Ricoh K-C1 Service Manual

Model K-C1

(Machine Code: B039/B040/B043)

SERVICE MANUAL

February 20th, 2001

Subject to change

!IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

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

4.If a job has started before the copier completes the warm-up or initializing period, keep hands away from the mechanical and electrical components because the starts making copies as soon as the warm-up period is completed.

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

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

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

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

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

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

LASER SAFETY

The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.

!WARNING

Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

!WARNING FOR LASER UNIT

WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes.

CAUTION MARKING:

Symbols and Abbreviations

This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations are as follows:

See or Refer to

! Clip ring

" Screw

#Connector

SEF	Short Edge Feed
LEF	Long Edge Feed

TABLE OF CONTENTS

1 INSTALLATION ...........................................................................		1-1
1.1	INSTALLATION REQUIREMENTS ...........................................................	1-1
	1.1.1 ENVIRONMENT ...............................................................................	1-1
	1.1.2 MACHINE LEVEL.............................................................................	1-2
	1.1.3 MINIMUM SPACE REQUIREMENTS...............................................	1-3
	1.1.4 POWER REQUIREMENTS ..............................................................	1-3
1.2	COPIER INSTALLATION ..........................................................................	1-4
	1.2.1 POWER SOCKETS FOR PERIPHERALS .......................................	1-4
	1.2.2 ACCESSORY CHECK......................................................................	1-4
	1.2.3 INSTALLATION PROCEDURE ........................................................	1-5
1.3	PLATEN COVER INSTALLATION ............................................................	1-8
	1.3.1 ACCESSORY CHECK......................................................................	1-8
	1.3.2 INSTALLATION PROCEDURE ........................................................	1-8
1.4	ARDF INSTALLATION ..............................................................................	1-9
	1.4.1 ACCESSORY CHECK......................................................................	1-9
	1.4.2 INSTALLATION PROCEDURE ........................................................	1-9
1.5	ADF INSTALLATION...............................................................................	1-11
	1.5.1 ACCESSORY CHECK....................................................................	1-11
	1.5.2 INSTALLATION PROCEDURE ......................................................	1-11
1.6	TWO-TRAY PAPER TRAY UNIT INSTALLATION ..................................	1-13
	1.6.1 ACCESSORY CHECK....................................................................	1-13
	1.6.2 INSTALLATION PROCEDURE ......................................................	1-13
1.7	ONE-TRAY PAPER TRAY UNIT INSTALLATION...................................	1-16
	1.7.1 ACCESSORY CHECK....................................................................	1-16
	1.7.2 INSTALLATION PROCEDURE ......................................................	1-16
1.8	IMB INSTALLATION................................................................................	1-19
	1.8.1 ACCESSORY CHECK....................................................................	1-19
	1.8.2 INSTALLATION PROCEDURE ......................................................	1-19
1.9	DRAM INSTALLATION ...........................................................................	1-20
1.10 ANTI-CONDENSATION HEATER INSTALLATION ..............................		1-21
1.11 TRAY HEATERS ...................................................................................		1-22
	1.11.1 UPPER TRAY HEATER ...............................................................	1-22
	1.11.2 LOWER TRAY HEATER (TWO-TRAY MODEL ONLY)................	1-23
	1.11.3 TRAY HEATERS FOR THE OPTIONAL PAPER FEED UNITS ...	1-24
1.12 KEY COUNTER INSTALLATION ..........................................................		1-27

2	PREVENTIVE MAINTENANCE SCHEDULES .............................		2-1
	2.1	PM TABLES ..............................................................................................	2-1
	2.2	HOW TO CLEAR THE PM COUNTER......................................................	2-3
3	REPLACEMENT AND ADJUSTMENT.........................................		3-1
	3.1	GENERAL CAUTIONS..............................................................................	3-1
		3.1.1 PCU (PHOTOCONDUCTOR UNIT) .................................................	3-1
		3.1.2 TRANSFER ROLLER .......................................................................	3-1
		3.1.3 SCANNER UNIT...............................................................................	3-1

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3.1.4 LASER UNIT ....................................................................................	3-2
3.1.5 FUSING UNIT...................................................................................	3-2
3.1.6 PAPER FEED...................................................................................	3-2
3.1.7 IMPORTANT ....................................................................................	3-2
3.2 SPECIAL TOOLS AND LUBRICANTS ......................................................	3-2
3.3 EXTERIOR COVERS & OPERATION PANEL..........................................	3-3
3.3.1 REAR COVER..................................................................................	3-3
3.3.2 REAR LOWER COVER (TWO-TRAY MODELS ONLY)...................	3-3
3.3.3 COPY TRAY.....................................................................................	3-4
3.3.4 LEFT UPPER COVER......................................................................	3-4
3.3.5 FRONT UPPER LEFT COVER AND OPERATION PANEL .............	3-4
3.3.6 RIGHT UPPER COVER ...................................................................	3-4
3.3.7 TOP REAR COVER..........................................................................	3-4
3.3.8 LEFT COVER ...................................................................................	3-5
3.3.9 FRONT LONG COVER ....................................................................	3-5
3.3.10 FRONT RIGHT COVER .................................................................	3-6
3.3.11 RIGHT REAR COVER....................................................................	3-6
3.3.12 RIGHT DOOR.................................................................................	3-7
3.3.13 BY-PASS TRAY..............................................................................	3-8
3.3.14 LEFT LOWER COVER (TWO-TRAY MODELS ONLY)..................	3-9
3.3.15 RIGHT LOWER COVER (TWO-TRAY MODELS ONLY) ...............	3-9
3.3.16 PLATEN COVER SENSOR............................................................	3-9
3.4 SCANNER SECTION ..............................................................................	3-10
3.4.1 EXPOSURE GLASS/DF EXPOSURE GLASS ...............................	3-10
Exposure Glass ..................................................................................	3-10
DF Exposure Glass.............................................................................	3-10
3.4.2 LENS BLOCK .................................................................................	3-11
3.4.3 EXPOSURE LAMP, LAMP STABILIZER BOARD ..........................	3-11
3.4.4 ORIGINAL WIDTH SENSOR..........................................................	3-12
3.4.5 ORIGINAL LENGTH SENSOR.......................................................	3-12
Sensor Positions.................................................................................	3-12
3.4.6 CHANGING THE ORIGINAL SENSOR POSITIONS (8K/16K) ......	3-13
Procedure ...........................................................................................	3-14
3.4.7 SCANNER MOTOR........................................................................	3-15
3.4.8 SCANNER H.P. SENSOR ..............................................................	3-15
3.4.9 ADJUSTMENT OF 2ND SCANNER POSITION.............................	3-16
3.4.10 ADJUSTMENT OF 1ST AND 2ND SCANNER ALIGNMENT .......	3-17
3.5 LASER UNIT ...........................................................................................	3-18
3.5.1 LOCATION OF “CAUTION” DECAL...............................................	3-18
3.5.2 TONER SHIELD GLASS ................................................................	3-19
3.5.3 LASER UNIT ..................................................................................	3-19
3.5.4 LD UNIT..........................................................................................	3-20
3.5.5 POLYGONAL MIRROR MOTOR....................................................	3-20
3.5.6 LASER UNIT ALIGNMENT ADJUSTMENT....................................	3-21
3.6 PCU SECTION ........................................................................................	3-22
3.6.1 PCU ................................................................................................	3-22
3.6.2 PICK-OFF PAWLS .........................................................................	3-22
3.6.3 TONER DENSITY SENSOR ..........................................................	3-22
3.6.4 OPC DRUM ....................................................................................	3-23

