired if the fi nish er is u sed. It is installed i n the LCT if the LC T is us ed and the finisher is not.

Sub-tray

Leveling shoe

1-13

Copier Installation 1 July 1994

When inch size originals are used, make a slot as

37.

shown to stop the original stopper at the 8

1/2

inch

position.

CAUTION When the slot is made, opera ting cautions must

be instructed to operators, so that operators can adjust the original stopper position correctly according to the original size set in the ADF. The A4 position and 8

1/2

inch position are very close. If the o riginal stopp er position is not proper, original misfeeds will occur.

Set the toner cartridge.

38.

CAUTION Shake the toner cartridge well be fore you s et it.

Set paper in each paper tray.

39.

CAUTION

Original stopper

Do not block the fan filter windows of the left and rear exterior covers.

1-14

1 July 1994 Machine Operation Check

1.3 Machine Operation Check

1.3.1 Stand-by operation check

200

Fusing Temp. [° C]

100

Power connection

The cleaning coil cooling fan, two ozone exhaust fans (behind the rear left cover), and cleaning unit cooling fan (behind the left cover) start turning.

Main switch ON

1. Configuring the first and second mirrors.

2. The fusing heater ON.

3. The OPC belt ON (2 turns).

4. The Tracking motor ON .

5. All the fans ON except for the duplex and ADF blowers.

1.3.2 Copier operation check CAUTION

175 ° C

175 to 180 ° C

Approx. 30 sec.

The Start key turns green.

The idling mode starts (30 seconds). The main motor repeats turning on and off four times during this period.

Before making copies, carry out forming for the developer, OPC belt, and cleaning carrier (in this order) using service tool [3-04].

Check the stand-by operation referring the above. Connect the power plug, then turn on the main switch.

2. Access the service tool, and do all formings.

3. Check that all the keys on the operation panel and paper tray down keys work properly.

4. Check that safety switches of the center door, upper right door, and copy tray work properly.

5. Place a sheet on the original table of the ADF and check that the ADF mode is selected.

Also, insert a sheet in the SADF table and check that the SADF mode is selected.

1-15

Machine Operation Check 1 July 1994

1.3.3 Copy quality check CAUTION Before checking copy image quality, check the toner density control data in the

service tool [4-02] screen. Perform setting C if the data is not correct. Also, check the AID reference voltage in the [4-03] screen using the PC-1 chart. Perform setting A if the value is not correct. (If the AID reference voltage is within the standard, you do not have to perform setting A.)

To check the copy image quality and paper transportation in the copier, make some copies in the platen cover (no ADF and SADF) and AID (Auto Image Density) modes using a test chart.

2. Follow the steps below to complete the image quality adjustment. (Refer to the following

page for the standards.)

1) Position a test chart on the exposure glass. Make copies to check the side-to-side registration. Adjust it by changing the paper tray position, if necessary. Repeat this step for all paper trays.

2) Select the paper tray which has the largest paper size.

3) Access the service tool and select the [5-02] screen. Check and adjust all items in that screen.

4) Leave the service tool, and select the paper tray which has another paper size.

5) Again, check and adjust the erase margin and duplex side fences width on the [5-02] screen. Repeat this step for each paper size which will be used by the customer.

6) To check and adjust the side-to-side registration of the back side of the copy, make copies in the duplex mode.

7) Remove the test chart from the exposure glass and insert an original in the SADF. Make copies to check and adjust the leading edge and side-to-side registration in the SADF mode.

8) Place some originals in the ADF. Make copies to check and adjust the side-to-side registration in the ADF mode.

CAUTION

a) The side-to-side registration must be checked for all paper trays. b) The erase margin and duplex side fence width must be checked for all paper sizes. c) If the erase margin is not sufficient, thin black lines may sometimes appear on

copies (especially on the side edges of copies in the ADF mode). This is because the side-to-side registration varies slightly on each copy if an operator does not set the original side guides securely. You have to make more than 10 copies and check that all of them are within specifications after the adjustment.

d) Check the side-to-side registration of the back side of the copy in the duplex mode before installing the peripherals. If the value is outside specifications, you have to remove the copier right cover.

Put about 20 originals on the ADF and make one set of copies in the single original duplex mode. Repeat this procedure for all paper trays.

4. Put about 100 originals on the ADF and make one set of copies in the 2-sided original du-

plex mode.

5. Insert an original in SADF and check that copying is normal.

6. If peripherals are installed, check that they works properly.

1-16

1 July 1994 Table of Image Quality Standards

1.4 Table of Image Quality Standards

Item Standard Measuring Method

Erase margin a) Leading edge 1

b) Trailing edge 1 c) Left side edge 1 d) Right side edge 1

< c+d ≤ 7 mm

≤a≤7 mm ≤b≤5 mm ≤c≤5 mm ≤d≤5 mm

Make one solid black copy and measure blank dimensions at four edges. After the adjustment, make more than 10 copies and check the variation.

Error in magnification In full size mode: Within

In magnification mode: Within

Registration Platen cover mode

a) Leading edge: 0

b) Left and right edges: 0 These values also valid on the 2-sided

copy.

ADF/SADF mode a) Leading edge:

--3 to +5 mm (ADF mode)

--4 to +6 mm (SADF mode)

b) Left and right edges: 0 The difference of the side-to-side

registration between the front and back side must be within 5 mm.

± 2 mm

± 0.5%

± 2 mm

± 5 mm

Copy a scale and measure copy dimensions.

±1.0%

Copy a test chart and compare the image position difference between the original and the copy. After the adjustment, make more than 10 copies and check the variation.

Skew Platen cover mode Copy a test chart and compare the image position difference

± 1 mm/200 mm or less. between the original and the copy.

ADF/SADF mode

± 1.5 mm/100 mm or less (on

a) smaller than A4/Letter paper).

± 1 mm/100 mm or less (on

b) A4/Letter or larger paper).

1-17

User Guidance Items 1 July 1994

1.5 User Guidance Items

This section contains important information regarding efficient operation of the machine.

1.5.1 Guidance items prior to the installation

Items requiring user approval after explanation. This has to be done before machine installation.

Paper to use

1. We recommend using neutral paper as copy paper to prevent abnormal images. Some acid

papers contain talc, and this white powder will appear on the OPC surface as spots. This causes abnormal copies, which have dirty spots on the background.

2. We recommend using lengthwise grain in all cases to prevent creased copies.

How the original influences copy images

1. In patched originals, shadows around the patched part appear on copies as black lines.

2. In OHP originals, drawn pictures and characters are copied double.

Smoothing original curls

To avoid transport trouble, advise users to correct large curls before setting the original. Refer to the illustrations and information given below.

Face curl (3 mm or less) No curl is acceptable for thick originals of 65 g/m

Back curl (10 mm or less)

The original cannot be transported if it curls (face curl).

or heavier.

2. The original cannot be transported if it curls down (back curl) 10 mm or more.

Original to use

There are some types of paper that should not to be used as originals with the ADF. The following are some examples:

1. Dog-eared, torn, or creased paper

2. Coated paper (carbon paper, thermal paper, etc.)

3. Curled paper

4. Originals that are glued or taped

1-18

1 July 1994 User Guidance Items

5. Translucent paper (including OHP)

NOTE

The above types of paper may be used as an original in the SADF mode.

6. Damp paper

7. Bound originals

8. Paper that is thicker or thinner than specified for this machine

Originals that have holes as shown cannot be used in the ADF mode.

A: No holes are allowed on the leading

edge. (To prevent multifeeding.)

B: No holes are allowed in these areas.

(The recycle arm may be caught in the holes.)

C: Holes larger than 6 mm in diameter are

not allowed on the trailing edge.

D: Holes larger than 10 mm in diameter are

not allowed in the center. (To prevent sensor’s misdetection.) This type of paper cannot be used in the SADF mode either.

[Leading edge]

100 mm

10 mm

50 mm

Paper replenishment

When the 2nd or 3rd paper tray runs out of paper and the indication Add paper lights in red, this means there are still about 50 sheets of paper left in the tray.

Fusing oil

The pick-off pawls of the fusing unit sometimes make slight oil marks on the leading edge of copies .

Copy image area

1. The blank range is provided as shown to prevent

original shadows on copies.

2. Damp copy paper will have an 8 mm blank margin

(or less) at the trailing edge of the front side, and if duplex copying, the back side will have a blank margin of 10 mm (or less) at the trailing edge.

Total of left and right should be 7 mm or less.

1-19

User Guidance Items 1 July 1994

1.5.2 Additional guidance items

Explain the following if the user is unfamiliar with the subject items.

Stacking duplex copies

When a large number of duplex copies (100 copies or more) are produced, we recommend using the finisher so they are stacked in the shift tray because toner from the stacked copies on the copier’s copy tray may be deposited by heat.

How the main switch is used

The ozone exhaust fans and transport vacuum fan continue to operate when the main switch is OFF to discharge air from the machine. This prevents image deterioration on the OPC caused by fumes, which is produced by the corona discharge. Also, heaters turn on when the main switch is OFF and prevent condensation on the mirror and lens and damp paper in trays. Advise users never to pull out the power plug or shut off power from the source. Tell them to use the main switch to power off.

Toner cartridge replacement

Used toner is collected in the toner cartridge and is never used again because it cannot be used for copying. Direct users about the following points.

1. Never pull the shutter again after the cartridge is set. If the shutter is pulled, the collected

toner is used again.

2. Firmly pull the vinyl sheet on the shutter when installing a new cartridge. If not, only about

half the amount of toner in the cartridge will fall to the development unit. This may cause a used toner blockage on the way from the cleaning unit.

Loading paper

When loading paper in the paper trays, do not exceed the load limit. It is indicated by a decal. If paper is excessively loaded, the top of the paper stack may hit the pick-up roller and damage it when the paper tray is set.

Loading original

When loading paper on the original table of the ADF, keep the maximum capacity (40 sheets for A3 or 11" x 17" original and 80 sheets for the other sizes original). The load limit is indicated by a decal. If originals are excessively set in the ADF, original misfeeding or multifeeding may occur because of the original separation system. The air knife cannot separate the originals when weight of the original stack is too heavy.

1-20

1 July 1994 Setting User and Service Tools

1.6 Setting User and Service Tools

Explain all user tool items and some of the service tools to the customer. Then, listen to the customer’s requests and set the copier accordingly.

Keep the set items using the following format. (If the main control board is replaced, you can set all items again using the format.)

1.6.1 User tools

* Bold letters in "Set Data" shows the initial setting.

no.

1 Total sheets copied ---2 Auto image density level selection [Lighter] [Normal] [Darker] 3 Copy/Original size selection [A3] [11 x 17] [A4] [8 4 Segment skip ---5 Date/Time setting ---6 Disable display Margin adjustment [ON] [OFF]

7 Disable units ---8 Select special tray Cover [Tray 1]

9 User access code ----

10 User Utility Select the finisher mode [Sort] [Stack]

11 Set staple position 1 staple upper 0 to 20 [ ] 10

12 Weekly timer

Description Set Data

Duplex [ON] [OFF] Magnification [ON] [OFF]

Slip sheet [Tray 1] [Tray 2] [Tray 3]

Staple in stack mode [Yes] [No] Auto tray switching [Yes] [No] 3-side full image copy [Yes] [No] Select count up or down mode [Up] [Down] Display the number of originals [Yes] [No] Exit originals to tray [Yes] [No] Select face up/down in stack mode [Face up] [Face down] Reverse back cover sheet [Yes] [No] Copy onto slip sheets [Yes] [No]

1 staple lower 0 to 20 [ ] 10 2 staples 0 to 20 [ ] 10

ON: 00:00, OFF: 23:59

1/2 x 13]

1-21

Setting User and Service Tools 1 July 1994

1.6.2 Service tools

* Bold letters in "Set Data" shows the initial setting.