ii

3.6.5 CHARGE ROLLER AND CLEANING BRUSH................................	3-24
3.6.6 CLEANING BLADE.........................................................................	3-24
3.6.7 DEVELOPER..................................................................................	3-25
3.6.8 AFTER REPLACEMENT OR ADJUSTMENT.................................	3-26
3.7 TONER SUPPLY MOTOR ......................................................................	3-27
3.8 PAPER FEED SECTION.........................................................................	3-28
3.8.1 PAPER FEED ROLLER..................................................................	3-28
3.8.2 FRICTION PAD ..............................................................................	3-28
3.8.3 PAPER END SENSOR...................................................................	3-28
3.8.4 EXIT SENSOR ...............................................................................	3-29
Non-duplex Models.............................................................................	3-29
Duplex Models ....................................................................................	3-29
3.8.5 BY-PASS FEED ROLLER AND
BY-PASS PAPER END SENSOR ..................................................	3-30
3.8.6 REGISTRATION ROLLER .............................................................	3-31
3.8.7 BY-PASS PAPER SIZE SENSOR..................................................	3-32
3.8.8 REGISTRATION CLUTCH .............................................................	3-32
3.8.9 REGISTRATION SENSOR.............................................................	3-33
3.8.10 UPPER PAPER FEED CLUTCH AND
BY-PASS FEED CLUTCH ............................................................	3-33
3.8.11 RELAY CLUTCH ..........................................................................	3-34
3.8.12 RELAY SENSOR..........................................................................	3-34
3.8.13 LOWER PAPER FEED CLUTCH
(TWO-TRAY MODELS ONLY) .....................................................	3-34
3.8.14 VERTICAL TRANSPORT SENSOR
(TWO-TRAY MODELS ONLY) .....................................................	3-35
3.8.15 PAPER SIZE SWITCH .................................................................	3-35
3.9 IMAGE TRANSFER.................................................................................	3-36
3.9.1 IMAGE TRANSFER ROLLER ........................................................	3-36
3.9.2 IMAGE DENSITY SENSOR ...........................................................	3-36
3.10 FUSING.................................................................................................	3-37
3.10.1 FUSING UNIT...............................................................................	3-37
3.10.2 THERMISTOR..............................................................................	3-37
3.10.3 FUSING LAMP .............................................................................	3-38
3.10.4 HOT ROLLER...............................................................................	3-38
3.10.5 THERMOFUSE AND THERMOSTAT ..........................................	3-39
3.10.6 HOT ROLLER STRIPPER PAWLS ..............................................	3-39
3.10.7 PRESSURE ROLLER AND BUSHINGS ......................................	3-40
3.10.8 NIP BAND WIDTH ADJUSTMENT ...............................................	3-41
3.11 DUPLEX UNIT (DUPLEX MODELS ONLY) ..........................................	3-42
3.11.1 DUPLEX EXIT SENSOR ..............................................................	3-42
3.11.2 DUPLEX ENTRANCE SENSOR ..................................................	3-42
3.11.3 DUPLEX INVERTER SENSOR ....................................................	3-42
3.11.4 DUPLEX TRANSPORT MOTOR..................................................	3-43
3.11.5 DUPLEX INVERTER MOTOR......................................................	3-43
3.11.6 DUPLEX CONTROL BOARD .......................................................	3-43
3.12 OTHER REPLACEMENTS....................................................................	3-44
3.12.1 QUENCHING LAMP .....................................................................	3-44
3.12.2 HIGH-VOLTAGE POWER SUPPLY BOARD ...............................	3-44

iii

3.12.3 IMB (MEMORY BOARD) ..............................................................	3-45
3.12.4 BICU (BASE-ENGINE IMAGE CONTROL UNIT).........................	3-45
3.12.5 IOB (I/O BOARD)..........................................................................	3-46
3.12.6 MAIN MOTOR ..............................................................................	3-46
3.12.7 REAR EXHAUST FAN..................................................................	3-46
3.12.8 LEFT EXHAUST FAN...................................................................	3-47
3.12.9 PSU (POWER SUPPLY UNIT).....................................................	3-47
3.12.10 GEARBOX..................................................................................	3-48
Replacement Procedure .....................................................................	3-48
Gear Arrangement Within the Gearbox...............................................	3-49
3.13 COPY ADJUSTMENTS: PRINTING/SCANNING ..................................	3-50
3.13.1 PRINTING ....................................................................................	3-50
Registration - Leading Edge/Side-to-Side...........................................	3-50
Blank Margin.......................................................................................	3-51
Main Scan Magnification.....................................................................	3-51
3.13.2 SCANNING...................................................................................	3-52
Registration: Platen Mode...................................................................	3-52
Magnification.......................................................................................	3-53
Standard White Density Adjustment ...................................................	3-54
3.13.3 ADF IMAGE ADJUSTMENT.........................................................	3-55
Registration and Blank Margin............................................................	3-55
Sub-scan Magnification.......................................................................	3-55

4 TROUBLESHOOTING .................................................................			4-1
4.1	SERVICE CALL CONDITIONS .................................................................		4-1
	4.1.1 SUMMARY .......................................................................................		4-1
	4.1.2 SC CODE DESCRIPTIONS .............................................................		4-2
4.2	ELECTRICAL COMPONENT DEFECTS ..................................................		4-8
	4.2.1 SENSORS ........................................................................................		4-8
	4.2.2 SWITCHES.......................................................................................		4-9
4.3	BLOWN FUSE CONDITIONS .................................................................		4-10
4.4	LED DISPLAY .........................................................................................		4-10
	4.4.1	BICU ...............................................................................................	4-10
	4.4.2	IOB .................................................................................................	4-10

5 SERVICE TABLES.......................................................................	5-1
5.1 USING SERVICE PROGRAM MODES.....................................................	5-1
Accessing SP Modes............................................................................	5-1
Accessing Copy Mode from within an SP Mode ...................................	5-1
How to Select a Program Number ........................................................	5-2
To Input a Value or Setting for an SP Mode .........................................	5-2
5.1.1 SP MODE TABLES ..........................................................................	5-3
SP1-XXX (Feed) ...................................................................................	5-3
SP2-XXX (Drum)...................................................................................	5-6
SP4-XXX (Scanner)............................................................................	5-11
SP5-XXX (Mode) ................................................................................	5-17
SP6-XXX (Peripherals) .......................................................................	5-24
SP7-XXX (Data Log)...........................................................................	5-26
5.1.2 TEST PATTERN PRINTING (SP5-902) .........................................	5-31

iv

5.1.3 INPUT CHECK (SP5-803) ..............................................................	5-32
5.1.4 OUTPUT CHECK (SP5-804) ..........................................................	5-36
Output Check Table............................................................................	5-36
5.1.5 COPY JAM HISTORY (SP7-903) ...................................................	5-37
5.1.6 SMC PRINTING (SP5-992) ............................................................	5-38
5.1.7 ORIGINAL JAM HISTORY DISPLAY (SP7-905) ............................	5-38
5.1.8 MEMORY ALL CLEAR (SP5-801)..................................................	5-39
Using a Flash Memory Card ...............................................................	5-39
Without Using a Flash Memory Card ..................................................	5-40
5.1.9 PROGRAM UPLOAD/DOWNLOAD ...............................................	5-41
Program Download (SP5-827)............................................................	5-41
Program Upload (SP5-826) ................................................................	5-42
5.1.10 NVRAM DATA UPLOAD/DOWNLOAD ........................................	5-43
NVRAM Data Download (SP5-825) ....................................................	5-43
NVRAM Data Upload (SP5-824).........................................................	5-44
5.1.11 APS AND PLATEN/ADF COVER SENSOR
OUTPUT DISPLAY (SP4-301) .....................................................	5-45
5.1.12 ADF APS SENSOR OUTPUT DISPLAY (SP6-901) .....................	5-46
5.1.13 SERIAL NUMBER INPUT (SP5-811) ...........................................	5-47
5.1.14 ID SENSOR ERROR ANALYSIS (SP2-221) ................................	5-48
5.2 USER TOOLS .........................................................................................	5-49
5.2.1 HOW TO ENTER AND EXIT USER TOOLS ..................................	5-49
5.2.2 USER TOOLS TABLE ....................................................................	5-49
System Setting Table..........................................................................	5-49
Copy Features Table ..........................................................................	5-50