Menu no. Description Set Data

1-01 Key operator access code 000 to 099 [ ] 000 1-02 Service access code 99900 to 99999 [ ] 99900 1-03 Service telephone number [ ] 1-04 Disable display Full size indicator: [OFF] [ON]

Tray keys in APS mode: [OFF] [ON]

Density keys in AID mode: [OFF] [ON] 1-05 Weekly timer This function can be set with user tool no. 12. 1-06 Toner supply amount [15%] [30%] [45%] [60%] 1-07 Charge wire cleaning [YES] [NO] 1-08 Option installation [Tray 4] [Finisher] [Key Counter] 2-01 Count up/down [UP] [DOWN] 2-02 Set user program number 0 to 10 [ ] 10 2-03 Set fixed reproduction ratios See the table below. 2-04 Delete fixed reproduction ratios No delete

[Initial Data]

[Set Data]

2-05 Set back side margin 0 to 21 mm in left or right.

2-06 Maximum copy number 1 to 9999 [ ] 9999 2-07 Staple copy limit 1 to 50 [ ] 50 2-08 Free/user access code operation [Free use][Access code] [Access code/super user mode] 2-09 3-side full image [YES] [NO] 2-10 Auto tray switching [YES] [NO] 2-11 Original count display [YES] [NO] 2-12 Set special paper tray [NO] [Tray 1] [Tray 2] [Tray 3] [Tray 4] 2-13 Auto reset , auto off Auto reset: [5 sec.] [1 min.] [3 min.] [

2-14 Key tone Loudness: [OFF] [Low] [Normal] [High]

2-15 Set exit tray copy limit [300] [350] [400] [NO] 2-16 Set initial display Display type selection: [Key operator] [Operator]

[ ] mm [Left] [Right] 5 mm Right

∞ ]

Auto off: [30 min.] [1 hr.] [3 hr.] [

Tone pitch: [1] [2] [3] [4] [5]

Auto tray selection: [YES] [NO]

Tray selection priority: [APS] [Tray 1] [Tray 2] [Tray 3] [Tray 4]

Image density level selection:

[AID]

Density levels [1] [2] [3] [4] [5] [6] [7]

Finishing: [No Staple] [1 upper] [1 lower] [2]

∞ ]

1-22

1 July 1994 Setting User and Service Tools

Menu no. Description Set Data

2-16 Set initial display Margin adjustment mode selection:

4-01 Process control Grid: [ ] step

4-02 Toner density control Target toner density: [ ] volts

4-04 OPC cleaning operation [OFF] [5K] [10K] [20K] 10K 4-05 Utility Mode no. 1 (0 to 15): [ ] 0

[No]

Front side:

0 to 21 mm in left or right

[ ] mm [Left] [Right] 0 mm

Back side:

0 to 21 mm in left or right

[ ] mm [Left] [Right] 5 mm Right

Duplex mode selection:

[No]

⇒ Duplex mode]

[Single

⇒ Duplex mode]

[Duplex

⇒ Single mode]

[Duplex

Reproduction mode selection:

[Full-size]

Fixed reproduction [ ] %

Zoom reproduction [ ] %

Auto paper selection [A3] [B4] [A4] [B5]

Copies number setting: 1 t0 9999 [ ] 1

Flash: [ ] step

Bias: [ ] step

Pcc: [ ] step

VD: [ ] volts

VL: [ ] volts

VPCC: [ ] volts

ID pattern level: [1] [2] [3] [4]

Mode no. 2 (0 to 15): [ ] 10

Mode no. 3 (0 to 15): [ ] 0

Mode no. 4 (0 to 15): [ ] 0

Mode no. 5 (0 to 15): [ ] 0

Mode no. 6 (ON or OFF): [ ] OFF

Mode no. 7 (ON or OFF): [ ] ON-8, 10

Mode no. 8 (ON or OFF): [ ] ON-10

Mode no. 9 (ON or OFF): [ ] OFF

Mode no. 10 (ON or OFF): [ ] ON-9

Mode no. 11 (ON or OFF): [ ] OFF

Mode no. 12 (ON or OFF): [ ] OFF

Mode no. 13 (ON or OFF): [ ] OFF

Mode no. 14 (ON or OFF): [ ] OFF

NOTE: When mode no. 5 is set at 8 to 15, modes no. 6 to 14 have

different functions. So, describe the set number of mode no. 5 with

"ON" when filling in the set data of modes no. 6 to 14. For example, if

mode no. 6 is turned ON while mode no. 5 is set at 8, describe the set

data of mode no. 6 as "ON-8". 5-02 Copy image Lead/trail edge erase: Lead [ ] mm, Trail [ ] mm

Side edge erase: Front [ ] mm, Rear [ ]mm

Lead edge registration: [ ] mm

Reproduction: [ ] %

Duplex side fences width: [ ] mm 5-03 Fusing temperature 0 to 15 [ ] 8 or 9 5-07 Set staple position This function can be set with user tool no 11.

1-23

Fusing

High

Voltage

Drive

Optics

Imaging

Process

Paper Feed Du-

plex

Control

Develop-

ment

Logging Data Sheet 1 July 1994

1.7 Logging Data Sheet

[3-01] Tray Copies

Size Tray 1 Tray 2 Tray 3 Tray 4 Total Duplex Finisher RDH

A3 -------B4 A4 B5

Sub Total --------

11 x 17 --------

1/2 x 14

1/2 x 11

Total

[3-04] Supply yield

OPC

Developer

CL Carrier

Staple 1

[3-07] Service Calls

Code Code Code

1 36 80 2 40 81 3 41 82 4 42 83 10 43 84 11 44 85 12 45 86 13 50 87 17 51 88 20 52 89 22 55 90 23 60 91 30 61 93 31 62 94 32 63 95 33 64 96 34 70 97 35 71 98

Date: Customer: Serial No. Copy Counter:

[3-02] Duplex/Finishing Copies

[3-05] Copier Misfeeds

Location ON OFF

Tray 1 Tray 2 Tray 3 Tray 4 Regist

Pick-off

Fusing

Sub Total

Duplex

gate

Exit gate

Exit tray

Horz.

Trans 1

Horz.

Trans 2

LCT Top

Duplex

Feed

Total

[3-06] RDH/Finisher Misfeeds

Location ON OFF

RDH Feed

RDH Trans

RDH Exit

Total

SADF Feed

SADF Exit

Total

Location ON OFF

Inverter

Unit

Finisher

Total

[3-08] Operation Time

Hours

Power ON

Fusing Lamp

Main Motor

OPC Belt Motor

Development

Motor

Wire Motor

Mark cleared item(s)

Developer

CL Carrier

[3-03] Original Feeds

3-01 3-05 3-02 3-06 3-03 3-07

OPC

Staple 1

1-24

SADF

1 July 1994 Logging Data Sheet

[4-01] Process Control

Setting

Grid

(step)

Shift (step)

Flash

[4-02] Toner Density Control

Date: Customer: Serial No. Copy Counter:

Bias

PCC

Target (volts)

Actual (volts)

VD VL VR

VPCC

ID Sensor

Actual

SG/VSP

ID Pattern Level

V (volts)

Lighter

1 2 3 4

(volts)

Darker

T. D. Sensor

Setting

Actual

Developer Forming

Target T. D. (volts)

Pattern Potential (volts)

1-25

Logging Data Sheet 1 July 1994

Logging Data Sheet (Misfeeds)

Item

Mark for data clear

Tray 1 ON

Tray 2 ON

Tray 3 ON

Tray 4 ON

Regist ON

Pick-off ON

Fusing ON

Sub total ON

Duplex

Gate

Exit

Gate

Exit Tray ON

Horz.

Trans. 1

Horz.

Trans. 2

LCT Top ON

Duplex

Feed Total ON

RDH Feed ON

RDH Trans ON

RDH Exit ON

Total ON

SADF Feed SADF Exit

Total

Inverter

Unit

Finisher ON

Total ON

Date

Counter

OFF

Customer

Serial No.

1-26

1 July 1994 Logging Data Sheet

Logging Data Sheet (Service Calls)

Item

Mark for data clear

1 2 3 4 10 11 12 13 17 20 22 23 30 31 32 33 34 35 36 40 41 42 43 44 45 50 51 52 55 60 61 62 63 64 70 71 80 81 82 83 84 85 86 87 88 89 90 91 93 94 95 96 97 98 99

Date

Counter

Customer

Serial No.

1-27

Tray 1

Tray 2

Tray 3 Tray 4

Duplex Finisher

RDH

Logging Data Sheet 1 July 1994

Logging Data Sheet (Copies/Originals)

Item Date

Counter

Mark for data clear

A3 A4 B5

11" x 17"

1/2 x 14"

1/2 x 11"

Sub total

A3 A4 B5

11" x 17"

1/2 x 14"

1/2 x 11"

Sub total

A3 A4 B5

11" x 17"

1/2 x 14"

1/2 x 11"

Sub total

A4 B5

1/2 x 14"

1/2 x 11"

Sub total

Total

A3 B4 A4 B5

11" x 17"

1/2 x 14"

1/2 x 11"

Total

A3 B4 A5 B5

11" x 17"

1/2 x 14"

1/2 x 11"

Total

A3 B4 A4 B5

11" x 17"

1/2 x 14"

1/2 x 11"

Total

SADF

Customer

Serial No.

1-28

Operation Time

Supply Yield

1 July 1994 Logging Data Sheet

Logging Data Sheet (Others)

Item Date

Counter

Power ON

Fusing Lamp

Main motor

OPC Belt motor Development motor Wire Cleaner Motor

OPC

Developer

Cleaning Carrier

Staple 1

[4-01] Process Control

Grid Setting (step)

Shift (step)

Flash Setting (step)

Shift (step)

Bias Setting (step)

Shift (step)

PCC Setting (step)

Shift (step)

VD Target (volts)

Actual (volts)

VL Target (volts)

Actual (volts)

VR Actual (volts))

VPCC Target (volts)

Actual (volts)

ID sensor Actual (volts)

[4-02] Toner Density Control

SP Actual (volts)

SG Actual (volts)

T.D. Sensor (volts)

SG/VSP

Target

T. D.

Pattern

Potential

Target (volts) Actual (volts) Target (volts) Actual (volts)

Remarks

Customer

Serial No.

1-29

1.8 LCT Installation

LCT Installation

1 July 1994

1.8.1 Accessories list

Name Diagram Quantity Use

Horizontal transport unit 1 This is the relay transport part between LCT

and the copier and is attached to the copier.

Rear side fence 1 Rear side fence for the tray when 11" x 8 1/2"

Lock lever assembly 1 Guide plate open/close lever to be attached

Knob assembly 1 Manual drive knob to be attached to the

Sub-tray auxiliary plate 1 Auxiliary stay when the sub-tray is fitted to

Docking pin 2 This is used for docking between LCT and

Zinc plated

Fixing stepped screw 2 Stud to install the sub-tray auxiliary plate.

Leveling shoe 4 For the docking position adjustment.

Wire saddle 2 For clamping the power harnesses of the

or 14" x 81/2" size paper (A4 size for the U.S.A. version machine) is used. (Not required if such paper is not used.)

to the horizontal transport unit.

horizontal transport unit.

LCT. (Not required when the finisher is used.)

the copier and is attached to the copier.

(Not required if the finisher is used.)

LCT and finisher to the exterior cover.

Pan head machine screw M4 x 6 6 For fixing the horizontal transport unit, lock

Grounding screw M4 x 8 1 For fixing the protective earth wire of the

Plated screw M4 x 6 2 For fixing the sub-tray auxiliary plate. Upper cover stopper 1 To prevent fall of something placed on the

lever and knob.

power supply harness (The copier side).

LCT upper cover when the cover is opened.

NOTE:

When the optional finisher is not used, the sub-tray (P/N-A0291460) must be ordered and used with the LCT.

1-30

1.8.2 Removing the clamps

1 July 1994

LCT Installation

1. Remove the strips of filament tape holding the

upper cover.

2. Open the upper cover, and remove the filament

tape and cushion.

Cushion

Filament tape

3. Remove the two screws so that the upper front

cover can slide up.

NOTE

The LCT upper front cover can be slid up to remove the misfed paper at the paper feed section.

4. Remove the right cover and rear cover.

5. Remove the rear side fixing bracket (4 screws).

6. Remove the front fixing bracket (2 screws) from

the right side.

7. Pull out the tray, and remove the two screws so

you can remove the front fixing bracket.

8. Reinstall the exterior covers.

Back side of front cover

Front

Upper cover

Upper front cover

Front fixing bracket

1-31

Front fixing bracket set screw

Fixing bracket

9. Pull out the paper feed tray, and remove the back

LCT Installation

1 July 1994

fence fixing cushion.

10. Remove the strips of filament tape from the table

bottom plate.

Cushion material

Filament tape

11. Take the horizontal transport unit out of the

accessory box, and remove the mylar protecting cardboard and strips of filament tape.

Filament tape

Mylar protecting cardboard

Filament tape

1-32

1.8.3 Setting up the LCT

1 July 1994

LCT Installation

1. Remove the copier right cover, rear right cover and

sub-tray auxiliary plate.

NOTE

The sub-tray auxiliary plate is no longer needed.

2. Insert the horizontal transport unit (accessory) in

the lower side of the duplex unit, and fasten the unit with the two M4 x 6 screws (accessory). At the same time, connect 4P connector of the unit to the copier.

Sub-tray auxiliary plate

Right cover

Horizontal transport unit

3. Open the right cover and fasten the lock lever

assembly and knob assembly with each of two M4 x 6 screws (all are the accessories).

CAUTION

While holding down the small white roller of the upper left guide plate, tighten the lock lever assembly. Be sure that the lock lever bracket pushes down the upper left guide plate when it is locked.

M4 x 6 (2)

4P connector

Right cover

Knob assembly

Lock lever assembly

1-33

4. Remove the shielding cover for the LCT harness

LCT Installation

1 July 1994

and the rear right cover from the copier. Remove one screw to remove the connector cover.

Connector cover

5. Pass the LCT power and signal harnesses through

the copier frame hole, and fix the harness fixing bracket with the two truss screws removed above.

6. Connect the 15P and 34P connectors respectively.

NOTE

The maximum load current of the LCT is 0.95 A.

7. Take the protective earth wire, feed it through

holes provided as shown, and fix it with the grounding screw (accessory).

8. Fit the connector cover and copier rear right cover

if the finisher will not be installed.

9. Set the two wire saddles (accessories) in the hole

of the LCT rear cover, and put the power cord from the LCT in it.

NOTE

One of the wire saddles is for the harness from the finisher.

M4 x 6 truss screws (2)

Protective earth wire

Grounding screw

Truss screw

LCT power and signal harnesses

15P connector

Harness fixing bracket

Shielding cover for LCT (lower side)

Frame hole

34P connector

Connector cover

10. Remove two blind caps from the copier right cover,

and reinstall the right cover. Then, install the docking pins to the copier base.

Right cover

Main body

Docking pin

1-34

11. Be sure the linking stay of the LCT is locked. Align

1 July 1994

LCT Installation

the copier docking pins with the LCT linking holes, and press the LCT until the pins click.

NOTE

If the finisher will be fitted, dock it with the copier after the finisher’s harnesses are connected to the copier.

12. Place the leveling shoes (accessories) under the

stands. Then, turn the stand nuts to align the docking position.

CAUTION

Align the position of the LCT with the copier. First, roughly adjust the LCT height on the basis of the exterior covers position. Then, open the LCT upper cover and check the lower paper guide plate position using a flat plate like a scale. Finally, align the paper transport guide plate height between the LCT and copier. This is to prevent paper misfeeds where the units connect.

NOTE

LCT

Linking stay

If the finisher is to be installed, do the position adjustment procedure after installing the finisher.

13. If the finisher is not used, remove the two screws

from the sub-tray auxiliary plate fitting holes. Then, fit the sub-tray auxiliary plate with the fixing stepped screws (both accessory), and set the sub-tray.

NOTE

The sub-tray must be ordered separately. The part number is A0291460.

14. Access service tool [1-08], and set the LCT

function.

Fixing stepped screw

LCT right cover

Sub-tray

Sub-tray auxiliary plate

1-35

1.9 Finisher Installation

Finisher Installation

1 July 1994

1.9.1 Accessories list

Check the quantity and condition of the accessories in the box according to the following list.

1. Cushion (575 x 15 x 5 mm) 1

2. Docking Pin 2

3. Docking Support Plate 1

4. Wire Clamp 1

5. Panhead Screw with Washer 1

6. Optical Fiber Cable 1

7. Power Harness 1

8. Panhead Screw M4 x 6 4

9. Ground Screw M4 x 8 (with Lock Washer) 2

10. Shift Tray 1

11. Plated Panhead Screw M4 x 8 4

12. Staple Cartridge 1

13. Original Set Position Decal 1

1-36

1.9.2 Removing the clamps

1 July 1994

Finisher Installation

CAUTION

Unplug the copier power cord before starting the following procedure.

1. Remove the strips of filament tape on the finisher

and remove the styrofoam blocks.

Filament tape

Styrofoam blocks

Filament tape

2. Remove the fixing screw and cut the bind for the

stapler using pliers.

Fixing screw

Filament tape

Bind

1-37

1.9.3 Harness connection to the copier

Finisher Installation

1 July 1994

1. Remove the copier right cover (2 screws). If the

LCT is not used, remove the two blind caps in the right cover and sub-tray auxiliary plate.

NOTE

The sub-tray auxiliary plate can no longer be used.

Auxiliary plate

Right cover

Blind caps

2. Remove the blind cover (upper side).

3. Remove the rear right cover (2 screws), then

remove the connector cover.

Rear right cover

Connector cover

Blind cover

1-38

4. Install the harness bracket of the power cord

1 July 1994

Finisher Installation

(accessory) with the two M4 x 6 pan head screws (accessories).

5. Take the grounding wire, feed it through hole

provided as shown. Secure it with the M4 x 8 grounding screw (accessory). The grounding screw must be firmly secured in place with a force 10 to 15 kgfcm torque.

6. Set the optical fiber cable connectors from the

copier and finisher in the sockets of the harness bracket. Also, connect 3P connector to the power cord.

CAUTION

The connectors (male) and sockets (female) must be set as shown.

Grounding wire

Harness bracket

Connector cover

3P connector

7. Reinstall the connector cover and rear right cover.

8. Install the copier right cover. If the LCT is not used,

install the two docking pins (accessories).

Optical fiber cable connectors

Right cover

Docking pins

1-39

1.9.4 Docking preparation

Finisher Installation

1 July 1994

NOTE

This procedure is required only when the LCT is used with the finisher.

1. Remove the right cover (5 screws) then remove

the two blind caps.

2. Install the two docking pins (accessory).

3. Remove the 4 screws.

4. Install the docking support plate (accessory).

Tighten the 4 screws removed in the above step while holding the plate up.

NOTE

The docking support plate is required to strengthen the docking parts in the LCT. The left side of the finisher is supported only by the two docking pins.

5. Reinstall the LCT right cover.

1.9.5 Harness connection and docking

1. Remove the inverter rear cover (4 screws).

Docking pins

Screws

Docking support plate

2. Pass the power cord and optical fiber cable

(connected to the copier side) through the harness docking hole. Then, secure the harness bracket with the two M4 x 6 screws (accessories). At the same time, bring the optical fiber cable into the clamp in the harness bracket and secure it with the wire clamp and panhead screw with washer (accessories).

CAUTION Clamp the optical fiber cable in the harness

bracket so that the portion between the finisher and LCT (or copier) is longer than that of the power cord.

3. Connect the power cord connector to the dc power

supply PCB and the optical fiber cable connector to the inverter control PCB. Then, secure the grounding wire with the M4 x 8 grounding screw (accessory) as shown. The grounding screw must be firmly secured in place with a force of 10 to 15 kgfcm torque.

CAUTION The optical fiber cable connector must be set to

the socket on the PCB properly as it has the setting direction.

4. Bind the power cord with the wire clamp.

5. Reinstall the inverter rear cover.

Inverter rear cover

Optical fiber cable connector

Harness bracket

Clamp

Wire clamp

Grounding screw

Harness docking hole

Wire clamp

Power cord connector

1-40

6. Stick the cushion (accessory) on the left side of the

1 July 1994

Finisher Installation

finisher as shown.

7. Open the finisher and inverter front doors. Then

remove the linking stay access hole cover (2 screws).

8. Be sure that the linking stay of the finisher is in the

lock position. Align the docking pins with the linking holes of the finisher, and press the finisher until the docking pins click. Reinstall the linking stay access hole cover.

9. Install the finisher shift tray with four M4 x 8 plated

panhead screws (accessories).

Cushion

0 to 2 mm

5 to 10 mm

Shift tray

Linking stay

10. Open the finisher front door and install the staple

cartridge (refer to the instruction decal on the rear side of the front door):

a) Pull out the staple unit. b) Release the lock lever and turn the

stapler counterclockwise until it locks. c) Remove the green plastic clip from the

staple cartridge, and install the cartridge in the stapler.

d) Set the stapler to its original position. e) Push the staple unit in its original posi

tion.

Staple unit

Cover

Green plastic clip

Lock lever

1-41

11. Put the two leveling shoes (accessories) under the

Finisher Installation

1 July 1994

stands.

12. From the front and rear, check the clearance

between the exterior covers of the finisher and copier (or LCT). It must be 3 to 7 mm. To adjust the position of the finisher with the copier (or LCT), turn the stand’s nuts as shown.

5 ± 2 mm

Leveling shoe

13. From the top of the finisher, check the position of

the finisher with the copier (or LCT). The finisher must be aligned with the copier (or LCT) as shown in the upper illustration. Adjust the finisher height by turning the stand’s nuts again, if necessary.

14. Stick the original set position decal (accessory) on

the RDH as shown.

15. Plug the power cord and turn on the main switch of

the copier. Wait for the copy stand-by condition.

16. Access service tool [1-08] and set the finisher

function.

17. Test the operation of the finisher.

NOTE:

• Select the staple mode (2 staple mode) and

make more than 10 sets of copies before starting the stapling operation test. This is because the staple unit performs stapling motion without staples until the first staple from the cartridge reaches the proper position for stapling. This procedure is required only after installing the first staple cartridge.

• If customer prefer the shift tray rise mode,

which is to rise the shift tray when the paper on the tray is removed during a copy run, turn on dip switch 101-1 on the finisher control PCB.

100 mm

0 ± 1 mm

Decal

0 ± 1 mm

10 mm

1-42

1.10 Printer Installation

1 July 1994

Printer Installation

1.10.1 Accessories list

Check the quantity and condition of the accessories in the box according to the following list.

Key counter bracket accessory check

1. Snap Bushing 1

2. Wire Clamp 2

3. Philips Sunken Head Screw - M3 x 8 2

4. Philips Pan Head Screw - M4 x 8 4

5. Philips Plated Screw - M4 x 8 4

6. Grounding Screw with Star Washer 2

7. Philips Plated Screw - M3 x 6 2

8. Key Counter Hole Blind Cover 1

9. Key Counter Fixing Plate 1

10. Printer Connector Hole Blind Cover 1

Printer connector unit accessory check

1. Grounding Screw with Star Washer 2

2. Philips Plated Screw - M4 x 8 1

3. Wire Clamp 1

NOTE:

The printer interface board (P/N A112 5060), printer harness (P/N A531 5420), 2 connector joint studs (2 x P/N 1102 4039), and 4 nylon studs (4 x P/N 1105 0193), which are the copier’s accessories, are required for the printer connector unit installation.

1.10.2 Installation procedure

1. Remove the exterior cover in the rear of the copy

tray (3 screws). Then, remove the two cover brackets (2 screws each).

2. Install the key counter/printer connector bracket

with four M4x8 philips pan head screws and one grounding screw (accessories).

3. Install the snap bushing (accessory) as shown.

4. Remove the copier rear right cover (2 screws).

5. Take the two connectors which are clamped

behind the key counter/printer connector bracket, then feed them through the hole in the bottom of the bracket as shown.

Exterior cover

Cover bracket

Snap bushing

Grounding screw

Connector bracket

Cover bracket

1-43

6. If an optional key counter is installed, install the

Printer Installation

1 July 1994

key counter receptacle with the two M3x8 philips sunken head screws and key counter fixing plate (accessories).

NOTE

The key counter must be one of the following:

- Hengstler (For the European version machine only)

- Hecon

- Veeder Root

Shorting connector

Key counter receptacle

Key counter fixing plate

7. Remove the shorting connector, then connect the

connectors from the key counter and copier.

8. Install the two wire clamps (accessories) and

clamp the harness as shown.