6 DETAILED SECTION DESCRIPTIONS .......................................		6-1
6.1	OVERVIEW ...............................................................................................	6-1
	6.1.1 COMPONENT LAYOUT ...................................................................	6-1
	6.1.2 PAPER PATH...................................................................................	6-3
	6.1.3 DRIVE LAYOUT ...............................................................................	6-4
6.2	BOARD STRUCTURE...............................................................................	6-5
	6.2.1 BLOCK DIAGRAM............................................................................	6-5
	1. BiCU (Base Engine and Image Control Unit) ....................................	6-6
	2. IOB (I/O Board).................................................................................	6-6
	3. SBU (Sensor Board Unit)..................................................................	6-6
	4. IMB (IMAC and Memory Board)........................................................	6-6
6.3	COPY PROCESS OVERVIEW .................................................................	6-7
6.4	SCANNING................................................................................................	6-9
	6.4.1 OVERVIEW ......................................................................................	6-9
	Lamp Stabilizer Fuse ............................................................................	6-9
	6.4.2 SCANNER DRIVE ..........................................................................	6-10
	6.4.3 ORIGINAL SIZE DETECTION IN PLATEN MODE.........................	6-11
6.5	IMAGE PROCESSING ............................................................................	6-13
	6.5.1 OVERVIEW ....................................................................................	6-13
	6.5.2 SBU (SENSOR BOARD UNIT).......................................................	6-14
	6.5.3 AUTO IMAGE DENSITY (ADS)......................................................	6-15
	In the SBU ..........................................................................................	6-15
	In the IPU............................................................................................	6-15

v

By Original Type .................................................................................	6-15
6.5.4 IPU (IMAGE PROCESSING UNIT).................................................	6-16
Overview.............................................................................................	6-16
Image Processing Modes ...................................................................	6-17
Image Processing Path.......................................................................	6-18
Original Modes....................................................................................	6-19
SP Modes for Each Image Processing Step .......................................	6-19
Auto Shading ......................................................................................	6-21
White Line Erase ................................................................................	6-22
Black Line Erase.................................................................................	6-22
Scanner Gamma (γ) Correction ..........................................................	6-23
Main Scan Magnification.....................................................................	6-24
Mirroring for ADF Mode ......................................................................	6-24
Filtering ...............................................................................................	6-25
ID Gamma (γ) Correction ....................................................................	6-26
Gradation Processing .........................................................................	6-27
6.5.5 IMB (MEMORY CONTROLLER AND DRAM) ................................	6-28
6.5.6 VIDEO CONTROL UNIT (VCU)......................................................	6-29
Fine Character and Image (FCI) .........................................................	6-29
Printer Gamma Correction ..................................................................	6-29
6.6 LASER EXPOSURE................................................................................	6-30
6.6.1 OVERVIEW ....................................................................................	6-30
6.6.2 AUTO POWER CONTROL (APC)..................................................	6-31
6.6.3 LD SAFETY SWITCH .....................................................................	6-32
6.7 PHOTOCONDUCTOR UNIT (PCU) ........................................................	6-33
6.7.1 OVERVIEW ....................................................................................	6-33
6.7.2 DRIVE.............................................................................................	6-34
6.8 DRUM CHARGE .....................................................................................	6-35
6.8.1 OVERVIEW ....................................................................................	6-35
6.8.2 CHARGE ROLLER VOLTAGE CORRECTION ..............................	6-36
Correction for Environmental Conditions ............................................	6-36
6.8.3 ID SENSOR PATTERN PRODUCTION TIMING............................	6-37
6.8.4 DRUM CHARGE ROLLER CLEANING ..........................................	6-38
6.9 DEVELOPMENT .....................................................................................	6-39
6.9.1 OVERVIEW ....................................................................................	6-39
6.9.2 DRIVE.............................................................................................	6-40
6.9.3 DEVELOPER MIXING ....................................................................	6-40
6.9.4 DEVELOPMENT BIAS ...................................................................	6-41
6.9.5 TONER SUPPLY............................................................................	6-42
Toner Bottle Replenishment Mechanism ............................................	6-42
Toner Supply Mechanism ...................................................................	6-43
6.9.6 TONER DENSITY CONTROL ........................................................	6-44
Overview.............................................................................................	6-44
Toner Density Sensor Initial Setting....................................................	6-46
Toner Concentration Measurement ....................................................	6-46
Vsp/Vsg Detection ..............................................................................	6-46
Toner Supply Reference Voltage (Vref) Determination.......................	6-46
Toner Supply Determination ...............................................................	6-46
Toner Supply Motor On Time Determinations.....................................	6-47

vi

6.9.7 TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS...........	6-48
ID Sensor............................................................................................	6-48
TD Sensor...........................................................................................	6-48
6.9.8 TONER NEAR END/END DETECTION AND RECOVERY............	6-49
Toner Near End Detection ..................................................................	6-49
Toner Near End Recovery ..................................................................	6-49
Toner End Detection...........................................................................	6-49
Toner End Recovery ...........................................................................	6-49
6.10 DRUM CLEANING AND TONER RECYCLING.....................................	6-50
6.10.1 DRUM CLEANING........................................................................	6-50
6.10.2 TONER RECYCLING ...................................................................	6-50
6.11 PAPER FEED........................................................................................	6-51
6.11.1 OVERVIEW ..................................................................................	6-51
6.11.2 PAPER FEED DRIVE MECHANISM ............................................	6-52
6.11.3 PAPER FEED AND SEPARATION MECHANISM........................	6-52
6.11.4 PAPER LIFT MECHANISM ..........................................................	6-53
6.11.5 PAPER END DETECTION ...........................................................	6-53
6.11.6 PAPER SIZE DETECTION...........................................................	6-54
Paper Tray ..........................................................................................	6-54
By-pass Tray.......................................................................................	6-55
6.11.7 SIDE FENCES..............................................................................	6-56
6.11.8 PAPER REGISTRATION..............................................................	6-56
6.12 IMAGE TRANSFER AND PAPER SEPARATION .................................	6-57
6.12.1 OVERVIEW ..................................................................................	6-57
6.12.2 IMAGE TRANSFER CURRENT TIMING......................................	6-58
6.12.3 TRANSFER ROLLER CLEANING................................................	6-59
6.12.4 PAPER SEPARATION MECHANISM...........................................	6-59
6.13 IMAGE FUSING AND PAPER EXIT......................................................	6-60
6.13.1 OVERVIEW ..................................................................................	6-60
6.13.2 FUSING DRIVE AND RELEASE MECHANISM ...........................	6-60
6.13.3 FUSING ENTRANCE GUIDE SHIFT............................................	6-61
6.13.4 PRESSURE ROLLER...................................................................	6-61
6.13.5 FUSING TEMPERATURE CONTROL..........................................	6-62
Overview.............................................................................................	6-62
Fusing Lamp Control...........................................................................	6-64
Fusing Temperature Control for Thick Paper at the By-pass Tray......	6-65
Pre-heat Mode (Fusing Idling) ............................................................	6-65
To Prevent Offset when Making Multiple Copies
on Small-width Paper..........................................................................	6-65
Reduced Copy Speed with Narrow Paper ..........................................	6-65
6.13.6 OVERHEAT PROTECTION .........................................................	6-66
6.14 DUPLEX UNIT.......................................................................................	6-67
6.14.1 OVERALL .....................................................................................	6-67
6.14.2 DRIVE MECHANISM....................................................................	6-68
6.14.3 BASIC OPERATION.....................................................................	6-69
Larger than A4 Short-edge/LT Short-edge..........................................	6-69
Up to A4 Short-edge/LT Short-edge ...................................................	6-70
6.14.4 FEED IN AND EXIT MECHANISM ...............................................	6-71
6.15 ENERGY SAVER MODES ....................................................................	6-72

vii

6.15.1 OVERVIEW ..................................................................................	6-72
6.15.2 LOW POWER MODE ...................................................................	6-73
Entering Low Power Mode..................................................................	6-73
What Happens in Low Power Mode....................................................	6-73
Returning to Stand-by Mode ...............................................................	6-74
6.15.3 NIGHT/OFF MODE.......................................................................	6-74
Entering Night/Off Mode .....................................................................	6-74
What Happens in Night/Off Mode .......................................................	6-75
Returning to Stand-by Mode ...............................................................	6-75

PERIPHERALS

AUTO REVERSE DOCUMENT FEEDER (B379)
1 OVERALL MACHINE INFORMATION...................................		B379-1
1.1	MECHANICAL COMPONENT LAYOUT ............................................	B379-1
1.2	ELECTRICAL COMPONENT LAYOUT..............................................	B379-2
1.3	DRIVE LAYOUT .................................................................................	B379-3

2 DETAILED SECTION DESCRIPTIONS .................................		B379-4
2.1	ORIGINAL SIZE DETECTION............................................................	B379-4
2.2	PICK-UP AND SEPARATION ............................................................	B379-6
2.3	ORIGINAL TRANSPORT AND EXIT..................................................	B379-7
	2.3.1 SINGLE-SIDED ORIGINALS.....................................................	B379-7
	2.3.2 DOUBLE-SIDED ORIGINALS ...................................................	B379-8
	2.3.3 ORIGINAL TRAILING EDGE SENSOR.....................................	B379-9
2.4	STAMP .............................................................................................	B379-10
2.5	TIMING CHARTS .............................................................................	B379-11
	2.5.1 SINGLE-SIDED ORIGINAL MODE (A3)..................................	B379-11
	2.5.2 SINGLE-SIDED ORIGINAL MODE (A3, STAMP MODE)........	B379-12
	2.5.3 DOUBLE-SIDED ORIGINAL MODE........................................	B379-13
	2.5.4 DOUBLE-SIDED ORIGINAL MODE (STAMP MODE).............	B379-14
2.6	JAM DETECTION.............................................................................	B379-15
2.7	OVERALL ELECTRICAL CIRCUIT ..................................................	B379-16
2.8	FREE RUN .......................................................................................	B379-17
	Procedure ....................................................................................	B379-17
	One-sided Free Run Process ......................................................	B379-17
	Two-sided Free Run Process ......................................................	B379-17

3 REPLACEMENT AND ADJUSTMENT.................................		B379-18
3.1	DF EXIT TABLE AND COVER .........................................................	B379-18
3.2	ORIGINAL FEED UNIT ....................................................................	B379-19
3.3	LEFT COVER ...................................................................................	B379-20
3.4	PICK-UP ROLLER............................................................................	B379-21
3.5	FEED BELT ......................................................................................	B379-22

viii

3.6	SEPARATION ROLLER ...................................................................	B379-23
3.7	ORIGINAL SET/ORIGINAL REVERSE SENSORS..........................	B379-24
3.8	ORIGINAL L/W SENSOR, TRAILING EDGE SENSOR ...................	B379-25
3.9	FEED CLUTCH, PICK-UP SOL, TRANSPORT MOTOR,
	FEED MOTOR..................................................................................	B379-26

	Exterior ........................................................................................	B379-26
	DF Feed Clutch............................................................................	B379-26
	Pick-up Solenoid..........................................................................	B379-26
	Transport Motor ...........................................................................	B379-26
	DF Feed Motor.............................................................................	B379-26
3.10	REGISTRATION SENSOR.............................................................	B379-27
3.11	STAMP SOLENOID AND ORIGINAL EXIT SENSOR ....................	B379-28

DOCUMENT FEEDER (B387)
1 OVERALL INFORMATION ....................................................		B387-1
1.1	MECHANICAL COMPONENT LAYOUT ............................................	B387-1
1.2	ELECTRICAL COMPONENT LAYOUT..............................................	B387-2
1.3	DRIVE LAYOUT .................................................................................	B387-3

2 DETAILED SECTION DESCRIPTIONS .................................		B387-4
2.1	ORIGINAL SIZE DETECTION............................................................	B387-4
2.2	PICK-UP AND SEPARATION ............................................................	B387-6
2.3	ORIGINAL TRANSPORT AND EXIT MECHANISM ...........................	B387-7
2.4	STAMP ...............................................................................................	B387-8
2.5	TIMING CHARTS ...............................................................................	B387-9
	2.5.1 A3 ..............................................................................................	B387-9
	2.5.2 A3, STAMP MODE ..................................................................	B387-10
2.6	JAM DETECTION.............................................................................	B387-11
2.7	OVERALL ELECTRICAL CIRCUIT ..................................................	B387-12
2.8	FREE RUN .......................................................................................	B387-13
	Procedure ....................................................................................	B387-13
	Free Run Process........................................................................	B387-13

3 REPLACEMENT AND ADJUSTMENT.................................		B387-14
3.1	EXTERIOR COVERS .......................................................................	B387-14
	3.1.1 REAR COVER.........................................................................	B387-14
	3.1.2 ORIGINAL TABLE ...................................................................	B387-14
	3.1.3 FRONT COVER ......................................................................	B387-14
	3.1.4 ORIGINAL ENTRANCE GUIDE ..............................................	B387-14
	3.1.5 DF FEED COVER....................................................................	B387-15
3.2	FEED UNIT.......................................................................................	B387-15
3.3	SEPARATION ROLLER ...................................................................	B387-15
3.4	PICK-UP ROLLER............................................................................	B387-16
3.5	FEED BELT ......................................................................................	B387-16
3.6	ORIGINAL SENSORS (WIDTH, LENGTH, TRAILING EDGE).........	B387-17
3.7	ORIGINAL SET SENSOR ................................................................	B387-18
3.8	TRANSPORT MOTOR .....................................................................	B387-18

ix

3.9 DF COVER OPEN SENSOR/FEED CLUTCH/ROM/
	DF DRIVE BOARD ...........................................................................	B387-19
	Exterior ........................................................................................	B387-19
	Feed Cover Open Sensor ............................................................	B387-19
	Feed Clutch .................................................................................	B387-19
	ROM ............................................................................................	B387-19
	DF Drive Board ............................................................................	B387-19
3.10	REGISTRATION SENSOR.............................................................	B387-21
3.11	PICK-UP SOLENOID .....................................................................	B387-21
3.12	STAMP SOLENOID........................................................................	B387-22

PAPER TRAY UNIT (B384)
1 OVERALL MACHINE INFORMATION...................................		B384-1
1.1	MECHANICAL COMPONENT LAYOUT ............................................	B384-1
1.2	ELECTRICAL COMPONENT LAYOUT..............................................	B384-2
1.3	DRIVE LAYOUT .................................................................................	B384-3

2 DETAILED DESCRIPTIONS ..................................................		B384-4
2.1	PAPER FEED AND SEPARATION MECHANISM .............................	B384-4
2.2	PAPER LIFT MECHANISM ................................................................	B384-5
2.3	PAPER END DETECTION .................................................................	B384-7
2.4	PAPER HEIGHT DETECTION ...........................................................	B384-8
	PAPER SIZE DETECTION ............................................................	B384-9
2.5	SIDE AND END FENCES ................................................................	B384-10
	Side Fences.................................................................................	B384-10
	End Fence ...................................................................................	B384-10