9. If the optional printer connector unit is not

installed, install the printer connector hole blind

cover with the two M3x6 philips plated screws (all are accessories).

10. If the optional printer connector unit is

installed, install it with the grounding screw and

M4x8 philips plated screw (accessories).

11. Connect the connector of the harness form the

copier to the PCB on the printer connector unit.

12. Install the 4 nylon studs, then the printer interface

board. Connect the connector of the harness from the printer connector unit to the interface board.

13. Install the printer harness with the two connector

joint studs.

NOTE

The printer interface board (P/N A112 5060), printer harness (P/N A531 5420), 2 connector joint studs (2 x P/N 1102 4039), and 4 nylon studs (4 x P/N 1105 0193), which are copier accessories, are required for the printer connector unit installation.

Connector joint studs

Grounding screw

Wire clamp

Connector

[E]

Optional printer connector unit

Blind cover

Printer interface board

Grounding screw

Nylon studs

Wire clamp

Printer harness

Blind cover

Fixing plate

14. Connect the other end of the printer harness to the

connector on the printer interface board.

15. Fix the grounding wire with the grounding screw

(accessory). Then, install the wire clamp (accessory) then clamp the printer harness with the clamp as shown.

16. 1If an optional key counter is not installed, install

the key counter hole blind cover with the two M3x8 philips sunken head screws and key counter fixing plate (accessories).

1-44

17. Install the key counter/printer connector bracket

1 July 1994

Printer Installation

cover [A] with the grounding screw [B] and the 4 M4x8 philips plated screws (accessories).

NOTE

If the optional printer connector is installed, a printer with a standard RS232C interface is required. Use a printer with the following functions:

Mode: Asynchronous Data format: Start/Stop/Data: 1 bit each Data bit length: 8 bits Parity permission: With Parity setting: Even parity Baud rate setting: 1,200 bps Connector: 25 pins, D-connector

Bracket cover

Grounding screw

1-45

SECTION 2

REPLACEMENT AND ADJUSTMENT

2. REPLACEMENT AND ADJUSTMENT

1 July 1994

Paper Feed

2.1 Paper Feed

2.1.1 Replacing the feed, reverse and pick-up rollers

PM cycle: Replace every 400K

NOTE

One set of the feed, reverse and pick-up rollers can feed up to approximately 150,000 sheets of paper. If the paper trays are not used evenly, replace the rollers that are worn more with the rollers that are worn less. Do this before any rollers wear out.

1. Press the tray down keys for all paper trays.

2. Turn off the main switch.

3. Pull out and remove the 1st tray (2 screws).

CAUTION

Note that the unit fixing screws are the stepped screw on the right side and the plated screw on the left side.

4. Pull out the 2nd and 3rd trays.

Stepped screw

Plated screw

5. Remove stop rings from rollers in the 1st, 2nd, and

3rd feed station.

6. Slide and remove rollers and replace rollers.

CAUTION

• Do not touch the new roller surfaces with

bare hands.

• Install the feed roller in the correct direction.

Paper feed roller

Pick-up roller

Reverse roller

2-1

2.1.2 Replacing parts in the paper feed unit

Paper Feed

1 July 1994

Replace parts in the paper feed unit when:

• Electric parts are changed (paper feed motor,

various sensors and pick-up solenoid).

• The grip roller is replaced.

Removing paper feed unit

1. Remove the inner cover(s) from the vertical

transport unit.

2. Remove the paper tray from the paper feed station

as it is required to remove the feed unit.

3. Disconnect and put the paper feed connector to

the far side.

4. Loosen the slot head fixing shaft and pull it about

10 mm in the direction of the arrow.

Remove for the 1st tray

Remove for the 2nd or 3rd tray

1st tray

2nd tray

3rd tray

Paper feed connector

5. When you need to remove the feed unit at the third

feed station, remove the oil pump unit bracket (2 screws).

(-) fixing shaft

Fitting screw

Oil pump unit bracket

Oil tube

2-2

6. Remove the screws from the paper feed unit fixing

1 July 1994

Paper Feed

bracket.

7. Hold the far side of the unit to move it to the right

and push the front to the far side to remove the unit.

Checking the unit

Bracket fixing screw

1. Remove the paper tray.

2. Loosen and pull the (slot head) fixing shaft without

removing the two screws from the paper feed unit fixing bracket.

3. The far side of the unit can be opened and closed

using the front as a fulcrum.

Replacing the torque limiter

1. Remove the paper feed unit.

2. To pull out the reverse roller, remove the stop ring.

3. Remove the reverse roller pressure arm stopper

(one screw).

4. To replace the torque limiter, lower the reverse

roller pressure arm.

CAUTION

• Because the torque limit pressure is

properly adjusted, do not loosen the torque limiter stopper screws.

• Never touch the reverse roller surface with

bare hands.

Breaker fixing screw

Reverse roller pressure arm

Stopper

Stop ring

Reverse roller

(Minus head) fixing shaft

[NG]

Stopper

Torque limiter

2-3

Replacing the pick-up solenoid

Paper Feed

1 July 1994

1. Remove the paper feed unit.

2. Mark the position of the solenoid bracket.

3. Remove the two solenoid bracket fixing screws

(gold color).

4. Remove the pick-up solenoid from the bracket and

replace it.

CAUTION

• Pull out one side of the plunger spring pin

about 4 mm and put it in the pick-up roller arm hole.

• The solenoid bracket should be in the

marked-off position. The pick-up roller rise amount various with the position.

5. Remove the E-ring from both sides and replace

the grip roller.

6. Assemble in the reverse order.

NOTE

The golden screw (zinc plated) shows the location adjusted at assembly during manufacture. Therefore, pay attention to how the screw is set originally before you start working. When the screw is loosened, adjustment is required.

4 mm

Pick-up solenoid

Gold screw

Pick-up roller arm

Solenoid bracket

2-4

2.1.3 Replacing parts in the paper trays

1 July 1994

Paper Feed

PM cycle: Lubricate the tray motor worm gear every 800K

1. Pull out the tray.

2. Remove the front and rear knobs (2 screws each),

and the tray bottom plate (6 screws). You can replace the anti-condensation heater and paper size sensors.

3. Remove the front tray cover (4 screws). You can

replace the front tray drive wire.

4. Remove the paper tray from the rails (2 screws)

when:

• Replacing the rear tray drive wire

• Replacing the tray motor and DC drive board

• Lubricating the worm gear

Tray drive wire layout diagram

The numbers shows the assembly steps.

FRONT REAR

Knob

Tray bottom plate

Front tray cover

2 turns clockwise (blue wire)

Secure the tension pulley

2 turns counterclockwise (blue wire)

2.5 turns counterclockwise

2.5 turns clockwise

Secure the tension pulley

2-5

2.1.4 Replacing the registration sensor

Paper Feed

1 July 1994

1. Turn off the main switch. Open the front door, and

remove two screws to allow it to open further.

2. Remove the inner cover (2 screws and one

connector).

CAUTION

Do not pull the harness to the cooling fan in the inner cover.

3. Turn the lever to release the development backup

roller of the OPC unit.

4. Remove the development unit fixing plate (one

screw), and slightly pull out the unit to disengage the joint gear at the rear of the unit.

5. Turn the development knob to collect the

developer on the development sleeve.

CAUTION

Be sure to collect the developer, because the developer may attach to the side plate of the OPC unit, fraying or damaging the OPC belt.

Lever

Development knob

Fixing bracket

6. Slide out the development unit.

7. Remove the registration sensor (2 screws and one

clamp).

8. Remove the main body rear left cover (2 screws).

9. Remove the connector going to the registration

sensor from the back.

10. Reassemble in the reverse order.

CAUTION

Never touch the OPC belt.

2.1.5 Replacing the registration motor

1. Turn off the main switch.

2. Remove the rear left cover, then remove the

cleaning coil cooling fan.

3. Disconnect the connector from the registration

motor.

4. Loosen two screws of the universal joint attached

to the registration motor shaft.

5. Remove two screws fixing the registration motor.

6. Replace the registration motor and reassemble it

in the reverse order.

Clamp

Fixing screw

Registration motor

Fixing screw

Registration sensor

Connector for registration motor

2-6

2.1.6 Cleaning the paper dust collecting vessel

1 July 1994

Paper Feed

PM cycle: Clean every 1,200K

1. Pull out the 3rd tray.

2. Turn off the main switch. Open the front door, and

remove two screws to allow it to open further.

3. Remove the inner cover from the lower of the

vertical transport unit (3 screws).

4. Remove the OPC unit inner cover (2 screws and a

connector).

CAUTION

Do not pull the connector of the cooling fan in the machine.

5. Turn the lever to release the development backup

roller of the OPC unit.

6. Remove the development unit fixing plate (one

screw), and slightly pull out the unit to disengage the joint gear at the rear of the unit.

7. Turn the development knob to collect the

developer on the development sleeve.

CAUTION

Be sure to collect the developer because it may stick to the side plate of the OPC unit, fraying or damaging the OPC belt.

Paper dust collecting vessel

Fixing screw

8. Slide out the development unit and remove the unit

from the rails.

9. Remove the vessel fixing screw from the front, and

remove the paper dust collecting vessel.

10. Clean inside of the vessel using a dry cloth, and

reassemble in the reverse order.

2-7

2.1.7 Removing the vertical transport unit

Paper Feed

1 July 1994

You will have to remove the vertical transport unit when:

• Replacing the drive system

• Replacing each roller

WARNING

• Due to the weight, two operators are required.

• Be sure to pull out the power cord during work.

1. Pull out all paper trays.

2. Turn off the main switch.

3. Open the upper right door.

4. Open the front door.

5. Remove all inner covers: fusing, vertical transport

upper and vertical transport lower.

6. Remove two screws each to remove all paper

trays.

CAUTION

Vertical transport upper inner cover

Plated screw

Fusing inner cover

Vertical transport lower inner cover

Stepped screw

Tray fixing screws are stepped screws on the right side and plated screws on the left side. Take care during reinstallation.

7. Remove the upper and lower door catch magnets

with their brackets.

Door catch magnet, upper bracket

Door catch magnet, lower bracket

2-8

8. Remove the horizontal transport unit inner cover.

1 July 1994

Paper Feed

9. Disconnect the front door switch harness

connectors.

CAUTION

Terminals on both sides are blue and the two center terminals are yellows. Re-install them correctly.

10. Disconnect the connector from the front door

sensor.

11. Mark off the position of the front door switch

bracket.

12. Remove the front door switch bracket (2 screws).

Front door sensor

Horizontal transport inner cover

Front door switch

13. Remove the fusing unit fixing stepped screw to

remove the unit.

14. Remove the transport unit inner cover.

15. Remove the oil receiver (2 screws).

16. Remove the oil pump unit bracket (2 screws) and

the tube on the oil tank side.

Fixing stepped screw

Oil receiver

Transport unit inner cover

Oil pump unit bracket

Oil tube

2-9

17. Remove the male and female connectors for all

Paper Feed

1 July 1994

paper feed units.

18. Remove the three cord clamp screws.

19. Remove the grounding screw from the ground wire

of the connector to the transport unit.

20. Remove the male and female connectors for the

transport unit from the stay.

21. Release the transport unit to the right.

22. Hang the dismounting and mounting arm of the

transport unit on the pin.

23. Remove the fixing screws from the transport unit to

remove the unit.

CAUTION

Connector for transport unit

Connector for paper feed unit

Grounding screw

Cord clamp screw

Stay

Carefully pull out the units so that the transfer and separation corona unit casing does not touch the rollers or pressure springs of the vertical transport unit.

24. Turn the lever to release the development backup

roller of the OPC unit.

25. Remove the development unit fixing plate (one

screw), and slightly pull out the unit to disengage the joint gear at the rear of the unit.

26. Turn the development knob to collect the

developer on the development sleeve.

CAUTION

Be sure to collect the developer because it may stick to the side plate of the unit, fray or damage the OPC belt.

Transport unit

Dismounting and mounting arm

Stay fixing screw

27. Slide out the development unit and remove the unit

from the rails.

28. Remove five M5 screws fixing the vertical transport

stay.

2-10

29. From the back of the machine, remove the

1 July 1994

Paper Feed

transformer then remove the three M5 screws holding the vertical transport unit.