3 REPLACEMENT AND ADJUSTMENT.................................		B384-11
3.1	FEED ROLLER REPLACEMENT.....................................................	B384-11
3.2	TRAY MAIN BOARD REPLACEMENT ............................................	B384-12
3.3	TRAY MOTOR REPLACEMENT......................................................	B384-12
3.4	RELAY CLUTCH REPLACEMENT ..................................................	B384-13
3.5	UPPER PAPER FEED CLUTCH REPLACEMENT ..........................	B384-14
3.6	LOWER PAPER FEED CLUTCH REPLACEMENT .........................	B384-15
3.7	LIFT MOTOR REPLACEMENT ........................................................	B384-16
3.8	PAPER END SENSOR REPLACEMENT.........................................	B384-17
3.9	VERTICAL TRANSPORT SENSOR REPLACEMENT .....................	B384-17
3.10 PAPER SIZE SWITCH REPLACEMENT .......................................		B384-18
PAPER TRAY UNIT (B385)
1 OVERALL MACHINE INFORMATION...................................		B385-1
1.1	MECHANICAL COMPONENT LAYOUT ............................................	B385-1
1.2	ELECTRICAL COMPONENT LAYOUT..............................................	B385-2
1.3	DRIVE LAYOUT .................................................................................	B385-3

x

2 DETAILED DESCRIPTIONS ..................................................		B385-4
2.1	PAPER FEED AND SEPARATION ....................................................	B385-4
2.2	PAPER LIFT MECHANISM ................................................................	B385-5
2.3	PAPER END DETECTION .................................................................	B385-7
2.4	PAPER HEIGHT DETECTION ...........................................................	B385-8
2.5	PAPER SIZE DETECTION.................................................................	B385-9
2.6	SIDE AND END FENCES ................................................................	B385-10
	Side Fences.................................................................................	B385-10
	End Fence ...................................................................................	B385-10

3 REPLACEMENT AND ADJUSTMENT.................................		B385-11
3.1	FEED ROLLER REPLACEMENT.....................................................	B385-11
3.2	TRAY MAIN BOARD REPLACEMENT ............................................	B385-12
3.3	TRAY MOTOR REPLACEMENT......................................................	B385-13
3.4	LIFT MOTOR REPLACEMENT ........................................................	B385-14
3.5	PAPER END SENSOR REPLACEMENT.........................................	B385-15
3.6	PAPER SIZE SWITCH REPLACEMENT .........................................	B385-15

SPECIFICATIONS.....................................................................		SPEC-1
1.	GENERAL SPECIFICATIONS.............................................................	SPEC-1
	Duplex Unit (B043 only) ................................................................	SPEC-4
2.	MACHINE CONFIGURATION.............................................................	SPEC-5
3.	OPTIONAL EQUIPMENT ....................................................................	SPEC-6
	ARDF ............................................................................................	SPEC-6
	ADF...............................................................................................	SPEC-7
	ONE-TRAY PAPER TRAY UNIT ..................................................	SPEC-8
	TWO-TRAY PAPER TRAY UNIT..................................................	SPEC-9
	16MB IMB (Copier Memory Unit)*.................................................	SPEC-9

xi

20 February, 2001

INSTALLATION REQUIREMENTS

1. INSTALLATION

!CAUTION

Before installing options, please do the following:

1.If there is a fax unit in the machine, print out all messages stored in the memory, the lists of user programmed items, and the system parameter list.

2.If there is a printer option in the machine, print out all data in the printer buffer.

3.Turn off the main switch and disconnect the power cord, the telephone line, and the network cable.

Installation

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

–Temperature and Humidity Chart–

Humidity
80%
54%
	Operation range
15%
10°C	27°C	32°C	Temperature
(50°F)	(80.6°F) (89.6°F)

B039I502.WMF

1-1

INSTALLATION REQUIREMENTS

20 February, 2001

1.	Temperature Range:	10°C to 32°C (50°F to 89.6°F)
2.	Humidity Range:	15% to 80% RH
3.	Ambient	Less than 1,500 lux (do not expose to direct sunlight).
	Illumination:
4.	Ventilation:	Room air should turn over at least 30 m3/hr/person
5.	Ambient Dust:	Less than 0.075 mg/m3 (2.0 x 10-6 oz/yd3)

6.Avoid areas exposed to sudden temperature changes:

1)Areas directly exposed to cool air from an air conditioner.

2)Areas directly exposed to heat from a heater.

7.Do not place the machine where it will be exposed to corrosive gases.

8.Do not install the machine at any location over 2,000 m (6,500 ft.) above sea level.

9.Place the copier on a strong and level base. (Inclination on any side should be no more than 5 mm.)

10.Do not place the machine where it may be subjected to strong vibrations.

1.1.2 MACHINE LEVEL

Front to back:	Within 5 mm (0.2") of level
Right to left:	Within 5 mm (0.2") of level

1-2

20 February, 2001

INSTALLATION REQUIREMENTS

1.1.3 MINIMUM SPACE REQUIREMENTS

Place the copier near the power source, providing clearance as shown:

[C]

Installation

[B]

[D]

A: Front > 750 mm (29.6")

B: Left > 10 mm (0.4")

C: Rear > 10 mm (0.4")

D: Right > 10 mm (0.4")

[A]

B039I145.WMF

NOTE: 1) The recommended 750 mm front space is sufficient to allow the paper tray to be pulled out. Additional front space is required to allow operators to stand at the front of the machine.

2)The recommended 10 mm right space is for installation only. Additional right space is required to allow operators to fix paper jams and use the by-pass tray.

1.1.4POWER REQUIREMENTS

!CAUTION

1.Make sure that the wall outlet is near the copier and easily accessible. After completing installation, make sure the plug fits firmly into the outlet.

2.Avoid multi-wiring.

3.Be sure to ground the machine.

1.Input voltage:

America, Taiwan:110 – 120 V, 50/60 Hz, 12 A Europe, Asia: 220 – 240 V, 50/60 Hz, 7 A

1-3

COPIER INSTALLATION

20 February, 2001

1.2 COPIER INSTALLATION

1.2.1 POWER SOCKETS FOR PERIPHERALS

!CAUTION

Rated voltage for peripherals

Make sure to plug the cables into the correct sockets.

ADF/ARDF

Rated voltage output connector for accessory Max. DC24 V

Paper Tray Unit

Rated voltage output connector for accessory Max. DC24 V

B039I119.WMF

1.2.2 ACCESSORY CHECK

Check that you have the accessories indicated below.

No.	Description	Q’ty
1	Operation Instructions - System Settings	1
2	Operation Instructions - Copy Reference	1
3	NECR - English (-10, -17)	1
4	NECR - Multi Language (-19, -27, -29, -69)	1
5	Model Nameplate (-10, -17, -22)	1
6	Model Name Decal (-22)	1

1-4

20 February, 2001

COPIER INSTALLATION

1.2.3 INSTALLATION PROCEDURE

!CAUTION

When installing the copier, make sure that the copier is unplugged.

1. Remove the strips of tape.

Installation

B039I102.WMF

2.Open the front door and remove the toner bottle holder [A].

3.Open the right door, and remove the PCU (Photoconductor Unit) [B].

[A]

[B]

B039I107.WMF

B039I108.WMF

1-5

COPIER INSTALLATION

20 February, 2001

4. Separate the PCU into two sections as shown (5 screws).

B039I114.WMF

	5. Distribute one pack of developer [A]
	evenly across the width of the		[A]
	development unit, into all openings.		[B]
	NOTE: 1)	To prevent foreign material
		from getting on the sleeve
		rollers, place a sheet of
		paper under the
		development unit.
	2)	Make sure not to spill the
		developer on the gears [B].
	3)	If it is necessary to turn the
		gear [B] to distribute the
		developer, make sure to do	B039I115.WMF
		so very minimally, otherwise
		the developer may spill.	[C]

6.	Reassemble and reinstall the PCU.	[E]
7.	Shake the toner bottle [C] several times. [D]
	NOTE: Be sure not to remove the toner
	bottle cap [D] until after shaking.

8. Unscrew the bottle cap [D] and insert the bottle into the holder.

NOTE: Do not touch the inner bottle cap [E].

9. Reposition the holder and press down the holder lever to secure the bottle.

10. Pull out the paper tray and turn the

paper size dial to the appropriate size. B039I504.WMF Adjust the end and side guides to match

the paper size.

NOTE: To move the side guides, first release the green lock on the rear side guide.