30. Disconnect the connectors of the harnesses from

the registration motor and registration sensor.

31. Disconnect the connector to paper feed motors in

all paper trays.

32. From the front, pull the vertical transport unit.

CAUTION

The unit is heavy so you will need a helper to lift it away.

33. Reinstall the unit in the reverse order.

CAUTION

• Fix the front door switch in the marked-off

position.

• Remove the pulley after the tension pulley

bracket is marked off.

• Do not loosen the two bracket fixing screws

(golden screws) on the front side at the same time when the registration roller or like is replaced. If they are removed, clearance with the OPC unit changes and transport trouble or skew in registration may occur.

• Tubes leading to the oil tank should not

sink below the oil level.

M5 screw

Connector for paper feed motor

Registration motor

Connectors

Timing belt layout diagram

Paper feed motor (No. 1)

Vertical transport roller

Grip roller drive

Pinch roller

Bracket fixing screw

Tension pulley bracket

Joint gear

Registration

Paper dust collecting roller

Registration roller

Paper dust collecting roller

Registration knob

Golden screw

2-11

Belt tension standard

Paper Feed

1 July 1994

3 mm deflection at 140 ± 90 g pressure.

2.1.8 Adjusting the side-to-side registration

100 mm

140 ± 90 g

3 mm

Standard value: 0 ± 2 mm in the platen cover mode.

1. Set paper in the paper tray to be checked.

CAUTION

Be sure to set the paper side guides of the paper tray securely.

2. Set the test chart on the exposure glass correctly.

3. Make a copy and measure the difference of the

side-to-side registration between the original and copy.

4. If the value does not match the standard value

then the following steps should be taken:

1) Pull out the paper tray and remove the tray front cover.

2) Loosen the lock nut and turn the tray stopper to change the paper tray position when set.

5. Make more than 10 continuous copies to check the

variation.

6. Be sure that all copies are within the standard

value. If problems still occur, repeat step 3 to 5.

CAUTION

Lock nut

Tray stopper

• An adjusting mechanism for the

side-to-side registration is provided for each tray.

• Because the side-to-side registration

adjustment mechanism is also provided on the original side (ADF and SADF), make adjustments for each tray on the basis of the platen cover mode.

2-12

2.1.9 Adjusting the leading edge registration

1 July 1994

Paper Feed

Standard value: 0 ±2 mm in the platen

cover mode.

1. Set paper in the paper tray.

CAUTION Be sure to set the paper side guides of the paper

tray securely.

2. Set the test chart on the exposure glass correctly.

3. Make a copy and measure the difference between the leading edge registration of the origi-

nal and the copy.

4. If the value does not match the standard, access service tool [5-02] and press the Registra-

tion key.

5. Change the value on the screen.

6. Make more than 10 continuous copies to check the variation.

7. Be sure that all copies are within the standard value. If problems still occur, repeat step 3 to

2-13

2.2 Optics

Optics

1 July 1994

2.2.1 Replacing the xenon lamp

PM cycle: Replace every 1,000K or when:

[(set value) + (shifted value)]

of the flash voltage step (Service tool [4-01]) exceeds 28.

CAUTION

If the cooling air flow to the xenon lamp and flash power supply unit becomes low, the flash voltage step will exceed 28 earlier than normal. Be sure to do the following PM.

PM: Every 200K clean the filters for the rear cooling fan, flash blower, exposure cooling fan, flash power cooling fan inside the left cover, and the flash power inside blower on the rear left cover.

WARNING

After you turn off the power, wait at least 1 minute for discharge before you start working.

1. Turn off the main switch.

2. Remove the left cover (2 screws).

3. Disconnect the two connectors to the exposure

cooling unit.

4. Remove the exposure cooling unit (4 screws).

5. Remove the xenon lamp connector (2 screws).

6. Remove the xenon lamp unit (2 screws).

Exposure cooling unit

Connector

2-14

WARNING

1 July 1994

Optics

• To avoid wiring problems of high voltage parts,

never disassemble the connector.

• Working near the lamp is dangerous. Never

work near the lamp without turning off the main switch and waiting at least 1 minute for discharge.

• Take care and check the position of the lamp

harness. (See illustration below.)

[OK]

Lamp harness

Xenon lamp connector

Connector fitting screw

Xenon lamp unit

Flash safety switch

Unit fitting screw

[NG]

7. Remove the xenon lamp upper cover (2 screws).

8. Remove the thermofuse.

9. Remove the roof reflector (2 screws).

10. Remove lamp cooling guide seal.

11. Remove the lamp clamps from the front and rear

(one screw each).

12. Replace the lamp and reassemble in reverse order.

13. When the machine is in the stand-by condition,

access service tool [4-03]. Using the PC-1 chart check the AID reference voltage. Perform setting A if the value is not correct.

Xenon lamp upper cover

Thermofuse

Roof reflector

Cooling guide seal

Lamp clamp

Xenon lamp

2-15

CAUTION

Optics

1 July 1994

• To avoid xenon lamp damage, firmly fit the

xenon lamp connectors to the sockets. Push each connector end with your fingers as shown. Then tighten two screws.

• When reinstalling the xenon lamp in the

unit, position the lamp exactly as shown. If the position is not correct, the life time of the lamp might be reduced. Insufficient light intensity will increase the lamp voltage rapidly due to the process control.

Xenon lamp connector

• If the lamp positioning tool (P/N-A0289330)

is available, the lamp installation becomes much easier. Fix the tool with the two screws and install the xenon lamp while pushing the lamp against the tool (see the illustration to the right). At that time, be sure that both the right and left edges of the lamp ("a" in the illustration) are the same length.

Same length at the right and left edges.

13.5 mm

Lamp positioning tool

2-16

2.2.2 Replacing the exposure glass

PM cycle: Clean it and check the resistance at every visit. Wipe with silicon oil to prevent original misfeeds caused by static electricity.

WARNING

Working near the xenon lamp is dangerous after removing the exposure glass. Never work near the lamp without turning off the main switch and waiting at least 1 minute for discharge.

1. Turn off the main switch.

2. Open the ADF unit.

3. Remove the front upper cover (2 screws).

4. Open the copy tray and remove the SADF

transport plate (one stepped screw on the rear and one plated screw on the front).

5. Loosen two screws of the back upper cover.

6. Remove the exposure glass. Clean it if necessary.

7. Check the resistance of the glass upper surface

using the beckman multimeter. Replace the exposure glass if necessary.

SADF transport plate

Front upper cover

Exposure glass surface resistance

standard: 55 KΩ or less.

8. When the machine is in the stand-by condition,

access service tool [4-03]. Using the PC-1 chart, check the AID reference voltage. Perform setting A if the value is not correct.

2.2.3 Replacing the mirror/lens motor

PM cycle: Lubrticate the motor worm gear every 1,200K

1. Remove the exposure glass.

2. Loosen two screws (1) to remove the opposite

reflector. Clean the reflector as required.

3. Remove four screws (2) to remove the front

reflector. Also, remove the rear reflector.

CAUTION

Be careful not to scratch the lamp reflector when removing the front and rear reflectors. After removing screws, pull out the reflector with the left side first.

Back shield cover

1st mirror shield unit

Lamp reflector

Front shield cover

Opposite reflector

4. Remove one screw (3) to remove the front shield

cover.

5. Remove one screw (4) to remove the back shield

cover.

6. Remove 8 fixing screws (5) to remove the 1st

mirror shield unit. Remove the unit upwards while raising the inside plate.

Front reflector

2-17

CAUTION

Optics

1 July 1994

The shaft should not come out of the shield unit.

7. To remove the fusing unit, pull out the unit and

remove one stepped screw.

8. Peel off three sheets of shielding mylar for the

mirror/lens motor fixing screws.

9. Remove the connectors for the mirror/lens motor

and mirror/lens home position sensor.

Connector for magnification home position sensor

Connector for mirror/lens motor

Shielding mylar

Two stepped screws

M5 screw

10. Put a screwdriver through the blind to loosen the

mirror/lens motor fixing screws (2 stepped screws and one M5 screw).

CAUTION

The 1st mirror unit drops if the screw is completely removed. Before removing the screws for the worm gear disengage, insert a screwdriver in the mirror unit fixing hole to hold the unit.

11. While holding the mirror/lens motor with one hand,

remove the three screws securing the motor.

CAUTION

Lubricate the worm gear of the mirror/lens motor with Mobil Temp. 78 every 1200 K. You do not have to remove the motor at that time.

12. Replace the motor and reinstall it in the reverse

order.

CAUTION

• Check and be sure that the worm gear of

the mirror/lens motor is correctly engaged.

• When power is turned ON, the mirror/lens

motor starts and stops when the 1st mirror unit activates the magnification home position sensor.

Mirror unit fixing hole

1st mirror unit

2-18

2.2.4 Replacing the first mirror

1 July 1994

Optics

PM cycle: Clean the 1st mirror every 200K

NOTE

To clean the 1st mirror, it does not need to be removed. Just remove the exposure glass to clean.

1. Remove the 2nd mirror according to the

instructions described below.

2. Remove the two set screws from the underside of

the 1st mirror.

3. Hold the underside of the mirror and slide it down

to remove it.

CAUTION

1st mirror

Take care not to drop the mirror.

4. Reinstall the mirror after cleaning.

5. When the machine is in the stand-by condition,

access service tool [4-03]. Using the PC-1 chart, check the AID reference voltage. Perform setting A if the value is not correct.

2.2.5 Replacing and cleaning the 2nd mirror

PM cycle: Clean as necessary at PM

1. Turn off the main switch.

2. Remove the left cover (2 screws).

3. Remove two set screws from the 2nd mirror.

CAUTION

Hold the 2nd mirror with one hand so it does not fall.

4. Move the 2nd mirror to the left (outside) to avoid

the DC power source, pulling it out then down.

5. After cleaning, reinstall it in the reverse order.

CAUTION

Set screw

Locating pin

Set the locating pin first to install the 2nd mirror unit. (See illustration.)

6. When the machine is in the stand-by condition,

access service tool [4-03]. Using the PC-1 chart, check the AID reference voltage. Perform setting A if the value is not correct.

2nd mirror

2-19

2.2.6 Replacing parts in the shield unit

Optics

1 July 1994

Removing the shield unit

1. Turn off the main switch.

2. Remove the left cover (2 screws).

3. Open the front door and remove two screws to

allow it to open further.

4. Remove the inner cover (2 screws and one

connector).

5. Remove the four connectors of the DC power

source.

6. Remove four fixing screws and loosen the lower

side screws to remove the DC power source.

7. Remove the two screws fixing the shield unit from

the left.

DC power source

Shield unit fixing screw

8. Disconnect the connector for the shield unit from

the front.

9. Remove the shield unit fixing screws (M6).

10. Pull out the shield unit to the left along the rail.

CAUTION

• Hold the front and back side plates, not the

shield screen to pull out the shield unit.

• Press the upper stays of the shield unit

against the far side of the front and rear rails, and fix the shield unit.

Shield unit

Rail

Shield unit

Shield unit fixing screw

Stay

Connector for shield unit

2-20

Replacing the shield motor

1 July 1994

Optics

1. Remove the shield unit.

2. Remove the shield motor cover (one screw).

3. Remove two fixing screws from the shield motor

and replace the motor.

Replacing the shield screen

1. Remove the shield unit.

2. Remove the timing belt fixing screws, front and

back, from the shield screen unit to enable replacement.

CAUTION

[FRONT SIDE]

Shield motor cover

Shield motor left and right

Timing belt fixing screw

Spring washer

Slider

[REAR SIDE]

Rail

• Do not lose the spring washer under the

fixing plate.

3. Remove one stepped screw and one pan head

screw to remove the back side of the timing belt tension. Remove the belt.

4. Loosen one tension fixing screw to remove the

front side belt.

5. Remove E-rings from the shield roller and pull out

the roller.

6. Move the shield screen slider to the center along

the rail and remove it from the back side. Clean the rail and slider with alcohol.

7. Replace the shield screen unit and re-install it in

the reverse order.

Adjusting belt tension

1. Loosen all tension fixing screws.

2. Tighten the screws when the tension spring works.

Shield screen

Shield roller

Stepped screw

Timing belt

2-21

Adjusting the shield screen position

Optics

1 July 1994

1. Adjust belt tension.

2. Move the slider to the center.

3. Turn the shield motor shaft gear by hand to move

the slider. Let it slide until the front or back slider is brought in contact with the stopper.

4. Bring the other slider in contact with the stopper

and turn the motor gear further by two teeth of the belt gear.

5. Tighten the fixing screw.

6. Turn the motor gear by hand again and check that

the shield screen moves smoothly without rolling.

NOTE

• If you detect rolling, repeat this procedure.

Dirt, toner, etc., should not be on the rail.

• To check tension of the shield screen, fully

close the leading and trailing edge of screen, and lightly press the center with your finger. Tension is OK if the screen returns easily and is not slackened when it is released.

7. The stays on the shield unit should fit to the main

body side rails first when the shield unit is reinstalled.

Timing belt fixing screw

Shield motor shaft

Slider

Stopper

2-22

2.2.7 Replacing the flash power supply unit

1 July 1994

Optics

WARNING

Before you start working, turn off the main switch and wait for at least one minute to allow for discharge.

1. Turn off the main switch.

2. Remove the left cover (2 screws).

3. Disconnect the connector from the flash exhaust

unit and remove four screws to remove it.

4. Remove the connectors for the xenon lamp

(2 screws).

5. Disconnect the 2P connector to the trigger

transformer.

Trigger transformer

Red

2P connector White line

Black

Flash power source line

(trigger)

Red wire (tape indicates polarity)

Black line (tape indicates polarity)

(+)

(-)

6. Remove three lines connected from the flash

power supply unit to xenon lamp connector together with the terminal fixed with two screws each.

7. Remove the rear left cover.

8. Disconnect two connectors (15P and 3P) from the

upper part of the flash power supply unit.

9. Remove the air blow guide (2 screws) from the

lower part of the flash power supply unit.

10. Remove the flash power supply unit.

Remove the upper two screws and only loosen the lower two.

11. Replace the flash power supply unit and

reassemble in the reverse order.

CAUTION

• Be sure to wire the three flash power

source lines correctly, the white wire (from the trigger transformer), red line and black line from the top. If wired incorrectly, the lamp may burn up.

• To avoid xenon lamp damage, firmly fit the

lamp connector to the socket. Push each connector end with your fingers. Then, tighten two screws.

Connector

Flash power supply unit

2-23

2.2.8 Checking the flash power supply output

Optics

1 July 1994

1. Remove the clear cover from the flash power

supply unit.

2. Connect the Beckman multimeter between J1(+)

and J2(-). (Range: 20V)

3. Access service tool [5-04], input/output test.

4. Select Lamp/Sol menu and press Charge key.

5. It is normal if the 1/1,000 value of the lamp output

can be read according to the combination of bits [0][1][2][3][4] as follows: * About 1.07V with [0] to [4] all OFF * About 2.00V with [0] to [4] all ON (full power)

2.2.9 Adjusting the uneven illuminance

CAUTION

This adjustment is usually prohibited. It seems difficult to return the illuminance to the original setting if you change the position of the front and rear reflectors.

CAUTION

Never work near the xenon lamp after the flash power is charged. Be sure to discharge it using the Discharge key ("Dis" key) in the service tool screen.

Hex socket screw

Reflector adjusting nut

Reflector adjustment shaft

Reflector adjustment bracket

1. Use graph paper of A3 size as the original.

2. Copy at the second level of the image density.

3. Check uneven illuminance and make adjustment

with front and rear reflectors.

CAUTION

At this time, set the whole density to the dark part at the trailing edge of the copy image.

4. After the adjustment, access service tool [4-03]

and check the AID reference voltage using the PC-1 chart. Perform setting A if the value is not correct.

CAUTION

When you cannot set the V L target data in the [4-01] screen due to too low value of the V L measured data, light quantity to the pattern may be too high. Therefore, adjust illuminance again to lower the light quantity to the pattern.

Front reflector

Set the whole to this density

Reflector

Reflector adjusting mechanism

Rear reflector

2-24

2.2.10 Adjusting the magnification

1 July 1994

Optics

Standard value:

±0.5% or less at length and at width in

the full size mode.

±1.0% or less at length and at width in

any other magnification ratios.

1. Copy a scale as an original.

2. Measure copy dimensions, and calculate the error

in magnification.

3. Access service tool [5-02]. Press the Magnification

key, and adjust the magnification.

4. Repeat this procedure to set the standard value.

2-25

2.3 OPC Unit

OPC Unit

1 July 1994

2.3.1 Replacing the OPC belt

PM cycle: Replace every 200K

1. Turn off the main switch.

2. Open the front door, then remove two screws to

allow it to open further.

3. Disconnect the connector from the fan and remove

the inner cover (2 screws).

4. Disconnect the charge corona connector.

5. Pull out the charge corona unit.

6. Release the cleaning backup roller by turning lever

(1).

7. Release the development backup roller by turning

lever (2).

8. Release the transport unit to the right side.

9. Turn the development knob and collect the

developer on the development sleeves.

CAUTION

• Be sure to collect the developer because it

may stick to the side plate of the OPC unit, damaging the OPC belt.

• To turn the development knob, slightly pull

out the unit and disengage the joint gear at the rear of the unit.

Charge corona connector

Charge corona unit

Development knob

Lever (1)

Transport unit

Lever (2)

10. Remove the OPC unit stay by turning the knob.

11. Slide out the OPC unit.

12. Turn lever (3) to loosen the tension of OPC belt.

13. Insert two OPC mounting/dismounting tubes in the

bosses and pull out the OPC belt this way.

OPC unit

OPC unit stay

Knob

Lever (3)

OPC mounting/dismounting tube

2-26

14. Set a new OPC belt.

1 July 1994

OPC Unit

CAUTION

• Set the OPC belt so the mark is on the far

side.

• Put far side of the OPC in the OPC sensor

and set it in the center.

• Never touch the OPC surface, and position

the OPC belt carefully to prevent bending it.

• Do not expose the OPC belt to daylight for

more than a few minutes. When not installed, keep the OPC belt in its case and store it in a cool, dark place. If copying is done while the exterior covers are off and in slight daylight, even after it is set in the copier, the copy image becomes extremely light.

• Never use alcohol or other chemicals to

clean the OPC.

15. Slowly turn lever (3) back to its original position

and put tension the OPC belt.

16. Press and set the OPC unit.

17. Fit the OPC unit stay.

18. Turn levers (1) and (2) to set the development and

cleaning backup rollers.

19. Shift the transport unit to the left.

20. Fit the charge corona unit and the connector.

21. Install the inner cover and doors in the reverse

order.

22. Turn on the main switch and wait for the machine

stand-by.

23. Access service tool [3-04] (or [4-04]) and perform

the OPC forming. Reset the supply yield counter for the OPC to 0 at the same time.

24. Select service tool [5-06] and check the tracking

operation. If necessary, adjust the tracking amount (see Adjusting the tracking amount section).

25. Select service tool [4-02] and check the VSG. If

the value is not between 2.5 and 4.5 volts or it is locked, perform setting C.

Mark

Lever (3)

OPC sensor

Charge corona unit

2-27

Lever (1)

Transport unit

Lever (2)

2.3.2 Replacing parts in the OPC unit

OPC Unit

1 July 1994

PM cycle: Every 400K clean: The OPC back cleaning pad, all rollers, OPC sensor, and quenching lamp filter. Every 800K: Lubricate the tracking sliders, and check the timing belt tension.

1. Remove the OPC belt by following the procedure

on the preceding page. Keep the OPC belt in its case.

2. Clean each part as follows:

Cleaning pad Wipe with a cloth damp with alcohol. Reverse

Drive and driven rollers

OPC sensor Blower brush

Replacing the quenching lamp

if it becomes dirty. Wipe with a dry cloth. Never use either,

toluene or another organic cleaning solvent.

PM cycle: Clean the lamp filter every 400K

1. Remove the OPC belt.

2. Pull down the two lamp connectors.

3. Remove two screws to remove the lamp fixing

bracket.

4. Remove three screws to remove the lamp filter.

5. Remove and replace the quenching lamp.

OPC belt

Packing case

Lamp fixing bracket

Quenching lamp

Lamp connector

Lamp filter

Removing the OPC unit

1. Remove the OPC belt.

2. From the back of the OPC unit, while holding down

the lock pawl with your fingers, pull out the OPC unit.

3. Erect the unit on the floor with the far side down.

WARNING

• Do not hold the frame and stays inside the unit

when you pull out it. Their edges are very sharp.

• If the slide guides keep slid out, it is dangerous

during working. Set the release lever on the far side of the rail parallel, and put slide guide on the main body side.

CAUTION

To reinstall the OPC unit, bring the roller bearing unit inside the slide guide to the front end of the rail. If the roller baring unit is kept on the far side, the roller bearings may drop when the unit is inserted.

Lock pawl

Release lever

2-28

Replacing the development backup roller

1 July 1994

OPC Unit

1. Remove the OPC unit.

2. Turn the lever to apply tension to the development

backup rollers.

3. While holding down the backup rollers with your

hand, set free the release hook.

Lever

Development backup roller

4. Remove the roller unit.

5. Replace the rollers.

CAUTION

If the backup rollers are changed or the arrangement of the three rollers are changed, this may affect the PG (Photoconductor Gap). Check copy image, and adjust the development motor speed if necessary (see Development unit section for the adjustment).

Release hook

Backup roller unit

2-29

Replacing the sector sensor and tracking motor

OPC Unit

1 July 1994

Fixing bracket

1. Remove two screws to remove the tracking motor

fixing bracket.

2. Remove two screws to replace the motor and

remove one screw to replace the sector sensor.

Replacing the quenching lamp stabilizer

1. Remove three screws to remove the QL stabilizer.

Lubricating the tracking slider

PM cycle: Lubricate every 800K

1. Lubricate the moving parts (front and rear of the

OPC unit) using G-40M.

Tracking motor

Sector sensor

QL stabilizer

Tracking slider

Replacing the OPC motor and timing belt

PM cycle: Check tension of the timing belt every 800K

1. Remove two screws to remove the motor.

2. When the motor is removed, the drive belt can be

also replaced.

Belt tension standard

Adjust by moving the OPC motor.

2 mm deflection at 200 ± 50 g pressure.

2 mm

OPC motor

OPC sensor

Drive roller

Drive belt

Set screw

200 ± 50 g

2-30

2.3.3 Cleaning the ground brush

1 July 1994

OPC Unit

PM cycle: Clean every 400K.

1. Pull out the OPC unit.

2. Wipe the ground brush at the front with a dry cloth.

3. Slightly pull out the development unit and turn the

development knob to collect the developer on the sleeves.

4. Pull out the development unit to clean the ground

brush at the rear.

2.3.4 Replacing the slide guide

Front ground brush

1. Remove the OPC unit.

2. Remove the stepped screw holding the slide guide.

3. Replace the slide guide.

CAUTION

Replace the slide guides as a set of the main body and OPC unit sides. If the fit is poor, the roller bearings inside the rail may get out of alignment when the unit is set.

Stepped screw

2-31

2.3.5 Adjusting the tracking amount

OPC Unit

1 July 1994

1. Access service tool [5-06].

2. Turn OPC motor ON.

3. Tracking from the front side to back side will start

displaying the transfer time on the screen. Tracking from the back to front then occurs.

4. If the transfer time is within the standard time, 60

sec. (120 sec. both ways), OK is displayed. If it is longer than the standard time, or if

there is a significant difference in the timing from one side to the other (more than 20 sec.), you will have to follow the adjustment procedure below.

5. If the interval from the front side to the back side is

too long, tighten the nut.

6. If the interval from the back side to the front side is

too long, loosen the nut.

7. Check the tracking time again. Leave the service

tool if it becomes OK.

2.3.6 Checking the tracking motor operation

OPC belt

Tracking adjusting nut

1. Access service tool [5-06].

2. Turn Tracking motor ON.

3. Read the measured and displayed tracking time.

4. The time is usually about 0.5 sec. If the time is 1

sec. or more, check the following items.

• Tracking motor damaged?

• Gears failing to mesh?

• Carrier sticking to worm gear?

• Slider lacks lubrication?

• Sector sensor defective?