1-6

20 February, 2001		COPIER INSTALLATION
11.	Install the optional ARDF, ADF, or platen cover ( 1.3/1.4/1.5).		Installation
12.	Plug in the main power cord and turn on the main switch. Perform TD Sensor
	Initialization (SP2-214).
13.	Select the correct display language using UP Mode (Language).
14.	Load the paper in the paper tray and make a full size copy, and check if the
	side-to-side and leading edge registrations are correct. If they are not, adjust
	the registrations ( 3.13 Copy Adjustments: Printing/Scanning).
15.	Initialize the electric total counter using SP7-825 in accordance with the type of
	service contract.
	NOTE: Select 1, then press the Original Type and OK keys at the same time. If
	the reset is successful, “Action completed” will appear on the LCD.

1-7

PLATEN COVER INSTALLATION

20 February, 2001

1.3 PLATEN COVER INSTALLATION

1.3.1 ACCESSORY CHECK

Check that you have the accessories indicated below.

No.		Description	Q’ty
1	Stepped Screw		2

1.3.2 INSTALLATION PROCEDURE

!CAUTION

Unplug the machine power cord before starting the following procedure.

1. Install the platen cover [A] (2 screws).

[A]

B039I120.WMF

1-8

20 February, 2001

ARDF INSTALLATION

1.4 ARDF INSTALLATION

1.4.1 ACCESSORY CHECK

Check the quantity and condition of the accessories against the following list.

No.		Description	Q’ty
1	Scale Guide		1
2	DF Exposure Glass		1
3	Stud Screw		2
4	Knob Screw		2
5	Original Size Decal		2
6	Screwdriver Tool		1

Installation

4	3	6	1

	5	2
		B379I500.WMF

1.4.2 INSTALLATION PROCEDURE

1. Remove the strips of tape.

B379I101.WMF

1-9

ARDF INSTALLATION

20 February, 2001

[C]	[D]	[E]	[B]
2. Remove the left scale [A] (2				[A]
			[F]
screws).
3. Place the DF exposure glass				[F]
[B] on the glass holder.
NOTE: When installing the DF
exposure glass, make
sure that the white
point [C] is face down.

4. Peel off the backing [D] of the double-sided tape attached to

the rear side of the scale guide B379I103.WMF [E], then install it (2 screws

removed in step 2).

5. Install the two stud screws [F].

6. Mount the DF on the copier, then slide the DF to the front.

7. Secure the DF unit with two screws [G].

8. Connect the cable [H] to the
copier.	[G]

[H]

B379I104.WMF

9. Attach the appropriate scale
decal [I] as shown.	[I]

10. Turn the main power switch on. Then check if the document feeder works properly.

11. Make a full size copy, and

	check that the side-to-side and
	leading edge registrations are
	correct. If they are not, adjust
	the side-to-side and leading	B379I501.WMF
	edge registrations. ( 3.13.3
	ADF Image Adjustment)

1-10

20 February, 2001

ADF INSTALLATION

1.5 ADF INSTALLATION

1.5.1 ACCESSORY CHECK

Check the quantity and condition of the accessories against the following list.

No.		Description	Q’ty
1	Scale Guide		1
2	DF Exposure Glass		1
3	Stud Screw		2
4	Fixing Screw		2
5	Original Size Decal		2
6	Screwdriver Tool		1

Installation

4	3	6	1

2

5

B387I500.WMF

1.5.2 INSTALLATION PROCEDURE

1. Remove the strips of tape.

B387I151.WMF

1-11

ADF INSTALLATION

2.Remove the left scale [A] (2 screws).

3.Place the DF exposure glass [B] on the glass holder. NOTE: When installing the DF

exposure glass, make sure that the white point [C] is face down.

4.Peel off the backing [D] of the double-sided tape attached to the rear side of the scale guide [E], then install it (2 screws removed in step 2).

5.Install the two stud screws [F].

6.Mount the DF on the copier, then slide the DF to the front.

7.Secure the DF unit with two screws [G].

8.Connect the cable [H] to the copier.

9.Attach the appropriate scale decal [I] as shown.

10.Turn the main power switch on. Then check if the document feeder works properly.

11.Make a full size copy, and check that the side-to-side and leading edge registrations are correct. If they are not, adjust the side-to-side and leading edge registrations. ( 3.13.3 ADF Image Adjustment).

[C][D] [E]

[G]

[I]

20 February, 2001

[B]

[F] [A]

[F]

B387I103.WMF

[H]

B387I104.WMF

B387I501.WMF

1-12

20 February, 2001

TWO-TRAY PAPER TRAY UNIT INSTALLATION

1.6 TWO-TRAY PAPER TRAY UNIT INSTALLATION

1.6.1 ACCESSORY CHECK

Check the quantity and condition of the accessories against the following list.

No.		Description	Q’ty
1	Screw – M4x10		10
2	Unit Holder		4
3	Adjuster		1
4	Unit Holder		2

Installation

1	2	3	4

B384I500.WMF

1.6.2 INSTALLATION PROCEDURE

[A]

B384I158.WMF	B384I001.WMF

1.Remove the strips of tape.

NOTE: After removing the tape that secures the peripheral components and cardboard to the paper tray, make sure that there is no tape and/or tape residue remaining on the tray.

2.Attach the adjuster [A] to the base plate, as shown. NOTE: If a table is installed, this step is unnecessary.

1-13

TWO-TRAY PAPER TRAY UNIT INSTALLATION

20 February, 2001

3. Remove the cover [A] (1 rivet).

[A]

B384I109.WMF

4. Set the copier on the paper tray unit. NOTE: When installing the copier, be

careful not to pinch the connecting harness.

B384I117.WMF

5.One-tray copier model (B039):

Remove the 1st tray cassette [B].

Two-tray copier models (B040/B043):

Remove the 2nd tray cassette [B].

6.

Install the two screws [C].

[B]

7.

Reinstall the tray cassette.

[C]

B384I106.WMF

1-14

20 February, 2001

8.Install the two brackets [A] (1 stepped screw each).

9.Connect the connecting harness

[B] to the copier.

NOTE: There are cutouts in the plug on both sides. The left side has one cutout, and the right side has two.

10.Reinstall the cover removed in step 3 (1 rivet).

TWO-TRAY PAPER TRAY UNIT INSTALLATION

[A]

[B]

B384I105.WMF

11. Install the four brackets [C] (2 screws each).

NOTE: If a table is installed, this step is unnecessary.

[C]

Installation

B384I007.WMF

12.Rotate the adjuster [D] to fix the machine in place.

NOTE: If a table is installed, this step is unnecessary.

13.Load the paper in the paper trays and make full size copies from each tray. Check if the side-to- side and leading edge registrations are correct. If they are not, adjust the registrations ( 3.13 Copy Adjustments: Printing/ Scanning).

[D]

B384I002.WMF

1-15

ONE-TRAY PAPER TRAY UNIT INSTALLATION

20 February, 2001

1.7 ONE-TRAY PAPER TRAY UNIT INSTALLATION

1.7.1 ACCESSORY CHECK

Check the quantity and condition of the accessories against the following list.

No.	Description	Q’ty
1	Screw – M4x10	2
2	Stepped Screw – M4x10	2
3	Unit Holder	2

1	2	3

B385I500.WMF

1.7.2 INSTALLATION PROCEDURE

B385I159.WMF

1.Remove the strips of tape.

NOTE: After removing the tape that secures the peripheral components and cardboard to the paper tray, make sure that there is no tape and/or tape residue remaining on the tray.

1-16

20 February, 2001

ONE-TRAY PAPER TRAY UNIT INSTALLATION

2. Remove the cover [A] (1 rivet).

[A]

B385I109.WMF

3. Set the copier on the paper tray unit. NOTE: When installing the copier, be

careful not to pinch the connecting harness.

B385I112.WMF

Installation

4. One-tray copier model (B039):

Remove the 1st tray cassette [B].

Two-tray copier models (B040/B043):

Remove the 2nd tray cassette [B].

[B]

B385I120.WMF

1-17

ONE-TRAY PAPER TRAY UNIT INSTALLATION

5.Install the two screws [A].