2-32

2.4 Charge Corona Unit, Eraser, and Potential Sensor

1 July 1994

Charge Corona Unit, Eraser, and Potential Sensor

2.4.1 Replacing the charge corona wires and wire cleaners

PM cycle: Clean every 200K and replace every 400K.

1. Turn off the main switch. Open the front door, and

remove two screws to allow it to open further.

2. Remove the inner cover (2 screws and one

connector).

3. Disconnect the connector from the charge corona

unit, and pull out the unit.

4. Remove the motor cover from the charge corona

unit.

5. Remove four screws to remove the cleaner unit.

6. Remove the two flat head screws to remove the

wire cleaners.

7. Clean the grid wires, end blocks, and casing.

8. Clean or replace the charge corona wires, corona

wire cleaner, and grid wire cleaner.

CAUTION

• Every 200K use a cloth damped with water

to clean the casing. Use a dry cloth to clean the corona wires.

• The corona wire joint should be in the end

block and the wire should be in the L groove corner.

• To prevent breaking the corona wire, turn

the screw shaft by hand and fit the cleaner bracket with the front end block. Then, install the wire cleaners and cleaner unit.

• Pay attention to the fitting direction of the

wire cleaner.

Cleaner unit

Motor cover

Grid wire cleaner

Corona wire cleaner

Cleaning motor

Flat head screw

Cleaner bracket

Corona wire cleaner

Screw shaft

Corona wire cleaner

End block

L groove

Cleaner bracket

9. Reassemble in the reverse order of disassembly.

10. Check the copy image. Loose the height fixing

screws and turn the cam to adjust the position of the front side of the unit if there is difference in density between the front and rear of the copy image.

Height adjusting cam

2-33

Height fixing screw

2.4.2 Cleaning the eraser and potential sensor

Charge Corona Unit, Eraser, and Potential Sensor

1 July 1994

PM cycle: Clean every 200K

1. Turn off the main switch. Open the front door, and

remove two screws to allow it to open further.

2. Remove the inner cover (2 screws and one

connector)

3. Disconnect a connector from the eraser blower.

4. Remove one screw to remove the eraser blower.

5. Pull out the eraser and wipe it off with a damp

cloth.

6. Pull the sensor connector out of the potential

control board.

7. Pull out the potential sensor and clean it.

CAUTION

Blow air to remove toner and dust from the electrode. To prevent clogging or jamming, do not use a rag.

8. Assemble in the reverse order of disassembly.

NOTE

Potential sensor

Clear by blowing air

The copy image density may change slightly after the potential sensor is replaced because the read potential value may differ slightly from the old sensor. Check data in the [4-02] screen after replacing it.

2.4.3 Checking the potential sensor

1. In the copy stand-by condition, measure the voltage between TP6 and TP1 (Ground) on the

interface board. If it is between 1.99 and 2.01 volts, the sensor B is normal. (If the sensor is

defective, it will be 7 to 9 volts or 0 volt.)

2. To turn on the sensor A, short connector CP2-2 and CP2-3 (Ground) on the potential control

board. Otherwise, select "Lamp/Sol" in service tool [5-04] and press "VD Sensor" key. Fol-

low the same procedure as the above to check the sensor A.

2-34

2.5 Transfer/Separation Corona Unit and Transport Unit

1 July 1994

Transfer/Separation Corona Unit and Transport Unit

2.5.1 Replacing the transfer and separation corona wires

PM cycle: Clean every 200K and replace the corona wires every 400K. Replace the receptacle and its two springs on the corona unit every 1,200K.

1. Turn off the main switch and open the front door.

2. Remove the screws to remove the knob (C) of the

transport unit.

3. Pull out the T/S corona unit.

4. Pull out the covers at the front and rear, and

remove the separation guides. Clean every 600K.

5. Replace or clean the corona wires with a cloth

damp with water. Also, clean the end blocks and casing.

6. Put anti-vibration rings in new wires and assemble

in the reverse order.

7. Replace the receptacle and its two springs on the

corona unit as required.

CAUTION

• Every 200K use a cloth damped with water

to clean the casing. Use a dry cloth to clean the corona wires.

• The corona wire has no directional

requirements but the anti-vibration ring should be in the space of the end block.

• The wire should be put in the L groove

corner of the end block.

Anti-vibration ring

Spring

Separation guide

Receptacle

Front end block cover

2-35

2.5.2 Replacing parts in the transport unit

Transfer/Separation Corona Unit and Transport Unit

1 July 1994

Removing the transport unit

1. Pull out first paper tray.

2. Turn off the main switch, and open the front and

upper right doors.

3. Remove each inner cover from the fusing, upper

vertical transport, and transport units.

4. Pull out the connector of the transport unit.

5. Shift the transport unit to the right.

6. Loosen the fixing screw of the mounting and

dismounting arm, and hook the arm on the pin.

7. Remove one screw fixing the transport unit.

8. Draw the fusing unit and pull out the transport unit.

CAUTION

Carefully pull out the unit so that the casing of the T/S corona unit is not brought in contact with rollers and pressure springs of the vertical transport unit.

Removing the vacuum unit

Drive joint

Fixing screw

Unit fixing screw

Connector

Mounting and dismounting arm

PM cycle: Clean the fusing entrance guide plate every 200K

1. Remove three screws (two on the front and one on

the far side) fixing the vacuum unit.

2. Slide the vacuum unit to the front to disengage the

drive joint.

3. Disconnect the connector from the separation

sensor.

4. Remove the unit and clean the fusing entrance

guide plate on the main body side. If the unit is not removed every 200K, remove the fusing unit and clean it from the top.

Transport belt

Fixing screw

Connector for separation sensor

2-36

Replacing the transport belt and roller

1 July 1994

Transfer/Separation Corona Unit and Transport Unit

PM cycle: Clean every 600K

1. Pull the joint side of the transport roller and slide

the roller.

2. Move the transport roller to the underside of the

guide plate.

3. Replace the transport belts and assemble them in

the reverse order.

NOTE

Drive the transport roller by hand and check that the transport belts are not put aside and rotate smoothly.

Transport belt

Transport roller

Joint

Replacing the separation sensor

1. Remove the transport belts.

2. Remove four screws to divide the transport guide

plate into upper and lower parts.

3. Replace the separation sensor and assemble in

the reverse order.

Replacing the transfer and separation power pack

1. Remove the transport unit and place it up side

down. Remove three screws to remove the power pack inner cover.

2. Pull out the power pack connector.

3. Disconnect the ground wire.

4. Remove the cord clamp and disconnect the cord

terminals.

5. Remove three screws to remove the power pack

and assemble in the reverse order.

Separation sensor

Power pack inner cover

Ground wire

Power pack

2-37

2.5.3 Replacing the transfer entrance guide mylar

Transfer/Separation Corona Unit and Transport Unit

1 July 1994

PM cycle: Replace every 800K

1. Measure the length between the leading edge of

the mylar and the corona unit casing as shown.

2. Replace the mylar and its bracket with new ones

(2 pan head screws).

3. Loosen the 2 flat head screws (mylar position

fixing screws) and turn the adjusting knobs so that the length between the mylar and corona unit casing becomes the same as the old one’s.

NOTE

The clearance between the mylar and OPC belt is

1.45 ± 0.1 mm when fitted to the main body. Note that transport trouble, irregular transfer, etc. may occur when the value changes.

4. If the whole T/S corona unit is replaced, adjust the

mylar position as follows: (1) Loosen the 2 flat head screws (mylar

position fixing screws) and install the T/S corona unit in the machine.

(2) Using the tracking motor ON key on the service tool [5-06], move down the front side of the tracking rollers. The OPC surface comes close to the leading edge of the transfer entrance guide mylar.

(3) Turn the front side of the adjusting knob so that the leading edge of the mylar is just in contact with the OPC surface.

(4) Remove the T/S corona unit.

OPC belt

Adjusting knob

Measuring

Front adjusting knob

(5) Turn the rear side of the adjusting knob to level the front and rear of the leading edge of the mylar. To do so, refer to the edge of the corona unit casing as shown.

(6) Turn the front and rear adjusting knobs 28 notches (2 turns) and 3 notches counter clockwise. Then, turn them 2 notches clockwise and tighten the mylar position fixing screws. (One notch turn of the knob moves the mylar 0.05 mm.)

NOTE

If the mylar position is not proper, an insufficient image transfer may occur on the leading edge of copies (blank or faint image).

Rear adjusting knob

2-38

2.6 Cleaning Unit

1 July 1994

Cleaning Unit

CAUTION

When you pull out the cleaning unit and turn the cleaning knob, toner will fall from the toner exit pipe of the unit. When you do this, place a sheet under the toner exit pipe to prevent the OPC unit from becoming dirty by toner.

2.6.1 Replacing the cleaning carrier

PM cycle: Replace every 400K

Cleaning unit fixing screw

Cleaning knob

1. Turn off the main switch. Open the front door, and

remove 2 screws to allow it to open further.

2. Remove the inner cover (2 screws and one

connector).

3. Remove the cleaning unit fixing screw.

4. Turn the lever to release the cleaning backup roller

of the OPC unit.

5. Grasp the knob of the cleaning unit and pull it out.

6. Put the cleaning carrier collecting vessel on the

bottom of the unit. Set its lever to the carrier collecting position to erect the rubber blade.

Cleaning carrier collecting vessel

lever

7. Loosen the main pole adjusting plate fixing screw

(gold screw) and move the main pole adjusting plate to the carrier collecting side.

CAUTION

Remember the position of the main pole adjusting plate. This position is sometimes different from one machine to another.

8. Turn the cleaning knob toward the arrow and

collect the cleaning carrier.

9. Remove the cleaning filter cover (4 screws), and

clean the inside from the above using the carrier collecting magnet.

10. Return the main pole adjusting plate to its original

position. Tighten the gold screw.

Cleaning roller gear

Main pole adjusting plate

Carrier collecting direction

2-39

Original position

Main pole position decal

Gold screw

11. Put one bag of cleaning carrier in the right side

Cleaning Unit

1 July 1994

spread evenly.

CAUTION

Never put in cleaning carrier on the left side (scavenging roller side).

12. Turn the cleaning knob to circulate the cleaning

carrier evenly on the cleaning roller.

NOTE

The cleaning unit has no agitation mechanism like as the development unit.

13. Assemble in the reverse order.

14. Turn on the main switch and wait for the copy

stand-by.

15. Access service tool [3-04] and perform the

cleaning carrier forming. At the same time, reset the supply yield counter for the cleaning carrier to

2.6.2 Replacing the air filters

Cleaning filter cover

Cleaning knob

Cleaning carrier

PM cycle: Rotate between left and right every 200K. Replace every 400K.

1. Slide out the cleaning unit.

2. Remove the filter cases (2 screws).

3. Rotate the filter right to left, or replace them.

CAUTION

The filters have a setting direction. Be sure that the side with a red line on the edge is facing the inside of the unit.

2.6.3 Replacing the scavenging blade

PM cycle: Inspect every 200K. Replace every 600K.

1. Slide out the cleaning unit, and remove cleaning

filter cover.

2. Remove the blade bracket (3 screws).

3. To replace the blade, remove the blade support

plate (4 screws).

NOTE

Projection

Hole

Scavenging blade

Blade bracket

Blade support plate

Filter case

Air filter

• Align the holes of the scavenging blade with

the projections of the blade support plate.

• If the blade is dirty, clean it with alcohol.

2-40

2.6.4 Replacing the scavenging roller

1 July 1994

Cleaning Unit

PM cycle: Inspect every 200K. Replace every 600K.

1. Remove the unit fixing screw and slide out the

cleaning unit.

2. Remove the filter cover, and remove the cleaning

carrier.

3. Remove the cleaning knob with the E-ring.

4. Remove the E-ring and drive gear from the

scavenging roller shaft.

5. Remove the other E-ring from the shaft, then take

off the two screws to remove the bearing case. Pull out the scavenging roller to replace it if required.

NOTE

If the scavenging roller is dirty, clean it.

6. Wipe off the internal air guide mylar with a dry

cloth.

7. Assemble in the reverse order.

NOTE

• Do not remove the doctor blade. If it is

removed, adjust the doctor gap to 2 ± 0.15 mm after the cleaning carrier is cleaned from between the doctor blade and the cleaning roller, after the unit is divided into two parts. (See Replacing the cleaning roller section)

• Clean the area near the scavenging roller

bearing thoroughly to remove any remaining cleaning carrier.