6.Reinstall the tray cassette.

[A]

7.Install the two brackets [B]. (1 stepped screw each).

8.Connect the connecting harness [C] to the copier.

NOTE: There are cutouts in the plug on both sides. The left side has one cutout, and the right side has two.

9.Reinstall the cover removed in step 2.

10.Load the paper in the paper tray and make full size copies from tray. Check if the side-to-side and leading edge registrations are correct. If they are not, adjust the registrations ( 3.13 Copy Adjustments: Printing/Scanning).

20 February, 2001

B385I118.WMF

[B]

[C]

B385I105.WMF

1-18

20 February, 2001

IMB INSTALLATION

1.8 IMB INSTALLATION

1.8.1 ACCESSORY CHECK

Click the quantity and condition of the accessory against the following list:

No.		Description	Q’ty
1	Screw – M3x6		3

Installation

1.8.2 INSTALLATION PROCEDURE

[A]

[C]

B039I934.WMF

[B]

[D]

B039I928.WMF

1.Remove the rear middle cover [A] (2 rivets).

2.Connect the connectors [B, C] and install the IMB [D] (3 screws).

3.Reinstall the rear middle cover.

1-19

DRAM INSTALLATION

20 February, 2001

1.9 DRAM INSTALLATION

[A]

B039I934.WMF

[B]

B039R942.WMF

NOTE: The IMB must be installed before installing the DRAM.

1.Remove the rear middle cover [A] (2 rivets).

2.Install the DRAM [B].

3.Reinstall the rear middle cover.

1-20

20 February, 2001

ANTI-CONDENSATION HEATER INSTALLATION

1.10 ANTI-CONDENSATION HEATER INSTALLATION

[A]

Installation

[B]

[C] [E]

[D]

B039I127.WMF

1.Remove the exposure glass ( 3.4.1).

2.Remove the left cover ( 3.3.8).

3.Pass the connector [A] through the opening [B].

4.Install the anti-condensation heater [C], as shown.

5.Join the connectors [A, D].

6.Clamp the harness with the clamp [E].

7.Reinstall the left cover and exposure glass.

1-21

TRAY HEATERS

20 February, 2001

1.11 TRAY HEATERS

1.11.1 UPPER TRAY HEATER

[B]

B039I020.WMF	[A]	B039I909.WMF

[E]

[C]

[D]

B039I121.WMF

[G]
[F]	B039I126.WMF

1.Remove the 1st tray cassette [A].

2.Remove the rear cover ( 3.3.1).

3.Remove the high voltage power supply board [B] with bracket (5 screws and 3 connectors).

4.Pass the connector [C] through the opening [D] and install the tray heater [E] (1 screw).

5.Install the relay cable [F], as shown.

6.Clamp the cable with the clamp [G].

7.Reinstall the 1st tray cassette, power pack, and rear cover.

1-22

20 February, 2001

TRAY HEATERS

1.11.2 LOWER TRAY HEATER (TWO-TRAY MODEL ONLY)

Installation

B039I129.WMF

[A]

[F]

B039I125.WMF

[E]	[C]
	[D]
B039I122.WMF

[G]

[B]

1.Remove the 2nd tray cassette [A].

2.Remove the rear lower cover ( 3.3.2).

3.B043 model only:

Remove the DCB [B] with bracket (4 screws and 3 connectors).

4.Pass the connector [C] through the opening [D] and install the tray heater [E] (1 screw).

5.Join the connectors [F, G].

6.Reinstall the 2nd tray cassette, DCB, and rear lower cover.

1-23

TRAY HEATERS

20 February, 2001

1.11.3 TRAY HEATERS FOR THE OPTIONAL PAPER FEED UNITS

1. Remove the rear cover for the paper tray unit [A] (2 screws).

2.Two-tray unit only: Remove the cable guide [B] (1 screw).

3.Install the clamps [C].

[A]

B039I202.WMF

- One-tray paper feed unit -

[C]

B039I007.WMF

- Two-tray paper feed unit -

[B]

[C]

B039I004.WMF

1-24

20 February, 2001

4.Pass the connector [A] through the opening [B].

5.Install the tray heater [C] (1 screw).

TRAY HEATERS

- One-tray paper feed unit -	[B]	Installation

[A]

[C]

B039I009.WMF

- Two-tray paper feed unit - [B]

[A]

[C]

B039I005.WMF

1-25

TRAY HEATERS

6.Clamp the cables [A], as shown.

7.Join the connectors [B].

8.Two-tray unit only: Reinstall the cable guide.

9.One-tray copier model (B039):

Remove the 1st tray cassette.

Two-tray copier models (B040/B043):

Remove the 2nd tray cassette.

10.Remove the two screws [C] and install the two hexagonal socket screws [D].

11.Reinstall the 1st tray and rear cover.

[C]

20 February, 2001

- One-tray paper feed unit -

[B]

[A]

[C]

B039I008.WMF

- Two-tray paper feed unit -

[B]

[B]

[A]	B039I006.WMF

[D]

B039I003.WMF

1-26

20 February, 2001

KEY COUNTER INSTALLATION

1.12 KEY COUNTER INSTALLATION

Installation

	[B]
	[C]
	[D]
B039I128.WMF	[A]

[E]

[F]

B039I100.WMF

1.Remove the left cover ( 3.3.8).

2.Remove the rear cover ( 3.3.1).

3.Remove the cap [A] with nippers.

4.Punch out the small hole [B] using a screwdriver.

5.Hold the key counter plate nuts [C] on the inside of the key counter bracket [D] and insert the key counter holder [E].

6.Secure the key counter holder to the bracket (2 screws).

7.Install the key counter cover [F] (2 screws).

1-27

KEY COUNTER INSTALLATION

20 February, 2001

	[C]
[F]	[B]	[A]
		B039I130.WMF
	[K]

[L]

		[J]
		[I]
	[E] [D] [H]	[G]
B039I131.WMF

8.Clamp the relay cable [A] with the clamps [B], as shown.

NOTE: The relay cable [A] is not included in the key counter bracket accessories.

9.Connect the connector [C] to CN306 on the IOB.

10.Reinstall the rear and left cover.

NOTE: When reinstalling the left cover, pass the relay cable connector [D] through the opening [E].

11.Install the stepped screw [F].

12.Install the relay cable [G] and join the connectors [D, H].

13.Join the connectors [I, J].

14.Hook the key counter holder assembly [K] onto the stepped screw [F].

15.Secure the key counter holder assembly with a screw [L].

16.Change the value of SP5-113 to “1”.

1-28

20 February, 2001

PM TABLES

2. PREVENTIVE MAINTENANCE SCHEDULES

2.1 PM TABLES

NOTE: 1) After carrying out PM, clear the PM counter (SP7-804).

2) PM intervals (60k, 80k, and 120K) indicate the number of prints.

Key: AN: As necessary			C: Clean R: Replace L: Lubricate I: Inspect
		EM	60k	120k	AN	NOTE
	OPTICS
	Reflector	C				Optics cloth
	1st mirror	C			C	Optics cloth
	2nd mirror	C			C	Optics cloth
	3rd mirror	C			C	Optics cloth
	Scanner guide rails	C				Do not use alcohol.
	Platen cover	I			C	Replace the platen sheet, if necessary.
						Blower brush or alcohol
	Exposure glass	C			C	Blower brush or alcohol
	Toner shield glass	C				Blower brush
	APS sensors	C				Blower brush
	DRUM AREA
	PCU		I
	Drum		R
	Developer		R
	Charge roller		R
	Cleaning brush		R
	(for charge roller)
	Cleaning blade		R
	(for OPC drum)
	Separation pawls		R
	Transfer roller			R
	ID sensor	C			C	Blower brush
	PAPER FEED
	Paper feed roller		C	R	C	Clean with water or alcohol.
	(in each feed tray)
	Friction pad		C	R	C	Clean with water or alcohol.
	(in each feed tray)
	Bottom-plate pad		C		C	Clean with water or alcohol.
	(in each feed tray)
	Paper feed roller		C		C	Clean with water or alcohol.
	(bypass tray)
	Friction pad		C		C	Clean with water or alcohol.
	(bypass tray)
	Bottom-plate pad		C		C	Clean with water or alcohol.
	(by-pass tray)
	Registration rollers		C		C	Clean with water or alcohol.
	Relay rollers		C		C	Clean with water or alcohol.

Preventive	Maintenance

2-1

PM TABLES						20 February, 2001
		EM	60k	120k	AN	NOTE
	Paper feed guides		C		C	Clean with water or alcohol.
	Paper-dust Mylar		C		C	Clean with water or alcohol.
	FUSING UNIT
	Hot roller		R
	Pressure roller			R
	Hot roller bushings			I
	Pressure-roller			R
	bushing
	Hot roller stripper			R	C	Dry cloth
	pawls
	Thermistor		C		C	Dry cloth

	80k	AN	NOTE
ADF, ARDF
Feed belt	R	C	Clean with water or alcohol.
Separation roller	R	C	Clean with water or alcohol.
Pick-up roller	R	C	Clean with water or alcohol.
Stamp		R	Replace when necessary.
White plate		C	Clean with water or alcohol.
DF exposure glass		C	Clean with water or alcohol.
Platen cover		C	Clean with water or alcohol.

	60k	120k	AN	NOTE
PAPER TRAY UNIT (ONE-TRAY AND TWO-TRAY MODELS)
Paper feed rollers		R	C	Dry or damp cloth
Bottom-plate pads	C		C	Dry cloth
Paper-feed guides	C		C	Clean with water or alcohol.
Friction pads		R	C	Dry or damp cloth
PAPER TRAY UNIT (TWO-TRAY MODEL ONLY)
Relay clutch		I
Feed clutches		I
Relay roller		C	C	Dry cloth

2-2

20 February, 2001

HOW TO CLEAR THE PM COUNTER

2.2 HOW TO CLEAR THE PM COUNTER

After PM, clear the PM counter (SP7-804).

1.Access SP mode 7-804.

2.Press the Original Type key and the OK or ! key at the same time to reset the counter. If the reset is successful, the display shows “Action completed.” If the reset fails, the display shows “Error!!!”

Preventive	Maintenance

2-3

20 February, 2001

GENERAL CAUTIONS

3. REPLACEMENT AND ADJUSTMENT

3.1 GENERAL CAUTIONS

Do not turn off the main switch while any of the electrical components are active. Doing so may result in damage to units (such as the PCU) as they are pulled out or replaced.

3.1.1 PCU (PHOTOCONDUCTOR UNIT)

The PCU consists of the OPC drum, charge roller, development unit, and cleaning components. Observe the following precautions when handling the PCU.

1.Never touch the drum surface with bare hands. If the drum surface is dirty or if you have accidentally touched it, wipe it with a dry cloth, or clean it with wet cotton and then wipe it dry with a cloth.

2.Never use alcohol to clean the drum. Alcohol will dissolve the drum surface.

3.Store the PCU in a cool dry place.

4.Do not expose the drum to corrosive gases (ammonia, etc.).

5.Do not shake a used PCU, as this may cause toner and developer to spill out.

6.Dispose of used PCU components in accordance with local regulations.

3.1.2 TRANSFER ROLLER

1. Never touch the surface of the transfer roller with bare hands.

2. Be careful not to scratch the transfer roller, as the surface is easily damaged.

3.1.3 SCANNER UNIT

1.Use alcohol or glass cleaner to clean the exposure and scanning glass. This will reduce the static charge on the glass.

2.Use a blower brush or a water-moistened cotton pad to clean the mirrors and lenses.

3.Take care not to bend or crease the exposure lamp’s ribbon cable.

4.Do not disassemble the lens unit. Doing so will throw the lens and copy image out of focus.

5.Do not turn any of the CCD positioning screws. Doing so will throw the CCD out of position.

Replacement	Adjustment

3-1

SPECIAL TOOLS AND LUBRICANTS

20 February, 2001

3.1.4 LASER UNIT

1.Do not loosen or adjust the screws securing the LD drive board on the LD unit. Doing so will throw the LD unit out of adjustment.

2.Do not adjust the variable resistors on the LD unit. These are adjusted at the factory.

3.The polygonal mirror and F-theta lens are very sensitive to dust.

4.Do not touch the toner shield glass or the surface of the polygonal mirror with bare hands.

3.1.5 FUSING UNIT

1.After installing the fusing thermistor, make sure that it is in contact with the hot roller and that the roller can rotate freely.

2.Be careful to avoid damage to the hot roller stripper pawls and their tension springs.

3.Do not touch the fusing lamp and rollers with bare hands.

4.Make sure that the fusing lamp is positioned correctly and that it does not touch the inner surface of the hot roller.

3.1.6 PAPER FEED

1. Do not touch the surface of the paper feed rollers.

2. To avoid misfeeds, the side and end fences in each paper tray must be positioned correctly so as to align with the actual paper size.

3.1.7 IMPORTANT

1.After installing a new PCU, you must run SP2-214 to initialize the TD sensor. After starting initialization, be sure to wait for it to reach completion (wait for the motor to stop) before re-opening the front cover or turning off the main switch.

2.If the optional tray heater or optics anti-condensation heater is installed, keep the copier's power cord plugged in even while the main switch is off, so that the heater(s) remain energized.

3.2 SPECIAL TOOLS AND LUBRICANTS

Part Number	Description	Q’ty
A0069104	Scanner Positioning Pins (4 pins/set)	1 set
A2929500	Test Chart S5S (10 pcs/set)	1 set
A0299387	FLUKE 87 Digital Multimeter	1
A2309352	4MB Flash Memory Card	1
A2579300	Grease Barrierta S552R	1
52039502	Grease G-501	1
B0399099	NVRAM – Minus Counter	1
G0219350	Loop-back Connector	1

3-2

20 February, 2001

EXTERIOR COVERS & OPERATION PANEL

3.3 EXTERIOR COVERS & OPERATION PANEL

3.3.1 REAR COVER

1.Unplug the DF cable [A].

2.Rear cover [B] (! x 6)

[A]

Replacement	Adjustment

[B]

B039R991.WMF

3.3.2 REAR LOWER COVER (TWO-TRAY MODELS ONLY)

1.Rear cover ( 3.3.1) or tray harness cover [C] (1 rivet).

2.Rear lower cover [D] (! x 2)

[D]	[C]
		B039R123.WMF

3-3

EXTERIOR COVERS & OPERATION PANEL

20 February, 2001

3.3.3 COPY TRAY

1. Duplex models only: Inverter tray [A]

2. Copy tray [B] (! x 2)

[A]

[B]	B039R152.WMF

3.3.4 LEFT UPPER COVER

[C]

1. Rear cover ( 3.3.1)

[G] 2. Left upper cover [C] (! x 2)

[B]

[E]

[F]

B039R002.WMF

3.3.5 FRONT UPPER LEFT COVER AND OPERATION PANEL

1.Front upper left cover [D] (! x 3)

2.Operation panel [E] (! x 3, " x 1)

3.3.6 RIGHT UPPER COVER

1. Right upper cover [F] (! x 1)

3.3.7 TOP REAR COVER

1.Platen cover or ARDF or ADF ( 1.2, 1.3, or 1.4)

2.Top rear cover [G] (! x 1)

3-4

20 February, 2001

3.3.8 LEFT COVER

1.Copy tray ( 3.3.3)

2.Rear cover ( 3.3.1)

3.Left cover [A] (! x 2)

EXTERIOR COVERS & OPERATION PANEL

[A]

Replacement

Adjustment

B039R924.WMF

3.3.9 FRONT LONG COVER

1.Open the front door [B].

2.Pull out the (top) paper tray.

3.Front long cover [C] (! x 4)

[C]

[B]

B039R929.WMF

3-5