Scavenging roller

Bearing case

Doctor blade

Cleaning knob

Drive gear

Cleaning roller

2-41

2.6.5 Replacing the PCC wire

Cleaning Unit

1 July 1994

PM cycle: Clean every 200K. Replace every 400K.

1. Remove the PCC corona unit fixing screw on the

cleaning unit and pull out the unit.

2. Remove the end block covers (front and rear).

3. Clean the PCC wire and casing, or replace the

PCC wire if required.

4. Assemble in the reverse order.

CAUTION

• Every 200K use a cloth damped with water

to clean the casing. Use a dry cloth to clean the corona wire.

• Check and be sure that the wire on the far

side is in the V-groove of the end block.

• Height adjustment is possible on this side

but is normally not done. Adjust to height

of 10 ±1 mm if the end block is replaced.

2.6.6 Removing the cleaning unit

Rear end block cover

PCC wire

Front end block cover

1. Remove the cleaning unit fixing screw, and slide

out the unit.

2. To pull the cleaning unit out of slide guide, pull the

cleaning unit while holding down the lock pawl.

CAUTION

• Because the slide guides have sharp edges,

keep them in the main body.

• Lay paper in place where the cleaning unit

is put. Be sure there is no metal debris present that can cause damage. Metal screws, paper clips, etc. attracted by the cleaning roller can scratch the roller and blade.

• Because the cleaning unit has no horizontal

agitating roller, do not tilt the unit when the cleaning carrier is in the unit.

• When the cleaning carrier is in the cleaning

unit, do not turn the unit up side down.

Slide guide

Lock pawl

2-42

2.6.7 Replacing the cleaning roller

1 July 1994

Cleaning Unit

1. Remove the cleaning carrier, then remove the unit.

2. Remove three screws to move the rear magnet

holder bracket together with the V-seal at the back of the unit.

3. Remove the C-ring, drive gear and V-seal. If too

tight, this can be done after dividing the unit casing.

V-seal

Drive gear

Rear magnet holder bracket

V-seal

4. Remove the front magnet holder bracket (4

screws) from the front of the unit, together with the main pole adjusting plate.

CAUTION

• Do not loosen the main pole adjusting plate

fixing screw (gold screw). If it needs to be loosened, remember the original position of the adjusting plate.

5. Remove the C-ring and the relay gear. It can be

done after dividing the unit casing if too tight.

Relay gear

Front magnet holder bracket

Main pole adjusting plate

2-43

6. Tilt the unit 90

Cleaning Unit

1 July 1994

the top.

so that the cleaning roller moves to

7. Disconnect the PCC power pack connector.

8. Remove the drawing rail (2 screw).

9. Divide the cleaning unit into two parts (4 screws).

10. Remove the front and rear bearings and bearing

cases (one C-ring each front and rear).

11. Remove the cleaning roller, and replace it.

12. Reassemble in the reverse order.

CAUTION

Drawing rail

Connecting screw

PCC power pack connector

Cleaning roller

Shaft

• Use a dry cloth to wipe and clean the inside.

• Confirm that the bias terminal board is in

close contact with the bearing case.

• Because the cleaning roller shaft moves, fit

the rear magnet holder bracket after the front magnet holder bracket is fitted.

• Take care that the two V-seals have the

different setting direction as shown.

• Use three M4 x 14 screws to fit the rear

magnet holder bracket. Gradually, tighten the three screws so that the inside V-seal just fits the cleaning roller shaft.

2.6.8 Replacing the slide guide

1. Remove the cleaning unit from the slide guides.

2. Remove the stepped screw from the front side and

replace the slide guide on the main body side.

3. Replace the guides as a pair on the main body

side, and on the cleaning unit side in the same way as the slide guide of the OPC unit. This is because the roller bearing inside the rail may come out of place when the unit is set.

M4 x 14 (3)

V-seal

2-44

2.6.9 Replacing the PCC power pack

1 July 1994

Cleaning Unit

1. Pull out the cleaning unit.

2. Take off the two power pack fitting screws.

3. Remove ground wire fixing screw, and disconnect

the connector and harness.

2.6.10 Checking the cleaning and scavenging bias

1. Pull out the cleaning unit.

2. Remove the varistor.

NOTE

PCC power pack

Power pack fitting screw

Although the cleaning power pack is a constant current type, the varistor makes the bias voltage to the cleaning roller constant. Removing the varistor allows for adjusting the amperage.

3. Remove the rear left cover and set an ammeter to

the cleaning power pack as shown.

NOTE

To measure the cleaning roller side, disconnect the wire from the "CL" terminal (indicated on the power pack). Then, set an ammeter between the wire connector and terminal. To measure the scavenging roller side, use the "S" terminal.

WARNING

When the main switch is ON, never touch anything inside the rear left cover to avoid possible injuries.

4. Turn on the main switch. After the copier enters

the stand-by condition, access the service tools.

5. Select [5-04] "I/O Test". Press the "Motor" key,

then press the "Main" and "OPC" keys. Press the "Lamp/Sol" key, then press the "QL" key.

NOTE

This procedure is necessary to avoid OPC deterioration.

CL S

Varistor

Cleaning power pack

Ammeter

2-45

6. Press the "P. Pack 2" key, then press the

Cleaning Unit

1 July 1994

"Cleaning Bias" key to measure the amperage. It must be --20 ± 0.5 µA.

7. Set an ammeter to the "S" terminal side, then

press the "Scav. Bias" key. The amperage must be

--10 ± 0.5 µA.

8. If the values do not meet the standards, adjust the

amperage by turning the VR above each terminal.

Standards

Cleaning Bias --20 ± 0.5 µA Scavenging Bias --10 ± 0.5 µA

Scavenging roller

Carrier (R1)

Cleaning roller

NOTE

When both the "Cleaning Bias" and "Scav. Bias" keys are ON, both amperages become --10 µA. Therefore, if the cleaning bias is measured while in a copy run, be sure to disconnect the scavenging bias terminal from the power pack.

SW1 in the middle figure to the right represents the "Scav. Bias" key and SW2 represents the "Cleaning Bias" key.

Ammeter

SW1

Carrier

SW2

OPC

Cleaning power pack

20µA -- 10µA = 10µA

2-46

10µA

20µA

When both SW1 and SW2 are turned on.

2.7 OPC Cleaning Unit

1 July 1994

OPC Cleaning Unit

2.7.1 Replacing the OPC cleaning brush

PM cycle: Replace the brush roller and lubricate the gear every 600K. Clean the brush fibers scattered inside and around the unit using a vacuum cleaner every 600K.

1. Turn off the main switch.

2. Open the front door. Remove two screws to allow

it to open further.

3. Pull out the 2P connector for the oscillating motor.

4. Remove the OPC cleaning unit fixing screw.

5. Pull out the OPC cleaning unit.

6. Remove the oscillating motor assembly (3 screws).

7. Remove the brush roller set screw.

8. Pull the brush roller drive joint toward the front and

pull out the brush roller.

9. Replace the brush roller and assemble it in the

reverse order.

CAUTION

Give the oscillating gear and its groove (including the pin) a thin coat of grease (G-40M) every 600K.

NOTE

Unit fixing screw

Brush roller set screw

Oscillating motor assembly

Drive joint

2P connector for oscillating motor

Brush roller

If the scattered brush fibers are not cleaned every 600K copies, the transfer or separation corona leakage tends to occur.

2.7.2 Replacing the oscillating motor

1. Remove the oscillating motor assembly.

2. Remove the gear cover (one screw).

3. Remove the oscillating gear (one Allen screw).

4. Remove the motor support plate (2 screws).

5. Remove the oscillating motor (2 screws) and

replace the motor.

6. Reassemble in the reverse order.

Motor gear

Gear cover

Fixing screws (3)

Oscillating motor assembly

Motor support plate

Oscillating motor

2-47

2.7.3 Replacing the OPC cleaning brush motor

OPC Cleaning Unit

1 July 1994

1. Turn off the main switch, and remove the rear left

cover (2 screws).

2. Remove the power cord clamp bracket (2 screws).

3. Remove the terminal block (2 screws).

4. To access the four screws securing the drive unit,

remove the arrester board with its bracket (2 screws).

5. Remove the OPC cleaning brush drive unit (four

M5 screws).

6. Remove the OPC cleaning brush motor (4 screws)

and replace the motor.

OPC cleaning brush motor

7. Reassemble in the reverse order.

2.7.4 Replacing the OPC cleaning brush pressure solenoid

OPC cleaning brush drive unit

Power cord clamp bracket

Terminalblock

1. Remove the OPC cleaning brush drive unit.

2. Remove the solenoid plunger (one E-ring).

3. Mark off the position of the OPC cleaning brush

pressure solenoid. Remove the solenoid (2 screws) and replace it.

4. Reassemble in the reverse order.

2.7.5 Replacing the OPC cleaning brush drive solenoid

1. Remove the OPC cleaning brush drive unit.

2. Mark the position of the OPC cleaning brush drive

solenoid, and remove the solenoid (2 screws).

3. Remove the plunger spring and replace the

solenoid.

4. Reassemble in the reverse order.

NOTE

OPC cleaning brush pressure solenoid

Lightly press down the OPC cleaning brush drive solenoid, and fix it when the plunger stroke comes to between 6.5 and 7.0 mm.

OPC cleaning brush drive solenoid

2-48

Plunger spring

2.8 Development Unit

1 July 1994

Development Unit

2.8.1 Replacing the developer and air filter

PM cycle: Replace the developer every 400K and air filter every 200K.

CAUTION

When you use a vacuum cleaner to clean the development unit, heavy electrostatic will occur. To avoid damage of electrical parts, be sure to do the following:

• Pull out the toner density control board.

• Disconnect the harness from the ID sensor

board and ground the board using the development unit grounding harness (main body’s accessory).

1. Turn off the main switch.

2. Open the front door, and remove two screws to

allow it to open further.

3. Remove the inner cover (2 screws and one

connector).

4. Turn the lever and release the development

backup roller of the OPC unit.

5. Remove the development unit fixing bracket (one

screw). Then, slightly pull out the unit to disengage the joint gear at the rear of the unit.

6. Turn the development knob to collect developer

from the development sleeves.

CAUTION

Fixing bracket

If you do not collect the developer, it might scatter or damage the OPC.

7. Slide out the development unit.

8. Put the developer collecting vessel under the unit,

and lay a vinyl sheet (developer’s accessory) on the collecting vessel.

9. Remove the developer collecting shutter fixing

screw and pull out the shutter.

10. To dump all the developer, turn the development

knob in the direction of the arrow.

11. Clean the developer collecting shutter using a dry

cloth.

12. Clean the side seals of the development unit.

NOTE

Clean the side seals every 200K to remove toner and paper dust. Replace the side seals if they are warped, or if there is a contact failure.

Side seal

Vinyl sheet

Developer collecting vessel

Developer collecting shutter

Development knob

2-49

Ricoh FT9101 Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

HEALTH SAFETY CONDITIONS

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1 July 1994 Installation Requirements

1 July 1994 Copier Installation

1 July 1994 Machine Operation Check

1 July 1994 Table of Image Quality Standards

User Guidance Items 1 July 1994

1 July 1994 Setting User and Service Tools

LCT Installation

Finisher Installation

Printer Installation

Paper Feed

Removing paper feed unit

Checking the unit

Replacing the torque limiter

Replacing the pick-up solenoid

Optics

Removing the shield unit

Replacing the shield motor

Replacing the shield screen

Adjusting belt tension

Adjusting the shield screen position

OPC Unit

Replacing the quenching lamp

Removing the OPC unit

Replacing the development backup roller

Replacing the sector sensor and tracking motor

Replacing the quenching lamp stabilizer

Replacing the OPC motor and timing belt

Charge Corona Unit, Eraser, and Potential Sensor

Transfer/Separation Corona Unit and Transport Unit

Removing the transport unit

Removing the vacuum unit

Replacing the transport belt and roller

Replacing the separation sensor

Replacing the transfer and separation power pack

Cleaning Unit

OPC Cleaning Unit

Development Unit